Bosch SM024 Installation manual

SM Series Electric Heat Kit
HK050 | HK100 | HK150 | HK200 |
8 733 904 449 (2013/04)
Installation Manual
2|
SM Series Electric Heat
Contents
INTRODUCTION .....................................................3
PRE-INSTALLATION...............................................3
Unpacking and Inspection .............................. 3
Components List ............................................3
Required Tools ...............................................4
Electric Heat Kit ....................................................4
Installation - Hardware..........................................5
Installation - Wiring ...............................................6
Thermostat Wire Connections ............................10
Site Line Voltage Connection..............................11
Wiring Diagram Replacement/Data Label
Placement ............................................................11
Unit Start Up........................................................11
Wiring Diagram....................................................12
Electric Heat Electrical Data ...............................17
Notes....................................................................18
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SM Series Electric Heat
SM Series Electric Heat
INTRODUCTION | 3
INTRODUCTION
The SM series HK Series Heater package is
designed for installation in the heat pump
model published in this document. Do not
install this heater kit in a heat pump not
specified in this manual.
Installation and servicing of this equipment
can be hazardous due to system pressure
and electrical components. Only trained
and qualified personnel should install,
repair, or service the equipment.
HK Series Heater Package can only be installed
on single phase units
Before performing service or maintenance
operations on the system, turn off main
power to the unit. Electrical shock could
cause personal injury or death.
A heater collar is installed in the SM models, no
need to order separately.
When working on equipment, always
observe precautions described in the
literature, tags, and labels attached to the
unit. 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.
Bosch HK Series Heater Package is a field
Installable electric resistance heater kit designed
for the SM series heat pumps.
The HK series heater package requires separate
electrical service connection, independent from
the heat pump’s power supply. Hence, installation
of this Heater Package will convert SM Series Heat
Pump into a two point power connection.
The HK series Heater Package is available in
several kW capacities. Unit tonnage vs Heater
Package capacity compatibility table is below.
(Figure#1)
The HK series Heater Package can be installed on
Vertical (VT), Horizontal (HZ) and Counter-flow
(CF) units. Eight and ninth character of the SM
heat pump signifies the configuration. Example:
SM024-1VTC.
Improper installation of the electric
resistance heater can result in severe injury
or death due to electrical shock or fire.
Only trained and qualified personnel should
install, repair, or service this equipment. All
electrical service connection to the heater
must be done to National and local
electrical Standard & codes.
DO NOT wire the heater elements into the
same circuit as the compressor.
SM Series Electric Heat
A heat pump thermostat with supplemental
electric heat feature is required to operate the
system when this kit is installed.
Figure 1: HEATER COMPATIBILITY
Unit
Model
HK0501201
(5kW)
HK1001201
(10kW)
HK1501201
(15kW)
HK2001201
(20kW)
SM024
X
SM036
X
X
SM048
X
X
X
SM060
X
X
X
X
SM070
X
X
X
X
x Heater Package Compatibiity
PRE-INSTALLATION
Unpacking and Inspection
1. UNPACK the HK heater kit and inspect for
contents and condition. If any part or the kit
appears damaged (i.e.: broken heater
elements, damage relays) or missing, do not
attempt to install the kit. Contact your local
distributor for further help.
2. Ensure that the heater kit package includes the
following components. Contact your local
distributor for further help.
Components List
•
•
•
•
•
Pre-wired heater electrical box (including
fuses on HK150 and HK200)
Heater elements
Heater element(s) protective metal cover
Wire harness pre-wired at one end .
New wiring diagram
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4 | Electric Heat Kit
•
•
SM Series Electric Heat
Adhesive back electrical data label
Clear hardware accessory bag containing:
• Heater element mounting 3/8 Philip-Hex
screws (4 for each element bank)
• Four Heater element cover mounting 3/8
Philip-Hex screws
• Two electrical box mounting 3/8 Philip-Hex
screws
• Push in wire-ties
• This installation manual
For technical assistance contact your local
distributor or Bosch Technical Support:
Figure # 3
(954) 776-5471 or
Bosch.Fhp.TechSupport@us.bosch.com.
