Toshiba HWS-803XWHM3-E User manual

Model name:
Outdoor Unit
HWS-803H-E(TR)
HWS-1103H-E(TR)
HWS-1403H-E(TR)
HWS-1103H8-E
HWS-1103H8R-E
HWS-1403H8-E
HWS-1403H8R-E
HWS-1603H8-E
HWS-1603H8R-E
AIR TO WATER HEAT PUMP
Hydro Unit
HWS-803XWHM3-E(TR)
HWS-803XWHT6-E(TR)
HWS-803XWHD6-E
HWS-803XWHT9-E
HWS-1403XWHM3-E(TR)
HWS-1403XWHT6-E(TR)
HWS-1403XWHD6-E
HWS-1403XWHT9-E(TR)
Hot Water Cylinder
HWS-1501CSHM3-E(-UK)
HWS-2101CSHM3-E(-UK)
HWS-3001CSHM3-E(-UK)
SERVICE MANUAL
A10-006

1
Contents
1 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 NEW REFRIGERANT (R410A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-1.Safety During Installation and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-2.Installing refrigerant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2-1.Steel pipe and joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2-2.Processing of piping materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-3.Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-3-1.Necessary tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-4.Recharging of refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-5.Brazing of pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-5-1.Materials of brazing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-5-2.Flux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-5-3.Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Outside Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-1.Hydro unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-2.Outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-3.Hot water cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-1.Hydro Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-2.Outdoor Unit (Single phase Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-3.Outdoor Unit (3 phase type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-4.Hot Water Cylinder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Key Electric Component Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1.Hydro Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-2.Outdoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-3.Hot Water Cylinder Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-4.Water Heat Exchange Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-5.Outdoor Control Board (Single phase Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6-6.Outdoor Unit Control (3 phase type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MCC-1596 (Compressor IPDU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MCC-1597 (Fan Motor IPDU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
MCC-1599 (Interface (CDB)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
MCC-1600 (Noise Filter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7 Refrigeration Cycle / Water System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-1.Water System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7-2.Refrigeration Cycle System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2
8 Operational Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9 Method of Defect Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9-1.Matters to be confirmed first. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9-1-1.Check the power supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9-1-2.Check for any miswiring of the connection cables between the hydro unit and the
outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9-1-3.About the installation of the temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9-2.Non-defective operation (program operation) … No fault code display appears.. . . . . . . . . . . . . . 82
9-3.Outline of the determination diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9-3-1.Procedure of defect diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9-3-2.How to determine from the check code on the remote control . . . . . . . . . . . . . . . . . . . . . 83
9-3-3.How to cancel a check code on the remote controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9-3-4.How to diagnose by error code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9-4.Diagnosis flow chart for each error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9-4-1.Hydro unit failure detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9-4-2.Outdoor Unit Failure Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
9-4-3.Temperature sensor, temperature-resistance characteristic table . . . . . . . . . . . . . . . . . 122
9-5.Operation check by PC board switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9-5-1.Operation check mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
9-6.Brief method for checking the key components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9-6-1.Hydro unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
9-6-2.Outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
10 Hydro unit and Outdoor Unit Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
11 Replacement of the Service P.C. Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
12 How to Exchange Main Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
13 Periodic Inspection Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
14 Part Exploded View, Part List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

3
1SAFETY 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, furniture, livestock, or pets.
[About symbols]
Indication Meaning of Indication
DANGER Indicates that a wrong operation may cause a service engineer and the third persons
around to get fatal or serious injuries.
WARNING 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.
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.
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>
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 ofhigh 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.
<Discharge between terminals>
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.
<Forbidden>
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
<Check earth ground>
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

4
<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 electric shock.
∗: For details, see the parts price list.
<Keep children away from unit>
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.
<Insulation treatment>
After connecting a cut lead with a crimp contact, discharge by facing the closed side upward.
• Connect lead wires with crimping terminals and turnthe closed end upwards to avoid exposure to water.
<Watch out for fire>
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.
<Use refrigerant carefully>
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.
<Be careful with wiring>
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.
<Check for water leak>
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.
WARNING

5
<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 MΩor higher.
• A low insulation resistance may cause a disaster at a customer site due to electrical leakage or an electric shock.
<Ventilate>
Ventilate if refrigerant gas leaks during service work.
• Should refrigerant gas catch fire, poisonous gases maybe 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 apart in the control board with your bare hand may cause an
electric shock. Take enough care to check circuits.
<Turn off the power breaker>
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.
<Always do>
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.
<Check after repair>
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 after re-installation>
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>
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
<Cooling check>
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 with torque wrench>
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.
WARNING

6
2NEW 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 refilledwith 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.
• Wheninstalling theunit thatcontainslargeamount ofrefrigerantsuch asAir toWater HeatPump, takemeasures
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.

