Hitachi SAMURAI Series Service Manual
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Hitachi SAMURAI Series Service Manual

Water cooled water chillers -modular-r134a-screw type
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SAMURAI SERIES
WATER COOLED WATER CHILLERS
-MODULAR-R134a-SCREW TYPE-
Service Manual
RCME-(40-70)WH1
Table of Contents
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Summary of Contents for Hitachi SAMURAI Series

  • Page 1 SAMURAI SERIES WATER COOLED WATER CHILLERS -MODULAR-R134a-SCREW TYPE- Service Manual RCME-(40-70)WH1...
  • Page 3 Contents C o n t e n t s General information Control Functions Servicing Troubleshooting SMGB0120 rev.0 - 11/2017...

  • Page 5: Table Of Contents

    General Index General Index General information ....................1 General notes ............................2 Safety and applied symbols ........................3 1.2.1 Norms and Regulations ........................... 3 Product guide ............................4 1.3.1  Classification of water chiller models ......................4 1.3.2  Product guide: Water chillers........................... 4 Control Functions ...................... 5 2.1  Control functions on the module......................
  • Page 6 General Index 2.4.1  Setting of switches on the setting PCB ......................48 2.4.2  Operation control of the module ........................49 2.5  Time chart ............................. 50 Servicing ........................51 LCD display for Service Menu ....................... 53 General notes ............................61 Cycle components ..........................62 3.3.1 Compressor removal ............................. 62 3.3.2  Overhaul work ............................... 65 3.3.3 ...
  • Page 7 General Index 3.4.10  Fuses (EF1, EF2, EF3. EFR, EFS, EFT) ....................84 3.4.11  Fuses (PFC) ..............................85 3.4.12 Relays ................................. 86 3.4.13  Main Switch ..............................87 Troubleshooting ....................... 89 4.1  Inspection of power source and connections ..................90 4.2  Inspection of PCB..........................91 4.3  Confirmation of operating value of protection devices and automatic operation devices ..... 91 Protection control function ........................92 Alarm indication ............................. 93 Summary of fault diagnosis ........................

  • Page 9: General Information

    1 General information G e n e r a l i n f o r m a t i o n Index General notes ............................2 Safety and applied symbols ........................3 1.2.1 Norms and Regulations ........................... 3 Product guide ............................4 1.3.1 ...

  • Page 10: General Notes

    1 General information General notes 1.1 General notes © Copyright 2017 Johnson Controls-Hitachi Air Conditioning Spain, S.A.U. – All rights reserved. No part of this publication may be reproduced, copied, filed or transmitted in any shape or form without the permission of  Johnson Controls-Hitachi Air Conditioning Spain, S.A.U.. Within the policy of continuous improvement of its products, Johnson Controls-Hitachi Air Conditioning Spain, S.A.U.  reserves the right to make changes at any time without prior notification and without being compelled to introducing them  into products subsequently sold. This document may therefore have been subject to amendments during the life of the  product. HITACHI makes every effort to offer correct, up-to-date documentation. Despite this, printing errors cannot be controlled  by HITACHI and are not its responsibility. As a result, some of the images or data used to illustrate this document may not refer to specific models. No claims will  be accepted 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 circumstance that might involve a potential hazard. No part of this document may be reproduced without written permission. If you have any questions, contact your service contractor of HITACHI. Check and make sure that the explanations of each part of this document correspond to your model.  Refer to the models codification to confirm the main characteristics of your system. Signal words (DANGER, CAUTION and NOTE) are used to identify levels of hazard seriousness. Definitions for  identifying hazard levels are provided below with their respective signal words. It is assumed that this unit will be operated and serviced by English speaking people. If this is not the case, the customer  should add safety, caution and operating signs in the native language of the personal. This water chiller has been designed for the working range described in the corresponding chapter. SMGB0120 rev.0 - 11/2017...

  • Page 11: Safety And Applied Symbols

    C A U T I O N • The text following this symbol contains information and instructions relating directly to your safety and physical wellbeing. • Not taking these instructions into account could lead to minor injuries to you and others in the proximities of the unit. • Not taking these instructions into account could lead to unit damage. In the texts following the caution symbol you can also find information on safe procedures during unit installation. N O T E • The text following this symbol contains information or instructions that may be of use or that require a more thorough explanation. • Instructions regarding inspections to be made on unit parts or systems may also be included. 1.2.1 Norms and Regulations Appropriate refrigerant The refrigerant used in each unit is identified on the specification label and manuals of the unit. HITACHI shall not be  held liable for any failure, trouble, malfunction or accident caused by units illegally charged with refrigerants other than  the specified one. Consequences of charging non-specified refrigerant It may cause mechanical failure, malfunction and other accidents. It may cause operational failure of protection and  safety devices of air conditioners. It may also cause lubrication failure of the sliding part of the compressor due to  deterioration of refrigerant oil. In particular, hydrocarbon refrigerants (such as propane, R441A, R443A, GF-08, etc.) are not allowed, since these are  combustible and may cause major accidents such as fire and explosion in case of improper handling. Once a non-specified refrigerant has been charged, no further servicing (including draining of refrigerant) shall be  performed, even in case of malfunction. Improper handling of refrigerant may be a cause of fire and explosion, and  servicing in such cases may be considered an illegal act. End clients and costumers shall be informed that servicing is not approved, and the installer who charged the non  specified refrigerant shall be asked to fix the unit. HITACHI will accept no responsibility for units that have been charged with non-specified refrigerant once.

  • Page 12: Product Guide

    1 General information Product guide 1.3 Product guide 1.3.1 Classification of water chiller models  Basic modules Unit type (Modular water chiller): RCM E = Made in Europe Position-separating hyphen (fixed) Capacity (HP): 40, 50, 60, 70 W = Water cooled H = R134a refrigerant Serie – 1.3.2 Product guide: Water chillers  Basic modules 3N~ 400V 50Hz Unit Code RCME-40WH1 8E040341 RCME-50WH1 8E050341 RCME-60WH1...

  • Page 13: Control Functions

    2 Control Functions C o n t r o l F u n c t i o n s Index Control functions on the module......................6 2.1.1 Water control ..............................9 2.1.2 Water temperature control ..........................10 2.1.3 Compressor Control ............................13 2.1.4 Control for recovery from power interruption (Option) ...................

  • Page 14: Control Functions On The Module

    2 Control Functions Control functions on the module 2.1 Control functions on the module  List of the main control functions Item Description Slide valve control The outlet water temperature of the chiller unit is detected with a thermistor, and the stroke of slide valve is controlled continuously by time-sharing.
  • Page 15 2 Control Functions Control functions on the module Item Description It is not possible to switch between remote and main unit control, and between cooling and heating, during Incorrect operation operation of the chiller unit. An alarm is output with respect to such incorrect operation, and to wrong DIP switch prevention settings.
  • Page 16 2 Control Functions Control functions on the module Item Description Water Temp Set Setting is possible in 0.5ºC units. 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 individual codes Display Pilot lamps: Lit on for power source: white, run: red, alarm: orange...

