Rcu - Rcup-Auz - SC2-P02Q
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HITACHI AIR-COOLED WATER CHILLERS - SCREW TYPE -
Technical Catalog ΙΙ – Installation, Operation and Maintenance Instructions – Models:
Step Capacity Control Type: For R407C
Continuous Capacity Control Type: For R407C
RCUP30AU RCUP38AU RCUP46AU RCUP51AU RCUP75AU RCUP90AU RCUP102AU RCUP135AU RCUP154AU RCUP179AU RCUP205AU RCUP256AU RCUP307AU
RCUP30AUZ RCUP38AUZ RCUP46AUZ RCUP51AUZ RCUP75AUZ RCUP90AUZ RCUP102AUZ RCUP135AUZ RCUP154AUZ RCUP179AUZ RCUP205AUZ RCUP256AUZ RCUP307AUZ
SC2-P02Q, 2009
IMPORTANT NOTICE ● HITACHI pursues a policy of continuing improvement in design and performance of products. The right is therefore reserved to vary specifications without notice. ● HITACHI cannot anticipate every possible circumstance that might involve a potential hazard. ● No part of this 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.
NOTE
:
Immediate hazards which WILL result in severe personal injury or death.
:
Hazards or unsafe practices which COULD result in severe personal injury or death.
:
Hazards or unsafe practices which COULD result in minor personal injury or product or property damage.
:
Useful information for operation and/or maintenance.
● If you have any questions, contact your distributor or dealer of HITACHI. ● This manual 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. Operate the air-cooled water chiller within this range.
Working Range Condensing Air Inlet Temperature Chilled Water Outlet Temperature
(oC) Maximum
Minimum
43
5
15
5
● This instructions should be considered as a permanent part of the air conditioning equipment and should remain with the air-cooled water chiller equipment.
TABLE OF CONTENTS 1. PREPARATION ......................................................................................................................... 1 Initial Check ............................................................................................................................... 1 Placing the Unit ......................................................................................................................... 1 Operation Space ........................................................................................................................ 2 Maximum Foundation Gradient ................................................................................................. 3 Center of Gravity ........................................................................................................................ 3 Weight Balance .......................................................................................................................... 4 Recommended Concrete Curbs ................................................................................................ 5 Transportation ........................................................................................................................... 8 2. INSTALLATION .......................................................................................................................... 9 Electrical Wiring ......................................................................................................................... 9 Water Piping ............................................................................................................................11 Minimum Internal System Water Volume ................................................................................. 12 Internal Water Volume in Water Cooler.................................................................................... 12 Chilled Water Pressure Drop ................................................................................................... 12 Water Control .......................................................................................................................... 13 Installation Final Check ........................................................................................................... 13 3. OPERATION INSTRUCTIONS ................................................................................................ 14 4. TEST RUNNING ...................................................................................................................... 15 Preparation .............................................................................................................................. 15 Test Running ........................................................................................................................... 15 Instruction after Test Running ................................................................................................. 15 5. CONTROLLER ADJUSTMENT ............................................................................................... 16 Controller Adjustment ............................................................................................................. 17 Unit Setting of PWB ................................................................................................................ 20 Final Check ............................................................................................................................. 20 6. SELF-INSPECTION FUNCTIONS ........................................................................................... 21 7. CONTROL SYSTEM................................................................................................................ 28 8. MAINTENANCE ...................................................................................................................... 34 Components ............................................................................................................................ 34 Lubrication ............................................................................................................................... 34 Deposits ................................................................................................................................... 34 Cleaning Method ...................................................................................................................... 35 Winter Shutdown ..................................................................................................................... 37 Spring Start-up ........................................................................................................................ 37 Part Replacement .................................................................................................................... 37 Refrigeration Cycle ................................................................................................................. 37 Compressor Removal .............................................................................................................. 39 Safety and Control Device Setting ........................................................................................... 40 Normal Operating Pressure .................................................................................................... 41 Characteristics of Sensors ...................................................................................................... 43 Test Running and Maintenance Record ................................................................................... 46 Daily Operation Records .......................................................................................................... 47 Special Notes on Refrigerant R407C ...................................................................................... 48 9. TROUBLESHOOTING ............................................................................................................. 49 10. PRESSURE CONVERSION TABLE ...................................................................................... 51
PREPARATION
1. PREPARATION Initial Check Installation Location - Confirm that the final installation location is provided with convenient piping and wiring work. Strong water runoff should be avoided. Installation Space - Check for obstacles which restrict condencer air flow or hamper maintenance work in the space specified in Fig. 1. Foundation - Check to ensure that 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 the 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, where factory-supplied foundation bolts should be sunk into concrete. Additionally, for 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 ensure 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 1)
Placing the Unit
● If leakage is detected, stop the unit and contact the installer or a service shop. Do not use a naked fire near the refrigerant gas. If a naked fire is utilized near the refrigerant gas, refrigerant is turned into a harmful phosgene compound.
● This unit is operated with refrigerant 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, keep a good ventilation to avoid choke during servicing.
● Check to ensure that valves for safety 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 practical 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 Operation Space 3,000mm Overhead Air Clearance
3,000mm Overhead Air Clearance
2,150mm C
h1
h2
C
h2
h1
2,150mm
A
A F
B
E
D
F
h1 < h2
B
E
D
h1 < h2
For Models RCUP30AU(Z)~RCUP154AU(Z)
For Models RCUP179AU(Z)~RCUP307AU(Z) Fig. 1 Operation Space
Refer to C, D Refer to C, D G
H
Refer to C, D
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.
J
Model RCUP30AU(Z) RCUP38AU(Z) RCUP46AU(Z) RCUP51AU(Z) RCUP75AU(Z) RCUP90AU(Z) RCUP102AU(Z) RCUP135AU(Z) RCUP154AU(Z) RCUP179AU(Z) RCUP205AU(Z) RCUP256AU(Z) RCUP307AU(Z)
2
Maintenance Space (mm) A B C D 1,900 1,900 100 1,200 1,900 1,900 100 1,200 1,900 1,900 100 1,200 1,900 1,900 100 1,200 3,800 1,900 100 1,200 3,800 1,900 100 1,200 3,800 1,900 100 1,200 5,700 1,900 100 1,200 5,700 1,900 100 1,200 7,700 1,900 1,200 1,200 7,700 1,900 1,200 1,200 9,600 1,900 1,200 1,200 9,600 1,900 1,200 1,200
E 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200
Air Intake Space (mm) F G H 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000 1,000 1,200 2,000
J 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200 1,200
PREPARATION Maximum Foundation Gradient
30mm
15mm
Fig. 2 Maximum Foundation Gradient
Center of Gravity Center of Gravity Model RCUP30AU(Z) RCUP38AU(Z) RCUP46AU(Z) RCUP51AU(Z) RCUP75AU(Z) RCUP90AU(Z) RCUP102AU(Z) RCUP135AU(Z) RCUP154AU(Z) RCUP179AU(Z)-1 RCUP179AU(Z)-2 RCUP205AU(Z)-1 RCUP205AU(Z)-2 RCUP256AU(Z)-1 RCUP256AU(Z)-2 RCUP307AU(Z)-1 RCUP307AU(Z)-2
X
Y
935 935 945 945 1,850 1,865 1,865 2,760 2,760 1,865 1,935 1,865 1,935 2,760 1,935 2,760 2,940
815 825 820 820 815 810 810 815 815 810 810 810 810 815 810 815 815
Operation Weight (kg) 1,370 1,420 1,495 1,535 2,590 2,750 2,830 4,435 4,555 2,750 2,750 2,830 2,830 4,555 2,830 4,555 4,555
RCUP30~154AU(Z), RCUP179~307AU(Z)-1 Piping Side
X
Y
Electrical Box
RCUP179~307AU(Z)-2 Piping Side
X
Y
Electrical Box Fig. 3 Center of Gravity
3
PREPARATION Weight Balance Weight Balance Model RCUP30AU(Z) RCUP38AU(Z) RCUP46AU(Z) RCUP51AU(Z)
Chilled Water Piping
1 295 310 320 325
Location (kg) 2 3 290 395 300 410 320 430 325 445
4 390 400 425 440
1
2
3
4
Electrical Box
Model RCUP75AU(Z) RCUP90AU(Z) RCUP102AU(Z) RCUP179AU(Z)-1 RCUP179AU(Z)-2 RCUP205AU(Z)-1 RCUP205AU(Z)-2 RCUP256AU(Z)-2
Model RCUP135AU(Z) RCUP154AU(Z) RCUP256AU(Z)-1 RCUP307AU(Z)-1 RCUP307AU(Z)-2
1 375 390 400 390 375 400 390 390
1 530 550 550 550 415
2 365 385 395 385 385 395 395 395
2 490 505 505 505 460
Location (kg) 3 4 350 515 375 545 390 555 375 545 390 520 390 555 400 540 400 540
3 450 460 460 460 505
5 500 535 550 535 535 550 550 550
6 485 520 540 520 545 540 555 555
Location (kg) 4 5 410 725 420 740 420 740 420 740 555 565
6 665 685 685 685 625
Chilled Water Piping 1
2
3
4
5
6
Electrical Box Electrical Box (RCUP75~102AU(Z), (RCUP179,205,256AU(Z)-2) RCUP179, 205AU(Z)-1)
7 610 625 625 625 685
8 555 570 570 570 745
Chilled Water Piping 1
2
3
4
5
6
7
8
Electrical Box (RCUP135,154AU(Z), RCUP256,307AU(Z)-1)
Electrical Box (RCUP307AU(Z)-2)
Fig. 4 Weight Balance
4
PREPARATION Recommended Concrete Curbs For Models RCUP30AU(Z), RCUP38AU(Z), RCUP46AU(Z) and RCUP51AU(Z)
For Models RCUP75AU(Z), RCUP90AU(Z) and RCUP102AU(Z)
Fig. 5-1 Recommended Concrete Curbs
5
PREPARATION Recommended Concrete Curbs For Models RCUP135AU(Z) and RCUP154AU(Z)
For Models RCUP179AU(Z) and RCUP205AU(Z)
Fig. 5-2 Recommended Concrete Curbs 6
PREPARATION Recommended Concrete Curbs For Models RCUP256AU(Z)
For Models RCUP307AU(Z)
Fig. 5-3 Recommended Concrete Curbs 7
PREPARATION Transportation 1) Rigging Hook wire cables and apply field-supplied spreader bars on the top of the unit (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 the unit weight. Check to ensure that the rigging bolts are tightly fixed to the unit. The rigging angle shall be greater than 60o as shown. The weight of the unit is indicated on the unit label.
Do not stand below the unit when rigging.
Put cloths between wires and the unit to avoid damages.
Fig. 6-1 Transportation by Rigging 2) Transportation by Roller When rooling the unit, put at least required 7 equalsized 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).
3) Declining the Unit during Transportation
Do not decline the unit more than an angle of 15o as shown in the figure during transportation. If declined more than an angle of 15o, the unit may fall down.
