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.)

- 4 -
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.

- 6 -
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.

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SECTION 2: OPERATION
OBSERVE THE FOLLOWING ITEMS FOR SAFE OPERATION
The instructions which are contained in this manual are classified into the following two types, which are
“WARNING” and “CAUTION”. These instructions are intended to provide important information for safe operation.
“WARNING” indicates the possibility of causing the user a fatal accident or serious injury if the unit is incorrectly
operated.
“CAUTION” indicates the possibility of causing the user injury or material damages if the unit is incorrectly
operated.
WARNING
1. ALWAYS plug into 120 V, 60 Hz, single phase electrical outlet.
2. Due to high surface temperatures, keep heater away from children, furniture and clothing while in operation.
3. DO NOT touch the Heater exchanger.
4. NEVER insert objects of any kind into the air intake or air outlet.
5. DO NOT unplug if your hands are wet. An electrical shock may occur.
6. DO NOT run power cord under carpets, rugs, or floor mats of any kind.
7. DO NOT apply any excessive force or pressure to the Power supply cord.
8. Make sure that the Plug is free of dust or debris.
9. DO NOT use an extension cord.
10. RISK OF INJURY FROM MOVING PARTS AND ELECTRICAL SHOCK. Disconnect power cord before
servicing.
CAUTION
1. Keep objects more than 20 in. (50 cm) away from front of unit.
2. DO NOT place animals, plants, or combustion equipment in a place which is subjected to the direct air flow of
the unit.
3. DO NOT ride or place objects on the unit.
4. DO NOT try to repair or alter unit by yourself.
5. DO NOT place flower vase or water containers on the top of the unit.
6. DO NOT block the air inlet or outlet.
7. To prevent abnormal operation and prolong heater life, be sure to perform routine maintenance.
How to shift the temperature indicator from Fahrenheit to Celsius
Cut the jumper wire “TP 5”on the main circuit board.

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- 11 -

- 12 -

- 13 -
TEST RUN
PREPARATION
1. Make sure there is no water leaking from the unit and piping.
2. Make sure electrical connections and grounding are wired properly.
3. Check for air trapped in the plumbing.
OPERATION
1. Plug into the receptacle.
2. Press the Power switch to ON position. Power lamp will come on.
3. When the hot water at the temperature of 100˚F (38˚C) or more flows into the unit, the Fan will start rotating.
POWER FAILURE RECOVERY SYSTEM
If at any time a power failure occurs during operation, the time, timer and temperature settings will be erased.
When the power returns, the unit will automatically restart with the following conditions.
Operation mode: The unit will restart in AUTO FAN mode.
TIMER: The Timer settings will be reset. Please reset the TIMER. (See page 11 TIMER OPERATION)
Set temperature: The Set temperature will resume to the previous temperature set.
Child Lock: The Child Lock will be restored to the previous setting.
The power lamp will blink to indicate that a power failure has occurred and that the time and timer has been
erased. To stop the blinking power lamp, press any button once.

- 14 -
ROUTINE MAINTENANCE
CAUTION: Be sure to unplug the unit before performing any checks or cleaning.
FOR OPTIMUM UNIT PERFORMANCE, THE PARTS SHOWN BELOW SHOULD BE CLEANED REGULARLY:
1. Clean Louvers (ONCE A
MONTH)
Dust and stains should be wiped off louvers with a damp cloth.
2. Clean Air Filter (ONCE A
MONTH)
A mesh filter is located on the cabinet’s rear side. Once a month slide the filter up to remove and vacuum
it clean. To remove the air filter, remove the two (2) screws by using Phillips head scr ewdriver.
WARNING: NEVER touch the Heat exchanger. It can very hot and cause injury.
SECTION 3: INSTALLATION
The instructions which are contained in this manual are classified into the following two types, which are “W ARNING”
and “CAUTION”. These instructions are intended to provide important information for safe operation.
“WARNING” indicates the possibility of causing the user a fatal accident or serious injury if the unit is incorr
ec
tly operated.
“CAUTION” indicates the possibility of causing the user injuries or material damages if the unit is incorr
ectly
operated.
WARNING
1. Improper installation, adjustment, modification, or service and maintenance by an unauthorized person may cause
SERIOUS UNIT DAMAGE, BODILY INJURY, HAZARD OR PROPERTY DAMAGE. This unit should be installed by a
licensed, authorized person(s) due to the necessity of making electrical and water connections. Refer to the
installation and operation instructions for assistance, or consult your dealer for further information.
2. HAZARD OF ELECTRICAL SHOCK! Before removing any access panels of unit for service, make sure the
electrical supply to the unit is shut off. Failure to do this may result in HAZARD, SERIOUS BODILY INJURY, OR
PROPERTY DAMAGE.
3. Check and comply with all state and local codes before beginning the installation.
CAUTION
1. Keep the area around the unit clean and free of flammable materials.
2. RISK OF FIRE AND ELECTRIC SHOCK. DO NOT apply any excessive force or pressure to the power supply cord.
Make sure the plug is free of dust. Be sure plug fits the receptacle securely.

