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MINISPLIT

Trouble Shooting Guide

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Table of Contents
Page

Descriptions

General Truble Shooting.........................................................................3


Electrical Trouble Shooting.....................................................................5
PC Board Trouble Shooting..................................................................15
MiniSplit unit startup Checklist..............................................................19

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1 - General Trouble-shooting Guide


Note : Open the main unit power switch before proceeding with any repair operations.
Symptoms

Remedy

Cause
No heating or cooling

The compressor and outdoor fan Power failure


Fuse blown or circuit breaker open
do not operate
Voltage is too low
Faulty contactor, thermostat or relay
Electrical connections loose
Faulty capacitor (single phase models)
Thermostat adjustment too low (in heating
mode) or too high (in cooling mode)
Incorrect wiring, terminals loose
Pressure switch tripped (depending on mode)

Contact the electrical utility company


Replace the fuse or reset the breaker
Find the cause and fix it
Replace the faulty component
Retighten the connections if necessary
Find the cause, then replace capacitor
Check thermostat setting

The outdoor fans runs but the


compressor will not start

Check the wiring and the compressor winding


resistance
Find the cause, then replace capacitor

Moter windings cut or grounded


Faulty capacitor (single phase models)

Check and retighten


Find the cause, then reset

Insufficient heating or cooling


Low refrigerant charge

Make sure there are no leaks

Remove charge,repair,evacuate and recharge

Insufficient airflow

Check the air filter, the damper positions.


Check that air is not being recycled
Check cleanliness of unit coils
Capillaries obstructed or orifice plugged
(humidity)
Liquid and gas lines insulated together

Clean or replace, set the air damper to the right


position
Clean the coils
Remove charge, repair, evacuate and recharge
Insulate them separately

The Compressor runs too long or continuously


Thermostat adjustment too high (in heating
mode) or too low (in cooling mode)
No fan operation or faulty fan
Refrigerant charge too low, leakage
Heating/cooling load underestimated
Air or incondensables in refrigerant circuit

The compressor runs


continuously

Change the setting


Check condenser air circulation
Find leak, repair and recharge
Reduce load or use next unit size up
Remove charge, evacuate and recharge

Unit short-cycles
The compressor starts but shuts
Too much or too little refrigerant
down quickly on thermal
Air or incondensibles in refrigerant circuit
Faulty compressor
Power supply voltage too high or too low
Faulty condenser (single phase models)
Faulty thermostat
Restriction in the refrigeration circuit
Frostec or plugged expansion device
Poor airflow on indoor or outdoor unit

Remove charge, evacuate and recharge


Remove charge, evacuate and recharge
Detemine the cause and replace compressor
Solve the problem
Detemine the cause and replace
Replace
Find restriction and repair.
Remove charge, evacuate and recharge
Clean the coil and the filter if necessary, check
that motors are operating properly
Check wire guages, etc
Faulty power supply
Changeover valve damaged or blocked open Replace it
(heat pump units)

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Trouble-shooting Guide (Cont'd)


Frosted Indoor coil
Ice build-up indoor coil

Low refrigerant charge, refrigerant leak


Insufficient airflow

Repair the leak and recharge


Check the condition of the air filters
Check the cleanliness of the indoor coil
Check fan motor operation
Check that the air damper opens correctly
(on unit equipped with a damper)
Install a low temperature kit

Low operating temperature limit exceeded

Unit noisy
Faulty installtion

Make sure vibration isolators have been installed. Tighten any loose components
Check piping collars.

Compressor noisy

Make sure that the compressor is not losing oil


Excessive oil or refrigerant charge

Repair and add oil


Repair or replace the thermostat

Electric heat does not work (on indoor units fitted with this option)
Thermostat incorrectly adjusted

Readjust the thermostat


Remove excess charge

Check continuity througn fuse


Safety thermostat opens

Replace faulty elements


Check indoor unit airflow
Check cleanliness of air filter and coil
Open air balancing dampers
If ducts are long, inhibit low, and perhaps even
medium fan speeds
Check that wiring complies with applicable diagrams

Thermostat
Safety device

Faultly unit wiring

Excessive or insufficient discharge pressure


Excessive discharge pressur

Insufficient discharge pressure

Out door coil dirty


Indoor unit fan (heating mode) or outdoor unit fan
(cooling mode) faulty
Excessive refrigerant charge
Air or incondensables in refrigerant circuit

