Heat controller inc troubleshooting

Heat Controller, Inc.

HBH SERIES

IOM Manual

42

Functional Troubleshooting

Fault

Htg Clg Possible Cause

Solution

Main power Problems

X

X

Green Status LED Off

Check Line Voltage circuit breaker and disconnect
Check for line voltage between L1 and L2 on the contactor
Check for 24VAC between R and C on CXM/DXM
Check primary/secondary voltage on transformer

HP Fault-Code 2

X

Reduced or no water flow

Check pump operation or valve operation/setting

High pressure

in cooling

Check water flow adjust to proper flow rate

X

Water Temperature out of range in
cooling

Bring water temp within design parameters

X

Reduced or no Air flow

Check for dirty air filter and clean or replace

in heating

Check fan motor operation and airflow restrictions
Dirty Air Coil- construction dust etc.
Too high of external static. Check static vs blower table

X

Air Temperature out of range in
heating

Bring return air temp within design parameters

X

X

Overcharged with refrigerant

Check superheat/subcooling vs typical operating condition
table

X

X

Bad HP Switch

Check switch continuity and operation. Replace

LP/LOC Fault-Code 3

X

X

Insufficient charge

Check for refrigerant leaks

Low Pressure/Loss of Charge

X

Compressor pump down at start-
up

Check charge and start-up water flow

FP1 Fault - Code 4

X

Reduced or no water flow

Check pump operation or water valve operation/setting

Water Coil low

temperature limit

in heating

Plugged strainer or filter. Clean or replace.
Check water flow adjust to proper flow rate

X

Inadequate anti-freeze level

Check antifreeze density with hydrometer

X

Improper temperature limit setting
(30°F vs 10°F [-1°C vs -12°C])

Clip JW3 jumper for antifreeze (10°F [-12°C]) use

X

Water Temperature out of range

Bring water temp within design parameters

X

X

Bad thermistor

Check temp and impedance correlation per chart

FP2 fault - Code 5

X

Reduced or no Air flow

Check for dirty air filter and clean or replace

Air Coil low

temperature limit

in cooling

Check fan motor operation and airflow restrictions
Too high of external static. Check static vs blower table

X

Air Temperature out of range

Too much cold vent air? Bring entering air temp within
design parameters

X

Improper temperature limit setting
(30°F vs 10°F [-1°C vs -12°C])

Normal airside applications will require 30°F [-1°C] only

X

X

Bad thermistor

Check temp and impedance correlation per chart

Condensate Fault-Code 6

X

X

Blocked Drain

Check for blockage and clean drain

X

X

Improper trap

Check trap dimensions and location ahead of vent

X

Poor Drainage

Check for piping slope away from unit
Check slope of unit toward outlet
Poor venting. Check vent location

X

Moisture on sensor

Check for moisture shorting to air coil

Over/Under Voltage-
Code 7

X

X

Under Voltage

Check power supply and 24VAC voltage before and during
operation.

(Auto resetting)

Check power supply wire size
Check compressor starting. Need hard start kit?
Check 24VAC and unit transformer tap for correct power
supply voltage

X

X

Over Voltage

Check power supply voltage and 24VAC before and during
operation.
Check 24VAC and unit transformer tap for correct power
supply voltage

Unit Performance
Sentinel-Code 8

X

Heating mode FP2>125°F [52°C] Check for poor air flow or overcharged unit.

X

Cooling Mode FP1>125°F [52°C]

OR FP2< 40ϒF [4ϒC]

Check for poor water flow, or air flow

No Fault Code Shown

X

X No compressor operation

See "Only fan operates"

X

X Compressor Overload

Check and Replace if necessary

X

X Control board

Reset power and check operation

Unit Short Cycles

X

X Dirty Air Filter

Check and Clean air filter

X

X Unit in "Test Mode"

Reset power or wait 20 minutes for auto exit.

X

X Unit selection

Unit may be oversized for space. Check sizing for actual

load of space.

X

X Compressor Overload

Check and Replace if necessary

Only Fan Runs

X

X Thermostat position

Insure thermostat set for heating or cooling operation

X

X Unit locked out

Check for lockout codes. Reset power.

