Bosch Greensource CDi TW Series Manual de usuario

Installation, Operation, and Maintenance Manual

Greensource CDi Series TW Model Water-to-Water Heat Pumps

Greensource

8733954853 (2020/04)

TW025 | TW035 | TW049 | TW061 | TW122

Greensource CDi Series TW Model

Greensource CDi Series TW Model8733954853 (2020/04)

2 |

Subject to change without prior notice

CONTENTS

Document Conventions .......................................................3

Key to Symbols............................................................ 3

Safety Warnings..................................................................3

Model Nomenclature ...........................................................4

Standard TW Package..........................................................5

General Description ..................................................... 5

Moving and Storage ............................................................5

Initial Inspection.......................................................... 5

Unit Installation ..................................................................6

Location Selection...............................................................6

Installation .........................................................................6

Piping ........................................................................ 6

Electrical .................................................................... 7

Specific Application Considerations .....................................8

Well Water Systems ..................................................... 8

Cooling Tower/Boiler Systems....................................... 9

Geothermal Systems.................................................. 11

Post-Installation System Checkout .....................................12

System Operation .............................................................12

Unit Start-up.....................................................................12

Sequence of Operation ......................................................12

Options ............................................................................13

Heat Recovery Package (HRP) ..................................... 13

Field-Installed Accessories ................................................13

Pump/Valve Relay...................................................... 13

Heat Recovery Package (HRP) Setup..................................14

Water Tank Preparation .............................................. 14

Water Tank Refill........................................................ 15

Initial Start-Up of a HRP System ................................... 15

Safety Devices and the UPM Controller...............................16

Safety Devices and the UPM II Controller ............................19

Water-To-Water Unit Controller .........................................22

Features................................................................... 22

Unit Sensors ............................................................. 22

Modes of Operation ................................................... 22

Unit Protection.......................................................... 23

Pump Cycling............................................................ 24

User Interface ........................................................... 24

Low-Temperature Loop Application.............................. 26

Initial Configuration.................................................... 27

Check-Out Sheet ...............................................................29

Water Quality Table...........................................................30

Troubleshooting ............................................................... 31

Unit Lockouts ............................................................33

Electric Data Table .....................................................33

UPM LED Status Indicator (Blink Code) Information ........33

Maintenance .................................................................... 34

Decommissioning Information ........................................... 34

Protecting the Environment .........................................34

Wiring Diagrams ............................................................... 35

Dimensional Drawings....................................................... 41

Terminology ..................................................................... 43

Acronyms .................................................................43

Terms.......................................................................43

Notes ............................................................................... 44

Greensource CDi Series TW Model

Greensource CDi Series TW Model8733954853 (2020/04)

3 | Document Conventions

Subject to change without prior notice

DOCUMENT CONVENTIONS

Key to Symbols

Warnings

The following keywords are defined and can be

used in this document:

•DANGER indicates a situation that, if not

avoided, will result in death or serious injury.

•WARNING indicates a situation that, if not avoided,

could result in death or serious injury.

•CAUTION indicates a situation that, if not avoided,

could result in minor to moderate injury.

•NOTICE is used to address practices not related to

personal injury.

Important Information

SAFETY WARNINGS

Warnings in this document are identified by

a warning triangle printed against a gray

background. Keywords at the start of the

warning indicate the type and seriousness

of the ensuing risk if measures to prevent

the risk are not taken.

This symbol indicates important

information where there is no risk to

property or people.

IMPORTANT: Read the entire instruction

manual before starting installation.

WARNING: Installation and servicing of this

equipment can be hazardous due to system

pressure and electrical components. Only

trained and qualified personnel should

install, repair, or service the equipment.

WARNING: Before performing service or

maintenance operations on the system, turn

off main power to the unit. Electrical shock

could cause personal injury or death.

CAUTION: When working on equipment,

always observe precautions described in

the literature, tags, and labels attached to

the unit. Follow all safety codes. Wear

safety glasses and work gloves. Use a

quenching cloth for brazing, and place a fire

extinguisher close to the work area.

NOTICE: To avoid the release of refrigerant

into the atmosphere, the refrigerant circuit

of this unit must be serviced only by

technicians who meet local, state, and

federal proficiency requirements.