15
Fig. 6-2 Transportation by Rollers 8
Fig. 6-3 Declining the Unit
o
INSTALLATION
2. INSTALLATION Electrical Wiring Tools and Instruments - One Set of Wiring tools and Electrical Tester (Clamp Meter) Schedule Check -
● 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 Ι, and ensure that 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 from an electric 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 field-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 the earthing wire through the connector to the screw terminals for main power and earthing in the magnetic switch box. The neutral wires for 380/50Hz and 415V/50Hz power supply should also be led through the connector. 4. Firmly connect the wires with wire terminals to unit screw terminals R, S, T and Mp according to Fig. 7. 5. Connect the wires between the power source and the field-supplied magnetic switches. 6. Consider that the main power source will not be left turned OFF, because it is necessary to energize the oil heater even during unit stoppage. NOTE • More than 179AU(Z) including 179AU(Z) unit consists of No.1 (Master) unit 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. RCUP30~154AU(Z) Control Circuit Terminals
3~Mp. 380V, 415V/50Hz 3~, 440V/60Hz
Magnetic Switch Box 3
TB2
1 2
1
2
Pump Power Supply
Power Source Terminals
*CMP
R S T Mp Main Power Switch (Field-Supplied)
Interlock for the Pump Contactor
PWBc *CSP
Y52P1
4
*ORP
*CMP Earth Terminal Main Power Wiring
Earth Wiring
Pump Operation Wiring (If Required)
Contactor for Chilled Water Pump Control Circuit Wiring Wire to Be Removed
*BSR1 *BSR2 *CMP *ORP *CSP *PLR1 *PLR2 *PLO1,2,3
Push Button Switch (ON) Push Button Switch (OFF) Contactor for Pump TB2 Overcurrent Relay for Pump Changeover Switch for Pump Operation Pilot Lamp for Remote Indication (Operation) *BSR2 Pilot Lamp for Remote Indication (Pump) (OFF) Pilot Lamp for Remote Indication (Alarm, Each Cycle) * : Field-Supplied
TB2 5
6
7
*BSR1 (ON)
Fig. 7-1 Field Wiring Connections
8
9
10
11
12
13
*PLR1 *PLP2 *PLO1 *PLO2 *PLO3
Indication Lamp Power Supply Remote Control Wiring and Remote Indication Wiring (If Required)
9
INSTALLATION RCUP179~307AU(Z) No.1 Unit (Master Unit) Control Circuit Terminals
Power Source Terminals
3~Mp. 380V, 415V/50Hz 3~, 440V/60Hz
1 2
No.2 Unit (Subsidiary Unit) Magnetic Switch Box
Control Circuit Terminals Power Source Terminals Magnetic Switch Box
3~Mp. 380V, 415V/50Hz 3~, 440V/60Hz
AB
AB
R S T Mp
R S T Mp
Main Power Switch (Field-Supplied)
Main Power Switch (Field-Supplied)
Earth Terminal
Earth Terminal Main Power Wiring
Main Power Wiring
Earth Wiring Control Circuit Wiring
1
Wire to Be Removed
2 3
*CMP
Interlock for the Pump Contactor (No. 1 Unit)
Pump Power Supply
TB2
Earth Wiring
Contactor for Chilled Water Pump
PWBc Y52P1
TB2
*CSP
5
6
*BSR2 (OFF)
4
7
*BSR1 (ON)
*ORP (No.1 Unit) *CMP TB2
No.1 Unit TB3
A
B
Pump Operation Wiring (If Required)
8
9
10
11
12
13
(179~205AU) *PLO1 *PLO2 -*PLR1 *PLP2 *PLO1 *PLO2 *PLO3 (256~307AU)
(No.1 Unit)
Indication Lamp Power Supply
TB3
A
B
No.2 Unit Control Wiring Between No.1 and No.2 Units *BSR1 *BSR2 *CMP *ORP *CSP *PLR1 *PLR2 *PLO1,2,3,4,5,6
Remote Control Wiring and Remote Indication Wiring (If Required) (For No.1 Unit) Shielded Wires DC12V (with Polarity Transmission)
TB2
8
9
11
12
13
(179~205AU) *PLO3 *PLO4 (256AU) *PLO4 *PLO5 *PLO4 *PLO5 *PLO6 (307AU)
Push Button Switch (ON) Push Button Switch (OFF) Contactor for Pump Overcurrent Relay for Pump Changeover Switch for Pump Operation Pilot Lamp for Remote Indication (Operation) Pilot Lamp for Remote Indication (Pump) Pilot Lamp for Remote Indication (Alarm, Each Cycle)
Indication Lamp Power Supply Remote Control Wiring and Remote Indication Wiring (If Required) (For No.2 Unit)
* : Field-Supplied
Fig. 7-2 Field Wiring Connections
10
10
INSTALLATION Water Piping When piping connections are performed: 1. Connect chilled water common piping (Field-supplied) between each cooler directly. Design the common water piping the chilled water distribution to each cooler is equal. Refer to the “Typical Water Common Piping” in Technical Catalog Ι. 2. Connect the water coolers in the same unit to the same common water piping. 3. Connect chilled water piping of the field with flanges to the common water piping, so that disconnection can be easily performed when required. 4. It is recommended for the piping of the chilled water inlet and outlet that flexible joints be utilized, so that vibration will not transmit. 5. Whenever permissible, sluice valves should be utilized for water piping, in order to minimize flow resistance and to maintain sufficient water flow. 6. Proper inspection should be performed to check for leaking parts inside and outside the system, by completely opening the chilled water inlet and outlet valves to the water cooler. 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. 7. Sufficiently perform insulation to keep the chilled water piping cool and to prevent sweating of the piping. 8. Under the condition where the ambient temperature is low in winter, there is a case where equipment and piping will become damaged during the 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 danger of freezing, completely drain the water from piping. Additionally, in a case where measures such as water draining are difficult, utilize antifreeze mixture of ethylene glycol type or propylene glycol type. 9. This product is equipped with plate type heat exchangers. In the plate type heat exchanger, water flows through a narrow space between the plates. Therefore, there is a possibility that freezing may occur if foreign particles or dusts are clogged. In order to avoid this clogging, provide a 20 mesh water strainer at the inlet of chilled water piping near the product. A 20 mesh water strainer is available as an option. 10. After performed the water piping, 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 and cleaning the water strainer filter. Check to ensure that no foreign particle and substance exists.
● 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. ● In the case of using brine, as the glycol brine is an organic compound, prevent it from entering into drain water. It may cause to raising BOD(COD). Contact a local industrial waste agent when you want to renounce the brine. Water Piping Example Chiller Unit
Water Pump
Heat Load Side
11
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. (m3) Model
RCUP30AU
RCUP38AU
RCUP46AU
RCUP51AU
RCUP75AU
RCUP90AU
RCUP102AU
RCUP135AU
50Hz
0.48
0.54
0.68
0.75
0.58
0.73
0.80
0.77
60Hz
0.57
0.64
0.80
0.86
0.66
0.85
0.93
0.88
Model
RCUP154AU
RCUP179AU
RCUP205AU
RCUP256AU
RCUP307AU
50Hz
0.84
0.78
0.86
0.84
1.67
60Hz
0.97
0.92
1.00
0.97
1.94
Model
RCUP30AUZ
RCUP38AUZ
RCUP46AUZ
RCUP51AUZ
RCUP75AUZ
50Hz
0.30
0.35
0.44
0.47
0.70
0.87
0.95
1.30
60Hz
0.35
0.41
0.50
0.55
0.82
1.00
1.10
1.49
RCUP90AUZ RCUP102AUZ RCUP135AUZ
Model RCUP154AUZ RCUP179AUZ RCUP205AUZ RCUP256AUZ RCUP307AUZ 50Hz
1.42
1.71
1.90
2.37
2.84
60Hz
1.65
2.03
2.19
2.74
3.29
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 (refer to page 17).
Internal Water Volume in Water Cooler (m3) Model RCUP30AU(Z) RCUP38AU(Z) RCUP46AU(Z) RCUP51AU(Z) RCUP75AU(Z) RCUP90AU(Z) RCUP102AU(Z)
Water Cooler 0.014 0.015 0.020 0.020 2 x 0.015 2 x 0.020 2 x 0.020
Chilled Water Pressure Drop
12
Model RCUP135AU(Z) RCUP154AU(Z) RCUP179AU(Z) RCUP205AU(Z) RCUP256AU(Z) RCUP307AU(Z)
Water Cooler 3 x 0.020 3 x 0.020 4 x 0.020 4 x 0.020 5 x 0.020 6 x 0.020
INSTALLATION Water Control When industrial water is applied for chilled water and 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. It is also necessary to analyze the quality of water by checking pH, electrical conductivity, ammonia ion content, sulfur content, and others, and to utilize industrial water only if problem is encountered through these checks. The following is the HITACHl standard water quality based on the JRA standard water quality. Chilled Water System Item
Circulating Water (20oC Less than)
Supply Water
Corrosion
Deposit of Scales
6.8 ~ 8.0 Less than 40 {Less than 400} Less than 50 Less than 50
6.8 ~ 8.0 Less than 30 {Less than 300} Less than 50 Less than 50
O
O
(mS/m) (25oC) {μS/cm} (25oC)(2) ( mgCl - / l) ( mgSO42- / l)
O
O
( mgCaCO3 / l)
Less than 50
Less than 50
O
( mgCaCO3 / l) ( mgCaCO3 / l) ( mgSiO2 / l)
Less than 70 Less than 50 Less than 30
Less than 70 Less than 50 Less than 30
O O O
Standard Quality pH (25oC) Electrical Conductivity Chloride Ion Sulfur Acid Ion The Amount of Acid Consumption (pH4.8) Total Hardness Calcium Hardness Silica L Reference Quality Total Iron Total Copper Sulfur Ion Ammonium Ion Remaining Chlorine Floating Carbolic Acid Index of Stability
Tendency (1)
(mgFe/ l) (mgCu/ l) ( mgS2- / l) ( mgNH4+/ l) ( mgCl / l) ( mgCO2 / l)
Less than 1.0 Less than 0.3 Less than 1.0 Less than 0.1 It shall not to be detected. Less than 1.0 Less than 0.1 Less than 0.3 Less than 0.3 Less than 4.0 Less than 4.0 6.8 ~ 8.0 -
O O
O O O O O O O
O
O
NOTES : (1)The mark “O” in the table means the factors concerned with tendency for corrosion and deposit of scales. (2)The value showed “{ }” are for reference only according to the former unit.
Installation Final Check Inspect the installation work according to all documents and drawings, the minimum check points shown in below.
INSTALLATION WORK CHECK LIST 1. Is the unit solidly mounted and leveled? 2. Is the installation location adequate? Space for Condenser Air Flow Space for Maintenance Work Noise and Vibration Sunshine and Rainfall Appearance 3. Is the water piping system adequate? Tube Size Water Drain Length Water Control Flexible Joint Air Purge Insulation Pressure Control
4. Is electrical wiring system adequate? Wire Size Tightened Connections Operation Control Devices Switch Size Fuse Size Safety Devices Voltage and Hz Interlock 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? (Mp phase also) 6. Are the stop valves for the condenser liquid line open? 7. Have the packing glands and the cap nuts for the stop valves been tightened?
13
OPERATION INSTRUCTIONS
3. OPERATION INSTRUCTIONS To Start the Unit 1. Open the water inlet and outlet valves. 2. After asssuring that all control switches have been cut OFF, and the “LOCAL/REMOTE” switch on the printed circuit board is in the “REMOTE” position, turn ON the power switch. 3. Confirm that phases, R, S and T and correctly connected. The correct phase connection can be checked by a phase sequence indicator. If not correctly connected, the compressor does 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 as shown in the right figure. 5. Operate the chilled water pump. 6. Depress the “*ON” push button switch. (*; Field-Supplied) 7. Set the chilled water temperature, if necessary. To Stop the Unit 1. Depress the “*OFF” push button switch. (*; Field-Supplied) 2. Switch OFF the main power source when the unit is shut down for a long period of time. Pilot Lamp The red LED indicates the normal operation. When the orange LED is activated, any one of the safety devices may be functioning. Please contact your service 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 Does Not Start 1. 2. 3. 4.
Is the main switch ON? Is the main fuse OK? Is the chilled water running? Are the thermostat calling for the cooling operation?
Poor Cooling Operation 1. Is sufficient air supplied to the condenser? 2. Are the thermostat properly set? 3. Are the operating pressures 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 water cooler plates. (It is recommended that a specialist be contacted for this type of work.)
14
TEST RUNNING
4. TEST RUNNING Preparation Tools and Instruments - High Pressure Compound Gauge, Low Pressure Compound Gauge, Electrical Tester and General Tools
● 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 and cleaning the water strainer filter before test running. 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 the HITACHl standard wiring label. 1. Switch ON the field-supplied pump, and the pump will be started immediately. Check the condition and operation state of these components. 2. Fully open the liquid line stop valve. 3. 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.
● When the unit is wired according to the HITACHl standard wiring shown on the wiring 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 phase 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 is correctly connected. The correct phase connection can be checked by a phase sequence indicator. If not, the compressor does not start due to activation of the reversal phase protection device. Cut the main switch and interchange two of 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 handling units. Check to ensure that the chilled water flows sufficiently and that other auxiliary equipment operate properly. b. Set the switch at the desired temperature. c. Depress 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 pressures by 7-segment on control panel. Refer to the discharge and suction pressure curves in page 41. f. Check to ensure that the thermostat functions properly. g. Check to ensure that the control and protective devices function properly (refer to Table in page 40). h. 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 screw rotors, resulting from the pressure difference between the discharge and the suction pressure. • Each compressor may show the different values of running current due to individual capacity control for each compressor. This is not abnormal.
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 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 operation season starts after long disconnection of the power source switch, please turn on the power source switch 12 hours before starting operation.
