Air Handling Unit

Climate 5000
AHU20~150C4E | AHU20~150C6E

en Installation, Operation and Maintenance Manual

8736862517 (2017/09)CN

Read the manual carefully prior to installation and operation the unit！

Observe the warnings in the manual！

Installation by an authourised person only！

 2 | Table of contents

Table of Contents

1 Key to symbols and safety introductions ... 3

1.1 Explanation of symbols ................................ 3
1.2 Product using safety .................... 3
1.3 Product description ..................... 3
1.4 Scope of product ....................... 3
1.5 Executive standard ..................... 4

2 Product information ...................................... 5

2.1 Product overview ....................... 5
2.2 Nomenclature .......................... 5
2.3 Product features ....................... 6
2.4 Performance parameters ................ 7
2.5 Outline dimension ...................... 8
2.6 Use and installation characteristics .......11

3 Engineering installation............................... 12
3.1 Delivery, unloading and storage ..........12
3.1.1 Delivery ..........................12
3.1.2 Unloading ........................12
3.2 Installation.............................12
3.2.1 Installation preparation .............12
3.2.2 Equipment installation .............12
3.2.3 Connection of heat exchanger ......13
3.2.4 Electrical equipment installation .....13
3.2.5 Trap installation ...................14

4 Unit start-up .................................................. 15

4.1 Confirmation ...........................15
4.2 Fan ...................................15
4.3 Heat exchanger ........................15
4.4 Humidifier .............................15

5 Maintenance.................................................. 16
5.1 Fan and motor .........................16
5.2 Filter ..................................16
5.3 Heat exchanger ........................16

6 Common faults and solutions ..................... 17

7 Packing list ................................................... 18

8 Notes ............................................................. 19

8736862517(2017/06) Climate 5000

 Key to symbols and safety instructions | 3

1 Key to symbols and safety introductions

The operator must be familiar with and conform to
1.1 Explanation of symbols all standards and regulations related to operation.
The operator/maintainer is obliged to ensure the
Warnings applicability of these documents to related equip-
ment. If there is any question before operation,
Warnings in this document are framed
please directly contact and confirm with related
and identified by a warning triangle
departments for any updating and/or newly
which is printed on a grey back-
ground. The word attached indicates available documents.
the type and severity of consequence
The information within this instruction may be
due to nonobservance of danger
updated without additional notice, as Bosch
prevention measures.
Thermotechnology (Shandong) Co., Ltd is in
Keywords indicate the seriousness of the hazard obedience to the strategy of constant product
in terms of the consequences of not following the development. Bosch Thermotechnology will not
safety instructions. make any commitment of providing the latest
• Notice Indicates may cause property damages. information for the holder of the instrument
initiatively. The user shall contact local Bosch
• Caution Indicates may cause minor to medium
Thermotechnology company for further information.
personal injuries.
• Warning Indicates may cause serious personal
injuries and/or risk of life.
1.3 Product description
• Danger Indicates would cause serious per- BOSCH Climate 5000 AHU-C air handling unit is
sonal injuries and/or risk of life. designed and manufactured by Bosch Thermo-
technology (Shandong) Co., Ltd which fulfill the
strict design and manufacturing standards of
Important information
ISO9000 certificate. The product can be used in
Important information where there is no various environment except in humid region,
risk of personal injuries or losses is outdoor, the environment with swirling dust and/or
identified by the symbol shown on the left. corrosively, and the place with potential explosion.
It is bordered by horizontal lines above
Read the instruction carefully, before operating,
and below the text.
checking and maintaining the unit. Air handling
unit is the air side equipment of water chilling air
Additional symbols conditioning system, with high professional and
technical request. All of the operations (including
Symbol Definition installation, commissioning and maintenance)
shall only be conducted by qualified professional
► a step in an action sequence
technicians through training.
a reference to a related part in the doc-
ument or to other related documents The manufacturer shall not be held for any
responsibility for damage or destruction due to
・ a list entry improper installation, commissioning, operation,
– a list entry (second level) maintenance or nonobservance of process and
guidance required in the instruction.
Table 1. Additional symbols

1.4 Scope of product

1.2 Product using safety
• Type of the unit
The manual is only applicable to specially trained
- AHU20C4L/R150/190E
operator/maintainer approved by the owner for
safely and correctly handling with work. The most - AHU25C4L/R150/190E
important thing is read and understand the - AHU30C4L/R150/210E
instrument and other references carefully before - AHU40C4L/R170/220E
any operation/maintenance on the equipment. - AHU50C4L/R210/260E

Climate 5000 8736862517(2017/09)

