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Home My WebLink About18412 45th Dr Ne_BLD5989_2025 Permit Packet Coversheet Community and Economic Development City of Arlington â€¢ 18204 59th Avenue NE â€¢ Arlington, WA 98223 â€¢ Phone (360) 403-3551 Permit Number: BLD5989 Permit Type: Residential Mechanical Address/Parcel: 19412 45th Dr Ne Completed (Month/Year): July 2024 Land Use Bonding or Assignment of Funds Notice of Decision o Confidential Documents. Contact the Staff Report City to obtain. 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Contact the Letters and Project Documents City to obtain. Calculations Topography (Existing Conditions) âœ” Project Specification Manuals CC&Râ€™s Reports Deeds / Easements / Conveyances Certificate of Occupancy /Dedications Inspections Developerâ€™s Agreement Other: Letters and Project Documents Page 1 of 1 Bosch BOVA Split System Heat Pump Condensing Units Up to 18 SEER 2-3-4-5 Ton Capacity R410A Installation Instructions 2 | Bosch IDS BOVA Installation Instructions Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 3 Table of Contents 1 Key to symbols and safety instructions 4 2 Unit location considerations 6 3 Unit preparation 8 4 Setting the unit 8 5 Refrigerant line considerations 9 6 Refrigerant line routing 10 7 Refrigerant line brazing 11 8 Refrigerant line leak check 13 9 Evacuation 13 10 Service valves 14 11 Electrical - low voltage 15 12 Electrical - high voltage 16 13 Start up 17 14 System charge adjustment 18 15 System operation and troubleshooting 21 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 4 | Bosch IDS BOVA Installation Instructions 1 Key to symbols and safety instructions 1.2 Safety Please read before proceeding 1.1 Key to symbols Warnings CAUTION: This document is customer property and is to remain with this unit. Please return to service information pack upon completion of work. Warnings in this document are identiï¬ ed by a warning triangle printed against a grey background. These instructions do not cover all variations in systems Keywords at the start of a warning indicate the type and seriousness or provide for every possible contingency to be met in of the ensuing risk if measures to prevent the risk are not taken. connection with the installation. Should further information be desired or should particular problems arise which are not covered sufficiently for the The following keywords are deï¬ ned and can be used in this document: purchaserâ€™s purposes, the matter should be referred to your installing dealer or local distributor. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could The manufacturer recommends installing only approved result in death or serious injury. matched indoor and outdoor systems. All of the manufacturerâ€™s split systems are A.H.R.I. rated only with TXV indoor systems. Some of the CAUTION indicates a hazardous situation which, if not avoided, could beneï¬ ts of installing approved matched indoor and outdoor split systems result in minor to moderate injury. are maximum eï¬ƒ ciency, optimum performance and the best overall system reliability. NOTICE is used to address practices not related to personal injury. This document contains a wiring diagram and service information. Important information This is customer property and is to remain with this unit. Please return to service information pack upon completion of work. This symbol indicates important information where there is no risk to people or property. CAUTION: This information is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage. WARNING: HAZARDOUS VOLTAGE Failure to follow this warning could result in property damage, severe personal injury, or death. Disconnect all electric power, Including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized. Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 5 WARNING: REFRIGERANT OIL WARNING: SERVICE VALVES Any attempt to repair a central air conditioning product may Failure to follow this warning will result in abrupt release result in property damage, severe personal injury, or death. of system charge and may result in personal injury and/ These units use R-410A refrigerant which operates at 50 to or property damage. Extreme caution should be exercised 70% higher pressures than R-22. Use only R-410A approved when opening the Liquid Line Service valve. Turn valve stem service equipment. Refrigerant cylin-ders are painted a counterclockwise only until the stem contacts the rolled edge. â€œRoseâ€ color to indicate the type of refrigerant and may No torque is required. contain a â€œdipâ€ tube to allow for charging of liquid refrigerant into the system. All R-410A systems with variable speed compressors use a PVE oil that readily absorbs moisture from the atmosphere To limit this â€˜hygroscopicâ€œ action. the system should remain sealed whenever possible. If a system WARNING: BRAZING REQUIRED has been open to the atmosphere for more than 4 hours, the Failure to inspect lines or use proper service tools may result compressor oil must be replaced. Never break a vacuum with in equipment damage or personal injury. if using existing air and always change the driers when opening the system for refrigerant lines make certain that all joints are brazed, not component replacement. soldered. CAUTION: HOT SURFACE WARNING: HIGH CURRENT LEAKAGE May cause minor to severe burning. Failure to follow this Failure to follow this warning could result in property damage, Caution could result in property damage or personal injury. severe personal injury, or death. Do not touch top of compressor. Grounding is essential before connecting electrical supply. CAUTION: CONTAINS REFRIGERANT Failure to follow proper procedures can result in personal illness or injury or severe equipment damage.System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening system. CAUTION: GROUNDING REQUIRED Failure to inspect or use proper service tools may result in equipment damage or personal injury. Reconnect all grounding devices. All parts of this product that are capable of conducting electrical current are grounded. if grounding wires, screws, straps, clips, nuts, or washers used to complete a path to ground are removed for service, they must be returned to their original position and properly fastened. CAUTION: INDOOR UNIT REQUIRED The indoor units must be matched with TXV. The model of TXV can be changed according to the system capacity. Bosch Thermotechnology Corp. | 12.2016 Data subject to change 6 | Bosch IDS BOVA Installation Instructions 2 Unit location considerations 2.2 Refrigerant piping limits 2.1 Unit dimensions Maximum line equivalent length = 100 feet. Unit Dimensions Maximum vertical equivalent length = 50 feet. Models H x W x L (Inches) Use only the line diameters indicated in Table 5.1. BOVA-36 24-15/16 x 29-1/8 x 29-1/8 If the suction line sets are greater than 60 feet do not use a larger suction BOVA-60 33-3/16 x 29-1/8 x 29-1/8 line than recommended. Table 1 The unitâ€™s weight values is on the carton box. When mounting the outdoor unit on a roof, be sure the roof will support the unitâ€™s weight. Properly selected isolation is recommended to prevent sound or vibration transmission to the building structure. W Standard Line Set 100â€™ Max Line Length H 50â€™ Max Line Lift L Figure 1 50â€™ Max Line Lift Figure 2 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 7 2.3 Location restrictions Ensure the top discharge area is unrestricted for at least 60 inches above the unit. Avoid Install Near Bedrooms Do not locate outdoor unit near bedrooms since normal operational sounds may be objectionable. Position unit to allow adequate space for unobstructed airï¬‚ ow, wiring, refrigerant lines, and serviceability. Min. 60â€ Unrestricted Allow a minimum of 12 in. clearance on one side of access panel to a wall and a minimum of 24 in. on the adjacent side of access panel. Min. 36â€ Min. 20â€ to Unrestricted Shrubbery Maintain a distance of 24 in. between units. Position unit so water, snow, or ice from roof or overhang cannot fall directly on unit. Access Panel See Fig. 3 and Fig. 4. Cold climate considerations (heat pump only) Figure 3 Precautions must be taken for units being installed in areas where snow accumulation and