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Bosch AHUW036A2 Service Manual

Split outdoor unit 230 v 1 n-/400 v 3 n-.
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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

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   Summary of Contents for Bosch 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...

  • Page 2: Table Of Contents

    Table of contents Table of contents Key to symbols and safety instructions Key to symbols Key to symbols and safety instructions ....2 Warnings Key to symbols .

  • Page 3: Error Handling Instructions For Split Outdoor Unit

    Names of units the refrigerant circuit. Supplier name for ODU BTT name for ODU ▶ For all work with refrigerant, wear suitable safety gloves and goggles. AHUW036A2 ODU Split 2 What to do if refrigerant leaks AHUW056A2 ODU Split 4 If refrigerant leaks and touches the skin, it can cause frostbite.

  • Page 4: Error Code 21

    Error handling instructions for Split outdoor unit HMI Error code ODU Error code Description Error characteristc Remark  Cond. Out-pipe Th Error (Open/ Sensor TH6 broken (5k >25 5664, 5665 Direct shut-down °C Short) 5632, 5633 Bad communication between Restart 3x/hour, Wiring between Mainboard and Inverter board Inverter-PCB and Main-PCB then blocked...

  • Page 5: Error Diagnosis And Countermeasure Flow Chart

    2.3.1 Error diagnosis and countermeasure flow chart Is installation condition normal? No -> 1. Check pipe clogging / distortion 2. Check covering (unit) 3. Check EEV connector assembly condition / normal operation 4. Check refrigerant pressure -> Reassemble or manage if abnormality found Are the resistance between each phase No ->...

  • Page 6

    Error handling instructions for Split outdoor unit 6 720 817 722-04.1I Fig. 4 ODU Split 11s, 13s, 15s 1. Wait until PCB (Inverter) DC voltage is discharged after main power is shut off. 2. Pull out V, W, U COMP connector. 3.

  • Page 7

    Error handling instructions for Split outdoor unit ODU Split 11t, 13t, 15t 6 720 817 722-05.1I Fig. 6 ODU Split 11t, 13t, 15t 1. Wait until PCB (Inverter) DC voltage is discharged after main power is shut off. PFC_IPM check 2.

  • Page 8: Error Code 22

    Error handling instructions for Split outdoor unit Error code 22 Display Check point & Normal code Title Cause of error condition Max. C/T -Input Over 1. Malfunction of Current Compressor 2. Blocking of Pipe 3. Low Voltage Input 4. Refrigerant, Pipe length, Blocked Table 7 Error code 22 2.4.1...

  • Page 9

    Error handling instructions for Split outdoor unit ODU Split 4, 6, 8 IN/I Black 6 720 817 722-06.1I Fig. 8 ODU Split 4, 6, 8 ▶ Check output of the CT sensor: DC 2.5 0.2V ODU Split 11s, 13s, 15s 6 720 817 722-07.1I Fig.

  • Page 10

    Error handling instructions for Split outdoor unit ODU Split 11t, 13t, 15t 6 720 817 722-08.1I Fig. 10 ODU Split 11t, 13t, 15t Inverter PCB CT sensing check point ▶ Check input current T_PFC and R_PFC ▶ Check output of the CT sensor: DC 2.5 0.2V Split ODU –...

  • Page 11: Error Diagnosis And Countermeasure Flow Chart

    Error handling instructions for Split outdoor unit Error code 23 2.5.1 Error diagnosis and countermeasure flow chart Is input voltage normal? No -> 1. Check power input voltage Display Check point & Normal code Title Cause of error condition DC link High •...

  • Page 12

    Error handling instructions for Split outdoor unit ODU Split 11s, 13s, 15s 6 720 817 722-10.1I Fig. 12 ODU Split 11s, 13s, 15s Split ODU – 6 720 817 722 (2015/06)

  • Page 13

    Error handling instructions for Split outdoor unit ODU Split 11t, 13t, 15t 6 720 817 722-11.1I Fig. 13 ODU Split 11t, 13t, 15t PFCM pin arrangement and pin numbers Split ODU – 6 720 817 722 (2015/06)

  • Page 14: Error Diagnosis And Countermeasure Flow Chart

    Error handling instructions for Split outdoor unit Error code 26 Display Check point & Normal code Title Cause of error condition • Compressor 1. Check the connection of compressor starting comp wire “U,V,W” position failure 2. Malfunction of compressor 3. Check the component of “IPM”, detection parts Table 11 Error code 26 2.6.1...

