Bosch CLIMATE 5000 Service Manual
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Bosch CLIMATE 5000 Service Manual

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SERVICE MANUAL
CLIMATE 5000 RAC SINGLE SPLIT (R32)

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  • Page 1 SERVICE MANUAL CLIMATE 5000 RAC SINGLE SPLIT (R32)

  • Page 2: Table Of Contents

    Temperature Sensor Resistance Value Table for TP ..58 3.1.13 8°C Heating (Optional) ........... 11 Pressure On Service Port (R32) ......59 3.1.14 Self clean (Optional) ..........11 CAUTION Risk of fire/flammable material CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 3: Safety Instructions

    Work in confined spaces shall be avoided. The area around the working space shall be sectioned off. Ensure that the area is free of flammable material. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 4: Checking For Leakage

    This process shall be repeated until no CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 5: Charging Procedures

    1.2.19 Recovery When removing refrigerant from a system, either for servicing or decommissioning, it is important that all refrigerants are removed or recovered correctly according standards. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 6: Specifications

    485 Wire-controller Connected SENSOR Wire-controller FOR SETTING NETADDRESS (CCM Comm.Bus) ENC3+F1 (MULTI-FUNCTION CONTROL BOARD) -----This symbol indicates the CODE element is optional,the actual NETADDRESS shape shall prevail. FACTORY SETTING Fig. 1. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 7: Outdoor Unit

    OPTIONAL MAIN CRANKCASE HEATER BLUE OR BOARD WHITE OPTIONAL BLUE OR WHITE WHITE HEATER OPTIONAL BLUE BLUE BLACK BLACK CN 7 COMPRESSOR ELECTRONIC EXPANSION DC-FAN VALVE OPTIONAL OPTIONAL DC-FAN Fig. 2. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 8 NOTE: As Ihe standby control needs, the cross section area of cable connected to W, 1,2 must be selected to suit the maximum system current. The maximum system current is equal to thesum of indoor unit TO INDOOR UNIT POWER SUPPLY Fig. 3. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 9: Product Features

    • When more than one temperature sensor is malfunctioning, the air conditioner ceases operation. • When the current exceeds the preset value, the current protection function activates and the compressor ceases operation. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 10: Heating Mode

    • T3 value stays 2K above parameter TCDE for 80 seconds. than 17°C) every hour. After 2 hours, the set temperature stops • Unit runs for 15 minutes consecutively in defrosting mode. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 11: Auto-Restart Function

    • To enter information inquiry status, complete the following proce- dure within ten seconds: • Press LED 3 times. • Press SWING 3 times. • If you are successful, you will hear beeps for two seconds. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 12 Causes of compressor 0-99 For a detailed explana- stop tion, contact technical support. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 13 Product Features Displayed code Explanation Displayed value Meaning Additional Notes Reserved 0-FF 2-28 5-20 5-25 Table 7. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 14: Maintenance And Disassembly

    Wait for 5 minutes then check whether the gauge needle moves after turning off the vacuum pump. If the gauge needle moves a. Check whether the vacuum pressure gauge indicates -1 bar backward, check whether there is gas leakage. (-14.5 Psi). CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 15: Refrigerant Recharge

    9. When the electronic scale displays the correct weight (refer to the gauge and the pressure of the low side to confirm), turn off the air conditioner, then disconnect the charge hose immediately from the gas valve service port. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 16: Re-Installation

    7. Disconnect the charge set and mount the caps of service port and liquid / gas valves. 8. Use a torque wrench to tighten the caps to a torque of 18 N.m. 9. Check for gas leakage. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 17 Wait for 5 minutes then check whether the gauge needle moves after turning off the vacuum pump. If the gauge needle moves backward, check whether there is gas leakage. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 18 6. Disconnect the charge hose from the vacuum pump. 7. Mount the caps of service port and liquid / gas valves. 8. Use a torque wrench to tighten the caps to a torque of 18 N.m. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 19 1. Mechanical connectors used indoors shall comply with local regulations. 2. When mechanical connectors are re-used indoors, sealing parts shall be renewed. When flared joints are re-used indoors, the flare part shall be re-fabricated. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 20: Disassembly

    6) Disconnect the connector for display board (see fig. 15). Filter Fig. 12. 3) Open the horizontal louver and push the hook towards left to open it (see fig. 13). Horizontal Louver Hook Fig. 13. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 21 8) Open the screw caps(2) and the remove the screws (see fig. 16). 9) Release the 4 hooks. Fig. 16. 10) Release the seven hooks in the back (see fig. 17). Fig. 15. Hooks Fig. 17. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 22 (see fig. 19). Electronic Box Cover Fixing Screw Fixing Screw Electronic Box Fig. 19. 2) Pull out the room temperature sensor (T1) and the coil temperature sensor (T2) (see fig. 20). Fig. 21. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 23 3) Remove the two screws on the evaporator located at the base of the bearing side (see fig. 26). Capacitor of Fan Motor Fig. 23. NOTICE: This section is for reference only. Actual unit appearance may vary. Screws Fig. 26. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 24 3) Remove the fixing screw (see fig. 30). 4) Pull out the fan motor and fan assembly from the side. Fixing Screw Fig. 30. NOTICE: This section is for reference only. Actual unit appearance may vary. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 25: Outdoor Unit

