Bosch DDC KIT User manual

Installation and Operation Manual DDC KIT
8 733 900 571
Revised 05-11

©Copyright 2011 Bosch, Inc All rights reserved

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
X 1
X 1
X 1
X 1
X 1
X 1
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
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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
O
C GRY
CONNECTION BLOCK
THERMOSTAT
T1
T2L2
L1
TRANSFORMER
CONTACTOR
COMPRESSOR
GRN
OR
G/Y
WHT
BLK
ALR
DRY HOT
ALR
C
C-GND
COND
FREEZE
R
G
HPC HPC LPC1 Y Y
CCRRDRY HOT
LPC2
POWER
C
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
OR
RED
BLK
ORG
OR
RED
FROM DDC CONTROL
BLK
BLU
RED
ORG
YEL
BRW
WHT
Figure #8 - DDC Termination BP-CP Models

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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
T1
T2L2
L1
TRANSFORMER
ECM MOTOR
INTERFACE BOARD
CONTACTOR
COMPRESSOR
RED
OR
ORG
ORG
OR
RED
BLK
ECM MOTOR
POWER HARNESS
GRN
OR
G/Y
WHT
BLK
ALR
DRY HOT
ALR
C
C-GND
COND
FREEZE
R
G
HPC HPC LPC1 Y Y
CCRRDRY HOT
LPC2
POWER
C
UNIT PROTECTION MODULE
STATUS
FREEZE NO YES
TEMP 35F 15F
LOCKOUT 4 2
RESET R Y
ALARM CONT PULSE
TEST YES NO
Y
R
C
CADM
COMFORT ALERT
DIAGNOSTIC MODULE
TRANSFORMER
PRIMARY LEADS
FROM DDC CONTROL
BLU
RED
YEL
WHT
BLK
ORG
BRW
PUR
DELAY
ADJUST
COOL
R
HUMC1NCW1EM
G O
Y2 Y1
CFM
HEAT
R
W1
Y2
O
G
Y1
EM
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
C
FROM UPM
ALARM OUTPUT
1
1 2 3
2
3
I/O ZONE 560
CONTROLLER
HOT
Gnd IN-4
24VAC
GND
LED IN-6 IN-5 Gnd 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
TO
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
CH
FROM UPM
ALARM OUTPUT
1
1
2
2
BLACK
WHITE
GREEN
RED
3
TERMINATION DETAIL
RH SENSORS FOR UNITS
WITH HOT GAS RE-HEAT
OPTION ONLY 3
W
4
4
I/O ZONE 560
CONTROLLER
HOT
Gnd IN-4
24VAC
GND
LED IN-6 IN-5 Gnd 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
TO
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