Toshiba HWS-1403XWHD6-E, HWS-803XWHD6-E, HWS-1403XWHT9-E, HWS-1403H-E, HWS-1603H8R-E SERVICE MANUAL

...

AIR TO WATER HEAT PUMP

SERVICE MANUAL

Model name:

A10-006

Hydro Unit

HWS-803XWHM3-E(TR) HWS-803XWHT6-E(TR) HWS-803XWHD6-E HWS-803XWHT9-E HWS-1403XWHM3-E(TR) HWS-1403XWHT6-E(TR) HWS-1403XWHD6-E HWS-1403XWHT9-E(TR)

Hot Water Cylinder

HWS-1501CSHM3-E(-UK) HWS-2101CSHM3-E(-UK)

Outdoor Unit

HWS-803H-E(TR) HWS-1103H-E(TR) HWS-1403H-E(TR) HWS-1103H8-E HWS-1103H8R-E HWS-1403H8-E HWS-1403H8R-E HWS-1603H8-E HWS-1603H8R-E

HWS-3001CSHM3-E(-UK)

Contents

1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 NEW REFRIGERANT (R410A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2-1.Safety During Installation and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2-2.Installing refrigerant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2-2-1.Steel pipe and joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2-2-2.Processing of piping materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2-3.Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-3-1.Necessary tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-4.Recharging of refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-5.Brazing of pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2-5-1.Materials of brazing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2-5-2.Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2-5-3.Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Outside Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-1.Hydro unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-2.Outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-3.Hot water cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-1.Hydro Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-2.Outdoor Unit (Single phase Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-3.Outdoor Unit (3 phase type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-4.Hot Water Cylinder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6 Key Electric Component Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6-1.Hydro Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6-2.Outdoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-3.Hot Water Cylinder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6-4.Water Heat Exchange Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6-5.Outdoor Control Board (Single phase Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6-6.Outdoor Unit Control (3 phase type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

MCC-1596 (Compressor IPDU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

MCC-1597 (Fan Motor IPDU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

MCC-1599 (Interface (CDB)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

MCC-1600 (Noise Filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7 Refrigeration Cycle / Water System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7-1.Water System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7-2.Refrigeration Cycle System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8 Operational Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9 Method of Defect Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

9-1.Matters to be confirmed first. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

9-1-1.Check the power supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

9-1-2.Check for any miswiring of the connection cables between the hydro unit and the

outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

9-1-3.About the installation of the temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

9-2.Non-defective operation (pro gram operation) … No fault code display appears.. . . . . . . . . . . . . . 82

9-3.Outline of the determination diagr am . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

9-3-1.Procedure of defect diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

9-3-2.How to determine from the check code on the remote control . . . . . . . . . . . . . . . . . . . . . 83

9-3-3.How to cancel a check code on the remote controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

9-3-4.How to diagnose by error code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

9-4.Diagnosis flow chart for each error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

9-4-1.Hydro unit failure detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

9-4-2.Outdoor Unit Failure Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

9-4-3.Temperature sensor, temperature-resistance characteristic table . . . . . . . . . . . . . . . . . 122

9-5.Operation check by PC board switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

9-5-1.Operation check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

9-6.Brief method for checking the key components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

9-6-1.Hydro unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

9-6-2.Outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

10 Hydro unit and Outdoor Unit Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

11 Replacement of the Service P.C. Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

12 How to Exchange Main Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

13 Periodic Inspection Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

14 Part Exploded View, Part List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

1 SAFETY PRECAUTIONS

The unit and this service guide list very important safety precautions. Understand the following details (indications and symbols) before reading the body text, and follow the instructions.

[About indication]

Indication Meaning of Indication

DANGER

WARNING

CAUTION

*Property damage indicates extended damage to property, furniture, livestock, or pets.

Indicates that a wrong operation may cause a service engineer and the third persons around to get fatal or serious injuries.

Indicates that a wrong operation may cause a service engineer and the third persons around to get fatal or serious injuries, or that unit defective after the operation may cause a user to have a similar serious accident.

Indicates that a wrong operation may cause a service engineer and the third persons around to get injuries or may cause property damage*, or that unit defective after the operation may cause a user to have a similar accident.

[About symbols]

Symbols Meaning of Symbols

Indicates a forbidden action. Specific forbidden actions are des c ribed in text near the symbol.

Indicates a forcible (must do) action. Specific forcible actions are described in text near the symbol.

Indicates a caution (including danger and warning). Specific cautions are described in picture or text inside or near the symbol.

DANGER

<Turn off the power breaker> Turn off the power breaker before removing the front panel and cabinet.

• Failure to do so may cause a high voltage electric shock, leading to death or injury.

• During an operation, the second side circuit of high pressure transmission(*) are applied with a high voltage of 230V or higher.

• Touching the circuit even with an electrical insulator, let alone a bare hand or body, causes an electric shock.

∗: For details, see the schematic.

<Discharge between terminals> When the front panel and cabinet are removed, make short-circuit current to discharge between high pressure

capacitor terminals.

• Failure to do so may cause a high voltage electric shock, leading to death or injury.

• After the power is turned off, the high pressure capacitor is still charged with high voltage.

<Forbidden> Do not turn on the power breaker after removing the front panel cabinet.

• Failure to do so may cause a high voltage electric shock, leading to death or injury.

WARNING

<Check earth ground> Before starting failure diagnosis or repair, check tha t the grou nd wire (∗) is connected to the unit ground terminal.

• An unconnected ground wire could cause an electric shock if electric leakage occurs.

• If the earth ground is not properly connected, ask an electrical worker for rework of the ground connection.

∗: Ground wire of class D grounding

WARNING

<No modification> Do not modify the unit.

• Do not disassemble or modify the parts also.

• A fire, an electric shock, or an injury may occur.

<Use specified parts> Use the specified parts (∗) when replacing them.

• Using parts other than specified ones may cause a fire or an electric shock.

∗: For details, see the parts price list.

<Keep children away from unit> Keep any person (including children) oth er than service eng ineers away from a fail ure diagnosis or repairin g place.

• A tool or disassembled parts may cause an injury.

• Advise the customer to keep the third persons (including children) away from the unit.

<Insulation treatment> After connecting a cut lead with a crimp contact, discharge by facing the closed side upward.

• Connect lead wires with crimping terminals and turn the closed end upwards to avoid exposure to water.

<Watch out for fire> Observe the following instructions when repairing the refrigerant cycle.

(1) Watch out for surrounding fire. Always put out the fire of stove burner or other devices before starting the repair.

Should the fire fail to be put out, the oil mixed with refrigerant gas could catch fire.

(2) Do no use a welder in a closed room.

A room with no ventilation may cause carbon monoxide poisoning.

(3) Keep away flammable mate rials.

The materials may catch the fire of a welder.

<Use refrigerant carefully> Check the refrigerant name to use the tools and members appropriate for the refrigerant.

