DAIKIN OIL COOLING UNIT INSTRUCTION MANUAL HP MODEL NAME 2 AKZ206-D39 AKZ206-D34A THANK YOU FOR PURCHASED DAIKIN OIL COOLING UNIT. Before you use the unit, please be sure to read this instruction manual for knoving how to use it correctly. @It vill also help when, with the machine in use, you have any questions or have experienced trouble of any kind about it. @After persuading, please keep this with the spares. ‘This instruction manual has contained in everything you should know when you use the OIL COOLING UNIT. onoene « Installation of each - Maintenance and inspection - Troubleshooting guide - CONTENTS Cautions in general Cautions for installation Electrical wiring Cautions for operation Names, functions and operation on control panel Alara functions -- thermistor HM1480-28(OIL COOLING UNIT) (NOTES ON SAFETY) MBefore use @Cerefully read our materials such as {NOTES ON SAFETY) , an operation uanual and specification for proper use. @Xeep the above materials for easy reference. (Note 1) This waterial contains extraction of iteas which should be particularly noted for ‘safety’. For other details, refer to your operation manual and specification. (Note 2) You are requested to incorporate the contents shown in this paper into the’ operation manual of your machine. WiAbout warks employed in this naterial A Danger = indicates an imainent hazardous situation which may result in fatality or serious injury if not avoided. Ay Warning => indicates a potential hazardous situation which could result in fatality or serious injury if not avoided. As Caution =» indicates a potential hazardous situation which could result in slight or wediua injury or property damage. Motes on safety (1General Ay Danger @Transportation, installation, piping, viring, oparation, aintenance and inspection should be done by experts. Ay Danger @Be sure to observe the following strictly when starting vork. “Be sure: to turn the pover off. Never keep wires alive. Ay Danger @Do not operate the unit in explosive atoaospheres, which may cause a fire or an accident resulting in injury or death. Ay Caution @0perate the unit exactly according to the specifications described in the catalog and the delivery specification. Failure to do this say cause serious accidents such as breakage of the main unit, injury, fire, and electric shock. Ay Caution @Renodeling of products by a custouer is beyond our varranty, for which the company shall have no liability. Ay Caution @Be sure to carry out daily inspection (shown in the operation manual or attached material). Ay Caution @Do not operate the unit in special atouospheres such as high temperature or high humidity. As Caution @Do not mount the oil cooling unit, hit it, or give external force on it, which way cause injury or damage. (2)Transportation/ transfer Observe the following strictly since the oil cooling unit is heavy in veight and very dangerous if dropped or turned over. (which way cause injury or damage. ) ‘A Danger @Check the weight of the oil cooling unit (shown in the asseably diagram). Hang only a unit within the rated load of a hoisting attachnent. A, Danger @Use a hanging hook securely at the exact designated position (shown in the assembly diagram). Ay Narning @Xeep avay fron the unit while carrying it by a hoisting attachnent. There is a fear of injury or damage due to dropping or turning over. Ay Caution @Fix the unit firaly to prevent novesent by tresbling or external force during transportation.(8)Installation/adjustment/test operation AM Caution Confirm the installing position of the oil cooling unit with the assenbly diagram, and fix it securely with bolts or foundation bolts. Ay Danger @Earth a ground terminal securely. Failure to do this may cause electric shock. Ay Caution @Do not interfere with ventilation around the outlet of the oil cooling unit with obstacles. Cooling vill be hindered, and ebnormal heating may cause “damage or @ burn” A Danger @A cover or ‘casing is provided on the rotating part for safety. Do not insert your finger through an opening, which may cause injury. Ay Caution @Fill the proper anount of usable oil into the oi] tank (when with oil tank). (As for proper anount, refer to the specification/operation manual. ) Ay Caution ©then performing test run of the oil cooling unit, observe the following strictly. Failure to do this may cause injury or damage. Wake sure that the main unit is in safety (not running, or running in safety from accident). ir inlet or (4)Niring/piping Ay Caution @Perfora wiring vork in accordance with [Electric installation standard) and [Interior wiring regulation] . Failure to do this may cause burning or fire. A Caution @Since a porer breaker is not included in the oil cooling unit. you are requested to prepare it. It is recommended to install other protective devices (such as earth leakage circuit breaker). A\ Danger @Connect with the