Required Tools
•
•
•
•
•
•
•
Phillips screwdriver
Small flat head screwdriver
5/16” socket and a ratchet or drill
Wire cutter
Wire stripper
Torque Phillips head screwdriver
Multi meter
ELECTRIC HEAT KIT
The Electric Heat field installed kit contains two
main electrical enclosures: Electric Heat Control
Box and Electric Heat Elements, both are located
in the blower compartment. (Figure#2 through #6)
The control box attaches to the corner post and
the heat elements to the blower heater collar in
the blower compartment.
Figure # 4
Figure # 5
Figure # 2
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SM Series Electric Heat
SM Series Electric Heat
Installation - Hardware | 5
5. Remove the heater collar cover plate(s).
(Figure#8)
Figure # 8
Figure # 6
[1] Heating element cover
[2] Electric Heat control box
INSTALLATION - HARDWARE
1. At Thermostat Turn system to “OFF”
2. Turn the main power to the heat pump to
“OFF” at the unit’s disconnect switch or
breaker panel.
6. In preparation for heater element installation
orient the heating elements with thermal
overloads (cutouts) are on the right side for VT
& CF and top for HZ.(Figure#9)
Proper Thermal Overloads (cutouts)
orientation is required for safe unit
operation.
Follow proper lockout/tag out procedure.
3. Prior to removing the blower panel, disconnect
unit display from the back of the
panel.(Figure#7)
Figure # 7
4. Remove the access panel(s) from the unit
exposing the blower section and compressor
section of the packaged heat pump unit.
Figure # 9
7. Insert heating element(s) into collar. Heating
element rods must be inserted into inner most
holes as shown in Figure#10. This will support and
prevent vibration of heater elements.
SM060 and SM070 models will have an
additional extension bracket mounted on
each cover plate. Heating element rods
must be aligned to extension brackets
accordingly.
SM Series Electric Heat
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6 | Installation - Wiring
SM Series Electric Heat
Figure # 10
If only one heating element is being installed,
install in into the position closest to the blower
wheel. Remaining opening to be covered using
(1) of the cover plates removed in step 5.
Figure # 12 5kW-10kW (HK050-100) Control Box
8. Secure each insert(s) with four of the supplied
sheet metal screws (Figure#11).
Figure # 11
Figure # 13 15kW-20kW (HK150-200) Control Box
INSTALLATION - WIRING
TO CONTROL TO BLOWER
SIGNALS MOTOR POWER
There are two Electric Heater control box layouts
depending on HK model. (Figures#12 & #13)
HR1 controls Heating Elements 1 and 3 and
HR2 controls heating elements 2 and 4.
ATTACH TO
ELECTRICAL
HEAT BOX
J12
J19
J39
Refer to wiring diagram on Pg13.
Electric Heater control box is completely prewired from the factory.
TRANSFORMER
POWER
Figure # 14 Electric Heat Harness
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SM Series Electric Heat
SM Series Electric Heat
Installation - Wiring | 7
Ensure no wires are pinched between the
metal parts
3. Connect red and black high voltage wires
originating from Electric Heater control box to
the Electric Heater elements as shown in
Figure#18. Terminate Black wires labeled HLS
at the thermal limits (cutouts) and Red wires
labeled HT at the heater element
connections.(Figure#17 &#18)
Each wire is labeled for ease of identification.
Reference wiring diagram on Pg13.
Figure # 15
1. Route the high voltage Red and Black wires,
originating from the Electric Heater control box
through grommets in the Electric Heater
Element cover as show in Figure#16.