- 15 -
Not less than 12 in.
(1 ft.)
WARNING: This unit must be installed in accordance with these instructions, local codes, ordinances and/or
in the absence of local codes National Plumbing standar ds.
Check and comply with all state and local codes before beginning the installation.
This unit should be installed by a licensed, authorized person(s) due to the necessity of making
electrical and water connections.
SELECTING A LOCA TION
Select a place to install the unit where hot water and electric supply are easily available.
1. Select a place which is free of combustible substances.
2. Select a place where proper maintenance and repair can be provided for the unit after installation.
3. Install the unit on level floor .
NOTE: The unit may be installed on the wall dir ectly.
Not less
than 4 in.
Not less
than 4 In.

- 16 -
PLUMBING
NOTE: Make sure the piping for the unit is laid out properly, and also check for any water leakage
Please use the two spanners to tighten the pipe connection. Use one spanner to fix the pipe connection, and
use the other one to tighten the screws with the proper torque.
CAUTION: DO NOT put a huge load on to the pipe connection. If a huge load is put on to the pipe connection,
it may cause deformation or disrepair.
1. Install heat insulation material on the water piping to prevent heat loss.
2. Copper or polyethylene pipe should be used for connecting pipes.
3. It is recommended to install shut-off valves on the supply and return sides for easy removal.
4. It is recommended to install a bypass loop in the water pipes with a shut-off valve.
5. Be sure to use anti-freezing solution, or non-scale block, or non-slime block, or corrosion-free water for the
circulation water.
Temperature of circulation water has to be less than 190˚F (87.8˚C)
Maximum allowable working pressure has to be less than 142 PSI
Supply opening NPT 1/2” Female Return opening NPT 1/2” Female
REMOVING TRAPPED
AIR
When operating for the first time, air may be trapped in the system. To release the air out of the piping and
the unit, follow the procedures below .
1. To remove the air release cover, remove the two (2) scr ews.
2. Loosen the Air release screw by using the flat head screwdriver. Release the air out of the piping.
3. Tighten the Air release screw after removing all trapped air.
4. Immediately wipe off any spilled water.
5. Attach the Air release cover.
Air Release Screw

- 17 -
PERMANENT WIRING INST ALLA TION
WARNING: TO AVOID ANY RISK OF FIRE AND ELECTRIC SHOCK. Make sure the Main circuit breaker and
power supply cord is disconnected before servicing. Electric shock may cause serious injury. It is
recommended that installation should be conducted by a Licensed Electrician.
PROCEDURE FOR PERMANENT WIRING
POWER SOURCE: 120V AC, 60Hz single phase
1. Turn off the Main circuit breaker. Disconnect power supply cord from the power source.
2. Remove the two
(2) screws and Junction box cover on the back side of unit.
3. Disconnect the ground wire
(green) from the power supply cord bracket.
4. Disconnect the two power supply wires from Junction box terminal.
5. Squeeze the strain relief bushing with adjustable pliers to remove the plastic bushing from the unit (right side).
Remove the power supply
cord.
6. Remove the Hole cap on the back side of the unit and put it in hole of the right side where the power
supply cor d was installed.
7. Use at least AWG 14/2 gauge copper wire to the Junction box, feed wire through hole to the right of
Junction box Cover and use 1/2 inch clamp connector to secure to Heat convector cabinet.
8. Affix the Junction box cover to the unit and insert screws.
Hole cap
Power supply cord Junction box cover
GROUND
POWER SUPPLY 120VAC
SINGLE PHASE 60Hz

- 18 -
EXTERNAL OUTPUT TERMINAL WIRING
This unit has an External output terminal for low-voltage (24 volts or less) contacts to connected to a circulation pump
control or zone valve. When connecting the circulation control or zone valve unit to this terminal, it is possible to stop
the circulation by the output from internal contact switch in the Heat convector. When the Power switch is ON and
there is a call for heat, the internal contact switch is closed. When Power switch is OFF or the Room temperature
reaches 4 degrees above Set temperature the internal contact switch is open.
WIRING FOR
EXTERNAL OUTPUT
1. Remove the four (4) screws and the cover on the back side of the unit.
2. Cut the rubber bushing of the cover by a cutter and insert the wire for the circulation control or zone valve.
3. Connect the wire to the terminal block in accordance with the color indication.
4. Fix the cover to the unit with the four (4) scr ews.
External output terminal
Rubber bushing Cover Universal Switching Relay,
control or Zone Valve.
POWER SUPPLY
24VAC 120VAC
CIRCULATI
ON WATER
PUMP
Note: Use at least
AWG 18
wir e.
Cover
[EXTERNAL
OUTPUT SPECIFICATIONS]
Contact Rating
3A 24VAC
Maximum Switching V oltage
30VDC
Maximum Carrying Current
5A
Maximum Switching Power
90W
Minimum Switching load
10mA 5VDC
After installation is completed, secure the unit to the wall with the wall fixing kit provided with the unit.
NOTE: Make sure the unit is parallel to the wall.
Wall bracket A Wall bracket B
Wooden
scr ew