porer cable in accordance with the wiring diagran in the specification or the operation aanual. Inproper connection may cause electric shock or fire. Ay Danger @Do not bend or pull the power cable or the notor’s lead wire by force, or put them between some objects, which may cause electric shock. (5)0peration Ay Caution OThe uotor casing. the outer board and the refrigerant pipe ay get considerably hot during operation. Take care not to contact thea vith your hand or body. which may cause a burn. A Caution @In case of abnormal conditions, stop operation immediately. Otherwise, damage, electric shock, fire or injury may be caused. A\ Danger @Do not operate vith the casing of the oil cooling unit or the terninal box cover of the sotor and other electric parts renoved, which may cause electric shock. Ay Caution @Do not perfora continuous operation exceeding the capacity of the motor. Overcurrent may cause burning of the coil or fire. Ay Danger @Be sure to turn the pover switch off when stopping operation. (6)Maintenance/ inspection A Caution ©The compressor, the frame of the motor and the refrigerant pipe will get considerably hot. Do not touch them vith bare hands, which way cause a burn. A\ Danger @Repair, disassenbly or renodelling should be performed by an expert. ‘Ay Caution @Periodically check the electric parts (switches for the motor, pressure, temperature, oil level). Follow the procedure shown in the operation manual or the attached sheet.1 CAUTIONS IN GENERAL 1-1 Operating. range Since Oil Cooling Unit is @ refrigeration machine, the operative room and oil temperatures are limited. Use Oil Cooling Unit in the renge shown below. ‘oom temperatre (C) 50 a z EC) = Inet 'of temperature (C) 1-2 Acceptable oils Hydraulic fluids (of mineral oil origin) and lubricating oil shall be used for this unit. ‘Therefore, the followng oll (fluid) shall not be used for this unit. 1) Fire-resistant hydraulic oil (hydraulic oils of phosphoric ester, chlorinsted hydrocarbon oils, water/slycol hydraulic oils and W/O and O/W emuision type hydraulic oils). 2) Weter and water soluble liquids. 3) Liquid chemicals and foods. 4) Cutting oils (fluid) end grinding oils (tiuid). 5) Fuel such as kerosene, gasoline. etc.2 CAUTIONS FOR INSTALLATION 2-1 Installation location ‘install in the following locations. 1) One solid and flat floor. 2) Away from direct sunlight and heat. 3) Where there is good ventilation and little humidity. 4) Where the discharged gas will not be drawn in again. 5) A place convenient for piping and wiring. 5) Where there is little dust, dirt. powder, oll mist, etc. Do not place anything in the way of ventilation within 500mm distance from intake and exhaust area. 2-2 Oilpiping and Suction strainer (Line Filter) 1) + Suction (Cit inlet) side.....~230~OnmHg (Vacuum pressure) + Discharge (Oil outlet) side......3kgf/or? or less. 2) Do not use more valves than necessary in the piping. Valves, even if fully open, cause & considerabie loss in pressure. 3) Use sealing tape around pipe connectins to prevent ar infitration and oil leakage. 2-3 Suction strainer (Line Filter) Din trapped in the evaporator of Oil Cooling Unit causes not only reduction of cooling capacity bbut also trouble with the compressor and oil pump. Consequently, attach a 100~150 mesh suction strainer thet causes litle pressure loss in the suction end of the oll piping. 2-4 Oil tank Oil tank capacity concerns responsibility and. stability of oil temperature very much in case of | cool it of . a eng Tie os Hee es pile. ona besis of recesary capacity we can maint wain machine (machine tool ). Model aK2206-039 Terk ceoacty | 750 L3 ELECTRICAL WIRING ‘°For electric wiring work, refer to the electric wiring plate attached to the _side of switch box cover. ‘*Do not change the wirings nor operate the electromagnetic switches manually inside the OlL COOL- ING UNT. 3-1 Power source capacity Rated voltage Power source capacity (KVA) ‘Three phase, 200 Volts ‘Three phase, 220 Volts 5 3-2 Circuit breakers Since this Oil Cooling Unit do not equipped the aain power over-current circuit breaker,be sure to install the breaker of rated current 15A. 3-3 Grounding and power source connection 1) Remove the switch box cover. In case of wiring from the right side, remove the roof too. 2) Pass the main power wires and ground wire (600V PVC insulated power wire, 2m? or more) ‘through the power wiring supply hole (s2?mm) in the left or right side panel and into the switch box. 3) Connect the ground wire to the ground terminal FAEAT [oxound weminal 4) Connect main power source wires R, S and T to the corresponding Li, LuandL.son the terminal strip (TB). 5) Connect power source wires for sil pomp R, S ond T to the corresponding U1.