Bosch Climate 5000 Series Bedienungsanleitung

Bosch DuctlessAirConditioner/HeatPumpOutdoorUnit

Climate5000Series

SingleZone(Regular,HyperHeat,LightCommercial)ODU

ServiceManual

2|BoschClimate5000SeriesDuctlessAirConditioner/HeatPumpOutdoorUnit ServiceManual

04.2020|BoschThermotechnologyCorp.Datasubjecttochange

ServiceManual BoschClimate5000SeriesDuctlessAirConditioner/HeatPumpOutdoorUnit |3

BoschThermotechnologyCorp.|04.2020 Datasubjecttochange

TableofContents

1 KeytoSymbolsandSafetyInstructions 4

1.1 KeytoSymbols 4

1.2 Safety 4

2 PartNamesandModelNumbers 6

2.1 ModelNumbers 6

3 DimensionsandClearances 7

4 InstallationDetails 8

4.1 TorqueRequirements 8

4.2 ConnectingtheCables 8

4.3 PipeLengthandElevation 8

4.4 FirstTimeInstallation 8

4.5 AddingtheRefrigeranttoanExistingSystem 9

4.6 Re-Installation/IndoorUnitNeedstobeRepaired 9

4.7 Re-InstallationWhiletheOutdoorUnitNeedstobeRepaired 10

4.8 OperationCharacteristics 11

5 ElectronicFunctions 12

5.1 Abbreviation 12

5.2 DisplayFunction 12

5.3 MainProtection 12

5.4 OperationModesandFunctions 13

6 ErrorCodes 18

6.1 ErrorCodes-WallMountedIndoorUnit 18

6.2 ErrorCodes-4-WayCassetteIndoorUnit 19

6.3 ErrorCodes- DuctedIndoorUnit 20

6.4 QuickCheckbyErrorCodes 21

7 WiringDiagrams 22

7.1 ODUPCB&IPM 22

7.2 IndoorWiringDiagram 33

7.4 OutdoorWiringDiagram 36

8 Diagnosis &Solution 41

8.1 EEPROMparametererror(E0/F4) 41

8.2 Indoor/outdoorunit’scommunication(E1) 42

8.3 Zerocrossingdetectionerror(E2) 45

8.4 Fanspeedhasbeenoutofcontrol(E3/F5) 46

8.5 Opencircuitorshortcircuitoftemperaturesensor 48

(E4/E5/F1/F2/F3/P7) 48

8.6 RefrigerantLeakageDetection(EC) 49

8.7 Water-levelAlarmMalfunction(EE) 50

8.8 Overloadcurrentprotection(F0) 51

8.9 IPMmalfunctionorIGBTover-strongcurrentprotection(P0) 52

8.10 Overvoltageortoolowvoltageprotection(P1) 55

8.11 HightemperatureprotectionofIPMmoduleor

compressor top (P2) 56

8.12 Invertercompressordriveerror(P4) 57

8.13 Lowpressureprotection(P6) 58

8.14 Hightemperatureprotectionofindoorcoilin

heating mode (J0) 59

8.15 Hightemperaturesensedatoutdoorcoil(J1) 60

8.16 Hightemperaturesensedatcompressordischargeline(J2) 61

8.17 PFCmoduleprotection(J3) 62

8.18 Communicationerrorbetweenoutdoorunitmain

PCBandIPM control(J4) 63

8.19 Highpressureswitchopen(J5) 64

8.20 Lowpressureswitchopen(P6/J6) 65

8.21 ACVoltageprotection(J8) 66

8.22 MainPartsCheck 67

9 DisassemblyGuide 73

9.1 Models:9KRegular:BMS500-AAS009-1CSXRA 73

9.2 Models:12KRegular:BMS500-AAS012-1CSXRA

9K&12KHyperHeat:BMS500-AAS009-1CSXHB,

BMS500-AAS012-1CSXHB 76

9.3 Models:18KRegular:BMS500-AAS018-1CSXRA 79

9.4 Models:18KHyperHeat:BMS500-AAS018-1CSXHB 82

9.5 Models:9K,12K&18KHyperHeat:

BMS500-AAS009-1CSXHB, BMS500-AAS012-1CSXHB,

BMS500-AAS018-1CSXHB 83

9.6 Models:24KRegular:BMS500-AAS024-1CSXRA

24KHyperHeat:BMS500-AAS024-1CSXHB

30K&36KLightCommercialforWallMountedIDU:

