Toshiba HWS-804XWHT6, HWS-1404XWHT6, HWS-804XWHT9, HWS-1404XWHM3, HWS-1404XWHT9 Quick Reference Manual

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Quick Reference

Air to Water Heat Pump

Series 4

Hydro Unit

HWS-

804H-**

HWS-

1104H-**

HWS-

1404H-**

HWS-

1104H8-**

HWS-

1404H8-**

HWS-

1604H8-**

HWS-

1104H8R-**

HWS-

1404H8R-**

HWS-

1604H8R-E

Back Up

Heater

HWS-804XWHM3-** P

- - - - - - - - ~, 3Kw

HWS-804XWHT6-** P

- - - - - - - - 3N, 6kW

HWS-804XWHT9-** P

- - - - - - - - 3N, 9kW

HWS-1404XWHM3-**

- P P P P P P P P ~, 3Kw

HWS-1404XWHT6-**

- P P P P P P P P 3N, 6kW

HWS-1404XWHT9-**

- P P P P P P P P 3N, 9kW

Outdoor Unit

Hydro Unit

HWS-1501

CSHM3-E

HWS-2101

CSHM3-E

HWS-3001

CSHM3-E

HWS-1501

CSHM3-UK

HWS-2101

CSHM3-UK

HWS-3001

CSHM3-UK

HWS-804XWHM3-** HWS-804XWHT6-** HWS-804XWHT9-** HWS-1404XWHM3-** HWS-1404XWHT6-** HWS-1404XWHT9-**

Hot Water Cylinder

Estia System

Component Combinations

Outdoor unit

Hydro unit

Hot Water

Hot water cylinder

Under floor heating

(Zone Control)

Radiator

Fan coil unit

(Heating or Cooling)

Heating or Cooling

New Features for 4 Series ESTIA:

 A-rated water circulating pump installed in hydro unit  Minimum target water temperature reduced to 7°C in cooling mode for improved compatibility with fan

coil units

 Hydro unit pump ON / OFF cycling function – to momentarily operate water pump during long periods of

system OFF

 Option to use an external cylinder thermostat, on locally supplied hot water cylinders, for domestic hot

water production

 Improved control for second remote controller when used with under floor heating  Improved control for ESTIA / boiler connection  New expansion vessel for hydro unit  New compressor for single phase ESTIA outdoor units

Note:

Under floor heating components, fan coil units, radiators, valves and other installation materials must be procured locally.

Notes on System Design

• The input water temperature to the hydro unit must be 50°C or less. This is especially important if the hydro unit is used in conjunction with any other external heating source (auxiliary boiler, electric booster heaters etc.) Unit failure or water leaks may result if the return water temperature, to the hydro unit, exceeds 50°C

• The minimum flow rate for the circulating water in the heating/cooling circuit must meet the following range:-

11, 14 and 16 kW: 17.5 L/minute or more 8 kW: 13 L/minute or more

If the flow rate becomes less than the flow rate specified above, the flow switch in the hydro unit is activated to stop operation. When thermostatic devices are used for temperature control a bypass valve must be fitted to the heating circuit, to ensure the minimum water flow rate is maintained in the event of all thermostatic devices closing at the same time

• Only use the water pump, built into the hydro unit, to circulate the water in the heating circuit

• The hydro unit back up heaters will operate to assist the heat pump capacity output during low ambient

conditions

• The hydro unit has been designed for indoor installations. Do not install outside where there is a risk of low ambient conditions. This may cause the water in the pipe work to freeze

• Make the water circuit closed. Never use it as an open circuit.

• To prevent damage to the system the volume of the circulating water must be 20 litres or more. If total

volume of water amount is less than 20 litres, then the unit may not function fully due to the operation of protective controls.

Installation Examples

Cooling and Heating with Domestic Hot Water

When both cooling and heating are used, install a 2-way valve (for cooling) to the pipe to the room for heating only.

Installation Examples (cont.)

2-Zone Temperature Control with Domestic Hot Water

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. This example is Heating only, if the Fan Coils are to be used for Cooling then a 2-Way valve must be fitted.

