Service BulletinDCI Inverter Diagnostics Single Head Systems SB085 Issue 2 MODELS AFFECTED: This Bulletin describes Diagnostic and Test procedures for the following models: XLLDCI9RCA XLLDCI12RCA XLLDCI18RC XLLDCI24RC XLLDCI30RC KLDCI9RCA KLDCI12RCA KLDCI18RCA SXDCI12RCA SXDCI18RCA GCLDCI9RC GCLDCI12RC GCLDCI18RC GCLDCI24RC GCLDCI30RC The XLLDCI9RCA, XLLDCI12RCA, KLDCI9RCA, KLDCI12RCA and SXDCI12RC Indoor units can also be used on the DUO, TRIO and QUATTRO Inverters, and the KLDCI18RC and SXDCI18RC can be used on the TRIO and QUATTRO. The information in this Bulletin for the Indoor units still applies when the Indoor unit is used in multi-head configurations. DESCRIPTION: This bulletin describes the diagnosis of these units, including general failures, Self-Diagnostics, Test functions, Sensor (Thermistor) checks and corrective actions. It covers single-head Inverter systems - the XLLDCI, KLDCI and SXDCI (indoor) and GCLDCI (outdoor) units. Since the multi-head systems use the above Indoor units, this Bulletin also applies to the Indoor Units of the Duo, Trio and Quattro Inverters. However, for complete diagnostic information on the multi-head units, please refer to the applicable Service Bulletins. 1. General Failures and Corrective Actions: The first step in diagnosing faults on these units is to review the symptoms as listed in Table 1 on page 4, and follow the diagnostic/corrective actions suggested. 2. Indoor Unit Diagnostics: On the Indoor Unit, to start the self-diagnostics, push and hold the MODE button for 5 seconds. The unit will start the self-diagnostics regardless of whether it is operating or in standby. The unit will continue in Standby, Cool or Heat while in Diagnostic mode. On the XLLDCI’s, the MODE button is located on the indoor unit under the filter cover on the right hand side (see the photo below). On the KLDCI units, the MODE button is located under the Return Air Grille, adjacent to the Standby and Operate LED’s. On the SXDCI units, the MODE button is located on the Display Panel at the top of the Unit. On holding the MODE button down, there will be 3 short beeps and the Cool and Heat (green and red) LED’s will begin flashing. COOL L.E.D. RESET Button MODE Button HEAT L.E.D. The diagnostic indication (if any) is shown by the pattern of flashes of the Heat (red) and Cool (green) L.E.D’s. The Heat (red) LED will flash 5 times in 5 seconds, then stop for 5 seconds, then flash again 5 times repeatedly. Diagnostic codes are shown by the sequence of Cool (green) LED flashes in step with the Heat (red) LED flashes. Use Table 2 "INDOOR Unit Diagnostic Codes", on page 5 to determine the fault. For example if on the Indoor Unit the green LED flashes with the second red LED flash (only) the fault is the Indoor Coil Sensor is shorted (2nd row of the table). XLLDCI Indoor Unit (with covers removed) Issued by: Greg Bugno Signed: Date: 19/8/2005 Page: 1 of 8 When an Outdoor diagnostic is shown on the Indoor Unit. shows the interpretation of the codes. The Status LED flashes five times. It takes 5 minutes for this voltage to dissipate after the unit is powered down. Operate.E. until the unit beeps three times.2 Display of Outdoor Diagnostics on the Indoor Unit: The Indoor Unit can display the diagnostics from the Outdoor unit as well as its’ own diagnostics. The table given in this bulletin reads left to right.D’s NOTE: There is a Diagnostic table printed on the cover of the Inverter Power Module. The method of displaying Outdoor diagnostics