BMS500-AAS030-1CSXRB,BMS500-AAS036-1CSXRB

36KLightCommercialforDucted&CassetteIDU:

BMS500-AAS036-1CSXLB 84

9.7 Models:48K&60KLightCommercial:

BMS500-AAS048-1CSXLB, BMS500-AAS060-1CSXLB 87

9.8 AllModels 90

4|BoschClimate5000SeriesDuctlessAirConditioner/HeatPumpOutdoorUnit ServiceManual

04.2020|BoschThermotechnologyCorp.Datasubjecttochange

1 Key toSymbolsandSafetyInstructions

1.1 KeytoSymbols

Warnings

WarningsinthisdocumentareidentiÀedbyawarningtriangle

printedagainstagraybackground.

Keywordsatthestartofawarningindicatethetypeandseriousness

oftheensuingriskifmeasurestopreventtheriskarenottaken.

ThefollowingkeywordsaredeÀnedandcanbeusedinthisdocument:

fDANGER indicatesahazardoussituationwhich,ifnotavoided,willresult

indeathorseriousinjury.

fWARNINGindicatesahazardoussituationwhich,ifnotavoided,could

resultindeathorseriousinjury.

fCAUTION indicatesahazardoussituationwhich,ifnotavoided,could

resultinminortomoderateinjury.

fNOTICEisusedtoaddresspracticesnotrelatedtopersonalinjury.

Importantinformation

Thissymbolindicatesimportantinformationwherethereisnoriskto

peopleorproperty.

1.2 Safety

Pleasereadsafetyprecautionsbeforeinstallation

Incorrectinstallationduetoignoringinstructionscancauseseriousdamageor

injury.

WARNING:ELECTRICALHAZARD

fDonotmodifythelengthofthepowersupplycordorusean

extensioncordtopowertheunit.

fDonotsharetheelectricaloutletwithotherappliances.

Improperorinsufficientpowersupplycancausefireor

electricalshock.

WARNING:INSTALLATIONREQUIREMENTS

fInstallationmustbeperformedbyalicensedcontractor,

andpertheinstructionsintheinstallationmanual.Improper

installationcancausewaterleakage,electricalshock,orfire.

fInNorthAmerica,installationmustbeperformedin

accordancewiththerequirementofNEC(NationalElectric

Code)andCEC(CanadianElectricCode)bylicensedand

qualifiedpersonnelonly.

fOnlycontactalicensedcontractorforrepairormaintenance

ofthisunit.

fOnlyusetheincludedaccessories,parts,andspecified

partsforinstallation.Usingnon-standardpartscancause

waterleakage,electricalshock,fire,andcancausetheunit

tofail.

fInstalltheunitinasolidlocationthatcansupporttheunit’s

weight.Ifthechosenlocationcannotsupporttheunit’s

weight,ortheinstallationisnotdoneproperly,theunitmay

dropandcauseseriousinjuryand/ordamage.

WARNING:

fThisproductcanexposeyoutochemicalsincludingLead

andLeadcomponents,whichareknowntotheState

ofCaliforniatocausecancerandbirthdefectsorother

reproductiveharm.Formoreinformationgotowww.

P65Warnings.ca.gov.

ServiceManual BoschClimate5000SeriesDuctlessAirConditioner/HeatPumpOutdoorUnit |5

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WARNING:ELECTRICALHAZARD

fForallelectricalwork,followalllocalandnationalwiring

standards,regulations,andtheInstallationManual.

