Bosch HBL56 Service manual

SERVICE MANUAL
for
300, 500, and 800 Series
Built-in Wall Ovens
This manual contains information that is necessary for
servicing the following Bosch electric built-in wall
ovens:
HBL8x50UC, HBL57x0UC, HBL56x0UC,
HBL54x0UC, HBL35x0UC, HBL33x0UC,
HBN56x0UC, HBN54x0UC, HBN35x0UC,
HBN34x0UC, HBN3350UC
This manual is designed to be used by qualified
service personnel only. Due to the complexity and the
risk of high-voltage electrical shock, Bosch does not
recommend that customers service their own units.
Models:
HBL8x50UC, HBL57x0UC, HBL56x0UC,
HBL54x0UC, HBL35x0UC, HBL33x0UC,
HBN56x0UC, HBN54x0UC, HBN35x0UC,
HBN34x0UC, HBN3350UC
Service Manual for Bosch Built-in Wall Ovens
TABLE OF CONTENTS
1 General ........................................................................................ 3
1.1
Models................................................................................... 3
1.2
Features and Options............................................................ 3
1.3
Data Plate.............................................................................. 4
1.4
Warranty................................................................................ 4
2 Operation..................................................................................... 4
2.1
Element Duty Cycles ............................................................. 4
2.1.1
Using Table 3 (Element Duty Cycles During Preheat) ... 5
2.2
Sequence of Events .............................................................. 5
2.3
Cooling Fans ......................................................................... 7
3 Component Accessibility........................................................... 8
3.1
Serviceable from Front .......................................................... 8
3.2
Serviceable from Top ............................................................ 8
3.3
Serviceable from Rear........................................................... 8
4 Service and Repair ..................................................................... 8
4.1
Doors..................................................................................... 8
4.1.1
Removing and Replacing the Door(s) ............................ 8
4.2
Door Latch/Motor Assembly .................................................. 9
4.3
Lamps.................................................................................. 10
4.3.1
Replacing Lamps ......................................................... 10
4.4
High Temperature Cutout (HTC) ......................................... 11
4.5
Convection Fan and Ring Element...................................... 11
4.6
Temperature Sensor ........................................................... 12
4.6.1
Setting Temperature Offsets ........................................ 12
4.7
Broil Element ....................................................................... 13
4.8
User Interface...................................................................... 13
4.8.1
Removing the User Interface ....................................... 14
4.9
PC Control Module (Relay Board)....................................... 15
4.10
Power Supply Module...................................................... 18
4.11
Halogen Light Transformer(s).......................................... 18
4.12
Convection Fan Motor ..................................................... 18
4.13
Bake Element (Upper Oven)............................................ 18
4.13.1 Removing the Bake Element........................................ 18
4.13.2 Reinstalling the Bake Element ..................................... 19
4.14
Cooling Fan Motor (Upper Oven) .................................... 19
5
6
7
8
9
Error Codes .............................................................................. 19
5.1
Error Code Table ................................................................ 19
5.2
Service Mode / Setting Option Code .................................. 20
5.2.1
HBL3/HBN3 ................................................................. 20
5.2.2
HBL5/HBN5 ................................................................. 21
5.2.3
HBL8............................................................................ 21
5.3
Option Codes ...................................................................... 22
Demo Mode............................................................................... 22
Troubleshooting....................................................................... 22
7.1
Fault Tree Diagram ............................................................. 23
7.2
Fault Tree ........................................................................... 25
7.3
Testing ................................................................................ 33
Wiring Diagrams and Schematics .......................................... 33
8.1
Wire Color Key.................................................................... 33
8.2
Strip Diagrams .................................................................... 34
Additional References ............................................................. 34
9.1
QuickFinder ........................................................................ 34
9.2
Technical Support............................................................... 34
Page 2 of 36
Service Manual for Bosch Built-in Wall Ovens
1
GENERAL
There are nine HBL (30”) and five HBN (27”) models in various
combinations and three colors (black, white, and stainless), included
in the 2007 Bosch 300, 500, and 800 Series Built-in Wall Oven
(BIWO) product line. These models include A (thermal), B
(convection), and C (convection with ring element) oven cavities. Two
in the series are combination models with microwaves – the
HBL57x0UC (with HMB50x0 traditional microwave) and HBL8750UC
(with HMB80x0 convection microwave).
HBL54x0UC
HBL34x0UC
HBL33x0UC
1.2
Single oven with true convection
Single oven with convection
Single oven with thermal
Features and Options
Cavity configuration and features by model appear below.
The 800 series models are stainless steel and have a glass user
interface (touch panel) with graphical displays. 500 series models are
available in black, white, and stainless, and have ergonomic,
retractable dials. The 300 series models, also available in three color
options, have ergonomic dials. Fast preheat capability, 2-hour selfclean, telescopic racks, and up to 16 cooking modes are among the
features offered.
The control panel and door skins on the stainless models are grade
304 stainless steel.
1.1
Table 1 Bosch 27” 300 and 500 Series Features by Model
Models
27” Ovens
HBN56x0UC
HBN54x0UC
HBN35x0UC
HBN34x0UC
HBN3350UC
Double oven with thermal/true convection
Single oven with true convection
Double oven with convection/thermal
Single oven with convection
Single oven with thermal
30” Ovens
HBL8750UC
HBL8650UC
HBL8450UC
HBL57x0UC
HBL56x0UC
Combo with true convection oven/convection micro
Double oven with true convection both cavities
Single oven with true convection
Combination with true convection oven /traditional micro
Double oven with true convection/thermal
Table 2 Bosch 30” 300, 500, and 800 Series Features by Model
Page 3 of 36
Service Manual for Bosch Built-in Wall Ovens
1.3
Data Plate
The data plate reflecting model number and FD number is located on
the underside of the interface control panel, as shown in Figure 1.