  • Page 17: Water Control

    2 Control Functions Control functions on the module 2.1.1 Water control Outlet water temperature of Chiller Unit is detected by Thermistor, and based on this value, compressor ON/OFF and the most suitable capacity is determined. Following shown the continuous capacity control and change of water temperature. Starting setting (example) Outlet...

  • Page 18: Water Temperature Control

    2 Control Functions Control functions on the module 2.1.2 Water temperature control 1 Automatic temperature adjustment Compressor run/stop and capacity control are performed by detecting water temperature of the chiller unit with thermistors. Water Temp Set ON/OFF Temperature Difference Stop Temperature Range Item Available range Setting range...
  • Page 19 2 Control Functions Control functions on the module 2 Method to change settings a. Water temperature settings COOL/HEAT COOL INPUT Select the setting value INPUT with up and down keys Register with [ENT] key Cancel with [CAN] key The part with the setting temperature currently enabled is illuminated N O T E •...
  • Page 20 2 Control Functions Control functions on the module b. Setting of other water 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.

  • Page 21: Compressor Control

    2 Control Functions Control functions on the module 2.1.3 Compressor Control 1 Startup control The chiller unit receives an operation order, the cool water pump starts up, and after interlock is complete and compressor delay time (initial setting: 0.5 minutes) has passed, compressor is started up. In continuous control type, startup takes place in a state in which the slide valve is moved to the smallest load position.
  • Page 22 2 Control Functions Control functions on the module 4 Setting 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 SMGB0120 rev.0 - 11/2017...

  • Page 23: Control For Recovery From Power Interruption (Option)

    2 Control Functions Control functions on the module 2.1.4 Control for recovery from power interruption (Option) When this function is enabled, even in the case of power interruptions exceeding 2 seconds in length, operation restarts automatically in the operation mode as before the power failure, once a 3-minute guard has passed. To enable this function, the DIP switch of option C on the settings PCB (PCB ) (DSW5-1#) has to be set to ON.

  • Page 24: Prevention Of Simultaneous Startup

    2 Control Functions Control functions on the module 2.1.5 Prevention of simultaneous startup This function prevents simultaneous startup when supplying power to multiple units (in case that all modules are working individually, not in a master-slave group) In case that multiple chiller units are installed, it may be thought that all of them will start operation simultaneously when 3 minutes have passed after entering in recovery from power interruption.

  • Page 25: Control For Prevention Of Wrong Operation And Wrong Settings

    2 Control Functions Control functions on the module 2.1.7 Control for prevention of wrong operation and wrong settings In the following cases, an alarm is output as wrong operation. 1 Wrong activation of the operation controls A wrong operation alarm is displayed when there is a remote input (including external thermo signal) while the unit is stopped, regardless of "local/remote switch"...
  • Page 26 2 Control Functions Control functions on the module  Current limit function (Power demand control) a. Contents of activation It is possible to operate below a maximum current limitation ratio previously 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.
  • Page 27 2 Control Functions Control functions on the module c. Setting method when cooling/heating mode is set In case of cooling/heating mode Display the input window with [INPUT] key Input the setting value with up and down keys Confirm with [ENT] key Cancel with [CAN] key N O T E Input the ratio corresponding to the “Standard current value” displayed on the LCD screen. Confirm the setting value displayed on “Current limitation setting value”. This control becomes disabled when selecting “100%”.
  • Page 28 2 Control Functions Control functions on the module d. Time chart Control setting value for overcurrent protection Maximum current Setting value of limitation value current limitation External signal X e. Wiring method Control board of the chiller unit Power Maximum current source of limitation switch the local...

  • Page 29: Forced Load Up Capacity Control From External Signal

    2 Control Functions Control functions on the module 2.1.9 Forced load up capacity control from external signal It is possible to force load up according to usage purpose. a. Contents of activation It is possible to force load up from the orders of local control panel. b.

  • Page 30: 2-Temperature Setting Function

    2 Control Functions Control functions on the module 2.1.10 2-temperature setting function Regarding to the setting temperature of water temperature control, it is possible to set 2 different temperatures, one for cooling and one for heating, and select which of these to be used as a setting temperature by means of a remote signal. This change is useful to cope with differences of load in usage, such as those between day and night operation.

  • Page 31: External Thermo Operation From External Contact

    2 Control Functions Control functions on the module 2.1.11 External thermo operation from external contact In case of setting the chiller unit to run/stop with the order of an external contact such as that of a (locally supplied) external thermo, capacity control function is disabled and operation is performed at 100% load. This function is mainly oriented to thermal storage operation.
  • Page 32 2 Control Functions Control functions on the module Thermo OFF temperature of the main unit remains enabled even during forced load operation. When performing thermal storage 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.

  • Page 33: Water Temperature Of The Control Target

    2 Control Functions Control functions on the module 2.1.12 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. ...

  • Page 34: Operation From Dc24V Contact Input

    2 Control Functions Control functions on the module 2.1.13 Operation from DC24V contact input  Outline The procedure to control operation from the DC24V contact of the local central controller is shown below. •  Level input •  Pulse input (1 switch) • ...
  • Page 35 2 Control Functions Control functions on the module b. Setting method COOL COOL/HEAT N O T E • 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. SMGB0120 rev.0 - 11/2017...
  • Page 36 2 Control Functions Control functions on the module  Pulse input type 1 a. Signal aspect and basic sequence For wiring Terminal board Section arranged as a local work Run/stop switch (to be prepared locally) Alarm output (DC24V, less than 0.8A) Relay coil for DC24V, etc.
  • Page 37 2 Control Functions Control functions on the module b. Setting method COOL COOL/HEAT Select "Pulse" Select "Pulse" N O T E • 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. SMGB0120 rev.0 - 11/2017...
  • Page 38 2 Control Functions Control functions on the module  Pulse input type 2 (external DC24V source) a. Signal aspect and basic sequence For wiring Remove (ON) signal (OFF) signal (OFF) (ON) Local works - parts to be arranged locally (field supplied) Time chart More than 5 min More than 200 ms...

  • Page 39: Thermo Off Function Selection

    2 Control Functions Control functions on the module 2.1.14 Thermo OFF function selection This function prevents thermo OFF of the chiller unit due to sudden changes of temperature or flow. Example of standard settings: Inlet water temperature Outlet water temperature Setting temperature Thermo OFF temperature Stop with 10 continued seconds at thermo OFF temperature Example of thermo OFF judgement extension Inlet water temperature Outlet water temperature 10 minutes...

