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Hitachi RCUE40AG2 Service Manual

Air cooled water chillers, cooling only and heat pump, cooling capacity 106/112 kw - 585/556/1030 kw
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AIR COOLED WATER CHILLERS
(COOLING ONLY AND HEAT PUMP)
Service Manual
RCUE40AG2-400AG2
Cooling capacity 112 kW - 1030 kW
RHUE40AG2-240AG2
Cooling capacity 106 kW - 585 kW
Heating capacity 110 kW - 556 kW

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Summary of Contents for Hitachi RCUE40AG2

  • Page 1 AIR COOLED WATER CHILLERS (COOLING ONLY AND HEAT PUMP) Service Manual RCUE40AG2-400AG2 Cooling capacity 112 kW - 1030 kW RHUE40AG2-240AG2 Cooling capacity 106 kW - 585 kW Heating capacity 110 kW - 556 kW...
  • Page 3 Specifi cations in this manual are subject to change without notice in order that HITACHI may bring the latest innovations to their customers. Whilst every effort is made to ensure that all specifi cations are correct, printing errors are beyond Hitachi’s control; Hitachi cannot be held responsible for these errors.
  • Page 5 Contents C o n t e n t s Product range and specifi cations Test run Electrical wiring diagrams Control system Troubleshooting Maintenance pag. 3 SMGB0003 rev.0 - 01/2007...

  • Page 7: Table Of Contents

    Contents Content Product range and specifi cations ................11 1.1. General data for RCUE40~400AG2 ..................... 12 1.2. General data for RHUE40~240AG2 ..................... 16 Test run ........................19 2.1. Check before test run ........................... 20 2.2. Test run method and check ........................22 2.3.
  • Page 8 Contents Content (Cont.) Troubleshooting .......................83 5.1. Initial check ............................84 5.2. Troubleshooting ..........................108 5.3. Analysis and countermeasure of abnormal running ................141 5.4. Thermistor characteristics ........................145 Maintenance ......................149 6.1. Maintenance criteria ........................... 150 6.2. Maintenance criteria of Screw Compressor..................152 6.3.
  • Page 9 Please check, according to the model name, which is your air conditioner type and how it is abbreviated and referred to in this service manual. CODIFICATION AIR COOLED WATER CHILLERS -SCREW TYPE Indication Indication Indication Model Model Model Model Indication code code code code RCUE40AG2 8E041072 RCUE100AG2 8E101072 RCUE180AG2 8E181072 RCUE280AG2 8E281072 RCUE50AG2 8E051072 RCUE120AG2 8E121072 RCUE210AG2 8E211072 RCUE320AG2...
  • Page 10 Contents AIR TO WATER HEAT PUMP CHILLERS -SCREW TYPE Model Indication code Model Indication code Model Indication code RHUE40AG2 9E041072 RHUE100AG2 9E101072 RHUE180AG2 9E181072 RHUE50AG2 9E051072 RHUE120AG2 9E121072 RHUE210AG2 9E211072 RHUE60AG2 9E061072 RHUE140AG2 9E141072 RHUE240AG2 9E241072 RHUE70AG2 9E071072 RHUE160AG2 9E161072 RHUE80AG2 9E081072 R H U E 6 0 A G 2...
  • Page 11 Contents REMOTE CONTROL DEVICES LIST Name Description Indication Code Figure CSC-5S Central Station 60291050 PSC-5T Seven Day Timer 60291052 REMOTE CONTROL DEVICES ACCESSORIES LIST Name Description Indication Code Figure PSC-5HR H-Link Relay 60291105 CENTRALISED CONTROLS LIST (Interfaces) Name Description Indication Code Figure HARC70-CE1 60559055...
  • Page 12 Contents CENTRALISED CONTROLS (Interfaces) ACCESSORIES LIST Name Description Indication Code Figure PM001-CT200 7E891930 Current Transformer Accessory (Power Meter Option Accessory for CSNET WEB) PM001-CT400 7E891931 Current Transformer Accessory 1000A PM001-CT1000 (Power Meter Option 7E891932 Accessory for CSNET WEB) Communication Set PM001-GW (Power Meter Option 7E891933...

  • Page 13: Product Range And Specifications

    P r o d u c t r a n g e a n d s p e c i f i c a t i o n s This chapter provides you with a fast review of the most important general data of the Air cooled water chillers and Air to water heat pump chillers of HITACHI. Content Product range and specifi...

  • Page 14: General Data For Rcue40~400Ag2

    Product range and specifications 1.1. General data for RCUE40~400AG2 MODEL RCUE40AG2 RCUE50AG2 RCUE60AG2 RCUE70AG2 Cooling Capacity Total Power input 36.4 42.7 52.3 59.8 3.08 3.04 2.98 2.98 Height 2.430 2.430 2.430 2.430 Outer Dimension Width 1.900 1.900 1.900 1.900 Depth 2.150...
  • Page 15 Product range and specifications MODEL RCUE80AG2 RCUE100AG2 RCUE120AG2 RCUE140AG2 Cooling Capacity Total Power input 69.6 85.4 104.5 119.6 2.96 3.04 2.99 2.98 Height 2.430 2.430 2.430 2.430 Outer Dimension Width 1.900 1.900 1.900 1.900 Depth 2.750 4.050 4.050 5.250 Cabinet colour Natural Grey Net weight 1.820...
  • Page 16 Product range and specifications MODEL RCUE160AG2 RCUE180AG2 RCUE210AG2 RCUE240AG2 Cooling Capacity Total Power input 139.1 156.8 179.4 208.7 2.96 2.98 2.98 2.96 Height 2.430 2.430 2.430 2.430 Outer Dimension Width 1.900 1.900 1.900 1.900 Depth 5.250 5.950 7.750 7.750 Cabinet colour Natural Grey Net weight 3.550...
  • Page 17 Product range and specifications MODEL RCUE280AG2 RCUE320AG2 RCUE350AG2 RCUE400AG2 Cooling Capacity 1030 Total Power input 239.2 278.2 299.0 347.8 Height 2.430 2.430 2.430 2.430 Outer Dimension Width 1.900 1.900 1.900 1.900 Depth 10.250 10.250 12.750 12.750 Cabinet colour Natural Grey Net weight 6.750 7.000...

  • Page 18: General Data For Rhue40~240Ag2

    Product range and specifications 1.2. General data for RHUE40~240AG2 MODEL RHUE40AG2 RHUE50AG2 RHUE60AG2 RHUE70AG2 Cooling Capacity Heating Capacity Total Power input in cooling 36.4 42.7 52.3 59.8 Total Power input in heating 40.7 44.5 54.3 67.7 Height Height 2.430 2.430 2.430 2.430 Outer Dimension...
  • Page 19 Product range and specifications MODEL RHUE80AG2 RHUE100AG2 RHUE120AG2 RHUE140AG2 Cooling Capacity Heating Capacity Total Power input in cooling 69.6 85.4 104.5 119.6 Total Power input in heating 67.7 89.0 108.6 135.5 Height Height 2.430 2.430 2.430 2.430 Outer Dimension Width 1.900 1.900 1.900...
  • Page 20 Product range and specifications MODEL RHUE160AG2 RHUE180AG2 RHUE210AG2 RHUE240AG2 Cooling Capacity Heating Capacity Total Power input in cooling 139.1 156.8 179.4 208.7 Total Power input in heating 135.5 162.9 203.2 203.2 Height Height 2.430 2.430 2.430 2.430 Outer Dimension Width 1.900 1.900 1.900...

