Csavarkompresszoros - SM GB0003 - r0 - 01-07-Service Manual RCUE AG2

AIR COOLED WATER CHILLERS
(COOLING ONLY AND HEAT PUMP)
Service Manual
RCUE40AG2-400AG2
Cooling capacity 112 kW - 1030 kW
RHUE40AG2-240AG2
Cooling capacity 106 kW - 585 kW
Heating capacity 110 kW - 556 kW
Specifications in this manual are subject to change without notice in order that HITACHI
may bring the latest innovations to their customers.
Whilst every effort is made to ensure that all specifications are correct, printing errors are
beyond Hitachi’s control; Hitachi cannot be held responsible for these errors.
Contents
0. C o n t e n t s
Product range and specifications 1

Test run 2
Electrical wiring diagrams 3
Control system 4
Troubleshooting 5
Maintenance 6
pag. 3
SMGB0003 rev.0 - 01/2007
Contents
Content
1. Product range and specifications ............................................................................ 11
1.1. General data for RCUE40~400AG2 ..................................................................................................... 12
1.2. General data for RHUE40~240AG2 ..................................................................................................... 16
2. Test run....................................................................................................................19
2.1. Check before test run ........................................................................................................................... 20
2.2. Test run method and check .................................................................................................................. 22
2.3. Restart of Test Run ............................................................................................................................... 25
2.4. Instruction at delivery............................................................................................................................ 27
2.5.Warning & Cautions .................................................................................................................................. 28
3 Electrical Wiring Diagram ........................................................................................31

3.1. Power Wiring Diagram.......................................................................................................................... 32
3.2. Power Wiring Diagram (FAN) ............................................................................................................... 37
3.3. Control PCB (PCBc) ............................................................................................................................. 38
3.4. Input / Output PCB (PCBd)................................................................................................................... 40
3.5. Power Wiring Diagram (MCB Option)................................................................................................... 43
3.6. Diagram abbreviations descriptions ..................................................................................................... 48
4. Control system ........................................................................................................49

4.1. List of Main Control Function ................................................................................................................ 50
4.2. Water control ........................................................................................................................................ 52
4.3. Compressor control ............................................................................................................................. 53
4.4. Current limit control .............................................................................................................................. 54
4.5. Reverse protection control.................................................................................................................... 55
4.6. Restart control after power failure ........................................................................................................ 56
4.7. Operation error/wrong setting prevention control [40 – 40] ................................................................. 57
4.8. Forced capacity control ........................................................................................................................ 57
4.9. Second water temperature setting........................................................................................................ 58
4.10. Heat storage operation by external order ............................................................................................. 64
4.11. Operation by DC24V input (Remote Control) ....................................................................................... 65
4.12. Installation of switch for snow measure (Fan manual operation) ......................................................... 68
4.13. Switch for confirmation of high pressure cut......................................................................................... 69
4.14 Antifreeze control in winter ................................................................................................................... 69
4.15. Saving energy priority mode, silence priority mode (night shift), only cooling ...................................... 70
4.16. Defrost (only air-cooled heat pump type) ............................................................................................. 72
4.17. Thermo off selection function ............................................................................................................... 75
pag. 5
SMGB0003 rev.0 - 10/2006
Contents
Content (Cont.)
5. Troubleshooting .......................................................................................................83
5.1. Initial check ........................................................................................................................................... 84
5.2. Troubleshooting .................................................................................................................................. 108
5.3. Analysis and countermeasure of abnormal running ........................................................................... 141
5.4. Thermistor characteristics .................................................................................................................. 145
6. Maintenance ..........................................................................................................149
6.1. Maintenance criteria ........................................................................................................................... 150
6.2. Maintenance criteria of Screw Compressor........................................................................................ 152
6.3. Maintenance of Water Quality ............................................................................................................ 153
6.4. Cleaning of water side heat exchanger .............................................................................................. 157
6.5. Check items in daily operation............................................................................................................ 160
6.6. Caution on handling of R407C ........................................................................................................... 160
6.7. Manual at compressor overall check and parts check........................................................................ 162
6.8. Refrigerant cycle diagrams ................................................................................................................. 166
6.9. Overhaul work .................................................................................................................................... 170
6.10. Vacuuming Procedure ........................................................................................................................ 170
6.11. Additional refrigerant insertion ............................................................................................................ 172
pag. 6
SMGB0003 rev.0 - 10/2006
Contents
 Units Code List
NOTE:
MODELS Please check, according to the model name, which is your air conditioner type and how it is abbreviated and referred
CODIFICATION to in this service manual.
AIR COOLED WATER CHILLERS -SCREW TYPE
Indication Indication Indication

Model Model Model Model Indication code
code code code
RCUE40AG2 8E041072 RCUE100AG2 8E101072 RCUE180AG2 8E181072 RCUE280AG2 8E281072

RCUE70AG2 8E071072 RCUE160AG2 8E161072 RCUE400AG2 8E401072
RCUE80AG2 8E081072
RCUE60AG2
Series
Refrigeration Capacity
Refrigerant: 407C
Unit Europe
Cooling
Air condensed
pag. 7
SMGB0003 rev.0 - 10/2006
Contents
AIR TO WATER HEAT PUMP CHILLERS -SCREW TYPE
Model Indication code Model Indication code Model Indication code
RHUE40AG2 9E041072 RHUE100AG2 9E101072 RHUE180AG2 9E181072

RHUE70AG2 9E071072 RHUE160AG2 9E161072
RHUE80AG2 9E081072
RHUE60AG2
Series
Refrigeration Capacity
Refrigerant: 407C
Unit Europe
Heat pump Air condensed
pag. 8
SMGB0003 rev.0 - 10/2006
Contents
REMOTE CONTROL DEVICES LIST
Name Description Indication Code Figure
CSC-5S Central Station 60291050
PSC-5T Seven Day Timer 60291052
REMOTE CONTROL DEVICES ACCESSORIES LIST

PSC-5HR H-Link Relay 60291105
CENTRALISED CONTROLS LIST (Interfaces)

HARC70-CE1 60559055
Lonwork BMX Interface
HARC70-CE1 OP 60559056
CSNET WEB
CSNET WEB 7E891924
pag. 9
SMGB0003 rev.0 - 10/2006
Contents
CENTRALISED CONTROLS (Interfaces) ACCESSORIES LIST

PM001-CT200 7E891930 NEW

Current Transformer Accessory
(Power Meter Option
Accessory for CSNET WEB)
PM001-CT400 7E891931 NEW
Current Transformer Accessory 1000A

PM001-CT1000 (Power Meter Option 7E891932 NEW
Communication Set
PM001-GW (Power Meter Option 7E891933 NEW
Power Meter Option NEW

PM001 7E891934
(For CSNET WEB)
Touch Screen Option NEW

TS001 7E891935
(For CSNET WEB)
Wall Support for Touch Screen

TS001-WS (Touch Screen Option 7E891936 NEW
Table Support for Touch Screen

TS001-TS (Touch Screen Option 7E891937 NEW
pag. 10
SMGB0003 rev.0 - 10/2006
Product range and
specifications
1. P r o d u c t r a n g e a n d s p e c i f i c a t i o n s
This chapter provides you with a fast review of the most important general data of the Air cooled water chillers and Air to
water heat pump chillers of HITACHI.
1
Content
1. Product range and specifications ............................................................................ 11
1.1. General data for RCUE40~400AG2 ..................................................................................................... 12
1.2. General data for RHUE40~240AG2 ..................................................................................................... 16
page 11
SMGB0003 rev.0-01/2007
Product range and
specifications
1.1. General data for RCUE40~400AG2
MODEL RCUE40AG2 RCUE50AG2 RCUE60AG2 RCUE70AG2
Cooling Capacity kW 112 130 156 178
Total Power input kW 36.4 42.7 52.3 59.8
COP - 3.08 3.04 2.98 2.98

Height mm 2.430 2.430 2.430 2.430
Outer Dimension Width mm 1.900 1.900 1.900 1.900
Depth mm 2.150 2.150 2.150 2.750
Cabinet colour - Natural Grey
Net weight Kg 1.430 1.470 1.560 1.760
Compressor type - Semi-hermetic screw type
Models - 40ASC-Z 40ASC-Z 50ASC-Z 60ASC-Z
Quantity - 1 1 1 1
Oil heater W 150 150 150 150

- Continuous Capacity Control
Capacity control
% 15~100
Water cooler type - Brazing Plate Type
Condenser type - Multi-Pass cross finned tube
Fan Motor (pole) kW 0.38 (8)

Quantity - 4 4 4 6
Refrigerant type - R407C (Factory charged)
Flow control - Electronic expansion valve
Number of independent circuits - 1 1 1 1
Quantity of refrigerant (kg) - 39 46 41 48
Oil type - JAPAN ENERGY FREOL UX300 (Ester)
Water pipe connection Inch 3” Victaulic (1xInlet/1xOutlet)
Control system - Micro-processor control
Chilled water outlet temperature ºC -10 (Option) 5~15
Condenser air inlet temperature ºC -15~46
Permissible water pressure max. MPa 1.0
Reverse Phase Protection, Fuse and Thermal Relay for Compressor,
Internal Thermostat for Compressor, Compressor Oil Heater,
Fuse and Internal Thermostat for Fan Motor, Control Circuit Fuse,
Safety and protection devices - High Pressure Switch, Low Pressure Control,
High Pressure Relief Valve, Discharge Gas Temperature Control,
Suction Gas Temperature Control, Freeze Protection Control
and Compressor Operation Hour Meter
Power suply - 3~, N/380-415V/50Hz
 NOTE:
The nominal cooling capacities are based on the European Standard EN12055.
− Chilled Water Inlet / Outlet Temperature : 12/7 °C
− Condenser Inlet Air Temperature : 35 °C
page 12
SMGB0003 rev.0-01/2007
Product range and
specifications
Cooling Capacity
Total Power input

kW
kW
206
69.6
260
85.4
312
104.5
356
119.6
1
COP - 2.96 3.04 2.99 2.98
Height mm 2.430 2.430 2.430 2.430
Depth mm 2.750 4.050 4.050 5.250
Net weight Kg 1.820 2.830 3.000 3.420
Compressor type - Semi-Hermetic screw type
Quantity - 1 2 2 2
Oil heater W 150 150x2 150x2 150x2

Capacity control
% 15~100

Quantity - 6 8 8 12
Quantity of refrigerant - 64 92 82 96
3” Victaulic (1xInlet/
1xOutlet)
 NOTE:
page 13
SMGB0003 rev.0-01/2007
Product range and
specifications
COP - 2.96 2.98 2.98 2.96

Height mm 2.430 2.430 2.430 2.430
Depth mm 5.250 5.950 7.750 7.750
Net weight Kg 3.550 4.450 5.070 5.250
Quantity - 2 3 3 3
Oil heater W 150x2 150x3 150x3 150x3

Capacity control
% 15~100

Quantity - 12 12 18 18
2xOutlet)
 NOTE:
page 14
SMGB0003 rev.0-01/2007
Product range and
specifications
COP
Height mm
- 3.0
2.430
3.0
2.430
3.0
2.430
3.0
2.430
1
Depth mm 10.250 10.250 12.750 12.750
Net weight Kg 6.750 7.000 8.450 8.750
Quantity - 4 4 5 5
Oil heater W 150x4 150x4 150x5 150x5

Capacity control
% 15~100

Quantity - 24 24 30 30
Water pipe connection Inch 3” Victaulic (4xInlet/4xOutlet) 3” Victaulic (5xInlet/5xOutlet)
 NOTE:
page 15
SMGB0003 rev.0-01/2007
Product range and
specifications
1.2. General data for RHUE40~240AG2
MODEL RHUE40AG2 RHUE50AG2 RHUE60AG2 RHUE70AG2

Heating Capacity kW 110 127 152 185
Total Power input in cooling kW 36.4 42.7 52.3 59.8
Total Power input in heating kW 40.7 44.5 54.3 67.7
Height mm 2.430 2.430 2.430 2.430
Depth mm 1.900 1.900 1.900 2.500
Net weight Kg 1.550 1.600 1.670 1.880
Quantity - 1 1 1 1
Oil heater W 150
Capacity control
% 15~100
Water side heat exchanger - Brazing plate type
Air side heat exchanger - Multi-Pass cross finned tube
Quantity - 4 4 4 6
Heated water outlet temperature ºC 35~55
Condenser air inlet temperature ºC -15~46 for cooling operation
Evaporator air inlet temperature ºC DB: -9.5~21/ WB:-10~15.5 for heating operation
 NOTES:
(1) The nominal cooling capacities are based on the European Standard EN12055.
− Chilled Water Inlet / Outlet Temperature : 12/7 ºC
− Condenser Inlet Air Temperature : 35 ºC
(2) The nominal heating capacities are based on the European Standard EN12055.
− Heated Water Inlet / Outlet Temperature : 40/45 ºC
− Evaporator Inlet Air Temperature : 6 ºC (WB)
page 16
SMGB0003 rev.0-01/2007
Product range and
specifications
1
Height mm 2.430 2.430 2.430 2.430
Depth mm 2.500 3.800 3.800 5.500
Net weight Kg 1.950 3.050 3.250 3.670
Quantity - 1 2 2 2
Oil heater W 150 150x2
Capacity control
% 15~100
Quantity - 6 8 8 12
1xOutlet)
 NOTES:
page 17
SMGB0003 rev.0-01/2007
Product range and
specifications

Height mm 2.430 2.430 2.430 2.430
Depth mm 5.000 5.700 7.500 7.500
Net weight Kg 3.780 4.780 5.440 5.650
Quantity - 2 3 3 3
Oil heater W 150x2 150x3
Capacity control
% 15~100
Quantity - 12 12 18 18
2xOutlet)
 NOTES:
page 18
SMGB0003 rev.0-01/2007
Test run
2. Te s t r u n
This chapter describes the procedure of test run of the Air cooled water chillers and the Air to water heat pump chillers.
Content
2.
2.1.
Test run....................................................................................................................19
Check before test run ........................................................................................................................... 20
2
2.1.1. Cabinet ......................................................................................................................................................... 20
2.1.2. Refrigerant System ...................................................................................................................................... 20
2.1.3. Electrical System.......................................................................................................................................... 21
2.1.4. Water System ............................................................................................................................................... 22
2.2. Test run method and check .................................................................................................................. 22

2.2.1. Check before Test Run................................................................................................................................. 22
2.2.2. Cooling operation (low pressure, high pressure) ......................................................................................... 23
2.2.3. Heating operation (low pressure, high pressure) ......................................................................................... 23
2.2.4. Electrical consumption percentage .............................................................................................................. 24
2.3. Restart of Test Run ............................................................................................................................... 25

2.3.1. Check of high pressure switch (cooling operation) ...................................................................................... 26
2.3.2. Check of low pressure cut control ................................................................................................................ 26
2.3.3. Temperature controller ................................................................................................................................. 26
2.3.4. Check of refrigerant leakage ........................................................................................................................ 26
2.4. Instruction at delivery............................................................................................................................ 27
2.5.Warning & Cautions .................................................................................................................................. 28

2.5.1. During product and electrical installation ..................................................................................................... 28
2.5.2. During operation........................................................................................................................................... 28
2.5.3. During repair and relocation ......................................................................................................................... 29
2.5.4. Other cautions .............................................................................................................................................. 29
pag. 19
SMGB0003 rev.0-01/2007
Test run
2.1. Check before test run
Confirm there is no problem regarding chiller installation space and requirements. See
technical catalogue for more details.
Check the following items at the beginning of the season and before first test run.
2.1.1. Cabinet
 Exterior and − Confirm there is no damage in exterior and interior

interior caused during transportation or at installation.
− Remove foreign matters and dust and clean it.
− Confirm individually if screw and washer are fixed well
using screw driver or wrench.
− Confirm visually if heat insulation, tape and label plates
are fixed well.
 Drain pan − Confirm visually if there is no clogging nor rust in drain. In

case of the rust, arrange it painting.
 Air side heat − Check visually if there is no dust between fins. In case of
exchanger dust, wash the part with fin cleaner.
 Fan part − Confirm there is no deformation nor any trouble in fan or

fan protection net.
− Confirm if fan spins smoothly.
− Confirm if screws are not loosed. (especially check if
shaft and runner are fixed)
− Confirm if there is no strange noise during the revolution.
CAUTION:
Do not use domestic 2.1.2. Refrigerant System
detergent as a
forming agent at  System in − Confirm individually if screws are fixed well using
refrigerant leakage general screwdriver or wrench.
check. The followings
are recommended: − Confirm if there is no gas leakage using foaming agent or
− Snove (Nupro, leak tester especially in flanges, screws, and flare parts.
USA),
− Gupflex  Compressor − Confirm visually if there is no oil leakage from suction

(Yokogawa,
Japan) and discharge flange.
Gas leakage
detection device is
not compatible with
 Fuse plug − Confirm visually if fuse plug is not inflated abnormally.
one for R22. The
sensibility of the
device for R22 is
little, therefore, do not
divert it.
 Stop valve − Confirm if the stop valve for refrigerant in outlet of air side
for liquid heat exchanger is fully opened.
refrigerant
pag. 20
SMGB0003 rev.0-01/2007
Test run
2.1.3. Electrical System
 Fuse − Confirm visually if fuse is suitable. See technical catalogue

for detail regulation of fuse.
 Electrical − Confirm individually if screws in installation part and wire

device connection part are not loosed using driver. Check it
2
carefully since devices might be damaged if screws in wire
connection part are not tightened well.
− Confirm if the insulation resistance is more than 1MΩ in
500 V DC 500V DC. In case of below 1MΩ, do not operate the unit
since insulation of electrical device has failure.
Fig.1  Compressor − Check if insulation works well. Do not operate the unit in
case of below 3MΩ in 500V DC (fig.1)
 Fan motor − Check if insulation works well. Do not operate the unit in
case of below 3MΩ in 500V DC. (fig.1)
100 ºC
over  Wire in the − Confirm touching directly with hands if the wiring is not
unit removed or loosed.
− Confirm the covered insulation part. Pay attention not to
Fig.2
touch it by wet hand or to touch directly the edge of metal
plate or high temperature part of electrical devices. (fig.2)
 Local wiring − Confirm if earth wire is installed correctly and not broken.
− Confirm if R, S, and T phase are connected correctly.
− Confirm the local wiring size. If the volume is not sufficient,
it may cause extreme heating or fire.
 Electrical − Confirm if convex part of electrical expansion valve coil

expansion is well fixed to concave part of electrical expansion valve
valve body.
pag. 21
SMGB0003 rev.0-01/2007
Test run
2.1.4. Water System
 Quality − Confirm if the water quality follows the guideline detailed in

control the technical catalogue.
 Diameter of − Strange noise or abnormal vibration can occur if water

water pipe pump is not installed well or water pipe is too long. Confirm
valve open
the piping in the following sample method (fig.3)
open
− Open the inlet/outlet valve of water and pass the
close
direction
liquid type water inside the water heat exchanger and pipes.
direction
− While operating the water pump, remove the air
water inside the water pipe from the plug or automatic air-
state of removing valve.
opening
− Continue operating the pump and confirm if there
Fig.3 is no water leakage, strange noise nor abnormal
vibration.
− Remove the air from the pump and pass the water inside
all the system.
− Check if water is not leaked in all the system.
− Confirm if the valve is open.
− Confirm if strainer (correspondent to 20 mesh) prepared
in local is installed in water inlet pipe near the unit. When
checking at the beginning of the season, check also if there
is any dust or foreign materials in strainer.
 Water − In case of short periods, there is no problem if water

temperature temperature goes outside of service limits. However, chiller
unit may be damaged working for more then 30 minutes
out of standard specifications. Service limit of water
temperature is as follows.
− Chilled water temperature (outlet): -10(option)~5~15°C
− Warm water temperature (outlet): 35~55°C
2.2. Test run method and check
2.2.1. Check before Test Run
1. Need to apply electricity to oil heater. Power ON 12 hours before the first
start up.
2. Screw compressor start-up. Confirm if there is no strange noise or abnormal
vibration in 1~2 minutes after compressor operation.
3. Confirmation of standard operating pressures. Stop the operation once and
re-start the unit after more than 3 minutes. Confirm if pressure is correct after
15 minutes of compressor operation referring for “Fig.6 Standard operation
pressure” and “Fig.6 Water side heat exchanger washing area”.
4. Positive revolution of fan. Confirm if fan is spinning in counter clockwise
rotation observing the fan from the above.
5. Check of gas leakage.Confirm if gas is not leaked after stopping the
operation.
pag. 22
SMGB0003 rev.0-01/2007
Test run
2.2.2. Cooling operation (low pressure, high pressure)
High pressure (MPa)

Low pressure (MPa)
 Cooling operation:
 Fig.4
Chilled water outlet temperature (ºC) Ambient DB temperature (ºC) 2

2.2.3. Heating operation (low pressure, high pressure)
High pressure (MPa)

Low pressure (MPa)
 Heating operation:
 Fig.5
Ambient WB temperature (ºC) Heated water outlet temperature (ºC)
Low pressure and high pressure, corresponding to outlet temperature and

ambient DB temperature, are within the below area (at 100% operation) normally.
Fig. Standard operation pressure (at 100% operation)
Area need to clean

High pressure (MPa)
Low pressure (MPa)
Saturated
curve
 Fig.6 Saturated
curve
Area need to clean
Chilled water outlet temperature (ºC) Warm water outlet temperature (ºC)
(Cooling operation) (Heating operation)
CAUTION:
For installation and
test run under low
ambient temperature,
like at the beginning NOTE:
of summer, it is Fig.6 area need to be cleaned water side heat exchanger
possible to decrease
low pressure
abnormally.
In such case, heating
operation should be
run firstly and then
cooling operation.
(In case of air-cooled
heat pump)
pag. 23
SMGB0003 rev.0-01/2007
Test run
2.2.4. Electrical consumption percentage
Electrical consumption percentage is 100% in the following standard conditions at cooling

and heating operation:
 Cooling operation: 50 Hz electrical consumption percentage (cooling)
Air side heat exchanger inlet ambient

DB 35°C,
Chilled water inlet temperature 12°C,
Chilled water outlet temperature 7°C.
Electrical consumption percentage (%)
 Fig.7
Chilled water outlet temperature (ºC)
 Heating operation: 50 Hz electrical consumption percentage (heating)
Air side heat exchanger inlet ambient

DB 7°C, WB temperature 6°C,
Warm water inlet temperature 40°C,
Warm water outlet temperature 45°C
Electrical consumption percentage (%)
 Fig.8
Warm water outlet temperature (ºC)
pag. 24
SMGB0003 rev.0-01/2007
Test run
2.3. Restart of Test Run
After a series of items are confirmed from the beginning to the end of test run, restart the unit and check also the
following items.
Items Check point Criteria and method Remarks
− Momentary voltage at
compressor start-up is over
rated voltage ±15%
2
− Operation voltage is within Unbalance of voltage
Voltage makes current value
rated voltage: ±10% change significantly.
− Unbalance between voltage:
within 2%, in any case, within
3%.
High pressure − See the diagrams in sub-

Low pressure chapter 2.2.2 and 2.2.3.
Operation:
operation register Ambient temperature DB, WB
Chilled water inlet temperature − See figures 4 and 5.
Chilled water outlet temperature
Activation temperature of chilled water

temperature controller − Confirm the activation
Activation temperature of warm water temperature changing the
temperature controller setting temperature
(air-cooled type)
− Below 6 times in a hour and

Frequency of compressor start-up and non stop operation time is
stop
over 5 minutes.
Refrigerant Is there no abnormal vibration and − Confirm

system: contact in pipe or capillary?
cycle in general − Confirm if there is too much
compressor Frost in compressor Caution in mid-term
frost.
− Confirm if there is no strange

Electrical system: Is electrical device (relay etc) activated
normally? activation like noise, spark or
electrical device Is activation time of timer normal?
chattering.
If it needs to adjust
it with water volume,
Is there no trouble in discharge water adjust it in the
pressure nor in operation noise? discharge side of
Water system: pump.
Pump
− Re-check if there is no
Is there any clogging in strainer? dust nor foreign matters in
strainer.
pag. 25
SMGB0003 rev.0-01/2007
Test run
2.3.1. Check of high pressure switch (cooling operation)
 Cooling operation: 1. Operate the unit in local operation mode.

