Page 1

-Technical Catalog ⅡInstallation, Operation and Maintenance

Instructions

For Models: RCU(G)75AHYZ1

RCU(G)270AHYZ1

RCU(G)100AHYZ1

RCU(G)300AHYZ1

RCU(G)120AHYZ1

RCU(G)330AHYZ1

RCU(G)150AHYZ1

RCU(G)350AHYZ1

RCU(G)180AHYZ1

RCU(G)360AHYZ1

RCU(G)200AHYZ1

RCU(G)380AHYZ1

RCU(G)240AHYZ1

RCU(G)400AHYZ1

HITACHI AIR-COOLED WATER CHILLERS -SCREW TYPE-

Z0011542


IMPORTANT NOTICE HITACHI pursues a policy of continuing improvement in design and performance of products. The right therefore is reverse to vary specifications without notice. HTACHI can not anticipate every possible circumstance that might involve a potential hazard. No part of this manual may be reproduced without written permission. Signal words (DANGER, WARNING and CAUTION) are used to identify levels of hazard seriousness. Definitions for identifying hazard levels are provided below with their respective signal words:

DANGER

: Immediate hazards which WILL result in severe personal injury or death.

WARNING

: Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION

: Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. : Useful information for operation and /or maintenance.

NOTE

If you have any questions, please contact your contactor or dealer of HITACHI. This technical catalog II gives a common description and information for this air-cooled water chiller which you operate as well as for other models. This air-cooled water chiller has been designed for the following temperatures. Please operate the air-cooled water chiller within this range.

W orking Range Item Chilled W ater Outlet Temperature Condenser Air Inlet Temperature

Standard 5 ~ 15 ℃ 5 ~ 43 ℃

This technical catalog II should be considered as a permanent part of the air-cooled water chiller equipment and should remain with the air-cooled water chiller equipment.


TABLE OF CONTENTS OPERATION INSTRUCTIONS 1. PREPARATION ............................................................................................................................................ 1 Initial Check.................................................................................................................................................1 Placing the Unit ...........................................................................................................................................1 Center of Gravity ........................................................................................................................................ 3 Weight Balance .......................................................................................................................................... 3 Recommended Concrete Curb................................................................................................................... 4 Transportation ............................................................................................................................................ 7 2. INSTALLATION ............................................................................................................................................ 8 Electrical Wiring ......................................................................................................................................... 8 Water Piping............................................................................................................................................. 10 Minimum Internal System Water Volume ................................................................................................. 11 Water Control ........................................................................................................................................... 12 Installation Final Check ............................................................................................................................ 12 3. Test Running ............................................................................................................................................. 13 Preparation............................................................................................................................................... 13 Test Running............................................................................................................................................ 13 Instruction after Test Running .................................................................................................................. 13 4. CONTROLLER ADJUSTMENT .................................................................................................................. 14 Controller adjustment ............................................................................................................................... 14 5. SELF-INSPECTION FUNCTIONS .............................................................................................................. 18 6. CONTROL SYSTEM ................................................................................................................................... 23 7. MAINTENANCE .......................................................................................................................................... 25 Components............................................................................................................................................. 25 Lubrication................................................................................................................................................ 25 Winter Showdown .................................................................................................................................... 26 Spring Start-up ......................................................................................................................................... 26 Part replacement ...................................................................................................................................... 26 Refrigerant Cycle...................................................................................................................................... 26 Compressor Removal............................................................................................................................... 28 Normal Operating Pressure...................................................................................................................... 30 Special Notes on Refrigerant, R407C ...................................................................................................... 34 8. Troubleshooting ........................................................................................................................................ 35


OPERATION INSTRUCTIONS

HITACHI Air-Cooled Water Chillers Model: RCU(G)75AHYZ1, Pilot Lamp 1.The red lamp indicates the normal operation. 2.When the orange lamp is activated, any one of the safety devices may be functioning. Please contact your services shop if this condition is detected. Daily Checking 1.Check for abnormal sounds and vibration. 2.Check the unit amperage. 3.Check the operating pressure. Troubleshooting Unit Dose Not Start 1.Is the main switch ON? 2.Is the main fuse OK? 3.Is the chilled water running?

To Start the Unit:

To Stop the Unit:

1.Fully open the inlet and outlet valve. 1. Depress the “*OFF” bush button switch. 2.After assuring that all control switches have been (*Field-Supplied) cut OFF and the “LOCAL/REMOTE” switch on the Note: printed circuit board is in the “REMOTE” position, turn Do not cut the main power switch in order to keep the ON the power switch. 3.Confirm that phases, R, S and T are correctly connected. activation of the oil heater. The correct phase connection can be checked by a phase sequence indicator. If not correctly connected, the compressor dose not start due to activation of a reversal phase protection device. Cut the main switch and interchange two of three terminals R,S and T at the main power source terminals. 4.Fully open the liquid line stop valves.( ) 5.Operate the chilled water pump. 6.Depress the “*ON” push button switch (*Field-Supplied) 7.Set the thermostat at the desired temperature.

4.Are the thermostat calling for the cooling operation? Poor Cooling Operation 1.Is sufficient air supplied to the condenser? 2.Is the thermostat properly set? 3.Is the operation pressure normal? 4.Is sufficient water running through the water cooler? Maintenance 1.Remove any obstacles to condenser air flow, and clean the condenser. 2.Clean the unit with a cleaner. 3.Clean the condenser and water cooler. (It is recommended that a specialist be contacted for this type of work.)


Model: RCU(G)100, 120,150AHYCZ1

OPERATION INSTRUCTIONS

Pilot Lamp 1.The red lamp indicates the normal operation. 2.When the orange lamp is activated, any one of the safety devices may be functioning. Please contact your services shop if this condition is detected. Daily Checking 1.Check for abnormal sounds and vibration. 2.Check the unit amperage. 3.Check the operating pressure. Troubleshooting Unit Dose Not Start 1.Is the main switch ON? 2.Is the main fuse OK? 3.Is the chilled water running?

To Start the Unit:

To Stop the Unit:

1.Fully open the inlet and outlet valve. 1. Depress the “*OFF” bush button switch. 2.After assuring that all control switches have been (*Field-Supplied) cut OFF and the “LOCAL/REMOTE” switch on the Note: printed circuit board is in the “REMOTE” position, turn Do not cut the main power switch in order to keep the ON the power switch. 3.Confirm that phases, R, S and T are correctly connected. activation of the oil heater. The correct phase connection can be checked by a phase sequence indicator. If not correctly connected, the compressor dose not start due to activation of a reversal phase protection device. Cut the main switch and interchange two of three terminals R,S and T at the main power source terminals. 4.Fully open the liquid line stop valves. ( ) 5.Operate the chilled water pump. 6.Depress the “*ON” push button switch (*Field-Supplied) 7.Set the thermostat at the desired temperature.

HITACHI Air-Cooled Water Chillers

4.Are the thermostat calling for the cooling operation? Poor Cooling Operation 1.Is sufficient air supplied to the condenser? 2.Is the thermostat properly set? 3.Is the operation pressure normal? 4.Is sufficient water running through the water cooler? Maintenance 1.Remove any obstacles to condenser air flow, and clean the condenser. 2.Clean the unit with a cleaner. 3.Clean the condenser and water cooler. (It is recommended that a specialist be contacted for this type of work.)


OPERATION INSTRUCTIONS

HITACHI Air-Cooled Water Chillers Model: RCU(G)180、200AHYZ1 Pilot Lamp 1.The red lamp indicates the normal operation. 2.When the orange lamp is activated, any one of the safety devices may be functioning. Please contact your services shop if this condition is detected. Daily Checking 1.Check for abnormal sounds and vibration. 2.Check the unit amperage. 3.Check the operating pressure. Troubleshooting Unit Dose Not Start 1.Is the main switch ON? 2.Is the main fuse OK? 3.Is the chilled water running? 4.Are the thermostat calling for the cooling operation?

To Start the Unit: 1.Fully open the inlet and outlet valve. 2.After assuring that all control switches have been cut OFF and the “LOCAL/REMOTE” switch on the To Stop the Unit: printed circuit board is in the “REMOTE” position, turn 1. Depress the “*OFF” bush button switch. ON the power switch. (*Field-Supplied) 3.Confirm that phases, R, S and T are correctly connected. Note: The correct phase connection can be checked by a phase sequence indicator. If not correctly connected, the Do not cut the main power switch in order to keep the compressor dose not start due to activation of a reversal activation of the oil heater. phase protection device. Cut the main switch and interchange two of three terminals R,S and T at the main power source terminals. 4.Fully open the liquid line stop valves. ( ) 5.Operate the chilled water pump. 6.Depress the “*ON” push button switch (*Field-Supplied) 7.Set the thermostat at the desired temperature.

Poor Cooling Operation 1.Is sufficient air supplied to the condenser? 2.Is the thermostat properly set? 3.Is the operation pressure normal? 4.Is sufficient water running through the water cooler? Maintenance 1.Remove any obstacles to condenser air flow, and clean the condenser. 2.Clean the unit with a cleaner. 3.Clean the condenser and water cooler. (It is recommended that a specialist be contacted for this type of work.)


OPERATION INSTRUCTIONS

HITACHI Air-Cooled Water Chillers Model: RCU(G)240, 270, 300AHYZ1 Pilot Lamp 1.The red lamp indicates the normal operation. 2.When the orange lamp is activated, any one of the safety devices may be functioning. Please contact your services shop if this condition is detected. Daily Checking 1.Check for abnormal sounds and vibration. 2.Check the unit amperage. 3.Check the operating pressure. Troubleshooting Unit Dose Not Start 1.Is the main switch ON? 2.Is the main fuse OK?

To Start the Unit:

To Stop the Unit:

1.Fully open the inlet and outlet valve. 1. Depress the “*OFF” bush button switch. 2.After assuring that all control switches have been (*Field-Supplied) cut OFF and the “LOCAL/REMOTE” switch on the Note: printed circuit board is in the “REMOTE” position, turn Do not cut the main power switch in order to keep the ON the power switch. 3.Confirm that phases, R, S and T are correctly connected. activation of the oil heater. The correct phase connection can be checked by a phase sequence indicator. If not correctly connected, the compressor dose not start due to activation of a reversal phase protection device. Cut the main switch and interchange two of three terminals R,S and T at the main power source terminals. 4.Fully open the liquid line stop valves.( ) 5.Operate the chilled water pump. 6.Depress the “*ON” push button switch (*Field-Supplied) 7.Set the thermostat at the desired temperature.

3.Is the chilled water running? 4.Are the thermostat calling for the cooling operation? Poor Cooling Operation 1.Is sufficient air supplied to the condenser? 2.Is the thermostat properly set? 3.Is the operation pressure normal? 4.Is sufficient water running through the water cooler? Maintenance 1.Remove any obstacles to condenser air flow, and clean the condenser. 2.Clean the unit with a cleaner. 3.Clean the condenser and water cooler. (It is recommended that a specialist be contacted for this type of work.)


OPERATION INSTRUCTIONS

HITACHI Air-Cooled Water Chillers Model: RCU(G)330, 350AHYZ1 Pilot Lamp 1.The red lamp indicates the normal operation. 2.When the orange lamp is activated, any one of the safety devices may be functioning. Please contact your services shop if this condition is detected. Daily Checking 1.Check for abnormal sounds and vibration. 2.Check the unit amperage. 3.Check the operating pressure. Troubleshooting Unit Dose Not Start 1.Is the main switch ON? 2.Is the main fuse OK?

