Bosch Geothermal Heat Pumps Instructions for use

Bosch Geothermal Heat Pumps

For Residential Applications

Applications Manual

|Bosch Geothermal Heat Pumps

Bosch Thermotechnology Corp.Data subject to change

Applications Manual

Applications Manual Bosch Geothermal Heat Pumps | 3

Bosch Thermotechnology Corp. Data subject to change

Table of Contents

1 Explanation of symbols 5

2 Introduction 6

3 Residential Bosch Geothermal Heat Pump

System Applications 7

4 Residential Bosch Geothermal Heat Pumps 8

4.1 Bosch Self-Contained (Package) and Split-

System Water-to-Air Heat Pumps 9

4.2 Bosch Water-to-Water Heat Pumps 11

4.3 Bosch Air Handling Unit for the Retrot Market 12

4.4 Bosch Water-to-Air Geothermal Heat Pump

Operation 13

4.5 Bosch Water-to-Air Geothermal Heat Pump

Ratings 15

4.6 Bosch Geothermal Heat Pump

Equipment Sizing 17

5 Ground Heat Exchanger Types 35

6 Open-Loop Geothermal Heat Pump Systems 36

6.1 Open-Loop Geothermal Heat Pump System

Water Quantity 37

6.2 Open-Loop Geothermal Heat Pump System

Water Quality 38

6.3 Open-Loop Geothermal Heat Pump System

Water Disposal 41

6.4 Open-Loop Geothermal Heat Pump System

Design 43

6.5 Water Well Criteria and Terminology 43

6.6 Groundwater Well Pumps 44

6.7 Geothermal Standing Column System 45

7 Closed-Loop Geothermal Heat Pump Systems 46

8 Ground Heat Source or Heat Sink for Closed-Loop

Ground Heat Exchangers 47

9 Closed-Loop Ground Heat Exchanger Design

Considerations 48

9.1 Series or Parallel Congurations 48

9.2 Ground Characteristics 49

9.3 Soil Analysis 49

9.4 Closed-Loop Design Fundamentals 53

9.5 Soil & Groundwater Temperature 54

9.6 Piping 55

9.7 Pipe Fusion Methods 56

9.8 Heat Transfer Fluids (Antifreeze) 58

9.9 Closed-Loop Conguration 60

9.10 Underground Piping Installation Criteria 61

9.11 Closed-Loop Header Design 62

10 Vertical Closed-Loop Ground Heat Exchangers

(Vertical Loops) 64

10.1 Groundwater Effects 65

10.2 Piping Installation and Borehole Alignment 66

10.3 Loop Field Identication 68

10.4 Location of Vertical Closed-Loops 69

10.5 Borehole Construction 70

10.6 Typical Methods Used for Vertical Borehole

Construction 71

10.7 Vertical Borehole Backll 72

10.8 Proper Grouting 73

10.9 Vertical Closed-Loop Grouting

Recommendations 74

10.10 Grout Material 74

10.11 Grouting Procedures 75

11 Horizontal Closed-Loop Ground Heat Exchangers

(Horizontal Loops) 76

11.1 Horizontal - Loop Layout 77

11.2 Trench Safety 81

11.3 “Slinky™” Ground Heat Exchangers 82

11.4 Racetrack Closed-Loop Ground Heat

Exchangers 83

11.5 Horizontal Directional Drilling (HDD)

Closed-Loop Ground Heat Exchangers 84

11.6 Pond and Lake Geothermal Applications 85

12 Residential Structure Pipe Entry/Exit 88

13 Interior Piping 90

14 Ground Loop Pumping Package (GLP) 92

14.1 Flow Centers for Closed-Loop Ground

Heat Exchangers 92

14.2 Pressurized Flow Centers 92

14.3 Non-Pressurized Flow Centers 93

14.4 General Flow Center Criteria 94

15 Closed-Loop Flushing and Purging 95

|Bosch Geothermal Heat Pumps

Bosch Thermotechnology Corp.Data subject to change

Applications Manual

Table of Contents (Continued)

