Page 1 FILE No. AE0-2203W AIR TO WATER HEAT PUMP Service Manual Model name: Outdoor unit Hydro unit -All In One Type- HWT-401HW-E(TR) HWT-602S21SM3W-E(TR) HWT-601HW-E(TR) HWT-602S21SM6W-E(TR) HWT-602S21ST6W-E(TR) HWT-801HW-E(TR) HWT-602S21MM3W-E(TR) HWT-1101HW-E(TR) HWT-602S21MM6W-E(TR) HWT-1401HW-E(TR) HWT-801HRW-E HWT-602S21MT6W-E(TR) HWT-1101HRW-E HWT-1102S21SM3W-E(TR) HWT-1401HRW-E HWT-1102S21SM6W-E(TR) HWT-1102S21ST6W-E(TR) HWT-801H8W-E HWT-1102S21ST9W-E(TR) HWT-1101H8W-E HWT-1102S21MM3W-E(TR) HWT-1401H8W-E HWT-801H8RW-E...
Page 2: Table Of Contents
Contents 1 Specifications ......................18 2 Construction views (External views) ................ 23 2-1.Hydro unit ............................23 2-2.Outdoor unit ............................. 24 3 Refrigeration cycle / Water system diagram ............26 3-1.Water system diagram ........................26 3-2.Refrigeration cycle system diagram ....................28 4 Wiring diagram ......................
Page 3 6-7. Charging additional refrigerant ......................62 6-7-1.[Assumed gas leak] ......................62 6-7-2. [Limiting the additional charge] ................... 62 6-7-3. [Cautions on charging additional refrigerant] ..............62 6-8.General safety precautions for using R32 refrigerant ..............63 6-8-1.Recovery ..........................63 6-8-2.Decommissioning ....................... 63 6-8-3.Labelling ..........................
Page 4 Air to Water Heat Pump made by Toshiba Carrier Air- conditioning Europe Sp. z o.o. or, alternatively, he or she has been instructed in such matters by an individual or individuals who have been trained and is thus thoroughly acquainted with the knowledge related to this work.
Page 5 Definition of protective gear When the Air to Water Heat Pump is to be transported, installed, maintained, repaired or removed, wear protective gloves and “safety” work clothing. In addition to such normal protective gear, wear the protective gear described below when undertaking the special work detailed in the table below.
Page 6 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. The important contents concerned to the safety are described on the product itself and on this Service Manual. Please read this Service Manual after understanding the described items thoroughly in the following contents (Indications / Illustrated marks), and keep them.
Page 7 Warning indications on the Air to Water Heat Pump [Confirmation of warning label on the main unit] Confirm that labels are indicated on the specified positions If removing the label during parts replace, stick it as the original. This mark is for R32 refrigerant only. Refrigerant type is written on nameplate of Outdoor Unit.
Page 8 Precaution for safety The appliance shall be installed in accordance with national wiring regulations. Capacity shortages of the power circuit or an incomplete installation may cause an electric shock or fire. DANGER Before carrying out the installation, maintenance, repair or removal work, be sure to set the circuit breaker to the OFF position.
Page 9 WARNING Before starting to repair the Air to Water Heat Pump, read carefully through the Service Manual, and repair the Air to Water Heat Pump by following its instructions. Only qualified service person (*1) is allowed to repair the Air to Water Heat Pump. Repair of the Air to Water Heat Pump by unqualified person may give rise to a fire, electric shocks, injury, water leaks and/or other problems.
Page 10 WARNING If, in the course of carrying out repairs, it becomes absolutely necessary to check out the electrical parts with the electrical parts box cover of one or more of the indoor units and the service panel of the outdoor unit removed in order to find out exactly where the trouble lies, wear insulated heat-resistant gloves, insulated boots and insulated work overalls, and take care to avoid touching any live parts.
Page 11 WARNING The refrigerant used by this Air to Water Heat Pump is the R32. Check the used refrigerant name and use tools and materials of the parts which match with it. For the products which use R32 refrigerant, the refrigerant name is indicated at a position on the outdoor unit where is easy to see.
Page 12 WARNING When the refrigerant gas leaks, find out the leaked position and repair it surely. If the leaked position cannot be found out and the repair work is interrupted, pump-down and tighten the service valve, otherwise the refrigerant gas may leak into the room. When gas touches to fire such as fan heater, stove or cocking stove, it may generate noxious gases, causing a fire though the refrigerant gas itself is innocuous.
Page 13 WARNING Only a qualified installer (*1) or qualified service person (*1) is allowed to install the Air to Water Heat Pump. If the Air to Water Heat Pump is installed by an unqualified individual, a fire, electric shocks, injury, water leakage, noise and/or vibration may result.
Page 14 Explanations given to user • If you have discovered that the fan grille is damaged, do not approach the outdoor unit but set the circuit breaker to the OFF position, and contact a qualified service person to have the repairs done. Do not set the circuit breaker to the ON position until the repairs are completed.
Page 15 Refrigerant R32 This Air to Water Heat Pump adopts a new HFC type refrigerant (R32) which does not deplete the ozone layer. (1) Safety caution concerned to refrigerant R32 Be sure that water, dust, the former refrigerant or the former refrigerating oil is not mixed into the refrigerating cycle of the Air to Water Heat Pump with refrigerant R32 during installation work or service work.
Page 16 worked upon prior to any removal of sealed covers, etc. If it is absolutely necessary to have an electrical supply to equipment during servicing, then a permanently operating form of leak detection shall be located at the most critical point to warn of a potentially hazardous situation. Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not altered in such a way that the level of protection is affected.
Page 17 (3) Pipe materials For the refrigerant pipes, copper pipe and joints are mainly used. It is necessary to select the most appropriate pipes to conform to the standard. Use clean pipes or joints to which little impurities adhere. (1) Copper pipe <Piping>...
Page 18 (4) Tools : R410A tools available, : Partly unavailable, : R410A tools unavailable Installation / service tools Applicability to R32 Air to Applicability to R22 Air to Water Heat Pump or not Water Heat Pump or not Tools / Equipment specification 1 Flare tool Clutch type...
Page 19: Specifications
Specifications Unit name Hydro unit HWT-602S21SM3W-E, HWT-602S21SM6W-E HWT-602S21ST6W-E, HWT-602S21MM3W-E HWT-602S21MM6W-E, HWT-602S21MT6W-E Outdoor unit HWT-401HW-E HWT-601HW-E Heating capacity *1 (kW) Cooling capacity *2 (kW) Variable range of compressor frequency 10 - 80 Hz 10 - 100 Hz Power source 1 phase 50 Hz 220-240 V Operation mode Heating Cooling...
Page 20 Unit name Hydro unit HWT-1102S21SM3W-E, HWT-1102S21SM6W-E HWT-1102S21ST6W-E, HWT-1102S21ST9W-E HWT-1102S21MM3W-E, HWT-1102S21MM6W-E HWT-1102S21MT6W-E, HWT-1102S21MT9W-E Outdoor unit HWT-801H(R)W-E HWT-1101H(R)W-E Heating capacity *1 (kW) 11.0 Cooling capacity *2 (kW) Variable range of compressor frequency 10 - 90 Hz 10 - 100 Hz Power source 1 phase 50 Hz 220-240 V Operation mode Heating...
Page 21 Unit name Hydro unit HWT-1402S21SM3W-E, HWT-1402S21SM6W-E HWT-1402S21ST6W-E, HWT-1402S21ST9W-E HWT-1402S21MM3W-E, HWT-1402S21MM6W-E HWT-1402S21MT6W-E, HWT-1402S21MT9W-E Outdoor unit HWT-1401H(R)W-E Heating capacity *1 (kW) 14.0 Cooling capacity *2 (kW) 10.0 Variable range of compressor frequency 10 - 82 Hz Power source 1 phase 50 Hz 220-240 V Operation mode Heating Cooling...
Page 22 Unit name Hydro unit HWT-1102S21SM3W-E, HWT-1102S21SM6W-E HWT-1102S21ST6W-E, HWT-1102S21ST9W-E HWT-1102S21MM3W-E, HWT-1102S21MM6W-E HWT-1102S21MT6W-E, HWT-1102S21MT9W-E Outdoor unit HWT-801H8(R)W-E HWT-1101H8(R)W-E Heating capacity *1 (kW) 11,0 Cooling capacity *2 (kW) Variable range of compressor frequency 10 - 53 Hz 10 - 64 Hz Power source 3 phase 50 Hz 380-415V Operation mode Heating...
Page 23 Unit name Hydro unit HWT-1402S21SM3W-E. HWT-1402S21SM6W-E HWT-1402S21ST6W-E. HWT-1402S21ST9W-E HWT-1402S21MM3W-E. HWT-1402S21MM6W-E HWT-1402S21MT6W-E. HWT-1402S21MT9W-E Outdoor unit HWT-1401H8(R)W-E Heating capacity *1 (kW) 14.0 Cooling capacity *2 (kW) 10.0 Variable range of compressor frequency 10 - 82 Hz Power source 3 phase 50 Hz 380-415V Operation mode Heating Cooling...
Page 24: Construction Views (External Views)
Construction views (External views) 2-1. Hydro unit HWT-602S21SM3W-E(TR), HWT-602S21SM6W-E(TR), HWT-602S21ST6W-E(TR), HWT-602S21MM3W-E(TR) HWT-602S21MM6W-E(TR), HWT-602S21MT6W-E(TR), HWT-1102S21SM3W-E(TR), HWT-1102S21SM6W-E(TR) HWT-1102S21ST6W-E(TR), HWT-1102S21ST9W-E(TR), HWT-1102S21MM3W-E(TR), HWT-1102S21MM6W-E(TR) HWT-1102S21MT6W-E(TR), HWT-1102S21MT9W-E(TR), HWT-1402S21SM3W-E(TR), HWT-1402S21SM6W-E(TR) HWT-1402S21ST6W-E(TR), HWT-1402S21ST9W-E(TR), HWT-1402S21MM3W-E(TR), HWT-1402S21MM6W-E(TR) HWT-1402S21MT6W-E(TR), HWT-1402S21MT9W-E(TR)
Page 25: 2-2.Outdoor Unit
2-2. Outdoor unit HWT-401HW-E(TR), HWT-601HW-E(TR)
Page 26 HWT-801HW-E(TR), HWT-1101HW-E(TR), HWT-1401HW-E(TR), HWT-801HRW-E, HWT-1101HRW-E HWT-1401HRW-E, HWT-801H8W-E, HWT-1101H8W-E, HWT-1401H8W-E, HWT-801H8RW-E HWT-1101H8RW-E, HWT-1401H8RW-E...
Page 27: Refrigeration Cycle / Water System Diagram
Refrigeration cycle / Water system diagram 3-1. Water system diagram...
Page 28 HEATING ONLY Hydro unit Outdoor unit Installation example of water circuit HEATING ONLY 2-way valve Shower Bath Kitchen Panel radiator Shower Bath Kitchen Fan coil Heating Cooling Floor heating Outdoor unit Hydro unit 1 zone 1 zone Outdoor unit Hydro unit Conventional boiler Panel radiator Panel radiator...
Page 29: 3-2.Refrigeration Cycle System Diagram
3-2. Refrigeration cycle system diagram HWT-602S21***W-E HWT-401HW-E, HWT-601HW-E Outdoor unit Hydro unit Heating / Hot water supply Defrosting / Cooling Plate-type High-pressure switch water heat pressure Expansion vessel exchanger sensor Air vent valve Monometer Overpressure preventive valve 4-way valve Compressor Three-Way Outdoor heat exchanger valve...
