Hitachi RCME-AH1 Service Manual Download

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SAMURAI SERIES

AIR COOLED WATER CHILLERS AND

AIR TO WATER HEAT PUMP

-MODULAR-R134a-SCREW TYPE-

RCME-(40-70)AH1

RCME-(080-210)/(2-3)AH1

Service Manual

RHME-(40-70)AH1

RHME-(080-210)/(2-3)AH1

Summary of Contents for RCME-AH1

Page 1: ...SAMURAI SERIES AIR COOLED WATER CHILLERS AND AIR TO WATER HEAT PUMP MODULAR R134a SCREW TYPE RCME 40 70 AH1 RCME 080 210 2 3 AH1 Service Manual RHME 40 70 AH1 RHME 080 210 2 3 AH1 ...

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Page 3: ...Contents SMGB0082 rev 1 07 2015 General information Control Functions Servicing Troubleshooting Co n tents 1 2 3 4 I ...

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Page 5: ...trol from external signal 25 2 1 11 2 temperature setting function 26 2 1 12 External thermo operation from external contact 27 2 1 13 Water Temperature of the Control Target 29 2 1 14 Operation from DC24V contact input 30 2 1 15 Attachment of snowfall switch Forced fan operation 35 2 1 16 Silence priority mode Night shift Only in cooling operation 36 2 1 17 Thermo OFF function selection 37 2 1 18...

Page 6: ...ss inside the module for servicing 77 3 4 Removing covers 78 3 4 1 Unit description 78 3 4 2 Panels on the left 2 panels or right side 2 panels 79 3 4 3 Front cover E Box compressor side 79 3 4 4 Front cover Hex lower cover 80 3 4 5 Rear cover water connection side 80 3 4 6 Water pipes support 81 3 4 7 Protection net Air cooler grille 82 3 5 Cycle components 83 3 5 1 Compressor removal 83 3 5 2 Ov...

Page 7: ...cal components 99 3 6 1 Replacement of the electrical box assy 99 3 6 2 Open electrical box doors 100 3 6 3 Replacement of lamps and push buttons 101 Removal of the PCB s 102 3 6 4 Removal of the LCD screen 104 3 6 5 Transformer TF1 106 3 6 6 Transformers TF2 TF3 TF4 106 3 6 7 Overcurrent relay ORC 107 3 6 8 Contactors CMC CMCD CMCS 107 3 6 9 Fuses EF1 EF2 EF3 EFR EFS EFT 108 3 6 10 Fuses PFC 108 ...

Page 8: ...tics 160 4 12 1 Thermistor temperature characteristics All temperature except ambient and discharge gas 160 4 12 2 Thermistor temperature characteristics for ambient temperature 160 4 12 3 Thermistor temperature characteristics for discharge gas temperature 160 4 13 Pressure sensor characteristics 161 4 13 1 High pressure sensor 161 4 13 2 Low pressure sensor 161 4 14 Procedures for trouble 162 ...

Page 9: ...1 General information Index 1 1 General notes 2 1 2 Safety and applied symbols 3 1 3 Product guide 4 1 3 1 Classification of water chiller models 4 1 3 2 Product guide Air cooled water chillers RCME 5 1 3 3 Product guide Air to water heat pump RHME 6 ...

Page 10: ...cepted based on the data illustrations and descriptions included in this document No type of modification must be made to the equipment without prior written authorisation from the manufacturer HITACHI pursues a policy of continuing improvement in design and performance of products The right is therefore reserved to vary specifications without notice HITACHI cannot anticipate every possible circum...

Page 11: ... wellbeing Not taking these instructions into account could lead to serious very serious or even fatal injuries to you and others in the proximity of the unit Hazards or unsafe practices which could result severe personal injury or death In the texts following the danger symbol you can also find information on safe procedures during unit installation CAUTION The text following this symbol contains...

Page 12: ...ng hyphen fixed Capacity HP 40 50 60 70 A Air cooled H R134a refrigerant Series 1 R C H M E XX A H 1 Factory built modules combinations Unit type Modular water chiller RCM Air cooled water chiller RHM Air to water heat pump E Made in Europe Position separating hyphen fixed Total capacity HP 080 090 100 110 120 130 140 150 160 170 180 190 200 210 Position separating slash fixed Nº of modules 2 3 A ...

Page 13: ...E071341 Factory built modules combinations 3N 400V 50Hz Modules of 2 units Code Modules of 3 units Code RCME 080 2AH1 8E080201 RCME 090 2AH1 8E090201 RCME 100 2AH1 8E100201 RCME 110 2AH1 8E110201 RCME 120 2AH1 8E120201 RCME 130 2AH1 8E130201 RCME 140 2AH1 8E140201 RCME 150 3AH1 8E150301 RCME 160 3AH1 8E160301 RCME 170 3AH1 8E170301 RCME 180 3AH1 8E180301 RCME 190 3AH1 8E190301 RCME 200 3AH1 8E2003...

Page 14: ...binations 3N 400V 50Hz Modules of 2 units Code Modules of 3 units Code RHME 080 2AH1 9E080201 RHME 090 2AH1 9E090201 RHME 100 2AH1 9E100201 RHME 110 2AH1 9E110201 RHME 120 2AH1 9E120201 RHME 130 2AH1 9E130201 RHME 140 2AH1 9E140201 RHME 150 3AH1 9E150301 RHME 160 3AH1 9E160301 RHME 170 3AH1 9E170301 RHME 180 3AH1 9E180301 RHME 190 3AH1 9E190301 RHME 200 3AH1 9E200301 RHME 210 3AH1 9E210301 ...

Page 15: ...18 Selection of enabling disabling of alarm release by means of remote stop 38 2 1 19 Limitation setting for pump feedback waiting time 39 2 1 20 Inlet water temperature thermo OFF function 40 2 1 21 Intermitent fan operation 41 2 1 22 Switch for confirmation of high pressure cut Cooling operation 42 2 1 23 Switch for confirmation of low pressure cut Cooling operation 43 2 1 24 Switch for confirma...

Page 16: ...ill be different Compressor Control Once that Compressor delay time has passed after pump startup compressor starts up with Υ Δ control performs startup unload control during 60 seconds and then shifts to capacity control The settings of Compressor delay time can be changed in the range between 30 seconds and 10 minutes in 30 second steps Please set a delay time adjusted to the characteristics of ...

Page 17: ... operation and heating operation have 2 setting temperatures each and it is possible to select which setting temperature is valid by external signal input In case of operating with a different extraction temperature such as heat storage or air conditioning it is not necessary to change the setting temperature of the main chiller unit Forced load up from external contact Forced load up is conducted...

Page 18: ... stored and then they are deleted from the oldest Also for the most recent 3 cases the data of each sensor right before occurrence 10 seconds before and 20 seconds before as well as data regarding each setting and operation conditions are stored and it is possible to check them later on This supports the early identification of the causes of alarm occurrence Water Temp Set Setting is possible in 0...

Page 19: ...at Thermo OFF and re start at T2 Load up I zone Load up II zone Load Down zone Thermo off zone Load up I status Load up II status Neutral status Load down status Stop status Load up II status Neutral status Neutral status Neutral zone Starting setting example Method of outlet temperature detection 1 Load up I control at over 9 C The capacity is changed a lot in order to approximate the target temp...

