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- TROUBLESHOOTING -
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
Alarm occurs
Stop Operation
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
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
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.
Yes
4
TROUBLESHOOTING
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
Yes
Check high pressure.
Check cycle.
5
TROUBLESHOOTING
[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
Shortage of Water
Check wiring
connection. Air Mixed
Clogging of Strainer
6
TROUBLESHOOTING
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
Shortage of Water
Check wiring
Air Mixed
connection.
Clogging of Strainer
7
TROUBLESHOOTING
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)
8
TROUBLESHOOTING
[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
Yes
9
TROUBLESHOOTING
Check wiring
connection.
(Disconnecting or
Incorrect)
Yes
Compressor motor is locked.
Check wiring
connection.
10
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Yes
Yes
11
TROUBLESHOOTING
Yes
Yes
12
TROUBLESHOOTING
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.
13
TROUBLESHOOTING
No
Yes
No (Correct Phase)
14
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Yes
NOTES:
15
TROUBLESHOOTING
Alarm
Product Model Thermistor PCB Connector
Code
RCUP30~307A(T)U(Z)
Chilled water inlet temperature thermistor PCBC CN3
RCUP34~202WU(Z)
16
TROUBLESHOOTING
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.
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
17
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Yes
18
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Yes
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)
No. 1
Outlet water temperature thermistor 1 PCBC CN6
Unit
No. 2
Outlet water temperature thermistor 1 PCBC CN6 Unit
19
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Yes
20
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21
TROUBLESHOOTING
22
TROUBLESHOOTING
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
Yes
No
Discharge Pressure
Sensor Abnormality
23
TROUBLESHOOTING
Is connector CN29Ps on No
the printed circuit board Repair plug and
for Relay (PCBD) correctly wiring.
connected?
Yes
Yes
Yes
Yes
Is suction gas pressure sensor Remove the clogging in
connecting pipe clogging? the pipe.
No
Suction Pressure
Sensor Abnormality
24
TROUBLESHOOTING
Yes
Replace printed circuit
board for CPU (PCBC).
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
25
TROUBLESHOOTING
No
Apply field-supplied pump
protection circuit with water
temperature thermostat (max.
65°C) to prevent overheating
of water temperature.
Yes
No
Is setting of dip switch Set dip switch correctly.
correct?
Yes
26
TROUBLESHOOTING
Is connector PCN206 on No
Printed Circuit Board for Correctly connect plug
Relay (PCBD) correctly and repair wiring.
connected?
Yes
Check wiring
connection.
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
Short-Circuit of
Conductive Foreign Particle Remove particle and replace fuse.
Printed Circuit Board
Crankcase Heater Failure Measure resistance. Replace crankcase heater and fuse.
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.
28
TROUBLESHOOTING
Incorrect Connection
Check circuit by tester. Repair connections.
Printed Circuit Printed Circuit Board
Board Failure Failure
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.
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
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.
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.
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:
Temperature (°C)
32
TROUBLESHOOTING
Resistance (kΩ)
Temperature (°C)
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.