Part Troubleshooting What is in this part? This part contains the following chapters: Chapter See page Troubleshooting 2 Error Codes: Hydro-box 7 Error Codes: Outdoor Units Error Codes: System Malfunctions Additional Checks for Troubleshooting 9 Part Troubleshooting
2 Part Troubleshooting
Troubleshooting Troubleshooting Part. What Is in This Chapter? Introduction When a problem occurs, you have to check all possible malfunctions. This chapter gives a general idea of where to look for malfunctions. Not all repair procedures are described. Some procedures are considered common practice. Overview This chapter contains the following topics: Topic See page.2 Procedure of Self-Diagnosis by Remote Controller. Fault-diagnosis by Remote Controller. Overview of Error Codes 6 Part Troubleshooting
Troubleshooting.2 Procedure of Self-Diagnosis by Remote Controller The inspection/test button The following modes can be selected by using the [Inspection/Test Operation] button on the remote control. System settings can be made. Auto restart Backup heater operation Others Following codes can be checked. Malfunction codes Indoor model code Outdoor model code Depress Inspection/Test Operation button for more than seconds. Local setting mode Depress Inspection/Test Operation button for more than seconds. Press Inspection/Test Operation button once. Inspection mode Normal mode After 0 seconds Service mode Press Inspection/Test Operation button once. Service data can be obtained. Malfunciton code history Temperature data of various sections Press Inspection/Test Operation button once. Press Inspection/Test Operation button once. Or after 0 minutes. Test operation mode Thermostat is forcibly turned on. Remark Above information is general. Not all settings are applicable for ALTHERMA. Part Troubleshooting
Troubleshooting. Fault-diagnosis by Remote Controller Explanation If operation stops due to malfunction, the remote controller s operation LED blinks, and malfunction code is displayed. (Even if stop operation is carried out, malfunction contents are displayed when inspection mode is entered.) The malfunction code enables you to tell what kind of malfunction caused operation to stop. See page -6 for malfunction code and malfunction contents. Malfunction code Inspection/Test button Inspection display Part Troubleshooting
Troubleshooting. Overview of Error Codes Hydro-box Outdoor Unit System malfunctions Malfunction code Malfunction contents See page 80 Inlet water temperature thermistor abnormality 0 8 Outlet water temperature thermistor abnormality 0 89 Water heat exchanger freez-up abnormality?? 7H Flow abnormality?? 8H Outlet water temperature too high?? AA Booster heater thermal protector is open?? A Hydro-box PCB abnormality 8 A Freez-up protection or High pressure control 9 C0 Flow switch abnormality?? C Heat exchanger thermistor abnormality 0 EC Sanitary water temperature too high?? HC Sanitary water temperature thermistor abnormality 0 E Outdoor unit PCB abnormality 2 E OL Activation (compressor overload) E6 Compressor lock E7 DC fan lock 6 E8 Input over current 7 EA Heating / Cooling switching failure 9 F Discharge pipe temperature control 2 F6 Too high condensing pressure 2 H0 Sensor abnormailty 2 H6 Compressor start up failure 27 H8 CT or related abnormailty 29 H9 Outdoor temperature thermistor or related abnormality J Discharge pipe thermistor failure J6 Heat exchanger thermistor or related abnormality P Radiation fin thermistor or related abnormality L Switch box temperature rize L Radiation fin (power transistor) temperature rize L Output over current (inverter PCB) 7 U0 Refrigerant failure 2 U2 Low-voltage or over-voltage detection U Signal transmission error (indoor outdoor unit) U7 Signal transmission error (indoor outdoor unit) 7 UA Combination error (indoor outdoor unit) or spare parts PCB?? 6 Part Troubleshooting
2 Error Codes: Hydro-box Error Codes: Hydro-box Part 2. What Is in This Chapter? Introduction Shutdown In the first stage of the troubleshooting sequence, it is important to correctly interpret the error code on the remote controller display. The error code helps you to find the cause of the problem. For some errors, the system only shuts down when the error occurs several times. This means that you have to wait until the system shuts down to be able to see the flashing LED on the front panel and the error code on the remote controller. Overview This chapter contains the following topics: Topic See page 2.2 A Hydro-box PCB Abnormality 8 2. A Freeze-up Protection Control or High Pressure Control 9 2. C, 8, 80, HC Thermistor or Related Abnormality (Hydro-box) 0 Part Troubleshooting 7
Error Codes: Hydro-box 2.2 A Hydro-box PCB Abnormality Error code A Method of malfunction detection Evaluation of zero-cross detection of power supply by hydro-box. Malfunction decision conditions When there is no zero-cross detection in approximately 0 continuous seconds. Supposed causes Faulty hydro-box PCB Faulty connector connection Troubleshooting Connector connection check (note). Is it normal? Correct connections. Replace PCBs. Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 8 Part Troubleshooting
Error Codes: Hydro-box 2. A Freeze-up Protection Control or High Pressure Control Error code A Method of malfunction detection High pressure control (heat pump model only) During heating operations, the temperature detected by the hydro-box heat exchanger thermistor is used for the high pressure control (stop, outdoor fan stop, etc.) The freeze-up protection control (operation halt) is activated during cooling operation according to the temperature detected by the hydro-box heat exchanger thermistor. Malfunction decision conditions High pressure control During heating operations, the temperature detected by the hydro-box heat exchanger thermistor is above 6 C Freeze-up protection When the hydro-box heat exchanger temperature is below 0 C during cooling operation. Supposed causes Detection error due to faulty hydro-box heat exchanger thermistor. Detection error due to faulty hydro-box PCB. Troubleshooting Check No. 06 Hydro-box heat exchanger thermistor check Does it conform to the thermistor characteristic chart? Replace the hydro-box PCB. Replace the thermistor (replace the hydro-box PCB). See also "Check No.06" on page -. Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. Part Troubleshooting 9
