Z0011542-2008-A Air-Cooled AHYZ1 Series TC2

For Models:
RCU（G）40AHYZ1 RCU（G）200AHYZ1
-Technical Catalog Ⅱ- RCU（G）100AHYZ1 RCU（G）330AHYZ1
Installation, Operation and Maintenance
Instructions RCU（G）160AHYZ1 RCU（G）380AHYZ1
HITACHI AIR-COOLED WATER CHILLERS

-SCREW TYPE-
IMPORTANT:
READ AND UNDERSTAND THIS
MANUAL BEFORE USING THESE
AIR-COOLED WATER CHILLERS.
KEEP THIS MANUAL FOR FUTURE
REFERENCE.
Z0011542
IMPORTANT NOTICE
z HITACHI pursues a policy of continuing improvement in design and performance of products. The right
therefore is reserved to vary specifications without notice.
z HTACHI can not anticipate every possible circumstance that might involve a potential hazard.
z No part of this manual may be reproduced without written permission.
z 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:
DANGER : Immediate hazards which WILL result in severe personal injury or death.
WARNING : Hazards or unsafe practices which COULD result in severe personal injury or death.
CAUTION : Hazards or unsafe practices which COULD result in minor personal injury or
product or property damage.
NOTE : Useful information for operation and /or maintenance.
z If you have any questions, please contact your contactor or dealer of HITACHI.
z This technical catalog II gives a common description and information for this air-cooled water chiller
which you operate as well as for other models.
z This air-cooled water chiller has been designed for the following temperatures. Please operate the
air-cooled water chiller within this range.
W orking Range
Item Standard
Chilled W ater Outlet Temperature 5～15℃
Condenser Air Inlet Temperature 5～43℃
z This technical catalog II should be considered as a permanent part of the air-cooled water chiller
equipment and should remain with the air-cooled water chiller equipment.
TABLE OF CONTENTS
OPERATION INSTRUCTIONS
1.PREPARTION………………...……..……………………………………………………………………………1
Initial Check…………...…...………………………………………………………………………………….1
Placing the Unit…………………..…………………………………………………………………………...1
Center of Gravity……….………..…………………………………………………………………………….3
Weight Balance…………….………..…………………………………………………………………………3
Recommended Concrete Curb………….…….……...…………………………………………………….. 4
Transportation…………….…..……………………………………………………………………………….7
2.INSTALLATION………….……...………………………………………………………………………………8
Electrical Wiring………………….………………………………………………………………………….8
Water Piping………………...………………………………………………….……………………..…… 10
Minimum Internal System Water Volume..……………..……….……………………………………11
Water Control……………………………………………………………………………………………….12
Installation Final Check…………………………………….…..………………………………………..12
3.TEST RUNNING………….………...…………………………………………………………………………13
Preparation……..…………………..…………………………………………………………………….. 13
Test Running………………………...……………………………………………………………………..13
Instruction after Test Running………………………..………………………………………………..13
4.CONTROLLER ADJUSTMENT…………………..………………………………………………….……..14
Controller adjustment……………………..……………………………………………………………..19
5.SELF-INSPECTION FUNCTION……………………………………………………………………..……22
6.CONTROL SYSTEM……………………………………………………..…………………………………...27
7.MAINTENANCE…………………………………………..………………………………………................29
Components..………………………………..…………………………………………………………….29
Lubrication…………………………………...……………………………………………………….......29
Cleaning method……………………………...……………………………………………………….......30
Winter Showdown………………………...………………………………………………………….......31
Spring Start-up…………………………..……………….………………………………………………31
Part Replacement………………………….…………….……………………………………………....31
Refrigerant Cycle…………………………………………………………………………………………31
Compressor Removal……………………………………..……………………………………………...33
Normal Operating Pressure………………………………..…………………………………………..36
Special Notes on Refrigerant,R407C……………………………………………………………………..40
8.Trouble Shooting……………………….…………….……………………………………………………….41
OPERATION INSTRUCTIONS HITACHI Air-Cooled Water Chillers
Model: RCU(G)40、50、60、75AHYZ1，
Air Discharge
Air Side Heat-Exchanger
Pilot Lamp
1．The red lamp indicates the normal operation.
Air Inlet Air Inlet 2．When the orange lamp is activated, any one of the safety
devices may be functioning.
Please contact your services shop if this condition is
detected.
Rigging holes(4-φ50)
Mounting Holes(4-φ26)
Earth Connection Terminal Screw Type Compressor Daily Checking
1．Check for abnormal sounds and vibration.
2．Check the unit amperage.
3．Check the operating pressure.
NOTE：
Fan
1.It should surpport the water pipings properly to avoid its weight press on the unit directly Troubleshooting
Wiring Hole for Power Supply
2.Water connection flanges( 90mm inner diameter )are supplied by factory with the unit. Unit Dose Not Start
1．Is the main switch ON?
2．Is the main fuse OK?
3．Is the chilled water running?
4．Are the thermostats calling for the cooling operation?
To Start the Unit： To Stop the Unit：
1．Fully open the inlet and outlet valve. 1． Depress the “*OFF” bush button switch.
2．After assuring that all control switches have been (*Field-Supplied) Poor Cooling Operation
cut OFF and the “LOCAL/REMOTE” switch on the 1．Is sufficient air supplied to the condenser?
Note：
printed circuit board is in the “REMOTE” position, turn
ON the power switch. Do not cut the main power switch in order to keep the 2．Is the thermostat properly set?
3．Confirm that phases, R, S and T are correctly connected. activation of the oil heater. 3．Is the operation pressure normal?
The correct phase connection can be checked by a 4．Is sufficient water running through the water cooler?
phase sequence indicator. If not correctly connected, the
compressor dose not start due to activation of a reversal
phase protection device. Cut the main switch and Maintenance
interchange two of three terminals R,S and T at the main 1．Remove any obstacles to condenser air flow, and
power source terminals. clean the condenser.
4．Fully open the liquid line stop valves.( )
2．Clean the unit with a cleaner.
5．Operate the chilled water pump.
6．Depress the “*ON” push button switch 3．Clean the condenser and water cooler. (It is
(*Field-Supplied) recommended that a specialist be contacted for this
7．Set the thermostat at the desired temperature. type of work.)
OPERATION INSTRUCTIONS Model: RCU(G)100, 120,150AHYCZ1
Pilot Lamp
Air Discharge
Air Side Heat-Exchanger 1．The red lamp indicates the normal operation.
2．When the orange lamp is activated, any one of the safety
Air Inlet Air Inlet
detected.
Rigging Holes(4-φ50) Daily Checking

Screw Type Compressor Mounting Holes(6-φ26)
Earth Connection Terminal

Troubleshooting
NOTE：
Fan
Unit Dose Not Start
Wiring Hole for Power Supply
1.It should surpport the water pipings properly to avoid its weight press on the unit directly.
2.Water connection flanges( 142mm inner diameter)are supplied by factory with the unit. 2．Is the main fuse OK?
2．After assuring that all control switches have been (*Field-Supplied) Poor Cooling Operation
cut OFF and the “LOCAL/REMOTE” switch on the Note： 1．Is sufficient air supplied to the condenser?
printed circuit board is in the “REMOTE” position, turn 2．Is the thermostat properly set?
ON the power switch. Do not cut the main power switch in order to keep the
3．Confirm that phases, R, S and T are correctly connected. activation of the oil heater. 3．Is the operation pressure normal?
The correct phase connection can be checked by a 4．Is sufficient water running through the water cooler?
phase sequence indicator. If not correctly connected, the Maintenance
1．Remove any obstacles to condenser air flow, and
phase protection device. Cut the main switch and
interchange two of three terminals R,S and T at the main clean the condenser.
power source terminals. 2．Clean the unit with a cleaner.
4．Fully open the liquid line stop valves. ( ) 3．Clean the condenser and water cooler. (It is
5．Operate the chilled water pump. recommended that a specialist be contacted for this
6．Depress the “*ON” push button switch
type of work.)
(*Field-Supplied)
7．Set the thermostat at the desired temperature.
HITACHI Air-Cooled Water Chillers
Model: RCU(G)160、180、200AHYZ1
Pilot Lamp
Air Discharge
Air Inlet Air Inlet devices may be functioning.
detected.
Rigging Holes
(4-φ50)
Mounting Holes
Daily Checking
Earth Connection Terminal Screw Type Compressor (8-φ26)
Fan
NOTE： Troubleshooting
Wiring Hole
for Power Supply 1.It should surpport the water pipings properly to avoid
Unit Dose Not Start
its weight press on the unit directly 1．Is the main switch ON?
2.Water connection flanges( 142mm inner diameter )
are supplied by factory with the unit. 2．Is the main fuse OK?
To Start the Unit：
1．Fully open the inlet and outlet valve.
2．After assuring that all control switches have been Poor Cooling Operation
cut OFF and the “LOCAL/REMOTE” switch on the To Stop the Unit： 1．Is sufficient air supplied to the condenser?
printed circuit board is in the “REMOTE” position, turn 2．Is the thermostat properly set?
1． Depress the “*OFF” bush button switch.
ON the power switch. 3．Is the operation pressure normal?
(*Field-Supplied)
3．Confirm that phases, R, S and T are correctly connected.
The correct phase connection can be checked by a Note： 4．Is sufficient water running through the water cooler?
phase sequence indicator. If not correctly connected, the Do not cut the main power switch in order to keep the Maintenance
compressor dose not start due to activation of a reversal activation of the oil heater. 1．Remove any obstacles to condenser air flow, and
clean the condenser.
interchange two of three terminals R,S and T at the main
power source terminals. 2．Clean the unit with a cleaner.
4．Fully open the liquid line stop valves. ( ) 3．Clean the condenser and water cooler. (It is
5．Operate the chilled water pump. recommended that a specialist be contacted for this
6．Depress the “*ON” push button switch type of work.)
(*Field-Supplied)
7．Set the thermostat at the desired temperature.
Model: RCU(G)240, 270, 300AHYZ1
Pilot Lamp
Minimum) Air Discharge
Air Side Heat-Exchanger Air Side Heat-Exchanger

Air Inlet Air Inlet
detected.
Rigging Holes(8-φ50)
Screw Type Compressor Screw Type Compressor Screw Type Compressor Screw Type Compressor Mounting Holes(12-φ26)
Daily Checking
Earth Connection Terminal Earth Connection Terminal
No.1 Water Outlet No.1 Water Inlet No.2 Water Outlet

