Download - Daikin Service Manual 8

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SiOCU05-001

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Thank you very much for usual patronage to Daikin products.

We have completed and pleased to present the Oil Cooling Unit (Model 8) Service Manual.

We at Daikin provide an extensive lineup of models to respond to high-accuracy

temperature control and needs for energy saving with the Oil Cooling Unit and appreciate

your further loyal patronage.

This Service Manual includes information on troubleshooting and a variety of services.

Please make use of the Service Manual for your servicing of the Oil Cooling Unit.

After Sales Service Division

June 2005

Preface

Name of information Models listed Date of issue

Oil Cooling Unit

(Model 8)

Service Manual

• AKZ148 to 908

• AKZJ188 to 908

June

2005

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1 List of Models..................................... 6

2 Standard Specifications.................... 81. Principle of Oil Cooling Unit...................................82. List of Basic Performance/Specifications.............103. Operating Limits ..................................................14

3 Wiring Diagrams .............................. 15

4 Piping Diagrams .............................. 28

5 Control Panel ................................... 491. Name and Function of Each Part ........................492. Operation Procedure by Mode.............................51

2-1. Normal Mode.............................................512-2. Operation Setting Mode ............................522-3. Monitor Mode ............................................542-4. Timer Setting Mode ...................................542-5. Operation Lock Mode ................................542-6. Parameter Setting Mode ...........................552-7. Auto Tuning Mode......................................62

6 Functions.......................................... 641. Operation Flow Chart ..........................................642. Functions .............................................................653. List of Malfunctions/Warnings..............................66

7 Troubleshooting............................... 671. Troubleshooting According to Symptoms.............672. Equipment Data checking Procedure ..................683. Troubleshooting According to Malfunction Codes

.............................................................................693-1. Control Panel Operation Procedure ..........693-2. List of Malfunction Codes..........................703-3. Troubleshooting Flow Chart.......................71

8 Removing Procedure....................... 961. AKZ148 to 908.....................................................962. AKZJ188 to 908.................................................104

9 Replacement Procedure................ 1121. Procedure for Replacing Main PC Board...........1122. Procedure for Replacing EV Valve Main Unit ....113

10 Miscellaneous Reference Data ..... 1141. Thermistor Temperature/Resistance

Characteristics ...................................................1142. Refrigerant (R410A) Characteristics..................1143. Procedure for Mounting Optional Parts .............115

3-1. Machine Body Synchronization Thermistor/Optional Oil Temperature Thermistor ........115

3-2. Communication PC Board (Option).........116

OIL COOLING UNIT (MODEL 8) SERVICE MANUAL

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Replacem

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iscellaneous R

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The specifications and others of this Service Manual are subject to change without notice for product improvements.

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2

SAFETY PRECAUTIONS Be sure to observe the precautions shown below.

The following section describes precautions to prevent personal injury or damage. Hazardous situations, which can occur due to mishandling of the equipment, are classified by the safety alert symbols shown below.

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3

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4

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5

MEMO

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1List of Models

6

TypeModel Name

Page Listed

Standard Type Individual Specification Standard Specification Wiring Diagram Piping Diagram

Recirculation type

Standard type

AKZ148 10 15 28

AKZ328 10 15 28

AKZ438 10 15 28

AKZ568 11 18 28

AKZ908 11 18 28

Equipped with circuit breaker

AKZ148-B 10 15 28

AKZ328-B 10 15 28

AKZ438-B 10 15 28

AKZ568-B 11 18 28

AKZ908-B 11 18 28

CE Safety Standard

compatible

AKZ148-C 10 15 28

AKZ328-C 10 15 28

AKZ438-C 10 15 28

AKZ568-C 11 18 28

AKZ908-C 11 18 28

Different Voltages compatible (with built-in transformer)

AKZ148-E1 10 16 28

AKZ148-E2 10 16 28

AKZ148-E3 10 16 28

AKZ328-E1 10 16 28

AKZ328-E2 10 16 28

AKZ328-E3 10 16 28

AKZ438-E1 10 16 28

AKZ438-E2 10 16 28

AKZ438-E3 10 16 28

AKZ568-E1 11 19 28

AKZ568-E2 11 19 28

AKZ568-E3 11 19 28

AKZ908-E1 11 19 30

AKZ908-E2 11 19 30

AKZ908-E3 11 19 30

Equipped with heater

AKZ148-H 10 17 38

AKZ328-H 10 17 38

AKZ438-H 10 17 38

AKZ568-H 11 20 40

AKZ908-H 11 20 42

Equipped with oil tank

AKZ148-T (1) 10 15 32

AKZ328-T (1) 10 15 32

AKZ438-T (1) 10 15 32

AKZ568-T 11 18 34

AKZ908-T 11 18 36

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List of Models

7

Lis

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Mo

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ls

TypeModel Name

Page Listed

Standard Type Individual Specification Standard Specification Wiring Diagram Piping Diagram

Dipping Open type

Standard type

AKZJ188 12 21 46

AKZJ358 12 21 46

AKZJ458 12 21 46

AKZJ568 13 24 46

AKZJ908 13 24 46

Equipped with circuit breaker

AKZJ188-B 12 21 46

AKZJ358-B 12 21 46

AKZJ458-B 12 21 46

AKZJ568-B 13 24 46

AKZJ908-B 13 24 46

CE Safety Standard

compatible

AKZJ188-C 12 21 46

AKZJ358-C 12 21 46

AKZJ458-C 12 21 46

AKZJ568-C 13 24 46

AKZJ908-C 13 24 46

Different Voltages compatible

(equipped with transformer)

AKZJ188-E1 12 22 46

AKZJ188-E2 12 22 46

AKZJ188-E3 12 22 46

AKZJ358-E1 12 22 46

AKZJ358-E2 12 22 46

AKZJ358-E3 12 22 46

AKZJ458-E1 12 22 46

AKZJ458-E2 12 22 46

AKZJ458-E3 12 22 46

AKZJ568-E1 13 25 46

AKZJ568-E2 13 25 46

AKZJ568-E3 13 25 46

AKZJ908-E1 13 25 46

AKZJ908-E2 13 25 46

AKZJ908-E3 13 25 46

Equipped with heater

AKZJ188-H 12 23 46

AKZJ358-H 12 23 46

AKZJ458-H 12 23 46

AKZJ568-H 13 26 46

AKZJ908-H 13 26 46

×

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2 Standard Specifications

8

Principle of Oil Cooling Unit1

Through the compressor, the refrigerant gas turns to be high-temperature and high-pressure compressed gas to facilitate cooling and liquefaction with the condenser.

The condenser cools and condenses the high-temperature and high-pressure gas produced through the compressor with air to convert the gas into high-temperature and high-pressure liquid.

The pressure reducing mechanism presses and decompresses this high-temperature and high-pressure liquid to convert it into low-temperature and low-pressure liquid, thus facilitating evaporation with the cooler.

Through the cooler, the low-temperature and low-pressure gas produced through the pressure reducing mechanism draws heat from oil to evaporate (cool the oil), thus providing low-temperature and low-pressure gas.

The Oil Cooling Unit is a cooling unit using a refrigeration cycle shown in Figure above, which is different from air conditioners in the object to cool. The Oil Cooling Unit is subject to cooling of oil, while air conditioners are subject to cooling of air. Consequently, knowledge required for basic services is the same as that for air conditioners but different in some points particularly from the air conditioners. The following section describes these different points.

1. Functions of Electronic Expansion ValveThe electronic expansion valve is used for capacity control at a frequency below the minimum compressor operating frequency, thus having characteristics shown below.

q While in low capacity operation, the electronic expansion valve uses the low-pressure region, which no air conditioners use.

w The fully closed point of electronic expansion valve (fully closed pulse of EV valve) should be set with the PC board by each unit. (In order to replace the EV valve or PC board, pay attention to this point.)

2. Oil PumpSince the Oil Cooling Unit is subject to cooling of oil, an oil pump is incorporated in place of a fan on the indoor side. The following section describes the features of the oil pump.

q When the external resistance reaches 0.5 MPa or more, the relief valve will be activated.w Since the external resistance block (field piping) is an item to be designed by the user, attention should be paid.

3. Characteristics of Electrical SystemBasically, the electrical system is the same as that of air conditioners but has the following characteristics.

q The Oil Cooling Units has nothing equivalent to the operation switch. Be noted that the Oil Cooling Unit starts running as soon as the power supply turns ON. Normally, the Oil Cooling Unit exchanges signals with a machine tool and runs under ON-OFF control on the machine tool side.

w The Oil Cooling Unit has an enhanced readout function of internal product data. Refer to information in "7 Troubleshooting" to conduct servicing.

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Standard Specifications

9

Standard

Specifications

M M

For AKZ Series

For AKZJ Series

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10

2-1. AKZ Series

List of Basic Performance/Specifications20.5 1.2 1.5

AKZ148

-H-C-BStan-dard -T/-T1 *3

AKZ328 AKZ438

1.3/1.4 2.8/3.2

3-phase, 200/200 · 220VAC, 50/60 Hz

White

Shell end coil type

Cross fin coil type

φ 300 mm, 75 W

Trochoid pump

Propeller fan

0.4kW4P

Room temperature or unit temperature *5 (Factory set to Room temp. Mode 3)

inlet or outlet oil temperature (Factory set to inlet oil temperature)

-9.9 to +9.9 against reference temperature (Factory set to 0.0)

Inlet or outlet oil temperature

5 to 50

Overcurrent relay (pump motor), Reverse phase protector, Restart prevention timer, Low room temperature protection thermostat,High oil temperature protection thermostat, Low oil temperature protection thermostat, Pump relief valve, Discharge pipe temperature thermostat,

Condenser temperature thermostat, Refrigerant leakage detector, a set of inverter protectors, High pressure switch (-C only), Compressor protection thermostat (-C only), Overheat prevention temperature thermostat (-H only), and Boil-dry prevention switch (-H only)

Inverter control for Compressor revolutions + EV valve opening

5 to 45

5 to 50

1.4 to 200 (ISO VG2 to 32)

0.5 MPa or less

Within -30.7 kPa

Lubricating oil/Mineral oil based hydraulic fluid (However, not applicable to phosphate ester based hydraulic fluid, water, water-soluble liquid, chemicals, foods, fuels, cutting/grinding fluid, etc.)

Rc3/4

Rc1 1/4 Rc1 1/4Rc3/4 Rc3/4 Rc3/4 Rc3/4Rc1 1/4

Rc1/4 (Plug stop)

DC12/24V

3.8/4.3

1.20kVA/3.5A

12/14.4 24/28.8

0.5 0.6

1.70kVA/5.3A 2.31kVA/6.6A

1.32kVA/3.7A 1.73kVA/5.5A 2.35kVA/6.8A

1.33kVA/3.9A 1.75kVA/5.7A 2.45kVA/7.0A

0.49 0.72 0.98

62 65

0.4 kW or equivalent 0.75 kW or equivalent 1.1 kW or equivalent

Vertical 14.7 m/S2 (1.5G) 2.5 Hr (However, 10 to 100 Hz sweep/5 min.)

10

-E *4 -H-C-BStan-dard -T/-T1 *3 -E *4 -H-C-BStan

-dard -T/-T1 *3 -E *4

10— — 10— — 10— —

950360440650360440 820360465/*3

950360440 1090360440790360440 1055360465/*3

1090360440 1290360440990360440 1225360465/*3

1290360440

6252 67 110 6858 88 116 7767 97 125

— 15 — — 30/20 — — 30/20 —

2.6kVA

*43-phase, 200/200 · 220VAC, 50/60 Hz *43-phase, 200/200 · 220VAC, 50/60 Hz *43-phase, 200/200 · 220VAC, 50/60 Hz

1

— 2.6kVA— 2.6kVA —

— — 1— — 1— —

Operating range

Power supply *2

Oil Cooling Unit equivalent horsepower (HP)

Transformer capacity

Coated color

Compressor (Hermetic DC swing type)

Evaporator

Refrigerant control

Applicable oil

Noise level (1 m from front, 1 m above: anechoic chamber equivalent)

Transportation vibration performance

Mass

Wiring circuit breaker (rated current)

Oil tank (capacity)Localprocurement*7

Wiring circuit breaker(rated current)

Condenser

Model name

Cooling capacity (50/60 Hz) *1

Heater

Circuit voltage

Max. power consumptionMax. current consumption

Fan

Oil pump

(Selectable)

Tem

perature control

Synchronizationtype

Fixed type

Type

Motor

Type

Motor

Reference

Subject to control

Subject to control

Main circuit

Operation circuit

200V 50Hz

200V 60Hz

220V 60Hz

Outline dimensions (HWD)

Refilling quantity of refrigerant (New refrigerant: R410A)*6

Emergency openingpressure

Discharge rate

Range

Sync. range

Safety devices

Room temperature

Inlet oil temperature

Oil viscosity

Pressure loss outside product

Connection piping

Oil outlet

Oil inlet

Oil drain

Dischargeside

Suction side

kW

kW

mm

L/min

MPa

K

˚C

kg

˚C

˚C

mm2/S

dB (A)

A

L

A

kg

Note) *1. The cooling capacity represents figures at a standard point(of inlet oil temperature: 35˚C, room temperature: 35˚C, and oil viscosity: ISO VG32), subject to product tolerance of approximately ±5%.

