Heat Pump User Manual

ManualsBrandsToshiba ManualsHeat PumpHWS-802XWHT6-E

Toshiba

Model name:

Outdoor Unit

HWS-802H-E

HWS-1102H-E

HWS-1402H-E

AIR TO WATER HEAT PUMP

Hydro Unit

HWS-802XWHM3-E

HWS-802XWHT6-E

HWS-1402XWHM3-E

HWS-1402XWHT6-E

HWS-1402XWHT9-E

Hot Water Cylinder

HWS-1501CSHM3-E(-UK)

HWS-2101CSHM3-E(-UK)

HWS-3001CSHM3-E(-UK)

SERVICE MANUAL

A09-002

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

Summary of content (168 pages)

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+00A09-002_01EN_SVM_ALL_Air_to_Water.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 1 Monday, October 5, 2009 2:09 PM Contents 1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 NEW REFRIGERANT (R410A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2-1.Safety During Installation and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2-2.Installing refrigerant pipe . . . . . . . .
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 2 Monday, October 5, 2009 2:09 PM 9 Method of Defect Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 9-1.Matters to be confirmed first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 9-1-1.Check the power supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 9-1-2.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 3 Monday, October 5, 2009 2:09 PM 1 SAFETY PRECAUTIONS The unit and this service guide list very important safety precautions. Understand the following details (indications and symbols) before reading the body text, and follow the instructions. [About indication] Indication Meaning of Indication DANGER Indicates that a wrong operation may cause a service engineer and the third persons around to get fatal or serious injuries.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 4 Monday, October 5, 2009 2:09 PM WARNING Do not modify the unit. • Do not disassemble or modify the parts also. • A fire, an electric shock, or an injury may occur. Use the specified parts (∗) when replacing them. • Using parts other than specified ones may cause a fire or an electric shock. ∗: For details, see the parts price list.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 5 Monday, October 5, 2009 2:09 PM WARNING After the work is completed, check with an insulating-resistance tester (500V) that the insulation resistance between the live and dead-metal parts is 2 MΩ or higher. • A low insulation resistance may cause a disaster at a customer site due to electrical leakage or an electric shock. Ventilate if refrigerant gas leaks during service work.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 6 Monday, October 5, 2009 2:09 PM 2 NEW REFRIGERANT (R410A) This Air to Water Heat Pump adopts a new refrigerant HFC (R410A) to prevent destruction of the ozone layer. The working pressure of R410A refrigerant is 1.6 times higher than that of the conventional refrigerant R22.The refrigerant oil is also changed for the new refrigeration.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 7 Monday, October 5, 2009 2:09 PM 2-2. Installing refrigerant pipe 2-2-1. Steel pipe and joint For refrigerant piping, steel pipe and joints are mainly used. Select those comply with JIS (Japanese Industrial Standards) for a service work. Also, use such clean piping materials that less impurities attach to the inside of pipe and joints.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 8 Monday, October 5, 2009 2:09 PM 2-2-2. Processing of piping materials When installing refrigerant pipe, prevent water or dust from entering the pipe, and do not use oil other than lubricant used for Air to Water Heat Pump. Make sure that no refrigerant leak occurs. If piping needs lubrication, use lubricating oil whose water content is removed. After the oil is put in, be sure to seal the container with airproof cover or other covers.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 9 Monday, October 5, 2009 2:09 PM Flare connecting procedure and precautions 1) Make sure that the flare and connecting portions do not have any flaw and dust. 2) Correctly align the flared surface and the connecting axis. 3) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is the same as that for the conventional R22. If the torque is weak, gas leakage may occur.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 10 Monday, October 5, 2009 2:09 PM 2-3. Tools 2-3-1. Necessary tools In Air to Water Heat Pump using R410A, the service port diameter of packed valve of the outdoor unit is changed to prevent mixing of other refrigerant. To reinforce the pressure resistance, flare dimensions and opposite side dimensions of flare nut (For Ø 12.7 copper pipe) of the refrigerant piping are lengthened.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 11 Monday, October 5, 2009 2:09 PM 2-4. Recharging of refrigerant Recharge, if necessary, the specified amount of new refrigerant according to the following procedure. Recover the refrigerant, and check that no refrigerant remains in the refrigerant cycle. Open fully the handle of gauge manifold Lo, turn on the vacuum pump, and then perform vacuum evacuating. Connect the charge hose to packed valve service port on the outdoor unit's gas side.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 12 Monday, October 5, 2009 2:09 PM NOTE • Make sure that the setting is appropriate so that liquid can be charged. • A cylinder with siphon enables liquid to be charged without the cylinder turned upside down.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 13 Monday, October 5, 2009 2:09 PM 2-5. Brazing of pipes Type of flux • Non-corrosive flux It is generally a compound of borax and boric acid. It is effective when brazing temperature is higher than 800 °C. • Active solvent Most of this type of flux is generally used for silver brazing.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 14 Monday, October 5, 2009 2:09 PM 5) Use the reducing valve to adjust the nitrogen gas flow speed to 0.05 m3/hour or 0.02 MPa (0.2 kgf/cm2). 6) After the steps above, keep the nitrogen gas flowing until the pipe cools down to a certain extent. (Temperature where the pipe is cool enough to be touched by hands) 7) Remove the flux completely after brazing.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 15 Monday, October 5, 2009 2:09 PM 3 Specifications Unit name Hydro unit HWS-802XWHM3-E, 802XWHT6-E Outdoor unit HWS-802H-E Heating capacity *1 (kW) 8.0 Cooling capacity *2 (kW) 6.0 Variable range of compressor frequency 10 - 70 Hz Power source Single phase 50Hz 230V Operation mode Electric characteristic *1 *2 Heating Hydro unit Outdoor unit Total Operating noise *1 *2 *4 0.98 0.46 Power (kW) 0.101 0.097 Power factor (%) 91.5 91.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 16 Monday, October 5, 2009 2:09 PM Unit name Hydro unit HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E Outdoor unit HWS-1102H-E HWS-1402H-E Heating capacity *1 (kW) 11.2 14.0 Cooling capacity *2 (kW) 10.0 11.0 10 - 60Hz 10 - 70 Hz Variable range of compressor frequency Power source Single phase 50Hz 230V Operation mode Electric characteristic *1 *2 Hydro unit Cooling Heating Current (A) 0.63 0.61 0.67 0.63 Power (kW) 0.135 0.130 0.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 17 Monday, October 5, 2009 2:09 PM 4 Outside Drawing 4-1. Hydro unit HWS-802XWHM3-E, 802XWHT6-E 19.5 HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E 2-dia.12x17 long hole (for dia.8-10 anchor bolt) 355 B leg part 9 371.5 380 40 Anchor bolt long hole pitch 72.5 72.5 960 Anchor bolt long hole pitch 925 20 40.5 352 525 Manometer 20 40 2-dia.12x17 U-shape hole (for dia.8-10 anchor bolt) Hot water outlet connecting pipe 1 1/4" 135.5 116 186.