Installation example of water circuit:-

(1) (2)

(3) (4)

(5) (6)

The water circuit for a system without a buffer tank [ (1) , (2) , (3) , (5) ] requires 17.5l/min (804XWH = 13.0l/min) or more. This water flowing requires 5 or more branches of Floor heating or Radiators etc. Less than 5 branches may cause a flow deficiency. In this case, please provide a buffer tank and secondary pumps, as shown in (4). Please check how to install the boiler.

Hydro Unit – Exploded View

1. Expansion vessel

2. Hi Pressure switch (4.15 MPa)

3. Temperature sensor (for Heat pump outlet -TWO)

4. Pressure sensor

5. Heat exchanger

6. Flow switch (13.0 L/min 17.5 L/min)

7. Temperature sensor (for refrigerant -TC)

8. Temperature sensor (for water inlet -TWI)

9. Drain nipple

10. Water inlet connection

11. Refrigerant liquid connection

12. Air relief valve

13. Pressure relief valve (0.3 MPa (3 bar))

14. Thermal protector (auto)

15. Temperature sensor (for water outlet THO)

16. Thermal protector (Single operation)

17. A-rated water pump

18. Backup heater (3 kW, 3 kW x 2, 3 kW x 3)

19. Manometer

20. Water outlet connection

21. Refrigerant gas connection

Refrigerant Pipe Lengths and Height

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.

Minimum Pipe Length

HWS-804H-E : 5 m HWS-1104H**-E : 5 m HWS-1404H**-E : 5 m HWS-1604H**-E: 5m

Maximum Pipe Length and Height

H: Max. ±30 m (above or below) L: Max. 30 m

Note

 The maximum pipe length cannot be increased by increasing the

refrigerant charge

 The minimum pipe length cannot be decreased by reducing the

refrigerant charge

Refrigeration and Water Cycle Diagrams

Outdoor Unit: HWS-804H-E Hydro Units: HWS-804XWH**-E

Outdoor Units: HWS-1104H**-E, HWS-1404H**-E Hydro Units: HWS-1404XWH**-E

Outdoor Units: HWS-1104H8(R)-E, HWS-1404H8(R)-E, HWS-1604H8(R)-E Hydro Units: HWS-1404XWH**-E

Water Piping

WARNING

• Ensure that the heating circuit, and all components of the heating circuit, are installed in accordance with all National and local regulations

• The water pipes must not be installed where they are exposed to low ambient air temperatures. This is to

prevent the water freezing in the pipes

• Make sure that water pipes have sufficient pressure resistance (The setting value of the pressure relief valve is 0.3 MPa).

CAUTION

• Do not use zinc plated water pipes. When steel pipes are used, insulate both ends of the pipes.

• The water to be used must meet the water quality standards specified in EN directive 98/83 EC.

Water Circuit

• Install a strainer with 30 to 40 meshes (procure locally) at the

water inlet of the Hydro Unit

• Install drain cocks (procure locally) for water charge and discharge

at the lower part of the Hydro Unit

• The ESTIA system can only be used on pressurised heating

circuits. If the system is used on gravity fed heating circuits then system failure may occur

Water Piping Limitations

Design the water pipe length within the QH characteristics of the pump (flow-rate and pump head).

The maximum height difference for the water pipes is 7 metres.

Piping to hot water tank (option)

Water supplied to the hot water cylinder is branched by a motorized 3-way valve (procured locally). Connect the hot water cylinder to port A (open when energized) of the valve.

Piping to 2-zone operation (option)

To perform 2-zone temperature control circulate water using another pump (procured locally) through a motorized mixing valve (procured locally) and a buffer tank (procured locally).

Checking water volume and initial pressure of expansion vessel

The expansion vessel of the Hydro Unit has a capacity of 12 litres. The initial pressure of the expansion vessel is 0.1 MPa (1 bar). The pressure of the safety valve is 0.3 MPa (3 bar). Verify whether the capacity of the expansion vessel is sufficient using the following expression. If the volume is insufficient, install an appropriate external expansion vessel.

Action

< 12 L

Internal Expansion Vessel Size OK

> 12 L

Internal Expansion Vessel Size too small.

