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Bosch Greensource CDi TW Series Installation, Operation And Maintenance Manual

Water-to-water heat pumps
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Greensource CDi Series TW Model Water-to-Water Heat Pumps
Greensource
TW025 | TW035 | TW049 | TW061 | TW122
Installation, Operation, and Maintenance Manual

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  Summary of Contents for Bosch Greensource CDi TW Series

  • Page 1 Greensource CDi Series TW Model Water-to-Water Heat Pumps Greensource TW025 | TW035 | TW049 | TW061 | TW122 Installation, Operation, and Maintenance Manual...
  • Page 2: Table Of Contents

    Greensource CDi Series TW Model CONTENTS Troubleshooting ............... 31 Unit Lockouts ............33 Document Conventions ............3 Electric Data Table .............33 Key to Symbols............3 UPM LED Status Indicator (Blink Code) Information ..33 Safety Warnings..............3 Maintenance ..............34 Model Nomenclature ............4 Decommissioning Information ........... 34 Protecting the Environment .........34 Standard TW Package............5 General Description .............
  • Page 3: Document Conventions

    3 | Document Conventions Greensource CDi Series TW Model DOCUMENT CONVENTIONS Key to Symbols CAUTION: When working on equipment, always observe precautions described in Warnings the literature, tags, and labels attached to Warnings in this document are identified by the unit. Follow all safety codes. Wear a warning triangle printed against a gray safety glasses and work gloves.
  • Page 4: Model Nomenclature

    Greensource CDi Series TW Model Model Nomenclature | 4 MODEL NOMENCLATURE Fig. 1 Model Nomenclature Subject to change without prior notice Greensource CDi Series TW Model 8733954853 (2020/04)
  • Page 5: Standard Tw Package

    5 | Standard TW Package Greensource CDi Series TW Model STANDARD TW PACKAGE MOVING AND STORAGE If the equipment is not needed for immediate installation upon its arrival at the job site, it should be left in its shipping carton and stored in a clean and dry area.
  • Page 6: Unit Installation

    6 | Unit Installation Greensource CDi Series TW Model UNIT INSTALLATION Piping This section contains information on the following: Supply and return piping must be as large as the unit connections on the heat pump (larger on long Subject Page runs).
  • Page 7: Electrical

    Greensource CDi Series TW Model Installation | 7 Always check carefully for water leaks and repair appropriately. Units are equipped with female pipe thread fittings. Consult Unit Dimensional Drawings on page #41 and page #42. Teflon tape sealer should be used when connecting water piping connections to the units to insure against leaks and possible heat exchanger fouling.
  • Page 8: Specific Application Considerations

    8 | Specific Application Considerations Greensource CDi Series TW Model SPECIFIC APPLICATION pressure must always be maintained in the heat exchanger. This can be accomplished with either a CONSIDERATIONS control valve or a bladder-type expansion tank. Well Water Systems When using a single water well to supply both domestic water and the heat pump, care must be Copper is adequate for ground water that is not taken to ensure that the well can provide sufficient...
  • Page 9: Cooling Tower/Boiler Systems

    Greensource CDi Series TW Model Specific Application Considerations | 9 Cooling Tower/Boiler Systems No unit should be connected to the supply or return piping until the water system has been The cooling tower and boiler water loop completely cleaned and flushed to remove any dirt, temperature is usually maintained between 50°F piping chips, or other foreign material.
  • Page 10 10 | Specific Application Considerations Greensource CDi Series TW Model This diagram shows a typical installation and is for illustration purposes only. Ensure access to Heat Pump is not restricted. Fig. 6 Typical Cooling Tower and Boiler System Setup [1] Ball Valves [6] Vibration Pad [2] Hose Kits [7] Line-Voltage Disconnect...
  • Page 11: Geothermal Systems

