Bosch IDS BOVA 1.0 Betriebsanleitung

Technical Instructions

E-Box Replacement

Bosch IDS BOVA 1.0

3 Ton

BTC 761702110 B / 09.2022

Technical Instructions

IDS BOVA E-Box Replacement - BTC 761702110 B (09.2022)

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Technical Instructions

IDS BOVA E-Box Replacement - BTC 761702110 B (09.2022)

Table of Contents

1 Key to Symbols and Safety Instructions 4

1.1 Key to Symbols 4

2 Outdoor Unit Model Numbers 4

3 Components 4

4 Replacement Instructions 5

Technical Instructions

IDS BOVA E-Box Replacement - BTC 761702110 B (09.2022)

1 Key to Symbols and Safety Instructions

1.1 Key to Symbols

Warnings

Warnings in this document are identiﬁed by a

warning triangle printed against a grey background.

Keywords at the start of a warning indicate the type and seriousness

of the ensuing risk if measures to prevent the risk are not taken.

The following keywords are deﬁned and can be used in this document:

DANGER indicates a hazardous situation which, if not avoided, will result

in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could

result in minor to moderate injury.

NOTICE is used to address practices not related to personal injury.

Important information

This symbol indicates important information where

there is no risk to people or property.

2 Outdoor Unit Model Numbers

Bosch Part

Number BoschModelNumber Description

7739832068 BOVA-36HDN1-M18M 36kBTU, Inverter Condensing Unit

Table 1 ODU Model & Part Numbers

3 Components

The following components are included in the kit:

Figure 1

Components

Updated wiring diagram included in kit. Replace the old wiring diagram

on the back of the access panel.

Item Description Qty

1 3T Control Board + E-box 1

2 Replacement Manual 1

3 3T Bottom Access Panel 1

4 Screws 8

5 Zip Ties 8

6 Wiring Diagram 1

Table 2 3T E-Box Kit Components

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Technical Instructions

IDS BOVA E-Box Replacement - BTC 761702110 B (09.2022)

4 Replacement Instructions

1. Turn oﬀ power to the unit and wait at least 3 minutes.

WARNING:HAZARDOUSVOLTAGE380VOLTS DC

Wait 3 minutes after disconnecting power, then verify DC

voltage is less than 43 VDC at inverter test points P-N.

Components may store a dangerous electrical potential

of 380 Volts DC. Failure to follow these instructions could

result in personal injury or death.

2. Remove the access panel to the control board (Figure 2). Keep Screws for

re-use.

NOTICE:PRODUCT DAMAGE

Do not directly touch the components on the main board to

avoid static electricity damage.

Figure 2 Control Board Access

3. Cut the 6 zip ties to unbundle the control board wires

4. Cut the 2 zip ties around gaskets at the bottom of the E-box

5. Remove all of the component wires from the Control Board. Take a picture

before wire removal for dip switch and wiring reference.

The wires will need to be connected to the new control board once

installed.

To remove T3 and T4 sensors, remove white cover to disconnect sensor.

See Figure 3.

Figure 3

Push in

Remove white cover

Push in

6. Unscrew 16 screws to remove the top cover of the unit. When removing the

top cover, be careful not to damage the heat exchanger ﬁns. Lean top panel

against wall. Refer to Figure 4.

Ensure fan motor is removed from control board to remove top cover.

Figure 4 Remove Top Cover

Technical Instructions

IDS BOVA E-Box Replacement - BTC 761702110 B (09.2022)

7. Carefully pull the wires from the bottom left and right hole through the back

of the E-Box. See Figure 5.

Figure 5

Pull wires through left hole Pull wires through right hole

Remove Wires From Holes in E-Box

8. Unscrew the 7 screws to remove E-box. Slide E-box up to remove. Keep all

screws for reuse. Refer to Figure 6.

Remove E-box by ﬁrst lifting up and then out.

Figure 6

Slide upward

E-Box Removal

9. Unscrew 2 screws (red) on the panel and 2 screws (blue) mounting the “true

suction” service port. Remove Bottom Access Panel. Keep screws to re-install

later. See Figure 7.

Figure 7

“true

suction”

service

port

Remove Bottom Access Panel

10. Cut 3 zip ties bundling the reactor box white harness

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Technical Instructions

IDS BOVA E-Box Replacement - BTC 761702110 B (09.2022)

11. Unscrew 4 screws to remove reactor box and white wiring harness. This is not

needed for the new control board. Refer to Figure 8.