Error Codes: Hydro-box 2. C, 8, 80, HC Thermistor or Related Abnormality (Hydro-box) Error code C, 8, 80, HC Method of malfunction detection The temperatures detected by the thermistors are used to determine thermistor errors. Malfunction decision conditions When the thermistor input is more than.96 V or less than 0.0 V during compressor operation*. * (reference) When above about 22 C (less than 20 ohms) or below about 0 C (more than,860 kohms). Note: The values vary slightly in some models. Supposed causes Faulty connector connection Faulty thermistor Faulty PCB Troubleshooting Check the connector connection. Is it normal? Correct the connection. Check No. 06 Thermistor resistance check Is it normal? Replace the thermistor. (Replace the hydro-box PCB.) Replace the hydro-box PCB. C: Hydro-box heat exchanger thermistor 8: Outlet water temperature thermistor 80: Inlet water temperature thermistor HC: Sanitary water temperature thermistor See also "Check No.06" on page -. 0 Part Troubleshooting
Error Codes: Outdoor Units Error Codes: Outdoor Units Part. What Is in This Chapter? Introduction Overview In the first stage of the troubleshooting sequence, it is important to correctly interpret the error code on the remote controller display. The error code helps you to find the cause of the problem. This chapter contains the following topics: Topic See page.2 E Outdoor Unit PCB Abnormality 2. E OL Activation (Compressor Overload). E6 Compressor Lock. E7 DC Fan Lock 6.6 E8 Input Over Current Detection 7.7 EA Four Way Valve Abnormality 9.8 F Discharge Pipe Temperature Control 2.9 F6 High Pressure Control in Cooling 2.0 H0 Compressor Sensor System Abnormality 2. H6 Compressor Startup Failure 27.2 H8 CT or Related Abnormality 29. P, J, J6, H9 Thermistor or Related Abnormality (Outdoor Unit). L Switch Box Temperature Rise. L Radiation Fin Temperature Rise.6 L Output Over Current Detection 7 Part Troubleshooting
Error Codes: Outdoor Units.2 E Outdoor Unit PCB Abnormality Error code E Method of malfunction detection Detect within the programme of the microcomputer that the programme is in normal running order. Malfunction decision conditions When the programme of the microcomputer is in abnormal running order. Supposed causes Out of control of microcomputer caused by external factors Troubleshooting Noise Momentary fall of voltage Momentary power loss Defective outdoor unit PCB Power on again Error again? Replace the outdoor unit PCB. Check to see that the machine is grounded. Grounded? Carry out grounding work. The cause can be external factors other than malfunction. Investigate the cause of noise. Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 2 Part Troubleshooting
Error Codes: Outdoor Units. E OL Activation (Compressor Overload) Error code E Method of malfunction detection A compressor overload is detected through compressor OL. Malfunction decision conditions If the compressor OL is activated twice, the system will be shut down. The error counter will reset itself if this or any other error does not occur during the following 60-minute compressor running time (total time). * The operating temperature condition is not specified. Supposed causes Refrigerant shortage Four way valve malfunctioning Outdoor unit PCB defective Water mixed in the local piping Electronic expansion valve defective Stop valve defective Part Troubleshooting
Error Codes: Outdoor Units Troubleshooting Discharge pipe thermistor disconnected? Insert the thermistor in position. Check No. 06 Check the thermistors Malfunctioning Discharge pipe thermistor Replace the discharge pipe thermistor. Functioning Check No. 0 Check the electronic expansion valve. Functioning Check No. 0 Check the four way valve. Functioning Malfunctioning Malfunctioning Replace the valve itself or the coil. Replace the four way valve coil or the valve itself. Replace the outdoor unit PCB. Check No. Check the refrigerant line. Functioning Malfunctioning Refrigerant shortage Water mixed Stop valve defective Refer to the refrigerant line check procedure. Replace the outdoor unit PCB. See also: "Check No.0" on page - "Check No.0" on page -2 "Check No.06" on page - "Check No." on page -9 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. Part Troubleshooting
Error Codes: Outdoor Units. E6 Compressor Lock Error code E6 Method of malfunction detection A compressor lock is detected by checking the compressor running condition through the position detection circuit. Malfunction decision conditions Judging from current waveform generated when high-frequency voltage is applied to the compressor. The system will be shut down if the error occurs 6 times. Clearing condition: Continuous run for about minutes (normal) Supposed causes Compressor locked Troubleshooting Turn off the power. Disconnect the harnesses U, V and W. Check with the inverter checker ( ). Normal? Turn off the power and reconnect the harnesses. Turn on the power again and get the system restarted. Inverter checker Part No.: 2277 Correct the power supply or replace the PM. (Replace the outdoor unit PCB.) Emergency stop without compressor running? Replace the compressor. System shut down after errors repeated several times? Check the electronic expansion valve. Replace it as required. Replace the compressor. Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. Part Troubleshooting
Error Codes: Outdoor Units. E7 DC Fan Lock Error code E7 Method of malfunction detection A fan motor or related error is detected by checking the high-voltage fan motor rpm being detected by the Hall IC. Malfunction decision conditions Supposed causes Fan motor breakdown Troubleshooting The fan does not start in 0 seconds even when the fan motor is running. The system will be shut down if the error occurs 6 times. Clearing condition: Continuous run for about minutes (normal) Harness or connector disconnected between fan motor and PCB or in poor contact Foreign matters stuck in the fan Fan motor connector disconnected? Turn off the power and reconnect the connector. Foreign matters in or around the fan? Remove. Get started. Check No. Check the outdoor unit PCB rpm pulse input. Pulse signal inputted? Replace the outdoor unit fan motor. Replace the outdoor unit PCB. See also: "Check No." on page -6 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 6 Part Troubleshooting