  • Page 21: Test Run

    Test run Te s t r u n This chapter describes the procedure of test run of the Air cooled water chillers and the Air to water heat pump chillers. Content Test run ........................19 2.1. Check before test run ........................... 20 2.1.1.

  • Page 22: Check Before Test Run

    Test run 2.1. Check before test run Confi rm there is no problem regarding chiller installation space and requirements. See technical catalogue for more details. Check the following items at the beginning of the season and before fi rst test run. 2.1.1.

  • Page 23: Electrical System

    Test run 2.1.3. Electrical System Fuse Confi rm visually if fuse is suitable. See technical catalogue −  for detail regulation of fuse. Electrical Confi rm individually if screws in installation part and wire −  device connection part are not loosed using driver. Check it carefully since devices might be damaged if screws in wire connection part are not tightened well.

  • Page 24: Test Run Method And Check

    Test run 2.1.4. Water System Quality Confi rm if the water quality follows the guideline detailed in −  control the technical catalogue. Diameter of Strange noise or abnormal vibration can occur if water −  water pipe pump is not installed well or water pipe is too long. Confi rm the piping in the following sample method (fi...

  • Page 25: Cooling Operation (Low Pressure, High Pressure)

    Test run 2.2.2. Cooling operation (low pressure, high pressure)  Cooling operation:  Fig.4 Chilled water outlet temperature (ºC) Ambient DB temperature (ºC) 2.2.3. Heating operation (low pressure, high pressure)  Heating operation:  Fig.5 Ambient WB temperature (ºC) Heated water outlet temperature (ºC) Low pressure and high pressure, corresponding to outlet temperature and ambient DB temperature, are within the below area (at 100% operation) normally.

  • Page 26: Electrical Consumption Percentage

    Test run 2.2.4. Electrical consumption percentage Electrical consumption percentage is 100% in the following standard conditions at cooling and heating operation:  Cooling operation: 50 Hz electrical consumption percentage (cooling) Air side heat exchanger inlet ambient DB 35°C, Chilled water inlet temperature 12°C, Chilled water outlet temperature 7°C.

  • Page 27: Restart Of Test Run

    Test run 2.3. Restart of Test Run After a series of items are confi rmed from the beginning to the end of test run, restart the unit and check also the following items. Items Check point Criteria and method Remarks Momentary voltage at −...

  • Page 28: Check Of High Pressure Switch (Cooling Operation)

    Test run 2.3.1. Check of high pressure switch (cooling operation)  1. Operate the unit in local operation mode. Cooling operation: 2. When “High pressure cut confi rmation test” switch on PCB is pressed during local operation, fan is stopped forcedly and high pressure is increased. Then, high pressure switch turns ON.

  • Page 29: Instruction At Delivery

    Test run 2.4. Instruction at delivery 2.4. Instruction at delivery 2.4. Instruction at delivery When delivering the unit after test run, give an appropriate explanation to customers about operation method and periodical maintenance method etc as well as the following items. 1.

  • Page 30: Warning & Cautions

    Test run 2.5.Warning & Cautions 2.5.Warning & Cautions 2.5.Warning & Cautions 2.5.1. During product and electrical installation  WARNING Installation must be performed by distributors or specialists. Inadequate − installation may cause water leakage, electrical shock or fi re. Electrical work must be performed by person with qualifi cation. Inadequate −...

  • Page 31: During Repair And Relocation

    Test run 2.5.3. During repair and relocation  WARNING Turn OFF all powers when checking electrical parts, otherwise, it may result in − electrical shock. Do not touch protection device. It may result in failure, electrical shock, fi re − ...

  • Page 33: Electrical Wiring Diagram

    Diagrams l e c t r i c a l W i r i n g D i a g r a m s This chapter shows the electrical wiring diagrams for Chiller AG2 of Hitachi. Content Electrical Wiring Diagram ..................31 3.1.

  • Page 34: Power Wiring Diagram

    Electrical Wiring Diagrams 3.1. Power Wiring Diagram 3.1.1. Model: R(C/H)UE 40~80AG2 Drawing Code:  NOTE: XEKS1037_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter.

  • Page 35: Model: R(C/H)Ue 100~160Ag2

    Electrical Wiring Diagrams 3.1.2. Model: R(C/H)UE 100~160AG2 Drawing Code:  NOTE: XEKS1038_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 36: Model: R(C/H)Ue 180~240Ag2

    Electrical Wiring Diagrams 3.1.3. Model: R(C/H)UE 180~240AG2 Drawing Code:  XEKS1036_r1 NOTE: All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 37: Model: R(C/H)Ue 280~320Ag2

    Electrical Wiring Diagrams 3.1.4. Model: R(C/H)UE 280~320AG2 Drawing Code:  NOTE: XEKS1040_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 38: Model: R(C/H)Ue 350~400Ag2

    Electrical Wiring Diagrams 3.1.5. Model: R(C/H)UE 350~400AG2 Drawing Code:  NOTE: XEKS1041_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 39: Power Wiring Diagram (Fan)

    Electrical Wiring Diagrams 3.2. Power Wiring Diagram (FAN) 3.2.1. Model: R(C/H)UE 40~400AG2 Drawing Code:  NOTE: XEKS1042_r0 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter.

  • Page 40: Control Pcb (Pcbc)

    Electrical Wiring Diagrams 3.3. Control PCB (PCBc) 3.3.1. Model: R(C/H)UE 40~400AG2 Drawing Code:  NOTE: XEKS1043_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter.

  • Page 41: Model: R(C/H)Ue 280~400Ag2 (Secondary Pcbc)

    Electrical Wiring Diagrams 3.3.2. Model: R(C/H)UE 280~400AG2 (Secondary PCBc) Drawing Code:  NOTE: XEKS1045_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter.

  • Page 42: Input / Output Pcb (Pcbd)

    Electrical Wiring Diagrams 3.4. Input / Output PCB (PCBd) 3.4.1. Model: RCUE 40~240AG2 Drawing Code:  NOTE: XEKS1044_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter.

  • Page 43: Model: Rcue 280~400Ag2

    Electrical Wiring Diagrams 3.4.2. Model: RCUE 280~400AG2 Drawing Code:  NOTE: XEKS1046_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 44: Model: Rhue 40~240Ag2

    Electrical Wiring Diagrams 3.4.3. Model: RHUE 40~240AG2 Drawing Code:  NOTE: XEKS1047_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 45: Power Wiring Diagram (Mcb Option)

    Electrical Wiring Diagrams 3.5. Power Wiring Diagram (MCB Option) 3.5.1. Model: R(C/H)UE 40~80AG2 Drawing Code:  NOTE: XEKS1048_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter.

  • Page 46: Model: R(C/H)Ue 100~160Ag2

    Electrical Wiring Diagrams 3.5.2. Model: R(C/H)UE 100~160AG2 Drawing Code:  NOTE: XEKS1046_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 47: Model: R(C/H)Ue 180~240Ag2

    Electrical Wiring Diagrams 3.5.3. Model: R(C/H)UE 180~240AG2 Drawing Code:  NOTE: XEKS1050_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 48: Model: R(C/H)Ue 280~320Ag2

    Electrical Wiring Diagrams 3.5.4. Model: R(C/H)UE 280~320AG2 Drawing Code:  NOTE: XEKS1051_r1 All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 49: Model: R(C/H)Ue 350~400Ag2

    Electrical Wiring Diagrams 3.5.5. Model: R(C/H)UE 350~400AG2 Drawing Code:  XEKS1037_r1 NOTE: All the fi eld wiring equipment must comply with local codes. For more information about DWS confi guration, please refer to chapter 4 of this catalogue. See the diagram abbreviations description at the end of this chapter. pag.

