Bosch 19 SEER Series, Operation Manual

Page 1: ...Bosch Inverter Ducted Packaged Heat Pump 19 SEER Series 5 Ton Capacity R410A Installation Operation Manual BTC 761701105 A 2019 03 US ...

Page 2: ...2 Bosch Inverter Ducted Packaged Heat Pump Installation Operation Manual 03 2019 BTC 761701105 A Data subject to change ...

Page 3: ...Power Wiring 17 10 2 Grounding 17 10 3 Control Wiring 17 11 Start Up 19 11 1 System Start Up 19 12 System Charge Adjustment 20 12 1 Charging Weigh In Method 20 12 2 Subcooling Charging and Refrigerant Adjustment In Cooling Above 55 F Outdoor Temp 20 13 System Operation and Troubleshooting 22 13 1 Control Logic Description 22 13 2 Sensors Thermistors Pressure Transducer 22 13 3 Defrost Description ...

Page 4: ...r 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 m...

Page 5: ...operty damage or personal injury CAUTION HIGHPRESSURE 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 WARNING GROUNDINGREQUIRED Failure to inspect or use proper service tools may result in equipment damage or personal injury R...

Page 6: ... Valves HPS RV Indoor Fan Component Descriptions Component Descriptions HPS High pressure switch T3L Condensor outlet temp sensor PT Pressure transducer Tf Radiator temp sensor T2 Indoor coil temp sensor Th Comp return temp sensor T3 Condenser temp sensor EEV Electronic expansion valve T4 Ambient temp sensor RV Reversing valve T5 Comp discharge temp sensor COMP Compressor Table 1 Component Descrip...

Page 7: ...ions 3 1 Unit Dimensions Figure 2 2 1 4 6 5 8 6 5 8 15 1 2 8 1 16 W 2 3 16 5 1 2 6 5 8 6 5 8 9 5 16 B L Front H A 2 3 8 HeatPumpModel L W H A B BRB 60HWD1N1 M19 51 9 16 44 13 16 51 7 16 47 5 16 19 11 16 Table 2 Unit Dimensions HeatPumpModel Net Weight Gross Weight BRB 60HWD1N1 M19 561 lbs 255kg 596 lbs 271kg Table 3 Unit Weights ...

Page 8: ...nsions Back and Bottom Figure 3 Bottom view 4 3 4 12 15 16 OPTIONAL RETURN AIR OPENING OPTIONAL SUPPLY AIR OPENING C 2 3 16 D E E F Back view 6 3 16 5 3 16 H 13 9 16 SUPPLY DUCT OPENING RETURN DUCT OPENING H G HeatPumpModel C D E F G H BRB 60HWD1N1 M19 49 1 4 42 1 2 14 1 8 16 1 8 15 7 8 13 7 8 Table 4 Dimensions Back and Bottom ...

Page 9: ... Inverter Ducted Packaged Heat Pump 9 BTC 761701105 A 03 2019 Data subject to change 3 3 Dimensions Right and Top Figure 4 Top View Right side view Condensate drain connection 3 4 NPT Trap required 22 3 8 4 9 16 8 1 16 6 5 8 15 1 2 6 5 8 ...

Page 10: ...the unit When rigging lifting the unit the minimum height between the top of the rigging cables connection point and top of unit should be 36 in Refer to Figure 5 CAUTION Before lifting make sure the unit weight is distributed equally on the rigging cables so it will lift evenly CAUTION All panels must be secured in place when the unit is lifted The condenser coils should be protected from rigging...

Page 11: ...l code requirements for additional clearance requirements Figure 8 Min 24 Min 12 to Shrubbery Access Panel Supply Air Duct Figure 9 Min 24 Snow barrier 3 12 Elevation Snow legs pad Corrosive Environment Exposure to a corrosive environment may shorten the life of the equipment corrode metal parts and or negatively affect unit performance Corrosive elements include but are not limited to sodium chlor...

