Toshiba HWS-804XWHM3 series User manual

Quick Reference
Air to Water Heat Pump
Series 4

1
Hydro Unit
HWS-
804H-**
HWS-
1104H-**
HWS-
1404H-**
HWS-
1104H8-**
HWS-
1404H8-**
HWS-
1604H8-**
HWS-
1104H8R-**
HWS-
1404H8R-**
HWS-
1604H8R-E
Back Up
Heater
HWS-804XWHM3-** P
- - - - - - - - ~, 3Kw
HWS-804XWHT6-** P
- - - - - - - - 3N, 6kW
HWS-804XWHT9-** P
- - - - - - - - 3N, 9kW
HWS-1404XWHM3-**
-P P P P P P P P ~, 3Kw
HWS-1404XWHT6-**
-P P P P P P P P 3N, 6kW
HWS-1404XWHT9-**
-P P P P P P P P 3N, 9kW
Outdoor Unit
Hydro Unit
HWS-1501
CSHM3-E
HWS-2101
CSHM3-E
HWS-3001
CSHM3-E
HWS-1501
CSHM3-UK
HWS-2101
CSHM3-UK
HWS-3001
CSHM3-UK
HWS-804XWHM3-**
HWS-804XWHT6-**
HWS-804XWHT9-**
HWS-1404XWHM3-**
HWS-1404XWHT6-**
HWS-1404XWHT9-**
Hot Water Cylinder
P
Estia System
Component Combinations
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
New Features for 4 Series ESTIA:
A-rated water circulating pump installed in hydro unit
Minimum target water temperature reduced to 7°C in cooling mode for improved compatibility with fan
coil units
Hydro unit pump ON / OFF cycling function –to momentarily operate water pump during long periods of
system OFF
Option to use an external cylinder thermostat, on locally supplied hot water cylinders, for domestic hot
water production
Improved control for second remote controller when used with under floor heating
Improved control for ESTIA / boiler connection
New expansion vessel for hydro unit
New compressor for single phase ESTIA outdoor units
Note:
Under floor heating components, fan coil units, radiators, valves and other installation materials must be
procured locally.
Notes on System Design
• The input water temperature to the hydro unit must be 50°C or less. This is especially important if the
hydro unit is used in conjunction with any other external heating source (auxiliary boiler, electric booster
heaters etc.)
Unit failure or water leaks may result if the return water temperature, to the hydro unit, exceeds 50°C
• The minimum flow rate for the circulating water in the heating/cooling circuit 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 flow rate specified above, the flow switch in the hydro unit is activated
to stop operation.
When thermostatic devices are used for temperature control a bypass valve must be fitted to the heating
circuit, to ensure the minimum water flow rate is maintained in the event of all thermostatic devices closing
at the same time
• Only use the water pump, built into the hydro unit, to circulate the water in the heating circuit
• The hydro unit back up heaters will operate to assist the heat pump capacity output during low ambient
conditions
• The hydro unit has been designed for indoor installations. Do not install outside where there is a risk of
low ambient conditions. This may cause the water in the pipe work to freeze
• Make the water circuit closed. Never use it as an open circuit.
• To prevent damage to the system the volume of the circulating water must be 20 litres or more. If total
volume of water amount is less than 20 litres, then the unit may not function fully due to the operation of
protective controls.

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
(804XWH = 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. A-rated 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-804H-E : 5 m
HWS-1104H**-E : 5 m
HWS-1404H**-E : 5 m
HWS-1604H**-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 by increasing the
refrigerant charge
The minimum pipe length cannot be decreased by reducing the
refrigerant charge
Refrigeration and Water Cycle Diagrams
Outdoor Unit: HWS-804H-E
Hydro Units: HWS-804XWH**-E
Outdoor Units: HWS-1104H**-E, HWS-1404H**-E
Hydro Units: HWS-1404XWH**-E

8
Outdoor Units: HWS-1104H8(R)-E, HWS-1404H8(R)-E, HWS-1604H8(R)-E
Hydro Units: HWS-1404XWH**-E
Water Piping WARNING
• Ensure that the heating circuit, and all components of the heating circuit, are installed in accordance with
all National and local regulations
• The water pipes must not be installed where they are exposed to low ambient air temperatures. This is to
prevent the water freezing in the pipes
• 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
• The ESTIA system can only be used on pressurised heating
circuits. If the system is used on gravity fed heating circuits then
system failure may occur

9
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).

