Fujitsu G140DC6, G140LCT, K160DC9, K160LCT, K112LCT Maintenance Document

...

Air to water heat pum

Split System (single phase type)

Hydraulic unit

WS *G140DC6

Split System (3-phase type)

Hydraulic unit

WS *K160DC9

Outdoor unit

WO *G112LCT WO *G140LCT

Outdoor unit

WO *K112LCT WO *K140LCT WO *K160LCT

Document 1544-1 ~ 20/06/2012

Maintenance

Document

Intended for

professional use

Fujitsu General (Euro) GmbH

Werftstrasse 20

40549 Düsseldorf - Germany

Subject to change without notice

20/06/2012

Non contractual document

Contents

1 Control and test ..............................................................................................................5

1.1 Control of Electric Backups ............5 1.2 Sensor and Input Test Mode.......... 5

2 Faults ...............................................................................................................................6

2.1 Fault List.........................................6

2.1.1 Hydraulic Unit Fault..........................6

2.1.2 Outdoor Unit Fault............................8

2.2 Outdoor Unit Clearing.....................9

2.2.1 Failures with Error Code ..................9

2.2.2 Failures With No Error Code..........31

2.3 Sensor Values..............................35

2.3.1 Outdoor Unit Temperature Sensors35

2.3.2 Hydraulic Unit Temperature Sensors35

2.4 Service parts information..............36

3 Failures..........................................................................................................................41

3.1 Hydraulic, Electric and Refrigeration

Systems ...................................................41

3.1.1 Hydraulic System ...........................41

3.1.2 Electrical System ...........................42

3.1.3 Refrigeration System .....................43

4 Control Settings............................................................................................................46

4.1 General.........................................46

4.2 Function Table..............................47

4.3 Adjustment Function Details.........53

4.3.1 Date and Time Functions...............53

4.3.2 User Interface Functions................53

4.3.3 Time Program Functions (heating circuit

1 & 2, DHW, cooling) ..................................54

4.3.4 Heating Circuit 1 & 2 Functions .....55

4.3.5 Cooling Circuit 1 Functions ............62

4.3.6 DHW Functions..............................68

4.3.7 Swimming Pool Functions..............71

5 Annual Maintenance Services .....................................................................................92

5.1 Hydraulic Circuit ...........................92

5.2 Outdoor unit..................................92

2.4.1 Service parts information 1 :

Compressor ................................................36

2.4.2 Service parts information 2 : Inverter

compressor................................................. 37

2.4.3 Service parts information 3 : Outdoor

unit electronic expansion valve (EEV, EEV(INJ)) 38

2.4.4 Service parts information 4 : Outdoor

unit solenoid valve (SV).............................. 39

2.5 Operating Limits........................... 40

3.2 Compressor Operating Checks.... 45

3.3 Refrigeration Circuit Leak Test ....45

3.4 Troubleshooting ...........................45

4.3.8 Heat Pump Functions.................... 71

4.3.9 Supplementary source................... 73

4.3.10 DHW Tank Functions ....................74

4.3.11 Configuration Functions................. 76

4.3.12 Error Functions ..............................78

4.3.13 Maintenance / Special Operating Mode

Functions ....................................................80

4.3.14 Input / Output Testing Functions ...82

4.3.15 Status Functions............................ 83

4.3.16 Generator Diagnosis Functions..... 88

4.3.17 Consumer Diagnosis Functions ....89

5.3 Electrical ......................................92

5.4 Operating checks .........................92

20/06/2012

Split system (Single phase and 3-phase type)

6 Disassembly Process of Outdoor Unit........................................................................93

6.1 Single phase type ........................93

6.1.1 Appearance................................... 93

6.1.2 Service panel removal................... 93

6.1.3 Top panel removal ........................ 93

6.1.4 MAIN PCB, FILTER PCB, and

INDICATOR PCB removal ......................... 94

6.1.5 FAN MOTOR removal................... 96

6.1.6 VALVE COVER removal............... 96

6.1.7 RIGHT PANEL removal ................ 97

6.1.8 THERMISTOR removal................. 97

6.1.9 SOLENOID COIL removal ............ 98

6.1.10 EEV COIL removal........................ 99

6.1.11 PRESSURE SENSOR removal .... 99

6.1.12 COMPRESSOR removal .............. 99

6.2 3-phase type ................................99

6.2.1 Appearance................................... 99

6.2.2 Service panel removal................... 99

6.2.3 Insulation sheet removal................ 99

6.2.4 Main PCB removal......................... 99

6.2.5 INVERTER, PFC, FILTER, and

CAPACITOR PCB removal ........................99

6.2.6 FAN MOTOR removal ...................99

6.2.7 TOP PANEL removal..................... 99

6.2.8 PIPE COVER FRONT removal .....99

6.2.9 RIGHT PANEL removal.................99

6.2.10 REACTOR removal .......................99

6.2.11 THERMISTOR removal .................99

6.2.12 SOLENOID COIL removal.............99

6.2.13 EEV COIL removal ........................99

6.2.14 PRESSURE SENSOR removal.....99

6.2.15 COMPRESSOR removal...............99

6.3 Precautions for exchange of

refrigerant-cycle-parts ............................. 99

4 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

1 Control and test

1.1 Control of Electric Backups

H 33

Outdoor

Unit Fault

(370)

