Toshiba HFC series Installation Manual
AIR TO WATER HEAT PUMP
Installation Manual
Hydro Unit
Model name:
HWS-P804XWHM3-E
HWS-P804XWHT6-E
HWS-P804XWHT9-E
HWS-P1104XWHM3-E
HWS-P1104XWHT6-E
HWS-P1104XWHT9-E
English
Hydro Unit
Please read this Installation Manual carefully before installing the Air to Water Heat Pump.
• This Manual describes the installation method of the hydro unit.
• For installation of the outdoor unit, follow the Installation Manual attached to the outdoor unit.
Installation Manual
REFRIGERANT
This Air to Water Heat Pump uses an HFC refrigerant (R410A) in order to prevent destruction of the ozone
layer.
Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Accessory parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Preparations for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Precautions for safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Example of Hydro Unit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Main components of Hydro Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Hydro Unit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8 Start up and configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
11 Sensor temperature monitoring function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1-EN
–1–
Hydro Unit
1 General information
System combination
Outdoor Unit
Hydro Unit HWS-P804HR-E HWS-P1104HR-E Backup heater
HWS-P804XWHM3-E – ~, 3kW
HWS-P804XWHT6-E – 3N ~, 6kW
HWS-P804XWHT9-E – 3N~, 9kW
HWS-P1104XWHM3-E – ~, 3kW
HWS-P1104XWHT6-E – 3N~, 6kW
HWS-P1104XWHT9-E – 3N~, 9kW
220-230V model
General specifications
Installation Manual
Outdoor Unit
Single Phase model
Outdoor unit HWS-P804HR-E HWS-P1104HR-E
Power supply 220-230V ~ 50Hz
Type INVERTER
Function Heating & Cooling
Capacity (kW) 8.0 11.2
Heating
Cooling
Refrigerant R410A
Dimension HxWxD (mm) 1,340x900x320
Input (kW) 1.68 2.30
COP (W/W) 4.76 4.88
Capacity (kW) 6.0 10.0
Input (kW) 1.64 3.33
EER (W/W) 3.66 3.00
–2–
2-EN
Hydro Unit
Installation Manual
Hydro Unit
80 class
Hydro Unit HWS-P804XWHM3-E HWS-P804XWHT6-E HWS-P804XWHT9-E
Back up heater capacity 3.0 6.0 9.0
Power supply
Leaving water
temperature
for back up heater 220-230V ~ 50Hz 380-400V 3N~ 50Hz 380-400V 3N~ 50Hz
for hot water cylinder heater
(option)
Heating (°C) 20-60
Cooling (°C) 7-25
220-230V ~ 50Hz
112 class
Hydro Unit HWS-P1104XWHM3-E HWS-P1104XWHT6-E HWS-P1104XWHT9-E
Back up heater capacity 3.0 6.0 9.0
Power supply
Leaving water
temperature
for back up heater 220-230V ~ 50Hz 380-400V 3N~ 50Hz 380-400V 3N~ 50Hz
for hot water cylinder heater
(option)
Heating (°C) 20-60
Cooling (°C) 7-25
220-230V ~ 50Hz
Hot Water Cylinder (option)
Hot water cylinder (option)
Water volume (liter) 150 210 300
Power supply 220-230V ~ 50Hz
Max water temperature (°C) 75
Electric heater (kW) 2.7
Height (mm) 1,090 1,474 2,040
Diameter (mm) 550
Material Stainless steel
HWS-1501CSHM3-E
HWS-1501CSHM3-UK
HWS-2101CSHM3-E
HWS-2101CSHM3-UK
HWS-3001CSHM3-E
HWS-3001CSHM3-UK
2 Accessory parts
No. Parts name Quantity
1 Installation Manual (this document) 1
2 Owner’s Manual 1
Insulator for cooling
3-EN
3
5
Insulator
–3–
Hydro Unit
Installation Manual
3 Preparations for installation
Parts required to connect this product (Common items)
Category Part Specification Quantity
Strainer (water filter) 1 1/4" 30 to 40 meshes 1
Water piping
Electrical system
Options required for each function
Drain cock (for water charge) 1
Isolating ball valves
Earth leakage breaker for main power supply 30 mA 1
Earth leakage breaker for backup heater 30 mA 1
(Option)
Earth leakage breaker for hot water cylinder
heater
1 1/4"
for service 1 1/4"
30 mA 1
2
Purpose
Heating – –
Heating &Cooling (all
rooms)
Heating & Cooling
(partly heating only)
Hot water supply
2-zone control – –
Interlocking with boiler
In the Hydro Unit Purchased part
Part name Model name Part name Prescribed specification
– – Fan coil(s)
––
Hot water cylinder
150 L
210 L
300 L
Output control board
kit (1)
HWS-1501CSHM3-E
HWS-1501CSHM3-UK
HWS-2101CSHM3-E
HWS-2101CSHM3-UK
HWS-3001CSHM3-E
HWS-3001CSHM3-UK
TBC-PCIN3E Boiler
Radiator(s), Fan coil(s), Under
floor heating
Motorized 2-way valve (for
cooling)
Motorized 3-way valve
Earth leakage breaker
Motorized mixing valve
Circulator pump Other power supply
Buffer tank
Refer to “Control parts
specifications” on page 20.
