Bosch AD HP270-1 User manual

DOMESTIC HOT WATER HEAT PUMP
This document is confidential and restricted to exclusive use by the official technical
assistance of Bosch in the countries of destination of this product.
MANUAL FOR AFTER SALES TECHNICIANS

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1. INTRODUCTION...........................................................................................3
1.1 GENERAL DESCRIPTION ............................................................................................................ 3
1.2 ADVANTAGES,ARGUMENTS AND APPLICATIONS.......................................................................... 4
1.3 PRODUCT PRESENTATION ......................................................................................................... 7
2. COMMISSIONING AND START UP..............................................................8
2.1 PACKAGE RECEPTION /IDENTIFICATION OF THE APPLIANCE........................................................ 8
2.2 PRE-COMMISSIONING CHECK LIST............................................................................................ 11
3. INSTALLATION ACCESSORIES VENTING................................................13
4. VENTILATION ACCESSORIES ..................................................................17
5. COMPONENTS CHARACTERISTICS AND REPAIRS ...............................27
5.2COMPONENTS AND CHECKS IN THE STORAGE TANK................................................................... 30
5.3 HYDRAULIC CONNECTIONS –COLD WATER INLET ...................................................................... 31
5.4 HYDRAULIC CONNECTIONS –RECIRCULATION........................................................................... 33
5.5 HYDRAULIC CONNECTIONS -OPTIONAL ACCESSORIES .............................................................. 35
5.6 HYDRAULIC CONNECTIONS –HOT WATER OUTLET ................................................................... 36
5.7 STORAGE TANK ELEMENTS .................................................................................................... 37
6. HYDRAULIC SCHEMES –HEAT PUMP INTEGRATION ...........................38

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1. Introduction
Domestic Hot Water Heat Pumps (DHW-HP), with or without air connections ducts, use the heat existing in the
surrounding air, or the waste heat from the indoor air, as an energy source for DHW preparation.
These machines are commonly known as air-source hot water heat pump and they are energy-saving and
environmentally friendly equipments. They have an efficiency which is usually 3 times higher than the traditional
gas water heaters, oil-fired and gas boilers, electric water heaters, with a plug-and-play system structure and easy
maintenance.
The heat pump has generally three operation modes:
-normal mode –only heat pump operation
-combi mode–heat pump and electric resistance operation
-electric heater mode–only electric resistance operation
The heat source can be the waste heat as referred, but also the potential energy of unheated rooms, or the air
discharged from rooms with high humidity such as bathrooms, toilets and laundry rooms.
1.1 General description
This model of domestic hot water heat pump provides hot water for residential purposes using a closed refrigerant
unit filled with a refrigerant gas (R134a). This ensures the energy production, by taking out the energy from a cold
source - air, and delivering this energy to a secondary circuit –water - where a simple circulation pump, ensures
the water flow through a heat exchanger, heating the water stored in a tank.
(a) (b)
Pict.1 Refrigeration Unit (a) and Storage Tank (b)

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1.2 Advantages, arguments and applications
- The Heat pump works, even at night, producing hot water in a continuous way to store for the time of usage;
- Easy installation, similar with current installation of indirect storage tanks;
- Heat pump can deliver more hot water amount (continuous recovery);
- Can be installed in a cellar or ground division in the house, doing dehumidification and cooling of the place;
- Works well in humid climates or in cloudy humid days due to the wide range of air temperature;
- The efficiency increases as the surrounding air temperature increases.
Best applications of a heat pump
- Replacing electric water heaters or storage tanks;
- In residences with 4 or more people, with high hot water consumption;
- In commercial applications, where heat can be extracted from a hot plant room;
- In locations with humid conditions like laundries;
- Taking air from outside, especially to walls facing equator (warm and stable outdoor temperatures due to sun
exposition).
Where do not to install a heat pump
- In applications for low hot water demand;
- In unventilated cupboards or small rooms, unless a ducted air source is available;
- In heated rooms;
- Outdoor, with extreme freezing conditions;
- In living places, where the compressor noise can disturb.

