General Index General index General information ..................... 1 General notes ............................2 Safety and applied symbols ........................3 Product guide ............................4 1.3.1 Classification of water chiller models ......................4 1.3.2 Product guide: Water chillers........................... 4 Control Functions ......................5 2.1 Control functions on the module......................6 2.1.1 Water control ..............................9 2.1.2 Water temperature control ..........................
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General Index Run operation ............................51 2.4.1 Setting of switches on the setting PCB ......................51 2.4.2 Operation control of the module ........................52 2.5 Time chart ............................. 53 Servicing ........................55 LCD display for Service Menu ....................... 57 General notes ............................65 Cycle components ..........................66 3.3.1 Compressor removal ............................. 66 3.3.2 ...
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General Index 3.4.9 Contactors (CMC, CMCD, CMCS) ........................ 86 3.4.10 Fuses (EF1, EF2, EF3. EFR, EFS, EFT) ....................86 3.4.11 Fuses (PFC) ..............................87 3.4.12 Relays ................................. 88 3.4.13 Main Switch ..............................89 4. Troubleshooting ......................91 4.1 Inspection of power source and connections ..................92 4.2 Inspection of PCB..........................93 4.3 Confirmation of operating value of protection devices and automatic operation devices ..... 93 Protection control function ........................94 Caution indication ..........................
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1. General information G e n e r a l i n f o r m a t i o n Index General notes ............................2 Safety and applied symbols ........................3 Product guide ............................4 1.3.1 Classification of water chiller models ......................4 1.3.2 ...
1. General information Safety and applied symbols 1.2 Safety and applied symbols During normal system design work or unit installation, greater attention must be paid in certain situations requiring particu- lar care in order to avoid damage to the unit, the installation or the building or property. Situations that jeopardise the safety of those in the surrounding area or that put the unit itself at risk will be clearly indicated in this manual. To indicate these situations, a series of special symbols will be used to clearly identify these situations. Pay close attention to these symbols and to the messages following them, as your safety and that of others depends on it. D A N G E R • The text following this symbol contains information and instructions relating directly to your safety and phy- sical wellbeing.
1. General information Product guide 1.3 Product guide 1.3.1 Classification of water chiller models Basic modules Unit type (Modular water chiller): RCM E = Made in Europe Position-separating hyphen (fixed) Capacity (HP): 40, 50, 60 CL = Condenser Less H = R134a refrigerant – 1.3.2 Product guide: Water chillers Basic modules 3N~ 400V 50Hz Unit Code RCME-40CLH...
2. Control Functions C o n t r o l F u n c t i o n s Index 2.1 Control functions on the module......................6 2.1.1 Water control ..............................9 2.1.2 Water temperature control ..........................10 2.1.3 Compressor Control ............................13 2.1.4 Control for recovery from power interruption (Option) ................... 15 2.1.5 Prevention of simultaneous startup .......................
2. Control Functions Control functions on the module 2.1 Control functions on the module List of the main control functions Item Description Slide valve control The outlet water temperature of the chiller unit is detected with a thermistor, and the stroke of slide valve is controlled continuously by time-sharing. Example of cooling operation: Outlet Water Temperature Load up area Neutral Zone Setting Temperature (Hold) Load down area Capacity control range: 100~25%, Stop. Thermo ON-OFF control When operation load becomes light, outlet water temperature falls below the "Stop temperature range" against ...
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2. Control Functions Control functions on the module Item Description Anti-freezing for In order to prevent freezing caused by a decrease of water temperature in winter or under other low ambient winter temperature conditions, pump operation order is output automatically. (Automatic pump operation) N O T E Starting conditions can be selected locally from the 3 types below. • Water temperature under 15ºC (mainly for systems where the total pump head from the chiller unit to the load side is supported by a common pump.
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2. Control Functions Control functions on the module Item Description It is possible to determine thermo OFF from the inlet water temperature (return temperature from load) of the chiller unit. It is possible to change the settings of thermo OFF temperature. Thermo OFF judgement due to N O T E inlet temperature Since this function is optional, it is necessary to make the settings for the enabling of this function at the time of local installation. When an alarm occurs, the contents of the alarm, as well as the date and time of occurrence are recorded. ...
2. Control Functions Control functions on the module 2.1.1 Water control Outlet water temperature of Chiller Unit is detected by Thermistor, and based on this value, compressor ON/OFF and the most suitable capacity is determined. Following shown the continuous capacity control and change of water temperature. Starting setting (example) Outlet Tsc : 7ºC temperature Inlet T1: 1ºC temperature T2: 2ºC T3: 2ºC T4: 1ºC Memorizes the inlet temperature at Thermo-OFF and re-start at ∆T2 Load up I zone Tsc+ T2/3+ T4 9ºC (1.0~4.0ºC) Load up II zone (1.0~3.0ºC) Tsc+ T2/3 8ºC...
2. Control Functions Control functions on the module 2.1.2 Water temperature control 1 Automatic temperature adjustment Compressor run/stop and capacity control are performed by detecting water temperature of the chiller unit with thermistors. Water Temp Set ON/OFF Temperature Difference Stop Temperature Range Item Model Available range Setting range Setting range Step (ºC)
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2. Control Functions Control functions on the module 2 Method to change settings a. Water temperature settings INPUT The part with the setting temperature currently enabled is illuminated Select the setting value with up and down keys Register with [ENT] key Cancel with [CAN] key N O T E • [Set1]: This is the setting value of the master chiller unit, and water temperature control is normally performed against this setting value.
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2. Control Functions Control functions on the module b. Setting of other water temperature control settings Continuous control type Display the input window with [INPUT] key Input the setting value with up and down keys Register the input value and close the window by pressing the [ENT] key. Also, by pressing the [CAN] key the input value is not registered, and the window is closed. SMGB0097 rev.0 - 07/2015...
2. Control Functions Control functions on the module 2.1.3 Compressor Control 1 Startup control The chiller unit receives an operation order, the cool water pump starts up, and after interlock is complete and compressor delay time (initial setting: 0.5 minutes) has passed, compressor is started up. In continuous control type, startup takes place in a state in which the slide valve is moved to the smallest load position. Compressor delay time can be adjusted. change the setting value to one which is adequate for the local facilities, to avoid compressor startup before ensuring a sufficient cold water flow. 2 Normal Operation is performed with the smallest load for 1 minute after compressor startup. After finishing startup control, control is shifted to normal water temperature control. 3 Stop a. At Themo OFF Continuous control type stops suddenly. At this time, the compressor sounds as if it was counter-rotating, due to the ...
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2. Control Functions Control functions on the module 4 Setting method of compressor delay time Display the input window with [INPUT] key Input the setting value with up and down keys Register the input value and close the window by pressing the [ENT] key. Also, by pressing the [CAN] key the input value is not registered, and the window is closed SMGB0097 rev.0 - 07/2015...
2. Control Functions Control functions on the module 2.1.4 Control for recovery from power interruption (Option) When this function is enabled, even in the case of power interruptions exceeding 2 seconds in length, operation restarts automatically in the operation mode as before the power failure, once a 3-minute guard has passed. To enable this function, the DIP switch of option C on the settings PCB (PCB ) (DSW5-1#) has to be set to ON.
2. Control Functions Control functions on the module 2.1.5 Prevention of simultaneous startup This function prevents simultaneous startup when supplying power to multiple units (in case that all modules are working individually, not in a master-slave group) In case that multiple chiller units are installed, it may be thought that all of them will start operation simultaneously when 3 minutes have passed after entering in recovery from power interruption. (Note: When using the function to control the number of units, simultaneous startup is prevented by performing sequential startup automatically. ) To prevent this phenomenon, it is possible to shift the settings of time guard (3 minutes). Setting method By means of DIP switch setting (DSW3-1#, 3-2# ,3-3#), the following number of seconds are added to the time guard (3 minutes). DIP switches (DSW3-1#, 3-2#, 3-3#) are used for address setting when using the functions to control the number of units, but the addition of time to the 3-minutes guard is effective even if these functions are not used. In this case, it is not ...