    3) Remove the screws of the top cover and then remove the top cover (3 screws). One of the screws is located underneath the big handle (see fig. 33). Top Cover Fig. 33. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 26 Fig. 34. 5) Remove the screws of dust cover (1 screw) (see fig. 35). Fig. 36. NOTICE: Dust Cover This section is for reference only. Actual unit appearance may vary. Fig. 35. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 27 3) Remove the screws of the top cover and then remove the top cover (3 screws). One of the screws is located underneath the big handle (see fig. 38). Top Cover Dust Cover Fig. 40. Fig. 38. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 28 3) Remove the screws of the top cover and then remove the top cover (3 screws). One of the screws is located underneath the big handle (see fig. 43). Top Cover Fig. 43. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 29 5) Remove the screws of water collecting cover and then remove the dust cover (1 screw) (see fig. 45). Fig. 46. Dust Cover NOTICE: This section is for reference only. Actual unit appearance may vary. Fig. 45. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 30 3) Remove the screws of the top cover. (2 screws) (see fig. 48). AC Fan DC Fan Fig. 50. 6) Remove the fixing screws of the fan motor (4 screws) (see fig. 51). Fig. 48. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 31 3) Unfix the hooks and then open the electronic control box cover (4 hooks) (see fig. 53). Fig. 51. NOTICE: This section is for reference only. Actual unit appearance may vary. Hook Fig. 53. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 32 Electronic Expansion Valve Fig. 56. NOTICE: This section is for reference only. Actual unit appearance may vary. Fig. 55. NOTICE: This section is for reference only. Actual unit appearance may vary. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 33 Fig. 58. Electronic Expansion Valve NOTICE: This section is for reference only. Actual unit appearance may vary. Fig. 57. NOTICE: This section is for reference only. Actual unit appearance may vary. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 34 (see fig. 59). cover (see fig. 60). 2) Remove the four-way valve assembly with pliers. Terminal Cover Fig. 60. Fig. 59. NOTICE: This section is for reference only. Actual unit appearance may vary. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 35 3) Remove the hex nuts and washers securing the compressor, located on the bottom plate (see fig. 62). Fig. 63. NOTICE: This section is for reference only. Actual unit appearance may vary. Fig. 62. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 36: Troubleshooting

    The terminals are located on the bottom surface of the outdoor PCB. Discharging position Plug of soldering iron (Discharging period 10 seconds or more) Fig. 65. NOTICE: This picture is for reference only. Actual appearances may vary. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 37: General Troubleshooting

    Test the unit using the remote control. If the unit does not respond to the remote controller, replace the PCB of the indoor unit. If the unit responds, replace the display board. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 38: Error Diagnosis And Troubleshooting

    Low suction pressure Page 42-43 Unit runs continuously but insufficient Page 42-43 cooling Too cool Page 42-43 Compressor is noisy Page 42-43 Horizontal louver can not revolve Page 42-43 Table 11. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 39: Quick Maintenance By Error Code

    Compressor ✗ ✗ ✗ ✗ ✓ ✗ ✗ ✓ IPM board ✗ ✗ ✗ ✗ ✓ ✓ ✗ ✓ Outdoor unit ✗ ✗ ✗ ✗ ✗ ✗ ✗ ✗ Table 13. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 40 ✩ ✩ ✩ ✩ frequently Unit runs continuously but insuffi- ✩ ✩ ✩ ✩ ✩ ✩ ✩ ✩ cient cooling(heating) Unit is noisy ✩ ✩ Test method / remedy Table 14. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 41 ✩ Unit runs continuously but insufficient cooling ✩ ✩ ✩ Too cool ✩ ✩ Compressor is noisy Horizontal louver can not revolve ✩ ✩ ✩ Test method / remedy Table 15. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 42 Unit runs continuously but insufficient cooling ✩ ✩ ✩ ✩ ✩ ✩ ✩ ✩ Too cool Compressor is noisy ✩ ✩ ✩ ✩ ✩ Horizontal louver can not revolve Test method / remedy Table 16. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 43: Troubleshooting By Error Code

    P and UVWN; UVW and N. Digital tester Normal resistance value Digital tester Normal resistance value (+)Red (-)Black ∞ (+)Red (-)Black ∞ (Several MW) (Several MW) (+)Red Table 18. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 44: E0/F4 (Eeprom Parameter Error)

    The location of the EEPROM chip on the indoor and outdoor PCB is shown in the following two images: EEPROM Chip Fig. 69. EEPROM Chip NOTICE: Fig. 68. These images are for reference only. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 45: E1 (Indoor And Outdoor Unit Communication Error)