  • Page 15

    Error handling instructions for Split outdoor unit ODU Split 4, 6, 8 U, V, W 6 720 817 722-12.1I Fig. 14 ODU Split 4, 6, 8 CT sensing check point WVC connector check ODU Split 11s, 13s, 15s 6 720 817 722-13.1I Fig.

  • Page 16

    Error handling instructions for Split outdoor unit ODU Split 11t, 13t, 15t 6 720 817 722-14.1I Fig. 16 ODU Split 11t, 13t, 15t Split ODU – 6 720 817 722 (2015/06)

  • Page 17: Error Diagnosis And Countermeasure Flow Chart

    Error handling instructions for Split outdoor unit Error code 27 1. Set the multi tester to diode mode 2. Check short circuit between input signal pins which are placed below Display Check point & Normal PFC module code Title Cause of error condition 3.

  • Page 18

    Error handling instructions for Split outdoor unit ODU Split 4, 6, 8 6 720 817 722-15.1I Fig. 17 ODU Split 4, 6, 8 Short circuit check point After turning off the main power; R24N between the ends of the resistance will be measured to 620~670 Split ODU –...

  • Page 19

    Error handling instructions for Split outdoor unit ODU Split 11s/t, 13s/t, 15s/t 6 720 817 722-16.1I Fig. 18 ODU Split 11s/t, 13s/t, 15s/t ODU Split 11t/13t/15t ODU Split 11s/13s/15s Short circuit check point Split ODU – 6 720 817 722 (2015/06)

  • Page 20: Error Diagnosis And Countermeasure Flow Chart

    Error handling instructions for Split outdoor unit Error code 29 Display Check point & Normal code Title Cause of error condition Inverter • 1~ODU: 1. Overload operation (pipe compressor inverter clogging/covering/EEV over compressor defect/ refrigerant current input current overcharge) is 30A 2.

  • Page 21: Error Diagnosis And Countermeasure Flow Chart

    Error handling instructions for Split outdoor unit Error code 32 Display Check point & Normal code Title Cause of error condition High • Overload 1. Check outdoor fan temperatur operation constraint / screened / e in (outdoor fan flow structure discharge constraint, 2.

  • Page 22: Error Code 54

    Error handling instructions for Split outdoor unit 2.10 Error code 35 Display Check point & Normal code Title Cause of error condition • Excessive 1. Defective low pressure pressure decrease of sensor error pressure 2. Defective unit fan 3. Deformation because of damage of refrigerant pipe 4.

  • Page 23

    Error handling instructions for Split outdoor unit 2.11 Error code 41, 44, 45, 46, 48 2.11.1 Error diagnosis and countermeasure flow chart Is sensor connected to No -> 1. Connect sensor to PCB Display Check point & Normal PCB (inverter) (inverter) correctly code Title...

  • Page 24: Error Code 43

    Error handling instructions for Split outdoor unit 2.12 Error code 43 Display Check point & Normal code Title Cause of error condition High • Abnormal 1. Bad connection of pressure value of connector PCB (inverter) sensor sensor (open 2. Bad connection high error / short) pressure connector...

  • Page 25

    Error handling instructions for Split outdoor unit 2.13 Error codes 52, 53 Installerboard Main/ODU PCB Inverter PCB CANboard CH52 CH53 No Error Fig. 22 Error codes 52, 53 Waiting time of Error code that is sent to communication before Situation Description Installerboard by CAN error is generated...

  • Page 26

    Error handling instructions for Split outdoor unit ODU Split 11t, 13t, 15t Check point ▶ Check the transmission connector and LED (main and inverter) 6 720 817 722-21.1I Fig. 23 Error code 52 check point ODU Split 11t/13t/15t Insufficient insertion of wires Damage of wire coating: Interference with wires or wire coating damage with chopping 42/48/60k...

  • Page 27

    Error handling instructions for Split outdoor unit 2.13.2 Error code 53 Display code Title Cause of error Check point & Normal condition Communication • Poor communication 1. Power input AC 230V PCB(Heater) 2. The connector for transmission is disconnected -->PCB(Inverter) 3.

