BOSCH IDS Ultra Series Air Handler Installation Guide

Warnings
In warnings, signal words at the beginning of a warning are used to indicate the
type and seriousness of the ensuing risk if measures for minimizing danger are not
taken.

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

DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.

WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor to moderate injury.

NOTICE
NOTICE is used to address practices not related to personal injury.

Important information
The info symbol indicates important information where there is no risk to people
or property.

1.2 Explanation of Symbols Displayed on the Unit

symbol

1.3 Safety

Please read safety precautions before installation

WARNING
Improper or dangerous operation!
These instructions are intended as an aid to qualified licensed service personnel
for proper installation, adjustment 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 and possibly resulting in fire, electrical shock, property damage,
personal injury or death.

This document is customer property and is to remain with this unit. These
instructions do not cover all the different variations of systems nor does it provide
for every possible contingency to be met in connection with installation.

WARNING
Fire, electrical shock, property damage, personal injury, or death!
All phases of this installation must comply with NATIONAL, STATE AND LOCAL
CODES. If additional information is required please contact your local distributor.

Bosch IDS Heat Pump Ultra Series Air Handler – BTC 762003306 B (09.2024)

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

WARNING
Electrical shock!
The unit must be permanently grounded. Failure to do so can result in electrical
shock causing personal injury or death.

CAUTION
Fire, personal injury, property damage!
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 directly under the unit with no openings, registers or flexible
air ducts located in it. If flexible supply air ducts are used, they may be located only
in the vertical walls of rectangular plenum, a minimum of 6 inches from the solid
bottom. Metal plenum of duct may be connected to the combustible floor base, if
not, it must be connected to the unit supply duct exposed to the supply air opening
from the downflow unit. Exposing combustible (non-metal) material to the supply
opening of a downflow unit can cause a fire resulting in property damage, personal
injury or death.

NOTICE
Product damage!
Make sure the blower motor support is tight (3-motor mounting bolts – Figure 1).
Then check if wheel is tightly secured to motor shaft before operating unit.

Installation and Operating Instructions

blower motor

WARNING
Personal injury!

PROPOSITION 65: This appliance contains fiberglass insulation.
Respirable particles of fiberglass are known to State of California to cause
cancer.
All manufacturer products meet current federal OSHA Guidelines for
safety. California Proposition 65 warnings are required for certain
products, which are not covered by the 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 cancer or birth defects such as
fiberglass insulation, lead in brass, and combustion products from natural
vapor.
All “new equipment” shipped for sale in California will have 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 air-conditioning equipment, or
found in natural vapor 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)
◦ Formaldehyde
◦ Benzene

More details are available on the following websites: 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 IDS Heat Pump Ultra Series Air Handler – BTC 762003306 B (09.2024)

Installation and Operating Instructions

Flammable refrigerant!
Do not use means to accelerate the defrosting process or to clean, other than those
recommended by the manufacturer.
The appliance shall be stored in a room that does not have continuously operating
ignition sources (for example: open flames, an operating gas appliance or an
operating electric heater).
Do not pierce or burn the unit.
Be aware that refrigerants may not contain an odour.
If refrigerant gas leaks during installation, ventilate the area immediately.
Comply with national gas regulations.

NOTICE
Product damage!

Only use this unit in well-ventilated spaces and ensure that there are no obstructions
that could impede the airflow into and out of the unit. Do not use this unit in the
following locations:
• Locations with mineral oil.
• Locations with saline atmospheres, such as seaside locations.
• Locations with sulphurous atmospheres, such as near natural hot springs.
• Where high voltage electricity is present, such as in certain industrial
locations.
• On vehicles or vessels, such as trucks or ferry boats.
• Where exposure to oily or very humid air may occur, such as kitchens.
• In proximity to sources of electromagnetic radiation, such as highfrequency
transmitters or other high strength radiation devices.

WARNING
Personal injury, product damage!
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or persons who lack experience and
knowledge, unless they are supervised or have been given instructions concerning
the use of the appliance by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
Any person who is involved with working on or opening a refrigerant circuit
should hold a current valid certificate from an industry-accredited assessment
authority, which authorizes their competence to handle refrigerants safely in
accordance with an industry recognized assessment credential.
Servicing shall only be performed as recommended by the equipment manufacturer.
Maintenance and repair requiring the assistance of other skilled personnel shall be
carried out under the supervision of a person competent in the use of flammable
refrigerants.
Prior to beginning work on systems containing flammable refrigerants, safety checks
are necessary to minimize the risk of ignition.

WARNING
Electric shock, personal injury, product damage!
Be sure the air conditioner is grounded. In order to avoid electric shock, make sure
that the unit is grounded and that the ground wire is not connected to a gas or water
pipe, lightning conductor or telephone earth wire.
Do not operate the air conditioner with a wet hands. An electric shock may happen.
Do not touch the heat exchanger fins. These fins are sharp and could cut you.
To avoid oxygen deficiency, ventilate the room sufficiently if equipment with a
burner is used together with the air conditioner.
Arrange the drain hose to ensure smooth drainage. Incomplete drainage may cause
wetting of the building, furniture, etc.
Never touch the internal parts of the controller.
Do not remove the blower access panel. Some parts inside are dangerous to touch,
and machine troubles may occur.
Attention is drawn to the fact that additional transportation regulations may exist
with respect to equipment containing flammable gas. The maximum number
of pieces of equipment or the configuration of the equipment permitted to be
transported together will be determined by the applicable transport regulations.
Signs for similar appliances used in a work area are generally addressed by local
regulations and give the minimum requirements for the provision of safety and/
or health signs for a work location. All required signs are to be maintained and
employers should ensure that employees receive suitable and sufficient instruction
and training on the meaning of appropriate safety signs and the actions that need to
be taken in connection with these signs.
The effectiveness of signs should not be diminished by too many signs being placed
together.
Any pictograms used should be as simple as possible and contain only essential
details.
The storage of the appliance should be in accordance with the applicable
regulations or instructions, whichever is more stringent.
Storage package protection should be constructed such a way that mechanical
damage to the equipment inside the package will not cause a leak of the
REFRIGERANT CHARGE.
The maximum number of pieces of equipment permitted to be stored together will
be determined by local regulations.
Do not operate the air conditioner when using a room fumigation – type insecticide.
Failure to observe this precaution could cause the chemicals to become deposited
in the unit, which could endanger the health of those who are hypersensitive to
chemicals. It may also cause the refrigerant sensor to alarm.
Do not place appliances which produce open flame in places exposed to the air
flow from the unit or under the indoor unit. It may cause incomplete combustion or
deformation of the unit due to the heat.
Do not install the air conditioner in a location where flammable gas may leak out. If
the gas leaks out and stays around the air conditioner, a fire may occur.

WARNING
Personal injury!
The unit must be permanently grounded. Failure to do so may result in electrical
shock causing personal injury or death.

WARNING
Personal Injury, flammable refrigerant!
When repairing the refrigerating system, comply with the following precautions
prior to conducting work on the system:
• Work shall be undertaken according to controlled procedures to minimize
the risk of the presence of flammable gases or vapors while the work is
being performed.
• All maintenance staff and others working in the local area shall be
instructed on the nature of work being carried out. Work in confined
spaces shall be avoided.
• The area shall be checked with an appropriate refrigerant detector prior to
and during work, to ensure the technician is aware of potentially toxic or
flammable environment. Ensure that the leak detection equipment being
used is suitable for use with all applicable refrigerants, i.e., non-sparking,
adequately sealed or intrinsically safe.
• If any hot work is to be conducted on the refrigerating equipment or
any associated parts, appropriate fire extinguishing equipment shall
be available and easily accessible. Have a dry powder or CO2 fire
extinguisher adjacent to the charging area.
• When carrying out work in relation to a refrigerating system that involves
exposing any pipe work, no sources of ignition shall be used in such a
manner that it may lead to the risk of fire or explosion. All possible ignition
sources, including cigarette smoking, should be kept sufficiently far away
from the site of installation, repair, or removal and disposal of the unit,
during which refrigerant can possibly be released into the surrounding
space. Prior to beginning work, the area around the equipment is to be
surveyed to make sure that there are no flammable hazards or ignition
risks. “No Smoking” signs shall be clearly displayed.

WARNING
Personal Injury, flammable refrigerant!
Ensure that the area is in the open or that it is adequately ventilated before opening
the system or conducting any hot work. A degree of ventilation shall continue
during the period that the work is carried out. The ventilation should safely disperse
any released refrigerant and preferably expel it externally into the surroundings.
Where electrical components are being changed, they shall be fit according to
their purpose and to the correct specification. At all times the manufacturer’s
maintenance and service guidelines shall be followed. If in doubt, consult the
manufacturer’s technical department for assistance. The following checks shall be
applied to installations using flammable refrigerants:
• The actual refrigerant charge is in accordance with the room size within
which the refrigerant containing parts are installed.
• The ventilation machinery and outlets are operating adequately and are
not obstructed.
• If an indirect refrigerating circuit is being used, the secondary circuit shall
be checked for the presence of refrigerant.
• Equipment marking must remain visible and legible. Markings and signs
that are illegible shall be corrected.

