Bosch AHUW036A2 Service Manual Download Page 42

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Split ODU – 6 720 817 722 (2015/06)

Summary of Contents for AHUW036A2

Page 1: ...Service guide 230 V 1 N 400 V 3 N Split Outdoor unit 6 720 813 707 00 2I ODU Split 2 ODU Split 4 8 ODU Split 11t 15t ODU Split 11s 15s 6 720 817 722 2015 06 ...

Page 2: ...defined and can be used in this document NOTICE indicates a situation that could result in damage to property or equipment CAUTION indicates a situation that could result in minor to medium injury WARNING indicates a situation that could result in severe injury or death DANGER indicates a situation that will result in severe injury or death Important information Additional symbols 1 2 General safe...

Page 3: ... Split 13s AHUW156A2 166A2 ODU Split 15s AHUW128A2 ODU Split 11t AHUW148A2 ODU Split 13t AHUW158A2 168A2 ODU Split 15t Table 2 Names of units HMI Error code ODU Error code Description Error characteristc Remark 5600 5601 21 DC Peak IPM Fault IPM Intelligent Power module Restart 10x hour then blocked Compressor broken or too much refrigerant in compressor 5602 5603 22 CT 2 Max CT Restart after prob...

Page 4: ... kPa Heating Condensing temperature 64 2 C 4101 kPa Cooling 5642 5643 62 Temperature at heat sink is too high Restart after problem has vanished Heat sink temperature 85 C 5646 5647 65 Problem in heatsink temperature sensor Direct shut down Heat sink sensor Inverter PCB broken 5670 5671 67 ODU BLDC fan lock Restart 10x hour then blocked Fan blocked HMI Error code ODU Error code Description Error c...

Page 5: ...bnormality found Yes Aretheresistancebetweeneachphase and insulation resistance of inverter compressor normal No 1 Check resistance between each terminal of compressor 2 Check insulation resistance between compressor terminal and pipe Replace compressor if abnormality is found Yes Is compressor wire connection condition normal No 1 Check inverter PCB assembly 1 U V W connector cennection condition...

Page 6: ... If the value between P and N terminal of IPM is short 0 or open hundreds M PCB Inverter needs to be replaced IPM is damaged 5 Set the multi tester to diode mode 6 In case measured value is different from the table PCB Inverter needs to be replaced PCB Inverter is damaged Fig 5 PFC_IPM check 1 2 3 U V W 6 720 817 722 04 1I 27 26 25 24 23 22 21 P W V U Nw Nv Nu 0 4 0 6 V P W V U Nw Nv Nu 27 26 25 2...

Page 7: ...resistance mode 4 If the value between P and N terminal of IPM is short 0 or open hundreds M PCB Inverter needs to be replaced IPM is damaged 5 Set the multi tester to diode mode 6 In case measured value is different from the table PCB Inverter needs to be replaced PCB Inverter is damaged Fig 7 PFC_IPM check 6 720 817 722 05 1I 27 26 25 24 23 22 21 P W V U Nw Nv Nu 0 4 0 6 V P W V U Nw Nv Nu 27 26...

Page 8: ...hase and insulation resistance of inverter compressor normal No 1 Check resistance between each terminal of compressor 2 Check insulation resistance between compressor terminal and pipe Replace compressor if abnormality is found Yes Is compressor wire connection condition normal No 1 Check connection between PCB assembly and bridge diode misconnection disconnection 2 Check wire disconnection and w...

Page 9: ...plit 4 6 8 Fig 8 ODU Split 4 6 8 Check output of the CT sensor DC 2 5 0 2V ODU Split 11s 13s 15s Fig 9 ODU Split 11s 13s 15s 1 Inverter PCB 2 CT sensing check point Check output pin 2 3 of the CT sensor DC 2 5 0 2V IN I GND Black Red Vdc 6 720 817 722 06 1I 1 2 3 Vdc 6 720 817 722 07 1I 1 2 ...