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Application 1
Surrounding indoor air (Waste Heat) is a useful and free heat to use in this kind of air source Heat Pumps.
Pict.4 –Application 1
Application 2
Dehumidified air in laundry rooms can be used to dry the ambient air and prevent moisture damage caused by
dampness.
Pict.5 –Application 2

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Application 3
Indoor air of a room is extracted out from other places, like storage rooms, wine cellars, hobby rooms, furnace and
laundry rooms over an air duct, and is then cooled and dehumidified in the hot water heat pump and blown into the
room again.
This air ducting in the heated section of the system should be insulated with water-proof insulation to prevent
condensates creation.
Pict.6 –Application 3
Application 4
A pipe duct system with integrated by-pass flap, allows variable use of the heat contained in the air, extracted from
outdoor or indoor location, for hot water preparation.
Pict.7 –Application 4

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1.3 Product presentation
Apart of the main function of the heat pump operation with the required mandatory components of a air/water heat
pump with electrical backup installed for any eventual need, some models have an integrated internal coil for
external energy source a standing or wall hung boiler or even solar energy installation.
Picture 8 shows the internal constitution and main components:
1) Fan and evaporator group
2) Compressor
3) Condenser (Plate Heat Exchanger)
4) Filter dryer and expansion valve
5) Water circulation pump
6) Storage tank
7) Electrical resistance for backup
8) Internal coil for external backup (eg. solar)
Pict.8 –Elements of the Bosch Heat Pump
1
2
4
3
5
6
7
8

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2. Commissioning and start up
2.1 Package Reception / Identification of the Appliance
The Heat Pump has following information stickers:
-Packaging label (Pict. 9, 10 or 11)
-Type Plate –appliance identification type plate label (Pict. 15)
Packaging label includes following information:
Brand
Recycling and certification stamps
Order number
Countries of destination
Product designation
Weight
Bar code
Transport and storage conditions
Production date
Pict.9 –Packaging Label Junkers

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Pict.10 –Packaging Label Buderus
Pict.11 –Packaging Label Bosch
In order to ensure the correct transport conditions from factory to the end-user installation place, it is strongly
recommended the use of special and adequate transportation devices in order to ensure the minimum tilting, even
during transport in stairs and / or other obstacles, without damaging the appliance or any particular component.
Attention! Before switching the appliance on, ensure 30minutes rest time, in the final vertical installation position.

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Pict.12 –Example of transportation device
Pict.13 –Example of use
Attention: if the appliance is tilted more than 20º when touching the floor, the bottom of the tank cover can be
damaged and the feet can be deformed.
The type plate has the main important information about the product identification, indispensable for installers and
after sales technicians.

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Pict.14 –Type plate samples
Serial number codification 2510-102-000000-7736500169
2510 –Plant Identification
102 –Manufacturing Date –eg. Feb.2011 (see table 1)
000000 –Counter number
7736500169 –TT part number /order number
FD
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
2011
101
102
103
104
105
106
107
108
109
110
111
112
2012
201
202
203
204
205
206
207
208
209
210
211
212
2013
301
302
303
304
305
306
307
308
309
310
311
312
Table 1 –Production date (FD) codification
2.2 Pre-commissioning check list
After removing the packaging, check the unit visually, and take out the top EPP protection to perform a visual and
complete inspection, before its installation.

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Pict.15 –Remove the protection upper cap of the refrigeration unit
Unit:
Y N
❏❏ The unit is secure and correctly assembled.
❏❏ There is a clear air movement path and the minimum volume of place is > 20m3 (unducted)
❏❏ Wiring has been signed off.
Pipe work:
Y N
❏❏ Pipe work has been correctly installed and secured.
❏❏ Pipe work is correctly insulated.
Drainage:
Y N
❏❏ Pour some water into the siphon of safety and condensate drainage pan.
❏❏ Ensure that the water flows through the outlet and drainage hose, without leaking.
Electrical check list
Wiring:
Y N
❏❏ Carry out tests required under the wiring regulations.
❏❏ Do a polarity test.
❏❏ Electrical code compliance certificate is obtained and a copy is given to the owner.

