Hitachi 8E042340, Service Manual

Page 1: ...RCME 40 60 CLH Service Manual SAMURAI SERIES CONDENSERLESS WATER CHILLERS MODULAR R134a SCREW TYPE ...

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Page 3: ...Contents SMGB0097 rev 0 07 2015 General information Control Functions Servicing Troubleshooting 1 Contents 1 2 3 4 I ...

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Page 5: ...m external signal 24 2 1 11 2 temperature setting function 25 2 1 12 External thermo operation from external contact 26 2 1 13 Water Temperature of the Control Target 28 2 1 14 Operation from DC24V contact input 29 2 1 15 Thermo OFF function selection 34 2 1 16 Selection of enabling disabling of alarm release by means of remote stop 35 2 1 17 Limitation setting for pump feedback waiting time 36 2 ...

Page 6: ...2 Replacement of the pressure sensor PS 76 3 3 13 Replacement of the pressure relief valve 76 3 3 14 Replacement of the sight glass 76 3 3 15 Replacement of the stop valve x3 76 3 3 16 Repalacement of the thermistor Suction THMs 77 3 3 17 Replacement of the thermistor Discharge THMd 77 3 3 18 Replacement of the crankcase heater CH 77 3 3 19 Replacement of the thermistor Evaporation THMe 78 3 3 20 ...

Page 7: ...93 4 4 Protection control function 94 4 5 Caution indication 95 4 6 Summary of fault diagnosis 96 4 7 Method for fault diagnosis 98 4 8 Troubleshooting by alarm code 99 4 9 Analysis and countermeasure of abnormalities 123 4 10 Thermistor characteristics 127 4 10 1 Thermistor temperature characteristics All temperature except discharge gas 127 4 10 2 Thermistor temperature characteristics for disch...

Page 8: ...ation SMGB0097 rev 0 07 2015 1 1 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 Water chillers 4 ...

Page 9: ...ncluded 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 re served to vary specifications without notice HITACHI cannot anticipate every possible circumstance that might involve a potential hazard No part of ...

Page 10: ...l 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 contain...

Page 11: ...ler models Basic modules Unit type Modular water chiller RCM E Made in Europe Position separating hyphen fixed Capacity HP 40 50 60 CL Condenser Less H R134a refrigerant RCM E XX CL H 1 3 2 Product guide Water chillers Basic modules 3N 400V 50Hz Unit Code RCME 40CLH 8E042340 RCME 50CLH 8E052340 RCME 60CLH 8E062340 ...

Page 12: ...ol Target 27 2 1 14 Operation from DC24V contact input 28 2 1 15 Thermo OFF function selection 33 2 1 16 Selection of enabling disabling of alarm release by means of remote stop 34 2 1 17 Limitation setting for pump feedback waiting time 35 2 1 18 Inlet water temperature thermo OFF function 36 2 2 Control of the cooling cycle 38 2 2 1 Compressor Control 38 2 2 2 Expansion Valve Control 39 2 2 3 Ov...

Page 13: ...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 Set a delay time adjusted to the characteristics of the installation to prevent compressor startup until a sufficient flow of cold ...

Page 14: ...ation 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 during outdoor order non v...

Page 15: ... 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 5ºC units Display Main unit side LCD device Displays the status of the chiller unit Run stop contents of alarm operating pressure and temperature etc 7 Segment for backup of the LCD Displays the status of the unit and content of alarms with individ...

Page 16: ...t 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 17: ...ings locally depending on usage purpose but since the necessary volume of water will change 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 Step Seconds 10 1 1 1 ...

Page 18: ...ter with ENT key Cancel with CAN key 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 func tion Ext The setting value from an external source is displayed such as when a slave unit following the s...

Page 19: ...ter temperature control settings 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 Continuous control type ...

Page 20: ...old 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 inc...

Page 21: ...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 22: ...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 23: ... DIP switches DSW3 1 3 2 3 3 are used for address setting when using the functions to control the number of units but the addition of time to the 3 minutes guard is effective even if these functions are not used In this case it is not 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 24: ...mp a When outdoor temperature is under 2ºC When outdoor temperature falls under 2ºC the operation order of cold water circulation pump is output and the continuous operation of the cold water pump starts automatically Here when cold water temperature becomes higher than 15ºC operation becomes intermittent with the pump running for 5 minutes then stopped during 55 minutes When cold water temperatur...

