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Bosch LV009 Installation And Maintenance Manual

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LV MODEL
Installation and Maintenance Manual

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  Summary of Contents for Bosch LV009

  • Page 1 LV MODEL Installation and Maintenance Manual...
  • Page 2: Table Of Contents

    LV Heat Pump Series CONTENTS Units Mounted Non-Fused Disconnect Switch....22 Hot Gas Reheat............24 Hot Gas Bypass............25 Key to Symbols..............3 Internal 2-Way Water Valve..........25 Safety Warnings..............3 Economizer...............25 Model Nomenclature............4 Certified Performance Table..........26 General Description............5 Fan Motors Options............27 Permanent Split Capacitor Motors (PSC)......27 Moving and Storage............5 Constant Torque Motors (ECM)........28 Constant Airflow Motors (ECM)........30...
  • Page 3: Key To Symbols

    LV Heat Pump Series Key to Symbols | 3 KEY TO SYMBOLS WARNING: Before performing service or Warnings maintenance operations on the system, turn Warnings in this document are identified by off main power to the unit. Electrical shock a warning triangle printed against a grey could cause personal injury or death.
  • Page 4: Model Nomenclature

    4 | Model Nomenclature LV Heat Pump Series MODEL NOMENCLATURE Figure # 1 Not all Options are available on all models. 8 733 944 336 (2016/09) Subject to change without prior notice LV Heat Pump Series...
  • Page 5: General Description

    On board safety features will protect the major unit discrepancies. components from damage under most foreseeable Should you identify any issue, contact the Bosch installation and operation problems. Wholesaler / Distributor you purchased the unit from. LV Heat Pump Series...
  • Page 6: Step 3 Locate Unit

    6 | Installation LV Heat Pump Series Be sure that the location chosen for unit installation Remove any shipping brackets from the unit provides ambient temperatures maintained above attached to the pallet. freezing. Step 3- Locate the Unit Be sure the installation location is isolated from Locate the unit in an indoor area that allows easy access sleeping areas, private offices and other acoustically to the filter, front access panel and blower access panel,...
  • Page 7: Step 4 Mount The Unit

    LV Heat Pump Series Installation | 7 Step-4 Mount The Unit Mounting Horizontal Units Duct Flanges While horizontal units may be installed on any level surface strong enough to hold their weight, they are The Unit heat pump feature foldout return and supply air typically suspended above a ceiling by threaded rods.
  • Page 8: Hanging Bracket Kit

    8 | Installation LV Heat Pump Series Hanging Bracket Kit 2. Mount 4 Brackets to unit corner post using the bolts provided in the kit as shown on Figure # 5 Installation instructions All horizontal units come with Hanging Bracket Kit WARNING: Do not re-use screws removed to facilitate suspended unit mounting using threaded from the unit on step 1 to mount the...
  • Page 9: Step 5 Check Duct System

    LV Heat Pump Series Installation | 9 ° Step-5 Check Duct System Turn the blower panel 180 so that the blower support brackets are now at the bottom of the All units are provided with a return air duct flange and blower.
  • Page 10: Step 7 Pipe Connections

    10 | Installation LV Heat Pump Series Step 7-Pipe Connections Step 8 Wire Field Power Supply Depending on the application there are 3 types of WSHP High Voltage piping systems to choose from: water loop, ground All field-installed wiring must comply with the National water-and ground loop.
  • Page 11 LV Heat Pump Series Installation | 11 Low Voltage Thermostat to HVAC Equipment For heat pumps with PSC or constant torque fan motors, The thermostat may not function properly if the total all thermostat wiring is connected to a terminal block resistance of any of the thermostat to HVAC equipment located in the unit electrical box.
  • Page 12: Step 9 Wire Field Controls

    12 | Installation LV Heat Pump Series Step 9- Wire Field Controls Safety devices and the UPM control Each unit is factory provided with a UPM board Units Controls ECM-UPM controller that controls the compressor operation and monitors the safety. ECM Interface Board If the unit is being connected to a thermostat with a Thermostat wiring is connected to the 10 pin screw type...
  • Page 13: Safety Features

    LV Heat Pump Series Installation | 13 Safety features includes the following: • High pressure switch located in the refrigerant discharge line and wired across the HPC terminals on the complete UPM board • Low pressure switch located in the unit suction line and wired across terminals LPC1 and LPC2 on the complete UPM Board •...
  • Page 14: Freeze Sensor

