Bosch Greensource i QV Series Use and care manual

COMPRESSOR REPLACEMENT
QV/WQ SERIES
1
8733829556 (2021/07) Subject to change without prior notice
COMPRESSOR REPLACEMENT INSTRUCTIONS
(Illustrations showing Vertical unit
configuration. Parts and layout may vary based
on unit configuration)
Introduction
This document shows step-by-step instructions
that will assist in the removal and replacement
of the compressor for QV and WQ Series.
Warnings
Warnings in this document are
identified by a warning triangle
printed against a gray background.
Keywords at the start of the
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 situation that, if not
avoided, will result in death or serious injury.
• WARNING indicates a situation that, if not
avoided, could result in death or serious injury.
• CAUTION indicates a situation that, 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
property or people.
SAFETY WARNINGS
DANGER: PERSONAL INJURY HAZARD
Before performing service turn off
electrical power to unit and
observe the proper process of
locking-out power at the
main/disconnect box and follow all
safety precautions outlined in unit’s
IOM before performing any repairs
to unit.
WARNING: PERSONAL INJURY HAZARD
Installation and servicing of this
equipment can be hazardous due
to system pressure and electrical
components. Only trained and
qualified personnel should install,
repair, or service the equipment.
WARNING: PERSONAL INJURY HAZARD
When working on equipment,
always observe precautions
described in the literature, tags,
and labels attached to the unit.
Follow all safety codes. Wear safety
glasses and work gloves. Use a
quenching cloth for brazing, and
place a fire extinguisher close to
the work area.
WARNING: PERSONAL INJURY HAZARD
R410A is flammable when exposed
to open flame. Recover all
refrigerant prior to brazing.
NOTICE:
All refrigerant discharged
from this unit must be recovered
WITHOUT EXCEPTION.
Technicians must follow industry
accepted guidelines and all local,
state, and federal statutes for the
recovery and disposal of
refrigerants. If a compressor is
removed from this unit, refrigerant
circuit oil will remain in the
compressor. To avoid leakage of
compressor oil, refrigerant lines of
the compressor must be sealed after
it is removed.

COMPRESSOR REPLACEMENT
QV/WQ SERIES
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8733829556 (2021/07) Subject to change without prior notice
Tools required
•Flat head screwdriver
•Utility knife
•Awl
•1/2" Socket with long extension
•Pipe cutter for 3/8" - 7/8" copper
•Brazing Equipment
Compressor Encapsulation parts
overview are shown on figures 1 & 2
to use later as reference in the
instruction section.
Figure 1. Front encapsulation panels
Figure 2. Side encapsulation panels
Instructions
1) Turn off power and apply "Lock Out Tag
Out":
a. Remove line voltage connections and
ensure there is no power supply to the
lines.
2) Remove front access panel.
Figure 3. Access panel removal
3) Recover all refrigerant from heat pump
utilizing standard refrigerant recovery
techniques.
4) Removing Electrical Box
a. Remove screws holding Electrical Box to
unit base (bottom left) and to unit
corner post (top and bottom side of the
Electrical Box). See Figure 4.
b. Carefully unplug wire ties and wiring
(Compressor, motor, reversing valve,
high- and low-pressure switch, freeze
and condensate sensors) preventing
from freely moving the electrical box.
NOTE: Mark wires to facilitate re-wring
later.

COMPRESSOR REPLACEMENT
QV/WQ SERIES
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8733829556 (2021/07) Subject to change without prior notice
Figure 4. Electrical Box Screws Location
5) For Vertical Configuration only. Remove
compressor encapsulation screws that attach
the encapsulation to the divider (Qty 4).
Figure 5. Divider encapsulation screw locations
(Vertical unit configuration only)
6) Cut pipes shown on figure 6 to remove
reversing valve assembly.
Figure 6. Suggested locations to cut pipes
7) Remove Reversing valve assembly.
8) Remove (and save to re-install later)
insulation pads around suction and discharge
pipes.
9) Remove screws holding encapsulation panel
#3. See figure 7.
Figure 7. Encapsulation screw locations

COMPRESSOR REPLACEMENT
QV/WQ SERIES
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8733829556 (2021/07) Subject to change without prior notice
10) Remove encapsulation panel #3.
Figure 8. Encapsulation panel #3 removal
11) Remove the 1/2" compressor bolts
attaching the compressor to the unit and
remove the compressor. NOTE: Remove side
encapsulation panels #4 and #5 for easier
clearance to compressor.
Figure 9. Compressor bolt locations
12) Unplug power harness from old compressor
and un-braze Suction and discharge from old
compressor.
13) Braze suction and discharge to the new
compressor and re-install compressor power
plug. As soon as pipes are brazed, cover to
prevent compressor contamination.
14) Re-assemble encapsulation panels #1 and
#2.
Figure 10. Encapsulation panels #1 and #2
reassembly

COMPRESSOR REPLACEMENT
QV/WQ SERIES
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8733829556 (2021/07) Subject to change without prior notice
15) New compressor installation
a. Place new compressor in the unit with
encapsulation panels #1 and #2
already attached. NOTE: Maintain a
clearance of 1/8" between
encapsulation and pipes.
b. Re-install compressor bolts.
16) Encapsulation re-installation
a. If removed (at step 11), re-install
encapsulation panels #4 and #5 and
insert screws attaching panels to the
divider.
b. Screw front encapsulations panels #1
to divider.
c. Route compressor power plug through
encapsulation panel #3 electrical wires
opening.
Figure 11. Opening for electrical wires
d. Re-install front encapsulation panel #3.
e. Re-install suction and discharge pads.
See figure 12
Figure 12. Suction and discharge pads
17) Install filter drier between TXV and water
coil. See Figure 13.
18) Re-braze reversing valve assembly pipes.
It is imperative that the refrigerant
system remain clean and dry during
the above operations. A new bi-flow
liquid line dryer must be installed
19) Re-install and re-wire Electrical Box. Refer
to main unit wiring instructions.
20) Evacuate the unit and recharge according to
unit nameplate.
If you have any questions regarding the
information provided in this document,
please contact the Bosch Technical Support
Department by phone at 1-800-283-3787,
or via email at
[email protected]

COMPRESSOR REPLACEMENT
QV/WQ SERIES
6
8733829556 (2021/07) Subject to change without prior notice
Figure 13. Piping Schematic. Filter drier and overall components location.