Bosch TW Series Installation, Operation And Maintenance Manual Download Page 25

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Troubleshooting

TW Series Water to Water

6720220047 (2016/02)

Revised 02-16

ELECTRICAL DATA TABLE

Models

Voltage

Code

Rated

Voltage

Min/

Max

Compressor

QTY

RLA

LRA

Min

Circuit

Amps

Max

Fuse/

HACR

TW025

208-230/60/1

197/253

11.7

58.3

14.6

TW035

208-230/60/1

197/253

15.3

83.0

19.1

TW049

208-230/60/1

197/253

21.2

104.0

26.5

TW061

208-230/60/1

197/253

27.1

152.9

33.9

TW071

208-230/60/2

197/254

29.7

179.2

37.1

TW122

208-230/60/1

197/253

28.3

178.0

63.7

UPM Board LED Indications

Indication

Color

Blinks

Description

GREEN

Solid

18-30 VAC Power is present

RED

High pressure lockout

RED

Low pressure lockout

RED

Freeze sensor lockout

RED

Condensate overflow

RED

Brownout

RED

Evaporator Freeze condition

Summary of Contents for TW Series

Page 1: ...Installation Operation and Maintenance Manual TW Series 6720220047 2016 02 Water to Water ...

Page 2: ...Considerations 13 Well Water Systems 13 Cooling Tower Boiler Systems 13 Geothermal Systems 14 System Checkout 15 Considerations 15 Unit Start Up 16 Maintenance 16 Decommissioning 16 Water To Water Unit Controller 16 Features 16 Unit Sensors 16 Water Sensor 16 Changeover Sensor 16 Modes Of Operation 16 Off Mode 16 Heating Mode 16 Cooling Mode 17 Auto Changeover Mode 17 Unit Protection 17 Manual Loc...

Page 3: ...ns on the system turn off main power to the unit Electrical shock could cause personal injury or death WARNING 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 All refrigerant d...

Page 4: ...t Con guration US Unit Mounted Controller Transformer CS Remote Controlled 7 75 VA Source Side Coax Options Refrigeration Circuit Options C Copper X None N Cupro Nickel D Heat Recovery Package Water Connections General Electrical Options up to 5 available per unit F Front A EMS relay E Pump valve relay X N A H Flow proving switch N Comfort Alert Load Side Coax Options X As default for non used ele...

Page 5: ...ng 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 Location Locate 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 and electrical connecti...

Page 6: ...installed for branch circuit protection See 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 diag...

Page 7: ...perature between condensing water coil and thermal expansion valve If temperature drops below or remains at freeze limit trip for 30 seconds the controller will shut down the compressor and enter into a soft lockout condition The default freeze limit trip is 26 F however this can be changed to 15 F by cutting the R30 or Freeze1 resistor located on top of DIP switch SW1 Refer to Figure 4 item 3 for...

Page 8: ...the fault See L E D Fault Indication below for blink code explanation The remote device must have a malfunction detection capability when the UPM board is set to PULSE DISPLAY OUTPUT The Display output is a pulse output connected to the Unit Diagnostic Display UDD and it pulses 24VAC when the unit is in an lockout alarm condition TEST DIP SWITCH A test dip switch is provided to reduce all time del...

Page 9: ...omestic hot water tank and HRP heat exchanger in the Heat Pump The control circuit ensures that the HRP only operates when there is available heat from the compressor and when the water is within a safe temperature range of below 140 deg F When the heat pump compressor operates the HRP will monitor the temperature of the discharge gas from the compressor Once discharge gas is hot enough to provide...

Page 10: ...nk Refill 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 3 Depress the hot water tank pressure relief valve handle to ensure there is no air remaining in the tank 4 Carefully inspect all plumbing for water leaks Correct as required 5 Purge all air from HR by depressing the schrader valve on the HR Unit All...

Page 11: ...t is energized and the first stage of compressor capacity starts When the thermostat calls for second stage cooling Y2 the second stage or full compressor capacity is initiated Once the thermostat is satisfied the compressor shuts down accordingly Heating Mode The first two stages of heating Y1 Y2 operate in the same manner as cooling but with the reversing valve de energized Once the thermostat i...

