Bosch BVA Series Air Handler

2-3-4-5 Ton Capacity

R410A

Installation Instructions
 2 | Bosch IDS BVA Installation Instructions

Data subject to change 12.2016 | Bosch Thermotechnology Corp.

 Installation Instructions Bosch IDS BVA | 3

Table of Contents

1 Key to symbols and safety instructions 4

2 General 6

3 Applications 8

4 Electrical wiring 10

5 Airflow performance 12

6 Ductwork 13

7 Refrigerant connections 14

8 Air filter (not factory-installed) 14

9 Filter installation dimensions 15

10 Wiring diagram 16

11 Spare parts 19

Bosch Thermotechnology Corp. | 12.2016 Data subject to change

 4 | Bosch IDS BVA Installation Instructions

1 Key to symbols and safety instructions 1.2 Safety

Please read before proceeding
1.1 Key to symbols

Warnings DANGER:
 These instructions are intended as an aid to qualified licensed
service personnel for proper installation, adjustment
Warnings in this document are identified by a and operation of this unit. Read these instructions
warning triangle printed against a grey background. thoroughly before attempting installation or operation.
Keywords at the start of a warning indicate the type and seriousness Failure to follow these instruction may result in improper
installation,adjustment, service or maintenance possibly
of the ensuing risk if measures to prevent the risk are not taken.
resulting in fire, electrical shock, property damage, personal
injury or death.

The following keywords are defined and can be used in this document:

 DANGER indicates a hazardous situation which, if not avoided, will result This document is customer property and is to remain with this unit.
in death or serious injury.
These instructions do not cover all the different variations of systems nor
 WARNING indicates a hazardous situation which, if not avoided, could does it provide for every possible contingency to be met in connection
result in death or serious injury. with installation.

 CAUTION indicates a hazardous situation which, if not avoided, could

result in minor to moderate injury.
CAUTION:
 NOTICE is used to address practices not related to personal injury.
 All phases of this installation must comply with NATIONAL,
STATE AND LOCAL CODES. If additional information is
required please contact your local distributor..

Important information

This symbol indicates important information where

there is no risk to people or property. WARNING: HAZARDOUS VOLTAGE
 Disconnect all power to unit before installing or servicing.
More than one disconnect switch may be required to
deenergize the equipment. Hazardous voltage can cause
severe personal injury or death.

WARNING:
 If removal of the blower assembly is required, all disconnect
switches supplying power to the equipment must be
deenergized and locked (if not in sight of unit ) so the
field power wires can be safely removed from the blower
assembly. Failure to do so can cause electrical shock resulting
in personal injury or death.

WARNING:
 Because of possible damage to equipment or personal injury,
installation, service, and maintenance should be performed
by a trained, qualified service personnel. Consumer service
is recommended only for filter cleaning / replacement. Never
operate the unit with the access panels removed.

Data subject to change 12.2016 | Bosch Thermotechnology Corp.

 Installation Instructions Bosch IDS BVA | 5

WARNING: WARNING:
 These instructions are intended as an aid to qualified,  The unit must be permanently grounded. Failure to do so can
licensed service personnel for proper installation, adjustment result in electrical shock causing personal injury or death.
and operation of this unit. Read these instructions thoroughly
before attempting installation or operation. Failure to follow
these instructions may result in improper installation,
adjustment, service or maintenance, possibly resulting in fire,
electrical shock, property damage, personal injury or death. WARNING:
 The first 6 inches of supply air plenum and ductwork must
be constructed of sheet metal as required by NFPA 90B.
The supply air plenum or duct must have a solid sheet metal
bottom piece directly after the air handler unit with no
WARNING: PROPOSITION 65:
openings, registers or flexible air ducts located in it. If flexible
 This appliance contains fiberglass insulation. Respirable supply air ducts are used they may be located only in the side
particles of fiberglass are known to State of California to walls of the rectangular plenum, a minimum of 6 inches from
cause cancer. the solid bottom. Metal plenum of duct may be connected
to the non-combustible floor base for downflow. Exposing
 All manufacturer products meet current federal OSHA combustible non-metal. material to the supply opening of a
Guidelines for safety. California Proposition 65 warnings are downflow unit can cause a fire resulting in property damage,
required for certain products, which are not covered by the personal injury or death.
OSHA standards.

 California’s Proposition 65 requires warnings for products

sold in California that contain or produce any of over 600
listed chemicals known to the State of California to cause CAUTION:
cancer or birth defects such as fiberglass insulation, lead in
 Make sure the blower motor support is tight (3-motor
brass, and combustion products from natural gas.
mounting bolts - Fig. 1). Then check to see if wheel is tightly
 All “new equipment” shipped for sale in California will have secured to motor shaft before operation unit.
labels stating that the product contains and /or produces
Proposition 65 chemicals. Although we have not changed
our processes, having the same label on all our products
facilitates manufacturing and shipping. We cannot always
know “when, or if” products will be sold in the California
market.

