Black Diamond Equipment HYDROBOX 2 User manual

Designed and manufactured in New Zealand
Black Diamond Technologies
USER MANUAL

The Next Generation in Super Energy Efficient Hot Water Heating

1
CONTENTS
Introduction
• Introduction to Hydrobox 2 ................................................................................. Page 2
Features and Functions
• Features .............................................................................................................. Page 3
• Smart Operation ................................................................................................. Page 4
• Low Usage Conditions ....................................................................................... Page 4
• Modes .................................................................................................................. Page 4
• Mandatory Legionella Control ............................................................................ Page 4
Controller
• Control Panel ........................................................................................................ Page 5
• Power Button ........................................................................................................ Page 5
Operation
• Display Screens ............................................................................................. Pages 6–9
• Trouble Shooting ............................................................................................... Page 10
• Fault Codes and Descriptions .......................................................................... Page 11
• Important Information ....................................................................................... Page 12
• Water Storage Cylinder Requirements ............................................................. Page 12
• Electrical Requirements .................................................................................... Page 12
• Specifications ................................................................................................... Page 13
• Warnings ........................................................................................................... Page 13

2
INTRODUCTION
Thank you for purchasing your Black Diamond Hydrobox 2
Hot water heat pumps offer the highest levels of
energy efficiency with the ability to provide 3-4kW
of heat energy for every 1kW used. In addition to
this, hot water heat pumps also offer the cheapest
available kW/h rate for hot water heating.
Designed and Manufactured in New Zealand
Designed specifically for New Zealand conditions and
proven to perform down to -15°C, the Black Diamond
Hydrobox 2 System will withstand the harshest New
Zealand’s climate can deliver, all whilst continuing to
provide optimum results.
The Black Diamond Hydrobox 2 has two distinct
components – a Mitsubishi Electric Inverter Driven outdoor
unit and the indoor water heating Black Diamond Hydrobox.
Together this system is capable of saving up to 75% on
hot water heating costs compared with a resistive heating
element.
Energy Efficient Hot Water
The Black Diamond Hydrobox 2 operates in a similar
fashion to a standard heat pump; absorbing available heat
energy from the surrounding outdoor air. This heat energy
is then transferred and used to heat your home hot water
cylinder. The Black Diamond Hydrobox 2 can also detect
changes in outdoor ambient conditions and the incoming
water temperature, allowing adjustment to be made to
optimise the unit’s efficiency. This ensures the required
water temperature is delivered in the most energy efficient
manner without excess energy wastage.
Unique Patented Single Cycle Process
The Black Diamond Hydrobox 2 uses a unique patented
process capable of heating your hot water in one single
cycle. With the newly heated water injected into the top
of your hot water cylinder the Black Diamond Hydrobox 2
ensures continuous hot water supply even in periods of
high demand.

3
FEATURES
Hydrobox 2 Features
The Black Diamond Hydrobox 2 has many user friendly
intuitive functions and features including:
◆Starting Features
• Manual Power On/Standby
• Smart Meter Interface
• 7 Day Programmable Timer
• Ripple Feed Power Management Compatible
• Automatic Reheat
◆Automatic fall back heat switch to electric element
under fault conditions
◆Highly efficient defrost control
◆Low standby power consumption when not
heating water
◆Internal Power Usage Meter
◆Battery backup internal clock
◆Audible Alarm
• Over current
• Insufficient heating
• Over temperature
• No water
• Water leakage
• Refrigerant leakage
• Requires Service Life Servicing
- Heat exchanger clean
- Water pump replacement
Please note the Hydrobox must
be installed by persons qualified
in the trade (Plumbing, Electrical,
Refrigeration and any other
qualifications required by regulation,
standards or law), and must comply
with all applicable standards, codes
and regulations in force in the country
of installation.

