Bosch Climate 8000i Service Manual
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Bosch Climate 8000i Service Manual

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Service manual
Climate 8000i/8100i
CL8000i-Set 25 E, CL8000i-Set 35 E, CL8100i-Set 65 HE

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  • Page 1 Service manual Climate 8000i/8100i CL8000i-Set 25 E, CL8000i-Set 35 E, CL8100i-Set 65 HE...

  • Page 2: Table Of Contents

    Data Protection Notice ....... 74 4.5.7 Malfunction occurs......22 Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 3: Explanation Of Symbols And Safety Instructions

    ▶ Refrigerant must be recovered. Do not release it to the environment. Use the vacuum pump to draw the refrigerant out from the unit. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 4: Electricity

    Before you power on and start the unit, check that the cover of the electric control box is seated correctly and secured with screws. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 5: General Information

    General information General information External Dimension 2.1.1 Indoor Unit 0010033911-001 Fig. 1 Indoor unit dimensions (in mm) Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 6: Outdoor Unit

    Electrical data Phase Rated frequency Rated voltage Rated current cooling (Min. - Max.) 2.3 (0.7 - 2.9) 3.7 (0.7 - 5.2) Rated current heating (Min. - Max.) 2.9 (0.7 - 5.6) 4.5 (0.7 - 8.6 Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 7: Cl8100I

    Net weight (IDU/ODU) 11/39 Safety device Fuse, Micro computer controlled Electrical data Phase Rated frequency Rated voltage Rated current cooling (Min. - Max.) 3.7 (0.7 - 5.2) Rated current heating (Min. - Max.) 4.5 (0.7 - 8.6) Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 8: Electrical Specifications Indoor Unit

    Outdoor fan motor automatically starts operation in “AUTO”. Rated voltage Rated capacity Poles Fuse Fu1, Fu5 250 V / 20 A 250 V / 3.15 A 250 V / 2 A Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 9: Auto Mode

    • Temperature adjustment (within 2 °C range) automatic operation. • Temperature setting • Fan setting • Air flow direction • Power ON/OFF • Automatic operation mode setting • Plasmacluster mode • OD SILENT setting • SPOT setting Settings not memorised • Timer setting Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 10: Electrical Components And Wiring Diagrams

    [16] Thermistor (room temperature) [17] Thermistor (heat exchange) [18] Receiver board [19] Display board [20] Power supply circuit [21] Serial signal circuit FU1... Fuse Orange Yellow Gn/Ye Green/Yellow * some functions are optional (depending on model) Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 11: Outdoor Unit

    Grounding may damage the oscilloscope. ▶ Do not ground. DANGER Danger - electric shock by high current All components may be charged to high voltage as circuits share the same GND line. ▶ Do not touch electrical components. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 12: Micro Computer Control System

    Electrical components and wiring diagrams Micro computer control system 3.2.1 Indoor Unit Electrical wiring 0010033701-001 Fig. 6 Indoor unit wiring Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 13 DC Fan motor Vertical louver (V-louver) switch Horizontal louver (H-louver) Terminal board Thermistor Switch board Panel louver left Vertical Louver (V-louver) [10] Panel louver right [11] PCI LED [12] WLAN Module (optional) [13] PCI unit Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 14: Outdoor Unit

    Electrical components and wiring diagrams 3.2.2 Outdoor unit Electrical wiring 0010033914-001 Fig. 7 Outdoor unit wiring Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 15: Function And Operation Of Protective Procedures

    When in cooling or Automatic reset None None prevention outdoor unit 2-way valve remains below dehumidifying when temperature of 0 °C for 10 continuous minutes during operation 2-way valve rises cooling or dehumidifying operation. above 10 °C. Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 16 Compressor stops if there is short At compressor Operation OFF or ON Only after outdoor exchanger circuit in outdoor unit heat exchanger start up unit restarts four thermistor short- thermistor (TH2). times (complete circuit error shutdown). Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 17 None thermal fuse blown compressor stops if outdoor unit cannot start up of serial signal in the Terminal receive serial signal from indoor unit for board 30 seconds. Table 3 Protection device functions and operations Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 18: Air Conditioner Operation In Thermistor Error