 You may receive inquiries from customers about chemicals

found in, or produced by, some of our heating and
airconditioning equipment, or found in natural gas used with
some of our products. Listed below are those chemicals and
substances commonly associated with similar equipment in
our industry and other manufacturers.
— Glass Wool (Fiberglass) Insulation
— Carbon Monoxide (CO). BLOWER MOTOR MOUNTING BOLT
— Formaldehyde
— Benzene Figure 1

 More details are available at the websites for OSHA

(Occupational Safety and Health Administration), at www.
osha.gov and the State of California’s OEHHA (Office of
Environmental Health Hazard Assessment), at www.oehha.
org. Consumer education is important since the chemicals
and substances on the list are found in our daily lives. Most
consumers are aware that products present safety and health
risks, when improperly used, handled and maintained.

Bosch Thermotechnology Corp. | 12.2016 Data subject to change

 6 | Bosch IDS BVA Installation Instructions

2 General
The unit can be positioned for bottom air return in the upflow position, left and right
return in the horizontal position, top return in downflow position.

This Air Handler provides the flexibility for installation in any upflow , downflow or
horizontal application. Adjust motor speed tap through DIP switch to select correct
air flow according to blower performance table.

Top and side power and control wiring, accessible screw terminals for control wiring
all combine to make the installation easy, and minimize installation cost. See fig.3.

To ensure the proper installation, select a solid and level site. Ensure enough space is
maintained for installation and maintenance.

AIR FLOW

≥40’’ ≥40’’

Clearances in the Horizontal Position

!

! !
ı25’’
Front of unit

Clearances in the Vertical Position

Figure 2

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 Installation Instructions Bosch IDS BVA | 7

2.1 Unit dimensions

NOTE: 25” CLEARANCE IS REQUIRED IN THE FRONT

OF THE UNIT FOR FILTER AND COIL MAINTENANCE.
ELECTRICAL CONNECTIONS
THROUGH TOP OR EITHER SIDE
SUPPLY AIR

HIGH VOLTAGE CONNECTION 1- 3/ 4”, FLANGES ARE PROVIDED

1- 3/ 8”, 7/ 8” DIA KNOCK OUTS FOR FIELD INSTALLATION
5 6
10 1
A
W

LOW VOLTAGE CONNECTION

CIRCUIT BREAKER SWITCH

(FOR ELECTRIC HEATER ONLY)

VAPOR LINE CONNECTION COPPER TUBE (SWEAT)

LIQUID LINE CONNECTION COPPER TUBE (SWEAT)

AUXILIARY DRAIN CONNCECTION 3/4”

FEMALE PIPE THREAD (NPT)

AUXILIARY DRAIN CONNECTION 3/4”

FEMALE PIPE THREAD (NPT) D

PRIMARY DRAIN CONNCETION 3/4”

FEMALE PIPE THREAD (NPT)

UPFLOW UNIT SHOWN;

UNIT MAY BE INSTALLED UPFLOW, DOWNFLOW,
HORIZONTAL RIGHT, OR LEFT AIR SUPPLY.

Figure 3

Dimensions Inch [mm]

Model Size
Unit Height "H" In. [mm] Unit Width "W" In.[mm] Unit Length "D" In.[mm] Supply Duct "A" Liquid Line / Vapor Line
24 46-1/2"[1180] 19-5/8"[500] 21-5/8"[550] 18"[456] 3/8" / 3/4" [9.5]/[19]
36 46-1/2"[1180] 19-5/8"[500] 21-5/8"[550] 18"[456] 3/8" / 3/4" [9.5]/[19]
48 54-1/2"[1385] 22"[560] 24"[610] 19-1/2"[496] 3/8" / 7/8" [9.5]/[22]
60 54-1/2"[1385] 22"[560] 24"[610] 19-1/2"[496] 3/8" / 7/8" [9.5]/[22]

Table 1

Bosch Thermotechnology Corp. | 12.2016 Data subject to change

 8 | Bosch IDS BVA Installation Instructions

3 Applications 3.3 Horizontal

Horizontal right is the default factory configuration for the units. Conversion to
3.1 Vertical upflow
Horizontal left: A vertical upflow unit may be converted to horizontal left by removing
 Vertical Upflow configuration is the factory default on all models (see Fig 3). indoor coil assembly and reinstalling coil as shown for left hand air supply.

 If return air is to be ducted, install duct flush with floor. Use fireproof  Rotate the unit 90° into the horizontal left position, with the coil
resilient gasket 1/8 to 1/4 in. thick between the ducts, unit and floor. Set compartment on the right and the blower compartment on the left. See Fig.
unit on floor over opening. 5.

