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

2
|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

4
|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.

6
|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.
L
H
W
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

8
|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

10
|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.