Bosch Ids2.0 Bova-Bva Service Manual External Rev3
Bosch Ids2.0 Bova-Bva Service Manual External Rev3
Bosch Ids2.0 Bova-Bva Service Manual External Rev3
Service Manual
2 | Bosch IDS 2.0 Service Manual
Table of Contents
WARNING:
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.
2 Nomenclature
2.1 Bosch IDS BVA2.0
B V A – 24 W N1 – M 20
Efficiency
20: 20 SEER
Power Supply
M: 208/230V 1Ph, 60Hz
Refrigerant
N1: R410A
Function Type
W: Wired Controller
Nominal Capacity
24: 24×1,000BTU/H
36: 36×1,000BTU/H
48: 48×1,000BTU/H
60: 60×1,000BTU/H
Series
A: A Series
Unit Type
V: Vertical Air Handler
Bosch
Figure 1
B OV A – 36 H D N1 – M 20 G
Compressor Brand
G: GMCC
Efficiency
20: 20 SEER
Power Supply
M: 208/230V 1Ph, 60Hz
Refrigerant
N1: R410A
D-DC Inverter
Function Type
C: Condenser H: Heat Pump
Nominal Capacity
36 36×1,000BTU/H
60 60×1,000BTU/H
Series
A: A Series
Unit Type
OV: Discharge Type
Bosch
Figure 2
4 Dimensions
4.1 Bosch IDS BVA2.0
ELECTRICAL CONNECTIONS
THROUGH TOP OR EITHER SIDE
SUPPLY AIR
Figure 3
Table 2
Figure 4
Table 4
1 Seasonal Energy Efficiency Ratio; Certified per AHRI 210/240 Always check the rating plate for electrical data on the unit being
2 Energy Efficiency Ratio; Certified per AHRI 210/240 installed. The above data are for reference only.
3 HSPF = Heating Seasonal Performance Factor; Certified per AHRI 210/240
4 Jumper cut or dip switch off
Items in bold boxes meet the requirements for ENERGY STAR
6 Product Specifications
6.1 Bosch IDS BVA2.0
BVA024 BVA036 BVA048 BVA060
Cooling Capacity
Nominal Cooling (BTU/h) 24000 34600 47500 54500
Nominal Heating (BTU/h) 24000 34200 48000 56000
Blower
Diameter (mm) 10-5/8" (270) 10-63/64" (279) 10-63/64" (279) 10-63/64" (279)
Width (mm) 8-5/32" (207) 10-43/64" (271) 10-43/64" (271) 10-43/64" (271)
Fan Motor
Horsepower (HP) 1/3 1/2 3/4 3/4
Full Load Amps 2.6 3 4.5 4.5
Refrigeration System
Refrigerant Line Size¹
Liquid Line Size (O.D.) 3/8" 3/8" 3/8" 3/8"
Suction Line Size (O.D.) 3/4" 3/4" 7/8" 7/8"
Refrigerant Connection Size
Liquid Line Size (O.D.) 3/8" 3/8" 3/8" 3/8"
Suction Line Size (O.D.) 3/4" 3/4" 7/8" 7/8"
Expansion Device [TXV=Thermal Expansion Valve] TXV
Decibels dB(A)
High Speed 63 65 67 68
Medium Speed 59 62 63 64
Low Speed 55 58 59 60
Electrical Data
Voltage-Phase-Hz 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60
Minimum Circuit Ampacity ² 3.3 3.8 5.7 5.7
Max. Overcurrent Protection ³ 15 15 15 15
Min / Max Volts 172V/270V
Air Filter
Air Filter Sizes 18" x 20" 18" x 20" 20" x 22" 20" x 22"
Weight
Net Weight (without packaging)(lbs) 119 126 162 170
Gross Weight (including packaging)(lbs) ⁴ 132 139 180 188
Dimensions
Unit D x W x H (in.) 21-5/8 x 19-5/8 x 46-1/2 21-5/8 x 19-5/8 x 46-1/2 24 x 22 x 54-1/2 24 x 22 x 54-1/2
Unit D x W x H (in.)(with pallet and packaging) 25-3/8 x 22-5/16 x 52-9/16 25-3/8 x 22-5/16 x 52-9/16 27-11/16 x 24-11/16 x 60-5/8 27-11/16 x 24-11/16 x 60-5/8
Indoor Coil
Net face area-sq.ft. 4.02 4.02 5.99 5.99
Tube diameter 9/32" (7 mm) 9/32" (7 mm) 9/32" (7mm) 9/32" (7mm)
No.of rows 4 4 4 5
Fins per inch 17 17 17 17
Table 5
¹ Tested and rated in accordance with AHRI Standard 210/240.