Install appropriate external expansion vessel

V: Necessary total vessel capacity (L) Ɛ: Water expansion coefficient at average hot water temperature

Vs: Total water volume in the closed system (Do not include Hot Water Cylinder) P1: System pressure at tank setting position (Mpa_abs*).

(Pipe inner pressure during pump operation before heating device operates = water supply pressure)

P2: Maximum pressure used during operation at tank setting position (MPa_abs*).

(= safety valve setting pressure)

* The absolute pressure value (abs.) is obtained by adding the atmospheric pressure (0.1 MPa (1 bar)) to the gauge pressure.

Water temperature and expansion coefficient (Ɛ)

Hot water temperature

(°C)

Expansion rate

(Ɛ)

Hot water temperature

(°C)

Expansion rate

(Ɛ)

0.0002

0.0121

0.0000

0.0145

0.0000

0.0171

0.0003

0.0198

0.0008

0.0229

0.0017

0.0258

0.0029

0.0292

0.0043

0.0324

0.0050

0.0961

0.0078

0.0967

0.0100

Example

Maximum Hot Water temperature: 55°C Initial water charge: 0.2MPa System volume: 200 L.

Calculate Vessel capacity (V):-

In this case V < 12 L therefore the internal expansion vessel is sufficient, so there is no need to install an external expansion vessel.

V =

0.0145

200

(0.2 + 0.1) (0.3 + 0.1)

V =

11.6L

Pump QH curves

 HWS-804XWHM3-E, T6-E, T9-E

 HWS-1404XWHM3-E, T6-E,T9-E

Water charging

Charge the water, in the heating circuit, until the pressure gauge shows 0.2 MPa (2 bar). The hydraulic pressure may drop when the trial run begins. In this case, add water until the hydraulic pressure returns to 0.2MPa (2 bar) Air may enter the heating circuit if the hydraulic pressure is low.

Loosen the Air relief valve cap by two turns to release air (see diagram). Ensure all air is removed from the system. If air remains in the system

then the system operation may STOP.

Note: Due to the design of the electrical back up heater it is not recommended to add any corrosion inhibitors / additives to the heating circuit.

Water quality

The water used must satisfy EN directive 98/83 EC.

Piping insulation

It is recommended that insulation is fitted to all pipes. To perform optional cooling operation, apply insulation with a rating of 20t or more to all pipes.

Electrical Connections

E Box layout

Power Lines Schematic

Fuses (AC250V T30A): F1&F2: Hot water cylinder electric heater supply F3&F4: Back up heater 1 (3kW) F5&F6: Back up heater 2 (3kW) F7&F8: Back up heater 3 (3kW)

Fuses (AC250V T3.15A) F9&F10: A rated water pump

PCB’s: MCC-1214: TCB-PCMO3E (optional input PCB) MCC-1217: TCB-PCIN3E (optional output PCB) MCC-1431: Relay PCB for control of second

water pump, 2 way valve and booster heater outputs MCC-1511: Main hydro unit control / interface PCB

Contactors & Relays: RY01: Interlock relay – flow switch / back up

heater circuit

RY02: Power contactor for back up heater supply RY03: Control relay for back up heater s 2 & 3

operation

RY04: Power contactor for back up heater supply RY05: Power contactor for hot water cylinder

electric heater supply RY06: Control relay for mixing valve (2 zone) operation

Control Lines Schematic

Terminal Block Connections

Electrical supply / cable specifications Wiring specifications (power line)

Description

Model Name

HWS

Power Supply

Current

(Max)

Install

Fuse

Rating

Power

Cable

Connection Destination

Outdoor

Unit

Power

Input

1404H-E

220V-230V ~

50Hz

22.8A

25A

≥2.5mm

L, N

1104H-E

220V-230V ~

50Hz

22.8A

25A

≥2.5mm

804H-E

220V-230V ~

50Hz

19.2A

20A

≥2.5mm

1604H8(R)-E

380-400V 3N~

50Hz

14.6A

16A

≥2.5mm

L1, L2, L3,

1404H8(R)-E

380-400V 3N~

50Hz

14.6A

16A

≥2.5mm

1104H8(R)-E

380-400V 3N~

50Hz

14.6A

16A

≥2.5mm

Hydro

unit

electric

heater

power

Power

input

for

back

heater

1404XWHM3-E

220V-230V ~

50Hz

13A

16A

≥1.5mm

L, N

TB02

1404XWHT6-E

380-400V 3N~

50Hz

13A (13Ax2P)