WARNING
Personal Injury, flammable refrigerant!
Refrigerating pipe or components are installed in a position where they are
unlikely to be exposed to any substances which may corrode refrigerant containing
components, unless the components are constructed of materials that are
inherently resistant to corrosion or are suitably protected against corrosion.
Repair and maintenance of electrical components shall include initial safety checks
and component inspection procedures. If a fault exists that could compromise
safety, then no electrical supply shall be connected to the circuit until the fault has
been dealt with.
• That capacitors are discharged: this shall be done in a safe manner to avoid the possibility of sparking.
• That no live electrical components and wiring are exposed while charging, recovering or purging the system.
• That there is continuity of grounding.

WARNING
Flammable refrigerant!
Sealed electrical components shall be replaced.
Intrinsically safe components must be replaced.
Check that cabling will not be subject to wear, corrosion, excessive pressure,
vibration, sharp edges or any other adverse environmental effects. The check shall
also take into account the effects of aging or continual vibration from sources such
as compressors or fans.
Under no circumstances shall potential sources of ignition be used while searching
for or detection of refrigerant leaks. A halide torch (or any other detector using a
naked flame) shall not be used.
Electronic leak detectors may be used to detect refrigerant leaks but, in the case
of flammable refrigerants, the sensitivity may not be adequate, or may need recalibration.
(Detection equipment shall be calibrated in a refrigerant-free area.)
Ensure that the detector is not a potential source of ignition and is suitable for the
refrigerant used. Leak detection equipment shall be set at a percentage of the LFL
of the refrigerant and shall be calibrated for the refrigerant employed, and the
appropriate percentage of gas (25 % maximum) is confirmed.
If a leak is suspected, all naked flames shall be removed/extinguished.
If a leakage of refrigerant which requires brazing is found, all of the refrigerant shall
be recovered from the system, or isolated (by means of shut off valves) in a part of
the system remote from the leak.
Leak detection fluids are also suitable for use with most refrigerants but the use of
detergents containing chlorine shall be avoided as the chlorine may react with the
refrigerant and corrode the copper pipe-work.
Examples of leak detection fluids are:
• bubble method,
• fluorescent method agents.

Installation and Operating Instructions

WARNING
Flammable refrigerant!
When breaking into the refrigerant circuit to make repairs or for any other purpose
conventional procedures shall be used. However, for flammable refrigerants it is
important that best practice be followed, since flammability is a consideration. The
following procedure shall be adhered to:
• safely remove refrigerant following local and national regulations.
• evacuate.
• purge the circuit with inert gas.
• evacuate.
• continuously flush or purge with inert gas when using flame to open circuit, and.
• open the circuit.

The refrigerant charge shall be recovered into the correct recovery cylinders if
venting is not allowed by local and national codes. For appliances containing
flammable refrigerants, the system shall be purged with oxygen-free nitrogen to
render the appliance safe for flammable refrigerants. This process might need to
be repeated several times. Compressed air or oxygen shall not be used for purging
refrigerant systems.

For appliances containing flammable refrigerants, refrigerants purging shall
be achieved by breaking the vacuum in the system with oxygen-free nitrogen
and continuing to fill until the working pressure is achieved, then venting to
atmosphere, and finally pulling down to a vacuum. This process shall be repeated
until no refrigerant is within the system. When the final oxygen-free nitrogen charge
is used, the system shall be vented down to atmospheric pressure to enable work
to take place.

The outlet for the vacuum pump shall not be close to any potential ignition sources,
and ventilation shall be available.

Ensure that contamination of different refrigerants does not occur when using
charging equipment. Hoses or lines shall be as short as possible to minimize the
amount of refrigerant they contain.

Cylinders shall be kept upright. Ensure that the refrigeration system is grounded
prior to charging the system with refrigerant.

Label the system when charging is complete (if it is not already labeled).
Take extreme care not to overfill the refrigeration system.

WARNING
Flammable refrigerant!
Prior to recharging the system, it shall be pressure-tested with the appropriate
purging gas. The system shall be leak-tested on completion of charging but prior to
commissioning. A follow up leak test shall be carried out prior to leaving the site.
Before carrying out this procedure, it is essential that the technician is completely
familiar with the equipment and all its detail. It is recommended that all refrigerants
are recovered safely. Prior to the task being carried out, an oil and refrigerant
sample shall be taken in case analysis is required prior to re-use of reclaimed
refrigerant. It is essential that electrical power is available before the task is
commenced.

a. Become familiar with the equipment and its operation.
b. Isolate system electrically.
c. Before attempting the procedure ensure that:
• mechanical handling equipment is available, if required, for
handling refrigerant cylinders.
• all personal protective equipment is available and being used
correctly.
• the recovery process is supervised at all times by a competent
person.
• recovery equipment and cylinders conform to the appropriate
standards.
d. Pump down refrigerant system, if possible.
e. If a vacuum is not possible, make a manifold so that refrigerant can be
removed from various parts of the system.
f. Make sure that the cylinder is situated on the scales before recovery takes
place.
g. Start the recovery machine and operate it in accordance with the
manufacturer’s instructions.
h. Do not overfill cylinders. (No more than 80% volume liquid charge).
i. Do not exceed the maximum working pressure of the cylinder, even
temporarily.
j. When the cylinders have been filled correctly and the process has been
completed, make sure that the cylinders and the equipment are removed
from site promptly and all isolation valves on the equipment are closed off.
k. Recovered refrigerant shall not be charged into another refrigeration system
unless it has been cleaned and checked.

Equipment shall be labeled stating that it has been de-commissioned and emptied
of refrigerant. The label shall be dated and signed. Ensure that there are labels on
the equipment stating the equipment contains flammable refrigerant.
When removing refrigerant from a system, either for servicing or decommissioning,
it is recommended that all refrigerants are removed safely.

When transferring refrigerant into cylinders, ensure that only appropriate
refrigerant recovery cylinders are employed. Ensure that the correct number of
cylinders for holding the total system charge is available. All cylinders to be used
are designated for the recovered refrigerant and labelled for that refrigerant (i.e.
special cylinders for the recovery of refrigerant). Cylinders shall be complete with
pressure-relief valve and associated shut-off valves in good working order. Empty
recovery cylinders are evacuated and, if possible, cooled before recovery occurs.

WARNING
Flammable refrigerant!

The recovery equipment shall be in good working order with a set of instructions
concerning the equipment that is at hand and shall be suitable for the recovery of
the flammable refrigerant. If in doubt, the manufacturer should be consulted. In
addition, a set of calibrated weighing scales shall be available and in good working
order. Hoses shall be complete with leak-free disconnect couplings and in good
condition.

The recovered refrigerant shall be processed according to local legislation in the
correct recovery cylinder, and the relevant waste transfer note arranged. Do not
mix refrigerants in recovery units and especially not in cylinders.
If compressors or compressor oils are to be removed, ensure that they have been
evacuated to an acceptable level to make certain that flammable refrigerant does
not remain within the lubricant. The compressor body shall not be heated by an
open flame or other ignition sources to accelerate this process. When oil is drained
from a system, it shall be carried out safely.

Do not use the air conditioner for other purposes. In order to avoid any quality
deterioration, do not use the unit for the cooling of precision instruments, food,
plants, animals or works of art. Before cleaning, be sure to stop the operation, turn
the breaker off or unplug the supply cord. Otherwise, electric shock and injury may
occur.

To avoid electric shock or fire, make sure that a leak detector is installed. Never
touch the air outlet or the horizontal blades while the swing flap is in operation.
Fingers may be come caught or the unit may break down.
Never put any objects into the air inlet or outlet. Objects touching the fan at high
speed can be dangerous. Never inspect or service the unit by yourself. Ask a
qualified service person to perform this task.

Do not dispose of this product as unsorted municipal waste. This waste should be
collected separately for special treatment. Do not dispose of electrical appliances
as unsorted municipal waste. Use separate collection facilities. Contact your local
government for information regarding the connection systems available.
If electrical appliances are disposed of in landfills or dumps, hazardous substances
can leak into the groundwater and get into the food chain, hazardous to one’s health
and well-being.

To prevent refrigerant leak, contact your dealer.
When the system is installed and operates in a small room, it is required to
maintain the concentration of the refrigerant below the limit, in case a leak occurs.
Otherwise, oxygen in the room may be affected, resulting in a serious accident.