Page 30: Wiring Diagram
Wiring diagram 4-1. Hydro unit HWT-602S21SM3W-E(TR), HWT-602S21SM6W-E(TR), HWT-602S21ST6W-E(TR) HWT-1102S21SM3W-E(TR), HWT-1102S21SM6W-E(TR), HWT-1102S21ST6W-E(TR) HWT-1102S21ST9W-E(TR), HWT-1102S21MM3W-E(TR), HWT-1102S21MM6W-E(TR) HWT-1102S21MT6W-E(TR), HWT-1102S21MT9W-E(TR)
Page 31 HWT-1402S21SM3W-E(TR), HWT-1402S21SM6W-E(TR), HWT-1402S21ST6W-E(TR) HWT-1402S21ST9W-E(TR), HWT-1402S21MM3W-E(TR), HWT-1402S21MM6W-E(TR) HWT-1402S21MT6W-E(TR), HWT-1402S21MT9W-E(TR) Be sure to turn off all main power supply WARNING CAUTION switches or the circuit breaker before starting any electrical work. Perform the grounding from Electric shock may happen the earth terminal of the outdoor unit. Back up heater Don’t touch the electric parts.
Page 32: 4-2.Outdoor Unit
4-2. Outdoor unit HWT-401HW-E(TR), HWT-601HW-E(TR)
Page 33 HWT-801HW-E(TR), HWT-1101HW-E(TR) HWT-801HRW-E, HWT-1101HRW-E...
Page 34 HWT-1401HW-E(TR), HWT-1401HRW-E For D800-D805 and SW01-SW02, refer to the installation manual. DISPLAY P.C.board REACTOR REACTOR MCC-1646 Only for models with heater Heater P.C.board IPDU MCC-1675 P.C.board MCC-1758 Power supply To hydro unit 220-240V - 50Hz Symbol Part name Compressor FM01 Fan motor Color Indication Fuse 25A 250V -...
Page 35 HWT-801H8W-E, HWT-1101H8W-E, HWT-1401H8W-E HWT-801H8RW-E, HWT-1101H8RW-E, HWT-1401H8RW-E CN07 and CN08 are mounted : Case A REACTOR REACTOR REACTOR CN07 and CN08 are NOT mounted : Case B Case B Case A (Without wiring) PTC thermistor Noise Filter & Compressor IPDU board MCC-1780 Only for models with heater...
Page 36: 4-3.Hot Water Cylinder Unit
4-3. Hot water cylinder unit Double pole thermal cut out Blue Blue Green / Brown Yellow Brown TTW sensor Hot water cylinder heater Supply 220 - 240 V from hydro unit To hydro unit Cable size 1.5 mm (minimum)
Page 37: Key Electric Component Rating
Key electric component rating 5-1. Hydro unit HWT-602S21SM3W-E, HWT-602S21SM6W-E, HWT-602S21ST6W-E Model name No. Component name Type name Rating M3W-E M6W-E T6W-E Circulation pump for zone1 UPM 4LK 15-75 130 AC230 V 0.66 A (MAX Backup heater 3 kW SMP10E8304 3KW AC230 V 3 kW Backup heater 6 kW SMP10E8304 6KW...
Page 38 HWT-602S21MM3W-E, HWT-602S21MM6W-E, HWT-602S21MT6W-E Model name No. Component name Type name Rating M3W-E M6W-E T6W-E Circulation pump for zone1 UPM 4LK 15-75 130 AC230 V 0.66 A (MAX) Backup heater 3 kW SMP10E8304 3KW AC230 V 3 kW Backup heater 6 kW SMP10E8304 6KW AC230 V 6 kW Backup heater 6 kW...
Page 39 HWT-1102S21SM3W-E, HWT-1102S21SM6W-E, HWT-1102S21ST6W-E, HWT-1102S21ST9W-E Model name Type name Rating Component name M3W-E M6W-E T6W-E T9W-E Circulation pump for zone1 UPM 4LK 15-75 130 AC230 V 0.66 A (MAX) Backup heater 3 kW SMP10E8304 3KW AC230 V 3 kW Backup heater 6 kW SMP10E8304 6KW AC230 V 6 kW Backup heater 6 kW...
Page 40 HWT-1102S21MM3W-E, HWT-1102S21MM6W-E, HWT-1102S21MT6W-E, HWT-1102S21MT9W-E Model name Type name Rating Component name M3W-E M6W-E T6W-E T9W-E Circulation pump for zone1 UPM 4LK 15-75 130 AC230 V 0.66 A (MAX) Backup heater 3 kW SMP10E8304 3KW AC230 V 3 kW Backup heater 6 kW SMP10E8304 6KW AC230 V 6 kW Backup heater 6 kW...
Page 41 HWT-1402S21SM3W-E, HWT-1402S21SM6W-E, HWT-1402S21ST6W-E, HWT-1402S21ST9W-E Model name Component name Type name Rating M3W-E M6W-E T6W-E T9W-E Circulation pump for zone1 UPM 4LK 15-75 130 AC230 V 1.1 A (MAX) Backup heater 3 kW SMP10E8304 3KW AC230 V 3 kW Backup heater 6 kW SMP10E8304 6KW AC230 V 6 kW Backup heater 6 kW...
Page 42 HWT-1402S21MM3W-E, HWT-1402S21MM6W-E, HWT-1402S21MT6W-E, HWT-1402S21MT9W-E Model name Component name Type name Rating M3W-E M6W-E T6W-E T9W-E Circulation pump for zone1 UPM 4LK 15-75 130 AC230 V 1.1 A (MAX) Backup heater 3 kW SMP10E8304 3KW AC230 V 3 kW Backup heater 6 kW SMP10E8304 6KW AC230 V 6 kW Backup heater 6 kW...
Page 43: 5-2.Outdoor Unit
5-2. Outdoor unit HWT-401HW-E, HWT-601HW-E No. Component name Type name Rating Compressor DX150A1T-21F Outdoor fan motor ICF-140-A43-1 Output 43 W Reactor CH-102 18 mH, 16 A 4-way valve coil DXQ-1233 DC12 V Pulse motor valve (PMV) coil PQ-M10012-000313 DC12 V Compressor case thermostat US-622KXTMQO-SS OFF = 125 ±...
Page 44: 5-3.Hot Water Cylinder Unit
HWT-801H8(R)W-E, HWT-1101H8(R)W-E, HWT-1401H8(R)W-E No. Component name Type name Rating Compressor RX380A2TJ-20M Outdoor fan motor ICF-280-A100-1 Output 100 W Reactor(CH-100) CH-100-2Z 10 mH, 16 A 4-way valve coil DXQ-1233 DC12 V Pulse motor valve (PMV) coil UKV-A040 DC12 V PC board (Compressor) MCC-1780 PC board (Control) MCC-1781...
Page 45: 5-4.Water Heat Exchange Control Board
5-4. Water heat exchange control board HWT-602S21***W-E, HWT-1102S21***W-E, MCC-1753 (main) THO sensor TWO sensor CN602 CN600 Connector for TC sensor Backup heater thermostat MCC-1755 (CN03) CN601 CN611 CN603 Connector for Water flow sensor MCC-1755 (CN03) CN609 Connector for CN605 Low pressure sensor Connector for MCC-1755 (CN02) CN607...
Page 46 HWT-1402S21***W-E MCC-1753 (main) Connector for TWO sensor MCC-1755(CN03) THO sensor CN600 CN605 CN602 TC sensor Connector for Backup heater CN601 MCC-1755 (CN03) thermostat Water flow sensor CN603 CN611 TWI Sensor CN609 CN604 Connector for MCC-1755 (CN04) Connector for Low pressure sensor CN700~703 MCC-1755 (CN02) CN607...
Page 47 HWT-602S21***W-E, HWT-1102S21***W-E, WT-1402S21***W-E MCC-1755 (sub) Connector for MCC-1753 (CN700-703) CN04 Mixing valve Connector for Connector for Connector for Built-in MCC-1753 (CN711) MCC-1753 (CN707) MCC-1753 (CN303) circulation pump CN08 CN02 CN06 CN07 Connector for 3-way valve MCC-1753 (CN603, 605) CN03 External pump AC power supply CN01 External input...
Page 48: 5-5.Outdoor Control Board
5-5. Outdoor control board HWT-401HW-E, HWT-601HW-E MCC-1768 Lead wire compressor motor Connector for MCC-1646 CN807 FAN motor CN300 TE sensor CN600 CN700 TD sensor CN601 TL sensor CN604 Earth lead wire TS sensor 4-way valve CN603 CN704 TO sensor Thermostat for CN602 compressor High-pressure...
Page 49 HWT-801H(R)W-E, HWT-1101H(R)W-E, HWT-1401H(R)W-E MCC-1675 (Interface CDB) 2-way valve INJ Heater output CN707 CN709 Connector for TB2 (to hydro unit) CN01 Connector for MCC-1705 (CN20, 22) CN02 PD sensor CN607 PMV1 CN710 Connector for MCC-1705 (CN805) CN805 PMV2 CN711 Connector for MCC-1646 CN807 4-way valve...
Page 50 HWT-801H(R)W-E, HWT-1101H(R)W-E MCC-1705 (Compressor, Fan IPDU) Connector for FAN motor MCC-1675 (CN805) Compressor CN805 CN300 Case thermostat CN609 High-pressure switch CN690 Lead wire for power supply P01 (RED), P02 (WHI) Lead wire for Hydro unit P11 (RED), P12 (WHI) Lead wire for Lead wire for Fasten for MCC-1675 (CN02) compressor motor...
Page 51 HWT-1401HW-E, HWT-1401HRW-E MCC-1758 (Compressor, Fan IPDU) Connector for MCC-1675 FAN motor Terminal for compressor CN881 CN300 CN200(RED), CN201(WHI), CN202(BLK) FASTON-TAB for MCC-1675 CN03,CN06 Lead wire for REACTOR P04 (WHI), P05 (WHI) Lead wire for REACTOR P03 (GRY), P06 (GRY) Earth wire Compressor High-pressure switch Case thermostat...
Page 52 HWT-801H8(R)W-E, HWT-1101H8(R)W-E, HWT-1401H8(R)W-E MCC-1780(Compressor IPDU) Lead wire for Reactor (CH-100) P43, P23(BLK) Lead wire for Reactor Compressor (CH-100) CN233(BLK) P41, P21(RED) CN222(WHI) CN211(RED) PTC thermistor CN08(RED)* CN07(RED)* High-pressure switch Lead wire for Reactor CN690 (CH-100) P42, P22(WHI) Connector for MCC-1781 Connector for MCC-1781 CN10 CN805...
Page 53 HWT-801H8(R)W-E, HWT-1101H8(R)W-E, HWT-1401H8(R)W-E MCC-1781(CDB & FAN IPDU) Heater output 2-way valve INJ Connector for MCC-1780 CN709 CN707 CN02 Connector for MCC-1780 CN11 Connector for MCC-1780 CN611 Compressor Case thrmostat CN609 4-way valve CN701 PD sensor CN607 FAN motor CN302 TS sensor CN600 Connector for MCC-1780 TE sensor...
Page 54: Refrigerant (R32)
Refrigerant (R32) This Air to Water Heat Pump adopts the R32 refrigerant which does not damage the ozone layer. The working pressure of the new refrigerant R32 is 1.6 times higher than conventional refrigerant (R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the Air to Water Heat Pump using the new refrigerant during installation work or servicing time.
Page 55: 6-2.Refrigerant Piping Installation
6-2. Refrigerant piping installation 6-2-1. Piping materials and joints used For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.
Page 56: 6-2-2.Processing Of Piping Materials
6-2-2. Processing of piping materials When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil other than lubricating oils used in the installed Air to Water Heat Pump is used, and that refrigerant does not leak.
Page 57: 6-3.Tools
(2) Flare connecting procedures and precautions a) Make sure that the flare and union portions do not have any scar or dust, etc. b) Correctly align the processed flare surface with the union axis. c) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A or R32 is the same as that for conventional R22.