Error Codes: Outdoor Units.6 E8 Input Over Current Detection Error code E8 Method of malfunction detection An input over-current is detected by checking the input current value being detected by CT with the compressor running. Malfunction decision conditions The following CT input with the compressor running continues for 2. seconds. CT input: Above 20 A The system will be shut down if the error occurs 6 times. Clearing condition: Continuous run for about minutes (normal) Supposed causes Over-current due to compressor failure Over-current due to defective power transistor Over-current due to defective inverter main circuit electrolytic capacitor Over-current due to defective outdoor unit PCB Error detection due to outdoor unit PCB Over-current due to short-circuit Part Troubleshooting 7
Error Codes: Outdoor Units Troubleshooting An input over-current may result from wrong internal wiring. If the wires have been disconnected and reconnected for part replacement, for example, and the system is interrupted by an input over-current, take the following procedure: Get restarted and measure the input current. Input current flowing above its stop level? Replace the outdoor unit PCB. Check No. Check the main circuit electrolytic capacitor. Normal? Replace the electrolytic capacitor. Turn off the power and disconnect the harnesses U, V and W. Check with the inverter checker ( ). Inverter checker Part No.: 2277 Any LED off? Correct the power supply or replace the PM. (Replace the outdoor unit PCB.) Turn off the power, and reconnect the harnesses. Turn on the power again and get restarted. Check No. 08 Check the discharge pressure. Check No. 07 Check the installation condition. See also: "Check No.07" on page - "Check No.08" on page -6 "Check No." on page -62 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 8 Part Troubleshooting
Error Codes: Outdoor Units.7 EA Four Way Valve Abnormality Error code EA Method of malfunction detection The indoor air temperature thermistor, the hydro-box heat exchanger thermistor, the outdoor temperature thermistor and the outdoor unit heat exchanger thermistor are checked to see if they function within their normal ranges in the operating mode. Malfunction decision conditions A following condition continues over 0 minute after operating minutes. Cooling (Outlet water temperature hydro-box heat exchanger temperature) < -0 C Heating (Hydro-box heat exchanger temperature Outlet water temperature) < -0 C Supposed causes Connector in poor contact Thermistor defective Outdoor unit PCB defective Four way valve coil or harness defective Four way valve defective Foreign substance mixed in refrigerant Insufficient gas Part Troubleshooting 9
Error Codes: Outdoor Units Troubleshooting Four way valve coil disconnected (loose)? Correct. Harness out of connector? Reconnect. Check the continuity of the four way valve coil and harness. Disconnect the harness from the connector. Resistance between harnesses about kω±0.kω? Replace the four way valve coil. Check No. Check the four way valve switching output. Malfunctioning Replace the outdoor unit PCB. Functioning Any thermistor disconnected? Reconnect in position. Check No. 6 Check the thermistors. Malfunctioning Replace a defective thermistor. Functioning Check No. Check the refrigerant line. Functioning Malfunctioning Insufficient gas Water mixed Stop valve defective Refer to the refrigerant line check procedure. Replace the four way valve (defective or dust-clogged). See also: "Check No.0" on page -2 "Check No.06" on page - "Check No." on page -9 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 20 Part Troubleshooting
Error Codes: Outdoor Units.8 F Discharge Pipe Temperature Control Error code F Method of malfunction detection The discharge pipe temperature control (stop, frequency drooping, etc.) is checked with the temperature being detected by the discharge pipe thermistor. Malfunction decision conditions If a stop takes place 6 times successively due to abnormal discharge pipe temperature, the system will be shut down. If the temperature being detected by the discharge pipe thermistor rises above C, the compressor will stop. (The error is cleared when the temperature has dropped below C. Supposed causes Refrigerant shortage 7 class 20 07 The error counter will reset itself if this or any other error does not occur during the following 60-minute compressor running time (total time). Four way valve malfunctioning Discharge pipe thermistor defective (heat exchanger or outdoor temperature thermistor defective) Outdoor unit PCB defective Water mixed in the local piping Electronic expansion valve defective Stop valve defective Part Troubleshooting 2
Error Codes: Outdoor Units Troubleshooting Check No. 6 Check the thermistors. Functioning Malfunctioning Discharge pipe thermistor Outdoor unit heat exchanger thermistor Outdoor themperature thermistor Replace a defective thermistor. Check No. Check the electronic expansion valve. Malfunctioning Replace the valve itself or the coil. Functioning Check No. Check the refrigerant line. Functioning Malfunctioning Refrigerant shortage Four way valve malfunctioning Water mixed Stop valve defective Refer to the refrigerant line check procedure. Replace the outdoor unit PCB. See also: "Check No.0" on page - "Check No.06" on page - "Check No." on page -9 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 22 Part Troubleshooting
Error Codes: Outdoor Units.9 F6 High Pressure Control in Cooling Error code F6 Method of malfunction detection High-pressure control (stop, frequency drop, etc.) is activated in the cooling mode if the temperature being sensed by the heat exchanger thermistor exceeds the limit. Malfunction decision conditions Activated when the temperature being sensed by the heat exchanger thermistor rises above 60 C. (Deactivated when the said temperature drops below 0 C) Supposed causes The installation space is not large enough. Faulty outdoor unit fan Faulty electronic expansion valve Faulty defrost thermistor Faulty outdoor unit PCB Faulty stop valve Dirty heat exchanger Part Troubleshooting 2
