Bosch RP Series Installation, Operation And Maintenance Manual
  1. Manuals
  2. Brands
  3. Bosch Manuals
  4. Heat Pump
  5. RP Series
  6. Installation, operation and maintenance manual
Bosch RP Series Installation, Operation And Maintenance Manual

Bosch RP Series Installation, Operation And Maintenance Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Installation, Operation, and Maintenance Manual
RP Series Heat Pumps
RP024 | RP036 | RP048 | RP060 | RP070

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the RP Series and is the answer not in the manual?

Questions and answers

Related Manuals for Bosch RP Series

Summary of Contents for Bosch RP Series

  • Page 1 Installation, Operation, and Maintenance Manual RP Series Heat Pumps RP024 | RP036 | RP048 | RP060 | RP070...

  • Page 2: Table Of Contents

    Table of Contents Maintenance ..............42 Filter Changes ............42 Annual Checkup............42 Document Conventions ............4 Annual Condensate Drain Cleaning .......42 Key to Symbols............4 General Safety Instructions ........... 4 Handling Periodic Lockouts ..........42 Refrigerant Safety Warnings .......... 5 Servicing and Repair Information........42 Model Nomenclature ............7 Personal Protective Equipment ........42 Confined Space Work ..........42...
  • Page 3 Terms ..............76 Check-Out Sheet ...............77 Notes ................78 CP Series Heat Pumps — 8733851093 (2025/03)

  • Page 4: Document Conventions

    Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing, and place a fire extinguisher close to the work area. RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 5: Refrigerant Safety Warnings

    Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing and gloves when Risk of Fire! handling parts. Flammable Refrigerant Used—To be repaired only by trained service personnel. DO NOT puncture refrigerant tubing. RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 6 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. RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 7: Model Nomenclature

    ELECTRICAL OPTIONS: 1 — Painted Steel / 1/2" CC/EQ 2% X — As Default for Non-Used Electrical Codes L — Refrigerant Leak Sensor APPLICATION: G — Extended Range (Geothermal) Fig. 1 Model Nomenclature RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 8: General Description

    Water Heat Pump application points. All RP Water-to-Air Heat Pumps conform to UL 60335-2-40 by Intertek-ETL. RP series units are available in two basic configurations: Vertical Top-Supply Air (VT) and Horizontal End-Supply Air (HZ). Each of these configurations are available with either left- or right-hand return air.

  • Page 9: Operating Limits

    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: LWT: Leaving Water Temperature EWT: Entering Water Temperature Table 2 Operating Limits RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 10: Approved Supplementary Heaters

    Model: HK100-1501 Model: HK150-1501 Model: HK200-1501   — —    —             Table 3 Approved Supplementary Heaters 10 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 11: Inspecting And Storing The Equipment

    Note any visible damage or shortage on all copies of the freight bill. Concealed damage not discovered until after removing the units from packaging must be reported to Bosch by the original purchaser by filing a claim at: https://claims.bosch-homecomfort.us...

  • Page 12: Unit Installation

    DO NOT use RP series units for temporary heating, air conditioning or ventilation during construction, especially when plastering, sanding, or painting. Care should be taken to avoid introduction of dust, paint, or debris into the air coil.

  • Page 13: Minimum Conditioned Room Area

    NOTICE It is generally not necessary to anchor the unit unless required by local code. All major service access for the RP series vertical Equipment should never be used during construction due to models is from the front side of the unit. When installing the unit...

  • Page 14: Horizontal (Hz) Units

    Fig. 4 Straight-Through Orientation Fig. 2 Vibration Absorbing Pad 5.6 Horizontal (HZ) Units 5.6.1 Configuring the Horizontal Supply Air Orientation The supply air location on RP series horizontal units can be field converted from end blow to straight through or vice-versa. NOTICE STRAIGHT...

  • Page 15: Mounting Horizontal (Hz) Units

    HZ units. The rods must be securely anchored to the ceiling. Refer to the hanging bracket assembly and installation instructions for details. Fig. 6 Pitched Unit | 15 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 16 DANGER 1. Remove and discard factory provided screws from locations The rods must be securely anchored to the ceiling. where hanging brackets will be installed as shown in Fig. 8. 16 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 17: Condensate Drain

    5.8 Duct System away from the unit a minimum of 1/8” per foot to allow the All RP series models are provided with a supply air outlet collar condensate to flow away from the unit. and return air duct flange to facilitate duct connections.