Bosch assumes no responsibility for any repairs made on our
products by anyone other than authorized service technicians.
Find the complete product warranty statement in the Use and Care
Manual.
2
2.1
Figure 1 Data plate location
The first 4 positions of the FD number reflect the year/month the
product was built. FD numbers that begin with 87 were built in 2007;
88 = 2008; 89 = 2009, etc.
NOTICE
Be prepared to provide the complete Model Number and FD
number printed on the data tag of the unit when contacting Bosch
Customer Support or Technical Support for assistance.
1.4
OPERATION
Element Duty Cycles
A new PID algorithm controls the way in which the elements cycle on
and off during each cooking mode duty cycle. Every minute, the oven
temperature is compared to the set point and a recalculation occurs,
which results in varied element cycle times rather than the standard
fixed 60-second cycle.
During Preheat, however, a 2-point control is still used and there is a
defined element on-time. The following table reflects the duration and
start point by Preheat mode, for cavity types A, B, and C.
Technicians should have ample time to troubleshoot element
problems during the ~10-minute preheat period.
Warranty
The product is warranted to be free from defects in materials and
workmanship for a period of 12 months from date of purchase.
Bosch will pay for all repair labor and replacement parts found to be
defective due to materials and workmanship. Service must be
provided by a Factory Authorized Service Agency, during normal
working hours.
Page 4 of 36
Service Manual for Bosch Built-in Wall Ovens
Using the data in the table, below is an example of how the elements
cycle on and off during a 60-second Preheat cycle in True
Convection mode (see Cavity C):
HBL8450UC built in 01/2008 (see columns labeled -1-)
• Bake Element: After initial 30 seconds of the cycle, element
turns on and remains on for the final 30 seconds of the cycle.
• Ring Element: After initial 30 seconds of the cycle, element
turns on and remains on for the final 30 seconds of the cycle
(same as Bake Element).
• Broil Element: Turns on at the beginning of the cycle (0) and
remains on for the first 30 seconds of the cycle.
HBL8450UC built in 08/2008 (see columns labeled -2-)
• Bake Element: After initial 33 seconds of the cycle, element
turns on and remains on for the final 27 seconds of the cycle.
• Ring Element: After initial 36 seconds of the cycle, element
turns on and remains on for the final 24 seconds of the cycle.
• Broil Element: Turns on at the beginning of the cycle (0) and
remains on for the first 27 seconds of the cycle.
In Fast Preheat (available in cavities B and C with convection fan), the
same elements reflected in the table are used, but the broil element is
on ~10% longer, and the convection fan stays on as well.
Table 3 Element duty cycles during preheat by cavity type.
2.1.1
Using Table 3 (Element Duty Cycles During Preheat)
In Table 3, Duration is defined as the number of seconds an
element is turned on (e.g., 12 indicates the element will be on for 12
seconds.) Start Point is defined as the point in the cycle at which the
element will turn on (e.g., 30 indicates the element will turn on in the
30th second of the cycle).
It is important to note that during regulation (regular cooking period
that follows Preheat), different elements may be used and element
duty cycles will vary.
2.2
Sequence of Events
Figures 2 – 5 reflect the sequence of events which occur during
Preheat for the various cooking modes.
Page 5 of 36
Service Manual for Bosch Built-in Wall Ovens
Figure 2 Sequence of Events during Preheat: Convection Bake & Roast/ Bake, Roast, Warm, Proof,
Pizza, Pie, & Sabbath modes
Figure 3 Sequence of Events during Preheat: Convection Broil/Broil modes
Page 6 of 36
Service Manual for Bosch Built-in Wall Ovens
Figure 4 Sequence of Events during Preheat: True Convection
Figure 5 Sequence of Events during Preheat: Self-clean mode
2.3
Cooling Fans
Cooling fans will run for two minutes after the oven has been shut off,
regardless of the oven temperature. After two minutes, the fan will
continue to run until the interior temperature of the cavity reaches a
maximum of 350°.
(Early models were programmed with a lower shut-off temperature,
which resulted in a longer running time for the cooling fan.)
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Service Manual for Bosch Built-in Wall Ovens
3
COMPONENT ACCESSIBILITY
3.1
Serviceable from Front
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
Door
Door latch/motor assembly
Cavity lamps
High Temperature Cutout (HTC)
Convection ring element and convection fan assembly (except
motor)
Temperature sensor
Broil element
The user interface is serviceable from the front after sliding the oven
out from the wall ~ 4 inches.
3.2
Serviceable from Top
The PC control module (relay board) is serviceable from the top
access panel after sliding the oven out from the wall ~16 inches.
With the unit pulled completely away from the wall, the following
components are serviceable from the top after removing the top
panel:
ƒ
ƒ
ƒ
3.3
Halogen light transformers
Terminal block
Power supply
Serviceable from Rear
With the unit pulled completely away from the wall and the back
panel(s) removed, the following components can be serviced from the
rear:
ƒ
ƒ
ƒ
4
SERVICE AND REPAIR
m CAUTION
9
9
9
4.1
Sheet metal parts often have sharp edges. Avoid injury by
handling these parts with care.
Turn off the electrical power circuit to the oven at the main junction
box before servicing this unit.
For those checks requiring the use of electrical power, exercise
extreme care.
