Page 2 - Contents
1 Toshiba Contents 1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 NEW REFRIGERANT (R410A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2-1.Safety During Installation and Service . ....
Page 4 - SAFETY PRECAUTIONS; DANGER
3 Toshiba 1 SAFETY PRECAUTIONS The unit and this service guide list very important safety precautions.Understand the following details (indications and symbols) before reading the body text, and follow the instructions. [About indication] * Property damage indicates extended damage to property, furn...
Page 5 - Do not modify the unit.; WARNING
4 Toshiba <No modification> Do not modify the unit. • Do not disassemble or modify the parts also.• A fire, an electric shock, or an injury may occur. <Use specified parts> Use the specified parts ( ∗ ) when replacing them. • Using parts other than specified ones may cause a fire or an e...
Page 6 - Ventilate if refrigerant gas leaks during service work.; CAUTION; Tighten a flare nut with a torque wrench in the specified method.
5 Toshiba <Check insulation> After the work is completed, check with an insulating-resistance tester (500V) that the insulation resistance between the live and dead-metal parts is 2 M Ω or higher. • A low insulation resistance may cause a disaster at a customer site due to electrical leakage o...
Page 7 - -1. Safety During Installation and Service; • Ventilate if refrigerant gas leaks during service work.
6 Toshiba 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 r...
Page 8 - Copper pipe; Flared joint; The minimum wall thickness of socket joints
7 Toshiba 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 pi...
Page 9 - Flare and precautions; Cut slowly with a pipe cutter so that the pipe is not distorted.; Table 2-2-3 Flare processing related dimension for R410A
8 Toshiba 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 wa...
Page 10 - Flare connecting procedure and precautions; ) Correctly align the flared surface and the connecting axis.
9 Toshiba 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 R4...
Page 11 - Tools dedicated for R410A (The following tools must be for R410A); adjustment requires copper pipe gauge or other instrument.; General tools (Conventional tools are available); Use this by attaching vacuum pump
10 Toshiba 2-3. Tools 2-3-1. Necessary tools In Air to Water Heat Pump using R410A, the service port diameter of packed valve of the outdoor unit is changed to prevent mixing of other refrigerant. To reinforce the pressure resistance, flare dimensions and opposite side dimensions of flare nut (For Ø...
Page 12 - NOTE
11 Toshiba 2-4. Recharging of refrigerant Recharge, if necessary, the specified amount of new refrigerant according to the following procedure. NOTE • Never charge refrigerant exceeding the specified amount.• If the specified amount of refrigerant cannot be charged, charge it a little at a time whil...
Page 15 - ) Use the reducing valve to adjust the nitrogen
14 Toshiba 5) Use the reducing valve to adjust the nitrogen gas flow speed to 0.05 m 3 /hour or 0.02 MPa (0.2 kgf/cm 2 ). 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) Remov...
Page 16 - Specifications
15 Toshiba 3 Specifications *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 measurem...
Page 18 - Outside Drawing
17 Toshiba 4 Outside Drawing 4-1. Hydro unit HWS-802XWHM3-E, 802XWHT6-E HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E 960 Anchor bolt long hole pitch B leg part 40 380 40 20 20 72.5 72.5 2-dia.12x17 long hole (for dia.8-10 anchor bolt) 2-dia.12x17 U-shape hole (for dia.8-10 anchor bolt) A leg part Remot...
Page 22 - Wiring Diagram
21 Toshiba 5 Wiring Diagram 5-1. Hydro Unit 1 1 3 3 123456 1 456 23 WHI WHI Transformer ORN ORN RED RED BRW BRW CN102 (WHI) 1 1 3 23 CN101 (WHI) CN202 (YEL) BLK BLK CN201 (WHI) 2 2 1 1 Thermal protector (auto)75 ± 3 High pressure switch 4.15MPa RED YEL CN200 (RED) 23 3 1 7 2 GRN 2 2 8 1 CN211 (BLK) ...
Page 23 - Control board; an optional accessory or service wiring.