To Start the Unit:

To Stop the Unit:

1.Fully open the inlet and outlet valve. 1. Depress the “*OFF” bush button switch. 2.After assuring that all control switches have been (*Field-Supplied) cut OFF and the “LOCAL/REMOTE” switch on the Note: printed circuit board is in the “REMOTE” position, turn Do not cut the main power switch in order to keep the ON the power switch. 3.Confirm that phases, R, S and T are correctly connected. activation of the oil heater. The correct phase connection can be checked by a phase sequence indicator. If not correctly connected, the compressor dose not start due to activation of a reversal phase protection device. Cut the main switch and interchange two of three terminals R,S and T at the main power source terminals. 4.Fully open the liquid line stop valves.( ) 5.Operate the chilled water pump. 6.Depress the “*ON” push button switch (*Field-Supplied) 7.Set the thermostat at the desired temperature.

3.Is the chilled water running? 4.Are the thermostat calling for the cooling operation? Poor Cooling Operation 1.Is sufficient air supplied to the condenser? 2.Is the thermostat properly set? 3.Is the operation pressure normal? 4.Is sufficient water running through the water cooler? Maintenance 1.Remove any obstacles to condenser air flow, and clean the condenser. 2.Clean the unit with a cleaner. 3.Clean the condenser and water cooler. (It is recommended that a specialist be contacted for this type of work.)


OPERATION INSTRUCTIONS

HITACHI Air-Cooled Water Chillers Model: RCU(G)360, 380, 400AHYZ1, Pilot Lamp 1.The red lamp indicates the normal operation. 2.When the orange lamp is activated, any one of the safety devices may be functioning. Please contact your services shop if this condition is detected. Daily Checking 1.Check for abnormal sounds and vibration. 2.Check the unit amperage. 3.Check the operating pressure. Troubleshooting Unit Dose Not Start 1.Is the main switch ON? 2.Is the main fuse OK?

To Start the Unit:

To Stop the Unit:

1.Fully open the inlet and outlet valve. 1. Depress the “*OFF” bush button switch. 2.After assuring that all control switches have been (*Field-Supplied) cut OFF and the “LOCAL/REMOTE” switch on the Note: printed circuit board is in the “REMOTE” position, turn Do not cut the main power switch in order to keep the ON the power switch. 3.Confirm that phases, R, S and T are correctly connected. activation of the oil heater. The correct phase connection can be checked by a phase sequence indicator. If not correctly connected, the compressor dose not start due to activation of a reversal phase protection device. Cut the main switch and interchange two of three terminals R,S and T at the main power source terminals. 4.Fully open the liquid line stop valves.( ) 5.Operate the chilled water pump. 6.Depress the “*ON” push button switch (*Field-Supplied) 7.Set the thermostat at the desired temperature.

3.Is the chilled water running? 4.Are the thermostat calling for the cooling operation? Poor Cooling Operation 1.Is sufficient air supplied to the condenser? 2.Is the thermostat properly set? 3.Is the operation pressure normal? 4.Is sufficient water running through the water cooler? Maintenance 1.Remove any obstacles to condenser air flow, and clean the condenser. 2.Clean the unit with a cleaner. 3.Clean the condenser and water cooler. (It is recommended that a specialist be contacted for this type of work.)


PREPARATION

1. PREPARATION Initial Check Required Materials - Measure and architectural information regarding installation location. Installation Location - Confirm the final installation location is provided with convenient piping and wiring work. Strong water runoff should be avoided. Installation Space - Check for obstacles which hamper maintenance work in the space specified in Fig.1. Foundation - Check to ensure the foundation is flat, level, and sufficiently strong, taking into account the maximum foundation gradient (Fig.2) and the unit weight balance. Confirm elevation provision for unit on a solid base with an iron frame or concrete curbs shown in Fig.5-1 ,5-2 and 5-3 in order to obtain proper clearance beneath the unit for either rooftop or on-the-ground installation, provide a gravel or concrete space around the condenser air intake, in order to avoid air flow obstruction due to grass or other vegetation. Unit - Check to insure that the unit has been transported without damage. File a damage claim with the transportation companies if mishandling due to transportation company negligence is suspected. Transportation - Secure the route to the final installation location by confirming the packing dimensions. (Refer to the “Unit General Data’ in Technical Catalog I.)

Placing the Unit

DANGER If leakage is detected, stop the unit and contact the installer or a service shop. Don’t use a naked fire near the refrigerant gas. If a naked fire is utilized near the refrigerant gas, refrigerant gas is turned into harmful phosgene compound.

WARNING The unit is operated with refrigerant R22 or R407C, which is nonflammable and nonpoisonous. However, refrigerant itself is heavier than the atmosphere so that a floor is covered with refrigerant gas if refrigerant is leaked. Therefore, maintain good ventilation to avoid choke during servicing.

CAUTION Check to ensure that valves are correctly opened. if not opened, serious damage will occur to the compressor due to an abnormally high pressure. Tools and Instruments - pincers, Wrenches, Facilities to Transport and Place the Unit. Transportation - Transport the unit as close to the final installation location as practice before unpacking is accomplished. Provide adequate facilities to place the unit on the foundation, with sufficient consideration given to those individuals performing the installation. Unpacking - Follow the instructions marked on the packing.

1


PREPARATION

h1≤h2

h1≤h2

For Models RCU(G)75AHYZ1~RCU(G)200AHYZ1

For Models RCU(G)240AHYZ1~RCU(G)400AHYZ1

Fig.1 Operation Space

NOTES: 1. The height of the wall shall be smaller than that of the unit cabinet. 2. When the unit is installed at the location where the unit is encircled with walls and obstruction of free air circulation is suspected, consultation with HITACHI regarding the operation space is recommended.

RCU(G)75AHYZ1

2,100

1,200

100

900

1,200

2,000

1,200

RCU(G)100AHYZ1

4,200

1,200

100

900

1,200

2,000

1,200

RCU(G)120AHYZ1

4,200

1,200

100

900

1,200

2,000

1,200

RCU(G)150AHYZ1

4,200

1,200

100

900

1,200

2,000

1,200

RCU(G)180AHYZ1

6,300

1,200

100

900

1,200

2,000

1,200

RCU(G)200AHYZ1

6,300

1,200

100

900

1,200

2,000

1,200

RCU(G)240AHYZ1

9300(Minmum)

1,200

900

900

1,200

2,000

1,200

RCU(G)270AHYZ1

9300(Minmum)

1,200

900

900

1,200

2,000

1,200

RCU(G)300AHYZ1

9300(Minmum)

1,200

900

900

1,200

2,000

1,200

RCU(G)330AHYZ1

11400(Minmu m)

1,200

900

900

1,200

2,000

1,200

RCU(G)350AHYZ1

11400(Minmu m)

1,200

900

900

1,200

2,000

1,200

RCU(G)360AHYZ1

13500(Minmu m)

1,200

900

900

1,200

2,000

1,200

RCU(G)380AHYZ1

13500(Minmu m)

1,200

900

900

1,200

2,000

1,200

RCU(G)400AHYZ1

13500(Minmu m)

1,200

900

900

1,200

2,000

1,200

Fig.2 Maximum Foundation Gradient

Maximum Foundation Gradient The unit shall be installed vertically within the maximum foundation gradient as shown Fig.2. 2


PREPARATION Center of Gravity Center of Gravity Model RCU(G)75AHYZ1 RCU(G)100AHYZ1 RCU(G)120AHYZ1 RCU(G)150AHYZ1 RCU(G)180AHYZ1 RCU(G)200AHYZ1 RCU(G)240AHYZ1-1 RCU(G)240AHYZ1-2 RCU(G)270AHYZ1-1 RCU(G)270AHYZ1-2 RCU(G)300AHYZ1-1 RCU(G)300AHYZ1-2 RCU(G)330AHYZ1-1 RCU(G)330AHYZ1-2 RCU(G)350AHYZ1-1 RCU(G)350AHYZ1-2 RCU(G)360AHYZ1-1 RCU(G)360AHYZ1-2 RCU(G)380AHYZ1-1 RCU(G)380AHYZ1-2 RCU(G)400AHYZ1-1 RCU(G)400AHYZ1-2

Center of Gravity X Y 975 830 2,035 805 2,055 805 2,065 835 3,550 805 3,570 835 2,055 805 2,055 805 2,065 835 2,055 805 2,065 835 2,065 835 3,570 835 2,065 835 3,570 835 2,065 835 3,550 805 3,550 805 3,570 835 3,550 805 3,570 835 3,570 835

Operation Weight (kg) 2,332 4,112 4,312 4,403 6,006 6,152 4,312 4,312 4,403 4,312 4,403 4,403 6,006 4,403 6,006 4,403 6,006 6,006 6,152 6,006 6,152 6,152

Fig.3 Center of Gravity

Weight Balance Weight Balance Model RCU(G)75AHYZ1

Model RCU(G)100AHYZ1 RCU(G)120AHYZ1 RCU(G)150AHYZ1 RCU(G)240AHYZ1-1 RCU(G)240AHYZ1-2 RCU(G)270AHYZ1-1 RCU(G)270AHYZ1-2 RCU(G)300AHYZ1-1 RCU(G)300AHYZ1-2

Model RCU(G)180AHYZ1 RCU(G)200AHYZ1 RCU(G)330AHYZ1-1 RCU(G)330AHYZ1-2 RCU(G)350AHYZ1-1 RCU(G)350AHYZ1-2 RCU(G)360AHYZ1-1 RCU(G)360AHYZ1-2 RCU(G)380AHYZ1-1 RCU(G)380AHYZ1-2

1 563

Location(kg) 2 3 508 662

1 655 651 688 651 651 688 651 688 688

Location(kg) 2 3 4 610 590 756 643 628 817 665 651 807 643 628 817 643 628 817 665 651 807 643 628 817 665 651 807 665 651 807

1 654 688 654 688 688 688 654 654 688 654

2 671 696 671 665 696 665 671 671 696 671

3 674 707 674 651 707 651 674 674 707 674

4 601

5 756 799 800 799 799 800 799 800 800

6 745 776 794 776 776 794 776 794 794

Location(kg) 4 5 671 825 696 842 671 825 807 800 696 842 807 800 671 825 671 825 696 842 671 825

6 836 850 836 794 850 794 836 836 850 836

7 840 837 840

8 833 834 833

837

834

840 840 837 840

833 833 834 833

Fig.4 Weight Balance 3


PREPARATION Recommended Concrete Curb

CAUTION When the unit is installed on the ground, the weight of the concrete curbs should be greater than 1.5 to 2 times of the unit weight.

For Models: RCU(G)75AHYZ1

For Models: RCU(G)100AHYZ1, RCU(G)120AHYZ1, RCU(G)150AHYZ1

Fig.5-1 Recommended Concrete Curbs 4


PREPARATION For Models: RCU(G)180AHYZ1, RCU(G)200AHYZ1

For Models: RCU(G)240AHYZ1, RCU(G)270AHYZ1, RCU(G)300AHYZ1

Fig.5-2 Recommended Concrete Curbs 5


PREPARATION For Models: RCU(G)330AHYZ1, RCU(G)350AHYZ1

For Models: RCU(G)360AHYZ1, RCU(G)380AHYZ1, RCU(G)400AHYZ1

Fig.5-3 Recommended Concrete Curbs 6


PREPARATION Transportation 1)

Rigging Hook wire cables and factory-supplied spreader bars on the top of (refer to Fig.6-1) to prevent the unit panels from damage due to cable scratches. The unit should remain in an upright position even during rigging. The wire cable to rig the unit shall be 3(three) times stronger than unit weight. Check to ensure that the rigging bolts are tightly fixed to the unit. The rigging angle shall be greater than 60 as shown .The weight of the unit is indicated on the unit label.

