Daikin ESIE13-02 User manual

Service Manual
- Gas boiler
- EHYKOMB33AA / EHYKOMB33AA
- Hydro-box
- EHYHBH05AAV3 / RHYHBH05AAV3
- EHYHBH08AAV3 / RHYHBH08AAV3
- EHYHBX08AAV3 / RHYHBX08AAV3
- Outdoor unit
- EVLQ05CAV3 / RVLQ05CAV3
- EVLQ08CAV3 / RVLQ08CAV3
Hybrid
ESIE13-02

ESIE13-02
Table of Contents 2
3
1
4
5
1Introduction
1.1 About This Manual ....................................................................................... 6
1.2 About the Documentation ............................................................................ 8
1.3 For the User................................................................................................. 9
1.4 For the Installer............................................................................................ 10
Part 1
System Outline
1 Description
1.1 System Build-up........................................................................................... 18
1.2 Components and Connections .................................................................... 19
2 Functionality
2.1 System Operation ........................................................................................ 22
3WiringDiagrams
3.1 PCB Description .......................................................................................... 32
3.2 Overview Switch Box ................................................................................... 34
3.3 Cable Dimensions........................................................................................ 38
3.4 Piping Diagram ............................................................................................ 40
Part 2
Specifications
1 Gas Condensing Boiler
1.1 Technical Specifications .............................................................................. 42
2Hydro-box
2.1 Technical Specifications .............................................................................. 44

ESIE13-02
3 Table of Contents
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1
3 Outdoor Unit
3.1 Nominal Capacity and Nominal Input........................................................... 46
3.2 Technical Specifications .............................................................................. 47
Part 3
Commissioning
Part 4
Troubleshooting
1 Troubleshooting
1.1 General Troubleshooting Flowchart............................................................. 54
1.2 Overview of General Problems .................................................................... 55
1.3 Fault-diagnosis by Remote Controller.......................................................... 75
1.4 Fault-diagnosis Manual Reset in the Memory.............................................. 76
1.5 Troubleshooting by LED on the Hydro-box PCB ......................................... 79
1.6 Overview of Error Codes.............................................................................. 80
1.7 Overview of the Outdoor Safety Devices ..................................................... 83
1.8 Overview of the Hydro-box Safety Devices ................................................. 84
2 Error Codes: Gas Condensing Boiler
2.1 General Guidelines ...................................................................................... 85
2.2 Solving Problems Based on Symptoms....................................................... 86
2.3 Solving Problems Based on Error Codes .................................................... 87
2.4 Symptoms .................................................................................................... 89
3 Error Codes: Hydro-box
3.1 “A1” Malfunctioning Hydro-box PCB ............................................................. 94
3.2 “89” Water Heat Exchanger Frozen ............................................................. 95
3.3 “CJ, C4, 81, 80, HC, H1” Thermistor or Related Abnormality (Hydro-box) .......... 96
3.4 “7H” Hydro-box: Flow Error........................................................................... 97
3.5 “C0” Hydro-box: Flow Sensor Failure ........................................................... 100
3.6 “EC” Hydro-box: Domestic Hot Water Tank Temperature too High (> 89°C) 101
3.7 Warning “AH” Tank Disinfection Function Not Completed Correctly ............ 102

