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HITACHI WATER CHILLERS

- TROUBLESHOOTING -

Step Capacity Continuous Capacity


Control Type Control Type
RCUP30AU RCUP135AU RCUP30AUZ RCUP135AUZ
RCUP38AU RCUP154AU RCUP38AUZ RCUP154AUZ
Air-Cooled RCUP46AU RCUP179AU RCUP46AUZ RCUP179AUZ
Screw Type RCUP51AU RCUP205AU RCUP51AUZ RCUP205AUZ
For R407C RCUP75AU RCUP256AU RCUP75AUZ RCUP256AUZ
RCUP90AU RCUP307AU RCUP90AUZ RCUP307AUZ
RCUP102AU RCUP102AUZ
RCUP30ATU RCUP135ATU RCUP30ATUZ RCUP135ATUZ
RCUP38ATU RCUP154ATU RCUP38ATUZ RCUP154ATUZ
Air-Cooled
RCUP46ATU RCUP179ATU RCUP46ATUZ RCUP179ATUZ
Screw Type RCUP51ATU RCUP205ATU RCUP51ATUZ RCUP205ATUZ
For R407C RCUP75ATU RCUP256ATU RCUP75ATUZ RCUP256ATUZ
<Tropical> RCUP90ATU RCUP307ATU RCUP90ATUZ RCUP307ATUZ
RCUP102ATU RCUP102ATUZ
RCUP34WU RCUP101WU RCUP34WUZ RCUP101WUZ
Water-Cooled RCUP43WU RCUP128WU RCUP43WUZ RCUP128WUZ
Screw Type RCUP51WU RCUP151WU RCUP51WUZ RCUP151WUZ
For R407C RCUP67WU RCUP171WU RCUP67WUZ RCUP171WUZ
RCUP85WU RCUP202WU RCUP85WUZ RCUP202WUZ

P5414720, 2010
TROUBLESHOOTING

CONTENTS
ITEM PAGE
1. Outline of Failure Diagnosis ...........................................................................................2
2. Alarm Indication .............................................................................................................3
3. Failure Diagnosis Method ..............................................................................................4
4. Troubleshooting by Alarm Code .....................................................................................5
5. Analysis and Countermeasure for Abnormal Running .................................................28
6. Thermistor Characteristics ...........................................................................................32
(1) Thermistor Temperature Characteristics
(All Temperature except Ambient and Discharge Gas) ..........................................32
(2) Thermistor Temperature Characteristics (Ambient) ...............................................33
(3) Thermistor Temperature Characteristics (Discharge Gas Temperature) ...............33
TROUBLESHOOTING

1. Outline of Failure Diagnosis


In the case of abnormality, alarm LED on the control panel of unit and of remote control is
ON and segment indication on the control panel is flickering. To stop the unit, put it into stop
operation without power OFF(Main switch).

Alarm occurs

Segment Indication: Remote Control Run Indication: OFF


Abnormality Code Flickering. *One cycle continues running in more
Alarm Indication LED: ON than 2 cycles unit: ON
Remote Control Alarm Indication: ON
(Local Side)
(Remote Side)

Stop Operation

Yes Is abnormality code


in segment indication
confirmed?
No

Abnormality code is indicated


by indication mode of alarm
Occurrence Data.

Abnormality code is indicated


in the segment indication.

The last saved data before


alarm occurrence is confirmed.

Take proper measure


according to the alarm position

NOTES:
− After the stop operation, alarm indication is turned off and initial status 88 is displayed.
Abnormality code, which was activated before can be seen by entering “Indication Mode of Alarm
Occurrence Data”.
− When the power turns off and turns on, the indication on the display is initial status. Abnormal
code, which was activated before can be seen by entering “Indication Mode of Alarm Occurrence
Data”
− When the power turns off (Main switch), “The Last Saved Data before Alarm Occurrence” is
cleared.
− "The Last Saved Data before Alarm Occurrence” has only the last data before last alarm.
In case of before that, only alarm code is saved.

2
TROUBLESHOOTING

2. Alarm Indication
7-Segment indication shows the following abnormalities:
Without indication
Unit does not run. Check the power source.

With indication

Check the 7-segment


indication.

Alarm Code
Description of Abnormality
No.1~6 cycles
[ ]~[ ] Activation of High Pressure Switch
[ ]~[ ] Activation of Excessively Low Suction Pressure
[ ]~[ ] Activation of Overcurrent Relay for Fan Motor
[ ]~[ ] Activation of Internal Thermostat for Fan Motor (Option)
[ ]~[ ] Activation of Overcurrent Relay for Compressor
[ ]~[ ] Activation of Supplying Oil Protection by Thermistor
[ ]~[ ] Activation of Internal Thermostat for Compressor
[ ]~[ ] Alarm of Excessively Low Evaporator Inlet Refrigerant Temperature
[ ]~[ ] Alarm of Excessively Low Suction Gas Temperature
[ ]~[ ] Phase Abnormally (Only for 4 to 6 Cycle Unit)
[ ]~[ ] Abnormality of Outlet Chilled Water Thermistor
[ ]~[ ] Activation of Freeze Protection Control
[ ]~[ ] Activation of Water Overheating Protection Control
[ ]~[ ] Abnormality of Cooler Inlet Refrigerant Thermistor (Open/Short)
[ ]~[ ] Abnormality of Discharge Gas Temperature Thermistor (Open/Short)
[ ]~[ ] Abnormality of Liquid Refrigerant Temperature Thermistor (Open / Short)
[ ]~[ ] Abnormality of Thermistor for Freeze Protection (Open / Short)
[ ]~[ ] Abnormality of Suction Gas Temperature Thermistor (Open / Short)
[ ]~[ ] Abnormality of Discharge Gas Pressure Sensor (Open / Short)
[ ]~[ ] Abnormality of Suction Gas Pressure Sensor (Open / Short)
[ ]~[ ] Transmission Error between Expansion Valve PCB and Control PCB (Only for 4 to 6 Cycle Unit)
[ ] Phase Abnormality (Only for 1 to 3 cycle unit)
[ ] Abnormality of Inlet Chilled Water Thermistor (Open / Short)
[ ] Abnormality of Outlet Chilled Water Thermistor
[ ] Activation of Freeze Protection Control (Water Inlet Thermistor)
[ ] Activation of Water Overheating Protection Control by Thermistor
[ ] Abnormality of Ambient Temperature Thermistor (Open / Short)
[ ] Abnormal Condition of Feed Back Signal from Water Pump
[ ] Operation Error
[ ] Abnormal Transmitting between Control PCB (PCBC1, PCBC2) Master and Subsidiary Unit
[ ] Abnormal Transmitting between Expansion Valve PCB and Control PCB
[ ] Waiting of Pump Feed Back of Pump Operation
[ ] Abnormal Transmitting between Chiller and Remote Controller (If CSC-5S or HARC is connected.) (Option)
[ ]~[ ] Excessively Low Suction Pressure Retry Control

3
TROUBLESHOOTING

3. Failure Diagnosis Method

♦ General-check of failure diagnosis.