• A product using the refrigerant R410A has the refrigerant name prominently displayed on its outdoor unit. In addition, the diameter of the service port is changed from that of the conventional R22 to prevent incorrect filling.

Never use refrigerant other than R410A for Air to Water Heat Pump using R410A. Also, never use R410A for Air to Water Heat Pump using other refrigerant (such as R22).

• A mixture of R410A with different ones excessively raises the pressure in the refrigerant cycle, leading to an injury due to burst.

Do not make additional charge of the refrigerant.

• An additional charge when refrigerant gas leaks changes the refrigerant composition in the refrigerant cycle, causing the characteristics change of the Air to Water Heat Pump or excessive high pressure in the refrigerant cycle with more than the specified amount of refrigerant charged. This may cause burst or an injury. If the refrigerant gas leaks, perform refrigerant recovery or other operation to make the Air to Water Heat Pump contain no refrigerant, and then perform vacuuming. After that, refill the unit with the defined amount of liquid refrigerant. Never charge refrigerant exceeding the amount specified.

When the refrigerant cycle is refilled with refrigerant, do not enter air or refrigerants other than the specified refrigerant, R410A.

• A mixture of R410A with air or an inappropriate substance causes excessive high pressure inside the refrigerant cycle, leading to an injury due to burst.

Check that there is no refrigerant gas leak after the installation is completed.

• If it catches fire of a fan heater, a space heater, or a stove, poisonous gases may be produced.

<Be careful with wiring> After a repair is completed, be sure to reassemble the parts and put the wiring back to its original state. In addi tion,

be careful with the internal wiring not to be caught in a cabinet or panel.

• A defective assembly or wiring may cause a disaster at a customer site due to electrical leakage or a fire.

<Check for water leak> After the repair of a water pathway is completed, check that there is no water leak.

• In using the product, water leak may cause a fire at a customer site due to electrical leakage or an electric shock.

WARNING

<Check insulation> After the work is completed, check with an insulating-resistance tester (500V) that the insulation resistance between

the live and dead-metal parts is 2 MΩ or higher.

• A low insulation resistance may cause a disaster at a customer site due to electrical leakage or an electric shock.

<Ventilate> Ventilate if refrigerant gas leaks during service work.

• Should refrigerant gas catch fire, poisonous gases may be produced. A closed room full of leaking refrigerant results in the absence of oxygen; it is dangerous. Make sure to ventilate.

<Caution: electric shock> When checking a circuit while energized if necessary, use rubber gloves not to contact the live part.

• Contact with the live part may cause an electric shock.

• The unit contains high-voltage circuits. Contact with a part in the control board with your bare hand may cause an electric shock. Take enough care to check circuits.

<Turn off the power breaker> Because the electrical components are energized with high voltage, always turn off the power breaker before

starting to work.

• Failure to do so may cause an electric shock.

<Always do> Should refrigerant gas leak, find where the gas leaks and properly repair it.

• To stop the repair work because the leakage location cannot be identified, perform refrigerant recovery and close the service valve. Failure to do so may cause the refrigerant gas to leak in a room. Although refrigerant gas alone is harmless, if it catches fire of a fan heater, a space heater, or a stove, poisonous gases may be produced.

When installing the unit or re-installing it after relocation, follow the installation guide for proper operation.

• A defective installation may cause a refrigerant cycle defective, a water leak, an electric shock, or a fire.

<Check after repair> After a repair is completed, check for any abnormality.

• Failure to do so may cause a fire, an electric shock, or an injury.

• Turn off the power breaker to perform check.

After a repair is completed (and the front panel and cabinet are placed), make a test run to check for any abnormality such as smoke or abnormal sound.

• Failure to do so may cause a fire or an electric shock. Place the front panel and cabinet before making a test run.

<Check after re-installation> Check that the following are properly performed after re-installation.

(1) The ground wire is properly connected. (2) The installation is stable without any tilt or wobbles.

Failure to check them may cause a fire, an electric shock, or an injury.

CAUTION

<Wear gloves> Wear gloves (∗) when performing repair.

• Failure to do so may cause an injury when accidentally contacting the parts.

∗: Thick gloves such as cotton work gloves

<Cooling check> Perform service work when the unit becomes cool enough after the operation.

• High temperature of compressor piping or other equipment after a cooling or heating operation may cause burn.

<Tighten with torque wrench> Tighten a flare nut with a torque wrench in the specified method.

• A flare nut tightened too much might crack after a long period, causing refrigerant leak.

2 NEW REFRIGERANT (R410A)

This Air to Water Heat Pump adopts a new refrigerant HFC (R410A) to prevent destruction of the ozone layer. The working pressure of R410A refrigerant is 1.6 times higher than that of the conventional refrigerant R22.The

refrigerant oil is also changed for the new refrigeration. Therefore, during installation or service work, be sure that water, dust, former refrigerant, or refrigeration machine oil does not enter the refrigerant cycle of the new type refrigerant Air to Water Heat Pump. A wrong installation or service operation may cause a serious accident. Read carefully the following instructions to use the tools or members for R410A for safety work.

2-1. Safety During Installation and Service

• Use only the refrigerant R410A for Air to Water Heat Pump using R410A. A mixture of R410A with different ones excessively raises the pressure in a refrigerant cycle, leading to an injury due to burst.

• Check the refrigerant name to use the tools and members appropriate for the refrigerant. A product using the refrigerant R410A has the refrigerant name prominently displayed on its outdoor unit. In addition, the diameter of the service port is changed from that of the conventional R22 to prevent incorrect filling.

• Ventilate if refrigerant gas leaks during service work. Should refrigerant gas catch fire, poisonous gases may be produced. A closed room full of leaking refrigerant results in the absence of oxygen; it is dangerous. Make sure to ventilate.

• When the refrigerant cycle is refilled with refrigerant, do not mix air or refrigerants other than the specified refrigerant, R410A. A mixture of R410A with air or an inappropriate substance causes exce ssive high pressure inside the refrig erant cycle, leading to an injury due to burst.

• Check that no refrigerant gas leaks after the installation is completed. Should a refrigerant gas leak in a room and catch fire, poisonous gases may be produced.

• When installing the unit that contains lar ge amount of refrigerant such as Air to Water Heat Pump, take measures to prevent the refrigerant from exceeding the threshold concentration in case it leaks. Should leaking refrigerant exceed the threshold concentration could cause an accident due to oxygen deficient.

• When installing the unit or re-installing it after relocation, follow the installation guide for proper operation. A defective installation may cause a refrigerant cycle defective, a water leak, an electric shock, or a fire.

• Do not modify the product. Do not disassemble or modify the parts also. A fire, an electric shock, or an injury may occur.

2-2. Installing refrigerant pipe

2-2-1. Steel pipe and joint

For refrigerant piping, steel pipe and joints are mainly used. Select those comply with JIS (Japanese Industrial Standards) for a service work. Also, use such clean piping materials that less im purities attach to the inside of pipe and joints.

