Bosch BOVA, BOVA-36, BOVA-60 Installation Instructions Manual
Bosch BOVA 2.0 Split System Heat Pump
Condensing Units Up to 20.5 SEER
2-3-4-5 Ton Capacity
R410A
Installation Instructions
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Bosch IDS 2.0 BOVA Installation Instructions
Data subject to change
02.2019 | Bosch Thermotechnology Corp.
Installation Instructions Bosch IDS BOVA | 3
Table of Contents
1 Key to Symbols and Safety Instructions 4
1.1 Key to Symbols 4
1.2 Safety 4
2 Unit Location Considerations 6
2.1 Unit Dimensions 6
2.2 Refrigerant Piping Limits 6
2.3 Location Restrictions 7
3 Unit Preparation 8
3.1 Prepare the Unit for Installation 8
4 Setting the Unit 8
4.1 Pad Installation 8
5 Refrigerant Line Considerations 9
5.1 Refrigerant Line and Service Valve Connection Sizes 9
5.2 Required Refrigerant Line Length 9
5.3 Refrigerant Line Insulation 9
5.4 Reuse Existing Refrigerant Lines 9
6 Refrigerant Line Routing 10
6.1 Precautions 10
7 Refrigerant Line Brazing 11
7.1 Braze The Refrigerant Lines 11
8 Refrigerant Line Leak Check 13
8.1 Check For Leaks 13
9 Evacuation 13
9.1 Evacuate the Refrigerant Lines and Indoor Coil 13
13 Start Up 20
13.1 System Start Up 20
14 System Charge Adjustment 21
14.1 Charging: Weigh-In Method 21
14.2 Subcooling Charging And Refrigerant Adjustment In Cooling
(Above 55°F Outdoor Temp.) 21
15 System Operation and Troubleshooting 24
15.1 Control Logic Description 24
15.2 Sensors (Thermistors/Pressure Transducer) 24
15.3 Pressure Equalizer Valve (PEV) 24
15.4 Defrost Description 24
15.5 Compressor Crankcase Heater Description 25
15.6 Reversing Valve Operation 25
15.7 Protection Functions 25
15.8 Fault Code Table 26
15.9 Parameter Point Check Table 27
15.10 Control Board Overviews 28
15.11 Error Code Troubleshooting 30
15.12 Temperature and Resistance Relationship Tables (for Sensors) 36
15.13 Temperature and Resistance Relationship Tables (for T5 & Tf Sensors) 37
16 Wiring Diagram 39
17 Care and Maintenance 40
17.1 Cleaning Precautions 40
17.2 Maintenance – Pre-Season Inspection 40
10 Service Valves 14
10.1 Open the Service Valves 14
11 Electrical - Low Voltage 15
11.1 Low Voltage Maximum Wire Length 15
11.2 Low Voltage Hook-Up Diagrams 15
11.3 Thermostat Wiring Diagrams 15
12 Electrical - High Voltage 19
12.1 High Voltage Power Supply 19
12.2 High Voltage Disconnect Switch 19
12.3 High Voltage Ground 19
Bosch Thermotechnology Corp. | 02.2019
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Bosch IDS 2.0 BOVA Installation Instructions
1 Key to Symbols and Safety Instructions
1.1 Key to Symbols
Warnings
Warnings in this document are identifi ed 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 defi ned 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
1.2 Safety
Please read before proceeding
WARNING: ELECTRICAL HAZARD 380 VOLTS DC
Failure to follow this warning could result in property
damage, severe personal injury, or death.
WAIT THREE (3) MINUTES after disconnecting power
prior to touching electrical components as they may hold a
dangerous charge of 380 VDC,then verify DC Voltage is less
than 42VDC at inverter TEST POINTS P-N.
NOTICE:
This document is customer property and is to remain with
this unit. Please return to service information pack upon
completion of work.
These instructions do not cover all variations in systems
or provide for every possible contingency to be met in
connection with the installation.