DANGER Do not stand below the unit when rigging.

CAUTION Put cloths between wires and the unit to avoid damages.

Fig.6-1 Transportation by Rigging

2)

Transportation by Roller When rolling the unit, put at least required 7 equal-sized rollers under the base frames. Each roller must carry both the outer frames, and must be suited to balance the unit (see the center of gravity in Fig.3).

Fig.6-2 Transportation by Rollers 7

3)

Declining the Unit during Transportation

CAUTION Do not decline the unit more than an angle of 15째 as shown in the figure during transportation. If declined more than an angle of 15째, the unit may fall down.

Fig.6-3 Declining the Unit


INSTALLATION

2. INSTALLATION Electrical Wiring Tools and Instruments - One set of wiring tools and electrical tester (Clamp Meter) Schedule Check-

CAUTION Confirm that the field-selected electrical components (main power switch, fuses, wires, conduit connections. wire terminals and others) are properly selected according to the “Electrical Data’ in Technical Catalog I and ensure they comply with national and local codes. It is recommended that the main power switch be locked at the “OFF” position, to prevent against accidental supply of power during equipment servicing. Check to ensure that an earthing wire is correctly connected to the unit. This wire protects unit from an electrical shock. Utilization of an earth leakage breaker is recommended. Main Power Wiring Procedures - Confirm that electrical power is not being supplied to the installation location prior to any electrical installation work. 1. Install the fielded-supplied main switch box (es) at a properly selected location. 2. Install conduit connectors in the hole for the power wiring. 3. Lead main power wires and earthing wire through the connector to the screw terminals for main power and earthing in the magnetic switch box. The neutral wire for 380v/50Hz and 415V/50Hz power supply should also be led through the connector. 4. Firmly connect the wires with wire terminals to unit screw terminal R, S, T and MP according to Fig.7. 5. Connect the wires between the power source switch and the field-supplied magnetic switch. 6. Consider that the main power source switch will not be left turned OFF easily. Because it is necessary to energize the oil heater even during unit stoppage. NOTE More than 240AHYZ1 including 240AHYZ1 unit consists of No.1(Master)and No.2 (Subsidiary) unit. It is required to supply the main power source for each (No.1 and No.2) unit. Control Wiring – Connect the interlock wiring and control wiring between the unit terminals and the magnetic switches for the water pumps, according to Fig.7 or the wiring label. The main connection to terminal Mp is required. RCU(G)75~200AHYZ1 Control Circuit Terminals Electrical Box Power Source Terminals

Interlock for the Pump

3

PWBc

Contactor 1 2

TB2

1

2

*CMP

R S T Mp

Y52P1

Pump Power Supply

3~Mp, 380V, 415V/ 50Hz

Main Power Switch (Field-Supplied)

4

*ORP

*CMP

Earth Terminal Main Power Wiring

*CSP

Earth Wiring Control Circuit Wiring

Contactor for Water Pump

Pump Operation Wiring

Chilled

(If Required) TB

8

9

10

11

12

Wire to be Removed 2 Push Button Switch(ON) Push Button Switch (OFF) *PLR1 *PLR2 *PLO1 *PLO2 *PLO3 Contactor for Pump 5 6 7 Over Current Relay for Pump TB2 Changeover Switch for Pump Operation Pilot Lamp for Remote Indication (Operation) *BSR2 *BSR1 Indication Lamp Power Supply (ON) *PLR2 Pilot Lamp for Remote Indication(Pump) (OFF) Remote Control Wiring and Remote *PLO1,2,3 Pilot Lamp for Remote Indication(Alarm, Indication Wiring(If Required) Each Cycle) Fig.7-1 Field Wiring Connections

*BSR1 *BSR2 *CMP *ORP *CSP *PLR1

8

13


INSTALLATION RCU(G)240~400AHYZ1 No.1 Unit (Master Unit)

No.2 Unit (Subsidiary)

Control Circuit Terminals Power Source Terminals

3~Mp, 380,415V/50Hz

Control Circuit Terminals Power Source Terminals Electrical Box

Electrical Box

1 2

3~Mp, 380V,415V / 50Hz

42 43

42 43

R S T Mp

R S T Mp

Main Power Switch (Field-Supplied)

Main Power Switch (Field-Supplied)

Earth Terminal Earth Wiring

Main Power Wiring

Earth Terminal

Main Power Wiring

Earth Wiring

Contactor for Chilled Water Pump Control Circuit Wiring

1

TB2

2

Wire to be Removed 3 PWBc

Interlock for the Pump Contactor

(No.1 Unit)

Pump Power Supply

*CMP

Y52P1

42

43

6

7

*CSP *BSR2 (OFF)

4

*BSR1 (ON)

(No.1 Unit)

*ORP

No.1 Unit TB3

5

TB2

*CMP

TB2

9

8

*PLR1

Pump Operation Wiring

10

11

12

*PLO1 *PLO2 *PLP2 *PLO1 *PLO2

13 --*PLO3

(If Required)

240~300AHYZ1 330~400AHYZ1

(No.1 Unit) Indication Lamp Power Supply TB3

42

43

No.2 Unit

Shielded Wires

Remote Control Wiring and Remote Indication Wiring (If Required)

DC12V (With Non-polarity Transmission )

(For No.1 Unit)

Control Wiring between No.1 and No.2 Units TB2 *BSR1 *BSR2 *CMP *ORP *CSP *PLR1

Push Button Switch(ON) Push Button Switch (OFF) Contactor for Pump Over Current Relay for Pump Changeover Switch for Pump Operation Pilot Lamp for Remote Indication (Operation) *PLR2 Pilot Lamp for Remote Indication(Pump) *PLO1,2,3,4,Pilot Lamp for Remote Indication(Alarm, 5,6 Each Cycle)

8

9

10 *PLO3 *PLO4 *PLO4

*PLO4 *PLO5 *PLO5

12

*PLO6

Indication Lamp Power Supply Remote Control Wiring and Remote Indication Wiring (If Required)

(For No.1 Unit) 9

11

240~300AHYZ1 330~360AHYZ1 360~400AHYZ1


INSTALLATION Water Piping When piping connections are performed: 1.

Connect all pips with flanges as close possible to the unit, so that disconnection can be easily performed when required.

2.

It is recommended for the piping of the chilled water inlet and outlet that flexible joints be utilized, so that vibration will not be transmit.

3.

Whenever permissible, sluice valves should be utilized for water piping, in order to minimize flow resistance and to maintain sufficient water flow.

4.

Proper inspection should be performed to check for leaking parts inside and outside the system, by completely opening the chilled water inlet and outlet valve, Additionally, equip valves to the inlet and outlet piping. Equip an air purge cock on the inlet piping and a drain cock on the outlet piping. The cock handle should be removed so that the cock can not be opened under normal circumstances. If this cock is opened during operation, trouble will occur due to water blow-off.

5.

Sufficiently perform insulation to keep the chilled water piping cool and to prevent sweating of the piping.

6.

Under the condition where the ambient temperature is low in winter. There is a case where equipment and piping will become damaged during shutdown periods at night, because the water in the pump or piping will be frozen. To prevent freezing of the water. It is effective to operate the pumps even during the shutdown periods. In the case where there is still a danger of freezing, completely drain the water from the piping. Additionally, in a case where measures such as water draining are difficult, utilize antifreeze mixture of ethylene glycol type or propylene glycol type.

CAUTION Never use an antifreeze mixture of the salt type. Because it possesses strong corrosion characteristics, and water equipment will be damaged. In case of connecting some units to the same water piping, design the water piping so that the water distribution to each unit is equal (Refer to figure below).Imbalance of water distribution may cause a serious damage like a water freezing in the heat-exchanger.

Chilled Unit

Water Pump

Heat Load Side

10


INSTALLATION Minimum Internal System Water Volume To ensure the cooling operation at least 5 minutes without interruption, the internal chilled water volume in the piping system should be greater than the minimum volume as shown below. Minimum Internal System Water Volume (m3) Model

RCU(G)75AHYZ1 RCU(G)100AHYZ1 RCU(G)120AHYZ1 RCU(G)150AHYZ1 RCU(G)180AHYZ1 RCU(G)200AHYZ1 RCU(G)240AHYZ1

Minimum internal System Volume Model

0.75

1.35

1.50

1.50

2.25

2.25

3.00

RCU(G)270AHYZ1 RCU(G)300AHYZ1 RCU(G)330AHYZ1 RCU(G)350AHYZ1 RCU(G)360AHYZ1 RCU(G)380AHYZ1 RCU(G)400AHYZ1

Minimum internal System Volume

3.00

3.00

3.75

3.75

4.50

4.50

4.50

Note: Minimum internal system water volume in the above table is for standard ON/OFF differential. In case of changing ON/OFF differential, minimum internal system water volume shall be increased as follows. ON/OFF Differential

Minimum Internal System Water Volume

2 (Standard)

100%

1.5

130%

1

200% Internal Water Volume in Water Cooler (m3) Model RCU(G)75AHYZ1 RCU(G)100AHYZ1 RCU(G)120AHYZ1 RCU(G)150AHYZ1 RCU(G)180AHYZ1 RCU(G)200AHYZ1 RCU(G)240AHYZ1 RCU(G)270AHYZ1 RCU(G)300AHYZ1 RCU(G)330AHYZ1 RCU(G)350AHYZ1 RCU(G)360AHYZ1 RCU(G)380AHYZ1 RCU(G)400AHYZ1

11

Water Cooler 0.07 0.14 0.14 0.14 0.21 0.21 0.28 0.28 0.28 0.35 0.35 0.42 0.42 0.42


INSTALLATION Water Control

CAUTION When industrial water is applied for chilled water or condenser water, industrial water rarely causes deposits of scales or other foreign substances on equipment. However, well water or river water may in most cases contain suspended solid matter, organic matter, and scales in great quantities. Therefore, such water should be subjected to filtration or softening treatment with chemicals before application as chilled water. Sand or mud contained in chilled water can settle down in the water cooler and restrict the flow of water, causing a freezing accident. It is also necessary to analyze the equality of water by checking PH ,electrical conductivity, ammonia ion content sulphur content, and others, and to utilize industrial water only if problem is encountered through these checks. The following is the HITACHI standard water quality based on the JRA standard water quality. Table. 1 tendency1)

Chilled water system

Item

Circulating water (20℃ less than)

Supply water

6.8 ~ 8.0

6.8 ~ 8.0

Standard quality pH (25℃)

Corrosion Deposits of scales ○

○ ○

Electrical conductivity(mS/m)(25℃) (2)

Less than 40

Less than 30

Chlorine Ion( mgCl―/ l ) Sulfur acid ion ( mgSO42―/ l ) The amount of acid consumption (pH4.8) ( mgCaCO3/ l )

Less than 50

Less than 50

Less than 50

Less than 50

Less than 50

Less than 50

Total Hardness( mgCaCO3/ l )

Less than 70

Less than 70

Calcium Hardness ( mgCO3/ l )

Less than 50

Less than 50

Silica L ( mgSiO2/ l )

Less than 30

Less than 30

Less than 1.0

Less than 0.3

Less than 1.0

Less than 0.1

Less than 1.0

Less than 0.1

Less than 0.3

Less than 0.3

Less than 4.0

Less than 4.0

-

-

Reference quality Total iron (mgFe/ l ) Total copper (mgCu/ l ) Sulpher ion ( mgS2―/ l )

Ammonium ion ( mgNH4+/ l ) Remaining chlorine ( mgCl/ l ) Floating carbonic acid ( mgCO2/ l ) Index of stability

Note: (1)The Mark “○” in the table means the factor concerned with the tendency of corrosion or deposits of scales.