    Cold and cold air discharges. speed or stops, and and indoor unit fan frequency does not does not rotate. increase. Table 4 Air conditioner operation in thermistor error - IDU Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 19: Outdoor Unit

    Heating Operation not Normal operation. Outdoor unit Normal operation. Outdoor unit affected thermistor short- thermistor open- circuit error circuit error indication. indication. Table 5 Air conditioner operation in thermistor error - ODU Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 20: Thermistor Temperature Characteristics

    Pipe thermistor TH2 Resistance Room temperature thermistor TH1 Temperature Tester R / kΩ 15 kΩ 0°C 10 kΩ 25°C T / °C 0010033718-002 Fig. 10 TH2, TH3, TH4, TH5 resistances CN.. Connector Resistance Temperature Tester Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 21: General Troubleshooting Chart

    6 and 7 of connector CN11). Dew condensation on light Check for water and rust. Signal should be received within range Take moisture-proof measure for receiving unit. specified in manual. lead wire outlet of light receiving section. Table 11 Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 22: Louvers Do Not Move

    (C8, C9). ▶ To discharge stored electricity, unplug the power cord and connect the plug of a soldering iron (230VAC, 30W) between the positive and negative terminals of the inverter electrolytic capacitor (C8, C9). Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 23: Malfunction (Parts) Check Method

    V, W. The normal resistance between P and either of them is infinite or Fig. 11 - when using a digital tester - several mega-Ohm. When using a digital tester, the (+) and (-) tester lead wires must be reversed. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 24: Dc Current Error (6-0 Error)

    Securely fix IPM with screws Checking the AC power supply voltage when Connect stable power supply compressor rotate (rated voltage ±10 %)yields abnormal results. Continue with  Cooling mode Cooling mode is on Continue with  Heating mode Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 25 Checking outdoor heat exchanger yields abnormal Clean outdoor heat exchanger results.. Check the refrigerant amount Check the discharge pressure Check the installation condition 1) Check to make sure thermistors are installed in correct portions. See section 4.4 "Thermistor Temperature Characteristics". Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 26: Outdoor Unit Check Method

    Power supply output is 5VDC? Malfunction of IC1 •Micro-computer oscillator error •Malfunction of mircro-computer reset IC •Malfunction of micro-computer LED is flashing Normal Malfunction of serial signal circuit. ▶Check wiring between indoor and outdoor units. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 27: Troubleshooting Guide

    • after indicating for 3 minutes (when you pressed the Stop or Temp. button). • after indicating for 5 minutes (when you pressed AUX). • when unit receives signal of operation start. • when unit receives signal of operation stop. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 28: Self-Diagnosis Function (By Remote Control)

    ▶ Replace the outdoor 2-way valve thermistor short circuit. unit control PCB circuit error. ▶ No abnormality found assembly. in above inspections (1) and (2). Heatsink thermistor error. – Replace the outdoor unit control PCB Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 29 ▶ Go to “DC Over Current Error (6-0 error)”. DC Current outdoor IPM pin level error. ▶ Check the IPM is ▶ Replace the outdoor units do not attached correctly to unit PCB. operate. the outdoor unit IPM PCB. Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 30 ▶ Replace the 4-way for proper operation. valve. EEPROM error CPU (outdoor) 10-time Indoor and – ▶ Replace the outdoor RAM data error. outdoor unit control PCB units do not assembly. CPU error – operate. Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 31 PCB assembly. DC low voltage ▶ Check the AC power ▶ Correct the supply voltage for installation. fluctuation. ▶ No abnormality found ▶ Replace the PCB in above inspection. assembly. Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 32 ▶ Confirm assembly. communication error. blinking or outdoor and related circuit. ▶ Confirm WLAN module. units Wireless router connection ▶ Check Wireless router. ▶ Confirm connecting operate. error. with wireless router. ▶ Confirm setting of wireless router. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 33: Other Malfunction Error Indications/Buzzers