X

X Compressor Overload

Check compressor overload. Replace if necessary.

X

X Thermostat wiring

Check thermostat wiring at heat pump. Jumper Y and R

for compressor operation in test mode.

Plugged Air Filter

Restricted Return Air Flow

X

X

X

X

Replace Air Filter

Find & eliminate restriction. Increase return duct
and/or grille size.

The most common cause of a mini split failure is improper installation. Whether you are experiencing an issue with your unit or just trying to learn how to do it right the first time around, this guide will take you through the most common problem with a mini split.

Communication Issues

Using the proper mini split communication wire is critical to a properly functioning unit. While some manuals may only call for 18 gauge wire it is always recommended to use 14 gauge 4 conductor wire (14/4) for most systems. Most local codes require 14 gauge wire, so using something smaller will not pass inspection in many areas. The wire should be stranded, not solid core. Solid core wire has been known to cause more issues. Make sure the wire you select is rated for indoor and outdoor use. If you are installing a unit in a commercial application, an armored cable is usually required. As with anything, check your local electrical codes and consult an electrician to ensure proper installation.

Improper wiring can lead to the following common problems:

• Poor Signal. Symptoms of poor signal include:
  • Inconsistent operation
  • Unit working in some modes, but not others
  • Outdoor unit powers up but indoor unit does not
  • Indoor unit has power, but will not operate
• Damaged or destroyed boards or compressor
  • Improper wiring can cause other system components to fail and require replacement.
• Odd or loud noises
• Communication error codes being displayed
  • Error codes may be visible on the indoor unit or outdoor board
  • Look for a series of lights blinking or a special code displayed

Grounding Issues

Grounding is important for any device that contains electronics. An air conditioner is no different. The control boards used in a modern mini split system are very much a miniature computer. These boards are susceptible to power surges, stray electrical energy, and RF (radio frequencies). Grounding the outdoor unit helps prevent some of the stray energy from getting into the board.

If your condenser is not grounded properly, you may experience some issues, such as improper operation. Worst case, you can have board and/or compressor failure. Improper grounding can cause the same problems as no ground.

When wiring your system, make sure the connections are correct. Most systems will have a terminal block with L1, L2 and C. L1 and L2 are your hot lines. C is your common or ground. You can add a fourth wire to add an additional ground, which never hurts. Grounding the chassis of the condenser to a ground rod also adds an extra level of protection. If you use a grounding rod, check it on occasion for deterization.

If you are unsure about grounding, consult with an electrician.

Refrigerant Issues

All modern mini split systems use R-410A. This refrigerant is much more environmentally friendly than the older R-22. It operates at a much higher pressure than other refrigerants and requires special care to ensure a properly functioning system. Make sure that you are using the right gauges for R-410A.

Most systems come precharged with some refrigerant, but depending on the length of your line set, more might need to be added. The installation manual for your unit will specify the weight of refrigerant needed per foot of line set. Always follow these guidelines exactly. An improper amount of refrigerant can lead to many issues, including:

• Too little of a charge
  • System may not run at all and may show an error code
  • The system may produce loud noises
  • It might not be able to maintain the temperature in the space
  • It might not properly dehumidify
  • It might only function in cooling mode but not in heating mode
• Too much of a charge
  • System may not turn on
  • Loud noises can be heard from the unit.
  • Unit may not be able to hold the temperature or may overshoot the setpoint

The use of a proper line set is also critical to system performance. Each mini split system will specify the proper size line set it needs including the size of the pipes, the minimum and maximum length, and the maximum height difference between the indoor and outdoor unit. Trying to reuse an old line set that is not correct for your system will result in failure.

Line sets must be insulated. Unlike a central system, both lines require insulation. At least ½” insulation must be used to ensure proper performance. Make sure the entire line is insulated all the way up to the flair connections. No bare copper should be visible.

Always make sure to completely vacuum the lines before introducing any refrigerant into the system. Any contaminants in the lines could lead to severe damage to internal components or the system not working at all. It’s also important to pressure test the system. This will make sure that there are no leaks.