Should further information be desired or should particular
problems arise which are not covered sufficiently for the
purchaser’s purposes, the matter should be referred to your
installing dealer or local distributor.
This symbol indicates important information where
there is no risk to people or property.
The manufacturer recommends installing only approved
matched indoor and outdoor systems. All of the manufacturer’s split
systems are AHRI rated only with TXV indoor systems. Some of the
benefi ts of installing approved matched indoor and outdoor split
systems are maximum effi ciency, optimum performance and the best
overall system reliability.
This document contains a wiring diagram and service information.
This is customer property and is to remain with this unit. Please return to
service information pack upon completion of work.
WARNING:
This information is intended for use by individuals
possessing adequate backgrounds of electrical and
mechanical experience. Any attempt to repair a central air
conditioning product may result in personal injury and/or
property damage.
Data subject to change
02.2019 | Bosch Thermotechnology Corp.
Installation Instructions Bosch IDS BOVA | 5
WARNING: HAZARDOUS VOLTAGE
Failure to follow this warning could result in property
damage, severe personal injury, or death.
Disconnect all electric power, Including remote disconnects
before servicing. Follow proper lockout/tagout procedures
to ensure the power cannot be inadvertently energized.
WARNING: REFRIGERANT OIL
Any attempt to repair a central air conditioning product may
result in property damage, severe personal injury, or death.
These units use R-410A refrigerant which operates at
50 to 70% higher pressures than R-22. Use only R-410A
approved service equipment. Refrigerant cylinders are
painted a “Rose” color to indicate the type of refrigerant
and may contain a “dip” tube to allow for charging of liquid
refrigerant into the system. All R-410A systems with variable
speed compressors use a POE oil (VG74 or equivalent )
that readily absorbs moisture from the atmosphere. To
limit this ‘hygroscopic“ action, the system should remain
sealed whenever possible. If a system has been open to
the atmosphere for more than 4 hours, the compressor oil
must be replaced. Never break a vacuum with air and always
change the driers when opening the system for component
replacement.
CAUTION: GROUNDING REQUIRED
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.
WARNING: SERVICE VALVES
Failure to follow this warning will result in abrupt release
of system charge and may result in personal injury and/
or property damage. Extreme caution should be exercised
when opening the Liquid Line Service valve. Turn valve stem
counterclockwise only until the stem contacts the rolled
edge.
WARNING: BRAZING REQUIRED
Failure to inspect lines or use proper service tools may result
in equipment damage or personal injury. If using existing
refrigerant lines make certain that all joints are brazed, not
soldered.
WARNING: HOT SURFACE
May cause minor to severe burning. Failure to follow this
Caution could result in property damage or personal injury.
Do not touch top of compressor.
CAUTION: CONTAINS REFRIGERANT
Failure to follow proper procedures can result in personal
illness or injury or severe equipment damage.System
contains oil and refrigerant under high pressure. Recover
refrigerant to relieve pressure before opening system.
CAUTION: INDOOR UNIT REQUIRED
The indoor units must be matched with TXV. The model of
TXV can be changed according to the system capacity.
WARNING: HIGH CURRENT LEAKAGE
Failure to follow this warning could result in property
damage, severe personal injury, or death.
Grounding is essential before connecting electrical supply.
WARNING:
This product can expose you to chemicals including Lead
and Lead components, which are known to the State
of California to cause cancer and birth defects or other
reproductive harm. For more information go to www.
P65Warnings.ca.gov.
Bosch Thermotechnology Corp. | 02.2019
Data subject to change
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Bosch IDS 2.0 BOVA Installation Instructions
2 Unit Location Considerations
2.1 Unit Dimensions
Unit Dimensions
Models H x W x L (Inches)
BOVA-36 24-15/16 x 29-1/8 x 29-1/8
BOVA-60 33-3/16 x 29-1/8 x 29-1/8
Table 1
The unit’s weight values are on the carton box.
When mounting the outdoor unit on a roof, be sure the roof will support the unit’s
weight. Properly selected isolation is recommended to prevent sound or vibration
transmission to the building structure.
