Toshiba Heat Pump HWS 1402H E User Manual

A09-002

AIR TO WATER HEAT PUMP

SERVICE MANUAL

Model name:

Hydro Unit

Outdoor Unit

HWS-802XWHM3-E

HWS-802XWHT6-E

HWS-1402XWHM3-E

HWS-1402XWHT6-E

HWS-1402XWHT9-E

HWS-802H-E

HWS-1102H-E

HWS-1402H-E

Hot Water Cylinder

HWS-1501CSHM3-E(-UK)

HWS-2101CSHM3-E(-UK)

HWS-3001CSHM3-E(-UK)

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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.Check for any miswiring of the connection cables between the hydro unit and the

outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

9-1-3.About the installation of the temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

9-2.Non-defective operation (program operation) … No fault code display appears.. . . . . . . . . . . . . . 65

9-3.Outline of the determination diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

9-3-1.Procedure of defect diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

9-3-2.How to determine from the check code on the remote control . . . . . . . . . . . . . . . . . . . . . 66

9-3-3.How to cancel a check code on the remote controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

9-3-4.How to diagnose by error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9-4.Diagnosis flow chart for each error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9-4-1.Hydro unit failure detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9-4-2.Outdoor Unit Failure Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

9-4-3.Temperature sensor, temperature-resistance characteristic table . . . . . . . . . . . . . . . . . 101

9-5.Operation check by PC board switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

9-5-1.Operation check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

9-6.Brief method for checking the key components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

9-6-1.Hydro unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

9-6-2.Outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

10 Hydro unit and Outdoor Unit Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

11 How to Exchange Main Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

12 Periodic Inspection Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

13 Part Exploded View, Part List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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1 SAFETY PRECAUTIONS

Understand the following details (indications and symbols) before reading the body text, and follow the instructions.

The unit and this service guide list very important safety precautions.

[About indication]

Indication

Meaning of Indication

Indicates that a wrong operation may cause a service engineer and the third persons

around to get fatal or serious injuries.

DANGER

Indicates that a wrong operation may cause a service engineer and the third persons

around to get fatal or serious injuries, or that unit defective after the operation may cause

a user to have a similar serious accident.

WARNING

CAUTION

Indicates that a wrong operation may cause a service engineer and the third persons

around to get injuries or may cause property damage*, or that unit defective after the

operation may cause a user to have a similar accident.

* Property damage indicates extended damage to property, furniture, livestock, or pets.

[About symbols]

Symbols

Meaning of Symbols

Indicates a forbidden action.

Specific forbidden actions are described in text near the symbol.

Indicates a forcible (must do) action.

Specific forcible actions are described in text near the symbol.

Indicates a caution (including danger and warning).

Specific cautions are described in picture or text inside or near the symbol.

DANGER

Turn off the power breaker before removing the front panel and cabinet.

• Failure to do so may cause a high voltage electric shock, leading to death or injury.

• During an operation, the second side circuit of high pressure transmission(*) are applied with a high voltage of 230V

or higher.

• Touching the circuit even with an electrical insulator, let alone a bare hand or body, causes an electric shock.

∗: For details, see the schematic.

When the front panel and cabinet are removed, make short-circuit current to discharge between high pressure

capacitor terminals.

• Failure to do so may cause a high voltage electric shock, leading to death or injury.

• After the power is turned off, the high pressure capacitor is still charged with high voltage.

Do not turn on the power breaker after removing the front panel cabinet.

• Failure to do so may cause a high voltage electric shock, leading to death or injury.

WARNING

Before starting failure diagnosis or repair, check that the ground wire (∗) is connected to the unit ground terminal.

• An unconnected ground wire could cause an electric shock if electric leakage occurs.

• If the earth ground is not properly connected, ask an electrical worker for rework of the ground connection.

∗: Ground wire of class D grounding

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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.

Keep any person (including children) other than service engineers away from a failure diagnosis or repairing place.

• A tool or disassembled parts may cause an injury.

• Advise the customer to keep the third persons (including children) away from the unit.

After connecting a cut lead with a crimp contact, discharge by facing the closed side upward.

• Connect lead wires with crimping terminals and turn the closed end upwards to avoid exposure to water.

Observe the following instructions when repairing the refrigerant cycle.

(1) Watch out for surrounding fire. Always put out the fire of stove burner or other devices before starting the repair.

Should the fire fail to be put out, the oil mixed with refrigerant gas could catch fire.

(2) Do no use a welder in a closed room.

A room with no ventilation may cause carbon monoxide poisoning.

(3) Keep away flammable materials.

The materials may catch the fire of a welder.

Check the refrigerant name to use the tools and members appropriate for the refrigerant.

• A product using the refrigerant R410A has the refrigerant name prominently displayed on its outdoor unit. In

addition, the diameter of the service port is changed from that of the conventional R22 to prevent incorrect filling.

Never use refrigerant other than R410A for Air to Water Heat Pump using R410A. Also, never use R410A for Air to

Water Heat Pump using other refrigerant (such as R22).

• A mixture of R410A with different ones excessively raises the pressure in the refrigerant cycle, leading to an injury

due to burst.

Do not make additional charge of the refrigerant.

• An additional charge when refrigerant gas leaks changes the refrigerant composition in the refrigerant cycle,

causing the characteristics change of the Air to Water Heat Pump or excessive high pressure in the refrigerant

cycle with more than the specified amount of refrigerant charged. This may cause burst or an injury. If the

refrigerant gas leaks, perform refrigerant recovery or other operation to make the Air to Water Heat Pump contain

no refrigerant, and then perform vacuuming. After that, refill the unit with the defined amount of liquid refrigerant.

Never charge refrigerant exceeding the amount specified.

When the refrigerant cycle is refilled with refrigerant, do not enter air or refrigerants other than the specified

refrigerant, R410A.

• A mixture of R410A with air or an inappropriate substance causes excessive high pressure inside the refrigerant

cycle, leading to an injury due to burst.

Check that there is no refrigerant gas leak after the installation is completed.

• If it catches fire of a fan heater, a space heater, or a stove, poisonous gases may be produced.

After a repair is completed, be sure to reassemble the parts and put the wiring back to its original state. In addition,

be careful with the internal wiring not to be caught in a cabinet or panel.

• A defective assembly or wiring may cause a disaster at a customer site due to electrical leakage or a fire.

After the repair of a water pathway is completed, check that there is no water leak.

• In using the product, water leak may cause a fire at a customer site due to electrical leakage or an electric shock.

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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.

• Should refrigerant gas catch fire, poisonous gases may be produced. A closed room full of leaking refrigerant

results in the absence of oxygen; it is dangerous. Make sure to ventilate.

<Caution: electric shock>

When checking a circuit while energized if necessary, use rubber gloves not to contact the live part.

• Contact with the live part may cause an electric shock.

• The unit contains high-voltage circuits. Contact with a part in the control board with your bare hand may cause an

electric shock. Take enough care to check circuits.

Because the electrical components are energized with high voltage, always turn off the power breaker before

starting to work.

• Failure to do so may cause an electric shock.

Should refrigerant gas leak, find where the gas leaks and properly repair it.

• To stop the repair work because the leakage location cannot be identified, perform refrigerant recovery and close

the service valve. Failure to do so may cause the refrigerant gas to leak in a room. Although refrigerant gas alone

is harmless, if it catches fire of a fan heater, a space heater, or a stove, poisonous gases may be produced.

When installing the unit or re-installing it after relocation, follow the installation guide for proper operation.

• A defective installation may cause a refrigerant cycle defective, a water leak, an electric shock, or a fire.

After a repair is completed, check for any abnormality.

• Failure to do so may cause a fire, an electric shock, or an injury.

• Turn off the power breaker to perform check.

After a repair is completed (and the front panel and cabinet are placed), make a test run to check for any abnormality

such as smoke or abnormal sound.

• Failure to do so may cause a fire or an electric shock. Place the front panel and cabinet before making a test run.

Check that the following are properly performed after re-installation.

(1) The ground wire is properly connected.

(2) The installation is stable without any tilt or wobbles.

Failure to check them may cause a fire, an electric shock, or an injury.

CAUTION

Wear gloves (∗) when performing repair.

• Failure to do so may cause an injury when accidentally contacting the parts.

∗: Thick gloves such as cotton work gloves

Perform service work when the unit becomes cool enough after the operation.

• High temperature of compressor piping or other equipment after a cooling or heating operation may cause burn.

Tighten a flare nut with a torque wrench in the specified method.

• A flare nut tightened too much might crack after a long period, causing refrigerant leak.

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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. Therefore, during installation or service work, be sure that

water, dust, former refrigerant, or refrigeration machine oil does not enter the refrigerant cycle of the new type

refrigerant Air to Water Heat Pump. A wrong installation or service operation may cause a serious accident.

Read carefully the following instructions to use the tools or members for R410A for safety work.

2-1. Safety During Installation and Service

• Use only the refrigerant R410A for Air to Water Heat Pump using R410A.

A mixture of R410A with different ones excessively raises the pressure in a refrigerant cycle, leading to an injury

due to burst.

• Check the refrigerant name to use the tools and members appropriate for the refrigerant.

A product using the refrigerant R410A has the refrigerant name prominently displayed on its outdoor unit. In

addition, the diameter of the service port is changed from that of the conventional R22 to prevent incorrect filling.

• Ventilate if refrigerant gas leaks during service work.

Should refrigerant gas catch fire, poisonous gases may be produced. A closed room full of leaking refrigerant

results in the absence of oxygen; it is dangerous. Make sure to ventilate.

• When the refrigerant cycle is refilled with refrigerant, do not mix air or refrigerants other than the specified

refrigerant, R410A.

A mixture of R410A with air or an inappropriate substance causes excessive high pressure inside the refrigerant

cycle, leading to an injury due to burst.

• Check that no refrigerant gas leaks after the installation is completed.

Should a refrigerant gas leak in a room and catch fire, poisonous gases may be produced.

• When installing the unit that contains large amount of refrigerant such as Air to Water Heat Pump, take measures

to prevent the refrigerant from exceeding the threshold concentration in case it leaks.

Should leaking refrigerant exceed the threshold concentration could cause an accident due to oxygen deficient.

• When installing the unit or re-installing it after relocation, follow the installation guide for proper operation.

A defective installation may cause a refrigerant cycle defective, a water leak, an electric shock, or a fire.

• Do not modify the product. Do not disassemble or modify the parts also.

A fire, an electric shock, or an injury may occur.

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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.

Copper pipe

Use copper pipe of the “copper and copper alloy seamless pipe” type with attach oil quantity of 40 mg / 10 m or less.

Do not use pipe that is cracked, distorted, or discolored (especially inside).The expansion valve or capillary may

get clogged with impurities.

Considering that Air to Water Heat Pump using R410A is higher in pressure than those using the conventional R22,

be sure to select the material that comply with the standard.

Table 2-1 shows the thickness of copper pipe used for R410A.

Never use commercially available thin-walled copper pipe of 0.8 mm thick or less.

Table 2-1 Wall thickness of copper pipe

Wall thickness (mm)

Nominal diameter

Outer diameter

9.52

R410A

0.80

3/8

5/8

15.88

1.00

Joints

For the joint of copper pipe, flared joint and socket joint are used. Remove impurities from a joint before using it.

• Flared joint

A flared joint cannot be used for the copper pipe whose outer diameter is 20 mm or larger. A socket joint can be

used instead in that case.

Table 2-2-3 and 2-2-4 show the dimensions of flare pipe, the end of flared joint, and flare nuts.

• Socket joint

A socket joint is used to connect the thick-walled pipe of mainly 20 mm or larger in diameter.

Table 2-2 shows the wall thickness of socket joints.

Table 2-2 The minimum wall thickness of socket joints

Reference of outer diameter of

copper pipe connected (mm)

Minimum joint wall thickness

(mm)

Nominal diameter

3/8

5/8

9.52

15.9

0.80

1.00

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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.

Flare and precautions

1) Cut a pipe.

Cut slowly with a pipe cutter so that the pipe is not distorted.

2) Remove burr and flaw.

A burr or flaw in a flare part may cause refrigerant leak. Remove carefully all the burrs, and clean up the

cut ends before installation.

3) Insert a flare nut.

4) Flare

Figure 2-2-1

Flare dimension

Check that the clasps and copper pipe are clean. Flare

correctly using the clasp. Use a flare tool for R410A or the

conventional one. Flare processing dimension varies

depending on the flare tool type. When using the

conventional flare tool, use a gauge for size adjustment

to secure the A dimension.

Table 2-2-3 Flare processing related dimension for R410A

A (mm)

Conventional flare tool

Nominal

diameter

Outer diameter

(mm)

Wall thickness

(mm)

Flare tool for R410A

clutch type

Clutch type

Butterfly-nut type

2.0 to 2.5

3/8

5/8

9.52

15.9

0.8

1.0

0 to 0.5

1.0 to 1.5

2.0 to 2.5

Table 2-2-4 Dimension of flare for R410A and flare nut

Dimension (mm)

Nominal

diameter

Outer diameter

(mm)

Wall thickness

(mm)

Flare nut width

(mm)

3/8

5/8

9.52

15.9

0.8

1.0

13.0

19.1

13.2

19.7

9.7

15.9

24.5

Figure 2-2-2 Relationship between flare nut and flare surface

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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. If it is too strong,

the flare nut may crack and may be made non-removable. When choosing the tightening toque, comply

with values designated by products. Table 2-2-5 shows reference values.

NOTE

When applying oil to the flare surface, be sure to use oil designated by the product. Using any other oil deteriorates

the lubricating oil, possibly causing the compressor to burn out.

Table 2-2-5 Tightening torque of flare for R410A (Reference values)

Nominal diameter

Outer diameter (mm)

Tightening torque N•m (kgf•m)

33 to 42 (3.3 to 14.2)

3/8

5/8

9.52

15.9

66 to 82 (6.8 to 8.2)

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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.

Because the refrigerating machine oil is changed, mixing of oil may generate sludge, clog capillary, or cause other

problems. Accordingly, the tools to be used include:

• tools dedicated for R410A (Those that cannot be used for the conventional refrigerant, R22)

• tools dedicated for R410A, but can be also used for the conventional refrigerant, R22

• tools that can be used for the conventional refrigerant, R22.

The following table shows the tools dedicated for R410A and their interchangeability.

Tools dedicated for R410A (The following tools must be for R410A)

Tools whose specifications are changed for R410A and their interchangeability

Conventionalrefrigerant

R410A Air to Water Hear Pump

Air to Water Heat Pump

installation

No.

Tool to be used

Usage

For R410A

Existenceofnew

equipment

Conventional

equipment can be

used

New equipment can be

used with conventional

refrigerant

Flare tool

Pipe flaring

Yes

*(Note 1)

Yes

*(Note 1)

Copper pipe gauge for

adjusting projection margin

Flaring by conventional

flare tool

Torque wrench (For Ø15.9)

Gauge manifold

Connection of flare nut

Evacuating, refrigerant

charge, run check, etc.

Yes

Charge hose

Vacuum pump adapter

Vacuum evacuating

Refrigerant charge

Yes

Electrical balance for

refrigerant charging

Refrigerant cylinder

Leakage detector

Charging cylinder

Refrigerant charge

Gas leakage check

Refrigerant charge

Yes

*(Note 2)

* (Note 1) Flaring for R410A by using the conventional flare tool requires projection margin adjustment. This

adjustment requires copper pipe gauge or other instrument.

* (Note 2) A charging cylinder for R410A is currently under development.

General tools (Conventional tools are available)

In addition to the above dedicated tools, the following equipment also available for R22 is necessary as the general

tools.

1. Vacuum pump

4. Reamer

5. Pipe bender

6. Level vial

9. Hole core drill (Ø65)

10. Hexagon wrench

(Opposite side 4mm)

11. Tape measure

12. Metal saw

Use this by attaching vacuum pump

adapter.

2. Torque wrench (For Ø6.35)

3. Pipe cutter

7. Screwdriver (+, –)

8. Spanner or Monkey wrench

Also prepare the following equipment for other work methods or run check.

1. Clamp meter

2. Thermometer

3. Insulation resistance meter

4. Electroscope

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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.

When the compound gauge's pointer indicates

-0.1 MPa (-76cmHg), close fully the handle Lo and turn

off the vacuum pump.

Connect the charge hose to the vacuum pump

adapter.

Let the equipment stay as it is for one to two minutes

and check that the compound gauge pointer does not

return.

Open fully both packed valves on the liquid and

gas sides.

Place the refrigerant cylinder to the electronic balance,

connect the connecting hose to the cylinder and the

connecting port of the electronic balance, and then

charge liquid refrigerant.

(For refrigerant charging, see the figure below)

NOTE

• Never charge refrigerant exceeding the specified amount.

• If the specified amount of refrigerant cannot be charged, charge it a little at a time while running refrigerant

recovery (pump down).

• Do not make additional charging.

An additional charge when refrigerant leaks changes the refrigerant composition in the refrigerant cycle,

causing the characteristics change of the Air to Water Heat Pump or excessive high pressure in the refrigerant

cycle with more than the specified amount of refrigerant charged. This may cause burst or an injury.

Fig. 2-4-1 Configuration of refrigerant charging

(Hydro unit)

(Outdoor unit)

Open

Refrigerant cylinder (with siphon)

Check valve

Open

Open Close

Open/close valve

for charging

Service port

Electronic balance for refrigerant charging

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NOTE

• Make sure that the setting is appropriate so that liquid can be charged.

• A cylinder with siphon enables liquid to be charged without the cylinder turned upside down.

[Cylinder without siphon]

[Cylinder with siphon]

Gauge manifold

Outdoor unit

Siphon pipe

Refrigerant

cylinder

Refrigerant

cylinder

Electronic balance

NOTE

• Because R410A is HFC mixed refrigerant, charging with gas changes the charged refrigerant composition,

causing the equipment characteristics to change.

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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.

2-5. Brazing of pipes

2-5-1. Materials of brazing

Silver brazing metal

• Active solvent

Most of this type of flux is generally used for silver

brazing.

It features the increase of oxide film while moving the

capability to the borax-boric acid compound to add

compounds such as potassium fluoride, potassium

chloride, or sodium fluoride.

Silver brazing metal is an alloy mainly composed of

silver and copper.

It uses iron, copper, or copper alloy, and is relatively

expensive though it excels in soldering.

Phosphor bronze brazing metal

Phosphor bronze brazing metal is generally used to

join copper or copper alloy.

Piping materials for brazing and brazing

metal / flux

Low temperature brazing metal

Low temperature brazing metal is generally called

solder, and is an alloy of tin and lead. Do not use it for

refrigerant piping because its adhesive capacity is low.

Brazing metal to be

Piping material

Flux to be used

used

Phosphor copper

Silver

Copper - Copper

Copper - Iron

Iron - Iron

Do not use

Paste flux

Vapour flux

NOTE

Silver

• Phosphor bronze brazing metal tends to react with

sulfur, producing a fragile compound water solution.

This may cause gas leakage. Therefore, use other

type of brazing metal at a hot spring resort or similar

place, and coat the surface with coatings.

NOTE

• Do not enter flux into the refrigerant cycle.

• If chlorine contained in the flux remains within the

pipe, the lubricating oil deteriorates. Because of

this, use a flux that does not contain chlorine.

• To braze the pipe again while performing service

work, use the same type of brazing metal.

• When adding water to the flux, use water that does

not contains chlorine. (e.g. distilled water or ion-

exchange water)

2-5-2. Flux

• Remove the flux after brazing.

Why flux is necessary

2-5-3. Brazing

• Removing all the oxide film and any foreign matter

on the metal surface assists the flow of brazing

metal.

Brazing must be performed by a person qualified and

experienced with theoretical knowledge since the

operation requires sophisticated techniques.

Perform brazing while flowing dry nitrogen gas (N2) to

prevent oxide film from forming during brazing

application to the inside of the pipe.

• Flux prevents the metal surface from being oxidized

in the course of brazing.

• Reducing the brazing metal's surface tension

enables the brazing metal to adhere for better metal

processing.

NOTE

Characteristics of flux

• The activation temperature of flux matches the

brazing temperature.

• Never use gas other than nitrogen gas.

Brazing method to prevent oxidation

1) Attach a reducing valve and a flow meter to the

nitrogen cylinder.

• A wide effective temperature range makes flux hard

to carbonize.

• It is easy to remove slag after brazing.

2) Use a copper pipe to direct the piping material,

and attach the flow meter to the balance.

• The corrosive action to the treated metal and brazing

metal is minimum.

3) Apply a mark to the clearance between the

piping material and the copper pipe filled with

nitrogen to prevent the back flow of the

nitrogen gas.

• The good performance of flux gives no harm to a

human body.

Since flux works in a complicated manner as

described above, select an appropriate type of flux

according to metal treatment type, brazing metal and

brazing method, or other conditions.

4) If the nitrogen gas flows out, be sure to keep

open the piping end.

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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.

Fig 2-5-1

Prevention of oxidation during brazing

Flow meter

Stop valve

Nitrogen gas cylinder

Pipe

From nitrogen cylinder

Nitrogen gas

Robber plug

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3 Specifications

Outdoor unit

Unit name

Hydro unit

HWS-802XWHM3-E, 802XWHT6-E

HWS-802H-E

Heating capacity *1 (kW)

Cooling capacity *2 (kW)

8.0

6.0

Variable range of compressor frequency

Power source

10 - 70 Hz

Single phase 50Hz 230V

Operation mode

Heating

Cooling

0.46

0.097

91.7

8.90

2.033

99.3

9.36

Electric characteristic *1 *2

Hydro unit

Current (A)

0.98

0.101

91.5

8.26

1.859

97.8

9.24

Power (kW)

Power factor (%)

Current (A)

Outdoor unit

Power (kW)

Power factor (%)

Starting current (A)

Total

Operating noise *1 *2 *4

Hydro unit (dB(A))

Outdoor unit (dB(A))

Coefficient of performance *1 *2

Hydro unit

4.08

2.82

Outer dimension

Height (mm)

Width (mm)

Depth (mm)

925

525

355

Net weight (kg)

Color

Silky shade (Munsell 1Y8.5/0.5)

Remote controller

Outer dimension *3

Height (mm)

Width (mm)

Depth (mm)

Motor output (W)

Flow rate (L/min)

Type

120

Circulating pump

125 (MAX)

22.9

17.2

Non-self-suction centrifugal pump

Heat exchanger

Outer dimension

Plate-type heat exchange

Outdoor unit

Height (mm)

Width (mm)

Depth (mm)

890

900

320

Net weight (kg)

Color

Silky shade (Munsell 1Y8.5/0.5)

1400

Compressor

Motor output (W)

Type

Twin rotary type with DC-inverter variable speed control

Model

DA220A2F-22L

Fan motor

Standard air capacity (m /min)

Motor output (W)

50.0

Refrigerant piping

Connection method

Hydro unit

Flare connection

Liquid

Gas

Ø9.52

Ø15.9

Outdoor unit

Liquid

Gas

Ø9.52

Ø15.9

Maximum length (m)

Maximum chargeless length (m)

Maximum height difference (m)

Minimum length (m)

Refrigerant name

Refrigerant

R410A

Charge amount (kg)

Pipe diameter

1.8

Water piping

R1 1/4

Maximum length (m)

Maximum height difference (m)

Maximum working water pressure (kPa)

Hydro unit (°C)

None (Need the flow rate 17.5 /min or more)

300

Operating temperature range

Operating humidity range

Wiring connection

5-32

Outdoor unit (°C)

-20-43

15-85

Hydro unit (%)

Outdoor unit (%)

15-100

Power wiring

3 wires: including ground line (Outdoor unit)

4 wires: including ground line

Connecting line

*1 Heating performance measurement conditions: outside air temperature 7 or 6 °C, water supply temperature 30 °C, outlet temperature 35 °C, refrigerant piping length 7.5 m (no height

difference), capacity 97%, COP 95%, operating noise +3 dB

*2 Cooling performance measurement conditions: outside air temperature 35 °C, water supply temperature 12 °C, outlet temperature 7 °C, refrigerant piping length 7.5 m (no height

difference), capacity 97%, COP 95%, operating noise +3 dB

*3 • The remote controller should be shipped with the hydro unit.

• Use two 1.5-meter wires to connect the hydro unit with the remote controller.

*4 The outdoor unit operating noise is measured at the point of 1m away from the unit back surface center and 1m high from the ground. The hydro unit operating noise is measured at the

point of 1m away from the unit front surface center.

The value of the operating noise varies depending on room structure where the unit is installed.

*5 Do not leave the hydro unit at 5 °C or below.

*6 Check the water piping for leakage under the maximum operating pressure.

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Unit name

Hydro unit

HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E

Outdoor unit

HWS-1102H-E

11.2

HWS-1402H-E

14.0

Heating capacity *1 (kW)

Cooling capacity *2 (kW)

10.0

11.0

Variable range of compressor frequency

Power source

10 - 60Hz

10 - 70 Hz

Single phase 50Hz 230V

Operation mode

Heating

Cooling

0.61

0.130

92.7

14.88

3.39

99.1

15.49

Heating

Cooling

0.63

0.135

93.2

17.47

3.945

98.1

18.10

Electric characteristic *1 *2

Hydro unit

Current (A)

0.63

0.135

93.2

10.14

2.265

96.9

10.77

0.67

0.145

94.0

13.57

3.005

96.4

14.24

Power (kW)

Power factor (%)

Current (A)

Outdoor unit

Power (kW)

Power factor (%)

Starting current (A)

Total

Operating noise *1 *2 *4

Hydro unit (dB(A))

Outdoor unit (dB(A))

Coefficient of performance *1 *2

Hydro unit

4.66

2.84

4.45

2.69

Outer dimension

Height (mm)

Width (mm)

Depth (mm)

925

525

355

Net weight (kg)

Color

Silky shade (Munsell 1Y8.5/0.5)

Remote controller

Outer dimension *3

Height (mm)

Width (mm)

Depth (mm)

Motor output (W)

Flow rate (L/min)

Type

120

Circulating pump

190 (MAX)

32.1

28.9

40.1

31.5

Non-self-suction centrifugal pump

Heat exchanger

Outer dimension

Plate-type heat exchange

Outdoor unit

Height (mm)

Width (mm)

Depth (mm)

1340

900

320

Net weight (kg)

Color

Silky shade (Munsell 1Y8.5/0.5)

2500

Compressor

Motor output (W)

Type

Twin rotary type with DC-inverter variable speed control

Model

DA422A3F-25M

Fan motor

Standard air capacity (m /min)

Motor output (W)

103.0

100 × 2

Refrigerant piping

Connection method

Hydro unit

Flare connection

Liquid

Gas

Ø9.52

Ø15.9

Outdoor unit

Liquid

Gas

Ø9.52

Ø15.9

Maximum length (m)

Maximum chargeless length (m)

Maximum height difference (m)

Minimum length (m)

Refrigerant name

Refrigerant

R410A

Charge amount (kg)

Pipe diameter

2.7

Water piping

R1 1/4

Maximum length (m)

Maximum height difference (m)

Maximum working water pressure (kPa)

Hydro unit (°C)

None (Need the flow rate 13 /min or more)

300

Operating temperature range

Operating humidity range

Wiring connection

5-32

Outdoor unit (°C)

-20-43

15-85

Hydro unit (%)

Outdoor unit (%)

15-100

Power wiring

3 wires: including ground line (Outdoor unit)

4 wires: including ground line

Connecting line

*1 Heating performance measurement conditions: outside air temperature 7 or 6 °C, water supply temperature 30 °C, outlet temperature 35 °C, refrigerant piping length 7.5 m (no height

difference), capacity 97%, COP 95%, operating noise +3 dB

*2 Cooling performance measurement conditions: outside air temperature 35 °C, water supply temperature 12 °C, outlet temperature 7 °C, refrigerant piping length 7.5 m (no height

difference), capacity 97%, COP 95%, operating noise +3 dB

*3 • The remote controller should be shipped with the hydro unit.

• Use two 1.5-meter wires to connect the hydro unit with the remote controller.

*4 The outdoor unit operating noise is measured at the point of 1m away from the unit back surface center and 1m high from the ground. The hydro unit operating noise is measured at the

point of 1m away from the unit front surface center.

The value of the operating noise varies depending on room structure where the unit is installed.

*5 Do not leave the hydro unit at 5 °C or below.

*6 Check the water piping for leakage under the maximum operating pressure.

