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Hitachi RCUE40AG1-400AG1 Service Manual

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Service Manual
Maintenance Instructions.
AIR COOLED
WATER CHILLERS
-SCREW TYPE-
RCUE40AG1-400AG1 (R407C)
Cooling Capacity 108 kW - 1068 kW

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   Summary of Contents for Hitachi RCUE40AG1-400AG1

  • Page 1

    Service Manual Maintenance Instructions. AIR COOLED WATER CHILLERS -SCREW TYPE- RCUE40AG1-400AG1 (R407C) Cooling Capacity 108 kW - 1068 kW...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1.TROUBLESHOOTING ......................... 1 1.1. O ......................2 UTLINE OF AILURE IAGNOSIS 1.2. A ..........................3 LARM NDICATION 1.3. F AILURE IAGNOSIS ETHOD 1.4. A ...............21 NALYSIS AND COUNTERMEASURE OF BNORMAL UNNING 2. ELECTRICAL WIRING........................ 27 2.1. C ..........................27 USTOMER WIRING 2.2.

  • Page 5: Troubleshooting

    TROUBLESHOOTING 1 TROUBLESHOOTING 1.1. OUTLINE OF FAILURE DIAGNOSIS In the case of abnormality, alarm lamp of remote control and alarm LED on the control panel are ON. And segment indication on the control panel is flickering. For stopping the unit, put it into stop operation without power OFF. Alarm occur Segment Indication: Remote Control Run Indication:...

  • Page 6: Alarm Indication

    TROUBLESHOOTING 1.2. 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 Excessively Low Pressure   Low Pressure Protection by Suction Gas Thermistor ...

  • Page 7: Failure Diagnosis Method

    TROUBLESHOOTING 1.3. FAILURE DIAGNOSIS METHOD 1.3.1. GENERAL CHECK OF FAILURE DIAGNOSIS. In the case of no segment indication, unit cannot operate. Is 220-240V supplied Check the power to the unit?: source switch Is 220-240V supplied to Is fuse broken? Replace fuse transformer primary side? Wiring check Is R phase or S...

  • Page 8

    TROUBLESHOOTING [] ~ [] Excessively Low Suction Pressure In case of the suction pressure is less than 0.31 Mpa during 90 seconds, the unit will stop at once and indicate “[ ]”. 3 minuts later, the unit will start again. This Alarm code is indicated when it occurs 3 times during 30 ...

  • Page 9

    TROUBLESHOOTING [] ~ [] Low Pressure Protection by Suction Gas Thermistor This alarm code is indicated when the suction temperature is lower than -2°C during 10 seconds. Is the wiring of connector in the Plug correctly and Printed Circuit Board for Relay repair wiring (PCB ) correct?

  • Page 10

    TROUBLESHOOTING []~[] Excess Low Temperature of Cooler Inlet Refrigerant In case of the cooler inlet refrigerant temperature is lower than -3°C during 10 seconds, the unit will stop at once and indicate “[ ]”. 3 minutes later, the unit will start again. This alarm code is indicated when it occurs 3 times during 30 ...

  • Page 11

    TROUBLESHOOTING [] Activation of Freeze Protection Control This alarm code is indicated when the water inlet or outlet temperature is lower than 2°C. Is connectors on the Printed Circuit Board correctly connected? Plug correctly and :CN4,CN6,CN7,CN3 repair wiring :CN23Te2 Pull out connector and measure thermistor resistance Replace Thermistor Is resistance correct?

  • Page 12

    TROUBLESHOOTING ] ~ [] Activation of high pressure switch (PSH This alarm code is indicated when the discharge pressure is higher than 2.74 Mpa. Is 220-240V the voltage between connector (Activate immediately) PCN203 PIN1 and Is alarm activated just after connector PCN 203 Check running?

  • Page 13

    TROUBLESHOOTING [] ~ [] Activation of Discharge Gas Thermostat This alarm code is indiacted when the temperature in discharge pipe is higher than 140ºC Is connector CN24Td on the Wiring check (breaking of wire, printed circuit board for relay wrong wiring) (PCB ) correctly connected Pull out connector and...

  • Page 14

    TROUBLESHOOTING [] ~ [] Activation of Compressor Internal Thermostat This alarm code is indicated when the compressor internal thermostat is higher than 115ºC Is 220-240V the voltage between connector PCN204 Check Printed PIN1 and connector Is alarm activated just after Circuit Board for PCN 204 PIN3 on running?