    Greensource CDi Series TW Model Specific Application Considerations | 11 Geothermal Systems Closed-loop and pond applications require specialized design knowledge. No attempt at these installations should be made unless the dealer has received specialized training. Using the Ground Loop Pumping Package (GLP), makes the installation easy.
  • Page 12: Post-Installation System Checkout

    (Y2) the second stage (or full-compressor • Bosch recommends the following capacity) is initiated. Once the thermostat is guidelines for wiring between a thermostat satisfied, the compressor shuts down accordingly. and the unit: 18 GA up to 60 foot, 16 GA up to 100 ft and 14 GA up to 140 ft.
  • Page 13: Options

    13 | Options Greensource CDi Series TW Model OPTIONS FIELD-INSTALLED ACCESSORIES Heat Recovery Package (HRP) Pump/Valve Relay The heat recovery package is a factory-installed The field-installed pump relay can be used to option on TW series heat pumps. The HRP can be energize a supply pump or solenoid valve when used to heat potable water during unit operation there is a call for compressor operation.
  • Page 14: Heat Recovery Package (Hrp) Setup

    14 | Heat Recovery Package (HRP) Setup Greensource CDi Series TW Model HEAT RECOVERY PACKAGE (HRP) SETUP NOTICE: All piping from HRP to domestic Water Tank Preparation water tank must be copper. 1. Turn off electrical or fuel supply to the water heater.
  • Page 15: Water Tank Refill

    Greensource CDi Series TW Model Heat Recovery Package (HRP) Setup | 15 Water Tank Refill Initial Start-Up of a HRP System 1. Open the cold water supply to the tank. NOTICE: Make sure all valves in the heat 2. Open a hot water faucet to vent air from the recovery water piping system are open.
  • Page 16: Safety Devices And The Upm Controller

    16 | Safety Devices and the UPM Controller Greensource CDi Series TW Model SAFETY DEVICES AND THE UPM CONTROLLER When a malfunction light is used for TW025, TW035, TW049, and TW061 models are diagnostic purposes, the connection is equipped with the Unit Protection Module (UPM). made at the contact connection...
  • Page 17 Greensource CDi Series TW Model Safety Devices and the UPM Controller | 17 The UPM Board includes the following features: • ANTI-SHORT CYCLE TIMER: 5-minute delay on For Reference break timer to prevent compressor short Only cycling. • RANDOM START: Each controller has an unique random start delay ranging from 270 to 300 seconds on initial power up to reduce the chance of multiple unit simultaneously starting...
  • Page 18 Greensource CDi Series TW Model Safety Devices and the UPM Controller | 18 NOTICE: The freeze sensor will not guard If 24 VAC output is needed, R must be wired against the loss of water. A flow switch is to ALR-COM terminal; 24 VAC will be recommended to prevent unit from running available to the ALR-OUT terminal when the if water flow is lost or reduced.
  • Page 19: Safety Devices And The Upm Ii Controller | 19

    Greensource CDi Series TW Model Safety Devices and the UPM II Controller | 19 SAFETY DEVICES AND THE UPM II CONTROLLER When a malfunction light is used for The TW122 Model is equipped with the Unit diagnostic purposes, the connection is Protection Module II (UPM II).
  • Page 20 Greensource CDi Series TW Model Safety Devices and the UPM II Controller | 20 • LOW-PRESSURE BYPASS TIMER: If the compressor is running and the low-pressure NOTICE: If the unit is employing a fresh switch opens, the controller will keep the water system (no anti-freeze protection), it compressor ON for 120 seconds.
  • Page 21 Greensource CDi Series TW Model Safety Devices and the UPM II Controller | 21 • INTELLIGENT RESET: If a fault condition is initiated, the 5-minute delay on break time NOTICE: Operation of unit in test mode can period is initiated and the unit will restart after lead to accelerated wear and premature these delays expire.
  • Page 22: Water-To-Water Unit Controller

