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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 1 Monday, October 5, 2009 2:09 PM
A09-002
AIR TO WATER HEAT PUMP
SERVICE MANUAL
Model name:
Hydro Unit Outdoor Unit
HWS-802XWHM3-E HWS-802H-E
HWS-802XWHT6-E HWS-1102H-E
HWS-1402XWHM3-E HWS-1402H-E
HWS-1402XWHT6-E
HWS-1402XWHT9-E
Hot Water Cylinder
HWS-1501CSHM3-E(-UK)
HWS-2101CSHM3-E(-UK)
HWS-3001CSHM3-E(-UK)
Toshiba
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 1 Monday, October 5, 2009 2:09 PM Contents 1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 NEW REFRIGERANT (R410A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2-1.Safety During Installation and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2-2.Installing refrigerant pipe .
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 2 Monday, October 5, 2009 2:09 PM 9 Method of Defect Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 9-1.Matters to be confirmed first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 9-1-1.Check the power supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 9-1-2.Check for any mis
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 3 Monday, October 5, 2009 2:09 PM 1 SAFETY PRECAUTIONS The unit and this service guide list very important safety precautions. Understand the following details (indications and symbols) before reading the body text, and follow the instructions. [About indication] Indication Meaning of Indication Indicates that a wrong operation may cause a service engineer and the third persons DANGER around to get fatal or serious injuries. Indicates that a wr
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 4 Monday, October 5, 2009 2:09 PM WARNING Do not modify the unit. � Do not disassemble or modify the parts also. � A fire, an electric shock, or an injury may occur.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 5 Monday, October 5, 2009 2:09 PM WARNING After the work is completed, check with an insulating-resistance tester (500V) that the insulation resistance between the live and dead-metal parts is 2 MΩ or higher. � A low insulation resistance may cause a disaster at a customer site due to electrical leakage or an electric shock. Ventilate if refrigerant gas leaks during service work. � Should refrigerant gas catch fir
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 6 Monday, October 5, 2009 2:09 PM 2 NEW REFRIGERANT (R410A) This Air to Water Heat Pump adopts a new refrigerant HFC (R410A) to prevent destruction of the ozone layer. The working pressure of R410A refrigerant is 1.6 times higher than that of the conventional refrigerant R22.The refrigerant oil is also changed for the new refrigeration. Therefore, during installation or service work, be sure that water, dust, former refrigerant, or refrigerati
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 7 Monday, October 5, 2009 2:09 PM 2-2. Installing refrigerant pipe 2-2-1. Steel pipe and joint For refrigerant piping, steel pipe and joints are mainly used. Select those comply with JIS (Japanese Industrial Standards) for a service work. Also, use such clean piping materials that less impurities attach to the inside of pipe and joints. Copper pipe Use copper pipe of the “copper and copper alloy seamless pipe” type with attach oil quantity of 4
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43° - 45° +00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 8 Monday, October 5, 2009 2:09 PM 2-2-2. Processing of piping materials When installing refrigerant pipe, prevent water or dust from entering the pipe, and do not use oil other than lubricant used for Air to Water Heat Pump. Make sure that no refrigerant leak occurs. If piping needs lubrication, use lubricating oil whose water content is removed. After the oil is put in, be sure to seal the container with airproof cover or other covers
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 9 Monday, October 5, 2009 2:09 PM Flare connecting procedure and precautions 1) Make sure that the flare and connecting portions do not have any flaw and dust. 2) Correctly align the flared surface and the connecting axis. 3) Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is the same as that for the conventional R22. If the torque is weak, gas leakage may occur. If it is too strong, the fla
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 10 Monday, October 5, 2009 2:09 PM 2-3. Tools 2-3-1. Necessary tools In Air to Water Heat Pump using R410A, the service port diameter of packed valve of the outdoor unit is changed to prevent mixing of other refrigerant. To reinforce the pressure resistance, flare dimensions and opposite side dimensions of flare nut (For Ø 12.7 copper pipe) of the refrigerant piping are lengthened. Because the refrigerating machine oil is changed, mixing of oil