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88 burring hole) 7 Z arrow view 83 327 178 Knockout for lower part of piping 60 68 (12- 3 embossed) 52 150 383 518 178 550 178 900 600 Air outlet 75 46 17.5 365 118 128 Optional mounting hole 20 Air inlet 34 170 Portion A 80 135 Refrigerant gas connection ( 15.9 flare) 18 ( 18 30 151 80 Mounting bolt hole 12 17 long hole) Details of portion A 40 Refrigerant liquid connection ( 9.5 flare) 96 39 55 95 17.
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7 Z arrow view 83 128 118 150 68 60 52 Knockout for lower part of piping Optional mounting hole (24- 3 embossed) 360 327 178 383 518 178 550 34 170 178 900 70 Portion A 600 Air outlet 75 46 17.5 17.5 365 74 20 88 burring hole) Air inlet 80 Z 135 18 1 2 1 2 18 30 Refrigerant gas connection ( 15.9 flare) 151 80 Mounting bolt hole ( 12 17 long hole) Details of portion A 40 Refrigerant liquid connection ( 9.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 20 Monday, October 5, 2009 2:09 PM 4-3. Hot water cylinder HWS-2101CSHM3-E(-UK) HWS-3001CSHM3-E(-UK) 550 595 595 550 2040 2066.6 Specification for UK only 1474 1497.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 21 Monday, October 5, 2009 2:09 PM 5 Wiring Diagram 5-1. Hydro Unit WARNING *Option THO *Option LPS CN10 (WHI) YEL 9 9 8 BLU 7 7 6 BRW 5 5 4 3 2 WHI 1 1 WHI RED CR10 RY 10 CR11 RY 11 CR12 RY 12 RY 13 CR13 CN02 (WHI) 5 4 3 2 1 5 4 3 2 1 RED BLU ORN GRN BRW 5 4 3 2 1 6 5 4 3 2 1 Color indentification 6A 6B 6C 6D RED BLK WHI BLK BLK BLK BLK BLK BLK 7A 7B GRY Electric shock may happen. Don't touch the electric parts.
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External input (White) (White) (White) (Yellow) (White) (White) (Yellow) (Blue) Operating power (White) 4-way valve coil (White) G W Earth screw Hydro unit Earth screw Outdoor unit (White) (White) Control board HMS-1102, 1402H-E only (White) (White) Upper Reactor R B R W Red 50Hz 230V White Power supply single phase Earth screw B Item nam Compressor Fan motor Pulse motor valve coil Discharge temperature sonsor Suction temperature sensor Heat exchange sensor 1 Heat exchange
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 23 Monday, October 5, 2009 2:09 PM 5-3. Hot Water Cylinder Unit Blue Green / Yellow Double pole thermal cut out Blue Brown Brown 1 2 TB03(230V) Green / Yellow A B TB06(TTW) TTW sensor Hot water cylinder heater Supply 230 V from hydro unit Cable size 1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 24 Monday, October 5, 2009 2:09 PM 6 Key Electric Component Rating 6-1. Hydro Unit HWS-802XWHM3-E, 802XWHT6-E Model name No. 1 2 Component name Circulating pump Backup heater 6 kW Type name M3-E T6-E O O O O UPS025-65 K 130 Rating AC230 V 0.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 25 Monday, October 5, 2009 2:09 PM HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E Model name No. Component name Type name Rating M3-E T6-E T9-E 1 Circulating pump O O 2 Backup heater 6 kW O O 3 Backup heater 9 kW 4 Water heat exchange temperature sensor (TC sensor) O 5 Water inlet temperature sensor (TWI sensor) 6 O UPS25-80 130 AC230 V 0.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 26 Monday, October 5, 2009 2:09 PM 6-2. Outdoor Unit HWS-802H-E No. Component name Type name Rating 1 Compressor DA220A2F-22L 2 Outdoor fan motor ICF-280-A60-1 Output 60 W 4-way valve coil VHV-01AP552B1 AC230 full-wave rectifier input, alive time 10 sec or less 4 Pulse motor valve (PMV) coil CAM-MD12TF-15 DC12 V 5 Compressor case thermostat US-622KXTMQO-SS OFF: 125±4°C ON: 90±5°C 6 Reactor CH-56 5.8 mH, 18.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 27 Monday, October 5, 2009 2:09 PM HWS-1102H-E, 1402H-E No. Component name Type name Rating 1 Compressor DA422A3F-25M 2 Outdoor fan motor (x2) ICF-280-A100-1 Output 100 W 3 Reactor (x2) CH-44 1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 28 Monday, October 5, 2009 2:09 PM 6-3. Hot Water Cylinder Unit Model name No. Component name 1501 CSH M3-E (-UK) 2101 CSH M3-E (-UK) 3001 CSH M3-E (-UK) Type name 1 Hot water cylinder heater O O O – 2 Hot water cylinder temperature sensor (TTW sensor) O O O – O O O – 3 Thermal cut-out Rating AC230 V 2.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 29 Monday, October 5, 2009 2:09 PM 6-4.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 30 Monday, October 5, 2009 2:09 PM 6-5. Outdoor Control Board HWS-802H-E Reactor connection connector Power circuit protection fuse F100 (250 V, 3.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 31 Monday, October 5, 2009 2:09 PM HWS-1102H-E, 1402H-E Fan motor output (Lower) CN300(White) Fan motor output (Upper) CN400(White) Compressor output terminals CN202 CN201 CN200 Electrolytic capacitors Case thermostat connector CN609(Blue) Power circuit protection fuse F100(250V,3.
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Outdoor unit 8,11,14kw TC Backup heater Ø1 : 3kW Ø3 : 6kW Ø3 : 9kW Local hot water system 3.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 33 Monday, October 5, 2009 2:09 PM Installation example of water circuit (1) (2) (3) (4) (5) (6) The water circuit for a system without buffer tank ((1), (2), (3), (5)) requires 5 or more branches of Floor heating or Radiator etc. Less than 5 branches may cause a flow deficiency. In this case, please provide a buffer tank and secondary pumps as shown in (4).