*2 Voltage fluctuation range is to be within ±10%. If the voltage fluctuates outside the range of ±10%, separate consultation will be recommended.

*3 The outline dimensions for T1 specification units are as shown below.AKZ148-T1: 810 360 535AKZ328-T1: 980 360 535AKZ438-T1: 1180 360 535

*4 Different voltage units are available in three models, i.e., -E1, -E2, and -E3, subject to the power supply. E1: 3-phase, 220/230V, 50/60 Hz E2: 3-phase, 380/400/415V, 50/60 Hz E3: 3-phase, 440/460/480V, 50/60 Hz

*5 The machine body synchronization thermistor, which is an optional part, is required.

*6 -C Models are provided with MSDS (Material Safety Data Sheet) of R410A refrigerant.

*7 This part should be separately procured by the customer. (A circuit breaker should be mounted on the main machine side, including -B Model.)

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11

Standard

Specifications

2.0 3.0

5.0/5.6 8.0/9.0

AKZ568 AKZ908

3.21kVA/9.4A 5.02kVA/15.2A

3.30kVA/9.5A 5.14kVA/15.6A

3.34kVA/9.2A 5.20kVA/14.5A

1.5 kW or equivalent 2.2 kW or equivalent

-H -T -E *3Stan-dard -B -C

1410470560 1375470580 13604705901110470560 1520560680 1485560700 14705606951220560620

115 130 18297

— 50 — — 70 —

150 160 210125

—

3-phase, 200/200 · 220VAC, 50/60 Hz *3 3-phase, 200/200 · 220VAC, 50/60 Hz

3-phase, 200/200 · 220VAC, 50/60 Hz

DC12/24V

White

Shell end coil type

Cross fin coil type

Propeller fan

0.75kW4P

Trochoid pump

30/36

0.6


inlet or outlet oil temperature (Factory set to inlet oil temperature)


Inlet or outlet oil temperature

5 to 50

5 to 45

5 to 40

1.4 to 200 (ISO VG2 to 32)

0.5 MPa or less

Within -30.7 kPa

Lubricating oil/Mineral oil based hydraulic fluid (However, not applicable to phosphate ester based hydraulic fluid, water, water-soluble liquid, chemicals, foods, fuels, cutting/grinding fluid, etc.)

Rc 1 1/4

Rc 1 1/4

Rc1/4 (Plug stop)


Overcurrent relay (pump motor), Reverse phase protector, Restart prevention timer, Low room temperature protection thermostat,High oil temperature protection thermostat, Low oil temperature protection thermostat, Pump relief valve, Discharge pipe temperature thermostat,

Condenser temperature thermostat, Refrigerant leakage detector, a set of inverter protectors, High pressure switch (-C only), Compressor protection thermostat (-C only), Overheat prevention temperature thermostat (-H only), and Boil-dry prevention switch (-H only)


*3

— 5kVA — 6kVA

-H -T -E *3Stan-dard -B -C

2 —— 3 ——

φ 400mm, 90W4P φ 450mm, 150W4P

1.25 1.53

65 67

15 20

— 15 —— 20

Power supply *2



Coated color


Evaporator

Refrigerant control

Applicable oil



Mass


Oil tank (capacity)Localprocurement*7


Condenser

Model name


Heater

Circuit voltage


Fan

Oil pump

(Selectable)

Tem

perature control

Synchronizationtype

Fixed type

Type

Motor

Type

Motor

Reference

Subject to control

Subject to control

Main circuit

Operation circuit

200V 50Hz

200V 60Hz

220V 60Hz


Refilling quantity of refrigerant (New refrigerant: R410A) *5

Emergency openingpressure

Discharge rate

Range

Sync. range

Safety devices

Operating range

Room temperature

Inlet oil temperature

Oil viscosity

Pressure loss outside product

Connection piping

Oil outlet

Oil inlet

Oil drain

Dischargeside

Suction side

kW

kW

mm

L/min

MPa

K

˚C

kg

˚C

˚C

mm2/S

dB (A)

A

L

A

kg

Note) *1. The cooling capacity represents figures at a standard point (of inlet oil temperature: 35 ˚C, room temperature: 35 ˚C, and oil viscosity: ISO VG32), subject to product tolerance of approximately ±5%.

*2 Voltage fluctuation range is to be within ±10%. If the voltage fluctuates outside the range of ±10%, separate consultation will be recommended.*3 Different voltage units are available in three models, i.e., -E1, -E2, and -E3, subject to the power supply.

E1: 3-phase, 220/230V, 50/60 Hz E2: 3-phase, 380/400/415V, 50/60 Hz E3: 3-phase, 440/460/480V, 50/60 Hz

*4 The machine body synchronization thermistor, which is an optional part, is required.*5 -C Models are provided with MSDS (Material Safety Data Sheet) of R410A refrigerant.*6 This part should be separately procured by the customer. (A circuit breaker should be mounted on the main machine side, including -B Model.)

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12

2-2. AKZJ Series0.5 1.2 1.5

AKZJ188

-C-BStan-dard -H

AKZJ358 AKZJ458

1.6/1.8 3.2/3.5

3-phase, 200/200 · 220VAC, 50/60 Hz

DC12/24V

White

Open coil type

Cross fin coil type

φ 300mm, 75W

Propeller fan

1-pahse, 50W, 4P

Trochoid agitator


Tank liquid temperature



5 to 50

5 to 45

5 to 50

0.5 to 200

62


10

Oil tank (400 mm or more in depth), Feed pump, Float switch, and return filter

Water-soluble cutting/grinding fluid, cutting/grinding oil, Lubricating oil, Hydraulic fluid, and Industrial water(However, not applicable to chemicals, foods, and fuels)


Fan motor inner thermostat, Agitator inner thermostat, Reverse phase protector, Restart prevention timer, Low room temperature protection thermostat,High oil temperature protection thermostat, Low oil temperature protection thermostat, Discharge pipe temperature thermostat, condenser temperature thermostat, Refrigerant leakage detector, a set of inverter protectors, No-fuse circuit breaker (-B only),

High pressure switch (-C only), Compressor protection thermostat (-C only), Overheat prevention temperature thermostat (-H only), and Fuse (-H only)

4.2/4.5

0.4kW or equivalent 0.75kW or equivalent 1.1kW or equivalent

0.58

4138 103

—10— 10— 10—— —

4744 109 5653 118

0.81 1.15

-E *3 -C-BStan-dard -H -E *3 -C-BStan

-dard -H -E *3

*33-phase, 200/200 · 220VAC, 50/60 Hz *33-phase, 200/200 · 220VAC, 50/60 Hz *33-phase, 200/200 · 220VAC, 50/60 Hz

— 1 — — 1 — — 1 —

1.07kVA/3.1A 1.35kVA/5.7A Same asStandard unit

Same asStandard unit








1.76 kVA/5.2A 1.76 kVA/5.9A 1.94kVA/5.7A 1.94 kVA/5.9A

1.09kVA/3.2A 1.35kVA/5.6A 1.78 kVA/5.2A 1.78 kVA/5.8A 1.96kVA/5.7A 1.96 kVA/5.8A

1.07kVA/2.8A 1.62kVA/6.1A 1.79 kVA/4.9A 1.79 kVA/6.3A 1.98kVA/5.3A 1.98 kVA/6.3A

— 2.2 kVA — 2.2kVA — 2.2kVA

980360440 980450630 1120360440 1120450630 1320360440 1320450630

Power supply *2



Coated color


Evaporator

Refrigerant control

Applicable oil



Mass


Localprocurement *6

Other than wiring circuit breaker


Condenser

Model name


Heater

Circuit voltage


Fan

(Selectable)

Tem

perature control

Synchronizationtype

Fixed type

Motor

Motor

Type

Type

Reference

Subject to control

Subject to control

Main circuit

Operation circuit

200V 50Hz

200V 60Hz

220V 60Hz



Range

Sync. range

Safety devices

Operating range

Room temperature


Oil viscosity

Agitator

kW

kW

mm

K

˚C

kg

˚C

˚C

mm2/S

dB(A)

A

A

kg





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13

Standard

Specifications

2.0

3-phase, 200/200 · 220VAC, 50/60 Hz

DC12/24V

Open coil type

Cross fin coil type

Propeller fan

1-pahse, 50W, 4P

Trochoid agitator





5 to 50

5 to 45

5 to 50

0.5 to 200


Oil tank (400 mm or more in depth), Feed pump, Float switch, and return filter

Water-soluble cutting/grinding fluid, cutting/grinding oil, Lubricating oil, Hydraulic fluid, and Industrial water(However, not applicable to chemicals, foods, and fuels)


Fan motor inner thermostat, Agitator inner thermostat, Reverse phase protector, Restart prevention timer, Low room temperature protection thermostat,High oil temperature protection thermostat, Low oil temperature protection thermostat, Discharge pipe temperature thermostat, condenser temperature thermostat, Refrigerant leakage detector, a set of inverter protectors, No-fuse circuit breaker (-B only),

High pressure switch (-C only), Compressor protection thermostat (-C only), Overheat prevention temperature thermostat (-H only), and Fuse (-H only)

White

3.0

5.0/5.6 8.0/9.0

1.5kW or equivalent 2.2kW or equivalent

φ 400 mm, 90 W 4P φ 450 mm, 150 W 4P

1.25 1.65

65 68

15

AKZJ568 AKZJ908

-H-C-BStandard -E *3 -H-C-BStandard -E *3

2— — 4— —

4.0kVA/11.4A3.3kVA/9.4A Same as Standard unit 7.5kVA/21.6A3.9kVA/11.2A Same as Standard unit

4.0kVA/11.4A3.3kVA/9.4A Same as Standard unit 7.5kVA/21.6A4.1kVA/11.7A Same as Standard unit

Same as Standard unit4.8kVA/12.5A3.4kVA/9.0A Same as Standard unit 9.0kVA/23.7A4.3kVA/11.2A

2208683 160 140132

203020

—— 15 —— 20

— 5kVA — 6kVA

1450470500 1450560710 1630560620 1630655830

3-phase, 200/200 · 220VAC, 50/60 Hz *3 3-phase, 200/200 · 220VAC, 50/60 Hz *3Power supply *2



Coated color


Evaporator

Refrigerant control

Applicable oil



Mass


Localprocurement *6

Other than wiring circuit breaker


Condenser

Model name


Heater

Circuit voltage


Fan

(Selectable)

Tem

perature control

Synchronizationtype

Fixed type

Motor

Motor

Type

Type

Reference

Subject to control

Subject to control

Main circuit

Operation circuit

200V 50Hz

200V 60Hz

220V 60Hz



Range

Sync. range

Safety devices

Operating range

Room temperature


Oil viscosity

Agitator

kW

kW

mm

K

˚C

kg

˚C

˚C

mm2/S

dB(A)

A

A

kg





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14

3-1. Operating RangeThe Oil Cooling Unit has its operating limits.Be sure to use the Oil Cooling Unit in the range shown below.

Operating Limits3

3-2. Applicable Oil Since this Oil Cooling Unit is designed for lubricating oils and hydraulic fluid (of mineral oil base), the following oil (liquid) is not applicable.

1) Flame-resistant hydraulic fluid Phosphate ester base Chlorinated hydrocarbon base Water + Glycol base W/O, O/W emulsion base

2) Water and water-soluble liquid3) Chemical liquid and fluid food4) Cutting oil (fluid) and grinding oil (fluid)5) Fuels including kerosene, gasoline, and others

5 10 15 3520 30 40 50

Oil inlet temperature ()*

50

45

40

30

20

10

15

5

* "Tank liquid temperature" in the case of Dipping Open type (AKZJ Series)

Roo

m te

mpe

ratu

re (

)

Op e r a

t io n a l

Ra n g e

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15

3 Wiring DiagramsW

iring

D

iagra

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1-1. AKZ148 (-B) (-C) (-T), AKZ328 (-B) (-C) (-T), AKZ438 (-B) (-C) (-T)

1925750R

AKZ Series1

Wiring Diagram

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16

1925778D

Wiring Diagram

1-2. AKZ148-E1/E2/E3, 328-E1/E2/E3, 438-E1/E2/E3

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1925806D

Wiring Diagram

1-3. AKZ148-H/328-H/438-H

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1925775G

Wiring Diagram

1-4. AKZ568 (-B) (-C) (-T), 908 (-B), (-C), (-T)

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1925799E

Wiring Diagram

1-5. AKZ568-E1/E2/E3, 908-E1/E2/E33

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20

1925814E

Wiring Diagram

1-6. AKZ568-H/908-H

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1925776F

Wiring Diagram

2-1. AKZJ188 (-B) (-C), 358 (-B) (-C), 458 148 (-B) (-C)

AKZJ Series2

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1925796D

Wiring Diagram

2-2. AKZ188-E1/E2/E3, 358-E1/E2/E3, 458-E1/E2/E3

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1925809C

Wiring Diagram

2-3. AKZJ188-H/358-H/458-H

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24

1925792D

Wiring Diagram

2-4. AKZJ568 (-B) (-C), 908 (-B), (-C)

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1925815B

Wiring Diagram

2-5. AKZJ568-E1/E2/E3, 908-E1/E2/E33

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3 Wiring Diagrams

1925810E

Wiring Diagram

2-6. AKZJ568-H/908-H

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27

MEMO

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1-1. AKZ148 to 568 (-B) (-C) (-E1) (-E2), (-E3)

AKZ Series1

No. Part Name Symbol Function

1 Compressor M2CThis compressor is a swing compressor with a built-in DC motor, which is driven under the inverter control by changing the operating frequency according to values specified under the capacity control.