² Wire size should be determined in accordance with National Electrical Codes;
extensive wire runs will require larger wire sizes.
³ Must use time-delay fuses or HACR-type circuit breakers of the same size as noted.
⁴ Weight shown includes packaging
³ Must use time-delay fuses or HACR-type circuit breakers of the same size as • Unit is factory charged with refrigerant for 15’ of ⅜” liquid line.
noted. System charge must be adjusted per Installation Instructions Final
Charge Procedure.
⁴ Weight values are estimated.
• TXV is required at indoor unit to match our outdoor unit.
Table 7
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 8
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input
power
Table 9
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 10
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 11
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 12
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 13
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 14
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 15
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 16
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 17
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Table 18
TC refer to total capacity S/T: refer to the ratio of sensible heat and total capacity kW: refer to total input power
Fan motor
PCB
HPS
T5
T3L
PT RV
Condenser Compressor
Accumulator
EEV
Heat Sink
Tf
T4
Th PEV
Figure 5
8.2 5 Ton
Fan motor
T5
HPS
T3
T3L
PT RV
Condenser Compressor
Accumulator
EEV
Heat sink
Tf
T4
Th PEV
Note: Please reference Table 18 for abbreviaon and parts descripon.
Figure 6
E FAN
FAN ON
FAN
H EEV
Indoor unit
N
Thermostat "ON"
Strainer PEV
C HPS
B L Th High pressure gas
T5 High pressure liquid
Low pressure
A INV
Accumulator
Compressor
Outdoor unit
E FAN
FAN ON
H EEV FAN
F Strainer Strainer P O
Liquid Service Valve
T3 Bi-flow Filter Drier TXV
Indoor unit
N Thermostat "ON"
Strainer PEV
C HPS
L Th
B High pressure gas
T5 High pressure liquid
Low pressure
A INV
Accumulator
Compressor
Outdoor unit
The inverter compressor’s speed is controlled based on coil pressures monitored by the
A INV Comp. Inverter Compressor
unit's pressure transducer (PT)
Compressor discharge
B T5 Used for compressor discharge temperature protection and EEV control in heating mode.
temperature sensor
— High Pressure Switch opens at P > 580 PSIG, the compressor and outdoor fan
stop.
C HPS High Pressure Switch
— High Pressure Switch closes at P < 435 PSIG, the compressor and outdoor fan
restart.
G T4 Outdoor Ambient Temperature sensor Used for ambient protection and fan control in heating mode, and defrost control.
Fully open during cooling mode and adjusted during heating mode. Controlled in heating
H EEV Electronic Expansion Valve
mode via compressor discharge superheat.
10 Control Defrost Termination Settings (SW5) offers different defrost termination options for
enhanced defrost for different geographical and outdoor conditions.
10.1 Crankcase Heater Control
The crankcase heater only operates when the compressor is OFF (i.e. during
standby). Refrigerant migration during the OFF cycle can result in noisy start-ups,
therefore a Crankcase Heater (CCH) is used to minimize refrigerant migration
thereby minimizing start-up noise and/or compressor damage. Its purpose is to
warm the compressor during the OFF cycle, driving refrigerant from compressor.
SW5
After extended shutdown periods (high voltage power off) in cold weather, it
is recommended to allow CCH to be energized for at least 12 hours prior to ON
compressor operation by applying line voltage to heat pump with thermostat OFF. 1 2
OFF
If there is no fault code and the unit is in defrost mode, the LED display will show Operating time is Defrosting extended
ON
“dF**” (** shows the frequency of compressor in Hz). The unit can enter defrost reduced by 10% for 60 seconds
mode via logic or manually. OFF Normal Normal Default
The Demand Defrost Control (DDC) monitors the outdoor unit coil temperature Remarks Enter defrost Quit defrost
using thermistor (T3). A second thermistor (T4) monitors outdoor ambient
temperature. Based on these parameters, as well as accumulative run time and Table 20
high pressure, the DDC calculates proper initiation of defrost.
Any one of the below three conditions is required to enter defrost: Manual Defrost:
1. System must have a call for heat and have been operating for a minimum of
1. The calculated temperature difference between the outdoor temperature
8 minutes.
(T4) and the coil temperature (T3) is called Delta T. After Delta T is achieved
and continues for 3 minutes. 2. Press “Force” button on inverter board for 6 seconds to begin manual defrost.