Thepowersupplytotheoutdoorunitrequiresaservice

disconnectattheunit. Onlyuseadedicatedcircuit. Never

shareapowersourceconnectedtothissystem.Insufficient

electricalcapacityordefectsinelectricalworkcancause

electricalshockorfire.

fForallelectricalwork,usethespecifiedcables.Connect

cablestightly,andclampthemsecurelytopreventexternal

forcesfromdamagingtheterminal.Improperelectrical

connectionscanoverheatandcausefire,andmayalso

causeshock.

fAllwiringmustbeproperlyarrangedtoensurethatthe

controlboardcovercancloseproperly.Ifthecontrolboard

coverisnotclosedproperly,itcanleadtocorrosionand

causetheconnectionpointsontheterminaltoheatup,

catchfire,orcauseelectricalshock.

fIncertainfunctionalenvironments,suchaskitchens,server

rooms,etc.,theuseofspeciallydesignedair-conditioning

unitsishighlyrecommended.

fIfthepowersupplycordisdamaged,itmustbereplaced

bythemanufacturer,itsserviceagentorsimilarlyqualified

personssuchasalicensedelectricianinordertoavoida

hazard.

fTheproductmustbeproperlygroundedatthetimeof

installation,orelectricalshockmayoccur.

CAUTION:BURNHAZARD

fForunitsthathaveanauxiliaryelectricheater,donot

installtheunitwithin1meter(3feet)ofanycombustible

materials.

fDonotinstalltheunitinalocationthatmaybeexposed

tocombustiblegasleaks.Ifcombustiblegasaccumulates

aroundtheunit,itmaycausefire.

fDonotoperateyourairconditionerinawetroomsuchasa

bathroomorlaundryroom.Toomuchexposuretowatercan

causeelectricalcomponentstoshortcircuit.

NOTICE:PROPERTYDAMAGE

fInstallcondensatedrainagepipingaccordingtothe

instructionsinthismanual.Impropercondensatedrainage

maycausewaterdamagetoyourhomeandproperty.

CAUTION:CONTAINS REFRIGERANT

fThisair-conditioningunitcontainsfluorinatedgases.For

specificinformationonthetypeofgasandtheamount,

pleaserefertotherelevantlabelontheoutdoorunititself.

fInstallation,service,maintenanceandrepairofthisunit

mustbeperformedbyacertifiedtechnician.

fProductremovalandrecyclingmustbeperformedbya

certifiedtechnician.

fIfthesystemhasaleak-detectionsysteminstalled,itmust

becheckedforleaksatleastevery12months.

fWhentheunitischeckedforleaks,properrecord-keepingof

allchecksisstronglyrecommended.

6|BoschClimate5000SeriesDuctlessAirConditioner/HeatPumpOutdoorUnit ServiceManual

04.2020|BoschThermotechnologyCorp.Datasubjecttochange

2 PartNamesandModelNumbers

2.1 ModelNumbers

Voltage IndoorType Capacity IndoorUnits RegularOutdoorUnits HyperHeatOutdoorUnits