EJP lock signal (l 2920) HEAT PUMP DHW auxiliary 1st stage elec. auxiliary 2nd stage elec. auxiliary Boiler backup

(1) subject to authorization by EX2 (2) provided the outdoor temperature is less than the setting on "2884 or 3700" (+2° from the beginning)

OFF ON (1) ON (2) ON (2) ON (2)

Load-shedding (EJP) Off-peak/peak

0 V 230 V 230 V 0 V 230 V 0 V 230 V

ON ON OFF ON ON ON OFF ON OFF OFF ON OFF ON OFF ON OFF OFF ON ON ON OFF ON OFF OFF ON ON ON OFF ON ON ON ON ON ON OFF

1.2 Sensor and Input Test Mode

EX 1 EX 2 EX 3

hours

"released"

"locked"

External fault

(369)

LINE SENSOR INPUT OUTPUT WATERSTAGE

7700 QX Relay test

7710 UX1 Output test

7712 UX1 PWM-Signal

7722 DO2 Cooling mode

7723 D3 Heat pump

7724 UX3 Output test ("Inverter" command)

7725 UX3 Voltage signal (Ux3)

7820 BX1 Sensor temp (HP flow temperature)

7821 BX2 Sensor temp (HP return temperature)

7822 BX3 Sensor temp (DHW temperature)

7823 BX4 Sensor temp (Outside temperature)

7911 EX1 Input (Power shedding, EJP)

7912 EX2 Input (Tariffs day/night)

7913 EX3 Input (External fault)

7973 BX31 Sensor temp (Mixing circuit temp.)

7976 BX34 Sensor temp (Swimming pool exchanger temperature)

7996 H33 Contact state

Maintenance Document 1544-1 5

Split system (Single phase and 3-phase type)

2 Faults

2.1 Fault List

2.1.1 Hydraulic Unit Fault

Faults which occur on the Hydraulic Unit are shown by the symbol

. Press the info key for details on the cause of the fault. The following information is displayed:

 Description of the error  Location of the error (sensor or contact)  Reset. Depending on its type, the fault can be

manually or automatically deleted:

No.: Designation of error

10: Outdoor sensor X86 No No Yes 33: Flow sensor HP X70 No No Yes 44: Return sensor HP X70 No No Yes 50: DHW sensor 1 X84 No No Yes 60: Room sensor 1 No No Yes 65: Room sensor 2 No No Yes 105: Maintenance message No No Yes 121: Flow temp HC1 (too low) No No Yes 122: Flow temp HC2 (too low) No No Yes 127: Legionella temp No No Yes

369: External fault (safety component)

370: Thermodynamic source* No No No

No connection

* A fault in the outdoor unit is indicated by LED located on the Hydraulic Unit interface board.

LED display

LED 2 (green) LED 1(red) 1 Flash 1 Flash Communication error between Hydraulic Unit and Outdoor unit. 4 Flashes 1 Flash Heat pump capacity signal error (Open or short). 4 Flashes 2 Flashes Hydraulic Unit heat-exchange thermistor Error. 6 Flashes 3 Flashes Inverter error. 6 Flashes 4 Flashes Active filter error. 7 Flashes 1 Flash Discharge thermistor error. 7 Flashes 2 Flashes Compressor thermistor error. 7 Flashes 3 Flashes Heat-exchange thermistor (outlet) error.

7 Flashes 4 Flashes Outdoor thermistor error. 7 Flashes 7 Flashes Heat sink thermistor error. 7 Flashes 8 Flashes Expansion valve thermistor error. 8 Flashes 4 Flashes Current sensor error. 8 Flashes 6 Flashes Pressure sensor error. 9 Flashes 4 Flashes Current trip. 9 Flashes 5 Flashes Detection of compressor position error.

9 Flashes 7 Flashes Outdoor unit fan motor error. 10 Flashes 1 Flash Discharge temperature protection. 10 Flashes 3 Flashes Compressor temperature protection. 10 Flashes 5 Flashes Low pressure abnormal. Continuous flashing (1 sec ON / 1 sec OFF) Pump down operation.

