FSXN Series Installer Training

WELCOME
SET-FREE FSXN
INSTALLER TRAINING
Prepared
Prepared by:
by:
HITACHI
HITACHI Service
Service Department
Department
INSTALLING SET-FREE FSXN
1.PRODUCT STANDARDS, FEATURES & SPECIFICATIONS
2.GUIDE TO R-410A REFRIGERANT
3.INSTALLATION STANDARDS
4.INSTALLATION PROCEDURES
5.PRODUCT START-UP & OPERATION
6.COMMON ALARM CODES & TROUBLESHOOTING
SET-FREE FSXN SERIES
PRODUCT STANDARDS, FEATURES &
GENERAL SPECIFICATIONS
 Heat Pump operation
 Heat Recovery operation

Normal Cooling/ Heating
Heat Pump operation
Mode operation
HEAT RADIATION
HEAT ABSORPTION HEAT ABSORPTION
Cool mode Cool mode

Combination of heating
Heat Recovery operation
And cooling at the same time
HEAT RELEASE
HEAT ABSORPTION
HEATING COOLING
Previous model type
To indoor unit
MODULAR TYPE
To indoor unit
BASE UNIT
TWO SIZES OF OUTDOOR MODULAR UNIT
12 hp
8 TO 12 hp
18 hp
14 TO 18 hp
30 hp Differ
Sameinheight
depth
width 54 hp
Elevator can be used to transport
the base unit separately.
ROTATIONAL OPERATION to Distribute load of outdoor units
1 2
3
3 1 2
2 3 1
OUB L E BACK UP OPERATION FUNCTION
D
STOP
RUN RUN
RUN
RUN
2.1.One
Outdoor unit breakdown
compressorbreakdown
Emergency operation
HITACHI SPECIAL TRAINING COURSE (SET-FREE)
FEATURES
OTHERS
Other compressor
Increment of more than 5 Hz
HITACHI PATENTED PRECISE

INVERTER TECHN OLOGY
HITACHI
Hitachi inverter compressor

Increment of 1 Hz.
AUTO JUDGEMENT – REFRIGERANT CHARGE
 Refrigerant cycle temperature

 Refrigerant saturation temperature
 Outdoor unit Expansion valve data
 Indoor unit data
WIDE WORKING RANGE
 Extending the flexibility in

installation space
 Adjusting to climatic
environment
43 C
O
 High external
static pressure
Restart
Operation
automatically
condition memorized
when
Power
when power
resumes
failure
Maintenance check
 Manual Inspection
 Hitachi Service Checker
Service checker
 All have each own unique features
 Adjustable air flow (more flexibility)
 Adjustable capacity
CENTRAL STATION (DX)
For huge air conditioning system
CENTRAL STATION (DX)
For huge air conditioning system
 Manage maximum 2048 groups of air conditioner

 2560 Indoor units , controlled & monitor with one pc
 Advance but easy control function
FEATURES
Automatic Simple Judgment System for Refrigerant Amount

Use this automatic judgment function to check whether or not the refrigerant amount is sufficient in
one (1) refrigerant cycle.
< Factor for Judgment >

Appropriate refrigerant amount is calculated based upon the following data.
(1) Refrigerant Cycle Temperature
(2) Refrigerant Saturation Temperature
(3) Outdoor Unit Expansion Valve Data
(4) Indoor Unit Data
< Procedure for Judgment of Refrigerant Charge Amount >

(1) Judgment starts by pressing the PSW (for prevention of malfunction) after setting DSW.
(2) Judgment takes max. 30 minutes.
(3) Cooling operation automatically starts when judging.
SET-FREE FSXN SERIES
GUIDE TO R-410A
REFRIGERANT
GUIDE TO R-410A REFRIGERANT





SET-FREE
FSXN SERIES
INSTALLATION STANDARDS
Basic System Requirements
Prepared by:
HITACHI Service Department
Basic System Requirements
- Capacity Combination of Outdoor Units (ACCU)
- Correct Capacity Combination of Indoor Units (AHU)
- Piping Kits
- Wired or Wireless Remote Controllers
- Correct Field Refrigerant Piping Combination
- Correct Power and Transmission Wire Sizing
- Correct Power Supply Input to the Indoor and Outdoor Units
OUTDOOR UNIT INSTALLATION
RAS-42FSXN
MAAP MARIVELES
BATAAN



PIPING STANDARDS
Piping Selection
PIPING STANDARDS
Piping Selection
PIPING STANDARDS
Piping Selection
PIPING STANDARDS
Piping Restrictions
PIPING STANDARDS
Piping Restrictions
PIPING STANDARDS
Piping Restrictions
PIPING STANDARDS
Piping Restrictions
● Available for Design & Installation up to Max. Piping Length 165m, Total Piping Length 1000m
Expanded Installation Conditions for Large and Big-Height-Difference Buildings.
Between Outdoor Units Between O.U and I.U.
・ Max. Piping Length : 10m ・ Max. Piping Length : 150m→ 　 165m
・ Height Difference : 0.1m ・ Total Piping Length : 300m → 1000m*1
Height Difference between Between First Branch and I.U.

