Bosch Climate 5000i / CL5000iU W 26 E / CL5000iU W 35 E Manual

Explanation of symbols

In warnings, signal words at the beginning of a warning are used to indicate the type and seriousness of the ensuing risk if measures for minimizing danger are not taken.
The following signal words are defined and can be used in this document:

DANGER indicates that severe or life-threatening personal injury will occur.

WARNING indicates that severe to life-threatening personal injury may occur.

CAUTION indicates that minor to medium personal injury may occur.
NOTICE
NOTICE indicates that material damage may occur.

The info symbol indicates important information where there is no risk to people or property.
Table 61

Symbol	Meaning
	Warning regarding flammable substances: the refrigerant R32 used in this product is a gas with low combustibility and low toxicity (A2L or A2).
	Wear protective gloves during installation and maintenance work.
	Maintenance by a qualified person should be done while following the instructions of the service manual.
	For operation follow the instructions of the user manual.

Product Information

Scope of delivery

Key to Fig. 1:

1. Outdoor unit (filled with refrigerant)
2. Indoor unit (filled with nitrogen)
3. Cold catalyst filter (black) and bio filter (green)
4. Drainage elbow with gasket (for outdoor unit with floor or wall mounting bracket)
5. Remote control
6. Remote control holder with fixing screw
7. Fixing materials (5 screws and 5 wall plugs)
8. Set of printed documents for product documentation
9. 5-core communication cable (optional accessory)
10. 4 anti-vibration couplings for the outdoor unit

Product dimensions and minimum clearances

Indoor unit and outdoor unit
Figures 2 to 4.

Refrigerant lines
Key to Fig. 5:

1. Gas-side pipe
2. Liquid-side pipe
3. Siphon-shaped elbow as oil separator

If the outdoor unit is positioned higher than the indoor unit, install a siphon-shaped elbow on the gas side after no more than 6 m and every 6 m thereafter (Fig. 5, [1]).

• Observe maximum pipe length and maximum difference in height between indoor unit and outdoor unit.

Table 63 Pipe Length and Drop Height

1. Gas side or liquid side
2. Measured from lower edge to lower edge.

Table 64 Pipe diameter depending on unit type

Table 65 Alternative pipe diameter

Table 66

Information on refrigerant

This device contains fluorinated greenhouse gases as refrigerant. The device is hermetically sealed. You will find the information on the refrigerant according to the Regulation (EU) No 517/2014 on fluorinated greenhouse gases in the operating instructions of the device.

Information for the installer: If you refill refrigerant, enter the additional charge size and the total charge size of the refrigerant in the table "information on refrigerant" of the operating instructions.

Installation

Before installation

Risk of injury from sharp edges!

• Wear protective gloves during installation.

Danger of burns!
During operation the pipes become hot.

• Make sure, that the pipes cooled down before touching them.

• Check the scope of delivery for damage.
• Check whether a hissing sound due to negative pressure can be detected when opening the pipes of the indoor unit.

Requirements for installation site

• Observe minimum clearances (Figs. 2 to 3).

Indoor unit

• Do not install the indoor unit in a room in which open ignition sources (for example: open flames, an operating wall mounted gas boiler or an operating electric heating system) are in operation.
• The installation site must not be higher than 2000 m above sea level.
• Keep the air inlet and air outlet clear of any obstacles to allow the air to circulate freely. Otherwise bad performance and higher noise level may occur.
• Keep TV, radio and and similar appliances at least 1 m away from the unit and the remote control.
• Mount the indoor unit on a wall that absorbs vibrations.
• Take minimum room area into account.

Table 67 Minimum room area

If the installation height is lower, the floor area must be accordingly larger.

Outdoor unit

• The outdoor unit must not be exposed to machine oil vapour, hot spring vapour, sulphur gas, etc.
• Do not install the outdoor unit directly next to water or where it is exposed to sea air.
• The outdoor unit must always be kept free of snow.
• There must be no disruption caused by exhaust air or operating noise.
• Air should be able to circulate freely around the outdoor unit, but the appliance must not be exposed to strong wind.
• Condensate that forms during operation must be able to drain off easily. Lay a drain hose if required. In cold regions, installation of a drain hose is not advisable as it could freeze.
• Place the outdoor unit on a stable base.

Unit installation

NOTICE
Incorrect assembly can cause material damage.
If the unit is assembled incorrectly, it may fall off the wall.

