Bosch HP200-1 Technical Manual Download

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6-720-821-364 SM HP270

– 250 - 200 2016/12 en

Pump Xylem (Lowara)

(D5 PWM3-38/700T)

8 – 24 V dc

Solenoid Valve

230 V / 50 Hz (4.5 W)

(2.2 kΩ)

Fan EBM Paspt

(R2E220-RA38-16)

230 (196 - 253) Vac

50 (47,5 - 52,7) Hz

Speed 1: 50 W / Speed 2: 85 W

Fan EC controlled

230 V

Start Fan Capacitor

2 µF

Run Fan Capacitor

6.3 µF

Compressor Highly

230 (198 - 264) Vac

50 (47,5 - 52,5) Hz

490W

Start Compressor

Capacitor

15 µF

Compressor Protection

(Thermal cut out)

Bimetallic thermal switch

(open at 160ºC, close at 70ºC)

High Pressure Switch

Danfoss

Temp. = 60ºC

Opening pressure = 27 barg*

Closing pressure = 20 barg*

Electric heater resistance

230 V / 50 Hz (R=27Ω)

Electric Heater in module

230 V / 50 Hz (R=26,5Ω)

Safety Thermostat

sec

= 90ºC (+8ºC / -5ºC)

Safety Thermostat

T sec = 90ºC

Control Unit

Input 230 V (+10% / -15%), 50

* Relative pressures

Table 10 – Components identification

Entrance in the service mode:

Press “Menu” + “Ok” button for more than 5 sec

Pict.19 – Enter in service mode

T > 3 sec

Summary of Contents for HP200-1

Page 1: ...P 200 250 270 L This document is confidential and restricted to exclusive use by the official technical assistance of Bosch in the countries of destination of this product TECHNICAL MANUAL FOR AFTER SALES AND SERVICE TECHNICIANS ...

Page 2: ...eratures 5ºC 35ºC Negative working temperatures 10ºC 35ºC Note In case the air temperature is out of the specified working range the appliance automatically activates the electrical back up if in Combi mode One hour after the warning display HOT or COLD has appeared the appliance checks the air temperature and in case it is within the range values returns to heat pump mode operation The control lo...

Page 3: ...to 60ºC Electric Heater Mode Temperature adjustment 30ºC to 70ºC Table 1 Operation Modes Conditions for operation The heat pump compressor is activated according to the following conditions and control unit settings nevertheless following sequence is always verified when connecting to the main power when an error code is reseated or the appliance stops due to reaching the selected temperature In t...

Page 4: ...heater to ensure minimum 40ºC hot water in tank in combi or in heat pump mode From FD 555 July 2015 HPAF0503 10ºC 35ºC models HPAF0703 5ºC 35ºC models o Set Point default set point of 50ºC was changed to 54ºC due to ErP directive o Operation in Automatic Mode in previous version was not possible to deactivate the external booster heater boiler boil ON according the defined automatic program mode P...

Page 5: ...mpressor Off when 5ºC Tair 3d 10ºC for more than 60 min and compressor is ON for more than 60 min The number of air defrost 8d will depend on other conditions listed in this manual This new software version brings additionally an air defrost sequence activated during 45 min when 0ºC Tair 5ºC as due to ErP directive and to decrease electrical consumption for cold climate the appliance wilkl be allo...

Page 6: ...Page 6 from 56 6 720 821 364 SM HP270 250 200 2016 12 en Pict 2 Parameters overview in main and sub menu of HP270 2 ...

Page 7: ... ON or 1 min ON everyday if compressor is OFF ON if compressor cannot work due air temperature conditions Tair 10ºC or Tair 35ºC or Tbot 55ºC or T top 60ºC Heat Pump Mode Conditions Man Aut ON if 10ºC Tair 35ºC and T bot 60ºC OFF OFF Electric Heater Mode Conditions Man Aut OFF OFF OFF 1 min ON every hour ON Full Mode Conditions ON if compressor is ON Note If Duct On starts 2 min before compressor ...