Copper pipe

Use copper pipe of the “copper and copper alloy seamless pipe” type with attach oil quantity of 40 mg / 10 m or less. Do not use pipe that is cracked, distorted, or discoloured (especially inside).The expansion valve or capillary may get clogged with impurities. Considering that Air to Water Heat Pump using R410A is higher in pressure than those using the conventional R22, be sure to select the material that comply with the standard. Table 2-1 shows the thickness of copper pipe used for R410A. Never use commercially available thin-walled copper pipe of 0.8 mm thick or less.

Table 2-1 Wall thickness of copper pipe

Wall thickness (mm)

Nominal diameter Outer diameter R410A

3/8 9.52 0.80 5/8 15.88 1.00

Joints

For the joint of copper pipe, flared joint and socket joint are used. Remove impurities from a joint before using it.

• Flared joint A flared joint cannot be used for the copper pipe whose outer diameter is 20 mm or larger. A socket join t can be used instead in that case. Table 2-2-3 and 2-2-4 show the dimension s of flare pipe, the end of flared joint, and flare nuts.

• Socket joint A socket joint is used to connect the thick-walled pipe of mainly 20 mm or larger in diameter. Table 2-2 shows the wall thickness of socket joints.

Table 2-2 The minimum wall thickness of socket joints

Nominal diameter

3/8 9.52 0.80 5/8 15.9 1.00

Reference of outer diameter of

copper pipe connected (mm)

Minimum joint wall thickness

(mm)

2-2-2. Processing of piping materials

When installing refrigerant pipe, prevent water or dust from entering the pipe, and do not use oil other than lubricant used for Air to Water Heat Pump. Make sure that no refrigerant leak occurs.

If piping needs lubrication, use lubricating oil whose water content is removed. After the oil is put in, be sure to seal the container with airproof cover or other covers.

Flare and precautions

1) Cut a pipe.

Cut slowly with a pipe cutter so that the pipe is not distorted.

2) Remove burr and flaw.

A burr or flaw in a flare part may cause refrigerant leak. Remove carefully all the burrs, and clean up the cut ends before installation.

3) Insert a flare nut.

4) Flare

Check that the clasps and copper pipe are clean. Flare correctly using the clasp. Use a flare tool for R410A or the conventional one. Flare processing dimension varies depending on the flare tool type. When using the conventional flare tool, use a gauge for size adjust me n t to secure the A dimension.

Figure 2-2-1 Flare dimension

Table 2-2-3 Flare processing related dimension for R410A

Nominal

diameter

3/8 9.52 0.8 0 to 0.5 1.0 to 1.5 2.0 to 2.5 5/8 15.9 1.0 0 to 0.5 1.0 to 1.5 2.0 to 2.5

Outer diameter

(mm)

Wall thickness

(mm)

Flare tool for R410A

clutch type

Table 2-2-4 Dimension of flare for R410A and flare nut

Nominal

diameter

3/8 9.52 0.8 13.0 13.2 9.7 20 18 5/8 15.9 1.0 19.1 19.7 15.9 24.5 26

Outer diameter

(mm)

Wall thickness

(mm)

ABCD

Dimension (mm)

Figure 2-2-2 Relationship between flare nut and flare surface

45° - 46°

A (mm)

Conventional flare tool

Clutch type Butterfly-nut type

Flare nut width

(mm)

DCB A

43° - 45°

Flare connecting procedure and precautions

1) Make sure that the flare and connecting portions do not have any flaw and dust.

2) Correctly align the flared surface and the connecting axis.

3) Tighten the flare with designated torque by means of a torque wrench. The tightenin g to rque fo r R4 10A is the same as that for the conventional R22. If the torque is weak, gas leakage may occur. If it is too strong, the flare nut may crack and may be made non-removable. When choosing the tightening toque, comply with values designated by products. Table 2-2-5 shows reference values.

NOTE

When applying oil to the flare surface, be sure to use oil designated by the product. Us ing any other oil deteriorates the lubricating oil, possibly causing the compressor to burn out.

Table 2-2-5 Tightening torque of flare for R410A (Reference values)

Nominal diameter Outer diameter (mm) Tightening torque N•m (kgf•m)

3/8 9.52 33 to 42 (3.3 to 14.2) 5/8 15.9 66 to 82 (6.8 to 8.2)

2-3. Tools

2-3-1. Necessary tools

In Air to Water Heat Pump using R410A, the service port diameter of packed valve of the outd oor un it is change d to prevent mixing of other refrigerant. To reinforce the pressure resistance, flare dimensions and opposite side dimensions of flare nut (For Ø 12.7 copper pipe) of the refrigerant piping are lengthened.

Because the refrigerating machine oil is changed, mixing of oil may generate sludge, clog capillary, or cause other problems. Accordingly, the tools to be used include:

• tools dedicated for R410A (Those that cannot be used for the conventional refrigerant, R22)

• tools dedicated for R410A, but can be also used for the conventional refrigerant, R22

• tools that can be used for the conventional refrigerant, R22. The following table shows the tools dedicated for R410A and their interchangeability.

Tools dedicated for R410A (The following tools must be for R410A)

Tools whose specifications are changed for R410A and their interchangeability

R410A Air to Water Hear Pump

No. Tool to be used Usage

1 Flare tool Pipe flaring Yes *(Note 1) Yes 2 3 Torque wrench (For Ø15.9) Connection of flare nut Yes No No

4 Gauge manifold 5 Charge hose 6 Vacuum pump adapter Vacuum evacuating Yes No Yes

7 8 Refrigerant cylinder Refrigerant charge Yes No No

9 Leakage detector Gas leakage check Yes No Yes

10 Charging cylinder Refrigerant charge *(Note 2) No No

Copper pipe gauge for

adjusting projection margin

Electrical balance for

refrigerant charging

Flaring by conventional

flare tool

Evacuating, refrigerant charge, run check, etc.

Refrigerant charge Yes No Yes

For R410A

Existence of new

equipment

installation

Conventional

equipment can be

used

Yes *(Note 1) *(Note 1)

Yes No No

Conventional refrigerant

Air to Water Heat Pump

installation

New equipment can be

used with conventional

refrigerant

* (Note 1) Flaring for R410A by using the conventional flare tool requires projection margin adjustment. This

adjustment requires copper pipe gauge or other instrument.

* (Note 2) A charging cylinder for R410A is currently under development.

General tools (Conventional tools are available)

In addition to the above dedicated tools, the following equipment also available for R22 is necessary as the general tools.

1. Vacuum pump Use this by attaching vacuum pump

adapter.

4. Reamer 9. Hole core drill (Ø65)

5. Pipe bender 10. Hexagon wrench (Opposite side 4mm)6. Level vial

2. Torque wrench (For Ø6.35) 7. Screwdriver (+, –) 11. Tape measure

3. Pipe cutter 8. Spanner or Monkey wrench 12. Metal saw

Also prepare the following equipment for other work methods or run check.