• Only install the unit on a solid flat wall. The wall must be capable of supporting the weight of the unit.
• Only use screws and wall plugs that are suitable for the wall type and weight of the unit.

Installing the indoor unit

• Open the box at the top and lift the indoor unit out and up (Fig. 6).
  
• Place the indoor unit with the moulded parts of the packaging face down (Fig. 7).
  
• Undo screw and remove the mounting plate on the rear of the indoor unit.
• Determine the installation location, taking the minimum clearances into consideration (Fig. 2).
• Attach the mounting plate centrally with a screw and wall plug to the wall and level out (Fig. 8).
  
• Fasten the mounting plate with a further four screws and wall plugs so that the the mounting plate lies flat on the wall.
• Drill wall outlet for the piping (wall outlet should be behind the indoor unit as a recommendation Fig. 9).
  
• Change the position of the condensate pipe if necessary (Fig. 10).
  

The pipe fittings on the indoor unit are generally located behind the indoor unit. We recommend extending the pipes before mounting the indoor unit.

• Establish pipe connections as described in Chapter "Pipework connection".

• Bend the piping in the required direction if necessary, and knock out an opening on the side of the indoor unit (Fig. 12).
  
• Route the piping through the wall and attach the indoor unit to the mounting plate (Fig. 13).
  
• Fold up the top cover and remove one of the two filter elements (Fig. 14).
  
• Insert the filter which is included in the scope of delivery into the filter element, and mount the filter element again.

If it is necessary to take the indoor unit off the mounting plate:

• Pull the underside of the casing down in the area of the two recesses and pull the indoor unit forwards (Fig. 15).
  

Installing the outdoor unit

• Place the box so it is facing upwards.
• Cut and remove the packing straps.
• Pull the box up and off and remove the packaging.
• Prepare and mount a floor or wall mounting bracket, depending on the type of installation.
• Mount or hang the outdoor unit using the anti-vibration coupling for the feet which is supplied with the unit or is provided on site.
• When installing on the floor or wall mounting bracket, attach the supplied drainage elbow and gasket (Fig. 16).
  
• Remove the cover for the pipe connections (Fig. 17).
  
• Establish pipe connections as described in Chapter "Pipework connection".
• Mount the cover for the pipe connections again.

Pipework connection

Connecting refrigerant lines to the indoor and outdoor unit

Discharge of refrigerant due to leaky connections
Refrigerant may be discharged if pipe connections are incorrectly installed. Reusable mechanical connectors and flared joints are not allowed indoors.

• Tighten flared connections only once.
• Always make new flared connections after loosening.

Copper pipes are available in metric and imperial sizes, the flare nut thread is however the same. The flared fittings on the indoor and outdoor unit are intended for imperial sizes.

• When using metric copper pipes, replace the flare nuts with nuts of a suitable diameter (Tab. 68).

• Determine pipe diameter and length.
• Cut the pipe to length using a pipe cutter (→Fig. 11).
  
• Deburr the inside of the pipe at both ends and tap to remove swarf.
• Insert the nut onto the pipe.
• Widen the pipe using a flaring tool to the size indicated in the tab. 68. It must be possible to slide the nut up to the edge but not beyond it.
• Connect the pipe and tighten the screw fitting to the torque specified in the tab. 68.
• Repeat the above steps for the second pipe.

NOTICE
Reduced efficiency due to heat transfer between refrigerant pipes

• Thermally insulate the refrigerant lines separately.

• Fit the insulation on the pipes and secure.

Table 68 Key data of pipe connections

External diameter of pipe Ø [mm]	Tightening torque [Nm]	Flared opening diameter (A) [mm]	Flared pipe end	Pre-assembled flare nut thread
6.35 (1/4")	18-20	8.4-8.7		3/8"
9.53 (3/8")	32-39	13.2-13.5		3/8"

Connecting condensate pipe to the indoor unit

The condensation catch pan of the indoor unit has two connections. A condensate hose and bung are mounted on these connections at the factory and can be replaced (Fig. 12).

• Only route the condensate hose with a slope.

Checking tightness and filling the system

Checking tightness
Observe the national and local regulations when carrying out the tightness test.

• Remove the caps on the three valves (Fig. 18, [1], [2] and [3]).
  