Error Codes: Outdoor Units Troubleshooting Check the installation space. Check No. 7 Installation condition check Normal Abnormal Change the air outlet grille position. Change the installation location. Clean the heat exchanger. Check No. 9 Outdoor fan check Normal Check No. Electronic expansion valve check Abnormal Replace fan motor. Repair the connector or fan motor lead wires. Judgment Normal Check No. 6 Heat exchanger thermistor check Abnormal Replace the electronic expansion valve or coil. Replace the PCB. Judgment Normal Abnormal Replace the heat exchanger thermistor. Replace PCB. See also: "Check No.0" on page - "Check No.06" on page - "Check No.07" on page - "Check No.09" on page -7 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 2 Part Troubleshooting
Error Codes: Outdoor Units.0 H0 Compressor Sensor System Abnormality Error code H0 Method of malfunction detection Fault condition is identified by the supply voltage and the DC voltage which is detected before the compressor startup. Fault condition is identified by compressor current which is detected right after the compressor startup. Malfunction decision conditions Supposed causes Reactor disconnection The detected valve of the supply voltage and the DC voltage is obviously low or high. The compressor current doesn't run when the compressor is started. Compressor disconnection Outdoor unit PCB defective Compressor defective Part Troubleshooting 2
Error Codes: Outdoor Units Troubleshooting Turn off the power Reactor connection check Connection OK? Connect properly. Compressor connection check Connection OK? Reactor check Disconnect the reactor from the outdoor unit PCB and measure the resistance value between reactor terminals with tester. Connect properly. 0Ω or less? Replace the reactor. Compressor check Disconnect the compressor relay harness from the outdoor unit PCB and measure the resistance value between the terminals of each compressor with tester. Between all each terminal 0Ω or less? Replace the compressor or the compressor relay harness. Check the operation again and if the error appears again, replace the outdoor unit PCB. Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 26 Part Troubleshooting
Error Codes: Outdoor Units. H6 Compressor Startup Failure Error code H6 Method of malfunction detection A compressor startup failure is detected by checking the compressor running condition through the position detection circuit. Malfunction decision conditions The compressor fails to start in about seconds after the compressor run command signal is sent. Clearing condition: Continuous run for about minutes (normal) The system will be shut down if the error occurs 8 times. Supposed causes Compressor relay cable disconnected Compressor itself defective Outdoor unit PCB defective Stop valve closed Input voltage out of specification Part Troubleshooting 27
Error Codes: Outdoor Units Troubleshooting Check No. Check for short-circuit. Normal Replace the outdoor unit PCB, outdoor unit fan. Check the electrolytic capacitor voltage. DC20±0V? Replace the outdoor unit PCB. Electricals or compressor harnesses connected as specified? Turn off the power. Disconnect the harnesses U, V and W. Reconnect as specified. Inverter checker Part No.: 2277 Check with the inverter checker ( ). Any LED off? Correct the power supply or replace the outdoor unit PCB. Replace the compressor. See also: "Check No." on page -6 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 28 Part Troubleshooting
Error Codes: Outdoor Units.2 H8 CT or Related Abnormality Error code H8 Method of malfunction detection A CT or related error is detected by checking the compressor running frequency and CT-detected input current. Malfunction decision conditions The compressor running frequency is below Hz and the CT input is below 0. V. (The input current is also below 0. A.) If this error repeats times, the system will be shut down. The error counter will reset itself if this or any other error does not occur during the following 60-minute compressor running time (total time). Supposed causes Power transistor defective Internal wiring broken or in poor contact Reactor defective Outdoor unit PCB defective Part Troubleshooting 29
Error Codes: Outdoor Units Troubleshooting Turn off the power and turn it on again. Get the system started. * Running current as shown at right with relay cable or 2? Current (guideline) Capacitor charged when the hydro-box or outdoor unit main relay turns on Replace the outdoor unit PCB. Check No. 2 Check the capacitor voltage. Rising with increasing frequency 2 sec Time DC80±0V? Turn off the power. Disconnect the harnesses U, V and W. Inverter checker Part No.: 2277 Measure the rectifier input voltage. Check with the inverter checker ( ). Any LED off? Turn off the power and reconnect the above harnesses. Then turn on the power again and get the system restarted. Correct the power supply or replace the PM. (Replace the outdoor unit PCB.) Compressor running? Replace the outdoor unit PCB. Voltage within the allowable range (Supply voltage±%)? Replace the compressor. Replace the outdoor unit PCB. Check the supply voltage. See also: "Check No.2" on page -60 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 0 Part Troubleshooting
Error Codes: Outdoor Units. P, J, J6, H9 Thermistor or Related Abnormality (Outdoor Unit) Error code P, J, J6, H9 Method of malfunction detection This type of error is detected by checking the thermistor input voltage to the microcomputer. [A thermistor error is detected by checking the temperature.] Malfunction decision conditions The thermistor input is above.96 V or below 0.0 V with the power on. Error J is judged if the discharge pipe thermistor temperature is smaller than the condenser thermistor temperature. Supposed causes Connector in poor contact Thermistor defective Outdoor unit PCB defective Hydro-box PCB defective Condenser thermistor defective in the case of J error (outdoor unit heat exchanger thermistor in the cooling mode, or hydro-box heat exchanger thermistor in the heating mode) Part Troubleshooting
