SMGB0002 r0 07-05

AIR COOLED
WATER CHILLERS
-SCREW TYPE-
Maintenance Instructions.
Service Manual
RCUE40AG1-400AG1 (R407C)
Cooling Capacity 108 kW - 1068 kW
0
TABLE OF CONTENTS
1.TROUBLESHOOTING................................................................................................................. 1
1.1. OUTLINE OF FAILURE DIAGNOSIS.............................................................................................................2
1.2. ALARM INDICATION.................................................................................................................................3
1.3. FAILURE DIAGNOSIS METHOD4
1.4. ANALYSIS AND COUNTERMEASURE OF ABNORMAL RUNNING.......................................................................21
2. ELECTRICAL WIRING................................................................................................................ 27
2.1. CUSTOMER WIRING .................................................................................................................................27
2.2. WIRING DIAGRAM....................................................................................................................................29
2.3. MAIN CIRCUIT BOARD ..............................................................................................................................41
TROUBLESHOOTING
1/1
1 TROUBLESHOOTING
1.1. OUTLINE OF FAILURE DIAGNOSIS
In the case of abnormality, alarm lamp of remote control and alarm LED on the control panel are ON. And segment indication on
the control panel is flickering. For stopping the unit, put it into stop operation without power OFF.
Alarm occur
Segment Indication:
Abnormality Code Flickering.
Alarm Indication: ON
(Local Side)
Remote Control Run Indication:
ON
Remote Control Alarm Indication: ON
(Remote Side)
Stop Operation
Is abnormality code
in segment indication
confirmed?
Abnormality code is indicated
by indication mode of alarm
Occurence Data.
Abnormality code is indicated
in the segment indication.
Take proper measure
according to the alarm position
J NOTE:
- After the stop operation, alarm indication is turned off and initial status 88 is displayed. And then abnormality code, which
activated before is indicated by Indication Mode of Alarm Occurrence Data.
- When the power turns off and turns on, the indication is initial status. And then abnormal code, which activated before is
indicated by Indication Mode of Alarm Occurrence Data
Yes
No
1/2
TROUBLESHOOTING
1.2. ALARM INDICATION
7-Segment indication shows the following abnormalities
Unit does not run Check the power source
Check the 7-segment
indication
Alarm Code
No.1~6 cycles
Description of abnormality
[LL]~[LoLo] Excessively Low Pressure
[LL]~[LoLo] Low Pressure Protection by Suction Gas Thermistor
[L]~[Loo] Excess Low Temperature of Cooler Inlet Refrigerant
[Llo]~[Lolo]
Freezing Protection Control by Cooler Inlet Refrigerant Temperature and excess low suction pressure (retry
operation)
[] Activation of Freezing Protection Control
[LH]~[LoHo] Activation of High Pressure Switch
[Lo]~[Looo] Activation of Discharge Gas Thermostat
[L]~[Loo] Activation of Compressor Internal Thermostat
[L']~[Lo'] Phase Abnormally
[L']~[Lo'] Error communication between Ctrl. PCB and Fan Speed Ctrl. PCBs (Low Ambient Fan Speed Ctrl. Option)
[Lc']~[Loc'] Failure of Thermistor set before Expansion Valve (Open / Short)
[L']~[Lo'o] Activation of Fan Motor Internal Thermostat
[cccc] Failure of Ambient Temperature Thermistor (Open / Short)
[Lc]~[Loc] Failure of Cooler Inlet Refrigerant Thermistor (Open/Short)
[Lc]~[Loc] Failure of Discharge Gas Thermistor (Open/Short)
[Lc']~[Loc'] Failure of water oulet temperature thremistor i cooler siter (Open / Short)
[Lco]~[Loco] Failure of Suction Gas Thermistor (Open / Short)
[Lc]~[Loc] Failure of Discharge Gas Pressure Sensor (Open / Short)
[LcB]~[LocB] Failure of Suction Gas Pressure Sensor (Open / Short)
[LlLl] Error communication between Ctrl. PCB (PCB
C1
, PCB
C2
)
[] Failure of Water Inlet Temperature (Open / Short)
[cc] Failure of Water Outlet Temperature Thermistor (Open / Short)
[''] Failure of Water Outlet 2 Temperature Thermistor (Open/Short)
[oo] Failure of Water Outlet 3 Temperature Thermistor (Open/Short)
[''] Malfunction
[L]~[Loo] Activation of Differential Pressure Control
[L']~[Lo'o] Activation of Thermal Relay for Compressor
[L'l]~[Lo'l] No Feedback Signal from Water Pump
[Llo]~[Lolo] Alarm of Excessively High Water -Temperature
[oLoL] Alarm of Water Failure (Differential Water Pressure Switch Option)
[HlHl] Activation of Additional Protection Device (Option)
" " - " " : Flickering. XX - XX : SEG1-SEG2
With indication
Without indication
TROUBLESHOOTING
1/3
1.3. FAILURE DIAGNOSIS METHOD
1.3.1. GENERAL CHECK OF FAILURE DIAGNOSIS.
In the case of no segment indication, unit cannot operate.
Is 220-240V supplied
to the unit?:
Check the power
source switch
Is 220-240V supplied to
transformer primary side?
Is fuse broken? Replace fuse
Wiring check
and repair
Is R phase or S
phase failure?
Wiring check
Is 30V in PIN1~PIN2,
16.3V IN PIN3~PIN4,
19.6V IN PIN5~PIN6 of the
printed circuit board for CPU
