Toshiba ESTIA HWS-1102H-E Service Manual Download Page 1

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Toshiba

Model name:

Outdoor Unit

HWS-802H-E
HWS-1102H-E
HWS-1402H-E

AIR TO WATER HEAT PUMP

Hydro Unit

HWS-802XWHM3-E
HWS-802XWHT6-E
HWS-1402XWHM3-E
HWS-1402XWHT6-E
HWS-1402XWHT9-E

Hot Water Cylinder

HWS-1501CSHM3-E(-UK)
HWS-2101CSHM3-E(-UK)
HWS-3001CSHM3-E(-UK)

SERVICE MANUAL

A09-002

+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 1 Monday, October 5, 2009 2:09 PM

Summary of Contents for ESTIA HWS-1102H-E

Page 1: ... HWS 1102H E HWS 1402H E AIR TO WATER HEAT PUMP Hydro Unit HWS 802XWHM3 E HWS 802XWHT6 E HWS 1402XWHM3 E HWS 1402XWHT6 E HWS 1402XWHT9 E Hot Water Cylinder HWS 1501CSHM3 E UK HWS 2101CSHM3 E UK HWS 3001CSHM3 E UK SERVICE MANUAL A09 002 ...

Page 2: ... Flux 13 2 5 3 Brazing 13 3 Specifications 15 4 Outside Drawing 17 4 1 Hydro unit 17 4 2 Outdoor unit 18 4 3 Hot water cylinder 20 5 Wiring Diagram 21 5 1 Hydro Unit 21 5 2 Outdoor Unit 22 5 3 Hot Water Cylinder Unit 23 6 Key Electric Component Rating 24 6 1 Hydro Unit 24 6 2 Outdoor Unit 26 6 3 Hot Water Cylinder Unit 28 6 4 Water Heat Exchange Control Board 29 6 5 Outdoor Control Board 30 7 Refr...

Page 3: ...om the check code on the remote control 66 9 3 3 How to cancel a check code on the remote controller 66 9 3 4 How to diagnose by error code 67 9 4 Diagnosis flow chart for each error code 74 9 4 1 Hydro unit failure detection 74 9 4 2 Outdoor Unit Failure Detection 91 9 4 3 Temperature sensor temperature resistance characteristic table 101 9 5 Operation check by PC board switch 102 9 5 1 Operation...

Page 4: ...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 highe...

Page 5: ...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 characteri...

Page 6: ...ne 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 ...

Page 7: ... 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...

Page 8: ...hickness 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 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 joint ...

Page 9: ...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 adjustment to secure the A dimension Table 2 2 3 Flare processing related dimension for R410A Table 2 2 4 Dimension of flare for R410A and flare nut Figure 2...

Page 10: ... 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 Using any other oil deteriorates the lubricating oil possibly causing the compressor to burn out Table 2 2 5 Tight...

Page 11: ... 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 Also prepare the following equipment for other work methods or run check No Tool to be used Usage R410A Air to Water Hear Pump installation Conventionalrefrigerant Air to Water Heat Pump installation For R410A Existenceofnew equip...

Page 12: ...cover 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 ga...

Page 13: ...d upside down NOTE Because R410A is HFC mixed refrigerant charging with gas changes the charged refrigerant composition causing the equipment characteristics to change Cylinder with siphon Cylinder without siphon Gauge manifold Outdoor unit Refrigerant cylinder Electronic balance Gauge manifold Outdoor unit Refrigerant cylinder Electronic balance Siphon pipe ...

Page 14: ...te type of flux according to metal treatment type brazing metal and brazing method or other conditions 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 ...

Page 15: ...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 M Flow meter Stop valve From nitrogen cylinder Nitrogen gas Robber plug Pipe Nitrogen gas cylinder ...

Page 16: ...7 Power factor 91 5 91 7 Outdoor unit Current A 8 26 8 90 Power kW 1 859 2 033 Power factor 97 8 99 3 Total Starting current A 9 24 9 36 Operating noise 1 2 4 Hydro unit dB A 29 29 Outdoor unit dB A 49 49 Coefficient of performance 1 2 4 08 2 82 Hydro unit Outer dimension Height mm 925 Width mm 525 Depth mm 355 Net weight kg 50 Color Silky shade Munsell 1Y8 5 0 5 Remote controller Outer dimension ...

Page 17: ...r 93 2 92 7 94 0 93 2 Outdoor unit Current A 10 14 14 88 13 57 17 47 Power kW 2 265 3 39 3 005 3 945 Power factor 96 9 99 1 96 4 98 1 Total Starting current A 10 77 15 49 14 24 18 10 Operating noise 1 2 4 Hydro unit dB A 29 29 29 29 Outdoor unit dB A 49 49 51 51 Coefficient of performance 1 2 4 66 2 84 4 45 2 69 Hydro unit Outer dimension Height mm 925 Width mm 525 Depth mm 355 Net weight kg 54 Co...

Page 18: ...a 12x17 long hole for dia 8 10 anchor bolt 2 dia 12x17 U shape hole for dia 8 10 anchor bolt A leg part Remote controler 135 5 158 186 5 59 5 144 5 116 19 5 352 37 5 925 54 Hot water outlet connecting pipe 1 1 4 Water inlet connecting pipe 1 1 4 Gas line dia 15 88 Liquid line dia 9 52 309 5 259 Drain nipple 371 5 355 40 5 40 5 9 Anchor bolt long hole pitch Manometer 525 19 5 ...

Page 19: ...gerant piping outlet Indoor and outdoor connecting line outlet Power source intake hole 38 knockout hole 9 5 flare Refrigerant liquid connection Refrigerant gas connection 15 9 flare Optional mounting hole 12 3 embossed Knockout for lower part of piping Z arrow view 17 5 150 600 550 52 383 365 74 128 118 17 5 60 200 380 75 46 48 54 34 170 40 96 30 39 40 320 12 890 55 94 24 55 95 95 64 18 80 151 40...

Page 20: ...nockout for lower part of piping Z arrow view Z Refrigerant gas connection Refrigerant liquid connection 1 2 1 2 95 55 12 64 1 1340 320 30 55 95 94 18 80 151 400 24 55 95 18 80 135 155 613 605 900 70 581 74 581 178 178 178 518 52 550 360 655 327 Optional mounting hole 24 3 embossed 60 68 534 121 534 85 7 7 Drain hole 25 burring hole 5 Drain hole 20 88 burring hole Air inlet 12 17 long hole 12 17 U...

Page 21: ...ot water cylinder 550 595 2066 6 2040 550 595 1114 1090 595 1497 6 1474 550 Specification for UK only Specification for UK only Specification for UK only HWS 3001CSHM3 E UK HWS 2101CSHM3 E UK HWS 1501CSHM3 E UK ...

Page 22: ...RED 56 57 58 WHI YEL RY603 Thermal protector single operation Thermal protector single operation Thermal protector single operation OFF ON SW14 1L1 3L2 5L3 6T3 4T2 2T1 1L1 3L2 5L3 6T3 4T2 2T1 1L1 3L2 5L3 6T3 4T2 2T1 1 1 N BRW BLU BRW BLU GRY BLU BLK BLU BRW BLU BLK BLU BRW BLU HWS 1402XWHT6 E HWS 802XWHT6 E HWS 802XWHM3 E HWS 1402XWHM3 E TFI B A TTW Option B A Remote controller HWS AMS11E Option 3...

Page 23: ...tem nam Compressor Fan motor Pulse motor valve coil Discharge temperature sonsor Suction temperature sensor Heat exchange sensor 1 Heat exchange sensor 2 Outdoor temperature sensor Compressor case thermostat Fuse 25 A 250 VAC Fuse 10A 250 VAC 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 indicate...

Page 24: ...linder Unit 1 2 TB03 230V A B TB06 TTW Supply 230 V from hydro unit Cable size 1 5 mm2 minimum To hydro unit Green Yellow Green Yellow Blue Double pole thermal cut out Blue Brown Brown TTW sensor Hot water cylinder heater ...

