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Samsung Eco Heating System 2010-15

Service Manual

Model Numbers:
RC090MHXEA and RC160MHXEA
This is the Freedom Heat pumps service manual for Samsung
air sourced heat pumps from 2010 – 2015.
Its all the work of Freedom Heat Pumps, if you like it and
would like a version for the current units you need to come on
service partner training click here.
https://www.freedomhp.co.uk/training/
www.freedomhp.co.uk
©G Hendra Nov 18
1

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Table of Contents

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   Summary of Contents for Samsung RC090MHXEA

  • Page 1: Service Manual

    Service Manual Model Numbers: RC090MHXEA and RC160MHXEA This is the Freedom Heat pumps service manual for Samsung air sourced heat pumps from 2010 – 2015. Its all the work of Freedom Heat Pumps, if you like it and would like a version for the current units you need to come on service partner training click here.
  • Page 2 Self-Test mode With the power OFF, remove the front of the remote controller, slide it upwards, turn it over DON’T TOUCH THE PCB, there are 8 dip switches near the red sensor, using a small screwdriver flick dip switch 1 and 5 to on. Cooling will no longer be available and test run will be activated.
  • Page 3 Operation Button Display Enter test mode – hold Blue set button and the Test button together for 5 seconds Run the water circulation pump (B6 live) – Press the Heating on/off button Run the Backup heater/boiler (B2 live) – press the Mode button (Heating) Run the immersion heater (Terminal A3&A4) –...
  • Page 4 On the main MIM control PCB there are 7 orange leds above the relays When lit: Led 500 immersion heater A4 live Led 501 backup heater stage 1 B2 live Led 502 backup heater stage 2 B3 live Led 503 backup boiler (hybrid) B4 live Led 504 pump running B6 live Led 505 Hot water valve open...
  • Page 5 What makes the unit go? When operating the unit measures the water flow and return temperatures across the outdoor heat exchanger. T/S 2 and T/S1 in the diagram below. If the delta T (temp difference across T/S1 and T/S2) is 5 degrees C the unit is happy, this is its main control feature.
  • Page 6 Interogating the outdoor unit Using the 4 buttons at the bottom of the main PCB on the outdoor unit PCB you can run the units in test modes Normal display Is flashing between AdFO-0000- Button K3 resets the unit, it’s a quick way of resetting the power. By pressing button K4 you enter the service mode, here you can monitor the units operation.
  • Page 7 My unit seems to be struggling and is freezing up? In cold weather we get reports that units are freezing up excessively or the unit is not achieving high enough radiator and floor temperatures: This can be caused by the unit having a fault or it not being big enough for the job.
  • Page 8 Also see E231 it could be the coil sensor reading a high temperature. Not enough hot water If it is reported that the temperature of the hot water is too low a few tests need to be made. Make sure the tank sensor is in the pocket 1/3 of the way from the top of the cylinder, it must be above the immersion coil.
  • Page 9: Legionella Protection

