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Bosch Climate 5000 Series Ductless Air Conditioner / Heat Pump Multi Zone Outdoor Units

Service Manual

08.2020

Bosch Thermotechnology Corp.

Data subject to change

7. Disconnect the connectors and wires connected the PCB from other parts.

Connectors:

CN17: T3/T4 Temperature sensor (2p/2p,white)

CN7: Discharge temperature sensor (2p,white)

CN15:T2B-A,B,C temperature sensor (2p/2p/2p,white)

CN18/CN19/CN22: Electronic expansion valve A,B,C
(6p/6p/6p,red/red/red)

CN25/CN23/CN20: S-A,S-B,S-C (3p/3p/3p,white/white/white)

Wires:

CN1/CN2: 4-way valve (blue-blue)

CN5/CN6: Crankcase heating cable (red-red)

CN3:L1-IN (red)

CN4:L2-IN (black)

Figure 119

CN15 CN7

CN17

CN18/CN19/CN22

CN1/CN2

CN3

CN5/CN6

CN4

CN20
CN23
CN25

8. Disconnect the grounding wire (yellow-green).

Figure 120

9. Remove

PCB.

Summary of Contents for BMS500-AAM018-1CSXHB

Page 1: ...Bosch Ductless Air Conditioner Heat Pump Climate 5000 Series Multi Zone Outdoor Units Service Manual ...

Page 2: ...2 Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units Service Manual 08 2020 Bosch Thermotechnology Corp Data subject to change ...

Page 3: ...tem BMS500 AAM036 1CSXRA BMS500 AAM036 1CSXHB 9 4 5 For Model 48K Multi Zone Regular System BMS500 AAM048 1CSXRA 10 5 Wiring Diagram 10 6 Installation Details 11 6 1 Torque Requirements 11 6 2 Connecting the Cables 11 6 3 Pipe Length and the Elevation 11 6 4 First Time Installation 11 6 5 Adding the Refrigerant to an Existing System 12 6 7 Operation Characteristics 14 7 Electronic Functions 15 7 1...

Page 4: ...G ELECTRICAL HAZARD f Do not modify the length of the power supply cord or use an extension cord to power the unit f Do not share the electrical outlet with other appliances Improper or insufficient power supply can cause fire or electrical shock WARNING INSTALLATION REQUIREMENTS f Installation must be performed by a licensed contractor and per the instructions in the installation manual Improper ...

Page 5: ... be replaced by the manufacturer its service agent or similarly qualified persons such as a licensed electrician in order to avoid a hazard f The product must be properly grounded at the time of installation or electrical shock may occur WARNING FIRE HAZARD f For units that have an auxiliary electric heater do not install the unit within 1 meter 3 feet of any combustible materials f Do not install...

Page 6: ...1CSXRA BMS500 AAM027 1CSXHB 36K 4 BMS500 AAM036 1CSXRA BMS500 AAM036 1CSXHB 48K 5 BMS500 AAM048 1CSXRA ȉ Table 1 2 2 Indoor Models Voltage Capacity WallMountedIndoorUnits 4 WayCassetteIndoorUnits DuctedIndoorUnits 208 230V 9K BMS500 AAU009 1AHWXB BMS500 AAU009 1AHCXB BMS500 AAU009 1AHDXB 12K BMS500 AAU012 1AHWXB BMS500 AAU012 1AHCXB BMS500 AAU012 1AHDXB 18K BMS500 AAU018 1AHWXB BMS500 AAU018 1AHCX...

Page 7: ... Figure 1 Split Type Outdoor Unit H W W H A B D OutdoorModel OutdoorUnitDimensionsmm in WxHxD MountingDimensions mm in DistanceA DistanceB BMS500 AAM018 1CSXRA 845x702x363 33 27x27 6x14 3 540 21 26 350 13 8 BMS500 AAM027 1CSXRA BMS500 AAM027 1CSXHB BMS500 AAM036 1CSXRA BMS500 AAM036 1CSXHB 946x810x410 37 24x31 9x16 14 673 26 5 403 15 87 BMS500 AAM036 1CSXHB BMS500 AAM048 1CSXRA 952x1333x415 37 5x5...

Page 8: ...ischarge temp sensor T4 Ambient temp sensor INDOOR OUTDOOR EXV A CAPILLARY A CHECK VALVE CAPILLARY TUBE EXV B CAPILLARY B LIQUID VALVE B GAS VALVE B Accumulator T2B A Evaporator temp sensor outlet T2B B 4 2 For Model 18K Multi Zone Hyper Heat System BMS500 AAM018 1CSXHB Figure 3 LIQUID VALVE A GAS VALVE A HEAT EXCHANGE EVAPORATOR HEAT EXCHANGE CONDENSER Compressor 4 WAY VALVE COOLING HEATING T2 Ev...