1. Clamp meter 3. Insulation resistance meter

2. Thermometer 4. Electroscope

2-4. Recharging of refrigerant

Recharge, if necessary, the specified amount of new refrigerant according to the following procedure.

Recover the refrigerant, and check that no refrigerant remains in the refrigerant cycle.

Connect the charge hose to packed valve service port on the outdoor unit's gas side.

Connect the charge hose to the vacuum pump adapter.

Open fully both packed valves on the liquid and gas sides.

Open fully the handle of gauge manifold Lo, turn on the vacuum pump, and then perform vacuum evacuating.

When the compound gauge's pointer indicates

-0.1 MPa (-76cmHg), close fully the handle Lo and turn off the vacuum pump.

Let the equipment stay as it is for one to two minutes and check that the compound gauge pointer does not return.

Place the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and then charge liquid refrigerant.

(For refrigerant charging, see the figure below)

NOTE

• Never charge refrigerant exceeding the specified amount.

• If the specified amount of refrigerant cannot be charged, charge it a little at a time while running refrigerant recovery (pump down).

• Do not make additional charging. An additional charge when refrigerant leaks changes the refriger ant composition in the refrigerant cycle, causing the characteristics change of the Air to Water Heat Pump or excessive high pressure in the refrigerant cycle with more than the specified amount of refrigerant charged. This may cause burst or an injury.

Fig. 2-4-1 Configuration of refrigerant charging

(Hydro unit)

Refrigerant cylinder (with siphon)

Check valve

CloseOpen

Open/close valve for charging

Electronic balance for refrigerant charging

(Outdoor unit)

Open

Service port

NOTE

• Make sure that the setting is appropriate so that liquid can be charged.

• A cylinder with siphon enables liquid to be charged without the cylinder turned upside down.

[Cylinder without siphon]

Gauge manifold

Outdoor unit

Siphon pipe

Gauge manifold

Refrigerant cylinder

Electronic balance

[Cylinder with siphon]

Outdoor unit

Refrigerant cylinder

Electronic balance

NOTE

• Because R410A is HFC mixed refrigerant, charging with gas changes the charged refrigerant composition, causing the equipment characteristics to change.

2-5. Brazing of pipes

2-5-1. Materials of brazing

Silver brazing metal

Silver brazing metal is an alloy mainly composed of silver and copper.

It uses iron, copper, or copper alloy, and is relatively expensive though it excels in soldering.

Phosphor bronze brazing metal

Phosphor bronze brazing metal is generally used to join copper or copper alloy.

Low temperature brazing metal

Low temperature brazing metal is generally called solder, and is an alloy of tin and lead. Do not u se it for refrigerant piping because its adhesive capacity is low.

NOTE

• Phosphor bronze brazing metal tends to react with sulfur, producing a fragile compound water solution. This may cause gas leakage. Therefore, use other type of brazing metal at a hot spring resort or similar place, and coat the surface with coatings.

• To braze the pipe again while performing service work, use the same type of brazing metal.

2-5-2. Flux

Type of flux

• Non-corrosive flux It is generally a compound of borax and boric acid. It is effective when brazing temperature is higher than 800 °C.

• Active solvent Most of this type of flux is generally used for silver brazing. It features the increase of oxide film while moving the capability to the borax-boric acid compound to add compounds such as potassium fluoride, potassium chloride, or sodium fluoride.

Piping materials for brazing and brazing metal / flux

Piping material

Copper - Copper Phosphor copper Do not use

Copper - Iron Silver Paste flux

Iron - Iron Silver Vapour flux

NOTE

• Do not enter flux into the refrigerant cycle.

• If chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates. Because of this, use a flux that does not contain chlorine.

• When adding water to the flux, use water that does not contains chlorine. (e.g. distilled water or ionexchange water)

• Remove the flux after brazing.

Brazing metal to be

used

Flux to be used

Why flux is necessary

• Removing all the oxide film and any foreign matter on the metal surface assists the flow of brazing metal.

• Flux prevents the metal surface from being oxidized in the course of brazing.

• Reducing the brazing metal's surface tension enables the brazing metal to adhere for better metal processing.

Characteristics of flux

• The activation temperature of flux matches the brazing temperature.

• A wide effective temperature range makes flux hard to carbonize.

• It is easy to remove slag after brazing.

• The corrosive action to the treate d metal and brazing metal is minimum.

• The good performance of flux gives no harm to a human body. Since flux works in a complicated manner as described above, select an appropriate type of flux according to metal treatment type , brazing metal and brazing method, or other conditions.

2-5-3. Brazing

Brazing must be performed by a person qualified and experienced with theoretical knowledge since the operation requires sophisticated techniques. Perform brazing while flowing dry nitrogen gas (N2) to prevent oxide film from forming during brazing application to the inside of the pipe.

NOTE

• Never use gas other than nitrogen gas.

Brazing method to prevent oxidation

1) Attach a reducing valve and a flow meter to the nitrogen cylinder.

2) Use a copper pipe to direct the piping material, and attach the flow meter to the balance.

3) Apply a mark to the clearance between the piping material and the copper pipe filled with nitrogen to prevent the back flow of the nitrogen gas.

4) If the nitrogen gas flows out, be sure to keep open the piping end.

5) Use the reducing valve to adjust the nitrogen gas flow speed to 0.05 m (0.2 kgf/cm

/hour or 0.02 MPa

6) After the steps above, keep the nitrogen gas flowing until the pipe cools down to a certain extent. (Temperature where the pipe is cool enough to be touched by hands)

7) Remove the flux completely after brazing.

Fig 2-5-1 Prevention of oxidation during brazing

Flow meter

Stop valve

Nitrogen gas cylinder

From nitrogen cylinder

Pipe

Nitrogen gas

Robber plug

3 Specifications

Unit name Hydro unit HWS-803XWHM3-E, 803XWHT6-E, 803XWHD6-E, 803XWHT9-E

Heating capacity *1 (kW) 8.0 Cooling capacity *2 (kW) 6.0 Variable range of compressor frequency 10 - 70 Hz Power source Single phase 50Hz 220 - 230V Operation mode Heating Cooling Electric characteristic *1 *2 Hydro unit Current (A) 0.98 0.46

Operating noise *1 *2 *4 Hydro unit (dB(A)) 29 29

Coefficient of performance *1 *2 4.40 2.82 Hydro unit Outer dimension Height (mm) 925

Outdoor unit Outer dimension Height (mm) 890

Refrigerant piping Connection method Flare connection

Refrigerant Refrigerant name R410A

Water piping Pipe diameter R1 1/4

Operating temperature range Hydro unit (°C) 5-32

Operating humidity range Hydro unit (%) 15-85

Wiring connection Power wiring 3 wires: including ground line (Outdoor unit)

*1 Heating performance measurement conditions: outside air temperature 7 °C, water supply temperature 30 °C, outlet temperature 35 °C, refrigerant piping length 7.5 m (no height

difference).

