Bosch HK050-1XXX-RE, HK075-1XXX-RE, HK100-1XXX-RE, HK150-1XXX-RE, HK200-1XXX-RE Installation Instructions Manual

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HK SERIES ELECTRIC HEATER PACKAGE

INSTALLATION INSTRUCTIONS

TABLE OF CONTENTS

Introduction .......................................................... 2

Pre-Installation ..................................................... 2

Components List ................................................... 2

Installation ............................................................ 3

Packaged Units (CE/TAxxx-xVT,

CE/TAxxx-xHZ, CE/TAxxx-xCF) ............................ 3

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Split Units (CE/TAxxx-xAV,

CE/TAxxx-xAH, TAxxx-xAC) .................................. 6

CE-VT / HZ & TA-HZ (TA025-HZ excluded) Units ..... 6

Units with 5, 7.5, or 10 kW Electrical

Heater Elements (HK050, HK075, HK100) .......... 8

Units with 15 or 20 kW Electrical

Heater Elements (HK150, HK200) ....................... 8

Split Units (CE/TAxxx-xAV,

CE/TAxxx-xAH, TAxxx-xAC) ................................ 10

TA-VT & TA025-HZ Units ....................................... 10

Units with 5, 7.5, or 10 kW Electrical

Heater Elements (HK050, HK075, HK100) ........ 12

Units with 15 or 20 kW Electrical

Heater Elements (HK150, HK200) ..................... 12

Electric Heater Electrical Data ............................ 14

Field Installed Electric Heater Kit Availability ...... 14

Typical Wiring Diagrams ................................. 15-16

Introduction

HK Series

INTRODUCTION

Bosch HK Series Heater Package is a eld

installable electric resistance heater kit designed for use with the CE and TA series heat pumps.

The HK series heater package requires separate electrical service connection, independent from the heat pump’s power supply. DO NOT wire the heater elements into the same circuit as the compressor.

Note:

• A heater collar is installed in the CE and TA

models, no need to order separately.

• The series heater packages are designed for

installation in the heat pump model published in this document. Do not install this heater kit in a

heat pump not specied in this manual. Refer to

Table 3 on page 18 for compatibility.

• A heat pump thermostat with supplemental

electric heat feature is required to operate the system when this kit is installed.

• 18 AWG wire will be needed to connect the

thermostat to the electrical box for the “W1” & “EM” connections. See wiring diagrams at the end of this manual.

Improper installation of the electric resistance heater can result in severe injury or death due

to electrical shock or re.

Only trained and qualied personnel should

install, repair, or service this equipment.

All electrical service connection to the heater must be done to National and local electrical Standard & codes.

PRE-INSTALLATION

1. UNPACK the HK heater kit and inspect for contents and condition. If any part or the kit appears damaged (i.e.: broken heater elements, damage relays) or missing, do not attempt to install the kit. Contact your local distributor for further help

2. Ensure that the heater kit package includes the following components. Contact your local distributor for further help.

COMPONENTS LIST:

The following components should be found in the heater kit package:

a. Pre-wired heater electrical box

b. Heater elements pre-wired to the heater

electrical box

Table 1: Electric Heater Compatibilitytor Only)

Units 5kW 7.5 & 10 kW 15 kW 20 kW

TA025

TA035

TA049

TA061

TA071

CE025

CE035

CE049

CE061

CE071

ü ü

ü ü ü ü

ü ü

ü ü ü ü

x x

c. Heater element(s) protective metal cover

d. Wire harness pre-wired at one end (used only in

units in which a second electrical box is added)

e. New wiring diagram

f. Adhesive back electrical data label

g. Clear hardware accessory bag containing:

• Heater element mounting screws (4 for each

element bank)

• Heater element cover mounting screws (2 for

each cover)

• Two yellow wire nuts (used only for packaged

units; discard for split systems)

• Four electrical box mounting screws (used

only in units in which a second electrical box is added)

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h. 2 x 30 amp fuses + 2 x 60 amp fuses for 15kW

heater packages only

i. 4 x 60 amp fuses for 20kW heater packages

only

j. This installation manual

The heater element mounting screws and the

heater element cover mounting screws are the same type of screw. Quantities used will depend

on the heater package type.