Refer to “Control parts
specifications” on page 20.
Refer to “Control parts
specifications” on page 20.
Other power supply.
Signal 12 V input function is
required for boiler.
Optional parts
No. Part name Model name Application Remarks
Boiler-linked output, Alarm output
1 External output board TCB-PCIN3E
2 External input board TCB-PCMO3E
Defrost signal output, compressor operation signal
output
Cooling/heating thermostat input
Emergency stop signal input.
Use specified products for the outdoor unit, Hydro Unit, and hot water cylinder.
Do not use commercially available products.
Use parts that conform to prescribed specifications for parts to be connected to the Hydro Unit.
If unspecified products or parts are used, a malfunction, failure or fire may be caused.
–4–
Up to two boards (according to
applications)
Up to two boards (according to
applications)
4-EN
Hydro Unit
Installation Manual
4 Precautions for safety
General safety precautions
Ensure that all Local, National and International regulations are satisfied.
• Read the “Precautions for safety” carefully before installation.
• The precautions described below include the important items regarding safety – Observe them without fail.
• After the installation work has been completed, perform a test run to check for any problems. Follow the Owner’s
Manual to explain how to use and maintain the unit to the customer.
• Turn off the main power supply switch (or breaker) before unit maintenance.
• Ask the customer to keep the Installation Manual along with the Owner’s Manual.
Refrigerant precautions
• If a refrigerant leak is suspected contact the dealer who supplied the system, in the case of a recharge of
refrigerant ask service personnel for details of the leak and confirmation of the repairs completed.
The refrigerant used in the system is harmless.
• Generally the refrigerant does not leak, however, if the refrigerant should leak into a room and a heater or stove
burner in the room is lit, toxic gas may be generated.
• Do not install the system in a location subject to a risk of exposure to a combustible gas.
If a combustible gas leaks and stays around the unit a fire may occur.
• Install the refrigerant pipe securely during installation and before operation.
If the compressor is operated with no pipe work connected and valves open the compressor will suck air which
would result in over pressurization of the system which may result in bursting or injury.
Observe the same precautions for refrigerant recovery work (pump back procedure to outdoor unit) and do not
disconnect pipe work until refrigerant is recovered and valves closed.
WARNING
Installation precautions
• Ask an authorized dealer or qualified installation professional to install/maintain the Air to Water Heat Pump System.
Inappropriate installation may result in water leaks, electric shock or fire.
• Electrical work must be performed by a qualified electrician in accordance with the installation manual.
An inappropriate power supply capacity or installation may result in fire.
• When completing any electrical works to the system ensure that all Local, National and International regulations are
satisfied.
Inappropriate grounding may result in electric shock.
• Ensure all electrical cables, used for the ESTIA installation, comply with all Local and National regulations. Check all
electrical terminations are secure and tight.
• Earth wire connections.
• Install an earth leakage breaker without fail.
Incomplete grounding can cause electric shock.
Do not earth wires to gas pipes, water pipes, lightning rods or telephone cable earth wires.
• This unit must be connected to the main power supply using a circuit breaker or switch with a contact separation of
at least 3 mm.
• Be sure to turn off all main power supply switches or the circuit breaker before starting any electrical work.
Ensure all power switches are off, failure to do so can cause electric shock.
Use an exclusive power circuit for the Air to Water Heat Pump system using the rated voltage.
• Ensure correct connection of interconnecting wire between Outdoor Unit and Hydro Unit.
