Hitachi YUTAKI Series User manual

Air to water
Heat pump
RHUE-3AVHN•
RHUE-4AVHN•
RHUE-5A(V)HN•
RHUE-6A(V)HN•
YUTAKI SERIES
RHUE-A(V)HN

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

3
Contents
Service Manual
SMGB0066 rev.0 - 12/2009
0
1
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ContentsContents
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5
General index
SMGB0066 rev.0 - 12/2009
Contents
Service Manual
0

1. Units installation.............................................................................................................................15
1.1. RHUE-(3~6)A(V)HN ....................................................................................................................17
1.1.1. Transportation ........................................................................................................................................17
1.1.2. Center of gravity.....................................................................................................................................18
1.1.3. Installation space ...................................................................................................................................19
1.1.4. Place provision.......................................................................................................................................20
1.1.5. Optional parts.........................................................................................................................................22
1.2. Accessories Installation...............................................................................................................27
1.2.1. Pump kit ................................................................................................................................................27
1.2.2. WEH - Water Electric Heater..................................................................................................................28
1.2.3. DHWT - Domestic Hot Water Tank.........................................................................................................30
2. Water pipe installation....................................................................................................................33
2.1 General notes..............................................................................................................................34
2.2. Piping work connection considerations .......................................................................................35
2.2.1. Minimum water volume description........................................................................................................35
2.2.2. Correction factor due to use of glycol.....................................................................................................37
2.3. Water control ...............................................................................................................................37
2.4. Water check valve .......................................................................................................................38
2.5. Accessories hydraulic installation................................................................................................39
2.5.1. Pump kit .................................................................................................................................................39
2.5.2. WEH- Water Electric Heater...................................................................................................................40
2.5.3. DHWT- Domestic Hot Water Tank..........................................................................................................42
2.5.4. Water drain discharge connection..........................................................................................................44
3. Electrical wiring connections and diagram.....................................................................................45
3.1. General check .............................................................................................................................46
3.2. Electrical wiring connection.........................................................................................................47
3.2.1. Field minimum wire sizes for the power source .....................................................................................48
3.2.2. Main switches and fuses ........................................................................................................................49
3.3. Setting the DIP switches .............................................................................................................49
3.4. LED indication .............................................................................................................................53
3.5. Accessories electrical installation................................................................................................54
3.5.1. Pump kit .................................................................................................................................................54
3.5.2. WEH- Water Electric Heater...................................................................................................................57
3.5.3. DHWT- Domestic Hot Water Tank..........................................................................................................59

Contents
Service Manual
6General index
SMGB0066 rev.0 - 12/2009
3.6. Electrical wiring diagrams............................................................................................................65
3.6.1. Electrical wiring diagram for models RHUE-(3~6)AVHN........................................................................66
3.6.2. Electrical wiring diagram for RHUE-(5/6)AHN........................................................................................67
4. Control system...............................................................................................................................69
4.1. Systemconguration,settingsandcontrolsystem .....................................................................73
4.1.1. Description .............................................................................................................................................73
4.1.2. System controller overview ....................................................................................................................73
4.1.3. Contents of the controller pack ..............................................................................................................74
4.1.4. Quick-start installation steps ..................................................................................................................74
4.1.5. Abbreviations & terminology ..................................................................................................................75
4.1.6. Applicationcongurations ......................................................................................................................75
4.1.7. Principle of bi-valent or mono-energetic operation.................................................................................76
4.1.8. Mono-Valent Systems (CONF 1)............................................................................................................77
4.1.9. Mono-Energetic Systems (CONF 2).......................................................................................................78
4.1.10. Bi-valent Systems - Parallel Operation (CONF3)...................................................................................79
4.1.11. Bi-Valent System - Parallel Operation - Mixing Loop (CONF 4).............................................................80
4.1.12. Bi-Valent System - Serial Operation (CONF 5) ......................................................................................80
4.2. Supply setpoint calculation..........................................................................................................81
4.3. Heating control functions.............................................................................................................82
4.3.1. Heating Circuit – General.......................................................................................................................82
4.3.2. Heating Characteristic Curve (OTC Control)..........................................................................................82
4.3.2.1. Room Setpoint Parallel Shift ..................................................................................................................................83
4.3.2.2. Room Temperature Compensation ........................................................................................................................84
4.3.3. Heating Circuit Minimum/Maximum Temperature Limits ........................................................................84
4.3.4. Heating Circuit (Secondary) Pump ........................................................................................................85
4.3.5. Automatic No-Load Function..................................................................................................................85
4.4. DHW control functions.................................................................................................................85
4.4.1. DHW Storage Tank Loading...................................................................................................................85
4.4.2. DHW Control ..........................................................................................................................................86
4.4.3. Maximum DHW Loading Time................................................................................................................87
4.4.4. DHW Electric Heater ..............................................................................................................................88
4.4.4.1. DHW Electric Heater ..............................................................................................................................................88
4.4.4.2. Using the Boiler for DHW loading...........................................................................................................................89
4.4.5. Using the Boiler for DHW loading ..........................................................................................................90
4.4.6. Response of the Heat pump to a DHW demand....................................................................................90
4.4.7. DHW Time Program ...............................................................................................................................90
4.5. Heatpump control functions.........................................................................................................91
4.5.1. Heatpump Control ..................................................................................................................................91
4.5.2. Heatpump Setting Control Signal...........................................................................................................92
4.5.3. Heatpump Sensor Offset........................................................................................................................92
4.5.4. Heatpump Maximum Return High Limit .................................................................................................93
4.5.5. Heatpump Operating Limits ...................................................................................................................93
4.5.6. Tariff Switch (Heat Pump blocking) Input ...............................................................................................94