 4 | Key to symbols and safety instructions

- AHU60C4L/R210/240E
- AHU70C4L/R300/320E
- AHU80C4L/R300/320E
- AHU90C4L/R280/350E
- AHU100C4L/R350/420E
- AHU120C4L/R320/390E
- AHU150C4L/R390/440E
- AHU20C6L/R130/170E
- AHU25C6L/R130/170E
- AHU30C6L/R130/190E
- AHU40C6L/R150/200E
- AHU50C6L/R190/240E
- AHU60C6L/R190/220E
- AHU70C6L/R280/300E
- AHU80C6L/R280/300E
- AHU90C6L/R260/320E
- AHU100C6L/R320/390E
- AHU120C6L/R300/360E
- AHU150C6L/R360/420E
• Air volume: 2000~15000 m³/h
• External total pressure: 80~290 Pa
• Cooling capacity: 11.6~108.0 kW
• Heating capacity: 21.0 ~190.0 kW
• The standard of power supply: 380V/ 3N/ 50Hz
• Maximum working pressure of unit: ≤ 1.6MPa

1.5 Executive standard

The executive standard of the unit: JB/T 9066-
1999 “Cabinet Fan Coil Unit”.

8736862517(2017/09) Climate 5000

 Product information | 5

2 Product information
• High performance heat exchanger
2.1 Product overview The air handling unit use unique pipe arrange-
ment of heat exchanger, which could improve
The air handling unit is a unit that improve indoor 10%-30% heat exchange efficiency compared
air quality by adjust indoor temperature, humidity with traditional pipe laying.
and purified indoor air which cooling, dehumidified
or heating a proportion of indoor return air and • Unique design of air inlet and outlet
outdoor fresh air or fully fresh air with external
cool water or hot water passing heat exchanger The filter of air inlet is flange structure, which
and exhausted by fan. can also be non-woven filter in accordance with
the requirements of clients.
• Extensive performance and usage
• International advanced processing and
The air handling unit can be extensively used in manufacturing technology
public buildings and various industrial occa-
sions, such as shopping mall, hotel, hall, The company has the most advanced panel
gymnasium, textile, metallurgy, machinery, processing equipment and manufacturing line
health, electronic instrument, etc.. for heat, which provides reliable quality guaran-
tee for air handling unit.

2.2 Nomenclature

BOSCH Climate 5000 AHU S 60 C 4 L 300 E

Export
(Out of CN)
Nx=Customized Product
(x=null,1,2,3)
Omitted:Standard
Total Pressure: Pa
左
L：Left , R: Right

Coil Rows:quantity of rows

Product Type:
C:Celling Suspend
J:Remote Jet
Air Flow: *100m /h
3 V:Vertical Type
HI:Horizontal Type I
S:Series Single Skin HⅡ:Horizontal Type Ⅱ
Omitted:Series Double Skin HⅢ:Horizontal Type Ⅲ
Air Handling Unit
Value Level: 1000~9000

Category: Climate
Brand: Bosch

• ‘Bosch Climate 5000’ will be more for communication purpose (brochure/ website etc.)
• Standard Power Supply is 380V/ 50Hz/ 3 Phase

Figure 1. Nomenclature

Climate 5000 8736862517(2017/09)

 6 | Product information

- External profile: color coating profile

No. Naming Meaning
- Internal profile: galvanized profile
1 Bosch Brand
- Insulation material: 45 kg/m3, polyurethane foam
2 Climate Type
- Aluminum profile
3 5000 Value level 1000-9000 - Rubber sealing spacer
4 AHU Air handling unit - PVC profile, package margin
5 60 Air volume: x100 m3/h - High density PU foam
6 C Product type: C ceiling suspend - Metal section
- Washer
7 4 Coil pipe: 4 rows/6 rows
8 L/R L: left R: right • Easy to maintain
9 130 External static pressure: Pa The detecting gate of the unit is designed on the
Customized Product, x=null, 1, 2, side face for later service and maintenance.
10 Nx
3… Omitted: Standard
11 E Export (Out of CN)
Table 2. Nomenclature table

2.3 Product features

• Double-shell structure
The product use unique and creative double- Figure 3. Maintain schematic diagram
shell structure that fixed on the aluminum alloy
frame with engineering plastic junction tightly. • Optimizing crane
The company employs outstanding antifreezing The internal of the unit crane uses high strength
technology to create the double-shell structure Rexroth aluminum frame, which making the
which has passed the highest standard test. connection of the frame more light, beautiful,
solid and steady.

