BOSCH SS1B16-32 Geothermal Heat Pumps Instruction Manual

Installation Manual
Smart Start Assist—Field Install Kit
For SM/LM Single-Phase Units

DOCUMENT CONVENTIONS

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Warnings

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

• DANGER indicates a situation that, if not avoided, will result in death or serious injury.
• WARNING indicates a situation that, if not avoided, could result in death or serious injury.
• CAUTION indicates a situation that, if not avoided, could result in minor to moderate injury.
• NOTICE is used to address practices not related to personal injury.

Important Information

This symbol indicates important information where there is no risk to property or people.

SAFETY WARNINGS

IMPORTANT: Read the entire instruction manual before starting installation or service.

DANGER: PERSONAL INJURY HAZARD
Installation and servicing of this equipment can be hazardous due to system pressure and electrical components. Only trained and qualified personnel should install, repair, or service the equipment.
DANGER: ELECTRIC SHOCK
Before performing service or maintenance operations on the system, turn off the electrical power to the unit and observe the proper process of locking-out power at the main/ disconnect box. Electrical shock could cause personal injury or death
WARNING: PERSONAL INJURY
When working on equipment, always observe precautions described in the unit’s IOM, tags, and labels attached to the unit. Follow all safety codes.

CAUTION: PERSONAL INJURY HAZARD
Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing and gloves when handling parts.

SMART START FIELD INSTALL KIT

Kit Contents

General Description
The BOSCH Smart Start Assist Kit is designed for SM and LM single-phase units. The kit contains two main parts; both are installed on top of the unit’s electrical box (e-box).
The Smart Start Assist attaches to the e-box top via a mounting plate, that, itself attaches to the Smart Start Assist as shown in Figure #1.

Physical Characteristics

[85°]
CASE MATERIAL| ABS Flameproof UL-94 V0| ABS Flameproof UL-94 V0
IP RATING| IP20| IP20
LINE CONDUCTORS/AWG| 14–6| 14–6
LINE CONDUCTOR STRIP LENGTH, IN. [MM]| 0.47 [12]| 0.47 [12]
MINIMUM LINE CONDUCTOR LENGTH, IN. (MM)| 15.7 [400]| 15.7 [400]
LINE TERMINAL TIGHTENING TORQUE, IN-LBS (N-M)| 11.5 [1.3]| 11.5 [1.3]
START WINDING & COMPRESSOR COMMON, AWG| 16–12| 16–12

Operating Characteristics

Operations

INSTALLATION OF SMART START ASSIST
The Smart Start Assist Kit includes all components required for installation. The Smart Start Assist (SSA) module attaches to the unit by clipping onto its plastic holder (base).
The Smart Start Assist module can be mounted with its terminal block facing left or right, depending on the unit configurations (left or right discharge air).
Required Tools

• Small Flat Head Screwdriver
• Phillips Screwdriver
• Torque Screwdriver
• Drill with 1/8” Bit

DANGER: ELECTRIC SHOCK
Before performing service or maintenance operations on the system, turn off the electrical power to the unit and observe the proper process of locking-out power at the main/ disconnect box. Electrical shock could cause personal injury or death

Disconnecting Power and Removing Panels

1. Remove power to the unit. Be sure to follow all applicable state and federal laws and regulations concerning lock out and tag out for the power source. Use a multi-meter to verify there is no power at the unit.
   The unit may contain two (2) power sources. Ensure both are de-energized and locked out/tagged out.

2. Unscrew the visible screws on the main unit access panels and remove the panels in order to access the main unit electrical control box.

Hardware Installation
Follow the steps below to mount the Smart Start Assist (SSA) module to the top of the electrical control box.

Both Horizontal (HZ) and Vertical (VT) configurations use the same mounting procedure.

1. Remove the mounting base from the Smart Start Assist module. To do this, use a small flat screwdriver and press outwards on the clip-on tabs, located on either side of the module. Refer to Fig. 2.
2. Attach the mounting base to the main unit electrical box as follows.