2. Control Functions Control functions on the module 2.1.7 Anti-Freezing Control for Winter When operation is stopped during winter, the temperature of cold water decreases and may induce freezing of the water- side heat exchanger or the piping system. The outdoor temperature and cold water temperature are detected, to operate the cold water circulation pump automatically, and protect the chiller unit from freezing. There are 2 modes to define the run/stop conditions of the cold water circulation pump. Select the most appropriate mode depending on the system structure and usage purpose. 1 Mode I (Factory default) Mode I is used mainly for systems composed of 1 chiller unit, or those with fixed flow. Since the entire water circuit is protected, the cold water pump is operated from a comparatively high water temperature. Example of system where Mode I is recommended Load 3-Way Valve △ Chiller unit Cold water circulation pump a. When outdoor temperature is under 2ºC When outdoor temperature falls under 2ºC, the operation order of cold water circulation pump is output, and the continuous operation of the cold water pump starts automatically. Here, when cold water temperature becomes higher than 15ºC, operation becomes intermittent, with the pump running for 5 minutes, then stopped during 55 ...
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2. Control Functions Control functions on the module 2 Mode II Mode II is used mainly for systems containing multiple chiller units, or those with variable flow. To avoid alteration of the water temperature of the rest of chiller units in operation, the pump is operated with a low water temperature. Load △ Secondary pump Chiller unit Chiller unit Primary pump a. When outdoor temperature is under 2ºC When outdoor temperature falls under 2ºC, the operation order of the pump is output, and the continuous operation of the cold water circulation pump starts automatically. Here, when cold water temperature becomes higher than 5ºC, operation becomes intermittent, with the pump running for 5 minutes, then stopped during 55 minutes. When cold water temperature rises even further, above 7ºC, the pump operation order output is set to OFF. b. Automatic release of anti-freezing operation This operation is released when outdoor temperature becomes higher than 4ºC. Explanation of codes More than More than Continuous pump operation Less than Less than △...
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2. Control Functions Control functions on the module Mode selection method N O T E This control is not performed when [Disable] is selected. In this case, make sure to implement anti-freeze measures on site, such as pump automatic operation or the installation of a heater at the water-side heat exchanger of the chiller unit.
2. Control Functions Control functions on the module 2.1.8 Control for prevention of wrong operation and wrong settings In the following cases, an alarm is output as wrong operation. 1 Wrong activation of the operation controls A wrong operation alarm is displayed when there is a remote input (including external thermo signal) while the unit is stopped, regardless of "local/remote switch" being switched to local (local operation mode). Also, while on remote operation mode, even if there is a local input (run switch on the control display part of the main unit) while the unit is stopped, it is ignored and no alarm is displayed. 2 Wrong local/remote activation When switching the operation mode from local to remote, or from remote to local, using the "local/remote switch" while the chiller unit is in operation, the chiller unit is stopped and a wrong operation alarm is displayed. 3 Wrong setting of DIP switches A wrong setting alarm (40-40) is displayed upon power ON in case that DIP switches are set to an impossible setting. 2.1.9 Demand control It is a control that allows to cause a forced thermo OFF of the chiller unit with orders from the local control panel (by means of peak cut, etc.) or to restrain the maximum limit of compressor operating capacity. Since it also allows to force a change of the operation capacity, in response to the load of the facility, it is a convenient function to perform temperature control from the local control panel. Forced thermo OFF function a.
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2. Control Functions Control functions on the module Current limit function (Power demand control) a. Contents of activation It is possible to operate below a maximum current limitation ratio previously set at the LCD screen. The selection to enable or release the setting value is performed with the order signal from the local control board. Also, the overcurrent protection control is always enabled, even in a state where this function is disabled. b. Setting method when cooling mode is set Display the input window with [INPUT] key Input the setting value with up and down keys Confirm with [ENT] key Cancel with [CAN] key SMGB0097 rev.0 - 07/2015...
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2. Control Functions Control functions on the module c. Time chart Control setting value for overcurrent protection Maximum current Setting value of limitation value current limitation External signal X d. Wiring method Control board of the chiller unit Power Maximum current source of limitation switch the local control board 2 0V N O T E •...
2. Control Functions Control functions on the module 2.1.10 Forced load up capacity control from external signal It is possible to force load up according to usage purpose. a. Contents of activation It is possible to force load up from the orders of local control panel. b. Time chart Normal Normal operation operation Forced load up Forced load Capacity control Normal...
2. Control Functions Control functions on the module 2.1.11 2-temperature setting function Regarding to the temperature setting of water temperature control, it is possible to set 2 different temperatures, and select which of these to be used as a setting temperature by means of a remote signal. This change is useful to cope with differences of load in usage, such as those between day and night operation. Measurement method Install the switch for exchanging the 2 temperatures between terminals [23] and [24]. When [23]-[24] are short-circuited, the mark next to "Temp Set2" on the water temperature setting screen is illuminated, to indicate that the 2 temperature setting has become enabled. 2 - temperature Disabled settings enabled N O T E • Before operating the chiller unit, select which temperature to use as setting temperature from the 1st and the 2nd (switch selection), then operate the chiller unit (it is possible to switch during operation, but it may cause instability of the operation, such as instant thermo OFF, etc.) •...
2. Control Functions Control functions on the module 2.1.12 External thermo operation from external contact In case of setting the chiller unit to run/stop with the order of an external contact such as that of a (locally supplied) external thermo, capacity control function is disabled and operation is performed at 100% load. This function is mainly oriented to thermal storage operation. It is not possible to use this function together with the function to control the number of units. Setting method 1 Set the local/remote switch (SW2 on PCBa) to remote side. 2 Connect the forced load operation switch to [24]-[25] of terminal block. 3 The wiring side used together by normal remote operation (air conditioning operation) and forced load operation (thermal storage operation) is shown. Remove the wiring between ...
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2. Control Functions Control functions on the module Thermo OFF temperature of the main unit remains enabled even during forced load operation. When performing thermal storage from an external thermo, set the external thermo to activate before the thermo OFF temperature of the main unit. In case of stop by thermo OFF temperature of the main unit, operation restarts automatically. When performing thermal storage from the main unit thermo, it is possible to prevent restart by turning the pump OFF with optional function "Pump operation in ON/OFF Cont.". Setting method Select "OFF" SMGB0097 rev.0 - 07/2015...
2. Control Functions Control functions on the module 2.1.13 Water Temperature of the Control Target It is possible to select which water temperature to use for capacity control and thermo OFF judgement, either "Inlet" or "Outlet". Use the outlet water temperature (factory default setting) in normal conditions. Setting method Select "IN" SMGB0097 rev.0 - 07/2015...
2. Control Functions Control functions on the module 2.1.14 Operation from DC24V contact input Outline The procedure to control operation from the DC24V contact of the local central controller is shown below. • Level input • Pulse input (1 switch) • Pulse input (2 switches) Arrange the settings and additional wiring necessary for each of them, as shown in the following sections. Available only in remote mode during independent operation of the chiller unit. Level input a. Signal aspect and basic sequence For wiring Terminal board Section arranged as a local work Run/stop switch (to be prepared locally) Alarm output (DC24V, less than 0.8A) Relay coil for DC24V, etc. (to be prepared locally) (The relay coil is powered on in case of alarm) Do not connect a LED or a ...
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2. Control Functions Control functions on the module b. Setting method N O T E • Do not bundle the additional wiring together with other control circuits, and in particular with wiring for 230V or 400V. • Put the additional wiring separately inside a metallic pipe, or use a shielded wire. SMGB0097 rev.0 - 07/2015...
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2. Control Functions Control functions on the module Pulse input type 1 a. Signal aspect and basic sequence For wiring Terminal board Section arranged as a local work Run/stop switch (to be prepared locally) Alarm output (DC24V, less than 0.8A) Relay coil for DC24V, etc. (to be prepared locally) (The relay coil is powered on in case of alarm) Do not connect a LED or a relay of internal diode type. Time chart More than More than 200ms 200ms Switch Keep more than 5 minutes Chiller unit Stop N O T E Pulse input indicates an ON input of the same switch when changing the status of the chiller unit, as shown in the...
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2. Control Functions Control functions on the module b. Setting method Select "Pulse" N O T E • Do not bundle the additional wiring together with other control circuits, and in particular with wiring for 230V or 400V. • Put the additional wiring separately inside a metallic pipe, or use a shielded wire. SMGB0097 rev.0 - 07/2015...