• Connect the Schrader opener [6] and pressure gauge [4] to the Schrader valve [1].
• Screw in the Schrader opener and open the Schrader valve [1].
• Leave valves [2] and [3] closed and fill the system with nitrogen until the pressure is 10% above the maximum operating pressure.
• Check whether the pressure is still the same after 10 minutes.
• Discharge the nitrogen until the maximum operating pressure is reached.
• Check whether the pressure is still the same after at least 1 hour.
• Discharge nitrogen.

Filling the system
NOTICE
Malfunction due to incorrect refrigerant
The outdoor unit is filled with R32 refrigerant at the factory.

• If refrigerant needs to be topped up, only use the same refrigerant. Do not mix refrigerant types.

• Evacuate and dry system with a vacuum pump (Fig. 18, [5]) until the pressure is approx. −1 bar (or approx. 500 microns).
• Open the valve at the top [3] (liquid side).
• Use a pressure gauge [4] to check whether the flow is unobstructed.
• Open valve at bottom [2] (gas side).The refrigerant is distributed round the system.
• Afterwards, check the pressure ratios.
• Unscrew the Schrader opener [6] and close the Schrader valve [1].
• Remove the vacuum pump, pressure gauge and Schrader opener.
• Reattach the valve caps.
• Reattach the cover for pipe connections to the outdoor unit.

Electrical connection

General notes

Risk to life from electric shock!
Touching live electrical parts can cause an electric shock.

• Before working on electrical parts, disconnect all phases of the power supply (fuse/circuit breaker) and lock the isolator switch to prevent unintentional reconnection.

• Work on the electrical system must only be carried out by an authorised electrician.
• An authorised electrician must determine the correct conductor cross-section and circuit breaker. The maximum current consumption of the technical data (see chapter "Tech data") is decisive for this purpose.
• Observe safety measures according to national and international regulations.
• If you identify a safety risk in the mains voltage, or if a short circuit occurs during installation, inform the operator in writing and do not install the appliances, until the problem has been resolved.
• All electrical connections must be made in accordance with the electrical connection diagram.
• Only use a special tool to cut cable insulation.
• Connect the cable to the existing mounting clips/cable glands using suitable cable ties (scope of delivery).
• Do not connect any additional consumers to the mains power supply of the device.
• Do not mix up live and PEN conductor. This can lead to malfunctions.
• If the mains power supply is fixed, install an overvoltage protector and isolator which is designed for 1.5 times the maximum power input of the appliance.

Connecting the indoor unit

The indoor unit is connected to the outdoor unit using a 5-core communication cable of the type H07RN-F. The conductor cross-section of the communication cable should be at least 1.5 mm².
NOTICE
Material damage due to incorrectly connected indoor unit
Voltage is supplied to the indoor unit via the outdoor unit.

• Only connect the indoor unit to the outdoor unit.

To connect the communication cable:

• Fold up the top cover (Fig. 19).
  
• Undo screw and remove cover of the interface panel.
• Remove screw and cover [1] of the terminal (Fig. 20).
  
• Knock out an opening for the cable feed [3] on the rear of the indoor unit and feed the cable through.
• Secure cable to the strain relief [2] and connect to the terminals W, 1(L), 2(N), S and .
• Note assignment of wires to the terminals.
• Reattach the covers.
• Route the cable to the outdoor unit.

Connecting the outdoor unit

A power cable (3-core) is connected to the outdoor unit and the communication cable is connected to the indoor unit (5-core). Use cables of the type H07RN-F with sufficient conductor cross-section and protect the mains power supply with a fuse (Table 69).
Table 69

• Undo the screw and remove the cover of the electrical connection (Fig. 21).
  
• Secure the communication cable to the strain relief and connect to the terminals W, 1(L), 2(N), S and (assignment of wires to terminals same as indoor unit) (Fig. 22).
  
• Secure power cable to the strain relief and connect to the terminals L, N and .
• Reattach cover.

Commissioning

Commissioning checklist

Table 70

Functional test

The system can be tested once the installation including tightness test has been carried out and the electrical connection has been established:

• Connect the power supply.
• Switch on indoor unit with the remote control.
• Press the Mode key to set the cooling mode ().
• Press arrow key () until the lowest temperature is set.
• Test cooling mode for 5 minutes.
• Press the Mode key to set the heating mode ().
• Press arrow key () until the highest temperature is set.
• Test heating mode for 5 minutes.
• Ensure freedom of movement of horizontal louver.