2. After “Minimum Run Time” (MRT) is achieved. MRT is based on outdoor 10.2.2 Oil Return Operation
ambient temperature (T4), for example:
In order to prevent the compressor from operating in a low oil condition, the oil
— MRT is 4 hours when: T4 < 23°F return operation is conducted to recover oil to the compressor. The LED display will
show “A**” during oil return operation (** shows the frequency of compressor).
— MRT is 2 hours when: 23°F ≤ T4 < 42°F
3. After the high pressure saturation temperature drops below 82°F for 20
minutes.
Defrost will terminate once outdoor coil temperature (T3) reaches 64° F for a
period of 1 minute or defrost time has exceeded 8 minutes.
Table 21 Compressor frequency during force mode 1. When SW6-3 dip switch is set to the "ON" position and the unit is in heating
* assumes the J2 dip switch on the outdoor control board is flipped to OFF (forcing mode, the Anti-Cold Air Fan Delay function will activate based on the
unit to 2 or 4 ton). following entry conditions (all 3 conditions must be met):
a. Indoor Coil Temperature (T2) < 82.4℉
b. Electric heat kit is turned off
c. There is a call for Y1 from thermostat to indoor unit
2. This function will deactivate if ONE OF the following exit conditions are met
OR the system has been operating in heating mode for 15 minutes.
a. T2 ≥ 89.6℉
b. Heater kit is turned on
c. The system is NOT running Heat mode
3. During the heating mode, if one of the exit conditions of Anti-Cold Air is
satisfied, the blower motor will turn on in first stage fan speed.
4. During the heating mode, if all of the entry conditions of Anti-Cold Air are met
and maintained for 120s, the blower motor will change to first stage speed.
No. Setting Up the Unit Consider non-default dipswitch positions as needed, refer to
1
section 11.3.2 and 11.3.4
1 Be sure to consider maximum lineset lengths
2 Set thermostat to OFF prior to unit charging
Ensure proper clearances and location restrictions for
2
outdoor and indoor unit No. Unit Charging
3 Ensure outdoor unit is installed on a pad Determine proper charging method: weigh in method or
No. Check Refrigerant Lines 1 charge by subcooling. If design superheat and subcooling
cannot be achieved, refer to section 13.9 for troubleshooting.
1 Ensure proper lineset diameters
2 Ensure proper insulation and routing After 20 minutes of unit operation, ensure proper drainage of
2
3 Braze refrigerant lines using proper techniques condensate on indoor and outdoor units
4 Perform leak check 3 Force unit into Manual Defrost to verify functionality.
5 Properly evacuate lines Table 23
6 Open service valves, ensure they are fully open
No. Low Voltage Wiring
1 Ensure low voltage wiring does not exceed maximum length
11.3 Dip Switch Settings
2 Ensure proper gage wire is used
11.3.1 Outdoor Unit Dip Switch Settings
Connect thermostat wiring as shown in wiring diagrams in
3
IOM SW4 SW5 J2 USB SW1 SW3 SW2
No. High Voltage Wiring
Connect high voltage power supply ensuring proper safety
1
precautions are followed
2 Install high voltage disconnect switch
3 Ensure proper grounding on indoor and outdoor units
Table 22
Figure 10 3 Ton
NOTICE:
Power should be turned off when adjusting dip switches.
In most scenarios, it is recommended to keep all outdoor unit board dip switch
positions in their manufacturer default positions. There are some specific scenarios
when it makes sense to change dip switch settings:
SW4-3: Default is OFF position (enabled), allows for coil/condenser
target temperature to drift +/- 4°F based on previous hour of operation in
an attempt to optimize run time. If dip switch is changed to ON, software
requires a “hard” target for coil temperature and does not drift to optimize
runtime.
Reason to change from default: In zoning applications but only as needed
as a result of customer expectations and/or performance.
SW4-4: Default is OFF position, system uses the default target coil
temperatures. If dip switch is changed to ON, this reduces the target coil
temperature by 4°F in cooling and increases target coil temperature by 4°F
in heating. Reason to change from default: Recommended to be used
Figure 11 5 Ton
only as-needed as a result of customer expectations and/or performance
(i.e. not getting enough capacity, or not dehumidifying well enough).
Switch Position Function
SW1 Push Button Reserved SW5-1: Default is OFF position, uses default defrost operating time
(maximum of 8 minutes). If dip switch is changed to ON, default defrost
SW2 Push Button For check point data
time is reduced by 10%.