*2 Cooling performance measurement conditions: outside air temperature 35 °C, water s upply temperature 12 °C, outlet temperature 7 °C, refrigerant piping length 7.5 m (no height

difference).

*3 • The remote controller should be shipped with the hydro unit.

• Use two 1.5-meter wires to connect the hydro unit with the remote controller.

*4 The outdoor unit operating noise is measured at the point of 1m away from the unit back surface centre and 1m high from the ground. The hydro unit operating noise is measu r ed at the

point of 1m away from the unit front surface centre.

The value of the operating noise varies depending on room structure where the unit is installed. *5 Do not leave the hydro unit at 5 °C or below. *6 Check the water piping for leakage under the maximum operating pressure.

Outdoor unit HWS-803H-E

Power (kW) 0.101 0.097

Outdoor unit Current (A) 7.64 8.90

Total Starting current (A) 8.62 9.36

Outdoor unit (dB(A)) 49 49

Net weight (kg) 50 Color Silky shade (Munsell 1Y8.5/0.5) Remote controller

Outer dimension *3

Circulating pump Motor output (W) 125 (MAX)

Heat exchanger Plate-type heat exchange

Net weight (kg) 63 Color Silky shade (Munsell 1Y8.5/0.5) Compressor Motor output (W) 1400

Fan motor Standard air capacity (m3/min) 50.0

Hydro unit Liquid Ø9.52

Outdoor unit Liquid Ø9.52

Maximum length (m) 30 Maximum chargeless length (m) 30 Maximum height difference (m) ±30 Minimum length (m) 5

Charge amount (kg) 1.8

Maximum length (m) None (Need the flow rate 13 /min or more) Maximum height difference (m) ±7 Maximum working water pressure (kPa) 300

Outdoor unit (°C) -20-43

Outdoor unit (%) 15-100

Connecting line 4 wires: including ground line

Power factor (%) 91.5 91.7

Power (kW) 1.719 2.033 Power factor (%) 97.8 99.3

Width (mm) 525 Depth (mm) 355

Height (mm) 120 Width (mm) 120 Depth (mm) 16

Flow rate (L/min) 22.9 17.2 Type Non-self-suction centrifugal pump

Width (mm) 900 Depth (mm) 320

Type Twin rotary type with DC-inverter variable speed control Model DA220A2F-22L

Motor output (W) 60

Gas Ø15.9

Unit name Hydro unit HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E

Heating capacity *1 (kW) 11.2 14.0 Cooling capacity *2 (kW) 10.0 11.0 Variable range of compressor frequency 10 - 60Hz 10 - 70 Hz Power source Single phase 50Hz 220 - 230V Operation mode Heating Cooling Heating Cooling Electric characteristic *1 *2 Hydro unit Current (A) 0.63 0.61 0.67 0.63

Operating noise *1 *2 *4 Hydro uni t (dB(A)) 29 29 29 29

Coefficient of performance *1 *2 4.77 2.84 4.50 2.70 Hydro unit Outer dimension Height (mm) 925

Outdoor unit Outer dimension Height (mm) 1340

Refrigerant piping Connection method Flare connection

Refrigerant Refrigerant name R410A

Water piping Pipe diameter R1 1/4

Operating temperature range Hydro unit (°C) 5-32

Operating humidity range Hydro unit (%) 15-85

Wiring connection Power wiring 3 wires: including ground line (Outdoor unit)

*1 Heating performance measurement conditions: outside air temperature 7 °C, water supply temperature 30 °C, outlet temperature 35 °C, refrigerant piping length 7.5 m (no height

difference). *2 Cooling performance measurement conditions: outside air temperature 35 °C, water s upply temperature 12 °C, outlet temperature 7 °C, refrigerant piping length 7.5 m (no height

difference). *3 • The remote controller should be shipped with the hydro unit.

• Use two 1.5-meter wires to connect the hydro unit with the remote controller.

*4 The outdoor unit operating noise is measured at the point of 1m away from the unit back surface centre and 1m high from the ground. The hydro unit operating noise is measur ed at the

point of 1m away from the unit front surface centre.

Outdoor unit HWS-1103H-E HWS-1403H-E

Power (kW) 0.135 0.130 0.145 0.135

Outdoor unit Current (A) 9.94 14.88 13.37 17.47

Total Starting current (A) 10.57 15.49 14.04 18.10

Outdoor unit (dB(A)) 49495151

Net weight (kg) 54 Color Silky shade (Munsell 1Y8.5/0.5) Remote controller

Outer dimension *3

Circulating pump Motor output (W) 190 (MAX)

Heat exchanger Plate-type heat exchange

Net weight (kg) 93 Color Silky shade (Munsell 1Y8.5/0.5) Compressor Motor output (W) 2500

Fan motor Stand ard air capacity (m3/min) 103.0

Hydro unit Liquid Ø9.52

Outdoor unit Liquid Ø9.52

Maximum length (m) 30 Maximum chargeless length (m) 30 Maximum height difference (m) ±30 Minimum length (m) 5

Charge amount (kg) 2.7

Maximum length (m) None (Need the flow rate 17.5 /min or more) Maximum height difference (m) ±7 Maximum working water pressure (kPa) 300

Outdoor unit (°C) -20-43

Outdoor unit (%) 15-100

Connecting line 4 wires: including ground line

Power factor (%) 93.2 92.7 94.0 93.2

Power (kW) 2.2153.392.9653.945 Power factor (%) 96.9 99.1 96.4 98.1

Width (mm) 525 Depth (mm) 355

Height (mm) 120 Width (mm) 120 Depth (mm) 16

Flow rate (L/min) 32.1 28.9 40.1 31.5 Type Non-self-suction centrifugal pump

Width (mm) 900 Depth (mm) 320

Type Twin rotary type with DC-inverter variable speed control Model DA422A3F-25M

Motor output (W) 100 × 2

Gas Ø15.9

Unit name Hydro unit HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E

Heating capacity *1 (kW) 11.2 14.0 16.0 Cooling capacity *2 (kW) 10.0 11.0 13.0 Variable range of compressor frequency 10 - 60Hz 10 - 60 Hz 10 - 70 Hz Power source 3 phase 50Hz 380 - 400V Operation mode Heating Cooling Heating Cooling Heating Cooling Electric characteristic *1 *2 Hydro unit Current (A) 0.63 0.61 0.67 0.63 0.69 0.66

Operating noise *1 *2 *4 Hydro unit (dB(A)) 29 29 29 29 29 29

Coefficient of performance *1 *2 4.69 2.84 4.36 2.70 4.30 2.71 Hydro unit Outer dimension Height (mm) 925

Outdoor unit Outer dimension Height (mm) 1340

Refrigerant piping Connection method Flare connection

Refrigerant Refrigerant name R410A

Water piping Pipe diameter R1 1/4

Operating temperature range Hydro unit (°C) 5-32

Operating humidity range Hydro unit (%) 15-85

Wiring connection Power wiring 5 wires: including ground line (Outdoor unit)

*1 Heating performance measurement conditions: outside air temperature 7 °C, water supply temperature 30 °C, outlet temperature 35 °C, refrigerant piping length 7.5 m (no height

difference). *2 Cooling performance measurement conditions: outside air temperature 35 °C, water s upply temperature 12 °C, outlet temperature 7 °C, refrigerant piping length 7.5 m (no height

difference). *3 • The remote controller should be shipped with the hydro unit.