prolonged below-freezing temperatures occur. Units should be elevated 3-12 inches above the pad or rooftop, depending on local weather. This addi-tional height will allow drainage of snow and ice melted durIng defrost cycle prior to its refreezlng. Ensure that drain holes in unit base pan are not obstructed, preventing drainage of defrost water (Fig. 5). If possible, avoid locations that are likely to accu-mulate snow drifts. if not possible, a snow drift barrier should be installed around the unit to prevent a build-up of snow on the sides of the unit. Min. 20â€ to Shrubbery Min. 36â€ to Shrubber Access Panel Figure 4 Min 12" Snow barrier Snow legs 3- 12" Elevation pad Figure 5 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 8 | Bosch IDS BOVA Installation Instructions 3 Unit preparation 3.1 Prepare the unit for installation STEP 1 - Check for damage and report promptly to the carrier any damage found to the unit (Fig. 6). The charge port can be used to check to be sure the refrigerant charge has been retained during shipment. Figure 7 The dimension see Unit Dimensions. Figure 6 4 Setting the unit 4.1 Pad installation When installing the unit on a support pad, such as a concrete slab, consider the following: See Detail A The pad must be at least 1-2â€ larger than the unit on all sides. The pad must be separate from any structure. The pad must be level. The pad must be high enough above grade to allow for drainage. #7 X 3/8â€ Self Tapping Screws (Donâ€™t Exceed 3/8â€ long) The pad location must comply with National, State, and Local codes. Brackets: 2" width, 1/16" thickness, Detail A height as required. These instructions are intended to provide a method to tie-down system to Available from distributor cement slab as a securing procedure for high wind areas. Check Local or in market place. Codes for tie-down methods and protocols. 1/4â€ Î§ 1-1/2â€ Hex Washer Head Concrete Screws (3/16â€ Pilot Hole Needed. Pilot Hole Should Be1/4â€ Deeper Than The Fastener Embedment) Figure 8 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 9 5 Refrigerant line considerations 5.4 Reuse existing refrigerant lines 5.1 Refrigerant line and service valve connection sizes Suction line Liquid line CAUTION: Models Suction line Liquid line connection connection If using existing refrigerant lines make certain that all joints are brazed, not soldered. BOVA-36 3/4 3/8 3/4 3/8 BOVA-60 7/8 3/8 7/8 3/8 Table 2 For retroï¬ t applications, where the existing refrigerant lines will be used, the following precautions should be taken: 5.2 Required refrigerant line length Ensure that the refrigerant lines are the correct size. Refer to Section 5.1 listed and Table 2. Determine required line length (Fig. 9). Ensure that the refrigerant lines are free of leaks, acid, and oil. The manufacturer recommends installing only approved matched indoor and outdoor systems. All of the manufacturerâ€™s split systems are A.H.R.I. rated only with TXV indoor systems. Some of the beneï¬ ts of installing approved matched indoor and outdoor split systems are maximum eï¬ƒ ciency, optimum per-formance and the best overall system reliability. Line Length Figure 9 5.3 Refrigerant line insulation The Suction Line must always be insulated. DO NOT allow the Liquid Line and Suction Line to come in direct (metal to metal) contact. Suction Line Liquid Line Insulation Figure 11 Figure 10 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 10 | Bosch IDS BOVA Installation Instructions 6 Refrigerant line routing Comply with National, State, and Local Codes when isolating line sets from joists, rafters, walls, or other structural elements. 6.1 Precautions Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines. For Example: When the refrigerant lines have to be fastened to floor joists or other framing in a structure, use isolation type hangers. Isolation hangers should also be used when refrigerant lines are run in stud spaces or enclosed ceilings. Where the refrigerant lines run through a wall or sill, they should be insulated and isolated. Isolate the lines from all ductwork. Minimize the number of 90Âº turns. 8 Feet Maximum Joist/Rafter Isolator Side View 8 Feet Maximum Line Set Secure Suction line from joists using isolators every 8 ft. Secure Liquid Line directly to Suction line using tape, wire, or other appropriate method every 8 ft. Isolation From Joist/Rafter Figure 12 8 Feet Maximum Wall Isolator Line Set Side View 8 Feet Maximum Secure Suction Line using isolators every 8 ft. Secure Liquid Line directly to Suction Line using tape, wire, or other appropriate method every 8 ft. Isolation In Wall Spaces Figure 13 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 11 Wall Sealant Ductwork Insulation Suction Line Isolator Line Set Isolation Through Wall DO NOT hang line sets from duc twork Figure 14 7 Refrigerant line brazing 7.1 Braze the refrigerant lines 1. Remove caps or plugs. Use a deburing tool to debur the pipe ends. Clean both internal and external surfaces of the tubing using an emery cloth. Figure 15 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 12 | Bosch IDS BOVA Installation Instructions 2. Remove the pressure tap cap from both service valves. Field supplied and installed 3-4" from valve Figure 18 Figure 16 3. Purge the refrigerant lines and indoor coil with dry nitrogen. 5. Replace the pressure tap caps after the service valves have cooled. This pipe must have a thimble Figure 17 Figure 19 4. Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge (Fig. 18). Braze the refrigerant lines to the service valves. Check liquid line ï¬ lter drierâ€™s directional ï¬‚ ow arrow to conï¬ rm correct direction of refrigeration ï¬‚ ow (away from outdoor unit and toward evaporator coil) as illustrated. Braze the ï¬ lter drier to the Liquid Line. Continue the dry nitrogen purge. Do not remove the wet rag until all brazing is completed. Remove the wet rag before stopping the dry nitrogen purge. Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 13 8 Refrigerant line leak check 9 Evacuation 8.1 Check for leaks 9.1 Evacuate the refrigerant lines and indoor coil 1. Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry nitrogen. Do not open the service valves until the refrigerant lines and indoor coil leak check and evacuation are complete. 150 PSI G 1. Evacuate until the micron gauge reads no higher than 350 microns, then close the valve to the vacuum pump. 0350 Microns ON OFF Figure 20 Figure 22 2. Check for leaks by using a soapy solution or bubbles at each brazed location. 2. Observe the micron gauge. Evacuation is complete if the micron gauge does not rise above 500 microns in one (1) minute. Once evacuation is complete blank oï¬€ the vacuum pump and micron gauge, and close the valves on the manifold gauge set. 1 MIN. Figure 23 Figure 21 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 14 | Bosch IDS BOVA Installation Instructions 10 Service valves 10.1 Open the service valves Cap 5/16â€ Hex Wrench for Suction Service Valve WARNING: Unit Side 3/16â€ Hex Wrench Extreme caution should be exercised when opening the of Service for Liquid Service Valve Liquid Line Service Valve. Turn counterclock wise until the Valve valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release Rolled Edge to of system charge and may result in personal injury and /or Captivate Stem property damage. Hex Headed Valve System Leak check and evacuation must be com pleted before opening the service valves. The Suction Service Valve must be opened ï¬ rst BEFORE opening the Service Port Liquid Service Valve! 1. Remove service valve cap (Fig 24). Figure 24 2. Fully insert hex wrench into the stem and back out counterclockwise until valve stem just touches the rolled edge (approximately five (5) turns.) 3. Replace the valve stem cap to prevent leaks. Tighten finger tight plus an additional 1/6 turn. 4. Repeat STEPS 1 - 3 for Liquid Service Valve. Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 15 11 Electrical - low voltage 11.1 Low Voltage Maximum Wire Length Table 3 deï¬ nes the maximum total length of low voltage wiring from the outdoor unit, to the indoor unit, and to the thermostat. 