Page 12: ...o the roof curb is critical for a water tight seal Install gasketing material supplied with the field supplied roof curb Improperly applied gasketing also can result in air leaks and poor unit performance NOTICE The unit must be secured to the curb by installing screws through the bottom of the curb flange and into the unit base rails Figure 10 A A A A SUPPLY AIR RETURN AIR 1 1 E F C C 12 1 16 12 ...

Page 13: ...atts 435 450 466 479 494 507 521 535 551 Tap 5 SCFM 2339 2307 2247 2204 2135 2056 1922 1800 1659 Watts 695 707 725 734 747 746 737 719 686 Table 6 Boldoutlinedareasrepresentairflowoutsideoftherequired300 450cfm ton range NOTES 1 The high stage airflow must be used as the rated airflow for the full load operation of machine 2 The rated airflow of systems without electric heater kits requires between 30...

Page 14: ...Optional IDP has a Passive Dehumidification function which lowers the fan speed first stage with a DH call from the thermostat This function requires proper DH wiring from the indoor unit to the thermostat with a humidistat If DH wire is not connected the unit will still function normally 7 Ductwork Field ductwork must comply with the National Fire Protection Association NFPA 90A NFPA 90B and any ap...

Page 15: ...oofed Be sure to note supply and return openings Refer to Fig 3 for information concerning supply and return air duct dimensions Figure 12 Return Air Supply Air Roof Flashing Angle Iron Frame Rooftop Installation Frame Mounting Rooftop Installation Frame Mounting Figure 13 SHEET METAL SCREWS HORIZONTAL RETURN AIR COVER HORIZONTAL SUPPLY AIR COVER Figure 14 Roof Flashing Return Air Supply Air Roof ...

Page 16: ...in pan do not overtighten Over tightening fittings can split pipe connections on the drain pan 9 Air Filter Not Factory Installed Filters and filter racks are not included with the unit and must be field supplied An external filter or other means of filtration must be properly sized for a maximum of 300 feet min air velocity or what is recommended for the type of filter installed Filter application and ...

Page 17: ...ized larger than the branch circuit protection Supply circuit power wiring must be 221 F minimum copper conductors only See Table 8 for ampacity wire size and circuit protector requirements Supply circuit protective devices may be either fuses or HACR type circuit breakers 1 3 8 knockouts inside the cabinet are provided for connection of power wiring to electric heater Power wiring is connected to...

Page 18: ...COOL here represents 2 stages of fan cooling only the compressor modulates separately from the fan THERMOSTAT UNIT CONTROL BOARD TERMINAL STRIP Y1 Y2 jumped for fan control not related to compressor operation 2 COOL here represents 2 stages of fan cooling only the compressor modulates separately from the fan THERMOSTAT UNIT CONTROL BOARD TERMINAL STRIP THERMOSTAT UNIT CONTROL BOARD TERMINAL STRIP ...

Page 19: ...HK 15J 11 3 15 2 54 2 62 5 68 79 70 80 EHK 20J 15 20 2 72 2 83 3 91 105 100 110 Table 9 Electrical Data With Electric Heat 1 Minimum Circuit Ampacity 2 Maximum Over Current Protection per Standard UL 1995 3 Fuse or HACR circuit breaker size installed at factory or field installed Max Fuse Breaker Sizes listed in Table 9 are for electric heater ONLY DOES NOT include breaker size for the unit refer t...

Page 20: ...ratures For outdoor ambient temperatures below 55 F use weigh in charge method It is important to return in the spring or summer to accurately charge the system in the cooling mode when outdoor ambient temperature is above 55 F Figure 22 55ºF Outdoor Temp1 120ºF Outdoor Temperature Above 55ºF 55ºF Outdoor Temp2 Outdoor Temperature Below 55ºF For best results the indoor temperature should be kept b...

Page 21: ...ling BRB 60HWD1N1 M19 12 F 4 F Table 12 5 Adjust refrigerant level to attain proper gauge pressure Add refrigerant if the subcooling reading from Table 11 is lower than the designed value Table 12 Connect gauges to refrigerant bottle and unit as illustrated Figure 25 Purge all hoses Open tank Stop adding refrigerant when subcooling matches the charging chart Table 11 Final Subcooling value Recover...

