Toshiba HWS-P805XWHM3-E, HWS-P805XWHT9-E, HWS-P1105XWHT9-E, HWS-P1105XWHT6-E, HWS-P1105XWHM3-E User Manual

AIR TO WATER HEAT PUMP

Installation Manual

Hydro Unit

Model name:

HWS-P805XWHM3-E

HWS-P805XWHT6-E

HWS-P805XWHT9-E

HWS-P1105XWHM3-E

HWS-P1105XWHT6-E

HWS-P1105XWHT9-E

English

Hydro Unit	Installation Manual

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.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
6	Main components of Hydro Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
7	Hydro Unit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
8	Group Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
9	Start up and configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	32
10	Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	55
11	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	56
12	Technical parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	63

1-EN

– 1 –

Hydro Unit	Installation Manual

1 General information

System combination

Outdoor Unit

Hydro Unit

HWS-P805HR-E

HWS-P1105HR-E

HWS-P805H8R-E

HWS-P1105H8R-E

HWS-P1405H8R-E

Backup heater

HWS-P805XWHM3-E

-

-

-

~, 3kW

HWS-P805XWHT6-E

-

-

-

3N~, 6kW

HWS-P805XWHT9-E

-

-

-

3N~, 9kW

HWS-P1105XWHM3-E

-

-

~, 3kW

HWS-P1105XWHT6-E

-

-

3N~, 6kW

HWS-P1105XWHT9-E

-

-

3N~, 9kW

single phase model

3 phase model

General specifications

Outdoor Unit

Single Phase model

Outdoor unit

HWS-P805HR-E

HWS-P1105HR-E

Power supply

220-230 V ~ 50 Hz

Type

INVERTER

Function

Heating & Cooling

Capacity

(kW)

8.0

11.2

Heating

Input

(kW)

1.68

2.30

COP

(W/W)

4.76

4.88

Capacity

(kW)

6.0

10.0

Cooling

Input

(kW)

1.64

3.33

EER

(W/W)

3.66

3.00

Refrigerant

R410A

Dimension

HxWxD

(mm)

1,340x900x320

Cord heater

(W)

75

3 Phase model

Outdoor Unit

HWS-P805H8R-E

HWS-P1105H8R-E

HWS-P1405H8R-E

Power supply

380-400V 3N~ 50Hz

Type

INVERTER

Function

Heating & Cooling

Capacity

(kW)

8.0

11.2

14.0

Heating

Input

(kW)

1.71

2.34

3.16

COP

4.68

4.80

4.44

Capacity

(kW)

6.0

10.0

11.0

Cooling

Input

(kW)

1.64

3.33

3.90

EER

3.66

3.00

2.82

Refrigerant

R410A

Dimension

H×W×D

(mm)

1,340×900×320

Cord heater

(W)

75

– 2 –

2-EN

Hydro Unit Installation Manual

Hydro Unit

8 kW model

	Hydro Unit		HWS-P805XWHM3-E	HWS-P805XWHT6-E	HWS-P805XWHT9-E
Back up heater capacity		(kW)	3.0	6.0	9.0
	for back up heater		220-230 V ~ 50 Hz	380-400 V 3N~ 50 Hz	380-400 V 3N~ 50 Hz
Power supply
	for hot water cylinder heater			220-230 V ~ 50 Hz
	(option)
Leaving water	Heating	(°C)		20-60
temperature	Cooling	(°C)		7-25

11 kW model

	Hydro Unit		HWS-P1105XWHM3-E	HWS-P1105XWHT6-E	HWS-P1105XWHT9-E
Back up heater capacity		(kW)	3.0	6.0	9.0
	for back up heater		220-230 V ~ 50 Hz	380-400 V 3N~ 50 Hz	380-400 V 3N~ 50 Hz
Power supply
	for hot water cylinder heater			220-230 V ~ 50 Hz
	(option)
Leaving water	Heating	(°C)		20-60
temperature	Cooling	(°C)		7-25

Hot Water Cylinder (option)

Hot water cylinder (option)		HWS-1501CSHM3-E	HWS-2101CSHM3-E	HWS-3001CSHM3-E
		HWS-1501CSHM3-UK	HWS-2101CSHM3-UK	HWS-3001CSHM3-UK
Water volume	(liter)	150	210	300
Power supply			220-230 V ~ 50 Hz
Max water temperature	(°C)		75
Electric heater	(kW)		2.7
Height	(mm)	1,090	1,474	2,040
Diameter	(mm)		550
Material			Stainless steel