24 Volts - Wire size Max. wire length 18 AWG 150 Ft. 16 AWG 225 Ft. 14 AWG 300 Ft. Table 3 11.2 Low voltage hook-up diagrams Air Handler Hook-up Diagram Access Panel Low Voltage connection must be made inside the outdoor unit case. Figure 25 Notes: W2 1. Be sure power supply agrees with equipment nameplate. B 2. Power wiring and grounding of equipment must comply with local codes. C 3. Low voltage wiring to be No. 18 AWG minimum conductor. R 4. â€œ____â€ The electric auxiliary heat connection. Y G THERMOSTAT ACK L B G R C w1 C Y B D/W INDOOR UNIT OUTDOOR UNIT Control Wiring for H/P Systems. Figure 26 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 16 | Bosch IDS BOVA Installation Instructions 12 Electrical - high voltage 12.2 High voltage disconnect switch 12.1 High voltage power supply Install a separate disconnect switch at the outdoor unit. Field provided ï¬‚ exible electrical conduit must be used for high voltage wiring. WARNING: LIVE ELECTRICAL COMPONENTS! During installation, testing, servicing, and trouble shooting of this product, it may be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury. The high voltage power supply must agree with the equipment nameplate. Power wiring must comply with national, state, and local codes. Follow instructions on unit wiring diagram located on the inside of the control box cover and in the Service Facts document included with the unit. Figure 28 12.3 High voltage ground Ground the outdoor unit per national, state, and local code requirements. Figure 27 Figure 29 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 17 13 Start up 5. Set system thermostat to ON. 13.1 System start up 1. Ensure Sections 7, 8, 9, 10, 11, 12, and 13 have been completed. 2. Set System Thermostat to OFF. TUE Inside Set To Following Schedule EM HEAT OFF COOL DONE CANCEL OFF DONE CANCEL Figure 33 Figure 30 3. Turn on disconnect to apply power to the indoor and outdoor units. ON OFF Figure 31 4. Wait one (1) hour before starting the unit if compressor crankcase heater is used and the outdoor ambient temperature is below 70 ÂºF. 60 MIN. Figure 32 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 18 | Bosch IDS BOVA Installation Instructions 14 System charge adjustment 14.2 Subcooling charging and refrigerant adjustment in cooling (above 55Â°F outdoor temp.) 14.1 Charging: weigh-in method 1. Check the outdoor ambient temperatures. Weigh-In method can be used for the Initial installation, or anytime a system charge is being replaced. weigh-In Method can also be used when power is not available to Subcooling (in cooling mode) is the only recommended method of charging the equipment site or operating conditions (indoor/Outdoor temperatures) are not In above 55ÂºF outdoor ambient temperatures. range to verify with the subcooling charging method. For outdoor ambient temperatures below 55ÂºF , use weigh-in charge method. A B C Note:It is important to return in the spring or summer to accurately charge the system in the cooling mode when outdoor ambient temperature is above 55ÂºF. Charge multiplier for Model Factory Charge interconnecting refrigerant tube length All models The data on nameplate 0.6 oz/ft Outdoor Outdoor Temperature Temperature Table 4 Above 55ÂºF Below 55ÂºF The factory charge in the outdoor unit is suï¬ƒ cient for 15 feet of standard size interconnecting liquid line. 120ÂºF 55ÂºF 55ÂºF New Installations â€” Calculating additional charge for lineset greater than 15 ft. 1. Total Line Length (ft) = _________(a) 2. Standard Lineset (ft) = 15 (b) Outdoor Temp1 Outdoor Temp2 3. (a) minus (b) = _________(c) 4. Refrigerant Multiplier = 0.6 oz/ft (d) Figure 34 5. Refrigerant Adder (c*d) = _________(e)* For best results the indoor temperature should be kept between 70ÂºF to 80ÂºF. *If lineset is less than 15 ft, (e) = 0 Sealed-System Repairs â€” Calculating total system charge. 1. Total Line Length (ft) = _________(a) 2. Standard Lineset (ft) = 15 (b) 80 ÂºF 3. (a) minus (b) = _________(c) 70ÂºF 4. Refrigerant Multiplier = 0.6 oz/ft (d) 5. Refrigerant Adder (c*d) = _________(e)* 6. Factory Charge (namplate) = _________(f) 7. Total System Charge (e+f) = ________ _ *If lineset is less than 15 ft, (e) = 0 Indoor Temp Figure 35 The only mode approved for validating system charge is while in Cooling "Charge Mode". Outdoor Temperature must be between 55Â°F and 120Â°F 2. Ensure Sections 7, 8, 9, 10, and 13 have been completed. with Indoor Temperature kept between 70Â°F and 80Â°F. 3. Stabilize the system. After starting the system in cooling mode, short press â€œFORCEâ€button, and â€œ â€ symbol appears in 10 minutes, operate the system for a minimum of twenty (20) minutes. Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 19 After twenty (20) minutes stabilization period, maintain continuous Final Superheat (Â°F) operation while adjusting refrigerant charge or TXV, after which operate Suction system for a minimum of ï¬ ve (5) minutes for system to stabilize, otherwise Temp 8 10 12 14 16 18 20 22 repeat step 3. (Â°F) Suction Gage Pressure (PSI) 40 101 97 93 89 86 82 78 75 42 105 101 97 93 89 86 82 78 44 110 105 101 97 93 89 86 82 46 114 110 105 101 97 93 89 86 20 MIN. 48 118 114 110 105 101 97 93 89 50 123 118 114 110 105 101 97 93 52 128 123 118 114 110 105 101 97 54 133 128 123 118 114 110 105 101 Figure 36 56 138 133 128 123 118 114 110 105 4. Calculate superheat value on suction valves (According to Table 4 ) 58 143 138 133 128 123 118 114 110 Measured Suction Line Temp. = ________ÂºF 60 148 143 138 133 128 123 118 114 Measured Suction Line Pressure = _______ PSIG 62 153 148 143 138 133 128 123 118 64 159 153 148 143 138 133 128 123 Calculate superheat value = ________ÂºF 66 164 159 153 148 143 138 133 128 68 170 164 159 153 148 143 138 133 70 176 170 164 159 153 148 143 138 72 182 176 170 164 159 153 148 143 Table 4 R-410A Refrigerant chart - Final Superheat Final Supercooling(Â°F) Suction Temp 6 7 8 9 10 11 12 13 107! (Â°F) Liquid Gage Pressure (PSI) Insulation 55 173 176 179 182 185 188 191 195 60 188 191 195 198 201 204 208 211 Figure 36 65 204 208 211 215 218 221 225 229 70 221 225 229 232 236 239 243 247 5. Calculate subcooling value on liquid valves (According to Table 5 ) 75 239 243 247 251 255 259 262 266 Measured Suction Line Temp. = ________ÂºF 80 259 262 266 270 275 279 283 287 Measured Suction Line Pressure = _______ PSIG 85 279 283 287 291 295 300 304 309 Calculate superheat value = ________ÂºF 90 300 304 309 313 318 322 327 331 95 322 327 331 336 341 346 351 355 100 346 351 355 360 365 370 376 381 105 370 376 381 386 391 397 402 407 110 397 402 407 413 418 424 430 435 115 424 430 435 441 447 453 459 465 120 453 459 465 471 477 483 489 496 125 483 489 469 502 508 515 521 528 Table 5 R-410A Refrigerant chart- Final Subcooling Insulation Model 24/36 48/60 Design subcooling 10Â°F Â± 2Â°F 8Â°F Â± 2Â°F Figure 37 Table 6 If calculated subcooling value is lower than the design subcooling value (Table 6), please add refrigerant. Repeat the steps above. Bosch Thermotechnology Corp. | 12.2016 Data subject to change 20 | Bosch IDS BOVA Installation Instructions 6. Adjust refrigerant level to attain proper gage pressure. 