Table of contents 4.5.8 Compressor does not start ..... . 20 Table of contents 4.5.9 Operation stops after a few minutes and restarts, and this process repeats .
Explanation of symbols and safety instructions Explanation of symbols and safety instructions Explanation of symbols General safety instructions Warnings 1.2.1 Overview In warnings, signal words at the beginning of a warning are used to This service manual is intended for service engineers. All instructions indicate the type and seriousness of the ensuing risk if measures for must be observed.
Explanation of symbols and safety instructions 1.2.2 Refrigerant 1.2.3 Electricity H Warning H Warning ▶ Take appropriate precautions to prevent refrigerant ▶ Make sure you switch off the power of the unit leakage. If the refrigerant gas leaks, ventilate the before you open the electric control box, and area immediately.
General information General information External Dimension 2.1.1 Indoor Unit 0010033695-001 Fig. 1 Indoor unit (in mm) 2.1.2 Outdoor unit 71.5 10.5 37.5 164.5 167.5 0010033696-001 Fig. 2 Outdoor unit (in mm) Air heat Pump 6000i/6100i – 6721840684 (2021/05)
General information Specification 2.2.1 CL6000i ... models Type CL6000i-Set 25 E CL6000i-Set 35 E Unit CL6000i-W 25 E CL6000i-W 35 CL6000i 25 E CL6000i 35 E General Rated cooling capacity (Min. - Max.) 2.5 (0.9 - 3.0) 3.5 (0.9- 4.2) Rated heating capacity (Min.
General information 2.2.2 CL6100i ... models Type CL6100i-Set 50 HE CL6100i-Set 65 HE Unit CL6100i-W 50 HE CL6100i-W 65 HE CL6100i 50 HE CL6100i 65 HE General Rated cooling capacity (Min. - Max.) 2.5 (0.9 - 3.0) 3.5 (0.9- 4.2) Rated heating capacity (Min.
General information 2.2.3 Electrical Specifications Indoor Unit 2.3.4 Auto mode CL6000i ... Description Unit In automatic mode, the device automatically switches between heating Indoor fan motor and cooling mode to maintain the desired temperature. Rated voltage For further information on auto mode of CL6000i ... models see Rated capacity Installation Manual, chapter Setting main operating mode.
Electrical components and wiring diagrams Electrical components and wiring diagrams Wiring Diagram 3.1.1 Indoor Unit CN13A CN402 CN11 CN401 CN80 CN301 250 V 3.15 A CN10 CN209 GnYe 0010033698-001 Fig. 3 Wiring diagram - indoor unit Indoor unit Outdoor unit terminal board Control board unit (indoor unit) Adapter V-louver SW...
Electrical components and wiring diagrams Micro computer control system 3.2.1 Indoor Unit Electrical wiring 0010033701-001 Fig. 5 Micro computer control system - indoor unit Receiver board DC Fan motor Vertical louver (V-louver) switch Horizontal louver (H-louver) Terminal board Thermistor Switch board Panel louver L Vertical Louver (V-louver) [10] Panel louver R...
Electrical components and wiring diagrams 3.2.2 Outdoor unit Electrical wiring 0010033702-001 Fig. 6 Micro computer comnrol sysstem - outdoor unit To terminal board (2) Red To compressor Orange To control box (Green/Yellow) [10] To compressor White To terminal board (N) Blue [11] To compressor Red To terminal board (1) Brown [12] To reactor (Grey)
Function and Operation of Protective Procedures Function and Operation of Protective Procedures Control 4.1.5 Start up control When the air conditioner starts in the cooling mode, if the room 4.1.1 Restart Control temperature is 2 °C higher than the set temperature the air conditioner Once the compressor stops operating, it will not restart for 180 seconds operates with the operating frequency at maximum.
Function and Operation of Protective Procedures Protection Device Functions and Operations These models have following thermistors The errors for the thermistors that are not mentioned above are irrelevant. • Indoor unit: TH1, TH2 • Outdoor unit: TH1, TH2, TH3, TH4, TH5 These indoor units don’t have power relay.
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Function and Operation of Protective Procedures Operation Self-diagnosis result display Function Description Detection period Reset condition Indoor unit error Indoor Outdoor display unit unit 11 Thermistor Compressor stops if high and low values 3 minutes after Operation OFF or ON Only after outdoor installation error or of temperatures detected by outdoor compressor start...
