Bosch ODU Split 2, ODU Split 4, ODU Split 6, ODU Split 8, ODU Split 11s Service Manual
...
Service guide
230 V 1 N~/400 V 3 N~
Split Outdoor unit
6 720 813 707-00.2I
ODU Split 2
ODU Split 4...8
ODU Split 11t...15t
ODU Split 11s...15s
6 720 817 722 (2015/06)
Table of contents
Split ODU – 6 720 817 722 (2015/06)
2
Table of contents
1 Key to symbols and safety instructions . . . . . . . . . . . . . . . . . . . 2
1.1 Key to symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Error handling instructions for Split outdoor unit . . . . . . . . . . 3
2.1 Names of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 List of error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Error code 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3.1 Error diagnosis and countermeasure flow chart . . . . . . . 5
2.4 Error code 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.1 Error diagnosis and countermeasure flow chart . . . . . . . 8
2.5 Error code 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.1 Error diagnosis and countermeasure flow chart . . . . . 11
2.6 Error code 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6.1 Error diagnosis and countermeasure flow chart . . . . . 14
2.7 Error code 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7.1 Error diagnosis and countermeasure flow chart . . . . . 17
2.8 Error code 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.8.1 Error diagnosis and countermeasure flow chart . . . . . 20
2.9 Error code 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.9.1 Error diagnosis and countermeasure flow chart . . . . . 21
2.10 Error code 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.10.1 Error diagnosis and countermeasure flow chart . . . . . 22
2.11 Error code 41, 44, 45, 46, 48 . . . . . . . . . . . . . . . . . . . 23
2.11.1 Error diagnosis and countermeasure flow chart . . . . . 23
2.12 Error code 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.12.1 Error diagnosis and countermeasure flow chart . . . . . 24
2.13 Error codes 52, 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.13.1 Error code 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.13.2 Error code 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.14 Error code 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.15 Error code 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.16 Error code 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.16.1 Error diagnosis and countermeasure flow chart . . . . . 29
2.17 Error code 62, 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.17.1 Error diagnosis and countermeasure flow chart . . . . . 30
2.18 Error code 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.18.1 Error diagnosis and countermeasure flow chart . . . . . 32
3 Check compressor resistances . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Compressor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5 Check system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6 Electronic expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7 Fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8 Replacement procedure for INV PCB . . . . . . . . . . . . . . . . . . . 39
9 Other pre - checkings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1 Key to symbols and safety instructions
1.1 Key to symbols
Warnings
The following keywords are defined and can be used in this document:
• NOTICE indicates a situation that could result in damage to property
or equipment.
• CAUTION indicates a situation that could result in minor to medium
injury.
• WARNING indicates a situation that could result in severe injury or
death.
• DANGER indicates a situation that will result in severe injury or
death.
Important information
Additional symbols
1.2 General safety instructions
These installation instructions are intended for plumbers, heating
engineers and electricians.
▶ Read any installation instructions (outdoor unit, heating controls,
etc.) carefully before starting the installation.
▶ Observe the safety instructions and warnings.
▶ Observe national and regional regulations, technical rules and
guidelines.
▶ Record all work carried out.
Intended use
This outdoor unit must only be used as a heat appliance in a sealed hot
water heating system for domestic purposes.
Any other use is considered inappropriate. Any damage that results from
such use is excluded from liability.
Installation, commissioning and servicing
Installation, commissioning and servicing must only be carried out by an
authorised contractor.
▶ Only use original spares.
Electrical work
Electrical work must only be carried out by qualified electricians.
▶ Before starting electrical work:
– Isolate all poles of the mains voltage and secure against
reconnection.
– Using suitable means, test that the power supply is disconnected.
▶ Also see connection diagrams of other system components.
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.
This symbol indicates important information where
there is no risk to people or property.
Symbol Explanation
▶ Step in an action sequence
Cross-reference to another part of the document
• List entry
– List entry (second level)
Table 1
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
3
Handling refrigerant
The air to water outdoor unit is filled with R410A refrigerant.
▶ Only qualified and authorised refrigeration engineers may work on
the refrigerant circuit.
▶ For all work with refrigerant, wear suitable safety gloves and goggles.
What to do if refrigerant leaks
If refrigerant leaks and touches the skin, it can cause frostbite.
▶ In case of a refrigerant leak, never touch any part of the air to water
outdoor unit.
▶ Avoid skin or eye contact with refrigerant.
▶ Seek medical attention if you get refrigerant on your skin or in your
eyes.
▶ If the refrigerant leaks please contact your installer immediately.
Handover to the user
When handing over the heating system, instruct the user in its operation
and operating conditions.
▶ Explain the operation - with particular emphasis on all safety-related
actions.
