Hitachi RCUE40AG1-400AG1 User Manual Download

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AIR COOLED
WATER CHILLERS
-SCREW TYPE-

Maintenance Instructions.

Service Manual

RCUE40AG1-400AG1 (R407C)
Cooling Capacity 108 kW - 1068 kW

Summary of Contents for RCUE40AG1-400AG1

Page 1: ...AIR COOLED WATER CHILLERS SCREW TYPE Maintenance Instructions Service Manual RCUE40AG1 400AG1 R407C Cooling Capacity 108 kW 1068 kW ...

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Page 3: ... 1 1 1 OUTLINE OF FAILURE DIAGNOSIS 2 1 2 ALARM INDICATION 3 1 3 FAILURE DIAGNOSIS METHOD4 1 4 ANALYSIS AND COUNTERMEASURE OF ABNORMAL RUNNING 21 2 ELECTRICAL WIRING 27 2 1 CUSTOMER WIRING 27 2 2 WIRING DIAGRAM 29 2 3 MAIN CIRCUIT BOARD 41 ...

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Page 5: ...on ON Remote Side Stop Operation Is abnormality code in segment indication confirmed Abnormality code is indicated by indication mode of alarm Occurence Data Abnormality code is indicated in the segment indication Take proper measure according to the alarm position NOTE After the stop operation alarm indication is turned off and initial status 88 is displayed And then abnormality code which activa...

Page 6: ...nternal Thermostat Failure of Ambient Temperature Thermistor Open Short Failure of Cooler Inlet Refrigerant Thermistor Open Short Failure of Discharge Gas Thermistor Open Short Failure of water oulet temperature thremistor i cooler siter Open Short Failure of Suction Gas Thermistor Open Short Failure of Discharge Gas Pressure Sensor Open Short Failure of Suction Gas Pressure Sensor Open Short Erro...

Page 7: ... transformer Wiring check Connector check Is 26 7V in PIN1 PIN2 17 6V in PIN3 PIN4 17 6V in PIN5 PIN6 of the printed circuit board for CPU PCBc connector CN2B and CN2C Is voltage in each test PIN of printed circuit board for CPU 5 V part VCCO5 GND1 V5B GND1 VCCO5N GND1 VCCR GND1 15V part VCC15T GND1 15V part VCC15T GND1 24V part VCC24 GND1 VCC24T GND1 Power Source Circuit Malfunction Replace Print...

Page 8: ...cated when it occurs 3 times during 30 minutes It will retry until 2 times Is connector CN 29Ps on the printed circuit board for relay PCBD correctly connected Wiring Check No Shortage of Refrigerant Gas Leakage Clogging of expansion valve Clogging of strainer Clogging of low pressure side pipe Stop Valve malfunction Shortage of Water Pump reverse rotation Air mixed Deposits on Water Cooler Plates...

Page 9: ...sistance correct Check Printed Circuit Board for Relay PCBD Thermistor resistance KΩ Temperature C Thermistor for Suction Gas Temperature characteristics Clogging of water strainer Yes No Yes Check the water flow rate Check temperature of inlet and outlet Pump reverse rotating check Check the air mixing Clogging of expansion valve Clogging of strainer No Check chilled water thermostat setting valu...

Page 10: ...Relay PCBD correctly connected Plug correctly and repair wiring Pull out connector and measure thermistor resistance Is resistance correct Replace Thermistor Check printed circuit board for Relay PCBD No Yes Yes No Yes Check water flow rate Check the temperature of Inlet and Outlet Check pump reverse rotation Check water strainer clogging Check air mixing Check Chilled water thermostat setting val...

Page 11: ...nd repair wiring Pull out connector and measure thermistor resistance Is resistance correct Replace Thermistor Check printed circuit board Thermistor resistance KΩ Temperature C Thermistor for Water Temperature characteristics No Yes Yes No Yes Check water flow rate Check the temperature of Inlet and Outlet Check pump reverse rotation Check water strainer clogging Check air mixing Check Chilled wa...

Page 12: ...pressure switch PSH1 6 reset button activated Reset Cycle Check Is 220 240V the voltage between connector PCN203 PIN1and connector PCN 203 PIN3 on the Printed Circuit Board for Relay PCBD1 6 Wiring check breaking of wire wrong wiring Is 220 240V the voltage between connector PCN203 PIN1 and connector PCN 203 PIN3 on the Printed Circuit Board for Relay PCBD1 6 Wiring Check Check Printed Circuit Boa...