Page 9: ...Y B LIQUID VALVE B GAS VALVE B EXV C CAPILLARY C LIQUID VALVE C GAS VALVE C Accumulator T2B A Evaporator temp sensor outlet T2B B T2B C 4 4 For Models 36K Multi Zone Regular 36K Multi Zone Hyper Heat System BMS500 AAM036 1CSXRA BMS500 AAM036 1CSXHB Figure 5 LIQUID VALVE A GAS VALVE A HEAT EXCHANGE EVAPORATOR HEAT EXCHANGE CONDENSER Compressor 4 WAY VALVE COOLING HEATING T2 Evaporator temp sensor m...

Page 10: ... T1 Room temp sensor T3 Condenser temp sensor T4 Ambient temp sensor INDOOR OUTDOOR EXV A CAPILLARY A CHECK VALVE CAPILLARY TUBE EXV B CAPILLARY B LIQUID VALVE B GAS VALVE B EXV C CAPILLARY C LIQUID VALVE C GAS VALVE C EXV D CAPILLARY D LIQUID VALVE D GAS VALVE D EXV E CAPILLARY E LIQUID VALVE E GAS VALVE E Compressor 4 WAY VALVE T5 Discharge temp sensor Accumulator High pressure switch Low pressu...

Page 11: ...und Meter Pressure Gauge Handle Lo Handle Hi 0 1MPa Shut Off Knob Low Refrigerant Manifold Blue Shut Off Knob High Charge Refrigerant Hose Vacuum Pump 1 Completely tighten the Áare nuts of the indoor and outdoor units conÀrm that both the liquid service and gas service valves are set to the closed position 2 Connect the refrigerant manifold blue hose with the shut off knob of the low side to the g...

Page 12: ...ervice port cap to a torque of 18N m Be sure to check for gas leakage Recover the refrigerant as per Refrigerant Recovery and Recycling Equipment manufacturers speciÀcation Refrigerant charging Figure 9 Indoor Unit Liquid Side Gas Side Outdoor Unit Liquid Service Line Gas Service Line Open Check Valve Open Electronic Scale CLOSE OPEN Refrigerant Cylinder Procedure 1 Connect the charge hose to the ...

Page 13: ...ct to change For models BMS500 AAM027 1CSXRA BMS500 AAM036 1CSXRA BMS500 AAM048 1CSXRA BMS500 AAM018 1CSXHB BMS500 AAM027 1CSXHB BMS500 AAM036 1CSXHB For above models there is a set of master valve which will allow installer to vacuum and recycle the refrigerant at a faster speed Ensure master valves are fully open prior to system operation Figure 10 ...

Page 14: ... AAM018 1CSXHB BMS500 AAM027 1CSXHB BMS500 AAM036 1CSXHB 30ºC 50ºC 22ºF 122ºF 30ºC 30ºC 22ºF 86ºF 0ºC 50ºC 32ºF 122ºF Table 8 Equation to convert Celsius to Fahrenheit F 1 8 x C 32 NOTICE f If the system is used beyond the above conditions certain safety protection features may come into operation and cause the unit to operate abnormally NOTICE f The room relative humidity should be less than 80 I...

Page 15: ...90 C 194 F 7 2 3 Fan speed is out of control If outdoor fan speed is lower than 100RPM or higher than 2400RPM for 60 seconds or more the unit stops and LED displays E8 failure code 7 2 4 Inverter module protection The Inverter module has a protection function for current voltage and temperature If these protections happen the corresponding code will display on the indoor unit and the unit will sto...

Page 16: ...ion time is no less than 3 minutes 7 2 10 Oil Return 1 If the compressor frequency continues to be lower than the set frequency 35Hz for about 120 minutes the unit raises the frequency to 60Hz for about 100 seconds and then resumes with the former frequency 2 The EXV continues at 300 pulse while indoor units maintain their operation 7 2 11 Low Outdoor Ambient Temperature Protection f When the comp...

Page 17: ... code N Capacity area a b c d e f 3 2 1 5 1 0 5 0 Model 9K 12K 18K 24K HP 1 0 1 2 1 5 2 5 Table 11 The Ànal result is an integer Then modify it according to a T2 average correction Figure 17 ć 7 DYHUDJH HFUHDVH IUHTXHQF HHS IUHTXHQF QFUHDVH IUHTXHQF Use the following table and Ànal capacity request to conÀrm the operating frequency Frequency Hz 0 COO L_F1 COO L_F2 COO L_F2 4 COO L_F2 5 Amendatory ...

Page 18: ...nutes in defrost mode Defrosting Action Figure 19 oﬀ on Cool F9 10S 30S TimeA 10S 4 way valve defros ng Defros ng over compressor Indoor fan Outdoor fan EXV open frequency Max10minutes frequency Compressor stops oﬀ An cold control oﬀ 480P 480Pfor240s Condition of ending defrosting If any one of following items is satisÀed defrost mode will stop and the machine will return to normal heating mode f ...

