Bosch BOVA Series Installation Instructions Manual
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Bosch BOVA Series Installation Instructions Manual

Split system heat pump condensing units up to 18 seer 2-3-4-5 ton capacity
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Bosch BOVA Split System Heat Pump
Condensing Units Up to 18 SEER
2-3-4-5 Ton Capacity
R410A
Installation Instructions

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Summary of Contents for Bosch BOVA Series

  • Page 1: Installation Instructions

    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 Data subject to change 12.2016 | Bosch Thermotechnology Corp.

  • Page 3: Table Of Contents

    Installation Instructions Bosch IDS BOVA | 3 Table of Contents Key to symbols and safety instructions Unit location considerations Unit preparation Setting the unit Refrigerant line considerations Refrigerant line routing Refrigerant line brazing Refrigerant line leak check Evacuation Service valves...

  • Page 4: Key To Symbols And Safety Instructions

    4 | Bosch IDS BOVA Installation Instructions Key to symbols and safety instructions Safety Please read before proceeding Key to symbols Warnings CAUTION:  This document is customer property and is to remain with this unit. Please return to service information pack upon completion of work.
  • Page 5 Installation Instructions Bosch IDS BOVA | 5 WARNING: REFRIGERANT OIL WARNING: SERVICE VALVES   Any attempt to repair a central air conditioning product may Failure to follow this warning will result in abrupt release result in property damage, severe personal injury, or death.

  • Page 6: Unit Location Considerations

    6 | Bosch IDS BOVA Installation Instructions Unit location considerations Refrigerant piping limits Unit dimensions  Maximum line equivalent length = 100 feet.  Maximum vertical equivalent length = 50 feet. Unit Dimensions Models H x W x L (Inches) ...
  • Page 7 Installation Instructions Bosch IDS BOVA | 7 Location restrictions Ensure the top discharge area is unrestricted for at least 60 inches above the unit. Avoid Install Near Bedrooms Do not locate outdoor unit near bedrooms since normal operational sounds may be objectionable.

  • Page 8: Unit Preparation

    8 | Bosch IDS BOVA Installation Instructions Unit preparation Prepare the unit for installation  STEP 1 - Check for damage and report promptly to the carrier any damage found to the unit (Fig. 6).  The charge port can be used to check to be sure the refrigerant charge has been retained during shipment.

  • Page 9: Refrigerant Line Considerations

    Installation Instructions Bosch IDS BOVA | 9 Refrigerant line considerations Reuse existing refrigerant lines Refrigerant line and service valve connection sizes CAUTION: Suction line Liquid line Models Suction line Liquid line connection connection  If using existing refrigerant lines make certain that all joints are brazed, not soldered.

  • Page 10: Refrigerant Line Routing

    1 0 | Bosch IDS BOVA Installation Instructions Refrigerant line routing Comply with National, State, and Local Codes when isolating line sets from joists, rafters, walls, or other structural elements. Precautions Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines.

  • Page 11: Refrigerant Line Brazing

    Installation Instructions Bosch IDS BOVA | 11 Wall Sealant Duc twork Insulati on Suc tion Line Isolator Line Set DO NOT hang line sets from duc twork Isolation Through Wall Figure 14 Refrigerant line brazing Braze the refrigerant lines 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.
  • Page 12 1 2 | Bosch IDS BOVA Installation Instructions Remove the pressure tap cap from both service valves. Field supplied and installed 3-4" from valve Figure 18 Figure 16 Replace the pressure tap caps after the service valves have cooled. Purge the refrigerant lines and indoor coil with dry nitrogen.

  • Page 13: Refrigerant Line Leak Check

    Installation Instructions Bosch IDS BOVA | 13 Refrigerant line leak check Evacuation Check for leaks Evacuate the refrigerant lines and indoor coil Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry nitrogen. Do not open the service valves until the refrigerant lines and indoor coil leak check and evacuation are complete.

  • Page 14: Service Valves

    1 4 | Bosch IDS BOVA Installation Instructions Service valves 10.1 Open the service valves 5/16” Hex Wrench or Sucti on Service Valve WARNING: Unit S ide 3/16” Hex Wrench  Extreme caution should be exercised when opening the of Service or Liqu id Service Valve Liquid Line Service Valve.

