Toyotomi HC-190 User manual

SERVICE MANUAL
HEAT CONVECTOR
HC-190

CONTENTS
SECTION 1: DESCRIPTION
SPECIFICATIONS………………………...................................................................... 1
DIMENSIONAL OUTLINE........................................................................................... 2
OPERATING CONTROLS AND PART NAME............................................................ 3
ACCESSORY PARTS............................................................................................... 3
WIRING DIAGRAM..................................................................................................... 4
OUTLINE OF OPERATION........................................................................................ 5
DESCRIPTION OF FUNCTIONAL COMPONENTS AND PARTS............................. 6
SECTION 2: OPERATION ＆INSTALLATION
OBSERVE THE FOLLOWING ITEMS FOR SAFE OPERATION.............................. 9
OPERATION.............................................................................................................. 10
TEST RUN................................................................................................................. 13
ROUTINE MAINTENANCE........................................................................................ 14
SECTION 3: INSTALLATION
INSTALLATION....................................................................................................….14
SECTION 4: DISASSEMBLING
HOW TO DISASSEMBLE......................................................................................….19
SECTION 5: TIME CHART
TIME CHART............................................................................................................. 23
SECTION 6: TROUBLESHOOTING
TROUBLESHOOTING CHECK LIST........................................................................ 36
PARTS DESCRIPTION............................................................................................ 39

