Bosch Geothermal Heat Pumps Instructions for use

Bosch Geothermal Heat Pumps
For Residential Applications
Applications Manual

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Applications Manual

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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

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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

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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.

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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.

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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

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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

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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

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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