2. When “High pressure cut confirmation test” switch on PCB is pressed during
local operation, fan is stopped forcedly and high pressure is increased. Then,
high pressure switch turns ON. (Alarm stop) This confirmation switch is set in
every cycle (see fig.9) (to restart the compressor, high pressure switch must be
rearmed manually next to each compressor)
NOTE:
See “HIgh pressure
confirmation” in
chapter 4 “Control
functions” for the
details.
 Fig.9
CAUTION:
It is recommended that
this confirmation test
3. After confirmation, alarm should be released by unit stop operation. When alarm
be performed at load-
up state, operation for is released, high pressure cut confirmation test is also released.
a few minutes after
start-up.
2.3.2. Check of low pressure cut control

Low pressure is decreased by closing the stop valve. Then, low pressure cut
device is activated (Alarm stop).
<Activation conditions for low pressure cut control>
Activated in 3 seconds at low pressure sensor detection pressure of below
0.049MPa
2.3.3. Temperature controller

It is difficult to check the temperature controller accurately in an installation place,
however, the following method helps to grasp the setting state roughly.
1. Temperature controller is set in high temperature side for chilled water, and in
low temperature side for warm water.
2. Measure the set temperature at compressor stop, and compare it with actual
inlet water temperature.
2.3.4. Check of refrigerant leakage

It is possible for screws to be loosened at delivery. Take 10~15 seconds at least in one
position to check the leakage.
pag. 26
SMGB0003 rev.0-01/2007
Test run
2.4. Instruction at delivery

When delivering the unit after test run, give an appropriate explanation to customers about operation method and
periodical maintenance method etc as well as the following items.
1. Apply the electricity to oil heater
Do not turn off the power source of unit during normal use in order that electricity is applied to oil
heater. In case of re-starting the unit after a long time, turn on the power 12 hours before operation
start. Oil heater avoids the damage of shaft and rotor, preventing the foaming of lubrication oil in
compressor at start-up. (Heats oil to approx. 40ºC)
2
2. If chiller unit is not used for a long time, drain the water out of pipes using water-drawing or air-drawing
plug.
3. Anti-freeze in winter
− To avoid freezing, which might damage devices or pipes, it is needed to be installed some insulation in pump
and water pipes.
− This chiller has a function to operate chilled (warm) water circulation pump automatically in case of
decreasing outside temperature during unit stop, therefore, do not turn off the power source during season.
In case of turning off, draw the water out of chiller unit.
4. In case of fire,
Turn all power OFF
5. The unit will not display failure in spite of the following cases.
− During operation and after unit stop, if there is water flowing noise. However, this is a refrigerant flowing
noise, and it is not a failure.
− Compressor is not operated (fuses are out) although operation switch is ON while temperature controller is
being activated. This is not a failure, but operation is started when temperature control (Thermostat) turns
ON.
− In screw type chiller unit, there is a noise in the compressor rotors when it is stopped. Refrigerant is flowed
back temporally, and this is not a failure.
6. The refrigerant used in this unit is incombustible, non-toxic and odourless safe. However, toxic gas is
produced when leaked refrigerant is exposed to fire and oxygen will be lacked due to that refrigerants
gravity is higher than air. Therefore, in case that refrigerant is leaked or eye or throat are irritated, stop the
use of fire, and ventilate well, then contact a distributor.
7. About operation method
Standard method of use is described in the operation manual attached with the product. Operation
method would be changed if special modification were realized by request of the customers. Give a
clear explanation to the customers that it is necessary to contact a distributor or Customer Service
Centre of manufactures in case that operation, not described in the manual, must be performed.
8. For customers’ continued safety
For customers’ safety, give plain and sufficient explanation and instruction to them about the contents
of “Please observe safety precautions fully” described in Installation Manual and “For safety use”
described the Operation Manual, and tell them to read them very carefully.
Cautions are divided into “Alarm” and “Caution”:
“Alarm” includes cases where it is possible to lead to a dangerous result like death or severe injury.
Cases described in “Caution” may also lead a grave result depending on the situations. Therefore,
please read them carefully and follow the instruction.
Operation Manual should be kept where any user can reach.
pag. 27
SMGB0003 rev.0-01/2007
Test run
2.5.Warning & Cautions
2.5.1. During product and electrical installation
WARNING − Installation must be performed by distributors or specialists. Inadequate

installation may cause water leakage, electrical shock or fire.
− Electrical work must be performed by person with qualification. Inadequate
electrical work may cause electrical shock.
− Confirm if earth wire is connected. Earth wire is determined according to the
technical criteria of electrical installation.
− Do not use wire or copper wire in stead of a fuse inside the unit or in the switch
for power source. It may cause heat or fire in case of abnormal current.
− Confirm if fuse is correct and adequate. In case of setting inadequate fuse, like
high volume fuse, fuse would not melt in spite of abnormal current, and cause
fire. See installation check manual attached with the unit for correct fuse volume.
− Confirm the open/close state of valves according to label or operation manual.
Especially, confirm if inlet valve is open in those products that have inlet valve
of condenser. Operation with the valve close may cause explosion due to the
abnormal increase of high pressure.
− Use only specified refrigerant. Nitrogen gas should be used in air tight test. The
use of combustible gas like oxygen and acethylene may cause fire or explosion.
2.5.2. During operation

WARNING
 Fig.10 − Do not touch the switch with wet hand. It may cause electrical shock (fig.10).
− Do not use any sprays such as insecticide, lacquer, hair spray or other
flammable gases near the unit. It may cause fire. (fig.11)
− Do not operate with cover of electrical box open. To touch the electrical part may
cause electrical shock.
− Turn OFF all power source immediately in case that unit is not stopped in spite
 Fig.11 of the stop operation or that refrigerant is leaked or chilled water is discharged. It
may cause electrical shock, fire and explosion. Contact a distributor of Customer
Service Centre of manufacturer in such case. (fig.12)
− Do not press repeatedly the operation switch. It avoids a normal activation of
protection device and may result in failure, electrical shock and fire.
− Turn OFF main power in case of safety devise is activated frequently or
 Fig.12 operation switch is not activated steadily. There is a possibility of ground leakage
or overcurrent and may result in electrical shock or fire. Contact a distributor of
Customer Service Centre of manufacturer in such case. (fig.12)
− Safe refrigerant (Fluorocarbon), incombustible, non-toxic and odourless, is used.
In case that Fluorocarbon is leaked and touched with fire, it would be a cause
of toxic gas production and of lack of oxygen. Contact a distributor of Customer
Service Centre of manufacturer in such case. (fig.13)
 Fig.13 − Do not put fingers or sticks etc into the air inlet and outlet. These units have high
speed rotating fans and it is dangerous that any object touches them.
− Do not remove the protection net air inlet and outlet. These units have high
speed rotating fans and it is dangerous that any object touches them.
− Do not touch hot temperature parts. It may cause burn. (fig.14)
 Fig.14
pag. 28
SMGB0003 rev.0-01/2007
Test run
2.5.3. During repair and relocation
WARNING − Turn OFF all powers when checking electrical parts, otherwise, it may result in
electrical shock.
− Do not touch protection device. It may result in failure, electrical shock, fire
 Fig.12
and explosion if these devices are touched, the setting value can be changed
or short-circuited.
− In case of troubles (smell something burning etc), stop the operation and
2
turn OFF main power immediately. Operation with abnormal state may cause
failure, electrical shock and fire. Contact a distributor of Customer Service
Centre of manufacturer in such case (fig.12)
− Consult to a distributor of Customer Service Centre of manufacturer in case of
repair and relocation. Inadequate installation may cause electrical shock
2.5.4. Other cautions
CAUTION: − Do not pour water inside the unit.

− Do not modify the units. Modification or the use of unspecified parts may
cause failure, electrical shock and fire.
− Maintain the units on firm ground.
− In case of fire turn OFF the main power. Use oil or distinguish for electrical fire
in fire control.
− Do not touch hot temperature parts. It may cause burn.
− Consult with a distributor or qualified service person in case of disposal of
unit since refrigerant should be pull out correctly. The law prohibits indecent
discharge of refrigerant in air.
pag. 29
SMGB0003 rev.0-01/2007
Electrical Wiring
Diagrams
3. Electrical Wiring Diagrams
This chapter shows the electrical wiring diagrams for Chiller AG2 of Hitachi.
Content
3 Electrical Wiring Diagram ........................................................................................31
3.1. Power Wiring Diagram.......................................................................................................................... 32
3.1.1. Model: R(C/H)UE 40~80AG2 ....................................................................................................................... 32
3.1.2. Model: R(C/H)UE 100~160AG2 ................................................................................................................... 33
3
3.1.3. Model: R(C/H)UE 180~240AG2 ................................................................................................................... 34
3.1.4. Model: R(C/H)UE 280~320AG2 ................................................................................................................... 35
3.1.5. Model: R(C/H)UE 350~400AG2 ................................................................................................................... 36
3.2. Power Wiring Diagram (FAN) ............................................................................................................... 37

3.2.1. Model: R(C/H)UE 40~400AG2 ..................................................................................................................... 37
3.3. Control PCB (PCBc) ............................................................................................................................. 38

3.3.1. Model: R(C/H)UE 40~400AG2 ..................................................................................................................... 38
3.3.2. Model: R(C/H)UE 280~400AG2 (Secondary PCBc) .................................................................................... 39
3.4. Input / Output PCB (PCBd)................................................................................................................... 40

3.4.1. Model: RCUE 40~240AG2 ........................................................................................................................... 40
3.4.2. Model: RCUE 280~400AG2 ......................................................................................................................... 41
3.4.3. Model: RHUE 40~240AG2 ........................................................................................................................... 42
3.5. Power Wiring Diagram (MCB Option)................................................................................................... 43

3.5.1. Model: R(C/H)UE 40~80AG2 ....................................................................................................................... 43
3.5.2. Model: R(C/H)UE 100~160AG2 ................................................................................................................... 44
3.5.3. Model: R(C/H)UE 180~240AG2 ................................................................................................................... 45
3.5.4. Model: R(C/H)UE 280~320AG2 ................................................................................................................... 46
3.5.5. Model: R(C/H)UE 350~400AG2 ................................................................................................................... 47
3.6. Diagram abbreviations descriptions ..................................................................................................... 48
pag. 31
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.1. Power Wiring Diagram
3.1.1. Model: R(C/H)UE 40~80AG2
Drawing Code:
XEKS1037_r1  NOTE:
All the field wiring equipment must comply with local codes.
For more information about DWS configuration, please refer to chapter 4 of this catalogue.
See the diagram abbreviations description at the end of this chapter.
pag. 32
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.1.2. Model: R(C/H)UE 100~160AG2
Drawing Code:
pag. 33
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.1.3. Model: R(C/H)UE 180~240AG2
Drawing Code:
pag. 34
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.1.4. Model: R(C/H)UE 280~320AG2
Drawing Code:
pag. 35
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.1.5. Model: R(C/H)UE 350~400AG2
Drawing Code:
pag. 36
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.2. Power Wiring Diagram (FAN)
3.2.1. Model: R(C/H)UE 40~400AG2
Drawing Code:
pag. 37
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.3. Control PCB (PCBc)
3.3.1. Model: R(C/H)UE 40~400AG2
Drawing Code:
pag. 38
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.3.2. Model: R(C/H)UE 280~400AG2 (Secondary PCBc)
Drawing Code:
pag. 39
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.4. Input / Output PCB (PCBd)
3.4.1. Model: RCUE 40~240AG2
Drawing Code:
pag. 40
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.4.2. Model: RCUE 280~400AG2
Drawing Code:
pag. 41
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.4.3. Model: RHUE 40~240AG2
Drawing Code:
pag. 42
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.5. Power Wiring Diagram (MCB Option)
3.5.1. Model: R(C/H)UE 40~80AG2
Drawing Code:
pag. 43
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.5.2. Model: R(C/H)UE 100~160AG2
Drawing Code:
pag. 44
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.5.3. Model: R(C/H)UE 180~240AG2
Drawing Code:
pag. 45
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.5.4. Model: R(C/H)UE 280~320AG2
Drawing Code:
pag. 46
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.5.5. Model: R(C/H)UE 350~400AG2
Drawing Code:
pag. 47
SMGB0003 rev.0 - 01/2007
Electrical Wiring
Diagrams
3.6. Diagram abbreviations descriptions
Mark Name Remark Mark Name Remark

MCn Compressor Motor PCBB1,B2 Printed Circuit Board for Operation
MF11-N6 Condenser Fan Motor PCBC1,C2 Printed Circuit Board for CPU
MI Main Isolator PCBD1 Printed Circuit Board for Relay
CMC1 Contactor for Compressor Motor PCBE11~ Printed Circuit Board for Fan Control
Contactor for Compressor Motor PCBF1,F2 PCB for Electronic Expansion Valve
CMCsn
(Start Operation)
PCBG1,G2,G3 PCB for DC Fan control
Contactor for Compressor Motor
CMCDn Water Pressure Switch,
(Delta Operation) WP Option
Water Flow Switch
CMF11-N2 Contactor for Condenser Fan Motor
SVEn Solenoid Valve for Economizer
or optional Circuit
EFCn Fuse for Compressor Motor
Breaker PSWn Pressure Switch for Economizer
Overcurrent Relay for Compressor EHn Cooler Heater
ORCn
Motor
TF1,2,3,4,5,6,7 Transformers
or optional Circuit
EFF11-N4 Fuse for Condenser Fan Motor 4WNn 4-way valve
Breaker
ITC1-n Internal Thermostat for Compressor SW2~8 External Swich
ITFn5,n6 Internal Thermostat for Fan Motor Pilot Lamp for caution signal (from
CL
Fans)
CHn Crankcase Heater
Push Button Switch for Starting
PBSR1
ARn,H,R Auxiliary Relay (REMOTE)
OFF: 2.74Mpa Push Button Switch for Stoppage
PSHn High Pressure Switch PBSR2
ON: Manual Reset (REMOTE) Field Supplied
Pdn High Pressure Sensor Pilot Lamp for Remote Indication
RLn
(Unit Operation)
Psn Low Pressure Sensor
Pilot Lamp for Remote Indication
OLn
THMi Inlet Water Temperature Thermistor (Alarm)
Outlet Water Temperature CMP Contactor for Pump
THMW01n
Thermistor
TRP Thermal Relay for Pump
THMr2 n Cooler Inlet Refrigerant Thermistor
N:1~n
Suction Gas Temperature
THMn
Thermistor
THMIwon2 Water Temperature cooler backside
THMd n Discharge Gas Thermistor Symbol Description
Or optional Circuit
PFCn Fuse holder for Compresor Motor Terminals
Breaker
Fuse holder for Compresor Fan Or optional Circuit Closed-end Connector
PFFn
Motor Breaker
THMa Ambient Temperature Thermistor Field-supplied
NFn Noise Filter (PCB) – ·· – ·· – Field Wiring

NFA,B,11~9N Noise Filter (PCB)
––––– Earth Wiring
MVn Electronic Expansion Valve (Exp.v)
CT1,2 Current sensor ––––––– Factory wiring
FF11~N4 Fan five protection 12A

MFFn Fan motor inside Electrical Box N Model
CA11~N6 Capacitors for Fan
1 R(C/H)UE 40, 50, 60, 70, 80AG2
EF1~3, R,S,T Fuse 6A
SV11-N1 Solenoid Valve for Starting 2 RC/H)UE 100, 120,140, 160AG2
SV12-N2 Solenoid Valve for Load-down 3 R(C/H)UE 180, 210, 240AG2

SV13-N3 Solenoid Valve for Load-up
4 RCUE 280, 320AG2
TMn Hour Meter
PCBA Printed Circuit Board for Display 5 RCUE 350,400AG2
pag. 48
SMGB0003 rev.0 - 01/2007
Control system
4.C o n t r o l s y s t e m
Content
4. Control system ........................................................................................................49
4.1. List of Main Control Function ................................................................................................................ 50
4.2. Water control ........................................................................................................................................ 52

4.2.1. Automatic temperature adjustment .............................................................................................................. 52
4.3. Compressor control ............................................................................................................................. 53

4.3.1. Starting control ............................................................................................................................................. 53
4
4.3.2. Rotation control ........................................................................................................................................... 53
4.4. Current limit control .............................................................................................................................. 54

4.4.1. Actuation of current limiter ........................................................................................................................... 54
4.4.2. Standard setting value of unload time .......................................................................................................... 54
4.5. Reverse protection control.................................................................................................................... 55
4.6. Restart control after power failure ........................................................................................................ 56

4.6.1. Restart control after momentary power failure (<2 sec) ............................................................................... 56
4.6.2. Restart function after power failure <Option> (>2 sec) ................................................................................ 56
4.7. Operation error/wrong setting prevention control [40 – 40] ................................................................. 57
4.8. Forced capacity control ........................................................................................................................ 57
4.9. Second water temperature setting........................................................................................................ 58
4.10. Heat storage operation by external order ............................................................................................. 64
4.11. Operation by DC24V input (Remote Control) ....................................................................................... 65
4.12. Installation of switch for snow measure (Fan manual operation) ......................................................... 68
4.13. Switch for confirmation of high pressure cut......................................................................................... 69
4.14 Antifreeze control in winter ................................................................................................................... 69
4.15. Saving energy priority mode, silence priority mode (night shift), only cooling ...................................... 70
4.16. Defrost (only air-cooled heat pump type) ............................................................................................. 72
4.17. Thermo off selection function ............................................................................................................... 75

4.17.1 Fan Control .................................................................................................................................................... 76
4.17.2 Electronic expansion valve............................................................................................................................. 78
4.17.3. Protection Controls....................................................................................................................................... 81
pag. 49
SMGB0003 rev.0-01/2007
Control System
4.1. List of Main Control Function

Item Contents
− Outlet water temperature of water side heat exchanger
is detected by thermistor and the position of
Water temp.
Automatic water temperature control compressor slide valve is controlled continuously.
control
− The range of capacity control: 100~15%, Stop (all
models)
1. Starting control
− ∆ control (5 seconds), Starting unload control (30
sec before capacity control).
− Prevention of excessive compressor re-starts (3
2. Time Guard
minutes)
Compressor
− Prevention of compressors’ simultaneous start (1
3. Sequential starting control
minute delay) (Unit with more than 1 cycle)
− Balance of each compressor running hours (more than
4. Rotation control
1 cycle)
− When unit current reaches to the setting value, power
Current limit control supply capacity load is reduced. Therefore, unload
operation is performed forcedly for some minutes.
− 3 phase status is detected to avoid the operation in
Reverse protection control reverse phase or open phase (before starting and
during running of unit).
− In case of momentary power failure (13mm seconds ≤
time ≤ 2 seconds, and under –20% of power voltage),
Restart function from momentary power failure
unit is stopped, and then is restarted when the voltage
is back.
− In case of power failure of over 2 seconds, the units
are restarted after power supply is back.
− In case of long-term power failure, the units are
restarted when oil heater has electricity for a certain
Automatic restart function from power failure <option> period after the power supply is back.
− The units are not started automatically if power failure
happens during stop.
− It is an optional setting by Dip Switch (DSW1 pin2).
− Alarm is output for such operation errors that
changeover from remote to local or from cooling to
heating and wrong setting.
Operation error/ wrong setting prevention control
− In case that operation order is input by remote
controller when local operation is selected, alarm is
output as safety.
− Forced capacity operation (forced Thermo OFF, forced
capacity control) is performed by external signal
Forced load control attending to special needs of load.
− Control is performed externally by a no-voltage contact
for each compressor.
− It is possible to adjust 2 setting temperatures.
− 1st temperature is set by rotary switch, and 2nd
temperature is set by key operation on the 7 segment.
Second water temperature setting
− According to the usage state of loading side, setting
temperature can be switched by external signal (no-
voltage contact input).
pag. 50
SMGB0003 rev.0-01/2007
Control system
Item Contents
− Full load operation is performed by external order (no-
voltage contact input).
Ice/Heat storage operation by external order − Chiller unit stops when the water temperature reaches
the setting value (no capacity control).
− Dip Switch setting is necessary.
− It is possible to operate only fans by an external order
as a countermeasure against snow while units are
Fan forced operation function stopped.
− Run or Stop operation is performed by a no-voltage
contact .
− While the actuation of high pressure interrupt device is
High pressure cut confirmation test (only cooling) confirmed, unit is operated with fan forcedly stopped.
4
− Push button is set on PCB for every cycle number.
− Operation order to pump is output automatically by
Pump automatic operation function in winter chiller in order to avoid freezing due to the decrease of
chilled water temperature during unit stop in winter.
− It is to keep high pressure at low values when ambient
temperature below 30 ºC.
“Saving energy” priority mode <option> (only cooling) − Since fan speed is increased, it is a saving energy
operation more than a silence operation.
− It is an optional setting by Dip Switch.
− It is focused on a silent operation of the unit reducing
the fan speed.
− Since the revolution number is reduced during night
or mid-term period, efficiency is changed hardly in all
“Silence priority” mode <option> (only cooling) around the year.
− Silence is given priority over saving energy.
− It is an optional setting by Dip Switch. It is possible to
switch from the remote controller by the external signal
(no-voltage contact ).
− When fan full speed operation is not needed, fan
revolution number is reduced, and low noise operation
is performed.
Night shift mode <option> (only cooling)
− Ambient temperature target: function is valid under 30
°C (noise value 1-~-2dB) (changeover by no-voltage a
contact input)
− There are two methods to judge Thermo OFF, possible
to select.
1. Immediate Thermo OFF by Thermo OFF
temperature
Thermo OFF selection function
2. No immediate Thermo OFF if Thermo OFF
temperature continues for 3 minutes. (however, if
outlet water temperature is out of the range, it will
be immediate Thermo OFF)
pag. 51
SMGB0003 rev.0-01/2007
Control System
4.2. Water control
4.2.1. Automatic temperature adjustment
− 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.
− Possible range of water temperature setting (°C):
Cooling –10(option)~15, Heating: 35~55 (outlet water temperature control)
− Capacity control : 100~15%, stop
− The minimum range of temperature adjustment (°C): 0,5
− Restarting of unit after thermo-OFF is done depending on inlet water temperature.
Memorizes the inlet After restart, outlet temp. is detected and

temperature at Thermo-OFF the performance is increased by load-up
and re-start at ∆T2 operation in order that temp. be closer to
set temp. as earlier as possible.
Between setting temp (Tsc) and

range of neutral zone (∆T3),
capacity control balanced by load is
done to keep the temp steady.
Between setting temp (Tsc) and

range of stop (∆T1), load-down is
performed.
Method of outlet temp detection
In case of standard setting: outlet setting temp 7°C, neutral zone (∆T3) 2°C (change of outlet water temp 7~9°C).
Range of stop temp (∆T1) 1°C (stop temp 6°C), range of restart temp 2°C.
1. Load-up I control at over 10°C (The capacity is changed a lot in order to approximate the target temp.
quickly)
2. Load-up II control at 9~10 °C (The capacity is changed moderately)
3. In neutral zone (9~7°C), load is balanced and performance is not changed.
4. Under neutral zone (below 7°C) load-down control is performed and performance is decreased.
5. Stop temp: Compressor is stopped at 6 °C. The inlet temp of that time is saved.
6. When inlet temp becomes 2°C higher than that of at stop, re-start signal is output and unit is re-started after
at least 3 min guard.
7. Control mode after re-start is the same as listed before.
pag. 52
SMGB0003 rev.0-01/2007
Control system
4.3. Compressor control

Compressor Control:
1. Starting control
2. Time Guard
3. Sequential starting control
 Compressor control 4. Rotation control
4.3.1. Starting control

Starting control, Time Guard and Sequential starting control.
These three controls are performed in the control circuit on PCB.
− ∆ starting control of screw compressor ( operation lasts 5 seconds),
at minimum load. (for 30 seconds)
Time guard function which limits the frequency of Run/Stop when cooling/
4
−
heating load is small (at minimum 3 minutes of stop time to avoid more than
6 ON/OFF in one hour)
− Sequential starting control which reduces the starting current of the unit.
(Cycles start sequentially with a 1 minute delay between each one. Finally all
work together for 30 seconds before capacity control starts.).
4.3.2. Rotation control

Run/Stop order of compressor is modified in each Run/Stop in order to balance
the compressors operation time and unit life is prolonged.
Stop the
compressor
whose operation
time is longest
No. 1 ON
Compressor
OFF
No. 2 ON
Compressor
OFF
Stop the Operate the
compressor compressor
whose Operate first
operation
time is
longest
pag. 53
SMGB0003 rev.0-01/2007
Control System
4.4. Current limit control
Unit has a function to perform automatically forced unload when the power consumption
is over a certain set point.
4.4.1. Actuation of current limiter
When unit current detected by CT reaches to the setting value, forced unload
operation is performed for some minutes to reduce the power capacity load. (See
the figure below)
Load is down until actual current value is 95% of setting value, and then load
down signal is output for 12 seconds to keep the load.
Current value and forced unload operation time are set on PCBa (current limit
setting).
 Current limit setting
Actuation
Unit current
Current value
Set value
Release the actuation

Set value
-5%
T min/hour (standard: 30 m)
Time
Forced unload
Segment indication
Cooling : [←→]
Heating : [←→]
[
4.4.2. Standard setting value of unload time

− Current standard setting value of each model is shown in the below figure:
 Current limit control

Decide the period to continue forced load
down (setting value x 10 min)
Units First
digit decimal
place Y
X 10 min.
RSW7
40A 40 HP
1 X 50 HP
, X
RSW6 RSW5 60 HP
50A 70 HP
Adjust the calculated 80 HP
setting value
Ejemplo RCUE80AG2 Ejemplo RCUE40AG2
1 6 1 2
, X 50 = 80 A
, X 40 = 48 A
RSW6 RSW5 RSW6 RSW5
pag. 54
SMGB0003 rev.0-01/2007
Control system
 Reverse protection control: 4.5. Reverse protection control
Screw compressor compresses the refrigerant to a determined pressure by decreasing

the space formed by male/female rotor and slide valve. If the rotor revolution direction
is reversed, the suction side and discharge side are reversed and the functioning of the
compressor will not be correct.
Therefore, 3 phase input status is detected and operation is not performed in case of
reverse phase or open phase.
Reverse phase
3 phase input status
Alarm 
detection
UNIT STATUS
OFF
4
Open phase T phase:
open phase
R phase:
open phase Alarm 
S phase:
open phase
Reverse phase
UNIT STATUS
ON
Open phase T phase:

open phase
R phase:
UNIT GOES OFF
open phase
S phase:
open phase
pag. 55
SMGB0003 rev.0-01/2007
Control System
 Restart control after power failure: 4.6. Restart control after power failure
4.6.1. Restart control after momentary power failure (<2 sec)

NOTE: In momentary power failure, all settings are saved, so after 3 minutes time guard,
Momentary power failure: Power unit is run automatically with the same operation mode as before the power
failure of 13m seconds~2 seconds, failure.
below 160V.
In case of a power failure of over 2
seconds, it is possible to re-start the
unit by optional function. If restart
function after power failure is not
selected, the units are not re-started 4.6.2. Restart function after power failure <Option> (>2 sec)
in spite of ending the power failure.
In that case, the units should be
started according to the operation
start process. When this function is valid, even in spite of over 2 seconds power failure, units are
run automatically with the same operation mode as before the power failure (after
delay time guard).
To be valid this function, DSW1- pin 2 on PCBb shall be ON.
Power failure over 2 sec.