No.2 Water Inlet
NOTES：
1.This chiller consists of unit No.1 and No.2 and should be
separately shipped.
2.Support the water pipes with stay not to give
the weight of water pipes directly to the unit.
3.Provide a field-supplied common water piping
Wiring Hole for at the water coolers to connect unit No.1 and No.2.
Power Supply Fan Furthermore,for RCU240,300AHYZ1:as the No.1 unit and No.2 unit
Wiring Hole for
Power Supply
have a same water flow rate, it just needs to control the common water volume
to the chiller; for RCU270AHYZ1:because the chilled water flow rate
Troubleshooting
between No.1and No.2 unit is different, It is necessary to
control the water volume of each unit with adjusting valves.
4.It needs to field-connect the control wiring between the
Unit Dose Not Start
No.1 unit and No. 2 unit.
2．After assuring that all control switches have been (*Field-Supplied)
cut OFF and the “LOCAL/REMOTE” switch on the Poor Cooling Operation
Note：
printed circuit board is in the “REMOTE” position, turn 1．Is sufficient air supplied to the condenser?
2．Is the thermostat properly set?
3．Confirm that phases, R, S and T are correctly connected. activation of the oil heater.
The correct phase connection can be checked by a 3．Is the operation pressure normal?
phase sequence indicator. If not correctly connected, the 4．Is sufficient water running through the water cooler?
interchange two of three terminals R,S and T at the main Maintenance
power source terminals. 1．Remove any obstacles to condenser air flow, and
4．Fully open the liquid line stop valves.( ) clean the condenser.
(*Field-Supplied) 3．Clean the condenser and water cooler. (It is
7．Set the thermostat at the desired temperature. recommended that a specialist be contacted for this
type of work.)
Model: RCU(G)330, 350AHYZ1
Pilot Lamp
(Minimum)
Air Discharge
Air Inlet Air Inlet
detected.
P
Mounting Holes(14-φ26)
Earth Connection Terminal Screw Type Compressor Earth Connection Terminal Screw Type Compressor Screw Type Compressor
Daily Checking
No.2WaterInlet
No.1Water Outlet No.1WaterInlet No.2Water Outlet
NOTES：
separately shipped.
Wiring Hole for
at the water coolers to connect unit No.1 and No.2.
Power Supply
Fan Furthermore,for RCU330,350AHYZ1,because the chilled water
flow rate between No.1and No.2 unit is different,It is necessary to
Troubleshooting
5.The dimension of No.2 unit marked with P is 300mm. Unit Dose Not Start
Note：
printed circuit board is in the “REMOTE” position, turn 1．Is sufficient air supplied to the condenser?
phase sequence indicator. If not correctly connected, the 4．Is sufficient water running through the water cooler?
type of work.)
Model: RCU(G)360, 380, 400AHYZ1,
Pilot Lamp
(Minimum)
Air Discharge

Air Side Heat-Exchanger Air Side Heat-Exchanger
Air Inlet Air Inlet devices may be functioning.

detected.
Mounting Holes(16- φ26)
Earth Connection Terminal Screw Type Compressor Earth Connection Terminal Screw Type Compressor
Daily Checking
No.1 Water Outlet No.1 Water Inlet No.2 Water Outlet No.2 Water Inlet
NOTES：
separately shipped.
Wiring Hole for

Fan
at the water coolers to connect unit No.1 and No.2.
Power Supply
Furthermore,for RCU360,400AHYZ1:as the No.1 unit and No.2 unit
have a same water flow rate, it just needs to control the common water volume
to the chiller; for RCU380AHYZ1:because the chilled water flow rate
between No.1and No.2 unit is different, It is necessary to
Troubleshooting
Unit Dose Not Start
1．Is the main switch ON？
2．Is the main fuse OK？
3．Is the chilled water running？
4．Are the thermostats calling for the cooling operation？
Note：
printed circuit board is in the “REMOTE” position, turn 1．Is sufficient air supplied to the condenser？
phase sequence indicator. If not correctly connected, the 4．Is sufficient water running through the water cooler？
type of work.)
PREPARATION
1. PREPARATION
Initial Check
Required Materials - Measure and architectural information regarding installation location.
Installation Location - Confirm the final installation location is provided with convenient piping and wiring work. Strong
water runoff should be avoided.
Installation Space - Check for obstacles which hamper maintenance work in the space specified in Fig.1.
Foundation - Check to ensure 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 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 clearance beneath the unit for either rooftop
or 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 insure that the unit has been transported without damage. File a damage claim with the transportation
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 I.)
Placing the Unit
DANGER
z If leakage is detected, stop the unit and contact the installer or a service shop. Don’t use a naked fire near the
refrigerant gas. If a naked fire is utilized near the refrigerant gas, refrigerant gas is turned into harmful
phosgene compound.
WARNING
z The unit is operated with refrigerant R22 or R407C, which is nonflammable and nonpoisonous. However,
refrigerant itself is heavier than the atmosphere so that a floor is covered with refrigerant gas if refrigerant is
leaked. Therefore, maintain good ventilation to avoid choke during servicing.
CAUTION
z Check to ensure that 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 practice before unpacking is accomplished.
Provide adequate facilities to place the unit on the foundation, with sufficient consideration given to those individuals
performing the installation.
Unpacking - Follow the instructions marked on the packing.
1
PREPARATION
h1≤h2 h1≤h2
For Models RCU(G)40AHYZ1～RCU(G)200AHYZ1 For Models RCU(G)240AHYZ1～RCU(G)400AHYZ1
Fig.1 Operation Space
NOTES:
1. The height of the wall shall be smaller than
that of the unit cabinet.
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
with HITACHI regarding the operation space is
recommended.
Model Maintain Space (mm) Air Inlet Space (mm)

A B C D E F G
RCU(G)40AHYZ1 2,100 1,200 100 900 1,200 2,000 1,200
RCU(G)50AHYZ1 2,100 1,200 100 900 1,200 2,000 1,200
RCU(G)60AHYZ1 2,100 1,200 100 900 1,200 2,000 1,200
RCU(G)75AHYZ1 2,100 1,200 100 900 1,200 2,000 1,200
RCU(G)100AHYZ1 4,200 1,200 100 900 1,200 2,000 1,200
RCU(G)120AHYZ1 4,200 1,200 100 900 1,200 2,000 1,200
RCU(G)150AHYZ1 4,200 1,200 100 900 1,200 2,000 1,200
RCU(G)160AHYZ1 6,300 1,200 100 900 1,200 2,000 1,200
RCU(G)180AHYZ1 6,300 1,200 100 900 1,200 2,000 1,200
RCU(G)200AHYZ1 6,300 1,200 100 900 1,200 2,000 1,200
RCU(G)240AHYZ1 8,500(Minimum) 1,200 900 900 1,200 2,000 1,200
RCU(G)400AHYZ1 12,700(Minimum) 1,200 900 900 1,200 2,000 1,200 Fig.2 Maximum Foundation Gradient
Maximum Foundation Gradient

The unit shall be installed vertically within the maximum foundation gradient as shown Fig.2.
2
PREPARATION
Center of Gravity
Center of Gravity
Center of Gravity Operation

Model
X Y Weight(kg)
RCU(G)40AHYZ1 975 830 2156
RCU(G)50AHYZ1 975 830 2206
RCU(G)60AHYZ1 975 830 2279
RCU(G)75AHYZ1 975 830 2,332
RCU(G)100AHYZ1 2,035 805 4,112
RCU(G)120AHYZ1 2,055 805 4,312
RCU(G)150AHYZ1 2,065 835 4,403
RCU(G)160AHYZ1 3,550 805 5,413
RCU(G)180AHYZ1 3,550 805 6,006
RCU(G)200AHYZ1 3,570 835 6,152
RCU(G)240AHYZ1-1,2 2,055 805 4,312
RCU(G)270AHYZ1-1 2,065 835 4,403 Fig.3 Center of Gravity
RCU(G)270AHYZ1-2 2,055 805 4,312
RCU(G)300AHYZ1-1,2 2,065 835 4,403
RCU(G)330AHYZ-1 3,570 835 6,006
RCU(G)330AHYZ-2 2,065 835 4,403
RCU(G)350AHYZ-1 3,570 835 6,152
RCU(G)350AHYZ-2 2,065 835 4,403
RCU(G)360AHYZ-1,2 3,550 805 6,006
RCU(G)380AHYZ-1 3,570 835 6,152
RCU(G)380AHYZ-2 3,550 805 6,006
RCU(G)400AHYZ-1,2 3,570 835 6,152
Weight Balance
Weight Balance
Weight Destribution (kg)
Model
1 2 3 4
RCU(G)40AHYZ1 520 469 612 555
RCU(G)50AHYZ1 532 480 626 568
RCU(G)60AHYZ1 550 496 646 587
RCU(G)75AHYZ1 563 508 662 601

Model
1 2 3 4 5 6
RCU(G)100AHYZ1 655 610 590 756 756 745
RCU(G)120AHYZ1 651 643 628 817 799 776
RCU(G)150AHYZ1 688 665 651 807 800 794
RCU(G)240AHYZ1-1,2 651 643 628 817 799 776
RCU(G)270AHYZ1-1 688 665 651 807 800 794
RCU(G)270AHYZ1-2 651 643 628 817 799 776
RCU(G)300AHYZ1-1 688 665 651 807 800 794

Model
1 2 3 4 5 6 7 8
RCU(G)160AHYZ1 590 605 608 605 744 754 757 751
RCU(G)180AHYZ1 654 671 674 671 825 836 840 833
RCU(G)200AHYZ1 688 696 707 696 842 850 837 834
RCU(G)330AHYZ1-1 654 671 674 671 825 836 840 833
RCU(G)330AHYZ1-2 688 665 651 807 800 794
RCU(G)350AHYZ1-1 688 696 707 696 842 850 837 834
RCU(G)350AHYZ1-2 688 665 651 807 800 794
RCU(G)360AHYZ1-1,2 654 671 674 671 825 836 840 833
RCU(G)380AHYZ1-1 688 696 707 696 842 850 837 834
RCU(G)380AHYZ1-2 654 671 674 671 825 836 840 833
RCU(G)400AHYZ1-1,2 688 696 707 696 842 850 837 834 Fig.4 Weight Balance
3
PREPARATION
Recommended Concrete Curb

CAUTION
z When the unit is installed on the ground, the weight of the concrete curbs should be greater than 1.5 to 2
times of the unit weight.
For Models: RCU(G)40、50、60、75AHYZ1
Drain Ditch
6-Vibration Proof Rubber Mat ［Tubing Side］
Foundation Bolt
（4-M20×300）
☆Foundation Bolt
☆Nut
3
☆Washer
☆Bushing
☆Vibration Proof Rubber Mat

Steel Plate（1mm)
［Compressor Side］
☆：Supplied by Factory
Steel Plate（1mm): Field Supply
Concrete Mortar Cement

Drain Ditch
For Models: RCU(G)100、120、150AHYZ1
Drain Ditch 10-Vibration Proof Rubber Mat
Foundation Bolt
（6-M20×300）
☆Foundation Bolt
☆Nut
☆Washer
☆Bushing

