Bosch MC Series Installation, Operation And Maintenance Manual
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Bosch MC Series Installation, Operation And Maintenance Manual

Bosch MC Series Installation, Operation And Maintenance Manual

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Installation, Operation, and Maintenance Manual
MC Series Heat Pumps
(R454B)
MC360 | MC480 | MC600 | MC720

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Summary of Contents for Bosch MC Series

  • Page 1 Installation, Operation, and Maintenance Manual MC Series Heat Pumps (R454B) MC360 | MC480 | MC600 | MC720...
  • Page 2 Installation, Operation, and Maintenance Manual MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 3: Table Of Contents

    9.2 Checking Scroll Compressor Rotation 17.7 Check Cabling 9.2.1 Correcting Direction of Rotation 17.8 Detection of Flammable Refrigerants 17.9 Removal and Evacuation 10 Start-up 17.10 Charging Procedures 10.1 Unit Start Up Cooling Mode 17.11 Recovery MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 4 Belt-Drive Motor 21.4 Two-Stage, Three-Phase Standard Unit with Dual-Point Power and Belt-Drive Motor 21.5 DDC Control 6126 21.6 DDC I/O Flex EX8160 22 Terminology 22.1 Acronyms 22.2 Terms 23 Check-Out Sheet MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 5: Document Conventions

    Use a quenching cloth for brazing, and place a fire 1.1.2 Important information extinguisher close to the work area. The info symbol indicates important information where there is no risk to property or people. MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 6: Refrigerant Safety Warnings

    Children should be supervised to ensure that they do not play with the appliance. To avoid the release of refrigerant into the atmosphere, the refrigerant circuit of this unit must be serviced only by technicians who meet local, state, and federal proficiency requirements. MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 7 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. MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 8: Model Nomenclature

    Modulating Hot Gas Reheat N — Modulating Hot Gas Reheat with Straight Cool S — Straight Cool T — Hot Gas Bypass with Straight Cool X — None Figure 1 Model Nomenclature MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 9: General Description

    Note: Maximum and minimum operating limits may not be combined. Refer to Engineer Submittal Sheet on the product information page. (See the QR code on the back page of the IOM). Acronyms: EXT: Extended Range application option STD: Standard application option LWT: Leaving Water Temperature EWT: Entering Water Temperature MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 10: Inspecting And Storing The Equipment

    If the equipment is not needed for immediate installation upon its arrival at the job discovered until after removing the units from packaging must be reported to Bosch site, it should be left in its shipping factory condition and stored in a clean and dry area.

  • Page 11: Unit Installation

    This section contains information on the following: Product damage! • Location Selection—page 11 MC series units are not approved for outdoor installation; therefore, they must be • Minimum Conditioned Room Area—page 12 installed inside a structure in a conditioned space.

  • Page 12: Minimum Conditioned Room Area

    3778 MC600 (32.2) (8.1) (194.5) (175.5) (156.0) (140.4) (117.0) (1605) (6420) 1056 1946.5 1756.2 1561.0 1404.9 1170.8 3512 MC720 (29.9) (7.5) (180.8) (163.2) (145.0) (130.5) (108.8) (1492) (5968) Table 3 12 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 13: Protecting The Unit During Construction

    Once the unit is properly positioned on the job site, cover it with either a shipping All MC Series models are provided with a supply air outlet collar and return air duct carton, vinyl film, or an equivalent protective covering. Cap opens ends of pipes flange to facilitate duct connections.

  • Page 14: Installation Of Pressure Regulating Valves

    The water flow can be accurately set by measuring the water-to- refrigerant heat exchangers water-side pressure drop. See the unit specification sheets for the water flow and pressure drop information. 14 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 15: Electrical-Power Supply Wiring

    All field-installed wiring must comply with the National Electric Code as well as all Product damage! applicable local codes. Power to the unit must be within the operating voltage range indicated on the unit’s nameplate or on the performance data sheet. MC Series Heat Pumps - 8733850301 (2025/02) US | 15...

  • Page 16: Electrical-Low-Voltage Wiring

    208-V option is ordered. For job sites with a 208-V power supply, the primary leads on the unit transformer will need to be changed from 240-V to 208- V. Refer to the unit wiring diagrams starting on page 54. 16 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 17: Thermostats With A Malfunction Light

    Exceeding the transformer capacity will result in low control voltage, erratic unit 18 AWG (0,75mm2) 385 ft. (117m) operation, or damage to the heat pump. Table 5 Length by Wire Gauge for Thermostat to HVAC Equipment Wiring MC Series Heat Pumps - 8733850301 (2025/02) US | 17...