4
Smart Operation
The Black Diamond Hydrobox 2 has been designed to
maximise performance and cost savings, utilising optimised
control.
When not heating water, the power is switched off to the
outdoor unit, lowering standby power usage and increasing
efficiency. The system can be further optimised by choosing
the times of the day that it can operate as the higher
the ambient temperature, the more efficient the system
operates. Colder water at the input side also increases the
efficiency.
Mandatory Legionella Control
The Hydrobox 2 System can automatically activate the
electric element. The electric element is automatically
turned on for 1 hour per week after a deep disinfect cycle
for mandatory legionella control.
Low Usage Conditions
Where the system has not been activated within 1.5 days, a
Disinfection Cycle will be completed. This is carried out at
1pm on the second day since last being active.
Modes
The Black Diamond Hydrobox 2 can be set in one of three
modes.
Normal – 40°C return temperature
When operating in Normal Mode, the Hydrobox 2 unit
continues to heat the water in the Water Storage Cylinder
until the draw off/return water temperature reaches 40°C. This
ensures 90% of the user’s Water Storage Cylinder is over 60°C.
Economic – 40°C return temperature
When operating in Economy Mode the Hydrobox 2 heats
the water over a longer period using less energy.
Disinfect – 50°C return temperature
Disinfect Mode ensures that the bottom of the tank reaches
above 50°C. This mode is recommended for poor quality,
non-town supplied water, such as rain water and untreated
river water.
PLEASE NOTE: For the Hydrobox 2
timers to function correctly the system
cannot be connected to a traditional
ripple mains relay plan. If you are
connected to such plan discuss the
best options for your specific location
with your electricity retailer.

5
CONTROLLER
Control Panel
The Hydrobox 2 Controller is an easy to use 4 button
control panel with a LED display which automatically lights
up when a button is pressed. Once installed the unit should
not require adjustment outside use of the 7 Day Timer.
Power Button Features
On/Standby
• Press the power button to turn the system on.
Off – Holiday mode
• Hold down the power button for 4 seconds to turn
the system off.
External Element On/Off
• Holding down the power button for 10 seconds will
turn the external element on/off.
Unit Activation
The Hydrobox 2 System is either force activated (turned on
by the user) or it will automatically power on from Standby
where:
• The power is connected or recovers from a power cut
• The water tank temperature drops by 20°C
• The power is connected because it has been turned
on by a traditional ripple power relay
• The unit has been turned on by one of the 7 timers
• The system has not been in a heating cycle for 1.5
days and turns on at 1pm the following day
Unit Standby
The system will automatically switch to Standby (STBY)
when:
• The return water temperature reaches 40°C in Normal
Mode and ECO Mode or when it reaches 50°C in
Disinfect Mode
• The unit has been turned off by one of the 7 timers
• The unit has been manually turned off
Please note that the system will not
automatically restart if the Restart
Sensor has not dropped by 20°C from
the last heating cycle.
Mode ECON Ver-4.22
Release Aug 20 2018
Mode ECON Ver-4.22
Release Aug 20 2018

6
OPERATION
Display Screens
The Hydrobox 2 features 20 display screens. The following
is a list of the display screens in sequential order:
• Standby Screen
• Set Point/Temperature Screen
• Set Mode Screen
• IP/MAC Address Screen
• Time/Date Screen
• Summer/Winter Time Set Screen
• Timer 1 Screen
• Timer 2 Screen
• Timer 3 Screen
• Timer 4 Screen
• Timer 5 Screen
• Timer 6 Screen
• Timer 7 Screen
• Water Temperature Screen
• OD Refrigeration Screen
• ID Refrigeration Screen
• Water Pump Speed Screen
• External Tank Temperature Probes Screen
• Water Flow Meter Screen
• Water Usage Meter Screen
• Water Meter Calibration Screen
To scroll through the above screens simply press the
Select/Mode button and then press the Down or
Up buttons to scroll through.
Standby Screen
The screen above indicates that none of the timers are set.
If one of the 7 timers is set, the display will indicate this. In
the example below “TMR1247” indicates that timers 1, 2, 4
and 7 are set.
To power on the Hydrobox 2 press the Power button to
turn on.
The main LED screen and the green power LED will
illuminate (see Fig. 1) to indicate the unit is on. If the green
power LED is flashing this indicates one or more of the 7
timers is set.
When powered on the set temperature, date, time and
mode will be displayed, along with the timers which are
currently active. Should the unit be operating due to one
of the set timers the timer will flash at 1 second intervals to
indicate that it is in timer operation.
Set Point/Temperature Screen
The Hydrobox 2 System is set to 62°C as factory standard.
However the set temperature adjustment range is from
55–63°C.
To change the set temperature, use the following steps:
• Press the button – the indicated Set Temp will
flash.
• The temperature can now be adjusted with the
Down or Up buttons.
• Once the desired set temp is showing confirm by
pressing – the Set Temp will stop flashing to
indicate this has been confirmed.
When setting the temperature please note the system will
revert back to normal operation and the Set Temp will be
locked out and stop flashing should no buttons be pressed
for 5 seconds.
62. c
20/08/18 12:55 ECON
62. c
20/08/18 12:55 ECON
STBY TMR1247 1403
20/08/18 12:55 ECON0
STBY TMR1247 1403
20/08/18 12:55 ECON0
STBY 0000
20/08/18 12:55 ECON0
STBY 0000
20/08/18 12:55 ECON0
Power
Button
Select/Mode
Button
Scroll Down
Button
Scroll Up
Button
Mode ECON Ver-4.22
Release Aug 20 2018
Mode ECON Ver-4.22
Release Aug 20 2018
Fig. 1

