HITACHI AIR-COOLED WATER CHILLERS

- SCREW TYPE -

Technical Catalog ΙΙ
– Installation, Operation and Maintenance Instructions –
Models:

Step Capacity Control Type: Continuous Capacity Control Type:

For R407C For R407C

RCUP30AU RCUP30AUZ
RCUP38AU RCUP38AUZ
RCUP46AU RCUP46AUZ
RCUP51AU RCUP51AUZ
RCUP75AU RCUP75AUZ
RCUP90AU RCUP90AUZ
RCUP102AU RCUP102AUZ
RCUP135AU RCUP135AUZ
RCUP154AU RCUP154AUZ
RCUP179AU RCUP179AUZ
RCUP205AU RCUP205AUZ
RCUP256AU RCUP256AUZ
RCUP307AU 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.

: Immediate hazards which WILL result in severe personal injury

or death.

: Hazards or unsafe practices which COULD result in severe per-

sonal injury or death.

: Hazards or unsafe practices which COULD result in minor per-

sonal injury or product or property damage.

NOTE : 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 oper-
ate 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 (oC)

Maximum Minimum
Condensing Air
43 5
Inlet Temperature
Chilled Water
15 5
Outlet Temperature

● 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 clear-
ance 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 trans-
portation 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 re-
frigerant 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 indi-
viduals performing the installation.
Unpacking - Follow the instructions marked on the packing.

1
 PREPARATION
Operation Space
3,000mm 3,000mm
Overhead Air Overhead Air
Clearance
Clearance

2,150mm
2,150mm C

C
h1

h2

h1

h2
A
A
F
B D F
B
E D
E
h1 < h2 h1 < h2

For Models RCUP30AU(Z)~RCUP154AU(Z) For Models RCUP179AU(Z)~RCUP307AU(Z)

Fig. 1 Operation Space

NOTES:
Refer to C, D
1. The height of the wall shall be smaller than that
Refer to C, D of the unit cabinet.
G H
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
Refer to C, D with HITACHI regarding the operation space is
recommended.
J

Maintenance Space (mm) Air Intake Space (mm)

Model
A B C D E F G H J
RCUP30AU(Z) 1,900 1,900 100 1,200 1,200 1,000 1,200 2,000 1,200
RCUP38AU(Z) 1,900 1,900 100 1,200 1,200 1,000 1,200 2,000 1,200
RCUP46AU(Z) 1,900 1,900 100 1,200 1,200 1,000 1,200 2,000 1,200
RCUP51AU(Z) 1,900 1,900 100 1,200 1,200 1,000 1,200 2,000 1,200
RCUP75AU(Z) 3,800 1,900 100 1,200 1,200 1,000 1,200 2,000 1,200
RCUP90AU(Z) 3,800 1,900 100 1,200 1,200 1,000 1,200 2,000 1,200
RCUP102AU(Z) 3,800 1,900 100 1,200 1,200 1,000 1,200 2,000 1,200
RCUP135AU(Z) 5,700 1,900 100 1,200 1,200 1,000 1,200 2,000 1,200
RCUP154AU(Z) 5,700 1,900 100 1,200 1,200 1,000 1,200 2,000 1,200
RCUP179AU(Z) 7,700 1,900 1,200 1,200 1,200 1,000 1,200 2,000 1,200
RCUP205AU(Z) 7,700 1,900 1,200 1,200 1,200 1,000 1,200 2,000 1,200
RCUP256AU(Z) 9,600 1,900 1,200 1,200 1,200 1,000 1,200 2,000 1,200
RCUP307AU(Z) 9,600 1,900 1,200 1,200 1,200 1,000 1,200 2,000 1,200

2
 PREPARATION
Maximum Foundation Gradient

30mm

15mm

Fig. 2 Maximum Foundation Gradient

Center of Gravity

Center of Gravity Operation RCUP30~154AU(Z), RCUP179~307AU(Z)-1

Model Weight
X Y
(kg) Piping Side
RCUP30AU(Z) 935 815 1,370
RCUP38AU(Z) 935 825 1,420
X
RCUP46AU(Z) 945 820 1,495
RCUP51AU(Z) 945 820 1,535
RCUP75AU(Z) 1,850 815 2,590
RCUP90AU(Z) 1,865 810 2,750 Y
RCUP102AU(Z) 1,865 810 2,830
RCUP135AU(Z) 2,760 815 4,435
RCUP154AU(Z) 2,760 815 4,555
Electrical Box
RCUP179AU(Z)-1 1,865 810 2,750
RCUP179AU(Z)-2 1,935 810 2,750
RCUP205AU(Z)-1 1,865 810 2,830 RCUP179~307AU(Z)-2
RCUP205AU(Z)-2 1,935 810 2,830
RCUP256AU(Z)-1 2,760 815 4,555 Piping Side
RCUP256AU(Z)-2 1,935 810 2,830
RCUP307AU(Z)-1 2,760 815 4,555 X
RCUP307AU(Z)-2 2,940 815 4,555

Electrical Box

Fig. 3 Center of Gravity

3
 PREPARATION
Weight Balance

Weight Balance Chilled Water Piping

Location (kg) 1 2
Model
1 2 3 4
RCUP30AU(Z) 295 290 395 390
RCUP38AU(Z) 310 300 410 400
RCUP46AU(Z) 320 320 430 425
RCUP51AU(Z) 325 325 445 440 3 4

Electrical Box

Location (kg)
Model
1 2 3 4 5 6 Chilled Water Piping
RCUP75AU(Z) 375 365 350 515 500 485 1 2 3
RCUP90AU(Z) 390 385 375 545 535 520
RCUP102AU(Z) 400 395 390 555 550 540
RCUP179AU(Z)-1 390 385 375 545 535 520
RCUP179AU(Z)-2 375 385 390 520 535 545
4 5 6
RCUP205AU(Z)-1 400 395 390 555 550 540
RCUP205AU(Z)-2 390 395 400 540 550 555 Electrical Box Electrical Box
RCUP256AU(Z)-2 390 395 400 540 550 555 (RCUP75~102AU(Z), (RCUP179,205,256AU(Z)-2)
RCUP179, 205AU(Z)-1)

Location (kg)
Model
1 2 3 4 5 6 7 8
RCUP135AU(Z) 530 490 450 410 725 665 610 555
RCUP154AU(Z) 550 505 460 420 740 685 625 570
RCUP256AU(Z)-1 550 505 460 420 740 685 625 570
RCUP307AU(Z)-1 550 505 460 420 740 685 625 570
RCUP307AU(Z)-2 415 460 505 555 565 625 685 745

Chilled Water Piping

1 2 3 4

5 6 7 8

Electrical Box Electrical Box

(RCUP135,154AU(Z), (RCUP307AU(Z)-2)
RCUP256,307AU(Z)-1)

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 3) Declining the Unit during Transportation

When rooling the unit, put at least required 7 equal-
sized rollers under the base frames, Each roller
must carry both the outer frames, and must be suited Do not decline the unit more than an angle of 15o as
to balance the unit (see the center of gravity in Fig. 3). shown in the figure during transportation. If declined
more than an angle of 15o, the unit may fall down.

o
15

Fig. 6-2 Transportation by Rollers Fig. 6-3 Declining the Unit

8
 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 con-
nections, wire terminals and others) are properly selected according to the “Electrical Data” in Techni-
cal 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 ac-
cidental 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 re-
quired.
RCUP30~154AU(Z)
Magnetic Switch Box
Control Circuit Terminals
Power Source Terminals 3
PWBc