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2. Control Functions Control functions on the module Pulse input type 2 (external DC24V source) a. Signal aspect and basic sequence For wiring Remove (ON) signal (OFF) signal (OFF) (ON) Local works - parts to be arranged locally (field supplied) Time chart More than 5 min More than 200 ms Stop Unit Stop b. Setting method Since it applies remote control, it is not required to change any settings at the LCD screen. N O T E • Do not bundle the additional wiring together with other control circuits, and in particular with wiring for 230V or 400V. •...
2. Control Functions Control functions on the module 2.1.15 Thermo OFF function selection This function prevents thermo OFF of the chiller unit due to sudden changes of temperature or flow. Example of standard settings: Inlet water temperature Outlet water temperature Setting temperature Thermo OFF temperature Stop with 10 continued seconds at thermo OFF temperature Example of thermo OFF judgement extension Inlet water temperature Outlet water temperature 10 minutes Does not stop immediately even if temperature becomes lower than thermo OFF temperature Stop with 10 continued minutes below thermo OFF temperature This function is used in cases in which the water flow is reduced temporarily, such as when opening and closing the valves installed in the water piping system, or when switching the number of cold (hot) water circulating pumps in operation. However, ...
2. Control Functions Control functions on the module Mode selection method Select "10 minutes" 2.1.16 Selection of enabling/disabling of alarm release by means of remote stop The release of an alarm in case that the chiller unit has stopped due to an alarm is achieved by stop control (it is possible to stop both from the stop button of the main unit or from remote stop control). But it is possible to configure this alarm release to make it valid only from the stop button on the main unit (alarm cannot be released by remote stop control). This function is valid for places where there is a remote device for automatic stop order when an alarm is emitted. Select dissable SMGB0097 rev.0 - 07/2015...
2. Control Functions Control functions on the module 2.1.17 Limitation setting for pump feedback waiting time Flow at the start of operation of the chiller unit ° Chiller Unit Operation Order Reception Waiting for Pump Feedback ¢ Interlock achieved In case that setting time is Compressor operation after compressor delay £ exceeded time count Alarm Output § The flow in the upper figure is followed upon start of operation of the chiller unit. The state of ¢ is kept in case that there is no input of pump feedback signal between ¢ and £, or when the difference between inlet and outlet temperature of cold water is too large. This function shifts to § "Alarm" in case that the state of ¢...
2. Control Functions Control functions on the module 2.1.18 Inlet water temperature thermo OFF function Normally thermo OFF judgement is carried out from outlet water temperature, but when enabling this setting, the judgement of thermo OFF is carried out also from inlet water temperature. (Thermo OFF judgement by outlet water temperature is also enabled)(Water temperature control is carried out from outlet water temperature even in case that this function is enabled ) It is effective when there is the need to set thermo OFF with the return water temperature from the load. Setting method SMGB0097 rev.0 - 07/2015...
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2. Control Functions Control functions on the module Select "Enable" Display the input window with [INPUT] key Thermo ON conditions are the same as in Input the setting value with up and down keys normal outlet water temperature control. Confirm with [ENT] key It is possible to switch the setting values with “2.1.11 2-temperature setting func- Cancel with [CAN] key tion”. SMGB0097 rev.0 - 07/2015...
2. Control Functions Control of the cooling cycle 2.2 Control of the cooling cycle 2.2.1 Compressor Control The compressor mounted on this product is equipped with a system to adjust the amount of discharge (slide valve). The slide valve is installed on the screw rotor, and performs the adjustment of the amount of discharge with the change of bypass amount by hydraulic activation. In the case of load up Cylinder part To suction side Discharge Slide valve Suction Piston Rotor Spring Solenoid valve (203) Solenoid valve (202) To suction side Oil supply Solenoid valve (201) Oil supply In case of load down Cylinder part To suction side Bypass Discharge ...
2. Control Functions Control of the cooling cycle 2.2.2 Expansion Valve Control The expansion valve used in this product is an electronic expansion valve. The electronic expansion valve is composed by the main unit and a coil. The control functions of the electronic expansion valve are as shown below. 1 Basic control 0 (zero) point adjustment Power ON 0 (zero) point adjustment is conducted as an initialization (detection of base point) upon power ON. This control is 0 (Zero) point adjustment performed to make the control pulses recognized by the microprocessor and the actual pulse number to match at 0, by outputting a full closure order (under 0 pulse) for the opening of the expansion valve. During execution, Compressor startup the ...
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2. Control Functions Control of the cooling cycle 2 Protection controls The basic control follows the contents of section 1, but the following functions are also implemented for the protection of the product. a. Low pressure over-increase prevention control In case of continued operation conditions of low pressure higher than 0.5 MPa, the valve is forced to close and momentarily set somewhat close in comparison with the opening under normal control. b. Discharge gas superheat decrease prevention control During normal operation (during suction gas superheat control), in case of continued operation conditions of discharge gas superheat temperature lower than 5ºC, the valve is forced to close and momentarily set somewhat close in comparison with the opening under normal operation. c. Discharge gas temperature overheat prevention control In case of continued operation conditions of discharge gas temperature higher than 80ºC, overheating of discharge gas temperature is prevented by controlling the opening so as to make discharge gas temperature become 75ºC. d. Evaporated gas temperature decrease prevention control In case of continued operation conditions of evaporated gas temperature (refrigerant inlet temperature of the water ...
2. Control Functions Control of the cooling cycle Image diagram of 0 (zero) point adjustment If the compressor does not stop in 200 hours Restart after 3 minutes In superheat control Thermo OFF Thermo ON Time If more than 24 hours have passed since the last 0 (zero) point Forced 0 (zero) point adjustment adjustment, then 0 (zero) point adjustment is performed during is performed Thermo OFF. 2.2.3 Overcurrent protection control There is a function to force unload in case that the upper limit of running current of the unit is about to be exceeded. It is possible to change the setting value of overcurrent protection control from the "Service" menu. Activation of overcurrent protection When the running current of the unit reaches the upper limit of running current, the power source capacity load is abated by means of forced unload operation. (See figure below). Load ...
2. Control Functions Control of Master/Slave group 2.3 Control of Master/Slave group 2.3.1 Summary of control of Master/Slave group In addition to the operation as a single chiller unit, this product allows the operation of multiple chiller units as a single heat source system. 1 Features • The function to control the Master/Slave group comes equipped as standard, and thus an exclusive controller is not necessary. • It is possible to connect up to 8 modules to 1 group. •...
2. Control Functions Control of Master/Slave group 2.3.3 Operation method One group composed of multiple modules using the functions to control the number of units is called a "system". 1 Operation Order (Required) Input "System Operation Order" for the chiller unit set as Unit 1. It is also possible to put the system to operation from the "Local system operation switch" installed inside the electrical box. Control board of unit number 1 System operation order switch (*) System System operation Stop Stop order switch *System operation orders are level signals N O T E Pay attention to the fact that it is different from the Run/Stop Order (Terminal No.
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2. Control Functions Control of Master/Slave group 5 Remote Forced Stop (Alarm Reset) / System Recovery Wiring Connect to each chiller unit to force stop of a chiller unit in operation from a remote location, to reset an alarm, or to return to the system a chiller unit that had been excluded from the target of the control of Master/Slave group. (When a chiller unit is stopped because of an alarm, or by a forced stop order, it becomes excluded from the target of the control of Master/Slave group (detached). It is necessary to perform system recovery operation in order to regain the target of the control of Master/Slave group. Also, in case of using it to reset an alarm, it is necessary to enable the optional function (LCD screen setting) "Remote stop reset" at each of the chiller units. Remove the connection System recovery signal between 5 and 6 Forced stop-Alarm reset signal (System recovery (Forced stop signal) signal) (Alarm reset) More than 200ms More than 200ms Relevant Alarm Unit Stop Output Forced stop Alarm reset More than 200ms Detached ...
2. Control Functions Control of Master/Slave group 6 External thermo operation Functions concentrated in unit 1 (master unit) By inputting the signal of the following wiring to unit 1, their settings become enabled for all the chiller units in the same group. • 2-temperature setting • Night shift • Maximum current limitation 2.3.4 Other functions of the control of Master/Slave group 1 About Detachment Modules stopped by an alarm stop or by a forced stop during operation, as well as modules that have lost communication with Master module, become excluded from the target of the control of Master/Slave group. (The same applies for Master module).