For the SM model:
a. Align the bracket to the edge of the electrical box.
b. Center the base across the top of the electrical box.
c. Mark hole pattern on mounting base to be drilled. Refer to Fig. 3.
d. Drill 1/8” holes in the mounting base. Refer to Fig. 4.
e. Mount the base using the provided screws (two (2) #8 screws). Refer to Fig. 5.

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For the LM model:
a. Position the front of the mounting base 1″ from the most forward mounting hole on top of the electrical box.
b. Center the base across the top of the electrical box.
c. Mark hole pattern on mounting base. Refer to Fig. 6.
d. Drill 1/8” holes in the mounting base. Refer to Fig. 7.
e. Mount the base using the provided screws (two (2) #8 screws). Refer to Fig. 8.

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3. Insert the Smart Start Assist module into the bracket so that slot in the module engages with the edge clip of the mounting bracket. Refer to Fig. 9.

Wiring Instructions
The Smart Start Assist module comes with a termination block located at the front of the device.
The Smart Start Assist kit comes with its own harness with wires labeled according to the terminal block on the Smart Start Assist module for easy identification.
Torque all terminals according to torque specifications of the Smart Start Assist module (refer to Physical Characteristics table on page #4) and contactor (refer to component label for torque requirements).
Electrical Box (e-box) shown in Fig. 10 and Fig. 15 are for reference only. The actual components in the unit’s electrical box vary depending on the installed options.

Wiring Instructions for SM Models

1. Perform the following at the main unit’s control box (refer to Fig. 11):
   a. Disconnect the R-signal wire (red) of the compressor harness from the side of the T2 terminal on the compressor contactor.
   b. Pull the compressor wires out of the electrical box to be rewired at a later step.
   c. Disconnect the red wire that connects the run capacitor to the compressor contactor and remove it from the unit.

2. Locate the Smart Start harness provided with the kit, and route harness wires through the hole in the top of the electrical box. Refer to Fig. 12.

3. Perform the following at the Smart Start Assist module terminals, using Smart Start harness (See Fig. 12):
   a. Insert the TAN RUN CAP wire into the RC terminal
   b. Insert the RED T2 wire into the T2 terminal
   c. Insert the BLUE START CAP wire into the S terminal
   d. Insert the BLACK COMMON wire into the C terminal

4.  Perform the following at the compressor contactor, using the Smart Start harness (See Fig. 13):
   a. Connect the BLACK COMMON signal wire to the T1 blade connector of the contactor.
   b. Insert the RED T2 signal wire into the T2 screw-down terminal of the contactor and secure.

5. Route the R-signal wire of the compressor harness through the large hole in the top of the control box and insert it into the Smart Start Assist R connector. Refer to Fig.14.

Wiring Instructions for LM Models

1. Perform the following at the main unit’s control box (refer to Fig. 16):
   a. Disconnect the R-signal wire (red) of the compressor harness from the side of the T2 terminal on the compressor contactor.
   b. Pull the compressor wires out of the electrical box to be rewired at a later step.
   c. Disconnect the red wire that connects the run capacitor to the compressor contactor and remove it from the unit.

2. Locate Smart Start Assist metal cover and make sure all wires that are to be terminated on the Smart Start Assist terminal block pass through the 7/8” bushing. Refer to Fig. 15.

3. Perform the following at the Smart Start Assist module terminals, using the Smart Start harness (See Fig. 17):
   a. Insert the TAN RUN CAP wire into the RC terminal
   b. Insert the RED T2 wire into the T2 terminal
   c. Insert the BLUE START CAP wire into the S terminal
   d. Insert the BLACK COMMON wire into the C terminal

4. Insert the R-signal wire of the compressor harness into the Smart Start Assist R connector. Refer to Fig. 17.

5. Route the wiring out from the hole in the sheet metal cover and down the side of the electrical box and then in through the bottom hole towards the compressor contactor and capacitor. Refer to Fig. 18.