• Use two 1.5-meter wires to connect the hydro unit with the remote controller.

*4 The outdoor unit operating noise is measured at the point of 1m away from the unit back surface centre and 1m high from the ground. The hydro unit operating noise is measu r ed at the

point of 1m away from the unit front surface centre.

Outdoor unit HWS-1103H8(R)-E HWS-1403H8(R)-E HWS-1603H8(R)-E

Power (kW) 0.135 0.130 0.145 0.135 0.150 0.140

Outdoor unit Current (A) 4.03 5.65 5.23 6.50 5.95 7.50

Total Starting current (A) 4.66 6.26 6.06 7.13 4.26 8.16

Outdoor unit (dB(A)) 495051515252

Net weight (kg) 54 Color Silky shade (Munsell 1Y8.5/0.5) Remote controller

Outer dimension *3

Circulating pump Motor output (W) 190 (MAX)

Heat exchanger Plate-type heat exchange

Net weight (kg) 93 Color Silky shade (Munsell 1Y8.5/0.5) Compressor Motor output (W) 2500

Fan motor Standard air capacity (m3/min) 103.0

Hydro unit Liquid Ø9.52

Outdoor unit Liquid Ø9.52

Maximum length (m) 30 Maximum chargeless length (m) 30 Maximum height difference (m) ±30 Minimum length (m) 5

Charge amount (kg) 2.7

Maximum length (m) None (Need the flow rate 17.5 /min or more) Maximum height difference (m) ±7 Maximum working water pressure (kPa) 300

Outdoor unit (°C) -20-43

Outdoor unit (%) 15-100

Connecting line 4 wires: including ground line

Power factor (%) 93.2 92.7 94.0 93.2 94.5 92.3

Power (kW) 2.255 3.39 3.065 3.945 3.570 4.660 Power factor (%) 81.187.084.988.087.090.0

Width (mm) 525 Depth (mm) 355

Height (mm) 120 Width (mm) 120 Depth (mm) 16

Flow rate (L/min) 32.128.940.131.545.837.3 Type Non-self-suction centrifugal pump

Width (mm) 900 Depth (mm) 320

Type Twin rotary type with DC-inverter variable speed control Model DA422A3F-27M

Motor output (W) 100 × 2

Gas Ø15.9

4 Outside Drawing

4-1. Hydro unit

HWS-803XWHM3-E, 803XWHT6-E, 803XWHD6-E, 803XWHT9-E HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E

40.540.5

371.5 355

2-dia.12x17 long hole (for dia.8-10 anchor bolt)

B leg part

92554

72.5 72.5 Anchor bolt

2020

960

Anchor bolt long hole pitch

525

380

long hole pitch

19.5

352

Manometer Remote controler

A leg part

Drain nipple Water inlet

connecting pipe 1 1/4"

259

2-dia.12x17 U-shape hole (for dia.8-10 anchor bolt)

309.5

11619.5

Hot water outlet connecting pipe 1 1/4"

135.5

186.5

158

37.5

Gas line dia.15.88 Liquid line dia.9.52

59.5144.5

4-2. Outdoor unit

HWS-803H-E

Name Description

Refrigerant piping outlet

Indoor and outdoor

connecting line outlet

Power source intake hole 38 knockout hole

Mounting bolt hole

( 12 17 U-shape hole)

Mounting bolt hole

( 12 17 long hole)

54 48

Portion B

Drain hole ( 25 burring hole)

200

Air inlet

380

170

Air outlet

Details of portion B

Details of portion A

Portion A

383

600

150

320

900

550

Refrigerant gas

Refrigerant liquid

connection

( 9.5 flare)

890

( 15.9 flare)

255 247

400

151

155

135

178

518

327

178

17.5

Air inlet

128

365

118

534

17.5

5-Drain hole ( 20 88 burring hole)

581

165 148

(12- 3 embossed)

Optional mounting hole

Knockout for lower part of piping

Z arrow view

HWS-1103H-E, 1403H-E, 1103H8(R)-E, 1403H8(R)-E, 1603H8(R)-E

Description

38 knockout hole

Name

Refrigerant piping outlet

Indoor and outdoor

connecting line outlet

Power source intake hole 2

Mounting bolt hole

( 12 17 long hole)

Portion B

Mounting bolt hole

( 12 17 U-shape hole)

Details of portion B

Details of portion A

54 48

9555

1340

320

( 15.9 flare)

Refrigerant gas connection

( 9.5 flare)

Refrigerant liquid connection

613 605

400

151

155

1880

135

Drain hole ( 25 burring hole)

200

Air inlet

380

17.5

170

Air inlet

128

118 74

Portion A

600

900

Air outlet

383

150

52 550

17.5 365

5-Drain hole ( 20 88 burring hole)

53412153485

360 655

518

327

178 178 178

70 581 74 581

(24- 3 embossed)

Optional mounting hole

Knockout for lower part of piping

Z arrow view

4-3. Hot water cylinder

HWS-3001CSHM3-E(-UK)

550

5952066.6

Specification

for UK only

2040

HWS-2101CSHM3-E(-UK)

550

5951497.6

Specification

for UK only

1474

HWS-1501CSHM3-E(-UK)

550

5951114

Specification

for UK only

1090

5 Wiring Diagram

5-1. Hydro Unit

Color identification

BLK : BLACK BRW : BROWN GRY : GRAY PNK : PINK WHI : WHITE

WHI WHI

YEL

5251

WPM

*See DIP SW13_1

BLU

2WV

BLU : BLUE GRN : GREEN ORN : ORANGE RED : RED YEL : YELLOW

BRW

WARNING

CAUTION

YEL BLU

BRW

WHI

WHI RED

WHI

RED

WHI

YEL

BH 3WV

(2-wire spring return)

WHI

YEL

RED

3WV

(3-wire SPST type)

(3-wire SPDT type)

TB 05

Type 1

TB 05

Type 2

Type 3

787 6 55 4 3 2

3 2

Perform the grounding from the earth terminal in the terminal block of the outdoor unit.

Electric shock may happen. Don't touch the electric parts.