2 Accumulator —The accumulator is installed before the compressor suction and used to prevent the entry of liquid refrigerant in the compressor and further efficiently return lubricating oil to the compressor.

3 Condenser —Used to air cool the refrigerant to turn it from high-temperature and-pressure gaseous state to high-temperature and -pressure liquid state.

4 Fan M3FThe feedback control of fan revolutions is performed for heat exchange through the condenser.

5 Evaporator —Used to heat low-temperature, low-pressure liquid refrigerant decompressed through the electronic expansion valve (with oil being cooled) to make it low-temperature, low-pressure gas.

6 Rubber hose —Located at the entrance to and the exit of the oil pump and used to prevent the vibrations of the oil pump from transmitting to the piping system and equipment.

7 Oil pump M1P Used to recirculate oil.

8 Relief valve —The relief valve is a protective device to be activated when the pressure of oil piping system reaches the specified level or higher, thus setting the pressure back to the normal level.

9Electronic expansion valve (EV valve)

Y1EThe EV valve varies its opening according to values specified under the capacity control, thus making the control of refrigerant recirculation quantity.

10 Filter — Used to prevent the entry of foreign matters in the EV valve.

11High pressure switch(-C only)

S3PHIn order to avoid an increase of high pressure when a malfunction occurs, used to display the malfunction code “E3” if the high pressure reaches 4.1 MPa, thus stopping the system due to malfunction.

12Compressor protection thermostat(-C only)

S2BWhen the compressor head exceeds a temperature of 115°C, used to display the malfunction code “E5”, thus stopping the system due to malfunction.

13Outlet oil temperature thermistor

Th-2Used to detect the oil outlet temperature (targeted control temperature) from the evaporator.

14Room temperature thermistor

Th-3Used to detect the synchronization source temperature while in synchronization temperature control mode.

15Inlet oil temperature thermistor

Th-4Used to detect the oil inlet temperature (targeted control temperature) to the evaporator.

16Machine body synchronization thermistor


17EV valve outlet temperature thermistor

Th-6While in zero point adjustment, used to detect variations in the EV valve outlet temperature, thus recognizing the Fully Closed point.

18Condensing temperature thermistor

Th-7Used to detect the condensing temperature and, when the condensing temperature reaches a high level, thus displaying the malfunction code “E3” to stop the system due to malfunction.

19Discharge gas temperature thermistor

Th-8Used to detect the discharge pipe temperature and, when the discharge pipe temperature exceeds 112°C, thus displaying the malfunction code “E5” to stop the system due to malfunction.

20Pump outlet temperature thermistor

Th-10 Used to detect the oil pump outlet temperature.

21 Oil drain —Used to stop Rc1/4 at the plug. (The evaporator oil can be discharged from this oil drain for maintenance.)

25 Low-pressure gauge port — Used to mount a gauge for maintenance.

*For the layout of parts, refer to information on pages 44 and 45.

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HCY400646D

AKZ148 to 568 (-B) (-C) (-E1) (-E2), (-E3)

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1-2. AKZ908 (-B) (-C) (-E1) (-E2), (-E3)No. Part Name Symbol Function






























21 Oil drain —Used to stop Rc1/4 at the plug. (The evaporator oil can be discharges from this oil drain for maintenance.)


*For the layout of parts, refer to information on page 45.

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HCY400655B

AKZ908 (-B) (-C) (-E1) (-E2), (-E3)

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1-3. AKZ148 to 438-TNo. Part Name Symbol Function





























22 Oil tank —Used to store oil at all times, thus responding to a sharp fluctuation in oil quantity in the piping system.

23Oil charge port & Air breather

—Used to fill oil into the oil tank and normally serve as a ventilation hole for the oil tank.

24 Oil level indicator — Used to indicate oil quantity in the oil tank.



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HCY400650C

AKZ148 to 438-T

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1-4. AKZ568-TNo. Part Name Symbol Function



































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HCY400666B

AKZ568-T

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1-5. AKZ908-TNo. Part Name Symbol Function

































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HCY400667A

AKZ908-T

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1-6. AKZ148 to 438-HNo. Part Name Symbol Function





























22Boil-dry protection pressure switch

S4PHUsed to detect a drop of oil quantity in the piping system through a flow switch, thus stopping the system due to malfunction.

23Overheat prevention temperature thermostat

S4B1Used to indicate the malfunction code “AA” to stop the system due to malfunction when heater oil temperature exceeds 70°C.

24 Heater J1H This is an electric heater used to heat oil.


26 Angle check valve —This valve is a “resistor” so as not to malfunction the pressure switch.Without the angle check valve, the system may erroneously recognize that there is no oil to stop running due to malfunction “AA”.


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HCY400665C

AKZ148 to 438-H

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1-7. AKZ568-HNo. Part Name Symbol Function





























22 Flow switch S4PHUsed to detect a drop of oil quantity in the piping system through a flow switch, thus stopping the system due to malfunction.

23Overheat prevention temperature switch





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HCY400679A

AKZ568-H

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1-8. AKZ908-HNo. Part Name Symbol Function



























22 Flow switch S4PHUsed to detect a drop of oil quantity in the piping system through a flow switch, thus stopping the system due to malfunction.

23Overheat prevention temperature switch





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HCY400672

AKZ908-H

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44

1-9. Layout of Functional PartsAKZ148 to 438

No. Part Name No. Part Name No. Part Name

q Compressor i Relief valve !5 Inlet oil temperature thermistor

w Accumulator o Electronic expansion valve !7 EV valve outlet temperature thermistor

e Condenser !0 Filter !8 Condensing temperature thermistor

r Fan !1 High pressure switch !9 Discharge gas temperature thermistor

t Evaporator !2 Compressor protection thermostat @0 Pump outlet temperature thermistor

y Rubber hose !3 Outlet oil temperature thermistor @1 Oil drain

u Oil pump !4 Room temperature thermistor @2 Low-pressure gauge port

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AKZ568/908


q Compressor i Relief valve !5 Inlet oil temperature thermistor

w Accumulator o Electronic expansion valve !7 EV valve outlet temperature thermistor

e Condenser !0 Filter !8 Condensing temperature thermistor

r Fan !1 High pressure switch !9 Discharge gas temperature thermistor

t Evaporator !2 Compressor protection thermostat @1 Oil drain

y Rubber hose !3 Outlet oil temperature thermistor @2 Low-pressure gauge port

u Oil pump !4 Room temperature thermistor

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2-1. AKZJ188 to 908 (-B) (-C) (-E1) (-E2), (-E3) (-H)

AKZJ Series2

No. Part Name Symbol Function





5 Cooling coil —Used to heat low-temperature, low-pressure liquid refrigerant decompressed through the electronic expansion valve (with oil being cooled) to make it low-temperature, low-pressure gas.



7 Strainer — Used to prevent the entry of foreign matters in the EV valve.







11Liquid temperature thermistor










16 Agitator motor M1KUsed to rotate the agitator propeller provided within the open coil for efficient cooling/heating of the oil in the oil tank.

17 Feed pump — This feed pump is to be locally procured.

18 Heater J1HThis is an electric heater used to heat oil and only provided in units with the suffix -H.



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HCY400668A

AKZJ188 to 908 (-B) (-C) (-E1) (-E2), (-E3) (-H)

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2-2. Layout of Functional PartsAKZJ188 to 908


q Compressor u Strainer !4 Condensing temperature thermistor

w Accumulator i High pressure switch !5 Discharge gas temperature thermistor

e Condenser o Compressor protection thermostat !6 Agitator motor

r Fan !0 Room temperature thermistor !7 Heater

t Cooling coil !1 Liquid temperature thermistor !8 Low-pressure gauge port

y Electronic expansion valve !3 EV valve outlet temperature thermistor

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Name and Function of Each Part1

No. ItemDisplay

Operation/FunctionDisplay Name

qLamp display

block A

POWERPower supply

lampThis lamp will light up at all time when the power supply turns ON.

ALARMMalfunction

lampThis lamp will blink or light up when a malfunction occurs.

TIMER Timer lampThis lamp will light up while the system stops in timer mode.

wLamp display

block B

NORMAL Normal modeThis lamp will light up while normal mode is selected and blink while in auto tuning mode or special monitor mode.

SETTINGOperation

setting modeThis lamp will light up while in operation setting mode and blink while in parameter setting mode.

MONITOR Monitor modeThis lamp will light up while monitor mode is selected and blink while in service mode.

TIMERTimer setting

modeThis lamp will light up while in timer setting mode.

eMode No./Data No. display

MODE

—

Used to display the following contents while in each mode.• Normal or operation setting mode

……… The current operation mode No. is displayed.• Monitor setting mode

……… No. of data that is displayed on the data display block is displayed.

• Parameter setting mode ……… “P” is displayed while in parameter setting.

r Data displayDATA

—Used to display a variety of data.(Data displayed varies with setting mode or data No.)

tOperation

button

SELECT button

Used to switch each mode.

DOWN button Used to decrease Mode No./Data No./Data Value by 1.

UP button Used to increase Mode No./Data No./Data Value by 1.

SAVE buttonUsed to save Mode No./Data No./Data, the setting of which is being changed.

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Nine operation modes listed in Table below are available on the control panel.For normal operation, modes 1 to 4 and 8 and 9 are used.Other modes 5, 6, and 7 may interfere with the operation of the Oil Cooling Unit. Therefore, before using, be sure to thoroughly understand the functions of these modes.

Mode Function LED status

1 Normal modeUsed to display the current “operation mode” and “target temperature”. When the power supply turns ON, the system will be automatically brought to this mode.

“NORMAL” lamp ON

2 Operation setting mode Used to change the setting of “operation mode” and “target temperature” “SETTING” lamp ON

3 Monitor mode Used to display values detected by each sensor. “MONITOR” lamp ON

4 Time setting mode Used to make ON timer setting. “TIMER” lamp ON

5 Operation lock mode (factory setting)

Used to stop the operation of Oil Cooling Unit regardless of setting conditions.

All lamps except for “POWER” OFF

6 Parameter setting mode

Used to make settings shown below.qTo make setting of combination of signals output to

external contact when a malfunction or warning occurs.wTo make automatic setting of controlled variables for PI control.eTo make manual setting of controlled variables for PI control.rTo make warning setting for the protection of devices.

“SETTING” lamp blinking

7 Auto tuning mode Used to automatically compute controlled variables for PI control and set them with parameters.

“NORMAL” lamp blinking

8 Special monitor mode Used to check for a variety of current data. “NORMAL” lamp blinking

9 Service monitor mode Used to check for the history of malfunction codes and a variety of data.

“MONITOR” lamp blinking

(1) Mode shifting operationNormally, use the button to shift mode.

In order to shift to special mode, press and hold multiple buttons in combination for a period of two seconds.

CAUTIONThe system is set to “operation lock mode”

at factory. To start operation, release the operation lock mode.

If the malfunction prevention switch on the main PC board turns ON, no operation settings will be made. If so, turn OFF this switch.

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2-1. Normal ModeWhen the power supply turns ON, the system will be automatically brought to this mode.This mode is used to display the following contents according to the status of the Oil Cooling Unit.

Operation Procedure by Mode2

Status Display of control panel Remarks

Normal operation

NORMAL

SETTING

MONITOR

TIMER

POWER ALARM TIMER

MODE DATA

• POWER lamp: ON• MODE: Operation mode No. displayed• DATA: Target operating temperature displayed

MalfunctionNORMAL

SETTING

MONITOR

TIMER

POWER ALARM TIMER

MODE DATA

• POWER lamp: ON• ALARM lamp: Blinking when the malfunction level 1 occurs

ON when the malfunction level 2 occurs• MODE: OFF• DATA: Blinking malfunction code displayed

Operation locked

NORMAL

SETTING

MONITOR

TIMER

POWER ALARM TIMER

MODE DATA

• POWER lamp: ON• MODE: OFF

• DATA: Blinking ‘LOC’ displayed

To unlock, press and hold the for a period of two seconds.

While operation lock mode, the Oil Cooling Unit stops all operations including the pump operation.

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2-2. Operation Setting ModeThis mode is used to make settings of operation mode and target temperature.

Furthermore, if the malfunction prevention switch on the main PC board turns ON, no operation mode settings will be made. In this case, turn OFF this switch to make these settings.

[Setting procedure](1) Turn ON the power supply.

When the power supply turns ON, the system will be brought to “normal mode” to display the current operation mode and target control value.

