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

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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.

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Installation Instructions
Bosch BCA Series Air Handler - BTC 761703106 A (03.2023)
3 Dimensional Data
3.1 Uncased Unit Dimensions
Figure 1
F
C
E
BD
Top
Back
Right
Left
Uncased unit dimensions
Model
Size
Dimensions Inch [mm]
Unit Length
A
Unit Height
B
Unit Width
C
Supply Air Height
D
Supply Air Length
E
Mounting
F
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
E
C
A
F
D
B
G
H
Left
Right
Cased unit dimensions
Casings are sold separately as an accessory.
Model
Size
Dimensions Inch [mm]
Unit
Length
A
Unit
Height
B
Unit
Width
C
Supply Air
Height
D
Supply Air
Length
E
Mounting
F
Return Air
Cutout
Length
G
Return Air
Cutout
Height
H
Max Filter
Length
J
Max Filter
Width
K
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

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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]
18
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
24
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
30
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
36
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.

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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]
18
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
24
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
30
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
36
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.