on the Indoor Unit is as follows: . on page 6. For example. the normal convention in Englishspeaking countries. the Heat LED flashing in place of the Status LED. the Standby. The Indoor unit will give three beeps.1 Display on Outdoor Unit: There is a set of 3 L. GCLDCI Outdoor Unit Diagnostic L. The unit will switch between Indoor and Outdoor diagnostics whenever the Mode button is pressed momentarily. Filter & Timer LED’s are on steady. if the Fault LED flashes only once. above. Table 3.E. See the photo to the right. The display on the Inverter Power Module shows the last fault even if the system has recovered from that fault. Operate. under the top cover of the Outdoor Unit. on the third flash of the Status LED. when showing the Outdoor diagnostic on the Indoor unit. When showing the Indoor diagnostic.To show the Outdoor diagnostics in place of the Indoor diagnostics. The Fault LED may or may not flash with each Status LED flash. or use the Remote Control to change the setpoint or operating mode.D’s on the Inverter Power Module. .E. Issued by: Greg Bugno Signed: Date: 19/8/2005 Page: 2 of 8 . That table has to be read from right to left. the Standby. press the Mode button momentarily. Faults from which the system has recovered will be cleared on exiting diagnostic mode. and the Cool LED flashing in place of the Fault LED. 3. "OUTDOOR Unit Diagnostic Codes". pauses. The fault code display is similar to that used on the Indoor unit. To get out of Diagnostic mode press and hold the Mode button again for 5 Seconds. then flashes 5 times again.Service Bulletin DCI Inverter Diagnostics Single Head Systems SB085 Issue 2 3. and then display the Outdoor diagnostic. DANGER! Shock Hazard! The Outdoor Unit is powered with 380VDC. These L. the Diagnostic is indicating that the Compressor Top Sensor is shorted.D’s display the status of the Outdoor unit at all times when power is "On". it has the same fault code as when displayed on the Outdoor Unit. Filter & Timer LED’s flash. Outdoor Unit Diagnostics: 3.Initiate the display of the Indoor diagnostics as in 2. so these measurements must be done carefully to avoid the risk of electrical shock or a short which could damage the IPM PCB. The Voltage-Temperature chart is given on page 8 of this Bulletin. without removing the IPM cover. it should show a superheat of 6oK. Superheat measurements on the system are meaningless. To put the unit into Test Mode. 5.Service Bulletin DCI Inverter Diagnostics Single Head Systems SB085 Issue 2 4. and unplugging the sensor from the PCB. Checking the Refrigerant Circuit . Test mode stops the dynamic adjustment of the system. the Operating Point can be changed by selecting the appropriate Indoor Fan speed. as given by the table on page 8.Put Multimeter probes here to measure DC voltage across CTT sensor. Date: 19/8/2005 Page: 3 of 8 . and sets the Electronic Expansion Valve to a fixed opening. These sensors can also be checked in a "Power Off" condition. Checking the Sensors: The sensors on the Indoor Unit can be checked using the usual methods. at Nominal Capacity (Indoor Fan Speed on High). The unit will show the diagnostics as described above. select the appropriate Indoor Fan speed. When the unit is running Cooling in Test Mode. check the sensor voltage against the actual Outdoor Coil Temperature. change the Setpoint (using the Remote) to 16oC (cooling) or 30oC (heating). The sensors on the Outdoor unit are not readily accessible.TEST MODE: A Test Mode is available on