  • Page 18: Low-Voltage Va Draw

    Total VA draw Total Draw Is Dependant on the Options Installed Installed Table 8 Low-Voltage VA Draw Table Units supplied with 100VA Transformer(s) from factory (360 QTY 1; 480-720 QTY 2) 18 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 19: Specific Application Considerations

    [1] Flex Duct Connection [2] Solenoid Valve, Slow Closing [3] Pressure Tank (optional) [4] Ball Valves [5] Condensate Drain Connection [6] P/T Ports (optional) [7] Line Voltage Connection [8] Low-Voltage Control Connection MC Series Heat Pumps - 8733850301 (2025/02) US | 19...

  • Page 20: Cooling Tower/Boiler Systems

    Figure 7 Typical Cooling Tower and Boiler System Setup 1] Supply and Return Line of Central System [2] Ball Valves [3] Hose Kits (optional) [4] Line-Voltage Control Connection [5] Low-Voltage Control Connection [6] Flex Duct Connection 20 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 21: Water-Quality Considerations

    Fouling due to iron bacteria can also pose problems in some open loop installations. Iron bacteria fouling can quickly degrade system performance and plug heat exchangers. Air in the water system will greatly accelerate the fouling or corrosion process. MC Series Heat Pumps - 8733850301 (2025/02) US | 21...
  • Page 22 < 10 ppm, < 600 µm size** Erosion Maximum Water Velocity 6 ft/sec 6 ft/sec Table 9 Water Quality * No "rotten egg" smell present at < 0.5 ppm H2S. ** Equivalent to 30 mesh strainer 22 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 23: Post-Installation System Checkout

    (See 16.7 Pulley Alignment and Belt Tensioning Procedure on page 36.) 9.2 Checking Scroll Compressor Rotation Scroll compressors, like the ones used on the MC series, are phase sensitive. When out of phase, the compressors will run in reverse. After a few minutes of reverse operation, the compressor internal overload protection will open, activating the unit lockout.

  • Page 24: Start-Up

    Once the unit has begun to run, check for warm air delivery at the unit grille. Check air temperature rise across the coil when compressor is operating. Check for vibration, noise, and water leaks. 24 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 25: Safety Devices And The Upm Controller Overview

    [7] Air Coil Freeze Connection (FREEZE 2) [8] Condensate Overflow Sensor [9] Ground Connection [10] UPM Board Settings DIP Switch [11] A2L Sensor [12] 24VAC Power Common [13] 24VAC Power Input MC Series Heat Pumps - 8733850301 (2025/02) US | 25...

  • Page 26: Second-Stage Upm Board/S

    [9] UPM Board Settings DIP Switch [10] A2L Sensor [11] 24VAC Power Common [12] 24VAC Power Input [13] UPM Standoff [14] Power LED [15] Fan (Fan in the event of an A2L leakage) 26 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 27 Figure 10 MC Freeze Sensor Locations • Air coil freeze protection sensors are mounted close to evaporator coil between the thermal expansion valve and evaporator coil. (Refer to Fig. 10.) MC Series Heat Pumps - 8733850301 (2025/02) US | 27...

  • Page 28: Upm Default Settings And Dip Switch Positions

    LED Status Indicator displays either a solid green indicating no faults or will blink a fault code in red. (Refer to Table 11 for a description of the blink codes.) 28 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 29 (above Refrigerant Leak 15% LFL, refer to leak detection system section) Lost communications with the Second- Second-Stage UPM Board Fault Stage UPM board Table 11 UPM Fault Blink Codes MC Series Heat Pumps - 8733850301 (2025/02) US | 29...

  • Page 30: Leak Detection System

    Lockout DIP switch position “1” is set to "OFF" or "ON")(See Table 10) before 60 minutes, the unit will go into a hard lockout and requires a manual lockout reset. 30 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 31: Upm Sequence Of Operation

    Installation, Operation, and Maintenance Manual 13 UPM Sequence of Operation Figure 13 UPM Sequence of Operation MC Series Heat Pumps - 8733850301 (2025/02) US | 31...