    Check the reactor. Is the error resolved? Replace the Is it normal? reactor Replace the outdoor PCB. Replace the outdoor PCB. Power on. Is the error resolved? Replace the indoor PCB. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 46: E2 (Zero Crossing Detection Error Diagnosis And Solution)

    Check the connections and power supply. Correct the connections. Turn on the unit when the Is it normal? power supply is good. Indoor main PCB is defective. Replace indoor main PCB. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 47: E3/F5 (Fan Speed Is Operating Outside Of The Normal Range)

    Check the wiring of fan motor. Is it improperly Ensure proper connections wired? Measure the voltage for the fan motor from the PCB. Is it within normal Replace the indoor/outdoor PCB parameters? Replace the fan motor CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 48 100V(208~240V power supply) or 50V(115V power supply), the PCB may be defect and need to be replaced. Input Terminal Black White White Black Fig. 72. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 49: E4/E5/F1/F2/F3 (Open Circuit Or Short Circuit Of Temperature Sensor Diagnosis And Solution)

    PCB. Is it properly wired? Ensure proper connections. Measure the resistance value of the sensor. Is it within acceptable parameters? Replace the Sensor. Replace indoor or outdoor PCB Fig. 73. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 50: E7 (Indoor Pcb /Display Board Communication Error)

    Check the wirings and connection. Are all the connections Correct the connection or replace good? the Wirings. Replace the indoor main PCB. Is the error extinguished? Replace the Display board. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 51: Ec (Refrigerant Leakage Detection Diagnosis And Solution)

    Replace the indoor Is it securely attached? Check system for leakages. Repair the leakage and recharge the Are any leakages present? refrigerant. Check System for blockages and clear blockages if present. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 52: F0 (Overload Current Protection Diagnosis And Solution)

    Check the connections and wires. Are they properly Ensure proper connections or replace connected? the wires. Check the reactor. Replace outdoor PCB. Is it in working range? Replace the outdoor unit. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 53: P0 (Ipm Malfunction Or High Current Protection Diagnosis And Solution)

    Please refer to the solution of the “Fan Speed is Out of Is the function OK? Control”malfunction. Check the compressor resistance values. Are the values within Replace the compressor. acceptable ranges? Replace the outdoor PCB. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 54: P1 (High / Low Voltage Protection Diagnosis And Solution)

    The voltage between P and N is: - During standby: DC 310V,340V or 380V Replace the IPM board. - During start-up: 220V~400V Check the reactor. Replace outdoor PCB. Is it in working range? Replace the reactor. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 55: P2 (High Temperature Protection Of Ipm Module Diagnosis And Solution)

    • Connection problems Troubleshooting and repair: Check the fastening screws on the PCB and IPM radiator. Are they fixed tightly? Replace the outdoor control PCB. Tighten the screws and apply silicon grease. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 56: P4 (Inverter Compressor Drive Error Diagnosis And Solution)

    Check the outdoor fan and the outdoor unit ventilation. Does it function Please refer to “Fan Speed properly? Malfunction” Check the compressor resistance values. Are they within Replace the compressor. acceptable ranges? Replace the outdoor PCB. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 57: Appendix

    0.26408 17.8005 3.07075 0.77709 0.25757 16.9341 2.95896 0.75373 0.25125 16.1156 2.84421 0.73119 0.24512 15.3418 2.73823 0.70944 0.23916 14.6181 2.63682 0.68844 0.23338 13.918 2.53973 0.66818 0.22776 13.2631 2.44677 0.64862 0.22231 Table 20. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 58: Temperature Sensor Resistance Value Table For Tp

    19.69 1.632 104.6 18.96 4.849 99.69 18.26 4.703 95.05 17.58 4.562 90.66 16.94 4.426 86.49 16.32 4.294 82.54 15.73 4.167 78.79 15.16 4.045 75.24 14.62 3.927 71.86 14.09 3.812 Table 21. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)

  • Page 59: Pressure On Service Port (R32)

    1.14 80/67 0.72 0.73 0.87 0.97 0.95 0.91 0.93 0.98 1.14 1.21 90/73 0.79 0.80 0.98 1.07 1.05 0.97 1.02 1.08 1.26 1.33 Table 24. 70/59 75/63 80/67 90/73 Fig. 74. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 60 (8.33/6.11) (2.78/0.56) (-2.78/-5) (-8.33/-10.56) (-17/-19) (-27/-28) 3.09 2.91 2.58 2.33 2.12 1.89 1.68 3.32 3.06 2.71 2.59 2.38 2.09 1.94 3.45 3.21 2.84 2.68 2.54 2.19 2.04 Table 27. Fig. 75. CLIMATE 5000 RAC SINGLE SPLIT (R32) – 6720894076 (2019/08)
  • Page 64 Bosch Thermotechnik GmbH Junkersstrasse 20-24 D-73249 Wernau www.bosch-thermotechnology.com...

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R32

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