Bosch DDC KIT User manual

Installation and Operation Manual DDC KIT

8 733 900 571

Revised 05-11

8 733 900 571

Revised 05-11 Subject to change without prior notice

TABLE OF CONTENTS

THE ZONE CONTROLLER............................................................................. 4

SPECIFICATIONS ........................................................................................ 4

INSTALLATION PROCESS ........................................................................... 5

Mounting Holes........................................................................................ 5

Install Sensors ......................................................................................... 5

Routing Wire Harness .............................................................................. 6

DDC Wiring Diagrams .................................................................................. 8

For use with TW Models........................................................................... 8

For use with BP, CP, CE and TA models .................................................... 9

Table of Contents DDC KIT 3

Subject to change without prior notice Revised 05-11

8 733 900 571

THE ZONE CONTROLLER

The Digital Direct Control board also known as DDC

and shown in Figure #1 is used in most congure to

order applications.

It is BACnet® native which makes it exible and easy

to integrate into existing Building Automation

Systems (BAS). The controller provides the end user

with a superior amount of information when

compared to a traditional thermostat.

The controller is programmed in the factory with

software versions that suit the different application

for the models offered by Bosch. User settings such

as the time and schedules can be preprogrammed or

also change during the installation of the product.

SPECIFICATIONS

Power: 24VAC ± 10%, 50-60Hz, 20VA power

consumption (Single Class II 70VA or 100VA option

available)

Physical: Rugged plastic housing protects circuitry.

Environmental Operating Range: 40° to 130°F (-17.8°

to 54.4°C); 10 to 90% relative humidity, non-

condensing

Figure #1 - Zone Controller

Digital Outputs: Five digital outputs relay contacts

rated at 1A resistive @ 24VAC; congured as dry

contact, normally open.

Universal Inputs: 8 inputs. Inputs 1 and 2 are

congurable for 0-5VDC, 10K ohm thermistor, or

dry contact; inputs 3 and 4 support thermistor or

dry contact only; inputs 5 and 6 support

thermistor, dry contact, or LogiStat.

Standard Communication Ports:

Comm Port: 3-pin port congurable for ARC156

(BACnet-over- ARC156) or EIA-

485communications (BACnet MS/TP, Modbus

RTU, orN2).

Rnet Port: 4-pin port for interface with remote

mounted BACview6 or RS sensors

Local Access Port: For local communication with a

laptop computer running WebCTRL or for

communication with a BACview6.

Status Indication: Visual (LED) status of network

communication, running, errors, power, and all

digital outputs

Battery: Lithium 3V coin cell battery, CR2032, provides

a minimum of 10,000 hours of Data retention

during power outages

Protection: Surge and transient protection circuitry for

power and communications.

Listed by: FCC Part 15 - Subpart B - Class A. Pending

listings at the time of publishing this document: UL

916 (PAZX), cUL C22.2 No. 205-M1983 (PAZX7),

CE (1997).

Weight: 0.6 lbs. (0.27 Kg).

Overall Dimensions: 5-1/16” (width) by 5-11/16”

(height) by 1-1/2” (recommended panel depth).

129mm (width) by 144mm (height) by 38mm

(recommended panel depth).

Mounting Hole Dimensions: Two mounting holes

center line as at left with 5-9/16” (141mm)

Spacing (height)

4 DDC KIT The Zone Controller

8 733 900 571

Revised 05-11 Subject to change without prior notice

Use provided wire tie to secure sensor to strap.

Fasten screw by using a screw driver. Do not use a

drill as it may strip the screw.

Remove cork insulation and route sensor wire leads

to electrical box along with existing wires through

knock out available on blower divider panel as

shown in Figure #2.

To install second sensor on condenser water coil,

remove insulation tape from top pipe near the

corner post of the water coil and place sensor as

shown in Figure #4.

Use provided wire ties to secure sensor to coil pipe

as shown in Figure #5.

Use provided cork insulation tape to cover sensor

completely.

Use provided insulation tape to cover both pipe

and sensor as shown in Figures #6 and #7

respectively.

Finally Route sensor wire leads into unit electrical

box.

Separate and identify sensors wire leads for

harness connection later.

X 1 Evaporator Coil

Figure #3 - Discharge Air Temperature (DAT) location

INSTALLATION PROCESS

Mounting Holes

Controller shall be installed on the right side of unit;

mounting holes are available on DDC panel behind

the electrical box as shown in Figure #2.

The DDC kit includes all components required for

the installation.