 Reinstall the indoor coil 180° from original position. Ensure the retaining
Lightly tighten the drain connections so they do not leak. Using excessive channel is fully engaged with the coil rail. See Fig. 5.
force may/will cause damage to the unit.(see Fig.3&4)
 Secondary drain pan kits are recommended when the unit is configured for
the horizontal position over a finished ceiling and/or living space.

Refrigerant
connections -
1-9/16 see Fig. 3
for details. Drain

AIRFLOW
connections -
see Fig. 3
for details.

5/16
2-13/16
1-1/4

2-15/16 5/16 1-3/8

2-15/16
VERTICAL DOWNFLOW APPLICATION
(lower front service panel removed “view”.)

Figure 4 Dimensions for front connect coil

A
1:4

ENSURE THE RETAINING

CHANNEL IS FULLY ENGAGED
3.2 Vertical downflow WITH THE COIL RAIL.
DETAIL A
Conversion to Vertical Downflow:
RAILS
A vertical upflow unit may be converted to vertical downflow. Remove the door and A
indoor coil and reinstall 180° from original position. See Fig 5.

To comply with Safety Standars and the National Electric Code for
downflow application, the circuit breaker(s) on field installed electric
heater kits refer to electric heater kit installation manual for more detail. AIRFLOW
The breaker switch “on” position and marking are up and, “off” position
and marking are down.

CAUTION: RAILS
HORIZONTAL LEFT APPLICATION
 When using the unit with electric heater kits, the switch on (lower front service panel removed “view”.)
the front of panel is used for these heaters only.

Figure 5

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 Installation Instructions Bosch IDS BVA | 9

STRAPS
TOP AIR STOP HORIZONTAL ADAPTER KIT

REAR WATER CATCHER

SUCTION LINE CONNECTION

LIQUID LINE CONNECTION

TXV

AUXILIARY HORIZONTAL
DRAIN CONNECTION

VERTICAL DRAIN PAN

PRIMARY DRAIN
CONNECTION

AUXILIARY UPFLOW/DOWNFLOW
DRAIN CONNECTION

Figure 6

CAUTION:
 Horizontal units must be configured for right hand air supply
or left hand air supply. Horizontal drain pan must be located
under indoor coil. Failure to use the drain pan can result in
property damage.

3.4 Installation in an unconditioned space

There are two pairs of coil rails in the air handler for default and counter
flow application. If the air handler is installed in an unconditioned space,
the two unused coil rails should be removed to minimize air handler
surface sweating. The coil rails can be easily removed by taking off the 6
mounting screws from both sides of the cabinet.

Bosch Thermotechnology Corp. | 12.2016 Data subject to change

 1 0 | Bosch IDS BVA Installation Instructions

4 Electrical wiring 4.3 Grounding

Field wiring must comply with the National Electric Code (C.E.C. in Canada) and any
WARNING:
applicable local ordinance.
 The unit must be permanently grounded. Failure to do so can
result in electrical shock causing personal injury or death.
WARNING: HAZARDOUS VOLTAGE
 Disconnect all power to unit before installing or servicing.
 Grounding may be accomplished by grounding metal conduit when installed
More than one disconnect switch may be required to
in accordance with electrical codes to the unit cabinet.
deenergize the equipment. Hazardous voltage can cause
severe personal injury or death.
 Grounding may also be accomplished by attaching ground wire(s) to ground
lug(s) provided in the unit wiring compartment.

 Use of multiple supply circuits require grounding of each circuit to lug(s)

4.1 Power wiring
provided in unit.
It is important that proper electrical power is available for connection to the unit
being installed. See the unit nameplate, wiring diagram and electrical data in the
installation instructions.
4.4 Electrical data
 If required, install a branch circuit disconnect of adequate size, located
within sight of, and readily accessible from the unit. Maximum
Circuit
Model Voltage Hertz HP Speeds Circuit
Amps
Protector
When the Electric Heater is installed, units may be equipped with one or
24 208/230 60 1/3 5 3.5 15(A)
two 30-60 amp. circuit breakers. These breaker(s) protect the internal
wiring in the event of a short circuit and serve as a disconnect. Circuit 36 208/230 60 1/2 5 5.1 15(A)
breakers installed within the unit do not provide over-current protection of 48 208/230 60 3/4 5 7.5 15(A)
the supply wiring and therefore may be sized larger than the branch circuit 60 208/230 60 3/4 5 7.5 15(A)
protection.
Table 2

 Supply circuit power wiring must be 75°C minimum copper conductors

only. See Electrical Data In this section for ampacity, wire size and circuit
protector requirement. Supply circuit protective devices may be either fuses
or “HACR” type circuit breakers.