1 2 3

C
6 5

Figure 4. Optimizing crane diagram

Figure 2. Double-shell structure

8736862517(2017/09) Climate 5000

 Product information | 7

2.4 Performance parameters

• 4PR parameters
AHU AHU AHU AHU AHU AHU AHU AHU AHU AHU AHU AHU
Model Unit
20C4E 25C4E 30C4E 40C4E 50C4E 60C4E 70C4E 80C4E 90C4E 100C4E 120C4E 150C4E

Air Flow m3/h 2000 2500 3000 4000 5000 6000 7000 8000 9000 10000 12000 15000

Nominal Cooling
kW 11.6 13.9 17.5 22.7 29.2 35.9 42.6 47.1 51.5 57.1 67.6 86.1
Capacity
Nominal Heating
kW 21.0 26.5 32.1 42.6 53.8 64.7 75.9 83.1 92.5 103.5 125.4 157.1
Capacity

Water Flow m3/h 0.55 0.66 0.83 1.08 1.39 1.71 2.03 2.25 2.45 2.72 3.22 4.10

Water Pressure
kPa 23 15 24 17 30 35 53 62 28 31 33 39
Drop
Static Pressure
Pa 80 80 80 130 130 130 180 180 190 230 230 230
（Ⅰ）
Total Pressure
Pa 150 150 150 170 210 210 300 300 280 350 320 390
（Ⅰ）
Static Pressure
Pa 130 130 130 180 180 180 240 240 240 290 290 290
（Ⅱ）
Total Pressure
Pa 190 190 210 220 260 240 320 320 350 420 390 440
（Ⅱ）
Table 3. 4PR parameters

• 6PR parameters
AHU AHU AHU AHU AHU AHU AHU AHU AHU AHU AHU AHU
Model Unit
20C6E 25C6E 30C6E 40C6E 50C6E 60C6E 70C6E 80C6E 90C6E 100C6E 120C6E 150C6E

Air Flow m3/h 2000 2500 3000 4000 5000 6000 7000 8000 9000 10000 12000 15000

Nominal Cooling
kW 13.8 17.9 23.0 29.7 37.1 46.9 52.6 59.3 64.1 71.5 86.0 108.0
Capacity
Nominal Heating
kW 25.0 31.5 38.0 50.7 63.0 76.6 88.8 98.6 109.0 128.0 152.0 190.0
Capacity

Water Flow m3/h 0.66 0.85 1.09 1.42 1.77 2.24 2.54 2.83 3.06 3.41 4.10 5.15

Water Pressure
kPa 15 25 43 36 24 78 40 47 23 25 29 26
Drop
Static Pressure
Pa 60 60 60 110 110 110 160 160 160 210 210 210
（Ⅰ）
Total Pressure
Pa 130 130 130 150 190 190 280 280 260 320 300 360
（Ⅰ）
Static Pressure
Pa 110 110 110 160 160 160 220 220 220 270 270 270
（Ⅱ）
Total Pressure
Pa 170 170 190 200 240 220 300 300 320 390 360 420
（Ⅱ）
Table 4. 6PR parameters
• Cooling condition: • Heating condition:
- Inlet air temp 27°C DB/19.5°C WB - Inlet air temp 21°C DB
- Inlet water temp 7°C, outlet water temp 12°C. - Inlet water temp 60°C.

Climate 5000 8736862517(2017/09)

 8 | Product information

2.5 Outline dimension

• AHU20CE-30CE

Figure 5. Outline dimensions diagram for AHU20CE-30CE

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 Product information | 9

• AHU40CE-150CE

Figure 5. Outline dimensions diagram for AHU40CE-150CE

Climate 5000 8736862517(2017/09)

 Length Width Height Air Inlet Dimension
(mm) (mm) (mm) Air Outlet Dimension(mm) (mm)
Model
L W H A B C D E F G

AHU20CE 1107 816 540 265 234 / 124 167 756 485

8736862517(2017/09)
AHU25CE 1107 964 540 265 234 / 138 167 904 485
10 | Product information

AHU30CE 1127 1112 540 293 256 / 0 167 1052 485

AHU40CE 1187 1420 540 265 234 178 189 167 1360 485

AHU50CE 1187 1716 540 265 234 178 89 167 1656 485

AHU60CE 1187 1820 592 293 256 208 104 169 1760 537
AHU70CE 1241 2081 592 304 268 238 119 167 2021 537

AHU80CE 1292 2116 647 337 295 258 129 167 2056 592
AHU90CE 1292 2347 647 337 295 258 129 167 2287 592

AHU100CE 1184 2434 679 337 295 258 129 167 2374 624

AHU120CE 1238 2457 775 401 342 318 159 167 2397 720
AHU150CE 1265 2528 903 401 342 318 159 167 2468 848
Table 5. Ouline dimensions for AHU20CE-150CE

• Remark:
Condensate pipe should use DN25 externally threaded tubes.