¥i and Wi on the terminal strip (1B),Wiring procedure tT exhaust air Changing wires for reverse phase ‘When the power source is connected to the reverse phase. Change the two wires; R and S, as ‘shown in the Fig. below. If in reverse phase, an alarm display is indicated on the control pane! bby the individual abnormality display function. (Refer to P.25) uy t2 ta ue 3 18 Y 1B _ we be poet > toe3-4 Remote control 1) Wiring procedure We as incicated below for remote control. Parts to be prepared. Pat Wiring material "Sige poe shelethrow renote contol 7 ‘Switch or “a” contact capable of transmit ting control signal HVSF 0.15 yen wire [AkE206-039 [1 0mA (DC12V) 2) Remove the short-circuit wire (terminal Nos. [10 -{ 11.) from the terminel strip inside ‘the switch box Refer to the layout on the electrical schematic plate attached to the Of the front panel. (Refer to the figure below.) ‘Senciat wee Gemoved 3) Connect Nos. (10 Jand (1] ].0n the terminal strip with the remote control operation ‘switch or “a” contact capable of transmitting a control signal. (Refer to the figure below.) 4) Outside ourput connection are as shown in the figure below. Please use connecting terminals on necessity. (Refer to P.24 about Time chart.) 30Z 30¥Y 52PAX I, Se aBSGING UNIT 6 ae aheo de de SS = ae eves on) Seacoieg Power Fane4 cautions FOR OPERATION 4-1. NEVER RUN WITHOUT OIL IN THE MACHINE. (This causes damage to the ol pump, etc.) 4-2 Prevent air from being mixed into the oil piping system. (tf air is mixed in, it causes noise) 4-3 Since the deley timer is installed, the OIL COOLING UNIT will not start again immediately after it wes stopned in order to protect the compressor from being overloaded. This is normal and does ‘not indicate any problem with the OIL COOLING UNIT. 4-4 Install the crain pipe to the oil pan by all means. Further, do not install a drain pipe to the oil drain since itis for servicing purpose.5. NAMES, FUNCTIONS AND OPERATIONS ON CONTROL PANEL 1 tion af control panel > ese lt ‘panel and operations are shown in the next figure, Incicaro ism 2) ‘Pump operation = seer) Jado Nang Jedaatr lamp Indicator emp Incicater amo (eae goer emo CPiter sign = yell) (bower - green) / (Compressor operation’ (abnormality — rec) / 7 I / b \ heath L ect) wi Senor Fahey i they Fanetion key (ede eanber) (Ther) Th dey ley S = Cheset of fitter sign) 3) LED indicators LED Content Indicator lamp [This lamp lights up when +5V voltage (power—green) | is supplied to controller. Indicator lamp | This lamp lights up when pump runs, (pump —green) _| (Protective input 52Pa is on ) Indicator lamp | This lamp lights up when compressor runs, (comp. green) *1 | Indicator lamp | This lamp lights up when heater runs, Cheater-green) | (CPU directs 52H to be on ) Indicator lamp | This lamp lights up or flickers when an (alaro—red ) | abnormality occurs. In case alara (levell). it flickers Indicator lamp | This lamp flickers as a warning of filter ch (filter—yellov) | oked , when cumulative operating time runs into some hours that set before by parameter, ¥1:Apply to heater optional type 4) LCD display Content FNC display | It shows present operational node. MODE display | It shows present teap. control mode, DATA _ display | It shows setting teap. by ‘C. TIMER display | It shows timer is in use or not and ON/OFF setting tine, 75) Keys Cotent TFUNCI key This key is used to select the operati-| (setting of function) | onal mode. Before [ENT] operation, you can cancel the input data by [FUNCJ key. TENT key Tf you fix the input data,push this ke- (fix input data ) y Ttd key Use to make a choice of numerical data. Cid key fd key se to select the items. THa keyOperation mode There are seven operation nodes, as shown belos. Function Operation] selection Description inode display section Operation | OFF Prohibit all key operations except lock cancellation, Jock and operation of the pup notor(factory setting). ‘The data display séction shows flashing”Lock” indication. Normal | NOWAL loispiay the target operation value. illiminates| (Main operation node) Data {SETTING —_|For operation data setting. setting | illuminates Monitor |MONITOR [Display data such as sensor temperatures. value | illuninates display Timer | TIMER For the ON/OFF tine setting of tier operation. setting |illuninates Paraneter|SETTING |For setting the paraneter that determine the operation setting |flashes | characteristic of the oil cooling unit. Service [MONITOR |Clear the E6 alara and display the uonitor value for monitor [flashes — |service value display ‘The normal”, "data setting”,"nonitor value setting” and" timer setting”modes are commonly used, and the mode changes in a set order every time the FUNC key is pressed. A special procedure aust be folloved to change to other modes. The key operation and operation node changing order are shown in the diagram on the next page.Press thef = Jandl—+ j [Operation lock oF Press the Jandi— J keys simultaneously | ~- keys simultaneously for to seconds. for to seconds. TFUNC Normal © Timer setting ~~ CENT) FUNC] TENT) FUNC] Operation data | {FUNC] |Nonitor value setting display Press theft Jand! Press thel'=Jand!