Bosch IDS BOVA 1.0 Owner's manual

Technical Instructions
E-Box Replacement
Bosch IDS BOVA 1.0
3 Ton
BTC 761702110 B / 09.2022

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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

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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
1
3
45
6
2
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

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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
T4
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

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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

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

United States and Canada
Bosch Thermotechnology Corp.
65 Grove St.
Watertown, MA 02472
Tel: [phone]
Fax: [phone]
www.bosch-thermotechnology.us
BTC 761702110 B / 09.2022
Bosch Thermotechnology Corp. reserves the right
to make changes without notice due to continuing
engineering and technological advances.