Z0011975-2017-A Rcuf - Azy1 TC Ii PDF

Type
R134a
RCUF45AZY1 RCUF220AZY1
-Technical Catalog II- RCUF60AZY1 RCUF270AZY1
Installation, Operation and
Maintenance Instruction RCUF120AZY1 RCUF360AZY1
Hitachi Single and Air-cooled Water Chilling Unit AZY1 Series
-Screw Type-
Cautions
Before using 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
of operating conditions and can't

output 100%.
Unit operating range

(ºC)
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.
Energy efficiency Energy efficiency

● Model Model
level level
RCUF45AZY1 3 RCUF220AZY1 3
*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
Initial startup after shutdown ............................................................................................................. 27
Prolonged shutdown in winter ............................................................................................................ 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: RCUF45/50AZY1
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.
Maintenance work
How to start the main engine (remote control switch): 1. Remove objects impeding air flow at the side of the
1. Open the water inlet and outlet valves. heat exchanger, and clean the air-side heat
2. Switch on the power switch, after control switches are "OFF" and the How to shut down the exchanger.
"field/remote" switches on the PCB are at "remote" position. main engine: 2. Clean the main engine's surface.
3. Verify if phases R, S and T are correctly wired, and the correct wiring can be 1. Press "OFF" of operating 3. Rinse the pipeline of the water-side heat exchanger.
detected by a phase-sequence indicator. If the wiring is incorrect, the phase- switch. (This work should be conducted by professional
sequence reversal protection device will not allow the compressor to start. Cautions: personnel)
Switch off the power switch, and exchange any terminal of two phases out of In order to make the oil
the main power supply's three phases. heater actuate, please don't
4. Set the changeover switch to "refrigeration". cut off the main power
5. Start the refrigeration (heating) water pump. switch.
6. Press "ON".
Operation instruction Hitachi single and air-cooled water
chilling unit
Type: RCUF60AZY1
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:
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
How to start the main engine (remote control switch): engine is correct.
1. Open the water inlet and outlet valves. 4. Check if the water-side heat exchanger's water
2. Switch on the power switch, after control switches are "OFF" volume is sufficient.
and the "field/remote" switches on the PCB are at "remote" Maintenance work
position. 1. Remove objects impeding air flow at the side of
How to shut down the main engine:
3. Verify if phases R, S and T are correctly wired, and the correct
1. Press "OFF" of operating switch. the heat exchanger, and clean the air-side heat
wiring can be detected by a phase-sequence indicator. If the
Cautions: exchanger.
wiring is incorrect, the phase-sequence reversal protection
In order to make the oil heater actuate, please 2. Clean the main engine's surface.
device will not allow the compressor to start. Switch off the
don't cut off the main power switch. 3. Rinse the pipeline of the water-side heat
power switch, and exchange any terminal of two phases out
of the main power supply's three phases. exchanger. (This work should be conducted by
4. Set the changeover switch to "refrigeration". professional personnel)
5. Start the refrigeration (heating) water pump.
6. Press "ON".
unit
Type: RCUF90/100/120AZY1
Indicator:
Daily check:
Trouble removal:
sufficient.
are correct.
is correct.
Maintenance work
How to start the main engine (remote control switch):
How to shut down the main engine: 1. Remove objects impeding air flow at the side of the
1. Press "OFF" of operating switch.
2. Switch on the power switch, after control switches are "OFF" and exchanger.
Cautions:
the "field/remote" switches on the PCB are at "remote" position. 2. Clean the main engine's surface.
In order to make the oil heater actuate,
3. Verify if phases R, S and T are correctly wired, and the correct 3. Rinse the pipeline of the water-side heat
please don't cut off the main power
wiring can be detected by a phase-sequence indicator. If the wiring exchanger. (This work should be conducted by
switch.
is incorrect, the phase-sequence reversal protection device will not professional personnel)
allow the compressor to start. Switch off the power switch, and
exchange any terminal of two phases out of the main power
supply's three phases.
4. Set the changeover switch to "refrigeration".
6. Press "ON".
unit
Type: RCUF150/180AZY1
Indicator:
Daily check:
Trouble removal:
sufficient.