15
CONTROLLER ADJUSTMENT
5. CONTROLLER ADJUSTMENT
Fig. 8-1 Switch Arrangement of PWBB RCUP30~154AU(Z)
RCUP179~307AU(Z) No.1 Unit
PWBG
DSW1
PWBG
DSW2
DSW1
DSW2
Fig. 8-2 Switch Arrangement of PWBG 16
No.2 Unit PWBG
DSW1
DSW2
CONTROLLER ADJUSTMENT Controller Adjustment Setting, functions are followings. $ Chilled Water Temperature Setting Switch = RSW1 and RSW2 * Step Capacity Control Type (RCUP - AU) Switches “RSW1” and “RSW2” are used for setting a required chilled water inlet temperature. = 12 oC for chilled water inlet temperature is recommended. The RSW1 and RSW2 dials are already set at 1 and 2. Setting at the figures from 3 to 9 of the RSW2 dial should not be permitted. * Continuous Capacity Control Type (RCUP - AUZ) Switches “RSW1” and “RSW2” are used for setting a required chilled water outlet temperature. = 7 oC for chilled water outlet temperature is recommended. The RSW1 and RSW2 dials are already set at 0 and 7. Setting at the figures from 3 to 9 of the RSW2 dial should not be permitted.
$ Differential Setting Switch (Neutral Zone Setting Switch) = RSW8 * Step Capacity Control Type (RCUP - AU) Thermostat ON/OFF Differential Temperature Setting Switch. = 4 degree is standard. The RSW8 dial is already set at 4 = 4 degree. The figures at the RSW8 dial mean as follows. Figure Differential (degree) Step Differential (degree) Minimum Internal System Water Volume Ratio (%)
1 1 0.5 400
2 2 1 200
3 3 1 130
4 4 1 100 (Standard Setting)
NOTE 1. Even if the temperature is set at temperature except 1 to 4, the temperature is automatically set at 4. 2. Calculate and secure the required internal system water volume if this setting is changed at the site.
* Continuous Capacity Control Type (RCUP - AUZ) Neutral Zone Temperature Setting Switch = 2 degree is standard. The RSW8 dial is already set at 3 = 2 degree. The figures at the RSW8 dial mean as follows. Figure Band (degree)
0 0.5
1 1.0
2 1.5
3 2.0
4 2.5
5 3.0
6 3.5
7 4.0
8 4.5
9 5.0
$ Continuous Capacity Control Setting Switch = DSW5 For only Continuous Capacity Control Type (RCUP - AUZ) *Temperature Band for Stop Setting Switch = 1 degree is standard. The figures 1 and 2 of the DSW5 switch are already set at figure 1 = ON side, figure 2 = OFF side. The locations at the figures 1 and 2 of the DSW5 mean as follows. Figure Location Band (degree) DSW7-3 ON
1 ON
2 ON
1 ON
0.5 1.0
2 OFF
1 OFF
1.0 1.5
2 ON
1 OFF
1.5 2.0
2 OFF 2.0 2.0
Standard Wide min. load
* Temperature Band for Restart Setting Switch = 2 degree is standard. The figures 3 and 4 of the DSW5 switch are already set at figure 3 = ON side, figure 4 = OFF side. The locations at the figures 3 and 4 of the DSW5 mean as follows. Figure Location Band (Degree)
3 ON
4 ON 1.0
3 ON
4 OFF 2.0
3 OFF
4 ON 3.0
3 OFF
4 OFF 4.0
* Differential Temperature of Load-up 2 Mode Setting Switch = 1 degree is standard. The figure 5 of the DSW5 switch is already set at ON side. The locations at the figure 5 of the DSW5 mean as follows. Figure Location Band (Degree)
5 ON 1.0
5 OFF 3.0
17
CONTROLLER ADJUSTMENT * Output Signal Time for Load-up 1 Mode Setting Switch = 12 seconds is standard. The figure 6 of the DSW5 switch is already set at ON side. The locations at the figure 6 of the DSW5 mean as follows. Figure Location Time (Second)
6 ON 12
6 OFF 24
* Output Signal Time for Load-up 2 and Load-down Mode Setting Switch = 2 seconds is standard. The figures 7 and 8 of the DSW5 switch are already set at figure 7 = ON side, figure 8 = ON side. The locations at the figures 7 and 8 of the DSW5 mean as follows. Figure Location Time (Second)
7 ON
8 ON
7 ON
2
8 OFF
7 OFF
4
8 ON
7 OFF
6
8 OFF 8
* Interval of Output Signal Time for Load-up and Load-down Mode Setting Switch = 60 seconds is standard. The figures 9 and 10 of the DSW5 switch are already set at figure 9 =ON side, figure 10 = ON side. The locations at the figures 9 and 10 of the DSW5 mean as follows. Figure Location Time (Second)
9 ON
10 ON
9 ON
60
10 OFF
9 OFF
90
10 ON 120
9 OFF
10 OFF 30
$ 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”. The compressor will be started after setting time (3 minutes is standard). Factory set of switch “DSW2” is 3. The meaning of the figures at switch “DSW2” is as follows. DSW2 1 2 ON ON OFF ON ON OFF OFF OFF
Time (minute) 0.5 10 6 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 3 ON ON OFF
4 OFF OFF ON
Depress Switch SW9 SW10 No. 1 Cycle No. 2 Cycle No. 3 Cycle No. 4 Cycle No. 5 Cycle No. 6 Cycle
$ Manual Set Switch = figures 1,2,3,4,5 and 6 of DSW3 Switch “DSW3-1” is for No.1 Compressor, “DSW3-2” for No.2, “DSW3-3” for No.3, “DSW3-4” for No.4 and “DSW3-5” for No.5. If necessary to stop any compressors, turn these switches (DSW3-1, DSW3-2, DSW3-3, DSW3-4 and DSW3-5) to the “OFF” side, the compressor corresponding to these switches are turned to the “OFF” side will be stopped.
NOTE 1. Switch “DSW3-2” shall be always turned to the “OFF” side in RCUP30AU(Z)~RCUP51AU(Z). 2. Switch “DSW3-3” shall be always turned to the “OFF” side in RCUP30AU(Z)~RCUP102AU(Z). 3. Switch “DSW3-4” shall be always turned to the “OFF” side in RCUP30AU(Z)~RCUP154AU(Z). 4. Switch “DSW3-5” shall be always turned to the “OFF” side in RCUP30AU(Z)~RCUP205AU(Z). 5. Switch “DSW3-6” shall be always turned to the “OFF” side in RCUP30AU(Z)~RCUP256AU(Z).
18
CONTROLLER ADJUSTMENT $ Selection of Differential Control = figure 4 of DSW6 For only Step Capacity Control Type (RCUP – AU) Switch “DSW6-4” is a selection switch for Normal Operation Mode / Differential Control Mode. Switch “DSW6-4” should be turned to the “OFF” side. However, Differential Mode is required, turn the “DSW6-4” to the “ON” side. By setting this switch at the “ON” side, ON/OFF differential of the thermostat is changed according to the following conditions. This setting shall be performed when the unit is stopped. This switch is set at the “OFF” side before shipment. (1) In the case that water temperature decrease is smaller than 2 deg 20 minutes after compressor start-up, the OFF temperature of the thermostat is increased 2 deg higher than the normal point, resulting in 2 deg differential. Refer to (a) and (c) in the figure below. (2) In the case that water temperature decrease is larger than 2 deg 20 minutes after compressor start-up the differential of 4 deg is remains unchanged. Refer to (b) the figure below. (3) The differential is controlled when the operating conditions are as shown in the following figure. (b)
(c) 4deg.
T=20min.
2deg.
ON Point
tw
Water Temp. tw(C )
(a)
OFF Point more than 20min.
less than 20min.
Water Temperature Change when the Differential Remains Unchanged
more than 20min.
Time T (min.)
$ Selection Switch for Cooling/Heating Operation = SW8 = Models : RCUP30AU(Z)~RCUP307AU(Z) are for cooling only. So that Heating Function is not available. The SW8 Selection Switch must be turned to the 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 required Local operation, 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 (“OFF”) side. If required Local operation, 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 DSW1 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.
19
CONTROLLER ADJUSTMENT Unit Setting of PWB The same CPUs as a 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…. RCUP30AU(Z)~RCUP154AU(Z) Master………… RCUP179AU(Z)~RCUP307AU(Z)-No.1 Unit Subsidiary…… RCUP179AU(Z)~RCUP307AU(Z)-No.2 Unit 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 RSW8 to “4”. 4) Then is indicated. 5) Set DSW1-2, 3, 4 to “ON” and RSW8 to “2”. 6) The present setting is indicated, and check 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 SEG1 is changed from “U1” to “U2”. Check whether the mode is changed or not and change to the required setting by pressing the “+” or “,” switch for 1 (one) second. 8) Change the setting change mode to indication mode by pressing the “+” and “,” 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.
20
SELF-INSPECTION FUNCTIONS
6. 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 turned ON. Function of 7-Segment Light Emitted Diode on Control Panel is as shown in the table below.
7-Segment on Control Panel Code
Content
Remarks No.1, No.2, No.3, No.4, No.5 and No.6
C1-H1
C2-H2
C3-H3
C4-H4
C5-H5
C6-H6
Activation of High Pressure Switch
C1-L1
C2-L2
C3-L3
C4-L4
C5-L5
C6-L6
Alarm of Excessively Low Suction Pressure
C1-F1
C2-F2
C3-F3
C4-F4
C5-F5
C6-F6
Activation of Overcurrent Relay for Fan Motor
C1-t1
C2-t2
C3-t3
C4-t4
C5-t5
C6-t6
Alarm of Excessively Low Suction Gas Temperature (THMS1~6)
C1-41
C2-42
C3-43
C4-44
C5-45
C6-46
Activation of Internal Thermostat for Fan Motor
C1-51
C2-52
C3-53
C4-54
C5-55
C6-56
Activation of Overcurrent Relay for Compressor
C1-61
C2-62
C3-63
C4-64
C5-65
C6-66
Activation of Supplying Oil Protection by Thermistor (THMD1~6, THMoB1~6)
C1-71
C2-72
C3-73
C4-74
C5-75
C6-76
Activation of Internal Thermostat for Compressor Motor
13
13
13
13
13
13
C1-13
C2-13
C3-13
C4-13
C5-13
C6-13
Activation of Freeze Protection by Thermistor (THMo1~6, THMoB1~6)
14
14
14
14
14
14
Activation of Water Temperature Overheating Protection by Thermistor (THMo1~6)
C1-14
C2-14
C3-14
C4-14
C5-14
C6-14
C1-91
C2-92
C3-93
C4-94
C5-95
C6-96
C1-P6
C2-P6
C3-P6
C4-P6
C5-P6
C6-P6
5P
5P
5P
5P
5P
5P
05
05
05
-
-
-
Abnormality in Reverse Phase or Single Phase
30~154AU(Z)
C1-05
C2-05
C3-05
C4-05
C5-05
C6-05
Abnormality in Reverse Phase or Single Phase
179~307AU(Z)
11
11
11
11
11
11
Abnormality in Thermistor for Chilled Water Inlet (THMi)
C1-12
C2-12
C3-12
C4-12
C5-12
C6-12
Abnormality in Thermistor for Chilled Water Oultet (THMo1~6)
No.1, No.2, No.3, No.4, No.5 and No.6
C1-21
C2-21
C3-21
C4-21
C5-21
C6-21
Abnormality in Thermistor for Water Cooler Refrigerant Inlet Temperature (THME1~6)
C1-23
C2-23
C3-23
C4-23
C5-23
C6-23
Abnormality in Thermistor for Discharge Gas Temperature (THMD1~6)
C1-24
C2-24
C3-24
C4-24
C5-24
C6-24
Abnormality in Thermistor for Liquid Temperature (THML1~6)
C1-25
C2-25
C3-25
C4-25
C5-25
C6-25
Abnormality in Thermistor for Freeze Protection (THMoB1~6)
C1-26
C2-26
C3-26
C4-26
C5-26
C6-26
Abnormality in Thermistor for Suction Gas (THMS1~6)
C1-27
C2-27
C3-27
C4-27
C5-27
C6-27
Abnormality in Pressure Sensor for Discharge Pressure (PDCN1~6)
C1-28
C2-28
C3-28
C4-28
C5-28
C6-28
Abnormality in Pressure Sensor for Suction Pressure (PSCN1~6)
22
22
22
22
22
22
Abnormality in Thermistor for Ambient Temperature (THMa)
40
40
40
40
40
40
Alarm for Operation Error
Activation of Freeze Protection by Thermistor (THMi1)
Activation of Water Temperature Overheating Protection by Thermistor (THMo1~6) Alarm of Excessively Low Evaporator Inlet Refrigerant Temperature (THME1~6) Excessively Low Suction Pressure Retry Control Abnormal Condition of Feed Back Signal from Pump
Max. 2 times in 30 minutes Immediately after Operation
EU
EU
EU
-
-
-
Abnormality in Transmission to PWBG
30~154AU(Z)
01-EU
02-EU
03-EU
04-EU
05-EU
06-EU
Abnormality in Transmission to PWBG
179~307AU(Z)
03-03
03-03
03-03
03-03
03-03
03-03
Abnormality in Transmission to HARC or CSC-5S
Option
C1-41
C2-42
C3-43
C4-44
C5-45
C6-46
Activation of Internal Thermostat for Fan Motor
Option
Abnormality in Transmission or Abnormality Setting between Master and CP-CP CP-CP CP-CP CP-CP CP-CP CP-CP 179~307AU(Z) Subsidiary Unit
(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. Code
Content
C1-88
C2-88
C3-88
C4-88
C5-88
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
Remarks
PU-PU PU-PU PU-PU PU-PU PU-PU PU-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 C1-E0
C2-E0
C3-E0
C4-E0
C5-E0
C6-E0
Electronic Expansion Valve Initializing
21
SELF-INSPECTION FUNCTIONS (3) Function for indication of Operation Condition The setting temperature, chilled water temperature sensed at thermistor, suction, discharge pressure sensed by pressure sensor, the setting differential temperature and the last alarm code are digitally indicated on the control panel. Push the check " " switch for more than 3 seconds.
