Toshiba HWS-803H-E User manual

1st Draft: 22/10/10
AIR TO WATER HEAT PUMP
Series 3
FILE NO : A10-002P
Quick Reference

1
Estia System
Estia Outdoor Unit
HWS-803H-E (TR) 8.0kW Inverter: single phase
HWS-1103H-E (TR) 11.2kW Inverter: single phase
HWS-1403H-E (TR) 14.0kW Inverter: single phase
HWS-1103H8-E 11.2kW Inverter: three phase
HWS-1403H8-E 14.0kW Inverter: three phase
HWS-1603H8-E 16.0kW inverter: three phase
HWS-1103H8R-E 11.2kW Inverter; three phase with heater cord
HWS-1403H8R-E 14.0kW Inverter: three phase with heater cord
HWS-1603H8R-E 16.0kW Inverter: three phase with heater cord
Estia Hydro Unit
HWS-803XWHM3-E (TR) Plate Heat exchanger and 3kW Backup Heater
HWS-803XWHT6-E (TR) Plate Heat exchanger and 6kW Backup Heater
HWS-803XWHD6-E Plate Heat exchanger and 6kW Backup Heater
HWS-803XWHT9-E Plate Heat exchanger and 9kW Backup Heater
HWS-1403XWHM3-E (TR) Plate Heat exchanger and 3kW Backup Heater
HWS-1403XWHT6-E (TR) Plate Heat exchanger and 6kW Backup Heater
HWS-1403XWHD6-E Plate Heat exchanger and 6kW Backup Heater
HWS-1402XWHT9-E (TR) Plate Heat exchanger and 9kW Backup Heater
Outdoor unit
Hydro unit
Hot Water
Hot water
cylinder
Under floor heating
(Zone Control)
Radiator
Fan coil unit
(Heating or Cooling)
Heating or Cooling

2
Estia Hot Water Cylinder (EU)
HWS-1501CSHM3-E 150L Stainless Steel Tank (with EU Accessories)
HWS-2101CSHM3-E 210L Stainless Steel Tank (with EU Accessories)
HWS-3001CSHM3-E 300L Stainless Steel Tank (with EU Accessories)
Estia Hot Water Cylinder (UK)
HWS-1501CSHM3-UK 150L Stainless Steel Tank (with UK Accessories)
HWS-2101CSHM3-UK 210L Stainless Steel Tank (with UK Accessories)
HWS-3001CSHM3-UK 300L Stainless Steel Tank (with UK Accessories)
Note:
Under floor heating, Fan Coil units, Radiators, valves and Hot Water Piping are procured locally.
Notes on System Design
• The input water temperature to the Hydro Unit must be 55°C or less.
Especially, be careful when there is an external heating source such as a boiler.
When hot water over 55°C returns, it may result in a failure of the unit or water leakage.
• The flow rate of the circulating water must meet the following range:-
11, 14 and 16 kW 17.5 L/minute or more
8 kW 13 L/minute or more
If the flow rate becomes less than the minimum, the protective device is activated to stop operation.
Ensure the flow rate with a bypass valve, etc. when you use a flow rate valve for the Hydro Unit.
• Do not drive water by power other than the pump built in the Hydro Unit.
• The backup heater operates supplementary to exert a prescribed capacity when the heat pump
cannot exert its capacity at a low outside temperature.
• Install the Hydro Unit and water pipes in a place in which they do not freeze.
• Make the water circuit closed. Never use it as an open circuit.
• To prevent damage to the system the circulating water must be 20 litres or more. If total water
amount is not enough, the unit may not function fully due to protective operation.
Components required for each function
Function Toshiba Supply Procure locally
Part name Model code Part name
Heating - -
Radiator(s),
Fan coil(s),
Under floor heating
Heating & Cooling
(All Rooms) - - Fan coil(s) only
Heating & Cooling
(partly heating only) - -
Fan coil(s) plus
Radiator(s)
or Under floor heating
Motorized 2-way valve
Hot Water Supply
150L Hot water cylinder HWS-1501CSHM3-E
Motorized 3-way valve
Earth leakage breaker
150L Hot water cylinder HWS-1501CSHM3-UK
210L Hot water cylinder HWS-2101CSHM3-E
210L Hot water cylinder HWS-2101CSHM3-UK
300L Hot water cylinder HWS-3001CSHM3-E
300L Hot water cylinder HWS-3001CSHM3-UK
2-zone control - -
Motorized mixing valve
Circulator pump
Buffer tank
Interlocking with boiler External output board TBC-PCIN3E Boiler

