Bosch LM Series User manual

Installation, Operation and Maintenance Manual

LM Series Heat Pump

8 733 905 315 (2013/9)

LM024 | LM036 | LM048 | LMO60 | LM070

2| LM Series Heat Pump

LM Series Heat Pump8 733 905 315 (2013/9) Subject to change without prior notice

CONTENTS

Standard package.............................................................. 4

General Description........................................................... 4

Moving and Storage........................................................... 5

Initial Inspection ............................................................... 5

Location............................................................................ 5

Blower Configurability....................................................... 5

Return and Discharge Duct Flanges .................................... 6

Mounting Vertical Units ..................................................... 6

Mounting horizontal Units .................................................. 6

Condensate Drain.............................................................. 7

Duct System...................................................................... 7

Piping............................................................................... 8

Electrical .......................................................................... 8

Safety Devices and the UPM Controller ......................... 10

ECM INTERFACE BOARD- Constant Airflow Motor (Option)..

Dehumidification Method Selector ............................... 14

Constant Torque Motors (ECM) ........................................ 14

Options........................................................................... 15

Hot Gas Reheat (HGRH).............................................. 15

Electric Heat ............................................................. 15

Constant Airflow Motor............................................... 15

Fan Status Switch ...................................................... 15

Pump Status Switch ................................................... 15

DPS Water Flow Proving ............................................. 16

Valve End Switch ....................................................... 16

Pump Relay............................................................... 16

Sequence of Operation .................................................... 16

Cooling Mode ............................................................ 16

Heating Mode............................................................ 16

Application Considerations .............................................. 18

Cooling Tower/Boiler Systems ..................................... 18

Geothermal Systems .................................................. 20

System Checkout ............................................................ 21

Unit Start-up ................................................................... 21

Maintenance ................................................................... 21

Access to Internal Components for Vertical (VT) Units ..... 22

Unit Check-Out Sheet ...................................................... 23

Customer Data .......................................................... 23

Unit Nameplate Data .................................................. 23

Operating Conditions ................................................. 23

Auxiliary Heat............................................................ 23

Troubleshooting ..............................................................24

Electronic Thermostat Installation ....................................29

Operating Temperatures and Pressures ............................30

Airflow Tables..................................................................35

Wiring Diagrams ..............................................................37

WIRING HARNESS DRAWINGS ..........................................50

Dimensional Drawings......................................................54

Horizontal - Straight Through .......................................55

Horizontal - Hanging bracket location ............................56

Vertical.....................................................................57

Notes ..............................................................................58

| 3LM Series Heat Pump

8 733 905 315 (2013/9)Revised 09-13

MODEL NOMENCLATURE

LM 024 - 1 VT C - F L T - T A

Size Revision Level

024 A - Current

036

048 Fan/Motor Options

060 A - Constant Airflow ECM

070 T - Constant Torque ECM

Voltage Discharge Air Configuration

1 208-230/60/1 T - Top (VT only)

2 277/60/1 S - Straight (HZ only)

3 208-230/60/3 E - End (HZ only)

4 460/60/3

Return Air Configuration

Cabinet Configuration

L - Left

HZ - Horizontal

R - Right

VT - Vertical

Water Connections

Coax Options

F - Front

C - Copper

N - Cupro-Nickel

Installation and servicing of this equipment

can be hazardous due to system pressure

and electrical components. Only trained

and qualified personnel should install,

repair, or service the equipment.

Before performing service or maintenance

operations on the system, turn off main

power to the unit. Electrical shock could

cause personal injury or death.

When working on equipment, always

observe precautions described in the

literature, tags, and labels attached to the

unit. Follow all safety codes. Wear safety

glasses and work gloves. Use a quenching

cloth for brazing, and place a fire

extinguisher close to the work area.

All refrigerant discharged from this unit

must be recovered WITHOUT EXCEPTION.