Page 25: ...0 kΩ 25 C 9 Pressure switch O O Operating pressure 4 15 MPa 0 0 3 MPa 10 Low pressure sensor O O Operating pressure 0 20 MPa 11 Bimetal thermostat auto O O Operating temperature 75 3 C DC42 V 0 2 A 12 Bimetal thermostat single operation O O Operating temperature 95 5 C AC250 V 16 A 13 Flow switch O O Operating flowing quantity 13 L min 14 Output board OP OP OP TCB PCIN3E AC230 V 0 5 A DC24 V 1 A 1...

Page 26: ...witch O O O Operating pressure 4 15 MPa 0 0 3 MPa 10 Low pressure sensor O O O Operating pressure 0 20 MPa 11 Thermal protector auto O O O Operating temperature 75 3 C DC42 V 0 2 A 12 Thermal protector single operation O O O Operating temperature 95 5 C AC250 V 16 A 13 Flow switch O O O Operating flowing quantity 18 L min 14 Output board OP OP OP OP TCB PCIN3E AC230 V 0 5 A DC24 V 1 A 15 Input boa...

Page 27: ...ICF 280 A60 1 Output 60 W 3 4 way valve coil VHV 01AP552B1 AC230 full wave rectifier input alive time 10 sec or less 4 Pulse motor valve PMV coil CAM MD12TF 15 DC12 V 5 Compressor case thermostat US 622KXTMQO SS OFF 125 4 C ON 90 5 C 6 Reactor CH 56 5 8 mH 18 5 A 7 PC board MCC 1571 Input 1Ø AC230 V 23 V 50 60 Hz ...

Page 28: ...CF 280 A100 1 Output 100 W 3 Reactor x2 CH 44 1 4 mH 25 A 4 4 way valve coil UKV A038 AC230 V full wave rectifier input alive time 10 sec or less 5 Pulse motor valve PMV coil VHV 01AP552B1 DC12 V 6 Board MCC 1560 Input 3Ø AC230 V 23 V 50 60 Hz 7 Compressor case thermostat US 622KXTMQO SS OFF 125 4 C ON 90 5 C ...

Page 29: ...el name Type name Rating 1501 CSH M3 E UK 2101 CSH M3 E UK 3001 CSH M3 E UK 1 Hot water cylinder heater O O O AC230 V 2 75 KW 2 Hot water cylinder temperature sensor TTW sensor O O O 10 kΩ 25 C 3 Thermal cut out O O O Operating temperature Manual reset 82 C 3k 2k ...

Page 30: ...Flow switch connector CN200 Pressure switch connector CN201 Overheat protection thermostat input connector CN202 TWO sensor connector CN205 TWI sensor connector CN204 THO sensor connector CN206 TTW sensor connector CN214 Low pressure sensor connector CN207 CN212 Remote control connector CN41 TC sensor connector CN203 TFI sensor connector CN213 Backup heater 1 drive connector CN605 Mixing valve dri...

Page 31: ...03 Temperature sensor connectors TL CN604 White TD CN603 White TO CN602 Yellow TE CN601 White TS CN600 White Alive error display LEDs D800 804 Yellow D805 Green PMV connector CN710 White Initialization switch SW802 Power circuit protection fuse F01 250V 25A Connecting cable connector CN04 White Connecting cable protection fuse F03 250 V 10 A Earth lead wire P09 Black Power supply connection lead w...

Page 32: ...alization switch SW802 4 way valve protection fuse F700 250V 3 15A plastic case Power supply protection fuses F01 250V 25A Earth lead wire P09 Black Connecting cable connector CN04 White Connecting cable protection fuse F03 250V 10A Electrolytic capacitors Compressor output terminals CN202 CN201 CN200 Power supply connection lead wires P01 Red P02 White P03 Black Temperature sensor connectors TL C...

Page 33: ... valve set 3 5bar Boiler local Drain cock for water charge locally procured Cylinder heater Ø1 2 75kW Relief valve UK 90 C 10 bar Water outlet Water inlet Reducing valve UK 3 5bar Pressure relief Set value 7bar UK Water heat exchanger max 10bar Backup heater Ø1 3kW Ø3 6kW Ø3 9kW Flow sw Thermal protector auto set 75 3 C Thermal protector Single operation set 95 5 C Low pressure sensor Pressure swi...

Page 34: ...er circuit for a system without buffer tank 1 2 3 5 requires 5 or more branches of Floor heating or Radiator 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 1 2 3 4 5 6 ...

Page 35: ...valve STF 218G Pulse motor valve CAM B30YGTF 2 Outdoor heat exchanger Accumulator 1800 cc Compressor DA220A2F 22L Heating Hot water supply Defrosting Cooling Hydro unit P TE TO TS TD Outdoor unit 4 way valve STF 0401G Pulse motor valve UKV 25D100 Outdoor heat exchanger Accumulator 2500 cc Compressor DA422A3F 25M Heating Hot water supply Defrosting Cooling TWO THO TWI Hydro unit Expansion vessel Ba...

Page 36: ... 9 Night setback operation 10 FROST PROTECTION operation 11 AUTO operation 12 Nighttime low noise operation 39 47 8 3 Hydro Unit Control 1 Capacity control compressor high temperature release low temperature release 2 Heater control 3 Circulation pump control 4 Flow switch control 5 Mixing valve control 2 temperature heating control 6 Q H characteristics of hydro unit 7 Automatic restart control 8...

Page 37: ... signals transmit and receive Remote control settings Heating Temperature setting Hot water supply Temperature setting Cooling Temperature setting Auto Temp Anti Bacteria Frost protection Hot waterboost Water heat exchange Sub board Outdoor unit control Serial signals transmit and receive Outdoor unit contro Inverter frequency control Waveform synthesis function Calculation function Temperature ca...

Page 38: ...he left while also controlling the circulation pump backup booster heater ON OFF water 2 way valve and water 3 way valve 4 The outdoor unit controls the compressor outdoor fan motor electric expansion valve and 4 way valve based on the operation signals transmitted by the hydro unit Item Operation flow and applicable data etc Operation description Hydro unit control HOT WATER button set to ON Circ...

Page 39: ... controlling the circulation pump water 2 way valve and water 3 way valve 4 The outdoor unit controls the compressor outdoor fan motor pulse motor valve and 4 way valve based on the operation signals transmitted by the hydro unit Item Operation flow and applicable data etc Operation description Hydro unit control ZONE1 2 button set to ON Circulation pump ON OFF control Water 3 way valve control Wa...

Page 40: ...ration may be selected depending on the outside air temperature Related FC 3 When the outside temperature is 0 C or below the boil up temperature will be higher that setting temperature in hot water supply mode Operation mode Controlled object Cooling only Heating only Hot water supply only Heating and Hot water Cooling and Hot water Heat pump select for heating Heat pump select for hot water supp...

Page 41: ... selection 1 2 When TWI TSC_F d zone in the right figure is met the heat pump operation is selected Thermostat status OFF When TWI TSC_F e zone in the right figure is met the thermostat status OFF is selected 3 Operation stop condition When the following condition is met the heating operation stops The remote controller gives a stop instruction 1 When the outside temperature is 20 C or below the h...

Page 42: ...s performed in the heating side and a heating operation in the hot water supply side Operation mode by zone Note that after a heat pump operation for Hot water supply is selected in f zone when the operation moves to a heater operation for hot water and then 5 minutes has passed Hot water supply operation in b zone the operation mode changes as follows When TTW 45 C FC changeable is met the operat...

Page 43: ... are performed and a heater operation is performed in the Hot water supply side 1 In J zone the hydro unit setting has a priority and when the set temperature is reached the boiler output also becomes OFF Setting FC_3E to 1 makes the boiler has a priority and even if the hydro unit set temperature is reached the boiler output remains ON 2 The boiler operation only gives boiler instruction from the...