—>J keys simultaneously for| keys simultaneously for ‘two seconds. ‘two seconds. v Service monitor Paraneter setting| value display mlm FUNC) | TENT) 105-8 Ordinary operation mode Introduction It is written here that the operation mode and display of setting temp. of Oil cooling unit. 2)Display 1.Normal mode Operation mode is shown in mode display and setting temp. . control target are shown insta display. Wode display Data display Na_| Mode Weaning Signs Degree 0 [oil inlet temp. Oil inlet fixed control 1 | Returning oi! temp. Returning oil fixed control 2 |Wachine body temp. |Wachine body fixed control tem 3 [Oi] inlet and air [Oil inlet teap. synchronous control (Control target) 4 [Oil inlet and mach-[0j1 inlet ine body temp. syn- chronous control 5 [Returning oil and [Returning Jair temp. synchrono- joil us control @ [Returning oil and [Returning pachine body temp. joil synchronous control 7 |Returning oi1 and [Returning oil inlet temp. oil synchronous control % (Wachine body and [Wachine body air temp. synchrono4tenp. jus control 9 [Direct control of [Directed % cooling capacity of|of capacity | 0~100 % 5.0~50.0 | © inverter compressor2 Alara mode Operation node is shown in node display and alam code is shown in data display. Mode display Data display No, Mode Meaning Sings Degree |] Written above Alara code | Alarm code flickers | light 9 off 3) The way of operations L Filter sign reset Filter sign LED lights up when oil cooling unit has run over the time which is set before by parameter set hour. In this case you can light off the LED by [ENTJ key. 2. Locked operation In normal operation, you can wake locked operation node by pushing T+) [-+] keys at once for tyo seconds. In locked operation aode, Flock flickers in data display and FWANUALS or [AUTOJ sign in timer display lights off. In locked operation node, only paticular operation that pushing [J [+] keys at once for tro seconds can cancel this mode. By translating in locked operation mode, it could prevent sone accident from pover supply before installation. 3.Adjusting.the day and tine . Conducting the following table process in normal operation mode advances the display of the day of the week, hours and minutes. There is no carry to hours from minutes or to week fron hours. Day of the week | Press the [J and [+J keys simultaneously Hours Press the [1 J and [tJ keys simultaneously Minutes Press the [| J and [J keys simultaneously 125-4Setting operation mode 1)0utline It is written here that the vay of changing the setting node and setting value of temp. control. 2)Wode and of its range ta | Mode Target Range Degree 0 [oil iniet teap. oil inlet fixed control 1 [Returning oi! temp. | Returnirg ot | §.0~50.0 | *C fixed control 2 |Wachine body temp. |Wachine body fixed control temp. 3 [Oil inlet and air [01] inlet temp. synchronous control 4 [Oil inlet and wach-|0i1 inlet ine body temp. syn- chronous control ~9.9~9.9 K 5 [Returning oil and |Returning ir temp. synchrono- oil us control 6 |Returning oil and |Returning machine body temp. joil synchronous control 7 |Returning oil and |Returning oil inlet temp. oil synchronous control a chine body and |Wachine body ir temp. synchrono, temp. us control 9 [Direct control of Directed % cooling capacity of |of capacity | 0~100 % inverter compressor 1, Fixed temp. control(mode 0~2) It controls the temp. of control target to set temp.. 2. Synchronous temp. control(node 3~8) It controls the temp. of control target to the temp. below control target temp.-base temp. +setting value(off set) 133.Direct control of cooling capacity(sode 9) It controls not. temp. -control but cooling capacity. ON/OFF type:conpressor off at 0X, runs at >0%. INV typercompressor off at O%,runs at >0% according with figure below. Caneaning ae cling coonty(%) 3)The way of operations 1.Change of running node In [setting mode, running aode nuaber is flickered in LCD display, [tJ [4 J arrow keys can select your shoice of running aode aua- ber . 2.Change of setting data In mode number flickering, push [—j key,next data display flicker- s.And you can select your choice of setting value by [tJ [44 arrow keys. 3. Fix or cancel the choice You can fix your choice by [ENT key.When fixed, buzzer bells for a second vith lighting on set value and return to noraal operation node. Before you determine your choice, [FUNC] key can cancel all your choice, running aode and setting data. In setting your choice of setting value, /— key can cancel the setting data and then you can remove to select the running mode. Notice 1. Three areas, a fixed temp. control,a synchronous control and @ direct control of cooling capacity exist in a inner seaory area. And set value ina same area, for exaaple ina fixed temp. control 35.0°C set in running mode [0 J is commonly used in running node f1J because of same area that fixed temp. control. 