Page 25: ...p 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 pum...

Page 26: ...n method NOTE This control is not performed when Disable is selected In this case make sure to implement anti freeze measures on site such as pump automatic operation or the installation of a heater at the water side heat exchanger of the chiller unit Select pressing Mode I Mode II Disable keys ...

Page 27: ... with orders from the local control panel by means of peak cut etc or to restrain the maximum limit of compressor operating capacity Since it also allows to force a change of the operation capacity in response to the load of the facility it is a convenient function to perform temperature control from the local control panel Forced thermo OFF function a Contents of activation When it is required to...

Page 28: ...viously set at the LCD screen The selection to enable or release the setting value is performed with the order signal from the local control board Also the overcurrent protection control is always enabled even in a state where this function is disabled b Setting method when cooling mode is set Display the input window with INPUT key Input the setting value with up and down keys Confirm with ENT ke...

Page 29: ...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 30: ...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 31: ...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 operation but it may cause instability of the oper...

Page 32: ...d forced 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 Keep more than 5 minu...

Page 33: ...e from an external thermo set the external thermo to activate before the thermo OFF temperature of the main unit In case of stop by thermo OFF temperature of the main unit operation restarts automatically When performing thermal storage from the main unit thermo it is possible to prevent restart by turning the pump OFF with optional function Pump operation in ON OFF Cont Setting method Select OFF ...

Page 34: ...7 2 2 1 13 Water Temperature of the Control Target It is possible to select which water temperature to use for capacity control and thermo OFF judgement either Inlet or Outlet Use the outlet water temperature factory default setting in normal conditions Setting method Select IN ...

Page 35: ...lable 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 Do not connect a LED or a relay of internal diode type Run stop switch to be prepared loc...

Page 36: ... SMGB0097 rev 0 07 2015 29 2 b Setting method 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 inside a metallic pipe or use a shielded wire ...

Page 37: ...l 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 Do not connect a LED or a relay of internal diode type Time chart Switch 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 unit as ...

Page 38: ...97 rev 0 07 2015 31 2 b Setting method Select Pulse 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 inside a metallic pipe or use a shielded wire ...

Page 39: ...nged 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 inside...

Page 40: ...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 41: ...r unit has stopped due to an alarm is achieved by stop control it is possible to stop both from the stop button of the main unit or from remote stop control But it is possible to configure this alarm release to make it valid only from the stop button on the main unit alarm cannot be released by remote stop control This function is valid for places where there is a remote device for automatic stop ...

Page 42: ...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 43: ...ut when enabling this setting the judgement of thermo OFF is carried out also from inlet water temperature Thermo OFF judgement by outlet water temperature is also enabled Water temperature control is carried out from outlet water temperature even in case that this function is enabled It is effective when there is the need to set thermo OFF with the return water temperature from the load Setting m...

Page 44: ...itions are the same as in normal outlet water temperature control It is possible to switch the setting values with 2 1 11 2 temperature setting func tion Display the input window with INPUT key Input the setting value with up and down keys Confirm with ENT key Cancel with CAN key Select Enable I ...

Page 45: ...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 46: ...peration 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 ...

Page 47: ...rced to open and momentarily set somewhat open in comparison with 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 A...

Page 48: ... 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 ...

Page 49: ... 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 Set the addresses in ascending order without leaving gaps Example Set unit numbers from 1 to 5 if there are 5 unit...

Page 50: ... in the case of standalone operation of the Chiller Unit 2 Pump Interlock Wiring Required Input the feedback signal of the pump to all the chiller units also necessary in the case of batch pump Chiller units without pump feedback signal input will not operate Pump feedback signal 3 Pump operation order wiring Not required for specifications with pump mounted Connect the wiring since pump operation...

Page 51: ...n in order to regain the target of the control of Master Slave group Also in case of using it to reset an alarm it is necessary to enable the optional function LCD screen setting Remote stop reset at each of the chiller units 5 5 Forced stop signal Alarm reset System recovery signal Remove the connection between 5 and 6 5 5 System recovery signal Forced stop Alarm reset signal 5 More than 200ms ON...