Incorrect connection of the interconnecting cable may result in the damage of electrical parts.
• Ensure refrigeration system remains sealed to external gases and air.
Should air or other gases contaminate the refrigeration circuit, high system pressures could result in burst pipes and
injuries.
• Do not modify or bypass any of safety guards or switches in this system.
• After unpacking the outdoor unit, examine the unit carefully for any possible damage.
• Do not install in any place that might increase the vibration of the unit.
• To avoid personal injury (with sharp edges), be careful when handling parts.
5-EN
–5–
Hydro Unit
• Perform installation work properly in accordance with the installation manual.
Inappropriate installation may result in water leaks, electric shock or fire.
• Tighten all flare nuts with a torque wrench in the specified manner.
Excessive tightening of the flare nut may result in cracking of the pipe work or flare nut which may result in a
refrigerant leakage.
• Wear heavy duty gloves during installation work to avoid injury.
• Install the outdoor unit securely in a location where the base can sustain the weight adequately.
• In enclosed areas, if the refrigerant leaks during installation vacate and ventilate immediately.
• After installation is complete ensure and confirm that refrigerant does not leak.
If refrigerant leaks into a room and flows near a fire source noxious gas may be generated.
• Do not block any drain hoses. Hoses may come off and electric shocks may occur.
• Do not hit the manometer, because it is made of glass. It is breakable.
Installation Manual
Notes on system design
• The inlet water temperature to the Hydro Unit must be 60°C or less.
Especially, be careful when there is an external heating source such as a boiler.
When hot water over 60°C returns, it may result in a failure of the unit or water leakage.
• The flow rate of the circulating water must meet the following range.
11 kW 18 L/minute or more
8 kW 13 L/minute or more
If the flow rate becomes less than the minimum, the protective device is activated to stop the operation.
To ensure the minimum flow rate of the water system, install a bypass valve on one water circuit. Please note
this circuit must contain a minimum of 20 liters. If total water amount is not enough, the unit may not function fully
due to protective operation.
• Do not drive water by power other than the pump built in the Hydro Unit.
• The back up heaters, in the hydro unit, are designed to assist the heat pump during periods of low ambient
conditions.
• Ensure the Hydro unit and the connecting water pipes are installed in a location that is not exposed to low
ambient temperatures which could result in the water circuit freezing.
• The system operation is designed around a closed water circuit. Do not use an open circuit design.
• Circulating water must be 20 liters or more.
• Please turn on the main power supply to up to 12 hours before the start of the operation, and don’t turn off the
power all the time during the period of use.
–6–
6-EN
Hydro Unit
Installation Manual
5 Example of Hydro Unit installation
Example of installation for cooling and heating
When both cooling and heating modes are required a 2-way valve must be installed to isolate the radiator or underfloor heating circuit.
▼ Fig. 5-01
Strainer (40 mesh / 0.4 mm)
Drain Cock for water
Charge and Drain
Indirect Sanitary
Hot Water Cylinder
TTW
Isolating
Ball
Valves
M
Fan Coil Units
(Cooling or Heating)
Diverting 3-Way
Valve for
Sanitary Hot
Water Cylinder
2-Way
M
Valve
Use the 2way valve to
isolate the
heating
circuit when
in cooling
mode.
2-Way
M
Valve
Radiators (Heating Only)
[2-Way Valve Control]
Use it when do not
operate cooling.
7-EN
Alternative to Radiators
Under-floor Heating
(Heating Only)
[2-Way Valve Control]
–7–
Hydro Unit
Installation Manual
Example of 2-zone temperature control and hot water supply
system
The following shows an example of the 2-zone temperature control.
A buffer tank and a water pump are required for the 2-zone temperature control.
▼ Fig. 5-02
Hi-Pressure
By-Pass
Valve
Temperature
Regulating
Valve
(Mechanical)
TRV
Temp.
Regulating
Valve
(Mechanical)
Strainer (40 mesh / 0.4 mm)
Drain Cock for water
Charge and Drain
TTW
Isolating
Valves
(Service)
Diverting
3-Way
Valve for
Sanitary
Hot
Water
Cylinder
M
TRV
Zone 1
Fan Coil Unit (Heating
or Cooling)
Motorized 2-Way Valve
is required if fan coil
M
units are in cooling
operation.