  • Page 15: Electrical - Low Voltage

    Installation Instructions Bosch IDS BOVA | 15 Electrical - low voltage 11.1 Low Voltage Maximum Wire Length Table 3 defi nes the maximum total length of low voltage wiring from the outdoor unit, to the indoor unit, and to the thermostat.

  • Page 16: Electrical - High Voltage

    1 6 | Bosch IDS BOVA Installation Instructions Electrical - high voltage 12.2 High voltage disconnect switch Install a separate disconnect switch at the outdoor unit. 12.1 High voltage power supply Field provided fl exible electrical conduit must be used for high voltage wiring.

  • Page 17: Start Up

    Installation Instructions Bosch IDS BOVA | 17 Start up Set system thermostat to ON. 13.1 System start up Ensure Sections 7, 8, 9, 10, 11, 12, and 13 have been completed. Set System Thermostat to OFF. Inside Set To Following...

  • Page 18: System Charge Adjustment

    1 8 | Bosch IDS BOVA Installation Instructions 14 System charge adjustment 14.2 Subcooling charging and refrigerant adjustment in cooling (above 55°F outdoor temp.) 14.1 Charging: weigh-in method Check the outdoor ambient temperatures. Weigh-In method can be used for the Initial installation, or anytime a system charge is being replaced.
  • Page 19 Installation Instructions Bosch IDS BOVA | 19 After twenty (20) minutes stabilization period, maintain continuous Final Superheat (°F) Suction operation while adjusting refrigerant charge or TXV, after which operate Temp system for a minimum of fi ve (5) minutes for system to stabilize, otherwise (°F)
  • Page 20 2 0 | Bosch IDS BOVA Installation Instructions Adjust refrigerant level to attain proper gage pressure. Record System Information for reference (Table 7). Record system pressures and temperatures after charging is complete. Add refrigerant if the design subcooling is lower than the chart value.

  • Page 21: System Operation And Troubleshooting

    Installation Instructions Bosch IDS BOVA | 21 15 System operation and troubleshooting  TF = IPM Radiator Temperature) (Table 2) — Inverter High Temperature Protection 15.1 Control logic description  Pressure transducer (Table 3)  The variable speed system adopts the same 24VAC control as any —...

