DIAGNOSTIC MANUAL SPLIT SYSTEM AIR-CONDITIONER MODELS:

ELECTROLUX HOME PRODUCTS PTY LTD
ABN 51 004 762 341
Issue: 3
Date: 11/10
Technical Publication Nº KSSSI90
WEB SITE ADDRESS: www.partnship.com.au
KELVINATOR
SPLIT SYSTEM
AIR-CONDITIONER
DIAGNOSTIC MANUAL
MODELS:
KSV53HRA
KSV62HRA
KSV70HRA
 Copyright 2010 ELECTROLUX HOME PRODUCTS PTY LTD Technical Services
Indoor Unit & PCB test board Error Display.
DISPLAY
Not Operating
E0
E1
E5
E52
E6
L2 & PA
P0
P1
P2
P4
LO & P91
LED STATUS
PAGE
No operation by use of remote control
EEPROM parameter error
Indoor / outdoor units communication protection
Open or short circuit of outdoor condenser pipe & compressor temperature sensors
Open or short circuit of outdoor ambient temperature sensor
Open or short circuit of room or evaporator temperature sensor
High-temperature protection of condenser
Module protection
Over voltage or too low voltage protection
Temperature protection of compressor top - low refrigerant charge
Inverter compressor drive error
Evaporator high-frequency low-temperature limit
3 to 5
6
7 to 15
16 & 17
16 & 17
18
19 & 20
21 & 22
23
24 & 25
26 & 27
28 & 29
Page 2 KSSSI90
Not Operating:
# While the unit is in “stand by” mode, check if the green stand by light is flashing at 1 Hertz?
# Try operating the unit by the forced operations button: By pressing the button once, the unit should
activate in Auto mode. By pressing this button twice, within five seconds, the unit should activate in
Cooling mode.
If the unit can be operated by the forced operations button & the green stand by light was flashing on the
display PCB assembly, prior to pressing forced operation button, check the remote controller.
If the unit can be operated by the forced operations button & the green stand by light was off on the
display PCB, replace the display PCB assembly.
Stand by indicator on Display PCB assembly.
Button located on top right hand side of
indoor unit behind filter cover.
Page 3 KSSSI90
# If the unit cannot be operated by the use of the remote control or the forced operation button, proceed
as follows:
# Check the wiring configuration from the indoor unit to the outdoor unit. Is it wired up correctly in
accordance to the wiring diagram provided on the underside of the plastic outdoor terminal cover?
# Check the supply voltage to the outdoor terminal block.
# Check the supply voltage from the outdoor terminal block to the indoor terminal block.
Active & Neutral wires from mains supply.
Active, Neutral & Communication wires
connecting from outdoor terminal block to
indoor terminal block.
Active, Neutral & Communication wires from
outdoor terminal block.
Page 4 KSSSI90
# Check the supply voltage from the indoor PCB to the transformer.
If there is 240 Volts AC from this connection point on the indoor PCB, replace the transformer.
If there is no supply voltage from this point, replace the indoor main PCB.
Transformer AC voltage connection points.
Page 5 KSSSI90
E0 error:
# The E0 error indicates there is a software issue/program chip fault on the main indoor PCB assembly.
# Replace the main indoor PCB assembly.
If any one of the program chips fail, as highlighted by
the red arrows, this could cause an E0 error.
Page 6 KSSSI90
E1 error (Indoor Unit)
# Disconnect the main power supply to the outdoor unit by means of the isolation switch. After
approximately one minute, turn the power supply back on & attempt to operate the unit on heating or
cooling mode by the use of the remote control.
If E1 fault has not cleared:
# Check the continuity of the (3uF) indoor fan capacitor mounted vertically inside the indoor control box
assembly.
# Measure the resistance of the Blue & Black wires that connect from the 3uF capacitor to the indoor fan
motor. The resistance reading should be approximately “322 Ohms”, at an ambient temperature of 22ºC.
3uF indoor fan capacitor.
3uF capacitor mounted inside the indoor
control box assembly.
Ohms reading of indoor fan motor.
Page 7 KSSSI90
E1 error (Outdoor Unit)
If E1 fault has not cleared:
Check the continuity of the “Bridge Rectifier” as illustrated below.
Turn off the power & let the inverter electrolytic capacitors completely discharge.
Identify the diodes individual ‘Plus’ and ‘Minus’ connections so as to test each diode's forward and
reverse resistance values. The diagrams listed below illustrate the method of achieving this.
Set the multimeter to a DC Mega Ohms setting.
Place the Positive probe on the
~ pin of the rectifier & the Negative probe on the + pin of the rectifier.
Place the Positive probe on the O pin of the rectifier & the Negative probe on the + pin of the rectifier.
