Installation and Maintenance Manual 6 720 220 047 Revised 03-11 TW Series Water to Water
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TW Series / Water to Water 3 Table of Contents Table of Contents Model Nomenclature..................................................................................... 3 Initial Inspection........................................................................................... 4 Installation.................................................................................................... 4 Electrical......................................................................................................
TW Series / Water to Water 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 Caution and that there is no visible damage; note any shortages or damage on all copies of the freight bill. In the event of damage or shortage, remember that the purchaser is responsible for filing the Caution necessary claims with the carrier.
Minimal System Volume where water released during start-up or maintenance could cause damage below the unit. MINIMAL SYSTEM VOLUME Bosch recommends that the total fluid volume in the system be not less than 6 gallons per nominal ton of cooling capacity on both the load and source sides. ELECTRICAL Always disconnect power to the unit before servicing to prevent injury or death due to electrical shock. n All field wiring must comply with local and national fire, safety and electrical codes.
n 6 TW Series / Water to Water used due to high pressure drop and poor throttling characteristics. Never exceed the recommended water flow rates. Serious damage or erosion of the water to refrigerant heat exchanger could occur. Improper heat exchanger fluid flow due to piping, valving or improper pump operation is hazardous to the unit and constitutes abuse which will void the heat exchanger and compressor warranty. Always check carefully for water leaks and repair appropriately.
Well Water Systems TW Series / Water to Water 7 water side pressure drop. See specification sheets for water flow and pressure drop information. WELL WATER SYSTEMS (Figure #2) Water quantity should be plentiful, between 1.5 and 3.0 gpm per ton of cooling, and of good quality. To avoid the possibility of freezing in the heating mode, the well water should be above 50˚F. Water pressure must always be maintained in the heat exchanger by placing a water control valve on the outlet of the water-to-water unit.
TW Series / Water to Water *A water-to-water series Heat Pump/Liquid Chiller can be utilized for direct pool/spa heating without a secondary heat exchanger. In this application cupro-nickel heat exchangers must be used. Automatic chemical feeders must never be installed up stream of the unit. An external bypass should be installed to avoid over-flowing the heat exchanger to prevent coil erosion. The pool pH levels and chemical balances must be maintained to avoid possible heat exchanger damage.
TW Series / Water to Water 9 Cooling Mode compressor in a two stage unit). When the set point is satisfied the compressor is turned off. In a two stage unit after the first stage activation if the water temperature drops an additional two degrees below the set point, the second stage (terminal Y2) will be activated (if control is configured for both compressors). Both stages will be on until the set point is satisfied.
TW Series / Water to Water or reoccurs within the next 60 minutes, the unit will go into a hard lockout and requires a manual lockout reset. During this period the fault LED will indicate the cause of the fault. A 120 second time delay is built into the low pressure switch to avoid nuisance trips with low fluid temperatures. While in a soft lockout condition the display will show the specific fault (for example LP1) and the “service” LED will turn on according to the malfunction mode.
TW Series / Water to Water 11 LED Indicators up button will increment the set point at a rate of 4 degrees per second. • When pressed with the down arrow for 5-seconds, the control will display the current temperature scale (Fahrenheit or Celsius). • Used to change the settings for: temperature scale, dead band, test mode, initial delay, compressor, pump, and malfunction settings.
TW Series / Water to Water For example: Initial Configuration Cooling set point = 45˚F a time out period while configuring. This will also provide a record of the initial configuration settings. Differential = 1˚F First display field The heat pump will cycle on in cooling at 46˚F. If a two stage machine, stage 2 will come on at 48˚F or 2˚F degrees above set point and one degree differential. The unit will shut off at set point. Temperature scale OC or OF.
System Checkout reset to DE. The ND setting could be selected at start-up to avoid prolonged waiting periods during commissioning. Once selected hit the “mode” key to advance. Setting:______________________ Sixth display field Compressor setting, (Si) single or (Du) dual. Use the up or down arrows to select. Hit the “mode” key to advance. This is only applicable on multi stage units. If set to Si on a dual circuit unit the second stage will not come on. Must be set to “DU” for al TW models.
n 14 TW Series / Water to Water Heat Recovery Package HEAT RECOVERY PACKAGE TYPICAL CONNECTION PIPING The Heat Recovery package is a factory mounted option. It consists of a forced pumped unit that employs a circulating pump to move water through a double wall/vented heat exchanger and returns the heated water to the water tank. The water is heated by superheated refrigerant discharge gas from the compressor.
TW Series / Water to Water 15 Water Tank Refill WATER TANK REFILL: INITIAL START-UP: 1. Open the cold water supply to the tank. 2. Open a hot water faucet to vent air from the system until water flows from the faucet, then close. 1. Make sure all valves in heat recovery water piping system are open. NEVER OPERATE HR PUMP DRY. 3. Depress the hot water tank pressure relief valve handle to ensure there is no air remaining in the tank. 2. Turn on the heat pump.
Operating Pressures 16 TW Series / Water to Water CHILLER MODE Table 1 - R410A Units - Full Load Cooling Mode Operating Pressures (PSIG) Entering Source Condenser Temperature °F 75 °F Entering Fluid Temp °F 85 °F 95 °F Suction Pressure Discharge Pressure Suction Pressure Discharge Pressure Suction Pressure Discharge Pressure 65 99-116 290-320 107-123 325-358 107-123 370-400 55 91-107 265-311 91-107 303-350 99-116 370-400 45 76-91 265-311 76-91 295-345 83-99 358-390 BOILER MO
Wiring Diagrams TW Series / Water to Water 17 Figure #6 Typical Wiring Diagrams Two Stage - Single Phase Revised 03-11 Subject to change without prior notice 6 720 220 047
TW Series / Water to Water Wiring Diagrams Typical Wiring Diagrams Two Stage - Single Phase Solid State Unit Controller 6 720 220 047 Subject to change without prior notice Revised 03-11
TW Series / Water to Water 19 Unit Check-Out Sheet Unit Check-out Sheet Water to Water Customer Data Customer Name _________________________________________________ Date ___________________________________ Address _________________________________________________________ __________________________________________________________________ Phone ___________________________________________________________ Unit Number __________________________ Unit Nameplate Data Unit Make ________________________________
TW Series / Water to Water Troubleshooting Troubleshooting Problem Possible Cause Checks and Corrections Compressor does not operate Power Supply Off Apply power, close disconnect Blown Fuse Replace fuse or reset circuit breaker. Check for correct fuses Broken or loose wires Replace or tighten the wires. Check for loose or broken wires at compressor, capacitor, or contactor. Voltage supply low If voltage is below minimum voltage specified on unit data plate, contact local power company.
TW Series / Water to Water 21 Troubleshooting Unit short cycles Insufficient cooling or heating Revised 03-11 Unit oversized Recalculate heating and or cooling loads. Wiring and controls Loose connections in the wiring or a defective compressor contactor. Fluid Volume Inadequate load side fluid volume. Unit undersized Recalculate heating and or cooling loads. If excessive, possibly adding insulation and shading will rectify the problem. Unit may be short of refrigerant.
TW Series / Water to Water Notes 6 720 220 047 Revised 03-11 Subject to change without prior notice
Notes Revised 03-11 TW Series / Water to Water 23 Subject to change without prior notice 6 720 220 047
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