Doors
On double ovens, the Bosch logo is located on the lower oven outer
door glass.
30” models ending with Customer Service Index (KI) /01 were
produced with 4-pane doors. Subsequent models have 3-pane doors.
4.1.1
Removing and Replacing the Door(s)
m CAUTION
Avoid injury when removing and replacing oven doors.
9 Be sure oven is cool enough for handling.
9 Position hinges properly (see Figure 6).
9 Grasp only by sides, not by the handle.
9 Do not force door open or closed.
9 Handle with care–door weighs ~38 pounds.
Convection fan motor
Bake element
Cooling fan(s)
Page 8 of 36
Service Manual for Bosch Built-in Wall Ovens
To remove the door…
1. Open door completely.
2. Flip hinge levers back to open as shown below.
Figure 6 Opening the hinge lever
3. Close door until it remains open ~6 inches.
4. Using both hands, lift door up and out.
To replace the door…
1. Position door as if it were open ~6 inches and insert hinges
into slots.
2. Open door completely.
3. Flip hinge levers forward to close as shown below.
4.2
Door Latch/Motor Assembly
The motorized door latch (MDL) mechanism (120V 5W) has 2
switches - the door switch and the lock/unlock switch. The latch will
automatically lock when mode and temperature selectors are set to
CLEAN, and unlock when the oven cools to ~490°F. It is serviced as
an assembly.
If the latch becomes stuck in the locked position, turning the unit off
and back on will open the latch if the cavity temperature <450°. If latch
is stuck in partially locked position, press SELF CLEAN, then ON/OFF.
The latch can be tested in Service mode.
To remove the latch/motor assembly:
1. Remove 3 T20 screws securing trim piece to frame (do not
remove 2 screws on either side of latch).
2. Pull trim forward about 1”, then slightly to the right or left to
clear the screw tab (see Figure 8).
3. Slip hands under trim and lift upper plate while sliding trim and
latch toward you.
Screw
Tab
Door
Switch
Lock/
Unlock
Switch
Figure 7 Closing hinge lever
4. Close and open door to check operation.
•
•
Hinges should be replaced in pairs.
The 300, 500, and 800 series ovens do not have serviceable
hinge receivers.
Figure 8 Door latch/motor assembly
Page 9 of 36
Service Manual for Bosch Built-in Wall Ovens
4.3
4.3.1
Lamps
The operation of the cavity lights is determined by the state of the
lights, the state of the oven, and the button(s) pressed. The table
below illustrates the results after each button press.
Current state
of lights
Upper Lower
OFF
OFF
Current state of
oven
Upper
Lower
OFF
OFF
ON
OFF
OFF
ON
ON
ON
Key(s)
Pressed
DOES NOT MATTER
UPPER+LIGHT
LOWER+LIGHT
DOES NOT MATTER
ON
OFF
OFF
ON
OFF
ON
OFF
OFF
ON
ON
DOES NOT MATTER
DOES NOT MATTER
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
ON
ON
DOES NOT MATTER
DOES NOT MATTER
ON
ON
OFF
ON
OFF
ON
OFF
OFF
ON
ON
DOES NOT MATTER
DOES NOT MATTER
LIGHT
LIGHT
LIGHT
LIGHT
LIGHT
LIGHT
LIGHT
LIGHT
UPPER+LIGHT
LOWER+LIGHT
LIGHT
LIGHT
LIGHT
LIGHT
UPPER+LIGHT
LOWER+LIGHT
LIGHT
LIGHT
LIGHT
LIGHT
UPPER+LIGHT
LOWER+LIGHT
Resulting state
of lights
Upper
Lower
ON
ON
ON
OFF
OFF
ON
ON
ON
ON
OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
ON
OFF
ON
OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
ON
OFF
OFF
OFF
ON
OFF
OFF
ON
OFF
ON
OFF
OFF
ON
OFF
Replacing Lamps
The number and type of lamps in each cavity will vary, depending on
model. Two types of bulbs are used: 10-watt, 12-volt bi-pin halogen
light bulbs or 40- (30”) or 25-watt (27”) incandescent appliance bulbs.
Handle all bulbs with a clean, dry cloth.
m CAUTION
9
9
9
Turn off power to the oven at the fuse or breaker box–light socket
is live with door open.
Be sure oven and lights are cool to the touch.
Handle glass lenses carefully.
4.3.1.1
Halogen Side Lamp (Vertical-style)
1. Remove racks and rack support.
2. Firmly push the top mounting clip up and back (toward oven
wall), until it releases the glass cover.
Top
mounting
clip
Table 4 Operation of cavity lights
The lights will automatically illuminate whenever the oven door is
opened, and turn off when the door is closed.
Figure 9 Vertical-style side lamp
Page 10 of 36
Service Manual for Bosch Built-in Wall Ovens
3. Pull the halogen bulb straight out from its socket.
4. Using a clean, dry cloth, insert the new bulb.
5. Reinsert the bottom of the glass cover (smooth side out) into
the bottom clip, and firmly push the top of the cover into the
upper clip until it snaps into place.
6. Restore power to the unit.
4.3.1.2
Halogen Side Lamp (Horizontal-style)
1. Remove racks and rack support.
2. Slide tip of flat-blade screwdriver between fixing clip and lamp
housing, while supporting lens cover along bottom edge.
Figure 11 Round halogen ceiling lamp (L); traditional lamp with 40W or 25W appliance
bulb (R).
4.4
Holder
clip
Slide screwdriver
between fixing clip
and lamp housing.
Figure 10 Horizontal-style side lamp
3.