Steel Plate（1mm)
Steel Plate（1mm) : Field Supply
Drain Ditch Concrete Mortar Cement
Fig.5-1 Recommended Concrete Curbs
4
PREPARATION
14-Vibration
Drain Ditch Proof Rubber Mat ［Tubing Side］
Foundation Bolt
☆Foundation Bolt
☆Nut
☆Washer
☆Bushing
Steel Plate（1mm)
Compressor Side Steel Plate（1mm) : Field Supply
10-Vibration Proof 10-Vibration Proof

Drain Ditch Rubber Mat ［Tubing Side］ Rubber Mat ［Tubing Side］
Foundation Bolt Foundation Bolt

（6-M20×300）（6-M20×300）
［Compressor Side］［Compressor Side］
☆Foundation Bolt
☆Nut
☆Washer
☆Bushing

Steel Plate（1mm)
5
PREPARATION
For Models: RCU(G)330、350AHYZ1

Drain Ditch
Rubber Mat ［Tubing Side］ Rubber Mat ［Tubing Side］

（6-M20×300）
［Compressor Side］［Compressor Side］
☆Foundation Bolt
☆Nut
☆Washer
☆Bushing
Steel Plate（1mm)
Steel Plate（1mm): Field Supply

Drain Ditch Rubber Mat ［Tubing Side］ Rubber Mat ［Tubing Side］
Compressor Side Compressor Side
☆Foundation Bolt
☆Nut
☆Washer
☆Bushing

Steel Plate（1mm)
6
PREPARATION
Transportation
1) Rigging
Hook wire cables with factory-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 unit weight. Check to ensure that the rigging bolts are tightly fixed to
the unit. The rigging angle shall be greater than 60℃ as shown .The weight of the unit is indicated on the unit label.
DANGER
Do not stand below the unit when rigging.
CAUTION
Put cloths between wires and the unit to avoid damages.
greater than 60℃
Fig.6-1 Transportation by Rigging
2) Transportation by Roller 3) Declining the Unit during Transportation

When rolling the unit, put at least required 7
equal-sized rollers under the base frames. Each roller CAUTION
must carry both the outer frames, and must be suited
to balance the unit (see the center of gravity in Fig.3). Do not decline the unit more than an angle of 15° as
shown in the figure during transportation. If declined
more than an angle of 15°, the unit may fall down.
Fig.6-2 Transportation by Rollers Fig.6-3 Declining the Unit
7
INSTALLATION
2. INSTALLATION
Electrical Wiring
Tools and Instruments - One set of wiring tools and electrical tester (Clamp Meter)
Schedule Check-
CAUTION
z Confirm that the field-selected electrical components (main power switch, fuses, wires, conduit connections.
wire terminals and others) are properly selected according to the “Electrical Data’ in Technical Catalog I and
ensure they comply with national and local codes.
z It is recommended that the main power switch be locked at the “OFF” position, to prevent against accidental
supply of power during equipment servicing.
z Check to ensure that an earthing wire is correctly connected to the unit. This wire protects unit from an
electrical 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 fielded-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, neutral wire and earthing wire through the connection holes to the wiring terminals in the electric
box.
4. Firmly connect the wires to the R, S, T and MP wiring screw terminals according to Fig.7.
5. Connect the power source wires of the unit to the field-supplied magnetic switch in main switch box (es).
6. Consider that the main power source switch will not be left turned OFF easily. Because it is necessary to energize the oil
heater even during unit stoppage.
NOTE
More than 240AHYZ1 including 240AHYZ1 unit consists of No.1(Master)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 wiring for interlock control of the unit and the magnetic switches of the water pumps,
according to Fig.7 or the wiring label. The connection to terminal Mp for the main power source is required.
RCU(G)40～200AHYZ1
Control Circuit Terminals
Power Source Terminals Electrical Box Interlock for the Pump 3
PWBc
Contactor
3～Mp, 380V, 415V/ 50Hz 1 2 *CSP
TB2 1 2 Y52P1
Pump Power Supply
R S T Mp *CMP 4
Main Power Switch

(Field-Supplied) *ORP
Earth Terminal *CMP
Earth Wiring
Main Power Wiring
Control Circuit Wiring Pump Operation Wiring
Contactor for Chilled
Water Pump (If Required)
Wire to be Removed TB 8 9 10 11 12 13
2
*BSR1 Push Button Switch(ON)
*BSR2 Push Button Switch (OFF)
*CMP Contactor for Pump *PLR1 *PLR2 *PLO1 *PLO2 *PLO3
5 6 7
*ORP Over Current Relay for Pump TB2
*CSP Changeover Switch for Pump Operation
*PLR1 Pilot Lamp for Remote Indication
(Operation) *BSR2 *BSR1 Indication Lamp Power Supply
*PLR2 Pilot Lamp for Remote Indication(Pump) (OFF) (ON)
*PLO1,2,3 Pilot Lamp for Remote Indication(Alarm, Remote Control Wiring and Remote
Each Cycle) Indication Wiring(If Required)
Fig.7-1 Field Wiring Connections
8
INSTALLATION
RCU(G)240～400AHYZ1
No.1 Unit (Master Unit) No.2 Unit (Subsidiary)
Control Circuit Terminals Control Circuit Terminals
Power Source Terminals Electrical Box Power Source Terminals Electrical Box
3～Mp, 380,415V/50Hz 1 2 42 43 3～Mp, 380V,415V / 50Hz 42 43
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
1 2
TB2 Wire to be Removed
3
PWBc 5 6 7
*CMP TB2
*CSP
Pump Power Supply
Y52P1
Interlock for the *BSR2 *BSR1
Pump Contactor 4 (OFF) (ON)
(No.1 Unit)
(No.1 Unit)
*ORP
No.1 Unit
TB2 8 9 10 11 12
*CMP
TB3 42 43 13
*PLO1 *PLO2 ---
Pump Operation Wiring *PLR1 *PLP2 *PLO1 *PLO2 *PLO3 240～300AHYZ1
(If Required) 330～400AHYZ1
(No.1 Unit)
Indication Lamp Power Supply

TB3 42 43 Shielded Wires Remote Control Wiring and Remote
DC12V Indication Wiring (If Required)
No.2 Unit
(With Non-polarity Transmission )
(For No.1 Unit)
Control Wiring between No.1 and
No.2 Units
TB2 8 9 10 11 12
*PLO3 *PLO4
*BSR1 Push Button Switch(ON)
*PLO4 *PLO5
*BSR2 Push Button Switch (OFF) *PLO4 *PLO5 *PLO6 240～300AHYZ1
*CMP Contactor for Pump 330～360AHYZ1
*ORP Over Current Relay for Pump 360～400AHYZ1
*CSP Changeover Switch for Pump Operation
*PLR1 Pilot Lamp for Remote Indication Indication Lamp Power Supply
(Operation)
*PLR2 Pilot Lamp for Remote Indication(Pump)
Remote Control Wiring and Remote
*PLO1,2,3，4，Pilot Lamp for Remote Indication(Alarm, Indication Wiring (If Required)
5,6 Each Cycle)
(For No.1 Unit)
Fig.7-2 Field Wiring Connections
9
INSTALLATION
Water Piping
When piping connections are performed:
1. Connect all pips with flanges as close possible to the unit, so that disconnection can be easily performed when required.
2. It is recommended for the piping of the chilled water inlet and outlet that flexible joints be utilized, so that vibration will
not be transmit.
3. Whenever permissible, sluice valves should be utilized for water piping, in order to minimize flow resistance and to
maintain sufficient water flow.
4. Proper inspection should be performed to check for leaking parts inside and outside the system, by completely opening
the chilled water inlet and outlet valve,
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.
5. Sufficiently perform insulation to keep the chilled water piping cool and to prevent sweating of the piping.
6. Under the condition where the ambient temperature is low in winter. There is a case where equipment and piping will
become damaged during 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 shutdown periods. In the case where there is
still a danger of freezing, completely drain the water from the piping. Additionally, in a case where measures such as
water draining are difficult, utilize antifreeze mixture of ethylene glycol type or propylene glycol type.
CAUTION
z Never use an antifreeze mixture of the salt type. Because it possesses strong corrosion characteristics, and
water equipment will be damaged.
z 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.
Chilled Unit
Water Pump
Heat Load Side
10
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.
Minimum Internal System Water Volume (m3)

RCU40AHYZ1 RCU50AHYZ1 RCU60AHYZ1 RCU75AHYZ1 RCU100AHYZ1 RCU120AHYZ1 RCU150AHYZ1 RCU160AHYZ1 RCU180AHYZ1
Model
RCUG40AHYZ1 RCUG50AHYZ1 RCUG60AHYZ1 RCUG75AHYZ1 RCUG100AHYZ1 RCUG120AHYZ1 RCUG150AHYZ1 RCUG160AHYZ1 RCUG180AHYZ1
Volume
0.42 0.51 0.64 0.68 1.02 1.28 1.37 1.54 1.92
（m3）
RCU200AHYZ1 RCU240AHYZ1 RCU270AHYZ1 RCU300AHYZ1 RCU330AHYZ1 RCU350AHYZ1 RCU360AHYZ1 RCU380AHYZ1 RCU400AHYZ1
Model
RCUG200AHYZ1 RCUG240AHYZ1 RCUG270AHYZ1 RCUG300AHYZ1 RCUG330AHYZ1 RCUG350AHYZ1 RCUG360AHYZ1 RCUG380AHYZ1 RCUG400AHYZ1
Volume
2.05 2.57 2.65 2.74 3.29 3.42 3.85 3.98 4.11
（m3）
Note: Minimum internal system water volume in the above table is setting according to the standard neutral zone
temperature. In case of changing the setting, minimum internal system water volume shall be increased as follows..
Water Neutral Zone Temperature Minimum Internal System Water Volume

2℃（Standard） 100%
1.5℃ 130%
1℃ 200%
Internal Water Volume in Water Cooler (m3)