    14 | Installation LV Heat Pump Series Freeze Sensor ° The default setting for the freeze limit trip is 26 If 24 VAC output is needed. R must be wired to ° (sensor number 1); however this can be changed to 15 ALR-COM terminal;...
  • Page 15: Pre-Start-Up

    LV Heat Pump Series Pre-Start-Up | 15 Air coil To obtain maximum performance, clean the air coil THERMOSTAT OPTIONS before starting the unit. A 10% solution of dishwasher First Stage Compressor Operation detergent and water is recommended for both sides of the coil.
  • Page 16: Scroll Compressor Rotation

    16 | Start-Up LV Heat Pump Series Two factors determine the operating limits of a unit: entering air temperature and water temperature. Whenever any of these factors are at a minimum or maximum level, the other two factors must be at a normal level to ensure proper unit operation.
  • Page 17: Sequence Of Operation Upm

    LV Heat Pump Series Start-Up | 17 Sequence Of Operation START RESET ON R RESET ON Y1 = ON R = 24VAC POWER/ SWITCHES/SENSOR CLEAR FAULTS STATUS CHECK BLINK CODE ON STATUS LED COUNTER SOFT LOCKOUT V > 18VAC NEEDED? RECORD ALARM START COUNTER (IF APPLICABLE) CNT = CNT+1...
  • Page 18: Sequence Of Operation Ecm

    18 | Start-Up LV Heat Pump Series Figure # 14 8 733 944 336 (2016/09) Subject to change without prior notice LV Heat Pump Series...
  • Page 19: Unit Start Up Cooling Mode

    LV Heat Pump Series Start-Up | 19 Unit Start Up Cooling Mode WARNING: Open the disconnect switch and Adjust the unit thermostat to the warmest position. Slowly reduce the thermostat position until the secure it in an open position before flushing compressor activates.
  • Page 20: Antifreeze

    20 | Application Considerations LV Heat Pump Series After pressurization, be sure to remove the plug from the end of the loop pump motor to allow trapped air to be discharged and to ensure the motor housing has been flooded. Be sure the loop flow center provides adequate flow through the unit by checking pressure drop across the heat exchanger.
  • Page 21: Cooling Tower/Boiler Systems

    LV Heat Pump Series Application Considerations | 21 Cooling Tower/Boiler Systems Geothermal Closed Loop Systems These systems typically use a common loop temperature Operation of an LV Series unit on a closed loop ° ° maintained at 50 F to 100 F.
  • Page 22: Open Well Water Systems

    22 | Water Quality LV Heat Pump Series Open Well Water Systems WATER QUALITY When a water well is used exclusively for supplying NOTICE: Failure to ensure proper water water to the heat pump, the pump should operate only quality and flow rates can shorten the life of when the Heat Pump operates.
  • Page 23: Water Quality Table

    LV Heat Pump Series Water Quality Table | 23 WATER QUALITY TABLE Table 5: Water Quality POTENTIAL PROBLEM Water Characteristic Acceptable Value Copper Cupro-Nickel pH (Acidity/Alkalinity) Hardness (CaCO3, MgCO3) < 350 ppm < 350 ppm SCALING Ryznar Stability Index 6.0 - 7.5 6.0 - 7.5 Langelier Saturation Index -0.5 - +0.5...
  • Page 24: Piping

    24 | Piping LV Heat Pump Series PIPING OPTIONS Supply and return piping must be as large as the unit Extended Range Option connections on the heat pump (larger on long runs). LV heat pumps are supplied standard with capillary style Never use flexible hoses of a smaller inside diameter expansion device tuned to typical boiler/tower system than that of the water connections on the unit.
  • Page 25: Hot Gas Bypass

    LV Heat Pump Series Options | 25 Economizer At water temperatures of 85° F, the reheat coil can recover 95% to 100% of the sensible capacity of the LV series heat pumps can be provided an optional water evaporator. At water temperatures below 60°F, the side economizer.
  • Page 26: Certified Performance Table