Page 8: ...l by measuring current Electric heater integration in module Change of pump Electronically controlled with variable speed Change of Fan Electronically controlled Pict 4 Detail of impact in hydraulic circuit with electric heater in top of module and new pump From FD 660 Dec 2016 HPAF2801 5ºC 35ºC models HP200 250 1 Introduction of HP 200 250 1 Platform Product Changes New Tank Platform 200 250 litr...

Page 9: ...sor is ON Note If Duct On starts 2 min before compressor and if Duct Off starts 1 min before compressor in order to update air temperature value ON if 10ºC Tair 35ºC and T dis 61ºC and T top 58ºC same for 5ºC model OFF ON if compressor is ON or ON if E heater ON when compressor is OFF ON if compressor cannot work due air temperature conditions Tair 10ºC or Tair 35ºC or T dis 63ºC or T top 60ºC Eco...

Page 10: ... protect both the module and the tank and is active in all conditions specially when the appliance is set in Heat Pump standby OFF and Holyday Hol modes Note In order to ensure the anti freeze protection activation the mains plug must not be disconnected Pict 6 Heat Pump Diagram Model HP270 2 10ºC 35ºC Module Protection Start Up Condition TBottom 4ºC Module Protection Stop Condition Until T bottom...

Page 11: ... 60ºC during 10 min or Leg function time 48h 24 hours in combi and 24 hours in BOOST Conditions for air defrost sequence Air defrost sequence is activated in both 5ºC 35ºC and 10ºC 35ºC models when 5ºC Tair 10ºC for more than 60 min and compressor is ON for more than 60 min as well with recurrence determined by the temperature measured by Tbottom sensor Pict 7 Status diagram for air defrost Condit...

Page 12: ... New Behaviour only in HPAF0703 In addition to current function in 5ºC 35ºC models an additional air defrost sequence is programmed When 0ºC Tair 3d 5ºC will last for more than 60 min and compressor is ON for more than 60 min the evaporator defrost will start The fan will run during 45 min to defrost evaporator and in the meanwhile the electric heater will heat up the water Condition HPAF0703 1701...

Page 13: ...ompressor ON Compressor ON Time for pre gas defrost HP270 2 Tbottom 25ºC Time 2 min Tbottom 25ºC and 40ºC Time 1 min Tbottom 40ºC Time 0 5 min Gas Defrost sequence stops when Tfins 6ºC or gas defrost lasts for more than 30 min Condition 1 Compressor is ON for more than 180 min Condition 2 1 Compressor is ON for more than 60 min and Tair Tfins 3 5ºC for more than 1 min Solenoid OFF Condition 2 2 Co...

Page 14: ...ments Pict 11 Control Unit and cables overview Main Cable supply Pict 12 Mains Power Supply Mains Plug Solenoid Water Pump High Pressure Switch PCB AC Connector PCB Connector Compressor Connections Capacitor Connection Brown Blue Brown Blue Grey Grey White Blue Black Grey Black ...

Page 15: ...he compressor should never be operated while under vacuum otherwise internal arcing can damage some parts The compressor should not be left opened in the atmosphere for more than 5 minutes Highly model WHP01900BSV Specification from supplier Standard condition 1 9 kW of heating capacity 475 W input Thermal protection included temperature limiter opens at 160ºC closes at 70ºC 270 ml of oil capacity...

Page 16: ...0 R chassis 0 Attention In case of continuity the compressor is defected Electric test to compressor Thermal Protection This function is ensured by a bimetallic temperature limiter which opens its contact when high temperature T 160ºC 10ºC is reached during operation Testing of thermal protection limiter Open contact Close contact temperature activation T 160ºC normal operation T 70ºC Table 4 Comp...

Page 17: ...r resistance measurement PCB Connector Capacitor 2 Capacitor 1 Fan Connector Brown Brown Brown Black Blue Contact Normally Closed Not OK contact opened OK 0Ω contact closed 230 V ac between L N Note Continuity Test performed at atmospheric pressure or when component is stopped HP 270 2 Controlled by 2 capacitors Start 2µF Speed Control 6 3 µF 230 V ac between L N Input Voltage is fix Variable spee...