Momentary power
failure 13 m/s~2 sec,
under 160V
In case that function of
restart from power failure is
selected.
3 min 3 min
Time guard Time guard

Selected by Dip Switch
NOTE:
In case that power failure occurs
during unit stop, the units shall
be stopped when power supply
returns.
pag. 56
SMGB0003 rev.0-01/2007
rev.0-11/2006
Control system
4.7. Operation error/wrong setting prevention control [40 – 40]

 Operation error/wrong setting
prevention control [40-40]: Alarm is output in the following cases.
1. Operation error
− While the unit is stopped, there is a input (including external Thermo signal) from
the remote controller in spite of local operation mode.
− However, alarm is not indicated if there is a local input (operation switch of unit
body) while the unit is stopped in remote operation mode.
2. Local /Remote operation error
− To switch local  remote or remote  local while the unit is running, unit is
stopped and alarm is output. [40-40]
3. Cooling/Heating operation error
− To operate heating during cooling or to operation in cooling during heating, unit is
stopped and alarm is output. [40-40]
4. Wrong setting of Dip Switch

− Dip Switch is set wrongly, alarm is indicated at power ON. 4
 Forced capacity control:
4.8. Forced capacity control
This is a control to do Thermo OFF forcedly or to be shifted to the desired capacity by a

external control.
Since it is possible to change the operation capacity forcedly according to the load, it is
very useful if it is needed to control the temperature by a external signal.
1. Forced Thermo OFF function
NOTE: a) Contents
This control is individual In case that it is required to stop a compressor temporally, the order can be
for each compressor. given forcedly through the customer wiring terminals. After receiving this signal,
compressor shall be Thermo OFF forcedly. When this order is released, normal
operation is performed.
Automatic operation Thermo OFF Automatic operation

by Thermo by Thermo
Unit
Running operation
External
signal
b) Wiring method (custormer wiring terminal)

Wire as follows (n: nº of compressor).
pag. 57
SMGB0003 rev.0-01/2007
Control System
2. Forced capacity control

a) Contents
Compressor operation capacity is set forcedly through customer wiring terminals.
Order signal pattern and compressor operation capacity are shown as below.
Compressor forced operation capacity

Normal operation
HOLD LOAD DOWN LOAD UP
Xa ON ON OFF OFF
Xb ON OFF ON OFF
b) Wiring method (customer wiring terminal)
 Second water temperature 4.9. Second water temperature setting

setting:
According to the day run / night run or classification of load application, temperature
setting can be changed remotely.
Thanks to the two setting temperatures and the two control procedures for water
temperature (capacity control and full load or energy storage) these can be combined to
have the following possibilities.
1) Air-conditioning (capacity control ) + Air-conditioning (capacity control)
2) Air-conditioning (capacity control) + Heat storage operation (100-0%)
3) Heat storage operation (100-0%) + Heat storage operation (100-0%)
Air-conditioning temperature is set by rotary switch on operation PCB and heat storage
temperature is set by using “▲or▼” switch on indication PCB (7 segment).
 Operation mode and setting
Switch: Air-
Water temp Dip Switch Setting water
Operation mode conditioning/ Operation signal
control setting temp
heat storage
Air-conditioning Capacity control - Air-conditioning Rotary Switch Local / remote
1)
Air-conditioning Capacity control - heat storage Segment Local / remote
Air-conditioning Capacity control External Thermo Air-conditioning Rotary Switch Local / remote
2)
Heat storage 100-0% External Thermo heat storage Segment External Thermo
Heat storage 100-0% External Thermo Air-conditioning Rotary Switch External Thermo
3)
Heat storage 100-0% External Thermo heat storage Segment External Thermo
pag. 58
SMGB0003 rev.0-01/2007
Control system
1. Air-conditioning operation 1 (capacity control) + Air-conditioning operation 2 (capacity control)

The below example: chilled water outlet temperature 7°C and chilled water outlet temperature 10°C in
cooling.
 Running operation:
− Run/Stop signal is received from local or remote.
a) Dip Switch Setting
It is not necessary. Set it as factory default.
b) Setting of air-conditioning temperature 1
Set chilled water outlet temperature as 7°C.
Set chilled water outlet temperature as 7ºC
4
c) Setting of air-conditioning temperature 2
Set chilled water outlet temperature as 10°C using “▲or▼” switch on indication PCB. (see item
(4) for the setting method)
d) Wiring for switch

Wire as the below figure. Terminal No.23-24 wiring makes 2nd setting temperature valid.
Switch for
setting temp.
220-240V
2. Air-conditioning operation (capacity control) + heat storage operation (100-0%)

The below example: chilled water outlet temperature 7°C (capacity control) in cooling and chilled water outlet
temperature 10°C in heat storage.
 Running operation:
− Run/Stop signal: Local or remote (cooling), external Thermo (heat storage)
− Water temperature is set by air-conditioning / heat storage switch. Air-conditioning / heat storage = Air-
conditioning setting water temperature / heat storage setting water temperature.
pag. 59
SMGB0003 rev.0-01/2007
Control System
− In case that operation signal is input in local at heat storage operation, capacity control operation is
performed.
In option A, 3 and 4 are ON.
b) Setting of operation PCB of unit body (setting of air-conditioning temperature)
c) Temperature setting by indication PCB

Set chilled water outlet temperature as 10°C using “▲or▼” switch on indication PCB.
d) Wiring for the switch and external Thermo contact input
Wire as follows.
Remove it in case of remote control
External
thermo
NOTE:
contactor
AC: Air-conditioning
HS: Heat Storage
pag. 60
SMGB0003 rev.0-01/2007
Control system
3. Heat storage operation 1 (100-0%)+ heat storage operation 2 (100-0%)

The below example: chilled water outlet temperature 7°C and chilled water outlet temperature 10°C in
cooling.
 Running operation
− Run/Stop signal is received from external Thermo contact.
− Water temperature is set by the switch to set the temperature.
− If operation signal is input in local, capacity control operation is performed. Do not connect the wiring for
remote operation.
b) Setting of operation PCB of unit body (setting of air-conditioning temperature)
c) Temperature setting by indication PCB

Set chilled water outlet temperature as 10°C using “▲or▼” switch on indication PCB.
pag. 61
SMGB0003 rev.0-01/2007
Control System
d) Wiring for the switch and external Thermo contact input

Wire as follows.
With short circuit wiring
External
Thermo
Contactor
NOTE: Don’t connect

AC: Air-conditioning
HS: Heat Storage
4. Setting method of second temperature

Second temperature setting mode is set by pressing “▼” switch for more then 3 sec. on indication PCB with
Unit power ON. By pressing “▲or▼” switch during this mode, each second temperature of chilled water
temperature and warm water temperature is set.
 Second temperature set mode
− Press “▼” switch on normal display on 7 segment more than 3 seconds with Unit power ON. Indication
of the segment is changed to “tS-Cd” and it is indicated alternatively with actual chilled water second
temperature setting value.
− With this status, by pressing “▲or▼” switch, indication of the segment is changed to “tS-Hd” and it is
indicated alternatively with actual warm water second temperature setting value (heat pump units).
− And, by pressing “▼” switch on indication PCB more than 3 seconds, we return to normal indication
display.
In this case, 6ºC In this case, 48ºC
pag. 62
SMGB0003 rev.0-01/2007
Control system
 Temperature setting method

The following operation is performed from the status of chilled water second temperature setting value
or warm water second temperature setting value. Here, the example of chilled water second temperature
setting is shown.
Value is changed each time SW3, SW4 are

pressed, NOTE: This value is not saved at this
Press SW3, SW4 moment
simultaneously more
than 3 sec. Setting value to be
modified is indicated.
“tS-Cd” is indicated alternatively with actual

chilled water second temperature setting value
4
and at this moment the value is saved. Press SW3, SW4 simultaneously
more than 3 sec.
In this case, 12.5°C
pag. 63
SMGB0003 rev.0-01/2007
Control System
4.10. Heat storage operation by external order
 Heat storage operation by

1. Operation control
external order:
It is a control that runs unit by External Thermostat order. It forces unit to work at
full load with no capacity control. (It is valid only at remote setting)
2. Setting method
a) Dip Switch (DSW1) on the PCBB is set as follows before power ON.
b) Connection to external Thermo

− Connection to Chiller unit is as follows.
− Connect with terminal No. 40, 41 of TB3 within the electrical box.
Unit Wiring in local (parts: purchased in local)
Remove it in case remote controller switch is used
(normal)
Applied power
(heat storage) source AV200V
under 1A
(normal)
(heat Heat storage/normal

storage) changeover switch
Heat storage / normal

changeover switch
Run order
Run/Stop order contactor Stop (2 poles ON-OFF)
contactor by order contactor by (purchased in local)
external Thermo external Thermo
(purchased in local) (purchased in local) Terminal circuit
(*) In case of only heat storage operation, wiring of ( ) part is not necessary
pag. 64
SMGB0003 rev.0-01/2007
Control system
ATTENTION:
− Dip Switch for this control should be set before power ON.
− Local external Thermo does not run/stop by pulse signal order.
− Normal operation order and heat storage operation order shall be input to Chiller unit separately.
− Local external Thermo order shall have at minimum 5 minutes interval of continuous operation order (5 min in
case of stop).
− Additional wiring shall be put into a metal pipe independently, or shield line shall be used.
− During control by external Thermo, Chiller unit stops when water temperature reaches to the setting value of
Chiller unit, and automatically starts again. Therefore, set the temperature in external Thermo higher than that
of chiller unit.
− If Thermo setting value of body side is set “higher” at cooling and “lower” at heating, unit is stopped earlier than
the stop order from external Thermo.
− Switch normal / heat storage operation during unit stop.
4
4.11. Operation by DC24V input (Remote Control)
1. Outline
Operation control by DC24V is explained here.
− Operation signal pattern: 1. Level input, 2. 1 pulse input, 3. 2 pulse input.
− Set as follows and perform additional wiring in each 3 cases.
− This control is not compatible with other remote Run/Stop order.
2. Level input
a) Signal and basic sequence
Arrangement
in local
Terminal
Run/Stop switch
(prepared in local)
Switch
Alarm output Switch

(DC24V, under 0.8A)
Relay coil etc for

DC24V (prepared in
local) (Relay coil has
electricity at alarm
occurrence)
Note: Do not connect
LED or relay built-in
diode.
pag. 65
SMGB0003 rev.0-01/2007
Control System
b) Setting method
Dip Switch for optional function setting on PCBB is set as follows before power ON.
ON
ATTENTION:
− Additional wiring should not be connected to other operation circuit, especially wiring for 220-240V.
− Additional wiring shall be put into a metal pipe independently or shield line shall be used.
3. Pulse input (I)

Arrangement
in local
Terminal
Run/Stop switch
(prepared in local)
Over 200 m Over 3 min Over 200 m
Alarm output
(DC24V, under 0.8A) Switch
Relay coil etc for Switch

DC24V (prepared in
local) (Relay coil has
electricity at alarm
occurrence)
Note: Do not connect
LED or relay built-in
diode.
b) Setting method
Dip Switch for optional function setting on PCBB is set as follows before power ON.
ATTENTION:
pag. 66
SMGB0003 rev.0-01/2007
Control system
4. Pulse input (II)
Remove it
More than 200 m
More than 3 min. More than 200 m
4
Construction in local, parts prepared in local
b) Setting method
It is an application of remote control and it is unnecessary to modify the setting of PCB.
ATTENTION:
pag. 67
SMGB0003 rev.0-01/2007
Control System
4.12. Installation of switch for snow measure (Fan manual operation)
 Installation of switch for snow If a switch for snow measure is installed, it is connected to terminal #31 and #32 in
measureHeat storage operation customer wiring terminals. When the switch is ON, fan is operated during unit stop or
by external order: Thermo OFF.
However, the fan is not operated in the following cases:
− When local is set
− During alarm occurrence
− When the switch has been ON before power ON (including power failure)
− Fan manual operation is stopped by the stop switch of unit body
Customer
Terminal
Switch
(prepared
in local)
Chiller unit side Installation in local
ATTENTION:
− It is possible to insert a automatic contactor like a snow relay in this switch part.
− This switch can be used only at remote control. Pay attention to it at Unit check.
− Once the fan is started-up by this switch, fan continues running at least for
10 minutes if it is not stopped by the switch during this period. (In case of
emergency, stop the fan by the stop switch of unit)
− This switch is locally purchased.
pag. 68
SMGB0003 rev.0-01/2007
Control system
4.13. Switch for confirmation of high pressure cut

 Switch for confirmation of high
pressure cut Switching to this test mode makes easy to confirm if the device for cutting high pressure
is activated.
 Operation method
Switch for confirmation of high

pressure cut
After unit is operated (cooling) in local

operation mode, press the switch
“confirmation of high pressure cut”,
and the fan corresponding to every
compressor is stopped forcedly. And unit
is stopped by alarm since the pressure
of high pressure side is increased, which
4
makes high pressure cut device activated.
Perform unit stop operation to release
alarm stop and fan forced stop.
− To Stop/Start all fans of each cycle follow the below table:
 PCBa1 PCBa1 SW9 SW10
Cycle 1
Cycle 2
Cycle 3
 PCBa2
PCBa2 SW9 SW10
Cycle 4
Cycle 5
4.14 Antifreeze control in winter
It happens sometimes that chilled water temperature is decreased so much that heat
exchanger of water side or piping system are frozen during operation stop in winter.
This control prevents Chiller unit from freezing by operating chilled and warm water
circulation pump automatically after detecting ambient and chilled water temperature.
1. Ambient temperature is below 2°C
When ambient temperature is below 2°C, operation order is sent to pump and
continuos operation of chilled water circulation pump is started automatically.
When chilled water is over 15°C, intermittent operation (5 min of operation and
55 min of stop) is performed.
pag. 69
SMGB0003 rev.0-01/2007
Control System
2. Automatic release of antifreeze control

This operation is released only when ambient temperature is over 4°C.
Pump continuous
operation
Pump intermittent
operation (operation:
5min, stop: 55 min)
Pump stop
Change course
of chilled water
temperature
ATTENTION:
In case that ambient temperature of chilled/warm water circulation system is lower than that of
the Unit installation place, Thermostat for ambient temperature shall be introduced in the place
with the lowest temperature and shall be connected to pump operation order circuit in parallel.
4.15. Saving energy priority mode, silence priority mode (night shift),
only cooling
 Saving energy priority
mode, silence priority
mode (night shift), only It is possible to select 3 types of fan control depending on the installation place or use
cooling.
applications PCBb
1. Standard mode
− Fan control (revolution number control)
suitable to ambient temperature.
− Good balance from the view of saving
energy and silence.
2. Saving energy priority mode

− Fan control (revolution number control)
tries to keep discharge pressure as low as
possible at night or during midterm period.
− Saving energy has the priority to silence.
3. Silence priority mode (night shift)

− Smaller revolution number for silence
purpose at night or during midterm period.
− Little fan noise mode.
pag. 70
SMGB0003 rev.0-01/2007
Control system
Silence priority mode is valid by a no-voltage contactor input in Dip Switch setting of Standard mode or Saving
energy priority mode, therefore, such changeover as saving energy mode in daytime and silence priority mode at
night can be performed from remote controller.
Silence priority
ON/OFF
4
Silence priority mode (night shift) Saving energy priority mode
Silence effect by reduction High COP effect by reduction

of fan revolution number: of high pressure : about 10%
about 2dB (Noise: same as at high
(COP: same as at high ambient temp.)
ambient temp.)
Standard mode
NOTE:
The above figure is an image, and the real effect differs from temperature condition.
pag. 71
SMGB0003 rev.0-01/2007
Control System
 Defrost (only air-cooled

heat pump type) 4.16. Defrost (only air-cooled heat pump type)
Ambient temperature, evaporating temperature and evaporating pressure are detected

during heat operation to detect the frost volume. By the changeover of 4 way valve,
reverse-cycle defrosting is performed.
 Defrosting start conditions
2 min from starting unload (*) Normal: 55min. At longest: 115min.
Compressor operation >

designed time (limitation of
defrost interval)*
Automatic
Evaporating temp≤-6 ºC AND

(air side HE inlet refrigerant)
(ambient temp) - (evaporating

temp) ≥ ambient temp corrected
value (detection of frost vol.)
Low pressure Ps ≤ 0.1MPa AND OR Defrost
Manual defrost SW ON
Manual
AND
Not during defrost operation
− Defrosting is performed for 6 minutes at longest. (automatic stop when all frost is
taken out).
− In case that all frost is taken out very quickly, the period till next frost is extended
automatically in order to avoid too much defrost.
− Warm water outlet temperature is lower than inlet temperature due to the reverse
cycle defrost.
pag. 72
SMGB0003 rev.0-01/2007
Control system
Confirmation of defrost
conditions
Fan 0 Hz order, Changeover

of 4 way valve
Capacity control hold
10 sec count
Water side HE inlet

refrigerant temp ≤ 0ºC ?
Yes
4
Load-down output
No (10sec output)
Yes
Water side HE inlet
refrigerant temp ≤2ºC ?
Load-up
No
continuous output
Capacity control hold
3 min from defrost? start?
Yes
Yes
Yes High pressure ≥2.4MPa ?
Water side HE inlet
refrigerant temp ≤10ºC ?
if during fan operation, No
Yes
fan 0Hz order
6 min from defrost? start?
Fan operation control?
Yes No
High pressure ≥2.1MPa ?

No
Yes
Fan operation start

Confirmation of defrost
finish conditions
pag. 73
SMGB0003 rev.0-01/2007
Control System
Confirmation of defrost finish

conditions
Yes
Is fan running?
No
Fan 6Hz order output
Yes
High pressure ≥2.6MPa ?
No
No
10min since 6Hz order
output?
Yes
Start running with Max

frequency
Yes
High pressure ≤1.5MPa ?
No
No
10min since running with
Max frequency?
Yes
Changeover of 4 way
valve
30 sec count
(Staring unload continued)
Release of defrost control
pag. 74
SMGB0003 rev.0-01/2007
Control system
 Thermo off selection 4.17. Thermo off selection function

function
It is a function to prevent the Chiller unit from going Thermo OFF due to a sudden
change of temperature or flow volume (inverter water pumps). It is possible to select it
by DSW7-pin 3 on operation PCB. Standard is set at delivery.
PCBC
1. Standard setting
 Standard setting
4
Immediate stop when reaching to Themo OFF temp
2. Setting to continue Thermo OFF temperature for a certain period
 Setting to continue
Thermo OFF
temperature
Not immediate stop although reaching to

Thermo OFF temperature Stop if the status under Thermo OFF
temperature continues for 3 min.
NOTE:
However, it becomes Thermo OFF immediately once outlet water temperature is decreased
until protection values
pag. 75
SMGB0003 rev.0-01/2007
Control System
4.17.1 Fan Control
1. Cooling operation
In this series, fan speed is controlled by inverters and adjusts depending on discharge pressure. Target high
pressure is set based on the ambient temperature, and revolution number is increased / decreased by PID
control. The unit number is not changed.
Inverter output Max Frequency

Max Frequency: 66
Min Frequency: 10
Silence priority mode
Standard mode
Saving energy priority mode
 Fan control imaged High pressure

figure
Fan speed is increased when

high pressure is almost below
the target
Fan frequency
Start-up at 10 Hz
Fan speed is increased when

high pressure is almost over
the target
− Recalculation of fan speed is done every 10 sec.

− Calculation is not performed when high pressure target value is within ±0.1MPa.
− The following control is performed in case of sudden change.
pag. 76
SMGB0003 rev.0-01/2007
Control system
Prevention of high pressure excess increase
 Discharge pressure ≥ 2.2MPa out put +10Hz

 Discharge pressure ≥ 2.5 MPa out put max. frequency
Prevention of high pressure excess decrease
 Discharge pressure ≤ 0.9 MPa out put -10Hz

 Discharge pressure ≤ 0.8 MPa out put min. frequency
2. Heating operation
Basically unit is operated with Max frequency, but under the following conditions revolution number control is
4
performed.
Prevention of low pressure excess increase
Fan speed control is activated if “suction pressure ≥ 0.6 MPa” and “ambient temperature ≥ 25ºC”
*Released at ambient temperature ≤ 20 °C
pag. 77
SMGB0003 rev.0-01/2007
Control System
4.17.2 Electronic expansion valve

Model of expansion valve
Model: MKV-1610D-Q5
Refrigerant: R407C
Parts No.: C4340 Nº Name Qty. Material
Stem 1 SUS303

  Guide 1 SUS304
  Case 1 SUS305
  Spring Pin 1 SUS420
  Slider 1 SUS304
  Under cover 1 SUS304


  Bear ring 1 SUS440C

  Guide 1 C3771

  Body 1 C3771
  
Copper union 1 C1220
   (side)
Coil spring A 1 SUS304
 
  Coil spring B 1 SUS304
  Snap ring B 1 S65CM
   Snap Ring C 1 SUS304
  Connection lot 1 SUS303


  Copper union 1 C1220

  (under)
Needle 1 SUS303
  
Collar 2 C3604
 
Ball 1 SUS440C

Ring spring 1 SUS304

Disk spring 1 SUS304

Leaf spring tray 1 C3604

Leaf spring 2 SUS304

Piston 2 PTFE

Piston cylinder 1 SUS303

Snap Ring A 1 SK-5M

Wave spring 2 S65M
 washer
Female 1 Cu alloy

Male 1 SUS303

Magnet 1 Ferrite

Connection fitting 1 A6D61
Coil spring C 1 SUS304
Fixing bracket 1 SUS303
pag. 78
SMGB0003 rev.0-01/2007
Control system
In this series, electronic expansion valve is used. Electronic expansion valve is consisted in the body (figure), Coil,
and PCB for expansion valve running (PCBG (VD PCB)).
1. The range of opening of expansion valve

The opening of expansion valve is managed by pulse number. The range is 116~656 pulse. During stop, it is
stand-by with 10 pulse.
2. PCB for expansion valve running

PCBG (VD PCB) is used. The pulse number of the opening of expansion valve is indicated in the segment on
VD PCB.
3. Zero point adjustment

Zero point is adjusted by initialization at power ON. The order of opening of expansion valve is closed fully
4
(less than 0 pulse) and both control pulse number recognized in micro computer and real pulse number are
adjusted to zero. During this adjustment, “Cn-Eo” is indicated in the segment. (n= Unit No.)
Zero point adjustment is also performed “ at the first compressor stop after 24 hours since the last zero point
adjustment”., to modify the error between control pulse number and real pulse number. If compressore has
not stopped for over 200 hours, compressor is to be stopped forcedly (forced Thermo OFF) and zero point
is adjusted. Then, unit is re-started after 3 minutes guards. It is possible to cancel this forced zero point
adjustment by Dip Switch selection on expansión valve PCB.
4. During normal operation

Temperature of compressor suction gas superheat is calculated from the temperature detected by Thermistor
of compressor suction refrigerant gas and the pressure detected by the sensor for suction pressure, and the
opening is determined by calculation value to reach target superheat. (Control cycle: 28 seconds)
5. Prevention control for discharge refrigerant gas overheat

When discharge gas refrigerant temperature is over 100°C, expansion valve is opened forcedly and excess
increase of discharge gas refrigerant temperature is prevented. (Td control).
pag. 79
SMGB0003 rev.0-01/2007
Control System
6. Prevention control for freezing

If it is detected that refrigerant inlet temperature of water side heat exchanger is decreased, expansion valve
shall be open so that decrease of refrigerant temperature is prevented, which leads to anti-freeze in the
water side heat exchanger.
a) Normal Control
At finishing starting unload,

Open at a certain degree
Opening of expansion valve
Compressor
Operation start Thermo OFF or stop
During super
heat control
Power on
Opening degree for starting unload
Time
Standby at 10 pulse Standby at 10 pulse
Zero point adjustment at Power ON
b) Zero Point Adjustment (imaged figure)
If compressor is not stop over 200h
Re-start in 3min
Superheat control
Thermo OFF
Thermo ON
Time
Zero point adjustment during Thermo OFF Forced zero point adjustment
If 24 h has passed since the last adjustment
c) Prevention Control for Discharge Refrigerant Gas Overheat (imaged figure)
Compressor discharge gas

refrigerant temp. (Td)
Opening more if Td is over 107ºC
Re-activation of Td control
Release if Td is below 70°C
Time
Fix the opening if Td is over 100°C
(Td control)
pag. 80
SMGB0003 rev.0-01/2007
Control system
4.17.3. Protection Controls
This series has a protection control to resolve abnormal status before reaching to the alarm status, occurrence.
Control Name Conditions Contents Release conditions

High pressure Hold after load-down 10 second
High pressure ≧2.6MPa 30 min and High pressure < 2.5MPa
protection output
Cooling only:
Low presssure Low pressure ≦0.333MPa When it is continued for 1 min, 10 min and --Cooling only:
protection (1) hold after load-down 10 second
<COOLING> Heating: output Low pressure≧0.363MPa
Low pressure ≦0.314MPa
Cooling only:
-Compressor stop: retry code
Low presssure Low pressure ≦0.333MPa [Cn-P6]
protection (2) Heating: -
-Re-start in 3 min
<COOLING> Low pressure ≦0.314MPa (alarm: 3 times in 30min)
90 sec
Protection of -Compressor stop: retry code
Discharge gas refrigerant [Cn-P5]
overheat of temp≧130°C -
4
discharge gas -Re-start in 3 min
temperature 1min
(alarm: 3 times in 90min)
Prevention of [Cn-P5]
Actuation of internal Thermo of
overheat of -Re-start at internal Thermo -
motor for compressor
compressor restart
Prevention of Inlet refrigerant temperature -output of fan inverter frequency
decrease of of water side heat exchanger 6Hz 30 min or high pressure≧2.0MPa during
evaporating ≦–4.5°C -Fan inverter frequency is 20Hz at fan is fixed at 20Hz
temperature (1)
3 sec high pressure≧1.8MPa
<COOLING>
Prevention of Inlet refrigerant temperature
decrease of of water side heat exchanger Hold after output of load-up 10
evaporating 30 min
≦–5.5°C second
temperature (2)
10 sec
<COOLING>
Prevention of -Compressor stop: retry code
Inlet refrigerant temperature
decrease of [Cn-P6]
of water side heat exchanger
evaporating ≦–6.5°C -Re-start in 3 min
temperature (3)
3 sec (alarm: 3 times in 30min)
<COOLING>
Suction refrigerant gas [Cn-P6]
Anti-freezing (1) temperature ≦–2°C -
<COOLING> -Re-start in 3 min
10 sec
Anti-freezing (2) Chilled water outlet temperature Hold after output of load-down 10 30 min
<COOLING> ≦2.5°C second
Protection of High pressure – low Hold after output of load-up 12 High pressure – low pressure > 0.3MPa
pressure difference pressure≦0.3MPa second 1min
Prevention of -Pump stop

excess increase Warm water temperature < 60°C
-Alarm output
of warm water Warm water temperature ≧65°C
temperature -[PU-PU] is flickering in the (Automatic release of alarm)
<Compressor Stop> segment
pag. 81
SMGB0003 rev.0-01/2007
Troubleshooting
5. T r o u b l e s h o o t i n g
Content
5. Troubleshooting .......................................................................................................83
5.1. Initial check ........................................................................................................................................... 84
5.1.1. Check of power supply and connection ....................................................................................................... 84
5.1.2. Check on PCB.............................................................................................................................................. 85
5.1.3. Confirmation of activation value of protection device an Automatic operation device ................................. 96
5.1.4. Individual indication for activation of protection device ................................................................................ 97
5.1.5. Modification of PCBC configuration ............................................................................................................ 100