Installation Final Check Inspect the installation work according to all documents and drawings, Table.2 shows the minimum check points. Table.2 Installation work check list 1. 2.

Is the unit solidly mounted and leveled? Is the installation location adequate?

4. Is electrical wiring system adequate?

Space for Condenser Air Flow

Tightened Connections

Switch Size

Operation Control Devices

Space for Maintenance Work

Fuse Size

Safety Devices

Noise and Vibration

Voltage and Hz

Interlock

Sunshine and Vibration

5.

Have the R, S and T phases of the water chiller correctly been connected to the R, S and T phases of the main power source, respectively?

6.

Are the stops valves for the condenser liquid line open?

7.

Have the packing glands and the cap nuts for the stop valves been tightened?

Appearance 3.

Wire Size

Is the water piping system adequate? Tube Size Water Drain Length

Water Control

Flexible Joint

Air Purge

Insulation

Pressure Control

12


INSTALLATION

3. Test Running Preparation Tools and Instruments – High Pressure Compound Gauge. Low Pressure Compound Gauge. Electrical Tester and general Tools.

CAUTION Switch ON the main power switch, and energize the oil heater for 12 hours before start-up, to sufficiently warm the oil. Check to ensure that valves are correctly opened. If not opened, serious damage will occur to the compressor due to an abnormally high pressure. Remove the foreign particles and substances from the water piping perfectly by operating the water pump to circulate the chilled water through the chilled water piping without going through the water coolers . Check to ensure that no foreign particle and substance exists in the chilled water piping. Test Running Test running should be accomplished as follows. When the unit is wired according to HITACHI standard wiring label. Switch ON the field-supplied pump and the pump will be started immediately. Check the condition and operation state of these components. Fully open the liquid line stop valve. Set the operation switch to “ON�, and the compressor will be started in a few minutes after this operation. Test running should be accomplished as follows.

CAUTION When the unit is wired according to the HITACHI standard wring shown ON the wring label. Switch on the main power switch, and energize the oil heater for 12 hours before start-up to sufficiently warm the oil Each rotation direction of two rotors in the compressor is fixed so that a reversal protection device is equipped. However, the rotation direction should be checked with a following method. Confirm that phases R, S and T for the compressor are correctly connected. The correct phase connection can be checked by a phase sequence indicator. If not, the compressor does not start due to the activation of the reversal phase protection device. Cut the main switch and interchange two of the three terminals, R, S and T on the main terminals at the field connection side in the unit. a. Operate the pump for chilled water and other auxiliary equipment such as fan coil units and air handing units. Check to ensure that the chilled water flow sufficiently and that other auxiliary equipment operates properly. b. Set the dial switch at the desired temperature. c. Press the ON push button, the condenser fans will start to operate and the compressor will be started. d. Check the rotation direction of the condenser fans. e. After system operation becomes stabilized, check the discharge and suction pressure by 7-segment on control panel. Refer to the discharge and suction pressure curves in page30. f. Check to ensure that the control and protective devices function properly (Refer to Table 3 in pages 29. g. Starting timer and unload-starting timer are set at five (5), thirty (30) seconds and three(3) minutes, respectively, in accordance with operation characteristics. Therefore, local adjustment should be avoided. Note A loud sound occurs when this compressor is stopped after the normal operation. However, this sound indicates no abnormalities and stops within a few seconds by the activation of the check valve. This sound is due to the reverse rotation of the compressor rotor, resulting from the pressure deference between the discharge and suction pressure. Each compressor may show the different values of running current due to individual capacity control for each compressor.

Instruction after Test Running When the test running is completed, please instruct customers about operation and periodic maintenance methods before leaving the unit, by using Installation, Operation and Maintenance Manual. A special attention is required to the following items.

CAUTION Do not cut off the power source switch during the operating season. When the power source switch is cut off, the oil heater for screw compressor is not energized, and the compressor might be damaged due to oil foaming at starting. When the power source switch is cut off for a long period unit shutdown, please turn on the power source switch 12 hours before starting operation to energized the oil heater. 13


CONTROLLER ADJUSTMENT

4. CONTROLLER ADJUSTMENT

Fig.7 Location of Controller

Controller adjustment Setting, functions are followings. Chilled Water Temperature Setting Switch=RSW1 and RSW2 ☆ Switches”RSW1” and “RSW2” are used for setting a required chilled water outlet temperature. =7 for chilled water outlet temperature is recommended. The RSW1 and RSW2 dials are already set at 7 and 0 at factory. Setting at the figures from 3 to 9 of the RSW2 dial should not be permitted. 14


CONTROLLER ADJUSTMENT Differential Setting Switch (Neutral Zone Setting Switch) =RSW8 ☆ =2 is standard. The RSW8 dial is already set at 3=2 . The figures at the RSW8 dial mean as follow. Figure Band ( )

0

1

2

3

4

5

6

7

8

9

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

Continuous Capacity Control Setting Switch=DSW5 ☆Temperature band for stop setting switch =1 is standard. The figure 1 and 2 of the DSW5 switch are already set at figure 1=ON side, figure 2=OFF side. The location at the figure 1 and 2 of the DSw5 switch mean as follow. Figure Location

1

2

1

2

1

2

1

2

ON

ON

ON

OFF

OFF

ON

OFF

OFF

Band( )

0.5

1.0

1.5

2.0

Standard

DSW7-3 ON

1.0

1.5

2.0

2.0

Wide min. load

☆ Temperature Band for Restart Setting Switch =2 is standard. The figure 3 and 4 of the DSW5 switch are already set at figure 3=ON side, figure 4=OFF side. The location at the figure 3 and 4 of the DSW5 switch mean as follow. Figure Location

3

4

3

4

3

4

3

4

ON

ON

ON

OFF

OFF

ON

OFF

OFF

Band(degree)

1.0

2.0

3.0

4.0

☆ Differential Temperature of Load-up 2 Mode Setting Switch =1 is standard. The figure 5 of the DSW5 switch is already set at ON side. The location at the figure 5 of the DSW5 switch mean as follow. Figure Location

5

5

ON

OFF

Band(degree)

1.0

3.0

☆ Output Signal Time for Load-up 1 Mode Setting Switch =12 second is standard. The figure 6 of the DSW5 switch is already set at ON side. The location at figure 6 of the DSW5 switch mean as follows. Figure Location

6

6

ON

OFF

Time(second)

12

24

☆ Output Signal Time of the Load-up 2 and Load-down Mode Setting Switch =4 second is standard. The figure 7 and 8 of the DSW5 switch are already set at figure 7=ON side, figure 8=OFF side. The location at figure 7 and 8 of the DSW5 switch mean as follows. Figure

7

8

7

8

7

8

7

8

Location ON ON ON OFF OFF ON OFF OFF Time(second) 2 4 6 8 Interval of Output Signal Time for Load-up and Load-down Mode Setting Switch. =60 second is standard. The figure 9 and 10 of the DSW5 switch are already set at figure 9=ON side, figure 10= ON side. The location at figure 9 and 10 of the DSW5 switch mean as follows. Figure Location Time(second) 15

9

10

9

10

9

10

9

10

ON

ON

ON

OFF

OFF

ON

OFF

OFF

60

90

120

30


CONTROLLER ADJUSTMENT Setting of Compressor Cycling Protection Start=figures 1 and 2 of DSW2 Switches”DSW2-1’and ”DSW2-2’ are used for setting the compressor Cycling protection timer. Set the operation switch to ‘ON” side, the compressor will be started after this setting time (3 minutes is standard.).Factory set of switch ”DSW2’ is 3.The meaning of the figure at switch”DSW2” is as follow. DSW2

Time

1

2

(Minute)

ON

ON

0.5

OFF

ON

10

ON

OFF

6

OFF OFF 3 No. of Cycle for Checking High Pressure Cut-Off Setting Switch= figures 3 and 4 of DSW2 Switches”DSW2-3’and”DSW2-4’ are used for setting the No. of cycle for checking high pressure cut-off. If necessary to check high pressure cut-off, Set these switches and depress “SW9” or “SW10” during operation. (This function is available during “Local Operation”.) DSW2

Depress Switch

3

4

SW9

SW10

OFF

OFF

No.1 Cycle

No.2 Cycle

ON

OFF

No.3 Cycle

No.4 Cycle

OFF

ON

No.5 Cycle

No.6 Cycle

Manual Set Switch =figure 1, 2, 3, 4, 5 and 6 of DSW3 Switch “DSW3-1” is for No.1 compressor, Switch “DSW3-2” is for No.2 compressor, Switch “DSW3-3” is for No.3 compressor, Switch “DSW3-4” is for No.4 compressor. Switch “DSW3-5” is for No.5 compressor. If necessary to stop any compressors, turn these switches (DSW3-1, DSW3-2, DSW3-3, DSW3-4 and DSW3-5) to “OFF” side, the compressors corresponding to these switches which are turned to the “OFF” side will be stopped. NOTE 1. Switch”DSW3-2” shall be always turned to the “OFF” side in RCU(G)75AHYZ1. 2. Switch”DSW3-3 shall be always turned to the “OFF” side in RCU(G)75AHYZ1.~RCU(G)150 AHYZ1. 3. Switch”DSW3-4” shall be always turned to the “OFF” side in RCU(G)75AHYZ1~RCU(G)200 AHYZ1. 4. Switch”DSW3-5” shall be always turned to the “OFF” side in RCU(G)75AHYZ1~RCU(G)300 AHYZ1. 7- Switch”DSW3-6” shall be always turned to the “OFF” side in RCU(G)75AHYZ1~RCU(G)350 AHYZ1. Selection Switch for Cooling/Heating Operation =SW8 =Models: RCU75AHYZ1~RC400 AHYZ1 are for cooling only. So that heating function is not available. The SW8 selection switch must be turned to upper side. Selection Switch for Local/Remote Operation=SW6 =Remote operation is standard. So that the SW6 selection switch is turned to the lower side. If local operation is necessary, the SW6 selection switch is turned to the upper side. Selection Switch for Local/Remote Pump Operation=SW7 =The SW7 selection switch is turned to the lower side (OFF). If local operation is necessary, the SW7 selection switch is turned to the upper (“ON”) side. Other switches=SW5,the figures 7,8,9 and 10 of the DSW3 switch, the figures 1,2 and 3 of the DSW6, the figures 1,2 and 4 of the DSW7,DSW4 and RSW3,4,9 and DSW 1. This control panel is equipped with other switches: the SW5 selection switch for chilled water/brine, the figures 7,8,9 and 10 of the DSW3,the figures 1,2 and 3 of DSW6,the figures 1,2 and 4 of DSW7 and RSW3,4,9 selection switch for operation mode. Setting change of these switches are not available. It is recommended that the setting is not changed at site.Also, the DSW1 switch is equipped with. This switch is used for only checking, resulting in easy troubleshooting. 16


CONTROLLER ADJUSTMENT

Unit Setting of PWB The same CPUs as hardware are used with the master, subsidiary and independent units. Therefore, it is required to set the PWB “Master”,” Subsidiary” or ”Independent” before operation and after self check of PCB. The PWB original setting is”Subsidiary”. The models and required PWB setting are as follows. Independent…RCU(G)75AHYZ1,

RCU(G)100AHYZ1,

RCU(G)120AHYZ1,

RCU(G)150AHYZ1,

RCU(G)180AHYZ1,

RCU(G)200AHYZ1 Master……….. RCU(G)240AHYZ1-No.1unit ~RCU(G)400AHYZ1-No.1 unit Subsidiary…… RCU(G)240AHYZ1-No.2unit ~RCU(G)400AHYZ1-No.2 units The setting procedure is as follows. 1)

Set DSW1-1 to “ON”.