Technicians must follow industry accepted

guidelines and all local, state, and federal

statutes for the recovery and disposal of

refrigerants. If a compressor is removed

from this unit, refrigerant circuit oil will

remain in the compressor. To avoid leakage

of compressor oil, refrigerant lines of the

compressor must be sealed after it is

removed.

To avoid equipment damage, DO NOT use

these units as a source of heating or cooling

during the construction process. Doing so

may affect the unit’s warranty. The

mechanical components and filters will

quickly become clogged with construction

dirt and debris, which may cause system

damage.

4| Standard package LM Series Heat Pump

LM Series Heat Pump8 733 905 315 (2013/9) Subject to change without prior notice

STANDARD PACKAGE

Figure # 1

[1] LM Series Water-to-Air Heat Pump

[2] Installation and Operation Manual

[3] Hanging Bracket Kit (Hz Units Only)

GENERAL DESCRIPTION

LM Series Water-to-Air Heat Pumps provide the

best combination of performance and efficiency

available. All units are performance certified to

American Heating and Refrigeration Institute

(AHRI) ISO Standard 13256-1. All LM Water-to-Air

Heat Pumps conform to UL1995 standard and are

certified to CAN/CSA C22.1 No 236 by Intertek-

ETL.

The Water-to-Air Heat Pumps are designed to

operate with entering fluid temperature between

20°F to 90°F in the heating mode and between

30°F to 120°F in the cooling mode.

LM Series Water-to-Air Heat Pumps are available in

Vertical (VT) and Horizontal (HZ) configurations.

VT and HZ units Discharge Air Orientation is Field

Configurable with the purchase of a separate kit.

Several factory installed options are available:

Hot Gas Reheat, Electric Heat, Sound Package,

Smart Start, Constant Airflow Blower Motor, 2” 4-

sided filter racks, MERV 8 & 13 filters, Differential

Pressure Switch (DPS) Water Flow Proving Switch,

Auxiliary Pump Relay, Air Flow Proving Sensor,

Zone Valve and Internal Water Pump. See Pg#15

for more detail.

Safety devices are built into each unit to provide

the maximum system protection possible when

properly installed and maintained. Each unit has an

external LED error code display, allowing unit

diagnosis without opening the cabinet.

Basic Horizontal Unit layout and connections are

shown in Figure #2 . For more detail on both the

Vertical and Horizontal units, refer to the

Dimensional Drawings on Pg#55 through Pg#58.

50° Minimum Entering Water Temperature

(EWT) for well water applications with sufficient

water flow to prevent freezing. Antifreeze

solution is required for all closed loop

applications. Cooling Tower/Boiler and

Geothermal applications should have sufficient

antifreeze solution to protect against extreme

conditions and equipment failure. Frozen water

coils are not covered under warranty. Other

equivalent methods of temperature control are

acceptable.

Electric Heat is available as a factory installed

option ONLY.

Moving and Storage | 5LM Series Heat Pump

8 733 905 315 (2013/9)Revised 09-13

Figure # 2 Left-Hand Unit (Right-Hand Unit is opposite view)

[1] Air handler access panel

[2] Condensing section access panel

[3] Condensate drain connection

[4] Water connection

[5] Electrical connection knockout

[6] Electric Heat electrical connection knockout

(Optional)

[7] Blower outlet (Supply Air)

[8] LED Error Code

MOVING AND STORAGE

If the equipment is not needed for immediate

installation upon its arrival at the job site, it should

be left in its shipping carton and stored in a clean,

dry area. Units must only be stored or moved in the

normal upright position as indicated by the “UP”

arrows on each carton at all times.

INITIAL INSPECTION

Be certain to inspect all cartons or crates on each

unit as received at the job site before signing the

freight bill. Verify that all items have been received

and that there are no visible damages; note any

shortages or damages on all copies of the freight

bill. In the event of damage or shortage, remember

that the purchaser is responsible for filing the

necessary claims with the carrier. Concealed

damages not discovered until after removing the

units from the packaging must be reported to the

carrier within 24 hours of receipt.