  • Page 40: Selection Of Enabling/Disabling Of Alarm Release By Means Of Remote Stop

    2 Control Functions Control functions on the module  Mode selection method COOL COOL/HEAT Select "10 minutes" Select "10 minutes" 2.1.15 Selection of enabling/disabling of alarm release by means of remote stop The release of an alarm in case 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 ...

  • Page 41: Limitation Setting For Pump Feedback Waiting Time

    2 Control Functions Control functions on the module 2.1.16 Limitation setting for pump feedback waiting time Flow at the start of operation of the chiller unit ° Chiller Unit Operation Order Reception Waiting for Pump Feedback ¢ Interlock achieved In case that setting time is Compressor operation after compressor delay £...

  • Page 42: Inlet Water Temperature Thermo Off Function

    2 Control Functions Control functions on the module 2.1.17 Inlet water temperature thermo OFF function Normally thermo OFF judgement is carried out from outlet water temperature, but 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.
  • Page 43 2 Control Functions Control functions on the module (II) COOL COOL/HEAT Select "Enable" Thermo ON conditions are Display the input window the same as in normal outlet with [INPUT] key water temperature control. Input the setting value with It can be set for both cooling up and down keys and heating operation.

  • Page 44: Control Of The Cooling Cycle

    2 Control Functions Control of the cooling cycle 2.2 Control of the cooling cycle 2.2.1 Compressor Control The compressor mounted on this product is equipped with a system to adjust the amount of discharge (slide valve). The slide valve is installed on the screw rotor, and performs the adjustment of the amount of discharge with the change of bypass amount by hydraulic activation.

  • Page 45: Expansion Valve Control

    2 Control Functions Control of the cooling cycle 2.2.2 Expansion Valve Control The expansion valve used in this product is an electronic expansion valve. The electronic expansion valve is composed by the main unit and a coil. The control functions of the electronic expansion valve are as shown below. 1 Basic control ...
  • Page 46 2 Control Functions Control of the cooling cycle 2 Protection controls The basic control follows the contents of section 1, but the following functions are also implemented for the protection of the product. a. Low pressure over-increase prevention control In case of continued operation conditions of low pressure higher than 0.5 MPa, the valve is forced to close and momentarily set somewhat close in comparison with the opening under normal control.

  • Page 47: Overcurrent Protection Control

    2 Control Functions Control of the cooling cycle  Image diagram of 0 (zero) point adjustment If the compressor does not stop in 200 hours Restart after 3 minutes In superheat control Thermo OFF Thermo ON Time If more than 24 hours have passed since the last 0 (zero) point Forced 0 (zero) point adjustment adjustment, then 0 (zero) point adjustment is performed during is performed...

  • Page 48: Control Of Master/Slave Group

    2 Control Functions Control of Master/Slave group 2.3 Control of Master/Slave group 2.3.1 Summary of control of Master/Slave group In addition to the operation as a single chiller unit, this product allows the operation of multiple chiller units as a single heat source system.

  • Page 49: Operation Method

    2 Control Functions Control of Master/Slave group 2.3.3 Operation method One group composed of multiple modules using the functions to control the number of units is called a "system". 1 Operation Order (Required) Input "System Operation Order" for the chiller unit set as Unit 1. It is also possible to put the system to operation from the "Local system operation switch"...
  • Page 50 2 Control Functions Control of Master/Slave group 5 Remote Forced Stop (Alarm Reset) / System Recovery Wiring Connect to each chiller unit to force stop of a chiller unit in operation from a remote location, to reset an alarm, or to return to the system a chiller unit that had been excluded from the target of the control of Master/Slave group.

  • Page 51: Other Functions Of The Control Of Master/Slave Group

    2 Control Functions Control of Master/Slave group 6 External thermo operation Functions concentrated in unit 1 (master unit) By inputting the signal of the following wiring to unit 1, their settings become enabled for all the chiller units in the same group.

  • Page 52: Setting Items

    2 Control Functions Control of Master/Slave group 5 Rotation Control When starting up the modules, the modules with the shortest operation time have priority. (Comparison is carried out between units with the same priority order settings, though) When stopping modules, the modules with the longest operation time have priority.
  • Page 53 2 Control Functions Control of Master/Slave group ¢ Setting temperature difference Sets the target difference between water inlet and outlet temperature to increase the number of units in operation. £ Temperature range of addition Sets the range of change of inlet water temperature to add units, in case that the difference of temperature reaches the temperature difference set at ¢.

  • Page 54: Method For Setting And Confirmation Of Operation Conditions Through The Lcd Screen

    2 Control Functions Control of Master/Slave group 2.3.6 Method for setting and confirmation of operation conditions through the LCD screen Conducts the setting of the control of Master/Slave group and confirmation of operation conditions through the LCD  screen. In the case of master In the case of slave unit unit (unit 1) setting (units 2 to 8) setting Set the setting temperature difference (when the 1st water temperature setting is enabled) Set the setting temperature difference (when...
  • Page 55 2 Control Functions Control of Master/Slave group [Status screen of the control of Master/Slave group] SMGB0120 rev.0 - 11/2017...

  • Page 56: Run Operation

    2 Control Functions Run operation 2.4 Run operation 2.4.1 Setting of switches on the setting PCB 1 Pump operation switch By setting the switch ON while the module is stopped, Pump Operation pump operation order is output. 2 Local / Remote switch Switches whether the operation control of the module Local is performed locally or remotely.

  • Page 57: Operation Control Of The Module

    2 Control Functions Run operation 2.4.2 Operation control of the module 1 In the case of remote control Operation order Confirm that the cold water inlet/outlet valve is fully open Power ON Power ON the pump for cold water circulation Cooling Set the locally installed “Cooling/Heating” switch to “Cooling” Press the “Run”...

  • Page 58: Time Chart

    2 Control Functions Time chart 2.5 Time chart Continous capacity control (Cooling operation) Power source Run control Control Stop control Heating (ON)/Cooling(OFF) Protection Pump feedback device Common (Other than above) Thermo Thermo Load Power source display (Main unit) Pump operation Pump operation display (Remote) Operation display (Main unit) Operation display (Remote)

  • Page 59: Servicing

    3 Servicing S e r v i c i n g Index LCD display for Service Menu ....................... 53 General notes ............................61 Cycle components ..........................62 3.3.1 Compressor removal ............................. 62 3.3.2 Overhaul work ............................... 65 3.3.3 Recovering the refrigerant ..........................67 3.3.4 Replacement of the condenser ........................
  • Page 60 3 Servicing 3.4.7 Transformers (TF2, TF3, TF4) ........................83 3.4.8 Overcurrent relay (ORC) ..........................83 3.4.9 Contactors (CMC, CMCD, CMCS) ........................ 84 3.4.10 Fuses (EF1, EF2, EF3. EFR, EFS, EFT) ....................84 3.4.11 Fuses (PFC) ..............................85 3.4.12 Relays ................................. 86 3.4.13 Main Switch ..............................