Page 13: ...correctly connected Wiring check breaking of wire wrong wiring Pull out connector and measure thermistor resistance Is resistance correct Replace Thermistor Thermistor resistance KΩ Temperature C Thermistor for Discharge Gas Temperature characteristics Yes No Yes Shortage of Refrigerant Gas Leakage Check Valve Malfunction Clogging of expansion valve Expansion valve opening check Clogging of strain...

Page 14: ...Wiring Check Phase Abnormality This alarm code is indicated when the power source phase failure or reverse phase occur Is power source phase failure or reverse phase Power Supply Wiring Check Is printed circuit board for relay PCBD connector R S T correctly connected Connection repair Is the power source of connector R S T part phase failure or reverse phase Repair to correct phase Check printed c...

Page 15: ...rinted circuit board for CPU PCBC correctly connected Plug correctly and repair wiring Is connector on the printed circuit board for Fan speed control PCBE correctly connected Plug correctly and repair wiring Check the Printed circuit board for Fan speed control PCBE Replace the printed circuit board for Fan Speed PCBE Replace the printed circuit board for CPU PCBC Normal Yes Yes No No Abnormal ...

Page 16: ... motor internal thermostat is higher than 135ºC Is alarm activated just after running Is 220 240V the voltage between connector PCN206 PIN1 and connector PCN206 PIN3 on the Printed Circuit Board for Relay PCBD Check Printed Circuit Board for Relay PCBD Wiring check breaking of wire wrong wiring Is 220 240V the voltage between connector PCN206 PIN1 and connector PCN206 PIN3 on the Printed circuit b...

Page 17: ...rmistor Abnormality Outlet Water Temperature Thermistor Abnormality Ambient Temperature Thermistor Abnormality Is connector on the printed circuit board for CPU PCBc correctly connected Plug Wiring Repair Pull out connector and measure thermistor resistance Is resistance correct Replace thermistor Replace printed circuit board for CPU PCBC Thermistor resistance KΩ Thermistor resistance KΩ Temperat...

Page 18: ... Ω Resistance 179 kΩ Is printed circuit board for relay PCBD connector CN23Te2 correctly connected Plug Wiring Repair Disconnect connector and measure resistance Is the resistance correct Replace thermistor Replace printed circuit board for relay PCBD Thermistor resistance KΩ Temperature C Thermistor for Cooler Inlet Refrigerant characteristics No Yes No Yes ...

Page 19: ...r below table Is connector CN24 Td on the Printed Circuit Board for Relay PCBD correctly connected Connect correctly Pull out connector and measure thermistor resistance Is resistance correct Replace thermistor Check Printed Circuit Board Thermistor resistance KΩ Air temperature C Thermistor for Discharge Gas Temperature characteristics No Yes No Yes ...

Page 20: ...ce 179 kΩ Is printed circuit board for relay PCBD connector CN25Ts correctly connected Plug Wiring Repair Disconnect connector and measure resistance Is the resistance correct Replace thermistor Replace printed circuit board for relay PCBD Thermistor resistance KΩ Temperature C Thermistor for Suction Gas Temperature characteristics No Yes No Yes ...

Page 21: ...ed circuit board for relay PCBD Replace the printed circuit board for relay PCBD Is less than DC 0 1V or more than DC 4 9V between connector CN28Pd PIN2 and PIN3 on the printed circuit board for relay PCBD when discharge gas pressure sensor is connected Replace the printed circuit board for relay PCBD Is discharge gas pressure sensor connecting pipe clogging Remove clogging in the pipe Discharge g...

Page 22: ...and PIN3 on the printed circuit board for relay PCBD when suction gas pressure sensor is connected Replace the printed circuit board for relay PCBD Is suction gas pressure sensor connecting pipe clogging Remove clogging in the pipe Suction gas Pressure Sensor Abnormality Error comunication between Ctrl PCB This alarm code is indicated when the transmission signal between Ctrol PCB is missing more ...

Page 23: ...evice and printing board Is it changed over to remote side during local operation It is incorrect operation that changeover to Remote Side during Local Operation Do not perform it Check printed circuit board for display PCBA Check printed circuit board for operation PCBB Check printed circuit board for CPU PCBC Activation of Differential Pressure Control This alarm code is indicated when the press...