Page 18: ...0ºC 35ºC AC Water Pump use of multimeter AC voltage measurement and Ohm measurement DC water pump Note Only HP270 3 Table 5 Electric connections overview 230 V ac between L N 230 V ac between L N Internal Resistance Speed 1 600 Ω Speed 2 452 Ω Speed 3 305 Ω Coil 2 2 kΩ Input 8 24 V dc Variable Speed PWM signal Input V dc brown Ground white Feedback of speed Hz yellow PWM signal Green ...

Page 19: ...ersed in the storage tank Electric Heater 2 kW Attention Do not change the pre set temperature set point at maximum Safety cut out value 90ºC 8ºC 5ºC Electrical supply test Between L N 230 V ac Note ensure that HP is in E Heater mode PCB Connector AC Earth Connectors Blue Green Yellow Brown Green Yellow Green Yellow Blue Brown 2 Temperature pre set at 80ºC 1 Reset thermal cut out 230 V ac E Heater...

Page 20: ...resistance measurement Continuity test Table 6 Electric Backup Heater components overview only HP270 2 Table 7 Procedure to remove electric heater HP270 2 1 Drainage of water 2 E Heater cover protection removal 3 Thermostat Removal 4 Unscrew earth connection 5 E Heater removal 6 Ensure new gasket when reassembling 0 Ω 27 Ω ...

Page 21: ... tube construction integrated in the hp module Input Voltage 230 V ac Input Power 2 kW Thermal Cut Out bipolar safety thermostat bimetallic contact safety thermostat Resistance 27 Ohm 26 5 Ohm Table 8 characteristics between old new electric heater design Pict 16 Electric Heater integrated in module HP270 3 HP200 250 1 Advantages Easier maintenance not required to empty water tank to perform Elect...

Page 22: ...onnector Bottom temperature connector HP270 2 Fins temperature sensor Top temperature sensor Air temperature sensor Black Black White Blue Blue Bimetallic type with contacts normally closed Temp activ 90ºC Attention manual reset can only be done if contact temperature is 30ºC open tap to cool down circuit and activate Purg Discharge temperature connector HP270 3 ...

Page 23: ... a 8kΩ type with characteristic listed on table 9 Temperature ºC NTC Resistance Ω 8kΩ type fins NTC NTC Resistance Ω 10kΩ type air hot NTC NTC Resistance Ω 10 1kΩ type cold or discharge NTC 10 37450 55330 5 29710 42320 0 23730 32650 30400 5 19090 25390 25902 10 15450 19900 20247 15 12580 15710 15950 20 10310 12490 12657 25 8495 10000 10115 30 7037 8057 8138 35 5860 6531 6589 40 4905 5327 5367 45 4...

Page 24: ...Compressor Capacitor 15 µF X X X X Compressor Protection Thermal cut out Bimetallic thermal switch open at 160ºC close at 70ºC X X X X High Pressure Switch Danfoss Temp 60ºC Opening pressure 27 barg Closing pressure 20 barg X X Electric heater resistance 230 V 50 Hz R 27Ω X X Electric Heater in module 230 V 50 Hz R 26 5Ω X X Safety Thermostat T sec 90ºC 8ºC 5ºC X X Safety Thermostat T sec 90ºC X X...

Page 25: ...re of the evaporator Tfins NTC in the fins ºC 5d Temperature in the inlet for coil of the tank NTC in coil external systems ºC 6d Temperature in the middle of the tank NTC in pocket external systems ºC 7d Current Consumption Instantaneous electrical consumption A 8d Number of air defrost procedures 9d Number of gas defrost procedures 10d Components Operation visual info only Note day of the week c...

Page 26: ...NTC in coil external systems ºC 6d Temperature in the middle of the tank NTC in pocket external systems ºC 7d Current Consumption Instantaneous electrical consumption A 8d Number of air defrost procedures 9d Number of gas defrost procedures 10d Pump speed Hz 11d Fan speed Hz 12d Pump Voltage V 13d Components Operation visual info only Note day of the week corresponds to a component 1 Pump 2 Fan sp...