In the case of no segment indication, unit can not operate.

No
Is proper voltage supplied Check the power
to the unit? source switch.

Yes

No Yes
Is 220-240V supplied to Is fuse for power Replace fuse.
transformer primary side? source blown out?

Yes No

Yes
Is R phase or S Check wiring and
phase failure? repair.

No Check wiring
connection.
Is 30V in PIN1~PIN2,
No Yes
16.3V in PIN3~PIN4,
19.6V in PIN5~PIN6 of the Check the power Replace
printed circuit board for source switch. transformer.
CPU (PCBc) connector
CN2A?
No
Yes Check wiring and
connector.

Is 28.3V in PIN1~PIN2,
No Yes
17.6V in PIN3~PIN4,
17.6V in PIN5~PIN6 of the Check the power Replace
printed circuit board for source switch. transformer.
CPU (PCBc) connector
CN2B?
No
Yes Check wiring and
connector.

Is voltage in each test PIN of printed


circuit board for CPU?
5 V part:
VCCO5-GND1, VCCO5N-GND1 Power Source Circuit
V5B-GND1, VCCR-GND1 No Malfunction
+15V part:
Replace Printed Circuit
VCC15T-GND1 (only more than 2 cycles unit)
- 15V part:
Board for CPU (PCBC).
VCC15T-GND1
24V part:
VCC24-GND1
VCC24T-GND1

Yes

Are connector FCN1, FCN2 on the printed


circuit board for CPU (PCBC) and Printed No
Circuit Board for indication and setting Repair connector.
(PCBA, PCBB) correctly connected and
checked loose connection?

Yes Check Printed Circuit


Board for Indication and
Setting (PCBA, PCBB).
Check Printed Circuit
Board for CPU (PCBC).

4
TROUBLESHOOTING

4. Troubleshooting by Alarm Code

Alarm code Activation of High Pressure Switch (PSH)

[Alarm Stop Reason] [PCB Monitoring Position]


High pressure (Pd) is increased to No. 1 Cycle: PCBD (I/O PCB) PCN203
more than 2.98MPa (Air-Cooled Type) No. 2 Cycle: PCBE (I/O PCB) PCN203 No.1 Unit
/ 2.38MPa (Water-Cooled Type),
No. 3 Cycle: PCBF (I/O PCB) PCN203
and high pressure switch (PSH) is
activated. No. 4 Cycle: PCBD (I/O PCB) PCN203
No. 5 Cycle: PCBE (I/O PCB) PCN203 No.2 Unit
Yes No. 6 Cycle: PCBF (I/O PCB) PCN203
(activated
immediately)
Is alarm activated just Is high pressure switch No
after running? Reset the switch.
(PSH) reset?

Yes
No
(activated
after a while) Is 220-240V the voltage
between connector Yes Check Printed Circuit
PCN203 PIN1 and PIN3 Board for Relay
on the Printed Circuit (PCBD).
Board for Relay (PCBD)?

No Check wiring connection.


No (disconnecting or
(Activated after incorrect wiring)
compressor
running) Yes (PCB is
Is alarm activated in 3 normal.)
minutes after running Is high pressure switch Getting dusty of air side heat
operation? (PSH) activated? exchanger.

No
Yes
Check high pressure.

Check cycle.

Is 220-240V the voltage


between connector No Check wiring connection.
PCN203 PIN1 and PIN3 (disconnecting or
on the Printed Circuit incorrect wiring)
Board for Relay (PCBD)?

Yes Check Printed Circuit


Board for Relay
(PCBD).

Is 220-240V the voltage


between connector No
PCN203 PIN1 and Check wiring
connector PCN203 PIN3 connection.
on the Printed Circuit
Board for Relay (PCBD)?
Yes

Check Printed Circuit


Board for Relay
(PCBD).

5
TROUBLESHOOTING

Alarm code Activation of Excessively Low Suction Pressure

[Alarm Stop Reason] [PCB Monitoring Position]


- Suction pressure (Ps) is less than No. 1 Cycle: PCBD (I/O PCB) CN29Ps
0.333MPa (Air-Cooled Type) / No. 2 Cycle: PCBE (I/O PCB) CN29Ps No.1 Unit
0.363MPa (Water-Cooled Type) during
No. 3 Cycle: PCBF (I/O PCB) CN29Ps
90 seconds. (Electronic Control)
No. 4 Cycle: PCBD (I/O PCB) CN29Ps
* Alarm Stop: 3 retries during 30 minutes.
(Compressor stop, automatic restart in 3 No. 5 Cycle: PCBE (I/O PCB) CN29Ps No.2 Unit
minutes.) No. 6 Cycle: PCBF (I/O PCB) CN29Ps

[Retry Code]
No. 1 Cycle: C1-P6
No. 2 Cycle: C2-P6
No. 3 Cycle: C3-P6
No. 4 Cycle: C4-P6
No. 5 Cycle: C5-P6
No. 6 Cycle: C6-P6

Is connector CN29Ps
on the Printed Circuit Yes
Board for Relay (PCBD) Shortage of Refrigerant / Gas Leakage
correctly connected?
Clogging of Expansion Valve
No
Clogging of Low Pressure Side Piping

Check valve malfunction.

Shortage of Water

Pump Reverse Rotation

Check wiring
connection. Air Mixed

Clogging of Strainer

Too Much Water in Refrigerant

Water Stain in Water Side Heat Exchanger

6
TROUBLESHOOTING

Alarm code Excessively Low Suction Pressure

[Alarm Stop Reason] [PCB Monitoring Position]


Suction pressure (Ps) is less than No. 1 Cycle: PCBD (I/O PCB) CN29Ps
0.049MPa (Air-Cooled and Water- No. 2 Cycle: PCBE (I/O PCB) CN29Ps No. 1 Unit
Cooled type) during 3 seconds.
No. 3 Cycle: PCBF (I/O PCB) CN29Ps
(Electronic Control)
No. 4 Cycle: PCBD (I/O PCB) CN29Ps
No. 5 Cycle: PCBE (I/O PCB) CN29Ps No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) CN29Ps

Is connector CN29Ps
on the Printed Circuit Yes
Board for Relay (PCBD) Shortage of Refrigerant / Gas Leakage
correctly connected?
Clogging of Expansion Valve
No
Clogging of Low Pressure Side Piping

Check valve malfunction.

Shortage of Water

Pump Reverse Rotation

Check wiring
Air Mixed
connection.