2. Running node Some type of oil cooling unit can select limitted ruaning node of 0-9. And in not permitted mode, [---] lights on in a data display. In such a case nothing can be set. 145-5. Operation ofmonitering data mode 1)0utline This mode is displaying the data of temp. that is measured by sensor. 2)Content Na | Content Range Degree Notice 0 | Machine body temp. 1_| Returning oil temp. 2 | Air temp. -99.9~99.9 c 3 [0i1 inlet temp. 4 [aT No$-Nol 5 [Present frequency of INV| 0~ % Bz 6 [Direct control value % o~ 100 x 7 8 | NOT USE aaa Light 9 off Notice 1)Mesureable range of the sensor of this cooling unit is between -40°C and +180°C. In case the sensor is shorten or opened, -99.9°C is displayed. 3)0peration 1.In the monitor mode, [0 J flickers in the aode display and you can choose any mode by Ftd [tJ keys. (Monitoring data is displayed in date display according to setting Ma.) 155-6. Operation of tiner setting 1outline Timer operation has two mode [MANUAL| , [AUTOJ .And they are defined by next belov. Mode | Content WANUAL | Timer not in use AUTO [Timer in use Timer can be set only once each ON/OFF tine in a day from Sunday to Saturday. Generally, set time is used frou 00:00 to23:59. But in this unit, from 00:00 to 29:59 is able to be used in case of running all night. 2)0peration 1. Timer setting node In this mode, [MANUALJ or [AUTO] flickers and you can choose either of thea by [tJ [4 J keys. 2.Setting day of the week Push f+] key,day of the week flickers. (WON flickers at first and you can choose any day and of its ON/OFF time by [tJ [4 J keys.And [+ J key returns to timer setting mode 1). 3.Setting hour You can choose any time from 00 to 29 by [tJ [4 J keys. And [+ J key returns to the mode of setting day of the week 2). 4.Setting ninutes You-can choose any time from 00 to 59 by [tJ [4 J keys. And [+] key returns to the mode of setting hour 3). 5.Fix or cancel the choice You can fix your choice by [ENTJ key.When fixed, buzzer bells for a second with lighting on set value and return to normal operation node. Before you determine your choice, [ FUNC) key can cancel all your choice.5-7. Operation of parameter set Outline Setting the parameters concerned vith the dynamic chracteristics of this cooling unit. 2)Content and of its range ta [Content Range Notice 0 [filter sign setting tine [1~9 | Means x1 0 0 hour 1_| Alara level of option port | 1.2 2 3 NoT USE SOME 4 [5 | Proportional gain of 1~100 | 48 is set in factory temp. control 6 | Integral gain of 1~100 | 48 is set in factory temp. control 7 8 NOT USE teat 9 3)Changing Na(0-9) 1.In this mode, [0 J flickers in the mode display and you can choose any & by [tJ [4 J keys. (Parameter data is displayed in data display according to selected NM.) 2. Changing the parameter set da’ Push [J key during the M flickers, parameter data starts to flicker.And you can choose any value by [tj [4 J keys. 4. Fix or cancel the choice You can fix your choice by [ENT key. When fixed, buzzer bells for a second with lighting on set value and return to normal opera- tion mode. Before you determine your choice, [FUNC] key can cancel all your choice. In setting your choice of setting value, [-J key can cancel the setting data and then you can remove to select the M0-9. Ww5-8 Operation of service monitor DOutline ‘This mode is used to release the E6 alarm and indicate the monitor value for service. 2)Display data and its range ‘The folloving table shows the display monitor value for iten No. Ttea Na] Mode Display value | Unit | Remarks 0 | Latest abnormal code | Alarm code | OFF | Then abnormal Iten Na 1 to 9 and A to F are monitor for service. 186. Alarm functions 6-1, Summary of alarm functions 1) Summary This oil conlang unit AKZ iS for cooled orl 40 heating area af machine. keeping machine temp. constant by Supplying And 30, incase of some abmormality occurs, it MS two alarm Jevels and Junctions that one isnot Sto? the pump motor ant the other iswstop rt. That 75 because stopping the pamp moter damages the mair\ spindle of machine tool by not a supply the oad article alarm indicator lamp ey [paar F520 | Stop the pump mater carnal of _lighting Not Stop the punp moter 6-2. Level and priority level of alarm Tt 1s defined that level 1 is high level abrmand level 2 is low level alarm . Tt 15 whitten below that the alarm level and its Sunction . Note.) Alarm Ais occured titst. Alarm B is occured late . 1) Single alarm occure everdtion stop VSS with Fae, WLLL iedivin) diglay ow —1.. 2.2... 0.00 2) Some alarms occured 1. Both alarm level A and B is Same. Alarm A outputs contineous/7 neglecting alarm B per ow source t ‘bvormality A sineraly 3 content (© of display L:2. Alawm level A is higher than alarm leve! B Alarm A outputs contineously neglecting alarm B 3.Alarm leye! Ais lower than alarm level B At sitst alatm A outputs but alarm B outputs as soon as B sccurs . 