Page 27: ...e barg Suction Temperature ºC Superheating ºC 5 1 6 3 4 7 15 2 5 10 4 7 35 4 0 21 4 7 Table 14 Design data Optional only if refrigerant specialist is using refrigeration analysis tools Pict 20 measurement points for gas specialist Sub cooling _______ºC optional High Pressure _____ barg Condenser Evaporator outlet temperature _____ ºC Evaporator inlet temperature _______ºC Condenser inlet compresso...

Page 28: ... 10 35 2 35 23 7 10 21 2 50 21 4 2734 30 10 1 10 30 30 0 1 0 2 8 30 34 8 52 6 29 1 1172 30 7 1 7 3 5 30 35 4 55 1 29 8 1318 30 15 1 15 9 5 30 36 60 31 1400 30 20 1 20 12 3 30 36 4 60 8 31 2 1562 30 25 1 25 16 30 36 8 62 1 32 3 1660 30 35 1 35 23 7 30 40 3 66 38 7 2515 30 10 2 10 10 3 30 33 6 40 7 27 879 30 0 2 0 1 9 30 35 49 29 1220 30 7 2 7 4 5 30 36 53 30 1465 30 15 2 15 10 5 30 36 6 57 31 3 161...

Page 29: ...ction boiler solar thermal or solar photovoltaic The appliance detects and or activates the most efficient energy source among the available sources There are 2 possible kits Photo Voltaic PV kit Pict 21 Connection box for PV connection with HP TTNR 7736501838 System kit boiler and solar thermal kit Pict 22 Connection box and accessories for STS WB FB connection with HP TTNR 7736501839 ...

Page 30: ...th wall hung boiler floor standing boiler use TTNR 7736501839 Boil In Boil Out NTC Tank NTC Coil 3 HP with Solar Thermal System use TTNR 7736501839 NTC Tank NTC Coil Pict 23 Connections for external systems Following dual combination is also possible 4 HP with Solar Thermal System and PV use TTNR 7736501839 NTC Tank NTC Coil PV PV 5 HP with wall hung or floor standing boiler and PV use TTNR 773650...

Page 31: ...b menu contains following parameters for activation of compatibility mode between HP and external system 5 1 1 The HP should maximize the use of energy when there is a PV production For that Suel should be defined according needs and in both situations On Off the Syst message appears in display blinking and operation is the achievement of the Tma while PV is available default is 50ºC but can be de...

Page 32: ...ly work if there is PV energy in production With PV heat pump switch ON to reach Tma Without PV heat pump switch ON to ensure T min 5 1 2 The Cont parameter aims the adaptation of the signal output for detection of PV production according the selection of the existent inverter Normally Open Inverter with contacts normally open no PV production In case of solar gain contacts close and HP starts cou...

Page 33: ...er PV Example 1 End user wants maximum profit from PV system When SuEL On the HP will only start when T top T min and PV production is detected and confirmed during 10 min If the HP reach the normal set point SuEL On and the defined Tma Set point the appliance is kept ON while the PV signal is active however and If the PV signal is OFF more than 10 minutes the HP is switched Off The HP will turn O...

Page 34: ...he solar source thermal power is considered to be insufficient the HP should remain working in parallel HP Solar Pict 25 Representative scheme of Solar Thermal System with HP Refer to the IM of accessory 6720808239 for instruction of parameters selection and definition acess Coil Within the Coil parameter only one type of external system can be selected solar system can be used with HP but without...

Page 35: ...start up of HP default setting is 35ºC and values can be selected between 20ºC and Tset 3ºC dTon setting for temperature differential at which the HP is switched ON default setting is 6ºC available range from 2ºC 10ºC Note the differential temperature for comparison with defined default dton is measured as T dif T tank T coil T tank minimum value measure by T top in HP or T tank supplied sensor as...