Page 44: ...s to the usual operation after 60 minutes The remote controller display during a hot water boost operation is the same as the set temperature display of a usual Hot water supply operation The usual set temperature change is used for changing the set temperature during a hot water boost operation Change the BOOST set temperature with FC_09 if necessary Related FC Item Operation flow and applicable ...

Page 45: ... the hot water supply start condition TTW 38 C and forcibly performs a hot water operation During ANTI BACTERIA operation Forcible hot water operation at 75 C the hot water set temperature display is not changed If it is changed from the remote controller the normal hot water set temperature will be changed Related FC Item Operation flow and applicable data etc ANTI BACTERIA button set to ON Anti ...

Page 46: ...NE1 2 button and then the FROST PROTECTION button starts a heating operation at the set temperature of 15 C Pressing again the FROST PROTECTION button cancels the FROST PROTECTION operation The remote controller displays F as the temperature during FROST PROTECTION A set temperature change during a FROST PROTECTION operation cancels the operation Related FC Item Operation flow and applicable data ...

Page 47: ...A A Long pressing the AUTO button during an AUTO operation activates the Auto Curve FC change mode enabling the set Auto Curve water temperature to be changed in the 5K range FC_27 Even if the temperature setting is changed during an AUTO operation the operation continues An AUTO operation works with a heating operation only not with a cooling or a hot water supply operation Related FC Item Operat...

Page 48: ...y changing the remote controller FC_09 How to set 1 Press the TEMP and TEST button at the same time for 4 seconds or longer Shifted to the nighttime low noise setting mode The Code No field displays 09 and the DATA 0000 and being displayed blink 2 Press TIME to set enable 1 or disable 0 Pressing SET change DATA and display to be lit and the setting is confirmed When 1 as enable is set the nighttim...

Page 49: ...e temperature difference Detects the number of compressor rotations Compares the Hz signal correction amount and the current operation Hz and changes the compressor output according to the difference The control details are the same for hot water supply heating and cooling Item Operation flow and applicable data etc Temperature settings TSC_H TSC_F Hz signal correction Number of compressor rotatio...

Page 50: ...tarts when 140 seconds has passed after the stop and TC 3 C is not detected for 20 minutes the abnormal stop counter is cleared 10 times of compressor abnormal stop stops the operation of heat pump and confirms the abnormality Display A11 If the heat pump operation is switched to other operation the abnormality detection counter is reset to 0 TC TWO C Item Operation flow and applicable data etc T1...

Page 51: ...tion started and select the ZONE A D The backup heater control increases decreases or maintains the number of heaters every 10 minutes FC depending on the difference between the heating set temperature TSC_F and the heater outlet temperature THO When the heating set temperature TSC_F is reached the hydro stops energizing the backup heater The single phase model of 3 kW has the backup heater 1 only...

Page 52: ...control 2 4 Forcible heater energization To prevent freeze the unit energizes or stops energizing a backup heater 3 kW regardless of the unit status not operated or in operation Object to be controlled Backup heater 1 Energization start condition TWO 4 or TWI 4 or THO 4 2 Energization stop condition TWO 5 and TWI 5 and THO 5 Defrosting ends according to the usual heater control 2 5 No heater opera...

Page 53: ... starts the pump when a boiler instruction is given and 65 C TWI and TWO and THO is met Operation when DP_SW10 1 ON HP operation only is selected The pump stops only when the hot water cylinder heater is in operation The pump does not stop with the heating thermostat off 3 2 Circulation pump Enhanced pump P2 Pump type AC motor rated voltage 230V directly connectable to the unit with the rated outp...

Page 54: ...cteristics 6 1 HWS 801XWHM3 E T6 E 6 2 HWS 1402XWHM3 E T6 E T9 E Item Operation flow and applicable data etc TSC_ΔT 2 TSC_ΔT 2 TSC_ΔT 2 2 TSC_ΔT Control value 1 step Open 0 step 1 step Close Initial value Driving range 1 step Control cycle 6 0 12 3 WV move 7 5 degs 4 mins FC FC No Setting item Default Setting available range 0C Mixing Valve operation time 60 30 240 secs 59 Mixing Valve control tim...

Page 55: ...eating operation Night Set Back 8 Piping freeze prevention control This control operates when the power is on regardless the remote controller setting ON or OFF To prevent frost bursting of the water piping for hot water supply and heating the unit flows water with the circulation pump when the temperature sensor value falls below a certain temperature 8 1 Piping freeze prevention control 1 1 Star...

Page 56: ...tarts 2 Determination cancellation condition At the next time of defrosting the start condition is not met 3 Error display If freeze determination cancellation condition is not met A4 error is displayed 8 4 Piping freeze prevention control 4 When the value of Ps sensor is low freeze prevention is activated regardless of a heat pump operation mode 1 Determination condition Lo pressure sensor detect...

Page 57: ...ture by 1 degree every 30 minutes 11 Forcible stop control Option board TCB PCMO3E is necessary Connect the connection cable to the water heat exchange board CN210 When CLOSE occurs between HEAT and COM of TCB PCM03E the RED LED on the option board lights and the operation hot water supply heating cooling stops To restart the operation use the operation button of the remote controller 12 Output si...

Page 58: ... equipment is repaired first check that the resistance of each sensor or the refrigerant cycle has no problem then start the operation 2 Discharge temperature release control This control detects an abnormality of the refrigerant cycle or compressor to perform failure prevention This control reduces operation frequency if the PMV control does not lower the outlet temperature or if the outlet tempe...

Page 59: ...electronic parts such as a compressor drive element and compressor from failing The current release control value I is selected from the following table according to the TO sensor value Current release control value I Item Operation flow and applicable data etc Outdoor unit current inverter Main circuit control current Compressor operation Hz down Outside air temperature TO Current release point s...

Page 60: ...0 320 380 480 500 Lower 200 200 200 280 360 400 500 520 W9 WA WB WC WD WE WF 802H E 520 570 600 630 670 710 740 1102 1402H E Upper 530 610 640 660 720 780 890 Lower 550 630 660 700 740 820 910 TL C 58 55 38 35 WE tap 1 tap 20 secs Up to the maximum number of rotation for each zone 1 tap 20 secs Up to the minimum number of rotation for each zone Number of rotation hold Temperature range Less than 2...

Page 61: ...ty Clean the filter and restart the operation For 802H E For 1102H E For 1402H E Item Operation flow and applicable data etc TE C 24 21 18 15 1 tap 20 secs to W1 2 tap 20 secs to W1 2 tap 20 secs to W1 Stop time count Number of revolutions hold 1 tap 20 secs Up to the maximum tap for each zone Temperature range Less than 20 Hz 20 Hz or more to less than 45 Hz 45 Hz or more Maximum Maximum Maximum ...

Page 62: ...Open Item Operation flow and applicable data etc Heating operation starts 2 5 10 23 25 2 TE C 0 10 15 39 45 55 d min D zone A zone B zone C zone 1 1 In 10 to 15 minutes after the heating operation starts the lowest value of TE is recorded as TEO and the lowest temperature of To as ToO 2 Inside brackets For 802H E To Normal A Zone Maintain TEO TE ToO To 3 C for 20 secs B Zone Maintain TEO TE ToO To...

Page 63: ...n 10 minutes after the operation start the compressor may not stop for protection This status is not abnormal The operation duration time of the compressor varies depending on a operation status 2 If the operation stops with the remote controller the operation does not continue 9 Over current protection control 1 A detection of abnormal current with the over current protection control stops the co...

Page 64: ...w after 150 seconds 4 When the compressor stops in 2 the abnormality detection counter is cleared when the operation continues for 10 minutes If the counter counts 10 times error code is displayed and the compressor does not restart 5 For details about an check code displayed see the check code list Item Operation flow and applicable data etc C Heating TC Cooling TL a b c d e Abnormal stop Frequen...

Page 65: ...am operation Non defective program operations for the protection of the heat pump unit 9 3 Outline of the determination diagram 9 3 1 Procedure of defect diagnosis 9 3 2 How to determine from the check code display on the remote controller 9 3 3 How to cancel a check code on the remote controller 9 3 4 How to diagnose by error code With reference to the check code roughly identify the defect from ...