5.1.6. Check function ........................................................................................................................................... 104
5.2. Troubleshooting .................................................................................................................................. 108

5.2.1. Outline of failure diagnosis ......................................................................................................................... 108
5
5.2.2. Alarm indication.......................................................................................................................................... 109
5.2.3. Failure diagnosis method ............................................................................................................................ 111
5.3. Analysis and countermeasure of abnormal running ........................................................................... 141
5.4. Thermistor characteristics .................................................................................................................. 145

5.4.1. Thermistor temperature characteristics (All temperature except discharge gas) ....................................... 145
5.4.2. Thermistor temperature characteristics (Ambient) ..................................................................................... 146
5.4.3. Thermistor temperature characteristics (Discharge gas temperature) ....................................................... 147
pag. 83
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.1. Initial check
5.1.1. Check of power supply and connection

In case of abnormality in Chiller unit, check the following items firstly.
Nº Check Item Check Method
1 Is power supply or fuse broken? Measure secondary voltage of breaker and current carrying of fuse by tester.
Pull out the connection of secondary side in Transformer and measure the
voltage by tester. Confirm if the voltage corresponds to the indication in
Transformer.
White Transformer in unit

Red
Red
Blue
Rated
Circuit and voltage
Load
Blue
Orange
Red
Orange
Does secondary power of

2 transformer supply correctly?
White
Red
Red
Circuit and voltage
Blue
Rated
Load
Blue
Orange
Red
Orange
Green
Confirm if wiring is not loose nor wiring is wrong referring to the electricity
circuit.
− Insertion of connector of Thermistor or Compressor Sensor
Wiring loose?
3 − Insertion of connector of Flat Cable
Wrong wiring?
− Insertion of connector of Transformer Connector
− Insertion of each connector in 200V circuit.
pag. 84
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.1.2. Check on PCB
Configuration for standard version. Standard values are the ones shown on PCB drawing and table below.
 PCBB1 (RHUE40~400 AG2)
MODEL DSW3 DSW4 RSW5

5
RHUE40AG2
RHUE50AG2
RHUE60AG2
RHUE70AG2
RHUE80AG2
RHUE100AG2
RHUE120AG2
RHUE140AG2
RHUE160AG2
RHUE180AG2
RHUE210AG2
RHUE240AG2
pag. 85
SMGB0003 rev.0 - 01/2007
Troubleshooting
 PCBB1 (RCUE40~400 AG2)
RCUE40AG2
RCUE50AG2
RCUE60AG2
RCUE70AG2
RCUE80AG2
RCUE100AG2
RCUE120AG2
RCUE140AG2
RCUE160AG2
RCUE180AG2
RCUE210AG2
RCUE240AG2
RCUE280AG2
RCUE320AG2
RCUE350AG2
RCUE400AG2
pag. 86
SMGB0003 rev.0 - 01/2007
Troubleshooting
 PCBB2 (RCUE280~400 AG2)
RCUE40AG2
5
RCUE50AG2
RCUE60AG2
RCUE70AG2
RCUE80AG2
RCUE100AG2
RCUE120AG2
RCUE140AG2
RCUE160AG2
RCUE180AG2
RCUE210AG2
RCUE240AG2
RCUE280AG2
RCUE320AG2
RCUE350AG2
RCUE400AG2
pag. 87
SMGB0003 rev.0 - 01/2007
Troubleshooting
 DESCRIPTION:
− PCBB1 DSW1: Setting of Low Voltage for Remote Control

(PCBB2 DSW1: No function)
Dip Switch Setting

MODE
(DSW1 of Main PCB)
NORMAL
MODE
(Now low voltage control)
MODE 1
(Hi/Lo)
MODE 2
(Pulse)
− PCBB1 DSW2: Starting Delay

DSW2-1,2: Setting for Starting Delay of Compressor [min]
Figure 1 2 1 2 1 2
Location ON ON ON OFF OFF ON OFF OFF
Time (minute) 0.5 6 10 3
DSW2-3: ON; Low noise and night shift Opt.

DSW2-4: ON: High Efficiency Opt.
− PCBB1,B2 DSW3: Mode Switch A
DSW3-1,2,3: Enable of compressor No.1,2,3 (PCBB1)

DSW3-1,2: Enable of compressor No.4,5 (PCBB2)
DSW3-4,5,6,7: Enable of DC Fan Motor No.11,12,13,14 – Cycle Nº1 (PCBB1)
DSW3-4,5,6,7: Enable of DC Fan Motor No.41,42,43,44 – Cycle Nº4 (PCBB2)
DSW3-8,9,10: H-LINK ADDRESS [000 by deffault on PCBB1];
Use same address in PCBG1,G2 (DSW4-1,2,3)
DSW3-8,9,10: H-LINK ADDRESS [001 by deffault PCBB2 ];
Use same address in PCBG3 (DSW4-1,2,3)
pag. 88
SMGB0003 rev.0 - 01/2007
Troubleshooting
− PCBB1 DSW4: Optional Function A

(PCBB2 DSW4: No function except DSW4-7 in ON: HAPE CHILLER)
DSW4-1: OFF for RCUEXXXAG2 models
ON for RHUEXXXAG2 models
DSW4-2,7: ON / DSW4-3,4,5,6,8: OFF ; Configuration for HAPE Chillers

DSW4-3: ON: Not Available Option
DSW4-4: ON; Enable of Brine Option
DSW4-9,10: Compressor Model
Figure 9 10 9 10 9 10 9 10
Location OFF ON ON OFF ON ON OFF OFF
Compressor 40 HP 40 HP 50 HP 60 HP
Time (minute) 40 HP 50 HP 60 HP 70,80 HP
− PCBB1 DSW5: Continuous Capacity Control

(PCBB2: No function)
DSW5-1,2: Temperature band for Thermo OFF 5

Figure 1 2 1 2 1 2 1 2
Band (degree) 0.5 1.0 1.5 2.0
DSW5-3,4: Temperature band for Compressor re-start
Figure 3 4 3 4 3 4 3 4
Band (degree) 1.0 2.0 3.0 4.0
DSW5-5: Temperature band for LOAD UP2 This chart is based on a Temp. Setting of 7ºC
Figure 5 5 Water
Temperature
Location ON OFF
Load up 1 Mode
Band (degree) 1.0 3.0
Set by
DSW5 Load up 2 Mode
5 pin
Set by
DSW5,
3&4 pin
Water Oultet
Temperature
Set by Inlet Water Temp
RSW8 when system is
Neutral zone
stopped with Thermo
Setting
OFF MODE
Temperature
Set by Load Down Mode

DSW5,
1&2 pin
Thermo OFF
Standard setting
pag. 89
SMGB0003 rev.0 - 01/2007
Troubleshooting
− DSW5-6: Pulse width in Seconds for Load Up Slide Valve in compressor in LOAD UP1 Mode.
(SVn-UP: Coil energizing)
Figure 6 6
Location ON OFF
Time (minute) 12 24
− DSW5-7,8: Pulse width in Seconds for Load Up Slide Valve in compressor in LOAD UP2 Mode.
Figure 7 8 7 8 7 8 7 8
Time (minute) 2 4 6 8
− DSW5-9,10: Frequency of Load Up Slide Valve in compressor.

Pulse width [DSW5-6]
Frequency
Pulse width [DSW5-9,10]
− PCBB1 DSW6: Optional Function B

(PCBB2 DSW6: No function. Keep DSW6-4 in OFF)
DSW6-2: ON: Pump freeze protection activated (Tambient = 2ºC)
OFF: Pump freeze protection disabled
[DSW6-1,3,4: OFF; Not available]
Pulse width [DSW5-6]
Frequency
Pulse width [DSW5-9,10]
− PCBB1 DSW7: Optional Function C

DSW7-1,2: Temperature Range for Brine Opt.
[DSW7-1,2: Both in ON; this function is not available)
Figure 1 2 1 2 1 2
Location OFF OFF ON OFF OFF ON
Time Range Standard -5~5 ºC -10~6 ºC
DSW7-3: ON; Thermo OFF is delayed after Outlet Temperature is below Thermo OFF setting for 3 min.
DSW7-4: ON: Used only in case of remote control through H-LINK (e.g.:CSC-5S, HARC)
pag. 90
SMGB0003 rev.0 - 01/2007
Troubleshooting
− PCBB1 RSW1,2 (SW5): Setting Temperature in Cooling Mode with to digits and the sign indicated in
SW5
(PCBB2 RSW1,2 & SW5: No function)
In case of Brine 2 Option can be set negative temperatures.
− PCBB1 RSW3,4: Setting Temperature in Heating Mode with to digits (Only available in Heat Pump
Models- RHUEXXXAG2)
(PCBB2 RSW3,4: No function)
5
− PCBB1 RSW5,6,7: CT Sensor function (Supplied as standard)
(PCBB2 RSW5,6,7: No function)
Num. “X” Model (HP) 40A 40 HP

1 X 50 HP
2 40 , X
RSW6 RSW5 60 HP
50A 70 HP
3 50/100 80 HP
5 60/120/180
Y
X 10 min.
6 70/140/210/280/350 RSW7
7 80/160/240/320/400
Compressor load is kept for period when CT sensor measures set current
e.g.:
RCUE40AG2: Compressor load is “down” and “hold” for 30min (Y=3; 3*10min) when compressor current is
higher than 48 A (X=2; 1.2*40A).
− PCBB1 RSW8: Temperature band for Neutral Zone (See also DSW5)
(PCBB2 RSW8: No function)
Figure 0 1 2 3 4 5 6 7 8 9
Band (degree) 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
pag. 91
SMGB0003 rev.0 - 01/2007
Troubleshooting
− PCBB1 RSW9: Temperature setting for one Defrost condition [Evaporator. Temp.- Ambient Temp.:
2~20ºC]
(PCBB2 RSW9: No function)

1 2x1=2ºC
2 2x2=4ºC
…
99x2=18ºC
010x2=20ºC]
− PCBB1 SW5: See explanation for PCBB1 RSW1,2

(PCBB2 SW5: No function)
− PCBB1 SW6: Remote unit control. Standard is

PCBB1 SW7: Pump operation

− PCBB1 SW8: Operation Mode.

pag. 92
SMGB0003 rev.0 - 01/2007
Troubleshooting
− PCBB1,B2 SW9, SW10: High Cut check (Fan Stop for Check)
SW9 (PCBB1): ON  Checking Cycle 1
SW9 + SW10 (PCBB1): ON  Checking Cycle 3
− PCBB1 SW11, SW12: Manual Defrost (Only Heat Pump models)

(PCBB2 : Not available function)
SW11 + SW12 (PCBB1): ON  Checking Cycle 3
5
 DIP SWITCH SETTING PCBC1,C2 (MAIN CONTROL PCB; Master & Subsidiary)
DSW-1: H-LINK end resistance (ON only PCB C1)
DSW-2: Fuse protection
pag. 93
SMGB0003 rev.0 - 01/2007
Troubleshooting
 DIP SWITCH SETTING PCBe1~e5 (FAN MODULE FOR DC FAN MOTORS)
 DIP SWITCH SETTING PCBF1~F2. (EXP. VALVE CONTROL PCB)
pag. 94
SMGB0003 rev.0 - 01/2007
Troubleshooting
 DIP SWITCH SETTING PCBG1,G2,G3 (FAN CONTROL PCB)

Standard Setting
H-LINK:
DSW4-1~3
Manual stop of DC Fans

(same than DSW3 4~7
on PCBn
N.A
5
H-LINK end Resistence
All pins in OFF
pag. 95
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.1.3. Confirmation of activation value of protection device an Automatic operation device
 Protection device
Activation value of protection device is as follows:
Name Activation value
High pressure block device 2.74 MPa (re-start manually)
Cooling Prevention control for low pressure decrease 0.314 MPa (Electron control)
Low pressure block device 0.049 MPa (Electron control)
High pressure block device 2.74 MPa (re-start manually)

Heating
Prevention control for low pressure decrease 0.049 MPa (Electron control)
40 HP 55 A
50 HP 60 A
Excess current in relay
for compressor
60 HP 70 A
70 HP 85 A
80 HP 90 A
Prevention control for freezing 2°C (Electron control)
Prevention control for suction gas decrease -2°C
Internal Thermostat for Compressor 115°C
Prevention control for overheating of discharge gas 140°C
Fusible plug 72°C
Safety valve 3.0 MPa
Fuse for operation circuit 10, 5, 3A
NOTE:
Safety valve is installed in all models
pag. 96
SMGB0003 rev.0 - 01/2007
Troubleshooting
 Automatic operation device

The value of automatic operation device is set as follows:
Item (unit) Setting value Remarks
Variable: 30 sec ~ 10 min

Time guard Min (standard value: 3 min) (Note 1)
-Δ switch Sec 5
Relay for only Electron control
starting control
Staring unload Sec 30
Sequential Min 1
starting (Note 2)
NOTES:
1. It should be normally over 3 min.
2. In all chiller units there is a timer which prevents compressors starting at the same time.
5.1.4. Individual indication for activation of protection device
 Indication in the segment

Status of unit and activation of the different protection devices are indicated on the display. This indication
5
helps to make a diagnosis about the unit, indicating if it is running well, and it can help to solve different
inconvenients on the system.
Indication on the segment at normal operation (standard menu display) is as follows:
Segment indication abnormal

Contents
code
 ~    Power ON
No. of cycle
Wait for pump feed
  back
State
Procedure of ex.
 ~    valve zero reset
 ~    After pump feed back
 ~    At cooling operation
 ~    At heating operation
At activation of
 ~    current limit
At Alarm
 ~     At thermo OFF
 ~     At stop operation
NOTES:
− C1~C5 means No of cycle. (C1: Cycle 1)
− Number of cycle whose manual set switch is ON is indicated alternately.
− It is a state from the output of pump operation signal to the confirmation of pump interlock. In case that
pump interlock is confirmed immediately, it is possible that the indication is not checked visually since the
indication time is too short.
pag. 97
SMGB0003 rev.0 - 01/2007
Troubleshooting
 Abnormal code of segment indication part

In this section “abnormal code” is explained. See subchapter 5.2.3 “Method of failure
diagnosis” for the concrete treatment.
Segment Indication
Contents
abnormal code
  Activation of High Pressure Block Devise(63H)
   Activation of Suction Pressure Block Device


Activation of Prevention Control for Suction Pressure Block
  Decrease
  Activation of Thermal Relay for Compressor (51C)

Individual Alarm (stop only the corresponding cycle)
  Activation of Discharge Gas Thermistor (Td)

  Activation of Compressor Thermostat (49C)
Ex. High pressure interrupt device for

  Activation of Evaporating Temperature Thermistor (Tr)
unit 1 is activated
(Cooling operation in unit 2)
  Activation of Suction Gas Thermistor (Ts)
Phase Abnormality (Reverse Phase / Phase Failure) [Individual
 
  
power source spec: Option]
Flickering alternately
  Outlet Chilled Water Thermistor Abnormality in some cycles
  Activation of Freeze Protection Control Abnormality in some cycles
    
Activation of Water Overheating Protection Control Abnormality in
some cycles
Ex. Phase detection abnormality   Evaporating Temperature Thermistor Abnormality

(common abnormality)
  Abnormality of discharge gas temperature Thermistor
   



Liquid Temperature Thermistor Abnormality
Abnormality of Outlet Water Temperature Thermistor for Protection

Flicker
  Suction Gas Temperature Thermistor Abnormality

  Discharge Pressure Sensor Abnormality
  Suction Pressure Sensor Abnormality
  Abnormality of Setting Fan Number
  Phase Abnormality (Reverse Phase / Phase Failure)
  Inlet Chilled Water Thermistor Abnormality
  Outlet Chilled Water Thermistor Abnormality in 1 cycle
  Activation of Freeze Protection Control Abnormality in 1 cycle

Common Alarm (Stops unit)
Activation of Water Overheating Protection Control Abnormality in

  1 cycle
  Ambient Temperature Thermistor Abnormality
  52P Pump Interlock Signal Abnormality

  Operation Error / Setting Error
  Error Communication between Ctrl. PCB and Ex. Valve PCB
Error Communication between Ctrl. PCB and Fan Speed control
  PCB
  Inverter Speed Control Abnormality
  Inverter Excess Current Protection Abnormality
  Inverter Position Detection Abnormality
Transmission Abnormality between Inverter and CPU PCB or
  between Fan Speed Control PCB
  Voltage Shortage or Excess Voltage in Inverter

During Activation of Pump Stop Control by Excess Increase of
  Water Temperature
(flicker)
  Water Shortage Protection Switch Activation (at 63W use; Option)

System Controller Connection Abnormality (at CSC-5S connection:
  Option)
pag. 98
SMGB0003 rev.0 - 10/2006
Troubleshooting
 Indication of inverter (fan module) for control of fan revolution number

Fan module has protection control and indicates abnormal code on the segment.
− List of inverter abnormal code
Segment Indication
Contents
abnormal code
  Inverter Speed Control Abnormality
  Inverter Excess Current Protection Abnormality
  Inverter Position Detection Abnormality

Transmission Abnormality between Inverter and CPU PCB or between
  Fan Speed Control PCB
  Voltage Shortage or Excess Voltage in Inverter
− List of state at inverter retry
Segment Indication
5
Contents
abnormal code
During retry control at simultaneous abnormal in some (majority) fans
  (Fan single retry)
  Abnormal code during retry control in Fn-4m, Fn-5m
NOTES:
“n”: Cycle Nº (n=1-5)
“m”: Fan Nº (m=1-4)
In case of fan abnormal operation, retry is performed in every case and in case that the same abnormal
operation occurs in specified times within specified period, unit is stopped by alarm.
Retry:
1. Retry in fan by itself (compressor keeps operating. Re-start in 10 seconds)
2. Retry in cycle by itself (compressor also stops. Re-start in 3 minutes).
In case of retry in cycle by itself, retry is indicated like above “list of state at inverter retry”. In case of retry in
fan by itself, it is possible to confirm which fan is being retried in check mode.
pag. 99
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.1.5. Modification of PCBC configuration
Every Chiller is delivered with the correct priority configuration (Master PCB and slave PCB). In case of a
Control PCB delivered as a spare part, it will be necessary to set the correct priority configuration because it
is not known where it will be applied (Chiller model).
In case that this priority configuration is not correct, the Chiller cannot operate. See next point.
 Problem detection
When the priority configuration is not correct, on the 7 segment it is displayed:
:
7 segments on PCBA shows the above message and no alarm message is shown.
 Configuration
To establish the right priority configuration in each PCBC it is necessary to connect an operation
PCB (PCBA and PCBB) to the corresponding Control PCBC. It means that in case of a CHILLER Electric Box
with 5 cycles, it is necessary to connect an additional operation PCB (PCBA and PCBB) to establish the right
priority configuration in this subsidiary control PCB (PCB C2)
Next drawings shows the controls required for this procedure.
PCBA
Seven Segment nº1
Seven Segment nº2
SW4
SW3
pag. 100
SMGB0003 rev.0 - 01/2007
Troubleshooting
PCBB
5
 Checking of current priority configuration
1. Power supply OFF (Main Switch turned-off)

2. Put DSW1-1 from Operation PCB in ON (PCBB)
3. Electric Box Power supply ON (M.I. switch ON)

4. Put DSW1-2,3,4 from Operation PCB in ON (PCBB)
5. Rotate RSW8 from Operation PCB at position nº2: RSW8
6. See that in the 7 segments on Operation (PCBA) shows:
:x
(“X”: 0, 1 or 2)
pag. 101
SMGB0003 rev.0 - 01/2007
Troubleshooting
7. The right priority configuration follows the next table criteria.
7 segments
: Setting for main control PCB (PCBC) in all CHILLERS up to 240 HP
: Setting for main control PCB (PCBC1) in Cooling Only CHILLERS with 4 or 5 cycles.
: Setting for subsidiary control PCB (PCBC2) in Cooling Only CHILLERS with 4 or 5 cycles
 Modification of priority configuration
Check previous table for the correct configuration
1. Modification of the priority number: “”, “”, “”
7 segments
:x “X” is the priority number of the PCB (0, 1 or 2), according to the above table
2. Priority number is changeable only in “U2” position, it means that first it is necessary to set U2 in 7
segments pushing the SW3 and SW4 at the same time in Operation PCB (PCBA) during 3 seconds.
7 segments
:x “X” is the priority number (0, 1 or 2) that you can select following the next point.
3. For modifying “X” value is necessary to push during 1 second SW3 or SW4 of Operation PCB (PCBA)
depending if you want to increase (DSW3) or decrease (DSW4) the priority number
4. Push at the same time DSW3 and DSW4 for 3 seconds for fixing at “U1” the corresponding priority
number established before in “U2”.
5. Switch OFF the power supply in the Electrical Box (M.I. switch OFF)
6. Switch ON the power supply in the Electrical Box (M.I. switch ON)
7. See on the Operation PCB, in the 7 segments, the right configuration number according to the table on
point 7. On the contrary repeat again all steps and select the right configuration number.
8. Restore the initial setting: DWS1, RSW8-3
Confirm the initial setting for these switches with the Technical Catalogue considering the options included
in the model. The standard setting values are the next:
DSW1 RSW8
NOTE:
In case of additional option DSW1 and RSW8 can be different
pag. 102
SMGB0003 rev.0 - 01/2007
Troubleshooting
− Flowchart at abnormal occurrence
Abnormal occurrence in Abnormal occurrence in fan

refrigerant cycle
Is
it judged
Could it that it is possible to NO
NO
be a temporal continue operation although fan
phenomenon due to an is stopped temporally
accidental factor?
YES
YES
- Stop the compressor of
- Stop the correspondent fan
- Stop the compressor of correspondent cycle
- Count retry times
correspondent cycle - Count retry times
- Count retry times
Retry
control by NO
Retry the same abnormal
control by
5
YES reason is performed specified
the same abnormal times within specified
reason is performed specified period?
times within specified (*) Fan restart by itself
period? YES - no indication of retry code
(fan under retry is indicated
1
NO in check mode)
abnormal
NO - correspondent fan is re-
fan per 1 cycle?
- Retry code is indicated started in 10 sec.
And are all fan manual set
- Compressor is re-started
SW ON?
in 3 min.
YES
(*) Cycle retry
- Correspondent fan is stopped - indication of retry code
REMOTE OUTPUT (ALARM)
- compressor is re-started
terminals (n54~n55)
in 3 min.
- No indication of alarm code (fan
under stop by abnormal function is
indicated in check mode)
(Alarm stop)
- compressor of correspondent
cycle is stopped
- indication of alarm code
Operation continues
 Abnormal indication of Option / Remote Controller Switch
Indication lamp of remote controller side distinguishes “Run”, “Alarm”, and ”Stop”:
-“Run”: Red light indication lamp on.

-“Alarm”: Light red indication lamp on. Light orange indication lamp on: in case of option switch use
-“Stop”: Light red indication lamp off.
pag. 103
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.1.6. Check function
 Check mode
By pressing [▲] (SW3) on PCB more than 3 seconds, control state of chilled water temperature, each
refrigerant cycle pressure/ temperature etc are indicated. (it is possible both during stopping and during
running), (*mode shall not be shifted in case of alarm).
Pressing again [▲] (SW3) on PCB more than 3 seconds enables you to see the different values but with
decimals
Dot is indicated, which

means that it is check mode
     
Normal indication State
Indication of check mode
- Nº 1 cycle (C1)
- During cooling (Co)
Press more than 3 sec.
By pressing [▲][▼], indication is changed. The followings are the contents.

Example of code indication (alternately
Item Contents
flicker)
Latest
In case of latest alarm = activation of No. 1 high pressure
protection
device state
(alarm code)
   block device
(if alarm code is not saved, it is “00-00”.
1. Pd (high pressure) indication [MPa]

   .   -Example of Pd of No.1 = 1.42MPa
-Example of Pd of No. 2 = 1.43MPa
   .   } Indication of unit of 2 cycles

(Indication of only the unit whose manual set SW is ON)
2. Ps (low pressure) indication [MPa]
  .  -in case of Ps of No. 1 = 0.41MPa

-In case of unit of 2 cycles, [C2-PS].
3. Td (discharge gas temp) indication [ºC]
    -in case of Td of No. 1 = 81ºC

-In case of unit of 2 cycles, [C2-td].
4. Ts (suction gas temp) indication [ºC]
    -in case of Ts of No. 1 = -2ºC

-In case of unit of 2 cycles, [C2-tS].
5. Tr (Plate heat exchanger inlet refrigerant temp)
indication [ºC]
Refrigerant
cycle state     -in case of Td of No. 1 = 5ºC
-In case of unit of 2 cycles, [C2-tr].
6. Te (Refrigerant liquid temp) indication [ºC]
   -in case of Te of No. 1 = 35ºC

-In case of unit of 2 cycles, [C2-tE].
7. Inlet water temperature indication [ºC]

   -in case of inlet water temperature = 12ºC
8-1. Outlet water temperature indication [ºC]
 
-in case of outlet water temperature = 7ºC
 (For units with more than one cycle, this is the average
value)
8-2. Individual outlet water temperature indication [ºC]
 
In 2 cycles, chilled water outlet temp every cycle is
 indicated. (no indication in case of 1 cycle)
-in case of outlet water temp of No.1 = 7ºC
  
-in case of outlet water temp of No.2 = 7ºC
*Unit whose manual set SW is OFF is indicated.
pag. 104
SMGB0003 rev.0 - 01/2007
Troubleshooting

Item Contents
flicker)
1. Chilled water setting temperature indication [ºC]
-in case of setting temperature = 12ºC
   -integer round up is indicated in case of +0.5ºC setting
2. Warm water setting temperature indication [ºC] (only

heat pump type)
   -in case of setting temperature = 40ºC

-integer round up is indicated in case of +0.5ºC setting
Setting state
indication 3. Chilled water second temperature setting indication
  
[ºC]
 -in case of setting temperature = 5ºC
*only at alarm selection
4. Warm water second temperature setting indication
    [ºC] (only heat pump type)

-in case of setting temperature = 45ºC
*It is indicated only if heat storage is selected.
  5. Neutral zone range indication [ºC]
Ambient
temperature   Ambient temperature indication [ºC]
5
indication -In case of 35ºC
Capacity control state in every cycle

Continuous control spec:
 
Capacity *Load-up [UP] / Neutral Zone [nU] / Load down [d0]
control state
indication
 Thermo OFF [- - ].
*In case of 2 cycles, [C2-Ld]
Protection control state is indicated in every cycle.
    *Protection control is assigned in 7 segment. Control

under activation is lighted. (example in the left
side: No. 1 cooling operation and Td control under
}
}
activation) Starting
capacity control Silence mode
Operation mode Protection Pd control
control state Night Shift mode
Protection Ps control Td control

control
activation Pressure Liquid bypass control
state indication
 
difference
control
Unload control by outlet
Tr control
temp detection of back
side
Current limit control
In case of 2 cycles, [C2-FC]
    Fan control state and order frequency are indicated in

every cycle.
(example in the left side: Fan No. 2 and No. 4 of No.
1 cycle are under retry, Fan No. 1 is under stop by
}
}
abnormality, other fans are under operation with 44

Fan control state Order Hz)
frequency Fan control state
*~: Fan number

Fan control
state indication
Abnormal stop
Light the position correspondent to the fan
In case of 2 cycles, [C2-FC]
Control
software ROM
Nº indication  .    Indication of ROM NO. (ex: 239)
The following operation makes change from check mode back to normal mode.
1. Press [▲] (SW3) more than 3 sec.
2. In case that un-input state continues 1 hour.
pag. 105
SMGB0003 rev.0 - 01/2007
Troubleshooting
 Alarm occurrence data

Alarm occurrence data is indicated by pressing [▲] (SW3) [▼] (SW4) on PCB. (It is possible to do during
stop / operation). (*Mode should not be shifted during alarm occurrence)
Flicker alternately
    .     
Normal indication State
The latest alarm code
- Nº 1 cycle (C1)
- Under cooling (Co) Press them simultaneously more than 3 sec.
[Way to clear alarm occurrence data]

(valid only during stop (Power ON)
Press while pressing at the same time
By pressing [▲][▼], indication is changed. The followings are the contents.