I.U. and O.U. : 50m*a ・ Max. Piping Length after Branch
:30m→ 40m
a)
In case the outdoor unit is installed
at a higher level than indoor units. If
the outdoor unit is installed lower than
indoor units, the maximum height
Height Difference (between
difference is 40m. Highest and Lowest I.U.)
: 15m (as is)
Between First Branch and I.U.

・ Max. Piping Length : 40m→90m *2
NOTES:
*1: The piping length is limited by additional refrigerant charging quantity when the total piping length is over 300m in above system.
*2: The installation number of indoor units is limited when piping length between first branch and furthest indoor unit is over 40m.
PIPING STANDARDS
Piping Restrictions
PIPING STANDARDS
Piping Restrictions
PIPING STANDARDS
Piping Restrictions
PIPING STANDARDS
Piping Restrictions
PIPING STANDARDS
Piping Installation
PIPING STANDARDS
Piping Installation
PIPING STANDARDS
Piping Installation
Proper installation of piping kit
A. HORIZONTAL INSTALLATION:
PIPING STANDARDS
Piping Installation
Proper installation of piping kit
B. VERTICAL INSTALLATION:
PIPING STANDARDS Wrong installation

Piping Installations
ACTUAL PROBLEM ON SITE:
Wrong installation
Piping Kit and Drain provision:

ELECTRICAL DATA STANDARDS




WORKING RANGES
Temperature Working Range
Cooling Operation Heating operation
minimum 21 C 15 C
Indoor
unit
maximum 32 C 27 C
minimum -5C - 20 C
Outdoor
unit
maximum 43 C 15 C
Prepared by:
COMBINATION CAPACITY
Indoor unit and Outdoor Unit Combination
Caution and Limitation

a. Correctly select indoor unit capacity limit. If not selected, normal operation will be not
available due to the capacity limit. (alarm 31 occur)
VOLUME RATION = 50 TO 130 %
If wrong capacity of indoor unit was used

- Refrigerant flow rate will be short
- Liquid back/ Refrigerant will be too big.
- See alarm code 31 Service manual
Prepared by:
Reduced Total Outdoor unit Capacity
a. Combination capacity: In the case that all the indoor units are simultaneously operated.
The total indoor unit capacity should be the same of the outdoor unit capacity. If the
indoor unit capacity is greater than the outdoor unit, the indoor unit capacity will be
decreased when all indoor units are operated.
10 HP
2 HP 2.5 HP 1 HP 2 HP 2.5 HP
10 HP
b. The system cooling/ heating capacities are determined by the outdoor unit capacity.
Prepared by:
Load Diversity
10 HP
2.5 HP 2.5 HP 3 HP 2.5 HP 2.5 HP
13 HP
10
OUTDOOR HP
Load diversity = = 0.77
INDOOR HP
13
Prepared by:
SET-FREE
FSXN SERIES
INSTALLATION PROCEDURES
Proper Tools
70
BRAZING KIT SET
For Conducting field brazing works for copper
pipes. Including silver brazing lead and Flux.
AC/DC VOLT MULTI-CLAMP METER

For Testing Voltage and Current before and
during equipment operation
INSULATION RESISTANCE METER

For Testing Field wiring Insulation resistance
to Equipment Body to Earth Ground
Digital Anemometer
For Measuring Air Velocity of the Blower:
Aid in Measuring the air flow of a given Air
Handling Units and air blowers.
HEXAGON WRENCH
For handling stop Valves with hexagonal keys
PIPE OR TUBE BENDERS
For bending pipes to desired angle

NO SHORT CUTS!
77
SERVICE SPACE
SERVICE SPACE
SERVICE SPACE
SERVICE SPACE
CONCRETE FOUNDATION
CONCRETE FOUNDATION
DRAIN WATER TREATMENT

REFRIGERANT PIPING WORKS




TABLE 6.1 PIPING SIZE OF OUTDOOR UNITS (mm)