Model Volume(No.1) Model Volume(No.1/No.2)
RCU40AHYZ1, RCUG40AHYZ1 0.08 RCU200AHYZ1, RCUG200AHYZ1 0.21
RCU50AHYZ1, RCUG50AHYZ1 0.07 RCU240AHYZ1, RCUG240AHYZ1 0.14/0.14
1、RCU(G)40AHYZ1
2、RCU(G)50AHYZ1
3、RCU(G)60AHYZ1
RCU(G)75AHYZ1
Water Cooler Pressure Drop(kPa)
4、RCU(G)100AHYZ1
5、RCU(G)120AHYZ1
RCU(G)150AHYZ1
RCU(G)240AHYZ1-1
RCU(G)240AHYZ1-2
RCU(G)270AHYZ1-1
RCU(G)270AHYZ1-2
RCU(G)300AHYZ1-1
RCU(G)300AHYZ1-2
RCU(G)330AHYZ1-2
RCU(G)350AHYZ1-2
6、RCU(G)160AHYZ1
RCU(G)180AHYZ1
RCU(G)200AHYZ1
RCU(G)330AHYZ1-1
RCU(G)350AHYZ1-1
RCU(G)360AHYZ1-1
RCU(G)360AHYZ1-2
RCU(G)380AHYZ1-1
RCU(G)380AHYZ1-2
RCU(G)400AHYZ1-1
RCU(G)400AHYZ1-2
3
Chilled Water Flow Rate of Each Water Cooler(m /h)
(Total Flow Rate /Number of Cooler）
11
INSTALLATION
Water Control
CAUTION
When industrial water is applied for chilled 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. Sand or mud contained in chilled water can settle down in the water cooler and
restrict the flow of water, causing a freezing accident. It is also necessary to analyze the equality of water by checking PH,
electrical conductivity, ammonia ion content sulfur content, and others, and to utilize industrial water only if problem is
encountered through these checks. The following is the HITACHI standard water quality.
Table. 1
Chilled water system tendency1)
Item
Circulating water (less than 20℃) Supply water Corrosion Deposits of scales
Standard quality
6.8 ~　8.0 6.8 ~　8.0 ○ ○
pH (25℃)
Electrical conductivity(mS/m)(25℃) (2) Less than 40 Less than 30 ○ ○
Chlorine Ion( mgCl―/ l ) Less than 50 Less than 50 ○
Sulfur acid ion ( mgSO42―/ l ) Less than 50 Less than 50 ○
The amount of acid consumption (pH4.8)
Less than 50 Less than 50 ○
( mgCaCO3/ l )
Total Hardness( mgCaCO3/ l ) Less than 70 Less than 70 ○
Calcium Hardness ( mgCO3/ l ) Less than 50 Less than 50 ○
Silica L ( mgSiO2/ l ) Less than 30 Less than 30 ○
Reference quality
Less than 1.0 Less than 0.3 ○ ○
Total iron (mgFe/ l )
Total copper (mgCu/ l ) Less than 1.0 Less than 0.1 ○
Sulpher ion ( mgS2―/ l ) ○
Ammonium ion ( mgNH4+/ l ) Less than 1.0 Less than 0.1 ○
Remaining chlorine ( mgCl/ l ) Less than 0.3 Less than 0.3 ○
Floating carbonic acid ( mgCO2/ l ) Less than 4.0 Less than 4.0 ○
Index of stability - - ○ ○
Note:
（1）The Mark “○” in the table means the factor concerned with the tendency of corrosion or deposits of scales.
Installation Final Check
Inspect the installation work according to all documents and drawings, Table.2 shows the minimum check points.
Table.2 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 Raining 5. Have the R, S and T phases of the water chiller correctly
Appearance been connected to the R, S and T phases of the main
power source, respectively?
3. Is the water piping system adequate?
Tube Size Water Drain 6. Are the stops 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
12
INSTALLATION
3. Test Running
Preparation
Tools and Instruments – High Pressure Compound Gauge, Low Pressure Compound Gauge, Electrical Tester and general
Tools.
CAUTION
z Switch ON the main power switch, and energize the oil heater for 12 hours before start-up, to sufficiently warm
the oil.
z Check to ensure that valves are correctly opened. If not opened, serious damage will occur to the compressor
due to an abnormally high pressure.
z 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 clean
the strainer. 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 HITACHI standard wiring label.
z Switch ON the field-supplied pump and the pump will be started immediately. Check the condition and operation state
of these components.
z Fully open the liquid line stop valve.
z 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.
CAUTION
z When the unit is wired according to the HITACHI standard wring shown ON the wring label, switch on the main
power switch, and energize the oil heater for 12 hours before start-up to sufficiently warm the oil
z Each rotation direction of two rotors in the compressor is fixed because a reversal protection device is
equipped. Moreover, the rotation direction should be checked with following method.
Confirm that phases R, S and T for the compressor are correctly connected. The correct phase
connection can be checked by a phase sequence indicator. If not, the compressor does not start due to
the activation of the reversal phase protection device.
Cut the main switch and interchange two of the three phases of R, S and T connected to the main power
wiring terminals of the unit.
a. Operate the pump for chilled water and other auxiliary equipment such as fan coil units ,check to ensure
that the chilled water flow is sufficient and other auxiliary equipment operates properly.
b. Set the dial switch at the desired temperature.
c. Press the ON push button, the condenser fans will start first and the compressor will start subsequently.
d. Check the rotation direction of the condenser fans.
e. After the system operation becomes stable, check the discharge and suction pressure by 7-segment on
control panel. Refer to the discharge and suction pressure curves in page36.
f. Check to ensure that the control & protective devices are in normal state (Refer to Table 3 in pages 34, 35.
g. The time settings of the CCP calculagraph for star-Delta starting and starting to load-up are five (5) and
thirty (30) seconds, respectively, local adjustment should be avoided.
Note
A loud sound occurs when this compressor is stopped after the normal operation. However, this sound indicates
no abnormalities and stops within a few seconds by the activation of the check valve. This sound is due to the
reverse rotation of the compressor rotor, resulting from the pressure difference between the discharge and suction
pressure.
Each compressor may show the different values of running current due to individual capacity control for each
compressor.
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
items.
CAUTION
z 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.
z When the power source switch is cut off for a long period unit shutdown, please turn on the power source
switch 12 hours before starting operation to energized the oil heater.
13
CONTROLLER ADJUSTMENT
4. CONTROLLER ADJUSTMENT
Fig.8 Location of Controller
14
Control Panel of Printed Circuit Board (for Each Model)

RCU40AHYZ1 RCUG40AHYZ1
15
16
RCU240、270AHYZ1 RCUG240、270AHYZ1
17
RCU360、380AHYZ1 RCUG360、380AHYZ1
18
Controller adjustment
Setting, functions are followings.
★ Chilled Water Temperature Setting Switch=RSW1 and RSW2

☆ Switches”RSW1” and “RSW2” are used for setting a required chilled water outlet temperature.
=7℃ for chilled water outlet temperature is recommended. The RSW1 and RSW2 dials are already set at 7 and 0 at
factory. Setting at the figures from 3 to 9 of the RSW2 dial should not be permitted.
★ Differential Setting Switch (Neutral Zone Setting Switch) =RSW8

☆ =2 ℃ is standard. The RSW8 dial is already set at 3=2 ℃.
The figures at the RSW8 dial mean as follow.
Figure 0 1 2 3 4 5 6 7 8 9
Band (℃) 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

☆Temperature band for stop setting switch
=1℃ is standard. The figure 1 and 2 of the DSW5 switch are already set at figure 1=ON side, figure 2=OFF side.
The location at the figure 1 and 2 of the DSw5 switch mean as follow.
Figure 1 2 1 2 1 2 1 2
Location ON ON ON OFF OFF ON OFF OFF
Band(℃) 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 ℃ is standard. The figure 3 and 4 of the DSW5 switch are already set at figure 3=ON side, figure 4=OFF side.
The location at the figure 3 and 4 of the DSW5 switch mean as follow.
Figure 3 4 3 4 3 4 3 4
Band(degree) 1.0 2.0 3.0 4.0
☆ Differential Temperature of Load-up 2 Mode Setting Switch

=1℃ is standard. The figure 5 of the DSW5 switch is already set at ON side.
The location at the figure 5 of the DSW5 switch mean as follow.
Figure 5 5
Location ON OFF
Band(degree) 1.0 3.0
☆ Output Signal Time for Load-up 1 Mode Setting Switch

=12 second is standard. The figure 6 of the DSW5 switch is already set at ON side.
The location at figure 6 of the DSW5 switch mean as follows.
Figure 6 6
Location ON OFF
Time(second) 12 24
☆ Output Signal Time of the Load-up 2 and Load-down Mode Setting Switch
=2 second is standard. The figure 7 and 8 of the DSW5 switch are already set at figure 7=ON side, figure 8=ON side.
The location at figure 7 and 8 of the DSW5 switch mean as follows.
Figure 7 8 7 8 7 8 7 8
Time(second) 2 4 6 8
19
☆ Interval of Output Signal Time for Load-up and Load-down Mode Setting Switch.
=60 second is standard. The figure 9 and 10 of the DSW5 switch are already set at figure 9=ON side, figure 10= ON
side.The location at figure 9 and 10 of the DSW5 switch mean as follows.
Figure 9 10 9 10 9 10 9 10
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
DSW2 Time
protection timer. Set the operation switch to ‘ON” side, the compressor will be
started after this setting time (3 minutes is standard.).The meaning of the figure at 1 2 (Minute)
switch”DSW2” is as follow.
ON ON 0.5
★ No. of Cycle for Checking High Pressure Cut-Off Setting Switch= figures 3
and 4 of DSW2 OFF ON 10
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 ON OFF 6
switches and depress “SW9” or “SW10” during operation. OFF OFF 3
(This function is available during “Local Operation”.)
DSW2 Depress Switch Cooling operation:

1. Depress“SW9”or“SW10”during the cooling
3 4 SW9 SW10 operation and “Local Operation”.
2. All fans corresponding to the no.of cycle shown in
OFF OFF No.1 Cycle No.2 Cycle
the table left is forced to stop
ON OFF No.3 Cycle No.4 Cycle 3. Then the discharge pressure rise, the high
pressure switch will be activated and the unit will
OFF ON No.5 Cycle No.6 Cycle stop due to alarm.
4. This function will be resumed by stopping the unit.
ON ON No.1 Cycle No.2 Cycle
★ Manual Set Switch =figure 1, 2, 3, 4, 5 and 6 of DSW3