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2. Control Functions Control of Master/Slave group 5 Rotation Control When starting up the modules, the modules with the shortest operation time have priority. (Comparison is carried out between units with the same priority order settings, though) When stopping modules, the modules with the longest operation time have priority. If the operation with the minimum number of operating units continues for a long time, forced rotation control is conducted. 6 Priority order setting It is possible to set the desired order of priority in operation, when there are machines with different capacities or when inverter type and continuous control type are mixed together. (Maximum 8 steps) Module Priority order setting In this case, module 1 is operated first, as it has the highest priority, and then a rotation control is performed among modules 2 to 4, which have the same priority order. 7 Function to cancel the control of Master/Slave group It is possible to cancel the functions to control the number of units when simultaneous thermo ON/OFF of all the units is required with without performing the control of Master/Slave group. (Possible in 1-pump systems only) N O T E Setting method: In 1-pump system settings, set both waiting time for effect of addition and waiting time for effect of reduction to "0".
2. Control Functions Control of Master/Slave group 2.3.6 Method for setting and confirmation of operation conditions through the LCD screen Conducts the setting of the control of Master/Slave group and confirmation of operation conditions through the LCD screen. In the case of master In the case of slave unit unit (unit 1) setting (units 2 to 8) setting Set the setting temperature difference (when the 1st water temperature setting is enabled) Set the setting temperature difference (when the 2nd water temperature setting is enabled) If there are more than 5 units con- nected, shift to priority setting screen of units after unit 5 SMGB0097 rev.0 - 07/2015...
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2. Control Functions Control of Master/Slave group [Status screen of the control of Master/Slave group] SMGB0097 rev.0 - 07/2015...
2. Control Functions Run operation 2.4 Run operation 2.4.1 Setting of switches on the setting PCB 1 Pump operation switch By setting the switch ON while the module is stopped, Pump Operation pump operation order is output. 2 Local / Remote switch Switches whether the operation control of the module Local is ...
2. Control Functions Run operation 2.4.2 Operation control of the module 1 In the case of remote control Operation order Confirm that the cold water inlet/outlet valve is fully open Power ON Power ON the pump for cold water circulation Press the “Run” button Operation of pump for cold water circulation starts Operation of compressor starts after compressor delay time has passed Stop order Press the “Stop” button N O T E It is possible to stop the module by means of the stop switch in the Master module, even if it is in remote operation. It is also possible to stop by remote controller switch even during local operation.
2. Control Functions Time chart 2.5 Time chart Continous capacity control (Cooling operation) Power source Run control Control Stop control Protection Pump feedback device Common (Other than above) Thermo Thermo Load Power source display (Main unit) Pump operation Pump operation display (Remote) Operation display (Main unit) Operation display (Remote) Alarm display (Main unit) Alarm display (Remote) 0.6 s 0.6 s Contact for formation of self-holding Electronic expansion valve Compressor 6C Compressor 52C Compressor 42C Alarm display (Remote)
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3. Servicing S e r v i c i n g Index LCD display for Service Menu ....................... 57 General notes ............................65 Cycle components ..........................66 3.3.1 Compressor removal ............................. 66 3.3.2 Overhaul work ............................... 68 3.3.3 Recovering the refrigerant ..........................70 3.3.4 ...
3. Servicing LCD display for Service Menu 3.1 LCD display for Service Menu INPUT SCREEN EXAMPLE (Latest version will be shown) (2 sec.) MAIN SCREEN MENU N O T E This screen will be shown after clicking on the INPUT button. Increases the value. Decreases the value Accepts the value Cancels the operation Pictogram description...
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3. Servicing LCD display for Service Menu Auto expansion valve initialize SERVICE MENU SCREEN (1/2) Superheat setting SERVICE MENU SCREEN (1/2) SMGB0097 rev.0 - 07/2015...
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3. Servicing LCD display for Service Menu Expansion valve manual operation SERVICE MENU SCREEN (1/2) Overcurrent protection setting SERVICE MENU SCREEN (1/2) SMGB0097 rev.0 - 07/2015...
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3. Servicing LCD display for Service Menu Sensor adjust SERVICE MENU SCREEN (1/2) N O T E When a sensor is giving a different value than the actual value, a correction can be set. Example: Real temperature: 25.0º C Thermistor value: 24.0º...
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3. Servicing LCD display for Service Menu Comp Hr Setting SERVICE MENU SCREEN (1/2) N O T E When PCBb is replaced, the previous information related to compressor operating time and number of restarts can be entered form the service menu ...
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3. Servicing LCD display for Service Menu 4-20 mA input SERVICE MENU SCREEN (/2) Continuous control SERVICE MENU SCREEN (/2) Order dissable SERVICE MENU SCREEN (/2) SMGB0097 rev.0 - 07/2015...
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3. Servicing LCD display for Service Menu Default Set SERVICE MENU SCREEN (/2) N O T E • This function resets all data and returns to the initial values, except for the warning and alert history and accumulated operating time-period and operating time of the compressor. •...
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3. Servicing LCD display for Service Menu Delete log SERVICE MENU SCREEN (/2) N O T E This function deletes the stored data concerning to the alarms and cautions. SMGB0097 rev.0 - 07/2015...
3. Servicing General notes 3.2 General notes Before starting to remove any component, take into account the following notes: D A N G E R • Before performing any of the service operations described in this chapter, turn all the main switches off and place security lockers or convenient warning indicators in order to prevent them from turning on accidentally. •...
3. Servicing Cycle components 3.3 Cycle components C A U T I O N • All operations in the refrigerant cycle require to collect the refrigerant. In those cases proceed as explained in”3.3.3 Recovering the refrigerant” D A N G E R Turn OFF all the power source switches and ensure that the module is totally stopped before to get inside.
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3. Servicing Cycle components a. Power supply wiring Power supply cable hose (R, S, T) b. Control wiring connector (QCN4) and Pd and Ps cables (QCN13). Connector QCN13 Connector QCN4 6 Remove the 8 screws fixing the compressor. Un- Right side. From E Box screw the screws fixing the structure (HEX10), as shown in the picture Screws (x8) Left side. From E Box SMGB0097 rev.0 - 07/2015...
8 Use a portable crane or a lift truck to remove the compressor: Introduce the forks under the compressor supports and gently pull backwards. C A U T I O N Compressor is heavy, two persons and a portable crane or similar are required. 3.3.2 Overhaul work Perform the work according to “Semi-hermetic Hitachi Screw Compressor Manual”. When removing a compressor from the refrigeration cycle, high pressure part shall be separated between the projecting part flange of compressor and the upper cover of oil separator. Do not separate high pressure part between the check valve and the projecting part flange of compressor, as collected refrigerant would be spilled out. High-pressure side Disconnect from this part Low-pressure side...
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3. Servicing Cycle components Replacement of oil inside compressor To replace the oil of the compressor proceed as explained below: Collect all refrigerant as described in chapter “3.3.3 Recovering the refrigerant” 2 With a module capacity of 50~75%, perform the operation ensured by suction gas superheat for about 10 minutes, and after recovering the refrigerant as explained in Recovery of refrigerant in the Installation and Operation manual, turn power off and perform the following operation. 3 Oil extraction work Remove the plugs for oil extraction (A-B) at 2 places in screw compressor, and measure the amount of extracted oil. It is not possible to extract the oil from the inside of compressor by just removing one plug, so always remove the 2 plugs. 4 Check of oil strainer Remove the oil strainer cover (C), and confirm the state of the internal oil strainer. In case of finding any abnormality such as dirt or any damage, clean or replace the part as adequate. 5 Oil charge work Attach the oil strainer, the oil strainer cover (C) and the oil extraction plugs (A-B). Connect the charge hose to the check joint (Discharge pressure outlet). Let the oil be absorbed by the charge hose while performing vacuum from the check joint of the suction side. (Charge the amount of oil that had been extracted in the above point "Oil extraction work") 6 After completing the operation, perform vacuum again and charge refrigerant (check in the Installation and Operation Manual, Maintenance chapter). N O T E •...