Page 58: 6-4.Recharging Of Refrigerant
6-4. Recharging of refrigerant When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. Recover the refrigerant, and check no refrigerant remains in the equipment. When the compound gauge’s pointer has indicated –0.1 MPa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s Connect the charge hose to packed valve service...
Page 59: 6-5.Brazing Of Pipes
NOTE (1) Be sure to make setting so that liquid can be charged. (2) When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down. R32 refrigerant is a Single-component refrigerant that does not change its composition. Although it is possible to charge the refrigerant with either liquid or gas, charge it with liquid.
Page 60: 6-5-2.Flux
6-5-2. Flux 6-5-3. Brazing As brazing work requires sophisticated techniques, (1) Reason why flux is necessary experiences based upon a theoretical knowledge, it • By removing the oxide film and any foreign matter on must be performed by a person qualified. the metal surface, it assists the flow of brazing filler.
Page 61: 6-6.Instructions For Re-Use Piping Of R22 Or R407C
6-6. Instructions for re-use piping of R22 or R407C Instruction of works: (3) The pipes are left as coming out or gas leaks. The existing R22 and R407C piping can be reused (Poor refrigerant) for our Air to Water Heat Pump R32 products •...
Page 62: Branching Pipe For Simultaneous Operation System
• Otherwise rust may generate when moisture or foreign matter due to dewing enters in the pipes. In the concurrent twin system, when TOSHIBA- specified branching pipe is used, it can be reused. • The rust cannot be removed by cleaning, and a new piping work is necessary.
Page 63: 6-6-6.Handling Of Existing Pipe
6-7. Charging additional 6-6-6. Handling of existing pipe refrigerant When using the existing pipe, carefully check it for the following: • Wall thickness (within the specified range) Amount of additional refrigerant shall be restricted by • Scratches and dents the following explanation to ensure the reliability. •...
Page 64: 6-8.General Safety Precautions For Using R32 Refrigerant
6-8. General safety precautions for using R32 refrigerant 6-8-1. Recovery 6-8-2. Decommissioning • When removing refrigerant from a system, either for • Before carrying out this procedure, it is essential that servicing or decommissioning, it is recommended the technician is completely familiar with the good practice that all refrigerants are removed equipment and all its details.
Page 65: Operational Description
Operational description This chapter describes the working circuit and control of Air to Water Heat Pump about the following operations. Item Page 7-1. Basic Operation 1) Operation control 2) Hot water supply operation 60 to 62 3) Heating operation 4) Cooling operation 7-2.
Page 66 Operation description Item Operation flow and applicable data, etc. 7-1. 1. Purpose 1) Operation control Basic The operations of the Remote controller Operation hydro unit and the outdoor unit are controlled according to Operation Remote controller settings user-defined operation condition selection <Heating>...
Page 67 Operation description Item Operation flow and applicable data, etc. 2) Hot water supply operation Hot water supply operation 7-1. Basic 1. Purpose Hot water supply Operation Hot water supply Hot water temperature: 40°C to 65°C operation start 2. Details This section performs hot water supply operation according to Circulation pump “ON/OFF”...
Page 68 Operation description Item Operation flow and applicable data, etc. 4) Cooling operation 1. Purpose 7-1. Basic Cooling Operation Cooling operation 2. Details Cooling temperature: 7°C to 25°C This section performs start cooling operation according to cooling conditions specified for Circulation pump “ON/OFF” control the steps on the left.
Page 69 Item Operation flow and applicable data, etc. 7-2. 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 Method 401, 601...
Page 70 Item Operation flow and applicable data, etc. 7-2. Operation Mode Single phase 801, 1101 and Control Method Cooling operation range Heat pump operation range of hot water supply and heating. * With the exception of TO 25°C or higher for heating. Heat pump operation range of hot water supply and heating, until discharge temperature...
Page 71 Operation flow and applicable data, etc. Item 7-2. Operation Mode Single phase 1401 and Control 3 phase 801, 1101, 1401 Method Cooling operation range Heat pump operation range of hot water supply and heating. * With the exception of TO 25°C or higher for heating.
Page 72 Operation flow and applicable data, etc. Item 7-2. 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 73 Item Operation flow and applicable data, etc. 7-2. 3) Heating operation Operation Mode <Operation only for ZONE1> and Control • This operation is enabled when DN_6B9 is set to "0000" (default). Method • The remote controller displays settings, and only the set temperature of can be changed.
Page 74 Item Operation flow and applicable data, etc. 7-2. 4) Cooling operation Operation Mode Pressing the [ ] button twice, starts a cooling operation. and Control 1) Operation start condition Method Pressing the [ ] button twice, starts a cooling operation. Heat pump operation (Cooling) 2) Operation mode selection...
Page 75 Item Operation flow and applicable data, etc. 7-2. 6) Simultaneous operations of “hot water supply” and “cooling” Operation Mode * The heat pump runs for the hot water supply side when TTW is less than 38°C. and Control The heat pump maintains a supply of hot water for up to 30 minutes during a simultaneous operation. Method Hot water supply side Cooling side...
Page 76 Item Operation flow and applicable data, etc. 7-2. 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.
Page 77 Item Operation flow and applicable data, etc. 7-2. Related DN Operation Mode Setting item Default Variable range and Control Method Boiler-heat pump switching temperature -10°C -20 - 20°C Control priority between the hydro unit and boiler 0: Hydro unit control Independent temperature (Control valid for operating heat pump mode) control for the hydro unit...
Page 78 Item Operation flow and applicable data, etc. 7-2. 9) Anti bacteria operation Operation Mode An Anti bacteria operation regularly performs a Hot water supply operation with the set temperature TSC_H = 65°C and Control (can be set with DN_0A). Method 1) How to operate •...
Page 79 Item Operation flow and applicable data, etc. 7-2. 10) Night setback operation Operation Mode A Night setback 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 80 Item Operation flow and applicable data, etc. 7-2. 12) Auto operation Operation Mode An Auto operation sets the water temperature TSC_F depending on the outside air temperature TO. and Control Method 1) How to operate • Pressing the remote controller [ ] button and then setting Auto mode "ON"...
Page 81 Item Operation flow and applicable data, etc. 7-2. 13) Night time low-noise operation Operation Mode A night time low-noise operation reduces operation frequency and the number of outdoor fan rotations for a certain and Control period during night time as noise control for urban operation. Method Single phase 1101...
Page 82 Item Operation flow and applicable data, etc. 7-3. 1-2) Low 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 of a heat pump operation is used. The values of T7 through T10 varies depending on TWI.
Page 83 Item Operation flow and applicable data, etc. 7-3. 2) Heater control Hydro Unit Control 2-1) Hot water supply operation During a hot water heat pump operation, the unit energizes the backup heater when any of following conditions are met. Note that when the hot water supply set temperature (TSC_F) is reached, the unit stops energizing the heater. •...
Page 84 Item Operation flow and applicable data, etc. 7-3. 2) Control at the time of heating heater operation Hydro Unit Control • Controlled Object: Backup heater, Booster heater The backup heater control starts when 3 minutes has passed after the heating heater operation started. The backup heater control increases, decreases, or maintains the number of heaters every 10 minutes (DN) depending on the difference between the heating set temperature (TSC_F) and the heater outlet temperature (THO).
Page 85 Item Operation flow and applicable data, etc. 7-3. 2-5) No heater operation Hydro Unit Control According to the DN setting, the unit switches the energize / not energize for the hot water cylinder, backup heater, and booster. For details, see 9-1. (Caution) All heater should be added to this Air to water system.
Page 86 Item Operation flow and applicable data, etc. 7-3. Example of pump speed control (heating and hot water supply mode including defrost operation) Hydro Unit Control Item Status FL_max Heating target considered TO X°C Target flow rate Heating target considered TO Y°C Hot water supply target FL_min 0 L/min...
Page 87 Item Operation flow and applicable data, etc. 7-3. 3-6) Controlling the built-in circulation pump P1 during cooling operation controlled with the room temperature Hydro Unit Control thermostat or room temperature remote controller. You can change the action of the built-in circulation pump P1 by setting DN_65. •...
Page 88 Item Operation flow and applicable data, etc. 7-3. 4) Control by the flow sensor Hydro Unit Control Whether water flows or not is judged with the valve of water flow sensor. Without water-flow determination from the flow sensor after the hot water supply operation, heating operation, or cooling operation, The HP, backup heater and booster heater are not energized.
Page 89 Item Operation flow and applicable data, etc. 7-3. 6-3) Control method Hydro Unit Control • The water temperature setting at starting operation is 40°C (DN_9D) at heating and 20°C (DN_96) at cooling. If the temperature setting calculated by Auto curve at starting operation will be used instead of the fixed temperature 40°C (DN_9D), DN_B5 should be set to “1”.
Page 90 Item Operation flow and applicable data, etc. 7-3. 7) Room temperature control with the thermostat Hydro Unit Control You can install a commercially available thermostat to control room temperature. 7-1) Installing the room temperature thermostat • Connect its connection cable to CN21 port on the PC board (MCC-1755) of the hydro unit. •...
Page 91 Item Operation flow and applicable data, etc. 7-3. 7-4)Cooling thermostat operation Hydro Unit Control When the cooling thermostat does not reach the assigned temperature (the circuit between (2) and (5) is open), cooling starts under the setting that water temperature for cooling is 20°C (DN_96). If the cooling thermostat has not reached the assigned temperature 30 minutes after cooling had started, the water temperature setting is turned down 1 degree, and the same action will be repeated every 30 minutes until the thermostat reaches the assigned temperature.
Page 92 Item Operation flow and applicable data, etc. 7-3. 8) Control of Mode selection and forced stop & restart Hydro Unit Control You can change the operation mode and force the operation ON/OFF. • Connect its connection cable to CN21 port on the PC board (MCC-1755) of the hydro unit. Non-voltage contacts CN21 MCC-1755...
Page 93 Item Operation flow and applicable data, etc. 7-3. 9) Control of limit of heat pump operation (Tempo1, 2) Hydro Unit Control 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.
Page 94 Item Operation flow and applicable data, etc. 7-3. 10) Connection to a Smart Grid network (SG ready) Hydro Unit Control The operating mode is controlled through volt free contacts incorporated into the energy meter. • Connect its connection cable to CN21 port on the PC board of the hydro unit. Optional inputs to Hydro Unit This unit has eight input ports.
Page 95 Item Operation flow and applicable data, etc. 7-3. 11) Output signal control Hydro Unit Control (Connect its connection cable to the CN22 terminal on the PC board (MCC-1755) in the hydro unit.) Additional Hydro Unit outputs This unit has four output ports. They are selectable by DN. Table1 shows the selectable output functions and default settings.
Page 96 Item Operation flow and applicable data, etc. 12) Q-H characteristics of hydro unit Hydro Unit The following shows the Q-H characteristics. Control Hydraulic heat exchanger (6,11kW) QH characteristics Minimum flow rate Out of range Hydro unit (wall mounted) Q-H characteristics (230 V) Pump duty 100% Flow rate [L/min]...
Page 97 Item Operation flow and applicable data, etc. 7-3. 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 98 Item Operation flow and applicable data, etc. 7-3. 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 180 seconds passes (defrosting and cooling) Low pressure sensor detects PS <...
Page 99 Item Operation flow and applicable data, etc. 7-4. 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 100 Item Operation flow and applicable data, etc. 7-4. 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 101 Item Operation flow and applicable data, etc. Single phase outdoor unit Heating, Hot water supply CT (A) Current release value (A) Outside temperature TO (degree °C) 12.4 401 / 601 29 ≤ TO 11 < TO < 29 12.4 - (TO - 11) × 4.4 / 18 TO ≤...