3~Mp. 380V, 415V/50Hz *CSP

3~, 440V/60Hz 1 2 Y52P1
Pump Power Supply

1 2 TB2

4
*CMP
R S T Mp

*ORP
Main Power Switch Interlock for the
(Field-Supplied) Pump Contactor
*CMP

Earth Terminal
Pump Operation Wiring
Main Power Wiring Earth Wiring Contactor for Chilled (If Required)
Water Pump
Control Circuit Wiring
Wire to Be Removed
8 9 10 11 12 13
*BSR1 Push Button Switch (ON) TB2
*BSR2 Push Button Switch (OFF)
*CMP Contactor for Pump 5 6 7
TB2 *PLR1 *PLP2 *PLO1 *PLO2 *PLO3
*ORP Overcurrent Relay for Pump
*CSP Changeover Switch for Pump Operation
*PLR1 Pilot Lamp for Remote Indication (Operation)
*PLR2 Pilot Lamp for Remote Indication (Pump) *BSR2 *BSR1
*PLO1,2,3 Pilot Lamp for Remote Indication (OFF) (ON)
Indication Lamp Power Supply
(Alarm, Each Cycle)
* : Field-Supplied Remote Control Wiring and Remote
Indication Wiring (If Required)
Fig. 7-1 Field Wiring Connections

9
 INSTALLATION

RCUP179~307AU(Z)

No.1 Unit (Master Unit) No.2 Unit (Subsidiary Unit)

Magnetic Switch Box Control Circuit Terminals
Control Circuit Terminals
Power Source Terminals Power Source Terminals Magnetic Switch Box

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

3~, 440V/60Hz 1 2 AB 3~, 440V/60Hz AB

R S T Mp R S T Mp

Main Power Switch Main Power Switch

(Field-Supplied) (Field-Supplied)

Earth Terminal Earth Terminal

Main Power Wiring Main Power Wiring
Earth Wiring Earth Wiring
Contactor for Chilled
Water Pump
Control Circuit Wiring

Wire to Be Removed
1 2
TB2
3
PWBc

TB2 5 6 7
*CMP *CSP
Y52P1
Pump Power Supply

*BSR2 *BSR1
Interlock for the 4 (OFF) (ON)
Pump Contactor

(No. 1 Unit)
*ORP
(No.1 Unit)

*CMP
8 9 10 11 12 13
TB2
No.1 Unit Pump Operation Wiring *PLO1 *PLO2 -- (179~205AU)
(If Required) *PLR1 *PLP2 *PLO1 *PLO2 *PLO3 (256~307AU)
TB3 A B
(No.1 Unit)

Indication Lamp Power Supply

Remote Control Wiring and Remote

Indication Wiring (If Required)
TB3 A B (For No.1 Unit)
Shielded Wires
No.2 Unit DC12V 8 9 10 11 12 13
TB2
(with Polarity Transmission)
Control Wiring Between
No.1 and No.2 Units *PLO3 *PLO4 (179~205AU)
*PLO4 *PLO5 (256AU)
*PLO4 *PLO5 *PLO6 (307AU)
*BSR1 Push Button Switch (ON)
*BSR2 Push Button Switch (OFF)
*CMP Contactor for Pump
*ORP Overcurrent Relay for Pump
*CSP Changeover Switch for Pump Operation Indication Lamp Power Supply
*PLR1 Pilot Lamp for Remote Indication (Operation)
Remote Control Wiring and Remote
*PLR2 Pilot Lamp for Remote Indication (Pump)
Indication Wiring (If Required)
*PLO1,2,3,4,5,6 Pilot Lamp for Remote Indication
(For No.2 Unit)
(Alarm, Each Cycle)
* : Field-Supplied

Fig. 7-2 Field Wiring Connections

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 Pip-
ing” 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 com-
pletely 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 shut-
down 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 for-
eign 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 per-
fectly by operating the water pump to circulate the chilled water through the chilled water piping without go-
ing 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 character-
istics, 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 RCUP90AUZ RCUP102AUZ RCUP135AUZ

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

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 Water Cooler Model Water Cooler
RCUP30AU(Z) 0.014 RCUP135AU(Z) 3 x 0.020
RCUP38AU(Z) 0.015 RCUP154AU(Z) 3 x 0.020
RCUP46AU(Z) 0.020 RCUP179AU(Z) 4 x 0.020
RCUP51AU(Z) 0.020 RCUP205AU(Z) 4 x 0.020
RCUP75AU(Z) 2 x 0.015 RCUP256AU(Z) 5 x 0.020
RCUP90AU(Z) 2 x 0.020 RCUP307AU(Z) 6 x 0.020
RCUP102AU(Z) 2 x 0.020

Chilled Water Pressure Drop

12
 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 en-
countered through these checks. The following is the HITACHl standard water quality based on the JRA
standard water quality.

Chilled Water System Tendency (1)

Item Circulating Water Deposit of
(20oC Less than) Supply Water Corrosion
Scales
Standard Quality
pH (25oC) 6.8 ~ 8.0 6.8 ~ 8.0 O O
(mS/m) (25oC) Less than 40 Less than 30
Electrical Conductivity {Less than 400} {Less than 300}
O O
{μS/cm} (25oC)(2)
Chloride Ion ( mgCl - / l) Less than 50 Less than 50 O
Sulfur Acid Ion ( mgSO42- / l) Less than 50 Less than 50 O
The Amount of Acid
( mgCaCO3 / l) Less than 50 Less than 50 O
Consumption (pH4.8)
Total Hardness ( mgCaCO3 / l) Less than 70 Less than 70 O
Calcium Hardness ( mgCaCO3 / l) Less than 50 Less than 50 O
Silica L ( mgSiO2 / l) Less than 30 Less than 30 O
Reference Quality
Total Iron (mgFe/ l) Less than 1.0 Less than 0.3 O O
Total Copper (mgCu/ l) Less than 1.0 Less than 0.1 O
Sulfur Ion ( mgS2- / l) It shall not to be detected. O
Ammonium Ion ( mgNH4+/ l) Less than 1.0 Less than 0.1 O
Remaining Chlorine ( mgCl / l) Less than 0.3 Less than 0.3 O
Floating Carbolic Acid ( mgCO2 / l) Less than 4.0 Less than 4.0 O
Index of Stability 6.8 ~ 8.0 - 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? 4. Is electrical wiring system adequate?
2. Is the installation location adequate? Wire Size Tightened Connections
Space for Condenser Air Flow Switch Size Operation Control Devices
Space for Maintenance Work Fuse Size Safety Devices
Noise and Vibration Voltage and Hz Interlock
Sunshine and Rainfall 5. Have the R, S and T phases of the water chiller cor-
Appearance rectly been connected to the R, S and T phases of the
3. Is the water piping system adequate? main power source? (Mp phase also)
Tube Size Water Drain 6. Are the stop valves for the condenser liquid line open?
Length Water Control 7. Have the packing glands and the cap nuts for the stop
Flexible Joint Air Purge valves been tightened?
Insulation Pressure Control

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. Is the main switch ON?
2. Is the main fuse OK?
3. Is the chilled water running?
4. Are the thermostat calling for the cooling operation?
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 rever-
sal phase protection device.
Cut the main switch and interchange two of three terminals, R, S and T on the main terminals at the field con-
nection 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 con-
trol 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, respec-
tively, 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 abnor-
malities 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 No.2 Unit
PWBG PWBG PWBG

DSW1 DSW2 DSW1 DSW2 DSW1 DSW2

Fig. 8-2 Switch Arrangement of PWBG

16
 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 1 2 3 4
Differential (degree) 1 2 3 4
Step Differential (degree) 0.5 1 1 1
Minimum Internal System 400 200 130 100
Water Volume Ratio (%) (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 0 1 2 3 4 5 6 7 8 9
Band (degree) 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

$ Continuous Capacity Control Setting Switch = DSW5

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 1 2 1 2 1 2 1 2
Location ON ON ON OFF OFF ON OFF OFF
Band (degree) 0.5 1.0 1.5 2.0 Standard
DSW7-3 ON 1.0 1.5 2.0 2.0 Wide min. load

