Toshiba HWS-803XWHM3-E Service Manual
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Toshiba HWS-803XWHM3-E Service Manual

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See also: Owner's Manual , Installation Manual
AIR TO WATER HEAT PUMP

SERVICE MANUAL

Model name:
Hydro Unit
HWS-803XWHM3-E(TR)
HWS-803XWHT6-E(TR)
HWS-803XWHD6-E
HWS-803XWHT9-E
HWS-1403XWHM3-E(TR)
HWS-1403XWHT6-E(TR)
HWS-1403XWHD6-E
HWS-1403XWHT9-E(TR)
Hot Water Cylinder
HWS-1501CSHM3-E(-UK)
HWS-2101CSHM3-E(-UK)
HWS-3001CSHM3-E(-UK)
Outdoor Unit
HWS-803H-E(TR)
HWS-1103H-E(TR)
HWS-1403H-E(TR)
HWS-1103H8-E
HWS-1103H8R-E
HWS-1403H8-E
HWS-1403H8R-E
HWS-1603H8-E
HWS-1603H8R-E
A10-006

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Summary of Contents for Toshiba HWS-803XWHM3-E

  • Page 1: Service Manual

    A10-006 AIR TO WATER HEAT PUMP SERVICE MANUAL Model name: Hydro Unit Outdoor Unit HWS-803XWHM3-E(TR) HWS-803H-E(TR) HWS-803XWHT6-E(TR) HWS-1103H-E(TR) HWS-803XWHD6-E HWS-1403H-E(TR) HWS-803XWHT9-E HWS-1103H8-E HWS-1403XWHM3-E(TR) HWS-1103H8R-E HWS-1403XWHT6-E(TR) HWS-1403H8-E HWS-1403XWHD6-E HWS-1403H8R-E HWS-1403XWHT9-E(TR) HWS-1603H8-E HWS-1603H8R-E Hot Water Cylinder HWS-1501CSHM3-E(-UK) HWS-2101CSHM3-E(-UK) HWS-3001CSHM3-E(-UK)

  • Page 2: Table Of Contents

    Contents 1 SAFETY PRECAUTIONS ..........3 2 NEW REFRIGERANT (R410A).
  • Page 3 8 Operational Description ..........43 9 Method of Defect Diagnosis .

  • Page 4: Safety Precautions

    SAFETY PRECAUTIONS The unit and this service guide list very important safety precautions. Understand the following details (indications and symbols) before reading the body text, and follow the instructions. [About indication] Indication Meaning of Indication Indicates that a wrong operation may cause a service engineer and the third persons DANGER around to get fatal or serious injuries.
  • Page 5 WARNING <No modification> Do not modify the unit. • Do not disassemble or modify the parts also. • A fire, an electric shock, or an injury may occur. <Use specified parts> Use the specified parts (∗) when replacing them. • Using parts other than specified ones may cause a fire or an electric shock. ∗: For details, see the parts price list.
  • Page 6 WARNING <Check insulation> After the work is completed, check with an insulating-resistance tester (500V) that the insulation resistance between the live and dead-metal parts is 2 MΩ or higher. • A low insulation resistance may cause a disaster at a customer site due to electrical leakage or an electric shock. <Ventilate>...

  • Page 7: New Refrigerant (R410A)

    NEW REFRIGERANT (R410A) This Air to Water Heat Pump adopts a new refrigerant HFC (R410A) to prevent destruction of the ozone layer. The working pressure of R410A refrigerant is 1.6 times higher than that of the conventional refrigerant R22.The refrigerant oil is also changed for the new refrigeration. Therefore, during installation or service work, be sure that water, dust, former refrigerant, or refrigeration machine oil does not enter the refrigerant cycle of the new type refrigerant Air to Water Heat Pump.

  • Page 8: 2-2.Installing Refrigerant Pipe

    2-2. Installing refrigerant pipe 2-2-1. Steel pipe and joint For refrigerant piping, steel pipe and joints are mainly used. Select those comply with JIS (Japanese Industrial Standards) for a service work. Also, use such clean piping materials that less impurities attach to the inside of pipe and joints.

  • Page 9: 2-2-2.Processing Of Piping Materials

    2-2-2. Processing of piping materials When installing refrigerant pipe, prevent water or dust from entering the pipe, and do not use oil other than lubricant used for Air to Water Heat Pump. Make sure that no refrigerant leak occurs. If piping needs lubrication, use lubricating oil whose water content is removed. After the oil is put in, be sure to seal the container with airproof cover or other covers.
  • Page 10 Flare connecting procedure and precautions 1) Make sure that the flare and connecting portions do not have any flaw and dust. 2) Correctly align the flared surface and the connecting axis. 3) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is the same as that for the conventional R22.

  • Page 11: 2-3.Tools

    2-3. Tools 2-3-1. Necessary tools In Air to Water Heat Pump using R410A, the service port diameter of packed valve of the outdoor unit is changed to prevent mixing of other refrigerant. To reinforce the pressure resistance, flare dimensions and opposite side dimensions of flare nut (For Ø...

  • Page 12: 2-4.Recharging Of Refrigerant

    2-4. Recharging of refrigerant Recharge, if necessary, the specified amount of new refrigerant according to the following procedure. Recover the refrigerant, and check that no Open fully the handle of gauge manifold Lo, turn on the refrigerant remains in the refrigerant cycle. vacuum pump, and then perform vacuum evacuating.
  • Page 13 NOTE • Make sure that the setting is appropriate so that liquid can be charged. • A cylinder with siphon enables liquid to be charged without the cylinder turned upside down. [Cylinder with siphon] [Cylinder without siphon] Gauge manifold Gauge manifold Outdoor unit Outdoor unit Siphon pipe...

  • Page 14: 2-5.Brazing Of Pipes

    2-5. Brazing of pipes Type of flux • Non-corrosive flux 2-5-1. Materials of brazing It is generally a compound of borax and boric acid. It is effective when brazing temperature is higher than 800 °C. Silver brazing metal • Active solvent Silver brazing metal is an alloy mainly composed of Most of this type of flux is generally used for silver silver and copper.
  • Page 15 5) Use the reducing valve to adjust the nitrogen gas flow speed to 0.05 m /hour or 0.02 MPa (0.2 kgf/cm 6) After the steps above, keep the nitrogen gas flowing until the pipe cools down to a certain extent. (Temperature where the pipe is cool enough to be touched by hands) 7) Remove the flux completely after brazing.

  • Page 16: Specifications

    Specifications Unit name Hydro unit HWS-803XWHM3-E, 803XWHT6-E, 803XWHD6-E, 803XWHT9-E Outdoor unit HWS-803H-E Heating capacity *1 (kW) Cooling capacity *2 (kW) Variable range of compressor frequency 10 - 70 Hz Power source Single phase 50Hz 220 - 230V Operation mode Heating...
  • Page 17 Unit name Hydro unit HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E Outdoor unit HWS-1103H-E HWS-1403H-E Heating capacity *1 (kW) 11.2 14.0 Cooling capacity *2 (kW) 10.0 11.0 Variable range of compressor frequency 10 - 60Hz 10 - 70 Hz Power source Single phase 50Hz 220 - 230V Operation mode Heating Cooling...
  • Page 18 Unit name Hydro unit HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E Outdoor unit HWS-1103H8(R)-E HWS-1403H8(R)-E HWS-1603H8(R)-E Heating capacity *1 (kW) 11.2 14.0 16.0 Cooling capacity *2 (kW) 10.0 11.0 13.0 Variable range of compressor frequency 10 - 60Hz 10 - 60 Hz 10 - 70 Hz Power source 3 phase 50Hz 380 - 400V Operation mode...

  • Page 19: Outside Drawing

    Outside Drawing 4-1. Hydro unit HWS-803XWHM3-E, 803XWHT6-E, 803XWHD6-E, 803XWHT9-E HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E 2-dia.12x17 long hole (for dia.8-10 anchor bolt) 371.5 72.5 72.5 B leg part Anchor bolt long hole pitch Manometer Remote controler 2-dia.12x17 U-shape hole A leg part (for dia.8-10 anchor bolt)

  • Page 20: 4-2.Outdoor Unit

    4-2. Outdoor unit HWS-803H-E...
  • Page 21 HWS-1103H-E, 1403H-E, 1103H8(R)-E, 1403H8(R)-E, 1603H8(R)-E...

  • Page 22: 4-3.Hot Water Cylinder

    4-3. Hot water cylinder HWS-2101CSHM3-E(-UK) HWS-3001CSHM3-E(-UK) Specification for UK only Specification for UK only HWS-1501CSHM3-E(-UK) Specification for UK only...