For technical assistance contact your local distributor or Call Bosch Technical Support: 866-642-3198

3. Ensure following tools and supplies, needed for installation, are available:

• Phillips screwdriver

• Small ﬂ at head screwdriver

• 5/16” socket and a ratchet or drill

• Wire cutter

STEP 2: Remove the heater collar cover plate(s) to

install the heater elements. (See Figure 1).

Figure #1 – Showing Collar mounted on blower housing, element location and collar plate(s)

STEP 3: Identify retainer pins on the end of the heater element(s). These pins are to be inserted in holes visible in the back of the heater collar. This stabilizes the heater element and prevents vibration of the heater elements.

• Wire stripper

• 18 AWG wire (connect thermostat to the

electrical box)

• Torque Phillips head screwdriver

• Volt meter

INSTALLATION

Packaged Units (CE/TAxxx-xVT, CE/TAxxx-xHZ, CE/TAxxx-xCF)

This section is for packaged units only. See sections below for installation instructions for split systems.

STEP 1: DISCONNECTING THE POWER:

a. Turn system to “OFF” from your Thermostat

b. Turn the power to the heat pump to “OFF” at

the unit’s disconnect switch or breaker panel.

c. Remove the access panel(s) from the unit

exposing the blower section and compressor section of the packaged heat pump unit. Place the panel mounting screws aside in a safe place as they will need to be reused when putting the panels back on.

STEP 4: Slide the heater element(s) into the mounting opening(s) on the heater collar, making sure that the retainer pins engage in the holes in the back of the collar.

It may be necessary to lower the blower in order

to complete this task.

When installing the heater elements into the heater collar, ensure that the thermal overloads are on the right side; this will be the “L1” side. Secure each insert(s) with four of the supplied sheet metal screws provided (See Figure 2).

It may be necessary to remove the line voltage

wires that are connected to the element(s) from heater electrical box in order to complete installation.

Remove the wires from heater contactor and

terminal block at “L1” only. If wires are removed during installation, ensure that they are marked

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Installation

HK Series

for proper reconnection. When reconnecting the line voltage wires to the contactor, apply 22 in-lbs of torque.

STEP 5: Install the element cover over the heater element(s). These are secured with a tab at one end of the cover and two of the supplied sheet metal screws at the other end (See Figure 2). Ensure that heater wires are routed through the plastic bushing on the heater element cover.

The mounting holes for the heater box have been pre-punched in the posts. Make sure no wires are pinched between the metal parts. Connect or reconnect wires from the heater element(s) as was marked in step 4 or follow electrical wiring diagram for corresponding model at the end of this manual.

STEP 7: Route the loose ends of the yellow, blue,

red, purple, and the two black wire leads from the long side of the wire harness plug from the heater electrical box to the heat pump electrical box in the

compressor compartment. Route these wires

through the access hole in the divider panel together where the existing blower motor wires are routed.

STEP 8: CONNECTING HIGH VOLTAGE WIRES

a. In the heat pump electrical box, disconnect the

two line voltage wires that connect the transformer and blower motor to the “LINE 1” side of the compressor contactor.

b. Cut the wire terminal off of the following wires

and strip off the insulation:

Figure #2 – With Collar removed insert heater element(s) (one shown in this diagram), wires not shown in diagram.

Ensure unused slot is covered with a collar plate.

STEP 6: INSTALLING THE HEATER CONTROL BOX:

a. Vertical Units - Install the heater control box

between the unit corner posts at the top of the blower section.

b. Horizontal Units (Straight through

con guration) - Mount the heater electrical box

in the rear of the unit, attached to the electrical post on the opposite side of the blower.

c. Horizontal Units (End Blow Con guration)

- Mount the heater electrical box in the rear of the unit, attached to the electrical post on the opposite side of the blower motor.

• One of the black wires from the wire harness

• The transformer wire disconnected in Step

8(a)

• The black blower motor wire disconnected in

Step 8(a)

c. Connect the three wires that were cut and

stripped in Step 8(b) together using a yellow wire nut connector supplied with the kit. Secure with electrical tape.

d. Disconnect the two line voltage wires that

connect the transformer and blower motor to the “LINE2” side of the compressor contactor.

e. Cut the terminal connections off of the

following wires and strip off the insulation:

• The remaining black wire from the wire

harness

• The transformer wire disconnected in Step

8(d)

• The white blower motor wire disconnected in

Step 8(a)

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f. Connect the three wires that were cut and

stripped in Step 8(e) together using a yellow wire nut connector supplied with the kit. Secure with electrical tape.

g. Reference Figure 3 and/or the appropriate

wiring diagram at the end of the manual to ensure that all connections are correct.

