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Bosch ES025 Installation And Maintenance Manual

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ES Series Heat Pump
ES025 | ES035 | ES049 | ESO61 | ES071
Installation and Maintenance Manual

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  Summary of Contents for Bosch ES025

  • Page 1 ES Series Heat Pump ES025 | ES035 | ES049 | ESO61 | ES071 Installation and Maintenance Manual...
  • Page 2: Table Of Contents

    ES Series CONTENTS Troubleshooting.............. 25 Model Nomenclature............3 Electronic Thermostat Installation ........29 Initial Inspection..............4 Operating temperatures and Pressures......30 General Description............4 Wiring diagrams.............. 35 Moving and Storage............4 Notes ................39 Location................4 INSTALLATION ..............5 MOUNTING VERTICALLY..........5 MOUNTING HORIZONTALY..........5 HANGING BRACKET KIT..........6 CONDENSATE DRAIN ............7 Duct System..............7 Piping ................8 Electrical ................8...
  • Page 3: Model Nomenclature

    ES Series Model Nomenclature | 3 MODEL NOMENCLATURE Figure # 1 ES Series T111970291 (2015/01)
  • Page 4: Initial Inspection

    4 | Initial Inspection ES Series INITIAL INSPECTION WARNING: 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. WARNING: Before performing service or maintenance operations on the system, turn off main power to the unit.
  • Page 5: Moving And Storage

    ES Series Moving and Storage | 5 INSTALLATION NOTE: 50° Minimum Entering Water MOUNTING VERTICALLY Temperature (EWT) for well water applications Vertical units up to six tons are available in left or with sufficient water flow to prevent freezing. right air return configurations. Vertical units Antifreeze solution is required for all closed loop should be mounted level on a vibration absorbing applications.
  • Page 6: Hanging Bracket Kit

    6 | Hanging Bracket Kit ES Series 2. Mount 4 Brackets to unit corner post using the bolts provided in the kit as shown on Figure#6. NOTE: IF unit is located in a crawl space, the bottom of the unit MUST be at least 4” above WARNING: Do not re-use screws removed grade to prevent flooding of the electrical parts from the unit on step 1 to mount the...
  • Page 7: Condensate Drain

    ES Series CONDENSATE DRAIN | 7 CONDENSATE DRAIN DUCT SYSTEM If equipped with float style condensate Supply air duct and return air duct flanges are overflow switch, final adjustment must be shipped unfolded with unit. made in the field. A supply air outlet collar and return air duct flange A drain line must be connected to the heat pump are provided on all units to facilitate duct and pitched away from the unit a minimum of 1/8”...
  • Page 8: Piping

    8 | Piping ES Series The return air inlet to the heat pump must have at NOTE: Do not overtighten the connections. least one 90 degree turn away from the space return air grille. If air noise or excessive air flow are a problem, the Flexible hoses should be used between the unit blower speed can be changed to a lower speed to and the rigid system to avoid possible vibration.
  • Page 9: Ecm Interface Board

    ES Series Thermostat Connections | 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 Electronic Commutated Motor (ECM) DC fan motor and...
  • Page 10 Heater COOL/ Model Cool/ Cool/ EMERG PLUS MINUS HEAT/ Only Heat Heat Heat Heat DELAY ES025 ES035 1200 1200 1200 1400 1000 ES049 1000 1600 1600 1600 1800 1400 ES061 1200 1400...
  • Page 11: Safety Devices And The Upm Controller

    ES Series Safety Devices and the UPM Controller | 11 SAFETY DEVICES AND THE UPM • High pressure switch located in the refrigerant discharge line and wired across the HPC CONTROLLER terminals on the UPM • Low pressure switch located in the unit refrigerant suction line and wired across terminals LPC1 and LPC2 on the UPM.
  • Page 12 12 | Safety Devices and the UPM Controller ES Series If 24 VAC output is needed R must be wired to UPM DIP SWITCH DEFAULT POSITION ALR-COM terminal; 24 VAC will be available o the ALR-OUT terminal when the unit is in the lockout alarm condition.
  • Page 13 ES Series Safety Devices and the UPM Controller | 13 • L.E.D. FAULT INDICATION: Two L.E.D. indicators are provided: Green: Power L.E.D. indicates 18-30 VAC present on board. Red: Fault indicator with the following blink codes; 1 - High Pressure Lockout 2 - Low Pressure Lockout 3 - Freeze Sensor Lockout 4 - Condensate Overflow...
  • Page 14: Upm Sequence Of Operation

    14 | UPM Sequence of Operation ES Series UPM SEQUENCE OF OPERATION START RESET ON R RESET ON R = 24VAC Y1 = ON POWER/ SWITCHES/SENSOR CLEAR FAULTS STATUS CHECK BLINK CODE ON STATUS LED SOFT LOCKOUT COUNTER V > 18VAC RECORD ALARM NEEDED? START COUNTER (IF APPLICABLE)
  • Page 15: Electric Heater Package Option