  • Page 23: Wiring Diagram

    HWS-803XWHT9-E : Installed HWS-1403XWHM3TR : Not installed Type 2 Type 2 HWS-1403XWHT9-E : Installed (3-wire SPST type) (3-wire SPST type) HWS-803XWHM3-E : Not installed Type 3 HWS-1403XWHM3-E : Not installed (3-wire SPDT type) TB 01 Thermal protector Thermal protector Thermal protector...

  • Page 24: 5-2.Outdoor Unit (Single Phase Type)

    5-2. Outdoor Unit (Single phase Type) HWS-803H-E, HWS-1103H-E, HWS-1403H-E...

  • Page 25: 5-3.Outdoor Unit (3 Phase Type)

    5-3. Outdoor Unit (3 phase type) HWS-1103H8(R)-E, -1403H8(R)-E, -1603H8(R)-E P.C. board MCC-1596 P.C. board MCC-1597 (1103H8R-E 1403H8R-E 1603H8R-E) only Hydro unit indicates the teminal block. Alphanumeric characters in the cycle indicate terminal No. The two-dot chain line indicates the wiring procured locally. indicates the P.C.

  • Page 26: 5-4.Hot Water Cylinder Unit

    5-4. Hot Water Cylinder Unit Double pole thermal cut out Blue Blue Green / Brown Yellow Brown TB03(230V) TB06(TTW) TTW sensor Hot water cylinder heater Supply 220 - 230 V from hydro unit To hydro unit Cable size 1.5 mm (minimum)

  • Page 27: Key Electric Component Rating

    Key Electric Component Rating 6-1. Hydro Unit HWS-803XWHM3-E, T6-E, D6-E, T9-E Model name Component name Type name Rating M3-E T6-E D6-E T9-E Circulating pump UPS025-65 K 130 AC230 V 0.54 A (MAX) Backup heater 6 kW AC 400 V (3N) 6 kW (AC230 V 3 kW –...
  • Page 28 HWS-1403XWHM3-E, T6-E, D6-E, T9-E Model name Component name Type name Rating M3-E T6-E D6-E T9-E Circulating pump UPS25-80 130 AC230 V 0.83 A (MAX) Backup heater 6 kW AC 400 V (3N) 6 kW (AC230 V 3kW – compatible) Backup heater 9 kW AC 400 V (3N) 9 kW –...

  • Page 29: 6-2.Outdoor Unit

    6-2. Outdoor Unit HWS-803H-E Component name Type name Rating Compressor DA220A2F-22L Outdoor fan motor ICF-280-A60-1 Output 60 W 4-way valve coil VHV-01AP552B1 AC220 - 230 full-wave rectifier input, alive time 10 sec or less Pulse motor valve (PMV) coil CAM-MD12TF-15 DC12 V Compressor case thermostat US-622KXTMQO-SS...
  • Page 30 HWS-1103H-E, 1403H-E Component name Type name Rating Compressor DA422A3F-25M Outdoor fan motor (x2) ICF-280-A100-1 Output 100 W Reactor (x2) CH-44 1.4 mH, 25 A 4-way valve coil AC220 - 230 V full-wave rectifier input, alive time 10 sec or less Pulse motor valve (PMV) coil UKV-A038 DC12 V...
  • Page 31 HWS-1103H8(R)-E, 1403H8(R)-E, 1603H8(R)-E Component name Type name Rating Compressor DA422A3F-27M Outdoor fan motor (x2) ICF-280-A100-1 Output 100 W Reactor CH-78 4.2 mH, 16 A Reactor CH-68 18 mH, 5 A 4-way valve coil STF-01A5502E1 AC220 - 230 V Pulse motor valve (PMV) coil UKV-A038 DC12 V PC board (Compressor)

  • Page 32: 6-3.Hot Water Cylinder Unit

    6-3. Hot Water Cylinder Unit Model name 1501 2101 3001 Component name Type name Rating M3-E M3-E M3-E (-UK) (-UK) (-UK) Hot water cylinder heater – AC230 V 2.75 KW Hot water cylinder temperature 10 kΩ (25°C) sensor – (TTW sensor) Thermal cut-out Operating temperature –...

  • Page 33: 6-4.Water Heat Exchange Control Board

    6-4. Water Heat Exchange Control Board HWS-803XWHM3-E, 803XWHT6-E, 803XWHD6-E, 803XWHT9-E HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E TC sensor connector TTW sensor connector CN203 CN214 Low pressure sensor connector Remote control TFI sensor Relay board connector CN207, CN212 connector connector CN501 CN41 CN213...

  • Page 34: 6-5.Outdoor Control Board (Single Phase Type)

    6-5. Outdoor Control Board (Single phase Type) HWS-803H-E Reactor connection connector Electrolytic capacitors Compressor output terminals Fan motor output Power circuit protection CN202 CN300 (White) fuse CN201 F100 (250 V, 3.15 A, CN200 plastic case) Case thermostat connector CN609(Blue) 4-way valve connector CN701(White) Compressor ON output connector...
  • Page 35 HWS-1103H-E, 1403H-E Compressor output terminals Fan motor output (Lower) Fan motor output (Upper) Electrolytic capacitors CN202 CN300(White) CN400(White) CN201 CN200 Case thermostat connector CN609(Blue) Power circuit protection fuse F100(250V,3.15A, plastic case) 4-way valve connector CN701(White) Compressor ON output connector CN704(Blue) Heator output connector CN703(Grey)

  • Page 36: 6-6.Outdoor Unit Control (3 Phase Type)

    6-6. Outdoor Unit Control (3 phase type) HWS-1103H8(R)-E, 1403H8(R)-E, 1603H8(R)-E MCC-1596 (Compressor IPDU) CN851 CN101 (Red) (White) Connector for MCC-1597 (CN505) Connector for MCC-1597 (CN502) CN13 (Black) Terminal for power relay Electric circuit protective fuse (500V, 31.5A) CN12 (White) Terminal for MCC-1600 (CN17) Electric circuit protective fuse (500V, 31.5A) CN11...

  • Page 37: Mcc-1597 (Fan Motor Ipdu)

    MCC-1597 (Fan Motor IPDU) CN750 CN700 CN500 (White) (Blue) (Red) Fan motor output (Upper side) Fan motor output (Lower side) Connector for MCC-1600 (CN23) and reactor CH68 CN504 CN602 F500 (Blue) (Black) Connector for MCC-1599 Connector for MCC-1600 (CN51) Electric circuit protective fuse (CN802) (250V, 15A) P501...

  • Page 38: Mcc-1599 (Interface (Cdb))

    MCC-1599 (Interface (CDB)) CN708 CN608 (Blue) (White) Connector for power relay coil Connector for MCC-1600 (CN50) CN02 (Red) CN802 (White) Connector for MCC-1600 (CN10 and CN19) Connector for MCC-1597 (CN504) CN700 (Yellow) Power supply protective fuse (250V, 3.15A) 4-way valve connector Temp.sensor connector CN604 (White) TL sensor...

  • Page 39: Mcc-1600 (Noise Filter)

    MCC-1600 (Noise Filter) CN05 CN16 (Red) CN10 (Red) (Red) ower supply terminal (L1) erminal for power relay erminal for MCC-1599 (CN02) and Terminal for PTC thermistor aristor protective fuse (250V, 6.3A) CN06 (White) ower supply terminal (L2) CN17 (White) erminal for MCC-1596 (CN02) aristor protective fuse (250V, 6.3A)

  • Page 40: Refrigeration Cycle / Water System Diagram

    Refrigeration Cycle / Water System Diagram 7-1. Water System Diagram...
  • Page 41 Installation example of water circuit The water flowing for a system without buffer tank ((1), (2), (3), (5)) requires17.5 /min (803XWH 13.0 /min) or more. This water flowing 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).

  • Page 42: 7-2.Refrigeration Cycle System Diagram

    7-2. Refrigeration Cycle System Diagram HWS-803XWHM3-E, HWS-803XWHT6-E, HWS-803XWHD6-E, HWS-803XWHT9-E/HWS- 803H-E Outdoor unit Hydro unit Heating / Hot-water supply Expansion vessel Defrosting / Cooling pressure Manometer sensor Water vent valve Air vent valve Backup heater Pressure switch Compressor Plate-type 4-way valve...
  • Page 43 HWS-1403XWHM3-E, HWS-1403XWHT6-E, HWS-1403XWHD6-E, HWS-1403XWHT9-E/ HWS-1103H8(R)-E, HWS-1403H8(R)-E, HWS-1603H8(R)-E Outdoor unit Hydro unit Heating / Hot-water supply Expansion vessel Defrosting / Cooling pressure Manometer Muffler sensor Pressure switch Ø25 x L210 Ø25 x L180 Water vent valve Air vent valve Backup heater Pressure switch Compressor Plate-type...

