Technical Catalog II-Installation, Operation and Maintenance Manual

Type
R134a
RCUF45AZPY1 RCUF200AZPY1
-Technical Catalog II- RCUF60AZPY1 RCUF270AZPY1
Installation, Operation and RCUF100AZPY1 RCUF320AZPY1
Maintenance Manual RCUF120AZPY1 RCUF360AZPY1
Hitachi Single and Air-cooled Water Chilling Unit AZPY1 Series
-Screw Type-
Cautions
Before installing the air-cooled water chilling unit, please
read this manual carefully, and maintain it properly for
future reference.
Important Notice
●Hitachi continuously improves product design and performance, and you may not be notified if any change is
made to the specifications.
●Hitachi doesn't foresee any circumstances which may result in potential hazards.
●This manual is prohibited from reproduction without prior consent from Hitachi.
●Signaling statements (DANGER, WARNING and CAUTION) are intended for authentication of hazard
classification, and the explanations to the hazards in relation to various signaling statements are as follows:
DANGER: Direct hazards possibly lead to severe personal injury or death.
WARNING: Hazards or insecure operations may lead to severe personal injury or death.
Hazards or insecure operations may lead to minor personal injury or product or

CAUTION: property damage.
NOTICE: Data are helpful to use and maintenance.
• If required, please contact your contractor or the distributor of Hitachi.
• The manual provides the common descriptions and data for single and air-cooled cooling water chilling units
of the other types.
• The single and air-cooled water chilling unit is designed on the basis of the following temperature, to which the
unit's operation is subject to:
Unit run range
When covered by shadows, the

unit may activate protective
actions according to the variation
Environmental temperature DB (ºC)
of operating conditions and can't

output 100%.
Unit operating range
Outlet water temperature (ºC)

• This manual is a permanent accessory to the single and air-cooled water chilling unit and shall be retained
inside the unit.
• The below Table states the energy efficiency level for the unit described in the manual.
● Model Energy efficiency level Model Energy efficiency level

RCUF45AZPY1 2 RCUF200AZPY1 2
*According to national standards: GB19577-2015 is the basis for the determination of the energy efficiency level.
Contents
Use Instruction
1. Preparations ..................................................................................................................................... 1
Preliminary check ............................................................................................................................. 1
Placement of the unit ........................................................................................................................ 1
Gravity center of the unit ................................................................................................................... 3
Weight balancing .............................................................................................................................. 3
Noise level ........................................................................................................................................ 4
Recommended concrete diagram ..................................................................................................... 5
Transport ........................................................................................................................................... 9
2. Installation Work .............................................................................................................................. 10
Wire connection ................................................................................................................................ 10
Water pipe connection ...................................................................................................................... 13
Minimum water volume in the system ............................................................................................... 13
Water quality control ......................................................................................................................... 15
Check after installation ...................................................................................................................... 16
3. Test Run ........................................................................................................................................... 17
Preparations ..................................................................................................................................... 17
Test run ............................................................................................................................................. 17
Instruction after test run .................................................................................................................... 17
4. Controller Settings .......................................................................................................................... 18
5. Control System ................................................................................................................................ 21
6. Maintenance and Servicing ............................................................................................................ 25
Component ....................................................................................................................................... 25
Lubricating ........................................................................................................................................ 25
Stagnancy ......................................................................................................................................... 25
Cleaning methods ............................................................................................................................. 25
Prolonged shutdown in winter ............................................................................................................. 27
Initial startup after shutdown ............................................................................................................. 27
Replacement of parts ........................................................................................................................ 27
Paint replenishment of the unit enclosure ......................................................................................... 27
Refrigerant circulation ....................................................................................................................... 27
Removal of the compressor .............................................................................................................. 29
Settings of the safety and control device .......................................................................................... 30
Normal operating pressure ............................................................................................................... 31
Special precautions of R134a refrigerant .......................................................................................... 35
7. Troubleshooting ............................................................................................................................... 36
Operation instruction Hitachi single and air-cooled water chilling unit
Type: RCUF45/50AZPY1
Indicator:
1. Red indicator states normal operating state.
2. When the orange indicator is on, it states that some
protective device may actuate.
If this situation is found, please contact your
maintenance personnel.
Daily check:
1. Check if there is any abnormal noise and vibration.
2. Check the current of the unit.
3. Check the operating pressure.
Trouble removal:
The main engine can't initiate
1. Is the power supply connected?
2. Is the fuse burnt out?
3. Is the chilling water running?
4. Is the temperature controller responsive to refrigeration
(heating)?
Insufficient refrigeration (heating) capacity
1. Check if the air supply to the air heat exchanger is
sufficient.
2. Check if the settings of the temperature controller are
correct.
3. Check if the operating pressure of the main engine is
correct.
4. Check if the water-side heat exchanger's water volume
is sufficient.
How to start the main engine (remote control switch): Maintenance work
1. Open the water inlet and outlet valves. 1. Remove objects impeding air flow at the side of the heat
2. Switch on the power switch, after control switches exchanger, and clean the air-side heat exchanger.
2. Clean the main engine's surface.
are "OFF" and the "field/remote" switches on the
3. Rinse the pipeline of the water-side heat exchanger.
PCB are at "remote" position. How to shut down the main (This work should be conducted by professional
3. Verify if phases R, S and T are correctly wired, and engine: personnel)
the correct wiring can be detected by a phase- 1. Press "OFF" of operating switch.
sequence indicator. If the wiring is incorrect, the Cautions:
phase-sequence reversal protection device will not In order to make the oil heater
allow the compressor to start. Switch off the power actuate, please don't cut off the
switch, and exchange any terminal of two phases main power switch.
out of the main power supply's three phases.
4. Set the changeover switch to "refrigeration".
5. Start the refrigeration (heating) water pump.
6. Press "ON".
Operation instruction Hitachi single and air-cooled water chilling unit
Type: RCUF60AZPY1
Indicator:
2. When the orange indicator is on, it states that some
protective device may actuate.
Daily check:
Trouble removal:
4. Is the temperature controller responsive to refrigeration
(heating)?
sufficient.
2. Check if the settings of the temperature controller are
correct.
3. Check if the operating pressure of the main engine is
How to start the main engine (remote control switch): correct.
1. Open the water inlet and outlet valves. 4. Check if the water-side heat exchanger's water volume is
2. Switch on the power switch, after control switches are sufficient.
"OFF" and the "field/remote" switches on the PCB are Maintenance work
How to shut down the main 1. Remove objects impeding air flow at the side of the heat
at "remote" position.
engine: exchanger, and clean the air-side heat exchanger.
3. Verify if phases R, S and T are correctly wired, and 2. Clean the main engine's surface.
1. Press "OFF" of operating
the correct wiring can be detected by a phase- 3. Rinse the pipeline of the water-side heat exchanger. (This
switch.
sequence indicator. If the wiring is incorrect, the work should be conducted by professional personnel)
Cautions:
phase-sequence reversal protection device will not
In order to make the oil heater
allow the compressor to start. Switch off the power
actuate, please don't cut off the
switch, and exchange any terminal of two phases out
main power switch.
of the main power supply's three phases.
6. Press "ON".
Operation instruction Hitachi single and air-cooled water chilling
unit
Type: RCUF90/100AZPY1
Indicator:
2. When the orange indicator is on, it states that
some protective device may actuate.
Daily check:
Trouble removal:
4. Is the temperature controller responsive to
refrigeration (heating)?
sufficient.
2. Check if the settings of the temperature controller
are correct.
3. Check if the operating pressure of the main engine
is correct.
How to start the main engine (remote control switch): 4. Check if the water-side heat exchanger's water
1. Open the water inlet and outlet valves. volume is sufficient.
Maintenance work
2. Switch on the power switch, after control switches are 1. Remove objects impeding air flow at the side of
"OFF" and the "field/remote" switches on the PCB are the heat exchanger, and clean the air-side heat
at "remote" position. exchanger.
How to shut down the main engine:
3. Verify if phases R, S and T are correctly wired, and 2. Clean the main engine's surface.
1. Press "OFF" of operating switch. 3. Rinse the pipeline of the water-side heat
the correct wiring can be detected by a phase-
Cautions: exchanger. (This work should be conducted by
sequence indicator. If the wiring is incorrect, the
In order to make the oil heater actuate, professional personnel)
phase-sequence reversal protection device will not
please don't cut off the main power
allow the compressor to start. Switch off the power
switch.
switch, and exchange any terminal of two phases out
of the main power supply's three phases.
6. Press "ON".
unit
Type: RCUF120AZPY1
Indicator:
2. When the orange indicator is on, it states
that some protective device may actuate.
Daily check:
1. Check if there is any abnormal noise and
vibration.
Trouble removal:
How to start the main engine (remote control switch): Insufficient refrigeration (heating) capacity
1. Open the water inlet and outlet valves. 1. Check if the air supply to the air heat
2. Switch on the power switch, after control switches are exchanger is sufficient.
"OFF" and the "field/remote" switches on the PCB are 2. Check if the settings of the temperature
at "remote" position. How to shut down the main controller are correct.
3. Verify if phases R, S and T are correctly wired, and the engine: 3. Check if the operating pressure of the main
correct wiring can be detected by a phase-sequence 1. Press "OFF" of operating switch. engine is correct.
indicator. If the wiring is incorrect, the phase-sequence Cautions: 4. Check if the water-side heat exchanger's
reversal protection device will not allow the compressor In order to make the oil heater water volume is sufficient.
to start. Switch off the power switch, and exchange any actuate, please don't cut off the main Maintenance work
terminal of two phases out of the main power supply's power switch. 1. Remove objects impeding air flow at the side
three phases. of the heat exchanger, and clean the air-side
4. Set the changeover switch to "refrigeration". heat exchanger.
5. Start the refrigeration (heating) water pump. 2. Clean the main engine's surface.
6. Press "ON". 3. Rinse the pipeline of the water-side heat
exchanger. (This work should be conducted
by professional personnel)
unit
Type: RCUF135/150 AZPY1
Indicator:
Daily check:
vibration.
Trouble removal:
at "remote" position. controller are correct.
3. Verify if phases R, S and T are correctly wired, and 3. Check if the operating pressure of the main
1. Press "OFF" of operating switch.
the correct wiring can be detected by a phase- engine is correct.
Cautions:
sequence indicator. If the wiring is incorrect, the 4. Check if the water-side heat exchanger's
In order to make the oil heater actuate,
phase-sequence reversal protection device will not water volume is sufficient.
allow the compressor to start. Switch off the power Maintenance work
switch.
switch, and exchange any terminal of two phases out 1. Remove objects impeding air flow at the side
of the main power supply's three phases. of the heat exchanger, and clean the air-side
exchanger. (This work should be conducted by
professional personnel)
unit
Indicator:

