Bosch BCA Series User manual

Installation Instructions

Split System Heat Pump

Bosch BCA Series

Ceiling Mounted Air Handler Units | 1.5-3 Ton Capacity | R410A

BTC 761703106 A / 03.2023

2 |

Installation Instructions

Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)

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Installation Instructions

Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)

Table of Contents

1 Key to Symbols and Safety Instructions 4

1.1 Key to Symbols 4

1.2 Safety 4

2 General 5

3 Dimensional Data 6

3.1 Uncased Unit Dimensions 6

3.2 Cased Unit Dimensions 7

4 Mounting 8

5 Electrical wiring 8

5.1 Power Wiring 8

5.2 Control Wiring 8

5.3 Grounding 8

5.4 Electrical Data 8

6 Airow Performance 9

6.1 Uncased Unit 9

6.2 Cased Unit 10

6.3 Required Airﬂow Range for Normal Operation 11

7 Ductwork 12

8 Refrigerant Connections 13

8.1 Condensate Drain Connection 13

9 Air Filter (Not Factory-Installed) 14

10 Maintenance 15

10.1 Cleaning Precautions 15

10.2 Regular Maintenance 15

11 Wiring Diagrams 16

11.1 Unit Wiring 17

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Installation Instructions

Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)

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:

fDANGER: indicates a hazardous situation which, if not avoided, will result

in death or serious injury.

fWARNING: indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

fCAUTION: indicates a hazardous situation which, if not avoided, could

result in minor to moderate injury.

fNOTICE: 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.

1.2 Safety

Please read before proceeding

WARNING:

These instructions are intended as an aid to qualiﬁed, licensed

service personnel for proper installation, adjustment and

operation of this unit. Read these instructions thoroughly

before attempting installation or operation. Failure to follow

these instruction may lead to improper installation, adjustment,

service or maintenance possibly resulting in ﬁre, electrical shock,

property damage, personal injury or death.

This document is customer property and is to remain with this unit.

These instructions do not cover all the diﬀerent variations of systems nor

does it provide for every possible contingency to be met in connection

with installation.

WARNING: FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE,

PERSONAL INJURY, OR DEATH

All phases of this installation must comply with NATIONAL, STATE

AND LOCAL CODES. If additional information is required please

contact your local distributor.

WARNING: ELECTRICAL SHOCK

Disconnect all power to unit before installing or servicing. More

than one disconnect switch may be required to deenergize the

equipment. Hazardous voltage can cause severe personal injury or

death.

WARNING: ELECTRICAL SHOCK

If removal of the blower assembly is required, all disconnect

switches supplying power to the equipment must be deenergized

and locked (if not in sight of unit) so the ﬁeld power wires can be

safely removed from the blower assembly. Failure to do so can

cause electrical shock resulting in personal injury or death.

WARNING: FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE,

PERSONAL INJURY, OR DEATH

Because of possible damage to equipment or personal injury,

installation, service, and maintenance should be performed

by trained, qualiﬁed service personnel. Consumer service is

recommended only for ﬁlter cleaning / replacement. Never operate

the unit with the access panels removed.

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Installation Instructions

Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)

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.

WARNING: ELECTRICAL SHOCK

The unit must be permanently grounded. Failure to do so can

result in electrical shock causing personal injury or death.

CAUTION: FIRE HAZARD

The material of plenum and ductwork must meet the latest edition

of the NFPA 90B standard.

2 General

The unit is designed for horizontal orientation and is suitable for ceiling installations

in conditioned space and are paired with IDS Light Condensers. The units have a

factory−installed TXV and are available in 18,000 through 36,000 Btuh nominal

cooling capacities.

The unit is equipped with sweat−type connections and is vapor−charged with dry

nitrogen. Units are designed for horizontal applications only. Local codes may limit

this free−air−return type unit to installation in single−level applications.

NOTICE:

The installed unit must have the required clearances as shown

in Section 3. Failure to follow these instructions may result in

equipment damage and/or premature equipment failure.

WARNING: FIRE HAZARD

Keep ﬂammable material and vapors, such as gasoline, away from

the air handler. Failure to follow these instructions can result in

death, explosion, or ﬁre.