TABLE 6.2 PIPING SIZE OF INDOOR UNIT (mm)
Diameter (in)
1/4
3/8
1/2
5/8
7/8
1
-
1 1/4
1 1/2
-
1 3/4

FLARING AND JOINTS ITEM 6.2

HANDLING STOP VALVES

HANDLING STOP VALVES



STOP VALVES FOR COOLING ONLY SET-UP
Install Liquid & Gas

Piping Here & Insulate
Use this Stop Valve in Properly
CH unit Configuration
Only


LEAK TESTING AND VACUUM DRYING
450 PSI for FSXN R-

410A System
Vacuum Drying for more

than If no vacuum gauge 4
Hours



DRAIN PIPING WORKS

With Drain Pump
DRAIN PIPING WORKS

Without Drain Pump
DRAIN PIPING WORKS

Without Drain Pump
ELECTRICAL WIRING
Field Wire Connections
ELECTRICAL WIRING
Recommended Field Wire and Circuit Breaker Size Selection
ELECTRICAL WIRING
Minimum Field Wire Selection Power Source
ELECTRICAL WIRING
Notes for Selection
WORKING RANGES
Power Ranges
POWER SUPPLY:
Working Voltage= + / -10% Rated Voltage
Starting Voltage (Voltage Drop) = higher than 85%

of rated voltage or >195.5 VAC for 230 Volts AC Units
Voltage Imbalance= within 2.5% deviation from each

voltage at each main terminal of Outdoor unit
Recommended Voltage Drop Across Wire =/< 2 %
118
WORKING RANGES
Power Ranges

Solving Voltage Imbalance:
248 238
4.2 Greatest voltage – Average voltage
Voltage X 100%
=
Imbalance 238
Average voltage
Ave. voltage = ( 248+230+236)/3

= 238 V
Greatest voltage = 248 V
119
Voltage Drop
120
Theoretical Voltage Drop Sample Computation
PROBLEM:
RAS- 18FSXN 220Volts 60Hz

Max Current = 59 amps
Assuming Wire Size = 14 mm2 or 6 AWG
Total Wire Length = 250 meters
Compute Voltage Drop.

Is it Within 2% of Recommended Voltage Drop?
Answer:
VD = 59 * ((1.295928 / 1000) * 250)

= 59 * (.001295928 * 250)
= 59 * .323982
VD = 19.114938
% Voltage Drop = VD / Power Rate / 100

= 19.114938 / 220 / 100
= 8.686363
RESULT = FAIL over 2% Wire Too Long or Wire Diameter Small
121
ELECTRICAL WIRING
Voltage Drop
ELECTRICAL WIRING
Theoretical Voltage Drop Sample Computation
RAS- 18FSXN 220Volts 60Hz

Max Current = 59 amps
Assuming Wire Size = 14 mm2 or 6 AWG
Total Wire Length = 250 meters
Compute Voltage Drop.

Is it Within 2% of Recommended Voltage Drop?
Answer:
VD = 59 * (1.295928 / 1000) * 250

= 59 * .001295928 * 250
VD = 19.114938
% Voltage Drop = VD / Power Rate / 100

= 19.114938 / 220 / 100
= 8.686363
RESULT = FAIL over 2% Wire Too Long or Wire Diameter Small

ELECTRICAL WIRING
Notes for Selection
WORKING RANGES
Power Ranges
POWER SUPPLY:

Problem occurred when Voltage is Unbalance:
SINGLE
L1 = 248 V PHASING
L2 = 230 V
L3 = 236 V
Prepared by:
WORKING RANGES
Power Ranges
Why unit doesn’t run if phasing is reverse?
Because correct phasing moves the compressor scroll at correct direction.
If phasing is reverse, unit will not run to protect the compressor from damaging.
Scroll compressor requires one direction movement.
If phase is incorrect “05” is indicated

8 Phase check
Change one of the phase
R S T
TESTING OF CORRECT PHASING
Check using REVERSE PHASE
READER.
REVERSE PHASING To unit
R S T
Do not interchange wire above the terminal board. This will

Damage the unit From power source
Move the R and T wires below the terminal board if reverse
Occurred.
SCROLL COMPRESSOR PRINCIPLE
DISCHARGE
Why 3 phase should not be reversed?
SUCTION
SCROLL COMPRESSOR PRINCIPLE
DISCHARGE
Why 3 phase should not be reversed?
SUCTION
EXERCISE:
Voltage 1: Voltage balance Judgement