Fault description

Heat-exchange thermistor (intermediate) error.

Compressor start up error.

 Manual delete: the text displayed when pressing

the info key shows "reset ?". Press OK once, the yes flashes; press again to confirm deletion of the fault.

 Faults whose deletion is automatic are

automatically reset.

 Heat pump op: shows whether or not the heat pump

operates despite the fault.

Location

(connection)

Reset

Manual Auto

the polarity of the room sensor is not respected.

- - No

HP op

6 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Faults external to the heat pump

Any safety device (e.g. thermostat pressure switch) wired to input Ex3 (E20) allows external problems to be reported and the heat pump to be immediately

stopped. For example, a safety thermostat on the heating floor can be wired to input Ex3 (E20) to avoid excessively high temperatures in the floor.

Figure 1: Typical Wiring of External Devices

Maintenance Document 1544-1 7

Split system (Single phase and 3-phase type)

2.1.2 Outdoor Unit Fault

When the system is switched back on after a power outage, the Hydraulic Unit may display fault 370 for a few tens of seconds. This is not a serious problem. It simply means that the outdoor unit is running its tests. Once the tests have been completed, the fault should disappear.

On the outdoor unit

When an error occurs:

- The diode “ERROR” (2) blinks

Press once on the switch “ENTER” (SW4)

- The “ERROR” (2) diode blinks several times depending on the error’s type

If it doesn't, if a fault has occurred on the outdoor unit as indicated by the Hydraulic Unit, you must remove the front (right-hand) facing from the outdoor unit. Faults are coded by LED flashes. Error messages are listed in the table below:

LED display on the outdoor unit (single phase and 3-phase)

LED display

Hydraulic Unit

Green Red

1 flash 1 flash

4 flashes 1 flash 22 flashes Heat pump capacity signal error 4 4 flashes 2 flashes 22 flashes Hydraulic Unit Heat ex. Sensor error 5 6 flashes 3 flashes 18 flashes Inverter error. 20

6 flashes 4 flashes 19 flashes

7 flashes 1 flash 2 flashes Discharge thermistor error. 7 7 flashes 2 flashes 8 flashes Compressor thermistor error. 11

7 flashes 3 flashes

7 flashes 4 flashes 7 flashes Outdoor temperature thermistor error. 9 7 flashes 7 flashes 9 flashes Heat sink thermistor error. 10 7 flashes 8 flashes 6 flashes Expansion valve thermistor error. 14 8 flashes 6 flashes 3 flashes Pressure sensor error. 24 9 flashes 4 flashes 13 flashes Current trip (permanent stoppage). 15

9 flashes 5 flashes

9 flashes 7 flashes

10 flashes 1 flash 11 flashes Discharge temperature protection (permanent stoppage). 22 10 flashes 3 flashes 12 flashes Compressor temperature protection (permanent stoppage). 25 10 flashes 5 flashes 20 flashes Low pressure abnormal. 26

Continuous flashing Pump down operation.

Continuous

lighting

Off

Outdoor unit

Off Serial reverse transfer error. 1 1 flash Serial forward transfer error. 2

5 flashes Heat-exchange thermistor (intermediate) error. 12 4 flashes Heat-exchange thermistor (outlet) error. 8

14 flashes Detection of compressor position error (permanent stoppage). 33 15 flashes Compressor start up error (permanent stoppage). 17

16 flashes Outdoor unit fan 1 motor error. 17 flashes Outdoor unit fan 2 motor error.

Diagnosis Clear

Active filter error (single phase) 21 P.F.C. error (3-phase) 27

Defrosting.

8 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

2.2 Outdoor Unit Clearing

This section describes the techniques which can be used to identify the failure.

2.2.1 Failures with Error Code

Clear 1: Serial reverse transfer error

Hydraulic Unit LED: Outdoor Unit LED: Off

Probable causes:

 Misconnection.  External cause.  Main PCB failure.

Check:

1-1. Stop the system and start it again (disconnection time 1min):

Is the error still displayed?

2. Check the connections:

- Check the connection between the hydraulic unit and the outdoor unit.

- Check the connections between the outdoor unit main board and the active filter board.

3. Check the power supply voltage:

- Check that an AC 198 – 264 V voltage exists between terminals N and L on the outdoor unit terminal block.

4. Check the serial signal:

- Check the voltage between terminals 2 and 3 of the outdoor terminal block. The voltage must fluctuate between AC 70 V and AC 130 V.

- If it doesn't, replace Main PCB.

Green 1 flash / Red 1 flash

YES NO

1-2. Check for external causes:

- Check the system's overall isolation.

- Check for any equipment generating electromagnetic waves which interfere with the communication between the hydraulic unit and the outdoor unit.