* Temperature Band for Restart Setting Switch

= 2 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 3 4 3 4 3 4 3 4
Location ON ON ON OFF OFF ON OFF OFF
Band (Degree) 1.0 2.0 3.0 4.0

* Differential Temperature of Load-up 2 Mode Setting Switch

= 1 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 5 5
Location ON OFF
Band (Degree) 1.0 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 6 6
Location ON OFF
Time (Second) 12 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 7 8 7 8 7 8 7 8
Location ON ON ON OFF OFF ON OFF OFF
Time (Second) 2 4 6 8

* Interval of Output Signal Time for Load-up and Load-down Mode Setting Switch
= 60 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 9 10 9 10 9 10 9 10
Location ON ON ON OFF OFF ON OFF OFF
Time (Second) 60 90 120 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 Time
1 2 (minute)
ON ON 0.5
OFF ON 10
ON OFF 6
OFF OFF 3

$ No. of Cycle for Checking High Pressure Cut-Off Setting Switch = figures 3 and 4 of DSW2
Switches “DSW2-3” and “DSW2-4” are used for setting the No. of cycle for checking high pressure cut-off. If necessary
to check high pressure cut-off, set these switches and depress “SW9” or “SW10” during operation.
(This function is available during “Local Operation”.)
DSW2 Depress Switch
3 4 SW9 SW10
ON OFF No. 1 Cycle No. 2 Cycle
ON OFF No. 3 Cycle No. 4 Cycle
OFF ON No. 5 Cycle No. 6 Cycle

$ Manual Set Switch = 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 tempera-
ture 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.

(a) ON Point (b) (c)

Water Temp. tw(C )

2deg.
tw

4deg.
T=20min.
OFF Point
more than more than 20min.
less than 20min.
20min.

Time T (min.)
Water Temperature Change
when the Differential Remains Unchanged

$ 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 indi-
cation 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

C1-H1 C2-H2 C3-H3 C4-H4 C5-H5 C6-H6 Activation of High Pressure Switch No.1, No.2, No.3, No.4,
No.5 and No.6
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 Activation of Freeze Protection by Thermistor (THMi1)
C1-13 C2-13 C3-13 C4-13 C5-13 C6-13 Activation of Freeze Protection by Thermistor (THMo1~6, THMoB1~6)
Activation of Water Temperature Overheating Protection by Thermistor
14 14 14 14 14 14
(THMo1~6)
Activation of Water Temperature Overheating Protection by Thermistor
C1-14 C2-14 C3-14 C4-14 C5-14 C6-14
(THMo1~6)
Alarm of Excessively Low Evaporator Inlet Refrigerant Temperature
C1-91 C2-92 C3-93 C4-94 C5-95 C6-96
(THME1~6)
Max. 2 times in
C1-P6 C2-P6 C3-P6 C4-P6 C5-P6 C6-P6 Excessively Low Suction Pressure Retry Control
30 minutes
Immediately after
5P 5P 5P 5P 5P 5P Abnormal Condition of Feed Back Signal from Pump
Operation
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) No.1, No.2, No.3, No.4,
No.5 and No.6
C1-12 C2-12 C3-12 C4-12 C5-12 C6-12 Abnormality in Thermistor for Chilled Water Oultet (THMo1~6)
Abnormality in Thermistor for Water Cooler Refrigerant Inlet Temperature
C1-21 C2-21 C3-21 C4-21 C5-21 C6-21
(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
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 Remarks
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
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. Push the check " " switches
for more than 3 seconds.

The Alarm Code Normal Operation Condition Checking

Occurrence Data 1 "88" "Co" "oF" Indication
Please refer to page 25 for details Please refer to page 23 for details
of this function. of this function.

This indication mode is switched to

Push the check " " and " " the normal mode by pushing the
switches simultaneously for more check " " switch for more than
than 3 seconds. 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.)

PWBA (Control Panel) This dot shows checking indication mode.

(CHECK)

SW3 SW4
㔚Ḯ (CHECK)
(POWER)
(ON) (OFF) Normal Indication Checking Indication Mode
ㆇォ
(OPERATION)
⼊ႎ
(ALARM)
SW3 SW4 - No. 1 Cycle (C1)
- Cooling Operation (Co) Push for more than 3 seconds.

Hereafter, the indication is switched whenever “+” or “,” is pushed. The indicated contents are as follows.

Example of Indicating Code

Items Contents
(Alternate Blinking)
In case of the last alarm "Activation of
Last Alarm High Pressure Switch of No. 1 Cycle"
SW3
("00-00" means no alarm code is memorized.)

State of (a) Pd (Discharge Pressure) Indication [MPa]

SW4
- Example: No. 1 Cycle Pd 1.42MPa
SW3
Refrigerant
- Example: No. 2 Cycle Pd 1.43MPa
Cycle - Example: No. 3 Cycle Pd 1.41MPa
SW4

SW3
In Case of Multi-Cycle Unit
(Only refrigerant cycle No. at "ON" side on
SW4
Manual Set Switch are indicated. This is
SW3 adaptive for the following item (b) to (h)-2.)
(b) Ps (Suction Pressure) Indication [MPa]
SW4 - Example: No. 1 Cycle Ps 0.41MPa
SW3 - "C2-PS" ~ "C6-PS" are indicated continuously for multi-cycle unit.
(c) Td (Discharge Gas Temperature) Indication [oC]
SW4 - Example: No. 1 Cycle Td 81oC
SW3
- "C2-td" ~ "C6-td" are indicated continuously for multi-cycle unit.
(d) Ts (Suction Gas Temperature) Indication [oC]
SW4 - Example: No. 1 Cycle Ts -2oC
SW3
- "C2-ts" ~ "C6-ts" are indicated continuously for multi-cycle unit.
(e) Tr (Water Cooler Inlet Refrigerant Gas Temperature) Indication [oC]
SW4 - Example: No. 1 Cycle Tr 5oC
SW3 - "C2-tr" ~ "C6-tr" are indicated continuously for multi-cycle unit.
(f) Te (Liquid Refrigerant Temperature) Indication [oC]
SW4 - Example: No.1 Cycle Te 35oC
SW3
- "C2-te" ~ "C6-te" are indicated continuously for multi-cycle unit.
(g) Inlet Water Temperature Indication [oC]
SW4 - Example: Chilled Water Inlet Temperature 12oC
SW3

(h)-1 Outlet Water Temperature Indication [oC]

SW4 - Example: Chilled Water Outlet Temperature 7oC
SW3 (In multi-cycle unit, average of each cycle is indicated.)

SW4

23
SELF-INSPECTION FUNCTIONS

SW3

(h)-2 Each Outlet Water Temperature Indication [oC]

SW4 The outlet chilled water temperatures are indicated
SW3
in multi-cycle unit each cycle.
(There is no indication for one cycle unit.)
SW4 - Example: No. 1 Cycle Chilled Water Outlet Temperature 7oC
- Example: No. 2 Cycle Chilled Water Outlet Temperature 7oC
SW3

- Example: No. 3 Cycle Chilled Water Outlet Temperature 8oC

SW4

SW3

(a) Preset Temperature of Chilled Water Indication [oC]

SW4
Setting - Example: Preset Temperature of Chilled Water 12oC
SW3

(b) Second Preset Temperature of Chilled Water Indication [oC]

SW4 - Example: Second Preset Temperature of Chilled Water 5oC
* Only when the second preset temperature is selected, it is indicated.
SW3 Please refer to (3)-4.
(c) ON/OFF Differential (In Case of Step Capacity Control)/
SW4 Neutral Zone(In Case of Continuous Capacity Control)
SW3
Indication [oC]

Ambient Ambient Temperature Indication [oC]

SW4
Temperature - Example: Ambient Temperature 35oC
SW3

(Step Capacity Cntrol) The capacity control of each compressor is indicated.