(PCB
c
) connector CN2A
Is the wiring of
transformer broken?
Replace
transformer
Wiring check
Connector check
Is the wiring of
transformer broken?
Replace
transformer
Wiring check
Connector check
Is 26.7V in PIN1~PIN2,
17.6V in PIN3~PIN4,
17.6V in PIN5~PIN6 of the
(PCB
c
) connector CN2B
and CN2C
Is voltage in each test PIN of printed circuit board
for CPU
5 V part VCCO5-GND1
V5B-GND1
VCCO5N-GND1
VCCR-GND1
+15V part VCC15T-GND1
- 15V part VCC15T-GND1
24V part VCC24-GND1
VCC24T-GND1
Power Source Circuit
Malfunction
Replace Printed
Circuit Board for
CPU (PCB
C
)
Are connector FCN1, FCN2
on the printed circuit board for
CPU (PCB
C
) and Printed
Circuit Board for Display and
Operation (PCB
A
, PCB
B
)
correctly connected and
checked loose connection?
Connector Repair
Check Printed
Circuit Board for
Display and
Operation (PCB
A
,
PCB
B
)
Check Printed
Circuit Board for
CPU (PCB
C
)
No
Yes
Yes
Yes
Yes
No
No
Yes
Yes
Yes
No
Yes
No
No
No
No
No
Yes
Yes
No
1/4
TROUBLESHOOTING
! [LL] ~ [LoLo] Excessively Low Suction Pressure
In case of the suction pressure is less than 0.31 Mpa during 90 seconds, the unit will stop at once and indicate
[Llo]~[Lolo]. 3 minuts later, the unit will start again. This Alarm code is indicated when it occurs 3 times during 30
minutes (It will retry until 2 times.).
Is connector CN 29Ps on the
printed circuit board for relay
(PCB
D
) correctly connected?
Wiring Check
No
Shortage of Refrigerant Gas Leakage
Clogging of expansion valve
Clogging of strainer
Clogging of low pressure side pipe
Stop Valve malfunction
Shortage of Water
Pump reverse rotation
Air mixed
Deposits on Water Cooler Plates
Clogging of Water Strainer
Yes
TROUBLESHOOTING
1/5
! [LL] ~ [LoLo] Low Pressure Protection by Suction Gas Thermistor
This alarm code is indicated when the suction temperature is lower than -2C during 10 seconds.
Is the wiring of connector in the
Printed Circuit Board for Relay
(PCB
D
) correct?
Plug correctly and
repair wiring
Replace thermistor
Pull out connector and measure
thermistor resistance. Is
resistance correct?
Check Printed Circuit Board
for Relay (PCB
D
)
Thermistor
resistance
(K)
Temperature (C)
Thermistor for Suction Gas Temperature
characteristics
Clogging of water strainer
Yes
No
Yes
Check the water flow rate.(Check temperature
of inlet and outlet.)
Pump reverse rotating check
Check the air mixing
No
Check chilled water thermostat setting value
(Within the working range)
Shortage of refrigerant Gas Leakage
Clogging of low pressure pipe
Malfunction of Check valve
Yes
Malfunction of Expansion Valve
1/6
TROUBLESHOOTING
! [L]~[Loo] Excess Low Temperature of Cooler Inlet Refrigerant
In case of the cooler inlet refrigerant temperature is lower than -3C during 10 seconds, the unit will stop at once and indicate
[Llo]~[Lolo]. 3 minutes later, the unit will start again. This alarm code is indicated when it occurs 3 times during 30
minutes (It will retry until 2 times)
Is connector CN27Tr2 on the
printed circuit board for Relay
(PCB
D
Plug correctly and
repair wiring
thermistor resistance.
Is resistance correct?
Replace Thermistor
Check printed circuit board for
Relay (PCB
D
)
No
Yes
Yes
No
Yes
Check water flow rate (Check the
temperature of Inlet and Outlet)
Check pump reverse rotation
Check water strainer clogging
Check air mixing
Check Chilled water thermostat
setting value (It shall be within
the unit working range)
Shortage of Refrigerant Gas
Leakage
Clogging of low pressure side pipe
Check Valve Malfunction
Expansion Valve Malfunction
TROUBLESHOOTING
1/7
! [] Activation of Freeze Protection Control
This alarm code is indicated when the water inlet or outlet temperature is lower than 2C.
Is connectors on the Printed
Circuit Board correctly connected?
PCB
C
:CN4,CN6,CN7,CN3
PCB
D
:CN23Te2
Plug correctly and
repair wiring
thermistor resistance
Replace Thermistor
Check printed circuit board
Thermistor
resistance
(K)
Temperature (C)
Thermistor for Water Temperature
characteristics
No
Yes
Yes
No
Yes
Check water flow rate (Check the
temperature of Inlet and Outlet)
Check pump reverse rotation
Check water strainer clogging
Check air mixing
Check Chilled water thermostat
setting value (It shall be within
the working range)
1/8
TROUBLESHOOTING
! LH] ~ [LoHo] Activation of high pressure switch (PSH
1~6
)
This alarm code is indicated when the discharge pressure is higher than 2.74 Mpa.
Is alarm activated just after
running?
Is 220-240V the voltage
between connector
PCN203 PIN1 and
connector PCN 203
PIN3 on the Printed
Circuit Board for Relay
(PCB
D
1~6)?
PCB
D
Check
Is alarm activated in 3
minutes after running
operation?
Wiring Check
(breaking of wire,
wrong wiring)
Is high pressure switch
(PSH1~6) activated?
Check clogging
in air side heat
exchanger
High Pressure
Check Is high pressure
switch (PSH1~6) reset
button activated?
Reset
Cycle Check
between connector
PCN203 PIN1and
connector PCN 203
PIN3 on the Printed
Circuit Board for Relay
(PCB
D
1~6)?
Wiring check
(breaking of wire,
wrong wiring)
between connector PCN203
PIN1 and connector PCN 203
PIN3 on the Printed Circuit Board
for Relay (PCB
D
1~6)?
Wiring Check
Check Printed
Circuit Board for
Relay (PCB
D
1~6)