Maintenance Document 1544-1 9

Split system (Single phase and 3-phase type)

Clear 2: Serial forward transfer error

Hydraulic Unit LED: Outdoor Unit LED: 1 flash

Probable causes:

 Misconnection.  External cause.  Interface PCB failure.

Check:

Green 1 flash / Red 1 flash

1-1. Stop the system and start it again (disconnection time 1min):

Is the error still displayed?

YES NO

2. Check the connections:

- Check the connection between the hydraulic unit and the outdoor unit.

- Check the connections between the outdoor unit main board and the active filter board.

3. Check the power supply voltage:

- Check that an AC 198 – 264 V voltage exists between terminals N and L on the outdoor unit terminal block.

4. Check the serial signal:

- Check the voltage between terminals 2 and 3 of the outdoor terminal block. The voltage must fluctuate between AC 70 V and AC 130 V.

- If it doesn't, replace Interface PCB.

1-2. Check for external causes:

- Check the system's overall isolation.

- Check for any equipment generating electromagnetic waves which interfere with the communication between the hydraulic unit and the outdoor unit.

10 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 4: Heat pump capacity signal error

Hydraulic Unit LED: Outdoor Unit LED: 22 flashes

Probable causes:

 Misconnection.  Sensor failure.  Interface PCB failure.

Check:

Green 4 flashes / Red 1 flash

1. Check connection interface PCB and Heat pump regulator PCB:

- See if the connector has been disconnected.

- See if the connection is correct.

- Check for any damage on the sensor cable.

After solving the misconnection problem, switch the heat pump back on.

2. Check resistance value:

3 pin of CN22 – M < 10Ω

3. Replace interface PCB:

If check point 1 and 2 do not improve the symptom, replace Interface PCB.

Maintenance Document 1544-1 11

Split system (Single phase and 3-phase type)

Clear 5: Hydraulic Unit Heat exchanger thermistor error

Hydraulic Unit LED: Outdoor Unit LED: 22 flashes

Probable causes:

 Misconnection.  Sensor failure.  Interface PCB failure.

Check:

Green 4 flashes / Red 2 flashes

1. Check the sensor connection:

- See if the connector has been removed

- See if the connection is correct

- Check for any damage on the sensor cable.

After solving the misconnection problem, switch the heat pump back on.

2. Remove the sensor and check its resistance value :

- Check the resistance value. Temperature (°C)

Resistance (k)

- If the thermistor is faulty, replace it.

0 5 10 15 20 25 30 35 40 45 50 176 134 103 80,3 62,9 49,7 39,6 31,7 25,6 20,8 17,1

3. Check the electronic board voltage:

- Make sure circuit diagram of hydraulic unit and check terminal voltage at thermistor

(DC5.0V)

Gray

Black

Gray

- If there is no voltage, replace Interface PCB.

12 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 7: Discharge thermistor error

Hydraulic Unit LED:

Green 7 flashes / Red 1 flash

Outdoor Unit LED: 2 flashes

Probable causes:

 Misconnection.  Sensor failure.  Main PCB failure.

Check:

1. Check the sensor connection:

- See if the connector has been disconnected.

- See if the connection is correct.

- Check for any damage on the sensor cable.

After solving the misconnection problem, switch the heat pump back on.

2. Remove the sensor and check its resistance value:

- Check the resistance value Temperature (°C) 0 5 10 15 20 30 40 50 Resistance (kΩ) 168 130 101 79 63 40 26,3 17,8

Temperature (°C) 60 70 80 90 100 120 Resistance (kΩ) 12,3 8,7 6,3 4,6 3,4 2

- If the thermistor is faulty, replace it.

3. Check the electronic board voltage:

Make sure circuit diagram of outdoor unit and check terminal voltage at thermistor (DC5.0V)

THERMISTOR (COMPRESSOR)

THERMISTOR (OUTDOOR)

THERMISTOR (PIPE)

THERMISTOR (DISCHARGE)

THERMISTOR (HEAT SINK)

THERMISTOR (PIPE MID)

THERMISTOR (EXPANSION)

- If there is no voltage, replace Main PCB.

Maintenance Document 1544-1 13

Split system (Single phase and 3-phase type)

Clear 8: Heat-exchange thermistor (outlet) error :

Hydraulic Unit LED:

Green 7 flashes / Red 3 flashes

Outdoor Unit LED: 4 flashes

Probable causes:

 Misconnection.  Sensor fault.  Main PCB failure.

Check:

1. Check the sensor connection:

After solving the misconnection problem, switch the heat pump back on.

- See if the connector has been disconnected.

- See if the connection is correct.

- Check for any damage on the sensor cable.