Page 66: ...urs about the operation please confirm whether it falls under any of the contents in the following table If it does please understand that the symptom is not a defect of the equipment and it is an operation necessary for the control and maintenance of the heat pump unit Table 9 2 1 Non defective operation No Operation of the heat pump system Explanation 1 The compressor sometimes does not operate ...

Page 67: ...lease perform a repair If its abnormality is determined the abnormality is noticed by indicating the check code on the remote control check code display part while letting off a buzzer 9 3 3 How to cancel a check code on the remote controller 1 Press or button on the operation side to clear the check code 2 Press to stop a buzzer for an abnormality only Although the above procedure cancels the che...

Page 68: ...ow switch 2 74 A02 Temperature increase error heating When one of the TWI TWO and THO sensors exceeds 70 C Heating O Hot water O 1 Check the water inlet water outlet and heater outlet TWI TWO THO sensors 2 Defect of the backup heater defect automatic reset thermostat 1 75 A03 Temperature increase error hot water supply When the TTW sensor exceeds 85 C Heating O Hot water O 1 Check the hot water cy...

Page 69: ...of heating or hot water supply 2 Check the heater power circuit backup or hot water cylinder heater Power supply voltage breaker power supply connection 1 83 E03 Regular communication error between hydro unit and remote controller When there is no regular communication from the remote control for 3 min or when no remote control is equipped O 1 Check remote control connection 2 Defect in the remote...

Page 70: ...heck for any disconnection body or connection wiring of the low pressure sensor 2 Check the resistance value of the low pressure sensor 1 89 F29 EEROM error Inconsistency is detected once without verify ACK after writing to EEPROM 1 Replace the water heat exchange control board 1 90 F30 Extended IC error When the extended IC is abnormal 1 Replace the water heat exchange control board 1 90 L07 Comm...

Page 71: ...100 F13 TH sensor error Open or short circuit in the heat sink temperature sensor O 1 Check the resistance value and connection of the heat sink temperature sensor TH 1 100 F15 TE TS sensors error Open or short circuit in the temperature sensors O 1 Check for any wrong installation of the heat exchange temperature sensor TE and the suction temperature sensor TS 1 100 F31 EEPROM error O 1 100 H01 C...

Page 72: ...astening and heat sink grease between the outdoor control board and the heat sink 2 Check the heat sink fan duct 3 Check the resistance value of the heat sink temperature sensor TH 4 95 P15 Detection of gas leak When the discharge temperature sensor TD exceeds 106 C for consecutive 10 min When the suction temperature sensor TS exceeds 60 C for cooling or 40 C for heating for 10 consecutive min O 1...

Page 73: ...e motor fan 2 Check the connection of the fan motor cable connector 3 Check the power supply voltage AC230 V 23 V 1 4 98 P26 Short circuit of the compressor driver element error When an abnormal short circuit of IGBT is detected O 1 P26 abnormality occurs when operating with the compressor wiring disconnected Check the control board 2 No abnormality occurs when operating with the compressor wiring...

Page 74: ... the remote control and the base unit of the indoor unit detected on the remote control side Stop Automatic reset Displayed when the abnormality is detected Defect in the reception of the remote control 1 Check the remote control crossover 2 Check the remote control 3 Check the hydro power supply wiring 4 Check the water heat exchanger board E02 Defect in the signal transmission to the hydro unit ...

Page 75: ...ntify causes and resolve strainer Excess air noise comes from inside the pump Flow switch is connected to board Built in pump is connected to board Flow switch is normal Chattering noise comes from flow switch Pump stops 2 3 minutes after its rotation started TC sensor characteristic is correct Yes Yes A01 occurs Operation restarts Water heat exchanger control board is defective replace it Perform...

Page 76: ...or higher Yes Correct water circuit To prevent hot water of other circuits from entering Yes Hot water from boiler or other circuits does not come in No Failure of backup heater Too large heater input thermostat short circuit Replace heater unit Yes Backup heater is energized No Measure heater current Start Replace water heat exchange control board Yes Flow switch is normal No Replace flow switch ...

Page 77: ...Hot water cylinder heater is energized Yes No At normal temperature tank thermostat is energized Yes Replace hot water cylinder thermostat No Hot water cylinder thermostat operates Yes Operation temperature 82 C Start Replace water heat exchange control board Replace Mg sw No Mg sw RY05 for heater operates Yes Operating noise at normal time ...

Page 78: ...econd pump Set DP_SW11 1 to ON No No No No inside strainer etc Chattering from flow switch Water heat exchanger board DP_SW11 1 is ON Power is connect to backup heater terminal Backup heater terminal has 230ACV 23V Start Operation restart Replace water heat exchange control board Perform air vent Set heater breaker to ON Check indoor wiring Replace flow switch No Yes Yes Yes Yes Replace backup hea...

Page 79: ...ater terminal Yes Yes Restart TWI 4 TWO 4 or THO 4 is detected Circulation pump keeps being energized or 3 minutes passed after the start No No Place power cable for backup heater Set breaker for backup heater to ON or Check indoor electronic wiring No Backup heater element is conductive Yes Replace TWI TWO and THO sensors No See characteristic table in page 101 TWI TWO THO sensor characteristics ...

Page 80: ...r less branches Remove sufficiently excess air Place buffer tank and the second pump No Excess air noise comes from inside pump Chattering noise comes from flow switch Start No No Yes Lower set temperature Yes Continued operation at high outside air temperature and at 50 C or higher set temperature No Attach TWO sensor No TWO sensor is attached to pipe Yes Replace pressure switch No Pressure switc...

Page 81: ...iciently excess air Place buffer tank and the second pump No Excess air noise comes from inside pump Chattering noise comes from flow switch Start No No Yes Raise set temperature Yes Cooling overload operation Continued operation at low outside temperature and at 15 C or lower set temperature No Defrost outdoor unit where frost remains Yes Defrosting takes 15 mins or longer Frost remains No Replac...

Page 82: ...ater Yes Flow switch is normal Yes No At normal temperature overheat preventive thermostat is normal Yes Start Replace water heat exchange control board or overheat preventive thermostat failure Replace water heat exchange control board or overheat preventive thermostat failure After the control board is replaced if the same operation repeats the overheat preventive thermostat is determined as def...

Page 83: ...ger water pipe to a branch or 5 or less branches Remove sufficiently excess air Place buffer tank and the second pump No Excess air noise comes from inside pump Chattering noise comes from flow switch Start No No Yes Attach TWI sensor No TWI sensor is attached to pipe Yes Replace TWI or TWO sensor No TWI and TWO sensor characteristics are normal Yes Yes Yes Replace water heat exchange control boar...

Page 84: ... cylinder heater After 1 hour since heater operation started neither TWI 15 C nor TTW 20 C is met Freeze prevention control is detected once No No Place electric wire for backup heater Place electric wire for hot water cylinder Set breaker for backup heater to ON Set breaker for hot water cylinder to ON or check indoor wiring No Backup heater element is conductive Yes Replace hot water cylinder he...

Page 85: ...ard If defective replace it No Check item code 14 No Yes Hydro unit Internal wiring and connecting wire 1 2 3 are correct Correct wiring and connecting wire No Yes CN04 connector and terminal block 1 2 3 wiring are normal Correct connector and terminal block wiring No Yes When power is on again D502 Amber LED blinks Check water heat exchanger board If defective replace it No Yes ...

Page 86: ...Start Replace water heat exchange control board Correct TD sensor connection Replace TD sensor No No TD sensor connector CN603 is connected Yes TD sensor resistance characteristic is normal Yes Start Replace water heat exchange control board Correct TE sensor connection Replace TE sensor No No TE sensor connector CN601 is connected Yes TE sensor resistance characteristic is normal Yes Start Replac...