  • Page 50: Diagram Abbreviations Descriptions

    Electrical Wiring Diagrams 3.6. Diagram abbreviations descriptions Mark Name Remark Mark Name Remark Compressor Motor PCBB1,B2 Printed Circuit Board for Operation MF11-N6 Condenser Fan Motor PCBC1,C2 Printed Circuit Board for CPU Main Isolator PCBD1 Printed Circuit Board for Relay CMC1 Contactor for Compressor Motor PCBE11~ Printed Circuit Board for Fan Control...

  • Page 51: Control System

    Control system C o n t r o l s y s t e m Content Control system ......................49 4.1. List of Main Control Function ........................ 50 4.2. Water control ............................52 4.2.1. Automatic temperature adjustment ......................52 4.3. Compressor control ..........................53 4.3.1.

  • Page 52: List Of Main Control Function

    Control System 4.1. List of Main Control Function Item Contents Outlet water temperature of water side heat exchanger − is detected by thermistor and the position of compressor slide valve is controlled continuously. Water temp. Automatic water temperature control control The range of capacity control: 100~15%, Stop (all −...
  • Page 53 Control system Item Contents Full load operation is performed by external order (no- − voltage contact input). Chiller unit stops when the water temperature reaches Ice/Heat storage operation by external order − the setting value (no capacity control). Dip Switch setting is necessary. Dip Switch setting is necessary.

  • Page 54: Water Control

    Control System 4.2. Water control 4.2.1. Automatic temperature adjustment 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. Possible range of water temperature setting (°C): −...

  • Page 55: Compressor Control

    Control system 4.3. Compressor control Compressor Control: 1. Starting control 2. Time Guard 3. Sequential starting control  Compressor control 4. Rotation control 4.3.1. Starting control Starting control, Time Guard and Sequential starting control. These three controls are performed in the control circuit on PCB. ∆...

  • Page 56: Current Limit Control

    10 min. RSW7 40 HP 50 HP 60 HP RSW5 RSW6 70 HP 80 HP Adjust the calculated setting value Ejemplo RCUE40AG2 Ejemplo RCUE80AG2 40 = 48 A 50 = 80 A RSW5 RSW5 RSW6 RSW6 pag. 54 SMGB0003 rev.0-01/2007...

  • Page 57: Reverse Protection Control

    Control system 4.5. Reverse protection control  Reverse protection control: Screw compressor compresses the refrigerant to a determined pressure by decreasing the space formed by male/female rotor and slide valve. If the rotor revolution direction is reversed, the suction side and discharge side are reversed and the functioning of the compressor will not be correct.

  • Page 58: Restart Control After Power Failure

    Control System Control System Control System  4.6. Restart control after power failure Restart control after power failure: 4.6.1. Restart control after momentary power failure (<2 sec)  In momentary power failure, all settings are saved, so after 3 minutes time guard, NOTE: unit is run automatically with the same operation mode as before the power Momentary power failure: Power...

  • Page 59: Operation Error/Wrong Setting Prevention Control [40 - 40]

    Control system 4.7. Operation error/wrong setting prevention control [40 – 40]  Operation error/wrong setting Alarm is output in the following cases. prevention control [40-40]: 1. Operation error While the unit is stopped, there is a input (including external Thermo signal) from −...

  • Page 60: Second Water Temperature Setting

    Control System 2. Forced capacity control a) Contents Compressor operation capacity is set forcedly through customer wiring terminals. Order signal pattern and compressor operation capacity are shown as below. Compressor forced operation capacity Normal operation HOLD LOAD DOWN LOAD UP b) Wiring method (customer wiring terminal) ...
  • Page 61 Control system 1. Air-conditioning operation 1 (capacity control) + Air-conditioning operation 2 (capacity control) The below example: chilled water outlet temperature 7°C and chilled water outlet temperature 10°C in cooling. Running operation:  Run/Stop signal is received from local or remote. −...
  • Page 62 Control System In case that operation signal is input in local at heat storage operation, capacity control operation is − performed. a) Dip Switch Setting In option A, 3 and 4 are ON. In option A, 3 and 4 are ON. b) Setting of operation PCB of unit body (setting of air-conditioning temperature) Set chilled water outlet temperature as 7°C.
  • Page 63 Control system 3. Heat storage operation 1 (100-0%)+ heat storage operation 2 (100-0%) The below example: chilled water outlet temperature 7°C and chilled water outlet temperature 10°C in cooling. Running operation  Run/Stop signal is received from external Thermo contact. −...
  • Page 64 Control System d) Wiring for the switch and external Thermo contact input Wire as follows. With short circuit wiring External Thermo Contactor  NOTE: Don’t connect AC: Air-conditioning HS: Heat Storage 4. Setting method of second temperature Second temperature setting mode is set by pressing “▼” switch for more then 3 sec. on indication PCB with Unit power ON.
  • Page 65 Control system Temperature setting method  The following operation is performed from the status of chilled water second temperature setting value or warm water second temperature setting value. Here, the example of chilled water second temperature setting is shown. Value is changed each time SW3, SW4 are pressed, NOTE: This value is not saved at this Press SW3, SW4 moment...

  • Page 66: Heat Storage Operation By External Order

    Control System 4.10. Heat storage operation by external order  Heat storage operation by 1. Operation control external order: It is a control that runs unit by External Thermostat order. It forces unit to work at full load with no capacity control. (It is valid only at remote setting) 2.

  • Page 67: Operation By Dc24V Input (Remote Control)

    Control system  ATTENTION: Dip Switch for this control should be set before power ON. − Local external Thermo does not run/stop by pulse signal order. − Normal operation order and heat storage operation order shall be input to Chiller unit separately. −...
  • Page 68 Control System b) Setting method Dip Switch for optional function setting on PCB is set as follows before power ON before power ON.  ATTENTION: Additional wiring should not be connected to other operation circuit, especially wiring for 220-240V. − Additional wiring shall be put into a metal pipe independently or shield line shall be used.
  • Page 69 Control system 4. Pulse input (II) a) Signal and basic sequence Remove it More than 200 m More than 3 min. More than 200 m Construction in local, parts prepared in local b) Setting method It is an application of remote control and it is unnecessary to modify the setting of PCB. ...

  • Page 70: Installation Of Switch For Snow Measure (Fan Manual Operation)

    Control System 4.12. Installation of switch for snow measure (Fan manual operation) If a switch for snow measure is installed, it is connected to terminal #31 and #32 in  Installation of switch for snow customer wiring terminals. When the switch is ON, fan is operated during unit stop or measureHeat storage operation by external order: Thermo OFF.

  • Page 71: Switch For Confi Rmation Of High Pressure Cut

    Control system 4.13. Switch for confi rmation of high pressure cut  Switch for confi rmation of high Switching to this test mode makes easy to confi rm if the device for cutting high pressure pressure cut is activated. Operation method ...

