Bosch CE SPLIT Installation And Maintenance Manual

Installation and Maintenance Manual
CE Split
Series
6 720 220 049
Revised 03-11
©Copyright 2011 Bosch, Inc All rights reserved
Table of Contents
TABLE OF CONTENTS
Model Nomenclature .................................................................................... 3
Initial Inspection .......................................................................................... 4
General Description ..................................................................................... 4
Moving and Storage ..................................................................................... 4
Safety Considerations .................................................................................. 4
Location ....................................................................................................... 4
Installation ................................................................................................... 5
Condensate Drain ........................................................................................ 6
Duct System ................................................................................................. 6
Electrical ...................................................................................................... 7
Electric Heater Package Option ................................................................... 7
Thermostat Connections ............................................................................. 9
Safety Devices & the UPM Controller ......................................................... 10
Sequence of Operation Two-Stage Units .................................................... 11
Piping ........................................................................................................ 12
Well Water Systems .................................................................................... 15
Cooling Tower / Boiler Application ............................................................. 15
Earth Coupled Systems .............................................................................. 16
System Checkout ....................................................................................... 16
Unit Start-Up .............................................................................................. 16
Heat Recovery Package .............................................................................. 16
Maintenance .............................................................................................. 18
Unit Specications ..................................................................................... 19
Wiring Diagrams ......................................................................................... 20
Two Stage Multi-Step - Single Phase - Air Handler .................................. 20
Two Stage - Single Phase - Condensing Section ..................................... 21
Operating Pressures & Temperatures ........................................................ 22
Unit Check Out ........................................................................................... 26
Trouble Shooting ........................................................................................ 27
CE Split Series
3
MODEL NOMENCLATURE
Condensing Section
CE 049 - 1 CS C - F X X
SERIES: CE
NOMINAL CAPACITY: (049 = 49,000 BTUH) 025, 035, 049, 061, 071 AVAILABLE
VOLTAGE DESIGNATIONS: 1-208-230/1/60
CABINET CONFIGURATION: CS-CONDENSING SECTION
Air Handler
CE 049 - 1 AV X - X L T
SERIES: CE
NOMINAL CAPACITY: (049 = 49,000 BTUH) 025, 035, 049, 061, 071 AVAILABLE
VOLTAGE DESIGNATIONS: 1-208-230/1/60
CABINET CONFIGURATION: AV-VERTICAL AIR HANDLER AH-HORIZONTAL AIR HANDLER
NOT USED FOR CONDENSING SECTIONS
NOT USED FOR CONDENSING SECTIONS
WATER CONNECTION F-FRONT
HEAT EXCHANGER MATERIAL C-COPPER N-CUPRO NICKEL
SUPPLY AIR LOCATION: T - VT TOP S-HZ STRAIGHT THRU E-HZ END BLOW
RETURN AIR LOCATION L-LEFT R-RIGHT
NOT USED FOR AIR HANDLERS
NOT USED FOR AIR HANDLERS
Revised 03-11 Subject to change without prior notice
Initial Inspection
4
CE Split Series
INITIAL INSPECTION
Be certain to inspect all cartons or crates on each unit as received at the job site before signing the freight bill. Verify that all items have been received and that there are no visible damages; note any shortages or damages on all copies of the freight bill. In the event of damage or shortage, remember that
the purchaser is responsible for ling the necessary
claims with the carrier. Concealed damages not discovered until after removing the units from the packaging must be reported to the carrier within 24 hours of receipt.
GENERAL DESCRIPTION
These Split System Heat Pumps provide the best
combination of performance and efciency
available. Safety devices are built into each unit to provide the maximum system protection possible when properly installed and maintained.
The CE Split Water-to-Air Heat Pumps are Underwriters Laboratories (UL) and (cUL) listed for safety. The Water-to- Air Heat Pumps are designed to
operate with entering uid temperature between
20°F to 80°F in the heating mode and between 50°F
to 110°F in the cooling mode. Efciencies and capacities will vary as entering uid and return air
temperatures vary.
required, stack units as follows: Vertical units no more than two high. Horizontal units no more than three high.