Page 20: ...e to change settings locally depending on usage purpose but since the necessary volume of water will change please change the settings only upon confirmation of the amount of the retained volume of water in the entire local system Output Cycle Load up I Output time Load up II Output time Load down Output time Setting range Seconds 10 120 Default 30 10 120 Default 10 2 120 Default 2 2 120 Default 2...

Page 21: ...unit is setting in only cool heat mode The part with the setting temperature currently enabled is illuminated NOTE Set1 This is the setting value of the master chiller unit and water temperature control is normally performed against this setting value Set2 This is the setting value when 2 temperature setting function is enabled see 2 1 11 2 temperature setting function Ext The setting value from a...

Page 22: ...ter 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 ...

Page 23: ... 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 pressure differential between high and low pressure b Upon alarm i...

Page 24: ...etting 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 ...

Page 25: ...tion is not selected it is necessary to restart operation Power failure exceeding 2 seconds Power source status ON OFF ON OFF ON OFF ON OFF Pump operation order Chiller unit operation status Compressor operation status min min Time guard Time guard Selected from DIP switches NOTE When this function is enabled recovery upon restoration of the power supply returns to the state before the power inter...

Page 26: ...s 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 minute guard is effective even if these functions are not used In this case it is not necessary to connect transmission cables between each chiller unit Unit No DSW3 PCBA Added time 1 2 3 4 1 OFF OFF OFF OFF 0 s 2 OFF OFF ON OFF 5 s 3 OFF ON OFF OFF 1...

Page 27: ...mp a When outdoor temperature is under 2ºC When outdoor temperature falls under 2ºC the operation order of cold hot water circulation pump is output and the continuous operation of the cold hot water pump starts automatically Here when cold hot water temperature becomes higher than 15ºC operation becomes intermitent with the pump running for 5 minutes then stopped during 55 minutes When cold water...

Page 28: ...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 diagram of automatic operation control of the pump to prevent freezing in winter Mode II 2 4 5 3 2 4 7 5 3 7 a When outdoor temperature is decreasing b When outdoor temperature is increasing Explanation of codes Continuous pump ...

Page 29: ...ntrol is not performed when Disable is selected In this case please 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 In the case of air cooled systems Select pressing Mode I Mode II Disable keys ...

Page 30: ... 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 ...

Page 31: ...al 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 In the case of air cooled systems Display the input window with INPUT key Input the setting value with up and down keys Confirm with ENT key Cancel with CAN key NOTE Input the ratio corresponding to the Standard current value displayed on the LC...

Page 32: ...ng the function to control the number of units however excluding the connection to group controller arrange the wiring to unit no 1 master unit This function becomes enabled in all the units when inputting the signal to unit no 1 setting value is also common with the setting value of unit no 1 Signal input to chiller units with address settings between unit no 2 and 8 are invalid In case of connec...

Page 33: ...SW5 Control board of the chiller unit Forced load up switch Power source of the local control board NOTE Thermo OFF judgement protection devices and protection control from the setting temperature of the main unit are always enabled and this control gives them priority When using the function to control the number of units however excluding the connection to group controller arrange the wiring to ...

Page 34: ... 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 9 Disabled 2 temperature settings enabled NOTE 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 opera...

Page 35: ...rced load operation thermal storage operation is shown 5 6 7 24 25 2 0V 3 2 0V 3 SW2 SW2 Remove the wiring between 5 and 6 if it is connected Local Remote PBSR2 OFF PBSR1 OFF Thermal storage Switch between air conditioning and thermal storage Thermal storage Forced load operation switch Air conditioning Air conditioning Time chart Forced load operation switch Chiller unit Please keep more than 5 m...

Page 36: ...hermo please 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 In the case of air coole...

Page 37: ...erature 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 Please use the outlet water temperature factory default setting in normal conditions Setting method In the case of air cooled systems Select IN ...

Page 38: ...e only in remote mode during independent operation of the chiller unit Level input a Signal aspect and basic sequence For wiring 9 Terminal board Section arranged as a local work 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 Please do not connect a LED or a relay of internal diode type Run stop switch to be prepared ...

Page 39: ...31 2 b Setting method In the case of air cooled systems NOTE Please do not bundle the additional wiring together with other control circuits and in particular with wiring for 230V or 400V Please put the additional wiring separately inside a metallic pipe or use a shielded wire ...

Page 40: ...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 Please do not connect a LED or a relay of internal diode type Time chart Switch Please keep more than 5 minutes More than 200ms More than 200ms ON OFF Run Stop Chiller unit NOTE Pulse input indicates an ON input of the same switch when changing the status of the chiller u...

Page 41: ...Setting method Select Pulse In the case of air cooled systems NOTE Please do not bundle the additional wiring together with other control circuits and in particular with wiring for 230V or 400V Please put the additional wiring separately inside a metallic pipe or use a shielded wire ...

Page 42: ...arranged locally field supplied Time chart 5 5 5 5 ON OFF ON ON Run Stop Unit More than 5 min More than 200 ms ON OFF Run Stop b Setting method Since it applies remote control it is not required to change any settings at the LCD screen NOTE 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 in...

Page 43: ... operation of the fan with the stop button on the main unit of the chiller unit Wiring of snowfall switch please arrange wiring to each module 26 24 Terminal board Chiller unit side Local works section Snowfall switch Supplied locally NOTE It is possible to install and use automatic snow relays into this switch part The use of this switch is only enabled during remote operation It is necessary to ...

Page 44: ... to switch in the middle of operation For wiring Control board of the chiller unit Silence priority mode Open Disable Closed Enabled Time chart Silence priority mode signal Operation mode of FAN ON OFF Night shift Standard Cooling Heating Switch Operation mode of the system Heating Cooling Heating Cooling Silence priority mode Night shift Standard mode Outdoor temperature ºC High pressure MPa Effe...

Page 45: ...ure Example of thermo OFF judgement extension 7 6 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 wat...

Page 46: ...e 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 fo...

Page 47: ...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 continues for a certain amount of time Initial value for the standard specification Unlimited Initial value for the specification with pump mounted 5 minutes Setting ran...

Page 48: ... 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 In the case of air cooled systems Select Enable Display the input window with INPUT key Input the setting value with up and down keys Confirm with ENT key Cancel with CAN key Thermo ON conditions are the sa...

Page 49: ...the fan due to snowfall when the unit is stopped in winter Starting conditions Outdoor temperature under 4ºC Chiller unit in remote control settings Compressor stopped The fan is operated when all of these are fulfilled operation at minimum frequency NOTE It is possible to cancel this function Setting method for cancel In the case of air cooled systems Select Disable ...

Page 50: ...cal Cooling Heating Push for more than 100ms Press the push button switch No 1 PSW3 indicated as High pressure cut check on the upper left side of the control PCB after having operated the chiller unit in cooling operation in local operation mode When pushing the push button switch the group of fans is forced to stop After this the pressure of high pressure side increases activating the high press...