ESIE13-02
Table of Contents 4
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4 Error Codes: Outdoor Units
4.1 “E1” Outdoor Unit PCB Abnormality.............................................................. 103
4.2 “E3” Abnormal High Pressure (Detected by the HPS).................................. 104
4.3 “E4” Actuation of Low Pressure Sensor ....................................................... 106
4.4 “E5” Compressor Motor Lock ....................................................................... 109
4.5 “E7” Malfunction of Outdoor Unit Fan Motor................................................. 111
4.6 “E9” Malfunction of Electronic Expansion Valve........................................... 114
4.7 “F3” Malfunctioning in Discharge Pipe Temperature .................................... 117
4.8 “H3” Malfunctioning HPS System ................................................................. 119
4.9 “H9, J3, J5, J6, J7, J8” Thermistor or Related Abnormality (Outdoor Unit) .... 121
4.10 “J1” Malfunction of Pressure Sensor ............................................................ 122
4.11 “L1” Faulty Outdoor PC Board ...................................................................... 124
4.12 “L4” Radiation Fin Temperature Increased .................................................. 126
4.13 “L5” DC Output Overcurrent (Instantaneous)............................................... 128
4.14 “L8” DC Output Overcurrent (Instantaneous)............................................... 130
4.15 “L9” Stall Prevention (Time Lag) .................................................................. 132
4.16 “LC” Malfunction of Transmission System (Between Control PCB and Inverter
PCB) ...................................................................................................... 134
4.17 “P1” Open Phase or Power Supply Voltage Imbalance ................................ 136
4.18 “P4” Malfunction of Radiator Fin Temperature Thermistor........................... 137
4.19 “PJ” Malfunction of Radiator Fin Temperature Thermistor........................... 138
5 Error Codes: System Malfunctions
5.1 “U0” Gas Shortage (Malfunction) ................................................................. 139
5.2 “U2” Abnormal Power Supply Voltage.......................................................... 141
5.3 “U3” Underfloor Heating Screed Dry-out Failure .......................................... 143
5.4 “U4” Malfunction of Transmission between Hydro-box and Outdoor Unit .... 144
5.5 “UF” Malfunction of Transmission between Hydro-box and Outdoor Unit or Gas
Shortage ................................................................................................ 146
5.6 “U5” Malfunction of Transmission between Hydro-box and Remote Controller
148
5.7 “UA” Indoor-Outdoor Combination Problem ................................................. 149
6 Additional Checks for Troubleshooting
6.1 Check No.1 - Outdoor Unit: Checking the Installation Condition ................. 150
6.2 Check No.2 - Outdoor Unit: Checking the Expansion Valve........................ 151
6.3 Check No.3 - Checking the Thermistors...................................................... 152
6.4 Check No.4 - Resistance Conversion Table (Ambient, Coil, Fin) ................ 153
6.5 Check No.5 - Resistance Conversion Table (Discharge Pipe Sensor)........ 155
6.6 Check No.6 - Evaluation of Abnormal High Pressure.................................. 156
6.7 Check No.7 - Evaluation of Abnormal Low Pressure................................... 157
6.8 Check No.8 - Clogged Points ...................................................................... 158
6.9 Check No.10 - Outdoor Unit: Fan Speed Pulse........................................... 159
6.10 Check No.11 - Outdoor Unit: Check for Power Transistor ........................... 160
6.11 Check No.13 - Check for Inadequate Refrigerant........................................ 161
6.12 Check No.14 - Check for Excessive Refrigerant Charging.......................... 162
6.13 Check No.15 - Check for Factors Causing Wet Operation .......................... 163
6.14 Check No.16 - Troubleshooting Yonos Para Inverter Pump (Only for EH/VB004-
008)........................................................................................................ 164

ESIE13-02
5 Table of Contents
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5
1
Part 5
Repair
1 Tips and Tricks
Part 6
Maintenance
1 Maintenance Schedule
1.1 Maintenance ................................................................................................ 168

Introduction ESIE13-02
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1 Introduction
1.1 About This Manual
Target group This service manual is intended for and should only be used by qualified engineers.
Purpose of this
manual
This service manual contains all the information you need to carry out the necessary repair and
maintenance tasks for the Daikin Altherma Hybrid.
Six parts This service manual consists of an introduction and six parts:
Note
Part See page
Part 1–System Outline 17
Part 2–Specifications 41
Part 3–Commissioning 51
Part 4–Troubleshooting 53
Part 5–Repair 165
Part 6–Maintenance 167
Manual Contents Gas boiler
section
Heat
pump
sec-
tion
Outdoor
unit
ECPEN13-729_Daikin Altherma
hybrid heat pump_tcm135-285966
general system
explanations
xxx
EEDEN14-729_EHYHBH-AV3_EHY
HBX-AV3_EHYKOMB-AA_LR_tcm13
5-304475
technical data book x x
EEDEN14-729_EVLQ-CV3_LR_tcm1
35-304456
technical data book x
ECPEN13-732_Daikin Altherma
hybrid heat pump engineering
guide_tcm135-298162
engineering guide x x x
AD130276-1_EHYKOMB33AA_tcm1
35-290423
CE declaration x x x
4P349694-1_tcm135-290654 addendum book for
optional equipment
x
4PEN349693-1_2013_05_tcm135-29
0662
general safety pre-
cautions
xxx
4PEN349695-1_tcm135-290651 installation in a nut-
shell
xxx

ESIE13-02 Introduction
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3
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4PEN349587-1A_2013_05_tcm135-2
90364
installation manual x
4PEN353067-1_2013_07_tcm135-29
0386
installation and
operation manual
x
4PEN344906-1_2013_02_tcm135-29
0349
installation manual x
4PEN353731_1B_2013_10_tcm135-
304271
field setting table x
4PEN349588-1_2013_05_tcm135-29
0399
operation manual x
Manual Contents Gas boiler
section
Heat
pump
sec-
tion
Outdoor
unit

