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Bosch HP270-2 Technical Manual

Domestic hot water heat pump
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TECHNICAL MANUAL FOR AFTER SALES AND
SERVICE TECHNICIANS

DOMESTIC HOT WATER

HEAT PUMP 200 / 250 / 270 L
This document is confidential and restricted to exclusive use by the official technical
assistance of Bosch in the countries of destination of this product.

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  Summary of Contents for Bosch HP270-2

  • Page 1: Domestic Hot Water

    TECHNICAL MANUAL FOR AFTER SALES AND SERVICE TECHNICIANS DOMESTIC HOT WATER HEAT PUMP 200 / 250 / 270 L This document is confidential and restricted to exclusive use by the official technical assistance of Bosch in the countries of destination of this product.
  • Page 2 1) Introduction Domestic Hot Water Heat Pumps (DHW-HP), with or without air connections ducts, use the heat existing in the surrounding air, or the wasted heat from the indoor air, as energy source for DHW preparation. This model of domestic hot water heat pump provides hot water for residential purposes, using a closed refrigerant unit filled with R134a.
  • Page 3 2.1) Operation Modes Operation Modes (HP 270-2) Comment = 50ºC / 54ºC (default value depends Combi Mode software version) (default selection from factory) Temperature adjustment: 30ºC to 70ºC Heat Pump Mode Temperature adjustment: 30ºC to 60ºC Electric Heater Mode Temperature adjustment: 30ºC to 70ºC New Platform (HP270-3 and HP200/250-1) Standby Combi Mode...
  • Page 4 From FD ≥ 306 (June 2013) until FD ≤ 453 (May 2014): HPAF0501 (-10ºC / + 35ºC models) HPAF0701 (+5ºC / +35ºC models) Operation Mode described during manual. From FD ≥ 454 (June 2014): HPAF0502 (-10ºC / + 35ºC models) HPAF0702 (+5ºC / +35ºC models) Changes done in new version:...
  • Page 5 Comfort Improvement – to improve comfort a waiting time was introduced, so while heating, the appliance will be able to detect if the user is tapping water. In situations where the storage tank has an uniform temperature near the set point and a tapping is detected, the heat pump will stop for 1 hour to maximize the use of hot water in top part.
  • Page 6 Pict.2 – Parameters overview in main and sub menu of HP270-2 Page 6 from 56 6-720-821-364 SM HP270 – 250 - 200 2016/12 en...
  • Page 7 ≥ T bottom module tank Pict.3 – Heat Pump Diagram (Model HP270-2: -10ºC / +35ºC) Operation Modes Applicable to HP-2 with software version: HPAF0501 / 0502 / 0503 (-10ºC / + 35ºC models) HPAF0701 / 0702 / 0703 (+5ºC / +35ºC models)
  • Page 8 From FD ≥ 660 (Dec 2016): HPAF2501 (-10ºC / + 35ºC models) (HP270-3) HPAF2701 (+5ºC / +35ºC models) (HP270-3) Introduction of HP 270-3 Model Product Changes: New HMI concept; Remove of “Rcir” parameter; Replacement of Tank Bushes; Replacement of charging / measurement point cover; Magnesium Anode in tank bottom but possible control by measuring current;...
  • Page 9 Pict.5 – Parameters overview in main and sub menu of HP270-3 / HP200/250-1 Applicable to HP-3 with software version: HPAF2501 (-10ºC / + 35ºC models) (HP270-3) HPAF2701 (+5ºC / +35ºC models) (HP270-3) HPAF2801 (+5ºC / +35ºC models) (HP200/250-1) Operation Mode Evaporator Compressor Solenoid...
  • Page 10 Only HP270-3 and HP200/250-1: Integrated E-Heater in module Pump + Electric Heater ON Pump + Electric Heater ON Pict.6 – Heat Pump Diagram (Model HP270-2: -10ºC / +35ºC) Page 10 from 56 6-720-821-364 SM HP270 – 250 - 200 2016/12 en...
  • Page 11 Legionela disinfection: From both manual (instantaneous) and automatic (weekly operation) selection, the legionela function will assure the COMBI mode operation during the 1 24 hours (compressor until T > 60ºC and only E-Heater until T > 70ºC), nevertheless and if this was not enough to complete LEG function, the HP switch to FULL mode. Stop condition: >...
  • Page 12 Changes in Air Defrost sequence (Attention: only +5ºC / +35ºC model) Current Behaviour: Air defrost sequence is activated when 5ºC < T < 10ºC for more than 60 min and compressor is ON for more than 60 min. the nº of cycles depends on detection of following additional conditions. Condition (HPAF0702 / HPAF0703): <...
  • Page 13 Compressor Compressor Fan ON Fan OFF Solenoid Solenoid Time for pre-gas defrost (HP270-2): < 25ºC / Time = 2 min bottom > 25ºC and < 40ºC / Time = 1 min bottom > 40ºC / Time = 0.5 min bottom Gas Defrost sequence stops when >...