3. Servicing Cycle components 3.3.3 Recovering the refrigerant With a vacuum pump a. Make sure that the system is powered off. b. Completely close the stop valve. c. Connect the vacuum pump system to the check joints of the refrigerant line. d. Check for any leakage at the flare nuts connections. e. Operate the vacuum pump for 1 or 2 hours, or until the pressure decreases lower than a pressure of 756 mmHg in vacuum. f. Use a scale to take note of the quantity of refrigerant charged into the tank in order to provide the same quantity when charging the circuit. Recovery tank RCME-CLH unit Vacuum pump Scale Manifold gauge 3.3.4 Replacement of the cooler 1 Unscrew the 4 screw of the refrigerant inlet pipe flange and the 4 screws of the outlet refrigerant ...
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3. Servicing Cycle components 2 Remove the 2 Victaluic connections from the water connections. Victaulic connections 3 Screw eyebolts to both sides of the cooler to the bolts for that purpose. Fasten a textile belt to proceed to lift the cooler. C A U T I O N Do not never use chains or metallic ropes to lift the cooler as they can damage it.
3. Servicing Cycle components 3.3.5 Replacement of expansion Valve 1 Collect the refrigerant as explained in section “3.3.3 Recovering the refrigerant” 2 Firmly hold the coil of the expansion valve and Expansion valve coil pull out upward. It is easier to remove the ex- pansion valve coil if it is rotated while pulling it Expansion valve 3 Remove the brazed parts using a blowtorch and ...
3. Servicing Cycle components 3.3.6 Filter drier There are two possible main maintenance operations to do with the filter drier: the substitution of the inner core due to its adsorption saturation or the substitution of the whole unit due to some damage. Solid core substitution Follow the next steps in order to proceed to replace the inner core of the filter drier: 1 Remove the 8 screws (1) that fixes the top cov- er (2). Carefully, remove the spring (3), the top cover gasket (4), the wing nut (5) and the lock washer (6). 2 Retire the top plate (7) and then the felt gasket 3 Take the solid core (9) out and proceed to the replacement. 4 When reassembling after replacing the solid core, perform the procedure in the reverse order ...
3. Servicing Cycle components 3.3.7 Replacement of the check valve The best way to replace the check valve is disassembling it from its location and later, unbrazing it from the pipes. Follow the next steps for a correct disassembling: 1 Remove the thermistor (THMd). Thermistor (THMd) a. Cut and remove the plastic bands that fixes the insulation of the discharge pipe thermis- tor (THMd). b. Loosen the screw fixing the thermistor. c. Remove the thermistor. Plastic bands Screw 2 Remove the 4 screws of the inlet pipe flange. 3 Remoce the fixing clamp. Inlet pipe flange 4 Screws Fixing clamp 4 Remove the 4 screws that fixes the check valve Allen screw (x4) to its location at the discharge outlet. 5 Remove the 4 Allen screws that fixes the cover of the check valve.
3. Servicing Cycle components 3.3.8 Replacement of the stop valve (with check joint) 1 Remove the brazed parts using a blowtorch and Stop valve Check joint previously cooling the pipe side and the stop valve unit with wet cloth in order to avoid braz- ing material enter inside the pipes. Brazed parts 3.3.9 Replacement of the high pressure switch (PSH) 1 Disconnect the cables (9 and 10 of the Pressure High pressure switch (PSH) Screw switch from the E-box of the compressor termi-...
3. Servicing Cycle components 3.3.12 Replacement of the pressure sensor (PS) 1 Disconnect the cables (7 and 8 of the pressure sensor form the E-box of the compressor termi- nal board). 2 Unscrew the sensor and proceed to its replace- ment 3 When reassembling proceed in reverse order than removing. Pressure sensor (PS) 3.3.13 Replacement of the pressure relief valve 1 Remove the relief valve unscrewing the valve with a spanner.
3. Servicing Cycle components 3.3.16 Repalacement of the thermistor (Suction, THMs) 1 Remove the insulation of the suction pipe. 2 Loosen the screw fixing the thermistor. 3 At the E-box, disconnect the CN27 contact (or the Faston terminals 7 and 8 of multiple contact QCN3) 4 Remove the thermistor. Thermistor THMs 5 When reassembling after replacing the thermis- tor (THMd), perform the procedure in the re- verse order than removing. Screw Suction pipe 3.3.17 Replacement of the thermistor (Discharge, THMd)
3. Servicing Cycle components 3.3.19 Replacement of the thermistor (Evaporation, THMe) 1 Cut and remove the plastic bands that fixes Thermistor THMe the insulation of the discharge pipe thermistor (THMe). 2 Loosen the screw fixing the thermistor. 3 At the E-box, disconnect the CN26TD contact (or the Faston terminals 9 and 10 of multiple Evaporation pipe contact QCN3) 4 Remove the thermistor.
3. Servicing Cycle components 3.3.21 Thermistor (Cooler water outlet, THMwo2) 1 Unscrew the nut of the cable gland 2 Gently pull the sensor wiring upwards. Thermistor (THMwo2 C A U T I O N Sensor sheath is full of sealing silicone. Use gloves and eye goggles for protection in order to avoid possible injuries to eyes and skin.
3. Servicing Electrical components 3.4 Electrical components 3.4.1 The E-box 1 Turn the main switch off. If main switch is not turned off it is not possible to open the door. 2 Open the E-box door using the provided key for electrical box cam locks. N O T E When the right door is open, the left one may eas- ily open by pulling backwards.
3. Servicing Electrical components 3.4.3 Replacement of lamps and push buttons Lamps and push buttons are placed in the left door of the E-box. To replace anyone of the open the E-box until get access to the left door and proceed as follows: Replacement of the lamps 1 Remove the wirings connected to the lamp hold- Phillips screws (x2) er using a Phillips screwdriver. 2 Remove the nut fixing the lamp holder to the E- box door. 3 Replace the lamp and proceed to assembly in reverse order than removing Replacement of the push buttons 1 Remove the wirings connected to the push but- Phillips screws ...
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3. Servicing Electrical components Second level components PCBc Electric transformer PCBa Fuses Relays Access to second level electric components To have acces to the main control and power components of the unit into the E-box, follow the next steps: Fixation assembly 1 Firmly pull the plate 2 Pull until release the fixation 3 Keep pulling until the plate is in hor- assembly izontal at the top SMGB0097 rev.0 - 07/2015...
3. Servicing Electrical components Clamp lever 4 Push the clamp lever to fix the plate in horizontal position at the top. 3.4.5 Removal of the PCB’s PCBa 7- segment display Pressure switches (PSW) Plastic holder PSW1, PSW2 Switches (SW) Plastic holder SW1, SW2 Pressure switches (PSW) PSW3, PSW4 PSW5 PSW6 a. Remove the PCB by press- ing the expanded part of the 4 Rotary switches ...
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3. Servicing Electrical components PCBc Plastic holder a. Remove the PCB by pressing the expanded part of the 4 plastic holders, using long-nose pliers, as shown in the picture below. b. Pull the PCB out from the PCB plate. Plastic holder PCBd Plastic holder a. Remove the PCB by pressing the expanded part of the 4 plastic holders, using long-nose pliers, as shown in the picture below.
3. Servicing Electrical components 3.4.6 Transformer (TF1) To have access to electrical transformer TF1, follow the steps described in “Second level components” in chapter “3.4.4 Access to electrical components” 1 Remove all the wirings corresponding to TF1. As shown in the image. 2 Remove the 2 screws that fix the TF1 to the plate to CN1 to CN2A Screws (x2) 3.4.7 Transformers (TF2, TF3, TF4) To remove any of the TF2, 3 or 4, simply open left door of the E-box, and follow the next steps according to the transformer to remove. 1 Remove all the wirings corresponding to the transformer Screws to remove. (As shown the image) 1 Remove the 2 screws that fix the transformer to the plate. to PCN239 to CN56 to PCN238...
3. Servicing Electrical components 3.4.9 Contactors (CMC, CMCD, CMCS) C A U T I O N In RCME-WH units, contactors are used for the delta start automation. Take note where each cable is connected in order to avoid any mistake when reassembling. An incorrect connection may result in a compressor damage. To proceed to the removal of contactors, follow the steps described below.