SW4 Capacity * Step Capacity Control: "100" "75" "50" [%]
Control * Continuous Capacity Control:
Load-Up "UP" / Neutral Zone "nU" / Load-Down "dO"
(Continuous Capacity Control)

- Thermo-OFF "- -"

- Unload-Starting "10"
SW3
- "C2-Ld" ~ "C6-Ld" are indicated continuously for multi-cycle unit.
The protection control operating state of each cycle is indicated.
SW4 Protection - The protection control is allocated in each part of seven segments, and
Control each part lights when each protection control is operating.
Operating (Example: "Td control is operation when the No. 1 cycle is
Mode of Operation operating in cooling mode.")
State of Protection Unload-Starting
Pd Control
Control
Td Control
Ps Control Liquid By-pass Control
(At Stopping)
(Only Indication(This function
Differential Pressure is not available in this unit.))
Control
Unload for Freeze Protection
Tr Control Current Limitation Control
Td Retrying control
- "C2-PC" ~ "C6-PC" are indicated continuously for multi-cycle unit.
SW3

Number of Operating Fan Indication

SW4 Fan Control (If the number of operating fan is zero, "0" is indicated.)
(Example : The number of operating fan is 4.)
SW3 Number of Operating Fan

Software Software No. is indicated.

SW4
ROM No. (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) Alternate Blinking

(CHECK)

SW3 SW4
㔚Ḯ
(POWER)
(CHECK) The alarm occurred last.
ㆇォ
(ON) (OFF) Normal Indication
(OPERATION)
⼊ႎ
(ALARM)
SW3 SW4 - No. 1 Circuit (C1)
- Cooling Operation (Co) Push simultaneously for more than 3 seconds.

Hereafter, the indication is switched every time “+“ or “,“ is pushed. The indicated contents are as follows.

Example of Indicating Code

Items Contents
(Alternate Blinking)
The alarm The alarm is indicated from the last. (Max. 10 Data Memorized)
occurred last. (When the number of alarm is 5, it is indicated from "No. 5".)
SW3
In Case of Latest Alarm "Activation of Pressure
. . Switch of No. 1 Circuit"
SW4
. . (If no alarm code is memorized, it is indicated "00-00".)
SW3 . .

The alarm In Case of 5th Alarm "Abnormal Condition of Feed

SW3
SW4
occurred 5th. Back Signal from Pump"
. .
SW4
. .
SW3 . .

The alarm
SW4
occurred 1st. 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 si-
multaneously 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)

SW3 SW4
It is effective only while indicating The alarm occurred last.
the last alarm.

Push for more than 3 seconds.

*1 These data are preserved only about the last occurence alarm.
*2 These data are deleted by power supply OFF.
*3 It returns to the mode of alarm occurrence after “- - - -” blinks twice when no data is preserved.
*4 The indicated item is switched by “+” (SW3) and “,” (SW4) as well as the cheking indication.
*5 The following items are indicated by the addition though the indicated data is the same as the item indicated in the
checking indication.

Example of Indicating Code

Items Contents
(Alternate Blinking)
.
. .
Refrigerant .
Liquid .
SW3
Temperature
Outlet Water Outlet Water Temperature on Back Side of
SW4
Temperature Heat Exchanger on Water Side Display [oC]
SW3
on Back Side - In Case of Outlet Water Temperature on
of Water Back Side of No. 1 Circuit 7oC
SW4 Side Heat - In Case of Outlet Water Temperature on
SW3
Exchanger Back Side of No. 2 Circuit 7oC
- In Case of Outlet Water Temperature on
SW4 Back Side of No. 3 Circuit 8oC
SW3

. .
.
SW4
. .
SW3
Fan Control .

Open Level Opening Level of Electronic Expansion Valve

SW4
of Electronic - In Case of Opening Level of Expansion Valve
SW3

Expansion of No. 1 Circuit 242 pulse

Valve - In case of Opening Level of Expansion Valve
SW4 of No. 2 Circuit 240 pulse
SW3
- In case of Opening Level of Expansion Valve
of No. 3 Circuit 245 pulse
SW4 (* 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 si-
multaneously 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 Push the check " " switch. : -0.5oC

SEG1 SEG2 SEG1 SEG2

Push the switches until
becoming the required
temperature.

Push the check " " and " " switches

simultaneously for more than 3 seconds.

SEG1 SEG2

Display of "tS-Cd" and new second preset

chilled water temperature are alternately
SEG1 SEG2
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
7. CONTROL SYSTEM
Standard Operating Sequence for RCUP30AU, RCUP38AU, RCUP46AU and RCUP51AU

Control Stage Starting Control Capacity Safety Devices Shut Down

Control Devices Control
Main Power Switch OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
Water Pump - OFF ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
CONTROL SYSTEM

Operation Switch (ON/OFF) - - - ON - - - - - - - - OFF - OFF -

Controller FLD - - - - - - - - -
ULD(75%) - - - - - - - - - - - - - - -
ULD(50%) - - - - - - - - - - - - - - -
Safety Devices No.1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS
Pilot Lamp OFF OFF OFF ON ON ON ON ON ON ON ON FLK OFF ON OFF OFF
Motor for Fan MF11~14 OFF OFF OFF OFF ON ON ON ON ON ON ON OFF OFF ON OFF OFF
Oil Heater CH1 OFF ON ON ON OFF OFF OFF OFF OFF ON OFF ON ON OFF ON OFF
STA DLT DLT DLT DLT DLT DLT
Motor for Compressor MC1 OFF OFF OFF OFF (ULD) (ULD) (FLD) (ULD) (ULD) OFF (FLD) OFF OFF (FLD) OFF OFF
15% 15% 100% 75% 50% 100% 100%
Solenoid Valve SV11 OFF OFF OFF OFF ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF OFF
SV12 OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF
SV13 OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF
Time Schedule 5 sec.

3min. 30sec.

Minimum 3 min.

CLS: Close, OPN: Open, STA: Star, DLT: Delta

ULD: Unload, FLD: Full Load, FLK: Flicker
 Standard Operating Sequence for RCUP75AU, RCUP90AU and RCUP102AU

Control Stage Starting Control Capacity Control Safety Devices Shut Down
Control Devices
Main Power Switch OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
Water Pump - OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
Operation Switch (ON/OFF) - - - ON - - - - - - - - - - - - - - OFF - OFF -
Controller FLD - - - - - - - - - - -
ULD(75%) - - - - - - - - - - - - - - - - - - - - -
ULD(50%) - - - - - - - - - - - - - - - - - - - - -
ULD(25%) - - - - - - - - - - - - - - - - - - - -
Safety Devices No.1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN OPN CLS CLS CLS CLS
No.2 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS
Pilot Lamp OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON FLK FLK OFF ON OFF OFF
Motor for Fan MF11~14 OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF ON OFF OFF
MF21~24 OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON OFF OFF ON OFF OFF
Oil Heater CH1 OFF ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF ON ON OFF ON ON ON OFF ON OFF
CH2 OFF ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF ON OFF OFF ON ON OFF ON OFF
Motor for Compressor MC1 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF (ULD) (ULD) (FLD) (FLD) (FLD) (FLD) (FLD) (ULD) (ULD) OFF OFF (FLD) OFF OFF OFF (FLD) OFF OFF
15% 15% 100% 100% 100% 100% 100% 50% 50% 100% 100%
MC2 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF OFF OFF OFF (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) OFF (FLD) (FLD) OFF OFF (FLD) OFF OFF
15% 15% 100% 100% 100% 50% 50% 100% 100% 100%
Solenoid Valve SV11 OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF
SV12 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF
SV21 OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF
SV22 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF
Time Schedule 5 sec. 5 sec.

30 sec. 30 sec.

