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Bosch BOVA Series Installation Instructions Manual

2.0 split system heat pump, condensing units up to 20.5 seer, 2-3-4-5 ton capacity, r410a
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Bosch BOVA 2.0 Split System Heat Pump
Condensing Units Up to 20.5 SEER
2-3-4-5 Ton Capacity
R410A
Installation Instructions

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  Summary of Contents for Bosch BOVA Series

  • Page 1 Bosch BOVA 2.0 Split System Heat Pump Condensing Units Up to 20.5 SEER 2-3-4-5 Ton Capacity R410A Installation Instructions...
  • Page 2 2 | Bosch IDS 2.0 BOVA Installation Instructions 02.2019 | Bosch Thermotechnology Corp. Data subject to change...
  • Page 3: Table Of Contents

    Installation Instructions Bosch IDS BOVA | 3 Table of Contents 1 Key to Symbols and Safety Instructions 13 Start Up 1.1 Key to Symbols 13.1 System Start Up 1.2 Safety 14 System Charge Adjustment 2 Unit Location Considerations 14.1 Charging: Weigh-In Method 2.1 Unit Dimensions...
  • Page 4: Key To Symbols And Safety Instructions

    4 | Bosch IDS 2.0 BOVA Installation Instructions 1 Key to Symbols and Safety Instructions 1.2 Safety Please read before proceeding 1.1 Key to Symbols Warnings WARNING: ELECTRICAL HAZARD 380 VOLTS DC Warnings in this document are identifi ed by a ...
  • Page 5 Installation Instructions Bosch IDS BOVA | 5 WARNING: HAZARDOUS VOLTAGE CAUTION: GROUNDING REQUIRED   Failure to follow this warning could result in property Failure to inspect or use proper service tools may result damage, severe personal injury, or death.
  • Page 6: Unit Location Considerations

    6 | Bosch IDS 2.0 BOVA Installation Instructions 2 Unit Location Considerations  Maximum line equivalent length = 150 feet.  2.1 Unit Dimensions Maximum vertical equivalent length = 50 feet.  Use only the line diameters indicated in Table 2.
  • Page 7: Location Restrictions

    Installation Instructions Bosch IDS BOVA | 7 2.3 Location Restrictions Cold climate considerations (heat pump only) Ensure the top discharge area is unrestricted for at least 60 inches above the unit. Precautions must be taken for units being installed in areas where Do not locate outdoor unit near bedrooms since normal operational sounds may be snow accumulation and prolonged below-freezing temperatures occur.
  • Page 8: Unit Preparation

    8 | Bosch IDS 2.0 BOVA Installation Instructions 3 Unit Preparation 3.1 Prepare the Unit for Installation  Check for damage and report promptly to the carrier any damage found to the unit (Fig. 6).  The charge port can be used to ensure the refrigerant charge has been retained during shipment.
  • Page 9: Refrigerant Line Considerations

    Installation Instructions Bosch IDS BOVA | 9 5 Refrigerant Line Considerations 5.4 Reuse Existing Refrigerant Lines 5.1 Refrigerant Line and Service Valve Connection Sizes CAUTION: MINOR TO MODERATE BURNS Suction Line Liquid Line  Suction Line Liquid Line If using existing refrigerant lines, make certain that all joints...
  • Page 10: Refrigerant Line Routing

    1 0 | Bosch IDS 2.0 BOVA Installation Instructions 6 Refrigerant Line Routing   Comply with National, State, and local codes when isolating linesets from joists, rafters, walls, or other structural elements. 6.1 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 Ductwork Insulation Suction Line Isolator Lineset DO NOT hang linesets from ductwork Isolation Through Wall Figure 13 7 Refrigerant Line Brazing 7.1 Braze The Refrigerant Lines 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.
  • Page 12 1 2 | Bosch IDS 2.0 BOVA Installation Instructions Remove the pressure tap cap from both service valves. Shipped in package field installed 3-4" from valve Figure 17 Figure 15 Replace the pressure tap caps after the service valves have cooled.
  • Page 13: Refrigerant Line Leak Check

    Installation Instructions Bosch IDS BOVA | 13 8 Refrigerant Line Leak Check 9 Evacuation 8.1 Check For Leaks 9.1 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 2.0 BOVA Installation Instructions 10 Service Valves 10.1 Open the Service Valves 5/16" Hex Wrench for Suction Service Valve WARNING: MODERATE TO SEVERE BURNS 3/16" Hex Wrench  Unit Side Extreme caution should be exercised when opening the...
  • Page 15: Electrical - Low Voltage