22 Toshiba 5-2. Outdoor Unit Control board (Blue) ( White ) HMS-1102, 1402H-E only ( White ) ( White ) Upper ( White ) Operating power 4-way valve coil Reactor 230V 50Hz Earth screw Earth screw Earth screw Hydro unit Outdoor unit Power supply single phase ( Yellow ) ( White ) ( White ) ( Yellow ) ( ...
Page 25 - Key Electric Component Rating; Component name
24 Toshiba 6 Key Electric Component Rating 6-1. Hydro Unit HWS-802XWHM3-E, 802XWHT6-E O ········· AppliedOP······· Optional accessory No. Component name Model name Type name Rating M3-E T6-E 1 Circulating pump O O UPS025-65 K 130 AC230 V 0.54 A (MAX) 2 Backup heater 6 kW O O – AC 400 V (3N) 6 kW (AC...
Page 32 - Electrolytic capacitors
31 Toshiba HWS-1102H-E, 1402H-E Fan motor output (Upper)CN400(White) Fan motor output (Lower)CN300(White) Case thermostat connectorCN609(Blue) Power circuit protectionfuseF100(250V,3.15A,plastic case) 4-way valve connectorCN701(White) Compressor ON output connectorCN704(Blue) External input connecto...
Page 33 - Refrigeration Cycle / Water System Diagram
32 Toshiba 7 Refrigeration Cycle / Water System Diagram 7-1. Water System Diagram M M Fan coil unit Radiator unit Floor heating By-pass valve (locally procured) By-pass valve (locally procured) Moterized mixing valve (locally procured) AC230V Buffer tank(locally procured) AC pump (locally procured) ...
Page 34 - Installation example of water circuit
33 Toshiba Installation example of water circuit 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 sh...
Page 35 - Outdoor unit
34 Toshiba 7-2. Refrigeration Cycle System Diagram HWS-802XWHM3-E, 802XWHT6-E/802H-E HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E/1102H-E, 1402H-E P TWO THO TWI TC TE TO TS TD Outdoor unit Refrigerant R410A ... 1.8 kg Expansion vessel Backup heater Manometer Low pressure sensor Pressure switch Water ve...
Page 36 - Operational Description; Item
35 Toshiba 8 Operational Description This chapter describes the working circuit and control of Air to Water Heat Pump about the following operations. Item Page 8-1 Basic Operation 1) Operation control 2) Hot water supply operation 3) Heating operation 4) Cooling operation 36-38 8-2 Operation Mode an...
Page 40 - TTW sensor
39 Toshiba Item Operation flow and applicable data, etc. 8-2. Operation Mode and Control Method The following shows the operation modes and controlled objects. O Possible × Not possible 1) Hot water supply operation1) Operation start condition When the [HOT WATER] remote controller button is pressed...
Page 45 - Usual hot water supply operation
44 Toshiba 8-2. Operation Mode and Control Method 8) Anti bacteria (ANTI BACTERIA) operationAn anti bacteria operation regularly performs a Hot water supply operation with the set temperature TSC_H = 75°C (can be set with FC_0A). 1) How to operate • Pressing the [HOT WATER] button and then the remot...
Page 62 - In 10 to 15 minutes after the heating; Outdoor PMV
61 Toshiba 8-4. Outdoor unit control 6) Defrosting controlThis 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 ...
Page 65 - Method of Defect Diagnosis; Procedure of defect diagnosis
64 Toshiba 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...
Page 66 - -1-2. Check for any miswiring of the connection cables between; part of the copper piping are attached with each other tightly.; Operation of the heat pump system
65 Toshiba 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 t...
Page 67 - -3. Outline of the determination diagram; control; or
66 Toshiba 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 f...
Page 68 - Defect mode detected by the water heat exchange
67 Toshiba 9-3-4. How to diagnose by error code Defect mode detected by the water heat exchange O ... Possible× .... Not possible Check code Diagnostic functional operation Determination and action Number of abnormalities for confirmation Detailed item Operational cause Backup present Automat ic res...