Mixing 3-Way
M
Valve for Under
Floor Heating
External Pump for
Under Floor Heating
Indirect Sanitary Hot
Water Cylinder
–8–
TFI
Direct Buffer tank for
Under Floor Heating
Zone 2
Under-floor Heating
(2-Way Valve Control)
8-EN
Hydro Unit
6 Main components of Hydro Unit
Exploded view and description for Hydro Unit
▼ Fig. 6-01
Installation Manual
1
2
3
4
5
6
7
8
9
10
1 : Expansion vessel
2 : Temperature sensor (for Heat pump outlet -TWO)
3 : Pressure sensor
4 : Heat exchanger
5 : Flow switch (13 L/min (8 kW), 18 L/min (11 kW))
6 : Temperature sensor (for refrigerant -TC)
7 : Temperature sensor (for water inlet -TWI)
8 : Drain nipple
9 : Water inlet connection
10 : Refrigerant liquid connection
11 : Air relief valve
12 : Pressure relief valve (0.3 MPa (3 bar))
13 : Thermal protector (auto)
14 : Temperature sensor (for water outlet THO)
15 : Thermal protector (Single operation)
16 : Water pump
17 : Backup heater (3 kW, 3 kW x 2, 3 kW x 3)
18 : Manometer
19 : Water outlet connection
20 : Refrigerant gas connection
11
12
13
14
15
16
17
18
19
20
9-EN
–9–
Hydro Unit
E-box layout
▼ Fig. 6-02
Installation Manual
Main P.C. board
MCC-1511
Trans
former
External output
P.C. board MCC1217 (Option)
External output
P.C. board MCC1217 (Option)
Relay P.C. board
MCC-1431
Fuse
(
F9 F10
Relay
(RY06)
)
MG-SW (RY05)
Relay
(RY03)
Relay
(RY01)
Fuse
MG-SW (RY04)
MG-SW (RY02)
External input
P.C. board MCC1214 (Option)
–10–
TB 07
TB07
10-EN
Hydro Unit
Installation Manual
7 Hydro Unit
installation
WARNING
• To protect yourself from injury, always use PPE
(Personal Protective Equipment), that is, wear gloves.
• Install the Hydro Unit by at least two persons.
• Install the Hydro Unit in a place strong enough to
withstand the following weights:
Hydro Unit weight with no water 60
(P1104)
Hydro Unit weight with full water 80
(P1104)
CAUTION
• Do not install the unit in a place where water freezes.
• Do not install the Hydro Unit in a place where
combustible gas may leak.
• Do not install the Hydro Unit in a place exposed to rain
or water.
• Do not install the Hydro Unit near equipment which
generates heat.
• Do not install the Hydro Unit to a movable object.
• Do not install the Hydro Unit in a place exposed to
vibration.
• The unit must be installed in accordance with national
wiring regulation.
• The Hydro Unit must not be installed in a high humidity
condition area.
kg (P804) 65 kg
kg (P804) 85 kg
Positioning
Service space
Secure a service space for the Hydro Unit.
• Do not install the Hydro Unit in a place where heat
stagnates.
▼ Fig. 7-01
200 mm
100 mm
500 mm
350 mm
Mounting
Install M10 bolts at the positions shown below and
secure them with nuts.
▼ Fig. 7-02
380 mm
500 mm
M10
Handling, unpacking, and
checking the Hydro Unit
• The unit should be checked when it is delivered, and
any damage reported immediately to the courier
claims the department.
960 mm
NOTE
If customer worried about vibration of ESTIA, please
insert vibration isolating material between the product
and the wall, when installing the product.
11-EN
–11–
Hydro Unit
Installation Manual
The Hydro Unit can be installed directly without using
the fixing angles.
However, the back side of the Hydro Unit can be highly
heated, therefore, the installing surface must be heatresistant.
▼ Fig. 7-03
Remove the M5a screws to
detach the fixing angles.
▼ Fig. 7-04
380
▼ Fig. 7-05
M10
860
M10
Refrigerant piping
WARNING
• THIS SYSTEM ADOPTS HFC REFRIGERANT
(R410A) WHICH DOES NOT DESTROY THE
OZONE LAYER.
• The characteristics of R410A refrigerant are: ease to
absorb water, oxidizing membrane or oil, and its
pressure is approximately 1.6 times higher that of
R22. Accompanied with the new refrigerant the oil has
also been changed. Therefore during installation work
prevention of the invasion of water, dust, former
refrigerant or oil is of a paramount importance.