Page 52: ...t event occurs 2 About recovery method to system from detachment state Modules that have been once detached are not subject to the control of Master Slave group unless performing recovery operation However modules that have become detached because of transmission abnormality are recovered automatically as soon as transmission is restored Perform recovery operation after removing the causes of the ...

Page 53: ...ation control is performed among modules 2 to 4 which have the same priority order 7 Function to cancel the control of Master Slave group It is possible to cancel the functions to control the number of units when simultaneous thermo ON OFF of all the units is required with without performing the control of Master Slave group Possible in 1 pump systems only NOTE Setting method In 1 pump system sett...

Page 54: ...which 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 opera...

Page 55: ...nd confirmation of operation conditions through the LCD screen 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 con nected shift to priority setting sc...

Page 56: ...2 Control Functions Control of Master Slave group SMGB0097 rev 0 07 2015 49 2 Status screen of the control of Master Slave group ...

Page 57: ...e during inspection or maintenance works an alarm is output to the remote side in case that any operation order was input remotely SW2 Local Remote 3 ON OFF button Performs as ON button for operation when in local control setting The OFF button is always enabled regardless of local remote setting When OFF button is pushed the module is detached from the group The rest of the modules will keep oper...

Page 58: ...ster 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 inside 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 the el...

Page 59: ...isplay Remote Operation display 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 ON OFF ON OFF ON OFF Run Run Stop Stop Unit Contact for formation of self holding Electronic expansion valve Compressor 6C1 Compressor 52C1 Compressor 42C1 Protection device ON ...

Page 60: ...nt of the pressure relief valve 76 3 3 14 Replacement of the sight glass 76 3 3 15 Replacement of the stop valve x3 76 3 3 16 Repalacement of the thermistor Suction THMs 77 3 3 17 Replacement of the thermistor Discharge THMd 77 3 3 18 Replacement of the crankcase heater CH 77 3 3 19 Replacement of the thermistor Evaporation THMe 78 3 3 20 Replacement of the thermistor Cooler water inlet THMwi 78 3...

Page 61: ...3 Servicing SMGB0097 rev 0 07 2015 54 3 4 8 Overcurrent relay ORC 85 3 4 9 Contactors CMC CMCD CMCS 86 3 4 10 Fuses EF1 EF2 EF3 EFR EFS EFT 86 3 4 11 Fuses PFC 87 3 4 12 Relays 88 3 4 13 Main Switch 89 ...

Page 62: ...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 63: ...3 Servicing LCD display for Service Menu SMGB0097 rev 0 07 2015 56 Auto expansion valve initialize SERVICE MENU SCREEN 1 2 Superheat setting SERVICE MENU SCREEN 1 2 ...

Page 64: ...3 Servicing LCD display for Service Menu SMGB0097 rev 0 07 2015 57 3 Expansion valve manual operation SERVICE MENU SCREEN 1 2 Overcurrent protection setting SERVICE MENU SCREEN 1 2 ...

Page 65: ...58 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 66: ...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 67: ...3 Servicing LCD display for Service Menu SMGB0097 rev 0 07 2015 60 4 20 mA input SERVICE MENU SCREEN 2 Continuous control SERVICE MENU SCREEN 2 Order dissable SERVICE MENU SCREEN 2 ...

Page 68: ...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 69: ...3 Servicing LCD display for Service Menu SMGB0097 rev 0 07 2015 62 Delete log NOTE This function deletes the stored data concerning to the alarms and cautions SERVICE MENU SCREEN 2 ...

Page 70: ...des security gloves it is a must to wear convenient eye protection NOTE The images and pictures shown in this chapter except when the contrary is indicated correspond to the RCME 50WH model Processes described are equally valid to all RCME WH models NOTE When brazing operations are required check to ensure whether there are flammable materials around when using the burner for pipe connections Oil ...