Page 71 - Defect mode detected by the outdoor unit
70 Toshiba Defect mode detected by the outdoor unit O ... Possible× .... Not possible Check code Diagnostic functional operation Determination and action Number of abnormalities for confirmation Detailed item Operational cause Backup present Automat ic reset F04 TD sensor error Open or short circuit...
Page 74 - Defect mode detected by the remote control
73 Toshiba Defect mode detected by the remote control Check code Diagnostic functional operation Determination and action Operational cause Status of air- conditioning Condition Not displaying at all (cannot operate by the remote control) No communication between hydro unit an remote controller • Th...
Page 75 - -4. Diagnosis flow chart for each error code
74 Toshiba 9-4. Diagnosis flow chart for each error code 9-4-1. Hydro unit failure detection [A01] Error Pump flow determination Pump rotates Replace TC sensor Remove waste Dirt clogging inside water circuit 12 M or longer water pipe to a branch, or 5 or less branches Fit buffer tank and the second ...
Page 76 - [A02] Error Temperature rise and error short circuit
75 Toshiba [A02] Error Temperature rise and error short circuit Replace TWI, TWO, and THO sensors No (TWI,TWO,THO 70°C) TWI, TWO, and THO sensor characteristics are correct Yes No Water outlet temperature is 70°C or higher Yes Correct water circuit (To prevent hot water of other circuits from enteri...
Page 77 - [A03] Error Temperature rise and error short circuit
76 Toshiba [A03] Error Temperature rise and error short circuit Replace TTW sensor No (TTW 85°C is detected) TTW sensor characteristic is correct Yes No Hot water cylinder heater is energized Yes No At normal temperature, tank thermostat is energized Yes Replace hot water cylinder thermostat No Hot ...
Page 79 - [A05] Error Piping freeze prevention control
78 Toshiba [A05] Error Piping freeze prevention control Water heat exchange control board DPSW11-1 is ON Replace backup heater and safety valve Set water heat board DPSW11-1 to ON No (Backup heater NG) Backup heater terminal has 230ACV ( ± 23V) Power is connect to built-in heater terminal Yes Yes Re...
Page 84 - [A12] Error Heating or Hot water supply heater failure
83 Toshiba [A12] Error Heating or Hot water supply heater failure Water heat exchanger board DPSW11-1,2 is ON Replace booster heater unit and safety valve Set water heat board DPSW11-1,2 to ON A12 abnormality detection No (Backup heater NG) Backup heater or hot water cylinder terminal has 230ACV ( ±...
Page 90 - [F23] Error Lo pressure sensor detach failure
89 Toshiba [F20] Error TFI detach failure [F23] Error Lo pressure sensor detach failure Attach TFI sensor to pipe Replace TFI sensor No No TFI sensor is attached to pipe Yes TFI sensor characteristic is normal Yes Replace TWI sensor No (See characteristic table on page 101) (See characteristic table...
Page 91 - disappears; Set indoor unit capacity data
90 Toshiba [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 ...
Page 92 - Diagnosis procedure for each check code; to narrow down the check details.
91 Toshiba 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 sa...
Page 101 - Replace outdoor control board
100 Toshiba [F12] <Indication 1> <Indication 2> [Suction temperature sensor (TS) failure] [F13] <Indication 1> <Indication 2> [Heat sink temperature sensor (TH) failure] [F15] <Indication 1> <Indication 2> [Heat exchanger sensor (TE, TS) wrong wiring] [F31] <In...
Page 102 - table
101 Toshiba 9-4-3. Temperature sensor, temperature-resistance characteristic table TC, TWI, TWO, TFI, TTW, TE, TS, TO sensors TD, TL sensors Typical value Typical value Temperature (°C) Resistance value (k Ω ) Temperature (°C) Resistance value (k Ω ) (Minimum) (Standard) (Maximum) (Minimum) (Standar...
