Bosch EC Installation Manual
EC Large Series
072, 096, 120, 150, 151, 180, 181, 210, 240, 242, 300, 360.
Installation, operation and Maintenance Manual
T111970289 (01/15)
2 | EC Series
CONTENTS
Model Nomenclature.......................................................... 3
Initial Inspection................................................................4
General Description........................................................... 4
Moving and Storage...........................................................5
Location............................................................................ 5
INSTALLATION .................................................................. 5
MOUNTING VERTICALLY...............................................5
MOUNTING HORIZONTALY............................................ 5
CONDENSATE DRAIN .........................................................6
Duct System...................................................................... 6
Piping ...............................................................................7
Electrical .......................................................................... 7
ECM INTERFACE BOARD............................................... 8
Thermostat Connections ....................................................9
Safety Devices and the UPM Controller .............................10
Unit Nameplate Data.................................................. 24
Operating Conditions................................................. 24
Auxiliary Heat ........................................................... 24
troubleshooting .............................................................. 25
Belt drive Motor
Table...............................................................................28
Blower Performance
Table..............................................................................29
Water side Pressure Drop
Table...............................................................................30
Operating temperatures and Pressures.............................31
Wiring diagrams.............................................................. 34
Notes ............................................................................. 46
Key to symbols and safety instructions
Key to symbols
Warnings
Electronic Thermostat Installation.....................................13
Water Quality...................................................................15
UPM Sequence of Operation............................................. 14
Water Quality table...........................................................15
Heat Recovery Package ...................................................16
Typical Connection Piping (HRP).................................. 16
Water Tank PrECaration:............................................. 16
HR Water Piping ........................................................ 16
Water Tank Refill .............................................................17
Initial Start-Up........................................................... 17
Hot Gas Reheat (HGRH)..............................................17
Sequence of Operation ....................................................18
Cooling Mode ............................................................18
Heating Mode............................................................18
Application considerations............................................... 18
Well Water Systems ................................................... 18
Installation of Pressure Regulating Valves......................... 19
Cooling Tower/Boiler Systems.......................................... 19
Geothermal (Earth-Coupled) Systems ..........................21
Warnings in this document are identified by a warning
triangle printed against a grey background.
Keywords at the start of a warning indicate the type and
seriousness of the ensuing risk if measures to prevent
the risk s are not taken.
The following keywords are defined and can be used in
this document:
• NOTE indicates a situation that could result in
damage to property or equipment.
• CAUTION indicates a situation that could result in
minor to medium injury.
• WARNING indicates a situation that could result in
severe injury or death.
• DANGER indicates a situation that will result in
severe injury or death.
System Checkout.............................................................22
Unit Start-up ................................................................... 22
Maintenance ...................................................................23
Unit Check-Out Sheet ......................................................24
Customer Data ..........................................................24
EC SeriesT111970289 (2015/01) Subject to change without prior notice
MODEL NOMENCLATURE
Model Nomenclature | 3EC Series
ter w/ Expander
1
6XXX XS B A
X
ols
lower Monitor Relay E - Pump/valve relay H - Flow proving switch Z - EMS + Pump/valve relay
EC 300- 4VTC-SBSIUA-XXTXXXXXX1XXX
072 STANDARD/SPECIAL
096 S - Standard
120 A - Special #1
150 B - Special #2
180 OPEN
SIZE B - Bosch
EC CODE STRING LEVEL
360 M - Blo wer Standard, Mo tor Rotated
210 MOTOR BLOWER ORIENTATI ON
240 X - Blower and Motor Standard Orientation
300 B - Blower Rotated 180 Deg, Motor Standard
4460/60/3 A - 1
5 575/60/3 B - 1.5
1 208-230/60/1 X - N/A
3 208-230/60/3 MOTOR HP (BELT DRIVE ONLY)