7
General index
SMGB0066 rev.0 - 12/2009
Contents
Service Manual
0
4.6. Boiler control functions................................................................................................................95
4.6.1. Boiler Control..........................................................................................................................................95
4.6.2. Supply-Return Difference Check............................................................................................................96
4.6.3. Boiler Minimum On / Off Times ..............................................................................................................97
4.6.4. Boiler Waiting Time ................................................................................................................................97
4.6.5. Maximum Outdoor Temperature for Boiler Operation ............................................................................97
4.7. Electric heater control functions ..................................................................................................98
4.7.1. Electric Heater Control ...........................................................................................................................98
4.7.2. Supply-Return Difference Check............................................................................................................99
4.7.3. Electric Heater Waiting Time ................................................................................................................100
4.7.4. Electric Heater Return High Limit Check..............................................................................................100
4.7.5. Maximum Outdoor Temperature for Electrical Heater Operation .........................................................101
4.8. Mixing valve control functions ...................................................................................................101
4.8.7. Mixing Valve Control ............................................................................................................................101
4.8.2. Mixing / Bypass Valve Control..............................................................................................................102
4.8.3. Mixed Heating Circuit Maximum Temperature Limit Protection............................................................102
4.8.4. Mixing Valve Opening Delay ................................................................................................................102
4.9. General functions ......................................................................................................................103
4.9.1. System Frost Protection.......................................................................................................................103
4.9.2 Automatic Summer Switch-Off .............................................................................................................103
4.9.3. Pump and Valve Seizure Protection.....................................................................................................104
4.9.4. Screed Function (Drying for New Floors).............................................................................................104
4.10. Parameter tables.......................................................................................................................105
4.10.1 Installer Parameters .............................................................................................................................105
4.10.1. Engineering Parameters ......................................................................................................................106
4.11. Conversion table: heat pump supply temperature to mA ..........................................................108
4.12. R resistance tables....................................................................................................................108
4.13. Technical data ...........................................................................................................................109
4.13.1. System Controller (XEK23232 A).........................................................................................................109
4.13.2. Water Temperature Sensor (XEK35524 A) ..........................................................................................109
4.13.3. Outdoor Temperature Sensor (XEK35438 A) .......................................................................................109
4.14. Mounting....................................................................................................................................110
4.14.1. Fitting or removing the front cover ....................................................................................................... 110
4.14.2. Wall Mounting....................................................................................................................................... 110
4.14.3. Mounting on a DIN-rail ......................................................................................................................... 111
4.15. Mounting the Sensors ............................................................................................................... 111
4.15.1. Water Temperature Sensor .................................................................................................................. 111
4.15.2. Outside Temperature Sensor ............................................................................................................... 112