7
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 theinside of pipe
and joints.
Copper pipe
Usecopper pipeof the“copper andcopper alloyseamlesspipe” typewith attachoil quantityof 40mg /10 m orless.
Do not use pipe that is cracked, distorted, or discoloured (especially inside).The expansion valve or capillary may
get clogged with impurities.
Considering that Airto Water Heat Pump using R410A is higherin pressure than those using the conventionalR22,
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
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
Wall thickness (mm)
Nominal diameter Outer diameter R410A
3/8 9.52 0.80
5/8 15.88 1.00
Nominal diameter Reference of outer diameter of
copper pipe connected (mm) Minimum joint wall thickness (mm)
3/8 9.52 0.80
5/8 15.9 1.00

8
2-2-2. Processing of piping materials
Wheninstallingrefrigerant pipe,prevent water ordust from enteringthe pipe, anddo not use oilotherthan 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
Check that the clasps and copper pipe are clean. Flare
correctlyusingthe clasp.Usea flaretoolfor R410Aorthe
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
Table 2-2-4 Dimension of flare for R410A and flare nut
Figure 2-2-2 Relationship between flare nut and flare surface
Nominal
diameter Outer diameter (mm) Wall thickness (mm)
A (mm)
Flare tool for R410A
clutch type Conventional flare tool
Clutch type Butterfly-nut type
3/8 9.52 0.8 0 to 0.5 1.0 to 1.5 2.0 to 2.5
5/8 15.9 1.0 0 to 0.5 1.0 to 1.5 2.0 to 2.5
Nominal
diameter Outer diameter (mm) Wall thickness (mm) Dimension (mm) Flare nut width
(mm)
ABCD
3/8 9.52 0.8 13.0 13.2 9.7 20 18
5/8 15.9 1.0 19.1 19.7 15.9 24.5 26
A
D
Figure 2-2-1
Flare dimension
DCB A
45° - 46°
43° - 45°

9
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)
3/8 9.52 33 to 42 (3.3 to 14.2)
5/8 15.9 66 to 82 (6.8 to 8.2)

10
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 beused 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
*(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.
Also prepare the following equipment for other work methods or run check.
No. Tool to be used Usage
R410A Air to Water Hear Pump
installation Conventionalrefrigerant
Air to Water Heat Pump
installation
For R410A
Existenceofnew
equipment
Conventional
equipment can be
used
New equipment can be
used with conventional
refrigerant
1 Flare tool Pipe flaring Yes *(Note 1) Yes
2Copper pipe gauge for
adjusting projection margin Flaring by conventional flare tool Yes *(Note 1) *(Note 1)
3 Torque wrench (For Ø15.9) Connection of flare nut Yes No No
4 Gauge manifold Evacuating, refrigerant
charge, run check, etc. Yes No No
5 Charge hose
6 Vacuum pump adapter Vacuum evacuating Yes No Yes
7Electrical balance for
refrigerant charging Refrigerant charge Yes No Yes
8 Refrigerant cylinder Refrigerant charge Yes No No
9 Leakage detector Gas leakage check Yes No Yes
10 Charging cylinder Refrigerant charge *(Note 2) No No
1. Vacuum pump
Use this by attaching vacuum pump
adapter.
4. Reamer 9. Hole core drill (Ø65)
5. Pipe bender 10. Hexagon wrench
(Opposite side 4mm)6. Level vial
2. Torque wrench (For Ø6.35) 7. Screwdriver (+, –) 11. Tape measure
3. Pipe cutter 8. Spanner or Monkey wrench 12. Metal saw
1. Clamp meter 3. Insulation resistance meter
2. Thermometer 4. Electroscope

11
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 refrigerantcannot 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
(For refrigerant charging, see the figure below)
Recover the refrigerant, and check that no
refrigerant remains in the refrigerant cycle.
Connect the charge hose to packed valve service
port on the outdoor unit's gas side.
Connect the charge hose to the vacuum pump
adapter.
Open fully both packed valves on the liquid and
gas sides.
Open fully the handle of gauge manifold Lo, turn on the
vacuum pump, and then perform vacuum evacuating.
When the compound gauge's pointer indicates
-0.1 MPa (-76cmHg), close fully the handle Lo and turn
off the vacuum pump.
Let the equipment stay as it is for one to two minutes
and check that the compound gauge pointer does not
return.
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.
(Hydro unit)
(Outdoor unit)
Open
Open
Service port
Check valve
Open/close valve
for charging
Electronic balance for refrigerant charging
CloseOpen
Refrigerant cylinder (with siphon)