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 34 Monday, October 5, 2009 2:09 PM 7-2.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 35 Monday, October 5, 2009 2:09 PM 8 Operational Description This chapter describes the working circuit and control of Air to Water Heat Pump about the following operations.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 36 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. Operation description 8-1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 37 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. 8-1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 38 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. 8-1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 39 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. The following shows the operation modes and controlled objects. 8-2.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 40 Monday, October 5, 2009 2:09 PM Item 8-2. Operation Mode and Control Method Operation flow and applicable data, etc. 2) Heating operation • This operation is enabled when DP_SW12_2 ZONE1 is set to "ON" (default). • The remote controller displays settings, and only the set temperature of can be changed.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 41 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. 3) Cooling operation 8-2. Operation Pressing the [ZONE1, 2] button and then [OPERATION MODE] starts a cooling operation. Mode and Control Method 1) Operation start condition TWI Pressing the [ZONE1, 2] button and then [OPERATION MODE] starts a cooling operation. TSC_F 2) Operation mode selection An operation mode is determined according to the temperature of TWI sensor.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 42 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. 5) Simultaneous operations of "hot water supply" and "cooling" 8-2. Operation For simultaneous operations of "hot water supply" and "cooling", basically cooling runs by a heat pump operation, and Mode and hot water supply by a heater operation.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 43 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. 7) Hot water boost operation 8-2. Operation A hot water boost operation boils water quickly to the set temperature TSC_H = 75°C (FC_09).
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 44 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. 8) Anti bacteria (ANTI BACTERIA) operation 8-2. Operation An anti bacteria operation regularly performs a Hot water supply operation with the set temperature TSC_H = 75°C (can Mode and be set with FC_0A).
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 45 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. 9) Night set back (NIGHT SET BACK) operation 8-2. Operation A night set back operation performs heating at 5°K lower and cooling at 5°K temperatures against the remote controller Mode and set temperature from the setting start time (22:00) to the end time (6:00) every day. Control Method Note) • Set the remote controller time before starting a NIGHT SET BACK operation.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 46 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. 11) AUTO operation 8-2. An auto operation sets the water temperature TSC_F depending on the outside temperature TO by following the table Operation below. Mode and Control Method 1) How to operate • Pressing the remote controller [ZONE1, 2] button and then the [AUTO] button starts AUTO operation for heating.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 47 Monday, October 5, 2009 2:09 PM Item Operation flow and applicable data, etc. 12) Nighttime low-noise operation 8-2. A night time low-noise operation reduces operation frequency and the number of outdoor fan rotations for a certain period Operation during nighttime as noise control for neighborhood. Mode and Control Method Maximum operation frequency 40.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 48 Monday, October 5, 2009 2:09 PM Item 8-3. Hydro Unit Control Operation flow and applicable data, etc. 1) Capacity control (compressor, high-temperature release, low-temperature release) This unit controls the compressor frequency and heater output so that the water outlet temperature matches the remote controller set temperature.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 49 Monday, October 5, 2009 2:09 PM Item 8-3. Hydro Unit Control Operation flow and applicable data, etc. 1-2) High temperature release control A heat pump operation is performed as shown in the table below according to the TC sensor detecting temperature. • For the detected temperature, TC (= TWO + 2 degree) of a heat pump operation is used. The values of T7 through T10 vary depending on TWI.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 50 Monday, October 5, 2009 2:09 PM Item 8-3. Hydro Unit Control Operation flow and applicable data, etc. 2) Heater control 2-1) Hot water supply operation During a hot water heat pump operation, the unit energizes the hot water cylinder heater (2.75 kW) when all the following conditions are met. Note that when the hot water supply set temperature (TSC_F) is reached, the unit stops energizing the heater.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 51 Monday, October 5, 2009 2:09 PM Item 8-3. Hydro Unit Control Operation flow and applicable data, etc. 2) Control at the time of heating heater operation • Controlled Object: Backup heater, Booster heater The backup heater control starts when 13 minutes has passed after the heating heat pump operation started.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 52 Monday, October 5, 2009 2:09 PM Item 8-3. Hydro Unit Control Operation flow and applicable data, etc. 3) Circulation pump control One circulation pump (enhancing pump P2) can be connected to the unit in addition to the built-in circulation pump P1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 53 Monday, October 5, 2009 2:09 PM Item 5) Mixing Valve control (2-temperature heating control) To set different radiator unit supply temperatures or floor heating supply temperatures, the unit performs Mixing Valve control.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 54 Monday, October 5, 2009 2:09 PM Item 8-3. Hydro Unit Control Operation flow and applicable data, etc. 7) Automatic restart control The unit records operation information before a power outage and retrieves the information after the power is on again to restart automatically the operation with the information. 7-1) Operation during remote controller • The operation status before a power outage automatically restarts after the power is on again.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 55 Monday, October 5, 2009 2:09 PM Item 8-3. Hydro Unit Control Operation flow and applicable data, etc. 8-2) Piping freeze prevention control 2 TC and TWO activates freeze prevention regardless of a heat pump operation mode. 1) Determination condition: TWO>20°C, 2*TC+TWO<-12°C is continuously detected for 30 seconds or longer. Or TWO 20°C, TC+TWO<4°C is continuously detected for 30 seconds or longer.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 56 Monday, October 5, 2009 2:09 PM Item 3. Hydro Unit Control Operation flow and applicable data, etc. 10) Room temperature thermostat control (Option board TCB-PCM03E is necessary. Connect the connection cable to the water heat exchange board CN211.) When the room thermostat is connected and heating or cooling operates with DP_SW12-4 set to ON, an room thermostat operation is performed.