Bosch IDS BOVA15 Installation Instructions Manual Download

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Installation Instructions

Bosch IDS BOVA15 Split System Heat Pump - BTC 761701317 A (02.2022)

WARNING: HAZARDOUS VOLTAGE



When measuring resistance , make sure the unit is powered
off and wait 3 min before taking measurement.

Figure 53

(Compressor over current protection)

Are

you running in force

mode?

Quit force mode

Is there abnormal

pressure in the

system?

Restart system

Are the service valves

open?

Open the service valves

Is the system
overcharged?

Adjust refrigerant

Replace high

pressure switch

Is the

compressor current

>11.5A for 2/3T and

>15.5A for

4/5T?

Replace compressor

Yes

Is the

ambient temperature

>120°F?

Clear any blockage in the

refrigerant,Correct poor

heat exchange (air flow

restriction, motor failure)

Is the

high pressure switch

wired correctly and resistance

≥1Ω?

Check

PFC module: power

on the unit, when the fan is

running, is the voltage

between P-N (CN3)

<310V?

Replace

Control Board

Yes

WARNING: HAZARDOUS VOLTAGE



When measuring resistance , make sure the unit is powered
off and wait 3 min before taking measurement.

Figure 54

(High compressor discharge temperature (T5) protection)

Restart System

Is the

resistance of T5

in range of Table

16?

Replace T5 sensor

Are

you running in force

mode?

Quit force mode

Is there abnormal

pressure in the

system?

Are the service valves

open?

Open the service valves

Yes

Is the

ambient temperature

>120°F?

Clear any blockage in the

refrigerant,Correct poor

heat exchange (air flow

restriction, motor failure)

Is the system

undercharged?

Adjust refrigerant

Yes

Is the

EEV/TXV working

normally?

Adjust or replace

EEV/TXV

Yes

Is the

compressor current >11.5A

for 2/3T and >15.5A for

4/5T?

Replace compressor

Yes

Check

the winding resistance:

1.The resistance of two windings (U,V,W)

<1.5Ω for 2/3T and <1Ω for 4/5T

2.The resistance between compressor

winding and ground

>10MΩ

Replace compressor

Yes

Summary of Contents for IDS BOVA15

Page 1: ...Installation Instructions Split System Heat Pump Bosch IDS BOVA15 IDS Light Condensing Units 2 5 Ton Capacity R410A BTC 761701317 A 02 2022 ...

Page 2: ...2 Installation Instructions Bosch IDS BOVA15 Split System Heat Pump BTC 761701317 A 02 2022 ...

Page 3: ...imum Wire Length 15 11 2 Low Voltage Hook Up Diagrams 15 11 3 Thermostat Wiring Diagrams 15 12 Electrical High Voltage 17 12 1 High Voltage Power Supply 17 12 2 High Voltage Disconnect Switch 17 12 3 High Voltage Ground 17 13 Start Up 18 13 1 System Start Up 18 14 System Charge Adjustment 19 14 1 Charging Weigh In Method 19 14 2 Subcooling Charging And Refrigerant Adjustment In Cooling Above 55 F ...

Page 4: ...nents as they may hold a dangerous charge of 380 VDC then verify DC Voltage is less than 42VDC at inverter TEST POINTS P N NOTICE This document is customer property and is to remain with this unit Please return to service information pack upon completion of work These instructions do not cover all variations in systems or provide for every possible contingency to be met in connection with the inst...

Page 5: ...esult in personal illness or injury or severe equipment damage System contains oil and refrigerant under high pressure Recover refrigerant to relieve pressure before opening system CAUTION INDOORUNITREQUIRED The indoor units must be matched with TXV The model of TXV can be changed according to the system capacity CAUTION GROUNDINGREQUIRED Failure to inspect or use proper service tools may result i...

Page 6: ...pacity Model Liquid Line Suction Line TotalEquivalent Length Feet 25 50 75 100 InchO D Maximum Vertical Separation Feet 24K 3 8 3 4 Std 25 50 45 40 5 8 Opt 25 50 45 40 36K 3 8 3 4 Std 25 50 50 50 5 8 Opt 25 50 50 50 48K 3 8 7 8 Std 25 50 50 40 3 4 Opt 25 50 50 40 60K 3 8 7 8 Std 25 50 50 40 3 4 Opt 25 50 50 40 1 1 8 Opt 25 40 N A N A Table 2 Standard line size is recommended N A Application not re...

