Bosch IDS BOVA 1.0 - User Manual

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Summary

Key to Symbols and Safety Instructions

Key to Symbols

Explains warning symbols and keywords like DANGER, WARNING, CAUTION, NOTICE.

E-Box Replacement Procedure

Initial Disassembly and Access

Steps for powering off, removing access panel, and disconnecting wires.

E-Box and Panel Removal

Instructions for removing the E-box and the bottom access panel.

Reactor Box and New E-Box Installation

Procedure for removing the reactor box and installing the new E-box.

Wiring Routing and Panel Reassembly

Guides on routing wires and reassembling panels after E-box replacement.

Final Wiring Connections and Checks

Connecting wires according to diagram and performing final checks.

Summary

Key to Symbols and Safety Instructions

Key to Symbols

Explains warning symbols and keywords like DANGER, WARNING, CAUTION, NOTICE.

E-Box Replacement Procedure

Initial Disassembly and Access

Steps for powering off, removing access panel, and disconnecting wires.

E-Box and Panel Removal

Instructions for removing the E-box and the bottom access panel.

Reactor Box and New E-Box Installation

Procedure for removing the reactor box and installing the new E-box.

Wiring Routing and Panel Reassembly

Guides on routing wires and reassembling panels after E-box replacement.

Final Wiring Connections and Checks

Connecting wires according to diagram and performing final checks.

This document provides technical instructions for the E-Box Replacement in the Bosch IDS BOVA 1.0 3 Ton Inverter Condensing Unit. It outlines the necessary steps and components for replacing the E-Box, which houses the control board and associated wiring, ensuring proper functionality and safety during the process.

Function Description:

The E-Box replacement procedure involves exchanging the existing control board and its enclosure with a new kit. The control board is the central electronic component that manages the operation of the Bosch IDS BOVA 1.0 outdoor unit, including the compressor, fan motor, and various sensors. It processes input from sensors, controls the refrigeration cycle, and communicates with the indoor unit and thermostat. The replacement ensures continued reliable operation of the heat pump system. The kit includes a new 3T Control Board + E-box, a replacement manual, a 3T Bottom Access Panel, screws, zip ties, and an updated wiring diagram. The updated wiring diagram is crucial for correct re-installation and replaces the old diagram on the back of the access panel.

Important Technical Specifications:

The replacement is specifically for the Bosch IDS BOVA 1.0 3 Ton unit, identified by Bosch Part Number 7739832068 and Bosch Model Number BOVA-36HDN1-M18M, which is a 36kBTU Inverter Condensing Unit. The procedure involves handling hazardous DC voltage up to 380 Volts, requiring a waiting period of at least 3 minutes after disconnecting power and verifying DC voltage is less than 43 VDC at inverter test points P-N. The control board manages various electrical connections, including those for the compressor, OD fan, motor capacitor, and multiple temperature sensors (T3, T4, T5, PT). The thermostat wires connect to the CN9 wire harness, and L1 and L2 high voltage connections are made to the terminal block. Field-supplied wire nuts for low voltage connections should be 22-16 gauge. The unit is AHRI Certified (Unitary Sma HP, AHRI Standard 210/240), and ETL Listed by Intertek, indicating compliance with industry performance and safety standards. Certification applies only when the complete system is listed with AHRI.

Usage Features:

The E-Box replacement is a maintenance procedure rather than a user-facing feature. It ensures the continued optimal performance of the Bosch IDS BOVA 1.0 heat pump system. Proper installation of the new E-Box and control board restores the unit's ability to regulate temperature effectively, manage energy consumption through its inverter technology, and maintain communication with the indoor unit. The replacement kit includes all necessary components to facilitate a complete and correct exchange, ensuring the unit operates as designed after the service. The new control board will maintain the same dip switch settings (SW4/SW5/J2) as the replaced board, which are critical for proper system configuration.

Maintenance Features:

The document details a step-by-step maintenance procedure for replacing the E-Box. Key steps include:

Power Disconnection and Safety: Turning off power and waiting 3 minutes to allow stored DC voltage to dissipate, followed by verification of low DC voltage. This is a critical safety measure due to the 380 Volts DC potential.
Access Panel Removal: Removing the access panel to the control board, retaining screws for reuse.
Sensor Disconnection: Removing T3 and T4 sensors by disconnecting their white covers.
Top Cover Removal: Unscrewing 16 screws to remove the top cover, taking care not to damage heat exchanger fins. The fan motor must be disconnected from the control board before removing the top cover.
Wire Management: Cutting zip ties bundling control board wires and E-box gaskets, and taking a picture of existing wiring for reference before disconnecting all component wires from the old control board.
E-Box Removal: Unscrewing 7 screws to remove the old E-box, sliding it up and out.
Bottom Access Panel Removal: Unscrewing 2 screws from the panel and 2 screws mounting the "true suction" service port to remove the Bottom Access Panel.
Reactor Box Removal: Unscrewing 4 screws to remove the reactor box and its white wiring harness, which are not needed for the new control board. Caution is advised as the reactor box is heavy.
New E-Box Installation: Sliding the new E-box into place from the top, ensuring it aligns with guide rails, and securing it with saved screws.
Wiring Routing: Routing compressor wires and ground to the top of the E-box and securing them with a wire clip. All other component wires are fed through the right gasket hole, with the orange CCH wire routed through a separate slot.
Bottom Access Panel and Sensor Reinstallation: Mounting the new Bottom Access Panel with 4 screws, securing the true suction service port, and reinstalling the T4 temperature sensor.
Top Panel Reinstallation: Placing the top panel back on, ensuring wires from the top panel, OD fan, motor capacitor, and capacitor ground are fed through the E-box slot, then securing the panel with screws.
Wiring Connections: Connecting all wires to the new control board according to the provided wiring diagram, including thermostat wires to the CN9 harness and L1/L2 to the high voltage terminal block.
Final Checks: Double-checking all wire connections, grounding, and screw positions, and verifying SW4/SW5/J2 dip switch positions match the original configuration.
Access Panel Reinstallation: Screwing the access panel back onto the control board.

The instructions emphasize safety warnings regarding hazardous voltage and product damage due to static electricity or improper handling. Grounding requirements are highlighted to prevent equipment damage or personal injury. The use of zip ties for securing wiring is also specified.