Bosch BOVA Series User manual

Bosch BOVA Split System Heat Pump

Condensing Units Up to 18 SEER

2-3-4-5 Ton Capacity

R410A

Installation Instructions

|Bosch IDS BOVA Installation Instructions

12.2016 |Bosch Thermotechnology Corp.Data subject to change

Installation Instructions Bosch IDS BOVA | 3

Bosch Thermotechnology Corp. |12.2016 Data subject to change

Table of Contents

1 Key to symbols and safety instructions 4

2 Unit location considerations 6

3 Unit preparation 8

4 Setting the unit 8

5 Refrigerant line considerations 9

6 Refrigerant line routing 10

7 Refrigerant line brazing 11

8 Refrigerant line leak check 13

9 Evacuation 13

10 Service valves 14

11 Electrical - low voltage 15

12 Electrical - high voltage 16

13 Start up 17

14 System charge adjustment 18

15 System operation and troubleshooting 21

|Bosch IDS BOVA Installation Instructions

12.2016 |Bosch Thermotechnology Corp.Data subject to change

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.

1.2 Safety

Please read before proceeding

CAUTION:

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 met in

connection with the installation.

Should further information be desired or should particular

problems arise which are not covered sufficiently for the

purchaser’s purposes, the matter should be referred to your

installing dealer or local distributor.

The manufacturer recommends installing only approved

matched indoor and outdoor systems. All of the manufacturer’s split

systems are A.H.R.I. rated only with TXV indoor systems. Some of the

beneﬁts of installing approved matched indoor and outdoor split systems

are maximum eﬃciency, optimum performance and the best overall

system reliability.

This document contains a wiring diagram and service information.

This is customer property and is to remain with this unit. Please return to

service information pack upon completion of work.

CAUTION:

This information is intended for use by individuals possessing

adequate backgrounds of electrical and mechanical

experience. Any attempt to repair a central air conditioning

product may result in personal injury and/or property

damage.

WARNING: HAZARDOUS VOLTAGE

Failure to follow this warning could result in property damage,

severe personal injury, or death.

Disconnect all electric power, Including remote disconnects

before servicing. Follow proper lockout/tagout procedures to

ensure the power cannot be inadvertently energized.

Installation Instructions Bosch IDS BOVA | 5

Bosch Thermotechnology Corp. |12.2016 Data subject to change

WARNING: REFRIGERANT OIL

Any attempt to repair a central air conditioning product may

result in property damage, severe personal injury, or death.

These units use R-410A refrigerant which operates at 50 to

70% higher pressures than R-22. Use only R-410A approved

service equipment. Refrigerant cylin-ders are painted a

“Rose” color to indicate the type of refrigerant and may

contain a “dip” tube to allow for charging of liquid refrigerant

into the system. All R-410A systems with variable speed

compressors use a PVE oil that readily absorbs moisture

from the atmosphere To limit this ‘hygroscopic“ action. the

system should remain sealed whenever possible. If a system

has been open to the atmosphere for more than 4 hours, the

compressor oil must be replaced. Never break a vacuum with

air and always change the driers when opening the system for

component replacement.

CAUTION: HOT SURFACE

May cause minor to severe burning. Failure to follow this

Caution could result in property damage or personal injury.

Do not touch top of compressor.

CAUTION: CONTAINS REFRIGERANT

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.

CAUTION: GROUNDING REQUIRED

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.

CAUTION: INDOOR UNIT REQUIRED

The indoor units must be matched with TXV. The model of TXV

can be changed according to the system capacity.

WARNING: SERVICE VALVES

Failure to follow this warning will result in abrupt release

of system charge and may result in personal injury and/

or property damage. Extreme caution should be exercised

when opening the Liquid Line Service valve. Turn valve stem

counterclockwise only until the stem contacts the rolled edge.

No torque is required.

WARNING: BRAZING REQUIRED

Failure to inspect lines or use proper service tools may result

in equipment damage or personal injury. if using existing

refrigerant lines make certain that all joints are brazed, not

soldered.

WARNING: HIGH CURRENT LEAKAGE

Failure to follow this warning could result in property damage,

severe personal injury, or death.

Grounding is essential before connecting electrical supply.

|Bosch IDS BOVA Installation Instructions

12.2016 |Bosch Thermotechnology Corp.Data subject to change

2 Unit location considerations

2.1 Unit dimensions

Unit Dimensions

Models H x W x L (Inches)

BOVA-36 24-15/16 x 29-1/8 x 29-1/8

BOVA-60 33-3/16 x 29-1/8 x 29-1/8

Table 1

The unit’s weight values is on the carton box.

When mounting the outdoor unit on a roof, be sure the roof will support the unit’s

weight. Properly selected isolation is recommended to prevent sound or vibration

transmission to the building structure.

Figure 1

2.2 Refrigerant piping limits

Maximum line equivalent length = 100 feet.

Maximum vertical equivalent length = 50 feet.

Use only the line diameters indicated in Table 5.1.

If the suction line sets are greater than 60 feet do not use a larger suction

line than recommended.

Standard Line

Set 100’ Max

Line Length

50’ Max

Line Lift

50’Max

LineLift

Figure 2

Installation Instructions Bosch IDS BOVA | 7

Bosch Thermotechnology Corp. |12.2016 Data subject to change

2.3 Location restrictions

Ensure the top discharge area is unrestricted for at least 60 inches above the unit.

Do not locate outdoor unit near bedrooms since normal operational sounds may be

objectionable.