16A

≥1.5mm

L1, L2, L3,

1404XWHT9-E

380-400V 3N~

50Hz

13A (13Ax3P)

16A

≥1.5mm

804XWHM3-E

220V-230V ~

50Hz

13A

16A

≥1.5mm

L, N

804XWHT6-E

380-400V 3N~

50Hz

13A (13Ax2P)

16A

≥1.5mm

L1, L2, L3,

804XWHT9-E

380-400V 3N~

50Hz

13A (13Ax3P)

16A

≥1.5mm

Power input for DHW cylinder heater

220V-230V ~

50Hz

12A

16A

≥1.5mm

L, N

TB03

Outdoor – hydro unit connection

- - -

≥1.5mm

1, 2, 3

TB01

Hydro unit to DHW cylinder

- - -

≥1.5mm

1, 2

TB03

Wiring specification (control line)

Description

Line Spec

Current (Max)

Length (Max)

Cable Diameter

Connection Destination

3 way diverting valve

2 or 3 wire

100mA

12m

1.0mm

7, 8, 9 (TB05)

2 way valve (cooling)

2 wire

100mA

12m

1.0mm

3, 4 (TB05)

3 way mixing valve (2 zone)

3 wire

100mA

12m

1.0mm

1, 2, 3

2, 3, 4

(TB04)

2 zone thermo sensor (TFI)

2 wire

100mA

1.0mm

C, D (TB06)

HW cylinder thermo sensor (TTW)

2 wire +GND

(screened cable)

100mA

1.0mm

A, B (TB06)

2nd remote controller

2 wire

50mA

50m

≥ 0.5mm

1, 2 (TB07)

Control parts specifications

Component

Power

Current (Max)

Specification

3 way diverting valve

AC 230V

100mA

Default: 2 wire spring return valve or 3 wire SPST valve Option: 3 wire SPDT valve (set DPSW13_1 to ON)

2 way valve (cooling )

AC 230V

100mA

2 wire spring return valve (normally OPEN)

3 way mixing valve (2 zone

control)

AC 230V

100mA

Default drive time = 60 seconds to 90° 3 wire SPST or SPDT with drive times to 90° between 30 and 240 seconds

Output line specifications

Description

Output

Current

(Max)

Voltage

(Max)

Cable

Length

(Max)

Comments

External water pump (P2)

AC230V

1A - 12m

External booster heater

AC230V

1A - 12m

Output enabled when outdoor air temperature is ≤ -20°C

Alarm output

No volt contacts

0.5A

AC230V

12m

DC24V

12m

Boiler output

No volt contacts

0.5A

AC230V

12m

Output enabled when outdoor air temperature is ≤ -10°C (output trigger temperature can be changed using FC23)

DC24V

12m

Defrost output

No volt contacts

0.5A

AC230V

12m 1A

DC24V

12m

Compressor ON output

No volt contacts

0.5A

AC230V

12m 1A

DC24V

12m

Input line specifications

Description

Input

Cable Length (Max)

External stop control

No voltage

12m

Cylinder thermostat

No voltage

12m

Room thermostat (cooling)

No voltage

12m

Room thermostat (heating)

No voltage

12m

CAUTION

Earthing arrangements

The Hydro Unit and related equipment must be earthed in accordance with your local and national electrical regulations. It is essential that the equipment is earthed to prevent the electric shock and damage to the equipment.

Electrical connection to hydro unit

• Remove the front cover and the electrical box cover from the Hydro Unit.

• The Hydro Unit power cable, for the electrical back up heaters, must be sized in accordance with the

Wiring Specifications table shown on page 15

• Connect the Hydro Unit power cable, for the electrical back up heaters, to Terminal 02 as shown below.