The refrigerant in the air conditioner is safe and normally does not leak.
If the refrigerant leaks into the room and encounters the fire of a burner, a heater or
a cooker, a harmful gas could be released.
Turn off any combustible heating devices, ventilate the room, and contact the
dealer where the unit was purchased.

Do not use the air conditioner until a service person confirms that the refrigerant
leak is repaired.
Keep ventilation openings clear of obstruction.

2 General

The unit can be positioned for bottom air return in the upflow position, left and right
air return in the horizontal position and top air return in downflow position.
This air handler provides the flexibility for installation in any upflow, downflow or
horizontal application. Adjust the motor speed tap through the DIP switch (located
on the Air Handler’s control board) to select correct air flow according to airflow
performance table (Table 15). Please refer to wiring diagram for Dip Switch
settings.

WARNING
Fire hazard !
Do not install unit in an area where flammable materials are present due to the risk
of an explosion resulting in serious injury or death.

WARNING
Personal injury, product damage!
If the supporting structural members are not strong enough to take the unit’s
weight, the unit could fall out of place and cause serious injury.

If a return-air duct is not installed, carefully select the place and method of product
installation so that air flow into the product will not be blocked.
The unit should be installed in a level position to ensure proper condensation
drainage. Up to an additional ¼” rise over the width or depth of the unit is allowed
to create additional sloping towards the drain.
Install the indoor and outdoor unit, power supply wiring and connecting wires at
least 3.5 ft. away from televisions or radios in order to prevent image interference
or noise.

Please refer to Figure 44 for high and low voltage wiring connections.
To ensure the proper installation, select a solid and level site. Ensure enough
clearance is maintained for installation and maintenance. Refer to figure 2.

clearance

NOTICE
Product damage!
The installed unit must have the required clearances as shown in Figure 2. Failure
to follow these instructions may result in equipment damage and/or premature
equipment failure.

WARNING
Fire hazard !
Keep flammable material and vapors, such as gasoline, away from the air handler.
Failure to follow these instructions can result in death, explosion, or fire.

2.1 Installations in High Humidity Environments
When the unit is installed in a hot and humid place, if the humidity inside the
installation space exceeds 86°F and RH 80%, it is recommended to insulate the
cabinet exterior. Use glass wool or polyethylene foam as insulation; the thickness
should be more than 2 in. and it must fit inside the installation space opening.
Condensation may come from the surface of the insulation. Be sure to use
insulation that is designed for use with HVAC Systems. Condensation may be
produced on surface during cooling operation. It is also recommended to use
auxiliary drain pan and secure the unit firmly to prevent it from falling. See Figures
3, 4, 5, & 6.
EHK knockout must be free of insulation so power can still be toggled to unit. Panels
need to be removable for access to interior of the unit.

Refer to local code requirements for usage of auxiliary drain pans.

WARNING
Fire hazard !
These instructions are exclusively intended for qualified contractors and authorized
installers. Work on the refrigerant circuit with flammable refrigerant in safety group
A2L may only be carried out by authorized heating contractors.These heating
contractors must be trained in accordance with UL 60335-2-40, Annex HH. The
certificate of competence from an industry accredited body is required. Work on
electrical equipment may only be carried out by a qualified electrician. Before initial
commissioning, all safety related points must be checked by the particular certified
heating contractors. The system must be commissioned by the system installer or a
qualified person authorized by the installer. For installation of the indoor unit, refer
to the corresponding installation and operation manual. If an indoor unit is installed
in an unventilated area, the area shall be so constructed that should any refrigerant
leak, it will not stagnate so as to create a fire or explosion hazard. The appliance
shall be stored so as to prevent mechanical damage from occurring. Do not stack
combustible materials on the surface of the indoor unit.

drain pan

NOTICE
Product damage!
Inner extra drain pan is recommended to be installed for 4 and 5 ton vertical
downflow applications installed in high humidity environments. This inner extra
drain pan can be ordered from the manufacturer as a spare part. Refer to Figure 6.

NOTICE
Product damage!
For high humidity installations which include electric heat strips, it is
recommended to install spacing brackets (available as a spare part from the
manufacturer) between the heater and the heater collar to prevent condensation
from forming on the collar.

Installation and Operating Instructions

air stop Figure 7 Indoor coil and drain pan set-up

2.2 Unit Dimensions

parts Figure 8

Model Size

Dimensions Inch [mm]

Unit Height “H”

Unit Width “W”

Unit Length “D”

Supply Duct “A”

Liquid Line | Vapor Line

54-1/2 [1385]

22 [560]

24 [610]

19-1/2 [496]

3/8 | 7/8 [9.5] | [22]

2.3 Components

components

Figure 9

COMPONENT IDENTIFICATION:

Main Control Board
Motor
Blower Housing

All Aluminum Coil
R454B-TXV
A2L Refrigerant Sensor

2.4 A2L Refrigerant Sensor

R454B refrigerant leakage sensor is configured for the indoor unit: To meet
different installation scenarios, the refrigerant sensor has two installation
positions. Before installing the indoor unit, check whether the refrigerant sensor is
correctly installed according to Section 3.

CAUTION
Fire hazard !
The refrigerant leakage sensor can only use the factory model or the specified model
indicated in the corresponding manual.
The R454B refrigerant leakage sensor must be used to activate the refrigerant shutoff
device,the alarm device, incorporated circulation airflowor other emergency
controls, which shall give anelectrical signal at a predetermined alarm setpoint in
response to leaked refrigerant.
The location of leakage sensors shall be chosen in relation to the different
installation scenarios.Please refer to the indoor unit installationmanual for specific
requirements.
The installation of the refrigerant leakage sensor shall allow access for checking,
repair or replacement by an authorized person.
The refrigerant leakage sensor shall be installed so its function can be verified easily.
The refrigerant leakage sensor shall be protected to prevent tampering or
unauthorized resetting of the pre-set value.
To be effective, the refrigerant leakage sensor must be electrically powered at all
times after installation, other than when servicing.
If the refrigerant leakage sensor detects a refrigerant leak, the fan will be turned on
to the maximum, the compressor will stop running. You should immediately leave the
leak area and notify a professional for handling.
The service life of the refrigerant sensor is 15years, and it should be replaced after
the service life.

WARNING
Fire, explosion, personal injury!
LEAK DETECTION SYSTEM installed on indoor unit. Unit must be powered except
for service.

NOTICE
Product damage!
R454B refrigerant leakage sensor is configured for the indoor unit. The operation
of fan can be initiated the by R454B refrigerant sensor, which meets the
incorporated circulation airflow requirements.
The allowed maximum refrigerant charge (Mmax) and the required minimum room
area (Amin) can be determined according to Table 6 and Tables 7-9.

3 Applications
3.1 Vertical Upflow
• Vertical Upflow configuration is the factory default on all models (see Figure 3).
• If return air is to be ducted, install duct flush with floor. Use fireproof
resilient gasket 1/8 to 1/4 in. thick between the ducts, unit and floor. Set
unit on floor over opening.

Torque applied to drain connections should not exceed 15 ft.lbs. For vertical
upflow and horizontal right installations, dimensions for refrigerant and drain pipes
may be found in Figure 10.

drain

3.2 Vertical Downflow
Conversion to Vertical Downflow:
A vertical upflow unit may be converted to vertical downflow. Remove the coil
access panel, refrigerant leak sensor, and indoor coil and reinstall 180° from
original position. See Figure 11.

airflow

3.3 Horizontal

Horizontal right is the default factory configuration for all models.

Conversion to Horizontal Left:
A vertical upflow unit may be converted to horizontal left by removing indoor coil
assembly and the refrigerant leak detection sensor. Reinstall the indoor coil and the
refrigerant sensor for left hand air supply. See Figure 12.
• Rotate the unit 90° into the horizontal left position, with the coil
compartment on the right and the blower compartment on the left.
• Remove the coil access panel
• Remove the refrigerant leak detection sensor and indoor coil
• Reinstall the indoor coil 180° from original position. Ensure the retaining
channel is fully engaged with the coil rail. See Figures 12 and 13.
• An additional field supplied drain pan kit is recommended when the unit
is configured for the horizontal position over a finished ceiling and/or
living space.

Steps for Changing Cabinet Orientation to Vertical Downflow OR Horizontal
Left Orientation
1. Remove the screws and zipties securing the refrigerant, T1, and T2 sensors.
Cut the zip tie holding wire loop in step 1A and remove the wire loop and T1
sensors from the bottom of the evaporator.
2. Remove the A2L refrigerant sensor from the coil and reconnect it to the side
of cabinet as shown in step 2. (Figure 12, Step 2).
3. Thread the T1 and T2 sensors through the wire loop as shown in Figure 12
step 2A. Reattach refrigerant, T1, and T2 sensors to the proper location as
shown in Figure 12, step 3 using field supplied zip ties to ensure that they
can not move around. Ensure that the wire loop is tightened.

vertical

downflow

NOTICE
Product damage!
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.