4.2 Control wiring

Class 2 low voltage control wiring should not be run in conduit with main
power wiring and must be separated from power wiring, unless class 1
wire of proper voltage rating is used.

 Low voltage control wiring should be 18 Awg. color-coded. For lengths

longer than 100 ft., 16 Awg. wire should be used.

 Low voltage control connections are made to low voltage pigtails within air
handler control box.

 See wiring diagrams attached to indoor and outdoor sections to be

connected.

 Make sure, after installation, separation of control wiring and power wiring
has been maintained.

Data subject to change 12.2016 | Bosch Thermotechnology Corp.

 Installation Instructions Bosch IDS BVA | 11

4.5 Electrical kit MCA/MOP data

Air Handler (kW)Electric MIN. Circuit Ampacity MAX.Fuse or Breaker (HACR) Ampacity Fan Speed
Heat Kit Model
Model Heat 240 VAC 208 VAC 240 VAC 208 VAC 1 2 3 4 5
WEHK05A 5 28.5 24.9 30 25 ● ● ● ● ●
WEHK08A 24 7.5 41.5 36.3 45 40 X X ● ● ●
WEHK10A 10 54.5 47.6 60 50 X X ● ● ●
WEHK05A 5 29.7 26.2 30 30 ● ● ● ● ●
WEHK08A 7.5 42.7 37.5 45 40 X ● ● ● ●
WEHK10A 36 10 55.8 48.8 60 50 X X ● ● ●
55.8+26.1 48.8+22.6 60+30 50+25
WEHK15B 15 X X ● ● ●
81.8 * 75.3 * 90 * 80 *
WEHK05A 5 33.6 30.1 35 35 ● ● ● ● ●
WEHK08A 7.5 46.6 41.4 50 45 ● ● ● ● ●
WEHK10A 10 59.6 52.7 60 60 X ● ● ● ●
48 59.6+26.1 52.7+22.6 60+30 60+25
WEHK15B 15 X X ● ● ●
85.7 * 75.3 * 90 * 80 *
59.6+52.1 52.7+45.2 60+60 60+50
WEHK20B 20 X X X ● ●
111.7 * 97.8 * 125 * 100 *
WEHK05A 5 33.6 30.1 35 35 X X ● ● ●
WEHK08A 7.5 46.6 41.4 50 45 X X ● ● ●
WEHK10A 10 59.6 52.7 60 60 X X ● ● ●
60 59.6+26.1 52.7+22.6 60+30 60+25
WEHK15B 15 X X ● ● ●
85.7 * 75.3 * 90 * 80 *
59.6+52.1 52.7+45.2 60+60 60+50
WEHK20B 20 X X X ● ●
111.7 * 97.8 * 125 * 100 *

Table 3

Heat kit suitable for AHU multi position installation.

[ ● means available, X means not available, * means single circuit ]

Heater Kit Accessories

Model Description 24 36 48 60
WEHK05A 5kW Heat Kit,Double Pole Breaker ● ● ● ●
WEHK08A 7.5kW Heat Kit,Double Pole Breaker ● ● ● ●
WEHK10A 10kW Heat Kit,Double Pole Breaker ● ● ● ●
WEHK15B 15kW Heat Kit,Double Pole Breaker X ● ● ●
WEHK20B 20kW Heat Kit,Double Pole Breaker X X ● ●

Table 4

[ ● means available, X means not available ]

Bosch Thermotechnology Corp. | 12.2016 Data subject to change

 1 2 | Bosch IDS BVA Installation Instructions

5 Airflow performance
Airflow performance data is based on cooling performance with a coil and no filter
in place. Check the performance table for appropriate unit size selection. External
static pressure should stay within the minimum and maximum limits shown in the
table below in order to ensure proper operation of both cooling, heating, and electric
heating operation.

SCFM
External Static Pressure-Inches W.C.[kPa]
Air Handler Model Size Motor Speed
0.1[.02] 0.2[. 05] 0.3[.07] 0.4[.10] 0.5[.12] 0.6[.15] 0.7[.17] 0.8[.20]