  • Page 15

    TROUBLESHOOTING []~[] Error comunication between Ctrl. PCB and Fan speed Ctrl. PCB This alarm code is indicated when the transmission signal is missing more than 5 seconds. Is connector CN14A on the Plug correctly and printed circuit board for CPU repair wiring (PCB ) correctly connected?

  • Page 16

    TROUBLESHOOTING []~[] Thermistor set before Expansion Valve Abnormality This alarm code is indicated when the thermistor resistance is out of range (72 Ω ≤ Resistance ≤ 179 kΩ) Is printed circuit board for relay (PCB ) connector CN22Te1 Plug, Wiring Repair correctly connected? Disconnect connector and measure resistance.

  • Page 17

    TROUBLESHOOTING [] [] [] [] [][]~ [] Temperature Thermistor Abnormality This alarm code is indicated when the thermistor resistance is out of range. (Water Temperature Thermistor: 240 Ω ≤ Resistance ≤ 39 kΩ) (Ambient Temperature Thermistor: 240 Ω ≤ Resistance ≤ 600 kΩ) [] Inlet Water Temperature Thermistor Abnormality [] [] [] Outlet Water Temperature Thermistor Abnormality [] Ambient Temperature Thermistor Abnormality...

  • Page 18

    TROUBLESHOOTING []~ [] Cooler Inlet Refrigerant Temperature Thermistor Abnormality This alarm code is indicated when the thermistor resistance is out of range (72 Ω ≤ Resistance ≤ 179 kΩ) Is printed circuit board for relay (PCB ) connector CN23Te2 Plug, Wiring Repair correctly connected? Disconnect connector and measure resistance.

  • Page 19

    TROUBLESHOOTING []~[] Discharge Gas Temperature Thermistor Abnormality This alarm code is indicated when the thermistor resistance is out of range (Refer below table). Is connector CN24 Td on the Printed Circuit Board for Relay Connect correctly (PCB ) correctly connected? Pull out connector and measure thermistor resistance.

  • Page 20

    TROUBLESHOOTING []~[] Suction Gas Thermister Abnormality This alarm code is indicated when the thermistor resistance is out of range (72 Ω ≤ Resistance ≤ 179 kΩ) Is printed circuit board for relay (PCB ) connector CN25Ts Plug, Wiring Repair correctly connected? Disconnect connector and measure resistance.

  • Page 21

    TROUBLESHOOTING [] [] Discharge Gas Pressure Sensor Abnormality Malfunction of pressure sensor Is connector CN28Pd on the printed circuit board for relay Connect correctly (PCB ) correctly connected? Is DC24V between Replace the connector CN28Pd PIN1 and printed circuit board PIN3 on the printed circuit for relay (PCB board for relay (PCB...

  • Page 22

    TROUBLESHOOTING [] [] Suction Gas Pressure Sensor Abnormality Malfunction of pressure sensor Is connector CN29Ps on the printed circuit board for relay Connect correctly (PCB ) correctly connected? Is DC5V between Replace the connector CN29Ps PIN1 and printed circuit board PIN3 on the printed circuit for relay (PCB board for relay (PCB...

  • Page 23

    TROUBLESHOOTING [] Alarm for Operation Error Performed incorrect operation. It is incorrect that Yes (Normal No (Remote) Is changeover to operation changeover Running) Is local operation? local side during remote to local side during operation? remote operation. Do not perform it. Yes (Local) Wiring Check between Is 220-240V between PIN1-PIN3...

  • Page 24

    TROUBLESHOOTING [] ~ [] Activation of Thermal Relay for Compressor This alarm code is indicated when the compressor running current is more than thermal Relay Setting Value. Is 220-240V the voltage between Yes (activated immediately) connector PCN207 Check Printed PIN1 and connector Is alarm activated just after Circuit Board for PCN 207 PIN3 on...

  • Page 25: Analysis And Countermeasure Of Abnormal Running

    TROUBLESHOOTING 1.4. ANALYSIS AND COUNTERMEASURE OF ABNORMAL RUNNING Chiller unit has various kinds of protection device. When the operation is not correct status due to the activation of some protection device, refer to the table below and find out the main reason to take a countermeasure. 1 failure can affect other different conditions.

  • Page 26

    TROUBLESHOOTING Repair the wiring Wiring Connection Failure Check circuit by tester connection Printed Circuit Board Failure Check circuit by tester Check Printed Circuit Board Replace Printed Circuit Printed Circuit Board by self- Failure Board checking function Pump runs, but neither fan nor Replace remote Remote Control Switch Failure...

