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

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|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

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|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.

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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.

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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

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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

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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

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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

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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.

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Isolation Through Wall DO NOT hang line sets from duc twork
Sealant
Insulati on
Suction Line
Wall
Ductwork
Isolator
Line Set
Figure 14
7 Refrigerant line brazing
7.1 Braze the refrigerant lines
1. Remove caps or plugs. Use a deburing tool to debur the pipe ends. Clean both
internal and external surfaces of the tubing using an emery cloth.
Figure 15

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2. Remove the pressure tap cap from both service valves.
Figure 16
3. Purge the refrigerant lines and indoor coil with dry nitrogen.
This pipe
must have
a thimble
Figure 17
4. Wrap a wet rag around the valve body to avoid heat damage and continue the
dry nitrogen purge (Fig. 18).
Braze the refrigerant lines to the service valves.
Check liquid line filter drier’s directional flow arrow to confirm correct direction
of refrigeration flow (away from outdoor unit and toward evaporator coil) as
illustrated. Braze the filter drier to the Liquid Line.
Continue the dry nitrogen purge. Do not remove the wet rag until all brazing is
completed.
Remove the wet rag before stopping the dry nitrogen purge.
Field supplied
and installed
3-4" from valve
Figure 18
5. Replace the pressure tap caps after the service valves have cooled.
Figure 19

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8 Refrigerant line leak check
8.1 Check for leaks
1. Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry
nitrogen.
150 PSI
G
Figure 20
2. Check for leaks by using a soapy solution or bubbles at each brazed location.
Figure 21
9 Evacuation
9.1 Evacuate the refrigerant lines and indoor coil
Do not open the service valves until the refrigerant lines and indoor coil
leak check and evacuation are complete.
1. Evacuate until the micron gauge reads no higher than 350 microns, then close
the valve to the vacuum pump.
0350
Microns
ON OFF
Figure 22
2. Observe the micron gauge. Evacuation is complete if the micron gauge does not
rise above 500 microns in one (1) minute.
Once evacuation is complete blank off the vacuum pump and micron gauge,
and close the valves on the manifold gauge set.
1MIN.
Figure 23

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10 Service valves
10.1 Open the service valves
WARNING:
Extreme caution should be exercised when opening the
Liquid Line Service Valve. Turn counterclock wise until the
valve stem just touches the rolled edge. No torque is required.
Failure to follow this warning will result in abrupt release
of system charge and may result in personal injury and /or
property damage.
Leak check and evacuation must be com pleted before opening the service
valves.
The Suction Service Valve must be opened first BEFORE opening the
Liquid Service Valve!
1. Remove service valve cap (Fig 24).
2. Fully insert hex wrench into the stem and back out counterclockwise until valve
stem just touches the rolled edge (approximately five (5) turns.)
3. Replace the valve stem cap to prevent leaks. Tighten finger tight plus an
additional 1/6 turn.
4. Repeat STEPS 1 - 3 for Liquid Service Valve.
Cap
Rolled Edge to
Captivate Stem
Hex Headed
Val v e Sy s t em
Service Port
3/16” Hex Wrench
for Liquid Service Valve
5/16” Hex Wrench
for Suction Service Valve
Unit S ide
of Service
Val ve
Figure 24

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11 Electrical - low voltage
11.1 Low Voltage Maximum Wire Length
Table 3 defines the maximum total length of low voltage wiring from the outdoor unit,
to the indoor unit, and to the thermostat.
24 Volts - Wire size Max. wire length
18 AWG 150 Ft.
16 AWG 225 Ft.
14 AWG 300 Ft.
Table 3
11.2 Low voltage hook-up diagrams
Air Handler Hook-up Diagram
Low Voltage connection
must be made inside the
outdoor unit case.
Access
Panel
Figure 25
THERMOSTAT
C
INDOOR UNIT OUTDOOR UNIT
Y
R
GY
B
LA
CK
G
C
CB
R
B
Control Wiring for H/P Systems.
W2
D/W
w1
Notes:
1. Be sure power supply agrees with
equipment nameplate.
2. Power wiring and grounding of
equipment must comply with local codes.
3. Low voltage wiring to be No. 18 AWG
minimum conductor.
4. “____” The electric auxiliary heat
connection.
Figure 26