  • Page 61: Lcd Display For Service Menu

    3 Servicing LCD display for Service Menu 3.1 LCD display for Service Menu INPUT SCREEN EXAMPLE (2 sec.) (Latest version will be shown) MAIN SCREEN MENU N O T E This screen will be shown after clicking on the INPUT button. Increases the value.
  • Page 62 3 Servicing LCD display for Service Menu  Auto expansion valve initialize SERVICE MENU SCREEN (1/2)  Superheat setting SERVICE MENU SCREEN (1/2) SMGB0120 rev.0 - 11/2017...
  • Page 63 3 Servicing LCD display for Service Menu  Expansion valve manual operation SERVICE MENU SCREEN (1/2)  Overcurrent protection setting SERVICE MENU SCREEN (1/2) SMGB0120 rev.0 - 11/2017...
  • Page 64 3 Servicing LCD display for Service Menu  Sensor adjust SERVICE MENU SCREEN (1/2) N O T E When a sensor is giving a different value than the actual value, a correction can be set. Example: Real temperature: 25.0ºC Thermistor value: 24.0ºC Input 1.0ºC the correction value System recognizes as :24.0 + 1.0 = 25.0ºC SMGB0120 rev.0 - 11/2017...
  • Page 65 3 Servicing LCD display for Service Menu  Comp Hr Setting SERVICE MENU SCREEN (1/2) N O T E When PCBc is replaced, the previous information related to compressor operating time and number of restarts can be entered from the service menu ...
  • Page 66 3 Servicing LCD display for Service Menu  4-20 mA input SERVICE MENU SCREEN (2/2)  Continuous control SERVICE MENU SCREEN (2/2)  Order dissable SERVICE MENU SCREEN (2/2) SMGB0120 rev.0 - 11/2017...
  • Page 67 3 Servicing LCD display for Service Menu  Default Set SERVICE MENU SCREEN (2/2) N O T E • This function 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.
  • Page 68 3 Servicing LCD display for Service Menu  Delete log SERVICE MENU SCREEN (2/2) N O T E This function deletes the stored data concerning to the alarms and cautions. SMGB0120 rev.0 - 11/2017...

  • Page 69: General Notes

    3 Servicing General notes 3.2 General notes Before starting to remove any component, take into account the following notes: D A N G E R • Before performing any of the service operations described in this chapter, turn all the main switches off and place security lockers or convenient warning indicators in order to prevent them from turning on accidentally. • It is recommended to turn the power supply off for some operations. • In all electrical works be sure there is no voltage. Check it with a multimeter. C A U T I O N • In case of sharped edged parts, as covers, use security gloves to avoid getting injured.

  • Page 70: Cycle Components

    3 Servicing Cycle components 3.3 Cycle components C A U T I O N • All operations in the refrigerant cycle require to collect the refrigerant. In those cases proceed as explained in”3.3.3 Recovering the refrigerant” D A N G E R •...
  • Page 71 3 Servicing Cycle components 4 Loosen the screw at the metallic band, which fixes the Thermistor. Softly pull the thermistor Thermistor THMs) backwards. Screw 5 Remove all the wiring of the compressor. a. Power supply wiring Power supply cable hose (R, S, T) b.
  • Page 72 3 Servicing Cycle components 6 Remove the 8 screws fixing the compressor. Right side. From E Box Unscrew the screws fixing the structure (HEX10), as shown in the picture Screws (x8) Left side. From E Box 7 Remove the “U” rod, fix to the structure. “U”Rod Screw 8 Use a portable crane or a lift truck to remove...

  • Page 73: Overhaul Work

    Cycle components 3.3.2 Overhaul work Perform the work according to “Semi-hermetic Hitachi 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.
  • Page 74 3 Servicing Cycle components  Replacement of oil inside compressor To replace the oil of the compressor proceed as explained below: 1 Collect all refrigerant into a condenser before this work. Recover the rest of refrigerant from the water cooler and the compressor.

  • Page 75: Recovering The Refrigerant

    3 Servicing Cycle components 3.3.3 Recovering the refrigerant  Recovering the refrigerant by “Pump-down” procedure The steps to follow for recovering the refrigerant by “pump-down” are described below: 1 Collect all refrigerant into the condenser: a. Circulate the chilled water sufficiently through the water cooler, and operate the unit for 10 minutes. Check to ensure that the oil level is maintained at a stable condition.
  • Page 76 3 Servicing Cycle components 3 Remove the 2 Victaluic connections from the Victaulic connections water connections. 4 Screw eyebolts to both sides of the condenser to the bolts for that purpose. Fasten a textile belt to proceed to lift the condenser. C A U T I O N Do not never use chains or metallic ropes to lift the condenser as they can damage the condenser.

  • Page 77: Replacement Of The Cooler

    3 Servicing Cycle components 3.3.5 Replacement of the cooler 1 Unscrew the 4 screw of the refrigerant inlet pipe flange and the 4 screws of the outlet Outlet pipe flange refrigerant pipe flange. 4 Screws Bolt Cooler Spring washer Flange Flat washer plate Inlet pipe flange...

  • Page 78: Replacement Of Expansion Valve

    3 Servicing Cycle components 3.3.6 Replacement of expansion Valve 1 Collect the refrigerant as explained in section “3.3.3 Recovering the refrigerant” 2 Firmly hold the coil of the expansion valve Expansion valve coil and pull out upward. It is easier to remove the expansion valve coil if it is rotated while pulling it up.

  • Page 79: Filter Drier

    3 Servicing Cycle components 3.3.7 Filter drier There are two possible main maintenance operations to do with the filter drier: the substitution of the inner core due to its adsorption saturation or the substitution of the whole unit due to some damage. ...

  • Page 80: Replacement Of The Check Valve

    3 Servicing Cycle components 3.3.8 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 (THMd). Thermistor (THMd) a.

  • Page 81: Replacement Of The Stop Valve (With Check Joint)

    3 Servicing Cycle components 3.3.9 Replacement of the stop valve (with check joint) 1 Remove the brazed parts using a blowtorch Stop valve Check joint and previously cooling the pipe side and the stop valve unit with wet cloth in order to avoid brazing material enter inside the pipes.

  • Page 82: Replacement Of The Pressure Sensor (Psw)

    3 Servicing Cycle components 3.3.13 Replacement of the pressure sensor (PSW) 1 Disconnect the cables (7 and 8 of the pressure sensor form the E-box of the compressor terminal board). 2 Unscrew the sensor and proceed to its replacement 3 When reassembling proceed in reverse order than removing.

  • Page 83: Repalacement Of The Thermistor (Suction, Thms)

    3 Servicing Cycle components 3.3.17 Repalacement 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 7 and 8 of multiple Thermistor contact QCN3) THMs...

