Daikin EDLQO5CAV3 User manual

Daikin Altherma Monobloc CA
ESIE15-08B
Service
Manual
EBLQO5 / O7CAV3
EDLQO5 / O7CAV3 EKCB07CAV3 EK2CB07CAV3 EKMBUHCA3V3 EKMBUHCA9WA

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The present publication is drawn up by way of information only and does not constitute an offer binding upon Daikin Europe N.V..
Daikin Europe N.V. has compiled the content of this publication to the best of its knowledge. No express or implied warranty is
given for the completeness, accuracy, reliability or fitness for particular purpose of its content and the products and services
presented therein. Specifications are subject to change without prior notice. Daikin Europe N.V. explicitly rejects any liability for
any direct or indirect damage, in the broadest sense, arising from or related to the use and/or interpretation of this publication. All
content is copyrighted by Daikin Europe N.V..

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Table of contents
Part 1. Introduction ....................................................................................................................9
1. Version log ....................................................................................................................................................9
2. Safety precautions ........................................................................................................................................9
2.1. Meaning of symbols ..........................................................................................................................................9
2.2. Warnings .........................................................................................................................................................10
2.3. Cautions ..........................................................................................................................................................11
2.4. Information ......................................................................................................................................................12
3. General operation of Daikin Altherma CA low temperature heat pump ......................................................13
4. How to use this book ...................................................................................................................................15
4.1. Interactive information flow ..............................................................................................................................15
4.2. Parts of the book .............................................................................................................................................16
4.2.1. The introduction chapter .............................................................................................................................16
4.2.2. The troubleshooting chapter .......................................................................................................................16
4.2.3. The repair chapter .......................................................................................................................................16
4.2.4. The maintenance chapter ...........................................................................................................................16
4.2.5. Appendices .................................................................................................................................................16
4.3. Contact information .........................................................................................................................................16
Part 2. Troubleshooting ...........................................................................................................17
1. Error codes .................................................................................................................................................17
1.1. How to retrieve error codes .............................................................................................................................17
1.2. How to reset error codes .................................................................................................................................18
1.3. History of error codes and warnings ................................................................................................................18
2. Error code based troubleshooting ...............................................................................................................19
2.1. “AA-00” – Back up heater safety error .............................................................................................................19
2.2. “AC-00” – Booster heater thermal protector is open .......................................................................................20
2.3. “AH-00” – Disinfection operation error .............................................................................................................21
2.4. “AJ-03” – Domestic hot water heat duration is too long (warning) ..................................................................21
2.5. “A1-00” – Zero cross detection problem ..........................................................................................................22
2.6. “A1-01” – Hydro PCB A1P abnormality ...........................................................................................................22
2.7. “A5-00” – Freeze-up prevention (refrigerant) ..................................................................................................22
2.8. “CJ-02” – User interface room temperature error ............................................................................................23
2.9. “C0-00” – Flow sensor error ............................................................................................................................23
2.10. “C0-01” – Flow switch warning ......................................................................................................................23
2.11. “C0-02” – Flow switch error ...........................................................................................................................24
2.12. “C4-00” – Refrigerant liquid thermistor R3T abnormality ...............................................................................24
2.13. “EA-00” – 4-way valve malfunction ................................................................................................................24
2.14. “EC-00” – Domestic hot water temperature error ..........................................................................................25
2.15. “E1-00” – Outdoor unit PCB abnormality .......................................................................................................25
2.16. “E3-00” – High pressure abnormality (refrigerant) .........................................................................................26
2.17. “E4-00” – Actuation of sensor (low pressure) ................................................................................................26
2.18. “E5-00” – Compressor motor lock .................................................................................................................27
2.19. “E6-00” – Compressor startup defect ............................................................................................................27
2.20. “E7-00” – Malfunction of outdoor unit fan motor ............................................................................................28
2.21. “E8-00” – Power input overvoltage ................................................................................................................28
2.22. “E9-00” – Expansion valve abnormality .........................................................................................................29
2.23. “F3-00” – Discharge pipe temperature control ..............................................................................................29
2.24. “F6-00” – Abnormal high pressure in cooling ................................................................................................30
2.25. “HC-00” – Domestic hot water temperature error ..........................................................................................31
2.26. “H0-00” – Voltage/current sensor problem ....................................................................................................31