Page 87: ...characteristic table on page 101 Correct TO sensor connection Replace TO sensor No No TO sensor connector CN602 is connected Yes TO sensor resistance characteristic is normal Yes Start See characteristic table on page 101 Replace water heat exchange control board Correct TWI sensor connection Replace TWI sensor No No See characteristic table on page 101 TWI sensor connector CN205 is connected Yes ...

Page 88: ...water heat exchange control board Correct TTW sensor connection Replace TTW sensor No No See characteristic table on page 101 TTW sensor connector CN214 is connected Yes TTW sensor characteristic is normal Yes Start Replace water heat exchange control board Correct TFI sensor connection Replace TFI sensor No No See characteristic table on page 101 TFI sensor connector CN213 is connected Yes TFI se...

Page 89: ...Yes THO sensor characteristic is normal Yes Start Replace water heat exchange control board Attach THO sensor to pipe Replace THO sensor No No THO sensor is attached to pipe Yes THO sensor characteristic is normal Yes Replace TWO sensor No See characteristic table on page 101 See characteristic table on page 101 TWO sensor characteristic is normal Yes Start Replace water heat exchange control boar...

Page 90: ...cteristic table on page 101 TWI sensor characteristic is normal Yes Replace TWO sensor No See characteristic table on page 101 TWO sensor characteristic is normal Yes Start Replace water heat exchange control board Attach lo pressure sensor Replace lo pressure sensor Yes No Lo pressure sensor is detached CN207 212 No When operation is stopped lo pressure sensor is normal 1 Yes Start 1 How to deter...

Page 91: ... In group control one or more individual for group address exist At the time of power on detecting the above failure automatically activates the automatic address setting mode Check code is not output Note that if the above failure is detected in the automatic address setting mode a check code may be output L09 Error L16 Error In DP_SW12 2 3 of main unit water heat exchanger if ZONE1 is not set an...

Page 92: ...r more LEDs of D800 through D804 lit yellow indicates that a failure occurred Indication 1 With the status above pressing the SW800 button for one second causes the yellow LED to blink Indication 2 Pressing again SW800 for one second or longer returns to Indication 1 The combination of Indication 1 and Indication 2 can determine what kind of abnormality Check code Outdoor LED indication Check and ...

Page 93: ...lve operates normally No Yes Wiring connection is normal Compressor lead board side compressor side reactor power lead Check and correct wiring connection No Yes CN609 connector and case thermostat is normal Correct connector Replace case thermostat Check for piping collapse and break If defective repair or replace it No Yes If case thermostat is short circuited cooling and heating can operate Che...

Page 94: ...n MCUs Indication 1 Indication 2 Heat sink temperature sensor TH failure See F13 details Indication 1 Indication 2 EEPROM failure See F31 details Indication 1 Indication 2 Model not set See L10 details Indication 1 Indication 2 Heat sink overheat failure See P07 details Indication 1 Indication 2 Gas leakage failure See P15 details Indication 1 Indication 2 4 way valve invert failure See P19 detail...

Page 95: ...ndication 2 Power source failure voltage defective open phase Check code Outdoor LED indication Check and Action procedure No specific description indicates outdoor unit parts No gas leakage Appropriate refrigerant amount Correct defective portion Re charge refrigerant Check outdoor control board If defective replace it No Yes Pulse motor valve is normal Correct defective portion Replace defective...

Page 96: ...ion sheet between Q300 400 and the heat sink Check outdoor control board If defective replace it Yes No Ventilation flue of heat sink is cleared Blower is not blocked Short circuit etc Remove obstacles Deal with short circuit No Yes Check outdoor control board If defective replace it No gas leakage Appropriate refrigerant amount Correct defective portion Re charge refrigerant No Yes Pulse motor va...

Page 97: ...ard is good With digital tester Although values shown has some range if its maximum value is 180DCV or higher the board is good Check code Outdoor LED indication Check and Action procedure No specific description indicates outdoor unit parts Temperature sensor check TE sensor CN601 TS sensor CN600 Hydro TWO sensor If defective repair or replace it 4 way valve check If defective replace it 4 way va...

Page 98: ...ck outdoor fan If defective replace or tighten it Yes Outdoor fan operates normally No Check the same item as those for P22 abnormality Reset the power source and perform a trail operation according to the season Something prevents outdoor unit heat exchange Clogged heat exchanger short circuit No Yes Check for refrigerant overcharged clogged cycle pipe break abnormal overload etc If defective rep...

Page 99: ...and Action procedure No specific description indicates outdoor unit parts Check outdoor control board If defective replace it Power voltage is normal 230ACV 23V No Yes Yes Check wiring Request power source repair When not energized the fan motor can be smoothly rotated by hand Fan motor coil resistance is normal Between red white leads 12 20 Between white black leads 12 20 Between black red leads ...

Page 100: ...utdoor unit parts TD sensor connector CN603 is connected Correct TD sensor connection Replace outdoor control board No TD sensor resistance characteristic is normal Replace TD sensor No See the characteristic table on page 101 Yes Yes TE sensor connector CN601 is connected Correct TE sensor connection Replace outdoor control board No Yes TE sensor resistance characteristic is normal Replace TE sen...

Page 101: ...tor CN600 is connected Correct TS sensor connection Replace outdoor control board No Yes TS sensor resistance characteristic is normal Replace TS sensor No Yes Replace outdoor control board TE and TS sensor is attached to the correct position Correct sensor attaching position Replace outdoor control board No Yes TE sensor resistance characteristic is normal Replace TE sensor No See the characteris...

Page 102: ... 12 26 55 28 03 40 5 013 5 192 5 375 50 17 00 17 92 18 86 50 3 312 3 451 3 594 60 11 74 12 34 12 95 60 2 236 2 343 2 454 70 8 269 8 668 9 074 70 1 540 1 623 1 709 80 5 925 6 195 6 470 80 1 082 1 146 1 213 90 4 321 4 507 4 696 90 0 7740 0 8237 0 8761 100 3 205 3 336 3 468 100 0 5634 0 6023 0 6434 0 10 0 10 20 30 40 50 60 10 20 30 40 50 60 70 80 90 100 0 0 0 5 10 15 20 50 100 150 200 10 20 30 40 50 ...

Page 103: ... 3 sec 3 3WV_W 4 Mixing valve Alive for 30 sec in the forward direction Alive for 30 sec in the reverse direction 5 Built in AC pump Alive not alive for 20 sec 6 Extended AC pump 1 Alive not alive for 20 sec 7 Extended AC pump 2 Alive not alive for 20 sec Reserved 8 Water heat exchange backup heater Repeat heater 1 heater 2 and OFF every 20 sec The built in AC pump operates 9 Hot water cylinder he...

Page 104: ...and measure the resistance value with a tester Normal temperature 2 Circulating pump AC pump Type UPS025 65K 130 802XWH E UPS25 80 130 1402XWH E Remove the connection cover of the pump and measure the resistance with a tester Temperature 0 C 10 C 20 C 30 C Sensor Water heat exchange temperature TC sensor 33 8 kΩ 20 35 kΩ 12 59 kΩ 7 99 kΩ Water inlet temperature TWI sensor Water outlet TWO sensor H...

Page 105: ...al temperature 6 Discharge temperature TD sensor Remove the connector and measure the resistance value with a tester Red White Black Location Resistance value Red White 1 04 1 16 Ω White Black 1 04 1 16 Ω Black Red 1 04 1 16 Ω At 20 C Red White Black Location Resistance value 802H E Red White 32 6 3 3 Ω White Black Black Red 1102 1402H E Red White 14 8 1 5 Ω White Black Black Red 1 White 6 Red 3 O...

Page 106: ...FF 10_3 Enhanced pump2 Interlock Yes No Yes OFF 10_4 OFF SW11 Switching details Factory setting Remarks 11_1 Internal backup heater Energized Yes No Energized OFF 11_2 Hot water cylinder heater Energized Yes No Energized OFF 11_3 Booster heater Energized Yes No Energized OFF 11_4 OFF SW12 Switching details Factory setting Remarks 12_1 Hot water supply Yes OFF 12_2 ZONE1 Yes OFF 12_3 ZONE2 No OFF 1...