NOTICE: All refrigerant discharged from this

unit must be recovered WITHOUT

EXCEPTION. Technicians must follow

industry accepted guidelines and all local,

state, and federal statutes for the recovery

and disposal of refrigerants. If a compressor

is removed from this unit, refrigerant circuit

oil will remain in the compressor. To avoid

leakage of compressor oil, refrigerant lines

of the compressor must be sealed after it is

removed.

NOTICE: To avoid equipment damage, DO

NOT use these units as a source of heating

or cooling during the construction process.

Doing so may affect the unit's warranty. The

mechanical components and filters will

quickly become clogged with construction

dirt and debris, which may cause system

damage or failure.

WARNING: This product can expose you to

chemicals including Lead and Lead

components, which are known to the State

of California to cause cancer and birth

defects or other reproductive harm.

For more information go to

www.P65Warnings.ca.gov.

Model Nomenclature | 4Greensource CDi Series TW Model

8733954853 (2020/04)Greensource CDi Series TW Model Subject to change without prior notice

MODEL NOMENCLATURE

Fig. 1 Model Nomenclature

1 2 345

7 8910111213141516171819202122232425262728293031323334353637383940

TW 025

1CSN- F XXXC B - XX GXXXXXX7XXXXXXXXX SSA

SERIES

SIZE

025, 035, 049,

061, 122

VOLTAGE

1 208-230/60/1

CABINET CONFIGURATION

US- UNIT-MOUNTED CONTROLLER

CS- REMOTE CONTROLLED

COAX OPTIONS

C- COPPER

N- CUPRO

NICKEL

WATER CONNECTIONS

F- FRONT

RETURN AIR CONFIGURATION

X- N/A

DISCHARGE AIR CONFIGURATION

X- N/A

FAN/MOTOR OPTIONS

X- N/A

LOAD-SIDE COAX OPTIONS

C- COPPER

REVISION LEVEL

CODE STRING REV LEVEL

STANDARD/SPECIAL

SS- STANDARD

OPEN

BLOWER PULLEY (BELT DRIVE ONLY)

X- N/A

ELECTRIC HEAT

X- NONE

CABINET CONSTRUCTION

K- PRE-PAINTED STEEL/ ½” STANDARD 1.5LB DUAL-DENSITY FIBERGLASS/EQ

APPLICATION

G- EXTENDED RANGE (GEOTHERMAL)

GENERAL ELECTRICAL OPTIONS (UP TO 5 AVAILABLE PER UNIT)

REFRIGERATION CIRCUIT OPTIONS

D- HEAT RECOVERY PACKAGE

X- NONE

MOTOR SHEAVE (BELT DRIVE ONLY)

X- N/A

AIR FILTRATION

X- NONE

ECONOMIZER

X- NONE

WATER FLOW CONTROL OPTIONS

X- NONE

OPEN

CONTROLS

X- STANDARD

TRANSFORMER

7-75 VA

B- CURRENT

SOURCE-SIDE

X- AS DEFAULT FOR NON-USED ELECTRICAL CODES

OPEN

Greensource CDi Series TW Model

Greensource CDi Series TW Model8733954853 (2020/04)

5 | Standard TW Package

Subject to change without prior notice

STANDARD TW PACKAGE

Fig. 2 TW Series Water-to-Water Heat Pump

[1] TW Series Water-to-Water

[2] Installation and Operation Manual

General Description

The Greensource CDi Series TW Model Water-to-

Water Heat Pumps provide the best combination

of performance and efficiency available.

All units are performance certified to American

Heating and Refrigeration Institute (AHRI) ISO

Standard 13256-2. All TW Water-to-Water Heat

Pumps conform to UL1995 standard and are

certified to CAN/CSA C22.2 No 236 by Intertek-

ETL. The TW Water-to-Water Heat Pumps are

designed to operate with entering fluid

temperature between 30°F to 90°F in the heating

mode and between 50°F to 110°F in the cooling

mode.

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. Units must only be stored or moved

in the normal upright position as indicated by the

“UP” arrows on each carton at all times.

Initial Inspection

Be certain to inspect all cartons or crates on each

unit as received at the job site before signing the

freight bill. Verify that all items have been received

and that there are no visible damages; note any

shortages or damages on all copies of the freight

bill. In the event of damage or shortage, remember

that the purchaser is responsible for filing the

necessary claims with the carrier. Concealed

damages not discovered until after removing

the units from the packaging must be reported to

the carrier within 24 hours of receipt.