L
L
W
W
Maximum line equivalent length = 150 feet.
Maximum vertical equivalent length = 50 feet.
Use only the line diameters indicated in Table 2.
If the suction linesets are greater than 50 feet, do not use a larger suction
line than recommended.
Standard Lineset
Lineset 150' Max
Line Length
Figure 1
2.2 Refrigerant Piping Limits
Liquid
System
Capacity
Model
2 Ton 3/8 *
3 Ton 3/8 *
4 Ton 3/8 *
5 Ton 3/8 *
Table 2
* Standard line size is recommended;
N/A: Application not recommended;
Refrigerant charge: refer to Sec. 14
Suction
Line
Line
Inch O.D. Maximum Vertical Separation - Feet
3/4 Std. 25 50 45 40 30 25
5/8 Opt. 25 50 45 40 30 25
3/4 Std. 25 50 50 50 35 25
5/8 Opt. 25 50 50 50 35 25
7/8 Std. 25 50 50 40 30 25
3/4 Opt. 25 50 50 40 30 25
7/8 Std. 25 50 50 40 30 25
3/4 Opt. 25 50 50 40 30 25
1 1/8 Opt. 25 40 N/A N/A N/A N/A
H
H
Total Equivalent Length - Feet
25 50 75 100 125 150
50' Max
Line Lift
50' Max
Line Lift
Figure 2
Data subject to change
02.2019 | Bosch Thermotechnology Corp.
Installation Instructions Bosch IDS BOVA | 7
2.3 Location Restrictions
Ensure the top discharge area is unrestricted for at least 60 inches above the unit.
Do not locate outdoor unit near bedrooms since normal operational sounds may be
objectionable.
Position unit to allow adequate space for unobstructed airfl ow, wiring, refrigerant
lines, and serviceability.
Allow a minimum of 12 in. clearance on one side of control board access panel to a
wall and a minimum of 24 in. on the adjacent side of control board access panel.
Maintain a distance of 24 in. between units.
Position unit where water, snow, or ice from roof or overhang cannot fall directly
on unit.
See Fig. 3 and Fig. 4.
Avoid Installations
Near Bedrooms
Min. 60" Unrestricted
Min. 12" to
Shrubbery
Min. 24"
Unrestricted
Cold climate considerations (heat pump only)
Precautions must be taken for units being installed in areas where
snow accumulation and prolonged below-freezing temperatures occur.
Units should be elevated 3-12 inches above the pad or rooftop,
depending on local weather. This additional height will allow drainage of
snow and ice melted during defrost cycle prior to its refreezing. Ensure
that drain holes in unit base pan are not obstructed, which could prevent
the drainage of defrost water (Fig. 5).
If possible, avoid locations that are prone to snow drifts. If not possible,
a snow drift barrier should be installed around the unit to prevent a
build-up of snow on the sides of the unit.
Min. 12"
Snow
barrier
Snow legs
3-12" Elevation
Figure 3
Min. 12" to
Shrubbery
Access Panel
Min. 24" to
Shrubbery
Access Panel
Pad
Figure 5
Corrosive Environment
Exposure to a corrosive environment may shorten the life of the equipment,
corrode metal parts, and/or negatively aff ect unit per formance. Corrosive elements
include, but are not limited to: sodium chloride, sodium hydroxide, sodium sulfate,
and other compounds commonly found in ocean water, sulfur, chlorine, fl uorine,
fertilizers, and various chemical contaminants from industry/manufacturing
plants. If installed in areas which may exposed to corrosive environments, special
attention should be given to the equipment placement and maintenance.
Lawn sprinklers/hoses/waste water should not spray directly on the unit
cabinet for prolonged periods of time.
In coastal areas: locate the unit on the side of the building away from the
waterfront.
Fencing or shrubbery may provide some shielding protection to the unit,
however minimum unit clearances must still be maintained.
Approximately every three months, wash the outdoor coil and any
exposed cabinet surfaces.