3 min. 1 min.
(4 min.)
Minimum 3 min.
The Compressor which stopped first will be started first.
CLS: Close, OPN: Open, STA: Star, DLT: Delta
ULD: Unload, FLD: Full Load, FLK: Flicker
CONTROL SYSTEM

29
30
Standard Operating Sequence for RCUP135AU and RCUP154AU
Control Stage Starting Control Capacity Control Safety Devices Shut Down
Control Devices
Main Power Switch OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
Water Pump - OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
Operation Switch (ON/OFF) - - - ON - - - - - - - - - - - - - - - - - - OFF - OFF -
Controller FLD - - - - - - - - - -
ULD(66%) - - - - - - - - - - - - - - - - - - - - - - - - -
ULD(33%) - - - - - - - - - - - - - - - - - - - - - - - - -
CONTROL SYSTEM

ULD(17%) - - - - - - - - - - - - - - - - - - - - - - - -
Safety Devices No.1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN OPN OPN CLS CLS CLS CLS
No.2 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN OPN CLS CLS CLS CLS
No.3 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS
Pilot Lamp OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON FLK FLK FLK OFF ON OFF OFF
Motor for Fan MF11~14 OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF ON OFF OFF
MF21~24 OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF ON OFF OFF
MF31~34 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON OFF OFF ON OFF OFF
Oil Heater CH1 OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF ON ON ON OFF ON OFF
CH2 OFF ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF ON ON ON OFF ON OFF
CH3 OFF ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF ON ON OFF ON OFF
Motor for Compressor MC1 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF (ULD) (ULD) (FLD) (FLD) (FLD) (FLD) (FLD) (FLD) (FLD) (FLD) (ULD) OFF OFF OFF (FLD) OFF OFF OFF OFF (FLD) OFF OFF
15% 15% 100% 100% 100% 100% 100% 100% 100% 100% 50% 100% 100%
MC2 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF OFF OFF OFF (ULD) (ULD) (FLD) (FLD) (FLD) (FLD) (FLD) (ULD) (ULD) OFF OFF (FLD) (FLD) OFF OFF OFF (FLD) OFF OFF
15% 15% 100% 100% 100% 100% 100% 50% 50% 100% 100% 100%
MC3 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF (ULD) (ULD) (FLD) (FLD) (FLD) (ULD) (ULD) OFF (FLD) (FLD) (FLD) OFF OFF (FLD) OFF OFF
15% 15% 100% 100% 100% 50% 50% 100% 100% 100% 100%
Solenoid Valve SV11 OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF
SV12 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
SV21 OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF
SV22 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
SV31 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF
SV32 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF
Time Schedule 5 sec. 5 sec. 5 sec.

30 sec. 30 sec. 30 sec.

3 min. 1 min. 1 min.

(4 min.) (5 min.)
Minimum 3 min.
The Compressor which stopped first will be started first.
CLS: Close, OPN: Open, STA: Star, DLT: Delta
ULD: Unload, FLD: Full Load, FLK: Flicker
 Standard Operating Sequence for RCUP30AUZ, RCUP38AUZ, RCUP46AUZ and RCUP51AUZ

Control Stage Starting Control Capacity Control Safety Devices Shut Down
Control Devices
Main Power Switch OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
Water Pump - OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
Operation Switch (ON/OFF) - - - ON - - - - - - - - - - - OFF - OFF -
Controller Load up - - - - - - - - - - - - - - - - -
Neutral - - - - - - - - - - - - - -
Load down - - - - - - - - - - - - - - - -
Safety Devices No.1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS
Pilot Lamp OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON FLK OFF ON OFF OFF
Motor for Fan MF11~14 OFF OFF OFF OFF ON ON ON ON ON ON ON ON OFF ON OFF OFF ON OFF OFF
Oil Heater CH1 OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON ON ON ON OFF
STA DLT DLT DLT DLT DLT DLT DLT DLT DLT
Motor for Compressor MC1 OFF OFF OFF OFF (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) OFF (ULD) OFF OFF (FLD) OFF OFF
15% 15% 15~99% 100% 100% 15~99% 15~99% 15% 15~99% 100%
Solenoid Valve SV11 OFF OFF OFF ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF
SV12 OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF
SV13 OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
Time Schedule 5 sec.

3 min. 30 sec.

Minimum 3 min.

CLS: Close, OPN: Open, STA: Star, DLT: Delta

ULD: Unload, FLD: Full Load, FLK: Flicker
CONTROL SYSTEM

31
32
Standard Operating Sequence for RCUP75AUZ, RCUP90AUZ and RCUP102AUZ

Control Stage Starting Control Capacity Control Safety Devices Shut Down
Control Devices
Main Power Switch OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
Water Pump - OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
Operation Switch (ON/OFF) - - - ON - - - - - - - - - - - - - - OFF - OFF -
Controller Load up - - - - - - - - - - - - - - - - - -
Neutral - - - - - - - - - - - - - - - - - -
Load down - - - - - - - - - - - - - - - - - - -
CONTROL SYSTEM

Safety Devices No.1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN OPN CLS CLS CLS CLS
No.2 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS
Pilot Lamp OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON FLK FLK OFF ON OFF OFF
Motor for Fan MF11~14 OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFF OFF ON OFF OFF
MF21~24 OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON OFF ON ON OFF OFF OFF OFF OFF
Oil Heater CH1 OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON ON ON ON ON OFF
CH2 OFF ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF ON ON ON ON OFF
Motor for Compressor MC1 STA DLT STA DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF (ULD) (ULD) (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) OFF (ULD) OFF OFF OFF (FLD) OFF OFF
15% 15% 15% 15% 15-99% 100% 100% 15-99% 15-99% 15% 15-99% 100%
MC2 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF OFF OFF (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) OFF (ULD) (ULD) OFF OFF (FLD) OFF OFF
15% 15% 15-99% 100% 100% 15-99% 15-99% 15% 15-99% 15-99% 100%
Solenoid Valve SV11 OFF OFF OFF ON ON ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF
SV12 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFF
SV13 OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
SV21 OFF OFF OFF ON ON ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF
SV22 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFF
SV23 OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF ON OFF OFF ON OFF OFF OFF OFF OFF
Time Schedule 5 sec. 5 sec.

60 sec. 30 sec.

3 min.

Minimum 3 min.
The Compressor which stopped first will be started first.
CLS: Close, OPN: Open, STA: Star, DLT: Delta
ULD: Unload, FLD: Full Load, FLK: Flicker
 Standard Operating Sequence for RCUP135AUZ and RCUP154AUZ

Control Stage Starting Control Capacity Control Safety Devices Shut Down
Control Devices
Main Power Switch OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
Water Pump - OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
Operation Switch (ON/OFF) - - - ON - - - - - - - - - - - - - - - - - OFF - OFF -
Controller Load up - - - - - - - - - - - - - - - - - - - - -
Neutral - - - - - - - - - - - - - - - - - - - -
Load down - - - - - - - - - - - - - - - - - - - - - -
Safety Devices No.1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN OPN OPN CLS CLS CLS CLS
No.2 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN OPN CLS CLS CLS CLS
No.3 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS
Pilot Lamp OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON FLK FLK FLK OFF ON OFF OFF
Motor for Fan MF11~14 OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFF OFF OFF ON OFF OFF
MF21~24 OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON OFF ON ON OFF OFF OFF ON OFF OFF
MF31~34 OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON OFF ON ON ON OFF OFF ON OFF OFF
Oil Heater CH1 OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON ON ON ON OFF ON OFF
CH2 OFF ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF ON ON ON OFF ON OFF
CH3 OFF ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF ON ON OFF ON OFF
Motor for Compressor MC1 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF (ULD) (ULD) (ULD) (ULD) (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) OFF (ULD) OFF OFF OFF OFF (FLD) OFF OFF
15% 15% 15% 15% 15% 15% 15-99% 100% 100% 15-99% 15-99% 15% 15-99% 100%
MC2 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF OFF OFF (ULD) (ULD) (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) OFF (ULD) (ULD) OFF OFF OFF (FLD) OFF OFF
15% 15% 15% 15% 15-99% 100% 100% 15-99% 15-99% 15% 15-99% 15-99% 100%
MC3 STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
OFF OFF OFF OFF OFF OFF OFF OFF (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) OFF (ULD) (ULD) (ULD) OFF OFF (FLD) OFF OFF
15% 15% 15-99% 100% 100% 15-99% 15-99% 15% 15-99% 15-99% 15-99% 100%
Solenoid Valve SV11 OFF OFF OFF ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF
SV12 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF
SV13 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
SV21 OFF OFF OFF ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF
SV22 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF
SV23 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
SV31 OFF OFF OFF ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF OFF OFF
SV32 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF
SV33 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF
Time Schedule 5 sec. 5 sec. 5 sec.