4.
5.
6.
7.
Gently twist screwdriver to loosen the lens cover.
Remove cover and fixing clip.
Grasp halogen bulb and pull it straight out from its socket.
Using a clean, dry cloth, insert new bulb into socket.
Reinsert lens cover into the holder clip and gently push back
until fixing clip snaps into place.
8. Restore power to the unit.
4.3.1.3
Halogen Ceiling Lamp and Incandescent Cavity Lamp
1. Unscrew glass cover.
2. Pull halogen bulb straight out of its socket, or unscrew
appliance bulb.
3. Using a clean, dry cloth, insert the new bulb.
4. Replace the glass cover.
5. Restore power to the unit.
High Temperature Cutout (HTC)
The HTC is a normally closed switch which will interrupt the relay
supply voltage in the event of a high temperature event caused by a
malfunctioning control module.
The HTC is located in the plenum, behind and to the left of the MDL.
Although it cannot be easily removed or replaced, a screwdriver can
be used to reach the reset button located on the top center of the HTC
after the latch plate has been removed.
4.5
Convection Fan and Ring Element
All models except the HBL33/HBN33 and the lower cavity of the
HBL56/HBN56 and HBL35/HBN35 models, which have a thermal
oven cavity, are configured with convection capabilities in the upper
and/or lower ovens. The HBL34/HBN34 and HBL35/HBN35 models
have a convection fan only, and the remaining models with convection
cavities have both a convection fan and a convection (also called a
“ring” or “3rd”) element, which gives the ovens true (or genuine
European) convection capability.
Depending on the cooking mode selected, the fan may be used, with
or without the ring element, to circulate heat evenly throughout the
cavity in various cooking modes.
Page 11 of 36
Service Manual for Bosch Built-in Wall Ovens
The ring element (240V 2000W) and/or fan blade are easily accessed
on the rear wall of the oven cavity behind the convection baffle. The
convection fan motor is accessible only from the rear of the unit.
Refer to the Element Strip Diagram to test the element at the control
module, or
1. Remove 2 T20 screws on either side of the element terminals.
2. Pull the element toward you so that terminal wires are inside
the oven cavity.
3. Disconnect the wires from the terminals.
4. Use an ohmmeter to check for resistance of ~29 ohms.
4.6
Temperature Sensor
Use an ohmmeter to check the resistance of the sensor. Normal
ranges (based on cavity temperature) are shown in Table 5.
through the HBL8, HBL5/HBN5 menu options by pressing FAST
until the Oven temp or Probe temp option is reached. On the
HBL3/HBN3 models, press TEMP to advance through the menu.
PREHEAT
4.6.1
Setting Temperature Offsets
In some cases, it may be necessary to adjust the oven temperature if
food is consistently under- or over-cooked. Temperature offsets can
be entered by the customer from the Customer Settings or Setup
menu to raise or lower the cavity temperature during Bake,
Convection Bake, Roast, Convection Roast, and Speed Convection
modes (all heating modes which operate between 250°F and 550°F).
A +25° offset will result in a cavity temperature of 350° when the
temperature knob is set to 325° for any of the cooking modes listed
above. Similarly, a -25° offset will result in a cavity temperature of
300° when the temperature knob is set to 325°.
The adjusted temperature cannot be less than 250°F or greater than
550°F.
4.6.1.1 HBL3/HBN3
The oven must be turned off with no timer running in order to access
the menu.
Table 5 Normal temperature sensor resistance readings temperature
Real-time cavity and probe temperatures can be measured while in
Service Mode (refer to the section entitled Service Mode or the
Service Guide for instructions). After entering Service mode, advance
1. Press and hold Temp for two seconds to access the Customer
Settings menu.
2. Press Timer to advance through the menu.
3. When CS7: Oven Temperature Offset (for upper/single oven)
or CS8: Oven Temperature Offset (for lower oven) appears,
use the Settings dial to set the desired value.
4. Confirm by pressing Timer.
5. Press Temp to exit the Customer Settings menu.
4.6.1.2 HBL5/HBN5
The Cooking Mode dial and Settings dial must be in the Off position
in order to access the menu.
Page 12 of 36
Service Manual for Bosch Built-in Wall Ovens
1. Press and hold Info for two seconds to access the Setup
menu.
2. Press the arrows UV to advance through the menu to Oven
Temperature Offset.
3. Rotate the Settings dial to set the desired value.
4. Press the arrows UV to advance to the next menu item,
which will confirm the offset entry.
5. Press Info to exit the Setup menu.
Note: for double ovens, an offset can be entered separately for each
oven by selecting either Up. Offset or Lo. Offset from the menu.
2. Remove the 2 T20 screws on either side of the element
terminals.
3. Pull the element toward you so that the terminal wires are
inside the oven cavity.
4. Disconnect the wires from the inner broil element terminals.
5. Use an ohmmeter to check for resistance of ~16 ohms.
4.8
User Interface
Figure 12 reflects the variations of the B1, B2, and B3 user interfaces
used in the Bosch ovens.
4.6.1.3 HBL8x50
The oven must be Off in order to access the menu.
1. Press and hold Info for two seconds to access the Setup
menu.
2. Press the arrows UV to advance through the menu to Oven
Temperature Offset.
3. Press + and – to set the desired value.
4. Press the arrows UV to advance to the next menu item,
which will confirm the offset entry.
5. Press Info to exit the Setup menu.
Note: for double ovens, an offset can be entered separately for each
oven by selecting either Up. Offset or Lo. Offset from the menu.
