Bosch WTVC SERIES Setup guide

W
W
WT
T
TV
V
VC
C
C G
G
GA
A
AS
S
S D
D
DR
R
RY
Y
YE
E
ER
R
R R
R
RE
E
EP
P
PA
A
AI
I
IR
R
R I
I
IN
N
NS
S
ST
T
TR
R
RU
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UC
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CT
T
TI
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IO
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ON
N
N
1SAFETY ........................................................ 2
2INSTALLATION............................................ 3
2.1 Basic installation ................................................................ 3
2.2 Exhaust vents...................................................................... 3
2.3 Feet (leveling legs).............................................................. 3
2.4 AQUASTOP®(aqua secure)................................................ 4
2.5 General installation warnings ............................................ 4
3OPERATION................................................. 5
3.1 Controls ............................................................................... 5
4COMPONENTS............................................. 6
4.1 WTVC Gas Dryer Components .......................................... 6
4.2 Operation ........................................................................... 14
5REPAIR....................................................... 15
5.1 Disassembly / Reassembly .............................................. 15
5.2 Kit Installation ................................................................... 25
5.3 Diagnosing (troubleshooting).......................................... 26
5.4 Dryer noise ........................................................................ 27
5.5 Customer diagnosing ....................................................... 27
5.6 Maintenance ...................................................................... 28
6FAULT DIAGNOSTICS............................... 29
6.1 Overheating fault codes ................................................... 32
7TECHNICAL SPECIFICATIONS ................ 33
7.1 Dryer ratings ..................................................................... 33
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1 SAFETY
cDanger of electric shock.
hDanger of fire or explosion from gas.
hWARNING Modern appliances are very powerful and use high
technology devices to safely control that power. Failure to use
the correct procedures and the approved parts can create
serious hazards for the person servicing the appliance and for
the user of an appliance with a bad repair. If you do not know
how to service the appliance, do not attempt to do so!
To avoid the risk of serious injury or death while servicing these
appliances:
hBe certain that all power is removed from the appliance before
beginning service.
hCarefully follow all servicing instructions. Verify the instructions
if there are any that you don't fully understand.
hRead and heed all Cautions and Warnings on the appliance
and those with the replacement parts.
hUse caution and proper protective gear when handling chassis
panels. Some of the edges that are not normally exposed may
be very sharp.
To avoid risk of serious injury or death to the users of the appliances:
hCarefully follow all service instructions.
hUse only parts authorized for the application.
hKnow the testing requirements needed to verify the safety of
the service action.
hUse proper, calibrated test equipment.
hDo all indicated safety tests and record results.
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2 INSTALLATION
2.1 Basic installation
Dryers shall be installed according to national and local codes.
2.2 Exhaust vents
2.2.1 Locating exhaust vent
Vent is factory installed to the rear of dryers. Rear factory vent can be
changed to the bottom or right side using kits (sales accessories).
2.2.2 Installing vent ducts
For best drying, use shortest possible duct length and fewest # of
elbows.
Use the table below when selecting ducting.
# 90º Turns / Maximum Length
Elbows Rigid Duct Flexible Duct
0 20 m 14 m
1 17 m 11 m
2 14.5 m 9 m
3 12 m 7 m
4 9 m 5 m
2.3 Feet (leveling legs)
Using a level front to back and side to side, adjust feet (leveling legs)
until dryer is level. When moving dryers, screw in feet completely
before moving dryers to avoid damage.
To adjust feet (leveling
legs), rotate left to right to
lower dryer.
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2.4 AQUASTOP®(aqua secure)
AQUASTOP®water inlet hoses prevent water from leaking. They
connect like standard hoses with no special installation needed. If an
inner hose ever should leak, the hose shuts off and it’s indicator
shows red. Hoses are one-time and must be replaced when
indicators are red.
2.5 General installation warnings
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3 OPERATION
3.1 Controls
Controls are shown below. Rotate the knob to the desired drying
program and push the Start/Pause button.
There are option buttons for delicate fabrics and saving energy. Dryer
status is shown in LED’s at the left of the display.
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4 COMPONENTS
4.1 WTVC Gas Dryer Components
Basic components are control module, gas burner, gas igniter, flame
sensor, drive motor with fan, two NTC temperature sensors, two hi-
limit temperature protectors, moisture sensor and broken belt switch.
Gas dryers are set up for natural gas and can be converted to LP
using a kit (WTZ1280).
4.1.1 Gas burner assembly
Burner assemblies include an NTC temperature sensor and a
manually resettable hi-limit temperature protector. The NTC is
mounted at the rear of the assembly near where it attaches to the
vent.