Route all Red wired together through the same
grommet and black wires through the second
grommet.
la
Figure # 17
1
2
Figure # 16
[1] Red wire
[2] Black wire
2. For Vertical (VT) and Horizontal (HZ) units
install the heater control box between the unit
corner posts at the bottom of the of the blower
section. Counter flow (CF) units install the
heater control box between the unit corner
posts at the bottom of the of the blower
section. (Figure#2 through #6)
Figure # 18
4. Install the cover for the control box with the
provided screws.
5. Remove and retain cork tape covering the hole
in the divider panel.
Orient the heater control box with contactor(s)
towards the bottom.
Holes for Control Box are pre-punched in the
corner post.
SM Series Electric Heat
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8 | Installation - Wiring
SM Series Electric Heat
6. On the wiring harness supplied with this kit
identify J39 plug. (Figure#19)
Figure # 19
7. Route J39 plug through the hole in the divider
panel and mate the plug to the receiving
connector P39 on the side of the electric heat
control box.
8. Re-apply cork tape to the divider panel hole.
9. Route the other end of the harness (3
connector end) along the already installed
blower harness, and terminate it at the unit
electrical box (E-Box). Use tie-wraps every 1218 inches for a neater finish. (Figure#20- #22)
Figure # 21 P12 Control Signal Plug (three position)
Figure # 22 Transformer Power
10. In the heat pump electrical box, disconnect the
J19/P19 high voltage wires that connect the
blower motor to the “line voltage” these wires
are located on the left hand side of the e-box
shown in the picture below.(Figure#23)
Figure # 20 J19 Blower Power Plug (two position)
Figure # 23
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SM Series Electric Heat
SM Series Electric Heat
11. Mate J19 plug originating from the electric
heat control box (red and black wires) with
P19 plug originating from blower harness at EBox.(Figure#24)
When mating plugs, push both connectors
together until they snap with a click.
Installation - Wiring | 9
13. Route the two line voltage wires that derived
from the P19 plug, these wires should be
routed under the contactor along the bottom
of the electrical box.(Figure#27)
When routing wiring avoid sharp edges as
these can chafe wiring insulation, exposing
the conductor. This can result in equipment
damage and personal injury.
Figure # 24
12. Disconnect the red and black line voltage
harness (8733901778) from the transformer
primary side and the contactor line side, and
remove the harness from the E-box
entirely.(Figure#25 & #26)
Figure # 27
14. Connect red and black wires from electric heat
harness to transformer primary winding per
wire labels.
15. There will be one harness (black and white
wires) left connected to the compressor
contactor. Remove and discard this loose
harness from the contactor.(Figure#28)
Figure # 25 Transformer primary
Figure # 28
Figure # 26 Primary disconnected
SM Series Electric Heat
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10 | Installation - Wiring
SM Series Electric Heat
16. There should now be one plug left labeled P12
on the electric heat harness. Mate this plug to
its counterpart plug already available on the
left hand side of the e-box labeled
J12.(Figure#29 & #30)
Figure # 31
18. Remove (2) screws as shown. (Figure#32)
Figure # 29
Figure # 32
19. Mount Heater Element cover to blower collar
using (4) 3/8 Philip-Hex screws. (Figure#33)
Figure # 30
17. Ensure heater element wires are routed
through the plastic bushings available in the
kit, and perform a continuity test to ensure all
connections are secure. See Figure #31.
Use bottom holes on the plate to inset the plastic
grommets and prevent the wires from laying on
sharp edges
Figure # 33
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SM Series Electric Heat
SM Series Electric Heat
20. Use push in wire ties to secure cables to cover
and blower bracket.(Figure#34)
Figure # 34
THERMOSTAT WIRE CONNECTIONS
1. Assure that two low voltage wires are available
from the thermostat to make the “W1” and
“EM” connections. If these wires are not
located, they will need to be pulled and routed
from the back of the thermostat to main
thermostat connections on the electrical box
or to the motor control board.
2. Strip the insulation off of the “W1” and “EM”
wires and insert into the thermostat control
wire block or on the motor control board
thermostat interface. Connect the other end of
the wires to the back of the thermostat to the
supplemental and emergency heat terminals.