8. Record System Information for reference (Table 7). Record system pressures and temperatures after charging is complete. Add refrigerant if the design subcooling is lower than the chart value. Description Value Outdoor model number Measured Outdoor Ambient Â°F Connect gages to refrigerant bottle and unit as illustrated (Fig 38). Measured Indoor Ambient Â°F Purge all hoses. Measured Liquid Line Temp Â°F Measured Suction Line Temp Â°F Open bottle. Liquid Gage Pressure PSIG Stop adding refrigerant when subcooling. matches the charging chart (Table Suction Gage Pressure PSIG 5) Final Subcooling value. Table 7 Recover refrigerant if the design subcooling is lower than the chart value. Figure 38 7. Stabilize the system. Wait 5 minutes for the system condition to stabilize between adjustments. When the subcooling match the chart, the system is properly charged. Remove gages. Replace service port caps to prevent leaks. Tighten finger tight plus an additional 1/6 turn. 20 MIN. Figure 39 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 21 15 System operation and troubleshooting TF = IPM Radiator Temperature) (Table 2) â€” Inverter High Temperature Protection 15.1 Control logic description Pressure transducer (Table 3) The variable speed system adopts the same 24VAC control as any â€” Operating speed control conventional Heat Pump. â€” Electronic Expansion Valve (EEV) control (ODU) The compressorâ€™s speed is controlled based on coil pressures monitored â€” High pressure protection (heating mode) by pressure transducer. To insure stable and adequate capacity, the â€” Low pressure protection (cooling mode) compressor speed will modulate relative to evaporator pressure during cooling operation and relative to condensing pressure during heating operation. The target pressure can auto-matically adjust based on 15.3 Defrost description compressor operation so optimal capacity can be achieved. Target pressure can manually be adjusted (SW4) to achieve improved dehumidification and The Demand Defrost Control (DDC) monitors the ODU coil temperature capacity demands. using thermistor (T3). A second thermistor (T4) monitors outdoor ambient temperature. Based on these parameters, as well as accumulative run time and high pressure, the DDC calculates proper initiation of defrost. The following three conditions are required to enter defrost: 1. Outdoor coil temperature T3 < 34Â°F and a corresponding minimum outdoor ambient temperature is met. 2. After â€œMinimum Run Timeâ€ (MRT) is achieved. MRT is based on outdoor ON ambient temperature (T4), for example: OFF 1 2 3 4 â€” MRT is 4 hours when: T4 < 23Â°F â€” MRT is 2 hours when: 23Â°F â‰¤ T4 < 42Â°F 3. After the high pressure saturation temperature drops below 82Â°F for 20 minutes. Figure 40 Defrost will terminate once outdoor coil temperature (T3) reaches 64Â°F for Switch Description a period of 1 minute or defrost time has exceeded 8 minutes. SW4-1 Not used Defrost Termination Settings (SW5) offers different defrost termination SW4-2 Not used options for enhanced defrost for different geographical &/or outdoor ON Adaptive capacity output disable conditions. SW4-3 OFF Adaptive capacity output enable ON Accelerated cooling/heating SW4-4 OFF Normally cooling/heating Table 8 SW5 ON 15.2 Sensors (thermistors/pressure transducer) OFF 1 2 t3 = Outdoor Coil Temperature (Table 1) â€” High/Low temperature protection Figure 41 â€” Outdoor fan control (cooling mode) â€” Defrost control (heating mode) â€” Ambient Temperature forecast Defrosting choice SW5-1 SW5-2 Remarks Operating time is Defrosting extended T4 = Ambient Temperature (Table 1) ON reduced by 10% for 60 seconds â€” Operating condition permission OFF Normal Normal Default â€” Defrosting condition permission Remarks Enter defrost Quit defrost â€” Outdoor fan control (heating mode) Table 8 T5 = Compressor Discharge Temperature (Table 2) â€” High/Low temperature protection â€” Electronic Expansion Valve (EEV) control (ODU) Bosch Thermotechnology Corp. | 12.2016 Data subject to change 22 | Bosch IDS BOVA Installation Instructions Manual Defrost: 15.6 Protection functions 1. System must have a call for heat and have been operating for a minimum Outdoor coil temperature protection (T3) of 8 minutes. 2. Press â€œForceâ€ button on inverter board for 6 seconds to begin forced i. If T3 > 143.6Â°F, compressor is de-energized defrost. ii. If T3 < 129.2Â°F, compressor is energized 3. Wait approximately 40 seconds for defrost to initiate. Ambient temperature protection (T4) 4. Once defrost initiates, the display will indicate â€œdFâ€. i. If 50Â°F â‰¤ T4 < 140Â°F, unit can ope rate in cooling 5. Defrost test will terminate automatically, after which the display will ii. If -4Â°F â‰¤ T4 < 86Â°F, unit can operate in heating indicate running speed. 6. If a second defrost test is required, repeat step 3 after 5 minutes. iii. If T4 < 6.8Â°F, heat pump will provide 24V control to indoor unit energizing electric heat (if installed). Discharge Temperature (DT) protection (T5) 15.4 Compressor crankcase heater description i. If DT > 239Â°F during cooling mode, the compressor will stop. Refrigerant migration during the OFF cycle can result in noisy start-ups, therefore ii. If DT < 194Â°F during cooling mode, the compressor will restart. a crankcase heater (CCH) is used to minimize refrigerant migration thereby iii. If DT > 221Â°F during heating mode, the compressor will stop. minimizing start-up noise and/or bearing â€œwash outâ€. All CCHs must be installed on the lower half of the compressor shell. Its purpose is to warm the compressor iv. If DT < 167Â°F during heating mode, the compressor will restart. on the OFF cycle, driving refrigerantfrom compressor. At initial start-up or after High pressure protection (HPS) (mechanical open/close pressure switch) extended shutdown periods, allow CCH to be energized for at least 12 hours prior to compressor operation by applying line voltage to heat pump with thermostat OFF. i. HPS opens at P > 580 PSIG, the compressor and outdoor fan stop. ii. HPS closes at P < 435 PSIG, the compressor and outdoor fan restart. CCH operation energizes: Low pressure protection (LP) 1. First time line voltage is applied and compressor discharge temperature T5 < 104Â°F. i. If Low Pressure < 43.5 PSI for 5 minutes during cooling mode, the compressor and outdoor fan will stop.System will attempt to run again 2. In process of defrosting. after 6 minutes. 3. Compressor stops running for 4 hours and outdoor ambient temperature T4 < 50Â°F or T5 < 104Â°F. Module (inverter) protection (TF) CCH operation de-energizes: i. If TF > 176Â°F, the compressor and outdoor fan will stop. 1. Compressor discharge temperature T5 â‰¥ 113Â°F. ii. If TF< 145Â°F, the compressor and outdoor fan will restart. 15.5 Reversing valve operation Reversing valve energizes during heat mode and de-energizes in cool mode. Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 23 15.7 Fault code table Code Fault Description E4 Temperature sensor fault(T3, T4, T5, TF) E5 High/low voltage protection E6 DC fan motor fault E7 Compressor discharge sensor(T5) is seated fault E9 EEPROM fault Eb System lockup, 2 times (E6) protection in 10 minutes H0 Communication fault in main control chip H4 System lockup, 3 times (P6) protection in 60 minutes H5 System lockup, 5 times (P2) protection in 100 minutes H8 Pressure transducer(PT) fault Hb High pressure(PT) protection in Heating P0 High module radiator temperature (TF)protection P1 High pressure switch(HPS)protection P2 Low pressure(PT) Protection in cooling P3 Compressor over current protection P4 High compressor discharge temperature(T5) protection P5 condensor coil temperature(T3) protection in cooling P6 The IPM module protection PH Low discharge superheat protection F1 High pressure switch(HPS) fault C3 The condensor coil sensor(T3) is seated fault in cooling L0-L9 The IPM module protection (the same as P6,only for analysis) AtL Ambient Temperature Limited System Protection Status Codes Indication under charge model L Running indication under T3 limited condition D Running indication under T5 limited condition P Running indication under compressor ratio limited condition F Running indication under Tf limited condition C Running indication under current limited condition U Running indication under low voltage limited condition H Running indication under high pressure(PT) limited condition in heating A Running indication under return oil model dF Running indication under defrost model Table 9 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 24 | Bosch IDS BOVA Installation Instructions 15.8 Parameter point check table To display system parameters, press the â€œCheckâ€ button to index through the series of parameters available. The first time you press on the â€œCheckâ€ button, it will display the sequence, and after 1 second it will display the value of the parameter. If you press the â€œCheckâ€ button again, it will display the next sequence. Normal Status, last two digits will display under following conditions i. Unit not operating(Standby Mode); â€œoutdoor ambient temperatureâ€. ii. Unit operating; displays â€œcompressor operating frequencyâ€. After 20 seconds on same parameter, display will revert back to normal status. If a system protection is active, first digit will display â€œstatus codeâ€. No. Point check content Example Remark 0 Outdoor unit capacity H3 H3=Heat Pump 3 ton 0 standby, 1 Outdoor