  • Page 18: Piping

    Occasionally these valves produce a flow noise that can be reduced by applying some back pressure. To accomplish this, slightly close the leaving isolation valve. 18 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 19: Electrical-Power Supply Wiring

    Antifreeze may be added before, during, or after the flushing indicated on the unit’s nameplate or on the performance data process. Refer to the Antifreeze section below for more detail. sheet. | 19 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 20 All 208/230-V units are factory wired to 240V by default. For job sites with a 208-V power supply, the primary leads on the unit transformer will need to be changed from 240V to 208V. Refer to the unit wiring diagram for details. 20 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 21: Electrical-Low-Voltage Wiring

    The reversing valve on the RP series is energized when the unit is in cooling mode. Position thermostats on an interior wall away from supply ducts.

  • Page 22: Standard Construction

    Because remote temperature sensors measure resistance, very long cable runs can cause slight errors in the measurement. For the highest temperature reading accuracy, avoid exceeding the maximum recommended wire lengths show in Table 8. 22 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 23: Ecm Interface Board

    [2] Blower CFM Adjustment [8] Reheat Digital Outputs [3] Motor Settings [9] Thermostat Outputs [4] HGRH Indication [10] 24 VAC [5] Thermostat Contact Inputs [11] Hot Gas Re-Heat Enable Switch [6] CFM Count Indicator | 23 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 24: Specific Application Considerations

    [10] P/T Ports (optional) [4] Ball Valves [11] Line Voltage Connection [5] Solenoid Valve Slow Closing [12] Control Panel/Thermostat [6] Condensate Drain Connection [13] Unit Line Voltage Disconnect [7] Drain Valves 24 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 25: Cooling Tower/Boiler Systems

    [3] P/T Ports (optional) [11] Control Panel/Thermostat [4] Hose Kits [12] Condensate Drain Connection [5] Ball Valves [6] Supply and Return Line of Central System [7] Flex Duct Connection [8] Hanging Bracket Assembly | 25 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 26: Geothermal Closed-Loop Systems

    Using Bosch Flow Centers makes the installation easier. (Refer to Fig. 17) Anti-freeze solutions must be used when low loop temperatures Operation of an RP series unit on a closed loop application are expected to occur. requires the extended range option.

  • Page 27: 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. | 27 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 28 < 10 ppm, < 600 µm size** Erosion Maximum Water Velocity 6 ft/sec 6 ft/sec * No "rotten egg" smell present at < 0.5 ppm H ** Equivalent to 30 mesh strainer Table 9 Water Quality Table 28 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 29: Post-Installation System Checkout

    9.2 Checking Scroll Compressor Rotation Scroll compressors, like the ones used on the RP series, are NOTICE phase sensitive. When out of phase, the compressors will run in reverse. After a few minutes of reverse operation, a scroll Do not use fan rotation as an indication of the unit’s phase...

  • Page 30: Start-Up

    Allow five minutes between tests for the pressure to equalize. 1. Turn thermostat to lowest setting and set thermostat switch to HEAT position. 2. Slowly turn the thermostat to a higher temperature until the compressor activates. 30 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 31: Safety Devices And The Upm Controller Overview

    When a malfunction light is used for diagnostic purposes, the [10] UPM Settings DIP Switch (SW1) connection is made at the dry contact connection terminals of [11] A2L Sensor the UPM board. [12] 24VAC Power Common | 31 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 32 120 seconds, the controller will shut down the compressor and enter into a soft-lockout condition. The default freeze limit trip is 25°F. 32 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 33: Upm Default Settings And Dip Switch Positions

    UPM board is set starting at the same time after power up or after a power to "PULSE." interruption, in order to avoid creating a large electrical spike. | 33 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 34 Both the status LED and the alarm contact will be active. The status LED will be active, 34 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 35: Upm Sequence Of Operation

    Safety Devices and the UPM Controller Overview 12.3 UPM Sequence of Operation Fig. 22 UPM Sequence of Operation Flowchart | 35 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 36: Options

    The control circuit ensures that the HRP only operates when there is available heat from the compressor, and when the domestic hot water is within a safe temperature range of below 120 deg. F. 36 | RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 37 Diagram is for illustration purposes only. Ensure access to All piping from HRP to domestic water tank must be copper or Heat Pump is not restricted. any metal of stronger alloy. | 37 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 38 4. Allow the unit to operate for 20 to 30 minutes to ensure it is functioning properly. The pump will shut off when the Heat Recovery entering water temperature reaches 120°F. 38 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 39: Fan Motor Options