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4 Outside Drawing

4-1. Hydro unit

HWS-802XWHM3-E, 802XWHT6-E

HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E

525

2-dia.12x17 long hole

(for dia.8-10 anchor bolt)

371.5

355

72.5

380

Anchor bolt

72.5

B leg part

long hole pitch

Manometer

Remote controler

2-dia.12x17 U-shape hole

(for dia.8-10 anchor bolt)

A leg part

Hot water outlet

connecting pipe 1 1/4"

19.5

116

Gas line dia.15.88

Liquid line dia.9.52

Drain nipple

Water inlet

connecting pipe 1 1/4"

144.5

309.5

59.5

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4-2. Outdoor unit

HWS-802H-E

5 5

9 5

2 4

8 9 0

4 0

9 4

9 5

5 5

4 0

2 5 5

2 4 7

1 5 5

5 5

5 4

4 8

9 5

1 7 0

3 4

4 6

5 3 4

5 8 1

1 6 5

1 4 8

1 2 8

7 4

1 1 8

3 6 5

1 7 . 5

6 5

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HWS-1102H-E, 1402H-E

9 5 5 5

2 4

1 3 4 0

4 0

9 4

5 5

9 5

4 0

6 1 3

6 0 5

1 5 5

9 5 5 5

5 4

4 8

1 7 0

3 4

4 6

5 8 1

5 3 4

7 4

1 2 1

6 5 5

5 8 1

5 3 4

7 0

8 5

1 2 8 1 1 8

7 4

3 6 0

1 7 . 5

3 6 5

1 7 . 5

6 5

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4-3. Hot water cylinder

HWS-2101CSHM3-E(-UK)

HWS-3001CSHM3-E(-UK)

550

Specification

for UK only

Specification

for UK only

HWS-1501CSHM3-E(-UK)

550

Specification

for UK only

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5 Wiring Diagram

5-1. Hydro Unit

WARNING

*Option

Perform the grounding from the

earth terminal in the terminal

block of the outdoor unit.

Remote

TWI

TWO

THO

*Option

TTW

controller

(HWS-AMS11E)

LPS

TFI

Remote

controller

Color indentification

BLK : BLACK

BLU : BLUE

(HWS-AMS11E)

BRW : BROWN GRN : GREEN

CAUTION

GRY : GRAY

PNK : PINK

WHI : WHITE

ORN : ORANGE

RED : RED

YEL : YELLOW

Electric shock may happen.

Don't touch the electric parts.

TB 07

7A 7B

6A 6B ⁶C ⁶D TB 06

*Option p.c.board

CN10

(WHI)

GRN

CN41

(BLU)

CN203 CN204 CN205 CN206 CN207

(YEL) (BRW) (RED) (WHI) (BLU)

CN212

(WHI)

CN214

(WHI)

CN213

(WHI)

YEL

Boiler control O/P

Alerm O/P

GRN

Relay

CR10

CN208

(BLU)

p.c.board

BLU

(MCC-1217)

CR11

CR12

CR13

RED

BLU

ORN

GRN

PJ20

TB1

BRW

CN501

(YEL)

CN02

(WHI)

GRN

BRW

Operation O/P

Defrost O/P

Relay

p.c.board

(MCC-1217)

CN209

(GRN)

WHI

CN01

(WHI)

PJ20

WHI

RED

Relay

p.c.board

(MCC-1431)

YEL

Photocoupler input

p.c.board

(MCC-1214)

Emergency stop I/P

Hot water cylinder

thermostat I/P

F01 (5A)

CN210

(RED)

P.C.board

(MCC-1511)

PJ17

BLK

YEL

Photocoupler input

p.c.board

(MCC-1214)

CN211

(BLK)

BLU

Cooling thermostat I/P

Heating thermostat I/P

CN603

(YEL)

WPM

BRW

PJ17

SW14

YEL

GRN

RED

SW01

RED

WHI

CN200

(RED)

Flow switch

SW02

CN601

(RED)

BLK

CN201

(WHI)

High pressure switch

4.15MPa

YEL

WHI

SW10 SW11 SW12 SW13

BLK

CN202

(YEL)

Thermal protector (auto)

SW06

SW07

BRW

RED

ORN

RED

CN602

(WHI)

WHI WHI

CN102

(WHI)

TB 05

TB 04

41 42 ⁴3 ⁴4

51 52 ⁵3 ⁵4 ⁵5 ⁵6 ⁵7 ⁵8 59

RY604

RY605

RY606

RY607

CN101

(WHI)

Transformer

WHI

F100

Fuse

T5A

WPM 2WV BH

3WV

MIXV

BLK

CN604

(BLU)

CN605

(YEL)

CN606

(BLU)

CN305 CN100

(GRN) (WHI)

Type 1

(3-wire SPST type)

250V

(2-wire spring return)

HWS-802XWHT6-E

: Installed

HWS-1402XWHT6-E : Installed

HWS-1402XWHT9-E : Installed

HWS-802XWHM3-E : Not installed

HWS-1402XWHM3-E : Not installed

TB 05

TB 04

57 ⁵8 59

41 42 ⁴3 ⁴4

MIXV

Symbol

Parts name

RY01

WPM

Water pump motor

3-way valve (local)

2-way valve (local)

Mixing valve (local)

Water heat exchanger temperature sensor

Water heat exchanger inlet temperature sensor

Water heat exchanger outlet temperature sensor

Backup heater outlet temperature sensor

Hot water cylinder temperature sensor

Floor heating inlet temperature sensor

3WV

2WV

MIXV

TWI

TWO

THO

TTW

TFI

Type 2

(3-wire SPST type)

Type 2

(3-wire SPDT type)

WHI

PNK

ORN

Booster heater

Type 3

Relay01

Relay06

RY01 RY06

(3-wire SPDT type)

LPS

Low pressure sensor

Terminal block

Backup heater1,2,3 Heater AC230V, 3kW

Thermal protector

(single operation)

Thermal protector

(single operation)

Thermal protector

(single operation)

Backup heater

Thermal protector

(single operation)

Backup heater

Thermal protector

(single operation) 95

1L1 3L2 5L3

1L1 3L2

1L1 3L2 5L3

2T1 4T2 6T3

1L1 3L2 5L3

2T1 4T2 6T3

1L1 3L2 5L3

2T1 4T2 6T3

1L1 3L2 5L3

2T1 4T2 6T3

RY05

RY02

RY04

RY02

RY04

RY02

2T1 4T2

2T1 4T2 6T3

BLK

GRY

F1, F2

Fuse

F1 F2

AC250V

T30A

F3 F4 F5 F6 F7 F8

F3 F4 F5 F6

F3 F4

F3, F4

Fuse

AC250V

T30A

Fuse

AC250V

T30A

AC250V

T30A

TB 01

TB 03

11 12 ¹3

31 32

*Option

TB 02

L1 L2 L3

TB 02

L1 L2

Outdoor

unit

Power supply

230V 50Hz

Power supply

400V 3N 50Hz

Power supply

400V 3N 50Hz

Power supply

230V 50Hz

HWS-802XWHT6-E

HWS-1402XWHT6-E

HWS-802XWHM3-E

HWS-1402XWHM3-E

Power supply

230V 50Hz

Hot water cylinder

HWS-1402XWHT9-E

1. The one-dot chain line indicates wiring at the local site, and

the dashed line indicates accessories sold separately and

service wires, respectively.

, and

indicates the terminal board and the numberals

indicate the terminal numbers.

indicates P.C. board.

* Be sure to fix the electric parts cover surely with screws.

(Otherwise water enters into the box resulting in malfunction.)

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5-2. Outdoor Unit

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5-3. Hot Water Cylinder Unit

Double pole thermal cut out

Blue

Green /

Yellow

Brown

1 2

TB03(230V)

Green /

Yellow

TB06(TTW)

TTW sensor

Hot water cylinder heater

Supply 230 V from hydro unit

Cable size 1.5 mm²(minimum)

To hydro unit

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6 Key Electric Component Rating

6-1. Hydro Unit

HWS-802XWHM3-E, 802XWHT6-E

Model name

No.

Component name

Circulating pump

Type name

Rating

M3-E

T6-E

UPS025-65 K 130 AC230 V 0.54 A (MAX)

Backup heater 6 kW

AC 400 V (3N) 6 kW (AC230 V 3 kW

–

compatible)

Backup heater 9 kW

AC400V (3N) 9 kW

10 kΩ (25°C)

Water heat exchange

temperature sensor

(TC sensor)

–

Water inlet temperature sensor

(TWI sensor)

10 kΩ (25°C)

–

Water outlet temperature sensor

(TWO sensor)

Heater outlet water temperature

sensor

–

(THO sensor)

Floor inlet temperature sensor

(TFI sensor)

10 kΩ (25°C)

Pressure switch

–

Operating pressure 4.15 MPa +0 -0.3 MPa

Operating pressure 0.20 MPa

10 Low pressure sensor

11 Bimetal thermostat (auto)

Operating temperature 75 3°C DC42 V / 0.2 A

Operating temperature 95 5°C AC250 V / 16 A

Bimetal thermostat (single

–

operation)

13 Flow switch

–

Operating flowing quantity 13 L/min

AC230 V 0.5 A DC24 V 1 A

Contact input

14 Output board (OP)

15 Input board (OP)

16 Remote control

TCB-PCIN3E

TCB-PCM03E

HWS-AMS11E

Water 3-way valve terminal

AC230 V 0.1 A

–

2Wire, 3Wire SPST, SPDT type mountable

18 Water 2-way valve terminal

AC230 V 0.1 A 2Wire type mountable

Mixing valve terminal

AC230 V 0.1 A

3Wire SPST, SPDT type mountable

20 Circulating pump terminal

21 Booster heater terminal

22 Fuse

–

AC230 V 1.0 A

AC 250 V 30 A

O·········Applied

OP·······Optional accessory

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HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E

Model name

No.

Component name

Circulating pump

Type name

Rating

AC230 V 0.83 A (MAX)

M3-E T6-E T9-E

UPS25-80 130

Backup heater 6 kW

Backup heater 9 kW

–

AC 400 V (3N) 6 kW (AC230 V 3kW compatible)

AC 400 V (3N) 9 kW

Water heat exchange

temperature sensor

(TC sensor)

10 kΩ (25°C)

–

Water inlet temperature sensor

(TWI sensor)

10 kΩ (25°C)

–

Water outlet temperature sensor

(TWO sensor)

Heater outlet water temperature

sensor

–

(THO sensor)

Floor inlet temperature sensor

(TFI sensor)

10 kΩ (25°C)

Pressure switch

–

Operating pressure 4.15 MPa +0 -0.3 MPa

Operating pressure 0.20 MPa

10 Low pressure sensor

11 Thermal protector (auto)

Operating temperature 75 3°C DC42 V / 0.2 A

Operating temperature 95 5°C AC250 V 16 A

Thermal protector (single

–

operation)

13 Flow switch

Operating flowing quantity 18 L/min

AC230 V 0.5 A DC24 V 1 A

Contact input

14 Output board (OP)

15 Input board (OP)

16 Remote control

OP TCB-PCIN3E

OP TCB-PCM03E

HWS-AMS11E

Water 3-way valve terminal

AC230 V 0.1 A

–

2Wire, 3Wire SPST, SPDT type mountable

18 Water 2-way valve terminal

AC230 V 0.1 A 2Wire type mountable

Mixing valve terminal

AC230 V 0.1 A

3Wire SPST, SPDT type mountable

20 Circulating pump terminal

21 Booster heater terminal

22 Fuse

–

AC230 V 1.0 A

AC 250 V 30 A

O·········Applied

OP·······Optional accessory

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6-2. Outdoor Unit

HWS-802H-E

No.

Component name

Compressor

Type name

DA220A2F-22L

ICF-280-A60-1

Rating

Outdoor fan motor

4-way valve coil

Output 60 W

VHV-01AP552B1

AC230 full-wave rectifier input, alive time

10 sec or less

Pulse motor valve (PMV) coil

Compressor case thermostat

Reactor

CAM-MD12TF-15

US-622KXTMQO-SS

CH-56

DC12 V

OFF: 125 4°C ON: 90 5°C

5.8 mH, 18.5 A

PC board

MCC-1571

Input 1Ø, AC230 V 23 V,

50/60 Hz

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HWS-1102H-E, 1402H-E

No.

Component name

Compressor

Type name

DA422A3F-25M

ICF-280-A100-1

CH-44

Rating

Outdoor fan motor (x2)

Reactor (x2)

Output 100 W

1.4 mH, 25 A

4-way valve coil

UKV-A038

AC230 V full-wave rectifier input, alive time 10 sec or less

DC12 V

Pulse motor valve (PMV) coil

Board

VHV-01AP552B1

MCC-1560

Input 3Ø, AC230 V 23 V, 50/60 Hz

OFF = 125 4 °C, ON = 90 5 °C

Compressor case thermostat

US-622KXTMQO-SS

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6-3. Hot Water Cylinder Unit

Model name

1501 2101 3001

No.

Component name

Type name

Rating

CSH CSH CSH

M3-E M3-E M3-E

(-UK) (-UK) (-UK)

Hot water cylinder heater

–

AC230 V 2.75 KW

Hot water cylinder temperature

sensor

10 kΩ (25°C)

(TTW sensor)

Operating temperature

Thermal cut-out

–

Manual reset 82°C (+3k/-2k)

O·········Applied

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6-4. Water Heat Exchange Control Board

HWS-802XWHM3-E, 802XWHT6-E

HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E

TC sensor connector

TTW sensor connector

CN214

CN203

Low pressure sensor connector

CN207, CN212

Remote control

connector

CN41

TFI sensor

connector

CN213

Relay board connector

CN501

THO sensor connector

CN206

TWI sensor connector

CN204

TWO sensor connector

CN205

Pressure switch connector

CN201

Overheat protection thermostat

input connector

CN202

Flow switch connector

CN200

Option board

connector

CN208-CN211

Transformer connector

CN102

Built-in pump

connector

CN603

Transformer input connector

CN101

Hot water cylinder

drive connector

CN601

AC power supply connector

CN100

3WV drive connector

CN602

Serial input connector

CN305

Backup heater 2 drive connector

CN606

Mixing valve drive

connector

CN604

Backup heater 1 drive

connector

CN605

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6-5. Outdoor Control Board

HWS-802H-E

Reactor connection connector

Electrolytic capacitors

Compressor output terminals

Fan motor output

CN300 (White)

Power circuit protection

fuse

F100 (250 V, 3.15 A,

plastic case)

CN202

CN201

CN200

Case thermostat connector

CN609(Blue)

4-way valve connector

CN701(White)

Compressor ON

output connector

CN704(Blue

)

Heater output connector

CN703(Grey)

External input connector

CN610(Yellow)

Special operation switches

SW801

SW804

Display change-over switches

SW800

SW803

Temperature sensor connectors

TL CN604(White

TD CN603(White

TO CN602(Yellow

TE CN601(White

TS CN600(White

)

Alive, error display LEDs

D800 804(Yellow

D805(Green

)

4-way valve protection

fuse

F700 (250 V, 3.15 A,

plastic case)

Power circuit protection

fuse

F01 (250V, 25A)

PMV connector

CN710 (White)

Initialization switch

SW802

Power supply connection lead

wires

P01(Red)

P02(White)

Connecting cable connector

CN04(White)

Hydro-outdoor communication signal LEDs

D503 (Green, Outdoor => Hydro)

Connecting cable protection fuse

F03 (250 V, 10 A)

Earth lead wire

P09 (Black)

D502 (Amber, Hydro => Outdoor)

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HWS-1102H-E, 1402H-E

Compressor output terminals

Fan motor output (Lower)

CN300(White)

Fan motor output (Upper)

CN400(White)

Electrolytic capacitors

CN202

CN201

CN200

Case thermostat connector

CN609(Blue)

Power circuit protection

fuse

F100(250V,3.15A,

plastic case)

4-way valve connector

CN701(White)

Compressor ON output

connector

CN704(Blue)

External input connector

CN610(Yellow)

Special operation switches

SW801

SW804

Display change-over

switches

SW800

SW803

Temperature sensor

connectors

TL CN604(White)

TD CN603(White)

TO CN602(Yellow)

TE CN601(White)

TS CN600(White)

Alive, abnormal display LEDs

D800 804(Yellow)

D805(Green)

Power supply connection

lead wires

P01(Red)

P02(White)

P03(Black)

PMV connector

CN710(White)

4-way valve protection fuse

F700(250V,3.15A

plastic case)

Initialization switch

SW802

Earth lead wire

P09(Black)

Connecting cable connector

CN04(White)

Hydro-outdoor communication

signal LEDs

D503 (Green, Outdoor =>Hydro)

D502 (Amber, Hydro => Outdoor)

Connecting cable protection fuse

F03(250V,10A)

Power supply protection fuses

F01

(250V,25A)

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7 Refrigeration Cycle / Water System Diagram

7-1. Water System Diagram

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Installation example of water circuit

(1)

(2)

(4)

(6)

(3)

(5)

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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7-2. Refrigeration Cycle System Diagram

HWS-802XWHM3-E, 802XWHT6-E/802H-E

Outdoor unit

Hydro unit

Heating / Hot-water supply

Defrosting / Cooling

Low

pressure

sensor

Expansion vessel

Manometer

TWO

Water vent valve

Air vent valve

Backup heater

Pressure switch

Compressor

(DA220A2F-22L)

Plate-type

water heat

exchanger

4-way valve

(STF-218G)

Safety valve

Circulating pump

(UPS025-65 K 130)

THO

Pulse motor valve

(CAM-B30YGTF-2)

TWI

Outdoor heat^TE

exchanger

Flow switch

(VH-8706)

Accumulator

(1800 cc)

Refrigerant R410A ... 1.8 kg

HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E/1102H-E, 1402H-E

Outdoor unit

Hydro unit

Heating / Hot-water supply

Defrosting / Cooling

Low

pressure

sensor

Expansion vessel

Manometer

TWO

Water vent valve

Air vent valve

Backup heater

Pressure switch

Compressor

(DA422A3F-25M)

Plate-type

water heat

exchanger

4-way valve

(STF-0401G)

Safety valve

Circulating pump

(UPS25-80 130)

Pulse motor valve

(UKV-25D100)

THO

TWI

Outdoor heat ^TE

exchanger

Flow switch

(VH-8705)

Accumulator

(2500 cc)

Refrigerant R410A ... 2.7 kg

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8 Operational Description

This chapter describes the working circuit and control of Air to Water Heat Pump about the following operations.

Item

Page

Basic Operation

1)Operation control

2)Hot water supply operation

3)Heating operation

4)Cooling operation

8-1

36-38

Operation Mode and Control Method

1)Hot water supply operation

2)Heating operation

3)Cooling operation

4)Simultaneous operation of “hot water supply" and "heating”

5)Simultaneous operation of “how water supply" and "cooling”

6)Boiler-assisted heating operation

7)HOT WATER BOOST operation

8)Anti bacteria

8-2

39-47

9)Night setback operation

10) FROST PROTECTION operation

11) AUTO operation

12) Nighttime low-noise operation

Hydro Unit Control

1)Capacity control (compressor, high-temperature release, low-temperature release)

2)Heater control

3)Circulation pump control

8-3

4)Flow switch control

48-56

5)Mixing valve control (2-temperature heating control)

6)Q-H characteristics of hydro unit

7)Automatic restart control

8)Piping anti-freezing control

Outdoor Unit Control

1)PMV (Electronic control valve) control

2)Outlet temperature release control

3)Current release control

4)Current releases shift control

5)Outdoor fan control

8-4

57-63

6)Defrosting control

7)Winding heating control

8)Continued operation prevention under short-circuit conditions

9)Overcurrent protection control

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Item

Operation flow and applicable data, etc.

Operation description

8-1.

Basic

Operation

1) Operation control

Remote controller

1. Purpose

The operations of the

hydro unit and the

outdoor unit are

controlled according to

user-defined operation

condition settings.

2. Details

The operation controls

include those shown in

the left.

Operation

condition selection

Remote control settings

<Heating> Temperature setting

<Hot water supply > Temperature setting

<Cooling> Temperature setting

Heating: Run/Stop

Hot water supply: Run/Stop

Cooling: Run/Stop

Auto Temp

3. Operations

Anti Bacteria

Frost protection

Hot waterboost

1) An operation condition

is selected with the

remote controller.

2) Setting the remote

controller button to

“ON” transmits a signal

to the hydro unit.

Serial signals transmit

and receive

AC 230 V for Hot water cylinder heater

AC 400 V (3N~) for Back up heater

Hydro

unit

3) The hydro unit

controller controls the

operations shown in

the left while also

controlling the water 2-

way valve, water 3-way

valve, circulation

pump, mixing valve,

hot water cylinder

heater, and backup

heater.

4) The hydro unit

controller transmits an

operation instruction to

the outdoor unit, and

uses serial signals to

transmit and receive

control statuses.

5) The outdoor unit

control unit performs

the operation controls

shown in the left while

also controlling the

compressor, outdoor

fan motor, pulse motor

valve, and 4-way valve.

Serial signals

Thermostat (Cooling/Heating)

transmit and receive

Forcible stop input

Water heat

exchange

Abnormal stop output

Sub board

Defrosting output

Operation output

Boiler "ON/OFF"

Booster Heater

2WV_W

3WV_W

Hot water supply

heater MG

Condensed temperature sensor (TC)

Water inlet temperature sensor (TWI)

Water outlet temperature sensor (TWO)

Water heater outlet temperature sensor (THO)

Hot water cylinder (TTW)

Floor inlet sensor (TFI)

Overheat prevention thermostat

Flow switch

Mixing Valve

Water heat

exchange

control board

Pressure switch

Lo pressure sensor

Hot water cylinder heater

Backup heater 1 power-relay

Backup heater 2 power-relay

Serial signals

transmit and receive

AC pump 1 (Built-in pump)

Serial

communication

Outdoor

unit

AC 230 V for heat pump

Outdoor unit contro

Serial signals

Compressor

Outdoor fan motor

Inverter

Inverter frequency control

Waveform synthesis function

Calculation function (Temperature calculation)

AD conversion function

Rapid heating function

Compressor restart

Delay function

G-Tr overcurrent prevention function

Defrosting operation function

transmit and receive

Outdoor

unit control

Td sensor

Ts sensor

Te sensor

To sensor

PMV

4-way valve

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Item

Operation flow and applicable data, etc.

Operation description

8-1.

Basic

Operation

2) Hot water supply operation

Hot water supply operation

1. Purpose

Hot water supply

[HOT WATER]

button set to "ON"

Hot water temperature: 40 to 75

°C

2. Details

This section performs hot

water supply operation

according to heating

conditions specified for

the steps in the left.

3. Operations

Circulation pump "ON/OFF" control

Water 3-way valve control

Hot water cylinder heater control

Hydro unit

control

1) Set the [HOT WATER]

remote controller

button to “ON”.

2) The hydro unit

controller starts to

transmit a hot water

supply operation signal

to the outdoor unit

control unit.

3) The hydro unit

performs the operation

controls shown in the

left while also

Operation instruction

signal transmit

Number of compressor revolutions control

Number of outdoor fan motor revolutions control

Pulse motor valve control

Outdoor unit

control

4-way valve control

controlling the

circulation pump, hot

water cylinder heater

“ON/OFF”.

4) The outdoor unit

controls the

compressor, outdoor

fan motor, electric

expansion valve, and

4-way valve based on

the operation signals

transmitted by the

hydro unit.

3) Heating operation

Heating operation

1. Purpose

Heating

ZONE1, 2

button set to "ON"

Heating temperature: 20 to 55

°C

2. Details

This section performs

heating operation

according to heating

conditions specified for

the steps in the left.

3. Operations

Circulation pump "ON/OFF" control

Water 3-way valve control

Water 2-way valve control

Mixing Valve control

Backup heater control

Booster heater control

Hydro unit

control

1) Set the [ZONE1, 2]

remote controller

button to “ON”.

Operation instruction

signal transmit

2) The hydro unit

controller starts to

transmit a heating

operation signal to the

outdoor control unit.

3) The hydro unit

performs the operation

controls shown in the

left while also

Number of compressor revolutions control

Number of outdoor fan motor revolutions control

Pulse motor valve control

Outdoor unit

control

4-way valve control

controlling the

Set temperature

(TSC_F)

circulation pump,

backup booster heater

“ON/OFF”, water 2-

way valve, and water 3-

way valve.

[

]

°C

A(40)

B(35)

C(30)

D(25)

E(20)

4) The outdoor unit

controls the

compressor, outdoor

fan motor, electric

expansion valve, and

4-way valve based on

the operation signals

transmitted by the

hydro unit.

-20

A, B, C, D, E Setting available range 20 to 55

°C

T1 Setting available range

T3 Setting available range

-15 to 0

0 to +15

°C

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Item

Operation flow and applicable data, etc.

Operation description

8-1.

Basic

Operation

4) Cooling operation

1. Purpose

Cooling

2. Details

This section performs

cooling operation

according to cooling

conditions specified for

the steps in the left.

3. Operations

ZONE1, 2

button set to "ON"

Cooling temperature: 10 to 25

°C

Circulation pump "ON/OFF" control

Water 3-way valve control

Water 2-way valve control

Hydro unit

control

1) Set the [ZONE1, 2]

remote controller

button to “ON”.

2) The hydro unit

controller starts to

transmit a cooling

operation signal to the

outdoor unit control

unit.

3) The hydro unit

controller performs the

operation controls

shown in the left while

also controlling the

circulation pump, water

2-way valve, and water

3-way valve.

Operation instruction

signal transmit

Number of compressor revolutions control

Number of outdoor fan motor revolutions control

Pulse motor valve control

Outdoor unit

control

4-way valve control

NOTE:

No coding mode in default setting. When use the cooling mode, please change the

FC02 to “0”.

4) The outdoor unit

controls the

compressor, outdoor

fan motor, pulse motor

valve, and 4-way valve

based on the operation

signals transmitted by

the hydro unit.

Related FC

FC No.

Setting item

Cooling mode availability

Default

Setting available range

1: No

0: Yes

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Item

Operation flow and applicable data, etc.

8-2.

The following shows the operation modes and controlled objects.

Operation

Mode and

Control Method

Operation

mode

Heating and Hot water

Cooling and Hot water

Heat pump select

for hot water

supply

Heat pump select

for hot water

supply

Heat pump select

for heating

Heat pump select

for cooling

Hot

water

supply

only

Cooling Heating

only

Hot

Heating

side

water

supply

side

Heating

side

water

supply

side

Cooling

side

water

supply

side

Cooling

side

water

supply

side

Controlled

object

Heat pump

Backup

heater

Hot water

cylinder

heater

O Possible

Not possible

1) Hot water supply operation

1) Operation start condition

When the [HOT WATER] remote controller button is pressed and

the following operation start condition is met, the operation starts.

• TTW < 38°C is detected.

2) Operation mode determination

An operation mode is determined according to the temperature

of TTW sensor.

• Heat pump operation selection *1 *2

TTW sensor

• When TTW < 38°C (a zone in the right figure) is met, the heat

pump operation is selected.

(Hot water cylinder unit)

• Heater operation selection

When 45°C TTW < TSC_H (b zone in the right figure) is

met, the heater operation is selected.

• Thermostat status "OFF" selection

When TTW TSC_H is met, the thermostat status "OFF" is

selected.

TTW

TSC_H

c Zone

a Zone

(Temperature set with

Thermostat OFF

3) Operation stop

The operation stops in the following cases.

• The remote controller gives a stop instruction.

• TTW TSC_H is met.

remote controller)

Heater operation

b Zone

HP_H OFF 45°C

HP_H ON 38°C

*1: When the outside temperature is -20°C or below, the heater

operation is selected even if the TTW temperature falls into "a

zone".

Heat pump

operation

*2: When "Hot water supply" and "Heating" are simultaneously in

operation, the heater operation may be selected depending on

the outside air temperature.

TSC_H is hot water temperature

set with remote controller

Related FC

FC No.

Setting item

Upper limit of hot water supply temperature

Lower limit of hot water supply temperature

Heat pump start temperature

Default

75°C

40°C

38°C

45°C

0°C

Setting available range

60-80°C

40-60°C

20-45°C

Heat pump end temperature

40-50°C

Outside air correction start temperature for hot water supply*

-20-10°C

Outside air correction temperature for hot water supply*

3 deg

0 -15 deg

*3:When the outside temperature is 0°C or below, the boil-up temperature will be higher that setting temperature in hot

water supply mode.

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Item

Operation flow and applicable data, etc.

8-2.

2) Heating operation

• This operation is enabled when DP_SW12_2 ZONE1 is set to "ON" (default).