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1.2 About the Documentation
The original documentation is written in English. All other languages are translations.
The precautions described in this document cover very important topics, follow them carefully.
All activities described in the installation manual must be performed by an authorized installer.
1.2.1 Meaning of warnings and symbols
DANGER
Indicates a situation that results in death or serious injury.
DANGER: RISK OF ELECTROCUTION
Indicates a situation that could result in electrocution.
DANGER: RISK OF BURNING
Indicates a situation that could result in burning because of extreme hot or cold tem-
peratures.
WARNING
Indicates a situation that could result in death or serious injury.
CAUTION
Indicates a situation that could result in minor or moderate injury.
NOTICE
Indicates a situation that could result in equipment or property damage.
INFORMATION
Indicates useful tips or additional information.
DANGER: RISK OF EXPLOSION
Indicates a situation that could result in explosion.
DANGER: RISK OF POISONING
Indicates a situation that could result in poisoning.
WARNING: PROTECT AGAINST FROST
Indicates a situation that could result in equipment or property damage.

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1.3 For the User
If you are not sure how to operate the unit, contact your installer.
The appliance is not intended for use by persons, including children, with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been given
supervision or instruction concerning use of the appliance by a person responsible for their safety.
Children must be supervised to ensure that they do not play with the product.
Units are marked with the following symbol:
This means that electrical and electronic products may not be mixed with unsorted household
waste. Do NOT try to dismantle the system yourself: the dismantling of the system, treatment of
the refrigerant, of oil and of other parts must be done by an authorized installer and must comply
with applicable legislation. Units must be treated at a specialized treatment facility for reuse,
recycling and recovery. By ensuring this product is disposed of correctly, you will help to prevent
potential negative consequences for the environment and human health. For more information,
contact your installer or local authority.
Batteries are marked with the following symbol:
This means that the batteries may not be mixed with unsorted household waste. If a chemical
symbol is printed beneath the symbol, this chemical symbol means that the battery contains a
heavy metal above a certain concentration. Possible chemical symbols are: Pb: lead (>0.004%).
Waste batteries must be treated at a specialized treatment facility for reuse. By ensuring waste
batteries are disposed of correctly, you will help to prevent potential negative consequences for the
environment and human health.
CAUTION
Do NOT rinse the unit. This may cause electric shocks or fire.
NOTICE
Do NOT place any objects or equipment on top of the unit.
Do NOT sit, climb or stand on the unit.

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1.4 For the Installer
1.4.1 General
If you are not sure how to install or operate 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.
NOTICE
Improper installation or attachment of equipment or accessories could result in elec-
tric shock, short-circuit, leaks, fire or other damage to the equipment. Only use acces-
sories, optional equipment and spare parts made or approved by Daikin.
WARNING
Make sure installation, testing and applied materials comply with applicable legisla-
tion (on top of the instructions described in the Daikin documentation).
CAUTION
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 chil-
dren, can play with them. Possible risk: suffocation.
DANGER: RISK OF BURNING
Do NOT touch the refrigerant piping, water piping or internal parts during and
immediately after operation. It could be too hot or too cold. Give it time to return to
normal temperature. If you must touch it, wear protective gloves.
Do NOT touch any accidental leaking refrigerant.
NOTICE
Provide adequate measures to prevent that the unit can be used as a shelter by small
animals. Small animals that make contact with electrical parts can cause malfunc-
tions, smoke or fire.
CAUTION
Do NOT touch the air inlet or aluminium fins of the unit.
NOTICE
Do NOT place any objects or equipment on top of the unit.
Do NOT sit, climb or stand on the unit.