6. Perform the following at the compressor contactor, using the Smart Start harness (See Fig. 19):
   a. Connect the TAN RUN CAP signal wire to the blade connector of the capacitor that is closest to the contactor.
   b. Connect the BLUE START CAP signal wire to the blade connector of the capacitor that is near the edge of the control box.

Performing Functionality Check and Installing Cover

1. Verify that the installation and termination of all the wires match the electrical schematic shown in Fig. 21.
   This diagram is shown as optional in all LM and SM product wiring diagrams. For more detail please refer to the LM/SM manual.

2. Secure the sheet-metal cover plate included in the kit to cover the Smart Start Assist terminal block. Refer to Fig. 20.

MODES OF OPERATIONS

Fig. 22 Smart Start Basic Operation

SOFTWARE CHARACTERISTICS

LED FLASH CODES
A Red LED indicator will flash under the following conditions:

• Low Voltage
• Lockout on Three (3) Failed Starts
• Lockout on Over Current
• Cycle Delay/Fault Mode

LED fault indicator is turned off in normal running mode.

Low Voltage
(Flash Code = Rapid Flash, 10 per second)

• Displays when “Low-Supply Voltage” is detected before and after a soft start.
• If “Low-Supply Voltage” is detected before a start, a restart is attempted after 50 seconds.
• If “Low-Supply Voltage” is detected after a start, a restart is attempted after 3 seconds.

Lockout on Three (3) Failed Starts (Flash Code = Triple Flash every 3 seconds, 3/3 seconds)

• Displays after a failure to start on Three (3) consecutive start attempts.
• Restart is attempted after 50 minutes
• The standard lockout period is revised to 3 minutes after a successful start.

In circumstances where the compressor may have seized or is unable to start due to failure of other components in the HVAC system, the software checks for three (3)  consecutive failed starts.
On the third sequential failed start, the program goes into Lockout for 50 minutes.
On failing to get a good start even after 50 minutes, it will attempt a restart again after the duration of 50 minutes.
Once a good start is eventually achieved, it will reset the hard-start counter and will again require three (3) failed starts to force it back into Lockout mode. Lockouts can be cleared anytime through a power reset of the Sure Start Assist device.

Lockout on Overcurrent
(Flash Code = Slow Flash, 1 Flash every 3 seconds)

• Displays when “Overcurrent” is detected in the running mode of the compressor motor.
• The overcurrent limit is 25A for the 08–16A version and 50A for the 16–32A-rated version.
• It also displays if the internal Klixon of the compressor trips on overheat.
• Restart is attempted after 10 minutes.

To limit the current in the compressors from extending abnormally beyond its stated capacities, Sure Start Assist is also equipped with overcurrent-limit protection. For models rated from 16–32A, it is designed to trip in overload conditions exceeding 50A. In smaller models, it is designed to cut off power to the compressor when the current draw exceeds 25A. On an overcurrent lockout, Sure Start Assist attempts a restart automatically after 10 minutes.
Both failed start lockout and overcurrent-limit protection have been designed to prevent the compressor from drawing abnormal currents in conditions not feasible for the compressor operation.

Cycle Delay/Fault Mode
(Flash Code = Slow Steady Flash, 1 per second)

• Displays for cycle delay between two consecutive soft starts or other faults are mentioned below.
• Restart is attempted after a default period of 3 minutes
• Other possible reasons for this fault mode indicator can be due to:
• Incorrect wiring during installation
• A failed soft start attempt
• Intermittent power loss (duration longer than 100ms)
• Frequency out of range, or
• A failed run capacitor

NOTES

8733831984

Bosch Thermotechnology Corp.
65 Grove Street, Watertown, MA 02472
Phone: +1 800-283-3787 | Fax: +1 603-965-7568
www.bosch-climate.us.com
Revised 04/2022
8733831984

References

• Home | Bosch Home Comfort

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