(2) Shift to “operation setting mode”.

While in normal mode, press the button to shift to “operation setting mode”. (The MODE display will blink.)

(3) Select mode No.

Press the or button to select a desired mode No. (The MODE display will remain blinking.)

Press the button to save the mode No. (The MODE display will light up and the DATA display will blink.)

(4) Make setting of target temperature.

Press the or button to set to a desired target temperature. (The DATA display will remain blinking.)

Press button to save the target temperature. (The DATA display will light up.)

(5) Return to normal mode.

Press the button three times to return to normal mode.

(For reference) Mode and data will be saved when the button is pressed with the data block blinking and displayed.

If the button is pressed before saving, the mode and data in process of changing will be discarded and the system will keep running under the previous setting.

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*1. Fixed temperature control: The set value is used as a target temperature for this control.*2. Synchronization control: The target temperature is used as a value calculated by the following expression for this

control.

Target temperature = Base temperature for synchronization + Offset value

However, if the result of calculation falls short of 5.0°C, the target temperature will be adjusted to 5.0°C. If it exceeds 50.0°C, the target temperature will be adjusted to 50.0°C.

*3. Direct capacity control: Used to control the cooling capacity as set. (Setting the capacity to 0% will stop the compressor.)

Note 1) Setting operation mode to No. 4 or No. 6 without mounting the machine body synchronization thermistor (Th-5: Option) will display the malfunction code “H1” to disable the compressor operation.

2) Depending on the model of Oil Cooling Unit, some of the operation modes will not be functional.If the operation mode selected is not functional, the data block will display “— — —” to disable settings.

List of operation modes

Mode No.Setting item

Settable rangeAKZ Series AKZJ Series

0Inlet oil temperature under fixed temperature control (*1)

Liquid temperature under fixed temperature control (*1) 5.0 to 50.0°C

(Factory set to 20.0°C)1

Outlet oil temperature under fixed temperature control (*1)

(Not used)

2 (Not used) (Not used) —

3 (Factory setting)

Inlet oil temperature offset value under room temperature synchronization control (*2)

Liquid temperature offset value under room temperature synchronization control (*2)

-9.9 to 9.9°C(Factory set to 0.0°C)

4Inlet oil temperature offset value under machine body temperature synchronization control (*2)

Liquid temperature offset value under machine body temperature synchronization control (*2)

5Outlet oil temperature offset value under room temperature synchronization control (*2)

(Not used)

6Outlet oil temperature offset value under machine body temperature synchronization control (*2)

(Not used)



9Cooling capacity under direct capacity control (*3)

Cooling capacity under direct capacity control (*3)

0 to 100%(Factory set to 0%)

Set value above

• In the case of room temperature synchronization control, a value detected by the room temperature thermistor (Th-3)

• In the case of machine body synchronization control, a value detected by the machine body synchronization thermistor (Th-5: Option)

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2-5. Operation Lock ModeThis mode is used to lock the Oil Cooling Unit to the stop status and prohibit operations of buttons except for the UNLOCK button.

While in a normal use mode (i.e., normal, operation setting, or monitor mode), press and hold the or mode for a period of two seconds. “Loc” on the data display block will blink to put the system into locked status.

To release operation lock mode, also press and hold the or button for a period of two seconds.

NORMAL

TIMER

MONITOR

SETTING

ALARMPOWER TIMER

MODE DATA

In order to start or stop the Oil Cooling Unit on the control panel, start with this operation.

2-3. Monitor ModeThis mode is used to display temperatures detected by each sensor and Inlet/Outlet status.

Using the or button makes it possible to select data No.

Data No.

Contents

AKZ Series AKZJ Series

0 Machine body temperature (Th-5) *1 Machine body temperature (Th-5) *1

1 Outlet oil temperature (Th-2) *1 Not used *1

2 Room temperature (Th-3) *1 Room temperature (Th-3) *1

3 Inlet oil temperature (Th-4) *1 Inlet oil temperature (Th-4) *1

4 Pump outlet temperature (Th-10) *1 Pump outlet temperature (Th-10) *1

5Difference in temperature between oil inlet and outlet (Th-4 - Th-2) *1

Not used *1

6Value instructed by direct capacity control (%) *1

Value instructed by direct capacity control (%) *1

7 Revolutions of INV compressor (rps) Revolutions of INV compressor (rps)

8 Spare Spare

9Setting status with communication PC board (option) mounted

Setting status with communication PC board (option) mounted

*1: If the thermistor is not connected or contains a broken wire, 99.9 will be displayed for the temperature.

2-4. Timer Setting ModeThis mode is used to display ON timer setting and timer value (in hours up to a maximum of 99 hours).

Use the or button to make setting of the timer value. Saving the input with the button will put the system into timer status, thus stopping the Oil Cooling Unit operation.

To release the timer status, set the timer value to “0”.

TIMER

SETTING

ALARMPOWER TIMERNORMAL

MONITOR

MODE DATA

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2-6. Parameter Setting ModeThis mode is used to make settings of the following parameters to determine the basic operation of Oil Cooling Unit.

Setting of external output procedure when a malfunction or warning occurs...........n01 to n03Setting of conditions for auto tuning .........................................................................n04 and N05Setting of gain rate for temperature control ..............................................................n06 to n09Setting of monitoring subject for temperature warning.............................................n10, n12, n14, n16, and n18Setting of operating temperature (difference) for temperature warning....................n11, n13, n15, n17 and n19Setting of YES or NO of use of parallel communication ...........................................n20Setting of minimum pulse for EV valve.....................................................................n24

Furthermore, if the malfunction prevention switch on the main PC board turns ON, no operation settings will be made. In this case, turn OFF this switch.

(1) Setting procedureWith ‘P’ blinking in the MODE block, use the or button to select a parameter No.

The DATA block displays the parameter No. selected for a period of approximately 0.5 seconds and then data.

When the button is pressed, the DATA block will start blinking and displaying.

Use the or button to change data and the button to save the data.

Pressing the button before saving the data will discard the data to return to the previous value.

[Note] Parameters are classified into two groups: One group of parameters becomes enabled on the spot, while the other group of parameters requires turning ON the power supply again.To make judgment of which group the parameters belong to, refer to List of parameters.

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Parameter No Item Min.

valueMax. value

Default value at factory setting

Power reset required

Remarks

n00 (Not used) 0 0 0 —

n01 External output when a malfunction or warning occurs 0 11 0 Output s ignal to “60-61”,

“60-63” and “66-67”

n02 Operation setting 1 for external signal input 0 3 0 Input signal from terminal Nos. “12-13”

n03 Operation setting 2 for external signal input 0 2 0 Input signal from connector CN2

n04 Setting of auto tuning end conditions 0.0 10.0 8.0 Setting of oil outlet drop temperature

n05 Setting of response coefficient for auto tuning 0.1 10.0 AKZ : 2.0

AKZJ : 7.0 —

n06 Setting of control gain P (in the case of small temperature differential) 1 999

AKZ : 40AKZJ188 ~ 458

: 120AKZJ568·908

• n06, n08 : 90• n07, n09 : 30

Defaul t value var ies with models.

n07 Setting of control gain I (in the case of small temperature differential) 1 999

n08 Setting of control gain P (in the case of large temperature differential) 1 999

n09 Setting of control gain I (in the case of large temperature differential) 1 999

n10 Setting of monitoring subject for warning 1 0 465 0

S e t t i n g s o f “ m o n i t o r i n g sub jec t ” a n d “ o pe ra t i ng tempera tu re ” t o i ssue a temperature warning.Setting of a total of 5 items can be made.For details, refer to information in section “(4) Temperature warning” (on page 59 and later).

n11 Setting of operating temperature for warning 1 0.0 60.9 0.0









n20 Setting of YES or NO of use of parallel communication 0 1 0 Option is required to provide.

N21to

n23(Not used) — — —

Never change the setting of these parameters. Doing so will result in a malfunction.

n24 Setting of minimum pulse for EV valve 0 999 Default value varies with types of EV valve.

In order to replace the main P C b o a r d o r e l e c t r o n i c expansion valve, the minimum pulse should be set to “0” and operation to detect fully open pulse should be performed. (For details, refer to pages 112 and 113.)

N25to

N38(Not used) — — —

Never change the setting of these parameters. Doing so will result in a malfunction.

(2) List of parameters

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One placeTens place

Output to terminal block (X2M)

Setting 0 (Factory setting) 1

OutputTerminal

No.Normal

Power failure

Malfunction NormalPower failure

Malfunction

Malfunction output

60 – 61 ON OFF OFF OFF OFF ON60 – 63 OFF ON ON ON ON OFF

Setting 0 (Factory setting) 1

OutputTerminal

No.Normal

Power failure

Warning NormalPower failure

Warning

Warning output 66 – 67 ON OFF OFF OFF OFF ON

Output with communication PC board (option) used

Pin No. Setting 0 (Factory setting) 1

1 (D0) When the warning 1 occurs: OFF When the warning 1 occurs: ON2 (D1) When the warning 2 occurs: OFF When the warning 2 occurs: ON3 (D2) When the warning 3 occurs: OFF When the warning 3 occurs: ON4 (D3) When the warning 4 occurs: OFF When the warning 4 occurs: ON5 (D4) When the warning 5 occurs: OFF When the warning 5 occurs: ON6 (D5) (Not used)7 (D6) When the malfunction level 1 occurs: OFF / When the malfunction level 2 occurs: ON8 (D7) When the malfunction occurs: OFF When the malfunction occurs: ON

9 (COM) Common (+24V)

(3) Parameter No. n01: External output when a malfunction or warning occursWhen a malfunction or warning occurs, used to make setting of combination of output to each contact.

n02: OP contact levelUsed to make setting of operation for input signal (OP signal) to the connection terminals (12 and 13: OP terminals) of optional safety equipment on the terminal block (X2M).

“0”: OP terminal not used (factory setting)“1”: Used to implement the malfunction level 1 when the connection terminals (12 and 13) turn OFF.“2”: Used to implement the malfunction level 2 when the connection terminals (12 and 13) turn OFF.“3”: Used to implement the malfunction level 1 (respond to the flow switch) when the connection terminals

(12 and 13) do not turn ON after a lapse of 30 seconds since the pump starts operation.[Note] Just connecting the optional safety device to the OP terminals will not enable the protective function. Be

sure to make this parameter setting.

n03: OP2 contact levelUsed to setting of operation for input signal to the CN2 (OP2) on the main PC board (A1P).

“0”: CN2 terminal not used (factory setting)“1”: Used to implement the malfunction level 1 when the CN2 contact turns OFF.“2”: Used to implement the malfunction level 2 when the CN2 contact turns OFF.

[Note] The OP2 may be used for an option at factory setting.

n04: Setting of auto tuning end conditionsWhile in auto tuning mode, if the oil outlet temperature falls by the degree set with this parameter, the auto tuning will end. (For details, refer to information in Section 2-7.)

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n05: Setting of response coefficient for auto tuningUsed to make setting of response coefficient to calculate the optimum control variable for auto tuning (Section 2-7).qMake this value smaller. . Stability will be upgraded, but responsiveness will be degraded.wMake this value larger. . Responsiveness will be upgraded, but stability will be degraded.

n06 to n09: Setting of gain rate for temperature control• n06: Control gain P (in the case of small temperature differential)• n07: Control gain I (in the case of small temperature differential)• n08: Control gain P (in the case of large temperature differential)• n09: Control gain I (in the case of large temperature differential)Parameters n06 to n09 are used to make setting of gain for temperature control.In the case of small temperature differential between the control target and the control subject, use gains of n06 and n07.In the case of large temperature differential between the control target and the control subject, use gains of n08 and n09.

n10, n12, n14, n16, and n18: Setting of monitoring subject for temperature warningUsed to make setting of monitoring subject for temperature warning and also operation contents when conditions are met.

n11, n13, n15, n17, and n19: Setting of operating temperature (differential) for temperature warningUsed to make setting of operating temperature (differential) to issue a temperature warning.

n20: Setting of YES or NO of use of parallel communicationUsed to make setting of whether or not to perform parallel data communication with the main machine.

“0”: Not performed (Factory setting)“1”: Performed

Setting this parameter to “0” with a communication extension PC board (option) connected will make it possible to use parallel output from the extension PC board as individual output of alarm status or temperature warning.

n21 to n23: Not usedNever change the setting of these parameters. Doing so will result in a malfunction.

n24: Setting of minimum pulse for EV valveUsed to make optimum setting of minimum pulse for the EV valve by equipment.(Factory setting to the optimum pulse for EV valve concerned.)

n25 to n28: Not usedNever change the setting of these parameters. Doing so will result in a malfunction.

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(4) Temperature warningThis function alerts you to the necessity to check for Oil Cooling Unit when the monitoring temperature exceeds the set temperature range. When the temperature warning is detected, operations of compressor, fan, and others will vary with settings (of operations after temperature warning is detected (C) as per table shown below).

(4)-1. Detailed settingsqBased on the following expression, make settings of “monitoring subject (a)”/“monitoring subject (b)” and

“temperature to issue a warning (d)”.