Page 19: ...hen calculates their average After comparing each indoor s T2B with the average the outdoor gives the following modiÀcation commands f If T2B average the relevant valve needs to open 16P more f If T2B average the relevant valve s open range remains as is f If T2B average the relevant valve needs to close 16P more This modiÀcation is carried out every 2 minutes 7 4 4 2 Heating Mode The initial open...

Page 20: ...status it will display the code name for 2 seconds the details are as follows Enquiryinformation Displayingcode Meaning T1 T1 Indoor room temperature T2 T2 Coil temperature of evaporator T3 T3 Coil temperature of condenser T4 T4 Outdoor ambient temperature T2B Tb Coil temperature of evaporator TP TP Compressor discharge temperature TH TH Compressor suction temperature Targeted Frequency FT Targete...

Page 21: ... 109 b0 b1 b9 110 111 119 c0 c1 c9 120 121 129 d0 d1 d9 130 131 139 E0 E1 E9 140 141 149 F0 F1 F9 150 151 159 Indoor fan speed Outdoor fan speed 0 OFF 1 2 3 4 Low speed Medium speed High speed Turbo For some big capacity motors 14 FF Actual fan speed Display value turns to decimal value and then multiply 10 The unit is RPM For some small capacity motors display value is from 14 FF hexadecimal the ...

Page 22: ...fety WARNING ELECTRICAL HAZARD f Electricity power is still kept in capacitors even though power supply is shut off Do not forget to discharge the electricity in capacitor Figure 24 Electrolytic Capacitors HIGH VOLTAGE CAUTION The value of resistance is between 1500Ƅ to 2000Ƅ The voltage in P3 and P4 in outdoor PCB is about 310V The voltage in P5 and P6 in outdoor PCB is about 310V ...

Page 23: ...r T2B malfunction F2 F1 F3 F6 E5 Over voltage or under voltage protection P1 E6 PFC module protection E8 Outdoor fan speed malfunction F5 F1 No A Indoor unit coil outlet temp sensor malfunction F2 No B Indoor unit coil outlet temp sensor malfunction F3 No C Indoor unit coil outlet temp sensor malfunction F4 No D Indoor unit coil outlet temp sensor malfunction F5 No E Indoor unit coil outlet temp s...

Page 24: ...P5 P6 IDU PCB z ODU PCB z z z z z z z z z z z z z z Display Board IDU Fan Motor ODU Fan Motor z z T1 Sensor T2 Sensor z T2B Sensor z T3 Sensor z z T4 Sensor z T5 Sensor z z Water Level Switch Condensate Pump Reactor Compressor z IPM Board z z Over Load Protector z z z z PFC Module z PFC Module Inductance z Bridge RectiÀer Wiring Mistake z z z z z z z z z Refrigerant Charge Leak z z z z System Bloc...

Page 25: ... 1 FRQWUROHG E 5 UHOD HU FRQQHFW WR WKH KHDWHU ZKHQ KHDWHU LV 21 RXWSXW 9 1 1 FRQWUROHG E 5 UHOD HU 1 1 FRQWUROHG E 5 UHOD HU FRQQHFW WR WKH ZKHQ ZD LV 21 RXWSXW 9 3 1 FRQQHFW WR WKH HDUWK FRQQHFW WR WKH DUWK 2SWLRQDO 3 1 25 0 3 FRQQHFW WR 3 12 86 1 1 1 1 1 FRQQHFW WR WKH WHUPLQDO 9 3XOVH ZDYH EHWZHHQH 1 1 6LJQDO ZLUH 12 86 1 1 1 1 1 1 1 C 12 86 1 RQQHFW WR OHFWULF SDQVLRQ 9DOYH 9 9 9 SXOVH ZDYH E...

Page 26: ...5 B 5 B 5 1 5 5 5 37 86 7 5 7 30 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 26 7 30 6 0 0 5 1 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 5 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 B 5 B 5 B 5 B 5 B 5 B 5 5 5 1B 203 1B5HDFWRU 5 5 5 5 5 4 5 5 B 5 SRZHU VXSSO 1 1 1 FRQQ...

Page 27: ... H WHUQDO GULYH IDQ PRWRU RXSXW WHUPLQDO FXUUHQW ORRS FRPPXQLFDWLRQ FXUUHQW ORRS FRPPXQLFDWLRQ FXUUHQW ORRS FRPPXQLFDWLRQ FXUUHQW ORRS FRPPXQLFDWLRQ FXUUHQW ORRS FRPPXQLFDWLRQ GLJLWDO GLVSOD XVH 7 9 FRQQHFW WR KLJK DQG ORZ SUHVVXUH VHQVRU FRQQHFW WR WUPS VHQVRU XVH 9 FRQQHFW WR HDUWK 1 UHVHUYH GLJLWDO GLVSOD EXWWRQ WHVW UHSRUW FRQQHFW WR GHWHFWRU 1 1 1 1 IDQ PRWRU FDSDFLWRU FRQQHFWRU 1 1 211 7 72 ...