▶ Explain that conversions and repairs must only be carried out by an
approved contractor.
▶ Point out the need for inspections and maintenance for safe and
environmentally-compatible operation.
▶ The installation and operating instructions must be given to the user
for keeping.
2 Error handling instructions for Split outdoor unit
2.1 Names of units
2.2 List of error codes
Supplier name for ODU BTT name for ODU
AHUW036A2 ODU Split 2
AHUW056A2 ODU Split 4
AHUW076A2 ODU Split 6
AHUW096A2 ODU Split 8
AHUW126A2 ODU Split 11s
AHUW146A2 ODU Split 13s
AHUW156A2/166A2 ODU Split 15s
AHUW128A2 ODU Split 11t
AHUW148A2 ODU Split 13t
AHUW158A2/168A2 ODU Split 15t
Table 2 Names of units
HMI Error code ODU Error code Description Error characteristc Remark
5600, 5601 21 DC Peak (IPM Fault)
IPM = Intelligent Power module
Restart 10x/hour,
then blocked
Compressor broken or too much refrigerant in
compressor
5602, 5603 22 CT 2 (Max CT) Restart after
problem has
vanished
Inverter current > 14 A
5604, 5605 23 DC Link Voltage is low or high Restart after
problem has
vanished
Direct voltage
1~: <140 VDC or >480 (3kW: 420) VDC
3~: <320VDC or >780VDC
5610, 5611 26 Problem in DC Compressor
positioning
Restart 10x/hour,
then blocked
Wrong orientation of compressor connections
(UVW)
5612, 5613 27 PSC Fault Restart 10x/hour,
then blocked
High current IGBT (check reactor)
5616, 5617 29 High current at Compressor
phases
Restart 10x/hour,
then blocked
5618, 5619 32 Temperature at discharge-pipe is
too high
Restart after
problem has
vanished
Hot gas temperature TH5 >105 °C (check
refrigerant load)
5666, 5667 35 Low Pressure error Restart 3x/hour,
then blocked
Low Pressure < 0 kPa
( – 49.5 °C)
5622, 5623 41 Problem in discharge-pipe
temperature sensor
Direct shut-down Sensor TH5 broken (200k >25 °C)
5662, 5663 43 High-pressure sensor (Open/
Short)
Direct shut-down LP/HP sensor broken
5624, 5625 44 Problem in ambient temperature
sensor
Direct shut-down Sensor TH7 broken (10k >25 °C)
5626, 5627 45 Problem in condenser-middle-pipe
temperature sensor
Direct shut-down Sensor TH8 broken (5k >25 °C)
5628, 5629 46 Problem in suction-pipe
temperature sensor
Direct shut-down Sensor TH4 broken (5k >25 °C)
Table 3 Error codes
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
4
2.3 Error code 21
Fig. 1 Resistance measurement on compressor
[1] Compressor
[2] Copper pipe
5664, 5665 48 Cond. Out-pipe Th Error (Open/
Short)
Direct shut-down Sensor TH6 broken (5k >25 °C)
5632, 5633 52 Bad communication between
Inverter-PCB and Main-PCB
Restart 3x/hour,
then blocked
Wiring between Mainboard and Inverter board
damaged (3~ phase only)
5634, 5635 53 Bad communication between Can-
PCB and Main-PCB
Direct shut-down Wiring between Mainboard and CAN-PCB
damaged
5636, 5637 54 Phase sequence incorrect Restart 10x/hour,
then blocked
only 2 phases or incorrect rotation field
(3~ phase only)
5668, 5669 55 CAN Communication error (CAN-
PCB <=> Installerboard)
Direct shut-down Wiring between CAN-PCB and Indoor unit
damaged
5638, 5639 60 EEPROM Checksum mismatched Direct shut-down Change EEPROM
5640, 5641 61 Temperature at condenser-pipe is
too high
Restart after
problem has
vanished
Condensing temperature >65.3°C (4199 kPa)
{Heating}
Condensing temperature >64.2
°C(4101 kPa)
{Cooling}
5642, 5643 62 Temperature at heat sink is too
high
Restart after
problem has
vanished
Heat sink temperature >85 °C
5646, 5647 65 Problem in heatsink temperature
sensor
Direct shut-down Heat sink sensor / Inverter-PCB broken
5670, 5671 67 ODU BLDC fan lock Restart 10x/hour,
then blocked
Fan blocked
HMI Error code ODU Error code Description Error characteristc Remark
Table 3 Error codes
When the outdoor unit (ODU) is blocked the error can be
acknowledged by power ON/OFF.
