Hitachi SAMURAI Series User manual

RCME-(40-60)CLH
Service Manual
SAMURAI SERIES
CONDENSERLESS WATER CHILLERS
-MODULAR-R134a-SCREW TYPE-

Contents
SMGB0097 rev.0 - 07/2015
1. General information
2. Control Functions
3. Servicing
4. Troubleshooting
1. Contents
1
2
3
4
I

SMGB0097 rev.0 - 07/2015
III
General Index
General index
1. General information ..................................................................................................... 1
1.1 General notes..........................................................................................................................................2
1.2 Safety and applied symbols .................................................................................................................... 3
1.3 Product guide ..........................................................................................................................................4
1.3.1 Classication of water chiller models .............................................................................................................. 4
1.3.2 Product guide: Water chillers........................................................................................................................... 4
2. Control Functions......................................................................................................... 5
2.1 Control functions on the module.............................................................................................................. 6
2.1.1 Water control ................................................................................................................................................... 9
2.1.2 Water temperature control............................................................................................................................. 10
2.1.3 Compressor Control ...................................................................................................................................... 13
2.1.4 Control for recovery from power interruption (Option)................................................................................... 15
2.1.5 Prevention of simultaneous startup ............................................................................................................... 16
2.1.6 Reverse prevention control ........................................................................................................................... 16
2.1.7 Anti-Freezing Control for Winter .................................................................................................................... 17
2.1.8 Control for prevention of wrong operation and wrong settings...................................................................... 20
2.1.9 Demand control ............................................................................................................................................. 20
2.1.10 Forced load up capacity control from external signal .................................................................................. 24
2.1.11 2-temperature setting function..................................................................................................................... 25
2.1.12 External thermo operation from external contact ........................................................................................ 26
2.1.13 Water Temperature of the Control Target .................................................................................................... 28
2.1.14 Operation from DC24V contact input .......................................................................................................... 29
2.1.15 Thermo OFF function selection ................................................................................................................... 34
2.1.16 Selection of enabling/disabling of alarm release by means of remote stop ................................................ 35
2.1.17 Limitation setting for pump feedback waiting time....................................................................................... 36
2.1.18 Inlet water temperature thermo OFF function ............................................................................................. 37
2.2 Control of the cooling cycle ................................................................................................................... 39
2.2.1 Compressor Control ...................................................................................................................................... 39
2.2.2 Expansion Valve Control ............................................................................................................................... 40
2.2.3 Overcurrent protection control....................................................................................................................... 42
2.3 Control of Master/Slave group...............................................................................................................43
2.3.1 Summary of control of Master/Slave group ................................................................................................... 43
2.3.2 Setting method .............................................................................................................................................. 43
2.3.3 Operation method.......................................................................................................................................... 44
2.3.4 Other functions of the control of Master/Slave group .................................................................................... 46
2.3.5 Setting items.................................................................................................................................................. 48
2.3.6 Method for setting and conrmation of operation conditions through the LCD screen.................................. 49

SMGB0097 rev.0 - 07/2015
IV
General Index
2.4 Run operation........................................................................................................................................51
2.4.1 Setting of switches on the setting PCB ......................................................................................................... 51
2.4.2 Operation control of the module .................................................................................................................... 52
2.5 Time chart .............................................................................................................................................53
3. Servicing .................................................................................................................... 55
3.1 LCD display for Service Menu............................................................................................................... 57
3.2 General notes........................................................................................................................................65
3.3 Cycle components.................................................................................................................................66
3.3.1 Compressor removal ..................................................................................................................................... 66
3.3.2 Overhaul work ............................................................................................................................................... 68
3.3.3 Recovering the refrigerant ............................................................................................................................ 70
3.3.4 Replacement of the cooler ............................................................................................................................ 70
3.3.5 Replacement of expansion Valve .................................................................................................................. 72
3.3.6 Filter drier ...................................................................................................................................................... 73
3.3.7 Replacement of the check valve ................................................................................................................... 74
3.3.8 Replacement of the stop valve (with check joint) .......................................................................................... 75
3.3.9 Replacement of the high pressure switch (PSH)........................................................................................... 75
3.3.10 Replacement of the pressure sensor (Pd)................................................................................................... 75
3.3.11 Replacement of the pressure sensor (Ps) ................................................................................................... 75
3.3.12 Replacement of the pressure sensor (PS) .................................................................................................. 76
3.3.13 Replacement of the pressure relief valve .................................................................................................... 76
3.3.14 Replacement of the sight glass ................................................................................................................... 76
3.3.15 Replacement of the stop valve (x3)............................................................................................................. 76
3.3.16 Repalacement of the thermistor (Suction, THMs) ....................................................................................... 77
3.3.17 Replacement of the thermistor (Discharge, THMd)..................................................................................... 77
3.3.18 Replacement of the crankcase heater (CH) ................................................................................................ 77
3.3.19 Replacement of the thermistor (Evaporation, THMe).................................................................................. 78
3.3.20 Replacement of the thermistor (Cooler water inlet, THMwi)........................................................................ 78
3.3.21 Thermistor (Cooler water outlet, THMwo2) ................................................................................................. 79
3.3.22 Thermistor (Cooler water outlet, THMwo) ................................................................................................... 79
3.3.23 Replacement of the solenoid valves (SVa, SVb, SVc) ................................................................................ 79
3.4 Electrical components ...........................................................................................................................80
3.4.1 The E-box...................................................................................................................................................... 80
3.4.2 Removal of the LCD screen .......................................................................................................................... 80
3.4.3 Replacement of lamps and push buttons ...................................................................................................... 81
3.4.4 Access to electrical components ................................................................................................................... 81
3.4.5 Removal of the PCB’s ................................................................................................................................... 83
3.4.6 Transformer (TF1) ......................................................................................................................................... 85
3.4.7 Transformers (TF2, TF3, TF4)....................................................................................................................... 85
3.4.8 Overcurrent relay (ORC) ............................................................................................................................... 85