CN10 (WHI)

CR10 CR11 CR12 CR13

CN01 (WHI)

F01 (5A)

PNK

RED

MIXV

(3-wire SPDT type)

PNK

RED

MIXV (3-wire SPST type)

WHI

RY 11

RY 10

RY 13

ORN

RY 12

Relay

p.c.board

(MCC-1431)

WPM

TB 04

Type 1

TB 04

Type 2

CN02 (WHI)

LNNL

(HWS-AMS11E)

55 4 3 2 11

Remote

controller

GRY

BLK

*Option

Remote

controller

(HWS-AMS11E)

TB 07

WHI

RED BLU ORN GRN BRW

BLU BRW

RED WHI

YEL WHI

RED

WHI

GRY

BLK

BLK 2

1 CN41

CN203

(YEL)

(BLU)

6 5

5 4

CN501 (YEL)

3 2

313

CN603

(YEL)

313

CN601 (RED)

5 3

CN602

(WHI)

RY601RY600RY603 RY602

RY604

CN604

(BLU)

WHI

RED

468

PNK

ORN

RED

THOTWOTWITC

LPS

BLK

BLK 1 1

CN204 (BRW)

111

CN206

CN205

(RED)

P.C.board

(MCC-1511)

(WHI)

WHI

BLK

RED

CN207

CN212

(BLU)

(WHI)

SW01 SW02

12 43

SW10 SW11 SW12 SW13

CN605

(YEL)

1 1

BLK

RY606RY605

1 WHI

ORN

RY 02

WHI WHI

1234 1234 123 41234

SW06

CN606

(BLU)

1 1

WHI 6

487

RY607

3 3

RY 04RY03

ON21ON

SW07

PNK

*Option

TTW

TFI

TB 06

BRW

RED

1 CN213

CN214

(WHI)

SW14

OFF

CN305

CN100

(GRN)

(WHI)

WHI

RED

GRY

Symbol

WPM 3WV 2WV 2-way valve (local) MIXV BH RY01~RY06 LPS

RED

CN208

(BLU)

CN209 (GRN)

CN210 (RED)

CN211

(BLK)

CN200 (RED)

CN201

(WHI)

CN202

(YEL)

CN102

(WHI)

CN101

(WHI)

F100 Fuse T5A 250V~

Water pump motor 3-way valve (local)

Mixing valve (local) Booster heater Relay01~Relay06 Low pressure sensor Heater AC230V, 3kWBackup heater1, 2, 3

GRN

414

PJ20

GRN

414

PJ20

YEL

414

PJ17

YEL

414

PJ17

YEL

GRN

RED

BLK

323

BRW

RED

ORN

WHI

BLK

P100

HWS-803XWHT6-E : Installed HWS-1403XWHT6-E : Installed HWS-803XWHD6-E : Installed HWS-1403XWHD6-E : Installed HWS-803XWHT9-E : Installed HWS-1403XWHT9-E : Installed HWS-803XWHM3-E : Not installed HWS-1403XWHM3-E : Not installed

Parts name

Relay p.c.board (MCC-1217)

Photocoupler input p.c.board

(MCC-1214)

Photocoupler input p.c.board

(MCC-1214)

Pressure switch

4.15MPa

Thermal protector (auto)

Symbol

TC TWI TWO THO TTW TFI TB

3 2

TB1

3 2

TB1

3 2 1

TB1

3 2 1

TB1

Flow switch

75 5

Transformer

HWS-803XWHT6TR : Installed

HWS-1403XWHT6TR : Installed HWS-1403XWHT9TR : Installed HWS-803XWHM3TR : Not installed HWS-1403XWHM3TR : Not installed

Parts name

Water heat exchanger temperature sensor Water heat exchanger inlet temperature sensor Water heat exchanger outlet temperature sensor Backup heater outlet temperature sensor Hot water cylinder temperature sensor Floor heating inlet temperature sensor Terminal block

*Option p.c.board

Boiler control O/P Alerm O/P

Compressor operation O/P

Defrost O/P

Emergency stop I/P

Cooling thermostat I/P Heating thermostat I/P

1. The one-dot chain line indicates wiring at the local site, and the dashed line indicates accessories sold separately and service wires, respectively.

, and indicates the terminal board and the numberals ndicate the terminal numbers.

indicates P.C. board.

* Be sure to fix the electric

parts cover surely with screws. (Otherwise water enters into the box resulting in malfunction.)

WHI

RED

12111

Power supply 220 - 230V~ 50Hz or 380 - 400V~ 50Hz

TB 03

GRY TB 01

Outdoor unit

BRW

BLU

Hot water cylinder

1L1

3L2

4T2

2T1

BLU

BRW

F1 F2

BRW

Power supply 220 - 230V~ 50Hz

RY05

BLU

F1, F2 Fuse AC250V T30A

YEL/GRN

*Option

5L3

1L1

3L2

RY02

6T3

4T2

2T1

GRY

BRW

BLU

F3F4F6F5F8

BLU

BLK

BLU

BRW

L1L2

Power supply

380 - 400V 3N~ 50Hz

L12L3

2T1

BLU

GRY

Thermal protector (Single operation)

95 5

Thermal protector (Single operation)

95 5

5L3

6T3

4T2

BLK

BLU

F3~8 Fuse AC250V T30A

TB 02

Thermal protector (Single operation)95 5

RY04

BLU

Backup heater 1

Backup heater 2

Backup heater 3

HWS-803XWHT9-E HWS-1403XWHT9-E HWS-1403XWHT9TR

RY02

4T22T1 6T3

BLU

BRW

F3 F6

BLK

BLU

BRW

Power supply

380 - 400V 3N~ 50Hz

3L51L12L3

BLK

1L2

Thermal protector (Single operation)

1L1 3L2

2T1 4T2

F3~6 Fuse AC250V T30A

BLU

95 5

5L3

RY04

6T3

BLU

TB 02

Backup heater 1

Backup heater 2

HWS-803XWHT6-E HWS-1403XWHT6-E HWS-803XWHT6TR HWS-1403XWHT6TR

5L31L1 3L2

6T32T1 4T2

BLU

BRW

BLU

BRW

Power supply

220 - 230V~ 50Hz

Thermal protector (Single operation)

95 5

RY02

F3,F4 Fuse AC250V T30A

TB 02

Backup heater 1

HWS-803XWHM3-E HWS-1403XWHM3-E HWS-803XWHM3TR HWS-1403XWHM3TR

RY02

4T22T1 6T3

BLU

BRW

F3 F6

BLU

BRW

Power supply

220 - 230V 3~ 50Hz

3L51L12L3

BLK

1L2

BLK

BLU

Thermal protector (Single operation)

95 5

Thermal protector (Single operation)

95 5

1L1 3L2

2T1 4T2

F3~6 Fuse AC250V T30A

TB 02

5L3

6T3

BLU

Backup heater 1

Backup heater 2

RY04

HWS-803XWHD6-E HWS-1403XWHD6-E

5-2. Outdoor Unit (Single phase Type)

HWS-803H-E, HWS-1103H-E, HWS-1403H-E

Compressor

Fan motor

Pulse motor valve coil

Discharge temperature sonsor

Suction temperature sensor

Heat exchange sensor 1

Heat exchange sensor 2

Outdoor temperature sensor

Linetilter

4-way valve coil

Compressor case thermostat

Fuse 25 A, 250 VAC

Fuse 10A, 250 VAC

Reactor

Upper

RWB

(White)

White)

(

Symbol Item name

White)

(

20SF

Control board

an optional accessory or service wiring.