This indication is available in the case that only for the last alarm is indicated in "The Alarm Code Occurrence Data 1".
The Alarm Code Occurrence Data 2 (The refrigerant cycle data just before the last alarm) Please refer to page 26 for details of this function.
This indication mode is switched to the normal mode by pushing the check " " and " " switches simultaneously for more than 3 seconds again, or automatically switched when 30 seconds pass after operating the switches.
This indication mode is switched to the normal mode by pushing the check " " and " " switches simultaneously for more than 3 seconds again, or automatically switched when 30 seconds pass after operating the switches.
The Alarm Code Occurrence Data 1
Push the check " " switches for more than 3 seconds.
Normal Operation Condition "88" "Co" "oF"
Checking Indication Please refer to page 23 for details of this function.
Please refer to page 25 for details of this function.
Push the check " " and " " switches simultaneously for more than 3 seconds.
This indication mode is switched to the normal mode by pushing the check " " switch for more than 3 seconds again, or automatically switched when 30 seconds pass after operating the switches.
This indication mode is switched to the normal mode by pushing the check " " switch for more than 3 seconds again, or automatically switched when 30 seconds pass after operating the switches. Push the check " " switch for more than 3 seconds.
The Setting Mode of Second Preset Temperature Please refer to page 27 for details of this function.
Attention!! The option remodeling is necessary to use this function. It's possible only to set the second preset temperature.
22
SELF-INSPECTION FUNCTIONS (3)-1 Checking Indication Chilled water temperature and the states of refrigerant cycle (Pressure, Temperature, etc.) can be indicated by pushing check switch “+” (SW3) on the printed circuit board for more than 3 seconds. (Both while be stopping and operating) (*It is impossible to switch to this mode while indicating alarm.) This dot shows checking indication mode.
PWBA (Control Panel)
(CHECK)
SW3 SW4 㔚Ḯ (POWER) ㆇォ (OPERATION) ⼊ႎ (ALARM)
(CHECK) (ON)
(OFF)
SW3 SW4
Normal Indication - No. 1 Cycle (C1) - Cooling Operation (Co)
Checking Indication Mode Push for more than 3 seconds.
Hereafter, the indication is switched whenever “+” or “,” is pushed. The indicated contents are as follows.
Items Last Alarm SW3
SW4 SW3
State of Refrigerant Cycle
Example of Indicating Code (Alternate Blinking)
Contents In case of the last alarm "Activation of High Pressure Switch of No. 1 Cycle" ("00-00" means no alarm code is memorized.) (a) Pd (Discharge Pressure) Indication [MPa] - Example: No. 1 Cycle Pd 1.42MPa - Example: No. 2 Cycle Pd 1.43MPa - Example: No. 3 Cycle Pd 1.41MPa
SW4 SW3
SW4 SW3
SW4 SW3
SW4 SW3
SW4 SW3
SW4 SW3
SW4 SW3
SW4
In Case of Multi-Cycle Unit (Only refrigerant cycle No. at "ON" side on Manual Set Switch are indicated. This is adaptive for the following item (b) to (h)-2.) (b) Ps (Suction Pressure) Indication [MPa] - Example: No. 1 Cycle Ps 0.41MPa - "C2-PS" ~ "C6-PS" are indicated continuously for multi-cycle unit. (c) Td (Discharge Gas Temperature) Indication [oC] - Example: No. 1 Cycle Td 81oC - "C2-td" ~ "C6-td" are indicated continuously for multi-cycle unit. (d) Ts (Suction Gas Temperature) Indication [oC] - Example: No. 1 Cycle Ts -2oC - "C2-ts" ~ "C6-ts" are indicated continuously for multi-cycle unit. (e) Tr (Water Cooler Inlet Refrigerant Gas Temperature) Indication [oC] - Example: No. 1 Cycle Tr 5oC - "C2-tr" ~ "C6-tr" are indicated continuously for multi-cycle unit. (f) Te (Liquid Refrigerant Temperature) Indication [oC] - Example: No.1 Cycle Te 35oC - "C2-te" ~ "C6-te" are indicated continuously for multi-cycle unit. (g) Inlet Water Temperature Indication [oC] - Example: Chilled Water Inlet Temperature 12oC
SW3
SW4 SW3
(h)-1 Outlet Water Temperature Indication [oC] - Example: Chilled Water Outlet Temperature 7oC (In multi-cycle unit, average of each cycle is indicated.)
SW4
23
SELF-INSPECTION FUNCTIONS
SW3
(h)-2 Each Outlet Water Temperature Indication [oC] The outlet chilled water temperatures are indicated in multi-cycle unit each cycle. (There is no indication for one cycle unit.) - Example: No. 1 Cycle Chilled Water Outlet Temperature 7oC - Example: No. 2 Cycle Chilled Water Outlet Temperature 7oC - Example: No. 3 Cycle Chilled Water Outlet Temperature 8oC
SW4 SW3
SW4 SW3
SW4 SW3
SW4
(a) Preset Temperature of Chilled Water Indication [oC] - Example: Preset Temperature of Chilled Water 12oC
Setting
SW3
(b) Second Preset Temperature of Chilled Water Indication [oC] - Example: Second Preset Temperature of Chilled Water 5oC * Only when the second preset temperature is selected, it is indicated. Please refer to (3)-4.
SW4
SW3
(c) ON/OFF Differential (In Case of Step Capacity Control)/ Neutral Zone(In Case of Continuous Capacity Control) Indication [oC]
SW4 SW3
SW4 SW3
Ambient Temperature Indication [oC] - Example: Ambient Temperature 35oC
Ambient Temperature
The capacity control of each compressor is indicated. * Step Capacity Control: "100" "75" "50" [%] * Continuous Capacity Control: Load-Up "UP" / Neutral Zone "nU" / Load-Down "dO"
(Step Capacity Cntrol) SW4
Capacity Control (Continuous Capacity Control)
- Thermo-OFF "- -" - Unload-Starting "10" - "C2-Ld" ~ "C6-Ld" are indicated continuously for multi-cycle unit.
SW3
SW4
Protection Control Operating
Mode of Operation State of Protection Control
The protection control operating state of each cycle is indicated. - The protection control is allocated in each part of seven segments, and each part lights when each protection control is operating. (Example: "Td control is operation when the No. 1 cycle is operating in cooling mode.") Pd Control
Unload-Starting Td Control
Ps Control
(At Stopping)
Differential Pressure Control
Liquid By-pass Control (Only Indication(This function is not available in this unit.)) Unload for Freeze Protection
Tr Control
Current Limitation Control Td Retrying control
- "C2-PC" ~ "C6-PC" are indicated continuously for multi-cycle unit. SW3
SW4
Number of Operating Fan Indication (If the number of operating fan is zero, "0" is indicated.) (Example : The number of operating fan is 4.)
Fan Control Number of Operating Fan
SW3
SW4
Software ROM No.
Software No. is indicated. (Example: "C-209")
* By following operation, this mode is switched to the normal mode. 1. " " (SW3) is pushed for 3 seconds or more. 2. The uninput continues for one hour.
24
SELF-INSPECTION FUNCTIONS (3)-2 Indication Mode of Alarm Occurrence Data 1 The control of abnormal stoppage including activation of safety devices is memorized and indicated on the control panel. Alarm occurrence data 1 can be indicated by pressing switch “+” (SW3) and “,” (SW4) on the printed circuit board for more than 3 seconds. (*It is impossible to switch to this mode while indicating alarm.) PWBA (Display Substrate)
(CHECK)
Alternate Blinking
SW3 SW4 㔚Ḯ (POWER) ㆇォ (OPERATION) ⼊ႎ (ALARM)
(CHECK) (ON)
(OFF)
SW3 SW4
Normal Indication - No. 1 Circuit (C1) - Cooling Operation (Co)
The alarm occurred last.
Push simultaneously for more than 3 seconds.
Hereafter, the indication is switched every time “+“ or “,“ is pushed. The indicated contents are as follows.
Items
Example of Indicating Code (Alternate Blinking)
The alarm occurred last.
SW3
SW4 SW3
SW4 SW3
SW4 SW3
SW4
. . .
. . .
The alarm occurred 5th. . . . The alarm occurred 1st.
Contents The alarm is indicated from the last. (Max. 10 Data Memorized) (When the number of alarm is 5, it is indicated from "No. 5".) In Case of Latest Alarm "Activation of Pressure Switch of No. 1 Circuit" (If no alarm code is memorized, it is indicated "00-00".) In Case of 5th Alarm "Abnormal Condition of Feed Back Signal from Pump"
. . . In Case of 1st Alarm "Alarm for Operation Error"
*1 This indication mode is switched to the normal mode by pushing the check “+” (SW3) and “,” (SW4) switches simultaneously for more than 3 seconds again, or automatically switched when 30 seconds passed after operating the switch. *2 The alarm code are deleted from old one when the number of occurrence is over 10.
25
SELF-INSPECTION FUNCTIONS (3)-3 Alarm Occurrence Data 2 (Refrigerant Cycle Data Just before Last Alarm) Each sensor data just before stopping can be indicated about the last alarm while indicating the alarm occurrence data 1. (This indication is available in the case that only for the last alarm is indicated in “Alarm Code Occurrence Data 1”.
Alternate Blinking
(CHECK)
It is effective only while indicating the last alarm.
SW3 SW4
The alarm occurred last.
Push for more than 3 seconds. *1 *2 *3 *4 *5
These data are preserved only about the last occurence alarm. These data are deleted by power supply OFF. It returns to the mode of alarm occurrence after “- - - -” blinks twice when no data is preserved. The indicated item is switched by “+” (SW3) and “,” (SW4) as well as the cheking indication. The following items are indicated by the addition though the indicated data is the same as the item indicated in the checking indication.
Items . . Refrigerant Liquid Temperature
SW3
SW4 SW3
SW4 SW3
Example of Indicating Code (Alternate Blinking)
Contents
. . . Outlet Water Temperature on Back Side of Heat Exchanger on Water Side Display [oC]
Outlet Water Temperature on Back Side of Water Side Heat Exchanger
- In Case of Outlet Water Temperature on Back Side of No. 1 Circuit 7oC - In Case of Outlet Water Temperature on Back Side of No. 2 Circuit 7oC - In Case of Outlet Water Temperature on Back Side of No. 3 Circuit 8oC
SW4 SW3
SW4 SW3
SW4 SW3
SW4 SW3
SW4
. . . Fan Control Open Level of Electronic Expansion Valve
. . . Opening Level of Electronic Expansion Valve - In Case of Opening Level of Expansion Valve of No. 1 Circuit 242 pulse - In case of Opening Level of Expansion Valve of No. 2 Circuit 240 pulse - In case of Opening Level of Expansion Valve of No. 3 Circuit 245 pulse (* Range of Opening Level: 116~656 pulse)
*1 This indication mode is switched to the normal mode by pushing the check “+” (SW3) and “,” (SW4) switches simultaneously for more than 3 seconds again, or automatically switched when 30 seconds passed after operating the switches. *2 This indication mode is switched to the mode of alarm occurrence data 1 by pushing the check “,” (SW4) switch for more than 3 seconds.