  • Page 84: Replacement Of The Thermistor (Evaporation, Thme)

    3 Servicing Cycle components 3.3.20 Replacement of the thermistor (Evaporation, THMe) 1 Cut and remove the plastic bands that fixes Thermistor the insulation of the discharge pipe thermistor THMe (THMe). 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 Evaporation contact QCN3)

  • Page 85: Thermistor (Cooler Water Outlet, Thmwo2)

    3 Servicing Cycle components 3.3.22 Thermistor (Cooler water outlet, THMwo2) 1 Unscrew the nut of the cable gland 2 Gently pull the sensor wiring upwards. Thermistor (THMwo2) C A U T I O N Sensor sheath is full of sealing silicone. Use gloves and eye goggles for protection in order to avoid possible injuries to eyes and skin.

  • Page 86: Electrical Components

    3 Servicing Electrical components 3.4 Electrical components 3.4.1 The E-box 1 Turn the main switch off. If main switch is not turned off it is not possible to open the door. 2 Open the E-box door using the provided key for electrical box cam locks.

  • Page 87: Replacement Of Lamps And Push Buttons

    3 Servicing Electrical components 3.4.3 Replacement of lamps and push buttons Lamps and push buttons are placed in the left door of the E-box. To replace anyone of the open the E-box until get access to the left door and proceed as follows: ...
  • Page 88 3 Servicing Electrical components Second level components PCBc Electric transformer PCBa 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...

  • Page 89: Removal Of The Pcb's

    3 Servicing Electrical components Clamp lever 4 Push the clamp lever to fix the plate in horizontal position at the top. 3.4.5 Removal of the PCB’s  PCBa 7- segment display Pressure switches (PSW) Plastic holder PSW1, PSW2 Switches (SW) Plastic holder SW1, SW2 Pressure switches (PSW)
  • Page 90 3 Servicing Electrical components  PCBc 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. Plastic holder ...

  • Page 91: Transformer (Tf1)

    3 Servicing Electrical components 3.4.6 Transformer (TF1) To have access to electrical transformer TF1, follow the steps described in “Second level components” in chapter “3.4.4 Access to electrical components” 1 Remove all the wirings corresponding to TF1. As shown to CN1 in the image.

  • Page 92: Contactors (Cmc, Cmcd, Cmcs)

    3 Servicing Electrical components 3.4.9 Contactors (CMC, CMCD, CMCS) C A U T I O N In RCME-WH1 units, 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.

  • Page 93: Fuses (Pfc)

    3 Servicing Electrical components 3.4.11 Fuses (PFC)  Removal 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.

  • Page 94: Relays

    3 Servicing Electrical components  Removal of the PFC fuse holder In case the fuse holder has suffered any damage and replacement is needed, follow the step described below. 1 Pull the fuse housing backwards. 2 Remove the Hex screws and wiring. PFC1-1 PFC2-3 PFC3-5...

  • Page 95: Main Switch

    3 Servicing Electrical components 3.4.13 Main Switch To remove the main switch, follow the next steps 1 Turn the switch off in order to be able to open the E box MIT/L3 MIS/L2 MIR/L1 door 2 Open the E-box door. 4 flat screws 3 Remove the wiring.

  • Page 97: Troubleshooting

    4 Troubleshooting T r o u b l e s h o o t i n g Index Inspection of power source and connections ..................90 Inspection of PCB..........................91 4.3 Confirmation of operating value of protection devices and automatic operation devices ..... 91 Protection control function ........................92 4.5 Alarm indication .............................

  • Page 98: Inspection Of Power Source And Connections

    4 Troubleshooting Inspection of power source and connections 4.1 Inspection of power source and connections In case that there is any abnormality in the activation of the chiller unit, first perform the following check. Check item Inspection method Examine the secondary voltage of the breaker and the passage of electric Is the power source breaker or the fuse broken? current through the fuse with a tester. Remove the connection of the secondary side of the transformer, and measure the (AC) voltage with a tester. Confirm that the voltage shown on the transformer is being output. Internal transformer of the unit White 3 0. 0Ｖ Blue At rated 230Ｖ...

  • Page 99: Inspection Of Pcb

    4 Troubleshooting Inspection of PCB 4.2 Inspection of PCB The standard setting of switches, etc., on the PCB is as Control System chapter in the Installation and Operation Manual. Confirm that they are being set correctly. 4.3 Confirmation of operating value of protection devices and automatic operation devices The activation values of protection devices are as follows: Name Operating value 2.02MPa High pressure (Manual recovery) 0.13MPa or below Low/High pressure interruption device (Electronic control) Low pressure...

  • Page 100: Protection Control Function

    4 Troubleshooting Protection control function 4.4 Protection control function This Chiller unit is provided with protection control functions to release abnormal statuses before reaching alarm because of abnormality occurrence. Name of Display protection control Conditions for operation Description of control Release conditions (Compressor frequency control) Segment  I1 < Setting  I1 > Setting value×0.97 Overcurrent  Load up prohibition value×0.95 Current protection  I1 > Setting value limited...

  • Page 101: Alarm Indication

    4 Troubleshooting Alarm indication 4.5 Alarm indication In case of occurrence of sensor abnormalities while the chiller unit is stopped, or of abnormalities that would not trigger an alarm stop, a warning is output to the outside and warning display is conducted. The mark is shown on the LCD Screen during warning external output. The content of warning is shown in the table below. Warning icon is Spanner mark shown Caution is Warning illuminated contents display Yellow during occurrence of warning Warning indication Contents of warning Notes When compressor is stopped while Freeze prevention...

  • Page 102: Summary Of Fault Diagnosis

    4 Troubleshooting Summary of fault diagnosis 4.6 Summary of fault diagnosis 1 Alarm In case of an alarm, the alarm light at the remote side and the alarm light on the display PCB of the main unit become illuminated, and the background of the LCD Screen of the main unit side becomes red. In case of stopping a unit in which an alarm has occurred, perform a stop operation instead of turning power OFF. Alarm occurrence LCD Display: Shows the details Remote operation display lamp: Lit ON (Background colour turns red) Alarm display lamp: Lit ON Remote alarm display lamp: Lit ON Faulty PCB segment: Abnormality code (Remote side) Stop control Checked the details of abnormality in “Status” screen? Abnormality code is shown in “History” screen Check details of abnormality of LCD part Check data stored immediately before alarm occurrence Processing position of the alarm part N O T E •...
  • Page 103 4 Troubleshooting Summary of fault diagnosis 2 Caution Abnormalities that are not a hindrance for operation, but could lead to serious failure if neglected, are output as warnings. Caution occurrence Remote caution display lamp: Lit ON LCD Display: Show mark (Remote side) Confirmation of details of abnormality in “Status” screen Processing position of the caution part 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 • Check wiring between the CPU PCB and transformer Transition of the LCD Screen upon power ON   SMGB0120 rev.0 - 11/2017...