Page 28: ...5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 26 5 30 30 1 1 1 1 1 1 1 1 1 1 287 1 5 5 5 5 5 5 5 5 1 SRZHU VXSSO FRQQHFW WR WKH WHUPLQDO 9 1 1 1 3 LQGXFWDQFH WHUPLQDO 1 77 9 5XQQLQJ 3 725 9ROWDJH 9 VWDQGE 1...

Page 29: ...000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 29 Bosch Thermotechnology Corp 08 2020 Data subject to change 8 3 5 PCB Multi Zone Regular 48K Hyper Heat 36K BMS500 AAM048 1CSXRA BMS500 AAM036 1CSXHB Figure 29 ...

Page 30: ...uctless Air Conditioner Heat Pump Multi Zone Outdoor Units Service Manual 08 2020 Bosch Thermotechnology Corp Data subject to change 8 3 6 IPM Multi Zone Regular 48K Hyper Heat 36K BMS500 AAM048 1CSXRA BMS500 AAM036 1CSXHB Figure 30 ...

Page 31: ... ȋȋ 9K 1HP 12K 1 2HP 18K 1 5HP 4 Indoor unit B capacity 5 Indoor unit C capacity 6 Indoor unit D capacity 7 Indoor unit E capacity 8 Indoor unit A capacity demand code Norm code HP 9K 1HP 12K 1 2HP 18K 1 5HP 9 Indoor unit B capacity demand code 10 Indoor unit C capacity demand code 11 Indoor unit D capacity demand code 12 Indoor unit E capacity demand code 13 Outdoor unit amendatory capacity deman...

Page 32: ...e display value is a hex number For example the digital display tube shows Cd it means AD value is 205 36 AD value of voltage The display value is a hex number For example the digital display tube shows Cd it means AD value is 205 37 EXV open angle for A indoor unit Actual data 4 If the value is higher than 99 the digital display will show a decimal point For example if the digital display shows 2...

Page 33: ...l Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 33 Bosch Thermotechnology Corp 08 2020 Data subject to change 8 5 Outdoor Wiring Diagram 8 5 1 Regular Multi Zone 18K Figure 32 ...

Page 34: ...34 Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units Service Manual 08 2020 Bosch Thermotechnology Corp Data subject to change 8 5 2 Regular Multi Zone 27K Figure 33 ...

Page 35: ...Service Manual Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 35 Bosch Thermotechnology Corp 08 2020 Data subject to change 8 5 3 Regular Multi Zone 36K Figure 34 ...

Page 36: ...36 Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units Service Manual 08 2020 Bosch Thermotechnology Corp Data subject to change 8 5 4 Regular Multi Zone 48K Figure 35 ...

Page 37: ...ervice Manual Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 37 Bosch Thermotechnology Corp 08 2020 Data subject to change 8 5 5 Hyper Heat Multi Zone 18K Figure 36 ...

Page 38: ...8 Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units Service Manual 08 2020 Bosch Thermotechnology Corp Data subject to change 8 5 6 Hyper Heat Multi Zone 27K Figure 37 ...

Page 39: ...ervice Manual Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 39 Bosch Thermotechnology Corp 08 2020 Data subject to change 8 5 7 Hyper Heat Multi Zone 36K Figure 38 ...

Page 40: ...EPROM chip Supposed causes f Incorrect installation of indoor to outdoor control wire or line voltage wiring f PCB faulty Table 19 Troubleshooting Figure 39 If error continues Power off then restart the unit 2 minutes later Replace the outdoor main PCB EEPROM a read only memory whose contents can be erased and reprogrammed using a pulsed voltage For the location of EEPROM chip please refer to the ...

Page 41: ... outdoor unit PCB assembly include wiring Check wiring on the outdoor and indoor terminal following the wiring diagram Are all connec ons correct Yes No Measure Vs is it moving alternately between positive value and negative value Vs is the voltage between S and L2 Turn on all the indoor units and check if the error code is shown on all indoor units display Turn off the indoor units Is IPM power L...

Page 42: ...tdoor unit The red pin of multimeter connects with 2 old L2 port while the black pin is for 3 port When AC is normal running the voltage will move alternately between positive value and negative value Figure 42 IPM board 18K 27K Models Figure 43 Opera ng Standby IPM board Regular 36K 48K Models HyperHeat 27K 36K Models Figure 44 Standby Opera ng Power Opera ng Figure 45 Check point button press 1 ...

Page 43: ...ses f Improper Incorrect Wiring f IPM faulty f Outdoor PCB faulty Table 21 Troubleshooting Figure 46 Communication malfunction between IPM board and outdoor PCB Is there at least one LED in the IPM board lit Check the signal wire between the IPM module and the PCB Reconnect and retry Is the error still displaying Replace IPM board and then check whether the system can run normally Replace the elec...

Page 44: ...Thermotechnology Corp Data subject to change Note f Use a multimeter to test the DC voltage between black pin and white pin of signal wire The normal value should be around 5V Figure 47 f Use a multimeter to test the DC voltage between black pin and red pin of signal wire The normal value should be around 12V Figure 48 ...