  • Page 72: Saving Energy Priority Mode, Silence Priority Mode (Night Shift), Only Cooling

    Control System 2. Automatic release of antifreeze control This operation is released only when ambient temperature is over 4°C. Pump continuous Pump continuous Pump continuous Pump continuous Pump continuous Pump continuous Pump continuous Pump continuous Pump continuous Pump continuous Pump continuous operation operation operation...
  • Page 73 Control system Silence priority mode is valid by a no-voltage contactor input in Dip Switch setting of Standard mode or Saving energy priority mode, therefore, such changeover as saving energy mode in daytime and silence priority mode at night can be performed from remote controller. Silence priority ON/OFF Silence priority mode (night shift)

  • Page 74: Defrost (Only Air-Cooled Heat Pump Type)

    Control System  Defrost (only air-cooled 4.16. Defrost (only air-cooled heat pump type) heat pump type) Ambient temperature, evaporating temperature and evaporating pressure are detected during heat operation to detect the frost volume. By the changeover of 4 way valve, reverse-cycle defrosting is performed.
  • Page 75 Control system Confi rmation of defrost conditions Fan 0 Hz order, Changeover of 4 way valve Capacity control hold 10 sec count Water side HE inlet refrigerant temp ≤ 0ºC ? Load-down output (10sec output) Water side HE inlet refrigerant temp ≤2ºC ? Load-up continuous output Capacity control hold...
  • Page 76 Control System Confi rmation of defrost fi nish conditions Is fan running? Fan 6Hz order output High pressure ≥2.6MPa ? 10min since 6Hz order output? Start running with Max frequency High pressure ≤1.5MPa ? 10min since running with Max frequency? Changeover of 4 way valve 30 sec count...

  • Page 77: Thermo Off Selection Function

    Control system 4.17. Thermo off selection function  Thermo off selection function It is a function to prevent the Chiller unit from going Thermo OFF due to a sudden change of temperature or fl ow volume (inverter water pumps). It is possible to select it by DSW7-pin 3 on operation PCB.

  • Page 78: Fan Control

    Control System 4.17.1 Fan Control 1. Cooling operation In this series, fan speed is controlled by inverters and adjusts depending on discharge pressure. Target high pressure is set based on the ambient temperature, and revolution number is increased / decreased by PID control.
  • Page 79 Control system Prevention of high pressure excess increase ≥ Discharge pressure 2.2MPa out put +10Hz  ≥  Discharge pressure 2.5 MPa out put max. frequency Prevention of high pressure excess decrease ≤  Discharge pressure 0.9 MPa out put -10Hz ≤...

  • Page 80: Electronic Expansion Valve

    Control System 4.17.2 Electronic expansion valve Model of expansion valve Model: MKV-1610D-Q5 Refrigerant: R407C Parts No.: C4340 Nº Name Qty. Material Stem SUS303   Guide SUS304   Case SUS305   Spring Pin SUS420   Slider SUS304 ...
  • Page 81 Control system In this series, electronic expansion valve is used. Electronic expansion valve is consisted in the body (fi gure), Coil, and PCB for expansion valve running (PCB (VD PCB)). 1. The range of opening of expansion valve The opening of expansion valve is managed by pulse number. The range is 116~656 pulse. During stop, it is stand-by with 10 pulse.
  • Page 82 Control System 6. Prevention control for freezing If it is detected that refrigerant inlet temperature of water side heat exchanger is decreased, expansion valve shall be open so that decrease of refrigerant temperature is prevented, which leads to anti-freeze in the water side heat exchanger.

  • Page 83: Protection Controls

    Control system 4.17.3. Protection Controls This series has a protection control to resolve abnormal status before reaching to the alarm status, occurrence. Control Name Conditions Contents Release conditions High pressure Hold after load-down 10 second High pressure ≧2.6MPa 30 min and High pressure < 2.5MPa protection output Cooling only:...

  • Page 85: Troubleshooting

    Troubleshooting T r o u b l e s h o o t i n g Content Troubleshooting .......................83 5.1. Initial check ............................84 5.1.1. Check of power supply and connection ....................... 84 5.1.2. Check on PCB.............................. 85 5.1.3. Confi rmation of activation value of protection device an Automatic operation device ......... 96 5.1.4.

  • Page 86: Initial Check

    Troubleshooting 5.1. Initial check 5.1.1. Check of power supply and connection In case of abnormality in Chiller unit, check the following items fi rstly. Nº Check Item Check Method Is power supply or fuse broken? Measure secondary voltage of breaker and current carrying of fuse by tester. Pull out the connection of secondary side in Transformer and measure the Pull out the connection of secondary side in Transformer and measure the voltage by tester.

  • Page 87: Check On Pcb

    Troubleshooting 5.1.2. Check on PCB Confi guration for standard version. Standard values are the ones shown on PCB drawing and table below. (RHUE40~400 AG2)  MODEL DSW3 DSW4 RSW5 RHUE40AG2 RHUE50AG2 RHUE60AG2 RHUE70AG2 RHUE80AG2 RHUE100AG2 RHUE120AG2 RHUE140AG2 RHUE160AG2 RHUE180AG2 RHUE210AG2 RHUE240AG2 pag.
  • Page 88 Troubleshooting (RCUE40~400 AG2)  MODEL DSW3 DSW4 RSW5 RCUE40AG2 RCUE50AG2 RCUE60AG2 RCUE70AG2 RCUE80AG2 RCUE100AG2 RCUE120AG2 RCUE140AG2 RCUE160AG2 RCUE180AG2 RCUE210AG2 RCUE240AG2 RCUE280AG2 RCUE320AG2 RCUE350AG2 RCUE400AG2 pag. 86 SMGB0003 rev.0 - 01/2007...
  • Page 89 Troubleshooting (RCUE280~400 AG2)  MODEL DSW3 DSW4 RSW5 RCUE40AG2 RCUE50AG2 RCUE60AG2 RCUE70AG2 RCUE80AG2 RCUE100AG2 RCUE120AG2 RCUE140AG2 RCUE160AG2 RCUE180AG2 RCUE210AG2 RCUE240AG2 RCUE280AG2 RCUE320AG2 RCUE350AG2 RCUE400AG2 pag. 87 SMGB0003 rev.0 - 01/2007...
  • Page 90 Troubleshooting DESCRIPTION:  DSW1: Setting of Low Voltage for Remote Control − (PCB DSW1: No function) Dip Switch Setting MODE (DSW1 of Main PCB) NORMAL MODE (Now low voltage control) MODE 1 (Hi/Lo) MODE 2 (Pulse) DSW2: Starting Delay − (PCB DSW2: No function) DSW2-1,2: Setting for Starting Delay of Compressor [min]...
  • Page 91 Troubleshooting DSW4: Optional Function A − (PCB DSW4: No function except DSW4-7 in ON: HAPE CHILLER) DSW4-1: OFF for RCUEXXXAG2 models ON for RHUEXXXAG2 models DSW4-2,7: ON / DSW4-3,4,5,6,8: OFF ; Confi guration for HAPE Chillers DSW4-3: ON: Not Available Option DSW4-4: ON;...
  • Page 92 Troubleshooting DSW5-6: Pulse width in Seconds for Load Up Slide Valve in compressor in LOAD UP1 Mode. − (SVn-UP: Coil energizing) Figure Location Time (minute) DSW5-7,8: Pulse width in Seconds for Load Up Slide Valve in compressor in LOAD UP2 Mode. −...
  • Page 93 Compressor load is kept for period when CT sensor measures set current e.g.: RCUE40AG2: Compressor load is “down” and “hold” for 30min (Y=3; 3*10min) when compressor current is higher than 48 A (X=2; 1.2*40A). RSW8: Temperature band for Neutral Zone (See also DSW5) −...
  • Page 94 Troubleshooting RSW9: Temperature setting for one Defrost condition [Evaporator. Temp.- Ambient Temp.: − 2~20ºC] (PCB RSW9: No function) 1 2x1=2ºC 2 2x2=4ºC … 99x2=18ºC 010x2=20ºC] SW5: See explanation for PCB RSW1,2 − (PCB SW5: No function) SW6: Remote unit control. Standard is −...
  • Page 95 Troubleshooting SW9, SW10: High Cut check (Fan Stop for Check) − B1,B2 SW9 (PCB ): ON  Checking Cycle 1 SW10 (PCB ): ON  Checking Cycle 2 SW9 + SW10 (PCB ): ON  Checking Cycle 3 SW9 (PCB ): ON ...
  • Page 96 Troubleshooting DIP SWITCH SETTING PCB (FAN MODULE FOR DC FAN MOTORS)  e1~e5 DIP SWITCH SETTING PCB . (EXP. VALVE CONTROL PCB)  F1~F2 pag. 94 SMGB0003 rev.0 - 01/2007...
  • Page 97 Troubleshooting DIP SWITCH SETTING PCB (FAN CONTROL PCB)  G1,G2,G3 Standard Setting H-LINK: DSW4-1~3 Manual stop of DC Fans (same than DSW3 4~7 on PCBn H-LINK end Resistence All pins in OFF pag. 95 SMGB0003 rev.0 - 01/2007...