  • Page 32: Unit Sequence Of Operation By Mode

    Once the thermostat is satisfied, the compressor shuts down and the fan ramps down to either fan-only mode or OFF over a span of 30 seconds. 32 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 33: Factory-Installed Options

    There are several ways to control the heat pumps with hot gas reheat. You should choose the means that best suits your specific application. Most heat pump A number of options are available on MC Series of Heat Pumps. The following compatible thermostats in conjunction with a humidistat are acceptable for use.

  • Page 34: Hot Gas Bypass

    If at any time the water temperature rises above the aquastat set point the MBV will be energized in the bypass mode and fluid MC series heat pumps can be provided an optional waterside economizer. The will bypass the economizer coil.

  • Page 35: Maintenance

    • air flow problems, or • air temperature problems Use of the pressure and temperature charts for the unit may be required to properly determine the cause. MC Series Heat Pumps - 8733850301 (2025/02) US | 35...

  • Page 36: Pulley Alignment And Belt Tensioning Procedure

    Using a gauge, apply 4 lb of force to the center of the belt and adjust the tension until a deflection of 1/64-in. is achieved for every inch of shaft center distance. (Refer to Fig. 15.) 36 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 37: Servicing And Repair Information

    At all times the manufacturer's maintenance and service guidelines must be followed. If in doubt, consult Bosch service and support All work must be undertaken under a controlled procedure to minimize the risk of a for assistance.

  • Page 38: Checks To Electrical Devices

    Ensure the system is leak-tested on completion of charging but prior to commissioning. A follow-up leak test must be carried out prior to leaving the site. 38 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 39: Recovery

    The compressor body must NOT be heated by an open flame or other ignition sources to accelerate this process. When oil is drained from a system, it must be carried out safely. MC Series Heat Pumps - 8733850301 (2025/02) US | 39...

  • Page 40: Decommissioning Information

    Equipment must be labeled stating that it has been decommissioned and collection site. emptied of refrigerant. The label must be dated and signed. Ensure that there are labels on the equipment stating the equipment contains flammable refrigerant. 40 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 41: Unit Troubleshooting

    After the compressor has cooled, check the continuity of the compressor windings. If the windings are open, Compressor Windings Open replace the compressor. MC Series Heat Pumps - 8733850301 (2025/02) US | 41...
  • Page 42 Check the TXV for possible restriction or defect. Replace if necessary. The refrigerant system may be contaminated with moisture or non-condensable. Reclaim the refrigerant, replace Moisture, Non-Condensable the filter dryer, evacuate the refrigerant system, and recharge with the factory-recommended charge. 42 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 43 High water temperature is Closed Check to see if sensor is not attached securely to line." Scaled or Fouled Heat Low heat output Clean the heat exchanger. Exchanger Table 13 Unit Troubleshooting MC Series Heat Pumps - 8733850301 (2025/02) US | 43...
  • Page 44 Is the Fault LED blink- ing four (4) times on Low-pressure fault— If Yes, Circuit 2 is affected. Check the refrigerant pressure with a gauge set. the 1st & 2nd stage Low refrigerant. UPMs? 44 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 45 Check the air filter and return air duct work for blockage. Condensate fault— Blocked return air. • Check that there is adequate space between the return air opening and the walls or other obstructions on free return applications. MC Series Heat Pumps - 8733850301 (2025/02) US | 45...
  • Page 46 1st & 2nd stage UPMs? Check that the harness is connected from the A2L sensor side. Check if there are any hissing or gurgling noises in the system. 46 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 47 Check the A2L sensor is going to both the 1st and 2nd ing twelve (12) times between the UPM 1st stage UPMs. No compressor Cooling or Heating on the 1st & 2nd stage & UPM 2nd stages. operation UPMs? Table 14 MC Series Heat Pumps - 8733850301 (2025/02) US | 47...

