Bosch Climate 5000 Series User manual

Bosch Ducted Type (Medium & High Static)
Air Conditioner / Heat Pump
Climate 5000 Series
Installation Manual

2 |Bosch Climate 5000 Series Ducted Type (Medium & High Static) Air Conditioner / Heat Pump Installation Manual
05.2019 |Bosch Thermotechnology Corp.
Data subject to change

Installation Manual Bosch Climate 5000 Series Ducted Type (Medium & High Static) Air Conditioner / Heat Pump | 3
Bosch Thermotechnology Corp. |05.2019 Data subject to change
Table of Contents
1 Key to Symbols and Safety Instructions 4
1.1 Key to Symbols 4
1.2 Safety 4
2 Components 6
3 Installation Summary 7
4 System Components 8
4.1 9K ~ 48K Models (Medium Static) 8
4.2 60K Model (High Static) 9
5 Indoor Unit Installation 10
6 Outoor Unit Installation 20
7 Refrigerant Piping Connection 23
7.1 Connection Instructions – Refrigerant Piping 23
8 Connecting Signal/Power Cable 25
8 Air Evacuation 28
8.1 Preparations and Precautions 28
8.2 Evacuation Instructions 28
8.3 Adding Refrigerant 29
9 Electrical and Gas Leak Checks 30
9.1 Electrical Safety Checks 30
9.2 Gas Leak Checks 30
10 Test Run 31
10.1 Before Test Run 31
10.2 Test Run Instructions 31
11 Disposal Guidelines 32

4 |Bosch Climate 5000 Series Ducted Type (Medium & High Static) Air Conditioner / Heat Pump Installation Manual
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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 safety precautions before installation
Incorrect installation due to ignoring instructions can cause serious damage or
injury.
WARNING: ELECTRICAL HAZARD
Do not modify the length of the power supply cord or use an
extension cord to power the unit.
Do not share the electrical outlet with other appliances.
Improper or insufficient power supply can cause fire or
electrical shock.
WARNING: INSTALLATION REQUIREMENTS
Installation must be performed by a licensed contractor,
and per the instructions in the installation manual. Improper
installation can cause water leakage, electrical shock, or fire.
In North America, installation must be performed in
accordance with the requirement of NEC (National Electric
Code) and CEC (Canadian Electric Code) by licensed and
qualified personnel only.
Only contact a licensed contractor for repair or maintenance
of this unit.
Only use the included accessories, parts, and specified
parts for installation. Using non-standard parts can cause
water leakage, electrical shock, fire, and can cause the unit
to fail.
Install the unit in a solid location that can support the unit’s
weight. If the chosen location cannot support the unit’s
weight, or the installation is not done properly, the unit may
drop and cause serious injury and/or damage.
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.

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WARNING: ELECTRICAL HAZARD
For all electrical work, follow all local and national wiring
standards, regulations, and the Installation Manual.
The power supply to the outdoor unit requires a service
disconnect at the unit. Only use a dedicated circuit. Never
share a power source connected to this system. Insufficient
electrical capacity or defects in electrical work can cause
electrical shock or fire.
For all electrical work, use the specified cables. Connect
cables tightly, and clamp them securely to prevent external
forces from damaging the terminal. Improper electrical
connections can overheat and cause fire, and may also
cause shock.
All wiring must be properly arranged to ensure that the
control board cover can close properly. If the control board
cover is not closed properly, it can lead to corrosion and
cause the connection points on the terminal to heat up,
catch fire, or cause electrical shock.
In certain functional environments, such as kitchens, server
rooms, etc., the use of specially designed air-conditioning
units is highly recommended.
If the power supply cord is damaged, it must be replaced
by the manufacturer, its service agent or similarly qualified
persons such as a licensed electrician in order to avoid a
hazard.
The product must be properly grounded at the time of
installation, or electrical shock may occur.
CAUTION: BURN HAZARD
For units that have an auxiliary electric heater, do not
install the unit within 1 meter (3 feet) of any combustible
materials.
Do not install the unit in a location that may be exposed
to combustible gas leaks. If combustible gas accumulates
around the unit, it may cause fire.
Do not operate your air conditioner in a wet room such as a
bathroom or laundry room. Too much exposure to water can
cause electrical components to short circuit.
NOTICE: PROPERTY DAMAGE
Install condensate drainage piping according to the
instructions in this manual. Improper condensate drainage
may cause water damage to your home and property.
CAUTION: CONTAINS REFRIGERANT
This air-conditioning unit contains fluorinated gasses. For
specific information on the type of gas and the amount,
please refer to the relevant label on the outdoor unit itself.
Installation, service, maintenance and repair of this unit
must be performed by a certified technician.
Product removal and recycling must be performed by a
certified technician.
If the system has a leak-detection system installed, it must
be checked for leaks at least every 12 months.
When the unit is checked for leaks, proper record-keeping of
all checks is strongly recommended.