SMGB0097 rev.0 - 07/2015
V
General Index
3.4.9 Contactors (CMC, CMCD, CMCS) ................................................................................................................ 86
3.4.10 Fuses (EF1, EF2, EF3. EFR, EFS, EFT) .................................................................................................... 86
3.4.11 Fuses (PFC) ................................................................................................................................................ 87
3.4.12 Relays ......................................................................................................................................................... 88
3.4.13 Main Switch ................................................................................................................................................. 89
4. Troubleshooting ......................................................................................................... 91
4.1 Inspection of power source and connections ........................................................................................92
4.2 Inspection of PCB..................................................................................................................................93
4.3 Conrmation of operating value of protection devices and automatic operation devices ..................... 93
4.4 Protection control function..................................................................................................................... 94
4.5 Caution indication..................................................................................................................................95
4.6 Summary of fault diagnosis................................................................................................................... 96
4.7 Method for fault diagnosis ..................................................................................................................... 98
4.8 Troubleshooting by alarm code ............................................................................................................. 99
4.9 Analysis and countermeasure of abnormalities...................................................................................123
4.10 Thermistor characteristics ................................................................................................................... 127
4.10.1 Thermistor temperature characteristics (All temperature except discharge gas) ...................................... 127
4.10.2 Thermistor temperature characteristics for discharge gas temperature.................................................... 127
4.11 Pressure sensor characteristics .......................................................................................................... 128
4.11.1 High-pressure sensor ................................................................................................................................ 128
4.11.2 Low-pressure sensor ................................................................................................................................. 128
4.12 Procedures for trouble.........................................................................................................................128

1. General information
SMGB0097 rev.0 - 07/2015
1
1
1. General information
Index
1.1 General notes..........................................................................................................................................2
1.2 Safety and applied symbols .................................................................................................................... 3
1.3 Product guide ..........................................................................................................................................4
1.3.1 Classication of water chiller models .............................................................................................................. 4
1.3.2 Product guide: Water chillers........................................................................................................................... 4

1. General information
General notes
SMGB0097 rev.0 - 07/2015
2
1.1 General notes
© Copyright 2014 HITACHI Air Conditioning Products Europe, S.A.U. – All rights reserved.
No part of this publication may be reproduced, copied, led or transmitted in any shape or form without the permission of
HITACHI Air Conditioning Products Europe, S.A.U.
Within the policy of continuous improvement of its products, HITACHI Air Conditioning Products Europe, S.A.U. reserves
the right to make changes at any time without prior notication and without being compelled to introducing them into prod-
ucts subsequently sold. This document may therefore have been subject to amendments during the life of the product.
HITACHI makes every effort to offer correct, up-to-date documentation. Despite this, printing errors cannot be controlled by
HITACHI and are not its responsibility.
As a result, some of the images or data used to illustrate this document may not refer to specic models. No claims will be
accepted based on the data, illustrations and descriptions included in this document.
No type of modication must be made to the equipment without prior, written authorisation from the manufacturer.
HITACHI pursues a policy of continuing improvement in design and performance of products. The right is therefore re-
served to vary specications without notice.
HITACHI cannot anticipate every possible circumstance that might involve a potential hazard.
No part of this document may be reproduced without written permission.
If you have any questions, contact your service contractor of HITACHI.
Check and make sure that the explanations of each part of this Technical Catalogue correspond to your water chiller model.
Refer to the models codication to conrm the main characteristics of your system.
Signal words (DANGER, WARNING and CAUTION) are used to identify levels of hazard seriousness. Denitions for iden-
tifying hazard levels are provided below with their respective signal words.
It is assumed that this unit will be operated and serviced by English speaking people. If this is not the case, the customer
should add safety, caution and operating signs in the native language of the personal.
This water chiller has been designed for the working range described in the corresponding chapter.

1. General information
Safety and applied symbols
SMGB0097 rev.0 - 07/2015
3
1
1.2 Safety and applied symbols
During normal system design work or unit installation, greater attention must be paid in certain situations requiring particu-
lar care in order to avoid damage to the unit, the installation or the building or property.
Situations that jeopardise the safety of those in the surrounding area or that put the unit itself at risk will be clearly indicated
in this manual.
To indicate these situations, a series of special symbols will be used to clearly identify these situations.
Pay close attention to these symbols and to the messages following them, as your safety and that of others depends on it.
DANGER
• The text following this symbol contains information and instructions relating directly to your safety and phy-
sical wellbeing.
• Not taking these instructions into account could lead to serious, very serious or even fatal injuries to you and
others in the proximity of the unit.
• Hazards or unsafe practices which could result severe personal injury or death.
In the texts following the danger symbol you can also nd information on safe procedures during unit installation.
CAUTION
• The text following this symbol contains information and instructions relating directly to your safety and physical wellbeing.
• Not taking these instructions into account could lead to minor injuries to you and others in the proximities of the unit.
• Not taking these instructions into account could lead to unit damage.
In the texts following the caution symbol you can also nd information on safe procedures during unit installation.
NOTE
• The text following this symbol contains information or instructions that may be of use or that require a more thorough
explanation.
• Instructions regarding inspections to be made on unit parts or systems may also be included.