  • Page 14 3) Electric Measurements Pict.11 – Control Unit and cables overview Main Cable supply Mains Plug Compressor Connections Grey-Grey Black Blue High Pressure Switch Capacitor White Connection Solenoid Black Brown - Blue Water Pump Brown - Blue Grey Connector PCB: AC Connector Pict.12 –...
  • Page 15 Pict.13 – Compressor Connection Detail Compressor After turn ON the appliance, the compressor should operate for more than 5 minutes. The compressor should be operated for more than 20 seconds within 15 minutes after charging refrigerant into the system to ensure proper lubrication The compressor should never be operated while under vacuum, otherwise, internal arcing can damage some parts.
  • Page 16 Between C – R > 0 Checking Continuity and Resistance (Ω): Highly ≈ 5.84 Ω Between C – S > 0 Highly ≈ 7.62 Ω Between R – S > 12 Ω (values @ 20ºC) Check earth connection Electric test to compressor: C –...
  • Page 17 Blue Black Brown Brown Capacitor 2 Brown Capacitor 1 Connector Pict.14 – Fan Connection (HP270-2) (EBM Papst) AC controlled HP 270-2 230 V ac between L / N Controlled by 2 capacitors Start = 2µF Note: Only Speed Control = 6.3 µF...
  • Page 18 Solenoid valve (use of multimeter: 230 V ac between L / N Coil: 2.2 kΩ AC voltage measurement and measurement of coil resistance) Note: only models with gas defrost - 10ºC / +35ºC AC Water Pump (use of multimeter: 230 V ac between L / N Internal Resistance: AC voltage Speed 1 - 600 Ω...
  • Page 19 E-Heater Cable Earth Connectors Green-Yellow Green-Yellow Blue Brown Connector AC Green-Yellow Blue Brown E-Heater Connection Pict.15 – Electric Heater Connection (only HP-2) Electric Heater and Thermostat A thermostat control activates the electric heater of 2kW immersed in the storage tank. Attention: Do not change the 1-Reset –...
  • Page 20 27 Ω for Ohmic resistance measurement. Continuity test: 0 Ω Table 6 – Electric Backup Heater components overview (only HP270-2) 2. E-Heater cover protection 1. Drainage of water 3. Thermostat Removal removal 4. Unscrew earth 6. Ensure new gasket when 5.
  • Page 21 Electric Heater integrated in module (improving modularity) The electrical heater backup is ensured through a new type integrated in the module and in line with the condenser plate heat exchanger. Current HP270-2 New HP270-3 Electric Heater Type Standard copper heating element...
  • Page 22 < 30ºC (open tap to cool down circuit and activate Purg) Pict.17 – Safety Thermostat location for reset in HP270-3 Cable of sensors Fins temperature Bottom temperature sensor connector (HP270-2) White Blue Discharge temperature connector (HP270-3) Air temperature Blue sensor...
  • Page 23 1074 1048 Table 9 – NTC characteristic Model Model Model Model Component Characteristics HP270-2 HP270-2 HP270-3 HP200/250-1 +5ºC / +35ºC -10ºC / +35ºC -10ºC / +35ºC +5ºC / +35ºC Air Flow NTC (T air) R 10k = 25ºC = 10000 Ω...
  • Page 24 Pump Xylem (Lowara) 8 – 24 V dc (D5 PWM3-38/700T) 230 V / 50 Hz (4.5 W) Solenoid Valve (2.2 kΩ) 230 (196 - 253) Vac Fan EBM Paspt 50 (47,5 - 52,7) Hz (R2E220-RA38-16) Speed 1: 50 W / Speed 2: 85 W Fan EC controlled 230 V Start Fan Capacitor...
  • Page 25 “-- --“) cleaning of the historical memory of the last 10 failures test display (all segments ON) Table 11 – Service Mode Parameters HP270-2 and HP200/250-1 Page 25 from 56 6-720-821-364 SM HP270 – 250 - 200 2016/12 en...
  • Page 26 Service mode Active symbol on Description Unit parameter the display Set point temperature of hot water on control ºC unit Temperature of Hot Water (T ºC (NTC in the top of the tank) Temperature of discharge water (T ºC (NTC after condenser in module) Temperature of air in circulation (T ºC (NTC between air admission and evaporator)
  • Page 27 4) Refrigerant Cycle Type of refrigerant: R134a - GWP = 1300 / ODP = 0.00, Ebullition temperature = - 26.1ºC, Gas charge: 400 g Discharge Subcooling Water Compressor Outlet Pressure (ºC) Temperature (ºC) Temperature (ºC) (barg) 3 - 5 11.5 3 - 5 3 - 5 Table 13 - Design data...
  • Page 28 The aim of following data is to help technician detects if behaviour and heat up time is normal depending of conditions (thermal power calculation was considering a flow rate of 3.5 l/min (speed 1)) Tank Ambient Module Module Water In Water Out Cond.