2. Remove the sensor and check its resistance value :

- Check the resistancer value Temperature (°C) -10 -5 0 10 15 20 25 30 Resistance (kΩ) 27,5 20,9 16,1 12,4 9,73 7,67 6,1 3,95

- If the thermistor is faulty, replace it.

3. Check the electronic board voltage:

- Make sure circuit diagram of outdoor unit and check terminal voltage at thermistor

(DC5.0V)

THERMISTOR (COMPRESSOR)

THERMISTOR (OUTDOOR)

THERMISTOR (PIPE)

THERMISTOR (DISCHARGE)

THERMISTOR (HEAT SINK)

THERMISTOR (PIPE MID)

THERMISTOR (EXPANSION)

- If there is no voltage, replace Main PCB.

14 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 9: Outdoor temperature thermistor error

Hydraulic Unit LED:

Green 7 flashes / Red 4 flashes

Outdoor Unit LED: 7 flashes

Probable causes:

 Misconnection.  Sensor failure.  Main PCB failure.

Check:

1. Check the sensor connection :

- See if the connector has been disconnected.

- See if the connection is correct.

- Check for any damage on the sensor cable.

After solving the misconnection problem, switch the heat pump back on.

2. Remove the sensor and check its resistance value :

- Check the resistance value. Temperature (°C) -20 -10 -5 0 5 10 15 20 30 40 50 60 70 Resistance (kΩ) 115 62,3 46,6 35,2 26,9 20,7 16,1 12,6 7,97 5,18 3,45 2,36 1,65

- If the thermistor is faulty, replace it.

3. Check the electronic board voltage:

- Make sure circuit diagram of outdoor unit and check terminal voltage at thermistor (DC5.0V)

THERMISTOR (COMPRESSOR)

THERMISTOR (OUTDOOR)

THERMISTOR (PIPE)

THERMISTOR (DISCHARGE)

THERMISTOR (HEAT SINK)

THERMISTOR (PIPE MID)

THERMISTOR (EXPANSION)

- If there is no voltage, replace Main PCB.

Maintenance Document 1544-1 15

Split system (Single phase and 3-phase type)

Clear 10: Heat Sink Thermistor error

Hydraulic Unit LED:

Green 7 flashes / Red 7 flashes

Outdoor Unit LED: 9 flashes

Probable causes:

 Misconnection.  Sensor failure.  Main PCB failure.

Check:

1. Check the sensor connection :

- See if the connector has been disconnected.

- See if the connection is correct.

- Check for any damage on the sensor cable.

After solving the misconnection problem, switch the heat pump back on.

2. Remove the sensor and check its resistance value :

- Check the resistance value.

Temperature (°C) 0 5 10 15 20 30 40 50 Resistance (kΩ) 15,8 12,2 9,5 7,5 5,9 3,78 2,50 1,69

Temperature (°C) 60 70 80 90 100 120 Resistance (kΩ) 1,17 0,83 0,6 0,44 0,33 0,19

- If the thermistor is faulty, replace it.

3. Check the electronic board voltage:

- Make sure circuit diagram of outdoor unit and check terminal voltage at thermistor (DC5.0V)

THERMISTOR (COMPRESSOR)

THERMISTOR (OUTDOOR)

THERMISTOR (PIPE)

THERMISTOR (DISCHARGE)

THERMISTOR (HEAT SINK)

THERMISTOR (PIPE MID)

THERMISTOR (EXPANSION)

- If there is no voltage, replace Main PCB.

16 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 11: Compressor thermistor error

Hydraulic Unit LED:

Green 7 flashes / Red 2 flashes

Outdoor Unit LED: 8 flashes

Probable causes:

 Misconnection.  Sensor failure.  Main PCB failure.

Check:

1. Check the sensor connection:

- See if the connector has been removed

- See if the connection is correct

- Check for any damage on the sensor cable.

After solving the misconnection problem, switch the heat pump back on.

2. Remove the sensor and check its resistance value :

- Check the resistance value. Temperature (°C) 0 5 10 15 20 30 40 50 Resistance (kΩ) 168 130 101 79 63 40 26,3 17,8

Temperature (°C) 60 70 80 90 100 120 Resistance (kΩ) 12,3 8,7 6,3 4,6 3,4 2

- If the thermistor is faulty, replace it.

3. Check the electronic board voltage:

- Make sure circuit diagram of outdoor unit and check terminal voltage at thermistor (DC5.0V)

THERMISTOR (COMPRESSOR)

THERMISTOR (OUTDOOR)

THERMISTOR (PIPE)

THERMISTOR (DISCHARGE)

THERMISTOR (HEAT SINK)

THERMISTOR (PIPE MID)

THERMISTOR (EXPANSION)

- If there is no voltage, replace Main PCB.