16 Bosch Geothermal Water-to-Water

Heat Pump Applications 98

16.1 Bosch Geothermal Water-to-Water Heat

Pump Components 98

16.2 Bosch Geothermal Water-to-Water Heat

Pump Sizing Criteria 99

16.3 Bosch Geothermal Water-to-Water Heat

Pump and Radiant Floor Heating 100

16.4 Bosch Geothermal Water-to-Water Heat

Pumps and Fan Coil Units/Air Handlers 101

16.5 Bosch Geothermal Water-to-Water Heat

Pump Buffer Tank Application 102

16.6 Bosch Geothermal Water-to-Water Heat

Pump Piping Design 103

16.7 Bosch Geothermal Water-to-Water Heat

Pump Sequence of Operation 104

16.8 Bosch Geothermal Water-to-Water Heat

Pump Piping System Installation 105

17 Bosch Geothermal Heat Pump System

Options 106

17.1 Bosch Cupronickel Coaxial Heat Exchanger 106

17.2 Bosch Heat Recovery Package (HRP) 106

17.3 Bosch Hot Gas Reheat (HGR) 108

17.4 Emerson Comfort Alert™ Diagnostic Module 110

17.6 Differential Pressure Switch 116

17.7 Electric Heat 116

17.8 Sound Package 116

17.9 Soft Start (SecureStart™) 116

18 Bosch Geothermal System Integration 117

18.1 Bosch Geothermal Water-to-Air Heat Pump

and Solar Thermal Water Heating

Integrated Systems 119

18.2 Bosch Geothermal Water-to-Air Heat Pump

and Tankless Water Heating Integrated

Systems 120

18.3 Bosch Geothermal Water-to-Water Heat

Pump and Condensing Gas Boiler

Integrated System 121

19 Bosch Complete - Net Zero Energy Home 122

19.1 Bosch Experience Center at Serenbe

(BECS) Projects 122

Applications Manual Bosch Geothermal Heat Pumps | 5

Bosch Thermotechnology Corp. Data subject to change

1 Explanation of symbols

Warnings

Warnings are indicated in the text by a warning

triangle and a gray background.

Signal words at the beginning of a warning are used to

indicate the type and seriousness of the ensuing risk if

measures for minimizing damage are not taken.

fNOTE indicates that damage to property may occur.

fCAUTION indicates that personal injury may occur.

fWARNING indicates that possible severe personal

injury may occur.

fDANGER indicates that severe personal injury or

death may occur.

Important information

Important information that presents no risk to

people or property is indicated with this symbol.

It is separated by horizontal lines above and below

the text.

WARNING:

Follow each appliances' instructions precisely.

For assistance or further information, contact a

trained and certied installer, service provider, or the

gas licensed plumber or gas tter.

Application drawings in this manual are conceptual

only and do not purport to address all design,

installation, code, or safety considerations.

The diagrams in this manual are for reference use by

code ofcials, designers and licensed installers. It is

expected that installers have adequate knowledge of

national and local codes, as well as accepted industry

practices, and are trained on equipment, procedures,

and applications involved. Drawings are not to scale.

|Bosch Geothermal Heat Pumps

Bosch Thermotechnology Corp.Data subject to change

Applications Manual

2 Introduction

This Applications Manual is intended to present some of

the most common applications of Bosch geothermal heat

pumps for residential applications. Application drawings

are shown with system application schematics where

applicable. Auxiliary equipment depicted represents Bosch

equipment where applicable. There are a wide variety

of techniques, practices and strategies possible when

installing geothermal heat pumps. It is the responsibility of

the installing contractor to determine the best solution for

the particular geothermal heat pump system application.

Bosch geothermal heat pumps, if properly designed and

installed, are one of the most efcient forms of space

heating, as well as space cooling and water heating

available today. In this applications manual, we will provide

a complete review of geothermal heat pump technology,

components and operation, as well as guidance on the

design and installation of ground heat exchangers and

Bosch geothermal heat pump systems for domestic use

(residential). This manual is focused on both contractors

and designers. It provides detailed guidance, focused on

the issues to be considered when selecting systems and

components and estimating system performance.

Although this manual covers many common applications

for our Bosch geothermal heat pumps, system possibilities

are numerous and varied. Should you encounter an

application that is not covered in this manual or have any

questions regarding any of its content, we encourage you

to contact your local sales representative or us directly at

Bosch Thermotechnology Corp.