6 |

Installation Instructions

Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)

3 Dimensional Data

3.1 Uncased Unit Dimensions

Figure 1

Top

Back

Right

Left

Uncased unit dimensions

Model

Size

Dimensions Inch [mm]

Unit Length

Unit Height

Unit Width

Supply Air Height

Supply Air Length

Mounting

Liquid Line/

Vapor Line

18 37-1/4 [946] 37-1/4 [946] 37-1/4 [946] 6-1/2 [165] 30 [762] 34-11/16 [881] 3/8/ 3/4 [9.5/ 19]

24 37-1/4 [946] 37-1/4 [946] 37-1/4 [946] 6-1/2 [165] 30 [762] 34-11/16 [881] 3/8/ 3/4 [9.5/ 19]

30 49-1/4 [1251] 49-1/4 [1251] 49-1/4 [1251] 6-1/2 [165] 42 [1067] 46-11/16 [1186] 3/8/ 3/4 [9.5/ 19]

36 49-1/4 [1251] 49-1/4 [1251] 49-1/4 [1251] 6-1/2 [165] 42 [1067] 46-11/16 [1186] 3/8/ 3/4 [9.5/ 19]

Table 1

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Installation Instructions

Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)

3.2 Cased Unit Dimensions

Figure 2

Left

Right

Cased unit dimensions

Casings are sold separately as an accessory.

Model

Size

Dimensions Inch [mm]

Unit

Length

Unit

Height

Unit

Width

Supply Air

Height

Supply Air

Length

Mounting

Return Air

Cutout

Length

Return Air

Cutout

Height

Max Filter

Length

Max Filter

Width

Liquid Line/

Vapor Line

18 43-3/8 [1102] 11-1/8 [283] 28-3/8 [720] 6-7/8 [174] 30-3/8 [771] 41-5/16 [1050] 28 [711] 7 [178] 39 [990] 15-9/16 [395] 3/8/ 3/4 [9.5/ 19]

24 43-3/8 [1102] 11-1/8 [283] 28-3/8 [720] 6-7/8 [174] 30-3/8 [771] 41-5/16 [1050] 28 [711] 7 [178] 39 [990] 15-9/16 [395] 3/8/ 3/4 [9.5/ 19]

30 55-3/8 [1407] 11-1/8 [283] 28-3/8 [720] 6-7/8 [174] 42-3/16 [1071] 53-5/16 [1354] 40 [1016] 7 [178] 51 [1295] 15-9/16 [395] 3/8/ 3/4 [9.5/ 19]

36 55-3/8 [1407] 11-1/8 [283] 28-3/8 [720] 6-7/8 [174] 42-3/16 [1071] 53-5/16 [1354] 40 [1016] 7 [178] 51 [1295] 15-9/16 [395] 3/8/ 3/4 [9.5/ 19]

Table 2

8 |

Installation Instructions

Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)

4 Mounting

Mounting slots on the top of the unit are provided for attachment of the unit to

supporting structure. The supporting structure must be designed to safely support

the full weight of the unit. Field supplied washers and bolts capable of supporting

the unit load should be used to secure the unit to the supporting structure at the

mounting slots.

The unit must be mounted level to ensure proper drainage of condensate. If the

supporting structure is not level at the mounting attachment, then spacers must be

used to level the unit.

5 Electrical wiring

Field wiring must comply with the National Electric Code (C.E.C. in Canada) and

any applicable local ordinances.

WARNING: ELECTRICAL SHOCK

Disconnect all power to unit before installing or servicing. More

than one disconnect switch may be required to deenergize the

equipment. Hazardous voltage can cause severe personal injury or

death.

5.1 Power Wiring

It is important that proper electrical power is available for connection to the unit

being installed. See the unit nameplate, wiring diagram, and electrical data in the

installation instructions for more detailed requirements.

fIf required, install a branch circuit disconnect of adequate size, located

within sight, and readily accessible from the unit.

fSupply circuit power wiring must be 221°F minimum copper conductors

only. See Electrical Data In this section for ampacity, wire size and circuit

protector requirements. Supply circuit protection devices may be either

fuses or “HACR” type circuit breakers.

fHigh voltage wiring must be connected to the red and black wiring in the

control section of the air handler.

5.2 Control Wiring

Low voltage control wiring should not be run in conduit with high voltage

wiring. Keep distance between the two conduits per local codes.

f18 AWG. color-coded low voltage wire should be used for lengths less than

100ft. For wire lengths longer than 100 ft., 16 AWG. wire should be used.

fFor low voltage wire connection location, see Figures 1 and 2.

fSee wiring diagram located on the bottom of air handler for proper wiring

instruction.

fAfter installation, ensure separation of low voltage and high voltage wiring

is maintained.