the single-head inverter units to facilitate checking the Refrigerant circuit. The unit should be powered down before removing the cover. as shown in the photo to the right. To end Test Mode. as well as operating in Test mode. Issued by: Greg Bugno Signed: Example . by removing the front panel of the outdoor unit. referenced to an outside air temp of 35oC and a return air temp of 27oC. Inverter Power Module PCB (with cover removed) The DC voltage across any sensor can then be measured by putting a multimeter probes onto the solder pads of the PCB. sets the compressor and fans to run at a fixed speed. exit from Diagnostic Mode by pressing and holding the MODE button until three beeps are heard. In Test Mode. When not in this mode.e.. turn the unit "On" using the Remote Control. Nominal and Maximum. The Sensors’ resistance can then be measured.i.Minimum. These levels are selected according to the Indoor Fan speed selected by the Remote Control. if checking the OCT sensor. The sensors are floating at about 160VDC above AC Ground. They can be accessed by removing the cover of the IPM Module. and compared to the specified resistace at that temperature. The capacity of the unit can be checked at three different levels . as follows: Indoor Fan on Low speed: Minimum Capacity Indoor Fan on High speed: Nominal Capacity Indoor Fan on Auto: Maximum Capacity. as shown. since the operating conditions are continually changing. then press and hold the Mode button on the Indoor Unit until 3 beeps are heard. and powered up after the cover has been removed. This voltage should be checked against the temperature that the sensor should be reporting . check display and display wiring. If OK. if OK. Unit in heat mode Change to cool mode and check. and indoor fan speed is not changed by remote control command.Service Bulletin SB085 Issue 2 DCI Inverter Diagnostics Single Head Systems TABLE 1 - General Faults & Corrective Actions No 1 SYMPTOM Power supply indicator (Red LED) does not light up PROBABLE CAUSE No power supply 2 Unit does not respond to remote control command Remote control message not received by the indoor unit. and follow the actions described. Wrong jumper settings Check and open drainage tube. Check remote control batteries. replace IPM. if not OK replace controller Replace controller PCB problem Electronics control problem or protection Electronic control or power supply problem Problem with outdoor electronics or outdoor fan Electronics or power connection to RV Perform diagnostics and follow the actions described. If OK. and follow the actions described. replace motor. 3 Unit responds to remote control message but Operate indicator (Green LED) does not light up Indoor fan does not start (louvers are opened and Green LED does light up) Problem with display PCB 4 5 6 7 8 9 10 11 12 13 14 15 16 Indoor fan works when unit is OFF. Compressor does not start Compressor stops during operation and Green LED remains on Compressor is on but outdoor fan does not work Unit works in wrong mode (cool instead of heat or heat instead of cool) All components are operating properly but no cooling or no heating Compressor is over heated and unit does not generate capacity Units goes into protections and compressor is stopped with no clear reason Compressor motor is generating noise and no suction occurs Water leakage from indoor unit Freezing of outdoor unit in heat mode and outdoor unit base is blocked with ice Unit operates with wrong fan speeds or wrong frequency