Page 51: ...efrosting Press the push button switch Nº 1 PSW5 indicated as Manual defrosting on the setting PCB of the main unit after having operated the chiller unit in cooling operation in local operation mode The electronic expansion valve becomes fully close activating the low pressure control NOTE Take into account that pressing this switch during heating operation causes a manual defrosting It is disabl...

Page 52: ...tion In the case of load up Suction gas Discharge gas To suction side Slide valve Rotor Oil supply Solenoid valve 202 Solenoid valve 203 Solenoid valve 201 To suction side Cylinder part Piston Rod Spring Oil supply In case of load down Suction gas Bypass Discharge gas To suction side Slide valve Rotor Oil supply Solenoid valve 202 Solenoid valve 203 Solenoid valve 201 To suction side Cylinder part...

Page 53: ...eriod of PI control is 10 seconds The target high pressure is set according to the image beside but the high low pressure difference required by the compressor is set with preference Calculations are not performed when the target value for high pressure lies within 0 0 1 MPa The following controls are enabled to respond to sudden changes High pressure over increase prevention With high pressure 1 ...

Page 54: ...eration information of the LCD screen displays Adjusting 0 zero point of the expansion valve while the segment display becomes Cn E0 n stands for unit number Startup control I The opening is predetermined for 1 minute after compressor startup Startup control II The opening is controlled within a predetermined amount of variation until the discharge gas superheat TdSH which is calculated from the h...

Page 55: ...h the opening under normal control e Forced control In case of continued conditions of suction gas superheat higher than 8ºC with a cold water output setting temperature higher than 25ºC the valve is forced to open and momentarily set somewhat open in comparison with the opening under normal control f 0 zero point adjustment control As a correction of the deviation between the number of control pu...

Page 56: ...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 down control is continued until reaching 98 of setting value for current limit Load up c...

Page 57: ...automati cally extended from the standard 55 minutes to 115 minutes to avoid performing unnecessary defrosting 1 Since it is defrosting by reverse cycle hot water outlet temperature becomes lower than inlet temperature In case of using the functions to control the number of units there is an automatic adjustment to avoid multiple chiller units more than half when 5 of more units are in operation t...

Page 58: ...nt temperature of water side heat exchanger Tr 0ºC Capacity control hold Fan operation start Fan stop 0Hz order Tr 0ºC Tr 5ºC Pd 1 1 MPa During fan operation 1 minute has passed since start of defrosting Tr 2ºC Yes No Yes Yes No Compressor load down output 5 seconds output Compressor load up output 5 seconds output No Yes Yes No Yes Yes Pd 1 4 MPa No 7 minutes have passed since start of defrosting...

Page 59: ...eration Fan 7 Hz order output Pd 1 5 MPa 19 seconds have passed since 7 Hz order output Pd 1 0 MPa 60 seconds have passed since maximum frequency Fan maximum frequency operation start Switching of 4 way valve Compressor startup unload output 60 seconds count Defrosting control release Yes No No No Yes Pd High pressure COO72CN 3Pd Yes Yes Yes No No From previous page ...

Page 60: ...ith transmission wires b Setting of terminal resistance Perform the setting of the terminal resistance Choose one unit which may be any from unit 1 to 8 and switch ON up DSW7 1 of its CPU PCB PCBC c Setting of address For all the chiller units in the same group configure address settings Please set the addresses in ascending order without leaving gaps Example Set unit numbers from 1 to 5 if there ...

Page 61: ...ting mode required for air cooled heat pump Not necessary for air cooled Connect Cooling Heating Switching Wiring to the chiller unit set as Unit 1 Control board of unit number 1 Heating Cooling heating switch Cooling 27 28 Operation mode of the system Heating Cooling Cooling heating switch Heating Cooling 2 Pump Interlock Wiring Required Input the feedback signal of the pump to all the chiller un...

Page 62: ...No 23 System cooling heating mode 〇 Air chilled heat pump only Chiller Unit Module Operation 〇 Pump Operation 〇 Alarm 〇 Warning 〇 Defrosting 〇 Air chilled heat pump only Chiller unit module Cooling heating module 〇 Usually the same as system mode It depends on the setting of module body during local operation and forced operation Unit 1 usually displays system mode Air chilled heat pump only ...

Page 63: ... 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 5 5 Forced stop signal Alarm reset System recovery signal Please remove the connection between 5 and 6 System recovery signal Forced stop Alarm reset signal 5 More than 200ms ON ...

Page 64: ...ocal remote switch in the PCBa SW2 set to local side become detached too It is not possible to output operation orders to modules under detachment It is possible to operate modules in local setting with the Run button in the control panel of the modules as well as with forced operation order Also system operation continues even if a detachment event occurs 2 About recovery method to system from de...

Page 65: ...r 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 7 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 co...

Page 66: ...hich the next reduction process is prohibited after having reduced once stop of 1 unit Recommended 3 minutes Number of Units at Startup Sets the number of modules to be started up upon system start up Maximum number of operating units Sets the upper limit of the number of modules that can be operated at the same time Minimum number of operating units Sets the minimum number of modules to be operat...

Page 67: ...ion conditions through the LCD screen Setting screen of the control of Master Slave group In the case of master unit unit 1 setting In the case of slave unit 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 connected sh...

Page 68: ...2 Control Functions Control of Master Slave group SMGB0082 rev 1 07 2015 60 Status screen of the control of Master Slave group The operation status of each unit is shown by pressing the keys 2 to 8 ...

Page 69: ...ocally or remotely By setting it to local for instance during inspection or maintenance works an alarm is output to the remote side in case that any operation order was input remotely Standard Remote SW2 Local Remote 4 Cooling Heating switch Selects between cooling and heating when in local control setting Enabled only for air cooled heat pump systems When switching during operation it produces a ...

Page 70: ...om the Master module such as during test run or in servicing Operation order Stop order Press the Stop button Close the door inside the electrical parts box Close the door of the electrical parts box Close the door inside the electrical parts box then close the door of the electrical parts box Open the door inside the electrical parts box Preparations for remote control complete Open the door of t...

Page 71: ...splay Main unit Operation display Remote Alarm display Main unit Alarm display Remote Alarm display Remote Operation status Pump Stop ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF O N OFF ON OFF ON OFF ON OFF ON OFF Run Run Stop Stop Load up Load up Load up 2 Load down Thermo OFF Thermo ON Unit Contact for formation of self holding Electronic expansion valve Compressor 6C1 Compres...

Page 72: ...or formation of self retention Electronic expansion valve Compressor 6C1 Compressor 52C1 Compressor 42C1 Fan 52F1 4 way valve 211 For starting 2011 For capacity control Down 2012 For capacity control Up 2013 Alarm display Remote Defrosting operation display Remote Operation Status Pump Unit Solenoid valve Output Common output Input ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON ...

Page 73: ...tronic expansion valve Compressor 6C1 Compressor 52C1 Compressor 42C1 Fan 52F1 4 way valve 211 For starting 2011 For capacity control Down 2012 For capacity control Up 2013 Alarm display Remote Defrosting operation display Remote Operation Status Pump Unit Solenoid valve Output Common output Input ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON ...