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1.4.2 Installation site
Provide sufficient space around the unit for servicing and air circulation.
Make sure the installation site withstands the unit’s weight and vibration.
Make sure the area is well ventilated.
Make sure the unit is level.
Make sure that the floor, where the unit will be installed, is level.
Make sure walls sensitive to heat (e.g. wood) are protected by suitable insulation.
ONLY operate the gas boiler if a sufficient supply of combustion air is ensured. In case of a
concentric air/flue gas system dimensioned according to the specifications of this manual, this is
fulfilled automatically and there are no other conditions for the equipment installation room. This
method of operation applies exclusively.
This gas boiler is NOT designed for room air dependent operation.
Do NOT install the unit in the following places:
In potentially explosive atmospheres.
In places where there is machinery that emits electromagnetic waves. Electromagnetic waves may
disturb the control system, and cause malfunction of the equipment.
In places where there is a risk of fire due to the leakage of flammable gases (example: thinner or
gasoline), carbon fibre, ignitable dust.
In places where corrosive gas (example: sulphurous acid gas) is produced. Corrosion of copper
pipes or soldered parts may cause the refrigerant to leak.
In bathrooms.
In places where frost is possible. Ambient temperature around the indoor unit should be >5°C.
1.4.3 Refrigerant
Only use phosphoric acid deoxidised seamless copper with annealed temper grade.
NOTICE
Make sure refrigerant piping installation complies with applicable legislation. In
Europe, EN378 is the applicable standard.
NOTICE
Make sure the field piping and connections are not subjected to stress.
WARNING
During tests, NEVER pressurize the product with a pressure higher than the maxi-
mum allowable pressure (as indicated on the nameplate of the unit).
WARNING
Take sufficient precautions in case of refrigerant leakage. If refrigerant gas leaks,
ventilate the area immediately. Possible risks:
Excessive refrigerant concentrations in a closed room can lead to oxygen
deficiency.
Toxic gas may be produced if refrigerant gas comes into contact with fire.
WARNING
Always recover the refrigerants. Do NOT release them directly into the environment.
Use a vacuum pump to evacuate the installation.

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1.4.4 Brine
If applicable. See the installation manual or installer reference guide of your application for more
information.
1.4.5 Water
Avoid damages caused by deposits and corrosion. To prevent corrosion products and deposits,
observe the applicable regulations of technology.
Measures for desalination, softening or hardness stabilization are necessary if the filling and top-up
water have a high total hardness (>3 mmol/l-sum of the calcium and magnesium concentrations,
calculated as calcium carbonate).
Using filling water and top-up water which does NOT meet the stated quality requirements can cause
a considerably reduced service life of the equipment. The responsibility for this is entirely that of the
user.
WARNING
The selection of the brine MUST be in accordance with the applicable legislation.
WARNING
Take sufficient precautions in case of brine leakage. If brine leaks, ventilate the area
immediately and contact your local dealer.
NOTICE
Make sure water quality complies with EU directive 98/83 EC.

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1.4.6 Electrical
Install power cables at least 1 meter away from televisions or radios to prevent interference.
Depending on the radio waves, a distance of 1 meter may not be sufficient.
DANGER: RISK OF ELECTROCUTION
Turn OFF all power supply before removing the switch box cover, connecting
electrical wiring or touching electrical parts.
Disconnect the power supply for more than 1 minute, and measure the voltage at
the terminals of main circuit capacitors or electrical components before servicing.
The voltage MUST be less than 50 V DC before you can touch electrical
components. For the location of the terminals, see the wiring diagram.
Do NOT touch electrical components with wet hands.
Do NOT leave the unit unattended when the service cover is removed.
WARNING
If NOT factory installed, a main switch or other means for disconnection, having a
contact separation in all poles providing full disconnection under overvoltage cate-
gory III condition, shall be installed in the fixed wiring.
WARNING
ONLY use copper wires.
All field wiring must be performed in accordance with the wiring diagram supplied
with the product.
NEVER squeeze bundled cables and make sure they do not come in contact with
the piping and sharp edges. Make sure no external pressure is applied to the
terminal connections.
Make sure to install earth wiring. Do NOT earth the unit to a utility pipe, surge
absorber, or telephone earth. Incomplete earth may cause electrical shock.
Make sure to use a dedicated power circuit. NEVER use a power supply shared by
another appliance.
Make sure to install the required fuses or circuit breakers.
Make sure to install an earth leakage protector. Failure to do so may cause electric
shock or fire.
When installing the earth leakage protector, make sure it is compatible with the
inverter (resistant to high frequency electric noise) to avoid unnecessary opening
of the earth leakage protector.
WARNING
After finishing the electrical work, confirm that each electrical component and
terminal inside the electrical components box is connected securely.
Make sure all covers are closed before starting up the unit.