Operation

Mode and

Control Method

• The remote controller displays

settings, and only the set temperature of

can be changed.

• This operation is enabled when DP_SW12_2 ZONE1 is set to "ON" (default) and DP_SW12_3 ZONE2 to "ON".

• The remote controller displays

can be changed.

settings, and the set temperatures of

• To set temperatures for

• For 2 temperatures control, the flow adjustment of MIXING VALVE controls the water temperature of

details,

see the description on MIXING VALVE control in 8-3-5.

and

, use SELECT to switch

and

. For

1) Operation start condition

TWI

Pressing the [ZONE1, 2] button of remote controller starts a

heating operation. *1 *2

Thermostat off

operation

e zone

2) Operation mode selection

TSC_F

C_f = 0

An operation mode is determined according to the temperature

of TWI sensor.

diff2K

• Heat pump operation selection *1 *2

When TWI < TSC_F (d zone in the right figure) is met, the heat

pump operation is selected.

d zone

• Thermostat status "OFF"

When TWI TSC_F (e zone in the right figure) is met, the

thermostat status "OFF" is selected.

Heat pump operation

TSC_F is a heating temperature

set with remote controller

3) Operation stop condition

When the following condition is met, the heating operation stops.

• The remote controller gives a stop instruction.

*1: When the outside temperature is -20°C or below, the heater

operation is selected even if the TTW temperature falls into "d

zone".

*2: When "Hot water supply" and "Heating" are simultaneously in

operation, the heater operation may be selected depending on

the outside air temperature.

Related FC

FC No.

Setting item

Default

Setting available range

37-55°C

Upper limit of heating (Zone1) limited temperature

Lower limit of heating (Zone1) limited temperature

Upper limit of heating (Zone2) limited temperature

Lower limit of heating (Zone2) limited temperature

20-37°C

37-55°C

20-37°C

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Item

Operation flow and applicable data, etc.

8-2.

3) Cooling operation

Pressing the [ZONE1, 2] button and then [OPERATION MODE] starts a cooling operation.

Operation

Mode and

Control Method

1) Operation start condition

TWI

Pressing the [ZONE1, 2] button and then [OPERATION MODE]

starts a cooling operation.

Heat pump operation

(cooling)

TSC_F

d zone

2) Operation mode selection

An operation mode is determined according to the temperature

of TWI sensor.

(Temperature set with

remote controller)

Diff : 2k

e zone

Thermostat off operation

TSC_F

• Heat pump operation selection *1 *2

When TWI TSC_F (d zone in the right figure) is met, the heat

pump operation is selected.

TSC is a cooling temperature

set with the remote controller

• Thermostat status "OFF"

When TWI < TSC_F (e zone in the right figure) is met, the

thermostat status "OFF" is selected.

3) Operation stop condition

When either of the following conditions is met, the cooling

operation stops.

• The remote controller gives a stop instruction.

• The operation is switched to heating.

*1: When the outside temperature is 10°C or below, cooling does

not start even if the TWI temperature falls into "d zone".

Related FC

FC No.

Setting item

Default

1: No

Setting available range

0: Yes

Cooling mode availability

Upper limit of cooling setting temperature

Lower limit of cooling setting temperature

18-30°C

10-18°C

4) Simultaneous operations of "hot water supply" and "heating"

At the time of "Hot water supply" and "Heating" simultaneous

operation, the operation mode is select as follows depending on

the outside air temperature.

Hot water

f zone

supply heat

pump priority

operation

Diff : 5deg

• f zone Operation with hot water supply priority

A heat pump operation is performed in the hot water supply side,

and a heating operation in the heating side.

• g zone Operation with heating priority

A heat pump operation is performed in the heating side, and a

heating operation in the hot water supply side.

(Note)

g zone

Heating heat

pump priority

operation

Diff : 5deg

-20

Heater operation

h zone

Operation mode by zone

Zone

Hot water supply side

Heat pump *

Heater

Heating side

Stop *

Heat pump

Heater

* Note that after a heat pump operation for "Hot water supply" is selected in f zone, when the operation moves to a

heater operation for "hot water" and then 5 minutes has passed (Hot water supply operation in b zone), the operation

mode changes as follows.

Zone

Hot water supply side

Heating side

Heater

Heat pump

When TTW 45°C (FC: changeable) is met, the operation ends f' zone and returns to f zone.

Related FC

FC No.

Setting item

Default

30 min

Setting available range

0-120min

Maximum HP operation time in “hot water supply” + “heating

mode”

Priority mode switch temperature (D)

-20-20°C

* Note: When user selects “hot water supply” and “ZONE1,2”, and Heat pump selects hot water supply mode, the

Maximum operating time of heat pump is 30 mins.

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Item

Operation flow and applicable data, etc.

8-2.

5) Simultaneous operations of "hot water supply" and "cooling"

For simultaneous operations of "hot water supply" and "cooling", basically cooling runs by a heat pump operation, and

hot water supply by a heater operation.

Operation

Mode and

Control Method

Hot water supply side

Cooling side

Normal

Heater *

Heat pump *

* Note that after a "cooling" heat pump operation is selected, if the thermostat off status continues for 10 minutes and

TTW < 38°C is met, the operation switches to a hot water supply operation.

Hot water supply side

Cooling side

Cooling

thermostat off

10 min. passed

Heat pump

Stop

When TTW 45°C (FC: changeable) is met, the operation returns to the normal mode.

6) Boiler-assisted heating operation

This operation is enabled when DPSW13_2 is ON (A boiler exists).

• I zone Heat pump operation

A heat pump operation is usually performed.

• J zone Heat pump operation + Boiler operation *1

A heat pump + boiler operations (*2) are performed, and a heater operation is performed in the Hot water supply side.

I zone

Heat pump

operation

J zone

Heat pump

boiler operation

*1: In J zone, the hydro unit setting has a priority, and when the set temperature is reached, the boiler output also becomes

OFF.

Setting FC_3E to "1" makes the boiler has a priority, and even if the hydro unit set temperature is reached, the boiler

output remains "ON".

*2: The boiler operation only gives boiler instruction from the hydro unit through the option board.

Related FC

FC No.

Setting item

Default

Setting available range

Heat pump only / Simultaneous operation switching TO

temperature (E)

-10

-20-20°C

Hydro unit setting / Boiler set temperature priority switching

0: Priority on

hydro unit

setting

1: Priority on boiler setting

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Item

Operation flow and applicable data, etc.

8-2.

7) Hot water boost operation

A hot water boost operation boils water quickly to the set temperature TSC_H = 75°C (FC_09).

Operation

Mode and

Control Method

1) How to operate

• When pressing the [HOT WATER BOOST] button after pressing the remote controller [HOT WATER] button, a heat

pump operation in progress in the heating side switches to in the hot water side, and continues the operation

regardless of the hot water supply start condition, TTW < 38°C. In addition, the hot water cylinder is immediately

energized to start a Hot water supply operation under TSC_H = 75°C.

• A hot water boost operation returns to the usual operation after 60 minutes.

• The remote controller display during a hot water boost operation is the same as the set temperature display of a usual

Hot water supply operation.

• The usual set temperature change is used for changing the set temperature during a hot water boost operation.

Change the BOOST set temperature with FC_09, if necessary.

HOT WATER button set to "ON"

HOT WATER BOOST button set to "ON"

Heating side

Current heat pump

operation

Switches to Hot water

supply operation

Hot water

supply side

75 Hot water operation

°C

60 minutes passed

Usual operation

Related FC

FC No.

Setting item

HOT WATER BOOST set temperature

HOT WATER BOOST operation time

Default

75°C

Setting available range

40-80°C

60 mins

30-180 mins

Every 10 mins

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Item

Operation flow and applicable data, etc.

8-2.

8) Anti bacteria (ANTI BACTERIA) operation

An anti bacteria operation regularly performs a Hot water supply operation with the set temperature TSC_H = 75°C (can

be set with FC_0A).

Operation

Mode and

Control Method

1) How to operate

• Pressing the [HOT WATER] button and then the remote controller [ANTI BACTERIA] button changes the setting to

TSC_H = 75°C at the set cycle and time (both can be set with the remote controller FC) to start ANTI BACTERIA

operation.

• The first auti bacteria operation starts when press the [ANTI BACTERIA] button and starting time come.

• When the set temperature 75°C is reached after the ANTI BACTERIA operation started, the set temperature remains

another 30 minutes (can be set with FC_0B).

• The priority zone determined by the outside temperature selects an operation, Hot water heat pump or hot water

supply heater.

• The hot water heat pump operation, when selected, ignores the hot water supply start condition (TTW < 38°C) and

forcibly performs a hot water operation.

• During ANTI BACTERIA operation (Forcible hot water operation at 75°C), the hot water set temperature display is

not changed. If it is changed from the remote controller, the normal hot water set temperature will be changed.

HOT WATER button set to "ON"

ANTI BACTERIA button set to "ON"

Anti bacteria start time

75 hot water supply operation

°C

75 hot water supply operation for 30 minutes

°C

Usual hot water supply operation

(Set temperature: 40 to 75

°C

)

°C

Caution

• During a 75°C hot water supply operation with ANTI

BACTERIA, the remote controller does not display 75°C.

• Be careful not to burn yourself; Output water may be hotter

than that displayed on the remote controller.

Related FC

FC No.

Setting item

Anti bacteria set temperature

Anti bacteria holding time

Default

75°C

Setting available range

70-80°C

30 mins

22:00

0 - 60 mins

Remote control Anti bacteria start time

0:00-22:00

Remote control Anti bacteria operation cycle

7 days

Every day to 10 days

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Item

Operation flow and applicable data, etc.

8-2.

9) Night set back (NIGHT SET BACK) operation

A night set back operation performs heating at 5°K lower and cooling at 5°K temperatures against the remote controller

set temperature from the setting start time (22:00) to the end time (6:00) every day.

Operation

Mode and

Control Method

Note) • Set the remote controller time before starting a NIGHT SET BACK operation.

• The set time can be changed with remote controller FC.

Related FC

FC No.

Setting item

Default

Setting available range

Remote controller Night set back start Time setting

22:00

0:00-23:00

Remote controller Night set back end Time setting

6:00

0:00-23:00

3 -20 deg

Night set back setting Temperature width

5 deg

10) FROST PROTECTION operation

A frost protection operation performs heating at the set temperature RSC_F = 15°C (FC).

1) How to operate

• Pressing the remote controller [ZONE1, 2] button and then the [FROST PROTECTION] button starts a heating

operation at the set temperature of 15°C.

• Pressing again the [FROST PROTECTION] button cancels the FROST PROTECTION operation.

• The remote controller displays "F" as the temperature during FROST PROTECTION.

• A set temperature change during a FROST PROTECTION operation cancels the operation.

Related FC

FC No.

Setting item

FROST PROTECTION Yes / No

FROST PROTECTION Set temperature

Default

1: Yes

15°C

Setting available range

0: No

10-20°C

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Operation flow and applicable data, etc.

8-2.

11) AUTO operation

An auto operation sets the water temperature TSC_F depending on the outside temperature TO by following the table

below.

Operation

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. An

operation starts at the set temperature of straight -line approximation for the following: water temperature 40°C with

the outside temperature -20°C (FC), 35°C with -10 °C (T1)(FC), 30°C with 0°C (FC), 25°C with 10°C (T3), and 20°C

with 20°C (TC).

• For 2-temperature control, although Auto-Curve in ZONE2 shows 80% of that of ZONE1 (FC), the water temperature

setting does not fall below 20°C.

• During an AUTO operation, pressing again the [AUTO] button returns to the usual manual set heating operation.

• The remote controller displays "A" as the temperature during an AUTO operation.

(When 2-temperature control is enabled, the remote controller displays "A" "A".)

• Long-pressing the [AUTO] button during an AUTO operation activates the Auto-Curve FC change mode, enabling

the set Auto-Curve water temperature to be changed in the 5K range. (FC_27)

• Even if the temperature setting is changed during an AUTO operation, the operation continues.

• An AUTO operation works with a heating operation only, not with a cooling or a hot water supply operation.

Auto-Curve

ZONE1

40(A)

35(B)

30(C)

25(D)

Auto-Curve

ZONE2

20(E)

-20

-10

(T1)

(T3)

Related FC

FC No.

Setting item

Default

Setting available range

-5 to 5 k

Set temperature shift with heating set to Auto

Outside air temperature T1 temperature

Outside air temperature T3 temperature

-10°C

10°C

40°C

35°C

30°C

25°C

20°C

80%

-15-0°C

0-15°C

Set temperature when out side air temperature is -20 °C.

Set temperature when out side air temperature is -10 °C (T1).

Set temperature when out side air temperature is 0 °C.

Set temperature when out side air temperature is 10 °C (T3).

Set temperature when out side air temperature is 20 °C.

20-55°C

Auto-Curve ratio of

ZONE2

0-100%

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Operation flow and applicable data, etc.

8-2.

12) Nighttime low-noise operation

A night time low-noise operation reduces operation frequency and the number of outdoor fan rotations for a certain period

during nighttime as noise control for neighborhood.

Operation

Mode and

Control Method

Maximum operation frequency 40.2 Hz (Hot water supply/ Heating/ Cooling)

Maximum fan tap

460 rpm (802H-E)

500 rpm (1102H-E, 1402H-E)

The nighttime low-noise operation is enabled/ disabled by changing the remote controller FC_09.

1) Press the TEMP.

noise setting mode)

The Code No. field displays "09", and the DATA "0000",

and TEST

button at the same time for 4 seconds or longer. (Shifted to the nighttime low-

, and being displayed blink.

2) Press TIME

Pressing SET

to set enable "1" or disable "0".

change DATA and display to be lit and the setting is confirmed.

(When "1" as enable is set, the nighttime low-noise setting is enabled, the control starts at the set start time.)

3) Press TEST

status.

to exit the nighttime low-noise time setting mode. The

and

goes out, returning to its original

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Operation flow and applicable data, etc.

8-3.

1) Capacity control (compressor, high-temperature release, low-temperature release)

Hydro Unit

Control

This unit controls the compressor frequency and heater output so that the water outlet temperature matches the remote

controller set temperature.

1-1) Compressor control

• Calculates the different between the remote controller set temperature (TSC_H, TSC_F) and the water outlet

temperature (Hot water supply: THO, Heating: TWO).

• Sets the Hz signal correction amount that determines the number of compressor rotations by the temperature

difference.

• Detects the number of compressor rotations.

• Compares the Hz signal correction amount and the current operation Hz, and changes the compressor output

according to the difference.

* The control details are the same for hot water supply, heating, and cooling.

Remote controller

Hydro unit

Temperature settings

(TSC_H, TSC_F)

Water outlet temperature

(THO, TWO)

TSC_H-THO for hot water supply

TSC_F-TWO

for heating/cooling

Hz signal correction

Number of compressor

rotation detection

Hz signal correction Operation Hz

Inverter output change

Number of compressor

rotation change

Compressor frequency changeable range 10 Hz to 70 Hz (802, 1402H-E)

10 Hz to 60 Hz (1102H-E)

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Operation flow and applicable data, etc.

8-3.

1-2) High temperature release control

Hydro Unit

Control

A heat pump operation is performed as shown in the table below according to the TC sensor detecting temperature.

• For the detected temperature, TC (= TWO + 2 degree) of a heat pump operation is used. The values of T7 through

T10 vary depending on TWI. (See the table below)

• If the compressor frequency instruction from the hydro unit is less then 10 Hz, the compressor stops.

• TC > 62°C causes the compressor to stop abnormally. When the compressor restarts 140 seconds after the stop

and TC > 62°C is not detected for 20 minutes, the abnormal stop counter is cleared. 10 times of compressor

abnormal stop stops the operation of heat pump, and confirms the abnormality (Display: A11).

* If the heat pump operation is switched to other operation, the abnormality detection counter is reset to 0.

Zone

Control operation

TC (TWO+2)

T11

Forcible stop

O (down)

Increase compressor frequency by 1.2 Hz every

60 secs.

(62.0°C

)

Increase compressor frequency by 0.6 Hz every

60 secs.

T10

P (slow down)

Q (keep)

Decrease compressor frequency to 70% every

10 secs.

Decrease compressor frequency by 3 Hz every

10 secs.

(slow up)

R2 (slow up)

Keep compressor frequency.

S (normal)

TC=TWO+2deg

(°C)

TWI

T10

61.0

60.5

60.0

T11

TWI<30

57.0

56.5

56.0

59.0

58.5

58.0

60.0

59.5

59.0

62.0

30 TWI<35

35 TWI<40

40 TWI<45

45 TWI<50

50 TWI

1-3) Low 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 of a heat pump operation is used. The values of T7 through T10 varies

depending on TWI. (See the table below)

• If the compressor frequency instruction from the hydro unit is less then 10 Hz, the compressor stops.

• TC < 3°C causes the compressor to stop abnormally. When the compressor restarts when 140 seconds has

passed after the stop and TC < 3°C is not detected for 20 minutes, the abnormal stop counter is cleared. 10 times

of compressor abnormal stop stops the operation of heat pump, and confirms the abnormality (Display: A11).

* If the heat pump operation is switched to other operation, the abnormality detection counter is reset to 0.

Zone

Control operation

TC (TWO)

S (normal)

Increase compressor frequency by 1.2 Hz every

60 secs.

R2 (slow up)

Increase compressor frequency by 0.6 Hz every

60 secs.

(slow up)

Q (keep)

Decrease compressor frequency to 70% every

10 secs.

P (slow down)

Decrease compressor frequency by 3 Hz every

10 secs.

T10

T11

O (down)

Keep compressor frequency.

Forcible stop

TC=TWO

(°C)

TWI

8.0

8.5

9.0

9.5

6.0

6.5

7.0

7.5

T10

4.0

4.5

5.0

5.5

T11

TWI<10

10.0

10.5

11.0

11.5

3.0

10 TWI<15

15 TWI<20

20 TWI

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Operation flow and applicable data, etc.

8-3.

Hydro Unit

Control

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.

• When 30 minutes has passed after the hot water heat pump operation started.

• The water inlet temperature (TWI) reaches 50°C.

• The hot water cylinder sensor reaches the HP_OFF temperature (45°C-FC).

• The HP_ON temperature (38°C-FC) is reached without the hot water HP status.

• HOT WATER BOOST operation is in progress.

TTW

Abnormality detection

Z zone

Y zone

Diff : 2K

Heater off

X zone

Heater on

TSC_H-4

TSC_H

Hot Water Boost

Heater on only with

HP_OFF(45)

Hot Water Boost in operation

(Heater on without

hot water HP)

HP_ON (38)

(Hot water HP start)

2-2) Heating operation

1) Heater control at the time of heat pump operation

• Object to be controlled: Backup heater

The backup heater control starts when 13 minutes has passed after the heating heat pump operation started and

select the ZONE (A-D). The backup heater control increases, decreases, or maintains the number of heaters

every 10 minutes (FC) depending on the difference between the heating set temperature (TSC_F) and the heater

outlet temperature (THO). When the heating set temperature (TSC_F) is reached, the hydro stops energizing

the backup heater.

THO

E zone

Abnormality detection

Diff : 2K

D zone

Heater off

TSC_F-2

Heater output down every

5, 10, 15, or 20 minutes

C zone

B zone

TSC_F-4

TSC_F-6

Diff : 2K

KEEP

Diff : 2K

A zone

Heater output up every

10, 20, 30, or 40 minutes

Status

Heater ON / OFF

Backup heater 3 kW = ON

Backup heater 9 kW = ON

Heater 1

Heater 2

The single-phase model of 3 kW has the backup heater 1 only.

The three-phase model of 6 kW has heater 1+2 of 6 kW.

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Operation flow and applicable data, etc.

8-3.

Hydro Unit

Control

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.

The backup heater control increases, decreases, or maintains the number of heaters every 10 minutes (FC)

depending on the difference between the heating set temperature (TSC_F) and the heater outlet temperature

(THO). Note that when the heating set temperature (TSC_F) is reached, the unit stops energizing the heater.

THO

E zone

Abnormality detection

Diff : 2K

D zone

Heater off

TSC_F-0

Heater output down every

5, 10, 15, or 20 minutes

C zone

TSC_F-2

Diff : 2K

B zone

KEEP

TSC_F-4

Diff : 2K

A zone

Heater output up every

10, 20, 30, or 40 minutes

Status

Heater 1

Heater 2

Heater 3

Heater ON / OFF

Backup heater 3 kW = ON

Backup heater 9 kW = ON

Heater 2 + Booster heater

The single-phase model of 3 kW has the backup heater 1 only.

The three-phase model of 6 kW has heater 1+2 of 6 kW.

Contact point output only is available for booster heater.

Related FC

FC No.

Setting item

Hot water supply heat pump start temperature

Hot water supply heat pump stop temperature

Heater control of down time

Default

38°C

Setting available range

20-45°C

45°C

40-50°C

1:10 mins

0:10 mins

0:5 mins 2:15 mins 3:20 mins

1:20 mins 2:30 mins 3: 40 mins

Heater control of up time

2-3) Heater control at the time of defrosting

• Object to be controlled: Backup heater

THO

When a defrosting operation starts during the heating heat

pump operation, the unit energizes a backup heater (3 kW)

according to the heater outlet temperature sensor (THO) and

the set temperature (TSC_F) as follows.

TSC_F

Heater off

TSC_F-β (β=2)

Heater 1

TSC_F-α (α=4)

1) When the heater outlet temperature sensor (THO) drops to

the temperature of 2°C below the set temperature

Status

Heater ON / OFF

Heater 1 Backup heater 3 kW = ON

Defrosting ends according to the usual heater control.

2-4) Forcible heater energization

To prevent freeze, the unit energizes or stops energizing a backup heater (3 kW) regardless of the unit status, not

operated or in operation.

• Object to be controlled: Backup heater

1) Energization start condition: TWO < 4 or TWI < 4 or THO < 4

2) Energization stop condition: TWO 5 and TWI 5 and THO

Defrosting ends according to the usual heater control.

2-5) No heater operation

According to the DP_SW11 setting, the unit switches the energize/ not energize for the hot water cylinder, backup

heater, and booster. For details, see 10-1.

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Operation flow and applicable data, etc.

8-3.

3) Circulation pump control

Hydro Unit

Control

One circulation pump (enhancing pump P2) can be connected to the unit in addition to the built-in circulation pump P1.

DP_SW10-1, 3 within the water heat exchanger enables the built-in pump P1 to be set either to usual energization or

only HP and backup heater energization, and also enables the enhancing pump P2 to be set either to interlocked or

non-interlocked with the built-in pump.

Item

AC pump

Heater ON / OFF

01: None

Initial value

Switch

02: None

03: Enhanced pump (P2)

Interlock / Non-interlock with

built-in pump

OFF: Interlock

SW10-3

04: None

Existence &

position setting

*1 The pump 1 in HP operates only in hot water supply side.

*2 Setting the enhancing pump P2 to non-interlock sets the pump P1 to usual energization.

3-1) Circulation pump (Built-in pump P1)

Pump type: AC motor, rated voltage 230V, manually changeable 3-level pump speed

The pump operation starts when the following condition is met.

• The [HOT WATER] or [ZONE1, 2] button is pressed.

The pump operation ends when the following condition is met.

• Pressing the [HOT WATER] or [ZONE1, 2] button stops the about 1 minute later.

The pump operation stops or re-starts as follows:

• Stops for 30 seconds when the operation mode changes.

• Stops the pump when a boiler instruction is given and 70°C TWI or TWO or THO is met.

• Re-starts the pump when a boiler instruction is given and 65°C > TWI and TWO and THO is met.

Operation when DP_SW10-1 "ON: HP operation only" is selected

• The pump stops only when the hot water cylinder heater is in operation. The pump does not stop with the heating

thermostat off.

3-2) Circulation pump (Enhanced pump P2)

Pump type: AC motor, rated voltage 230V, directly connectable to the unit with the rated output of up to 200W.

DP_SW10-3 enables the pump P2 to be set either to interlock or non-interlock with the built-in pump P1. Setting to

non-interlock sets the pump1 to usual energization.

4) Flow switch operation

Setting the flow switch to On or OFF determines whether water flows in the water heat exchanger.

Model

HWS-802**-E

HWS-1402**-E

Criteria for water flowing

Flow 13 L/min or more

Flow 17.5 L/min or more

Criteria for water not flowing

Flow less than 13 L/min

Flow less than 17.5 L/min

When start the hot water supply, heating, or cooling operation, failure to determine whether water flows does not energize

HP, the backup heater, and booster heater. The "A01" error code display also blinks in this case.

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Operation flow and applicable data, etc.

8-3.

Hydro Unit

Control

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.

When Mixing Valve "Yes" is selected, the unit controls Mixing Valve every 4 minutes (FC) based on the difference TSC_Δ

T between the Zone2 set temperature and TFI (floor inlet water temperature sensor) temperature as follows:

TSC_ΔT

-2 TSC_ΔT < 2

-2 > TSC_ΔT

Control value

+ 1 step (Open)

0 step

- 1 step (Close)

Initial value

Driving range

1 step

Control cycle

0-12

3 WV move 7.5 degs

4 mins (FC)

For 2-temperature control, DP_SW12-3 Zone2 "Yes" must be selected.

Related FC

FC No.

Setting item

Mixing Valve operation time

Mixing Valve control time

Default

Setting available range

30 - 240 secs

1 - 30 mins

6) Q-H characteristics of hydro unit

The following shows the Q-H characteristics.

6-1) HWS-801XWHM3-E, T6-E

Hydraulic heat exchanger(8kW)QH characteristics

Minimum flow rate

SW3

SW2

Out of

Operation

Range

SW1

Flow rate(L/min)

6-2) HWS-1402XWHM3-E, T6-E, T9-E

Hydraulic heat exchanger(14kW)QH characteristics

Minimum flow rate

SW3

Out of Operation

Range

SW2

SW1

Flow rate(L/min)

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Operation flow and applicable data, etc.

8-3.

7) Automatic restart control

Hydro Unit

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. (The merit functions

are also enabled)

• Approximately 6 hours or more after a power outage

The operation status before a power outage automatically restarts after the power is on again.

But the merit functions (Night Set Back, Anti Bacteria) are disabled.

The remote controller time displays "--:--". (The merit functions are disabled)

7-2) Operation during forcible automatic operation

A forcible automatic operation is performed when the power is on again after a power outage.

7-3) Operation during defrosting operation

When the power is on again after a power outage, the usual operation restarts.

Note: The operation details recorded before a power outage

Operation mode: Hot water supply, Heating, Cooling, Hot water supply + Heating, Hot water supply + Cooling

Set temperature: Hot water set temperature, Heating set temperature, Cooling set temperature

Merit function:

Hot water supply operation (Anti Bacteria)

Heating operation (Night Set Back)

8) Piping freeze prevention control

This control operates when the power is on regardless the remote controller setting ON or OFF.

To prevent frost bursting of the water piping for hot water supply and heating, the unit flows water with the circulation

pump when the temperature sensor value falls below a certain temperature.

8-1)Piping freeze prevention control 1

1) Start condition: TWO < 4°C or THWI < 4°C.or THO < 4°C

2) End condition: TWO 5°C and TWI 5°C and THO 5°C

3)-1 How to operate (circulation pump)

• When the circulation pump is not in operation, if the sensor detects the freeze prevention control start

temperature, the unit operate the circulation pump.

• During a freeze prevention operation, a heat pump operation does not start.

• When neither [HOT WATER] nor [ZONE1, 2] is in operation, if the end condition is not met when 3 minutes has

passed after an operation starts, the unit performs the operation in 3)-2 to prevent freeze.

3)-2 How to operate (circulation pump + backup heater)

• When neither [HOT WATER] nor [ZONE1, 2] is in operation, if the end condition is not met when 3 minutes has

passed after an operation starts.

• End condition: TWO 5°C and TWI 5°C and THO 5°C

• Heating with the set temperature 55°C operates.

3)-3 Abnormal stop

• If a freeze prevention operation continues for 30 minutes and does not meet the end condition, the operation

stops as abnormal stop. (Remote controller check code: A5)

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8-3.

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.

2) Determination cancellation conditions

Hydro Unit

Control

• The stop or operation mode is changed by the remote controller

• The mode is defrosting at the time of determination

At the next time of defrosting, the start condition is not met.

• The mode is other than defrosting at the time of determination

After cooling, heating, hot water heat pump restarts, the start condition is not met for 10 minutes.

3) Error display

• If freeze determination cancellation condition is not met, A4 error is displayed.