12
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.
NOTE
• Because R410A is HFC mixed refrigerant, charging with gas changes the charged refrigerant composition,
causing the equipment characteristics to change.
[Cylinder with siphon] [Cylinder without siphon]
Gauge manifold Outdoor unit
Refrigerant
cylinder
Electronic balance
Gauge manifold Outdoor unit
Refrigerant
cylinder
Electronic balance
Siphon pipe

13
2-5. Brazing of pipes
2-5-1. Materials of brazing
Silver brazing metal
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.
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.
NOTE
• Phosphor bronze brazing metal tends to react with
sulfur,producingafragilecompoundwatersolution.
This may cause gas leakage. Therefore, use other
type ofbrazing metal ata hot spring resort orsimilar
place, and coat the surface with coatings.
• To braze the pipe again while performing service
work, use the same type of brazing metal.
2-5-2. Flux
Why flux is necessary
• Removing all the oxide film and any foreign matter
on the metal surface assists the flow of brazing
metal.
• 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.
Characteristics of flux
• The activation temperature of flux matches the
brazing temperature.
• A wide effective temperature range makes flux hard
to carbonize.
• It is easy to remove slag after brazing.
• Thecorrosiveactionto thetreatedmetalandbrazing
metal is minimum.
• 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
accordingtometaltreatmenttype,brazingmetaland
brazing method, or other conditions.
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.
• Active solvent
Most of this type of flux is generally used for silver
brazing.
Itfeaturestheincreaseof oxidefilmwhile movingthe
capability to the borax-boric acid compound to add
compounds such as potassium fluoride, potassium
chloride, or sodium fluoride.
Piping materials for brazing and brazing
metal / flux
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.
• When adding water to the flux, use water that does
not contains chlorine. (e.g. distilled water or ion-
exchange water)
• Remove the flux after brazing.
2-5-3. Brazing
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.
NOTE
• Never use gas other than nitrogen gas.
Brazing method to prevent oxidation
1) Attach a reducing valve anda flow meter to the
nitrogen cylinder.
2) Use a copper pipe to direct the piping material,
and attach the flow meter to the balance.
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.
4) If the nitrogen gas flows out, be sure to keep
open the piping end.
Piping material Brazing metal to be
used Flux to be used
Copper - Copper Phosphor copper Do not use
Copper - Iron Silver Paste flux
Iron - Iron Silver Vapour flux

14
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
MFlow meter
Stop valve
From nitrogen cylinder
Nitrogen gas
Robber plug
Pipe
Nitrogen gas cylinder

15
3Specifications
*1 Heating performance measurement conditions: outside air temperature 7 °C, water supply temperature 30 °C, outlet temperature 35 °C, refrigerant piping length 7.5 m (no height
difference).
*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).
*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 centre and 1m high from the ground. The hydro unit operating noise is measured at the
point of 1m away from the unit front surface centre.
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.
Unit name Hydro unit HWS-803XWHM3-E, 803XWHT6-E, 803XWHD6-E, 803XWHT9-E
Outdoor unit HWS-803H-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 220 - 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) 7.64 8.90
Power (kW) 1.719 2.033
Power factor (%) 97.8 99.3
Total Starting current (A) 8.62 9.36
Operating noise *1 *2 *4 Hydro unit (dB(A)) 29 29
Outdoor unit (dB(A)) 49 49
Coefficient of performance *1 *2 4.40 2.82
Hydro unit Outer dimension Height (mm) 925
Width (mm) 525
Depth (mm) 355
Net weight (kg) 50
Color Silky shade (Munsell 1Y8.5/0.5)
Remote controller
Outer dimension *3 Height (mm) 120
Width (mm) 120
Depth (mm) 16
Circulating pump Motor output (W) 125 (MAX)
Flow rate (L/min) 22.9 17.2
Type Non-self-suction centrifugal pump
Heat exchanger Plate-type heat exchange
Outdoor unit Outer dimension Height (mm) 890
Width (mm) 900
Depth (mm) 320
Net weight (kg) 63
Color Silky shade (Munsell 1Y8.5/0.5)
Compressor Motor output (W) 1400
Type Twin rotary type with DC-inverter variable speed control
Model DA220A2F-22L
Fan motor Standard air capacity (m3/min) 50.0
Motor output (W) 60
Refrigerant piping Connection method Flare connection
Hydro unit Liquid Ø9.52
Gas Ø15.9
Outdoor unit Liquid Ø9.52
Gas Ø15.9
Maximum length (m) 30
Maximum chargeless length (m) 30
Maximum height difference (m) ±30
Minimum length (m) 5
Refrigerant Refrigerant name R410A
Charge amount (kg) 1.8
Water piping Pipe diameter R1 1/4
Maximum length (m) None (Need the flow rate 13 /min or more)
Maximum height difference (m) ±7
Maximum working water pressure (kPa) 300
Operating temperature range Hydro unit (°C) 5-32
Outdoor unit (°C) -20-43
Operating humidity range Hydro unit (%) 15-85
Outdoor unit (%) 15-100
Wiring connection Power wiring 3 wires: including ground line (Outdoor unit)
Connecting line 4 wires: including ground line