  • Page 29 5) EXTERNAL SYSTEMS WORKING PRINCIPLE The “External Systems” accessory gives to the appliance the multi-source energy management function (boiler, solar thermal or solar photovoltaic). The appliance detects and/or activates the most efficient energy source among the available sources. There are 2 possible kits: Photo Voltaic (PV kit) Pict.21 –...
  • Page 30 The connection box contains a terminal of connections to be used according the different needs and / or compatible appliances. 1) HP with Solar Photovoltaic (use TTNR: 7736501838):   PV– 2) HP with wall hung boiler / floor standing boiler (use TTNR: 7736501839): ...
  • Page 31 5.1) Photovoltaic Mode: HP detects if PV is producing electric energy and will turn itself on in order to maximize usage of own generated electricity. Pict.24 – Representative scheme with HP and PV Refer to the IM of accessory (6720808239) for instruction of parameters selection and definition (acess Phot) The “Phot”...
  • Page 32 - to be selected when PV system is feeding the house, in order to ensure hot water even without PV energy as the solar electricity is mainly fed into the grid - to be selected when PV system is connected directly to the HP and solar electricity is used for own consumption first and only excess electricity is fed into the grid Resume: “Suel”...
  • Page 33 If “POr” ON, the appliance switch On as soon as energy is generated by PV system. Example.  When in Man mode, HP turn ON to maximize use of PV.  Even in Auto mode (P1 / P2 / P3) and during a standby period, the HP turn ON to maximize use of PV. The defined programming doesn’t have priority over the PV.
  • Page 34  The HP will just reach the normal set point  The HP will turn ON if:  PV signal active more than 10 min, T top < T set-3ºC 5.2) Solar mode HP detects if the thermal solar system is working, and stop the operation of the heat pump in order to maximize the gain from thermal solar energy.
  • Page 35 The 2 supplied NTC sensors, should be connected according scheme below in order to optimize the solar thermal energy detection when solar pump is activated by the solar control. NTC sensor in Tank Pocket NTC sensor in Coil Pict.26 – Connections in the external system box – “Sol” Specifications: T min –...
  • Page 36 “dTof” – setting for temperature differential at which the HP is switched OFF default setting is 10ºC (available range from 4ºC – 15ºC) Note: the differential temperature for comparison with defined/default “dtof” is measured as: T dif = T coil – T tank T tank = minimum value measure by T top in HP or T tank (supplied sensor assembled in pocket at middle of the tank) T coil = value measure by supplied sensor assembled in inlet of indirect coil.
  • Page 37  HP in COMBI and air temperature outside operating range  HP in COMBI and T set > 60ºC  HP in FULL mode (or when AutoFull was defined by user and activated according detected conditions) Pict.27 – Representative scheme of system with HP and wall hung boiler If the “Boiler Mode”...
  • Page 38  boiler can be used and connected with HP, but without any control of priorities or management from the HP, so boiler will work always in parallel with Hp.  HP system has priority in order to maximize thermal gain from the surrounded air, however the HP is able to manage the system in order to use only the boiler as a backup instead of the integrated electrical heater of 2 kW.
  • Page 39 Pict.29 – Connection of cable “boil IN” / “boil out” in the boiler replacing DHW NTC sensor (note: exemplificative drawing – not model specific) Specifications: T min – lower limit of temperature in storage tank to allow start up of Electric Heater . default setting is 35ºC and values can be selected between 20ºC and “Tset-3ºC”.
  • Page 40 Note: For Software HP1501 / 1701 (HP270-3) and 2501 (HP200/250-1) Only “dTon” needs to be defined and automatically the dtoff is set up to dton + 2ºC “dTon” – setting for temperature differential at which the HP is switched ON default setting is 6ºC (available range from 2ºC –...
  • Page 41 6) Troubleshooting Code E01 – Lock Out error (reset by pressing OK for more than 3 sec) Fault in the hot water NTC temperature sensor (in the top of the tank) (10 kΩ type) The NTC sensor is Note: Ensure NTC connection wire is interrupted or in short NTC top (hot water) correctly plugged in control unit...
  • Page 42 See spare part list sensor is assembled correctly Plug NTC connection wire and turn ON unit Problem solved? Replace control unit See spare part list only HP270-2 Page 42 from 56 6-720-821-364 SM HP270 – 250 - 200 2016/12 en...