2)

Supply power to the unit.

3)

Set DSW1-1, 3 to “ON” and DSW8 to “4”.

4)

Then “24” and “LO” is indicated.

5)

Set DSW1-2, 3, 4 to “ON” and RSW8 “2”.

6)

The present setting is indicated, and checks the setting of PWB. The indicated code is shown in the below table. If the PWB setting is different from required setting, change the PWB as following procedure.

SEG1

SEG2

Setting Independent Master Subsidiary

Indicated Code Table 7)

Change the indication mode to setting change mode by pressing the “△” and ”

“ switches simultaneously for more

than 3(three) seconds. If the mode is changed, indicated code of SEG1is changed from “U1” to “U2”. Check whether the mode is changed or not and change to the required setting by pressing the “△” or ” 8)

Change the setting change mode to indication mode by pressing the “△” and ”

“ switch for 1(one) second. “ switches simultaneously for more

than 3(three) seconds. The PWB setting is registered at this moment. Check to ensure that the mode is changed to the indication mode to check the indicated code of SEG1 is changed to “U1”.If this procedure is not performed, the setting is not registered in PWB. 9)

After setting, cut power supply. And reset the DSW1-1, 2, 3, 4 and RSW8 to the original position.

If setting is unsuitable, unit will not operate. When new PCB is replaced, please set as above method.

Final Check Supply power to the unit, and check for any alarm code. If alarm occurs, check for loosen connectors and position of the thermistor connectors.

17


SELF-INSPECTION FUNCTIONS

5. SELF-INSPECTION FUNCTIONS (1) Alarm Indication If the unit is operated under abnormal conditions, an alarm code (refer to the table below) is indicated and the “alarm” LED lamp is lighted. Function of 7-segment light emitted diode on control panel is as shown in the table below.

7-Segment on Control Panel

C1-H1 C1-L1 C1-F1

C2-H2 C2-L2 C2-F2

Code C3-H3 C4-H4 C3-L3 C4-L4 C3-F3 C4-F4

C5-H5 C5-L5 C5-F5

Content C6-H6 Activation of High Pressure Switch C6-L6 Alarm of Excessively Low Suction Pressure. C6-F6 Activation of Overcurrent Relay for Fan Motor

C1-t1

C2-t2

C3-t3

C4-t4

C5-t5

C6-t6

C1-41 C1-51 C1-61

C2-42 C2-52 C2-62

C3-43 C3-53 C3-63

C4-44 C4-54 C4-64

C5-45 C5-55 C5-65

C6-46 Activation of Internal Thermostat for Fan Motor C6-56 Activation of Overcurrent Relay for Compressor C6-66 Activation of Supplying Oil Protection by Thermistor (THMD1~6)

C1-71 C1-81

C2-72 C2-82

C3-73 C3-83

C4-74 C4-84

C5-75 C5-85

C6-76 Activation of Internal Thermostat for Comp. Motor C6-86 Activation or Freeze Protection by Thermistor (THMo1~6).

C1-P6 80 5P

C2-P6 80 5P

C3-P6 80 5P

C4-P6 80 5P

C5-P6 80 5P

C6-P6 Excessively Low Suction Pressure Retry Control. 80 Activation or Freeze Protection byThermistor (THMi1). 5P Abnormal Condition of Feed Back Signal from Pumps

C1-05 11 C1-12

C2-05 11 C2-12

C3-05 11 C3-12

C4-05 11 C4-12

C5-05 11 C5-12

C1-23

C2-23 C3-23

C4-23

C5-23

C1-25

C2-25

C3-25

C4-25

C5-25

C1-26 C1-27

C2-26 C2-27

C3-26 C3-27

C4-26 C4-27

C5-26 C5-27

C1-28

C2-28

C3-28

C4-28

C5-28

22 40

22 40

22 40

22 40

22 40

C6-05 Abnormality in Reverse Phase or Signal Phase 11 Abnormality in Thermistor for Chilled Water Inlet (THMi1). C6-12 Abnormality in Thermistor for Chilled Water outlet (THMo1 ~6). C6-23 Abnormality in Thermistor for Discharge Gas Temperature (THMD1~6). C6-25 Abnormality in Thermistor for Freeze Protection (THMoB1 ~6). C6-26 Abnormality in Thermistor for Suction Gas (THMS1~6). C6-27 Abnormality in Pressure Sensor for Discharge Pressure (PDCN1~6). C6-28 Abnormality in Pressure Sensor for Suction Pressure (PSCN1~6). 22 Alarm of Thermistor for Ambient Temperature (THMa) 40 Alarm for Operation Error.

Remarks NO.1,NO.2,NO.3,, NO.3,NO.4,,NO.5 and NO.6

Alarm of Excessively Low Suction Gas Temperature (THMS1~6)

Immediately after Operation

NO.1,NO.2,NO.3,, NO.3,NO.4,,NO.5 and NO.6

(2) Nominal Indication If the unit is operated under a normal operation condition, the operation code (refer to the table below) is indicated on 7-Segment LEDs of the control panel.

C1-88

C2-88

Code C3-88 C4-88

C5-88

Content C6-88 Power Supply,After Stoppage

C1-Co

C2-Co

C3-Co

C4-Co

C5-Co

C6-Co Cooling Operation

C1-oF

C2-oF

C3-oF

C4-oF

C5-oF

C6-oF Stoppage by Thermostat

C1-PU

C2-PU

C3-PU

C4-PU

C5-PU

C6-PU Pump Operation Only,Waiting of Pump Feed Back

C1-Ct

C2-Ct

C3-Ct

C4-Ct

C5-Ct

C6-Ct Activation of Current Limiter

C1-C.o

C2-C.o

C3-C.o

C4-C.o

C5-C.o

C6-C.o Activation of Switch for Checking High Pressure Cut-off

Remarks

18


SELF-INSPECTION FUNCTIONS (3) Function for Indication of Operation Condition The setting temperature, chilled water temperature sensed at the thermistor, suction, discharge pressure sensed by pressure sensor,the setting differential temperature and the last alarm code are digitally indicated on the control panel.

This indication mode is change to the normal mode by pressing the check “ ”and “ ”switches simultaneously for more than 3(three) seconds again, or automatically changed when 30 seconds pass after operating the switch.

Press the check “ ” switch for more than 3 (three) seconds.

Normal Operation Condition “88”“Co”“oF”

The Alarm Code Occurrence Data

Checking Indication This indication mode is changed to the normal mode by pressing the check “ ”switch for more than 3(three) seconds again, or automatically changed when 30 seconds pass after operating the switch.

Press the check “ ”and“ ”switches simultaneously for more than 3 (three) seconds. Press the check “ ”switch for more than 3 (three) seconds.

This indication mode is changed to the normal mode by pressing the check “ “ and “ “switches simultaneously for more than 3(three) seconds again, or automatically changed when 30 seconds pass after operating the switch.

Capacity Control Indication This indication is available only while the check “ ”switch is pressed.

Note: Each indication mode shall be changed from the normal mode.

19


SELF-INSPECTION FUNCTIONS Checking Indication

In

Case

of

No.1

Cycle

Discharge

The alarm code occurred last “ ”

Press the check “ ” Switch

P

h

h k“ ”

i h

No.1 Unit Operation Conditions “ ”

“ ”

Discharge Pressure (MPa) Suction Pressure (MPa) Suction Gas Temperature (℃)

This dot shows checking indication mode.

No.2 Unit Operation Conditions “ ”

“ ”

Discharge Pressure (MPa) Suction Pressure (MPa) Suction Gas Temperature (℃)

In Case of No.4 Cycle Suction Gas Temp.2

No.3 Unit Operation Conditions Discharge Pressure (MPa) Suction Pressure (MPa) Suction Gas Temperature (℃) “ ”

“ ”

In Case of Chilled Water Outlet Temp.7

Inlet Water Temperature(℃)

““ ””

“ “” ”

Outlet Water Temperature(℃) In Case of Setting Water Outlet Temp.12 “ ” “ ” “ ” “ ” Setting Water Temperature(℃) “ ”

“ ”

Neutral Zone temperature( ) “ ”

“ ”

In Case of Ambient Temperature 35

Ambient Temperature ( ) “ ”

“ ”

ROM Version No. In Case of ROM Version No. 190

20


SELF-INSPECTION FUNCTIONS (4) Indication Mode of Alarm Occurrence Data The content of abnormal stoppage including activation of safety devices is memorized and indicated on the control panel. Alarm Occurrence Data (Max.10 data)

In case of No.1 cycle high pressure alarm occurrence.

Press the check “

” Switch

In case of No.2 cycle high pressure alarm occurrence.

NOTE 1. 2.

21

This indication mode is automatically changed to the normal mode when 30 seconds pass after operating the switch If an abnormal operation is occurred under this indication mode, this indication mode is changed to the alarm indication mode.


SELF-INSPECTION FUNCTIONS

Capacity Control Indication ”Example

No.1 Compressor Load Up Change Automatically No.2 Compressor Hold

No.3 Compressor Load Down No.4 Compressor Thermo-off Starting Control

Normal Mode

22


CONTROL SYSTEM

6. CONTROL SYSTEM Standard Operating Sequence for RCU(G)75AHYZ1 Control Stage Control Devices Main Power Switch Water Pump Operation Switch (ON/OFF) Load up Controller Neutral Load down Safety Devices No.1 Pilot Lamp Motor for Fan MF11~14 Oil Heater CH1

OFF — — — — — CLS OFF OFF OFF

ON OFF — — — — CLS OFF OFF ON

ON ON — — — — CLS OFF OFF ON

Motor for Compressor

MC1

OFF

OFF

OFF

Solenoid Valve

SV11 SV12 SV13

OFF OFF OFF

OFF OFF OFF

OFF OFF OFF

Starting Control ON ON ON — — — CLS ON OFF OFF

ON ON — — — — CLS ON ON OFF STA OFF (ULD) 15% ON ON OFF OFF OFF OFF 3 min.