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2.27. “H1-00” – Optional temperature sensor error (indoor ambient) ..................................................................... 32
2.28. “H3-00” – High pressure switch abnormality ................................................................................................. 32
2.29. “H6-00” – Malfunction of position detection sensor ....................................................................................... 32
2.30. “H8-00” – Malfunction of compressor input (CT) system .............................................................................. 33
2.31. “H9-00” – Outdoor air thermistor (R3T) abnormality ..................................................................................... 33
2.32. “JA-00 / JI-00” – Pressure sensor abnormality .............................................................................................. 34
2.33. “J3-00” – Discharge thermistor (R1T) abnormality ........................................................................................ 34
2.34. “J6-00” – Heat exchanger thermistor (R2T) abnormality ............................................................................... 34
2.35. “J7-00” – Malfunction of intermediate heat exchanger thermistor ................................................................. 35
2.36. “J8-00” – Malfunction of liquid pipe thermistor .............................................................................................. 35
2.37. “LC-00” – Transmission system abnormality ................................................................................................. 35
2.38. “L1-00” – Outdoor main PCB abnormality ..................................................................................................... 36
2.39. “L3-00” – Switch box temperature abnormality ............................................................................................. 36
2.40. “L4-00” – Radiation fin temperature abnormality ........................................................................................... 37
2.41. “L5-00” – Output overcurrent detection ......................................................................................................... 37
2.42. “L8-00” – Electronic thermal overload ........................................................................................................... 38
2.43. “PJ-00” – Defective capacity setting .............................................................................................................. 38
2.44. “UA-00” – Indoor-Outdoor PCB combination ................................................................................................ 38
2.45. “UA-16” – Communication warning between hydro PCB A1P and control box PCB .................................... 39
2.46. “UA-21” – PCB combination malfunction ...................................................................................................... 39
2.47. UA-22” – Communication warning between control box and option box ...................................................... 40
2.48. “UA-60” – PCB combination malfunction ...................................................................................................... 40
2.49. “UF-00” – Communication error between hydro PCB A1P and outdoor main PCB or gas shortage ............ 41
2.50. “U0” – Refrigerant shortage .......................................................................................................................... 41
2.51. “U3-00” – Abnormal stop of underfloor heating dry-out scheduled operation ............................................... 42
2.52. “U4-00” – Defective indoor-outdoor transmission ......................................................................................... 42
2.53. “U5-00” – Transmission error between user interface and hydro PCB A1P ................................................. 43
2.54. “U7-00” – Transmission malfunction between outdoor unit main PCB and inverter PCB ............................. 43
2.55. “7H-01” – Water flow abnormality ................................................................................................................. 43
2.56. “7H-04” – Water flow abnormality during DHW operation ............................................................................. 44
2.57. “7H-05” – Water flow abnormality during space heating operation ............................................................... 45
2.58. “7H-06” – Water flow abnormality during defrost/cooling operation .............................................................. 45
2.59. “8F-00” – Backup heater outlet water temperature error during domestic hot water operation ....................45
2.60. “8H-00” – Backup heater outlet water temperature error .............................................................................. 46
2.61. “80-00” – R4T entering water thermistor abnormality ................................................................................... 46
2.62. “81-00” – Leaving water thermistor R1T abnormality .................................................................................... 46
2.63. “89-01” – Plate heat exchanger freeze-up error ............................................................................................ 47
2.64. “89-02” – Plate heat exchanger freeze-up warning during space heating / DHW production ....................... 47
2.65. “89-03” – Plate heat exchanger warning during defrost ................................................................................ 48
3. Symptom based troubleshooting ............................................................................................................... 49
3.1. Capacity shortage - General ........................................................................................................................... 49
3.2. Capacity shortage - Space heating ................................................................................................................. 51
3.3. Capacity shortage - Domestic hot water operation ......................................................................................... 53
3.4. The system does not start/operate .................................................................................................................. 54
3.5. Inaccurate temperature control (for both domestic hot water and space heating operation) .......................... 55
3.6. Water leakage or water release via the water pressure relieve valve ............................................................. 56
3.7. Power consumption too high ........................................................................................................................... 57
3.8. Increased sound level - water pump ............................................................................................................... 58
3.9. Increased sound level - compressor ............................................................................................................... 58
3.10. Tapping water related ................................................................................................................................... 59
3.10.1. High water pressure at tapping point ........................................................................................................59
3.10.2. Tapping water has white colour ................................................................................................................59
3.10.3. Bad odour from tapping water ...................................................................................................................59
3.11. Compressor related ....................................................................................................................................... 60
3.11.1. Compressor does not start ........................................................................................................................60
3.11.2. Compressor does not increase frequency ................................................................................................60
3.12. Pump related ................................................................................................................................................. 62

