Bosch Greensource CDi TW Series User manual

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
6
7 8910111213141516171819202122232425262728293031323334353637383940
TW 025
-
1CSN- F XXXC B - XX GXXXXXX7XXXXXXXXX SSA
SERIES TW 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.
1
2
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
8
Specific Application
Considerations
8
Post-Installation
System Checkout
12
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
9
87
6
5
4
3
2
1
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.