Maintenance Document 1544-1 17

Split system (Single phase and 3-phase type)

Clear 12: Heat-exchange thermistor (intermediate) error

Hydraulic Unit LED:

Green 7 flashes / Red 3 flashes

Outdoor Unit LED: 5 flashes

Probable causes:

 Misconnection.  Sensor failure.  Main PCB failure.

Check:

1. Check the sensor connection:

After solving the misconnection problem, switch the heat pump back on.

- See if the connector has been disconnected.

- See if the connection is correct.

- Check for any damage on the sensor cable.

2. Remove the sensor and check its resistance value :

- Check the resistance value Temperature (°C) -10 -5 0 10 15 20 25 30 Resistance (kΩ) 27,5 20,9 16,1 12,4 9,73 7,67 6,10 3,95

- If the thermistor is faulty, replace it.

3. Check the electronic board voltage:

- Make sure circuit diagram of outdoor unit and check terminal voltage at thermistor (DC5.0V)

THERMISTOR (COMPRESSOR)

THERMISTOR (OUTDOOR)

THERMISTOR (PIPE)

THERMISTOR (DISCHARGE)

THERMISTOR (HEAT SINK)

THERMISTOR (PIPE MID)

THERMISTOR (EXPANSION)

- If there is no voltage, replace Main PCB.

18 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 14: Expansion valve thermistor error

Hydraulic Unit LED:

Green 7 flashes / Red 8 flashes

Outdoor Unit LED: 6 flashes

Probable causes:

 Misconnection.  Sensor failure.  Main PCB failure.

Check:

1. Check the sensor connection:

- See if the connector has been removed

- See if the connection is correct

- Check for any damage on the sensor cable.

After solving the misconnection problem, switch the heat pump back on.

2. Remove the sensor and check its resistance value :

- Check the resistance value. Temperature (°C) 0 5 10 15 20 30 40 50 Resistance (kΩ) 168 130 101 79 63 40 26,3 17,8

Temperature (°C) 60 70 80 90 100 120 Resistance (kΩ) 12,3 8,7 6,3 4,6 3,4 2

- If the thermistor is faulty, replace it.

3. Check the electronic board voltage:

- Make sure circuit diagram of outdoor unit and check terminal voltage at thermistor (DC5.0V)

THERMISTOR (COMPRESSOR)

THERMISTOR (OUTDOOR)

THERMISTOR (PIPE)

THERMISTOR (DISCHARGE)

THERMISTOR (HEAT SINK)

THERMISTOR (PIPE MID)

THERMISTOR (EXPANSION)

- If there is no voltage, replace Main PCB.

Maintenance Document 1544-1 19

Split system (Single phase and 3-phase type)

Clear 15: Current trip (permanent stoppage)

Hydraulic Unit LED: Outdoor Unit LED: 13 flashes

Probable causes:

 Connection failure.

 Outdoor Heat Exchanger clogged.

 Outdoor Fan operation failure.

 Compressor failure.

 Main PCB failure.

Check:

Green 9 flashes / Red 4 flashes

1. Check connections condition in control unit:

- Check if the terminal connection is loose.

- Check if connector is removed.

- Check if connector is erroneous connection.

- Check if cable is open.

on correcting the removed connector or mis-wiring, reset the power.

2. Check Outdoor Heat Exchanger:

- Is there any obstructing the air flow route?

- Is there any clogging of outdoor unit Heat Exchanger?

If clogged, clear the clog.

3. Check Outdoor Fan:

- Check Outdoor Fan Motor. (Refer to Clear 18)

If the Fan Motor is failure, replace it.

4. Check Compressor:

Refer to “Service parts information 2 : Inverter compressor If it is abnormal, replace compressor.

5. Replace Inverter PCB:

If Check Point 1 ~ 4 do not improve the symptom, replace Inverter PCB.

20 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 17: Compressor startup error (permanent stoppage)

Hydraulic Unit LED: Outdoor Unit LED: 15 flashes

Probable causes:

 Misconnection of the various electrical components.  Main PCB failure.  Compressor failure.

Check:

Green 9 flashes / Red 5 flashes

1. Check connections condition in control unit:

- Check if the terminal connection is loose.

- Check if connector is removed.

- Check if connector is erroneous connection.

- Check if cable is open.

Upon correcting the removed connector or mis-wiring, reset the power.

2. Check Compressor:

Refer to “Service parts information 2 : Inverter compressor If it is abnormal, replace compressor.

3. Replace the electronic board :

- If steps 1 and 2 do not solve the problem, replace Inverter PCB.