Issued by: Greg Bugno Signed: CORRECTIVE ACTION Check power supply.. Check refrigeration system.5. replace Control Box Assy. If still not OK replace Control Box Assy. If power supply is OK check fuse in Outdoor Unit. Date: 19/8/2005 Page: 4 of 8 . if OK. Refrigerant leak Check outdoor fan motor as per section 12. Replace display PCB. -----------------------------------------------------------------------------------------------------------------Problem with PCB Change to high speed and check power or capacitor supply to motor is higher than 130VAC (for Triac controlled motor) or higher than 220VAC for fixed speed motors. If still not OK replace Control Box Assy. Check if unit is operating from EEPROM parameters. Check RV operation with direct 230VAC power supply. Connect base heater. replace display PCB. Check RV power connections. Perform Self-Diagnostics on the Outdoor Unit. if batteries are OK. and coil is still not warm. Perform Self-diagnostics. If OK replace IPM. if OK replace capacitor. if OK. check Indoor Unit display.3 of the Service Manual If not OK. Phase order to compressor is wrong Indoor unit drain tube is blocked Check compressor phase order. EEV problem Check EEV Control problem or refrigeration system problem Perform Indoor & Outdoor Self-diagnostics. - - - - 3 Return Air Sensor is disconnected. They are model codes only. ✺ ✺ ✺ ✺ - - 8 No Communication. 3. Indoor fan or PCB Fault - - 11 Outdoor unit fault ✺ - 17 Anti Freeze Protection.0kW) - 31 MODEL D (7. This may not be a fault. Issued by: Greg Bugno Signed: Date: 19/8/2005 Page: 5 of 8 . - - - - 7 Communication Mismatch. 4. see the table on P.Cool LED 1 Indoor Coil Sensor is disconnected. If more than one fault occurs. MODEL D" are not faults.Heat LED 1✺ Problem NOTES: 2✺ 3✺ 4✺ 5✺ Green Flashes . Diagnostic Codes 17 through 21 show that the system is operating in a Protection Mode. Diagnostic codes of "MODEL A.5kW) - - 29 MODEL B (3. - - 19 Outdoor Unit Protection. - - - - 9 No Encoder.2kW) ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ 0 No Fault - - - - - - - - 1.7. in order of priority from the top of the Table to the bottom. only one fault will be indicated at a time. Please refer to the Service Manual to determine if the Protection Mode is appropriate or not. ✺ ✺ ✺ - - _ 4 Return Air Sensor is shorted.5kW) ✺ - 30 MODEL C (5. ✺ ✺ ✺ ✺ ✺ ✺ - - - 18 De-icing. ✺ ✺ ✺ - - 20 Indoor Coil HP Protection - - - 21 Overflow Protection ✺ - ✺ ✺ 24 EEPROM Not updated - - - 25 Bad EEPROM ✺ - - 26 Bad Communication - - 27 Using EEPROM Data ✺ ✺ ✺ 28 MODEL A (2. MODEL B. 2. For suggested corrective action. ✺ - - - - 2 Indoor Coil Sensor is shorted. MODEL C.Service Bulletin SB085 Issue 2 DCI Inverter Diagnostics Single Head Systems TABLE 2 1 INDOOR Unit TABLE Diagnostic Codes 5 Seconds 5 Flashs . 2.I/D Cool LED or O/D Fault LED ✺ - ✺ ✺ ✺ - - ✺ - ✺ ✺ ✺ - ✺ - ✺ ✺ ✺ - ✺ ✺ - ✺ No Fault - - - - - - - - - - - - ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ - - - - - - - ✺ ✺ - - - - - - - ✺ - - ✺ ✺ - - - - - - - ✺ - ✺ ✺ ✺ ✺ ✺ ✺ - - ✺ ✺ ✺ ✺ - - - - - ✺ ✺ - - ✺ ✺ ✺ ✺ - ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ ✺ - 1. Note that the Fault Table printed on the Electronics cover of the Outdoor Unit shows the fault code flashes listed from right to left. The code in this Bulletin is correct. Note also that Fault 0. Issued by: Greg Bugno Signed: Date: 19/8/2005 Page: 6 of 8 . 