8-3) Piping freeze prevention control 3

This control applies only when defrosting is in operation.

1) Determination condition: During defrosting, TWI 15°C is continuously detected for 30 seconds or longer (After

the stop, the unit restarts.)

2) Determination cancellation condition

• At the next time of defrosting, the start condition is not met.

3) Error display

• If freeze determination cancellation condition is not met, A4 error is displayed.

8-4) Piping freeze prevention control 4

When the value of Ps sensor is low, freeze prevention is activated regardless of a heat pump operation mode.

1) Determination condition: Lo pressure sensor detects PS < 0.2 MPa and 30 seconds passes (defrosting and

cooling) (During a defrosting operation for cooling and heating, or hot water supply)

Lo pressure sensor detects PS < 0.2 MPa and 10 minutes passes (heating and hot water

supply operation)

2) Determination cancellation condition

• After a restart, the start condition is not met for 30 minutes.

• At the next time of defrosting, the start condition is not met. (Defrosting operation for heating or hot water supply)

3) Error display

• If freeze determination cancellation condition is not met, A8 error is displayed.

9) High return water protect control.

The hydro unit protects against high return water which made by separate boiler system.

TWI, TWO, THO

A02 error detect

(Diff : 2K)

Normal operation

When A02 error appeared, the built-in pump will stop.

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Operation flow and applicable data, etc.

3. Hydro Unit

Control

10) Room temperature thermostat control (Option

TCB-PCMO3E

board TCB-PCM03E is necessary. Connect

the connection cable to the water heat

exchange board CN211.)

PJ17

When the room thermostat is connected and

heating or cooling operates with DP_SW12-4

set to ON, an room thermostat operation is

performed.

CN210

Red

CN211

Black

Terminal label

10-1)Heating thermostat operation

When the heating room thermostat is OPEN, the usual heating AUTO operation is performed.

After 30 minutes has passed, if the heating room thermostat continues to be in the OPEN status, the operation raises

the water temperature by 1 degree every 30 minutes. The same heater control as that of the usual HP operation

applies to the backup heater and booster heater.

When the heating room thermostat is CLOSE, the heat pump performs thermostat off. During the thermostat off, the

operation lowers the set water temperature by 1 deg every 30 minutes. When the thermostat off is completed, the

backup heater and booster heater stops being energized.

10-2)Cooling thermostat operation

When the cooling room thermostat is CLOSE, the usual cooling operation is performed. (Initial set water temperature

20°C)

After 30 minutes has passed, if the room thermostat continues to be in the OPEN status, the operation lowers the

water temperature by 1°C every 30 minutes.

When the cooling room thermostat is OPEN, the heat pump performs thermostat off. During the thermostat off, the

operation raises the set water temperature by 1 degree every 30 minutes.

Indoor thermostat

contact point

Correction control

Heating operation

Cooling operation

OPEN

Setting shift UP

Thermostat ON

Thermostat OFF

Up water temperature by 1 deg every 30 Lower water temperature by 1 deg every

mins

Setting shift DOWN Thermostat OFF

30 mins

Thermostat ON

Lower water temperature by 1 deg every Up water temperature by 1 deg every 30

30 mins mins

11) Forcible stop control (Option board TCB-PCMO3E is necessary. Connect the connection cable to the water heat

exchange board CN210.)

• When CLOSE occurs between "HEAT" and "COM" of TCB-PCM03E, the RED LED on the option board lights and

the operation (hot water supply, heating, cooling) stops. To restart the operation, use the operation button of the

remote controller.

12) Output signal control 1 (Option board TCB-PCIN3E is necessary. Connect the connection cable to the water heat

exchange board CN208.)

• If an error detecting signal is output, CLOSE occurs between the terminal 1 and 2.

• If a boiler output signal is output, CLOSE occurs between the terminal 3 and 4.

• In either signal above is output, the red LED on the Option board lights.

13) Output signal control 2 (Option board TCB-

TCB-PCIN3E

PCIN3E is necessary. Connect the connection

cable to the water heat exchange board

CN209.)

PJ20

CN208

Blue

• When defrosting is in operation, CLOSE

occurs between the terminal 1 and 2.

• When the compressor is in operation,

CLOSE occurs between the terminal 3 and

In either signal above is output, the red LED on

the OP board lights.

CN209

Green

Terminal label

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Operation flow and applicable data, etc.

8-4.

1) PMV (Pulse motor valve) control

Outdoor unit

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.

• At the time of a cooling operation, PMV is controlled with the usual target value of 1 to 4 K temperature difference

between TS sensor and TC sensor.

• At the time of a hot water supply or heating operation, PMV is controlled with the usual target value of 2 to 4 K (for

802H-E) or -1 to 4 K (for 1102, 1402H-E) temperature difference between TS sensor and TE sensor.

• For both cooling and heating, if the cycle is overheated, PMV is controlled using the TD sensor.The usual target value

is 91°C for a cooling operation, and 96°C for a heating operation.

* A defective sensor may cause liquid back flow or abnormal overheat of the compressor, significantly shortening the

compressor life. If the compressor or other equipment is repaired, first check that the resistance of each sensor or

the refrigerant cycle has no problem, then start the operation.

2) Discharge temperature release control

This control detects an abnormality of the refrigerant cycle or compressor to perform failure prevention.

• This control reduces operation frequency if the PMV control does not lower the outlet temperature or if the outlet

temperature rapidly rises. The frequency control is broken down to the unit of 0.6 Hz to stabilize the cycle.

• If the discharge temperature detects the abnormal stop zone, the compressor stops and then restarts after 150

seconds. The abnormality detection counter is cleared when the operation continues for 10 minutes. If detected 4

times, the error code is displayed and the compressor does not restart.

* An abnormality could occur due to too less refrigerant, PMV defective, or cycle stuck.

• For details about an error displayed, see the check code list.

TD [°C

]

Abnormal stop

111

Frequency normal down

109

106

103

Frequency slow down

Frequency hold

Frequency slow up

(up to the point instructed)

As instructed

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Operation flow and applicable data, etc.

8-4.

3) Current release control

Outdoor unit

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.

• The number of compressor rotation instructed by the hydro unit is used to determine whether the current value

exceeds the specified value.

• If exceeds, the number of compressor rotation is reduced to the most approximate number instructed by the hydro

unit within the specified value range.

Outside air temperature (TO)

Current release point setting

Outdoor unit current inverter

Main circuit control current

Operation current Settings

Compressor operation Hz down

Yes

Current degradation

Capacity control continue

Heating

Current release value (A)

Outside temperature

TO (degree °C)

802H-E

12.0

1102, 1402H-E

12.0

35 TO

15 TO < 35

TO < 15

20.0 - (To - 15) × 0.4

20.0

20.0 - (To - 15) × 0.4

20.0

Cooling

Current release value (A)

Outside temperature

TO (degree °C)

802H-E

9.5

1102, 1402H-E

44 TO

15.0

17.7

20.0

39 TO < 44

10 TO < 39

13.0

16.0

No cooling operation available for TO < 10°C.

(A) CT

20.0

12.0

4) Current releases shift control

During a cooling operation, this control prevents the electronic parts, such as a compressor drive element, and

compressor from failing.

• The current release control value (I) is selected from the following table according to the TO sensor value.

Current release control value (I)

Temperature range

50°C TO

802H-E

10.5

1102H-E

14.1

1402H-E

14.1

45°C TO < 50°C

39°C TO < 45°C

TO < 39°C

10.5

14.1

14.0

14.1

16.4

16.0

14.1

16.4

TO abnormal

10.5

14.1

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Item

Operation flow and applicable data, etc.

8-4.

Outdoor unit

control

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.

The number of fan tap rotation allocation [rpm]

200

230

240

200

260

240

200

300

260

280

340

320

360

380

400

420

480

500

460

500

520

802H-E

Upper

Lower

1102,

1402H-E

520

530

550

570

610

630

600

640

660

630

660

700

670

720

740

710

780

820

740

890

910

802H-E

Upper

Lower

1102,

1402H-E

5-1) Cooling fan control

• The TL sensor, TO sensor and operation frequency control the outdoor fan. The control is performed by 1 tap of

the DC fan control (14 taps).

• For 60 seconds after the start, the maximum fan tap for each zone that is shown in the following table is fixed. After

that, the fan is controlled according to the TL sensor temperature.

TL [°C

]

WE 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)

HWS-802H-E

20 Hz or more to less

than 45 Hz

Less than 20 Hz

45 Hz or more

Temperature range

Minimum

Maximum

Minimum

Maximum

Minimum

Maximum

38°C TO

29°C TO < 38°C

15°C TO < 29°C

5°C TO < 15°C

0°C TO < 5°C

-4°C TO < 0°C

TO < -4°C

OFF

TO abnormal

HWS-1102H-E, 1402H-E

20 Hz or more to less

than 45 Hz

Less than 20 Hz

45 Hz or more

Temperature range

Minimum

Maximum

Minimum

Maximum

Minimum

Maximum

38°C TO

(WB for 1102)

29°C TO < 38°C

15°C TO < 29°C

5°C TO < 15°C

0°C TO < 5°C

-4°C TO < 0°C

TO < -4°C

TO abnormal

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Operation flow and applicable data, etc.

8-4.

5-2) Hot water supply and heating fan control

Outdoor unit

control

1) The TE sensor, TO sensor and operation frequency control the outdoor fan.

(The minimum W1 to the maximum are controlled according to the table below.)

2) For 3 minutes after the start, the maximum fan tap for each zone that is shown in the following table is fixed. After

that, the fan is controlled according to the TE sensor temperature.

3) If TE 24°C continues for 5 minutes, the operation stops. No error code is displayed for this; the status is the same

as the usual thermostat off. The operation restarts after 150 seconds. This intermittent running is not abnormal.

4) If the situation in 3) frequently occurs, the possible cause is that the filter in the air inlet part of the hydro unit is

dusty. Clean the filter, and restart the operation.

TE [°C

]

-2 tap/20 secs (to W1)

Stop time count

-2 tap/20 secs (to W1)

-1 tap/20 secs (to W1)

Number of revolutions hold

+ 1 tap/20 secs

(Up to the maximum tap for each zone)

For 802H-E

20 Hz or more to less

than 45 Hz

Less than 20 Hz

45 Hz or more

Temperature range

Maximum

10°C TO

5°C TO < 10°C

-3°C TO < 5°C

-10°C TO < -3°C

TO < -10°C

TO abnormal

For 1102H-E

20 Hz or more to less

than 45 Hz

Less than 20 Hz

45 Hz or more

Temperature range

Maximum

10°C TO

5°C TO < 10°C

-3°C TO < 5°C

-10°C TO < -3°C

TO < -10°C

TO abnormal

For 1402H-E

20 Hz or more to less

than 45 Hz

Less than 20 Hz

45 Hz or more

Temperature range

Maximum

10°C TO

5°C TO < 10°C

-3°C TO < 5°C

-10°C TO < -3°C

TO < -10°C

TO abnormal

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Item

Operation flow and applicable data, etc.

8-4.

Outdoor unit

control

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.

1) During a heating operation, defrosting is performed when the TE sensor meets any of the conditions in A through D

zones.

2) During defrosting, when TE sensor maintains 12°C or higher for 3 seconds or 7°C TE < 12°C for a minute, the

defrosting ends. Also, when defrosting continues for 10 minutes even if the TE sensor temperature is below 7°C, the

defrosting ends.

3) After the defrosting, stop the compressor for approx. 40 seconds before starting a heating operation.

4) Switching the jumper "J805" and "J806" of the outdoor control board can change the time of d above mentioned.

(Factory setting: 150 minutes)

Heating operation starts

[°C]

[min]

-2

-5

A zone

-10

D zone

*¹In 10 to 15 minutes after the heating

operation starts, the lowest value of

TE is recorded as TEO, and the

lowest temperature of To as ToO.

*²Inside brackets: For 802H-E

B zone

-23

(-25)*²

C zone

To Normal

A Zone

B Zone

Maintain " (TEO - TE) - (ToO - To) 3°C" for 20 secs

Maintain " (TEO - TE) - (ToO - To) 2°C" for 20 secs

Maintain " TE -23°C" for 20 secs (1102, 1402H-E)

Maintain " TE < -25°C" for 20 secs (802H-E)

C Zone

D Zone

Accumulate compressor operation status of TE < -2°C for 150 mins

To Normal

A Zone

B Zone

Maintain " TEO - TE 3°C" for 20 secs

Maintain " TEO - TE 2°C" for 20 secs

Maintain " TE -23°C" for 20 secs (1102, 1402H-E)

Maintain " TE < -25°C" for 20 secs (802H-E)

C Zone

D Zone

Accumulate compressor operation status of TE < -2°C for 150 mins

Jumper switching

O: Short circuit ×: Open

J805

J806

d (1102,1402H-E)

150 mins (Factory setting)

90 mins

d (802H-E)

150 mins (Factory setting)

90 mins

60 mins

30 mins

Defrosting operation

OFF

Compressor

Outdoor fan

4-way valve

OFF

500pulse

200pulse

Outdoor PMV 0pulse

30s 40s

0s 10s 30s

40s

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Item

Operation flow and applicable data, etc.

8-4.

7) Winding heating control

Outdoor unit

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.

Also, when starting an operation long after the power left off, first energize the compressor before starting the

operation in the same way as a trial run.

3) Energization is determined by the TD sensor and TO sensor. If the TO sensor fails, the TE sensor automatically takes

over the operation. Determine whether the TO sensor fails by checking the LED outside.

4) If TD is 30°C or higher, the energization stops.

(Usual)

Not energized

18°C

*Energization

15°C

condition

Intermittently energized

10 mins: ON / 5 mins: OFF

Output "equal to 40W"

TD 30°C

10°C

°C

Continuously energized

Output "equal to 40W"

(when TO sensor fails)

Not energized

20°C

*Energization

condition

TD 30°C

18°C

12°C

Intermittently energized

10 mins: ON / 5 mins: OFF

Output "equals to 40W"

10°C

Continuously energized

Output "equals to 40W"

Notes

During winding energization, energizing noise may be heard, but this is not abnormal.

8) Short circuit operation prevention control

1) In 10 minutes after the operation start, the compressor may not stop for protection. This status is not abnormal. (The

operation duration time of the compressor varies depending on a operation status.)

2) If the operation stops with the remote controller, the operation does not continue.

9) Over current protection control

1) A detection of abnormal current with the over current protection control stops the compressor.

2) Set the abnormality detection counter to 1, and restarts the compressor after 150 seconds.

3) When the stop by over current protection control counts 8 times, error code is displayed and the compressor does

not restart.

(Remote controller error code display: HO1)

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Item

Operation flow and applicable data, etc.

8-4.

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.

Outdoor unit

control

3) When the compressor stops in 2), the operation restarts when the temperature returns to the usual operation zone

("e" or below) after 150 seconds.

4) When the compressor stops in 2), the abnormality detection counter is cleared when the operation continues for 10

minutes. If the counter counts 10 times, error code is displayed and the compressor does not restart.

5) For details about an check code displayed, see the check code list.

Heating TC

Cooling TL

[°C]

Abnormal stop

Frequency normal down

Frequency slow down

Frequency hold

Frequency slow up

(up to the point instructed)

As instructed

802H-E

1102H-E, 1402H-E

Heating

Cooling

Heating

Cooling

TC (TWO+2)

61°C

TC (TWO+2)

62°C

63°C

62°C

60°C

58°C

54°C

63°C

62°C

60°C

58°C

54°C

56°C

57°C

54°C

55°C

52°C

53°C

48°C

49°C

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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.

Procedure of defect diagnosis

Matters to be confirmed first 9-1-1 Check the power supply voltage

Remark

Check the power supply for the heat pump

hot water heater, the crossover between

the hydro unit and the outdoor unit, and the

installation of temperature sensors.

9-1-2 Check for any miswiring of the connection

cables between the hydro unit and the

outdoor unit

9-1

9-1-3 About the installation of the temperature

sensor

Non-defective operation (program operation)

Non-defective program operations for the

protection of the heat pump unit.

9-2

9-3

Outline of the determination

diagram

9-3-1 Procedure of defect diagnosis

With reference to the "check code",

roughly identify the defect from the defect

diagnosis for the heat pump hot water

heater and determine the defective part

from individual symptoms.

9-3-2 How to determine from the check code

display on the remote controller

9-3-3 How to cancel a check code on the

remote controller

9-3-4 How to diagnose by error code

Diagnosis flow chart for each

error code

9-4-1 Hydro unit failure detection

9-4-2 Outdoor unit failure detection

9-4

9-4-3 Temperature sensor, temperature-

resistance characteristic table

Operation check by PC board 9-5-1 Operation check mode

The operation check mode allows to

determine good or not by checking the

operation of the 4-way valve, 2-way valve

and pulse motor valve.

9-5

9-6

Brief method for checking the 9-6-1 Hydro unit

key components

How to determine the presence of any

defect particularly in functional parts.

9-6-2 Outdoor unit

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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. Make sure the interconnecting

connections between the hydro unit and the outdoor unit terminal blocks are connected to the correct terminal

numbers. If not connected correctly, the heat pump system does not operate. However, a miswiring would not

cause damage to the equipment.

9-1-3. About the installation of the temperature sensor

If each sensor is removed due to the replacement of the water heat exchange or inverter board, or the replacement

of the refrigeration cycle parts, make sure to put the sensor back to the position where it was before.

• Each sensor position has a marking. Make sure to put it back to the exact position.

• Make sure to install it with a sensor holder so that the temperature sensing part of the sensor and the straight

part of the copper piping are attached with each other tightly.

• If the installation of the sensor is incomplete or the installed position is wrong, it will not perform a normal control

operation and may cause a defect such as a malfunction of the equipment or an occurrence of an abnormal

sound, etc.

9-2. Non-defective operation (program operation) … No fault

code display appears.

In order to control the heat pump unit, there are the following operations as the built-in program operations in the

microcomputer. If a claim occurs about the operation, please confirm whether it falls under any of the contents in

the following table.

If it does, please understand that the symptom is not a defect of the equipment, and it is an operation necessary

for the control and maintenance of the heat pump unit.

Table 9-2-1 Non-defective operation

No.

Operation of the heat pump system

Explanation

The compressor sometimes does not operate even within the The compressor does not operate during the operation of the

range of compressor “ON”.

compressor reboot timer (3 min). Even after the power

activation, the compressor reboot timer continues to be active.

During the hot water supply or heating operation, without

reaching the set temperature, the compressor operation

frequency stays at a frequency of less than the maximum Hz or heat exchanger) or the current release control.

lowers down.

It may be caused by the high temperature release control

(release protection control by the temperature of the water

The “Stop” operation on the remote control will not stop the

circulating pump. (The same for hot water supply, heating and exchanger after stopping, the operation continues for 1 min

cooling) after the compressor is stopped.

In order to deal with the temperature increase in the heat

“ON” on the remote control will not operate the compressor. (It When the outdoor temperature (TO sensor detection

will not operate even after the reboot delay timer elapsed)

temperature) is -20°C or lower, the heat pump will not operate

in order to protect the compressor, and the heater will operate

instead.

When the power is turned on, it starts operation without

operating the remote control.

• The auto restart operation may be working.

• The antifreeze operation may be working.

• If the TWI, TWO or THO sensor detects a temperature

below 4°C, the operation changes from circulating pump

--->> circulating pump + heater.)

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9-3. Outline of the determination diagram

The first determination of whether a defective part is in the hydro unit or the outdoor unit can be performed by the

following method.

9-3-1. Procedure of defect diagnosis

In the case of a defect, please apply the following procedure in order to find the defective part.

Confirm the check

code on the remote

control display

Check code

A01-A12

Yes

Defect in Hydro unit

Defect

Yes

Abnormality in the

communication or setting

system

Check code

L07-L16

Abnormality in the water

heat exchange or outdoor

unit sensor system

Check code

FXX

Yes

Abnormality in the outdoor unit or hot-water

tank unit

9-3-2. How to determine from the check code on the remote

control

If the defect is limited by the check code displayed on the remote control, please repair the defect based on the

table on the next page.

The check codes are separated into two groups: software and hardware errors.

Since a hardware error cannot be cancelled without a part replacement etc., please perform a repair.

If its abnormality is determined, the abnormality is noticed by indicating the check code on the remote control check

code display part while letting off a buzzer.

Check code display part

9-3-3. How to cancel a check code on the remote controller

(1) Press

ZONE1,2

HOT WATER

button (on the operation side) to clear the check code.

(2) Press

to stop a buzzer for an abnormality only.

Although the above procedure cancels the check code, the hardware error will be displayed again until the

hardware repair is completed.

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9-3-4. How to diagnose by error code

Defect mode detected by the water heat exchange

O ... Possible

×.... Not possible

Diagnostic functional operation

Number of

abnormalities Detailed

Check

code

Determination and action

Backup Automat

present ic reset

for

item

Operational cause

confirmation

Pump or flowing quantity error

1) Detected by TC sensor

TC 63°C is detected in the heating or

hot water supply heat pump operation

(except for defrosting).

1. Almost no or little water flow.

• Not enough vent air

2)Detected by flow switch abnormality

• Dirt clogging in the water piping

system.

When no signal of the flow switch is

showing 2 min after the built-in pump

operation started.

• The water piping is too long.

• Installation of buffer tank and

secondary pump

A01

3)Detection of chattering abnormality in

the flow switch input

Chattering detection: Detects input

changes (OFF⇔ON) 4 times within

10 seconds during operation.

4)Disconnection of the flow switch

connector

1. Disconnection of the flow switch

connector.

When the stopped built-in pump starts

its operation, the flow switch status is

detecting "water flow".

2. Defect of the flow switch.

Temperature increase error (heating)

When one of the TWI, TWO and THO

sensors exceeds 70°C.

1. Check the water inlet, water outlet

and heater outlet (TWI, TWO, THO)

sensors.

Heating

A02

A03

Hot water

2. Defect of the backup heater (defect

automatic reset thermostat).

Temperature increase error (hot water Heating

1. Check the hot water cylinder sensor

(TTW).

supply)

Hot water

When the TTW sensor exceeds 85°C.

2. Check the hot water cylinder thermal

cut-out.

Antifreeze operation

1. Almost no or little water flow.

• Dirt clogging in the water piping

system.

1)TWO>20°C condition:

2×TC+TWO < -12°C is detected.

• The water piping is too long.

2)TWO 20°C condition:

TC+TWO < 4°C is detected.

2. Check the heater power circuit.

• Power supply voltage, breaker,

power supply connection

Heating2

Hot water2

Cooling4

3)TWI 10°C is detected during

defrosting.

A04

3. Set the presence of the backup

heater.

4. Check the water inlet, water outlet

and heat exchange (TWI, TWO, TC)

sensors.

Piping antifreeze operation

Activating the heater under the condition

of TWO<4orTWI<4orTHO<4 does not

achieve TWO,TWI,THO 5°C after 30

min elapsed.

1. Check the heater power circuit.

• Power supply voltage, breaker,

power supply connection

A05

2. Check the water inlet, water outlet

and heater outlet sensors (TWI,.

TWO, THO).

3. Disconnection of the backup heater.

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Diagnostic functional operation

Number of

abnormalities Detailed

Check

code

Determination and action

Backup Automat

present ic reset

for

item

Operational cause

confirmation

Pressure switch operation

1. Almost no or little water flow.

2. Defect of the flow switch.

The pressure switch operates for 300

A07 sec continuously during the heat pump

operation.

3. On-load operation under the above

conditions.

4. Defect in the pressure switch.

Low pressure sensor operation error

1. Almost no or little water flow.

2. Defect of the flow switch.

The low pressure sensor detected 0.2

MPa or less.

A08

3. On-load cooling or prolonged

defrosting (a lot of frost formation)

under the above conditions.

4. Defect in the low pressure sensor.

Overheat protection operation

1. No water (heating without water) or

no water flow.

When the thermostat of the backup

2. Defect of the flow switch.

heater activates during the operation of

A09

the heat pump or backup heater.

3. Defect of the backup heater (poor

automatic reset thermostat).

When the thermostat operation is

activated while it has been stopped.

Operation of the release protection

When the TWO release counts to 10.

A11

Heating

Cooling

1. Almost no water flow.

2. Defect of the flow switch.

3. Check the water outlet temperature

sensor (TWO).

Hot water

Heating, hot water heater

1. Activated by a large load of heating

or hot water supply.

The antifreeze control is detected under

the condition of TWI<20°C while

2. Check the heater power circuit

(backup or hot water cylinder

heater).

• Power supply voltage, breaker,

power supply connection

A12

TWI>15°C, TTW>20°C is not detected

after the heater backup.

Regular communication error

between hydro unit and remote

1. Check remote control connection.

2. Defect in the remote control.

controller

E03

—

When there is no regular communication

from the remote control for 3 min, or

when no remote control is equipped.

Regular communication error

1. Check the serial circuit.

• Miswiring of the crossover between

the water heat exchanger and the

outdoor unit

between hydro unit and outdoor unit

E04

The serial signal cannot be received

from outdoor.

TC sensor error

1. Check the resistance value and

connection of the heat exchange

temperature sensor (TC).

F03 Open or short circuit in the heat

exchange temperature sensor.

TWI sensor error

1. Check the resistance value and

connection of the water inlet

temperature sensor (TWI).

F10 Open or short circuit in the water inlet

temperature sensor.

TWO sensor error

1. Check the resistance value and

connection of the water outlet

temperature sensor (TWO).

F11 Open or short circuit in the water outlet

temperature sensor.

TTW sensor error

1. Check the resistance value and

connection of the hot water cylinder

sensor (TTW).

F14 Open or short circuit in the hot water

cylinder sensor.

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Diagnostic functional operation

Number of

abnormalities Detailed

Check

code

Determination and action

Backup Automat

present ic reset

for

item

Operational cause

confirmation

TFI sensor error

1. Check the resistance value and

disconnection of the floor-inlet

temperature sensor (TFI).

F17 Open or short circuit in the floor

temperature sensor.

THO sensor error

1. Check the resistance value and

disconnection of the heater outlet

temperature sensor (THO).

F18 Open or short circuit in the heater outlet

temperature sensor.

Detection of THO disconnection error

F19 When TWO–THO>15K is detected and

30 sec elapsed.

1. Check for any disconnection of the

heater outlet temperature sensor

(THO).

TFI sensor error

1. Check any disconnection of the

floor-inlet temperature sensor (TFI).

F20 When TWO–TFI>30K is detected and

TFI<TWI–5K is detected.

Low pressure sensor error

1. Check for any disconnection (body

or connection wiring) of the low

pressure sensor.

When PS<0.07 MPa is detected for 2

F23

sec or more.

2. Check the resistance value of the

low pressure sensor.

EEROM error

1. Replace the water heat exchange

control board.

F29 Inconsistency is detected once without

verify ACK after writing to EEPROM.

Extended IC error

F30

1. Replace the water heat exchange

control board.

When the extended IC is abnormal.

Communication error

L07

Individual hydro units have a group line.

1. Replace the water heat exchange

control board.

Communication error

1. Check the setting of the FC01

capability specifications.

The capability of the hydro unit has not

L09

HWS-802xx-E = 0012

HWS-1402xx-E = 0017

been set.

Setting error

L16 When ZONE1 has not been set, while

ZONE2 has been set.

1. Check the body DP-SW12_2,3.

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Defect mode detected by the outdoor unit

O ... Possible

×.... Not possible

Diagnostic functional operation

Number of

abnormalities Detailed

Check

code

Determination and action

Backup Automat

present ic reset

for

item

Operational cause

confirmation

TD sensor error

1. Check the resistance value and

connection of the discharge sensor

(TD).

F04 Open or short circuit in the discharge

temperature sensor.

TE sensor error

1. Check the resistance value and

connection of the heat exchange

temperature sensor (TE).

F06 Open or short circuit in the heat

exchange temperature sensor.

TL sensor error

1. Check the resistance value and

connection of the heat exchange

temperature sensor (TL).

F07 Open or short circuit in the heat

exchange temperature sensor.

TO sensor error

1. Check the resistance value and

connection of the outdoor

temperature sensor (TO).

F08 Open or short circuit in the outdoor

temperature sensor.

TS sensor error

1. Check the resistance value and

connection of the suction

temperature sensor (TS).

F12 Open or short circuit in the suction

temperature sensor.

100

TH sensor error

1. Check the resistance value and

connection of the heat-sink

temperature sensor (TH).

F13 Open or short circuit in the heat-sink

temperature sensor.