Follow these steps to mount controller on the side

of the unit:

• Align controller with pilot holes as shown in

Figure #2.

• Secure controller to unit by using (#10)

provided screws.

For Horizontal units remove DDC panel and install

sensors rst as directed in the Install sensors

section of this manual.

Install Sensors

The two provided sensor must be installed in the

blower housing and the condenser water coil

respectively.

Drill a pilot hole on blower assembly (as shown in

Figure #3) to secure sensor with provided screw

and strap. It is recommended to use a 9/64”

diameter metal bit.

Use provided plastic strap and screw to secure

discharge air temperature sensor (metal portion) to

blower housing as shown in Figure #3.

X 1

Optonal

Installation—

Protection

Cover

DDC

Panel

Divider

Panel

DDC

Harness

Figure #2 - DDC Mounting Location

Installation Process DDC KIT 5

Subject to change without prior notice Revised 05-11

8 733 900 571

Wire ties securing sensor to pipe

Routing Wire Harness

Rout wire harness through unit corner post and

assure wires are inside unit electrical box. Terminate

DDC digital output wires on unit terminal block

according to the provided DDC wiring diagram. On

units with ECM interface board cut provided

terminals and connect wires on ECM control board

as shown on Figure #9

Terminate DAT and LWT sensors according to DDC

wiring diagram.

Terminate DDC digital input 4 wires on Unit

Protection Module (UPM) alarm contact by using the

Dry and Hot contacts of the UPM. Set UPM jumper to

dry and the DIP switch to pulse.

6 DDC KIT Routing Wire Harness

Figure #4 - Leaving Water Temperature Location

Figure #5 - Leaving Water Sensor with wire ties

Caution

Avoid sharp edges on unit cabinet during

installation

Caution

Sensor must be on a clean surface of the

metal portion of coil

Figure #6 - Sensor with insulating tape

Sensor Insulating tape

Figure #7 - Final Sensor installation

Pipe Insulating tape

C C

C GRY

CONNECTION BLOCK

THERMOSTAT

T2L2

TRANSFORMER

CONTACTOR

COMPRESSOR

GRN

G/Y

WHT

BLK

ALR

DRY HOT

ALR

C-GND

COND

FREEZE

HPC HPC

LPC1

Y Y

CCRRDRY HOT

LPC2

POWER

UNIT PROTECTION MODULE

STATUS

FREEZE NO YES

TEMP 35F 15F

LOCKOUT 4 2

RESET R Y

ALARM CONT PULSE

TEST YES NO

TRANSFORMER

PRIMARY LEADS

LEADS FROM

BLOWER MOTOR

ORG

RED

BLK

ORG

RED

FROM DDC CONTROL

BLK

BLU

RED

ORG

YEL

BRW

WHT

Figure #8 - DDC Termination BP-CP Models

8 733 900 571

Revised 05-11 Subject to change without prior notice

Terminate/mate male terminals from DDC harness

with female terminals from the sensors, Discharge

Air Temp Sensor mates to the purple set of wires, and

the Leaving Water Temp Sensor mates to the white set

of wires. Roll excess wires and use wire tie to secure

to DDC harness. Finally, to conclude installation of

DDC, install room sensor close to unit’s return air

stream, use four (4) conductor cable and rout to

connect sensor to controller’s R-net port as shown

on unit wiring diagram.

Although the images of this document are a good

representation of the unit electrical layout the

installer must refer to the DDC and unit wiring

diagrams as the ultimate guide for electrical

reference. This installation shall be performed by a

trained and/or certied HVAC/Electrical technician.

Data plate included in package to be placed to the

right of the data plate of the unit

DDC Termination CE-TA Models DDC KIT 7

T2L2

TRANSFORMER

ECM MOTOR

INTERFACE BOARD

CONTACTOR

COMPRESSOR

RED

ORG

RED

BLK

ECM MOTOR

POWER HARNESS

GRN

G/Y

WHT

BLK

ALR

DRY HOT

ALR

C-GND

COND

FREEZE

HPC HPC

LPC1

Y Y

CCRRDRY HOT

LPC2

POWER

UNIT PROTECTION MODULE

STATUS

FREEZE NO YES

TEMP 35F 15F

LOCKOUT 4 2

RESET R Y

ALARM CONT PULSE

TEST YES NO

CADM

COMFORT ALERT

DIAGNOSTIC MODULE

TRANSFORMER

PRIMARY LEADS

FROM DDC CONTROL

BLU

RED

YEL

WHT

BLK

ORG

BRW

PUR

DELAY

ADJUST

COOL

HUMC1NCW1EM

G O

Y2 Y1

CFM

HEAT

C1 (RCom)