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Data subject to change
2 Components
The air conditioning / heat pump system comes with the following components. Use
all of the installation parts and components to install the air conditioner. Improper
installation may result in water leakage, electrical shock and fire, or cause the
equipment to fail.
Name Image Quanity
Soundproof / insulation sheath 2
Drain joint 1
Seal ring 1
Copper nut (60k model only) 2
Display control unit 1
Magnetic ring for S1/S2 wire (36k & 48k models only) 1
Magnetic ring for connective cable 1
Magnetic ring for wired controller wire (9k & 12k models only) 1
Owner‘s manual ― ― ― ― ― ― ― ― ― 1
Installation manual ― ― ― ― ― ― ― ― ― 1
Table 1

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3 Installation Summary
Figure 1
LN
123
4
5
MC MC
6
7
Install the indoor unit
(Page 10) Install the outdoor unit
(Page 20)
Install the drainpipe
(Page 16)
Evacuate the refrigeration system
(Page 28) Connect the wires
(Page 25) Connect the refrigerant pipes
(Page 23)
Perform a test run
(Page 31)

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05.2019 |Bosch Thermotechnology Corp.
Data subject to change
4 System Components
4.1 9K ~ 48K Models (Medium Static)
Figure 2
Air outlet
Air inlet
Air filter
Drain hose
Electric control cabinet
Refrigerant connecting pipe
Screw
Air filter
Illustrations in this manual are for explanatory purposes. The actual
shape of your indoor unit may be slightly different. The actual shape
shall prevail.

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4.2 60K Model (High Static)
Figure 3
Air outlet
Air inlet
Drain hose
Refrigerant connecting pipe
Electric control cabinet
Air filter
Heat exchanger
Illustrations in this manual are for explanatory purposes. The actual
shape of your indoor unit may be slightly different. The actual shape
shall prevail.

10 |Bosch Climate 5000 Series Ducted Type (Medium & High Static) Air Conditioner / Heat Pump Installation Manual
05.2019 |Bosch Thermotechnology Corp.
Data subject to change
5 Indoor Unit Installation
Before installing the indoor unit, refer to the label on the product box to
make sure that the model number of the indoor unit pairs with the model
number of the outdoor unit.
Step 1: Select installation location
Before installing the indoor unit, you must choose an appropriate location. The
following are standards that will help you choose an appropriate location for the
unit.
Proper installation locations meet the following standards:
—Good air circulation
—Convenient drainage of condensate
—Noise from the unit will not disturb other people
—Firm and solid ‒ the location will not vibrate
—Strong enough to support the weight of the unit and other parts
—A location at least three feet from all other electrical devices (e.g.,
TV, radio, computer)
DO NOT install unit in the following locations:
—Near any source of heat, steam, or combustible gas
—Near flammable items such as curtains or clothing
—Near any obstacle that might block air circulation
—Near the doorway
—In a location subject to direct sunlight
Required space for installation
9K ~ 48K Models
Figure 4
Left
side Right
side
Strong and durable ceiling
Indoor unit
>4in (10cm) >11.8in (30cm)
>0.8in (2cm)
>0.8in (2cm)
>11.8in (30cm)
8ft 2in (250cm)
or more
Floor
Service access Ceiling
(Open ceiling application)
B
Required space maintenance
9K ~ 48K Models
Figure 5
Air outlet
Air inlet
7.9in (200mm)
or more 11.8in (300mm)
or more
Required space maintenance
60K Model
Figure 6
23.6in (600mm)
or more
19.7in (500mm)
or more