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3.12.1. Water pump behaviour ..............................................................................................................................62
3.13. User interface (no or strange display) ...........................................................................................................62
3.14. Outdoor unit is iced up (defrost problem) ......................................................................................................63
3.15. Energy metering is 'wrong' ............................................................................................................................63
3.16. Water volume/flow related .............................................................................................................................64
4. Component checklist - Water Circuit ...........................................................................................................65
4.1. Backup heater E1H, E2H, E3H .......................................................................................................................65
4.1.1. Overall power circuit check .........................................................................................................................66
4.1.2. Resistance check ........................................................................................................................................67
4.1.3. Isolation check ............................................................................................................................................67
4.2. Booster heater E4H .........................................................................................................................................69
4.3. Thermistors .....................................................................................................................................................70
4.4. Water pump M1P (Main Supply Pump) ...........................................................................................................73
4.5. Water pump M2P (DHW pump) ......................................................................................................................75
4.6. Plate type heat exchanger ...............................................................................................................................77
4.7. Thermal protector backup heater Q1L ............................................................................................................79
4.8. Water flow sensor B1L ....................................................................................................................................81
4.9. Water flow switch S1L .....................................................................................................................................83
4.10. 3-way valve M3S ...........................................................................................................................................84
4.11. Extension PCB A4P ......................................................................................................................................86
5. Component checklist - Refrigerant Circuit ..................................................................................................88
5.1. Required tools for component check ...............................................................................................................88
5.2. Thermistors .....................................................................................................................................................88
5.3. Compressor M1C ............................................................................................................................................91
5.4. Muffler .............................................................................................................................................................93
5.5. Pressure sensor S1NPH .................................................................................................................................94
5.6. High pressure switch S1PH .............................................................................................................................96
5.7. Electronic expansion valve Y1E ......................................................................................................................97
5.8. 4-way valve Y1R .............................................................................................................................................99
5.9. Inverter PCB2 ................................................................................................................................................101
5.10. Fan motor ....................................................................................................................................................103
Part 3. Repair ..........................................................................................................................105
1. General Repair procedures .......................................................................................................................105
1.1. Refrigerant handling procedures ...................................................................................................................105
1.1.1. Refrigerant recovery .................................................................................................................................106
1.1.2. Refrigerant pump down .............................................................................................................................107
1.2. Pipe work procedures ....................................................................................................................................108
1.3. Products ........................................................................................................................................................109
1.3.1. Required products when servicing the Daikin Altherma Monobloc CA .....................................................109
1.4. Tools ..............................................................................................................................................................109
1.4.1. Required special tooling when servicing the Daikin Altherma Monobloc CA ............................................109
2. Unit specific repair procedures Monobloc CA ...........................................................................................110
2.1. Unit specific refrigerant and water procedures ..............................................................................................110
2.1.1. Removing the hydrobox top plate assembly .............................................................................................110
2.1.2. Removing the hydrobox front plate ...........................................................................................................111
2.1.3. Removing the top plate .............................................................................................................................112
2.1.4. Removing the front plate assembly ...........................................................................................................113
2.1.5. Removing the compressor sound insulation .............................................................................................114
2.2. Parts replacement procedures ......................................................................................................................115
2.2.1. Replacing the propeller fan blade assembly .............................................................................................115
2.2.2. Replacing the DC fan motor assembly .....................................................................................................116
2.2.3. Replacing the switch box ..........................................................................................................................117
2.2.4. Replacing the PCB1 main .........................................................................................................................119
2.2.5. Replacing the PCB2 inverter .....................................................................................................................122
2.2.6. Replacing a thermistor ..............................................................................................................................124
2.2.7. Replacing the compressor ........................................................................................................................125
2.2.8. Replacing the 4-way valve coil ..................................................................................................................127