TE, TS sensors error

1. Check for any wrong installation of

the heat exchange temperature

sensor (TE) and the suction

temperature sensor (TS).

Open or short circuit in the temperature

F15

100

sensors.

F31 EEPROM error

Compressor breakdown

1 When the operation frequency lowers

due to the current release 40 sec or

later after the compressor activation

and it stops by underrunning the

minimum frequency.

1. Check the power supply voltage

(AC230 V 23 V).

2. Over-loaded condition of the

refrigeration cycle.

H01

2 When the operation frequency lowers

due to the current limit control and it

stops by underrunning the minimum

frequency.

3. Check that the service valve is fully

open.

3 When an excess current is detected

0.8 sec or later after the compressor

activation.

Compressor lock

1. Defect of compressor (lock)

– Replace the compressor.

1 When the input current is more than

zero 20 sec or later after the

compressor activation and the

activation has not been completed.

H02

2. Defect of compressor wiring (open

phase).

Defect in the current detection circuit

1. Replace the outdoor inverter control

board.

H03

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Diagnostic functional operation

Number of

abnormalities Detailed

Check

code

Determination and action

Backup Automat

present ic reset

for

item

Operational cause

confirmation

Operation of case thermostat

When the case thermostat exceeds

125°C.

1. Check the refrigeration cycle (gas

leak).

2. Check the case thermostat and

connector.

H04

3. Check that the service valve is fully

open.

4. Defect of the pulse motor valve.

5. Check for a kinked piping.

Unset service PC board jumper

L10

L29

1. Cut J800-J803.

Jumpers J800-J803 have not been cut.

The communication between the

outdoor PC board MUCs error

No communication signal between IPDU

and CDB.

1. Replace the outdoor control board.

The outlet temperature error

When the discharge temperature sensor

(TD) exceeds 111°C.

1. Check the refrigeration cycle (gas

leak).

P03

2. Defect of the pulse motor valve.

3. Check the resistance value of the

discharge temperature sensor (TD).

P04 The high pressure switch error

The power supply voltage error

P05 When the power supply voltage is

extremely high or low.

1. Check the power supply voltage.

(AC230 V 23 V)

Overheating of heat-sink error

1. Check the thread fastening and

heat-sink grease between the

outdoor control board and the heat-

sink.

When the heat-sink exceeds 105°C.

P07

2. Check the heat-sink fan duct.

3. Check the resistance value of the

heat-sink temperature sensor (TH).

Detection of gas leak

1. Check the refrigeration cycle (gas

leak).

When the discharge temperature sensor

(TD) exceeds 106°C for consecutive 10

min.

2. Check that the service valve is fully

open.

3. Defect of the pulse motor valve.

4. Check for a kinked piping.

When the suction temperature sensor

P15

(TS) exceeds 60°C for cooling or 40°C

5. Check the resistance value of the

discharge temperature sensor (TD)

and the suction temperature sensor

(TS).

for heating for 10 consecutive min.

The 4-way valve inversion error

When the heat exchange temperature

sensor (TE) exceeds 30°C or the suction

1. Check the operation of the 4-way

valve unit or the coil characteristics.

2. Defect of the pulse motor valve.

P19

3. Check the resistance value of the

heat exchange temperature sensor

(TE) and the suction temperature

sensor (TS).

temperature sensor (TS) exceeds 50°C

during the heat pump operation.

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Diagnostic functional operation

Number of

abnormalities Detailed

Check

code

Determination and action

Backup Automat

present ic reset

for

item

Operational cause

confirmation

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.

1. Check that the service valve is fully

open.

2. Defect of the pulse motor valve.

3. Check the outdoor fan system

(including clogging).

P20

4. Over-filling of refrigerant.

5. Check the resistance value of the

heat exchange temperature sensor

(TL) and the water outlet

When the water outlet sensor (TWO)

detects 60°C during the heating or hot

water supply operation.

temperature sensor (TWO).

Outdoor fan system error

When a DC fan rotor position detection

NG, element short circuit, loss of

synchronization, or abnormal motor

current occurs.

1. Check the lock status of the motor

fan.

2. Check the connection of the fan

motor cable connector.

P22

1-4

3. Check the power supply voltage

(AC230 V 23 V).

Short circuit of the compressor driver

element error

1. P26 abnormality occurs when

operating with the compressor

wiring disconnected … Check the

control board.

When an abnormal short circuit of IGBT

is detected.

P26

2. No abnormality occurs when

operating with the compressor

wiring disconnected … Compressor

rare short.

Compressor rotor position error

The rotor position in the compressor

cannot be detected.

1. Even if the connection lead wire of

the compressor is disconnected, it

stops due to an abnormality in the

position detection … Replace the

inverter control board.

P29

2. Check the wire wound resistor of the

compressor. Short circuit

… Replace the compressor.

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Defect mode detected by the remote control

Diagnostic functional operation

Check code

Determination and action

Status of air-

Operational cause

conditioning

Condition

No communication between hydro Stop

–

Defect in the remote control power

supply

Not

displaying at

all

unit an remote controller

• The remote control wiring is not

connected correctly.

• The hydro unit has not been turned

on.

1. Check the remote controller wiring.

2. Check the remote controller.

(cannot

3. Check the hydro unit power supply

wiring.

operate by

the remote

control)

4. Check the water heat exchange

control board.

No communication between hydro Stop

Displayed when Defect in the reception of the remote

unit and remote controller

• Disconnection of the crossover

between the remote control and the

base unit of the indoor unit

(detected on the remote control

side).

(Automatic reset) the abnormality control

is detected.

1. Check the remote control crossover.

2. Check the remote control.

E01

3. Check the hydro power supply wiring.

4. Check the water heat exchanger

board.

Defect in the signal transmission Stop

Displayed when Defect in the transmission of the remote

to the hydro unit.

(Detected on the remote control side)

(Automatic reset) the abnormality control

is detected.

E02

E09

1. Check the transmitter circuit inside the

remote control.

… Replace the remote control.

Several remote control base units Stop

(Detected on the remote control side) (The handset

continues)

Displayed when 1.2 Check several base units with the

the abnormality

is detected.

remote control

… The base unit is only one, and others

are handsets.

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9-4. Diagnosis flow chart for each error code

9-4-1. Hydro unit failure detection

[A01] Error Pump flow determination

[A01] occurs

Operation restarts

No (No pump sound)

Pump rotates

Perform

air vent

Yes

Flow switch is

connected to board

Connect flow switch

connector to board

Yes

Excess air noise

comes from inside

the pump

Yes

Built-in pump is

connected to board

Connect pump

connector to board

Yes

Replace flow switch

Replace pump

Flow switch is normal

Yes

Chattering noise comes

from flow switch

Pump stops 2-3

minutes after its rotation

started

Yes

Flow shortage

(Identify causes, and resolve)

TC sensor characteristic

is correct

Replace TC sensor

Remove waste

Dirt clogging inside

water circuit

Yes

(strainer)

12 M or longer water

pipe to a branch,

or 5 or less branches

Fit buffer tank and the

second pump

Attach or replace

flow switch

Flow switch is normal

Yes

Water heat exchanger control board

is defective, replace it

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[A02] Error Temperature rise and error short circuit

Start

(TWI,TWO,THO 70°C)

TWI, TWO, and THO

sensor characteristics are

correct

Replace TWI, TWO,

and THO sensors

Yes

Flow switch is normal

Yes

Replace flow switch

Water outlet

temperature is 70°C

or higher

Yes

Hot water from

boiler or other circuits does

not come in

Correct water circuit

(To prevent hot water of

other circuits from entering)

Yes

Failure of backup heater

(Too large heater input,

thermostat short circuit)

Backup heater is energized

(Measure heater current)

Replace water heat exchange control board

Replace heater unit

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[A03] Error Temperature rise and error short circuit

Start

(TTW 85°C is detected)

TTW sensor

characteristic is correct

Replace TTW sensor

Yes

Hot water cylinder heater

is energized

Yes

Mg-sw (RY05) for

heater operates

Replace Mg-sw

Operating noise at normal time

Yes

At normal

temperature, tank thermostat

is energized

Yes

Hot water cylinder

thermostat operates

Replace hot water

cylinder thermostat

Operation

temperature 82°C

Yes

Replace water heat exchange control board

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[A04] Error Freeze prevention control

When the outside temperature or inlet water temperature is low (approx. 20°C or lower) and the room load is large

(operation frequency rating), the freeze prevention control may be activated.

Start

Operation restart

Perform

air vent

Secure water

circulation amount

Excess air

inside pump

Replace flow switch

Dirt clogging

inside water circuit

Yes

(inside strainer, etc)

12 M or longer

water pipe to

a branch, or 5 or

less branches

Fit buffer tank and the

second pump

Yes

Circulation

flow shortage

Chattering from

flow switch

Water heat

exchanger board DP_SW11-1

is ON

Set DP_SW11-1 to ON

Yes

Backup

heater terminal has

230ACV ( ± 23V)

Power is

connect to backup

heater terminal

Yes

Connect backup heater

power cable

Yes

Set heater breaker to ON

Check indoor wiring

Backup

heater element

is conductive

(Backup heater NG)

Replace backup heater unit

Yes

TC, TWO, TWI

sensor characteristics

are correct

Replace TC, TWO,

and TWI sensors

(See Characteristic table on page 101)

Yes

Replace water heat

exchange control board

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[A05] Error Piping freeze prevention control

Restart

TWI 4, TWO 4, or

THO 4 is detected

Circulation pump keeps

being energized or 3 minutes

passed after the start

Water heat

exchange control board

Set water heat board

DPSW11-1 to ON

DPSW11-1 is ON

Yes

Backup heater terminal

has 230ACV ( ± 23V)

Yes

Power is connect to

built-in heater terminal

Place power cable for

backup heater

Yes

Set breaker for backup heater

to ON, or Check indoor

electronic wiring

(Backup heater NG)

Replace backup heater

and safety valve

Backup heater element

is conductive

Yes

TWI, TWO, THO

sensor characteristics

are correct

Replace TWI, TWO,

and THO sensors

(See characteristic table in page 101)

Yes

Replace water heat

exchange control board

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[A07] Error Pressure switch operation (Hot water supply/Heating operation)

Start

Flow switch is normal

Yes

Replace flow switch

Remove sufficiently

excess air

Excess air

noise comes from

inside pump

Yes

Secure water

circulation amount

Waste stuck inside

water circuit

Remove waste

12 M or longer water

pipe to a branch,

or 5 or less branches

Place buffer tank and

the second pump

Chattering

noise comes from

flow switch

Circulation flow

shortage

Continued

operation at high outside air

temperature and at 50°C or higher

set temperature

Yes

Lower set temperature

TWO sensor

is attached

to pipe.

Attach TWO sensor

Yes

Pressure switch

is normal

Replace pressure switch

Yes

Replace water heat

exchange control board

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[A08] Error Lo pressure sensor lowering operation failure (Cooling/Defrosting operation)

Start

Replace flow switch

Flow switch is normal

Yes

Remove sufficiently

excess air

Excess air

noise comes from

inside pump

Yes

Secure water

circulation amount

Waste stuck inside

water circuit

Remove waste

12 M or longer water

pipe to a branch,

or 5 or less branches

Place buffer tank and

the second pump

Chattering

noise comes from

flow switch

Circulation flow

shortage

Continued

operation at low outside

temperature and at 15°C or lower

set temperature

Yes

Raise set temperature

(Cooling overload operation)

Defrosting

takes 15 mins or longer

(Frost remains)

Yes

Defrost outdoor unit

where frost remains

Lo pressure sensor

is normal

Replace lo pressure sensor

Yes

Replace water heat

exchange control board

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[A09] Error Overheat prevention thermostat failure (Hot water supply/Heating operation)

Start

Put water into water circuit

(Recommended: 1 - 2 Bar)

Water cycle contains water

Yes

Replace flow switch

Flow switch is normal

Yes

At normal temperature,

overheat preventive thermostat

is normal

Replace heater unit

exchanger air vent valve

Yes

Replace water heat exchange control board

or overheat preventive thermostat failure

*Replace water heat exchange control board or overheat preventive thermostat failure: After the control

board is replaced, if the same operation repeats, the overheat preventive thermostat is determined as

defective (does not operate at 75°C).

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[A11] Error Release protection operation

Start

Flow switch is normal

Replace flow switch

Yes

Remove sufficiently

excess air

Excess air

Yes

Waste stuck inside

water circuit

Secure water

circulation amount

noise comes from

inside pump

Remove waste

12 M or longer water

pipe to a branch,

or 5 or less branches

Place buffer tank and

the second pump

Chattering

noise comes from

flow switch

Yes

Circulation flow

shortage

TWI sensor is

attached to pipe

Attach TWI sensor

Yes

TWI and TWO

sensor characteristics

are normal

Replace TWI or TWO sensor

Yes

Replace water heat

exchange control board

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[A12] Error Heating or Hot water supply 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

nor TTW 20°C is met

A12 abnormality detection

Water heat

Set water heat board

DPSW11-1,2 to ON

exchanger board DPSW11-1,2

is ON

Yes

Backup heater or

hot water cylinder terminal

has 230ACV ( ± 23V)

Place electric wire for

backup heater

Place electric wire for

hot water cylinder

Power is connect

to backup heater or hot water

cylinder terminal

Yes

Set breaker for backup

heater to ON

Set breaker for hot water

cylinder to ON

or check indoor wiring

Replace booster heater

unit and safety valve

Backup heater element

is conductive

(Backup heater NG)

Yes

Hot water

cylinder heater element

is conductive

Replace hot water

cylinder heater

(Hot water cylinder heater NG)

(Refer to hot water

cylinder guide)

Yes

TWI, TTW sensor

characteristics are

normal

Replace TWI or TTW

sensor

(See characteristic table in page 101)

Yes

Replace water heat

exchange control board

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[E04] Error

Outdoor unit operates

Yes

Group address

of remote controller is

correctly set

Check item code "14"

Yes

Hydro unit

Internal wiring and

connecting wire (1, 2, 3)

are correct

Correct wiring and

connecting wire

Yes

CN04 connector

and terminal block (1, 2, 3) wiring

are normal

Correct connector and

terminal block wiring

Yes

Check water heat

exchanger board

If defective, replace it

When power is

on again, D502 (Amber LED)

blinks

Yes

Check water heat exchanger

control board

Check outdoor control board

If defective, replace it

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[F03] Error TC sensor failure

Start

TC sensor

connector (CN203) is

connected

Correct TC sensor

connection

Yes

TC sensor

resistance characteristic

is normal

Replace TC sensor

Yes

Replace water heat exchange control board

[F04] Error TD sensor failure

Start

TD sensor

connector (CN603) is

connected

Correct TD sensor

connection

Yes

TD sensor

resistance characteristic

is normal

Replace TD sensor

Yes

Replace water heat exchange control board

[F06] Error TE sensor failure

Start

TE sensor

connector (CN601) is

connected

Correct TE sensor

connection

Yes

TE sensor

resistance characteristic

is normal

Replace TE sensor

Yes

Replace water heat exchange control board

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[F07] Error TL sensor failure

Start

TL sensor

connector (CN604) is

connected

Correct TL sensor

connection

Yes

TL sensor

resistance characteristic

is normal

Replace TL sensor

(See characteristic table on page 101)

Yes

Replace water heat exchange control board

[F08] Error TO sensor failure

Start

TO sensor

connector (CN602) is

connected

Correct TO sensor

connection

Yes

TO sensor

resistance characteristic

is normal

Replace TO sensor

(See characteristic table on page 101)

Yes

Replace water heat exchange control board

[F10] Error TWI sensor failure

Start

TWI sensor

connector (CN205) is

connected

Correct TWI sensor

connection

Yes

TWI sensor

characteristic is normal

Replace TWI sensor

(See characteristic table on page 101)

Yes

Replace water heat exchange control board

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[F11] Error TWO sensor failure

Start

TWO sensor

connector (CN205) is

connected

Correct TWO sensor

connection

Yes

TWO sensor

characteristic is normal

Replace TWO sensor

(See characteristic table on page 101)

Yes

Replace water heat exchange control board

[F14] Error TTW sensor failure

Start

TTW sensor

connector (CN214) is

connected

Correct TTW sensor

connection

Yes

TTW sensor

characteristic is normal

Replace TTW sensor

(See characteristic table on page 101)

Yes

Replace water heat exchange control board

[F17] Error TFI sensor failure

Start

TFI sensor

connector (CN213) is

connected

Correct TFI sensor

connection

Yes

TFI sensor

characteristic is normal

Replace TFI sensor

(See characteristic table on page 101)

Yes

Replace water heat exchange control board

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[F18] Error THO sensor failure

Start

THO sensor

connector (CN206) is

connected

Correct THO sensor

connection

Yes

THO sensor

characteristic is normal

Replace THO sensor

(See characteristic table on page 101)

Yes

Replace water heat exchange control board

[F19] Error THO sensor detach failure

Start

THO sensor

is attached to pipe

Attach THO sensor

to pipe

Yes

THO sensor

characteristic is normal

Replace THO sensor

Replace TWO sensor

(See characteristic table on page 101)

Yes

TWO sensor

characteristic is normal

(See characteristic table on page 101)

Yes

Replace water heat exchange control board

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[F20] Error TFI detach failure

Start

TFI sensor

is attached to pipe

Attach TFI sensor

to pipe

Yes

TFI sensor

characteristic is normal

Replace TFI sensor

Replace TWI sensor

Replace TWO sensor

(See characteristic table on page 101)

Yes

TWI sensor

characteristic is normal

(See characteristic table on page 101)

Yes

TWO sensor

characteristic is normal

(See characteristic table on page 101)

Yes

Replace water heat exchange control board

[F23] Error Lo pressure sensor detach failure

Start

Lo pressure sensor

is detached (CN207, 212)

Yes

Attach lo pressure sensor

Replace lo pressure sensor

When operation

is stopped, lo pressure sensor

is normal *1

Yes

Replace water heat exchange control board

*1 How to determine: When operation is stopped

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[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. 1 mins)

(Power on) Handy remote

"Setting"

disappears

Reboot

(reset)

controller displays

"Setting"

(Repeat)

[F30] Error Enhanced IC failure

Enhanced IC on water heat exchanger control board is abnormal.

Replace the water heat exchanger control board to a service board.

[L07] Error

L07: In group control, one or more "individual" for group address exist.

At the time of power on, detecting the above failure automatically activates the automatic address setting

mode.

(Check code is not output)

Note that if the above failure is detected in the automatic address setting mode, a check code may be output.

[L09] Error

Yes

Hydro unit capacity

is not set

Set indoor unit capacity data

Setting item code (FC) = 01

8 kW = 12

14 kW = 17

Water heat exchange control

board (MCC-1511) Check

If defective, replace it

[L16] Error

In DP_SW12-2, 3 of main unit water heat exchanger, if ZONE1 is not set and ZONE2 is set, [L16] displays

abnormality.

Set correctly DP_SW12-2, 3.

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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. This may cause indication inconsistency

between the remote controller and LED.

Outdoor board LED indication method

Dip switch setting

SW803 1 only is ON

• Setting 1 only of SW803 to ON indicates the latest failure.

Because the error history is recorded, you can see the detail

even after the power is once turned off. (Not including outside

air temperature sensor (TO) failure)

SW803 All OFF (Initial status)

• After check work is done or when outside air temperature

sensor (TO) failure is detected, set all the SW803 switches to

OFF.

(An abnormality now is indicated.)

Indication switching

• One or more LEDs of D800 through D804 lit yellow indicates

that a failure occurred. <Indication 1>

(Normal) (Abnormality occurs)(Press SW800)

• With the status above, pressing the SW800 button for one

second causes the yellow LED to blink. <Indication 2>

• Pressing again SW800 for one second or longer returns to

<Indication 1>.

• The combination of <Indication 1> and <Indication 2> can

determine what kind of abnormality.

D800 (yellow)

D801 (yellow)

D802 (yellow)

D803 (yellow)

D804 (yellow)

D805 (green)

(Example of outlet temperature sensor failure)

Off Light Blink

Outdoor LED

Check code

Check and Action procedure

(No specific description indicates outdoor unit parts.)

indication

[H01]

[Compressor fails]

Power voltage is normal.

230ACV 23V

Improve power line

Yes

Wiring connection is normal.

Compressor lead (Board side, compressor

side reactor lead, power lead)

Check and correct wiring

connection

Yes

Abnormally over loaded

Deal with or remove causes

Check outdoor control board

If defective, replace it

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Outdoor LED

indication

Check and Action procedure

(No specific description indicates outdoor unit parts.)

Check code

[H02]

[Compressor lock]

Power voltage is normal.

230ACV 23V

Improve power line

Yes

Wiring connection is normal.

Compressor lead (board side,

compressor side) reactor, power lead

Check and correct

wiring connection

Compressor is normal.

Yes

Lock compressor and

replace it.

Refrigerant stays inside.

Yes

TE, TS sensor pulse

motor valve check

If defective, replace

Pulse motor valve operates

normally.

Yes

Check outdoor board

If defective, replace it

[H04]

[Case thermostat operation]

CN609 connector and case

thermostat is normal.

Correct connector

Replace case thermostat

Yes

If case thermostat is short circuited,

cooling and heating can operate.

Check outdoor board

If defective, replace it

Yes

No gas leakage.

Enough Refrigerant.

Correct defective portion

Re-charge refrigerant

Yes

Open fully service valve

Service valve is fully opened.

Yes

Correct defective portion

Replace defective parts

Pulse motor valve is normal.

Yes

Check for piping collapse and break.

If defective, repair or replace it.

[L10]

[Model not set] Only when service board is used

Cut jumper line by following the instruction

comes with the service board package

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Outdoor LED

indication

Check and Action procedure

(No specific description indicates outdoor unit parts.)

Check code

[L29]

* Any of the following abnormality may occur.

Seeing the LED on the outdoor board can determine which abnormality occurs.

Communication failure between MCUs, Heat sink temperature sensor (TH) failure, EEPROM

failure, Model not specified, Heat sink overheat failure, gas leakage detection, 4-way valve

invert failure

[Communication failure between MCUs]

Check outdoor control board

If defective, replace it

[Heat sink temperature sensor (TH) failure] → See [F13] details

[EEPROM failure] → See [F31] details

[Model not set] → See [L10] details

[Heat sink overheat failure] → See [P07] details

[Gas leakage failure] → See [P15] details

[4-way valve invert failure] → See [P19] details

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Outdoor LED

indication

Check and Action procedure

(No specific description indicates outdoor unit parts.)

Check code

[P03]

[Abnormal outlet temperature]

Yes

No gas leakage.

Appropriate refrigerant amount.

Correct defective portion

Re-charge refrigerant

Yes

Correct defective portion

Replace defective parts

Pulse motor valve is normal.

Yes

Deal with or remove

causes

Abnormally over loaded

CN603 connector is normal.

TD sensor resistance is normal

Correct connector

Replace sensor

Yes

Check outdoor control board

If defective, replace it

[P04]

* Any of the following abnormality may occur.

Seeing the LED on the outside board can determine which abnormality occurs.

Power source failure (Vdc), Hi pressure protection operation, Case thermostat operation

[Case thermostat operation] → See [H04] details

[Power source failure (Vdc)] → See [P05] details

[Hi pressure protection operation] → See [P20] details

[P05]

[Power source failure (voltage defective, open phase)]

Yes

Power voltage abnormally

Check electric work

drops or rise (230ACV

23V)

Check outdoor control board

If defective, replace it

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Outdoor LED

indication

Check and Action procedure

(No specific description indicates outdoor unit parts.)

Check code

[P07]

[Heat sink overheat failure]

The screws are loose in motor

drive element, Q200/300/400,

of outdoor control board and

rectifier, DB01/02/03.

Radiation grease was not applied

to backside of Q200, DB01,

DB02, or DB03.

Apply radiation grease as

needed Tighten screws

(Be sure to place back

the insulation sheet

between Q300/400 and

the heat sink.)

Yes

Ventilation flue of heat sink

is cleared, Blower is not blocked

(Short circuit, etc.).

Remove obstacles,

Deal with short circuit

Yes

Check outdoor control board

If defective, replace it

[P15]

[Gas leakage detection]

No gas leakage.

Appropriate refrigerant amount.

Yes

Correct defective portion

Re-charge refrigerant

Yes

Correct defective portion

Replace defective parts

Pulse motor valve is normal.

Yes

Open fully service valve

Repair or replace pipe

Service valve is fully opened.

Yes

Piping collapse

Temperature sensor check

Discharge sensor CN603

Suction sensor CN600

Correct connector

Replace sensor

Check outdoor control board

If defective, replace it

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Outdoor LED

indication

Check and Action procedure

(No specific description indicates outdoor unit parts.)

Check code

[P19]

[4-way valve invert failure]

4-way valve operates normally.

(Check piping temperature at the

time of cooling/heating operation)

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 .

Replace 4-way coil

Yes

Check outdoor board

If defective, replace it

Outdoor control board operation

check (See below)

4-way valve check

If defective, replace it

Outdoor control board operation check direction (Self-hold valve)

1)With the dip switch SW804 set as in the table below, pressing SW801 for approx. 1 second

can check the operation of switching to cooling cycle or to heating cycle.

• The board are energized for 10 seconds.

• Take more than a minute for the next check because the parts (coil, resistance R700)

generate large heat.(This does not apply when no coil is connected.)

2)After the check, set all the SW804 dip switches to OFF.

Switching to cooling cycle

Switching to heating cycle

SW804 SW801

CN701

SW804 SW801

CN701

Press

180DCV or higher

Note: Check with a tester

With an analog tester: If a tester shows 180DCV or higher, the board is good.

With digital tester:

Although values shown has some range, if its maximum value is

180DCV or higher, the board is good.

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Outdoor LED

indication

Check and Action procedure

(No specific description indicates outdoor unit parts.)

Check code

[P20]

[Hi pressure protection operation]

Open fully service valve

Service valve is fully opened.

Yes

Heating season

Heating operation

Reset the power source and perform

a trail operation according to the season.

Cooling season

Cooling operation

Outdoor TL sensor is normal.

(Measure resistance)

Replace sensor

Yes

Check outdoor fan

If defective, replace or tighten it

Outdoor fan is free from crack

or looseness.

Yes

Check the same item as

Outdoor fan operates normally.

those for [P22] abnormality

Yes

Something prevents outdoor unit

heat exchange

- Clogged heat exchanger

- short circuit

Yes

Remove the disturbing

element

Check for refrigerant overcharged, clogged

cycle, pipe break, abnormal overload, etc.

If defective, repair defective portion

Something prevents heat

exchange of hydro unit.

- Clogged filter

- Clogged heat exchanger

- Short circuit

Yes

Remove the

disturbing element

Check for refrigerant overcharged, clogged

cycle, pipe break, abnormal overload, etc.

If defective, repair defective portion

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Outdoor LED

indication

Check and Action procedure

(No specific description indicates outdoor unit parts.)

Check code

[P22]

[Blower system failure]

Check wiring

Request power source repair

Power voltage is normal

(230ACV 23V)

Yes

When not energized, the fan motor

can be smoothly rotated by hand.

Fan motor coil resistance is normal.

Between red - white leads 12 -20

Between white - black leads 12 - 20

Between black - red leads 12 - 20

Replace fan motor

Yes

Check outdoor control board

If defective, replace it

Outdoor fan sole operation check

1)With the dip switch SW804 set as in the table below, pressing SW801 for approx. 1 second

can check the outdoor fan sole operation. Perform this check to determine which of upper or

lower fan has a problem.

• When SW801 is pressed again for 1 second or when 2 minutes has passed, the fan stops.

2)After the check, set all the SW804 dip switches to OFF.

Outdoor fan sole operation

SW804

SW801

Press

[P26]

[Compressor drive element shorted out]

The connection between compressor

lead and reactor is correct.

(Check with wiring diagram)

Correct wiring

Yes

A operation without compressor lead No

does not cause the same problem.

Replace outdoor board

Yes

Compressor check

(rare short circuit, etc.)

If defective, replace it

[P29]

[Position detection circuit failure]

Check outdoor control board

If defective, replace it

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Outdoor LED

indication

Check and Action procedure

(No specific description indicates outdoor unit parts.)

Check code

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.