3
Installation Examples
Cooling and Heating with Domestic Hot Water
When both cooling and heating are used, install a 2-way valve (for cooling) to the pipe to the room
for heating only.

4
Installation Examples (cont.)
2-Zone Temperature Control with Domestic Hot Water
The following shows an example of the 2-zone temperature control.
A buffer tank and a water pump are required for the 2-zone temperature control. This example is
Heating only, if the Fan Coils are to be used for Cooling then a 2-Way valve must be fitted.

5
Installation example of water circuit:-
(1) (2)
(3) (4)
(5) (6)
The water circuit for a system without a buffer tank [ (1) , (2) , (3) , (5) ] requires 17.5l/min
(803XWH = 13.0l/min) or more. This water flowing requires 5 or more branches of Floor heating or
Radiators 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).
Please check how to install the boiler.

6
Hydro Unit – Exploded View
1 : Expansion vessel
2 : Hi Pressure switch (4.15 MPa)
3 : Temperature sensor (for Heat pump outlet -TWO)
4 : Pressure sensor
5 : Heat exchanger
6 : Flow switch (13.0 L/min 17.5 L/min)
7 : Temperature sensor (for refrigerant -TC)
8 : Temperature sensor (for water inlet -TWI)
9 : Drain nipple
10 : Water inlet connection
11 : Refrigerant liquid connection
12 : Air relief valve
13 : Pressure relief valve (0.3 MPa (3 bar))
14 : Thermal protector (auto)
15 : Temperature sensor (for water outlet THO)
16 : Thermal protector (Single operation)
17 : Water pump
18 : Backup heater (3 kW, 3 kW x 2, 3 kW x 3)
19 : Manometer
20 : Water outlet connection
21 : Refrigerant gas connection

7
Refrigerant Pipe Lengths and Height
The length and height of the refrigeration pipe must be within the following values.
As long as the Hydro Unit is installed within these ranges, no additional refrigerant is required.
Minimum Pipe Length
HWS-803H-E : 5 m
HWS-1103H**-E : 5 m
HWS-1403H**-E : 5 m
HWS-1603H**-E: 5m
Maximum Pipe Length and Height
H: Max. ±30 m (above or below)
L: Max. 30 m
Note
The maximum pipe length cannot be increased using additional
refrigerant.
Refrigeration and Water Cycle Diagrams
Outdoor Unit: HWS-803H-E
Hydro Units: HWS-803XWH**-E
Outdoor Units: HWS-1103H**-E, HWS-1403H**-E
Hydro Units: HWS-1403XWH**-E

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Outdoor Units: HWS-1103H8(R)-E, HWS-1403H8(R)-E, HWS-1603H8(R)-E
Hydro Units: HWS-1403XWH**-E
Water Piping WARNING
• Install water pipes according to the regulations of respective countries.
• Install water pipes in a freeze-free place.
• Make sure that water pipes have sufficient pressure resistance
(The setting value of the pressure relief valve is 0.3 MPa).
CAUTION
• Do not use zinc plated water pipes. When steel pipes are used, insulate both ends of the pipes.
• The water to be used must meet the water quality standards specified in EN directive 98/83 EC.
Water Circuit
• Install a strainer with 30 to 40 meshes (procure locally) at
the water inlet of the Hydro Unit.
• Install drain cocks (procure locally) for water charge and
discharge at the lower part of the Hydro Unit.
• Make the piping route a closed circuit. (An open circuit may
cause a failure).