Page 45: ...ion decision conditions If the sampling voltage is lower than 0 06V or higher than 4 94V the LED will display the failure Supposed causes f Improper Incorrect Wiring f Sensor faulty f Indoor Outdoor PCB faulty Table 22 Troubleshooting Figure 49 Check the connections between temperature sensor and PCB the connections correct Correct the connections No Yes Yes Replace indoor or outdoor PCB Replace t...

Page 46: ...ng Figure 51 Voltage protection Check the voltage of outdoor unit power is the voltage between L L1 and N L2 about 187 264VAC Check the power supply Check whether the voltage of IPM board P and N GND is normal DC277 356V for 18K 27K models DC277 410V for for 36K 48K models Replace bridge rectifiers and then check whether the system can run normally for 48K model Replace IPM board and then check wh...

Page 47: ...ology Corp 08 2020 Data subject to change Figure 52 IPM Board for 18K 27K models Figure 53 P or E1 E2 E3 N GND Bridge rectifier for 18K 27K models Remark Measure the DC voltage between and port The normal value should be between 190V 250V for 18K 27K models Bridge rectifier for18K 27K models IPM Module for 18K 27K models ...

Page 48: ...48 Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units Service Manual 08 2020 Bosch Thermotechnology Corp Data subject to change Figure 54 IPM board for 36K model ...

Page 49: ... Pump Multi Zone Outdoor Units 49 Bosch Thermotechnology Corp 08 2020 Data subject to change Figure 55 IPM board for 48K model Bridge rectifier for 48K model Remark Measure the DC voltage between and port The normal value should be 190V 250V IPM Module for 48K model only ...

Page 50: ... f PFC module inductance faulty f PFC module faulty Table 24 Troubleshooting Figure 56 PFC module protection Check whether the connecting line between main board and the PFC module IPM module is connected tightly Yes Check whether the voltage range of P N on IPM module is normal DC277 356V for 18K 27K models DC 277 410V for 36K model No Check whether the inductance of PFC module is good If the ind...

Page 51: ...nual Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 51 Bosch Thermotechnology Corp 08 2020 Data subject to change Figure 57 Inductance Figure 58 Two ports of the inductance ...

Page 52: ...ff then restart the unit 3 minutes later Is it still displaying the error code Shut off the power supply rotate the fan by hand Does it rotate properly Shut off the power supply rotate the fan by hand Does it rotate properly The unit operates normally The unit operates normally Find out the cause and have it solved For Find out the cause and have it solved For example check whether the fan is bloc...

Page 53: ...nd when the unit is in standby measure the voltage of pin1 pin3 pin3 pin4 in fan motor connector If the value of the voltage is not in the range showing in below table the PCB must have problems and need to be replaced Figure 60 Figure 61 Vs Vcc Vsp FG DC motor voltage input and output NO Color Signal Voltage 1 Red Vs Vm 200 380V 2 3 Black GND 0V 4 White Vcc 13 5 16 5V 5 Yellow Vsp 0 6 5V 6 Blue F...

Page 54: ...g Measure the resistance of the high pressure protector if the protector is normal the value should be 0 Yes Yes Correct wiring No Replace the high pressure protector No Check if the high pressure protector is broken Check whether the outdoor ambient temperature is higher than 50ć Check whether the outdoor ambient temperature is higher than 50ć No top the unit Stop the unit Yes Yes Ensure the outd...

Page 55: ...Service Manual Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 55 Bosch Thermotechnology Corp 08 2020 Data subject to change Figure 63 ...

Page 56: ... the resistance of the low pressure protector If the protector is normal the value should be o Yes Yes Replace outdoor Replace outdoor PCB No No Check if low pressure protector is damaged Check whether the outdoor ambient temperature is Check whether the outdoor ambient temperature is within the system operation range refer to table 8 No Stop the Stop the system Yes No Check whether valve core of ...

Page 57: ...Service Manual Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 57 Bosch Thermotechnology Corp 08 2020 Data subject to change Figure 65 ...

Page 58: ...igerant system is ok Check whether the outdoor ambient temperature is higher than 50ć Check whether the outdoor ambient temperature is higher than 50ć No Stop the system Yes Check whether the Check whether the outdoor unit has proper ven la on and clearance No Make sure the outdoor unit has proper ven la on and clearance Yes Check if there any leakage with refrigerant pipe No then use the high pre...

Page 59: ...Service Manual Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 59 Bosch Thermotechnology Corp 08 2020 Data subject to change Figure 67 ...

Page 60: ...whether the compressor discharge temp is more than 11 Check whether the compressor discharge temp is more than 115 C 239 F compressor discharge temp sensor and PCB according to wiring diagrams Check whether the connection is corect between compressor discharge temp sensor and PCB according to wiring diagrams Measure the resistance value of compressor discharge Measure the resistance value of compr...