Page 7: ...ge of snow and ice melted during defrost cycle prior to its refreezing Ensure that drain holes in unit base pan are not obstructed which could prevent the drainage of defrost water Fig 5 If possible avoid locations that are prone to snow drifts If not possible a snow drift barrier should be installed around the unit to prevent a build up of snow on the sides of the unit Figure 5 Min 12 Snow barrie...

Page 8: ... on all sides The pad must be separated 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 Figure 7 ...

Page 9: ...tal to metal contact Figure 10 Liquid Line Suction Line Insulation 5 4 Reuse Existing Refrigerant Lines CAUTION MINORTOMODERATEBURNS 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 ...

Page 10: ...l or sill they should be insulated and isolated Isolate the lines from all ductwork Minimize the number of 90º turns Figure 11 Side View 8 Feet Maximum 8 Feet Maximum Joist Rafter Isolator Lineset Secure Suction Line from joists using isolators every 8 ft Secure Liquid Line directly to Suction Line using tape wire or other appropriate method every 8 ft Isolation From Joist Rafter Figure 12 Side Vi...

Page 11: ...et Ductwork Suction Line Sealant Insulation Wall Isolation Through Wall DO NOT hang linesets from ductwork 7 Refrigerant Line Brazing 7 1 Braze The Refrigerant Lines 1 Remove caps or plugs Use a deburring tool to deburr the pipe ends Clean both internal and external surfaces of the tubing using an emery cloth Figure 14 ...

Page 12: ...efrigerant lines to the service valves Braze the ﬁlter drier to the Liquid Line All units come standard with a bi ﬂow ﬁlter drier Braze the ﬁlter drier to the liquid line using caution not to push the refrigerant line too hard past the stop within the ﬁlter drier this could damage the drier Continue the dry nitrogen purge Do not remove the wet rag until all brazing is completed Remove the wet rag ...

Page 13: ... 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 Figure 21 0350 Microns ON OFF 2 Observe the micron gauge Evacuation is complete if the micron gauge does not rise above 500 mic...

Page 14: ...valves The brazed lineset valves should be used for leak checking and vacuuming Using the separate suction port for this process will result in loss of charge The Suction Service Valve must be opened ﬁrst BEFORE opening the Liquid Service Valve 1 Remove Service Valve Cap Fig 23 2 Fully insert hex wrench into the stem and back out counterclockwise until valve stem just touches the rolled edge appro...

Page 15: ... supply agrees with equipment nameplate Power wiring and grounding of equipment must comply with local codes Low voltage wiring to be No 18 AWG minimum conductor Field installed electric auxiliary heat connection Single stage auxiliary heating supported by 2H thermostat Twin stage auxiliary heating supported by 3H thermostat W1 The first stage of field installed electric auxiliary heat W2 The seco...

Page 16: ...16 Installation Instructions Bosch IDS BOVA15 Split System Heat Pump BTC 761701317 A 02 2022 Figure 26 Thermostat Wiring Diagram for BOVA15 BVA15 Matched System ...

Page 17: ...nts could result in death or serious injury The high voltage power supply must match the equipment nameplate 208 230V 1PH 60Hz Power wiring must comply with national state and local codes Follow instructions on unit wiring diagram located on the inside of the control box access panel and refer to wiring diagram in this IOM 12 2 High Voltage Disconnect Switch Install a separate disconnect switch at...

Page 18: ...ave been completed 2 Set System Thermostat to OFF Figure 29 3 Turn on disconnect to apply power to the indoor and outdoor units Figure 30 ON OFF 4 Upon initial unit installation wait one 1 hour before starting the unit if compressor crankcase heater is used and the outdoor ambient temperature is below 70 ºF Figure 31 60 MIN 5 Set system thermostat to ON Figure 32 ...

Page 19: ...ystem Repairs Calculating total system charge 1 Total Line Length ft _________ a 2 Standard Lineset ft 15 b 3 a minus 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 Force Mode Out...

Page 20: ...ign subcooling value Table 9 please add refrigerant Repeat steps 3 through 5 If the superheat is out of range refer to Troubleshooting section of this IOM Suction Temp F FinalSuperheat F 6 8 10 12 14 16 18 20 22 Suction Gauge Pressure PSI 40 105 101 97 93 89 86 82 78 75 42 109 105 101 97 93 89 86 82 78 44 114 109 105 101 97 93 89 86 82 46 118 114 109 105 101 97 93 89 86 48 123 118 114 109 105 101 ...