unit mode 2 2 cooling, 3 heating 2 Outdoor unit set compressor speed 3 Opening of EEV Actual value 4 T3(outdoor coil temp.) (Â°F ) 5 T4 (outdoor ambient temp.) (Â°F ) 6 T5(compressor discharge temp.) (Â°F ) 7 Reserved 8 Te (evaporating temp.) (Â°F ) 9 Tc (condensing temp.) (Â°F ) 10 Tf (module temp.) (Â°F ) 11 Pe (evaporating pressure) (PSI) 12 Pc (evaporating pressure) (PSI) 13 Compressor discharge superheat (Â°F ) Actual value 14 Reserved 15 Reserved 16 Compressor current (A) 17 Reserved 18 Fan speed 19 Reserved 20 Reserved Compressor discharge superheat (only useful for heating 21 Target Value mode) (Â°F ) 22 Reserved 23 Last Fault Code 24 Software version 25 Remarkâ€œ--â€ Table 10 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 25 15.9 Control board overviews For 2436 model 18 17 16 15 14 13 12 11 10 19 9 8 20 7 6 5 4 21 3 2 EEPROM chip 1 22 23 24 THE FACTORY SETTING FOR 36K MODEL, CUT OFF J2 JUMP FOR 24K MODEL. Figure 42 * The photo is just for reference,actual unit will verify. No. Function description No. Function description 1 Compressor wiring terminal 13 Temp. controller connecting port 2 Reactor wiring terminal(connect a reactor between 2 and 3 ) 14 Function dial code SW4 3 Reactor wiring terminal(connect a reactor between 2 and 3 ) 15 Spot check button 4 Defrosting function dial codeSW5 16 Forced operation button 5 Pressure transducer port 17 Reserved 6 Air discharge temp.sensor port 18 Digital tube display 7 Outdoor temp.sensor port(HP only) 19 Fan control port 8 Condenser temp.sensor port 20 Crankcase heating zone control terminal 9 Radiator temp.sensor port 21 Short wire 10 High pressure switch port 22 Power supply connecting terminal 11 EEV drive port(HP only) 23 Power supply connecting terminal 12 Reversing valve port 24 Indicator lamp Table 11 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 26 | Bosch IDS BOVA Installation Instructions For 4860 model Main control board 19 21 14 15 16 17 18 20 22 1 2 3 4 EEPROM 5 chip 6 7 8 13 9 12 11 10 THE FACTORY SETTING FOR 36K MODEL, CUT OFF J2 JUMP FOR 24K MODEL. Figure 43 * The photo is just for reference,actual unit will verify. No. Function description No. Function description 1 EEV driving port (HP only) 12 The voltage between 12 and 13 is 380Vdc (Compressor is running ) 2 High pressure switch port 13 The voltage between 12 and 13 is 380Vdc (Compressor is running ) 3 Radiator temp. sensor port 14 DC motor control port 4 Condenser temp.sensor port 15 Nixie tube display 5 Outdoor temp.sensor port (HP only) 16 Reserved 6 Air discharge temp.sensor port 17 Defrosting functiondialcode SW5 7 Pressure transducer 18 Function dial code SW4 8 Connection wire port between main boards 19 Point check button 9 DC motor driving source (15V-P2) 20 Temp. controller connection port 10 The voltage between 10 and 11 is 380Vdc (Compressor is running ) 21 Forced operation button 11 The voltage between 10 and 11 is 380Vdc (Compressor is running ) 22 4-way valve port (HP only) Table 12 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 27 For 4860 model Drive board 23 24 25 26 36 27 35 34 33 32 31 30 29 28 Figure 44 * The photo is just for reference,actual unit will verify. No. Function description No. Function description 23 Connect the cathode of the rectiï¬ er bridge 30 AC power supply output port 24 DC motor driving source(15V-P2) 31 AC power supply output port 25 The voltage between 25 and 26 is 380Vdc (Compressor is running ) 32 Compressor connection terminal 26 The voltage between 25 and 26 is 380Vdc (Compressor is running ) 33 The voltage between 33 and 36 is 380Vdc (Compressor is running ) 27 Connection wire port between main boards 34 Reactor L1 wiring terminal 28 AC power supply input port 35 Reactor L2 wiring terminal 29 AC power supply input port 36 The voltage between 33 and 36 is 380Vdc (Compressor is running) Table 13 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 28 | Bosch IDS BOVA Installation Instructions 15.10 Error code troubleshooting Error Code Description P5 ( Condenser coil temperature(T3) protection in cooling) Diagnosis Handling P1 High pressure switch(HPS)protection P5 Condenser coil temperature(T3) protection in cooling Check whether the service No Open the service valves Hb High pressure(PT) protection in Heating valves are open P3 Compressor over current protection Yes Table 14 Check whether T3 is normal No according to Table 1(between Replace the T3 sensor temperature and resistance) P1 (High pressure switch(HPS)protection) Yes Diagnosis Handling Check whether outdoor unit Yes Replace the fan or motor is abnormal or whether Check whether the service No the outdoor condenser coil is remove all the barriers valves are open Open the service valve blocked No Yes Check whether there is short Yes Do something to avoid air Check whether the switch No Reseat the wires according circuit in air outlet and inlet side return short circuit wires is seated normally to wiring diagram No Yes Check whether the charge is correct by subcooling No Adjust refrigerant charge Check whether high pressure No according to installation guide Replace high pressure switch switch is close in charge mode when cooling Yes Yes Check whether there is normal No Adjust or repair the TXV Check whether indoor and No Exclude all fault reasons of throttle throttle outdoor units are normal by and restart valve, filter and airflow Yes Yes Cooling mode refers to P5 Figure 46 Heating mode refers to Hb Figure 45 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 29 Error Code Description Hb ( High pressure(PT) protection in Heating) P0 High module radiator temperature (TF) protection Diagnosis Handling Table 15 Check whether the service No Open the service valve valves are open P0 (High module radiator temperature (TF)protection) Diagnosis Handling Yes Check whether there`s dust or Check whether indoor unit is No Exclude indoor unit fault fallen leaves influencing Yes Clean all the dust normal by filter and airflow reasons and restart and fallen leaves radiator Yes No Check whether the Tf is Check whether indoor air inlet Yes Remove e.g. indoor side normal according to Table No E-heater or other heat Replace Tf sensor temp. is over 86Â°F 2(between temperature and sources resistance) No Yes Restart system and check No Restart system and check No Reseat the EEV throttle whether the fan and motor Replace the fan and motor whether EEV is working can normally operate Yes Yes Make a comparison between No Reseat or replace the Operate system and check No Operate normally the pressure gauge and the PT sensor whether there`s the same fault read from check data Yes Yes Figure 47 Figure 49 P3 ( Compressor over current protection) Error Code Description Diagnosis Handling P2 Low pressure(PT) Protection in cooling H5 System lockup, 5 times (P2) protection in 100 minutes Check whether the service No Open the service valve valves are open P4 High compressor discharge temperature(T5) protection Yes Table 16 Check whether outdoor unit motor is abnormal and the Yes Replace the fan or outdoor condenser coil is remove all the barriers P2 ( Low pressure(PT) Protection in cooling) blocked H5 ( System lockup, 5 times (P2) protection in 100 minutes) No Diagnosis Handling Check whether compressor No Wiring correctly according to wiring is normal the wiring diagram Check whether the service No Open the service valve valves are open Yes Yes Check whether compressor No insulation resistance is greater Replace compressor Check whether indoor unit is Exclude indoor unit No than 100Kâ„¦ normal by valve, filter, airflow fault reasons and and throttle restart Yes Yes Restart system and check whether the difference of high and low Yes Check whether the charge is Replace compressor pressure is more than 30 PSI after correct by subcooling No Adjust the charge compressor running 10 min according to installation guide in charge mode when cooling No Yes Check whether the No compressor current is more Replace the board Check whether the pressure transduce is measuring No Replace the pressure than 18A when protection properly from the 8th or 11th transducer data of check when cooling Yes Yes Replace the compressor Figure 50 Figure 48 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 30 | Bosch IDS BOVA Installation