    2) Operation over 19,000 hours. The unit will stop releasing ions.The LED lamp will flash when unit tries to start plasmacluster operation. Other operations (e.g. cooling and heating) can run as usual. Table 20 Indoor unit indicator during operation Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 34 (Displays “17-0” when malfunction code is called out). 0010033778-001 Malfunction diagnosis display None (Displays “17-0” when malfunction code is called out). 0010033779-001 Malfunction diagnosis display “18-1” 0010033780-001 Malfunction diagnosis display “18-1” 0010033781-001 Table 21 Erroneous wiring Indoor unit Outdoor unit Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 35: Refrigeration Cycle

    [10] Expansion valve [11] Condenser [12] Coil Heating Cooling a – e outlet temperatures Standard Condition Indoor side Outdoor side Dry-bulb Temp. ( °C) Relative Humidity (%) Dry-bulb Temp. ( °C) Relative Humidity (%) Cooling Table 22 Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 36: Temperature At Each Part And Pressure In 3-Way Valve

    1) To enter cooling max, start the unit with remote control setting 16 °C and high fan speed. Check the data within 30 min after start cooling. 2) Refer to installation manual for how to enter test run. Table 24 Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 37: Performance Curves

    Fig. 15 Fig. 17 Capacity in kW Indoor air outlet temperature in °C Outdoor air temperature in °C Outdoor air temperature in °C T/˚C 0010033934-001 Fig. 16 Power consupmtion in W Outdoor air temperature in °C Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 38 14.0 29.0 13.0 26.0 12.0 /˚C /˚C 0010033938-001 0010033941-001 Fig. 20 Fig. 23 Indoor air outlet temperature in °C Indoor air outlet temperature in °C Outdoor air temperature in °C Outdoor air temperature in °C Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 39 14.4 34.0 13.7 32.0 13.0 /˚C /˚C 0010033944-001 0010033929-001 Fig. 26 Fig. 29 Indoor air outlet temperature in °C Indoor air outlet temperature in °C Outdoor air temperature in °C Outdoor air temperature in °C Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 40: Disassembly Procedure

    Power consupmtion in W Outdoor air temperature in °C Heating 40.0 37.5 35.0 32.5 0010033519-001 30.0 Fig. 34 Outdoor Air Temp. (°C) 0010033932-001 Fig. 32 Indoor air outlet temperature in °C Outdoor air temperature in °C Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 41 ▶ After the lever axis and panel center axis get away from the unit, move ▶ Slide air filters out of the filter guide. the panel to left side to take it out. 0010033525-001 0010033522-001 Fig. 40 Fig. 37 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 42 ▶ Remove the earth screw and the terminal of ground lead wire, cut the Fig. 42 band fixing thermistor. ▶ Repeat procedure for the right side panel. ▶ Pull the hook and take the box cover out. 0010033533-001 Fig. 46 0010033530-001 Fig. 43 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 43 ▶ Remove the left and right screws fixing the filter guide. 0010033537-001 0010033535-001 Fig. 51 Fig. 48 ▶ Unhook the middle part hook, rotate the filter guide to open it. 0010033574-001 Fig. 49 0010033538-001 Fig. 52 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 44 ▶ Rotate the assembly and pull it out. ▶ Remove three screws fixing the drain pan assembly. 0010033544-001 Fig. 57 0010033540-001 ▶ Unscrew the fixing screw between cross flow fan and fan motor. Fig. 54 0010033545-001 0010033541-001 Fig. 58 Fig. 55 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 45 ▶ Enlarge the angle between tube assembly and cabinet. ▶ Take out the evaporator. Fig. 60 ▶ Hold the cross flow fan and move it out right side first. 0010033548-001 Fig. 61 0010033551-001 Fig. 64 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 46 ▶ Move the Lead Wire to remain space for removing the special Fig. 69 screw A558. ▶ Slide the PCI base1 assemby to take it out. 0010033558-001 Fig. 70 0010033554-001 Fig. 67 Position of screw A558 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 47 ▶ Remove the screw, rotate the motor and take it out. Fig. 72 ▶ After the horizontal louver (H-louver) reaches the maximum angle position, separate it from two louver supports and make the louver bend to take it out. 0010033564-001 Fig. 76 0010033561-001 Fig. 73 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 48 ▶ Remove two screws, take out the panel gear case R. 0010033569-001 Fig. 81 ▶ Remove the screw to move out the joint cover. 0010033566-001 Fig. 78 ▶ Unfix the screw, move the motor out. 0010033570-001 Fig. 82 0010033567-001 Fig. 79 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 49 ▶ Remove two screws, take out the panel gear case L. 0010033576-001 Fig. 87 0010033572-001 ▶ Release the hook, then take out the limit switch. Fig. 84 ▶ Remove the screw, rotate the motor and take it out. 0010033577-001 Fig. 88 0010033573-001 Fig. 85 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 50 Fig. 89 Fig. 92 ▶ Release four hooks fixing the LED case, then lift it to take it out. 0010033579-001 Fig. 90 ▶ Release the hook and move out the PCI LED unit. 0010033580-001 Fig. 91 Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 51: Outdoor Unit