are correct.
is correct.
1. Open the water inlet and outlet valves. volume is sufficient.
2. Switch on the power switch, after control switches are "OFF" and Maintenance work
the "field/remote" switches on the PCB are at "remote" position. 1. Remove objects impeding air flow at the side of the
3. Verify if phases R, S and T are correctly wired, and the correct heat exchanger, and clean the air-side heat
Cautions:
wiring can be detected by a phase-sequence indicator. If the wiring
In order to make the oil heater actuate, exchanger.
is incorrect, the phase-sequence reversal protection device will not
please don't cut off the main power 2. Clean the main engine's surface.
allow the compressor to start. Switch off the power switch, and
switch. 3. Rinse the pipeline of the water-side heat
exchange any terminal of two phases out of the main power
supply's three phases. exchanger. (This work should be conducted by
4. Set the changeover switch to "refrigeration". professional personnel)
6. Press "ON".
unit
Indicator:
Daily check:
Trouble removal:
sufficient.
are correct.
is correct.
Maintenance work
2. Switch on the power switch, after control switches are "OFF" How to shut down the main engine:
1. Press "OFF" of operating switch. exchanger.
and the "field/remote" switches on the PCB are at "remote" 2. Clean the main engine's surface.
position. Cautions:
In order to make the oil heater actuate, 3. Rinse the pipeline of the water-side heat
3. Verify if phases R, S and T are correctly wired, and the exchanger. (This work should be conducted by
correct wiring can be detected by a phase-sequence please don't cut off the main power switch.
professional personnel)
indicator. If the wiring is incorrect, the phase-sequence
reversal protection device will not allow the compressor to
start. Switch off the power switch, and exchange any terminal
of two phases out of the main power supply's three phases.
6. Press "ON".
unit
Type: RCUF270AZY1
Indicator:
Daily check:
Trouble removal:
sufficient.
are correct.
is correct.
Maintenance work
2. Switch on the power switch, after control switches are "OFF" exchanger.
Cautions:
position. 3. Rinse the pipeline of the water-side heat
please don't cut off the main power switch.
correct wiring can be detected by a phase-sequence professional personnel)
6. Press "ON".
unit
Indicator:
Daily check:
Trouble removal:
sufficient.
are correct.
is correct.
1. Open the water inlet and outlet valves.
Maintenance work
2. Switch on the power switch, after control switches are "OFF" How to shut down the main engine:
1. Remove objects impeding air flow at the side of the
and the "field/remote" switches on the PCB are at "remote" 1. Press "OFF" of operating switch.
heat exchanger, and clean the air-side heat
position. Cautions:
exchanger.
3. Verify if phases R, S and T are correctly wired, and the correct In order to make the oil heater actuate,
2. Clean the main engine's surface.
wiring can be detected by a phase-sequence indicator. If the please don't cut off the main power switch.
3. Rinse the pipeline of the water-side heat
wiring is incorrect, the phase-sequence reversal protection
exchanger. (This work should be conducted by
device will not allow the compressor to start. Switch off the
professional personnel)
power switch, and exchange any terminal of two phases out
of the main power supply's three phases.
6. Press "ON".
unit
Type: RCUF400/420AZY1
Indicator:
Daily check:
Trouble removal:
sufficient.
are correct.
is correct.
Maintenance work
Cautions:
2. Switch on the power switch, after control switches are "OFF" exchanger.
please don't cut off the main power switch.
position. 3. Rinse the pipeline of the water-side heat
correct wiring can be detected by a phase-sequence professional personnel)
6. Press "ON".
unit
Type: RCUF450AZY1
Indicator:
Daily check:
Trouble removal:
sufficient.
are correct.
is correct.
Maintenance work
1. Remove objects impeding air flow at the side of the
How to start the main engine (remote control switch): How to shut down the main engine: heat exchanger, and clean the air-side heat
1. Open the water inlet and outlet valves. 1. Press "OFF" of operating switch. exchanger.
2. Switch on the power switch, after control switches are "OFF" Cautions: 2. Clean the main engine's surface.
and the "field/remote" switches on the PCB are at "remote" In order to make the oil heater actuate, 3. Rinse the pipeline of the water-side heat
position. please don't cut off the main power switch. exchanger. (This work should be conducted by
3. Verify if phases R, S and T are correctly wired, and the professional personnel)
correct wiring can be detected by a phase-sequence
6. Press "ON".
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
Figure 1 Maximum inclination
1