Item Contents
flicker)
Latest
activation of
protection
device (alarm
code)
 .      The latest alarm is indicated firstly. (Max 10).
In case of 5 alarm is saved, no.5 is indicated firstly.
In case of the latest alarm = No.1 high pressure block
device activation
If there is no saved alarm code, [00-00]
5th oldest
 . 
Activation of
protection
device
   The 5th oldest alarm [pump interlock abnormality].
(alarm code)
The 10th alarm [Error operation]
 .     *Alarm of more than10th oldest is renewed
The following operation makes change from alarm occurrence indication mode back to normal mode.
1. Press [▲] (SW3) [▼] (SW4) more than 3 sec.
2. In case that un-input state continues 30 seconds.
3 Alarm Data Indication Function (The Last Saved Data before Alarm Occurrence)
Regarding the latest alarm, the last sensor data before stop can be indicated, while alarm occurrence is
indicated. (Data is indicated by the following operation during the latest alarm occurrence indication)
-Alarm data of the latest alarm occurrence is only saved.
-Alarm data is cleared by Power OFF
-In case that data is not saved, alarm occurrence data mode after flickering [- - -] twice.
4 To switch indication items, Press [▲] (SW3) [▼] (SW4).
5 Indication data is the same as the one of check mode. However, the next items are indicated as an additional.
pag. 106
SMGB0003 rev.0 - 01/2007
Troubleshooting

Item Contents
flicker)
Refrigerant liquid
Outlet water temp (backside of heat exchanger of
Outlet water temp
(backside of heat
   water side) [ºC]
exchanger of water -In case of No. 1 outlet water temp is 7ºC

side)
 
-In case of No. 2 outlet water temp is 7ºC

Fan control state
Indication of electron expansion valve opening
     -In case of No. 1 opening is 242 pulse.
     -In case of No. 2 opening is 240 pulse.
The following operation makes change from alarm data indication mode to normal mode.
5
1. Press [▲] (SW3) [▼] (SW4) more than 3 sec.
2. In case that un-input state continues 30 seconds.
The following operation makes change from alarm data indication mode to alarm occurrence data mode.
1. Press [▼] (SW4) more than 3 sec.
 Electron expansion valve opening indication
By pressing [Ο] (PSW1) on PCB for electron expansion valve more than 3 seconds, actual expansion valve
order opening (pulse) is indicated on the segment. (it is possible during stop / operation)
Once pulses are displayed, pushing again PSW1 enables you to check each cycles expansion valve
position.
PWBG (VD PCB)
Flicker
alternately
Press it more
than 3 sec.
Segment for check
Check switch
PULSES OPENING %
10 (Thermo OFF) 1,5 %
112 (Min. running value) 17%
* Light off by pressing [Ο] more than 3 seconds. 656 (Max. running value) 100%
pag. 107
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.2. Troubleshooting
5.2.1. Outline of failure diagnosis

In the case of abnormality, alarm LED on the control panel of unit and of remote control is
ON and segment indication on the control panel is flickering. To stop the unit, put it into stop
operation without power OFF(Main switch).
Alarm occur
Remote Control Run Indication: OFF

Segment Indication:
Abnormality Code Flickering. *One cycle continues running in more
than 2 cycles unit: ON
Alarm Indication Led: ON
Remote Control Alarm Indication: ON
(Local Side)
(Remote Side)
Stop Operation
Yes
Is abnormality code
in segment indication
confirmed?
No
Abnormality code is indicated

by indication mode of alarm
Occurrence Data.
Abnormality code is indicated

in the segment indication.
The last saved data before

alarm occurrence is confirmed
Take proper measure

according to the alarm position
NOTES:
− After the stop operation, alarm indication is turned off and initial status 88 is displayed.
Abnormality code, which was activated before can be seen by entering “Indication Mode of
Alarm Occurrence Data”.
− When the power turns off and turns on, the indication on the display is initial status. Abnormal
code, which was activated before can be seen by entering “Indication Mode of Alarm
Occurrence Data”
− When the power turns off (Main switch), “The Last Saved Data before Alarm Occurrence” is
cleared.
− "The Last Saved Data before Alarm Occurrence” has only the last data before last alarm. In case
of before that, only alarm code is saved.
pag. 108
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.2.2. Alarm indication

7-Segment indication shows the following abnormalities:
Without indication
Unit does not run Check the power source
With indication
Check the 7-segment

indication
Alarm Code
Description of abnormality
No.1~6 cycles
[]~[] Activation of High Pressure Switch
[ ]~[ ] Excessively Low Pressure


[]~[] Activation of Low Pressure Protection Control
[]~[] Activation of Fan Motor Internal Thermostat (Only for 70,80,140,160,210,240,280,320,350 and 400HP)
[]~[]
5
Activation of Thermal Relay for Compressor or Chattering alarm or Malfunction of Auxiliary Relay Arn
[]~[] Activation of Discharge Gas Thermostat
[]~[] Activation of Compressor Internal Thermostat
[]~[] Excess Low Temperature of Cooler Inlet Refrigerant
[]~[] Low Pressure Protection by Suction Gas Thermistor
[]~[] Phase Abnormally (Only for 4 and 5 cycle unit)
[]~[] Failure of Water Outlet Thermistor (Only for 2 – 5 cycle unit)
[]~[] Activation of Freeze Protection Control (Only for 2 – 5 cycle unit)
[]~[] Activation of Water Overheating Protection Control
[]~[] Failure of Cooler Inlet Refrigerant Thermistor (Open/Short)
[]~[] Failure of Discharge Gas Thermistor (Open/Short)
[]~[] Failure of Thermistor set before Expansion Valve (Open / Short)
[]~[] Failure of Water Outlet Thremistor at Rear Side of Water Cooler (Open / Short)
[]~[] Failure of Suction Gas Thermistor (Open / Short)
[]~[] Failure of Discharge Gas Pressure Sensor (Open / Short)
[]~[] Failure of Suction Gas Pressure Sensor (Open / Short)
[]~[] Incorrect Setting of Fan Number
[]~[] No Feedback Signal from Water Pump
[]~[] Fan Inverter Rotation Abnormality *1
[]~[] Activation of Fan Inverter Over Current Protection Control *1
[]~[] Fan Inverter Phase Abnormality *1
[]~[] Error Communication between Inverter PCB and Control or Fan Control PCB *1
[]~[] Inverter Power Supply Abnormality *1
[] Phase Abnormality (Only for 1 – 3 cycle unit)
[] Failure of Water Inlet Thermistor (Open / Short)
[] Failure of Water Outlet Thermistor (Open / Short) (Only for 1 cycle unit)
[] Activation of Freezing Protection Control (Only for 1 cycle unit)
[] Activation of Water Overheating Protection Control
[] Failure of Ambient Temperature Thermistor (Open / Short)
[] Pump interlock Signal abnormality

*1 : [] Right side Segment shows Fan No.
pag. 109
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm Code
Description of abnormality
No.1~5 cycles
[] Incorrect Operation
[] Error communication between Ctrl. PCB (PCBC1, PCBC2)
[] Error communication between Expansion Valve PCB and Cntrol PCB
[  ]
  Error communication between Fan Contol PCB and Cntrol PCB
“ [] ” Alarm of Excessively High Water -Temperature
[] Alarm of Water Failure (Differential Water Pressure Switch Option)
[] Activation of Additional Protection Device (Option)
[] Error communication between Chiller and Remote Controller (If CSC-5S is connected.)
[]~[] Retry Operation (More Than 3 Fans Retry at The Same Time)
[]~[] Retry Operation (by Alarm Fx-41 or Fx-51, x: Cycle No.)
[]~[] Retry Operation (by Alarm Cx-6x or Cx-7X, x: Cycle No.)
[]~[] Retry Operation (by Alarm Cx-9x or Cx-LX, x: Cycle No.)
“ - " : Flickering
pag. 110
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.2.3. Failure diagnosis method
 General check of failure diagnosis.

In the case of no segment indication, unit can not operate.
No
Is 380-415V supplied Check the power
to the unit?: source switch
Yes
No Yes
Is 220-240V supplied to Is fuse broken? Replace fuse
transformer primary side?
No
Yes
Is R phase or S Yes
Wiring check
phase failure? and repair
5
No
Wiring check
Is 30V in PIN1~PIN2, No Yes
16.3V in PIN3~PIN4,
Check the power
19.6V in PIN5~PIN6 of the Replace
source switch
printed circuit board for transformer
CPU (PCBc) connector
CN2A?
No Wiring check
Yes
Connector check
Is 26.7V in PIN1~PIN2, No Yes

17.6V in PIN3~PIN4, Check the power Replace
17.6V in PIN5~PIN6 of the source switch transformer
printed circuit board for
CPU (PCBc) connector
CN2B? No Wiring check
Connector check
Yes
Is voltage in each test PIN of printed

circuit board for CPU
5 V part:
VCCO5-GND1, VCCO5N-GND1 Power Source Circuit
V5B-GND1, VCCR-GND1 No Malfunction
+15V part:
Replace Printed Circuit
VCC15T-GND1 (only more than 2 cycles unit)
- 15V part:
Board for CPU (PCBC)
VCC15T-GND1
24V part:
VCC24-GND1
VCC24T-GND1
Yes
Are connector FCN1, FCN2 on the printed No

circuit board for CPU (PCBC) and Printed Connector Repair
Circuit Board for Display and Operation
(PCBA, PCBB) correctly connected and
checked loose connection?
Yes
Check Printed Circuit
Board for Display and
Operation (PCBA,
PCBB)
pag. 111
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code 

Activation of High Pressure Switch (63H)

[Alarm Stop Reason] [PCB Monitoring Position]

High pressure (Pd) is increased No. 1 Cycle: PCBD1 (I/O PCB )PCN203
to more than 2.74MPa, and high No. 2 Cycle: PCBD2 (I/O PCB )PCN203
pressure switch (63H) is activated. No. 3 Cycle: PCBD3 (I/O PCB )PCN203
No. 4 Cycle: PCBD4 (I/O PCB )PCN203
No. 5 Cycle: PCBD5 (I/O PCB )PCN203
Yes
(activated
immediately) No
Is alarm activated just Is high pressure switch Reset the switch
after running? (63H) reset?
Yes
Yes
Yes
Is 220-240V the voltage
between connector Check Printed Circuit
PCN203 PIN1 and Board for Relay
connector PCN203 PIN3 (PCBD)
on the Printed Circuit
Board for Relay (PCBD)?
Wiring check
No (disconnecting, wiring
error)
Yes (PCB is
Is alarm activated in 3 normal) <COOLING>
minutes after running Is high pressure switch
(63H) activated? Clogging of air side heat exchanger
operation?
Check of high pressure
Yes No
Cycle check
<HEATING>
Shortage of Water
Pump reverse rotation
Air mixed
Expansion valve malfunction
Water stain in water side heat

exchanger
Clogging of Water Strainer
Is 220-240V the voltage

No Wiring check
between connector (disconnecting, wiring
PCN203 PIN1 and error)
connector PCN203 PIN3
Board for Relay (PCBD)? Check Printed Circuit
Yes
Is 220-240V the voltage Board for Relay
between connector No (PCBD)
PCN203 PIN1 and Wiring Check
connector PCN203 PIN3
Yes

Board for Relay
(PCBD)
pag. 112
SMGB0003 rev.0 - 01/2007
Troubleshooting
 
 
Alarm code Excessively low suction pressure
 

Suction pressure (Ps) is less than No. 1 Cycle: PCBD1 (I/O PCB) CN29Ps
0.049MPa during 3 seconds. No. 2 Cycle: PCBD2 (I/O PCB) CN29Ps
(electron control, cooling and
No. 3 Cycle: PCBD3 (I/O PCB) CN29Ps
heating)
Is connector CN 29Ps Yes

on the Printed Circuit Shortage of Refrigerant / Gas Leakager
Board for Relay (PCBD)
correctly connected? Clogging of expansion valve
No Clogging of low pressure side piping
Stop Valve malfunction
Shortage of Water
5
Air mixed
Wiring Check Clogging of Strainer
Too much water in refrigerant
Water stain in water side heat exchanger
pag. 113
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Activation of suction pressure protection control



-Suction pressure (Ps) is less than No. 1 Cycle: PCBD1 (I/O PCB) CN29Ps
0.333MPa during 90 seconds. (Electronic No. 2 Cycle: PCBD2 (I/O PCB) CN29Ps
control, air-cooled type)
-Suction pressure (Ps) is less than
0.314MPa during 90 seconds. (Electronic
control, air-cooled heat pump type No. 5 Cycle: PCBD5 (I/O PCB) CN29Ps
(only cooling operation))
*Alarm stop: 3 retries during 30 minutes.
(Compressor stop, automatic restart in 3
minutes)
[Retry Code]
No. 1 Cycle: C1-P6
No. 2 Cycle: C2-P6
No. 3 Cycle: C3-P6
No. 4 Cycle: C4-P6
No. 5 Cycle: C5-P6
Is connector CN 29Ps Yes

on the Printed Circuit Shortage of Refrigerant / Gas Leakager
correctly connected? Clogging of expansion valve
No Clogging of low pressure side piping
Stop Valve malfunction
Shortage of Water
Air mixed
Wiring Check Clogging of Strainer
Too much water in refrigerant
Water stain in water side heat exchanger
pag. 114
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Activation of Thermal Relay for Compressor (51C)



-Operation current for any compressor No. 1 Cycle: PCBD1 (I/O PCB) PCN207
is increased too much and activates the No. 2 Cycle: PCBD2 (I/O PCB) PCN207
Thermal Relay.
No. 3 Cycle: PCBD3 (I/O PCB) PCN207
-Chattering of external protection device
connected to the chiller (eg: flow switch)
Yes
(activated
immediately) Is 220-240V the voltage
Yes
Is alarm activated just after between connectorPCN207
PIN1 and connector PCN 207
5
running operation? Board for input/output
PIN3 on the Printed Circuit
(PWBD)
No (Activate
after a while)
No
Wiring Check
(breaking of wire,
wrong wiring)
Is 220-240V the voltage No (Printed circuit

between connector board is normal)
Excessive or short power source voltage
PCN207 PIN1 and
connector PCN 207 PIN3
on the Printed Circuit Interphase of power source voltage is imbalanced.
Compressor motor is locked
Yes
Insulation of compressor motor is lowered
Power fuse for compressor motor is broken
Power source terminal screw loosened
Thermal relay for compressor failure
Compressor slide valve malfunction
Wiring check Flow Switch is Chattering
Auxiliary Relay Arn malfunction
pag. 115
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Activation of Discharge Gas Thermistor (Td)



1.- Discharge gas temperature from the No. 1 Cycle: PCBD1 (I/O PCB) CN24Td
compressor is increased to 130°C and No. 2 Cycle: PCBD2 (I/O PCB) CN24Td
continues for 1 minute.
No. 3 Cycle: PCBD3 (I/O PCB) CN24Td
2.- During the time counting in 1 minute,
temperature is increased over 140°C
during more than 3 seconds. No. 5 Cycle: PCBD5 (I/O PCB) CN24Td
*In case of nº 2, alarm stop: 3 retries
during 90 minutes. (Compressor stop,
automatic restart in 3 minutes)
[Retry Code]
No. 1 Cycle: C1-P5
No. 2 Cycle: C2-P5
No. 3 Cycle: C3-P5
No. 4 Cycle: C4-P5
No. 5 Cycle: C5-P5
Is connector CN24Td on No
the Printed Circuit Board Plug correctly and
for Relay (PCBD) correctly repair wiring
connected?
Yes
No
Pull out connector and
measure thermistor Replace thermistor
resistance. Is resistance
correct?
Yes Yes
Shortage of refrigerant/ gas leakage
Check valve malfunction
Clogging of expansion valve
Expansion valve opening check
Expansion valve malfunction

Board for Relay
(PCBD)
pag. 116
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Activation of Internal Thermostat for Compressor



The electrical motor of the compressor No. 1 Cycle: PCBD1 (I/O PCB) PCN204
is overheated and internal Thermostat is No. 2 Cycle: PCBD2 (I/O PCB) PCN204
activated.
(Automatic restart after compressor stop
and Thermostat recover) No. 5 Cycle: PCBD5 (I/O PCB) PCN204
[Retry Code]
No. 1 Cycle: C1-P5
No. 2 Cycle: C2-P5
No. 3 Cycle: C3-P5
No. 4 Cycle: C4-P5
5
No. 5 Cycle: C5-P5
Is 220-240V the voltage Yes

Yes between connector
Is alarm activated just Check Printed Circuit
PCN204 PIN1 and Board for Relay
after running?
connector PCN 204 PIN3 (PCBD)
No (Activate
after a while)
No
Wiring Check
(breaking of wire,
wrong wiring)
No (Printed
Is 220-240V the voltage Circuit Board is Excessive or short power source voltage
between connector normal)
PCN204 PIN1 and
connector PCN 204 PIN3 Interphase of power source voltage is imbalanced.
on the Printed board for
Relay (PCBD)? Compressor motor is locked
Yes Expansion valve opening check
Insulation of compressor motor is lowered
Wiring Check
pag. 117
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Excess Low Temperature of Cooler Inlet Refrigerant (Tr)


- Refrigerant temperature in water side heat No. 1 Cycle: PCBD1 (I/O PCB) CN27Tr2
exchanger inlet (Tr) is less than –6.5°C during 3 No. 2 Cycle: PCBD2 (I/O PCB) CN27Tr2
seconds. (only for cooling operation)
No. 3 Cycle: PCBD3 (I/O PCB) CN27Tr2
(Compressor stop, automatic restart in 3 minutes)
- Refrigerant temperature in water side heat
exchanger inlet (Tr) is less than -35°C during 10
[Retry Code]
seconds. (only for defrosting operation)
No. 1 Cycle: C1-P6
- If the time between the end of a defrost, and
the confirmation of the conditions to start again a No. 2 Cycle: C2-P6
defrost in the same cycle is less then 13 minutes. No. 3 Cycle: C3-P6
*No retry during defrosting operation. Alarm stop No. 4 Cycle: C4-P6
immediately. No. 5 Cycle: C5-P6
No
Is the wiring of connector
Plug correctly and
in the Printed Circuit Board
repair wiring
for Relay (PCBD) correct?
Yes
No
correct?
Yes Yes
Check the water flow rate.(Check
temperature of inlet and outlet.)
Clogging of water strainer
Pump reverse rotating check
Check the air mixing

Board for Relay Check chilled water thermostat setting value
(PCBD) (Within the working range)
Shortage of refrigerant / Gas leakage
Clogging of low pressure pipe
Malfunction of check valve
Malfunction of expansion valve
pag. 118
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Low Pressure Protection by Suction Gas Thermistor (Ts)


- Suction Gas Temperature (Ts) is lower than –2°C No. 1 Cycle: PCBD1 (I/O PCB) CN25Ts
during 10 seconds. (only cooling operation) No. 2 Cycle: PCBD2 (I/O PCB) CN25Ts
*Alarm stop: 3 retries during 30 minutes. No. 3 Cycle: PCBD3 (I/O PCB) CN25Ts
(Compressor stop, automatic restart in 3 minutes)
No. 4 Cycle: PCBD4 (I/O PCB) CN25Ts
[Retry Code] No. 5 Cycle: PCBD5 (I/O PCB) CN25Ts
No. 1 Cycle: C1-P6

No. 2 Cycle: C2-P6
No. 3 Cycle: C3-P6
No. 4 Cycle: C4-P6
No. 5 Cycle: C5-P6
Is the wiring of connector

in the Printed Circuit Board
No
Plug correctly and
repair wiring
5
for Relay (PCBD) correct?
Yes
No
correct?
Yes Yes
Check the water flow rate.(Check
temperature of inlet and outlet.)
Clogging of water strainer
Pump reverse rotating check
Check the air mixing

Board for Relay Check chilled water thermostat setting value
(PCBD) (Within the working range)
Shortage of refrigerant / Gas leakage
Clogging of low pressure pipe
Malfunction of check valve
Malfunction of expansion valve
pag. 119
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  No Feedback Signal from Water Pump
[Alarm Stop Reason] ATTENTION:

Pump operation feedback signal (terminals 1-2) is
OFF during pump Interlock (CMP) ON (terminals
3-4) During pump operation (during unit stop),
*It is available once feedback signal confirmed. Alarm is reset by
1. Feedback signal reconfirm
2. Pump stop
[PCB Monitoring Position]
3. Unit operation
PCBc (CPU PCB) PCN24
It is not reset by stop operation.
No (Printed
Circuit Board
Is 220-240V the voltage is normal) Yes
between connector PCN4 Is thermal relay for pump Check pump lock
PIN1 and connector PCN4 (TRP) activated?
PIN3 on the Printed Circuit
Board for CPU (PCBc)?
No
Yes
Check thermal relay

for pump
Printed Circuit Board

for CPU (PCBc) check
Check wiring around
pump and thermal
relay for pump
pag. 120
SMGB0003 rev.0 - 01/2007
Troubleshooting

Alarm code  Phase Abnormality (Reverse Phase / Phase Failure)


Power source connected to unit is reversed phase No. 1 ~ No. 3 Cycle: PCBD1 (I/O PCB) R, S, T
or open phase. No. 4 and No. 5 Cycle: PCBD4 (I/O PCB) R, S, T
*In case of 1~3 cycle unit, “05-05”
In case 4, 5 cycle unit, “C1-05 ~ C5-05”.
Yes (Phase Failure,
5
Is 3 phase power source Reverse Phase) Power Supply,
phase failure or reverse Wiring Check
phase?
No
Is printed circuit board No

for relay (PCBD1, D4) Connection repair
connector R.S.T correctly
connected?
Yes
Is the power source of Yes Repair to correct

connector R.S.T part
phase
phase failure or reverse
phase?
No (Correct Phase)
Check printed
circuit board for
relay (PCBD)
pag. 121
SMGB0003 rev.0 - 01/2007
Troubleshooting

Alarm code  Activation of Freeze Protection Control


- Chilled water temperature is lower than PCBC (CPU PCB) CN3 (for inlet), CN4 (for No. 1 cycle
2°C.(standard unit) (only cooling operation) outlet), CN6 (for No. 2 cycle outlet), CN7 (for No. 3 cycle
- PCBC PCN13 wiring is broken. outlet)
*”13-13” : for 1 cycle unit or if alarm PCBD1 (I/O PCB) CN23Te2 (for No. 1 cycle protection)
is detected in inlet water temperature PCBD2 (I/O PCB) CN23Te2 (for No. 2 cycle protection)
Thermistor or PCN13 wiring is broken.
PCBD3 (I/O PCB) CN23Te2 (for No. 3 cycle protection)
“C1-13 ~ C5-13”: It is detected in outlet
PCBC (CPU PCB) PCN13
water temperature in more than 2 cycle
units.
No
Is connectors on the Plug correctly and
Printed Circuit Board repair wiring
correctly connected?
Yes
No
measure thermistor Replace Thermistor
resistance
Is resistance correct?
Check water flow rate (Check the
Yes Yes temperature of Inlet and Outlet)
Check pump reverse rotation
Check water strainer clogging
Check printed circuit Check air mixing

board for CPU (PCBC)
Check Chilled water thermostat setting value
(It shall be within the working range)
NOTE:
− One inlet temperature Themistor is installed in each unit.
− Two outlet temperature Thermistors are installed in every heat exchanger in water side.
− The below table shows the relation between Thermistor and alarm indication as well as
connecting Printed Circuit Board (PCB).
pag. 122
SMGB0003 rev.0 - 01/2007
Troubleshooting
Abnormal
Product Model Thermistor PCB Connector
Code
Chilled water outlet temperature Thermistor 1 PCBC CN4

RCUE 40 ~ 80 AG2
RHUE 40 ~ 80AG2

Chilled water outlet temperature Thermistor 2 PCBD1 CN23
(backside cooler)
Chilled water outlet temperature Thermistor 1 PCBC1 CN4


(backside cooler)


(backside cooler)

RCUE 80 ~ 400 AG2
RHUE 80 ~ 240 AG2

5
Chilled water outlet temperature Thermistor 2
(backside cooler) PCBD3 CN23


(backside cooler)


(backside cooler)
RCUE 40 ~ 400 AG2

 Chilled water inlet temperature Thermistor PCBC CN3
RHUE 40 ~ 240 AG2
pag. 123
SMGB0003 rev.0 - 01/2007
Troubleshooting