115V WallMounted 12k BMS500-AAS012-0AHWXB BMS500-AAS012-0CSXRB

208-230V WallMounted

9k BMS500-AAU009-1AHWXB BMS500-AAS009-1CSXRA BMS500-AAS009-1CSXHB

12k BMS500-AAU012-1AHWXB BMS500-AAS012-1CSXRA BMS500-AAS012-1CSXHB

18k BMS500-AAU018-1AHWXB BMS500-AAS018-1CSXRA BMS500-AAS018-1CSXHB

24k BMS500-AAU024-1AHWXB BMS500-AAS024-1CSXRA BMS500-AAS024-1CSXHB

30k BMS500-AAS030-1AHWXB BMS500-AAS030-1CSXRB

36k BMS500-AAS036-1AHWXB BMS500-AAS036-1CSXRB

208-230V Cassette

9k BMS500-AAU009-1AHCXB BMS500-AAS009-1CSXRA BMS500-AAS009-1CSXHB

12k BMS500-AAU012-1AHCXB BMS500-AAS012-1CSXRA BMS500-AAS012-1CSXHB

18k BMS500-AAU018-1AHCXB BMS500-AAS018-1CSXRA BMS500-AAS018-1CSXHB

24k BMS500-AAU024-1AHCXB BMS500-AAS024-1CSXRA BMS500-AAS024-1CSXHB

36k BMS500-AAU036-1AHCXB BMS500-AAS036-1CSXLB

48k BMS500-AAU048-1AHCXB BMS500-AAS048-1CSXLB

208-230V Ducted

9k BMS500-AAU009-1AHCXB BMS500-AAS009-1CSXRA BMS500-AAS009-1CSXHB

12k BMS500-AAU012-1AHCXB BMS500-AAS012-1CSXRA BMS500-AAS012-1CSXHB

18k BMS500-AAU018-1AHCXB BMS500-AAS018-1CSXRA BMS500-AAS018-1CSXHB

24k BMS500-AAU024-1AHCXB BMS500-AAS024-1CSXRA BMS500-AAS024-1CSXHB

36k BMS500-AAU036-1AHCXB BMS500-AAS036-1CSXLB

48k BMS500-AAU048-1AHCXB BMS500-AAS048-1CSXLB

60k BMS500-AAU048-1AHCXB BMS500-AAS048-1CSXLB

Table 1

ForSingleZoneOutdoorUnits,pleaserefertoSingleZoneOutdoor

ServiceManual.

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3 DimensionsandClearances

Figure 1

OutdoorModel OutdoorUnitDimensionsmm(in.) MountingDimensions

WxHxD Amm(in.) Bmm(in.)

BMS500-AAS009-1CSXRA 770x555x300(30.3x21.85x11.81) 487(19.2) 298(11.73)

BMS500-AAS012-0CSXRB,BMS500-AAS012-1CSXRA,BMS500-AAS009-1CSXHB,

BMS500-AAS012-1CSXHB 800x554x333(31.5x21.8x13.1) 514(20.24) 340(13.39)

BMS500-AAS018-1CSXRA,BMS500-AAS018-1CSXHB, 845x702x363(33.27x27.6x14.3) 540(21.26) 350(13.8)

BMS500-AAS024-1CSXRA,BMS500-AAS024-1CSXHB,BMS500-AAS030-1CSXRB,

BMS500-AAS036-1CSXRB,BMS500-AAS036-1CSXLB, 946x810x410(37.24x31.9x16.14) 673(26.5) 403(15.87)

BMS500-AAS048-1CSXLB,BMS500-AAS060-1CSXLB 952x1333x415(37.5x52.5x16.34) 634(24.96) 404(15.9)

Table 2

Figure 2

More than 60cm (23.6in)

More than 70cm (27.6in)

More than 30cm (11.8in)

More than 60cm (23.6in)

(Service space)

Fence or

obstacles

More than 30cm (11.8in)

Outdoor Unit Clearances

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4 InstallationDetails

4.1 TorqueRequirements

OuterDiameterofTube

mm(in.) TighteningTorque

N•m(lbft) Max.Tightening

TorqueN•m(lbft)

Ø6.35(Ø0.25”) 1,500(11lb•ft) 1,600(11.8lb•ft)

Ø9.52(Ø0.375”) 2,500(18.4lb•ft) 2,600(19.18lb•ft)

Ø12.7( Ø0.5”) 3,500 (25.8lb•ft) 3,600 (26.55lb•ft)

Ø16(Ø0.63”) 4,500 (33.19lb•ft) 4,700 (34.67lb•ft)

Table 3

4.2 Connectingthe Cables

ThepowercordshouldbeselectedaccordingtothefollowingspeciÀcationssheet.

fCabletype:SOOWtype

ApplianceAmps AWGWireSize

10 18

13 16

18 14

25 12

30 10

Table 4

Thecablesizeandthecurrentofthefuseorswitcharedeterminedbythe

maximumcurrentindicatedonthenameplatewhichislocatedonthesidepanelof

theunit.Pleaserefertothenameplatebeforeselectingthecable,fuseandswitch.

Recommended:Ameansofdisconnectingthepower,shouldbewithin10feetof

theoutdoorunit.