    ▶ Disassemble the top cover after its removing 4 screws. 0010034072-001 Fig. 98 Lift it up a little on the right 0010034069-001 Open it outward and lift up a little on the left, then open. Fig. 95 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 52 ▶ Cut the wire fixing band fixing the transfer connector of the compressor and control box assembly. ▶ Disassemble the screw fixing control box assembly (1 screw). ▶ Disassemble the terminal of reactor and compressor. 0010034078-001 0010034075-001 Fig. 104 Fig. 101 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 53 ▶ Remove compressor cover (1 pcs). 0010034082-001 Fig. 108 Removing compressor cover 1 Compressor cover 0010034080-001 Fig. 106 ▶ Disassemble bulkhead assembly (2 screws). 0010034083-001 Fig. 109 Removing compressor cover 2 0010034084-001 Fig. 110 Removing assemble cover 0010034081-001 Fig. 107 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 54 0010034090-001 Fig. 115 ▶ Disassemble fan motor angle assembly (2 screws). 0010034087-001 Fig. 112 0010034091-001 Fig. 116 ▶ Disassemble fan motor angle (2 screws). 0010034088-001 Fig. 113 0010034092-001 Fig. 117 0010034089-001 Fig. 114 Thermistor clamps Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 55: Exchanging Electrical Parts Of The Outdoor Control Box Unit

    ▶ Disassemble lead wire connected with terminal board (5 pcs). 0010034097-001 Fig. 122 ▶ Unscrew 4 screws, then disassemble control board unit. 0010034094-001 Fig. 119 ▶ Disassemble terminal board, if terminal board is broken (1 screw) 0010034098-001 Fig. 123 0010034095-001 Fig. 120 Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 56 ▶ Reconnect terminals in order after exchanging the control basal Compress the clamp a little lamina. Note the following: ▶ Pull out the terminal straight along the blade connector. ▶ Do not pull on the wire to remove the terminal. 0010034102-001 Fig. 126 Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 57: Thermistor Assembly Installation Drawing

    Disassembly Procedure Thermistor Assembly Installation Drawing 0010034106-001 Fig. 130 Suction thermistor TH4 (Black) Compressor thermistor TH1 (Red) Outdoor temperature thermistor TH3 (Green) Heat exchange thermistor TH2 (Orange) 2 way valve thermistor TH5 (Yellow) Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 58: Troubleshooting

    20. Procedure Air conditioner operation stopped with error 1. Remove the connector from the PCB, and then Replace outdoor unit thermistor. measure the resistance. Is the resistance of the outdoor unit thermistor is OK? Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 59: Error Code 2: Overheat Error (Compressor Or Cycle)

    Refrigerant volume is OK? (Charge the specified amount of refrigerant after modified). Replace the expansion valve coil. After this, error is removed? Replace the outdoor unit PCB. After this, error is removed? Check the expansion valve. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 60: Error Code 5: Open Circuit Of Outdoor Unit Thermistor

    Is the outdoor unit thermistor connected? Connect outdoor unit thermistor firmly. First remove the connector from the PWB, Replace outdoor unit thermistor. and then measure the resistance. The resistance of outdoor unit thermistor is OK? Replace outdoor unit PCB. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 61: Error Code 6: Dc Current Error