Conversion in Horizontal Direction:
Horizontal right-hand supply can be changed to horizontal left-hand supply by
removing the indoor coil and reinstalling 180° from original.

3.4 Installation in an Unconditioned Space

NOTICE
Product damage!
There are two pairs of coil rails in the air handler for upflow and downflow
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 unscrewing the 6 mounting screws from both sides of the
cabinet.

3.5 Refrigerant Charge and Room Area Limitations

In UL/CSA 60335-2-40, R454B refrigerant is classified as class A2L, which is
mildly flammable. Therefore, R454B refrigerant is suitable for systems needing
additional refrigerant charge and which will limit the area of the rooms being served
by the system.
Similarly, the total amount of refrigerant in the system shall be less than or equal
to the allowable maximum refrigerant charge. The allowable maximum refrigerant
charge depends on the area of the rooms being served by the system.

charge

The terms in this section are explained as follows:
• Mc: The actual refrigerant charge in the system.
• A: the actual room area where the appliance is installed.
• Amin: The required minimum room area.
• Mmax:The allowable maximum refrigerant charge in a room.
• Qmin: The minimum circulation airflow.
• Anvmin:The minimum opening area for connected rooms.
• TAmin: The total area of the conditioned space (For appliances serving
one or more rooms with an air duct system).
• TA: The total area of the conditioned space connected by air ducts.

3.5.1 The Room Area Calculation Requirements

CAUTION
Flammable refrigerant!
The space considered shall be any space which contains refrigerant-containing
parts or into which refrigerant could be released.
The room area (A) of the smallest, enclosed,occupied space shall be used in the
determination of the refrigerant quantity limits.

For determination of room area (A) when used to calculate the refrigerant charge
limit, the following shall apply.
The room area (A) shall be defined as the room area enclosed by the projection to
the base of the walls, partitions and doors of the space in which the appliance is
installed.
Spaces connected by only drop ceilings, ductwork, or similar connections shall not
be considered a single space.
Units mounted higher than 70-55/64 inches and spaces divided by partition walls
that are no higher than 62-63/64 inches shall be considered a single space. Rooms
on the same floor and connected by an open passageway between the spaces
can be considered a single room when determining compliance to Amin, if the
passageway complies with all of the following.
1. It is a permanent opening.
2. It extends to the floor.
3. It is intended for people to walk through.
The area of the connected rooms, on the same floor,connected by permanent
opening in the walls and/or doors between occupied spaces, including gaps
between the wall and the floor, can be considered a single room when determining
compliance to Amin, provided all of the following conditions are met as Figure 15.
Low level opening:
1. The opening shall not be less than Anvmin in Table 5.
2. The area of any openings above 11-13/16 inches from the floor shall not be
considered in determining compliance with Anvmin.
3. At least 50% of the opening area of Anvmin shall be below 7-7/8 inches
from the floor.
4. The bottom of the opening is not more than 3-15/16 inches from the floor.
5. The opening is a permanent opening that cannot be closed.
6. For openings extending to the floor the height shall not be less than 25/32
inches above the surface of the floor covering.
High level opening:
1. The opening shall not be less than 50% of Anvmin in Table 5.
2. The opening is a permanent opening that cannot be closed.
3. The opening shall be at least 59 inches above the floor.
4. The height of the opening is not less than 25/32 inches.

Room size requirement:
1. The room into which refrigerant can leak, plus the connected adjacent
room(s) shall have a total area not less than Amin. Amin is shown in Tables 7-9.
2. The room area in which the unit is installed shall be not less than 20% Amin.
Amin is shown in Tables 7-9.

The requirement for the second opening can be met by drop ceilings, ventilation
ducts, or similar arrangements that provide an airflow path between the connected
rooms.

The minimum opening for natural ventilation (Anvmin) in connected rooms is
related to the room area (A), the actual refrigerant charge of refrigerant in the
system (Mc) , and the allowable MAXIMUM REFRIGERANT CHARGE in the system
(Mmax), Anvmin can be determined according to Table 5.

drop sealing

The minimum opening area for connected rooms:

mmax

Anvmin

ft²

100

120

140

160

180

200

220

240

260

280

300

320

340

360

380

400

420

440

460

m²

9.2

11.1

13.0

14.8

16.7

18.5

20.4

22.2

24.1

26.0

27.8

29.7

31.5

33.4

35.3

37.1

39.0

40.8

42.7

lb-oz

15-8

lb-oz

3-5

3-15

4-10

5-5

6-3

6-13

7-8

8-3

8-13

9-8

10-2

11-0

11-11

12-6

13-0

13-11

14-5

15-0

15-14

1.5

1.8

2.1

2.4

2.8

3.1

3.4

3.7

4.0

4.3

4.6

5.0

5.3

5.6

5.9

6.2

6.5

6.8

7.2

ft²

2.1

2.0

1.9

1.8

1.7

1.6

1.4

1.3

1.2

1.1

1.0

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

m²

0.19

0.18

0.17

0.16

0.15

0.14

0.13

0.12

0.11

0.10

0.09

0.07

0.06

0.05

0.04

0.03

0.02

0.01

0.00

Table 5

Note: Take the Mc=15lb 8oz as an example.
For appliances serving one or more rooms with an air duct system, The room area
calculation shall be determined based on the total area of the conditioned space
(TA) connected by ducts taking into consideration that the circulating airflow
distributed to all the rooms by the appliance integral indoor fan will mix and dilute
the leaking refrigerant before entering any room.

3.5.2 The Allowed Maximum Refrigerant Charge and Required Minimum Room
Area

If the fan incorporated to an appliance is continuously operated or operation is
initiated by a REFRIGERANT DETECTION SYSTEM with a sufficient CIRCULATION
AIRFLOW rate, the allowable maximum refrigerant charge (Mmax) and the required
minimum room area (Amin/TAmin) is shown in Table 6 and Tables 7-9.

The allowable maximum refrigerant charges:

A/TA

mmax

A/TA

mmax

ft²

100

120

140

160

180

200

220

240

260

280

300

320

340

360

380

400

420

440

460

m²

9.2

11.1

13.0

14.8

16.7

18.5

20.4

22.2

24.1

26.0

27.8

29.7

31.5

33.4

35.3

37.1

39.0

40.8

42.7

lb-oz

15-8

ft²

3-5

3-15

4-10

5-5

6-3

6-13

7-8

8-3

8-13

9-8

10-2

11-0

11-11

12-6

13-0

13-11

14-5

15-0

15-14

m²

1.5

1.8

2.1

2.4

2.8

3.1

3.4

3.7

4.0

4.3

4.6

5.0

5.3

5.6

5.9

6.2

6.5

6.8

7.2

lb-oz

2.1

2.0

1.9

1.8

1.7

1.6

1.4

1.3

1.2

1.1

1.0

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0.19

0.18

0.17

0.16

0.15

0.14

0.13

0.12

0.11

0.10

0.09

0.07

0.06

0.05

0.04

0.03

0.02

0.01

0.00

Table 6

The required minimum room area:

Amin/TAmin

lb-oz

2-2

2-9

3-0

3-7

3-15

4-6

4-13

5-4

5-11

6-2

6-9

7-0

7-7

7-15

8-6

8-13

9-4

9-11

1.0

1.2

1.4

1.6

1.8

2.0

2.2

2.4

2.6

2.8

3.0

3.2

3.4

3.6

3.8

4.0

4.2

4.4

ft²

64.6

77.6

89.4

102.3

115.2

128.1

141.1

154.0

165.8

178.7

191.6

204.6

217.5

230.4

243.3

255.2

268.1

281

m²

6.0

7.2

8.3

9.5

10.7

11.9

13.1

14.3

15.4

16.6

17.8

19.0

20.2

21.4

22.6

23.7

24.9

26.1

lb-oz

10-2

10-9

11-0

11-7

11-14

12 -5

12-12

13-3

13-10

14-1

14-8

14-15

15-6

15-14

16-5

16-12

17-3

4.6

4.8

5.0

5.2

5.4

5.6

5.8

6.0

6.2

6.4

6.6

6.8

7.0

7.2

7.4

7.6

7.8

ft²

293.9

306.8

319.7

331.6

344.5

357.4

370.3

383.2

396.2

409.1

420.9

433.8

446.8

459.7

472.6

485.5

497.3

m²

27.3

28.5

29.7

30.8

32.0

33.2

34.4

35.6

36.8

38.0

39.1

40.3

41.5

42.7

43.9

45.1

46.2

Table 7

The required minimum room area if installed at an altitude over 2000ft:

Altitude (m)		601-800		801-1000		1001-1200		1201-1400		1401-1600		1601-1800		1801-2000
Altitude (ft)		1970-2625		2626-3280		3281-3938		3940-4593		4596-5250		5251-5905		5908-6562
mc		Amin/TAmin
lb-oz	kg	ft²	m²	ft²	m²	ft²	m²	ft²	m²	ft²	m²	ft²	m²	ft²	m²
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20	0.9 1.4 1.8 2.3 2.7 3.2 3.6 4.1 4.5 5.0 5.4 5.9 6.4 6.8 7.3 7.7 8.2 8.6 9.1	60 90 119 149 178 207 237 266 297 326 355 385 414 444 473 502 532 561 591	5.5 8.3 11.0 13.8 16.5 19.2 22.0 24.7 27.5 30.2 32.9 35.7 38.4 41.2 43.9 46.6 49.4 52.1 54.9	62 92 122 153 183 214 244 274 305 335 365 396 426 457 487 517 547 577 609	5.7 8.5 11.3 14.2 17.0 19.8 22.6 25.4 28.3 31.1 33.9 36.7 39.5 42.4 45.2 48.0 50.8 53.6 56.5	63 94 124 156 187 218 248 279 311 342 372 403 434 466 496 527 558 589 619	5.8 8.7 11.5 14.4 17.3 20.2 23.0 25.9 28.8 31.7 34.5 37.4 40.3 43.2 46.0 48.9 51.8 54.7 57.5	65 96 129 160 192 223 256 287 319 351 383 415 446 478 510 542 573 605 637	6.0 8.9 11.9 14.8 17.8 20.7 23.7 26.6 29.6 32.6 35.5 38.5 41.4 44.4 47.3 50.3 53.2 56.2 59.1	66 98 131 163 195 228 260 292 324 357 390 422 455 487 519 552 584 616 648	6.1 9.1 12.1 15.1 18.1 21.1 24.1 27.1 30.1 33.1 36.2 39.2 42.2 45.2 48.2 51.2 54.2 57.2 60.2	67 101 134 167 201 234 267 301 333 366 400 433 467 500 533 567 600 632 666	6.2 9.3 12.4 15.5 18.6 21.7 24.8 27.9 30.9 34.0 37.1 40.2 43.3 46.4 49.5 52.6 55.7 58.7 61.8	69 101 134 167 201 234 267 301 333 366 400 433 467 500 533 567 600 632 666	6.4 9.3 12.4 15.5 18.6 21.7 24.8 27.9 30.9 34.0 37.1 40.2 43.3 46.4 49.5 52.6 55.7 58.7 61.8

Table 8

Altitude (m)		2001-2200		2201-2400		2401-2600		2601-2800		2801-3000		3001-3200		above 3200
Altitude (ft)		6565-7218		7221-7874		7877-8530		8533-9186		9190-9843		9846-10500		above 10500
mc		Amin/TAmin
lb-oz	kg	ft²	m²	ft²	m²	ft²	m²	ft²	m²	ft²	m²	ft²	m²	ft²	m²
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20	0.9 1.4 1.8 2.3 2.7 3.2 3.6 4.1 4.5 5.0 5.4 5.9 6.4 6.8 7.3 7.7 8.2 8.6 9.1	72 101 134 167 201 234 267 301 333 366 400 433 467 500 533 567 600 632 666	6.6 9.3 12.4 15.5 18.6 21.7 24.8 27.9 30.9 34.0 37.1 40.2 43.3 46.4 49.5 52.6 55.7 58.7 61.8	60 90 119 149 178 207 237 266 297 326 355 385 414 444 473 502 532 561 591	5.5 8.3 11.0 13.8 16.5 19.2 22.0 24.7 27.5 30.2 32.9 35.7 38.4 41.2 43.9 46.6 49.4 52.1 54.9	62 92 122 153 183 214 244 274 305 335 365 396 426 457 487 517 547 577 609	5.7 8.5 11.3 14.2 17.0 19.8 22.6 25.4 28.3 31.1 33.9 36.7 39.5 42.4 45.2 48.0 50.8 53.6 56.5	63 94 124 156 187 218 248 279 311 342 372 403 434 466 496 527 558 589 619	5.8 8.7 11.5 14.4 17.3 20.2 23.0 25.9 28.8 31.7 34.5 37.4 40.3 43.2 46.0 48.9 51.8 54.7 57.5	65 96 129 160 192 223 256 287 319 351 383 415 446 478 510 542 573 605 637	6.0 8.9 11.9 14.8 17.8 20.7 23.7 26.6 29.6 32.6 35.5 38.5 41.4 44.4 47.3 50.3 53.2 56.2 59.1	66 98 131 163 195 228 260 292 324 357 390 422 455 487 519 552 584 616 648	6.1 9.1 12.1 15.1 18.1 21.1 24.1 27.1 30.1 33.1 36.2 39.2 42.2 45.2 48.2 51.2 54.2 57.2 60.2	67 101 134 167 201 234 267 301 333 366 400 433 467 500 533 567 600 632 666	6.2 9.3 12.4 15.5 18.6 21.7 24.8 27.9 30.9 34.0 37.1 40.2 43.3 46.4 49.5 52.6 55.7 58.7 61.8

Table 9

22 | Bosch IDS Heat Pump Ultra Series Air Handler – BTC 762003306 B (09.2024)

Installation and Operating Instructions

The minimum circulation airflow:

Qmin

lb-oz

2-2

2-9

3-0

3-7

3-15

4-6

4-13

5-4

5-11

6-2

6-9

7-0

7-7

7-15

8-6

8-13

9-4

9-11

1.0

1.2

1.4

1.6

1.8

2.0

2.2

2.4

2.6

2.8

3.0

3.2

3.4

3.6

3.8

4.0

4.2

4.4

CFM

116

139

162

185

208

231

253

277

300

323

346

369

392

415

438

461

483

506

m³/h

196

235

274

313

352

391

430

470

509

548

587

626

665

704

743

782

821

860

lb-oz

10-2

10-9

11-0

11-7

11-14

12 -5

12-12

13-3

13-10

14-1

14-8

14-15

15-6

15-14

16-5

16-12

17-3

4.6

4.8

5.0

5.2

5.4

5.6

5.8

6.0

6.2

6.4

6.6

6.8

7.0

7.2

7.4

7.6

7.8

CFM

530

553

576

599

622

645

668

691

713

736

759

782

806

829

852

875

898

Table 10

CAUTION
Min. room area and airflow required!
The allowable maximum refrigerant charge in Table 6 or the required minimum
room area in Tables 7-9 is available only if the following conditions are met:
Minimum velocity of 3.28ft/s, which is calculated as the indoor unit airflow divided
by the nominal face area of the outlet. And the grill area shall not be deducted.
Minimum airflow rate must meet the corresponding values in Table 10, which is
related to the actual refrigerant charge of the system (Mc).
R454B refrigerant leakage sensor is configured.

The maximum refrigerant limit described above applies to unventilated areas. If
adding additional measures, such as areas with mechanical ventilation or natural
ventilation, The maximum refrigerant charge can be increased or the minimum
room area can be reduced.
R454B refrigerant leakage sensor is configured for the indoor unit, meets the
incorporated circulation airflow requirements, the maximum refrigerant charge or
minimum room area can be determined according to Table 6 or Tables 7-9.

4 Electrical wiring

Field wiring must comply with the National Electric Code (C.E.C. in Canada) and
any applicable local ordinances.

WARNING
Electrical shock!
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.

4.1 Power Wiring

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 for more detailed requirements.
• If required, install a branch circuit disconnect of adequate size, located
within sight, and readily accessible from the unit.

WARNING
Electrical shock!
The indoor unit air switch cannot be used as a circuit breaker and cannot be
operated by users. Maintenance personnel need to disconnect the main switch
before operation.

When the Electric Heater is installed, units may be equipped with one or 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 breakers installed within the unit do
not provide over-current protection of the supply wiring and therefore may be sized
larger than the branch circuit protection.

Supply circuit power wiring must be 167 °F (75 °C) minimum copper
conductors only. See Electrical Data In this section for ampacity, wire
size and circuit protector requirements. Supply circuit protection devices
may be either fuses or “HACR” type circuit breakers.

High voltage wiring may be run through knockout holes on the right, left
or top of the unit.
Three 7/8″, 1-3/8″, 1-3/4″ dia. concentric knockouts are provided for
running high voltage wiring to the unit.
High voltage wiring must be connected to the red and black wiring in the
control section of the air handler.

Ensure supply voltage to the unit is not more than 10% over / under rated
voltage
Power wiring is connected to the power terminal block in unit electric
cabinet

4.2 Control Wiring
NOTICE

Product damage!
Do not connect the communication cables with power on, otherwise it will damage
the circuit board.
Do not connect the power cables (high voltage) to the Hyper-Link (M1 M2)
communication wires or conventional 24VAC non-communicating control wires
(low voltage),otherwise it will damage the circuit board.
Do not interconnect different communication buses (M1, M2, C, B, Y, W, etc.),
otherwise it will damage the circuit board.
Do not squeeze or pull the unit connection, and make sure the wiring is not in
contact with the sharp edges of the sheet metal.
Make sure, after installation, separation of control wiring and power wiring has
been maintained.