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2.2.9. Replacing the 4-way valve ........................................................................................................................127
2.2.10. Replacing the high pressure switch S1PH ..............................................................................................129
2.2.11. Replacing the pressure sensor S1NPH ..................................................................................................130
2.2.12. Replacing the expansion valve Y1E motor .............................................................................................131
2.2.13. Replacing the water pump M1P ..............................................................................................................133
Part 4. Maintenance ................................................................................................................135
1. Yearly maintenance intervals and procedures ......................................................................................... 135
2. Maintenance procedures ......................................................................................................................... 135
2.1. Checking fluid pressure of Space Heating circuit .......................................................................................... 135
2.2. Checking the pressure relief valve hose ....................................................................................................... 135
2.3. Checking the pressure relief valve of Space Heating circuit ......................................................................... 136
2.4. Checking the relief valve of the Domestic Hot Water tank - field supply ....................................................... 136
2.5. Checking the filters of Space Heating circuit ................................................................................................. 136
2.6. Draining the Domestic Hot Water tank .......................................................................................................... 137
2.7. Anode ............................................................................................................................................................ 137
2.8. Descaling and chemical disinfection ............................................................................................................. 137
2.9. Checking the Switch box ............................................................................................................................... 138
2.10. Domestic hot water tank booster heater ..................................................................................................... 138
2.11. Backup heater insulation cover ................................................................................................................... 138
2.12. Domestic hot water tank .............................................................................................................................. 138
2.13. Heat exchangers ......................................................................................................................................... 138
Part 5. Appendix .....................................................................................................................139
1. Field settings ............................................................................................................................................ 139
2. Wiring diagram ......................................................................................................................................... 144
3. Piping diagram ......................................................................................................................................... 153
4. Components overview ............................................................................................................................. 154

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List of figures
General operation of the Daikin Altherma low temperature heat pump ....................................................................13
Required tools for component check .........................................................................................................................88
Required products ...................................................................................................................................................109
Required tools .........................................................................................................................................................109
Removing the hydrobox top plate assembly ...........................................................................................................110
Removing the hydrobox front plate .........................................................................................................................111
Removing the top plate ...........................................................................................................................................112
Removing the front plate assembly .........................................................................................................................113
Removing the compressor sound insulation ...........................................................................................................114
Removing the propeller fan blade assembly ...........................................................................................................115
Removing the DC fan motor assembly ...................................................................................................................116
Removing the switch box ........................................................................................................................................118
Removing the PCB assembly main - 1 ...................................................................................................................120
Removing the PCB assembly main - 2 ...................................................................................................................121
Removing the PCB assembly inverter - 2 ...............................................................................................................123
Thermistor location ..................................................................................................................................................124
Removing the compressor ......................................................................................................................................126
Removing the 4-way valve coil ................................................................................................................................127
Removing the 4-way valve ......................................................................................................................................128
Removing the high pressure switch S1PH ..............................................................................................................129
Removing the pressure sensor S1NPH ..................................................................................................................131
Removing the expansion valve Y1E motor .............................................................................................................132
Locking the expansion valve Y1E motor .................................................................................................................132
Removing the water pump M1P ..............................................................................................................................133
Field settings table ..................................................................................................................................................140
Wiring diagram EB/DLQO5/O7CAV3- 1 ..................................................................................................................144
Wiring diagram EB/DLQO5/O7CAV3- 2 ..................................................................................................................145
Wiring diagram EB/DLQO5/O7CAV3- 3 ..................................................................................................................146
Wiring diagram EB/DLQO5/O7CAV3- 4 ..................................................................................................................147
Wiring diagram EB/DLQO5/O7CAV3- 5 ..................................................................................................................148
Wiring diagram EB/DLQO5/O7CAV3- 6 ..................................................................................................................149
Wiring diagram EB/DLQO5/O7CAV3- 7 ..................................................................................................................150
Wiring diagram EB/DLQO5/O7CAV3- 8 ..................................................................................................................151
Wiring diagram EB/DLQO5/O7CAV3- 9 ..................................................................................................................152
Components overview EB/DLQO5/O7CAV3 ..........................................................................................................154