Page 107: ...o the normal stop state 2 2 How to set remote controller function code This operation can set the start and end time of the nighttime low noise anti bacteria night set back or other functions Procedure Perform the following when no operation is in progress 1 Press the TEST and CL and TEMP buttons at the same time for 4 seconds or longer See display appears on the left 2 Specify CODE NO FC with the...

Page 108: ... Heating switching temperature 0020 20 C 0020 20 C 0000 0 C 23 Priority mode Boiler Heat pump switching temperature 0020 20 C 0020 20 C 0010 10 C 24 Outside air temperature for hot water temperature correction start 0020 20 C 0010 10 C 0000 0 C 25 Hot water temperature correction value 0000 0K 0015 15K 0003 3K 26 Night set back change temperature range 0003 3K 0020 20K 0005 5K 27 Set temperature s...

Page 109: ...noise start time 0 23 0 00 to 23 00 22 22 00 0B Nighttime low noise end time 0 23 0 00 to 23 00 06 06 00 0C Anti bacteria start time 0 23 0 00 to 23 00 22 22 00 0D Anti bacteria start cycle 1 10 Every day to 10 day cycle 07 7 day cycle 0E Night operation start time 0 23 0 00 to 23 00 22 22 00 0F Night operation end time 0 23 0 00 to 23 00 06 06 00 11 Remote control Alarm Tone 0 Alarm Tone OFF 1 Al...

Page 110: ...the HOT WATER button and a hot water supply operation starts after 3 minutes See display The pump immediately starts 3 Pressing the HOT WATER button again stops the hot water supply operation For heating trial operation 1 Press the ZONE1 2 button and a heating operation starts after 3 minutes See display The pump immediately starts 2 Pressing the ZONE1 2 button again stops the heating operation Fo...

Page 111: ...reen appears 2 Set a temperature shift range with the TEMP button for temperature setting 5k to 5k 3 Press the SET button If lights the status is confirmed 4 Pressing the TEST button moves the unit to the normal stop state FC Item Details Fist shipment 29 Outside air temperature T1 temperature 0015 15 C 0000 0 C 0010 10 C 2B Outside air temperature T3 temperature 0000 0 C 0015 15 C 0010 10 C 2C Se...

Page 112: ...ay to be set Press the DAY button to select the current day The symbol moves along above the days moves by each button press from MO through SU 3 Set time Use the TIME button to set time Long press changes time display by 10 minutes 4 Pressing the SET button ends the time setting Ending the time setting changes the days and time to the lit state and returns to the normal display and indications go...

Page 113: ...cify set time operation mode and set temperature Time setting Use the TIME button to set time Operation mode Press HOT WATER for hot water supply ZONE1 2 for heating or ZONE1 2 for cooling and then press OPERATE MODE Pressing HOT WATER or ZONE1 2 again displays indicating stop When an operation mode is set appears for heating for cooling or for hot water supply and also the temperature set last ti...

Page 114: ...ting keeps a room with weak heating when users are not home for long hours 1 Press the ZONE1 2 button to start a heating operation This is available only for a normal heating operation No frost protection setting is provided to hot water supply and cooling 2 Pressing the FORST PROTECTION button displays the symbol and F for temperature setting See display The heating operation of 15 C is set In FC...

Page 115: ...fault 3 Pressing the NIGHT button again makes disappear and the normal operation starts How to set NIGHT operation start and end time 1 Press the NIGHT button for 4 seconds or longer Moves to the NIGHT time setting mode See display 0E in the Code No field and the current time displayed blink 2 Press the TIME button to set a desired start time Pressing SET changes the time to be lit and the setting...

Page 116: ... does not start How to set anti bacteria temperature and holding time In FC_0A or 0B See 2 2 the set temperature and holding time can be changed FC_0A Set temperature change range 70 to 80 C 75 C default FC_0B Holding time change range 0 to 60 minutes 30 minutes default How to set anti bacteria start time and cycle 1 Press the ANTI BACTERIA button for 4 seconds or longer See display Moves to the a...

Page 117: ... output from the outdoor unit during nighttime for neighbours Nighttime low noise operates with lower operation frequency and fan tap than usual only for the set time period The operation is the same as usual hot water supply heating or cooling Adjust the unit time before making the settings How to enable set start time and end time of nighttime low noise 1 Press the TEST and TEMP button at the sa...

Page 118: ...eration starts To perform defrosting again start with 1 above Performing the forced defrosting once cancels the forced defrosting setting above described 13 Rated Operation Setting The FC code setting See 2 2 can activate the rated operation mode during a heating operation Preparation 1 Press the remote controller buttons TEST SET and SELECT at the same time for 4 seconds or longer Make sure that ...

Page 119: ...mperature TWI C 07 Water outlet temperature TWO C 08 Water heater outlet temperature THO C 09 Floor inlet temperature TFI C 0A Hot water cylinder temperature TTW C 0B Mixing valve position step OE Lo pressure Ps 100 MPa Outdoor unit data Item code Data name Unit 60 Heat exchange temperature TE C 61 Outside air temperature TO C 62 Discharge temperature TD C 63 Suction temperature TS C 65 Heat sink ...

Page 120: ...y 2 To monitor other failure history press the TEMP button for temperature setting to change the failure history number item code Item code 01 Latest Item code 01 Old Note The failure history contains the last 4 failures 3 Pressing the TEST button returns to the normal display Notes Do not press the CL button Pressing the button deletes all the failure history of the hydro unit If the button is pr...

Page 121: ...eating or on a room temperature Power save setting When using the power save function set the switch to ON This setting controls the compressor frequency lowering about 10 according to the heat exchange temperature of the hydro unit during a heating or hot water supply operation Snow prevention fan control This control enables the function that prevents snow from entering the draft air duct throug...

Page 122: ...nd outdoor unit serial communication D503 Green LED Signal display signals from the outdoor unit of communication between hydro unit and outdoor unit serial communication D800 to D804 Yellow LED Abnormality indication All OFF of SW803 or the lit status of any of D800 to D804 indicates that the outdoor control unit detects an abnormality Setting SW803 to other than OFF shows details with LED indica...

Page 123: ...mality details of the current one is displayed This setting does not display a TO sensor failure Check for the failure with the setting for current abnormality See 2 2 Temperature sensor indication These switches indicate the temperature sensor detecting value TC TWO 2 heating hot water supply TC TWO cooling See 2 3 Current indication This switch indicates the current value in the outdoor unit See...

Page 124: ... TS failure Heat sink temperature sensor TH failure Heat exchanger suction sensor TE TS wrong wiring EEPROM failure Compressor break down Compressor lock Current detection circuit failure Faulty compressor case thermostat Not set up the capacity Communication failure between MCUs Other abnormality e g Compressor s loss of synchronism Abnormal discharge temperature Power failure Heat sink overheat ...

Page 125: ... 9 14 14 9 15 15 9 16 16 9 17 17 9 18 18 9 19 19 9 20 20 9 21 21 9 22 22 9 23 23 9 24 24 9 25 25 9 26 26 9 27 27 9 28 28 9 29 29 9 30 30 9 31 or higher 0 4 5 9 10 14 15 19 20 24 25 29 30 34 35 39 40 44 45 49 50 54 55 59 60 64 65 69 70 74 75 79 80 84 85 89 90 94 95 99 100 104 105 109 110 114 115 119 120 124 125 129 130 134 135 139 140 144 145 149 150 154 155 or higher 0 19 20 39 40 59 60 79 80 99 1...

Page 126: ...rms a fan motor operation When SW801 is pressed again or after 2 minutes the operation returns to the normal control Caution Although these controls are available during an operation basically perform them when no operation is in progress Performing these controls during an operation may cause dangerously rapid pressure change No operation particularly PMV full open operation Fully opens PMV Pulse...