Preparations
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
RCUF45-60AZY1 2,390 1,200 100 900 1,200 2,000 1,200
RCUF90AZY1 4,490 1,200 100 900 1,200 2,000 1,200
RCUF100AZY1 4,490 1,200 100 900 1,200 2,000 1,200
RCUF120AZY1 4,490 1,200 100 900 1,200 2,000 1,200
RCUF150AZY1 6,590 1,200 100 900 1,200 2,000 1,200
RCUF180AZY1 6,590 1,200 100 900 1,200 2,000 1,200
9,080
RCUF200AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
9,080
RCUF220AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
9,080
RCUF240AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
11,180
RCUF270AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
13,280
RCUF300AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
13,280
RCUF330AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
13,280
RCUF360AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
18,670
RCUF400AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
18,670
RCUF420AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
20,770
RCUF450AZY1 1,200 900 900 1,200 2,000 1,200
(Minimum)
2
Preparations
Gravity center of the unit

Gravity center Operating Gravity center Operating
Type Type
X Y weight X Y weight
RCUF45AZY1 1341 967 1640 RCUF180AZY1 3319 854 5130
RCUF50AZY1 1341 967 1690 RCUF270AZY1-1 3309 855 4890 Configuration
RCUF60AZY1 1345 960 1800 RCUF300AZY1-1 3309 855 4890
RCUF90AZY1 2268 901 3050 RCUF300AZY1-2 3309 855 4890 side
RCUF100AZY1 2272 903 3160 RCUF330AZY1-1 3309 855 4890
RCUF120AZY1 2281 900 3390 RCUF330AZY1-2 3319 854 5130
RCUF200AZY1-1 2272 903 3160 RCUF360AZY1-1 3319 854 5130
RCUF200AZY1-2 2272 903 3160 RCUF360AZY1-2 3319 854 5130
RCUF220AZY1-1 2272 903 3160 RCUF400AZY1-1 3309 855 4890
RCUF220AZY1-2 2281 900 3390 RCUF400AZY1-2 3309 855 4890
RCUF240AZY1-1 2281 900 3390 RCUF420AZY1-1 3309 855 4890
RCUF240AZY1-2 2281 900 3390 RCUF420AZY1-2 3309 855 4890
RCUF270AZY1-2 2281 900 3390 RCUF450AZY1-1 3309 855 4890
RCUF400AZY1-3 2272 903 3160 RCUF450AZY1-2 3309 855 4890
RCUF420AZY1-3 2281 900 3390 RCUF450AZY1-3 3309 855 4890
RCUF150AZY1 3309 855 4890 Figure 3 Gravity
center
Weight balancing
Configuration
Weight distribution
side
Type (kg)
1 2 3 4
RCUF45AZY1 386 435 434 385
RCUF50AZY1 398 449 447 396
RCUF60AZY1 424 480 476 420
Weight distribution (kg)
Type
1 2 3 4 5 6
Configuration
RCUF90AZY1 524 526 529 493 490 488 side
RCUF100AZY1 542 545 548 512 509 506
RCUF120AZY1 581 585 590 549 545 540
RCUF200AZY1-1 542 545 548 512 509 506
RCUF200AZY1-2 542 545 548 512 509 506
RCUF220AZY1-1 542 545 548 512 509 506
RCUF220AZY1-2 581 585 590 549 545 540
RCUF240AZY1-1 581 585 590 549 545 540
RCUF240AZY1-2 581 585 590 549 545 540 Configuration
side
RCUF270AZY1-2 581 585 590 549 545 540
RCUF400AZY1-3 542 545 548 512 509 506
RCUF420AZY1-3 581 585 590 549 545 540
Weight distribution (kg)
Type
1 2 3 4 5 6 7 8
RCUF150AZY1 646 644 651 649 576 578 572 574
RCUF180AZY1 677 673 686 682 605 610 596 601
RCUF270AZY1-1 646 644 651 649 576 578 572 574
RCUF300AZY1-1 646 644 651 649 576 578 572 574
RCUF300AZY1-2 646 644 651 649 576 578 572 574
RCUF330AZY1-1 646 644 651 649 576 578 572 574
RCUF330AZY1-2 677 673 686 682 605 610 596 601
RCUF360AZY1-1 677 673 686 682 605 610 596 601
RCUF360AZY1-2 677 673 686 682 605 610 596 601
RCUF400AZY1-1 646 644 651 649 576 578 572 574
RCUF400AZY1-2 646 644 651 649 576 578 572 574
RCUF420AZY1-1 646 644 651 649 576 578 572 574
RCUF420AZY1-2 646 644 651 649 576 578 572 574
RCUF450AZY1-1 646 644 651 649 576 578 572 574
RCUF450AZY1-2 646 644 651 649 576 578 572 574
RCUF450AZY1-3 646 644 651 649 576 578 572 574
3

Preparations
Noise level
Type Noise level (dB) Type Noise level (dB)
RCUF200AZY1 84 RCUF450AZY1 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 RCUF45/50/60AZY1
Figure 1 Schematic diagram of Figure 2 Schematic diagram of
dual rectangular foundation strip foundation Concrete
Concrete
Drainage tank Cement mortar Drainage tank Cement mortar
(Water Drainage tank Drainage tank Drainage tank

8. Anti‐vibration rubber pad Water pipe side Detail drawing of foundation
pipe side)
installation (not to scale)

Foundation bolt
4-M20x300
Foundation bolt
Nut
(Front side)
(Front side)
Washer
(Back side)
(Back side)
Lining
4. Anti-vibration rubber pad
4. Anti‐vibration rubber pad Anti-vibration rubber pad
Steel plate
Manufacturer's supplies
(Compressor side) (Compressor side)
5

Preparations
Unit type RCUF150/180AZY1
6

Preparations
Unit type RCUF270AZY1
60
140
7

Preparations
Unit type RCUF400/420AZY1
60
140
Unit type RCUF450AZY1
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 During transport, the unit inclination shall not exceed
two outer frames of the unit (see Figure 3 for the 15º, as shown in Figure 6-3.
gravity center of units) and be fit for balances of If the inclination exceeds 15º, the unit may overturn.
the unit.
Figure 6-3 Unit inclination
Figure 6-2 Rolling transport
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.
NOTICE
RCUF200AZY1, RCUF220AZY1, RCUF240AZY1, RCUF270AZY1, RCUF300AZY1, RCUF330AZY1,
RCUF360AZY1, RCUF400AZY1, RCUF420AZY1 and RCUF450AZY1 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) Indicator power supply
*PLR2 Indicator (pump operation)
*PLR3 Indicator (refrigeration operation) Remote control and remote display wiring (if needed)
*PLR4 Indicator (heating operation) (only for
heat pump unit)
*PLO1,2,3 Indicator (alarm)
*PLO4,5,6 Indicator (defrosting) (only for heat
pump unit)
10
Installation Work
Figure 7-1 Field wiring

RCUF90/100/120/200/220/240AZY1, RCUF270AZY1 NO2 and RCUF400/420AZY1 NO3
Dual cycle:
3
PWBc
*CSP
Y52P1
Pump Power Supply

4
*ORP
*CMP
*BSR1 Button switch (for startup)