60 sec. 60 sec. 30 sec.

3 min.

Minimum 3 min.
The Compressor which stopped first will be started first.
CLS: Close, OPN: Open, STA: Star, DLT: Delta
ULD: Unload, FLD: Full Load, FLK: Flicker
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 in-
tervals. 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 con-
tractor or dealer of HITACHI.
● Clean the water strainer filter periodically according to its clogging degree. If not cleaned periodi-
cally, 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 for-
eign 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 ex-
changer. 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 in-
staller.

● 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 us-
ing 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. Treat-
ment 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
Chilled Water Acid-resistant Type Water Pump
CHILLER Inlet piping
Hose
UNIT

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 bub-
bles 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 neutral-
izing 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.

0.8
Suction Gas Pressure

0.6
(MPa)

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 shut-
down, 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 pres-
sures. 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 equiv-
alent 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 mani-
fold.
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 RCUP30AU(Z) RCUP38AU(Z) RCUP46AU(Z) RCUP51AU(Z) RCUP75AU(Z) RCUP90AU(Z) RCUP102AU(Z) RCUP135AU(Z)

Refrigerant
28 34 40 42 2 x 34 2 x 40 2 x 42 3 x 40
Charge (kg)

Model RCUP154AU(Z) RCUP179AU(Z) RCUP205AU(Z) RCUP256AU(Z) RCUP307AU(Z)

Refrigerant
3 x 42 4 x 40 4 x 42 5 x 42 6 x 42
Charge (kg)

38
 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 danger-
ous, 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 de-
crease 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 min-
utes, 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 dis-
charge 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.

Oil Separator
Flange
Upper Part Cover

39
 MAINTENANCE

Safety and Control Device Setting

Step Control RCUP30AU RCUP38AU RCUP46AU RCUP51AU RCUP75AU RCUP90AU RCUP102AU
Model
Continuous Control RCUP30AUZ RCUP38AUZ RCUP46AUZ RCUP51AUZ RCUP75AUZ RCUP90AUZ RCUP102AUZ
For Compressor
High Pressure Control Manual Reset, Non-Adjustable (One Switch for Each Compressor Motor)
Cut-Out MPa 2.98 2.98 2.98 2.98 2.98 2.98 2.98
Low Pressure Control Control by Micro-Processor
Cut-Out MPa 0.05 0.05 0.05 0.05 0.05 0.05 0.05
Internal Thermostat Manual Reset, Non-Adjustable (One Switch for Each Compressor Motor)
Cut-Out o
C 115 115 115 115 115 115 115
Cut-In o
C 93 93 93 93 93 93 93
Overcurrent Relay Manual Reset, Non-Adjustable (One Three-Phase Set for Each Compressor Motor)
380V 50Hz A 64 72 90 114 72 90 114
415V 50Hz A 64 72 90 114 72 90 114
440V 60Hz A
Oil Heater One Heater for Each Compressor Motor
Capacity W 150 150 150 150 150 150 150
Discharge Gas Thermistor (One for Each Compressor)
Cut-Out o
C 140 140 140 140 140 140 140
CCP Timer Non-Adjustable (One Timer for Each Compressor)
Setting Time s 180 180 180 180 180 180 180
Star-Delta s 5 5 5 5 5 5 5
Unloading during Starting s 30 30 30 30 30 30 30
For Control Circuit
Fuse
Capacity 220/240V A 5 5 5 5 5 5 5
For Refrigerant Circuit (One for Each Circuit)
Fusible Plug
Melting Temperature o
C 72 72 72 72 72 72 72
Freeze Protection Control Control by Micro-Processor (One of Each Circuit)
Cut-Out o
C 2 2 2 2 2 2 2
Overcurrent Relay for Fan Motor Manual Reset, Non-Adjustable (One Three-Phase Set for Each Fan Motor)
380V 50Hz A 3.8 3.8 3.8 3.8 3.8 3.8 3.8
415V 50Hz A 3.8 3.8 3.8 3.8 3.8 3.8 3.8
440V 60Hz A
Pressure Relief Valve (One for Each Compressor)
Starting to Open MPa 3.3 3.3 3.3 3.3 3.3 3.3 3.3

Step Control RCUP135AU RCUP154AU RCUP179AU RCUP205AU RCUP256AU RCUP307AU

Model
Continuous Control RCUP135AUZ RCUP154AUZ RCUP179AUZ RCUP205AUZ RCUP256AUZ RCUP307AUZ
For Compressor
High Pressure Control Manual Reset, Non-Adjustable (One Switch for Each Compressor Motor)
Cut-Out MPa 2.98 2.98 2.98 2.98 2.98 2.98
Low Pressure Control Control by Micro-Processor
Cut-Out MPa 0.05 0.05 0.05 0.05 0.05 0.05
Internal Thermostat Manual Reset, Non-Adjustable (One Switch for Each Compressor Motor)
Cut-Out o
C 115 115 115 115 115 115
Cut-In o
C 93 93 93 93 93 93
Overcurrent Relay Manual Reset, Non-Adjustable (One Three-Phase Set for Each Compressor Motor)
380V 50Hz A 90 114 90 114 114 114
415V 50Hz A 90 114 90 114 114 114
440V 60Hz A
Oil Heater One Heater for Each Compressor Motor
Capacity W 150 150 150 150 150 150
Discharge Gas Thermistor (One for Each Compressor)
Cut-Out o
C 140 140 140 140 140 140
CCP Timer Non-Adjustable (One Timer for Each Compressor)
Setting Time s 180 180 180 180 180 180
Star-Delta s 5 5 5 5 5 5
Unloading during Starting s 30 30 30 30 30 30
For Control Circuit
Fuse
Capacity 220/240V A 5 5 5 5 5 5
For Refrigerant Circuit (One for Each Circuit)
Fusible Plug
Melting Temperature o
C 72 72 72 72 72 72
Freeze Protection Control Control by Micro-Processor (One of Each Circuit)
Cut-Out o
C 2 2 2 2 2 2
Overcurrent Relay for Fan Motor Manual Reset, Non-Adjustable (One Three-Phase Set for Each Fan Motor)
380V 50Hz A 3.8 3.8 3.8 3.8 3.8 3.8
415V 50Hz A 3.8 3.8 3.8 3.8 3.8 3.8
440V 60Hz A
Pressure Relief Valve (One for Each Compressor)
Starting to Open MPa 3.3 3.3 3.3 3.3 3.3 3.3

40
 MAINTENANCE

Normal Operating Pressure

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.

Discharge Gas Pressure

Suction Gas Pressure

0.6 2.5

2.0

(MPa)
0.4
(MPa)

1.5
Standard Working Range Standard Working Range
0.2
1.0

0
5 7 9 11 13 15 0 10 20 30 40
Chilled Water Outlet Temperature (oC) Condenser Inlet Temperature (oC)

1) Fire
If a fire accidentally occurs, turn OFF the main switch and use an extinguisher for an oil fire and elec-
tric 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 oc-
cur.