Daily check:
vibration.
Trouble removal:
Cautions:
switch.
unit
Type: RCUF240 AZPY1
Indicator:
Daily check:
vibration.
Trouble removal:
Cautions:
switch.
unit
Indicator:
Daily check:
vibration.
Trouble removal:
Cautions:
switch.
unit
Type: RCUF320 AZPY1
Indicator:
Daily check:
vibration.
Trouble removal:
Cautions:
switch.
unit
Type: RCUF360 AZPY1
Indicator:
Daily check:
vibration.
Trouble removal:
at "remote" position. How to shut down the main controller are correct.
3. Verify if phases R, S and T are correctly wired, and engine: 3. Check if the operating pressure of the main
the correct wiring can be detected by a phase- 1. Press "OFF" of operating switch. engine is correct.
sequence indicator. If the wiring is incorrect, the Cautions: 4. Check if the water-side heat exchanger's
phase-sequence reversal protection device will not In order to make the oil heater water volume is sufficient.
allow the compressor to start. Switch off the power actuate, please don't cut off the main Maintenance work
switch, and exchange any terminal of two phases out power switch. 1. Remove objects impeding air flow at the side
unit
Type: RCUF405/420/450 AZPY1
Indicator:
Daily check:
vibration.
Trouble removal:
Cautions:
switch.
Preparations
1. Preparations
Preliminary check
Required data -- review construction data in relation to the installation position
Installation position -- when determining the installation position of the unit, please make sure to provide
convenience for the installation of water pipes and wiring, and avoid passage of massive water in proximity.
Installation space -- Figure 2 displays the space required for the maintenance of the unit. Check if there
is any obstacle that impedes the air flow of the heat exchanger at the air side.
Base -- check and ensure the base is flat and of sufficient intensity, and calculate the base's maximum
inclination (Figure 1) and the unit's weight balancing (Figure 4). In order to acquire the appropriate ground
clearance to mount the unit on the ground, the unit is fixed to a steel frame or a concrete base. (See Figure
5.1 and 5.2) Besides, when it's mounted onto a base, space constructed by cement and sand or concrete
should be provided around the air-side heat exchanger of the unit to avoid obstruction of air flow due to
grass or other plants.
Unit -- check if the unit is damaged during transport. If it's suspicious that the unit may be damaged due
to neglect of the transport company during handling, you should demand compensation for damage from
the transport company.
Delivery -- make certain that the transport route to the installation position is sufficient for access by the
packing case of the unit. (Refer to Technical Data 1 "General Data of the Unit")
Placement of the unit
DANGER
• If the refrigerant is found to be leaked, please shut down the unit and contact your contractor or the
maintenance company. Do not approach open fire to the refrigerant. If open fire gets close to the
refrigerant, the refrigerant will turn into hazardous carbonyl chloride compounds.
WARNING
• The unit uses flame-retardant and non-toxic R134a refrigerant. Since the refrigerant is heavier than
air, if the refrigerant leaks, the ground will be covered by the refrigerant, therefore please keep a well
ventilated environment to prevent suffocation.
CAUTION
• Check the valves and ensure they are open correctly. If the valves are not open, the compressor will
be severely damaged due to the abnormal high pressure.
Tools and instruments -- pliers, adjustable wrenches, and tools for transporting and mounting the unit.
Transport -- don't open the packing case until the unit is delivered to the installation position.
-- Take appropriate means to place the unit on the base, giving full consideration to the feasibility of
the mounting steps.
Remove the packing case -- remove as per the instructions on the packing case.
Maximum base inclination. The unit should be installed vertically in the below Figure 1 within the
indicated maximum inclination

Preparations
Figure 1 Maximum inclination

1
Figure 2 Running space h1≤h2

NOTICE
1. The height of the wall shall not exceed the unit's height.
2. If the unit should be enclosed by walls, the air ventilation will not be in a good condition, so please
consult Hitachi for the matters in relation to installation space.
Running space of all unit series:
Maintenance space (mm) Air inlet space (mm)
Type
A B C D E F G
RCUF45/50AZPY1 2,390 1,200 100 900 1,200 2,000 1,200
RCUF60AZPY1 3,300 1,200 100 900 1,200 2,000 1,200
RCUF90AZPY1 4,490 1,200 100 900 1,200 2,000 1,200
RCUF100AZPY1 4,490 1,200 100 900 1,200 2,000 1,200
RCUF120AZPY1 6,310 1,200 100 900 1,200 2,000 1,200
RCUF135AZPY1 6,590 1,200 100 900 1,200 2,000 1,200
RCUF150AZPY1 6,590 1,200 100 900 1,200 2,000 1,200
RCUF180AZPY1 9,080 (minimum) 1,200 900 900 1,200 2,000 1,200

2
Preparations
Gravity center of the unit

Gravity center Operating Gravity center Operating
Type Type
weight weight
X Y X Y
RCUF45AZPY1 1348 991 1700 RCUF300AZPY1-2 3325 865 4950 Configuration
RCUF50AZPY1 1348 990 1800 RCUF320AZPY1-1 2277 915 3300
side
RCUF180AZPY1-1 2269 912 3100 RCUF405AZPY1-2 3320 860 4750
RCUF270AZPY1-1 3320 860 4750 RCUF450AZPY1-2 3325 865 4950 Figure 3 Gravity
center
RCUF300AZPY1-1 3325 865 4950
Configuration
Weight balancing side
Weight distribution (kg)

Type
1 2 3 4
RCUF45AZPY1 394 447 456 403
RCUF50AZPY1 417 474 483 426
RCUF60AZPY1 509 534 541 516

Type
1 2 3 4 5 6
RCUF90AZPY1 529 532 535 504 501 499
RCUF100AZPY1 562 566 569 538 534 531 Configuration
RCUF120AZPY1 669 672 675 648 645 642 side
RCUF180AZPY1-1 529 532 535 504 501 499
RCUF180AZPY1-2 529 532 535 504 501 499
RCUF200AZPY1-1 562 566 569 538 534 531
RCUF200AZPY1-2 562 566 569 538 534 531
RCUF240AZPY1-1 669 672 675 648 645 642
RCUF240AZPY1-2 669 672 675 648 645 642
RCUF320AZPY1-1 562 566 569 538 534 531
RCUF320AZPY1-2 562 566 569 538 534 531
RCUF320AZPY1-3 669 672 675 648 645 642
RCUF360AZPY1-1 669 672 675 648 645 642
RCUF360AZPY1-2 669 672 675 648 645 642
RCUF360AZPY1-3 669 672 675 648 645 642 Configuration

side
Type
1 2 3 4 5 6 7 8
RCUF135AZPY1 625 621 634 630 563 567 554 558
RCUF150AZPY1 650 644 661 655 588 594 577 583
RCUF270AZPY1-1 625 621 634 630 563 567 554 558
RCUF270AZPY1-2 625 621 634 630 563 567 554 558
RCUF300AZPY1-1 650 644 661 655 588 594 577 583
RCUF300AZPY1-2 650 644 661 655 588 594 577 583
RCUF405AZPY1-1 625 621 634 630 563 567 554 558
RCUF405AZPY1-2 625 621 634 630 563 567 554 558
RCUF405AZPY1-3 625 621 634 630 563 567 554 558
RCUF420AZPY1-1 650 644 661 655 588 594 577 583
RCUF420AZPY1-2 625 621 634 630 563 567 554 558
RCUF420AZPY1-3 625 621 634 630 563 567 554 558
RCUF450AZPY1-1 650 644 661 655 588 594 577 583
RCUF450AZPY1-2 650 644 661 655 588 594 577 583
RCUF450AZPY1-3 650 644 661 655 588 594 577 583
3

Preparations
Noise level
Type Noise level (dB) Type Noise level (dB)
RCUF135AZPY1 83 RCUF405AZPY1 87.5
Instruction:
According to the rule of JB/T4330 Noise Measurement of Refrigeration and Air-conditioning Equipment,
the noise level of the unit operating in standard refrigerating conditions shall be tested under the half-
anechoic chamber condition.
Because of the influence of the actual state of installation, the difference of operation and the effect of
ambient noise and echo, the actual noise level may be higher than the standard level (according to the
different installation condition, the noise level may higher than around 4-6dB).
The unit shall not be installed in a position where noise and exhaust are not allowed. The unit shall be
installed in a noise-sensitive position, with pre-design and installation of field noise insulation facilities, so
that the operating noise generated by the unit and influenced on the surrounding is within a controllable
range.
4

Preparations
Recommended concrete diagram
CAUTION
• In the event that the unit is installed on the ground, the weight of the concrete shall be 1.5 to 2 times
of the unit's weight.
Unit type RCUF45/50AZPY1
Figure 2 Schematic diagram of strip foundation
Figure 1 Schematic diagram of dual rectangular foundation
Concrete
Concrete
Drainage tank Cement mortar Drainage tank

Cement mortar
Water Drainage tank Drainage tank Drainage tank

8. Anti‐vibration rubber pad
pipe side Water pipe side
Detail drawing of foundation
installation (not to scale)
Foundation bolt
4-M20x300
Foundation bolt
Nut
Gasket
Front side
Back side
Front side
4. Anti-vibration
4. Anti‐vibration Back side Lining
rubber pad
rubber pad * Anti-vibration rubber pad
Steel plate (1 mm)
*Manufacturer's supplies
Compressor side Compressor side
Unit type RCUF60AZPY1

100
250
48
802
200 200
60 60
2204
1904
300
300
100
1102
100
50
250
100
100
190 1405 1405

100 3190 100
60
240
280
5

Preparations
6

Preparations
7

Preparations
60
140
8

Preparations
9

Preparations
Unit type RCUF405/420/450AZPY1
Figure 5.1 Recommended concrete diagram
8