Contents
Service Manual
8General index
SMGB0066 rev.0 - 12/2009
4.16. Electrical wiring .........................................................................................................................113
4.16.1. Wiring access ports.............................................................................................................................. 113
4.16.1. Wiring connections............................................................................................................................... 114
4.16.2 System component connections .......................................................................................................... 115
4.17. Systemcongurations............................................................................................................... 118
4.18. User interface............................................................................................................................123
4.18.1. Display..................................................................................................................................................123
4.18.2. Controls................................................................................................................................................123
4.19. Installationcongurationsettings ..............................................................................................124
4.19.1. Reviewing and setting the installer parameters ...................................................................................124
4.19.2. Installer parameter list..........................................................................................................................125
4.20. System testing...........................................................................................................................126
4.20.1. System start-up ....................................................................................................................................126
4.20.2. SYSTEM TEST ....................................................................................................................................126
4.20.3. REVIEWING THE OPERATIONAL DATA.............................................................................................127
4.20.4. MANUALLY OVERRIDING THE OUTPUTS ........................................................................................127
4.21. Expanding the system...............................................................................................................128
4.21.1. Additional mixing zone .........................................................................................................................128
4.21.2. Binding RF components together.........................................................................................................129
4.22. System MMI Pack (Room unit and RF receiver).......................................................................129
4.22.1. Room Unit installation guide ................................................................................................................129
4.22.1.1. Description ...........................................................................................................................................................129
4.22.1.2. Installation information .........................................................................................................................................130
4.22.1.3. Installing the System MMI Pack ...........................................................................................................................130
4.22.1.4. Installing the RF Receiver ....................................................................................................................................131
4.22.2. Installing the Room Unit .......................................................................................................................132
4.22.2.1. Power up ..............................................................................................................................................................132
4.22.2.2. RF Communication check (test mode).................................................................................................................132
4.22.2.3. Locating the Room Unit........................................................................................................................................133
4.22.3. Communication loss.............................................................................................................................133
4.22.4. Installer mode.......................................................................................................................................134
4.22.4.1. Entering installer mode.........................................................................................................................................134
4.22.4.2. Fail-Safe mode setup ...........................................................................................................................................134
4.22.4.3. UsingtheRoomUnitforspecicapplications......................................................................................................135
4.22.4.4. Using the special features of the Room Unit........................................................................................................135
4.22.5. Installer parameters table.....................................................................................................................136
4.22.5.1. Category 1 - Room Unit settings ..........................................................................................................................136
4.22.5.2. Category 2 - System settings ...............................................................................................................................137
4.22.6. Binding / Rebinding procedure.............................................................................................................137
4.22.7. Room Unit user guide ..........................................................................................................................138
4.22.7.1. Setting-up.............................................................................................................................................................139
4.22.7.2. Programming........................................................................................................................................................140
4.22.7.3. Operating..............................................................................................................................................................142
4.23. Device control system ...............................................................................................................143

9
General index
SMGB0066 rev.0 - 12/2009
Contents
Service Manual
0
4.24. Yutaki unit PCB .........................................................................................................................144
4.25. Safety and control device setting ..............................................................................................145
4.25.1. Defrost operation control......................................................................................................................147
4.25.2. Control of expansion valve...................................................................................................................149
5. Available optional functions..........................................................................................................151
5.1. Freeze protection ......................................................................................................................152
5.2. Restart after power failure.........................................................................................................152
5.3. Compressor ON/OFF control ....................................................................................................153
5.4. 3 Minutes guard control.............................................................................................................154
5.5. Power save mode......................................................................................................................154
6. Test run ........................................................................................................................................155
6.1. Checking procedure before the test run....................................................................................156
6.2. Test run procedure for Yutaki ....................................................................................................158
6.2.1. System controller testing......................................................................................................................160
7. Troubleshooting ...........................................................................................................................165
7.1. Initial troubleshooting ................................................................................................................166
7.1.1. Unit and System controller - Power Supply failure...............................................................................166
7.1.2. Abnormal operation of the devices.......................................................................................................168
7.1.3. Incidents of operation...........................................................................................................................174
7.2. Troubleshooting procedure .......................................................................................................175
7.2.1. Alarm code ...........................................................................................................................................177
7.3. Failure diagnosis method ..........................................................................................................216
7.4. Checking procedure for main parts ...........................................................................................218
7.4.1. RHUE-(3~6)AVHN. Procedure for checking the DIP-IPM. ...................................................................218
7.4.2. RHUE-(5/6)AHN. Procedure for checking the ISPM. ...........................................................................220
7.4.3. Checking capacitors CB1 & CB2. ........................................................................................................222
7.4.4. Fault diagnosis of DC fan motor...........................................................................................................223
7.5. Troubleshooting of control system ............................................................................................225
7.5.1. System controller..................................................................................................................................225
7.5.2. System MMI Pack ................................................................................................................................226