Alarm code  Activation of Water Overheating Protection Control


- Water outlet temperature is above 59°C PCBC (CPU PCB):
during compressor operation. (only heating
- CN4 (for No.1 cycle outlet control)
operation)
- CN6 (for No. 2cycle outlet control)
- PCBCPCN12 wiring is broken.
*”14-14” : 1 cycle unit
“C1-14 ~ C5-14 ”: more than 2 cycle units
Is connectors CN3 on the No

Plug correctly and
Printed Circuit Board for
Relay (PCBD)correctly repair wiring
connected?
Yes
No
measure thermistor Replace Thermistor
resistance
Check water flow rate (Check the
Yes Yes temperature of Inlet and Outlet)
Check pump reverse rotation
Check water strainer clogging
Check printed circuit Check air mixing

board for Relay
(PCBD) Check Chilled water thermostat setting value
(It shall be within the working range)
NOTE:
The below table shows the relation between Thermistor and alarm indication as well as
connecting Printed Circuit Board (PCB).
Abnormal
Code
RCUE 40 ~ 80 AG2
 Outlet water outlet temperature Thermistor 1 PCBC1 CN4
RHUE 40 ~ 80AG2
 Outlet water outlet temperature Thermistor 1 PCBC1 CN4
 Outlet water outlet temperature Thermistor 1 PCBC1 CN6
RCUE 80 ~ 400 AG2

 Outlet water outlet temperature Thermistor 1 PCBC1 CN7
RHUE 80 ~ 240 AG2
 Outlet water outlet temperature Thermistor 1 PCBC2 CN4
 Outlet water outlet temperature Thermistor 1 PCBC2 CN6
pag. 124
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Operation Error / Setting Error
[Alarm Stop Reason]

Wrong setting is performed in Dip Switch on Printed Circuit Board, or prohibited operation is performed.
No
Yes
Is alarm reset by stop Is setting of Dip Switch Check Printed Circuit
switch? correct? Board for Operation
(PCBB)
Yes No
Set Dip Switch correctly
and turn the power source
Yes (Normal ON again.
No (Remote) Running)
Is local operation? Is changeover to local side It is incorrect that
during remote operation? operation changeover to
local side during remote
Yes (Local) No operation.
5
Do not perform it.
Is 220-240V between No
PIN1-PIN3 of connector Wiring Check between
PCN16 on the printed remote control switch and
circuit board for CPU printed circuit board.
(PCBC)?
Yes
Yes
(Normal
Is optional wiring Yes Running)
Is the signal transmitted It is incorrect that remote
connected? operation signal is
from option device?
transmitted from option
device during local
operation.
Do not perform it.
No
No Wiring Check between
external device and
Yes printing board
(Normal
Is it changed over to Running)
remote side during local It is incorrect operation
operation? that changeover to
Remote Side during
Local Operation.
No
Do not perform it.
Check printed circuit

board for display (PCBA)
board for operation
(PCBB)
board for CPU (PCBC
pag. 125
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Inlet Chilled Water Thermistor Abnormality

Thermistor for inlet water temperature PCBC1 (CPU PCB) CN3
indicates abnormal value.
No
Is Printed Circuit Board for
Plug, Wiring Repair
Control (PCBC) connector
CN3 correctly connected?
Yes
Disconnect connector and No Replace Thermistor

measure resistance. Is the
resistance correct?
Yes
Replace printed circuit


Alarm code  Outlet Chilled Water Thermistor Abnormality


Thermistor for outlet water PCBC (CPU PCB) CN4 (for inlet),
temperature indicates abnormal CN6(for No. 2 cycle)
value.
*”12-12”: 1 cycle, “C1-12 ~ C5-12 ”:
more than 2 cycle units
No
Plug, Wiring Repair
Control (PCBC) connector
Yes [] Stop by abnormality of chilled water outlet Themistor for No.1 cycle
[] Stop by abnormality of chilled water outlet Themistor for No. 2 cycle

resistance correct?
Yes

NOTE:
The connector position differs from product model.
pag. 126
SMGB0003 rev.0 - 01/2007
Troubleshooting
Abnormal
Code
RCUE 40 ~ 80 AG2
 Outlet water temperature Thermistor 1 PCBC1 CN4
RHUE 40 ~ 80AG2
 Outlet water temperature Thermistor 1 PCBC1 CN4
 Outlet water temperature Thermistor 1 PCBC1 CN6
RCUE 80 ~ 400 AG2

 Outlet water temperature Thermistor 1 PCBC1 CN7
RHUE 80 ~ 240 AG2
 Outlet water temperature Thermistor 1 PCBC2 CN4
 Outlet water temperature Thermistor 1 PCBC2 CN6
Alarm code

Evaporating Temperature Thermistor Abnormality
5


Thermistor for inlet refrigerant No. 1 Cycle: PCBD1 (I/O PCB) CN27Tr2
temperature at water side heat No. 2 Cycle: PCBD2 (I/O PCB) CN27Tr2
exchanger indicates abnormal value.
No
Plug, Wiring Repair
Relay (PCBD) connector
CN27correctly connected?
Yes

resistance correct?
Yes

board for Relay (PCBD)
pag. 127
SMGB0003 rev.0 - 01/2007
Troubleshooting

Alarm code Discharge Gas Temperature Thermistor Abnormality


Thermistor for discharge gas No. 1 Cycle: PCBD1 (I/O PCB) CN24Td
temperature indicates abnormal No. 2 Cycle: PCBD2 (I/O PCB) CN24Td
value. No. 3 Cycle: PCBD3 (I/O PCB) CN24Td
Is Printed Circuit Board for No

Relay (PCBD) connector Plug, Wiring Repair
CN24Td correctly
connected?
Yes

resistance correct?
Yes

board for CPU (PCBD)

Alarm code Liquid Temperature Thermistor Abnormality


Thermistor for detection of air side No. 1 Cycle: PCBD1 (I/O PCB) CN22Te1
heat exchanger outlet (subcooled No. 2 Cycle: PCBD2 (I/O PCB) CN22Te1
liquid) temperature indicates
No. 3 Cycle: PCBD3 (I/O PCB) CN22Te1
abnormal value.

CN22Te1 correctly
connected?
Yes

resistance correct?
Yes

pag. 128
SMGB0003 rev.0 - 01/2007
Troubleshooting
 Abnormality of Outlet Water Temperature

Alarm code
 Thermistor for Protection

Thermistor for detection of water No. 1 Cycle: PCBD1 (I/O PCB) CN23Te2
side heat exchanger outlet No. 2 Cycle: PCBD2 (I/O PCB) CN23Te2
(backside=inside of heat exchanger)
temperature indicates abnormal
value. No. 4 Cycle: PCBD4 (I/O PCB) CN23Te2

Yes

5
resistance correct?
Yes

NOTE:
The connector position differs from product model.
Abnormal
Code
RCUE 40 ~ 80 AG2 Outlet water temperature Thermistor
 PCBD1
RHUE 40 ~ 80AG2 (backside of cooler)
Outlet water temperature Thermistor

 PCBD1
(backside of cooler)

 PCBD2
CN23
RCUE 80 ~ 400 AG2 Outlet water temperature Thermistor
 PCBD3
RHUE 80 ~ 240 AG2 (backside of cooler)

 PCBD4

 PCBD5
pag. 129
SMGB0003 rev.0 - 01/2007
Troubleshooting
 Suction Gas Temperature Thermistor

Alarm code
 Abnormality

[Alarm Stop Reason]
Thermistor for detection of
compressor suction gas refrigerant No. 2 Cycle: PCBD2 (I/O PCB) CN25Ts
temperature indicates abnormal No. 3 Cycle: PCBD3 (I/O PCB) CN25Ts
value. No. 4 Cycle: PCBD4 (I/O PCB) CN25Ts

CN25Ts correctly
connected?
Yes

resistance correct?
Yes

pag. 130
SMGB0003 rev.0 - 01/2007
Troubleshooting
 Discharge Pressure Sensor Abnormality

Alarm code


[Alarm Stop Reason]
No. 1 Cycle: PCBD1 (I/O PCB) CN28Pd
Discharge pressure sensor of
compressor indicates abnormal value. No. 2 Cycle: PCBD2 (I/O PCB) CN28Pd
Is connector CN28Pd on No
the printed circuit board Connect correctly
for relay (PCBD) correctly
connected?
Yes
Is DC24V between
connector CN28Pd PIN1
and PIN3 on the printed
No
5
circuit board for relay board for Relay (PCBD)
(PCBD)?
Yes
Is less than DC 0.1V

or more than DC 4.9V
between connector No
CN28Pd PIN2 and Replace printed circuit
PIN3 on the printed board for Relay (PCBD)
circuit board for relay
(PCBD) when discharge
gas pressuresensor is
connected?
Yes
Yes
Is discharge gas pressure Removing the clogging
sensor connecting pipe in the pipe.
Yes
clogging?
Discharge pressure
sensor abnormality
pag. 131
SMGB0003 rev.0 - 01/2007
Troubleshooting
 Suction Pressure Sensor Abnormality

Alarm code


[Alarm Stop Reason]
Suction pressure sensor of
compressor indicates abnormal No. 2 Cycle: PCBD2 (I/O PCB) CN29Ps
value.. No. 3 Cycle: PCBD3 (I/O PCB) CN29Ps
Is connector CN29Ps on No
the printed circuit board Connect correctly
for relay (PCBD) correctly
connected?
Yes
Is DC5V between
connector CN29Ps PIN1 No
and PIN3 on the printed Replace printed circuit
circuit board for relay board for Relay (PCBD)
(PCBD)?
Yes
Is less than DC 0.1V

or more than DC 4.9V No
between connector
CN29Ps PIN2 and PIN3
on the printed circuit board board for Relay (PCBD)
for relay (PCBD) when
discharge gas pressure
sensor is connected?
Yes
Yes
Is discharge gas pressure Removing the clogging
sensor connecting pipe in the pipe.
Yes
clogging?
Discharge pressure
sensor abnormality
pag. 132
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Ambient Temperature Thermistor

Abnormality
Thermistor for ambient temperature PCBC (CPU PCB) CN5

indicates abnormal value.
Is connector CN5 on the No

Printed Circuit Board for Plug, Wiring Repair
CPU (PCBc) correctly
connected?
Yes
Pull out connector and No Replace Thermistor

measure thermistor
resistance.
Yes
5
Replace Printed Circuit
Alarm code  Error Communication between Ctrl. PCB and Ex. Valve PCB

Communication between Ctrl PCB PCBC (CPU PCB) ~PCBG (VD board) VCN13
and Ex.Valve PCB is not performed
correctly during 30 seconds.

Printed Circuit Board for Plug correctly and
CPU (PCBC) correctly repair wiring
connected?
Yes
Is connector VCN13 No
on the Printed Circuit Plug correctly and
Board for Ex. valve repair wiring
control (PCBG) correctly
connected?
Yes
Check the Printed Circuit Abnormal Replace the Printed

Board for Ex.valve control Circuit Board for
(PCBG) Ex.Valve control
(PCBG)
Normal
Replace the Printed

Circuit Board for CPU
(PCBC)
pag. 133
SMGB0003 rev.0 - 01/2007
Troubleshooting
Error Communication between Ctrl. PCB and

Alarm code  Fan Speed control PCB

[Alarm Stop Reason]
PCBC (CPU PCB) CN11~ PCBH
Communication between Ctrl PCB
(Fan control PCB) CN8 ~ PCBJ
(PCBc) and fan speed PCB is
(Fan control PCB) CN8
not performed correctly during 30
seconds.
Is setting of Dip Switch No

on Printed Circuit Board
for Fan Speed Control Set Dip Switch correctly
(PCBH,PCBJ) is correct?
Yes

Printed Circuit Board for Plug correctly and
CPU (PCBC) correctly repair wiring
connected?
Yes
Is connector CN 8 on
the Printed Circuit Board No Replace printed circuit
for Fan Speed Control board for Relay (PCBD)
(PCBH, PCBJ) correctly
connected?
Yes
Does fuse (EER, EFS1)

No
Replace the fuse
Board for Fan Speed
Control (PCBH, PCBJ)
have electricity?
Yes
Is 23V in the connector

PCN11 on the Printed No Yes
Is wiring of transformer Replace the transformer
Circuit Board for Fan Speed breaking?
Control (PCBH, PCBJ)?
have electricity?
Yes No
Wiring check, connector
check
Is the voltage in the test

pattern on the Printed Power circuit failure.
No Replace the Printed
Circuit Board for Fan Speed
Control (PCBH, PCBJ)? Circuit Board for Fan
VCC05 – GND 5V Speed Control (PCBH,
PCBJ)
pag. 134
SMGB0003 rev.0 - 01/2007
Troubleshooting
 During Activation of Pump Stop Control by

Alarm code
(Flicker) Excess Increase of Water Temperature

Water temperature is increased to 65°C by heat PCBC (CPU PCB) CN3(for inlet), CN4(for outlet
generation in pump during only pump running control in Unit 1), CN6 (for outlet control in Unit 2)
(during compressor stop: during heat operation PCBD (I/O PCB) CN23Te2 (for protection of Unit 1)
Thermo OFF or during pump automatic operation
PCBE (I/O PCB) CN23Te2 (for protection of Unit 2)
in winter).
*If water temperature is decreased under 65°C
due to pump stop, it becomes normal status
automatically.
Since this is not an abnormality of chiller unit, it is
not saved in alarm occurrence data.
Is connector on the No
Printed Circuit Board Plug correctly and
correctly connected? repair wiring
Yes
Pull out connector and No

5
measure thermistor
resistance. Is resistance Replace Thermistor
correct?
Yes No
No problem as a
product.
Ask users to check the
Replace Printed Circuit installation.
 Abnormality of Fan Number Setting

Alarm code


[Alarm Stop Reason]
Thermistor for detection of
compressor suction gas refrigerant No. 2 Cycle: PCBD2 (I/O PCB) CN25Ts
temperature indicates abnormal No. 3 Cycle: PCBD3 (I/O PCB) CN25Ts
value. No. 4 Cycle: PCBD4 (I/O PCB) CN25Ts
No
Is setting of Dip Switch
Set Dip Switch correctly
correct?
Yes
No
Check Printed Circuit Replace printed circuit
Board for Operation board for Relay (PCBD)
(PCBB) and Printed
Circuit Board forYes
Fan
Speed Control (PCBH
and PCBJ )
pag. 135
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code  Water flow Protection Switch Activation (at 63W use;
Option)

[Alarm Stop Reason]
Water flow protection switch is
activated
No
Is chilled water flowing? Check the pump
Yes
Is water shortage
protection switch ON No
during pump running? Check water flow in the
pump
Clogging of water
Yes strainer
Check the water

Is 220-240V the voltage shortage protection
between connector PCN switch
10 PIN1 and connector No
PCN 10 PIN3 on the
Printed Circuit Board for Check wiring
CIU (PCBC)?
Yes
Check the Printed

Circuit Board for CPU
(PCBC)
System Controller Connection

Alarm code  Abnormality (at CSC-5S connection:

[Alarm Stop Reason]
PCBC (CPU PCB) CN11
At remote setting by remote controller,
transmission is not performed for 3
minutes once it is started.
No
Is setting of Dip Switch Set Dip Switch correctly
correct?
Yes
Check the setting of

CSC-5S side
pag. 136
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code   Inverter Speed Control Abnormality

 1m: m=Fan No.

The actual frequency is over the admissible value FANM (Fan Module)
of inverter order frequency.
*Alarm stop: 5 retries during 30 minutes.(only
corresponding fan is stopped, automatic restart in
10 seconds)
[Retry Code]
No code indication (indicated within the
check mode)
NOTE:
See "Inverter position detection abnormality" in the next page for flowchart
Inverter Excess Current Protection

Alarm code  
 1m: m=Fan No. Abnormality

1. DC electricity value of inverter is over the FANM (Fan Module)
admissible value.
2. Inverter temperature is increased over the limit.
3. Error signal is detected.
*Alarm stop: 5 retries during 30 minutes. (only
corresponding fan is stopped, automatic restart in 10
seconds)
[Retry Code]
No code indication (indicated within the
check mode)
NOTE:
See "Inverter position detection abnormality" in the next page for flowchart
pag. 137
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code   Inverter Position Detection Abnormality


The actual cycle is over the admissible value FANM (Fan Module)
calculated by inverter order frequency.
*Alarm stop: 5 retries during 30 minutes.(only [Retry Code]
corresponding fan is stopped, automatic
No code indication (indicated within the check
restart in 10 seconds))
mode)
Re-operate
Yes
Is motor operating? Possible alarm cause is to detect excess current by
head wind.
Use as it is since the product has no failure
No
Are there any foreign Yes

material within the fan? Take off the foreign material
No
Check if connector on the fan module, relay connector and PIN are OFF.
*Connector is different from models. Confirm it with operation circuit drawing
Yes
Is connector abnormal? Repair it
No
Re-operate
Yes
Is motor operating? Repaired
No
Replace fan motor
Re-operate
Yes
Is motor operating? Repaired
No (No indication)
Replace Printed Circuit Board

for Control or fan module
pag. 138
SMGB0003 rev.0 - 01/2007
Troubleshooting
  Transmission Abnormality between Inverter and

Alarm code CPU PCB or between Fan Speed Control PCB

Communication is not performed during a FANM (Fan Module)
certain period.
*Alarm stop: 3 retries during 30 minutes. [Retry Code]
(compressor stop, automatic restart in 3minutes)
No. 1 Cycle : F1-P8
No. 2 Cycle : F2-P8
No. 3 Cycle : F3-P8
No. 4 Cycle : F4-P8
No. 5 Cycle : F5-P8
No
Is fan module No. set Set Dip Switch correctly
correctly?
Yes
Is fan module supplied

power source?
No Is “fan interlock
confirmation switch” set
No
Set “normal”.
5
“normal”?
Yes Yes
Check fuse
Is connector CN201, No
202 on the fan module Plug correctly and
correctly connected? repair wiring
Yes
Check fan module
pag. 139
SMGB0003 rev.0 - 01/2007
Troubleshooting
Alarm code   Voltage Shortage or Excess Voltage in Inverter


Inverter DC voltage is under or over the setting FANM (Fan Module)
voltage level.
*Alarm stop: 3 retries during 30 [Retry Code]
minutes.(compressor stop, automatic restart in
No. 1 Cycle: F1-P8
3minutes)
No. 2 Cycle: F2-P8
No. 3 Cycle: F3-P8
No. 4 Cycle: F4-P8
Re-operate
No. 5 Cycle: F5-P8
Yes
No Check and investigate

Is power supply voltage
under 200V± 10%? the wiring system and
wiring volume.
Yes
Is voltage over 170V

during running?
Yes
Is voltage down by
operating some operating
devices?
No Fan is operated
normally and fan
frequency is increased.
Is LED201 of fan computer How is the running Fan is operated but Fan computer has
lightning ? status of fan at re- stopped immediately. failure.
operation?
Replace it.
Fan is operated with

low frequency and
stopped by increasing
the frequency.
Is fan computer connected
correctly?
Connect it correctly.
Yes
Does fuse have electricity?
Replace fuse
pag. 140
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.3. Analysis and countermeasure of abnormal running

Chiller unit has various kinds of protection devices. When the operation status is not correct due to the activation of
some protection device, refer to the table below and find out the main reason to apply a countermeasure.
One failure can affect other different conditions. Thus, do not check only 1 point but analyze it from overall viewpoint
in detail.
Phenomenon Cause Check Point Countermeasure
Power Failure Measure voltage by tester. Wait the recovery of power source
Power is OFF Check power switch. Power Switch ON
Eliminate short-circuit and replace

Wiring Short Circuit Check falling of wiring coating.
fuse.
Fuse for
power Eliminate the earth fault and replace
Wiring Earth Fault Measure insulation resistance.
source is fuse.
melted Compressor Motor Failure Replace compressor and fuse.
Measure the interphase
Fan Motor Failure resistance, insulation resistance. Replace fan motor and fuse
Eliminate short-circuit and replace

Wiring Short-circuit Check falling of wiring device.
fuse..
5
Earth Fault in Operation
Measure insulation resistance. Eliminate earth fault and replace fuse
Circuit
Magnetic Contactor for

Compressor Motor Failure
Fuse for Magnetic Contactor

Replace magnetic contactor and fuse.
operation for Fan Motor Failure
circuit is Measure the coil resistance.
Magnetic Contactor
melted
for pump motor Failure
Auxiliary Relay Coil Failure Replace auxiliary relay and fuse.

It does not
run when Solenoid Valve Coil Failure Replace solenoid coil and fuse.
operate
Printed Circuit Board Short-
Conductive Foreign Particle. Remove the particle and replace fuse
Circuit
Crankcase Heater Failure Measure resistance. Replace oil heater and fuse.
Measure the transformer

Trans Coil Failure Replace transformer.
secondary voltage.
Remote Control Wiring Incorrect Wiring Change wiring.
R, S, T phase of power source is phase Check the connection

Change to the correct phase.
failure or reverse phase. (05 alarm) of R, S, and T phase
Remote Control Switch Failure. Change-over Replace remote control switch.

switch of Printed Circuit Board is “Local” (40 Check changeover switch.
alarm) Turn changeover switch on “Remote
Printed Wiring Connection Failure Repair the wiring connection

Circuit
Check the current by tester.
Board
Replace the Printed Circuit Board
Failure Printed Circuit Board Failure
Pump Breaking of Coil

Magnetic
Contactor Measure the voltage of contact Replace magnetic contactor for pump
for Pump point of magnetic contactor
Loose Connection
Failure
(52P)
Check water freeze, clogging

Pump locked Remove it.
Pump of foreign particle.
Over-
Pump stops
current
before Pump Over-current Check the RC value and Change the RC value or
Relay
compressor relay RC Value Wrong pump running current. replace magnetic contactor.
Activated
running
(TRP) (5P
Alarm) Pump over-current Push reset button
Replace magnetic contactor.
relay failure and check running current.
pag. 141
SMGB0003 rev.0 - 01/2007
Troubleshooting
Repair the wiring

Wiring Connection Failure Check circuit by tester
connection
Printed Circuit
Board Failure Check circuit by tester Check
Printed Circuit Board Replace Printed Circuit
Printed Circuit Board by self-
Pump runs, Failure Board
checking function
but neither
fan nor Replace remote control
Remote Control Switch Failure Operative by the unit side
compressor switch.
run.
Coil Broken Check circuit by tester
Fan Magnetic
Measure the voltage between Replace magnetic
Contactor Failure
Contact Point Failure contact points of magnetic contactor.
(Cooling Operation)
contactor.
Pump and
compressor Measure the interphase
Fan Motor Failure Replace fan motor
run, but fan resistance
does not run
Wiring Connection
Failure Repair the wiring
Check circuit by tester
Printed Circuit Board connection.
Printed Circuit
Board Failure Failure
Measure the thermistor

Thermistor Malfunction Replace thermistor
resistance
Pump and
fan run but Coil Breaking Check circuit by tester
compressor Compressor
Measure the voltage between Replace magnetic
does not Magnetic Contactor
Contact points Failure contact points of electromagnetic contactor
run. Failure
contactor
Change water temperature or

Thermostat is activated. (Thermo-Off) It is not failure
change the setting temperature.
Measure the interphase

Compressor Motor Failure
resistance Replace compressor
Compressor Failure Beat noise from compressor
Consult with electric

Voltage at starting up is low. Measure the voltage
power company
Excessive dust in air side heat

exchanger
Remove it.
Inlet or outlet of air side heat
Insufficient air in air side exchanger is clogged
heat exchanger Shortage of Service Space for
Secure the service space
Chiller Unit
Change wiring for fan

Reverse Rotation of Fan Motor
motor
Air temperature through Air Short Circuits in Chiller Unit Remove short-circuits
air side heat exchanger Another heat source around
is excessively high Remove heat source
chiller unit
Refrigerant excessive Charge correct quantity

Check cycle temperature.
Discharge pressure charge of refrigerant
is excessively
Unit stops Turn off the unit and check
high, so that high Non-condensable gas in Charge refrigerant again
during the relation between water
pressure switch the refrigerant cycle after the evacuation
cooling temperature and pressure.
activates.
operation High pressure pipe
(C1-H1)~ (C6-H6)
clogging Check clogging
Expansion Valve
clogging Check clogging
Check Valve (Air side Remove clogging, or

heat exchanger side) replace check valve
clogging
Check the difference of

Replace or clean the
Strainer Clogging temperature before and after of
strainer
strainer.
Chilled water inlet

Check the status of heat
temperature of Water Confirm if it is within the working
load in detail and take a
side heat exchanger is range
countermeasure
excessively high
Suction gas temperature Charge correct quantity

Discharge gas Gas leakage or refrigerant
is excessively high of refrigerant after
control is activated shortage
(Excessively super heat) checking gas leakage
pag. 142
SMGB0003 rev.0 - 01/2007
Troubleshooting
Check valve
Suction gas
(Air heat exchanger side) Replace check valve
temperature
Discharge gas Malfunction
is excessively
control is activated high (excessive Expansion Valve Clogging Remove Clogging
(- alarm)~ superheat)
(- alarm) Strainer Clogging Replace or clean the strainer
Discharge gas Replace discharge gas

Check thermistor resistance
Thermistor Failure thermistor
Fan motor bearing

Lock Status Replace fan motor
failure
Single Phase
Check magnetic contactor Replace magnetic switch
Running
Motor Insulation Measure insulation

Replace fan motor
Deteriorated resistance
Thermal relay for
compressor is Power Voltage excessively Set voltage within working
activated high or low range during operation
(- alarm)~ Measure the voltage in each
(- alarm) Compressor Drive Power Voltage Phase
interphase and ask Power
Excessive Current Imbalance
Company for the advice
Compressor internal Discharge pressure is
thermostat is Analyze the cause
excessively high
5
activated
(- alarm)~ Power Fuse melted Replace power fuse
(- alarm) Loose Power Terminal
Retighten the screw
Single Phase Screw
Fan internal Running
Contact point of compressor
Unit stops thermostat is Motor magnetic Contactor Replace contact points
during activated Roughness
cooling (- alarm)~
operation (- alarm) Compressor Bearing
Lock Status
Failure
Replace compressor
Compressor Motor Measure insulation
insulation Failure resistance
Compressor Motor
Measure current of
Over-current relay Replace over-current Relay
compressor motor
Failure
Check freezing of water,

Pump locked Remove them
clogging of foreign particle
Pump over-current Pump Over-current

Check the RC value and Change the RC value or
relay is activated relay RC value
pump running current replace magnetic contactor
( alarm) Wrong
Pump Over-current Push reset button. Check

Replace magnetic contactor
relay Failure the running current
Check the difference of

Shortage of water
temperature between inlet Increase water flow
Flow
and outlet of chilled water
Water Strainer Clogging Clean the strainer
Pump reverse
Freeze protection Check rotative direction Repair to correct direction
rotated
control is activated
( alarm) Air mixed Open Air Vent Valve Evacuate Air
Thermistor Failure
( alarm) Check inlet temperature of
( alarm) Replace Thermistor
chilled water
( alarm)
( alarm)
pag. 143
SMGB0003 rev.0 - 01/2007
Troubleshooting
The heat load is bigger than cooling capacity Calculate heat load Replace to larger unit
Gas leakage or shortage Charge correct quantity after

Check super-heat.
of refrigerant checking gas leakage
Expansion Valve
Check clogging Remove clogging
Clogging
Check to make sure that no difference

Strainer Clogging of temperature before and after of the Replace strainer
Low pressure is excessively strainer exists.
low. Low pressure Piping Check to make sure that no difference
Remove clogging
Clogging of temperature between piping exists.
(Low-pressure control is Check to make sure that no difference

activated) Check Valve Malfunction of temperature before and after of Replace check valve
check valve exists.
(▪ ▪ ▪ ▪ ▪ )~(▪ ▪ ▪ ▪ ▪ alarm)
Check the difference of temperature
Shortage of water flow between inlet and outlet of chilled Increase water flow
water
Clogging of Water Strainer Replace or clean the strainer
Pump Reverse Rotation Check the rotation direction Repair to the correct direction
Air Mixed Open the air vent valve Evacuate the air
Deposits on water cooler

Check the scales inside of water cooler Clean water cooler
plates
Excessive dust in air-side heat

exchanger Remove it.
Unit is running,
Inlet or outlet of air-side heat
but the cooling
Air flow shortage in air- exchanger is clogged
capacity is
side heat exchanger
insufficient Shortage of Service Space for chiller
Secure the service space
unit
Reverse Rotation of Fan Motor Correct the wiring of fan motor
Air temperature through Air Short-circuits in Chiller Unit Repair short-circuit.