Display
code
Title Cause of error
Check point & Normal
condition
21 DC PEAK
(IPM fault)
-Instant over
current
-Over rated
current
-Poor insulation
of IPM
-An instant over current in
the U,V,W phase
-Comp lock
-The abnormal connection of
U,V,W
-Over load condition
-Overcharging of refrigerant
pipe length
-Outdoor fan has stopped
-Poor insulation of
compressor
Table 4 Error code 21
ODU model Resistance () at 25 °C
ODU Split 4
ODU Split 6
ODU Split 8
U-V
0.628
V-W
0.628
W-U
0.628
ODU Split 11s
ODU Split 13s
ODU Split 15s
U-V
0.438
V-W
0.438
W-U
0.438
ODU Split 11t
ODU Split 13t
ODU Split 15t
U-V
0.845
V-W
0.845
W-U
0.845
Table 5 Resistance between phases
V
U
W
6 720 817 722-01.1I
1
2
1
2.3.1 Error diagnosis and countermeasure flow chart
ODU Split 4, 6 and 8
Fig. 2 ODU Split 4, 6, 8
1. Wait until PCB (Inverter) DC voltage is discharged after main
power is shut off.
2. Pull out V, W, U COMP connector.
3. Set multi tester to resistance mode.
4. If the value between P and N terminal of IPM is short (0) or open
(hundreds M), PCB (Inverter) needs to be replaced, IPM is
damaged.
5. Set the multi tester to diode mode.
6. In case measured value is different from the table, PCB (Inverter)
needs to be replaced. PCB (Inverter) is damaged.
Fig. 3 PFC_IPM check
ODU Split 11s, 13s, 15s
Is installation condition normal? No -> 1. Check pipe clogging / distortion
2. Check covering (unit)
3. Check EEV connector assembly condition / normal
operation
4. Check refrigerant pressure
-> Reassemble or manage if abnormality found
Yes
Are the resistance between each phase
and insulation resistance of inverter
compressor normal?
No ->
1. Check resistance between each terminal of compressor
2. Check insulation resistance between compressor terminal
and pipe
-> Replace compressor if abnormality is found
Yes
Is compressor wire connection
condition normal?
No -> 1. Check inverter PCB assembly 1 U,V,W connector
cennection condition
2. Check wire disconnection and wiring
3. Check compressor terminal connection condition (bad
contact)
-> Reassemble if abnormality is found
Yes
Is inverter PCB assembly 1 normal? No -> 1. Check inverter PCB assembly 1 IPM normality
-> Replace inverter PCB assembly 1
Yes
Recheck power and installation
condition
Table 6 Error diagnosis and countermeasure chart
SPM3
27 26 25 24 23 22 21
P W V U Nw Nv Nu
6 720 817 722-02.1I
27 26 25 24 23 22 21
P W V U Nw Nv Nu
0.4 ~ 0.6 V
P W V U Nw Nv Nu
27 26 25 24 23 22 21
0.4 ~ 0.6 V
PFC_IPM check
U, V, W ‘ R S T
6 720 817 722-03.1I
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
6
Fig. 4 ODU Split 11s, 13s, 15s
1. Wait until PCB (Inverter) DC voltage is discharged after main power
is shut off.
2. Pull out V, W, U COMP connector.
3. Set multi tester to resistance mode.
4. If the value between P and N terminal of IPM is short (0) or open
(hundreds M), PCB (Inverter) needs to be replaced, IPM is
damaged.
5. Set the multi tester to diode mode.
6. In case measured value is different from the table, PCB (Inverter)
needs to be replaced. PCB (Inverter) is damaged.
Fig. 5 PFC_IPM check
1
2
3
UVW
6 720 817 722-04.1I
27 26 25 24 23 22 21
P W V U Nw Nv Nu
0.4 ~ 0.6 V
P W V U Nw Nv Nu
27 26 25 24 23 22 21
0.4 ~ 0.6 V
PFC_IPM check
U, V, W ‘ R S T
6 720 817 722-03.1I
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
7
ODU Split 11t, 13t, 15t
Fig. 6 ODU Split 11t, 13t, 15t
1. Wait until PCB (Inverter) DC voltage is discharged after main power
is shut off.
2. Pull out V, W, U COMP connector.
3. Set multi tester to resistance mode.
4. If the value between P and N terminal of IPM is short (0) or open
(hundreds M), PCB (Inverter) needs to be replaced, IPM is
damaged.
5. Set the multi tester to diode mode.
6. In case measured value is different from the table, PCB (Inverter)
needs to be replaced. PCB (Inverter) is damaged.