Clean the coil


Replace the fan

Refrigerant charge too low


Liquid line blocked or crushed
Compressor valves worn out or leaking

Find and repair the leak, top up refrigerant charge


Find obstructions and eliminate them.
Replace the compressor

Remove excess charge


Check the circuit, evacuate, and recharge

Excessive or insufficient suction pressure


Excessive suction pressure

Refrigerant overcharge
Remove excess refrigerant
Cycle changeover valve faulty or leaking (heat Replace the valve
pump units)

Insufficient suction pressure

Low refrigreant charge


Outdoor unit coil (heating mode) or indoor unit coil
(cooling mode) frosted
Insufficient airflow on the outdoor unit coil (heating
moed) or the indoor unit coil (cooling mode)
Suction line obstructed
Expansion device obstructed or iced up.
Poor contact the line and the defrost sensor in the
heating mode (heat pump units)
Condenser airflow too high (in the cooling mode)
in relation to outdoor air temperature

Add some refrigerant


Find cause and fix it
Make sure that the indoor or outdoor unit fan is
operating properly
Find obstruction and eliminate
Remove charge, evacuate, recharge
Reinstall the sensor correctly using a contact
compound. Insulate the assembly
Install a low temperature kit

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Electrical Trouble-shooting
1. Check before and after troubleshooting
WARNING
Hazardous voltage can cause ELECTRIC SHOCK or
DEATH. Disconnect power or turn off circuit breaker

before you start checking or servicing.

1.1. Check power supply wiring.


Check that power supply wires are correctly connected to terminals L and N on the terminal plate in
the in door unit.

1-2. Check inter-unit wiring.


Check that inter-unit wiring is correctly connected to the outdoor unit from the indoor unit.

1-3. Check power supply.


Check that voltage is in specified range (10% of the rating).
Check that power is being supplied.
1-4. Check lead wires and connectors in indoor and outdoor units.
Check that coating of lead wires is not damaged.
Check that lead wires and connectors are firmly connected.
Check that wiring is correct.

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2. Air conditioner does not operate.


2-1. Circuit breaker trips (or fuse blows).
A. When the circuit breaker is set to ON, it is tripped soon. (Resetting is not possible.)
There is a possibility of ground fault.
Check insulation resistance.
If resistance value is 2M or less, insulation is defective (NO).

* Set circuit breaker to OFF.

Remove inter-unit wires from

terminal plate in outdoor unit.


Measure insulation resistance
of outdoor unit.

NO

Insulation of
outdoor unit
is defective.
Measure insulation
resistance of electrical
parts in outdoor unit.

Remove inter-unit wires from

terminal plate in outdoor unit.


Then, pull the power plug out of
the wall outlet
Measure insulation resistance
of outdoor unit.

NO

Measure insulation
resistance of electrical
parts in outdoor unit.

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Insulation of
indoor unit
is defective.

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B. Circuit breaker trips in several minutes after turning the air conditioner on.
There is a possibility of short circuit.

Check capacity of circuit breaker.

NO

Capacity of circuit breaker is


suitable.

with suitable
one (larger capacity).
Replace

Measure resistance of outdoor fan


motor winding.

Measure resistance of compressor


motor winding.

2-2. Neither indoor nor outdoor unit runs.


A. Power is not supplied.
breaker
Circuit
Reset breaker.
is tripped.

Check power supply.


Power is being supplied to the
indoor unit.

Power failure

Wait for recovery


or contact power
company.

B. Check " OPERATION selector " switch in the indoor unit.

OPERATION selector switch is set


in ON position.

YES

Indoor PCB Ass'y is defective

NO

Set OPERATION selector switch


to ON.

See diagnostics

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D. Check remote control unit.


Try to run with another remote
control unit.

OK

First remote control unit is defective.

Check for residue buildup on


transmitter of remote control unit.

Check for residue buildup on remote


control receiver on front of indoor
unit.

Clean transmitter.

Clean receiver.

Replace the fuse.

E. Check fuse on the indoor PCB Ass'y.


Check fuse on indoor PCB Ass' y
for continuity.
(F)

If fuse has been blown,

OK

Check operation lamp to see


if light is ON.

OK

Indoor PCB Ass'y is defective.

F. Check TIMER on the remote control unit.


Timer is turned ON. Check to see
if start or stop is displayed on
remote control

YES

Cancel the timer mode.

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2-3. Only outdoor unit does not run.


A. Check setting temperature.

Is room temperature too low ?

NO

Try to lower setting temperature by


temperature setting button ( button).