High pressure is
excessively high air-side heat exchanger
Another Heat Source around the
is high Remove heat source
Chiller Unit
(High-pressure switch is
Refrigerant Excessive
activated) Check cycle temperature Charge the correct quantity
charge
Turn off the unit and check the relation

(▪ ▪ ▪ ▪ ▪ )~(▪ ▪ ▪ ▪ ▪ alarm) Non-condensable Gas in Evacuate and charge
between water temperature and
the Refrigerant Cycle. refrigerant again
pressure
High Pressure Pipe

Check clogging
Clogging
Remove clogging
Expansion Valve
Check clogging
Clogging

Strainer Clogging of temperature before and after Replace strainer.
strainer exists

Check valve mal-function of temperature before and after check Replace check valve.
valve exists.
Check pressure, cycle temperature,

Compressor Failure Replace compressor.
and current
Adjust the position of propeller

Propeller-fan contacts with shroud Investigate
fan
Installation error or
Check each bolt if loosen Tighten up.
loose bolt
Check suction gas temperature,

Liquid Compression Ensure superheat
pressure
Unit is running,
and it makes a Check suction gas temperature and
Noise from compressor Oil hammer Replace compressor
noise. oil level
No-current to oil heater

Check the current to oil heater. Replace oil heater.
at compressor stopping
Worn or damaged part in

Noise from inside of compressor Replace compressor.
the compressor
Beats of magnetic contactor Check the roughness of contact Replace contact points
Vibration of cabinet Check screws if loosen Tighten up
pag. 144
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.4. 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). Ambient temperature and outlet liquid refrigerant temperature air side heat exchanger.
The temperature characteristics are shown in the below figures:
5.4.1. Thermistor temperature characteristics (All temperature except discharge gas)
pag. 145
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.4.2. Thermistor temperature characteristics (Ambient)
pag. 146
SMGB0003 rev.0 - 01/2007
Troubleshooting
5.4.3. Thermistor temperature characteristics (Discharge gas temperature)
pag. 147
SMGB0003 rev.0 - 01/2007
Maintenance
6. M a i n t e n a n c e
This chapter describe the procedure of the maintenance of the Air cooled water chillers.
Content
6. Maintenance ......................................................................................149
6.1. Maintenance criteria ...................................................................................................150
6.2. Maintenance criteria of Screw Compressor................................................................152
6.3. Maintenance of Water Quality ....................................................................................153

6.3.1. Water to be used ............................................................................................................153
6.3.2. Criteria of Water .............................................................................................................153
6.3.3. Maintenance method of Water Quality ............................................................................155
6.4. Cleaning of water side heat exchanger ......................................................................157

6.4.1. Cleaning method> ...........................................................................................................158
6.5. Check items in daily operation....................................................................................160
6.6. Caution on handling of R407C ...................................................................................160

6.6.1. Refrigerant .....................................................................................................................160
6
6.6.2. Refrigerant oil ..................................................................................................................161
6.6.3. Refrigeration cycle complete parts .................................................................................162
6.6.4. Reference materials ........................................................................................................162
6.7. Manual at compressor overall check and parts check................................................162

6.7.1. Collection of refrigerant ..................................................................................................162
6.7.2. Structure and Start-up method of Compressor ..............................................................163
6.8. Refrigerant cycle diagrams .........................................................................................166

6.8.1. Refrigerant cycle diagram of Hitachi Air-Cooled Water Chiller
(RCUE 40, 50, 60, 70, 100, 120, 140, 180, 210, 280, 350 AG2) ...................................166
6.8.2. Refrigerant Cycle Diagram of Hitachi Air-Cooled Water Chiller
(RCUE 80, 160, 240, 320, 400 AG2) with economizer. ...................................................167
6.8.3. Refrigerant Cycle diagram of Hitachi Air-to-water Heat Pump Chiller
(RHUE 40, 50, 60, 70, 100, 120, 140, 180, 210AG2) .....................................................168
(RHUE 80, 160, 240 AG2) With economizer.) .................................................................169
6.9. Overhaul work ............................................................................................................170
6.10. Vacuuming Procedure ................................................................................................170

6.10.1. Vacuuming ......................................................................................................................170
6.10.2. Leave ..............................................................................................................................171
6.11. Additional refrigerant insertion ....................................................................................172

6.11.1. Confirmation of tank ........................................................................................................172
6.11.2. Measurement device used for refrigerant insertion .........................................................173
6.11.3. Procedure for refrigerant insertion ..................................................................................173
6.11.4. Check of leakage position ...............................................................................................174
6.11.5. Caution at Replacement of Expansion Valve ..................................................................175
pag. 149
SMGB0003 rev.0 - 11/2006
Maintenance
6.1. Maintenance criteria
Check
Check Item Criteria (procedure) Remarks
Frequency
1. General
Judge from aprox. 1m
Noise A/N Confirm if there is no abnormal noise. from the control panel
surface.
Vibration A/N Confirm visually if there is no abnormal vibration
2. Cabinet
Dirt A/N Clean with cloths
Outside board Rust A/N Perform repair painting with Anticorrosion paint
and inner
Vibration A/N Re-tighten screws
3. Refrigerant Circuit
Confirm if there is no refrigerant leakage by
using detecting device in each component
and pipe connection parts. As for checking
Refrigerant leakage once/ season for leakage in water cooler and condenser,
General confirm it with the air discharged to water inlet
and outlet, and in this, case water should be
drained.
once/ Perform visual check if there is no contact or
Capillary pipes
season resonance.
Confirm if there is no abnormal noise at starting,
Noise A/N operating and stop.
Confirm if there is no oil leakage or bleed from
Oil leakage bleed A/N the compressor.
Oil level A/N Perform visual check by sight glass.
once/
Insulation Resistance More than 3MΩ at 500V DC
season
once/
Oil Heater Apply current during compressor stop.
season
Compressor Ageing of Vibration once/
Touch and confirm if they have rubber elasticity.
Insulation rubber season
Pay special attention to noise, vibration and oil
Intermediate check (1) once/ 3,000 hr leakage etc.
Confirm if safety device and protection device See following
Intermediate check (2) once/ 6,000 hr function well. ”maintenance criteria
once/ 24,000 hr of Screw compressor”
(water-cooled) Overhaul the compressor and check it according for details
Overhauling 40,000 hr to the specialist’ advice.
(Air-cooled)
Condenser Fin clogging once / season Clean it spraying warm water (less than 40ºC).
(air-cooled)
See technical
Water flow, water temp. A/N Confirm if they are within the criteria catalogue for details.
once/ See technical
Water quality Confirm if it is within the criteria.
month catalogue for details.
Condenser Frequency of cleaning
(water-cooled) Cleaning Confirm if high pressure is within the criteria. differs depending on
A/N Perform the predetermined cleaning. result of water quality
or operation time.
If condenser is not used for intermediate or long
Drain water once/ season period, drain water. At this time, open also plug
for draining water and for removing air.
pag. 150
SMGB0003 rev.0 - 11/2006
Maintenance
Check
Check Item Criteria (procedure) Remarks
Frequency
3. Refrigerant Circuit (Cont.)
Frequency of cleaning
differs depending on
Cleaning once/ season Perform the predetermined cleaning. result of water quality
or operation time.
Adjust them so that standard operation pressure See technical
Water flow, water temp. A/N
Water Cooler is kept. catalogue for details.
once/ If the water cooler is not used for intermediate or Drain also water in
Drain water long period, drain water in the heat exchanger of pipes.
season water side.
See technical
Water quality once/ month Confirm if it is within the criteria. catalogue for details.
once/ Confirm if switching coolingheating is performed Only for air-cooled
4 way valve Operation
season smoothly. heat pump type
Expansion Confirm if low-pressure changes smoothly by See technical
valve Operation once/ month turning adjustable screw. catalogue for details.
(Mechanical)
Expansion once/ Touch it to confirm if it functions correctly when
valve Operation zero reset is performed automatically just after
(Electronic) season power ON.
Confirm if there is no pressure difference inlet
Strainer Clogging once/ month and outlet of strainer
Solenoid valve Operation once/ month Confirm if valve opens or closes smoothly.
Stop valve Operation once/ month Confirm if valve functions smoothly.
Confirm if it is activated correctly with the value Pay attention to
High pressure Operation Once / month of safety and control device setting in technical fluttering of contact
6
switch catalogue. parts at operation.
4. Electrical system
Supply voltage is as follows:
±10% rated voltage ±10% rated voltage
Supply voltage A/N

voltage for starting more
than 85% rated voltage
Electricity in More than 1MΩ at 500 V Mega in every

Insulation resistance once/ season
general electrical devices.
Connection of electrical Confirm if the terminal does not loose or coat of

once/ season
wire wire is not removed.
Earth wire once/ season Confirm if they are installed correctly.

Fuse once/ season Confirm if the capacity of fuses is correct.
Confirm if there is no abnormal noise or sparks The interval of
Magnetic contactor once/ season by switching ON OFF. switching ON⇔OFF is
Confirm if it is correct apparently. more than 3min.
Auxiliary relay once/ season Confirm if they are operated smoothly.

Electrical
component PCB once/ season Confirm if they are operated correctly.
Operation SW once/ season Confirm if they are operated smoothly.
Transformer once/ season Confirm if there is no abnormality apparently.
pag. 151
SMGB0003 rev.0 - 11/2006
Maintenance
6.2. Maintenance criteria of Screw Compressor
Classification Time and year Model Performance items
− Save of operation situation

Daily check Every day − (pressure, temperature, voltage, current value,
remarks etc.)
Every 6,000 hrs
− Operation check of safety device, protection device
Every one year
24,000 hrs
Periodically check air-cooled − Overhaul check of compressor and parts check
Every 5 years
40,000 hrs − Lubricant oil
water-cooled
Every 5 years
− According to purpose or conditions of use, work
Remarks Take the shorter period
items shall be added individually.
Year/month to change or check (min) Remark

Time 40.000 hr
3.000 hr 6.000 hr
(24.000 hr)
Item ( ) is for air-cooled.

1 month 6 month 1 year 5 year
(3 year)
Operation test of safety device and protection device
1 High pressure switch
Check of lubricant oil and change it
2 Refrigerant oil
3 Suction gas strainer, oil strainer.
Decomposition of compressor
4 Bearing
5 Rotor
6 thrust liner
Change them at the same

7 Set of tooth lock washer (tighten the nuts) time as bearing
8 Set of P.K.O ring
9 Set of Teflon ring
NOTE:
− : part change : part change if abnormality is detected in the check
− This table is applied in case that operation condition is good and operation record is fully equipped.
− Perform compressor check according to the compressor service manual and technical notice.
pag. 152
SMGB0003 rev.0 - 11/2006
Maintenance
6.3. Maintenance of Water Quality
This air-conditioning device uses water as a heat source (for cooling) or as a media (chilled water, heat water) for use of
heat. Therefore, it is necessary to select suitable water and control it to maintain the quality and performance and avoid
possible problems.
Serious failure of plate heat exchanger may stop the units function and cause high expenses for its repair. Therefore, it is
indispensable to promote the maintenance and selection of water for the chiller installation.
Read the below criteria of water quality very carefully to avoid any troubles.
In case of using some chemical products for water treatment, it is recommended to consult with manufacturers
specialised in water treatment, since characteristics of chemical agents may differ with product specifiactions.
6.3.1. Water to be used

Water to be supplied to the chiller should be running water (clean water), industrial water or groundwater.
Other special water like pure water cannot be used in the standard product.
6.3.2. Criteria of Water

The later table shows the guideline of water quality regulated by JRAIA. Each criteria is set for water for
cooling and for heating. The compliance of this criteria is premised on the product guarantee.
 Explanation of Main Items in Water Quality Maintenance>
− pH (hydrogen-ion concentration)
pH is used as a measure to judge acidity, neutral and alkalinity of water. It is a big factor in taste, corrosion,
6
purification effect in water treatment, disinfection effect in chloride treatment, water stain formation, and other
fields like analytic chemistry, biochemistry etc. The below figure shows an example of relation between pH
value and corrosion.
Penetration (mm/year)
Relation between pH and corrosion of soft steel
− Electrical conductivity
To know the outline of water quality, it is effective to measure electrical conductivity. This value is determined
by quality and quantity of dissolved chlorine, and generally water with a greater value of electrical
conductivity is not suitable since it has a lot of substance causing corrosion and lime.
− Chloride ion
Chloride ion has a important property regarding corrosion and corrosion is higher in water with big amount
of chloride ion although pH value is free of corrosion. Chloride ion does not have oxidise property, however
precious metal is penetrated if chloride ion combines with oxidant or dissolved oxygen.
− Sulfate ion
Sulfate ion is a cause of corrosion, but it gives an indication for line formation. If running water has a great
amount of sulfate ion, it will become rusty water.
pag. 153
SMGB0003 rev.0 - 11/2006
Maintenance
− Acid consumption (pH4.8) = M alkali level

It shows the volume of hydroxide, carbonate and bicarbonate in water. It is a base of
saturation index calculation or prevention of corrosion, rusty water and line formation.
− All hardness, calcium hardness
The volume of calcium ion and magnesium ion in water is indicated with mg/l
corresponding to the calcium carbonate . Hardness by calcium ion is called calcium
hardness. This is a cause of line trouble related with temperature, pH, and electrical
conductivity.
− Ionic silica
When metallic corrosion products (FE, Zn etc) increase in water, silica produces
compound products reacting with metallic corrosion products, which helps that line is
found easily.
− Iron
Iron exists in water as a bicarbonate, a chloride, a hydrosulfate,a hydroxide, iron
bacterium and an organoiron salt, and is a cause of rusty water or line trouble.
− Copper
Copper is often melt from copper pipes. Copper is a promoting factor of corrosion
against iron pipes or galvanized steel pipe.
− Sulfide ion
It is a sulfide dissolved in water. When pH is decreased, sulfide is dissolved to produce
H2S, which causes a heavy corrosion on many metal materials.
− Ammonium ion
When ammonium exist in water, copper and ammonium react together to produce
complex salt, which leads to copper evolution and finally to the corrosion. The volume
of ammonium, producing copper and complex salt, is equivalent in NH3+ H2O ↔NH4+
+OH-. When water pH value increases, the volume of ammonium also increases, and
the danger to corrosive becomes higher.
− Chlorine residual
It is chlorine remained in the water which has been chlorinated, and is a cause of
corrosion of copper etc.
− Free carbon dioxide
It is carbon dioxide gas dissolved in water, and is a cause of iron corrosion or action on
concrete.
− Ryzner Stability Index (RSI))
It is a measure of the grade of water corrosion and line production. It is calculated by
the following formula.
RSI = (9.3+A+B-C-D) x 2 –E
CAUTION A: Dissolved matter index=0.1 (electrical conductivity≒5~50mS/m)., 0.2 (electrical
In the beside data, only conductivity≒50~150mS/m)
chilled circulation water is
defined, however, stable B: Temperature index <Chilled water>=2.4, <Warm water>=1.6
index of 6~7 should be
kept in other cases. C: Calcium hardness index = log (calcium hardness) – 0.4
D: Oxygen consumption (pH4.8) index = log[Oxygen consumption (pH4.8)]
E: pH value
RSI < 6: Possibility of line production
6≦RSI < 7: Stable area
RSI≧7: Possibility of corrosion
pag. 154
SMGB0003 rev.0 - 11/2006
Maintenance
− Dissolved oxygen
It is an oxygen gas dissolved in water and is a great factor to promote the corrosion. Regarding copper
corrosion, possibility of corrosion is increased in dissolved oxygen volume of 5~15 (ml/l), and is decreased in
greater or less value than that.
Remarks: Oxygen consumption, all hardness and calcium hardness
If these values are greater, line is likely to be produced, and if they are fewer, corrosion is likely to be
caused. In the guideline presented in the table, only the upper value is limited, which is based on an idea of
prevention of line trouble and of that the corrosion can be judged by other method. Therefore, if there is no
worry about line trouble, it is better to keep these values high to prevent the possibility of corrosion.
Concretely, in chilled and warm water, if RSI is 6~7.5 (there is no worry about line problem), it is convenient
to maintain the below value to prevent the corrosion.
- Oxygen consumption (pH4.8) (mgCaCO3/l) =50~100
- All hardness (mgCaCO3/l) =50~200
- Calcium hardness (mgCaCO3/l) =below 150
6.3.3. Maintenance method of Water Quality
 Quality inspection of circulation water
1. Before test run, all criteria items in the table should be checked.
2. The first week after test run pH and electrical conductivity should be measured. In case of any
trouble, all items should be checked. 6
3. One month after test run, all items should be checked.
4. After that, water quality tendency should be captured in these 3 tests and afterward schedule should
be decided by these results. Even in the case of no trouble, pH and electrical conductivity should be
checked every month and all criteria items of water quality should be checked every half year.
 Action in case of water quality trouble
When the result of periodical inspection recognises some troubles in water quality, those actions as similar to
the following should be taken according to the situation.
1. Replace old water to new one or perform forced blow. (once a week ~ once a month)
2. Water should be treated with anti-corrosion agent or line inhibitor.
pag. 155
SMGB0003 rev.0 - 11/2006
Maintenance
 Other maintenance item
To maintain good water quality, it is necessary to consider the installation place. See the below for your
reference.
− Before installation
Maintenance item Measures
1. Installation place
− Analysis of water quality should be asked to a specialised
a). Study if installation place is suitable. company in water treatment. If it is a negative result,
water source should be changed or treatment system
(*). Abnormal wastewater from boiler or refrigerating should be changed after consulting with the company.
machine is not mixed with the chilled water.
2. System
a). Study if materials of heat exchanger, pipe, tank, valve
− Corrosion may concentrate to only one part due to the
etc are suitable.
difference of material in chilled and heating water system.
b). Prohibition of open the pipe connected with tank to
− Open the pipe to ambient air may promote the corrosion.
ambient air.
Pipe should be put inside the water.
c). Study of temperature, flow, pressure and minimum
− Control that these values be within the usage range.
holding water volume of chilled and heating water.
− Suitable brine for Hitachi’s product should be selected. Its

3. Water for use specification is accorded with Hitachi technical handbook
“caution in use of brine”.
a). Study of specification in case of brine.
− There is a case that special water like pure water may not
b). Study of specification in case of special water like pure use in standard Chiller unit. Especially, in case of pure
water. water, material should be made in SUS or certain water
treatment should be performed.
− After working
Maintenance item Measures
− Suitable measurement should be taken in case of

1. Confirm if there is no leakage in pump, valve, pipe etc.
the leakage
2. Study of temperature, flow, pressure and minimum − Control that these values be within the usage
holding water volume of chilled and heating water range. (once a day)
pag. 156
SMGB0003 rev.0 - 11/2006
Maintenance
6.4. Cleaning of water side heat exchanger
Plate heat exchanger is used in water side heat exchanger in this series .
Water passes through the clearance between plates in the plate heat exchanger,
therefore, dust or foreign materials should not exist there. (See the below structure
figure for your reference)
Strainer (correspondent to 20 mesh) should be installed in the inlet pipe of chilled water
(Strainer should be prepared in each case).
Line is produced based on the water quality, and it is possible to decrease the
performance or to break the plate due to the partial freezing caused by local clogging,
which leads to the refrigerant leakage. Cleaning of strainer as well as water side heat
exchanger should be performed periodically.
See the below cautions and normal cleaning method for your reference. Contact the
below detergent companies to the details.
Showa HQ (Gifu): +81-58-232-1131
Tokyo branch: +81-3-3580-6121
Osaka sales office: +81-6-6391-2051
Futuro +81-3-92-434-4143
Water (brine)
Water (brine)
CAUTION
1. Suitable cleaning agent for line should be selected. (According to the dirty, cleaning
agent differs)
2. Plate heat exchanger is made by stainless. (Copper material is used in the
connection of plate). Therefore, do not use a cleaning agent with “chlorine and
fluoride”. If it were used, heat exchanger should be damaged, which may cause the
refrigerant leakage.
3. After water discharge, wash the inside with water and then water treatment should
be performed in order to prevent the corrosion, rusty water or re-production of line.
4. Density of cleaning agent, cleaning time or temperature should be adjusted
according to the line.
5. After oxygen cleaning, neutralization treatment should be performed. Disposal of
waste water in neutralization treatment should be asked to the specialised company.
6. Cleaning agent or neutralization agent is corrosive or irritating to the body (skin,
eye etc). Therefore, when cleaning, put the protection materials (protection glasses,
protection grove, protection boots etc) on.
pag. 157
SMGB0003 rev.0 - 11/2006
Maintenance
6.4.1. Cleaning method>

Cleaning whole system using the existing pump and cleaning only water circuit
of chiller unit (single body cleaning) are the popular cleaning methods. Here, it is
explained how to do concretely in simple body cleaning.
Nº Name
 Chiller unit
 Water inlet
 acid-proof pump
 hose
 Cleaning solution
 Water outlet
Circulation tank
 (tank for cleaning)
Tank for waste
 water collection
 Step 1: Cleaning circuit installation
− Chiller unit operation is stopped.

− Circulation pump operation is stopped.
− Water inlet/outlet connection is removed from the water circuit of unit, and another
circulation circuit used the acid-proof pump is installed separately from the water
circuit.
 Step 2: Confirmation of circulation circuit

An acid-proof pump is run while water is put in the tank for cleaning, and confirm
− if water is not leaked from the cleaning circuit.

− If cleaning hose is fixed.
− if devices installed around the unit is not contaminated by cleaning liquid, possible to
overflow from the tank
− if air is not clogged.
− if there is no strange noise.
 Step 3: Cleaning
− Drain off the water in cleaning circuit.
− Adequate quantity of cleaning agent is put in the tank for cleaning and while diluting it,
operate the acid-proof pump so that the diluted cleaning liquid circulates in the circuit.
− Perform the circulation cleaning during prescribed time (it is determined in each
cleaning agent, although it differs from liquid type or density). It is necessary to
change the cleaning time according to the dirtiness.
pag. 158
SMGB0003 rev.0 - 11/2006
Maintenance
 Step 4: Wastewater treatment

− Acid-proof pump operation is stopped.
− Wastewater is put to the tank for wastewater collection.
− Water is put in the tank for cleaning and the tank is washed with pump.
− Water used before is also put to the tank for wastewater collection.
− While confirming with pH test paper, neutralization agent is added gradually to
neutralise the tank.
− Neutralised wastewater should be treated by industrial waste disposal contractor.
In case that wastewater is diluted by much abundant of water and drained to public
sewer, consult with a cleaning agent company in advance.
 Step 5: Neutrization treatment
− Water is put in the tank for cleaning.