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9k ~ 48k Model Dimensions
Figure 7
Air filter Air inlet from rear side
Air inlet from bottom side
Air filter
Test mouth & Test cover
Ø25mm (0.98in) Drain
connecting pipe (for pump)
Gas side
Liquid side
4-install hanger
Outside air intake Electric control box
Ø25mm (0.98in)
Drain pipe
Airflow
Airflow
Model Unit OutlineDimension Air Outlet Side Dimension Air Inlet Side Dimension Suspension
Position Refrigerant Pipe Location
ABCDEFGHI JKLMH1H2W1W2
9k / 12k mm 700 200 506 450 137 537 30 152 599 186 50 741 360 84 140 84 84
in 27.6 7.9 19.9 17.7 5.4 21.1 1.2 6.0 23.6 7.3 2.0 29.2 14.2 3.3 5.5 3.3 3.3
18k mm 880 210 674 600 140 706 50 136 782 190 40 920 508 78 148 88 112
in 34.7 8.3 26.5 23.6 5.5 27.8 2.0 5.4 30.8 7.5 1.6 36.2 20.0 3.1 5.8 3.5 4.4
24k mm 1100 249 774 700 140 926 50 175 1001 228 5 1140 598 80 150 130 155
in 43.3 9.8 30.5 27.6 5.5 36.5 2.0 6.9 39.4 9.0 0.2 44.9 23.5 3.2 5.9 5.1 6.1
36k mm 1360 249 774 700 140 1186 50 175 1261 228 5 1400 598 80 150 130 155
in 53.5 9.8 30.5 27.6 5.5 46.7 2.0 6.9 49.7 9.0 0.2 55.1 23.5 3.2 5.9 5.1 6.1
48k mm 1200 300 874 800 123 1044 50 227 1101 280 5 1240 697 80 150 185 210
in 47.2 11.8 34.4 31.5 4.8 41.1 2.0 8.9 43.4 11.0 0.2 48.8 27.4 3.2 5.9 7.3 8.3
Table 2

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Data subject to change
60k Model Dimensions
Figure 8
D
A
H
I
F
M N
K
E
J
G
O
L
C
B
Model Unit Outline Dimension Suspension
Position Air Outlet Side Dimension Air Inlet Side Dimension (Same as Air Outlet Side)
ABCDEFGHI JKLMNO
60k mm 858 1400 440 700 1436 1188 385 500 1000 280 1188 385 500 1000 280
in 33.8 55.1 17.3 27.5 56.5 46.7 15 20 39.3 11 46.7 15 20 39.3 11
Table 3
Number Name Description
1 Gas pipe connection Ø19
2 Liquid pipe connection Ø9.5
3 Drain pipe connection OD Ø25 ID Ø20
4 Drain pump ―
5 Power supply connection ―
6 Air discharge flange ―
Table 4