20, 6-3 Processing alarm generation 1)Alarm indication on the control panel The data display section of the control pane] shows the alarm code of the result of the alarm processing based on the alarm leve) priority. (only when the operation mode of the display panel is set to NORMAL or TIMER) The alarm indicator on the control panel lights or flickers as shown belov. Itea Alara indicator Level-1 abnornality|Plickers at 0.5-second intervals Level-2 abnoraali ty| ON ‘The buzzer also turns on. 2)kbnornality record in wenory Then an alarm is generated, the current values of the data in the following table are written in the error parameter menory area in the EEPROM. Mode No. Vode 0 |ALara code 1 [Inverter direction frequency 2 |Not used 3 |Equipaent temperature 4 |Returning oil temperature 5 Atmospheric tesperature 6 [Oil inlet temperature 7 |Divergence of EV valve 8 — |Cumulative compressor operating hours| ‘The data of the first abnormality that occurs after the power is turned on is written into the menory. Then multiple errors are generated and alarm switching occurs according to the priority-based processing(described in 6-2), the never error data is witten, 23)Clearing the alarm The alarm can be cleared by turning off the power and turning it back on. Cospressor overcurrent error B6, however, aust be reset in the service monitor node. (Error B6 cannot be cleared by turning the pover off.) (Prease note the folloving exception: If an abnormality of Level | is generated after the generation of error B6 and before its clearing operation, E6(Level-2 abnoruality) is overwritten. This cancels the error E6 condition, allowing the equipment to restart by turning the power off and back on again. 4)Clearing the error [ 86! 4-1. Operating method Select the service aonitor value display mode fron the operation node. Then this mode is selected, ‘0” flashes on the aode number display section. 4-2. Clearing the compressor overcurrent error [6 ‘The compressor overcurrent error is special alarm and this cannot be cleared by turning off the porer and turning it back on. This alarm is cleared by turning off the pover and turning it back on after flashing alarn code by pushing [-+J key with mode No. “0” and clearing the alarn menory by pushing [ENT] key. 225) Output of alarm 1 Port oxtput of external parallel comunicatzon Te-goes being on the port output of external pakallel commumicat7on, 2.Relay contact output Alarm occurs , 30¥ relay contact tobe OFF and 302 relay contact tobe OV The posrtien af relay contacts 7s written below a0y 30y ta 7 i = IR Li + | —+-0 302 L o> 7 TS FI 0 ED i353 /t_ i {+ By ORET1) ——0 © sithTime chart of external Output contacts Opefat-ion Neel ast owe Is oe " ati rr orn condition pecael gun a Power source ore Condit ten] controt 246-4 Alarmcode and level chart Definition chart about alarm code which printed circuit board detects is shorn table belov. [Alara code[Level [Content of abnormality Remark EI 1 [Printed circuit board failure Invalid capacity BS. 2 |6HChigh pressure svitch) actuation B5 2 |49CCbimetal of coupressor head teuperature) actuation EB 2 |5iC(compressor thermal) actuation or detecion of over-current in CT 9 2_Jelectrical expansion valve (short, braking) abnormality EH 1 [5iP(pump thersal) actuation BI 1/2 [0.P. (option protective device) actuation Hl 2 _|Tl, Th (short, braking) ebnormality 56 2 |CT current detection failure BE 1 |52Pa(puap magnet svitch) failure of actuation Fit 1_[Bigh oi} temperature abnormality FE 1 _[FLS¥ non-actuation JB 2_|Th2, Th4 (short, braking) abnormality Lo 2_|INV systen abnormality “4 2 [Beat radiation fin teuperature rise 15 2 [DC output over-current 18 2 |Blectrical thermal Lg 2_ [Prevention of stole ry 2 |Porer transistor abnorsality ic 2_[INV transaition abnormality PL 1__|Open phase Pa 2_|Sensor of heat radiation fin teup. abnormality U1 1 [Revarsal phase of pover sourse, frequency of power source, over current| v2 2 [Flash stop, shortage of voltage U6. 1 [Air conditioning, indicator CPU transaission abnormality ug 2 [Main machine seriel/parallel transuission failure 8 1 [System failure (EEPROM abnormality) w 2 |0P2 (slave)abnormality6-5 Alaram codes of control panel The following table shovs the difinition of alarm code of errors detective by the CPU of the display. Then the folloving alara is generated. (the alara code"El”is generated by the teaprature control PCB.) a Alara] Nane of alara Description code E-01 |Pover shut-off detection port error|The power shut-off detection port is renaining Lo. [E-02 [Key input port error ‘The key input port is renaining Lo. i |B-03 |L8D output error The LED output port is remaining Lo. E-04 |Buzzer/LEDA output port error The buzzer/LEDA output port is renaining Lo. 2-05 |RIC access error RIC cannot be accessed. E-06 |RIC memory data error RIC can be accessed, but the data in fmesory causes a check-sun error. Note 1)Since errores B-01 to E-05 are due to faulty hardware, resetting the equipment does not cance] these error. Note 2)As soon as error E-06 is generated, the data is initialized. Therefore, Tesetting the equipment cancels the error. 