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Water Piping Limitations
Design the water pipe length within the QH
characteristics of the pump (flow-rate and pump
head).
The maximum height difference for the water pipes is
7 metres.
Piping to hot water tank (option)
Water supplied to the hot water cylinder is branched by a motorized 3-way valve (procured locally).
Connect the hot water cylinder to port A (open when energized) of the valve.
Piping to 2-zone operation (option)
To perform 2-zone temperature control circulate water using another pump (procured locally)
through a motorized mixing valve (procured locally) and a buffer tank (procured locally).

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Checking water volume and initial pressure of expansion vessel
The expansion vessel of the Hydro Unit has a capacity of 12 litres.
The initial pressure of the expansion vessel is 0.1 MPa (1 bar).
The pressure of the safety valve is 0.3 MPa (3 bar).
Verify whether the capacity of the expansion vessel is sufficient using the following expression. If
the volume is insufficient, install an appropriate external expansion vessel.
V Action
< 12 L Internal Expansion Vessel Size OK
> 12 L Internal Expansion Vessel Size too small.
Install appropriate external expansion vessel
V: Necessary total vessel capacity (L)
Ɛ: Water expansion coefficient at average hot water temperature
Vs: Total water volume in the closed system (Do not include Hot Water Cylinder)
P1: System pressure at tank setting position (Mpa_abs*).
(Pipe inner pressure during pump operation before heating device operates = water supply
pressure)
P2: Maximum pressure used during operation at tank setting position (MPa_abs*).
(= safety valve setting pressure)
* The absolute pressure value (abs.) is obtained by adding the atmospheric pressure (0.1 MPa (1
bar)) to the gauge pressure.
Water temperature and expansion coefficient (Ɛ)Water temperature and expansion coefficient (Ɛ)
Hot water temperature
(°C)
Expansion rate
(Ɛ) Hot water temperature
(°C)
Expansion rate
(Ɛ)
0 0.0002 50 0.0121
4 0.0000 55 0.0145
5 0.0000 60 0.0171
10 0.0003 65 0.0198
15 0.0008 70 0.0229
20 0.0017 75 0.0258
25 0.0029 80 0.0292
30 0.0043 85 0.0324
35 0.0050 90 0.0961
40 0.0078 95 0.0967
45 0.0100 - -
Example
Maximum Hot Water temperature: 55°C
Initial water charge: 0.2MPa
System volume: 200 L.
Calculate Vessel capacity (V):-
In this case V < 12 L therefore the internal
expansion vessel is sufficient, so there is no need
to install an external expansion vessel.
V
=0.0145 x200
(0.2 + 0.1)
(0.3 + 0.1)
V
=11.6L
1-

11
Pump operation / configuration
HWS-803XWHM3-E, T6-E, D6-E, T9-E
HWS-1403XWHM3-E, T6-E, D6-E, T9-E

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Water charging
Charge water until the pressure gauge shows 0.2 MPa (2 bar).
Hydraulic pressure may drop when the trial run begins. In that case, add water.
Air may enter if the charged hydraulic pressure is low.
Loosen the Air relief valve cap by two turns to release air (see
diagram).
Loosen the cap of the pressure relief valve to release air. Water
may come out of the pressure relief valve.
Release the air completely from the water circuit. Failure to do so
may disable correct operation.
Water quality
The water used must satisfy EN directive 98/83 EC.
Piping insulation
It is recommended that insulation treatment be applied to all pipes. To perform optional cooling
operation, apply insulation treatment of 20 t or more to all pipes.

13
Electrical Connections
E Box layout
Power Lines Schematic

14
Control Lines Schematic
Terminal Block Connections

15
Electrical supply / cable specifications
Wiring specifications (power line)
Wiring specification (control line)

16
Control parts specifications
Output line specifications
Input line specifications
Description Input Maximum length
Emergency stop control Non-voltage 12 m
Cylinder thermostat input Non-voltage 12 m
Cooling thermostat input Non-voltage 12 m
Heating thermostat input Non-voltage 12 m