    MODEL WLHP GLHP Cooling Heating Cooling Heating Capacity Capacity Capacity Capacity LV007 6,100 12.20 7,800 5.30 6,800 15.10 4,900 3.40 LV009 8,200 12.40 9,900 4.70 8,700 14.60 5,700 3.20 LV012 10,900 12.20 13,000 4.30 11,800 14.10 8,700 3.20 LV015 14,200 12.80...
  • Page 27: Fan Motors Options

    LV Heat Pump Series Fan Motor Options | 27 FAN MOTOR OPTIONS Uncap the desired fan speed wire and terminate with a ¼” quick connect. Connect to the fan relay. Permanent Split Capacitor Motors (PSC) If the motor is a 460 V motor and the speed is changed from high to medium or low, connect the The standard motor for all LV series heat pumps is a PSC high speed motor lead to the orange intermediate...
  • Page 28: Constant Torque Motors (Ecm)

    28 | Fan Motor Options LV Heat Pump Series Table 7: PSC Motor Performance Data Rated Model Speed Airflow 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 LV-041 1200 1140 1080 1010 1300 1490 1400 1320 1240 1160 1080...
  • Page 29 LV Heat Pump Series Fan Motor Options | 29 Table 8: Constant Torque Blower Motor Data Rated Model Tap # Airflow 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 LV-015 LV-018 1010 LV-024 1160 1110 1050 LV-030 1070 1010...
  • Page 30: Constant Airflow Motors (Ecm)

    30 | Fan Motor Options LV Heat Pump Series Table 8: Constant Torque Blower Motor Data Rated Model Tap # Airflow 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1390 1370 1350 1320 1600 1580 1550 1530 1510 LV-048...
  • Page 31 LV Heat Pump Series Fan Motor Options | 31 Table 9: Constant Airflow Motor Performance Table Model Rated Fan Speed Airflow 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 A - Low LV-015 A - Normal A - Hi B - Low LV-018...
  • Page 32: Standard Blower Motor

    Total Unit FLA Amps /HARC 208-230/60/1 197/253 17.7 0.96 3.56 LV007 265/60/1 238/292 13.5 0.96 3.56 208-230/60/1 197/253 22.2 0.96 4.36 LV009 265/60/1 238/292 18.8 0.85 3.75 115/60/1 103/126 58.4 11.8 14.2 LV012 208-230/60/1 197/253 0.96 5.56 265/60/1 238/292 22.2 0.85...
  • Page 33: Constant Torque Ecm Blower Motor

    LV Heat Pump Series Standard Blower Motor | 33 Constant Torque ECM Blower Motor Table 11: Electrical Data Table - Constant Torque ECM Blower Motor Compressor Total MODEL Voltage Rated Voltage Motor Unit Circui Code Voltage Min/Max Motor Fuse 208-230/60/1 197/253 0.33 LV015...
  • Page 34: Constant Cfm Ecm Blower Motor

    34 | Standard Blower Motor LV Heat Pump Series Constant CFM ECM Blower Motor Table 12: Electrical Data Table - Constant CFM ECM Blower Motor Compressor Total MODEL Voltage Rated Voltage Motor Unit Circui Code Voltage Min/Max Motor Fuse 208-230/60/1 197/253 0.33 LV015...
  • Page 35: Troubleshooting

    LV Heat Pump Series Troubleshooting | 35 TROUBLESHOOTING UNIT TROUBLESHOOTING Problem Mode Check Possible Cause Action Cooling Heating Check water valves and/or pumps for High Pressure fault - no or proper operation. Check for water low water flow coil blockage. High Pressure fault - high Check water temperature - is it in water temperature...
  • Page 36 36 | Troubleshooting LV Heat Pump Series UNIT TROUBLESHOOTING Problem Mode Check Possible Cause Action Check condensate pan for high water Condensate fault - poor level. Check drain line for blockages, drainage double trapping or inadequate trapping. Check condensate pan for high water Is fault LED Blinking 4 level.
  • Page 37 LV Heat Pump Series Troubleshooting | 37 UNIT TROUBLESHOOTING Problem Mode Check Possible Cause Action Check for supply voltage at the load Open compressor side of the contactor. For 3 phase overload models check phase rotation and voltage at all 3 phases. Look for signs of heat on the wiring insulation.
  • Page 38 38 | Troubleshooting LV Heat Pump Series UNIT TROUBLESHOOTING Problem Mode Check Possible Cause Action Check for 24 VAC between "G" and "C". Check all wiring connections. No fan operation signal Make sure that the thermostat connection plug is securely connected.
  • Page 39 LV Heat Pump Series Troubleshooting | 39 UNIT TROUBLESHOOTING Problem Mode Check Possible Cause Action Fan speed setting too Consult blower performance table Air flow too high high and reduce fan speed if possible. Loss of refrigeration Check refrigerant pressures with Low refrigerant capacity gauge set.
  • Page 40: Temperature Pressure Table