Page 21: ... Recover refrigerant if the subcooling reading from Table 8 is higher than the design value Table 9 Figure 37 7 Stabilize the system Wait 5 minutes for the system condition to stabilize between adjustments When the subcooling matches the design value Table 9 the system is properly charged Remove gauges Replace service port caps to prevent leaks Tighten finger tight plus an additional 1 6 turn 8 Re...

Page 22: ...de Defrost control heating mode T4 Ambient Temperature Table 15 Operating condition permission Defrosting condition permission Outdoor fan control heating mode T5 Compressor Discharge Temperature Table 16 High Low temperature protection Electronic Expansion Valve EEV ODU heating mode only T3L Liquid Line Temperature Table 15 TF Control Board Temperature Table 16 Inverter High Temperature Protectio...

Page 23: ...or stops running for 3 hours outdoor ambient temperature T4 41 F OR compressor discharge temperature T5 53 6 F CCH operation de energizes 1 Compressor discharge temperature T5 60 8 F 2 Compressor start running 15 6 Reversing Valve Operation Reversing valve energizes during heat mode and de energizes in cool mode During a heat call on ﬁrst time operation the unit will run about 1 minute in cooling ...

Page 24: ...yphoon protection PH Low discharge superheat protection F1 High pressure switch protection HPS L0 L9 The IPM module protection AtL Ambient temperature Limited System Protection Status Codes Forced operation mode L Running indication under T3 limited condition D Running indication under T5 limited condition P Running indication under compressor ratio limited condition F Running indication under TF ...

Page 25: ...tection 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 Hz 66 3 T3 outdoor coil temp F 4 T4 outdoor ambient temp F 5 T5 compressor discharge temp F 6 Reserve 7 T3L liquid line temp F 8 Tf module temp F 9 Pe evaporating pressure PSI...

Page 26: ...rt 4 Thermostat wire connections 5 EEV port 6 Th sensor port 7 T3 T4 T3L sensor port 8 Pressure transducer port 9 T5 sensor port 10 Reserve 11 Reserve 12 High pressure switch port 14 SW1 FORCE BUTTON 15 LED 16 SW2 CHECK BUTTON 17 SW5 Dip SWITCH Defrost logic settings 18 Reserve 19 SW4 Dip SWITCH Control logic settings 13 Reserve 20 SW6 Dip SWITCH Select capacity 21 DC motor port 22 Compressor W po...

Page 27: ... 3 Reversing valve port 4 Thermostat wire connections 5 EEV port 6 Th sensor port 7 T3 T4 T3L sensor port 8 Pressure transducer port 9 T5 sensor port 10 Reserve 11 Reserve 12 High pressure switch port 14 SW1 FORCE BUTTON 15 LED 16 SW2 CHECK BUTTON 17 SW5 Dip SWITCH Defrost logic settings 18 Reserve 19 SW4 Dip SWITCH Control logic settings 13 Reserve 20 SW6 Dip SWITCH Select capacity 21 DC motor po...

Page 28: ... correctly Refer to wiring diagramfor correct connection Is the resistanceof T4 sensor in the range of Table 15 Yes No Yes Replace T4 sensor Is there another heat source near T3 T4 No Removeallother heatsources Yes Is the service valve closed or the connection pipe bent blocked Open service valve or replace the pipe Yes No WARNING HAZARDOUSVOLTAGE When measuring resistance make sure the unit is po...

Page 29: ...N3 310V Figure 45 E6 Outdoor DC fan motor fault Is ODU fanmotor wire CN3 connectiontocontrol boardsecure Secure connection Power off and remove blockage or replace fan blade Yes No Yes No Yes No Yes Is the fanblade damaged orisforeignmatterblocking thefan Are outdoor weather conditions preventingthefan fromoperating normally Power off until severe weather conditions subside Replace motor Is the mo...

Page 30: ... wiring Yes No No Yes Yes No Is the location of the T5 sensor wrong Are the T3 and T5 sensors wired correctly Replace T5 T3 Sensor Figure 47 E9 EEPROM IC14 fault Is EEPROM IC14 chip properly installed Power off and correct the connection Yes No Yes No Does EEPROM IC14 have poor contact Power off and correct the contact Replace control board Figure 48 H0 Communication fault in Main Control Chip Is ...

Page 31: ...ZARDOUSVOLTAGE When measuring resistance make sure the unit is powered off and wait 3 min before taking measurement Figure 50 P0 Control board is over heated Did the outdoor fanmotorfail Refer to control board replacement instructions to ensure there is good contact between the heat sink and control board Ensure there is no debris blocking the radiator Replace motor Replace controlboard Restart sy...