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SECTION 1: DESCRIPTION
SPECIFIC A TIONS
Model:
Type:
Heat Rating Range:
HC-190
Hot Water Heating, Floor Standing Type
4,050 to 20,000 BTU/h (1.2 to 5.9 kW)
*See the chart below for details.
Max. Allowable Pressure:
Heat Exchanger Capacity:
Flow Rate Range:
Hot Water Temperature:
Noise Level:
Air Volume:
Operation Mode:
Dimensions (W x H x D):
Weight:
Set Temperature Range:
Electrical Rating:
Electrical Current Fuse:
Heating Performance:
142 PSI (0.98 MPa)
0.16 gal. (0.6L)
0.5 gal./min. to 1.5 gal./min. (1.89 to 5.68 L/min.)
110°F –190°F (43℃- 87.8℃)
High: 40dBA Med: 35dBA Low: 23dBA
NOTE: Noise levels tested at 2.5m.
High: 226CFM Med: 141CFM Low: 64CFM
Auto Fan Mode - 4 fan speeds (High/Med/Low/OFF)
Manual Fan Mode - 3 fan speeds (High/Med/Low)
28-3/8”x 15-1/4”x 7-3/16”(720 x 387 x 182 mm)
27.5lbs. (12.5kg)
50°F –90°F (12℃- 30℃)
120 Volts AC, Single phase 60 Hz
High –37W (0.4A)
Med –16W
Low –9W
5A (BTU)
Circulation Water V olume
Fan Speed
Temperature of Circulation W a ter
GPM (L/min)
110˚F (43˚C)
120˚F (49˚C)
130˚F (54˚C)
140˚F (60˚C)
150˚F (66˚C)
160˚F (71˚C)
170˚F (77˚C)
180˚F (82˚C)
190˚F (88˚C)
0.5 GPM (1.89 L/min)
Lo w
4026 BTU
4991 BTU
5939 BTU
6905 BTU
7870 BTU
8818 BTU
9784 BTU
10732 BTU
11697 BTU
Medium
4987 BTU
6183 BTU
7357 BTU
8553 BTU
9748 BTU
10923 BTU
12118 BTU
13293 BTU
14488 BTU
High
5479 BTU
6775 BTU
8048 BTU
9345 BTU
10641 BTU
11914 BTU
13211 BTU
14484 BTU
15780 BTU
1
GPM (3.79 L/min)
Lo w
4372 BTU
5421 BTU
6451 BTU
7500 BTU
8548 BTU
9578 BTU
10627 BTU
11657 BTU
12706 BTU
Medium
5793 BTU
7182 BTU
8547 BTU
9936 BTU
11325 BTU
12690 BTU
14079 BTU
15443 BTU
16832 BTU
High
6427 BTU
7952 BTU
9449 BTU
10974 BTU
12498 BTU
13995 BTU
15520 BTU
17017 BTU
18541 BTU
1.5 GPM (5.68 L/min)
Lo w
4459 BTU
5529 BTU
6579 BTU
7649 BTU
8718 BTU
9769 BTU
10839 BTU
11889 BTU
12959 BTU
Medium
5993 BTU
7430 BTU
8841 BTU
10278 BTU
11716 BTU
13127 BTU
14564 BTU
15976 BTU
17413 BTU
High
6933 BTU
8578 BTU
10195 BTU
11841 BTU
13487 BTU
15103 BTU
16749 BTU
18365 BTU
20011 BTU
Room T empera ture: 68˚F (20˚C)
(kW)
Circulation Water V olume
Fan Speed
Temperature of Circulation W a ter
GPM (L/min)
110˚F (43˚C)
120˚F (49˚C)
130˚F (54˚C)
140˚F (60˚C)
150˚F (66˚C)
160˚F (71˚C)
170˚F (77˚C)
180˚F (82˚C)
190˚F (88˚C)
0.5 GPM (1.89 L/min)
Lo w
1.19 kW
1.47 kW
1.75 kW
2.03 kW
2.31 kW
2.59 kW
2.88 kW
3.15 kW
3.44 kW
Medium
1.48 kW
1.83 kW
2.17 kW
2.52 kW
2.87 kW
3.21 kW
3.57 kW
3.91 kW
4.26 kW
High
1.62 kW
2.00 kW
2.37 kW
2.75 kW
3.13 kW
3.51 kW
3.89 kW
4.26 kW
4.64 kW
1
GPM (3.79 L/min)
Lo w
1.29 kW
1.60 kW
1.90 kW
2.21 kW
2.51 kW
2.82 kW
3.12 kW
3.42 kW
3.73 kW
Medium
1.71 kW
2.12 kW
2.52 kW
2.93 kW
3.33 kW
3.73 kW
4.14 kW
4.54 kW
4.95 kW
High
1.90 kW
2.34 kW
2.78 kW
3.23 kW
3.68 kW
4.11 kW
4.56 kW
5.00 kW
5.45 kW
1.5 GPM (5.68 L/min)
Lo w
1.32 kW
1.63 kW
1.94 kW
2.25 kW
2.56 kW
2.87 kW
3.18 kW
3.49 kW
3.81 kW
Medium
1.77 kW
2.19 kW
2.61 kW
3.03 kW
3.45 kW
3.86 kW
4.28 kW
4.70 kW
5.12 kW
High
2.05 kW
2.53 kW
3.00 kW
3.48 kW
3.97 kW
4.44 kW
4.92 kW
5.40 kW
5.88 kW
Room Temperature: 68˚F (20˚C)
Hydraulic Resistance
Circulation Water V olume
Resistance
1.5 G(5.68 L/min)
7.0 PSI/48 kPa
1.0 G(3.79 L/min)
3.2 PSI/22 kPa
0.5 G(1.89 L/min)
0.9 PSI/6 kPa

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- 3 -
OPERATING CONTROLS AND PART NAMES
1. POWER switch: Main switch turns the unit on or off.
2. AUTO/MANUAL button: Button switches fan speed to either AUTO and MANUAL.
3. TIMER button: Button turns Timer operation mode on or off.
4. CHILD LOCK button: The button turns CHILD LOCK operation mode on or off.
5. POWER lamp: Light means the unit is in operation.
6. TIMER indicator: Light means the unit operating in Timer setting mode.
7. TEMP/TIMER/CLOCK set: TEMP/TIMER/CLOCK set modes can be set by pressing “–/hour” or
“+/min.” buttons.
8. Digital display: Displays clock, set temperature, room temperature and error code.
9. CHILD LOCK indicator: Light –The unit is in CHILD LOCK mode.
10. AUTO/MANUAL indicator: Light –Digital display shows fan speed mode.
11. AM/PM indicator: Light –Digital display shows current time.
12. Thermistor (Room Temperature Sensor) : Constantly senses room temperature and supplies information to the
unit so that desired room temperature can be maintained.
ACCESSORY PARTS
1. Installation and Operation Instructions
2. Warranty Card
3. Wall Fixing Kit (Wall bracket –2 sets, Screw –2 pcs., Wooden screw –2 pcs.)