17
CAUTION
Earthing arrangements
The Hydro Unit and related equipment must be earthed in accordance with your local and national
electrical regulations.
It is essential that the equipment is earthed to prevent the electric shock and damage to the
equipment.
Electrical connection to hydro unit
• Remove the front cover and the electrical box cover from the Hydro Unit.
• The Hydro Unit power cable must be sized in accordance with refer to “Electrical supply/cable
specifications”.
• Connect the Hydro Unit power cable to Terminal 02 as shown below.
Single Phase Units: Live conductor – Terminal L1
Neutral conductor – Terminal L2
Earth conductor – Earth terminal
Three Phase Units: Phase 1 conductor – Terminal L1
Phase 2 conductor – Terminal L2
Phase 3 conductor – Terminal L3
Neutral conductor – Terminal N
Earth conductor – Earth
• Ensure the Hydro Unit power cable is secured using the cable clamp fitted in the electrical box.
• Ensure the Hydro Unit power cable connection terminals are tight.
Outdoor unit to hydro unit electrical connection
• Ensure electrical circuits are isolated before commencing work.
• The Outdoor Unit to Hydro Unit interconnecting cable must be sized in accordance with refer to
“Electrical supply/cable specifications”.
• Connect the Outdoor Unit to Hydro Unit interconnecting cable as shown in the diagram above.
• Ensure the Outdoor Unit to Hydro Unit interconnecting cable is secured using the cable clamp
fitted in the electrical box.
• Ensure the Outdoor Unit to Hydro Unit interconnecting cable connection terminals are tight.

18
Electrical connection for external booster heater
CAUTION
• The maximum current available from the booster heater output is 1 A. Do not connect the
booster heater directly to Terminal Block 05 on the Hydro Unit. A separate contactor,
supplied locally, must be used to supply the booster heater.
• The booster heater can be installed only for room heating and cannot be used for hot water
supply.
• Install the booster heater downstream of the 3-way valve on the indoor unit side.
• The booster heater is an external heater, supplied locally, used to assist the Hydro Unit during
low ambient conditions.
• The AC230 V 1 A output from the Hydro Unit must only be used to energize an external contactor
(supplied locally).
• The output from the Hydro Unit is only enabled when either the outdoor air temperature to be
lower than -20°C.
• Ensure the external booster heater is installed and set up in accordance with all Local, National
and International regulations.
• Connect the external booster heater to the Hydro Unit
according to the diagram shown opposite:-
• The contactor will energize in the event of low ambient
conditions.
• A separate dedicated electrical supply must be used for
the external booster heater. This must be connected
through the contacts on the field supplied contactor.
Electrical connection for external additional pumps
CAUTION
• The maximum current available from the additional pump output is 1 A. Do not connect
the additional pump directly to Terminal Block 05 on the Hydro Unit. A separate contactor,
supplied locally, must be used to supply the additional pump.
• The Hydro Unit has the facility to connect an additional circulating pump, if required, into the
heating or cooling system.
• Install the pump so that its motive power does not affect the internal pump.
• The AC230 V 1 A output from the Hydro Unit must only be used to energize an external contactor
(supplied locally).
• The output for the pump is synchronized with the operation of the main circulating pump (P1)
inside the Hydro Unit.
• Ensure the pump is installed and set up in accordance with all Local, National and International
regulations.
• Connect the additional pump (P2) as shown in
the diagram opposite:-
• The contactor will energize synchronously with
operation of the main circulation pump (P1).
• A separate dedicated electrical supply must be
used for the pump. This must be connected
through the contacts on the field supplied
contactor.

19
3-way valve (diverter) connection
Required Valve Specification:
Electrical Specification: 230 V; 50 Hz; <100 mA
Valve Diameters: Port A, Port B: Ø 1 1/4"
Return Mechanism: 3 types of 3-way valve (diverter) can be used.
Set the 3-way valve in use with the DIP switch SW13-1 on the Hydro Unit board.
Diverter Valve Description SW13-1
Type 1 2-wire spring return OFF
Type 2 3-wire SPST OFF
Type 3 3-wire SPDT ON
NOTE
Continuous operation of the valve motor at the fully open position is not recommended.
• The 3-way diverter valve is used to select either domestic hot water or zone1 / zone2.
• Connect the 3-way diverter valve in accordance with the diagram below:-