- pin of the rectifier & the Negative probe on the ~ pin of the rectifier.
Place the Positive probe on the - pin of the rectifier & the Negative probe on the O pin of the rectifier.
Place the Positive probe on the
Note: Insure the multimeter probes are placed in their correct orientation as specified above.
Note: If any of the above tests indicate a “Short Circuit” replace the main PCB assembly.
All of the above tests should read several Mega Ohms.
Relevant test points on the main outdoor PCB.
Page 8 KSSSI90
If E1 fault has not cleared:
Check the continuity of the “IGBT” as illustrated below.
Turn off the power & let the inverter electrolytic capacitors completely discharge.
Identify the Negative DC, U, V & W soldered points so as to test each internal IGBT resistance value.
The diagrams listed below illustrate the method of achieving this.
Set the multimeter to a DC Mega Ohms setting.
Place the Negative probe on the Negative DC soldered point on the outdoor PCB & the Positive probe on
the U soldered point on the outdoor PCB.
Place the Negative probe on the Negative DC soldered point on the outdoor PCB & the Positive probe on
the V soldered point on the outdoor PCB.
Place the Negative probe on the Negative DC soldered point on the outdoor PCB & the Positive probe on
the W soldered point on the outdoor PCB.
Note: Insure the multimeter probes are placed in their correct orientation as specified above.
Note: If any of the above tests indicate a “Short Circuit” replace the main PCB assembly.
All of the above tests should read several Mega Ohms.
Relevant IGBT test points on the main outdoor PCB.
Page 9 KSSSI90
If E1 fault has not cleared:
# Check the wiring connection configuration from the indoor to the outdoor units, in accordance to the
wiring diagram attached to the inside of the outdoor units plastic terminal block cover.
# Check the continuity on the “S” communication wire from the indoor units connection point, to the
outdoor units connection point.
# Check the continuity, from one point to the other, of the two “S” wiring connection points on the
outdoor terminal block.
# Check the continuity of the yellow “S” wire & female spade terminal located on the top section of the
outdoor terminal block, to the soldered “S” wiring point on the outdoor main PCB.
#Check the various Earth connection points for correct termination.
Indoor terminal block
“S” communication points on outdoor terminal block.
“S” communication point on main outdoor
PCB.
Page 10 KSSSI90
If E1 fault has not cleared:
# Check the continuity of the active wiring connection on the main outdoor terminal block, to the (CN4)
soldered wiring point on the outdoor main PCB.
“CN4” point on outdoor main PCB.
Active wiring connection point on main outdoor
terminal block.
# Check the continuity of the neutral wiring connection on the main outdoor terminal block, to the
(CN5) soldered wiring point on the outdoor main PCB.
Neutral wiring connection point on main
outdoor terminal block.
“CN5” point on outdoor main PCB
Page 11 KSSSI90
If E1 fault has not cleared:
# Check the continuity of the red connection wire located on the 50uf capacitor to the “CN3” soldered
wiring point on the outdoor main PCB.
Caution: Discharge the 50uf capacitor prior to any service work.
Red connection wire to 50uf capacitor.
“CN3” connection point on main outdoor PCB.
Caution: Discharge the 50uf capacitor prior to any service work.
# Check the continuity of the orange connection wire located on the 50uf capacitor to the connection
point on the outdoor (R1815E) reactor.
Note: Check the continuity of the capacitor & reactor. If open circuit, this will also cause an E1 fault.
Orange connecting wire from (R1815E) reactor.
Orange connecting wire from the 50uf
capacitor.
Page 12 KSSSI90
Caution: Discharge the 50uf capacitor prior to any service work.
If E1 fault has not cleared:
# Check the continuity of the orange connection wire located on the left hand terminal of (R1815E)
reactor to the “CN1” soldered wiring point on the outdoor main PCB.
Note: Check the continuity of the reactor. If it’s open circuit, this will also cause an E1 fault.
“CN1” soldered connection point on outdoor
PCB.
Orange connecting wire from (R1815E) reactor.
If E1 fault has not cleared:
# Check the continuity of the wire that connects to the reactor (R1502) spade terminal located closest to
the front of the outdoor unit, too the “N-B” soldered connection point on the main outdoor PCB.
N-B soldered connection point.
Front terminal point.
Reactor (R1502)
Page 13 KSSSI90
If E1 fault has not cleared:
# Check the continuity of the wire that connects to the reactor (R1502) spade terminal located to the rear
of the outdoor unit, too the two terminal relay located under the main outdoor PCB.
Note: Check the continuity of the reactor. If it’s open circuit, this will also cause an E1 fault.
Rear terminal point.
Reactor (R1502)
Relay located under main outdoor PCB.