    22-27 129-158 289-353 28-34 121-148 211-258 13-16 21-26 139-170 300-366 8-10 30-37 60˚ 115-140 200-245 9-11 22-27 146-179 306-374 32-39 LV009 126-154 245-299 13-15 20-25 156-190 316-386 9-12 33-41 70˚ 119-146 232-284 9-11 21-26 163-200 322-394 35-43 130-159 278-340 12-15...
  • Page 41 LV Heat Pump Series | 41 OPERATING DATA COOLING HEATING ENTERING SUCTION DISCHARGE SUCTION DISCHARGE WATER WATER TEMP, WATER FLOW PRESSURE PRESSURE WATER TEMP AIR TEMP PRESSURE PRESSURE TEMP DROP, AIR TEMP MODEL ˚F PSIG PSIG RISE, ˚F DROP, ˚F PSIG PSIG ˚F...
  • Page 42 42 | LV Heat Pump Series OPERATING DATA COOLING HEATING ENTERING SUCTION DISCHARGE SUCTION DISCHARGE WATER WATER TEMP, WATER FLOW PRESSURE PRESSURE WATER TEMP AIR TEMP PRESSURE PRESSURE TEMP DROP, AIR TEMP MODEL ˚F PSIG PSIG RISE, ˚F DROP, ˚F PSIG PSIG ˚F...
  • Page 43 LV Heat Pump Series | 43 OPERATING DATA COOLING HEATING ENTERING SUCTION DISCHARGE SUCTION DISCHARGE WATER WATER TEMP, WATER FLOW PRESSURE PRESSURE WATER TEMP AIR TEMP PRESSURE PRESSURE TEMP DROP, AIR TEMP MODEL ˚F PSIG PSIG RISE, ˚F DROP, ˚F PSIG PSIG ˚F...
  • Page 44 44 | LV Heat Pump Series OPERATING DATA COOLING HEATING ENTERING SUCTION DISCHARGE SUCTION DISCHARGE WATER WATER TEMP, WATER FLOW PRESSURE PRESSURE WATER TEMP AIR TEMP PRESSURE PRESSURE TEMP DROP, AIR TEMP MODEL ˚F PSIG PSIG RISE, ˚F DROP, ˚F PSIG PSIG ˚F...
  • Page 45 LV Heat Pump Series | 45 OPERATING DATA COOLING HEATING ENTERING SUCTION DISCHARGE SUCTION DISCHARGE WATER WATER TEMP, WATER FLOW PRESSURE PRESSURE WATER TEMP AIR TEMP PRESSURE PRESSURE TEMP DROP, AIR TEMP MODEL ˚F PSIG PSIG RISE, ˚F DROP, ˚F PSIG PSIG ˚F...
  • Page 46: Waterside Pressure Drop Table

    LV Heat Pump Series WATERSIDE PRESSURE DROP TABLE Table 14: Water Flow Rate Water Side Pressure Drop with out Model (GPM) Internal Valve (PSI) Water Side Pressure Drop with Internal Valve (PSI) LV007 LV009 LV012 LV015 LV018 LV024 LV030 LV036 LV041 11.0 13.1 LV042 11.0...
  • Page 47: Compressor Characteristics

    15/370 265/60/1 13.5 5.34 6.77 15/440 LV007 HZ 208-230/60/1 17.7 4.08 6.63 15/370 265/60/1 13.5 5.34 6.77 15/440 LV009 VT & CF 208-230/60/1 22.2 2.95 7.35 15/370 265/60/1 18.8 4.27 10.74 10/440 LV009 HZ 208-230/60/1 22.2 2.95 7.35 15/370 265/60/1 18.8...
  • Page 48: Corner Weights (Hz)