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Step 2: Hang indoor unit
Wood:
Secure wood mounting to the beam with screws, then install the hanging screw
bolts.
Figure 9
Wood mounting
Roof beam
Hanging screw bolts
Ceiling
New concrete:
Inlay or embed the screw bolts.
Figure 10
(Blade shape insert) (Slide insert)
Original concrete:
Use an embedding screw bolt, crock, and stick harness.
Figure 11
Steel bar
Embedding screw bolt
(Pipe hanging and embedding screw bolt)
Steel roof beam structure:
Install and use the supporting steel angle.
Figure 12
Hanging screw bolt
Hanging
bolts
Supporting
angle steel
NOTICE: PROPERTY DAMAGE
The indoor unit must be completely aligned with the hole.
Ensure that the unit and the hole are the same size before
proceeding.
1. After selecting an installation location, align the refrigerant pipes, drain
pipes, as well as indoor and outdoor wires with their connection points
before mounting the unit.
2. Install hanging screw bolts.
3. Connect pipes and wires after installing indoor unit.
4. Drill 4 holes 10cm (4in.) deep at the ceiling hook positions. Be sure to hold
the drill at a 90° angle to the ceiling.
5. Secure the bolt using the washers and nuts provided.
6. Install the four suspension bolts.
7. Mount the indoor unit with at least two people to lift and secure it. Insert
suspension bolts into the unit’s hanging holes. Fasten them using the
washers and nuts provided.
Figure 13
8. Mount the indoor unit onto the hanging screw bolts. Position the indoor unit
flat using a level indicator to prevent leaks.
Figure 14
Screw nut
Washer
Hanging screw bolt
Overhang part
Shockproof cushion
Confirm the minimum drain tilt is 1/100 or more.

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Data subject to change
Step 3: Installing the dust proof net and canvas air passage
1. Install the dust proof net according to the installation manual.
2. Install the canvas air passage underneath the dust proof net.
Step 4: Duct and accessories installation
1. The air inlet and air outlet duct should be far enough to avoid ventilation short
circuiting.
2. Attach the duct to the indoor air outlet/inlet flange by using the type ST3.9 x
10 screw.
3. Connect the duct according to the following diagram:
Figure 15
Canvas tie-in Canvas tie-in
Air outlet
Isolation booth
Isolation booth
checking orifice
Air inlet
Air dust filter
4. Refer to the following static pressure guidelines when installing the indoor
unit.
MODEL(Btu/h) StaticPressure(Pa/in.wg)
9k/12k 0~40/0~0.16
18k 0~100/0~0.40
24k/36k/48k 0~160/0~0.64
60k 0~200/0~0.80
Table 5
Change the fan motor static pressure according to external duct static pressure.
Do not use indoor unit to support connecting duct's weight
When connecting the duct, use a nonflammable canvas tie-in
Change the fan motor static pressure corresponding to
external duct static pressure
An internal duct under-layer can be added to reduce noise
Step 5: Adjust the air inlet direction (If required from rear to bottom,
9k ~ 48k models only)
1. Take off the ventilation panel and flange.
Figure 16
Air return flange
Ventilation panel
2. Change the mounting positions of the ventilation panel and return air flange.
3. When installing the filter, fit it into the flange as illustrated in the following
figure.
Figure 17
Air return flange
Ventilation panel
All the figures in this manual are for demonstration purposes only. The
air conditioner you have purchased may be slightly different in design,
though similar in shape.
Step 6: Fresh air duct installation
Figure 18
Models: 9k ~ 60k
Ø125mm (4.92”) Ø160mm (6.3”)
Duct joint for fresh air

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Step 7: Motor and drain pump maintenance
9k ~ 48k models (the rear ventilated model is used as an example)
Motor maintenance:
1. Take out ventilation panel.
2. Take out blower housing.
3. Take out motor.
Figure 19
Motor
Blower housing
Ventilation panel
Pump maintenance:
1. Remove four screws from the drain pump.
2. Unplug the pump power supply and water level switch cable.
3. Detach the pump.
Figure 20
Pump
60k model
Motor maintenance (there are three methods):
Method 1 - Access from top
1. Remove the top cover as shown.
Figure 21
2. Loosen the four bolts and two screws on the front plate.
Figure 22
3. Remove the motor cord, take off the front side plate and repair the motor.
Figure 23
Method 2 - Access from bottom
1. Remove the bottom base cover as shown.
Figure 24