Function and Operation of Protective Procedures Operation Self-diagnosis result display Function Description Detection period Reset condition Indoor unit error Indoor Outdoor display unit unit 25 PAM over voltage Compressor stops if DC voltage is 400 V When in operation Operation OFF or ON Only after outdoor error or higher.
Function and Operation of Protective Procedures 4.3.2 Outdoor Unit Item Mode Control Operation When resistance is low Short-circuit When resistance is low Open-circuit (temperature judged (temperature judged higher than actual) higher than actual) Compressor Cooling Expansion valve Compressor operates, Compressor high Layer short-circuit or Outdoor unit discharge...
Function and Operation of Protective Procedures Thermistor Temperature Characteristics Before measuring resistances, disconnect connectors as shown above. 4.4.1 Indoor Unit 4.4.2 Outdoor unit Thermistor Connector Colour Thermistor Connector Colour Room temperature 3 – 4 Yellow Compressor thermistor TH1 1 – 2 Pipe temperature 1 –...
Function and Operation of Protective Procedures General troubleshooting chart These models have following thermistors • Indoor unit: TH1, TH2 • Outdoor unit: TH1, TH2, TH3, TH4, TH5 The errors for the thermistors that are not mentioned above are irrelevant. These indoor units don’t have power relay. 4.5.1 Indoor unit does not turn on Main cause...
Function and Operation of Protective Procedures 4.5.5 Louvers do not move Main cause Inspection method Normal value/condition Short-circuit Caught in sliding section. Operate to see if louvers are caught Louvers should operate smoothly. Remove or correct catching section. in place. Disconnected connector.
Function and Operation of Protective Procedures Malfunction (Parts) Check method 4.6.1 Procedure for determining defective outdoor unit IPM/compressor The following flow chart shows a procedure for locating the cause of a malfunction when the compressor does not start up and a DC over current indication error occurs.
Function and Operation of Protective Procedures 4.6.2 Diode bridge check method 4.6.4 IPM check method Turn off the power and let the inverter electrolytic capacitor (C5,C6) Turn off the power, let the large capacity electrolytic capacitor (C5,C6) discharge completely. Then use a tester and check continuity by discharge completely, and dismount the IPM.
Function and Operation of Protective Procedures 4.6.5 DC Current Error (6-0 error) 6-0 error memory is recorded Start Valves (2-way and 3-way) are closed Fully open stop valves Continue with Compressor rotation Compressor is rotating for more than 30 s Checking IPM lead wire (UVW) yields abnormal Modify the connection of compressor lead wire on results.
Function and Operation of Protective Procedures Heating mode Heating mode Checking indoor exchanger thermistor and discharge Modify or replace thermistor thermistor yields abnormal results. Checking indoor heat exchanger yields abnormal Clean indoor 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.
Function and Operation of Protective Procedures Troubleshooting Guide 4.7.1 Self-Diagnosis Function Indoor Unit WARNING Risk to life from electric shock! Touching live electrical parts can cause an electric shock. 1s 1s ▶ Before working on electrical parts, disconnect all phases of the power supply (fuse/circuit breaker) and lock the isolator switch to prevent unintentional reconnection.
Function and Operation of Protective Procedures Outdoor Unit • The self-diagnosis indicates the error information by flashing LED1 • The self-diagnosis of outdoor unit is displayed for about 3 – 10 on the outdoor unit. minutes. Then LED1 returns to the normal display. 0.5 s 0.5 s 0.5 s...
Function and Operation of Protective Procedures Chart for reading Self-Diagnosis Results Main malfunction Sub malfunction LED1 Problem Check Point Action (outdoor symptom Diagnosis Diagnosis unit) Normal Normal Normal Normal blinking condition Outdoor unit Heat exchanger thermistor 1-time Indoor and ▶ Measure the resistance ▶...
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Function and Operation of Protective Procedures Main malfunction Sub malfunction LED1 Problem Check Point Action (outdoor symptom Diagnosis Diagnosis unit) Outdoor unit Heat exchanger thermistor 5-time Indoor and ▶ Check connector of ▶ Correct the thermistor open- open circuit error. outdoor outdoor unit thermistor installation.
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Function and Operation of Protective Procedures Main malfunction Sub malfunction LED1 Problem Check Point Action (outdoor symptom Diagnosis Diagnosis unit) Cycle temperature Thermistor installation error 9-time Indoor and ▶ Check the thermistor ▶ Correct the or 4-way valve error. outdoor (heat exchanger) and installation.