Maintenance Document 1544-1 21

Split system (Single phase and 3-phase type)

Clear 18: Fan motor error (permanent stoppage)

Hydraulic Unit LED: Outdoor Unit LED: 16 flashes (fan 1), 17 flashes (fan 2)

Probable causes:

 Fan motor failure.  Motor protection.  Main PCB failure.

Check:

Green 9 flashes / Red 7 flashes

1. Check fan rotation:

- Switch off the heat pump and rotate the fan manually.

- If the fan or bearings are faulty, replace them.

2. Check the ambient temperature around the motor:

- Check excessively high temperature around the fan.

Wait until the temperature comes down again and switch the fan back on.

3. Check the main board output voltage:

- On the outdoor unit, check the output voltage (DC) of the following connectors:

Terminals Voltage

1 (red)/ 3 (black) 300 390V

4 (white)/3 (black) 15 ±2V

FAN MOTOR 1

(UPPER) FAN MOTOR 2

(LOWER)

CN802 CN803

If the voltage is incorrect, replace Main PCB.

22 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 20: Inverter error

Hydraulic Unit LED: Outdoor Unit LED: 18 flashes

Probable causes:

 Connection failure.

 Main PCB failure.

Check:

Green 6 flashes / Red 3 flashes

1. Check connections in control unit:

- Check if the terminal connection is loose.

- Check if connector is removed.

- Check if connector is erroneous connection.

- Check if cable is open.

Upon correcting the removed connector or mis-wiring, reset the power.

2. Replace Main PCB :

If Check Point 1 does not improve the symptom, replace Main PCB.

Maintenance Document 1544-1 23

Split system (Single phase and 3-phase type)

Clear 21: active filter error (only for single phase type)

Hydraulic Unit LED: Outdoor Unit LED: 19 flashes

Probable causes:

 Connection failure.  Active filter module failure.  Main PCB failure.

Check:

Green 6 flashes / Red 4 flashes

1. Check connections in control unit:

- Check if the terminal connection is loose.

- Check if connector is removed.

- Check if connector is erroneous connection.

- Check if cable is open.

Upon correcting the removed connector or mis-wiring, reset the power.

2. Replace Active Filter Module and Main PCB :

If Check Point 1 does not improve the symptom, replace Main PCB and Active Filter Module and execute the checkoperation again.

24 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 22: Discharge temperature protection (permanent stoppage) Hydraulic Unit LED: Outdoor Unit LED: 11 flashes Probable causes:

 Valve is close.

 EEV failure.

 Gas leak, less.

 Discharge Thermistor failure.

 Outdoor Fan operation failure.

 Outdoor Heat Exchanger clogged.

Check:

Green 10 flashes / Red 1 flashes

Cooling mode

1. Check if gas valve is open:

If it is not open, open it and check the operation.

2. Check EEV and Strainer:

Are EEV and Strainer open?

If EEV or Strainer is defective, replace it.

Heating mode

1. Check if liquid valve is open:

If it is not open, open it and check the operation.

2. Check EEV and Strainer:

Are EEV and Strainer open?

If EEV or Strainer is defective, replace it.

OK OK

3. Check if gas leak or less gas:

Measure gas pressure, if there is a leak, correct it.

If recharging refrigerant, make sure to perform vacuuming and recharge the specified amount.

4. Check Discharge Pipe Thermistor:

- Is it on the holder?

- Is there a cable pinched?

Check characteristics of thermistor (Refer to Clear 7), If defective, replace the thermistor

5. Check Outdoor Heat Exchanger:

- Is there any obstructing the air flow route?

- Is there any clogging of outdoor unit Heat Exchanger?

If clogged, clear the clog.

6. Check Outdoor Fan:

Check Outdoor Fan Motor. (Refer to Clear 18)

Maintenance Document 1544-1 25

Split system (Single phase and 3-phase type)

Clear 24: Pressure sensor error

Hydraulic Unit LED: Outdoor Unit LED: 3 flashes

Probable causes:

 Connector connection failure.

 Pressure Sensor failure.

 Main PCB failure.

Check:

Green 8 flashes / Red 6 flashes

1. Check connection of the Pressure Sensor:

- Check if the terminal connection is loose.

- Check if connector is removed.

- Check if connector is erroneous connection.

- Check if cable is open.

Upon correcting the removed connector or mis-wiring, reset the power.

2. Check output voltage of Main PCB :

Check voltage of Main PCB (Measure at Main PCB side connector)

1 pin(Red) - 3 pin(Black) DC5V +/- 5%

PRESSURE SENSOR

If the voltage is not correct, replace Main PCB.

3. Check output voltage of Pressure Sensor

Check voltage of Main PCB (Measure at Main PCB side connector)

2 pin(White) - 3 pIn(Black) Voltage is refer to the following graph.