  • Page 104: Method For Fault Diagnosis

    4 Troubleshooting Method for fault diagnosis 4.7 Method for fault diagnosis Summary of checks for fault diagnosis. Check the power Is 400V supplied to the unit? source switch Is 230V supplied to Is fuse broken? Replace fuse transformer (TF ) primary side? Is R phase or S phase Replace transformer failure? Wiring check.

  • Page 105: Troubleshooting By Alarm Code

    4 Troubleshooting Troubleshooting by alarm code 4.8 Troubleshooting by alarm code C1-H1 Alarm code High Pressure Switch Alarm stop reason Discharge pressure (Pd) increases up to 2.02MPa, activating high pressure switch (63H). PCB monitoring position PCBd (I/O PCB) PCN204 (High pressure interruption device (63H)) High pressure Operation control results Press the reset button of switch (63H) is being in immediate alarm high pressure switch reset The connection and insertion of connector Revision of connections PCN204 to PCBd (I/O...
  • Page 106 4 Troubleshooting Troubleshooting by alarm code C1-h1 Alarm code Discharge pressure over-increase Alarm stop reason Discharge pressure (Pd) becomes higher than 1.92MPa for more than 10 seconds. (Enabled for electronic control) N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control is performed until the second one. (Compressor stops, and restarts automatically after 3 minutes) Retry indication LCD: By touching “Inspection”, “Pd Retry” is shown in “No.1 Cycle”.
  • Page 107 4 Troubleshooting Troubleshooting by alarm code C1-L1 Alarm code Low pressure interruption control Alarm stop reason Suction pressure (Ps) becomes lower than 0.14MPa for more than 90 seconds. (Electronic control, only enabled in cooling) N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control is performed until the second one. (Compressor stops, and restarts automatically after 3 minutes) Retry indication LCD: By touching “Inspection”, “Ps Retry” is shown in “No.1 Cycle”.
  • Page 108 4 Troubleshooting Troubleshooting by alarm code C1-51 Alarm code Compressor overcurrent Alarm stop reason The running current for one compressor is increased above the value for activation of the overcurrent relay, thus activating the (thermal) overcurrent relay. PCB monitoring position PCBd (I/O PCB) PCN206 Operation control Overcurrent relay results in immediate Press the reset button of (51C1) is being reset activation of alarm the overcurrent relay Remove the wiring inserted into Check of wiring connector PCN206 on (disconnection) (I/O PCB) and mesure conductivity. Is there conductivity? Check of overcurrent relay (internal disconnection) Check of PCB (I/O PCB) I/O PCB is normal Overcurrent relay...
  • Page 109 4 Troubleshooting Troubleshooting by alarm code C1-61 Alarm code Discharge gas temperature increase Alarm stop reason 1 Temperature of refrigerant discharged from Compressor rises up to 130ºC for more than 1 minute. 2 During count of point 1, temperature rises even more, above 140ºC for more than 3 seconds. N O T E In the case of point 1, it causes alarm stop with 3 occurrences in 90 minutes. Retry control is performed until the second one. (Compressor stops, and restarts automatically after 3 minutes) Retry indication LCD: By touching "Inspection", "Td Retry" is shown in "No.1 Cycle".
  • Page 110 4 Troubleshooting Troubleshooting by alarm code C1-71 Alarm code Compressor Internal Thermo Activation Alarm stop reason Compressor motor overheats, activating internal thermo. (Activation point: 115ºC) N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control until the second one (Compressor stops, and restarts automatically once de thermostat returns to a normal operation temperature) Retry indication LCD: By touching “Inspection”, “49C Retry” is shown in “No.1 Cycle”.
  • Page 111 4 Troubleshooting Troubleshooting by alarm code C1-91 Alarm code Cooler Inlet Decrease Alarm stop reason Inlet refrigerant temperature of the heat exchanger Te(CN29) becomes lower than -6.5ºC for more than 3 seconds. (only enabled in cooling). N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control is performed until the second one. (Compressor stops, and restarts automatically after 3 minutes) Inlet refrigerant temperature of the heat exchanger Te(CN29) becomes lower than -35ºC for more than 10 seconds. (only enabled in defrosting) N O T E...
  • Page 112 4 Troubleshooting Troubleshooting by alarm code C1-t1 Alarm code Suction gas decrease Alarm stop reason Temperature of refrigerant suctioned into compressor (Ts) falls below -5ºC for more than 10 seconds. (only enabled in cooling) N O T E Causes alarm stop with 3 occurrences in 30 minutes. Retry control is performed until the second one. (Compressor stops, and restarts automatically after 3 minutes) Retry indication LCD: By touching “Inspection”, “Ts Retry” is shown in “No.1 Cycle”.
  • Page 113 4 Troubleshooting Troubleshooting by alarm code 13-13 Alarm code Freeze protection · Freeze prevention C1-13 Alarm stop reason Cold water temperature falls below 1ºC. (Only enabled in cooling) PCBc (CPU PCB) PCN12 short line is disconnected N O T E • In case of detection by inlet water temperature thermistor or in case of detection by disconnection of PCN12 short line “ 13-13 ” C1-13 •...
  • Page 114 4 Troubleshooting Troubleshooting by alarm code 14-14 Alarm code Hot Water Over-Increase C1-14 Alarm stop reason Outlet water temperature exceeds 62ºC during compressor operation. PCBc (CPU PCB) PCN13 short line is disconnected N O T E “ 14-14 ” in case that PCN13 short line is disconnected “ C1-14 ” in case of detection by outlet water temperature thermistor PCB monitoring position PCBc (CPU PCB) CN5 (Outlet water temperature thermistor Two1(for water temperature control)) PCBc (CPU PCB) PCN13 (Short line) Outlet water...
  • Page 115 4 Troubleshooting Troubleshooting by alarm code C1-21 Alarm code Cooler inlet THM abnormality (CN29) Alarm stop reason Thermistor for detection of inlet refrigerant temperature (Te) at the heat exchanger indicates an abnormal value. PCB monitoring position PCBd (I/O PCB) CN29 (Cooler inlet thermistor (Te)) N O T E Refer thermistor characteristics chapter The connection and insertion of connector Correction of CN29 on PCBd (I/O PCB) connections are correct Remove the connectors and measure thermistor resistance. Replace thermistor Is resistance value normal? Replace PCBC (I/O PCB) C1-23...
  • Page 116 4 Troubleshooting Troubleshooting by alarm code C1-24 Alarm code Liquid THM abnormality (CN24) Alarm stop reason Thermistor for detection of heat exchanger outlet (Tl) (condenser liquid) temperature indicates an abnormal value. PCB monitoring position PCBd (I/O PCB) CN24 (Liquid thermistor (Tl)) N O T E Refer thermistor characteristics chapter The connection and insertion of connector Correction of connections CN24 on PCBd (I/O PCB) are correct Removet he connectors and Replace thermistor measure thermistor resistance. Is resistance value normal? Replace PCBd (I/O PCB) C1-25...
  • Page 117 4 Troubleshooting Troubleshooting by alarm code C1-26 Alarm code Suction Gas THM Abnormality (CN27) Alarm stop reason Thermistor for detection of temperature of gas suctioned (Ts) by compressor indicates an abnormal value. PCB monitoring position PCBd (I/O PCB) CN27 N O T E Refer thermistor characteristics chapter. The connection and insertion of connector Correction of connections CN27 on PCBd (I/O PCB) are correct Remove the connectors and Replace thermistor measure thermistor resistance. Is resistance value normal? Replace PCB (I/O PCB)