SAFETY CONSIDERATIONS
Installation and servicing of this equipment can be hazardous due to system pressure and electrical
components. Only trained and qualied personnel
should install, repair, or service the equipment. Untrained personnel can perform basic functions of maintenance such as cleaning coils and replacing
lters.
Before performing service or maintenance operations on the system, turn off main power to the unit. Electrical shock could cause personal injury or death.
When working on equipment, always observe precautions described in the literature, tags, and labels attached to the unit. Follow all safety codes. Wear safety glasses and work gloves. Use a
quenching cloth for brazing, and place a re
extinguisher close to the work area.
The air handler blower should only be operated when a duct is installed and secured to heat pump duct collar in order to avoid possible injury.
LOCATION
50°F Min. EWT for well water applications with
sufcient water ow to prevent freezing. Antifreeze solution is required for all closed loop applications where the uid temperature may drop below 50°F. Cooling Tower/Boiler and Earth Coupled (Geo Thermal) applications should have sufcient antifreeze solution to protect against extreme conditions and equipment failure. Frozen water coils are not covered under warranty.
This product should not be used for temporarily heating/cooling during construction. Doing so may effect the units warranty.
MOVING AND STORAGE
If the equipment is not needed for immediate installation upon its arrival at the job site, it should be left in its shipping carton and stored in a clean, dry area. Units must only be stored or moved in the normal upright position as indicated by the “UP” arrows on each carton at all times. If unit stacking is
To maximize system performance, efciency and
reliability, and to minimize installation costs, it is always best to keep the refrigerant lines as short as possible. Every effort should be made to locate the air handler and the condensing section as close as possible to each other.
Figure #1
Subject to change without prior notice Revised 03-11
Installation
CE Split Series
5
INSTALLATION
Remove all shipping blocks under blower housing.
The installer should comply with all local codes and regulations which govern the installation of this type of equipment. Local codes and regulations take precedent over any recommendations contained in these instructions. In lieu of local codes, the equipment should be installed in accordance with the recommendations made by the National electric code, and in accordance with the recommendations made by the National Board of Fire Underwriters. All local seismic codes for seismic restraint of equipment, piping, and duct work shall be strictly adhered to.
CONDENSING SECTION
Locate the condensing section in an area that
provides sufcient space to make water and
electrical connections, allowing easy removal of the access panels. A 36" clearance in front of the unit is recommended. This will ensure proper work space for service personnel to perform maintenance or repair.
AIR HANDLER
Locate the air handler unit in an indoor area that
allows easy removal of the lter and access panels,
and has enough room for service personnel to
perform maintenance or repair. Provide sufcient
room to make electrical and duct connections. A 36" clearance in front of the unit is recommended. If the
unit is located in a conned space such as a closet,
provisions must be made for return air to freely enter the space. On horizontal units, allow adequate room below the unit for a condensate drain trap.
Sufcient space should be provided on the sides to allow for lter replacement on horizontal air
handlers and in the front for vertical air handlers. The air handler units are not approved for outdoor installation; therefore, they must be installed inside the structure being conditioned.
MOUNTING VERTICAL UNITS
Vertical units should bemounted level on a vibration absorbing pad slightly larger than the base to minimize vibration transmission to the building structure. (See Figure #2).
If the condensing section is installed in a location where ambient temperatures can fall below freezing, some form of freeze protection should be employed such as anti-freeze. Where the use of anti-freeze is not possible for example in a ground
water application the uid circulating pump should
operate continuously to prevent possible condenser freeze-up and to optimize overall system performance. Consult the factory in these instances for guidance.
Water freezes at 32°F. Frozen water coils are not covered under the limited product warranty. It is the installer’s responsibility to insure that the condensing section is installed in a location or has the proper controls to prevent rupturing the water coil due to freezing conditions.
Do not remove the protective caps or plugs from the service valves until the refrigerant lines are run and ready for nal connection.