[F04]

[F06]

[F07]

[F08]

[Discharge temperature sensor (TD) failure]

TD sensor connector

(CN603) is connected

Correct TD sensor

connection

Yes

See the

TD sensor resistance

characteristic is normal

Replace TD sensor

characteristic table

on page 101

Yes

Replace outdoor control board

[Heat exchanger temperature sensor (TE) failure]

TE sensor connector (CN601)

is connected

Correct TE sensor

connection

Yes

TE sensor resistance

characteristic is normal

Replace TE sensor

See the

Yes

characteristic table

on page 101

Replace outdoor control board

[Heat exchanger temperature sensor (TL) failure]

TL sensor connector (CN604)

is connected

Correct TL sensor

connection

YES

TL sensor resistance

Replace TL sensor

characteristic is normal

See the

YES

characteristic table

on page 101

Replace outdoor control board

[Outside air temperature sensor (TO) failure]

Correct TO sensor

connection

TO sensor connector (CN602)

is connected

Yes

TO sensor resistance

characteristic is normal

Replace TO sensor

See the

Yes

characteristic table

on page 101

Replace outdoor control board

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Outdoor LED

indication

Check and Action procedure

(No specific description indicates outdoor unit parts.)

Check code

[F12]

[Suction temperature sensor (TS) failure]

TS sensor connector

(CN600) is connected

Correct TS sensor

connection

Yes

TS sensor resistance

characteristic is normal

Replace TS sensor

Yes

Replace outdoor control board

[F13]

[Heat sink temperature sensor (TH) failure]

Replace outdoor control board

[F15]

[Heat exchanger sensor (TE, TS) wrong wiring]

TE and TS sensor is

attached to the correct position.

Correct sensor attaching

position

Yes

See the

characteristic table

on page 101

TE sensor resistance

characteristic is normal

Replace TE sensor

Replace TS sensor

Yes

TS sensor resistance

characteristic is normal

See the

characteristic table

on page 101

Yes

Replace outdoor control board

[F31]

[EEPROM failure]

Check outdoor control board

If defective, replace it

100

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9-4-3. Temperature sensor, temperature-resistance characteristic

table

TC, TWI, TWO, TFI, TTW, TE, TS, TO sensors

Typical value

TD, TL sensors

Typical value

Resistance value (kΩ)

(Standard)

55.73

Resistance value (kΩ)

Temperature

(°C)

Temperature

(°C)

(Minimum)

55.42

32.33

19.63

12.23

9.75

(Maximum)

60.04

(Minimum)

150.5

92.76

58.61

47.01

37.93

25.12

17.00

11.74

8.269

5.925

4.321

3.205

(Standard)

161.3

99.05

62.36

49.93

40.22

26.55

17.92

12.34

8.668

6.195

4.507

3.336

(Maximum)

172.7

105.6

66.26

52.97

42.59

28.03

18.86

12.95

9.074

6.470

4.696

3.468

-10

100

33.80

35.30

100

20.35

21.09

12.59

12.95

10.00

10.25

7.764

5.013

3.312

2.236

1.540

1.082

0.7740

0.5634

7.990

8.218

5.192

5.375

3.451

3.594

2.343

2.454

1.623

1.709

1.146

1.213

0.8237

0.6023

0.8761

0.6434

TC, TWI, TWO, TFI, TTW, TE, TS, TO sensors

-10

100

Temperature(°C)

TD, TL sensors

200

150

100

Temperature(°C)

* Since the TH sensor (outdoor unit heat-sink temperature sensor) is built in the

outdoor control board, the resistance value cannot be measured.

101

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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.

(2) Operation check

1) Turn on the hydro unit and the outdoor unit.

2) Set SW06_2 to "ON".

3) Rotate switch SW01 to position "1" and press tactile switch SW07 for 5 sec. or longer.

4) Rotating the rotary SW01 allows to check each operation.

5) Set the DIP SW06 "OFF" to finish.

Rotary

switch

Check contents

Remark

None

2WV_W

Alive for approx. 2 sec, not alive for 3

sec

3WV_W

Mixing valve

Alive for 30 sec in the forward direction

Alive for 30 sec in the reverse direction

Built-in AC pump

Alive / not alive for 20 sec

Extended AC pump 1

(Extended AC pump 2)

Reserved

Water heat exchange backup

heater

Repeat heater 1, heater 2, and OFF

every 20 sec

The built-in AC pump operates.

Hot water cylinder heater

Backup heater

Alive / not alive for 10 sec

The built-in AC pump and external AC pump

operate.

Check the alarm output.

Check the boiler output.

Check the defrost output.

Check the operation output.

Output for 10 sec / no output for 10 sec

Continuously alive

Built-in AC pump continuous

operation

Do not operate the AC pump alive

continuously without any water in hydro unit.

102

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9-6. Brief method for checking the key components

9-6-1. Hydro unit

No.

Component name

Check procedure

Water heat exchange

temperature

Remove the connector and measure the resistance value with a tester. (Normal temperature)

(TC) sensor

Temperature

0°C

10°C

20°C

30°C

Water inlet temperature

(TWI) sensor

Sensor

Water heat exchange temperature (TC) sensor

Water inlet temperature (TWI) sensor

Water outlet (TWO) sensor

Water outlet temperature

(TWO) sensor

33.8

20.35

12.59

7.99

Hot water cylinder temperature

(TTW) sensor

kΩ

Hot water cylinder temperature (TTW) sensor

Floor inlet temperature (TFI) sensor

Floor inlet temperature

(TFI) sensor

Circulating pump

AC pump

Remove the connection cover of the pump, and measure the resistance with a tester.

Type

Location

Resistance value

UPS025-65K 130

(802XWH**-E)

UPS25-80 130

(1402XWH**-E)

L−N

100-200 Ω

103

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9-6-2. Outdoor unit

No.

Component name

Check procedure

Compressor

Measure the resistance value of each winding with a tester.

Red

Type

Resistance

value

DA220A2F-22L

(802H-E)

Location

^Red− White

^White− Black

^Black− Red

1.04-1.16 Ω

DA422A3F-25M

(1102,1402H-E)

1.04-1.16 Ω

1.04-1.16 Ω At 20°C

White

Black

Outdoor fan motor

Type

Measure the resistance value of each winding with a tester.

Red

Location

Resistance value

ICF-280-A60-1

(802H-E)

Red

−

White

802H-E

White

Black

Red

32.6 3.3 Ω

ICF-280-A100-1

(1102,1402H-E)

Black

Red

−

White

1102,1402H-E White

−

Black

Red

14.8 1.5 Ω

White

Black

4-way valve coil

Type

Measure the resistance value.

1473 Ω 103 Ω

VHV-01AP552B1

Pulse motor valve coil

Type

Measure the resistance value.

1 White

Resistance

Location

CAM-MD12TF-15

(802H-E)

6 Red

value

3 Orange

^Red− White, Orange

42-50 Ω

^Red− Yellow, Blue

Condition 20°C

Yellow

Blue

Type

1 Black

6 Gray

3 Red

UKV-A038

(1102,1402H-E)

Resistance

value

Location

^Grey− Black, Red

43-49 Ω

^Grey− Yellow, Orange

43-49 Ω

Condition 20°C

Yellow Grey Orange

Suction temperature (TS) sensor Remove the connector and measure the resistance value with a tester.

Heat exchange temperature

(TE) sensor

10-20 kΩ (Normal temperature)

Temperature

Outdoor temperature (TO)

sensor

0°C

10°C

20.4

20°C

30°C

8.0

Sensor (kΩ)

Outdoor heat exchange temperature sensor (TE)

Suction temperature sensor (TS)

33.8

12.6

Discharge temperature (TD)

sensor

Remove the connector and measure the resistance value with a tester.

Temperature

0°C

10°C

20°C

62.4

30°C

40.2

Sensor (kΩ)

Discharge temperature sensor (TD)

161.3

99.0

104

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10Hydro unit and Outdoor Unit Settings

Hydro unit

1. Hydro unit Setting

1-1. Setting switch names and positions

SW01

SW12

SW11

SW13

SW02

SW07

SW10

1-2. SW02 (System switching 1)

SW02

02_1

02_2

02_3

02_4

Switching details

Factory setting

Remarks

–

OFF

–

OFF

–

Room thermostat

1-3. SW10 (Pump switching)

SW10

Switching details

Factory setting

10_1

10_2

10_3

10_4

–

OFF

Enhanced pump2 Interlock Yes/No

–

Yes

–

1-4. SW11 (Heater Yes/No switching)

SW11

11_1

11_2

11_3

11_4

Switching details

Factory setting

Internal backup heater Energized Yes/No

Hot water cylinder heater Energized Yes/No

Booster heater Energized Yes/No

–

Energized

–

OFF

1-5. SW12 (System switching 2)

SW12

12_1

12_2

12_3

12_4

Switching details

Factory setting

Hot water supply

Yes

–

OFF

ZONE1

ZONE2

–

OFF

1-6. SW13 (System switching 3)

SW13

13_1

13_2

13_3

13_4

Switching details

3WV SPST/SPSD Specification switching

Factory setting

SPST

OFF

Boiler placement

Auto Restart of power outage

–

OFF

Yes

–

105

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2. Hydro unit Function Code Setting

2-1. How to set function code

<Procedure> Perform the following when no operation is in progress.

1 Press the SET

buttons at the same time for 4 seconds or longer.

(See display

and TEST

and SELECT

)

2 Specify CODE NO. (FC) with the TEMP.

for temperature setting.

button

3 Select a setting data with the TIME

setting.

The value in the DATA item changes.

^{button for timer}2

4 Press the SET

confirmed)

button. (If

lights, the status is

To change the item to be set, go to 2.

5 Pressing the TEST

stop state.

button moves the unit to the normal

2-2. How to set remote controller function code

This operation can set the start and end time of the nighttime low noise, anti bacteria, night set back, or other

functions.

<Procedure> Perform the following when no operation is in progress.

1 Press the TEST

the same time for 4 seconds or longer. (See display

and CL

and TEMP.

buttons at

)

appears on the left.

2 Specify CODE NO. (FC) with the TEMP.

for temperature setting.

button

3 Select a setting data with the TIME

setting.

The value in the DATA item changes.

button for timer

4 Press the SET

status is normal)

button.(If the blinking changes to lit, the

To change the item to be set, go to 2.

1 5

5 Pressing the TEST

stop state.

button moves the unit to the normal

106

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Function code table

Item

Details

First shipment

01 Water heat exchanger capacity

0012: 802XWH**-E

0017: 1402XWH**-E

Depends on type

02 Cooling/Non-cooling switching

0000: Cooling

0000: 0 mins

0003: 30 mins

0040: 40°C

0070: 70°C

0000: 0 mins

0003: 30 secs

0018: 18°C

0010: 10°C

0037: 37°C

0020: 20°C

0037: 37°C

0020: 20°C

0060: 60°C

0040: 40°C

0020: 20°C

0040: 40°C

-0020: -20°C

0001: No cooling

0030: 30 mins

0006: 60 mins

0075: 75°C

0030: 30 mins

0006: 60 secs

0025: 25°C

0010: 10°C

0055: 55°C

0020: 20°C

0055: 55°C

0020: 20°C

0075: 75°C

0040: 40°C

0038: 38°C

0045: 45°C

0000: 0°C

07 Hot water HP operation mode upper time limit

08 Hot Water Boost operation time

0120: 120 mins

0018: 180 mins

0080: 80°C

0060: 60 mins

0024: 240 secs

0030: 30°C

0018: 18°C

0055: 55°C

0037: 37°C

0055: 55°C

0037: 37°C

0080: 80°C

0060: 60°C

0045: 45°C

0050: 50°C

0020: 20°C

09 Hot Water Boost set temperature

0A Anti bacteria set temperature

0B Anti bacteria holding time

0C Mixing valve drive time

18 Upper limit of cooling set temperature

19 Lower limit of cooling set temperature

1A Upper limit of heating (ZONE1) set temperature

1B Lower limit of heating (ZONE1) set temperature

1C Upper limit of heating (ZONE2) set temperature

1D Lower limit of heating (ZONE2) set temperature

1E Upper limit of hot water set temperature

1F Lower limit of hot water set temperature

20 Hot water HP start temperature

21 Hot water HP stop temperature

22 Priority mode Hot water supply/Heating switching

temperature

23 Priority mode Boiler/Heat pump switching temperature -0020: -20°C

0020: 20°C

0010: 10°C

-0010: -10°C

0000: 0°C

24 Outside air temperature for hot water temperature

correction start

-0020: -20°C

25 Hot water temperature correction value

26 Night set back change temperature range

27 Set temperature shift with heating Auto

29 Outside air temperature T1 temperature

2B Outside air temperature T3 temperature

0000: 0K

0003: 3K

0015: 15K

0020: 20K

0005: 5K

0003: 3K

0005: 5K

-0005: -5K

-0015: -15°C

0000: 0°C

0020: 20°C

0000: 0K

0000: 0°C

0015: 15°C

0055: 55°C

-0010: -10°C

0010: 10°C

0040: 40°C

2C Set temperature A with outside air temperature of -

20°C

2D Set temperature B with outside air temperature of T1

0020: 20°C

0055: 55°C

0100: 100%

0035: 35°C

0030: 30°C

0025: 25°C

0020: 20°C

0080: 80°C

0001: 10 mins

2E Set temperature C with outside air temperature of 0°C 0020: 20°C

2F Set temperature D with outside air temperature of T3 0020: 20°C

30 Set temperature E with outside air temperature of 20°C 0020: 20°C

31 Zone2 ratio with Zone1 as Auto

33 Heater control down time

0000: 0%

0000: 5 mins

0002: 15 mins

0001: 10 mins

0003: 20 mins

34 Heater control up time

0000: 10 mins

0002: 30 mins

0001: 20 mins

0003: 40 mins

0000: 10 mins

3A Frost protection function Yes/No

0000: No

0001: Yes

0015: 15°C

0000: No

3B Frost protection set temperature

0010: 10°C

0020: 20°C

3C Water 2-way energization (logical reverse) control

3E Heating HP/Boiler priority switching when using boiler

0000: No

0001: Yes (Reverse)

0000: Priority on HP

0001: Priority on boiler 0000: Priority on HP

107

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Remote controller function code table

FC Item

Details

Fist shipment

05 24H/12H display switching

09 Nighttime low-noise mode

0A Nighttime low-noise start time

0B Nighttime low-noise end time

0C Anti bacteria start time

0: 24H display

1: 12H (AM/PM) display 0: 24H display

1: Enabled 0: Disabled

0: Disabled

0 - 23 (0:00 to 23:00)

22: 22:00

06: 06:00

22: 22:00

0D Anti bacteria start cycle

0E Night operation start time

0F Night operation end time

11 Remote control Alarm Tone.

1 - 10 (Every day to 10-day cycle)

0 - 23 (0:00 to 23:00)

07: 7-day cycle

22: 22:00

0 - 23 (0:00 to 23:00)

06: 06:00

0: Alarm Tone OFF

1: Alarm Tone ON

108

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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.

1 Press the remote controller TEST button for 4 seconds or

longer to display "TEST" on the LCD screen.

2 Press the HOT WATER

button, and a hot water supply

)

operation starts after 3 minutes. (See display

(The pump immediately starts.)

3 Pressing the HOT WATER

water supply operation.

button again stops the hot

1, 4

2, 3

1 Press the ZONE1,2 button, and a heating operation

starts after 3 minutes. (See display )

(The pump immediately starts.)

2 Pressing the ZONE1,2

operation.

button again stops the heating

1, 4 2, 3

2 Press the ZONE1,2 button and then OPERATE MODE

, and a cooling operation starts after 3 minutes.

(The pump immediately starts.) (See display

)

3 Pressing the ZONE1,2

operation.

button again stops the cooling

1, 4 3

4 Press TEST

on the remote controller to exit the trial

operation mode.

109

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4. Auto Curve Setting

FC code setting can make flexible Auto-Curve settings.

1 Press the TEST

buttons at the same time for 4 seconds or longer.

(See display

and SET

and SELECT

)

(Make sure that no operation is in progress.)

2 Specify an item code (FC) from among 29 to 2F with the

TEMP.

button for temperature setting.

3 Set data with the TIME

button for timer setting.

lights, the status is

4 Press the SET

confirmed)

button. (If

5 Repeat 2 through 4 for each item.

6 Pressing the TEST

stop state.

button moves the unit to the normal

Item

Details

Fist shipment

-0010: -10°C

0010: 10°C

0040: 40°C

0035: 35°C

0030: 30°C

0025: 25°C

0020: 20°C

0080: 80%

29 Outside air temperature T1 temperature

2B Outside air temperature T3 temperature

-0015: -15°C

0000: 0°C

0015: 15°C

0055: 55°C

0100: 100%

2C Set temperature A with outside air temperature of -20°C 0020: 20°C

2D Set temperature B with outside air temperature of T1

2E Set temperature C with outside air temperature of 0°C

2F Set temperature D with outside air temperature of T3

0020: 20°C

30 Set temperature E with outside air temperature of 20°C 0020: 20°C

31 Zone2 ratio with Zone1 as Auto 0000: 0%

TSC-F

Set temperature (

Auto-Curve

Temperature shift

)

A(40)

Default Setting

B(35)

C(30)

D(25)

E(20)

-20

Outside

air temperature (TO)

(-10)

(+10)

• Auto-Curve temperature shift

Without Auto-Curve individually set, the set temperature can be

shifted in the range of 5k of the current setting. (The set temperature

is valid only when Auto operation is in progress.)

1 Press the AUTO TEMP

longer. (See display

button for 4 seconds or

)

(The remote controller FC setting screen appears.)

2 Set a temperature shift range with the TEMP.

button for temperature setting. (-5k to 5k)

3 Press the SET

confirmed)

button. (If

lights, the status is

4 Pressing the TEST

stop state.

button moves the unit to the normal

110

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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

The symbol moves along above the days. ( moves by each

button press from MO through SU.)

button to select the current day.

3 Set time.

Use the TIME

button to set time. Long press changes time

display by 10 minutes.

4 Pressing the SET

button ends the time setting. Ending

the time setting changes the days and time to the lit state

and returns to the normal display.

3 2

and

indications go out.)

111

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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. (See display

(Moves to the schedule setting mode)

button

)

The following blink:

, and P1 indications, items to be

set, the set temperature of ZONE1/2 and HOT WATER (previous

set temperature),

day (

), and time

2 Specify a day to be set.

Press the DAY button to move day

moves by each button press from MO through SU. From SU,

the symbol moves to MO through SU (Every day).

Press the SET button to confirm the day to be set.

to the day to be set.

(

3 Specify a step from among steps 1 to 8.

3,6,7 2,7

Press the STEP

button to specify a step to be set.

(The selection moves by each STEP

to 8, C, and L.)

button press among 1

Selecting "C" copies the day details already set. Go to 7.

Selection "L" clears the setting details.

Press the SET

button to confirm the step to be set.

4 Specify set time, operation mode, and set temperature.

Time setting:

Use the TIME

Press HOT WATER

ZONE1,2

button to set time.

Operation mode:

for hot water supply, ZONE1,2

for cooling, and then press OPERATE MODE

for heating, or

. Pressing

", indicating stop.

HOT WATER

or ZONE1,2

again displays "

When an operation mode is set, " " appears for heating, " " for cooling, or " " for

hot water supply, and also the temperature set last time is displayed.

Temperature setting: Use the SELECT

temperature with the TEMP.

button to select a mode

button.

and set

Press the SET

button to confirm the set time, operation mode, and set temperature to be set.

5 Repeat 2 through 4.

(If only one schedule is set, the setting applies to all the time period after the set time. Two schedule settings

are recommended.)

6 Pressing the SCHEDULE

button ends the schedule setting. Ending the schedule setting

button during the 5-second blinking changes

blinks the light . Pressing the SET

and the schedule operation starts.

to lit,

7 How to copy program

Select "C" in 3 and press the SET

button. (Copy source is determined.)

Press the DAY button to move

program setting to the copy target.

to the day of copy target. Pressing the SET

button overwrites the

To set more, repeat step 2 through 4. Pressing the SCHEDULE

button ends the schedule setting.

112

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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.

Pressing the CL

cancelled.

button during the 5-second blinking causes

to put out, and the schedule operation is

7. Frost Protection Setting

This setting keeps a room with weak heating when users are not home for long hours.

1 Press the ZONE1,2

button to start a heating operation.

(This is available only for a normal heating operation.)

(No frost protection setting is provided to hot water supply and cooling.)

2 Pressing the FORST PROTECTION button displays the

symbol and "F" for temperature setting. (See display )

The heating operation of 15°C is set.In FC_3B in 2-2 section, the set

temperature can be changed in the range of 10 to 55°C.

3 Pressing the FORST PROTECTION

disappear, and the set temperature returns to the normal heating

temperature. (Pressing the ZONE1,2 button ends both

button makes

the frost protection and the heating operation.)

2,3

1,3

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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.

A nighttime operation lowers the set temperature by 5K for heating and

raises 5K for cooling during the set time period (*1) from 22:00 to 6:00

(Default).

3 Pressing the NIGHT button again makes

and the normal operation starts.

disappear,

2,3

1 Press the NIGHT

button for 4 seconds or longer.

)

(Moves to the NIGHT time setting mode) (See display

"0E" in the Code No. field and the current time displayed blink.

2 Press the TIME

Pressing SET

confirmed.

button to set a desired start time.

changes the time to be lit and the setting is

3 Press the TEMP.

button to change Code No.

(The codes "0E" and "0F" only can be changed.)

4 Press the TIME

Pressing SET

confirmed.

button to set a desired end time.

changes the time to be lit and the setting is

1 5

5 Press the TEST

mode.

button to exit the NIGHT time setting

114

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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.

(Normal hot water supply operation)

button to start a hot water

(No anti bacteria setting is provided to heating and cooling.)

2 Pressing the ANTI BACTERIA

symbol. (See display

button displays the

)

(The set temperature does not change) The hot water supply operation

of 75°C starts.

The anti bacteria operation raises water temperature to 75°C with the

heat pump and heater, and automatically ends after 30 minutes.

3 After that, an anti bacteria operation automatically starts at the

set time and cycle.

2,4 1

4 Pressing the ANTI BACTERIA button makes

disappear, and the anti bacteria operation does not start.

In FC_0A or 0B (See 2-2), the set temperature and holding time can be changed.

FC_0A: Set temperature change range 70 to 80°C (75°C: default)

FC_0B: Holding time change range 0 to 60 minutes (30 minutes: default)

1 Press the ANTI BACTERIA

or longer. (See display

button for 4 seconds

)

(Moves to the anti bacteria time setting mode)

"0C" in the Code No. field and the currently set

indication blink.

and

2 Press the TIME

Pressing SET

button to set a desired start time.

changes DATE (set time) 0C, and

indication to be lit and the setting is confirmed.

3 Press the TEMP.

to "0d".

The "0d" and

button to change Code No.

indication blink.

4 Press the TIME

Pressing SET

button to set a desired cycle.

changes DATE (set time) 0d, and

indication to be lit and the setting is confirmed.

5 Press the TEST

button to exit the anti bacteria time setting mode.

115

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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.

(Normal hot water supply operation)

button to start a hot water

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.

HOT WATER BOOST operation with the heat pump and heater ends when

the water temperature reaches 75°C; however, the normal hot water supply

operation automatically starts after 60 minutes even if the temperature is

not as high as 75°C.

2,3 1

3 Pressing the HOT WATER BOOST button again makes

disappear, and the HOT WATER BOOST ends.

In FC_08 or 09 (See 2-2), the operation time and set temperature can be changed.

FC_08: Operation time change range 30 to 120 minutes (60 minutes: default)

FC_09: Set temperature change range 40 to 80°C (75°C: default)

11. Nighttime Low-noise Setting

• This setting is used to reduce noise output, from the outdoor unit, during

nighttime for neighbours. Nighttime low-noise operates with lower

operation frequency and fan tap than usual only for the set time period.

• The operation is the same as usual hot water supply, heating, or cooling.

• Adjust the unit time before making the settings.

<How to enable, set start time and end time of nighttime low-

noise>

1 Press the TEST

time for 4 seconds or longer. (See display

and TEMP.

button at the same

)

(Moves to the nighttime low-noise setting mode)

"09" displayed in the Code No. field and the DATA currently

displayed,

, and

blink.

4,6

2 Press TIME

Pressing SET

to set enabled "1" or disabled "0".

changes DATA and

indication to be lit and the setting is confirmed. (For DATA, only

button to change Code No. to "0A". DATA and indication again

button to set start time. Pressing SET changes DATA and

button to change Code No. to "0B". DATA and indication again

button to set end time. Pressing SET changes DATA and

to exit the nighttime low-noise time setting mode. and indications go

1 or 0 can be selected.)

3 Press the TEMP.

blink.

4 Press the TIME

indication to be lit and the setting is confirmed.

5 Press the TEMP.

blink.

6 Press the TIME

indication to be lit and the setting is confirmed.

7 Press TEST

out.

116

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12. Forced Defrosting Setting

The FC code setting (See 2-2) can activate the forced defrosting mode for the outdoor unit operation.

(Preparation)

1 Press the remote controller buttons, TEST

and SELECT , at the same time for 4 seconds

, SET

or longer.(Make sure that no operation is in progress.)

2 Specify CODE NO. (FC) 46 with the TEMP.

button for temperature setting.

3 Set DATA to 0001 with the TIME

button for timer

setting. (See display

(Factory setting is 0000)

)

4 Press the SET

normal)

button. (If OK

lights, the status is

5 Pressing the TEST

stop state.

button moves the unit to the normal

(Operation)

• Press the ZONE1,2

button.

• Set the operation to the heating mode.

• After a while, forced defrosting signals are transmitted to the outdoor unit, and the unit starts defrosting.

(Forced defrosting lasts for up to 10 minutes.)

• After the defrosting, the heating operation starts.

• To perform defrosting again, start with 1 above.

(Performing the forced defrosting once cancels the forced defrosting setting above described.)

13. Rated Operation Setting

The FC code setting (See 2-2) can activate the rated operation mode during a heating operation.

(Preparation)

1 Press the remote controller buttons TEST

and SELECT , at the same time for 4 seconds

, SET

or longer.(Make sure that no operation is in progress.)

2 Specify CODE NO. (FC) 91 with the TEMP.

button for temperature setting.

3 Set DATA to 0001 with the TIME

button for timer

setting. (See display

(Factory setting is 0000)

)

4 Press the SET

confirmed)

button. (If OK

lights, the status is

5 Pressing the TEST

stop state.

button moves the unit to the normal

(Operation)

• Press the ZONE1,2

button.

• Set the operation to the heating mode.

• After a while the outdoor unit starts an operation with the rated operation frequency.

3 horsepowers: HWS-802XWH**-E/HWS-802H-E 66.0Hz

4 horsepowers: HWS-1402XWH**-E/HWS-1102H-E 44.4Hz

5 horsepowers: HWS-1402XWH**-E/HWS-1402H-E 56.4Hz

117

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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

for 4 seconds or longer to call the service monitor mode.

and CL

buttons at the same time

The service monitor lights up, and the temperature of CODE No.

"00" displays at first. (See display

)

2 Press the TEMP. button for temperature setting

to change the item code to one to be monitored.

The following table shows the item codes.

1 3

Item code

Data name

Control temperature (Hot water cylinder)

Control temperature (Zone1)

Unit

°C

Control temperature (Zone2)

°C

Remote controller sensor temperature

Condensed temperature (TC)

Water inlet temperature (TWI)

Water outlet temperature (TWO)

Water heater outlet temperature (THO)

Floor inlet temperature (TFI)

°C

Hot water cylinder temperature (TTW)

Mixing valve position

°C

step

MPa

Lo pressure (Ps) × 100

Item code

Data name

Heat exchange temperature (TE)

Outside air temperature (TO)

Discharge temperature (TD)

Suction temperature (TS)

Unit

°C

Heat sink temperature (THS)

Current

°C

Heat exchanger coil temperature (TL)

Compressor operation Hz

°C

rpm

pls

Number of revolutions of outdoor fan (lower)

Number of revolutions of outdoor fan (upper)

Outdoor PMV position × 1/10

Item code

Data name

Unit

Micro computer energized accumulation time

Hot water compressor ON accumulation time

Cooling compressor ON accumulation time

Heating compressor ON accumulation time

Built-in AC pump operation accumulation time

× 100h

Hot water cylinder heater operation accumulation time × 100h

Backup heater operation accumulation time

Booster heater operation accumulation time

× 100h

3 Pressing the TEST

button returns to the usual display.

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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. (See display

)

2 To monitor other failure history, press the TEMP.

button for temperature setting to change the

failure history number (item code).

Item code "01" (Latest) ---> Item code "01" (Old)

Note: The failure history contains the last 4 failures.