Contents
Service Manual
10 General index
SMGB0066 rev.0 - 12/2009
7.6. Troubleshooting of accessories.................................................................................................227
7.6.1. Pump kit ...............................................................................................................................................227
7.6.2. WEH - Water Electric Heater................................................................................................................228
7.6.3. DHWT - Domestic Hot Water Tank.......................................................................................................228
8. Spare parts ..................................................................................................................................229
8.1. Spare parts of Yutaki .................................................................................................................230
8.1.1. Cycle and estructural parts ..................................................................................................................230
8.1.2. Electrical parts......................................................................................................................................231
8.2. Spare parts of accessories........................................................................................................233
8.2.1. WEH - Water Electric Heater................................................................................................................233
8.2.2. DHWT - Domestic Hot Water Tank.......................................................................................................234
9. Servicing......................................................................................................................................237
9.1. RHUE-(3~6)A(V)HN ..................................................................................................................239
9.1.1. Removing service cover.......................................................................................................................239
9.1.2. Removing air outlet grille......................................................................................................................239
9.1.3. Removing upper cover .........................................................................................................................240
9.1.4. Removing the lower part of service panel and rear panel....................................................................240
9.1.5. Removing Yutaki fan motor .................................................................................................................241
9.1.7. Removing the compressor ...................................................................................................................242
9.1.6. Mounting Yutaki fan motor....................................................................................................................242
9.1.8. Removing high pressure switch ...........................................................................................................245
9.1.9. Opening electrical box (P-mounting plate) ...........................................................................................246
9.1.10. Removing the coils for the reversing and solenoid valves ...................................................................247
9.1.11. Removing electronic expansion valve coils..........................................................................................248
9.1.12. Removing pressure switches ...............................................................................................................249
9.1.13. Removing reversing valve....................................................................................................................250
9.1.14. Removing expansion valves ................................................................................................................250
9.1.15. Removing solenoid valve .....................................................................................................................251
9.1.16. Removing electrical components .........................................................................................................252
9.1.17. Removing inverter components ...........................................................................................................253
9.1.18. Removing the ISPM .............................................................................................................................254
9.1.19. Removing the DIP-IPM.........................................................................................................................255
9.1.20. Removingtheelectrical-noiselter ......................................................................................................256
9.1.21. Removing other electrical components ................................................................................................257

11
Unit code list
SMGB0066 rev.0 - 12/2009
Contents
Service Manual
0
List of air to water units and accessories available in this Service Manual.
YUTAKI RHUE UNITS
AVHN UNITS AHN UNITS
Unit Code Unit Code
RHUE-3AVHN 9E311100
RHUE-4AVHN 9E411100
RHUE-5AVHN 9E511100 RHUE-5AHN 9E531100
RHUE-6AVHN 9E611100 RHUE-6AHN 9E631100
1~ 3N~
Meaningofmodelcodication:  - 5 VN
Unit type (made in Europe)
Compressor power (HP) 3/4/5/6
Air-to-water unit
Single phase
Heating only
R410A Refrigerant
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Contents
Service Manual
12 List of accessory codes
SMGB0066 rev.0 - 12/2009
LIST OF ACCESSORY CODES
Name Description Code Figure
STE1 Water temperature sensor 9E500004
RMPID1 Extension controller 9E500005
Pump Kit A Pump kit A (TOP-S 25/7) 9E500006
Pump Kit B Pump Kit B (TOP-S 25/10) 9E500007
EH61 Heater 6 kW EH61
BDHM1 Hydraulic separator BDHM1
VID3V1 3-way valve VID3V1
CDH2Z1 Disconnection vessel CDH2Z1
ASMSH1 Aquastat ASMSH1

13
List of accessory codes
SMGB0066 rev.0 - 12/2009
Contents
Service Manual
0
Name Description Code Figure
Domestic Hot Water
Tank
Enamelled / 200L.
DHWT200E-2.5H1E,1~230V50Hz 70544000
Domestic Hot Water
Tank
Enamelled / 300L.
DHWT300E-2.5H1E,1~230V50Hz 70544001
Domestic Hot Water
Tank
Stainless / 200L.
DHWT200S-2.5H1E,1~230V50Hz 70544100
Domestic Hot Water
Tank
Stainless / 300L.
DHWT300S-2.5H1E,1~230V50Hz 70544101

15
Contents
SMGB0066 rev.0 - 12/2009
Unit installation
Service Manual
1
 
This chapter provides information concerning the installation of Yutaki units.

1.1. RHUE-(3~6)A(V)HN ....................................................................................................................17
1.1.1. Transportation ........................................................................................................................................17
1.1.2. Center of gravity.....................................................................................................................................18
1.1.3. Installation space ...................................................................................................................................19
1.1.4. Place provision.......................................................................................................................................20
1.1.5. Optional parts.........................................................................................................................................22
1.2. Accessories Installation...............................................................................................................27
1.2.1. Pump kit ................................................................................................................................................27
1.2.2. WEH - Water Electric Heater..................................................................................................................28
1.2.3. DHWT - Domestic Hot Water Tank.........................................................................................................30