Figure 1, 2, 3, 4, 5 and 6 of DSW3 switch is for compressors No.1, No.2, No.3, No.4, No.5 and No.6 respectively. If
necessary to stop any compressors, turn these switches (DSW3-1, DSW3-2, DSW3-3, DSW3-4.DSW3-5and DSW3-6)
to “OFF” side, the compressors corresponding to these switches which are turned to the “OFF” side will be stopped.
NOTE
1. Switch”DSW3-2” shall be always turned to the “OFF” side in RCU(G)40、50、60、75AHYZ1.
2. Switch”DSW3-3 shall be always turned to the “OFF” side in RCU(G)40AHYZ1.～RCU(G)150 AHYZ1.
3. Switch”DSW3-4” shall be always turned to the “OFF” side in RCU(G)40AHYZ1～RCU(G)200 AHYZ1.
4. Switch”DSW3-5” shall be always turned to the “OFF” side in RCU(G)40AHYZ1～RCU(G)300 AHYZ1.
7- Switch”DSW3-6” shall be always turned to the “OFF” side in RCU(G)40AHYZ1～RCU(G)350 AHYZ1.
★The remote control of BMS (building manage system) system (LONWORKS) setting switch (optional function)
DSW3-7, DSW3-8, DSW3-9 and DSW3-10 are used for setting the
DSW3
No. of the unit
mode of the remote control and the number of the unit. (This function 8 9 10
is available just during the “remote control “. SW6 should be turned to OFF OFF OFF No. 1
OFF OFF ON No. 2
the lower side.) OFF ON OFF No. 3
DSW3-7 ON: remote control mode OFF ON ON No. 4
※ ： “LONWORKS” is the registered trade mark of ON OFF OFF No. 5
ON OFF ON No. 6
“ECHELON Co. Ltd”.
★ Selection Switch for Cooling/Heating Operation =SW8
=Models: RCU(G)40AHYZ1～RC400 AHYZ1 are for cooling only. So that heating function is not available.
The SW8 selection switch must be turned to upper side.
★ Selection Switch for Local/Remote Operation=SW6
=Local operation is standard. So that the SW6 selection switch is turned to the upper side. If remote operation is
necessary, the SW6 selection switch is turned to the lower side.
★ Selection Switch for Local/Remote Pump Operation=SW7
=The SW7 selection switch is turned to the lower side (OFF).
If local operation is necessary, the SW7 selection switch is turned to the upper (“ON”) side.
20
★ 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 DSW 1.
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,DSW4,DSW1 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 used for only checking, resulting in easy troubleshooting.
Unit Setting of PWB
The same CPUs as 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…RCU(G)40AHYZ1,RCU(G)50AHYZ1,RCU(G)60AHYZ1,RCU(G)75AHYZ1,RCU(G)100AHYZ1,
RCU(G)120AHYZ1, RCU(G)150AHYZ1, RCU(G)160AHYZ1,RCU(G)180AHYZ1, RCU(G)200AHYZ1

Master……….. RCU(G)240AHYZ1-No.1unit ～RCU(G)400AHYZ1-No.1 unit
Subsidiary…… RCU(G)240AHYZ1-No.2unit ～RCU(G)400AHYZ1-No.2 units
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 “24” and “LO” is indicated.
5) Set DSW1-2, 3, 4 to “ON” and RSW8 “2”.
6) The present setting is indicated, and checks 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 SEG1is 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
indication 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.
21
SELF-INSPECTION FUNCTIONS
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.
5. 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 lighted.
Definitions of the code shown by 7-segment light diode on control panel are as shown in the table below.
7-Segment code on Control Panel
Code Content Remark

5P 5P 5P 5P 5P 5P Abnormal Condition of Feed Back Signal from Pumps or Cooling Tower
6E 6E 6E 6E 6E 6E Activation of Water Flow Protector
AP AP AP AP AP AP Activation of Supplemental Protector
14 14 14 14 14 14 Activation of Thermostat for Water Temperature Going Up Too Quickly
EU EU EU EU EU EU Abnormality in Transmission to PWBG
22 22 22 22 22 22 Abnormality of Thermostat for Ambient Temperature
Common
11 11 11 11 11 11 Abnormality of Thermostat for Chilled Water Inlet
31 31 31 31 31 31 Abnormality of Thermostat for Hot Water Inlet
12 12 12 12 12 12 Abnormality in Thermostat for Chilled Water Outlet
32 32 32 32 32 32 Abnormality in Thermostat for Hot Water Outlet
13 13 13 13 13 13 Activation of Freeze Protection
05 05 05 05 05 05 Alarm by Reverse Phase or Single Phase
C1-H1 C2-H2 C3-H3 C4-H4 C5-H5 C6-H6 Activation of High Pressure Switch
C1-71 C2-72 C3-73 C4-74 C5-75 C6-76 Activation of Internal Thermostat for Compressor Motor.
C1-41 C2-42 C3-43 C4-44 C5-45 C6-46 Activation of Internal Thermostat for Fan Motor
C1-F1 C2-F2 C3-F3 C4-F4 C5-F5 C6-F6 Activation of Over-current Relay for Fan Motor
C1-51 C2-52 C3-53 C4-54 C5-55 C6-56 Activation of Over-current Relay for Compressor
C 1-EU C 2-EU C 3-EU C 4-EU C 5-EU C 6-EU Abnormality in Transmission to PWBG
C1-13 C2-13 C3-13 C4-13 C5-13 C6-13 Activation of Freeze Protection
C1-12 C2-12 C3-12 C4-12 C5-12 C6-12 Abnormality in Thermostat for Chilled Water Outlet
C1-32 C2-32 C3-32 C4-32 C5-32 C6-32 Abnormality in Thermostat for Hot Water Outlet
C1-28 C2-28 C3-28 C4-28 C5-28 C6-28 Abnormality in Pressure Sensor for Suction Pressure
C1-27 C2-27 C3-27 C4-27 C5-27 C6-27 Abnormality in Pressure Sensor for Discharge Pressure
C1-24 C2-24 C3-24 C4-24 C5-24 C6-24 Abnormality in Thermostat for Refrigerant Before Expansion Valve Respective
C1-26 C2-26 C3-26 C4-26 C5-26 C6-26 Abnormality in Thermostat for Suction Gas
C1-L1 C2-L2 C3-L3 C4-L4 C5-L5 C6-L6 Activation of Low Pressure Switch
C1-t1 C2-t2 C3-t3 C4-t4 C5-t5 C6-t6 Alarm of Excessively Low Suction Gas Temperature
C1-25 C2-25 C3-25 C4-25 C5-25 C6-25 Abnormality in Thermostat for Freeze Protection
C1-23 C2-23 C3-23 C4-23 C5-23 C6-23 Abnormality in Thermostat for Discharge Gas Temperature
C1-61 C2-62 C3-63 C4-64 C5-65 C6-66 Activation of Thermostat for Discharged Gas Temperature
Abnormality in Thermostat for Water Cooler Refrigerant Inlet
C1-21 C2-21 C3-21 C4-21 C5-21 C6-21
Temperature for R407C Unit Only
C1-P6 C2-P6 C3-P6 C4-P6 C5-P6 C6-P6 Abnormality in Chilled Water Inlet(The Unit Restart)
C1-91 C2-92 C3-93 C4-94 C5-95 C6-96 Abnormality in Chilled Water Inlet(The Unit Stop)
C1-14 C2-14 C3-14 C4-14 C5-14 C6-14 Activation of Thermostat for Water Temperature Going Up Too Quickly
C1-05 C2-05 C3-05 C4-05 C5-05 C6-05 Alarm by Reverse Phase or Single Phase
Operation
C1-88 C2-88 C3-88 C4-88 C5-88 C6-88 Power Supply , After Stoppage
Error
40 40 40 40 40 40 Alarm of Operation Error
Notes: the table above lists the definitions of all considered abnormality shown by 7-segment codes, the items of abnormality
which may appear depends on the type of the HITACHI chillers.
22
(2) Nominal Indication
If the unit is operated under a normal operation condition, the operation code (refer to the table below) is indicated by
7-Segment LEDs on 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
C1-PU C2-PU C3-PU C4-PU C5-PU C6-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
(3) Indication Function of Operation Condition

The setting temperature, chilled water temperature sensed at the thermistor, the setting differential temperature and the
last alarm code are digitally indicated on the control panel.
This indication mode is change to the normal mode by pressing

the check “ ”and “ ”switches simultaneously for more than 3(three)
seconds again, or automatically changed when 30 seconds have Press the check “ ” switch for more than 3 (three)
passed from previous operation of the switch. seconds.
Normal Operation
The Alarm Code Condition Checking Indication
Occurrence Data “88”“Co”“oF”
This indication mode is changed to the normal mode by
pressing the check “ ”switch for more than 3(three)
Press the check “ ”and“ ”switches seconds again, or automatically changed when 30
simultaneously for more than 3 (three) seconds have passed from the previous operation of
seconds. the switch.
This indication mode is changed to the normal mode by
Press the check “ ”switch for more than 3 pressing the check “ “ and “ “switches simultaneously for
(three) seconds. more than 3(three) seconds again, or automatically changed
when 30 seconds have passed from the previous operation
of the switch.
Capacity Control Indication

※This indication is available only while the check “ ”switch is being pressed.
Note:
Each indication mode must be switched from the normal mode.
23
Checking Indication
In Case of No.1 Cycle Discharge Pressure 1.45 MPa

The alarm code occurred last
“ ” Press the check “ ” Switch

P h h k“ ” i h
No.1 Cycle Operation Conditions
Discharge Gas Pressure (MPa)
“ ” “ ”
Suction Gas Pressure (MPa)
Discharge Gas Temperature (℃)
Suction Gas Temperature (℃)
In Case of No.4 Cycle Suction Gas Temp. 2℃
“ ” “ ”

“ ” “ ” In Case of Chilled Water Outlet Temp.7℃
Temperature after the expansion
valve(℃)
“ ” “ ”
Inlet Water Temperature(℃)
“ ” “ ”
“ ” “ ”
Outlet Water Temperature(℃)
In Case of Setting Water Outlet Temp.12℃
“ ” “ ”
“ ” Water Temperature(℃)
Setting “ ”
“ ” “ ”
Neutral Zone Temperature (℃)
“ ” “ ”
Capacity Control (%) In Case of Ambient Temperature 35℃

“ ” “ ”
Ambient Temperature (℃)
“ ” “ ”
ROM Version No.
In Case of ROM Version No. 1178
24
(4) Indication Mode of Alarm Occurrence Data

The cause of abnormal stoppage including activation of safety devices is memorized and indicated on
the control panel.
Alarm Occurrence Data (Max.10 data)
In case of No.1 cycle high pressure alarm occurrence.
“ ” Press the check “ ” Switch
In case of No.2 cycle high pressure alarm occurrence.
“ ” “ ”
NOTE
1. This indication mode will automatically switch to the normal mode when 30 seconds have passed from the previous
operating of the switch.
2. If an abnormal operation is occurred under this normal indication mode, this indication mode will be switched to the
alarm indication mode.
25
Capacity Control Indication
※Example
No.1 Compressor Load Up
Change Automatically
No.2 Compressor Hold
No.3 Compressor Load Down
No.4 Compressor
Thermo-off
Starting Control
Normal Mode
26
CONTROL SYSTEM
6. CONTROL SYSTEM
Standard Operating Sequence for RCU(G)40、50、60、75AHYZ1
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 —
Load up — — — — — — — — — — — — — — — — —
Controller 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 OFF 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%
SV11 OFF OFF OFF ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF
Solenoid Valve 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
5 sec.
3 min.
30 sec.
Minimum 3min.
Time Schedul
CLS：Close,OPN:Open,STA:Star,DLT:Delta
ULD: Unload,FLD:Full Load,FLK: Flicker
Standard Operating Sequence for RCU(G)100、120、150AHYZ1,
Control Stage
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 —
Load up — — — — — — — — — — — — — — — — — —
Controller Neutral — — — — — — — — — — — — — — — — — —
Load down — — — — — — — — — — — — — — — — — — —
No.1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN OPN CLS CLS CLS CLS
Safety Devices
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 ON OFF OFF OFF
MF11～14 OFF OFF OFF OFF ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFF ON OFF OFF OFF
Motor for Fan
MF21～24 OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON OFF ON ON OFF OFF OFF OFF OFF
CH1 OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON ON ON ON ON OFF
Oil Heater
CH2 OFF ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF ON ON ON ON OFF
STA DLT STA DLT DLT DLT DLT DLT DLT DLT DLT DLT
MC1 OFF OFF OFF OFF (ULD) (ULD) (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) OFF (ULD) OFF OFF OFF (FLD) OFF OFF
Motor For 15% 15% 15% 15% 15-99% 100% 100% 15-99% 15-99% 15% 15-99% 100%
Compressor STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
MC2 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%
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
Solenoid Valve
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
5 sec. 5 sec.
3 min. 60 sec. 30 sec.