Position unit to allow adequate space for unobstructed airﬂow, wiring, refrigerant

lines, and serviceability.

Allow a minimum of 12 in. clearance on one side of access panel to a wall and a

minimum of 24 in. on the adjacent side of access panel.

Maintain a distance of 24 in. between units.

Position unit so water, snow, or ice from roof or overhang cannot fall directly on unit.

See Fig. 3 and Fig. 4.

Cold climate considerations (heat pump only)

Precautions must be taken for units being installed in areas where

snow accumulation and prolonged below-freezing temperatures occur.

Units should be elevated 3-12 inches above the pad or rooftop, depending

on local weather. This addi-tional height will allow drainage of snow and ice

melted durIng defrost cycle prior to its refreezlng. Ensure that drain holes

in unit base pan are not obstructed, preventing drainage of defrost water

(Fig. 5).

If possible, avoid locations that are likely to accu-mulate snow drifts. if not

possible, a snow drift barrier should be installed around the unit to prevent

a build-up of snow on the sides of the unit.

Min. 20” to

Shrubbery

Avoid Install

Near Bedrooms

Min. 60” Unrestricted

Access Panel

Min. 36”

Unrestricted

Figure 3

Min. 20” to

Shrubbery

Min. 36” to

Shrubber

Access Panel

Figure 4

Min 12"

Snow

barrier

3- 12" Elevation

Snow legs

pad

Figure 5

|Bosch IDS BOVA Installation Instructions

12.2016 |Bosch Thermotechnology Corp.Data subject to change

3 Unit preparation

3.1 Prepare the unit for installation

STEP 1 - Check for damage and report promptly to the carrier any damage

found to the unit (Fig. 6).

The charge port can be used to check to be sure the refrigerant charge has

been retained during shipment.

Figure 6

4 Setting the unit

4.1 Pad installation

When installing the unit on a support pad, such as a concrete slab, consider the

following:

The pad must be at least 1-2” larger than the unit on all sides.

The pad must be separate from any structure.

The pad must be level.

The pad must be high enough above grade to allow for drainage.

The pad location must comply with National, State, and Local codes.

These instructions are intended to provide a method to tie-down system to

cement slab as a securing procedure for high wind areas. Check Local

Codes for tie-down methods and protocols.

Figure 7

#7 X 3/8” Self Tapping Screws

(Don’t Exceed 3/8” long)

Detail A

The dimension

see Unit Dimensions.

See Detail A

Brackets:

2" width, 1/16" thickness,

height as required.

Available from distributor

or in market place.

1/4” Χ 1-1/2” Hex Washer Head Concrete Screws

(3/16” Pilot Hole Needed. Pilot Hole Should Be1/4” Deeper

Than The Fastener Embedment)

Figure 8

Installation Instructions Bosch IDS BOVA | 9

Bosch Thermotechnology Corp. |12.2016 Data subject to change

5 Refrigerant line considerations

5.1 Refrigerant line and service valve connection sizes

Models Suction line Liquid line Suction line

connection

Liquid line

connection

BOVA-36 3/4 3/8 3/4 3/8

BOVA-60 7/8 3/8 7/8 3/8

Table 2

5.2 Required refrigerant line length

Determine required line length (Fig. 9).

Line Length

Figure 9

5.3 Refrigerant line insulation

The Suction Line must always be insulated. DO NOT allow the Liquid Line

and Suction Line to come in direct (metal to metal) contact.

Suction Line

Liquid Line

Insulation

Figure 10

5.4 Reuse existing refrigerant lines

CAUTION:

If using existing refrigerant lines make certain that all joints

are brazed, not soldered.

For retroﬁt applications, where the existing refrigerant lines will be used, the

following precautions should be taken:

Ensure that the refrigerant lines are the correct size. Refer to Section 5.1

listed and Table 2.

Ensure that the refrigerant lines are free of leaks, acid, and oil.

The manufacturer recommends installing only approved matched indoor

and outdoor systems. All of the manufacturer’s split systems are A.H.R.I.

rated only with TXV indoor systems. Some of the beneﬁts of installing

approved matched indoor and outdoor split systems are maximum

eﬃciency, optimum per-formance and the best overall system reliability.

Figure 11

|Bosch IDS BOVA Installation Instructions

12.2016 |Bosch Thermotechnology Corp.Data subject to change

6 Refrigerant line routing

6.1 Precautions

Take precautions to prevent noise within the building structure due to

vibration transmission from the refrigerant lines. For Example:

When the refrigerant lines have to be fastened to floor joists or

other framing in a structure, use isolation type hangers.

Isolation hangers should also be used when refrigerant lines are

run in stud spaces or enclosed ceilings.

Where the refrigerant lines run through a wall or sill, they should

be insulated and isolated.

Isolate the lines from all ductwork.

Minimize the number of 90º turns.

Isolation From Joist/Rafter

Side View

8FeetMaximum

Joist/Raft er

Isolator

Line Set

8 Feet Maximum

Secure Suc tion line from joists using isolators every 8 ft. Secure

Liquid Line directly to Suction line using tape, wire, or other

approp riate method every 8 ft.

Figure 12

Isolation In Wall Spaces

Side View

Wall

Isolator

Line Set

8 Feet Maximum

Secure Suction Line using isolators every 8 ft. Secure Liquid Line

directly to Suc tion Line using tape, wire, or other appropriate

method every 8 ft.

8FeetMaximum

Figure 13

Comply with National, State, and Local Codes when isolating line sets from

joists, rafters, walls, or other structural elements.

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