Capacity Control

ON ON ON ON — — — — — — — CLS CLS ON ON ON ON OFF OFF DLT DLT (ULD) (ULD) 15% 15-99% ON OFF OFF OFF OFF ON

ON ON — — — CLS ON ON OFF DLT (FLD) 100% OFF OFF ON

ON ON — — — CLS ON ON OFF DLT (FLD) 100% OFF OFF OFF

ON ON — — —

ON ON — —

Safety Devices

ON ON — — —

— CLS CLS CLS ON ON ON ON ON ON OFF OFF OFF DLT DLT DLT (ULD) (ULD) (ULD) 15-99% 15-99% 15% OFF OFF OFF ON OFF ON OFF OFF OFF

ON ON — — —

ON ON — —

ON ON — —

— CLS ON ON OFF DLT OFF (ULD) 15-99% ON OFF OFF OFF OFF OFF CLS ON OFF ON

Shut Down

— OPN FLK OFF ON

ON ON OFF — — — CLS OFF OFF ON

OFF

OFF

OFF OFF OFF

OFF OFF OFF

ON ON — — — CLS ON ON ON DLT (FLD) ※100% OFF OFF OFF

ON OFF OFF — — — CLS OFF OFF ON

OFF OFF — — — — CLS OFF OFF OFF

OFF

OFF

OFF OFF OFF

OFF OFF OFF

5 sec. 30 sec. Minimum 3min.

Time Schedul

CLS:Close,OPN:Open,STA:Star,DLT:Delta ULD: Unload,FLD:Full Load,FLK: Flicker

Standard Operating Sequence for RCU(G)100AHYZ1, RCU(G)120AHYZ1, RCU(G)150AHYZ1, Control Stage Control Devices Main Power Switch Water Pump Operation Switch (ON/OFF) Load up Neutral Controller Load down No.1 Safety Devices No.2 Pilot Lamp MF11~14 Motor for Fan MF21~24 CH1 Oil Heater CH2

Starting Control OFF — — — — — CLS CLS OFF OFF OFF OFF OFF

ON OFF — — — — CLS CLS OFF OFF OFF ON ON

ON ON — — — — CLS CLS OFF OFF OFF ON ON

ON ON ON — — — CLS CLS ON OFF OFF ON ON

MC1

OFF OFF OFF OFF

MC2

OFF OFF OFF OFF

SV11 SV12 SV13 SV21 SV22 SV23

OFF OFF OFF OFF OFF OFF

Motor For Compressor

Solenoid Valve

OFF OFF OFF OFF OFF OFF

OFF OFF OFF OFF OFF OFF

ON OFF OFF ON OFF OFF

Capacity Control

ON ON ON ON ON ON ON ON — — — — — — — — — — — — — — — — CLS CLS CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON OFF OFF ON ON OFF OFF OFF OFF ON ON OFF OFF STA DLT STA DLT (ULD) (ULD) (ULD) (ULD) 15% 15% 15% 15% STA DLT OFF OFF (ULD) (ULD) 15% 15% ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF

3 min.

ON ON —

ON ON —

ON ON — —

— — — — CLS CLS CLS CLS ON ON ON ON ON ON OFF OFF OFF OFF DLT DLT (ULD) (FLD) 15-99% 100% DLT DLT (ULD) (FLD) 15-99% 100% OFF OFF OFF OFF ON ON OFF OFF OFF OFF ON ON

5 sec.

5 sec.

60 sec.

30 sec.

ON ON — — —

ON ON — —

— — CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF DLT DLT DLT (FLD) (ULD) (ULD) 100% 15-99% 15-99% DLT DLT DLT (FLD) (ULD) (ULD) 100% 15-99% 15-99% OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF

Safety Devices

ON ON — — —

ON ON — — —

CLS CLS ON ON ON OFF OFF DLT (ULD) 15% DLT (ULD) 15% OFF ON OFF OFF ON ON

CLS CLS ON OFF OFF ON ON OFF

OFF ON OFF OFF ON OFF OFF

ON ON — —

ON ON —

ON ON —

Shut Down ON ON OFF — — — CLS CLS OFF OFF OFF ON ON

ON ON — —

— — — — — — CLS OPN OPN CLS CLS CLS OPN CLS ON FLK FLK ON ON OFF OFF ON ON ON OFF OFF OFF ON ON ON OFF OFF ON ON DLT DLT (ULD) OFF OFF OFF (FLD) 15-99% 100% DLT DLT DLT (ULD) (ULD) OFF OFF (FLD) 15-99% 15-99% 100% OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF

ON OFF OFF — — — CLS CLS OFF OFF OFF ON ON

OFF OFF — — — — CLS CLS OFF OFF OFF OFF OFF

OFF OFF

OFF OFF OFF OFF OFF OFF OFF OFF

OFF OFF OFF OFF OFF OFF

Minimum 3min. Time Schedul

The compressor which stopped first will be started first.

CLS:Close,OPN:Open,STA:Star,DLT:Delta ULD: Unload,FLD:Full Load,FLK: Flicker

23


Standard Operating Sequence for RCU(G)180AHYZ1, RCU(G)200AHYZ1 Control Stage Control Devices ON OFF — — — —

ON ON — — — —

ON ON ON — — —

ON ON — — — —

ON ON — — — —

ON ON — — — —

ON ON — — — —

ON ON — — — —

ON ON — — — —

ON ON —

ON ON —

— —

— —

MF11~14 MF21~24 MF31~34 CH1

CLS CLS CLS OFF OFF OFF OFF OFF

CLS CLS CLS OFF OFF OFF OFF ON

CLS CLS CLS OFF OFF OFF OFF ON

CLS CLS CLS ON OFF OFF OFF ON

CLS CLS CLS ON ON OFF OFF OFF

CLS CLS CLS ON ON OFF OFF OFF

CLS CLS CLS ON ON ON OFF OFF

CLS CLS CLS ON ON ON OFF OFF

CLS CLS CLS ON ON ON ON OFF

CLS CLS CLS ON ON ON ON OFF

CLS CLS CLS ON ON ON ON OFF

CLS CLS CLS ON ON ON ON OFF

CLS CLS CLS ON ON ON ON OFF

CH2 CH3

OFF OFF

ON ON

ON ON

ON ON

MC1

OFF

OFF

OFF

MC2

OFF

OFF

OFF

OFF

OFF

MC3

OFF

OFF

OFF

OFF

OFF

No.1 No.2 No.3

Pilot Lamp Motor for Fan

Oil Heater

Motor For Compressor

Solenoid Valve

ON ON ON ON STA DLT OFF (ULD) (ULD) 15% 15%

OFF OFF DLT (ULD) 15% STA OFF (ULD) 15%

OFF

OFF

OFF OFF DLT (ULD) 15% DLT (ULD) 15%

OFF OFF DLT (ULD) 15% DLT (ULD) 15% STA OFF (ULD)

SV11 SV12 SV13 SV21 SV22 SV23 SV31

OFF OFF OFF OFF OFF OFF OFF

OFF OFF OFF OFF OFF OFF OFF

OFF OFF OFF OFF OFF OFF OFF

ON OFF OFF ON OFF OFF ON

ON OFF OFF ON OFF OFF ON

ON OFF OFF ON OFF OFF ON

ON OFF OFF ON OFF OFF ON

ON OFF OFF ON OFF OFF ON

15% ON OFF OFF ON OFF OFF ON

SV32 SV33

OFF OFF

OFF OFF

OFF OFF

OFF OFF

OFF OFF

OFF OFF

OFF OFF

OFF OFF

OFF OFF

OFF OFF DLT (ULD) 15% DLT (ULD) 15% DLT (ULD)

OFF OFF OFF OFF DLT DLT (ULD) (FLD) 15-99% 100% DLT DLT (ULD) (FLD) 15-99% 100% DLT DLT (ULD) (FLD)

ON ON — —

ON ON — — —

ON ON — —

ON ON — — —

Safety Devices ON ON — — —

— CLS CLS CLS ON ON ON ON OFF

CLS CLS CLS ON ON ON ON OFF

CLS CLS CLS ON ON ON ON OFF

CLS CLS CLS ON OFF OFF OFF ON

100% OFF OFF ON OFF OFF ON OFF

100% 15-99% 15-99% 15% OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFF

ON OFF OFF ON OFF OFF ON

OFF OFF

OFF ON

OFF OFF

OFF OFF

5 sec.

5 sec.

5 sec.

60 sec.

60 sec.

30 sec.

ON ON — —

ON ON —

ON ON —

— —

CLS CLS CLS ON ON ON OFF OFF

OPN CLS CLS FLK OFF ON ON ON

OPN OPN CLS FLK OFF OFF ON ON

OFF OFF OFF OFF ON OFF OFF ON OFF OFF OFF OFF ON OFF OFF OFF DLT DLT DLT DLT DLT OFF OFF (FLD) (ULD) (ULD) (ULD) OFF (ULD) 100% 15-99% 15-99% 15% 15-99% DLT DLT DLT DLT DLT DLT OFF (FLD) (ULD) (ULD) (ULD) OFF (ULD) (ULD) 100% 15-99% 15-99% 15% 15-99% 15-99% DLT DLT DLT DLT DLT DLT DLT (FLD) (ULD) (ULD) (ULD) OFF (ULD) (ULD) (ULD)

15% 15-99% ON OFF OFF OFF OFF ON ON OFF OFF OFF OFF ON ON OFF OFF ON

ON ON — —

ON OFF

OFF OFF

ON OFF

Shut Down ON ON — —

— —

ON ON OFF — — —

OPN OPN OPN FLK OFF OFF OFF ON

CLS CLS CLS OFF OFF OFF OFF ON

ON ON

ON ON

OFF

OFF

OFF

15-99% 15-99% 15-99% OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

OFF OFF

OFF ON

OFF OFF

ON OFF OFF — — —

OFF OFF — — — —

CLS CLS CLS ON ON ON ON OFF

CLS CLS CLS OFF OFF OFF OFF ON

CLS CLS CLS OFF OFF OFF OFF OFF

OFF ON OFF ON DLT OFF (FLD) OFF 100% DLT OFF (FLD) OFF 100% DLT OFF (FLD) OFF

OFF OFF OFF

OFF

OFF

OFF OFF OFF OFF OFF OFF OFF

100% OFF OFF OFF OFF OFF OFF OFF

OFF OFF OFF OFF OFF OFF OFF

OFF OFF OFF OFF OFF OFF OFF

OFF OFF

OFF OFF

OFF OFF

OFF OFF

Minimum 3min.

The compressor which stopped first will be started first. CLS:Close,OPN:Open,STA:Star,DLT:Delta ULD: Unload,FLD:Full Load,FLK: Flicker

24

CONTROL SYSTEM

3 min. Time Schedule

Capacity Control

OFF — — — — —

Main Power Switch Water Pump Operation Switch (ON/OFF) Load up Neutral Controller Load down Safety Devices

Starting Control


MAINTENANCE

7. MAINTENANCE The unit should be periodically inspected according to the same items as those described in the paragraph titled “Test Running”. In order to ensure dependable performance and long life operation, the following additional items should be given particular attention.

WARNING If a fire accidentally occurs, turn OFF the main switch and use an extinguisher for an oil fire and an electric fire. Do not operate the unit near flammable gases such lacquer, paint, oil, etc. to avoid a fire or an explosion. Turn OFF the main switch when electrical box covers are removed for setting the temperature. Do not operate the unit without fixing panels.

WARNING Performed periodical maintenance according to the “INSTRUCTIONS” to maintain the unit in a good condition. Do not touch the parts at the discharge gas side by hand, since the pips at the discharge side are heated by refrigerant and the temperature becomes higher than 100 。 Do not utilize this unit for cooling or heating of drinking water or food. Comply with local codes and regulation. Turn OFF all the main switches if refrigerant leakage or chilled water leakage occurs. Also, if the unit can not be stopped by the control switch, turn OFF all the main switches for power supply.