Page 71: ...he unit is open except the electrical box and the inner parts are easily accessible 3 3 1 Compressor removal When Removing the Compressor Remove the compressor while completing the following procedures 1 Before any other operation collect all refrigerant as described in chapter 3 3 3 Recovering the refrigerant 2 Remove the bolts on the discharge and suction flanges of the compressor Bolts x4 Bolts...

Page 72: ...er supply cable hose R S T b Control wiring connector QCN4 and Pd and Ps cables QCN13 Connector QCN4 Connector QCN13 6 Remove the 8 screws fixing the compressor Un screw the screws fixing the structure HEX10 as shown in the picture Screws x8 Right side From E Box Left side From E Box ...

Page 73: ...hi Screw Compressor Manual When removing a compressor from the refrigeration cycle high pressure part shall be separated between the projecting part flange of compressor and the upper cover of oil separator Do not separate high pressure part between the check valve and the projecting part flange of compressor as collected refrigerant would be spilled out Low pressure side Disconnect from this part...

Page 74: ...ty such as dirt or any damage clean or replace the part as adequate 5 Oil charge work Attach the oil strainer the oil strainer cover C and the oil extraction plugs A B Connect the charge hose to the check joint Discharge pressure outlet Let the oil be absorbed by the charge hose while performing vacuum from the check joint of the suction side Charge the amount of oil that had been extracted in the...

Page 75: ... or until the pressure decreases lower than a pressure of 756 mmHg in vacuum f Use a scale to take note of the quantity of refrigerant charged into the tank in order to provide the same quantity when charging the circuit Recovery tank Vacuum pump Manifold gauge RCME CLH unit Scale 3 3 4 Replacement of the cooler 1 Unscrew the 4 screw of the refrigerant inlet pipe flange and the 4 screws of the out...

Page 76: ...cooler CAUTION Do not never use chains or metallic ropes to lift the cooler as they can damage it 4 Unscrew the 4 screw of the foot plate heat exchanger 2 Screws 2 Screws 5 Remove de cooler Softly lift the cooler and place it on a strong and stable surface CAUTION In spite of water shut off valves are closed water inside the plate heat exchanger and water pipe remain CAUTION Plate heat exchanger i...

Page 77: ...n expansion valve a This unit uses an electronic expansion valve which is normally closed when the compressor stops For this reason when the valve upstream of the expansion valve liquid outlet valve of the heat exchanger is closed refrigerant may accumulate between the liquid outlet valve of the heat exchanger and the expansion valve In case of removing the brazed part of the expansion valve alway...

Page 78: ...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 Protect the surroundings of the unit from the heat of the blo...

Page 79: ...c bands 2 Remove the 4 screws of the inlet pipe flange 3 Remoce the fixing clamp Inlet pipe flange 4 Screws Fixing clamp 4 Remove the 4 screws that fixes the check valve to its location at the discharge outlet 5 Remove the 4 Allen screws that fixes the cover of the check valve Once disassembled 6 Remove the cover of the check valve to protect the inner parts from the heat of the blowtorch when dis...

Page 80: ... proceed to its replace ment 4 When reassembling proceed in reverse order than removing High pressure switch PSH Clamp Screw 3 3 10 Replacement of the pressure sensor Pd 1 Disconnect the cables 4 5 and 6 of the pres sure sensor from the E box of the compressor terminal board 2 Remove the screw of the clamp that fixes the switch 3 Unscrew the switch and proceed to its replace ment 4 When reassembli...

Page 81: ... 3 3 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 Brazed parts 3 3 15 ...

Page 82: ...tion of the discharge pipe thermistor THMd 2 Loosen the screw fixing the thermistor 3 At the E box disconnect the CN26TD contact or the Faston terminals 9 and 10 of multiple contact QCN3 4 Remove the thermistor 5 When reassembling after replacing the thermis tor THMd perform the procedure in the re verse order than removing Discharge pipe Thermistor THMd Thermistor THMd Screw Plastic bands 3 3 18 ...

Page 83: ... order than removing Thermistor THMe Evaporation pipe Thermistor THMe Screw Plastic bands 3 3 20 Replacement of the thermistor Cooler water inlet THMwi 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 skin 3 Disconnect the 3 and 1 F...