If the room temperature is less than 17°C, the cooling mode must be switched on manually. This manual operation is only envisaged for testing and emergency situations.

• Otherwise, always use the remote control.

To switch on the cooling mode manually:

• Switch off the indoor unit.
• Press the key for the manual cooling mode twice with a thin object (Fig. 23).
  
• Press the Mode key on the remote control to exit cooling mode when it has been set manually.

In a system with multi-split air conditioner, manual operation is not possible.

Handover to the user

• When the system has been set up, hand over the installation manual to the customer.
• Explain to the customer how to use the system, referring to the operation manual.
• Advise the customer to carefully read the operation manual.

Troubleshooting

Faults with indication

Risk to life from electric shock!
Touching live electrical parts can cause an electric shock.

• Before working on electrical parts, disconnect all phases of the power supply (fuse/circuit breaker) and lock the isolator switch to prevent unintentional reconnection.

If a fault occurs during operation, a fault code appears in the display (e.g. EH 02).

If a fault is present for more than 10 minutes:

• Briefly interrupt the power supply and switch the indoor unit back on.

If a fault persists:

• Call customer service and provide the fault code and details of the appliance.

Table 71

1. Leak detection not active, if in a system with multi-split air conditioner.

1. Conflicting operating mode of indoor unit. This can occur in a multi split system, when different units operate in different modes. To solve the problem, adjust operating mode accordingly.

Note: units set to cooling/dry/fan mode will be affected with a mode conflict as soon as one other unit in the system is set to heating (heating is the priority system mode).

Faults not indicated

Table 72

1. A fuse for the overcurrent protection is located on the main PCB. The specification is printed on the main PCB and can also be found in the technical data.

Tech data

Table 73

General safety instructions

Notices for the target group
These installation instructions are intended for qualified persons who are skilled in dealing with refrigeration engineering and HVAC technology and also electrical systems. All system-relevant instructions must be observed. Failure to comply with instructions may result in material damage and personal injury, including danger to life.

• Before carrying out the installation, read the installation instructions of all system components.
• Observe the safety instructions and warnings.
• Follow national and regional regulations, technical regulations and guidelines.
• Record all work carried out.

Intended use
The indoor unit is intended for installation inside the building with connection to an outdoor unit and further system components, e.g. controls.
The outdoor unit is intended for installation outside the building with connection to an indoor unit or units and further system components, e.g. controls.
The air conditioning system is intended for commercial/residential use only where temperature deviations from adjusted set points do not lead to damage of living beings or materials. The air conditioning system is not suitable to set and maintain desired absolute humidity levels precisely.
Any other use is considered inappropriate. Any damage that may result from misuse is excluded from liability.
For installation at special locations (underground garage, mechanical rooms, balcony or at any semi-open areas):

• First refer to the requirements for the installation site in the technical documentation.

General dangers posed by the refrigerant

• This appliance is filled with refrigerant R32. If the refrigerant gas gets into contact with fire, it may generate toxic gas.
• Thoroughly ventilate the room if refrigerant leaks during the installation.
• Check the tightness of the system following the installation.
• Do not to let any other substance than the specified refrigerant (R32) into the refrigerant cycle.

Safety of electrical devices for domestic use and similar purposes
The following requirements apply in accordance with EN 60335-1 in order to prevent hazards from occurring when using electrical appliances:
"This appliance can be used by children of 8 years and older, as well as by people with reduced physical, sensory or mental capabilities or lacking in experience and knowledge, if they are supervised and have been given instruction in the safe use of the appliance and understand the resulting dangers. Children shall not play with the appliance. Cleaning and user maintenance must not be performed by children without supervision."
"If the power cable is damaged, it must be replaced by the manufacturer, its customer service department or a similarly qualified person, so that risks are avoided."

Handover to the user
When handing over the air conditioning system, explain the operation and operating conditions to the user.

• Explain operation – with particular emphasis on all safety-related actions.
• Highlight the following points in particular:
  • Point out that modifications or repairs may be carried out only by an approved contractor.
  • To ensure safe and environmentally compatible operation, an annual inspection, and also cleaning and maintenance if required, must be carried out.
• Point out the possible consequences (personal injury and possible danger to life or material damage) of not carrying out inspection, cleaning and maintenance correctly, or omitting it altogether.
• Hand over the installation and operating instructions to the user for safekeeping.