Figure 4
Bosch Thermotechnology Corp. | 02.2019
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Bosch IDS 2.0 BOVA Installation Instructions
3 Unit Preparation
3.1 Prepare the Unit for Installation
Check for damage and report promptly to the carrier any damage found to
the unit (Fig. 6).
The charge port can be used to ensure the refrigerant charge has been
retained during shipment.
Figure 7
Figure 6
4 Setting the Unit
4.1 Pad Installation
When installing the unit on a support pad, such as a concrete slab, consider the
following:
The pad must be at least 1-2” larger than the unit on all sides.
The pad must be separated from any structure.
The pad must be level.
The pad must be high enough above grade to allow for drainage.
The pad location must comply with National, State, and local codes.
These instructions are intended to provide a method to tie-down system
to cement slab as a securing procedure for high wind areas. Check local
codes for tie-down methods and protocols.
#7 X 3/8" Self-tapping screws
(Do not exceed 3/8" length screws!)
Detail A
See Section 2.1
for unit dimensions
See Detail A
Field-supplied brackets:
2" width, 1/16" thickness,
height as required.
Data subject to change
1/4” Χ 1-1/2” Hex washer head concrete screws
(3/16” pilot hole needed. Pilot hole should be 1/4” deeper
than the fastener embedment)
Figure 8
02.2019 | Bosch Thermotechnology Corp.
Installation Instructions Bosch IDS BOVA | 9
5 Refrigerant Line Considerations
5.1 Refrigerant Line and Service Valve Connection Sizes
Models
BOVA-36 3/4 3/8 3/4 3/8
BOVA-60 7/8 3/8 7/8 3/8
Table 3
Suction Line Liquid Line
Dimensions in inches
5.2 Required Refrigerant Line Length
Determine required line length (Fig. 9). Refer to Section 2.2.
Line Length
Suction Line
Connection
Liquid Line
Connection
5.4 Reuse Existing Refrigerant Lines
CAUTION: MINOR TO MODERATE BURNS
If using existing refrigerant lines, make certain that all joints
are brazed, not soldered.
For retrofi t applications, where the existing refrigerant lines will be used, the
following precautions should be taken:
Ensure that the refrigerant lines are the correct size. Refer to Section 2.2
and Table 2.
Ensure that the refrigerant lines are free of leaks, acid, and oil.
The manufacturer recommends installing only approved matched indoor
and outdoor systems. All of the manufacturer’s split systems are AHRI
rated only with TXV indoor systems. The benefi ts of installing approved
matched indoor and outdoor split systems are maximum effi ciency,
optimum performance and the best overall system reliability.
Figure 9
5.3 Refrigerant Line Insulation
The Suction Line must always be insulated. DO NOT allow the Liquid Line
and Suction Line to come in direct (metal to metal) contact.
Liquid Line
Suction Line
Insulation
Figure 10
Bosch Thermotechnology Corp. | 02.2019
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Bosch IDS 2.0 BOVA Installation Instructions
6 Refrigerant Line Routing
6.1 Precautions
Take precautions to prevent noise within the building structure due to
vibration transmission from the refrigerant lines. For example:
When the refrigerant lines have to be fastened to floor joists or
other framing in a structure, use isolation type hangers.
Isolation hangers should also be used when refrigerant lines are
run in stud spaces or enclosed ceilings.
Where the refrigerant lines run through a wall or sill, they should
be insulated and isolated.
Isolate the lines from all ductwork.
Minimize the number of 90º turns.
8 Feet Maximum
Comply with National, State, and local codes when isolating linesets
from joists, rafters, walls, or other structural elements.
Joist/Rafter
Isolator
Figure 11
Side View
Side View
8 Feet Maximum
Secure Suction Line from joists using isolators every 8 ft. Secure Liquid Line
directly to Suction Line using tape, wire, or other appropriate method every 8 ft.
Isolation From Joist/Rafter
8 Feet Maximum
8 Feet Maximum
Secure Suction Line using isolators every 8 ft. Secure Liquid Line directly to
Suction Line using tape, wire, or other appropriate method every 8 ft.