Page 84: ...o proceed as follows 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 skin 3 Disconnect the 3 and 1 Faston terminals or the CN5 connector at the E box 4 Replace the thermistor in reverse order than re moving NOTE Use sealant silicon...

Page 85: ...door first 3 4 2 Removal of the LCD screen The removal of the LCD screen have to be done from the inner of the left door at the E box 1 Remove the wirings a Remove the COM2 connector Using a flat screwdriver 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 connector 2 Using a Phill...

Page 86: ...s 1 Remove the wirings connected to the push but ton using a Phillips screwdriver 2 Remove the nut fixing the push button holder to the E box door 3 Replace the push button and proceed to assem bly in reverse order than removing Phillips screws x2 Nut 3 4 4 Access to electrical components PCB s are placed on 2 levels into the E box By simply opening the left door there is the PCBd In a second leve...

Page 87: ... PCBc Fuses Relays Access to second level electric components To have acces to the main control and power components of the unit into the E box follow the next steps Fixation assembly 1 Firmly pull the plate 2 Pull until release the fixation assembly 3 Keep pulling until the plate is in hor izontal at the top ...

Page 88: ...gment display Pressure 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 press ing the expanded part of the 4 plastic holders using long nose pliers as shown in the picture below b Pull the PCB out from the PCB plate ...

Page 89: ... expanded part of the 4 plastic holders using long nose pliers as shown in the picture below b Pull the PCB out from the PCB plate 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 below b Pull the PCB out from the PCB plate ...

Page 90: ...mers 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 shown the image 1 Remove the 2 screws that fix the transformer to the plate Screws Screws to PCN239 to CN56 to PCN238 to CN55 to PCN240 to CN57 3 4 8 Overcurrent relay ORC To remov...

Page 91: ...ow 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 reassembling proceed in reverse order than removing Screws Use a Phillips screwdriver to remove the screws 2 screws at the top and 1 screw at the bottom 3 4 10 Fuses EF1 EF2 EF3 EFR EFS EFT EF fuse series are mounted on DIN rail To replace any damaged f...

Page 92: ...s replacement following the next steps 1 Open the plastic cover that protects the fuse 2 Take the fuse puller tool a Push the red button b Slide the fuse puller tool up or down c Pull the fuse puller backwards 3 On the damaged fuse put the fuse puller tool and firmly push to fix the tool on the fuse Once the fuse is trapped pull the tool backwards ...

Page 93: ...ews and replace the fuse holder 3 3 Flat screw driver or 13mm spanner 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 4 12 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...

Page 94: ...steps 1 Turn the switch of in order to be able to open the E box door 2 Open the E box door 3 Remove the wiring Unscrew the nuts from the terminals 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 ...

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Page 96: ...5 4 6 Summary of fault diagnosis 96 4 7 Method for fault diagnosis 98 4 8 Troubleshooting by alarm code 99 4 9 Analysis and countermeasure of abnormalities 123 4 10 Thermistor characteristics 127 4 10 1 Thermistor temperature characteristics All temperature except discharge gas 127 4 10 2 Thermistor temperature characteristics for discharge gas temperature 127 4 11 Pressure sensor characteristics ...

Page 97: ... 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 Re...

Page 98: ...pressor 230V Type 400V Type RCME 40WH 100A 48A RCME 50WH 130A 55A RCME 60WH 160A 65A RCME 70WH 160A 80A 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 Safety valve for compressor 2 10MPa Diameter φ35mm The setting values of automatic operation devices are as fol...

Page 99: ...evention 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 Cooling Pd 1 41MPa Pd 1 44MPa Pd High pressure Load up prohibition Forced load down Cooling 10 minutes have passed or Pd 1 39MPa Pd 1 41MPa To Control High pressure over increase li...

Page 100: ...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 thermistor abnormality CN13 Disconnection or short circuit of the water supply ...

Page 101: ...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 that h...

Page 102: ... 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 103: ... 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 Y...

Page 104: ...on of high pressure switch Check of high pressure switch 63H Internal disconnection Check of wiring disconnection Excessive refrigerant load In case of cooling operation I O PCB is normal Check of PCBd I O PCB Yes No Yes No Revision of connections The connection and insertion of connector PCN204 to PCBd I O PCB are correct Yes No Yes No Yes No Remove the wires inserted in PCN204 on PCBd I O PCB an...