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1.4.7 Gas
The gas boiler is factory set to:
The type of gas quoted on the type identification plate or on the setting type identification plate.
The quitted gas pressure.
Operate the unit ONLY with the gas type and gas pressure indicated on these type identification plates.
Installation and adaptation of the gas system MUST be conducted by:
Personnel qualified for this work.
In compliance with valid gas installation related guidelines.
In accordance with applicable regulations of the gas supply company.
In accordance with local and national regulations.
Boilers that use natural gas MUST be connected to a governed meter.
Boilers that use liquid petroleum gas (LPG) MUST be connected to a regulator.
The size of the gas supply pipe should under no circumstance be less than 22 mm.
The meter or regulator and pipe work to the meter MUST be checked preferably by the gas supplier.
This is to ensure that the equipment works good and meets the gas flow and pressure requirements.
1.4.8 Gas exhaust
Flue systems must NOT be modified or installed in any way other than as described in the fitting
instructions. Any misuses or unauthorized modifications to the appliance, flue or associated
components and systems could invalidate the warranty. The manufacturer accepts no liability arising
from any such actions, excluding statutory rights.
It is NOT allowed to combine flue system parts purchased from different suppliers.
DANGER
If you smell gas:
Call immediately your local gas supplier and your installer.
Call the suppliers's number on the side of the LPG tank (if applicable).
Turn off the emergency control valve at the meter/regulator.
Do NOT turn electrical switches ON or OFF.
Do NOT strike matches or smoke.
Put out naked flames.
Open doors and windows immediately.
Keep people away from the affected area.

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1.4.9 Local legislation
Local regulations
for UK
It is law that all gas appliances are installed by a gas safe registered competent engineer and in
accordance with the following recommendations:
Current Gas Safety (Installation and Use) Regulations.
All current building regulations.
Building Standards (Scotland) Consolidated.
This appliance MUST be installed in accordance with the Gas (Safety and Use) Regulations,
current Building Regulations, Building Standards (Scotland), I.S.813 Installation of Gas Appliances
(Ireland), IEE Wiring Regulations (BS 7671), Health and Safety Document No. 635 (Electricity at
Work Regulations) and Local Water Authority Bye Laws.
UK Water Regulations and Bye Laws.
Health & Safety.
The installation MUST comply with the following British Standards codes of practice:
BS 5440: Flues and Ventilation for gas appliances of rated input NOT exceeding 70 kW (Part 1
Flues).
BS 5440: Flues and Ventilation for gas appliances of rated input NOT exceeding 70 kW (Part 2 Air
Supply).
BS 5546: 2000 Installation of gas hot water supplies for domestic purposes.
BS 5549: 1990 Forced circulation hot water systems.
BS 6700: 1997 Design, Installation, testing and maintenance of services supplying hot water.
BS 6798: 2000 Specification for installation of gas fired hot water boilers of rated input NOT
exceeding 70 kW.
BS 6891: 1998 Installation of low pressure gas pipe-work installation up to 35 mm (RI).
BS 7593: 1992 Code of practice for treatment of water in heating systems.
BS 7671: 2001 Requirements for electrical installations, IEE Wiring regulations.
BS7074:1: Code of practice for domestic and hot water supply.
EN12828: Central heating for domestic premises.
Potable water: all seals, joints and compounds (including flux and solder) and components used as
part of the secondary domestic water system MUST be approved by WRAS.

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ESIE13-02
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Part 1
System Outline
What is in this part? This part contains the following chapters:
Chapter See page
1–Description 18
2–Functionality 22
3–Wiring Diagrams 32

Description ESIE13-02
Part 1 – System Outline 18
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1 Description
1.1 System Build-up
The system combines a gas condensing boiler and a heat pump (hydro-box) for space heating and
domestic hot water. Depending on the position of the 3-way valve, the gas condensing boiler can either
be bypassed or not. The heat pump can either operate or not, depending on the active operation mode
(heat pump only, gas condensing boiler only or hybrid (= heat pump and gas condensing boiler)).
Wall hung
condensing boiler
Outdoor unit
HP hydro-box

ESIE13-02 Description
19 Part 1 – System Outline
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1.2 Components and Connections
1.2.1 Gas condensing boiler
Item Description Item Description
a Gas valve k Air supply cap
b Boiler control panel l Flue pipe adapter (use ONLY in combination
with the accompanying elbow in flue sets)
c Sensor S1 m Connection block/terminal strip X4
d Sensor S2 n Condensate drain pan
eFan oHotwatersensorS3
f Flow sensor p Condensate S3
g Space heating pressure sensor q Heat exchanger
h Mains lead 230 V AC without plug
(stripped)
r Operating panel and read-out
i Manual air bleed s Ionisation/ignition electrode
j Sight glass t Position of data plate
i
j
c
q
d
o
g
h
n
m
p
s
e
a
f
t
b
r
l k

Description ESIE13-02
Part 1 – System Outline 20
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1.2.2 Hydro-box
Item Description
aGasin
b Cold water in
c Refrigerant gas connection
d Refrigerant liquid connection
e Heating return
f Heating flow
g Hot water out
c
def
a
b
g