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Function and Operation of Protective Procedures Main malfunction Sub malfunction LED1 Problem Check Point Action (outdoor symptom Diagnosis Diagnosis unit) DC compressor Compressor start up error. 13-time Indoor and ▶ Check the colours (red, ▶ Correct the outdoor white, orange) of the installation.
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Function and Operation of Protective Procedures Main malfunction Sub malfunction LED1 Problem Check Point Action (outdoor symptom Diagnosis Diagnosis unit) Wiring between Serial short-circuit Lighting or Indoor unit ▶ Check the wiring ▶ Correct the wiring. units operates. between units. Outdoor unit does not operate.
Function and Operation of Protective Procedures Other Malfunction Error Indications/Buzzers Indoor unit indicator while not operating Main error code Malfcuntion LEDs flashing Description Vertical louver (V-louver) Operation lamp (green) and timer lamp The vertical louver (V-louver) L/R guide is (orange) on the indoor unit flash in a 1s either not assembled correctl, or cycle unassembled.
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Function and Operation of Protective Procedures Error without indication If EEPROM data has problem when power supply just connected, buzzer will sound continuously, but LED lamp remains off. Malfunction indications due to erroneous wiring during air conditioner installation: Inter-unit wiring Symptom Malfunction diagnosis display “18-1”...
To enter max cooling mode, start the unit with remote control setting 16 °C and high fan speed. Check the data within 30 min after starting cooling. Refer to installation manual for how to enter test run. Model CL6000i-Set 25 E CL6000i-Set 35 E Cooling...
Refrigeration Cycle Performance curves The following conditions are used for all units • Indoor fan speed: High • Indoor air temp.: Cooling 27 °C • Power source: 230V, 50Hz CL6000i-Set 25 E - cooling /˚C C/kW 17.0 16.0 15.0 14.0 13.0...
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Refrigeration Cycle CL6000i-Set 25 E - heating CL6000i-Set 35 E - cooling C/kW C/kW T/˚C T/˚C 0010033818-001 Fig. 17 Fig. 20 Capacity in kW Capacity in kW Outdoor air temperature in °C Outdoor air temperature in °C T/˚C T/˚C 0010033822-001 0010033819-001 Fig.
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Refrigeration Cycle CL6000i-Set 35 E - heating CL6100i-Set 65 HE - cooling C/kW C/kW T/˚C T/˚C 0010033824-001 0010033803-001 Fig. 23 Fig. 26 Capacity in kW Capacity in kW Outdoor air temperature in °C Outdoor air temperature in °C 1050 1000 T/˚C T/˚C 0010033804-001...
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Refrigeration Cycle CL6100i-Set 50 HE - heating CL6100i-Set 65 HE - cooling C/kW C/kW T/˚C T/˚C 0010033809-001 0010033806-001 Fig. 29 Fig. 32 Capacity in kW Capacity in kW Outdoor air temperature in °C Outdoor air temperature in °C T/˚C T/˚C 0010033810-001 0010033807-001 Fig.
Disassembly Procedure CL6100i-Set 65 HE - heating Disassembly Procedure C/kW Be sure to turn off the circuit breaker before disassembly procedure. When reassembling the unit after repairing, be sure to install screws to their original positions. The screws used are different in specifications such as corrosion- resistance treatment, tip shape and length.
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Disassembly Procedure ▶ Turn down the panel to open it. ▶ Press the lock lever on the left and right side and simultaneously slide them to the middle, then hold the lever, move the vertical louver (V- louver) base out. 0010033520-001 Fig.
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Disassembly Procedure ▶ Remove the screw fixing the side panel on the let. 0010033529-001 0010033526-001 Fig. 49 Fig. 46 ▶ Pull the hook and take the box cover out. ▶ Press the hook on the top of left hand side side panel, then pull the side panel towards yourself to take it out.
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Disassembly Procedure ▶ Remove the two screws shown below. 0010033532-001 Fig. 52 0010033535-001 ▶ Remove the earth screw and the terminal of ground lead wire. Fig. 55 ▶ Cut the band fixing the thermistor. 0010033574-001 Fig. 56 0010033533-001 ▶ Lower the top hook, then move the control box out. Fig.
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Disassembly Procedure ▶ Remove the left and right screw fixing the filter guide. ▶ Remove three screws fixing the drain pan assembly. 0010033537-001 Fig. 58 0010033540-001 ▶ Unhook the middle part and rotate the filter guide to open it up. Fig.