Line 1
230 v
Line 2 240 v
220 v 4.35% Fail
Line 3
Voltage 2:
Line 1
223 v
Line 2 225 v 1.04% Pass
220 v
Line 3
Prepared by:
ELECTRICAL WIRING
Use terminal lugs in terminating power line Use Terminal Lugs in terminating
connections to unit power supply terminal Transmission wires on Terminal bases
base
ELECTRICAL WIRING
ELECTRICAL WIRING
POWER SUPPLY
ELECTRICAL WIRING
NOTE: ALWAYS SECURE UNIT-TO-EARTH

GROUND WIRE CONNECTION
ELECTRICAL WIRING
ELECTRICAL WIRING
Field Wiring Depiction
INSULATION RESISTANCE TESTING
Insulation Resistance
Tester
Fix one test probe of the insulation tester to Apply on Terminal Bases of unit/s with Field
Earth Ground wire connection wiring Installation, Terminal bases of ELB,
of the installed unit Fuse or Breakers.
INSULATION RESISTANCE TESTING

SET-FREE
FSXN SERIES
PRODUCT START-UP
Product Start-Up Requirements

1.Approved Start-Up Request Form
2.Additional Refrigerant Charge Computation
3.Drawing Lay-out or As-Built Plan
of Pipe Runs with actual Pipe
Lengths, Pipe Diameters and Elbows
HITACHI PRODUCT START-UP REQUEST FORM:
ADDITIONAL REFRIGERANT CHARGE CALCULATION FORM:

REFRIGERANT:
Refrigerant charge
B. Feature of New Refrigerant (R-410A): (with siphon tube)
Cylinder
1) Secure sufficient liquid refrigerant

inside the cylinder. Residual liquid
Refrigerant
Approx. 5 to 10 %
2) Charge Liquid Refrigerant into the
system only.
Cylinder Refrigerant charge
(without siphon tube)
3) Do not consume the refrigerant
completely. It is recommended that 5 to
10 % of refrigerant be left on the
cylinder.
Residual liquid
Refrigerant
Approx. 5 to 10 %
CHARGING OF REFRIGERANT:
CORRECT CHARGING REFRIGERANT:

Compound gauge
- Use weighing Scale to accurately
Measure the correct amount of
refrigerant to be added on the
system.
Steps:
1. Get the weight of the Ref. tank.
2. Charge refrigerant by checking the
weight display on the weighing scale.
Outdoor
unit
20 Kg
Weighing scale
Indoor unit
Suction Discharge
-To compressor -from compressor
GAS PIPE
LIQUID PIPE
To unit
From indoor unit To indoor unit

Prepared by:
Refrigerant Tank HITACHI Service Department
Suction Discharge
-To compressor -from compressor
Compressor
GAS PIPE LIQUID PIPE
Refrigerant flow
to compressor
From indoor unit To indoor unit
Prepared by:
Refrigerant Tank HITACHI Service Department
3.0 Mechanical structure, Refrigerant cycle, & electrical wirings.

3.2.3 New Refrigerant
R-410A Compound Gauage
REFRIGERANT: 8-10 kg/cm2 24-34 kg/cm2
113-142 psi 341-483 psi
New Refrigerant Pressure reading:
Refrigerant High Side Pressure Low Side Pressure
R-22 18 - 24 Kg/cm2 256 – 341 PSI 4 – 6 kg / cm2 56 – 75 PSI
R-410A 24-34 Kg/cm2 381 – 483 psi 8 – 10 kg / cm2 113 – 142 psi
HITACHI SPECIAL TRAINING COURSE (SET-FREE FSXN)
COMPUTATION FOR ADDITIONAL

REFRIGERANT R-410A CHARGE
CHECK LIST ON TEST OPERATION
(1) GENERAL
No Check item Result

1 Was the Dip switch, DSW6 for piping length in O.U. set?
2 Was the Dip Switch, DSW3 for piping lift in O.U. set?
3 Is the transmitting wire contacting to power lines?
4 Was an earth wire connected?
5 Is there any short circuit?
6 Is there any Voltage abnormality among each phase (L1-L2, L2-

L3, L3-L1, L1-N) ?
SET-FREE
FSXN SERIES
OPERATIONS
CHECK LIST ON TEST OPERATION
(1) (2) REFRIGERANT CYCLE

A) Operation (Cooling/ Heating)
No Check item Result
1 Operate all the Indoor units ( “TEST RUN” mode)
2 Operate all the indoor units at High speed.
3 In case that the constant compressor is turned ON and OFF

repeatedly, Stop one indoor unit (small Capacity)
B) Sampling data
1 After the operation for more than 20 mins
2 Check PD and TD. Is Td –SH 20 to 40 deg?
3 Is Ps 0.8 tp 1.0 mpa?
4 Is PD 2.4 to 3.4 mpa ? If outdoor temperature is high, PD

becomes high
DIP SWITCH SETTINGS
INDOOR REF. CYCLE

AUTOMATIC SIMPLE JUDGMENT SYSTEM FOR REFRIGERANT AMOUNT


SUB Unit (C)