SCFM 1016 955 914 870 827 790 741 691 657
Tap(5)
Watts 139 146 157 165 174 185 195 202 209
SCFM 955 892 853 804 768 729 671 630 ---
Tap(4)
Watts 118 125 135 142 152 162 169 178 ---
Tap(3) SCFM 927 829 789 739 701 643 597 --- ---
24
-Default Setting Watts 109 105 113 121 131 137 147 --- ---
SCFM 887 766 671 631 567 522 465 --- ---
Tap(2)
Watts 97 87 83 93 99 108 112 --- ---
SCFM 829 698 547 366 347 277 234 --- ---
Tap(1)
Watts 81 71 60 54 60 64 72 --- ---
SCFM 1452 1403 1343 1287 1214 1144 1085 1022 968
Tap(5)
Watts 253 264 271 284 296 303 313 324 329
Tap(4) SCFM 1255 1203 1150 1062 995 920 854 797 719
-Default Setting Watts 170 182 193 201 212 221 229 239 244
SCFM 1109 1050 985 897 841 841 766 702 617
36 Tap(3)
Watts 126 136 147 154 164 170 180 187 195
SCFM 1020 907 818 733 673 586 520 --- ---
Tap(2)
Watts 103 98 109 114 124 129 139 --- ---
SCFM 962 807 627 551 450 380 296 --- ---
Tap(1)
Watts 90 80 71 79 83 93 96 --- ---
SCFM 2072 2013 1935 1923 1878 1830 1783 1736 1688
Tap(5)
Watts 447 464 489 497 514 530 545 558 570
SCFM 1860 1816 1735 1679 1640 1591 1542 1504 1481
Tap(4)
Watts 348 364 383 395 408 418 429 451 463
Tap(3) SCFM 1702 1651 1560 1547 1497 1438 1385 1331 1280
48
-Default Setting Watts 268 281 304 312 325 337 349 361 375
SCFM 1393 1358 1179 1155 1139 1074 1020 964 896
Tap(2)
Watts 227 234 258 269 270 283 296 313 325
SCFM 1365 1239 1078 1050 965 904 886 831 797
Tap(1)
Watts 220 226 243 264 269 281 293 301 317
SCFM 2054 2015 1947 1928 1886 1846 1804 1742 1654
Tap(5)
Watts 470 495 518 528 542 553 569 567 548
Tap(4) SCFM 1883 1840 1783 1754 1712 1670 1622 1579 1541
-Default Setting Watts 367 388 411 420 422 445 454 466 479
SCFM 1721 1674 1582 1566 1528 1484 1443 1401 1345
60 Tap(3)
Watts 289 305 327 330 341 353 365 378 387
SCFM 1515 1463 1386 1358 1308 1262 1215 1153 1073
Tap(2)
Watts 205 218 235 239 251 263 276 285 301
SCFM 1337 1265 1156 1148 1095 984 955 963 789
Tap(1)
Watts 145 157 173 178 186 197 212 225 235

Table 5

- Bold outlined areas represent airflow outside of the required 300-450 cfm/ton range.

Airflow based upon Air Handler Unit operating at 230V with no electric
SCFM means Standard Cubic Foot per Minute. heater kit and no filter. Airflow at 208V is approximately the same as
230V.

Data subject to change 12.2016 | Bosch Thermotechnology Corp.

 Installation Instructions Bosch IDS BVA | 13

The air distribution system has the greatest effect on airflow. The duct system is 6 Ductwork
totally controlled by the contractor. For this reason, the contractor should use only
industry-recognized procedures. Field ductwork must comply with the National Fire Protection Association NFPA 90A,
NFPA 90B and any applicable local ordinance.
Heat pump systems require a specified airflow. Each ton of cooling requires between
350 and 450 cubic feet of air per minute (CFM), or 400 CFM nominally.
Duct design and construction should be carefully done. System performance can be WARNING:
lowered dramatically through bad planning or workmanship.
 Do not, under any circumstances, connect return ductwork
to any other heat producing device such as fireplace insert,
Air supply diffusers must be selected and located carefully. They must be sized and
stove, etc. Unauthorized use of such devices may result in
positoined to deliver treated air along the perimerter of the space. If they are too
fire, carbon monoxide poisoning, explosion, personal injury
small for their intended airflow, they become noisy. If they are not located properly,
or property damage.
they cause drafts. Return air grilles must be properly sized to carry air back to the
blower. If they are too small, they also cause noise.
Sheet metal ductwork run in unconditioned spaces must be insulated and covered
The installers should balance the air distribution system to ensure proper quiet with a vapor barrier. Fibrous ductwork may be used if constructed and installed in
airflow to all rooms in the home. This ensures a comfortable living space. accordance with SMACNA Construction Standard on Fibrous Glass Ducts. Ductwork
An air velocity meter or airflow hood can be used to balance and verify branch and must comply with National Fire Protection Association as tested by U/L Standard
system airflow (CFM). 181 for Class I Air Ducts. Check local codes for requirements on ductwork and
insulation.

 Duct system must be designed within the range of external static pressure
the unit is designed to operate against. It is important that the system
airflow be adequate. Make sure supply and return ductwork, grills, special
filters, accessories, etc. are accounted for in total resistance. See airflow
performance tables in this manual.

