Bosch IDS Ultra BOVA60-19 Installation Instructions Manual
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Bosch IDS Ultra BOVA60-19 Installation Instructions Manual

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Installation Instructions
Bosch IDS Heat Pump
Ultra Series Condensing Unit
4 & 5 Ton Capacity | R454b

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Summary of Contents for Bosch IDS Ultra BOVA60-19

  • Page 1 Installation Instructions Bosch IDS Heat Pump Ultra Series Condensing Unit 4 & 5 Ton Capacity | R454b...
  • Page 2 Installation Instructions Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 3: Table Of Contents

    12 Service Valves 21.1 Cleaning Precautions 12.1 Open the Service Valves 21.2 Maintenance – Pre-Season Inspection 13 Electrical - Low Voltage 22 Disposal 13.1 Low Voltage Maximum Wire Length Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 4: Key To Symbols And Safety Instructions

    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. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 5 Recover refrigerant to relieve pressure before opening system. f Flammable Can cause injury or death.Disconnect all remote electric power supplies before refrigerant used. servicing. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 6 Be aware that refrigerants may not contain an odour. NOTICE Indoor unit required! The indoor units must be matched with R-454B TXV. The model of R-454B TXV can be changed according to the system capacity. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 7 If an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refrigerant. • Equipment marking must remain visible and legible. Markings and signs that are illegible shall be corrected. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 8 Cylinders shall be complete with pressure-relief valve and associated shut-off valves in good working order. Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 9 Do not use the air conditioner until a service person confirms that the refrigerant leak is repaired. Keep ventilation openings clear of obstruction. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 10: Gateway Related Warnings

    Operation is subject to the following two conditions: This device may not cause interference. This device must accept any interference, including interference that may cause undesired operation of the device. 10 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 11: Bosch Easyair Mobile App

    Scan QR Code Figure 1 Launch the Bosch EasyAir App, create a profile and add the unit to the app to view on-site and remote system data when starting up the system in Section 15.

  • Page 12: Refrigerant Piping Limits

    Refrigerant tubing lengths up to 36 in. may be buried without further special consideration. Do not bury lines longer than 36 in. 50' Max Line Lift Refrigerant piping limits Figure 4 12 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 13: Location Restrictions

    • In proximity to sources of electromagnetic radiation, such as high- frequency transmitters or other high strength radiation devices. See Fig. 5 and Fig. 6. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 13...

  • Page 14: Refrigerant Charge And Room Area Limitations

    • Approximately every three months, wash the outdoor coil and any exposed cabinet surfaces with clean water. 14 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 15: The Room Area Calculation Requirements

    The room area in which the unit is installed shall be not less than 20% Amin. Amin is shown in Table 6. Table 4 Note: Take the Mc=17 lbs 3 oz as an example. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 15...

  • Page 16: The Allowed Maximum Refrigerant Charge And Required Minimum Room Area

    158.7 257.9 the data in the tables 4, 5 ,6 & 7. Table 6 16 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 17: Unit Preparation

    The outdoor unit vapour service valve and liquid service valve need to be protected. than the fastener embedment) do not grab them when moving the outdoor unit. Figure 12 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 17...

  • Page 18: Mounting Antenna

    Mount antenna away from wall Figure 13 Building Wall Clip antenna by sliding downwards on louver. Secure cable to outdoor unit with two clips. Figure 14 18 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 19: Refrigerant Line Considerations

    IAPMO Uniform Mechanical Code, ICC International Mechanical Code. Inspection prior to being covered or enclosed,or CSA B52. All field joints shall be accessible for inspection prior to being covered or enclosed. Figure 16 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 19...
  • Page 20 Suc tion Line using tape, wire, or other appropriate Comply with National, State, and local codes when isolating linesets from joists, method every 8 ft. rafters, walls, or other structural elements. 20 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 21: Refrigerant Line Connection

    • Welded or brazed joints. • Joints in enclosures that vent to the unit or to the outside. Compliance is checked by inspection and tests. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 21...

  • Page 22: Refrigerant Line Brazing

    Remove the pressure tap cap from both service valves. Shipped in package field installed 3-4" from valve Figure 23 Figure 21 Purge the refrigerant lines and indoor coil with dry nitrogen. 22 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 23: Refrigerant Line Leak Check

    Pressurize the refrigerant lines and evaporator coil to 250 PSIG using dry nitrogen. 250 PSI G Figure 24 Figure 25 Check for leaks by using a soapy solution or bubbles at each brazed location. Figure 26 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 23...

  • Page 24: Evacuation

    Unit Side for Liquid Service Valve of Service Valve 1 MIN. Rolled Edge to Captivate Stem Hex Headed Valve System Figure 28 Service Port Figure 29 24 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 25: Electrical - Low Voltage

    Otherwise, the connectors may be loose or the terminal may be damaged when they are pulled. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 25...