9 Suction Temp Sensor is disconnected. in order of priority from the top of the Table to the bottom.Service Bulletin SB085 Issue 2 DCI Inverter Diagnostics Single Head Systems TABLE 3 OUTDOOR Unit Diagnostic Codes TABLE 2 5 Seconds 5 Flashes . see the Table on Page 7. 2 Outdoor Coil Sensor is shorted. For corrective action. 3. 24 No outdoor fan feed back 25 Outdoor fan locked. If more than one fault occurs. 11 Inverter Power Module Fault 12 Bad EEPROM 13 DC Under-voltage Protection. 10 Suction Temp Sensor is shorted. 7 Outdoor Air Sensor is disconnected. 26 Compressor locked 27 Bad Communication 0 NOTES: 1✺ 2✺ 3✺ 4✺ 5✺ Green Flashes . is shown as a different code. 8 Outdoor Air Sensor is Shorted.I/D Heat LED or O/D Status LED Fault No. 16 IDU-ODU Communication mismatch 17 No Communication 20 Heat Sink overheating 21 In Deice Mode 22 Compressor overheating 23 Compressor over current. 5 Heat Sink Sensor is disconnected. 15 AC Under-voltage Protection. 14 DC Over-voltage Protection. "NO FAULT". 6 Heat Sink Sensor is Shorted. Problem 1 Outdoor Coil Sensor is disconnected. 4 Compressor Top Sensor is shorted. 3 Compressor Top Sensor is disconnected. only one fault will be indicated at a time. not left to right. Replace sensors as required. mismatch No communication Communication wiring or ground Check Indoor & Outdoor wiring and wiring is not good. Communication quality is low reliability. System is using EEPROM data. wiring OK. No Communication Communication or Ground wiringCheck Indoor to Outdoor wiring and is not good. Issued by: Greg Bugno Signed: Date: 19/8/2005 Page: 7 of 8 . 25 Bad EEPROM Communication wiring or ground No action. the Inverter Power Module) Bad EEPROM Check sensor connections. Communication quality is poor. System using ROM parameters and not EEPROM parameters. Bad communication. replace motor. If still not OK. Replace sensors as required. 27 No action. Table 5: OUTDOOR DIAGNOSTICS CORRECTIVE ACTION Fault Diagnostic Probable Cause Corrective Action Code 1-10 11 12 13. Check outdoor unit power supply voltage. No Encoder Indoor electronics or fan motor. Outdoor Unit Fault Switch to Outdoor diagnostics. Check Indoor & Outdoor wiring and grounding. Indoor & Outdoor Indoor & Outdoor controllers are Replace Indoor controller communication different versions. Check resistances or voltage for accuracy. grounding. Check resistances or voltage for accuracy. replace Indoor controller. Using EEPROM data.. 26 Bad communication. DC under/over voltage AC under voltage Electronics hardware problem. Check all wiring and jumper settings.Service Bulletin SB085 Issue 2 DCI Inverter Diagnostics Single Head Systems Table 4: INDOOR DIAGNOSTICS CORRECTIVE ACTION Fault Diagnostic Probable Cause Corrective Action Code 1-4 All Sensor failures 7 Check sensor connections. Compressor lock. Check outdoor unit power supply voltage. unless special parameters are required for unit operation. If OK. (IPM is Electronics hardware problem. No problem. grounding. are required for unit operation. Check motor wiring. Check Indoor & Outdoor wiring & grounding. replace Outdoor Electronics No action. 8 9 11 24 EEPROM not updated. Switch unit to Standby & re-start. unless special parameters are required for unit operation. Replace Indoor Controller Communication Indoor and Outdoor controllers Mismatch are different versions. unless special parameters wiring is not good. 14 15 16 17 26 27 All Sensor failures IPM fault. 