    Installation Instructions Bosch IDS BOVA | 15 11 Electrical - Low Voltage 11.1 Low Voltage Maximum Wire Length Table 4 defi nes the maximum total length of low voltage wiring from the outdoor unit, to the indoor unit, and to the thermostat.
  • Page 16 1 6 | Bosch IDS 2.0 BOVA Installation Instructions Support 3H and 2C thermostat H/DH TH E RM O S TAT Note: Any time the electric heat elements are active, the indoor fan INDOOR UNIT will run in high stage.
  • Page 17 Installation Instructions Bosch IDS BOVA | 17 Wiring for 3H and 1C thermostat H/DH TH ERM OSTAT Note: Because Y1 and Y2 are jumped, the indoor fan will only run in high stage. INDOOR UNIT Note: Any time the electric heat...
  • Page 18 1 8 | Bosch IDS 2.0 BOVA Installation Instructions Wiring for 1H and 1C thermostat H/DH THERMOSTAT Note: Because Y1 and Y2 are jumped, the indoor fan will only run in high stage. INDOOR UNIT OUTDOOR UNIT Figure 29 Thermostat Wiring Diagram for BOVA2.0/BVA2.0 Matched System...
  • Page 19: Electrical - High Voltage

    Installation Instructions Bosch IDS BOVA | 19 12 Electrical - High Voltage 12.3 High Voltage Ground Ground the outdoor unit per national, state, and local code requirements. 12.1 High Voltage Power Supply WARNING: LIVE ELECTRICAL COMPONENTS!  During installation, testing, servicing, and trouble shooting of this product, it may be necessary to work with live electrical components.
  • Page 20: Start Up

    2 0 | Bosch IDS 2.0 BOVA Installation Instructions 13 Start Up Set system thermostat to ON. 13.1 System Start Up Ensure Sections 7, 8, 9, 10, 11, and 12 have been completed. Set System Thermostat to OFF. Figure 36 Figure 33 Turn on disconnect to apply power to the indoor and outdoor units.
  • Page 21: System Charge Adjustment

    Installation Instructions Bosch IDS BOVA | 21 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. Use weigh-in method the initial installation, or anytime a system charge is being Subcooling (in cooling mode) is the only recommended method of charging replaced.
  • Page 22 2 2 | Bosch IDS 2.0 BOVA Installation Instructions Stabilize the system. If calculated subcooling value is lower than the design subcooling value (Table 9), please add refrigerant. Repeat steps 3 through 5. After starting the system in cooling mode, short press “FORCE” button, and “...
  • Page 23 Installation Instructions Bosch IDS BOVA | 23 Adjust refrigerant level to attain proper gauge pressure. Record System Information for reference (Table 10). Record system pressures and temperatures after charging is complete. Add refrigerant if the subcooling reading from Table 8 is lower...
  • Page 24: System Operation And Troubleshooting

    2 4 | Bosch IDS 2.0 BOVA Installation Instructions 15 System Operation and Troubleshooting 15.2 Sensors (Thermistors/Pressure Transducer) 15.1 Control Logic Description  T3 = Outdoor Coil Temperature (Table 24) — High/Low temperature protection  The variable speed system adopts the same 24VAC control as any conventional —...
  • Page 25: Compressor Crankcase Heater Description

    Installation Instructions Bosch IDS BOVA | 25  Defrost Termination Settings (SW5) offers different defrost termination 15.6 Reversing Valve Operation options for enhanced defrost for different geographical and outdoor conditions.  Reversing valve energizes during heat mode and de-energizes in cool mode.
  • Page 26: Fault Code Table

    2 6 | Bosch IDS 2.0 BOVA Installation Instructions 15.8 Fault Code Table Code Fault Description (Sensor) The coil sensor is seated fault in cooling (T3) Temperature sensor fault (T3, T4, T5, Th, T3L, TF) High/low voltage protection DC fan motor fault...
  • Page 27: Parameter Point Check Table

    Installation Instructions Bosch IDS BOVA | 27 15.9 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 the “Check” button, it will display the sequence, and after 1 second it will display the value of the parameter.
  • Page 28: Control Board Overviews

    2 8 | Bosch IDS 2.0 BOVA Installation Instructions 15.10 Control Board Overviews Main Control Board for 24/36 ODU Model Function Description Compressor crankcase heater port Pressure equalizer valve port Reversing valve port Thermostat wire connections Th sensor port TF sensor port...
  • Page 29 Installation Instructions Bosch IDS BOVA | 29 Main Control Board for 48/60 ODU Model Function description Pressure equalizer valve port Compressor crankcase heater port Reversing valve port Thermostat wire connections EEV port Th sensor port TF sensor port T3 T4 T3L sensor port...
  • Page 30: Error Code Troubleshooting