4.7
Broil Element
All Bosch models have a recessed 10-pass (240V 3600W) broil
element.
Refer to the Element Strip Diagram to test the element at the control
module, or
1. Remove the 2 T20 screws securing the element to the broil
reflector.
Page 13 of 36
Service Manual for Bosch Built-in Wall Ovens
The user interface control board is assembled onto a chassis and the
entire assembly is serviced as a single unit.
4.8.1
Removing the User Interface
1. Slide unit out from wall ~ 4 inches.
2. Remove 2 T20 bolts from each side.
3. Grasp one corner of the interface panel and lift upward, then
pull it toward you (see Figure 13).
4. Repeat on the other side.
5. Disconnect the 3-wire yellow harness leading to PC control
module.
1
2
Figure 13 Each side of the user interface bracket has a tab n that rests in a slot on the
chassis u-profile o.
To remove the user interface board and chassis from the manifold
bracket, remove the 10 binding-head T20 screws securing the
interface chassis to the bracket (these screws are unique to the
interface – notice the serrated underside).
If the user interface assembly was difficult to remove, break the metal
tabs off (n) to make it easier to reinstall; use pliers to bend the tabs
back and forth until they break off.
Figure 12 Bosch user interfaces
Page 14 of 36
Service Manual for Bosch Built-in Wall Ovens
After installing a new user interface board, always reset the oven and
test.
4.9
PC Control Module (Relay Board)
To access the PC control module, pull the unit out from the wall 15-16
inches, and remove the access panel (3 T20 screws) on the top of the
unit. See Figure 14.
Figure 14 PC Control Module is visible after removing access panel.
Whenever possible, conduct troubleshooting tests at the control
module. Refer to Figures 15 -16 for plug and relay locations.
Rear
X102
X101
X103
X104
X105
X106
X107
X209
X1
X2
X110
X210
X204
X203
X3
X202
X201
X205
Front
X206
X207
Figures 16 Relay locations on the double oven control module
NOTICE
Figure 15 Plug locations on the double oven control module
More than 75% of the control modules returned to the factory are fully
functional. Before diagnosing a bad control module, be sure to
disconnect and reconnect each wire/wire harness.
Page 15 of 36
Service Manual for Bosch Built-in Wall Ovens
Use Table 6 as a reference guide to the plugs, pins, and wire colors
found on the PC control module.
PLUG
NO
X1
X2
X3
X108*
X101
PIN NO
X103
X104
FROM/TO
COMMUNICATION
5-position card-edge
Control Module to Power Supply Module
connector - WH
3-position card-edge
Control Module to User Interface Module
connector - YE
3-position card-edge
Control Module to Factory Service Port
connector - YE
2-position card-edge
Control Module to Meat Probe
connector - WH/GN
UPPER/SINGLE CAVITY ELEMENTS
1-OR
K102 Relay to Bake Element
X110
PIN NO
FROM/TO
3-Blank
N/A
4-BK
L1 to K106 Relay
5-BK
L1 to K106 Relay
6-Blank
N/A
7-Not Used
N/A
8-YE
K106 Relay to Broil Element
1-BU
High Temperature Cutout (HTC)
2-Not Used
N/A
3-BU
High Temperature Cutout (HTC)
UPPER/SINGLE CAVITY SMALL LOAD
X105
1-Blank
N/A
L1 to K102 Relay
2-YE
K112 Relay to Convection Fan
3-Blank
N/A
3-BU/WH
K114 Relay to Cooling Fan (L)
4-BK
L1 to K104 Relay
4-BU
K115 Relay to Cooling Fan (H)
5-Blank
N/A
5-BN
K115 to Light Transformer
6-BU**
K104 Relay to Ring Element
6-Blank
N/A
1-YE
K003 DLB Relay to Broil Element
7-BN
K117 Relay to Motorized Door Latch (MDL)
2-Not Used
N/A
8-RD
L2 to K117 Relay
3-Blank
N/A
1-YE
Door Switch
4-RD
L2 to K003 DLB Relay
2-YE
Door Switch
5-RD
L2 to K003 DLB Relay
3-Not Used
N/A
1-BU**
K002 DLB Relay to Ring Element
4-YE/BK
Latch Switch
2-RD
L2 to K002 DLB Relay
5-OR/BK
Latch Switch
3-Blank
N/A
6-VT/WH
Door Switch
4-RD
L2 to K001 DLB Relay
5-Blank
N/A
6-OR
2-BK
X102
PLUG
NO
X106
7-BN/WH
Door Switch
1-WH
Hall Effect Sensor
K001 DLB Relay to Bake Element
2-BK
Hall Effect Sensor
7-Blank
N/A
3-RD
Hall Effect Sensor
1-Blank
N/A
4-WH
Temperature Sensor
2-Blank
N/A
5-WH
Temperature Sensor
X107
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PLUG
NO
X110
PIN NO
FROM/TO
1-BU
High Temperature Cutout (HTC)
2-Not Used
N/A
3-BU
High Temperature Cutout (HTC)
PLUG
NO
X202
X203
X204
X210
FROM/TO
3-BU
High Temperature Cutout (HTC)
LOWER CAVITY SMALL LOAD
X205
LOWER CAVITY ELEMENTS
X201
PIN NO
1-YE
K212 Relay to Convection Fan
2-RD
L2 to K217 Relay
1-BU **
K204 Relay to Ring Element
3-BN
K216 to Light Transformer
2-Blank
N/A
4-Not Used
N/A
3-Blank
N/A
5-Not Used
N/A
4-BK **
L1 to K204 Relay
6-BN
K217 Relay to Motorized Door Latch (MDL)
5-BK
L1 to K202 Relay
1-YE
Door Switch
X206
6-Blank
N/A
2-YE
Latch Switch
7-OR
K202 Relay to Bake Element
3-YE/BK
Latch Switch
1-RD
L2
4-OR/BK
Latch Switch
2-RD
L2 to K006 DLB Relay
5-Not Used
N/A
3-Not Used
N/A
6-VT/WH
Door Switch
4-Not Used
N/A
5-YE
K006 DLB Relay to Broil Element
1-OR
K004 DLB Relay to Bake Element
2-Not Used
N/A
2-Not Used
N/A
3-WH
Temperature Sensor
3-RD
L2 to K004 DLB Relay
4-RD
Hall Effect Sensor
4-Blank
N/A
5-BK
Hall Effect Sensor
5-RD **
L2 to K005 DLB Relay
6-WH
Temperature Sensor
6-Blank
N/A
1-BU/WH
X105-P3 to Cooling Fan (L)
2-BU
X105-P4 to Cooling Fan (H)
7-BU **
K005 DLB Relay to Ring Element
1-YE
K206 to Broil Element
2-Not Used
N/A
3-Blank
N/A
4-BK
L1 to K206 Relay
5-BK
L1 to K206 Relay
1-BU
High Temperature Cutout (HTC)