Outdoor unit still


does not run.

Try to run using another remote


control unit.

OK

Remote control unit is defective.

B. Check power relay in outdoor unit.

Measure coil resistance of power


relay.
(PR)

OK

Check indoor PCB Ass'y.

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3. Some part of air conditioner does not operate.


3-1. Only indoor fan does not run.

Check fan rotation.


Tum fan gently once or twice by
hand.

Fan cannot
be turned.

Check fan casing


foreign matter on
inside.

Fan motor burnout


or foreign matter in
bearings.

foreign
matter or repair.
Remove

Repair or replace.

Measure resistance of indoor fan


motor winding.

OK

Check fan motor capacitor.

3-2. Only indoor fan does not run.

Check fan rotation.


Tum fan gently once or twice by
hand.

Fan cannot
be turned.

Check fan casing


foreign matter on
inside.

Fan motor burnout


or foreign matter in
bearings.

Measure resistance of outdoor fan


motor winding.

OK

Check fan motor capacitor.

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Remove foreign
matter or repair.

Repair or replace.

3-3. Only Compressor does not run.

Overload relay is working.


(Either OLR T or OLR A)

Check compressor motor


capacitor.

YES

Temperature of compressor
is abnormally high.

Measure resistance of
compressor motor winding.

YES

Refrigerant gas shortage.

YES

Charge refrigerant gas (R22).

NO
Messure Power supply
voltage.
The voltage is too low.

NO

Rotor may be locked up.

Measure resistance of power


relay.

3-4. Only flap motor does not run.

Measure resistance of flap motor


winding.

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4. Air conditioner operate, but abnormalities are observed.


4-1. Poor cooling.

Wide and narrow tubes between


indoor unit and outdoor unit are
insulated

NO

Insulate both wide and narrow


tubes separately and then
tape together.

YES

Measure temperature of suction and


discharge air of air conditioner.

Temperature
difference
is small.

gas (R22).

Possibility of
gas shortage.

Charge refrigerant

Temperature difference between


suction and discharge air is
large enough (approx. 10 deg. or more

Check for clogging of air filter.


Air filter is clogged.

Fan speed is set to LOW.

YES

Review cooling load estimate,


if performance of air conditioner is
normal.

Clean filter.

Set fan speed to either


HIGH or MEDIUM.

Reduce cooling load or


replace the air conditioner
with larger capacity unit.

Set temperature to higher


value using temperature
setting buttons of the remote
control unit.

4-2. Excessive cooling.


NO
Set temperature is suitable.

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CHECKING ELECTRICAL COMPONENTS


1. Measurement of Insulation
Resistance
The insulation is in good condition if the resistance
exceeds 2M .

1-1. Power Supply Wires


Clamp the grounding terminal of the power plug with a
lead clip of the insulation resistance tester and
meaure the resistance by placing a probe on either of
the two power terminals. (Fig. 1)
Then, also measure the resistance between the
grounding and other power terminals. Fig. 1)

NOTE
The shape of the power plug may differ from
that of the air conditioner which you are
servicing.
Fig.1

1-2. Indoor Unit


Clamp an aluminum plate fin or copper tube with the
lead clip of the insulation resistance tester and
measure the resistance by placing a probe on each
terminal screw except where the ground line is
connected on the terminal plate. (Fig. 2)
Fig.2

1-3. Outdoor Unit


Clamp a metallic part of the unit with the lead clip of
the insulation resistance tester and measure the
resistance by placing a probe on each terminal screw
where power supply lines are connected on the
terminal plate. (Fig. 2)

1-4. Measurement of Insulation


Resistance for Electrical Parts
Disconnect the lead wires of the desired electric part
from terminal plate, capacitor, etc. Similarly disconnect
the connector. Then measure the insulation resistance.
(Figs. 3 and 4)

Fig.3

NOTE
Refer to Electric Wiring Diagram.
If the probe cannot enter the poles because the hole is
too narrow then use a probe with a thinner pin.

Fig.4
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2. Checking continuity of Fuse


On PCB Ass'y
Remove the PCB Ass'y from the electrical
Component box. Then pull out the fuse from the PCB
Ass'y. (Fig. 5)
Fig.5

Check for continuity using a multimeter as shown in


Fig. 6.

3. Checking Motor Capacitor


Remove the lead wires from the capacitor terminals,
and then place a probe on the capacitor terminals as
shown in Fig. 7. Observe the deflection of the pointer,
setting the resistance measuring range of the
multimeter to the maximum value.