    Heater Model Model Heater AMPS Circuit Max. Fuse Min. 208V 240V 208V 240V 208V 240V ES025 thru 035 HP050-1XS 17.3 20.0 L1/L2 27.1 30.4 ES049 thru 071 HP050-1XM 17.3 20.0 L1/L2 27.1 30.4 ES049 thru 071 HP100-1XM 34.7...
  • Page 16: Heat Recovery Package

    16 | Heat Recovery Package ES Series HEAT RECOVERY PACKAGE 3. Close cold water inlet valve to water heater tank. The Heat Recovery Package (HRP) is a factory 4. Drain tank by opening drain valve on the mounted option. It consists of a forced pumped bottom of the tank, then open pressure relief unit that employs a circulating pump to move water through a double wall/vented heat...
  • Page 17: Water Tank Refill

    ES Series Water Tank Refill | 17 WATER TANK REFILL Initial Start-Up 1. Open the cold water supply to the tank. NOTE: Make sure all valves in heat recovery 2. Open a hot water faucet to vent air from the water piping system are open.
  • Page 18: Sequence Of Operation

    18 | Sequence of Operation ES Series SEQUENCE OF OPERATION APPLICATION CONSIDERATIONS Cooling Mode Well Water Systems Energizing the “O” terminal energizes the unit reversing valve in the cooling mode. The fan motor NOTE: In well water applications a slow starts when the “G”...
  • Page 19: Installation Of Pressure Regulating Valves

    ES Series Installation of Pressure Regulating Valves | 19 Figure # 18 [1] Line voltage disconnect (unit) A refrigerant tap is provided in the refrigerant line located between the reversing valve and the water- [2] Flex duct Connection to-refrigerant heat exchanger for proper [3] Low voltage control connection monitoring of the refrigerant pressures.
  • Page 20 20 | Cooling Tower/Boiler Systems ES Series When utilizing open cooling towers, chemical installed in the supply and return lines for unit water treatment is mandatory to ensure the water isolation and unit water flow balancing. Pressure/ is free from corrosive elements. A secondary heat temperature ports are recommended in both exchanger (plate frame) between the unit and the supply and return lines for system flow balancing.
  • Page 21: Geothermal (Earth-Coupled) Systems

    ES Series Cooling Tower/Boiler Systems | 21 Geothermal (Earth-Coupled) Systems installation easy. Anti-freeze solutions are utilized when low evaporating conditions are expected to Closed loop and pond applications require occur. Refer to the GLP installation manuals for specialized design knowledge. No attempt at these more specific instructions.
  • Page 22: System Checkout

    22 | System Checkout ES Series SYSTEM CHECKOUT UNIT START-UP After completing the installation, and before 1. Set the thermostat to the highest setting. energizing the unit, the following system checks 2. Set the thermostat system switch to “COOL”, should be made: and the fan switch to the “AUTO”...
  • Page 23 ES Series Maintenance | 23 3. Lubrication of the blower motor is not required, however may be performed on some motors to extend motor life. Use SAE-20 non- detergent electric motor oil. 4. The condensate drain should be checked annually by cleaning and flushing to insure proper drainage.
  • Page 24: Unit Check-Out Sheet

    Auxiliary Heat Unit Make __________________________________ Model Number: ______________________________ Serial Number _____________________________ Max Fuse Size (Amps) _______________________ Volts / Amps _______________________________ Bosch Group Entering Air Temperature _____________________ 601 NW 65th Court Leaving Air Temperature ______________________ Fort Lauderdale, FL 33309 MAIL TO: Phone: (954) 776-5471 Bosch.Fhp.TechSupport@us.bosch.com...
  • Page 25: Troubleshooting

    ES Series troubleshooting | 25 TROUBLESHOOTING UPM Board LED Indications NOTE: Troubleshooting Information Indication Solution column may reflect a possible Color Blinks Description fault that may be one of, or a GREEN Solid 18-30 VAC Power is present combination of causes and solutions. Check each cause and adopt “process High pressure lockout of elimination”...
  • Page 26 26 | troubleshooting ES Series Unit Troubleshooting Problem Possible Cause Checks and Correction UNIT OFF ON Discharge In “COOLING” mode: Lack of or inadequate water flow. Entering water HIGH PRESSURE pressure too high temperature is too warm. Scaled or plugged condenser. In “HEATING” CONTROL mode: Lack of or inadequate air flow.
  • Page 27 ES Series troubleshooting | 27 Compressor Ohms Model Start Winding Run Winding ES025 1.64 ES035 1.52 0.88 ES049 1.86 0.52 ES061 1.63 0.39 ES071 1.85 0.34 Tolerance +/- 7%. All resistance values must be measured with compressor at room temperature.
  • Page 28 28 | troubleshooting ES Series Comfort Alert Module -Flash Codes Status LED Status LED Description Status LED Troubleshooting Information Solution YELLOW "ALERT” Open Start Circuit 1. Run capacitor has failed (may not be bad, verify) FLASH CODE 6 Current only in run 2.
  • Page 29: Electronic Thermostat Installation