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Testing:
Y N
❏❏ Switch the system on.
❏❏ Ensure that the control unit and user operations are explained, as well as maintenance and
safety recommendations
Unit:
Y N
❏❏ The fan and compressor operates.
❏❏ There is no vibration of the unit.
❏❏ Air duct is correct orientated to the inlet and outlet of the unit.
❏❏ The manual operation is functioning
❏❏ The air purging valve is opened
Tank:
Y N
❏❏ Tank is levelled
❏❏ Tank is full of water 1)
1) See consequences on troubleshooting Chapter
Instructions check list:
Use of the system:
Y N
❏❏ Demonstrate how to set the controls and different modes, correctly
❏❏ Demonstrate how to check pressure relief valves
❏❏ Advise for service requirements
❏❏ Recommend reading the operating instructions manual
❏❏ Provide a service checklist
❏❏ Provide the warranty
❏❏ Provide contact names and numbers, in case of a need
❏❏ Recommend a periodical disinfection function for the water in the tank (LEG)
3. Installation Accessories Venting
The Heat Pump design allows two types of connections, in terms of ventilation (air suction / air discharge) –ducted
or not ducted.
In case of working with room ambient temperature, following conditions must be ensured:

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-Room volume ≥ 20 m3;
-Air must be free of corrosive agents.
Attention!
-The Heat Pump will work as a dehumidifier;
-The room ambient temperature will decrease while the Heat Pump is working.
Available Models:
-Indoor air versions –working air temperature of +5ºC to +35ºC
-Outdoor air versions –working air temperature of -10ºC to +35ºC
Pict.16 –Installation without ducts (unducted) –air flow
In case it is necessary, it is possible to get air from another source, connecting ducts to the inlet and outlet, with a
suction and discharge diameter of 160mm.
The total maximum equivalent length1) should not be more than 6m and the pressure losses should be limited in
maximum to 80 Pa.
1) Equivalent length is the sum of both suction and discharge ducts length, considering all elbows, with the
correspondent reduction.
Pict.17 –Installation with Ducts (ducted)

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For the ducted installation solution, the pipes can be connected to the exterior or to an adjacent room, as long as
the ambient air conditions are ensured.
The ambient air temperature for operation must be within +5ºC and +35ºC. In case of ducted installation to outside,
it is strongly recommended to use the wall facing the best sun exposition condition (south, in case of Europe).
a)indoor wall b)outdoor wall
Pict.18 –Ducts configuration
Ducts can be assembled horizontally or vertically.
Pict.19 –Possible ducts orientation vertical / horizontal passage

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Pict.20 –Air intake and exhaust from outside with flexible pipe DN160 and
respective wall and roof penetration
Following suggested accessories are marked with Bosch original quality label:

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4. Ventilation Accessories
Instruction
Accessory
Part Number
Image
4.1
Wall penetration
for vertical air
pipes
7 719 003 366
Installation Advice 6 720 618 377
4.2
Wall penetration
for horizontal air
pipes
7 719 003 334
Installation Advice 6 720 618 378
4.3
Assembly tool
Ø1 = 160 mm
7 746 901 002
Installation Advice 6 720 619 819
4.4
Air Duct with 500
mm length
Ø1 = 160 mm
7 746 900 698
Installation Advice 6 720 619 801

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Air Duct with 1000
mm length
Ø1 = 160 mm
7 746 900 702
Installation Advice 6 720 619 802
Air Duct with 2000
mm length
Ø1 = 160 mm
7 746 900 706
Installation Advice 6 720 619 803
4.5
Ventilation Elbow
Ø1 = 160 mm, 45°
7 746 900 690
Installation Advice 6 720 619 799
4.6
Ventilation Elbow
Ø1 = 160 mm, 87°
7 746 900 694
Installation Advice 6 720 619 800

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4.7
“T” inspection
accessory
Ø1 = 160 mm
7 746 900 714
Installation Advice 6 720 619 805
4.8
Inspection elbow
Ø1 = 160 mm
7 746 900 718
Installation Advice 6 720 619 806
Table 2 –Acessories List in PP
4.1) Instruction for Horizontal wall penetration accessory installation
Pict.21 –Photo of the horizontal wall penetration accessory

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