Preparations
Transport
1) Lifting
Use lifting metal rope and stay bar supplied by the manufacturer, to keep the unit surface being scratched
by the rope (see Figure 6-1) The strength borne by the lifting rope shall be 3 times larger than the unit
weight. Check and ensure whether the lifting hook tightly fastens the unit. The lifting angle shall be larger
than 60°. As shown in the Figure:
DANGER
When lifting, please don't stand under the unit.
CAUTION
Add cloth between ropes and units to prevent damage of units.
Figure 6-1 Lifting transport

2) Rolling transport 3) Unit inclination during transport
When the unit rolling, place 7 same size roll bars
DANGER
under the chassis. Each roll bar must support
two outer frames of the unit (see Figure 3 for the During transport, the unit inclination shall not
gravity center of units) and be fit for balances of exceed 15°, as shown in Figure 6-3.
the unit. If the inclination exceeds 15°, the unit may
overturn.
Figure 6-2 Rolling transport Figure 6-3 Unit inclination

9

Installation Work
2. Installation Work
Wire connection
Tools and apparatus -- a set of wiring tools and multi-meter (clamp meter).
Program check
WARNING
• Ensure that electrical parts (such as the main power switch, fuse, wire, wire duct joint, wire holder, etc.) used in the
construction site are selected according to the "Electrical Data" of Technical Data 1 and comply with local regulations.
• Before completion of the installation procedure of the unit, turn on the power supply to "Off" to prevent accidents.
• Check and ensure that the unit is correctly earthed. The earthing wire can prevent electric shock. It's recommended
to use leakage protector.
Main power supply wiring -- first confirm that no current passes through the site on which electrical elements are installed.
1. Install the switching control box of main power switches in an appropriate site.
2. Install the wire rubber mat on the main power supply wiring hole.
3. Connect the main power line, power supply neutral line and earthing wire to the unit's electrical cabinet through the
power wire connection hole, and appropriately connect the power wire to the wire holder and earth wire stud.
4. Securely connect the power wire to the terminal bolts of R, S, T and MP (see Figure 7).
5. Wire the main power line to the site supply electromagnetic switch.
6. The main power supply shall be in a site not prone to "OFF", as the oil heater needs to be operated even if the unit is
stopped.
Cautions:
RCUF180AZPY1, RCUF200AZPY1, RCUF240AZPY1, RCUF270AZPY1, RCUF300AZPY1, RCUF320AZPY1,
RCUF360AZPY1, RCUF405AZPY1, RCUF420AZPY1, and RCUF450AZPY1 are comprised of No.1 (main) unit and No.2/3
(subsidiary) unit. The main power supply of each unit is required to be connected in the field (No.1 and No.2/3).
Control wiring - interlocking wire control between the unit and pump AC contactor, as shown in Figure 7 or the wiring
nameplate, the main power supply shall be connected to MP.
RCUF45/50/60AZY1 Single cycle:
3
PWBc
*CSP
Y52P1
Pump Power Supply
4
*ORP
*CMP
Pump Power Wiring

*BSR1 Button switch (for startup) (if required)
*BSR2 Button switch (for shutdown)
*CMP AC contactor (for pump)
*ORP Overcurrent relay (for pump)
*CSCHR Switch (for heating/refrigeration changeover) (only for
heat pump unit)
*CSP Switch (for pump operation changeover)
*PLR1 Indicator (unit operation)
*PLR2 Indicator (pump operation)
*PLR3 Indicator (refrigeration operation)
*PLR4 Indicator (heating operation) (only for heat pump unit)
*PLO1,2,3 Indicator (alarm)
*PLO4,5,6 Indicator (defrosting) (only for heat pump unit)
Figure 7-1 Field wiring
10

Installation Work

RCUF90/100/120/200/220/240/320/360AZPY1 Dual cycle:
3
PWBc
*CSP
Y52P1
Pump Power Supply

4
*ORP
*CMP
*BSR1 Button switch (for startup)
*BSR2 Button switch (for shutdown)
*ORP Overcurrent relay (for pump) Pump Power Wiring
*CSCHR Switch (for heating/refrigeration changeover) (if required)
(only for heat pump unit)
*CSP Switch (for pump operation changeover)
*PLR4 Indicator (heating operation) (only for heat pump
unit)
Figure 7-2 Field wiring
RCUF135/150/270/300/405/420/450AZPY1 Ternary cycle:
3
PWBc
*CSP
Y52P1
Pump Power Supply
4
*ORP
*BSR1 Button switch (for startup)

*BSR2 Button switch (for shutdown) *CMP
*ORP Overcurrent relay (for pump)
*CSCHR Switch (for heating/refrigeration changeover) (only
for heat pump unit)
Pump Power Wiring
*CSP Switch (for pump operation changeover) (if required)
*PLR4 Indicator (heating operation) (only for heat pump
unit)
Figure 7-3 Field wiring 11

Installation Work
Cautions:
1. If using the long distance indication shown in the above diagram, please use a shielded wire to
avoid indication errors due to interferences.
2. The remote monitor's contact capacity is 240V, 5A.
12

Installation Work
Water pipe connection

When you are about to connect water pipes, please follow the following instructions:
1. Connectors or flanges must be used when water pipes are connected in proximity to the unit, to be removed easily
when required.
2. Flexible hoses shall be connected at the water pipes' inlets and outlets to reduce vibration.
3. Water pipe shall be properly supported, to avoid applying weight directly to the unit (also avoid applying load to the
heat recovery plate). Water pipe shall be properly supported, to avoid applying weight directly to the unit (also avoid
applying load to the heat recovery plate).
4. If permitted, valves shall be provided for the water pipes to effectively control water flow and reduce flow loss.
5. Check if there is any leakage in the system for internal and external through completely opening the inlet and outlet
valves of chilled water. And install valves for the piping of the inlet and outlet water. Please install a cleaning port for
the inlet water pipe and a discharge for the outlet water pipe. The handles for the ports shall be removed to prevent
accidental opening during normal operation. If the ports are opened accidentally during unit operation, it may result in
accidents due to complete water drainage.
6. Sufficient heat insulation materials shall be sheathed on the chilled water pipes to keep the temperature and prevent
condensation on the water pipes.
7. After connection of water pipes, please use operating pumps to circulate the chilled water in the chilled water pipes
rather than go through the water-side heat exchanger of the water chilling unit, to remove particles and impurities in
the water system and clean the water filters.
8. A filter with 10 meshes shall be installed at the water inlet of the evaporator.
9. Flexible hoses and 20-mesh filters shall be installed at the inlet and outlet of the heat recovery plate's water exchange
pipes.
CAUTION
• With the low air temperature outdoors in winter, when the unit stops operation, the water in water pumps and pipes may
be frozen, resulting in damage to the unit and water pipes. In order to prevent freezing, the water pumps can keep
running when the unit stops operation, or water in the water pipes shall be completed discharged. If the water discharge
is not feasible, anti-freezing reagents such as ethylene glycol or propylene glycol may be used.
• Please do not use salts for anti-freezing, because they are highly corrosive and will create damage to the unit.
• If multiple units are connected via one water pipe system, the water system must be designed carefully to equalize
water flow in and to each unit (as shown in the below Figure). Disequilibrium of water flow distribution may lead to many
hazards, such as water freezing in the heat exchanger, etc.
Chiller
Water Pump
Service Side
Minimum water volume in the system

In order to ensure continuous refrigeration of the unit in at least 5 min without disruption, the internal chilled
water flow of the water pipe system shall be larger than the minimum flow, as described below:
Chilled water flow
Type Maximum water flow Minimum water flow Type Maximum water flow Minimum water flow
(m3/h) (m3/h) (m3/h) (m3/h)
RCUF45AZPY1 39.4 13.8 RCUF200AZPY1 87.6/87.6 30.6/30.6
RCUF50AZPY1 43.8 15.3 RCUF240AZPY1 105.8/105.8 37/37
RCUF100AZPY1 87.6 30.6 RCUF320AZPY1 87.6/87.6/105.8 30.6/30.6/37
RCUF120AZPY1 105.8 37 RCUF360AZPY1 105.8/105.8/105.8 37/37/37
RCUF135AZPY1 118.1 41.3 RCUF405AZPY1 118.1/118.1/118.1 41.3/41.3/41.3
RCUF150AZPY1 131.4 45.9 RCUF420AZPY1 131.4/118.1/118.1 45.9/41.3/41.3
RCUF180AZPY1 78.7/78.7 27.5/27.5 RCUF450AZPY1 131.4/131.4/131.4 45.9/45.9/45.9
13

Installation Work
Water-side pressure loss diagram

Water-side heat exchanger pressure loss diagram
1 RCUF45AZPY1
RCUF50AZPY1
2 RCUF60AZPY1
3 RCUF90AZPY1
300
Water-side pressure loss (kPa)
RCUF100AZPY1
RCUF180AZPY1-1
200 RCUF180AZPY1-2
RCUF200AZPY1-1
2 4 5 RCUF200AZPY1-2
3
1 RCUF320AZPY1-1
100 RCUF320AZPY1-2
4 RCUF120AZPY1
RCUF240AZPY1-1
RCUF240AZPY1-2
RCUF320AZPY1-3
RCUF360AZPY1-1
RCUF360AZPY1-2
RCUF360AZPY1-3
5 RCUF135AZPY1
RCUF150AZPY1
RCUF270AZPY1-1
RCUF270AZPY1-2
RCUF300AZPY1-1
RCUF300AZPY1-2
10 RCUF405AZPY1-1
RCUF405AZPY1-2
10 100 200 RCUF405AZPY1-3
RCUF420AZPY1-1
Water flow of a single module in water-side heat exchanger (m/h)3 RCUF420AZPY1-2
RCUF420AZPY1-3
RCUF450AZPY1-1
RCUF450AZPY1-2
RCUF450AZPY1-3
Evaporator's internal water volume (m3) (m3)

Type Evaporator's internal Type Evaporator's internal
water volume water volume
RCUF45AZPY1 0.091 RCUF200AZPY1 0.187/0.187
RCUF100AZPY1 0.187 RCUF320AZPY1 0.187/0.187/0.223
RCUF180AZPY1 0.187/0.178 RCUF450AZPY1 0.273/0.273/0.273
Internal system's minimum water volume (m3) (m3)