Instructions Error Code Description P4 ( Compressor discharge sensor(T5) is seated fault) E4 Temperature sensor fault(T3, T4, T5, TF) Diagnosis Handling H8 Pressure transducer(PT) fault F1 High pressure switch(HPS) fault Check whether the service No Open the service valve valves are open Table 18 Yes Check whether the T5 is normal No according to Table 2(between Replace the T5 sensor E4 ( Temperature sensor fault(T3, T4, T5, TF)) temperature and resistance) Diagnosis Handling Yes Check whether the charge is Check whether sensor No Reseat the sensor correct by subcooling No Adjust the charge T3/T4/T5/Tf are seated and according to wiring diagram according to installation guide normal (T4 for Heat Pump only) in charge mode when cooling Yes Yes Unplug the sensor, Check Check whether the compres- No Replace the fault T3/T4 No whether the resistance of sor is normal (abnormal noise, Replace the compressor T3/T4 is in the range of Table 1 sensor abnormal vibration) Yes Yes Unplug the sensor, Check No Check whether the EEV is No Re-power and check whether the resistance of T5/Tf Replace the fault T5/Tf sensor normal for throttle when heating again,if the same, replace is in the range of Table 2 (wire seated .coil) the EEV Yes Yes Check whether the display the No same error code when Keep running Figure 51 re-powered on Yes Error Code Description PH Low discharge superheat protection Figure 53 Table 17 H8 ( Pressure transducer(PT) fault) PH ( Low discharge superheat protection) Diagnosis Handling Diagnosis Handling Check whether pressure No Wiring according to the Check whether T3/T5 are transducer(PT) wiring are No diagram correctly normal according to Table1, Replace fault sensors seated and normal Table 2 Yes Yes Check whether the pressure Check whether the pressure transduce is measuring No Replace the pressure transduce is measuring properly No Replace the pressure properly from the 8th or 11th transducer from the 8th or 11th data of check transducer data of check when cooling when cooling(from the 9th or 12th data of check when heatling) Yes Yes Check whether there is the No Check whether indoor unit is Keep running same fault normal by filter, airflow(motor), No Exclude indoor unit fault and coil(be blocked up) when reasons and restart cooling Yes Yes No 1.Not applicable for piston Check whether the suction 2.Adjust(close) the TXV superheat Figure 54 superheat is correct in cooling 3.To further adjust to SW4-4â€on Check whether the outdoor 1. Exclude outdoor unit fault fan is correct and outdoor No reasons and restart coil is blocked in heating 2. Ensure the reserving coil is seated well Yes Figure 52 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 31 F1 ( High pressure switch(HPS) fault) E7 Compressor discharge sensor(T5) is seated fault) Diagnosis Handling Diagnosis Handling Check whether the service No Check whether condenser coil No Reseat the sensor to valves are open Open the service valve sensor(T5) is seated to the discharge tube condenser coil Yes Yes Check whether high pressure No Wiring according to the switch(HPS) wiring is seated diagram correctly Check whether the sensor of No Wiring according to the and normal T3/T5 are connected accord- ing to wiring diagram wiring diagram correctly Yes Yes Check whether the No Replace high pressure resistance of HPS is close to switch Check whether the resistance 0Kâ„¦ No of T3/T5 is in the range of Replace the fault T3/T5 sensor Yes Table 1 and Table 2 Yes Check whether there is the No Keep running same fault Check whether there are other No Remove all the other heat Yes heat sources around T3/T5 sources Yes Figure 55 Check whether there is the Yes Keep running same fault Error Code Description C3 Condenser coil sensor(T3) is seated fault in cooling Figure 57 E7 Compressor discharge sensor(T5) is seated fault Table 19 Error Code Description E6 DC fan motor fault Eb System lockup, 2 times (E6) protection in 10 minutes C3 Condenser coil sensor(T3) is seated fault in cooling) Table 20 Diagnosis Handling When E6 appears occasionally, you don`t need to do anything, the system will restart Check whether condenser automatically after 6 minutes, of course, if you check the system of running, it will be No Reseat the sensor to coil sensor(T3) is seated condenser coil better. When Eb appears, you need to check the motor. to the condenser coil Yes Check whether the sensor of E6 DC fan motor fault) No Wiring according to the T3/T4/HPS are connected Eb System lockup, 2 times (E6) protection in 10 minutes) according to wiring diagram wiring diagram correctly Diagnosis Handling Yes Check whether DC motor wiring is reliably connected No Reseat the wiring Check whether the No Replace the fault according to the wiring according to wiring resistance of T3/T4 is in T3/T4 sensor diagram the range of Table 1 Yes Yes Check whether there are Check whether outdoor No Remove all the barriers No coil air return is blocked other heat sources around Remove all the other T3/T4 heat sources Yes Yes Check whether there is No 15V DC between the test Replace the control board Check whether there is the No point P8 and P2 Keep running same fault Yes Yes Check whether there is No the same fault Keep running Figure 56 Yes NOTE: Just for 4T/5T Figure 58 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 32 | Bosch IDS BOVA Installation Instructions Error Code Description E9 EEPROM fault E5 ( High/low voltage protection) H0 Communication fault in main control chip Diagnosis Handling E5 High/low voltage protection Check whether the power Make sure the power No supply voltage is between supply is within correct Table 21 187-253V range When E9/H0/E5 appears occasionally, and the system restart to run normally after Yes power supply again, you don`t need to do anything. Otherwise, you need to check Check whether the power wires are Replace the power supply the system. connected firmly, whether the power No wires or connect the power supply wires diameter meets the supply wires well requirements from the manufacture Yes E9 (EEPROM fault) Restart to the power supply No Diagnosis Handling and check whether the Replace the drive board compressor operates normally Yes Check whether the wiring is No Reseat the wiring according connected normally to wiring diagram Gauge and check whether there is 380V DC between the No Replace the drive board terminals P2 and P4 when Yes compressor is running Yes Restart to power on and No Reseat the wiring according check whether it is normal to wiring diagram Check whether there are Separate high-power high voltage equipment Yes equipment and power nearby supply Yes The fault is still No You need do nothing. Perhaps this fault is caused by accident, such as strong interference form electricity Replace the control board grid. System will recovery when Figure 61 electricity grid is normal Figure 59 H0 ( Communication fault in main control chip) Diagnosis Handling Check whether the wiring is No Reseat the wiring according connected normally to wiring diagram Yes Restart to power on and No 3T: Replace the control board check whether it is normal 5T: Reseat the communication wire Yes The fault is still You need do nothing. Perhaps this fault is caused by accident, such as No strong interference form electricity grid. 5T: Replace the control board System will recovery when electricity grid is normal The fault is still 5T: Replace the drive board Figure 60 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 33 Error Code Description Error Code Description P6 IPM module protection AtL Ambient Temperature Limited H4 System lockup, 3 times (P6/L0-9) protection in 60 minutes Table 23 L0-L9 IPM module protection (the same as P6, only for analysis) Table 22 When the ambient temperature returns to within the operating range, the When P6/L0-L9 appears occasionally, you don`t need to do anything, the system will system recovery automatically. restart automatically after 6 minutes, of course, if you check the system of running, it will be better. AtL ( Ambient Temperature Limited) P6/L0-L9 ( IPM module protection) Diagnosis Handling H4 ( System lockup, 3 times (P6/L0-9) protection in 60 minutes) Diagnosis Handling Check whether the ambient temperature is beyond the range Yes Normal