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Data subject to change
2. Loosen the four bolts from the front plate.
Figure 25
3. Remove the motor cord, take off the front side plate and repair the motor.
Figure 26
Method 3 - Repair it directly (only applicable to plastic scroll and fan wheel)
1. Take off the chassis assembly and filter .
2. Take off the volute.
3. Take off the motor.
Figure 27
Motor
Volute
Filter
Chassis assembly
Pump maintenance:
1. Remove four screws from the drain pump.
2. Unplug the pump power supply and water level switch cable.
3. Detach the pump.
Figure 28
Pump
Step 8: Drainpipe Installation
The drainpipe is used to drain water away from the unit. Improper installation may
cause unit and property damage.
NOTICE: SYSTEM FAILURE
Insulate all piping to prevent condensation, which could
lead to water damage.
If the drain pipe is bent or installed incorrectly, water may
leak and cause a water-level switch malfunction.
In HEAT mode, the outdoor unit will discharge water.
Ensure that the drain hose is placed in an appropriate area
to avoid water damage.
DO NOT pull the drain pipe forcefully. This may damage
the pipe.
Installation requires a polyethylene tube (exterior diameter = 3.7-3.9cm,
(1.4-1.5in) interior diameter = 3.2cm (1.2in)), which can be obtained
at your local hardware store or dealer.
Indoor Drainpipe Installation
1. Install the drainpipe as illustrated below.
Figure 29
(39-59in)
1-1.5m
Lean over 1/50
Ceiling
2. Attach the mouth of the drain hose to the unit’s outlet pipe. Sheath the
mouth of the hose and clip it firmly with a pipe clasp.
3. Cover the drainpipe with heat insulation to prevent condensation and
leakage.
Figure 30
Drain pipe
connecting
port
Drain hose
Pipe clasp Insulation

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NOTICE: EQUIPMENT DAMAGE
When using an extended drainpipe, tighten the indoor
connection with an additional protection tube. This prevents
it from pulling loose.
The drainpipe should slope downward at a gradient of at
least 1/100 to prevent water from flowing back into the air
conditioner.
To prevent the pipe from sagging, space hanging wires every
1-1.5m (39-59in).
If the outlet of the drainpipe is higher than the body’s pump
joint, provide a lift pipe for the exhaust outlet of the indoor
unit. The lift pipe must be installed no higher than 55cm
(21.7in) from the ceiling board. The distance between
the unit and the lift pipe must be less than 20cm (7.9in).
Incorrect installation could cause water to flow back into the
unit and flood.
To prevent air bubbles, keep the drain hose level or slightly
tilted up (<75mm / 3in).
Drainpipe installation for units with a pump
Figure 31
(39-59in)
20cm
(7.9in)
or less
55cm
(21.7in)
or less
Lean over 1/50
1-1.5m
Ceiling
0 - 75mm
(3in )
When connecting multiple drainpipes, install the pipes as illustrated
below.
Figure 32

53cm
(20.8in)
or less
10cm
(4in)
or more
4. Using a 65-mm (2.5in) core drill, drill a hole in the wall. Make sure that the
hole is drilled at a slight downward angle, so that the outdoor end of the
hole is lower than the indoor end by about 12mm (0.5in). This will ensure
proper water drainage (See Fig. 33). Place the protective wall cuff in the
hole. This protects the edges of the hole and will help seal it once you finish
installation.
Figure 33
Wall
IndoorOutdoor
≈ 12mm / 0.5 inch
NOTICE: PROPERTY DAMAGE
When drilling the hole, make sure to avoid wires, plumbing,
and other sensitive components.
5. Pass the drain hose through the wall hole. Make sure the water drains to a
safe location where it will not cause water damage or a slipping hazard.
NOTICE: PROPERTY DAMAGE
The drain pipe outlet should be at least 5cm (1.9in) above
the ground. If it touches the ground, the drain pipe may
become clogged and malfunction. If you discharge water
directly into a sewer, make sure that the drain has a U or
S pipe to catch odors that might otherwise come into the
house.