Type Capacity Type Capacity
RCUF45AZPY1 0.58 RCUF200AZPY1 2.57
14

Installation Work
Water quality control
CAUTION
When the evaporator uses industrial water, scale deposition or other foreign matters will be minor inside
the unit. However, well water and river water may contain massive suspended solids, organic substances
and scales, etc. Thus, when such water is used for the evaporator, filtration or chemical softening must be
made to the water. For muds from the chilled water deposit in the evaporator, it will block the chilled water
flow and result in water-freezing. Therefore, it's required to analyze water contents, such as PH,
conductivity, ammonium ion content, sulphur content, etc. If the above checks exceed limits, then only
industrial water can be used. The below Table states the water quality criteria of Hitachi for the evaporator
and the condenser.
Table 1
Item Chilled water system Trend
Recycling water Water Corrosion Squamous

(below 20ºC) supply object
sedimentation
Standard mass pH value (25 ºC) 6.8 - 8.0 6.8 - 8.0 ○ ○
Electric conductivity (mS/m) (25 ºC) Less than 40 Less than ○ ○
30
Chloride ion (mgCl- / l) Less than 50 Less than ○
50
Sulfuric acid ion (mgSO42- / 1) Less than 50 Less than ○
50
Acid consumption (pH4.8) (mgCaCO3 / l) Less than 50 Less than ○
50
Total hardness (mgCaCO3 / l) Less than 70 Less than ○
70
Calcium hardness (mgCaCO3 / l) Less than 50 Less than ○
50
Silicon L (mgSiO2 / l) Less than 30 Less than ○
30
See total iron content of quality (mgFe/ l) Less than 1.0 Less than ○ ○
0.3
Total copper content (mg Cu/ l) Less than 1.0 Less than ○
0.1
Chloride ion (mgS2- / l) Detection free ○
Ammonium ion (mg NH4+ / l) Less than 1.0 Less than ○
0.1
Residual chlorine (mgCl/ l) Less than 0.3 Less than ○
0.3
Free carbonic acid (MgCO2 / l) Less than 4.0 Less than ○
4.0
Stability index - - ○ ○
Cautions: (1) The symbol "○" in the Table means the factors that can cause corrosion and squamous object
deposits.
(2) Because the evaporator uses steel and copper (heat transfer pipe), which will rust, but this is
not an abnormal phenomenon.
15

Installation Work
Check after installation

Inspect all installation works according to all drawings and data. Table 2 lists essentials of the inspection.
Table 2 Inspection items of installation
1. If the unit is secured installed and leveled? 4. Is the electrical wiring system in line with
2. Is the installation position in line with the requirements?
requirements?
Space for the air-side heat exchanger's air Wire If the connections
flow capacity are fastened
Maintenance space Switch Operation control
Noise and vibration capacity device
Daylight and rain Fuse Safety device
capacity
Appearance
Voltage Interlock
and frequency
5. Are the R, S and T phases of the main power
supply respectively connected with the unit's R,
S and T phases?
3. Is the water pipe system compliant to 6. Is the shutoff valve on the condenser
requirements? refrigerant outlet completely open?
7. Are the sealing cap and nuts of the shutoff
Water pipe Water drainage valve fastened?
dimension
Length Water quality
control
Flexible hose Air purification
interface
Heat Pressure
insulation control
16

Test Run
3. Test Run
Preparations
Tools and instruments -- high pressure gauge, low pressure gauge, multimeter and general tools.
CAUTION
• Switch on the main power switch 12 h before startup of the unit, to power on the oil heater and enable sufficient
temperature of the lubricating oil.
• Check and ensure the valves are correctly opened to prevent damage to the compressor due to the abnormal high
pressure.
• Before test run, please use water pumps to circulate the chilled water in the chilled water pipes rather than through the
water-side heat exchanger of the water chilling unit, to remove solids and impurities in the water system and clean the
water filters. Ensure there are not foreign solids and impurities in the water system.
Test run
If the unit's wiring has been made according to Hitachi's standard wiring instructions, you can proceed with the running test
as per the following steps:
1. Press the magnetic switches of the water pump and cooling tower to start them, and check their operating conditions.
2. Completely open the liquid outlet shutoff valve of the condenser.
3. Turn the operating switch on the unit to "ON", and the compressor will start within minutes.
It's recommended to initiate test run according to the following steps:
CAUTION
• If the unit has been wired according to Hitachi's standard wiring diagram, then switch on the main power switch 12h
before startup of the unit, so that the oil heater can be powered on to enable sufficient temperature of the lubricating oil.
• In order to rotate the compressor's screw in the correct direction, the unit is equipped with a phase-sequence protector.
Its rotation direction can be determined as per the following method:
(1) Use a phase meter to detect if the phase sequence of R, S and T is correct, and if not, the compressor will not
start due to the phase-sequence reversal protector.
(2) In case of the above, first cut off the power supply, and exchange any two of the R, S and T phases of the unit's
power supply wiring.
a. Start auxiliary equipment, e.g. chilled water pump and fan coil, and check if the chilled water flow and other devices'
operation are normal.
b. Set the chilled and warm water to the required temperature.
c. Press the start (ON) button, the fan motor will first start and then the compressor.
d. Check the direction of the fan motor.
e. When the main engine's operation is steady, check the discharge and suction pressure through the 7 segment
codes on the control panel. See the refrigerant discharge and suction pressure curve on page 31.
f. Check if the temperature controller can work properly.
g. Check if the control and protective devices are normal (see Table 3 on page 30).
h. Star-triangle starting and unloading running timers are respectively set as 5s and 30s, and please do not change
the setting.
NOTICE
• When the compressor ceases operation, it will create noise, which is normal due to the fact that high and low pressure
equilibrium of the compressor upon shutdown causes the screw to rotate. Within seconds after actuation of the check
valve, the noise will disappear.
• Each compressor's operating current may not be identical due to capacity control, which is a normal phenomenon.
• Upon operation of the unit, condensation water may appear on the surface of the pipeline or the fin, and the customer
should take necessary discharge measures.
Instruction after test run
Upon completion of the test run, please introduce the measures of relevant operations and regular maintenance to the
customer according to the Manual of Installation, Operation and Maintenance. Pay special attention to the following matters:
CAUTION
• In a season with frequent operations, please do not cut off the power supply immediately after shutdown of the main
engine, otherwise the compressor's oil heater will not be able to heat, leading to damage to the compressor.
• If the compressor is not in service for a long period, do make sure to power on the oil heater 12h before startup of the
unit, to heat the oil in the compressor.
17

Controller Settings
4. Controller Settings
The schematic diagram of the control panel on the PCB is as shown in the Figure. 8.
Single cycle setting: Unit type RCUF45/50/60AZPY1
PWBB (CPU substrate) setting diagram PWBC

(I/01 substrate) setting
diagram
Figure 8 Controller indication diagram

Double cycle setting: Unit type RCUF90/100/120/200/220/320/360AZPY1
See horsepower setting in

below Table
PWBB (CPU substrate) setting PWBC PWBO

diagram (I/01 substrate) (I/02 substrate)
setting diagram setting diagram
18

Controller Settings
Ternary cycle setting: unit type RCUF135/150/270/300/405/420/450AZPY1
See horsepower
setting in below
Table

PWBB (CPU substrate) PWBC PWBO
PWBE
setting diagram (I/01 substrate) (I/02 substrate)
(I/03 substrate)
setting diagram setting diagram
setting diagram
PWBA (setting substrate) horsepower setting Table
Symbol 8 9 Content Model

settings
DSW1 1 0 50 RCUF45/50/90/100/135/150/180/200/270/300/405/420/450AZPY1,
horsepower RCUF320AZPY1 No.2/3
DSW1 0 1 60 RCUF60/120/240/360AZPY1, RCUF320AZPY1 No.1

horsepower
Instruction: "0" and "1" indicate OFF and ON,

Settings and functions are as follows:
 Manual setting switch
"DSW1-1" is used for No.1 compressor, "DSW1-2" is used for No.2 compressor, and "DSW1-3" is used for
No.3 compressor. If no compressor is required to start, turn the switches (DSW1-1, DSW1-2, DSW1-3) to
"OFF", and the corresponding compressors will not start (note: changing the settings during compressor
operation is invalid).
NOTICE
a. Switch "DSW1-2, 3, 4" of RCUF45/50/60AZPY1 should be put to the "OFF" side.
b. "DSW1-3, 4" of RCUF90/100/120/180/200/240/320/360AZPY1, the switch shall be on the "OFF' side.
c. "DSW1-4" of RCUF135/150/270/300/405/420/450AZPY1, the switch shall be on the "OFF' side.
 Local/remote control selector switch
Switch "SW2" is the selector switch for field/remote operation. The standard setting is a local control
operation, therefore, set the switch to the upper position of "LOCAL". For remote control operation, set the
switch to the lower position of "REMOTE".
 Compressor startup delay time setting = the first and second digits of DSW3
The first and second digits of the switch "DSW3" are used to set the protective timer of the compressor's
cyclic startup. When the operating switch is turned to "ON", the compressor will start upon expiry of the
setting time. The descriptions of the first and second digits of DSW3 are as follows:
19
Controller Settings
DSW3 Duration
1 2 (Min)
ON ON 0.5
OFF ON 10
ON OFF 6
OFF OFF 3
Cautions: the default setting of units is 3 min, please do not privately change the setting.
 Pump forced operation selector switch = SW1
Turn the selector switch SW1 to the lower side ("OFF")
If the forced operation is required, please turn the switch to "ON".
 Other switches: they are the default settings provided upon delivery of the unit.
20