1) (ES) 63H (high pressure switch) activation ‘This code is generated when 63H is tripped, or broken wire or connector (CN27) disconnection is detected. 2) {E5) 49C (compressor head thermal binetal) activation This code is generated when 49H is tripped, or broken wire or connector (CN26) disconnection is detected. 3) [B6) 51C (compressor overcurrent relay) activation, overcurrent detected by CT This code is generated vhen 51H is tripped, or broken vire or connector (CN24) disconnection is detected, or when the current detected by CT exceeds thé set value, 4) [£9] Faulty electronic expansion valve (short-circuit, broken vire) This code is generated in AKJ when disconnection of the connector (CN14) is detected during power ON operation. 5) (EH) S1P (pump overcurrent relay) activation This code is generated vhen 51P is tripped, or broken vire or connector (CN20) disconnection is detected. 268) [EJ] OP (option protection device) activation This code is generated when OP is tripped, or broken wire or faulty conection of the terminal board (No. 12,No. 13) is detected. ‘TD {HL} Faulty Th1 (equipment teaperature synshronizing theraistor) or Th3 (room temperature thermistor) This code is generated vhen broken vire or short-circuit in Thl (terminal board: No. 30, No. $1 or Th3 (CN43) is detected. The faulty thermistor can be identified by the sonitor code displayed on the control panel. The thermistor with a uonitor value of "-99.9°C" is the faulty one. 8) (86) Faulty current detection by CT This code is generated when the coupressor wires are not properly connected. 9) CHE] Faulty 52Pa (auxiliary magnet contact for pump uotor) operation This code is generated vhen 52Pa (auxiliary wagnet contact for pump motor) does not ‘turn ON or OFF in sync vith the ON/OFF signal of §2P (magnet for pup motor) fron the temperature control CPU. The cause can be broken wire in 52P, disconnected 52P connector (CN4); disconnected 52Pa connector (C22), faulty 52P magnet (broken wire, melting)or open L2 phase. 10) (FEY Abnormally high oil temperature This code is generated when the oil teaperature at the inlet exceeds the set value (60°C). 11) [FE) Faulty FLS¥ (flow svitch) operation In AKJ, the cause can be disconnected connector (CN23). 12) (JH) Faulty Th4 (liquid tenperature thermistor) This code is generated in AKJ when broken wire or short-circuit is detected in (N42 or ‘Th4 (CNAA). ‘The faulty thermistor can be identified by the monitor code displayed on the control panel. The thermistor with a monitor value of "-99.9°C” is the faulty one. 18) [PI] Open phase This code is generated when open LI or L3 phase is detected. In case of open L2 phase, error 52Pa (HH) is generated when 52P (pusp uagnet) turns ON. ar14) [U1] Power reverse phase, power frequency abnormality, overvoltage This code is generated vhen power reverse phase, power frequency abnormality (<45Hz, >65H2) or overvoltage (>242¥) is detected. ‘The power reverse phase and pover frequency. abnoraality check is conducted only once, immediately after porer ON operation, and overvoltage check is continuously perforned. Therefore, if error {U1] is generated during ordinary operation, the cause is always overvol tage. 15) [U6] Faulty communication between temperature controller and display CPU This code is generated vhen an error in the communication between the teuperature controller and display CPU is detected. If the display device communication is normal, the error code sent fron the tesperature control CPU to the control panel is displayed. If the error is generated in the coanunication operation with the control panel, the control panel camot receive the error code; therefore, there is a possibility that the control panel say not indicate the error code. To solve this problem, the control panel conducts its om communication error detection, and displays "U6" in case of a communication error. Then the communication error (U6) detected by the control panel is canceled, the control panel s detection function automatically resets, changing the error indication to the error code received frou the teuperature control CPU. Therefore, in some cases, the error code obtained through the communication may not agree with the displayed error code. 16) [U9] Paired operation: external parallel communication error ‘This code is generated when an external parallel communication error is detected during paired operation. ‘This code vill not be generated when the paired operation setting is not made. 17) CUR) System error (EEPROM error) This code is generated when there is an abnormality in the data in the EEPROM or when an error occurs during EEPROM data access. 