Page 102 Item Operation flow and applicable data, etc. 7-4. 4) Outdoor fan control Outdoor unit The outdoor side control part controls the number of fan motor rotations by receiving an operation instruction from the control Hydro side (Hydro unit) control part. For sensing the true outside temperature, fan is operated without compressor operation.
Page 103 Item Operation flow and applicable data, etc. 7-4. Outdoor unit Single phase outdoor unit 1401 control TG [ °C] WF tap + 1 tap / 20 secs (Up to the maximum number of rotation for each zone) Number of rotation hold - 1 tap / 20 secs (Up to the minimum number of rotation for each zone) 20 Hz or more to less...
Page 104 Item Operation flow and applicable data, etc. 7-4. 4-2) 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 105 Item Operation flow and applicable data, etc. 7-4. Outdoor unit 1101 control 20 Hz or more to less Less than 20 Hz 45 Hz or more than 45 Hz Temperature range Maximum Maximum Maximum 30°C ≤ TO 25°C ≤ TO < 30°C 20°C ≤...
Page 106 Item Operation flow and applicable data, etc. 7-4. 5) Defrosting control Outdoor unit 5-1) Defrost operation control This control defrosts the outdoor heat exchanger. The temperature sensor (TE sensor) of the outdoor heat exchanger 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 107 Item Operation flow and applicable data, etc. 7-4. Jumper switching O: Short circuit ×: Open Outdoor unit control J805 J806 150 min (Factory default) × 90 min × 60 min × × 30 min 5-2) Advance defrost operation When compressor temperature is low, defrosting preliminary operation will be carried out to carry defrosting smoothly in effect.
Page 108 Item Operation flow and applicable data, etc. 7-4. 6) 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 109 Item Operation flow and applicable data, etc. 7-4. 9) High pressure release control Outdoor unit 1) To prevent excessive high pressure rise, operating frequency is controlled by the PD sensor. control 2) If the PD sensor detects an abnormal stop zone pressure, the compressor stops and the abnormality detection counter increments.
Page 110 Item Operation flow and applicable data, etc. 7-4. 13) Start up from hibernation Outdoor unit This control operates at startup, in order to warm up the compressor by the heat from the water. control System is operated at a defrost cycle when the start condition is satisfied. System is switched to the normal heating operation when the end condition is satisfied.
Page 111: Method Of Failure Diagnosis
Method of failure diagnosis In order to diagnose the defective part of the heat pump system, first understand the symptom of the failure. (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 112: 8-1-1.Check The Power Supply Voltage
8-1. Matters to be confirmed first 8-1-1. Check the power supply voltage Check that the power supply voltage is AC220-240 V± 10% (signal phase) or AC380-415 V± 10% (3 phase). If the power supply voltage is not in this range, it may not operate normally. 8-1-2.
Page 113: 8-3.Outline Of The Determination Diagram
8-3. 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. 8-3-1. Procedure of failure diagnosis In the case of a defect, please apply the following procedure in order to find the defective part. Confirm the check Check code Failure in Hydro unit...
Page 114: 8-3-4.How To Diagnose By Check Code
8-3-4. How to diagnose by check code Failure mode detected by the Hydro Unit O ... Possible × ..Not possible Diagnostic functional operation Number of abnormalities Detailed Check Determination and action Backup Automatic item code Operational cause operation reset confirmation Flowing quantity failure 1.
Page 115 Diagnostic functional operation Number of abnormalities Detailed Check Determination and action item Backup Automatic code Operational cause operation reset confirmation Overheat protection operation 1. No water (heating without water) or When the thermostat of the backup no water flow. heater activates during the operation of 2.
Page 116 Diagnostic functional operation Number of abnormalities Detailed Check Determination and action Backup Automatic item code Operational cause confirmation operation reset Pump failure (for zone2) 1. Pump has stopped by a certain cause. • Low supply voltage. • High humidity around the electric box of the pump.
Page 117 Diagnostic functional operation Number of abnormalities Detailed Check Determination and action Backup Automatic item code Operational cause operation reset confirmation THO sensor failure 1. Check the resistance value and Open or short circuit in the heater outlet connection of the heater outlet temperature sensor.
Page 118 Diagnostic functional operation Number of abnormalities Detailed Check Determination and action Backup Automatic item code Operational cause operation reset confirmation Communication failure 1. Check the setting of the DN_11 The capability code for the hydro unit capability specifications. has not been set. 601 Hydro = 0010 1101, 1401 Hydro = 0015 Setting failure...
Page 119 Failure mode detected by the outdoor unit O ... Possible × ..Not possible Diagnostic functional operation Number of abnormalities Detailed Check Determination and action item code Backup Automatic Operational cause confirmation operation reset TD sensor failure 1. Check the resistance value and Open or short circuit in the discharge connection of the discharge sensor temperature sensor.
Page 120 Diagnostic functional operation Number of abnormalities Detailed Check Determination and action item code Backup Automatic Operational cause confirmation operation reset Failure in the current detection circuit 1. Check the connection of the connector and wiring. 2. Check the power supply voltage and frequency.
Page 121 Diagnostic functional operation Number of abnormalities Detailed Check Determination and action item code Backup Automatic Operational cause confirmation operation reset The high pressure switch failure 1. Almost no or little water flow. 2. Failure of the flow sensor. 3. Failure in the high pressure switch. 4.
Page 122 Diagnostic functional operation Number of abnormalities Detailed Check Determination and action item code Backup Automatic Operational cause confirmation operation reset Short circuit of the compressor driver 1. P26 abnormality occurs when operating with the compressor element failure wiring disconnected … Check the When an abnormal short circuit of IGBT outdoor control board.
Page 123: 8-4.Diagnosis Flow Chart For Each Check Code
8-4. Diagnosis flow chart for each check code 8-4-1. Hydro unit failure detection [A01] Flowing quantity failure [A01] occurs Operation restarts Built-in circulation pump rotates Perform air vent Connect pump Pump is connected connector to board to board Excess air noise Replace the pump comes from inside the pump...
Page 124 [A02] Temperature increase failure (heating) Start (TWI, TWO, THO ≥ 70°C) TWI, TWO, and THO Replace TWI, TWO, sensor characteristics are and THO sensors correct Flow sensor is normal Replace flow sensor Water outlet temperature is 70 °C or higher Hot water from Correct water circuit boiler or other circuits does...
Page 125 [A03] Temperature increase failure (hot water supply) Start (TTW ≥ 85°C is detected) TTW sensor Replace TTW sensor characteristic is correct Hot water cylinder heater is energized At normal temperature, tank thermostat is energized Hot water cylinder Replace hot water thermostat operates cylinder thermostat Operation...
Page 126 [A04] Antifreeze operation (1) When the outside temperature and 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 Excess air Secure water Dirt clogging...
Page 127 [A05] Piping antifreeze operation Restart < < 4, TWO 4, or < 4 is detected Circulation pump keeps being energized or 3 minutes passed after the start Hydro unit DN code setting DN code setting DN_6D2 = “0” DN_6D2 = “0” Backup heater terminal Check wiring construction has 220-240 V (±...
Page 128 [A08] Low pressure sensor operation failure Start Replace flow sensor Flow sensor 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, the second pump...
Page 129 [A09] Overheat protection operation Start Put water into water circuit Water cycle contains water (Recommended: 1 - 2 Bar) Replace flow sensor Flow sensor is normal Replace heater unit exchanger air vent valve At normal temperature, overheat preventive thermostat Check water heat is normal exchange control board If defective, replace it...
Page 130 [A10] Antifreeze operation (2) Start Flow sensor is normal Replace flow sensor Remove sufficiently excess air Excess air Secure water Waste stuck inside noise comes from Remove waste water circuit circulation amount inside pump 12 M or longer water Place buffer tank and pipe to a branch, the second pump or 5 or less branches...
Page 131 [A11] Operation of the release protection Start Flow sensor is normal Replace flow sensor Remove sufficiently excess air Excess air Waste stuck inside Secure water 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 132 [A12] Heating, hot water heater failure Restart Operation starts under 10 ≤ TWI <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 133 [A13] [A14] Pump failure Start Power terminal has Input appropriate voltage AC 220-240 V(±10%) Pump power input has AC 220-240 V High humidity around Resolve the cause the electric board of the pump Dew condensation to Resolve the cause the electric board of the pump Locking by a certain Resolve the cause...
Page 134 [E04] Regular communication failure between hydro unit and outdoor unit Outdoor unit failure occur (Check the display board of outdoor unit) The wiring and Correct wiring and connecting between outdoor connecting wire unit and hydro unit are correct Hydro unit CN01 connector and Correct connector and TB01 terminal block (1, 2, 3)
Page 135 [F04] TD sensor failure Start TD sensor Correct TD sensor connector (*) is connection connected 401, 601 = CN601 801, 1101, 1401 = CN603 (Including 3 phase) TD sensor Replace TD sensor resistance characteristic (Refer to Characteristic table on page 137) is normal PC board Check outdoor control board...
Page 136 [F08] TO sensor failure Start TO sensor Correct TO sensor connector (CN602) is connection connected TO sensor resistance characteristic Replace TO sensor is normal (Refer to Characteristic table on page 137) PC board Check outdoor control board <401, 601> MCC-1768 If defective, replace it <801, 1101, 1401>MCC-1675 <801, 1101, 1401>MCC-1781 (3 phase)
Page 137 [F14] TTW sensor failure Start TTW sensor connector Correct TTW sensor (CN603 (MCC-1753), CN03, connection CN20 (MCC-1755)) is connected TTW sensor Replace TTW sensor characteristic is normal (Refer to Characteristic table on page 137) PC board Check water heat exchange control board MCC-1753 If defective, replace it MCC-1755...
Page 138 [F19] Detection of THO disconnection failure Start THO sensor Attach THO sensor is attached to pipe to pipe THO sensor Replace THO sensor characteristic is normal (Refer to Characteristic table on page 137) TWO sensor Replace TWO sensor characteristic is normal (Refer to Characteristic table on page 137) Check water heat exchange control board PC board...
Page 139 [F20] TFI detach failure Start Mixing valve is attached Attach a mixing valve Mixing valve connection Make the mixing valve is correct connection correct (Refer to wiring diagram of hydro unit on page 27) Mixing valve setting Make the mixing valve is correct setting correct DN_0C: Mixing valve running time...
Page 140 [F23] Low pressure sensor failure Start Low pressure sensor Attach low pressure sensor is detached (CN607) When operation is stopped, low pressure sensor Replace low pressure sensor is normal *1 *1 How to determine: When operation is stopped Check water heat exchange control board PC board If defective, replace it MCC-1753...
Page 141 [F32] Flow sensor failure Start Flow sensor Correct flow sensor connector (CN609) connection is connected Flow rate detected by flow sensor is almost same Replace flow sensor as actual value Check water heat exchange control board PC board If defective, replace it MCC-1753 [F33] Flowing quantity failure Start...
Page 142 [L02] Combination failure The model name of the outdoor unit is not HWT-xxxxH(8)(R)W-E. Replace the outdoor unit with the proper model. And check the combination of INJ type or not is correct. [L07] Communication failure At the time of power on, detecting the above failure automatically activates the automatic address setting mode.
Page 143: 8-4-2.Outdoor Unit Failure Detection
8-4-2. 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 •...
Page 144 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [H01] [Compressor break down] Power voltage is normal Improve power line AC220-240 V±10% Wiring connection is normal Check and correct wiring Compressor lead (Board side, compressor connection side reactor lead, power lead) Abnormally over loaded...
Page 145 [H03] [Failure in the current detection circuit] The wiring construction is normal. correct wiring. Power supply voltage and frequency are normal. Check electric (AC380 - 415 V±10%, work. frequency 50Hz±10%) Compressor is normal. replace compressor PC board <401,601> MCC-1768 replace outdoor <801,1101>...