26
SELF-INSPECTION FUNCTIONS (3)-4 The Setting Mode of Second Preset Temperature ATTENTION!! The option remodeling is necessary to use this function. It is possible only to set the second preset temperature. Display of “tS-Cd” and the present second preset chilled water temperature are alternately indicated on the segment by switching to the second temperature setting mode. The example of setting the second preset chilled water temperature is shown below. SEG1
SEG2
SEG1
SEG2
In this case, the second preset temperature is "6.0oC". Push the check " " and " " switches simultaneously for more than 3 seconds. SEG1
SEG2
It switches to setting change mode.
Push the check "
" switch. : +0.5oC
SEG1
Push the check "
SEG2
SEG1
" switch. : -0.5oC
SEG2
Push the switches until becoming the required temperature. Push the check " " and " " switches simultaneously for more than 3 seconds. SEG1
SEG1
SEG2
SEG2
Display of "tS-Cd" and new second preset chilled water temperature are alternately indicated, and the new preset temperature is memorized at this point.
In this case, the second preset chilled water temperature is "12.5oC".
This mode is switched to the normal mode by pushing the check “,” switch for more than 3 seconds, or automatically switched when 30 seconds passed after operating the switches.
27
28
SV11 SV12 SV13
Solenoid Valve
Time Schedule
OFF
MC1
Motor for Compressor
OFF OFF OFF
OFF CLS OFF OFF OFF
Control Stage Control Devices Main Power Switch Water Pump Operation Switch (ON/OFF) FLD Controller ULD(75%) ULD(50%) No.1 Safety Devices Pilot Lamp Motor for Fan MF11~14 CH1 Oil Heater
OFF OFF OFF
OFF
ON OFF CLS OFF OFF ON
OFF OFF OFF
OFF
ON ON CLS OFF OFF ON
3min.
OFF OFF OFF
OFF
CLS ON OFF ON
ON ON ON
Minimum 3 min.
30sec.
CLS ON ON OFF DLT (FLD) 100% OFF OFF OFF
ON ON -
OFF OFF OFF
OFF
OPN FLK OFF ON
ON ON -
OFF OFF OFF
OFF
ON ON OFF CLS OFF OFF ON
Safety Devices
CLS ON ON OFF DLT (FLD) 100% OFF OFF OFF
ON ON -
OFF OFF OFF
OFF
ON OFF OFF CLS OFF OFF ON
OFF OFF OFF
OFF
OFF OFF CLS OFF OFF OFF
Shut Down
CLS: Close, OPN: Open, STA: Star, DLT: Delta ULD: Unload, FLD: Full Load, FLK: Flicker
Capacity Control ON ON ON ON ON ON ON ON ON ON ON ON CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF ON STA DLT DLT DLT DLT (ULD) (ULD) (FLD) (ULD) (ULD) OFF 15% 15% 100% 75% 50% ON ON OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF 5 sec.
Starting Control
Standard Operating Sequence for RCUP30AU, RCUP38AU, RCUP46AU and RCUP51AU
7. CONTROL SYSTEM
CONTROL SYSTEM
Time Schedule
Solenoid Valve
SV11 SV12 SV21 SV22
MC2
Control Stage Control Devices Main Power Switch Water Pump Operation Switch (ON/OFF) Controller FLD ULD(75%) ULD(50%) ULD(25%) No.1 Safety Devices No.2 Pilot Lamp Motor for Fan MF11~14 MF21~24 Oil Heater CH1 CH2 Motor for Compressor MC1
OFF OFF OFF OFF
OFF OFF OFF OFF
OFF
OFF
OFF
OFF
ON OFF CLS CLS OFF OFF OFF ON ON
OFF CLS CLS OFF OFF OFF OFF OFF
OFF OFF OFF OFF
OFF
OFF
ON ON CLS CLS OFF OFF OFF ON ON
3 min.
OFF OFF OFF OFF
OFF
OFF
CLS CLS ON OFF OFF ON ON
ON ON ON
ON ON -
ON ON -
ON ON -
ON ON -
ON ON -
30 sec.
ON ON -
ON ON -
ON ON -
CLS CLS CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF ON OFF OFF OFF OFF DLT DLT DLT (FLD) (ULD) (ULD) OFF 100% 50% 50% DLT DLT DLT DLT (FLD) (ULD) (ULD) (ULD) 100% 100% 50% 50% OFF OFF OFF ON OFF ON ON OFF OFF OFF OFF OFF OFF OFF ON ON
ON ON -
Capacity Control
1 min. (4 min.) Minimum 3 min. The Compressor which stopped first will be started first.
30 sec.
CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF ON ON ON ON ON ON OFF OFF OFF ON ON ON ON ON OFF DLT DLT DLT DLT STA DLT (ULD) (ULD) (FLD) (FLD) (FLD) (FLD) 15% 15% 100% 100% 100% 100% DLT STA DLT OFF OFF OFF (ULD) (ULD) (FLD) 15% 15% 100% ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF 5 sec. 5 sec.
ON ON -
Starting Control
Standard Operating Sequence for RCUP75AU, RCUP90AU and RCUP102AU
ON OFF ON OFF
OFF
OFF
ON ON CLS CLS ON ON ON ON ON
ON ON -
OFF OFF OFF OFF
OFF OFF OFF OFF
OFF
OFF
OFF OFF
ON ON OFF CLS CLS OFF OFF OFF ON ON
ON ON OPN OPN FLK OFF OFF ON ON CLS CLS ON ON ON OFF OFF DLT (FLD) 100% DLT (FLD) 100% OFF OFF OFF OFF
ON ON -
OFF OFF OFF OFF
OFF OFF OFF OFF
OFF
OFF
OFF OFF
OFF OFF CLS CLS OFF OFF OFF OFF OFF
ON OFF OFF CLS CLS OFF OFF OFF ON ON
Shut Down
CLS: Close, OPN: Open, STA: Star, DLT: Delta ULD: Unload, FLD: Full Load, FLK: Flicker
CLS OPN CLS CLS ON FLK ON OFF ON ON OFF ON OFF OFF DLT (FLD) OFF 100% DLT DLT (FLD) (FLD) 100% 100% OFF OFF OFF OFF OFF OFF OFF OFF
ON ON -
Safety Devices
CONTROL SYSTEM
29
30
Time Schedule
Solenoid Valve
SV11 SV12 SV21 SV22 SV31 SV32
MC3
MC2
Control Stage Control Devices Main Power Switch Water Pump Operation Switch (ON/OFF) Controller FLD ULD(66%) ULD(33%) ULD(17%) No.1 Safety Devices No.2 No.3 Pilot Lamp Motor for Fan MF11~14 MF21~24 MF31~34 Oil Heater CH1 CH2 CH3 Motor for Compressor MC1
OFF OFF OFF OFF OFF OFF
OFF
OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
OFF
OFF
ON OFF CLS CLS CLS OFF OFF OFF OFF ON ON ON
OFF CLS CLS CLS OFF OFF OFF OFF OFF OFF OFF
OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
ON ON CLS CLS CLS OFF OFF OFF OFF ON ON ON
3 min.
OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
CLS CLS CLS ON OFF OFF OFF ON ON ON
ON ON ON
ON ON -
ON ON -
ON ON -
ON ON -
OFF OFF OFF OFF OFF OFF OFF
OFF
OFF
30 sec.
OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF 5 sec.
OFF OFF OFF OFF OFF OFF OFF
OFF
CLS CLS CLS ON ON ON OFF OFF OFF ON DLT (FLD) 100% DLT (FLD) 100%
ON ON -
ON ON -
30 sec.
CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF DLT DLT (FLD) (FLD) 100% 100% DLT DLT (FLD) (FLD) 100% 100% STA DLT (ULD) (ULD) 15% 15% OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF 5 sec.
ON ON -
ON ON CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (FLD) 100% DLT (FLD) 100% DLT (FLD) 100% OFF OFF OFF OFF OFF OFF
1 min. 1 min. (4 min.) (5 min.) Minimum 3 min. The Compressor which stopped first will be started first.
30 sec.
ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 5 sec.
OFF
CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON ON ON OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF ON ON ON ON ON DLT DLT DLT STA DLT (ULD) (ULD) (FLD) (FLD) (FLD) 15% 15% 100% 100% 100% STA DLT OFF OFF OFF (ULD) (ULD) 15% 15%
ON ON -
Starting Control
Standard Operating Sequence for RCUP135AU and RCUP154AU
CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (FLD) 100% DLT (FLD) 100% DLT (FLD) 100% OFF OFF OFF OFF OFF OFF
-
ON ON -
ON ON -
ON ON -
CLS CLS CLS CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF DLT (ULD) OFF OFF 50% DLT DLT (ULD) (ULD) OFF 50% 50% DLT DLT DLT (FLD) (ULD) (ULD) 100% 50% 50% OFF ON ON ON OFF OFF OFF OFF ON ON ON OFF OFF OFF OFF OFF ON ON
ON ON -
Capacity Control
ON OFF ON OFF ON OFF
OFF
OFF
OFF
ON ON CLS CLS CLS ON ON ON ON ON ON ON OFF
OFF
DLT (FLD) OFF 100% DLT DLT (FLD) (FLD) 100% 100% OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
OPN OPN CLS FLK OFF OFF ON ON ON OFF
ON ON -
OPN CLS CLS FLK OFF ON ON OFF OFF OFF
ON ON -
OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
OPN OPN OPN FLK OFF OFF OFF ON ON ON
ON ON -
OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
ON ON OFF CLS CLS CLS OFF OFF OFF OFF ON ON ON CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (FLD) 100% DLT (FLD) 100% DLT (FLD) 100% OFF OFF OFF OFF OFF OFF
ON ON -
OFF OFF OFF OFF OFF OFF
OFF
OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
OFF OFF
OFF OFF CLS CLS CLS OFF OFF OFF OFF OFF OFF OFF
ON OFF OFF CLS CLS CLS OFF OFF OFF OFF ON ON ON
Shut Down
CLS: Close, OPN: Open, STA: Star, DLT: Delta ULD: Unload, FLD: Full Load, FLK: Flicker
CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (FLD) 100% DLT (FLD) 100% DLT (FLD) 100% OFF OFF OFF OFF OFF OFF
ON ON -
Safety Devices
CONTROL SYSTEM
SV11 SV12 SV13
Solenoid Valve
Time Schedule
OFF
MC1
Motor for Compressor
OFF OFF OFF
OFF CLS OFF OFF OFF
Control Stage Control Devices Main Power Switch Water Pump Operation Switch (ON/OFF) Load up Controller Neutral Load down No.1 Safety Devices Pilot Lamp Motor for Fan MF11~14 CH1 Oil Heater
OFF OFF OFF
OFF
ON OFF CLS OFF OFF ON
3 min.
OFF OFF OFF
OFF
ON ON CLS OFF OFF ON
Capacity Control
30 sec. Minimum 3 min.
ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON CLS CLS CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF STA DLT DLT DLT DLT DLT DLT DLT OFF (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) 15% 15% 15~99% 100% 100% 15~99% 15~99% 15% ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF ON ON OFF OFF OFF OFF 5 sec.
ON ON ON CLS ON OFF ON
Starting Control
Standard Operating Sequence for RCUP30AUZ, RCUP38AUZ, RCUP46AUZ and RCUP51AUZ
ON OFF OFF
OFF
CLS ON OFF ON
ON ON OPN FLK OFF ON
CLS ON ON OFF DLT (ULD) 15~99% OFF OFF OFF OFF OFF OFF
OFF
ON ON OFF CLS OFF OFF ON CLS ON ON ON DLT (FLD) 100% OFF OFF OFF
ON ON -
OFF OFF OFF
OFF
ON OFF OFF CLS OFF OFF ON
OFF OFF OFF
OFF
OFF OFF CLS OFF OFF OFF
Shut Down
CLS: Close, OPN: Open, STA: Star, DLT: Delta ULD: Unload, FLD: Full Load, FLK: Flicker
OFF OFF OFF
OFF
ON ON -
ON ON -
Safety Devices
CONTROL SYSTEM
31
32
Time Schedule
Solenoid Valve
SV11 SV12 SV13 SV21 SV22 SV23
MC2
Control Stage Control Devices Main Power Switch Water Pump Operation Switch (ON/OFF) Controller Load up Neutral Load down No.1 Safety Devices No.2 Pilot Lamp Motor for Fan MF11~14 MF21~24 Oil Heater CH1 CH2 Motor for Compressor MC1
OFF OFF OFF OFF OFF OFF
OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
OFF
ON OFF CLS CLS OFF OFF OFF ON ON
OFF CLS CLS OFF OFF OFF OFF OFF
OFF OFF OFF OFF OFF OFF
OFF
OFF
ON ON CLS CLS OFF OFF OFF ON ON
3 min.
