Bosch EC 036 -1 VT C - F User Manual

EC SERIES

Table of Contents

Model Nomenclature ..................................................................................................................	1
Introduction....................................................................................................................................	2
Initial Inspection............................................................................................................................	2
General Description.....................................................................................................................	2
Moving and Storage ....................................................................................................................	2
Safety Considerations .................................................................................................................	2
Location............................................................................................................................................	2
Installation.......................................................................................................................................	2
Condensate Drain.........................................................................................................................	3
Duct System....................................................................................................................................	3
Electrical ...........................................................................................................................................	4
Piping ................................................................................................................................................	4
Well Water Systems .....................................................................................................................	5
Cooling Tower / Boiler Application........................................................................................	5
Earth Coupled Systems...............................................................................................................	5
System Checkout ..........................................................................................................................	7
Unit Start-Up...................................................................................................................................	7
Maintenance...................................................................................................................................	8
Operating Pressures & Temperatures ...................................................................................	9
Unit Check-Out............................................................................................................................	16
Trouble Shooting .......................................................................................................................	17

MODEL NOMENCLATURE

EC

036

-1 VT C - F

L

T

SERIES:

EC

NOMINAL CAPACITY:

SUPPLY AIR LOCATION:

T - TOP

VOLTAGE DESIGNATION:

F - FRONT

R - REAR

0

- 115/1/60

S - STRAIGHT THRU

1

- 208/1/60 & 230/1/60

E - END BLOW

2

- 277/1/60

B - BOTTOM

3

- 208/3/60 & 230/3/60

RETURN AIR LOCATION:

4

- 460/3/60

5

- 575/3/60

L - LEFT

CABINET CONFIGURATION:

R - RIGHT

B - BACK

VT - VERTICAL

F - FRONT

HZ - HORIZONTAL

CF - COUNTERFLOW

WATER CONNECTION

HEAT EXCHANGER MATERIAL:

LOCATION:

F - FRONT

C - COPPER

N - CUPRO-NICKEL

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INTRODUCTION:

The EC Series uses scroll and reciprocating compressors and refrigerant R-410A to achieve high efficiency levels, quiet operation and reliable performance.

The new refrigerant provides performance similar to that of R-22 with one major advantage. Refrigerant R-410A is an HFC so it does not contain any ozone depleting HCFC's or CFC's.

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 filing 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:

The EC 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.

The EC Water-to-Air Heat Pumps are Underwriters Laboratories (UL), (CE) and (CUL) listed for safety. The EC Water-to-Air Heat Pumps are designed to operate with entering liquid temperature between 50° F and 100° F. With the extended range option, the heat pump can operate with entering liquid temperatures between 25° F and 110° F.

NOTE: 50° F Min. EWT for well water applications with sufficient water flow to prevent freezing. Antifreeze solution is required for all closed lop applications.

Cooling Tower/ Boiler and Earth Coupled (GeoThermal) applications should have sufficient antifreeze solution to protect against extreme conditions and equipment failure. Frozen water coils are not covered under warranty.

WARNING: 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 required, stack units as follows: Vertical units less than 6 tons, no more than two high. Horizontal units less than 6 tons, no more than three high. “Do not stack units larger than 6 tons.”

EC SERIES

SAFETY CONSIDERATIONS:

CAUTION: R-410A systems operate at higher pressures than standard R-22 systems. Do not use R-22 service equipment or components on R-410A equipment.

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. Untrained personnel can perform basic functions of maintenance such as cleaning coils and replacing filters.

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.

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.

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 water, 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 space. On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. 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.

INSTALLATION:

WARNING: Remove all shipping blocks under blower housing. Loosen compressor mounting bolts.

MOUNTING VERTICAL UNITS:

Vertical units up to five tons are available in left, right, front, or rear 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 #1). Vertical units larger than five tons

(Figure #1)

VIBRATION

PAD

FULL SIZE

(Figure #2)

EC SERIES

should be vibration isolated according to the design engineers specifications.

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 kits (P/N 930-004, or 006). (See Figure #2). The rods must be securely anchored to the ceiling. Refer to the hanging bracket assembly and installation instructions for details. Units larger than six tons include an integral angle iron frame with mounting holes present. (See unit horizontal detail drawing). 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 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 flooding of the electrical parts due to heavy rains.

CONDENSATE DRAIN:

WARNING: 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.

(Figure #3)

This connection must be in conformance with local plumbing codes. A trap must be installed in the condensate line to insure free condensate flow. (Units are not internally trapped). A vertical air vent is sometimes required to avoid

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air pockets. (See Figure #3). 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 unit should be pitched approximately 1/4" towards the drain in both directions, to facilitate condensate removal. (See Figure #4)

(Figure #4)

DUCT SYSTEM:

All EC models are provided with a return air duct flange, while a supply air outlet collar is provided on all models except the 6 thru 12 ton horizontal models to facilitate duct connections. Refer to the individual data specification sheet for physical dimensions of the collar and flange.