Error Codes: Outdoor Units Troubleshooting Turn on the power again. Error displayed again on remote controller? Reconnect. Connector or thermistor disconnected? Reconnect. Check No. 06 Check the thermistor resistance value. Normal? Replace defective one(s) of the following thermistors. Radiation fin thermistor Discharge pipe temperature thermistor Outdoor unit heat exchanger temperature thermistor Outdoor air thermistor Check No. 06 Check the hydro-box heat exchanger thermistor resistance value in the heating mode. hydro-box heat exchanger thermistor functioning? Replace the following thermistor. Hydro-box heat exchanger thermistor Replace the outdoor unit PCB. (Replace the hydro-box PCB.) P: Radiation fin thermistor J: Discharge pipe thermistor J6: Outdoor heat exchanger thermistor H9: Outdoor air thermistor See also: "Check No.06" on page - Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 2 Part Troubleshooting
Error Codes: Outdoor Units. L Switch Box Temperature Rise Error code L Method of malfunction detection An electrical box temperature rise is detected by checking the radiation fin thermistor with the compressor off. Malfunction decision conditions With the compressor off, the radiation fin temperature is above 9 C. (Reset is made when the temperature drops below 80 C.) Supposed causes Fin temperature rise due to defective outdoor unit fan Fin temperature rise due to short-circuit Fin thermistor defective Connector in poor contact Outdoor unit PCB defective Part Troubleshooting
Error Codes: Outdoor Units Troubleshooting Turn off the power and turn it on again. WARNING To cool down the electricals, the outdoor unit fan gets started when the radiation fin temperature rises above 9 C and stops itself when it drops below 80 C. Error again or outdoor unit fan activated? Check the radiation fin temperature. Above 9 C? Replace the outdoor unit PCB. Check No. 09 Check the outdoor unit fan or related. Functioning Malfunctioning Replace the fan motor. Correct the connectors and fan motor leads. Replace the outdoor unit PCB. Radiation fin dirty? Slightly dirty Too dirty Clean up the radiation fin. Check No. 07 Check the installation condition. See also: "Check No.06" on page - "Check No.07" on page - "Check No.09" on page -7 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. Part Troubleshooting
Error Codes: Outdoor Units. L Radiation Fin Temperature Rise Error code L Method of malfunction detection A radiation fin temperature rise is detected by checking the radiation fin thermistor with the compressor on. Malfunction decision conditions If the radiation fin temperature with the compressor on is above 0 C, The error is cleared when the temperature drops below 99 C. If a radiation fin temperature rise takes place times successively, the system will be shut down. The error counter will reset itself if this or any other error does not occur during the following 60-minute compressor running time (total time). Supposed causes Fin temperature rise due to defective outdoor unit fan Fin temperature rise due to short-circuit Fin thermistor defective Connector in poor contact Part Troubleshooting
Error Codes: Outdoor Units Troubleshooting Turn off the power and turn it on again to get the system started. Error displayed again? Check the radiation fin temperature. Above 0 C? Check the power transistor and fin for looseness. If they are found to be fit tightly, replace the PCB or the power transistor. Check No. 09 Check the outdoor unit fan or related. Functioning Malfunctioning Replace the fan motor. Correct the connectors and fan motor leads. Replace the outdoor unit PCB. Radiation fin dirty? Slightly dirty Too dirty Clean up the radiation fin. Check No. 07 Check the installation condition. See also: "Check No.06" on page - "Check No.07" on page - "Check No.09" on page -7 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 6 Part Troubleshooting
Error Codes: Outdoor Units.6 L Output Over Current Detection Error code L Method of malfunction detection An output over-current is detected by checking the current that flows in the inverter DC section. Malfunction decision conditions A position signal error occurs while the compressor is running. A speed error occurs while the compressor is running. An output over-current input is fed from the output over-current detection circuit to the microcomputer. The system will be shut down if the error occurs 6 times. Clearing condition: Continuous run for about minutes (normal) Supposed causes Over-current due to defective power transistor Over-current due to wrong internal wiring Over-current due to abnormal supply voltage Over-current due to defective PCB Error detection due to defective PCB Over-current due to closed stop valve Over-current due to compressor failure Over-current due to poor installation condition Part Troubleshooting 7
Error Codes: Outdoor Units Troubleshooting An output over-current may result from wrong internal wiring. If the wires have been disconnected and reconnected for part replacement, for example, and the system is interrupted by an output over-current, take the following procedure: Stop valve fully open? Fully open the stop valve. Turn off the power and turn it on again to get the system started. See if the same error occurs. Error again? Turn off the power and disconnect the harnesses U, V and W. Check with the inverter checker (*) Monitor the supply voltage, discharge and suction pressures, and other factors for a long term. Possible causes Instantaneous supply voltage drop Compressor motor overloaded Contact-induced electrical shortcircuit Keep on using as it is (monitor). Check the electricals' connectors and other fittings. Inverter checker Part No.: 2277 Any LED off? Check No. Check the power transistor. Correct the power supply or replace the PM. (Replace the outdoor unit PCB.) Normal? Turn off the power, and reconnect the harnesses. Turn on the power again and get restarted. Replace the PM. (Replace the outdoor unit PCB.) Check the supply voltage. Voltage as rated? Correct the power supply. Short-circuit or breakage between compressor's coil phases? Check No. 08 Check the discharge pressure. Replace the compressor. Check No. 07 Check the installation condition. 8 Part Troubleshooting