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12 Electrical - high voltage
12.1 High voltage power supply
WARNING: LIVE ELECTRICAL COMPONENTS!
During installation, testing, servicing, and trouble shooting of
this product, it may be necessary to work with live electrical
components. Failure to follow all electrical safety precautions
when exposed to live electrical components could result in
death or serious injury.
The high voltage power supply must agree with the equipment nameplate.
Power wiring must comply with national, state, and local codes.
Follow instructions on unit wiring diagram located on the inside of the control box
cover and in the Service Facts document included with the unit.
Figure 27
12.2 High voltage disconnect switch
Install a separate disconnect switch at the outdoor unit.
Field provided flexible electrical conduit must be used for high voltage wiring.
Figure 28
12.3 High voltage ground
Ground the outdoor unit per national, state, and local code requirements.
Figure 29

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13 Start up
13.1 System start up
1. Ensure Sections 7, 8, 9, 10, 11, 12, and 13 have been completed.
2. Set System Thermostat to OFF.
OFF
D
O
N
E
CANCEL
Figure 30
3. Turn on disconnect to apply power to the indoor and outdoor units.
ON
OFF
Figure 31
4. Wait one (1) hour before starting the unit if compressor crankcase heater is
used and the outdoor ambient temperature is below 70 ºF.
60 MIN.
Figure 32
5. Set system thermostat to ON.
D
O
NE CANC EL
TUE
EM HEAT
O
FF
CO
O
L
Following
Schedule
Inside Set To
Figure 33

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14 System charge adjustment
14.1 Charging: weigh-in method
Weigh-In method can be used for the Initial installation, or anytime a system charge
is being replaced. weigh-In Method can also be used when power is not available to
the equipment site or operating conditions (indoor/Outdoor temperatures) are not In
range to verify with the subcooling charging method.
ABC
Model Factory Charge
Charge multiplier for
interconnecting refrigerant
tube length
All models The data on nameplate 0.6 oz/ft
Table 4
The factory charge in the outdoor unit is sufficient for 15 feet of standard
size interconnecting liquid line.
New Installations — Calculating additional charge for lineset
greater than 15 ft.
1. Total Line Length (ft) = _________(a)
2. Standard Lineset (ft) = 15 (b)
3. (a) minus (b) = _________(c)
4. Refrigerant Multiplier = 0.6 oz/ft (d)
5. Refrigerant Adder (c*d) = _________(e)*
*If lineset is less than 15 ft, (e) = 0
Sealed-System Repairs — Calculating total system charge.
1. Total Line Length (ft) = _________(a)
2. Standard Lineset (ft) = 15 (b)
3. (a) minus (b) = _________(c)
4. Refrigerant Multiplier = 0.6 oz/ft (d)
5. Refrigerant Adder (c*d) = _________(e)*
6. Factory Charge (namplate) = _________(f)
7. Total System Charge (e+f) = ________ _
*If lineset is less than 15 ft, (e) = 0
The only mode approved for validating system charge is while in Cooling
"Charge Mode". Outdoor Temperature must be between 55°F and 120°F
with Indoor Temperature kept between 70°F and 80°F.
14.2 Subcooling charging and refrigerant adjustment in
cooling (above 55°F outdoor temp.)
1. Check the outdoor ambient temperatures.
Subcooling (in cooling mode) is the only recommended method of charging
above 55ºF outdoor ambient temperatures.
For outdoor ambient temperatures below 55ºF , use weigh-in charge method.
Note:It is important to return in the spring or summer to accurately charge the
system in the cooling mode when outdoor ambient temperature is above 55ºF.
55ºF
Outdoor Temp1
120ºF
Outdoor
Temperature
Above 55ºF
55ºF
Outdoor Temp2
Outdoor
Temperature
Below 55ºF
Figure 34
For best results the indoor temperature should be kept between 70ºF to 80ºF.
80 ºF
70ºF
Indoor Temp
Figure 35
2. Ensure Sections 7, 8, 9, 10, and 13 have been completed.
3. Stabilize the system.
After starting the system in cooling mode, short press “FORCE”button, and
“ ” symbol appears in 10 minutes, operate the system for a minimum of
twenty (20) minutes.