DEHUMIDIFY

Figure #9 - DDC Termination CE-TA Models

Subject to change without prior notice Revised 05-11

8 733 900 571

8 DDC KIT DDC Wiring Diagrams

Figure 10: DDC Wiring Diagram

For use with TW models

RY2Y1O

FROM UPM

ALARM OUTPUT

I/O ZONE 560

CONTROLLER

HOT

Gnd

IN-4

24VAC

GND

LED

IN-6

IN-5

Gnd

IN-3

Gnd

IN-2

Gnd

IN-1

+12V

Rnet -

Rnet +

Gnd

Shield

Net -

Net +

DO-5

DO-4

BUS

DO-1

DO-2

DO-3

FHP ORDER #

LINE # - UNIT #

FHP PART #

SW VERSION

2-17-2011

OPTIONAL COMPONENTS:

IN1 - CONTROLLER INPUT 1:

[ ] DIGITAL ENABLE SWITCH (NO)

IN5 - CONTROLLER INPUT 5:

[ ] CTS - CHANGEOVER TEMPERATURE SENSOR

IN6 - CONTROLLER INPUT 6:

[ ] CMS - CONTROL MODE SWITCH ( OFF HEAT/ ON COOL)

IN5

IN1

IN6

STANDARD COMPONENTS:

ELTS - ENTERING LOAD WATER TEMPERATURE SENSOR

LSTS - LEAVING SOURCE WATER TEMPERATURE SENSOR

LSTS

ELTS

DRY HOT

TO BE TERMINATED ON PUMP RELAY (A)

DENOTES FIELD TERMINATED COMPONENTS

UNIT TERMINAL BLOCK

BACnet

MS/TP

NETWORK

FROM UPM ALARM CONTACT

DENOTES OPTIONAL WIRING

Y2 ONLY USED ON TWO STAGE UNITS

8 733 900 571

Revised 05-11 Subject to change without prior notice

DDC Wiring Diagrams DDC KIT 9

Figure 11: DDC Wiring Diagram

For use with BP, CP, CE and TA models

R GY2Y1O

FROM UPM

ALARM OUTPUT

BLACK

WHITE

GREEN

RED

TERMINATION DETAIL

RH SENSORS FOR UNITS

WITH HOT GAS RE-HEAT

OPTION ONLY 3

I/O ZONE 560

CONTROLLER

HOT

Gnd

IN-4

24VAC

GND

LED

IN-6

IN-5

Gnd

IN-3

Gnd

IN-2

Gnd

IN-1

+12V

Rnet -

Rnet +

Gnd

Shield

Net -

Net +

DO-5

DO-4

BUS

DO-1

DO-2

DO-3

FHP ORDER #

LINE # - UNIT #

FHP PART #

SW VERSION

STANDARD COMPONENTS:

DATS - DISCHARGE AIR TEMPERATURE SENSOR

LWTS - LEAVING WATER TEMPERATURE SENSOR

LWTS

DATS

OPTIONAL COMPONENTS:

IN1 - CONTROLLER INPUT 1:

[ ] DE - DIGITAL ENABLE ( NO)

[ ] RHS - RELATIVE HUMIDITY SENSOR

IN5 - CONTROLLER INPUT5:

[ ] DFS - DIRTY FILTER SWITCH

IN6 - CONTROLLER INPUT6:

[ ] RTS - REMOTE TEMPERATURE SENSOR

IN1

IN6

IN5

IN1

2-17-2011

DRY HOT

IN1

Gnd

IN2

Gnd

H TERMINAL IS USED ON REHEAT

APPLICATIONS ONLY

DENOTES FIELD TERMINATED COMPONENTS

UNIT TERMINAL BLOCK

RS SENSOR TERMINATION DETAIL

BACnet

MS/TP

NETWORK

RELATIVE HUMIDITY SENSOR IS ALWAYS

TERMINATED ON INPUT 1 ON UNITS WITH

HOT GAS RE-HEAT OPTION

DENOTES OPTIONAL WIRING

TO DDC

IN 1 AND 2

RED

GREEN

WHITE

BLACK

RS -

SENSOR

FIELD

WIRING

DETAILS

641-241

ELECTRIC HEAT OUTPUT IS NOT AVAILABLE

ON UNITS WITH RE-HEAT OPTION

Subject to change without prior notice Revised 05-11

8 733 900 571

10 DDC KIT Notes

Table of contents

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