LOCATION

Locate the unit in an indoor area that allows easy

removal of the filter and access panels, with

enough room for service personnel to perform

maintenance or repair. Provide sufficient room to

make fluid, electrical, and duct connection(s). If

the unit is located in a confined space such as a

closet, provisions must be made for return air to

freely enter the face of unit’s air coil. On horizontal

units, allow adequate room below the unit for a

condensate drain trap and do not locate the unit

above supply piping.

BLOWER CONFIGURABILITY

To change configuration of the LM unit requires

the purchase of a separate Blower panel

Conversion Kit. Please refer to the Spare Parts

List_8733911143 (On website www.fhp-mfg.com)

and the Blower Configurability IM_8733911121.

For storage If unit stacking is required,

stack units as follows:

Do not stack 6 ton units!

Vertical units: less than 6 tons, no more

than two high.

Horizontals units: less than 6 tons, no more

than three high.

These units are not approved for outdoor

installation; therefore, they must be

installed inside the structure being

conditioned. Do not locate in areas that are

subject to freezing.

6| Return and Discharge Duct Flanges LM Series Heat Pump

LM Series Heat Pump8 733 905 315 (2013/9) Subject to change without prior notice

RETURN AND DISCHARGE DUCT

FLANGES

Return and discharge opening duct flanges are

shipped unfolded. Flanges bend lines are

perforated allowing easy bending using standard

sheet metal pliers or channel locks. (Figure #3)

Figure # 3

MOUNTING VERTICAL UNITS

Vertical units should be mounted level on a

vibration absorbing pad slightly larger than the

base to minimize vibration transmission to the

building structure. It is not necessary to anchor the

unit to the floor. (Figure #4).

Figure # 4

MOUNTING HORIZONTAL UNITS

While horizontal units may be installed on any level

surface strong enough to hold their weight, they

are typically suspended above a ceiling by

threaded rods. The manufacturer recommends

these be attached to the unit corners by hanger

bracket kits. The rods must be securely anchored

to the ceiling. Refer to the hanging bracket

assembly and installation instructions for details.

Plumbing connected to the heat pump must not

come in direct contact with joists, trusses, walls,

etc. Some applications require an attic floor

installation of the horizontal unit. In this case the

unit should be set in a full size secondary drain pan

on top of a vibration absorbing mesh.

The Secondary drain pan prevents possible

condensate overflow or water leakage damage to

the ceiling.

The secondary drain pan is usually placed on a

plywood base isolated from the ceiling joists by

additional layers of vibration absorbing mesh. In

both cases, a 3/4”drain connected to this

secondary pan should be run to an eave at a

location that will be noticeable.

Bend flanges one at a time, using standard

sheet metal pliers or channel locks.

On VT Units Condensate Drain pan is internally

sloped. There is no internal P-Trap.

Horizontal units installed above the ceiling

must conform to all local codes. An auxiliary

drain pan if required by code, should be at

least four inches larger than the bottom of

the heat pump.

VIBRATION

PAD FULL SIZE

Condensate Drain | 7LM Series Heat Pump

8 733 905 315 (2013/9)Revised 09-13

If the unit is located in a crawl space, the bottom

of the unit must be at least 4” above grade to

prevent flooding of the electrical parts during

heavy rains.

CONDENSATE DRAIN

Figure # 5

A drain line must be connected to the heat pump

and pitched away from the unit a minimum of 1/8”

per foot to allow the condensate to flow away from

the unit.

This connection must be in conformance with local

plumbing codes. A trap must be installed in the

condensate line to insure free condensate flow.

A vertical air vent is sometimes required to avoid

air pockets. The length of the trap depends on the

amount of positive or negative pressure on the

drain pan. A second trap must not be included.

DUCT SYSTEM

A supply air outlet collar and return air duct flange

are provided on all units to facilitate duct

connections.

Fold the d uct flange out wards along the perforated

line. Refer to unit Dimensional Drawings for

physical dimensions of the collar and flange.

