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
EC 036 -1 VT C-F L T
SERIES:
EC
NOMINAL CAPACITY:
VOLTAGEDESIGNATION:
0 - 115/1/60
1 - 208/1/60 & 230/1/60
2 - 277/1/60
3 - 208/3/60 & 230/3/60
4 - 460/3/60
5 - 575/3/60
CABINETCONFIGURATION:
VT - VERTICAL
HZ - HORIZONTAL
CF - COUNTERFLOW
HEAT EXCHANGER MATERIAL:
C - COPPER
N - CUPRO-NICKEL
MODEL NOMENCLATURE
SUPPLY AIR LOCATION:
T - TOP
F - FRONT
R - REAR
S - STRAIGHT THRU
E - END BLOW
B - BOTTOM
RETURN AIR LOCATION:
L - LEFT
R - RIGHT
B - BACK
F - FRONT
WATER CONNECTION
LOCATION:
F - FRONT
2
EC SERIES
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.
SAFETY CONSIDERATIONS:
CAUTION
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.
: R-410A systems operate at higher pressures
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:
WARNI NG:
housing. Loosen compressor mounting bolts.
Remove all shipping blocks under blower
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.
WA RN ING: 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.”
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
EC SERIES
3
should be vibration isolated according to the design
engineers specifications.
MOUNTING HORIZONTAL UN ITS:
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.
(Figure #2)
CONDENSATE DRAIN:
WA RN ING:
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.
If equipped with float style condensate
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.
(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
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.
4
EC SERIES
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 (6position 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.
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
Two blinks 1st Stage low pressure lockout
Three blinks
Four blinks
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.
1st Stage high pressure
lockout
2nd Stage high pressure
lockout
2nd Stage low pressure
lockout
NOTE: The blower motor will remain active during a
lockout condition.
–
• RANDO M 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
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
5
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 waterto-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.
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.
NO TE : 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.
WELL WATER SYS TEMS: (50° F E WT 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
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
EC SERIES
(Figure #5)
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
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