5.3 Grounding

DANGER: ELECTRICAL SHOCK

The unit must be permanently grounded. Failure to do so can

result in electrical shock causing personal injury or death.

fThe ground may consist of electrical wire or metal conduit when installed

in accordance with existing electrical codes.

fGrounding may also be accomplished by attaching ground wire(s) to

ground lug provided in the unit wiring compartment.

fUse of multiple supply circuits require grounding of each circuit to lug

provided in unit.

fGround lug is located on the upper right side of the cabinet.

5.4 Electrical Data

Model Voltage Hertz HP Speeds

Blower

Motor

FLA

Maximum

Circuit

Protector

18 208/230 60 1/3 5 2.6 15(A)

24 208/230 60 1/3 5 2.6 15(A)

30 208/230 60 1/3 5 2.6 15(A)

36 208/230 60 1/3 5 2.6 15(A)

Table 3

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Installation Instructions

Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)

6 Airow Performance

Airﬂow performance data is based on cooling performance with a coil and no ﬁlter

in place. Check the performance table for appropriate unit size selection.

External static pressure should stay within the minimum and maximum limits

shown in the table below in order to ensure proper operation of both cooling,

heating, and electric heating operation.

6.1 Uncased Unit

Model Motor Speed

SCFM, Uncased

External Static Pressure-Inches W.C. [kPa]

0[0] 0.1[.025] 0.15[.0375] 0.2[.050] 0.3[.075] 0.4[.100] 0.5[.125] 0.6[.150]

1741 670 638 612 545 470 403 336

2 925 860 819 788 727 655 588 500

3 1069 1005 973 941 886 826 683 550

4 1193 1140 1106 1071 970 850 700 560

51288 1221 1177 1133 1024 895 745 575

1741 670 638 612 545 470 403 336

2925 860 819 788 727 655 588 500

3 1069 1005 973 941 886 826 683 550

4 1193 1140 1106 1071 970 850 700 560

51288 1221 1177 1133 1024 895 745 575

1800 691 647 602 530 460 380 300

21025 921 871 820 723 628 536 448

31203 1106 1059 1011 916 822 729 636

4 1339 1266 1224 1181 1085 978 859 729

5 1468 1399 1361 1323 1253 1061 900 760

1800 691 647 602 530 460 380 300

21025 921 871 820 723 628 536 448

3 1203 1106 1059 1011 916 822 729 636

41339 1266 1224 1181 1085 978 859 729

51468 1399 1361 1323 1253 1061 900 760

Table 4 Air performance - uncased unit

Bold outlined areas represent airow outside of the required 300-450 cfm/ton

range.

NOTES:

1. Airﬂow data is without ﬁlter or electric heat. Electric Heater adds 0.05 in.

static pressure.

2. Use wet coil data for determining cooling airﬂow.

3. Bottom louver panel adds 0.05 in. static pressure.

10 |

Installation Instructions

Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)

6.2 Cased Unit

Model Motor Speed

SCFM, Cased, Back Return

External Static Pressure-Inches W.C. [kPa]

0[0] 0.1[.025] 0.15[.0375] 0.2[.050] 0.3[.075] 0.4[.100] 0.5[.125] 0.55[.1375]

1753 655 609 564 481 407 340 309

2 913 828 787 746 666 588 513 476

3 1044 982 945 904 810 700 575 500

4 1153 1058 1007 953 837 711 578 503

51163 1068 1017 963 847 719 580 506

1753 655 609 564 481 407 340 309

2913 828 787 746 666 588 513 476

3 1044 982 945 904 810 700 575 500

4 1153 1058 1007 953 837 711 578 503

51163 1068 1017 963 847 719 580 506

1801 700 651 602 508 418 331 288

21015 916 869 822 731 645 562 523

31177 1107 1069 1029 943 848 745 670

4 1327 1279 1245 1203 1098 963 795 692

5 1493 1404 1350 1289 1150 987 798 695

1801 700 651 602 508 418 331 288

21015 916 869 822 731 645 562 523

3 1177 1107 1069 1029 943 848 745 670

41327 1279 1245 1203 1098 963 795 692

51493 1404 1350 1289 1150 987 798 695

Table 5 Air performance - cased unit, back return

Bold outlined areas represent airow outside of the required 300-450 cfm/ton

range.

NOTES:

1. Airﬂow data is without ﬁlter or electric heat. Electric Heater adds 0.05 in.

static pressure.

2. Use wet coil data for determining cooling airﬂow.

3. Bottom louver panel adds 0.05 in. static pressure.

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