B
Bu ur rn ne er r
c
ch ha am mb be er r
Gas
valve
B
Bu ur rn ne er r
(
(v ve en nt tu ur ri i) )
F
Fl la am me e
s
se en ns so or r
I
Ig gn ni it te er r
H
Hi i- -l li im mi it t
B
Bu ur rn ne er r
c
ch ha am mb be e
r
r
B
Br ro ok ke en n b be el lt t
s
sw wi it tc ch h
F
Fr ro on nt t ( (b be ea ar ri in ng g) )
s
sh hi ie el ld d
M
Mo ot to o
r
r
Fan
Gas
valve
Push
button to
reset Hi-limit
red
Hi-
limit
p
rotector.
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4.1.2 Drive motor
4.1.3 Gas valve
The gas valve, whether natural gas or LP, includes the appropriate
regulator and jet (orifice).
4.1.4 Burner
The burner mounts next to the gas valve jet (orifice). A burner ring is
used for natural gas dryers to optimize performance.
The gas dryer burner circuit runs through the motor & Hi-limit. The
connection through the motor cuts out the burner if the motor isn’t
running.
Motor is rated 120
VAC, 60 Hz, 1/3 HP
(248.5 W), 5.0 A,
1725 RPM, 40ºC
ambient, class B
insulation. It drives
the fan (in front) and
drum (in rear, using
pulley shown).
Drum
belt
pulley
Fan
wheel
shaft
Burner
G
Ga as s v va al lv ve e
4.1.5 Gas leak testing (using soapy water)
Whenever gas connections are changed or disturbed, they should be
checked for leaks using a soapy water solution.
1. Reconnect all gas connections and turn on the gas supply to
the dryer, using household gas inlet pressure.
2. Apply soapy water solution with a spray bottle. Spray union
and brass connections completely.
3. Watch connections carefully for about two minutes. If there is a
leak, bubbles will form in the area of the leak. Soapy water will
not stay on connections long, so spray more solution on them
when soapy water isn’t visible.
4. If bubbles form around the union, tighten the connection and
repeat steps 3 and 4 until no bubbles form.
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5. If bubbles form around the brass connector or on the gas valve
itself, replace the leaking valve with a new one and repeat
steps 3, 4 and 6.
6. Clean all soapy water solution with a rag or paper towel.
7. Never use a flame to check for gas leaks!
4.1.6 Igniter
Igniters glow after
4.1.7 Flame sensor
Flame sensors detect flame out in 30 – 60 seconds and direct the
igniter to reignite flames.
4.1.8 Lint screen sensors
The front (bearing) shield contains two sensors – accessible after the
lint screen is removed. Along with the heater NTC and hi-limit
protector, the lint screen NTC and hi-limit protector provide
temperature regulation and safety.
30 seconds, reliably igniting gas flames.
Igniters can be damaged if not handled with care.
Hi-limit NTC
Hi-limit
NTC
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4.1.9 Broken belt switch
The broken belt switch prevents the dryer from running if the belt has
broken or been left disconnected. It must be manually reset (by
pushing the left plunger in (viewing rear of dryer) – the dryer will not
run if the switch hasn’t been reset.
4.1.10 Air exhaust duct
Air exhaust duct connects to the fan and allows exhausting through
the rear of dryers. Using kits (sales accessories), dryers can be
vented out the bottom or right side.
Fan
Vent
Push left plunger (toward
right) to reset broken belt
switch whenever drum or
belt has been removed for
any repair.
4.1.11 Fascia (control) panel
Fascia panel includes the knob, which is factory built into the panel
and cannot be obtained separately. Buttons can be obtained
separately.
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4.1.12 Moisture sensor
Moisture sensor consists of two electrodes (located just left of the lint
screen on the front bearing shield). Moisture from clothes completes
the circuit between the two sensors, showing clothes aren’t dry.
Placing the moisture sensor on the front shield eliminates sensors
inside drums and conductance brushes outside drums.
4.1.13 Door switch
Door switch engages the door, turning the light on and off and
notifying the dryer the door is closed for drying. To remove it, push
the two latches inward and slide the switch toward the front of the
dryer.
4.1.14 Fan wheel replacement
Even though WTVC and WTMC dryers use the same fan motor, they
do not use the same fan. Due to differing front bearing shield and lint
screen dimensions, air flows differently through the two dryers. Dryer
control software for each dryer is carefully matched to each fan to
provide the same drying results.
WTMC fan 491640 hasn’t been tested in
WTVC dryers and WTVC fan 648683
hasn’t been tested in WTMC dryers.
Fans must not be interchanged because
it will void the warranty, will affect the UL
certification, will affect drying and may
generate error codes.