Page 146 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [H04] [Case thermostat operation] <401, 601> CN500 Correct connector <801, 1101, 1401> CN609 (Including 3 phase) Replace case thermostat connector and case thermostat is normal If case thermostat is short circuited, Check outdoor board cooling and heating can operate...
Page 147 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [P02] [Converter circuit failure] correct wiring. Wiring construction is normal. Power supply voltage and frequency are normal. Check electric work. (AC380 - 415 V±10%, frequency 50Hz±10%) Check outdoor control board If PC board...
Page 148 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.High pressure protection operation 4.Case thermostat operation...
Page 149 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [P05] [Power source trouble] correct wiring. Wiring construction is normal. Power supply voltage is normal. (3 phase) <801,1101,1401> : Check electric work. AC380-415V ±10% Other than the above : AC220-240V ±10% PC board...
Page 150 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [4-way valve reversal trouble] [P19] Does 4-way valve Is the coil work correctly? resistance Replace (Check pipe temp. etc. value of 4-way 4-way valve coil in cooling/heating valve normal? operation)
Page 151 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [P20] [High pressure protection operation] Service valve is fully opened Open fully service valve Heating season Heating operation Reset the power source and perform test run matching to the season Cooling season Cooling operation...
Page 152 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [P22] [Fan system trouble] Power voltage is normal Check wiring construction Ask repair of power supply AC220 - 240 V±10% Rotate shaft of the fan motor by hands during power-OFF.
Page 153 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [F04] [Discharge temperature sensor (TD) failure] TD sensor connector is Correct TD sensor connected connection TD sensor resistance Replace TD sensor characteristic is normal Refer to the characteristic table on page 137...
Page 154 Outdoor LED Check and Action procedure Check code indication (No specific description indicates outdoor unit parts.) [F12] [Suction temperature sensor (TS) failure] Correct TS sensor TS sensor connector is connection connected TS sensor resistance Replace TS sensor characteristic is normal Refer to the characteristic table on page 137...
Page 155: Temperature Sensor, Temperature-Resistance Characteristic Table
8-4-3. Temperature sensor, temperature-resistance characteristic table TWI, TFI, TTW sensors Typical value Resistance value (kΩ) Temperature (°C) (Minimum) (Standard) (Maximum) 31.18 32.82 34.46 19.12 19.95 20.78 12.08 12.50 12.92 9.700 10.00 10.30 7.808 8.050 8.291 5.155 5.314 5.474 3.482 3.590 3.698 2.380 2.478...
Page 156: 8-5.Operation Check By Pc Board Switch
8-5. Operation check by PC board switch 8-5-1. Operation check mode This mode allows to check the operations of the water 2-way valve, water 3-way valve, mixing valve, and circulation 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 controllers “OFF”...
Page 157: 8-6.Brief Method For Checking The Key Components
8-6. Brief method for checking the key components 8-6-1. 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 (kΩ) (TWI) sensor Water heat exchange temperature (TC) sensor...
Page 158: 8-6-2.Outdoor Unit
8-6-2. Outdoor unit Component name Check procedure Compressor Measure the resistance value of each winding with a tester. Type 401HW-E, 601HW-E DX150A1T-21F Resistance Location (401HW-E, 601HW-E) value NX220A1FJ-20N Red ─ White 1.04 - 1.16 Ω (801HW-E, 1101HW-E) White ─ Black 1.04 - 1.16 Ω...
Page 159 Component name Check procedure Pulse motor valve coil PQ-M10012-000313 Type 1 White Resistance value Location PQ-M10012-000313 5 Red Red − White, Orange (401, 601) 46 ± 3.7 Ω 3 Orange Gray − Yellow, Blue UKV-A040 FAM-MD12TF-1 (801, 1101, 1401) Yellow Gray Blue UKV-25D302...
Page 160: Hydro Unit And Outdoor Unit Settings
Hydro unit and outdoor unit settings Hydro unit 1. Hydro unit Setting After DN code DN Description Default Change 1 Change 2 Change 3 Commissioning Used to activate external boiler output. 0 = external boiler output de-activated; 1 = external boiler output activated Used to when an external room thermostat is connected 0 = No external room thermostat;...
Page 161 2. DN Setting • Hydro unit DN code setting is available only for the header remote controller. • Set DN codes for various operation modes with the remote controller. 2-1. How to set hydro unit DN <Procedure> Perform the following when no operation is in progress. Press the [ ] button and the [ ] button at same time for 4...
Page 162 2-2. How to set remote controller DN <Procedure> Perform the following when no operation is in progress. Press the [ ] button and the [ ] button at same time for 4 seconds or longer on the top screen to display the “FIELD SETTING MENU”.
Page 163 DN table Item Details Factory default Cooling/Non-cooling switching 0000: Cooling 0001: Not cooling 0000: Cooling Central control address 0001 0128 None Hot water boost operation time (operating time) 0003: 30 min 0018: 180 min 0006: 60 min Hot water boost set temperature 0040: 40°C 0065: 65°C 0065: 65°C...
Page 164 Hydro unit backup heater up time 0000: 10 min 0000: 10 min 0001: 20 min 0002: 30 min 0003: 40 min Frost protection function Invalid/Valid 0000: Invalid 0001: Valid 0001: Valid Frost protection set temperature 0008: 8°C 0020: 20°C 0015: 15°C 2-way valve operation (logical reverse) control 0000: Activate during cooling 0000: Activate during...
Page 165 Item Details Factory default Set temperature B’ with outside temperature of T1 0020: 20°C 0055: 55°C (401 / 601), 0035: 35°C 0065: 65°C (801 / 1101) Set temperature E’ with outside temperature of 20°C 0020: 20°C 0055: 55°C (401 / 601), 0020: 20°C 0065: 65°C (801 / 1101) Group control...
Page 166 Item Details Factory default 0001:Yes 6B0 Boiler output enabled 0000: No 0000: No External room thermostat connected 0000: No 0001: Yes 0000: No Synchronisation of pump P1 and P2 0000: Non-synchronous 0001: Synchronous 0001: Synchronous Hot water supply is using 0000: Yes 0001: No 0000: Yes...
Page 167 Remote controller DN table Temperature correction by the room temperature sensor -10K - +10K: By 1K steps -1: -1K correction (cooling) Night time low-noise mode 0: Invalid 1: Valid 0: Invalid Night time low-noise start time 0 - 23 (0:00 to 23:00) 22: 22:00 Night time low-noise end time 0 - 23 (0:00 to 23:00)
Page 168 2-3. How to reset hydro DN (1) Procedure 1) Proceed the hydro DN setting screen. * See 9-2-1. Hydro DN setting 2) Press the [ ] long time in DN setting screen, and select “YES”. NOTE • After DN reset, it will take few minutes to back normal screen. First communication screen will continue for few minutes, but it is NOT trouble.
Page 169 3. Test run • Even if the outside air temperature or water temperature is outside the setting value range, Heating, Cooling and Hot water supply operation become possible. • Since the protection setting is disabled in the TEST mode, do not continue a test run longer than 10 minutes. <Procedure>...
Page 170 4. Auto Curve Setting • This function is available only for the header remote controller. • Set DN for various operation modes with the remote controller. <Procedure> Perform the following when no operation is in progress. Press the [ ] button and the [ ] button at same time for 4 seconds or longer on the top screen to display the “FIELD SETTING MENU”.
Page 171 <ZONE1> • An operation starts at the set temperature of straight -line approximation for the following: water temperature A°C with the outside temperature T0°C, B°C with T1°C, C°C with T2°C, D°C with T3°C, and E°C with 20°C. Related DN TSC_F (°C) Setting item Default range...
Page 172 Auto-Curve temperature shift • This function is available only for the header remote controller. • The set temperature can be shifted in the range of ±5K of the current setting. Press the [ ] / [ ] button to select “Auto mode” on the MENU MENU(1/2) screen.
Page 173 5. Clock Setting • Setting for the clock (date, month, year, time) Press the [ ] / [ ] button to select “Setting” on the MENU MENU(2/2) screen, then press the [ ] button. Anti bacteria Frost protection Setting Information Power consumption Press the [ ] / [...
Page 174 6. Scheduled Operation Setting 6-1. How to set scheduled operation • This function is available only for the header remote controller. • 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. •...
Page 175 Press the [ ] button. Condition setting Schedule timer confirm? Press the [ ] button to Fix. Mode : Operation mode (HEAT, COOL, HW (Hot water)) : ZONE1 setting temperature : ZONE2 setting temperature : Hot water supply operation setting temperature Start : Operation start time (0:00 - 23:59) : Operation end time (0:00 - 24:00, -- : --)
Page 176 To set up ranging over a day There are two methods. 1.If “24:00” is set to “END” and “00:00” is set to “START” next day, the previous operation status will be continued. And set the time you want to stop to “END”. 2.If “--”...
Page 177 To copy the settings of the previous day Press the [ ] button to select the day, then press the [ ] button Condition setting(1/2) to copy the settings of the previous day. WED THU FRI SAT SUN Mode Start - - : - - - - : - - - - : - -...
Page 178 Holiday setting • Set the days of the week when the schedule timer not used. Press the [ ] / [ ] button to select “Holiday setting” on the Schedule setting Schedule setting screen, then press the [ ] button. Condition setting Holiday setting Key lock...
Page 179 7. Frost protection Setting • This function performs operation with the minimum capacity (target water temperature:15°C) to prevent pipes from freezing in case the unit is not used for a long period due to absence. • Cancel schedule timer to start Frost protection operation. When Frost protection is operated with schedule timer on, it may stop during its operation.
Page 180 <How to set Frost protection operation end time> • This function is available only for the header remote controller. Press the [ ] / [ ] button to select “Frost protection” on the MENU(2/2) MENU screen. Anti bacteria Frost protection Setting Information Power consumption...
Page 181 8. NIGHT Operation Setting • This function is used for energy saving during specified time zone (sleeping hours, etc.). • For night time hours (sleeping hours, etc.), this function shifts the set temperature of heating or cooling by 5K. Press the [ ] / [ ] button to select an “Night setback”...
Page 182 9. Anti bacteria Setting • This setting regularly raises the hot water cylinder temperature to prevent bacteria from growing. • The Anti bacteria operation is performed to maintain the temperature (60°C) for the period (30 minutes) when the preset start time (22:00) comes according to the preset cycle (7 days). •...
Page 183 10. Hot water boost Setting • This function is used when temporarily giving priority to the hot water supply operation. The hot water supply operation is performed in preference to other operations with a target of the preset time (60 minutes) or the preset temperature (60°C).
Page 184 11. Night time Low-noise Setting • This function is available only for the header remote controller. • This setting is used to reduce noise output, from the outdoor unit, during night time for neighbors. Night time lownoise operates with lower operation frequency and fan tap than normal operation only for the set time period. Press the [ ] / [ ] button to select “Silent mode”...
Page 185 12. Forced Defrosting Setting • This function is available only for the header remote controller. • This function can active the forced defrosting mode for the outdoor unit. Press the [ ] button and the [ ] button at same time for 4 seconds or longer on the top screen to display the “FIELD SETTING MENU”.
Page 186 13. Display Function of Set Temperature and Other Settings • The sensor sensing temperature is displayed on the remote controller. • This function allows you to make sure whether the sensor is installed properly. ▼Sensor temperature display calling <Procedure> Press the [ ] button and the [ ] button at same time for 4 seconds or longer on the top screen to display the “FIELD SETTING MENU”.
Page 187 Item code Data name Unit °c Target temperature for hot water supply °c Target water temperature for Zone1 °c Target water temperature for Zone2 °c Remote controller sensor temperature °c Condensed temperature (TC) °c Water inlet temperature (TWI) °c Water outlet temperature (TWO) °c Water heater outlet temperature (THO) °c...