    ES Series Electronic Thermostat Installation | 29 ELECTRONIC THERMOSTAT INSTALLATION Position the thermostat subbase against the wall so that it is level and the thermostat wires protrude through the middle of the subbase. Mark the position of the subbase mounting holes and drill holes with a 3/16-inch bit.
  • Page 30: Operating Temperatures And Pressures

    14-17 18-20 98-122 291-356 20-23 50° 124-151 204-250 19-22 110-130 298-364 21-24 134-163 249-305 13-16 17-20 112-136 304-372 8-10 22-26 ES025 60° 128-156 233-287 18-21 117-143 312-381 23-28 Part 138-168 281-341 13-16 17-19 124-152 318-389 9-11 24-29 Load 70° 133-161...
  • Page 31 ES Series | 31 Operating Temperatures and Pressures COOLING HEATING 73-89 266-325 15-18 30° 77-94 272-333 16-19 117-143 189-231 14-17 18-22 86-105 279-341 17-21 40° 112-137 178-217 19-24 90-110 286-350 18-22 126-154 221-270 14-17 18-21 105-125 293-358 20-24 50° 121-148 207-253 19-23 109-130...
  • Page 32 32 | ES Series Operating Temperatures and Pressures COOLING HEATING 64-78 248-303 15-18 30° 67-82 254-311 16-19 109-134 183-224 18-22 19-23 75-91 261-319 17-21 40° 105-128 172-210 10-12 20-25 79-96 267-327 18-23 118-144 214-261 18-22 19-23 78-90 273-334 8-10 20-24 50°...
  • Page 33 ES Series | 33 Operating Temperatures and Pressures COOLING HEATING 68-84 256-313 19-23 30° 73-89 261-319 20-25 113-138 172-210 18-22 19-23 81-99 277-339 22-26 40° 110-134 161-196 12-14 20-24 86-105 283-346 23-28 116-142 206-252 17-21 19-23 93-114 299-365 24-29 50° 112-137 193-236 12-14...
  • Page 34 34 | ES Series Operating Temperatures and Pressures COOLING HEATING 71-87 259-316 19-23 30° 16.0 76-92 264-322 20-25 116-141 175-213 18-22 19-23 84-102 280-342 22-26 40° 16.0 113-137 164-199 12-14 20-24 89-108 286-349 23-28 119-145 209-255 17-21 19-23 96-117 302-368 24-29 50°...
  • Page 35: Blower Performance Data

    ES Series Blower performance data | 35 BLOWER PERFORMANCE DATA Constant Airflow ECM Motor Models Rated External Static Pressure (in of Water) Speed Airflow Adjust 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 025- Part Load Normal 025- Full Load Normal 1200 1200...
  • Page 36: Wiring Diagrams

    36 | Wiring diagrams ES Series WIRING DIAGRAMS Figure # 23 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. T111970291 (2015/01) Subject to change without prior notice ES Series...
  • Page 37 ES Series Wiring diagrams | 37 Figure # 24 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. ES Series T111970291 (2015/01)
  • Page 38 38 | Wiring diagrams ES Series Figure # 25 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. T111970291 (2015/01) Subject to change without prior notice ES Series...
  • Page 39: Notes

    ES Series Wiring diagrams | 39 Figure # 26 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. ES Series T111970291 (2015/01)
  • Page 40 40 | Wiring diagrams ES Series Figure # 27 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. T111970291 (2015/01) Subject to change without prior notice ES Series...
  • Page 41 ES Series Wiring diagrams | 41 Figure # 28 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. ES Series T111970291 (2015/01)
  • Page 42 42 | Wiring diagrams ES Series Figure # 29 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. T111970291 (2015/01) Subject to change without prior notice ES Series...
  • Page 43 ES Series Wiring diagrams | 43 Figure # 30 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. ES Series T111970291 (2015/01)
  • Page 44 44 | Wiring diagrams ES Series Figure # 31 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. T111970291 (2015/01) Subject to change without prior notice ES Series...
  • Page 45 ES Series Wiring diagrams | 45 Figure # 32 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. ES Series T111970291 (2015/01)
  • Page 46 46 | Notes ES Series NOTES T111970291 (2015/01) Subject to change without prior notice ES Series...
  • Page 47 ES Series Notes | 47 ES Series T111970291 (2015/01)
  • Page 48 Bosch Thermotechnology Corp 555 NW 65th Court Ft. Lauderdale, FL 33309 Phone: 954-776-5471 | Fax: 954-776-5529 www.bosch-climate-us Revised: 01/2015...

This manual is also suitable for:

Es049Es035Eso61Es071