A heat pump operating under extreme

conditions will have limitations on air/fluid

flow rates and/or temperatures.

NOTICE: 50° F Minimum Entering Water

Temperature (EWT) is recommended for

water applications with sufficient water

flow to prevent freezing. Antifreeze solution

is required for all closed-loop applications

and EWT below 50°F.

Geothermal applications should have

sufficient antifreeze solution to protect

against extreme conditions and equipment

failure. Frozen water coils are not covered

under warranty. Other equivalent methods

of temperature control are acceptable.

WARNING: For Storage if unit stacking is

required, stack unit as follows:

Do not stack units larger than 6 tons. For

units less than 6 tons, no more than three

high.

Greensource CDi Series TW Model

Greensource CDi Series TW Model8733954853 (2020/04)

6 | Unit Installation

Subject to change without prior notice

UNIT INSTALLATION

This section contains information on the following:

LOCATION SELECTION

Install the unit in an indoor area that allows easy

access to the panels, and has enough room for

service personnel to perform maintenance or

repair. Provide sufficient room to make fluid,

electrical, and duct connection(s).

INSTALLATION

The TW series unit must be mounted level on a

vibration absorbing pad slightly larger than the

base to minimize vibration transmission to the

building structure, It is not necessary to anchor the

unit to the floor. (See Fig. 3.)

Fig. 3 Vibration pad

Piping

Supply and return piping must be as large as the

unit connections on the heat pump (larger on long

runs).

Flexible hoses should be used between the unit

and the rigid system to avoid possible vibration.

TW units are supplied with either a copper or

optional cupro-nickel Water to refrigerant Heat

Exchanger. Copper is adequate for ground water

that is not high in mineral content. (See Table #8,

Water Quality.)

In conditions anticipating moderate scale

formation or in brackish water a cupro-nickel heat

exchanger is recommended.

Both the supply and discharge water lines will

sweat if subjected to low-water temperature.

These lines must be insulated to prevent damage

from condensation.

All manual flow valves used in the system must be

ball valves. Globe and gate valves must not be used

due to their high-pressure drop and poor throttling

characteristics.

Ball valves should be installed in the supply and

return lines for unit isolation and unit water flow

balancing.

Subject Page

Location Selection 6

Installation 6

Piping 6

Electrical 7

Safety Devices and

the UPM Controller

Specific Application

Considerations

Post-Installation

System Checkout

NOTICE: These units are not approved for

outdoor installation; therefore, they must

be installed inside a structure in a

conditioned space. Do not locate in areas

that are subject to freezing.

VIBRATION

PAD FULL

NOTICE: Never use flexible hoses of a

smaller inside diameter than that of the

fluid connections on the unit.

Proper testing is required to ensure the well

water quality is suitable for use with water

source equipment. When in doubt, use

cupro-nickel. (See the Water Quality Table

on page #30.)

NOTICE: Never exceed the recommended

water flow rates as per AHRI ratings since

serious damage or erosion of the water-to-

refrigerant heat exchanger could occur.

Installation | 7Greensource CDi Series TW Model

8733954853 (2020/04)Greensource CDi Series TW Model Subject to change without prior notice

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.

Electrical

Refer to electrical component box layout. (See Fig. 4)

Properly-sized fuses or HACR circuit breakers must

be installed for branch circuit protection. See the

unit nameplate for maximum fuse or breaker size.

The unit is provided with a concentric knock-out

for attaching common trade sizes of conduit.

Route power supply wiring through this opening.

Always connect the ground lead to the grounding

lug provided in the control box and power leads to

the line side of compressor contactor as indicated

on the wiring diagrams starting on page #35.

Fig. 4 Electrical component box layout

[1] Unit-Mounted Controller

[2] Transformer

[3] Compressor Contractor

[4] Seven-Pin Terminal Block

[5] Pump/Valve Relay (Field-Installed Accessory)

[6] Compressor Capacitor

[7] Chassis Ground Lug

Teflon tape sealer should be used when

connecting water piping connections to the

units to insure against leaks and possible

heat exchanger fouling.

NOTICE: Do not overtighten the

connections.

WARNING: Field wiring must comply with

local and national electric codes.

WARNING: Power to the unit must be

within the operating voltage range indicated

on the unit’s nameplate or on the

performance data sheet.

