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

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Installation, Operation, and Maintenance Manual
RL Series Heat Pumps
RL007 | RL009 | RL012 | RL015 | RL018 | RL024 | RL030 | RL036 | RL042 | RL048 | RL060 | RL070

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Summary of Contents for Bosch RL Series

  • Page 1 Installation, Operation, and Maintenance Manual RL Series Heat Pumps RL007 | RL009 | RL012 | RL015 | RL018 | RL024 | RL030 | RL036 | RL042 | RL048 | RL060 | RL070...

  • Page 2: Table Of Contents

    UPM Sequence of Operation......31 13 Fan Motor ..............32 13.1 Permanent Split Capacitor Motors (PSC) ....32 14 Maintenance .............35 14.1 Filter Changes ..........35 14.2 Annual Checkup ..........35 14.3 Annual Condensate Drain Cleaning.....35 15 Handling Periodic Lockouts ........35 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 3: 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. RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 4: Refrigerant Safety Warnings

    Sheet metal parts may have sharp edges or burrs. Use care Risk of Fire! and wear appropriate protective clothing and gloves when Flammable Refrigerant Used—Dispose of properly in handling parts. accordance with federal or local regulations. RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 5 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. RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 6: Model Nomenclature

    CABINET CONSTRUCTION: None A — G90 Steel / 1/2" 1.5 LB Dual-Density Fiberglass ELECTRICAL OPTIONS: X — APPLICATION: As Default for Non-Used Electrical Codes G — Extended Range (Geothermal) Fig. 1 Model Nomenclature RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 7: General Description

    RL series units are offered with a wide range of factory-installed options including: internal 2-way valves; DuoGuard™ air coils; 2“4-sided filter racks; MERV 13 filters (with constant airflow ECM motors);...

  • Page 8: 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 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 9: 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 10: Unit Installation

    Where access to side panels is limited, pre-removal of the control box side-mounting screws may be necessary for future servicing. NOTICE DO NOT use RL series units for temporary heating, air NOTICE conditioning or ventilation during construction, especially when plastering, sanding, or painting. Care should be taken to RL series units are not approved for outdoor installation;...

  • Page 11: Protecting The Unit During Construction

    RL heat pumps feature fold-out return and supply air duct flanges. These fold-out flanges come folded in from the factory to The supply air location on RL Series Horizontal units can be field allow the heat pumps to more easily fit through doorways and converted from end blow to straight through or vice-versa.
  • Page 12 Horizontal units installed above the ceiling must conform to all local codes. An auxiliary drain pan, if required by code, must be at least four inches larger than the bottom perimeter of the heat pump. Fig. 5 Blower Configuration 12 | RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 13 If the unit is located in a crawl space, the bottom of the unit must be at least four inches above grade to prevent flooding of the electrical parts due to heavy rains. Fig. 8 Screw Locations | 13 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 14: Condensate Drain

    Fig. 10. DANGER Fig. 11 Condensate Drain Installation The rods must be securely anchored to the ceiling. Fig. 10 Threaded Rod 14 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 15: Duct System

    5.7 Duct System Never use flexible hoses of a smaller inside diameter than that All RL Series models are provided with a supply air outlet collar of the water connections on the unit. and return air duct flange to facilitate duct connections.
  • Page 16 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. 16 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 17: Electrical-Power Supply Wiring

    Field wiring must be installed by qualified and trained personnel. WARNING Power to the unit must be within the operating voltage range indicated on the unit’s nameplate or on the performance data sheet. | 17 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 18: Electrical-Low-Voltage Wiring

    Strain-Relieving Flexible Conduit as Shipped from the Factory The reversing valve on the RL series is energized when the unit is in cooling mode. Position thermostats on an interior wall away from supply ducts. Wire Clamp...
  • Page 19 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 6. | 19 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 20: 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 20 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 21: Cooling Tower/Boiler Systems

    [9] Threaded Rod [2] Low-Voltage Control Connection [3] P/T Plugs (optional) [4] Hose Kits [5] Ball Valves [6] Supply and Return Line of Central System [7] Flex Duct Connection [8] Hanging Bracket Assembly | 21 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 22: Geothermal Closed-Loop Systems

    Anti-freeze solutions must be used low loop (Refer to Fig. 16) temperatures are expected to occur. Operation of an RL Series unit on a closed loop application requires the extended range option. NOTICE Refer to the GLP installation manuals for more specific Closed-loop and pond applications require specialized design instructions.