Temperature for monitoring subject (a) – Temperature for monitoring subject (b) = Temperature to issue a warning (d)

wMake settings of “YES/NO of external output of warning signal (c)” and “Resetting procedure after warning (c)”.eMake setting of the following “differential value (e) to specify the resetting temperature.

Resetting temperature = Temperature to issue a warning (d) ±(*) Differential value (e)

*If the temperature to issue a warning is set to the lower limit, take “+”. If it is set to the upper limit, take “–”.

(4)-2. Setting procedureTurning ON power supply:qTurn ON the power supply. (The system will be automatically put into “normal mode”.)Parameter setting mode:

wPressing and holding the button for a period of two seconds or more will put the system into “parameter setting mode”. (The MODE block will display blinking “P”.)

Settings of (a), (b), and (c):

eUse the or button to set to a desired parameter No. (n10, n12, n14, n16, or n18).

(After a lapse of 0.5 seconds, the DATA block will display data.)

rUse the or button to set (a), (b), and (c) to desired Nos.,

respectively.

tUse the button to save the Nos.

Operation after a temperature warning is detected (c)

Setting

No.Display ON/OFF

External output (*2)

Terminals 60-61/60-63 Terminals 66-67

0 (Warning function is not used.)

1

Warning (1E to 5E)

ON (*1)

No output

Warning output

2Compressor

only forcedly

stops.

Automatic

reset

No output

3 Warning output

4Malfunction code “FH” Manual reset Malfunction output

No output

5 Warning output

*1: “ON” follows thermostat ON/OFF control.*2: Output to external terminals follows the setting of parameter n01 (refer to page 57).

Monitoring subject (b)

Setting

No.

Display item



1 -Machine body temperature (Th-5) -Machine body temperature (Th-5)

2 -Outlet oil temperature (Th2) (Not used)

3 -Room temperature (Th-3) -Room temperature (Th-3)

4 -Inlet oil temperature (Th-4) -Liquid temperature (Th-4)

5 ≥Fixed value ≥Fixed value

6 ≤Fixed value ≤Fixed value

Monitoring subject (a)

Setting

No.

Display item



1 Machine body temperature (Th-5) Machine body temperature (Th-5)

2 Outlet oil temperature (Th2) (Not used)

3 Room temperature (Th-3) Room temperature (Th-3)

4 Inlet oil temperature (Th-4) Liquid temperature (Th-4)

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Settings of (d), and (e):

yUse the or button to set to a desired parameter No. (n11, n13, n15, n17, or n19).

(After a lapse of 0.5 seconds, the DATA block will display data.)

uUse the or button to set (d), and (e) to figures desired, respectively.

iUse the button to save the figures.

Returning to normal:

oPress the button to return to “normal mode”.

(Reference) List of typical temperature warning settingsAKZ Series

No. Item to monitor temperature

Setting of monitoring subject(n10,n12,n14,n16,n18)

Setting of operating temperature(n11,n13,n15,n17,n19)

(a) (b) (c) (d) (e)

Monitoring subject (1)


Operation after warning

Temperature to issue a warning

Differential value.

1 When temperature warning is not used (factory setting) 0 0 0 0 0

2 When the oil outlet temperature is higher than the machine body temperature 2 1 1,4,5

Make setting of temperature

differential range of 0 to 60.

—

3 When the oil outlet temperature is higher than the room temperature 2 3 1,4,5 —

4 When the oil outlet temperature is lower than the machine body temperature 1 2 1,2,3 Make setting of range of 1 to 9.5 When the oil outlet temperature is lower than the room temperature 3 2 1,2,3

6 When the oil inlet temperature is higher than the machine body temperature 4 1 1,4,5 —

7 When the oil inlet temperature is higher than the room temperature 4 3 1,4,5 —

8 When the oil inlet temperature is lower than the machine body temperature 1 4 1,2,3 Make setting of range of 1 to 9.9 When the oil inlet temperature is lower than the room temperature 3 4 1,2,3

10 When the oil outlet temperature is high 2 5 1,4,5 Make setting of temperature


—

11 When oil inlet temperature is high 4 5 1,4,5 —

12 When the oil outlet temperature is low 2 6 1,2,3 Make setting of range of 1 to 9.13 When the oil inlet temperature is low 4 6 1,2,3

AKZJ Series

No. Item to monitor temperature

Setting of monitoring subject(n10,n12,n14,n16,n18)

Setting of operating temperature(n11,n13,n15,n17,n19)

(a) (b) (c) (d) (e)



Operation after warning

Temperature to issue a warning

Differential value.

1 When temperature warning is not used (factory setting) 0 0 0 0 0

2 When the liquid temperature is higher than the machine body temperature 4 1 1,4,5 Make setting of temperature


—

3 When the liquid temperature is higher than the room temperature 4 3 1,4,5 —

4 When the liquid temperature is lower than the machine body temperature 1 4 1,2,3 Make setting of range of 1 to 9.5 When the liquid temperature is lower than the room temperature 3 4 1,2,3

6 When the liquid temperature is high 4 5 1,4,5 Make setting of temperature


—

7 When the liquid temperature is low 4 6 1,2,3Make setting of range of 1 to 9.

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(4)-3. Display while in temperature warning

(4)-4. Action against temperature warningIf the temperature warning is executed according to low oil temperature protection, this warning will be automatically reset when the temperature reaches the warning reset temperature. In contrast, if the temperature warning is executed according to high oil temperature protection, the power supply should be turned ON again (manually reset). In each case, probe the causes of fluctuations in oil temperature both on the main machine and the Oil Cooling Unit sides.

Particularly, on the Oil Cooling Unit side, check for the following points.• Whether or not oil quantity is kept at the normal level.• Whether or not there is any obstacle in the vicinity of air supply/exhaust opening.• Whether or not the filter is clogged.• Whether or not the condenser gets dirty.• Whether or not an improper model is selected.• Whether or not capacity is stepping down (the room temperature and oil temperature are below 35°C).• Whether or not the system runs according to direct capacity control.• Whether or not refrigerant gas has leaked out.• Whether or not sensors get dirty or damaged.• Whether or not the setting of temperature warning is properly made.

NORMAL

MONITOR

TIMER

SETTING

MODE DATA

POWER ALARM TIMER

Warning display

Content

1EOperation according to setting with parameter Nos. “n10” and “n11”





“ALARM” lamp: OFFDisplay of “DATA” block: Warning set number is blinked and displayed.

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2-7. Auto Tuning ModeThis mode is used to automatically compute controlled variables for PI control and set them with parameter n6 to n9.

(1) Setting procedure

Turning ON power supply:qTurn ON the power supply. (The system will be automatically put into “normal mode”.)

Auto tuning mode:wPressing and holding the buttons simultaneously for a period of two seconds or more will put the

system into “auto tuning mode”.

ePressing the button will initiate the auto tuning.

(The system will automatically go through the following steps.)

Step 0

Used to check for auto tuning conditions.

Step 1

Used to operate for the stabilization of initial conditions.

Step 2

Used to operate for g a t h e r i n g d a t a o n control subject.

Step 3

Used to compute and set the result with a parameter.

End of auto tuning

rPressing the button will return the system to “normal mode”.

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Note) 1. Before putting the system into auto tuning mode, be sure to make setting of operation mode (except for No. 9 while in operation setting mode) in order to determine the thermistor subject to control.

2. Initiate auto tuning from the state in which the room temperature is approximately equal to the oil temperature (i.e., stable state). Furthermore, perform the auto tuning with no load (in a stop state) on the main machine side.

3. If an “error” occurs while in auto tuning, the auto tuning will be disabled. In this case, press the button to return the system to “normal mode”.

Probe the causes of the error to take measures against the error and then perform the auto tuning again.4. In Step 2, the system runs at 100% capacity. Consequently, oil may be overcooled. Make adjustment of

overcooled oil with parameter No. 4 (Setting of auto tuning end conditions). (Set the conditions to as large value as possible to the extent that no damage is caused to the machine.)

5. In order to compute the optimum control variable based on data gathered, the setting of response coefficient should be made with the parameter No. 5.(Making the variable smaller provides a higher level of stability, while making it larger provides a higher level of responsiveness.)

6. Depending on the conditions of control subject (machine), the optimum control gain may not be computed at one time. In this case, perform multiple calculations to take an average value or use a mode value (except for an extreme value).

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6 Functions

Operation Flow Chart1

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FunctionsF

un

ctio

ns

Function Description

1 Stop

Stop due to malfunction

When a malfunction occurs while in running, used to stop compressor or else for protection.Stop due to malfunction is classified into the following two levels.

• Malfunction level 1: Compressor, pump, and fan all stop operation.• Malfunction level 2: Only the compressor stops running. (The pump and fan

keep operating.)

Stop due to temperature warning

When the monitoring temperature exceeds the set temperature while in operation, used to stop the compressor or else.

• Operation to stop: Only the compressor stops operation. (The pump and fan keep operating.)

• Resetting procedure (Two procedures are available according to setting.)

A Automatic resetting - After a lapse of “standby for restart”, the system will automatically restart operation.

B Manual resetting - After resetting the power supply on manual control, turning ON the circuit breaker again will restart operation.

*For details of temperature warning setting procedure, refer to information on page 59 and later.

2 Standby Standby for restartIn order to prevent frequent ON/OFF operations of the compressor and equalize pressure within the refrigerant system, used to stand by for the restart of the compressor for a period of 30 seconds after the compressor stops.

3Startup control

Startup control

For models AKZ(J)148 to 568, in order to start the compressor, used to increase the operating frequency to 46 Hz once and then operate the compressor at the minimum operating frequency.

AKZ(J)148 ~ 568

46Hz

38Hz

AKZ(J)908

25Hz2Hz/s

2Hz/s

Judgment of thermostat ON/OFF

Make ON/OFF judgment of the thermostat under the following conditions against the set temperature.Thermostat ON condition: Detected temperature ≥ Set (target) temperatureThermostat OFF condition: Detected temperature < Set (target) temperature

4Function control

(High-accuracy) oil temperature

control

Compressor control

In medium/high load regions (i.e., 60 to 100% of the product capacity), used to control the compressor operating frequency, thus making the oil temperature corresponding to the target temperature.

EV valve control

In low load regions (i.e., 5 to 60% of the product capacity), used to control the EV valve opening, thus making the oil temperature corresponding to the target temperature.

Auto tuning controlUsed to compute P/I gain for temperature control and then set it to parameter concerned.

5Protection

control

High pressure protection function

When high pressure shows an abnormal rise, used to stop only the compressor due to malfunction.

Stop due to detection by the thermistor of condenser (subject to all applicable models)Actuating temperature: 65°C or moreStop due to detection by the high pressure switch (only on -C models)Actuating pressure: 4.1MPa

Inverter protection function

When an abnormal inverter fin temperature is detected, used to stop only the compressor due to malfunction.

Actuating temperature: 95°C (AKZ(J)148 to 568)120°C (AKZ(J)908)

Functions2

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6 Functions

When a malfunction or warning occurs while in operation, the equipment will stop operation in progress and the status will be displayed.1. In order to protect functional parts, the compressor, oil pump, fan, or else stops.2. In order to alert the customer to the malfunction or warning, it is displayed by code or lamp.

No.Malfunction

level

ON/OFF Display

SubjectCompressor Oil pump Fan

Resetting

procedureDisplay

Malfunction

lamp

1 Level 1 OFF OFF OFFManual

resettingDisplay by

malfunction

code

Blink Malfunction code

(A6 to UJ)

For details, refer to page 70.2 Level 2 OFF ON ONManual

resettingON

3

Level 3

OFF ON ONAutomatic

resetting Display by

warning

OFF Warning

(1E to 5E)

For details, refer to page 61.4 ON ON ON — OFF

5 — OFF ON ONAutomatic

resettingNo display OFF

q Low room temperature

protection (*1)

w Low oil temperature

protection (*2)

*1: When the room temperature thermistor detects a temperature of -2°C or less, this protection will be activated.*2: When the inlet oil temperature thermistor detects a temperature of 2°C or less, this protection will be activated.

List of Malfunctions/Warnings3

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7 TroubleshootingTroubleshooting

Item Symptom Cause Measure

1

The uni t per forms no operation. (The POWER lamp on the operation panel does not turn ON.)

qMain power not supplied or power supply wires (L1 and L2) disconnected.

Supply power to the power supply terminals (R, S, and T) on the main PC board (A1P).

2 The pump does not operate.

qRemote control terminals (10 – 11) on the external terminal block (X2M) in the OFF position.

Check to be sure the connection of remote control input.

w“Operation lock mode” selected (Factory set to “operation lock mode”)

Unlock “operation lock mode” on the control panel. (Refer to page 54.)

3

The pump operates but no oil flows.A small quantity of oil recirculates and the pump makes a loud noise.

qUnfastened piping on the suction side of the pump.