  • Page 44: Operational Description

    Operational Description This chapter describes the working circuit and control of Air to Water Heat Pump about the following operations. Item Page 8-1. Basic Operation 1) Operation control 2) Hot water supply operation 44 to 46 3) Heating operation 4) Cooling operation 8-2.
  • Page 45 Item Operation flow and applicable data, etc. Operation description 8-1. 1) Operation control 1. Purpose Basic The operations of the Remote controller Operation hydro unit and the outdoor unit are controlled according to Operation Remote control settings user-defined operation condition selection <Heating>...
  • Page 46 Item Operation flow and applicable data, etc. Operation description 8-1. 2) Hot water supply operation Hot water supply operation Basic 1. Purpose Operation Hot water supply [HOT WATER] Hot water temperature: 40°C to 75°C 2. Details button set to "ON" This section performs hot water supply operation according to...
  • Page 47 Item Operation flow and applicable data, etc. Operation description 8-1. 4) Cooling operation 1. Purpose Basic Cooling Operation 2. Details ZONE1, 2 Cooling temperature: 10°C to 25°C This section performs button set to "ON" cooling operation according to cooling conditions specified for Circulation pump "ON/OFF"...
  • Page 48 Item Operation flow and applicable data, etc. 8-2. 1) Heat pump operation range of hot water supply, heating and cooling Operation Mode The heat pump operation range of hot water supply, heating and cooling is shown on the figures below. and Control 1) HWS-803XWH**-E Method...
  • Page 49 Item Operation flow and applicable data, etc. 8-2. The following shows the operation modes and controlled objects. Operation Mode Operation Heating and Hot water both operate Cooling and Hot water both operate and Control mode Method Heat pump select Heat pump select Heat pump select Heat pump select for hot water...
  • Page 50 Item Operation flow and applicable data, etc. 8-2. 3) Heating operation Operation Mode <Operation only for ZONE1> and Control • This operation is enabled when DP_SW12_2 ZONE1 is set to "OFF" (default). Method • The remote controller displays settings, and only the set temperature of can be changed.
  • Page 51 Item Operation flow and applicable data, etc. 8-2. 4) Cooling operation Operation Mode Pressing the [ZONE1, 2] button and then [OPERATION MODE] starts a cooling operation. and Control 1) Operation start condition Method Pressing the [ZONE1, 2] button and then [OPERATION Heat pump operation MODE] starts a cooling operation.
  • Page 52 Item Operation flow and applicable data, etc. Related FC FC No. Setting item Default Setting available range Maximum HP operation time for hot water heater, when “hot 30 min 0-120min water supply” + “heating mode” both operate. Priority mode switch temperature 0°C -20-20°C * Note: When user selects “hot water supply”...
  • Page 53 Item Operation flow and applicable data, etc. 8-2. 7) Boiler control Operation Mode The boiler assists the hot water supply operation and heating operation according to the boiler’s position. and Control Method 7-1) Boiler setting • TCB-PCIN3E optional P.C. board is required. Connect its connection cable to CN208 port on the PC board of the hydro unit.
  • Page 54 Item Operation flow and applicable data, etc. 8-2. 7-2) Boiler-output control Operation Mode • I zone: heat pump operation and Control Normally the heat pump operation is executed in the zone. Method • J zone: heat pump operation and boiler operation *1 In the zone, the heat pump + boiler operation (*2) is executed and the heater operation is executed in the hot-water- supply side.
  • Page 55 Item Operation flow and applicable data, etc. 8-2. 8) Hot water boost operation Operation Mode A hot water boost operation heats the water quickly to the set temperature TSC_H = 75°C (FC_09). and Control Method 1) How to operate • When pressing the [HOT WATER BOOST] button after pressing the remote controller [HOT WATER] button, a heat pump operation in progress in the heating side switches to in the hot water side, and continues the operation regardless of the hot water supply start condition, TTW <...
  • Page 56 Item Operation flow and applicable data, etc. 8-2. 9) Anti bacteria (ANTI BACTERIA) operation Operation Mode An anti bacteria operation regularly performs a Hot water supply operation with the set temperature TSC_H = 75°C (can and Control be set with FC_0A). Method 1) How to operate •...
  • Page 57 Item Operation flow and applicable data, etc. 8-2. 10) Night set back (NIGHT SET BACK) operation Operation Mode A night set back operation performs heating at 5K lower and cooling at 5K higher temperatures against the remote and Control controller set temperature from the setting start time (22:00) to the end time (6:00) every day. Method Note) •...
  • Page 58 Item Operation flow and applicable data, etc. 8-2. 12) AUTO operation Operation Mode An auto operation sets the water temperature TSC_F depending on the outside air temperature TO by following the table below. and Control Method 1) How to operate •...
  • Page 59 Item Operation flow and applicable data, etc. 8-3. 1) Capacity control (compressor, high-temperature release, low-temperature release) Hydro Unit Control This unit controls the compressor frequency and heater output so that the water outlet temperature matches the remote controller set temperature. 1-1) Compressor control •...
  • Page 60 Item Operation flow and applicable data, etc. 8-3. 1-2) High temperature release control Hydro Unit Control A heat pump operation is performed as shown in the table below according to the TC sensor detecting temperature. • For the detected temperature, TC (= TWO + 2 degree) of a heat pump operation is used. The values of T7 through T10 varies depending on TWI.
  • Page 61 Item Operation flow and applicable data, etc. 8-3. 2) Heater control Hydro Unit Control 2-1) Hot water supply operation During a hot water heat pump operation, the unit energizes the hot water cylinder heater (2.75 kW) when all the following conditions are met. Note that when the hot water supply set temperature (TSC_F) is reached, the unit stops energizing the heater.
  • Page 62 Item Operation flow and applicable data, etc. 8-3. 2) Control at the time of heating heater operation Hydro Unit Control • Controlled Object: Backup heater, Booster heater The backup heater control starts when 13 minutes has passed after the heating heat pump operation started. 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).
  • Page 63 Item Operation flow and applicable data, etc. 8-3. 3) Circulation pump control Hydro Unit Control One circulation pump (enhancing pump P2) can be connected to the unit in addition to the built-in circulation pump P1. You can change the settings of the built-in pump P1 and the enhancing pump P2 using DP_SW10-1, 2, and 3 in the hydro unit.
  • Page 64 Item Operation flow and applicable data, etc. 8-3. 4) Control by the flow switch Hydro Unit Control Whether water flows or not is judged with the ON/OFF of the flow switch. Model Determined that water flows when: Determined that water does not flow when: HWS-803**-E 13L or more water flows per minute Water less than 13L flows per minute...
  • Page 65 Item Operation flow and applicable data, etc. 8-3. 6-3) Control method Hydro Unit Control • The water temperature setting at starting operation is 40°C (FC_9D) at heating and 20°C (FC_96) at cooling. • The target water outlet temperature is adjusted by 1deg every 30 minutes based on the TSC_rc, the temperature setting on the remote control, and the room temperature (temperature indicated on the remote control: T_rc).
  • Page 66 Item Operation flow and applicable data, etc. 8-3. 7-2) Room temperature thermostat control setting TCB-PCMO3E Hydro Unit Control • Setting of DPSW on the hydro unit PJ17 :DP_SW02_4=”ON”(Default“OFF”) CN210 CN211 Black Terminal label 7-3)Heating thermostat operation When the heating thermostat does not reach the assigned temperature (the circuit between (1) and (3) is closed), heating starts under the setting that water temperature for heating is 40°C.
  • Page 67 Item Operation flow and applicable data, etc. 8-3. 8) Control of force stop and restart Hydro Unit Control The unit can be stopped and restarted with external input. By setting FC52 and FC61, you can set an operation mode to run/stop or can run/stop the unit in the mode assigned on the remote control. •...
  • Page 68 Item Operation flow and applicable data, etc. Basic operation logic There are 4 operation combination pattern for Heating & Hot water When open signal is input, the operation status change to the next status. For example, if current operation status is heating ON and hot water OFF, then next status to be heating OFF & hot water OFF when pulse is input Hydro unit memorize the status of the operation pattern before changing OFF status by close signal.
  • Page 69 Item Operation flow and applicable data, etc. 9) Control of limit of heat pump operation When the peak period of electric power charge is set due to the contract or other conditions, you can limit heat pump operation and give priority to boiler operation using an external input signal. (This control functions only during the period the signal is input.) •...
  • Page 70 Item Operation flow and applicable data, etc. 12) Q-H characteristics of hydro unit The following shows the Q-H characteristics. 12-1)HWS-803XWHM3-E, T6-E, D6-E, T9-E Hydraulic heat exchanger(8kW)QH characteristics Minimum flow rate 230V 230V 220V 220V 230V Out of Operation 220V Range...
  • Page 71 Item Operation flow and applicable data, etc. 8-3. 13) Automatic restart control Hydro Unit Control The unit records operation information before a power outage and retrieves the information after the power is restored to restart automatically the operation with the information. 13-1)Operation during remote controller •...
  • Page 72 Item Operation flow and applicable data, etc. 8-3. 14-4)Piping freeze prevention control 4 When the value of Ps sensor is low, freeze prevention is activated regardless of a heat pump operation mode. Hydro Unit Control 1) Determination condition: Low pressure sensor detects PS < 0.2 MPa and 90 seconds passes (defrosting and cooling) (During a defrosting operation for cooling and heating, or hot water supply) Low pressure sensor detects PS <...
  • Page 73 Item Operation flow and applicable data, etc. 8-4. 1) PMV (Pulse motor valve) control Outdoor unit Valve opening is controlled using the expansion valve with a pulse motor according to a heat pump operation status. control • PMV is controlled between 30 and 500 pulses during an operation. •...
  • Page 74 Item Operation flow and applicable data, etc. 8-4. 3) Current release control Outdoor unit The number of compressor rotation is controlled so that current value of the compressor drive circuit does not exceed the control specified value. • The outdoor unit detects the input current. •...
  • Page 75 Item Operation flow and applicable data, etc. 8-4. 4) Current releases shift control Outdoor unit During a cooling operation, this control prevents the electronic parts, such as a compressor drive element, and control 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) Temperature range 803H-E...
  • Page 76 Item Operation flow and applicable data, etc. 8-4. HWS-803H-E Outdoor unit control 20 Hz or more to less Less than 20 Hz 45 Hz or more than 45 Hz Temperature range Minimum Maximum Minimum Maximum Minimum Maximum 38°C 29°C TO < 38°C 15°C TO <...
  • Page 77 Item Operation flow and applicable data, etc. 8-4. 5-2) Hot water supply and heating fan control Outdoor unit control 1) The TE sensor, TO sensor and operation frequency control the outdoor fan. (The minimum W1 to the maximum are controlled according to the table below.) 2) For 3 minutes after the start, the maximum fan tap for each zone that is shown in the following table is fixed.
  • Page 78 Item Operation flow and applicable data, etc. For 1103H8(R)-E 20 Hz or more to less Less than 20 Hz 45 Hz or more than 45 Hz Temperature range Maximum Maximum Maximum 10°C 5°C TO < 10°C -3°C TO < 5°C -10°C TO <...