Pump Power Wiring
(if required)
*CSCHR Switch (for heating/refrigeration changeover) (only for
heat pump unit)
*CSP Switch (for pump operation changeover)
*PLR1 Indicator (unit 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)

RCUF150/180/300/330/360/450AZY1, RCUF270AZY1 NO1 and RCUF400/420AZY1
NO1/2 Ternary cycle:
3
PWBc
*CSP
Y52P1
Pump Power Supply
4
*BSR1 Button switch (for startup)

*ORP
*CSCHR Switch (for heating/refrigeration changeover) (only
for heat pump unit)
*CSP Switch (for pump operation changeover) *CMP
*PLR1 Indicator (unit operation)
*PLR3 Indicator (refrigeration operation)
*PLR4 Indicator (heating operation) (only for heat pump Pump Power Wiring
unit)
*PLO1,2,3 Indicator (alarm) (if required)
*PLO4,5,6 Indicator (defrosting) (only for heat pump unit)
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 (m3/h)
Maximum water
Type Minimum water flow Type Maximum water flow Minimum water flow
flow
RCUF45AZY1 49.0 13.6 RCUF240AZY1 133.2/133.2 37.0/37.0
RCUF50AZY1 54.2 15.1 RCUF270AZY1 133.2/162.5 37.0/45.2
RCUF60AZY1 66.6 18.5 RCUF300AZY1 162.5/162.5 45.2/45.2
RCUF90AZY1 97.9 27.2 RCUF330AZY1 162.5/199.6 45.2/55.5
RCUF100AZY1 108.4 30.1 RCUF360AZY1 199.6/199.6 55.5/55.5
RCUF120AZY1 133.2 37.0 RCUF400AZY1 162.5/162.5/108.4 45.2/45.2/30.1
RCUF150AZY1 162.5 45.2 RCUF420AZY1 162.5/162.5/133.2 45.2/45.2/37.0
RCUF180AZY1 199.6 55.5 RCUF450AZY1 162.5/162.5/162.5 45.2/45.2/45.2
RCUF200AZY1 108.4/108.4 30.1/30.1
RCUF220AZY1 108.4/133.2 30.1/37.0
13
Installation Work
Water-side pressure loss diagram

1,RCUF45AZY1
2,RCUF50AZY1
3,RCUF60AZY1
Water-side heat exchanger pressure loss diagram 4,RCUF90AZY1
Differential pressure (kPa)
300 5,RCUF100AZY1
RCUF200AZY1-1/2
200
RCUF220AZY1-2
RCUF400AZY1-3
6,RCUF120AZY1
100 RCUF220AZY1-1
RCUF240AZY1-1/2
RCUF270AZY1-2
50 RCUF420AZY1-3
7,RCUF150AZY1
RCUF270AZY1-1
RCUF300AZY1-1/2
RCUF330AZY1-2
RCUF400AZY1-1/2
RCUF420AZY1-1/2
10
RCUF450AZY1-1/2/3
10 30 50 100 200 300
8,RCUF180AZY1
3
Water flow rate(m /h) RCUF330AZY1-1
RCUF360AZY1-1/2
Internal water volume (m3) (m3)

Evaporator's internal water Evaporator's internal water
Type Type
volume volume
RCUF45AZY1 0.072 RCUF220AZY1 0.192/0.194
RCUF50AZY1 0.072 RCUF240AZY1 0.194/0.194
RCUF60AZY1 0.090 RCUF270AZY1 0.194/0.234
RCUF90AZY1 0.192 RCUF300AZY1 0.234/0.234
RCUF100AZY1 0.192 RCUF330AZY1 0.234/0.267
RCUF120AZY1 0.194 RCUF360AZY1 0.267/0.267
RCUF150AZY1 0.234 RCUF400AZY1 0.234/0.234/0.192
RCUF180AZY1 0.267 RCUF420AZY1 0.234/0.234/0.194
RCUF200AZY1 0.192/0.192 RCUF450AZY1 0.234/0.234/0.234
Internal system's minimum water volume (m3) (m3)
Type Capacity Type Capacity
RCUF45AZY1 0.68 RCUF220AZY1 1.50/1.85
RCUF50AZY1 0.75 RCUF240AZY1 1.85/1.85
RCUF60AZY1 0.92 RCUF270AZY1 1.85/2.25
RCUF90AZY1 1.36 RCUF300AZY1 2.25/2.25
RCUF100AZY1 1.50 RCUF330AZY1 2.25/2.77
RCUF120AZY1 1.85 RCUF360AZY1 2.77/2.77
RCUF150AZY1 2.25 RCUF400AZY1 2.25/2.25/1.50
RCUF180AZY1 2.77 RCUF420AZY1 2.25/2.25/1.85
RCUF200AZY1 1.50/1.50 RCUF450AZY1 2.25/2.25/2.25
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
Trend
Chilled water system
Item Recycling Squamous

water (below Water supply Corrosion object
20ºC) sedimentation
Standard mass pH value (25ºC) 6.8 - 8.0 6.8 - 8.0 ○ ○
Electric conductivity (mS/m) (25ºC) 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 /
Less than 50 Less than 50 ○
l)
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/
Less than 1.0 Less than 0.3 ○ ○
l)
Total copper content (mg Cu/ l) Less than 1.0 Less than 0.1 ○
Chloride ion (mgS2- / l) Detection free ○
Ammonium ion (mgNH4+ / 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 Wire capacity If the connections
air flow are fastened
Maintenance space Switch capacity Operation control
Noise and vibration device
Daylight and rain Fuse capacity Safety device
Appearance Voltage and Interlock
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 refrigerant
requirements? outlet completely open?
7. Are the sealing cap and nuts of the shutoff valve
Water pipe Water fastened?
dimension drainage
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 RCUF45/50/60AZY1
PWBC
PWBB (CPU substrate) setting diagram (I/01 substrate) setting
diagram
Figure 8 Controller indication diagram