2 Accessory parts

No.	Parts name		Quantity
1	Installation Manual (this document)		1
2	Owner’s Manual		1
	Insulator for cooling

3

5

Insulator

3-EN

– 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	Drain cock	(for water charge)	1
		Isolating ball valves	1 1/4"	2
			for service 1 1/4"
		Earth leakage breaker for main power supply	30 mA	1
	Electrical system	Earth leakage breaker for backup heater	30 mA	1
		(Option)	30 mA	1
		Earth leakage breaker for hot water cylinder
		heater

Options required for each function

	Purpose	In the Hydro Unit			Purchased part
		Part name		Model name	Part name	Prescribed specification
	Heating		–	–	Radiator(s), Fan coil(s), Under
					floor heating
	Heating &Cooling (all		–	–	Fan coil(s)
	rooms)
	Heating & Cooling		–	–	Motorized 2-way valve (for	Refer to “Control parts
	(partly heating only)				cooling)	specifications” on page 21.
		Hot water cylinder
			150 L	HWS-1501CSHM3-E
				HWS-1501CSHM3-UK	Motorized 3-way valve	Refer to “Control parts
	Hot water supply			HWS-2101CSHM3-E
			210 L		Earth leakage breaker	specifications” on page 21.
				HWS-2101CSHM3-UK
			300 L	HWS-3001CSHM3-E
				HWS-3001CSHM3-UK
					Motorized mixing valve	Refer to “Control parts
						specifications” on page 21.
	2-zone control		–	–
					Circulator pump	Other power supply
					Buffer tank
	Interlocking with boiler	Output control board		TCB-PCIN3E	Boiler	Other power supply.
						Signal 12 V input function is
		kit (1)				required for boiler.

Optional parts

	No.	Part name	Model name	Application	Remarks
				Boiler-linked output, Alarm output	Up to two boards (according to
	1	External output board	TCB-PCIN3E
				Defrost signal output, compressor operation signal
					applications)
				output
	2	External input board	TCB-PCMO3E	Cooling/heating thermostat input	Up to two boards (according to
				Emergency stop signal input.	applications)

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 –

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 Hydro Unit 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.

5-EN

– 5 –

Hydro Unit	Installation Manual

•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.

•Under no circumstances must not power cable be extended.

Connection trouble in the place where the cable may give rise to smoking and / or a fire.

•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.

•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.

– 6 –

6-EN

Hydro Unit	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.

•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.

7-EN

– 7 –

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

	Fan Coil Units
Isolating	(Cooling or Heating)
Ball
Valves
Strainer (40 mesh / 0.4 mm)	Diverting 3-Way
	Valve for
Drain Cock for water	Sanitary Hot
Charge and Drain	Water Cylinder

M	Radiators (Heating Only)
	[2-Way Valve Control]

	M	2-Way
		Valve
	Use the 2-
	way valve to
	isolate the
TTW	heating
	circuit when
	in cooling
	mode.

Indirect Sanitary
Hot Water Cylinder			M	2-Way				Use it when do not
				Valve				operate cooling.

Alternative to Radiators

Under-floor Heating (Heating Only) [2-Way Valve Control]

– 8 –

8-EN

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

Isolating Valves (Service)

Strainer (40 mesh / 0.4 mm)

Drain Cock for water

Charge and Drain

TTW

Indirect Sanitary Hot

Water Cylinder

Hi-Pressure		Temperature
By-Pass		Regulating
Valve		Valve
		(Mechanical)

TRV

Temp. Regulating Valve (Mechanical)

TRV

Zone 1

Diverting

Fan Coil Unit (Heating

3-Way

or Cooling)

Valve for

Sanitary

Hot

Water

Cylinder

M

Motorized 2-Way Valve is required if fan coil

Munits are in cooling operation.