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 stop-
page 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 regula-
tions.

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

Characteristics of Sensors
Resistance (kΩ)

Temperature (Co)

Fig. 9-1 Characteristic of Thermistor

(For Water Temperature and Refrigerant Temperature Excluding Discharge Gas Temperature)

43
 MAINTENANCE

Resistance (kΩ)

Temperature (Co)

Fig. 9-2 Characteristic of Thermistor (For Ambient Temperature)

44
 MAINTENANCE

Resistance (kΩ)

Temperature (Co)

Fig. 9-3 Characteristic of Thermistor (For Discharge Gas Temperature)

1.786+0.019 5+0.068
Output (V)

Output (V)

1.143+0.019 2.75+0.068

0.500+0.019 0.5+0.068
(0.37) (0.37)

(-0.1) 0 0.49 0.98 -1 0 1.72 3.43

Pressure(MPa) Pressure (MPa)

Fig. 10-1 Characteristic of Pressure Sensor Fig. 10-2 Characteristic of Pressure Sensor
(For Suction Pressure) (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 m /h
3
Pa Pa Pa
(for Water-Cooled type)
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
C Outlet o
C
4. Check Condenser Water Temperature: (for Water-Cooled Type)
Inlet o
C Outlet o
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
7. Check Running Current: A A A A A A
8. Commissioning Completely finished? Check Date Sign
If you have any further inquiry, please contact to Hitachi Agent or Distributor.

46
 MAINTENANCE

Daily Operation Records

Model:
Date:
Weather:
Time of Operation: Start, Stop. ( )
o
DB C
Ambient Temperature
o
WB C
o
Room Temperature C
High
MPa
Pressure
Low
Compressor MPa
Pressure
Voltage V
Current A
o
Condenser Inlet Inlet(DB) C
o
Air Temperature Outlet(DB) C
o
Chilled Water Inlet C
o
Temperature Outlet C
Current for Chilled Water Pump 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)
Interchangeability with R22 Reason of Non-Interchangeability and
Measuring Instruments
Attention Use
and Tool R407C ( : Strictly required)
Refrigerant Flaring Tool O • The flaring tools for R407C are applicable Flaring for Tubes
Pipe Extrusion to R22. Dimensional
Adjustment Control for
Gauge — Extruded Portion
of Tube after
Flaring
Pipe Bender O — Bending
Expanding Expanding
O —
Tool Tubes
Torque Connection of
O —
Wrench Flare Nut
Brazing • Perform correct brazing work. Brazing for
O
Tool Tubes
Nitrogen • Strict Control against Contamination Prevention from
Gas O (Blow nitrogen during brazing.) Oxidation during
Brazing
Lubrication Models Ref. Oil • Use a synthetic oil which is equivalent to Applying oil to
Oil RCUP-AU(Z) R407C UX300 the oil used in the refrigeration cycle. the Flared
• Synthetic oil absorbs moisture quickly. Surface
Vacuum Refrigerant • Check refrigerant cylinder color Refrigerant
Drying Cylinder ● Liquid refrigerant charging is required Charging
. regarding zeotropic refrigerant.
Refrigerant Vacuum The current ones are applicable. Vacuum
Charge Pump O However, it is required to mount a Pumping
vacuum pump adapter which can
Adapter for prevent from reverse flow when a
Vacuum ● vacuum pump stops, resulting in no
Pump reverse oil flow.
Manifold • No interchageability is available due to Vacuum
Valve ● higher pressure when compared with R22. Pumping,
Charging Do not use current ones to the new Vacuum Holding,
Hose refrigerant. If used, mineral oil will flow Refrigerant
● into the cycle and cause sludges, resulting Charging and
in clogging or compressor failure. Check of
Pressures
Charging
— — —
Cylinder
Weight Measuring
Scale Instrument for
O — Refrigerant
Charging
Refrigerant • The current gas leakage detector (R22) is Gas Leakage
Gas not applicable due to different detecting Check
Leakage ● method.
Detector

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 Check / Corresive Action
Controller Setting Is Incorrect 1. See "Controller Adjustment".
Unit Does Not Operate In the 2 module unit case, especially check
"Unit Setting of PWB".
Current to Unit Is Shut Off 1. Reset the power supply line to the unit.
Fuse for Operation Circuit Is Blown 1. Check for shorted components.
Out or Faulty Contact 2. Check for loose connection. Tighten or replace,
if necessary.
Condenser Fan Does Not Contactor Holding Coil Is Burned 1. Find the causes, and repair or replace.
Operate Out or Faulty Contact
Tripped Overcurrent Relay 1. Remove the causes, and reset the overcurrent
relay.
Low Voltage 1. Check the voltage of unit rating.
Shorted Motor or Terminals 1. Check the motor and terminals. Repair or replace,
if necessary.
Condenser Fan Is Not Operating 1. Remove all causes of inoperative fan.
Interlock Circuit for Chilled Water 1. Check the pump contactor. Repair or replace,
Pump Is Open if necessary.
Compressor Does Not 2. Check for the faulty pump.
Operate Electrical Protective Devices Are 1. Remove the causes, and reset the "ON" button.
Tripped See the following causes.
Incorrect Wiring Connection for 1. Interchange two of three terminals R, S and T at
Compressor Power Source the main power source terminals.
Compressor Stops on Excessively High Discharge Pressure 1. See "High Discharge Pressure".
High Pressure Switch Malfunction of High Pressure Switch 1. Readjust the setting or replace, if defective.
Excessively High Discharge Pressure 1. See "High Discharge Pressure" and "High
and Suction Pressure Suction Pressure".
High and Low Voltage, Single-Phase 1. Check the power supply line and contactors.
Compressor Stops on or Phase Imbalance Repair, if necessary.
Overcurrent Relay Loose Connection 1. Tighten the loose electrical connection or repair,
if necessary.
Faulty Compressor Motor 1. Check the compressor motor. Repair or replace,
if necessary.
Faulty Overcurrent Relay 1. Replace it, if necessary.
Excessively Low Chilled Water Outlet 1. Check for excessively low setting of the chilled
Compressor Stops on Temperature water setting knob.
Freeze Protection Defective Thermistor 1. Check for malfunction of the thermistor.
Thermostat Replace, if necessary.
Shortage of Chilled Water Flow 1. Check the rotation of the pump.
Air in Water Circuit 1. Purge air.
High or Low Voltage, Single-Phase 1. Check the power supply line and contactors.
or Phase Imbalance Repair, if necessary.
Compressors Stops on Excessive Superheat 1. Check for refrigerant leakage and faulty solenoid
Internal Thermostat or valve for liquid bypass.
Discharge Gas Defective Element 1. Check the contact of the internal thermostat
Thermostat during the cold condition.
Excessive High Discharge Pressure 1. See "High Discharge Pressure" and "High
and Low Suction Pressure Suction Pressure".
High Discharge Pressure or Low 1. See "High Discharge Pressure" and "Low
Suction Pressure Suction Pressure".
Insufficient Cooling Improper Thermostat Setting 1. Readjust the setting.
Defective Unload Mechanism 1. Adjust unload mechanism. Repair or replace
unloader parts, if necessary.
Slugging Due to Liquid Flooding 1. Check the superheat of suction gas. Keep the
Noisy Compressor Back to Compressor superheat in proper range.
Worn Parts 1. Check for the sound of internal parts. Replace
the compressor, if necessary.
Miscellaneous Noise Loose Fixed Screw 1. Tighten the screws of all parts.
Trouble with the Thermistor 1. Adjust the setting temperature.
2. Replace the thermistor.
Unloader Does Not Trouble with the Solenoid Valve 1. Check the coil in the solenoid valve.
Function 2. Check oil passage for clogging.
Worn Unloader Mechanism 1. Check the unloader system parts in the
compressor.

