Bosch
BOVA Split System Heat Pump
Condensing Units Up to 18 SEER 2-3-4-5 Ton CapacityR410A
Installation Instructions
Page 1: ...Bosch BOVA Split System Heat Pump Condensing Units Up to 18 SEER 2 3 4 5 Ton Capacity R410A Installation Instructions ...
Page 2: ...2 Bosch IDS BOVA Installation Instructions 12 2016 Bosch Thermotechnology Corp Data subject to change ...
Page 3: ...ion 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 ...
Page 4: ... in systems or provide for every possible contingency to be met in connection with the installation Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred to your installing dealer or local distributor The manufacturer recommends installing only approved matched indoor and outdoor syste...
Page 5: ...re 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 wire...
Page 6: ...door unit on a roof be sure the roof will support the unit s weight Properly selected isolation is recommended to prevent sound or vibration transmission to the building structure L H W Figure 1 2 2 Refrigerant piping limits Maximum line equivalent length 100 feet Maximum vertical equivalent length 50 feet Use only the line diameters indicated in Table 5 1 If the suction line sets are greater than...
Page 7: ...limate considerations heat pump only 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 un...
Page 8: ... 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 The pad location must comply with National State and Local codes These instructions are intended to provide a method to tie down system to cement slab as a securing procedure for high wind areas Check Local Codes for tie down methods and protocols Figur...
Page 9: ...Liquid Line Insulation Figure 10 5 4 Reuse existing refrigerant lines CAUTION If using existing refrigerant lines make certain that all joints are brazed not soldered For retrofit applications where the existing refrigerant lines will be used the following precautions should be taken Ensure that the refrigerant lines are the correct size Refer to Section 5 1 listed and Table 2 Ensure that the refri...
Page 10: ...ll or sill they should be insulated and isolated Isolate the lines from all ductwork Minimize the number of 90º turns Isolation From Joist Rafter Side View 8 Feet Maximum Joist Rafter Isolator Line Set 8 Feet Maximum 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 Figure 12 Isolation In Wa...
Page 11: ...ll DO NOT hang line sets from duc twork Sealant Insulation Suction Line Wall Ductwork Isolator Line Set 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 ...
Page 12: ...rogen purge Fig 18 Braze the refrigerant lines to the service valves Check liquid line filter drier s directional flow arrow to confirm correct direction of refrigeration flow away from outdoor unit and toward evaporator coil as illustrated Braze the filter 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 stoppin...
Page 13: ...tion 9 1 Evacuate the refrigerant lines and indoor coil Do not open the service valves until the refrigerant lines and indoor coil leak check and evacuation are complete 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 22 2 Observe the micron gauge Evacuation is complete if the micron gauge does not rise above 500...
Page 14: ...eak check and evacuation must be com pleted before opening the service valves The Suction Service Valve must be opened first BEFORE opening the Liquid Service Valve 1 Remove service valve cap Fig 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 finge...
Page 15: ...Ft 16 AWG 225 Ft 14 AWG 300 Ft Table 3 11 2 Low voltage hook up diagrams Air Handler Hook up Diagram Low Voltage connection must be made inside the outdoor unit case Access Panel Figure 25 THERMOSTAT C INDOOR UNIT OUTDOOR UNIT Y R G Y BLACK G C C B R B Control Wiring for H P Systems W2 D W w1 Notes 1 Be sure power supply agrees with equipment nameplate 2 Power wiring and grounding of equipment mus...
Page 16: ...nents 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 27 12 2 High voltage disconnect switch Install a separate disconnect ...
Page 17: ...2 Set System Thermostat to OFF OFF DONE CANCEL 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 ºF 60 MIN Figure 32 5 Set system thermostat to ON DONE CANCEL TUE EM HEAT OFF COOL Following Schedule Inside Set To Figure 33 ...
Page 18: ...nus b _________ c 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 The only mode approved for validating system charge is while in Cooling Charge Mode Outdoor Temperature must be between 55 F and 120 F with Indoor Temperature kept between 70 F and 80 F 14 2 Subcoolin...
Page 19: ... 82 46 114 110 105 101 97 93 89 86 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 56 138 133 128 123 118 114 110 105 58 143 138 133 128 123 118 114 110 60 148 143 138 133 128 123 118 114 62 153 148 143 138 133 128 123 118 64 159 153 148 143 138 133 128 123 66 164 159 153 148 143 138 133 128 68 170 164 159 153 14...
Page 20: ...cooling 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 8 Record System Information for reference Table 7 Record system pre...
Page 21: ...ssor Discharge Temperature Table 2 High Low temperature protection Electronic Expansion Valve EEV control ODU TF IPM Radiator Temperature Table 2 Inverter High Temperature Protection Pressure transducer Table 3 Operating speed control Electronic Expansion Valve EEV control ODU High pressure protection heating mode Low pressure protection cooling mode 15 3 Defrost description The Demand Defrost Con...