ON OFF OFF ON OFF OFF
OFF
OFF
ON ON ON CLS CLS ON OFF OFF ON ON
30 sec.
Minimum 3 min. The Compressor which stopped first will be started first.
60 sec.
ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF DLT DLT DLT DLT STA DLT STA DLT (ULD) (ULD) (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) 15% 15% 15% 15% 15-99% 100% 100% 15-99% DLT DLT DLT DLT STA DLT OFF OFF (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) 15% 15% 15-99% 100% 100% 15-99% ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF ON ON OFF OFF ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF ON ON OFF OFF 5 sec. 5 sec.
Starting Control
Standard Operating Sequence for RCUP75AUZ, RCUP90AUZ and RCUP102AUZ
ON ON -
CLS CLS CLS CLS ON ON ON ON ON ON OFF OFF OFF OFF DLT DLT (ULD) (ULD) 15-99% 15% DLT DLT (ULD) (ULD) 15-99% 15% OFF OFF OFF ON OFF OFF OFF OFF OFF ON OFF ON
ON ON -
Capacity Control
ON OFF OFF ON OFF OFF
OFF
OFF
CLS CLS ON OFF OFF ON ON
ON ON -
OFF
OFF
OFF OFF OFF OFF OFF OFF
OFF
OPN OPN FLK OFF OFF ON ON
OPN CLS FLK OFF ON ON OFF
DLT (ULD) 15-99% OFF OFF OFF OFF OFF ON
ON ON -
ON ON -
OFF OFF OFF OFF OFF OFF
OFF
OFF
ON ON OFF CLS CLS OFF OFF OFF ON ON CLS CLS ON ON OFF ON ON DLT (FLD) 100% DLT (FLD) 100% OFF OFF OFF OFF OFF OFF
ON ON -
OFF OFF OFF OFF OFF OFF
OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF OFF
OFF OFF CLS CLS OFF OFF OFF OFF OFF
ON OFF OFF CLS CLS OFF OFF OFF ON ON
Shut Down
CLS: Close, OPN: Open, STA: Star, DLT: Delta ULD: Unload, FLD: Full Load, FLK: Flicker
CLS CLS ON ON ON OFF OFF DLT (ULD) 15-99% DLT (ULD) 15-99% OFF OFF OFF OFF OFF OFF
ON ON -
Safety Devices
CONTROL SYSTEM
Time Schedule
Solenoid Valve
SV11 SV12 SV13 SV21 SV22 SV23 SV31 SV32 SV33
MC3
MC2
Control Stage Control Devices Main Power Switch Water Pump Operation Switch (ON/OFF) Controller Load up Neutral Load down No.1 Safety Devices No.2 No.3 Pilot Lamp Motor for Fan MF11~14 MF21~24 MF31~34 Oil Heater CH1 CH2 CH3 Motor for Compressor MC1
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 CLS CLS CLS OFF OFF OFF OFF ON ON ON
OFF CLS CLS CLS OFF OFF OFF OFF OFF OFF OFF
3 min.
OFF OFF OFF OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
ON ON CLS CLS CLS OFF OFF OFF OFF ON ON ON
60 sec.
30 sec.
Minimum 3 min. The Compressor which stopped first will be started first.
60 sec.
ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF ON ON ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF DLT DLT DLT DLT DLT DLT STA DLT OFF (ULD) (ULD) (ULD) (ULD) (ULD) (ULD) (ULD) (FLD) 15% 15% 15% 15% 15% 15% 15-99% 100% DLT DLT DLT DLT STA DLT OFF OFF OFF (ULD) (ULD) (ULD) (ULD) (ULD) (FLD) 15% 15% 15% 15% 15-99% 100% STA DLT DLT DLT OFF OFF OFF OFF OFF (ULD) (ULD) (ULD) (FLD) 15% 15% 15-99% 100% ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON 5 sec. 5 sec. 5 sec.
ON ON ON CLS CLS CLS ON OFF OFF OFF ON ON ON
Starting Control
Standard Operating Sequence for RCUP135AUZ and RCUP154AUZ
CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (FLD) 100% DLT (FLD) 100% DLT (FLD) 100% OFF OFF OFF OFF OFF OFF OFF OFF OFF
ON ON -
CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (ULD) 15-99% DLT (ULD) 15-99% DLT (ULD) 15-99% OFF ON OFF OFF ON OFF OFF ON OFF
ON ON CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (ULD) 15-99% DLT (ULD) 15-99% DLT (ULD) 15-99% OFF OFF OFF OFF OFF OFF OFF OFF OFF
ON ON -
CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (ULD) 15% DLT (ULD) 15% DLT (ULD) 15% OFF ON OFF OFF ON OFF OFF ON OFF
ON ON -
Capacity Control
ON OFF OFF ON OFF OFF ON OFF OFF
OFF
OFF
OFF
CLS CLS CLS ON OFF OFF OFF ON ON ON
ON ON -
OFF
OFF
DLT (ULD) OFF 15-99% DLT DLT (ULD) (ULD) 15-99% 15-99% OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON
OPN OPN OPN FLK OFF OFF OFF ON ON ON
OPN OPN CLS FLK OFF OFF ON ON ON OFF OPN CLS CLS FLK OFF ON ON ON OFF OFF
OFF OFF OFF OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
ON ON -
ON ON -
ON ON -
OFF OFF OFF OFF OFF OFF OFF OFF OFF
OFF
OFF
OFF
ON ON OFF CLS CLS CLS OFF OFF OFF OFF ON ON ON CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (FLD) 100% DLT (FLD) 100% DLT (FLD) 100% OFF OFF OFF OFF OFF OFF OFF OFF OFF
ON ON -
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 CLS CLS CLS OFF OFF OFF OFF OFF OFF OFF
ON OFF OFF CLS CLS CLS OFF OFF OFF OFF ON ON ON
Shut Down
CLS: Close, OPN: Open, STA: Star, DLT: Delta ULD: Unload, FLD: Full Load, FLK: Flicker
CLS CLS CLS ON ON ON ON OFF OFF OFF DLT (ULD) 15-99% DLT (ULD) 15-99% DLT (ULD) 15-99% OFF OFF OFF OFF OFF OFF OFF OFF OFF
ON ON -
Safety Devices
CONTROL SYSTEM
33
MAINTENANCE
8. 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 for particular attention.
● 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.
● Do not utilize this unit for cooling or heating of drinking water or food. Comply with local codes and regulations.
● Perform 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 pipes at the discharge side are heated by refrigerant and the temperature becomes higher than 100oC. ● 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.
Components Compressor - The semi-hermetic screw compressor requires periodic maintenance, including replacement of parts. See the HITACHI Service Handbook for Screw Compressors, for details. 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, oxidized contacts, foreign matter, and others. Control and Protective Devices - Do not readjust the settings in the field unless the setting is maintained at the point other than the point listed in Table in page 40.
Lubrication Compressor - The compressors are charged at the factory with the correct oil listed in “Component Detailed Data” in the Technical Catalog Ι 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.
Deposits Lime and other minerals in the chilled water tend to deposit on inside surfaces of plates over a long period of operation. As deposits of these minerals increase, excessive lower operation pressure are detected, indicating evidence of deposits on the water cooler. The figure in page 35 indicates the range where cleaning is required.
● Cleaning of plate type heat exchangers shall be performed by specialists. Please contact your contractor or dealer of HITACHI. ● Clean the water strainer filter periodically according to its clogging degree. If not cleaned periodically, the water strainer will be broken due to excessive pressure to the clogged strainer filter.
34
MAINTENANCE
This product is equipped with plate type heat exchangers. In the plate type heat exchanger, water flows through a narrow space between plates. Therefore, there is a possibility that freezing may occur if foreign particles or dusts are clogged. In order to avoid this clogging, provide a 20 mesh water strainer at the inlet of the chilled water piping near the product. If clogging in the plate type heat exchanger occurs seriously, this will cause insufficient cooling performance or local freezing in the plate type heat exchanger. It is strongly recommended that the heat exchanger be cleaned at the same time when the filter is cleaned. Pay attention to the following caution and normal cleaning method. For details, contact your Hitachi installer.
● Correctly select cleaning agent depending on scales in the plate type heat exchangers. The
cleaning chemicals are different depending on fouling degree. ● This plate type heat exchanger is made of stainless steel. Do not use a cleaning agent containing hydrochloric acid or fluorine compound. If used, the heat exchanger will be damaged, resulting in refrigerant leakage. ● After cleaning with cleaning agent, clean inside of water piping including the heat exchangers by using clean water. Perform water treatment (preventive treatment) in order to prevent the water circuit from corrosion or re-adhering of scales after cleaning. ● In the case that a cleaning agent is used, adjust concentration of the cleaning agent, cleaning period and temperature according to the scale degree. ● In the case that acid cleaning is performed, neutralization treatment is required after cleaning. Treatment for neutralization fluid should be performed by a waste fluid contractors. ● The cleaning agent and neutralizing agent have erosive and stimulative against eyes, skin, mucous membrane, etc. Therefore, use protection tools (protection glasses, protection gloves, protection shoes, protection cloth, protection mask, etc.) in order not to absorb or touch these agents during this cleaning work.
Cleaning Method CHILLER UNIT
Acid-resistant Type Water Pump
Chilled Water Inlet piping
Hose
Diluted Cleaning Fluid
Hose
Cleaning Water Tank
Waste Fluid Tank
Chilled Water Outlet Piping
35
MAINTENANCE 1. Installation of Cleaning Circuit (1) Stop the water chiller unit. (2) Stop the circulating water pump. (3) Disconnect the connections at the chilled water inlet and install a circulating water circuit by using an acid-resistant type water pump. 2. Check of Circulating Circuit Pour water in the cleaning tank and operate the acid-resistant type water pump. (1) Check to ensure that no water leakage exists. (2) Check to ensure that the water hose is firmly fixed. (3) Check to ensure that the cleaning agent will not damage equipment near the water chiller even if bubbles occur and touch them. (4) Check to ensure that good ventilation is available. (5) Check to ensure that no abnormal sound occurs. 3. Cleaning Work (1) Discharge water in the water circuit of the air conditioning system. (2) Supply diluted cleaning fluid from the cleaning water tank by operating the acid-resistant pump. (3) Circulate the cleaning fluid for an appropriate period of time(the operating time should be determined according to the type of cleaning agent, concentration and fouling degree). 4. Waste Fluid (1) Stop the acid-resistant pump. (2) Put the waste fluid into the waste fluid tank (3) Supply water into the cleaning tank and operate the pump for water cleaning. (4) Put the cleaning water into the waste fluid tank as same as the waste fluid. (5) Measure ph degree by using a ph test sheet and neutralize the waste fluid by gradually adding neutralizing agent. (6) After neutralization, ask a waste fluid treatment contractors to handle it. 5. Neutralization Treatment in the Water Piping (1) Put water into the cleaning tank. (2) Operate the acid-resistant pump after air-purging. (3) Measure the ph degree and gradually add neutralizing agent until the ph reaches ph =7. (4) Operate the pump for a specified period of time for neutralization. (5) Discharge the used water. (6) Operate the circulating pump and clean the circuit with water until no fouling fluid is observed. 6. Re-starting (1) Reconnect the water piping as they were so that the water chiller can operate. (2) After cleaning, perform water treatment (preventive treatment) in order to prevent the water circuit from corrosion.
Suction Gas Pressure (MPa)
0.8
0.6 Saturation Line 0.4 Area Requiring Cleaning 0.2 5
10
15
Chilled Water Outlet Temperature (oC)
36
MAINTENANCE Winter Shutdown 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. This 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 water cooler piping systems, as such water may freeze during the cold season. It is very helpful to supply brine (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 and the strainers. 3. Inspect the pump and other auxiliary equipment in the piping line. 4. Tighten all wiring connections and access panel.