  • Page 79: Outdoor Fan

    Item Operation flow and applicable data, etc. 8-4. 6) Defrosting control Outdoor unit This control defrosts the outdoor heat exchanger. The temperature sensor (TE sensor) of the outdoor heat exchanger control determines frost formation, and then defrosting is performed in the 4-way valve reverse defrosting method. 1) During a heating operation, defrosting is performed when the TE sensor meets any of the conditions in A through D zones.
  • Page 80 Item Operation flow and applicable data, etc. 8-4. 7) Winding heating control Outdoor unit 1) This control energizes the inactive compressor instead of the case heater to warm the compressor. The purpose is control to prevent the refrigerant from staying inside the compressor. 2) After the unit is installed, failure to perform energization for the given time period may cause the compressor to fail.
  • Page 81 Item Operation flow and applicable data, etc. 8-4. 10) High pressure release control Outdoor unit 1) To prevent excessive hi pressure rise, operation frequency is controlled by the TL sensor when cooling and by TWO control sensor when heating. 2) If the TL sensor when cooling or the TWO sensor when heating detects an abnormal stop zone temperature, the compressor stops and the abnormality detection counter increments.

  • Page 82: Method Of Defect Diagnosis

    Method of Defect Diagnosis In order to diagnose the defective part of the heat pump system, first understand the symptom of the defect. (1) Check the operation status. (It does not move, or it moves but stops, etc.) (2) Flashing display on the display part of the hydro unit. (3) Check the “check code”...

  • Page 83: 9-1-1.Check The Power Supply Voltage

    9-1. Matters to be confirmed first 9-1-1. Check the power supply voltage Check that the power supply voltage is AC220-230 V± 10 % (signal phase type), AC380-400 V± 10 % (3 phase type). If the power supply voltage is not in this range, it may not operate normally. 9-1-2.

  • Page 84: 9-3.Outline Of The Determination Diagram

    9-3. Outline of the determination diagram The first determination of whether a defective part is in the hydro unit or the outdoor unit can be performed by the following method. 9-3-1. Procedure of defect diagnosis In the case of a defect, please apply the following procedure in order to find the defective part. Confirm the check Check code Defect in Hydro unit...

  • Page 85: 9-3-4.How To Diagnose By Error Code

    9-3-4. How to diagnose by error code Defect mode detected by the water heat exchange O ... Possible × ..Not possible Diagnostic functional operation Number of Check abnormalities Detailed Determination and action code Backup Automat item Operational cause present ic reset confirmation Pump or flowing quantity error...
  • Page 86 Diagnostic functional operation Number of Check abnormalities Detailed Determination and action code Backup Automat item Operational cause present ic reset confirmation Pressure switch operation 1. Almost no or little water flow. The pressure switch operates for 300 2. Defect of the flow switch. ×...
  • Page 87 Diagnostic functional operation Number of Check abnormalities Detailed Determination and action code Backup Automat item Operational cause present ic reset confirmation TFI sensor error 1. Check the resistance value and × Open or short circuit in the floor connection of the floor-inlet temperature sensor (TFI).
  • Page 88 Defect mode detected by the outdoor unit O ... Possible × ..Not possible Diagnostic functional operation Number of Check abnormalities Detailed Determination and action code Backup Automat item Operational cause present ic reset confirmation TD sensor error 1. Check the resistance value and ×...
  • Page 89 Diagnostic functional operation Number of Check abnormalities Detailed Determination and action code Backup Automat item Operational cause present ic reset confirmation Operation of case thermostat 1. Check the refrigeration cycle (gas leak). When the case thermostat exceeds 2. Check the case thermostat and 125°C.
  • Page 90 Diagnostic functional operation Number of Check abnormalities Detailed Determination and action code Backup Automat item Operational cause present ic reset confirmation High pressure protection operation 1. Check that the service valve is fully open. When an abnormal stop occurs due to 2.
  • Page 91 Defect mode detected by the remote control Diagnostic functional operation Check code Determination and action Status of air- Operational cause Condition conditioning No communication between hydro Stop – Defect in the remote control power unit an remote controller supply displaying at •...