Page 10: ...outdoor unit Split ODU 6 720 817 722 2015 06 10 ODU Split 11t 13t 15t Fig 10 ODU Split 11t 13t 15t 1 Inverter PCB 2 CT sensing check point Check input current T_PFC and R_PFC Check output of the CT sensor DC 2 5 0 2V 6 720 817 722 08 1I 1 2 ...

Page 11: ...ing signal AHBW 8AO 0 4 0 6V Graphic 13 ODU Split 4 6 8 Fig 11 ODU Split 4 6 8 Display code Title Cause of error Check point Normal condition 23 DClinkHigh Low voltage DC link voltage is above 420Vdc DC link voltage is below 140Vdc 1 Check CN_ L CN_ N connection 2 Check input voltage 3 Check PCB DC link voltage sensor parts Table 9 Error code 23 Is input voltage normal No 1 Check power input volta...

Page 12: ...Error handling instructions for Split outdoor unit Split ODU 6 720 817 722 2015 06 12 ODU Split 11s 13s 15s Fig 12 ODU Split 11s 13s 15s Vdc P GND 6 720 817 722 10 1I ...

Page 13: ...Error handling instructions for Split outdoor unit Split ODU 6 720 817 722 2015 06 13 ODU Split 11t 13t 15t Fig 13 ODU Split 11t 13t 15t 1 PFCM pin arrangement and pin numbers 6 720 817 722 11 1I 1 ...

Page 14: ...rigerant pressure Reassemble or manage if abnormality found Yes Are the resistance between each phase and insulation resistance of inverter compressor normal No 1 Check resistance between each terminal of compressor 2 Check insulation resistance between compressor terminal and pipe Replace compressor if abnormality is found Yes Is compressor wire connection condition normal No 1 Check inverter PCB...

Page 15: ...nit Split ODU 6 720 817 722 2015 06 15 ODU Split 4 6 8 Fig 14 ODU Split 4 6 8 1 CT sensing check point 2 WVC connector check ODU Split 11s 13s 15s Fig 15 ODU Split 11s 13s 15s U V W GND Vdc U V W 6 720 817 722 12 1I 1 2 U W V GND 6 720 817 722 13 1I ...

Page 16: ...Error handling instructions for Split outdoor unit Split ODU 6 720 817 722 2015 06 16 ODU Split 11t 13t 15t Fig 16 ODU Split 11t 13t 15t 6 720 817 722 14 1I ...

Page 17: ...EV connector assembly condition normal operation 4 Check refrigerant pressure Reassemble or manage if abnormality found Yes Is input voltage normal No 1 CheckthatL Nphasevoltageis 230 15 1 2 Check that R S T N phase voltage is 380 15 3 Check connection condition and wiring if power is abnormal Yes Is AC input wire connection condition normal No 1 Check L N connection condition 2 Check wire disconn...

Page 18: ...utdoor unit Split ODU 6 720 817 722 2015 06 18 ODU Split 4 6 8 Fig 17 ODU Split 4 6 8 1 Short circuit check point 2 After turning off the main power R24N between the ends of the resistance will be measured to 620 670 6 720 817 722 15 1I 1 2 ...

Page 19: ...lit outdoor unit Split ODU 6 720 817 722 2015 06 19 ODU Split 11s t 13s t 15s t Fig 18 ODU Split 11s t 13s t 15s t 1 ODU Split 11t 13t 15t 2 ODU Split 11s 13s 15s 3 Short circuit check point 6 720 817 722 16 1I P T S R N U N V N W 1 2 3 ...

Page 20: ...rigerant pressure Reassemble or manage if abnormality found Yes Are the resistance between each phase and insulation resistance of inverter compressor normal No 1 Check resistance between each terminal of compressor 0 188 7 2 Check insulation resistance between compressor terminal and pipe over 50 M Replace compressor if abnormality is found Yes Is compressor wire connection condition normal No 1 ...

Page 21: ...sor LEV connector displaced poor LEV assembly 1 Check outdoor fan constraint screened flow structure 2 Check refrigerant leakage 3 Check if the sensor is normal 4 Check the status of EEV assembly Table 17 Error code 32 Is the heating water flow sufficient No 1 Check that the heating water circulation pump is working 2 Check that the heating water flow rate is sufficient 3 Check preassure gauge 1 5...