Ensure that the wires are connected to the correct matching terminal and all unused wires are capped with a wire nut. Severe damage to the unit, personal injury, or death can occur if wires are not connected securely to the correct terminal or loose wires come into contact with the cabinet or other components.

STEP 9: CONNECTING LOW VOLTAGE WIRES

a. The four remaining wires on the long end of the

wire harness are low voltage wires (Yellow,

Purple, Red, and Blue). Connect these wires to

the motor control board according to Table 2.

Table 2r Only)

Heater Box Heat Pump Box

Yellow R

Blue C1

Red W1

Purple EM

b. Reference Figure 3 and/or the appropriate

wiring diagram at the end of this manual to ensure that all connections have been made and are correct.

STEP 10: THERMOSTAT WIRE CONNECTIONS

a. Ensure that two low voltage wires are available

from the thermostat to make the “W1” and “EM” connections. If these wires are not located, they will need to be pulled and routed from the back of the thermostat to motor control board in the heater electrical box.

Figure #3 – Electrical Heater wiring interface with Heat Pump Electrical Box

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Installation

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b. Strip the insulation off of the “W1” and “EM”

wires and insert into the thermostat control wire block on the motor control board. Connect the other end of the wires to the back of the thermostat to the supplemental and emergency

heat terminals. Reference the user’s manual for

the thermostat for proper connection.

STEP 11: ROUTING NEW LINE VOLTAGE WIRES FROM CIRCUIT BREAKER PANEL TO HEATER ELECTRICAL BOX

a. Select the proper wire size based upon the

heater electrical load that the blower motor and

electric heater element(s) will require. Refer to

the data tag label that is included in the heater kit or the electrical data at the end of this manual. Ensure that all national and local electrical codes are followed for installation, wire sizing, and breaker sizing.

b. Select the proper breaker size based upon the

heater electrical load that the heat pump will

require. Refer to the data tag label that is

included in the heater kit or the electrical data at the end of this manual.

c. Route the new line voltage wiring and the

ground wire from the circuit breaker panel to the heat pump.

STEP 13: Remove the wiring diagram that is adhered to the back side of the front panel. Replace

with the wiring diagram that was included with the heater kit. Using spray adhesive glue is recommended.

STEP 14: Place the adhesive back heater data label next to the knockout in the post where the new electrical service for the fan motor and heater elements is entering the cabinet.

STEP 15: RESTORING POWER / TURNING ON THE UNIT

a. Turn the disconnect switch or breaker switch to

the “ON” position for the compressor and for the new separate circuit servicing the blower motor and the heating elements.

b. Test the unit in “COOLING” and “HEATING” to

ensure that full functionality of the unit has been restored.

c. Run the unit in heating mode with the heating

elements engaged for at least 10 minutes to ensure the unit does not shut down due to any temperature limiting device.

STEP 16: Install the cover on the heater electrical box and reinstall the heat pump access panel(s) with the screws that were set aside in Step 1.

d. Use the knockout provided in the heat pump

corner post as the entry for the electrical service wiring. A plastic bushing should be used to protect the wire insulation from the metal edge of the knockout.

e. Connect one of the line voltage wires to “L1”

terminal connection and the other line voltage wire to “L2” terminal connection. Torque to 22 in-lbs.

STEP 12: Use the ground lug provided in the heater

control box to connect the  eld ground from the

power supply.

The heater electrical power provides service to

the unit’s Transformer, electrical heat element(s), and blower motor only. The Compressor remains on the original and now isolated circuit.

Always contact your local distributor if there is ever any doubt

SPLIT UNITS (CE/TAXXX-XAV, CE/TAXXX-XAH, TAXXX-XAC)

This section is for CE vertical & horizontal split units and TA horizontal (excluding the TA025) split units only. See the section below for other split systems or the section above relating to packaged units.

CE-VT / HZ & TA-HZ (TA025-HZ excluded) Units Covered in this Section

Within this range of the units, the electric heater kit and the air handler will share a common electrical box, therefore a single complete new electrical box will be provided with the electrical heater kit.

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