Page 61: ...her the resistance of condenser e Check whether the resistance of condenser temp sensor is within normal range as deﬁned in Appendix 1 eplace the temperature sensor Replace the temperature sensor No No Check whether the outdoor ambient temperature is higher than Check whether the outdoor ambient temperature is higher than 50 C 122 F No Stop the system Yes Check if the outdoor unit Check if the out...

Page 62: ...line between the main board and the IPM module is connected tightly Yes Connect it tightly No No No Connect it well Check whether the connec ng line of the compressor is ght and connected correctly Replace the IPM module and check whether the system can operate normally No No Replace the PCB and check whether the system can work normally No Replace the compressor and check whether the system can w...

Page 63: ...ir flow system of indoor and outdoor units are obstructed Clear up the air inlet and outlet as well as the heat exchanger of indoor and outdoor units Yes No Yes Yes Turn off the power supply and turn it on 10 minutes later Check if the temperature on top of compressor Is more than 90 C 194 F No Check if there is any refrigerant leaking Refrigerant leak should be repaired and unit properly recharge...

Page 64: ...e after compressor and coil have returned to normal temperature to avoid injury f Disconnect the temperature sensor from PCB f Measure the resistance value of the sensor using a multi meter f Check corresponding temperature sensor resistance value table Appendix 1 Figure 72 The picture and the value are only for reference actual condition and speciÀc value may vary Temperature sensors f Room temp ...

Page 65: ... 44 36 97 6 13059 76 169 1 34105 116 241 0 4006 3 27 41 5878 37 99 5 87359 77 171 1 29078 117 243 0 38991 2 28 39 8239 38 100 5 62961 78 172 1 25423 118 244 0 37956 1 30 37 1988 39 102 5 39689 79 174 1 2133 119 246 0 36954 0 32 35 2024 40 104 5 17519 80 176 1 17393 120 248 0 35982 1 34 33 3269 41 106 4 96392 81 178 1 13604 121 250 0 35042 2 36 31 5635 42 108 4 76253 82 180 1 09958 122 252 0 3413 3...

Page 66: ...93 37 3 74 165 8 358 114 237 2 489 5 23 234 9 35 95 35 78 75 167 8 084 115 239 2 422 4 25 222 8 36 97 34 32 76 169 7 82 116 241 2 357 3 27 211 4 37 99 32 94 77 171 7 566 117 243 2 294 2 28 200 7 38 100 31 62 78 172 7 321 118 244 2 233 1 30 190 5 39 102 30 36 79 174 7 086 119 246 2 174 0 32 180 9 40 104 29 15 80 176 6 859 120 248 2 117 1 34 171 9 41 106 28 81 178 6 641 121 250 2 061 2 36 163 3 42 1...

Page 67: ...08 2020 Data subject to change 2 Compressor check Measure the resistance value of each winding by using the tester Figure 73 Position Resistance Value per Compressor Model 18K Regular 27K Regular 18K Hyper Heat 36K Regular 27K Hyper Heat 48K Regular 36K Hyper Heat Blue Red 1 72 0 75 0 65 0 37 Blue Black Red Black Table 36 Figure 74 ...

Page 68: ...s even when the power supply is off Ensure the capacitors are fully discharged before trouble shooting Turn off the power let the large capacity electrolytic capacitors discharge completely then dismount the IPM Use a digital tester to measure the resistance between P and UVWN UVW and N Digitaltester Normal resistance value Digital tester Normal resistance value Red Black Several MƄ Red Black Seve...

Page 69: ... a digital tester to measure the voltage When the unit operates in cooling mode value should be 0V When the unit operates in heating mode the value should be about 230VAC If the value of the voltage is not in the range the PCB may have problems and need to be replaced Figure 76 Step 2 Turn off the power use a digital tester to measure the resistance The value should be between 1 8 2 5 KƄ Figure 77...

Page 70: ... Units Service Manual 08 2020 Bosch Thermotechnology Corp Data subject to change 5 EXV check Step 1 Disconnect EXV connectors from PCB Figure 78 Step 2 Check the resistance value on EXV coil Colorofleadwire Normal Value Red Blue About 50Ƅ Red Yellow Brown Orange Brown White Table 38 ...

Page 71: ... on the your model number 9 1 Outdoor Unit BMS500 AAM018 1CSXRA 9 1 1 Removing the fan assembly 1 Stop operation of the system and turn OFF the power at the disconnect 2 Remove the air outlet grille Figure 79 3 Remove the hex nut that is Àxing the fan Figure 80 4 Remove the fan 5 Remove the top cover 3 screws Figure 81 Screws 6 Remove the black cover of the electrical control box Figure 82 7 Disco...

Page 72: ...g the panel plates 1 Stop operation of the system and turn OFF the power at the disconnect 2 Remove the front panel 6 screws Figure 85 Screws of front panel Screws of front panel Figure 86 Screws of front panel 3 Remove the big handle 4 screws Figure 87 Screws of big handle 4 Remove the right panel 2 screws from terminal block and 7 screws from right rear panel Figure 88 Screws of terminal board S...