3 Pressing the TEST

display.

button returns to the normal

1 3

<Notes>

Do not press the CL

button. Pressing the button deletes all the failure history of the hydro unit.

If the button is pressed and the history is deleted, perform power cycle.

If the current failure is the same as the one occurred last time before deleted, the history may not record the

current failure.

119

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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]

1 Remove the water in the hydro unit.

SW804 All OFF (Initial status)

(With the water remained in the hydro unit, performing

SW801 Press for

refrigerant recovery may freeze the water and burst the

approx. 1 sec

unit.)

2 Set all the SW804 dip switches to OFF (initial status),

and press the push-button switch SW801 for approx.

1 second.

SW805 (Green LED) blinks.

A cooling operation starts. (During the operation, D805

(green LED) blinks.

D800

D801

D802

D803

D804

D805

Note that this operation lasts for 10 minutes.

3 After 3 minutes has passed, close the liquid-side

valve.

4 After the refrigerant recovery is completed, close the

gas-side valve.

5 Press again the push-button switch SW801 for

approx. 1 second. The outdoor unit stops operation (cooling).

16-2. Outdoor unit settings (Existing piping, Power save, etc.)

The following settings are available with dip switch setting and jumper wire setting.

Function

Where to set

Control details

Existing piping

setting

When using a Ø19.1 pipe for the existing piping, set the switch to ON.

This case may decrease heating capacity depending on the outside air

temperature when heating or on a room temperature.

SW802

--- OFF

Power save setting

--- Existing piping setting

--- Power save setting

--- Snow prevention fan control

When using the power save function, set the switch to ON. This setting

controls the compressor frequency lowering (about 10%) according to the

heat exchange temperature of the hydro unit during a heating or hot water

supply operation.

* All OFF position at factory setting

Snow prevention

fan control

This control enables the function that prevents snow from entering the draft

air duct through the fan guard or a heat exchanger gap and causing moter

lock. If the outside air temperature is 0°C below, this control operates the

outdoor fan in W5 even if the compressor is not in operation.

Defrosting time

change

J805, J806

J807

If the defrosting interval is shorter than the standard, the jumper wire is cut.

For the control details or how to cut the jumper wire, see defrosting control.

Maximum

frequency change

If the maximum value of compressor frequency need to be lowered, cut the

jumper wire shown on the left.

This control lowers the maximum frequency when hot water supply, heating,

or cooling is in operation. (HWS-802H-E only)

In this case, the maximum capacity decreases.

Maximum frequency of compressor

HWS-802H-E

HWS-1102H-E

HWS-1402H-E

Model

Cooling Heating Cooling Heating Cooling Heating

Standard

J807 cut

70.2

53.4

70.2

64.2

60.0

70.2

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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.

For operation

Part number

SW800

Specification

Press button switch

Dip switch

Operation details

This switch switches the indications of LED (D800 to D804) on the outdoor control board.

SW803

SW801

Press button switch

Dip switch

This switch enables users to perform a special operation for maintenance and inspection.

This switch performs initial settings. (See 8-4-6)

SW804

SW802

Dip switch

For display

Part number

Specification

Operation details

Amber LED

Signal display (signals from the hydro unit) of communication between hydro unit and

outdoor unit (serial communication)

D502

Green LED

Yellow LED

Signal display (signals from the outdoor unit) of communication between hydro unit and

outdoor unit (serial communication)

D503

Abnormality indication

All OFF of SW803 or the lit status of any of D800 to D804 indicates that the outdoor

control unit detects an abnormality.

D800 to D804

Setting SW803 to other than OFF shows details with LED indication.

Green LED

Energization indication

This LED lights when the outdoor unit is energized.

During a special operation with the SW801 or SW804 operation, this LED blinks.

D805

Note: All the LEDs have no color when off.

SW804

SW801

Special operation switch (Operations

for maintenance and inspection)

SW800

SW803

LED indication switching switch

D800 (Yellow LED)

D801 (Yellow LED)

D802 (Yellow LED)

D803 (Yellow LED)

D804 (Yellow LED)

Abnormality indication

and other indications

D805 (Green LED) --- Energization indication

D800

D801

D802

D803

D804

D805

D503 (Green LED) --- Serial signal (Outdoor to hydro)

D502 (Amber LED) --- Serial signal (Hydro to Outdoor)

SW802 --- Initial settings switching

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(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)

SW803

This switch indicates the current abnormality.

Without an abnormality, the lights are off.

(See (2)-2)

Abnormal indication (Latest abnormality: Latest abnormality including the current one)

After the abnormality status is released, this setting enables users to see the previous abnormalities.

(Previous abnormality can be checked even if the power is once turned off.)

* If there is an abnormality now, the abnormality details of the current one is displayed.

* This setting does not display a TO sensor failure.

SW803

(Check for the failure with the setting for current abnormality.)

(See (2)-2)

Temperature sensor indication

These switches indicate the temperature sensor detecting value.

* TC=TWO+2 (heating, hot water supply)

TC=TWO (cooling)

SW803

(See (2)-3)

SW803

TWI

TC*

SW803

Current indication

This switch indicates the current value in the outdoor unit.

(See (2)-3)

SW803

Compressor operation frequency indication

This switch indicates the compressor operation frequency.

(See (2)-3)

PMV Openness indication

This switch indicates PMV (Pulse motor valve) position.

(See (2)-3)

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(2) -2. Abnormality indication

The current abnormality and the latest abnormality (including the current one) can be identified by the

LED D800 to D804 on the outdoor control board.

1) Setting all the SW803 dip switches to OFF indicates the current abnormality status.

2) Setting SW803 dip switch <1> only to ON indicates the previous abnormality (including the current

one).

3) An abnormality lights any of the LEDs from D800 to D804.(Indication 1)

4) Pressing the push-button switch SW800 for approx. 1 second switches indication.(Indication 2)

5) When SW800 is again pressed or 2 minutes has passed, the indication 1 status returns.

Legend)

Current abnormality Latest abnormality

SW803

---- Off

---- Light

---- Blink

Indication 1

(Initial indication) (SW800 operation)

Indication 2

Remote controller

Abnormality code

Abnormality details

Normal

---

Discharge temperature sensor (TD) failure

Heat exchanger temperature sensor (TE) failure

Heat exchanger temperature sensor (TL) failure

Outside air temperature sensor (TO) failure

Suction temperature sensor (TS) failure

F04

F06

F07, F06

F08

F12, F06

F13, L29

F15, F06

F31, L29

H01

Heat sink temperature sensor (TH) failure

Heat exchanger, suction sensor (TE, TS) wrong wiring

EEPROM failure

Compressor break down

Compressor lock

H02

Current detection circuit failure

Faulty compressor case thermostat

Not set up the capacity

H03

H04, P04

L10, L29

L29

Communication failure between MCUs

Other abnormality (e.g. Compressor's loss of synchronism)

Abnormal discharge temperature

Power failure

No abnormality confirmation

P03

P05, H03, P04

P07, L29

P15, L29

P19, L29

P20, P04

P22

Heat sink overheat failure

Gas leakage detection

4-way valve reverse failure

Hi pressure protection operation

Fan drive system failure

Compressor drive

P26

Compressor rotor position failure

P29

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(2)-3. Sensor, Current, Compressor operation frequency, PMV openness indication

The values detected by controller, such as temperature sensor or current values, can be easily checked.

Legend)

---- Off

---- Light

Compressor

operation

frequency

(r.p.s.)

Item setting

Temperature sensor (

)

Current

(A)

PMV openness

(pulse)

SW803 SW803 SW803 SW803 SW803

SW803

TC*

TCJ

SW803 SW803 SW803 SW803

*See p122

LED indication

less than

0-0.9

1-1.9

0-4

5-9

0-19

20-39

-20

2-2.9

10-14

40-59

3-3.9

15-19

60-79

4-4.9

20-24

80-99

5-5.9

25-29

100-119

120-139

140-159

160-179

180-199

200-219

220-239

240-259

260-279

280-299

300-319

320-339

340-359

360-379

380-399

400-419

420-439

440-459

460-479

480-499

500

6-6.9

30-34

5-9

7-7.9

35-39

10-14

15-19

20-24

25-29

30-34

35-39

40-44

45-49

50-54

55-59

60-64

65-69

70-74

75-79

80-84

85-89

90-94

95-99

8-8.9

40-44

9-9.9

45-49

10-10.9

11-11.9

12-12.9

13-13.9

14-14.9

15-15.9

16-16.9

17-17.9

18-18.9

19-19.9

20-20.9

21-21.9

22-22.9

23-23.9

24-24.9

25-25.9

26-26.9

27-27.9

28-28.9

29-29.9

30-30.9

31 or higher

50-54

55-59

60-64

65-69

70-74

75-79

80-84

85-89

90-94

95-99

100-104

105-109

110-114

115-119

120-124

125-129

130-134

135-139

140-144

145-149

150-154

155 or higher

100-104

105-109

110-114

115-119

120 or higher

sensor failure, not connected

* TD, TL, and TH show errors below the ordinary temperature because they are sensors for high temperature.

* Current value for the outdoor unit only is shown.

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(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.

4) When the push-button switch SW801 is pressed for approx. 1 second, or the dip switch SW804 is switched,

or the defined time for each function has passed, the each function stops and LED D805 (Green) returns

to continuous lit.

SW804

Operation when press button switch SW801 is pressed

Refrigerant recovery operation

The outdoor unit operates cooling. The hydro unit may freeze with this operation alone. Remove beforehand the

SW804

water in the hydro unit. (See 16-1)

Hydro unit cooling request

Performs a trial cooling operation. (See Note1)

SW804

Hydro unit heating request

Performs a trial heating operation.(See Note1)

Fan motor forcible operation

Forcibly performs a fan motor operation.

When SW801 is pressed again or after 2 minutes, the operation returns to the normal

control.

(No operation particularly)

Caution:

Although these

PMV full open operation

Fully opens PMV (Pulse motor valve).

controls are available

When SW801 is pressed again or after 2 minutes, the operation returns to the normal

control.

during an operation,

basically perform

them when no

operation is in

progress.

Performing these

controls during an

operation may cause

dangerously rapid

pressure change.

PMV full close operation

Fully closes PMV (Pulse motor valve).

When SW801 is pressed again or after 2 minutes, the operation returns to the normal

control.

PMV half open operation

Half opens (250 pulses) PMV (Pulse motor valve).

When SW801 is pressed again or after 2 minutes, the operation returns to the normal

control.

4-way valve relay operation (RY700, CN700 for check)

Sets 4-way valve energization relay (RY700) to ON.

When SW801 is pressed again or after 2 minutes, the operation returns to the normal

control.

Caution:

Do not connect the coil into the body when perform this operation.

125

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SW804

Operation when press button switch SW801 is pressed

Self-holding valve vacuum operation (Switch to heating cycle)

(RY700, RY701, RY705, CN701 for check)

SW804

Sets relay RY700, RY701, and RY705 to ON.

(CN701 Between 1 to 4 Voltage = Approx. 325V)

This function operates for 10 seconds. After that it becomes OFF.

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.

SW804

Caution:

Although these

controls are available

during an operation,

basically perform

them when no

SV valve relay operation (RY702, CN702 for check)

Sets SV valve relay (RY702) to ON.

operation is in

progress.

When SW801 is pressed again or after 2 minutes, the operation returns to the normal

control.

Performing these

controls during an

operation may cause

dangerously rapid

pressure change.

* HWS-1102 and 1402H-E do not have the parts mounted, so this operation is

unavailable.

Heater output relay operation (RY703, CN703 for check)

Sets relay for optional heater (RY703) to ON.

When SW801 is pressed again or after 2 minutes, the operation returns to the normal

control.

SW804

External output relay operation (RY704, CN704 for check)

Sets relay for external output (RY704) to ON.

When SW801 is pressed again or after 2 minutes, the operation returns to the normal

control.

(No operation particularly)

External output relay operation change

Note:

Do not use this setting.

(Note 1) The forced trial operation with this setting cannot be cancelled by the remote controller in the hydro unit.

Be sure to cancel the operation from the outdoor unit. (Press again SW801 for 1 second)

126

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11How to Exchange Main Parts

WARNING

Because the electrical components are energized with high voltage, always turn off the power breaker before

starting to work.

<Check>

After a repair is complete, perform a trial operation (after attaching the front panel, upper and lower cabinets, and

side cabinet) and check that no abnormality including smoke or abnormal noise occurs. Failure to do so may cause

a fire or an electric shock. Place the cabinets before making a trial operation.

Observe the following instructions when repairing the refrigerant cycle.

(1) Watch out for surrounding fire. Always put out the fire of stove burner or other devices before starting the repair.

Should the fire fail to be put out, the oil mixed with refrigerant gas could catch fire.

(2) Do not use a welder in a closed room.

A room with no ventilation may cause carbon monoxide poisoning.

(3) Keep away flammable materials.

The materials may catch the fire of a welder.

CAUTION

Wear gloves (∗) when performing repair.

Failure to do so may cause an injury when accidentally contacting the parts.

∗: Thick gloves such as cotton work gloves

1. Hydro Unit

No. Exchange parts name

Work procedure

Remarks

Common procedure

Wear gloves when performing the work.

Failure to do so may cause an injury when

accidentally contacting the parts.

Front panel

1. How to remove

1)Stop the hydro unit operation, and turn off the power

breaker.

2)Remove the front panel.

(ST1T Ø4 × 10 6 screws)

3)After unscrew the screws, remove the front panel by

pulling it toward you.

4)Remove the electric parts box cover (lower).

(ST2T Ø4 × 8 2 screws)

Front panel

Electric parts box

cover (lower)

5)Disconnect the power source cable and outdoor unit

connecting cable from the terminal block.

6)Remove the electric parts box cover (upper).

(ST2T Ø4 × 8 4 screws)

Electric parts

box cover (lower)

Electric parts box

cover (upper)

7)Disconnect the remote controller connecting cable

from the CN41 connector of the water heat

exchange board.

2. How to attach

1)Connect the remote controller connecting cable to

the water heat exchange board.

Electric parts

box cover (upper)

2)Attach the electric parts box cover (upper).

3)Connect the power source cable and outdoor unit

connecting cable to the terminal block, and fix with

the cord clamp.

4)Attach the electric parts box cover (lower).

5)Attach the front panel.

127

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No. Exchange parts name

Work procedure

Remarks

Remote controller

1.How to remove

1)Perform the step 1-1.

2)Remove the remote controller from the holder using

a flat-blade screwdriver. (Release the stopper.)

3)Disconnect the remote controller cable from the

terminal block on the back side of the remote

controller.

Remote

controller holder

Remote

controller

2.How to attach

1)Attach it in the reverse order of the removal.

Remote controller cable

Water heat

exchanger board

MCC-1511

1. How to remove

1)Perform the step 1-1.

2)Disconnect the connectors and lead cables

connected to other parts from the water heat

exchanger board.

1. Connector

CN100: TB 01 3P Connector (5P: White)

CN101: Trans (3P: White)

CN102: Trans (6P: White)

CN200: Float switch (3P: Red)

CN201: Pressure switch (2P: White)

CN202: Bimetal thermostat (3P: Yellow)

CN203: TC sensor (2P: Yellow)

CN204: TWI sensor (3P: Brown)

CN205: TWO sensor (2P: Red)

CN206: THO sensor (3P: White)

CN207: Lo pressure sensor (2P: Blue)

CN212: Lo pressure sensor (4P: White)

CN213: TB 06 4P Terminal block (3P: White)

CN214: TB 06 4P Terminal block (2P: White)

CN305: TB 01 3P Terminal block (3P: Green)

CN501: Relay board (6P: Yellow)

CN601: Relay 05 (3P: Red)

Water heat

exchanger board

CN602: TB 04 6P Terminal block (7P: White)

CN603: Pump (3P: Yellow)

CN604: Relay 06, TB 04 4P Terminal block (7P:

Blue)

CN605: Relay 01, Relay 02 (3P: Yellow)

CN606: Relay 03, Relay 04 (3P: Blue)

2. Round-shape terminal

100: Ground (ST2T Ø4 × 8 1 wire)

Note

When removing the connector, release the safety

lock of the housing.

3)Release the 6 stoppers of the water heat exchanger

board to remove the board.

128

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No. Exchange parts name

Work procedure

Remarks

Relay board

MCC-1431

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.

3)Release the 3 stoppers of the relay board to remove

the board.

Relay board

Electric parts

assembly

1. How to remove

1)Perform the step 1-1.

2)Disconnect the connectors and lead cables

connected to other parts from the water heat

exchanger board.

1. Connector

CN200: Float switch (3P: Red)

CN201: Pressure switch (2P: White)

CN202: Bimetal thermostat (3P: Yellow)

CN203: TC sensor (2P: Yellow)

CN204: TWI sensor (3P: Brown)

CN205: TWO sensor (2P: Red)

CN206 THO sensor (3P: White)

CN207: Lo pressure sensor (2P: Blue)

CN212: Lo pressure sensor (4P: White)

CN603: Pump (3P: Yellow)

Disconnect the heater power source cable (For

backup heater and hot water cylinder heater) from

the MgSW.

Electric parts assembly

Note

When removing the connector, release the safety

lock of the housing.

3)Remove the fixed screws.

(ST2T Ø4 × 8, 2 screws)

4)Remove the electric parts assembly by pulling it

toward you while pulling it upward because the

assembly back side has a hook holding structure.

129

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No. Exchange parts name

Work procedure

1. Side board (Right)

1)Perform the step 1-1.

Remarks

Side board (Right)

Side board

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)

2. Side board (Left)

1)Remove the fixed screws of the side board (Left).

(ST1T Ø4 × 10, 5 screws)

Side board (Left)

Upper board

1)Perform the step 1-1 and step 6.

2)Remove the fixed screws of the upper board.

(ST1T Ø4 × 10, 4 screws)

Upper

Bottom board

1)Perform the step 1-1 and step 6.

2)Remove the fixed screws of the bottom board.

(ST1T Ø4 × 10, 4 screws)

Bottom board

130

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No. Exchange parts name

Expansion vessel

Work procedure

Remarks

Expansion vessel

To replace a water circuit part, first close the water

supply source valve and the valve of water pipe

connected to the hydro unit.

1)Perform the step 1-1, step 5, 6, and 7.

2)Remove the fixed band of the expansion vessel.

(ST1T Ø4 × 8, 4 screws)

3)Remove the expansion vessel connection (three-

piece flare nut).

Expansion vessel

Fixed band

Replace the packing to new one when installing the

expansion vessel.

Part code

37595721

Service parts

Service packing assembly

After the expansion vessel replacement repair,

open the water supply source valve and water

piping valve to pass water through the hydro unit,

and check that the expasion vessel connection has

no water leakage.

Replace the packing to

new one when installing

the expansion vessel.

10 Relief valve

To replace a water circuit part, first close the water

supply source valve and the valve of water pipe

connected to the hydro unit.

Relief valve connecting hose

Internal diameter: 15mm, Length: 850L

Relief valve

1)Perform the step 1-1, step 5, 6, and 7.

2)Remove the quick fastener.

3)Remove the relief valve by pulling it upward.

The relief valve connection uses an O ring for water

seal. Be careful not to scratch the O ring; otherwise,

water leakage may occur.

After the relief valve replacement repair, open the

water supply source valve and water piping valve to

pass water through the hydro unit, and check that

the relief valve connection has no water leakage.

Quick

fastener

11 Air vent valve

To replace a water circuit part, first close the water

supply source valve and the valve of water pipe

connected to the hydro unit.

Air vent valve

1)Perform the step 1-1, step 5, 6, and 7.

2)Remove the air vent valve.

After the air vent valve replacement repair, open the

water supply source valve and water piping valve to

pass water through the hydro unit, and check that

the air vent valve connection has no water leakage.

131

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No. Exchange parts name

Work procedure

Remarks

12 Pump

To replace a water circuit part, first close the water

supply source valve and the valve of water pipe

connected to the hydro unit.

1. How to remove

1)Perform the step 1-1, step 5, 6, and 10.

2)Remove the fixed screws of the pump fixing board.

(ST1T Ø4 × 8, 2 screws)

3)Remove the 2 nuts of the heater connection and the

lower side of the pump.

4)Remove the pump fixing board.

(ST3T Ø6 × 16, 2 screws)

5)Remove the nut of the upper part of the pump.

Pump

fixing

board

2. How to attach

The pump connection uses a liquid packing for

water seal. When replacing the pump, use a

packing which was slathered with the liquid gasket.

Part code

37595721

37595722

Service parts

Packing

Nut

Liquid gasket

1)Attach a new pump in the reverse order of the

removal.

After the pump replacement repair, open the water

supply source valve and water piping valve to pass

water through the hydro unit, and check that the

pump connection has no water leakage.

Pump

Nut

Pump fixing board

132

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No. Exchange parts name

Work procedure

Remarks

13 Flow switch

To replace a water circuit part, first close the water

supply source valve and the valve of water pipe

connected to the hydro unit.

1. How to remove

1)Perform the step 1-1 and step 5.

2)Remove the flow switch.

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. How to attach

1)Attach a new flow switch in the reverse order of the

removal.

Note1)

As shown on the right,

place a flow sensor parallel to the water heat

exchanger inlet pipe so that the wire is place on

the right side from the front view.

Flow switch

Water heat inlet pipe

After the flow switch replacement repair, open the

water supply source valve and water piping valve to

pass water through the hydro unit, and check that

the flow switch connection has no water leakage.

Flow switch

14 Manometer

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 and 6.

2)Remove the manometer.

After the manometer replacement repair, open the

water supply source valve and water piping valve to

pass water through the hydro unit, and check that

the manometer connection has no water leakage.

Manometer

133

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No. Exchange parts name

Work procedure

Remarks

15 Heater assembly

To replace a water circuit part, first close the water

supply source valve and the valve of water pipe

connected to the hydro unit.

1. How to remove

Nut

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.

2. How to attach

The heater connection uses a liquid packing for

water seal. When replacing the heater, use a

packing which was slathered with the liquid gasket.

Heater

assembly

Part code

37595721

37595722

Service parts

Packing

Liquid gasket

1)Attach a new heater in the reverse order of the

removal.

After the heater assembly replacement repair, open

the water supply source valve and water piping

valve to pass water through the hydro unit, and

check that the heater connection has no water

leakage.

Insulator

Heater

assembly

16 TC sensor

TWI sensor

1. How to remove

1)Perform the step 1-1 and step 5.

2)Take the sensor out.

TWO sensor

THO sensor

TC sensor

Sensor diameter:

Tube color: Black

THO sensor

Sensor diameter:

Tube color: Gray

TWO sensor

Sensor diameter:

Tube color: Red

TWI sensor

Sensor diameter:

Tube color: Blue

134

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No. Exchange parts name

Work procedure

Remarks

17 Water heat

• 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.

exchanger assembly

Water

piping fixing

• Disconnect all the power source cable, outdoor

unit connection cable, and cylinder connection

cable.

1. How to remove

1)Perform the step 1-1, step 5, 6, and 8.

2)Remove the water pipe fixing board.

(ST2T Ø4 × 8, 2 screws)

3)Remove the refrigerant piping fixing board.

(ST2T Ø4 × 8, 3 screws)

4)Remove the nut of the heater connection.

5)Remove the fixed screws of the electric parts box

fixing board.

Refrigerant piping

fixing board

(ST2T Ø4 × 8, 4 screws)

6)Remove the side reinforcing board (left).

(ST2T Ø4 × 8, 6 screws) 3 for inside, 3 for outside

7)Remove the water heat exchanger fixing band.

(ST2T Ø4 × 8, 6 screws)

Nut

8)Remove the water heat exchanger assembly.

Electric parts

box fixing

The heater connection uses a packing for water

seal. Be careful not to scratch the packing;

otherwise, water leakage may occur.

2. How to attach

1)Attach a new water heat exchanger assembly in the

reverse order of the removal.

Side reinforcing board (left)

2)Restore all piping and wiring as in the original state,

and check that there is no water or refrigerant

leakage.

• After the water heat exchanger assembly

replacement repair, open the water supply source

valve and water piping source valve to pass

water through the hydro unit, and check that the

connection has no water leakage.

• After connecting the refrigerant pipe, check that

the connection has no refrigerant leakage.

Water heat exchanger

fixing band

The piping

structure slightly

differs in 14kW and

8kW specifications.

Water heat exchanger assembly

135

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2. Outdoor Unit

2-1. HWS-802H-E

Exchange parts

name

No.

Work procedure

Remarks

Common procedure

Note

Wear gloves when performing the work.

Failure to do so may cause an injury when

accidentally contacting the parts.

Front panel

1. How to remove

1)Stop the operation by remote controller and turn

off the breaker.

2)Remove the front panel.

(Hex Ø4 × 10, 2 screws)

• After unscrewing the screws, remove the front

panel while pulling it downward.

3)Disconnect the power source cable and

connecting cables between hydro and outdoor

from the cord plank and terminals.

4)Remove the top board.

Top board

(Hex Ø4 × 10, 5 screws)

2. How to attach

1)Attach the top board.

(Hex Ø4 × 10, 5 screws)

At this time, insert the back side fin guard between

the top board and the water heat exchanger (back

side).

2)Connect the power source cable and connecting

cables between indoor and outdoor to the

terminal, and fix them with the cord clamp.

Insert the back side fin guard

between the top board and the

heat exchanger (back side).

Note

The power source cable and connecting cable

between hydro and outdoor units must be fixed

along the connecting piping by using a cable tie

so that the cables do not contact the

compressor, gas side valve, gas side piping and

outlet pipe.

3)Attach the front panel.

(Hex Ø4 × 10, 2 screws)

136

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Exchange parts

name

No.

Work procedure

Remarks

Outlet cabinet

How to remove

1)Perform the step 1-1.

Water heat exchanger

Motor base Paring board

Outlet cabinet

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.

(ST1T Ø4 × 8, 1 screw)

6)Remove the screws of the outlet cabinet and fin

guard.

(Hex Ø4 × 10, 2 screws)

Fin guard

Side cabinet

1)Perform the step 1-1.

Inverter assembly

Side cabinet

2)Remove the screws that fixes the inverter

assembly and the side cabinet.

(ST1T Ø4 × 8, 2 screws)

3)Remove the screws of the side cabinet and valve

fixing board.

(ST1T Ø4 × 8, 2 screws)

4)Remove the screws of the side cabinet and piping

panel (back).

(Hex Ø4 × 10, 2 screws)

5)Remove the screws of the side cabinet and bottom

board.

(Hex Ø4 × 10, 1 screw)

6)Remove the screws of the side cabinet and water

heat exchanger.

(Hex Ø4 × 10, 3 screws)

7)Remove the side cabinet while shifting it upward.

(Inverter hook)

Valve fixing board

Piping panel (back)

137

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Exchange parts

name

No.

Work procedure

Remarks

Electric parts

replacement

1. Control board

1)Perform the step 1-1.

Compressor

lead

Reactor lead

Fan motor

Control board

Compressor

case

WARNING

thermostat

For 1 minute after the power is turned off, do not

disassemble the inverter to prevent an electric

shock.

2)Remove the connector connected to the control

board.

(Hydro power source, temperature sensor, electric

control valve coil, 4-way valve coil, compressor

case thermostat, fan motor)

Ground wire

Temperature

sensor

* Remove the connector by releasing the lock in the

housing.

Reactor

lead

3)Remove the lead cable connected to the control

board. (Torque at tightening is 1.47 0.1N•m)

Compressor lead U: CN200 Red

V: CN201 White

4-way valve coil

Electric control valve coil Indoor power source

W: CN202 Black

Remove the power source cable from the power

source terminal block.

Screw for fixing board

Screw for fixing element (7 screws)

(Torque at tightening is 2.5 0.1N•m)

4)Remove the ground wire of the control board.

(Truss B tight screw Ø4 × 6, 1 screw)

5)Remove the fixed screws of the control board.

(Collar screw for fixing element Ø3 × 16, 7 screws,

Pan S-tight screw for fixing the board Ø3 × 20, 1

screw)

6)Remove the control board.

(Supporter 5 positions)

Note) Removing the control board may be difficult

due to the heat release grease for the heat

sink.

Power source terminal block

7)Attach a new control board.

Note) • Be careful for not taking the compressor

lead V: CN201 White for the reactor lead

CN05 or 06 White.

(The compressor lead has a transparent

sleeve at its ring terminal. The reactor

lead ring terminal does not have sleeve.)

• Be sure to attach the aluminium board

(Q201) and the insulating sheet (Q300).