4.1.15 Mist care (on selected dryers)
Mist care (on selected dryers) sprays a mist of water into dryers to
refresh clothing and relax any wrinkles. Water sprays occasionally as
needed, determined by the control.
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A cold water inlet valve similar to washers is used.
A 90º elbow connects the hose to the nozzle (through a hex adapter).
It can be accessed by removing the front panel.
Dryers come with a “Y” adapter, allowing the cold water line to be split
and connected to both washer and dryer.
4.1.16 AQUASTOP®(aqua secure) inlet hoses
Hot and cold water AQUASTOP® inlet hoses eliminate leaking. The
AQUASTOP®hose consists of an inner hose (~ inlet water tubing)
and an outer hose (corrugated, ~ to drain hoses). If the inner hose
leaks, a small indicator window will show red, meaning the hose must
be replaced (hoses cannot be reused once a leak occurs).
AQUASTOP®hoses can be used with any washer (or misting dryer)
with standard US threads (3/4” NH, 11.5 threads/inch). They protect
homes and provide peace of mind for people on vacation and those
asleep, busy or who don’t shut off water valves when washers (and
misting dryers) aren’t in use.
Cold
water
inlet
valve
Indicator
window
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4.1.17 Round button assembly
The three (3) round buttons are joined by delicate plastic rods. Be
careful installing or removing buttons so button joining rods aren’t
broken.
4.1.18 Door glass cover
Complete door assemblies are not available. However, all door
components can be readily disassembled and replaced, including the
outer door glass cover and inner glass bowl.
4.1.19 Front felt drum seal
Dryers have a self-adhesive, Teflon coated, felt front seal which can
be replaced. When replacing the seal, make sure all old adhesive is
removed and no new adhesive gets onto the drum. Any excess
adhesive or residue may cause squeaking.
If the seal doesn’t fit snugly against the drum, it can be reshaped.
After the seal is attached to the drum, wet the seal thoroughly using a
spray bottle. Shape the seal toward the drum and run the dryer 20
minutes on a heated timed dry setting. Since felt shrinks when dried
rapidly, the seal will shrink to the drum and fit it snugly.
Felt seal
Drum wheels
4.1.20 Empty drum detection
Dryers shut down after 11 minutes if no moisture is detected. Dryers
can be immediately restarted.
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4.1.21 Wrinkle Block/Finished light
If the Wrinkle Block/Finished light is on while the display is off, an
internal switch (S3) on the control board has been damaged and the
entire control module has to be replaced.
4.1.22 Serial # label
The serial # label is located below the door and shows the model (E-
Nr) and serial # of the dryer.
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4.2 Operation
4.2.1 Gas burner operation
•Starting (& flame out) – Cool flame sensor is closed, which
bypasses secondary coil & turns on igniter & holding/booster
coils (to open dual valve). Secondary coil is off (so no gas
flows to burner). Igniter current is ~ 4 A.
•Running – Igniter heats up & opens flame sensor, which turns
off igniter & turns on secondary coil (so gas flows to burner).
Hot igniter ignites gas – flames keep flame sensor open.
Booster coil turns off since current flows thru secondary coil &
igniter (~ .1 A) – holding coil stays energized to keep gas
flowing.
4.2.2 AQUASTOP®(aqua secure) hose operation
The AQUASTOP®hose consists of a sealed inner and outer hose and
a leak detection / shut-off assembly. A spring holds a plunger open
allowing the inner hose to carry water. If an inner hose ever should
leak, water fills the outer hose where a sponge in the hose end
(connected to the water line) absorbs water, pulling a plunger down to
stop water flow and show red in the indicator window. The outer hose
is sealed and won’t leak.
Any remaining water pressure won’t re-open the hose, but will help
keep the hose closed.
The hose has a one-time failure duty. If an inner hose should ever
leak where the indicator shows red,the hose must be replaced.
AQUASTOP®hoses stop hose leaks, whether appliances are on or
not. They’re superior to braided hoses, whether nylon or ss, and can
be used with any washer (or misting dryer) with standard US threads
(3/4” NH, 11.5 threads/inch).
L
(120V)
N
Gas
valve
Igniter
Flame sensor (N.C.)
2n
d
ary
coil
Booster coil
1
2
3
4 5
1
G
Ga as s B Bu ur rn ne er r
C
Ci ir rc cu ui it t
Holding coil
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5 REPAIR
5.1 Disassembly / Reassembly
5.1.1 Top panel (worktop)
Remove two T-20 Torx screws (with washers) from top rear corners of
dryer, slide panel toward rear of dryer (~ ½ cm) and lift up panel.
When reassembling, slide panel forward and replace two screws.
5.1.2 Fascia (control) panel
Panels are held in place by plastic latches – no screws need to be
removed.
Remove top panel (5.1.1), then gently pry up top plastic latches.