  • Page 98: Confi Rmation Of Activation Value Of Protection Device An Automatic Operation Device

    Troubleshooting 5.1.3. Confi rmation of activation value of protection device an Automatic operation device Protection device  Activation value of protection device is as follows: Name Activation value High pressure block device 2.74 MPa (re-start manually) Cooling Prevention control for low pressure decrease 0.314 MPa (Electron control) Low pressure block device 0.049 MPa (Electron control)

  • Page 99: Individual Indication For Activation Of Protection Device

    Troubleshooting Automatic operation device  The value of automatic operation device is set as follows: Item (unit) Setting value Remarks Variable: 30 sec ~ 10 min Time guard (standard value: 3 min) (Note 1) -Δ switch Relay for only Electron control starting control Staring unload Sequential...
  • Page 100 Troubleshooting Abnormal code of segment indication part  In this section “abnormal code” is explained. See subchapter 5.2.3 “Method of failure diagnosis” for the concrete treatment. Segment Indication Contents abnormal code   Activation of High Pressure Block Devise(63H)  Activation of Suction Pressure Block Device ...
  • Page 101 Troubleshooting Indication of inverter (fan module) for control of fan revolution number  Fan module has protection control and indicates abnormal code on the segment. − List of inverter abnormal code Segment Indication Contents abnormal code   Inverter Speed Control Abnormality ...

  • Page 102: Modifi Cation Of Pcb Confi Guration

    Troubleshooting 5.1.5. Modifi cation of PCB confi guration Every Chiller is delivered with the correct priority confi guration (Master PCB and slave PCB). In case of a Control PCB delivered as a spare part, it will be necessary to set the correct priority confi guration because it is not known where it will be applied (Chiller model).
  • Page 103 Troubleshooting Checking of current priority confi guration  1. Power supply OFF (Main Switch turned-off) 2. Put DSW1-1 from Operation PCB in ON (PCB 3. Electric Box Power supply ON (M.I. switch ON) 4. Put DSW1-2,3,4 from Operation PCB in ON (PCB 5.
  • Page 104 Troubleshooting 7. The right priority confi guration follows the next table criteria. 7 segments   Setting for main control PCB (PCB ) in all CHILLERS up to 240 HP   Setting for main control PCB (PCB 1) in Cooling Only CHILLERS with 4 or 5 cycles. ...
  • Page 105 Troubleshooting − Flowchart at abnormal occurrence Abnormal occurrence in Abnormal occurrence in fan refrigerant cycle it judged Could it that it is possible to be a temporal continue operation although fan phenomenon due to an is stopped temporally accidental factor? Stop the compressor of Stop the correspondent fan correspondent cycle...

  • Page 106: Check Function

    Troubleshooting 5.1.6. Check function Check mode  By pressing [▲] (SW3) on PCB more than 3 seconds, control state of chilled water temperature, each refrigerant cycle pressure/ temperature etc are indicated. (it is possible both during stopping and during running), (*mode shall not be shifted in case of alarm). Pressing again [▲] (SW3) on PCB more than 3 seconds enables you to see the different values but with decimals Dot is indicated, which...
  • Page 107 Troubleshooting Example of code indication (alternately Item Contents fl icker) 1. Chilled water setting temperature indication [ºC] -in case of setting temperature = 12ºC      -integer round up is indicated in case of +0.5ºC setting 2. Warm water setting temperature indication [ºC] (only heat pump type) ...
  • Page 108 Troubleshooting Alarm occurrence data  Alarm occurrence data is indicated by pressing [▲] (SW3) [▼] (SW4) on PCB. (It is possible to do during stop / operation). (*Mode should not be shifted during alarm occurrence) Flicker alternately    ...
  • Page 109 Troubleshooting Example of code indication (alternately Item Contents fl icker) Refrigerant liquid Refrigerant liquid Outlet water temp (backside of heat exchanger of      water side) [ºC] Outlet water temp (backside of heat exchanger of water -In case of No. 1 outlet water temp is 7ºC side) ...

  • Page 110: Troubleshooting

    Troubleshooting 5.2. Troubleshooting 5.2.1. Outline of failure diagnosis In the case of abnormality, alarm LED on the control panel of unit and of remote control is ON and segment indication on the control panel is fl ickering. To stop the unit, put it into stop operation without power OFF(Main switch).

  • Page 111: Alarm Indication

    Troubleshooting 5.2.2. Alarm indication 7-Segment indication shows the following abnormalities: Without indication Unit does not run Check the power source With indication Check the 7-segment indication Alarm Code Description of abnormality No.1~6 cycles Activation of High Pressure Switch   Excessively Low Pressure ...
  • Page 112 Troubleshooting Alarm Code Description of abnormality No.1~5 cycles Incorrect Operation  Error communication between Ctrl. PCB (PCB , PCB  Error communication between Expansion Valve PCB and Cntrol PCB  Error communication between Fan Contol PCB and Cntrol PCB  ...