2-Not Used
N/A
X207
X209
7-BN/WH
Door Switch
1-WH
Hall Effect Sensor
* Not used on HBL3, HBN3
** HBL8, HBL5, HBN5 only
Table 6 Plugs and pins on the PC control module
To remove the PC control module…
1. Disconnect all wires.
2. Remove 1 T20 screw securing control module to chassis.
3. Slide module to the left to release the 3 tabs on the bottom of
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the module bracket from the 3 slots in the chassis.
Always reset the oven and test after changing the control module. In
some cases, a second reset may be necessary.
4.10
Power Supply Module
The power supply module (9.6V 12.5W) provides DC voltage to the
control module and user interface.
4.11
4.12
The convection fan motor is 120V 29W. To test the motor, check for
120V across X105 / Pin 2 (upper/single) or X205 / Pin 1 (HBL8650)
and chassis ground or neutral.
The motor is accessible from the rear, after removing the rear outer
sheet metal panel.
1. Disconnect the 2 wires from the motor terminals.
2. Remove 3 T20 screws from the arms of the motor assembly.
3. Use a tap and a hammer to dislodge the assembly from the
clips that secure it to the rear of the unit. (Position tap on the
arm secured by the rightmost clip.)
Halogen Light Transformer(s)
One transformer (120V-12V 40VA) is utilized per cavity. Triac
switches 120 VAC to the transformer. There are 4 terminals on the
new transformer, as shown in Figure 16.
The resistance between the primary terminals should measure ~12.8
ohms and the resistance between the secondary terminals should
measure ~0.32 ohms.
Secondary
LINE
Terminals
Convection Fan Motor
4.13
Bake Element (Upper Oven)
Refer to the Strip Element Diagram to test the element (240V 2000W)
at the control module, or disconnect the wires from the terminals and
use a meter to check for a reading of ~29 ohms.
To clear a path for removing the bake element, it is necessary to
remove the vertical air channel(s) and disconnect wires. Before
proceeding, note the position of the wires.
Primary
LOAD
Terminal
4.13.1
Removing the Bake Element
1. Pull wires out of plastic purse locks attached to upper and
lower vertical air channels.
2. Remove upper air channel (4 T20 screws).
3. To create a pathway for the bake element, disconnect OR
BN
X105-6
X205-4
OR
LINE
WH
Terminal
Block
LOAD
OR
wires from upper and lower bake element terminals; YE from
convection element terminals, BU/WH, BU, and WH from
cooling fan motor.
4. Drape the wires/harnesses to the side so they do not block the
element as it is pulled out.
5. Remove the screw between the element terminals.
Figure 17 Halogen light transformer
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6. Tuck insulation up into the oven wall as necessary.
7. While holding element terminals, lift element upward to clear
the outer edge of the compartment.
8. Hold element on both sides and lift upward as you slide it
straight out.
4.13.2
If the Hall effect sensor does not detect fan rotation, an error will
display. To test the upper fan at the control module, check voltage
across X105 / Pin 3 or 4 and neutral.
1. Remove 3 T20 screws securing the fan to the mounting
bracket.
2. Remove 3 T20 screws securing the bracket to the oven
housing.
3. Slide bracket up and out to release it from the 2 tabs holding it
in position.
4. Remove 3 T20 screws from the right side of the unit’s top
panel.
5. Lift the right corner of the top panel and remove the fan/motor.
Reinstalling the Bake Element
There are 2 tabs inside the element cavity, and the front tab will
prevent the element from going in all the way. Use a ruler or the
vertical air channel (after removing plastic purse locks) as a tool to
guide the element back in.
1. Place the tool inside the cavity, on top of the tab, then insert
the element on top of the tool and slide it in.
2. After the element is beyond the front tab, remove the tool.
3. Complete the installation.
4. Replace the plastic purse locks clips if they were removed
from the vertical air channel.
4.14
Cooling Fan Motor (Upper Oven)
5
ERROR CODES
A Service Guide with error code information, wiring diagrams, and
instructions for entering Service mode (if applicable) is packed with
every unit. Find it on the underside of the upper plenum access panel
as shown in Figure 19.