  • Page 92: 9-4.Diagnosis Flow Chart For Each Error Code

    9-4. Diagnosis flow chart for each error code 9-4-1. Hydro unit failure detection [A01] Error Pump flow determination [A01] occurs Operation restarts No (No pump sound) Pump rotates Perform Flow switch is Connect flow switch air vent connected to board connector to board Excess air noise comes from inside...
  • Page 93 [A02] Error Temperature rise and error short circuit Start (TWI,TWO,THO 70°C) TWI, TWO, and THO Replace TWI, TWO, sensor characteristics are and THO sensors correct Flow switch is normal Replace flow switch Water outlet temperature is 70°C or higher Hot water from Correct water circuit boiler or other circuits does (To prevent hot water of...
  • Page 94 [A03] Error Temperature rise and error short circuit Start (TTW 85°C is detected) TTW sensor Replace TTW sensor characteristic is correct Hot water cylinder heater is energized Mg-sw (RY05) for Replace Mg-sw heater operates Operating noise at normal time At normal temperature, tank thermostat is energized Hot water cylinder...
  • Page 95 [A04] Error Freeze prevention control When the outside temperature or inlet water temperature is low (approx. 20°C or lower) and the room load is large (operation frequency rating), the freeze prevention control may be activated. Start Operation restart Perform air vent Secure water Excess air Replace flow switch...
  • Page 96 [A05] Error Piping freeze prevention control Restart 4, TWO 4, or 4 is detected Circulation pump keeps being energized or 3 minutes passed after the start Water heat Set water heat board exchange control board DPSW11-1 to ON DPSW11-1 is ON Backup heater terminal has 220-230V (±...
  • Page 97 [A07] Error Pressure switch operation (Hot water supply/Heating operation) Start Flow switch is normal Replace flow switch Remove sufficiently excess air Excess air Secure water Waste stuck inside noise comes from Remove waste circulation amount water circuit inside pump 12 M or longer water Place buffer tank and pipe to a branch, the second pump...
  • Page 98 [A08] Error Low pressure sensor lowering operation failure (Cooling/Defrosting operation) Start Replace flow switch Flow switch is normal Remove sufficiently excess air Excess air Secure water Waste stuck inside noise comes from Remove waste circulation amount water circuit inside pump 12 M or longer water Place buffer tank and pipe to a branch,...
  • Page 99 [A09] Error Overheat prevention thermostat failure (Hot water supply/Heating operation) Start Put water into water circuit Water cycle contains water (Recommended: 1 - 2 Bar) Replace flow switch Flow switch is normal At normal temperature, Replace heater unit overheat preventive thermostat exchanger air vent valve is normal Replace water heat exchange control board...
  • Page 100 [A11] Error Release protection operation Start Flow switch is normal Replace flow switch Remove sufficiently excess air Excess air Secure water Waste stuck inside noise comes from Remove waste circulation amount water circuit inside pump 12 M or longer water Place buffer tank and pipe to a branch, the second pump...
  • Page 101 [A12] Error Heating or Hot water supply heater failure Restart Operation starts under 20°C Freeze prevention control is detected once Heater backup operation Heating: Booster heater Hot water supply: Hot water cylinder heater After 1 hour since heater operation started, neither TWI 15°C A12 abnormality detection nor TTW...
  • Page 102 [E04] Error Outdoor unit operates Hydro unit Internal wiring and Correct wiring and connecting wire (1, 2, 3) connecting wire are correct CN04 connector Correct connector and and terminal block (1, 2, 3) wiring terminal block wiring are normal When power is Check water heat on again, D502 (Amber LED) exchanger board...
  • Page 103 [F04] Error TD sensor failure Start TD sensor Correct TD sensor connector (CN603) is connection connected TD sensor Replace TD sensor resistance characteristic is normal Replace water heat exchange control board [F06] Error TE sensor failure Start TE sensor Correct TE sensor connector (CN601) is connection connected...
  • Page 104 [F08] Error TO sensor failure Start TO sensor Correct TO sensor connector (CN602) is connection connected TO sensor resistance characteristic Replace TO sensor (Refer to Charasteristic table on page 122) is normal Replace water heat exchange control board [F10] Error TWI sensor failure Start TWI sensor Correct TWI sensor...
  • Page 105 [F14] Error TTW sensor failure Start TTW sensor Correct TTW sensor connector (CN214) is connection connected TTW sensor Replace TTW sensor characteristic is normal (Refer to Charasteristic table on page 122) Replace water heat exchange control board [F17] Error TFI sensor failure Start TFI sensor Correct TFI sensor...
  • Page 106 [F19] Error THO sensor detach failure Start THO sensor Attach THO sensor is attached to pipe to pipe THO sensor Replace THO sensor characteristic is normal (Refer to Charasteristic table on page 122) TWO sensor Replace TWO sensor characteristic is normal (Refer to Charasteristic table on page 122) Replace water heat exchange control board...
  • Page 107 [F20] Error TFI detach failure Start Mixing valve is attached. Attach a mixing valve. Make the mixing valve Mixing valve connection (Refer to wiring diagram of hydro unit on connection correct. is correct. page 22) Mixing valve setting Make the mixing valve is correct.
  • Page 108 [F23] Error Low pressure sensor detach failure Start Lo pressure sensor Attach lo pressure sensor is detached (CN207, 212) When operation is stopped, lo pressure sensor Replace lo pressure sensor is normal *1 Replace water heat exchange control board *1 How to determine: When operation is stopped [F29] Error EEPROM failure A failure is detected in the IC10 non-volatile memory on the water heat exchanger board during a hot water supply unit operation.
  • Page 109 [L09] Error Hydro unit capacity Set indoor unit capacity data is not set Setting item code (FC_01) 8 kW = 12 14 kW = 17 Water heat exchange control board (MCC-1511) Check If defective, replace it [L16] Error In DP_SW12-2, 3 of main unit water heat exchanger, if ZONE1 is not set and ZONE2 is set, [L16] displays abnormality.

  • Page 110: 9-4-2.Outdoor Unit Failure Detection

    9-4-2. Outdoor Unit Failure Detection Diagnosis procedure for each check code • One check code may indicate multiple symptoms. In such a case, see the LED indication on the outdoor board to narrow down the check details. • The handy remote controller displays a check code only when the same failure repeatedly occurs while the LED on the outdoor board indicates an error even if it occurs only once.
  • Page 111 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [H02] [Compressor lock] <Indication 1> <Indication 2> Power voltage is normal. (AC220-230 V±10 %: single phase type). Improve power line (AC380-400 V±10 %: 3 phase type). Wiring connection is normal.
  • Page 112 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [L10] <Indication 1> <Indication 2> [Model not set] Only when service board is used Cut jumper line by following the instruction comes with the service board package [L29] * Any of the following abnormality may occur.
  • Page 113 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [Gas leakage failure] → See [P15] details [L29] <Indication 1> <Indication 2> [4-way valve invert failure] → See [P19] details <Indication 1> <Indication 2> [P03] <Indication 1>...
  • Page 114 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [P04] * Any of the following abnormality may occur. Seeing the LED on the outside board can determine which abnormality occurs. 1.High pressure sensor activated. 2.Power source failure (Vdc) 3.Hi pressure protection operation 4.Case thermostat operation...
  • Page 115 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [Case thermostat operation] → See [H04] details <Indication 1> <Indication 2> [Power source failure (Vdc)] → See [P05] details <Indication 1> <Indication 2> [Hi pressure protection operation] → See [P20] details <Indication 1>...
  • Page 116 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [P15] [Gas leakage detection] <Indication 1> <Indication 2> No gas leakage. Correct defective portion Appropriate refrigerant amount. Re-charge refrigerant Correct defective portion Pulse motor valve is normal. Replace defective parts Open fully service valve Service valve is fully opened.
  • Page 117 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [P19] [4-way valve invert failure] <Indication 1> <Indication 2> 4-way valve operates normally. (Check piping temperature at the time of cooling/heating operation) Temperature sensor check TE sensor CN601 TS sensor CN600 Hydro TWO sensor...
  • Page 118 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [P20] <Indication 1> <Indication 2> [Hi pressure protection operation] Service valve is fully opened. Open fully service valve Heating season Heating operation Reset the power source and perform a trail operation according to the season.
  • Page 119 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [P22] [Blower system failure] <Indication 1> <Indication 2> Power voltage is normal Check wiring (AC220-230 V±10 %: single phase type) Request power source repair (AC380-400 V±10 %: 3 phase type) When not energized, the fan motor can be smoothly rotated by hand.
  • Page 120 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) No code [Discharge abnormality] Compressor's loss of synchronism due to rapid load change, etc. <Indication 1> <Indication 2> * Although the outdoor LED indicates abnormality, the compressor restarts and no abnormality is confirmed.
  • Page 121 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [F08] [Outside air temperature sensor (TO) failure] <Indication 1> <Indication 2> Correct TO sensor TO sensor connector (CN602) connection is connected TO sensor resistance Replace TO sensor characteristic is normal Replace outdoor control board...
  • Page 122 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [F31] <Indication 1> <Indication 2> [EEPROM failure] PC-Board Check outdoor control board 803 to 1403H-E (MCC-1571) If defective, replace it 1103 to 1603H8(R)-E (MCC 1599)

  • Page 123: 9-4-3.Temperature Sensor, Temperature-Resistance Characteristic Table

    9-4-3. Temperature sensor, temperature-resistance characteristic table TC, TWI, TWO, TFI, TTW, TE, TS, TO sensors TD, TL sensors Typical value Typical value Ω Ω Resistance value (k Resistance value (k Temperature Temperature (°C) (°C) (Minimum) (Standard) (Maximum) (Minimum) (Standard) (Maximum) 55.73 55.42 60.04...

  • Page 124: 9-5.Operation Check By Pc Board Switch

    9-5. Operation check by PC board switch 9-5-1. Operation check mode This mode allows to check the operations of the water 2-way valve, water 3-way valve, mixing valve, and circulating pump. This operation is valid when the hydro unit and the outdoor unit are turned on the power. Operation check mode (1) Preparation 1) Turn all of the remote controls "OFF"...

  • Page 125: 9-6.Brief Method For Checking The Key Components

    9-6. Brief method for checking the key components 9-6-1. Hydro unit Component name Check procedure Water heat exchange Remove the connector and measure the resistance value with a tester. (Normal temperature) temperature (TC) sensor Temperature 0°C 10°C 20°C 30°C Water inlet temperature Sensor (TWI) sensor Water heat exchange temperature (TC) sensor...

  • Page 126: 9-6-2.Outdoor Unit

    9-6-2. Outdoor unit Component name Check procedure Compressor Measure the resistance value of each winding with a tester. 803 to 1403H-E Type DA220A2F-22L Resistance Location (803H-E) value − DA422A3F-25M 1.04-1.16 Ω White (1103,1403H-E) − 1.04-1.16 Ω White Black DA422A3F-27M − 1.04-1.16 Ω...
  • Page 127 Component name Check procedure Suction temperature (TS) sensor Remove the connector and measure the resistance value with a tester. Heat exchange temperature 10-20 kΩ (Normal temperature) (TE) sensor Temperature Outdoor temperature (TO) 0°C 10°C 20°C 30°C Sensor (kΩ) sensor Outdoor heat exchange temperature sensor (TE) 33.8 20.4 12.6...