  • Page 48: Specification Tables

    1111 1172 20,000 1034 1111 1172 21,000 1034 1111 1172 24,000 22,000 1034 1111 1172 23,000 1034 1111 1172 24,000 1072 1111 1172 25,000 1034 1072 1111 1172 Table 15 48 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 49 Installation, Operation, and Maintenance Manual 20.2 Blower Curves M C360 M C480 - 720 Figure 16 1000 CFM MC Series Heat Pumps - 8733850301 (2025/02) US | 49...
  • Page 50 Installation, Operation, and Maintenance Manual M C480 - 720 1000 CFM Figure 17 1000 CFM 50 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 51 136-167 363-446 8-10 36-43 119-148 373-451 20-24 18-22 135-167 361-447 17-20 36-44 118-146 334-406 10-13 19-23 157-191 390-477 10-12 40-48 121-151 420-504 19-24 18-22 120-149 379-458 10-13 18-22 Table 17 MC Series Heat Pumps - 8733850301 (2025/02) US | 51...
  • Page 52 140-171 351-434 9-11 37-44 118-147 360-438 19-24 17-21 140-172 350-436 18-21 37-45 117-145 329-401 9-12 18-22 162-196 377-464 10-12 41-49 120-150 406-490 19-23 17-21 119-148 374-453 9-12 17-21 Table 19 52 | MC Series Heat Pumps - 8733850301 (2025/02) US...

  • Page 53: Water-Side Pressure Drop Table

    90.0 MC480 120.0 160.0 12.0 16.7 75.0 112.5 MC600 150.0 200.0 16.3 90.0 135.0 MC720 180.0 11.8 240.0 20.3 Table 20 All values based upon pure water at 70° F. MC Series Heat Pumps - 8733850301 (2025/02) US | 53...
  • Page 54 21.1 Two-Stage, Three-Phase Standard Unit with Belt-Drive Motor Figure 18 FOR REFERENCE ONLY. Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 54 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 55 21.2 Two-Stage, Three-Phase Unit with Optional Components (MHGR) and Belt Drive Motor Figure 19 FOR REFERENCE ONLY. Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. MC Series Heat Pumps - 8733850301 (2025/02) US | 55...
  • Page 56 Installation, Operation, and Maintenance Manual Figure 20 FOR REFERENCE ONLY. Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 56 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 57 21.3 Two-Stage, Three-Phase Unit with DDC, Optional Components, and Belt-Drive Motor Figure 21 FOR REFERENCE ONLY. Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. MC Series Heat Pumps - 8733850301 (2025/02) US | 57...
  • Page 58 BO-2 BO-5 BO-3 BO-5 BO-8 BO-2 BO-1 Figure 22 FOR REFERENCE ONLY. Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 58 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 59 21.4 Two-Stage, Three-Phase Standard Unit with Dual-Point Power and Belt-Drive Motor Figure 23 FOR REFERENCE ONLY. Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. MC Series Heat Pumps - 8733850301 (2025/02) US | 59...
  • Page 60 BO-2 BO-5 BO-3 BO-5 BO-8 BO-2 BO-1 Figure 24 FOR REFERENCE ONLY. Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 60 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 61 21.5 DDC Control 6126 Figure 25 DDC Control 6126 FOR REFERENCE ONLY. Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. MC Series Heat Pumps - 8733850301 (2025/02) US | 61...
  • Page 62 21.6 DDC I/O Flex EX8160 Figure 26 DDC I/O Flex EX8160 FOR REFERENCE ONLY. Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 62 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 63 Decommissioning — Means the final shut-down and removal from operation or usage of a product or piece of equipment containing fluorinated greenhouse gases. Discharge Pressure — Referring to the pressure leaving compressor. MC Series Heat Pumps - 8733850301 (2025/02) US | 63...
  • Page 64 Discharge Pressure (psig)*: ____________________________________________________________________ ____________________________________________________________________ Suction Temperature*: ____________________________________________________________________ ____________________________________________________________________ Discharge Temperature*: ____________________________________________________________________ ____________________________________________________________________ Suction Superheat*: ____________________________________________________________________ ____________________________________________________________________ Entering TXV/Cap Tube Temperature*: ____________________________________________________________________ ____________________________________________________________________ Liquid Subcooling*: ____________________________________________________________________ ____________________________________________________________________ * Required for Troubleshooting ONLY 64 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 65 Installation, Operation, and Maintenance Manual NOTES: MC Series Heat Pumps - 8733850301 (2025/02) US | 65...
  • Page 66 Installation, Operation, and Maintenance Manual NOTES: 66 | MC Series Heat Pumps - 8733850301 (2025/02) US...
  • Page 67 Installation, Operation, and Maintenance Manual NOTES: MC Series Heat Pumps - 8733850301 (2025/02) US | 67...
  • Page 68 United States and Canada Bosch Thermotechnology Corp. 65 Grove St. Watertown, MA 02472 Tel: 800-283-3787 www.bosch-homecomfort.us 8733850301/ (2025/02) US Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.

This manual is also suitable for:

Mc360Mc480Mc600Mc720

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