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Disassembly Procedure ▶ Rotate the assembly and pull it out. ▶ Remove the screw to remove the fan cover. 0010033544-001 0010033547-001 Fig. 64 Fig. 67 ▶ Unscrew the fixing screw between cross flow fan and fan motor. ▶ Hold the cross flow fan and move it out with right side first. 0010033545-001 0010033548-001 Fig.
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Disassembly Procedure ▶ Remove the left and right screws fixing the Side Cover on the left and Drain Pan Assembly right (4 pcs in total). ▶ Cut the wire fixing band. 0010033550-001 Fig. 70 0010033553-001 Fig. 73 ▶ Enlarge the angle between tube assembly and cabinet. ▶...
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Disassembly Procedure ▶ Remove the connectors on left side, then unscrew screw A558. ▶ Lift it to take it out. 0010033560-001 0010033556-001 Fig. 79 Fig. 76 ▶ After the horizontal louver (H-louver) reached the maximum angle ▶ Slide the PCI base 1 assembly to take it out. position, separate it from the two louver supports, then bend the louver to take it out.
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Disassembly Procedure ▶ Loosen the two screws fixing the gear box and move it out. ▶ Remove two screws, take out the right hand side panel gear case. 0010033563-001 0010033566-001 Fig. 82 Fig. 85 ▶ Remove the screw, rotate the motor and take it out. ▶...
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Disassembly Procedure ▶ Slide the drain pan panel to take it out. ▶ Remove two screws, take out the left hand side panel gear case. 0010033569-001 Fig. 88 ▶ Remove the screw to move out the joint cover. 0010033572-001 Fig. 91 ▶...
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Disassembly Procedure ▶ Release four hooks fixing the LED case, then lift to take it out. 0010033579-001 Fig. 97 ▶ Release the hook and move out the PCI LED unit. 0010033576-001 Fig. 94 ▶ Release the hook, then take out the limit switch. 0010033580-001 Fig.
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Disassembly Procedure Control Unit NOTICE Risk of static discharge. Static charges can destroy sensitive electronics parts. ▶ Wear antistatic gloves. ▶ Slide the main PCB to move it. 0010033582-001 Fig. 100 Support pin 0010033585-001 Fig. 103 ▶ Unhook four hooks, then take out the display board unit. 0010033583-001 Fig.
Disassembly Procedure ▶ Release the hooks fixing receiver PCB and display PCB, and pull the Outdoor Unit PCB out. ▶ Remove the screw fixing the cover, then take the cover off. 0010033587-001 Fig. 105 ▶ Release four hooks on both sides, then remove the PCB holder. 0010033591-001 Fig.
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Disassembly Procedure ▶ Loosen the screws and remove the connecting cables from terminal ▶ Remove seven screws fixing the front panel, move it out. board. 0010033596-001 Fig. 113 Left side 0010033593-001 Fig. 110 ▶ Remove five screws and lift the top panel to take it off. 0010033597-001 0010033594-001 Fig.
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Disassembly Procedure ▶ Cut the wire fixing band. ▶ Remove both compressor covers. ▶ Remove two terminals from the reactor and all connectors on the control board unit. ▶ Remove compressor connector. 0010033602-001 0010033599-001 Fig. 119 Fig. 116 ▶ Unscrew the nut and remove the terminal cover. ▶...
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Disassembly Procedure ▶ Disconnect three terminals on the compressor. ▶ Unscrew the nut and carefully take out the propeller fan. 0010033604-001 0010033607-001 Fig. 121 Fig. 124 ▶ Remove two screws fixing the bulkhead and remove the bulkhead. ▶ Remove all screws and take out the motor. 0010033608-001 Fig.
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Disassembly Procedure Control Unit ▶ Cut the fixing band. ▶ Remove the screw fixing the earth wire. 0010033610-001 Fig. 126 0010033613-001 ▶ Remove the screw, then remove the terminal board. Fig. 129 ▶ Move out the heatsink holder. 0010033614-001 Fig. 130 0010033611-001 ▶...
Troubleshooting Troubleshooting WARNING ▶ All electrical work must be carried out by competent and suitably qualified, certified and accredited professionals and in accordance with all applicable legislation (all national, local and other laws, standards, codes, rules, regulations and other legislation that apply in a given situation). ▶...