    3 0 | Bosch IDS 2.0 BOVA Installation Instructions 15.11 Error Code Troubleshooting Error Code Description (Sensor) P5 ( Condenser coil temperature (T3) protection in cooling) High pressure switch (HPS) protection Diagnosis Handling Condenser coil temperature (T3) protection in cooling...
  • Page 31 Installation Instructions Bosch IDS BOVA | 31 Error Code Description Low pressure (PT) Protection in cooling and heating P3 ( Compressor over current protection) Diagnosis Handling System lockup, 5 times (P2) protection in 100 minutes High compressor discharge temperature(T5) protection...
  • Page 32 3 2 | Bosch IDS 2.0 BOVA Installation Instructions Error Code Description P4 (High compressor discharge temperature (T5) protection) Temperature sensor fault (T3, T4, T5,Th, T3L, TF) Diagnosis Handling Pressure transducer (PT) fault High pressure switch (HPS) fault Table 18...
  • Page 33 Installation Instructions Bosch IDS BOVA | 33 E7 Compressor discharge sensor (T5) is seated fault) F1 (High pressure switch (HPS) fault) Handling Diagnosis Handling Diagnosis Check whether compressor Check whether the service discharge sensor (T5) is Reseat the sensor to...
  • Page 34 3 4 | Bosch IDS 2.0 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 35 Installation Instructions Bosch IDS BOVA | 35 Error Code Description Error Code Description L0-L9 IPM module protection Ambient Temperature Limited Table 22 Table 23 When error codes L0-L9 appears occasionally, no action is necessary. The system will restart automatically after 6 minutes.
  • Page 36: Temperature And Resistance Relationship Tables (For Sensors)

    3 6 | Bosch IDS 2.0 BOVA Installation Instructions 15.12 Temperature and Resistance Relationship Tables (for Sensors) 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...
  • Page 37: Temperature And Resistance Relationship Tables (For T5 & Tf Sensors)

    Installation Instructions Bosch IDS BOVA | 37 15.13 Temperature and Resistance Relationship Tables (for T5 & Tf Sensors) TEMP F TEMP C RESISTANCE kΩ VOLTS DC TEMP F TEMP C RESISTANCE kΩ VOLTS DC -20.6 600.134 4.93 60.0 13.643 3.14 -17.8...
  • Page 38 3 8 | Bosch IDS 2.0 BOVA Installation Instructions SYSTEM FAULTS Display shows nothing System won't start P P P SYSTEM Capacity is insuffcient P P P Display is not normal when running Cool when hea ng requirement P2/H5 P P S...
  • Page 39: Wiring Diagram

    Installation Instructions Bosch IDS BOVA | 39 16 Wiring Diagram WARNING ELECTRIC HAZARD 380 VOLTS DC ELECTRIC HAZARD 380 VOLTS DC WAIT 3 MINUTES AFTER DISCONNECTING POWER,THEN VERIFY DC VOLTAGE LESS THAN 42 VDC AT INVERTER TEST POINTS P-N. TEST POINTS P-N. COMPONENTS MAY STORE A DANGEROUS ELECTRICAL POTENTIAL OF 380 VOLTS DC.
  • Page 40: Care And Maintenance

    4 0 | Bosch IDS 2.0 BOVA Installation Instructions 17 Care and Maintenance 17.2 Maintenance – Pre-Season Inspection At the beginning of each heating or cooling season, do the following: 17.1 Cleaning Precautions WARNING:  Any maintenance and cleaning of outdoor unit must be performed by qualified service personnel only.
  • Page 41 Installation Instructions Bosch IDS BOVA | 41 Notes: Bosch Thermotechnology Corp. | 02.2019 Data subject to change...
  • Page 42 4 2 | Bosch IDS 2.0 BOVA Installation Instructions 02.2019 | Bosch Thermotechnology Corp. Data subject to change...
  • Page 43 Installation Instructions Bosch IDS BOVA | 43 Bosch Thermotechnology Corp. | 02.2019 Data subject to change...
  • Page 44 United States and Canada Bosch Thermotechnology Corp. 65 Grove St. Watertown, MA 02472 Tel: 866-642-3198 Fax: 954-776-5529 www.boschheatingandcooling.com BTC 761701107 A / 02.2019...

This manual is also suitable for:

Bova-36Bova-60