7
Set Mode Screen
The mode description in the bottom right corner indicates
the heating mode the Hydrobox 2 is set to operate in. As
described previously there are three modes the Hydrobox
2 can be set to: Economic (ECON), Disinfect (DISIN) and
Normal (NORM)
To change Hydrobox operating mode use the following
steps:
• Press the button.
• Scroll through to the Set Mode Screen by pressing
Down or Up.
• The image below depicts the screen which should
now be seen.
• Press the button.
• The mode description (in this case ECON) will now
flash indicating it is ready to be changed.
• Scroll to the desired mode by pressing the
Down or Up buttons.
• Once the desired mode is showing, confirm by
pressing . The mode description will stop flashing
to indicate this has been confirmed.
Time/Date Screen
Please use the following steps to set the time and date:
• Press the button.
• Scroll to the Time/Date Screen by pressing the
Down or Up buttons.
• Press – the ‘date’ will begin flashing to indicate it
is ready to be changed.
• Use the Down or Up buttons to adjust.
• Press to proceed to setting the month and adjust
Down or Up to the correct month.
• Press to proceed to setting the year and adjust
Down or Up to the correct year.
• Press to proceed to setting the day and adjust
Down or Up to the correct day.
• Press to proceed to setting the hour and adjust
Down or Up to the correct hour.
• Press to proceed to setting the minutes and
adjust Down or Up to the correct minutes.
• Finally press to finish the Time/Date setting.
Summer/Winter Time Set Screen
To set the daylight saving start and stop days, please use
the following steps:
• Scroll to the Summer/Winter Time Screen by
pressing Down or Up.
• Press – the ‘Week’ description indicated will
begin flashing to indicate it is ready to be changed.
The following key denotes the week association:
-1ST = 1st Sunday
-2ND = 2nd Sunday
-3RD = 3rd Sunday
-4TH = 4th Sunday
-LST = Last Sunday
• Use Down or Up to adjust.
• Press to proceed to setting the day and adjust
Down or Up to the desired day.
• Press to proceed to setting the month and adjust
Down or Up to the desired month.
• Press to proceed to setting the time and adjust
Down or Up to the desired time.
• Press to proceed to setting the winter time week,
day, month and time using the same steps as above.
• Finally press to finish the Summer/Winter Time
setting.
Mode ECON Ver-4.22
Release Aug 20 2018
Mode ECON Ver-4.22
Release Aug 20 2018
Sum LST SUN SEP 0200
Win 1ST SUN APR 0300
Sum LST SUN SEP 0200
Win 1ST SUN APR 0300