Minimum 3min.
Time Schedul The compressor which stopped first will be started first.
27
Standard Operating Sequence for RCU(G)160、180、200AHYZ1
Control Stage
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 —
Load up — — — — — — — — — — — — — — — — — — — — —
Controller Neutral — — — — — — — — — — — — — — — — — — — —
Load down — — — — — — — — — — — — — — — — — — — — — —
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
Safety Devices 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
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
Motor for Fan 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 OFF ON ON OFF OFF ON OFF OFF
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
Oil Heater 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
STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
MC1 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%
STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
Motor For
MC2 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
Compressor
15% 15% 15% 15% 15-99% 100% 100% 15-99% 15-99% 15% 15-99% 15-99% 100%
STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
MC3 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%
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
Solenoid Valve 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
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
CONTROL SYSTEM
5 sec. 5 sec. 5 sec.
3 min. 60 sec. 60 sec. 30 sec.

Minimum 3min.
Time Schedule
The compressor which stopped first will be started first.
28
MAINTENANCE
7. 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
particular attention.
WARNING
z If a fire accidentally occurs, turn OFF the main switch and use an extinguisher for an oil fire and an electric fire.
z Do not operate the unit near flammable gases such lacquer, paint, oil, etc. to avoid a fire or an explosion.
z Turn OFF the main switch when electrical box covers are removed for setting the temperature. Do not operate the unit
without fixing panels.
WARNING
z Perform periodical maintenance according to the “INSTRUCTIONS” to maintain the unit in a good condition.
z Do not touch the parts at the discharge gas side by hand, since the pips at the discharge side are heated by refrigerant
and the temperature mat become higher than 100℃。
z Do not utilize this unit for cooling or heating of drinking water or food, comply with local codes and regulation to use it.
z Turn OFF all the main switches if refrigerant leakage or chilled water leakage occurs. In addition, if the unit can not be
stopped by the control switch, it can turn OFF the main switches for power supply to stop it.
Components
Compressor - Roller bearing and ball bearing are utilized in HITACHI screw compressor. The operation life of the bearings
is approximately 24,000 hours after installation so the replacement of the bearings for compressor is required every 24,000
hours of the compressor operation. For the details, refer to the service handbook for HITACHI screw compressors.
Air-Cooled Condenser – Inspect the condenser and remove any accumulated dirt from the coil, at regular intervals. 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; oxidize contacts, foreign matter and others.
Control and Protective Devices - Do not readjust the settings in the field unless the setting is maintained at a point other
than the point listed in Table 3.
Lubrication
Compressor - The compressors are charged at the factory with the correct oil listed in “Component Detailed Data” in the
HITACHI Technical Catalog I 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 chilled water tend to deposit at surface of the plate over a period of operation. Increase of these
minerals deposits will cause excessive power consumption, if excessively high discharge pressure or lower operation
pressure are detected, it may indicate evidence of deposits in the water cooler.
29
MAINTENANCE
Cleaning Method
(1) Installation of cleaning circuit
1.1 Stop the water chiller.
1.2 Stop the circulation water pump.
1.3 Disconnect the inlet/outlet of the chilled water and set up a circulating water circuit by using an acid-resistant type
pump.
(2)Check of Circulating Circuit

Pour water into the cleaning tank and operate the acid-resistant type water pump to ensure:
2.1No water leakage exists.
2.2The water hose is firmly fixed.
2.3The cleaning agent will not damage the facility near the water chiller even if bubbles occur or touch them.
2.4Good ventilation is available
2.5No abnormality noise exists
(3) Cleaning Work

3.1 Discharge water in the water circuit of the air conditioning system.
3.2 Supplies diluted cleaning fluid from the cleaning water tank by operating the acid-resistant pump.
3.3 Circulate the cleaning fluid for an appropriate period of time(the operating time should be determined according to the
type of cleaning agents, concentration and fouling thickness)
(4) Waste Fluid

4.1 Stop the acid-resistant pump.
4.2 Flow the waste fluid into the waste fluid tank.
4.3 Supply water into the cleaning tank and operate the pump for water cleaning.
4.4 Put the cleaning water into the waste fluid tank as same as the waste fluid.
4.5 Measure the PH degree using a PH test sheet, and neutralize the waste fluid by gradually adding neutralizing agent.
4.6 After neutralization, ask a waste fluid company to handle it.
(5) Neutralization Treatment in the Water Piping

5.1 Supply water into the cleaning tank.
5.2 Start the acid-resistant pump.
5.3 Measure the PH degree by using a PH test sheet, gradually add neutralizing agent until the pH reaches PH= 7.
5.4 Operate the acid-resistant pump for a specified period of time for neutralization.
5.5 Discharge the used water.
5.6 Operate circulating pump and clean circuit with water until no fouling fluid is observed.
(6) Re-starting
6.1 Connect the unit piping as they were so that the water chiller can operate normally.
6.2 After cleaning, perform water treatment (preventive treatment) in order to prevent the unit from corrosion.
Cooling Operation
0.8
R22 Saturation Line
Suction Gas Pressure
0.6
(MPa)
R407 Saturation Line

0.4
Area Requiring Cleaning

0.2
5 10 15
Chilled Water Outlet Temperature (℃)
MAINTENANCE 30
Winter Showdown
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. The unit should be covered during shutdown, in order to
protect it from dust and environmental conditions, and 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 and piping systems, as water may freeze during the
cold season, it is very helpful to supply 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.
3. Inspect the pump and other auxiliary equipment in the piping line.
4. Tighten all wiring connections.
CAUTION
When the main switch for this unit has been at the OFF position for an extended period of time, it should be switch ON at
least 12 hours before start-up, so that the oil in the compressor may be warmed enough, to prevent from foaming at start-up.
Part replacement
Replacement of parts should be undertaken by ordering from the HITACHI Spare Parts List.
CAUTION
Repainting of Outer Cabinets
Outer cabinets are baked with synthetic resin paint on galvanized steel for long durability.However, corrosion of cabinets
slowly proceeds and its speed depends on the ambient conditions.
In the case where the units are operated in severe conditons, such as higher temperature, higher humidity, and others, it is
recommended that outer cabinets be periodically painted.
Refrigerant Cycle
Strainer: Check whether the strainer is clogged before each operation of the unit.
Refrigerant Charge: Inspect the refrigerant charge of the system by checking the discharge and suction pressure.
Perform a leakage test, if any leakage is suspected, and always perform such a test after a refrigerant cycle component is
replaced. When the refrigerant charge is required, please follow the following instructions given for two cases:
(1) When the refrigerant gas completely leaked….
Before charging ,the entire cycle must be completely evacuated and dehydrated, a gauge manifold or equivalent 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 evacuating 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 charger 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 manifold.
Operate the unit after circulating the chilled water.
Repeat the following procedure until pressure becomes proper (refer to page 36).
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.
31
MAINTENANCE
Note: This is the circulation fig. of anyone cycle of these HITCHI chillers.
Mark Name Mark Name
1 Compressor 10 High Pressure Sensor
2 Condenser 11 High Pressure Switch
3 Cooler 12 Stop Valve
4 Thermal Expansion Valve 13 Solenoid Valve
5 Check Valve A High Pressure Gauge
6 Liquid Line Stop Valve B Low Pressure Gauge
7 Fusible Plug C Stop Valve
8 Pressure Relief Valve D Charging Cylinder
9 Low Pressure Sensor E Vacuum Pump
Refrigerant Charge
R22
Model RCU40A RCU50A RCU60AHYZ RCU75AH RCU100AH RCU120AHY RCU150AH RCU160AHY RCU180
HYZ1 HYZ1 1 YZ1 YZ1 Z1 YZ1 Z1 AHYZ1
50 2×42 2×43 2×47 3× 3×43
Charge(kg)
Model RCU200 RCU240 RCU270AHY RCU300AH RCU330AH RCU350AHY RCU360AH RCU380AHY RCU400
AHYZ1 AHYZ1 Z1 YZ1 YZ1 Z1 YZ1 Z1 AHYZ1
3×48 4×43 2×47+ 2×43 4×47 3×43+2x47 3×48+2×47 6×43 3×48+3×43 6×48
Charge(kg)
32
MAINTENANCE
R407C
Model RCUG40 RCUG50 RCUG60A RCUG75A RCUG100 RCUG120A RCUG150A RCUG160A RCUG180
AHYZ1 AHYZ1 HYZ1 HYZ1 AHYZ1 HYZ1 HYZ1 HYZ1 AHYZ1
48 48 2×43 2× 2×46 3×
Charge(kg)
Model RCUG200 RCUG240 RCUG270 RCUG300 RCUG330 RCUG350A RCUG360A RCUG380A RCUG400
AHYZ1 AHYZ1 AHYZ1 AHYZ1 AHYZ1 HYZ1 HYZ1 HYZ1 AHYZ1
3×46 4× 2×46+ 2× 4×46 3×+2×46 3×46+2×46 6× 3×46+3× 6×46
Charge(kg)
*: For the blanks in the above tables, please contact HITACHI or Hitachi’s dealers.
CAUTION
1. DO not charge OXYGERN, 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 dangerous, because explosion can
occur. It is recommended that compressed air, nitrogen or refrigerant is charged for these types of tests.
2. Mineral deposits on the copper tubes act as thermal insulators, and also act as resistance against water flow, causing
the water flow to decrease running through them, and resulting in a decreasing of the cooling capacity. Deposits on
the copper tube 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 is drained. As water in different localities contains different minerals, different acid are required, depending upon
the thickness of the deposits. Contact with contractors or dealers of Hitachi, for details.
3. The unit is equipped with an operation hour meter. In the case that the total operation time reaches 24,000 or 3 years
pass after installation, exchange the bearings of the compressor. For details, refer to the service handbook for HITACHI
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 plate in the electrical box in order not to operate the compressor except for this
cycle.
3. Circulate the chilled water sufficiently through the water cooler, and operate the water chiller for 10 minutes, 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 the circulating water through the water cooler.
6. Stop the water chiller when the low pressure reaches at an approximately 0.05Mpa. Do not operate at the pressure
lower than 0.05MPa.If operated, it will cause damage to the compressor.
7. Wait for several minutes. If the low pressure increases up to 0.15 to 0.20MPa, 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. (Note: in order to avoid refrigerant jetting,
remove the bolts a little slowly to discharge remained refrigerant.)
10. Remove all the wiring of the compressor.
11. Remove the bolts fixing the compressor and the flanges of the discharge and suction side.
12. Remove compressor.
1 to 12 points shown above instruct that remove the compressor during normal maintenance procedures (Example:
replacement of compressor bearings). If compressor removal is due to compressor fault (Can not work), please perform
maintenance according to 8 to 12 procedure.
33
MAINTENANCE
Table 3. Safety and Control Device Setting(R22)