Single Phase Units: Live conductor – Terminal L1

Neutral conductor – Terminal L2 Earth conductor – Earth terminal

Three Phase Units: Phase 1 conductor – Terminal L1

Phase 2 conductor – Terminal L2 Phase 3 conductor – Terminal L3 Neutral conductor – Terminal N Earth conductor – Earth

• Ensure the Hydro Unit power cable, for the electrical back up heaters, is secured using the cable clamp

fitted in the electrical box.

• Ensure the Hydro Unit power cable connection (for the electrical back up heaters) terminals are tight.

Outdoor unit to hydro unit electrical connection

• Ensure electrical circuits are isolated before commencing work.

• The Outdoor Unit to Hydro Unit interconnecting cable must be sized in accordance with the “Wiring

Specification” table shown on page 15

• Connect the Outdoor Unit to Hydro Unit interconnecting cable as shown in the diagram above.

• Ensure the Outdoor Unit to Hydro Unit interconnecting cable is secured using the cable clamp fitted in the

electrical box.

• Ensure the Outdoor Unit to Hydro Unit interconnecting cable connection terminals are tight.

HWS-804H-E HWS-1104H-E HWS-1404H-E

HWS-1104H8-E, H8R-E HWS-1404H8-E, H8R-E HWS-1604H8-E, H8R-E

Electrical connection for external booster heater

CAUTION

• The maximum current available from the booster heater output is 1 A. Do not connect the booster

heater directly to Terminal Block 05 on the Hydro Unit. A separate contactor, supplied locally, must be used to supply the booster heater.

• The booster heater can be installed only for room heating and cannot be used for hot water supply.

• Install the booster heater downstream of the 3-way valve on the heating circuit side of the installation

• The booster heater is an external heater, supplied locally, used to assist the Hydro Unit during low

ambient conditions.

• The AC230 V 1 A output from the Hydro Unit must only be used to energize an external contactor

(supplied locally).

• The output from the Hydro Unit is only enabled when either the outdoor air temperature to be lower than -

20°C.

• Ensure the external booster heater is installed and set up in accordance with all Local, National and

International regulations.

• Connect the external booster heater to the Hydro Unit

according to the diagram shown opposite:-

• The contactor will energize in the event of low ambient

conditions.

• A separate dedicated electrical supply must be used for the

external booster heater. This must be connected through the contacts on the field supplied contactor.

Electrical connection for external additional pumps

CAUTION

• The maximum current available from the additional pump output is 1 A. Do not connect the

additional pump directly to Terminal Block 05 on the Hydro Unit. A separate contactor, supplied locally, must be used to supply the additional pump.

• The Hydro Unit has the facility to connect an additional circulating pump, if required, into the heating or

cooling system.

• Install the pump so that its motive power does not affect the internal pump.

• The AC230 V 1 A output from the Hydro Unit must only be used to energize an external contactor

(supplied locally).

• The output for the pump is synchronized with the operation of the main circulating pump (P1) inside the

Hydro Unit.

• Ensure the pump is installed and set up in accordance with all Local, National and International

regulations.

• Connect the additional pump (P2) as shown in the

diagram opposite:-

• The contactor will energize synchronously with

operation of the main circulation pump (P1).

• A separate dedicated electrical supply must be

used for the pump. This must be connected through the contacts on the field supplied contactor.

3-way valve (diverter) connection

Required Valve Specification:

Electrical Specification: 230 V; 50 Hz; <100 mA Valve Diameters: Port A, Port B: Ø 1 1/4" Return Mechanism: 3 types of 3-way valve (diverter) can be used. Set the 3-way valve in use with the DIP switch SW13-1 on the Hydro Unit board.

Diverter Valve

Description

DPSW13-1

Type 1

2-wire spring return

OFF

Type 2

3-wire SPST

OFF

Type 3

3-wire SPDT

NOTE

Continuous operation of the valve motor at the fully open position is not recommended.

• The 3-way diverter valve is used to select either domestic hot water or zone1 / zone2 space heating

• Connect the 3-way diverter valve in accordance with the diagram below:-

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Toshiba HWS-804XWHT6, HWS-1404XWHT6, HWS-804XWHT9, HWS-1404XWHM3, HWS-1404XWHT9 Quick Reference Manual

Specifications and Main Features

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