Clogging of Strainer

Too Much Water in Refrigerant

Water Stain in Water Side Heat Exchanger

7
TROUBLESHOOTING

Alarm code Activation of Overcurrent Relay for Compressor


(ORC)

[Alarm Stop Reason] [PCB Monitoring Position]


- Operation current for any compressor No. 1 Cycle: PCBD (I/O PCB) PCN207
is increased too much and activates the No. 2 Cycle: PCBE (I/O PCB) PCN207 No. 1 Unit
overcurrent relay.
No. 3 Cycle: PCBF (I/O PCB) PCN207
No. 4 Cycle: PCBD (I/O PCB) PCN207
No. 5 Cycle: PCBE (I/O PCB) PCN207 No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) PCN207

Yes
(Activated
immediately) Is 220-240V the voltage Yes
Is alarm activated just after between connector PCN207 Check Printed Circuit
running operation? PIN1 and PIN3 on the Board for Relay
Printed Circuit Board for (PWBD).
Relay (PCBD)?
No (Activate No
after a while.)
Check wiring
connection.
(Disconnecting or
Incorrect)

Is 220-240V the voltage No (Printed circuit


between connector board is normal.)
PCN207 PIN1 and PIN3 Excessive or short power source voltage
on the Printed Circuit
Board for Relay (PCBD)?
Interphase of power source voltage is imbalanced.

Yes Compressor motor is locked.

Insulation of compressor motor is lowered.

Power fuse for compressor motor is broken.

Power source terminal screw loosened

Thermal relay for compressor failure


Check wiring
connection.
Compressor slide valve malfunction

8
TROUBLESHOOTING

Alarm code Activation of Supply Oil Protection


by Thermistor (Td)

[Alarm Stop Reason] [PCB Monitoring Position]


1. Discharge gas temperature from the No. 1 Cycle: PCBD (I/O PCB) CN24Td
compressor is increased to 130°C and No. 2 Cycle: PCBE (I/O PCB) CN24Td No. 1 Unit
continues for 1 minute.
No. 3 Cycle: PCBF (I/O PCB) CN24Td
2. During the time counting in 1 minute,
No. 4 Cycle: PCBD (I/O PCB) CN24Td
temperature is increased over 140°C
during more than 3 seconds. No. 5 Cycle: PCBE (I/O PCB) CN24Td No. 2 Unit
* In case of above reason 2, alarm stop: 3 No. 6 Cycle: PCBF (I/O PCB) CN24Td
retries during 90 minutes. (Compressor
stop, automatic restart in 3 minutes)

[Retry Code]
No. 1 Cycle: C1-P5
No. 2 Cycle: C2-P5
No. 3 Cycle: C3-P5
No. 4 Cycle: C4-P5
No. 5 Cycle: C5-P5
No. 6 Cycle: C6-P5

Is connector CN24Td on No
the Printed Circuit Board Correctly connect plug
for Relay (PCBD) correctly and repair wiring.
connected?
Yes

Pull out connector and No


measure thermistor resistance. Replace thermistor.
Is resistance correct?

Yes

Shortage of Refrigerant / Gas Leakage

Check valve malfunction.

Clogging of Expansion Valve

Check opening of expansion valve.

Expansion Valve Malfunction

Check Printed Circuit Board for Relay


(PCBD).

9
TROUBLESHOOTING

Alarm code Activation of Internal Thermostat for Compressor (IT)

[Alarm Stop Reason] [PCB Monitoring Position]


The electrical motor of the compressor No. 1 Cycle: PCBD (I/O PCB) PCN204
is overheated and internal thermostat is No. 2 Cycle: PCBE (I/O PCB) PCN204 No. 1 Unit
activated.
No. 3 Cycle: PCBF (I/O PCB) PCN204
*Alarm stop: 3 retries during 60 minutes.
No. 4 Cycle: PCBD (I/O PCB) PCN204
(Automatic restart after compressor stop
and thermostat recover) No. 5 Cycle: PCBE (I/O PCB) PCN204 No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) PCN204
[Retry Code]
No. 1 Cycle: C1-P5
No. 2 Cycle: C2-P5
No. 3 Cycle: C3-P5
No. 4 Cycle: C4-P5
No. 5 Cycle: C5-P5
No. 6 Cycle: C6-P5

Yes Is 220-240V the voltage


Is alarm activated just after between connector Yes Check Printed Circuit
running operation? PCN204 PIN1 and PIN3 Board for Relay
on the Printed Circuit (PCBD).
Board for Relay (PCBD)?
No (Activate
after a while.)
No

Check wiring
connection.
(Disconnecting or
Incorrect)

Is 220-240V the voltage No (Printed circuit


between connector board is normal.)
PCN204 PIN1 and PIN3 Excessive or Short Power Source Voltage
on the Printed board for
Relay (PCBD)?
Interphase of power source voltage is imbalanced.

Yes
Compressor motor is locked.

Insulation of compressor motor is lowered.

Check wiring
connection.

10
TROUBLESHOOTING

Alarm code Excessively Low Evaporator Inlet


Refrigerant Temperature (Tr)

[Alarm Stop Reason] [PCB Monitoring Position]


- Refrigerant temperature in water side heat No. 1 Cycle: PCBD (I/O PCB) CN27Tr2
exchanger inlet (Tr) is less than – 6.5°C No. 2 Cycle: PCBE (I/O PCB) CN27Tr2 No. 1 Unit
during 3 seconds.
No. 3 Cycle: PCBF (I/O PCB) CN27Tr2
*Alarm stop: 3 retries during 30 minutes.
No. 4 Cycle: PCBD (I/O PCB) CN27Tr2
(Compressor stop, automatic restart in 3
minutes) No. 5 Cycle: PCBE (I/O PCB) CN27Tr2 No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) CN27Tr2
[Retry Code]
No. 1 Cycle: C1-P6
No. 2 Cycle: C2-P6
No. 3 Cycle: C3-P6
No. 4 Cycle: C4-P6
No. 5 Cycle: C5-P6
No. 6 Cycle: C6-P6

Is the wiring of connector No Correctly connect plug


in the Printed Circuit Board
and repair wiring.
for Relay (PCBD) correct?

Yes

Pull out connector and No


measure thermistor resistance. Replace thermistor..
Is resistance correct?

Yes

Check water flow rate.


(Check temperature of inlet and outlet.)

Clogging of Water Strainer

Pump Reverse Rotating Check

Check air mixing.

Check chilled water thermostat setting


value (Within the working range).

Shortage of Refrigerant / Gas Leakage

Clogging of Low Pressure Pipe

Clogging of Expansion Valve

Malfunction of Check Valve

Malfunction of Expansion Valve

Check Printed Circuit Board for Relay


(PCBD).

11
TROUBLESHOOTING

Alarm code Excessively Low Suction Gas Temperature (Ts)

[Alarm Stop Reason] [PCB Monitoring Position]


- Suction Gas Temperature (Ts) is lower than No. 1 Cycle: PCBD (I/O PCB) CN25Ts
– 2°C during 10 seconds. No. 2 Cycle: PCBE (I/O PCB) CN25Ts No. 1 Unit
* Alarm stop: 3 retries during 30 minutes. No. 3 Cycle: PCBF (I/O PCB) CN25Ts
(Compressor stop, automatic restart in 3
No. 4 Cycle: PCBD (I/O PCB) CN25Ts
minutes)
No. 5 Cycle: PCBE (I/O PCB) CN25Ts No. 2 Unit
[Retry Code] No. 6 Cycle: PCBF (I/O PCB) CN25Ts
No. 1 Cycle: C1-P6
No. 2 Cycle: C2-P6
No. 3 Cycle: C3-P6
No. 4 Cycle: C4-P6
No. 5 Cycle: C5-P6
No. 6 Cycle: C6-P6

Is the wiring of connector No Correctly connect plug


in the Printed Circuit Board and repair wiring.
for Relay (PCBD) correct?