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Drainage test ( 9k ~ 48k models)
Check that the drainpipe is unobstructed.
This test should be performed on newly built houses before the ceiling is finished.
Units without a pump
1. Fill the water pan with 2 liters of water.
Figure 34
Stow tube
2. Check that the drainpipe is unobstructed.
Units with a pump
1. Remove the test cover.
Figure 35
Test cap
C
L
O
S
E
D
O
P
E
N
C
L
O
S
E
D
O
P
E
N
2. Fill the water pan with 2 liters of water.
Figure 36
Stow tube
3. Turn on the unit in COOLING mode. You will hear the drain pump. Check
whether the water is discharged properly (a 1-minute lag is possible,
depending on the length of the drain pipe), Check whether water leaks from
the joints.
4. Turn off the air conditioner and put the cap back on.
Drainage test ( 60k model)
Units without a pump
1. Fill the water pan with 2 liters of water.
Figure 37
Stow tube
2. Check that the drainpipe is unobstructed.

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Bosch Thermotechnology Corp. |05.2019 Data subject to change
Units with a pump.
1. Remove the test cover.
Figure 38
C
L
O
S
E
D
O
P
E
N
C
L
O
S
E
D
O
P
E
N
Test cap
2. Fill the water pan with 2 liters of water.
Figure 39
Stow tube
3. Turn on the unit in COOLING mode. You will hear the drain pump.Check
whether the water is discharged properly (a 1-minute lag is possible,
depending on the length of the drain pipe). Check whether water leaks from
the joints.
4. Turn off the air conditioner and put the cap back on.
If drain pump needs to be disabled
1. Remove cover of E-Parts box.
2. Unplug the "Pump" pin to disable pump.
3. Short connect the "CN5".
Figure 40
1
2
3
Vertical Mount (9k ~ 48k models only)
1. Disable pump.
2. Take off the cap on drain connector C.
3. Connect the drainpipe to drain connector C.
Figure 41
Connector C

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6 Outoor Unit Installation
Step 1: Select installation location
Before installing the outdoor unit, you must choose an appropriate location. The
following are standards that will help you choose an appropriate location for the
unit.
Proper installation locations meet the following standards:
—Meets all spatial minimum requirements shown in Installation Space
Requirements (Figure 42)
Figure 42
evoba)ni42
(
mc
0
6
60cm (24in)
on right
30cm (12in)
on left
200cm (79in)
in front
30cm (12in)
from back wall
—Good air circulation and ventilation
—Firm and solid ‒the location can support the unit and will not vibrate
—Noise from the unit will not disturb others
—Protected from prolonged periods of direct sunlight or rain
DO NOT install unit in the following locations:
—Near an obstacle that will block air inlets and outlets
—Near a public street, crowded areas, or where noise from the unit
will disturb others
—Near animals or plants that will be harmed by hot air discharge
—Near any source of combustible gas
—In a location that is exposed to large amounts of dust
—In a location exposed to excessive amounts of salty air
NOTICE
If the unit is exposed to heavy wind: Install unit so that air
outlet fan is at a 90° angle to the direction of the wind. If
needed, build a barrier in front of the unit to protect it from
extremely heavy winds. See Figures 43 and 44.
Figure 43
Strong wind
Strong wind
Figure 44
Strong
wind
Wind Baffle
NOTICE
If the unit is frequently exposed to heavy rain or snow:
—Build a shelter above the unit to protect it from the
rain or snow. Be careful not to obstruct air flow around
the unit.
The length of refrigerant piping will affect the performance and energy
efficiency of the unit. Nominal efficiency is tested on units with a pipe
length of 5 meters (16.5ft). A minimum pipe run of 3 meters (9.8ft) is
required to minimize vibration & excessive noise.
Refer to the table below for specifications on the maximum length and
drop height of piping.
Maximum length and drop height of refrigerant piping per unit model
Model Capacity(BTU/h) Max. Equivalent
Length m (ft)
Max. Height
Variation m (ft)
R410A
Inverter
Split Air
Conditioner
< 15,000 25 (82ft) 10 (33ft)
15,000 to < 24,000 30 (98.5ft) 20 (66ft)
24,000 to < 36,000 50 (164ft) 25 (82ft)
36,000 to 60,000 65 (213ft) 30 (98.5ft)
Table 6