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 57 Monday, October 5, 2009 2:09 PM Item 8-4. Outdoor unit control Operation flow and applicable data, etc. 1) PMV (Pulse motor valve) control Valve opening is controlled using the expansion valve with a pulse motor according to a heat pump operation status. • PMV is controlled between 30 and 500 pulses during an operation.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 58 Monday, October 5, 2009 2:09 PM Item 8-4. Outdoor unit control Operation flow and applicable data, etc. 3) Current release control The number of compressor rotation is controlled so that current value of the compressor drive circuit does not exceed the specified value. • The outdoor unit detects the input current. • The outside air temperature is detected and used to set the specified value of current.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 59 Monday, October 5, 2009 2:09 PM Item 8-4. Outdoor unit control Operation flow and applicable data, etc. 5) Outdoor fan control The outdoor side control part controls the number of fan motor rotations by receiving an operation instruction from the indoor side (Hydro unit) control part. * Although the fan motor is a DC motor, which has non-step variable numbers of rotations, it is limited to some steps for convenience of control.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 60 Monday, October 5, 2009 2:09 PM Item 8-4. Outdoor unit control Operation flow and applicable data, etc. 5-2) Hot water supply and heating fan 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.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 61 Monday, October 5, 2009 2:09 PM Item 8-4. Outdoor unit control Operation flow and applicable data, etc. 6) Defrosting 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.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 62 Monday, October 5, 2009 2:09 PM Item 8-4. Outdoor unit control Operation flow and applicable data, etc. 7) Winding heating control 1) This control energizes the inactive compressor instead of the case heater to warm the compressor. The purpose is 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.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 63 Monday, October 5, 2009 2:09 PM Item 8-4. Outdoor unit control Operation flow and applicable data, etc. 10) High temperature release control 1) To prevent excessive hi pressure rise, operation frequency is controlled by the TL sensor when cooling and by TWO sensor when heating. 2) If the TL sensor when cooling or the TWO sensor when heating detects an abnormal stop zone temperature, the compressor stops and the abnormality detection counter increments.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 64 Monday, October 5, 2009 2:09 PM 9 Method of Defect Diagnosis In order to diagnose the defective part of the heat pump system, first understand the symptom of the defect. (1) Check the operation status. (It does not move, or it moves but stops, etc.) (2) Flashing display on the display part of the hydro unit. (3) Check the “check code” by the remote control. Please refer to the following procedure of defect diagnosis for the identification. No.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 65 Monday, October 5, 2009 2:09 PM 9-1. Matters to be confirmed first 9-1-1. Check the power supply voltage Check that the power supply voltage is AC230 V±23 V. If the power supply voltage is not in this range, it may not operate normally. 9-1-2. Check for any miswiring of the connection cables between the hydro unit and the outdoor unit The hydro unit and the outdoor unit are connected with three connection cables.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 66 Monday, October 5, 2009 2:09 PM 9-3. Outline of the determination diagram The first determination of whether a defective part is in the hydro unit or the outdoor unit can be performed by the following method. 9-3-1. Procedure of defect diagnosis In the case of a defect, please apply the following procedure in order to find the defective part.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 67 Monday, October 5, 2009 2:09 PM 9-3-4. How to diagnose by error code Defect mode detected by the water heat exchange O ... Possible × ....
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 68 Monday, October 5, 2009 2:09 PM Diagnostic functional operation Check code A07 A08 A09 Operational cause Pressure switch operation The pressure switch operates for 300 sec continuously during the heat pump operation. Low pressure sensor operation error The low pressure sensor detected 0.2 MPa or less. Overheat protection operation When the thermostat of the backup heater activates during the operation of the heat pump or backup heater.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 69 Monday, October 5, 2009 2:09 PM Diagnostic functional operation Check code Operational cause Backup Automat present ic reset Determination and action Number of abnormalities Detailed for item confirmation F17 TFI sensor error Open or short circuit in the floor temperature sensor. × O 1. Check the resistance value and disconnection of the floor-inlet temperature sensor (TFI).
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 70 Monday, October 5, 2009 2:09 PM Defect mode detected by the outdoor unit O ... Possible × .... Not possible Diagnostic functional operation Check code Operational cause Backup Automat present ic reset Determination and action Number of abnormalities Detailed item for confirmation F04 TD sensor error Open or short circuit in the discharge temperature sensor. O × 1. Check the resistance value and connection of the discharge sensor (TD).
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 71 Monday, October 5, 2009 2:09 PM Diagnostic functional operation Check code Operational cause Backup Automat present ic reset O × 1. Check the refrigeration cycle (gas leak). 2. Check the case thermostat and connector. 3. Check that the service valve is fully open. 4. Defect of the pulse motor valve. 5. Check for a kinked piping. Operation of case thermostat When the case thermostat exceeds 125°C.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 72 Monday, October 5, 2009 2:09 PM Diagnostic functional operation Check code Operational cause P20 High pressure protection operation When an abnormal stop occurs due to the high pressure release control. When the heat exchange temperature sensor (TL) detects 63°C during the cooling operation. When the water outlet sensor (TWO) detects 60°C during the heating or hot water supply operation.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 73 Monday, October 5, 2009 2:09 PM Defect mode detected by the remote control Diagnostic functional operation Check code Operational cause No communication between hydro Stop Not unit an remote controller displaying at • The remote control wiring is not all connected correctly. (cannot • The hydro unit has not been turned operate by on.