16
*1 Heating performance measurement conditions: outside air temperature 7 °C, water supply temperature 30 °C, outlet temperature 35 °C, refrigerant piping length 7.5 m (no height
difference).
*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).
*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 centre and 1m high from the ground. The hydro unit operating noise is measured at the
point of 1m away from the unit front surface centre.
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.
Unit name Hydro unit HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E
Outdoor unit HWS-1103H-E HWS-1403H-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 220 - 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 0.135
Power factor (%) 93.2 92.7 94.0 93.2
Outdoor unit Current (A) 9.94 14.88 13.37 17.47
Power(kW) 2.2153.392.9653.945
Power factor (%) 96.9 99.1 96.4 98.1
Total Starting current (A) 10.57 15.49 14.04 18.10
Operating noise *1 *2 *4 Hydro unit (dB(A)) 29 29 29 29
Outdoorunit(dB(A)) 49495151
Coefficient of performance *1 *2 4.77 2.84 4.50 2.70
Hydro unit Outer dimension Height (mm) 925
Width (mm) 525
Depth (mm) 355
Net weight (kg) 54
Color Silky shade (Munsell 1Y8.5/0.5)
Remote controller
Outer dimension *3 Height (mm) 120
Width (mm) 120
Depth (mm) 16
Circulating pump Motor output (W) 190 (MAX)
Flow rate (L/min) 32.1 28.9 40.1 31.5
Type Non-self-suction centrifugal pump
Heat exchanger Plate-type heat exchange
Outdoor unit Outer dimension Height (mm) 1340
Width (mm) 900
Depth (mm) 320
Net weight (kg) 93
Color Silky shade (Munsell 1Y8.5/0.5)
Compressor Motor output (W) 2500
Type Twin rotary type with DC-inverter variable speed control
Model DA422A3F-25M
Fan motor Standard air capacity (m3/min) 103.0
Motor output (W) 100 × 2
Refrigerant piping Connection method Flare connection
Hydro unit Liquid Ø9.52
Gas Ø15.9
Outdoor unit Liquid Ø9.52
Gas Ø15.9
Maximum length (m) 30
Maximum chargeless length (m) 30
Maximum height difference (m) ±30
Minimum length (m) 5
Refrigerant Refrigerant name R410A
Charge amount (kg) 2.7
Water piping Pipe diameter R1 1/4
Maximum length (m) None (Need the flow rate 17.5 /min or more)
Maximum height difference (m) ±7
Maximum working water pressure (kPa) 300
Operating temperature range Hydro unit (°C) 5-32
Outdoor unit (°C) -20-43
Operating humidity range Hydro unit (%) 15-85
Outdoor unit (%) 15-100
Wiring connection Power wiring 3 wires: including ground line (Outdoor unit)
Connecting line 4 wires: including ground line