    22 | Water-To-Water Unit Controller Greensource CDi Series TW Model WATER-TO-WATER UNIT CONTROLLER Unit Sensors Bosch water-to-water heat pump controller (US- The unit controller is provided with two sensors: Unit Mounted Controller) offers a low cost, simple Water Sensor solution to the control of the unit. The control is...
  • Page 23: Unit Protection

    Greensource CDi Series TW Model Water-To-Water Unit Controller | 23 Heating Mode Auto-Changeover Mode When the unit is operated in the heating mode and The controller’s auto-changeover mode control the controlled-water temperature is below the set feature will switch from the heating mode to point minus the differential setting, terminal Y1 cooling mode and vice versa based on the setting will close and the unit will operate (first stage...
  • Page 24: Pump Cycling

    Greensource CDi Series TW Model Water-To-Water Unit Controller | 24 Operating Instructions A 120-second time delay is built into the low-pressure switch to avoid nuisance trips with Refer to Fig. 13 on page #22. low-fluid temperatures. While in a soft-lockout User Interface condition the display will show the specific fault (for example LP1) and the “service”...
  • Page 25 Greensource CDi Series TW Model Water-To-Water Unit Controller | 25 LED Indicators Setting Up The Controller Color Indication On unit power up the LED display will show the software version, temperature differential setting HEAT Indicates that the control is with the ability for the user to change it for ten in the HEATING mode seconds then will display “OFF”...
  • Page 26: Low-Temperature Loop Application

    Greensource CDi Series TW Model Water-To-Water Unit Controller | 26 Low-Temperature Loop Application 2. Disconnect the yellow wire labeled A and black wire labeled B. (See Fig. 15) In applications where fluid temperatures may fall below 40 F in a ground water or ground loop °...
  • Page 27: Initial Configuration

    Greensource CDi Series TW Model Water-To-Water Unit Controller | 27 4. Disconnect the yellow wire labeled D and black 6. Leave black wires labeled B and C wire labeled C. (See Fig. 17) disconnected. (See Fig. 15) Fig. 19 Leave B and C Disconnected This completes the Freeze Stat Bypass Field Rework.
  • Page 28 Greensource CDi Series TW Model Water-To-Water Unit Controller | 28 Fifth Display Field Please review all the following steps and enter the values you want to set at each display field to avoid Test mode setting, (DE) delay or (ND) no delay: a time out period while configuring.
  • Page 29: Check-Out Sheet

    Suction / Discharge Temp* Suction Superheat* Entering TXV / Cap Tube Temp* Liquid Subcooling* * Required for Troubleshooting ONLY Bosch Thermotechnology Corp. 65 Grove Street, Watertown, MA 02472 Phone: +1 (800) 283-3787 | Fax: +1 (603) 965-7568 www.bosch-climate.us.com Revised 04/2020...
  • Page 30: Water Quality Table

    30 | Water Quality Table Greensource CDi Series TW WATER QUALITY TABLE Water Quality POTENTIAL Water Characteristic Acceptable Value PROBLEM Copper Cupro-Nickel pH (Acidity/Alkalinity) 7–9 7–9 SCALING Hardness (CaCO , MgCO < 350 ppm < 350 ppm Ryznar Stability Index 6.0–7.5 6.0–7.5 Langelier Saturation Index...
  • Page 31: Troubleshooting

    Greensource CDi Series TW Model Troubleshooting | 31 TROUBLESHOOTING A possible fault may be one or a combination of causes and solutions. Check each cause and verify each before making any conclusion. Unit Troubleshooting Problem Possible Cause Checks and Corrections Power Supply Off Close disconnect, apply power Blown Fuse/Tripped...
  • Page 32 32 | Troubleshooting Greensource CDi Series TW Model Unit Troubleshooting Problem Possible Cause Checks and Corrections Recalculate heating and or cooling loads. If excessive, Unit Undersized possibly adding insulation and shading will rectify the problem. Fluid Flow Check for the lack of adequate fluid flow. Refrigerant Charge Refrigerant charge low causing inefficient operation.
  • Page 33: Unit Lockouts