49
TROUBLESHOOTING

Fault Possible Cause Check / Corresive Action

High Condenser Air Temperature or 1. Check the fan operation.
Insufficient Air Flow Through the 2. Check for coil clogging; clean, if necessary.
Condenser
Defective Check Valve or Partially 1. Check the valves and capillary tubes. Replace
High Discharge Pressure Closed Liquid Line Stop Valve if necessary.
Overcharged Refrigerant 1. Correctly charge the refrigerant.
Air or Non-Condensable Gas in the 1. Purge the gas from the refrigerant cycle.
Refrigerant Cycle
Suction Pressure Is Higher Than Standard 1. See "High Suction Pressure".
Extremely Cold Condenser Air 1. Check the ambient temperature.
Insufficient Refrigerant Charge 1. Add refrigerant.
Low Discharge Pressure Leakage from the Compressor 1. Replace the valve. Replace the compressor,
Discharge Valve if required.
Suction Pressure Is Lower Than Standard 1. See "Low Suction Pressure".
High Inlet Temperature of Chilled Water 1. Check the insulation of the piping.
High Suction Pressure 2. Check the insulation specifications.
Excessive Opening of Expansion Valve 1. Readjust the opening, or replace, if defective.
Low Inlet Temperature of Chilled Water 1. Check the insulation specifications.
Improperly Adjusted Expansion Valve 1. Adjust for correct superheat. Repair or replace,
Low Suction Pressure or Faulty Valve if necessary.
Insufficient Refrigerant Charge 1. Add refrigerant.
Excessive Oil in the Water Cooler 1. Purge oil.
Scales on Water Cooler Plates 1. Clean the plates.

50
 PRESSURE CONVERSION TABLE

10. PRESSURE COVERSION TABLE

MPa psi MPa psi MPa psi MPa psi MPa psi MPa psi
0.01 1.45 0.51 73.97 1.01 146.49 1.51 219.01 2.01 291.53 2.51 364.05
0.02 2.90 0.52 75.42 1.02 147.94 1.52 220.46 2.02 292.98 2.52 365.50
0.03 4.35 0.53 76.87 1.03 149.39 1.53 221.91 2.03 294.43 2.53 366.95
0.04 5.80 0.54 78.32 1.04 150.84 1.54 223.36 2.04 295.88 2.54 368.40
0.05 7.25 0.55 79.77 1.05 152.29 1.55 224.81 2.05 297.33 2.55 369.85
0.06 8.70 0.56 81.22 1.06 153.74 1.56 226.26 2.06 298.78 2.56 371.30
0.07 10.15 0.57 82.67 1.07 155.19 1.57 227.71 2.07 300.23 2.57 372.75
0.08 11.60 0.58 84.12 1.08 156.64 1.58 229.16 2.08 301.68 2.58 374.20
0.09 13.05 0.59 85.57 1.09 158.09 1.59 230.61 2.09 303.13 2.59 375.65
0.10 14.50 0.60 87.02 1.10 159.54 1.60 232.06 2.10 304.58 2.60 377.10
0.11 15.95 0.61 88.47 1.11 160.99 1.61 233.51 2.11 306.03 2.61 378.55
0.12 17.40 0.62 89.92 1.12 162.44 1.62 234.96 2.12 307.48 2.62 380.00
0.13 18.85 0.63 91.37 1.13 163.89 1.63 236.41 2.13 308.93 2.63 381.45
0.14 20.31 0.64 92.82 1.14 165.34 1.64 237.86 2.14 310.38 2.64 382.90
0.15 21.76 0.65 94.27 1.15 166.79 1.65 239.31 2.15 311.83 2.65 384.35
0.16 23.21 0.66 95.73 1.16 168.24 1.66 240.76 2.16 313.28 2.66 385.80
0.17 24.66 0.67 97.18 1.17 169.69 1.67 242.21 2.17 314.73 2.67 387.25
0.18 26.11 0.68 98.63 1.18 171.14 1.68 243.66 2.18 316.18 2.68 388.70
0.19 27.56 0.69 100.08 1.19 172.60 1.69 245.11 2.19 317.63 2.69 390.15
0.20 29.01 0.70 101.53 1.20 174.05 1.70 246.56 2.20 319.08 2.70 391.60
0.21 30.46 0.71 102.98 1.21 175.50 1.71 248.01 2.21 320.53 2.71 393.05
0.22 31.91 0.72 104.43 1.22 176.95 1.72 249.47 2.22 321.98 2.72 394.50
0.23 33.36 0.73 105.88 1.23 178.40 1.73 250.92 2.23 323.43 2.73 395.95
0.24 34.81 0.74 107.33 1.24 179.85 1.74 252.37 2.24 324.89 2.74 397.40
0.25 36.26 0.75 108.78 1.25 181.30 1.75 253.82 2.25 326.34 2.75 398.85
0.26 37.71 0.76 110.23 1.26 182.75 1.76 255.27 2.26 327.79 2.76 400.30
0.27 39.16 0.77 111.68 1.27 184.20 1.77 256.72 2.27 329.24 2.77 401.76
0.28 40.61 0.78 113.13 1.28 185.65 1.78 258.17 2.28 330.69 2.78 403.21
0.29 42.06 0.79 114.58 1.29 187.10 1.79 259.62 2.29 332.14 2.79 404.66
0.30 43.51 0.80 116.03 1.30 188.55 1.80 261.07 2.30 333.59 2.80 406.11
0.31 44.96 0.81 117.48 1.31 190.00 1.81 262.52 2.31 335.04 2.81 407.56
0.32 46.41 0.82 118.93 1.32 191.45 1.82 263.97 2.32 336.49 2.82 409.01
0.33 47.86 0.83 120.38 1.33 192.90 1.83 265.42 2.33 337.94 2.83 410.46
0.34 49.31 0.84 121.83 1.34 194.35 1.84 266.87 2.34 339.39 2.84 411.91
0.35 50.76 0.85 123.28 1.35 195.80 1.85 268.32 2.35 340.84 2.85 413.36
0.36 52.21 0.88 127.05 1.36 197.25 1.86 269.77 2.36 342.29 2.86 414.81
0.37 53.66 0.87 126.18 1.37 198.70 1.87 271.22 2.37 343.74 2.87 416.26
0.38 55.11 0.88 127.63 1.38 200.15 1.88 272.67 2.38 345.19 2.88 417.71
0.39 56.56 0.89 129.08 1.39 201.60 1.89 274.12 2.39 346.64 2.89 419.16
0.40 58.02 0.90 130.53 1.40 203.05 1.90 275.57 2.40 348.09 2.90 420.61
0.41 59.47 0.91 131.98 1.41 204.50 1.91 277.02 2.41 349.54 2.91 422.06
0.42 60.92 0.92 133.43 1.42 205.95 1.92 278.47 2.42 350.99 2.92 423.51
0.43 62.37 0.93 134.89 1.43 207.40 1.93 279.92 2.43 352.44 2.93 424.96
0.44 63.82 0.94 136.34 1.44 208.85 1.94 281.37 2.44 353.89 2.94 426.41
0.45 65.27 0.95 137.79 1.45 210.31 1.95 282.82 2.45 355.34 2.95 427.86
0.46 66.72 0.96 139.24 1.46 211.76 1.96 284.27 2.46 356.79 2.96 429.31
0.47 68.17 0.97 140.69 1.47 213.21 1.97 285.72 2.47 358.24 2.97 430.76
0.48 69.62 0.98 142.14 1.48 214.66 1.98 287.18 2.48 359.69 2.98 432.21
0.49 71.07 0.99 143.59 1.49 216.11 1.99 288.63 2.49 361.14 2.99 433.66
0.50 72.52 1.00 145.04 1.50 217.56 2.00 290.08 2.50 362.60 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)