8
Display Screens – continued
Timer Screens (T1–7)
The Hydrobox 2 System has a total of 7 timers. Each timer
can be set in one of four ways:
1. As an On/Off Timer
(The system is on for a set period.)
2. As an Off/On Timer
(The system does not turn on during a set period.)
3. As an On Timer
(The system turns on at a set time.)
4. As an Off Timer
(The system turns off at a set time.)
Each individual timer can be set to repeat daily, on specific
days of the week, on all weekdays, or on weekends only.
Each timer can be set individually by using the following
steps:
• Scroll through to the desired timer screen.
(T1 – T7) denote the timers available.
• Initially one of the four timer options must be
selected. To do so press – the On/Off description
will begin flashing to indicate it is ready to be
changed.
• Use Down or Up to adjust. If an On/Off or
On Timer is required press Down or Up until
On is indicated. If an Off/On or Off Timer is required
press Down or Up until Off is indicated.
• Press to proceed to setting the hour and adjust
Down or Up to the correct hour.
• Press to proceed to setting the minute and adjust
Down or Up to the correct minute.
• Press to proceed to setting the desired timer
occurrence and use Down or Up to select
DAY (daily), MON-SUN (a specific day), M2F
(weekdays), or WKD (weekend only).
• Press to proceed to setting the timer activation.
Should the timer be required use the Down or
Up buttons to adjust until On is indicated. To
deactivate the timer adjust until Off is indicated.
• Press to proceed to setting the second time line.
Setting this time will depend on the initial timer option
chosen.
-On/Off Timer set the hour and minute to the timer
you wish the system to turn off.
-Off/On Timer set the hour and minute to the timer
you wish the system to turn on.
-On Timer set the hour and minute to match
the same time chosen previously e.g. both time
selections should match.
-Off Timer set the hour and minute to match
the same time chosen previously e.g. both time
selections should match.
• Press to confirm and end the timer setting
process.
T1 On 00:00 DAY
OFF --- 00:00
T1 On 00:00 DAY
OFF --- 00:00

9
Technical and Service Screens
These screens display measurements and technical
information for technicians and service purposes. They
cannot be adjusted.
Water Temperature Screen
Indoor Unit Refrigeration Screen
The Indoor (ID) Temperature Screen displays the R134A
refrigerant measurements.
Outdoor Unit Refrigeration Screen
The Outdoor (OD) Temperature Screen displays the R32
refrigerant measurements.
Water Pump Speed Screen
External Tank Temperature Probes Screen
Water Flow Meter Screen
The Water Flow Meter Screen indicates the rate at which
water passes through the Hydrobox unit.
Water Usage Meter Screen
The Water Usage Meter Screen, when using an optional
water usage meter, indicates the rate at which heated water
is flowing from the storage water cylinder.
Water 22. c in 22. c out
22.
c inter -40. c use
Water 22. c in 22. c out
22.
c inter -40. c use
OD 22. cdis 22. ccon
22.
csub
OD 22. cdis 22. ccon
22.
csub
Temp In 22. c Out 22. c
Set Temp 62. c
Temp In 22. c Out 22. c
Set Temp 62. c
H2O Pump Speed 0%H2O Pump Speed 0%
ID 23. c discharge
22. c sub 23. c suction
ID 23. c discharge
22. c sub 23. c suction
Water Flow Meter:
4600 Pulses/Litre
Water Flow Meter:
4600 Pulses/Litre
Water Usage Meter:
1200 Pulses/Litre
Water Usage Meter:
1200 Pulses/Litre

10
TROUBLE SHOOTING
Trouble Shooting
The Hydrobox 2 System has two levels of fault codes:
Level 1
• Minor faults which are automatically self-corrected. These faults may be displayed but the system will continue to
function normally. Please refer to the Fault Codes and Descriptions chart on the opposite page. Please note that
some Level 1 faults may require a service call.
Level 2
• All Level 2 faults require a qualified service person to address. When these errors are detected the LCD display
will display the error number, the blue fault light will illuminate and the alarm buzzer will sound. The system will
automatically switch on the power to the external element (if connected) to ensure the storage water cylinder still has
hot water.
Water Leaks
In the event a water leak is discovered immediately turn off the Hydrobox 2 System. Proceed to call your plumber or
technical/service agent.
WARNING: Should FLT09 or FLT10 be displayed, or in the event a very loud whistling noise
coming from the water tank and bursts of air discharges from the tap, immediately turn the
Hydrobox off and if possible the water taps that isolate the Hydrobox from your water cylinder and
call your authorised installer/service agent.
As a precaution do not drink the water until the system has been inspected.
NOTE: If there has been a water supply outage or the water turned off for maintenance this will
also cause air bubbles in the water supply. The Hydrobox 2 has an internal Automatic Air Bleeder
Valve installed which in most cases will automatically remove air around the water pumps. If the
system has FLT03 or FLT09 or FLT14 shortly after the system starting, then ensure that the air has
been bled out of the Hydrobox System by turning off the water to the Storage Tank Isolation Valve,
ensuring that the cold and hot water supply valves to the Hydrobox 2 are open and turning on a
hot tap until the flow has no air bursts. Turn off the hot tap and open the Storage Tank Isolation
Valve. Manually press the power on button again.
NOTE: If the system has an FLT05 alarm ensure that the Restart Sensor placed half way up the
tank is plugged into CN46. Also check that the cable between the PTC Sensor and CN46 is not
damaged or open circuit. At 25°C the resistance between the two wires is 100k ohms.