Each 2-speed cooling fan (120V 28/41W) has 3 terminals (high
speed, low speed, and neutral) and a Hall effect sensor. There is tape
around the motor windings and the terminals are labeled N, H, and L
for reference, as shown in Figure 18.
Figure 19 Location of Bosch Built-in Oven Service Guide
5.1
Figure 18 Tape on cooling fan windings marked to designate terminals
Error Code Table
The following table is included in the oven Service Guide. The error
codes which begin with E2 apply to the lower cavity of double ovens.
Diagrams referenced in the table can also be found in the appropriate
Service Guide.
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CODE
E000
DESCRIPTION
Wrong module combination
E003
Electronics too hot
E005
Communication error
E009
ROM check error in user interface
E010
E011
Data memory error in user interface
Continuous pushing of single key
E012
Defective User Interface PCB temp.
sensor
ON/OFF key does not work
Continuous pushing of keys
E014
E032
E101/E201
E104/E204
E106/E206
E107/E207
E115/E215
E116
Cvt 1/Cvt 2 Temp. sensor open
Cvt 1/Cvt 2/Temp. sensor shorted
Cvt 1/Cvt 2 Door latch does not lock
Cvt 1/Cvt 2 Door latch does not
unlock
Cvt 1/Cvt 2 Temp. in unlocked cavity
too high
Cvt 1/Cvt 2 Probe error
CAUSE/ACTION
Control module and user
interface are mismatched. Set
Option Code properly.
User interface exceeds
185°F/85°C
Loss of communication
between user interface and
control module at start-up.
Check for ~4.9Vdc on middle
pin of communication
harness. Check connections
of all communication lines
and control module inputs.
User interface not getting all
information from control
module at start-up. Check for
loss of communication or
disconnected wire
somewhere in unit
Check user interface
assembly. Inspect touch
PCB.
10 seconds of multiple keys
being pressed.
Refer to Diagram 2/4
Refer to Diagram 2/4
Refer to Diagram 2/4
Refer to Diagram 2/4
Standard probe module is
part of the control module.
Refer to Diagram 1.
CODE
E118/E218
DESCRIPTION
Cvt 1/Cvt 2 Cooling fan supervision
error
E122
E123
E124/E224
Cvt 1/ Probe sensor temp. too high
or shorted.
Cvt 1/ Probe sensor temp. too low
Cvt 1/Cvt 2 Door switch error
E126/E226
Cvt 1/Cvt 2 Door latch error
E303
Electronics too hot
E309
E310
E312
ROM Check error in control module
Data memory error in control module
Defective control module PCB temp.
sensor
CAUSE/ACTION
Cooling fan speed is too low
or too high. Refer to Diagram
2/4. Ensure wire harness not
touching motor or pinched.
Confirm plenum not touching
fan end cap. Check Hall
Effect Sensor connection.
Check probe receptacle and
harness.
Door switch is in undefined
state. Refer to Diagram 2/4.
Door latch is in an undefined
state. Refer to Diagram 2/4.
Control module exceeds
212°F/100°C.
Table 7 Error codes
5.2
Service Mode / Setting Option Code
When both the user interface board and control module (relay board)
are replaced, the oven will display E000 (Wrong Module Combination)
fault code at start-up. To resolve, place the unit in Service Mode and
manually set the Option Code.
5.2.1
HBL3/HBN3
To enter service mode…
1.
Press and hold TEMP.
2.
Press and hold COOK TIME.
3.
Rotate the Cooking Mode dial out of the OFF position.
4.
Release the two buttons.
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To set the option code…
4.
Locate the 4-digit code on the label near the PC Control
Board in the upper plenum or in Table 8 below.
5.
Set the Option Code by rotating the Settings dial.
Figure 20 HBL3/HBN3 User interface
To set the option code…
5.
Locate the 4-digit code on the label near the PC Control
Board in the upper plenum or in Table 8 below.
6.
Press TEMP to advance to the Option Code (OC) screen.
7.
Press COOK TIME.
8.
Rotate the Settings dial to change the code.
To exit service mode…
9.
Rotate the Cooking Mode dial to the OFF position.
10. Rotate the Settings dial to set the time.
To exit service mode…
6. Rotate the (upper oven) Cooking Mode dial to the OFF
position.
7. Rotate the Settings dial to set the time.
8. Press
and rotate the Settings dial to set the date. (See
Use and Care Manual for further information about setting time
and date.)
To reset the oven…
9. Unplug the unit or turn the power off at the circuit breaker for
30 seconds.
10. Set the current time and date (see 7 and 8 above).
5.2.3
To reset the oven…
11. Unplug the unit or turn the power off at the circuit breaker for
30 seconds.
12. Rotate the Settings dial to set the time.
5.2.2
HBL5/HBN5
HBL8
To enter service mode…
1.
Press and hold START.
2.
Press and hold FAST PREHEAT.
3.
Press ON/OFF.
4.
Release all three buttons.
E000
To enter service mode…
1.
Press and hold START and FAST PREHEAT.
2.
Rotate the Cooking Mode dial out of the OFF position.
3.
Release the two buttons.
Wrong
Figure 22 HBL8 User interface
To set option code…
5.
Locate the 4-digit code on the label near the PC Control
Board in the upper plenum or in Table 8 below.
6.
Press FAST PREHEAT to advance to the Option Code
menu selection.
Figure 21 HBL5/HBN5 User interface
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Service Manual for Bosch Built-in Wall Ovens
7.
8.
Follow the instructions on the oven display and enter the
appropriate code.
To confirm the change after the code has been entered,
press FAST PREHEAT to advance to the next menu item.