SW3 Push Button Force mode/Manual defrost Reason to change from default: Can be used in mild/warm climates, where
ON Program For IDP it may take less time than usual to defrost the outdoor coil.
SW4-1
OFF* Program For IDS 2.0
SW5-2: Default is OFF position, uses default defrost operating time
SW4-2 Reserved Reserved (maximum of 8 minutes). If dip switch is changed to ON, default defrost
ON Adaptive capacity output disabled time is increased by 1 minute.
SW4-3
OFF* Adaptive capacity output enabled Reason to change from default: Can be used in colder climates, where it
may take more time than usual to defrost the outdoor coil.
ON Accelerated cooling/heating
SW4-4
OFF* Normal cooling/heating J2: Default is ON, which leaves the compressor capacity at default (3 or
ON Operating time is reduced by 10% 5 ton depending on the model). Regardless of if the matching air handler
SW5-1
OFF* Normal operation is 2 ton or 3 ton (when paired with the 3 ton condenser), or matching
air handler is 4 ton or 5 ton (when paired with 5 ton condenser), the
ON Defrosting extended for 60 seconds
SW5-2 J2 jumper can be left at default position. The compressor will ramp to
OFF* Normal operation required coil temperature regardless of paired air handler size.
ON* For 3/5 ton Capacity Reason to change from default: If you want (or need) to minimize maximum
J2 condenser capacity from 3 to 2 tons (3 ton condenser model) OR 5 to 4 tons
OFF For 2/4 ton Capacity
(5 ton condenser model).
Table 24 Outdoor unit dip switch settings
* Default setting
11.3.3 Indoor Unit Dip Switch Settings 11.3.4 When to Change Indoor Unit Dipswitch Settings
NOTICE:
Power should be turned off when adjusting dip switches.
In most scenarios, it is recommended to keep all indoor unit board dip switch
positions in their manufacturer default positions. There are some specific scenarios
when it makes sense to change dip switch settings:
SW6-1/2: Default positions vary by air handler size, see Table 25.
Changing the position of these dip switches changes the fan motor speed
settings for high and low speed.
Reason to change from default: The manufacturer recommends 350-450
CFM/ton, the static pressure and speed tap settings influence the CFM. Refer
to the air flow performance chart in the IOM to select fan speed settings
depending on your application.
Dip Switch Position Low Fan Speed High Fan Speed Default
SW6-1 OFF
1 2
SW6-2 OFF
SW6-1 OFF Default on 48 air
1 3
SW6-2 ON handler model
SW6-3: Default is ON position, which turns on the Anti-Cold Air Fan Delay
function. This function utilizes a sensor (T2) located on the indoor coil,
which prevents the blower from turning on until the coil has reached
a temperature of 89.6 deg F, at which point it will run in low speed.
The blower will exit the Anti-Cold Air Fan Delay function when the coil
temperature is above 100.4 deg F. This feature prevents cold air blowing
into the space during heating operation. If dip switch changes to ON, the
fan will operate in heating mode with a 90 second fan delay.
Reason to change from default: Recommended to be used only as-needed
as a result of customer expectations and/or performance
SW6-4: Default is OFF position, but the function of this dip switch is
simply reserved for future use (no functionality at this time).
Reason to change from default: Never recommend to change from default.