Page 22: ...nabled SW4 4 ON Accelerated cooling heating OFF Normally cooling heating Table 14 Factory Default Adaptive capacity function is a self learning function which allows a range of target coil temperatures to adapt for better unit operation and reduced short cycling Accelerated cooling heating function changes the initial target coil temperature to provide enhanced comfort by increasing unit capacity ...

Page 23: ...ter defrost Quit defrost Table 15 Manual Defrost 1 System must have a call for heat and have been operating for a minimum of 8 minutes 2 Press Force button on inverter board for 6 seconds to begin forced defrost 3 Wait approximately 40 seconds for defrost to initiate 4 Once defrost initiates the display will indicate dF 5 Defrost test will terminate automatically after which the display will indic...

Page 24: ... ii If DT 194 F during cooling mode the compressor will restart iii If DT 221 F during heating mode the compressor will stop iv If DT 167 F during heating mode the compressor will restart High Pressure HP protection mechanical open close pressure switch i High Pressure Switch opens at P 580 PSIG the compressor and outdoor fan stop ii High Pressure Switch closes at P 435 PSIG the compressor and out...

Page 25: ...n motor hurricane typhoon protection PH Low discharge superheat protection F1 High pressure switch protection HPS L0 L9 The IPM module protection AtL Ambient Temperature Limited System Protection Status Codes Forced operation mode L Running indication under T3 limited condition D Running indication under T5 limited condition P Running indication under compressor ratio limited condition F Running i...

Page 26: ... is active first digit will display status code No Pointcheckcontent Example Remark 0 Outdoor unit capacity H5 H5 Heat Pump 5 ton 1 Outdoor unit mode 2 0 standby 2 cooling 3 heating 2 Outdoor unit set compressor speed Hz 66 3 T3 outdoor coil temp F 4 T4 outdoor ambient temp F 5 T5 compressor discharge temp F 6 Th compressor suction temp F 7 T3L condenser outlet temp F 8 Tf module temp F 9 Pe evapo...

Page 27: ...valve port 4 Thermostat wire connections 5 EEV port 6 Th sensor port 7 TF sensor port 8 T3 T4 T3L sensor port 9 Pressure transducer port 10 T5 sensor port 11 Reserve 12 Reserve 13 Reserve 14 High pressure switch port 15 USB port 16 SW2 FORCE BUTTON 17 SW3 CHECK BUTTON 18 J2 Dip SWITCH Select capacity 19 SW5 Dip SWITCH Defrost logic settings 20 SW4 Dip SWITCH Control logic settings 21 Reserve 22 IC...

Page 28: ...or condenser coil is blocked No Check whether there is short circuit in air outlet and inlet side No Check whether the charge is correct by subcooling according to installation guide in charge mode when cooling Yes Yes Check whether there is normal throttle Replace the T3 sensor No Replace the fan or remove all the barriers Do something to avoid air return short circuit Yes Adjust refrigerant char...

Page 29: ... subcooling meet required values Refer to section 14 system charge adjustment Yes Is the blower fan motor working properly Is there any blockage on filter Are the EEV and outdoor fan motor working properly Yes Is the pressure transducer working properly Compare the data between pressure measurement and No 9 cooling or No 10 heating values by press check button Adjust charge No Fix all these and re...

Page 30: ... to wiring diagram No Replace the fault T3 T4 Th T3L sensor No Replace the fault T5 Tf sensor No No Yes seated and normal Keep running Figure 38 H8 Pressure transducer PT fault Diagnosis Handling Yes Yes Check whether there is the same fault No No Keep running No Check whether pressure transducer PT wiring are seated and normal Wire according to the diagram correctly Is the pressure transducer wor...

Page 31: ...ng Yes Check whether the sensor of T3 T5 are connected accord ing to wiring diagram Yes Check whether the resistance of T3 T5 is in the range of Table 27 and Table 28 Yes Check whether there are other heat sources around T3 T5 No Wire according to the wiring diagram correctly No Replace the fault T3 T5 sensor No Yes Check whether there is the same fault Keep running No No Check whether compressor ...