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 11 Monday, October 5, 2009 2:09 PM 2-4. Recharging of refrigerant Recharge, if necessary, the specified amount of new refrigerant according to the following procedure. Recover the refrigerant, and check that no Open fully the handle of gauge manifold Lo, turn on the refrigerant remains in the refrigerant cycle. vacuum pump, and then perform vacuum evacuating. Connect the charge hose to packed valve service When the compound gauge's pointer indic
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 12 Monday, October 5, 2009 2:09 PM NOTE � Make sure that the setting is appropriate so that liquid can be charged. � A cylinder with siphon enables liquid to be charged without the cylinder turned upside down. [Cylinder with siphon] [Cylinder without siphon] Gauge manifold Gauge manifold Outdoor unit Outdoor unit Siphon pipe Refrigerant Refrigerant cylinder cylinder Electronic balance Electronic balance NOTE � Because R410A is HFC mixed refrige
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 13 Monday, October 5, 2009 2:09 PM Type of flux 2-5. Brazing of pipes � Non-corrosive flux It is generally a compound of borax and boric acid. 2-5-1. Materials of brazing It is effective when brazing temperature is higher than 800 °C. Silver brazing metal � Active solvent Silver brazing metal is an alloy mainly composed of Most of this type of flux is generally used for silver silver and copper. brazing. It uses iron, copper, or copper alloy,
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 14 Monday, October 5, 2009 2:09 PM 5) Use the reducing valve to adjust the nitrogen 3 gas flow speed to 0.05 m /hour or 0.02 MPa 2 (0.2 kgf/cm ). 6) After the steps above, keep the nitrogen gas flowing until the pipe cools down to a certain extent. (Temperature where the pipe is cool enough to be touched by hands) 7) Remove the flux completely after brazing. Fig 2-5-1 Prevention of oxidation during brazing Flow meter M Stop valve Nitrogen g
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 15 Monday, October 5, 2009 2:09 PM 3 Specifications Unit name Hydro unit HWS-802XWHM3-E, 802XWHT6-E Outdoor unit HWS-802H-E Heating capacity *1 (kW) 8.0 Cooling capacity *2 (kW) 6.0 Variable range of compressor frequency 10 - 70 Hz Power source Single phase 50Hz 230V Operation mode Heating Cooling Electric characteristic *1 *2 Hydro unit Current (A) 0.98 0.46 Power (kW) 0.101 0.097 Power factor (%) 91.5 91.7 Outdoor unit Current (A) 8.26 8.90 Pow
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 16 Monday, October 5, 2009 2:09 PM Unit name Hydro unit HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E Outdoor unit HWS-1102H-E HWS-1402H-E Heating capacity *1 (kW) 11.2 14.0 Cooling capacity *2 (kW) 10.0 11.0 Variable range of compressor frequency 10 - 60Hz 10 - 70 Hz Power source Single phase 50Hz 230V Operation mode Heating Cooling Heating Cooling Electric characteristic *1 *2 Hydro unit Current (A) 0.63 0.61 0.67 0.63 Power (kW) 0.135 0.130 0.145
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 17 Monday, October 5, 2009 2:09 PM 4 Outside Drawing 4-1. Hydro unit HWS-802XWHM3-E, 802XWHT6-E HWS-1402XWHM3-E, 1402XWHT6-E, 1402XWHT9-E 525 2-dia.12x17 long hole (for dia.8-10 anchor bolt) 371.5 72.5 380 72.5 B leg part Anchor bolt 355 40 long hole pitch Manometer Remote controler 40 2-dia.12x17 U-shape hole A leg part (for dia.8-10 anchor bolt) Hot water outlet 19.5 116 connecting pipe 1 1/4" Gas line dia.15.88 Drain nipple Liquid line dia.
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 18 Monday, October 5, 2009 2:09 PM 4-2. Outdoor unit HWS-802H-E 18 Toshiba Drain hole ( 25 burring hole) 380 200 60 Portion B Air inlet Name Description Refrigerant piping outlet Mounting bolt hole 12 Air inlet Indoor and outdoor ( 12 17 long hole) connecting line outlet 75 Power source intake hole 38 knockout hole Air outlet Mounting bolt hole Portion A Details of portion A Details of portion B ( 12 17 U-shape hole) 39 383 150 6
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+00A09-002_01EN_SVM_ALL_Air_to_Water.book Page 19 Monday, October 5, 2009 2:09 PM HWS-1102H-E, 1402H-E 19 Toshiba Drain hole ( 25 burring hole) 380 Name Description 200 60 Portion B Air inlet Refrigerant piping outlet Mounting bolt hole 12 Indoor and outdoor 1 ( 12 17 long hole) connecting line outlet Air inlet 2 Power source intake hole 38 knockout hole 75 Mounting bolt hole Details of portion A Details of portion B ( 12 17 U-shape hole) Air outlet Portion A 383 70 39 150 600 96