A flexible connector is recommended for supply and return air 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 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.

If the unit will be installed in a new installation with new duct work, the installation should be designed using current ASHRAE procedures for duct sizing. If the unit will be connected to an existing duct system, 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 must be installed. Be certain to 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. If air noise or excessive air flow are a problem, the blower speed can be changed to a lower speed to reduce air flow.

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ELECTRICAL:

All field wiring must comply with local and national fire, safety and electrical codes. Power to the unit must be within the operating voltage range indicated on the unit's nameplate. On three phase units, phases must be balanced within 2%.

Properly sized fuses or HACR circuit breakers must be installed for branch circuit protection. See equipment rating plate for maximum size. The unit is supplied with an opening for attaching conduit. Be certain to connect the ground lead to the ground lug in the control box. Connect the power leads as indicated on the unit wiring diagram.

THERMOSTAT CONNECTIONS:

Thermostat wiring is connected to the 5-position (6- position on dual compressor models) low voltage terminal block located in the upper portion of the electrical box. The thermostat connections and their functions are as follows:

C	Transformer 24 VAC Common
O	Reversing Valve (energized in cooling)
Y	Compressor contactor
Y1	1ST stage compressor contractor (dual-
	compressor unit)
Y2	2ND stage compressor contractor (dual-
	compressor unit)
R	Transformer 24 VAC Hot
G	Fan

SAFETY DEVICES AND THE UPM CONTROLLER

Each EC unit is factory provided with a Unit Protection Module (UPM) that controls compressor operation and monitors the safety controls that protect the unit.

Safety controls include the following:

•High pressure switches located in the refrigerant discharge lines. One per refrigeration circuit.

•Low pressure switches located in the unit refrigerant suction lines. One per refrigeration circuit.

•Optional freeze protection sensor located on the leaving side of the water coil prevents unit operation below 35ºF. A freeze stat pin located on the board may be put in the YES or NO position depending whether the freeze stat is ordered.

NOTE: The factory default is in the YES position. If the freeze stat option is not ordered the pin must be relocated to the NO position.

•Optional Condensate overflow protection sensor located in the drain pan(s) of the unit and wired to the UPM board.

The UPM includes the following features:

•ANTI-SHORT CYCLE TIMER – 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.

•LOW PRESSURE BYPASS TIMER - The low pressure switch is bypassed for 120 seconds after compressor

EC SERIES

start-up to prevent nuisance low pressure lockouts during cold start-up in the heating mode.

•BROWNOUT/SURGE/POWER INTERRUPTION PROTECTION – a 20 millisecond window is monitored for the above condition. Should any of these conditions be detected, the 5-minute delay on break timer and the random start timer delay are initiated.

•MALFUNCTION OUTPUT – The controller has a set of wet contacts for remote fault indication.

•TEST SERVICE PIN – A jumper pin is provided to reduce all time delay settings to 5 seconds during troubleshooting or verification of unit operation. Note that operation of the unit in test mode can lead to accelerated wear and premature failure of the unit.

•L.E.D. FAULT INDICATION – Two L.E.D. indicators are provided as follows:

•GREEN: Power L.E.D. indicates 18 – 30 VAC present at the board.

•RED: Fault indicator with blink codes as follows:

SINGLE COMPRESSOR UNITS (UPM-I)

	One blink	High pressure lockout
	Two blinks	Low pressure lockout
	Three blinks	Freeze sensor lockout
	Four blinks	Condensate overflow
	Five blinks	Brownout Conditions
	DUAL COMPRESSOR UNITS (UPM-II)
	One blink	1st Stage high pressure
		lockout
	Two blinks	1st Stage low pressure lockout
	Three blinks	2nd Stage high pressure
		lockout
	Four blinks	2nd Stage low pressure
		lockout
	Five blinks	Freeze Protection lockout
	Six blinks	Condensate overflow lockout

•INTELLIGENT RESET - If a fault condition is initiated the 5 minute delay on break time period and the random start timer are initiated and the unit will restart after these delays expire. During this period the fault LED will indicate the cause of the fault. If the fault condition still exists or reoccurs before one hour, the unit will go into a hard lockout and requires a manual lockout reset. A condensate overflow fault will cause the unit to go into a hard lockout immediately.

•LOCKOUT RESET - A hard lockout can be reset by turning the unit thermostat off and then back on or by shutting off unit power at the circuit breaker.

NOTE: The blower motor will remain active during a lockout condition.