 Design the duct system in accordance with “ACCA” Manual “D” Design for
Residential Winter and Summer Air Conditioning and Equipment Selection.
Latest editions are available from: “ACCA” Air Conditioning Contractors
of America, 1513 16th Street, N.W., Washington, D.C. 20036. If duct
system incorporates flexible air duct, be sure pressure drop Information
(straight length plus all turns) shown in “ACCA” Manual “D” is accounted for
in system.

 Supply plenum should be attached to the 3/4” duct flanges supplied with
the unit. Attach flanges around the blower outlet.

If an elbow is included in the plenum close to the unit, it must not be

smaller than the dimensions of the supply duct flange on the unit.

The front flange on the return duct if connected to the blower casing must
not be screwed into the area where the power wiring is located. Drills or
sharp screw points can damage insulation on wires located inside unit.

 Secure the supply and return ductwork to the unit flanges, using proper
fasteners for the type of duct used and tape the duct-to-unit joint as
required to prevent air leaks.

Bosch Thermotechnology Corp. | 12.2016 Data subject to change

 1 4 | Bosch IDS BVA Installation Instructions

7 Refrigerant connections  Do not connect condensate drain line to a closed or open sewer pipe. Run
condensate to an open drain or run line to a safe outdoor area.
Keep the coil connections sealed until refrigerant connections are made. See
the Installation Instructions for the outdoor unit for details on line sizing, tubing  The drain line should be insulated where necessary to prevent sweating and
installation, and charging information. damage due to condensate forming on the outside surface of the line.

 Make provisions for disconnecting and cleaning of the primary drain line
Coil is shipped filled with Nitrogen. Evacuate the system before charging with
should it become necessary. Install a 3 inch trap in the primary drain line
refrigerant.
as close to the unit as possible. Make sure that the top of the trap is below
connection to the drain pan to allow complete drainage of pan (See Fig. 7).
Install refrigerant lines so that it does not block service access to the front of the unit.
Nitrogen should flow through the refrigerant lines while brazing.
 Auxiliary drain line should be run to a place where condensate will be
noticeable. Homeowner should be warned that a problem exists if water
Use a wet rag or an approved heat paste to protect the TXV sensing bulb during the
should begin running from the auxiliary drain line.
brazing process.
 Plug the unused drain connection with the plugs provided in the parts bag,
After the refrigerant line connections are made, seal the gap around the connections using a thin layer of teflon paste, silicone or teflon tape to form a water tight
with pressure sensitive gasket. seal.

7.1 Condensate drain connection  Test condensate drain pan and drain line after installation is complete. Pour
water into drain pan, enough to fill drain trap and line. Check to make sure
Consult local codes for specific requirements.
drain pan is draining completely, no leaks are found in drain line fittings, and
water is draining from the termination of the primary drain line.

CONDENSATE DRAIN TRAP

DO NOT OPERATE UNIT WITHOUT

8 Air filter (not factory-installed)
CONDENSATE DRAIN TRAP.
An external filter or other means of filtration must be properly sized for a maximum of
300 feet/min. air velocity or what is recommended for the type filter installed.
" 3

Filter application and placement are critical to airflow, which may affect the heating
UNIT
and cooling system performance. Reduced airflow can shorten the life of the
" 3

system’s major components, such as motor, elements, heat relays, evaporator coil or
compressor. Consequently, we recommend that the return air duct system have only
DO NOT OVERTIGHTEN DRAIN FITTING
one filter location. For systems without a return air filter grill, multiple filter grills can
UNIT MUST BE SLIGHTLY PITCHED be installed at each of the return air openings.
TOWARD DRAIN CONNECTION
TO APPROVED DRAIN If adding high efficiency filters or electronic air filtration systems, it is very important
that the air flow is not reduced. If air flow is reduced the overall performance and
efficiency of the unit will be reduced. It is strongly recommended that a professional
Figure 7
installation technician is contacted to ensure such filtration systems are installed
correctly.

1. When making drain fitting connections to the drain pan, use a thin layer
of Teflon paste, silicone or Teflon tape and install, hand tighten. Do not double filter the return air duct system. Do not filter the supply air
2. When making drain fitting connections to drain pan, do not overtighten duct system. This will change the performance of the unit and reduce
Over tightening fittings can split pipe connetions on the drain pan. airflow.

 Install drain lines so they do not block service access to front of the unit.
WARNING:
Minimum clearance of 24 inches is required for filter, coil or blower removal
and service access.  Do not operate the system without filters. A portion of the
dust suspended in the air may temporarily lodge In the duct
 Make sure unit is leveled or pitched slightly toward primary drain connection runs and at the supply registers. Any circulated dust particles
so that water will drain completely from the pan. (See Fig. 7) could be heated and charred by contact with the air handler
elements. This residue could soil ceilings, walls, drapes,
 Do not reduce drain line size to less than connection size provided on carpets and other articles in the house.
condensate drain pan. Soot damage may occur with filters in place, when certain
types of candles, oil lamps or standing pilots are burned.
 All horizontal drain lines must be pitched downward away from the unit a
minimum of 1/8” per foot of line to ensure proper drainage.