Mixing 3-Way

MValve for Under Floor Heating

External Pump for

Under Floor Heating

TFI

Direct Buffer tank for Under Floor Heating

Zone 2

Under-floor Heating

(2-Way Valve Control)

9-EN

– 9 –

Hydro Unit	Installation Manual

6 Main components of Hydro Unit

Exploded view and description for Hydro Unit

▼Fig. 6-01

1	11
	13
	14
12	15
3	16
2	17
4	18
5
6
7
8	19
9
10	20

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 : Overpressure preventive valve (0.43 MPa (4.3 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

– 10 –

10-EN

Hydro Unit	Installation Manual

E-box layout

▼Fig. 6-02
	Main P.C. board
	MCC-1511		Trans
			former
External output
P.C. board MCC-			Relay
1217 (Option)
			(RY03)
Fuse	Relay	MG-SW (RY05)	Relay
(F9 F10)(RY06)			(RY01)
External output
P.C. board MCC-
1217 (Option)			Fuse
Relay P.C. board
MCC-1431
		07
		TB	TB07
11-EN		– 11 –

MG-SW (RY04)

MG-SW (RY02)

External input P.C. board MCC1214 (Option)

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:

The weight of the hydro units is displayed on the product nameplate. When water enters the hydro unit, it gets even heavier by about 20 kg.

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.

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.

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	500 mm
100 mm	350 mm
500 mm

Mounting

Install M10 bolts at the positions shown below and secure them with nuts.

▼Fig. 7-02

380 mm		M10

960 mm

NOTE

If customer worried about vibration of Hydro Unit, please insert vibration isolating material between the product and the wall, when installing the product.

– 12 –

12-EN

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		▼Fig. 7-05
380

M10

860

M10

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°

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.

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

13-EN

– 13 –

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

Tightening

•Connect the refrigerant pipes, from the outdoor unit, to the Hydro Unit as shown below.

▼Fig. 7-09

Gas line Ø 15.88

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)	Liquid Side
			(mm)
	8 & 11 kW Hydro Unit	Ø 15.88	Ø 9.52

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.

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	Tightening Torque (N/m)
	(mm)
	9.5	33 to 42
	15.9	63 to 77

•To prevent damage, to the refrigerant pipes, use two spanners to tighten the flare nut connections to the required torque.

 Water pipe

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 overpressure preventive valve is 0.43 MPa. (4.3 bar)

CAUTION

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

– 14 –

14-EN

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 17).

The height of the pipe must be 7 m or less.

▼Fig.7-10

H < 7 m

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.)

▼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 inlet connection 1 1/4"

▼Fig. 7-12

Inlet

Isolating Ball Valve

Strainer (30 to 40 meshes)

Drain cock for water charge and discharge

Local arrangement

15-EN

– 15 –

Hydro Unit	Installation Manual

Piping to hot water cylinder (option)

Water supplied to the hot water cylinder is branched by a motorized 3-way valve (locally procured).

For the specifications of the motorized 3-way valve, refer to “Control parts specifications” on page 21. Connect the hot water cylinder to port A (open when energized) of the valve.

▼Fig. 7-13

to hydro unit

	room heating or cooling					to hot water cylinder
					AB
	Open when de-
	energized	B				A Open when energized

Piping to 2-zone operation

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

For the specifications of the motorized mixing valve, Refer to “Control parts specifications” on page 21.

▼Fig. 7-14

Motorized mixing valve

(locally procured) from hydro A unit

Water pump
(locally procured)	AB
Zone	B
2

to hydro unit

Buffer tank (locally procured)

Checking water volume and initial pressure of expansion vessel

The expansion vessel of the Hydro Unit has a capacity of 12 liters.

The initial pressure of the expansion vessel is 0.15 MPa (1.5 bar).

The pressure of the safety valve is 0.43 MPa (4.3 bar). Verify whether the capacity of the expansion vessel is sufficient using the following expression. If the volume is insufficient, add the capacity locally.

Expression for expansion vessel selection

V:Necessary total tank capacity ( )

: Water expansion coefficient at each hot water temperature

Vs: Total water amount in the system

P1: System pressure at tank setting position (MPaabs.)

= water supply pressure = 0.3 (MPaabs.) (recommended valve)

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

=safety valve setting pressure = 0.4 (MPaabs.)