  • Page 113: Failure Diagnosis Method

    Troubleshooting 5.2.3. Failure diagnosis method General check of failure diagnosis.  In the case of no segment indication, unit can not operate. Is 380-415V supplied Check the power to the unit?: source switch Is 220-240V supplied to Replace fuse Is fuse broken? transformer primary side? Is R phase or S Wiring check...
  • Page 114 Troubleshooting  Alarm code Activation of High Pressure Switch (63H)  [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCB (I/O PCB )PCN203 High pressure (Pd) is increased to more than 2.74MPa, and high No. 2 Cycle: PCB (I/O PCB )PCN203 pressure switch (63H) is activated.
  • Page 115 Troubleshooting       Alarm code Excessively low suction pressure       [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCB (I/O PCB) CN29Ps Suction pressure (Ps) is less than 0.049MPa during 3 seconds. No.
  • Page 116 Troubleshooting  Activation of suction pressure protection control Alarm code  [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCB (I/O PCB) CN29Ps -Suction pressure (Ps) is less than 0.333MPa during 90 seconds. (Electronic No. 2 Cycle: PCB (I/O PCB) CN29Ps control, air-cooled type) No.
  • Page 117 Troubleshooting  Activation of Thermal Relay for Compressor (51C) Alarm code  [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCB (I/O PCB) PCN207 -Operation current for any compressor is increased too much and activates the No. 2 Cycle: PCB (I/O PCB) PCN207 Thermal Relay.
  • Page 118 Troubleshooting  Activation of Discharge Gas Thermistor (Td) Alarm code  [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCB (I/O PCB) CN24Td 1.- Discharge gas temperature from the compressor is increased to 130°C and No. 2 Cycle: PCB (I/O PCB) CN24Td continues for 1 minute.
  • Page 119 Troubleshooting  Activation of Internal Thermostat for Compressor Alarm code  [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCB (I/O PCB) PCN204 The electrical motor of the compressor is overheated and internal Thermostat is No. 2 Cycle: PCB (I/O PCB) PCN204 activated.
  • Page 120 Troubleshooting  Excess Low Temperature of Cooler Inlet Refrigerant (Tr) Alarm code  [Alarm Stop Reason] [PCB Monitoring Position] - Refrigerant temperature in water side heat No. 1 Cycle: PCB (I/O PCB) CN27Tr2 exchanger inlet (Tr) is less than –6.5°C during 3 No.
  • Page 121 Troubleshooting  Low Pressure Protection by Suction Gas Thermistor (Ts) Alarm code  [Alarm Stop Reason] [PCB Monitoring Position] - Suction Gas Temperature (Ts) is lower than –2°C No. 1 Cycle: PCB (I/O PCB) CN25Ts during 10 seconds. (only cooling operation) No.
  • Page 122 Troubleshooting No Feedback Signal from Water Pump Alarm code   [Alarm Stop Reason] ATTENTION: Pump operation feedback signal (terminals 1-2) is OFF during pump Interlock (CMP) ON (terminals 3-4) During pump operation (during unit stop), *It is available once feedback signal confi rmed. Alarm is reset by 1.
  • Page 123 Troubleshooting  Alarm code Phase Abnormality (Reverse Phase / Phase Failure)   [Alarm Stop Reason] [PCB Monitoring Position] Power source connected to unit is reversed phase No. 1 ~ No. 3 Cycle: PCB (I/O PCB) R, S, T or open phase. No.
  • Page 124 Troubleshooting  Alarm code Activation of Freeze Protection Control   [Alarm Stop Reason] [PCB Monitoring Position] - Chilled water temperature is lower than (CPU PCB) CN3 (for inlet), CN4 (for No. 1 cycle 2°C.(standard unit) (only cooling operation) outlet), CN6 (for No. 2 cycle outlet), CN7 (for No. 3 cycle - PCB PCN13 wiring is broken.
  • Page 125 Troubleshooting Abnormal Product Model Thermistor Connector Code Chilled water outlet temperature Thermistor 1 RCUE 40 ~ 80 AG2  RHUE 40 ~ 80AG2 Chilled water outlet temperature Thermistor 2 CN23 (backside cooler) Chilled water outlet temperature Thermistor 1  Chilled water outlet temperature Thermistor 2 CN23 (backside cooler) Chilled water outlet temperature Thermistor 1...
  • Page 126 Troubleshooting  Alarm code Activation of Water Overheating Protection Control   [Alarm Stop Reason] [PCB Monitoring Position] - Water outlet temperature is above 59°C (CPU PCB): during compressor operation. (only heating CN4 (for No.1 cycle outlet control) operation) CN6 (for No. 2cycle outlet control) - PCB PCN12 wiring is broken.
  • Page 127 Troubleshooting Alarm code Operation Error / Setting Error  [Alarm Stop Reason] Wrong setting is performed in Dip Switch on Printed Circuit Board, or prohibited operation is performed. Is alarm reset by stop Check Printed Circuit Is setting of Dip Switch switch? Board for Operation correct?
  • Page 128 Troubleshooting Alarm code Inlet Chilled Water Thermistor Abnormality  [Alarm Stop Reason] [PCB Monitoring Position] Thermistor for inlet water temperature (CPU PCB) CN3 indicates abnormal value. Is Printed Circuit Board for Plug, Wiring Repair Control (PCB ) connector CN3 correctly connected? Disconnect connector and Replace Thermistor measure resistance.
  • Page 129 Troubleshooting Abnormal Product Model Thermistor Connector Code RCUE 40 ~ 80 AG2 Outlet water temperature Thermistor 1  RHUE 40 ~ 80AG2 Outlet water temperature Thermistor 1  Outlet water temperature Thermistor 1  RCUE 80 ~ 400 AG2 Outlet water temperature Thermistor 1 ...
  • Page 130 Troubleshooting   Alarm code Discharge Gas Temperature Thermistor Abnormality  [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCB (I/O PCB) CN24Td Thermistor for discharge gas temperature indicates abnormal No. 2 Cycle: PCB (I/O PCB) CN24Td value. No. 3 Cycle: PCB (I/O PCB) CN24Td No.
  • Page 131 Troubleshooting  Abnormality of Outlet Water Temperature Alarm code  Thermistor for Protection [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCBD1 (I/O PCB) CN23Te2 Thermistor for detection of water side heat exchanger outlet No. 2 Cycle: PCBD2 (I/O PCB) CN23Te2 (backside=inside of heat exchanger) No.
  • Page 132 Troubleshooting  Suction Gas Temperature Thermistor Alarm code  Abnormality [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCB (I/O PCB) CN25Ts Thermistor for detection of No. 2 Cycle: PCB (I/O PCB) CN25Ts compressor suction gas refrigerant temperature indicates abnormal No.
  • Page 133 Troubleshooting  Discharge Pressure Sensor Abnormality Alarm code  [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCB (I/O PCB) CN28Pd Discharge pressure sensor of No. 2 Cycle: PCB (I/O PCB) CN28Pd compressor indicates abnormal value. No. 3 Cycle: PCB (I/O PCB) CN28Pd No.
  • Page 134 Troubleshooting  Suction Pressure Sensor Abnormality Alarm code  [PCB Monitoring Position] [Alarm Stop Reason] No. 1 Cycle: PCBD1 (I/O PCB) CN29Ps Suction pressure sensor of No. 2 Cycle: PCBD2 (I/O PCB) CN29Ps compressor indicates abnormal value.. No. 3 Cycle: PCBD3 (I/O PCB) CN29Ps No.
  • Page 135 Troubleshooting Ambient Temperature Thermistor Alarm code  Abnormality [PCB Monitoring Position] [Alarm Stop Reason] (CPU PCB) CN5 Thermistor for ambient temperature indicates abnormal value. Is connector CN5 on the Printed Circuit Board for Plug, Wiring Repair CPU (PCBc) correctly connected? Pull out connector and Replace Thermistor measure thermistor...
  • Page 136 Troubleshooting Error Communication between Ctrl. PCB and Alarm code  Fan Speed control PCB [PCB Monitoring Position] [Alarm Stop Reason] (CPU PCB) CN11~ PCB Communication between Ctrl PCB (Fan control PCB) CN8 ~ PCB (PCBc) and fan speed PCB is (Fan control PCB) CN8 not performed correctly during 30 seconds.
  • Page 137 Troubleshooting  During Activation of Pump Stop Control by Alarm code (Flicker) Excess Increase of Water Temperature [PCB Monitoring Position] [Alarm Stop Reason] (CPU PCB) CN3(for inlet), CN4(for outlet Water temperature is increased to 65°C by heat control in Unit 1), CN6 (for outlet control in Unit 2) generation in pump during only pump running (during compressor stop: during heat operation (I/O PCB) CN23Te2 (for protection of Unit 1)
  • Page 138 Troubleshooting Water fl ow Protection Switch Activation (at 63W use;  Alarm code Option) [PCB Monitoring Position] [Alarm Stop Reason] (CPU PCB) PCN10 Water fl ow protection switch is activated Is chilled water fl owing? Check the pump Is water shortage protection switch ON Check water fl...
  • Page 139 Troubleshooting   Inverter Speed Control Abnormality Alarm code  1m: m=Fan No. [Alarm Stop Reason] [PCB Monitoring Position] The actual frequency is over the admissible value FANM (Fan Module) of inverter order frequency. *Alarm stop: 5 retries during 30 minutes.(only corresponding fan is stopped, automatic restart in 10 seconds) [Retry Code]...
  • Page 140 Troubleshooting   Inverter Position Detection Abnormality Alarm code  1m: m=Fan No. [Alarm Stop Reason] [PCB Monitoring Position] The actual cycle is over the admissible value FANM (Fan Module) calculated by inverter order frequency. *Alarm stop: 5 retries during 30 minutes.(only [Retry Code] corresponding fan is stopped, automatic No code indication (indicated within the check...
  • Page 141 Troubleshooting Transmission Abnormality between Inverter and   Alarm code CPU PCB or between Fan Speed Control PCB  1m: m=Fan No. [Alarm Stop Reason] [PCB Monitoring Position] Communication is not performed during a FANM (Fan Module) certain period. *Alarm stop: 3 retries during 30 minutes. [Retry Code] (compressor stop, automatic restart in 3minutes) No.
  • Page 142 Troubleshooting   Voltage Shortage or Excess Voltage in Inverter Alarm code  1m: m=Fan No. [Alarm Stop Reason] [PCB Monitoring Position] FANM (Fan Module) Inverter DC voltage is under or over the setting voltage level. *Alarm stop: 3 retries during 30 [Retry Code] minutes.(compressor stop, automatic restart in No.