Page 32: ...rol chip Diagnosis Handling Yes No action is necessary This fault may be caused by strong interference from the electric grid The system will recover when the electric supply stabilizes No No Yes No Check whether the wiring is connected normally Reseat the wiring according to wiring diagram Restart to power on and check whether it is normal Replace the control board Replace the control board Figur...

Page 33: ... Replace the compressor and check whether there is the same faultt Keep running No Replace the compressor No Check whether the compressor wiring is normal Reseat the wiring according to wiring diagram Replace the compressor ErrorCode Description AtL Ambient Temperature Limited Table 26 When the ambient temperature returns to within the operating range the system will recover automatically Figure 4...

Page 34: ... 4 47 105 40 6 5 057 1 93 15 9 4 57 948 4 39 110 43 3 4 509 1 79 20 6 7 49 652 4 30 115 46 1 4 028 1 67 25 3 9 42 645 4 21 120 48 9 3 606 1 55 30 1 1 36 710 4 10 125 51 7 3 233 1 43 40 4 4 27 386 3 86 130 54 4 2 902 1 32 45 7 2 23 732 3 73 135 57 2 2 610 1 22 50 10 0 20 610 3 59 140 60 0 2 350 1 13 55 12 8 17 939 3 45 145 62 8 2 119 1 04 60 15 6 15 648 3 30 150 65 6 1 914 0 96 65 18 3 13 681 3 15 ...

Page 35: ... 146 695 4 74 185 85 0 5 963 2 13 45 7 2 127 258 4 70 190 87 8 5 474 2 02 50 10 0 110 707 4 66 195 90 6 5 032 1 92 55 12 8 96 572 4 61 200 93 3 4 645 1 83 60 15 6 84 465 4 56 205 96 1 4 28 1 73 65 18 3 74 411 4 51 210 98 9 3 949 1 64 70 21 1 65 408 4 45 215 101 7 3 648 1 56 75 23 9 57 634 4 39 220 104 4 3 383 1 48 80 26 7 50 904 4 32 225 107 2 3 133 1 40 85 29 4 45 258 4 24 230 110 2 904 1 32 90 3...

Page 36: ...DEF T5 SENSOR DEF Tf SENSOR DEF HPS SENSOR DEF SYSTEM Display shows nothing C P S H P S System won t start C P P S S H P P S S Capacity is insufficient C P P P P S S S H P P P P S S S S Display is not normal when running C P H P Cool when heating requirement H P S REFRIGERANT CIRCUIT P1 C P P S P H P S P P2 H5 C P P S H P P S P3 C P P S P H P S P P5 C P P S S S H S P0 C P P S H P P S P4 C P S H P S ...

Page 37: ...ng heating Adaptive capacity output disable SW4 1 Defrosting extended for 60 seconds Normal ON OFF Adaptive capacity output enable OFF ON OFF ON Unused Unused Must be set at OFF position Must be set at ON position Number Point check content 0 Outdoor unit capacity example H3 Heat pump 3 ton 1 Outdoor unit mode 0 standby 2 cooling 3 heating 2 Outdoor uint set compressor speed Hz 3 T3 outdoor coil t...

Page 38: ...not use chemicals or chemically treated cloths to clean the unit Do not use benzene paint thinner polishing powder or other solvents to clean the unit Do not operate the system without a filter in place 14 2 Regular Maintenance Your heat pump must be inspected regularly by a qualified service technician 1 Inspect the air filter every ninety days or as often as needed If blocked or obstructed clean o...

Page 39: ...Installation Operation Manual Bosch Inverter Ducted Packaged Heat Pump 39 BTC 761701105 A 03 2019 Data subject to change ...

Page 40: ...United States Bosch Thermotechnology Corp 65 Grove Street Watertown MA 02472 Tel 866 642 3198 Fax 603 965 7581 www boschheatingandcooling com BTC 761701105 A 03 2019 ...