(Applying beforehand a bit of heat

release grease to the back side of the

insulating sheet can easily paste the

sheet to the heat sink.)

Control board

Aluminum board (Q201)

Insulating sheet (Q300)

Heat release grease

138

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Exchange parts

name

No.

Work procedure

Remarks

Electric parts

replacement

2. Reactor

1)Perform the step 1-1.

Relay connector

2)Remove the relay connector connected to the

control board.

3)Cut the binding tie that binds the compressor leads

and relay connectors.

4)Remove the reactor.

(Truss B tight screw Ø4 × 6, 2 screws)

5)Attach a new reactor.

Note)

Be sure to bind the removed binding tie by using

the commercially available binding tie.

Make sure that the fan motor lead and the reactor

body do not contact each other.

Control board

Reactor body

Fan motor lead

Binding tie

(Compressor lead, Relay connector)

139

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Exchange parts

name

No.

Work procedure

Remarks

Turn it right to loosen

Fan motor

1)Perform the step 1-1 and step 2.

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. (control board)

5)Remove the fan motor lead from the fan motor

lead fixing rubber on the through hole of the

parting board.

Flange nut

Propeller fan

6)Remove the fixed screws (4 for each) while

holding the fan motor so that it does not drop.

* Notes in assembling fan motor

• Tighten the flange nut in 4.95 N•m (50kgf•cm)

• To prevent the fan motor lead from contacting

the propeller fan, adjust the length of fan motor

lead fixing rubber so that it does not slack.

Attach the fan motor lead fixing rubber to the

parting board so that the projection part is

placed on the refrigerant cycle side.

Fan motor

• Make sure that the reactor body and the fan

motor lead do not contact each other.

Fan motor connector

• Be sure to bind the removed binding tie by

using the commercially available binding tie.

Note

Fix the fan motor lead to the motor base using a

metal tie so that the fan motor lead does not

contact the propeller fan.

Inverter

Fan motor

fixing rubber

Projection/Refrigerant

cycle side

Fan motor

140

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name

No.

Work procedure

Remarks

Compressor

Compressor lead

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.

Piping panel (Front)

(Hex Ø4 × 10, 2 screws)

Remove screws of the piping panel (Front and

Back).

(Hex Ø4 × 10, 1 screw)

Binding tie for

heat resistance

Pipe cover

TD sensor

4)Remove the piping panel (Back).

Remove screws of the piping panel (Back) and

bottom board.

(Hex Ø4 × 10, 2 screws)

5)Remove the valve fixing board.

Remove the bolt of the valve.

(Hex head bolt Ø6 × 15, 4 bolts)

Remove the screws of the valve fixing board and

parting board.

Compressor lead

(ST1T Ø4 × 8, 1 screw)

Compressor case

thermostat

Remove the screws of the valve fixing board and

accumulator.

(ST1T Ø4 × 8, 1 screw)

TS sensor

Pipe cover, Binding tie

Cut the binding tie of the discharge pipe and

suction pipe to remove each sensor and the pulse

motor valve coil lead.

6)Remove the soundproofing board. (Upper, Inward

winding, Outward winding)

Outlet pipe

Suction pipe

Accumulator

7)Remove the compressor terminal cover, and then

remove the compressor lead and compressor

case thermostat.

8)Remove the TD sensor fixed to the discharge pipe.

9)Remove the compressor lead. (Leave the ferrite

core attached to the electric parts box.)

Control board U: CN200 Red

V: CN201 White

Pipe cover, Binding tie

Sensors (TL, TO, TE, TS)

Motorized control valve coil lead

W: CN202 Black

(Torque at tightening is 1.47

0.1N•m)

Black pipe cover for heat resistance,

Binding tie for heat resistance

Sensors (TL, TO, TE, TD, TS)

Motorized control valve coil lead

Control board

Compressor lead

Ferrite core

141

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name

No.

Work procedure

Remarks

Compressor

Compressor lead

10) Remove the discharge and suction pipes

connected to the compressor by using a burner.

Remove

(Suction pipe)

Remove

(Outlet pipe)

WARNING

When removing the piping by burning the solder,

take enough care for a fire going off at the

moment the wax melts if oil remains inside the

piping.

Note)

Do not make fire flame contact with the 4-way

valve and pulse motor valve.

(This may cause an operation failure.)

11) Pull out the discharge and suction pipes of the

refrigerant cycle upward.

12) Remove the compressor bolts that fix the

compressor to the bottom board. (3 bolts)

13) Pull the compressor out toward you.

Compressor bolt

(3 bolts)

Note)

The compressor weighs 15 kg or more.

Two people should be required to handle it.

142

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Exchange parts

name

No.

Work procedure

2. Attach the compressor

1)Attach the compressor in the reverse order of the

removal.

Remarks

Compressor

Compressor lead

Compressor

lead

Wind ferrite core with

compressor lead for 4 times.

Note)

• Be sure to replace the compressor lead after the

compressor replacement. (Compressor lead

spare parts code: 43160591)

Ferrite core

At this time, wind the ferrite core with the

compressor lead for 4 times.

Bind the compressor lead that is long with a

commercially available binding tie. When doing

this, be careful for the compressor lead not to

contact the discharge pipe.

• Fix the removed sensors and pulse motor valve

coil lead to the outlet and suction pipes through

the piping cover by using a binding tie. At this

time, be careful for the sensors and pulse motor

valve coil lead not to contact the discharge pipe.

(To fix the sensors and leads, use the black

piping cover for heat resistance and a

commercially available binding tie for heat

resistance.)

0 to 50

(Compressor lead

positioning standard) available binding tie

Bind the lead at 2 positions

with a commercially

Place soundproofing board (Outward winding)

through between suction pipe and accumulator

Suction pipe

Accumulator

Header pipe

• Attach the soundproofing board (Inward

winding, Outward winding), as shown in the right

figure, through between the compressor and

between the piping and parting board.

• Place the compressor lead and the compressor

case thermostat so that they fall into between

the inward winding and outward winding of the

soundproofing board.

Place soundproofing

board (Inward winding)

through between suction

pipe and header pipe

Overlap soundproofing

board (Outward winding)

at this position

Soundproofing

board (Upper)

Piping cover, Binding tie, TS sensor

Outlet pipe

Soundproofing board

(Outward winding)

Do not make gap between soundproofing

boards (Upper and Outward winding)

Black piping cover for heat resistance,

and Binding tie for heat resistance

Sensors (TL, TO, TE, TD, TS)

Pulse motor valve coil lead

Keep sensors away

for not contacting outlet pipe

Suction pipe

Pulse motor valve coil lead

Piping cover, Binding tie

Sensors (TL, TO, TE, TS)

Pulse motor valve coil lead

143

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Remarks

3. Vacuuming

Compressor

Compressor lead

1)Connect the vacuum pump to the charge port of

the gas piping valve to operate the vacuum pump.

2)Perform vacuuming until the vacuum low pressure

gauge shows 1(mmHg).

Note)

Open fully the pulse motor valve before

vacuuming. With the valve closed, vacuuming

between the outdoor unit liquid valve and the pulse

motor valve may fail.

How to make pulse motor valve forcible full open

• Turn on the electric leakage breaker.

• Set the SW804 dip switch 1 and 3 on the outdoor

unit control board to ON.

SW804

SW801

• Press SW801 on the outdoor unit control board

for 1 second or longer.

• After pressing SW801 for 1 second or longer,

turn off the electric leakage beaker within 2

minutes.

4. Charge refrigerant

1)Add refrigerant whose amount is defined

according to the piping length from the valve

charge port. (HWS-802H : 1.8kg)

1. How to remove

Pulse motor valve coil

1)Perform the step 1-1 and step 3.

2)Remove the coil from the pulse motor valve body

while pulling the coil upward to release the spring

holding the copper pipe.

2. How to attach

1)Fix the spring to the copper pipe.

Spring

Pulse motor

valve body

144

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Remarks

Fan guard

1. How to remove

1)Perform the step 1-1 and step 2.

Outlet cabinet

Bellmouth

Note

Perform a replacement work on cardboard or

cloth to prevent the product from being

damaged.

2)Remove the outlet cabinet and put with the fan

guard side down.

3)Release the hooks (8 positions) of the fan guard.

2. How to attach

1)Press the hooks (8 positions) with hands from the

front side to fix them.

Fan guard

Hooks

Note

Check that all the hooks are fixed to the given

positions.

145

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2-2. HWS-1102H-E, 1402H-E

Exchange parts

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No.

Work procedure

Remarks

Common procedure

Note

Wear gloves when performing the work.

Failure to do so may cause an injury when

accidentally contacting the parts.

Front panel

1. How to remove

1)Stop the operation by remote controller and turn

off the breaker.

2)Remove the front panel.

(Hex Ø4 × 10, 2 screws)

• After unscrewing the screws, remove the front

panel while pulling it downward.

3)Disconnect the power source cable and

connecting cables between hydro and outdoor

from the cord clamp and terminals.

4)Remove the top board.

(Hex Ø4 × 10, 5 screws)

2. How to attach

1)Attach the top board.

(Hex Ø4 × 10, 5 screws)

2)Connect the power source cable and connecting

cables between indoor and outdoor to the

terminal, and fix them with the cord clamp.

Note

The power source cable and connecting cable

between hydro and outdoor units must be fixed

along the connecting piping by using a cable tie

so that the cables do not contact the

compressor, gas side valve, gas side piping and

outlet pipe.

3)Attach the front panel.

(Hex Ø4 × 10, 2 screws)

Top board

146

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Remarks

Outlet cabinet

How to remove

1) Perform the step 1-1.

Outlet cabinet

Heat exchanger

Motor base Paring board

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.

(ST1T Ø4 × 8, 1 screws)

6)Remove the screws of the outlet cabinet and fin

guard.

(Hex Ø4 × 10, 2 screws)

Fin guard

Inverter assembly

Side cabinet

1)Perform the step 1-1.

Side cabinet

2)Remove the screws that fixes the inverter

assembly and the side cabinet.

(ST1T Ø4 × 8, 2 screws)

3)Remove the screws of the side cabinet and valve

fixing board.

(ST1T Ø4 × 8, 2 screws)

4)Remove the screws of the side cabinet and piping

panel (back).

(Hex Ø4 × 10, 2 screws)

5)Remove the screws of the side cabinet and bottom

board.

(Hex Ø4 × 10, 1 screws)

6)Remove the screws of the side cabinet and fin

guard (heat exchanger).

(Hex Ø4 × 10, 5 screws)

7)Remove the side cabinet while shifting it upward

(inverter hook).

Valve fixing board

147

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Work procedure

Remarks

Electric parts

replacement

1. Control board

1)Perform the step 1-1.

Fan motor (upper)

Control board

Compressor

case

thermostat

Reactor lead

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

(Hydro power source, temperature sensor, electric

control valve coil, 4-way valve coil, compressor

case thermostat, fan motor)

* Remove the connector by releasing the lock in the

housing.

Compressor lead

Ground wire

Fan motor (lower)

Temperature

sensor

3)Remove the lead cable connected to the control

board.

Compressor lead U: CN200 Red

V: CN201 White

W: CN202 Black

4-way valve coil

Motorized control coil Indoor power source

Reactor lead CN05 White

CN06 White Relay connector

Screw for fixing

board

Screw for fixing element

(9 positions)

4)Remove the ground wire of the control board.

(Truss B tight screw Ø4 × 6, 1 screw)

5)Remove the fixed screws of the control board.

(Collar screw for fixing element Ø3 × 16, 9 screws,

Pan S-tight screw for fixing the board Ø3 × 20, 1

screw)

6)Remove the control board.

(Supporter 5 positions)

Note) Removing the control board may be difficult

due to the heat release grease for the heat

sink.

Hear release

grease

Insulating

sheet

Control board

7)Attach a new control board.

Note) • Be careful for not taking the compressor

lead V: CN201 White for the reactor lead

CN05 or 06 White.

(The compressor lead has a transparent

sleeve at its ring terminal. The reactor

lead ring terminal does not have sleeve.)

• Be sure to attach the insulating sheet.

(Applying beforehand a bit of heat

release grease to the back side of the

insulating sheet can easily paste the

sheet to the heat sink.)

148

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Remarks

Electric parts

replacement

2. Reactor

1)Perform the step 1-1.

Binding tie

(Compressor lead,

Reactor lead)

Reactor lead

2)Remove the reactor lead connected to the control

board.

CN05 White, CN06 White

Control board

3)Cut the binding tie that binds the compressor leads

and fan motor leads.

4)Remove the reactor.

(Truss B tight screw Ø4 × 6, 2 screw)

5)Attach a new reactor.

Note)

Be sure to bind the removed binding tie by using

the commercially available binding tie.

Make sure that the fan motor lead and the reactor

body do not contact each other.

Reactor lead

Binding tie

Reactor body

(Compressor lead,

Reactor lead)

Binding tie

(Fan motor lead,

Reactor lead)

Fan motor lead

149

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Fan motor

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. (control board)

Flange nut

(Remove the ferrite core of the lower fan motor to

use it again for a new fan motor.)

Propeller fan

5)Remove the fan motor lead from the fan motor

lead fixing rubber on the through hole of the

parting board.

6)Remove the fixed screws (4 for each) while

holding the fan motor so that it does not drop.

Fan motor

* Notes in assembling fan motor

Fan motor

connector (upper)

• Tighten the flange nut in 4.95 N•m (50kgf•cm).

• To prevent the fan motor lead from contacting

the propeller fan, adjust the length of fan motor

lead fixing rubber so that it does not slack.

Attach the fan motor lead fixing rubber to the

parting board so that the projection part is

placed on the refrigerant cycle side.

Fan motor

connector (lower)

• Make sure that the reactor body and the fan

motor lead do not contact each other.

• Be sure to bind the removed binding tie by

using the commercially available binding tie.

• Be sure to re-attach the ferrite core of the

lower fan motor. (Fix this with a commercially

available binding tie.)

Fan motor ferrite

core (lower)

Fan motor lead

fixing rubber

Note

Fix the fan motor lead to the motor base using a

metal tie so that the fan motor lead does not

contact the propeller fan.

Projection/Refrigerant

cycle side

Fan motor lead

fixing rubber

Projection/Refrigerant

cycle side

Fan motor

150

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Compressor

Compressor lead

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.

Piping panel (Front)

(Hex Ø4 × 10, 2 screws)

Piping panel (Back)

Piping cover

Remove screws of the piping panel (Front and

Back).

(Hex Ø4 × 10, 1 screws)

TD sensor

Binding tie

(for heat resistance)

4)Remove the piping panel (Back).

Remove screws of the piping panel (Back) and

bottom board.

(Hex Ø4 × 10, 2 screws)

5)Remove the soundproofing board. (Upper, Inward

winding, Outward winding)

Compressor lead

6)Remove the compressor terminal cover, and then

remove the compressor lead and compressor

case thermostat.

7)Remove the TD sensor fixed to the discharge

piping.

Compressor case thermostat

Control board

8)Remove the compressor lead. (Leave the ferrite

core attached to the electric parts box.)

Control board U: CN200 Red

V: CN201 White

W: CN202 Black

9)Remove the outlet and suction pipes connected to

the compressor by using a burner.

Compressor lead

WARNING

When removing the piping by burning the solder,

take enough care for a fire going off at the

moment the wax melts if oil remains inside the

piping.

Note)

Do not make fire flame contact with the 4-way

valve and pulse motor valve.

(This may cause an operation failure.)

Ferrite core

10) Pull out the discharge and suction pipes of the

refrigerant cycle upward.

11) Remove the compressor nuts that fix the

compressor to the bottom board. (3 nuts)

12) Pull the compressor out toward you.

Remove

(Outlet pipe)

Note)

The compressor weighs 20 kg or more.

Two people should be required to handle it.

Remove

(Suction pipe)

Compressor nut

(3 nuts)

151

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2. Attach the compressor

1)Attach the compressor in the reverse order of the

removal.

Remarks

Compressor

Compressor lead

Wind ferrite core with

compressor lead

for 4 times

Compressor lead

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.

• Attach the soundproofing board (Inward

winding, Outward winding), as shown in the right

figure, through between the compressor and

between the piping and parting board.

• Fix the TD sensor with a commercially available

heat resistant binding tie through the piping

cover so that the sensor do not contact the

discharge pipe.

Ferrite core

0 to 50

(Compressor lead positioning standard)

Place soundproofing board (Outward winding)

through between suction pipe and header pipe

Overlap soundproofing board

(Outward winding) at this position

3)Vacuuming

Header pipe

1)Connect the vacuum pump to the charge port and

check joint 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.

Suction pipe

Discharge pipe

Overlap soundproofing board (Inward winding)

at this position through between compressor,

outlet pipe, and suction pipe

How to make pulse motor valve forcible full open

• Turn on the electric leakage breaker.

• Set the SW804 dip switch 1 and 3 on the outdoor

unit control board to ON.

• Press SW801 on the outdoor unit control board

for 1 second or longer.

Do not make space between soundproofing boards

(Upper and Outward winding)

Soundproofing

board (Upper)

• After pressing SW801 for 1 second or longer,

turn off the electric leakage breaker within 2

minutes.

Rivet

4. Charge refrigerant

1)Add refrigerant whose amount is defined

according to the piping length from the valve

charge port. (HWS-1102H, 1402H : 2.7kg)

Make the other end of the

line go through under the rivet

Soundproofing board

(Outward winding)

SW804

SW801

152

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1. How to remove

Pulse motor valve coil

1)Perform the step 1-1.

2)Remove the coil from the pulse motor valve body

by pulling upward while rotating the coil.

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

Motorized

control valve coil

Fan guard

1. How to remove

1)Perform the step 1-1 and step 2.

Fan guard

Outlet cabinet

Bellmouth

Note

Perform a replacement work on cardboard or

cloth to prevent the product from being

damaged.

2)Remove the outlet cabinet and put with the fan

guard side down.

3)Release the hooks (8 positions) of the fan guard.

2. How to attach

1)Press the hooks (8 positions) with hands from the

front side to fix them.

Hooks

Note

Check that all the hooks are fixed to the given

positions.

153

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12Periodic 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. Power source measurement (No-load voltage)

3. Operation check

Annually

Electronic voltage measurement: 230V 23V

Hot water supply/ Heating/ Cooling operation check with

remote controller

4. Refrigerant leakage/ Water leakage inspection

Annually

Visual inspection and check with a leak tester: No leakage

must be found

5. Water heat exchanger inspection (Internal dirt and

clogging)

Checking for water dirtiness in a closed cycle, Cleaning

6. Inlet/ Outlet water temperature measurement

Temperature measurement: Temperature measurement

during an operation

7. Circulation pump inspection

No leakage or abnormal noise must be found (Replacement

every 10 years: Charged)

8. Air vent valve inspection

9. Expansion vessel

Annually

Water leakage, Air vent

Visual check for charge pressure abnormality, water

leakage, or corrosion

10. Heater assembly

Annually

Check for appearance damage, deformation, or loose

terminal

11. Flow switch

Annually

Operation check while running

12. Manometer

Water leakage, water pressure check

13. Safety valve

Water leakage, Appearance check, Drainage check

Check for loose connector and connecting terminal

14. Water heat exchanger control board, Terminal block

Outdoor unit

(HWS-802H-E, 1102H-E, 1402H-E)

Frequency

Periodic inspection details

1. Insulation measurement (Power source circuit/

Compressor)

Annually

Insulation measurement with a mega tester

2. Power source measurement (No-load voltage/ Rated

operation)

Annually

Electronic voltage measurement: 230V 23V

3. Operation frequency (Outdoor unit operation check)

4. Refrigerant leakage inspection

Annually

Frequency check by rated operation (See 10-13)

Visual inspection and check connection with a leak tester:

No leakage must be found

5. Air heat exchanger inspection (Dirt and clogging)

6. Fan inspection (Scratch, damage)

Annually

Visual inspection, Clear clogging

Check for scratches or damages to the fan or abnormal

motor sound

7. Cycle parts

(Compressor, 4-way valve, Pulse motor valve)

Annually

Operation check by trial run

8. Inverter control board, Terminal block

Annually

Check for loose connector and connecting terminal

Hot water cylinder

(HWS-150CSHM3-E(-UK),

210CSHM3-E(-UK), 300CSHM3-E(-UK))

Frequency

Periodic inspection details

1. Insulation measurement (Power source circuit)

2. Power source measurement (No-load voltage)

3. Water leakage inspection

Annually

Insulation measurement with a mega tester

Electronic voltage measurement: 230V 23V

Visual inspection for leakage: No leakage must be found

Check for loose connector and connecting terminal

4. Terminal block

5. Heater assembly

Check for appearance damage, deformation, or loose

terminal

6. Temperature, Pressure relief valve (Specification for

UK only)

Annually

Drainage check

154

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13Part Exploded View, Part List

Hydro Unit

155

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220

223

235

234

224

222

221

225

230

227

226

231

233

232

235

228

229

156

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Number of pieces per unit

Safety

Location

No.

HWS-

Part No.

Description

1402XW 1402XW 1402XW 802XWH 802XWH

HM3-E

HT6-E

HT9-E

M3-E

T6-E

201

202

203

204

205

206

207

208

209

210

211

212

213

214

215

216

217

218

219

220

221

222

223

224

225

226

227

228

229

230

231

232

233

234

235

236

37500802

37500800

37500801

37500803

37566705

37546861

37546862

37541733

37541734

37542708

37547757

37519776

37547756

37543706

37545713

37545714

37545715

43151273

37551736

37551735

43032441

37595721

37595720

4306V226

4316V338

43152401

43158187

43154156

43054107

43160297

43060059

43160565

43160566

4306A130

43160576

43160579

43160561

43050425

43150320

37595722

CABINET, FRONT

PLATE, UP

PLATE, SIDE

PLATE, DN, ASSY

REMOTE CONTROLLER

PIPE ASSY, WATER HEAT EXCHANGER

PUMP, WATER, ASSY

VESSEL, EXPANSION

VALVE, PRESSURE RELIEF

FASTENER, QUICK

VALVE, AIR VENT

METER, PRESSURE

HEATER ASSY

SWITCH, PRESSURE

SENSOR, LOW PRESSURE

SWITCH, FLOW

NIPPLE, DRAIN

PACKING, ASSY

RING, O, ASSY

PC BOARD ASSY

CONTACTOR, MAGNETIC

TRANSFORMER

RELAY, LY-1F

RELAY, LY1F

FUSE

FUSE, HOLDER

TERMINAL BLOCK, 3P, 20A

TERMINAL BLOCK, 6P, 20A

TERMINAL BLOCK, 9P, 20A

TERMINAL BLOCK, 4P, 20A

TERMINAL

TERMINAL, 4P

SENSOR ASSY, SERVICE

GASKET, LIQUID

157

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Outdoor Unit (HWS-802H-E)

158

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Number of pieces per unit

HWS-802H-E

Safety

Location

No.

Part No.

Description

001

002

003

004

005

006

007

008

009

010

011

012

013

014

015

016

017

018

019

020

021

022

023

024

025

026

027

028

029

030

031

032

033

034

035

43019904

43032441

43041798

43046493

43046451

43047246

43047669

43049739

43050407

43063317

43100437

43100438

43100440

43100452

43100453

43100454

43100455

43107276

43107277

43107278

43109422

43120244

43122113

4312C042

43146686

43146695

43146724

43148232

4314G278

4314N024

4314Q031

4314Q056

43160591

43194029

43197183

HOLDER, SENSOR

NIPPLE, DRAIN

COMPRESSOR, DA220A2F-22L

COIL, PMV

VALVE, 4-WAY, STF-0218G

BONNET, 3/8 IN

NUT, FLANGE

CUSHION, RUBBER

THERMOSTAT,BIMETAL

HOLDER,THERMOSTAT

PANEL, FRONT, PIPING

PANEL, BACK, PIPING

PLATE, ROOF

PANEL, SIDE

PANEL, AIR OUTLET

PANEL, FRONT

BASE ASSY

HANGER

GUARD, FIN, BACK

GUARD, FIN, SIDE

GUARD, FAN

FAN, PROPELLER, PB521

BELL MOUTH

MOTOR, FAN, ICF-280-A60-1

VALVE, PACKED, 9.52

VALVE, PULSE, MODULATING

VALVE, BALL, SBV-JA5GTC-1, R0HS

ACCUMULATOR, ASSY

CONDENSER ASSY

COIL, VALVE, 4WAY, VHV-01AP552B1

STRAINER

LEAD ASSY, COMPRESSOR

BONNET

BOLT, COMPRESSOR

159

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Inverter Assembly (HWS-802H-E)

Reactor

704

Control board assembly

711

Bushing

709

Collar

710

Fuse

707

Terminal (3P)

705

703

Terminal 3P

706

Sensor assembly

(F4)

Sensor holder (TO)

Sensor holder (TE)

Sensor holder (TS)

Sensor holder (TD)

708

702

712

713

TD, TL sensor

Sensor assembly

(F6)

701

TS, TE, TD sensor

160

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Number of pieces per unit

HWS-802H-E

Safety

Location

No.

Part No.

Description

SENSOR ASSY, SERVICE

701

702

703

704

705

706

707

708

709

710

711

712

713

43050425

43063325

43150319

43155188

43160565

43160581

43160589

43163055

43163059

43163060

4316V387

43063322

43063321

HOLDER, SENSOR

SENSOR ASSY, SERVICE

REACTOR, CH-56-2Z-T

TERMINAL BLOCK, 3P, 20A

TERMINAL

FUSE

HOLDER, SENSOR

SPACER, BUSH

SPACER, COLLAR

PC BOARD ASSY, MCC-1571

HOLDER,SENSOR

161

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Outdoor Unit (HWS-1102H-E, 1402H-E)

162

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Number of pieces per unit

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

Safety

Location

No.

Part No.

Description

001

002

003

004

005

006

007

008

009

010

011

012

013

014

015

016

017

018

019

020

021

022

023

024

025

026

027

028

029

030

031

032

033

034

035

036

037

43019904

43032441

43041794

43047246

43047669

43049739

43050407

43063317

43097212

43100437

43100438

43100439

43100440

43100441

43100442

43100443

43107274

43107275

43107276

43109422

43120244

43122113

4312C037

43146676

43146686

43146687

43146724

43148170

4314G266

4314G269

4314N023

4314N024

4314N025

4314Q031

4314Q032

43160591

43194029

HOLDER, SENSOR

NIPPLE, DRAIN

COMPRESSOR, DA422A3F-25M

BONNET, 3/8 IN

NUT, FLANGE

CUSHION, RUBBER

THERMOSTAT,BIMETAL

HOLDER,THERMOSTAT

NUT

PANEL, FRONT, PIPING

PANEL, BACK, PIPING

PANEL, FRONT

PLATE, ROOF

PANEL, SIDE

PANEL, AIR OUTLET

BASE ASSY

GUARD, FIN, SIDE

GUARD, FIN, BACK

HANGER

GUARD, FAN

FAN, PROPELLER, PB521

BELL MOUTH

MOTOR, FAN, ICF-280-A100-1

JOINT,CHECK

VALVE, PACKED, 9.52

VALVE, 4-WAY, STF-0401G

VALVE, BALL, SBV-JA5GTC-1, R0HS

ACCUMULATOR ASS'Y

CONDENSER ASSY, DOWN

CONDENSER ASSY, UP

VALVE, PLUS, MODULAING, UKV-25D100

COIL, VALVE, 4WAY, VHV-01AP552B1

COIL, PMV, UKV-A038

STRAINER

LEAD ASSY, COMPRESSOR

BONNET

163

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Inverter Assembly (HWS-1102H-E, 1402H-E)

Reactor

704

Control board assembly

711

Bushing

709

Collar

710

Fuse

707

Terminal (3P)

705

703

Terminal 3P

706

708

Sensor assembly

(F4)

Sensor holder (TO)

TD, TL sensor

Sensor assembly

(F6)

701

Sensor holder (TE)

702

TS, TE, TO sensor

164

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Number of pieces per unit

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

Safety

Location

No.

Part No.

Description

SENSOR ASSY, SERVICE

701

702

703

704

705

706

707

708

709

710

711

43050425

43063325

43150319

43158190

43160565

43160581

43160589

43163055

43163059

43163060

4316V357

HOLDER, SENSOR

SENSOR ASSY, SERVICE

REACTOR

TERMINAL BLOCK, 3P, 20A

TERMINAL

FUSE

HOLDER, SENSOR

SPACER, BUSH

SPACER, COLLAR

PC BOARD ASSY, MCC-1571

165

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166

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