  • Page 143: Analysis And Countermeasure Of Abnormal Running

    Troubleshooting 5.3. Analysis and countermeasure of abnormal running Chiller unit has various kinds of protection devices. When the operation status is not correct due to the activation of some protection device, refer to the table below and fi nd out the main reason to apply a countermeasure. One failure can affect other different conditions.
  • Page 144 Troubleshooting Repair the wiring Wiring Connection Failure Check circuit by tester connection connection Printed Circuit Check circuit by tester Check Board Failure Printed Circuit Board Replace Printed Circuit Printed Circuit Board by self- Failure Board Pump runs, checking function but neither Replace remote control fan nor Remote Control Switch Failure...
  • Page 145 Troubleshooting Check valve Check valve Suction gas (Air heat exchanger side) Replace check valve temperature Malfunction Malfunction Discharge gas is excessively control is activated high (excessive Expansion Valve Clogging Expansion Valve Clogging Expansion Valve Clogging Remove Clogging Remove Clogging Remove Clogging (-...
  • Page 146 Troubleshooting The heat load is bigger than cooling capacity The heat load is bigger than cooling capacity The heat load is bigger than cooling capacity The heat load is bigger than cooling capacity Calculate heat load Calculate heat load Calculate heat load Replace to larger unit Replace to larger unit Gas leakage or shortage...

  • Page 147: Thermistor Characteristics

    Troubleshooting 5.4. 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). Ambient temperature and outlet liquid refrigerant temperature air side heat exchanger. The temperature characteristics are shown in the below fi gures: 5.4.1.

  • Page 148: Thermistor Temperature Characteristics (Ambient)

    Troubleshooting 5.4.2. Thermistor temperature characteristics (Ambient) pag. 146 SMGB0003 rev.0 - 01/2007...

  • Page 149: Thermistor Temperature Characteristics (Discharge Gas Temperature)

    Troubleshooting 5.4.3. Thermistor temperature characteristics (Discharge gas temperature) pag. 147 SMGB0003 rev.0 - 01/2007...

  • Page 151: Maintenance

    Refrigerant Cycle Diagram of Hitachi Air-Cooled Water Chiller (RCUE 80, 160, 240, 320, 400 AG2) with economizer............167 6.8.3. Refrigerant Cycle diagram of Hitachi Air-to-water Heat Pump Chiller (RHUE 40, 50, 60, 70, 100, 120, 140, 180, 210AG2) .............168 6.8.4.

  • Page 152: Maintenance Criteria

    Maintenance 6.1. Maintenance criteria Check Check Item Criteria (procedure) Remarks Frequency 1. General Judge from aprox. 1m Noise Confi rm if there is no abnormal noise. from the control panel surface. Vibration Confi rm visually if there is no abnormal vibration Confi...
  • Page 153 Maintenance Check Check Item Criteria (procedure) Remarks Frequency 3. Refrigerant Circuit (Cont.) Frequency of cleaning differs depending on Cleaning once/ season Perform the predetermined cleaning. result of water quality or operation time. Adjust them so that standard operation pressure See technical Water fl...

  • Page 154: Maintenance Criteria Of Screw Compressor

    Maintenance 6.2. Maintenance criteria of Screw Compressor 6.2. Maintenance criteria of Screw Compressor 6.2. Maintenance criteria of Screw Compressor Classifi cation Time and year Model Performance items Save of operation situation − Daily check Every day (pressure, temperature, voltage, current value, −...

  • Page 155: Maintenance Of Water Quality

    Maintenance 6.3. Maintenance of Water Quality 6.3. Maintenance of Water Quality 6.3. Maintenance of Water Quality This air-conditioning device uses water as a heat source (for cooling) or as a media (chilled water, heat water) for use of heat. Therefore, it is necessary to select suitable water and control it to maintain the quality and performance and avoid possible problems.
  • Page 156 Maintenance Acid consumption (pH4.8) = M alkali level − It shows the volume of hydroxide, carbonate and bicarbonate in water. It is a base of saturation index calculation or prevention of corrosion, rusty water and line formation. All hardness, calcium hardness −...

  • Page 157: Maintenance Method Of Water Quality

    Maintenance Dissolved oxygen − It is an oxygen gas dissolved in water and is a great factor to promote the corrosion. Regarding copper corrosion, possibility of corrosion is increased in dissolved oxygen volume of 5~15 (ml/l), and is decreased in greater or less value than that.
  • Page 158 Control that these values be within the usage range. − holding water volume of chilled and heating water. Suitable brine for Hitachi’s product should be selected. Its − specifi cation is accorded with Hitachi technical handbook 3. Water for use “caution in use of brine”.

  • Page 159: Cleaning Of Water Side Heat Exchanger Cleaning Of Water Side Heat Exchanger

    Maintenance 6.4. Cleaning of water side heat exchanger 6.4. Cleaning of water side heat exchanger 6.4. Cleaning of water side heat exchanger Plate heat exchanger is used in water side heat exchanger in this series . Water passes through the clearance between plates in the plate heat exchanger, therefore, dust or foreign materials should not exist there.