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

▼Tank selection method

Water temperature and expansion coefficient

	Hot water	Expansion	Hot water	Expansion
	temperature		temperature
		rate		rate
	(°C)		(°C)
	0	0.0002	50	0.0121
	4	0.0000	55	0.0145
	5	0.0000	60	0.0171
	10	0.0003	65	0.0198
	15	0.0008	70	0.0229
	20	0.0017	75	0.0258
	25	0.0029	80	0.0292
	30	0.0043	85	0.0324
	35	0.0050	90	0.0361
	40	0.0078

450.0100

▼Fig. 7-15

)
capacity(	18
	16
	14
tank	12
	10
total	8
	6
Necessary	4
	2
	0

	0	50	100	150	200	250	300
V:	Vs: Total water amount in the system( )

*In case the maximum hot water temperature is 60ºC

Install an external expansion vessel when the capacity of the expansion vessel is insufficient.

– 16 –

16-EN

Hydro Unit	Installation Manual

Pump operation/configuration

▼Fig. 7-16

Head [m]

	Hydraulic heat exchanger (8 kW) QH characteristics
				Minimum flow rate
10
9
								Hydro unit QH-
8								Characteristics (220/230 V)
			Out of range
7
6							Pump duty
5							100%
4
3
2
1		Pump duty					Pump duty
		60%					80%
0
	0	5		10		15	20	25	30	35
						Flow rate [L/min]

▼Fig. 7-17
	Hydraulic heat exchanger (11 kW) QH characteristics
			Minimum flow rate
	10
	9				Hydro unit QH-
					Characteristics (220/230 V)
	8	Out of range
	7
					Pump duty
	6				100%
[m]
	5
Head
	4
	3		Pump duty
			80%
		Pump duty
	2
		60%
	1
	0	10	20	30	40	50
	0
			Flow rate [L/min]
17-EN			– 17 –

Hydro Unit	Installation Manual

Water charging

Charge water until the pressure gauge shows recommended valve 0.2 MPa (2 bar).

Hydraulic pressure may drop when the trial run begins. In that case, add water.

Air may enter if the charged hydraulic pressure is low. Loosen the purge valve cap by two turns to release air.

▼Fig. 7-18

Loosen 2 turns for proper venting

*Purge valve cap faces the front as factory default.

*The direction purge valve cap may change during transportation.

Water quality

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

Piping insulation

It is recommended that insulation treatment be applied to all pipes. To perform optional cooling operation, apply insulation treatment of 20 t or more to all pipes.

Electrical installation

WARNING

•Ensure electrical circuits are isolated before commencing the electrical installation.

•The electrical installation must be completed by a qualified electrician.

•The electrical installation must comply to all Local, National and International electrical installation regulations.

•This product must be earthed in accordance with Local, National and International electrical installation regulations.

Loosen the air vent screw of the pump, pull out air in the pump, and tighten again.

Loosen the cap of the pressure relief valve to release air.

Water may come out of the pressure relief valve. Release the air completely from the water circuit. Failure to do so may disable correct operation.

CAUTION

•The Hydro Unit must be connected to a dedicated power supply for the back up heater circuit.

•The electrical supply must be protected by a suitably sized over current protection device (fuse, MCB etc) and an earth leakage protection device.

•The Hydro Unit must be connected to the mains power supply using a isolating switch which disconnects all poles and has a contact separation of at least 3 mm.

•The cord clamps, attached to the Hydro Unit, must be used to secure the electrical cables.

•Wrong connection of electrical cables may result in electrical component failure or fire.

•Ensure the electrical cables are sized in accordance with the installation instructions.

– 18 –

18-EN

Hydro Unit	Installation Manual

Control line

▼Fig. 7-19

Pump (local)

Max 12 m

230 V 1 A

0.75 mm² or more

2Way-Valve for Max 12 m cooling stop 230 V 100 mA

0.75 mm² or more

Booster heater

(local) Max 12 m 230 V 1 A

0.75 mm² or more

3Way-Valve for hot water cylinder

Alert output (local)

Mixing-Valve type 2 for 2 zone control

1 2 3 4

TB04

Mixing-Valve type 1 for 2 zone control

Max 12 m 230 V 100 mA

0.75 mm² or more

CW N CCW	0.75 mm² or more
	Max 5 m shielded wire

Temp sensor in hot water cylinder

1

2

3

4

5

6

7

8

9

1	2	3	4
				A
				B
TB05	TB07		TB06	D
				C

1

2

CN208 CN209

	OPTION				OPTION
	PJ20				PJ20
1	2	3	4	1	2	3	4

A

B

Max 5 m shielded

wire 0.75 mm² or

more

Temp sensor for 2 zone control

Max 50 m

0.50 mm² or more

2nd remote controller

		Max 12 m non
		voltage 0.75 mm² or
		more
Boiler operation	Defrost output	Compressor
(local)	(local)	operation output