Double cycle setting: unit type RCUF90/100/120/200/220/240AZY1, RCUF270AZY1 No.2 and
RCUF400/420AZY1 No.3
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 RCUF150/180/300/330/360/450AZY1, RCUF270AZY1 No.1, and

RCUF400/420AZY1 No.1&2
PWBE
(I/03 substrate)
setting diagram
See
horsepower
setting in
below Table
PWBB (CPU substrate) PWBO

setting diagram PWBC
(I/02 substrate)
(I/01 substrate)
setting diagram
setting diagram
PWBA (setting substrate) horsepower setting Table

Content
Symbol 8 9 Model
settings
50 RCUF45/50/90/100/150/200/300/400/450AZY1, RCUF 270/420AZY1
DSW1 1 0
horsepower No.1, RCUF 220/330/420AZY1 No.2
60 RCUF60/120/180 AZY1, RCUF220/330AZY1 No.1, RCUF270AZY1
DSW1 0 1
horsepower No.2, RCUF420AZY1 No. 3
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 RCUF45/50/60AZY1 should be put to the "OFF" side.
b. Switch "DSW1-3, 4" of RCUF90/100/120AZY1, RCUF270AZY1 No.2, and RCUF400/420AZY1 No.3
should be put to the "OFF" side.
c. Switch "DSW1-4" of RCUF150/180/300/330/360/450AZY1, RCUF270AZY1 No.1, and
RCUF400/420AZY1 No.1/2 should be put to the "OFF' side.
19

Controller Settings
*Local/remote control selector switch

Switch "SW2" is the selector switch for field/remote operation. The standard setting is a local control
operation, therefore, the switch is originally set to "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:
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 3min, 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- LCD display content Seven- LCD display content
segment code segment code
display display
5P 5P Abnormal pump interlock 40-40 Error of unit quantity control
Anti-phase and default phase C1-F0 Fan quantity setting
05 05
protection Abnormal THM of the nutrient solution
Cn-24
01-01 Fault of starting circuit temperature (CN24)
Abnormal THM of the inlet water Cn-25 Abnormal THM of back outlet (CN25)
11-11
temperature (CN4) Cn-23 Abnormal THM of the exhaust (CN26)
Abnormal THM of the outlet water FAN abnormality detected (Fan of
12-12 F3－2m
temperature (CN5) No.3 unit)
Abnormal THM of the external air FAN abnormality detected (Fan of
22-22 F4－2m
(CN6) No.4 unit)
Abnormal THM of the inlet water FAN abnormality detected (Fan of
11-HE F5－2m
temperature (CN7) No.5 unit)
Water supply system 1 Temperature FAN abnormality detected (Fan of
2C-2C F6－2m
sensor is abnormal (CN13) No.6 unit)
Return water system 2 Temperature FAN abnormality detected (Fan of
2d-2d F7－2m
sensor is abnormal (CN14) No.7 unit)
Chilling water break (refrigeration in FAN abnormality detected (Fan of
6E-6E F8－2m
operation) No.8 unit)
Warm water break (heating in F1－2m FAN overcurrent (fan of No.1 unit)
6E-6E
operation) F2－2m FAN overcurrent (fan of No.2 unit)
Warm water break (heating in F3－2m FAN overcurrent (fan of No.3 unit)
6E-6E
operation)
F4－2m FAN overcurrent (fan of No.4 unit)
13-13 Anti-freeze protection
Activation of thermostat for water F5－2m FAN overcurrent (fan of No.5 unit)
14-14 F6－2m FAN overcurrent (fan of No.6 unit)
temperature going up too quickly
Abnormal communication of unit F7－2m FAN overcurrent (fan of No.7 unit)
03-03
quantity control F8－2m FAN overcurrent (fan of No.8 unit)
03-03 CPU-I/O abnormal communication FAN radiator fin over temperature (fan
03-03 Abnormal communication inside of I/O F1－2m
of No.1 unit)
03-03 Abnormal external communication FAN radiator fin over temperature (fan
03-03 COMP abnormal communication F2－2m
of No.2 unit)
03-03 Abnormal communication of pump FAN radiator fin over temperature (fan
Transmission of intelligent electric F3－2m
03-03 of No.3 unit)
meter FAN radiator fin over temperature (fan
40-40 Setting error F4－2m
of No.4 unit)
40-40 Unit quantity control setting error FAN radiator fin over temperature (fan
F5－2m
40-40 Insufficient quantity of running units of No.5 unit)
40-40 Transmission error (wrong wiring) FAN radiator fin over temperature (fan
F6－2m
40-40 Transmission error (wrong wiring) of No.6 unit)
40-40 Maloperation (remote → local) FAN radiator fin over temperature (fan
F7－2m
40-40 Maloperation (local → remote) of No.7 unit)
Maloperation (refrigeration → FAN radiator fin over temperature (fan
40-40 F8－2m
of No.8 unit)
heating)
F1－5m FAN under voltage (fan of No.1 unit)
Maloperation (heating →
40-40 F2－5m FAN under voltage (fan of No.2 unit)
refrigeration)
Maloperation (set to remote operation F3－5m FAN under voltage (fan of No.3 unit)
40-40 FAN under voltage (fan of No.4 unit)
under local mode) F4－5m
Maloperation (set to local operation F5－5m FAN under voltage (fan of No.5 unit)
40-40
under remote mode) F6－5m FAN under voltage (fan of No.6 unit)
21
Control System