    LV Heat Pump Series CORNER WEIGHTS (HZ) Configuration Left Hand Return Right Hand Return Model Total Left Front* Right Front* Left Back Right Back Left Front* Right Front* Left Back Right Back LV007-HZ LV009-HZ LV012-HZ LV015-HZ LV018-HZ LV024-HZ LV030-HZ LV036-HZ LV042-HZ...
  • Page 49: Wiring Diagrams

    LV Heat Pump Series Wiring Diagrams | 49 WIRING DIAGRAMS Figure # 19 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. LV Heat Pump Series 8 733 905 683 (2016/09)
  • Page 50 50 | Wiring Diagrams LV Heat Pump Series Figure # 20 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 8 733 944 336 (2016/09) Subject to change without prior notice LV Heat Pump Series...
  • Page 51 LV Heat Pump Series Wiring Diagrams | 51 Figure # 21 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. LV Heat Pump Series 8 733 905 683 (2016/09)
  • Page 52 52 | Wiring Diagrams LV Heat Pump Series Figure # 22 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 8 733 944 336 (2016/09) Subject to change without prior notice LV Heat Pump Series...
  • Page 53 LV Heat Pump Series Wiring Diagrams | 53 Figure # 23 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. LV Heat Pump Series 8 733 905 683 (2016/09)
  • Page 54 54 | Wiring Diagrams LV Heat Pump Series Figure # 24 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 8 733 944 336 (2016/09) Subject to change without prior notice LV Heat Pump Series...
  • Page 55 LV Heat Pump Series Wiring Diagrams | 55 Figure # 25 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. LV Heat Pump Series 8 733 905 683 (2016/09)
  • Page 56: Dimensional Drawings

    56 | Dimensional Drawings LV Heat Pump Series DIMENSIONAL DRAWINGS Vertical Recommen- ded Replacement Nominal Filter Size Condenser Water Connections Right side to discharge Filter Rack Height R/A Duct Flange Height R/A Duct Width Conden- sate Drain Water Outlet Water Inlet Left Side to Discharge...
  • Page 57: Horizontal

    LV Heat Pump Series Dimensional Drawings | 57 Horizontal Recommen- ded Replacement Nominal Filter Size Condenser Water Connections R/A Duct Flange Height Filter Rack Height Top to Discharge (FRE & FLS) End to Discharge (Straight) Discharge Height Top to Discharge (FLE &...
  • Page 58 58 | LV Heat Pump Series Overall unit dimension do not include filter rack, duct flanges or economizer. For economizer Dimensions horizontal units with the optional economizer kit may require field provided hanging provisions. All dimensions within +-0.125”. All condensate drain connections are 3/4”...
  • Page 59: Maintenance

    LV Heat Pump Series Maintenance | 59 MAINTENANCE INFORMATION ON DECOMMISSIONING Filter changes or cleaning are required at regular Only Trained and qualified technicians are allowed to intervals. The time period between filter changes decommission and dispose of equipment following will depend upon type of environment the applicable requirements and local codes.
  • Page 60: Terminology

    60 | Terminology LV Heat Pump Series TERMINOLOGY HP-Heat Pump HPC-Heat Pump Controller EEPROM- Electrically Erasable Programmable Read DDC- Digital Direct Controller Only Memory PCBA- Printed Circuit Board Assembly Suction Pressure - Pressure entering compressor LED- Light Emitted Diode Discharge Pressure - Pressure leaving compressor HPS- High Pressure Switch (R/A) - Return Air LPS- Low Pressure Switch...
  • Page 61: Unit Check Out Sheet

    Auxiliary Heat Unit Make __________________________________ Model Number: ______________________________ Serial Number _____________________________ Max Fuse Size (Amps) _______________________ Volts / Amps _______________________________ Bosch Thermotechnology Corp Entering Air Temperature _____________________ 555 NW 65th Court Leaving Air Temperature ______________________ Fort Lauderdale, FL 33309 Phone: 866-642-3198...
  • Page 62: Notes

    62 | NOTES LV Heat Pump Series NOTES 8 733 944 336 (2016/09) Subject to change without prior notice LV Heat Pump Series...
  • Page 63 LV Heat Pump Series NOTES | 63 LV Heat Pump Series 8 733 905 683 (2016/09)
  • Page 64 Bosch Thermotechnology Corp 555 NW 65th Court Ft.Lauderdale, FL 33309 Phone: 954-776-5471 | Fax: 954-776-5529 www.bosch-climate-us Revised: 09/2016...