Check Printed Circuit
Board for Relay ( PCB
D
1~6)
JNOTE:
To check the nominal value for pressure refer to safety and control device setting table to the technical catalogue
Yes
(Activate
immediately)
No (Activate
after a while)
Yes
(PCB is
normal)
Yes
No
No
Yes
No
Yes
No
Yes
Yes
No (Activate a while
after Compressor ON)
No
TROUBLESHOOTING
1/9
! [Lo] ~ [Looo] Activation of Discharge Gas Thermostat
This alarm code is indiacted when the temperature in discharge pipe is higher than 140C
Is connector CN24Td on the
(PCB
D
) correctly connected
Wiring check (breaking of wire,
wrong wiring)
Pull out connector and
measure thermistor resistance.
Replace Thermistor
Thermistor
resistance
(K)
Temperature (C)
Thermistor for Discharge Gas Temperature
characteristics
Yes
No
Yes
Shortage of Refrigerant Gas Leakage
Expansion valve opening check
Check PCB
D
1/10
TROUBLESHOOTING
! [L] ~ [Loo] Activation of Compressor Internal Thermostat
This alarm code is indicated when the compressor internal thermostat is higher than 115C
running?
Is 220-240V the
voltage between
connector PCN204
PIN1 and connector
PCN 204 PIN3 on
the Printed Circuit
Board for Relay
(PCB
D
) ?
Check Printed
Circuit Board for
Relay (PCB
D
)
Wiring Check
(breaking of wire,
wrong wiring)
between connector PCN204 PIN1
and connector PCN 204 PIN3 on
the Printed board for Relay
(PCB
D
)?
Wiring Check
! [L'] ~ [Lo'] Phase Abnormality
This alarm code is indicated when the power source phase failure or reverse phase occur.
Is power source phase
failure or reverse phase?
Power Supply,
Wiring Check
Is printed circuit board for relay
(PCB
D
) connector R.S.T correctly
connected?
Connection repair
Is the power source of
connector R.S.T part phase
failure or reverse phase?
Repair to correct
phase
Check printed
circuit board for relay
(PCB
D
)
Yes
Yes
No
No (Activate
after a while)
Yes
No (Printed Circuit
Board is normal)
Excessive or short power source voltage
Interphase of power source voltage is imbalanced.
Compressor motor is locked
Insulation of compressor motor is lowered
Yes (Phase Failure,
Reverse Phase)
No
No
Yes
No (Correct Phase)
Yes
TROUBLESHOOTING
1/11
! [L']~[Lo'] Error comunication between Ctrl. PCB and Fan speed Ctrl. PCB
This alarm code is indicated when the transmission signal is missing more than 5 seconds.
Is connector CN14A on the
(PCB
C
Plug correctly and
repair wiring
Is connector on the printed
circuit board for Fan speed
control (PCB
E
) correctly
connected
Plug correctly and
repair wiring
Check the Printed circuit board
for Fan speed control (PCB
E
)
Replace the printed
circuit board for
Fan Speed (PCB
E
)
Replace the printed circuit
board for CPU (PCB
C
)
Normal
Yes
Yes
No
No
Abnormal
1/12
TROUBLESHOOTING
! [Lc']~[Loc'] Thermistor set before Expansion Valve Abnormality
This alarm code is indicated when the thermistor resistance is out of range (72 Resistance 179 k)
(PCB
D
) connector CN22Te1
correctly connected?
Plug, Wiring Repair
Disconnect connector and
measure resistance. Is the
resistance correct?
Replace thermistor
Replace printed circuit
board for relay (PCB
D
)
! [L']~[Lo'o] Activation of Fan Motor Internal Thermostat
This alarm code is indicated when the fan motor internal thermostat is higher than 135C
Is alarm activated just
after running?
PIN1 and connector PCN206
PIN3 on the Printed Circuit
Board for Relay (PCB
D
)?
Check Printed Circuit
Board for Relay (PCB
D
)
Wiring check (breaking
of wire, wrong wiring)
PIN1 and connector PCN206 PIN3
on the Printed circuit board for
Relay (PCB
D
)?
Wiring check
No
Yes
No
Yes
Yes
(Activate
immediately)
Yes
No (activate
after a while)
Excessive or short power source
voltage
Interphase of power source
voltage is imbalanced
Fan Motor is locked
Insulation of Fan Motor is lowered
Yes
No
No (Printed Circuit
Board is normal)
TROUBLESHOOTING
1/13
! [] [cc] [''] [oo] [cccc][Lc']~ [Loc'] Temperature Thermistor Abnormality
This alarm code is indicated when the thermistor resistance is out of range.
(Water Temperature Thermistor: 240 Resistance 39 k)
(Ambient Temperature Thermistor: 240 Resistance 600 k)
[] Inlet Water Temperature Thermistor Abnormality
[cc] [''] [oo] Outlet Water Temperature Thermistor Abnormality
[cccc] Ambient Temperature Thermistor Abnormality
Is connector on the printed
circuit board for CPU (PCBc)
Plug, Wiring, Repair
Replace thermistor
Replace printed circuit board
for CPU (PCBC)
[] [cc] ['']
[Lc']~ [Loc']
[cccc]
Thermistor
resistance
(K)
Thermistor resistance
(K)
Temperature (C)
Thermistor for Water Temperature
characteristics
No
Yes
No
Yes
1/14
TROUBLESHOOTING
! [Lc]~ [Loc] Cooler Inlet Refrigerant Temperature Thermistor Abnormality
(PCB
D
) connector CN23Te2
Plug, Wiring Repair
resistance correct ?
Replace thermistor
D
)
Thermistor
resistance
(K)
Temperature (C)
Thermistor for Cooler Inlet Refrigerant
characteristics
No
Yes
No
Yes
TROUBLESHOOTING
1/15
! [Lc]~[Loc] Discharge Gas Temperature Thermistor Abnormality
This alarm code is indicated when the thermistor resistance is out of range (Refer below table).
Is connector CN24 Td on the
(PCB
D
Connect correctly
Replace thermistor
Check Printed Circuit Board
Thermistor
resistance
(K)
Air temperature (C)