Fig. 7 PFC_IPM check
6 720 817 722-05.1I
27 26 25 24 23 22 21
P W V U Nw Nv Nu
0.4 ~ 0.6 V
P W V U Nw Nv Nu
27 26 25 24 23 22 21
0.4 ~ 0.6 V
PFC_IPM check
U, V, W ‘ R S T
6 720 817 722-03.1I
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
8
2.4 Error code 22
2.4.1 Error diagnosis and countermeasure flow chart
Check Point
1. Check the power source (230V 15%).
2. Check that the fan operation is right.
3. Check the current.
4. Check the install condition.
5. Check the CT sensor output signal.
Display
code
Title Cause of error
Check point & Normal
condition
22 Max. C/T -Input Over
Current
1. Malfunction of
Compressor
2. Blocking of Pipe
3. Low Voltage Input
4. Refrigerant, Pipe length,
Blocked
Table 7 Error code 22
Is installation condition normal? No -> 1. Check pipe clogging / distortion
2. Check covering (unit)
3. Check EEV connector assembly condition / normal
operation
4. Check refrigerant pressure
-> Reassemble or manage if abnormality found
Yes
Are the resistance between each phase
and insulation resistance of inverter
compressor normal?
No -> 1. Check resistance between each terminal of compressor
2. Check insulation resistance between compressor terminal
and pipe
-> Replace compressor if abnormality is found
Yes
Is compressor wire connection
condition normal?
No -> 1. Check connection between PCB assembly and bridge diode
(misconnection, disconnection)
2. Check wire disconnection and wiring
3. Check compressor terminal connection condition (bad
contact)
-> Reassemble if abnormality is found
Yes
Is inverter PCB assembly 1 power
connection normal?
No -> 1. Check connection between PCB assembly 1 and bridge
diode (misconnection, disconnection)
-> Wiring again if abnormality is found
Yes
Is input voltage normal? No -> 1. Check L~N phase is 230V 15%
-> Check connection condition and wiring if power is
abnormal
Yes
Is PCB assembly 1 normal? No -> 1. Check PCB assembly 1 IPM normality
-> Replace inverter PCB assembly
Yes
Recheck power and installation
condition
Table 8 Error diagnosis and countermeasure chart
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
9
ODU Split 4, 6, 8
Fig. 8 ODU Split 4, 6, 8
▶ Check output of the CT sensor: DC 2.5 0.2V
ODU Split 11s, 13s, 15s
Fig. 9 ODU Split 11s, 13s, 15s
[1] Inverter PCB
[2] CT sensing check point
▶ Check output pin 2.3 of the CT sensor: DC 2.5 0.2V
IN/I
GND
Black
Red
Vdc
6 720 817 722-06.1I
1
2
3
Vdc
6 720 817 722-07.1I
1 2
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
10
ODU Split 11t, 13t, 15t
Fig. 10 ODU Split 11t, 13t, 15t
[1] Inverter PCB
[2] CT sensing check point
▶ Check input current T_PFC and R_PFC
▶ Check output of the CT sensor: DC 2.5 0.2V
6 720 817 722-08.1I
1
2
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
11
2.5 Error code 23
2.5.1 Error diagnosis and countermeasure flow chart
Check Point
1. Check the WCN_P(L), P(N) connection condition ate the main PCB
(heater). Refer to wiring diagram.
2. Check the DC link voltage at no operation of compressor (280V).
3. Check the DC link voltage at operation of compressor (340V).
4. Check the DC link sensing signal (AHBW**6AO): 2.4~2.8V
(Graphic 12).
5. Check the DC link sensing signal (AHBW**8AO): 0.4~0.6V
(Graphic 13).
ODU Split 4, 6, 8
Fig. 11 ODU Split 4, 6, 8
Display
code
Title Cause of error
Check point & Normal
condition
23 DC link High
/ Low
voltage
• DC link
voltage is
above
420Vdc
• DC link
voltage is
below
140Vdc
1. Check CN_(L), CN_(N)
connection
2. Check input voltage
3. Check PCB DC link
voltage sensor parts
Table 9 Error code 23
Is input voltage normal? No -> 1. Check power input voltage
Yes
Is inverter PCB
assembly 1 power
connection normal?
No ->
1. Check power connection state
Yes
Is PCB (Inverter)
normal?
No -> 1. Replace PCB assembly 1
Yes
Recheck power and
installation condition
Table 10 Error diagnosis and countermeasure chart
IN/I
GND
Vdc
6 720 817 722-09.1I
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
12
ODU Split 11s, 13s, 15s
Fig. 12 ODU Split 11s, 13s, 15s
Vdc
P
GND
6 720 817 722-10.1I
Error handling instructions for Split outdoor unit
Split ODU – 6 720 817 722 (2015/06)
13
ODU Split 11t, 13t, 15t
Fig. 13 ODU Split 11t, 13t, 15t
[1] PFCM pin arrangement and pin numbers
6 720 817 722-11.1I
1
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