Error Codes: Outdoor Units See also: "Check No.07" on page - "Check No.08" on page -6 "Check No." on page -6 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. Part Troubleshooting 9
Error Codes: Outdoor Units Troubleshooting 2 Any thermistor disconnected? Reconnect in position. Discharge pipe thermistor Hydro-box / outdoor unit heat exchanger thermistor * Outdoor air thermistor Stop valve closed? Open the stop valve. Check for gas leakage. Oil oozing at relay pipe connections? Repair the pipe flare or replace the square union. Oil oozing at internal piping? Check No. 0 Electronic expansion valve functioning? Change for a specified amount of fresh refrigerant. Compressor vibrating too much? Check the power transistor harness for looseness. Correct it as required. Also replace cracked pipe if any. Check the pipes for improper contact. Correct as required. Also replace cracked pipe if any. Replace the electronic expansion valve. Gas shortage error again? Check No. 06 Check the thermistors. Functioning Malfunctioning Replace the outdoor air thermistor, or the hydro-box or outdoor unit heat exchanger thermistor. () Replace the PCB. (2) Replace the compressor. Procedure complete See also: "Check No.0" on page - "Check No.06" on page - Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 0 Part Troubleshooting
Error Codes: System Malfunctions Error Codes: System Malfunctions Part. What Is in This Chapter? Introduction Overview In the first stage of the troubleshooting sequence, it is important to correctly interpret the error code on the remote controller display. The error code helps you to find the cause of the problem. This chapter contains the following topics: Topic See page.2 U0 Insufficient Gas 2. U2 Low-voltage Detection or Over-voltage Detection. U Signal Transmission Error (between Hydro-box and Outdoor Units). U7 Malfunction of Transmission between Remote Controller and Control box 7 Part Troubleshooting
Error Codes: System Malfunctions.2 U0 Insufficient Gas Error code U0 Method of malfunction detection Gas shortage detection I: A gas shortage is detected by checking the CT-detected input current value and the compressor running frequency. Malfunction decision conditions Gas shortage detection II: A gas shortage is detected by checking the difference between hydro-box heat exchanger temperature and room temperature as well as the difference between outdoor unit heat exchanger temperature and room temperature. Gas shortage detection I : DC current (A/Hz) Output frequency + However, when the status of running frequency > (Hz) is kept on for a certain time. Note: The values are different from model to model. 7 class 27 / 000 2. Gas shortage detection II : If a gas shortage error takes place times successively, the system will be shut down. The error counter will reset itself if this or any other error does not occur during the following 60-minute compressor running time (total time). Supposed causes Refrigerant shortage (refrigerant leakage) Poor compression performance of compressor Discharge pipe thermistor disconnected, or hydro-box or outdoor unit heat exchanger thermistor disconnected, room or outside air temperature thermistor disconnected Stop valve closed Electronic expansion valve defective 2 Part Troubleshooting
Error Codes: System Malfunctions Troubleshooting Any thermistor disconnected? Stop valve closed? Reconnect in position. Discharge pipe thermistor Hydro-box / outdoor unit heat exchanger thermistor Room temperature thermistor Outdoor air thermistor Open the stop valve. Check for gas leakage. Oil oozing at relay pipe connections? Repair the pipe flare or replace the square union. Oil oozing at internal piping? Check No. 0 Electronic expansion valve functioning? Change for a specified amount of fresh refrigerant. Compressor vibrating too much? Check the power transistor harness for looseness. Correct it as required. Also replace cracked pipe if any. Check the pipes for improper contact. Correct as required. Also replace cracked pipe if any. Replace the electronic expansion valve. Gas shortage error again? Malfunctioning Check No. 06 Check the thermistors. Replace the room temperature or outdoor air thermistor, or the hydro-box or outdoor unit heat exchanger thermistor. Functioning () Replace the PCB. (2) Replace the compressor. Procedure complete. See also: "Check No.0" on page - "Check No.06" on page - Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. Part Troubleshooting
Error Codes: System Malfunctions. U2 Low-voltage Detection or Over-voltage Detection Error code U2 Method of malfunction detection An abnormal voltage rise or drop is detected by checking the detection circuit or DC voltage detection circuit. Malfunction decision conditions An over-voltage signal is fed from the over-voltage detection circuit to the microcomputer, or the voltage being detected by the DC voltage detection circuit is judged to be below 0 V for 0. second. The system will be shut down if the error occurs 6 times. Clearing condition: Continuous run for about 60 minutes (normal) Supposed causes Supply voltage not as specified Over-voltage detector or DC voltage detection circuit defective PAM control part(s) defective Troubleshooting Check the supply voltage. Supply voltage as specified? Correct the power supply. Turn on the power again. System restarted? (Precaution before turning on the power again) Make sure the power has been off for at least 0 seconds. Disturbance factors Noise Power supply distortion Check for such factors for a long term. Try to get restarted a couple of times. Repeat a couple of times. Replace the PM. (Replace the outdoor unit PCB.) Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. Part Troubleshooting