Climate 5000
 Product information | 11

2.6 Use and installation characteristics

• Use characteristics
- More reliable performance
Compared with the single–shell structure of
other manufacturers, the innovation of double-
shell structure makes the whole unit more solid
and durable. Meanwhile, high-quality comp-
onents and high-level configuration applied to
Bosch ceiling air handling unit ensures the safe
use by user and the service life of unit.
- Lower cost
In addition to ensuring quality, the high-quality
configuration of each unit makes the service
life of unit longer, which dramatically saves the
cost and time of users.
- More comfortable operation
Owing to the brand-new design of double-shell
structure, Bosch ceiling air handling unit
continuously provides sufficient air volume with
less cooling energy, to create a comfortable
environment for client.

• Installation characteristics
The double-shell structure of Bosch ceiling
handling unit is derived from ingenious ad-
vanced technology, which is more solid than
the single-shell structure of other manufactur-
ers. And the high-quality components also
ensure safety operation and longer service life,
which dramatically saves the cost and time of
users.

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12 | Engineering installation

3 Engineering installation
The maximum length of the hoisting and the
3.1 Delivery, unloading and storage transported unit is 6150mm. The stress of unit
hoisting must be on the pedestal and the angle of
3.1.1 Delivery hoisting ropes is no more than 60°.
After the goods arrived, please check whether the
unit and accessories are all ready and have no 3.1.2.2 The method of carrying unit with forklift
damage. If there are any problems found, please Please pay attention to the center of gravity of
record them in time and give feedback to manu- unit and shovel pedestal when carrying with forklift.
facturer promptly with signature of the shipper.
3.1.2.3 Storage
3.1.2 Unloading
► Putthe pedestal of unit downward on the flat
backing board.
3.1.2.1 Hoisting diagram employed by unit
► The shell cannot be stressed directly.
Notice: Risk of falling!
► Do not remove the external plastic package.
Anti-sliding pin shall be used on both
sides of the hoisting steel, to prevent ► Store the goods at ventilated place.
any slip or slope caused by gravity
shifting.
3.2 Installation
• Selection of hoisting steel pipe
- When the shipping weight is less than 2000 3.2.1 Installation preparation
Kg, employ steel pipe with a diameter and
Notice: Risk of unit damage!
thickness of no less than Φ 42*6.
Do not climb and tread on the unit!
- When the shipping weight is less than 4000
Kg, employ steel pile with a diameter and
► Find the installation instruction at the spot
thickness of less than Φ 48*10.
where equipment and accessories material are
placed, assemble the spare parts and random
accessories.

3.2.2 Equipment installation

3.2.2.1 Hoisting for ceiling unit

Notice: Risk of falling!

Keep the unit flat during hoisting.

► Before unit is hoisted, preset four M16 bolts on

the ceiling in accordance with installation
dimension of the unit.
► After the unit is well placed, use four M16 bolts
and corresponding spring washer to fasten the
flat washer.

Figure 6. Hoisting diagram

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 Engineering installation | 13

Figure 7. Hoisting details

► The temperature and pressure of heat-transfer
3.2.3 Connection of heat exchanger medium in heat exchanger shall not exceed
standard and the heat exchanger shall be
Water outlet

Water inlet

furnished with defroster.

► When connecting pipe line, use pipe vice to
Water
clamp the pipe orifice of the heat exchanger
outlet
and then connect.
Air flow ► So does the connection of condenser pipe.
Water
inlet
3.2.4 Electrical equipment installation
Notice: Risk of burning motor!
In order to avoid wrong connection,
please complete the connection in
accordance with the circuit diagram.
Electrical equipment installation shall be imple-
mented in accordance with work instruction and
wire perforation and layout must be reasonable.
出水 three-phase four-wire, 380 V and 50 HZ AC
出 进 power is supplied to the unit. In order to avoid
水 水
进水
wire connection mistake, connection must be
done according to Figure 9.
出水

气流
进水

Figure 8. Connection of heat enchanger

Climate 5000 8736862517(2017/09)

14 | Engineering installation

• During unit installation, the phase loss/ phase

dislocation and overload protection device shall
be provided.
• According to the related national regulations,
terminal connection shall be not used for the
unit with motor power of no less than 15 kW
and the cable of the unit shall be connected to
motor directly.

3.2.5 Trap installation

Notice: Risk of poor drainage!
Water storage height difference (H) of
trap shall exceed the maximum positive
pressure and negative pressure of
equipment.
Each condensate water discharge pipe or over-
flow pipe must be installed with a trap and one
trap used by several discharge pipes shall be not
allowed.