  • Page 128: Hydro Unit And Outdoor Unit Settings

    Hydro unit and Outdoor Unit Settings Hydro unit 1. Hydro unit Setting 1-1. Setting switch names and positions SW01 SW12 SW13 SW02 SW11 SW07 SW10 SW06 1-2. SW02 (System switching 1) SW02 Switching details Factory default Remarks Boiler install position After 3WV heating side/Before 3WV After 3WV, Before 3 WV 02_1...
  • Page 129 1-6. SW13 (System switching 3) SW13 Switching details Factory default Remarks 13_1 3WV SPST/SPSD Specification switching SPST 13_2 Boiler output enabled 13_3 Auto Restart of power outage 13_4 – – 2. Hydro unit Function Code Setting 2-1. How to set function code <Procedure>...
  • Page 130 Function code table Item Details First shipment Water heat exchanger capacity *1 0012: 803XWH**-E 0017: 1403XWH**-E Depends on type Cooling/Non-cooling switching 0000: Cooling 0001: No cooling 0001: No cooling Hot water HP operation mode upper time limit 0000: 0 min 0120: 120 min 0030: 30 min Hot Water Boost operation time (operating time)
  • Page 131 Item Details First shipment External input contact logic (must be used in with 0000: CLOSE to stop system *2 0000:CLOSE to stop FC61) 0001: OPEN to stop system *2 0002: OPEN to stop system, CLOSE to restart system (Statics input) 0003: CLOSE to stop system, CLOSE again to restart system (plus input) Logic of 3-way valve’s action when powered (Single...
  • Page 132 Remote controller function code table Item Details Fist shipment Temperature correction by the room temperature sensor -10K~+10K: By 1K steps -1: -1K correction (heating) Temperature correction by the room temperature sensor -10K~+10K: By 1K steps -1: -1K correction (cooling) 24H/12H display switching 0: 24H display 1: 12H (AM/PM) display 0: 24H display...
  • Page 133 3. Trial Operation <Procedure> A trial operation is available with an actual operation in progress or stopped. A trial operation is available in any of the hot water supply, heating, or cooling mode. The compressor starts according to the trial operation frequency. A trial operation automatically stops after 30 minutes at the longest if not stopped with the remote controller.
  • Page 134 4. Auto Curve Setting FC code setting can make flexible Auto-Curve settings. <Preparation> Press the TEST and SET and SELECT buttons at the same time for 4 seconds or longer. (See display (Make sure that no operation is in progress.) Specify an item code (FC) from among 29 to 2F with the TEMP.
  • Page 135 5. Time Setting Press the TIME button for 4 seconds or longer. (The screen moves to the time setting mode.) (See display Day, time, , and indications blink. (Time setting is available during an operation.) Specify a day to be set. Press the DAY button to select the current day.
  • Page 136 6. Scheduled Operation Setting Schedule setting makes the following modes to be flexibly set: hot water supply, heating, cooling, hot water supply and heating, hot water supply and cooling, and stop, and set temperature. 6-1. How to set scheduled operation <Preparation>...
  • Page 137 6-2. How to start and cancel schedule operation <Operation start> Without schedule operation set, press the remote controller SCHEDULE button. blinks. Pressing the SET button during the 5-second blinking changes to lit, and the schedule operation starts. <Operation cancel> With schedule operation set, press the remote controller SCHEDULE button.
  • Page 138 8. NIGHT Operation Setting For night time hours, this setting changes set temperature of heating or cooling by 5k as save operation. Press the ZONE1,2 button to start a heating or a cooling operation. (See display (Night time operation is not available for hot water supply. Use the schedule operation.) Pressing the NIGHT button displays the...
  • Page 139 9. Anti Bacteria Setting This setting regularly raises the hot water cylinder temperature to prevent bacteria from growing. Press the HOT WATER button to start a hot water supply operation. (Normal hot water supply operation) (No anti bacteria setting is provided to heating and cooling.) Pressing the ANTI BACTERIA button displays the symbol.
  • Page 140 10. Hot Water Boost Setting This setting heats the water whenever necessary by using the heat pump and hot water cylinder heater. Press the HOT WATER button to start a hot water supply operation. (Normal hot water supply operation) Pressing the HOT WATER BOOST button displays the symbol.
  • Page 141 12. Forced Defrosting Setting The FC code setting (See 2-2) can activate the forced defrosting mode for the outdoor unit operation. (Preparation) Press the remote controller buttons, TEST , SET and SELECT , at the same time for 4 seconds or longer.(Make sure that no operation is in progress.) Specify CODE NO.
  • Page 142 13. Display Function of Set Temperature and Other Settings Sensor temperature display calling ■ <Details> This function calls the service monitor mode from the remote controller to show the data of the remote controller, the hydro unit, and outdoor unit. <Procedure>...
  • Page 143 14. Failure History Calling Function <Details> This function calls the previous failure details. <Procedure> Press the TEST and SET buttons at the same time for 4 seconds or longer to call the service check mode. The service check lights up with CODE No. "01" displayed at first, and the latest warning detail is displayed.
  • Page 144 Outdoor unit 15. Outdoor Unit Setting 15-1. Refrigerant recovery control Although HFC refrigerant is "Ozone depletion potential = 0", emission control is applied to it as a greenhouse effect gas. This model has a switch for the outdoor unit to perform an environment-friendly refrigerant recovery operation (pump down) when the model is replaced or discarded.
  • Page 145 15-2. Outdoor unit settings (Existing piping, Power save, etc.) The following settings are available with dip switch setting and jumper wire setting. Function Where to set Control details Existing piping When using a Ø19.1 pipe for the existing piping, set the switch to ON. setting This case may decrease heating capacity depending on the outside air SW802...
  • Page 146 15-3. Service support functions (LED indication, Switch operation method) The following settings are available with dip switches. (1) Overview Using 3 dip switches (SW802, SW803, SW804) and 2 push-button switches (SW800, SW801) can make settings available and confirm operations. For operation Part number Specification Operation details...
  • Page 147 <HWS-1103H8(R)-E, 1403H8(R)-E, 1603H8(R)-E> Enlarged view of SW804 SW805 LEDs D805 SW802 SW803 SW800 SW801 SW806 D804 D803 D802 D805 D801 D804 D803 D800 D802 D801 D800 D502 D503...
  • Page 148 (2) LED indication switching (SW800, SW803 operation) (2) -1. Indication switching list Operating SW803 can switch the indications of LED D800 to D804 on the outdoor control board. Switch Function and details Abnormality indication (Current abnormality) This switch indicates the current abnormality. SW803 Without an abnormality, the lights are off.
  • Page 149 (2) -2. Abnormality indication The current abnormality and the latest abnormality (including the current one) can be identified by the LED D800 to D804 on the outdoor control board. 1) Setting all the SW803 dip switches to OFF indicates the current abnormality status. 2) Setting SW803 dip switch <1>...
  • Page 150 (2)-3. Sensor, Current, Compressor operation frequency, PMV position indication The values detected by controller, such as temperature sensor or current values, can be easily checked. Legend) Light ---- ---- Compressor Item setting Temperature sensor ( Current PMV position operation (pulse) frequency (r.p.s.) SW803...
  • Page 151 (3) Special operation for maintenance and inspection (SW801, SW804) SW801 and SW804 can perform the following special operations for maintenance and inspection. 1) Switches the dip switch SW804. (See the table below) 2) Presses the push-button switch SW801 for approx. 1 second. 3) Starts the functions shown below.
  • Page 152 SW804 Operation when press button switch SW801 is pressed Self-holding valve vacuum operation (Switch to heating SW804 cycle) (RY700, RY701, RY705, CN701 for check) Sets relay RY700, RY701, and RY705 to ON. (CN701 Between 1 to 4 Voltage = Approx. 325V) This function operates for 10 seconds.

  • Page 153: Replacement Of The Service P.c. Board

    Replacement of the Service P.C. Board Setting the jumper wires and DIP switches Outdoor unit Service Parts(CDB) HWS-803H-E 431-6V-400(MCC-1571) HWS-1103H-E,1403H-E 431-6V-399(MCC-1571) HWS-1103H8(R)-E, 1403H8(R)-E, 1603H8(R)-E 302-6V-015(MCC-1599) Parts name Function Setting Jumper wire J800~J803 Model switching Cut these jumper wires according to the following table. J804~J811 Settings Set these jumper wires to the settings of the P.C.