  • Page 28

    Error handling instructions for Split outdoor unit 6 720 817 722-23.1I Fig. 25 ODU Split 4/6/8 EEPROM EEPROM 6 720 817 722-24.1I Fig. 26 ODU Split 11/13/15 ODU Split 11s/13s/15s ODU Split 11t/13t/15t Split ODU – 6 720 817 722 (2015/06)

  • Page 29: Error Code 61

    Error handling instructions for Split outdoor unit 2.16 Error code 61 Display Check point & Normal code Title Cause of error condition High • Overload 1. Check outdoor fan temperatur operation constraint / screened / e in (outdoor fan flow structure condenser constraint, 2.

  • Page 30: Error Code 62, 65

    Error handling instructions for Split outdoor unit 2.17 Error code 62, 65 Display code Title Cause of error Check point & Normal condition Heat sink temp high • Heat sink sensor detected high 1. Part no. :EBR37798101~09 temperature (85 °C) -Check the heat sink sensor: 10k...

  • Page 31

    Error handling instructions for Split outdoor unit [IPM] [PFCM] 6 720 817 722-25.1I Fig. 29 Error code 62, 65 check points ODU Split 4/6/8 PFCM: measuring resistance between no. 19, 20 pin ODU Split 11s/13s/15s ODU Split 11t/13t/15t Heat sink temperature output pin Split ODU –...

  • Page 32: Error Code 67

    Error handling instructions for Split outdoor unit 2.18 Error code 67 Display code Title Cause of error Check point & Normal condition Fan lock error • Fan RPM is 10 RPM or less for 5 1. ODU fan locking seconds when ODU fan starts or 2.

  • Page 33

    Error handling instructions for Split outdoor unit 6 720 817 722-27.1I Fig. 31 Error code 67 check points ODU Split 4/6/8 ODU Split 11s/13s/15s ODU Split 11t/13t/15t Split ODU – 6 720 817 722 (2015/06)

  • Page 34: Check Compressor Resistances

    Check compressor resistances Check compressor resistances 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 off the main power supply and make sure that all LED on the circuit boards are off.

  • Page 35: Compressor Replacement

    Compressor replacement Compressor replacement 1. Disconnect the unit from power supply. 2. Detach the motor plug from the compressor. 3. Remove the sound proof covering the faulty compressor. 4. Pump out the refrigerant completely. 5. Disconnect the brazing sections of the suction pipe by using brazing torch.

  • Page 36: Check System Parameters

    Check system parameters Check system parameters Temperature difference between inlet and outlet depends on water flow rate and exchange-surface of the heating system. Symptom Remark No temperature difference between water inlet and outlet Refrigerant completely leaked Power consumption is low (<80% of rated current) Check cycle Temperature difference is ok (5-10K) Leakage of refrigerant or clog of cycle...

  • Page 37

    Electronic expansion valve EEV valve operation • At power ON, open angle signal of 1400 pulses output and valve position is set to If valve operates smoothly, no noise and vibration occur and if valve is closed. Noise occurs. • Noise from the EEV can be confirmed by touching the EEV surface with a screw driver and listening to the EEV noise.

  • Page 38: Fan Motor

    Fan motor Remove and assemble the EEV coil ▶ Grip the A part tightly, and pull coil part upward. Fig. 37 6 720 817 722-32.1I Fig. 36 Remove and assemble the EEV coil Remove Assemble A part Fan motor Checking item Symptom Countermeasure 1.

  • Page 39: Replacement Procedure For Inv Pcb

    Replacement procedure for INV PCB 1. Disconnect the unit from power supply. Replacement procedure for INV PCB 2. Disassemble main PCB by unscrewing 2 screws (Figure 1). 3. Disassemble panel assembly (with cooling fan) by unscrewing for CAUTION: Be sure that INV PCB assembly is firmly screws (Figure 2).

  • Page 40

    Replacement procedure for INV PCB Attention! After replacing the INV PCB assembly, make sure that connection of the fan motor wires is correct. INV. PCB YELLOW YELLOW YELLOW YELLOW 6 720 817 722-40.1I Fig. 39 INV PCB fan motor connection Fan motor wire terminal (UP) Fan motor wire terminal (DOWN) Main PCB case...

  • Page 41: Other Pre - Checkings

    Other pre - checkings Other pre - checkings ▶ Check blockage of refrigerant circuit Are both check - valves completely open? ▶ Check function of fans – Check rotation speed – Check supply voltage ▶ Check function of water pump –...

  • Page 42

    Other pre - checkings Split ODU – 6 720 817 722 (2015/06)

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