Error Codes: System Malfunctions. U Signal Transmission Error (between Hydro-box and Outdoor Units) Error code U Method of malfunction detection The data received from the outdoor unit in hydro-box-outdoor unit signal transmission is checked whether it is normal. Malfunction decision conditions When the data sent from the outdoor unit cannot be received normally, or when the content of the data is abnormal. Supposed causes Faulty outdoor unit PCB. Faulty hydro-box PCB. Hydro-box-outdoor unit signal transmission error due to wiring error. Hydro-box-outdoor unit signal transmission error due to disturbed power supply waveform. Hydro-box-outdoor unit signal transmission error due to breaking of wire in the connection wires between the Hydro-box and outdoor units. Part Troubleshooting
Error Codes: System Malfunctions Troubleshooting Check the hydro-box - outdoor unit connection wires. Is there any wiring error? Check the outdoor unit's LED A. Correct the hydro-box - outdoor unit connection wires. Is LED A flashing? Check the voltage of the hydro-box - outdoor unit connection wires between No. and No. 2, and between No 2 and No.. Diagnose the outdoor unit. Is the voltage 0 V? Replace the connection wires between the indoor and outdoor units. Check No. 0 Check power supply waveform. Is there any disturbance? Replace hydro-box control PCB. Locate the cause of the disturbance of the power supply waveform, and correct it. See also: "Check No.0" on page -8 Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. 6 Part Troubleshooting
Error Codes: System Malfunctions. U7 Malfunction of Transmission between Remote Controller and Control box Error code U7 Method of malfunction detection Communication error between microcomputer mounted on the main microcomputer and PM. Malfunction decision conditions When the data sent from the PM can not be received successively for 9 sec. The abnormality is determined if the above fault conditions occurs once. Fault counter is reset when the data from the PM can be successfully received. Supposed causes Defective outdoor unit PCB Troubleshooting Turn the power off and turn it on again. Error again? Replace the outdoor unit PCB. The cause can be an external factor other than the malfunction. Monitor in long term. Caution Be sure to turn off power switch before connect or disconnect connector, or parts damage may be occurred. Part Troubleshooting 7
Error Codes: System Malfunctions 8 Part Troubleshooting
Additional Checks for Troubleshooting Additional Checks for Troubleshooting Part. What Is in This Chapter? Introduction Overview This chapter explains how you must check the units to carry out troubleshooting correctly. This chapter contains the following topics: Topic See page.2 Fan Motor Connector Output Check 0. Electronic Expansion Valve Check. Four Way Valve Performance Check 2. Thermistor Resistance Check.6 Installation Condition Check.7 Discharge Pressure Check 6.8 Outdoor Unit Fan System Check (With DC Motor) 7.9 Power Supply Waveforms Check 8.0 Inverter Units Refrigerant System Check 9. Capacitor Voltage Check 60.2 Power Transistor Check 6. Main Circuit Electrolytic Capacitor Check 62. Turning Speed Pulse Input on the Outdoor Unit PCB Check 6. Inverter Checker Check 6 Part Troubleshooting 9
Additional Checks for Troubleshooting.2 Fan Motor Connector Output Check Check No.0 Check connector connection. 2 Check motor power supply voltage output (pins -7). Check motor control voltage (pins -). Check rotation command voltage output (pins -2). Check rotation pulse input (pins -). 7 6 2 S Motor power supply voltage Unused Unused P.0V (reference potential) Motor control voltage ( VDC) Rotation command voltage (~ 6 VDC) Rotation pulse input 0 Part Troubleshooting
Additional Checks for Troubleshooting. Electronic Expansion Valve Check Check No.0 Conduct the followings to check the electronic expansion valve (EV). Check to see if the EV connector is correctly inserted in the PCB. Compare the EV unit and the connector number. 2 Turn the power off and back on again, and check to see if all the EVs generate latching sound. If any of the EVs does not generate latching noise in the above step 2, disconnect that connector and check the conductivity using a tester. Check the conductivity between pins, and 6, and between pins 2, and. If there is no conductivity between the pins, the EV coil is faulty. Harness 6P 6P Connector 2 6 Check -2-6- 6- If no EV generates latching sound in the above step 2, the outdoor unit PCB is faulty. If the conductivity is confirmed in the above step 2, mount a good coil (which generated latching sound) in the EV unit that did not generate latching sound, and check to see if that EV generates latching sound. If latching sound is generated, the outdoor unit PCB is faulty. If latching sound is not generated, the EV unit is faulty. Note Please note that the latching sound varies depending on the valve type. Part Troubleshooting
Additional Checks for Troubleshooting. Four Way Valve Performance Check Check No.0 Turn off the power and turn it on again. Start the heating-mode run. Four way valve coil Cooling / dry : No continuity Heating : Continuity S80 voltage at DC 220-20 V with compressor on? (Fig. ) Disconnect the four way valve coil from the connector and check the continuity. Replace the outdoor unit PCB. Four way valve coil resistance at 00 ohms? Replace the four way valve coil. Replace the four way valve. Voltage at S80 DC220-20V Compressor ON Time 2 Part Troubleshooting
Additional Checks for Troubleshooting. Thermistor Resistance Check Check No.06 Remove the connectors of the thermistors on the PCB, and measure the resistance of each thermistor using tester. The relationship between normal temperature and resistance is shown in the graph and the table below: Hydro-box SA8002 Tank thermistor SA8009 R2 C=20kΩ R20=7.Ω B=990 B= 77-20 97.8 kω 2 kω - 8.2 kω 877 kω -0 2.0 kω 0 kω - 8.2 kω 09 kω 0 6.8 kω 806. kω.0 kω 68.9 kω 0 9.9 kω 78.8 kω. kω 7. kω 20 2.9 kω 292.9 kω 2 9.9 kω 2. kω 0 6.0 kω 8. kω 2.99 kω 7. kω 0 0.8 kω 8.7 kω 8.669 kω 96. kω 0 7. kω 78.29 kω Part Troubleshooting
Additional Checks for Troubleshooting Tester Resistance range (k Ω) 0 (R2 = 20k Ω, B=90) 00 0 0 0 0 ( C) Part Troubleshooting