(local)

▼Fig. 7-20

51	52	53	54	55	56	57	58	59	41	42	43	44
WPM		2WV			BH		3WV			MIXV
		TB 05								TB 04		TB02
TB03

1

2

3

L1

L2

L3

N

L1

L2

L3

N

6A 6B 6C 6D		Don't apply	11	12 13	31 32	L N	L	N
		220-240V
TTW	TF1	or			HOT WATER CYLINDER
TB 06		breakdown		TB 01		TB 03		TB 02
		will occur.

TB01

to Outdoor unit

Hot

Input power

water

220-230 V ~

cylinder

50 Hz

Input power 220-230 V ~ 50 Hz

Input power 380-400 V 3N ~ 50 Hz

Sensor		Outdoor unit		Hot water cylinder		Backup heater
connection		connection		power supply		power supply

19-EN

– 19 –

Hydro Unit	Installation Manual

Electrical supply/cable specifications

▼Wiring specifications

	Description		Model name	POWER	Maximum	Installation	Power wire	Connection destination
			HWS-	SUPPLY	current	fuse rating
			P1105HR-E	220-230 V ~	22.8 A	25 A	4 mm² or more
				50 Hz
								,
				220-230 V ~
			P805HR-E		22.8 A	25 A	4 mm² or more
				50 Hz
	Outdoor
		Power	P1405H8R-E	380-400 V 3N~	14.6 A	16 A	2.5 mm² or more
	unit
		input		50 Hz
	power
				380-400 V 3N~				,		,
			P1105H8R-E		14.6 A	16 A	2.5 mm² or more
				50 Hz				,
			P805H8R-E	380-400 V 3N~	14.6 A	16 A	2.5 mm² or more
				50 Hz
			P1105XWHM3-E	220-230 V ~	13 A	16 A	1.5 mm² or more	,
				50 Hz
			P1105XWHT6-E	380-400 V 3N~	13 A(13 A x 2P)	16 A	1.5 mm² or more	,		,
				50 Hz
		Power	P1105XWHT9-E	380-400 V 3N~	13 A(13 A x 3P)	16 A	1.5 mm² or more	,
				50 Hz
	Hydro	input for								TB02
		backup
	inlet		P805XWHM3-E	220-230 V ~	13 A	16 A	1.5 mm² or more	,
		heater
	heater			50 Hz
	power		P805XWHT6-E	380-400 V	13 A(13 A x 2P)	16 A	1.5 mm² or more
								,		,
				3N~ 50 Hz
			P805XWHT9-E	380-400 V	13 A(13 A x 3P)	16 A	1.5 mm² or more	,
				3N~ 50 Hz
		Power input for cylinder		220-230 V ~	12 A	16 A	1.5 mm² or more	,		TB03
		heater		50 Hz
	Outdoor-Hydro unit		Connection				1.5 mm² or more	,	,	TB01
	Hydro -Cylinder		Connection				1.5 mm² or more	,		TB03

▼Wiring specifications (control line)

	Description	Line spec	Maximum	Maximum length		Connection
			current			destination
	3-way valve control	2 line or 3 line	100 mA	12 m	0.75 mm² or more	,	,
						(TB05)
	2-way valve control	2 line	100 mA	12 m	0.75 mm² or more	,	(TB05)
						,	,
	Mixing valve control	3 line	100 mA	12 m	0.75 mm² or more	or	,
						,
						(TB04)
	2-zone thermo sensor	2 line	100 mA	5 m	0.75 mm² or more	,	(TB06)
	Cylinder thermo sensor	2+GND(shielded	100 mA	5 m	0.75 mm² or more	,	(TB06)
		wire)
	Second remote controller	2 line	50 mA	50 m	0.5 mm² or more	,	(TB07)
	Group control (total)	2 line	50 mA	50 m	0.5 mm² or more	,	(TB07)
	Open protocol interface	2 line	100 mA	50 m	0.5 mm² or more	,	(TB07)

– 20 –

20-EN