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Page 75: ...cement of the stop valve with check joint 92 3 5 9 Replacement of the high pressure switch PSH 92 3 5 10 Replacement of the pressure sensor Pd 92 3 5 11 Replacement of the pressure sensor Ps 92 3 5 12 Replacement of the pressure sensor PSW 93 3 5 13 Replacement of the pressure relief valve 93 3 5 14 Replacement of the sight glass 93 3 5 15 Replacement of the crankcase heater CH 93 3 5 16 Replaceme...

Page 76: ...3 Replacement of lamps and push buttons 101 Removal of the PCB s 102 3 6 4 Removal of the LCD screen 104 3 6 5 Transformer TF1 106 3 6 6 Transformers TF2 TF3 TF4 106 3 6 7 Overcurrent relay ORC 107 3 6 8 Contactors CMC CMCD CMCS 107 3 6 9 Fuses EF1 EF2 EF3 EFR EFS EFT 108 3 6 10 Fuses PFC 108 3 6 11 Relays 109 3 6 12 Main Switch 110 3 6 13 Capacitors 110 ...

Page 77: ...or a factory purpose only and an additional password is re quired NOTE Acces password for authorized personnel only Password 1225 2 sec Latest version will be shown MAIN SCREEN MENU Pictogram description Back to main menu Back to main screen menu Next screen Previous Screen INPUT SCREEN EXAMPLE NOTE This screen will be shown after clicking on the INPUT button Increases the value Decreases the valu...

Page 78: ...3 Servicing LCD display for Service Menu SMGB0082 rev 1 07 2015 70 Auto expansion valve initialize SERVICE MENU SCREEN 1 2 Superheat setting SERVICE MENU SCREEN 1 2 ...

Page 79: ...3 Servicing LCD display for Service Menu SMGB0082 rev 1 07 2015 71 3 Expansion valve manual operation SERVICE MENU SCREEN 1 2 Overcurrent protection setting SERVICE MENU SCREEN 1 2 ...

Page 80: ...72 Sensor adjust SERVICE MENU SCREEN 1 2 NOTE 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 C Input 1 0º C the correction value System recognizes as 24 0º 1 0º 25 0º C ...

Page 81: ...Comp Hr Setting NOTE When PCBb is replaced the previous information related to compressor operating time and number of restarts can be entered form the service menu SERVICE MENU SCREEN 1 2 Confirm DSW set SERVICE MENU SCREEN 1 2 NOTE This function is not yet implemented ...

Page 82: ...3 Servicing LCD display for Service Menu SMGB0082 rev 1 07 2015 74 4 20 mA input SERVICE MENU SCREEN 2 Continuous control SERVICE MENU SCREEN 2 Order dissable SERVICE MENU SCREEN 2 ...

Page 83: ...on 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 When a wrong DIP switch DSW setting is performed do an initialization after set the DIP switch DSW correctly SERVICE MENU SCREEN 2 ...

Page 84: ...3 Servicing LCD display for Service Menu SMGB0082 rev 1 07 2015 76 Delete log NOTE This function deletes the stored data concerning to the alarms and cautions SERVICE MENU SCREEN 2 ...

Page 85: ...ce it quickly If exposed for a long period seal the suction and the discharge pipe Seal pipe ends using caps or tape To reassemble perform the procedures in reverse way To prevent contamination of the refrigerant with water or foreign particles do not expose open to atmosphere for long periods IMPORTANT NOTE The images and pictures shown in this chapter except when the contrary is indicated corres...

Page 86: ... 4 Removing covers 3 4 1 Unit description Front view Electrical box Upper box Electrical box Lower box Fans x4 Front Cover Right Cover x2 Rear view Left Cover x2 Air cooler panels Air cooler protection grille Rear Cover x2 Water pipe inlet Water pipe outlet ...

Page 87: ...OTE All locks have a mark to identify the lock position Open Close Open Close Close Open When pulling a resistance will be appreciated due to there are a snap connection in each corner of the cover 3 4 3 Front cover E Box compressor side Remove the 6 screws 3 on the right side and 3 on the left side of the panel The panel have 6 locks With the key female square key turn the locks 1 4 and then the ...

Page 88: ... the cover 6 screws 2 Remove the 2 screws at each corner of the HEX lower cover 2 screws 3 Inside of the unit remover the 4 screws fixing the supports of the HEX lower cover 2 2 screws 3 4 5 Rear cover water connection side Rear cover are split in to panels Remove the 6 screws 3 in left side and 3 in right side of the panel ...

Page 89: ... With the key female square key turn the locks 1 4 and then the cover is free to be removed 3 4 6 Water pipes support Remove both rear covers and disconnect de water pipe Victaulic connection Remove two screw at the top of water pipe support and two screw at bottom from inside side ...

Page 90: ...grille Each Module is equipped with 4 protection net each one fixed to the structure with 12 screws Ambient thermistor CAUTION In the front left protections net electrical box side is installed the ambient thermistor Remove the ambient thermistor before the removal of the protection net ...

Page 91: ...er as described in chapter 3 4 3 Front cover E Box compressor side b Remove the panels of the left and right sides as explained in chapter 3 4 2 Panels on the left 2 panels or right side 2 panels c Remove the HEX cover as explained in chapter 3 4 4 Front cover Hex lower cover Before any other operation collect all refrigerant as described in section Recovering the refrigerant by Pump down procedur...

Page 92: ... Remove the 4 screws fixing the compressor Screw Spring washer Flat washer Rubber mat Ruber bush Frame assembly Compressor feet Screws x4 9 Remove the check valve Remove the 4 bolts from the flange plate and pull it apart to give some space when removing the compressor 10 Remove the compressor Use a portable crane or a lift truck to remove the compressor Brazed parts Screw x4 Spring washer x4 Flat...

Page 93: ...ed 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 strain...

Page 94: ...t approximately 0 05 MPa Do not operate at a pressure lower than 0 05 MPa If operated it will cause a damage to the compressor e Wait for several minutes If the low pressure increases up to 0 45 to 0 5 MPa repeat the above steps 4 and 5 four or five times f Turn OFF the power supply of the unit and wait 15 min until hot parts become cool g After these works above almost all refrigerant is collecte...

Page 95: ...support 1 Remove the thermistors THMr2 as explained in chapter 3 5 19 Replacement of the thermistor x2 Evaporation THMr2 Thermistor THMr2 x2 Evaporation pipe 2 Remove the thermistor THMwo2 as explained in chapter 3 5 21 Thermistor Cooler water outlet THMwo2 Thermistor THMwo2 3 Remove the 2 flare nuts from the refrigerant cir cuit Flare nuts x2 4 Remove the 4 screws and their assemblies from the su...

Page 96: ...t pipe Victaulic couplings 7 Screw eyebolts to both sides of the condenser to the bolts for that purpose Fasten a textile belt to proceed to lift the condenser CAUTION Do not ever use chains or metallic ropes to lift the condenser as they can damage the condenser 8 Unscrew the 4 screw of the foot plate heat exchanger 9 Remove de condenser Softly lift the condenser and place it on a strong and stab...