  • Page 23: 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. | 23 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 24 < 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 7 Water Quality Table 24 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 25: Post-Installation System Checkout

    There is a time delay before the compressor will start. NOTICE A compressor running in reverse has a noisier than normal operation and a lower current draw than its rated value. | 25 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 26: Start-Up

    Allow five minutes between tests for the pressure or reversing valve 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. 26 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 27: 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 | 27 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 28 30 seconds, the controller will shut down the compressor and enter into a soft-lockout condition. The default freeze limit trip is 25°F. 28 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 29: Upm Default Settings And Dip Switch Positions

    Test function. When it is set to “ON,” it will reduce all time delays settings to 10 seconds during troubleshooting or verification of unit operation. ( Refer to Fig. 17, item [10])  Refer to Fig. 20)  | 29 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 30 120 seconds, the controller will shut the compressor down and enter into a soft-lockout condition. Both the status LED and the alarm contact will be active. The 30 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 31: Upm Sequence Of Operation

    Safety Devices and the UPM Controller Overview 12.3 UPM Sequence of Operation Fig. 21 UPM Sequence of Operation Flowchart | 31 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 32: Fan Motor

    Fan Motor 13 Fan Motor 13.1 Permanent Split Capacitor Motors (PSC) The standard motor for all RL series heat pumps is a three-speed PSC motor. If a speed change is required, follow the instructions below: 1. Disconnect power to the heat pump.
  • Page 33 1777 1774 1778 1776 1756 1749 1733 1728 1684 1659 1606 High 2028 2033 2029 2029 2030 2029 2024 1991 1969 1943 1906 1852 Table 10 PSC Motor Performance Data—Vertical Configuration | 33 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 34 1822 1814 1793 1777 1756 1724 1675 1626 1562 — — High 2092 2082 2068 2045 2020 1968 1932 1878 1815 1730 1640 1525 Table 11 PSC Motor Performance Data—Horizontal Configuration 34 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 35: Maintenance

    • air temperature problems. Use of the pressure and temperature charts for the unit may be required to properly determine the cause. | 35 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 36: 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 16.8 Check Cabling assistance. Check that cabling will not be subject to wear, corrosion,...

  • Page 37: Removal And Evacuation

    Ensure that the refrigerating system is earthed prior to  charging the system with refrigerant. Be sure to label the system when charging is complete (if not  already). Use extreme care not to overfill the refrigerating system.  | 37 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 38: Service Access

    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. 24.) 38 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 39: Decommissioning Information

    Before carrying out this procedure, it is essential that the Ensure that there are labels on the equipment stating the  technician is completely familiar with the equipment and all its equipment contains flammable refrigerant. detail. | 39 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 40: Troubleshooting

    No or low air flow Inspect the air coil for dirt/debris. blinking two (2) times? Check duct work—Are dampers closed or blocked? Low pressure fault— Check refrigerant pressure with a gauge set. Low refrigerant 40 | RL Series Heat Pumps — 8733842393 (2024/03)
  • Page 41 Check air filter and return air duct work for times? Condensate fault— blockage. Check that there is adequate space Blocked return air between the return air opening and walls or other obstructions on free return applications. | 41 RL Series Heat Pumps — 8733842393 (2024/03)
  • Page 42 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. 42 | RL Series Heat Pumps — 8733842393 (2024/03)
  • Page 43 Check that the wires from the thermostat to the energized Loose wire on “O” unit are securely connected and that the wires terminal from the electrical box to the reversing valve are connected. | 43 RL Series Heat Pumps — 8733842393 (2024/03)
  • Page 44 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 location a supply air duct. 44 | RL Series Heat Pumps — 8733842393 (2024/03)
  • Page 45 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 12 Unit Troubleshooting | 45 RL Series Heat Pumps — 8733842393 (2024/03)