Thermistor for Discharge Gas Temperature
characteristics
No
Yes
No
Yes
1/16
TROUBLESHOOTING
! [Lco]~[Loco] Suction Gas Thermister Abnormality
(PCB
D
) connector CN25Ts
Plug, Wiring Repair
resistance correct?
Replace thermistor
D
)
Thermistor
resistance
(K)
Temperature (C)
Thermistor for Suction Gas Temperature
characteristics
No
Yes
No
Yes
TROUBLESHOOTING
1/17
! [Lc] [Loc] Discharge Gas Pressure Sensor Abnormality
Malfunction of pressure sensor
Is connector CN28Pd on the
(PCB
D
Connect correctly
Is DC24V between
connector CN28Pd PIN1 and
PIN3 on the printed circuit
D
)?
Replace the
printed circuit board
for relay (PCB
D
)
Is less than DC 0.1V or
more than DC 4.9V between
connector CN28Pd PIN2 and
D
) when
discharge gas pressure
sensor is connected?
Replace the printed
circuit board for
relay (PCB
D
)
Is discharge gas
pressure sensor
connecting pipe clogging?
Remove clogging
in the pipe.
Discharge gas Pressure
Sensor Abnormality
Yes
Yes
Yes
Yes
No
No
No
No
1/18
TROUBLESHOOTING
! [LcB] [LocB] Suction Gas Pressure Sensor Abnormality
Malfunction of pressure sensor
Is connector CN29Ps on the
(PCB
D
Connect correctly
Is DC5V between
connector CN29Ps PIN1 and
D
)?
Replace the
printed circuit board
for relay (PCB
D
)
Is less than DC 0.1V or
more than DC 4.9V between
connector CN29Ps PIN2 and
D
) when
suction gas pressure
sensor is connected?
Replace the printed
circuit board for
relay (PCB
D
)
Is suction gas
pressure sensor
connecting pipe clogging?
Remove clogging
in the pipe.
Suction gas Pressure
Sensor Abnormality
! [LlLl] Error comunication between Ctrl. PCB
This alarm code is indicated when the transmission signal between Ctrol PCB is missing more than 30 seconds.
Is connector CN12 on the
Printed Circuit Board for
CPU (PCBc) correctly
connected?
Plug correctly
and repair wiring
Check the printed
circuit board
for CPU (PCB
C
)
Yes
Yes
Yes
Yes
No
No
No
No
No
Yes
TROUBLESHOOTING
1/19
! [''] Alarm for Operation Error
Performed incorrect operation.
Is local operation?
Is changeover to
local side during remote
operation?
It is incorrect that
operation changeover
to local side during
remote operation.
Do not perform it.
Wiring Check between
remote control switch
and printed circuit board.
Is 220-240V between PIN1-PIN3
of connector PCN16 on the printed
circuit board for CPU (PCB
C
)?
Check printed circuit
board for CPU (PCB
C
)
Is optional wiring connected?
Is the signal transmitted
from option device?
It is incorrect that
remote operation signal
is transmitted from
option device during
local operation.
Do not perform it.
Wiring Check between
external device
and printing board
Is it changed over to
remote side during local
operation?
It is incorrect operation
that changeover to
Remote Side during
Local Operation.
Do not perform it.
board for display (PCB
A
)
board for operation (PCB
B
)
board for CPU (PCB
C
)
! [L] ~ [Loo] Activation of Differential Pressure Control
This alarm code is indicated when the pressure difference between discharge and suction pressure is less than 0.3 Mpa
during 3 minutes.
Is connector CN28Pd
and CN29Ps on the
Relay (PCB
D
) correctly
connected?
Plug correctly
and repair wiring
No
No (Remote)
Yes (Local)
Yes (Normal
Running)
Yes
Yes (Normal
Running)
No
No
Yes
(Normal
Running)
No
No
Yes
No
Check Refrigerant oil strainer clogging
Check Refrigerant oil Quantity
Solenoid Valve for Compressor Malfunction
Compressor slide valve Malfunction
Yes
1/20
TROUBLESHOOTING
! [L'] ~ [Lo'o] Activation of Thermal Relay for Compressor
This alarm code is indicated when the compressor running current is more than thermal Relay Setting Value.
running operation?
Is 220-240V the
voltage between
connector PCN207
PIN1 and connector
PCN 207 PIN3 on
the Printed Circuit
Board for Relay
(PCB
D
) ?
Check Printed
Circuit Board for
Relay (PCB
D
)
Wiring Check
(breaking of wire,
wrong wiring)
Is 220-240V the voltage between
connector PCN207 PIN1 and
connector PCN 207 PIN3 on the
Printed board for Relay (PCB
D
)?
Wiring Check
! [L'l] ~ [Lo'l] No Feedback Signal from Water Pump
CMP pump feed back signal is not coming and Unit stops
Is 220-240V between PIN1 and
PIN3 of connector PCN4 on the
(PCB
C
)
Is pump thermal relay for
pump (TRP) activated?
Check pump
lock
Check thermal
relay for pump
Check printed circuit board for
CPU (PCB
C
)
Check wiring
around pump
and thermal relay
for pump
Yes (activated
immediately)
Yes
No
No (Activate
after a while)
Yes
No (Printed Circuit
Board is normal) Excessive or short power source voltage
Interphase of power source voltage is imbalanced.
Compressor motor is locked
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
Yes
No
No (Printed Circuit
Board is normal)
Yes
TROUBLESHOOTING
1/21
1.4. ANALYSIS AND COUNTERMEASURE OF ABNORMAL RUNNING
Chiller unit has various kinds of protection device. When the operation is not correct status due to the activation of some
protection device, refer to the table below and find out the main reason to take a countermeasure.
1 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
Wiring Short Circuit Check falling of wiring coating. Eliminate short-circuit and replace fuse.
Wiring Earth Fault Measure insulation resistance. Eliminate the earth fault and replace fuse.