Page 22: ...cable piping normal No 1 Check communication piping correction Yes Is amount of refrigerant normal No 1 Checkforpipecrackortraceof refrigerant leakage 2 Weld reconnect the cracked portion 3 Adjust the amount of recharge refrigerant Yes Is the strainer OK 1 1 If the temperature difference between inlet and outlet of strainer is so large that frost or ice formation can be seen or confirmed then clog...

Page 23: ...outdoor PCB inverter 45 Condenser Mid pipe sensor Open short Soldered poorly Internal circuit error 1 Bad connection of thermistor connector 2 Defect of thermistor connector open short 3 Defect of outdoor PCB inverter 46 Suction pipe sensor Open short Soldered poorly Internal circuit error 1 Bad connection of thermistor connector 2 Defect of thermistor connector open short 3 Defect of outdoor PCB ...

Page 24: ...value of sensor open short 1 Bad connection of connector PCB inverter 2 Bad connection high pressure connector 3 Defect of connector PCB inverter open short 4 Defect of PCB inverter Table 23 Error code 43 Is pressure sensor OK No 1 Replace the pressure sensor Yes Is sensor connected to PCB inverter correctly No 1 Connect sensor to PCB inverter correctly Yes After replacement of outdoor unit main P...

Page 25: ...o communication between CAN PCB and Installerboard CAN PCB does not send signals to Installerboard 55 ODU shuts down after 1 3 seconds from recognizing CAN communication error Table 25 Error codes 52 53 Display code Title Cause of error Check point Normal condition 52 PCB communica tion error Checkingthe communicati on state between main PCB and inverter PCB 1 Generation of noise source interferin...

Page 26: ... point Check the transmission connector and LED main and inverter Fig 23 Error code 52 check point ODU Split 11t 13t 15t 1 Insufficient insertion of wires 2 Damage of wire coating Interference with wires or wire coating damage with chopping 3 42 48 60k 4 Inverter PCB 5 Main PCB OK NG 6 720 817 722 21 1I 1 2 3 4 5 ...

Page 27: ...oor communication 1 Power input AC 230V 2 The connector for transmission is disconnected 3 The connection wires are miss connected 4 The communication line is shorted at GND 5 Transmission circuit of PCB inverter is abnormal 6 Transmission circuit of PCB heater is abnormal Table 28 Error code 53 Display code Title Cause of error Check point Normal condition 54 Open and reverse phase error Preventi...

Page 28: ...ructions for Split outdoor unit Split ODU 6 720 817 722 2015 06 28 Fig 25 ODU Split 4 6 8 Fig 26 ODU Split 11 13 15 1 ODU Split 11s 13s 15s 1 ODU Split 11t 13t 15t 6 720 817 722 23 1I EEPROM EEPROM 6 720 817 722 24 1I 1 2 ...

Page 29: ...V assembly Poor condenser pipe sensor assembly broken 1 Check outdoor fan constraint screened flow structure 2 Check if refrigerant is overcharged 3 Check the status of the EEV assembly 4 Check the status of sensor assembly Table 32 Error code 61 Is the unit properly installed No 1 Check fan locking 2 Remove blockings around heat exchanger 3 Maintain distance between unit and the wall 4 Check pipe...

Page 30: ... C unplugged Check the outdoor fan is running correctly 2 Part no EBR37798112 21 Check the soldered condition in the 22 23 pin of IPM PFCM Check the screw torque of IPM PFCM Check the spreadable condition of thermal grease on IPM PFCM Check the outdoor fan is running correctly 65 Heat sink sensor Connector connection error Faulty PCB Faulty sensor Open Short 1 Normal resistor 5k at 25 C unplugged ...

Page 31: ... 6 720 817 722 2015 06 31 Fig 29 Error code 62 65 check points 1 ODU Split 4 6 8 2 PFCM measuring resistance between no 19 20 pin 3 ODU Split 11s 13s 15s 4 ODU Split 11t 13t 15t 5 Heat sink temperature output pin IPM PFCM 1 2ྛ 1 2ྛ 6 720 817 722 25 1I 1 3 2 4 5 ...