When the main switch for this unit has been at the OFF position for an extended period of time, it should be switched ON at least 12 hours before start-up, so that oil in the compressor discharge casing may be warmed enough, to prevent oil foaming by the oil heater during start-up.
Part Replacement Replacement of parts should be undertaken by ordering from the HITACHI Spare Parts List.
Do not replace with spare parts which are not the equivalent.
Refrigeration Cycle Refrigerant Charge : Inspect the refrigerant charge of the system by checking the discharge and suction pressures. Perform a leakage test, if any leakage is suspected, and always perform such a test after a refrigeration cycle component is replaced. When refrigerant charge is required, follow the following instructions given for two cases : (1) When 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 evacuation 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 charging 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 circulating the chilled water. Repeat the following procedure until pressure becomes proper(refer to page 41). 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.
In the case of using refrigerant, use the skin gloves. Because directly touching the refrigerant will cause frostbite.
37
MAINTENANCE
Model Refrigerant Charge (kg) Model Refrigerant Charge (kg)
38
RCUP30AU(Z) RCUP38AU(Z) RCUP46AU(Z) RCUP51AU(Z) RCUP75AU(Z) RCUP90AU(Z) RCUP102AU(Z) RCUP135AU(Z) 28
34
40
42
2 x 34
RCUP154AU(Z) RCUP179AU(Z) RCUP205AU(Z) RCUP256AU(Z) RCUP307AU(Z) 3 x 42
4 x 40
4 x 42
5 x 42
6 x 42
2 x 40
2 x 42
3 x 40
MAINTENANCE
● Do not charge OXYGEN, 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 or nitrogen be charged for these types of tests. ● This chiller unit is operated only with R407C refrigerant of nonflammable gas. Do not change other refrigerant, oxygen, propane, alcohol or flammble and poisonous gases into the refrigerant cycle, because explosion or fire occur.
● Mineral deposits on water cooler plates act as thermal insulators, and also act as resistance against water flow, causing the decrease of water flow to running through them, and resulting in the decrease of the cooling capacity. Deposits on the plates 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 has been drained. As water in different localities contains different minerals, different acids are required, depending upon the thickness of the deposits. ● This unit is equipped with an operation hour meter. In the case that the total operation time reaches 24,000 hours or 3 years pass after installation, exchange the bearings of the compressor. For details, refer to the Service Handbook for HITACHl 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 in the magnetic switch box in order not to operate the compressor except for the 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 circulating water through the water cooler. 6. Stop the water chiller when the low pressure reaches at approximately 0.05 MPa. Do not operate at the pressure lower than 0.05 MPa. If operated, it will cause a damages to the compressor . 7. Wait for several minutes. If the low pressure increases up to 0.15 to 0.2 MPa, 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. In this case, detach the flange installed on the cover in the upper part of the oil separator about the discharge side. Do NOT detach the fixed bolt between the check valve and the discharge flange absolutely. If detached, the refrigerant will spout. Do NOT detach this bolt. If detached, the refrigerant will spout.
Check Valve Detach this bolt.
Flange
Oil Separator Upper Part Cover
39
MAINTENANCE Safety and Control Device Setting Model
Step Control Continuous Control
For Compressor High Pressure Control Cut-Out MPa Low Pressure Control Cut-Out MPa Internal Thermostat o Cut-Out C o C Cut-In Overcurrent Relay 380V 50Hz A 415V 50Hz A 440V 60Hz A Oil Heater Capacity W Discharge Gas Thermistor o C Cut-Out CCP Timer Setting Time s Star-Delta s Unloading during Starting s For Control Circuit Fuse Capacity 220/240V A For Refrigerant Circuit Fusible Plug o Melting Temperature C Freeze Protection Control o Cut-Out C Overcurrent Relay for Fan Motor 380V 50Hz A 415V 50Hz A 440V 60Hz A Pressure Relief Valve Starting to Open MPa Model
Step Control Continuous Control
For Compressor High Pressure Control Cut-Out MPa Low Pressure Control Cut-Out MPa Internal Thermostat o Cut-Out C o Cut-In C Overcurrent Relay 380V 50Hz A 415V 50Hz A 440V 60Hz A Oil Heater Capacity W Discharge Gas Thermistor o C Cut-Out CCP Timer Setting Time s Star-Delta s Unloading during Starting s For Control Circuit Fuse Capacity 220/240V A For Refrigerant Circuit Fusible Plug o Melting Temperature C Freeze Protection Control o Cut-Out C Overcurrent Relay for Fan Motor 380V 50Hz A 415V 50Hz A 440V 60Hz A Pressure Relief Valve Starting to Open MPa
40
RCUP30AU RCUP38AU RCUP46AU RCUP51AU RCUP75AU RCUP90AU RCUP102AU RCUP30AUZ RCUP38AUZ RCUP46AUZ RCUP51AUZ RCUP75AUZ RCUP90AUZ RCUP102AUZ Manual Reset, Non-Adjustable (One Switch for Each Compressor Motor) 2.98 2.98 2.98 2.98 2.98 2.98 Control by Micro-Processor 0.05 0.05 0.05 0.05 0.05 0.05 0.05 Manual Reset, Non-Adjustable (One Switch for Each Compressor Motor) 115 115 115 115 115 115 115 93 93 93 93 93 93 93 Manual Reset, Non-Adjustable (One Three-Phase Set for Each Compressor Motor) 64 72 90 114 72 90 114 64 72 90 114 72 90 114 2.98
150 140 180 5 30
One Heater for Each Compressor Motor 150 150 150 150 (One for Each Compressor) 140 140 140 140 140 Non-Adjustable (One Timer for Each Compressor) 180 180 180 180 180 5 5 5 5 5 30 30 30 30 30
150
5
5
72
72
2 3.8 3.8 3.3
5
5 (One for Each Circuit)
5
5
180 5 30 5
5
(One for Each Compressor) 3.3 3.3 3.3
3.3
3.3
3.3
One Heater for Each Compressor Motor 150 150 150 150 (One for Each Compressor) 140 140 140 140 Non-Adjustable (One Timer for Each Compressor) 180 180 180 180 5 5 5 5 30 30 30 30 5
5 5 (One for Each Circuit)
5
150 140 180 5 30 5
72
72 72 72 72 72 Control by Micro-Processor (One of Each Circuit) 2 2 2 2 2 2 Manual Reset, Non-Adjustable (One Three-Phase Set for Each Fan Motor) 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.3
180 5 30
3.8 3.8
Manual Reset, Non-Adjustable (One Switch for Each Compressor Motor) 2.98 2.98 2.98 2.98 2.98 2.98 Control by Micro-Processor 0.05 0.05 0.05 0.05 0.05 0.05 Manual Reset, Non-Adjustable (One Switch for Each Compressor Motor) 115 115 115 115 115 115 93 93 93 93 93 93 Manual Reset, Non-Adjustable (One Three-Phase Set for Each Compressor Motor) 90 114 90 114 114 114 90 114 90 114 114 114
140
140
72 72 72 72 Control by Micro-Processor (One of Each Circuit) 2 2 2 2 2 Manual Reset, Non-Adjustable (One Three-Phase Set for Each Fan Motor) 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8 3.8
RCUP135AU RCUP154AU RCUP179AU RCUP205AU RCUP256AU RCUP307AU RCUP135AUZ RCUP154AUZ RCUP179AUZ RCUP205AUZ RCUP256AUZ RCUP307AUZ
150
150
3.3
(One for Each Compressor) 3.3 3.3
3.3
3.3
72 2
MAINTENANCE Normal Operating Pressure
0.6 0.4 Standard Working Range
0.2 0 5
7
9
11
13
15
Chilled Water Outlet Temperature
Discharge Gas Pressure (MPa)
Suction Gas Pressure (MPa)
Low Pressure : The normal operating low pressure of the water chiller is indicated in the figure below ; lower than 0.3 MPa indicates an abnormal condition. Discharge Pressures : Normal operating discharge pressure is indicated in the figure below ; lower than 0.9 MPa or higher than 3.0 MPa indicates an abnormal condition.
(oC)
2.5 2.0 1.5 Standard Working Range
1.0
0
10
20
30
Condenser Inlet Temperature
40
(oC)
1) Fire If a fire accidentally occurs, turn OFF the main switch and use an extinguisher for an oil fire and electric fire. 2) Flammable Gases Do not operate the unit near the flammable gases such as lacquer, paint, oil, etc. to avoid a fire or an explosion. 3) Safety Devices Do not make a short-circuit at the protection line. If a short-circuit is made, a serious accident will occur. 4) Setting of Safety devices 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. 5) In the Case of Brazing Before the brazing work, remove flammble things around the place. Then, perform the brazing, because fire occur. 6) Warning of Rotational Things Do not insert fingers or rods and so forth into the air exhause and inhalation port. This can cause injury due to rotation of the fan and fan motor inside. Do not remove the protective screen of the air exhaust port. Removal of the protective screen can result in injury due to rotation of the fan inside.
41
MAINTENANCE
7) Activation of Safety Device In the case that one of safety devices is activated and 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 safety devices is activated, remove the cause by referring the “Troubleshooting” in the “INSTRUCTONS”, or call the local agency. 8) Setting of Safety devices Do not change the setting of safety devices, If changed, a serious accident will occur.
9) Periodical Maintenance Perform periodical maintenance according to the “INSTRUCTIONS” to maintain the unit in a good condition. 10) Service Panels and Electrical Box Cover Turn OFF the main switch when service panels or electrical box covers are removed for setting the temperature. Do not operate the unit without fixing panels. 11) Heated Pipe Do not touch the parts at discharge gas side by hand, since the pipes at the discharge side are heated by refrigerant and temperature becomes higher than 100oC. 12) Use Do not utilize this unit for cooling of drinking water or food. Comply with local codes and regulations. 13) Failure 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.
42
MAINTENANCE
Resistance (kΩ)
Characteristics of Sensors
Temperature (Co)
Fig. 9-1 Characteristic of Thermistor (For Water Temperature and Refrigerant Temperature Excluding Discharge Gas Temperature)
43
Resistance (kΩ)
MAINTENANCE
Temperature (Co)
Fig. 9-2 Characteristic of Thermistor (For Ambient Temperature)
44
Resistance (kΩ)
MAINTENANCE
Temperature (Co)
Fig. 9-3 Characteristic of Thermistor (For Discharge Gas Temperature)
5+0.068
Output (V)
Output (V)
1.786+0.019
1.143+0.019 0.500+0.019 (0.37) (-0.1)
0
0.49
0.98
Pressure(MPa)
Fig. 10-1 Characteristic of Pressure Sensor (For Suction Pressure)
2.75+0.068 0.5+0.068 (0.37) -1
0
1.72
3.43
Pressure (MPa)
Fig. 10-2 Characteristic of Pressure Sensor (For Discharge Pressure)
45
MAINTENANCE Test Running and Maintenance Record MODEL: RCUP MFG. No. COMPRESSOR MFG. No. CUSTOMER'S NAME AND ADDRESS: DATE: Before Operation 1. Check Installation Condition. e.g. Near the seaside or other worth environment which is not suitable and may cause abnormal operation condition? e.g. Short-circuited air circulation (for Air-Cooled) which may cause high operating pressure? 2. Is the unit clean inside and outside? 3. Check and confirm the liquid line stop valve fully open? (See "Operation Instructions") 4. Has the unit been checked for refrigerant leakage? 5. Are all cabinet panels free from rattling? 6. Confirm that each phase for the compressor power source is correctly connected. 7. Check Electrical Wiring & Check the contact condition of connector on all PCB. If necessary, pull out and insert the connectors including flat cable. 8. Check water strainer in front of Heat Exchanger (20 mesh) Cooler
Condenser(for Water-Cooled Type)
9. Has all water piping been checked for leakage? 10. Have the chilled water pump been lubricated? 11. Is there adequate flow for the heat exchanger? Check Condenser Water & Chilled Water flow rate.