Seven- LCD display content Seven- LCD display content
segment code segment code
display display
F7－5m FAN under voltage (fan of No.7 unit) Abnormal communication of fan (Fan
F6－4m
F8－5m FAN under voltage (fan of No.8 unit) of No.6 unit)
F1－5m FAN overvoltage (fan of No.1 unit) Abnormal communication of fan (Fan
F7－4m
of No.7 unit)
F2－5m FAN overvoltage (fan of No.2 unit)
Abnormal communication of fan (Fan
F3－5m FAN overvoltage (fan of No.3 unit) F8－4m
of No.8 unit)
F4－5m FAN overvoltage (fan of No.4 unit) Abnormal communication current
FAN overvoltage (fan of No.5 unit) F1－8m
F5－5m sensor of FAN(Fan of No.1 unit)
F6－5m FAN overvoltage (fan of No.6 unit) Abnormal communication current
F2－8m
F7－5m FAN overvoltage (fan of No.7 unit) sensor of FAN(Fan of No.2 unit)
Cn-26 Abnormal THM of the suction (CN27) Abnormal communication current
F3－8m
Cn-23 Abnormal THM of the exhaust (CN28) sensor of FAN(Fan of No.3 unit)
Abnormal THM of evaporation inlet Abnormal communication current
Cn-21 F4－8m
(CN29) sensor of FAN(Fan of No.4 unit)
Cn-23 Abnormal THM of the exhaust (CN30) Abnormal communication current
F5－8m
sensor of FAN(Fan of No.5 unit)
Abnormal THM of exhaust pressure
Cn-27 Abnormal communication current
sensor (CN31) F6－8m
Abnormal THM of suction pressure
Cn-27 FAN short-circuit detection (fan of
No.1 unit)
Abnormal THM of suction pressure
Cn-28 Short-circuit detection of FAN (Fan of
No.2 unit)
Cn-39 Abnormal current transformer (CN36)
Cn-hn High pressure cut-off protection Short-circuit detection of FAN (Fan of
F3－1m
No.3 unit)
Cn-Ln Low pressure cut-off protection
Short-circuit detection of FAN (Fan of
Cn-5n Overcurrent of compressor F4－1m
No.4 unit)
Temperature controller inside of the
Cn-7n Short-circuit detection of FAN (Fan of
compressor is triggered F5－1m
No.5 unit)
Temperature controller of preventing
exhaust overheating F6－1m
No.6 unit)
Temperature controller inside of the
fan is triggered F7－1m
No.7 unit)
Cn-Fn Fan overcurrent
FAN short-circuit detection (fan of
Cn-Ln Low pressure protection control F8－1m
No.8 unit)
Too low inlet temperature of
Cn-9n
evaporator
Cn-tn Too low suction temperature
Cn-6n Exhaust temperature
Cn-hn Too high pressure of high pressure
Cn-13 Anti-freeze
Activation of thermostat for water
Cn-14
temperature going up too quickly
FAN abnormality detected (Fan of
F1－2m
No.1 unit)
FAN abnormality detected (Fan of
F2－2m
No.2 unit)
F8－5m FAN overvoltage (fan of No.8 unit)
F1－4m
of No.1 unit)
F2－4m
of No.2 unit)
F3－4m
of No.3 unit)
F4－4m
of No.4 unit)
F5－4m
of No.5 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 RCUF45/50/60AZY1 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 RCUF90/100/120AZY1, RCUF270AZY1 No2 and RCUF400/420AZY1 No3 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 RCUF150/180/300/330/360/450AZY1, RCUF270AZY1 No1, and RCUF400/420AZY1 No1/2

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 "Instructions" to keep the unit in 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 - if 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)
26 Cleaning scope diagram

