Bosch WT Series - User Manual

Installation, Operation and Maintenance Manual
WW and WT Series
8733943362 2016/08
Water to Water

Summary

Key to Symbols and Safety Warnings

Warnings and Important Information

Defines warning symbols and important information indicators.

Safety Warnings and Precautions

Details hazards and safety precautions for installation and service.

Refrigerant Handling Notice

Specifies refrigerant recovery requirements by certified technicians.

Construction Use Prohibition

Advises against using units during construction to avoid damage.

Model Nomenclature

WT Model Nomenclature

Explains the coding system for WT model identification.

WW Model Nomenclature

Explains the coding system for WW model identification.

Standard WW;WT Package Overview

General Description and Certifications

Details performance, certifications, and operating temperature ranges.

Moving, Storage, and Inspection

Guidelines for handling, storing, and initially inspecting the unit.

Location and Piping Requirements

Recommendations for unit placement and piping size.

Installation Guidelines

Instructions for mounting the unit level on a vibration pad.

Electrical and Piping Considerations

Water Piping Recommendations

Guidance on water line insulation, valve types, and flow rates.

Electrical Safety and Wiring

Adherence to codes and proper wiring practices.

Voltage and Circuit Protection

Proper voltage supply and circuit breaker requirements.

UPM Control and Safety Devices

UPM I and UPM II Controller Diagrams

Diagrams illustrating safety devices on UPM controllers.

Thermostat Malfunction Light Connections

Instructions for connecting thermostat malfunction lights.

Safety Controls and UPM Operation

Pressure Switches and Freeze Protection

Details on high/low pressure switches and freeze protection.

UPM Board Settings and Features

Factory default settings and features of the UPM board.

UPM Timers and Protection Functions

Explanation of anti-short cycle, random start, and brownout protection.

Malfunction Output and 24 VAC Wiring

Configuration of malfunction output and 24VAC wiring.

UPM Functions and Options

Display Output and Test Mode

Functionality of display output and test dip switch.

Freeze Sensor and Lockout Reset

Freeze sensor operation and lockout reset procedures.

Heat Recovery Package (HRP) Introduction

Overview of the HRP option for heating potable water.

Heat Recovery Package (HRP) Details

HRP Freezing Precautions and Flow Proving

Preventing HRP freezing and DPS water flow proving.

Pump Relay and Comfort Alert Module

Function of pump relay and Comfort Alert Module.

HRP Water Tank Preparation and Piping

Steps for preparing the water tank and HR piping.

HRP Water Tank Refill Procedure

Procedure for refilling the water tank after service.

Sequence of Operation

Initial Start-Up Procedure

Steps for initial system startup and checks.

Cooling Mode Operation

Operation sequence for cooling mode with thermostat calls.

Heating Mode Operation

Operation sequence for heating mode with thermostat calls.

Sequence of Operation Flow

Operational Flow Diagram

Visual representation of the unit's operational sequence.

Application Considerations

Well Water Systems

Considerations for well water quality and piping.

Cooling Tower;Boiler Systems

Operational considerations for cooling tower/boiler systems.

Application Considerations

Air Elimination and Piping Notes

Importance of air removal and piping connection notes.

Geothermal Systems

Specialized requirements for geothermal installations.

System Flushing and Valve Operation

Procedure for system cleaning and valve operation.

System Checkout and Installation Considerations

Pre-Energization System Checks

Essential checks before energizing the unit.

Electrical Installation Guidelines

Guidelines for voltage, wiring gauge, and grounding.

Wiring Gauge and Additional Devices

Thermostat wiring gauge and device addition cautions.

Unit Control Panel and Modes of Operation

Control Panel Features and Sensors

Description of control panel features and unit sensors.

Modes of Operation Overview

Overview of available operating modes.

Off, Heating, and Cooling Modes

Detailed operation for Off, Heating, and Cooling modes.

Unit Protection and Control Logic

Auto Changeover Mode Logic

Logic and operation of the auto changeover mode.

Unit Protection and Fault Handling

Protection against faults and intelligent reset.

Brownout Protection and Manual Lockout

Protection against brownouts and manual lockout reset.

Lead-Lag Compressor Operation

Explanation of lead-lag functionality for dual compressors.

Pump Cycling and Operating Instructions

Pump Cycling Functionality

How the optional pump relay cycles pumps with the compressor.

User Interface and Button Functions

Description of the control panel interface and buttons.

LED Indicators and Freeze Stat Note

Explanation of LED indicators and freeze stat bypass.

User Adjustable Settings and Controller Setup

User Adjustable Settings Chart

Table of adjustable settings, ranges, and defaults.

Controller Startup and Initial Settings

Process of controller startup and initial setting adjustment.

Set Point and Differential Examples

Examples illustrating set point and differential calculations.

Initial Configuration Steps

Temperature Scale and Pump Operation

Configuration of temperature scale and pump operation mode.