Page 12: ...TEMP LIMIT Y1 ON TIME 30 SEC CON 0 POWER SWITCHES SENSOR STATUS CHECK START TIMER NO YES NO YES NO YES T ASC OR RS SEC YES NO NO YES START ANTI SHORT CYCLE INITIAL POWER UP YES NO START RANDOM START UP START COUNTER NEEDED YES COUNT 2 OR COUNT 4 BLINK CODE ON STATUS LED DISPLAY OUTPUT PULSE ALR OUTPUT ON PULSE NO YES HARD LOCKOUT CC OUTPUT OFF V 18VAC NO YES YES NO BLINK CODE ON STATUS LED NO RESE...

Page 13: ...hould be connected across Y1 and C1 on the interface board for all Make sure that the VA draw of the valve does not exceed the contact rating of the thermostat Figure 9 Figure 9 Example System Set up 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 Cooling Tower Boiler Syst...

Page 14: ...r the cleaning and flushing has taken place the unit may be connected to the water loop and should have all valves wide open Figure 10 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 lines of central system Geothermal Systems Closed loop and pond applications require specialized design kno...

Page 15: ...and adjust if necessary 7 Verify that vibration isolation has been provided 8 Unit is serviceable Be certain that all access panels are secured in place Considerations Always check incoming line voltage power supply and secondary control voltage for adequacy Transformer primaries are dual tapped for 208 and 230 volts Connect the appropriate tap to ensure a minimum of 18 volts secondary control vol...

Page 16: ...ED display of control temperature and set points F or C Display 50 60 Hertz operation Pump operation configurable for continuous or cycling operation with the compressor Compressor lead lag operation on units with dual compressors Malfunction output and service LED can be set to steady or pulsing to indicate fault condition Color LED s indication of mode of operation Set point retention in non vol...

Page 17: ...er mode control feature will switch from the heating mode to cooling mode and vice versa based on the setting of the change over sensor There will be a dead band where the control will not call for either heat or cool The dead band setting is adjustable in the configuration mode When the auto changeover mode is selected the changeover set point will be displayed for 5 seconds however this point is...

Page 18: ...emains in the memory If control has called for the second stage three times in a row and compressor setting is Du regardless of the lead lag setting control will switch the call to the other compressor The lead lag timer is reset and the lead lag setting still applies Pump cycling When ordered with the optional pump relay the controller will cycle either the load source or both pumps with the comp...

Page 19: ... point is achieved Stage 1 and stage 2 will cycle on and off according to the lead lag programmed interval Whenever there is a demand for heating and cooling and during the first stage of operation the temperature isn t changing then the control will activate the second stage after a three minute delay from the first stage activation This logic will apply when the control is powered up on a power ...

Page 20: ...selected hit the mode key to advance Value ______________________ Fourth display field Auto change over set point S2 Adjustable from 55 to 85 degrees Use up or down arrows to adjust Hit the mode key to advance The auto changeover sensor should be located in an area that will be indicative of whether the unit should be in the heating or cooling mode Value ______________________ Fifth display field ...

Page 21: ...___________ Load Side Fluid Flow gpm ______________________________ ______________________________ Source Side Leaving Fluid Temp _______________ _____________ _______________ _____________ Source SideFluid Flow gpm ______________________________ ______________________________ Compressor Volts Amps _______________ _____________ _______________ _____________ Source Fluid Type ______________________...

Page 22: ...Scaled or plugged condenser In HEATING mode Lack of or inadequate load side fluid flow Refrigerant charge The unit is overcharged with refrigerant Reclaim refrigerant evacuate and recharge with factor recommended charge High pressure Check for defective or improperly calibrated high pressure switch UNIT OFF ON LOW PRESSURE CONTROL Suction pressure too low In COOLING mode Lack of or inadequate Sour...

Page 23: ...h Codes Status LED Status LED Description Status LED Troubleshooting Information Solution YELLOW ALERT FLASH CODE 3 Short Cycling Compressor is running only briefly 1 Thermostat demand signal is intermittent 2 Time delay relay or control board defective 3 If high pressure switch present go to Flash Code 2 information 4 If low pressure switch present go to Flash Code 1 information YELLOW ALERT FLAS...

Page 24: ...sor motor winding resistance YELLOW ALERT FLASH CODE 8 Welded Contactor Compressor always runs 1 Compressor contactor has failed closed 2 Thermostat demand signal not connected to module YELLOW ALERT FLASH CODE 9 Low Voltage Control circuit 17VAC 1 Control circuit transformer is overloaded 2 Low line voltage contact utility if voltage at disconnect is low Check wiring connections Flash Code number...