  • Page 26: Communicating Set Up

    To connect the Hyper-Link (M1 M2) communication wires: Figure 33 Peel off the half-stripped wires of the pre-installed Hyper-Link (M1 M2) communication wires. CN10 Figure 31 26 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 27 Note: Any time the electric heat elements are active, the indoor fan will run in high stage. Support 4H and 2C thermostat communication mode setup Control wiring for HP systems Figure 35 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 27...
  • Page 28 Note: Any time the electric heat elements are active, the indoor fan will run in high stage. Support 2H and 2C thermostat communication mode setup Control wiring for HP systems Figure 37 28 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 29 Control wiring for HP systems Figure 39 Hyper-Link (M1 M2) communication mode and conventional 24VAC non- communicating thermostat control mode can not be used at the same time. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 29...

  • Page 30: Non-Communicating Set Up

    Plug the conventional 24VAC non-communicating control wires (C, B, Y and W) into CN31 on the control board. Peel off the half-stripped wires. Figure 43 CN31 Figure 41 30 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 31 Note: Any time the electric heat elements are active, the indoor fan will run in high stage. Support 4H and 2C thermostat non-communicating setup Control wiring for HP systems Figure 45 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 31...
  • Page 32 Note: Any time the electric heat elements are active, the indoor fan will run in high stage. Support 2H and 2C thermostat non-communicating setup Control wiring for HP systems Figure 47 32 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 33 Note: Any time the electric heat elements are active, the indoor fan will run in high stage. Support 3H and 1C thermostat non-communicating setup Control wiring for HP systems Figure 49 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 33...
  • Page 34 Line Line Line Diameter (AWG) Gauge Line Quantity Outdoor -Indoor Signal Line Line Diameter (AWG) Line Quantity Thermostat Signal Line Line Diameter (AWG) Table 11 34 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 35: Electrical - High Voltage

    It is recommended to install a appropriate surge protection device to safeguard the unit and other electrical components in the event of power surge Main fuse box/breaker panel Service disconnect switch High voltage disconnect switch Figure 51 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 35...

  • Page 36: Unit Type Selection

    Once power is supplied to the outdoor unit. LEDS on the Gateway will turn Figure 56 A LED sequence may flash on gateway for up to 6 minutes if there is a firmware update. 36 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 37 Installation Instructions Open up the Bosch EasyAir app and "Add a New Unit". The app will prompt you to scan the outdoor unit Serial Number and Gateway QR code. Figure 59 Upon initial unit installation, wait one (1) hour before starting the unit if...

  • Page 38: Communication With Bcc100/Bcc110 (Optional)

    Homeowner will find "Appliance Pairing" option in the outdoor unit setting tab. For multi-zone applications, multiple thermostats can be paired to the same outdoor unit. Figure 63 38 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 39: System Charge Adjustment

    The only mode approved for validating system charge is while in Cooling "Force Mode". Outdoor temperature must be between 55°F and 120°F with indoor Download and install the Bosch EasyAir app to assist in charging the unit. temperature kept between 70°F and 80°F.
  • Page 40 • Measured Liquid Line Pressure = _______ PSIG • Calculate subcooling value = ________ºF Insulation R-454B Refrigerant chart - Final Subcooling Table 16 Figure 69 40 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 41: Record The Refrigerant Charge Amount

    Wait 5 minutes for the system condition to stabilize between adjustments. When the subcooling matches the design value (Table 14), the system is properly charged. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 41...

  • Page 42: System Operation And Troubleshooting

    T3 = Outdoor Coil Temperature (Table 20) ◦ High/Low temperature protection ◦ Outdoor fan control (cooling mode) Download and install the Bosch EasyAir app to assist in troubleshooting the unit. ◦ Defrost control (heating mode) • T4 = Ambient Temperature (Table 20) ◦...

  • Page 43: Compressor Crankcase Heater Description

    12 hours prior to compressor operation by applying line voltage to heat • Low discharge superheat protection pump with thermostat OFF. Head discharge superheat HDSH<9°F last 40minutes. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 43...

  • Page 44: Fault Code Table

    High compressor discharge temperature protection (T5) Condensor coil temperature protection in cooling (T3) Hyper-Link (M1 M2) over current protection Low discharge superheat protection Table 21 44 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 45: System Protection Status Codes

    Hz), the unit will continue to run but in a limited condition. The only exception is when the system is in defrost mode, which only displays "dF" (without any numerical digits following). Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 45...

  • Page 46: Parameter Check Point Table

    T2: indoor unit coil temp.(°F) (only for communication mode) °F Indoor unit software version(only for communication mode) Demand Response Setting reserved Remark“--” Parameter check points Table 23 46 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 47: Control Board Overviews

    33. Fan motor port 34. Compressor: W port 35. Compressor: V port 36. Compressor: U port 37. Power input 9 10 38. Power input Figure 75 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 47...