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 74 Monday, October 5, 2009 2:09 PM 9-4. Diagnosis flow chart for each error code 9-4-1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 77 Monday, October 5, 2009 2:09 PM [A04] Error Freeze prevention control When the outside temperature or inlet water temperature is low (approx. 20°C or lower) and the room load is large (operation frequency rating), the freeze prevention control may be activated.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 90 Monday, October 5, 2009 2:09 PM [F29] Error EEPROM failure A failure is detected in the IC10 non-volatile memory on the water heat exchanger board during a hot water supply unit operation. Replace the service board. * If the unit does not have EEPROM inserted when the power is turned on, or if EEPROM data read or write is unavailable, automatic address mode repeats. In this case, the intensive control unit displays [97 Abnormal]. (Approx. 3 mins) (Approx.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 91 Monday, October 5, 2009 2:09 PM 9-4-2. Outdoor Unit Failure Detection Diagnosis procedure for each check code • One check code may indicate multiple symptoms. In such a case, see the LED indication on the outdoor board to narrow down the check details. • The handy remote controller displays a check code only when the same failure repeatedly occurs while the LED on the outdoor board indicates an error even if it occurs only once.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 92 Monday, October 5, 2009 2:09 PM Check code [H02] Outdoor LED indication Check and Action procedure (No specific description indicates outdoor unit parts.) [Compressor lock] No Power voltage is normal. 230ACV ± 23V Improve power line Yes Wiring connection is normal. Compressor lead (board side, compressor side) reactor, power lead No Check and correct wiring connection Yes No Compressor is normal.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 93 Monday, October 5, 2009 2:09 PM Check code [L29] Outdoor LED indication Check and Action procedure (No specific description indicates outdoor unit parts.) * Any of the following abnormality may occur. Seeing the LED on the outdoor board can determine which abnormality occurs.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 94 Monday, October 5, 2009 2:09 PM Check code [P03] Outdoor LED indication Check and Action procedure (No specific description indicates outdoor unit parts.) [Abnormal outlet temperature] No gas leakage. Appropriate refrigerant amount.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 95 Monday, October 5, 2009 2:09 PM Check code [P07] Outdoor LED indication Check and Action procedure (No specific description indicates outdoor unit parts.) [Heat sink overheat failure] The screws are loose in motor drive element, Q200/300/400, of outdoor control board and Yes rectifier, DB01/02/03. Radiation grease was not applied to backside of Q200, DB01, DB02, or DB03.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 96 Monday, October 5, 2009 2:09 PM [4-way valve invert failure] 4-way valve operates normally. (Check piping temperature at the time of cooling/heating operation) No Yes Temperature sensor check TE sensor CN601 TS sensor CN600 Hydro TWO sensor If defective, repair or replace it 4-way valve coil resistance is 1.3 to 1.6 k .
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 97 Monday, October 5, 2009 2:09 PM Check code [P20] Outdoor LED indication Check and Action procedure (No specific description indicates outdoor unit parts.) [Hi pressure protection operation] Service valve is fully opened. No Open fully service valve Yes Heating season Heating operation Reset the power source and perform a trail operation according to the season.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 98 Monday, October 5, 2009 2:09 PM Check code [P22] Outdoor LED indication Check and Action procedure (No specific description indicates outdoor unit parts.) [Blower system failure] Power voltage is normal (230ACV ± 23V) No Check wiring Request power source repair Yes When not energized, the fan motor can be smoothly rotated by hand. Fan motor coil resistance is normal.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 99 Monday, October 5, 2009 2:09 PM Outdoor LED indication Check and Action procedure (No specific description indicates outdoor unit parts.) No code [Discharge abnormality] Compressor's loss of synchronism due to rapid load change, etc. * Although the outdoor LED indicates abnormality, the compressor restarts and no abnormality is confirmed. * This may occur due to the open phase of the compressor or wiring detach.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 100 Monday, October 5, 2009 2:09 PM Check code [F12] Outdoor LED indication Check and Action procedure (No specific description indicates outdoor unit parts.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 101 Monday, October 5, 2009 2:09 PM 9-4-3. Temperature sensor, temperature-resistance characteristic table TC, TWI, TWO, TFI, TTW, TE, TS, TO sensors TD, TL sensors Typical value Temperature (°C) Typical value Resistance value (kΩ) (Minimum) (Standard) (Maximum) -10 55.42 55.73 60.04 0 32.33 33.80 10 19.63 20 Resistance value (kΩ) Temperature (°C) (Minimum) (Standard) (Maximum) 0 150.5 161.3 172.7 35.30 10 92.76 99.05 105.6 20.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 102 Monday, October 5, 2009 2:09 PM 9-5. Operation check by PC board switch 9-5-1. Operation check mode This mode allows to check the operations of the water 2-way valve, water 3-way valve, mixing valve, and circulating pump. Operation check mode (1) Preparation • Turn all of the remote controls "OFF" for the hot water supply and heating. • Turn off the hydro unit and the outdoor unit. • Remove the front panel of the hydro unit.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 103 Monday, October 5, 2009 2:09 PM 9-6. Brief method for checking the key components 9-6-1. Hydro unit No. 1 2 Component name Check procedure Water heat exchange temperature (TC) sensor Water inlet temperature (TWI) sensor Water outlet temperature (TWO) sensor Hot water cylinder temperature (TTW) sensor Floor inlet temperature (TFI) sensor Remove the connector and measure the resistance value with a tester.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 104 Monday, October 5, 2009 2:09 PM 9-6-2. Outdoor unit No. 1 Component name Compressor Type DA220A2F-22L (802H-E) DA422A3F-25M (1102,1402H-E) Check procedure Measure the resistance value of each winding with a tester. Red Location Resistance value Red − White 1.04-1.16 Ω White − Black 1.04-1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 105 Monday, October 5, 2009 2:09 PM 10 Hydro unit and Outdoor Unit Settings Hydro unit 1. Hydro unit Setting 1-1. Setting switch names and positions SW01 SW12 SW13 SW02 SW10 SW07 SW11 1-2. SW02 (System switching 1) SW02 02_1 02_2 02_3 02_4 Switching details Factory setting – – – Room thermostat – – – No Remarks OFF OFF OFF OFF 1-3.