Page 188 14. Failure History Calling Function • List of latest 10 alarm data: failure information of check code, date and time is displayed. <Procedure> Press the [ ] button and the [ ] button at same time for 4 seconds or longer on the top screen to display the “FIELD SETTING MENU”.
Page 189 15. Floor drying • This function is available only for the header remote controller. • This function is used for drying concrete etc. • Service personnel must operate the unit after setting the related DN code. • Operation is not started unless All the related DN codes are set. •...
Page 190 To start the operation Press the [ ] button and the [ ] button at same time for 4 seconds or longer on the top screen to display the “FIELD SETTING MENU”. Press the [ ] / [ ] button to select “Floor drying” on the FIELD SETTING MENU(1/2) FIELD SETTING MENU, then press the [ ] button.
Page 191 16. Power consumption • Shows latest power consumption. • This function is available only for the header remote controller. Press the [ ] / [ ] button to select “Power consumption” MENU(2/2) on the MENU screen, then press the [ ] button.
Page 192 17. Reset power consumption data • This function is available only for the header remote controller. Press the [ ] button and the [ ] button at same time for 4 seconds or longer on the top screen to display the “FIELD SETTING MENU”.
Page 193 18. Sensor information • Shows the value of sensor. Press the [ ] button and the [ ] button at same time for 4 seconds or longer on the top screen to display the “FIELD SETTING MENU”. Press the [ ] / [ ] button to select “Sensor information”...
Page 194 Outdoor unit 19. Outdoor Unit Setting 19-1. 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 195 19-2. Service support functions (LED indication, Switch operation method) The following settings are available with switches. (1) Overview Using 2 push-button switches (SW01, SW02) can make settings available and confirm operations. For operation Part number Specification Operation details Press button switch This switch switches the indications of LED (D800 to D804) on the outdoor control board.
Page 196 (2) LED indication switching (2) -1. Abnormality indication ▼ H WT-401HW-E, HWT-601HW-E, HWT-801H(R)W-E, HWT-1101H(R)W-E HWT-1401H(R)-E, HWT-801H8(R)W-E, HWT-1101H8(R)W-E, HWT-1401H8(R)W-E Diagnostic Procedure for Each Check Code (Outdoor Unit) 1) This section describes the diagnostic method for each check code displayed on the wired remote controller. 2) In some cases, a check code indicates multiple symptoms. In this case, confirm the LED display of the outdoor unit to narrow the contents to be confirmed.
Page 197 (2) -1-1.Current trouble indication LED indication Wired remote Name of trouble D800 D801 D802 D803 D804 D805 control trouble code Normal — Discharge temp. sensor (TD) trouble Heat exchanger temp. sensor (TE) trouble Heat exchanger temp. sensor (TL) trouble Outside temp. sensor (TO) trouble Suction temp.
Page 198 (2) -1-2.Latest (including current) trouble indication LED indication Name of trouble D800 D801 D802 D803 D804 D805 Normal Discharge temp. sensor (TD) trouble Heat exchanger temp. sensor (TE) trouble Heat exchanger temp. sensor (TL) trouble Outside temp. sensor (TO) trouble Suction temp.
Page 199 (2)-2. Sensor, Current, Compressor operation frequency, PMV position indication The values detected by controller, such as temperature sensor or current values, can be easily checked. [Method of Operation] 1) Confirm D800 to D804 are off (or rapidly flashing) and that D805 is lit up. If D800 to D804 are slowly flashing or D805 is flashing then push and hold down SW01 and SW02 at the same time for at least 5 seconds.
Page 200 3) Push SW02 to switch to the desired display item (Refer to (2) -2-2.). 4) To access the other display items repeat steps 1) to 3). 5) Before exiting ensure to perform step 1) and set the LED to the initial state (current abnormality indication). (2) -2-2.
Page 201 (3) Special operation for maintenance and inspection [Method of Operation] 1) Confirm the LED display shows the initial state. If not then return it to the initial state. 2) Push and hold down SW01 for at least 5 seconds. D804 will start slowly flashing. 3) Push SW01 until reaching the LED display function you wish to set.
Page 202: Replacement Of The Service Pc Board
Replacement of the service PC board WARNING Don’t open the PC board cover before 1 minute after power has been turned off beacuse an electric shock may be occurred. In the case of replacing the PC board, also confirm the chapter “11 How to exchange main parts”. 1.
Page 203: 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> Ensure that no water pressure is present when replacing the water circuit (circulation pump, heater unit, flow sensor, etc). After a repair is complete, perform a test run (after attaching the front panel, upper and lower cabinets, and side cabinet) and check that no abnormality including smoke or abnormal noise occurs.
Page 204 Exchange parts name Work procedure Remarks ② Top panel 1. Detachment ① Top panel 1. Perform No. (Front panel). 2. Unscrew the four screws. 3. Lift up the top panel. 2. Attachment 1. Reassembly in reverse order. screws ③ 1. Detachment Remote cotrol ①...
Page 205 Exchange parts name Work procedure Remarks ④ Circulation pump *1) To replace wate circuit parts, open the drain cock and reduce the water puressure in the Hydro unit. (ZONE1) 6,11kW (Check that the water puressure 0 bar on the meter.) Wait about 5 minutes to drain the warer in the Hydro unit.
Page 206 Exchange parts name Work procedure Remarks ④ Circulation pump NOTE (ZONE1) 14kW ④ screws clip Please be sure to read No. 1. Detachment ① ② 1. Perform No. (Front panel) (Top panel). 2. Turn off the power supplies, depressurize and drain the water curcuit.
Page 207 Exchange parts name Work procedure Remarks ⑤ Circulation pump NOTE Connection pipe (ZONE2) ④ clip Please be sure to read No. 1. Detachment ① ② 1. Perform No. (Front panel) (Top panel). 2. Turn off the power supplies, depressurize and drain the water curcuit.
Page 208 Exchange parts name Work procedure Remarks ⑥ Mixing valve Clip NOTE Clip (for 2 zone) ④ Clip Please be sure to read No. 1. Detachment ① ② 1. Perform No. (Front panel) (Top panel). 2. Turn off the power supplies, depressurize and drain the water curcuit.
Page 209 Exchange parts name Work procedure Remarks ⑧ Flow heater NOTE subassembly ④ 3kW, Please be sure to read No. 6kW, 1. Detachment ① ② 1. Perform No. (Front panel) (Top panel). 2. Turn off the power supplies, depressurize and drain the water curcuit. Flow heater 3.
Page 210 Exchange parts name Work procedure Remarks ⑩ Expansion vessel NOTE ④ Expansion vessel Please be sure to read No. Upper bar Brass B 1. Detachment ① ② 1. Perform No. (Front panel) (Top panel). 2. Turn off the power supplies, depressurize and drain Screws the water curcuit.
Page 211 Exchange parts name Work procedure Remarks ⑫ Flow sensor NOTE ④ Flow sensor Please be sure to read No. Clip 1. Detachment ① ② 1. Perform No. (Front panel) (Top panel). 2. Turn off the power supplies, depressurize and drain the water curcuit.
Page 212 Exchange parts name Work procedure Remarks ⑭ Safety valve DHW NOTE ④ Please be sure to read No. Safety valve DHW Nuts on 1. Detachment compression ① ② fittings 1. Perform No. (Front panel) (Top panel). 2. Turn off the power supplies, depressurize and drain Drain hose the water curcuit.
Page 213 Exchange parts name Work procedure Remarks ⑯ Access valves NOTE Access valve-1 ④ Please be sure to read No. 1. Detachment ① ② 1. Perform No. (Front panel) (Top panel). 2. Turn off the power supplies, depressurize and drain the water curcuit. 3.
Page 214 Exchange parts name Work procedure Remarks ⑰ Side cabinet 1. Detachment ① ② 1. Perform No. (Front panel) (Top panel). 2. Turn off the power supplies, depressurize and drain the water curcuit. 3. For right hand side panel: Remove the six screws from the support bracket.
Page 215 Exchange parts name Work procedure Remarks ⑲ BPHE + Low press. low pressure sensor NOTE sensor ④ Small, Large clip Please be sure to read No. flowsensor BPHE 1. Detachment ① ② 1. Perform No. (Front panel) (Top panel). clip 2.
Page 216 Exchange parts name Work procedure Remarks Water heat exchange 1. Detachment ① control board 1. Perform No. (Front panel). 2. Turn off the power supplies. Main 3. Unscrew the two screws. board(MCC-1753) 4. Lift up the E-BOX cover. * The round hole on the top of the E-BOX cover are fixed to the screw hook.
Page 217 2. Outdoor Unit 2-1. HWT-401HW-E(TR), HWT-601HW-E(TR) Exchange Work procedure Remarks parts name ① Common 1. Detachment procedure NOTE Wear gloves for this job. Otherwise, you may injure your hands on the parts, etc. Valve cover 1) Stop operation of the Air to water heat pump system and turn off the power breaker.
Page 218 Exchange Work procedure Remarks parts name ② Front cabinet 1. Detachment ① 1) Perform step 1 in 2) Remove the fixing screws (Φ4 × 8, 1 screw) used to secure the front cabinet and inverter cover, the screws (Φ4 × 10, 4 hexagon screws) used to secure the front cabinet at the bottom, and the fixing screws (Φ4 ×...
Page 219 Exchange Work procedure Remarks parts name ③ “Detachment (Inverter)” Inverter Inverter ② 1) Perform step 1 in assembly 2) Remove the fixing screw (Φ4 × 8, 1 screw) securing PL-COVER-PCB and the inverter box. 3) Remove the fixing screws (Φ4 × 8, 2 screws) for securing the motor base and the inverter box.
Page 220 Exchange Work procedure Remarks parts name ③ “How to check outdoor control board” Inverter ② assembly 1) Perform step in “Detachment (Inverter)”. 2) Remove the fixing screws (Φ4 × 8, 2 screws) for securing the motor base and the inverter box.
Page 221 Exchange Work procedure Remarks parts name ④ Control board “Detachment (outdoor control board)” P.C board base assembly 1) Remove the screws (Φ4 × 10, 2 screws) fixing inverter box and P.C. board base. 2) Remove the earth screw fixing inverter box and P.C.
Page 222 Exchange Work procedure Remarks parts name ⑤ 1. Detachment Side cabinet (right) Side cabinet Side cabinet (right) ② 1) Perform step 1 in Valve fixing plate 2) Remove the fixing screw (Φ4 × 8, 3 screws) used for securing the side cabinet (right) to the bottom plate and valve fixing plate.
Page 223 Exchange Work procedure Remarks parts name ⑦ 1. Detachment Compressor ① ② ③ ④ ⑤ 1) Perform step 1 in 2) Extract refrigerant gas. Partition 3) Remove the partition plate. plate (Φ4 × 8, 4 screws) 4) Remove the sound-insulation material. 5) Remove terminal cover of the compressor, Compressor and disconnect lead wire of the compressor...
Page 224 Exchange Work procedure Remarks parts name ⑨ 1. Detachment Electronic Coil-PMV Body-PMV ② ⑤ expansion valve 1) Perform step 1 in side cabinet (right). coil 2) Remove the coil by pulling it up from the electronic control valve body. Rotate 2.
Page 225 Exchange Work procedure Remarks parts name ⑪ TE sensor (outdoor heat exchanging temperature sensor) • Attachment Install the sensor onto the straight pipe part of the condenser outlet pipe. TE sensor lead Straight part Detail C TE sensor ⑫ TS sensor (Suction pipe temperature sensor) •...
Page 226 Exchange Work procedure Remarks parts name ⑮ TL sensor (outdoor heat exchanging temperature sensor) • Attachment Install the sensor onto the straight pipe part of the condenser outlet pipe. Straight part Detail E TL sensor lead TL sensor...