    For installations where constant air delivery is critical or where external static pressure drop can vary greatly (such as with high-MERV value filters) the RP series is offered with a constant air flow ECM motor option. This option provides ECM motor efficiency combined with a constant air delivery across a wide range of external static pressures.
  • Page 40 Air flow is 69% of tabulated values during fan-only operation. When passive dehumidification mode is enabled, air flow is 85% of tabulated value. CFM based on wet coil and 1" Merv 5 Throwaway. 40 | RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 41 Air flow is 69% of tabulated values during fan-only operation. When passive dehumidification mode is enabled, air flow is 85% of tabulated value. CFM based on wet coil and 1" Merv 5 Throwaway. | 41 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 42: Maintenance

    • air temperature problems. Use of the pressure and temperature charts for the unit may be required to properly determine the cause. 42 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 43: Checks To Electrical Devices

    Intrinsically-safe components must be replaced. for the purpose and to the correct specification. At all times the manufacturer's maintenance and service guidelines must be followed. If in doubt, consult Bosch service and support for 17.8 Check Cabling assistance. Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges, or any other adverse environmental effects.

  • Page 44: Removal And Evacuation

    Be sure to label the system when charging is complete (if not  already). Use extreme care not to overfill the refrigerating system.  Ensure the system is pressure-tested with the appropriate  purging gas prior to recharging the system. 44 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 45: Service Access

    Fig. 27 Screws and Welded Pins Locations for Horizontal Units Remove the three screws positioned above the motor.  Drop down and slide off the welded pins situated on the  opposite side from the motor. (See Fig. 26.) | 45 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 46: Decommissioning Information

    Before carrying out this procedure, it is essential that the  technician is completely familiar with the equipment and all its Ensure that there are labels on the equipment stating the  detail. equipment contains flammable refrigerant. 46 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 47: Troubleshooting

    Is the Fault LED flow Inspect the air coil for dirt/debris. blinking two (2) times? Check duct work—Are dampers closed or blocked? Low pressure Check refrigerant pressure with a gauge set. fault—Low refrigerant | 47 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 48 Check that the condensate sensor is mounted on Condensate fault— the drain pan, and the terminal is not touching False trigger sheet metal. 48 | RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 49 If not check the resistance of the compressor Burned out windings using the values shown in the compressor compressor characteristics chart. Note that the compressor must be cool (70° F) when checking the windings. | 49 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 50 Test (ON) while verifying that G to C has 24 volts. If the motor does not start, replace the ECM motor. If the motor starts, replace the ECM Interface Board. 50 | RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 51 Low refrigerant capacity High humidity Check unit performance against building load Unit oversized calculations. Short cycling Poor thermostat Make sure that the thermostat is not located near a location supply air duct. | 51 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 52 Clean/descale water coil. water coil elevating heat pressure Low air flow Check filter. elevating head Increase fan speed. pressure Fast-closing valves Change valves to slow-close type. Water hammer installed Table 14 Unit Troubleshooting 52 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 53: Specification Tables

    18–22 148–158 355–375 21–22 36–40 90° 116–132 330–354 9–12 18–22 174–184 382–402 11–12 41–45 119–135 404–428 18–21 18–22 — — — — 100° 118–134 377–401 9–12 18–22 — — — — | 53 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 54 19–23 154–186 330–416 17–20 37–45 90° 123–150 281–351 9–12 19–23 175–209 352–439 10–12 40–48 126–155 366–449 17–22 18–22 — — — — 100° 126–153 351–428 9–12 19–23 — — — — 54 | RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 55 120–148 312–384 8–11 19–23 173–207 368–455 9–11 42–50 121–151 354–438 17–21 18–22 — — — — 100° 122–151 356–435 8–11 18–22 — — — — Table 15 Operating Temperatures and Pressures | 55 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 56: Water-Side Pressure Drop Table

    12.0 RP048 12.0 16.0 11.3 RP060 15.0 20.0 13.5 RP070 18.0 24.0 11.2 11.6 Note: All values are based upon pure water at 70° F. Table 16 Water-Side Pressure Drop Table 56 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 57: Compressor Characteristics

    91.8 126.4 126.4 91.8 69.6 RP070 HZ 187.9 57.3 57.3 31.6 41.6 57.3 57.3 41.6 31.6 *The front is the control box end of the unit. Table 18 Corner Weights (HZ) | 57 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 58: Model 24 Thermistor (Freeze Sensor) Test Values

    Table 19 Model 24 Thermistor (Freeze Sensor) Test Values 19.90K 17.44K 15.31K 13.48K 11.88K 10.50K 9298 8250 7331 6532 5826 5209 4663 4182 3757 3381 3047 2750 2486 2251 2041 1854 58 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 59: Wiring Diagrams