PIPING:

Supply and return piping must be as large as the unit connections on the heat pump (larger on long runs). Never use flexible hoses of a smaller inside diameter than that of

EC SERIES

the water connections on the unit. 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. Should your well driller express concern regarding the quality of the well water available or should any known hazards exist in your area, we recommend proper testing 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.

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. Never exceed the recommended water flow rates. Serious damage or erosion of the water to refrigerant heat exchanger could occur.

Always check carefully for water leaks and repair appropriately. Units are equipped with female pipe thread fittings. Consult the specification sheets for sizes. Teflon tape sealer should be used when connecting water piping connections to the units to insure against leaks and possible heat exchanger fouling. 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.

Pressure/temperature ports are recommended in both the supply and return lines for system flow balancing. The water flow can be accurately set by measuring the water- to-refrigerant heat exchangers water side pressure drop. See the unit specification sheets for the water flow and pressure drop information.

CAUTION: Water piping exposed to extreme, low ambient temperatures is subject to freezing.

WELL WATER SYSTEMS: (50° F EWT Min.)

(Figure #5)

When a water well is used exclusively for supplying water to the heat pump, the pump should operate only when the heat pump operates. A 24 volt, double pole single throw (DP/ST) contactor can be used to operate the well pump with the heat pump.

When two or more units are supplied from one well, the pump can be wired to operate independently from either unit. Two 24-volt double pole single throw relays wired in parallel are required. An upsized VA transformer may be required in either case.

The discharge water from the heat pump is not contaminated in any manner and can be disposed of in various ways depending on local codes (i.e. discharge well, dry well, storm sewer, drain field, stream, pond, etc.)

COOLING TOWER / BOILER APPLICATION:

(Figure #6)

To assure adequate cooling and heating performance, the

5

cooling tower and boiler water loop temperature should be maintained between 50°F to 75°F in the heating mode and 60°F to 110°F in the cooling mode. In the cooling mode, heat is rejected from the unit into the water loop. A cooling tower provides evaporative cooling to the loop fluid; thus, maintaining a constant supply temperature to the unit. When utilizing an open cooling tower, chemical water treatment is mandatory to ensure the water is free of corrosive materials.

A secondary heat exchanger (plate frame between the unit and the open cooling tower) may also be used. It is imperative that all air is eliminated from the closed loop side of the heat exchanger to prevent condenser fouling.

In the heating mode, heat is absorbed from the water loop to the unit. A boiler can be utilized to maintain the loop within the proper temperature range.

No unit should be connected to the supply or return piping until the water system has been completely cleaned and flushed to remove dirt, piping chips or other foreign material. Supply and return hoses should be connected together during this process to ensure the entire system is properly flushed. After the cleaning and flushing has taken place the unit may be connected to the water loop and should have all valves wide open.

EARTH COUPLED SYSTEMS: (Figure #7)

Operation of an EC Series unit on a closed loop application requires the extended range option.

NOTE: Closed loop and pond applications require specialized design knowledge. No attempt at these installations should be made unless the dealer has received specialized training.

Utilizing Ground Loop Pumping Package (GLP), makes the installation easy. Anti-freeze solutions must be utilized when low evaporating conditions are expected to occur. Refer to the installation manuals for more specific instructions.

IN-WARRANTY MATERIAL RETURN:

When contacting your FHP Representative for service or replacement parts, refer to the model and serial number of the unit as stamped on the data plate attached to the unit.

All warranty material returned to the factory for credit must be accompanied by a material return material tag. Enter the information as called for on the tag in order to expedite handling and insure prompt issuance of credits.

Freight charges for all items returned to the factory shall be prepaid.The return of the part does not constitute an order for a replacement. Therefore, a purchase order must be entered through your nearest representative. The order shall include the part number, model number, and serial number of the unit involved. If the part is within the warranty period, and after our inspection of the returned part proves that the failure is due to faulty material or workmanship a credit or replacement part will be issued.

All warranty parts shall be returned freight prepaid to:

FHP Manufacturing Company

601 N.W. 65TH Court • Fort Lauderdale, FL 33309

6

(Figure #5)

EC SERIES

WELL WATER APPLICATIONS

(50°F EWT MIN.)

1.LINE VOLTAGE DISCONNECT

2.FLEX DUCT CONNECTION

3.LOW VOLTAGE CONTROL CONNECTION

4.LINE VOLTAGE CONNECTION

5.VIBRATION PAD

6.P/T PORTS

7.HOSE KITS (Optional)

8.BALL VALVES

9.SOLENOID VALVE SLOW CLOSING

10.CONDENSATE DRAIN CONNECTION

11.PRESSURE TANK (Optional)

NOTE: SEE FIGURE #3 FOR CONDENSATE DRAIN CONNECTION