VIBRATION
PAD
Figure #2
FULL SIZE
MOUNTING HORIZONTAL UNITS
While horizontal units may be installed on any level surface strong enough to hold their weight, they are typically suspended above a ceiling by threaded rods. The rods are usually attached to the unit corners by hanger bracket kit. (See Figure #3). The rods must be securely anchored to the ceiling. Refer to the hanging bracket assembly and installation instructions for details. All units require four mounting brackets at the corners. Horizontal units installed above the ceiling must conform to all local codes. An auxiliary drain pan if required by code, should be at least four inches larger than the bottom of the heat pump. Plumbing connected to
Revised 03-11 Subject to change without prior notice
6
CE Split Series
Figure #3
the heat pump must not come in direct contact with joists, trusses, walls, etc.
Some applications require an attic oor installation
of the horizontal air handler unit. In this case the unit should be set in a full size secondary drain pan on top of a vibration absorbing mesh. The secondary
drain pan prevents possible condensate overow or
water leakage damage to the ceiling. The secondary drain pan is usually placed on a plywood base isolated from the ceiling joists by additional layers of vibration absorbing mesh. In both cases, a 3/4" drain connected to this secondary pan should be run to an eave at a location that will be noticeable. If the unit is located in a crawl space, the bottom of the unit
must be at least 4” above grade to prevent ooding
of the electrical parts due to heavy rains.
CONDENSATE DRAIN
A drain line must be connected to the heat pump and pitched away from the unit a minimum of 1/8” per
foot to allow the condensate to ow away from the
unit.
Make sure that the unused drain pan opening is plugged prior to operating the air handler.
Condensate Drain
(Heat Pumps are not internally trapped). A vertical air vent is sometimes required to avoid air pockets. (See Figure #4). The length of the trap depends on the amount of positive or negative pressure on the drain pan. A second trap must not be included.
The horizontal air handler unit should be pitched approximately 1/4” towards the drain in both directions, to facilitate condensate removal. (See Figure #5)
Figure #5
DUCT SYSTEM
A supply air outlet collar and return air duct ange
are provided on all units to facilitate duct
connections. See Unit Specications for duct collar
connection sizes in the back of this manual.
A exible connector is recommended for supply and
return air duct connections on metal duct systems. All metal ducting should be insulated with a minimum of one inch duct insulation to avoid heat loss or gain and prevent condensate forming during the cooling operation. Application of the unit to uninsulated duct work is not recommended as the unit’s performance will be adversely affected. Do not connect discharge ducts directly to the blower
outlet. The factory provided air lter must be removed when using a lter back return air grill. The factory lter should be left in place on a free return
system.
Figure #4
This connection must be in conformance with local plumbing codes. A trap must be installed in the
condensate line to insure free condensate ow.
If the unit will be installed in a new installation which includes new duct work, the installation should be designed using current ASHRAE procedures for duct sizing. If the unit is to be connected to existing ductwork, a check should be made to assure that the duct system has the capacity to handle the air required for the unit application. If the duct system is too small, larger ductwork should be installed. Check for existing leaks and repair as necessary to ensure a tight air
Subject to change without prior notice Revised 03-11
Electrical
CE Split Series
7
seal within duct. The duct system and all diffusers
should be sized to handle the designed air ow
quietly. To maximize sound attenuation of the unit blower, the supply and return air plenums should be insulated. There should be no direct straight air path thru the return air grille into the heat pump. The return air inlet to the heat pump must have at least one 90 degree turn away from the space return air
grille. If air noise or excessive air ow are a problem,
the blower speed can be changed to a lower speed
to reduce air ow. (Refer to ECM motor interface
board section in this manual and Figure #6)
ELECTRICAL
Always disconnect power to the unit before servicing to prevent injury or death due to electrical shock or contact with moving parts.
All eld wiring must comply with local and national re, safety and electrical codes. Power to the unit
must be within the operating voltage range indicated on the unit’s nameplate.
the power leads as indicated on the unit wiring diagrams. (Refer to Figure#12)
ELECTRIC HEATER PACKAGE OPTION
Field installed internal electric heater packages are available for all units. Two circuit breakers are required when heater packages are utilized. The circuit breakers for the heater package (located in the electric heater package control box) provide power for the heater elements, the blower motor and the control circuit for the unit. The circuit breaker for the unit provides power for the compressor. This allows the electric heaters to continue to operate along with the blower motor in the case of unit compressor and/or compressor power supply failure. See HP Series Heater Kit
Instructions for eld installation. Each CE Series
model has a number of heater sizes available. Refer to Figure #7 for heater package compatibility with
specic CE Series units, models nomenclature and
electrical data.