NOTICE: Operation of unit on improper line

voltage or with excessive phase imbalance

will be hazardous to the unit, constitutes

abuse and may void the warranty.

Greensource CDi Series TW Model

Greensource CDi Series TW Model8733954853 (2020/04)

8 | Specific Application Considerations

Subject to change without prior notice

SPECIFIC APPLICATION

CONSIDERATIONS

Well Water Systems

Copper is adequate for ground water that is not

high in mineral content. Should your well driller

express concern regarding the quality of the well

water available or should any known hazards exist

in your area, we recommend proper testing to

ensure the well water quality is suitable for use

with water source equipment. (See the Water

Quality table on page #30.) In conditions

anticipating moderate scale formation or in

brackish water a cupro-nickel heat exchanger is

recommended. In well water applications, water

pressure must always be maintained in the heat

exchanger. This can be accomplished with either a

control valve or a bladder-type expansion tank.

When using a single water well to supply both

domestic water and the heat pump, care must be

taken to ensure that the well can provide sufficient

flow for both. In well water applications, a

slow-closing solenoid valve must be used and

installed on the leaving-water side of coaxial to

prevent water hammer. Solenoid valves should be

connected across Y1 and C for all. Make sure that

the VA draw of the valve does not exceed the

contact rating of the controls. (See Fig. 5.)

Fig. 5 Typical well water setup

[1] Pressure Tank

[2] Ball Valves

[3] Solenoid Valve

[4] Hose Kit

[5] P/T Kit

[6] Load-Side Connections

[7] Low-Voltage Control Connection

[8] Vibration Pad

[9] Line-Voltage Control Connection

WATER OUT

WATER IN

For Reference Only.

A typical setup is shown for

illustration purposes only.

Specific Application Considerations | 9Greensource CDi Series TW Model

8733954853 (2020/04)Greensource CDi Series TW Model Subject to change without prior notice

Cooling Tower/Boiler Systems

The cooling tower and boiler water loop

temperature is usually maintained between 50°F

to 100°F to ensure adequate cooling and heating

performance. In the cooling mode, heat is ejected

from the unit into the water loop. A cooling tower

provides evaporative cooling to the loop water

thus maintaining a constant supply temperature to

the unit. When utilizing open cooling towers,

chemical water treatment is mandatory to ensure

the water is free from corrosive elements. A

secondary heat exchanger (plate frame) between

the unit and the open cooling tower may also be

used. It is imperative that all air be eliminated from

the closed-loop side of the heat exchanger to

ensure against fouling. In the heating mode, heat is

absorbed from the water loop. A boiler can be

utilized to maintain the loop at the desired

temperature.

Cooling Tower/Boiler Systems Piping

Consult the specification sheets for pipe

connection sizes.

Ball valves should be installed in the supply and

return lines for unit isolation and unit water flow

balancing. Pressure/temperature ports are

recommended in both supply and return lines for

system flow balancing. Water flow can be

accurately set by measuring the water-to-

refrigerant heat exchangers’ water-side pressure

drop. (See specification sheets for water flow vs.

pressure drop information.)

No unit should be connected to the supply or

return piping until the water system has been

completely cleaned and flushed to remove any dirt,

piping chips, or other foreign material. Supply and

return hoses should be connected together during

this process to ensure the entire system is

properly flushed. After the cleaning and flushing

has taken place, the unit may be connected to the

water loop and should have all valves wide open.

NOTICE: Water piping exposed to extreme

low ambient temperatures is subject to

freezing.

Teflon tape sealer should be used when

connecting to the unit to insure against

leaks and possible heat exchanger fouling.

Do not overtighten the connections.

Flexible hoses should be used between the

unit and the rigid system to avoid possible

vibration.

Greensource CDi Series TW Model

Greensource CDi Series TW Model8733954853 (2020/04)

10 | Specific Application Considerations

Subject to change without prior notice

Fig. 6 Typical Cooling Tower and Boiler System Setup

[1] Ball Valves

[2] Hose Kits

[3] P/T Plugs

[4] Load-Side Connections

[5] Low-Voltage Control Connections

[6] Vibration Pad

[7] Line-Voltage Disconnect

[8] Supply and Return Line of Central System

This diagram shows a typical

installation and is for illustration

purposes only. Ensure access to

Heat Pump is not restricted.

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