Live Voltage Issues

The vast majority of mini split units require 208/230 volt service, but there are some that will work with 115 volts. Always make sure that your system is connected to the proper voltage. Even if the system is correctly wired to the proper voltage, issues can still occur depending on your electric service. If too high or too low of a voltage is delivered to the unit, damage to the boards can occur. Check the voltage at the unit before starting up the system and make sure it is within the approved range that the manufacturer states. If your voltage is too high, too low, or often fluctuates you should use a surge protector to make sure your system components are protected.

Water Leaking at the Indoor Unit

If you discover water leaking from the evaporator of your mini split there are several areas to check to determine the cause of the problem.

If you have a wall mounted indoor unit, the drain line must be pitched down at least 5 degrees when leaving the unit and going outside. Otherwise, the water can drip back into the room. If the the drain line is properly pitched, then the next step is to check for clogs in the line. You can use a gallo gun to clear any obstructions in the drain line.

A condensate pump can be used in installations where you are not able to drain with gravity. If you have a condensate pump and are experiencing leaking, check to make sure the condensate pump is properly wired and functioning. Make sure that the pump is installed properly and is not pumping higher than its rated height.

Environmental Issues

The temperature outside can impact a mini splits performance. If you have a heat pump unit and are trying to use it in cold weather, there are a few steps you can take to make it perform better.

If your unit has an optional drain pan heater, adding this can increase the temperature range in which the unit will operate. A wind baffle can also provide some help. Make sure that if you are in a location that gets snow your unit is installed on a stand or wall mount that is above the snow. You should also remove any snow from the top of the unit before operating. Overly windy areas can also negatively impact the unit.

If you are trying to use cooling at low temperatures for server room or other environments that call for cooling all year long, make sure you purchase a unit that offers low ambient cooling. A wind baffle will expand the range of the unit. Some system are designed with extreme ranges in mind. Make sure you check your units specifications when looking for all year cooling.

Repair or Replace?

If you have just purchased a new unit and are experiencing any of the issues outlined here, call your installer immediately to get them sorted out. If you are having trouble with an older mini split, it may be time for a new one. Replacing boards or compressors on older systems can be expensive and time consuming.

LG and Daikin are the leaders when it comes to reliable, long lasting mini split units. Exceptional build quality and commercial grade components are backed by industry leading warranties. Let our experts help you choose the best new mini split for your application.

2014-07-19

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Heat Controller, Inc.

Troubleshooting Tips

Stop the air conditioner immediately if one of the following errors occurs. Disconnect the power and contact

an authorized servicer.

If any of the following error codes appear on the LED window, disconnect the power and contact

an authorized servicer: E0, E1, E2, E3, E4, E5, E6, E7, E8, P0, P1, P2, P3, P4.

Call for

Fuse blows or circuit breaker trips frequently

service if

Other abnormal situations (such as burning smells) that can't be resolved using the steps outlined

below.

Symptoms

Possible Cause/Things to Check

Is there power supplied to the unit?

Fuse may have blown out or a circuit

Unit does

breaker has been tripped.

no start or

operate at

Batteries in remote controller may be dead

all

or installed incorrectly.

Is the unit's timer set?

Inappropriate temperature setting.

Air filter may be blocked

Poor cooling

or heating

(heat pump

Doors or windows are open.

models only)

performance

Air inlet or outlet of indoor or outdoor unit

are blocked.

Compressor time delay has been activated

If the problem persists after performing these checks, or if you notice burning smells, or the operation

indicator light flashes repeatedly, immediately stop operation, disconnect the power, and call an authorized

service center.

OWNER'S MANUAL

What should be done?

Wait for the power to be restored or call an

electrician to address any power supply problem.

Replace the fuse or flip the circuit breaker.

Replace the batteries and ensure the polarities

are correct.

Wait or cancel timer setting.

Set temperature correctly.

Clean the air filter to prevent air flow blockages.

Close the doors or windows within the area

being cooled/heated to increase efficiency and

performance.

Clear obstructions away, then restart the unit.

Wait approximately 3 minutes for the compressor

to turn on and the unit to begin cooling/heating.

12

VMH Inverter Mini-Split