21
20
19 17
No. Function Description
18 16
1 Compressor crankcase heater port
15 2 Pressure equalizer valve port
22
14 3 Reversing valve port
4 Thermostat wire connections
5 Th sensor port
6 TF sensor port
13
23 7 T3 T4 T3L sensor port
12
8 Pressure transducer port
11 9 T5 sensor port
10 10 Reserve
11 EEV port
9
12 Reserve
24 8
13 Reserve
25 7 14 High pressure switch port
26 6 15 SW2 FORCE BUTTON
5 16 SW3 CHECK BUTTON
17 Reserve
4
18 USB
3 19 J2 Dip SWITCH: Select capacity
20 SW5 Dip SWITCH:Defrost logic settings
21 SW4 Dip SWITCH:Control logic settings
22 LED
23 ECM motor port
24 Compressor: W port
25 Compressor: V port
26 Compressor: U port
27 27 Power input
28 Power input
28
1 2
19
18
17
No. Function description
21 16
1 Pressure equalizer valve port
24 23 22 20 15
2 Compressor crankcase heater port
3 Reversing valve port
4 Thermostat wire connections
5 EEV port
14
6 Th sensor port
13
25 7 TF sensor port
12
8 T3 T4 T3L sensor port
11
9 Pressure transducer port
10
10 T5 sensor port
26 9
11 Reserve
8
27 12 Reserve
7
13 Reserve
28
6 14 High pressure switch port
5 15 USB port
16 SW2 FORCE BUTTON
4 17 SW3 CHECK BUTTON
29 27 Compressor: V port
2 28 Compressor: U port
1 29 Power input
30
30 Power input
12.2 Fault Code and Limited Condition Descriptions Fault codes are displayed when an abnormal condition exists that could harm the
unit. Fault codes cause the compressor to shut off and force the unit into standby
Limited Condition Status codes are displayed when a condition exists that
mode until the abnormal condition goes away. When the abnormal condition
could harm the unit. To protect itself, the unit continues to run, but with limited
ceases, the unit will restart and operate as normal. The only exception is H5 which
compressor frequency. When these protection codes are visible, the unit is still
requires a hard restart. Service may be recommended for active fault codes, see
functioning, just not according to its normal logic. If condition worsens/persists, a
fault code troubleshooting section for more detail.
fault code will be displayed and the compressor will shut off. For Limited Condition
Status codes, no service is required. Service may be recommended for active fault
codes, see fault code troubleshooting section for more detail.
Limited Condition
Fault Code Fault Code Description Potential Cause
Status code
Motor failed
Fan blade damaged or blocked
E6 Outdoor DC fan motor fault.
Extreme weather conditions
Electrical issue
Limited Condition
Fault Code Fault Code Description Potential Cause
Status code
P** Running indication under compressor ratio limited condition Low temperature and low load
12.3.1 C3 Troubleshooting
Table 29
Procedure:
No
Yes
Did T3 sensor fail?1 Replace T3 sensor
No
Yes
Did T4 sensor fail?1 Replace T4 sensor
No
Figure 16
1) See Section 13.4
12.3.2 E4 Troubleshooting
Table 30
Procedure:
Yes
Yes
Is the T4 (ambient
No service required
temperature) <-4 °F?
No
No
Restart system
Figure 17
1) See Section 13.4
12.3.3 E5 Troubleshooting
Table 31
Procedure:
No
Yes
Is the high voltage power supply Correct power supply/call
<172V? utility provider
No
No
Restart system
Figure 18
12.3.4 E6 Troubleshooting
Motor failed
Fan blade damaged or blocked
Possible causes:
Extreme weather conditions
Electrical issue
Table 32
Procedure:
Yes
No
Are outdoor
weather conditions Yes Power off until severe
preventing the fan weather conditions subside
from operating
normally?
No
Yes
Did the outdoor fan
Replace motor
motor fail?1
No
Yes
Did the control
Replace control board
board fail?2
No
Restart system
Figure 19
1) See Section 13.6
2) See Appendix 1
12.3.5 E7 Troubleshooting
Table 33
Procedure:
No
Are T5 and Tf
connections at No Correct T5 and Tf
control board connections
correct?
Yes
No
Restart system
Figure 20
1) See Section 13.4
12.3.6 E9 Troubleshooting
Table 34
Procedure:
No
No
Replace PCB
Figure 21
12.3.7 H0 Troubleshooting
Procedure:
No
No
Replace PCB
Figure 22
12.3.8 H8 Troubleshooting
Table 36
Procedure:
Is the wiring
No
Secure wiring
secure?
Yes
No
Yes
Did the control
Replace control board
board fail?2
No
Restart system
Figure 23
1) See Section 13.2
2) See Appendix 1
12.3.9 P0 Troubleshooting
Table 37
Procedure:
No
No
Are T5 and Tf
No
connections at Correct T5 and Tf
control board connections
correct?
Yes
Yes
Did the Tf sensor
Replace Tf sensor
fail?2
No
Yes
Did the control
Replace the control board
board fail?3
No
Figure 24
1) See Section 13.6
2) SeeSection 13.4
3) See Appendix 1
Poor heat exchange on coil (cooling mode – outdoor coil, heating mode – indoor coil)
Fan motor failure (cooling mode – outdoor fan, heating mode – indoor fan)
Possible causes: Service valves not open
TXV/EEV/filter drier blocked
Over charged
Table 38
Procedure:
No No
Yes
No
No
Restart system
Figure 25
1) See Section 13.1
2) See Section 13.5
Poor heat exchange on coil (cooling mode – indoor coil, heating mode – outdoor coil)
Fan motor failure (cooling mode – indoor fan, heating mode – outdoor fan)
Possible causes: Service valves not open
TXV/EEV/filter drier blocked
Under charged
Table 39
Procedure:
P2 error code
P2 occurs 5 times in Yes H5 displayed, hard lockout System hard shut down
100 minutes
No
Yes Is there still a fault
Power on unit
code displayed?