SUB Unit (B)
Main Unit (A) PSW 1
DSW5 Pin #4
SET-FREE
FSXN SERIES
COMMON ALARM CODES &
TROUBLESHOOTING
Troubleshooting
Alarm 01
1. Caused by float switch being activated
2. Check Drain Pan water level
3. Check Drain pump if functional.
4. Clean Evaporator, drain pan and drain pump if with slime
Drain Problem Caused by slime inside the drain pump assembly, even
though the pump is working.
Prepared by:
Troubleshooting
No Alarm Code Display

1. Caused by Main PCB ROM Error system un-able to initialize
2. Do Emergency Operation Function
3. Replace Main PCB
Alarm 05
1. Caused by Single Phasing of the Power Supply
2. Check Circuit Breaker for Voltage Imbalance
3. Check for Busted fuse inside the unit.
4. Test for Insulation Resistance Leakage using Insulation Tester
5. Replace defective fuses or parts
Alarm 11
1. Check Air Inlet Thermistor of the indoor unit
2. Check if properly connected
3. Check correct thermistor resistance
4. Replace defective part
Prepared by:
Troubleshooting
Alarm codes
Abnormality during test run:
CONTROLLER (indoor) Break down indicator function

Unit no. Trouble id • This function tells the problem
countered by the unit
Designation number
OUTDOOR PCB • indoor units have designated
number code for easy troubleshooting
Unit no. Trouble
Trouble Identification
03 – Transmission
31 -- Incorrect wiring (indoor/outdoor) , incorrect capacity.
05 -- Reverse phasing.
01 -- Drain overflow(Push buttons)
11 -- Air inlet thermistor for Indoor unit problem
(7 Segment Display)
Troubleshooting
Alarm codes (outdoor)

Submit Drawing, Lay-out
(Push buttons)
(7 Segment Display)
05
03
01 Connection
Reverse
Tripping Phasing
problemdevice
of protection problem
(I.U , O.U)
(I.U)
ALARM CODE TABLE
Prepared by:
ALARM CODE TABLE
Prepared by:
ALARM CODE TABLE
Prepared by:
ALARM CODE TABLE
Prepared by:

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WELCOME

 Heat Recovery operation

HEAT ABSORPTION HEAT ABSORPTION

Cool mode Cool mode

HITACHI PATENTED PRECISE

Hitachi inverter compressor

 Refrigerant cycle temperature

 Extending the flexibility in

 Manage maximum 2048 groups of air conditioner

Automatic Simple Judgment System for Refrigerant Amount

< Factor for Judgment >

< Procedure for Judgment of Refrigerant Charge Amount >

GUIDE TO R-410A REFRIGERANT

GUIDE TO R-410A REFRIGERANT

GUIDE TO R-410A REFRIGERANT

GUIDE TO R-410A REFRIGERANT

GUIDE TO R-410A REFRIGERANT

Basic System Requirements

OUTDOOR UNIT INSTALLATION

OUTDOOR UNIT INSTALLATION

OUTDOOR UNIT INSTALLATION

OUTDOOR UNIT INSTALLATION

Height Difference between Between First Branch and I.U.

Between First Branch and I.U.

Proper installation of piping kit

Proper installation of piping kit

PIPING STANDARDS Wrong installation

Piping Kit and Drain provision:

ELECTRICAL DATA STANDARDS

ELECTRICAL DATA STANDARDS

ELECTRICAL DATA STANDARDS

ELECTRICAL DATA STANDARDS

Cooling Operation Heating operation

Caution and Limitation

VOLUME RATION = 50 TO 130 %

If wrong capacity of indoor unit was used

AC/DC VOLT MULTI-CLAMP METER

INSULATION RESISTANCE METER

PIPE OR TUBE BENDERS

For bending pipes to desired angle

DRAIN WATER TREATMENT

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

TABLE 6.1 PIPING SIZE OF OUTDOOR UNITS (mm)

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

Install Liquid & Gas

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

450 PSI for FSXN R-

Vacuum Drying for more

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

REFRIGERANT PIPING WORKS

DRAIN PIPING WORKS