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 106 Monday, October 5, 2009 2:09 PM 2. Hydro unit Function Code Setting 2-1. How to set function code Perform the following when no operation is in progress. 1 2 3 Press the SET and TEST and SELECT buttons at the same time for 4 seconds or longer. (See display ) Specify CODE NO. (FC) with the TEMP. for temperature setting. Select a setting data with the TIME setting. button button for timer 2 The value in the DATA item changes.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 109 Monday, October 5, 2009 2:09 PM 3. Trial Operation A trial operation is available with an actual operation in progress or stopped. A trial operation is available in any of the hot water supply, heating, or cooling mode. The compressor starts according to the trial operation frequency. A trial operation automatically stops after 30 minutes at the longest if not stopped with the remote controller.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 110 Monday, October 5, 2009 2:09 PM 4. Auto Curve Setting FC code setting can make flexible Auto-Curve settings. 1 Press the TEST and SET and SELECT buttons at the same time for 4 seconds or longer. (See display ) (Make sure that no operation is in progress.) 2 3 4 5 6 Specify an item code (FC) from among 29 to 2F with the TEMP. button for temperature setting. Set data with the TIME Press the SET confirmed) button.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 111 Monday, October 5, 2009 2:09 PM 5. Time Setting 1 Press the TIME button for 4 seconds or longer. (The screen moves to the time setting mode.) (See display ) Day, time, , and indications blink. (Time setting is available during an operation.) 2 Specify a day to be set. Press the DAY button to select the current day. The symbol moves along above the days. ( moves by each button press from MO through SU.) 3 Set time. Use the TIME button to set time.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 112 Monday, October 5, 2009 2:09 PM 6. Scheduled Operation Setting Schedule setting makes the following modes to be flexibly set: hot water supply, heating, cooling, hot water supply and heating, hot water supply and cooling, and stop, and set temperature. 6-1. How to set scheduled operation Set the remote controller time. 1 Press the remote controller SCHEDULE for 4 seconds or longer.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 113 Monday, October 5, 2009 2:09 PM 6-2. How to start and cancel schedule operation Without schedule operation set, press the remote controller SCHEDULE button. blinks. Pressing the SET button during the 5-second blinking changes to lit, and the schedule operation starts. With schedule operation set, press the remote controller SCHEDULE button. blinks.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 114 Monday, October 5, 2009 2:09 PM 8. NIGHT Operation Setting For nighttime hours, this setting changes set temperature of heating or cooling by 5k as save operation. 1 Press the ZONE1,2 operation. (See display button to start a heating or a cooling ) (Nighttime operation is not available for hot water supply. Use the schedule operation.) 2 Pressing the NIGHT button displays the symbol.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 115 Monday, October 5, 2009 2:09 PM 9. Anti Bacteria Setting This setting regularly raises the hot water cylinder temperature to prevent bacteria from growing. 1 Press the HOT WATER supply operation. button to start a hot water (Normal hot water supply operation) (No anti bacteria setting is provided to heating and cooling.) 2 Pressing the ANTI BACTERIA symbol.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 116 Monday, October 5, 2009 2:09 PM 10. Hot Water Boost Setting This setting heats the water whenever necessary by using the heat pump and hot water cylinder heater. 1 Press the HOT WATER supply operation. button to start a hot water (Normal hot water supply operation) 2 Pressing the HOT WATER BOOST symbol. (See display ) button displays the (The set temperature does not change) The hot water supply operation of 75°C starts.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 117 Monday, October 5, 2009 2:09 PM 12. Forced Defrosting Setting The FC code setting (See 2-2) can activate the forced defrosting mode for the outdoor unit operation. (Preparation) 1 2 3 Press the remote controller buttons, TEST , SET , and SELECT , at the same time for 4 seconds or longer.(Make sure that no operation is in progress.) Specify CODE NO. (FC) 46 with the TEMP. button for temperature setting. Set DATA to 0001 with the TIME setting.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 118 Monday, October 5, 2009 2:09 PM 14. Display Function of Set Temperature and Other Settings ■ Sensor temperature display calling
This function calls the service monitor mode from the remote controller to show the data of the remote controller, the hydro unit, and outdoor unit. 1 Press the TEST and CL buttons at the same time for 4 seconds or longer to call the service monitor mode.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 119 Monday, October 5, 2009 2:09 PM 15. Failure History Calling Function
This function calls the previous failure details. 1 Press the TEST and SET buttons at the same time for 4 seconds or longer to call the service check mode. The service check lights up with CODE No. "01" displayed at first, and the latest warning detail is displayed. The warning details of the current warning is displayed.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 120 Monday, October 5, 2009 2:09 PM Outdoor unit 16 Outdoor Unit Setting 16-1. 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. [How to operate] Remove the water in the hydro unit.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 121 Monday, October 5, 2009 2:09 PM 16-3. Service support functions (LED indication, Switch operation method) The following settings are available with dip switches. (1) Overview Using 3 dip switches (SW802, SW803, SW804) and 2 push-button switches (SW800, SW801) can make settings available and confirm operations.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 122 Monday, October 5, 2009 2:09 PM (2) LED indication switching (SW800, SW803 operation) (2) -1. Indication switching list Operating SW803 can switch the indications of LED D800 to D804 on the outdoor control board. Switch Function and details Abnormality indication (Current abnormality) This switch indicates the current abnormality. Without an abnormality, the lights are off.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 123 Monday, October 5, 2009 2:09 PM Indication 1 (Initial indication) D805 (Green) D801 (Yellow) D802 (Yellow) D803 (Yellow) D804 (Yellow) 2 3 4 Legend) ---- Off ---- Light ---- Blink 1 ON 1 ON 2 3 4 Current abnormality Latest abnormality SW803 SW803 D800 (Yellow) (2) -2.