WARNING
Electrical shock!

Low voltage control connections are made to low voltage pigtails extending from
top of air handler. The Hyper-Link(M1 M2) communication wires are preinstalled
on the main control board (CN9). The 24VAC non-communicating
control wires are placed in the accessory bag, to be connected to the C, B, Y, W
terminals (CN9) if the system were to operate in a non-communicating mode. The
connectors of communication cables must be connected reliably and protected
by insulation. The copper cables must not be exposed. Unused communication
cables should be insulated, and the copper cables must not be exposed. Avoid
sharp edges of the sheet metal for communication cables to prevent wear. If the
wear is serious, it may lead to short circuit or electric leakage and cause danger.
Do not pull the communication cables. The communication cables must be routed
as closely as possible, and when there is strong electromagnetic interference in
the environment, it is recommended to use shielded cables for communication
cables. Otherwise, the communication may be abnormal. When the shielded cables
are used, the shielding layers at both ends must be connected to sheet metal.
Power cords and communication cables must be separated from each other with a
distance of more than 2 inches to prevent interference.

Low voltage control wiring should not be run in conduit with high voltage wiring.
Keep distance between the two conduits per local codes.

• Maximum Low Voltage Wiring Length can be seen in Table 11.
Hyper-Link (M1 M2) Communication Wire Size Max Length
16/18 AWG 300 ft.
Conventional 24 volts – Wires Size Max Length
18 AWG 150 ft.
16 AWG 225 ft.
Table 11
• See wiring diagram located on inside of blower access panel of air
handler for proper wiring instruction.
• After installation, ensure separation of low voltage and high voltage
wiring is maintained.
Hyper-Link(M1 M2) Communication Mode is only available for specified models.

4.3 Grounding

WARNING
Electrical shock!
The unit must be permanently grounded. Failure to do so can result in electrical
shock causing personal injury or death.
• The ground may consist of electrical wire or metal conduit when installed
in accordance with existing electrical codes.
• Grounding may also be accomplished by attaching ground wire(s) to
ground lug provided in the unit wiring compartment.
• Use of multiple supply circuits require grounding of each circuit to lug
provided in unit.
• Ground lug is located on the upper right side of the cabinet.

4.4 Electrical Data

Model Voltage Frequency
(Hz)
Blower
Power
(hp)
Speeds
Minimum
Circuit
Ampacity (A)
Maximum
Circuit
Protector
48 208/230 60 3/4 5 7.8 15(A)
60 208/230 60 3/4 5 7.8 15(A)
Table 12

4.5 Electric Heat Kit MCA/MOP Data

Heat Kit Model

Air Handler

Model

Heat Kit

Power (kW)

Min. Circuit Ampacity

Max. Fuse or Breaker (HACR) Ampacity

Fan speed

240V

208V

240V

208V

EHK-05B

EHK-08B

EHK-10B

EHK-15B

EHK-15I

EHK-20B

EHK-20I

EHK-05B

EHK-08B

EHK-10B

EHK-15B

EHK-15I

EHK-20B

EHK-20I

7.5

32.8

46.9

57.8

57.8/25*

89.5**

57.8/50*

112**

32.8

46.9

57.8

57.8/25*

89.5**

57.8/50*

112**

29.5

41.7

51.1

51.1/21.7*

75.5**

51.1/43.3*

98.1**

29.5

41.7

51.1

51.1/21.7*

75.5**

51.1/43.3*

98.1**

60/30*

90**

60/50*

125**

60/30*

90**

60/50*

125**

60/30*

80**

60/45*

100**

60/30*

80**

60/45*

100**

•

Table 13

Suitable heat kits for AHU multi position installation

* only applies to 2 stage (15/20kW) EHK

** only applies to 3 stage (15/20kW) EHK

• Heat kit suitable for AHU 4-way position installation.

• Ampacities for MCA and Fuse/breaker including the blower motor

• 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.

Heater Kit Accessories

Model

Stages

Description

EHK-05B

EHK-08B

EHK-10B

EHK-15B

EHK-15I

EHK-20B

EHK-20I

5 kW Heat Kit, Double Pole Breaker

7.5 kW Heat Kit, Double Pole Breaker

10 kW Heat Kit, Double Pole Breaker

15 kW Heat Kit, Double Pole Breaker

20 kW Heat Kit, Double Pole Breaker

•

Table 14

[ • means available, X means not available ]

For certain electric heat kits, an adapter cable found in the accessory bag might be

required to connect the heater kit to the circuit board

26 | Bosch IDS Heat Pump Ultra Series Air Handler – BTC 762003306 B (09.2024)

Installation and Operating 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.

Air Handler

Model Size

Motor Speed

CFM Wet Coil Without Filter and Electric Heat

External Static Pressure-Inches W.C.[kPa]

0 0.1 0.2 0.3 0.4 0.5 0.58 0.6 0.7 0.8 0.9

Tap 1

Tap 2

Tap 3

Tap 4

Tap 5

Tap 1

Tap 2

Tap 3

Tap 4

Tap 5

Power / W

CFM

Power / W

CFM

Power / W

CFM

Power / W

CFM

Power / W

CFM

Power / W

CFM

Power / W

CFM

Power / W

CFM

Power / W

CFM

Power / W

CFM

211 220 230 239 247 257 268 269 279 289 298 1424 1373 1326 1269 1221 1157 1088 1075 1010 951 893 295 307 316 325 334 342 350 352 364 380 391 1605 1556 1512 1468 1422 1380 1337 1325 1272 1195 1141 400 413 423 434 442 453 461 463 472 485 497 1789 1748 1707 1665 1622 1578 1542 1534 1493 1447 1387

510 522 534 545 558 569 577 578 589 599 614 1953 1923 1881 1843 1791 1742 1717 1717 1675 1643 1604 624 638 653 665 677 690 700 701 711 711 709 2137 2096 2044 2013 1967 1918 1885 1875 1825 1783 1729 206 215 224 232 240 250 264 266 275 284 294 1419 1365 1311 1262 1213 1156 1060 1043 975 913 860 285 297 307 317 326 335 342 345 363 376 388 1603 1554 1510 1463 1419 1374 1343 1327 1233 1154 1095 390 400 411 421 432 443 450 452 462 474 495 1788 1746 1705 1664 1619 1577 1544 1534 1493 1444 1343 493 507 532 532 545 555 565 568 579 588 600 1951 1911 1834 1833 1795 1761 1728 1719 1678 1649 1604 619 629 640 653 666 677 687 689 699 708 706 2087 2055 2023 1982 1941 1909 1879 1873 1837 1807 1755

Table 15

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

NOTES:

1. The high stage airflow must be used as the rated airflow for the full load operation of machine.

2. The rated airflow of systems without electric heater kits requires between 300 and 450 cubic feet of air per minute (CFM).

3. The rated airflow of systems with electric heater kits requires between 350 and 450 cubic feet of air per minute (CFM).

4. The air distribution system has the greatest effect on airflow. Therefore, the contractor should use only industry-recognized procedures.

5. Duct design and construction should be carefully done. System performance can be lowered dramatically through poor design or workmanship.

6. Air supplier ducts should be located along the perimeter of the conditioned space and properly sized.

Improper location or insufficient air flow may cause drafts or noise in the ductwork.

7. Installers should balance the air distribution system to ensure proper quiet airflow to all rooms in the home. An air velocity meter or airflow hood can be used to balance and verify branch and system airflow (CFM).

8. Please refer to the wiring diagram for the default fan speeds for each model

Bosch IDS Heat Pump Ultra Series Air Handler – BTC 762003306 B (09.2024) | 27

Installation and Operating Instructions

5.1 Indoor Fan Motor Function

System operation and function

Autofan Speed

The IDS Ultra series air handlers supports up to four stage fan control depending on the difference between the set point and room temperature when paired with a BCC connected thermostat. Otherwise, an estimated different between room temperature and set point is used.

The X13 ECM motor supports 5 different speeds. Customers can select the desired maximum and minimum fan speeds through adjusting the SW6-1 and SW6-2 dip switches. Refer to the airflow performance table (Table 15) and figure 44 dip switch settings to determine the best way to configure the blower’s speeds

Two Stage Fan Control Non-Auto Fan Speed

The IDS Ultra series air handler also supports two stage fan control which requires a two stage thermostat (Y1&Y2). When there is a call for Y2, the blower motor will turn to high speed setting. When there is a call for Y1, the blower motor will turn to low speed setting. Unit will run at low speed setting when there is only G call. It will

run in high speed setting when there is W/W1/W2 signal (when the electric heat kit is on).