  • Page 118 4 Troubleshooting Troubleshooting by alarm code C1-27 Alarm code Discharge Pressure Sensor Abnormality (CN31) Alarm stop reason Discharge pressure sensor (Pd) of compressor indicates an abnormal value. PCB monitoring point PCBd (I/O PCB) CN31PD (Discharge pressure sensor (Pd)) N O T E Refer pressure sensor characteristics chapter. The connection and insertion of connector Revision of connections CN31Pd on PCBd (I/O PCB) are correct DC5V is being supplied between pin 1 and pin Replace PCBd (I/O PCB) 3 of connector CN31Pd on PCBd (I/O PCB) Is the voltage between pin 2 and pin 3 of connector CN31Pd on PCBd (I/O PCB) Replace PCBd (I/O PCB) lower than DC0.5V or higher than DC4.5V when discharge pressure sensor is connected? Elimination of the factors There is clogging inside the connection pipe of for clogging inside the discharge pressure sensor...
  • Page 119 4 Troubleshooting Troubleshooting by alarm code C1-28 Alarm code Suction pressure sensor abnormality (CN32) Alarm stop reason Suction pressure sensor (Ps) of compressor indicates an abnormal value. PCB monitoring position PCBd (I/O PCB) CN32PS (Suction pressure sensor (Ps)) N O T E Refer pressure sensor characteristics chapter. The connection and insertion of connector Revision of connections CN32Ps on PCBd (I/O PCB) is correct DC5V is being supplied between pin 1 and pin Replace PCBd (I/O PCB) 3 of connector C32Ps on PCBd (I/O PCB) Is the voltage between pin 2 and pin 3 of connector CN32Ps on PCBd (I/O PCB) Replace PCBd (I/O PCB) lower than DC0.5V or higher than DC4.5V when discharge pressure sensor is connected? Elimination of the factors There is clogging inside the connection pipe of for clogging inside the discharge pressure sensor...
  • Page 120 4 Troubleshooting Troubleshooting by alarm code C1-39 Alarm code Current sensor abnormality (CN36) Alarm stop reason Current sensor indicates an abnormal value (CT). PCB monitoring position PCBd (I/O PCB) CN36 (Current sensor (CT)) The connection and insertion of connector Revision of connections CN36 on PCBd (I/O PCB) is correct The connection and insertion of the connector of current sensor on the body of the Revision of connections unit are correct The power wiring of compressor passes Revision of wiring through the current sensor There are no changes to the characteristics Check of current sensor of the current sensor (The characteristics of the specifications. Check of...
  • Page 121 4 Troubleshooting Troubleshooting by alarm code 03-03 Alarm code 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) DSW1-5,6# of Set DSW correctly and PCBa (Setting PCB) reactivate power supply are correctly set DSW2-1,2# of Set DSW correctly and PCBd (I/O PCB) are reactivate power supply correctly set Terminal resistance correctly Set DSW correctly and set. Either DSW8-1# of reactivate power supply PCBc (CPU PCB) or DSW300- 1# of PCBd (I/O PCB) are set ON Check PCBc (CPU PCB) and PCBd (I/O PCB) SMGB0120 rev.0 - 11/2017...
  • Page 122 4 Troubleshooting Troubleshooting by alarm code 01-01 Alarm code Startup Circuit Failure Alarm stop reason Startup circuit fails to self-hold after reception of operation signal, or upon automatic recovery from instant power failure. PCB monitoring position PCBc (CPU PCB) PCN15,PCN17 The connection and insertion of connector Revision of connections PCN15 on PCBc (CPU PCB) is correct The connection and insertion of connector Revision of connections PCN17 on PCBc (CPU PCB) is correct The insertion of the terminal of relay AR Revision of connections correct Replace relay AR 05-05 Alarm code Reverse/Open Phase Alarm stop reason Power source connected locally is connected in reverse or in open phase.
  • Page 123 4 Troubleshooting Troubleshooting by alarm code 11-11 Alarm code Inlet water temperature abnormality (CN4) Alarm stop reason Thermistor for detection of inlet water temperature (Twi) indicates an abnormal value. PCB monitoring position PCBc (CPU PCB) CN4 (Inlet water temperature thermistor (Twi)) N O T E Refer thermistor characteristics chapter. The connection and insertion of the connector Revision of connections CN4 on PCBc (CPU PCB) is correct Remove the connector and measure the resistance value. Is the resistance value Replacement of thermistor normal? Replacement of PCBc (CPU PCB) 12-12 Alarm code Outlet water temperature THM abnormality (CN5) C1-12 Alarm stop reason Thermistor for detection of outlet water temperature (for water temperature control Two1) indicates an abnormal value.
  • Page 124 4 Troubleshooting Troubleshooting by alarm code 2C-2C Alarm code Water supply header temperature thermistor abnormality. (CN13) Alarm stop reason Thermistor for detection of indicates an abnormal value. water supply header temperature The connection and insertion of connector Revise connections CN13 on PCBc (CPU PCB) are correct Remove the connectors and measure thermistor Replace thermistor resistance. Is resistance value normal? Replace PCBc (CPU PCB) 2d-2d Alarm code Water return header temperature thermistor abnormality. (CN14) Alarm stop reason Thermistor for detection of indicates an abnormal value.
  • Page 125 4 Troubleshooting Troubleshooting by alarm code SP-SP Alarm code Pump Interlock Abnormality Alarm stop reason • Pump operation feedback signal turns OFF while Pump operation signal (Y52P1) is ON. N O T E It 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 (PCB is normal) The overcurrent 230V are being supplied between pin 1 and pin relay for the pump Examination of pump lock 3 of connector PCN5 on PCBc (CPU PCB)
  • Page 126 4 Troubleshooting Troubleshooting by alarm code 40-40 Alarm code Incorrect Setting Alarm stop reason The settings of the DIP switch are unrecognisable. The DIP switches of each PCB are set Set DIP switches correctly correctly and reactivate power The contacts of DIP The DIP switch settings are recognized switches on the setting as correct by switch setting check “SERVICE PCB are defective. MENU” Replace setting PCB Check PCB (CPU PCB) 40-40 Alarm code Incorrect operation Alarm stop reason A forbidden operation is performed during operation. Changed settings from Conducting this operation Wrong activation remote to local during remote results in wrong activation...
  • Page 127 4 Troubleshooting Troubleshooting by alarm code 40-40 Alarm code Incorrect Setting of control of Master/Slave group Alarm stop reason The settings of the DIP relative to the function to control the number of units switch are unrecognisable. PCB monitoring position PCBa (Setting PCB) DSW3-1~3, DSW6-1~3 PCBa (Setting PCB) RSW1 The rotatory switches of PCBA (Setting PCB) Set the number of of master module are correctly set connected units correctly The DIP switches on PCBA (Setting PCB) of Set the DIP switches each module are correctly set correctly The H-LINK transmission wiring between master module and slave modules is Check wiring disconnected or connected wrongly Check PCBc (CPU PCB) 40-40 Alarm code Wrong operation of Control of Master/Slave group Alarm stop reason Switching of cooling/heating operation order to master module while the system is in operation, when using the function of control of Master/Slave group. Retry indication No indication Switched cooling/ heating operation order Check of thermistors during system operation...
  • Page 128 4 Troubleshooting Troubleshooting by alarm code 40-40 Alarm code Transmission abnormality (Miswiring) Alarm stop reason The connection of wiring for transmission between modules (Transmission line between master and slaves) and the transmission wiring for connection of group controller is mixed. Retry indication No retry PCB monitoring position PCBc (CPU PCB) CN2 (Transmission port between modules) PCBc (CPU PCB) CN300 (Transmission port for group controller) The connection of Connect transmission wiring transmission wiring is correctly correct Check PCBc (CPU PCB) 6E-6E Alarm code Cold water suspension (Option) Alarm stop reason Suspension of water supply protection switch is activated. PCB monitoring position PCBc (CPU board) PCN10 Hot-and-chilled water is flowing with an amount Check the pump of flow higher than the usage...