Page 97: ...tronic expansion valve all models Economiser Electronic expansion valve Only in R C H ME 70AH1 models R C H ME 70AH1 R C H ME 40 50 AH1 To proceed to the replacement of this component follow the steps described below 1 Collect the refrigerant as explained in section 3 5 3 Recovering the refrigerant 2 Firmly hold the coil of the expansion valve and pull out upward It is easier to remove the expansi...

Page 98: ...al opening do not match In order to fix this always conduct a zero point adjustment power reactivation 3 5 6 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 as explained in chapter 3 5 18 Replacement of the thermistor Discharge...

Page 99: ... and proceed to the replacement 4 When reassembling after replacing the solid core perform the procedure in the reverse order than removing NOTE At reassembling oil or grease the top cover gasket and the thread of the cover screws 1 2 3 4 5 6 7 8 9 Filter drier unit replacement Replace the filter drier unit if any leakage or malfunction is detected Proceed following the steps explained below 1 Pro...

Page 100: ...to its replace ment 4 When reassembling proceed in reverse order than removing High pressure switch PSH Clamp Screw 3 5 10 Replacement of the pressure sensor Pd 1 Disconnect the cables 4 5 and 6 of the pressure sensor Ps from the QCN13 connector at the rear side of the Ebox 1 Remove the screw of the clamp that fixes the switch 2 Unscrew the switch and proceed to its replace ment 3 When reassemblin...

Page 101: ...kage Relief valve 3 5 14 Replacement of the sight glass To remove the sight glass proceed as follows 1 Remove the brazed parts using a blowtorch and previously cooling the pipe side and the sight glass with wet cloth in order to avoid brazing material enter inside the pipes 2 When reassembling after replacing the sight glass perform the procedure in the reverse or der than removing Sight glass Bra...

Page 102: ...replace the stop valve Use Teflon tape to seal the thread and avoid any leakage At expansion valves At filter drier Stop valve x3 3 5 17 Replacement 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 4C and 4D of multiple con tact QCN3 4 Remove the thermistor 5 When r...

Page 103: ...rform the procedure in the re verse order than removing Discharge pipe Thermistor THMd Thermistor THMd Screw Plastic bands 3 5 19 Replacement of the thermistor x2 Evaporation THMr2 1 Cut and remove the plastic bands that fixes the insulation of the discharge pipe thermistor THMr2 2 Loosen the screw fixing the thermistor 3 At the E box disconnect the CN29 contact or the Faston terminals 2C and 2D o...

Page 104: ...side the sensor sheath to protect and avoid any leakage Cable gland Fitting adaptor Sensor sheath Sensor Sensor wiring Thermistor THMwi 3 5 21 Thermistor Cooler water outlet THMwo2 1 Unscrew the nut of the cable gland 2 Gently pull the sensor wiring upwards CAUTION Sensor sheath is full of sealing silicone Use gloves and eye goggles for protection in order to avoid possible injuries to eyes and sk...

Page 105: ...n re moving NOTE Use sealant silicone inside the sensor sheath to protect and avoid any leakage Cable gland Fitting adaptor Sensor sheath Sensor Sensor wiring 3 5 23 Replacement of the solenoid valves SVa SVb SVc 1 Remove the screw with a Phillips screwdriver 1 Gently pull the coil and remove it from the valve 1 Remove 2 M6 screws that fixes the valve in the compressor 1 Replace the valve in rever...

Page 106: ...3 Remove the flare nut of the water outlet pipe Water inlet pipe Water outlet pipe Pressure differential device Flare nut for pres sure differential device inlet Flare nut for pres sure differential device outlet 4 Remove the flare nuts of the pipes inside the differential pressure device box 5 Remove the terminals 1 and 2 from the QCN9 connector at the rear side of the Ebox 6 Remove the 4 screws ...

Page 107: ...the Chiller module QCN7 QCN3 QCN5 QCN4 QCN8 1 QCN8 2 QCN13 QCN1 QCN2 2 Place lifting rings on the top of electrical box Fasten a textile belt to proceed to lift the electrical box CAUTION Do not never use chains or metallic ropes to lift the Ebox as they can damage it 3 Hold the electrical box with the crane or similar device through the 4 lifting rings 4 Remove the 4 screws located on the top of ...

Page 108: ... and 5 in the left 6 Lift slowly the electrical box until free and separate from the chiller module Screws x5 Screws x5 Left side Right side 7 To install the electrical box follow the process described in the previous paragraph in the reverse order 3 6 2 Open electrical box doors To open the doors the specific key is needed ...

Page 109: ...tons are placed inside the electrical box To replace anyone of the open the E box until get access to them Replacement of the lamps 1 Remove the wirings connected to the lamp hold 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 Nut Phillips screws x2 Replacement of the push buttons 1...

Page 110: ...ressure switches PSW PSW3 PSW4 PSW5 PSW6 Pressure switches PSW PSW1 PSW2 Switches SW SW1 SW2 DSW1 DSW2 DSW3 DSW4 DSW5 DSW6 Deep switches PSW Rotary switches RSW1 Plastic holder Plastic holder Plastic holder a Remove the PCB by pressing the expanded part of the 4 plas tic holders using long nose pli ers as shown in the picture b Pull the PCB out from the PCB plate ...

Page 111: ...sing the expanded part of the 4 plastic holders using long nose pliers as shown in the picture b Pull the PCB out from the PCB plate PCBd Plastic holder 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 b Pull the PCB out from the PCB plate ...

Page 112: ...reen 3 Pull the metallic plate where the LCD screen is attached Fan contactors Fan PCBE Fuses Capacitors a Remove the PCB by pressing the expand ed part of the 4 plastic holders using long nose pliers as shown in the picture b Pull the PCB out from the PCB plate 3 6 4 Removal of the LCD screen To remove the LCD Screen proceed as follows 1 Open the upper door of the Electrical box as explained in c...

Page 113: ...release the fixation assembly 4 Access to the rear side of the LCD screen is now avail able Continue reading to proceed to the removal of the LCD screen unit 5 Remove the wirings a Remove the COM2 connector Using a flat screwdriv er loosen the 2 screws of the COM2 port connector and pull backwards the connector a Remove the DC24V connector by pulling backwards COM2 port connector LCD power supply ...

Page 114: ...f the LCD screen 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 Screws x2 to CN2A to CN1 3 6 6 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 to remove As show...

Page 115: ...nits 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 1 Remove all the wiring with a Phillips screwdriver 2 Remove the screws that fixes the contactors to the plate 3 When reassem...

Page 116: ...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 ...

Page 117: ...er PFC1 1 PFC3 6 PFC2 4 PFC1 2 PFC3 5 PFC2 3 2 Phillips screwdriver 4 When reassembling perform the procedure in the reverse order than removing 3 6 11 Relays To remove any of the relays proceed as follows 1 Detach the Faston terminal from its connection 2 Remove the 2 screws fixing the relay to the plate 3 Replace the relay Faston terminals Phillips screws x2 4 When reassembling proceed in the re...