Control System
5. Control System
Auto inspection function
(1) Alarms display
If the unit is operating under abnormal circumstances, the "ALARM" indicator will on, the LCD panel will
display alarm information (see details in below Table), and please see detailed fault codes in the attached
data Z0011966 Operation Manual to the LCD Touchscreen of Hitachi R134a Air-cooled Screw Type Water
Chilling Unit. Checklist of alarm codes and LCD panel display
Seven-segment LCD display content
code display
5P 5P Abnormal pump interlock Seven-segment LCD display content
05 05 Anti-phase and default phase protection code display
01-01 Fault of starting circuit F3－2m FAN abnormality detected (Fan of No.3 unit)
11-11 Abnormal THM of the inlet water F4－2m FAN abnormality detected (Fan of No.4 unit)
temperature (CN4) F5－2m FAN abnormality detected (Fan of No.5 unit)
12-12 Abnormal THM of the outlet water F6－2m FAN abnormality detected (Fan of No.6 unit)
temperature (CN5) F7－2m FAN abnormality detected (Fan of No.7 unit)
22-22 Abnormal THM of the external air (CN6) F8－2m FAN abnormality detected (Fan of No.8 unit)
11-HE Abnormal THM of the inlet water
F1－2m FAN overcurrent (fan of No.1 unit)
temperature (CN7)
2C-2C Water supply system 1 Temperature F2－2m FAN overcurrent (fan of No.2 unit)
sensor is abnormal (CN13) F3－2m FAN overcurrent (fan of No.3 unit)
2d-2d Return water system 2 Temperature F4－2m FAN overcurrent (fan of No.4 unit)
sensor is abnormal (CN14) F5－2m FAN overcurrent (fan of No.5 unit)
6E-6E Chilling water break (refrigeration in F6－2m FAN overcurrent (fan of No.6 unit)
operation) FAN overcurrent (fan of No.7 unit)
F7－2m
6E-6E Warm water break (heating in operation)
F8－2m FAN overcurrent (fan of No.8 unit)
6E-6E Warm water break (heating in operation)
13-13 Anti-freeze protection F1－2m FAN radiator fin over temperature (fan of
No.1 unit)
14-14 Activation of thermostat for water
temperature going up too quickly F2－2m FAN radiator fin over temperature (fan of
No.2 unit)
03-03 Abnormal communication of unit quantity
control F3－2m FAN radiator fin over temperature (fan of
No.3 unit)
03-03 CPU-I/O abnormal communication
F4－2m FAN radiator fin over temperature (fan of
03-03 Abnormal communication inside of I/O
No.4 unit)
03-03 Abnormal external communication
03-03 COMP abnormal communication
No.5 unit)
03-03 Abnormal communication of pump
03-03 Transmission of intelligent electric meter
No.6 unit)
40-40 Setting error FAN radiator fin over temperature (fan of
F7－2m
40-40 Unit quantity control setting error No.7 unit)
40-40 Insufficient quantity of running units FAN radiator fin over temperature (fan of
F8－2m
40-40 Transmission error (wrong wiring) No.8 unit)
40-40 Transmission error (wrong wiring) F1－5m FAN under voltage (fan of No.1 unit)
40-40 Maloperation (remote → local)
F2－5m FAN under voltage (fan of No.2 unit)
40-40 Maloperation (local → remote)
40-40 Maloperation (refrigeration → heating)
40-40 Maloperation (heating → refrigeration)
40-40 Maloperation (set to remote operation
under local mode)
40-40 Maloperation (set to local operation under F7－5m FAN under voltage (fan of No.7 unit)
remote mode) F8－5m FAN under voltage (fan of No.8 unit)
40-40 Error of unit quantity control F1－5m FAN overvoltage (fan of No.1 unit)
C1-F0 Fan quantity setting F2－5m FAN overvoltage (fan of No.2 unit)
Cn-24 Abnormal THM of the nutrient solution F3－5m FAN overvoltage (fan of No.3 unit)
temperature (CN24) F4－5m FAN overvoltage (fan of No.4 unit)
Cn-25 Abnormal THM of back outlet (CN25)
F5－5m FAN overvoltage (fan of No.5 unit)
Cn-23 Abnormal THM of the exhaust (CN26)
21
Control System
Cn-26 Abnormal THM of the suction (CN27) F8－5m FAN overvoltage (fan of No.8 unit)
Cn-23 Abnormal THM of the exhaust (CN28) F1－4m Abnormal communication of fan (Fan of No.1
Cn-21 Abnormal THM of evaporation inlet unit)
(CN29) F2－4m Abnormal communication of fan (Fan of No.2
unit)
Cn-23 Abnormal THM of the exhaust (CN30)
F3－4m Abnormal communication of fan (Fan of No.3
Cn-27 Abnormal THM of exhaust pressure unit)
sensor (CN31) F4－4m Abnormal communication of fan (Fan of No.4
Cn-28 Abnormal THM of suction pressure unit)
F7－4m Abnormal communication of fan (Fan of No.7
sensor (CN34)
unit)
Cn-28 Abnormal THM of suction pressure F8－4m Abnormal communication of fan (Fan of No.8
sensor (CN35) unit)
Cn-39 Abnormal current transformer (CN36) F1－8m Abnormal communication current sensor of
Cn-hn High pressure cut-off protection FAN(Fan of No.1 unit)
Cn-Ln Low pressure cut-off protection F2－8m Abnormal communication current sensor of
Cn-5n Overcurrent of compressor FAN(Fan of No.2 unit)
F3－8m Abnormal communication current sensor of
Cn-7n Temperature controller inside of the
FAN(Fan of No.3 unit)
compressor is triggered Abnormal communication current sensor of
F4－8m
Cn-6n Temperature controller of preventing FAN(Fan of No.4 unit)
exhaust overheating F5－8m Abnormal communication current sensor of
Cn-4n Temperature controller inside of the fan is FAN(Fan of No.5 unit)
triggered F6－8m Abnormal communication current sensor of
Cn-Fn Fan overcurrent FAN(Fan of No.6 unit)
Cn-Ln Low pressure protection control F7－8m Abnormal communication current sensor of
FAN(Fan of No.7 unit)
Cn-9n Too low inlet temperature of evaporator
F8－8m Abnormal communication current sensor of
Cn-tn Too low suction temperature FAN(Fan of No.8 unit)
Cn-6n Exhaust temperature F1－1m FAN short-circuit detection (fan of No.1 unit)
Cn-hn Too high pressure of high pressure F2－1m Short-circuit detection of FAN (Fan of No.2
Cn-13 Anti-freeze unit)
Cn-14 Activation of thermostat for water F3－1m Short-circuit detection of FAN (Fan of No.3
temperature going up too quickly unit)
F1－2m FAN abnormality detected (Fan of No.1 F4－1m Short-circuit detection of FAN (Fan of No.4
unit)
unit)
F5－1m Short-circuit detection of FAN (Fan of No.5
F2－2m FAN abnormality detected (Fan of No.2 unit)
unit) F6－1m Short-circuit detection of FAN (Fan of No.6
unit)
F7－1m Short-circuit detection of FAN (Fan of No.7
unit)
F8－1m FAN short-circuit detection (fan of No.8 unit)
22

Control system
(2) Normal display

For the display of normal unit operation and other matters, please see details in the accessary data
Z0011966 Operation Manual to the LCD Touchscreen of Hitachi R134a Air-cooled Screw Type Water
Chilling Unit.
Standard work procedure
Single cycle RCUF45/50/60AZPY1 standard work procedure Table
Control level
Startup control Capacity control Safety device Shutdown
Control device
Main power switch OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
Chilled water pump — OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
Cooling water pump — OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
Operating switch (on, off) — — — ON — — — — — — — — — — — OFF — OFF —
Run up — — — — — — — — — — — — — — — — —
Neutral
Controller — — — — — — — — — — — — — —
band
Run down — — — — — — — — — — — — — — — —
Safety device No.1 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS
Power supply
OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
indicator
Operational
OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFF
indicator
Warning indicator OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF
Oil heater CH1 OFF ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON ON ON ON OFF
STA DLT DLT DLT DLT DLT DLT DLT DLT DLT
Compressor motor MC1 OFF OFF OFF OFF (ULD) (ULD) (ULD) (FLD) (FLD) (ULD) (ULD) (ULD) OFF (ULD) OFF OFF (FLD) OFF OFF
※1 ※1 ※1-99% 100% 100% ※1-99% ※1-99% ※1 ※1-99% ※100%
SV11 OFF OFF OFF ON ON ON OFF OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF OFF
Electromagnetic
SV12 OFF OFF OFF OFF OFF OFF OFF OFF OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF
valve SV13 OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
5sec.
3min.
30sec
3 min in minimum
Schedule
※1 25%
CLS：close OPN:open STA:star DLT:delta
ULD: unload FLD: fullload FLK: flicker
Dual cycle RCUF90/100/120/180/200/240/320/360AZPY1 standard work procedure Table

Control level
Control device
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
Chilled water pump — OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
Cooling water pump — OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
Operating switch (on, off) — — — ON — — — — — — — — — — — — — — OFF — OFF —
Run up — — — — — — — — — — — — — — — — — —
Neutral
Controller — — — — — — — — — — — — — — — — — —
band
Run 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 device
No.2 CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS CLS OPN CLS CLS CLS CLS
Power supply
OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
indicator
Operational
OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFF
indicator
Warning
OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFF
indicator
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
Compressor ※1 ※1 ※1 ※1 ※1-99% 100% 100% ※1-99% ※1-99% ※1 ※1-99% 100%
motor 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
※1 ※1 ※1-99% 100% 100% ※1-99% ※1-99% ※1 ※1-99% ※1-99% 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
Electromagnetic SV13 OFF OFF OFF OFF OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
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 OFF OFF OFF ON OFF OFF OFF OFF OFF
5sec 5 sec.
3min. 60sec.
30 sec. 3 min in minimum
The last started compressor will stare first
Schedule
※1 12.5%

CLS：close OPN:open STA:star DLT:delta 23
ULD: unload FLD: fullload FLK: flicker
Control system
Ternary cycle RCUF135/150/270/300/405/420/450AZPY1 standard work procedure Table

Control level
Control device
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
Chilled 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
Cooling 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
Operating switch
— — — ON — — — — — — — — — — — — — — — — — OFF — OFF —
(on, off)
Run up — — — — — — — — — — — — — — — — — — — — —
Neutral
Controller — — — — — — — — — — — — — — — — — — — —
band
Run 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 device 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
Power supply
OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF
indicator
Operational
OFF OFF OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF ON OFF OFF
indicator
Warning
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON OFF ON OFF OFF
indicator
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
※1 ※1 ※1 ※1 ※1 ※1 ※1-99% 100% 100% ※1-99% ※1-99% ※1 ※1-99% 100%
STA DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT DLT
Compressor
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
motor
※1 ※1 ※1 ※1 ※1-99% 100% 100% ※1-99% ※1-99% ※1 ※1-99% ※1-99% ※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
※1 ※1 ※1-99% 100% 100% ※1-99% ※1-99% ※1 ※1-99% ※1-99% ※1-99% 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
Electromagneti
c valve
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
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
5 sec. 5sec 5 sec.
3 min. 60 sec. 60 sec. 60 sec.