Voltage [V]

Pressure [MPa]

If the voltage is not correct, replace Presure Sensor.

26 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 25: Compressor temperature protection (permanent stoppage) Hydraulic Unit LED: Outdoor Unit LED: 12 flashes Probable causes:

 Valve is close.

 EEV failure.

 Gas leak, less.

 Compressor Thermistor failure.

 Outdoor Fan operation failure.

 Outdoor Heat Exchanger clogged.

Check:

Green 10 flashes / Red 3 flashes

Cooling mode

1. Check if gas valve is open:

If it is not open, open it and check the operation.

Heating mode

1. Check if liquid valve is open:

If it is not open, open it and check the operation.

2. Check EEV and Strainer:

Are EEV and Strainer open?

If EEV or Strainer is defective, replace it.

2. Check EEV and Strainer:

Are EEV and Strainer open?

If EEV or Strainer is defective, replace it.

OK OK

3. Check if gas leak or less gas:

Measure gas pressure, if there is a leak, correct it.

If recharging refrigerant, make sure to perform vacuuming and recharge the specified amount.

4. Check compressor temperature Thermistor:

- Is it on the holder?

- Is there a cable pinched?

Check characteristics of thermistor (Refer to Clear 11), If defective, replace the thermistor

5. Check Outdoor Heat Exchanger:

- Is there any obstructing the air flow route?

- Is there any clogging of outdoor unit Heat Exchanger?

If clogged, clear the clog.

6. Check Outdoor Fan:

Check Outdoor Fan Motor. (Refer to Clear 18)

Maintenance Document 1544-1 27

7. Replace Main PCB:

If Check Point 1 ~ 6 do not improve the symptom, replace Main PCB.

Split system (Single phase and 3-phase type)

Clear 26: Low pressure abnormal

Hydraulic Unit LED: Outdoor Unit LED: 20 flashes

Probable causes:

 Connector connection failure.

 Pressure Sensor failure.

 Main PCB failure.

 Gas leak, less.

Check:

Green 10 flashes / Red 5 flashes

1. Check connection of the Pressure Sensor:

- Check if the terminal connection is loose.

- Check if connector is removed.

- Check if connector is erroneous connection.

- Check if cable is open.

Upon correcting the removed connector or mis-wiring, reset the power.

2. Check output voltage of Main PCB :

Check voltage of Main PCB (Measure at Main PCB side connector)

1 pin(Red) - 3 pin(Black) DC5V +/- 5%

PRESSURE SENSOR

If the voltage is not correct, replace Main PCB.

3. Check if gas leak or less gas

Measure Gas pressure, if there is a leak, correct it.

If recharging refrigerant, make sure to perform vacuuming and recharge the specified amount.

4. Replace Pressure Sensor

If Check Point 1 ~ 3 do not improve the symptom, replace Pressure Sensor.

28 Maintenance Document 1544-1

Split system (Single phase and 3-phase type)

Clear 27: P.F.C. error (only for 3-phase type)

Hydraulic Unit LED: Outdoor Unit LED: 19 flashes

Probable causes:

 Connector connection failure.

 Main PCB failure.

 PFC PCB failure.

Check:

Green 6 flashes / Red 4 flashes

1. Check connections of between Main PCB and PFC PCB:

- Check if the terminal connection is loose.

- Check if connector is removed.

- Check if connector is erroneous connection.

- Check if cable is open.

Upon correcting the removed connector or mis-wiring, reset the power.

2. Check output voltage of Main PCB :

Check voltage of Main PCB (Measure at Main PCB side connector)

1 pin(brown) - 2 pin(Red) DC5V +/- 5%

If the voltage is not correct, replace Main PCB.

3. Replace PFC PCB

If Check Point 1, 2 do not improve the symptom, replace PFC PCB.

Maintenance Document 1544-1 29

Split system (Single phase and 3-phase type)

Clear 33: Detection of compressor position error (permanent stoppage)

Hydraulic Unit LED: Outdoor Unit LED: 14 flashes

Probable causes:

 Misconnection.  Main PCB failure.

Check:

Green 9 flashes / Red 5 flashes

1. Check connections condition in control unit:

- Check if the terminal connection is loose.

- Check if connector is removed.

- Check if connector is erroneous connection.

- Check if cable is open.

Upon correcting the removed connector or mis-wiring, reset the power.

2. Replace the electronic board :

- If steps 1 does not solve the problem, replace Main PCB.

30 Maintenance Document 1544-1

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Fujitsu G140DC6, G140LCT, K160DC9, K160LCT, K112LCT Maintenance Document

Specifications and Main Features

Frequently Asked Questions

User Manual