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WIRING DIAGRAM

- 5 -
OUTLINE OF OPERATION
Circulate the hot water and turn the unit ON, then, the motor start operating and revolve the fan in the
case that the room temperature is lower than set temperature and then blow the hot air with the hot water
heat that passed through inside the heat exchanger when you set the AUTO FAN MODE.
However, since the cold air would blow if the water temperature is low, the unit does not start operating
until the water temperature rise to 100°F（38℃）. Also, the fan start revolving when the water temperature
is 100°F（38℃） to 110°F（43℃）, and the blow becomes only Lo mode.
When the user set the MANUAL MODE, the unit operates with specified wind level without relation to
the room temperature.
AUTO FAN MODE: Depending on the room temperature, this mode controls fan level and make the room
warmer to the set temperature. If the room temperature rises 4°F（2℃） more than set temperature, the
fan stops operating automatically. After that, the room temperature drops little by little to the set
temperature, then the fan start operating. Also, if the hot water is flowing at the fan stops, the room
temperature may rise with natural heat of the heat exchanger. If the user connects circulation pump or
zone valve to the external output with specified connection way, the unit stops them in conformity with
stopping the circulation heat convector fan.

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DESCRIPTION OF FUNCTIONAL COMPONENTS AND PARTS
1. Heat Exchanger
Mainly, it is formed from the copper pipe at passing
water part and aluminum fin for radiating heat, it is
made compact and light, and also secured the
durability.
〇If the fin is deformed, it may cause to reduce the
air volume and output.
〇You must follow the flow rate within the range
described in the specifications. Because the copper
pipe may cause the erosion and leak the water if flow
rate at the water passing part is too fast.
〇There is an air release valve at the upper of
the pipe.
※O-ring: The inside diameter isφ0.2 inch (4.8mm).
The thickness is 0.07 inch (1.9mm).
Material: Silicon
2. Fan Motor （with Condenser）
The motor for operating fan and the
condenser for turning on the unit.
The control of the number of revolving
motor is phase control. The temperature
fuse is the inside of the unit.
VOLTAGE
AC120V
FREQUENCY
60Hz
NUMBER OF
MOTOR POLES
4
INSULATION CLASS
B
CAPACITOR
3μＦ
250ＶAC
CAPACITOR
ＦＡＮ

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3. Fan
The cross flow fan for blowing hot air
4. Main circuit board （with electric current fuse）
It controls fan and other functions depending on
the operation condition and sensor value.
〇Confirm the wires whether they are
connected correctly when the unit does
not operate properly.
〇When you connect the wires, please connect
the wires that their alphabet mark match the
marks on the main circuit board.
［The specification of electric current fuse］
・Outside dimension ：φ0.2×0.8 inch (5.2×20mm)
・Rated ：5A・AC125V
5. Transformer
Terminal No.
Input voltage
No load voltage
Ｊ１
AC120V 60Hz
Ｊ２
ＡＣ14Ｖ

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6. Room thermistor
This thermistor is for detecting the room temperature, and also it has a feature that the resistance
value changes depending on the room temperature.
Celsius
0℃
5℃
10℃
15℃
20℃
25℃
30℃
Fahrenheit
32°F
41°F
50°F
59°F
68°F
77°F
86°F
Resistance rate
35.2kΩ
26.9kΩ
20.7kΩ
16.1kΩ
12.6kΩ
10.0kΩ
8.0kΩ
7. Water Thermistor
This thermistor is for detecting the water temperature, and also it has a feature that the resistance
value changes depending on the temperature.
Celsius
0℃
10℃
20℃
30℃
40℃
50℃
60℃
70℃
80℃
Fahrenheit
32°F
50°F
68°F
85°F
104°F
122°F
140°F
158°F
176°F
Resistance rate
160ｋΩ
95.9kΩ
59.5kΩ
38.0kΩ
25.0kΩ
16.9kΩ
11.7kΩ
8.3kΩ
6.0Ω
8. Lamp Circuit Board
Shift the operation mode. Connect to the main circuit board with FFC cable.
9. FFC cable
This is a flat cable for connecting lamp circuit board and main circuit board. (23 core）
※Connect it to the main circuit board as the connecting part is upper side. Do not show anything on the
indication circuit board if it is connected the opposite side.