10
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 QH curves
HWS-804XWHM3-E, T6-E, T9-E
HWS-1404XWHM3-E, T6-E,T9-E

12
Water charging
Charge the water, in the heating circuit, until the pressure gauge shows 0.2 MPa (2 bar).
The hydraulic pressure may drop when the trial run begins. In this case, add water until the hydraulic
pressure returns to 0.2MPa (2 bar)
Air may enter the heating circuit if the hydraulic pressure is low.
Loosen the Air relief valve cap by two turns to release air (see diagram).
Ensure all air is removed from the system. If air remains in the system
then the system operation may STOP.
Note: Due to the design of the electrical back up heater it is not
recommended to add any corrosion inhibitors / additives to the
heating circuit.
Water quality
The water used must satisfy EN directive 98/83 EC.
Piping insulation
It is recommended that insulation is fitted to all pipes. To perform optional cooling operation, apply
insulation with a rating of 20t or more to all pipes.

13
Electrical Connections
E Box layout
Power Lines Schematic
Fuses (AC250V T30A):
F1&F2: Hot water cylinder electric heater supply
F3&F4: Back up heater 1 (3kW)
F5&F6: Back up heater 2 (3kW)
F7&F8: Back up heater 3 (3kW)
Fuses (AC250V T3.15A)
F9&F10: A rated water pump
PCB’s:
MCC-1214: TCB-PCMO3E (optional input PCB)
MCC-1217: TCB-PCIN3E (optional output PCB)
MCC-1431: Relay PCB for control of second
water pump, 2 way valve and booster heater
outputs
MCC-1511: Main hydro unit control / interface
PCB
Contactors & Relays:
RY01: Interlock relay –flow switch / back up
heater circuit
RY02: Power contactor for back up heater supply
RY03: Control relay for back up heater s 2 & 3
operation
RY04: Power contactor for back up heater supply
RY05: Power contactor for hot water cylinder
electric heater supply
RY06: Control relay for mixing valve (2 zone)
operation