Inlet
Outlet
∆P
Condenser Water (for Water-Cooled type)
3
m /h
Pa
Pa
Pa
Chilled Water
m3/h
Pa
Pa
Pa
12. Check 7-segment data before operation & during operation. Before Operation
During Operation
During Operation 1. Is the rotation direction of fan motors correct? (Air-Cooled Type) 2. Has the unit been operated for at least twenty minutes? 3. Check Chilled Water Temperature: Inlet
o
Outlet
C
o
C
o
C
4. Check Condenser Water Temperature: (for Water-Cooled Type) Inlet
o
Outlet
C
5. Check Suction Line Temperature and Superheat: Suction Line Temperature:
o
C
o
C
o
C
o
C
o
C
o
C
Superheat:
o
C
o
C
o
C
o
C
o
C
o
C
6. Check Pressure: Suction Pressure:
MPa
MPa
MPa
MPa
MPa
MPa
Discharge Pressure:
MPa
MPa
MPa
MPa
MPa
MPa
A
A
A
A
A
A
7. Check Running Current: 8. Commissioning Completely finished?
Check
Date
If you have any further inquiry, please contact to Hitachi Agent or Distributor.
46
Sign
MAINTENANCE Daily Operation Records Model: Date: Weather: Time of Operation: Start, Ambient Temperature
Stop. ( DB
o
C
WB
o
C
o
C
Room Temperature High Pressure Compressor
Low Pressure Voltage Current
MPa MPa V A
Condenser Inlet
Inlet(DB)
o
Air Temperature
Outlet(DB)
o
C
Chilled Water
Inlet
o
C
Temperature
Outlet
o
C
Current for Chilled Water Pump
)
C
A
NOTES:
47
MAINTENANCE Special Notes on Refrigerant R407C Please use tools and measuring instruments only for the new refrigerant which directly touch refrigerant. O : Interchangeability is available with current R22
● : Only for New Refrigerant R407C (No Interchangeability with R22) Measuring Instruments and Tool
Interchangeability with R22
Refrigerant Flaring Tool Pipe Extrusion Adjustment Gauge
O
R407C
—
Pipe Bender Expanding Tool Torque Wrench Brazing Tool Nitrogen Gas
Vacuum Drying . Refrigerant Charge
O
—
O
—
O
— • Perform correct brazing work.
O
• Strict Control against Contamination (Blow nitrogen during brazing.)
O
Lubrication Oil
RCUP-AU(Z) R407C UX300
Refrigerant Cylinder
●
Vacuum Pump
O
Adapter for Vacuum Pump Manifold Valve Charging Hose
Charging Cylinder Weight Scale
Refrigerant Gas Leakage Detector
Reason of Non-Interchangeability and Attention ( : Strictly required) • The flaring tools for R407C are applicable to R22.
Models
Ref.
● ● ●
Oil
• Use a synthetic oil which is equivalent to the oil used in the refrigeration cycle. • Synthetic oil absorbs moisture quickly. • Check refrigerant cylinder color Liquid refrigerant charging is required regarding zeotropic refrigerant. 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. • No interchageability is available due to higher pressure when compared with R22. Do not use current ones to the new refrigerant. If used, mineral oil will flow into the cycle and cause sludges, resulting in clogging or compressor failure.
—
—
O
●
— • The current gas leakage detector (R22) is not applicable due to different detecting method.
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 Applying oil to the Flared Surface Refrigerant Charging Vacuum Pumping
Vacuum Pumping, Vacuum Holding, Refrigerant Charging and Check of Pressures — Measuring Instrument for Refrigerant Charging Gas Leakage Check
NOTE • The component is different between current R22 models and RCUP-AU(Z). Please pay attention that it is unable to use some one.
48
TROUBLESHOOTING
9. TROUBLESHOOTING The following table shows efficient checking procedures for trouble. Fault
Possible Cause Controller Setting Is Incorrect
Unit Does Not Operate Current to Unit Is Shut Off Fuse for Operation Circuit Is Blown Out or Faulty Contact Condenser Fan Does Not Operate
Contactor Holding Coil Is Burned Out or Faulty Contact Tripped Overcurrent Relay Low Voltage Shorted Motor or Terminals Condenser Fan Is Not Operating Interlock Circuit for Chilled Water Pump Is Open
Compressor Does Not Operate
Compressor Stops on High Pressure Switch
Compressor Stops on Overcurrent Relay
Electrical Protective Devices Are Tripped Incorrect Wiring Connection for Compressor Power Source Excessively High Discharge Pressure Malfunction of High Pressure Switch Excessively High Discharge Pressure and Suction Pressure High and Low Voltage, Single-Phase or Phase Imbalance Loose Connection Faulty Compressor Motor
Compressor Stops on Freeze Protection Thermostat
Compressors Stops on Internal Thermostat or Discharge Gas Thermostat
Insufficient Cooling
Noisy Compressor
Faulty Overcurrent Relay Excessively Low Chilled Water Outlet Temperature Defective Thermistor Shortage of Chilled Water Flow Air in Water Circuit High or Low Voltage, Single-Phase or Phase Imbalance Excessive Superheat Defective Element Excessive High Discharge Pressure and Low Suction Pressure High Discharge Pressure or Low Suction Pressure Improper Thermostat Setting Defective Unload Mechanism Slugging Due to Liquid Flooding Back to Compressor Worn Parts
Miscellaneous Noise
Loose Fixed Screw Trouble with the Thermistor
Unloader Does Not Function
Trouble with the Solenoid Valve Worn Unloader Mechanism
Check / Corresive Action 1. See "Controller Adjustment". In the 2 module unit case, especially check "Unit Setting of PWB". 1. Reset the power supply line to the unit. 1. Check for shorted components. 2. Check for loose connection. Tighten or replace, if necessary. 1. Find the causes, and repair or replace. 1. Remove the causes, and reset the overcurrent relay. 1. Check the voltage of unit rating. 1. Check the motor and terminals. Repair or replace, if necessary. 1. Remove all causes of inoperative fan. 1. Check the pump contactor. Repair or replace, if necessary. 2. Check for the faulty pump. 1. Remove the causes, and reset the "ON" button. See the following causes. 1. Interchange two of three terminals R, S and T at the main power source terminals. 1. See "High Discharge Pressure". 1. Readjust the setting or replace, if defective. 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. 1. Replace it, if necessary. 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. 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 unloader 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. 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.
49
TROUBLESHOOTING Fault
High Discharge Pressure
Low Discharge Pressure
Possible Cause 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 Extremely Cold Condenser Air Insufficient Refrigerant Charge Leakage from the Compressor Discharge Valve Suction Pressure Is Lower Than Standard High Inlet Temperature of Chilled Water
High Suction Pressure
Low Suction Pressure
50
Excessive Opening of Expansion Valve Low Inlet Temperature of Chilled Water Improperly Adjusted Expansion Valve or Faulty Valve Insufficient Refrigerant Charge Excessive Oil in the Water Cooler Scales on Water Cooler Plates
Check / Corresive Action 1. Check the fan operation. 2. Check for coil clogging; clean, if necessary. 1. Check the valves and capillary tubes. Replace if necessary. 1. Correctly charge the refrigerant. 1. Purge the gas from the refrigerant cycle. 1. 1. 1. 1. 1. 1. 2. 1. 1. 1. 1. 1. 1.
See "High Suction Pressure". Check the ambient temperature. Add refrigerant. Replace the valve. Replace the compressor, if required. See "Low Suction Pressure". Check the insulation of the piping. Check the insulation specifications. Readjust the opening, or replace, if defective. Check the insulation specifications. Adjust for correct superheat. Repair or replace, if necessary. Add refrigerant. Purge oil. Clean the plates.
PRESSURE CONVERSION TABLE
10. PRESSURE COVERSION TABLE
MPa 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.20 0.21 0.22 0.23 0.24 0.25 0.26 0.27 0.28 0.29 0.30 0.31 0.32 0.33 0.34 0.35 0.36 0.37 0.38 0.39 0.40 0.41 0.42 0.43 0.44 0.45 0.46 0.47 0.48 0.49 0.50
psi 1.45 2.90 4.35 5.80 7.25 8.70 10.15 11.60 13.05 14.50 15.95 17.40 18.85 20.31 21.76 23.21 24.66 26.11 27.56 29.01 30.46 31.91 33.36 34.81 36.26 37.71 39.16 40.61 42.06 43.51 44.96 46.41 47.86 49.31 50.76 52.21 53.66 55.11 56.56 58.02 59.47 60.92 62.37 63.82 65.27 66.72 68.17 69.62 71.07 72.52
MPa 0.51 0.52 0.53 0.54 0.55 0.56 0.57 0.58 0.59 0.60 0.61 0.62 0.63 0.64 0.65 0.66 0.67 0.68 0.69 0.70 0.71 0.72 0.73 0.74 0.75 0.76 0.77 0.78 0.79 0.80 0.81 0.82 0.83 0.84 0.85 0.88 0.87 0.88 0.89 0.90 0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.99 1.00
psi 73.97 75.42 76.87 78.32 79.77 81.22 82.67 84.12 85.57 87.02 88.47 89.92 91.37 92.82 94.27 95.73 97.18 98.63 100.08 101.53 102.98 104.43 105.88 107.33 108.78 110.23 111.68 113.13 114.58 116.03 117.48 118.93 120.38 121.83 123.28 127.05 126.18 127.63 129.08 130.53 131.98 133.43 134.89 136.34 137.79 139.24 140.69 142.14 143.59 145.04
MPa 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 1.40 1.41 1.42 1.43 1.44 1.45 1.46 1.47 1.48 1.49 1.50
psi 146.49 147.94 149.39 150.84 152.29 153.74 155.19 156.64 158.09 159.54 160.99 162.44 163.89 165.34 166.79 168.24 169.69 171.14 172.60 174.05 175.50 176.95 178.40 179.85 181.30 182.75 184.20 185.65 187.10 188.55 190.00 191.45 192.90 194.35 195.80 197.25 198.70 200.15 201.60 203.05 204.50 205.95 207.40 208.85 210.31 211.76 213.21 214.66 216.11 217.56
MPa 1.51 1.52 1.53 1.54 1.55 1.56 1.57 1.58 1.59 1.60 1.61 1.62 1.63 1.64 1.65 1.66 1.67 1.68 1.69 1.70 1.71 1.72 1.73 1.74 1.75 1.76 1.77 1.78 1.79 1.80 1.81 1.82 1.83 1.84 1.85 1.86 1.87 1.88 1.89 1.90 1.91 1.92 1.93 1.94 1.95 1.96 1.97 1.98 1.99 2.00
psi 219.01 220.46 221.91 223.36 224.81 226.26 227.71 229.16 230.61 232.06 233.51 234.96 236.41 237.86 239.31 240.76 242.21 243.66 245.11 246.56 248.01 249.47 250.92 252.37 253.82 255.27 256.72 258.17 259.62 261.07 262.52 263.97 265.42 266.87 268.32 269.77 271.22 272.67 274.12 275.57 277.02 278.47 279.92 281.37 282.82 284.27 285.72 287.18 288.63 290.08
MPa 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29 2.30 2.31 2.32 2.33 2.34 2.35 2.36 2.37 2.38 2.39 2.40 2.41 2.42 2.43 2.44 2.45 2.46 2.47 2.48 2.49 2.50
psi MPa psi 291.53 2.51 364.05 292.98 2.52 365.50 294.43 2.53 366.95 295.88 2.54 368.40 297.33 2.55 369.85 298.78 2.56 371.30 300.23 2.57 372.75 301.68 2.58 374.20 303.13 2.59 375.65 304.58 2.60 377.10 306.03 2.61 378.55 307.48 2.62 380.00 308.93 2.63 381.45 310.38 2.64 382.90 311.83 2.65 384.35 313.28 2.66 385.80 314.73 2.67 387.25 316.18 2.68 388.70 317.63 2.69 390.15 319.08 2.70 391.60 320.53 2.71 393.05 321.98 2.72 394.50 323.43 2.73 395.95 324.89 2.74 397.40 326.34 2.75 398.85 327.79 2.76 400.30 329.24 2.77 401.76 330.69 2.78 403.21 332.14 2.79 404.66 333.59 2.80 406.11 335.04 2.81 407.56 336.49 2.82 409.01 337.94 2.83 410.46 339.39 2.84 411.91 340.84 2.85 413.36 342.29 2.86 414.81 343.74 2.87 416.26 345.19 2.88 417.71 346.64 2.89 419.16 348.09 2.90 420.61 349.54 2.91 422.06 350.99 2.92 423.51 352.44 2.93 424.96 353.89 2.94 426.41 355.34 2.95 427.86 356.79 2.96 429.31 358.24 2.97 430.76 359.69 2.98 432.21 361.14 2.99 433.66 362.60 3.00 435.11 1MPa = 145.038 psi
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Specification in this catalog are subject to change without notice, in order that HITACHI may bring the latest innovations to our customers.
Catalog No. SC2-P02Q, 2009 Printed in Japan (N)
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