  • Page 48: Error Code Troubleshooting

    Replace the indoor unit control board Figure 77 Is the resistance of T4 Replace T4 sensor in the range of Table 20? Restart system Figure 76 48 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 49 Has Fault cleared? Replace the A2L refrigerant sensor Replace ODU Control Board and power the unit back up again. and restart unit. Figure 81 Figure 79 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 49...
  • Page 50 Is the resistance of Replace the T4 sensor. sensor T4 not in range of table 15? Normal operation. Figure 84 Replace the control board. Figure 85 50 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 51 Replace the failed sensor. Did the sensor T3 Replace the failed sensor. fail? fail? Replace the control board. Replace the control board. Figure 87 Figure 86 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 51...
  • Page 52 Did the sensor T4 Replace the failed sensor. Replace the failed sensor. fail? fail? Replace the control board. Replace the control board. Figure 88 Figure 89 52 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 53 Replace the faulty temperature sensor temperature according to the Replace the control board. resistance temperature table? Figure 90 Replace the outdoor unit control board. Figure 91 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 53...
  • Page 54 Replace the outdoor unit Replace the outdoor unit control board. control board. Figure 92 Figure 93 54 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 55 35F (to be Replace the outdoor confirmed via check point #6 control board on the board), is the voltage at CN42 between 187-253V? Restart system Figure 94 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 55...
  • Page 56 Replace EEVA coil and Normal operation. restart. Is the fault cleared? Replace the outdoor unit control board Figure 96 Replace the outdoor unit control board. Figure 98 56 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 57 Did the pressure Replace the pressure transducer fail? transducer. Replace the Did the control board fail? control board. Figure 102 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 57...
  • Page 58 J00-JCF Compressor chip fault Replace the outdoor control board and restart Replace the control board and restart the system. the system Figure 108 Figure 106 58 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 59 Adjust the refrigerant charge overcharged? to the correct amount. Figure 110 Is there poor heat Replace the fan motor. exchange on the high pressure side? Figure 109 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 59...
  • Page 60 >1M ohm? Restart system after replacing the Replace the compressor and ODU control restart the system. board, has the fault cleared? Figure 112 60 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 61 Figure 113 Is the system Adjust the refrigerant charge undercharged? to the correct amount. Figure 114 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 61...
  • Page 62 Is the fault cleared? Is there poor heat Restart system Replace the fan motor. exchange on the high pressure side? Figure 116 Figure 115 62 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 63: Online Help Resources

    EEVA. EEVA failed? Adjust the refrigerant Is the system charge according to the overcharged with suggested sub cool and refrigerant? superheat. Restart system Figure 117 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 63...

  • Page 64: Temperature And Resistance Relationship Tables (For Sensors)

    1.57 76.67 1.28 82.22 1.00 87.78 0.91 93.33 0.76 98.89 0.65 104.44 0.56 for T3, T3L, T4, T6A, T6B, T7, T1, T2 sensors Table 24 64 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 65: Temperature And Resistance Relationship Tables (For T5 Sensors)

    20.53 54.44 16.71 60.00 13.64 65.67 11.21 71.11 9.31 76.67 7.75 82.22 6.50 87.78 5.47 93.33 4.65 98.89 3.95 104.44 3.38 for T5 Table 25 Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 65...

  • Page 66: Wiring Diagram

    Factory code Date Revision Refrigerant amount judgment: significantly insufficient Reserved Feb. 27th, 2024 16023000014172 Remark"--" Note: o31-o36 are only valid in force cooling mode. Figure 119 66 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 67: Ids Ultra Gateway Functionality

    5. Factory (Diagnostic) Button 6. Connect (Bluetooth) Button 7. Reset Button The Gateway Assembly includes the Gateway and Antenna, along with associated wiring harness and clips. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 67...

  • Page 68: Care And Maintenance

    When removing filter, do not touch metal parts in the unit. The sharp metal edges can cut you. Make sure nothing is blocking all air inlets and outlets Figure 121 68 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)

  • Page 69: Disposal

    Law requires that the collection, transportation and disposal of refrigerants must conform with the regulations governing the collection and destruction of hydrofluorocarbons. Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 69...
  • Page 70 Installation Instructions NOTES: 70 | Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024)
  • Page 71 Installation Instructions NOTES: Bosch IDS Heat Pump Ultra Series Condensing Unit - BTC 762003305 A (06.2024) | 71...
  • Page 72 United States and Canada Bosch Thermotechnology Corp. 65 Grove St. Watertown, MA 02472 Tel: 800-283-3787 www.bosch-homecomfort.us BTC 762003305 A / 06.2024 Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.

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