Page 103 - Operation check mode; ) Turn on the hydro unit and the outdoor unit.; Rotary
102 Toshiba 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 w...
Page 104 - -6. Brief method for checking the key components
103 Toshiba 9-6. Brief method for checking the key components 9-6-1. Hydro unit No. Component name Check procedure 1 Water heat exchange temperature (TC) sensor Water inlet temperature (TWI) sensor Water outlet temperature (TWO) sensor Hot water cylinder temperature (TTW) sensor Floor inlet temperat...
Page 106 - Hydro unit and Outdoor Unit Settings; Hydro unit
105 Toshiba 10 Hydro unit and Outdoor Unit Settings Hydro unit 1. Hydro unit Setting 1-1. Setting switch names and positions 1-2. SW02 (System switching 1) 1-3. SW10 (Pump switching) 1-4. SW11 (Heater Yes/No switching) 1-5. SW12 (System switching 2) 1-6. SW13 (System switching 3) SW02 Switching deta...
Page 107 - Hydro unit Function Code Setting; Perform the following when no operation is in progress.
106 Toshiba 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 and TEST and SELECT buttons at the same time for 4 seconds or longer. (See display ) 2 Specify CODE NO. (FC) with the TEMP. button f...
Page 108 - Function code table; FC
107 Toshiba Function code table FC Item Details First shipment 01 Water heat exchanger capacity 0012: 802XWH**-E0017: 1402XWH**-E Depends on type 02 Cooling/Non-cooling switching 0000: Cooling 0001: No cooling 0001: No cooling 07 Hot water HP operation mode upper time limit 0000: 0 mins - 0120: 120 ...
Page 109 - Remote controller function code table
108 Toshiba Remote controller function code table FC Item Details Fist shipment 05 24H/12H display switching 0: 24H display 1: 12H (AM/PM) display 0: 24H display 09 Nighttime low-noise mode 0: Disabled 1: Enabled 0: Disabled 0A Nighttime low-noise start time 0 - 23 (0:00 to 23:00) 22: 22:00 0B Night...
Page 111 - Auto Curve Setting; FC code setting can make flexible Auto-Curve settings.
110 Toshiba 4. Auto Curve Setting FC code setting can make flexible Auto-Curve settings. <Preparation> 1 Press the TEST and SET and SELECT buttons at the same time for 4 seconds or longer. (See display ) (Make sure that no operation is in progress.) 2 Specify an item code (FC) from among 29 to...
Page 112 - Press the TIME
111 Toshiba 5. Time Setting 1 Press the TIME button for 4 seconds or longer. (The screen moves to the time setting mode.) (See display ) Day, time, , and indications blink. (Time setting is available during an operation.) 2 Specify a day to be set. Press the DAY button to select the current day. The...
Page 113 - Scheduled Operation Setting
112 Toshiba 6. Scheduled Operation Setting Schedule setting makes the following modes to be flexibly set: hot water supply, heating, cooling, hot water supply and heating, hot water supply and cooling, and stop, and set temperature. 6-1. How to set scheduled operation <Preparation> Set the rem...
Page 114 - -2. How to start and cancel schedule operation; Frost Protection Setting
113 Toshiba 6-2. How to start and cancel schedule operation <Operation start> Without schedule operation set, press the remote controller SCHEDULE button. blinks. Pressing the SET button during the 5-second blinking changes to lit, and the schedule operation starts. <Operation cancel> Wi...
Page 115 - NIGHT Operation Setting;
114 Toshiba 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 button to start a heating or a cooling operation. (See display ) (Nighttime operation is not available for hot water supply. Use the sch...
Page 116 - Anti Bacteria Setting;
115 Toshiba 9. Anti Bacteria Setting This setting regularly raises the hot water cylinder temperature to prevent bacteria from growing. 1 Press the HOT WATER button to start a hot water supply operation. (Normal hot water supply operation)(No anti bacteria setting is provided to heating and cooling....