Page 25: ...3 1 15 3 83 0 19 1 30 TW049 1 208 230 60 1 197 253 1 21 2 104 0 26 5 45 TW061 1 208 230 60 1 197 253 1 27 1 152 9 33 9 60 TW071 1 208 230 60 2 197 254 1 29 7 179 2 37 1 60 TW122 1 208 230 60 1 197 253 2 28 3 178 0 63 7 90 UPM Board LED Indications Indication Color Blinks Description GREEN Solid 18 30 VAC Power is present RED 1 High pressure lockout RED 2 Low pressure lockout RED 3 Freeze sensor lo...

Page 26: ...5 CORROSION Hydrogen Sulfide H2S 0 5 ppm 10 50 ppm Sulfates 125 ppm 125 ppm Chlorine 0 5 ppm 0 5 ppm Chlorides 20 ppm 150 ppm Carbon Dioxide 50 ppm 50 ppm Ammonia 2 ppm 2 ppm Ammonia Chloride 0 5 ppm 0 5 ppm Ammonia Nitrate 0 5 ppm 0 5 ppm Ammonia Hydroxide 0 5 ppm 0 5 ppm Ammonia Sulfate 0 5 ppm 0 5 ppm Dissolved Solids 1 000 ppm 1 500 ppm IRON FOULING Iron Fe2 Iron Bacteria Potential 0 2 ppm 0 2...

Page 27: ...rams 27 TW Series Water to Water 6720220047 2016 02 Revised 02 16 WIRING DIAGRAMS Figure 13 FOR REFERENCE ONLY Actual unit wiring may vary from this example Always refer to the wiring diagram attached to the unit ...

Page 28: ... Water to Water TW Series Water to Water 6720220047 2016 02 Subject to change without prior notice Figure 14 FOR REFERENCE ONLY Actual unit wiring may vary from this example Always refer to the wiring diagram attached to the unit ...

Page 29: ...ing Diagrams 29 TW Series Water to Water 6720220047 2016 02 Revised 02 16 Figure 15 FOR REFERENCE ONLY Actual unit wiring may vary from this example Always refer to the wiring diagram attached to the unit ...

Page 30: ... Water to Water TW Series Water to Water 6720220047 2016 02 Subject to change without prior notice Figure 16 FOR REFERENCE ONLY Actual unit wiring may vary from this example Always refer to the wiring diagram attached to the unit ...

Page 31: ...ing Diagrams 31 TW Series Water to Water 6720220047 2016 02 Revised 02 16 Figure 17 FOR REFERENCE ONLY Actual unit wiring may vary from this example Always refer to the wiring diagram attached to the unit ...

Page 32: ... Water to Water TW Series Water to Water 6720220047 2016 02 Subject to change without prior notice Figure 18 FOR REFERENCE ONLY Actual unit wiring may vary from this example Always refer to the wiring diagram attached to the unit ...

Page 33: ...35 24 12 32 5 24 2 3 2 3 14 3 2 4 3 7 2 55 15 7 2 55 7 15 11 4 25 6 55 8 05 9 55 1 25 3 4 FPT 1 2 FPT TW049 24 12 32 5 24 2 3 2 1 14 3 2 65 2 7 2 65 14 75 2 65 7 15 11 4 25 6 55 8 05 9 55 1 25 1 FPT 1 2 FPT TW061 24 12 32 5 24 2 8 1 38 14 8 2 63 2 51 2 14 38 3 4 7 15 11 4 25 6 55 8 05 9 55 1 25 1 FPT 1 2 FPT TW071 24 12 32 5 24 3 2 25 17 25 2 25 3 25 2 25 17 2 25 7 15 11 4 25 6 55 8 05 9 55 1 25 1...

Page 34: ...r 6720220047 2016 02 Subject to change without prior notice MODEL A B C D E F G H J K L M Water Conn TW122 37 5 27 62 7 8 38 9 25 33 5 20 75 13 5 17 5 3 5 46 28 1 1 4 FPT NOTES All dimensions within 0 125 Specifications subject to change without notice ...

Page 35: ...aintenance or servicing or prior to the disposal of the products or equipment Recycling Means the reuse of a recovered fluorinated greenhouse gas following a basic cleaning process Reclamation Means the reprocessing of a recovered fluorinated greenhouse gas in order to match the equivalent performance of a virgin substance taking into account its intended use Decommissioning Means the final shut d...

Page 36: ...Bosch Thermotechnology Corp 555 N W 65th Court Ft Lauderdale FL 33309 Phone 866 642 3198 Fax 954 776 5529 www boschheatingandcooling com Revised 02 16 ...

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