Page 73: ...subject to change 9 1 3 Removing the electrical parts 1 Follow steps outlined in Section 9 1 1 2 Remove screws on IPM board 4 screws Figure 90 IPM board PCB board 3 Disconnect the connector for the Reactor A and Compressor B Figure 91 A B 4 Disconnect connectors as shown in Figure 94 Figure 92 CN1 5p white CN14 3p white CN4 red or brown CN5 blue ...

Page 74: ...rge temperature sensor 2p white f CN15 T2B A B temperature sensor 2p 2p white f CN18 CN19 Electronic expansion valve A B 6p 6p red red f CN25 CN23 S A S B 3p 3p white white Wires f CN1 CN2 4 way valve blue blue f CN5 CN6 Crankcase heating cable red red f CN3 L IN red f CN4 N IN black Figure 94 CN17 CN7 CN15 CN1 CN2 CN5 CN6 CN 3 CN 4 7 CN18 CN19 CN25 CN23 7 Disconnect the grounding wire yellow gree...

Page 75: ...d insulation material and crankcase heating cable 4 Remove terminal cover of compressor and disconnect wires of crankcase electric heater and compressor from the terminal 5 Remove the discharge pipe and suction pipe with a burner Figure 97 6 Remove the hex nuts and washers Àxing the compressor on bottom plate Figure 98 7 Lift the compressor from the base pan assembly 9 1 5 Removing the reactor 1 F...

Page 76: ...Detach the welded parts of 4 way valve and pipe Figure 101 1 Screw Welded parts 9 1 7 Removing the expansion valve 1 Follow steps outlined in Section 9 1 2 2 Remove the coils detach the welded parts of expansion valves and pipes Figure 102 Coils Expansion valves 9 2 Outdoor Unit BMS500 AAM027 1CSXRA BMS500 AAM018 1CSXHB BMS500 AAM027 1CSXHB 9 2 1 Removing the panel plate 1 Stop operation of the sy...

Page 77: ...h Thermotechnology Corp 08 2020 Data subject to change 4 Remove the right side panel 1 screw Figure 105 Screw 5 Remove the front panel 8 screws Figure 106 Screws of front panel Figure 107 Screws of front panel Screws of front panel 6 Remove the right rear panel 15 screws Figure 108 Screws of right rear panel ...

Page 78: ...s Figure 109 Screws of terminal board 9 2 2 Removing the fan assembly 1 Follow steps outlined in Section 9 2 1 2 Remove the hex nut Àxing the fan and then remove the fan Figure 110 3 Remove the cover of electrical control box cover Figure 111 4 Disconnect the fan motor connector CN14 from the IPM board Figure 112 5 Remove the four Àxing screws of the fan motor Then remove the fan motor Figure 113 ...

Page 79: ...rical parts 1 Follow steps outlined in Section 9 2 1 2 Remove the screws of the IPM board 4 screws Figure 114 IPM board 3 Disconnect the connector to reactor from PCB Figure 115 PCB board 4 Disconnect the compressor wire Figure 116 5 Disconnect wires between IPM board and PCB as shown below Figure 117 CN1 5p white CN14 3p white CN3 red or brown CN5 blue 6 Remove the IPM board Figure 118 ...

Page 80: ...hite f CN7 Discharge temperature sensor 2p white f CN15 T2B A B C temperature sensor 2p 2p 2p white f CN18 CN19 CN22 Electronic expansion valve A B C 6p 6p 6p red red red f CN25 CN23 CN20 S A S B S C 3p 3p 3p white white white Wires f CN1 CN2 4 way valve blue blue f CN5 CN6 Crankcase heating cable red red f CN3 L1 IN red f CN4 L2 IN black Figure 119 CN15 CN7 CN17 CN18 CN19 CN22 CN1 CN2 CN3 CN5 CN6...

Page 81: ...connect wires of compressor thermo and compressor from the terminal 5 Apply heat and remove discharge and suction pipes Figure 121 6 Remove the hex nuts and washers Àxing the compressor on bottom plate Figure 122 7 Lift the compressor from the base pan assembly 9 2 5 Removing the reactor 1 Follow steps outlined in Section 9 2 1 2 Disconnect the connection between the reactor and IPM board 3 Remove...

Page 82: ... steps outlined in Section 9 2 1 2 Remove Àxing screw of the coil and remove the coil 1 screw Figure 125 Coil 3 Detach the welded parts of 4 way valve and pipe Figure 126 Welded parts 9 2 7 Removing the expansion valve 1 Follow steps outlined in Section 9 2 1 and evacuate the refrigerant from the unit 2 Remove the coils and detach the welded parts of expansion valves pipes Figure 127 Expansion val...