Yes

Pull out connector and No


measure thermistor resistance. Replace thermistor.
Is resistance correct?

Yes

Check water flow rate.


(Check temperature of inlet and outlet.)

Clogging of Water Strainer

Check pump reverse rotation.

Check air mixing.

Check chilled water thermostat setting


value (Within the working range).

Shortage of Refrigerant / Gas Leakage

Clogging of Low Pressure Pipe

Clogging of Expansion Valve

Malfunction of Check Valve

Malfunction of Expansion Valve

Check Printed Circuit Board for Relay


(PCBD).

12
TROUBLESHOOTING

Alarm code Abnormal Condition of Feed back Signal


from Water Pump

[Alarm Stop Reason]


ATTENTION:
Pump operation feed back signal (terminals 1-2) is
OFF during pump interlock (CMP) ON (terminals
3-4) During pump operation (during unit stop),
*It is available once feedback signal confirmed. Alarm is reset by
1. Feed back signal reconfirm
2. Pump stop
[PCB Monitoring Position]
3. Unit operation
PCBc (CPU PCB) PCN24
It is not reset by stop operation.

No (Printed
Circuit Board
Is 220-240V the voltage is normal.)
between connector PCN4 Is thermal relay for pump Yes
PIN1 and connector PCN4 (CMP) activated? Check pump lock.
PIN3 on the Printed Circuit
Board for CPU (PCBc)?
No
Yes Check thermal relay
for pump.

Check Printed Circuit


Board for CPU (PCBC).
Check wiring around
pump and thermal
relay for pump.

13
TROUBLESHOOTING

Alarm code Phase Abnormality (Reverse Phase / Phase Failure)

[Alarm Stop Reason]


Power source connected to unit on site is reversed
phase or phase failure.
*In case of 1~3 cycle unit, “05-05”
In case 4, 5 and 6 cycle unit, “C1-05 ~ C6-05”.

[PCB Monitoring Position]


No. 1 ~ No. 3 Cycle: PCBD of No. 1 Unit (I/O PCB) R, S, T
No. 4 ~ No. 6 Cycle: PCBD of No. 2 Unit (I/O PCB) R, S, T

Yes (Phase Failure,


Is 3 phase power source Reverse Phase) Correctly connect
connected on site phase each phase of
failure or reverse phase? power source.

No

Is printed circuit board for No


Relay (PCBD) connector Repair wiring
R, S, T correctly connected? connection.

Yes

Is the power source of Yes


connector R, S, T part Repair to correct
phase failure or reverse phase.
phase?

No (Correct Phase)

Check Printed Circuit


Board for Relay
(PCBD).

14
TROUBLESHOOTING

Alarm code Activation of Freeze Protection Control

[Alarm Stop Reason] [PCB Monitoring Position]


- Chilled water temperature is lower than PCBC (CPU PCB) CN3 (for inlet), CN4 (for No. 1 and No.4
2°C.(standard unit) cycle outlet), CN6 (for No. 2 and No. 5 cycle outlet), CN7
- PCBC PCN13 wiring is broken. (for No. 3 and No. 6 cycle outlet)
*“13-13”: for 1 cycle unit or if alarm is PCBD (I/O PCB) CN23Te2 (for No. 1 and No. 4 cycle protection)
detected in inlet water temperature PCBE (I/O PCB) CN23Te2 (for No. 2 and No. 5 cycle protection)
thermistor or PCN13 wiring is burn out. PCBF (I/O PCB) CN23Te2 (for No. 3 and No. 6 cycle protection)
“C1-13 ~ C6-13”: It is detected in outlet
water temperature in more than 2 cycle
units.

Are connectors on the No Correctly connect plug


Printed Circuit Board and repair wiring.
correctly connected?
Yes

Pull out connector and


measure thermistor No
resistance. Replace thermistor.
Is resistance correct?

Yes

Check water flow rate.


(Check temperature of inlet and outlet.)

Check pump reverse rotation.

Check water strainer clogging.

Check air mixing.

Check chilled water thermostat setting


value (Within the working range).

Check Printed Circuit Board for CPU


(PCBC).

NOTES:

− One inlet temperature themistor is installed in each unit.


− Two outlet temperature thermistors are installed in every cooler in water side.
− The next page table shows the relations among thermistor, alarm code and connecting
Printed Circuit Board (PCB).

15
TROUBLESHOOTING

Alarm
Product Model Thermistor PCB Connector
Code

Chilled water outlet temperature thermistor 1 PCBC CN4


RCUP30~51A(T)U(Z)
RCUP34~128WU(Z) Chilled water outlet temperature thermistor 2
(backside cooler) PCBD CN23

Chilled water outlet temperature thermistor 1 PCBC CN4

Chilled water outlet temperature thermistor 2


(backside cooler) PCBD CN23

Chilled water outlet temperature thermistor 1 PCBC CN6


No. 1
Unit
Chilled water outlet temperature thermistor 2
(backside cooler) PCBE CN23

Chilled water outlet temperature thermistor 1 PCBC CN7

Chilled water outlet temperature thermistor 2


(backside cooler) PCBF CN23
RCUP75~307A(T)U(Z)
RCUP151~202WU(Z)
Chilled water outlet temperature thermistor 1 PCBC CN4

Chilled water outlet temperature thermistor 2


(backside cooler) PCBD CN23

Chilled water outlet temperature thermistor 1 PCBC CN6


No. 2
Unit
Chilled water outlet temperature thermistor 2
(backside cooler) PCBE CN23

Chilled water outlet temperature thermistor 1 PCBC CN7

Chilled water outlet temperature thermistor 2


(backside cooler) PCBF CN23

RCUP30~307A(T)U(Z)
Chilled water inlet temperature thermistor PCBC CN3
RCUP34~202WU(Z)

16
TROUBLESHOOTING

Alarm code Operation Error / Setting Error

[Alarm Stop Reason]


Wrong setting is performed in Dip Switch on Printed Circuit Board (PCBB), or prohibited operation is
performed.

No Yes
Is alarm reset by stop Is setting of Dip Switch Check Printed Circuit
switch? correct? Board for Setting (PCBB).

Yes No
Set Dip Switch correctly
and turn ON the power
source again.
No Yes (Normal
(Remote) Running)
Is the unit operated Is changeover switch
turned to local side during It is incorrect that
at “Local” mode?
remote operation? changeover switch is
turned to local side
Yes (Local) No during remote operation.
Do not perform it.

Check Printed Circuit


Board for CPU (PCBC).

