Bosch DDC Field Installation Guide for Water-to-Air Units

Introduction

This manual provides information for installing the FHP 560 and FHP 583 Control Boards, also known as the DDC, on commercial, water-to-air units in the field.

Safety Precautions:

• 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.
• Before performing service or maintenance, turn off the 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.

Unpacking and Inspection

Unpack the DDC kit and inspect the contents per Table 1. If any part of the kit appears damaged or missing, or if additional components are required (per Table 2), do not attempt to install the kit. Contact your local distributor for assistance.

Table 1: Kit Contents List

Table 1 (Continued): Kit Contents List

Table 2: Optional Accessories List

Required Tools and Materials

• 5/16 nut driver
• 9/64 drill bits
• Flat-head screwdriver

Unit Preparation

Follow all Electrical Safety and Lockout Procedures in accordance with local, state, and federal regulations.

1. Remove power from the unit. [!] Adhere to all Electrical Safety and Lockout Procedures.
2. Locate the front side of the Water-to-Air Heat Pump.
3. Remove the front-side panel to expose the electrical box.
4. Locate the Unit Protection Module (UPM) in the electrical box.
5. Verify part numbers as shown in Figure 1 & 2: Single Compressor UPM-I: 8 733 800 259 or Dual Compressor UPM-II: 8 733 800 260.
6. If UPM board(s) part numbers do not match the listed numbers, new UPM Board Kits (Table 2) will need to be ordered.

Figure 1 & 2 Description: These figures show the Unit Protection Module (UPM) boards, identifying the UPM Part Number, Freeze Sensor Contacts, and Alarm Contacts.

Mounting the Controller

The controller is mounted externally to the right-side panel of the Heat Pump. Locations are shown on a typical EC360 per Figure 3.

1. Locate the controller on the right side panel and align the harness with the top access knockout as shown in Figure 4.
2. Mark and drill holes for mounting the controller as indicated in Figure 3.
3. If necessary, assemble the harness onto the controller per the wiring diagram in Figure 6.
4. Use the supplied mounting screws to attach the controller to the right side of the unit.
5. Route the terminated ends of the harness through the top access knockout port (Figure 4) and into the adjacent electrical box.

Figure 3 Description: This diagram shows a water-to-air unit, indicating the electrical box, front-side panel, right-side panel, and the location for mounting the DDC controller using screws, including the top access knockout.

Figure 4 Description: This diagram illustrates the routing of the wire harness from the DDC controller through the top access knockout into the electrical box on the right-side panel of the unit. It notes that the diagram shows the corner post unfolded for clarity.

Terminal Block Connections

Refer to the wiring diagram in Figure 6 for detailed instructions on wiring the various components. Table 5 provides a general guide for connecting labeled wires:

Table 5: Wiring Chart

Wiring Instructions:

1. Inside the electrical box, connect power and signal wires to the corresponding terminal block locations per Figure 6, based on unit options.
2. For DATS and LWTS connections, install the provided thermistors at their respective locations per the chart/table in Figure 5.
3. Route thermistor wires into the electrical box and connect the terminated ends (female) of the thermistor wires to the terminated ends (male) of the corresponding DATS or LWTS leads from the DDC wire harness.

Wiring the Controller

Refer to Figure 6 for controller connection details.

Figure 6 Description: This is a detailed diagram of the DDC controller board, showing terminal blocks for UPM connections (OUT, COM), sensors (DATS, LWTS), and general wiring (C, O, Y1, Y2, R, G, H/W). It also illustrates connections for BACnet, power, and optional cards like the LON Card and Expansion Card. Specific wiring color codes are noted for options like HGRH, electric heater, and economizer.

Installing the Freeze Sensor

If the unit is already equipped with the freeze sensor option, verify sensor location per Figure 7 and skip these steps.

1. Route the provided freeze sensor to the refrigeration line of the water coil (Figure 7).
2. Use the two supplied tie-wraps to mount the sensor (Figure 8).
3. Use the provided cork tape to wrap the sensor (Figure 9).
4. Apply the provided pipe insulating tape to ensure good thermal connection to the sensor (Figure 4).
5. Connect the sensor wires to the UPM board at the locations specified in Figure 1 & 2:
   • For UPM-I units, connect the sensor on the water coil to Freeze 1.
   • For UPM-II units, connect the sensor on the water coil of the first compressor to Freeze 1, and the sensor on the water coil of the second compressor to Freeze 2.

Note: There is no polarity for these wires.

Figure 7 Description: Shows a water coil with the freeze sensor being routed to the refrigeration line, indicating an "old location" and a "relocated freeze sensor" position.

Figure 8 Description: Illustrates the freeze sensor being secured to the pipe using tie-wraps.

Figure 9 Description: Shows the freeze sensor wrapped with cork tape for insulation.

UPM to DDC Alarm Connection

1. Locate the Alarm (ALR) Contacts on the corresponding UPM-I or UPM-II board per Figure 1 & 2.

2. Connect the cables labeled OUT and COM from the DDC wiring harness to the spade connectors labeled OUT and COM on the UPM board.

DDC Wiring Diagrams

Figure 10: DDC Wiring Diagram for FHP 560

This diagram details the wiring for the FHP 560 controller. It includes termination details for remote and RH sensors, CO2 and RH sensors, LWTS, DATS, alarm output, and blower motor/fan status switches. It shows connections to the DDC controller, UPM board, and BACnet MS/TP network. Standard and optional components are listed, with notes on specific terminal usage and field-terminated components.

Figure 11: DDC Wiring Diagram for FHP 583

This diagram details the wiring for the FHP 583 controller. It is similar to the FHP 560 diagram but specific to the FHP 583 model. It includes termination details for sensors, UPM, alarm output, and blower motor/fan status switches, showing connections to the controller, UPM board, and BACnet network. Standard and optional components are listed, with notes on terminal usage and field-terminated components.

Unit Configuration

Figure 12: Unit Configuration - Zone Basic

This schematic diagram illustrates the "Zone Basic" configuration of a water-to-air unit. It shows the airflow path from return air through a filter, heat pump, and to supply air via a supply fan. The diagram highlights the integration of the unit-mounted DDC controller, a reversing valve, and sensors such as the Discharge Air Temperature Sensor (DATS) and Leaving Water Temperature (LWT) sensor. It also indicates control signals for fan enable/disable and compressor enable/disable. Various sensor types (RS-PRO, RS-PLUS, RS-BASE) are shown for zone temperature sensing.

Figure 13: Unit Configuration - Discharge Air Control

This schematic diagram illustrates the "Discharge Air Control" configuration of a water-to-air unit. It is similar to the Zone Basic configuration, showing the airflow path and component integration. The primary focus is on controlling the discharge air temperature, with the DATS sensor playing a key role. It depicts the reversing valve, heat pump, supply fan, and DDC controller, along with control signals for fan and compressor.

Notes

This section is reserved for additional notes and information.