The X13 ECM motor supports 5 speeds. Customer can select the suitable speed by adjusting the SW6-1 and SW6-2 dip switches. Refer to Airflow Performance Table (Table 15) for reference airflow. Refer to figure 44 for dip switches settings.

If 2 stage thermostat is not available, single stage thermostat may be used, please refer to Wiring Diagram section for wiring instructions. If Y1 and Y2 are jumped, the unit will only run in high stage fan speed.

Anti-Cold Air Fan Delay

The Anti-Cold Air Fan Delay function utilizies a temperature sensor (T2) located on the indoor coil, which prevents the blower from turning on until the coil has reached a certain temperature. This feature prevents cold air blow during heating operation.

1. When SW6-3 dip switch is set to the “OFF” position and the unit is in heating mode, the Anti-Cold Air Fan Delay function will activate based on the following entry conditions (all 3 conditions must be met):

a. Indoor Coil Temperature (T2) < 82.4°F
b. Electric heat kit is turned off
c. There is a call for Y1 from thermostat to indoor unit

2. This function will deactivate if ONE OF the following exit conditions are met OR the system has been operating in heating mode for 15 minutes.

a. T2 ≥ 89.6°F
b. Heater kit is turned on
c. The system is NOT running Heat mode
d. Pc ≥261.1psig

3. During the heating mode, if one of the exit conditions of Anti-Cold Air is satisfied, the blower motor will turn on in first stage fan speed.

4. During the heating mode, if all of the entry conditions of Anti-Cold Air are met and maintained for 120s, the blower motor will change to first stage speed.

Air handlers connected to water source heat pumps, or off brand units that energize the reversing valve with a call for cooling, should not run the b wire to the air handler. This will cause the anti cold air fan delay to trigger on a call for cooling.

Heating Fan Delay

If SW6-3 dip switch is set to the “ON” position and the unit is in heating mode, the blower will operate with a 90 second delay with the fan speed dictated by Y1 or Y2 signal.

Dehumidification (Optional)

The IDS Ultra series air handler has active and passive dehumidification modes depending on the wiring to the outdoor unit. When the air handler is communicating with an IDS Ultra series condensing unit, a DH call from a thermostat will lower the evaporator temperature and slow down the fan speed to dehumidify the space. If connecting to a condensing unit through conventional 24 VAC wiring, only the fan speed will be lowered.

If DH wire is not connected, the unit will still function normally.

28 | Bosch IDS Heat Pump Ultra Series Air Handler – BTC 762003306 B (09.2024)

Installation and Operating Instructions

6 Ductwork

Field ductwork must comply with the National Fire Protection Association NFPA 90A, NFPA 90B and any applicable local ordinance(s).

WARNING

Fire hazard and carbon monoxide !

Do not, under any circumstances, connect return ductwork to any other heat producing device such as fireplace insert, stove, etc. Unauthorized use of such devices may result in fire, carbon monoxide poisoning, explosion, personal injury or property damage.

Sheet metal ductwork run in unconditioned spaces must be insulated and covered with a vapor barrier. Fibrous ductwork may be used if constructed and installed in accordance with SMACNA Construction Standard on Fibrous Glass Ducts. Ductwork must comply with National Fire Protection Association as tested by U/L Standard 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 Section 5 of 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.

WARNING

Fire, explosion !

If appliances connected via an air duct system to one or more rooms are installed in a room with an area less than shown in section 3.5,that room shall be without continuously operating open flames (e.g. an operating gas appliance) or other potential ignition sources (for e.g. an operating electric heater, hot surfaces). A flame-producing device may be installed in the same space if the device is provided with an effective flame arrest.For appliances connected via an air duct system to one or more rooms, auxiliary devices which may be a potential ignition source shall not be installed in the duct work. Examples of such potential ignition sources are hot surfaces with a temperature exceeding 700°C and electric switching devices. For appliances connected via an air duct system to one or more rooms, only auxiliary devices approved by the appliance manufacturer or declared suitable with the refrigerant shall be installed in connecting ductwork.

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Installation and Operating Instructions

7 Refrigerant Connections

The suction pipe and liquid pipe of the indoor unit need to be protected and cannot be grabbed when moving the indoor unit.

Keep the coil connections sealed until refrigerant connections are made. Refer to the BOVA Installation, Operation, and Maintenance Manual for details on line sizing, tubing installation, and charging information.

Coil is factory charged with Nitrogen. Evacuate the system before charging with refrigerant.

Install refrigerant lines so that they do not block service access to the front of the unit.

Nitrogen should flow through the refrigerant lines while brazing.

Use a brazing shield to protect the cabinet’s paint and a wet rag to protect the rubber grommet and input pipe’s piston seal ring from being damaged by torch flames. Use a wet rag or an approved heat paste to protect the TXV sensing bulb during the brazing process. Refer to Figure 16.

After the refrigerant line connections are made, seal the gap around the connections with pressure sensitive gasket.

Use a wet rag to protect the sealing rings in the input pipe from being damaged by torch flames while brazing.

wet rag

Figure 16

After the brazing work is finished, make sure to check that there is no refrigerant leakage. After checking for vapor leaks, be sure to insulate the pipe connections, refer to Figure 17.

gap

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Installation and Operating Instructions

8 Condensate Drain Connection

Consult local codes for specific requirements.

Refer to Figure 18 and the information below for required condensate drain trap installation.

drain trap
Figure 18

When making drain fitting connections to the drain pan, use a thin layer of Teflon paste, silicone or Teflon tape and install by hand tightening.
When making drain fitting connections to drain pan, do not overtighten. Over tightening fittings can split pipe connections on the drain pan.

Ensure drain lines do not block access to front of the unit. Minimum
clearance of 24 inches is required for filter, coil or blower removal and
service access.
Make sure unit is leveled or pitched slightly toward primary drain
connection so that water will drain completely from the pan. Up to an
additional 1/4″ rise over the width or depth of the unit is allowed to create
additional sloping towards the drain. Unit must be positioned between
level and 1/4″ rise ,sloping toward the drain connections. See figures 19
to 22 for reference.
Do not reduce drain line size to less than connection size provided
on condensate drain pan. Use 3/4″ PVC piping for the drain piping
connections.
All horizontal drain lines must be pitched downward away from the unit at
a minimum of 1/8” per foot of line to ensure proper drainage.
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.
The drain line should be insulated where necessary to prevent sweating
and damage due to condensate forming on the outside surface of the line.
Make provisions for disconnecting and cleaning of the primary drain line
should it become necessary. Install a 3 inch trap in the primary drain line
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 Figure
18).
Auxiliary drain line should be run to a place where condensate will be
noticeable. Homeowner should be warned that a problem exists if water
should begin running from the auxiliary drain line.
Plug the unused drain connection with the plugs provided in the parts bag
provided with the unit. Use a thin layer of teflon paste, silicone or teflon
tape to form a water tight seal.
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
ensure 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.
Be sure to insulate the drain piping and drain socket since condensation
may cause water leakage.
Be sure to install a drain tap at the drain outlet since the inside of the unit
is at negative pressure relative to atmospheric pressure during operation.

downflow parts

view flow

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Installation and Operating Instructions

9 Air Filter (Not Factory-Installed)

Filters are not included with the unit and must be field supplied.

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 of filter installed.

Filter application and placement are critical to airflow, which may affect the heating and cooling system performance. Reduced airflow can shorten the life of the 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 one filter location. For systems without a return air filter grill, multiple filter grills can be installed at each of the return air openings.

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 installation technician is contacted to ensure such filtration systems are installed correctly.

Filters with MERV ratings between 8-11 are recommended. Any installed filters with a MERV rating above 11 will negatively impact air flow and system performance.

Do not double filter the return air duct system. Do not filter the supply air duct system. This will change the performance of the unit and reduce airflow.

WARNING
Fire hazard!

Do not operate the system without filters. A portion of the dust suspended in the air may temporarily lodge in the duct runs and at the supply registers. Any circulated dust particles could be heated and charred by contact with the air handler elements. This residue could soil ceilings, walls, drapes, carpets and other articles in the house. Soot damage may occur with filters in place, when certain types of candles, oil lamps or standing pilots are burned.

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Installation and Operating Instructions

9.1 Filter Installation Dimensions

filter dimension

Figure 23 Filter installation

Filters are not included with the unit and must be field supplied. Dimensional data

FILTER COVER MANUAL BOLT

Model

Filter Size

In. [mm]

“W”

In. [mm]

“D”

In. [mm]

“H”

In. [mm]

Return width “A”

In. [mm]

Return length “B”

In. [mm]

48/60

20×22 [508×559]

20.7 [526]

23.9 [608]

1 [25.4]

23 [584]

18.8 [478]

Table 16

Air filter removal / installation

• Remove bolts manually, remove air filter cover, see Figure 23.