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 124 Monday, October 5, 2009 2:09 PM ---- Light SW803 SW803 SW803 3 2 1 ON 2 3 2 1 ON ON 4 3 4 3 2 *See p122 1 ON 3 2 1 ON 3 2 1 ON 3 4 TCJ SW803 2 1 ON LED indication TC* SW803 4 TA SW803 4 TH SW803 4 PMV openness (pulse) 4 Compressor operation frequency (r.p.s.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 125 Monday, October 5, 2009 2:09 PM (3) Special operation for maintenance and inspection (SW801, SW804) SW801 and SW804 can perform the following special operations for maintenance and inspection. 1) Switches the dip switch SW804. (See the table below) 2) Presses the push-button switch SW801 for approx. 1 second. 3) Starts the functions shown below. During the start processing of each function, LED D805 (Green) blinks.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 126 Monday, October 5, 2009 2:09 PM SW804 1 ON 2 3 4 SW804 1 ON 2 3 4 SW804 1 ON 2 3 4 SW804 Self-holding valve release operation (Switch to cooling cycle) Sets relay RY700 to ON. (CN701 Between 1 to 4 Voltage = Approx. 325V) This function operates for 10 seconds. After that it becomes OFF.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 127 Monday, October 5, 2009 2:09 PM 11 How to Exchange Main Parts WARNING Because the electrical components are energized with high voltage, always turn off the power breaker before starting to work. After a repair is complete, perform a trial operation (after attaching the front panel, upper and lower cabinets, and side cabinet) and check that no abnormality including smoke or abnormal noise occurs.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 128 Monday, October 5, 2009 2:09 PM No. 2 Exchange parts name Remote controller Work procedure 1.How to remove 1) Perform the step 1-1. 2) Remove the remote controller from the holder using a flat-blade screwdriver. (Release the stopper.) 3) Disconnect the remote controller cable from the terminal block on the back side of the remote controller. 2.How to attach 1) Attach it in the reverse order of the removal.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 129 Monday, October 5, 2009 2:09 PM No. 4 Exchange parts name Relay board MCC-1431 Work procedure Remarks 1. How to remove 1) Perform the step 1-1. 2) Disconnect the connectors and lead cables connected to other parts from the relay board. 1. Connector CN01: TB 01 3P Terminal block (3P: White) CN02: Water heat exchanger board (5P: White) CN10: TB 05 9P Terminal block (9P: White) Note When removing the connector, release the safety lock of the housing.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 130 Monday, October 5, 2009 2:09 PM No. 6 Exchange parts name Side board Work procedure Remarks 1. Side board (Right) 1) Perform the step 1-1. 2) Remove the fixed screws of the side board (Right). (ST1T Ø4 × 10, 5 screws) 3) Remove the fixed screws of the side board (Right) and the manometer fixing board. (ST1T Ø4 × 10, 2 screws) Side board (Right) 2. Side board (Left) 1) Remove the fixed screws of the side board (Left).
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 131 Monday, October 5, 2009 2:09 PM No. 9 Exchange parts name Expansion vessel Work procedure To replace a water circuit part, first close the water supply source valve and the valve of water pipe connected to the hydro unit. 1) Perform the step 1-1, step 5, 6, and 7. 2) Remove the fixed band of the expansion vessel. (ST1T Ø4 × 8, 4 screws) 3) Remove the expansion vessel connection (threepiece flare nut).
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 132 Monday, October 5, 2009 2:09 PM No. Exchange parts name 12 Pump Work procedure Remarks To replace a water circuit part, first close the water supply source valve and the valve of water pipe connected to the hydro unit. 1. How to remove 1) Perform the step 1-1, step 5, 6, and 10. 2) Remove the fixed screws of the pump fixing board. (ST1T Ø4 × 8, 2 screws) 3) Remove the 2 nuts of the heater connection and the lower side of the pump.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 133 Monday, October 5, 2009 2:09 PM No. Exchange parts name 13 Flow switch Work procedure Remarks To replace a water circuit part, first close the water supply source valve and the valve of water pipe connected to the hydro unit. 1. How to remove 1) Perform the step 1-1 and step 5. 2) Remove the flow switch. The flow switch connection uses an O ring for water seal. Be careful not to scratch the O ring; otherwise, water leakage may occur. 2.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 134 Monday, October 5, 2009 2:09 PM No. Exchange parts name 15 Heater assembly Work procedure Remarks To replace a water circuit part, first close the water supply source valve and the valve of water pipe connected to the hydro unit. 1. How to remove 1) Perform the step 1-1, step 5, 6, 7, and 11. 2) Remove the nut of the heater connection. 3) Remove the 2 fixed screws of the heater. 4) Pull the heater out upward. 5) Remove the insulator from the heater.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 135 Monday, October 5, 2009 2:09 PM No. Exchange parts name 17 Water heat exchanger assembly Work procedure • Close the water piping source valve and the valve of water pipe connected to the hydro unit, and then remove the refrigerant and water piping. • Perform refrigerant recovery with the outdoor unit. • Disconnect all the power source cable, outdoor unit connection cable, and cylinder connection cable. 1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 136 Monday, October 5, 2009 2:09 PM 2. Outdoor Unit 2-1. HWS-802H-E No. 1 Exchange parts name Common procedure Work procedure Note Wear gloves when performing the work. Failure to do so may cause an injury when accidentally contacting the parts. 1. How to remove 1) Stop the operation by remote controller and turn off the breaker. 2) Remove the front panel.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 137 Monday, October 5, 2009 2:09 PM No. 2 Exchange parts name Outlet cabinet Work procedure How to remove 1) Perform the step 1-1. 2) Remove the screws of the outlet cabinet and parting board. (ST1T Ø4 × 8, 3 screws) 3) Remove the screws of the outlet cabinet and bottom board. (Hex Ø4 × 10, 2 screws) 4) Remove the screws of the outlet cabinet and motor base. (ST1T Ø4 × 8, 2 screws) 5) Remove the screws of the outlet cabinet and water heat exchanger.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 138 Monday, October 5, 2009 2:09 PM No. 4 Exchange parts name Electric parts replacement Work procedure 1. Control board 1) Perform the step 1-1. Remarks Control board WARNING For 1 minute after the power is turned off, do not disassemble the inverter to prevent an electric shock. 2) Remove the connector connected to the control board.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 139 Monday, October 5, 2009 2:09 PM No. 4 Exchange parts name Electric parts replacement Work procedure 2. Reactor 1) Perform the step 1-1. Remarks Relay connector 2) Remove the relay connector connected to the control board. 