Components Compressor - Roller bearing and ball bearing are utilized in HITACHI screw compressor. The operation life of the bearings is approximately 40,000 hours or 5 (five) years after installation so the replacement of the bearings for compressor is required every 40,000 hours of the compressor operation or every 5(five) years. For the details, refer to the service handbook for HITACHI screw compressors. Air-Cooled Condenser – Inspect the condenser and remove any accumulated dirt from the coil, at regular intervals. Other obstacles such as growing grass and pieces of paper, which might restrict air flow, should also be removed. Electrical Equipment - Always pay careful attention to working voltage, amperage, and phase balance. Check for faulty contact caused by loosened terminal connections; oxidize contacts, foreign matter and others. Control and Protective Devices - Do not readjust the settings in the field unless the setting is maintained at a point other than the point listed in Table 3.

Lubrication Compressor - The compressors are charged at the factory with the correct oil listed in “Component Detailed Data” in the HITACHI Technical Catalog I and the compressor nameplate. It is not necessary to add oil, if the refrigerant cycle remains sealed. Fan Motor –Bearing of all fan motors are pre-lubricated. Lubrication is not required.

25


MAINTENANCE Winter Showdown When shutting down the unit for winter, clean the inside and outside of the cabinet, and dry the unit. Pump down the refrigerant to the condenser and close the liquid outlet stop valves. The unit should be covered during shutdown, in order to protect it from dust and environmental conditions, be sure to tighten the packing glands and the cap nuts of the valves. Remove the drain plug and drain all residual water from the condenser and water cooler piping systems, as such water may freeze during the cold season, it is very helpful to supply anti-freezer to the piping systems.

Spring Start-up After any extended shutdown period, prepare the unit for operation as follows: 1. Thoroughly inspect and clean the unit. 2. Clean the water piping lines. 3. Inspect the pump and other auxiliary equipment in the piping line. 4. Tighten all wiring connections and access panel.

CAUTION When the main switch for this unit has been at the OFF position for an extended period of time, it should be switch ON at least 12 hours before start-up, so that the oil in the compressor discharge casing may be warmed enough, to prevent oil from foaming by the oil heater during start-up.

Part replacement Replacement of parts should be undertaken by ordering from the HITACHI Spare Parts List.

CAUTION Refrigerant Cycle Refrigerant Charge: Inspect the refrigerant charge of the system by checking the discharge and suction pressure. Perform a leakage test, if any leakage is suspected, and always perform such a test after a refrigerant cycle component is replaced. When the refrigerant charge is required, please follow the following instructions given for two cases: (1) When the refrigerant gas completely leaked‌. Before charging ,the entire cycle must be completely evacuated and dehydrated, a gauge manifold or equivalent piping preparation shown in the next page is recommended as a convenient procedure regarding both charging and evacuation. 1. Fully open all the stop valves. 2. Connect the evacuate line to the check joints of the high and the low pressure sides. 3. Completely evacuate the entire cycle with a vacuum pump. 4. Charge refrigerant to the refrigeration cycle by weighing the charger cylinder. The proper refrigerant charge is listed on the nameplate. 5. When charging by weight is stopped due to high ambient temperature, close the valve and operate the unit after circulating the chilled water through the water cooler. (2) When only additional refrigerant is required‌.. Connect a gauge manifold to check joint of low pressure side, and connect a charge cylinder to gauge manifold. Operate the unit after circulation the chilled water. Repeat the following procedure until pressure becomes proper (refer to page 29). 1. Charge the gas refrigerant a little slowly into refrigeration cycle from check joint for low pressure. 2. Check the pressure after refrigeration cycle becomes stable.

26


MAINTENANCE

Mark Name

Mark

Name

1 2 3 4 5 6

Compressor Condenser Cooler Thermal Expansion Valve Check Valve Liquid Line Stop Valve

10 11 12 13 A B

High Pressure Sensor High Pressure Switch Stop Valve Solenoid Valve High Pressure Gauge Low Pressure Gauge

7 8 9

Fusible Plug Pressure Relief Valve Low Pressure Sensor

C D E

Stop Valve Charging Cylinder Vacuum Pump

27


MAINTENANCE

CAUTION 1.

2.

3.

DO not charge OXYGERN, ACETYLENE or other flammable and poisonous gases into the refrigeration cycle when performing a leakage test or an airtight test, these types of gases are extremely dangerous, because explosion can occur. It is recommended that compressed air, nitrogen or refrigerant is charged for these types of tests. Mineral deposits on the copper tubes act as thermal insulators, and also act as resistance against water flow, causing the water flow to decrease running through them, and resulting in a decreasing of the cooling capacity. Deposits on the the copper tube should be inspected at regular intervals; experience with the water chiller will dictate accurate inspection intervals. These deposits should be removed by circulating diluted acid through the water passes after the water is drained. As water in different localities contains deferent minerals, different acid are required, depending upon the thickness of the deposits. Contact with contractors or dealers of Hitachi, for details. The unit is equipped with an operation hour meter. In the case that the total operation time reaches 24,000 or 3 years pass after installation, exchange the bearings of the compressor. For details, refer to the service handbook for HITACHI screw compressors.

Compressor Removal When Removing the Compressor - Remove the compressor while completing the following procedures: 1. Collect all refrigerant into a condenser before this work. 2. Turn off the switch, DSW3 of the PCB plate in the electrical box in order not to operate the compressor except for this cycle. 3. Circulate the chilled water sufficiently through the water cooler, and operate the water chiller for 10 minutes, and check to ensure that the oil level is maintained at a stable condition. 4. Stop the water chiller and completely close the liquid stop valve. 5. Operate the water chiller after the circulating water through the water cooler. 6. Stop the water chiller when the low pressure reaches at an approximately 0.05Mpa. Do not operate at the pressure lower than 0.05MPa.If operated, it will cause damage to the compressor. 7. Wait for several minutes. If the low pressure increases up to 0.15 to 0.20MPa, repeat the above procedures 5 and 6 four or five times. 8. Turn off the power supply to the unit. 9. Remove the bolts on the discharge and suction flanges of the compressor. (Note: in order to avoid refrigerant jetting, remove the bolts a little slowly to discharge remained refrigerant.) 10. Remove all the wiring of the compressor. 11. Remove the bolts fixing the compressor. 12. Remove compressor.1 to 12 points shown above instruct that remove the compressor during normal maintenance procedures (Example: replacement of compressor bearings). If compressor removal is due to compressor fault (Can not work), please perform maintenance according to 8 to 12 procedure.

28


MAINTENANCE Table 3. Safety and Control Device Setting Model For Compressor High Pressure Control Cut-Out MPa Low Pressure Control Cut-Out MPa Internal Thermostat Cut-Out ℃ Cut-In ℃ Overcurrent Relay 380V 50Hz A Oil Heater Capacity W Discharge Gas Thermostat Cut-Out ℃ Cut-In ℃ CCP Timer Setting Time s Star-Delta s Unloading during Starting s For Control Circuit Fuse A Capacity(220\240V) For Refrigerant Cycle Fusible Plug Melting Temperature ℃ Freeze Protection Control Cut-Out ℃ Overcurrent Relay for Fan Motor 380V 50Hz A Pressure Relief Valve Starting to Open MPa

RCU(G)75AHYZ1 RCU(G)100AHYZ1 RCU(G)120AHYZ1RCU(G)150AHYZ1RCU(G)180AHYZ1RCU(G)200AHYZ1RCU(G)240AHYZ1

2.98 0.05 115 93 88 150 70 100 180 5 30 6

Manual Reset, Adjustable(One Switch for Each Compressor Motor) 2.98 2.98 2.98 2.98 2.98 Control by Micro-Processor 0.05 0.05 0.05 0.05 0.05 Automatic Reset, Non-Adjustable(One Switch for Each Compressor Motor) 115 115 115 115 115 93 93 93 93 93  Manual Reset Adjustable (One Switch for Each Compressor Motor) 67 80 88 80 88 One Oil Heater for Each Compressor Motor 150 150 150 150 150 (One for Each Circuit) 70 70 70 70 70 100 100 100 100 100 Non-Adjustable (One Timer for Each Compressor Motor) 180 180 180 180 180 5 5 5 5 5 30 30 30 30 30 6

6

6

2.98 0.05 115 93 80 150 70 100 180 5 30

6

6

6

72

72

72

(One for Each Circuit) 72 2 3.3 3.13

72

72

72

2 2 2 2 2 Manual Reset, Adjustable(One Three-Phase Set for Each Fan Motor) 3.3 3.3 3.3 3.3 3.3 (One for Each Compressor) 3.13 3.13 3.13 3.13 3.13

2 3.3 3.13

Model RCU(G)270AHYZ1RCU(G)300AHYZ1 RCU(G)330AHYZ1RCU(G)350AHYZ1RCU(G)360AHYZ1RCU(G)380AHYZ1RCU(G)400AHYZ1 For Compressor Manual Reset, Adjustable(One Switch for Each Compressor Motor) High Pressure Control Cut-Out MPa 2.98 2.98 2.98 2.98 2.98 2.98 2.98 Control by Micro-Processor Low Pressure Control Cut-Out MPa 0.05 0.05 0.05 0.05 0.05 0.05 0.05 Internal Thermostat Automatic Reset, Non-Adjustable(One Switch for Each Compressor Motor) Cut-Out 115 115 115 115 115 115 115 ℃ Cut-In ℃ 93 93 93 93 93 93 93 Overcurrent Relay  Manual Reset Adjustable (One Switch for Each Compressor Motor) 380V 50Hz A 88\80 88 80\88 88 80 88\80 88 Oil Heater One Oil Heater for Each Compressor Motor Capacity W 150 150 150 150 150 150 150 Discharge Gas Thermostat (One for Each Circuit) Cut-Out ℃ 70 70 70 70 70 70 70 Cut-In ℃ 100 100 100 100 100 100 100 CCP Timer Non-Adjustable (One Timer for Each Compressor Motor) Setting Time s 180 180 180 180 180 180 180 Star-Delta s 5 5 5 5 5 5 5 Unloading during Starting s 30 30 30 30 30 30 30 For Control Circuit Fuse A 6 6 6 6 6 6 6 Capacity(220\240V) For Refrigerant Cycle Fusible Plug (One for Each Circuit) Melting Temperature ℃ 72 72 72 72 72 72 72 Freeze Protection Control Cut-Out ℃ 2 2 2 2 2 2 2 Overcurrent Relay for Fan Motor Manual Reset, Adjustable(One Three-Phase Set for Each Fan Motor) 380V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 Pressure Relief Valve (One for Each Compressor) Starting to Open MPa 3.13 3.13 3.13 3.13 3.13 3.13 3.13

29


MAINTENANCE Normal Operating Pressure Low pressure: the normal operation low pressure of the water chiller is indicated in the figure below: lower than 0.3 MPa indicates an abnormal condition. High pressure: the normal operation discharge pressure is indicated in the figure below: lower than 0.9 MPa or higher 2.8 MPa indicates an abnormal condition.