(Pg#55 through Pg#58)

A flexible connector is recommended for supply

and return air duct connections on metal duct

systems. All metal ducting should be insulated

with a minimum of one inch duct insulation to

avoid heat loss or gain and prevent condensate

forming during the cooling operation. Application

of the unit to uninsulated duct work is not

recommended as the unit’s performance will be

adversely affected.

The factory provided air filter must be removed

when using a filter back return air grill. The factory

filter should be left in place on a free return

system.

If the unit will be installed in a new installation

which includes new duct work, the installation

should be designed using current ASHRAE

procedures for duct sizing. If the unit is to be

connected to existing duct work, a check should

be made to assure that the duct system has the

capacity to handle the air required for the unit

application. If the duct system is too small, larger

duct work should be installed. Check for existing

leaks and repair.

The duct system and all diffusers should be sized

to handle the designed air flow quietly. To

maximize sound attenuation of the unit blower, the

supply and return air plenums should be insulated.

There should be no direct straight air path thru the

return air grille into the heat pump. The return air

inlet to the heat pump must have at least one 90

degree turn away from the space return air grille. If

air noise or excessive air flow are a problem, the

blower speed can be changed to a lower speed to

reduce air flow.

Horizontal (HZ) units must be installed

pitched toward the Condensate Drain

Connection 1/8” per foot.

HZ Heat Pump Drain Pan is not internally

sloped.

Supply air duct and return air duct flanges are

shipped unfolded with unit.

Do not connect discharge ducts directly to

the blower outlet.

8| Piping LM Series Heat Pump

LM Series Heat Pump8 733 905 315 (2013/9) Subject to change without prior notice

PIPING

Supply and return piping must be as large as the

unit connections on the heat pump (larger on long

runs).

LM units are supplied with either a copper or

optional cupro-nickel condenser. Copper is

adequate for ground water that is not high in

mineral content.

In conditions anticipating moderate scale

formation or in brackish water a cupro-nickel heat

exchanger is recommended.

Both the supply and discharge water lines will

sweat if subjected to low water temperature.

These lines should be insulated to prevent damage

from condensation. All manual flow valves used in

the system must be ball valves. Globe and gate

valves must not be used due to high pressure drop

and poor throttling characteristics.

Always check carefully for water leaks and repair

appropriately. Units are equipped with female pipe

thread fittings. Consult Unit Dimensional

Drawings. (Pg#55 through Pg#58)

Flexible hoses should be used between the unit

and the rigid system to avoid possible vibration.

Ball valves should be installed in the supply and

return lines for unit isolation and unit water flow

balancing.

ELECTRICAL

Refer to electrical component box layout.

(Figures #6-8)

Properly sized fuses or HACR circuit breakers must

be installed for branch circuit protection. See unit

nameplate for maximum fuse or breaker size.

The unit is provided with a concentric knock-out

for attaching common trade sizes of conduit, route

power supply wiring through this opening.

Always connect the ground lead to the grounding

lug provided in the control box and power leads to

the line side of compressor contactor as indicated

on the wiring diagram (Figures#25 through #31,

Pg#38 through Pg#47).

Never use flexible hoses of a smaller inside

diameter than that of the fluid connections

on the unit.

Proper testing is recommended to assure the

well water quality is suitable for use with water

source equipment.

Never exceed the recommended water flow

rates, as serious damage or erosion of the

water-to-refrigerant heat exchanger could

occur.

Teflon tape sealer should be used when

connecting water piping connections to the units

to insure against leaks and possible heat

exchanger fouling.

Do not overtighten the connections.

Field wiring must comply with local and

national electric codes.

Power to the unit must be within the

operating voltage range indicated on

the unit nameplate or on the

performance data sheet.

Operation of unit on improper line

voltage or with excessive phase

imbalance will be hazardous to the unit,

constitutes abuse and may void the

warranty.