When top latches are released, gently pull the panel straight out until
the bottom tabs release. Don’t tilt the panel to avoid breaking the
bottom tabs.
5.1.3 Control module
Remove control module from fascia panel progressively from left to
right, carefully releasing all plastic latches (so latches don’t break).
Gently pry up left side of control so latches don’t re-close. Control will
release from fascia panel and knob.
There are other latches, joining the control module housing together,
which don’t need to be released to remove the control module.
Don’t remove the knob to remove the control module. The control lifts
off completely from the panel, knob & buttons.
Don’t force controls out from fascia panels to avoid breaking plastic
parts. If modules don’t come out easily, the procedure hasn’t been
followed and plastic parts will break.
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Don’t cut cable mounts – cut cable
ties holding cables to mounts.
When reassembling, use new
cable ties.
Some controls have been wrongly replaced since fault codes stored in
washer or motor controls can’t be cleared. Controls are operating
properly and shouldn’t be replaced to clear fault codes.
5.1.4 Button caps (round / rectangular)
All button caps don’t snap onto buttons, but fit loosely – held in place
by the control after reassembly. When reassembling fascia (control)
panels, set panels face down so button caps don’t fall out.
5.1.5 Round button assembly
The (clear) round button assembly is connected by delicate plastic
rods. When removing buttons, gently pry out and remove them as a
group, not individually.
mCAUTION – 75% of all controls
returned for analysis check out OK. Most
control issues are due to loose
connections.
5.1.6 Bottom front panel (“toe kick”)
Removing the bottom front panel provides access to the maintenance
cover and is necessary for removing the front panel.
Carefully lift and block (up) front of dryer (to provide access to
screws). Remove three (3) screws, then carefully slide panel down
and away from dryer.

5.1.7 Door removal
To remove the door from the front panel, open the door, remove four
(4) M4.2x19 T-20 Torx hinge cover screws, remove the hinge cover
and lift the door up and away from the panel.
5.1.8 Door disassembly
The door isn’t available as a complete assembly, but is easily
disassembled and reassembled. It’s assembled using screws – no
plastic latches are used.
Turn the door inside-out (i.e. with inner
door glass facing up).
Remove two (2) M4.2x19 T-20 Torx latch cover screws and remove
the latch cover and latch out from the door.
Once latch has been removed, remove the remaining four (4) M4.2x19
and five (5) countersunk T-20 Torx screws from the inner door frame.
Lift the inner frame from the door.
The door glass bowl is shown here in the standard hinge right
position. Note the door glass and inner ring positions before removing
them as they change depending on the hinge position (right or left).
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Lift the door glass and the inner ring from the door.
Lift the outer door glass cover from the outer door frame.
5.1.9 Reversing door hinge
The door hinge can easily be reversed from factory right hinge to left
hinge position without any parts or kit. Complete instructions are
available separately – a shortened summary of those instructions are
copied here.
1) Remove door (5.1.7) and place it (front side down) on a protected
surface to avoid scratching the outer door frame and door glass.
Make sure hinge plastic bushings remain on the hinge.
2) Disassemble door (5.1.8) until only outer door frame and outer
door glass cover remain, including removing single screws under
the hinge and latch covers.
3) Rotate outer door frame and outer door glass cover 180º. All parts
will be reassembled in the same position and order they were
disassembled – when reassembly is completed, the hinge will be
rotated 180º.
180º
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4) Lift up the outer door glass and rotate it 90º clockwise. Don’t
rotate the outer door frame.
5) Reassemble all parts in the same position and order they were
disassembled (inner ring, glass bowl, inner frame) – when
reassembly is completed, the hinge will be rotated 180º.
Be sure to reinstall the single screws under the latch and hinge cover
plates.
90º
6) Move latch (to left side) and reassemble door latch cover.
7) Remove (left side) front panel latch cover by removing two (2)
screws.
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There is a retainer latch (“catch”) in both the left and right sides so
there’s no need to move them.
8) Remove hinge from right side of dryer by removing two (2) screws
and lifting the hinge up and away from the dryer. Move hinge to
left side of dryer and attach with two (2) screws. Make sure plastic
hinge bushings don’t fall off.
9) Reinstall front panel latch cover on the right side of the dryer with
(2) screws.
10) Place door onto hinge and reinstall door hinge cover with four (4)
screws to secure door to dryer.
5.1.10 Rear panel
Remove top panel (5.1.1) for better access to parts. Remove two T-
10 Torx screws holding rear panel to rear exhaust vent. Remove T-20
Torx screws holding rear panel to frame and to power connection
sheet. Lift panel out.
Two power connection sheet
screws.
Rear panel access is best for most repairs.
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