Page 22: ...process of defrosting 3 Compressor stops running for 4 hours and outdoor ambient temperature T4 50 F or T5 104 F CCH operation de energizes 1 Compressor discharge temperature T5 113 F 15 5 Reversing valve operation Reversing valve energizes during heat mode and de energizes in cool mode 15 6 Protection functions Outdoor coil temperature protection T3 i If T3 143 6 F compressor is de energized ii I...
Page 23: ...ver 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 SystemProt...
Page 24: ...ds on same parameter display will revert back to normal status If a system protection is active first digit will display status code No Pointcheckcontent Example Remark 0 Outdoor unit capacity H3 H3 Heat Pump 3 ton 1 Outdoor unit mode 2 0 standby 2 cooling 3 heating 2 Outdoor unit set compressor speed 3 Opening of EEV Actual value 4 T3 outdoor coil temp F 5 T4 outdoor ambient temp F 6 T5 compresso...
Page 25: ...actor 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 ...
Page 26: ...h 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...
Page 27: ...ply 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 supp...
Page 28: ...o Replace high pressure switch No Exclude all fault reasons and restart No Yes Cooling mode refers to P5 Heating mode refers to Hb Figure 45 P5 Condenser coil temperature T3 protection in cooling Diagnosis Handling Check whether the service valves are open Yes Check whether T3 is normal according to Table 1 between temperature and resistance Yes Check whether outdoor unit motor is abnormal or whet...
Page 29: ... to the wiring diagram Replace compressor No Yes Replace compressor No Replace the board Replace the compressor No Figure 48 ErrorCode Description P0 High module radiator temperature TF protection Table 15 P0 High module radiator temperature TF protection Diagnosis Handling Check whether there s dust or fallen leaves influencing radiator No Check whether the Tf is normal according to Table 2 betwe...
Page 30: ...r coil is blocked in heating No Replace the pressure transducer No No Exclude indoor unit fault reasons and restart No 1 Not applicable for piston 2 Adjust close the TXV superheat 3 To further adjust to SW4 4 on No 1 Exclude outdoor unit fault reasons and restart 2 Ensure the reserving coil is seated well Check whether T3 T5 are normal according to Table1 Table 2 Replace fault sensors Yes Figure 5...
Page 31: ...s Figure 56 E7 Compressor discharge sensor T5 is seated fault Diagnosis Handling Yes Check whether the sensor of T3 T5 are connected accord ing to wiring diagram Yes Check whether the resistance of T3 T5 is in the range of Table 1 and Table 2 Yes Check whether there are other heat sources around T3 T5 No Wiring according to the wiring diagram correctly No Replace the fault T3 T5 sensor No Yes Chec...
Page 32: ...accident such as strong interference form electricity grid System will recovery when electricity grid is normal No 5T Replace the control board 5T Replace the drive board No Yes The fault is still The fault is still No Check whether the wiring is connected normally Reseat the wiring according to wiring diagram Restart to power on and check whether it is normal 3T Replace the control board 5T Resea...
Page 33: ... fault Open the service valves No No No Keep running No Yes Replace the board and check whether there is the same fault Keep running No Yes Yes Replace the compressor and check whether there is the same faultt Keep running No Replace the compressor No Check whether the compressor wiring is normal Reseat the wiring according to wiring diagram Replace the compressor Figure 62 ErrorCode Description A...
Page 34: ... 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...
Page 35: ... 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 ...
Page 36: ...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 ...
Page 37: ...MENT WIRE MUST BE THE SAME GAUGE AND INSULATION TYPE AS ORIGINAL WIRE WARNING ELECTRIC HAZARD 380 VOLTS DC FORCED COOLING HEATING CHARGE MODEL RC 2 PFC INDUCTANCE L D P Compression ratio protection limit U The T3 sensor is not seated fault C Compressor current protection limit H Compressor oil return C3 Forced operation mode T3 high temperature limit T5 high temperature limit AtL F TF high tempera...
Page 38: ...TING CHECK SYSTEM PARAMETERS FORCED COOLING HEATING CHARGE MODEL ONLY FOR HP MODEL AMBIENT TEMPERATURE SENSOR FOR HP SYSTEM 10K RESISTANCE FOR COOLING ONLY SYSTEM L0 L9 IPM module protection or frequent power on off H4 F1 Temperature sensor fault T3 T4 T5 TF Hb High pressure PT protection in Heating 5 E 9 E 6 E High low voltage protection DC fan motor fault The discharge sensor T5 is not seated fa...
Page 39: ... 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 1...
Page 40: ...ut 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 assem...
Page 41: ...Installation Instructions Bosch IDS BOVA 41 Bosch Thermotechnology Corp 12 2016 Data subject to change Notes ...
Page 42: ...42 Bosch IDS BOVA Installation Instructions 12 2016 Bosch Thermotechnology Corp Data subject to change Notes ...
Page 43: ...Installation Instructions Bosch IDS BOVA 43 Bosch Thermotechnology Corp 12 2016 Data subject to change Notes ...
Page 44: ...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 ...