cooling:40Â°F-120Â°F Check whether the service No heating:5Â°F-86Â°F Open the service valves valves are open No Yes Check whether sensor T4 are No seated and normal (T4 for Reseat the sensor according Check whether the compressor No Reseat the wiring according Heat Pump only) to wiring diagram wiring is normal to wiring diagram Yes Yes Check whether compressor Unplug the sensor, Check No Replace the fault T3/T4 insulation resistance is greater No whether the resistance of T4 Replace the compressor sensor than 100Kâ„¦ is in the range of Table 1 Yes Yes Check whether the resistance of No You need do nothing. Try to compressor U/V/W are normal Replace the compressor start again Yes Check whether there is the No Figure 63 Keep running same fault Yes Replace the board and No check whether there is the Keep running same fault. Yes Yes Replace the compressor and No check whether there is the Keep running same faultt Figure 62 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 34 | Bosch IDS BOVA Installation Instructions TEMP F TEMP C RESISTANCE kÎ© VOLTS DC TEMP F TEMP C RESISTANCE kÎ© VOLTS DC -5 -20.6 107.732 4.65 90 32.2 7.225 2.36 0 -17.8 93.535 4.6 95 35 6.401 2.21 5 -15 79.521 4.54 100 37.8 5.683 2.07 10 -12.2 67.795 4.47 105 40.6 5.057 1.93 15 -9.4 57.948 4.39 110 43.3 4.509 1.79 20 -6.7 49.652 4.3 115 46.1 4.028 1.67 25 -3.9 42.645 4.21 120 48.9 3.606 1.55 30 -1.1 36.710 4.1 125 51.7 3.233 1.43 40 4.4 27.386 3.86 130 54.4 2.902 1.32 45 7.2 23.732 3.73 135 57.2 2.610 1.22 50 10 20.610 3.59 140 60 2.350 1.13 55 12.8 17.939 3.45 145 62.8 2.119 1.04 60 15.6 15.648 3.3 150 65.6 1.914 0.96 65 18.3 13.681 3.15 155 68.3 1.731 0.88 70 21.1 11.987 2.99 160 71.1 1.574 0.82 75 23.9 10.527 2.83 165 73.9 1.416 0.75 80 26.7 9.265 2.67 170 76.7 1.276 0.68 85 29.4 8.172 2.52 Table 24 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 35 TEMP F TEMP C RESISTANCE kÎ© VOLTS DC TEMP F TEMP C RESISTANCE kÎ© VOLTS DC -5 -20.6 600.134 4.93 140 60 13.643 3.14 0 -17.8 505.551 4.92 145 62.8 12.359 3.03 5 -15 427.463 4.91 150 65.6 11.214 2.91 10 -12.2 362.739 4.89 155 68.3 10.227 2.8 15 -9.4 308.891 4.87 160 71.1 9.308 2.68 20 -6.7 265.398 4.85 165 73.9 8.485 2.56 25 -3.9 227.481 4.83 170 76.7 7.746 2.45 30 -1.1 195.601 4.8 175 79.4 7.105 2.34 35 1.7 168.707 4.77 180 82.2 6.504 2.23 40 4.4 146.695 4.74 185 85 5.963 2.13 45 7.2 127.258 4.7 190 87.8 5.474 2.02 50 10 110.707 4.66 195 90.6 5.032 1.92 55 12.8 96.572 4.61 200 93.3 4.645 1.83 60 15.6 84.465 4.56 205 96.1 4.28 1.73 65 18.3 74.411 4.51 210 98.9 3.949 1.64 70 21.1 65.408 4.45 215 101.7 3.648 1.56 75 23.9 57.634 4.39 220 104.4 3.383 1.48 80 26.7 50.904 4.32 225 107.2 3.133 1.4 85 29.4 45.258 4.24 230 110 2.904 1.32 90 32.2 40.152 4.16 235 112.8 2.694 1.25 95 35 35.699 4.08 240 115.6 2.503 1.18 100 37.8 31.807 3.99 245 118.3 2.334 1.12 105 40.6 28.398 3.89 250 121.1 2.172 1.06 110 43.3 25.506 3.8 255 123.9 2.024 1 115 46.1 22.861 3.7 260 126.7 1.888 0.95 120 48.9 20.529 3.59 265 129.4 1.767 0.9 125 51.7 18.47 3.48 270 132.2 1.651 0.85 130 54.4 16.708 3.37 275 135 1.544 0.8 135 57.2 15.085 3.26 280 137.8 1.446 0.76 Table 25 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 36 | Bosch IDS BOVA Installation Instructions NSK-BD035I V= (7.9*PSIG*10-3)+0.5 Pe/Pc Pe/Pc Pe/Pc No. V No. V No. V PSIG PSIG PSIG 1 0.69 24.4 56 1.37 110.6 111 2.54 258.5 2 0.7 26.0 57 1.39 112.5 112 2.56 262.0 3 0.72 27.7 58 1.4 114.5 113 2.59 265.6 4 0.73 29.4 59 1.42 116.5 114 2.62 269.2 5 0.75 31.2 60 1.43 118.6 115 2.65 272.8 6 0.76 33.1 61 1.45 120.6 116 2.68 276.5 7 0.78 35.0 62 1.47 122.7 117 2.71 280.2 8 0.79 37.0 63 1.48 124.8 118 2.74 284.0 9 0.81 39.0 64 1.5 127.0 119 2.77 287.8 10 0.82 41.1 65 1.52 129.1 120 2.8 291.6 11 0.84 43.2 66 1.53 131.3 121 2.83 295.5 12 0.85 44.3 67 1.55 133.5 122 2.86 299.3 13 0.86 45.4 68 1.57 135.8 123 2.89 303.3 14 0.87 46.6 69 1.59 138.0 124 2.92 307.2 15 0.88 47.7 70 1.61 140.3 125 2.95 311.3 16 0.89 48.9 71 1.62 142.6 126 2.98 315.3 17 0.89 50.0 72 1.64 145.0 127 3.02 319.4 18 0.9 51.2 73 1.66 147.3 128 3.05 323.5 19 0.91 52.4 74 1.68 149.7 129 3.08 327.7 20 0.92 53.7 75 1.7 152.1 130 3.12 331.9 21 0.93 54.9 76 1.72 154.6 131 3.15 336.1 22 0.94 56.2 77 1.74 157.1 132 3.18 340.4 23 0.95 57.5 78 1.76 159.6 133 3.22 344.7 24 0.96 58.8 79 1.78 162.1 134 3.25 349.0 25 0.97 60.1 80 1.8 164.6 135 3.29 353.4 26 0.98 61.4 81 1.82 167.2 136 3.32 357.9 27 0.99 62.8 82 1.84 169.8 137 3.36 362.4 28 1.01 64.1 83 1.86 172.5 138 3.39 366.9 29 1.02 65.5 84 1.88 175.1 139 3.43 371.4 30 1.03 66.9 85 1.9 177.8 140 3.46 376.0 31 1.04 68.4 86 1.92 180.5 141 3.5 380.7 32 1.05 69.8 87 1.94 183.3 142 3.54 385.4 33 1.06 71.3 88 1.97 186.1 143 3.57 390.1 34 1.07 72.7 89 1.99 188.9 144 3.61 394.9 35 1.09 74.3 90 2.01 191.7 145 3.65 399.7 36 1.1 75.8 91 2.03 194.6 146 3.69 404.5 37 1.11 77.3 92 2.06 197.5 147 3.73 409.5 38 1.12 78.9 93 2.08 200.4 148 3.77 414.4 39 1.13 80.5 94 2.1 203.4 149 3.8 419.4 40 1.15 82.1 95 2.13 206.4 150 3.84 424.4 41 1.16 83.7 96 2.15 209.4 151 3.88 429.5 42 1.17 85.3 97 2.17 212.4 152 3.93 434.6 43 1.19 87.0 98 2.2 215.5 153 3.97 439.8 44 1.2 88.7 99 2.22 218.6 154 4.01 445.0 45 1.21 90.4 100 2.25 221.8 155 4.05 450.3 46 1.23 92.1 101 2.27 224.9 156 4.09 455.6 47 1.24 93.8 102 2.3 228.1 157 4.13 461.0 48 1.25 95.6 103 2.32 231.4 158 4.18 466.4 49 1.27 97.4 104 2.35 234.6 159 4.22 471.9 50 1.28 99.2 105 2.38 238.0 160 4.26 477.4 51 1.3 101.0 106 2.4 241.3 161 4.31 482.9 52 1.31 102.9 107 2.43 244.7 162 4.35 488.6 53 1.33 104.8 108 2.45 248.1 163 4.39 494.2 54 1.34 106.7 109 2.48 251.5 164 4.44 499.9 55 1.36 108.6 110 2.51 255.0 165 4.48 505.7 Table 26 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 37 16 Wiring diagrams 16.1 For BOVA 36 F HPST T3 T4 T5 PT SV1 EEV ONLY FOR HP MODEL Communication faultIPM module protectionLow dc voltage protectionIPM control faultCompressor phase errorFLASH:StandbyOFF:Control board faultON:Compressor operation 4 8 9 0 FF N RED LED FLSAH GREEN LEDO O W Y 2 P- E + C B AND W ONLY FOR HP MODELB 4 R 3 O 4 P C F U V W P N DSP1 CHECK L2 L1 USE COPPER CONDUCTORS ONLY PFC-L BROWN HL COM YELLOW YELLOW V W BLACKBLUEORANGE U ORANGECCH OT USED) W Y/G V (CHARGE MODEL) BROWNORANGE ORANGE U CHECK THE SYSTEM PARAMETERSTEST MODE (NFORCED COOLING /HEATINGFORCED DEFROSTING 1s 6s 1s 6s PRESSPRESSPRESSPRESS ON OFF CHECK FORCE 4 3 The factory Default* Operating time is reduced by 10%NormalDefrosting extended for 60 secondsNormal Adaptive capacity output disableAdaptive capacity output enableAccelerated cooling/heatingNormally cooling/heating ON OFF ONOFFONOFF Not usedNot used ONOFFONOFF CAPACITANCEPFC INDUCTANCE4-WAY VALVECONDENSER TEMPERATURE SENSORAMBIENT TEMPERATURE SENSOR( FOR HP SYSTEM)10K COMP. DISCHARGE TEMPERATURE SENSORRESISTANCE ( FOR COOLING ONLY SYSTEM)PRESSURE TRANSDUCERRADIATOR TEMP. SENSORCOMPRESSORELECTRIC EXPANSIVE VALVECRANKCASE HEATERHIGH PRESSURE SWITCH * * SW5-1SW5-2 Enter defrostQuit defrostSW4-1SW4-2SW4-3SW4-4Detailed reference manual instructions 3 T 4 T 5P T T TF RC 2PFC-LSV1 COMPEEVCCHHPSWARNING: CABINET MUST BE PERMANMENTLYGOUNDED AND ALL WIRING TO CONFORM TOI.E.C,N.E.C,C.E.C,C.L.C,AND LOCAL CODES AS APPLICABLEREPLACEMENT WIRE MUST BE THE SAME GAUGE ANDINSULATION TYPE AS ORIGINAL WIRE (T5) WARNINGCOMPONENTS MAY STORE A (PT) fault ressure switch(HPS) fault ELECTRIC HAZARD 380 VOLTS DCFault descriptionThe T3 sensor is not seated faultHigh pThe module radiator temperature (TF)protectionHigh pressure (HPS) protectionLow pressureCompressor over current protectionThe discharge temp.High condensor coil temp. (T3) protectionIPM module protectionProtectionLow discharge superheat protectionCommunication fault in main control chip3 times (P6) protection in 60 minutes,system lockup5 times (P2) protection in 100 minutes,system lockupProtectionPressure transducer(PT) short or open faultHigh pressure(PT) protection in HeatingTemperature sensor fault(T3High/low voltage protectionThe discharge sensor(T5) is not seated faultEEPROMIPM module protection or frequent power on/offForced operation modeT3 high temperature limitT4T5 high temperature limitT5Compression ratio protection limitTF)TF high temperature limitCompressor current protection limitVoltage protection limitCompressor oil returnDefrost modeAmbient Temperature Limited 9 WAIT 2 MINUTES AFTER