Reference the Thermostat User’s Manual for
proper connection.
Thermostat Wire Connections | 11
SITE LINE VOLTAGE CONNECTION
Routing New Line Voltage Wires
From Circuit Breaker Panel To Heater
Electrical Box
1. Select the proper wire size based upon the
heater electrical load that the blower motor
and electric heater element(s) will require.
Refer to the data tag label that is included in
the heater kit or the electrical data at the end
of this manual. Ensure that all national and
local electrical codes are followed for
installation, wire sizing, and breaker sizing.
2. Select the proper breaker size based upon the
heater electrical load that the heat pump will
require. Refer to the data tag label that is
included in the heater kit or the electrical data
at the end of this manual.
3. Route the new line voltage wiring and the
ground wire from the circuit breaker panel to
the heat pump.
4. Use the knockout provided in the heat pump
corner post as the entry for the electrical
service wiring. A plastic bushing should be
used to protect the wire insulation from the
metal edge of the knockout
5. Connect one of the line voltage wires to “L1”
terminal connection and the other line voltage
wire to “L2” terminal connection. Torque to 22
in-lbs.
6. Use the ground lug provided in the heater
control box to connect the field ground from
the power supply.
Figure # 35
SM Series Electric Heat
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12 | Wiring Diagram Replacement/Data Plate Placement
WIRING DIAGRAM REPLACEMENT/
DATA PLATE PLACEMENT
1. Remove the wiring diagram that is adhered to
the back side of the front panel. Replace with
the wiring diagram that was included with the
heater kit. Using spray adhesive glue is
recommended. See Figure #36
SM Series Electric Heat
UNIT START UP
1. Turn the disconnect switch or breaker switch
to the “ON” position for the compressor and
for the new separate circuit servicing the
blower motor and the heating elements.
2. Run the unit in heating mode with the heating
elements engaged for at least 10 minutes to
ensure the unit does not shut down due to any
temperature limiting device.
Figure # 36
2. Place the adhesive backed heater data label
above existing dataplate label.
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SM Series Electric Heat
SM Series Electric Heat
Wiring Diagram | 13
WIRING DIAGRAM
Figure # 37
SM Series Electric Heat
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14 | Wiring Diagram
SM Series Electric Heat
Figure # 38
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SM Series Electric Heat
SM Series Electric Heat
Wiring Diagram | 15
Figure # 39
SM Series Electric Heat
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SM Series Electric Heat
Figure # 40
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SM Series Electric Heat
SM Series Electric Heat
Wiring Diagram | 17
Figure # 41
SM Series Electric Heat
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18 | Electric Heat Electrical Data
SM Series Electric Heat
ELECTRIC HEAT ELECTRICAL DATA
HEATER
WATTS
MODEL
HEATER
AMPS
CIRCUIT
MCA
MOP
RATED kW
STAGE
240V
208V
240V
208V
FUSES
240V
208V
240V
208V
HK050-1201-RES
4.8
1
4,800
3,600
20.0
17.3
F1/F2
33.8
30.4
35
35
HK100-1201-RES
9.6
1
9,600
7,200
40.0
34.6
F1/F2
58.8
52.0
60
60
HK150-1201-RES
1
9,600
7,200
40.0
34.6
F1/F2
14.4
83.8
73.6
90.0
80.0
1+2
14,400
10,800
60.0
51.9
F3/F4
1
9,600
7,200
40.0
34.6
F1/F2
108.8
95.3
110
100
1+2
19,200
14,400
80.0
69.2
F3/F4
HK200-1201-RES
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SM Series Electric Heat
SM Series Electric Heat
Notes | 19
NOTES
SM Series Electric Heat
8 733 904 449 (2013/04)
601 N.W. 65th Court, Ft. Lauderdale, FL 33309
Phone: 866-642-3198 | Fax: 954-776-5529
www.boschtaxcredit.com | www.bosch-climate.us
(2013/04)