Page 105: ...he second 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 co...

Page 106: ... 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 Formation of lime deposit in water side heat exchanger M...

Page 107: ...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 single phase operation Decrease of insulation of compressor motor Malfunction of slide valve of compressor I O PCB is normal Check of PCBd I O PCB Overcurrent...

Page 108: ...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 109: ...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 110: ...hing 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 reverse rotation of pum...

Page 111: ...ycle 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 The connect...

Page 112: ...stment 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 PCBc CPU PCB ...

Page 113: ...ater 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 Remove ...

Page 114: ... 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 thermistor c...

Page 115: ... are correct Yes Yes No No Remove he 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 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 Two2 NOTE Refer the...

Page 116: ...of gas 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 Remove the connectors and measure thermistor resistance Is resistance value normal ...

Page 117: ...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 118: ...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 119: ... PCB is correct The connection and insertion of the connector of current sensor on the body of the unit are correct There are no changes 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 03 I O internal transmission A...

Page 120: ...c 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 1 2 of PCBd I O PCB are correctly set Yes Yes Yes DSW1 5 6 of PCBa Setting PCB are correctly set No No No Terminal resistance correctly set Either DSW8 1 of PCBc CPU PCB...

Page 121: ...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 122: ...CN4 on PCBc CPU PCB is correct Remove the connector and measure the resist ance 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 123: ...rs and measure thermistor resistance Is resistance value normal The connection and insertion of connector CN13 on PCBc CPU PCB are correct Alarm code 2d 2d Water return header temperature thermistor abnormality CN14 Alarm stop reason Thermistor for detection of water return header temperature indicates an abnormal value Replace thermistor Revise connections Replace PCBc CPU PCB Yes Yes No No Remov...

Page 124: ...tlet 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 overcurrent relay Check of thermistors Check the wiring around the pump and the overcurrent relay for the pump Check PCBc CPU PCB PCB is normal No No No No Yes Yes Yes The water is flowing The overcurrent relay fo...

Page 125: ...ration Alarm stop reason A forbidden operation is performed during operation Wrong activation Remote Local 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 Yes Yes ...

Page 126: ...c CPU PCB 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 operation...

Page 127: ...sion wiring correctly Check PCBc CPU PCB No Yes The connection of transmission wiring is correct Alarm code 6E 6E Cold Water Suspension Option Alarm stop reason Suspension of water supply protection switch is activated PCB monitoring position PCBc CPU board PCN10 Clogging of water strainer Check the water outage protection switch Check the pump flow Check of wiring Check the pump Check of PCBc CPU...

Page 128: ...or 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 Open phase or reverse phase connection of power...

Page 129: ...re 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 exces sively high discharge pressure Refrigerant overcharge Check cycle temperature Charge correct volume Mixture of non condens...

Page 130: ...ower company Discharge pressure too high Investigation to determine the cause Single phase operation Power source fuse blown Replace power 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 compress...

Page 131: ...rcharge Check cycle temperature Charge correct volume Mixture of non condensable gas in refrigerant cycle Stop the chiller unit and check the relation between water temperature and pressure Recharge refrigerant after vacuum pumping Clogging of pipes at discharge side Check for clogging Remove clogging Clogging of expansion valve Check for clogging Malfunction of expansion valve Check operation of ...

Page 132: ... figures 4 10 1 Thermistor temperature characteristics All temperature except discharge gas 17B18890 Temperature ºC Thermistor 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 10 2 Thermistor temperature characteristics for discharge gas temperature 1072 0 640 4 394 2 2...

Page 133: ... 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 on high pressure switch Excessively High Discharge Pressure See High Discharge Pressure Malfunction of High Pressure Switch Readjust the setting or replace if defective Compressor stops on overcurrent relay Excessively Hi...

Page 134: ...ck for the sound of internal parts Replace the compressor if necessary Miscellaneous noise Loose Fixed Screw 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...

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Page 137: ...ditioning 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 safety health and environmental requirements Hitachi Air Conditioning Products Europe S A U Ronda Shimizu 1 Políg Ind ...