1. indicates a terminal plate. The number inside indicates the terminal number.

2. The double-dashed line indicates a local wiring while the dashed line indicates

3. indicates a printed board.

4. For the hydro unit circuit, see the hydro unit wiring diagram.

220-230V

WhiteRed

50Hz

single phase

Power supply

Earth

screw

WR B

Hydro unit

valve

4-way

Earth screw

Outdoor unit

coil

Earth screw

(White)

(Blue)

HMS-1103,

1403H-E only

(Yellow)

input

External

White)

(

power

Operating

White)

(

White)

Yellow)

(

(White)

White)(White)(White)

(

5-3. Outdoor Unit (3 phase type)

HWS-1103H8(R)-E, -1403H8(R)-E, -1603H8(R)-E

P.C. board MCC-1596

P.C. board MCC-1597

Hydro unit

(1103H8R-E 1403H8R-E 1603H8R-E) only

indicates the teminal block. Alphanumeric characters in the cycle indicate terminal No. The two-dot chain line indicates the wiring procured locally. indicates the P.C. board. For the hydro unit circuit, refer to the wiring diagram of the indoor unit.

5-4. Hot Water Cylinder Unit

Green / Yellow

TB06(TTW)

To hydro unit

Blue

Double pole thermal cut out

Brown

TTW sensor

Hot water cylinder heater

Blue

Brown

TB03(230V)

Supply 220 - 230 V from hydro unit Cable size 1.5 mm

(minimum)

6 Key Electric Component Rating

6-1. Hydro Unit

HWS-803XWHM3-E, T6-E, D6-E, T9-E

No. Component name

Circulating pump Backup heater 6 kW

Backup heater 9 kW Water heat exchange

temperature sensor (TC sensor)

Water inlet temperature sensor

(TWI sensor) Water outlet temperature sensor

(TWO sensor) Heater outlet water temperature

sensor (THO sensor)

Floor inlet temperature sensor

(TFI sensor) Pressure switch

Low pressure sensor Bimetal thermostat (auto)

Bimetal thermostat (singl e

operation)

Flow switch

Output board (OP)

Input board (OP)

Remote control (Main)

Remote control (Sub) Water 3-way valve terminal

Water 2-way valve terminal Mixing valve terminal

Circulating pump terminal

Booster heater terminal

Fuse

Model name

Type name Rating

M3-E T6-E D6-E T9-E

OOOO

OOO –

OOOO –

OOOO – OP OP OP OP OP OP OP OP

OOOO OP OP OP OP

OOOO –

UPS025-65 K 130 AC230 V 0.54 A (MAX)

O–

TCB-PCIN3E AC230 V 0.5 A DC24 V 1 A TCB-PCM03E Contact input HWS-AMS11E HWS-AMS11E

AC 400 V (3N) 6 kW (AC230 V 3 kW compatible)

AC400V (3N) 9 kW 10 kΩ (25°C)

10 kΩ (25°C)

Operating pressure 4.15 MPa +0 -0.3 MPa

Operating pressure 0. 20 M Pa Operating temperature 75±3°C DC42 V

/ 0.2 A Operating temperature 95±5°C

AC250 V / 16 A Operating flowing quantity 13 /min

AC230 V 0.1 A 2Wire, 3Wire SPST, SPDT type mountable

AC230 V 0.1 A 2Wire type mountable AC230 V 0.1 A

3Wire SPST, SPDT type mountable AC230 V 1.0 A AC230 V 1.0 A AC 250 V 30 A

O·········Applied OP·······Optional accessory

HWS-1403XWHM3-E, T6-E, D6-E, T9-E

No. Component name

Circulating pump Backup heater 6 kW

Backup heater 9 kW Water heat exchange

temperature sensor (TC sensor)

Water inlet temperature sensor

(TWI sensor) Water outlet temperature sensor

(TWO sensor) Heater outlet water temperature

sensor (THO sensor)

Floor inlet temperature sensor

(TFI sensor) Pressure switch

Low pressure sensor Thermal protector (auto)

Thermal protector (single

operation)

Flow switch

Output board (OP)

Input board (OP)

Remote control (Main)

Remote control (Sub) Water 3-way valve terminal

Water 2-way valve terminal Mixing valve terminal

Circulating pump terminal

Booster heater terminal

Fuse

Model name

M3-E T6-E D6-E T9-E

OOOO

OOO –

OOOO –

OOOO – OP OP OP OP OP OP OP OP

OOOO OP OP OP OP

OOOO –

Type name Rating

UPS25-80 130 AC230 V 0.83 A (MAX)

AC 400 V (3N) 6 kW (AC230 V 3kW compatible)

O–

AC 400 V (3N) 9 kW 10 kΩ (25°C)

10 kΩ (25°C)

Operating pressure 4.15 MPa +0 -0.3 MPa

Operating pressure 0. 20 M Pa Operating temperature 75±3°C DC42 V

/ 0.2 A Operating temperature 95±5°C AC250

V 16 A

Operating flowing quantity 17.5 L/min TCB-PCIN3E AC230 V 0.5 A DC24 V 1 A TCB-PCM03E Contact input HWS-AMS11E HWS-AMS11E

AC230 V 0.1 A

2Wire, 3Wire SPST, SPDT type

mountable

AC230 V 0.1 A 2Wire type mountable

AC230 V 0.1 A

3Wire SPST, SPDT type mountable

AC230 V 1.0 A

AC 250 V 30 A

O·········Applied OP·······Optional accessory

6-2. Outdoor Unit

HWS-803H-E

No. Component name Type name Rating

Compressor DA220A2F-22L

Outdoor fan motor ICF-280-A60-1 Output 60 W 4-way valve coil VHV-01AP552B1 AC220 - 230 full-wave rectifier input, alive time

Pulse motor valve (PMV) coil CAM-MD12TF-15 DC12 V

Compressor case thermostat US-622KXTMQO-SS OFF: 125±4°C ON: 90±5°C

Reactor CH-56 5.8 mH, 18.5 A PC board MCC-1571 Input 1Ø, AC220 - 230 V ± 10 %,

10 sec or less

50/60 Hz

HWS-1103H-E, 1403H-E

No. Component name Type name Rating

Compressor DA422A3F-25M

Outdoor fan motor (x2) ICF-280-A100-1 Output 100 W

Reactor (x2) CH-44 1.4 mH, 25 A

4-way valve coil AC220 - 230 V full-wave rectifier input, alive time 10 sec or less

Pulse motor valve (PMV) coil UKV-A038 DC12 V

Board MCC-1560 Input 3Ø, AC230 V±23 V, 50/60 Hz

Compressor case thermostat US-622KXTMQO-SS OFF = 125 ± 4 °C, ON = 90 ± 5 °C

PC board MCC-1571 Input 1Ø, AC220 - 230 V ± 10 %, 50/60 Hz

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