RCU40AHY RCU50AHY RCU60AHYZ RCU75AHY RCU100AHY RCU120AHY RCU150AHY RCU160AHY RCU180AHY
Model
Z1 Z1 1 Z1 Z1 Z1 Z1 Z1 Z1
High pressure control Manual Reset, Adjustable(One Switch for Each Compressor Motor)
Cut Off MPa 2.98 2.98 2.98 2.98 2.98 2.98 2.98 2.98 2.98
Low pressure control Control by Micro-Processor
Cut Off MPa 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
Internal Thermostat Automatic Reset, Non-Adjustable(One Switch for Each Compressor Motor)
Cut Off ℃ 115 115 115 115 115 115 115 115 115
Cut In ℃ 93 93 93 93 93 93 93 93 93
Overcurrent Relay*1 　Manual Reset Adjustable (One Switch for Each Compressor Motor)
380V 50Hz A 55 67 86 92 67 86 92 67 86
For
415V 50Hz A 50 61 79 84 61 79 84 61 79
Compressor
Oil Heater One Oil Heater for Each Compressor Motor
Capacity W 150 150 150 150 150 150 150 150 150
Discharged Gas Thermostat (One for Each Circuit)
Cut Off ℃ 70 70 70 70 70 70 70 70 70
Cut In ℃ 100 100 100 100 100 100 100 100 100
CCP Calculagraph Non-Adjustable (One Timer for Each Compressor Motor)
Setting Time s 180 180 180 180 180 180 180 180 180
Star-Delta Starting s 5 5 5 5 5 5 5 5 5
From Start to Load-up s 30 30 30 30 30 30 30 30 30
Control Fuse
A 6 6 6 6 6 6 6 6 6
Circuit Capacity(220V/240V)
Fusible Plug (One for Each Circuit)
Melt Temperature ℃ 72 72 72 72 72 72 72 72 72
Refrigerant Frost-Proof Protection
Circuit Cut Off ℃ 2 2 2 2 2 2 2 2 2
Control of Exhaust Temperature
Cut Off ℃ 140 140 140 140 140 140 140 140 140
Overcurrent relay for motor of fan Manual Reset, Adjustable(One Three-Phase Set for Each Fan Motor)
380V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
415V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Discharged valve of pressure (One for Each Compressor)
Starting to Open MPa 3.13 3.13 3.13 3.13 3.13 3.13 3.13 3.13 3.13
RCU200AH RCU240AH RCU270AHY RCU300AH RCU330AHY RCU350AHY RCU360AHY RCU380AHY RCU400AHY
Model
YZ1 YZ1 Z1 YZ1 Z1 Z1 Z1 Z1 Z1
Cut Off MPa 2.98 2.98 2.98 2.98 2.98 2.98 2.98 2.98 2.98
Cut Off MPa 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
Cut Off ℃ 115 115 115 115 115 115 115 115 115
Cut In ℃ 93 93 93 93 93 93 93 93 93
380V 50Hz A 92 86 92/86 92 86/92 92 86 92/86 92
For
415V 50Hz A 84 79 84/79 84 79/84 84 79 84/79 84
Compressor
Capacity W 150 150 150 150 150 150 150 150 150
Cut Off ℃ 70 70 70 70 70 70 70 70 70
Cut In ℃ 100 100 100 100 100 100 100 100 100
Setting Time s 180 180 180 180 180 180 180 180 180
Control Fuse
A 6 6 6 6 6 6 6 6 6
Circuit Cut Off ℃ 2 2 2 2 2 2 2 2 2
Cut Off ℃ 140 140 140 140 140 140 140 140 140
380V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
415V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Note: The data marked with *1 is indicated for each compressor, as in a module the same compressors are
used, for these chillers greater than 240AHYZ1 including 240AHYZ1 which consist of two modules, when the
data for the compressor in the two modules are different, it is showed as data for one of the compressor in the
no.1 module / data for one of the compressor in the no.2 module.
34
MAINTENANCE
Table 3. Safety and Control Device Setting(R407C)

RCUG40A RCUG50A RCUG60A RCUG75A RCUG100A RCUG120A RCUG150A RCUG160A RCUG180A
Model
HYZ1 HYZ1 HYZ1 HYZ1 HYZ1 HYZ1 HYZ1 HYZ1 HYZ1
Cut Off MPa 2.98 2.98 2.98 2.98 2.98 2.98 2.98 2.98 2.98
Cut Off MPa 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
Cut Off ℃ 115 115 115 115 115 115 115 115 115
Cut In ℃ 93 93 93 93 93 93 93 93 93
380V 50Hz A 58 72 91 97 72 91 97 72 91
For
Compressor
415V 50Hz A 53 64 83 89 64 83 89 64 83
Capacity W 150 150 150 150 150 150 150 150 150
Cut Off ℃ 60 60 60 60 60 60 60 60 60
Cut In ℃ 90 90 90 90 90 90 90 90 90
Setting Time s 180 180 180 180 180 180 180 180 180
Control Fuse
A 6 6 6 6 6 6 6 6 6
Frost-Proof Protection
Refrigerant
Circuit Cut Off ℃ 2 2 2 2 2 2 2 2 2
Cut Off ℃ 140 140 140 140 140 140 140 140 140
380V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
415V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
RCUG200 RCUG240 RCUG270A RCUG300 RCUG330A RCUG350A RCUG360A RCUG380A RCUG400A
Model
AHYZ1 AHYZ1 HYZ1 AHYZ1 HYZ1 HYZ1 HYZ1 HYZ1 HYZ1
Cut Off MPa 2.98 2.98 2.98 2.98 2.98 2.98 2.98 2.98 2.98
Cut Off MPa 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
Cut Off ℃ 115 115 115 115 115 115 115 115 115
Cut In ℃ 93 93 93 93 93 93 93 93 93
380V 50Hz A 97 91 97\91 97 91\97 97 91 97\91 97
For
Compressor
415V 50Hz A 89 83 89\83 89 83\89 89 83 89\83 89
Capacity W 150 150 150 150 150 150 150 150 150
Cut Off ℃ 60 60 60 60 60 60 60 60 60
Cut In ℃ 90 90 90 90 90 90 90 90 90
Setting Time s 180 180 180 180 180 180 180 180 180
Control Fuse
A 6 6 6 6 6 6 6 6 6
Circuit Cut Off ℃ 2 2 2 2 2 2 2 2 2
Cut Off ℃ 140 140 140 140 140 140 140 140 140
380V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
415V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Note: The data marked with *1 is indicated for each compressor, as in a module the same compressors are
used, for these chillers greater than 240AHYZ1 including 240AHYZ1 which consist of two modules, when the
data for the compressor in the two modules are different, it is showed as data for one of the compressor in the
no.1 module / data for one of the compressor in the no.2 module.
35
MAINTENANCE
Normal Operating Pressure

Low pressure: the normal operation low pressure of the water chiller is indicated in the figure below: lower than 0.3 MPa
indicates an abnormal condition.

High pressure: the normal operation discharge pressure is indicated in the figure below: lower than 0.9 MPa or higher 2.8
MPa indicates an abnormal condition.
CAUTION
1. Periodical Maintenance
Please perform periodical maintenance according to the “INSTRUCTIONS” to maintain the unit in a good operation
condition.
2. Fire
If a fire accidentally occurs, please turn OFF the main switch and use an extinguisher for oil fire or electrical fire
3. Flammable Gas
Do not operate the unit near a flammable gases such lacquer, paint, oil, etc. to avoid a fire or an explosion.
4. Maintenance Panel and Electrical Box Covert
Turn OFF the main switch when service panel and electrical box cover are removed for setting the temperature. Do not
operate the unit without fixing panels.
5. Heated Pips
Do not touch the parts at the discharge gas side by hand, since the pips at the discharge side are heated by refrigerant
and the temperature may become higher than 100 degree.
6. Use
Do not utilize this unit for cooling or heating of drinking water or food. Please comply with local codes and regulation.
7. Failure
Please 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.
36
MAINTENANCE
CAUTION
1. Quick Response Over current Relay
This relay charged with mercury. Therefore, comply with local codes and regulations when this relay
is scrapped
2. Activation of safety device
In the case that one of safety devices is activated and the unit is stopped, remove the cause of the
stoppage and restart the unit. The protection devices are utilized to protect the unit from an abnormal
operation. Therefore, if one of the safety devices is activated, remove the cause by referring to the
“Troubleshooting” in the “INSTRUCTIONS”, or call the local agency.
3. Fuse
Utilize a fuse with a specified capacity. Do not use a steel wire or a copper wire instead of a fuse. If
an incorrect wire is utilized, a serious accident such as a fire will occur.
4. Safety Devices
Do not make a short-circuit at the protection line. If a short-circuit is made, a serious accident will
occur.
5. Protection devices setting
Do not change the setting of the safety devices, if changed, a serous accident will occur.
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.
37
MAINTENANCE
Table 4.Test Running and Maintenance Record.