Check the packing in the piping for condition and then refasten it if necessary.

wClogged suction strainer (on the main machine side)

• Clean the suction strainer.• If the oil in the oil tank gets foul, replace the oil.

eDropped oil level in the oil tank Refill the oil tank with oil.

rRel ief valve act ivated due to large pressure loss in the oil discharge piping Make the oil pipe diameter larger and the piping

shorter.tCavitation caused in the pump due to large pressure loss in the oil suction piping

4The pump operates but the compressor does not operate.

qCompressor stop due to temperature control – – –

wActivation of compressor restart protection timer (30-second timer)

Check to be sure the compressor starts up when the timer completes its operative period of time.

eActivation of low oil temperature protection (due to inlet oil temperature of 2°C or less)

Use at an inlet oil temperature of 5°C or more.

rActivation of low room temperature protection (due to room temperature of -2°C or less)

Use at a room temperature of 5°C or more.

tMode No. 9 set to 0% Change to proper operation mode.

5Both the pump and compressor operate but oil does not become cool.

qObstacle present near the air suction/exhaust opening

Remove the obstacle.

wDirty air filter Clean the air filter.

eStepping down operation in progress due to high room temperature

Check to sure the capaci ty in the operat ing temperature range with the catalog and then select a model having a proper capacity.rToo large heat load

tToo high set temperature Change the setting to a proper temperature.

yShortage of refrigerant gas if exhaust temperature is approximately equal to the room temperature, even though the compressor is in operation.

Recharge refrigerant.

6No operation settings can be made.

qIf “– – –” is displayed in the DATA block, the thermistor used for operation mode concerned is not connected.

Correct the connection of the thermistor.

wIf “– – –” is displayed for just a moment when the button (i.e., r ightmost switch) is pressed, mishandling prevention switch (SW1) is set to ON.

Set the mishandling prevention switch (SW1) on the main PC board to OFF.

7

Malfunction signals are output f rom terminals 64–65 on the external t e r m i n a l b l o c k i n a manner different from the conventional one.

qThe procedure for signal output when a malfunction occurs is different from that of Models 5 and 6.

The procedure is different from that for models AKS5 and AKZ6.Referring to information in “Parameter setting mode” on page 55, make proper settings.

If an operation shows an abnormality even through no malfunction code is displayed, refer to the following information to take measures.

Troubleshooting According to Symptoms1

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7 Troubleshooting

Using the control panel to put the system into “special monitor mode” will acquire a variety of data on the current equipment.

[Operation procedure]

While in normal mode (with the NORMAL lamp ON), press and hold the and buttons for a period of two seconds, the NORMAL lamp will start blinking to shift to special monitor mode.

Pressing the or button will make it possible to change data No. (display in the MODE block).

Furthermore, pressing the button while in special monitor mode will return the system to normal mode.

Display item of special monitor mode

Data No. Item0 [Current] Command frequency controlled by compressor inverter (rps)1 [Current] EV valve opening (pulse)2 [Current] Main circuit voltage (V)3 [Current] Primary current of main circuit (A)4 [Current] Inverter radiation fin temperature (°C)5 [Current] Control box temperature (°C)6 [Current] Discharge gas temperature (°C)7 [Current] Condenser saturated temperature (°C)8 [Current] EV valve outlet temperature (°C)9 [Current] DC fan revolutions (10 rpm)A Power supply frequency detected (Hz)B — (used for technical test) *C — (used for technical test) *D — (used for technical test) *E Control software Ver.F Inverter software Ver.

*: Since the data is used for technical test, do not change the setting on site.

<Special monitor mode>

<Normal mode>

Equipment Data checking Procedure2

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TroubleshootingTroubleshooting

Using the control panel to put the system into “service monitor mode” will make it possible to check the history of malfunction codes and data when a malfunction occurs.

<Service monitor mode>

3-1. Control Panel Operation Procedure<Normal mode>

While in normal mode (with the NORMAL lamp ON), press and hold the button for a period of two seconds, the MONITOR lamp will start blinking to shift to service monitor mode.

Pressing the or button will make it possible to change data No. (display in the MODE block).

Furthermore, pressing the button while in service monitor mode will return the system to normal mode.

Display item of special monitor modeData No. Item

0 Malfunction code 0 (latest)1 Malfunction code 12 Malfunction code 23 Malfunction code 34 Malfunction code 45 Malfunction code 56 Malfunction code 67 Malfunction code 78 Malfunction code 89 Malfunction code 9 (oldest)A [When a malfunction occurs] Machine body temperature [Th-5] (°C)B [When a malfunction occurs] Outlet oil temperature [Th-2] (°C)------ Not displayed on AKZJC [When a malfunction occurs] Room temperature [Th-3] (°C)

D [When a malfunction occurs] Inlet oil temperature [Th-4] (°C) --------Liquid temperature in the oil tank [Th-4] displayed on AKZJ (°C)

E [When a malfunction occurs] Discharge gas temperature [Th-8] (°C)F [When a malfunction occurs] Condenser saturated temperature [Th-7] (°C)H [When a malfunction occurs] EV valve outlet temperature [Th-6] (°C)J [When a malfunction occurs] Inverter frequency command (rps)L [When a malfunction occurs] EV valve opening (pulse)P [When a malfunction occurs] Main circuit voltage (V)U [When a malfunction occurs] Main circuit current (A)Y [When a malfunction occurs] Cumulative compressor operating time (minute)— Malfunction reset (Note 1)

(Note 1) Normally, ‘0’ is displayed. Setting this value to ‘77’ makes it possible to reset the control CPU. (Basically, it is recommended to clear the alarm through turning the power supply to the Oil Cooling Unit OFF and then ON. Use this function only if the power supply to the Oil Cooling Unit cannot be turned OFF individually.

Troubleshooting According to Malfunction Codes3

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7 Troubleshooting

3-2. List of Malfunction CodesMalfunction

codeMalfunction

levelMalfunction Malfunction decision condition

Troubleshooting Flow Chart

(Reference page)

A6 2 DC fan stop Actual fan revolution falls below 10 rpm while in fan revolution. 71

AA 2 Malfunction due to overheated heaterFor AKZ Series, the overheat prevention temperature switch reaches a temperature of 70°C.For AKZJ Series, the boil-dry prevention thermostat reaches a temperature of 105°C.

72

E1 1 System malfunctionCompressor ID No. (PC board jumper setting) ≠ Parameter horsepower setting

73

E3 2Malfunction due to high pressure or condenser temperature

The condenser temperature of 65°C or more continues for a period of 10 seconds. 74High pressure exceeds 4.2 MPa (only for -C models).

E5 2Malfunction due to discharge gas temperature or overheated compressor

The discharge gas temperature exceeds A for a period of 10 seconds (*1).75

The compressor head temperature exceeds 115°C.

E6 2 Compressor lock at startup The compressor revolutions are not detected at startup. 76

E9 2 Malfunction of electronic expansion valveThe malfunction is detected according to the EV valve opening and EV valve outlet temperature.

77

EH 1Actuation of pump overcurrent relay or actuation of agitator inner thermostat

The pump current exceeds B (*2). 78

EJ 1Actuation of boil-dry prevention switch of actuation of optional safety devices

The pressure reaches 0.03 MPa (for -H units up to AKZ438/AKZJ458).79The flow rate reaches 15 L/minute (for -H units up to AKZ568/AKZJ568).

The safety device connected to X2M 12-13 activates. (Short-circuit)

FE 1Malfunction due to oil pressure (rise in pump outlet temperature)

The pump outlet temperature exceeds 65°C. 80

FH 2Rise in oil inlet temperature or rise in tank liquid temperature

The oil inlet temperature exceeds 60°C for a period of consecutive 60 seconds.

81

H1 2Malfunction of room temperature thermistor or malfunction of machine body synchronization thermistor

The thermistor makes a short circuit or contains a broken wire. 82

J3 2 Malfunction of discharge gas temperature thermistor The thermistor makes a short circuit or contains a broken wire. 82

J5 2 Malfunction of EV valve outlet temperature thermistor The thermistor makes a short circuit or contains a broken wire. 82

J6 2 Malfunction of condenser temperature thermistor The thermistor makes a short circuit or contains a broken wire. 82

JE 2 Malfunction of pump outlet temperature thermistor The thermistor makes a short circuit or contains a broken wire. 82

JH 2Malfunction of outlet oil temperature thermistor or malfunction of inlet oil temperature thermistor

The thermistor makes a short circuit or contains a broken wire. 82

L0 2 Malfunction of inverter/compressor Any of the malfunction codes L4, L5, L8, L9, and LA is displayed. 83

L4 2 Rise in radiation fin temperature The temperature rises to 95°C (up to 568 class) or 120°C (on 908 class). 84

L5 2 Instantaneous overcurrent of power transistor The output overcurrent is input in the microcomputer. 85

L8 2 Compressor overload The compressor output revolutions reach an abnormal level. 86

L9 2 Faulty compressor startup The compressor does not smoothly rotate at startup. 87

LA 2 Malfunction of power transistor The microcomputer detects the malfunction of power transistor. 88

LC 2Malfunct ion of transmission between inverter CPU and temperature control CPU

The transmission between the inverter microcomputer and the temperature control microcomputer malfunctions.

89

P3 2 Malfunction of control box thermistor The thermistor makes a short circuit or contains a broken wire. 82

P4 2 Malfunction of fin temperature thermistor The thermistor makes a short circuit or contains a broken wire. 82

U0 2 Shortage of refrigerantqCommand capacity ≥ 95%wCondenser temperature - EV valve outlet temperature ≤ 5°C qand w continues for a period of three minutes.

90

U1 1Reverse phase/open phase of power supply or wire broken in fuse

Reverse phase or open phase is detected in the power supply circuit.

91

U2 2 Malfunction due to power supply voltage The power supply voltage drops below 170 V. 92

U9 2 Malfunction of transmission with slave unitWhile in pair operation of master and slave units, data transmission with other system malfunctions.

93

UH 2 System-related failure EEPROM causes a failure. 94

UJ 2 Actuation of external safety device A short circuit occurs between the terminals of CN2 on the main PC board. 95

Malfunction level 1 ... Pump OFF + Compressor OFF + Fan OFFMalfunction level 2 ... Pump ON + Compressor OFF + Fan ON

*1: 117°C: AKZ148/328 and AKZJ188/358 120°C: All models other than those shown left.*2: 2.5 A: AKZ148 to 438 3.6 A: AKZ568/908

067-070_[7]故障診断.indd 2005/06/02, 18:2270

71


5 Troubleshooting

Diagnosis Countermeasures

Control panel display

A6 DC Fan Stop

1 Applicable Models

AKZ148AKZ328AKZ438AKZJ188AKZJ358AKZJ458

2 Methods of Malfunction Detection

Use revolutions detected with a hall IC built in the fan motor.

3 Malfunction Decision Conditions

When the fan revolution falls below 10 rpm.

4 Supposed Causes

Faulty connector connection Faulty main PC board Faulty fan motor Surge in power supply Noise from power supply

circuit

3-3. Troubleshooting Flow Chart

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7 Troubleshooting

5 Troubleshooting



AA Malfunction due to Overheated Heater

1 Applicable Models

AKZ**8-HAKZJ**8-H(Al l models equipped with heater)


AKZ**8-H:Detect by superheat prevention temperature switch (S4B1)

AKZJ**8-HDetected by boil-dry prevention thermostat (S4B1 or S4B2)


AKZ**8-H:When the overheat prevention temperature switch is actuated.

Actuating temperature: 70°C AKZJ**8-H:

When the boil-dry prevention temperature switch is actuated.

Actuating temperature: 105°C(Resetting temperature: 99°C)

4 Supposed Causes

Inadequate oil quantity refilled Inadequate oil flow rate Faulty wiring of pump Faulty magnetic contactor Stains adhering around heater

(only on AKZJ**8-H)

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73

5 Troubleshooting



1 Applicable Models

AKZ**8AKZJ**8


Check with microcomputer whether or not E2PROM is normal.


When the combination of PC board and compressor is not normal.

4 Supposed Causes

Improper spare PC board used for servicing


EI Malfunction of System

071-095_[7]故障診断.indd 2005/06/02, 21:0773

74

7 Troubleshooting

5 Troubleshooting


1 Applicable Models

1. Malfunction due to condenser temperatureAKZ**8(All series including -C models)AKZJ**8(All series including -C models)

2. Malfunction due to high pressureAKZ**8-CAKZJ**8-C


1. Detect with the condenser temperature thermistor to be located in the middle of the condenser.

2. Detect the presence/absence of continuity with the high pressure switch to be located in the discharge pipe.


1. When the condenser temperature thermistor detects a temperature in excess of 65°C.

2. When the high pressure switch is actuated.

Actuating pressure: 4.1 MPa(Resetting pressure: 3.2 MPa)

4 Supposed Causes

Shield present around the equipment

Dirty air filter Room temperature too high Oil inlet temperature too high Faulty condenser temperature

thermistor Faulty high pressure switch Dirty or clogged condenser Faulty fan Short circuit of fan air

quantity


E3 Malfunction due to High Pressure or Condenser Temperature

071-095_[7]故障診断.indd 2005/06/02, 21:0774

75

5 Troubleshooting



1 Applicable Models

1. Malfunction due to discharge gas temperatureAKZ**8(All series including -C models)AKZJ**8(All series including -C models)

2. Malfunction due to overheated compressorAKZ**8-CAKZJ**8-C


1. Detect with the discharge gas temperature thermistor.

2. Detect the compressor protection thermostat.


1. When the discharge gas temperature thermistor detects a temperature of the following.

AKZ(J)148 to 358: 117°C AKZ(J)438 to 908: 120°C

2. When the compressor protection thermostat is actuated.Actuating temperature: 115°CResetting temperature: 85°C

4 Supposed Causes

Shield present around the equipment

Dirty air filter Room temperature too high Oil inlet temperature too high Fa u l t y d i s c h a r g e g a s

temperature thermistor Faulty compressor protection

thermostat Inadequate refrigerant quantity

(including slow leakage) Heat generated due to worn

compressor shaft Faulty EV valve Dirty or clogged condenser Short circuit


E5Malfunction due to Discharge Gas Temperature or Overheated Compressor

Ω

071-095_[7]故障診断.indd 2005/06/02, 21:0775

76

7 Troubleshooting

5 Troubleshooting


1 Applicable Models

AKZ**8 (All series)AKZJ**8 (All series)


Detect according to compressor revolutions at startup.