3. Servicing Electrical components 3.4.11 Fuses (PFC) Removal of the fuses Once the damaged fuse is detected proceed to its replacement following the next steps: 1 Open the plastic cover that protects the fuse 2 Take the fuse puller tool. a. Push the red button. b. Slide the fuse puller tool up or down. c. Pull the fuse puller backwards. 3 On the damaged fuse, put the fuse puller tool and firmly push to fix the tool on the fuse. Once the fuse is trapped pull the tool backwards. SMGB0097 rev.0 - 07/2015...
3. Servicing Electrical components Removal of the PFC fuse holder In case the fuse holder has suffered any damage and replacement is needed, follow the step described below. 1 Pull the fuse housing backwards. 2 Remove the Hex screws and wiring. PFC3-5 PFC1-1 PFC2-3 3 Remove the Phillips screws and replace the fuse holder. 2 Phillips 3+3 Flat screw driver screwdriver or 13mm spanner PFC1-2 PFC2-4 PFC3-6 4 When reassembling, perform the procedure in the reverse order than removing. 3.4.12 Relays To remove any of the relays, proceed as follows: 1 Detach the Faston terminal from its connection Phillips screws (x2) 2 Remove the 2 screws fixing the relay to the plate. 3 Replace the relay.
3. Servicing Electrical components 3.4.13 Main Switch To remove the main switch, follow the next steps 1 Turn the switch of in order to be able to open the E box MIT/L3 MIS/L2 MIR/L1 door 2 Open the E-box door. 3 Remove the wiring. Unscrew the nuts from the terminals 4 flat screws with a 13 mm spanker. 4 Remove the 4 screws with a flat screwdriver. 5 When reassembling, proceed in the reverse order than removing. MIT/L3 SMGB0097 rev.0 - 07/2015...
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4. Troubleshooting T r o u b l e s h o o t i n g Index 4.1 Inspection of power source and connections ..................92 4.2 Inspection of PCB..........................93 4.3 Confirmation of operating value of protection devices and automatic operation devices ..... 93 Protection control function ........................94 Caution indication ..........................95 Summary of fault diagnosis ........................96 4.7 ...
4. Troubleshooting Inspection of power source and connections 4.1 Inspection of power source and connections In case that there is any abnormality in the activation of the chiller unit, first perform the following check. Check Item Inspection Method Examine the secondary voltage of the breaker and the passage of electric Is the power source breaker or the fuse broken? current through the fuse with a tester. Remove the connection of the secondary side of the transformer, and measure the (AC) voltage with a tester. Confirm that the voltage shown on the transformer is being output. Internal transformer of the unit White 30.0 V Blue At rated 230V 15.5 V load Blue Orange 16.1 V Orange P C N2 A (C P U ...
4. Troubleshooting Inspection of PCB 4.2 Inspection of PCB The standard setting of switches, etc., on the PCB is as Control System chapter in the Installation and Operation Manual. Confirm that they are being set correctly. 4.3 Confirmation of operating value of protection devices and automatic operation devices The activation values of protection devices are as follows: Name Operating value 2.02MPa High pressure (Manual recovery) 0.13MPa or below Low/High pressure interruption device (Electronic control) Low pressure 0.01MPa or below (Electronic control) 230V Type 400V Type RCME-40WH 100A Overcurrent relay (for compressor) RCME-50WH 130A RCME-60WH 160A...
4. Troubleshooting Protection control function 4.4 Protection control function This Chiller unit is provided with protection control functions to release abnormal statuses before reaching alarm because of abnormality occurrence. Name of Display protection control Conditions for Operation Description of Control Release conditions (Compressor frequency control) Segment I1 < Setting I1 > Setting value×0.97 Overcurrent value×0.95 Load up prohibition Current protection...
4. Troubleshooting Caution indication 4.5 Caution indication In case of occurrence of sensor abnormalities while the chiller unit is stopped, or of abnormalities that would not trigger an alarm stop, a warning is output to the outside and warning display is conducted. The mark is shown on the LCD Screen during warning external output. The content of warning is shown in the table below. Warning icon is Spanner mark shown Caution is illuminated Warning contents display Yellow during occurrence of warning Warning indication Contents of warning Notes When compressor is stopped while Freeze prevention Water temperature is 1ºC or below the chiller unit is in operation *1 Inlet water temperature thermistor Disconnection or short-circuit of the inlet water When the chiller unit is stopped *2 abnormality (CN4) temperature thermistor Outlet water temperature thermistor ...
4. Troubleshooting Summary of fault diagnosis 4.6 Summary of fault diagnosis 1 Alarm In case of an alarm, the alarm light at the remote side and the alarm light on the display PCB of the main unit become illuminated, and the background of the LCD Screen of the main unit side becomes red. In case of stopping a unit in which an alarm has occurred, perform a stop operation instead of turning power OFF. Alarm occurrence LCD Display: Shows the details Remote operation display lamp: Lit ON (Background colour turns red) Alarm display lamp: Lit ON Remote alarm display lamp: Lit ON Faulty PCB segment: Abnormality code (Remote side) Stop control Checked the details of abnormality in “Status” screen? Abnormality code is shown in “History” screen Check details of abnormality of LCD part Check data stored immediately before alarm occurrence Processing position of the alarm part N O T E •...
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4. Troubleshooting Summary of fault diagnosis 2 Caution Abnormalities that are not a hindrance for operation, but could lead to serious failure if neglected, are output as warnings. Caution occurrence Remote caution display lamp: Lit ON LCD Display: Show mark (Remote side) Confirmation of details of abnormality in “Status” screen Processing position of the caution part 3 Troubleshooting of the LCD Screen In case that the screen does not proceed further from the display of the following figure on the below upon power ON, it is because transmission between the LCD Screen and the CPU PCB is not taking place. • Check wiring between the LCD Screen and the CPU PCB • Check wiring between the CPU PCB and transformer Transition of the LCD Screen upon power ON SMGB0097 rev.0 - 07/2015...
4. Troubleshooting Method for fault diagnosis 4.7 Method for fault diagnosis Summary of checks for fault diagnosis Check the power Is 400V supplied to the unit? source switch Is 230V supplied to Is fuse broken? Replace fuse transformer (TF ) primary side? Is R phase or S phase Replace transformer failure? Wiring check.
4. Troubleshooting Troubleshooting by alarm code 4.8 Troubleshooting by alarm code C1-H1 Alarm code High Pressure Switch Alarm stop reason Discharge pressure (Pd) increases up to 2.02MPa, activating high pressure switch (63H). PCB monitoring position PCBd (I/O PCB) PCN204 (High pressure interruption device (63H)) High pressure Operation control results Press the reset button of switch (63H) is being in immediate alarm high pressure switch reset The connection and insertion of connector Revision of connections PCN204 to PCBd (I/O PCB) are correct Remove the wires Check of high pressure inserted in PCN204 switch (63H) (Internal ...
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4. Troubleshooting Troubleshooting by alarm code C1-h1 Alarm code Discharge pressure over-increase Alarm stop reason Discharge pressure (Pd) becomes higher than 1.92MPa for more than 10 seconds. (Enabled for electronic control) N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control is performed until the second one. (Compressor stops, and restarts automatically after 3 minutes) Retry indication LCD: By touching “Inspection”, “Pd Retry” is shown in “No.1 Cycle”. ...
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4. Troubleshooting Troubleshooting by alarm code C1-L1 Alarm code Low pressure interruption control Alarm stop reason Suction pressure (Ps) becomes lower than 0.14MPa for more than 90 seconds. (Electronic control, only enabled in cooling) N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control is performed until the second one. (Compressor stops, and restarts automatically after 3 minutes) Retry indication LCD: By touching “Inspection”, “Ps Retry” is shown in “No.1 Cycle”. ...
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4. Troubleshooting Troubleshooting by alarm code C1-51 Alarm code Compressor overcurrent Alarm stop reason The running current for one compressor is increased above the value for activation of the overcurrent relay, thus activating the (thermal) overcurrent relay. PCB monitoring position PCBd (I/O PCB) PCN206 Operation control Overcurrent relay results in immediate Press the reset button of (51C1) is being reset activation of alarm the overcurrent relay Remove the wiring inserted into Check of wiring connector PCN206 on (disconnection) (I/O PCB) and mesure conductivity. Is there conductivity? Check of overcurrent relay (internal disconnection) Check of PCB (I/O PCB) I/O PCB is normal Overcurrent relay ...