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ESIE15-08B | Part 1. Introduction 1. Version log
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Part 1. Introduction
1. Version log
Version history.
2. Safety precautions
The precautions described in this document cover very important topics, follow them carefully.
All activities described in the service manual must be performed by an authorized person.
If you are not sure how to install, operate or service the unit, contact your dealer.
In accordance with the applicable legislation, it might be necessary to provide a logbook with the product containing at least:
information on maintenance, repair work, results of tests, stand-by periods, …
Also, at least, following information must be provided at an accessible place at the product:
• Instructions for shutting down the system in case of an emergency
• Name and address of fire department, police and hospital
• Name, address and day and night telephone numbers for obtaining service
In Europe, EN378 provides the necessary guidance for this logbook.
2.1. Meaning of symbols
Version code Description Date
Version A Document release 22/09/2015
ESIE15-08B Outdoor error code added (L3) 19/07/2016
WARNING
Indicates a situation that could result in death or serious injury.
WARNING: RISK OF ELECTROCUTION
Indicates a situation that could result in electrocution.
WARNING: RISK OF BURNING
Indicates a situation that could result in burning because of extreme hot or cold temperatures.
WARNING: RISK OF EXPLOSION
Indicates a situation that could result in explosion.
WARNING: RISK OF POISONING
Indicates a situation that could result in poisoning.

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2.2. Warnings
CAUTION
Indicates a situation that could result in equipment or property damage.
INFORMATION
Indicates useful tips or additional information.
WARNING
Improper installation or attachment of equipment or accessories could result in electric shock, short-circuit, leaks, fire
or other damage to the equipment. Only use accessories, optional equipment and spare parts made or approved by
Daikin.
WARNING
Make sure installation, testing and applied materials comply with applicable legislation (on top of the instructions
described in the Daikin documentation).
WARNING
Make sure the work site environment is clean and safe to work in. Beware of spilled fluids, like water, oil or other sub-
stances. Protect bystanders from injury and property from possible damage cause by service works.
WARNING
Wear adequate personal protective equipment (protective gloves, safety glasses,…) when installing, maintaining or
servicing the system.
WARNING
Tear apart and throw away plastic packaging bags so that nobody, especially children, can play with them. Possible
risk: suffocation.
WARNING
Do NOT touch the air inlet or aluminium fins of the unit.
WARNING
• Do NOT place any objects or equipment on top of the unit.
• Do NOT sit, climb or stand on the unit.
WARNING
During tests, NEVER pressurize the product with a pressure higher than the maximum allowable pressure (as indi-
cated on the nameplate of the unit).
WARNING
• Never mix different refrigerants or allow air to enter the refrigerant system.
• Never charge recovered refrigerant from another unit. Use recovered refrigerant only on the same unit where it was
recovered from, or have it recycled at a certified facility.
WARNING: RISK OF FIRE
• When reconnecting a connector to the PCB, do not apply force or damage the connector or the connector pins on
the PCB.