Page 227 2-2. HWT-801HW-E(TR), HWT-1101HW-E(TR), HWT-801HRW-E, HWT-1101HRW-E Exchange Work procedure Remarks parts name ① WARNING Common Front panel procedures Stop operation of the Air to water heat pump system and turn off breaker switch. Front panel Top cover CAUTION Ensure wearing of gloves when performing any work in order to avoid injury from parts, etc.
Page 228 Exchange Work procedure Remarks parts name ② 1. Detachment Plate stay Plate stay 1) Following to work of Detachment of  2) Remove the plate stay and base plate screws. (Φ4 × 10, 2 hexagon screws) 3) Remove plate stay. 2.
Page 229 Exchange Work procedure Remarks parts name ⑤ 1. Compressor, Fan IPDU (MCC-1705) Electrical Fig. 5-1 IPDU “Detachment (Compressor, Fan IPDU)” (MCC-1705) 1).Following to work of Detachment of  WARNING For 1 minute after the power is turned off, do not disas- Inverter box Inverter box semble the inverter to prevent an electric shock.
Page 230 Exchange Remarks parts name ⑤ Electrical Fig. 5-4 IPDU (MCC-1705) Screw Screw (continued) Supporters Inverter box hooks Inverter box hooks Screw Screw Screw Screws Fig. 5-5 Screws Coat the heat sink. Duct cover Duct cover Fig. 5-6 Fig. 5-7 Screws Heat sink screws Heat sink duct Screws...
Page 231 Exchange Remarks parts name ⑤ Electrical IPDU “Fix cables with binding band” (MCC-1705) (continued) [Binding band (A)] [Binding band (B)] Fix cables. Fix cables. (Board wires (P200, P201, P202) (Board wires (P01, P11, P12) and input power supply wires) and connecters (CN300, CN609) Input power supply wires Bundle the excess Bundle the excess...
Page 232 Exchange Work procedure Remarks parts name ⑥ Fig. 6-1 Electrical part 1. Interface CDB (MCC-1675) Screws COVER-EP (MCC-1675) “Detachment (Interface CDB)” 1).Following to work of Detachment of  P.C.board WARNING For 1 minute after the power is turned off, do not disas- semble the inverter to prevent an electric shock.
Page 233 Exchange Work procedure Remarks parts name ⑧ 1.Detachment Fan motor 1) Following to work of Detachment of  Propeller fan Propeller fan 2) Make sure that the fan motor and the propeller fan stop. Remove the flange nut from the fan motor and propel- Fan motor Fan motor ler fan.
Page 234 Exchange Work procedure Remarks parts name ⑧ 9) Cut the binding bands for the air duct fixing fan motor Fan motor (continued) and the motor base (2 position ). 10) Loosen the two claws on the motor base. 11) Remove the fixing screws (4 positions) while holding the fan motor so as not to fall it.
Page 235 Exchange Work procedure Remarks parts name ⑨ 1.Detachment Compressor WARNING compressor lead When removing the brazing part of the suction / discharge pipe of the compressor, remove the brazing part in a well- ventilated place after recovering the refrigerant. If recovery is insufficient, the refrigerant and refrigerating Piping panel (rear) Piping panel (rear) Piping panel (front)
Page 236 Exchange Work procedure Remarks parts name ⑨ 2. Attachment Compressor Compressor lead connector Compressor lead connector 1) Attach the compressor in the reverse process of compressor “1. Detachment”. lead (continued) • Also ensure to replace the compressor lead after replacing the compressor. •...
Page 237 Exchange Work procedure Remarks parts name ⑩ 1. Detachment PMV coil ④ 1) Following to work of Detachment of 2) Cut the binding band (4 positions) on the back surface 3) Pull the connector for PMV coil out of CDB 4) Remove the coil from the PMV body by rotating the coil (about 45°) while drawing the coil upward.
Page 238 Exchange Work procedure Remarks parts name ⑫ Liquid 1. Detachment injection ④ 1) Following to work of Detachment of line PMV coil 2) Cut the binding band (4 positions) on the back surface 3) Pull the connector for PMV coil out of CDB P.C. board. 2.
Page 239 Exchange Work procedure Remarks parts name ⑭ 1. Detachment Fan guard ③ Screws Screws 1) Following to work of Detachment of NOTE Do the work on a cardboard or a cloth to prevent the product from being scratched. 2) Remove the 4 screws that secure the fan guard. (Φ4 ×...
Page 240 2-3. HWT-1401HW-E(TR), HWT-1401HRW-E Exchange Work procedure Remarks parts name ① Common WARNING Front panel Front panel procedures Stop operation of the Air to water heat pump system and Front panel turn off breaker switch. Top cover CAUTION Ensure wearing of gloves when performing any work in order to avoid injury from parts, etc.
Page 241 Exchange Work procedure Remarks parts name 1. Detachment  Plate stay Plate stay 1) Following to work of Detachment of  2) Remove the plate stay and base plate screws. (Φ4 × 10, 2 hexagon screws) 3) Remove plate stay. 2.
Page 242 Exchange Work procedure Remarks parts name  Electrical 1. Compressor, Fan IPDU (MCC-1705) Fig. 5-1 IPDU Screws (Compres- “Detachment (Compressor, Fan IPDU)” sor lead) (MCC-1705) 1).Following to work of Detachment of  Spacer & CN201 (White) Reactor lead screw WARNING connector CN200 CN202...
Page 243 Exchange Work procedure Remarks parts name Fig. 6-1 Electrical part  1. Interface CDB (MCC-1675) CN01 CN707 CN709 (MCC-1675) “Detachment (Interface CDB)” 1).Following to work of Detachment of  P.C.board WARNING CN02 CN02 For 1 minute after the power is turned off, do not disas- CN607 CN607 semble the inverter to prevent an electric shock.
Page 244 Exchange Work procedure Remarks parts name 1.Detachment  Fan motor 1) Following to work of Detachment of  Propeller fan Propeller fan 2) Make sure that the fan motor and the propeller fan stop. Remove the flange nut from the fan motor and propel- Fan motor Fan motor ler fan.
Page 245 Exchange Work procedure Remarks parts name Fan motor 8) Cut the binding bands for the air duct fixing fan motor Motor base  (continued) and the motor base (2 position ). 9) Loosen the two claws on the motor base. 10) Remove the fixing screws (4 positions) while holding the fan motor so as not to fall it.
Page 246 Exchange Work procedure Remarks parts name ⑨ 1.Detachment Compressor WARNING compressor lead When removing the brazing part of the suction / discharge pipe of the compressor, remove the brazing part in a well- ventilated place after recovering the refrigerant. If recovery is insufficient, the refrigerant and refrigerating Piping panel (rear) Piping panel (rear) Piping panel (front)
Page 247 Exchange Work procedure Remarks parts name ⑨ 2. Attachment Compressor 1) Attach the compressor in the reverse process of compressor “1. Detachment”. lead (continued) • Also ensure to replace the compressor lead after replacing the compressor. • Install the sound insulation board (inner and outer) through the space between the Ferrite core Ferrite core...
Page 248 Exchange Work procedure Remarks parts name ⑩ 1. Detachment PMV coil PMV coil connector PMV coil connector 1) Following to work of Detachment of  2) Cut the binding band (B) (Thickness: 1.5 mm, Width: 4.6 mm) bundling the leads. 3) Pull the connector for PMV coil out of CDB 4) Remove the coil from the PMV body by rotating the coil (about 45°) while drawing the coil upward.
Page 249 Exchange Work procedure Remarks parts name ⑫ Liquid 1. Detachment Liquid injection line PMV coil connector Liquid injection line PMV coil connector injection 1) Following to work of Detachment of  line PMV coil 2) Cut the binding band (B) (Thickness: 1.5 mm, Width: 4.6 mm) bundling the leads.
Page 250 Exchange Work procedure Remarks parts name ⑭ 1. Detachment Fan guard Screws Screws 1) Following to work of Detachment of  NOTE Do the work on a cardboard or a cloth to prevent the product from being scratched. 2) Remove the 4 screws that secure the fan guard. (Φ4 ×...
Page 251 2-4. HWT-801H8(R)W-E, HWT-1101H8(R)W-E, HWT-1401H8(R)W-E Exchange Work procedure Remarks parts name ① Common * Refer to procedure No. of “2-3. HWT-1401HW-E(TR),  procedures HWT-1401HRW-E”. Front panel Top cover ② Plate stay * Refer to procedure No. of “2-3. HWT-1401HW-E(TR),  HWT-1401HRW-E”. ③...
Page 252 Exchange Work procedure Remarks parts name ⑤ Electrical [Fig. 5-2] IPDU (MCC-1780) Suppoters ⑥ 1. Interface CDB & FAN IPDU(MCC-1781) Electrical * See “5-5. Outdoor control board” IPDU - MCC-1781” for the location of each “Detachment(Interface CDB & FAN IPDU)” (MCC-1781) connector.
Page 253 Exchange Work procedure Remarks parts name ⑦ Reactor * Refer to procedure No. of “2-3. HWT-1401HW-E(TR),  (Attached HWT-1401HRW-E”. to the partition plate) ⑧ Reactor [Fig. 8-1] Refer to procedure No. of “2-3. HWT-1401HW-E(TR),  (Attached HWT-1401HRW-E”. to the However, refer to Fig. 8-1 for the connector position on partition the board of the Fan motor.
Page 254 Exchange Work procedure Remarks parts name ⑩ PMV coil Refer to procedure No. of “2-3. HWT-1401HW-E(TR), PMV coil connector  [Fig. 10-1] (Cycle) HWT-1401HRW-E”. However, refer to Fig. 10-1 for the connector position on the board of the PMV coil lead and the binding band (B). Cut the binding PMV coil band (B)
Page 255 Exchange Work procedure Remarks parts name ⑫ ⑫ Liquid [Fig. 12-1] Refer to procedure No. of “2-3. HWT-1401HW-E(TR), injection line HWT-1401HRW-E”. PMV coil connector PMV coil However, refer to Fig. 12-1 for the connector position on the board of the PMV coil lead and the binding band (B). Cut the binding PMV coil band (B)
Page 256 Exchange Work procedure Remarks parts name ⑭ ⑭ Fan guard Refer to procedure No. of “2-3. HWT-1401HW-E(TR), HWT-1401HRW-E”. ⑮ ⑮ [Reference] Refer to procedure No. of “2-3. HWT-1401HW-E(TR), Sensor HWT-1401HRW-E”. mount positions ⑯ Reactor CH-100 Reactor [Fig. 16-1] Reactor CH-100 (Attached 1.
Page 257: For Cooling Installation
For cooling installation If user install the Hydro unit to place humidity location or high humidity region, also user use cooling mode, please attach moisture- proof parts which parts are contained in Hydro unit. Insulator Insulator...
Page 258: 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 1. Insulation measurement (Power source circuit / Annually Insulation measurement with a mega tester Heater circuit) 2.
Page 259 Outdoor unit Frequency Periodic inspection details 1. Insulation measurement (Power source circuit / Annually Insulation measurement with a mega tester Compressor) 2. Power source measurement (No-load voltage / Rated Annually Electronic voltage measurement: operation) 220-240 V ±10% (Single phase type) 380-415 V ±10% (3 phase type) 3.
Page 260: Part Exploded View, Part List
Part exploded view, part list Hydro Unit...
Page 261 Hydro Unit 1 zone 2 zone...
Page 262 Hydro Unit Electric BOX(E-BOX) Assembly 2 zone 1 zone 2 zone...
Page 263 Hydro Unit Left side view Front view tank the sensor is in the tank.
Page 264 Hydro Unit Electric BOX(E-BOX) Assembly HWT-602S21***W-E / TR HWT-1102S21***W-E / TR HWT-1402S21***W-E / TR...