  • Page 160: Cleaning Method

    Maintenance 6.4.1. Cleaning method> Cleaning whole system using the existing pump and cleaning only water circuit of chiller unit (single body cleaning) are the popular cleaning methods. Here, it is explained how to do concretely in simple body cleaning. Nº Name ...
  • Page 161 Maintenance  Step 4: Wastewater treatment Acid-proof pump operation is stopped. − Wastewater is put to the tank for wastewater collection. − Water is put in the tank for cleaning and the tank is washed with pump. − Water used before is also put to the tank for wastewater collection. −...

  • Page 162: Check Items In Daily Operation

    Maintenance 6.5. Check items in daily operation 6.5. Check items in daily operation 6.5. Check items in daily operation Check items Check contents Result (write the value or X ) Check of around of chiller unit Remove the obstacle Good / NG Pressure, quantity and quality of chilled (heating) Good / NG water...

  • Page 163: Refrigerant Oil

    Ester series synthetic oil Name Ferreol UX300 of Japan Energy Fluid point Below -20°C kinematic viscosity (40 °C) 250~310mm2/s water saturation Aprox. 1600 ppm Model Reference Refrig. Qty. (kg) RCUE40AG2 RCUE40AG2 8E041072 RCUE50AG2 RCUE50AG2 8E051072 RCUE60AG2 RCUE60AG2 8E061072 RCUE70AG2 RCUE70AG2 8E071072...

  • Page 164: Manual At Compressor Overall Check And Parts Check

    Maintenance 6.6.3. Refrigeration cycle complete parts Organic materials (rubber, tefl on) used in compressor and control device use compatible parts with Freol UX300 and R407C. The pressure of R407C is higher than that of R22, and pressure strength of devices is increased. Therefore, devices for R407C are not compatible with that for R22.

  • Page 165: Structure And Start-Up Method Of Compressor Structure And Start-Up Method Of Compressor

    Maintenance 6.7.2. Structure and Start-up method of Compressor Structure of Compressor  The structure of compressor used in this series is shown below fi gures: 1. A screw of half-sealed compressor is composed with male rotors and female rotors which have 5~6 dies.
  • Page 166 Maintenance  Structure drawing of Nº Name Material 50ASP-H, 50ASP-Z 50ASP-H, 50ASP-Z:  Main casing FC250 Discharge  Screw rotor  Roller bearing  Motor  Motor casing FC250  Ball bearing  Slide valve   Piston  D casing FC250 Suction ...
  • Page 167 All Hitachi self-sealed screw compressors of rated output more than 22kW adapt - start-up system due to its high performance from the view of start-up current.

  • Page 168: Refrigerant Cycle Diagrams

    Maintenance 6.8. Refrigerant cycle diagrams 6.8. Refrigerant cycle diagrams 6.8. Refrigerant cycle diagrams 6.8.1. Refrigerant cycle diagram of Hitachi Air-Cooled Water Chiller (RCUE 40, 50, 60, 70, 100, 120, 140, 180, 210, 280, 350 AG2) Option Gauge manifold Option Option...

  • Page 169: Refrigerant Cycle Diagram Of Hitachi Air-Cooled Water Chiller (Rcue 80, 160, 240, 320, 400 Ag2) With Economizer

    Maintenance 6.8.2. Refrigerant Cycle Diagram of Hitachi Air-Cooled Water Chiller (RCUE 80, 160, 240, 320, 400 AG2) with economizer. Option Gauge manifold Option Option Option Chilled Water Inlet Charging Charging Evacuation Chilled Water Outlet Unit side Flange Connection Flare Connection...

  • Page 170: Refrigerant Cycle Diagram Of Hitachi Air-To-Water Heat Pump Chiller (Rhue 40, 50, 60, 70, 100, 120, 140, 180, 210Ag2)

    Maintenance 6.8.3. Refrigerant Cycle diagram of Hitachi Air-to-water Heat Pump Chiller (RHUE 40, 50, 60, 70, 100, 120, 140, 180, 210AG2) Gauge manifold Option Option Option Option Option Option Option Chilled Water Inlet Evacuation Charging Chilled Water Outlet Flange Connection...

  • Page 171: Refrigerant Cycle Diagram Of Hitachi Air-To-Water Heat Pump Chiller (Rhue 80, 160, 240 Ag2) With Economizer.)

    Maintenance 6.8.4. Refrigerant Cycle diagram of Hitachi Air-to-water Heat Pump Chiller (RHUE 80, 160, 240 AG2) With economizer.) Gauge manifold Option Option Option Option Option Option Option Chilled Water Inlet Charging Evacuation Chilled Water Outlet Flange Connection Unit side Flare Connection...

  • Page 172: Overhaul Work

    Maintenance 6.9. Overhaul work Perform the work according to “Dissolution and Composition Manual of Hitachi Half Sealed Screw Compressor”. When compressor is removed from refrigeration cycle, high pressure part should be separated between projecting part fl ange of compressor and upper cover of oil separator. Do not be separated between check valve and projecting part fl...

  • Page 173: Leave

    Maintenance Water evaporation> − In atmosphere pressure, water boils at 100°C, however, each time a pressure in pipes reaches to a vacuum state, water boils at lower temperature than 100°C. The lower this temperature is, the more water evaporates and vacuum drying is kept.

  • Page 174: Additional Refrigerant Insertion

    Maintenance 6.11. Additional refrigerant insertion 6.11. Additional refrigerant insertion 6.11. Additional refrigerant insertion According to the refrigerant characteristics, the followings should be taken into account.  CAUTION Refrigerant should be added in liquid state not in gas state. − Confi rm if the tanks are specialised for R407C. −...

  • Page 175: Measurement Device Used For Refrigerant Insertion

    Maintenance 6.11.2. Measurement device used for refrigerant insertion Measurement device for R407C is not compatible with that for R22 due to the following reasons, therefore, do not divert them. These devices should be controlled separately to avoid being mixed. Measurement device Reasons Remarks Manifold valve...

  • Page 176: Check Of Leakage Position

    Maintenance 1. After vacuuming, additional refrigerant should be inserted in liquid state with stop valve of liquid side and gas side close. (Confi rm the volume by the balance) In principal, collected refrigerant from water side heat exchanger to outside of ...

  • Page 177: Caution At Replacement Of Expansion Valve

    Maintenance 6.11.5. Caution at Replacement of Expansion Valve The replacement of expansion valve can be performed by collecting the refrigerant to air side heat exchanger in the method shown in the “1 Collection of Refrigerant”. And pay attention to the following points. Electrical expansion valve is used in this product, and its opening is almost closed (10 pulse) at compressor stop.
  • Page 182 HITACHI participa en el programa de certificación EUROVENT. Los productos cumplen con las especificaciones del directorio de productos certificados por EUROVENT. Hitachi Air Conditioning Products Europe, S.A. Ronda Shimizu,1 - Políg. Ind. Can Torrella 08233 Vacarisses (Barcelona) España ISO 9001, certificados por AENOR, España ISO 14001, certificados por AENOR, España...

This manual is also suitable for:

Rcue100ag2Rcue180ag2Rcue280ag2Rcue50ag2Rcue120ag2Rcue210ag2 ... Show all

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