Yes (Normal It is incorrect that remote


Running) operation signal is
Yes Is the signal transmitted
Is optional wiring transmitted from optional
connected? from optional device? device during local
operation.
No Do not perform it.
No

Check wiring connection


between external device
and printing circuit board

It is incorrect operation
Is it changed over to Yes (Normal Running) that changeover switch
remote side during local is turned to remote side
operation? during local operation.
Do not perform it.
No

Check printed circuit


board for indication
(PCBA).
Check printed circuit
board for setting (PCBB).
Check printed circuit
board for CPU (PCBC).

17
TROUBLESHOOTING

Alarm code Abnormality of Inlet Chilled Water Thermistor

[Alarm Stop Reason] [PCB Monitoring Position]


Thermistor for inlet water temperature PCBC (CPU PCB) CN3
indicates abnormal value.

Is Printed Circuit Board No


for CPU (PCBC) connector Repair Plug and Wiring.
CN3 correctly connected?

Yes

Disconnect connector and No


measure resistance. Replace Thermistor.
Is the resistance correct?
Yes
Replace printed circuit
board for CPU (PCBC).

18
TROUBLESHOOTING

Alarm code Abnormality of Outlet Chilled Water Thermistor

[Alarm Stop Reason] [PCB Monitoring Position]


Thermistor for outlet water temperature PCBC (CPU), CN4 (for No. 1 cycle),
indicates abnormal value. CN6 (for No. 2 cycle),
*“12-12”: 1 cycle, CN7 (for No. 3 cycle)
“C1-12 ~ C6-12”: more than 2 cycle units

Is Printed Circuit Board


for CPU (PCBC) connector No
Repair Plug and Wiring.
CN4, 6, 7 correctly
connected?
[ ]~[ ] Stop by abnormality of chilled water outlet thermistor for No. 1 unit
Yes
[ ]~[ ] Stop by abnormality of chilled water outlet thermistor for No. 2 unit

Disconnect connector and No


measure resistance. Replace Thermistor.
Is the resistance correct?

Yes

Replace printed circuit


board for CPU (PCBC).

NOTE:

The following table shows the relations among thermistor, alarm code and connecting Printed Circuit
Board (PCB).

Alarm
Product Model Thermistor PCB Connector
Code
RCUP30~51A(T)U(Z)
Outlet water temperature thermistor 1 PCBC CN4
RCUP34~128WU(Z)

Outlet water temperature thermistor 1 PCBC CN4

No. 1
Outlet water temperature thermistor 1 PCBC CN6
Unit

Outlet water temperature thermistor 1 PCBC CN7


RCUP75~307A(T)U(Z)
RCUP151~202WU(Z)
Outlet water temperature thermistor 1 PCBC CN4

No. 2
Outlet water temperature thermistor 1 PCBC CN6 Unit

Outlet water temperature thermistor 1 PCBC CN7

19
TROUBLESHOOTING

Alarm code Abnormality of Cooler Inlet Refrigerant Thermistor

[Alarm Stop Reason] [PCB Monitoring Position]


Thermistor for inlet refrigerant No. 1 Cycle: PCBD (I/O PCB) CN27Tr2
temperature at water cooler indicates No. 2 Cycle: PCBE (I/O PCB) CN27Tr2 No. 1 Unit
abnormal value.
No. 3 Cycle: PCBF (I/O PCB) CN27Tr2
No. 4 Cycle: PCBD (I/O PCB) CN27Tr2
No. 5 Cycle: PCBE (I/O PCB) CN27Tr2 No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) CN27Tr2

Is Printed Circuit Board for No


Relay (PCBD) connector Repair Plug and Wiring.
CN27Tr2 correctly
connected?
Yes

Disconnect connector and No


measure resistance. Replace Thermistor.
Is the resistance correct?

Yes

Replace printed circuit


board for Relay (PCBD).

Alarm code Abnormality of Discharge Gas


Temperature Thermistor

[Alarm Stop Reason] [PCB Monitoring Position]


Thermistor for discharge gas No. 1 Cycle: PCBD (I/O PCB) CN24Td
temperature indicates abnormal No. 2 Cycle: PCBE (I/O PCB) CN24Td No. 1 Unit
value.
No. 3 Cycle: PCBF (I/O PCB) CN24Td
No. 4 Cycle: PCBD (I/O PCB) CN24Td
No. 5 Cycle: PCBE (I/O PCB) CN24Td No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) CN24Td

Is Printed Circuit Board for No


Relay (PCBD) connector Repair Plug and Wiring.
CN24Td correctly
connected?
Yes

Disconnect connector and No


measure resistance. Is the Replace Thermistor.
resistance correct?
Yes
Replace printed circuit
board for Relay (PCBD).

20
TROUBLESHOOTING

Alarm code Abnormality of Liquid Refrigerant


Temperature Thermistor

[Alarm Stop Reason] [PCB Monitoring Position]


Thermistor for detection of condenser No. 1 Cycle: PCBD (I/O PCB) CN22Te1
outlet (subcooled liquid) temperature No. 2 Cycle: PCBE (I/O PCB) CN22Te1 No. 1 Unit
indicates abnormal value.
No. 3 Cycle: PCBF (I/O PCB) CN22Te1
No. 4 Cycle: PCBD (I/O PCB) CN22Te1
No. 5 Cycle: PCBE (I/O PCB) CN22Te1 No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) CN22Te1

Is Printed Circuit Board for No


Relay (PCBD) connector Repair Plug and Wiring.
CN22Te1 correctly
connected?
Yes

Disconnect connector and No


measure resistance. Is the Replace Thermistor.
resistance correct?
Yes
Replace printed circuit
board for Relay (PCBD).

21
TROUBLESHOOTING

Alarm code Abnormality of Thermistor for


Freeze Protection

[Alarm Stop Reason] [PCB Monitoring Position]


Thermistor for detection of water No. 1 Cycle: PCBD (I/O PCB) CN23Te2
cooler outlet (backside=inside No. 2 Cycle: PCBE (I/O PCB) CN23Te2 No. 1 Unit
of cooler) temperature indicates
No. 3 Cycle: PCBF (I/O PCB) CN23Te2
abnormal value.
No. 4 Cycle: PCBD (I/O PCB) CN23Te2
No. 5 Cycle: PCBE (I/O PCB) CN23Te2 No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) CN23Te2

Is Printed Circuit Board for No


Relay (PCBD) connector Repair Plug and Wiring.
CN23Te2 correctly
connected?
Yes

Disconnect connector and No


measure resistance. Replace Thermistor.
Is the resistance correct?
Yes
Replace printed circuit
board for Relay (PCBD).

Alarm code Abnormality of Suction Gas


Temperature Thermistor

[Alarm Stop Reason] [PCB Monitoring Position]


Thermistor for detection of No. 1 Cycle: PCBD (I/O PCB) CN25Ts
compressor suction gas refrigerant No. 2 Cycle: PCBE (I/O PCB) CN25Ts No. 1 Unit
temperature indicates abnormal
No. 3 Cycle: PCBF (I/O PCB) CN25Ts
value.
No. 4 Cycle: PCBD (I/O PCB) CN25Ts
No. 5 Cycle: PCBE (I/O PCB) CN25Ts No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) CN25Ts

Is Printed Circuit Board for No


Relay (PCBD) connector Repair Plug and Wiring.
CN25Ts correctly
connected?
Yes

Disconnect connector and No


measure resistance. Replace Thermistor.
Is the resistance correct?
Yes
Replace printed circuit
board for Relay (PCBD).