Page 24: ... Pump CMP pump feed back signal is not coming and Unit stops Is 220 240V between PIN1 and PIN3 of connector PCN4 on the printed circuit board for CPU PCBC Is pump thermal relay for pump TRP activated Check pump lock Check thermal relay for pump Check printed circuit board for CPU PCBC Check wiring around pump and thermal relay for pump Yes activated immediately Yes No No Activate after a while Yes...

Page 25: ...Replace auxiliary relay and fuse Solenoid Valve Coil Failure Measure the coil resistance Replace solenoid coil and fuse Printed Circuit Board Short Circuit Conductive Foreign Particle Remove the particle and replace fuse Fuse for operation circuit is melted Crankcase Heater Failure Measure resistance Replace oil heater and fuse Trans Coil Failure Measure the transformer secondary voltage Replace t...

Page 26: ...oltage at starting up is low Measure the voltage Consult with electric power company Excessive dust in air side heat exchanger Inlet or outlet of air side heat exchanger is clogged Remove it Shortage of Service Space for Chiller Unit Secure the service space Insufficient air in air side heat exchanger Reverse Rotation of Fan Motor Change wiring for fan motor Air Short Circuits in Chiller Unit Remo...

Page 27: ...ness Replace contact points Compressor Bearing Failure Lock Status Compressor Motor insulation Failure Measure insulation resistance Replace compressor Thermal relay for compressor is activated alarm alarm Compressor internal thermostat is activated alarm alarm Fan internal thermostat is activated alarm alarm Compressor Motor Over current relay Failure Measure current of compressor motor Replace o...

Page 28: ...Unit Repair short circuit Air temperature through air side heat exchanger is high Another Heat Source around the Chiller Unit Remove heat source Refrigerant Excessive charge Check cycle temperature Charge the correct quantity Non condensable Gas in the Refrigerant Cycle Turn off the unit and check the relation between water temperature and pressure Evacuate and charge refrigerant again High Pressu...

Page 29: ... RUN STOP SIGNAL ALARM SIGNAL DC24V LOW VOLTAGE REMOTE CONTROL MODE No Use Low Voltage Control Dip Switch Setting DSW1 of Main PCB NORMAL MODE No Low Voltage Control MODE1 Hi Lo ON OFF MODE 2 Pulse SETTING OF LOW VOLTAGE CONTROL NOTE 1 All the setting shall be performed before Power ON 2 Remote Local Change over Switch on Operation Switch shall be set to Remote 3 Terminals 1 17 are for AC220 240V ...

Page 30: ... n4 Internal Thermostat for Fan Motor PCBE1 En Printed Circuit Board for Fan Control OPTION CH1 n Crankcase Heater WP Water Pressure Switch Water Flow Switch OPTION AR1 n H R Auxiliary Relay PBSR1 Push Button Switch for Starting REMOTE OPTION PSH1 n High Pressure Switch OFF 2 74Mpa ON Manual Reset PBSR2 Push Button Switch for Stoppage REMOTE Pd1 n High Pressure Sensor RL Pilot Lamp for Remote Indi...

Page 31: ...ICAL WIRING 2 27 2 2 WIRING DIAGRAM 2 2 1 POWER CIRCUIT POWER CIRCUIT FOR RCUE 40AG1 RCUE 50AG1 RCUE 60AG1 RCUE 70AG1 Models RCUE 40AG1 RCUE 50AG1 RCUE 60AG1 RCUE 70AG1 Main Switch POWER CIRCUIT OPTION OPTION ...

Page 32: ...2 28 ELECTRICAL WIRING POWER CIRCUIT FOR RCUE 80AG1 RCUE 100AG1 RCUE 120AG1 RCUE 140AG1 Main Switch POWER CIRCUIT Models RCUE 80AG1 RCUE 100AG1 RCUE 120AG1 RCUE 140AG1 ...

Page 33: ...ELECTRICAL WIRING 2 29 POWER CIRCUIT FOR RCUE 150AG1 RCUE 180AG1 RCUE 200AG1 Main Switch POWER CIRCUIT Models RCUE 150AG1 RCUE 180AG1 RCUE 200AG1 ...

Page 34: ...2 30 ELECTRICAL WIRING POWER CIRCUIT FOR RCUE 240AG1 RCUE 270AG1 Main Switch POWER CIRCUIT Models RCUE 240AG1 RCUE 270AG1 ...