Page 127: ...rox 325V This function operates for 10 seconds After that it becomes OFF SV valve relay operation RY702 CN702 for check Sets SV valve relay RY702 to ON When SW801 is pressed again or after 2 minutes the operation returns to the normal control HWS 1102 and 1402H E do not have the parts mounted so this operation is unavailable Heater output relay operation RY703 CN703 for check Sets relay for option...

Page 128: ... an injury when accidentally contacting the parts Thick gloves such as cotton work gloves No Exchange parts name Work procedure Remarks 1 Common procedure Front panel Electric parts box cover lower Electric parts box cover upper 1 How to remove 1 Stop the hydro unit operation and turn off the power breaker 2 Remove the front panel ST1T Ø4 10 6 screws 3 After unscrew the screws remove the front pan...

Page 129: ...l thermostat 3P Yellow CN203 TC sensor 2P Yellow CN204 TWI sensor 3P Brown CN205 TWO sensor 2P Red CN206 THO sensor 3P White CN207 Lo pressure sensor 2P Blue CN212 Lo pressure sensor 4P White CN213 TB 06 4P Terminal block 3P White CN214 TB 06 4P Terminal block 2P White CN305 TB 01 3P Terminal block 3P Green CN501 Relay board 6P Yellow CN601 Relay 05 3P Red CN602 TB 04 6P Terminal block 7P White CN...

Page 130: ...ater heat exchanger board 1 Connector CN200 Float switch 3P Red CN201 Pressure switch 2P White CN202 Bimetal thermostat 3P Yellow CN203 TC sensor 2P Yellow CN204 TWI sensor 3P Brown CN205 TWO sensor 2P Red CN206 THO sensor 3P White CN207 Lo pressure sensor 2P Blue CN212 Lo pressure sensor 4P White CN603 Pump 3P Yellow Disconnect the heater power source cable For backup heater and hot water cylinde...

Page 131: ... 2 screws 2 Side board Left 1 Remove the fixed screws of the side board Left ST1T Ø4 10 5 screws 7 Upper board 1 Perform the step 1 1 and step 6 2 Remove the fixed screws of the upper board ST1T Ø4 10 4 screws 8 Bottom board 1 Perform the step 1 1 and step 6 2 Remove the fixed screws of the bottom board ST1T Ø4 10 4 screws No Exchange parts name Work procedure Remarks Side board Right Side board L...

Page 132: ...he expasion vessel connection has no water leakage Expansion vessel Expansion vessel Fixed band Replace the packing to new one when installing the expansion vessel To replace a water circuit part first close the water supply source valve and the valve of water pipe connected to the hydro unit The relief valve connection uses an O ring for water seal Be careful not to scratch the O ring otherwise w...

Page 133: ...arts name Work procedure Remarks To replace a water circuit part first close the water supply source valve and the valve of water pipe connected to the hydro unit The pump connection uses a liquid packing for water seal When replacing the pump use a packing which was slathered with the liquid gasket Part code Service parts 37595721 Packing 37595722 Liquid gasket After the pump replacement repair o...

Page 134: ...valve of water pipe connected to the hydro unit The flow switch connection uses an O ring for water seal Be careful not to scratch the O ring otherwise water leakage may occur After the flow switch replacement repair open the water supply source valve and water piping valve to pass water through the hydro unit and check that the flow switch connection has no water leakage Flow switch Flow switch W...

Page 135: ... the water supply source valve and the valve of water pipe connected to the hydro unit The heater connection uses a liquid packing for water seal When replacing the heater use a packing which was slathered with the liquid gasket Part code Service parts 37595721 Packing 37595722 Liquid gasket After the heater assembly replacement repair open the water supply source valve and water piping valve to p...

Page 136: ...ocedure Remarks Close the water piping source valve and the valve of water pipe connected to the hydro unit and then remove the refrigerant and water piping Perform refrigerant recovery with the outdoor unit Disconnect all the power source cable outdoor unit connection cable and cylinder connection cable The heater connection uses a packing for water seal Be careful not to scratch the packing othe...

Page 137: ...minals 4 Remove the top board Hex Ø4 10 5 screws 2 How to attach 1 Attach the top board Hex Ø4 10 5 screws At this time insert the back side fin guard between the top board and the water heat exchanger back side 2 Connect the power source cable and connecting cables between indoor and outdoor to the terminal and fix them with the cord clamp Note The power source cable and connecting cable between ...

Page 138: ... the step 1 1 2 Remove the screws that fixes the inverter assembly and the side cabinet ST1T Ø4 8 2 screws 3 Remove the screws of the side cabinet and valve fixing board ST1T Ø4 8 2 screws 4 Remove the screws of the side cabinet and piping panel back Hex Ø4 10 2 screws 5 Remove the screws of the side cabinet and bottom board Hex Ø4 10 1 screw 6 Remove the screws of the side cabinet and water heat ...

Page 139: ...tight screw for fixing the board Ø3 20 1 screw 6 Remove the control board Supporter 5 positions Note Removing the control board may be difficult due to the heat release grease for the heat sink 7 Attach a new control board Note Be careful for not taking the compressor lead V CN201 White for the reactor lead CN05 or 06 White The compressor lead has a transparent sleeve at its ring terminal The reac...

Page 140: ...s 4 Remove the reactor Truss B tight screw Ø4 6 2 screws 5 Attach a new reactor Note Be sure to bind the removed binding tie by using the commercially available binding tie Make sure that the fan motor lead and the reactor body do not contact each other No Exchange parts name Work procedure Remarks Relay connector Reactor body Fan motor lead Control board Binding tie Compressor lead Relay connecto...

Page 141: ...prevent the fan motor lead from contacting the propeller fan adjust the length of fan motor lead fixing rubber so that it does not slack Attach the fan motor lead fixing rubber to the parting board so that the projection part is placed on the refrigerant cycle side Make sure that the reactor body and the fan motor lead do not contact each other Be sure to bind the removed binding tie by using the ...

Page 142: ...nd the pulse motor valve coil lead 6 Remove the soundproofing board Upper Inward winding Outward winding 7 Remove the compressor terminal cover and then remove the compressor lead and compressor case thermostat 8 Remove the TD sensor fixed to the discharge pipe 9 Remove the compressor lead Leave the ferrite core attached to the electric parts box Control board U CN200 Red V CN201 White W CN202 Bla...

Page 143: ...ke fire flame contact with the 4 way valve and pulse motor valve This may cause an operation failure 11 Pull out the discharge and suction pipes of the refrigerant cycle upward 12 Remove the compressor bolts that fix the compressor to the bottom board 3 bolts 13 Pull the compressor out toward you Note The compressor weighs 15 kg or more Two people should be required to handle it No Exchange parts ...

Page 144: ...d between the piping and parting board Place the compressor lead and the compressor case thermostat so that they fall into between the inward winding and outward winding of the soundproofing board No Exchange parts name Work procedure Remarks Black piping cover for heat resistance and Binding tie for heat resistance Sensors TL TO TE TD TS Pulse motor valve coil lead Piping cover Binding tie Sensor...

Page 145: ...utdoor unit control board to ON Press SW801 on the outdoor unit control board for 1 second or longer After pressing SW801 for 1 second or longer turn off the electric leakage beaker within 2 minutes 4 Charge refrigerant 1 Add refrigerant whose amount is defined according to the piping length from the valve charge port HWS 802H 1 8kg 7 Pulse motor valve coil 1 How to remove 1 Perform the step 1 1 a...

Page 146: ...maged 2 Remove the outlet cabinet and put with the fan guard side down 3 Release the hooks 8 positions of the fan guard 2 How to attach 1 Press the hooks 8 positions with hands from the front side to fix them Note Check that all the hooks are fixed to the given positions No Exchange parts name Work procedure Remarks Outlet cabinet Bellmouth Hooks Fan guard ...

Page 147: ...wer source cable and connecting cables between hydro and outdoor from the cord clamp and terminals 4 Remove the top board Hex Ø4 10 5 screws 2 How to attach 1 Attach the top board Hex Ø4 10 5 screws 2 Connect the power source cable and connecting cables between indoor and outdoor to the terminal and fix them with the cord clamp Note The power source cable and connecting cable between hydro and out...