No service required
Yes
No
No
Restart system
Figure 26
1) See Section 13.1
2) See Section 13.2
12.3.12 P3 Troubleshooting
Poor heat exchange on coil (cooling mode – outdoor coil, heating mode – indoor coil)
Fan motor failure (cooling mode – outdoor fan, heating mode – indoor fan)
Service valves not open
Possible causes:
TXV/EEV/filter drier blocked
Over charged
Control board or compressor issue
Table 40
Procedure:
No No
Yes
Yes
No
No
Yes
Did the compressor
Replace compressor
fail? 3
No
Restart system
Figure 27
1) See Section 13.1
2) See Section 13.5
3) See Section 13.8
12.3.13 P4 Troubleshooting
Poor heat exchange on coil (cooling mode – outdoor coil, heating mode – indoor coil)
Fan motor failure (cooling mode – outdoor fan, heating mode – indoor fan)
Possible causes: Service valves not open
TXV/EEV/filter drier blocked
Over charged
Table 41
Procedure:
No No
Yes
Yes
If the system is
Yes
overcharged Follow IOM to adjust
refrigerant
No
Yes
Did T5 sensor fail? 2
Replace T5
No
Restart system
Figure 28
1) See Section 13.1
2) See Section 13.4
12.3.14 P5 Troubleshooting
Table 42
Procedure:
No No
Yes
Yes
No
Did T3 sensor
Yes
Replace T3
fail 2
No
Restart system
Figure 29
1) See Section 13.1
2) See Section 13.4
12.3.15 P8 Troubleshooting
Procedure:
Are outdoor
weather conditions Yes
Power off until severe
preventing the fan
weather conditions subside
from operating
normally?
No
Yes
Did the motor fail? 1 Replace motor
No
Restart System
Figure 30
1) See Section 13.6
12.3.16 PH Troubleshooting
Poor heat exchange on coil (cooling mode – indoor coil, heating mode – outdoor coil)
Fan motor failure (cooling mode – indoor fan, heating mode – outdoor fan)
Possible causes: Service valves not open
TXV/EEV/filter drier blocked
Under charged
Table 44
Procedure:
No No
Yes
Yes
No
No
Restart system
Figure 31
1) See Section 13.1
2) See Section 13.4
Table 45
Procedure:
No
No
No
No
No
Is the compressor
No
Replace compressor
operating normally? 1
Yes
Figure 32
1) See Section 13.8
Table 46
Procedure:
Is the ambient
temperature Yes No service required. Wait
for temperature to be within
beyond operating
range
range? 1
No
No
Yes
Did the T4 sensor
Replace T4 sensor
fail? 2
No
Restart system
Figure 33
1) Cooling:15~125°F, Heating:-4~86°F
2) See Section 13.4
Table 47
Procedure:
No
No
Yes
Is the wiring Refer to wiring diagram on
incorrect? the manual and correct it
No
Yes
Is LED working? Replace pressure
transducer
No
Yes
Is LED working? Replace outdoor blower
motor
No
Is compressor No
operating Replace compressor
normally? 1
Yes
Figure 34
1) See Section 13.8
Table 48
Procedure:
Yes
Is there 18-28VAC No
Correct thermostat wire
and 0VDC between
connection/replace the
Y&C and B&C at
thermostat
the outdoor unit?
Yes
No
Is there 230VAC No
power at high Correct power supply
voltage terminal?
Yes
Figure 35
1) If high voltage power to the unit is interrupted and then restored, the compressor
ALWAYS waits at least 3 mins before it starts via a thermostat Y call, the outdoor
fan motor will always start immediately upon thermostat Y call.
2) In cooling mode: There is at least a 6 minute delay between when the thermostat
is satisfied and compressor can turn back on with a Y call.
3) In heating mode: There is at least a 3 minute delay between when the thermostat
is satisfied and compressor can turn back on with a Y call.
No fault code displayed but poor capacity (the the heating or cooling capacity is insufficient, but the unit
Description:
is running)
Table 49
Procedure:
Yes
No
Yes
Check if there is Follow Section 13.1 to
abnormal check abnormal pressure
pressure?