  • Page 154: How To Exchange Main Parts

    How to Exchange Main Parts WARNING <Turn off the power breaker> Because the electrical components are energized with high voltage, always turn off the power breaker before starting to work. <Check> After a repair is complete, perform a trial operation (after attaching the front panel, upper and lower cabinets, and side cabinet) and check that no abnormality including smoke or abnormal noise occurs.
  • Page 155 Exchange parts name Work procedure Remarks Remote controller 1.How to remove 1) Perform the step 1-1. 2) Remove the remote controller from the holder using a flat-blade screwdriver. (Release the stopper.) Remote 3) Disconnect the remote controller cable from the controller holder terminal block on the back side of the remote controller.
  • Page 156 Exchange parts name Work procedure Remarks Relay board 1. How to remove MCC-1431 1) Perform the step 1-1. 2) Disconnect the connectors and lead cables connected to other parts from the relay board. 1. Connector CN01: TB 01 3P Terminal block (3P: White) CN02: Water heat exchanger board (5P: White) CN10: TB 05 9P Terminal block (9P: White) NOTE...
  • Page 157 Exchange parts name Work procedure Remarks Side board 1. Side board (Right) Side board (Right) 1) Perform the step 1-1. 2) Remove the fixed screws of the side board (Right). (ST1T Ø4 × 10, 5 screws) 3) Remove the fixed screws of the side board (Right) and the manometer fixing board.
  • Page 158 Exchange parts name Work procedure Remarks Expansion vessel 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. 1) Perform the step 1-1, step 5, 6, and 7. 2) Remove the fixed band of the expansion vessel.
  • Page 159 Exchange parts name Work procedure Remarks Pump To replace a water circuit part, first close the water supply source valve and the valve of water pipe connected to the hydro unit. 1. How to remove 1) Perform the step 1-1, step 5, 6, and 10. 2) Remove the fixed screws of the pump fixing board.
  • Page 160 Exchange parts name Work procedure Remarks Flow switch To replace a water circuit part, first close the water supply source valve and the valve of water pipe connected to the hydro unit. 1. How to remove 1) Perform the step 1-1 and step 5. 2) Remove the flow switch.
  • Page 161 Exchange parts name Work procedure Remarks Heater assembly To replace a water circuit part, first close the water supply source valve and the valve of water pipe connected to the hydro unit. 1. How to remove 1) Perform the step 1-1, step 5, 6, 7, and 11. 2) Remove the nut of the heater connection.
  • Page 162 Exchange parts name Work procedure Remarks Water heat • Close the water piping source valve and the valve exchanger assembly of water pipe connected to the hydro unit, and Water then remove the refrigerant and water piping. piping fixing • Perform refrigerant recovery with the outdoor unit.
  • Page 163 2. Outdoor Unit 2-1. HWS-803H-E Exchange parts Work procedure Remarks name Common procedure NOTE Front panel Wear gloves when performing the work. Failure to do so may cause an injury when accidentally contacting the parts. 1. How to remove 1) Stop the operation by remote controller and turn off the breaker.
  • Page 164 Exchange parts Work procedure Remarks name Outlet cabinet How to remove Water heat exchanger Outlet cabinet 1) Perform the step 1-1. 2) Remove the screws of the outlet cabinet and Motor base Paring board parting board. (ST1T Ø4 × 8, 3 screws) 3) Remove the screws of the outlet cabinet and bottom board.
  • Page 165 Exchange parts Work procedure Remarks name Electric parts 1. Control board replacement 1) Perform the step 1-1. Compressor Control board Reactor lead lead Compressor Fan motor case thermostat WARNING For 1 minute after the power is turned off, do not disassemble the inverter to prevent an electric shock.
  • Page 166 Exchange parts Work procedure Remarks name Electric parts 2. Reactor replacement 1) Perform the step 1-1. Relay connector 2) Remove the relay connector connected to the control board. 3) Cut the binding tie that binds the compressor leads and relay connectors. 4) Remove the reactor.
  • Page 167 Exchange parts Work procedure Remarks name Fan motor 1) Perform the step 1-1 and step 2. Propeller fan Turn it right to loosen 2) Remove the fan motor and the flange nut that fixes the propeller fan. • To loosen the flange nut, turn it clockwise. (Turn it counter clockwise for tightening.) 3) Remove the propeller fan.
  • Page 168 Exchange parts Work procedure Remarks name Compressor 1. Remove defective compressor Compressor lead 1) Perform refrigerant gas recovery. Piping panel (Back) 2) Perform the step 1-1 and step 2 and 3. 3) Remove the piping panel (Front). Remove screws of the piping panel (Front) and bottom board.
  • Page 169 Exchange parts Work procedure Remarks name Compressor 10) Remove the discharge and suction pipes Compressor lead connected to the compressor by using a burner. Remove Remove (Suction pipe) (Outlet pipe) 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.
  • Page 170 Exchange parts Work procedure Remarks name Compressor 2. Attach the compressor Compressor lead 1) Attach the compressor in the reverse order of the Compressor Wind ferrite core with lead compressor lead for 4 times. removal. NOTE • Be sure to replace the compressor lead after the compressor replacement.
  • Page 171 Exchange parts Work procedure Remarks name Compressor 3. Vacuuming Compressor lead 1) Connect the vacuum pump to the charge port of the gas piping valve to operate the vacuum pump. 2) Perform vacuuming until the vacuum low pressure gauge shows 1(mmHg). NOTE Open fully the pulse motor valve before vacuuming.
  • Page 172 Exchange parts Work procedure Remarks name Fan guard 1. How to remove 1) Perform the step 1-1 and step 2. Bellmouth Outlet cabinet 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.
  • Page 173 2-2. HWS-1103H-E, 1403H-E Exchange parts Work procedure Remarks name Common procedure NOTE Front panel Wear gloves when performing the work. Failure to do so may cause an injury when accidentally contacting the parts. 1. How to remove 1) Stop the operation by remote controller and turn off the breaker.
  • Page 174 Exchange parts Work procedure Remarks name Outlet cabinet How to remove Outlet cabinet Heat exchanger 1) Perform the step 1-1. 2) Remove the screws of the outlet cabinet and Motor base Paring board parting board. (ST1T Ø4 × 8, 4 screws) 3) Remove the screws of the outlet cabinet and bottom board.
  • Page 175 Exchange parts Work procedure Remarks name Electric parts 1. Control board Fan motor (upper) Control board replacement 1) Perform the step 1-1. Compressor case Reactor lead WARNING thermostat For 1 minute after the power is turned off, do not disassemble the inverter to prevent an electric shock. 2) Remove the connector connected to the control Compressor lead (Hydro power source, temperature sensor, electric...
  • Page 176 Exchange parts Work procedure Remarks name Electric parts 2. Reactor Binding tie replacement 1) Perform the step 1-1. (Compressor lead, Reactor lead) Reactor lead 2) Remove the reactor lead connected to the control board. Control board CN05 White, CN06 White 3) Cut the binding tie that binds the compressor leads and fan motor leads.
  • Page 177 Exchange parts Work procedure Remarks name Fan motor 1) Perform the step 1-1 and step 2. Propeller fan Turn it right 2) Remove the fan motor and the flange nut that fixes to loosen the propeller fan. • To loosen the flange nut, turn it clockwise. (Turn it counter clockwise for tightening.) 3) Remove the propeller fan.
  • Page 178 Exchange parts Work procedure Remarks name Compressor 1. Remove defective compressor Piping panel (Front) Compressor lead 1) Perform refrigerant gas recovery. 2) Perform the step 1-1 and step 3. 3) Remove the piping panel (Front). Remove screws of the piping panel (Front) and bottom board.
  • Page 179 Exchange parts Work procedure Remarks name Compressor 2. Attach the compressor Wind ferrite core with Compressor lead 1) Attach the compressor in the reverse order of the compressor lead removal. Compressor lead for 4 times NOTE • Be sure to replace the compressor lead after the compressor replacement.
  • Page 180 Exchange parts Work procedure Remarks name Pulse motor valve coil 1. How to remove 1) Perform the step 1-1. Recess Pulse motor valve body 2) Remove the coil from the pulse motor valve body by pulling upward while rotating the coil. 2.
  • Page 181 2-3. HWS-1103H8(R)-E, 1403H8(R)-E, 1603H8(R)-E Part name Procedure Remarks Common procedure WARNING Stop operation of the air conditioner and turn off breaker switch. CAUTION Ensure wearing of gloves when performing any work in order to avoid injury from parts, etc. 1. Detachment 1) Remove the service panel.
  • Page 182 Part name Procedure Remarks Discharge port 1. Detachment cabinet 1) Carry out the operation in 1. of 1) above. Heat exchanger Motor base 2) Remove the screws fixing the inverter assembly, the discharge port cabinet and the partition board. (ST1T Ø4 × 8, 4 pcs.) 3) Remove the screws for the discharge port cabinet and the bottom plate.
  • Page 183 Part name Procedure Remarks Side cabinet 1. Detachment 1) Carry out the operation in 1. of 1) above. Discharge port cabinet Side cabinet 2) Remove the screws fixing the inverter assembly Inverter ass’y and the side cabinet. (ST1T Ø4 × 10, 3 pcs.) 3) Remove the screws for the side cabinet and the valve fixing plate.
  • Page 184 Part name Procedure Remarks Inverter assembly 1. Detachment 1) Carry out the operation in 1. of 1), 1. of 3) above. 2) Remove the connectors connected to the Fan IPDU board, the connector connected to other components from the control board Cut the Cut the Cut the...
  • Page 185 Part name Procedure Remarks Interface board 1. Detachment (Control board) 1) Carry out the operation in 1. of 1), 1. of 3) above. MCC-1599 2) Remove lead wires and connectors to other components from the interface board (control board). CN01 : Indoor/Outdoor connection terminal (5P: White) CN02 : Power relay (3P: Red) CN600 : TS sensor (3P: White, tube: Gray)
  • Page 186 Part name Procedure Remarks Fan-IPDU board 1. Detachment MCC-1597 1) Carry out the operation in 1. of 1), 1. of 3) above. FAN-IPDU board 2) Remove lead wires and connectors to other components from the Fan-IPDU board. CN500 : Connection between reactor and noise filter board (7P, Red) CN502 : Compressor IPDU board (3P, White) CN504 : Interface board (5P, Blue)
  • Page 187 Part name Procedure Remarks Noise filter board 1. Detachment MCC-1600 1) Perform the operation in 1. of 1),1. of 4), 1.-2 of 5) Fan-IPDU boardg and 1.-2 of 6). 2) Remove the screws (3 positions) fixing the inverter assembly (front). Then slide the inverter assembly (front) upwardly and remove.
  • Page 188 Part name Procedure Remarks Compressor IPDU 1. Detachment board MCC-1596 1) Carry out the operation in 1. of 1), 1. of 4), 1. of 5), 1. of 6) and 1. of 7). 2) Remove the screw (4 positions) fixing the inverter assembly (IPDU).
  • Page 189 Part name Procedure Remarks Fan motor 1. Detachment 1) Carry out works of item 1 of 1) and work of 2). Propeller fan Propeller fan Propeller fan 2) Remove the flange nut fixing the fan motor and the propeller fan. •...
  • Page 190 Part name Procedure Remarks Compressor 1. Removal of defective compressor Compressor lead 1) Recover the refrigerant gas. Piping panel (Front) Piping panel (Front) Piping panel (Front) 2) Carry out work of item 1 of 1), 1 of 3) and 1 of 7). 3) Remove the piping panel (Front).
  • Page 191 Part name Procedure Remarks Compressor 2. Mounting of compressor Compressor lead 1) Mount the compressor in the reverse procedure Wrap the ferrite core with the compressor lead wire for 1 time. (Continued) for removal. Compressor lead Compressor lead Compressor lead NOTE •...
  • Page 192 Part name Procedure Remarks PMV coil 1. Detachment 1) Carry out work of item 1 of 1). Concave part PMV main unit 2) Turn the coil while pulling upward and then remove the coil from the PMV main unit. 2. Attachment 1) Surely match the positioning projection of the coil with the concave part of PMV main unit and then fix it.
  • Page 193 Part name Procedure Remarks Bottom plate heater 1. Detachment 1) Recover the refrigerant. (See 15-1. Refrigerant recovery control) Drain the water in the hydro unit before refrigerant recovery. 2) Execute steps 1-1, 2, and 3. 3) Detach the two fin guards. (9 pcs.