Page 36: ...ion The solar gain has priority so the display will display Syst as a warning message indicating the external source active Heat Pump Switch ON if T dif don for more than 3 min HP starts so the HP will operate in parallel to compensate the Insufficient Solar Gain In case we have Tdiff dtof and Tdiff dton we detect following behavior If HP is On keeps On If HP is Off keeps Off If T tank TMin the HP...

Page 37: ...m with HP and wall hung boiler If the Boiler Mode is active the Appliance should replace the electric heating element by the boiler gas or oil When the boiler is active the HMI should display the message SYST The message should alternate with the default display 3 sec SYST 10 sec default message Refer to the IM of accessory 6720808239 for instruction of parameters selection and definition acess co...

Page 38: ...l work always in parallel with Hp HP system has priority in order to maximize thermal gain from the surrounded air however the HP is able to manage the system in order to use only the boiler as a backup instead of the integrated electrical heater of 2 kW Pict 28 Connections in the external system box boil NTC sensor in Tank Pocket NTC sensor in Coil Cable 1 5 mm2 not supplied ...

Page 39: ... default dton is measured as T dif T tank T coil T tank minimum value measure by T top in HP or T tank supplied sensor assembled in pocket at middle of the tank T coil value measure by supplied sensor assembled in inlet of indirect coil dTof setting for temperature differential at which the E heater is switched OFF default setting is 10ºC available range from 4ºC 20ºC Note the differential tempera...

Page 40: ...TC connection 10 kΩ After 3 minutes the T_dif is checked if T_dif doff E heater is switched OFF the boiler is ON The boiler operates to ensure fast recovery and hot water instead of electrical energy as a backup to the compressor if T_dif don E heater is switched ON the boiler is not producing enough energy The boiler is not ensuring energy for example when enters in lockout due to absence of comb...

Page 41: ... circuit Ensure NTC connection wire is correctly plugged in control unit Unplug connection and Measure the NTC electrical resistance R Ω R 55 kΩ or 0 68 kΩ R Ω NTC value out of range NTC interrupted Plug NTC connection wire and turn ON unit Problem solved End Replace control unit See spare part list See spare part list Refer to table with values in Service Manual Yes No No Yes No Yes Note NTC top ...

Page 42: ...uit R 30 kΩ or 0 68 kΩ R Ω NTC value out of range NTC interrupted Plug NTC connection wire and turn ON unit Problem solved End Replace control unit See spare part list See spare part list Refer to table with values in Service Manual Yes No No Yes No Yes Note NTC bottom cold water Ensure NTC connection wire is correctly plugged in control unit Unplug connection and Measure the NTC electrical resist...

Page 43: ... or 0 68 kΩ R Ω NTC value out of range NTC interrupted Change wiring and ensure sensor is assembled correctly Plug NTC connection wire and turn ON unit Problem solved End Replace control unit See spare part list See spare part list Refer to table with values in Service Manual Yes No No Yes No Yes Ensure NTC connection wire is correctly plugged in control unit Unplug connection and Measure the NTC ...

Page 44: ... The Top NTC sensor is measuring a wrong temperature value Unplug the NTC connection wire and measure the NTC electrical resistance R Ω R Ω Current Temp ºC Replace wiring Refer to table with values in Service Manual Yes No Appliance connected with a solar thermal system Ensure set point in solar control is maximum 70ºC No Yes HP tank installed as back up and receiving pre heated water Ensure máx i...

Page 45: ... kΩ R Ω NTC value out of range NTC interrupted Plug NTC connection wire and turn ON unit Problem solved End Replace control unit See spare part list See spare part list Refer to table with values in Service Manual Yes No No Yes No Yes ATTENTION NTC attached to fins in evaporator Ensure NTC connection wire is correctly plugged in control unit Unplug connection and Measure the NTC electrical resista...

Page 46: ...Ω or 0 68 kΩ R Ω NTC value out of range NTC interrupted Replace NTC Plug NTC connection wire and turn ON unit Problem solved End Change accessory box Problem solved Replace control unit See spare part list See spare part list Refer to table with values in Service Manual Yes No No Yes No No Yes Yes ATTENTION NTC systems coil Tank Ensure NTC connection wire is correctly plugged in accessory box Unpl...