    Greensource CDi Series TW Model Troubleshooting | 33 Unit Lockouts Periodic lockouts almost always are caused by water flow problems. The lockout (shutdown) of the unit is a normal protective measure in the design of the equipment. If continual lockouts occur call a mechanic immediately and have them check for: water flow problems, water temperature problems.
  • Page 34: Maintenance

    34 | Maintenance Greensource CDi Series TW Model Components MAINTENANCE Many parts in the Heat Pump can be fully WARNING: Before performing service or recycled at the end of the product life. maintenance operations on the system, turn Contact your city authorities off the main power to the unit.
  • Page 35: Wiring Diagrams

    35 | Wiring Diagrams Greensource CDi Series TW Model WIRING DIAGRAMS Fig. 21 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. Subject to change without prior notice 8733954853 (2020/04) Greensource CDi Series TW Model...
  • Page 36 Greensource CDi Series TW Model Wiring Diagrams | 36 Fig. 22 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. Subject to change without prior notice Greensource CDi Series TW Model 8733954853 (2020/04)
  • Page 37 37 | Wiring Diagrams Greensource CDi Series TW Model Fig. 23 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. Subject to change without prior notice 8733954853 (2020/04) Greensource CDi Series TW Model...
  • Page 38 Greensource CDi Series TW Model Wiring Diagrams | 38 Fig. 24 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. Subject to change without prior notice Greensource CDi Series TW Model 8733954853 (2020/04)
  • Page 39 39 | Wiring Diagrams Greensource CDi Series TW Model Fig. 25 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. Subject to change without prior notice 8733954853 (2020/04) Greensource CDi Series TW Model...
  • Page 40 Greensource CDi Series TW Model Wiring Diagrams | 40 Fig. 26 FOR REFERENCE ONLY Actual unit wiring may vary from this example. Always refer to the wiring diagram attached to the unit. Subject to change without prior notice Greensource CDi Series TW Model 8733954853 (2020/04)
  • Page 41: Dimensional Drawings

    41 | Dimensional Drawings Greensource CDi Series TW Model DIMENSIONAL DRAWINGS Fig. 27 Dimensional Drawings Subject to change without prior notice 8733954853 (2020/04) Greensource CDi Series TW Model...
  • Page 42 Greensource CDi Series TW Model Dimensional Drawings | 42 Fig. 28 Dimensional Drawings (TW122) Subject to change without prior notice Greensource CDi Series TW Model 8733954853 (2020/04)
  • Page 43: Terminology

    Greensource CDi Series TW Model Terminology | 43 TERMINOLOGY equivalent performance of a virgin substance, taking into account its intended use. Acronyms COP — Coefficient of Performance. The COP provides a Recovery — Referring to the collection and storage of measure of performance for heat pumps that is fluorinated-greenhouse gases from products (including analogous to thermal efficiency for power cycles.
  • Page 44: Notes

    Greensource CDi Series TW Model Notes | 44 NOTES Subject to change without prior notice Greensource CDi Series TW Model 8733954853 (2020/04)
  • Page 45 Greensource CDi Series TW Model Notes | 45 NOTES Subject to change without prior notice Greensource CDi Series TW Model 8733954853 (2020/04)
  • Page 46 Greensource CDi Series TW Model Notes | 46 NOTES Subject to change without prior notice Greensource CDi Series TW Model 8733954853 (2020/04)
  • Page 47 Greensource CDi Series TW Model Notes | 47 NOTES Subject to change without prior notice Greensource CDi Series TW Model 8733954853 (2020/04)
  • Page 48 Bosch Thermotechnology Corp. 65 Grove Street, Watertown, MA 02472 Phone: +1 (800) 283-3787 | Fax: +1 (603) 965-7568 www.bosch-climate.us.com Revised 04/2020 8733954853...