VOLTAGE N - Both Blowe r and Motor Rotated 180 Deg
VT - Vertical D - 3
HZ - Horizontal E - 5
CABINET CONFIGURATION C - 2
X - No condenser 8 - 2" 2 Sided Fi lter Rack
C - Copper 1 - Standard Throw Away
COAX OPTIONS AIR FILTRATION
F - Front ECONOMIZER
N - Cupro-Nickel 3 - 2" 4 Sided Filter Rack with 1" Filter
WATER CONNECTIONS OPEN
B - Back X - None
F - Front CONTROLS
L - Left X - Standard
R - Right M - DDC - Multi-Protocol (BacNET, Modbus, N2)
S - Side X - None
X - N/A E - Economizer With 3 Way Valve and Contr
RETURN AIR CONFIGURATION H - Hot Water Coil
DISCHARGE AIR CONFIGURA TION P - DDC - Multi-Protocol (BacNET, Modbus, N2) w/ Expander
T - Top L - DDC - LonWorks
F - Front G - DDC - LonWorks w/ Expander
S - Straight Through T - DDC - Multi-Protocol (BacNET, Modbus, N2) with Inver
E - End Blow J - DDC - Multi-Protocol (BacNET, Modbus, N2) with Inverter
R - Rear I - Inverter
FAN/MOTOR OPTIONS K - DDC - Lon Works with Inverter
U - Uncoated TRANSFORM ER
D - DuoGuard 7 - 75 VA
AIR COIL V - Carrier Open Protocol Controller w/ Inverter
B - Belt Drive O - Carrier Open Protocol Controller
I - Belt Drive, I nverter Duty C - DDC - LonWorks with Inv erter
A - Current REF RIGERATION CIRCUIT OPTIONS
REVISIO N LEVEL 1 - 100 VA
A - G90 Steel / 1/2" Stand ard 1.5LB Dual Density Fiber glass C - Hot Gas Bypass with Hot Gas Re heat
X - None H - Hot Gas Reheat - On/O
CABINET CONSTRUCTION B - Hot Gas Bypass
ELECTRIC HEAT X - None
F - G90 Steel / 1/2" Closed Cell Foam, Extra Quiet GENERAL ELECTRICAL OPTIONS(UP TO 5 AVAIL ABLE PER UNIT
D - G90 Steel / 1/2" Standard 1.5L B Dual Density Fiberglass , Extra Quiet S - Straight Cool
C - G90 Steel / 1/2" Closed Cell Foam M - Modulating Hot Gas Reheat
APPLICATION A - EMS relay D - Phase Monitor G - Boilerless control X - As default for non used electrical codes
T - TXV Option B - B
G - EXTENDED RANGE W/ SCHRADER VALVE (Geothermal) C - Compressor Mon itor Relay M - Wire to 208 V K - Fire Alarm Rel ay/Dual Power
Figure # 1
T111970289 (2015/01)EC Series
4 | Initial Inspection EC Series
WARNING: Installation and servicing of this
equipment can be hazardous due to system
pressure and electrical components. Only
trained and qualified personnel should
install, rECair, or service the equipment.
WARNING: Before performing service or
maintenance operations on the system, turn
off main power to the unit. Electrical shock
could cause personal injury or death.
CAUTION: 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 fire
extinguisher close to the work area.
NOTE: All refrigerant discharged from this
unit must be recovered WITHOUT
EXCECTION. Technicians must follow
industry accECted guidelines and all local,
state, and federal statutes for the recovery
and disposal of refrigerants. If a compressor
is removed from this unit, refrigerant circuit
oil will remain in the compressor. To avoid
leakage of compressor oil, refrigerant lines
of the compressor must be sealed after it is
removed.
NOTE: To avoid equipment damage, DO
NOT use these units as a source of heating
or cooling during the construction process.
Doing so may affect the unit’s warranty. The
mechanical components and filters will
quickly become clogged with construction
dirt and debris, which may cause system
damage.
INITIAL INSPECTION
1
2
3
Figure # 2
[1] EC Series Water-to-Air Heat Pump
[2] Installation and Operation Manual
[3] Hanging Bracket kit (HZ unit only)
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 filing the
necessary claims with the carrier. Concealed
damages not discovered until after removing the
units from the packaging must be rECorted to the
carrier within 24 hours of receipt.
GENERAL DESCRIPTION
EC Series Water-to-Air Heat Pumps provide the
best combination of performance and efficiency
available. Safety devices are built into each unit to
provide the maximum system protection possible
when properly installed and maintained.
NOTE: To avoid the release of refrigerant
into the atmosphere, the refrigerant circuit
of this unit must be serviced only by
technicians who meet local, state, and
federal proficiency requirements.
All EC water to Air Heat Pumps conform to UL1995
standard and are certified to CAN/CSA C22.2 No
236 by Intertek-ETL.The Water-to-Air Heat Pumps
are designed to operate with entering fluid
temperature between 20°F to 90°F in the heating
mode and between 30°F to 120°F in the cooling
mode.
EC SeriesT111970289 (2015/01) Subject to change without prior notice
NOTE: 50° Minimum Entering Water
Temperature (EWT) for well water applications
with sufficient water flow to prevent freezing.
Antifreeze solution is required for all closed loop
applications. Cooling Tower/Boiler and
Geothermal applications should have sufficient
antifreeze solution to protect against extreme
conditions and equipment failure. Frozen water
coils are not covered under warranty.
NOTE: This product should not be used for
temporarily heating/cooling during construction.
Doing so may Affect 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.
For storage If unit stacking is required,
stack units as follows:
Moving and Storage | 5EC Series
INSTALLATION
MOUNTING VERTICALLY
Vertical units up to six tons are available in left or
right air return configurations. Vertical units
should be mounted level on a vibration absorbing
pad slightly larger than the base to minimize
vibration transmission to the building structure. It
is not necessary to anchor the unit to the floor.