Page 118: ...als with a 13 mm spanker 4 Remove the 4 screws with a flat screwdriver 5 When reassembling proceed in the reverse order than removing T MIT L3 R MIR L1 S MIS L2 4 flat screws MIT L3 3 6 13 Capacitors 1 Disconnect all the wires connected to the capacitors CB1 4 The wires have polar characters Identify the wire mark and the indication on the capacitor when reconnecting the wiring 2 Loosen the 4 nut ...

Page 119: ...for judgement of failure of Fan Module Inverter 120 4 9 Method for fault diagnosis 122 4 10 Troubleshooting by alarm code 123 4 11 Analysis and countermeasure of abnormalities 153 4 12 Thermistor characteristics 160 4 12 1 Thermistor temperature characteristics All temperature except ambient and discharge gas 160 4 12 2 Thermistor temperature characteristics for ambient temperature 160 4 12 3 Ther...

Page 120: ...n on the transformer is being output Voltage and circuit 30 0Ｖ 230Ｖ 15 5Ｖ 16 1Ｖ PCN2A CPU PCB 5 3 T1 Red White Internal transformer of the unit Red Red Blue Blue Orange Orange At rated load 30 0Ｖ 230Ｖ 15 5Ｖ 16 1Ｖ PCN239 PCN240 I O PCB 5 3 T1 and Red At rated load Green Orange Orange Blue Blue Red Red White Internal transformer of the unit 230Ｖ 20 1Ｖ PCN238 㻔㻵㻛㻻㻌㻼㻯㻮㻕 5 3 T 1 Red At rated load Red R...

Page 121: ...a Electronic control Overcurrent relay for compressor 230V Type 400V Type R C H ME 40AH1 100A 50A R C H ME 50AH1 130A 64A R C H ME 60AH1 160A 80A R C H ME 70AH1 160A 80A Anti freezing control 1ºC Electronic control Suction gas decrease prevention control 5ºC Compressor Internal Thermostat 115ºC Control for prevention of discharge gas overheat 140ºC Fusible plug 72ºC Control Circuit Fuse 10A 5A 3A ...

Page 122: ...nce of abnormality related to the cooling cycle Occurrence of abnormality related to the fan Compressor stops Count of number of retries Only the relevant fan stops Count of number of retries Compressor stops Count of number of retries Operation continues Occurrence of retry control due to the same phenomenon a defined number of times before the end of timer count Occurrence of retry control due t...

Page 123: ...e F1 5 1 4 Overvoltage FAN Overvoltage retry F1 P8 FAN Overvoltage Fan Unit number Fan Overvoltage F1 5 1 4 Transmission Abnormality FAN Transmission abnormality retry F1 P8 FAN Transmission Fan Unit number Fan Transmission F1 4 1 4 Momentary power failure detection FAN momentary power failure retry Microcomputer Reset FAN Microcomputer reset retry Earth Detection FAN Earth detection retry FAN Ear...

Page 124: ...se Prevention Twp 2ºC Twp 1 5ºC Twp Outlet water temperature Protection Load up prohibition Forced load down 30 seconds passed and Twp 2ºC Twp 2ºC Outlet water temperature limited Discharge Pressure Over increase Prevention Pd 1 84MPa Pd 1 86MPa Pd High pressure Load up prohibition Forced load down 10 minutes have passed or Pd 1 76MPa Pd 1 84MPa To Control High pressure over increase limited Sucti...

Page 125: ...ty CN27 Disconnection or short circuit of the suction gas thermistor When the chiller unit is stopped 2 Discharge pressure sensor abnormality CN31 Disconnection or short circuit of the high pressure sensor When the chiller unit is stopped 2 Suction pressure sensor abnormality CN32 Disconnection or short circuit of the low pressure sensor When the chiller unit is stopped 2 Water supply header therm...

Page 126: ...ity in Status screen LCD Display Shows the details Background colour turns red Alarm display lamp Lit ON Faulty PCB segment Abnormality code Remote operation display lamp Lit ON Remote alarm display lamp Lit ON NOTE When performing a stop operation the background of the alarm display becomes white for a moment and the Alarm history check function allows to display the details of the abnormality th...

Page 127: ... screen Processing position of the caution part LCD Display Show mark Remote caution display lamp Lit ON 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 Chec...

Page 128: ...nce this measurement method takes polarity into account please adjust the colours and terminals of the tester probe as shown in the table Accurate values cannot be measured with a digital tester Please measure with an analogue tester Tester Probe Red Black Resistance Criteria P2 R P2 S P2 T R N S N T N P2 U P2 V P2 W U N V N W N 1kΩ or greater R P2 S P2 T P2 N R N S N T U P2 V P2 W P2 N U N V N W ...

Page 129: ...normality of the Fan transmission circuit The Fan is controlled by setting of 4 addresses at the PCBd I O PCB The transmission system scheme is as shown in the figure below PCBd I O PCB CN23A CN 206 CN 207 CN 206 CN 207 CN 206 CN 207 CN 206 FANM 11 FANM 12 FANM 13 FANM 14 In an event such as a failure of fan motor it is possible to detach a fan module from the control range by turning its manual s...

Page 130: ...c connector CN2A Are connector CN1 on the printed circuit board for CPU PCBc connector CN21 on the I O printed circuit board PCBd and Printed Circuit Board for Display and Operation PCBA correctly connected and checked loose connection Is 20 4V in PIN1 PIN2 I O printed circuit board PCBd connector CN55 Is there power source Is there power source No No No No No No Yes Yes Yes Yes Yes Yes No Yes No ...

Page 131: ...r Reverse rotation of pump Air mixture Clogging of water strainer Malfunction of expansion valve Excessive refrigerant load Suction air temperature excessively high out of usage range Opening of liquid stop valve forgotten Formation of lime deposit in water side heat exchanger Suction air temperature excessively high out of usage range In case of cooling operation I O PCB is normal Check of PCBd I...

Page 132: ...nd one Compressor stops and restarts automatically after 3 minutes Retry indication LCD By touching Inspection Pd Retry is shown in No 1 Cycle Retry code C1 P2 PCB monitoring position PCBd I O PCB CN31PD Discharge pressure sensor Alarm code C1 1 Low pressure interruption device Alarm stop reason Suction pressure Ps becomes lower than 0 01MPa for more than 3 seconds Enabled for electronic control c...

Page 133: ...Cycle Retry code C1 P6 PCB monitoring position PCBd I O PCB CN32PS Suction pressure sensor Open the stop valve Lack of refrigerant Gas leakage Revision of connections Replacement of pressure sensor Clogging Malfunction of expansion valve Clogging of low pressure side pipes Insufficient volume of water Reverse rotation of pump Air mixture Clogging of strainer Excessive humidity in refrigerant Forma...

Page 134: ...osition PCBd I O PCB PCN206 Check of PCBd I O PCB Press the reset button of the overcurrent relay Check of wiring disconnection Check of overcurrent relay internal disconnection Power source voltage too high or too low Phase unbalance of the power source voltage Lock status of compressor motor Power source fuse Loosening of screws of power source terminal Inspection of electromagnetic switches sin...