Compressor Motor Failure Replace compressor and fuse.
Fuse for
power
source is
melted
Fan Motor Failure
Measure the interphase
resistance, insulation resistance.
Replace fan motor and fuse
Wiring Short-circuit Check falling of wiring device. Eliminate short-circuit and replace fuse..
Earth Fault in Operation Circuit Measure insulation resistance. Eliminate earth fault and replace fuse
Magnetic Contactor for
Compressor Motor Failure
Magnetic Contactor
for Fan Motor Failure
Magnetic Contactor
for pump motor Failure
Replace magnetic contactor and fuse.
Auxiliary Relay Coil Failure Replace auxiliary relay and fuse.
Solenoid Valve Coil Failure
Measure the coil resistance.
Replace solenoid coil and fuse.
Printed Circuit Board Short-Circuit Conductive Foreign Particle. Remove the particle and replace fuse
Fuse for
operation
circuit is
melted
Crankcase Heater Failure Measure resistance. Replace oil heater and fuse.
Trans Coil Failure
Measure the transformer
secondary voltage.
Replace transformer.
Remote Control Wiring Incorrect Wiring Change wiring.
R, S, T phase of power source is phase
failure or reverse phase. (05 alarm)
Check the connection
of R, S, and T phase
Change to the correct phase.
Remote Control Switch Failure. Change-over switch
of Printed Circuit Board is Local (40 alarm)
Check changeover switch.
Replace remote control switch.
Turn changeover switch on Remote
Wiring Connection Failure Repair the wiring connection
Replace the Printed Circuit Board
Printed
Circuit
Board
Failure
Printed Circuit Board Failure
Check the current by tester.
Breaking of Coil
It does not
run when
operate
Pump
Magnetic
Contactor
for Pump
Failure
(52P)
Loose Connection
Measure the voltage of contact
point of magnetic contactor
Replace magnetic contactor for pump
Pump locked
Check water freeze, clogging
of foreign particle.
Remove it.
Pump Over-current
relay RC Value Wrong
Check the RC value and
pump running current.
Change the RC value or
replace magnetic contactor.
Pump stops
before
compressor
running
Pump Over-
current
Relay
Activated
(TRP) (5P
Alarm)
Pump over-current
relay failure
Push reset button
and check running current.
Replace magnetic contactor.
1/22
TROUBLESHOOTING
Wiring Connection Failure Check circuit by tester
Repair the wiring
connection
Printed Circuit Board
Failure
Failure
Check circuit by tester Check
Printed Circuit Board by self-
checking function
Replace Printed Circuit
Board
Remote Control Switch Failure Operative by the unit side
Replace remote
control switch.
Coil Broken Check circuit by tester
Pump runs,
but neither
fan nor
compressor
run.
Fan Magnetic Contactor
Failure (Cooling
Operation) Contact Point Failure
Measure the voltage between
contact points of magnetic
contactor.
Replace magnetic
contactor.
Fan Motor Failure
resistance
Replace fan motor
Pump and
compressor
run, but fan
does not run
Wiring Connection Failure
Failure
Check circuit by tester
Repair the wiring
connection. Printed Circuit Board
Failure
Thermistor Malfunction Measure the thermistor resistance Replace thermistor
Coil Breaking Check circuit by tester
Compressor Magnetic
Contactor Failure
Contact points Failure
Measure the voltage between
contact points of electromagnetic
contactor
Replace magnetic
contactor
Thermostat is activated. (Thermo-Off)
Change water temperature or
change the setting temperature.
It is not failure
Compressor Motor Failure
resistance
Pump and
fan run but
compressor
does not run.
Compressor Failure Beat noise from compressor
Replace compressor
Voltage at starting up is low. Measure the voltage
Consult with electric
power company
Excessive dust in air side heat
exchanger
Inlet or outlet of air side heat
exchanger is clogged
Remove it.
Shortage of Service Space for
Chiller Unit
Secure the service
space
Insufficient air in air side
heat exchanger
Reverse Rotation of Fan Motor
Change wiring for fan
motor
Air Short Circuits in Chiller Unit Remove short-circuits
Air temperature through air
side heat exchanger is
excessively high
Another heat source around
chiller unit
Remove heat source
Refrigerant excessive
charge
Check cycle temperature.
Charge correct
quantity of refrigerant
Non-condensable gas in
the refrigerant cycle
Turn off the unit and check the
relation between water
temperature and pressure.
Charge refrigerant
again after the
evacuation
High pressure pipe
clogging
Check clogging
Expansion Valve clogging
Check Valve (Air side heat
exchanger side) clogging
Check clogging
Remove clogging, or
replace check valve
Strainer Clogging
Check the difference of
temperature before and after of
strainer.
Replace or clean the
strainer
Discharge pressure is
excessively high, so that
high pressure switch
activates.
(C1-H1)~ (C6-H6)
Chilled water inlet
temperature of Water side
heat exchanger is
excessively high
Confirm if it is within the working
range
Check the status of
heat load in detail and
take a countermeasure
Unit stops
during
cooling
operation
Discharge gas control is
activated
Suction gas temperature is
excessively high
(Excessively super heat)
Gas leakage or refrigerant
shortage
Charge correct
quantity of refrigerant
after checking gas