DISCONNECTING POWER,THENVERIFY DC VOLTAGE LESS THAN 42 VDC AT INVERTERTEST POINTS P2-P4.DANGEROUS ELECTRICAL POTENTIAL OF 380 VOLTS DC.FAILURE TO FOLLOW THIS WARNING COULD RESULTIN PERSONAL INJURY OR DEATH2 P 3 P 4 5 0 H 5 7E 9 -L L D P F C U H C3F1 P0 P1 P P P6PH H4H5H8 Hb E4 E E 0 DFAtL CODE L Figure 64 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 38 | Bosch IDS BOVA Installation Instructions 16.2 For BOVA 60 W F 3 4 Y HPST T T T5 PT B EEV C SV1 ONLY FOR HP MODEL ONLY FOR HP MODEL B AND W ONLY FOR HP MODEL L2 L1 RED USE COPPER CONDUCTORS ONLY CN9 CN1 LLOWYE P 8 N6 C 4 3 FORCE + BROWN P4 P2 - TEST POINTS N U V W P P K IS C D E H C + OWNBR P10 - P9 N 19 _ _1 C N IN N V DB1 BLUE V W 35 BLUE ORANGEORANGE YELLOWYELLOW 2 U 14 CCH W V Communication faultIPM module protectionLow dc voltage protectionIPM control faultCompressor phase errorFLASH:StandbyOFF: Control board faultON:Compressor operation U RED PFC-L PFC-L 4 8 9 0 FF N RED LED FLSAH GREEN LEDO O ON OFF 4 3 The factory Default * (CHARGE MODEL) Operating time is reduced by 10%NormalDefrosting extended for 60 secondsNormal CHECK SYSTEM PARAMETERSTEST MODE (NOT USED)FORCED COOLING /HEATINGFORCED DEFROSTING ON OFF Adaptive capacity output disableAdaptive capacity output enableAccelerated cooling/heatingNormally cooling/heating1s 6s 1s 6s ONOFFONOFF PRESSPRESSPRESSPRESS PFC INDUCTANCE4-WAY VALVECONDENSER TEMPERATURE SENSORAMBIENT TEMPERATURE SENSOR( FOR HP SYSTEM)10K COMP. DISCHARGE TEMPERATURE SENSORRESISTANCE ( FOR COOLING ONLY SYSTEM)PRESSURE TRANSDUCERRADIATOR TEMP. SENSORCOMPRESSORELECTRIC EXPANSIVE VALVECRANKCASE HEATERHIGH PRESSURE SWITCH Not usedNot used ONOFFONOFF CHECK FORCE * * T SW5-1 PFC-LSV1T3 T4 T5 P TFCOMPEEVCCHHPSWARNING: CABINET MUST BE PERMANMENTLYGOUNDED AND ALL WIRING TO CONFORM TOI.E.C,N.E.C,C.E.C,C.L.C,AND LOCAL CODES AS APPLICABLEREPLACEMENT WIRE MUST BE THE SAME GAUGE ANDINSULATION TYPE AS ORIGINAL WIRE SW5-2 Enter defrostQuit defrostSW4-1SW4-2SW4-3SW4-4Detailed reference manual instructions (T5) WARNINGCOMPONENTS MAY STORE A (PT) fault ressure switch(HPS) fault ELECTRIC HAZARD 380 VOLTS DCFault descriptionThe T3 sensor is not seated faultHigh pThe module radiator temperature (TF)protectionHigh pressure (HPS) protectionLow pressureCompressor over current protectionThe discharge temp.High condensor coil temp. (T3) protectionIPM module protectionProtectionHurricane protection of the fan motorLow discharge superheat protectionCommunication fault in main control chipProtection3 times (P6) protection in 60 minutes,system lockup5 times (P2) protection in 100 minutes,system lockupPressure transducer(PT) short or open faultHigh pressure(PT) protection in HeatingTemperature sensor fault(T3High/low voltage protectionDC fan motor faultThe discharge sensor(T5) is not seated faultEEPROM2 times (E6) protection in 10 minutes,system lockupIPM module protection or frequent power on/offT4Forced operation modeT5T3 high temperature limitT5 high temperature limitTF)Compression ratio protection limitTF high temperature limitCompressor current protection limitVoltage protection limitCompressor oil returnDefrost modeAmbient Temperature Limited WAIT 2 MINUTES AFTER DISCONNECTING POWER,THENVERIFY DC VOLTAGE LESS THAN 42 VDC AT INVERTERTEST POINTS P2-P4.DANGEROUS ELECTRICAL POTENTIAL OF 380 VOLTS DC.FAILURE TO FOLLOW THIS WARNING COULD RESULTIN PERSONAL INJURY OR DEATHC3F1 P0 P1 P2 P3 P4 P 5 P6 P8 PHH0 H4H5H8 Hb E4 E5E 6 E7E 9E b 0-L9 L D P F C U H DFAtL CODE L Figure 65 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 39 17 Spare parts 17.1 For BOVA 36 Main Control Board 2.4 2 3 2.1 2.3 2.2 Figure 66 No. Part Name Qty BOVA 36 (3 Ton) No. Part Name Qty BOVA 36 (3 Ton) 1 Upside board ass'y 1 8733941794 16 High pressure valve Ass'y 1 8733941821 2 E-part box ass'y 1 8733941795 16.1 Block valve 1 8733941822 2.1 Main control board ass'y 1 8733941796 16.2 One way valve 1 8733941823 2.2 Wire joint 1 8733941797 16.3 Electronic expansion valve body 1 8733941824 2.3 Wire joint, 5p 1 8733941798 16.4 EEV solenoid wire rings 1 8733941825 2.4 Capacitor for fan motor 1 8733941799 17 meter connector ass'y 1 8733941826 3 E-part box ass'y 1 8733941800 17.1 Pipe joint 1 8733941827 4 Nut 1 8733941801 18 Gas-liquid separator 1 8733941828 5 Fan 1 8733941802 19 Compressor 1 8733941829 6 Motor 1 8733941803 20 Chassis Parts 1 8733941830 7 Top conver ass'y 1 8733941804 21 Rubber Cap 1 8733941831 8 Top cover veil 1 8733941805 22 Soundproof cotton 1 8733941832 9 Bolt and washer assembly 4 8733941806 23 Rear clapboard ass'y 1 8733941833 10 Supporting board 3 8733941807 24 Compressor electric heater (with spring) 1 8733941834 11 Clapboard ass'y 1 2 8733941808 25 Compressor Discharge Temp. sensor ass'y 1 8733941835 12 Clapboard ass'y 2 2 8733941809 26 Condenser Pipe Temp. sensor ass'y 1 8733941836 13 Condenser components 1 8733941810 13.1 Condenser 1 8733941811 13.2 Condenser output pipe ass'y 1 8733941812 13.3 Condenser input pipe ass'y 1 8733941813 13.4 Condenser connection pipe ass'y 1 8733941814 14 4-way valve ass'y 1 8733941815 14.1 4-way valve ass'y 1 8733941816 14.2 Pressure sensor 1 8733941817 14.3 Pressure controller 1 8733941818 14.4 Block valve 1 8733941819 15 Suction pipe ass'y 1 8733941820 Table 27 Bosch Thermotechnology Corp. | 12.2016 Data subject to change 40 | Bosch IDS BOVA Installation Instructions 17.2 For BOVA 60 Main Control Board 2.1 2.6 2.2 2.5 2.3 2.4 2.7 Figure 67 No. Part Name Qty BOVA 60 (5 Ton) No. Part Name Qty BOVA 60 (5 Ton) 1 Side board ass'y 1 8733941837 15.2 Pressure controller 1 8733941857 2 E-part box ass'y 1 8733941838 15.3 Pressure sensor 1 8733941817 2.1 Main control board ass'y 1 8733941839 15.4 Block valve 1 8733941858 2.2 Three phase bridge 1 8733941840 16 Suction pipe ass'y 1 8733941859 2.3 Wire joint, 5p 1 8733941798 17 High-pressure valve ass'y 1 8733941860 2.4 Wire joint, 3p 1 8733941841 17.1 One way valve 1 8733941823 2.5 Main control board ass'y 1 8733941842 17.2 Electronic expansion valve body 1 8733941861 2.6 EMC Solenoid 4 8733941843 17.3 EEV solenoid wire rings 1 8733941862 2.7 Electric reactor 2 8733941844 17.4 Block valve 1 8733941822 3 Nut 1 8733941801 18 Gas-liquid separator 1 8733941863 4 Fan 1 8733941802 19 meter connector ass'y 1 8733941864 5 Electrical installation bolt 4 8733941845 19.1 Pipe joint 1 8733941827 6 BLDC 1 8733941846 20 Chassis Parts 1 8733941830 7 Top conver ass'y 1 8733941804 21 Compressor 1 8733941865 8 Top cover veil 1 8733941805 22 Compressor electric heater (with spring) 1 8733941866 9 Bolt and washer assembly 4 8733941806 23 Compressor Discharge Temp. sensor ass'y 1 8733941867 10 Motor installation board ass'y 1 8733941847 24 Condenser Pipe Temp. sensor ass'y 1 8733941868 11 Side board ass'y 2 2 8733941848 25 Ambient Temp. sensor ass'y 1 8733941869 12 Side board ass'y 2 8733941849 26 Rear clapboard ass'y 1 8733941833 13 Supporting board 3 8733941850 27 Rubber Cap 1 8733941831 14 Condenser ass'y 1 8733941851 28 Soundproof cotton 1 8733941870 14.1 Condenser connection pipe ass'y 1 8733941814 14.2 Condenser 1 8733941852 14.3 Condenser outlet pie ass'y 1 8733941853 14.4 Condenser inlet pie ass'y 1 8733941854 15 4-way valve ass'y 1 8733941855 15.1 4-way valve ass'y 1 8733941856 Table 28 Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 41 Notes: Bosch Thermotechnology Corp. | 12.2016 Data subject to change 42 | Bosch IDS BOVA Installation Instructions Notes: Data subject to change 12.2016 | Bosch Thermotechnology Corp. Installation Instructions Bosch IDS BOVA | 43 Notes: Bosch Thermotechnology Corp. | 12.2016 Data subject to change United States and Canada Bosch Thermotechnology Corp. 50 Wentworth Avenue Londonderry, NH 03053 Tel: 866-642-3198 Fax: 954-776-5529 www.boschheatingandcooling.com BTC 761701102 D / 12.2016 !"! #$%& '() !"* +,%-& ! ". +,%-+//00 1) +,%-232425 6 3#-% 7) 8#- 9, :;<=>>;?@ABC=<DE>F@GA 4%##HI#J 77K1!'*'"*1 * L,M#- F 4NMO &MP#H4#0 3#-0M%#- 6( Q%%M-%R#M STUC;DVCE<D=W X 3#/ X00M/ Y 9Z0 O# !"! 4M0 ![ * +00\-/# 7]D;<DEKG;<C] # *=]@CW^ VV]C;;C>=WC;@]D_<DGE[`EC]=AC [`EC]*BGEC aGEDE> . '() b " K ) c ! 3#-%#0 !GE<]=@<G]*]DA=]d!GE<=@<*BGECVV]C;;!GE<]=@<G]d_CD@CE;C D@CE;C^ 1) ![1![ ! ".! S S e! *YY K ![![ 1) ![1![ ! ".! S S ![ b T ![![ 1) ![1![ ([e ! ".! 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