− Acid-proof pump is operated while air is pulled out.
− While confirming with pH test paper, neutralization agent is added gradually so that pH
value be 7~9.
− After pump is operated for prescribed time, neutrization treatment is finished.
− After finishing neutrization treatment, neutrization liquid is drained to public sewer.
− Circulation pump is operated and circulation system is washed sufficiently until dirty
liquid is totally out.
 Step 6: Re-start operation

6
− Water pipe is installed as before the cleaning.
− After cleaning, water treatment is performed to prevent the corrosion occurred at
operation start.
pag. 159
SMGB0003 rev.0 - 11/2006
Maintenance
6.5. Check items in daily operation
Check items Check contents Result (write the value or X )
1 Check of around of chiller unit Remove the obstacle Good / NG
Pressure, quantity and quality of chilled (heating)

2 Good / NG
water Check them while pouring water
3 Pipe of chilled (heating) water Good / NG
4 Check of screws and bolts etc Re-tighten those which are loosed Tightened / No tightened
5 Re-tightening of electrical wiring terminal Re-tighten all by driver Tightened / No tightened
6 Leakage of water pipe Confirm it while pouring water Yes / No
7 Dirtiness of air side heat exchanger Clean it by pouring hot (40°C) water. Done / No done
8 Clogging of drain pump Confirm it while pouring water Yes / No
9 Cleaning of inside/outside of machine room Done / No done
10 Compressor Good / NG
11 Air side heat exchanger Good / NG
12 Water side heat exchanger Good / NG
13 Expansion valve Good / NG
14 4 way valve (only cooled heat pump) Good / NG

Check valves, flare parts,
15 Solenoid valve Good / NG
welding parts etc.
16 Stop valve Good / NG
17 Strainer Good / NG
18 Pipe, capillary tube Good / NG
19 High pressure block switch Good / NG
20 Cleaning of inside/outside of unit Done / no done
21 Interphase voltage of compressor More than 180V Good / NG
22 Vibration and noise Check compressor, fan, pipe etc. Abnormal / Normal
Operation adjustment and automatic operation Check the activation of ON, OFF,
23 Good / NG
mechanism temperature adjustment
Check the activation value and setting
24 High pressure block switch Good / NG
value.
25 Indication light Good / NG
Check the state of switch from cooling

26 4 way valve (only cooled heat pump) Good / NG
to heating and vice versa.
27 Solenoid valve Good / NG
28 Instruction on operation method Done / No done
29 Inlet temperature of chilled (heating) water °C
30 Outlet temperature of chilled (heating) water °C
31 Inlet DB(WB) temperature of air side heat °C ( °C)

exchanger
32 Water flow of water side heat exchanger m3/h
33 High pressure MPa
34 Low pressure MPa
35 Operation voltage V
36 Operation current A
6.6. Caution on handling of R407C
6.6.1. Refrigerant
The refrigerant is HFC type refrigerant whose ozone destruction coefficient is ZERO. If other refrigerant is
mixed, the property of refrigerant is changed and may cause a problem. The following points should be taken
into account on its handling.
− Refrigerant should be added in liquid state not in gas state. R407C is nonazeotropic refrigerant mixture,
and compositions of boiling point are different. Therefore, if it is added in gas state, refrigerant, easy to
evaporate, is added and refrigerant, hard to evaporate, remains in a refrigerant tank.
− Confirm if the tanks specialised for R407C.
− The tank should be set so that refrigerant can be added in gas state.
− The valves or hose for charge should be specialised for R407C.
pag. 160
SMGB0003 rev.0 - 11/2006
Maintenance
6.6.2. Refrigerant oil

Freol UX300 of Japan Energy is used as a refrigerant oil due to its high compatibility with R407C. Other
refrigerant oil cannot be used, therefore, pay attention not to be mixed with others at maintenance. The
hygroscopicity is the same as a conventional Icematic SW220HT of Castrol, therefore, moisture maintenance is
not changed. (Icematic SW220HT as well as Ferreol UX300 are ester series refrigerant oil, therefore, open to the
ambient air as short as possible)
Type Ester series synthetic oil

Name Ferreol UX300 of Japan Energy
Fluid point Below -20°C
kinematic viscosity (40 °C) 250~310mm2/s
water saturation Aprox. 1600 ppm
Model Reference Refrig. Qty. (kg)

RCUE40AG2 8E041072 39
RCUE50AG2 8E051072 46
RCUE60AG2 8E061072 41
RCUE70AG2 8E071072 48
RCUE80AG2 8E081072 64
RCUE100AG2 8E101072 92
RCUE120AG2
RCUE140AG2
RCUE160AG2
8E121072
8E141072
8E161072
82
96
128
6
RCUE180AG2 8E181072 123
RCUE210AG2 8E211072 144
RCUE240AG2 8E241072 192
RCUE280AG2 8E281072 192
RCUE320AG2 8E321072 256
RCUE350AG2 8E351072 240
RCUE400AG2 8E401072 320
RHUE40AG2 9E041072 39
RHUE50AG2 9E051072 46
RHUE60AG2 9E061072 41
RHUE70AG2 9E071072 48
RHUE80AG2 9E081072 64
RHUE100AG2 9E101072 92
RHUE120AG2 9E121072 82
RHUE140AG2 9E141072 96
RHUE160AG2 9E161072 128
RHUE180AG2 9E181072 123
RHUE210AG2 9E211072 144
RHUE240AG2 9E241072 192
pag. 161
SMGB0003 rev.0 - 11/2006
Maintenance
6.6.3. Refrigeration cycle complete parts

Organic materials (rubber, teflon) used in compressor and control device use compatible parts with Freol
UX300 and R407C.
The pressure of R407C is higher than that of R22, and pressure strength of devices is increased. Therefore,
devices for R407C are not compatible with that for R22. Use specified devices when replacing the
compressor and refrigeration cycle parts at maintenance.
Do not put R407C to the units for R22 .
6.6.4. Reference materials

The following materials are published as a reference for R407C handling. Please see for them.
− Implementation, service and maintenance of Package Air conditionings with R407C. (material No.: HR-
325)
− Implantation and service technique of devices used HFC series (JRAIA)
6.7. Manual at compressor overall check and parts check
The refrigerant (R407C) used in this unit is HFC refrigerant and does not cause the destruction of ozone layer in
contrast with CFC or HCFC refrigerant.
However, its global heating coefficient is the same level as HCFC refrigerant, therefore it is important to control the
discharge. Also, it is necessary to collect refrigerant at disposal of device or at arrangement of devices.
Collection of refrigerant, vacuuming and additional insertion of refrigerant at compressor overall check and parts
check are shown in the following.
Handling of R407C alternative refrigerant is described in “Implantation / Service Technical of Devices used HFC
Refrigerant”.
6.7.1. Collection of refrigerant

Refrigerant at airside heat exchanger should be collected in case of compressor overall check and parts
check. However, at replacement or arrangement of airside heat exchanger itself, valve and fusible plug
of airside heat exchanger, refrigerant of airside heat exchanger and other high pressure parts cannot be
collected, and refrigerant inside the refrigeration cycle is needed to be collected using refrigerant collection
device.
1. Liquid outlet valve (A) of airside heat exchanger is fully closed.

2. Chiller unit is operated with chilled water fully flowing.
owing (In case of air-cooled heat pump type it is
operated in cooling mode)
3. Chiller unit is stopped when pressure of low pressure side is decreased to aprox. 0.05MPa. Do NOT
operate Chiller unit under 0.05MPa. Such operation may cause a compressor failure.
4. After a few minutes later when pressure of low pressure side is increased to 0.45~0.5MPa, chiller
unit is re-operated and (2) and (3) are repeated 4~5 times.
5. This above operation enables the major part of refrigeration cycle to be collected in airside heat
exchanger and high pressure pipe (between (B) and (A)).
6. Refrigerant, remained in low pressure side pipe and water cooling device, should be collected from
stop valve (D) using refrigerant collection device.
pag. 162
SMGB0003 rev.0 - 11/2006
Maintenance
6.7.2. Structure and Start-up method of Compressor
 Structure of Compressor
The structure of compressor used in this series is shown below figures:
1. A screw of half-sealed compressor is composed with male rotors and female rotors which have 5~6
dies.
2. Capacity is controlled by bypassing the refrigerant moving the slide valve(#7), a part of casing, to a
shaft direction by a hydraulic piston(#9).
The standard specification of motor(#4), built-in the casing, is 200W and start-up.
 Structure drawing of
40ASP-H, 40ASP-Z:
Nº Name Material
 Main casing FC250

Discharge
 Screw rotor
 Roller bearing
 Motor


Motor casing
Ball bearing
FC250
6
 Slide valve
 Rod
 Piston
 D casing FC250
Suction
 E cover SM400B
 Terminal
 Gas strainer
 C cover SM400B
pag. 163
SMGB0003 rev.0 - 11/2006
Maintenance
 Structure drawing of Nº Name Material

50ASP-H, 50ASP-Z:
50ASP-Z
Discharge
 Screw rotor
 Roller bearing
 Motor
 Motor casing FC250
 Ball bearing
 Slide valve
 Rod
 Piston
 D casing FC250
Suction
 E cover SM400B
 Terminal
 Gas strainer
 C cover SM400B
 Structure drawing of
60ASP-H, 60ASP-Z:
Nº Name Material

Discharge
 Screw rotor
 Roller bearing
 Motor
 Motor casing FC250
 Ball bearing
 Slide valve
 Rod
 Piston
Suction  D casing FC250
 E cover SM400B
 Terminal
 Gas strainer
 C cover SM400B
pag. 164
SMGB0003 rev.0 - 11/2006
Maintenance
 Start-up method
Normally more than 22kW compressor has start-up, partly waiting start-up as well as normal start-up
due to its high start-up current.
All Hitachi self-sealed screw compressors of rated output more than 22kW adapt - start-up system
due to its high performance from the view of start-up current.
Like shown in the figure 9/18, at start-up, coil of the stator is connected as a star ( ), and 1/root3 of power
voltage is added to each phase. When motor is accelerated and compressor starts to run normally, the
connection is changed to a delta ( ) to add the power voltage to all phase fully.
 Start-up method:
Line voltage=1
6
At start-up ( connection) At operation ( connection)
The real wiring is shown in the below figure
1. The connection of U~X, V~Y and W~Z is a motor, which is inside of screw compressor.
2. At start ( ) connection 52C, 6C:ON 42C:OFF
3. At operation ( ) connection 52C, 42C:ON 6C:OFF
 Real Wiring:
Wiring
pag. 165
SMGB0003 rev.0 - 11/2006
Maintenance
6.8. Refrigerant cycle diagrams
6.8.1. Refrigerant cycle diagram of Hitachi Air-Cooled Water Chiller

(RCUE 40, 50, 60, 70, 100, 120, 140, 180, 210, 280, 350 AG2)
Option
Gauge
manifold
Option Option Option
Chilled Water Inlet
Charging Evacuation
Chilled Water Outlet
Unit side
Flange Connection
Flare Connection
Solder Connection
Refrigerant Cycle
No. Name No. Name

1 Compressor 12 Sight Glass
2 Air-Cooled Condenser 13 Compressor Safety Valve (Option)
3 Water Cooler 14 Stop Valve (Option)
4 Filter Drier 15 Stop Valve (Option)
5 Electronic Expansion Valve 16 Compressor Dual Safety Valve (Option)
6 Check Valve 17 Stop Valve
7 Stop Valve (with check Joint) A High Pressure Gauge
8 High Pressure Switch B Low Pressure Gauge
9 Pressure Sensor (Low) C Stop Valve
10 Pressure Sensor (High) D Charging Cylinder
11 Pressure Relief Valve E Vacuum Pump
NOTE:
R407C shall be charged by LIQUID.
pag. 166
SMGB0003 rev.0 - 11/2006
Maintenance
6.8.2. Refrigerant Cycle Diagram of Hitachi Air-Cooled Water Chiller

(RCUE 80, 160, 240, 320, 400 AG2) with economizer.
Option
Gauge
manifold
6
Option
Option Option
Chilled Water Inlet
Charging Evacuation
Unit side Flange Connection

Flare Connection
Solder Connection
Refrigerant Cycle
No. Name No. Name

1 Compressor 15 Stop Valve (Option)
2 Air Cooled Condenser 16 Compressor Dual Safety Valve (Option)
3 Water Cooler 17 Pressure Switch
4 Filter Drier 18 Solenoid Valve
5 Electronic Expansion Valve 19 Capillary Tube
6 Check Valve 20 Economizer
7 Stop Valve (with check Joint) 21 Strainer
8 High Pressure Switch 22 Stop Valve
9 Pressure Sensor (Low) A High Pressure Gauge
10 Pressure Sensor (High) B Low Pressure Gauge
11 Pressure Relief Valve C Stop Valve
12 Sight Glass D Charging Cylinder
13 Compressor Safety Valve (Option) E Vacuum Pump
14 Stop Valve (Option)
NOTE:
R407C shall be charged by LIQUID.
pag. 167
SMGB0003 rev.0 - 11/2006
Maintenance

(RHUE 40, 50, 60, 70, 100, 120, 140, 180, 210AG2)
Gauge
manifold
Option
Option
Option Option
Chilled Water Inlet
Charging Evacuation
Chilled Water Outlet Flange Connection
Flare Connection
Solder Connection
Unit side
Refrigerant Cycle
No. Name No. Name

1 Compressor 12 Sight Glass
2 Air-Side Heat Exchanger 13 Compressor Safety Valve (Option)
3 Water Side Heat Exchanger 14 Stop Valve (Option)
4 Biflow drier 15 Stop Valve (Option)
5 Electronic Expansion Valve 16 Compressor Dual Safety Valve (Option)
6 Check Valve 17 Stop Valve
7 Stop Valve (with check Joint) A High Pressure Gauge
8 High Pressure Switch B Low Pressure Gauge
9 Pressure Sensor (Low) C Stop Valve
10 Pressure Sensor (High) D Charging Cylinder
11 Pressure Relief Valve E Vacuum Pump
NOTE:
R407C shall be charged by LIQUID
pag. 168
SMGB0003 rev.0 - 11/2006
Maintenance

(RHUE 80, 160, 240 AG2) With economizer.)
Gauge
manifold
Option
Option
Option
6
Chilled Water Inlet
Charging Evacuation
Flange Connection
Unit side Flare Connection
Solder Connection
Refrigerant Cycle
No. Name No. Name

1 Compressor 16 Compressor Dual Safety Valve (Option)
2 Air Side Heat Exchanger 17 4-Way Valve
3 Water Side Heat Exchanger 18 Accumulator
4 Biflow drier 19 Liquid Tank
5 Electronic Expansion Valve 20 Solenoid Valve
6 Check Valve 21 Capillary Tube
7 Stop Valve (with check Joint) 22 Economizer
8 High Pressure Switch 23 Strainer
9 Pressure Sensor (Low) 24 Pressure Switch
10 Pressure Sensor (High) A High Pressure Gauge
11 Pressure Relief Valve B Low Pressure Gauge
12 Sight Glass C Stop Valve
13 Compressor Safety Valve (Option) D Charging Cylinder
14 Stop Valve (Option) E Vacuum Pump
15 Stop Valve (Option)
NOTE:
R407C shall be charged by LIQUID
pag. 169
SMGB0003 rev.0 - 11/2006
Maintenance
6.9. Overhaul work

Perform the work according to “Dissolution and Composition Manual of Hitachi Half Sealed
Screw Compressor”.
When compressor is removed from refrigeration cycle, high pressure part should be separated
between projecting part flange of compressor and upper cover of oil separator. Do not
be separated between check valve and projecting part flange of compressor, or collected
refrigerant is ejected.
Check valve Projecting part flange of

compressor Do not remove these bolts
or refrigerant is ejected
Separate from
this part
Check valve
Upper cover of Remove these
oil separator bolts firstly
Projecting part flange of compressor
Upper cover of oil separator
6.10.Vacuuming Procedure
Although refrigerant is collected to airside heat exchanger by the above collection operation,
it is necessary to be vacuumed due to that refrigerant cycle of low pressure side pipe and of
water side heat exchanger are open.
Vacuum should be performed in the following 2 positions.
− Stop valve for refrigerant insertion ((D) part)
− Check joint of compressor suction side ((E) part)
*Capillary for compound gauge in low pressure side is installed in check joint. This
capillary should be removed from check joint.
Vacuuming procedure is shown in the following.
6.10.1. Vacuuming
− Manifold valve, vacuuming pump and vacuuming gauge for R407C are connected.
− Operate vacuuming pump for at least 1~2 hours until vacuum grade be below
–755mmHg (5Torr).
pressure Manifold valve

Abnormal for vacuuming
(leakage, water
atmosphere in pipes)
pressure
CAUTION
If vacuum grade
is not decreased
to –755mmHg in
Connect to (D)
1 hour, confirm (E) parts
if there is no
leakage or if water
(Refrigerant
is not in the pipes,
tank for R407C)
and then keep
vacuuming other
1 hour. Vacuuming pump
(prevention of adverse
current)
Vacuum Leave
(1~2 hrs) (1 hour)
− Confirmation of vacuum
Vacuum gauge should be used to measure a target vacuum, however, it is
impossible to read the vacuum gauge installed in the manifold very accurately.
It is recommended to use a digital vacuum measure device, available in the
market.
pag. 170
SMGB0003 rev.0 - 11/2006
Maintenance
− Water evaporation>
In atmosphere pressure, water boils at 100°C, however, each time a pressure in
pipes reaches to a vacuum state, water boils at lower temperature than 100°C.
The lower this temperature is, the more water evaporates and vacuum drying is
kept.
CAUTION If there is a possibility of dew condensation, vacuum (vacuuming time) should be

controlled more strictly since water does not evaporate easily and it is difficult to know
the degree of dew condensation. It is desirable to control the vacuum grade as a
–755~758 mmHg (5~2 Torr).
6.10.2. Leave
After finishing vacuuming, manifold valve is closed and vacuum pump is

stopped, and then leave it for 1 hour to confirm if a pressure measured by
vacuum gauge is not increased.
CAUTION
1. This process should be performed since air can be leaked due to the
negative pressure although air leakage is not confirmed in air tight test.
2. In case of increasing pressure, it is possible that there is a slight
leakage in some positions. Perform air tight test again, and perform
vacuum drying again after repaired.
pag. 171
SMGB0003 rev.0 - 11/2006
Maintenance
6.11. Additional refrigerant insertion
According to the refrigerant characteristics, the followings should be taken into account.
CAUTION − Refrigerant should be added in liquid state not in gas state.

− Confirm if the tanks are specialised for R407C.
− The tank should be set so that refrigerant can be added in gas state.
− The valves or hose for charge should be specialised for R407C.
6.11.1. Confirmation of tank
1. Paining color is different from types of refrigerant. And a mark stamped in

inspection also serves for the confirmation of refrigerant .
Painting color:
R407C: Brown
2. The refrigerant tank has two specifications as shown in the below. In any case,
liquid refrigerant should be added.
The same structure as conventional tank. Tank specialized for R407C

<no siphon pipe> <with siphon pipe···Label attached>
Siphon pipe
If the edge of siphon pipe becomes

above the superficies of liquid
refrigerant, it should take gas out.
It is convenient to use manifold
valve with sight glass to confirm if
refrigerant is added in liquid state.
Do not add refrigerant while being stand It is possible to add refrigerant while being stand
pag. 172
SMGB0003 rev.0 - 11/2006
Maintenance
6.11.2. Measurement device used for refrigerant insertion
Measurement device for R407C is not compatible with that for R22 due to the following reasons, therefore,
do not divert them. These devices should be controlled separately to avoid being mixed.
Measurement device Reasons Remarks
Manifold valve
− Pressure-proof criteria is different

− Material spec. of packing is different
(question of deterioration)
Pay special attention not to use a hose for
Hose for charge
− If R22 is mixed, sludge is occurred due to charge for R22.
the flow of mineral oil to devices, which
may cause a clogging of cycle or accident
in compressor.
It is possible to change the composition
when putting from refrigerant tank to
Charging cylinder charging cylinder.
Under studying the handling.
Detection method is different
6
−
Detector of gas leakage − Sensor of conventional detector of gas

leakage is very low, and practically it is
impossible to use.
NOTE:
The specification of connection screw is different from measurement device for R410A.
− R407C, R404A UNF7/16
− R410A UNF1/2
6.11.3. Procedure for refrigerant insertion
R407C should be added in liquid state.
Manifold valve (with

sight glass)
Specialized for R407C
Refrigerant tank
(with siphon pipe)
Connect
to (C) (D)
parts
Brown
Hose for charge

Balance
pag. 173
SMGB0003 rev.0 - 11/2006
Maintenance
1. After vacuuming, additional refrigerant should be inserted in liquid state with stop
valve of liquid side and gas side close. (Confirm the volume by the balance)
In principal, collected refrigerant from water side heat exchanger to outside of
CAUTION refrigeration cycle by collection device is measured to determine the volume. If
Do NOT add
it is impossible to measure it, use the following figure to determine the volume,
refrigerant in gas confirming the balance pressure after collection operation.
state from suction
side of compressor 2. If it is impossible to add regulated volume due to the lower ambient temperature,
(gas side stop valve). compressor is operated in cooling mode and liquid refrigerant should be added from
stop valve for refrigerant insertion (C). Then, regulated volume is added with the
liquid side stop valve (high pressure side) open a little bit.
6.11.4. Check of leakage position
Check steadily again using the

Insertion of additional refrigerant detector of gas leakage specialized
for R407C
Alarm:
Check for refrigerant leakage should be performed steadily. The refrigerant used
in this unit is incombustible, non-toxic and odourless safe one. However, toxic gas
is produced when leaked refrigerant is exposed to fire. And oxygen will be lacked
due to that refrigerant, its gravity is higher than air, is spread in the floor.
CAUTION
Refrigerant should
be added in a
suitable volume
since excess or
less insertion cause
Additional refrigerant insertion volume per 1 cycle (kg)
alarm or accident of
compressor.
Pressure of low pressure side after collection operation (MPa)
pag. 174
SMGB0003 rev.0 - 11/2006
Maintenance
6.11.5. Caution at Replacement of Expansion Valve
The replacement of expansion valve can be performed by collecting the

refrigerant to air side heat exchanger in the method shown in the “1 Collection of
Refrigerant”. And pay attention to the following points.
Electrical expansion valve is used in this product, and its opening is almost
closed (10 pulse) at compressor stop. Therefore, when removing the welding of
expansion valve, it is important not to remain the refrigerant between liquid outlet
valve of air side heat exchange (A) and expansion valve.
1. In case of the model with economiser
 With economizer: Liquid outlet valve of air side

heat exchanger (A)
Ex. valve
Close
10 pulse (close)
To compressor
From air side

heat exchanger
6
This flare should be removed Economiser
before heating (*) part
2. In case of the model without economiser
The coil should be removed

while refrigerant is being Applicable model:
 Without economizer: Liquid outlet valve of air side
heat exchanger (A) collected
Close
CAUTION
Ex. Valve
There will be a clearance
between control value
and actual value of
expansion valve opening,
therefore, zero point
adjustment (re-input of
power source) should be
realized.
This operation makes expansion valve open in spite of compressor stop by low pressure
setting.
Compressor is started up
Operate chiller unit and when starting unload is Close outlet valve of air side
Remove the coil of ex. valve
finished heat exchanger
pag. 175
SMGB0003 rev.0 - 11/2006
HITACHI participa en el programa de certificación EUROVENT.
Los productos cumplen con las especificaciones del directorio
de productos certificados por EUROVENT.
Hitachi Air Conditioning Products Europe, S.A.

Ronda Shimizu,1 - Políg. Ind. Can Torrella
08233 Vacarisses (Barcelona) España
ISO 9001, certificados por AENOR, España
ISO 14001, certificados por AENOR, España
Hitachi Air Conditioning Systems Operation

Shimizu-shi, Shizuoka-ken, Japan
ISO 9001, certificados por JQA, Japón
ISO 14001, certificados por JQA, Japón
Hitachi Air Conditioning Products (M) Sdn. Bnd.

Lot No. 10, Jalan Kemajan Bangi Industrial Estate
43650 Bandar Baru Bangi, Selangor Darul Ehsan, Malasia
Certificación ISO 9001, Malasia
Certificación ISO 14001, Malasia
SMGB0003 rev.0 - 01/2007 - Printed in Spain

Csavarkompresszoros - SM GB0003 - r0 - 01-07-Service Manual RCUE AG2

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AIR COOLED WATER CHILLERS

(COOLING ONLY AND HEAT PUMP)

Product range and speciﬁcations 1

1.2. General data for RHUE40~240AG2 ..................................................................................................... 16

2.2. Test run method and check .................................................................................................................. 22

2.3. Restart of Test Run ............................................................................................................................... 25

2.4. Instruction at delivery............................................................................................................................ 27

2.5.Warning & Cautions .................................................................................................................................. 28

3 Electrical Wiring Diagram ........................................................................................31

3.2. Power Wiring Diagram (FAN) ............................................................................................................... 37

3.3. Control PCB (PCBc) ............................................................................................................................. 38

3.4. Input / Output PCB (PCBd)................................................................................................................... 40

3.5. Power Wiring Diagram (MCB Option)................................................................................................... 43

3.6. Diagram abbreviations descriptions ..................................................................................................... 48

4. Control system ........................................................................................................49

4.2. Water control ........................................................................................................................................ 52

4.3. Compressor control ............................................................................................................................. 53

4.4. Current limit control .............................................................................................................................. 54

4.5. Reverse protection control.................................................................................................................... 55

4.6. Restart control after power failure ........................................................................................................ 56

4.7. Operation error/wrong setting prevention control [40 – 40] ................................................................. 57

4.8. Forced capacity control ........................................................................................................................ 57

4.9. Second water temperature setting........................................................................................................ 58

4.10. Heat storage operation by external order ............................................................................................. 64

4.11. Operation by DC24V input (Remote Control) ....................................................................................... 65

4.13. Switch for conﬁrmation of high pressure cut......................................................................................... 69

4.14 Antifreeze control in winter ................................................................................................................... 69

4.16. Defrost (only air-cooled heat pump type) ............................................................................................. 72

4.17. Thermo off selection function ............................................................................................................... 75

5.2. Troubleshooting .................................................................................................................................. 108

5.3. Analysis and countermeasure of abnormal running ........................................................................... 141

5.4. Thermistor characteristics .................................................................................................................. 145

6.2. Maintenance criteria of Screw Compressor........................................................................................ 152

6.3. Maintenance of Water Quality ............................................................................................................ 153

6.4. Cleaning of water side heat exchanger .............................................................................................. 157

6.5. Check items in daily operation............................................................................................................ 160

6.6. Caution on handling of R407C ........................................................................................................... 160

6.7. Manual at compressor overall check and parts check........................................................................ 162

6.8. Refrigerant cycle diagrams ................................................................................................................. 166

6.9. Overhaul work .................................................................................................................................... 170

6.10. Vacuuming Procedure ........................................................................................................................ 170

6.11. Additional refrigerant insertion ............................................................................................................ 172

 Units Code List

AIR COOLED WATER CHILLERS -SCREW TYPE

Indication Indication Indication

RCUE40AG2 8E041072 RCUE100AG2 8E101072 RCUE180AG2 8E181072 RCUE280AG2 8E281072

RCUE70AG2 8E071072 RCUE160AG2 8E161072 RCUE400AG2 8E401072

AIR TO WATER HEAT PUMP CHILLERS -SCREW TYPE

Model Indication code Model Indication code Model Indication code

RHUE40AG2 9E041072 RHUE100AG2 9E101072 RHUE180AG2 9E181072

RHUE70AG2 9E071072 RHUE160AG2 9E161072

REMOTE CONTROL DEVICES LIST

Name Description Indication Code Figure

CSC-5S Central Station 60291050

PSC-5T Seven Day Timer 60291052

REMOTE CONTROL DEVICES ACCESSORIES LIST

PSC-5HR H-Link Relay 60291105

CENTRALISED CONTROLS LIST (Interfaces)

CENTRALISED CONTROLS (Interfaces) ACCESSORIES LIST