Troubleshooting Error code 2: Overheat error (Compressor or cycle) Error subcodes Remedy • 2-0: Compressor high temperature error Check the failure of compressor. • 2-1: Compressor discharge overheat Possible causes • 2-2: Outdoor unit pipe overheat • Ambient temperature of compressor becomes quite high. •...
Troubleshooting Error code 6: DC current error Remedy Additional Information Check the cause due to compressor or PCB. Procedure depending on the case: • Case 1: Error occurs before starting the compressor. • Case 2: Error occurs within the first second of starting the compressor.
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Troubleshooting Procedure for case 3 Air conditioner operation stopped with error 6 after starting compressor (over 1 second). Heating mode Power supply fluctuation or momentary power failure? Connect stable power supply. IPM is floating from the heat sink? Fix IPM with screws securely. Air filter and heat exchanger of indoor unit Clean the filter and heat exchanger of indoor unit.
Troubleshooting Error code 7: AC current error Error subcodes • 7-3: AC current deficiency error. • 7-0: AC over current error. Remedy • 7-1: AC current error when compressor OFF. Check the cause due to PCB or another parts. • 7-2: AC maximum current error. Air conditioner operation stopped with error 7.
Troubleshooting Error code 9: Cycle error Remedy Additional Information Check the cause due to PCB or another parts. Error code 9 occurs when there is no temperature difference between TH2 and TH5 3 minutes after operation. • 4-way valve error. •...
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Troubleshooting Cooling mode Continue with Indoor unit pipe thermistor Cooling mode: •Outdoor unit heat exchanger pipe: higher temperature? •Outdoor unit 2-way valve pipe: lower temperature? Connect CN4 (outdoor unit/ Connection of CN4 (outdoor unit/ PCB) properly. PCB) is correct? Replace 4-way Resistance of 4-way valve coil is valve coil.
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Troubleshooting Heating mode Continue with Indoor unit pipe Heating mode: thermistor •Outdoor unit heat exchanger pipe: lower temperature? •Outdoor unit 2-way valve pipe: higher temperature? Connect CN4 Connection of CN4 (outdoor unit/PCB) is correct? (outdoor unit/ PCB) properly. Replace 4- Resistance of 4-way valve coil is normal? way valve coil.
Troubleshooting Error code 11: Outcoor unit fan motor error Error subcodes • 11-4: Detection error of inverter current • 11-1: DC fan driver IC error • 11-5: open connector error. • 11-2: DC fan lock error Remedy • 11-3: Detection error of negative rotation before compressor start Check the cause due to PCB or DC fan motor.
Troubleshooting Procedure Error 13-2 13-2 error: Compressor rotation error Check outdoor unit PCB Check point: Replace outdoor unit PCB. 1. Soldering failure in IPM shunt resistor (e. g. R230/231/232/233/234)? 2. IPM has short failure? See section 4.6.1 "Procedure for determining defective outdoor unit IPM/compressor".
Troubleshooting 7.10 Error code 17: Serial open error Error subcodes • Poor connection of the wiring between the units connecting the indoor unit and the outdoor unit • 17-0: Serial open error. • Defective terminal board of indoor unit/outdoor unit. Possible causes •...
Troubleshooting 7.11 Error code 18: Serial short error Error subcodes • Indoor unit serial circuit failure. • 18-0: Serial short. • Outdoor unit serial circuit failure. • 18-1: Incorrect wiring. Remedy Possible causes Determine if the units connecting cable is incorrectly inserted or the control board is defective.
Troubleshooting 7.13 Error code 24-0: WLAN module communication error Remedy Determine whether the cause is a connector or a board (WLAN module, main board). 24-0 WLAN module communication Error. The WLAN module and the connector on the Connect correctly. main board are correctly connected? Replace WLAN module to normal one.
Troubleshooting 7.15 Error code 26-1: Indoor unit room temperature thermistor open short error Error subcodes Remedy • 26-1: Room temperature thermistor error. Determine whether the cause is room temperature thermistor or indoor unit PCB. • 26-2: Pipe thermistor error. Room temperature thermistor error. Is the room temperature thermistor connected Connect the Yes connectors correctly.
Troubleshooting 7.16 Error code 26-2: Indoor unit pipe thermistor open short error Error subcodes Remedy • 26-1: Room temperature thermistor error. Determine whether the cause is pipe thermistor or indoor unit PCB. • 26-2: Pipe thermistor error. Pipe thermistor error. Is the room pipe thermistor connected correctly? Connect the connectors correctly.
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...
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