22
TROUBLESHOOTING

Alarm code Abnormality of Discharge Pressure Sensor

[Alarm Stop Reason] [PCB Monitoring Position]


Discharge pressure sensor of No. 1 Cycle: PCBD (I/O PCB) CN28Pd
compressor indicates abnormal value. No. 2 Cycle: PCBE (I/O PCB) CN28Pd No. 1 Unit
No. 3 Cycle: PCBF (I/O PCB) CN28Pd
No. 4 Cycle: PCBD (I/O PCB) CN28Pd
No. 5 Cycle: PCBE (I/O PCB) CN28Pd No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) CN28Pd

Is connector CN28Pd on No
the printed circuit board Repair plug and
for Relay (PCBD) correctly wiring.
connected?
Yes

Is DC24V applied
between connector No
CN28Pd PIN1 and PIN3 Replace printed circuit
on the printed circuit board for Relay (PCBD).
board for Relay (PCBD)?

Yes

Is voltage under DC0.1V


or over DC4.9V between
connector CN28Pd PIN2 No
and PIN3 on the printed Replace printed circuit
circuit board for Relay board for Relay (PCBD).
(PCBD) when discharge
gas pressure sensor is
connected?

Yes

Is discharge gas pressure Yes


sensor connecting pipe Remove the clogging in
clogging? the pipe.

No

Discharge Pressure
Sensor Abnormality

23
TROUBLESHOOTING

Alarm code Abnormality of Suction Gas Pressure Sensor

[Alarm Stop Reason] [PCB Monitoring Position]


Suction pressure sensor of No. 1 Cycle: PCBD (I/O PCB) CN29Ps
compressor indicates abnormal value. No. 2 Cycle: PCBE (I/O PCB) CN29Ps No. 1 Unit
No. 3 Cycle: PCBF (I/O PCB) CN29Ps
No. 4 Cycle: PCBD (I/O PCB) CN29Ps
No. 5 Cycle: PCBE (I/O PCB) CN29Ps No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) CN29Ps

Is connector CN29Ps on No
the printed circuit board Repair plug and
for Relay (PCBD) correctly wiring.
connected?
Yes

Is DC5V applied between


connector CN29Ps PIN1 No
Replace printed circuit
and PIN3 on the printed
board for Relay (PCBD).
circuit board for Relay
(PCBD)?

Yes

Is voltage under DC0.1V


or over DC4.9V between
connector CN29Ps PIN2 No
and PIN3 on the printed Replace printed circuit
circuit board for Relay board for Relay (PCBD).
(PCBD) when suction
gas pressure sensor is
connected?

Yes

Yes
Is suction gas pressure sensor Remove the clogging in
connecting pipe clogging? the pipe.

No

Suction Pressure
Sensor Abnormality

24
TROUBLESHOOTING

Alarm code Abnormality of Ambient


Temperature Thermistor

[Alarm Stop Reason] [PCB Monitoring Position]


Thermistor for ambient temperature PCBC (CPU PCB) CN5
indicates abnormal value.

Is connector CN5 on the No


Printed Circuit Board for Correctly connect plug
CPU (PCBc) correctly and repair wiring.
connected?
Yes

Pull out connector and


measure thermistor No
resistance. Replace Thermistor.
Is resistance correct?

Yes
Replace printed circuit
board for CPU (PCBC).

Alarm code Abnormal Transmitting between Control PCB


and Expansion Valve PCB

[Alarm Stop Reason] [PCB Monitoring Position]


Transmission between Ctrl PCB PCBC (CPU PCB) ~PCBG (VD board) VCN13
and Ex.Valve PCB is not performed
correctly during 30 seconds.

Is connector CN13 on No
the Printed Circuit Board Correctly connect plug
for CPU (PCBC) correctly and repair wiring.
connected?
Yes

Is connector VCN13
on the Printed Circuit No
Correctly connect plug
Board for Ex. valve
and repair wiring.
control (PCBG) correctly
connected?

Yes

Check the Printed Circuit Abnormal Replace the Printed


Board for Ex.valve control Circuit Board for
(PCBG). Ex.Valve control
(PCBG).
Normal

Replace the Printed


Circuit Board for CPU
(PCBC).

25
TROUBLESHOOTING

Alarm code Waiting of Pump Feed Back


(Flicker) of Pump Operation

[Alarm Stop Reason] [PCB Monitoring Position]


Water temperature is increased to 65°C by PCBC (CPU PCB) CN3 (for inlet), CN4 (for No. 1 and No.4
heat generation of pump during only pump cycle outlet), CN6 (for No. 2 and No. 5 cycle outlet), CN7
running (during compressor stop: during (for No. 3 and No. 6 cycle outlet)
pump automatic operation in winter). PCBD (I/O PCB) CN23Te2 (for No. 1 and No. 4 cycle protection)
*If water temperature is decreased under PCBE (I/O PCB) CN23Te2 (for No. 2 and No. 5 cycle protection)
65°C due to pump stop, it becomes normal
PCBF (I/O PCB) CN23Te2 (for No. 3 and No. 6 cycle protection)
status automatically.
Since this is not an abnormality of chiller unit,
it is not saved in alarm occurrence data.

Is actual water Yes Secure sufficient holding water


temperature 65°C quantity in consideration of heat
or more? generation of pump.

No
Apply field-supplied pump
protection circuit with water
temperature thermostat (max.
65°C) to prevent overheating
of water temperature.

Are connectors on the No Correctly connect plug


Printed Circuit Board and repair wiring.
correctly connected?

Yes

Pull out connector and


measure thermistor No
Replace Thermistor.
resistance.
Is resistance correct?
Yes

Replace Printed Circuit


Board for CPU (PCBC).

Abnormal Transmitting between Chiller and Remote


Alarm code
Controller (If CSC-5S or HARC is connected: Option)

[Alarm Stop Reason] [PCB Monitoring Position]


At remote setting by remote controller, PCBC (CPU PCB) CN11
transmission is not performed for 3
minutes once it is started.
Or dip switch setting is incorrect.

No
Is setting of dip switch Set dip switch correctly.
correct?

Yes

Check the setting of


CSC-5S side.

26
TROUBLESHOOTING

Alarm code Activation of Internal Thermostat for Fan Motor


(Option) (Air-Cooled Type Only)

[Alarm Stop Reason] [PCB Monitoring Position]


PCN206 of I/O PCB is blown out. No. 1 Cycle: PCBD (I/O PCB) PCN206
No. 2 Cycle: PCBE (I/O PCB) PCN206 No. 1 Unit
No. 3 Cycle: PCBF (I/O PCB) PCN206
No. 4 Cycle: PCBD (I/O PCB) PCN206
No. 5 Cycle: PCBE (I/O PCB) PCN206 No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) PCN206

Is connector PCN206 on No
Printed Circuit Board for Correctly connect plug
Relay (PCBD) correctly and repair wiring.
connected?
Yes

Check wiring
connection.