11
Fault Codes and Descriptions
Fault
Code Fault Description Level Buzzer
External
Element
Turned on
User Action Action
FLT01 Water pump Adj,
Water too hot 1 No No System will retry –
FLT02 Water pump Adj,
Water too cold 1 No No System will retry –
FLT03 R134A thermal cut out
activated 1 No No System will retry Will shut down for 3 minutes and restart – refer to
note 1
FLT04 R134A thermal cut out
activated 4 times 2Yes Yes Call for service Unit has had 3 FLT03 errors in the same run – fault
alarm activated and external element turned on
FLT05 Tank Sensor not
detected 1Yes No Call for service
The system will still heat the water tank but will not
be able to sense when to restart the heating cycle –
refer to note 2
FLT06 No OD Startup Data
detected 1 No No System will retry Will become a level 2 after 5 attempts
FLT07 Outdoor unit not
responding 1 No No System will retry Will become a level 2 after 5 attempts
FLT08 Outdoor current too
high > 9A 2Yes Yes Call for service Outdoor unit using too much power
FLT09 IA too high >= 3A 2 Yes Yes Call for service Indoor compressor using too much power – refer
to note 1
FLT10 Possible refrigerant
gas leak 2Yes Yes Call for service Turn off power and water taps to Hydrobox
FLT11 Defrost WE < 4.0 2 Yes Yes Call for service Water too cold to defrost possible water pump fault
FLT12 TC < 2.0 2 Yes Yes Call for service Not enough energy for defrost
FLT13 IA too high 2 Yes Yes Call for service Indoor compressor fault
FLT14 R134A discharge
temp too high > 90.0 2Yes Yes Call for service Indoor compressor over heated – refer to note 1
FLT15 R32 discharge temp
too high > 85.0 2Yes Yes Call for service Outdoor unit discharge too high
FLT16 Reverse water pump
test 2Yes Yes Call for service Reverse water pump may be faulty
FLT17 R134A refrigerant
charge low 1 No No Call for service Check for possible R134A refrigerant leaks and
recharge as per service manual to 200 grams
FLT18 R134A refrigerant too
high 1 No No System will retry Indoor compressor current too high – refer to note 1
FLT19 Outdoor unit has
errored 1 No No System will retry Will become a level 2 after 5 attempts
FLT20 Critical outdoor
shutdown 2Yes Yes Call for service Major fault call for service
FLT21 R134A refrigerant
charge too low 1Yes Yes Call for service Check for possible R134A refrigerant leaks and
recharge as per service manual to 200 grams
FLT22
Not enough heat
energy from outdoor
unit after 15 minutes
from start-up
1 No No Call for service if
fault continues
Possible refrigerant charge issue with outdoor unit
or damaged refrigerant pipe work