# If there is a open circuit in any of the (R1502) reactor connection points, check the two point plug
located on the harness which runs between the main outdoor PCB & the (R1502) reactor.
Connection plug.
Page 14 KSSSI90
#Check the outdoor LED light code configuration.
During “Standby” conditions the LED’s work in this sequence:
LED 1 (Yellow) is FLASHING at 1 Hz
LED 5 (Red) is OFF
LED 6 (Green) is ON
During “Normal Operating” conditions the LED’s work in this sequence:
LED 1 (Yellow) is ON
LED 5 (Red) is ON
LED 6 (Green) is OFF
During “E1” fault the LED’s work in this sequence:
LED 1 (Yellow) is FLASHING at 5 Hz
LED 5 (Red) is OFF
LED 6 (Green) is ON.
Note: If the outdoor PCB is in the E1 fault sequence, this would indicate there is a potential fault with
the indoor main PCB.
If the indoor main PCB has been replaced and the E1 fault still exists or there is no LED light sequence
available on the outdoor main PCB, check all the wiring connection points, as previously illustrated, on
the main outdoor PCB in conjunction with the wiring diagram. If all wiring connection points are okay,
this would indicate the outdoor main PCB has failed & would also need to be replaced.
Page 15 KSSSI90
E5 error:
# Check the “condenser coil & compressor discharge sensors” for correct connection.
# Check the continuity of both sensor, if the sensor is open circuit, change it.
Compressor discharge temperature sensor
Condenser coil pipe temperature sensor
E52 error:
# Check the “condenser coil air temperature sensor” for correct connection.
# Check the continuity of the sensor, if the sensor is open circuit, change it.
Condenser coil air temperature sensor
Page 16 KSSSI90
#Check the LED light code configuration.
During normal operating conditions the LED’s work in this sequence:
LED 1 (Yellow) is ON
LED 5 (Red) is ON
LED 6 (Green) is OFF
During “E5” fault the LED’s work in this sequence:
LED 1 (Yellow) is FLASHING at 5 Hz
LED 5 (Red) is OFF
LED 6 (Green) is ON.
Note: If all the above checks relating to the sensors & wiring have been completed, yet the E5 fault still
exists, this would indicate the outdoor main PCB has failed & would need to be replaced.
Page 17 KSSSI90
E6 error:
# Check the two indoor temperature sensors for correct connection to the indoor main PCB.
# Check the continuity of the sensors, if ether of the sensors are open circuit, change them.
# If E6 fault code is still displayed after replacing one or both of the indoor sensor, replace the indoor
main PCB.
Evaporator coil “air” temperature sensor
Evaporator coil “pipe” temperature sensor
Note: the outdoor LED light configuration will not be affected by this fault.
Page 18 KSSSI90
L2 & PA error:
If the “PA” error appears, check the following components.
# Check the condenser fan for correct operation. If the fan motor is not operating check the five pin
connector for correct termination. If the termination of the plug is okay check the continuity of each
voltage point.
Check the Resistance value of the condenser fan motor plug, from the following points.
Note: The following resistance values were measured at an ambient temperature of 20ºC.
Brown & Black = 0.3 Ohms.
Brown & Red = 84.2 Ohms.
Brown & Yellow = 132.0 Ohms.
Brown & Blue = 230 Ohms.
Page 19 KSSSI90
If the resistance values are okay:
# Check the five soldered AC voltage points located on the main outdoor PCB.
Note: The following voltage readings were measured when the unit was run in Cooling mode, with a set
temperature of 17ºC.
FAN-C to FAN-M = 220 Volts
FAN-C to FAN-H = 200 Volts
FAN-C to FAN-N = 240 Volts
FAN-C to 4-WAY = 240 Volts
# If there is no AC voltage at any of these points, replace the main outdoor PCB.
Page 20 KSSSI90
P0 error:
If the compressor is not operating, check the following components.
# Check number “2” (Run) flag terminal, for correct termination.
# Check number “3” (Start) flag terminal, for correct termination.
# Check the continuity of the Black number “2” spade terminal wire connected to the compressor, to the
“W” point soldered on the main PCB.
# Check the continuity of the Blue number “3” spade terminal wire connected to the compressor, to the
“U” point soldered on the main PCB.
Page 21 KSSSI90
# Measure the resistance windings of the compressor.
The resistance value will range between 0.45 to 0.88 ohms at an ambient temperature range of 20 to
25ºC.
Note: the resistance value should be the same value across any terminal combination.
#Check the LED light code configuration.