(See Figure #3).
Do not stack units larger than 6 tons.
Vertical units less than 6 tons, no more than
two high.
Horizontals units less than 6 tons, no more
than three high.
LOCATION
Locate the unit in an indoor area that allows easy
removal of the filter and access panels, and has
enough room for service personnel to perform
maintenance or repair. Provide sufficient room to
make fluid, electrical, and duct connection(s). If
the unit is located in a confined space such as a
closet, provisions must be made for return air to
freely enter the face of unit’s air coil. On horizontal
units, allow adequate room below the unit for a
condensate drain trap and do not locate the unit
above supply piping.
NOTE: These units are not approved for
outdoor installation; therefore, they must
be installed inside the structure being
conditioned. Do not locate in areas that are
subject to freezing.
Figure # 3
MOUNTING HORIZONTALY
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 the
base frame support rails , with mounting holes present
(See Figure #4). The rods must be securely anchored
to the ceiling. 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 the heat pump must not come
in direct contact with joists, trusses, walls, etc.some
applications require an attic floor installation of
the horizontal 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 overflow 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 eaves at a location that will be
noticeable.
T111970289 (2015/01)EC Series
6 | CONDENSATE DRAIN EC Series
NOTE: IF unit is located in a crawl space, the
bottom of the unit MUST be at least 4” above
grade to prevent flooding of the electrical parts
due to heavy rains.
Figure # 5
The horizontal unit should be pitched
approximately 1/4” towards the drain in both
directions, to facilitate condensate removal. (See
Figure #6)
Figure # 4
NOTE: Plumbing connected to the heat
pump must not come in direct contact with
joists, trusses, walls, etc.
CONDENSATE DRAIN
If equipped with float style condensate
overflow switch, final adjustment must be
made in the field.
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 flow away from
the unit.
This connection must be in conformance with local
plumbing codes. A trap must be installed in the
condensate line to insure free condensate flow.
(Heat Pumps are not internally trapped).
A vertical air vent is sometimes required to avoid
air pockets.(See Figure #5).
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.
Figure # 6
DUCT SYSTEM
Supply air duct and return air duct flanges are
shipped unfolded with unit.
A supply air outlet collar and return air duct flange
are provided on all units to facilitate duct
connections. Fold the duct flange outwards along
the perforated line. Refer to unit Dimensional
Drawings for physical dimensions of the collar and
flange. (Pg#33 through Pg#34)
A flexible 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.
EC SeriesT111970289 (2015/01) Subject to change without prior notice
NOTE: Application of the unit to no insulated
duct work is not recommended as the unit’s
performance will be adversely affected.
NOTE: The factory provided air filter must be
removed when using a filter back return air grill.
The factory filter should be left in place on a free
return system
Piping | 7EC Series
EC units are supplied with either a copper or
optional cupro-nickel condenser. Copper is
adequate for ground water that is not high in
mineral content.
NOTE: Proper testing is recommended to
assure the well water quality is suitable for use
with water source equipment.
In conditions anticipating moderate scale
formation or in brackish water a cupro-nickel heat
exchanger is recommended.
NOTE: Do not connect discharge ducts
directly to the blower outlet.
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 duct work,
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 duct work should be installed. Check
for existing leaks and repair.
The duct system and all diffusers should be sized
to handle the designed air flow 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.
NOTE: Both the supply and discharge water
lines will sweat if subjected to low water
temperature. These lines should be insulated to
prevent damage from condensation.
All manual flow valves used in the system must be
ball valves. Globe and gate valves must not be used
due to high pressure drop and poor throttling
characteristics.
NOTE: Never exceed the recommended
water flow rates as serious damage or
erosion of the water-to-refrigerant heat
exchanger could occur.
Always check carefully for water leaks and rECair
appropriately. Units are equipped with female pipe
thread fittings. Consult Unit Dimensional
Drawings. (Pg#33 through Pg#34)
NOTE: Teflon tape sealer should be used when
connecting water piping connections to the units
to insure against leaks and possible heat
exchanger fouling.
If air noise or excessive air flow are a problem, the
blower speed can be changed to a lower speed to
reduce air flow.
(Refer to ECM motor interface board section in
Figure#11)
PIPING
Supply and return piping must be as large as the
unit connections on the heat pump (larger on long
runs).
NOTE: Never use flexible hoses of a smaller
inside diameter than that of the fluid
connections on the unit.
NOTE: Do not overtighten the connections.
Flexible hoses should be used between the unit
and the rigid system to avoid possible vibration.
Ball valves should be installed in the supply and
return lines for unit isolation and unit water flow
balancing.
ELECTRICAL
Refer to electrical component box layout.
(Figure#10)
WARNING: Field wiring must comply
with local and national electric codes.
T111970289 (2015/01)EC Series
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