Data subject to change 12.2016 | Bosch Thermotechnology Corp.

 Installation Instructions Bosch IDS BVA | 15

9 Filter installation dimensions

FILTER RAILS

FILTER COVER
“H”
BOLT

RET
URN “A ”
AIR
OPE ”
NING
DEP
“B
TH
“D” ”
“W

NOTE:
Air filter is an optional part, not factory
installed.

Figure 8

Dimensional data

Filter Size "W" "D" "H" Return width "A" Return length "B"
Model
IN [mm]" IN [mm] IN [mm] IN [mm] IN IN

24/36 18Χ20[457Χ508] 18.3[466] 21.6[548] 1[25.4] 20.8 16.3

48/60 20Χ22[508Χ559] 20.7[526] 23.9[608] 1[25.4] 23 18.8

Table 6

Air filter removal / installation

 Remove bolts manually, remove air filter cover, see Fig. 6;

 Hold the edge of the air filter and extract out .

 Install new filter so that the arrow on the filter is in the same direction as
airflow.

Bosch Thermotechnology Corp. | 12.2016 Data subject to change

 1 6 | Bosch IDS BVA Installation Instructions

10 Wiring diagram Electric wiring gauge for H/P systems

Model(Btu/h) 24 36 48 60
WARNING: HIGH VOLTAGE! Phase Single
Power
 Disconnect all power before servicing or installing this unit. Voltage/frequency 208/230VAC, 60Hz
Multiple power sources may be present. Failure to do so may Input Current Fuse Indoor unit (A) 15A 15A 15A 15A
cause property damage, personal injury or death.
Indoor Unit Power Line Quantity 3 3 3 3
Line Line Diameter(AWG) 14 14 14 14
 To avoid the electrical shock, please please ensure the air conditioner is Outdoor Unit Power Line Quantity 3 3 3 3
properly grounded. The main power plug in the air conditioner has been Line Line Line Diameter(AWG) 14 12 10 10
joined with the ground wiring, please do not alter. Gauge
Outdoor -Indoor Line Quantity 4 4 4 4
 Do not strain the power wiring. Signal Line Line Diameter(AWG) 18 18 18 18

Thermostat Signal Line Quantity 5 5 5 5

Line Line Diameter(AWG) 18 18 18 18

Table 7
W2
B
C If indoor unit has auxiliary heating already installed and a different
R auxiliary heating unit is required, the indoor unit (A) and indoor line
Y diameters will be different.
G

THERMOSTAT

G R C w1 C Y B D/W WARNING:
 These units must be wired and installed in accordance with all
INDOOR UNIT OUTDOOR UNIT
National and Local Safety Codes.

Figure 9 Control Wiring for H/P systems

Broken lines means H/P system with electric heating. Thermostat Wiring
please refer to the Owner’s Manual of the thermostat.

 When connecting the air conditioner with the ground, observe the local
codes.

 If necessary, connect wiring to the power fuse or circuit breaker.

Data subject to change 12.2016 | Bosch Thermotechnology Corp.

 Installation Instructions Bosch IDS BVA | 17

For ECM Motor (Size 24/48K)

CAUTION:
NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND

Notes:
1: Use copper wire (75 min) only between disconnect swicth and unit . FM
2: To be wired in accordance with NEC and local codes.
3: If any of the original wire supplied must be replaced,
use the same of equivalent type wire.
4: Connect R to R, G to G, etc. see outdoor instruction for details.
5: Change dip switch SW1 settings to choose the blower speed.
6: Check airflow performance table to ensure appropriate operations.

Figure 10

For ECM Motor (Size 36/60K)

CAUTION:
NOT SUITABLE FOR USE ON SYSTEMS EXCEEDING 150V TO GROUND

Notes:
1: Use copper wire (75 min) only between disconnect swicth and unit . FM
2: To be wired in accordance with NEC and local codes.
3: If any of the original wire supplied must be replaced,
use the same of equivalent type wire.
4: Connect R to R, G to G, etc. see outdoor instruction for details.
5: Change dip switch SW1 settings to choose the blower speed.
6: Check airflow performance table to ensure appropriate operations.