leakage
TROUBLESHOOTING
1/23
Check valve
(Air heat exchanger side)
Malfunction
Replace check valve
Expansion Valve Clogging Remove Clogging
Suction gas
temperature is
excessively high
(excessive
superheat)
Strainer Clogging Replace or clean the strainer
Discharge gas
control is activated
(L-o alarm)~
(Lo-oo alarm)
Discharge gas
Thermistor Failure
Check thermistor resistance
Replace discharge gas
thermistor
Fan motor bearing
failure
Lock Status Replace fan motor
Single Phase
Running
Check magnetic contactor Replace magnetic switch
Motor Insulation
Deteriorated
Measure insulation resistance Replace fan motor
Power Voltage excessively high
or low
Set voltage within working
range during operation
Power Voltage Phase
Imbalance
Measure the voltage in each
interphase and ask Power
Company for the advice
Compressor Drive
Excessive Current
Discharge pressure is
excessively high
Analyze the cause
Power Fuse melted Replace power fuse
Loose Power Terminal Screw Retighten the screw
Single Phase
Running
Contact point of compressor
Motor magnetic Contactor
Roughness
Replace contact points
Compressor
Bearing Failure
Lock Status
Compressor Motor
insulation Failure
Measure insulation resistance
Replace compressor
Thermal relay for
compressor is
activated
(L-' alarm)~
(Lo-'o alarm)
Compressor internal
thermostat is
activated
(L- alarm)~
(Lo-o alarm)
Fan internal
thermostat is
activated
(L-' alarm)~
(Lo-'o alarm)
Compressor Motor
Over-current relay
Failure
Measure current of compressor
motor
Replace over-current Relay
Pump locked
Check freezing of water,
clogging of foreign particle
Remove them
Pump Over-current
relay RC value
Wrong
Check the RC value and pump
running current
Change the RC value or
replace magnetic contactor
Pump over-current
relay is activated
('l alarm)
Pump Over-current
relay Failure
Push reset button. Check the
running current
Replace magnetic contactor
Shortage of water
Flw
temperature between inlet and
outlet of chilled water
Increase water flow
Water Strainer Clogging Clean the strainer
Pump reverse
rotated
Check rotative direction Repair to correct direction
Air mixed Open Air Vent Valve Evacuate Air
Unit stops
during
cooling
operation
Freeze protection
control is activated
( alarm)
Thermistor Failure
( alarm)
(c alarm)
(' alarm)
(o alarm)
Check inlet temperature of
chilled water
Replace Thermistor
1/24
TROUBLESHOOTING
The heat load is bigger than cooling capacity Calculate heat load Replace to larger unit
Gas leakage or shortage of
refrigerant
Check super-heat.
Charge correct quantity after
checking gas leakage
Expansion Valve Clogging Check clogging Remove clogging
Strainer Clogging
Check to make sure that no
difference of temperature
before and after of the strainer
exists.
Replace strainer
Low pressure Piping
Clogging
between piping exists.
Remove clogging
before and after of check valve
exists.
Replace check valve
Shortage of water flow
temperature between inlet and
outlet of chilled water
Increase water flow
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
Low pressure is excessively
low.
(Low-pressure control is
activated)
(LL )~(LoLo alarm)
Deposits on water cooler
plates
Check the scales inside of
water cooler
Clean water cooler
Excessive dust in air-side heat
exchanger
Inlet or outlet of air-side heat
exchanger is clogged
Remove it.
Shortage of Service Space for
chiller unit
Secure the service space
Air flow shortage in air-side
heat exchanger
Reverse Rotation of Fan Motor Correct the wiring of fan motor
Air Short-circuits in Chiller Unit Repair short-circuit.
Air temperature through air-
side heat exchanger is high
Another Heat Source around
the Chiller Unit
Remove heat source
Refrigerant Excessive charge Check cycle temperature Charge the correct quantity
Non-condensable Gas in the
Refrigerant Cycle.
Turn off the unit and check the
relation between water
temperature and pressure
Evacuate and charge
refrigerant again
High Pressure Pipe Clogging Check clogging
Expansion Valve Clogging Check clogging
Remove clogging
High pressure is excessively
high
(High-pressure switch is
activated)
(LH )~(LoHo alarm)
Strainer Clogging
before and after strainer exists
Replace strainer.
Check valve mal-function
before and after check valve
exists.
Replace check valve.
Unit is running,
but the cooling
capacity is
insufficient
Compressor Failure
Check pressure, cycle
temperature, and current
Replace compressor.
Propeller-fan contacts with shroud Investigate
Adjust the position of propeller
fan
Installation error or loose bolt Check each bolt if loosen Tighten up.
Liquid Compression
Check suction gas temperature,
pressure
Ensure superheat
Oil hammer
Check suction gas temperature
and oil level
Replace compressor
No-current to oil heater at
compressor stopping
Check the current to oil heater. Replace oil heater.
Noise from compressor
Worn or damaged part in the
compressor
Noise from inside of
compressor
Replace compressor.
Beats of magnetic contactor Check the roughness of contact Replace contact points
Unit is running,
and it makes a
noise.
Vibration of cabinet Check screws if loosen Tighten up
ELECTRICAL WIRING
2/25
2. ELECTRICAL WIRING
2.1. CUSTOMER WIRING
I
n