No
Restart System
Figure 36
Table 50
Procedure:
Yes
No
Was ductwork Refer to IOM and follow
installed properly? local codes
Yes
No
Is the system
properly charged? Refer to IOM
Yes
No
Is there still poor
No service required
dehumidification?
Yes
Change SW4-4 to on
position on outdoor board.
Set indoor fan to lower
speed using SW6-1, SW6-2
on indoor board
No
Is there still poor
No service required
dehumidification?
Yes
No
Is there still poor
No service required
dehumidification?
Yes
Figure 37
No
No No
No
Is there blockage Yes Switch between Does the Yes Replace bi-flow
cooling and heating problem
in the bi-flow filter still persist? filter drier
several times
drier? 3
Extreme If the
Abnormal temperature is out of
Yes
temperature Shutdown unit
pressure operation range
condition
Poor heat
Poor heat
exchange Yes
exchange Is the motor Follow section 13.6
on ODU
not running? to check ODU motor
No
Are the clearances Fix clearances,
for the ODU correct? refer to IOM
Poor heat
NOTE: exchange
1) Is the temperature difference Is the motor Yes Follow section 13.7
on IDU not running? to check ODU motor
before and after the EEV
extremely high?
2) Is the temperature difference
before and after the TXV No
extremely high? Are the clearances Fix clearances,
for the IDU correct? refer to IOM
3) Is there more than 2℉ before
and after the drier in force
mode?
Is there any Yes
blockage on Clean air filter
air filter?
Refrigerant Follow IOM
overcharge or to correct
undercharge refrigerant charge
Figure 38
No
GND Black
Make measurement
of 5V DC voltage
Does voltage = No
Replace control board
5V(DC)?
Yes
Does
gage measured
pressure value equal
No
Replace pressure transducer
value obtained from
graph (± 50psi)?
CAUTION:
Be careful of static electricity when handling pressure
Yes transducer, especially in dry weather.
Restart system
Figure 39
Is there a fast
“clicking” noise
Yes Are there signs of Yes Follow section 13.1 to
abnormal high/low check for abnormal
when heating mode
pressure? pressure
begins?
No No
No service required
No
Is the voltage
between Red wire Replace control board
& GND =12V(DC)
Yes
Is the voltage
between No
White/Yellow/Orange Replace EEV
/Blue &
GND=12V(DC)
Restart system
GND
Figure 40
Yes
Is ambient temperature Out of operating range.
below -4°F? No service required.
Is the corresponding
temperature from
the resistance value
Yes
No service required
chart ±15°F from
check point data?
No
T3/T4/T3L Temperature Sensor
Replace sensor
Figure 41
Yes
HPS
Location
Unplug HPS from control
board and measure
resistance at wiring harness
Yes
Is resistance ≥ 1Ω? Replace HPS
No
Is there an active
Yes Refer to Section 13.1 to check
error code? for abnormal pressure
No
HPS is functioning properly.
No service required.
Figure 42
No
Do the No
resistance values meet the Replace ODU motor
requirement from
Table 1?
Yes
Re-connect motor wiring
harness at CN3, power on unit
and give call for heating/cooling
Yes
Measure
DC voltage between No
P&N pins (Red & Black wire), Replace control board
is the voltage 370-
385V(DC)?
Yes
Measure
DC voltage between No
+15V&N pins (White & Black Replace control board
wire), is the voltage 14-
18V(DC)?
Yes
Measure
DC voltage between No
VSP&N pins (Yellow & Black Replace control board
wire), is the voltage 1.9-
5.1V(DC)?
Yes
Restart system
Figure 43
No
No
Is there 230V(AC) Fix the wire connection or
power supply? power supply
Yes
Is there 18-
28V(AC) between No
CN33 terminals on Replace transformer
IDU control board?
Yes
CN35
Is there 18- No
28V(AC) between
R&C terminals on Replace the control board
IDU control board?
Yes
Is there 18- No
28V(AC)between Y1&C Fix low voltage
wiring/replace the
terminals on IDU control thermostat
board?
24V(AC) depends on SW6-1&2 dipswitch fan
speed settings. High or low speed depends on if
Yes Y1 (low) or Y2 (high) call. Measure between
speed pin and C (brown wire).
Yes
Is there 24V(AC) No
between the pins at Replace the control board
CN35 on IDU
control board?
Yes
Is there
230V(AC) between No
CN39 & black wire connected Replace the control board
to transformer?