3) Cut the binding tie that binds the compressor leads and relay connectors. 4) Remove the reactor. (Truss B tight screw Ø4 × 6, 2 screws) 5) Attach a new reactor.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 140 Monday, October 5, 2009 2:09 PM No. 5 Exchange parts name Fan motor Work procedure 1) Perform the step 1-1 and step 2. Remarks Propeller fan Turn it right to loosen 2) Remove the fan motor and the flange nut that fixes the propeller fan. • To loosen the flange nut, turn it clockwise. (Turn it counterclockwise for tightening.) 3) Remove the propeller fan. 4) Remove the connector for fan motor from the inverter.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 141 Monday, October 5, 2009 2:09 PM No. 6 Exchange parts name Compressor Compressor lead Work procedure Remarks 1. Remove defective compressor 1) Perform refrigerant gas recovery. Piping panel (Back) 2) Perform the step 1-1 and step 2 and 3. 3) Remove the piping panel (Front). Remove screws of the piping panel (Front) and bottom board. (Hex Ø4 × 10, 2 screws) Remove screws of the piping panel (Front and Back).
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 142 Monday, October 5, 2009 2:09 PM No. 6 Exchange parts name Compressor Compressor lead Work procedure 10) Remove the discharge and suction pipes connected to the compressor by using a burner. Remarks Remove (Outlet pipe) Remove (Suction pipe) WARNING When removing the piping by burning the solder, take enough care for a fire going off at the moment the wax melts if oil remains inside the piping.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 143 Monday, October 5, 2009 2:09 PM No. 6 Exchange parts name Compressor Compressor lead Work procedure 2. Attach the compressor 1) Attach the compressor in the reverse order of the removal. Remarks Compressor lead Wind ferrite core with compressor lead for 4 times. Note) • Be sure to replace the compressor lead after the compressor replacement.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 144 Monday, October 5, 2009 2:09 PM No. 6 Exchange parts name Compressor Compressor lead Work procedure Remarks 3. Vacuuming 1) Connect the vacuum pump to the charge port of the gas piping valve to operate the vacuum pump. 2) Perform vacuuming until the vacuum low pressure gauge shows 1(mmHg). Note) Open fully the pulse motor valve before vacuuming. With the valve closed, vacuuming between the outdoor unit liquid valve and the pulse motor valve may fail.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 145 Monday, October 5, 2009 2:09 PM No. 8 Exchange parts name Fan guard Work procedure 1. How to remove 1) Perform the step 1-1 and step 2. Remarks Bellmouth Outlet cabinet Note Perform a replacement work on cardboard or cloth to prevent the product from being damaged. 2) Remove the outlet cabinet and put with the fan guard side down. 3) Release the hooks (8 positions) of the fan guard. 2.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 146 Monday, October 5, 2009 2:09 PM 2-2. HWS-1102H-E, 1402H-E No. 1 Exchange parts name Common procedure Work procedure Note Wear gloves when performing the work. Failure to do so may cause an injury when accidentally contacting the parts. Remarks Front panel 1. How to remove 1) Stop the operation by remote controller and turn off the breaker. 2) Remove the front panel.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 147 Monday, October 5, 2009 2:09 PM No. 2 Exchange parts name Outlet cabinet Work procedure How to remove 1) Perform the step 1-1. 2) Remove the screws of the outlet cabinet and parting board. (ST1T Ø4 × 8, 4 screws) 3) Remove the screws of the outlet cabinet and bottom board. (Hex Ø4 × 10, 2 screws) 4) Remove the screws of the outlet cabinet and motor base. (ST1T Ø4 × 8, 2 screws) 5) Remove the screws of the outlet cabinet and heat exchanger.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 148 Monday, October 5, 2009 2:09 PM No. 4 Exchange parts name Electric parts replacement Work procedure 1. Control board 1) Perform the step 1-1. WARNING For 1 minute after the power is turned off, do not disassemble the inverter to prevent an electric shock.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 149 Monday, October 5, 2009 2:09 PM No. 4 Exchange parts name Electric parts replacement Work procedure 2. Reactor 1) Perform the step 1-1. 2) Remove the reactor lead connected to the control board. CN05 White, CN06 White Remarks Binding tie (Compressor lead, Reactor lead) Reactor lead Control board 3) Cut the binding tie that binds the compressor leads and fan motor leads. 4) Remove the reactor.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 150 Monday, October 5, 2009 2:09 PM No. 5 Exchange parts name Fan motor Work procedure Remarks 1) Perform the step 1-1 and step 2. Turn it right to loosen Propeller fan 2) Remove the fan motor and the flange nut that fixes the propeller fan. • To loosen the flange nut, turn it clockwise. (Turn it counterclockwise for tightening.) 3) Remove the propeller fan. 4) Remove the connector for fan motor from the inverter.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 151 Monday, October 5, 2009 2:09 PM 6 Exchange parts name Compressor Compressor lead Work procedure 1. Remove defective compressor 1) Perform refrigerant gas recovery. 2) Perform the step 1-1 and step 3. 3) Remove the piping panel (Front). Remove screws of the piping panel (Front) and bottom board. (Hex Ø4 × 10, 2 screws) Remove screws of the piping panel (Front and Back). (Hex Ø4 × 10, 1 screws) 4) Remove the piping panel (Back).
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 152 Monday, October 5, 2009 2:09 PM No. 6 Exchange parts name Compressor Compressor lead Work procedure 2. Attach the compressor 1) Attach the compressor in the reverse order of the removal. Note) • Be sure to replace the compressor lead after the compressor replacement. (Compressor lead spare parts code: 43160591) At this time, wind the ferrite core with the compressor lead for 4 times.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 153 Monday, October 5, 2009 2:09 PM No. 7 Exchange parts name Work procedure Pulse motor valve coil 1. How to remove 1) Perform the step 1-1. 2) Remove the coil from the pulse motor valve body by pulling upward while rotating the coil. Remarks Recess Pulse motor valve body 2. How to attach 1) Fix the coil by exactly adjusting the coil positioning projection to the recess of the pulse motor valve body. Positioning projection 8 Fan guard 1.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 154 Monday, October 5, 2009 2:09 PM 12 Periodic Inspection Items For a long-term safe operation of this equipment, perform periodic inspection and parts replacement. Hydro unit (HWS-802**-E, 1402**-E) Frequency Periodic inspection details 1. Insulation measurement (Power source circuit/ Heater circuit) Annually Insulation measurement with a mega tester 2.
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