Page 148: ...Perform the step 1 1 2 Remove the screws that fixes the inverter assembly and the side cabinet ST1T Ø4 8 2 screws 3 Remove the screws of the side cabinet and valve fixing board ST1T Ø4 8 2 screws 4 Remove the screws of the side cabinet and piping panel back Hex Ø4 10 2 screws 5 Remove the screws of the side cabinet and bottom board Hex Ø4 10 1 screws 6 Remove the screws of the side cabinet and fin...

Page 149: ...crew for fixing the board Ø3 20 1 screw 6 Remove the control board Supporter 5 positions Note Removing the control board may be difficult due to the heat release grease for the heat sink 7 Attach a new control board Note Be careful for not taking the compressor lead V CN201 White for the reactor lead CN05 or 06 White The compressor lead has a transparent sleeve at its ring terminal The reactor lea...

Page 150: ...t screw Ø4 6 2 screw 5 Attach a new reactor Note Be sure to bind the removed binding tie by using the commercially available binding tie Make sure that the fan motor lead and the reactor body do not contact each other No Exchange parts name Work procedure Remarks Reactor lead Reactor lead Reactor body Fan motor lead Binding tie Compressor lead Reactor lead Binding tie Compressor lead Reactor lead ...

Page 151: ...gth of fan motor lead fixing rubber so that it does not slack Attach the fan motor lead fixing rubber to the parting board so that the projection part is placed on the refrigerant cycle side Make sure that the reactor body and the fan motor lead do not contact each other Be sure to bind the removed binding tie by using the commercially available binding tie Be sure to re attach the ferrite core of...

Page 152: ...N201 White W CN202 Black 9 Remove the outlet and suction pipes connected to the compressor by using a burner WARNING When removing the piping by burning the solder take enough care for a fire going off at the moment the wax melts if oil remains inside the piping Note Do not make fire flame contact with the 4 way valve and pulse motor valve This may cause an operation failure 10 Pull out the discha...

Page 153: ...ve may fail How to make pulse motor valve forcible full open Turn on the electric leakage breaker Set the SW804 dip switch 1 and 3 on the outdoor unit control board to ON Press SW801 on the outdoor unit control board for 1 second or longer After pressing SW801 for 1 second or longer turn off the electric leakage breaker within 2 minutes 4 Charge refrigerant 1 Add refrigerant whose amount is define...

Page 154: ...and step 2 Note Perform a replacement work on cardboard or cloth to prevent the product from being damaged 2 Remove the outlet cabinet and put with the fan guard side down 3 Release the hooks 8 positions of the fan guard 2 How to attach 1 Press the hooks 8 positions with hands from the front side to fix them Note Check that all the hooks are fixed to the given positions No Exchange parts name Work...

Page 155: ... exchanger control board Terminal block Annually Check for loose connector and connecting terminal Outdoor unit HWS 802H E 1102H E 1402H E Frequency Periodic inspection details 1 Insulation measurement Power source circuit Compressor Annually Insulation measurement with a mega tester 2 Power source measurement No load voltage Rated operation Annually Electronic voltage measurement 230V 23V 3 Opera...

Page 156: ...155 13Part Exploded View Part List Hydro Unit 201 203 208 202 219 236 218 209 210 211 213 203 214 215 206 216 207 212 204 205 217 ...

Page 157: ...156 220 223 235 234 222 225 226 231 232 229 228 235 233 230 221 224 227 ...

Page 158: ...3 37545714 HEATER ASSY 1 1 213 37545715 HEATER ASSY 1 214 43151273 SWITCH PRESSURE 1 1 1 1 1 215 37551736 SENSOR LOW PRESSURE 1 1 1 1 1 216 37551735 SWITCH FLOW 1 1 1 1 1 217 43032441 NIPPLE DRAIN 1 1 1 1 1 218 37595721 PACKING ASSY 1 1 1 1 1 219 37595720 RING O ASSY 1 1 1 1 1 220 4306V226 PC BOARD ASSY 1 1 1 1 1 221 4316V338 PC BOARD ASSY 1 1 1 1 1 222 43152401 CONTACTOR MAGNETIC 2 3 3 2 3 223 43...

Page 159: ...158 Outdoor Unit HWS 802H E 021 016 015 023 022 029 020 024 013 019 005 030 028 031 032 026 017 004 003 006 027 025 034 008 007 035 010 009 011 033 002 001 014 018 012 ...

Page 160: ...F 1 014 43100452 PANEL SIDE 1 015 43100453 PANEL AIR OUTLET 1 016 43100454 PANEL FRONT 1 017 43100455 BASE ASSY 1 018 43107276 HANGER 2 019 43107277 GUARD FIN BACK 1 020 43107278 GUARD FIN SIDE 1 021 43109422 GUARD FAN 1 022 43120244 FAN PROPELLER PB521 1 023 43122113 BELL MOUTH 1 024 4312C042 MOTOR FAN ICF 280 A60 1 1 025 43146686 VALVE PACKED 9 52 1 026 43146695 VALVE PULSE MODULATING 1 027 4314...

Page 161: ...03 Sensor assembly F4 TD TL sensor TS TE TD sensor 705 707 Terminal 3P Fuse 706 Terminal 3P 708 Sensor holder TO 702 Sensor holder TE 712 Sensor holder TS 713 Sensor holder TD 711 Control board assembly 704 Reactor 710 Collar 709 Bushing 701 Sensor assembly F6 ...

Page 162: ...ENSOR 1 703 43150319 SENSOR ASSY SERVICE 2 704 43155188 REACTOR CH 56 2Z T 2 705 43160565 TERMINAL BLOCK 3P 20A 1 706 43160581 TERMINAL 1 707 43160589 FUSE 1 708 43163055 HOLDER SENSOR 1 709 43163059 SPACER BUSH 1 710 43163060 SPACER COLLAR 1 711 4316V387 PC BOARD ASSY MCC 1571 1 712 43063322 HOLDER SENSOR 1 713 43063321 HOLDER SENSOR 1 ...

Page 163: ...162 Outdoor Unit HWS 1102H E 1402H E 020 015 021 022 029 030 017 013 018 028 026 032 019 014 011 031 024 034 035 001 002 033 027 037 004 003 016 025 006 009 008 005 010 012 007 036 023 ...

Page 164: ...UTLET 1 1 016 43100443 BASE ASSY 1 1 017 43107274 GUARD FIN SIDE 1 1 018 43107275 GUARD FIN BACK 1 1 019 43107276 HANGER 3 3 020 43109422 GUARD FAN 2 2 021 43120244 FAN PROPELLER PB521 2 2 022 43122113 BELL MOUTH 2 2 023 4312C037 MOTOR FAN ICF 280 A100 1 2 2 024 43146676 JOINT CHECK 1 1 025 43146686 VALVE PACKED 9 52 1 1 026 43146687 VALVE 4 WAY STF 0401G 1 1 027 43146724 VALVE BALL SBV JA5GTC 1 R...

Page 165: ...1 1 2 2 3 3 R R S S T T 703 Sensor assembly F4 705 707 Terminal 3P Fuse 706 Terminal 3P 708 Sensor holder TO 702 Sensor holder TE 711 Control board assembly Reactor 710 Collar 709 Bushing 701 Sensor assembly F6 TD TL sensor TS TE TO sensor 704 ...

Page 166: ...ERVICE 3 3 702 43063325 HOLDER SENSOR 1 1 703 43150319 SENSOR ASSY SERVICE 2 2 704 43158190 REACTOR 2 2 705 43160565 TERMINAL BLOCK 3P 20A 1 1 706 43160581 TERMINAL 1 1 707 43160589 FUSE 1 1 708 43163055 HOLDER SENSOR 1 1 709 43163059 SPACER BUSH 1 1 710 43163060 SPACER COLLAR 1 1 711 4316V357 PC BOARD ASSY MCC 1571 1 1 ...

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