Yes
Replace motor
Figure 44
13.8 Compressor
Does
compressor appear Yes
to be running properly No service required
(i.e. no abnormal
noise)?
No
Yes
Is there 24VAC No
between Y&C on Fix thermostat
control board
Yes
Resistance (Ω) 3T 5T
Between U and V <1.5 <1
Is the voltage Yes Between V and W <1.5 <1
between P-N Replace control board
(CN3)< 310V DC? Between W and U <1.5 <1
Between U/V/W and ground >10M >10M
No
Yes
Power off and unplug
compressor wires, measure
resistances (see Table 1)
Yes
Are
resistances correct
according to Table 1? (Resistance No
values can change +/-0.5 ohms Replace compressor
depending on equipment
& temperature)
Yes
Yes
Is there an active Follow fault code specific
fault code? troubleshooting steps
No
Replace compressor
Figure 45
Is ambient temp
within 55-120°F? No Temperature out of range,
Is indoor temperature charge unit via weigh in
between 70-80°F? method. Refer to IOM
Yes
Short press “Force” button (SW2), and Model Range SC/°F SH/°F
operate the system for at least 20 min
A 10±2 10~18
24K/36K B 8±2 7~10
C 6±2 5~7
Measure and calculate superheat and
subcool, refer to IOM for instructions A 8±2 9~18
48K B 6±2 7~9
C 5±2 5~7
Are SH and SC in A 8±2 8~18
Yes
Range A or B in No service required 60K B 6±2 6~8
Table
C 5±2 5~7
No
Adjust charge according to IOM NOTE: Use Range A for indoor units with adjustable TXV and
non-adjustable TXV.
Use Range B for indoor units with non-adjustable TXV.
Are SH and SC in Yes
Range A or B in No service required
Table
No
Verify SH and SC are
No correctly measured and
Are SH and SC in refrigerant is being
Range C in Table adjusted correctly, refer
to IOM
Yes
No
Yes
No
Figure 46
No
Did the fuse blow
on the outdoor board? No service required
Yes
Fuse
Location
Power off unit
Yes
Did the ODU motor Replace ODU motor
fail? 1
No
Yes
Did the compressor Replace compressor
fail? 2
Fuse
No Location
Figure 47
1) See Section 13.6
2) See Section 13.8
No
Did fuse#1 blow on
No service required
the indoor board?
Fuse#1 Type 32V/3A
Fuse#2 Type 230V/ 3.15A
Function Protect control board
Yes
Replace fuse#1
Fuse#1
Location
Is the thermostat No
wiring correct Correct thermostat wiring
according to the
wiring diagram?
No
No
Did fuse#2 blow on
No service required
the indoor board?
Yes
Replace indoor
control board
Check if the No
resistance between
Correct thermostat wiring
CN39 & Ground
>1MΩ
Yes
Figure 48
Appendix
Appendix 1 Outdoor Unit Control Board
GR/W
BR/V
BK/U
WHITE
BLUE
Figure 49
LED Display DSP1 CODE or numbers When there is high voltage power to unit
CN3
DC motor control power 14-18V(DC) When there is call from thermostat
(+15V-N)
CN3
DC voltage 370-385V(DC) When compressor starts
(P-N)
LED light LED 1/2/3 Light or flash When there is call from thermostat
Reversing valve (RV) CN12 Light or flash When there is B call from thermostat
PEV - Pressure Equalization Valve CN17 172-270V(AC) At initial power on/start up sequence
CN13
EEV – Electronic Expansion Valve 12V(DC) When there is B call from thermostat
(All pins-GND)
CN16
PT - Pressure transducer 5V (DC) When there is high voltage power to unit
(+5V-GND)
Compressor U-V, V-W, W-U <1.5Ω (3T), <1Ω (5T) When power OFF at breaker
Figure 50
CN5
(Y1-C, Y2-C, R-C, G-C)
Thermostat connection 18-30V(AC) When there is call from thermostat
CN4
(Dh-C, B-C, W1-C, W2-C)
LED light LED 4 Light or flash When there is high voltage power to unit
CN6
Electric heat 172-270V(AC) When there is a call for electric heat
(W1-C, W2-C)
Low voltage power supply to board CN33 18V-30V(AC) When there is high voltage power to unit
1) Depends on SW6-1&2 dipswitch fan speed settings. High or low speed depends
on if Y1 (low) or Y2 (high) call. Measure between speed pin and C (brown wire).
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Fax: 603-965-7581
www.bosch-thermotechnology.us