Unit installation
Service Manual
16 Contents
SMGB0066 rev.0 - 12/2009
danger
Electrical hazard. Risk of death.-
Before gaining access to terminals or performing any maintenance operation, turn OFF all power switches-
and disconnect all supply circuits.
Check that the LED201 (red) located on the DIP-IPM is OFF.-
Do not touch the electrical components when LED201 (Red) is ON in order to avoid an electrical shock.-
Do not touch the electrical components of the PCB directly.-
warning
Damage by water. Electrical hazard.-
Install the unit indoors to prevent water contact. The water proof class is IPX0.-
Install the unit where no high level of oil mist, salty air or sulphurous atmosphere exists.-
Attach a water proof cover in order to prevent water getting into the unit when installing.-
Risk of explosion. A re may occur. Use of inammable agent may cause explosion or re. For cleaning -
operation, use non-inammable and nontoxic cleaning liquid.
Oxygen deciency. Toxic gases may be produced. Work with sufcient ventilation. Working in an enclosed -
space is dangerous. Toxic gas may be produced when cleaning agent is heated to high temperature by, e.g.,
being exposed to re.
Electric shock. Electrical hazard. In order to avoid electric shock or re, pay attention not to clamp cables when -
attaching the service cover.
Electrical hazard. Electrical discharge. This unit contains condensers that might remain charged once the unit-
is switched off. Wait at least ve minutes after the stop of the unit before to start any cleaning or maintenance
operation, allowing the discharge of the condensers.
caution
Malfunction. Unit failure. When installing more than one unit together, keep clearance of more than 500 mm -
between units and avoid obstacles that could hamper air intake.
Malfunction. Short circuit. Keep cleareance of more than 3000 mm between the wall (without vent holes) and air-
inlet/outlet.
Electromagnetic contamination. Equipment failures. Install the unit as far as possible (being at least 3 meters) -
from electromagnetic wave radiator, such as medical equipment.
Overheat of the unit. Malfunction. Install the unit in the shade or not exposed to direct sunshine or direct-
radiation from high temperature heat source.
Sharp ns. Risk of injury. Aluminium ns have very sharp edges. Pay attention to the ns in order to avoid injury. -
Use gloves.
note
This appliance is not intended to be used by people (including children) with reduced physical, sensory or-
mental capabilities, or lack of experience and knowledge, unless they have been given supervision and
instruction concerning the use of the appliance by a person responsible for their safety.
For easy operation and maintenance, install the unit with sufcient clearance around it as shown in the next -
pages.
Transport the package as close as possible to the intallation location before unpacking.-
Make sure that the foundation is at, levelled and strong enough.-
Install the unit in a place where no seasonal wind might directly blow into the outdoor fan.-
Install the unit in a restricted area not accessible by the general public.-
Cleaning liquid shall be collected after cleaning operation.-

17
RHUE-(3~6)A(V)HN
SMGB0066 rev.0 - 12/2009
Unit installation
Service Manual
1

 
warning
Malfunction. Unit failure. Do not put any foreign material into the unit and make sure that none exists inside the -
unit before the installation or test run.
 
Whenhangingtheunit,ensureitsbalanceandliftitupsmoothlyandsafely.Donotremoveanypackingmaterialsuntilthe
unitispositionedandhangtheunitunderpackingconditionwithtworopes,asshowninthegurebelow.
Over 60º
0.7 to 1.0 m
Do not remove the
plastic band or the
corrugate paper frame
Pass the wire ropes
through each lifting hole
in the wooden base as
shown
Wire rope
warning
Crush hazard. Can cause seriour injury. -
Lift the unit with 2 wire ropes and without removing its factory packaging. Make sure that the unit is lifted-
smoothly and does not lean.
Do not attach lifting equipment to the plastic band or the corrugated paper frame, since the ropes might slip or -
break the materials.
note
Make sure that the exterior of the unit is adequately protected with cloth or paper.-
Do not hold the unit with the handles or the air outlet parts. Steel plates may be deformed. Use gloves.-

Unit installation
Service Manual
18 RHUE-(3~6)A(V)HN
SMGB0066 rev.0 - 12/2009
 
Whentheunitisliftedmanually(usingthehandles),payattentiontothefollowing:donotremovethewoodenbasefrom
theunittopreventitsoverturning.Payattentiontothecenterofgravityshowninthebelowgure.
Center of
gravity
 



a b h
RHUE-3AVHN 130 705 223 545
RHUE-4AVHN 130 705 223 545
RHUE-5AVHN 135 695 228 560
RHUE-5AHN 140 695 228 560
RHUE-6AVHN 139 695 228 560
RHUE-6AHN 144 695 228 560
note
It is recommended that at least two people participate when lifting is done manually.-