3 min in minimum
Schedule ※1 8%
The last started compressor will start first
CLS：close OPN:open STA:star DLT:delta
ULD: unlode FLD:fulllode FLK:flicker
24

Maintenance and Servicing
6. Maintenance and Servicing

The unit shall be regularly inspected according to the items described in the "running test" section. In order
to ensure reliability and use life, please pay special attention to the following supplemented items.
WARNING
• In case of fire, immediately cut off the main power supply and implement fire extinguishers adaptable
to oil fire and electrical fire.
• Do not operate the unit in proximity to flammable gases, such as paint, coating, gasoline, etc., to avoid
fire or explosion.
• Switch off the main power supply before opening the electrical cabinet's cover plate for temperature
adjustment. If the cover plate is not securely closed, do not operate the unit.
CAUTION
• Conduct regular maintenance as per the "Instruction" to keep the unit in a good condition.
• Do not touch the refrigerant exhaust parts, as the copper tube at the exhaust side is heated by the
refrigerant and its temperature can exceed 100ºC.
• Do not use the unit for direct refrigeration or heating of drinking water and food, please comply with
local statutes and regulations.
• In case of refrigerant leakage or chilled water/hot water leakage, shut all main switches. Besides, if the
unit can't be shut down by control switches, you can switch off the main power switch to shut down the
unit.
Component
Compressor - it the compressor operates for every 24,000h or 5 years (subject to the earlier one),
the compressor shall be dismantled for major overhaul. For details, please see the maintenance
manual for Hitachi screw type compressors. (Please contact the after-sales service department for specific
operation, and the contact number is 400-163-1108).
Electrical devices - pay attention to the operating voltage, current and phase balance on a regular
basis. Check if there is any poor contact due to terminal block connection looseness, contactor oxidation,
foreign matters, etc.
Control and protection devices - do not privately change the setting values, unless the setting
values are different from the values in Table 3 on page 30.
Lubricating
Compressor - appropriate lubricating oil has been filled in the compressor during manufacturing. See
details in "Detailed Compressor Data" in technical data 1 and on the compressor nameplate. Oil sight glass
observation: when the unit is operating, the minimum requirement is that the oil level should be seen
continuously.
If the compressor operates for every 12,000h or 2 years (subject to the earlier one), the lubricating oil of
the compressor should be replaced. (Please contact the after-sales service department for specific
operation, and the contact number is 400-163-1108).
Fan motor - the bearing of the fan motor has be pre-lubricated, and lubrication is not required
during operation.
Stagnancy
After operation for a certain period, calcium carbonate and other minerals in the chilled water tend to
deposit on the surface. If the sediment increases, it will consume excessive electricity. If the exhaust
pressure is excessively high or the suction pressure is excessively low, it indicates that there is massive
deposition inside the water-side heat exchanger. The Figure on page 26 indicates the scope of required
cleaning.
Cleaning methods
1. Install the cleaning circuit:
(1) Water chilling unit shutdown.
(2) Power off the circulating water pump.
(3) Disconnect the connection of chilled water inlet/outlet or hot water inlet/outlet, and mount an anti-acid
water pump to form a circulating water circuit.
25

2. Check the circulation circuit:

Fill purified water in the cleaning water tank, and start the anti-acid water pump
(1) Check and ensure there is no water leakage.
(2) Check and ensure the water pipes are securely installed.
(3) Check and ensure the cleaning agent doesn't damage the equipment even the agent is bubbling
or attached to the equipment near the water chilling unit.
(4) Check and ensure a well-ventilated environment.
(5) Check and ensure there is no abnormal noise.
3. Cleaning
(1) Discharge the remaining water in the air-conditioning water system.
(2) Use the anti-acid water pump to fill the diluted cleaning agent in the cleaning water tank in the unit.
(3) Circulate the cleaning solution for a period (dependent on the type and concentration of the
cleaning agent and the thickness of the deposition).
4. Waste liquid
(1) Stop the anti-acid water pump.
(2) Discharge the waste liquid into the waste tank.
(3) Fill water in the cleaning water tank, and start the water pump for water cleaning.
(4) Discharge the water post cleaning into the waste tank.
(5) Use PH test paper to test the PH value, and gradually add neutralizer to neutralize the waste liquid.
(6) After neutralization, contact the waste liquid disposal company for further treatment.
5. Neutralization of water pipes
(1) Fill water in the cleaning water tank.
(2) Start the anti-acid water pump.
(3) Use PH test paper to test the PH value, and gradually add neutralizer to neutralize the waste liquid
till PH=7.
(4) Start the anti-acid water pump for a period to allow the neutralization reaction.
(5) Discharge the water post neutralization.
(6) Start the circulating water pump to clean the circulation system, until there is no incrustation coming
out in the water.
6. Restart the unit
(1) Reconnect the unit's water pipes, and start the unit for normal operation.
(2) Following the cleaning, you may implement water treatment (preventive measures) to prevent
corrosion of the water circuit.
Refrigeration in operation
Low pressure (MPa)
Cleaning area
Saturation curve
Cooling outlet temperature (ºC) Low pressure

cutoff (0.01MPa)
Cleaning scope diagram
26

Prolonged shutdown in winter

If the unit is not to be used in winter, it's recommended to completely discharge the water in the heat
exchanger and the water pipes to prevent water-freezing in winter. It's preferable to add ant-freezing
agents in the water pipes.
Initial startup after shutdown
In order to restart the unit after a long period of shutdown, please make the following necessary
preparation:
1. Completely check and clean the unit.
2. Clean the water pipeline.
3. Check the water pump, water tower, regulating valves and other devices of the water pipe system.
4. Fasten all electric wire connections.
CAUTION
When the main power switch has been off for a long period, the power switch must be turned on 12h before
startup of the unit, so that the lubricating oil in the compressor can be heated by the oil heater and won't
create oil bubbles.
Replacement of parts
All replaced parts shall be ordered with reference to the parts Table.
CAUTION
Do not replace with any inconsistent parts.
Paint replenishment of the unit enclosure
The unit enclosure is made of galvanized steel plates and coated with a synthetic resin coating, which is
anti-corrosive. However, it is still subject to slow corrosion, and the rate of the corrosion is dependent on
the use environment.
With the difference of external air conditions, the rate of corrosion will vary. When the unit is operating in
a severe environment, e.g. high temperature, high humidity or other harsh environment, it's recommended
to provide regular coating replenishment to the unit enclosure.
Refrigerant circulation
Filters: before the unit is started each time, check the filter for any obstruction.
Refrigerant injection: whether to inject the refrigerant is determined through detection of the unit's
discharge pressure value and suction pressure value. And leakage detection shall be conducted. If any
suspicious leakage is found or any replacement of the refrigerant circulation system's any part is
considered necessary, leakage test shall be conducted. If the refrigerant injection is necessary, please
proceed as per the following instructions:
(1) When the refrigerant has been completely leaked...
Extract the circulation system for vacuum and remove the moisture completely before injection Extract
vacuum and inject the refrigerant as per the below Figure.
1. Open all shutoff valves.
2. Connect the extraction pipe with the high pressure end and low pressure end.
3. Use the vacuum pump to completely extract the air and moisture.
4. Inject appropriate refrigerant as per the mass set out on the main engine's nameplate.
5. When the injection ceases due to high environmental temperature, cut off the valves and start
the unit if there is circulating chilled water or warm water in the unit. Inject as per (2) "If only minor
refrigerant is required".
(2) If only minor refrigerant is required...
Connect the extraction pipe with the low pressure end, and feed refrigerant to the extraction pipe.
Start the main engine when there is circulating chilled water or warm water in the unit. Proceed as per
the following steps until the pressure becomes normal.
1. Slowly inject the refrigerant gas to the refrigerant circulation system and check the discharge
pressure and suction pressure.
2. When the unit's chilled water circulation is steady, check the unit's pressure.
27
Unit circulation system schematic (with economizer)

Mark Name Specification
1 Compressor
(R134a)
2 Gravity check 50A
valve
3 Exhaust hot dip
resistor
4 Gas piping
5 Vertical air heat
exchanger
6 Inclined air heat
exchanger
7 Fan
8 Service valve
9 Fusible plug
10 Manual ball valve
11 Economizer
12 Filter
13 Electromagnetic
valve
14 Throttling valve
15 Electronic
expansion valve
16 Evaporator
17 Safety valve
18 Suction thermistor
Unit circulation system schematic (without economizer)
Mark Name Specification
1 Compressor
(R134a)
2 Gravity check 50A
valve
3 Exhaust hot dip
resistor
4 Gas piping
5 Vertical air heat
exchanger
6 Inclined air heat
exchanger
7 Fan
8 Service valve
9 Fusible plug
10 Manual ball valve
11 Filter
12 Electronic
expansion valve
13 Evaporator
14 Safety valve
15 Suction thermistor
Refrigerant injection volume
Type RCUF RCUF RCUF RCUF RCUF RCUF RCUF RCUF RCUF
45AZPY1 50AZPY1 60AZPY1 90AZPY1 100AZPY1 120AZPY1 135AZPY1 150AZPY1 180AZPY1
Refrigerant
injection 58*3 58*3
volume (kg)
Lubricating oil
injection 8*3 8*3
volume (l)
Type RCUF RCUF RCUF RCUF RCUF RCUF RCUF RCUF RCUF
200AZPY1 240AZPY1 270AZPY1 300AZPY1 320AZPY1 360AZPY1 405AZPY1 420AZPY1 450AZPY1
Refrigerant
injection 58*6 58*6 58*9 58*9 58*9
volume (kg)
Lubricating oil
injection 8*6 8*6 8*9 8*9 8*9
volume (l)
WARNING
Refrigerants other than those specified are prohibited! !
Refrigerant for the chilled water air-conditioning unit is specified.
If a refrigerant not specified is injected into the unit, it may lead to mechanical failure, malfunction and
faults, or even result in major safety accidents.
Especially, when a refrigerant containing HC (such as propane) is leaked, it may result in fire, explosion
and other severe disasters with strong combustibility, which is very dangerous!
28
Therefore, only refrigerant designated by unit manufacturers can be employed.