  • Page 22: Reversing Valve Operation

    2 2 | Bosch IDS BOVA Installation Instructions 15.6 Protection functions  Manual Defrost: System must have a call for heat and have been operating for a minimum  Outdoor coil temperature protection (T3) of 8 minutes. If T3 > 143.6°F, compressor is de-energized Press “Force”...
  • Page 23 Installation Instructions Bosch IDS BOVA | 23 15.7 Fault code table Code Fault Description Temperature sensor fault(T3, T4, T5, TF) High/low voltage protection DC fan motor fault Compressor discharge sensor(T5) is seated fault EEPROM fault System lockup, 2 times (E6) protection in 10 minutes...
  • Page 24 2 4 | Bosch IDS BOVA Installation Instructions 15.8 Parameter point check table  To display system parameters, press the “Check” button to index through the series of parameters available. The first time you press on the “Check” button, it will display the sequence, and after 1 second it will display the value of the parameter.
  • Page 25 Installation Instructions Bosch IDS BOVA | 25 15.9 Control board overviews For 2436 model EEPROM chip THE FACTORY SETTING FOR 36K MODEL, CUT OFF J2 JUMP FOR 24K MODEL. Figure 42 * The photo is just for reference,actual unit will verify.
  • Page 26 2 6 | Bosch IDS BOVA Installation Instructions For 4860 model Main control board EEPROM chip THE FACTORY SETTING FOR 36K MODEL, CUT OFF J2 JUMP FOR 24K MODEL. Figure 43 * The photo is just for reference,actual unit will verify.
  • Page 27 Installation Instructions Bosch IDS BOVA | 27 For 4860 model Drive board 24 25 Figure 44 * The photo is just for reference,actual unit will verify. Function description Function description Connect the cathode of the rectifi er bridge AC power supply output port...
  • Page 28 2 8 | Bosch IDS BOVA Installation Instructions 15.10 Error code troubleshooting Error Code Description P5 ( Condenser coil temperature(T3) protection in cooling) Handling Diagnosis High pressure switch(HPS)protection Condenser coil temperature(T3) protection in cooling Check whether the service Open the service valves...
  • Page 29 Installation Instructions Bosch IDS BOVA | 29 Error Code Description Hb ( High pressure(PT) protection in Heating) High module radiator temperature (TF) protection Diagnosis Handling Table 15 Check whether the service Open the service valve valves are open P0 (High module radiator temperature (TF)protection)
  • Page 30 3 0 | Bosch IDS BOVA Installation Instructions Error Code Description P4 ( Compressor discharge sensor(T5) is seated fault) Temperature sensor fault(T3, T4, T5, TF) Diagnosis Handling Pressure transducer(PT) fault High pressure switch(HPS) fault Check whether the service Open the service valve...
  • Page 31 Installation Instructions Bosch IDS BOVA | 31 F1 ( High pressure switch(HPS) fault) E7 Compressor discharge sensor(T5) is seated fault) Diagnosis Handling Diagnosis Handling Check whether condenser coil Check whether the service Reseat the sensor to Open the service valve...
  • Page 32 3 2 | Bosch IDS BOVA Installation Instructions Error Code Description EEPROM fault E5 ( High/low voltage protection) Diagnosis Handling Communication fault in main control chip High/low voltage protection Check whether the power Make sure the power supply voltage is between...
  • Page 33 Installation Instructions Bosch IDS BOVA | 33 Error Code Description Error Code Description IPM module protection Ambient Temperature Limited System lockup, 3 times (P6/L0-9) protection in 60 minutes Table 23 L0-L9 IPM module protection (the same as P6, only for analysis)
  • Page 34 3 4 | Bosch IDS BOVA Installation Instructions TEMP F TEMP C RESISTANCE kΩ VOLTS DC TEMP F TEMP C RESISTANCE kΩ VOLTS DC -20.6 107.732 4.65 32.2 7.225 2.36 -17.8 93.535 6.401 2.21 79.521 4.54 37.8 5.683 2.07 -12.2 67.795...
  • Page 35 Installation Instructions Bosch IDS BOVA | 35 TEMP F TEMP C RESISTANCE kΩ VOLTS DC TEMP F TEMP C RESISTANCE kΩ VOLTS DC -20.6 600.134 4.93 13.643 3.14 -17.8 505.551 4.92 62.8 12.359 3.03 427.463 4.91 65.6 11.214 2.91 -12.2 362.739...
  • Page 36 3 6 | Bosch IDS BOVA Installation Instructions NSK-BD035I V= (7.9*PSIG*10-3)+0.5 Pe/Pc Pe/Pc Pe/Pc PSIG PSIG PSIG 0.69 24.4 1.37 110.6 2.54 258.5 26.0 1.39 112.5 2.56 262.0 0.72 27.7 114.5 2.59 265.6 0.73 29.4 1.42 116.5 2.62 269.2 0.75 31.2...
  • Page 37 Installation Instructions Bosch IDS BOVA | 37 Wiring diagrams 16.1 For BOVA 36 Figure 64 Bosch Thermotechnology Corp. | 12.2016 Data subject to change...
  • Page 38 3 8 | Bosch IDS BOVA Installation Instructions 16.2 For BOVA 60 Figure 65 Data subject to change 12.2016 | Bosch Thermotechnology Corp.
  • Page 39 Installation Instructions Bosch IDS BOVA | 39 Spare parts 17.1 For BOVA 36 Main Control Board Figure 66 Part Name BOVA 36 (3 Ton) Part Name BOVA 36 (3 Ton) Upside board ass'y 8733941794 High pressure valve Ass'y 8733941821 E-part box ass'y 8733941795 16.1...
  • Page 40 4 0 | Bosch IDS BOVA Installation Instructions 17.2 For BOVA 60 Main Control Board Figure 67 Part Name BOVA 60 (5 Ton) Part Name BOVA 60 (5 Ton) Side board ass'y 8733941837 15.2 Pressure controller 8733941857 E-part box ass'y 8733941838 15.3...
  • Page 41 Installation Instructions Bosch IDS BOVA | 41 Notes: Bosch Thermotechnology Corp. | 12.2016 Data subject to change...
  • Page 42 4 2 | Bosch IDS BOVA Installation Instructions Notes: Data subject to change 12.2016 | Bosch Thermotechnology Corp.
  • Page 43 Installation Instructions Bosch IDS BOVA | 43 Notes: Bosch Thermotechnology Corp. | 12.2016 Data subject to change...
  • 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...

This manual is also suitable for:

Bova-36Bova-60

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