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.
2/26
ELECTRICAL WIRING
PARTS LIST
(n=1~N)
Mark Name Remark Mark Name Remark
MC
1-n
Compressor Motor THMs
1-n
Suction Gas Temperature
Thermistor
MF
11-n4
Condenser Fan Motor THMI
1-n
Liquid Temperature Thermistor OPTION
MI Main Isolator EF
1~3, R,S,T
Fuse 6A
CMC
1-n
Contactor for Compressor Motor SV
11-n1
Solenoid Valve for Starting
CMC
s1-sn
Contactor for Compressor Motor
(Start Operation)
SV
12-n2
Solenoid Valve for Load-down
CMC
D1-Dn
Contactor for Compressor Motor
(Delta Operation)
SV
13-n3
Solenoid Valve for Load-up
CMF
11-n4
Contactor for Condenser Fan
Motor
TM
1-n
Hour Meter
EFC
1-n
Fuse for Compressor Motor
or optional
Circuit Breaker
PCB
A
Display
ORC
1-n
Overcurrent Relay for Compressor
Motor
PCB
B
Operation
EFF
11-n4
Fuse for Condenser Fan Motor
or optional
Circuit Breaker
PCB
C1,C2
Printed Circuit Board for CPU
ITC
1-
n
Internal Thermostat for
Compressor
PCB
D1-Dn
ITF
11-n4
Internal Thermostat for Fan Motor PCB
E1-En
Printed Circuit Board for Fan
Control
OPTION
CH
1-n
Crankcase Heater WP
Water Pressure Switch,
Water Flow Switch
OPTION
AR
1-n,H,R
Auxiliary Relay PBSR
1
Push Button Switch for Starting
(REMOTE)
OPTION
PSH
1-n
High Pressure Switch
OFF: 2.74Mpa
ON: Manual
Reset
PBSR
2
Push Button Switch for
Stoppage (REMOTE)
Pd
1-n
High Pressure Sensor RL
Pilot Lamp for Remote
Indication (Unit Operation)
Ps
1-n
Low Pressure Sensor OL
1-n
Pilot Lamp for Remote
Indication (Alarm)
THM
i
Inlet Water Temperature
Thermistor
CMP Contactor for Pump
THM
01,
02,03
Outlet Water Temperature
Thermistor
TRP Thermal Relay for Pump
Field
Supplied
THMr2
1-n
Cooler Inlet Refrigerant Thermistor SVEn Solenoid Valve for Economizer
THMd
1-n
Discharge Gas Thermistor PSWn
Pressure Switch for
Economizer
PFC
1-n
Fuse holder for Compresor Motor
Or optional
Circuit Breaker
EHF
1-n
Cooler Heater
PFF
1-n
Fuse holder for Compresor Fan
Motor
Or optional
Circuit Breaker
TF
1,2,3,4,5
Transformers
THM
a
Atmosphere Temperature
Thermistor
Model N
RCUE 40, 50, 60, 70AG1 1
RCUE 80, 100, 120,140AG1 2
RCUE 150, 180, 200AG1 3
RCUE 240, 270AG1 4
RCUE 300,330AG1 5
RCUE 360,400AG1 6
ELECTRICAL WIRING
2/27
2.2. WIRING DIAGRAM
2.2.1. POWER CIRCUIT
POWER CIRCUIT FOR RCUE 40AG1, RCUE 50AG1, RCUE 60AG1, RCUE 70AG1
M
o
d
e
l
s
R
C
U
E