When the compressor revolutions are not detected.

4 Supposed Causes

Compressor locked


E6 Compressor Lock at Startup

Replace the compressor.

071-095_[7]故障診断.indd 2005/06/02, 21:0776

77

5 Troubleshooting



1 Applicable Models



Detect the malfunction according to the EV valve opening and outlet temperature.


When the EV valve outlet temperature does not rise to an adequate level even through the EV valve opening is increased.

When the EV valve outlet temperature does not fall to an adequate level even though the EV valve opening is decreased.

4 Supposed Causes

Faulty EV valve coil Faulty main PC board Faulty mounting of EV valve

coil Inadequate oil level


E9 Malfunction of Electronic Expansion Valve

Ω

071-095_[7]故障診断.indd 2005/06/02, 21:0777

78

7 Troubleshooting

5 Troubleshooting


1 Applicable Models



qFor AKZ**8:Detect with the pump motor overcurrent relay (F1M).

wFor AKZJ**8:Detect with the agitator inner thermostat (S1B).


qWhen the pump motor overcurrent relay is actuated.Actuating current for AKZ148 to 438: 2.5 AActuating current for AKZ568 and 908: 3.6 A

wWhen the agitator inner thermostat contact is opened.Actuating temperature: 135°C

4 Supposed Causes

qFor AKZ series: Erroneous pump wiring Defective oil piping by

customer Faulty oil pump Incompatible viscosity of oil

used

wFor AKZJ series Erroneous agitator wirings Faulty agitator motor


EHActuation of Pump Overcurrent Relay or Agitator Inner Thermostat

071-095_[7]故障診断.indd 2005/06/02, 21:0778

79

5 Troubleshooting



1 Applicable Models

qAKZ148- to 438-HwAKZ568- and 908-HeModels other than AKZ**8-H

and with opt ional safety equipment mounted


qAKZ148- to 438-H:Detect with the boil-dry prevention pressure switch (S5P).

wAKZ568- and 908-HDetect with the boil-dry prevention flow switch (S4PH).

eModels other than AKZ**8-H:Detect with the optional safety devices.


qAKZ148- to -438H:Actuating (open) pressure:

0.03 MPawAKZ568- and 908-H:

Actuating (open) flow rate: 15 L/minute

eModels other than AKZ**8-H:Actuating (open) pressure of the optional safety devices.

4 Supposed Causes

Faulty main PC board High path resistance of oil

piping Faulty boil-dry prevention

pressure switch Faulty boil-dry prevention

flow switch High viscosity of oil used


EJActuation of Boil-dry Prevention Switch or Optional Safety devices

071-095_[7]故障診断.indd 2005/06/02, 21:0779

80

7 Troubleshooting

5 Troubleshooting


1 Applicable Models

AKZ148 to 568


Detect the malfunction with the pump outlet temperature thermistor (Th-10).


When the pump outlet temperature exceeds 65°C.

4 Supposed Causes

Closed oil piping system Large pressure loss in oil

piping system Faulty main PC board


FEMalfunction due to oil Pressure (Rise in Pump Outlet Temperature)

071-095_[7]故障診断.indd 2005/06/02, 21:0780

81

5 Troubleshooting



1 Applicable Models



qAKZ**8:Detect with the inlet oil temperature thermistor (Th-4).

wAKZJ**8Detect with the liquid temperature thermistor (Th-4).


When the inlet oil temperature or the liquid temperature in the tank exceeds 60°C.

4 Supposed Causes

Faulty inlet oil temperature thermistor

Improper model selection Dirty air filter Improper operation mode Defective oil piping Faulty main PC board


FH Rise in Oil Inlet Temperature or Tank Liquid Temperature

071-095_[7]故障診断.indd 2005/06/02, 21:0781

82

7 Troubleshooting

5 Troubleshooting


1 Applicable Models



Detect malfunction according to resistance detected with thermistor.


When the thermistor contains a broken wire or short-circuited.

4 Supposed Causes

Faulty thermistor Faulty main PC board Faulty thermistor connection

Control panel displayHI,J3,J5,J6,JE,JH,P3,P4

Malfunction of Thermistors

071-095_[7]故障診断.indd 2005/06/02, 21:0782

83

5 Troubleshooting



1 Applicable Models




4 Supposed Causes


LO Malfunction of Inverter/Compressor

Any of the following malfunctions has occurred.

: Rise in radiation fin temperature : Instantaneous overcurrent of power

transistor : Compressor overloaded : Faulty compressor startup : Malfunction of power transistor

While in service monitor mode (refer to page 69), check to be sure the malfunction code and then take measures according to the applicable “Troubleshooting flow chart”.

071-095_[7]故障診断.indd 2005/06/02, 21:0783

84

7 Troubleshooting

5 Troubleshooting


1 Applicable Models



Detect with the fin temperature thermistor mounted on the radiation fin.


When the temperature detected with the fin temperature thermistor exceeds any of the following values. AKZ(J)148 to 568: 95°C AKZ(J)980: 120°

(Retry: 10 times)

4 Supposed Causes

Faulty main PC board Blocked ventilation opening Dirty radiation fin Ambient temperature too

high


L4 Rise in Radiation Fin Temperature

071-095_[7]故障診断.indd 2005/06/02, 21:0784

85

5 Troubleshooting



1 Applicable Models

AKZ568 and 908AKZJ568 and 908


Detect according to current passing through the power transistor.


When the output overcurrent is input from the output overcurrent detection circuit to the microcomputer.

(Retry: 10 times)

4 Supposed Causes

Faulty compressor coil Overcurrent due to the stall

of compressor Faulty power transistor Noise to power supply line


L5 Instantaneous Overcurrent of Power Transistor

Ω

071-095_[7]故障診断.indd 2005/06/02, 21:0785

86

7 Troubleshooting

5 Troubleshooting


1 Applicable Models



Detect according to the output revolutions of the compressor.


qWhen the revolutions are not output

wWhen the revolutions reach 1/2 of the target revolutions

eWhen the revolutions detected are too fast

(Retry: 10 times)

4 Supposed Causes

Compressor overloaded Compressor mechanically

locked Faulty main PC board Faulty power supply voltage

(e.g. instantaneous power failure or slow-down of voltage

Noises present in the power supply line

Lightning surge


L8 Compressor Overloaded

Ω

071-095_[7]故障診断.indd 2005/06/02, 21:0786

87

5 Troubleshooting



1 Applicable Models



Detect according to the compressor revolutions at startup.


When the compressor does not rotate smoothly.

(Retry: 10 times)

4 Supposed Causes

Faulty pressure equalization Faulty compressor wire

connections Faulty compressor

(incomplete lock) Faulty main PC board Faulty EV valve


L9 Faulty Compressor Startup

071-095_[7]故障診断.indd 2005/06/02, 21:0787

88

7 Troubleshooting

5 Troubleshooting


1 Applicable Models



Detect according to current passing through the power transistor.


When the output overcurrent is input from the output overcurrent detection circuit to the microcomputer.

(Retry: 10 times)

4 Supposed Causes

Faulty compressor coil Overcurrent due to the stall

of compressor Faulty power transistor Noise to power supply line


LA Instantaneous Overcurrent of Power Transistor

Ω

071-095_[7]故障診断.indd 2005/06/02, 21:0788

89

5 Troubleshooting



1 Applicable Models



Check communication conditions between the inverter microcomputer and the temperature control microcomputer


When the transmission is not performed normally for a period of given time or more.

(Retry: 20 times)

4 Supposed Causes

Faulty main PC board External noises or else


LCMalfunction of Transmission between Inverter CPU and Temperature Control CPU

071-095_[7]故障診断.indd 2005/06/02, 21:0789

90

7 Troubleshooting

5 Troubleshooting


1 Applicable Models



Detect the condenser temperature and the EV valve outlet temperature and make judgment of refrigerant quantity.


When q and w continue for a period of 180 seconds.qCommand capacity ≥ 95%wCondenser temperature

– EV valve outlet temperature ≤ 5°C

4 Supposed Causes

Shortage of refrigerant Clogged refrigerant piping Moisture choke Broken piping


U0 Shortage of Refrigerant

071-095_[7]故障診断.indd 2005/06/02, 21:0790

91

5 Troubleshooting



1 Applicable Models



Detect each phase in power supply phase detection circuit.


qWhen reverse phase or open phase is detected in the power supply line.

wWhen any wire in the fuses [FU1 to FU3] used in the pump motor (on the AKZ series) or the agitator motor (on the AKZJ ser ies) is broken.

4 Supposed Causes

Reverse phase in power supply line

Open phase in power supply line

Faulty main PC board Overloaded operation of oil

pump Short circuit or poor

insulation of oil pump coil Short circuit or poor

insulation of agitator coil Noises in power supply line


UIReverse Phase/Open Phase of Power Supply or Broken Wire in Fuse

071-095_[7]故障診断.indd 2005/06/02, 21:0791

92

7 Troubleshooting

5 Troubleshooting


1 Applicable Models



Detect according to voltages of the inverter power supply DC unit.


1. When an instantaneous power failure occurs.

2. When the power supply voltage drops below the rating × 90%.

4 Supposed Causes

Inadequate power supply voltage

Instantaneous power failure Faulty main PC board


U2 Malfunction due to Power Supply Voltage

×

071-095_[7]故障診断.indd 2005/06/02, 21:0792

93

5 Troubleshooting



1 Applicable Models

Master unit side of model using the communication PC board (option)


Check with the microcomputer whether or not the transmission with the slave unit is normally performed.


When the transmission between the master unit and the slave unit is not performed normally for a period of given time or more.

4 Supposed Causes

Faulty main PC board Faulty connection in the

transmission line Faulty communication PC

board External noises or else


U9 Malfunction of Transmission with Slave Unit

071-095_[7]故障診断.indd 2005/06/02, 21:0793

94

7 Troubleshooting

5 Troubleshooting


1 Applicable Models



Check with the microcomputer whether or not E2PROM is normal.


When the E2PROM causes a failure.

4 Supposed Causes

Faulty main PC board External noises or else


UH System-related failure

Replace the main PC board. (For replacement

procedure, refer to page 112.)

071-095_[7]故障診断.indd 2005/06/02, 21:0794

95

5 Troubleshooting



1 Applicable Models

AKZ**8 or AKZJ**8, which are connected to an external safety device, respectively


Detect open or short circuit between terminals through the CN2 terminal on the main PC board.


When the circuit between the CN2 terminals becomes open.

4 Supposed Causes

Actuation of external safety device

Faulty main PC board Without mounting the

external safety device, parameter setting mode is enabled. (Set to any bit other than “0” with parameter No.3.


UJ Actuation of External Safety Device

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8 Removing Procedure

Work Procedure Point

WARNING

Before removing work, be sure

to turn OFF all power supplies.

q Unscrew the two screws

that hold the front panel

and then remove it.

w Unfasten the screws to

rotate the air thermistor

retainer upward.

e Unscrew the four screws

that hold the top panel

and then remove it.

r Pull out the air filter

downward.

t Unscrew the eight screws

that hold the left side panel

and then lift this panel.

y Unscrew the eight screws

that hold the right side

panel to slide this panel

upward and then pull out it

sideward.

Top panel

Left side panel

Air filter

Front panel

Air thermistor retainer

Right side panel

Top panel

Air filter

Front panel


Switch box (lid)

Procedure for Removing of Outside Panel Block



and then remove it.



retainer upward.

e Unscrew the five screws


and then remove it.

r Unscrew the two screws

that hold the switch box

(lid) and then remove it.

t Pull out the air filter

downward.

y Unscrew the 10 screws



u Unscrew the 12 screws




sideward.

[AKZ148 to 438]

[AKZ568 and 908]

AKZ148 to 9081

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97


Removing Procedure

Re

movin

g

Pro

ced

ure

WARNING



Following the Procedure for

Removing of Outside Panel Block,

remove the top panel, left side

panel, and right side panel.

q Pull out the fan motor connector

from the main PC board.

w Unscrew the two screws that

hold the bell mouth mounting

plate fixing the fan motor to

remove this plate and then

pull out it to the front.

e Remove the

washer-based nut that

hold the propeller fan and

then remove the fan.

r Unscrew the four screws

that hold the fan motor

and then remove it.