Page 117 - Hot Water Boost Setting;
116 Toshiba 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 button to start a hot water supply operation. (Normal hot water supply operation) 2 Pressing the HOT WATER BOOST button displays the sym...
Page 118 - Forced Defrosting Setting
117 Toshiba 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 , SET , and SELECT , at the same time for 4 seconds or longer.(Make sure that no operation is in p...
Page 119 - Display Function of Set Temperature and Other Settings; The following table shows the item codes.
118 Toshiba 14. Display Function of Set Temperature and Other Settings ■ Sensor temperature display calling <Details> This function calls the service monitor mode from the remote controller to show the data of the remote controller, the hydro unit, and outdoor unit. <Procedure> 1 Press t...
Page 120 - Failure History Calling Function; This function calls the previous failure details.
119 Toshiba 15. Failure History Calling Function <Details> This function calls the previous failure details. <Procedure> 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" displa...
Page 121 - Remove the water in the hydro unit.
120 Toshiba 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 refrig...
Page 122 - The following settings are available with dip switches.
121 Toshiba 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 oper...
Page 123 - Switch
122 Toshiba (2) LED indication switching (SW800, SW803 operation) (2) -1. Indication switching list Operating SW803 can switch the indications of LED D800 to D804 on the outdoor control board. Switch Function and details Abnormality indication (Current abnormality) This switch indicates the current ...
Page 125 - sensor failure, not connected
124 Toshiba (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. * TD, TL, and TH show errors below the ordinary temperature because they are sensors for high temperatur...
Page 126 - Operation when press button switch SW801 is pressed
125 Toshiba (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...
Page 128 - How to Exchange Main Parts; A room with no ventilation may cause carbon monoxide poisoning.; Exchange parts name
127 Toshiba 11 How to Exchange Main Parts 1. Hydro Unit WARNING <Turn off the power breaker>Because the electrical components are energized with high voltage, always turn off the power breaker before starting to work. <Check>After a repair is complete, perform a trial operation (after at...
Page 131 - Upper
130 Toshiba 6 Side board 1. Side board (Right) 1) Perform the step 1-1. 2) Remove the fixed screws of the side board (Right). (ST1T Ø4 × 10, 5 screws) 3) Remove the fixed screws of the side board (Right) and the manometer fixing board. (ST1T Ø4 × 10, 2 screws) 2. Side board (Left) 1) Remove the fixe...
Page 132 - Expansion vessel
131 Toshiba 9 Expansion vessel 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). Replace the packing to new one when installing the expansion vessel. 10 Relief valve ...
Page 135 - Nut
134 Toshiba 15 Heater assembly 1. How to remove 1) Perform the step 1-1, step 5, 6, 7, and 11.2) Remove the nut of the heater connection.3) Remove the 2 fixed screws of the heater.4) Pull the heater out upward.5) Remove the insulator from the heater. 2. How to attach 1) Attach a new heater in the re...
Page 137 - Exchange parts
136 Toshiba 2. Outdoor Unit 2-1. HWS-802H-E No. Exchange parts name Work procedure Remarks 1 Common procedure Note Wear gloves when performing the work.Failure to do so may cause an injury when accidentally contacting the parts. 1. How to remove 1) Stop the operation by remote controller and turn of...
Page 151 - Propeller fan
150 Toshiba 5 Fan motor 1) Perform the step 1-1 and step 2. 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 in...
Page 155 - Periodic Inspection Items
154 Toshiba 12 Periodic Inspection Items For a long-term safe operation of this equipment, perform periodic inspection and parts replacement. <Inspection items> Hydro unit (HWS-802**-E, 1402**-E) Frequency Periodic inspection details 1. Insulation measurement (Power source circuit/ Heater circ...
Page 156 - Part Exploded View, Part List; Hydro Unit
155 Toshiba 13 Part Exploded View, Part List Hydro Unit 201 203 208 202 219 236 218 209 210 211 213 203 214 215 206 216 207 212 204 205 217 +00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 155 Monday, October 5, 2009 2:09 PM
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