17
*1 Heating performance measurement conditions: outside air temperature 7 °C, water supply temperature 30 °C, outlet temperature 35 °C, refrigerant piping length 7.5 m (no height
difference).
*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).
*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 centre and 1m high from the ground. The hydro unit operating noise is measured at the
point of 1m away from the unit front surface centre.
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.
Unit name Hydro unit HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E
Outdoor unit HWS-1103H8(R)-E HWS-1403H8(R)-E HWS-1603H8(R)-E
Heating capacity *1 (kW) 11.2 14.0 16.0
Cooling capacity *2 (kW) 10.0 11.0 13.0
Variable range of compressor frequency 10 - 60Hz 10 - 60 Hz 10 - 70 Hz
Power source 3 phase 50Hz 380 - 400V
Operation mode Heating Cooling Heating Cooling Heating Cooling
Electric characteristic *1 *2 Hydro unit Current (A) 0.63 0.61 0.67 0.63 0.69 0.66
Power (kW) 0.135 0.130 0.145 0.135 0.150 0.140
Power factor (%) 93.2 92.7 94.0 93.2 94.5 92.3
Outdoor unit Current (A) 4.03 5.65 5.23 6.50 5.95 7.50
Power (kW) 2.255 3.39 3.065 3.945 3.570 4.660
Powerfactor(%) 81.187.084.988.087.090.0
Total Starting current (A) 4.66 6.26 6.06 7.13 4.26 8.16
Operating noise *1 *2 *4 Hydro unit (dB(A)) 29 29 29 29 29 29
Outdoorunit(dB(A)) 495051515252
Coefficient of performance *1 *2 4.69 2.84 4.36 2.70 4.30 2.71
Hydro unit Outer dimension Height (mm) 925
Width (mm) 525
Depth (mm) 355
Net weight (kg) 54
Color Silky shade (Munsell 1Y8.5/0.5)
Remote controller
Outer dimension *3 Height (mm) 120
Width (mm) 120
Depth (mm) 16
Circulating pump Motor output (W) 190 (MAX)
Flowrate(L/min) 32.128.940.131.545.837.3
Type Non-self-suction centrifugal pump
Heat exchanger Plate-type heat exchange
Outdoor unit Outer dimension Height (mm) 1340
Width (mm) 900
Depth (mm) 320
Net weight (kg) 93
Color Silky shade (Munsell 1Y8.5/0.5)
Compressor Motor output (W) 2500
Type Twin rotary type with DC-inverter variable speed control
Model DA422A3F-27M
Fan motor Standard air capacity (m3/min) 103.0
Motor output (W) 100 × 2
Refrigerant piping Connection method Flare connection
Hydro unit Liquid Ø9.52
Gas Ø15.9
Outdoor unit Liquid Ø9.52
Gas Ø15.9
Maximum length (m) 30
Maximum chargeless length (m) 30
Maximum height difference (m) ±30
Minimum length (m) 5
Refrigerant Refrigerant name R410A
Charge amount (kg) 2.7
Water piping Pipe diameter R1 1/4
Maximum length (m) None (Need the flow rate 17.5 /min or more)
Maximum height difference (m) ±7
Maximum working water pressure (kPa) 300
Operating temperature range Hydro unit (°C) 5-32
Outdoor unit (°C) -20-43
Operating humidity range Hydro unit (%) 15-85
Outdoor unit (%) 15-100
Wiring connection Power wiring 5 wires: including ground line (Outdoor unit)
Connecting line 4 wires: including ground line

18
4Outside Drawing
4-1. Hydro unit
HWS-803XWHM3-E, 803XWHT6-E, 803XWHD6-E, 803XWHT9-E
HWS-1403XWHM3-E, 1403XWHT6-E, 1403XWHD6-E, 1403XWHT9-E
960
Anchor bolt long hole pitch
B leg part
40
380
40
2020
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
Remote controler
135.5
158
186.5
59.5144.5
11619.5
352
37.5
92554
Hot water outlet
connecting pipe 1 1/4"
Water inlet
connecting pipe 1 1/4"
Gas line dia.15.88
Liquid line dia.9.52
309.5
259
Drain nipple
371.5
355
40.540.5
9
Anchor bolt
long hole pitch
Manometer
525
19.5

19
4-2. Outdoor unit
HWS-803H-E
Portion B
Drain hole ( 25 burring hole)
Portion A
Air outlet
900
Air inlet
Air inlet
5-Drain hole ( 20 88 burring hole)
( 12 17 long hole)
Mounting bolt hole
Details of portion A Details of portion B Mounting bolt hole
( 12 17 U-shape hole)
Name Description
Refrigerant piping outlet Indoor and outdoor connecting line outlet
Power source intake hole 38 knockout hole
( 9.5 flare)
Refrigerant liquid connection
Refrigerant gas connection
( 15.9 flare)
Optional mounting hole
(12- 3 embossed)
Knockout for lower part of piping
Z arrow view
17.5
150 600
550
52
383
365
74 128
118 17.5
60
200
380
75
46
48
54
34
170
40
96
30
39
40
320
12
890
55
94
24
55 95
95
64
18 80
151
400
12
255
155
95
55
247
18
80
178 135
518
327
178 178
68
60
148
165 581
534
7
65
83 7