Additional Checks for Troubleshooting.6 Installation Condition Check Check No.07 Installation condition check Check the allowable dimensions of the air suction and discharge area. Normal Abnormal Change the position of the air discharge grille or the installation location. Does the discharged air from other outdoor unit cause an increase of the suction air temperature? Change the position of the air discharge grille or the installation location. Is the heat exchanger very dirty? Is the air flow blocked by obstacles or winds blowing in the opposite direction? Clean the heat exchanger. Change the installation location or direction. Check the outside air temperature (temperature of air taken in by the outdoor unit). (The outside air temperature shall be C or lower.) Part Troubleshooting
Additional Checks for Troubleshooting.7 Discharge Pressure Check Check No.08 Discharge pressure check High Replace compessor. Is the stop valve open? Is the connection pipe deformed? Open the stop valve. Replace the pipe installed at the site. Are the heat exchanger and air filter dirty? Clean. Replace the compressor. 6 Part Troubleshooting
Additional Checks for Troubleshooting.8 Outdoor Unit Fan System Check (With DC Motor) Check No.09 Check the outdoor unit fan system. Outdoor unit fan running? Fan motor lead wire connector disconnected? Reconnect. Outdoor unit fan system functioning. Go to Check No.. Part Troubleshooting 7
Additional Checks for Troubleshooting.9 Power Supply Waveforms Check Check No.0 Measure the power supply waveform between pins and on the terminal board, and check the waveform disturbance. Check to see if the power supply waveform is a sine wave. Check to see if there is waveform disturbance near the zero cross (sections circled). 8 Part Troubleshooting
Additional Checks for Troubleshooting.0 Inverter Units Refrigerant System Check Check No. Refrigerant system check Is the discharge thermistor disconnected from the holder? Correct the problem. Is any moisture found in sight glass? Check for gas leaks. See the section on insufficient gas detection. Conduct the check after operating the equipment for a sufficient length of time. Conduct vacuum drying. Replace the refrigerant. Part Troubleshooting 9
Additional Checks for Troubleshooting. Capacitor Voltage Check Check No.2 Before this checking, be sure to check the main circuit for short-circuit. Checking the capacitor voltage With the circuit breaker still on, measure the voltage according to the drawing of the model in question. Be careful never to touch any live parts Multimeter (DC voltage range) Reactor lead wire Compressor lead wire Fan motor lead wire Electronic expansion valve lead wire OL lead wire Thermistor lead wire Reversing solenoid valve lead wire (Heat pump type only) 60 Part Troubleshooting
Additional Checks for Troubleshooting.2 Power Transistor Check Check No. Checking the power transistor Never touch any live parts for at least 0 minutes after turning off the circuit breaker. If unavoidably necessary to touch a live part, make sure the power transistor's supply voltage is below 0 V using the tester. For the UVW, make measurements at the Faston terminal on the board or the relay connector. Tester's negative terminal Power transistor (+) UVW Power transistor ( ) UVW Tester's positive terminal Normal resistance UVW Power transistor (+) UVW Several kω to several MΩ Power transistor ( ) Abnormal resistance 0 or W V U Part Troubleshooting 6
Additional Checks for Troubleshooting. Main Circuit Electrolytic Capacitor Check Check No. Checking the main circuit electrolytic capacitor Never touch any live parts for at least 0 minutes after turning off the circuit breaker. If unavoidably necessary to touch a live part, make sure there is no DC voltage using the tester. Check the continuity with the tester. Reverse the pins and make sure there is continuity. Keep the tester in the resistance measuring range. When the pointer swings, it means the capacitor functions. If the pointer does not swing at all, or if it swings all the way but does not return, it means the capacitor malfunction. 62 Part Troubleshooting
Additional Checks for Troubleshooting. Turning Speed Pulse Input on the Outdoor Unit PCB Check Check No. Propeller fan motor Make sure the voltage of 20±0V is being applied. Stop the operation first and then the power off, and disconnect the connector S70. 2 Make sure there is about DC 20 V between pins and 7. With the system and the power still off, reconnect the connector S70. Make a turn of the fan motor with a hand, and make sure the pulse (0- V) appears twice at pins and. If the fuse for fan motor protection is blown out, the outdoor-unit fan may also be in trouble. Check the fan too. If the voltage in Step (2) is not applied, it means the PCB is defective. Replace the PCB. If the pulse in Step () is not available, it means the Hall IC is defective. Replace the DC fan motor.if there are both the voltage (2) and the pulse (), replace the PCB. PCB S70 Turning speed pulse input (0- V) 2 V 6 7 DC20V Propeller fan motor: S70 Part Troubleshooting 6
Additional Checks for Troubleshooting. Inverter Checker Check Check No.6 Characteristics If an abnormal stop occurs due to compressor startup failure or overcurrent output when using the inverter unit, it is difficult to judge whether it results from the compressor failure or another failure (control PC Board, power transistor, etc.). The inverter analyzer makes it possible to judge the cause of trouble easily and securely. (Connect this analyzer as a quasi compressor instead of a compressor and check the output of the inverter.) Operation method Be sure to turn the power off. 2 Install the inverter analyzer instead of a compressor. Note: Make sure the charged voltage of the built-in smoothing electrolytic capacitor drops to 0 VDC or below before carrying out the service work. () Remove the faston terminals from the terminal block of the compressor. (2) Connect the faston terminals to the terminals of the Inverter Analyzer. Compressor Inverter Analyzer Be careful not to touch the terminals (U,V,W) with each other. Otherwise, high voltage is applied. Reference: If the connector terminal of the compressor is not a faston terminal (difficult to remove the wire on the terminal), it is possible to connect a wire available on site to the unit from the output side of the PCB. (Do not connect it to the compressor at the same time, otherwise it may result in incorrect detection.) Turn the power on and operate the air conditioner. 6 Part Troubleshooting