Figure 8 Reactor Box Removal

CAUTION:PERSONALINJURY

Reactor box is heavy, be careful when removing.

NOTICE: PRODUCTDAMAGE

Potential risk for fan motor/blades to become damaged if

reactor box and connected white wiring harness are not

removed from unit.

12. Unit should look like should look like Figure 9.

Figure 9 E-box, Bottom Access Panel, Reactor Box Removed

13. Slide in the new E-box in from the top and secure with screws saved in Step

8. Note: The sides of the E-box should line up and slide into the guide rails on

the unit. Refer to Figure 10.

Figure 10

Left Corner Right Corner

Top Corner of E-Box

Technical Instructions

IDS BOVA E-Box Replacement - BTC 761702110 B (09.2022)

14. Route the compressor wires and compressor ground to the top of the E-box

and secure using wire clip. Refer to Figure 11.

Figure 11

3 Compressor Wires

Compressor Ground Wire

Wire Clip

E-box High Voltage Routing

CAUTION:GROUNDINGREQUIRED

Failure to inspect or use proper service tools may result

in equipment damage or personal injury. Reconnect all

grounding devices. All parts of this product that are capable

of conducting electrical current are grounded. If grounding

wires, screws, straps, clips, nuts, or washers used to

complete a path to ground are removed for service, they

must be returned to their original position and properly

fastened.

15. All other component wires should be fed through the right gasket hole. Feed

the wires through the hole one by one. Route the CCH wire (orange wire)

through the separate slot on the E-box. Refer to ﬁgure 12.

Figure 12

All other

component wires

Place orange CCH

wire through slot

Routing Wires to Front of Board

16. Mount new Bottom Access Panel on with 4 screws and secure the true

suction service port. Careful when sliding the true suction service port into

the slot on the panel.

17. Make sure to reinstall T4 temperature sensor in Bottom Access Panel, refer to

Figure 13. Lock sensor in strainer and push up through hole in panel.

Figure 13

End of sensor

Lock

Strainer

T4 Sensor Reinstallation

18. Put top panel back on. Make sure the wires from the top panel, OD fan wire,

Motor capacitor and capacitor ground (for 3T units), are fed through the slot

at the top left of the E-box.

Figure 14

For 3T: - Motor Capacitor (red, brown)

- Ground (yellow)

Compressor

Ground

Compressor

Wires

OD Fan

Wires

Top Panel Wiring to E-box

19. Secure top panel with screws from step 6

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Technical Instructions

IDS BOVA E-Box Replacement - BTC 761702110 B (09.2022)

20. Connect all wires according to the wiring diagram. See Figure 15.

Figure 15

Fasten all wires and tighten all screws.

BLUE

BLACK

RED

Note: Compressor color labels on

PCB are different than the actual color

of the compressor wires

Note: There is no PEV

CN17 does not need to be connected.

Note: Blue Wire (10k Resistance) at

CN7 does not need to be connected.

To Thermostat & Air Handler

3T Control Board with All Wires Connected

10 |

Technical Instructions

IDS BOVA E-Box Replacement - BTC 761702110 B (09.2022)

21. Feed thermostat wires through the Bottom Access Panel to the CN9 wire

harness on the control board. Splice wires and use ﬁeld supplied wire nuts to

make connection. See Figure 17.

Figure 16 Thermostat Wiring Connection

- Low voltage connection must be made inside the outdoor unit control

board access panel.

- There is no terminal block for low voltage connections, wires must be

spliced using ﬁeld supplied wire nuts.

- Field supplied wire nuts should be 22-16 gauge.

- Refer to unit wiring diagram for more information.

22. Make sure all wires are secured and not interfering with control board. Feed

zip ties through holes in the E-box to secure wiring. Refer to Figure 18.

Figure 17

23. Feed L1, L2 and GND through the Bottom Access Panel.

24. Connect L1 and L2 to high voltage terminal block. Refer to Figure 19.

Figure 18 High Voltage Terminal Block

25. Check SW4/SW5/J2 dip switch positions. Make sure they are the same

as what was conﬁgured on the replaced control board. Refer to IOM or the

picture taken in Step 3.

26. Double check all wire connections, grounding, and screw positions before

powering on.

27. S

crew the access panel to the control board back on using screws from Step 2.

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