For enclosed refrigerant, there are introductions on manual matched with the unit or nameplate of the unit's
ontology. Be sure to use designated refrigerant.
If there are faults, malfunctions and other adverse events resulted from the refrigerant beyond operating
requirements, unit manufacturers and construction units not related to the enclosure on refrigerant shall
not undertake any accountability.
CAUTION
• Be sure not to inject oxygen, acetylene or other flammable or toxic gases into the refrigerant circulation
system for leakage test or seal test. The foregoing types of the gas may present an explosion hazard.
Therefore, only compressed air, nitrogen or refrigerant can be filled with for leakage tests.
• If the mineral deposition is attached to water heat exchanger, heat exchange will be affected.
Meanwhile, flow resistance will be increased while refrigerating capacity decreased. Sediment can be
produced after the main engine runs for a period. Such sediment can be cleaned with dilute acid
running evaporators. While water content in different areas contains different minerals, different acidic
substances should be used for removal. Therefore, please entrust experienced chemical companies
to deal with
• The unit is equipped with a running timer, for example, bearing on compressor needs to be changed
once the running time reaches 24,000h or 5 years (subject to the earlier one). Please see Maintenance
Manual on Hitachi Screw Compressor.
Removal of the compressor
To remove the compressor, please follow these steps:
1. Recycle the refrigerant into the condenser prior to removal.
(1). Use DSW3 switch on the PCB in the electrical cabinet to turn off the other cycles of the compressor.
(2). Fully circulate chilled water and cooling water, run the unit after 10 minutes to check and confirm
whether the compressor oil surface is stable.
(3). Stop operating the unit and fully turn off the shutoff valve of the condenser.
(4). Start the unit again, when the low pressure reaches about 0.01MPa, the unit will automatically
stop running.
(5). Wait for a few minutes. Observe the low pressure, if the low pressure increases to 0.03Mpa to
0.05Mpa, then repeat step 4 for 5 times.
2. Cut off the power supply units.
3. Remove the bolts in the flange of exhaust and air suction ports in compressors (note: in order to
prevent refrigerant injection, slowly release the bolts and gently discharge the residual refrigerant.)
4. Remove connected wires from the compressor.
5. Remove the fixing bolts on the compressor, then demount it.
The foregoing 1-5 are the steps for removing compressors in the normal maintenance practices (such as
change bearing on compressor). Please follow step 2 to 5 for removal if there are faults in compressors.
29
Settings of the safety and control device
Table 3 Settings of the safety and control device

RCUF45 RCUF50 RCUF60 RCUF90 RCUF100 RCUF120 RCUF135 RCUF150 RCUF180
Type
AZPY1 AZPY1 AZPY1 AZPY1 AZPY1 AZPY1 AZPY1 AZPY1 AZPY1
Manual reset, adjustable (one switch for each compressor motor)

Cutting off with high
pressure control
MPa 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Cutting off with low Micro-processor control

pressure control MPa 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
Cut off and connect Automatic reset, non-adjustable
to built-in ºC 150 150 150 150 150 150 150 150 150
Compressor temperature
detector ºC 93 93 93 93 93 93 93 93 93
Overcurrent relay Manual reset, adjustable (one switch for each compressor motor)
380V 50Hz A 72 80 100 72 80 100 80 100 100
One switch for each compressor motor
Oil heater power
W 150 150 150 150 150 150 150 150 150
Cyclic protection Non-adjustable (one timer for each compressor)
for compressors Sec. 180 180 180 180 180 180 180 180 180
Timer Sec. 5 5 5 5 5 5 5 5 5
Setting time
Star-triangle Sec. 30 30 30 30 30 30 30 30 30
Unloaded start
Electric Fuse capacity
A 4 4 4 4 4 4 4 4 4
manipulation 220V
Fusible plug 1 cycle
melting
temperature ºC 72 72 72 72 72 72 72 72 72
Temperature
detector
Refrigerant
refrigeration and ºC 1 1 1 1 1 1 1 1 1
circulation
cutting off for anti-
system
freeze protection
Cutting off with
exhaust
ºC 140 140 140 140 140 140 140 140 140
temperature
control
Overcurrent relay of fan motor 380V Manual reset, adjustable (one set of motor for each fan)
50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
1 cycle
Set-pressure on safety valve
MPa 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02
Type RCUF200 RCUF240 RCUF270 RCUF300 RCUF320 RCUF360 RCUF405 RCUF420 RCUF450
AZPY1 AZPY1 AZPY1 AZPY1 AZPY1 AZPY1 AZPY1 AZPY1 AZPY1
Manual reset, adjustable (one switch for each compressor motor)

Cutting off with
high pressure
control
MPa 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
Cutting off with low Micro-processor control

pressure control MPa 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
Cut off and Automatic reset, non-adjustable
Compressor connect to built-in ºC 150 150 150 150 150 150 150 150 150
temperature
detector ºC 93 93 93 93 93 93 93 93 93
Overcurrent relay Manual reset, adjustable (one switch for each compressor motor)
380V 50Hz A 100/80 100 80/100 80 100/80 100 100 80/100 100
One switch for each compressor motor
Oil heater power
W 150 150 150 150 150 150 150 150 150
Cyclic protection Non-adjustable (one timer for each compressor)
for compressors Sec. 180 180 180 180 180 180 180 180 180
Timer Sec. 5 5 5 5 5 5 5 5 5
Setting time
Star-triangle Sec. 30 30 30 30 30 30 30 30 30
Unloaded start
Electric Fuse capacity A 4 4 4 4 4 4 4 4 4
manipulation 220V
Fusible plug 1 cycle
melting
temperature ºC 72 72 72 72 72 72 72 72 72
Temperature
Refrigerant detector
circulation refrigeration and ºC 1 1 1 1 1 1 1 1 1
system cutting off for anti-
freeze protection
Cutting off with
exhaust ºC 140 140 140 140 140 140 140 140 140
temperature
control
Overcurrent relay of fan motor 380V Manual reset, adjustable (one set of motor for each fan)
50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
1 cycle
Set-pressure on safety valve
MPa 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02

30
Normal operating pressure
• Cooling operation (low pressure ˙high pressure)
<Cooling operation>
High pressure (MPa)

Low pressure (MPa)
External air dry bulb temperature (ºC)

Cooling outlet temperature (ºC)
CAUTION
1) Periodic maintenance
Please maintain the unit regularly in accordance with this manual to keep the unit running.
2) Fire
In the event of a fire, turn off the main power switch and use a fire extinguisher suitable for oil
or electrical fires.
3) Flammable gas
Operating the unit next to flammable gases is not allowed, such as: paint, gasoline, etc., to
prevent fire and explosion.
4) Service panel and electrical cabinet cover
When opening the service panel and electrical cabinet cover to set temperatures, please turn
off the main power supply. Before shutting down the service panel and electrical cabinet cover,
please do not operate the unit.
5) Heated piping
Please do not touch the exhaust piping by hand, since the exhaust piping is heated by high
temperature refrigerant, the temperature may exceed 100ºC.
6) Use
Please do not use the unit to directly cool the drinking water or food. When using, please
comply with local regulations.
7) Unit fault
If there is leakage of unit refrigerant and chilled water, please turn off the power supply of the
unit. In addition, if the unit cannot be closed with the control switch, please turn off all the main
power switch.
31

CAUTION
1. Safety device
The unit of any safety device action will shut down, and please restart it after eliminating faults.
A safety device is used for protecting the unit from normal operation.
Therefore, there is something wrong with safety devices, please refer to "trouble removal" in
this manual or contact with local agents for eliminating faults.
2. Fuse
Please use the fuse with the specified capacity. Steel and copper wires cannot be replaced,
otherwise, and severe damages or fire alarms of the unit should be incurred.
3. Safety device
Lines cannot be protected by short-circuit, otherwise serious accidents will be caused.
4. Set safety device
Setting of safety devices cannot be modified, otherwise serious accidents will be caused.
Electric elements cannot be touched, except for touching the operating switch in the course
of operation.
The buttons on electromagnetic switches cannot be pressed, otherwise serious accidents will
be caused.
32

Table 4 Test run and maintenance record

Type: RCUF**AZPY1 Factory No. of the unit:
Factory No. of the compressor:
Name and address of the customer:
Date:
Before operation:
1. Check the installation conditions.
For example: seaside regions and other considerable or inadaptable environments may result in malfunctions of the unit.
2. Does it clean inside and outside of the unit?
3. Check and determine whether the shutoff valve is fully open. (See "use instruction")
4. Does the unit undergo a refrigerant leak detection?
5. Does all cover of the unit sound?
6. Make sure that each phase of the compressor power supply is properly connected.
7. Check whether the unit contactor wiring is firm.
8. Check whether there is leak detection on water pipes?
9. Check whether all the pumps, fans and motors are lubricated.
10. Check whether the direction of rotation of fan motors is correct.
11. Check whether the water is sufficient for going through waterside heat exchangers.
Check the flow rate of chilled water/hot water. Inlet Outlet ᇞP
3
m /h____ Pa_______ Pa_______
Chilled water/hot water
______________
12. Check whether seven-segment code works properly before and during operation of the unit.
Before operation During operation

During operation
1. Has the unit been in operation for at least 20 min?
2. Check the temperature of chilled water or hot water:
Inlet Outlet
3. Check the air temperature of air heat exchanger:
Inlet Outlet
4. Check the suction temperature and overheat degree of the refrigerant:
The suction temperature of
the refrigerant:
Overheat degree:
5. Pressure check
Discharge pressure
Suction pressure
6. Check the working

current
7. Are all the operations
above completed? Inspection Date Signature
If you want to learn more, please contact Hitachi or its distributor.
Maintenance and servicing
33

Table 5 Daily operation record
Type:
Weather:
Date:
Operating time: startup ( ) stop ( )
Outdoor Dry bulb ºC
temperature Wet bulb ºC
Indoor temperature ºC
Compressor High MPa
pressure
Low MPa
pressure
Voltage V
Current A
Air-side heat Inlet (dry ºC
exchanger bulb)
Air Outlet (dry ºC
temperature bulb)
Chilled water Inlet ºC
temperature Outlet ºC
Current of chilled water A
pump
Note
34