Page 265 HWS-CPR01W-E...
Page 266 HWT-602S21***W-E / TR Number of pieces per unit (HWT-) Description 43P00025 PANEL,FRONT, ASSY 43P00021 PANEL, RIGHT SIDE, ASSY 43P00022 PANEL, TOP 43P00023 PANEL, TOP 43P00026 PANEL, BACK, ASSY 43P00024 PANEL, LEFT SIDE, ASSY 43P44004 HEAT EXCHANGER, PIPE ASSY 43P57007 HEATER ASSY, 3KW 43P57008 HEATER ASSY, 6KW 43P77003 PUMP, WATER, ASSY 43P77005 PUMP, WATER, ASSY...
Page 267 HWT-602S21***W-E / TR Number of pieces per unit (HWT-) Location No. Part No. Description Safety 43D50004 SENSOR, TWI 43D50001 SENSOR, TWO 43D50002 SENSOR, THO 43D50005 SENSOR, TC 43P50024 SENSOR, TTW 43D50006 SENSOR, TFI 43P66001 REMOTE CONTROLLER 43P69024 PC BOARD ASSY, MCC1753 43P69015 PC BOARD ASSY, MCC1755 43P60004...
Page 268 HWT-1102S21***W-E / TR Number of pieces per unit (HWT-) Location Part No. Description Safety 43P00025 PANEL, FRONT, ASSY 43P00021 PANEL, RIGHT SIDE, ASSY 43P00022 PANEL, TOP 43P00023 PANEL, TOP 43P00026 PANEL, BACK, ASSY 43P00024 PANEL, LEFT SIDE, ASSY 43P44005 HEAT EXCHANGER, PIPE ASSY 43P57007 HEATER ASSY, 3KW 43P57008...
Page 269 HWT-1102S21***W-E / TR Number of pieces per unit (HWT-) Location No. Part No. Description Safety 43D50004 SENSOR, TWI 43D50001 SENSOR, TWO 43D50002 SENSOR, THO 43D50005 SENSOR, TC 43P50024 SENSOR, TTW 43D50006 SENSOR, TFI 43P66001 REMOTE CONTROLLER 43P69024 PC BOARD ASSY, MCC1753 43P69015 PC BOARD ASSY, MCC1755 43P60004...
Page 270 HWT-1402S21***W-E / TR Number of pieces per unit (HWT-) Location Part No. Description Safety 43P00025 PANEL, FRONT, ASSY 43P00021 PANEL, RIGHT SIDE, ASSY 43P00022 PANEL, TOP 43P00023 PANEL, TOP 43P00026 PANEL, BACK, ASSY 43P00024 PANEL, LEFT SIDE, ASSY 43P44006 HEAT EXCHANGER, PIPE ASSY 43P57007 HEATER ASSY, 3KW 43P57008...
Page 271 HWT-1402S21***W-E / TR Number of pieces per unit (HWT-) Location No. Part No. Description Safety 43D50004 SENSOR, TWI 43D50001 SENSOR, TWO 43D50002 SENSOR, THO 43D50005 SENSOR, TC 43P50024 SENSOR, TTW 43D50006 SENSOR, TFI 43P66001 REMOTE CONTROLLER 43P69025 PC BOARD ASSY, MCC1753 43P69015 PC BOARD ASSY, MCC1755 43P60004...
Page 272 Outdoor Unit (HWT-401HW-E(TR), HWT-601HW-E(TR))
Page 273 Inverter Assembly (HWT-401HW-E(TR), HWT-601HW-E(TR))
Page 274 Number of pieces per unit Safety Location Part No. Description HWT- HWT- 401HW-E / TR 601HW-E / TR 43P00012 PANEL, AIR OUTLET, ASSY 43P00013 PANEL, SIDE, RIGHT, ASSY 43P00014 PANEL, SIDE, LEFT, ASSY 43P00015 PANEL, ROOF, ASSY 43P00016 COVER, PACKED, VALVE 43P19003 GUARD, FAN "COMPRESSOR, ASSY,...
Page 275 Outdoor Unit (HWT-801HW-E(TR), HWT-1101HW-E(TR), HWT-801HRW-E, HWT-1101HRW-E)
Page 276 Inverter Assembly (HWT-801HW-E(TR), HWT-1101HW-E(TR), HWT-801HRW-E, HWT-1101HRW-E)
Page 277 Number of pieces per unit Safety Location HWT- HWT- HWT- HWT- Part No. Description 801HW 801HRW 1101HW 1101HRW -E / TR -E / TR 43P00005 PANEL, AIR OUTLET 43P00017 PANEL, FRONT, ASSY 43P00020 PANEL, SIDE, RIGHT, ASSY 43P00008 PANEL, ROOF, ASSY 43P00009 PANEL, FRONT, PIPING 43P00010...
Page 278 Outdoor Unit (HWT-1401HW-E (TR), HWT-1401HRW-E)
Page 279 Inverter Assembly (HWT-1401HW-E (TR), HWT-1401HRW-E)
Page 280 Number of pieces per unit Safety Location Part No. Description HWT- HWT- 1401HW-E / TR 1401HRW-E 43P00005 PANEL, AIR OUTLET 43P00017 PANEL, FRONT, ASSY 43P00020 PANEL, SIDE, RIGHT, ASSY 43P00008 PANEL, ROOF, ASSY 43P00009 PANEL, FRONT, PIPING 43P00010 PANEL, BACK, PIPING, ASSY 43P00011 STAY 43P09001...
Page 281 Outdoor Unit (HWT-801H8(R)W-E, HWT-1101H8(R)W-E, HWT-1401H8(R)W-E)
Page 282 Inverter Assembly (HWT-801H8(R)W-E, HWT-1101H8(R)W-E, HWT-1401H8(R)W-E)
Page 283 Number of pieces per unit Safety Location HWT-801H8W-E HWT-801H8RW-E Part No. Description HWT-1101H8W-E HWT-1101H8RW-E HWT-1401H8W-E HWT-1401H8RW-E 43P00005 PANEL, AIR OUTLET 43P00017 PANEL, FRONT, ASSY 43P00020 PANEL, SIDE, RIGHT, ASSY 43P00008 PANEL, ROOF, ASSY 43P00009 PANEL, FRONT, PIPING 43P00010 PANEL, BACK, PIPING, ASSY 43P00011 STAY 43P09001...
Page 284: Appendix
Appendix PC board Replacement Procedure Manual REPLACEMENT OF SERVICE PC BOARD (MCC-1753) [Requirement of replacing the Hydro unit Main PC board assembly] In the memory of the Hydro unit Main PC board before replacement, the type and the capacity code of the model have been stored at the factory, and the customer setup data have been stored after installation.
Page 285 ❐1 Readout of the setup data from the memory 1 Readout of the setup data from the memory Readout of the Memory (factory setup data and customer setup data) Readout of the Memory (factory setup data and customer setup data) 1. Press the [ ] button and the [ ] button at same time for at least 4 sec.
Page 286 2 Replacement of service main PC board Refer to the Service Manual for more detail. WARNING For 1 minute after the power is turned off, do not disassemble the inverter to prevent an electric shock. Detachment 1. Remove all connectors connected to the main PC board and remove a screw of earth lead wire. 2.
Page 287 ❐3 Setting of the setup data to the memory 3 Setting of the setup data to the memory The default setup data are stored in the memory of the service main PC board. The default setup data are stored in the memory of the service main PC board. 1.
Page 288 Hydro Unit DN table Factory default Item Details Wall Mouned type All In One type 2 series Cooling/Non-cooling switching 0000: Cooling 0001: Non cooling 0000: Cooling Central control address 0001 - 0128 None Hot Water boost operation time (operating 0003: 30 min 0018: 180 min 0006: 60 min time)
Page 289 Item Details Factory default Wall Mouned type All In One type 2 series 3A Frost protection function Invalid/Valid 0000 Invalid 0001: Valid 0001: Valid Frost protection temperature 0008 8 °C 0020: 20 °C 0015: 15 °C 2-w ay valve operation (logical reverse) 0000 Activate during cooling Deactivate during 0000: Activate during cooling...
Page 290 Factory default Item Details Wall Mouned type 1 All In One type 2 series Set temperature B’ with outside temperature 0020: 20 °C - 0055: 55 °C(401/601), 0035: 35°C of T1 0065: 65 °C(801/1101/1401) Set temperature E with outside temperature 0020: 20 °C - 0055: 55 °C(401/601), 0020: 20°C...
Page 291 Factory default Item Details Wall Mouned type 1 All In One type 2 series Boiler output enabled 0000: No 0001:Yes 0000: No Boiler install position after 3WV heating side 0000: After 3WV heating side 0000: After 3WVheating Not Use / before 0001: Before 3WV side External cylinder thermostat connected...
Page 292 43P-69-001 P.C.Board Replacement Procedure Manual P.C.Board Replacement Procedure Manual P . C. Bo a r d (M C C- 1 7 6 8 ) P.C.Board (MCC-1768) Replacement Procedure Manual R e p l a c em e n t P r oc e d u r e M a nu a l ! WARNING WARNING Don’t open the inverter cover before 1 minute after power has been turned off because an electric shock may be occurred.
Page 293 43P-69-006 P.C.Board Replacement Procedure Manual PC board Replacement Procedure Manual P.C.Board (MCC-1675) Replacement Procedure Manual REPLACEMENT OF SERVICE PC BOARD ! WARNING WARNING Don’t open the inverter cover before 1 minute after power has been turned off because an electric shock may be occurred. Don’t open the inverter cover before 1 minute after power has been turned off because an electric shock may be occurred.
Page 294 43P- 69- 020 43P- 69- 020 PC board Replacement Procedure Manual P.C.Board Replacement Procedure Manual PC board Replacement Procedure Manual REPLACEMENT OF SERVICE PC BOARD P.C.Board (MCC-1781) REPLACEMENT OF SERVICE PC BOARD Replacement Procedure Manual ! WARNING ! WARNING Don’t open the inverter cover before 5 minute after power has been turned off Don’t open the inverter cover before 5 minute after power has been turned off because an electric shock may be occurred.
Page 295 HWT-401HW-E(TR) Pressure Pipe surface temperature (˚C) Com- Water Conditions Indoor / Outdoor pressor Outdoor temp. conditions Dis- Entering Leaving revolu- (MPa) (kg/cm Suction heat ex- BPHE Flowrate (DB/WB) (˚C) charge water water tions per changer second (TD) (TS) (TE) (TC) (TWI) (TWO) L/min...
Page 296 HWT-801HW-* Pressure Pipe surface temperature (˚C) Com- Water Conditions Indoor / Outdoor pressor Outdoor temp. conditions Dis- Entering Leaving revolu- (MPa) (kg/cm Suction heat ex- BPHE Flowrate (DB/WB) (˚C) charge water water tions per changer second (TD) (TS) (TE) (TC) (TWI) (TWO) L/min...
Page 297 HWT-1401HW-* Pressure Pipe surface temperature (˚C) Com- Water Conditions Indoor / Outdoor pressor Outdoor temp. conditions Dis- Entering Leaving revolu- (MPa) (kg/cm Suction heat ex- BPHE Flowrate (DB/WB) (˚C) charge water water tions per changer second (TD) (TS) (TE) (TC) (TWI) (TWO) L/min...
Page 298 HWT-1101H8W-E Pressure Pipe surface temperature (˚C) Com- Water Conditions Indoor / Outdoor pressor Outdoor temp. conditions Dis- Entering Leaving revolu- (MPa) (kg/cm Suction heat ex- BPHE Flowrate (DB/WB) (˚C) charge water water tions per changer second (TD) (TS) (TE) (TC) (TWI) (TWO) L/min...
Page 299 MEMO...

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Toshiba HWT-602S21SM3W-E(TR) Service Manual

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