Figure 11

Bosch Thermotechnology Corp. | 12.2016 Data subject to change

 Figure 12
Unit Wiring

Data subject to change

1 8 | Bosch IDS BVA

8
6
8
6
4
2 6 6 4
5 5 2

CN6
4 4 BLUE
8 3 3
6 PCB 2 2
1 1 8
6
W2 4
2
WHITE W1 4
2

HEATER KIT PLUG

8
6
RED
6 6 4 1 L 2 L
5 5 2

CN6
4 4 BLUE
3 3 L1 L2
PCB 2 2
1 1 8
6 10kW HEAT KIT 7.5kW CB1 50A
ITEH W1W 4 10kW CB1 60A
2 7.5kW HEAT KIT

HEATER KIT PLUG

RED

1 L 2 L 1 L2
L L2 8
6

L1 L2 L1 L2 W2 4
2
15kW HEAT KIT (5kW + 7.5kW)/CB50A
20kW HEAT KIT/CB60A

8
6

6 6 4
5

6
6 5 2
6

CN6
5 5 4 4 BLUE
3 3

CN6
4 4 BLUE
3 3 PCB 2 2
1 1 8
PCB 2 2 6
1
8
1 6
WHITE W1 4
2
WHITE W1 4
2
HEATER KIT PLUG

HEATER KIT PLUG

RED
RED
1 L 2 L 1 L2
L L2
1 L 2 L
L1 L2 L1 L2
L1 L2

15kW HEAT KIT (10kW + 5kW)

5kW HEAT KIT
Installation Instructions

12.2016 | Bosch Thermotechnology Corp.

 Installation Instructions Bosch IDS BVA | 19

11 Spare parts

20 21 22 23 24 25 26 27

19
2
18
17 3

4
16 4.1
4.2
15 5
14.4.2
14.4.1
14.4
14.3
14.2
14.1
14

13 12 11 10 8 7 9 6

Figure 13

No. Part Name Qty BVA 24 (2 Ton) BVA 36 (3 Ton) BVA 48 (4 Ton) BVA 60 (5 Ton)
1 Top Pan, Cabinet 1 8733941881 8733941881 8733941910 8733941910
2 Ground Lug 1 8733941882 8733941882 8733941882 8733941882
3 Duct, Discharge 1 8733941883 8733941933 8733941911 8733941911
4 Main Control Board, Assy 1 8733941884 8733941884 8733941884 8733941884
4.1 Main Control Board 1 8733941885 8733941885 8733941885 8733941885
4.2 Bracket, Mounting 1 8733941886 8733941886 8733941886 8733941886
5 Transformer 1 8733941887 8733941887 8733941887 8733941887
6 Wrapper, Cabinet 1 8733941888 8733941888 8733941912 8733941912
7 Downflow Coil Support (Right) 1 8733941889 8733941889 8733941913 8733941913
8 Downflow Coil Support (Left) 1 8733941890 8733941890 8733941914 8733941914
9 Support Bracket (Middle) 1 8733941891 8733941891 8733941915 8733941915
10 Upflow Coil Support (Right) 1 8733941892 8733941892 8733941916 8733941916
11 Upflow Coil Support (Left) 1 8733941893 8733941893 8733941917 8733941917
12 Support Bracket (Lower) 1 8733941894 8733941894 8733941918 8733941918
13 Cover, Filter 1 8733941895 8733941895 8733941919 8733941919
14 Evaporator Assy 1 8733941896 8733941896 8733941928 8733941931
14.4.1 Distributor 1 8733941897 8733941897 8733941921 8733941921
14.4.2 Expansion valve 1 8733941898 8733941898 8733941929 8733941932
15 Drain Pan, Horizontal 1 8733941899 8733941899 8733941922 8733941922
16 Drain Pan, Vertical 1 8733941900 8733941923 8733941923 8733941923
17 Drain Pan Clamp 1 8733941901 8733941901 8733941901 8733941901
18 Drain Pan Support 2 8733941902 8733941902 8733941902 8733941902
19 Coil Door, Cabinet 1 8733941903 8733941903 8733941924 8733941924
20 Plate, Refrig Line Access 1 8733941904 8733941904 8733941904 8733941904
21 Blower Door, Cabinet 1 8733941905 8733941905 8733941925 8733941925
22 Mounting Bracket, Motor 1 8733941906 8733941906 8733941906 8733941906
23 Mounting Legs, Motor 3 8733941907 8733941907 8733941907 8733941907
24 Blower Assy, Wrapper/Wheel 1 8733941908 8733941926 8733941926 8733941926
25 Blower Motor 1 8733941909 8733941934 8733941930 8733941930
Table 8

Bosch Thermotechnology Corp. | 12.2016 Data subject to change

United States and Canada

Bosch Thermotechnology Corp.

50 Wentworth Avenue
Londonderry, NH 03053

Tel: 866-642-3198
Fax: 954-776-5529
www.boschheatingandcooling.com

BTC 761701101 E / 012.2016