    Legionella protection Legionella The legionella function operates the immersion heater in the hot water cylinder once a week or every day to disinfect the hot water tank. We normally encourage engineers to set the legionella function to start at 3 am on Tuesday morning and to heat the tank to 60C for 10 mins.
  • Page 10 The Operation of the HW cylinder The operation of the HW cylinder is as follows: Factory set, if the hot water set temperature is set to + 48C the unit will start heating the cylinder when the temperature drops 5C below set point (43C), it will heat the cylinder until 2 degrees above set point or 50C.
  • Page 11 Warm rads in summer After HW mode is finished the compressor stops and the HW valve close, the heating valve opens (there is always one valve open) this means any hot water left in the pipework will be pumped around the heating circuit for the 6-minute run on. Some end users experience a rise in radiator temp during this period.
  • Page 12 If you are experiencing high run costs check the following: It’s always assumed that the whole electricity bill is the heat pump, but this is not the case, what is the background usage (lights TV, internet hot tub etc.?) this could be anywhere from 0 to 100% of this bill.
  • Page 13 Tank timers and solar When using solar thermal it’s a good idea to time clock the cylinder so it’s off all day allowing the solar to work. Set an on time: Press daily button once, no 1 and on shows, press set (grey), press up or down until the tap symbol shows at the top of the screen with 2 dots, press set, adjust hours with up or down button to 3 am, press set, minutes flash, press set.
  • Page 14 Weather Comp In almost all cases we run our systems using an external run signal, be it a stat, switch, timer or signal from an under floor heating manifold, these are connected to the control box as per the diagram below. By using these terminals, the water flow temperature is weather compensated, meaning flow temperature varies with the ambient air temperature.
  • Page 15 Cold Weather Protection The Samsung unit has a number of cold weather protection functions these include: The heat pump cannot operate if the water in the system is less than 10C, if the unit detects the heat exchanger is less than 10C it does two things: Firstly, the pump is switched on for a couple of minutes to bring water in from the system indoors to maintain the temperature.
  • Page 16 S3 sound meter. Note these readings do not relate to the figures given in proper sound testing carried out by Samsung in Anechoic chambers with covers on at 1m. The figures should be used for reference purposes only.
  • Page 17 We use switch 2 to activate the sensor in the remote controller, this can (but don’t) be used to control the unit using the Samsung controller as a room stat. In this mode the unit runs in weather comp. both as a function of outdoor temperature (see weather comp) and as it gets close to the set temperature the unit also drops the flow temperature.
  • Page 18 E101, E102, E201 and E202 E101 shows on the indoor unit if the outdoor unit has been off for more than 5 minutes E201 and E102 is a communication error between indoor control box and the outdoor unit. E202 shows on the outdoor unit if the indoor unit has been off for more than 5 minutes The communication is carried out using the F1 and F2 cable between the two units.
  • Page 19 Electrically testing the communications With unit completely powered up but NOT running Set your multimeter to DC Voltage, and place the probes on F1 and F2 on the indoor mim PCB, If the voltage reading is fluctuating between 160mV and 210mV the units are communicating healthily and there is no problem.
  • Page 20 E177 emergency stop The mim control box pcb is faulty. E203 E203 is caused by the inverter board not being connected to the main PCB in the outdoor unit. The fault will be displayed on the outdoor unit, the compressor will not run. To fix the error TURN OFF THE POWER and wait 2 mins before touching anything.
  • Page 21 E221, Temperature Sensors E221 is an error with the outdoor unit air sensor mounted on the back of the unit in a black tube at the top. It’s connected to the main PCB in connector at the top right of the PCB called CN43 in a white and red plug;...
  • Page 22 E231, Temperature Sensors E231 is an error with the outdoor refrigerant coil sensor. It’s connected to the main PCB in connector at the top right of the PCB called CN43 in a white and red plug; it’s the 3 and 4 wire from the bottom.
  • Page 23 E251, Temperature Sensors E251 is an error with the compressor discharge pipe sensor. It’s the blue sensor on the pipe leaving the compressor. It’s connected to the main PCB in connector at the top right of the PCB called CN43 in a white and red plug; it’s the 3 and 4 wire from the top.
  • Page 24 E320 Temperature Sensors E320 is an error with the compressor body sensor. It’s the blue sensor under the wiring cover on top of the compressor; it’s the size of a £1 coin It’s connected to the main PCB in connector at the top right of the PCB called CN43 in a white and red plug;...
  • Page 25 E403 – Cold weather shutdown E403 is a very, very rare error where the compressor refuses to kick in because the temperature outside AND inside is too cold, it all comes down to where the remote controller is located (If located in an unheated space, you’ll find this fault). You’ll also find this fault if you have left the power off to the outdoor unit in cold weather for a long period of time.
  • Page 26 E407 fault code High pressure trip, and flow rate problems. An E407 fault is caused by the unit tripping out on high refrigerant pressure; it will be showing on the PCB of the outdoor unit In almost all cases its caused by crap in the water heat exchanger.
  • Page 27 Test 2 if the unit passes test one you now need to start the unit up, when it starts up watch the outdoor unit, if it starts up and operates for about a minute and then trips on E407 the unit is running against a refrigeration blockage, its highly likely that the expansion valve is not opening quickly enough.
  • Page 28 E416 compressor discharge temperature high. See E251 E425 – phase power rotation error you get this if you put 3 phase pcb in a single phase unit E440 This is a very unusual fault that is unlikely to ever come up. This will only appear on the outdoor unit when there is a heating request when the outdoor temperature is above 30C.
  • Page 29 E458 Outdoor fan no 1 (top) error E458 is caused by the top fan not turning. On a single fan size 9 units, it is possible to see this problem because you will be able to hear the compressor running but the fan will not be moving.
  • Page 30 E460 An E460 fault only affects split units. The fault will display for about a minute when the unit is powered up. The fault will then change to E101. This would point towards a communication error between the indoor and outdoor unit. The fault is actually caused by the small PCB (circled) on the front of the main PCB in the outdoor unit being loose.