4
0
A
G
1
R
C
U
E

5
0
A
G
1
R
C
U
E

6
0
A
G
1
R
C
U
E

7
0
A
G
1
M
a
i
n

S
w
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c
h
P
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W
E
R

C
I
R
C
U
I
T
(
O
P
T
I
O
N
)
(
O
P
T
I
O
N
)
2/28
ELECTRICAL WIRING
POWER CIRCUIT FOR RCUE 80AG1, RCUE 100AG1, RCUE 120AG1, RCUE 140AG1
M
a
i
n

S
w
i
t
c
h
P
O
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s
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8
0
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1
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1
0
0
A
G
1
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C
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E

1
2
0
A
G
1
R
C
U
E

1
4
0
A
G
1
ELECTRICAL WIRING
2/29
POWER CIRCUIT FOR RCUE 150AG1, RCUE 180AG1, RCUE 200AG1
M
a
i
n

S
w
i
t
c
h
P
O
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R

C
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M
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1
5
0
A
G
1
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1
8
0
A
G
1
R
C
U
E

2
0
0
A
G
1
2/30
ELECTRICAL WIRING
POWER CIRCUIT FOR RCUE 240AG1, RCUE 270AG1
M
a
i
n

S
w
i
t
c
h
P
O
W
E
R

C
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M
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2
4
0
A
G
1
R
C
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E

2
7
0
A
G
1
ELECTRICAL WIRING
2/31
M
o
d
e
l
s
R
C
U
E

3
0
0
A
G
1
R
C
U
E

3
3
0
A
G
1
M
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n

S
w
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c
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P
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C
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C
U
I
T
2/32
ELECTRICAL WIRING
M
o
d
e
l
s
R
C
U
E

3
6
0
A
G
1
R
C
U
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4
0
0
A
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1
M
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n

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w
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P
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T
ELECTRICAL WIRING
2/33
2.2.2. CONTROL CIRCUIT
CONTROL CIRCUIT FOR RCUE 40AG1, RCUE 50AG1, RCUE 60AG1, RCUE 70AG1
M
o
d
e
l
s
R
C
U
E

4
0
A
G
1
R
C
U
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5
0
A
G
1
R
C
U
E

6
0
A
G
1
R
C
U
I
E

7
0
A
G
1
C
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N
T
R
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F
A
N

S
P
E
E
D
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T
R
L

(
O
P
T
I
O
N
)
2/34
ELECTRICAL WIRING
CONTROL CIRCUIT FOR RCUE 80AG1, RCUE 100AG1, RCUE 120AG1, RCUE 140AG1
C
O
N
T
R
O
L

C
I
R
C
U
I
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M
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l
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8
0
A
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1
R
C
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1
0
0
A
G
1
R
C
U
E

1
2
0
A
G
1
R
C
U
E

1
4
0
A
G
1
F
A
N

S
P
E
E
D
C
T
R
L
.

(
O
P
T
I
O
N
)
ELECTRICAL WIRING
2/35
CONTROL CIRCUIT FOR RCUE 150AG1, RCUE 180AG1, RCUE 200AG1
C
O
N
T
R
O
L

C
I
R
C
U
I
T
F
A
N

S
P
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E
D
C
T
R
L
.

(
O
P
T
I
O
N
)
M
o
d
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l
s
R
C
U
E

1
5
0
A
G
1
R
C
U
E

1
8
0
A
G
1
R
C
U
E

2
0
0
A
G
1
2/36
ELECTRICAL WIRING
CONTROL CIRCUIT FOR RCUE 240AG1, RCUE 270AG1
C
O
N
T
R
O
L

C
I
R
C
U
I
T
M
o
d
e
l
s
R
C
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E

2
4
0
A
G
1
R
C
U
E

2
7
0
A
G
1
F
A
N

S
P
E
E
D
C
T
R
L
.

(
O
P
T
I
O
N
)
ELECTRICAL WIRING
2/37
F
A
N

S
P
E
E
D
C
T
R
L
.

(
O
P
T
I
O
N
)
M
o
d
e
l
s
R
C
U
E

3
0
0
A
G
1
R
C
U
E

3
3
0
A
G
1
C
O
N
T
R
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L

C
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I
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F
A
N

S
P
E
E
D
C
T
R
L
.

(
O
P
T
I
O
N
)
2/38
ELECTRICAL WIRING
F
A
N

S
P
E
E
D
C
T
R
L
.

(
O
P
T
I
O
N
)
C
O
N
T
R
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L

C
I
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C
U
I
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M
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R
C
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3
6
0
A
G
1
R
C
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E

4
0
0
A
G
1
F
A
N

S
P
E
E
D
C
T
R
L
.

(
O
P
T
I
O
N
)
ELECTRICAL WIRING
2/39
2.3. MAIN CIRCUIT BOARD
MAIN PRINTED CIRCUIT BOARD (MASTER)
R
e
m
o
t
e

c
o
n
t
r
o
l

S
w
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c
h

(
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-
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1
SMGB0002-rev.0 - 07/05 - Printed in Spain
Hitachi Air Conditioning Products (M) Sdn. Bnd.
Lot No. 10, Jalan Kemajan Bangi Industrial Estate
43650 Bandar Baru Bangi
Selangor Darul Ehsan, Malaysia
Certification ISO 9001, Malaysia
Hitachi Air Conditioning Products Europe, S.A.
Ronda Shimizu, 1 - Polg. Ind. CanTorrella
08233 Vacarisses (Barcelona) Espaa
ISO9002 certified byAENOR, Spain
HITACHI is participating in the EUROVENT Certification Programme.
Products are as specified in the EUROVENT Directory of Certified
Products.
Products are manufactured according to the ISO certification system.
Air Conditioning Systems Operation, Shimizu shi,
Shizuoka
-
-ken, Japan: ISO9001 certified by JQA, Japan

SMGB0002 r0 07-05

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