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 valve 50A
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
RCUF RCUF RCUF RCUF RCUF RCUF RCUF RCUF RCUF
Type
45AZY1 50AZY1 60AZY1 90AZY1 100AZY1 120AZY1 150AZY1 180AZY1 200AZY1
Refrigerant
injection 54 54 60 2*54 2*54 2*62 3*58 3*62 4*54
volume (kg)
Lubricating oil
injection 8 8 8 2*8 2*8 2*8 3*8 3*8 4*8
volume (l)
RCUF RCUF RCUF RCUF RCUF RCUF RCUF RCUF RCUF
Type
220AZY1 240AZY1 270AZY1 300AZY1 330AZY1 360AZY1 400AZY1 420AZY1 450AZY1
Refrigerant
injection 2*62+2*58 4*62 3*58+2*62 6*58 3*62+3*58 6*58 6*58+2*54 6*58+2*62 9*58
volume (kg)
Lubricating oil
injection 4*8 4*8 5*8 6*8 6*8 6*8 8*8 8*8 9*8
volume (l)
28
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!
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
Type RCUF45 RCUF50 RCUF60 RCUF90 RCUF100 RCUF120 RCUF150 RCUF180 RCUF200
AZY1 AZY1 AZY1 AZY1 AZY1 AZY1 AZY1 AZY1 AZY1
Cutting off with Manual reset, adjustable (one switch for each compressor motor)
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 Micro-processor control
low pressure MPa 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
control
Cut off and Automatic reset, non-adjustable
connect 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
Oil heater power One switch for each compressor motor
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
temperature ºC 140 140 140 140 140 140 140 140 140
control
Overcurrent relay of fan motor Manual reset, adjustable (one set of motor for each fan)
380V 50Hz A 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3 3.3
Set-pressure on safety valve 1 cycle
MPa 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02 1.02
Type RCUF220 RCUF240 RCUF270 RCUF300 RCUF330 RCUF360 RCUF400 RCUF420 RCUF450
AZY1 AZY1 AZY1 AZY1 AZY1 AZY1 AZY1 AZY1 AZY1
Cutting off with Manual reset, adjustable (one switch for each compressor motor)
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 Micro-processor control
low pressure MPa 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
control
Cut off and Automatic reset, non-adjustable
connect 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 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
refrigeration and ºC
circulation cutting 1 1 1 1 1 1 1 1 1
system off for anti-
freeze protection
Cutting off with
exhaust
temperature ºC 140 140 140 140 140 140 140 140 140
control
Overcurrent relay of fan motor Manual reset, adjustable (one set of motor for each fan)
380V 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>
Low pressure (MPa)
High 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 100℃.
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**AZY1 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
Chilled water/hot water _____ m3/h____ Pa_______ Pa_______
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.
33

Table 5 Daily operation record
Type:
Weather:
Date:
Operating time: startup ( ) stop ( )
Outdoor Dry bulb ºC
temperature Wet bulb ºC
Indoor temperature ºC
High
MPa
pressure
Low
Compressor MPa
pressure
Voltage V
Current A
Air-side heat Inlet (dry
ºC
exchanger bulb)
Air Outlet (dry
temperature ºC
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
expanding ○ Pipe expanding
tool The pipe expanding tool of R134a
Checklist of and R22 are interchangeable
Dimension control
flaring -
after flaring
dimension
Pipe-
bending ○ - Bend pipe
machine
Pipe
Refrigerant expanding ○ - Pipe expanding
pipe machine
Torque Connection of the
○ -
wrench flaring nut
Tool of
Copper pipe
welding ○ Correct welding.
welding
copper pipe
Nitrogen Strict control is required to prevent
Prevent oxidation
○ air pollution (use of nitrogen at
at welding
welding)
Lubricating Different from UX300 of R22 Oil used for flaring
ZE-GLES RB68
oil system, mixing is not allowed. surface
Refrigerant Check the color of the refrigerant
tank tank . For elemental refrigerant, it
● Refill refrigerant
is recommended to fill in the form
of liquid to improve the efficiency.
Adaptor ○ The existing one could be used.
Connector However, a vacuum adapter is
of vacuum required to prevent the Vacuum pumping
●
pumps countercurrent when the vacuum
pump stops.
Various The pressure is lower than R22
●
valves system and is interchangeable.
Vacuum
drying
Filling Do not use the old pipes to the Vacuum pump,
flexible hose new refrigerant unit. Once be vacuum keeping,
change
refrigerant used, the mineral oil will flow into refrigerant filling
● the circulation and cause and pressure
deposition. check
Result in obstruction and damage
of compressor
Filling tank - - -
Poidometer Measurement
○ - instrument of
refrigerant filling
Leaking
The refrigerant checking method is
detector of ○ -
the same with R22 system
refrigerant
35
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.
1. Check short-circuit part.
The fuse of starting circuit is burnt-
2. Check the loose contact part, and tighten or
out or loose contact
replace it if necessary.
The coil of AC fan contactor is burnt-
1. Find out the reason, and repair or replace it.
out or loose contact
1. Find out the reason, and reset the setting
Setting error of overcurrent relay
The fan does value of overcurrent relay
not work Too low voltage 1. Check the voltage of the unit.
1. Check the motor or terminal, and repair or
Motor or terminal short-circuit
replace it if required
The fan does not work 1. Find the reason why the fan does not work.
1. Check the connection of water pumps. If
Disconnection of inter-lock
required, please maintain or replace it.
equipment of chilled water pump
2. Check the pump not started.
The
1. Troubleshooting and then pressing the "ON"
compressor Error of electrical protection design
button to see if there is any fault.
cannot start
1. Conduct intermodulation on any 2 phases
Connection error of compressor
among the R, S, T 3 phases of power supply
main power supply wiring
wiring.
Too high exhaust pressure 1. See "high discharge pressure".
The
1. For faults, reset the setting value or replace
compressor Fault of the high pressure switch
the parts.
stops for high
Too high exhaust pressure and 1. See "high discharge pressure" and "high
pressure
suction pressure suction pressure".
High voltage or low voltage, and 1. Check the power line and its connection, and
Compressor
single phase or phase is imbalance maintain or replace it if necessary.
stops for the
Loose wire 1. Tighten or replace it if required.
disconnection
1. Check the compressor coil, and repair or
of overcurrent Burnt-out of compressor coil
replace it if required.
relay
Burnt-out of overcurrent relay 1. Replacement.
Too low outlet water temperature of 1. Check if the setting value of outlet water
The chilling water temperature is too low.
compressor
1. If there is any fault of thermistor, replace it if
stops for anti- Fault of thermistors
required.
freeze
Insufficient chilled water flow 1. Check the opening degree of water pumps.
protection
Air exists in the water circuit 1. Exhaust gas.
(refrigeration
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 1. Check the leakage of refrigerant and the faults
Overheating motor
compressor of bypass capillary tubes.
stops for 1. Check the internal temperature detector when
Component fault
internal 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 1. Recalibrate unloading device, and repair or
Fault of unloading devices
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.