Motor base

Fan motor

Propeller fan

Bell mouth mounting plate

Bell mouth mounting plate fixing screws

Washer-based nut

Fan motor

Hexagon socket head screw

Propeller fan

Fan guide

Fan guide fixing screw

Procedure for Removing of Propeller Fan/Fan Motor

q Pull out the fan motor

connector from the

inverter PC board.

w Unscrew the two screws

that hold the fan guide

fixing the fan motor to

remove this guide and

then pull out it to the front.

e Use a hexagonal wrench

to remove the propeller

fan.



and then remove it.

[AKZ148 to 438]

[AKZ568 and 908]

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98



WARNING



Following the Procedure

for Removing of Outside

Panel Block, remove the

top panel, left side panel,

and right side panel.

q Remove each harness

from the electrical

component assembly.

w Unscrew the two fixing

screws that hold the

electrical component

assembly and then slide

this assembly to the left to

remove it.

Electrical component assemblyFixing screw

Fixing screw

Electrical component assembly

Fixing screw

Fixing screw

Procedure for Removing of Switch Box

q Remove all harnesses

from the electrical

component assembly.






remove it.

[AKZ148 to 438]

[AKZ568 and 908]

In order to replace the


assembly, replace the

setting data referring

to information in “Main

PC board replacement

procedure” (on page 112).

096-103_[8]-1取外要領-01.indd 2005/06/08, 8:5498

99


Removing Procedure

Re

movin

g

Pro

ced

ure

WARNING






top panel.

CN1

Main PC board

Hook

Hook

Procedure for Removing of PC Board (AKZ148 to 438)

q Disconnect the lead wire

connector (CN1) and then

pull out the lead wire.

w Push the two stoppers that

hold the control panel and

then remove the control

panel.

1. Remove the cont ro l

panel.

q Disconnect all harnesses


w Unscrew the four screws

that hold the radiation fin

and also one vibration

isolating screw.

e Unhook the four hooks

that hold the main PC

board and remove this PC

board while peeling off the

radiation fin.


main PC board, replace

the setting data referring




2. Remove the main PC

board

096-103_[8]-1取外要領-01.indd 2005/06/08, 8:5499

100



WARNING






top panel.

CN1

Inverter PC board

Main PC board

Hook

Hook

Procedure for Removing of PC Board (AKZ568 and 908)







panel.


panel.






isolating screw.





radiation fin.







CAUTION

The inverter PC board cannot

be removed individually. Be

sure to replace it by the set of

electrical component assembly.


board

096-103_[8]-1取外要領-01.indd 2005/06/08, 8:54100

101


Removing Procedure

Re

movin

g

Pro

ced

ure

WARNING








Provide a container to

receive oil under the

evaporator.

q Unscrew the cone screw

that holds the oil inlet

thermistor.


that hold the inlet socket.

e Unfasten the hose clamp

at the oil pump outlet.


that hold the pump motor

base.

t Remove the oil pump

while pulling out the inlet

and outlet hoses.

Inlet socket

Oil inlet thermistor

Evaporator

Container

Oil pump

(Inlet side)

(Outlet side)Hose clamp

Inlet socket

Oil inlet thermistor

Oil pump

(Inlet side)

(Outlet side)

Container

Evaporator

Hose clamp

Procedure for Removing Oil Pump

[AKZ148 to 438]

[AKZ908]

When the hose band

on the oilpump outlet is

unfastened, the large

amount (approx. 1 liter) of

oil flows out.

Provide a contaimer to

receive it.

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102



WARNING







and right side panel. EV valve coil

EV valve main unit

Brazed sections

Strainer

EV valve outlet temperature thermistor

Thermistor fixing spring

High pressure switch

Service port

Procedure for Removing of EV Valve / High Pressure Switch

Remove the EV valve.

q Recover the refrigerant

through the service port.

w Pull out the EV valve coil

upward.

e Remove the EV valve

outlet thermistor.

r Disconnect the two brazed

sections that hold the EV

valve main unit and then

remove it.

Before removing work,

be sure to recover the

refrigerant.


EV valve main unit,

perform the “pulse

detection operation

with the EV valve fully

closed” referring to the

“Replacement procedure”

(on page 113).

When mounting the EV

valve main unit, mount

the strainer without

fail. (For the mounting

direction, refer to Figure

on the left.)

Remove the high pressure switch.

q Use two spanners to

remove the high pressure

switch.

Since the service port

is provided with a check

valve, the high pressure

switch can be removed

without discharging the

refrigerant.

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103


Removing Procedure

Re

movin

g

Pro

ced

ure

WARNING








Brazed sections

Compressor lead wire

Compressor mounting nut

Procedure for Removing of Compressor



w Disconnect the lead wire

from the compressor

terminal.

e Unscrew the three nuts

that hold the compressor.


sections that hold the

compressor and then

remove it.

Before Removing work,


refrigerant.

U

N

W

V

Compressor terminal symbol

(Red)

(Brown)

(Blue)

(Yellow)

096-103_[8]-1取外要領-01.indd 2005/06/08, 8:54103

104



WARNING





and then remove it.



retainer upward.

e Unscrew the four screws


and then remove it.

r Pull out the air filter

downward.

t Unscrew the eight screws



y Unscrew the eight screws




sideward.

Top panel

Right side panelLeft side

panel

Front panel

Air filter


Top panel

Front panel

Switch box (lid)

Air filter


Procedure for Removing of Outside Panel Block



and then remove it.



retainer upward.

e Unscrew the five screws


and then remove it.

r Unscrew the two screws

that hold the switch box

(lid) and then remove it.

t Pull out the air filter

downward.

y Unscrew the 10 screws



u Unscrew the 12 screws




sideward.

[AKZJ188 to 458]

[AKZJ568 and 908]

AKZJ188 to 9082

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105


WARNING



Removing Procedure

Re

movin

g

Pro

ced

ure







connector from the main

PC board.


that hold the bell mouth

mounting plate fixing the

fan motor to remove this

plate and then pull out it to

the front.

e Remove the

washer-based nut that

hold the propeller fan and

then remove the fan.



and then remove it.

Motor base

Fan motor

Propeller fan

Washer-based nut

Bell mouth mounting plate

Bell mouth mounting plate fixing screws

Procedure for Removing of Propeller Fan/Fan Motor


connector from the inverter

PC board.


that hold the fan guide fixing

the fan motor to remove

this guide and then pull out

it to the front.

e Use a hexagonal wrench to

remove the propeller fan.


that hold the fan motor and

then remove it.

[AKZJ188 to 458]

[AKZJ568 and 908]

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106



WARNING








q Remove each harness

from the electrical

component assembly.






remove it.


Fixing screw

Fixing screw

Procedure for Removing of Switch Box

q Remove all harnesses

from the electrical

component assembly.






remove it.

[AKZJ188 to 458]


Fixing screwFixing screw

[AKZJ568 and 908]



assembly, replace the

setting data referring




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107


WARNING



Removing Procedure

Re

movin

g

Pro

ced

ure




top panel.

CN1

Control panel

Main PC board

Hook

Hook







panel.


panel.






isolating screw.





radiation fin.







Procedure for Removing of PC Board (AKZJ188 to 458)


board.

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108



WARNING






top panel.

CN1

Control panel

Inverter PC board

Main PC board

Hook

Hook







Procedure for Removing of PC Board (AKZJ568 and 908)







panel.


panel.




that hold the radiation fin.





radiation fin.


board.

CAUTION

The inverter PC board cannot

be removed individually. Be

sure to replace it by the set of

electrical component assembly.

104-111_[8]-2取外要領-02.indd 2005/06/07, 10:22108

109


WARNING



Removing Procedure

Re

movin

g

Pro

ced

ure

Procedure for Removing of EV Valve / High Pressure Switch





and right side panel. EV valve coil

EV valve main unit

Brazed sections

Strainer

EV valve outlet temperature thermistor

Thermistor fixing spring

High pressure switch

Service port

Remove the EV valve.



w Pull out the EV valve coil

upward.

e Remove the EV valve

outlet thermistor.


sections that hold the EV

valve main unit and then

remove it.



refrigerant.


EV valve main unit,

perform the “pulse

detection operation

with the EV valve fully

closed” referring to the

“Replacement procedure”

(on page 113).

When mounting the EV

valve main unit, mount

the strainer without

fail. (For the mounting

direction, refer to Figure

on the left.)

Remove the high

pressure switch.

q Use two spanners to

remove the high pressure

switch.

Since the service port

is provided with a check

valve, the high pressure

switch can be removed

without discharging the

refrigerant.

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110



WARNING








Brazed sections

Compressor lead wire

Compressor mounting nut

Procedure for Removing of Compressor



w Disconnect the lead wire

from the compressor

terminal.

e Unscrew the three nuts

that hold the compressor.


sections that hold the

compressor and then

remove it.



refrigerant.

U

N

W

V

Compressor terminal symbol

(Red)

(Brown)

(Blue)

(Yellow)

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111


WARNING



Removing Procedure

Re

movin

g

Pro

ced

ure

Procedure for Removing of Agitator Motor / Evaporator






Remove the agitator

motor.

q Disconnect the motor

connector.

w Unscrew the one screw

that holds the agitator

plate and then remove it.

e Unscrew the four external


agitator motor and then

remove it.

Remove the evaporator.

q Place the equipment on

the worktable.

w Discharge the refrigerant


e Remove the two legs from

the bottom frame.


sections (*1).

*1: Four brazed sections

on J568 and J908

models.

t Pull the evaporator

downward to remove it.

Agitator motor

Agitator plate

Legs

Brazedsections

Evaporator

Agitator motor

Agitator plate

Legs

Evaporator

Brazedsections

[AKZJ188 to 458]

[AKZJ568 and 908]

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112

9 Replacement Procedure

For the replacement of the main PC board, check to be sure the model name of the main unit of Oil Cooling Unit corresponds to the applicable model of the PC board and then following the procedure shown below.

↓

Procedure for Replacing Main PC Board1

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113

Replacement Procedure

Replacem

ent P

rocedure

In order to replace the EV valve main unit, be sure to perform the pulse detection operation with the EV valve fully closed. (The reason is that the pulse to fully close the EV valve varies.)Replace the EV valve main unit according to the following procedure. (In order to only replace the EV valve coil, the detection operation is not needed to perform.)

↓

Procedure for Replacing EV Valve Main Unit2

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114

10 Miscellaneous Reference Data

Ω

Figure and Table below show the characteristics of thermistors used in this Oil Cooling Unit.In order to check the thermistors for troubleshooting, disconnect the connector to measure the resistance of the thermistor concerned and then compare the measured resistance with the characteristic value.

Temperature (°C) 0 10 15 20 25 30 35 40 45 50 55 60 65

Resistance (kΩ) 67.33 40.38 31.69 25.08 20.00 16.07 13.01 10.60 8.69 7.17 5.95 4.97 4.17

Temperature (°C) 70 75 80 85 90 95 100 105 110 115 120 125 130

Resistance (kΩ) 3.51 2.98 2.54 2.17 1.86 1.61 1.39 1.21 1.06 0.92 0.81 0.72 0.63

Thermistor Temperature/Resistance Characteristics1

Refrigerant (R410A) Characteristics2

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115

Miscellaneous Reference Data

Miscellaneous

Reference D

ata

3-1. Machine Body Synchronization Thermistor/Optional Oil Temperature ThermistorqSymbol and intended use by typeMounting this optional part to the oil piping of the main machine makes it possible to detect and control the temperature.

wMounting procedure

AKZ 8-OP-K5

AKZ 8-OP-Y10

AKZ 8-OP-Y5

AKZ 8-OP-A10

AKZ 8-OP-A5

AKZ 8-OP-K10

Ω

φ×

Procedure for Mounting Optional Parts3

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116

10 Miscellaneous Reference Data

3-2. Communication PC Board (Option)Mounting this communication PC board to the Oil Cooling Unit and then linking with the main machine enables the following functions.1. Operation modes and operation settings can be changed from the main machine.2. Malfunction codes and temperature data (i.e., machine body temperature, room temperature, inlet oil temperature,

outlet oil temperature, temperature differential between inlet and outlet, and inverter frequency) can be read on the main machine side.

××

××

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K

Thank you very much for usual patronage to Daikin products.

We have completed and pleased to present the Oil Cooling Unit (Model 8) Service Manual.

We at Daikin provide an extensive lineup of models to respond to high-accuracy

temperature control and needs for energy saving with the Oil Cooling Unit and appreciate

your further loyal patronage.

This Service Manual includes information on troubleshooting and a variety of services.

Please make use of the Service Manual for your servicing of the Oil Cooling Unit.

After Sales Service Division

June 2005

Preface

Name of information Models listed Date of issue

Oil Cooling Unit

(Model 8)

Service Manual

• AKZ148 to 908

• AKZJ188 to 908

June

2005

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SiOCU05-001