Operating the unit with improper line voltage or with excessive phase imbalance is hazard­ous to the unit and constitutes abuse and is not covered under warranty.
Properly sized fuses or HACR circuit breakers must be installed for branch circuit protection. See equipment rating plates for maximum size.
Both the air handler and condensing units are provided with a concentric knock-out in the front right corner post for attaching common trade sizes of conduit. Route power supply wiring through this opening. Flexible wiring and conduit should be used to isolate vibration and noise from the building structure. Be certain to connect the ground lead to the ground lug in each of the control boxes. Connect
LOW VOLTAGE CONTROL WIRING
The CE series units incorporate the ECM variable speed fan motor and control interface board. The thermostat should be connected to the air handlers and then from the air handler to the condensing section. The low voltage power supply is located in the air handler.
In this application utilize a 9 conductor cable from the thermostat to the air handler and 7 conductor cable from the air handler to the condensing section.
Each model has a number of heater sizes available. Refer to Figure #7 for heater package compatibility
with specic units, model nomenclature and
electrical data.
Figure 6: Motor Prole Air Flow Table CFM Two Stage Units
Model Fan
Only
CE025 450 500 800 800 800 900 700 A
CE035 700 800 1200 1200 1200 1400 1000 A
CE049 900 1000 1600 1600 1600 1800 1400 B
CE061 1200 1400 2000 2000 2000 2100 1900 A
CE071 1600 1600 2200 2200 2200 2300 1900 A
Y1
COOL/
HEAT
Y2
COOL/
HEAT
AUX
HEAT
EMERG
HEAT
PLUS
ADJ
MINUS
ADJ
TAP COOL/
HEAT/DELAY
Revised 03-11 Subject to change without prior notice
8
CE Split Series
Heater Package Compatibility
Figure 7: Heater Package Compatibility
Model Heater Model KW Heater Amps Circuit MCA Max. Fuse AWG
Min.
208V 240V 208V 240V 208V 240V
CE025 thru 035 HP050-1XS 4.8 17.3 20.0 L1/L2 27.1 30.4 30 30 8
CE049 thru 071 HP050-1XM 4.8 17.3 20.0 L1/L2 27.1 30.4 30 30 8
CE025 thru 035 HP075-1XS 7.2 23.6 30.0 L1/L2 34.9 42.9 40 45 8
CE049 thru 071 HP075-1XM 7.2 23.6 30.0 L1/L2 35.7 43.8 40 45 8
CE025 thru 035 HP100-1XS 9.6 34.7 40.0 L1/L2 48.8 55.4 50 60 6
CE049 thru 071 HP100-1XM 9.6 34.7 40.0 L1/L2 49.5 56.3 50 60 6
CE049 thru 071 HP150-1XM
HP150-1XM
CE049 thru 071 HP200-1XM
HP200-1XM
All heaters rated single phase 60 Hz, and include unit fan load. All fuses type “D” time delay or HACR type breaker or HRC FORM 1. Wire size based on 60 deg. C copper conductors.
14.4
14.4
19.2
19.2
52.0
34.7
17.3
69.3
34.7
34.7
60.0
40.0
20.0
80.0
40.0
40.0
SINGLE
L1/L2 L3/L4
SINGLE
L1/L2 L3/L4
71.2
49.5
21.7
92.9
49.5
43.4
81.3
56.3
25.0
106.3
56.3
50.0
80 60 25
100
50 45
90 60 25
110
60 50
4 6
10
2 6 6
Units supplied with internal electric heat require two (2) separate power supplies: one for the unit compressor and one for the electric heater elements, blower motor and control circuit. Refer to Figure #7 for wiring instruc­tions, minimum circuit ampacities and maxi­mum fuse/breaker sizing.