Special precautions of R134a refrigerant

Please use the new special tools of the refrigerant and the measurement instrument for direct contact with
the refrigerant.
○: Interchangeable with R22 refrigerant
●: R134a only (non-interchangeable with R22 refrigerant)
Interchangeable Reason of non-interchangeability
Tool and measurement
with R 134a and precautions ( : strict Usage
instrument
/R22 refrigerant requirements)
Pipe ○ The pipe expanding tool of R134a
expanding and R22 are interchangeable Pipe expanding
tool
Checklist of -
Dimension control
flaring
dimension
after flaring
Pipe-bending ○
- Bend pipe
machine
Pipe ○
expanding - Pipe expanding
Refrigerant machine
pipe ○
Torque Connection of the
-
wrench flaring nut
Tool of ○ Correct welding.
Copper pipe
welding
copper pipe
welding
○ Strict control is required to prevent
Prevent oxidation
Nitrogen air pollution (use of nitrogen at
welding)
at welding
Lubricating ZE-GLES RB68 Different from UX300 of R22 Oil used for flaring
oil system, mixing is not allowed. surface
● Check the color of the refrigerant
Refrigerant tank. For elemental refrigerant, it is
Refill refrigerant
tank recommended to fill in the form of
liquid to improve the efficiency.
Adaptor ○  The existing one could be used.
● However, a vacuum adapter is
Connector of
required to prevent the Vacuum pumping
vacuum
countercurrent when the vacuum
pumps
pump stops.
Various ● The pressure is lower than R22
Vacuum valves system and is interchangeable.
Vacuum pump,
drying ●  Do not use the old pipes to the
vacuum keeping,
change new refrigerant unit. Once be used,
refrigerant filling
refrigerant Filling the mineral oil will flow into the
flexible hose
and pressure
circulation and cause deposition.
Result in obstruction and damage of check
compressor.
Filling tank - - -
○ - Measurement
Poidometer instrument of
refrigerant filling
Leaking ○ The refrigerant checking method is -
detector of the same with R22 system
refrigerant
35

Troubleshooting
7. Troubleshooting
The below Table is for the efficient troubleshooting.
Fault Possible reasons Check/correction
Power off the unit 1. Power on the unit again.
The fuse of starting circuit is burnt- 1. Check short-circuit part.
out or loose contact 2. Check the loose contact part, and tighten or
replace it if necessary.
The fan does The coil of AC fan contactor is 1. Find out the reason, and repair or replace it.
not work burnt-out or loose contact
Setting error of overcurrent relay 1. Find out the reason, and reset the setting
value of overcurrent relay
Too low voltage 1. Check the voltage of the unit.
Motor or terminal short-circuit 1. Check the motor or terminal, and repair or
replace it if required
The fan does not work 1. Find the reason why the fan does not work.
The Disconnection of inter-lock 1. Check the connection of water pumps. If
compressor equipment of chilled water pump required, please maintain or replace it.
cannot start 2. Check the pump not started.
Error of electrical protection design 1. Troubleshooting and then pressing the "ON"
button to see if there is any fault.
Connection error of compressor 1. Conduct intermodulation on any 2 phases
main power supply wiring among the R, S, T 3 phases of power supply
wiring.
The Too high exhaust pressure 1. See "high discharge pressure".
compressor Fault of the high pressure switch 1. For faults, reset the setting value or replace
stops for high the parts.
pressure Too high exhaust pressure and 1. See "high discharge pressure" and "high
suction pressure suction pressure".
Compressor High voltage or low voltage, and 1. Check the power line and its connection, and
stops for the single phase or phase is imbalance maintain or replace it if necessary.
disconnection Loose wire 1. Tighten or replace it if required.
of Burnt-out of compressor coil 1. Check the compressor coil, and repair or
overcurrent replace it if required.
relay Burnt-out of overcurrent relay 1. Replacement.
The Too low outlet water temperature of 1. Check if the setting value of outlet water
compressor chilling water temperature is too low.
stops for anti- Fault of thermistors 1. If there is any fault of thermistor, replace it if
freeze required.
protection Insufficient chilled water flow 1. Check the opening degree of water pumps.
(refrigeration Air exists in the water circuit 1. Exhaust gas.
in operation) High voltage or low voltage, and 1. Check the power line and its connection, and
single phase or phase is imbalance maintain or replace it if necessary.
The Overheating motor 1. Check the leakage of refrigerant and faults of
compressor bypass capillary tubes.
stops for Component fault 1. Check the internal temperature detector
internal when the motor cools down.
temperature Too high exhaust pressure and too 1. See "high discharge pressure" and "low
detector and low suction pressure suction pressure".
exhaust Too high exhaust pressure and too 1. See "high discharge pressure" and "low
thermistor low suction pressure suction pressure".
Insufficient Temperature setting error 1. Reset.
refrigerating Fault of unloading devices 1. Recalibrate unloading device, and repair or
capacity replace it if required.
Abnormal The compressor intakes liquid 1. Check overheat degree of refrigerant air and
noise of refrigerant from the evaporator keep it in a proper range.
compressors Aging of compressors 1. Check noise parts, and maintain or replace
36
Troubleshooting
compressor if required.
There is Loose screw part 1. Tighten all the screw parts
noise. Insufficient intensity of installation 2. See Guide for Installation
foundation
Fault of thermistors 1. Reset temperature. 2. Replace thermistor.
It cannot be Electromagnetic valve fault 1. Check if there is blockage of solenoid valve
unloaded coil and oil circuit.
Aging of unloading devices 1. Check the unloading device of compressors.
High air temperature of air-heat 1. Work condition of fans. 2. Air-heat exchanger
exchanger or insufficient air has obstacles, remove them if required.
exhaustion.
High Faults of the shutoff valve and 1. Check valve component or bypass capillary
discharge shutdown of partial liquid pipe valve pipe, and replace it if required.
pressure Over filling of refrigerant 1. Discharge excessive refrigerant.
(refrigeration Air or non-condensable gas exists 1. Discharge gases from the system.
in operation) in the system.
Suction pressure is above normal 1. See "high suction pressure".
value
Too cold of side air from air-heat 1. Check the environmental temperature.
exchanger
Low exhaust Insufficient filling of refrigerant 1. Fill sufficient refrigerant.
pressure Leakage of discharge valve from 1. Replace the valve, and change the
(refrigeration compressors. compressor if desired.
in operation) Suction pressure is below normal 1. See "low suction pressure".
value
High suction High temperature of inlet chilled 1. Check the thermal insulation of water pipes.
pressure water 2. Check the thermal insulation specification.
(refrigeration The openness of the expansion 1. Readjust the valve, and replace it in case of
in operation) valve is too large faults.
Low temperature of inlet chilled 1. Check the thermal insulation specification.
water
Low suction Improper adjustment on expansion 1. Adjust overheat degree properly, and
pressure valves or fault maintain or replace it if required.
(refrigeration Insufficient filling of refrigerant 1. Fill sufficient refrigerant.
in operation) Too much oil in evaporator 1. Discharge excessive oil.
Incrustation in evaporator 1. Remove incrustation.
Insufficient water flow 1. Check the temperature difference between
inlet and outlet water
37

The technical instructions in this data are subject to change at any time without notice in advance. This could help HITACHI
bring the newest technical creativity to customers.
Johnson Controls–Hitachi Wanbao Air-conditioning(Guangzhou)Co., Ltd.
© 2017 Johnson Controls–Hitachi Wanbao Air-conditioning(Guangzhou)Co., Ltd.
Printed in China №: Z0012017-2017-A

Technical Catalog II-Installation, Operation and Maintenance Manual

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Technical Catalog II-Installation, Operation and Maintenance Manual

Încărcat de

Drepturi de autor:

Formate disponibile

Type

DANGER: Direct hazards possibly lead to severe personal injury or death.

Hazards or insecure operations may lead to minor personal injury or product or

NOTICE: Data are helpful to use and maintenance.

• If required, please contact your contractor or the distributor of Hitachi.

Unit run range

When covered by shadows, the

of operating conditions and can't

Unit operating range

Outlet water temperature (ºC)

● Model Energy efficiency level Model Energy efficiency level

Figure 1 Maximum inclination

Figure 2 Running space h1≤h2

RCUF150AZPY1 6,590 1,200 100 900 1,200 2,000 1,200

RCUF180AZPY1 9,080 (minimum) 1,200 900 900 1,200 2,000 1,200

RCUF200AZPY1 9,080 (minimum) 1,200 900 900 1,200 2,000 1,200

RCUF240AZPY1 12,720 (minimum) 1,200 900 900 1,200 2,000 1,200

RCUF270AZPY1 13,280 (minimum) 1,200 900 900 1,200 2,000 1,200

RCUF300AZPY1 13,280 (minimum) 1,200 900 900 1,200 2,000 1,200

RCUF320AZPY1 16,290 (minimum) 1,200 900 900 1,200 2,000 1,200

RCUF360AZPY1 19,930 (minimum) 1,200 900 900 1,200 2,000 1,200

Gravity center of the unit

Weight distribution (kg)

Weight distribution (kg)

RCUF360AZPY1-2 669 672 675 648 645 642

RCUF360AZPY1-3 669 672 675 648 645 642 Configuration

Recommended concrete diagram

Drainage tank Cement mortar Drainage tank

Water Drainage tank Drainage tank Drainage tank

Steel plate (1 mm)

Unit type RCUF60AZPY1

190 1405 1405

Unit type RCUF90/100AZPY1

Unit type RCUF120AZPY1

Unit type RCUF135/150AZPY1

Unit type RCUF180/200AZPY1

Unit type RCUF240AZPY1

Unit type RCUF270/300AZPY1

Unit type RCUF320AZPY1

Unit type RCUF360AZPY1

Unit type RCUF405/420/450AZPY1

Figure 5.1 Recommended concrete diagram

Figure 6-1 Lifting transport

Figure 6-2 Rolling transport Figure 6-3 Unit inclination

Pump Power Wiring

Pump Power Supply

*BSR1 Button switch (for startup)

Figure 7-3 Field wiring 11

Water pipe connection

Minimum water volume in the system

Water-side pressure loss diagram

Evaporator's internal water volume (m3) (m3)

Internal system's minimum water volume (m3) (m3)

Water quality control

Recycling water Water Corrosion Squamous

Check after installation

Instruction after test run

PWBB (CPU substrate) setting diagram PWBC

Figure 8 Controller indication diagram

See horsepower setting in

PWBB (CPU substrate) setting PWBC PWBO

Ternary cycle setting: unit type RCUF135/150/270/300/405/420/450AZPY1

PWBA (setting substrate) horsepower setting Table