During normal operating conditions the LED’s work in this sequence:
LED 1 (Yellow) is ON
LED 5 (Red) is ON
LED 6 (Green) is OFF
During “P0” fault the LED’s work in this sequence:
LED 1 (Yellow) is FLASHING at 5 Hz
LED 5 (Red) is OFF
LED 6 (Green) is FLASHING at 5 Hz
Note: If the LED’s are “NOT” On or Flashing, check the supply voltage to the board. If supply voltage
is okay, this would indicate the main outdoor PCB has failed.
Page 22 KSSSI90
P1 error:
# Check the supply voltage to the outdoor unit.
Is it within 160 to 270 Volts?
Note: If the voltage is below 200 Volts, this can reduce the condenser fan speed, thus reducing the unit’s
efficiency.
If the voltage is within its voltage limits:
# Check the AC voltage from the active spade terminal to the CN4 soldered wiring point on the outdoor
main PCB.
“CN4” point on outdoor main PCB.
Active wiring connection point on main outdoor
terminal block.
# Check the AC voltage from the Neutral spade terminal to the CN5 soldered wiring point on the
outdoor main PCB.
Neutral wiring connection point on main
outdoor terminal block.
“CN5” point on outdoor main PCB
Note: if the supply AC voltage is available at both the CN4 and CN5 points & P1 fault still appears,
replace the main outdoor PCB assembly.
Page 23 KSSSI90
P2 error:
If the compressor is not operating, check the following components.
# Check the three compressor flag terminals for correct termination & sequence.
# Check the continuity & sequence of the three wires soldered to the main PCB (U, V & W), to the three
flag terminals connected to the compressor.
Correct wiring sequence from main outdoor PCB to compressor:
U to Blue (Start)
V to Red (Common)
W to Black (Run)
Page 24 KSSSI90
# Check the overload protector located next to the three compressor terminals.
Note: This overload is “normally closed”.
#Check the LED light code configuration.
During normal operating conditions the LED’s work in this sequence:
LED 1 (Yellow) is ON
LED 5 (Red) is ON
LED 6 (Green) is OFF
During “P2” fault the LED’s work in this sequence:
LED 1 (Yellow) is FLASHING at 2 Hz
LED 5 (Red) is OFF
LED 6 (Green) is ON.
Note: If the LED’s are “NOT” On or Flashing, check the supply voltage to the board. If supply voltage
is available to the board, this would indicate the outdoor PCB assembly has failed.
Page 25 KSSSI90
P4 error:
If the compressor is not operating, check the following components.
# Check number “1” (Common) flag terminal, for correct termination.
# Check the continuity of the Red number “1” spade terminal wire connected to the compressor, to the
“V” point soldered on the main PCB.
Page 26 KSSSI90
# Measure the resistance windings of the compressor.
The resistance value will range between 0.45 to 0.88 ohms at an ambient temperature range of 20 to
25ºC.
Note: the resistance value should be the same value across any terminal combination.
#Check the LED light code configuration.
During normal operating conditions the LED’s work in this sequence:
LED 1 (Yellow) is ON
LED 5 (Red) is ON
LED 6 (Green) is OFF
During “P4” fault the LED’s work in this sequence:
LED 1 (Yellow) is FLASHING at 5 Hz
LED 5 (Red) is ON
LED 6 (Green) is FLASHING at 5 Hz
Note: If the LED’s are “NOT” On or Flashing, check the supply voltage to the board. If supply voltage
is okay, this would indicate the main outdoor PCB has failed.
Page 27 KSSSI90
P91 & LO error:
If the “P91 & or LO” error appears, check the following components.
# Check the evaporator fan for correct operation. If the fan motor is not operating check the five pin
connector for correct termination. If the termination of the plug is okay check the continuity of each
voltage point.
Check the Resistance value of the evaporator fan motor plug, from the following points:
Note: The following resistance values were measured at an ambient temperature of 20ºC.
Grey & Blue = 37.2 Ohms.
Grey & Yellow = 73.7 Ohms.
Grey & Red = 100.9 Ohms.
Grey & White = 300 Ohms.
5 pin plug terminal points.
Indoor Fan Motor plug fitting.
Page 28 KSSSI90
Wire colours from left to right:
Grey, Blue, Yellow, Red & White.
If the resistance values are okay:
# Check the five soldered AC voltage points located on the underside of the main indoor PCB.
Note: The following voltage readings were measured when the unit was run in “Cooling mode, with a
set temperature of 17ºC, at High fan speed.
White to Grey = 315 Volts
White to Blue = 287 Volts
White to Yellow = 259 Volts
White to Red = 238 Volts
AC voltage points on rear of indoor
main PCB.
Side view of AC voltage points & fan motor
connector plug on indoor main PCB.
# If there is no AC voltage at any of these points, replace the main indoor PCB.
Page 29 KSSSI90