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After twenty (20) minutes stabilization period, maintain continuous
operation while adjusting refrigerant charge or TXV, after which operate
system for a minimum of five (5) minutes for system to stabilize, otherwise
repeat step 3.
20 MIN.
Figure 36
4. Calculate superheat value on suction valves (According to Table 4 )
Measured Suction Line Temp. = ________ºF
Measured Suction Line Pressure = _______ PSIG
Calculate superheat value = ________ºF
Insulation
107!
Figure 36
5. Calculate subcooling value on liquid valves (According to Table 5 )
Measured Suction Line Temp. = ________ºF
Measured Suction Line Pressure = _______ PSIG
Calculate superheat value = ________ºF

Insulation
Figure 37
If calculated subcooling value is lower than the design subcooling value
(Table 6), please add refrigerant. Repeat the steps above.
Suction
Temp
(°F)
Final Superheat (°F)
8 10121416182022
Suction Gage Pressure (PSI)
40 101 97 93 89 86 82 78 75
42 105 101 97 93 89 86 82 78
44 110 105 101 97 93 89 86 82
46 114 110 105 101 97 93 89 86
48 118 114 110 105 101 97 93 89
50 123 118 114 110 105 101 97 93
52 128 123 118 114 110 105 101 97
54 133 128 123 118 114 110 105 101
56 138 133 128 123 118 114 110 105
58 143 138 133 128 123 118 114 110
60 148 143 138 133 128 123 118 114
62 153 148 143 138 133 128 123 118
64 159 153 148 143 138 133 128 123
66 164 159 153 148 143 138 133 128
68 170 164 159 153 148 143 138 133
70 176 170 164 159 153 148 143 138
72 182 176 170 164 159 153 148 143
Table 4 R-410A Refrigerant chart - Final Superheat
Suction
Temp
(°F)
Final Supercooling(°F)
678910111213
Liquid Gage Pressure (PSI)
55 173 176 179 182 185 188 191 195
60 188 191 195 198 201 204 208 211
65 204 208 211 215 218 221 225 229
70 221 225 229 232 236 239 243 247
75 239 243 247 251 255 259 262 266
80 259 262 266 270 275 279 283 287
85 279 283 287 291 295 300 304 309
90 300 304 309 313 318 322 327 331
95 322 327 331 336 341 346 351 355
100 346 351 355 360 365 370 376 381
105 370 376 381 386 391 397 402 407
110 397 402 407 413 418 424 430 435
115 424 430 435 441 447 453 459 465
120 453 459 465 471 477 483 489 496
125 483 489 469 502 508 515 521 528
Table 5 R-410A Refrigerant chart- Final Subcooling
Model 24/36 48/60
Design subcooling 10°F ± 2°F 8°F ± 2°F
Table 6

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6. Adjust refrigerant level to attain proper gage pressure.
Add refrigerant if the design subcooling is lower than the chart value.
Connect gages to refrigerant bottle and unit as illustrated (Fig 38).
Purge all hoses.
Open bottle.
Stop adding refrigerant when subcooling. matches the charging chart (Table
5) Final Subcooling value.
Recover refrigerant if the design subcooling is lower than the chart value.
Figure 38
7. Stabilize the system.
Wait 5 minutes for the system condition to stabilize between adjustments.
When the subcooling match the chart, the system is properly charged.
Remove gages.
Replace service port caps to prevent leaks. Tighten finger tight plus an
additional 1/6 turn.
20 MIN.
Figure 39
8. Record System Information for reference (Table 7).
Record system pressures and temperatures after charging is complete.
Description Value
Outdoor model number
Measured Outdoor Ambient °F
Measured Indoor Ambient °F
Measured Liquid Line Temp °F
Measured Suction Line Temp °F
Liquid Gage Pressure PSIG
Suction Gage Pressure PSIG
Table 7