  • Page 46: Specification Tables

    18–23 — — — — 90° 116–145 310–376 8–9 18–23 — — — — 117–148 357–434 9–12 18–22 — — — — 100° 118–147 354–427 7–10 18–22 — — — — 46 | RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 47 20–24 155–188 335–406 14–16 39–44 90° 114–146 330–403 9–10 20–24 — — — — 116–150 381–469 11–16 20–23 — — — — 100° 116–149 374–456 8–10 20–24 — — — — | 47 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 48 19–23 145–155 354–374 18–19 37–41 90° 112–129 356–374 8–11 19–23 — — — — 116–133 436–454 16–19 18–22 — — — — 100° 114–131 404–422 8–11 18–22 — — — — 48 | RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 49 21–25 131–141 334–354 17–18 35–39 90° 121–137 338–362 8–12 21–25 153—163 356—376 9—10 39—43 124–140 414–438 17–20 20–24 — — — — 100° 123–139 383–407 8–11 20–24 — — — — | 49 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 50 19–23 145–165 364–384 13–14 37–41 90° 116–132 352–372 8–11 20–24 157—177 379—399 9—10 39—43 118–134 417–437 12–15 19–23 — — — — 100° 118–134 398–418 8–11 19–23 — — — — 50 | RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 51 104–132 333–405 8–11 21–25 153—187 377—464 9—11 44—52 105–135 382–466 10–15 20–24 — — — — 100° 105–134 376–455 8–11 20–24 — — — — Table 13 Operating Temperatures and Pressures | 51 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 52: Water-Side Pressure Drop Table

    All values are based upon pure water at 70° F. PD (psi) = [ (Wtr Flow (gpm)^1.8) * k const ] / 2.31 PD (psi) = (Wtr Flow (gpm) / CV)^2 * Specific Gravity Table 14 Water-Side Pressure Drop Table 52 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 53: Compressor Characteristics

    4.91 — 208–230/1/60 0.336 0.921 — — — 80µF/370V 208–230/3/60 — — 0.542 — RL070 460/3/60 — — 2.161 — 575/3/60 — — 4.91 3.75 4.91 — Table 15 Compressor Characteristics | 53 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 54: Corner Weights (Horizontal Cabinets Only)

    60.4 90.6 85.0 60.4 60.2 RL070 HZ 134.4 38.6 41.1 27.3 27.4 41.1 38.6 27.4 27.3 *The front is the control box end of the unit. Table 16 Corner Weights (HZ) 54 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 55: Model 24 Thermistor (Freeze Sensor) Test Values

    Table 17 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 | 55 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 56: Wiring Diagrams

    20.1 Single-Stage, Single-Phase, Standard Unit with Permanent Split Capacitor (PSC) Motor Fig. 26 Single-Stage, Single-Phase, Standard Unit with PSC Motor FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. 56 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 57: Dimensional Drawings

    Return) Table 18 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. | 57 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 58 Dimensional Drawings Fig. 27 Vertical (VT) Unit Drawings 58 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 59: 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. | 59 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 60 Dimensional Drawings Fig. 28 Horizontal (HZ) Units Dimensional Drawings 60 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 61: Service Clearance

    Note: The local electric codes may require 36" or more clearance at the electrical control box Motor access clearance 18” Minimum 24” Optimum Fig. 29 Vertical and Horizontal Cabinet Service Clearance | 61 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 62: Terminology

    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. 62 | RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 63: 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 | 63 RL Series Heat Pumps — 8733842393 (2024/05)

  • Page 64: Notes

    Notes 24 Notes 64 | RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 65 Notes Notes | 65 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 66 Notes Notes 66 | RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 67 Notes Notes | 67 RL Series Heat Pumps — 8733842393 (2024/05)
  • Page 68 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...

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