• Hold the edge of the air filter and pull out.

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

• If reusable filter is being used, please clean according to the manufacturer’s specification prior to re-installation.

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Installation and Operating Instructions

10 Maintenance

For continuing high performance and to minimize possible equipment failure, periodic maintenance must be performed on this equipment.

10.1 Cleaning Precautions

WARNING

Improper or dangerous operation, personal injury!

Any unit repairs must be performed by qualified service personnel only.

WARNING

Electrical shock!

Always turn off your heat pump and disconnect its power supply before cleaning or maintenance.

WARNING CAUTION

Personal injury!

When removing filter, do not touch metal parts in the unit. The sharp metal edges can cut you.

NOTICE

Product damage!

Do not use chemicals or chemically treated cloths to clean the unit .

Do not use benzene, paint thinner, polishing powder or other solvents to clean the unit.

Do not operate the system without a filter in place.

10.2 Regular Maintenance

Your heat pump must be inspected regularly by a qualified service technician. Your annual system inspection must include:

1. Inspect the air filter every ninety days or as often as needed. If blocked or obstructed, clean or replace at once.

2. Inspection and/or cleaning of the blower wheel housing and motor. 3. Inspection and cleaning of indoor and outdoor coils as required.

4. Inspection and/or cleaning of the indoor coil drain pan and drain lines, as well as auxiliary drain pan and lines.

5. Check all electrical wiring and connections. Correct as needed, referring to the wiring diagram.

11 Disposal

Components and accessories from the units are not part of ordinary domestic waste.

Complete units , compressors, motors etc. are only to be disposed of via qualified disposal specialists.

This unit uses hydrogen fluorocarbons. Please contact the dealer when you want to dispose of this unit. Law requires that the collection, transportation and disposal of refrigerants must conform with the regulations governing the collection and destruction of hydrofluorocarbons.

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Installation and Operating Instructions

12 Wiring Diagrams

WARNING

Electrical shock!

Disconnect all power before servicing or installing this unit. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death.

DANGER

Electrical shock!

This unit must be properly grounded and protected by a circuit breaker or fuse.

WARNING

Electrical shock!

These units must be wired and installed in accordance with all National and Local Safety Codes.

• To avoid electrical shock, please ensure:

◦ The heat pump is properly grounded

◦ The main power plug to the heat pump has been joined with the ground wiring (DO NOT ALTER THIS).

• Do not strain the power wiring.

Low-voltage wires include indoor unit connect with outdoor unit and the indoor unit connect with the thermostats.

The wires between the indoor unit and the outdoor unit are classified into two modes: conventional 24VAC non-communicating thermostat control and PQ communication. PQ communication mode is only available for specified models.

Dashed lines in the following thermostat wiring diagrams refer to optional wiring (wiring for Passive Dehumidification Function and/OR Electric Heat). For thermostat wiring please refer to the Owner’s Manual of the thermostat.

Dh wiring is optional and requires a thermostat with a humidistat. Dh functions as Passive Dehumidification and will downstage the indoor fan to first stage. System will operate according to normal sequence of operations if Dh wiring is absent.

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Installation and Operating Instructions

12.1 Communicating Set Up

Dip switch configurations for communicating mode (default)
To setup the units as communication mode enable the indoor unit to transmit data
effectively with a paired Bosch outdoor unit.

outdoor

Figure 24

• The factory default mode is Hyper-Link(M1 M2) communication between the outdoor and indoor units and 24VAC connection with the thermostat.

• This device can be configured to utilize conventional 24VAC connections between the indoor and outdoor units.

• Hyper-Link(M1 M2) communication mode is only available with a matched indoor unit which has Hyper-Link(M1 M2) communication function.

• If there are 2 or more systems (communication) in the same area, make sure the low voltage wires are connected to the right unit that are connected to the same refrigerant line.

Low voltage wire connections with the outdoor unit, communicating
1. Peel off the half-stripped wires of the pre-installed communication wires
2. Connect the Hyper-Link(M1M2)communication wires to the field supplied

wire nut
Figure 25

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Installation and Operating Instructions

Communicating thermostat wiring diagrams

system

system part

system setup

Hyper-Link (M1 M2) communication mode and conventional 24VAC noncommunicating
thermostat control mode can not be used at the same time.

12.2 Non-Communicating Set Up

Dip switch configurations for non-communicating mode

mode
Figure 32

• This is not the factory default configuration, and both dipswitches must
be in this state exactly to utilize conventional 24VAC connections between
the indoor and outdoor units.
• The above pictures are for indication, the actual object may be different.

Low voltage wire connections with outdoor unit, non-communicating
1. Loosen the rubber ring of the communication cables hole, and remove the
Hyper-Link(M1M2) communication wires through the communication hole.

Installation and Operating Instructions

42 | Bosch IDS Heat Pump Ultra Series Air Handler – BTC 762003306 B (09.2024)

2. Remove conventional 24VAC non-communicating control wires (C, B, Y, and
W) from the accessory bag and plug it into CN5 on the circuit board

3. Thread the four field supplied low voltage wires through the hole, and
tighten the rubber ring of the low voltage wire hole.

4. Connect the conventional 24VAC non-communicating control wires (C, B, Y,
and W) to four field supplied wires.

Non- communicating thermostat wiring diagrams

keyboard

keyboard parts

Product damage!
Do not interconnect different communication wires or conventional 24VAC noncommunicating
thermostat control wires (M1M2, CBYW, etc.), otherwise it will

wiring

wiring diagram

13 LED Flashing Troubleshooting

Indoor unit fault codes can be diagnosed via observing the behavior of LED1. The
number of flashes per cycle correspond to certain faults as described below.

cycle cycle parts

cycle buttons

cycle diagram

Online Help Resources
Alternatively, please visit our Service & Support webpage to find FAQs, videos,
service bulletins, and more; www.boschheatingcooling.com/service or use your
cellphone to scan the code below.

cycle map

damage the control board. The following example shows incorrect wiring.

Documents / Resources

BOSCH IDS Ultra Series Air Handler [pdf] Installation Guide
BTC 762003306 B, 09.2024, IDS Ultra Series Air Handler, Air Handler, Handler

References

User Manual

IDS Ultra Series Air Handler

1 Key to Symbols and Safety Instructions 1.1 Key to Symbols

1.2 Explanation of Symbols Displayed on the Unit

1.3 Safety

Installation and Operating Instructions

WARNING Personal injury!

Installation and Operating Instructions

NOTICE Product damage!

Installation and Operating Instructions

WARNING Flammable refrigerant!

2 General

Installation and Operating Instructions

2.2 Unit Dimensions

2.3 Components

COMPONENT IDENTIFICATION:

2.4 A2L Refrigerant Sensor

3.3 Horizontal

3.4 Installation in an Unconditioned Space

3.5 Refrigerant Charge and Room Area Limitations

3.5.1 The Room Area Calculation Requirements

Installation and Operating Instructions

4 Electrical wiring

4.1 Power Wiring

4.2 Control Wiring NOTICE

WARNING Electrical shock!

4.3 Grounding

4.4 Electrical Data

4.5 Electric Heat Kit MCA/MOP Data

Heater Kit Accessories

Installation and Operating Instructions

5 Airflow Performance

Installation and Operating Instructions

5.1 Indoor Fan Motor Function

System operation and function

Two Stage Fan Control Non-Auto Fan Speed

Anti-Cold Air Fan Delay

Heating Fan Delay

Dehumidification (Optional)

Installation and Operating Instructions

6 Ductwork

WARNING

Installation and Operating Instructions

7 Refrigerant Connections

Installation and Operating Instructions

8 Condensate Drain Connection

Installation and Operating Instructions

9 Air Filter (Not Factory-Installed)

WARNING Fire hazard!

Installation and Operating Instructions

9.1 Filter Installation Dimensions

FILTER COVER MANUAL BOLT

Air filter removal / installation

Installation and Operating Instructions

10 Maintenance

10.1 Cleaning Precautions

10.2 Regular Maintenance

11 Disposal

Installation and Operating Instructions

12 Wiring Diagrams

Installation and Operating Instructions

12.1 Communicating Set Up

Installation and Operating Instructions

Communicating thermostat wiring diagrams

12.2 Non-Communicating Set Up

Non- communicating thermostat wiring diagrams

13 LED Flashing Troubleshooting

Documents / Resources

References

Related Posts

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1 Key to Symbols and Safety Instructions
1.1 Key to Symbols

WARNING
Personal injury!

NOTICE
Product damage!

WARNING
Flammable refrigerant!

4.2 Control Wiring
NOTICE

WARNING
Electrical shock!

WARNING
Fire hazard!