  • Page 194: Periodic Inspection Items

    Periodic Inspection Items For a long-term safe operation of this equipment, perform periodic inspection and parts replacement. <Inspection items> Hydro unit Frequency Periodic inspection details (HWS-803**-E, 1403**-E) 1. Insulation measurement (Power source circuit/ Heater Annually Insulation measurement with a mega tester circuit) 2.

  • Page 195: Part Exploded View, Part List

    Part Exploded View, Part List Hydro Unit...
  • Page 197 Number of pieces per unit Safety Location HWS- HWS- HWS- HWS- HWS- HWS- HWS- HWS- Part No. Description 1403XW 1403XW 1403XW 1403XW 803XW 803XW 803XW 803XW HM3-E HT6-E HD9-E HT9-E HM3-E HT6-E HD6-E HT9-E 37500802 CABINET, FRONT 37500800 PLATE, UP 37500801 PLATE, SIDE 37500803...
  • Page 198 Outdoor Unit (HWS-803H-E)
  • Page 199 Number of pieces per unit Safety Location Part No. Description HWS-803H-E 43019904 HOLDER, SENSOR 43032441 NIPPLE, DRAIN 43041798 COMPRESSOR, DA220A2F-22L 43046493 COIL, PMV 43046451 VALVE, 4-WAY, STF-0218G 43047246 BONNET, 3/8 IN 43047669 NUT, FLANGE 43049739 CUSHION, RUBBER 43050407 THERMOSTAT,BIMETAL 43063317 HOLDER,THERMOSTAT 43100437 PANEL, FRONT, PIPING...
  • Page 200 Inverter Assembly (HWS-803H-E) Reactor Control board assembly Bushing Collar Fuse Terminal (3P) Terminal 3P Sensor assembly (F4) Sensor holder (TO) TD, TL sensor Sensor holder (TE) Sensor assembly (F6) Sensor holder (TS) TS, TE, TD sensor Sensor holder (TD)
  • Page 201 Number of pieces per unit Safety Location Part No. Description HWS-803H-E 43050425 SENSOR ASSY, SERVICE 43063325 HOLDER, SENSOR 43150319 SENSOR ASSY, SERVICE 43155188 REACTOR, CH-56-2Z-T 43160565 TERMINAL BLOCK, 3P, 20A 43160581 TERMINAL 43160589 FUSE 43163055 HOLDER, SENSOR 43163059 SPACER, BUSH 43163060 SPACER, COLLAR 4316V399...
  • Page 202 Outdoor Unit (HWS-1103H-E, 1403H-E)
  • Page 203 Number of pieces per unit Safety Location Part No. Description HWS-1103H-E HWS-1403H-E 43019904 HOLDER, SENSOR 43032441 NIPPLE, DRAIN 43041794 COMPRESSOR, DA422A3F-25M 43047246 BONNET, 3/8 IN 43047669 NUT, FLANGE 43049739 CUSHION, RUBBER 43050407 THERMOSTAT,BIMETAL 43063317 HOLDER,THERMOSTAT 43097212 43100437 PANEL, FRONT, PIPING 43100438 PANEL, BACK, PIPING 43100439...
  • Page 204 Inverter Assembly (HWS-1103H-E, 1403H-E) Reactor Control board assembly Bushing Collar Fuse Terminal (3P) Terminal 3P Sensor assembly (F4) Sensor holder (TO) TD, TL sensor Sensor assembly (F6) Sensor holder (TE) TS, TE, TO sensor...
  • Page 205 Number of pieces per unit Safety Location Part No. Description HWS-1103H-E HWS-1403H-E 43050425 SENSOR ASSY, SERVICE 43063325 HOLDER, SENSOR 43150319 SENSOR ASSY, SERVICE 43158190 REACTOR 43160565 TERMINAL BLOCK, 3P, 20A 43160581 TERMINAL 43160589 FUSE 43163055 HOLDER, SENSOR 43163059 SPACER, BUSH 43163060 SPACER, COLLAR 4316V400...
  • Page 206 Outdoor Unit (HWS-1103H8(R)-E, 1403H8(R)-E, 1603H8(R)-E) 41 , 42 , 43 38 , 39 , 40 32 , 33 29 , 30 44 , 45 31 , 4 , 10 7 , 9 , 35 5 , 11 , 12...
  • Page 207 Model name HWS Location Part No. Description 1103H8(R)-E 1403H8(R)-E 1603H8(R)-E 43019904 Holder, Sensor 43032441 Nipple, Drain 43047246 Bonnet, 3/8 IN 43047669 Nut, Flange 43049739 Cushion, Rubber 4304C703 Compressor, DA422A3F-27M 43050407 Thermostat, Bimetal 43060029 Filter, Noise 43063317 Holder, Thermostat 43197164 Nut, Flange 43100437 Panel, Front, Piping 43100438...
  • Page 208 Inverter Assembly (HWS-1103H8(R)-E, 1403H8(R)-E, 1603H8(R)-E) 718 , 719 718 , 719...
  • Page 209 Model name HWS Location Part No. Description 1103H8(R)-E 1403H8(R)-E 1603H8(R)-E 43154177 Relay, 480V, 20A 43158207 Reactor, CH-68 43153006 PTC-Thermistor, ZPROYCE101A500 43050425 Sensor Ass’y, TC (F6) 43150319 Sensor Ass’y, TD (F4) 43160565 Terminal Block, 3P, 20A, AC250A 43160579 Terminal, 30A, 4P 43060859 Fuse Block, 30A, 250V, FH153-PB P.C.

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