Page 32: ...arting 1 ODU fan locking 2 Heat sink assembly of PCB assembly 1 condition abnormal 3 Defect of temperature sensing circuit part defect of PCB inverter Table 36 Error code 67 Is ODU fan motor assembly condition normal No 1 Check ODU fan motor assembly condition and fan locking Reassemble or replace if abnormality is found Yes Is ODU fan motor normal No 1 Set the multi tester to diode mode 2 Check v...

Page 33: ... handling instructions for Split outdoor unit Split ODU 6 720 817 722 2015 06 33 Fig 31 Error code 67 check points 1 ODU Split 4 6 8 2 ODU Split 11s 13s 15s 3 ODU Split 11t 13t 15t 6 720 817 722 27 1I 2 3 1 ...

Page 34: ...tween the coils Disconnect the compressor motor plug Measure the resistance between the coils The resistance should be equal Fig 32 Check compressor resistances 1 Compressor 2 Copper pipe WARNING Electric shock Even if the ODU is disconnected from power supply it takes some time to discharge the remaining electricity of the electrolytic capacitor Before conducting a service or repairing job switch...

Page 35: ...bers before tightening the fixing nuts of the compressor 8 Remove the rubber caps put on the suction and discharge pipes of the new compressor to release the sealing nitrogen gas 9 Brazethesuctionanddischargepipetothecompressorwithbrazing torch 10 Conduct air tight test to check that the piping system is free from leakage 11 Re connect the power cable to the terminal board of the compressor 12 Att...

Page 36: ...eakage of refrigerant or clog of cycle Defective compressor Temperature difference is ok 5 10K Power consumption is high over rated current Too much refrigerant Temperature difference is ok 5 10K Power consumption is in range of rated current 10 Normal operation Table 38 Temperature difference and power consumption Suction pressure Outlet temperature Reason Result Higher than normal value Higher t...

Page 37: ...iving circuit failure 1 Disconnect the EEV connector from control board and connect testing LED 2 Main power ON pulse signal is out from EEV for 17 seconds If the LEDs do not turn on or are in on state continuously then the driving circuit is abnormal Check and replace unit control board Unit EEV locking 1 If EEV is locked in no load state the driving motor rotate and clicking sound always occurs ...

Page 38: ...e 2 For wrong wiring For following wiring 1 Check connection status 2 Check contact of the connector 3 Check that parts are firmly secured by tightening screws 4 Check connection of polarity 5 Check short circuit and grounding 6 For failure of motor Measure winding resistance of the motor coils 7 For failure of circuit board Replace the circuit board in following procedures if problems occur again...

Page 39: ...PCBassemblywithcontrolcase makesurethatPCBcaseisinserted surelyintheslitofcontrolcase Confirmthatthereisnogapbetween INV PCB case and control case Figure 4 5 Re assemble panel assembly and main PCB Fig 38 Replacement of INV PCB CAUTION Be sure that INV PCB assembly is firmly assembled with control case If any gap is present it will cause product malfunction Confirm that there is no gap between INV...

Page 40: ...Fan motor wire terminal UP 2 Fan motor wire terminal DOWN 3 Main PCB case 4 To Fan motor 5 To Fan motor Attention After replacing the INV PCB assembly make sure that connection of the fan motor wires is correct YELLOW RED YELLOW RED YELLOW RED YELLOW RED INV PCB UP DOWN UP DOWN 2 3 1 5 4 6 720 817 722 40 1I ...

Page 41: ...ircuit Are both check valves completely open Check function of fans Check rotation speed Check supply voltage Check function of water pump Check rotation speed Check supply voltage Check heat transfer Clean heat exchangers Check refrigerant charge Sub cooling very high Overfilled Refill refrigerant with gauge ...

Page 42: ...Other pre checkings Split ODU 6 720 817 722 2015 06 42 ...

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