  • Page 31 E464 An E464 fault is caused by the unit tripping out on high compressor current; this is caused by the compressor having to work excessively hard, the compressor being faulty or the PCB which drives the compressor being faulty. Is the unit working too hard.? Very likely in new installations If the water returning to the unit is not significantly lower in temperature than the flow, in other words no heat is being rejected in the house.
  • Page 32 Testing the inverter pcb 16kW Set your meter to Ohms put the red lead on P shown and measure the resistance to each of the 3 compressor terminals, the reading should be the same on all 3 terminals it should be above 2M Ohms.
  • Page 33 Testing the inverter pcb 16kW Set your meter to Ohms put the red lead on N shown and measure the resistance to each of the 3 compressor terminals, the reading should be the same on all 3 terminals it should be above 2M Ohms.
  • Page 34 Testing the inverter pcb 9kW Set your meter to Ohms put the red lead on the diode shown and measure the resistance to each of the 3 compressor terminals, the reading should be the same on all 3 terminals it should be above 4M Ohms.
  • Page 35 Testing the inverter pcb 9kW Set your meter to Ohms put the red lead on the solder blob shown and measure the resistance to each of the 3 compressor terminals, the reading should be the same on all 3 terminals it should be above 4M Ohms. www.freedomhp.co.uk ©G Hendra Nov 18...
  • Page 36 How to replace the Inverter PCB Power off the unit first and wait 2 mins till all the leds go out. Pull the two black cables off the front of the plastic clips and remove the 2 screws. The PCB needs to be pulled forward at the front by 50mm and then slides out complete with the cooling fins.
  • Page 37 We had one-unit size RD160 with this fault which was caused by the inverter pcb being faulty, new pcb and it works Just had an rc090mhxea unit with the same problem. Looks like the inverter pcb does cause this problem.
  • Page 38 E467 This fault will appear on the outdoor unit PCB display. It means that there is a connection issue with the compressor or the compressor has a fault. The first thing to check is if the cable from the compressor is fully connected to the inverter PCB as shown on the right hand picture.
  • Page 39 E470 Eeprom not written to outdoor PCB, needs a replacement PCB. E475 Bottom fan error This error only appears on size 16 units RC160MHXEA. It happens when fan 2 (bottom) is faulty. The fault is clear to see as only the top fan will be spinning when the unit is running.
  • Page 40 E500 IPM (inverter) overheating If you don’t use heat paste or don’t tighten the screws into the heat sink you will see E500. Tighten the screws, put heat paste under the chip s and check the fan motor top runs when the compressor is running E554 Gas leak error.
  • Page 41 E602 On the back of the controller you can see 8 dip switches; these are used to programme the unit. If you hold the remote controller with the red sensor at the top from factory all of them are switched off. Down Switch 1 is on the left, if switch 4 is set to on or up the controller will not start up properly, all that will be seen is some flashing lines going in a circle under schedule, and will show E602 error after 5 mins.
  • Page 42 E601 and E604 E601 and E604 is a communication error between the remote controller and the indoor PCB. Firstly make sure the controller cables are connected to the PCB in the right order. F4 is black, F3 is red, V2 is brown and V1 is orange. The cable plugs into the back of the PCB using a white plug, it only fits in one place.
  • Page 43 E653 E653 is a fault with the sensor in the back of the remote controller red see photo This sensor cannot be unplugged for testing so with the power on, press the blue set button until a house symbol appears with a thermometer by it, this is measuring the temperature at the remote controller.
  • Page 44 E901 E901 is an error with the outdoor unit, lower (inlet or return) water heat exchanger sensor. It’s connected to a yellow plug on the bottom right of the main PCB connector CN44 in a yellow plug; it’s the top two wires You can view this sensor in the test mode from the remote controller inside.
  • Page 45 E902 E902 is an error with the outdoor unit, upper (outlet or flow) water heat exchanger sensor. It’s connected to a yellow plug on the bottom right of the main PCB connector CN44 in a yellow plug; it’s the middle two wires You can view this sensor in the test mode from the remote controller inside.
  • Page 46 E903 E903 is an error with the red back up heater sensor connected to the white plug in the bottom right hand corner of the PCB of the MIM indoor control PCB, this error only shows if field setting 4021 is set to 1. When field setting 4021 is set to 1 this sensor is used to measure the flow temperature, it replaces the one in the outdoor unit (see fault E902).
  • Page 47 E904 E904 indicates a problem with the blue hot water cylinder sensor in the MIM control box E904 only shows if field setting 3011 is set to 1 (unit has a tank) To test this sensor press the blue set button until the tap icon appears, this will show the temperature its measuring, if this reading differs from the tank temperature the sensor will need replacing.
  • Page 48 E906 E906 is an error with the outdoor unit, refrigerant sensor mounted under the expansion valve sensor. It’s connected to a yellow plug on the bottom right of the main PCB connector CN44 in a yellow plug; it’s the bottom two wires This sensor is red;...
  • Page 49 Temperature Sensor Errors E221, E231, E251, E320, E653, E901, E902, E903, E904, E906 Temperature sensor errors are a pretty easy fault to diagnose and usually results in replacement of the sensor that the error code corresponds to. But, it’s still worth checking to see if the sensor is at fault before changing it.
  • Page 50 Using a meter, measure the resistance of the sensor, to do this un plug the sensor from the PCB, set your meter to the ohms or Ω setting, Measure resistance across the sensor and compare the reading from the meter to the tables below. All sensors change resistance with temperature, it’s important to check the sensor reads the correct value for the temperature it is measuring.
  • Page 51 E911 and my units keep stopping E911 is a simple fault; the flow speed through the unit is not high enough. You should have a flow meter installed, if you haven’t now is the time to buy one. If you look into the flow meter you can see the flow in litres per minute.
  • Page 52 E912 E912 means that the Samsung unit can detect flow when it thinks the pump is not running. Go to the test function on the controller by holding down the test button and blue set button. TEST or 7357 will show, see picture.

This manual is also suitable for:

Rc160mhxea

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