CAUTION 1. Periodical Maintenance Please perform periodical maintenance according to the “INSTRUCTIONS� to maintain the unit in a good operation condition. 2. Fire If a fire accidentally occurs, please turn OFF the main switch and use an extinguisher for oil fire or electrical fire 3. Flammable Gas Do not operate the unit near a flammable gases such lacquer, paint, oil, etc. to avoid a fire or an explosion. 4. Maintenance Panel and Electrical Box Covert Turn OFF the main switch when service panel and electrical box cover are removed for setting the temperature. do not operate the unit without fixing panels. 5. Heated Pips Do not touch the parts at the discharge gas side by hand, since the pips at the discharge side are heated by refrigerant and the temperature becomes higher than 100 degree. 6. Use Do not utilize this unit for cooling or heating of drinking water or food. Please comply with local codes and regulation. 7. Failure Please turn OFF all the main switches, if refrigerant leakage or chilled water leakage occurs. Also, if the unit can not be stopped by the control switch, turn OFF all the switches for power source.

30


MAINTENANCE

CAUTION 1. Quick Response Over current Relay This relay charged with mercury. Therefore, comply with local codes and regulations when this relay is scrapped 2. Activation of safety device In the case that one of safety devices is activated and the unit is stopped, remove the cause of the stoppage and restart the unit. The protection devices are utilized to protect the unit from an abnormal operation. Therefore, if one of the safety devices is activated, remove the cause by referring to the “Troubleshooting” in the “INSTRUCTIONS”, or call the local agency. 3. Fuse Utilize a fuse with a specified capacity. Do not use a steel wire or a copper wire instead of a fuse. If an incorrect wire is utilized, a serious accident such as a fire will occur. 4. Safety Devices Do not make a short-circuit at the protection line. If a short-circuit is made, a serious accident will occur. 5. Protection devices setting Do not change the setting of the safety devices, if changed, a serous accident will occur. Do not touch any electrical parts except for the operation switches during the operation. Do not press the button on the magnetic switch, if pressed, a serious accident will occur.

31


MAINTENANCE

Table 4.Test Running and Maintenance Record. MODEL: RCU(G)

MFG.NO. COMPRESSOR

MFG.NO

CUSTOMERS NAME AND ADDRESS DATE: 1. 2. 3. 4. 5.

Is there adequate water flow for the water cooler? Has all water piping been checked for leakage? Have the chilled water pump been fabricated? Has the unit been operated for at least twenty minutes? Check chilled water temperature:

Inlet 6. Check condenser Air Temperature:

Outlet

Inlet Outlet 7. Check suction line temperature and superheat: Suction Line Temperature Superheat 8. Check pressure Discharge Pressure

MPa

MPa

MPa

Suction Pressure 9. Check running current

MPa

MPa

MPa

A

A

A

MPa ℃ MPa ℃ A ℃

MPa

MPa

MPa

MPa

A

MPa

10. Has the unit been checked for refrigerant leakage? 11. Is the unit clean inside and outside? 12. Are all cabinet panels free from ratting? 13. Confirm that each phase for the compressor power source is correctly connected. 14. Is the rotation direction of fan motors correct?

32


MAINTENANCE

Table.5 Daily Operating Records Model: Date: Weather Time of Operation: Start. Ambient

DB

Temperature

WB

Stop: (

Room Temperature Compressor

High

MPa

pressure Low

MPa

pressure Voltage

V

Current

A

Condenser Inlet Air

Inlet(DB)

Temperature

Outlet(DB)

Chilled Water

Inlet

Temperature

outlet

Current for Chilled Water Pump NOTES:

33

A

)


MAINTENANCE

Special Notes on Refrigerant, R407C Please use tools and measuring instruments only for the new refrigerant which directly touch refrigerant. ○: Interchangeability is available with current R22 ●: Only for new Refrigerant R407C (No interchangeability with R22).

Measuring Instruments and Tool Flaring Tool Extrusion Adjustment Gauge Pipe Bender Expanding Tool Torque Wrench Refrigerant Brazing Tool Pipe Nitrogen Gas

Lubrication Oil

Vacuum Drying .

Interchangeability with R22 R407C

Reason of No-interchangeability and attention. (◎:Strictly required)

○ — ○ ○ ○ ○ ○

SW220HT

·The Flaring tools for R407C are applicable to R22

Use Flaring for Tubes Dimensional Control for Extruded Portion of Tube after Flaring Bending Expanding Tubes Connection of Flare Nut Brazing for Tubes Prevention from Oxidation during Brazing

— — — *Perform correct brazing work. *Strict Control again Contamination(Blow nitrogen during brazing.) Applying oil to the Flared *Use a synthetic oil which is Surface equivalent to the oil used in the refrigeration cycle. *Synthetic oil absorbs moisture quickly. ·Check Refrigerant cylinder Color Refrigerant Charging ◎Liquid refrigerant charging is required regarding zeotoropic refrigerant Vacuum Pumping ◎The current ones are applicable.However,it is required to mount a vacuum pump adapter which can prevent from reverse flow when a vacuum pump stops,resulting in no reverse oil flow.

Refrigerant Cylinder

Refrigerant Vacuum Pump charge

Adapter for Vacuum Pump

Manifold Valve

Charging Hose

Charging Cylinder

oil will flow into the cycle and cause sludges,resulting in clogging or compressor failure. —

Weight Scale

Refrigerant Gas Leakage Detector

*The current gas leakage detector(R22) is not applicable due to different detecting method.

*No interchangeability is available Vacuum Pumping Vacuum due to higher pressure when Holding,Refrigerant compared with R22. Charging and Check of ◎Do not use current ones to the new refregerant.If used,mineral Pressures

— Measuring Instrument for Refrigerant Charging Gas Leakage Check

NOTE *The component is different between models RCU-AHYZ1 and RCUG-AHYZ1. Please pay attention that it is unable to use same one. 34


MAINTENANCE

8. Troubleshooting The following table shows efficient checking procedures for trouble. Fault

Possible Cause

Unit Does Not Operate Condenser Operate

Fan

Not

Compressor Does Not Operate

Compressor Stops on High Pressure Switch Compressor Stops on Overcurrent Relay

Compressors Stops on Freeze Protection Thermostat

Check/Corrective Action 1. See “Controller Adjustment” in the 2 module unit Controller Setting is Incorrect case, especially checks “Unit Setting of PWB”. Current to Unit Is Shut Off 1. Reset the power supply line to the unit. Fuse for Operation Circuit is Blown Out or 1. Check for shorted components. Faulty Contact 2. Check for Loose connection. Tighten or replace, if necessary. Contactor Holding Coil is Burned Out or 1. Find the cause ,and repair or replace Faulty Contact 1.Remove the cause ,and reset the overcurrent Tripped Overcurrent Relay relay Low Voltage 1. Check the voltage of unit rating. 1. Check the Motor and Terminals. Shorted Motor or Terminals Repair or replace, if necessary. Condenser Fan Is Not Operating. 1. Remove all the causes of inoperative fan. Interlock Circuit for Chilled Water Pump Is 1. Check the Pump contactor. Repair or replace, if Open necessary. 2. Check for the faulty pump. 1. Remove the causes, and reset the “ON” button. Electrical Protective Devices Are Tripped See the following cause. Incorrect Wiring Connection for Compressor 1. Interchange two of three terminals R,S and T at power Source the main power source terminals. Excessively High Discharge Pressure

1.See “High Discharge Pressure”

Malfunction of High Pressure Switch

1. Readjust the setting or replace, if defective.

Excessively High Discharge Pressure and Suction Pressure High or Low Voltage, Single-Phase or Phase Imbalance Loose Connection Faulty Compressor Motor

1.See “High Discharge Pressure” and “High Suction Pressure” 1. Check the power supply line and contactors. Repair, if necessary. 1. Tighten the loose electrical connection or repair, if necessary. 1. Check the Compressor motor. Repair or replace, if necessary.

Faulty Overcurrent Relay

1.Replace it, if necessary

Excessively Low Chilled Temperature Defective Thermistor

Water

Outlet

1. Check for excessively low setting of the chilled water setting knob. 1. Check for malfunction of the thermistor. Replace, if necessary. 1. Check the rotation of the pump.

Air in Water Circuit High or Low Voltage, Single-Phase or Phase Imbalance

1. Purge air. 1. Check the power supply line and contactors. Repair, if necessary. 1.Check for refrigerant leakage and faulty solenoid valve for liquid bypass 1. Check the contact of the internal thermostat during the cold condition. 1.See “High Discharge Pressure” and “High Suction Pressure” 1.See “High Discharge Pressure” and “low Suction Pressure” 1. Readjust the setting. 1. Adjust unload mechanism. Repair or replace unloaded parts, if necessary. 1. Check the superheat of suction gas. Keep the superheat in proper range. 1. Check for the sound of internal parts. Replace the compressor, if necessary.

Shortage of Chilled Water Flow Compressor Stops on Internal Thermostat or Discharge Gas Thermostat

Excessive Superheat

Insufficient Cooling

Defective Element Excessive High Discharge Pressure and Low Suction Pressure. High Discharge Pressure or Low Suction Pressure Improper Thermostat Setting Defective Unload Mechanism

Noise Compressor

Slugging Due to Liquid Flooding Back to Compressor Worn Parts

35


MAINTENANCE Fault Miscellaneous Noise Unloader Does Not Function

Possible Cause Loose Fixed Screw Trouble with the Thermistor Trouble with the Solenoid Valve Worn Unloader Mechanism

High Pressure

Low Pressure

Discharge

Discharge

High Suction Pressure

Low Suction Pressure

High Condenser Air Temperature or Insufficient Air Flow Through the Condenser Defective Check Valve or Partially Closed Liquid Line Stop Valve. Overcharged Refrigerant Air or Non-Condensable Gas in the Refrigerant Cycle. Suction Pressure is Higher Than Standard

Check/Corrective Action 1. Tighten the screws of all parts. 1. Adjust the setting temperature. 2. Replace the thermistor. 1. Check the coil in the solenoid valve. 2. Check oil passage for clogging. 1. Check the unloader system parts in the compressor. 1. Check the tan operation. 2. Check for coil clogging; clean, if necessary. 1. Check the valves and capillary tubes. Replace, if necessary. 1. Purge the refrigerant. 1.Purge the gas from the refrigerant cycle. 1. See “High Suction Pressure”.

Extremely Cold Condenser Air Insufficient Refrigerant Charge

1. Check the ambient temperature. 1. Add refrigerant.

Leakage from the Compressor Discharge Valve

1. Replace the valve. Replace the compressor, if required

Suction Pressure is Lower than Standard

1. See “Low Suction Pressure”.

High Inlet Temperature of Chilled Water Excessive Opening of Expansion Valve

1. Check the insulation of the piping 2. Check the insulation specification. 1. Readjust the opening, or replace, if defective.

Low Inlet Temperature of Chilled Water

1. Check the insulation specification.

Improperly Adjusted Expansion Valve or Faulty Valve Insufficient Refrigerant Charge

1.Adjust for correct superheat.Repair or replace,if necessary 1. Add Refrigerant.

Excessive Oil in the Water Cooler

1.Purge Oil

36


Specifications in this catalogue are subject to change without notice in order that HITACHI may bring the latest innovations to their customers.

Z0011542-2007-A

Z0011542-2007-A  

Z0011542 -Technical Catalog Ⅱ- Installation, Operation and Maintenance RCU(G)75AHYZ1 RCU(G)100AHYZ1 RCU(G)120AHYZ1 RCU(G)150AHYZ1 RCU(G)180A...

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