Alarm code Activation of Overcurrent Relay for


Fan Motor (Air-Cooled Type Only)

[Alarm Stop Reason] [PCB Monitoring Position]


PCN202 of I/O PCB is blown out. No. 1 Cycle: PCBD (I/O PCB) PCN202
No. 2 Cycle: PCBE (I/O PCB) PCN202 No. 1 Unit
No. 3 Cycle: PCBF (I/O PCB) PCN202
No. 4 Cycle: PCBD (I/O PCB) PCN202
No. 5 Cycle: PCBE (I/O PCB) PCN202 No. 2 Unit
No. 6 Cycle: PCBF (I/O PCB) PCN202

Is connector PCN202 on No
Printed Circuit Board for Correctly connect plug
Relay (PCBD) correctly and repair wiring.
connected?
Yes

Check wiring
connection.

27
TROUBLESHOOTING

5. Analysis and Countermeasure for Abnormal Running


Chiller unit has various kinds of protection devices. When the operation status is not correct due to the activation of
some protection device, refer to the table below and find out the main reason to apply a countermeasure.
One failure can affect other different conditions. Thus, do not check only 1 point but analyze it from overall
viewpoint in detail.

Phenomenon Cause Check Point Countermeasure

Power Failure Measure voltage by tester. Wait recovery of power source.

Power is OFF Check power switch. Power Switch ON

Check for any uncovered Remove cause of short-circuit


Short-Circuit between Wires
part of wires. and replace fuse.
Melted Remove cause of short-circuit
Fuse at Short-Circuit of Wires to Earth Measure insulation resistance.
and replace fuse.
Power
Source Compressor Motor Failure Replace compressor and fuse.
Measure interphase resistance
and insulation resistance.
Fan Motor Failure Replace fan motor and fuse

Check for any uncovered Remove cause of short-circuit


Short Circuit between Wires
part of wires. and replace fuse.

Remove cause of short-circuit


Earth Fault in Operation Circuit Measure insulation resistance.
and replace fuse.

Magnetic Contactor for


Compressor Motor Failure

Magnetic Contactor Replace magnetic contactor and


Melted for Fan Motor Failure fuse.
Fuse at
Control Magnetic Contactor Measure coil resistance.
Circuit for Pump Motor Failure

Auxiliary Relay Coil Failure Replace auxiliary relay and fuse.


Unit does not
operate.
Solenoid Valve Coil Failure Replace solenoid valve coil and fuse.

Short-Circuit of
Conductive Foreign Particle Remove particle and replace fuse.
Printed Circuit Board

Crankcase Heater Failure Measure resistance. Replace crankcase heater and fuse.

Transformer Coil Failure Measure voltage at secondary side. Replace transformer.

Incorrect Wiring for Remote Control Check Wiring. Correctly connect wiring.

Faulty or Reverse Phase for R, S, T Phase of Check connection of Correctly connect each phase of
Power Source (05 alarm) R, S and T phase. power source.

Remote Control Switch Failure Replace remote control switch.


Changeover switch of Printed Circuit Check changeover switch. Turn changeover switch
Board is turned “Local” (40 alarm). on “Remote” side.

Printed Incorrect Connection Correctly connect wiring.


Circuit
Board Replace Printed Circuit Board.
Failure Printed Circuit Board Failure Check current by tester.

Pump Disconnected Coil


Magnetic Replace magnetic contactor for
Contactor pump.
for Pump Measure voltage between
Failure Insufficient Contacting
contacting parts.
(CMP)

Check chilled water frozen or


Over- Pump Locked Remove it.
clogging.
current
Pump stops
relay for
before RC value of overcurrent relay Measure RC value and Change RC value or
pump is
compressor for pump is wrong. pump running current. replace magnetic contactor.
activated.
running.
(ORP)
Pump Overcurrent Relay Push reset button
(5P Alarm) Replace magnetic contactor.
Failure and measure running current.

28
TROUBLESHOOTING

Incorrect Connection Check circuit by tester. Repair connections.


Printed Circuit Check circuit by tester.
Board Failure Printed Circuit Board Replace Printed Circuit
Check Printed Circuit Board by
Failure Board.
self-checking function.
Pump runs, but
Replace remote
neither fan nor Remote Control Switch Failure Operative by unit side.
control switch.
compressor run.
Burnt-Out Coil Check circuit by tester.
Fan Magnetic
Measure voltage between Replace magnetic
Contactor
Insufficient Contacting contacting parts of magnetic contactor.
Failure
contactor.

Pump and comp- Measure resistance between


ressor run, but Fan Motor Failure Replace fan motor.
two wires.
fan does not run.

Incorrect Connection
Check circuit by tester. Repair connections.
Printed Circuit Printed Circuit Board
Board Failure Failure

Thermistor Malfunction Measure thermistor resistance. Replace thermistor.

Pump and
Burnt-Out Coil Check circuit by tester.
fan run, but Compressor
compressor Magnetic Measure voltage between Replace magnetic
does not run. Contactor Insufficient Contacting contacting parts of magnetic contactor.
Failure contactor.
Thermostat is activated. (Thermo-Off) Change chilled water temp. It is not failure.
Measure resistance between
Compressor Motor Failure
two wires.
Replace compressor.
Check for abnormal sound from
Compressor Failure
compressor.
Consult with electric
Voltage at starting up is low. Measure voltage.
power company.
Excessive Dust in Air Side
Heat Exchanger
Remove it.
Obstacles at Inlet or Outlet of
Insufficient Air Flow Air Side Heat Exchanger
to Air Side Heat
Exchanger Insufficient Operation Space
Secure operation space.
for Chiller Unit
Connect wiring of
Reverse Rotation of Fan Motor
fan motor.
Remove causes of
Excessively High Air Air Short-Circuits in Chiller Unit
short-circuits.
Temperature to Air Side
Heat Exchanger Another Heat Source around
Discharge Remove heat source.
Chiller Unit
pressure is
Excessively Charged Correctly charge
excessively Check cycle temperature.
Refrigerant refrigerant.
Unit stops high, so that
during cooling high pressure Turn off unit and check relation
switch activates. Non-Condensable Gas Evacuate and charge
operation. between water temperature and
(C1-H1 Alarm)~ in Refrigerant Cycle refrigerant again.
pressure.
(C6-H6 Alarm)
High Pressure Pipe
Remove clogging.
Clogging
Expansion Valve Remove clogging, or
Check clogging.
Clogging replace expansion valve.
Remove clogging, or
Check Valve Clogging.
replace check valve.

Check temperature difference


Strainer Clogging Replace or clean strainer.
between inlet and outlet of strainer.