This Applications Manual is not a substitute for

any of the Bosch geothermal heat pump Installation

and Maintenance manuals. All specications are

subject to change.

Applications Manual Bosch Geothermal Heat Pumps | 7

Bosch Thermotechnology Corp. Data subject to change

3 Residential Bosch Geothermal

Pump System Applications

The application of Bosch geothermal heat pump systems is

increasing rapidly in the residential sector. These systems

offer exceptional efciency because they use the relatively

constant temperature of the earth to heat and cool. Heat

removed from a residential structure during summer

months is collected and then rejected to the earth, then

stored for retrieval during the winter months. As the

earth's ground temperature is typically more moderate

than the outdoor air temperature, the annual energy

efciency is improved. In addition, the stored heat in the

earth can then be absorbed during winter months when

heating is required, and then used to heat the home. As

this heat comes from the ground, it can result in enhanced

savings in fossil fuel consumption and provide a reduction

in the emission of greenhouse gases, as well as other

pollutants.

Today, geothermal heat pump systems are referred to by

several different names. These include geothermal, earth-

coupled, geoexchange, groundwater, ground-coupled,

closed-loop, open-loop, and water-source heat pump

systems, just to mention a few. All geothermal heat pump

systems are an environmentally sound energy alternative.

And, geothermal heat pump systems are becoming more

“price-competitive” with conventional conditioning

systems.

A Bosch geothermal heat pump system (Fig. 1) will consist

of a Bosch geothermal heat pump coupled with a ground

heat exchanger to reject or add heat to the structure as

necessary. The ground heat exchanger may be a “Closed-

loop” system of buried HDPE piping, water pumped from a

groundwater well (”Open-loop” system), or a closed-loop

system in a large body of water. Other hybrid ground heat

exchanger methods also are available.

Fig. 1 Residential geothermal heat pump overview

|Bosch Geothermal Heat Pumps

Bosch Thermotechnology Corp.Data subject to change

Applications Manual

4 Residential Bosch Geothermal

Heat Pumps

Bosch geothermal heat pump systems provide space

heating and cooling, as well as water heating (Fig. 2). A

complete Bosch geothermal heat pump system is dened

as a geothermal unit with all the necessary functional

components, except for installation materials. The Bosch

geothermal heat pump system includes three principal

components (listed below) and as an option, a device

called a heat recovery package, or “desuperheater”, which

can be factory-added to provide domestic hot water when

there is a demand for space heating or cooling with the

Bosch geothermal heat pump system. These optional

devices make use of excess heat during the cooling

cycle and use some of the heat during the heating cycle

to supplement hot water production. Dedicated water

heaters can be added which operate whenever there is a

demand for hot water.

Fig. 2 Residential geothermal heat pump products

fGeothermal earth connection sub-system:

Using the earth as the heat source and heat sink, this

sub-system consists of a series of pipes which are

commonly called a “ground heat exchanger” or “loop”,

or an open well system used to obtain water to pass

through the geothermal heat pump.

fGeothermal heat pump sub-system:

Unit (or units) that exchange heat between the fluid

and the air that conditions the structure.

fDistribution sub-system:

An air-delivery system that delivers the conditioned air

to the structure.

The foundation of any Bosch geothermal heat pump

system is the Bosch geothermal heat pump unit itself. The

most commonly used unit in these systems is the Bosch

self-contained (package) water-to-air heat pump. Bosch

offers split systems as well, which allow the condensing

section (compressor section) to be located remotely from

the air handler section, but still within the structure.

Additionally, Bosch offers a water-to-water geothermal

heat pump for specic applications. These Bosch water-to-

water geothermal heat pumps can heat or chill water

for radiant oor applications, chilled water/fan coil

applications or domestic hot water generation.

The typical Bosch geothermal heat pump consists of a

compressor (rotary or scroll), an air-to-refrigerant coil

(or “air” coil), a bi-directional thermal expansion valve,

a reversing valve, a unit control board, a bi-directional

drier, a water-to-refrigerant coil and various relays and

safety devices. These components comprise the basic

geothermal heat pump refrigerant circuit to transfer heat

to and from the ground to the home (Fig. 3,4,5). All Bosch

geothermal heat pump units are designed for HFC-410A

refrigerant.