287, Installation of each thermistor Tnstalltionof each thermistor in thls machine is shown below. Termina| number in electrical wiring diagram Temperature 30-31 (PCB3) | Machine body temperature (Th-1) CN42_ (PCBI) Returning oil temperature ( Th-2) (N43 _(PCBI) Room temperature ( Th-3) CN44 (PCR1) __ HTemperature of oil inlet in oil cooling unit (Th-4) | PcB3—_—| Pci Tha The. Th?8 MAINTENANCE AND INSPECTION 8-1 Repair work with safty In conducting the waintenance and inspection work, be sure to put the operation mode in the locked operation mode to turn OFF the main pover supply. (It is extremely dangerous to conduct the work since there is a possibility of electrification or coming in contact with rotating objects if the equipment remains operated. ) 8-2 Casing 1)Polish the casing surface vith dry cloth. If the surface is heavily fouled, renove the dirt vith high quality soap or neutral detergent. Never pour water direct to the equipnent. (Operation of as-vetted equipment may lead to electrical leakage or fire. ) 2)To prevent coatings from peeling off,do not use brushes, polishing porder, acids, solvets Such as benzine etc, hot water, and so on. Tank and return filter (by local arrangement) Iaintain the liquid level in the tank in normal position to prevent the liquid leakage caused by liquid. Note that the liquid should be controlled so as to be kept clean at all times. 2)Clean up periodically the return filter for use on the return(liquid inlet)side of ‘tank to prevent such reduction of liquid volume in the tank as is caused by clogging of dirt. Air filter 1)Be sure to wash the air filter once every 2 weeks with neutral detergent. If dirt or dust is accumulated on the air filter, the filtering capacity is lovered by reduction in air flow and, at the same tine, the protective device of compressor Will operate to prevent a smooth operation. 2)If the equipsent is put into operation without the air filter, the resultant loss of dust removal effect vill result in fouling of the equipnent(especially, condenser), thus leading to a cause of trouble. Then the condenser is heavily fouled,clean it up with brush,air gun,etc. Case of long-time shutdown DUse care to prevent dirt, dust, water, etc. From coming into the OIL COOLIG UNIT. 2)Be sure to put the operation mode in the locked operation node to turn OFF the main pover supply. 3)Teke precautions so that no oily dirt and dust will deposit on the condenser surface of refrigerator. 304 TROUBLESHOOTING GUIDE Check the following if the OIL COOLING UNIT does not function property. If the OIL COOLING UNIT still does not function properly, contact our office and give the following particulars: (1) model, (2) manufacturing No. ((1) and (2) ere on the machine nameplate], (3) condition of the machine (as much detail as possible.) ven [onion cae cams Power's OVE | Powe rear one dou saab rr 6S FR power ener ono | ” ratte (green) does not light rs @ crea cat ae bom, ra ae Sock arcree ne or. ast pone ie open 1 crouit. I" oreo craitoae OF tune cra eke ON O mateenraneme | toed ond ret be roe ercurex route ee cat. Powers ONEutan = sbrormaity lamacred) "Refer to P26 ~P. 2% 2 | Saee ORefer to R26~P28 a) Pumo runs but no oil © Oil piping on suction side is fon jose tow tot papper foutburo noc, @ Suan sare cose SO he soon aren Surge be ol neck ki tea. 3 @ Tekot is olon Teasaneneash “muy Gow poe tre oliong cases lt us oe done oe mn Oo : cane Rronrebt | © Tremasattincions ‘Sate tenet habe conoresor eee ecae mronecueon eat cere =, te conresco’ ss The comoresor wor tt Tolterowetse's to lw 4 ‘Wait until oll temperature Thermostat (delay timer ad eae Reo the tier ered check it aul tre compressor ts @ Tremmostat is damaged. ‘Replace thermoset. 31‘Compressor worked © Power is oft, Check the main power source. ‘but the pump and creme soe ‘and abnormality. oe, Se cna [ines | Saas oe soem, avin cnn, = onan (igewmrecs womans veeme [Pr a cote (See, eee ies ‘Remove the obstacies.. (&) Comoressor ‘suction/exhaust ports. — ® Ambient (room) temperature {is to0 high, © Oil temperature is t00 high. (Use the unit within ics ‘operation range. tf there is a neat source, remove it ‘Use at low oi! temperanure @ Compressor does not run. ‘*Compressor must be replaced (service). © Oil viscosity is too high. Replace with lower viscosity a GIP)is ected. |@ Fan aotor does not run. heck the fan Cantor). | © sone 2530 same 05 3 TH An ebremaity | @ The corral creat boards The conivolcreut Boers took pece atthe} cut of order. must be replaced. aa board (YC) Pump, compressor © Same as 6-D 0D Same as 6-D to and fon nn bt ait. Js pot cooled. @ Same es 8 Sane 083 @ Over-loading. ‘*Eliminate the cause of overoading © Setting of thermostat too ‘-#Set it properly. ih. © Lack of refrigerant gas. ‘Recharge (efigerent gas).