To prevent the charging of incorrect refrigerants into
the system the service valve connection ports have
also increased in size.
• The use of R410A tools is required for correct
installation of the system.
• The use of the correct pipe sizes and wall thicknesses
of copper pipe work is required for the correct
installation of the system.
CAUTION
• Ensure all refrigerant pipes are protected from the
invasion of dust and water.
• Ensure all pipe work connections are tightened to the
required torque settings detailed in this section.
• Perform an air tight using Oxygen Free Nitrogen
(OFN) only.
• Evacuate the air in the pipe work using a vacuum
pump.
• Check for refrigerant gas leaks at all connections
throughout the pipe work.
Secure the Hydro Unit with
plain washers and nuts.
Install the Hydro Unit so that its tilting angle falls within
the range below.
▼ Fig. 7-06
± 1°
▼ Fig. 7-07
± 1°
NOTE
The Air to Water Heat Pump system uses R410A
refrigerant. It is important that copper pipes used for
refrigerant piping have the following wall thickness:
• 0.8 mm for Ø6.4 mm, Ø9.5 mm and Ø12.7 mm
• 1.0 mm for Ø15.9 mm
–12–
12-EN
Hydro Unit
Installation Manual
Refrigeration pipe
The length and height of the refrigeration pipe must be
within the following values.
As long as the Hydro Unit is installed within these
ranges, no additional refrigerant is required.
▼ Fig. 7-08
Outdoor unit
L
H
H: Max. ±30 m (above or below)
L: Max. 30 m
Min. 5 m
Refrigerant pipe sizes
Hydro Unit Model Gas Side (mm)
8 & 11 kW Hydro Unit Ø 15.88 Ø 9.52
Liquid Side
(mm)
Flaring
• Cut the refrigerant pipes to the correct length using a
pipe cutter. Remove any burrs that may be on the
pipes as these may cause refrigerant leaks or
component failure in the refrigeration cycle.
• Place the correct size flare nuts onto the pipes (use
the flare nuts supplied with the Hydro Unit or use
flare nuts designed specifically for R410A
refrigerant) and then flare the pipes using the correct
flaring tool.
Tightening
• Connect the refrigerant pipes, from the outdoor unit,
to the Hydro Unit as shown below.
▼ Fig. 7-09
Gas line Ø 15.88
Liquid line Ø 9.52
• Align the flare connection on each pipe with the
corresponding outlet connection on the Hydro Unit.
Tighten the flare nuts, using fingers, to secure the
pipes in place.
• Tighten the flare nuts, using a torque wrench, to the
tightening torques shown below:
Outer Ø of Copper Pipe
(mm)
9.5 33 to 42
15.9 63 to 77
Tightening Torque (N/m)
• To prevent damage, to the refrigerant pipes, use two
spanners to tighten the flare nut connections to the
required torque.
Water pipe
13-EN
WARNING
• Install water pipes according to the regulations of
respective countries.
• Install water pipes in a freeze-free place.
• Make sure that water pipes have sufficient pressure
resistance.
The setting value of the pressure relief valve is 0.3
MPa. (3 bar)
CAUTION
• Do not use zinc plated water pipes. When steel pipes
are used, insulate both ends of the pipes.
–13–
Hydro Unit
Installation Manual
• The water to be used must meet the water quality
standard specified in EN directive 98/83 EC.
Water pipe
Design the water pipe length within the QH
characteristics of the pump (Refer to “Fig. 7-16” and “Fig.
7-17” on page 16).
The height of the pipe must be 7 m or less.
▼ Fig.7-10
H < 7 m
▼ Fig. 7-11
Attention
To avoid water leak,
exchange the seal
tapes to new one.
Attention
Water (used at test
in factory before
shipping) may be
found in the caps.
Hot water outlet
connection 1 1/4"
Water circuit
• Install a strainer with 30 to 40 meshes (locally
procured) at the water inlet of the Hydro Unit.
• Install drain cocks (locally procured) for water charge
and discharge at the lower part of the Hydro Unit.
• Make the piping route a closed circuit. (An open
water circuit may cause a failure.)
Water inlet connection
1 1/4"
▼ Fig. 7-12
Inlet
Isolating Ball Valve
Strainer (30 to 40
meshes)
Drain cock for
water charge
and discharge
–14–
Local arrangement
14-EN
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