Fig. 3

Applications Manual Bosch Geothermal Heat Pumps | 9

Bosch Thermotechnology Corp. Data subject to change

Fig. 4

Fig. 5

Special Bosch geothermal heat pump features can

include two-stage scroll compressors, hermetic rotary

compressors, permanent split capacitor blowers (PSC),

brushless permanent magnet blowers (BPMs), variable

speed electro-commutated blower motors (ECMs),

accumulators and specialized blower control boards

(Motor Control Interface Boards), as well as other options.

4.1 Bosch Self-Contained (Package) and Split-

System Water-to-Air Heat Pumps

Bosch has a variety of choices for self-contained

residential geothermal heat pumps. Multiple air ow

congurations for most any installation are also available.

Several of the Bosch geothermal heat pump offerings

are equipped with an exclusive sound package. The

compressor is surrounded by a multi-density sound blanket

and the units come standard with a provisions to separate

a vibrating compressor from the exterior cabinet. This

arrangement helps by reducing sound and vibration to an

absolute minimum.

4.1.1 Bosch Basic Geothermal Heat Pump Series

Bosch’s Energy Star rated basic series water-to-air

geothermal heat pump is available from ½ ton through 6

tons in either vertical or horizontal congurations (Fig.

6). This single stage geothermal heat pump unit offers

best-in-class energy efciency and lower operating costs,

providing the ultimate value for the money.

Fig. 6 Bosch Basic Geothermal Heat Pump Series

|Bosch Geothermal Heat Pumps

Bosch Thermotechnology Corp.Data subject to change

Applications Manual

4.1.2 Bosch Two-Stage Geothermal Heat Pump Series

For greater performance, Bosch offers an Energy Star

rated water-to-air geothermal ready heat pump equipped

with a two-stage compressor and a variety of superior

standard features (Fig. 7). An Electronically Commutated

Motor (ECM) is factory programmed to vary the air ow

based on full or part load compressor operation, resulting

in additional energy savings of up to 60% and a greater

level of comfort in living areas. All two-stage units in this

series are equipped with a Motor Control Interface Board

(MCI) providing un-parallel blower control. These 2 to 6

ton units are available in vertical, horizontal, counter ow

or split system congurations, providing a modern design

to satisfy every application.

Fig. 7 Bosch Two-Stage Geothermal Heat Pump Series (Self-

Contained)

Fig. 8 Bosch Two-Stage Geothermal Heat Pump Series

(Split System)

4.1.3 Bosch Premium Geothermal Heat Pump Series

The most popular self-contained residential water-to-air

geothermal heat pumps are the Bosch Premium two-stage

series geothermal heat pumps, compliant with Energy

Star Tier 3 criteria (Fig. 9). This luxurious two-stage unit

features improved cost, aesthetics, serviceability, sound,

power and energy efciency, and is available in vertical,

horizontal, counter ow and split system congurations

from 2 to 6 tons. Its energy efciency makes this unit the

best-in-class in operating cost savings. Requiring less

energy compared to other manufacturers, these two-

stage units achieve the same output to cool or heat a

home, helping reduce energy costs. These Bosch Premium

Geothermal Heat Pumps offer eld congurability (air

return and supply discharge) reducing inventory costs,

extremely quiet operation, tin-plated hairpin "air" coils,

closed-cell (ber-free) internal insulation and pre-painted

sheet metal cabinets. An added feature useful to the

contractor is externally mounted fault indication. This

feature communicates unit operation without having to

remove the door to the circuit board, displaying operating

alerts at a glance. This device potentially speeds up

service/diagnostics.

This unit can be serviced entirely from the front, offers

a removable electrical box and a brushless permanent

magnet (BPM) blower, designed similar to variable speed

with similar efciency, but without the programming.

Electronics are "built in" providing better performance VS

External Static Pressure (ESP) compared to other blowers

(PSC).

All in all, this unit provides superior design, durability,

reliability, and indoor air quality.

Fig. 9 Bosch Premium Geothermal Heat Pump

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