4.3 PipeLengthand Elevation

Capacity Pipesize

Liquidside

(in/mm) Gasside

(in/mm)

9K 1/4"/Ɓ6.35 3/8"/Ɓ9.52

12K 1/4"/Ɓ6.35 1/2"/Ɓ12.7

18K

24K

3/8"/Ɓ9.52 5/8"/Ɓ15.9

30K

36K

48K

60K 3/8"/Ɓ9.52 3/4"/Ɓ19

Table 5

Capacity Precharged

length

(ft/m)

MaxPipe

Length

(ft/m)

Maxdifference

inheight

(ft/m)

Additionalcharge

foreachft

(oz)

25/7.6

82/25 33/10 0.1612K

18K 98/30 66/20

24K 164/50 82/25

0.32

30K

36K

213/65 98/3048K

60K

Table 6

4.4 First Time Installation

4.4.1 AirPurgingwithVacuumPump

Figure 3

(Indoor Unit) (Liquid Side)

(Gas Side)

(Outdoor Unit)

Liquid Service Line

Gas Service Line

Manifold Valve

Compound Meter Pressure

Gauge

Handle Lo Handle Hi

-0.1MPa

Shut-Off Knob

Low Refrigerant

Manifold/Blue

Shut-Off Knob High

Charge/Refrigerant Hose

Vacuum

Pump

1. CompletelytightentheÁarenutsoftheindoorandoutdoorunits,conÀrm

thatboththeliquidserviceandgasservicevalvesaresettotheclosed

position.

2. Connecttherefrigerantmanifold,bluehosewiththepushpinofshut-off

knobofthelowsidetothegasservicevalveport.

3. Connecttherefrigerantmanifold,yellowhosetotheshut-offhighside

connectiontothevacuumpump.

4. Fullyopentheshut-offknoblowsideofthemanifoldvalve.

5. Operatethevacuumpumptoevacuate.

6. Performevacuationfor30minutesandcheckwhethertherefrigeration

lowsidepressuregaugeindicates-0.1Mpa(14.5Psi).Ifthemeterdoesnot

indicate-0.1Mpa(14.5Psi)afterevacuatingfor30minutes,itshouldbe

evacuated20minutesmore.Ifthepressurecan’tachieve-0.1Mpa(14.5Psi)

afterevacuating50minutes,pleasecheckiftherearesomeleakage

points.Fullyclosetheshut-offknoblowsideofthemanifoldandstopthe

operationofthevacuumpump.ConÀrmthatthegaugeneedledoesnotmove

(approximately5minutesafterturningoffthevacuumpump).

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7. Makesurethepressuredisplayinthepressureindicatorisalittlehigherthan

theatmosphericpressure.Thenremovethechargehosefromthegasservice

valve.

8. Fullyopentheliquidservicevalveandgasservicevalveandsecurelytighten

thecapofthegasservicevalve.Systemisnowevacuatedandcharged.

(EnsurethattheunitischargedperthedeÀnedspeciÀcationsshowneither

onthenameplateofoutdoorunitorEngineeringSubmittalSheet.).

Gasleakcheck(Usesoapbubblemethod):

Applysoapywateroraliquidneutraldetergentontheindoorunit

connectionsoroutdoorunitconnectionsbyasoftbrushtocheckfor

leakageoftheconnectingpointsofthepiping.Ifbubblescomeout,the

pipesareleaking.

4.5 AddingtheRefrigeranttoan ExistingSystem

Figure 4

(Indoor Unit) (Liquid Side)

(Gas Side)

(Outdoor Unit)

Liquid Service Line

Gas Service Line

Check Valve

Charging

Cylinder

Electronic Scale

OPEN CLOSE

Procedure

1. Connecttherefrigerantmanifold,bluesuctionhosetothegasservice

valve'sserviceport,opentheliquidservicevalveandthegasservicevalve.

Connecttherefrigerantmanifold,yellowhosetothevalveatthebottomof

thecylinder.

2. Purgetheairfromtherefrigerantmanifold,yellowhose.Openthevalveatthe

bottomofthecylinderandpressthecheckvalveontherefrigerantmanifold

topurgetheair.

CAUTION:CONTAINS REFRIGERANT

fLiquidrefrigerantcancausefrostbite.Handlewithcare.

3. Putthechargingcylinderontotheelectronicscaleandrecordtheweight.

4. Operatetheairconditionerincoolingmode.

5. Openthevalves(lowside)ontherefrigerantmanifoldandchargethesystem

withliquidrefrigerant.

6. Whentheelectronicscaledisplaystheproperweight(refertothegaugeand

thepressureofthelowside),turnofftherefrigerantlowsidevalveandthe

refrigerantcylindervalve.Thenturnofftheunittoremovethehosefromthe

gasservicevalve.