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4. Troubleshooting Troubleshooting by alarm code C1-61 Alarm code Discharge gas temperature increase Alarm stop reason 1 Temperature of refrigerant discharged from Compressor rises up to 130ºC for more than 1 minute. 2 During count of point 1, temperature rises even more, above 140ºC for more than 3 seconds. N O T E In the case of point 1, it causes alarm stop with 3 occurrences in 90 minutes. Retry control is performed until the second one.
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4. Troubleshooting Troubleshooting by alarm code C1-71 Alarm code Compressor Internal Thermo Activation Alarm stop reason Compressor motor overheats, activating internal thermo. (Activation point: 115ºC) N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control until the second one (Compressor stops, and restarts automatically once de thermostat returns to a normal operation temperature) Retry indication LCD: By touching “Inspection”, “49C Retry” is shown in “No.1 Cycle”. ...
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4. Troubleshooting Troubleshooting by alarm code C1-91 Alarm code Cooler Inlet Decrease Alarm stop reason Inlet refrigerant temperature of the heat exchanger (Te) becomes lower than -6.5ºC for more than 3 seconds. (only enabled in cooling). N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control is performed until the second one. (Compressor stops, and restarts automatically after 3 minutes) Inlet refrigerant temperature of the heat exchanger (Tr) becomes lower than -35ºC for more than 10 seconds. (only enabled ...
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4. Troubleshooting Troubleshooting by alarm code C1-t1 Alarm code Suction gas decrease Alarm stop reason Temperature of refrigerant suctioned into compressor (Ts) falls below -5ºC for more than 10 seconds. N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control is performed until the second one. (Compressor stops, and restarts automatically after 3 minutes) Retry indication LCD: By touching “Inspection”, “Ts Retry” is shown in “No.1 Cycle”. ...
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4. Troubleshooting Troubleshooting by alarm code 13-13 Alarm code Freeze protection · Freeze prevention C1-13 Alarm stop reason Cold water temperature falls below 1ºC. PCBc (CPU PCB) PCN12 short line is disconnected N O T E • In case of detection by inlet water temperature thermistor or in case of detection by disconnection of PCN12 short line “13-13” • In case of detection by outlet rear thermistor (for protection) or outlet water temperature thermistor (for control) “C1-13” PCB monitoring position PCBc (CPU PCB) CN4 (Inlet water temperature thermistor (Twi)), CN5 (Outlet water temperature thermistor (for water ...
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4. Troubleshooting Troubleshooting by alarm code 14-14 Alarm code Hot Water Over-Increase C1-14 Alarm stop reason Outlet water temperature exceeds 62ºC during compressor operation. PCBc (CPU PCB) PCN13 short line is disconnected N O T E “14-14” in case that PCN13 short line is disconnected “C1-14” in case of detection by outlet water temperature thermistor PCB monitoring position PCBc (CPU PCB) CN5 (Outlet water temperature thermistor Two1(for water temperature control)) PCBc (CPU PCB) PCN13 (Short line) Outlet water ...
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4. Troubleshooting Troubleshooting by alarm code C1-21 Alarm code Cooler inlet THM abnormality (CN29) Alarm stop reason Thermistor for detection of inlet refrigerant temperature (Te) at the heat exchanger indicates an abnormal value. PCB monitoring position PCBd (I/O PCB) CN29 (Cooler inlet thermistor (Te)) N O T E Refer thermistor characteristics chapter The connection and insertion of connector Correction of CN29 on PCBd (I/O PCB) connections are correct Remove the connectors and measure thermistor resistance. Replace thermistor Is resistance value normal? Replace PCBC (I/O PCB) ...
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4. Troubleshooting Troubleshooting by alarm code C1-24 Alarm code Liquid THM abnormality (CN24) Alarm stop reason Thermistor for detection of heat exchanger outlet (Tl) temperature indicates an abnormal value. PCB monitoring position PCBd (I/O PCB) CN24 (Liquid thermistor (Tl)) N O T E Refer thermistor characteristics chapter The connection and insertion of connector Correction of connections CN24 on PCBd (I/O PCB) are correct Remove he connectors and measure thermistor resistance. Replace thermistor Is resistance value normal? Replace PCBd (I/O PCB) ...
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4. Troubleshooting Troubleshooting by alarm code C1-26 Alarm code Suction Gas THM Abnormality (CN27) Alarm stop reason Thermistor for detection of temperature of gas suctioned (Ts) by compressor indicates an abnormal value. PCB monitoring position PCBd (I/O PCB) CN27 N O T E Refer thermistor characteristics chapter. The connection and insertion of connector Correction of connections CN27 on PCB (I/O PCB) are correct Remove the connectors and Replace thermistor measure thermistor resistance. Is resistance value normal? Replace PCB (I/O PCB) ...
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4. Troubleshooting Troubleshooting by alarm code C1-27 Alarm code Discharge Pressure Sensor Abnormality (CN31) Alarm stop reason Discharge pressure sensor (Pd) of compressor indicates an abnormal value. PCB monitoring point PCBd (I/O PCB) CN31PD (Discharge pressure sensor (Pd)) N O T E Refer pressure sensor characteristics chapter. The connection and insertion of connector Revision of connections CN31Pd on PCBd (I/O PCB) are correct DC5V is being supplied between pin 1 and pin Replace PCBd (I/O PCB) 3 of connector CN31Pd on PCBd (I/O PCB) Is the voltage between pin 2 and pin 3 of connector CN31Pd on PCBd (I/O PCB) Replace PCBd (I/O PCB) lower than DC0.5V or higher than DC4.5V when discharge pressure sensor is connected? Elimination of the factors There is clogging inside the connection pipe of for clogging inside the discharge pressure sensor pipe Replacement of discharge pressure ...
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4. Troubleshooting Troubleshooting by alarm code C1-28 Alarm code Suction pressure sensor abnormality (CN32) Alarm stop reason Suction pressure sensor (Ps) of compressor indicates an abnormal value. PCB monitoring position PCBd (I/O PCB) CN32PS (Suction pressure sensor (Ps)) N O T E Refer pressure sensor characteristics chapter. The connection and insertion of connector Revision of connections CN32Ps on PCBd (I/O PCB) is correct DC5V is being supplied between pin 1 and pin Replace PCBd (I/O PCB) 3 of connector C32Ps on PCBd (I/O PCB) Is the voltage between pin 2 and pin 3 of connector CN32Ps on PCBd (I/O PCB) Replace PCBd (I/O PCB) lower than DC0.5V or higher than DC4.5V when discharge pressure sensor is connected? Elimination of the factors There is clogging inside the connection pipe of for clogging inside the discharge pressure sensor pipe Replacement of discharge pressure ...
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4. Troubleshooting Troubleshooting by alarm code C1-39 Alarm code Current sensor abnormality (CN36) Alarm stop reason Current sensor indicates an abnormal value (CT). PCB monitoring position PCBd (I/O PCB) CN36 (Current sensor (CT)) The connection and insertion of connector Revision of connections CN36 on PCBd (I/O PCB) is correct The connection and insertion of the connector of current sensor on the body of the Revision of connections unit are correct The power wiring of compressor passes Revision of wiring through the current sensor There are no changes to the characteristics Check of current sensor of the current sensor (The characteristics of the specifications. Check of current sensor differ in standard specification and DIP switches special voltage specification) Replacement of current sensor C1-03 Alarm code...
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4. Troubleshooting Troubleshooting by alarm code 03-03 Alarm code CPU—I/O transmission Alarm stop reason Transmission is not performed correctly between CPU PCB(PCBc) and I/O PCB (PCBd). PCB monitoring position PCBc (CPU PCB) CN1~PCBd (I/O PCB) CN21 (H-LINK transmission) DSW1-5,6# of Set DSW correctly and PCBa (Setting PCB) reactivate power supply are correctly set DSW2-1,2# of Set DSW correctly and PCBd (I/O PCB) are reactivate power supply correctly set Terminal resistance correctly Set DSW correctly and set. Either DSW8-1# of ...