  • Page 27

    TROUBLESHOOTING Check valve (Air heat exchanger side) Replace check valve Suction gas Malfunction temperature is Discharge gas excessively high control is activated (excessive Expansion Valve Clogging Remove Clogging superheat) (- alarm)~ (- alarm) Strainer Clogging Replace or clean the strainer Discharge gas Replace discharge gas Check thermistor resistance...

  • Page 28

    TROUBLESHOOTING The heat load is bigger than cooling capacity Calculate heat load Replace to larger unit Gas leakage or shortage of Charge correct quantity after Check super-heat. refrigerant checking gas leakage Expansion Valve Clogging Check clogging Remove clogging Check to make sure that no difference of temperature Strainer Clogging Replace strainer...

  • Page 29: Electrical Wiring

    ELECTRICAL WIRING 2. ELECTRICAL WIRING 2.1. CUSTOMER WIRING...

  • Page 30

    ELECTRICAL WIRING PARTS LIST (n=1~N) Mark Name Remark Mark Name Remark Suction Gas Temperature Compressor Motor THMs Thermistor Condenser Fan Motor THMI Liquid Temperature Thermistor OPTION 11-n4 Main Isolator Fuse 1~3, R,S,T Contactor for Compressor Motor Solenoid Valve for Starting 11-n1 Contactor for Compressor Motor Solenoid Valve for Load-down...

  • Page 31: Wiring Diagram

    ELECTRICAL WIRING 2.2. WIRING DIAGRAM 2.2.1. POWER CIRCUIT POWER CIRCUIT FOR RCUE 40AG1, RCUE 50AG1, RCUE 60AG1, RCUE 70AG1...

  • Page 32

    ELECTRICAL WIRING POWER CIRCUIT FOR RCUE 80AG1, RCUE 100AG1, RCUE 120AG1, RCUE 140AG1...

  • Page 33

    ELECTRICAL WIRING POWER CIRCUIT FOR RCUE 150AG1, RCUE 180AG1, RCUE 200AG1...

  • Page 34

    ELECTRICAL WIRING POWER CIRCUIT FOR RCUE 240AG1, RCUE 270AG1...

  • Page 35

    ELECTRICAL WIRING POWER CIRCUIT FOR RCUE 300AG1, RCUE 330AG1...

  • Page 36

    ELECTRICAL WIRING POWER CIRCUIT FOR RCUE 360AG1, RCUE 400AG1...

  • Page 37

    ELECTRICAL WIRING 2.2.2. CONTROL CIRCUIT CONTROL CIRCUIT FOR RCUE 40AG1, RCUE 50AG1, RCUE 60AG1, RCUE 70AG1...

  • Page 38

    ELECTRICAL WIRING CONTROL CIRCUIT FOR RCUE 80AG1, RCUE 100AG1, RCUE 120AG1, RCUE 140AG1...

  • Page 39

    ELECTRICAL WIRING CONTROL CIRCUIT FOR RCUE 150AG1, RCUE 180AG1, RCUE 200AG1...

  • Page 40

    ELECTRICAL WIRING CONTROL CIRCUIT FOR RCUE 240AG1, RCUE 270AG1...

  • Page 41

    ELECTRICAL WIRING CONTROL CIRCUIT FOR RCUE 300AG1, RCUE 330AG1...

  • Page 42

    ELECTRICAL WIRING CONTROL CIRCUIT FOR RCUE 360AG1, RCUE 400AG1...

  • Page 43: Main Circuit Board

    ELECTRICAL WIRING 2.3. MAIN CIRCUIT BOARD MAIN PRINTED CIRCUIT BOARD (MASTER)

  • Page 44

    ELECTRICAL WIRING RELAIS PRINTED CIRCUIT BOARD (SUBSIDIARY)

  • Page 45

    ELECTRICAL WIRING RELAYS PRINTED CIRCUIT BOARD...

  • Page 46

    ELECTRICAL WIRING RELAYS PRINTED CIRCUIT BOARD...

  • Page 48

    Ronda Shimizu, 1 - Políg. Ind. Can Torrella 08233 Vacarisses (Barcelona) España ISO 9002 certified by AENOR, Spain HITACHI is participating in the EUROVENT Certification Programme. Products are as specified in the EUROVENT Directory of Certified Products. Products are manufactured according to the ISO certification system.

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