Page 35: ...ELECTRICAL WIRING 2 31 POWER CIRCUIT FOR RCUE 300AG1 RCUE 330AG1 Models RCUE 300AG1 RCUE 330AG1 Main Switch POWER CIRCUIT ...

Page 36: ...2 32 ELECTRICAL WIRING POWER CIRCUIT FOR RCUE 360AG1 RCUE 400AG1 Models RCUE 360AG1 RCUE 400AG1 Main Switch POWER CIRCUIT ...

Page 37: ...ELECTRICAL WIRING 2 33 2 2 2 CONTROL CIRCUIT CONTROL CIRCUIT FOR RCUE 40AG1 RCUE 50AG1 RCUE 60AG1 RCUE 70AG1 Models RCUE 40AG1 RCUE 50AG1 RCUE 60AG1 RCUIE 70AG1 CONTROL CIRCUIT FAN SPEED CTRL OPTION ...

Page 38: ...2 34 ELECTRICAL WIRING CONTROL CIRCUIT FOR RCUE 80AG1 RCUE 100AG1 RCUE 120AG1 RCUE 140AG1 CONTROL CIRCUIT Models RCUE 80AG1 RCUE 100AG1 RCUE 120AG1 RCUE 140AG1 FAN SPEED CTRL OPTION ...

Page 39: ...ELECTRICAL WIRING 2 35 CONTROL CIRCUIT FOR RCUE 150AG1 RCUE 180AG1 RCUE 200AG1 CONTROL CIRCUIT FAN SPEED CTRL OPTION Models RCUE 150AG1 RCUE 180AG1 RCUE 200AG1 ...

Page 40: ...2 36 ELECTRICAL WIRING CONTROL CIRCUIT FOR RCUE 240AG1 RCUE 270AG1 CONTROL CIRCUIT Models RCUE 240AG1 RCUE 270AG1 FAN SPEED CTRL OPTION ...

Page 41: ...ELECTRICAL WIRING 2 37 CONTROL CIRCUIT FOR RCUE 300AG1 RCUE 330AG1 FAN SPEED CTRL OPTION Models RCUE 300AG1 RCUE 330AG1 CONTROL CIRCUIT FAN SPEED CTRL OPTION ...

Page 42: ...2 38 ELECTRICAL WIRING CONTROL CIRCUIT FOR RCUE 360AG1 RCUE 400AG1 FAN SPEED CTRL OPTION CONTROL CIRCUIT Models RCUE 360AG1 RCUE 400AG1 FAN SPEED CTRL OPTION ...

Page 43: ...CIRCUIT BOARD MAIN PRINTED CIRCUIT BOARD MASTER Remote control Switch RSW A option MAIN PRINTED CIRCUIT BOARD MASTER Differential Water Pressure Switch Option FAN SPEED CTRL OPTION BMS CONNECTION POWER OPERATION OPERATION ALARM CHECK ...

Page 44: ...ECTRICAL WIRING RELAIS PRINTED CIRCUIT BOARD SUBSIDIARY Model RCUE 300AG1 RCUE 330AG1 RCUE 360AG1 RCUE 400AG1 RELAYS PRINTED CIRCUIT BOARD SUBSIDIARY PCB C MASTER only RCUE 300AG1 400AG1 Fan Speed Ctrl option ...

Page 45: ...AL WIRING 2 41 RELAYS PRINTED CIRCUIT BOARD Model RCUE 40 50 60 70AG1 RCUE 80 100 120 140AG1 RCUE 150 180 200AG1 RCUE 240 270AG1 OPTION ONLY RELAYS PRINTED CIRCUIT BOARD Except RCUE 40 80 AG1 DUMMY THERMI DM 1 ...

Page 46: ...TED CIRCUIT BOARD ONLY Model RCUE 300 330AG1 RCUE 360 400AG1 RELAYS PRINTED CIRCUIT BOARD OPTION No cables n 3 5 for RCUE300 330AG1 No cables n 4 6 for RCUE360 400AG1 No cables n 3 5 for RCUE300 330AG1 No cables n 4 6 for RCUE360 400AG1 ...

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Page 48: ...ioning Products Europe S A Ronda Shimizu 1 Políg Ind CanTorrella 08233 Vacarisses Barcelona España ISO 9002 certified byAENOR 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 Air Conditioning Systems Operation Shimizu shi Shizuoka ken J...

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