Page 135: ...e Compressor stops and restarts automatically after 3 minutes Retry indication LCD By touching Inspection Td Retry is shown in No 1 Cycle Retry code C1 P5 PCB monitoring position PCBd I O PCB CN26TD Discharge gas thermistor Lack of refrigerant Gas leakage Malfunction of check valve Clogging of expansion valve Malfunction of expansion valve Adjustment of expansion valve Replace thermistor Check of ...

Page 136: ...on 49C Retry is shown in No 1 Cycle Retry code C1 P5 PCB monitoring position PCBd I O PCB PCN207 Internal thermo for compressor 49C Power source too high or too low Phase unbalance of the power source voltage Lock status of compressor motor Decrease of insulation of compressor motor Check of wiring disconnection Revision of connections Check of compressor internal disconnection Check of PCBd I O P...

Page 137: ... LCD By touching Inspection Cooler Inlet Retry is shown in No 1 Cycle Retry code C1 P6 PCB monitoring position PCBd I O PCB CN29 Cooler inlet thermistor Lack of refrigerant Gas leakage Malfunction of check valve Clogging of water strainer Clogging of low pressure side pipes Adjustment of cold water thermo settings Shall be within usage range Malfunction of expansion valve Adjustment of air mixture...

Page 138: ...wn in No 1 Cycle Retry code C1 P6 PCB monitoring position PCBd I O PCB CN27 Suction gas thermistor Clogging of water strainer Adjustment of cold water thermo settings Shall be within usage range Adjustment of air mixture Adjustment of reverse rotation of pump Adjustment of water quantity adjustment of inlet outlet water temperature Replace thermistor Correction of connections Check of PCBd I O PCB...

Page 139: ...exchanger Adjustment of reverse rotation of pump Adjustment of water amount inlet outlet water temperature Replace thermistor Correction of connections Check PCBc CPU PCB and PCBd I O PCB Yes Yes Yes No No Cold water temperature has actually dropped under 1ºC due to low inlet water temperature lowered low pressure etc Confirmed from data immediately before The connection and insertion of connector...

Page 140: ... side heat exchanger Adjustment of reverse rotation of pump Adjustment of water amount inlet outlet water temperature Replace thermistor Correction of connections Check PCBc CPU PCB The connection and insertion of connector CN5 in PCBc CPU PCB are correct Yes Yes Yes No No No Outlet water temperature increased over 62ºC during compressor operation Confirmed from data immediately before Please remo...

Page 141: ...emove the connectors and measure thermistor resistance Is resistance value normal The connection and insertion of connector CN29 on PCBd I O PCB are correct Alarm code C1 23 Discharge gas THM abnormality CN26 Alarm stop reason Thermistor for detection of discharge gas temperature Td indicates an abnormal value PCB monitoring position PCBd I O PCB CN26 Discharge gas thermistor Td NOTE Refer thermis...

Page 142: ... are correct Yes Yes No No Please remove the connectors and measure thermistor resistance Is resistance value normal Alarm code C1 25 Outlet rear side THM abnormality CN25 Alarm stop reason Thermistor for detection of water side heat exchanger outlet Two2 rear side internal part of the heat exchanger indicates an abnormal value PCB monitoring position PCBd I O PCB CN25 Outlet rear side thermistor ...

Page 143: ...as suctioned Ts by compressor indicates an abnormal value PCB monitoring position PCBd I O PCB CN27 NOTE Refer thermistor characteristics chapter Replace thermistor Correction of connections Replace PCBd I O PCB The connection and insertion of connector CN27 on PCBd I O PCB are correct Yes Yes No No Please remove the connectors and measure thermistor resistance Is resistance value normal ...

Page 144: ...tions Replace PCBd I O PCB Replace PCBd I O PCB Elimination of the factors for clogging inside the pipe Replacement of discharge pressure sensor Yes Yes Yes Yes No No No No The connection and insertion of connector CN31Pd on PCBd I O PCB are correct DC5V is being supplied between pin 1 and pin 3 of connector CN31Pd on PCBd I O PCB There is clogging inside the connection pipe of discharge pressure ...

Page 145: ...tions Replace PCBd I O PCB Replace PCBd I O PCB Elimination of the factors for clogging inside the pipe Replacement of discharge pressure sensor Yes Yes Yes Yes No No No No The connection and insertion of connector CN32Ps on PCBd I O PCB is correct DC5V is being supplied between pin 1 and pin 3 of connector C32Ps on PCBd I O PCB There is clogging inside the connection pipe of discharge pressure se...

Page 146: ...anges to the characteristics of the current sensor The characteristics of the current sensor differ in standard specification and special voltage specification The power wiring of compressor passes through the current sensor Alarm code C1 f0 Setting of number of Fan units Alarm stop reason Fan is asked to operate when all fan manual set switches are set to OFF PCB monitoring position PCBd I O PCB ...

Page 147: ...correct Alarm code 03 03 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 Set DSW correctly and reactivate power supply Set DSW correctly and reactivate power supply Set DSW correctly and reactivate power supply Check PCBc CPU PCB and PCBd I O PCB DSW2 ...

Page 148: ...correct The connection and insertion of connector PCN17 on PCBc CPU PCB is correct The insertion of the terminal of relay XR is correct Alarm code 05 05 Reverse Open Phase Alarm stop reason Power source connected locally is connected in reverse or in open phase PCB monitoring position PCBd I O PCB 3 phase support R S T Inspect power source and voltage Manual correction of connection and insertion ...

Page 149: ... PCBc CPU PCB is correct Please remove the connector and measure the resistance value Is the resistance value normal Alarm code 12 12 C1 12 Outlet water temperature THM abnormality CN5 Alarm stop reason Thermistor for detection of outlet water temperature for water temperature control Two1 indicates an abnormal value PCB monitoring position PCBc CPU PCB CN5 Outlet water temperature thermistor Two1...

Page 150: ...of PCBc CPU PCB Yes Yes No No The connection and insertion of the connector CN6 on PCBc CPU PCB is correct Please remove the connector and measure the resistance value Is the resistance value normal Alarm code 2C 2C Water supply header temperature thermistor abnormality Alarm stop reason Thermistor for detection of water supply header temperature indicates an abnormal value Replace thermistor Revi...

Page 151: ... 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 Examination of pump lock Examination of pump overc...

Page 152: ...on results in wrong activation Conducting this operation results in wrong activation Conducting this operation results in wrong activation Conducting this operation results in wrong activation Check PCBA Settings PCB and PCBc CPU PCB Check PCBA Settings PCB and PCBc CPU PCB Check PCBA Settings PCB and PCBc CPU PCB Check PCBA Settings PCB and PCBc CPU PCB Check PCBA Settings PCB and PCBc CPU PCB Ye...

Page 153: ...CB Yes Yes Yes No No No The rotatory switches of PCBA Setting PCB of master module are correctly set The DIP switches on PCBA Setting PCB of each module are correctly set The H LINK transmission wiring between master module and slave modules is disconnected or connected wrongly Alarm code 40 40 Wrong operation of Control of Master Slave group Alarm stop reason Switching of cooling heating operatio...