7. Replacevalvestemcapsontheserviceport.Useatorquewrenchtotighten

theserviceportcaptoatorqueof18N.m. Besuretocheckforgasleakage.

4.6 Re-Installation/IndoorUnitNeeds tobeRepaired

Collectingtherefrigerantintothe outdoor unit (passiverecovery)

Figure 5

(Indoor Unit) (Liquid Side)

(Gas Side)

(Outdoor Unit)

Liquid Service Line

Gas Service Line

Open

Procedure

1. RemovethevalvestemcapsandconÀrmthatboththeliquidandgasservice

valvesaresettotheopenedposition. Ifnotopened,useappropriatehex

wrenchtoopenthevalvestems.

2. Connectrefrigerantgaugelowsidehose(blue) tothegasservicevalve's

serviceport

3. Airpurgingoftherefrigerantmanifold,bluehose:Openthelowsidevalveof

manifoldslightlytopurgeairfromthehosefor5secondsandthencloseit

quickly.

4. Settheliquidservicevalvetothecloseposition.

5. Operatetheairconditioneratthecoolingcycleandstopitwhenthegauge

indicates0.1Mpa(14.5Psi).

6. Setthegasservicevalvetotheclosedpositionimmediately.Dothisquickly

sothatthegaugeendsupindicating0.3Mpa(43.5Psi)to0.5Mpa(72.5Psi).

Disconnecttherefrigerantmanifold,andtightentheliquidandgasservice

valve’sstemnuts.Useatorquewrenchtotightenthegasservicevalve's

serviceportcaptoatorqueof18N.m.Besuretocheckforgasleakage.

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4.7 Re-InstallationWhilethe OutdoorUnitNeedstobeRepaired

Evacuationforthewholesystem

Figure 6

(Indoor Unit) (Liquid Side)

(Gas Side)

(Outdoor Unit)

Liquid Service Line

Gas Service Line

Open

Vacuum Pump

Open

Procedure:

1. ConÀrmthatboththeliquidandgasservicevalvesaresettotheopened

position.

2. Connectthevacuumpumptogasservicevalve’sserviceport.

3. Evacuateforapproximatelyonehour.ConÀrmthattherefrigerantmanifold

lowsideindicates-0.1Mpa(14.5Psi).

4. Closethevalve(Lowside)onthechargeset,turnoffthevacuumpump,and

conÀrmthatthegaugeneedledoesnotmove(approximately5minutesafter

turningoffthevacuumpump).

5. Disconnectthechargehosefromthevacuumpump.

Refrigerantcharging

Figure 7

(Indoor Unit) (Liquid Side)

(Gas Side)

(Outdoor Unit)

Liquid Service Line

Gas Service Line

Open

Check Valve

Open

Charging

Cylinder

Electronic Scale

OPEN

Procedure:

1. Connectthechargehosetothechargingcylinder,opentheliquidandthe

gasservicevalve.Connectthechargehosewhichyoudisconnectedfromthe

vacuumpumptothevalveatthebottomofthecylinder.

2. Purgetheairfromthechargehose.Openthevalveatthebottomofthe

cylinderandpressthecheckvalveonthechargesettopurgetheair(be

carefuloftheliquidrefrigerant).

3. Putthechargingcylinderontotheelectronicscaleandrecordtheweight.

4. Openthevalves(Lowside)ontherefrigerantmanifoldandchargethesystem

withliquidrefrigerantIfthesystemcannotbechargewiththespeciÀed

amountofrefrigerant,orcanbechargedwithalittleatatime(approximately

150g(5.3oz)eachtime),operatingthesysteminthecoolingcycle;

however,onetimeisnotsufÀcient,waitapproximately1minuteandthen

repeattheprocedure.

5. Whentheelectronicscaledisplaystheproperweight,disconnectthecharge

hosefromthegasservicevalve’sserviceportimmediately.Ifthesystemhas

beenchargedwithliquidrefrigerantwhileoperatingthesystem,turnoffthe

systembeforedisconnectingthehose.

6. Mountthevalvestemcapsandtheserviceport.Usetorquewrenchtotighten

theserviceportcaptoatorqueof18N.m.Besuretocheckforgasleakage.

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