  • Page 129: Analysis And Countermeasure Of Abnormalities

    4 Troubleshooting Analysis and countermeasure of abnormalities 4.9 Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Measure voltage with a Power failure Wait for power return tester Power is not coming in Check main power switch Turn main power switch ON Check wire coating Replace fuse after correcting Short circuit between wires damage short circuit Ground fault (Earth) of Measure insulation Replace fuse after correcting Power source...
  • Page 130 4 Troubleshooting Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Check connection with a Bad connection of wiring Correct wiring connection tester Check connection with a Faulty PCB Pump is tester operating, but Faulty PCB Replace PCB Check PCB with self- compressor is diagnosis not operating. Operation is possible by Replace remote control Failure of remote control switch activation from the main switch unit side Bad connection of wiring Check connection with a Correct wiring connection tester...
  • Page 131 4 Troubleshooting Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Malfunction of check valve Replace check valve Suction gas temperature is Clogging of expansion valve Remove clogging too high (excessive super Discharge heat) gas over- Malfunction of the expansion increase is Replace expansion valve valve activated Failure of thermistor for Replace thermistor for Check connection with a tester control of discharge gas control of discharge gas Replace electromagnetic Single phase operation Check electromagnetic switch switch Power supply voltage too high...
  • Page 132 4 Troubleshooting Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Stop the chiller unit and check the relation Mixture of non-condensable gas in Recharge refrigerant after between water refrigerant cycle vacuum pumping temperature and pressure Clogging of pipes at discharge side Activation Remove clogging of high Clogging of expansion valve pressure Check for clogging switch Remove clogging, or replace due to Clogging of check valve check valve...
  • Page 133 4 Troubleshooting Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Automatic defrosting Failure of thermistor for Check activation of thermistor mechanism Replace thermistor for defrosting defrosting for defrosting does not Abnormal activate. adherence Check and compare the of frost to Inlet temperature of the condenser is short- resistance of thermistor at Replace the thermistor the heat circuited. actual temperature exchanger during heating Check and compare the operation. Faulty low pressure sensor indicated value of low pressure Replace low pressure sensor...
  • Page 134 4 Troubleshooting Analysis and countermeasure of abnormalities Phenomenon Cause Check Item Action · Countermeasure Conduct heating load Set the machine to a larger Load bigger than heating capacity. calculation capacity Charge correct refrigerant Gas leakage or insufficient Check super heat volume after checking gas Suction amount of refrigerant leakage pressure is too low. Clogging of expansion valve Check for clogging Remove clogging (Low Malfunction of expansion Check operation of expansion Replace expansion valve pressure valve valve interruption control Check whether there is...

  • Page 135: Thermistor Characteristics

    4 Troubleshooting Thermistor characteristics 4.10 Thermistor characteristics The thermistor is installed in this product to detect the cycle temperature such as water temperature (inlet-outlet of water side heat exchanger), and outlet liquid refrigerant temperature from the heat exchanger. The thermistor temperature characteristics are shown in the below figures: 4.10.1 Thermistor temperature characteristics (All temperature except discharge gas) 19,3 14,4 10,9 2,5 2,0 1,6 1,3 1,1 0,9 0,7 0,6 0,5 0,4 0,4 0,3 -20 -15 -10 -5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 17B18890 Temperature (ºC) 4.10.2 Thermistor temperature characteristics for discharge gas temperature...

  • Page 136: Pressure Sensor Characteristics

    4 Troubleshooting Pressure sensor characteristics 4.11 Pressure sensor characteristics 4.11.1 High-pressure sensor (Mpa) 4.11.2 Low-pressure sensor (0.3) (-0.1) (Mpa) 4.12 Procedures for trouble The following table shows efficient checking procedures for trouble. Fault Possible cause Check/corrective action 1. C heck the pump contactor. Repair or replace, if necessary. Interlock circuit for chilled water pump is open 2. Check for the faulty pump. Compressor does not Remove the causes, and reset the “ON” button. operate Electrical protective devices are tripped.
  • Page 137 4 Troubleshooting Procedures for trouble The following table shows efficient checking procedures for trouble. Fault Possible cause Check/corrective action Check for excessively low setting of the chilled Excessively low chilled water outlet temperature water setting knob. Compressor stops Check for malfunction of the thermistor. Replace, if Defective thermistor on freeze protection necessary. control. Shortage of chilled water flow Check the rotation of the pump. Air in water circuit Purge air. Check the power supply line and contactor. Repair, High or low voltage, single-phase or phase imbalance if necessary. Compressor stops on Excessive superheat Check for refrigerant leakage. internal thermostat Check the contact of the internal thermostat during or discharge gas Defective element the cold condition.
  • Page 140 Johnson Controls-Hitachi Air Conditioning Spain, S.A.U. Ronda Shimizu, 1 - Políg. Ind. Can Torrella 08233 Vacarisses (Barcelona) España HITACHI certifies that our products have met EU consumer safety, health and environmental requirements. Johnson Controls-Hitachi Air Conditioning Spain, S.A.U. is certified with: ISO 9001 of AENOR, Spain for its Quality Management accordance with the standard.

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