12
Water Storage Cylinder Requirement
The Hydrobox 2 has been designed for retrofit to an existing water storage cylinder or new installation.
The Water Storage Cylinder must have an effective diffuser on the bottom water feed and be well insulated to ensure the
cylinder remains stratified. For mains pressure systems the water pressure must be limited to 500 kPa (5 bar). A water
strainer must be used on the water supply to the cylinder. The installation of the Water Storage Cylinder must be carried out
by a registered plumber and meet the required government regulations.
Flexible metal enclosed hoses are recommended for connections between the Hydrobox unit and fixed water terminals. This
ensures added earthquake protection and vibration noise reduction.
Floor mount of the Hydrobox 2 is preferred as hollow internal walls will act as a drum skin and amplify the compressor
vibration into audible sound.
Electrical Requirements
The Hydrobox 2 outdoor unit must be installed in accordance with the installation instructions typical of standard heat pump/
air-conditioning units. A 4 core 1.5mm² cable is required between the indoor and outdoor units and a lockable isolation
switch by NZ law required beside the outdoor unit. A lockable isolation switch is also recommended for the mains power
supply feed to the Hydrobox unit. Power is taken from the normal water tank element source.
For more details please refer to the installation manual.
IMPORTANT INFORMATION
◆The unit should not be installed, relocated, disassembled, altered, or repaired by the end user.
• Improperly handled units may cause fire, electric shock, injury, water leakage, etc. Consult your supplier for advice
before any work is carried out around the unit.
• If the power supply cord is damaged, it must be replaced by the manufacturer or its service representative in order to
avoid a hazard.
◆When installing, relocating, or servicing the unit, make sure that no substance other than the specified
refrigerants (R32 in the outdoor unit and R134A in the Hydrobox unit) enters the refrigerant circuit.
• Any presence of foreign substance such as air can cause abnormal pressure rise and may result in explosion or
injury.
• The use of any refrigerant other than that specified for the system will cause mechanical failure, system malfunction,
or unit breakdown. In the worst case, this could lead to a serious product safety issue.
◆This appliance is not intended for use by persons (including children) with reduced physical, sensory or
mental capabilities, or lack of experience and knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for their safety.
• Children should be supervised to ensure that they do not play with the appliance.
◆During operation the water pipes and refrigerant pipes get hot and should not be touched. Doing so may
cause serious injury.

13
WARNING
Consult your supplier for correct and safe installation of the Black Diamond Hydrobox 2.
• This unit should not be installed by persons other than authorised technicians. An improperly installed unit
may cause fire, electric shock, injury, water leakage etc.
Dedicated power supply required.
• A non-dedicated power supply may cause overheating or fire.
Do not install the unit where flammable gas could leak.
• If gas leaks and accumulates around the outdoor unit, it may cause an explosion.
Earth the unit correctly.
• Do not connect the earth wire to a gas pipe, water pipe, lightning rod, or a telephone ground wire. Improper
earthing may cause electric shock.
All water pipes between the Hydrobox unit and the storage water cylinder must be insulated.
All refrigerant pipes between the Hydrobox unit and the outdoor unit must be insulated.
SPECIFICATIONS
Heating
Capacity Rated [kW] 3.4
Min-Max [kW] 0.9 – 4.5
Input Rated [kW] 0.82
Min-Max [kW] 0.004 – 1.40
Sound Level Outdoor (SPL) [dBA] 49
Power Supply (Powered from indoor unit) 240V / Single Phase / 50 Hz
Controller In-built 7 Day Timer, External
Temperature Probe, Ripple mains feed compatible, DRED compatible
Water Piping
Diameter (Inlet/Outlet) [inch] ½
Water Flow [L/minute] 0.6 – 2.4
Water Head Height Min [m] 5
Water Pressure Max [kPa] 500
Water Temperature Range Input [°C] 5 – 55
Refrigerant
Piping
Diameter (Liquid/Gas) [mm] 6.35 / 9.52
Max. Length/Height [m] 20 / 12
Chargeless Piping Length [m] 7
Indoor Unit
Dimensions (W x D x H) [mm] 455 x 240 x 395
Weight [kg] 23.1
Refrigerant Type R134A
Quantity [g] 200g (+/– 10g)
Outdoor Unit
Dimensions (W x D x H) [mm] 800 x 285 x 550
Weight [kg] 33
Refrigerant Type R32
Quantity [g] 970
Operation Range
Outdoor Heating [°C] -15 / +24
Reporting Ethernet connection (Standard), Optional Water Inlet Temperature Probe, Optional Water Outlet Temperature
Probe, Optional Water Usage Meter, Optional Water Flow Meter

Models, features and specifications are subject to change and amendment at anytime. February 2020
Black Diamond Technologies Limited
Exclusive distributor of Mitsubishi
Electric products in New Zealand.
AUCKLAND
BRANCH
Unit 1, 4 Walls Road
PO Box 12726
Penrose, Auckland 1642
Phone [phone]
CHRISTCHURCH
BRANCH
44 Halwyn Drive
PO Box 16904
Hornby, Christchurch 8441
Phone [phone]
WELLINGTON
OFFICE
1 Parliament Street
PO Box 30772
Lower Hutt 5040
Phone [phone]
Fax [phone]