Isolation On Walls
Lineset
Wall
Isolator
Linesets
Figure 12
Data subject to change
02.2019 | Bosch Thermotechnology Corp.
Installation Instructions Bosch IDS BOVA | 11
Wall
Sealant
Ductwork
Insulation
Suction Line
Isolator
Lineset
Isolation Through Wall
Figure 13
7 Refrigerant Line Brazing
7.1 Braze The Refrigerant Lines
1. Remove caps or plugs. Use a deburring tool to deburr the pipe ends. Clean
both internal and external surfaces of the tubing using an emery cloth.
DO NOT hang linesets from ductwork
Figure 14
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Bosch IDS 2.0 BOVA Installation Instructions
2. Remove the pressure tap cap from both service valves.
Shipped in package
field installed
3-4" from valve
Figure 15
3. Purge the refrigerant lines and indoor coil with dry nitrogen.
This pipe
must have
a thimble
Figure 16
4. Wrap a wet rag around the valve body to avoid heat damage and continue the
dry nitrogen purge (Fig. 17).
Braze the refrigerant lines to the service valves.
Braze the fi lter drier to the Liquid Line.
Figure 17
5. Replace the pressure tap caps after the service valves have cooled.
Figure 18
All units come standard with a bi-fl ow fi lter drier. Braze the fi lter drier to
the liquid line, using caution not to push the refrigerant line too hard past
the stop within the fi lter drier (this could damage the drier).
Continue the dry nitrogen purge. Do not remove the wet rag until all brazing
is completed.
Remove the wet rag before stopping the dry nitrogen purge.
Data subject to change
02.2019 | Bosch Thermotechnology Corp.
Installation Instructions Bosch IDS BOVA | 13
150 PSI
G
8 Refrigerant Line Leak Check
8.1 Check For Leaks
1. Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry
nitrogen.
Figure 19
9 Evacuation
9.1 Evacuate the Refrigerant Lines and Indoor Coil
Do not open the service valves until the refrigerant lines and indoor coil
leak check and evacuation are complete.
1. Evacuate until the micron gauge reads no higher than 350 microns, then
close the valve to the vacuum pump.
0350
Microns
ON
OFF
Figure 21
2. Check for leaks by using a soapy solution or bubbles at each brazed location.
Figure 20
2. Observe the micron gauge. Evacuation is complete if the micron gauge does
not rise above 500 microns in one (1) minute.
Once evacuation is complete, turn off the vacuum pump and micron gauge,
and close the valves on the manifold gauge set.
1MIN.
Figure 22
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Bosch IDS 2.0 BOVA Installation Instructions
10 Service Valves
10.1 Open the Service Valves
WARNING: MODERATE TO SEVERE BURNS
Extreme caution should be exercised when opening the
Liquid Line Service Valve. Turn counterclockwise until
the valve stem just touches the rolled edge. No torque is
required. Failure to follow this warning will result in abrupt
release of system charge and may result in personal injury
and /or property damage.
Leak check and evacuation must be completed before opening the
service valves. The brazed lineset valves should be used for leak
checking and vacuuming. Using the separate suction port for this
process will result in loss of charge.
The Suction Service Valve must be opened fi rst BEFORE opening the
Liquid Service Valve.
1. Remove Service Valve Cap (Fig. 23).
Figure 23
Cap
Unit Side
of Service
Val ve
Service Port
5/16" Hex Wrench
for Suction Service Valve
3/16" Hex Wrench
for Liquid Service Valve
Rolled Edge to
Captivate Stem
Hex Headed
Valve System
2. Fully insert hex wrench into the stem and back out counterclockwise until
valve stem just touches the rolled edge (approximately five (5) turns.)
3. Replace the Valve Stem Cap to prevent leaks. Tighten finger tight plus an
additional 1/6 turn.
4. Repeat STEPS 1 - 3 for Liquid Service Valve.
Data subject to change
02.2019 | Bosch Thermotechnology Corp.
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