Dead Band and Auto Changeover Set Point

Setting the dead band and auto changeover set point.

Test Mode, Compressor, Lead Lag, Malfunction Settings

Configuration of test mode, compressor, lead lag, and malfunction.

Troubleshooting - General Unit Issues

Unit Troubleshooting - No Power;Fuse

Troubleshooting steps for units not running due to power or fuse issues.

Unit Troubleshooting - High Pressure

Troubleshooting causes for high pressure lockouts.

Unit Troubleshooting - Low Pressure

Troubleshooting causes for low pressure lockouts.

Unit Troubleshooting - Short Cycles

Troubleshooting causes for units short cycling.

Troubleshooting - Cooling;Heating and Comfort Alert

Unit Troubleshooting - Insufficient Output

Troubleshooting insufficient cooling or heating output.

Comfort Alert Module Flash Codes

Troubleshooting using Comfort Alert Module flash codes.

Comfort Alert Module Flash Codes

Flash Codes 5-7

Interpretation of Comfort Alert Module flash codes 5 through 7.

Flash Codes 8-9

Interpretation of Comfort Alert Module flash codes 8 through 9.

Troubleshooting - HRP, Lockouts, and LED Indications

HRP Troubleshooting

Troubleshooting specific issues with the Heat Recovery Package.

Unit Lockouts and Causes

Understanding and addressing unit lockouts.

UPM I and UPM II Board LED Indications

Interpreting LED status indications on UPM boards.

Electrical Data Table WW

WW Model Electrical Specifications

Table detailing electrical data for WW models.

Electrical Data Table WT

WT Model Electrical Specifications

Table detailing electrical data for WT models.

Water Pressure Drop WW

WW Model Pressure Drop Data

Table showing water pressure drop for WW models.

Water Pressure Drop WT

WT Model Pressure Drop Data

Table showing water pressure drop for WT models.

Water Quality Table

Acceptable Water Quality Values

Table listing acceptable water quality parameters for copper/cupro-nickel.

Wiring Diagrams - Components and Notes

Standard Components Legend

Legend for standard components in wiring diagrams.

Optional Components Legend

Legend for optional components in wiring diagrams.

Wiring Diagram Notes

Important notes and cautions for wiring diagrams.

Wiring Diagrams - Components and Notes

Standard Components Legend

Legend for standard components in wiring diagrams.

Optional Components Legend

Legend for optional components in wiring diagrams.

Wiring Diagram Notes

Important notes and cautions for wiring diagrams.

Wiring Diagrams - Components and Notes

Standard Components Legend

Legend for standard components in wiring diagrams.

Optional Components Legend

Legend for optional components in wiring diagrams.

Wiring Diagram Notes

Important notes and cautions for wiring diagrams.

Wiring Diagrams - Components and Notes

Standard Components Legend

Legend for standard components in wiring diagrams.

Optional Components Legend

Legend for optional components in wiring diagrams.

Wiring Diagram Notes

Important notes and cautions for wiring diagrams.

Wiring Diagrams - Components and Notes

Standard Components Legend

Legend for standard components in wiring diagrams.

Optional Components Legend

Legend for optional components in wiring diagrams.

Wiring Diagram Notes

Important notes and cautions for wiring diagrams.

Wiring Diagrams - Components and Notes

Standard Components Legend

Legend for standard components in wiring diagrams.

Optional Components Legend

Legend for optional components in wiring diagrams.

Wiring Diagram Notes

Important notes and cautions for wiring diagrams.

Wiring Diagrams - Components and Notes

Standard Components Legend

Legend for standard components in wiring diagrams.

Optional Components Legend

Legend for optional components in wiring diagrams.

Wiring Diagram Notes

Important notes and cautions for wiring diagrams.

Wiring Diagrams - Components and Notes

Standard Components Legend

Legend for standard components in wiring diagrams.

Optional Components Legend

Legend for optional components in wiring diagrams.

Wiring Diagram Notes

Important notes and cautions for wiring diagrams.

Dimensional Drawings WW

WW Model Dimensions and Connections

Detailed dimensions and connection points for WW models.

Dimensional Drawings WT

WT Model Dimensions and Connections

Detailed dimensions and connection points for WT models.

Unit Start-Up, Maintenance, and Decommissioning

Unit Start-Up Procedure

Step-by-step guide for starting up the unit.

Maintenance and Decommissioning Information

Requirements for annual maintenance and decommissioning.

Environmental Protection and Recycling

Information on protecting the environment and recycling components.

Terminology

Glossary of Technical Terms

Definitions of technical terms used in the manual.

Unit Check-Out Sheet

Customer and Unit Nameplate Data

Fields for recording customer and unit identification data.

Operating Conditions Recording

Fields for recording operating conditions in cooling and heating modes.

Notes

General Notes Section

Blank section for user notes or additional information.

Bosch WT Series Specifications