    Fully open 2-way valve and 3-way valve. Check the pressure with gauge manifold. Check the pipe connections for refrigerant leaks. Refrigerant volume is OK? Charge the specified amount of refrigerant after modified. Check compressor. When outdoor unit PCB is OK. Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 62 Obstacle near outdoor unit? Remove the obstacle near outdoor unit. Outdoor unit fan motor operate? Replace outdoor unit PCB. Another outdoor unit fan motor can operate? Replace outdoor unit PCB. Check outdoor unit fan motor. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 63: Error Code 7: Ac Current Error

    Check pipe temperature of 2-way valve in compressor Check the pipe connections for refrigerant leaks. operating. Charge the specified amount of refrigerant after modified. •In cooling mode, get cool? •In heating mode, get warm? Replace outdoor unit PCB. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 64: Error Code 9: Cycle Error

    2-way valve properly. mode CN4 (ODU PCB) connected is properly? Connect CN4 (ODU PCB) properly. Compressor Compressor cord connected correctly? (for PCB and Replace outdoor unit PCB. compressor). Connect compressor cord correctly. Climate 8000i/8100i – 6721840685 (2021/05)
  • Page 65 CN4 (outdoor unit PCB) has AC voltage just before compressor start? Replace 4-way valve. Operating sound of 4-way valve switching? Charge the specified amount of Check the pressure with gauge manifold. refrigerant. Refrigerant volume is OK? Replace outdoor unit PCB. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 66: Error Code 11: Outcoor Unit Fan Motor Error

    Check the cause due to PCB or DC fan motor. Procedure Air conditioner operation stopped with error 11. Fan motor connector (CN3) is connected firmly? Connect CN3 firmly. Replace outdoor unit fan motor. Does the error still Replace outdoor unit PCB. exist? Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 67: Error Code 13: Compressor Rotation Error

    2. IPM has short failure? See section 4.6.4 "IPM check method". Compressor is normal? Replace compressor. Compressor is not locked? The AC power supply voltage is 10 % Replace outdoor unit. lower than rated voltage? Connect stable power supply. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 68: Error Code 14: Pam Error

    AC power supply voltage is normal? Connect stable power supply. Within rated voltage ±10 %. AC power supply voltage is unstable? Replace outdoor unit PCB. Check to power company. About voltage fluctuation, instantaneous voltage drop and breaker capacity. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 69: Error Code 17: Serial Open Error

    Check the terminal of the reactor lead is inserted. Is it inserted until it locks properly? Insert the reactor lead until it locks properly. Check the reactor. Is the reactor open? Replace the outdoor unit PCB. Replace reactor. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 70: Error Code 18: Serial Short Error

    Insert the connector correctly. Turn the indoor fan lightly with your finger to rotate Replace indoor unit fan motor. smoothly (whether the fan does not physically rotate due to foreign matter, etc.). Replace indoor unit PCB. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 71: Error Code 24-0: Wlan Module Communication

    Move the WLAN router closer. After this, try paring operation. Is pairing successful? Replace WLAN module to normal one. After this, try paring operation. Is pairing successful? Replace WLAN module. Replace WLAN router. Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 72: Error Code 26-1: Indoor Unit Room Temperature Thermistor Open Short Error

    Is the lead wire coating of the room temperature Replace Room temperature thermistor assembly. thermistor torn and short-circuited? Measure the room temperature thermistor resistance (about 10 kohm at 25 °C). Replace indoor unit PWB. 0010035160-001 Fig. 131 Room temperature thermistor Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 73: Error Code 26-2: Indoor Unit Pipe Thermistor Open Short Error

    Is the lead wire coating of the room temperature Replace pipe thermistor. thermistor torn and short-circuited? Measure the room temperature thermistor resistance (about 4.4431kohm at 25 °C). Replace indoor unit PCB 0010035161-001 Fig. 132 Pipe thermistor Climate 8000i/8100i – 6721840685 (2021/05)

  • Page 74: Environmental Protection And Disposal

    Data Protection Officer, Information Security and Privacy (C/ISP), This symbol means that the product must not be disposed Robert Bosch GmbH, Postfach 30 02 20, 70442 Stuttgart, GERMANY. of with other waste, and instead must be taken to the waste...
  • Page 76 Bosch Thermotechnik GmbH Junkersstrasse 20-24 D-73249 Wernau www.bosch-thermotechnology.com...

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