Connection point logic is as follows:
Table 1: Low Voltage Connection Points
Function From
24 HVAC Common C C1 C C
24 VAC Hot R R R R
Fan Operation G G
Reversing Valve (3)
1st Stage Compressor Operation
2nd Stage Compressor Operation
Condensate Sensor (1)
Alarm Output (From UPM) (2)
Auxilliary Electric Heat (4)
Emergency Heat (4)
Thermostat
O O O O
Y1 Y1 Y1 Y1
Y2 Y2 Y2 Y2
L Splice ALR
W/W1/W2 W1
E EM/W2
To Air
Handler
From Air
Handler
CS CS
Condensing
To
Section
TABLE 1 NOTES
1. For the condensate overow sensor, connect
‘CS’ at the condensing section to ‘CS’ at the air handler. Be sure to ground power supply.
2. If service LED is utilized connect ‘ALR’ terminal on the UPM board to ‘L’ on the thermostat sub base. The wiring may be spliced in the air handling unit. The ‘ALR’ output is hot (R) so check thermostat instruction manual to ensure compatibility.
3. ‘O’ – reversing valve is energized in the cooling mode. Fail safe is to heating.
4. Utilized when electric strip heater package present.
ECM INTERFACE BOARD
Figure #8 - ECM Interface Board
Subject to change without prior notice Revised 03-11
Thermostat Connections
CE Split Series
9
THERMOSTAT CONNECTIONS
Thermostat wiring is connected to the 10 pin screw type terminal block on the lower center portion of the ECM Interface Board. In addition to providing a connecting point for thermostat wiring, the interface board also translates thermostat inputs into control commands for the variable speed programmable ECM DC fan motor and displays an LED indication of operating status. The thermostat connections and their functions are as follows:
Y2 Second Stage Compressor Operation
Y1 First Stage Compressor Operation
G Fan
O Reversing Valve (energized in cooling)
W1 Auxiliary Electric Heat (runs in
conjunction with compressor)
EM/W2 Emergency Heat (electric heat only)
NC Transformer 24 VAC Common (extra
connection)
C1 Transformer 24 VAC Common (primary
connection)
R Transformer 24 VAC Hot
HUM Dehumidication Mode
If the unit is being connected to a thermostat with a malfunction light, this connection is made at the unit malfunction output or relay.
If the thermostat is provided with a malfunction light powered off of the common (C) side of the transformer, the unit must be provided with a malfunction relay (Bosch option # 660-006) to properly energize the light. The relay coil will be wired across the (ALR) and (C) contacts on the unit’s UPM board and the relay’s normally open contacts across (ALR) and the malfunction light connection on the thermostat. If the thermostat is provided with a malfunction light powered off of the hot (R) side of the transformer, then the thermostat malfunction light connection should be connected directly to the (ALR) contact on the unit’s UPM board.
To the left of the thermostat connection block are a row of 2 red and 4 green LED’s. These LED’s indicate the operating status of the unit. They are labeled as follows:
EM (red) Emergency Heat On
W1 (red) Auxiliary Heat On
O (green) Reversing Valve Energized, unit is in
cooling mode
Y2 (green) Second Stage Compressor On
Y1 (green) First Stage Compressor On
G (green) Fan On
Just above the connector block is a single red LED labeled CFM that will blink intermittently when the unit is running. This LED indicates the air delivery of the blower at any given time. Each blink of the LED represent 100 CFM of air delivery so if the LED blinks 12 times, pauses, blinks 12 times, etc. the blower is delivering 1200 CFM. Refer to Figure #6 for factory programmed air delivery settings for the CE Split Series.
Just above and to the right of the thermostat connection block are four sets of jumper pins labeled ADJ, DELAY, HEAT and COOL. The ADJ set of pins are labeled NORM, (+), (-) and TEST. AP units will all be set on the NORM position from the factory,
however, airow can be increased (+) or decreased
(-) by 15% from the pre-programmed setting by relocating the jumper in this section. The TEST position is used to verify proper motor operation. If a motor problem is suspected, move the ADJ jumper to the TEST position and energize G on the thermostat connection block. If the motor ramps up to 100% power, then the motor itself is functioning normally. Always remember to replace the jumper to NORM, (+) or (-) after testing and reset the unit thermostat to restore normal operation.
Do not set the ADJ jumper to the (-) setting when electric heaters are installed. Doing so may cause the heaters to cycle on their thermal overload switches, potentially shortening the life of the switches.