7
TROUBLESHOOTING
Use the Fault Tree Diagram and Fault Tree on the following pages to
guide troubleshooting efforts.
To exit service mode…
9.
Press ON/OFF to exit Service Mode.
10. Follow the instructions on the display to set the time and the
date.
To reset the oven…
11. Unplug the unit or turn the power off at the circuit breaker for
30 seconds.
12. Follow the instructions on the display to set the current time
and date.
Always confirm that the error has been cleared and the oven is
functioning normally after setting the option code.
5.3
Option Codes
Model
HBL33
HBL34
HBL35
HBL54
HBL56
HBL57
HBL84
Option Code
0150
0250
0750
0351
0851
0351
0351
Model
HBL86
HBL87
HBN33
HBN34
HBN35
HBN54
HBN56
Option Code
0951
0351
0140
0240
0740
0341
0841
Table 8 Bosch option codes
6
DEMO MODE
The display and lights will work on 120VAC when the black and red
wires are tied together.
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7.1
Fault Tree Diagram
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7.2
Fault Tree
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7.3
Testing
Test with wire harness off at pin header or with circuits open.
Plug
X102
and
X103
Pins
4, 5
X105
7
2, 4
Operates
Upper oven
double line break
relay coil
Upper door latch
motor
X105
6
X105
1
Upper oven
convection motor
Rotisserie motor
X106
1 (common),
6, 7
Upper oven door
latch
X107
4, 5
Upper oven
sensor
X107
1, 2, 3
Cooling fan
motors
X207
1,4,5
X202
and
X203
1, 2
X205
6
X205
3, 5
1
Lower oven
double line break
relay coil
Lower door latch
motor
Lower oven
convection motor
Explanation
No fail code. If double line break relay
does not close, L2 (120 volts) will not
reach upper oven bake, broil,
convection elements.
Will accept all modes except selfclean. When oven set to self-clean,
display will be on constantly, doors
will not lock and self-clean will not
start. E106 will appear.
No fail code. Lower oven convection
motor will not work.
No failure code. Rotisserie will not
rotate.
If latch position is not detected during
normal operation, E124/126 will be
displayed.
Controls function normal. When
sensor opens, E101 code will appear.
If sensor shorts, E104 will appear.
Cooling fan is on constantly.
Will accept modes. In ~45 seconds,
E118 will appear in upper oven
display or E218 will appear in lower
oven display when hall sensor does
not detect fan rotation.
No fail code. If double line break relay
does not close, L2 (120 volts) will not
reach lower oven bake, broil,
convection elements.
Will accept all modes except selfclean. When oven set to self-clean,
display will be on constantly, doors
will not lock and self-clean will not
start. E206 will appear.
No fail code. Lower oven convection
motor will not work. Relay will snap
closed.
Plug
X206
Pins
1 (common),
6, 7
Operates
Lower oven door
latch
X207
3, 6
Lower oven
sensor
X2
Sends display
signal to display
X2
Sends
communication
signals to display
Explanation
If latch position is not detected during
normal operation, E224/226 will be
displayed.
Control functions normal. When
sensor opens, E201 code will appear.
If sensor shorts, E204 will appear.
Cooling fan is on constantly.
Glass control panel is completely
dead. 3-position connector
(ground/voltage/data line) should
measure 9.6 VDC.
If no communication between
electronic modules, E005 will display.
Connector positions 1-2 should
measure ~5 VDC.
Table 9 Troubleshooting
8
WIRING DIAGRAMS AND SCHEMATICS
The wire color key (Table 10) and element strip diagrams (Figures 2324) are shown below. For schematics, please refer to the Built-in
Oven Service Guide (Wiring Diagram) which can be found on
QuickFinder or in the upper oven plenum, near the control module.
8.1
Wire Color Key
BK
GN
VT
BN/WH
VT/WH
Black
Green
Violet
Brown/White
Violet/White
BN
OR
WH
BU/WH
YE/BK
Brown
Orange
White
Blue/White
Yellow/Black
BU
RD
YE
OR/BK
Blue
Red
Yellow
Orange/Black
Table 10 Wire color key
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Service Manual for Bosch Built-in Wall Ovens
8.2
Strip Diagrams
9
ADDITIONAL REFERENCES
9.1
QuickFinder
For further information, please refer to the following documents on
QuickFinder:
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
Figure 23 Upper (Cavity 1) / Single oven strip diagram
ƒ
ƒ
Wiring Diagram (Built-in Oven Service Guide)
Installation Instructions
Use and Care Manual
HMB8020/8050/8060 Convection Microwave Use and Care
Manual
HMB8020/8050/8060 Convection Microwave Installation
Instructions
HMB8020/8050/8060 Convection Microwave Service Manual
HMB5020/5050/5060 Traditional Microwave Use and Care
Manual
HMB5020/5050/5060 Traditional Microwave Installation
Instructions
HMB5020/5050/5060 Traditional Microwave Service Manual
Exploded views, parts lists, and related service and parts notes are
also available on QuickFinder. Visit http://portal.mch.bshg.com/portal.
NOTICE
Not all service parts are shown on the QuickFinder exploded
views; review the parts list for additional information.
9.2
Technical Support
To reach Bosch technical support, call the toll free TechLine at
Figure 24 Lower (Cavity 2) oven strip diagram
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888 522-6724. Technicians are available to assist you Monday –
Friday, between the hours of 5am and 5pm, Pacific Time.
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Notes
58300000139357 ARA EN B
BSH Home Appliances Corporation
5551 McFadden Ave., Huntington Beach, CA 92649
February 2009
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