14
Control Lines Schematic
Terminal Block Connections

15
Electrical supply / cable specifications
Wiring specifications (power line)
Description
Model Name
HWS
Power Supply
Current
(Max)
Install
Fuse
Rating
Power
Cable
Connection
Destination
Outdoor
Unit
Power
Power
Input
1404H-E
220V-230V ~
50Hz
22.8A
25A
≥2.5mm2
L, N
-
1104H-E
220V-230V ~
50Hz
22.8A
25A
≥2.5mm2
804H-E
220V-230V ~
50Hz
19.2A
20A
≥2.5mm2
1604H8(R)-E
380-400V 3N~
50Hz
14.6A
16A
≥2.5mm2
L1, L2, L3,
N
-
1404H8(R)-E
380-400V 3N~
50Hz
14.6A
16A
≥2.5mm2
1104H8(R)-E
380-400V 3N~
50Hz
14.6A
16A
≥2.5mm2
Hydro
unit
electric
heater
power
Power
input
for
back
up
heater
1404XWHM3-E
220V-230V ~
50Hz
13A
16A
≥1.5mm2
L, N
TB02
1404XWHT6-E
380-400V 3N~
50Hz
13A (13Ax2P)
16A
≥1.5mm2
L1, L2, L3,
N
1404XWHT9-E
380-400V 3N~
50Hz
13A (13Ax3P)
16A
≥1.5mm2
804XWHM3-E
220V-230V ~
50Hz
13A
16A
≥1.5mm2
L, N
804XWHT6-E
380-400V 3N~
50Hz
13A (13Ax2P)
16A
≥1.5mm2
L1, L2, L3,
N
804XWHT9-E
380-400V 3N~
50Hz
13A (13Ax3P)
16A
≥1.5mm2
Power input for DHW
cylinder heater
220V-230V ~
50Hz
12A
16A
≥1.5mm2
L, N
TB03
Outdoor –hydro
unit connection
-
-
-
-
≥1.5mm2
1, 2, 3
TB01
Hydro unit to DHW
cylinder
-
-
-
-
≥1.5mm2
1, 2
TB03
Wiring specification (control line)
Description
Line Spec
Current (Max)
Length (Max)
Cable Diameter
Connection
Destination
3 way diverting
valve
2 or 3 wire
100mA
12m
1.0mm2
7, 8, 9 (TB05)
2 way valve
(cooling)
2 wire
100mA
12m
1.0mm2
3, 4 (TB05)
3 way mixing
valve (2 zone)
3 wire
100mA
12m
1.0mm2
1, 2, 3
or
2, 3, 4
(TB04)
2 zone thermo
sensor (TFI)
2 wire
100mA
5m
1.0mm2
C, D (TB06)
HW cylinder
thermo sensor
(TTW)
2 wire +GND
(screened cable)
100mA
5m
1.0mm2
A, B (TB06)
2nd remote
controller
2 wire
50mA
50m
≥ 0.5mm2
1, 2 (TB07)

16
Control parts specifications
Component
Power
Current (Max)
Specification
3 way diverting valve
AC 230V
100mA
Default: 2 wire spring return valve or 3 wire SPST
valve
Option: 3 wire SPDT valve (set DPSW13_1 to ON)
2 way valve (cooling )
AC 230V
100mA
2 wire spring return valve (normally OPEN)
3 way mixing valve (2 zone
control)
AC 230V
100mA
Default drive time = 60 seconds to 90°
3 wire SPST or SPDT with drive times to 90° between
30 and 240 seconds
Output line specifications
Description
Output
Current
(Max)
Voltage
(Max)
Cable
Length
(Max)
Comments
External water
pump (P2)
AC230V
1A
-
12m
External booster
heater
AC230V
1A
-
12m
Output enabled when outdoor air
temperature is ≤ -20°C
Alarm output
No volt contacts
0.5A
AC230V
12m
1A
DC24V
12m
Boiler output
No volt contacts
0.5A
AC230V
12m
Output enabled when outdoor air
temperature is ≤ -10°C (output trigger
temperature can be changed using FC23)
1A
DC24V
12m
Defrost output
No volt contacts
0.5A
AC230V
12m
1A
DC24V
12m
Compressor ON
output
No volt contacts
0.5A
AC230V
12m
1A
DC24V
12m
Input line specifications
Description
Input
Cable Length (Max)
External stop control
No voltage
12m
Cylinder thermostat
No voltage
12m
Room thermostat (cooling)
No voltage
12m
Room thermostat (heating)
No voltage
12m

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, for the electrical back up heaters, must be sized in accordance with the
Wiring Specifications table shown on page 15
• Connect the Hydro Unit power cable, for the electrical back up heaters, 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, for the electrical back up heaters, is secured using the cable clamp
fitted in the electrical box.
• Ensure the Hydro Unit power cable connection (for the electrical back up heaters) 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 the “Wiring
Specification” table shown on page 15
• 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.
HWS-804H-E
HWS-1104H-E
HWS-1404H-E
HWS-1104H8-E, H8R-E
HWS-1404H8-E, H8R-E
HWS-1604H8-E, H8R-E

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 heating circuit side of the installation
• 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
DPSW13-1
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 space heating
• Connect the 3-way diverter valve in accordance with the diagram below:-