The other three sets of jumper pins are used to select the proper program in the ECM motor for the unit. Refer to Figure #7 for the proper jumper placement.
Always disconnect power before changing jumper positions on the interface board and reset the unit afterward.
To the left of the red and green status LED’s is a row of 1/4” male quick connects. These are used to pass
Revised 03-11 Subject to change without prior notice
10
CE Split Series
Safety Devices and the UPM Controller
thermostat inputs on to the rest of the control circuit. Remember to always turn off unit power at the circuit breaker before attaching or disconnecting any wiring from these connections to avoid accidental short circuits that can damage unit control components.
SAFETY DEVICES AND THE UPM CONTROLLER
Each unit is factory provided with a Unit Protection Module (UPM) that controls the compressor operation and monitors the safety controls that protect the unit.
Safety controls include the following:
• High pressure switch located in the refrigerant
discharge line and wired across the HPC terminals on the UPM
• Low pressure switch located in the unit refrigerant
suction line and wired across terminals LPC1 and LPC2 on the UPM.
• Optional freeze protection sensor located on the
leaving side of the water coil prevents unit operation below 35°F or 15°F (depending on dip switch setting). The freeze dip switch must be set to “ON”.
The factory default for the Freeze setting is in
“ON” position. If the freeze stat option is not ordered, the switch must be repositioned to the
“OFF” position.
• Condensate overow protection sensor located in
the drain pan of the unit and connected to the ‘COND’ terminal on the UPM board.
The UPM includes the following features:
ANTI-SHORT CYCLE TIME—5 minute delay on break timer to prevent compressor short cycling.
RANDOM START—Each controller has a unique random start delay ranging from 270 to 300 seconds to reduce the chances of multiple units simultaneously starting after initial power up or after a power interruption, creating a large electrical spike.
LOW PRESSURE BYPASS TIMER—If the compressor is running and the low pressure switch opens, then the control will keep the compressor on for 120 seconds. After 2 minutes if the low pressure switch remains open, the control will shut down the compressor and
enter a soft lockout. The compressor will not be energized until the low pressure switch closes and the anti-short cycle time delay expires. If the low pressure switch opens 2–4 times in 1 hour, the unit will enter a hard lock out and need to be reset.
BROWNOUT/SURGE/POWER INTERRUPTION PROTECTION—The brownout protection in the UPM
board will shut down the compressor if the incoming power falls below 18 VAC. The compressor will remain off till the voltage goes above 18 VAC and the anti short cycle timer (300 seconds) times out. The unit will not go into a hard lockout.
MALFUNCTION OUTPUT—The controller has a set of wet contacts for remote fault indication or dry contacts for communication with a DDC controller or BMS. The fault output will depend on the dip switch setting for “ALARM”. If it set to “CONST’, a constant signal will be produced to indicate a fault has occurred and the unit requires inspection to determine the type of fault. If it is set to “PULSE”, a pulse signal is produced and a fault code is detected by a remote device indicating the fault. See L.E.D. Fault Indication below for blink code explanations. The remote device must have a malfunction detection capability when the UPM board is set to “PULSE”.
TEST DIP SWITCH—A test dip switch is provided to reduce all time delay settings to 5 seconds during
troubleshooting or verication of unit operation.
Note that operation of the unit while in test mode can lead to accelerated wear and premature failure of the unit. The “TEST” switch must be set back to “NO” for normal operation.
FREEZE SENSOR—This is optional and can be set to ignore or monitor a freeze sensor. There are 2
congurable freeze points, 35°F & 15°F. The unit
will enter a soft lock out until the temperature climbs above the set point and the anti-short cycle time delay has expired. The freeze sensor may not
provide protection in the case of loss of ow in the heating mode. A ow switch or pressure
differential switch is recommended to prevent unit
operation in case of loss of ow.
If unit is employing a fresh water system (no
anti-freeze protection), it is extremely important to have the “Freeze” switch set to 35°F in order to shut down the unit at the appropriate leaving water temperature and protect your heat pump from freezing if a freeze sensor is included.
Subject to change without prior notice Revised 03-11
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