MODEL: RCU(G) MFG.NO.
COMPRESSOR MFG.NO
CUSTOMERS NAME AND ADDRESS
DATE:
1. Is there adequate water flow for the water cooler?
2. Has all water piping been checked for leakage?
3. Have the chilled water pump, fan motor, motor been lubricated?
4. Has the unit been operated for at least twenty minutes?
5. Check chilled water temperature:
Inlet ℃ Outlet ℃
6. Check condenser Air Temperature:
Inlet ℃ Outlet ℃
7. Check suction line temperature and superheat:
Suction Line Temperature ℃ ℃ ℃ ℃ ℃ ℃
Superheat ℃ ℃ ℃ ℃ ℃ ℃
8. Check pressure
Discharge Pressure MPa MPa MPa MPa MPa MPa
℃
Suction Pressure MPa MPa MPa MPa MPa MPa
9. Check running current ℃
A A A A A MPa
℃
10. Has the unit been checked for refrigerant leakage?
11. Is the unit clean inside and outside?
12. Are all cabinet panels free from ratting?
13. Confirm that each phase for the compressor power source is correctly connected.
14. Is the rotation direction of fan motors correct?
38
MAINTENANCE
Table.5 Daily Operating Records
Model:
Date:
Weather
Time of Operation: Start. Stop: ( )
Ambient DB ℃
Temperature WB ℃
Room Temperature ℃
Compressor High MPa
pressure
Low MPa
pressure
Voltage V
Current A
Condenser Inlet Air Inlet(DB) ℃

Temperature Outlet(DB) ℃
Chilled Water Inlet ℃
Temperature outlet ℃
Current for Chilled Water Pump A
NOTES:
39
MAINTENANCE
Special Notes on Refrigerant, R407C

Please use tools and measuring instruments only for the new refrigerant which directly touch refrigerant.
○: Interchangeability is available with current R22
●: Only for new Refrigerant R407C (No interchangeability with R22).
Interchangeability Reason of No-interchangeability
Measuring Instruments and
with R22 and attention. Use
Tool
R407C (◎:Strictly required)
Flaring Tool ○ Flaring for Tubes
·The Flaring tools for R407C are Dimensional Control for
Extrusion
— applicable to R22 Extruded Portion of Tube
Adjustment Gauge
after Flaring
Pipe Bender ○ — Bending
Expanding Tool ○ — Expanding Tubes
Torque Wrench ○ — Connection of Flare Nut
Refrigerant Brazing Tool ○ *Perform correct brazing work. Brazing for Tubes
Pipe *Strict Control again Prevention from
Nitrogen Gas ○ Contamination(Blow nitrogen Oxidation during Brazing
during brazing.)
*Use a synthetic oil which is Applying oil to the Flared
equivalent to the oil used in the Surface
Lubrication Oil SW220HT refrigeration cycle.
*Synthetic oil absorbs moisture
quickly.
·Check Refrigerant cylinder Color Refrigerant Charging
Vacuum
Refrigerant ◎Liquid refrigerant charging is
Drying ●
Cylinder required regarding zeotoropic
.
refrigerant
◎The current ones are Vacuum Pumping
Refrigerant
Vacuum Pump ○ applicable.However,it is required
charge
to mount a vacuum pump adapter
which can prevent from reverse
flow when a vacuum pump
Adapter for
● stops,resulting in no reverse oil
Vacuum Pump
flow.
*No interchangeability is available Vacuum Pumping
Manifold Valve ● due to higher pressure when Vacuum
compared with R22. Holding,Refrigerant
◎Do not use current ones to the Charging and Check of
new refregerant.If used,mineral Pressures
Charging Hose ● oil will flow into the cycle and
cause sludges,resulting in
clogging or compressor failure.
Charging Cylinder — — —
Measuring Instrument for
Weight Scale ○ —
Refrigerant Charging
*The current gas leakage Gas Leakage Check
Refrigerant Gas
● detector(R22) is not applicable
Leakage Detector
due to different detecting method.
NOTE
*The component is different between models RCU-AHYZ1 and RCUG-AHYZ1. Please pay attention that it is unable to
use same one.
40
MAINTENANCE
8. Troubleshooting
The following table shows efficient checking procedures for trouble.
Fault Possible Cause Check/Corrective Action
1. See “Controller Adjustment” in the 2 module unit
Unit Does Not Operate Controller Setting is Incorrect case, especially checks “Unit Setting of PWB”.
Condenser Fan Not Current to Unit Is Shut Off 1. Reset the power supply line to the unit.
Operate Fuse for Operation Circuit is Blown Out or 1. Check for shorted components.
Faulty Contact 2. Check for Loose connection. Tighten or
replace, if necessary.
Contactor Holding Coil is Burned Out or 1. Find the cause ,and repair or replace
Faulty Contact
1.Remove the cause ,and reset the overcurrent
Tripped Overcurrent Relay relay
Low Voltage 1. Check the voltage of unit rating.
1. Check the Motor and Terminals.
Shorted Motor or Terminals Repair or replace, if necessary.
Compressor Does Not Condenser Fan Is Not Operating. 1. Remove all the causes of inoperative fan.
Operate Interlock Circuit for Chilled Water Pump Is 1. Check the Pump contactor. Repair or replace, if
Open necessary.
2. Check for the faulty pump.
1. Remove the causes, and reset the “ON” button.
Electrical Protective Devices Are Tripped See the following cause.
Incorrect Wiring Connection for Compressor 1. Interchange two of three terminals R,S and T at
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.
Compressor Stops on Excessively High Discharge Pressure and 1.See “High Discharge Pressure” and “High
Overcurrent Relay Suction Pressure Suction Pressure”
High or Low Voltage, Single-Phase or Phase 1. Check the power supply line and contactors.
Imbalance Repair, if necessary.
Loose Connection 1. Tighten the loose electrical connection or
repair, if necessary.
1. Check the Compressor motor.
Faulty Compressor Motor Repair or replace, if necessary.
Faulty Overcurrent Relay 1.Replace it, if necessary

Compressors Stops on Excessively Low Chilled Water Outlet 1. Check for excessively low setting of the chilled
Freeze Protection Temperature water setting knob.
Thermostat Defective Thermistor 1. Check for malfunction of the thermistor.
Replace, if necessary.
Shortage of Chilled Water Flow 1. Check the rotation of the pump.
Air in Water Circuit 1. Purge air.
Compressor Stops on High or Low Voltage, Single-Phase or Phase 1. Check the power supply line and contactors.
Internal Thermostat or Imbalance Repair, if necessary.
1.Check for refrigerant leakage and faulty
Discharge Gas Excessive Superheat solenoid valve for liquid bypass
Thermostat 1. Check the contact of the internal thermostat
Defective Element during the cold condition.
Excessive High Discharge Pressure and 1.See “High Discharge Pressure” and “Low
Low Suction Pressure. Suction Pressure”
Insufficient Cooling High Discharge Pressure or Low Suction 1.See “High Discharge Pressure” and “low
Pressure Suction Pressure”
Improper Thermostat Setting 1. Readjust the setting.
Defective Unload Mechanism 1. Adjust unload mechanism. Repair or replace
unloaded parts, if necessary.
Slugging Due to Liquid Flooding Back to 1. Check the superheat of suction gas. Keep the
Noise Compressor Compressor superheat in proper range.
Worn Parts 1. Check for the sound of internal parts. Replace
the compressor, if necessary.
41
MAINTENANCE
Fault Possible Cause Check/Corrective Action

Miscellaneous Noise Loose Fixed Screw 1. Tighten the screws of all parts.
Weak Installation Foundation 1. See the installation guide
Unloader Does Not Trouble with the Thermistor 2. Adjust the setting temperature.
Function 3. Replace the thermistor.
Trouble with the Solenoid Valve 1. Check the coil in the solenoid valve.
2. Check oil passage for clogging.
Worn Unloader Mechanism 1. Check the unloader system parts in the
compressor.
High Discharge High Condenser Air Temperature or 1. Check the tan operation.
Pressure Insufficient Air Flow Through the Condenser 2. Check for coil clogging; clean, if necessary.
Defective Check Valve or Partially Closed 1. Check the valves and capillary tubes. Replace,
Liquid Line Stop Valve. if necessary.
Overcharged Refrigerant 1. Purge 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”.
Low Discharge Extremely Cold Condenser Air 1. Check the ambient temperature.
Pressure Insufficient Refrigerant Charge 1. Add refrigerant.
Leakage from the Compressor Discharge 1. Replace the valve. Replace the compressor, if
Valve required
Suction Pressure is Lower than Standard 1. See “Low Suction Pressure”.
High Suction Pressure High Inlet Temperature of Chilled Water 1. Check the insulation of the piping
2. Check the insulation specification.
Excessive Opening of Expansion Valve 1. Readjust the opening, or replace, if defective.
Low Suction Pressure Low Inlet Temperature of Chilled Water 1. Check the insulation specification.
Improperly Adjusted Expansion Valve or 1.Adjust for correct superheat. Repair or replace,
Faulty Valve if necessary
Insufficient Refrigerant Charge 1. Add refrigerant.
Excessive Oil in the Water Cooler 1.Purge oil
Scales on Water Cooler 1.Clean the cooler
42
Specifications in this catalogue are subject to change without notice in order that HITACHI may bring the latest innovations to their customers.
Z0011542-2008-A

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HITACHI AIR-COOLED WATER CHILLERS

NOTE : Useful information for operation and /or maintenance.

Rigging Holes(4-φ50) Daily Checking

2．Check the unit amperage.

2．Check the unit amperage.

2．When the orange lamp is activated, any one of the safety

No.1 Water Outlet No.1 Water Inlet No.2 Water Outlet

2．When the orange lamp is activated, any one of the safety

Air Inlet Air Inlet devices may be functioning.

Wiring Hole for

Placing the Unit

Model Maintain Space (mm) Air Inlet Space (mm)

Maximum Foundation Gradient

Center of Gravity Operation

Weight Destribution (kg)

Weight Destribution (kg)

Recommended Concrete Curb

☆Vibration Proof Rubber Mat

Concrete Mortar Cement

For Models: RCU(G)100、120、150AHYZ1

Drain Ditch 10-Vibration Proof Rubber Mat

☆Vibration Proof Rubber Mat

Drain Ditch Concrete Mortar Cement

Fig.5-1 Recommended Concrete Curbs

For Models: RCU(G)160、180、200AHYZ1

Compressor Side Steel Plate（1mm) : Field Supply

Drain Ditch Concrete Mortar Cement

For Models: RCU(G)240、270、300AHYZ1

10-Vibration Proof 10-Vibration Proof

Foundation Bolt Foundation Bolt

［Compressor Side］ ［Compressor Side］

Drain Ditch Concrete Mortar Cement

☆Vibration Proof Rubber Mat

Fig.5-2 Recommended Concrete Curbs

For Models: RCU(G)330、350AHYZ1

14-Vibration Proof 10-Vibration Proof

Foundation Bolt Foundation Bolt

［Compressor Side］ ［Compressor Side］

Drain Ditch Concrete Mortar Cement

For Models: RCU(G)360、380、400AHYZ1

14-Vibration Proof 14-Vibration Proof

Foundation Bolt Foundation Bolt

Compressor Side Compressor Side

Drain Ditch Concrete Mortar Cement

☆Vibration Proof Rubber Mat

Fig.5-3 Recommended Concrete Curbs

greater than 60℃

Fig.6-1 Transportation by Rigging

2) Transportation by Roller 3) Declining the Unit during Transportation

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

Main Power Switch

Earth Terminal *CMP

3～Mp, 380,415V/50Hz 1 2 42 43 3～Mp, 380V,415V / 50Hz 42 43

Main Power Switch Main Power Switch

Earth Terminal Earth Terminal

Control Circuit Wiring

Indication Lamp Power Supply

［Compressor Side］［Compressor Side］

［Compressor Side］［Compressor Side］