Page 83: ... AAM036 1CSXRA 9 3 1 Removing the panel plate 1 Stop operation of the system and turn OFF the power at the disconnect 2 Remove the big handle 4 screws Figure 128 Screws of big handle 3 Remove the top cover 4 screws Figure 129 Screws of top cover 4 Remove the front right panel 1 screw Figure 130 Right front side panel screw 5 Remove front panel 8 screws Figure 131 Screws of front panel ...

Page 84: ...ervice Manual 08 2020 Bosch Thermotechnology Corp Data subject to change Figure 132 Screws of front panel Screws of front panel 6 Remove terminal board and water collector cover Figure 133 Screws of terminal board 7 Remove right and rear panel 16 screws Figure 134 Screws of right rear panel ...

Page 85: ...ove the fan Figure 135 3 UnÀx the hooks and then open the electronic control box cover Figure 136 4 Disconnect the fan motor connector CN19 Figure 137 5 Remove the four Àxing screws of the fan motor then remove the motor Figure 138 9 3 3 Removing the electrical parts 1 Follow steps outlined in Section 9 3 1 2 Pull out connectors of reactor compressor and PFC inductor Figure 139 3 Disconnect CN53 C...

Page 86: ...or 2p white f CN13 T2B A B C D temperature sensor 2p 2p 2p 2p white f CN18 CN17 CN21 CN20 Electronic expansion valve A B C D 6p 6p 6p red red red f CN30 CN29 CN28 CN27 S A S B S C S D 3p 3p 3p 3p white f CN9 High and low pressure switch 2p 2p white Wires f CN3 CN22 4 way valve blue blue f CN4 CN40 Crankcase heating cable black red f CN10 CN44 Crankcase heating cable black red f CN1 L1 IN red f CN2...

Page 87: ...of compressor and disconnect wires 5 Remove the discharge and suction pipes with a burner Figure 143 6 Remove the hex nuts and washers Àxing the compressor on bottom plate Figure 144 7 Lift the compressor from the base pan assembly 9 3 5 Removing the 4 way valve 1 Follow steps outlined in Section 9 3 1 2 Recover refrigerant from the refrigerant circuit 3 Remove the coil 1 screw and detach the weld...

Page 88: ...Removing the fan assembly 1 Stop operation of the system and turn OFF the power at the disconnect 2 Remove the air outlet grille 8 screws Figure 147 3 Remove the nut Àxing the fan and remove the fan Figure 148 4 Remove the top cover 4 screws Figure 149 Screws of top cover 5 Remove the front side panel 1 screw Figure 150 6 Disconnect the fan motor connectors FAN1 3p white and FAN2 3p white from DC ...

Page 89: ...of the fan motor Then remove the fan motor Figure 152 9 4 2 Removing the panel plate 1 Stop operation of the air conditioner and turn OFF the power breaker 2 Remove the big handle and water collector 4 screws Figure 153 Screws of Water collector Screws of big handle 3 Remove side and rear panel 17 screws Figure 154 Screws of terminal board Screws of right rear panel Screws of right rear panel ...

Page 90: ...llow U ǃV ǃW black CN9 10p white 4 Remove the screws of the IPM board to remove it 5 Disconnect the connectors and wires connected from the PCB Connectors f CN8 Discharge temperature sensor 2p white f CN12 Heat sink temperature sensor 2p red f CN9 T3 T4 temperature sensor 2p 2p white f CN11 T2B A B C D E temperature sensor 2p 2p 2p 2p 2p white f CN15 CN23 CN26 CN30 CN33 Electronic expansion valve ...

Page 91: ...Units 91 Bosch Thermotechnology Corp 08 2020 Data subject to change Figure 158 CN30 CN23 CN33 CN26 CN15 CN10 CN3 CN1 CN13 CN16 CN21 CN29 CN37 CN8 CN12 CN9 CN11 CN17 CN18 CN19 CN20 CN24 CN25 6 Disconnect the ground wire yellow green after removing the big handle Figure 159 7 Remove PCB Figure 160 ...

Page 92: ...r and compressor from the terminal 5 Remove the discharge pipe and suction pipe with a burner Figure 161 6 Remove the hex nuts and washers Àxing the compressor on bottom plate Figure 162 7 Lift the compressor from the base pan assembly 9 4 5 Removing the 4 way valve 1 Follow steps outlined in Section 9 4 2 2 Recover refrigerant from the refrigerant circuit 3 Remove the coil 1 screw and detach the ...

Page 93: ...Service Manual Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 93 Bosch Thermotechnology Corp 08 2020 Data subject to change ...

Page 94: ...94 Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units Service Manual 08 2020 Bosch Thermotechnology Corp Data subject to change ...

Page 95: ...Service Manual Bosch Climate 5000 Series Ductless Air Conditioner Heat Pump Multi Zone Outdoor Units 95 Bosch Thermotechnology Corp 08 2020 Data subject to change ...

Page 96: ...United States and Canada Bosch Thermotechnology Corp 65 Grove Street Watertown MA 02472 Tel 866 642 3198 Fax 603 965 7581 www boschheatingandcooling com BTC 769002303 A 08 2020 ...

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