Page 47: ...oil or sol mode were not activated accidentally The NTC sensor is interrupted or in short circuit R 55 kΩ or 0 68 kΩ R Ω NTC value out of range NTC interrupted Replace NTC Plug NTC connection wire and turn ON unit Problem solved End Change accessory box Problem solved Replace control unit See spare part list See spare part list Refer to table with values in Service Manual Yes No No Yes No No Yes Y...

Page 48: ...through condenser End Circulation Water Pump is in operation Pump operation is normal Ensure that Impeller of circulation pump is not blocked open front screw Impeller of circulation pump is operative Check if pump connection is plugged measure electrical input Purge air from sanitary circuit No Measure Resistance Speed 1 600 Ω Speed 2 450 Ω Speed 3 300 Ω Yes No High Pressure Switch with contacts ...

Page 49: ...ter flow through condenser is as specified Ensure circulation pump is in speed 1 and ensure plate heat exchanger is free of sediments debris Water shortage for more than 12 h NTC sensor top out of pocket Too much refrigerant Check air presence and purge hydraulic circuit in module No Yes Remove gas charge and ensure system has 400 gr Yes Correct position and ensure enter 30 cm until white sticker ...

Page 50: ...electrical heater element Thermal Cut out activated safety thermostat due to over temperature Reset thermostat manually No Problem persists End Yes Possible defective E Heater Measure resistance 27 Ω In case of HP with coil connected to solar ensure máx set point in solar control of 70ºC In case of need drain tank and clean E heater ensuring that thermostat pocket is not touching heating element I...

Page 51: ...nd measure supply voltage End Appliance installed without ducts Check run start capacitor Ensure air NTC is in specified location Yes Minimum room volume is 20 m3 Minimum air ventilation grille 220 cm2 No Yes Clearances are as stated in IM Minimum room height 2 2 m install elbows at module casing to avoid cold air recirculation No Yes Problem solved Yes No No Measure air flow at module casing inle...

Page 52: ...ssion is lower than 5ºC or 10ºC according to the model 1 Self Reset error after normal temperature conditions are reached control unit check temperature 1 hour after the code display Failure in low pressure side due to insufficient refrigerant gas flow Expansion valve is correctly assembled and bulb insulated Dry filter is saturated blocked No Yes Correct position and ensure insulation is correctl...

Page 53: ...peration 30 min before warning Yes No Check air presence and purge hydraulic circuit in module set PURG mode pump will turn at maximum speed Water flow through condenser is as specified NTC sensor top out of pocket Ensure circulation pump is operative and ensure plate heat exchanger is free of sediments debris No Yes Yes Correct position and ensure enter 30 cm until white sticker High Pressure Swi...

Page 54: ...odule Activate PURG function in SET mode Purge using manual air vent between pump and condenser Attention water will exit by valve and precautions are needed to protect surrounded components Thermal Cut out activated safety thermostat due to over temperature Reset thermostat manually measure also continuity between terminals No Problem persists End Yes Possible defective E Heater Ensure that therm...

Page 55: ...eset by pressing OK for more than 3 sec only HP 270 3 Circulation pump with insufficient rotation Sensor out of position Correct position and ensure enter 30 cm until white sticker Note due to new bottom sensor position it is possible to detect if top NTC is correctly placed Measure input signal to pump Brown White 8 24 V dc Pump is blocked Open pump by removing motor from housing Yes Remove dirti...

Page 56: ...lectric Heater Error displayed only if E heater activated for LEG Anti Freeze backup during Combi Mode E heater Mode Bosch Termotecnologia S A Aveiro Plant Measure input signal to fan 230 V is constantly supplied Ensure connection in control unit Fan Blades with dirtiness Remove volute to inspect blades of fan by cleaning it Yes Sensor out of position Correct position and ensure clip is inserted a...

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