  • Page 43 Code E03 – Lock Out Error (reset by pressing OK for more than 3 sec) Fault in the air NTC temperature sensor (yellow mark) (10 kΩ type) The NTC sensor is Ensure NTC connection wire is Note: interrupted or in short correctly plugged in control unit NTC module (air) circuit...
  • Page 44 Code E04 – Warning Code (self reset when press OK * and T top < 75ºC) Temperature in storage tank higher than 80ºC (Detected by the hot water NTC in the top of the tank) * Note: appliance will work if a start condition is reached, however error must be acknowledge by the user. The Top NTC sensor is Unplug the NTC connection wire measuring a wrong...
  • Page 45 Code E05 – Lock Out Error (reset by pressing OK for more than 3 sec) Fault in the evaporator fins NTC temperature sensor (white cables) (8kΩ type) The NTC sensor is ATTENTION: Ensure NTC connection wire is interrupted or in short NTC attached to fins in evaporator correctly plugged in control unit circuit...
  • Page 46 Code E06 – Warning Code Setting buttons pressed for more than 30 seconds. Self Reset error after release the buttons Code E07 * – Lock Out error (reset by pressing OK for more than 3 sec) Fault in the coil NTC temperature sensor The NTC sensor is ATTENTION: Ensure NTC connection wire is...
  • Page 47 Code E08 * – Lock Out Error (reset by pressing OK for more than 3 sec) Fault in the pocket (middle of tank) NTC temperature sensor * Note: external system must be active (Boiler or Solar) in order to allow display of this error. Error is only displayed 2 min after the condition is detected by control unit.
  • Page 48 Code E09 – Lock Out Error (reset by pressing OK for more than 3 sec) Fault in High Pressure circuit side SW HPAF0501 / 0701 – Lock out (electrical heater backup needs manual activation after reset in case of error persist) SW >...
  • Page 49 Check Compressor No continuity should be measured between compressor terminal and chassis: C – chassis ≠ 0 R – chassis ≠ 0 S – chassis ≠ 0 Ensure compressor resistance is ok (at 20ºC) C – R ≈ 5.84 Ω C –...
  • Page 50 Code E10 – Lock Out Error (reset by pressing OK for more than 3 sec) Fault in the E-heater (detection by the current sensor in control unit: I < 6A) The Thermostat is switching off Ensure thermostat is in maximum Ensure NTC top is before HP reach set point fully inserted...
  • Page 51 Code E11 – Lock Out Error (reset by pressing OK for more than 3 sec) Fault in the low pressure circuit side SW HPAF0501 / 0701 – Lock out (electrical heater backup needs manual activation after reset in case of error persist) SW >...
  • Page 52 Failure in low pressure side due to insufficient refrigerant gas flow Expansion valve is Correct position and ensure correctly assembled and insulation is correctly assembled bulb insulated? Dry filter is saturated / Measure inlet / outlet blocked? temperature (should be +/- the same) Refrigerant circuit with Low charge leads to reduced...
  • Page 53 Note: The following troubleshooting procedure is applicable to the new range Code A09 – Warning Message (HP 200_250-1 / 270-3) Possible water shortage Note: Even if after A09 display the problem is overcome, message is kept until set point achievement. Compressor re-tries operation at end of 1 hour after stop with warning activation.
  • Page 54 Code EF6 – Lock Out Error (reset by pressing OK for more than 3 sec) (HP 200_250-1 / 270-3) Detected an incorrect purge of system with E-heater in normal operation (detected by NTC T dis > 85ºC) Air presence in hydraulic Activate PURG function in SET mode circuit in module Purge using manual air vent between...
  • Page 55 Code E13 – Lock Out Error (reset by pressing OK for more than 3 sec) (HP 200_250-1 / 270-3) Incorrect position of Top NTC temperature sensor (reading of tank top temperature) Note: detection done by NTC T dis > T top +30ºC during 3 min) Sensor out of Correct position and ensure enter +/- Note: due to new bottom sensor...
  • Page 56 Error displayed only if E-heater activated for LEG / Anti-Freeze / backup during Combi Mode / E-heater Mode) Correct position and ensure clip is inserted Sensor out of and in contact with copper pipe position? Bosch, Termotecnologia S.A Aveiro Plant Page 56 from 56 6-720-821-364 SM HP270 – 250 - 200 2016/12 en...

This manual is also suitable for:

Hp270-3Hp200-1Hp250-1