Water storage height (H) of trap (mm water column)

= the maximum positive pressure or negative
pressure of equipment (Pa)/10.

In working condition of positive pressure or

Figure 9. Electrical circuit diagram negative pressure, the maximum water storage
height of trap→ Figure 10.
Code Name Code Name

Automatic
KA KM AC contactor
control switch

HL1 Power light HL2 Fault indicating light

XT Wiring board SA Option switch

M Motor

Table 6. Code explanation

Please read the following installation
reference and suggestions carefully
before installation and follow them during
installation.

• Electrical equipment installation of unit shall be

implemented in strict accordance with related
national electrical equipment installation regu-
lation and the selection of cable shall be done
in accordance with the capacity of the unit.
• Strictly prohibit phase loss/ phase dislocation
and overcurrent operation and prohibit open- * H=Unit inside static pressure (mmH2O) + 20
ing air outlet and non-operation.
Figure 10. Maximum water storage height of trap

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 Unit start-up | 15

4 Unit start-up

4.1 Confirmation
• Before start-up, please ensure
- All transportation safety devices are dismantled.
- There is no loose material inside of the unit
- Air flue and various power lines are well
connected
- All components are in right operation
- The pipe of trap is full of water.

4.2 Fan
Notice: Risk of injury!
Do not start the fan when the regulating
valve is closed; do not open or dis-
mantle the access door of the unit
during unit operation.
► Check rotating direction of the fan, which shall
be the same with rotating mark of the fan.
► Check whether the protector of motor is working
normally.

4.3 Heat exchanger

Notice:Beware of freezing!
Pay attention to freeze-proofing of heat
exchanger in winter.

► Ifthere is anti-freezing sensor, the whole anti-

freezing line must be checked.
► When the waterway is working normally, water
pipe vent valve of heat exchanger shall be
opened and closed when air is exhausted.

4.4 Humidifier
Start it in accordance with the type of humidifier to
be installed and with reference to the separated
instruction of humidifier.

Climate 5000 8736862517(2017/09)

 16 | Maintenance

5 Maintenance
Notice: Beware of electric shock!
The main power shall be cut off before
any maintenance is implemented. All
parts which is easy to be worn shall be
checked regularly (at least once a quarter).

5.1 Fan and motor

• Lubed-for-life bearing used for fan is free from
maintenance and other fan bearings shall be
oiled in accordance with the service time
regulated by manufacturer.
• Check the noise of motor and fan bearing and
change them if needed.

5.2 Filter
It is suggested that the air filter shall be washed
once a week, especially when the air volume and
cooling capacity are reducing
• The following maintenance works shall be
done every six months,
► Clean the dust on regulating valve.
► Check regulating valve can move freely after
removing the driver.
► Check the driver of regulating valve.

5.3 Heat exchanger

Notice:
Do not damage aluminum foil when
using high pressure clean water/ air.

• The defroster shall be checked when winter is

coming and water in heat exchanger which is
not in service during winter shall be fully
exhausted.
• The cleanliness of heat exchanger shall be
checked regularly and the heat exchanger shall
be cleaned with clean water or compressed air
if necessary.

8736862517(2017/09) Climate 5000

 Common faults and solutions | 17

6 Common faults and solutions

Fault item Reason Solution

Dirty filter Clean or change

Low air volume
Blocked air inlet Unchock

Noisy fan bearing Repair or change

Unit high noise
Dirty filter Clean or change

Cold (hot) water is not cold (hot) Decrease (increase) water temperature

Low water flow volume Incease flow rate

Unsufficient cooling
(heating) capacity
Low air volume Increase air volume

Blocked gate of water pan Unchock

Bad heat preservation of pipe line

Heat preservation
and pipe fitting

Leakage
Uneven installation Leveling

Frost-crack heat exchanger Repair or replace

Table 7. Common faults and solutions

Climate 5000 8736862517(2017/09)

 18 | Packing list

7 Packing list

Packing List
CTN: 1
Model and
Type Name Quantity Unit
specification

Local
Unit See data plate 1 Set
machine

Qualification certification 1 Copy

Manual —— 1 Copy
Print

Accessories
Packing list —— 1 Copy

Open-box list —— 2 Copy

Table 8. Packing list

8736862517(2017/09) Climate 5000

 Notes | 19

8 Notes

Climate 5000 8736862517(2017/09)

Bosch Thermotechnology (Shandong) Co., Ltd
No. 77 Dongfeng Road, Huantai, Zibo/ P.R. China
Tel: (+86) 0533-8553888
Fax: (+86) 0533-8552777
Post code: 256404
www.bosch-climate.cn