Chilled water inlet Check status of heat


Confirm if it is within
temperature of cooler is load in detail and take a
working range.
excessively high. countermeasure.

Discharge gas Suction gas temperature Charge correct quantity of


Gas Leakage or
thermostat is is excessively high refrigerant after checking
Refrigerant Shortage
activated. (excessively superheat). gas leakage.

29
TROUBLESHOOTING

Check valve
Suction gas
(air heat exchanger side) Replace check valve.
Discharge gas temperature is
malfunction.
thermostat is excessively high
activated. (excessive Expansion Valve Clogging Remove clogging.
(C1-61 Alarm)~ superheat).
Strainer Clogging Replace or clean strainer.
(C6-66 Alarm)
Discharge Gas Replace discharge gas
Check thermistor resistance.
Thermistor Failure thermistor.
Fan Motor Bearing
Lock Status. Replace fan motor.
Failure

Single Phase
Check magnetic contactor. Replace magnetic switch.
Running

Motor Insulation Measure insulation


Replace fan motor.
Depressed resistance.
Overcurrent relay
for compressor is Power Voltage Excessively Set voltage within working
activated. High or Low range during operation.
(C1-51 Alarm)~
Excessively Measure voltage between
(C1-56 Alarm) Imbalance among Phase at
Compressor each phase and ask Power
Power Source
Running Current Company for the advice.
Compressor internal
thermostat is Discharge pressure is
activated. Check for causes.
excessively high.
(C1-71 Alarm)~
(C6-76 Alarm) Power Fuse Melted Replace power fuse.

Unit stops Looseness of Screws for


Overcurrent relay Single Phase Tightly fix screws.
during Power Source
for fan motor is Running
cooling Deterioration of Contact of
activated. Replace contact points.
operation. Magnetic Switch for Comp.
(C1-F1 Alarm)~
(C6-F6 Alarm) Compressor Bearing
Lock Status
Failure
Replace compressor.
Compressor Motor Measure insulation
Insulation Failure resistance.
Compressor Motor
Measure current of
Overcurrent Relay Replace overcurrent relay.
compressor motor.
Failure
Check chilled water freezing
Pump Locked Remove them.
or clogging.
Pump overcurrent
Pump Overcurrent Measure RC value and pump Change RC value or replace
relay is activated.
Relay RC value Wrong running current. magnetic contactor.
(5P Alarm)
Pump Overcurrent Push reset button and
Replace magnetic contactor.
Relay Failure measure running current.
Check temperature difference
Shortage of Chilled
between inlet and outlet of Increase chilled water flow.
Water Flow
chilled water.

Freeze protection Water Strainer Clogging Clean strainer.


thermostat is
Pump Reverse Rotated Check rotative direction. Repair to correct direction.
activated.
(13 Alarm) Air Mixed Open air purge valve. Evacuate air.
Thermistor Failure
Check inlet temperature of
(11 Alarm) Replace thermistor.
chilled water.
(12 Alarm)

30
TROUBLESHOOTING

The heat load is bigger than cooling capacity. Calculate heat load. Replace to larger unit.
Gas Leakage or Correctly charge refrigerant
Measure superheat.
Shortage of Refrigerant after repairing gas leakage.
Expansion Valve Clogging Check clogging. Remove clogging.
Check temperature difference
Strainer Clogging between before and after Replace strainer.
strainer.

Low Pressure Piping Check temperature difference


Remove clogging.
Low pressure is Clogging between before and after piping.
extremely low.
(Low pressure Check temperature difference
Check valve
control is activated.) between before and after check Replace check valve.
malfunction.
valve.
(C1-L1 Alarm)~ Check temperature difference
(C6-L6 Alarm) Shortage of Water
between before and after inlet Increase water flow.
Flow
and outlet chilled water.
Replace or clean water
Clogging of Water Strainer
strainer.
Pump Reverse Rotation Check rotation direction. Repair to correct direction.

Air Mixed Open air purge valve. Evacuate the air.


Scales on Water Cooler Check scales inside of
Clean water cooler.
Plates water cooler.
Excessive Dust in Air-Side
Insufficient Heat Exchanger
Remove it.
Cooling Obstacles at Inlet or Outlet of
Insufficient Air Flow
Operation Air-Side Heat Exchanger
to Air-Side Heat
Exchanger Insufficient Operation Space
Secure operation space.
for Chiller Unit
Reverse Rotation of Fan Motor Correct wiring of fan motor.

Excessively High Air Air Short-Circuits in Chiller Unit Remove causes of short-circuit.
High pressure is Temperature to Air-Side Another Heat Source around
excessively high. Heat Exchanger Remove heat source.
Chiller Unit
(High pressure
switch is activated.) Excessively Charged
Check cycle temperature. Correctly charge refrigerant.
Refrigerant
(C1-H1 Alarm)~
(C6-H6 Alarm) Turn off unit and check relation
Non-Condensable Gas Evacuate and charge
between water temperature and
in Refrigerant Cycle. refrigerant again.
pressure.
High Pressure Pipe
Check clogging. Remove clogging.
Clogging
Expansion Valve Remove clogging or replace
Check clogging.
Clogging expansion valve.
Check temperature difference
Strainer Clogging between before and after Replace or clean strainer.
strainer.
Check temperature difference
Check valve malfunction. between before and after check Replace check valve.
valve.
Check pressure, cycle
Compressor Failure Replace compressor.
temperature, and current.
Adjust position of
Propeller-fan contacts with shroud. Investigate.
propeller fan.
Faulty Installation or
Check each bolt if loosen. Tighten up.
Loose Bolt
Liquid Refrigerant Check suction gas temperature
Ensure superheat.
Compression and pressure.
Operation Abnormal Sound Check suction gas temperature
with Abnormal Oil Hammer Replace compressor.
from Compressor and oil level.
Sound
No Heating by
Check current to oil heater. Replace oil heater.
Oil Heater
Wear or Breakage of Abnormal Sound from
Replace compressor.
Internal Comp. Parts Inside of Compressor
Humming Sound from Magnetic Contactor Check roughness of contact. Replace contact points.

Abnormal Vibration of Cabinets Check screws if loosen. Tighten up.

31
TROUBLESHOOTING

6. Thermistor characteristics

The thermistor is installed in this product to detect the cycle temperature such as water temperature (inlet-outlet of
water side heat exchanger). Ambient temperature and outlet liquid refrigerant temperature air side heat exchanger.
The temperature characteristics are shown in the figures below:

(1) Thermistor temperature characteristics


(All temperature except ambient and discharge gas)
Resistance (kΩ)

Temperature (°C)

32
TROUBLESHOOTING

(2) Thermistor temperature characteristics (Ambient)

Resistance (kΩ)

Temperature (°C)

(3) Thermistor temperature characteristics (Discharge gas temperature)


Resistance (kΩ)

Temperature (°C)

33
Specification in this catalog are subject to change without notice, in order that HITACHI may bring the latest innovations to our customers.

Catalog No. P5414720, 2010 Printed in Japan (SE)

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