Page 154: ...nsmission wiring is correct Alarm code F1 11 14 Fan Earth Detection NOTE Fan number is indicated by the last digit example F1 11 for fan number 1 F1 14 for fan number 4 Alarm stop reason Earth detection or overcurrent detection Retry indication LCD By touching Inspection No 1 Cycle Fan earth detection retry is shown in Fan Status PCB monitoring position PCBEN Fan module Replace the fan module Chec...

Page 155: ...No 1 Cycle Fan error retry Fan overcurrent retry Fan fin temperature retry are shown in Fan Status PCB monitoring position PCBEN Fan module NOTE Please refer to Fan earth detection in the previous page fro the flowchart of Fan error detection In the case of Fan fin temperature increase Restart operation Please apply silicon grease covering the entire contact surface Eliminate the clogging of the a...

Page 156: ...m Yes Abnormal Not normal Yes Yes Yes Yes No No No No No It can be reproduced Rarely occurs It trips immediately The current check of fan motor exceeds 10A Turn power source OFF remove faston terminals U V W on the fan module and turn DSW1 1 of the fan module ON Up In that state reactivate power and try to operate Does it trip release zero A detection Voltage during operation is higher than rated ...

Page 157: ...s in 30 minutes Retry control is performed until the second one Compressor stops and restarts automatically after 3 minutes Retry indication LCD View FAN transmission fault retry and 1 cycle by touching the Check Retry code Fn P8 PCB monitoring position PCBEN Fan module Check of the fuse Revision of connections Check of fan module Set the DIP switches correctly Yes Yes Yes No No No The unit number...

Page 158: ...he Check Retry code Fn P8 PCB monitoring position PCBEN Fan module What is the operation status of the fan upon operation restart Operation without abnormalities and increase of fan frequency The fan runs but it stops immediately It runs at low frequency but stops as soon as frequency starts to rise Connect correctly Replace the fuse There is abnormality in fan module Please replace it Inspect the...

Page 159: ...r 4 Alarm stop reason Fan motor is started operation but the current value is less than 1 5A Fan motor is started operation but according the fan position inverter control the current value is less than 4 0A Retry indication LCD Fan Current Sensor Abnormality Retry code No indication PCB monitoring position PCBEN Fan module Replace the fan module Check fan motor No Yes Yes No Restart Fan motor ope...

Page 160: ... Yes Yes Yes No No No Water flow or water pressure is normally out of range The connection and insertion of connector PCN10 on PCBc CPU PCB are correct Remove the wiring attached to connector PCN10 on PCBc CPU PCB and check conductivity Is there any conductivity Alarm code 6C 6C Water flow switch activation in condenser Not available Alarm stop reason Protection of water supply protection switch i...

Page 161: ...r Faulty electromagnetic switch coil of pump motor Faulty coil of the auxiliary relay Replace auxiliary relay and fuse Faulty solenoid valve coil Replace solenoid valve and coil Faulty oil heater Adherence of conductive dirt Remove dirt and replace fuse Faulty transformer coil Measure secondary voltage of transformer Replace transformer Miswiring of remote control wiring Check wiring Change wiring...

Page 162: ...ure Faulty compressor motor Measure resistance between wires Compressor replacement Faulty compressor Howling sounds originating from compressor Chiller Unit stops during Cooling operation Low voltage at startup Voltage measurement Consult with the power company Activation of high pressure switch due to excessively high discharge pressure Insufficient airflow to air side heat exchanger Excessive a...

Page 163: ...wer source fuse Loosening of terminal type screws of power source Retighten screws Check rough contact of electromagnetic contactor of compressor motor Replace contact Faulty compressor bearing It becomes locked Compressor replacement Insulation failure of compressor motor Measure insulation resistance Activation of overcur rent relay for pump Pump locked Check frozen water clogging by foreign bod...

Page 164: ...ction of the expansion valve Replace expansion valve Failure of thermistor for control of discharge gas Check connection with a tester Replace thermistor for control of discharge gas Activation of over current protection control for fan Defective bearing of fan motor It becomes locked Replace fan motor Single phase operation Check electromagnetic switch Replace electromagnetic switch Decreased ins...

Page 165: ...nce at the check valve Replace check valve Insufficient volume of water Check cold water inlet outlet temperature difference Increase volume of water Pump inverse rotation Check rotational direction Fix to correct direction Air mixture Try to open ventilator valve Ventilator Formation of lime deposit inside water side heat exchanger Check for dirt at the water side heat exchanger Clean water side ...

Page 166: ...unit is air short circuited Remove short circuit Defrosting is not completely conducted Check thermistor for defrosting Replace thermistor for defrosting Check 4 way valve Replace 4 way valve Discharge pressure too high High pressure switch activation Insufficient volume of water Check cold water inlet outlet temperature difference Increase volume of water Pump inverse rotation Check rotational di...

Page 167: ...tion of loosening of each tightening bolt Tighten bolts even more Liquid compression Check temperature and pressure of suction gas Secure super heat Oil hammer Check temperature and amount of oil in suction gas Check or replace compressor Oil heater is not being supplied power during stop Check the power supply to the oil heater Replace oil heater Exhaustion and damage inside the compressor Abnorm...

Page 168: ...rmistor resistance kΩ 19 3 14 4 10 9 8 3 6 4 5 0 3 9 3 1 2 5 2 0 1 6 1 3 1 1 0 9 0 7 0 6 0 5 0 4 0 4 0 3 0 3 0 5 10 15 20 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 4 12 2 Thermistor temperature characteristics for ambient temperature 17C59663 105 4 77 9 58 2 44 0 33 6 25 9 20 2 15 8 12 5 10 0 8 0 6 5 5 3 4 3 3 6 3 0 2 5 0 20 40 60 80 100 120 20 15 10 5 0 5 10 15 20 25 30 35 40...

Page 169: ...g Pressure sensor characteristics SMGB0082 rev 1 07 2015 161 4 4 13 Pressure sensor characteristics 4 13 1 High pressure sensor 0 2 5 5 0 4 5 2 5 0 5 V Mpa 4 13 2 Low pressure sensor 0 1 0 2 0 4 5 2 5 0 3 V Mpa 0 5 0 1 ...

Page 170: ...ate Interlock Circuit for Chilled Water Pump is Open 1 Check the pump contactor Repair or replace if necessary 2 Check for the faulty pump Electrical Protective Devices Are Tripped Remove the causes and reset the ON button See the following causes Incorrect Wiring Connection for Compressor Power Source Interchange two of three terminals R S and T at the main power source terminals Compressor stops...

Page 171: ...crew Tighten the screws of all parts Unloaded Does not Function Trouble with the Thermistor 1 Adjust the setting temperature 2 Replace the thermistor Trouble with the Solenoid Valve 1 Check the coil in the solenoid valve 2 Check oil passage for clogging Worn Unloader Mechanism Check the unloaded system parts in the compressor High Discharge Pressure High Condenser Air Temperature or Insufficient A...

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Page 174: ...the standard ISO 14001 of JACO Japan for its Environmental Management accordance with the standard Hitachi Air Conditioning Products Europe S A U is certified with ISO 9001 of AENOR Spain for its Quality Management accordance with the standard ISO 14001 of AENOR Spain for its Environmental Management systems accordance with the standard Hitachi certifies that our products have met EU consumer safe...

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