Fig.6

The capacitor is "good" if the pointer bounces to a


great extent and then gradually returns to its original
position.
The range of deflection and deflection time differ
according to the capacity of the capacitor.

Fig.7

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SYSTEM TEST AND DIAGNOSTICS


TEST OPERATION MODE
1) This is a diagnostic mode to check the functioning of a unit. In installations with multiple
units it is possible to start the Test Operation Mode in all of the units sequentially and run
the test mode in parallel, thus shortening the time for service calls. By consulting the
status of each unit a diagnosis can be made of any problems or normal operation can be
verified.
2) Test Operation mode carries out the following operational sequence and then returns to
stop operation in normal mode after the Test operation is finished. In the case of Cool only
systems the sequence will be completed after STEP 2. If a problem is encountered during
Test Operation mode then the unit will indicate this as shown in the chart below and the
LED Display will flash according to the LED Diagnotic Codes.
3) To start this mode, the emergency switch must be pressed for at least 10 seconds while in
normal operating mode. To interrupt this mode, press the emergency switch again for at
least 10 seconds.

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Test Operation Mode


In cool only mode
STEP1 Cool mode, Fan LO

Input
Cool mode, Fan LO

Operation time
7 minutes

Step 1

Fan only high

Minutes
3

Step 2

Cool mode : fan high

Cool mode : fan med

Cool mode : fan low

Step 3

Stop Waiting

Step 4

Heating mode : fan high


Heating mode : fan med

4
2

Heating mode : fan low

Wait

Step 5

Diagnostic

Diagnostic

Any timer settings entered before the start of the Test Operation Mode will not affected by
the Test operation Mode.
Failure display follows the conditions below.
Status
Low HP temp < 18C
Coil temp >40C(cooling)
Overheat 65C(heating)
Anti Freeze
Low voltage
Sensor fail
Cooling fail
Heating fail

Operation
fan stop and louver full open
fan stop and louver full open
louver full open
louver full open
halt
stop
stop
stop

Terminating condition
Coil temp 20C
Coil temp 38C
Coil temp 50C
Coil temp 5C
return to normal range
system reset
system reset
system reset

DIAGNOSTIC INFORMATION FUNCTION


1) The control is equipped with a diagnostic information system to report operation of the unit as
well as operational failures.
2) These are reported via different flashing patterns of the 3 indicator lights on the unit. The chart
below shows the light patterns for the various operational, protrction and failure modes.
3) This feature is intended to provide information to the consumer as well as for service of the units.

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LED DIAGNOSTIC OTPUT CODES

Status

Power

Timer

Operation

OFF(with power on)


ON (Temperature satisfied)
Waiting for delay
Compressor started
Sleep mode
Start timer set
Stop timer set
Low HP temp < 18C
Coil temp > 40C (cooling)
Overheat > 62 (heating)
Anti Freeze
Low voltage
Sensor fail
Cooling fail
Heating fail
Emergency operation
Test operation
Filter

O
X
X
X
X
X
X
X
X
X
X
F-2
F-1
F-2
F-3
F-3
F-1
F-3

O
O
F-1
O
X
F-2
F-3
O
O
F-1
F-2
O
O
O
O
Note 1
F-1
F-3

O
O
O
X
X/O
X/O
X/O
F-1
F-2
F-1
F-2
O
F-1
F-2
F-3
Note 1
F-1
F-3

Mode
Normal Operation
Normal Operation
Normal Operation
Normal Operation
Normal Operation
Normal Operation
Normal Operation
Protection
Protection
Protection
Protection
Protection
Reset-Call Service Technician
Reset-Call Service Technician
Reset-Call Service Technician
Operational
Operational
Protection

Light Pattem codes


X = On, O = OFF
F-1 = ON:0.5sec,OFF:0.5sec
F-2 = ON:1.0sec,OFF:0.5sec
F-3 = ON:0.5sec, OFF:1.sec

Notes
1) In emergency mode, the Power ligh will flash and the other lights will indicate the operation as
above.
2) If the test operation was completed or was interrupted by the user, then the operation of the unit
will resume operation in the mode that was selected before the Test Operation Mode was
initiated.
3) Lights will flash during the time that the units is held off, due to Low Voltage. If the voltage has
passed through the reset voltage and the unit is waiting for the time delay, the lights will go to
normal operation.
4) The lights will show the LED Diagnostic code even when the unit is off.

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Name, address and phone number of your contractor :

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