    GN/YL Fig. 28 Two-Stage, Single-Phase, Standard Unit with CA Motor FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. | 59 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 60: Two-Stage, Single-Phase Unit With Optional Components And Ca Motor

    Fig. 29 Two-Stage, Single-Phase Unit with Optional Components and CA Motor FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 60 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 61: Two-Stage, Single-Phase Unit With Dual Power, Electric Heat, And Ca Motor

    Fig. 30 Two-Stage, Single-Phase Unit with Dual Power, Electric Heat, and CA Motor FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. | 61 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 62: Two-Stage, Single-Phase Unit With Dual Power, Optional Components, Electric Heat, And Ca Motor

    Fig. 31 Two-Stage, Single-Phase Unit with Dual Power, Optional Components, Electric Heat, and CA Motor FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 62 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 63: Two-Stage, Three-Phase, Standard Unit With Ct Motor

    GN/YL Fig. 32 Two-Stage, Three-Phase Standard Unit with CT Motor FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. | 63 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 64: Two-Stage, Three-Phase Unit With Optional Components And Ct Motor

    Fig. 33 Two-Stage, Three-Phase Unit with Optional Components and CT Motor FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 64 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 65: Two-Stage, Three-Phase, Standard Unit With Ca Motor

    GN/YL Fig. 34 Two-Stage, Three-Phase, Standard Unit with CA Motor FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. | 65 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 66: Two-Stage, Three-Phase Unit With Optional Components And Ca Motor

    Fig. 35 Two-Stage, Three-Phase Unit with Optional Components with CA Motor FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 66 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 67: Dimensional Drawings

    Return) Table 20 Vertical (VT) Unit Dimensions • Specifications subject to change without notice. • All dimensions within ±0.125". • Overall unit dimensions do not include filter rack or duct flanges. | 67 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 68 Dimensional Drawings Fig. 36 Vertical (VT) Unit Drawings 68 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 69: Vertical (Vt) Cabinet Options Dimensions

    • Filter rack dimensions does not include 1" duct flange. • 2" filter racks can accept either a 1" or 2" filter. • 4" filter racks can accept either a 2" or 4" filte | 69 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 70 Dimensional Drawings Fig. 37 Vertical Cabinet Options Drawing 70 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 71: Horizontal (Hz) Unit Dimensions

    • All dimensions within ±0.125". • Overall unit dimensions do not include filter rack or duct flanges. • Unit sizes 015–070 can be field converted between end blow and straight-through supply air configurations. | 71 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 72 Dimensional Drawings Fig. 38 Horizontal (HZ) Units Dimensional Drawings 72 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 73: Horizontal (Hz) Cabinet Options Dimensions

    • Filter rack dimensions does not include 1" duct flange. • 2" filter racks can accept either a 1" or 2" filter. • 4" filter racks can accept either a 2" or 4" filter. | 73 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 74 Dimensional Drawings Fig. 39 Horizontal (HZ) Cabinet Options Drawing 74 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 75: Service Clearance

    Dimensional Drawings 22.5 Service Clearance Vertical Cabinet Service Clearance Horizontal Cabinet Service Clearance Fig. 40 Vertical and Horizontal Cabinet Service Clearance | 75 RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 76: Terminology

    Decommissioning — Means the final shut-down and removal from operation or usage of a product or piece of equipment containing fluorinated greenhouse gases. 76 | RP Series Heat Pumps — 8733851699 (2025/04)

  • Page 77: Check-Out Sheet

    Source Fluid Type: Fluid Flow (gpm)*: Fluid-Side Pressure Drop*: Suction Pressure (psig)*: Discharge Pressure (psig)*: Suction Temperature*: Discharge Temperature*: Suction Superheat*: Entering TXV/Cap Tube Temperature*: Liquid Subcooling*: * Required for Troubleshooting ONLY | 77 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 78 Notes 25 Notes 78 | RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 79 Notes Notes | 79 RP Series Heat Pumps — 8733851699 (2025/04)
  • Page 80 Additional Product Information Page To see additional product information and documentation, please visit the product page: www.bosch-homecomfort.com/us/ or scan the QR code below. Bosch Thermotechnology Corp. 65 Grove Street Watertown, MA 02472 Tel: +1 (800) 283-3787 Fax: +1 (603) 965-7568...

This manual is also suitable for:

Rp024Rp036Rp048Rp060Rp070

Table of Contents