52 0.99 1.48 2.977 27.31 4.452 13.98 3.097 44.57 3.179 3.783 52.071 55.02 3.610 70.59 4.69 3. Ohms 683 664 646 628 610 593 577 562 546 532 517 504 490 477 465 453 441 429 418 408 397 387 377 368 359 350 341 333 325 317 309 302 294 287 280 274 267 261 255 249 243 RAT ICT OCT DC Volts 4.94 3.46 4.40 4.56 3.41 2.186 74.326 20.494 4.08 1.40 1.48 0.58 4.12 CTT HST DC Volts 0.65 3.18 0.99 4.68 1.173 1.495 5.685 7.60 2.90 2.32 3.17 3.62 4.024 7.60 3.676 4.17 2.30 3.57 1.300 3.320 4.91 0.35 0.062 2.328 62.22 3.13 3.06 2.15 0.03 4.13 3.69 Note: RAT = Return Air Thermistor ICT = Indoor Coil Thermistor OCT = Outdoor Coil Thermistor CTT = Compressor Top Thermistor HST = Heat Sink Thermistor All types of thermistor have the same nominal resistance at a given temperature.24 4.38 3.68 3.55 2.135 2.78 3.73 1.83 0.67 CTT HST DC Volts 3.06 2.47 4. Date: 19/8/2005 Page: 8 of 8 .055 6. All the Thermistors on the Outdoor unit are at a high DC voltage relative to AC Ground.38 2.93 2.250 1.923 1.70 2.73 1.102 1.12 0.65 4.12 4.18 3.56 4.13 0.535 28.05 3.787 13.11 0.69 0.550 RAT ICT OCT DC Volts 2.36 1.42 3.581 59.19 4.72 0.289 19.47 CTT HST DC Volts 2.95 2.33 1.08 4.66 4.72 0.061 1.65 0.32 4.844 3.550 42.75 2.992 11.28 2.14 0.10 2.46 3.48 4.56 0.58 4.644 2.72 2.123 24.54 4.63 3.423 21.28 2.97 3.66 1.54 2.79 1.92 3.38 0.05 1.699 3.84 CTT HST DC Volts 0.21 2.08 1.50 0.44 4.00 3.98 1.81 3.42 4.77 2.26 0.49 4.39 3.89 0.01 2.20 0.85 2. Issued by: Greg Bugno Signed: DANGER .508 16.309 18.39 2.12 0.66 4.276 5.34 3.36 4.26 3.92 1.56 3.61 4.52 3.36 3.34 2.332 66.680 15.001 9.966 5.64 Temp oC 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 Resist.13 1.45 3.37 1. Ohms 2.004 974 945 917 889 863 838 813 790 767 745 724 703 RAT ICT OCT DC Volts 3.913 37.80 2.41 4.86 0.13 4.844 2.068 1.10 4.50 0.57 4.74 2.88 2.62 1.14 2.26 1.22 1.32 1.44 2.363 7.80 2.52 1.154 3.02 1.377 1.38 4.28 3.461 10.15 0.22 4.41 3.159 39.796 1.320 84.65 4.19 0.66 3.53 4.65 2.59 3.817 23.586 22.54 4.VOLTAGE TABLE Temp oC -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Resist.381 8.22 1.37 4.42 1.61 3.50 2.17 1.10 0.21 3.12 1.384 17. Ohms 107.51 2.155 14.157 RAT ICT OCT DC Volts 0.77 1.69 2.17 2.61 4.00 3.62 4.04 1. so they develop different DC voltages when operating.54 3.66 2.62 3.51 1.04 3.55 3.53 4.63 4.46 0.47 1.73 3.37 0.09 3.57 4.455 10.736 1.01 4.60 3.81 1.24 0.60 2.57 2.763 6.17 0.21 0.44 3.29 1.29 0.63 1.859 1.16 0.44 0.570 1.99 Temp oC 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 Resist.996 3.59 0.58 3.47 1.27 4.76 3.27 0.64 3.35 4.519 1.92 0.991 1.44 1.700 49.725 5.33 2.03 2.75 0.60 4.96 1.896 15.211 1.62 4.559 11.42 0.49 3.49 3.484 6.60 4.291 1.067 4.211 2.560 3.31 2.081 79.63 2.33 0.45 4.624 1.945 10.23 3.62 0.66 4.867 4.45 0.66 4.59 4.51 4.51 3.90 1.64 3.64 4.508 26.62 0.64 4.75 0.23 2.84 1.17 4.423 1.51 4.57 0.53 0.373 2.427 3.07 3.756 8.387 100.09 3.036 1.54 0.87 0.10 0.11 3.95 2.19 3.80 0.38 3.85 2.44 2.52 4.15 1.19 1.89 3.219 5.33 4.SHOCK HAZARD The Outdoor PCB always has 380VDC on it whenever power is ON.83 0.15 Temp oC 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 Resist.66 3.816 33.53 3.470 1.46 3.65 4.290 2.30 0.Service Bulletin SB085 Issue 2 DCI Inverter Diagnostics Single Head Systems Table 6: INVERTER THERMISTOR TEMPERATURE .33 3.95 0.56 4.61 4.931 89.68 0.87 3.951 2.42 3.25 0.29 4.24 2.09 0.47 0.55 1.55 4.22 0.58 1. Ohms 12.30 3.63 3.333 1.RESISTANCE .26 3.79 0.43 4.59 0.32 0.90 2.39 4.95 3.801 35.27 1.95 0.20 4.67 0.137 1.48 3.35 3.67 3.948 32.15 4.942 94. However they use different circuitry.460 2.40 0.64 4.42 0.742 2.84 1.25 3.28 4.63 4.88 1.809 47.50 3.565 9.190 30.06 4.25 4.150 8.50 4.70 1.83 2.77 0.679 1.64 4.