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4. Troubleshooting Troubleshooting by alarm code 01-01 Alarm code Startup Circuit Failure Alarm stop reason Startup circuit fails to self-hold after reception of operation signal, or upon automatic recovery from instant power failure. PCB monitoring position PCBc (CPU PCB) PCN15,PCN17 The connection and insertion of connector Revision of connections PCN15 on PCBc (CPU PCB) is correct The connection and insertion of connector Revision of connections PCN17 on PCBc (CPU PCB) is correct The insertion of the terminal of relay XR is Revision of connections correct Replace relay XR 05-05 Alarm code Reverse/Open Phase Alarm stop reason Power source connected locally is connected in reverse or in open phase. ...
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4. Troubleshooting Troubleshooting by alarm code 11-11 Alarm code Inlet water temperature abnormality (CN4) Alarm stop reason Thermistor for detection of inlet water temperature (Twi) indicates an abnormal value. PCB monitoring position PCBc (CPU PCB) CN4 (Inlet water temperature thermistor (Twi)) N O T E Refer thermistor characteristics chapter. The connection and insertion of the connector Revision of connections CN4 on PCBc (CPU PCB) is correct Remove the connector and measure the resist- Replacement of thermistor ance value. Is the resistance value normal? Replacement of PCBc (CPU PCB) 12-12 Alarm code Outlet water temperature THM abnormality (CN5) C1-12 Alarm stop reason Thermistor for detection of outlet water temperature (for water temperature control Two1) indicates an abnormal value.
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4. Troubleshooting Troubleshooting by alarm code 2C-2C Alarm code Water supply header temperature thermistor abnormality. (CN13) Alarm stop reason Thermistor for detection of indicates an abnormal value. water supply header temperature The connection and insertion of connector Revise connections CN13 on PCBc (CPU PCB) are correct Remove the connectors and measure thermistor Replace thermistor resistance. Is resistance value normal? Replace PCBc (CPU PCB) 2d-2d Alarm code Water return header temperature thermistor abnormality. (CN14) Alarm stop reason Thermistor for detection of ...
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4. Troubleshooting Troubleshooting by alarm code SP-SP Alarm code Pump Interlock Abnormality Alarm stop reason • Pump operation feedback signal turns OFF while Pump operation signal (Y52P1) is ON. N O T E It is enabled after establishment of interlock. • Pump operation feedback signal is not input within the time defined at "Waiting time for pump feedback" in optional functions. Or in case that Cold (hot) water inlet/outlet temperature differential exceeds 1.5ºC, and water conduction conditions have not been confirmed. PCB monitoring position PCBc (CPU PCB) PCN5 (PCB is normal) The overcurrent 230V are being supplied between pin 1 and pin relay for the pump Examination of pump lock 3 of connector PCN5 on PCBc (CPU PCB) (51P) is activated Examination of pump...
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4. Troubleshooting Troubleshooting by alarm code 40-40 Alarm code Incorrect Setting Alarm stop reason The settings of the DIP switch are unrecognisable. The DIP switches of each PCB are set Set DIP switches correctly correctly and reactivate power The contacts of DIP The DIP switch settings are recognized switches on the setting as correct by switch setting check “SERVICE PCB are defective. MENU” Replace setting PCB Check PCB (CPU PCB) 40-40 Alarm code Incorrect operation Alarm stop reason A forbidden operation is performed during operation. Changed settings from Conducting this operation ...
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4. Troubleshooting Troubleshooting by alarm code 40-40 Alarm code Incorrect Setting of control of Master/Slave group Alarm stop reason The settings of the DIP relative to the function to control the number of units switch are unrecognisable. PCB monitoring position PCBa (Setting PCB) DSW3-1~3, DSW6-1~3 PCBa (Setting PCB) RSW1 The rotatory switches of PCBA (Setting PCB) Set the number of of master module are correctly set connected units correctly The DIP switches on PCBA (Setting PCB) of Set the DIP switches each module are correctly set correctly The H-LINK transmission wiring between master module and slave modules is Check wiring disconnected or connected wrongly Check PCBc (CPU PCB)
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4. Troubleshooting Troubleshooting by alarm code 40-40 Alarm code Transmission abnormality (Miswiring) Alarm stop reason The connection of wiring for transmission between modules (Transmission line between master and slaves) and the transmission wiring for connection of group controller is mixed. Retry indication No retry PCB monitoring position PCBc (CPU PCB) CN2 (Transmission port between modules) PCBc (CPU PCB) CN300 (Transmission port for group controller) The connection of Connect transmission wiring transmission wiring is correctly correct Check PCBc (CPU PCB) 6E-6E Alarm code...
4. Troubleshooting Analysis and countermeasure of abnormalities 4.9 Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Power failure Measure voltage with a tester Wait for power return Power is not coming in Check main power switch Turn main power switch ON Replace fuse after correcting Short circuit between wires Check wire coating damage short circuit Power Ground fault (Earth) of Replace fuse after correcting Measure insulation resistance source wiring ground fault...
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4. Troubleshooting Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Bad connection of wiring Check connection with a tester Correct wiring connection Pump is Faulty PCB operating, but Check connection with a tester Faulty PCB Replace PCB compressor is Check PCB with self-diagnosis not operating. Operation is possible by activation Replace remote control Failure of remote control switch from the main unit side switch Bad connection of wiring Check connection with a tester Correct wiring connection Faulty PCB Faulty PCB Defective thermistor Measure resistance of thermistor...
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4. Troubleshooting Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Malfunction of check valve Replace check valve Suction gas temperature is Clogging of expansion valve Remove clogging too high (excessive super Discharge heat) gas over- increase is Malfunction of the expansion valve Replace expansion valve activated Failure of thermistor for Replace thermistor for Check connection with a tester control of discharge gas control of discharge gas Replace electromagnetic...
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4. Troubleshooting Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Set the machine to a larger Load bigger than cooling capacity. Calculate heat load. capacity Gas leakage or insufficient Charge correct refrigerant volume Check super heat amount of refrigerant after checking gas leakage Suction Clogging of expansion valve Check for clogging Remove clogging pressure is Malfunction of the expansion Check operation of expansion too low. Replace expansion valve valve valve Check whether there is temp ...
4. Troubleshooting Thermistor characteristics 4.10 Thermistor characteristics The thermistor is installed in this product to detect the cycle temperature such as water temperature (inlet-outlet of water side heat exchanger), and outlet liquid refrigerant temperature from the heat exchanger. The thermistor temperature characteristics are shown in the below figures: 4.10.1 Thermistor temperature characteristics (All temperature except discharge gas) 19,3 14,4 10,9 2,5 2,0 1,6 1,3 1,1 0,9 0,7 0,6 0,5 0,4 0,4 0,3 -20 -15 -10 -5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 17B18890 Temperature (ºC) 4.10.2 Thermistor temperature characteristics for discharge gas temperature...
4. Troubleshooting Pressure sensor characteristics 4.11 Pressure sensor characteristics 4.11.1 High-pressure sensor (Mpa) 4.11.2 Low-pressure sensor (0.3) (-0.1) (Mpa) 4.12 Procedures for trouble The following table shows efficient checking procedures for trouble. Fault Possible Cause Check/Corrective Action 1. C heck the pump contactor. Repair or replace, if necessary. Interlock Circuit for Chilled Water Pump is Open 2. Check for the faulty pump. Compressor does not Remove the causes, and reset the “ON” button. operate Electrical Protective Devices Are Tripped. See the following causes.
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4. Troubleshooting Procedures for trouble The following table shows efficient checking procedures for trouble. Fault Possible Cause Check/Corrective Action Check for excessively low setting of the chilled Excessively Low Chilled water Outlet Temperature water setting knob. Compressor stops Check for malfunction of the thermistor. Replace, if Defective Thermistor on freeze protection necessary. control. Shortage of Chilled Water Flow Check the rotation of the pump. Air in water Circuit Purge air. Check the power supply line and contactor. Repair, High or low voltage, single-phase or phase imbalance if necessary. Compressor stops on Excessive Superheat Check for refrigerant leakage. internal thermostat Check the contact of the internal thermostat during or discharge gas Defective Element the cold condition.
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Hitachi Air Conditioning Products Europe, S.A.U. Ronda Shimizu, 1 - Políg. Ind. Can Torrella 08233 Vacarisses (Barcelona) España Hitachi certifies that our products have met EU consumer safety, health and environmental requirements. Hitachi Air Conditioning Products Europe, S.A.U. is certified with:...