36
compressors 1. Check noise parts, and maintain or replace

Aging of compressors
compressor if required.
Loose screw part 1. Tighten all the screw parts
There is Insufficient intensity of installation
2. See Guide for Installation
noise. foundation
Fault of thermistors 1. Reset temperature. 2. Replace thermistor.
1. Check if there is blockage of solenoid valve
It cannot be Electromagnetic valve fault
coil and oil circuit.
unloaded.
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.
Faults of the shutoff valve and 1. Check valve component or bypass capillary
shutdown of partial liquid pipe valve pipe, and replace it if required.
High Over filling of refrigerant 1. Discharge excessive refrigerant.
discharge Air or non-condensable gas exists in
1. Discharge gases from the system.
pressure the system.
(refrigeration Suction pressure is above normal
1. See "high suction pressure".
in operation) value
Too cold of side air from air-heat
1. Check the environmental temperature.
exchanger
Insufficient filling of refrigerant 1. Fill sufficient refrigerant.
Low exhaust
Leakage of discharge valve from 1. Replace the valve, and change the
pressure
compressors. compressor if desired.
(refrigeration
Suction pressure is below normal
in operation) 1. See "low suction pressure".
value
High temperature of inlet chilled 1. Check the thermal insulation of water pipes. 2.
High suction water Check the thermal insulation specification.
pressure The openness of the expansion 1. Readjust the valve, and replace it in case of
(refrigeration valve is too large faults.
in operation) Low temperature of inlet chilled
1. Check the thermal insulation specification.
water
Improper adjustment on expansion 1. Adjust overheat degree properly, and maintain
valves or fault or replace it if required.
Low suction
Insufficient filling of refrigerant 1. Fill sufficient refrigerant.
pressure
Too much oil in evaporator 1. Discharge excessive oil.
(refrigeration
Incrustation in evaporator 1. Remove incrustation.
in operation)
1. Check the temperature difference between
Insufficient water flow
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.
© Johnson Controls–Hitachi Wanbao Air-conditioning(Guangzhou)Co., Ltd.

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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)

Energy efficiency Energy efficiency

Figure 1 Maximum inclination

Figure 2 Running space h1≤h2

Gravity center of the unit

Recommended concrete diagram

Drainage tank Cement mortar Drainage tank Cement mortar

(Water Drainage tank Drainage tank Drainage tank

(Compressor side) (Compressor side)

Unit type RCUF90/100/120AZY1

Unit type RCUF150/180AZY1

Unit type RCUF200/220/240AZY1

Unit type RCUF270AZY1

Unit type RCUF300/330/360AZY1

Unit type RCUF400/420AZY1

Figure 5.1 Recommended concrete diagram

Figure 6-1 Lifting transport

Figure 6-3 Unit inclination

Figure 6-2 Rolling transport

Pump Power Wiring

Figure 7-1 Field wiring

Pump Power Supply

*BSR1 Button switch (for startup)

Figure 7-2 Field wiring

*BSR1 Button switch (for startup)

Figure 7-3 Field wiring

Water pipe connection

Minimum water volume in the system

Water-side pressure loss diagram

Internal water volume (m3) (m3)

Water quality control

Item Recycling Squamous

Check after installation

Table 2 Inspection items of installation

Figure 8 Controller indication diagram

See horsepower setting in

PWBB (CPU substrate) setting PWBC PWBO

Ternary cycle setting: unit type RCUF150/180/300/330/360/450AZY1, RCUF270AZY1 No.1, and

PWBB (CPU substrate) PWBO

PWBA (setting substrate) horsepower setting Table

*Local/remote control selector switch

(2) Normal display

CLS：close OPN:open STA:star DLT:delta 23

Ternary cycle RCUF150/180/300/330/360/450AZY1, RCUF270AZY1 No1, and RCUF400/420AZY1 No1/2

5 sec. 5sec 5 sec.

3 min. 60 sec. 60 sec. 60 sec.

6. Maintenance and Servicing

2. Check the circulation circuit:

Cleaning area Saturation

26 Cleaning scope diagram

Prolonged shutdown in winter

Unit circulation system schematic (with economizer)

Mark Name Specification

Settings of the safety and control device

Chilled water/hot water _ m3/h Pa_ Pa_____