Units supplied with internal electric heat require

two (2) separate power supplies:

1) Unit compressor

2) Electric Heat, Blower Motor and Control

Circuit.

--------------------------------------------------------------

Refer to the ELECTRIC HEATER PACKAGE

OPTION section and Pg#38 through Pg#47 for

wiring diagrams. See data plate for minimum

circuit ampacities and maximum fuse/breaker

sizing.

Electrical | 9LM Series Heat Pump

8 733 905 315 (2013/9)Revised 09-13

Figure # 6 - Single Phase Unit

Figure # 7 EBox Cover

Figure # 8 Three Phase Unit

[1] Compressor contactor

[2] Emergency Relay (Option)

[3] Second Stage Relay

[4] Hot Gas Reheat Relay (Option)

[5] Cooling Relay

[6] Unit Protection Module (UPM)

[7] Terminal block Low-Voltage

[8] Auxiliary Relay (Option)

[9] Transformer

[10] Capacitor

[11] ECM Interface Board(Option, mounts on E-

Box cover)

[12] Phase Monitor

[13] Fan Status Switch (Option)

[14] Pump Status Switch (Option)

[15] Terminal Block 460V Units (Option)

[16] Comfort Alert Module (Option)

[17] DDC (Option)

[18] LonWorks Card (Option)

[19] Input Expansion Module (Option)

[20] Smart Start Assist (Option)

[21] Ground Lug

110

10 | Electrical LM Series Heat Pump

LM Series Heat Pump8 733 905 315 (2013/9) Subject to change without prior notice

Safety Devices and the UPM Controller

Figure # 9

[1] Board Power Indicator

[2] UPM Status LED Indicator

[3] Water Coil Freeze Protection Temperature

Selection [R30]

[4] Air Coil Freeze Protection Temperature

Selection

[5] UPM Board Settings

[6] Water Coil Freeze Connection

[7] Air Coil Freeze Connection

[8] LED Status-Diagnostic Connection

[9] 24VAC Power Input

[10] Compressor Contact Output

[11] High Pressure Switch Connection

[12] Call for Compressor Y1

[13] Low Pressure Switch Connection

[14] 24VAC Power Common

[15] Condensate Overflow Sensor

[16] Dry Contact

[17] UPM Ground Standoff

Each unit is factory provided with a Unit Protection

Module (UPM) that controls the compressor

operation and monitors the safety controls that

protect the unit.

Safety controls include the following:

• High pressure switch located in the refrigerant

discharge line and wired across the HPC

terminals on the UPM

• Low pressure switch located in the unit

refrigerant suction line and wired across

terminals LPC1 and LPC2 on the UPM.

• Water side freeze protection sensor, mounted

close to condensing water coil, monitors

refrigerant temperature between condensing

water coil and thermal expansion valve. If

temperature drops below or remains at freeze

limit trip for 30 seconds, the controller will

shut down the compressor and enter into a

soft lockout condition. The default freeze limit

trip is 30°F, however this can be changed to

15°F by cutting the R30 or Freeze1 resistor

located on top of DIP switch SW1. Refer to

Figure #9, item [3] for resistor location. (Refer

to Figure #10 for sensor location)

Figure # 10

If the unit is being connected to a thermostat

with a malfunction light, this connection is made

at the unit malfunction output or relay. Refer to

Figure #9.

If the thermostat is provided with a malfunction

light powered off of the common (C) side of the

transformer, a jumper between “R” and “COM”

terminal of “ALR” contacts must be made.

7910

1213

If the thermostat is provided with a malfunction

light powered off of the hot (R) side of the

transformer, then the thermostat malfunction

light connection should be connected directly to

the (ALR) contact on the unit’s UPM board.

UPM Board Dry Contacts are Normally Open

(NO)

If unit is employing a fresh water system (no

anti-freeze protection), it is extremely

important to have the Freeze1 R30 resistor

set to 30°F in order to shut down the unit at

the appropriate leaving water temperature

and protect your heat pump from freezing if

a freeze sensor is included.

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