Page 32: ...nnected correctly and resistance 1Ω Replace high pressure switch Yes No No Yes Is the ambient temperature 120 F No Yes Yes Is there abnormal pressure in the system No Yes Is the system overcharged Yes No No Figure 52 P2 Low pressure protection H5 System lockout P2 occurs 5 times in 100 minutes Restart system Are the service valves open Open the service valves Is the system undercharged Adjust refr...

Page 33: ...t when the fan is running is the voltage between P N CN3 310V Replace Control Board Yes No WARNING HAZARDOUSVOLTAGE When measuring resistance make sure the unit is powered off and wait 3 min before taking measurement Figure 54 P4 High compressor discharge temperature T5 protection Restart System Is the resistance of T5 in range of Table 16 Replace T5 sensor Are you running in force mode Quit force...

Page 34: ...he ambient temperature 120 F Clear any blockage in the refrigerant Correct poor heat exchange airflow restriction motor failure Is the system overcharged Adjust refrigerant No Yes Yes No Is the EEV TXV working normally Adjust or replace EEV TXV Yes No Yes Are T3 and T5 sensors correctly placed after service Ensure they are properly placed No Figure 56 P8 DC outdoor fan motor protection Areoutdoor ...

Page 35: ...refrigerant No Yes Yes No Is the resistance of T3 in range of Table 15 Replace T3 sensor No Yes No Isthe EEV TXVworking normally Adjust or replace EEV TXV Yes Figure 58 L0 L9 IPM module protection Is the power supply stable Does the unit run normally for at least 1 hour Check for blockage in EEV TXV or Filter Drier Correct the power supply Remove blockage Replace compressor Power off and wait 3 mi...

Page 36: ...rature Limited Condition Is the ambient temperature beyond operating range Cooling mode 40 120 F Heating mode 5 86 F Is the thermostat set to energize O B in heating mode Is the resistance of T4 in the range of Table 15 No service required Wait for temperature to be within range Correct thermostat setting Replace T4 sensor Restart system Is the T4 sensor seated correctly Refer to wiring diagramfor...

Page 37: ... 6 5 057 1 93 15 9 4 57 948 4 39 110 43 3 4 509 1 79 20 6 7 49 652 4 30 115 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 10 125 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 0 20 610 3 59 140 60 0 2 350 1 13 55 12 8 17 939 3 45 145 62 8 2 119 1 04 60 15 6 15 648 3 30 150 65 6 1 914 0 96 65 18 3 13 681 3 15 155 68 3 1 7...

Page 38: ... 85 0 5 963 2 13 45 7 2 127 258 4 70 190 87 8 5 474 2 02 50 10 0 110 707 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 4 280 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 40 85 29 4 45 258 4 24 230 110 0 2 904 1 32 90 32 2 40 152 4 1...

Page 39: ...ensing temp F 15 Target of the compressor discharge superheat heating mode only Target value F 16 Compressor diacharge superheat F 17 Opening of EEV 18 Outdoor fan speed 19 Compressor current A 20 Power AC voltage Input V 21 Compressor input dc voltage V 22 Continuous running time of the compressor min 23 Last fault code 24 Software version 25 Remark HPS High pressure switch T5 Comp discharge temp...

Page 40: ... F 15 Target of the compressor discharge superheat heating mode only Target value F 16 Compressor diacharge superheat F 17 Opening of EEV 18 Outdoor fan speed 19 Compressor current A 20 Power AC voltage Input V 21 Compressor input dc voltage V 22 Continuous running time of the compressor min 23 Last fault code 24 Software version 25 Remark HPS High pressure switch T5 Comp discharge temp sensor PT ...

Page 41: ... Always turn off your heat pump and disconnect the power supply before cleaning or maintenance NOTICE Do not use chemicals or chemically treated cloths to clean the unit Do not use benzene paint thinner polishing powder or other solvents to clean the unit 17 2 Maintenance Pre Season Inspection At the beginning of each heating or cooling season do the following Figure 62 Turn off the unit and disco...

Page 42: ...42 Installation Instructions Bosch IDS BOVA15 Split System Heat Pump BTC 761701317 A 02 2022 NOTES ...

Page 43: ... 43 Installation Instructions Bosch IDS BOVA15 Split System Heat Pump BTC 761701317 A 02 2022 NOTES ...

Page 44: ... 65 Grove St Watertown MA 02472 Tel 866 642 3198 Fax 954 776 5529 www bosch thermotechnology us BTC 761701317 A 02 2022 Bosch Thermotechnology Corp reserves the right to make changes without notice due to continuing engineering and technological advances ...

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