INVERTER CHECKER
Equipment for testing and diagnostic of the
FUJITSU-GENERAL
inverter split systems
USER MANUAL
UTQ-TOOLBOX contains:
UTQ-COMP - checker for DC compressors
UTQ-DCFM - checker for DC fan motors
UTQ-STPM - EEV stepper motor and louver motor checker
UTQ-COMSIM - simulation of indoor and outdoor units, monitoring of communication
UTQ-COMTEST - checker of correct unit wiring and their communication
UTQ-LOGGER - recording device for communication data
UTQ-UPGC - USB data cable for software upgrade of the inverter checker modules
UTI-FG-BT - monitoring of FGL using Bluetooth module and mobile
UTQ-CASE - carrying case
SAFETY PRECAUTIONS
WARNING
This mark indicates procedures which, if improperly performed, might lead to the
death or serious injury of the user.
•
All work associated with installing and connecting the checkers may be performed only by a
person with qualifications in the field installation and servicing of Fujitsu air conditioning and must
be licensed to work on electrical and cooling equipment.
•
The compliance with installation instructions provided in this documentation is necessary for
ensure technical parameters and reliable operation.
•
Do not turn on the power of the unit until all installation work is complete.
•
During the tests: Do not touch the exposed connectors! There is high voltage and a danger of
electric shock.
CAUTION
•
This mark indicates procedures which, if improperly performed, might possibly
result in personal harm to the user, or damage to property.
The manufacturer is not liable for damages caused by failure to comply with technical
specifications, errors in installation, maintenance and improper use of the product.
COMPRESSOR CHECKER
Functional testing of inverter DC compressors
Preparation for testing:
•
Disconnect the cables of the compressor from the outdoor unit PCB.
•
Use an ohmmeter (with a range of megaohms) for checking possibility of short circuit or leakage
between the connector contacts and the motor frame. All values must be outside of top of the
range of the ohmmeter. Otherwise, the motor is defective. Do not continue with testing, the
checker could be damaged.
•
Check the resistance between the compressor leads with ohmmeter. The value of resistance of
the motor winding can be, depending on the compressor, in the order of tenths to whole Ohms. It
is essential that the resistance of all winding showed the same value. If any value is significantly
different, the engine is defective. Do not continue with testing, the checker could be damaged.
•
Connect the power cord lead to the 230VDC power supply of the tester (fused at least with 16A
circuit breaker). The switch ‘’POWER’’ must be in position ‘’O’’, switch ‘’TEST’’ in position ‘’STOP’’
and the desired speed of compressor must be set by switch in position ‘’LOW’’
•
Connect the cable of the checker to the three connectors of compressor windings and ground
clamp to the frame or chassis of the outdoor unit.
Test of the compressor
1. Turn on the tester by switch ‘’POWER’’
2. After pressing the TEST switcher, the compressor will start and its speed is gradually increasing
from zero to 50% of the maximal speed. LED during the test alternate between red and green.
3. Please do check the running compressors check by hearing in case that shows any unusual
noises.
4. After the test of the compressor, the final result is indicated by LED ‘’Status’’
Continuous green light … compressor is OK
Red flashing … compressor is faulty (detailed errors identification - see Table)
Green flashing … checker error (detailed errors identification - see Table)
In case of a positive test result from position ''LOW'‘, the test can be repeated again with a speed
switch in position '‘HIGH'‘. This mode will increase speed gradually up to the maximum of 100%.
CAUTION
Before each repetition of the test is necessary wait at least three minutes until
the pressures in the refrigerant circuit gets balanced again!
COMPRESSOR CHECKER
RED and GREEN flashes alternately
GREEN lights continuously
The TEST is running
The compressor is OK
ERROR of the compressor :
RED flashes
2x it’s not possible reach the maximum rotor speed
3x phase currents asymmetry - different winding
resistances
4x winding insulation resistance to ground <1MOhm
5x supply current limit exceeded
6x compressor spin failed
ERROR of the Checker:
GREEN flashes
2x DC bus low voltage +350 V (less than 300V) – check
the power supply of the tester
3x high temperature of heat sink – please leave the tester
cool down
RED flashing rapidly
Firmware of checker is faulty – upgrade was not
successful. In this case, it is necessary to repeat the
upgrade again (see chapter - UPGRADING cable).
Testing software – see the example of testing with the result: Compressor is OK
DC MOTOR CHECKER
Functional testing of DC fan motors of indoor and outdoor units
2 - colour LED
Function switcher
The connector box
Tested DC motor
Main switch
Controller of manual speed adjustment
Power lead
Test process:
-
-
-
Turn off the power of the unit and wait a few minutes for the power supply capacitors to discharge.
Disconnect the DC motor connector from the control PCB of the unit.
Turn the rotor of the fan by hand. If you can feel a significant resistance, the motor is faulty. In that
case, do not continue with testing, the checker could be damaged.
Use an ohmmeter (with a range of megaohms) for checking possibility of short circuit or leakage
between some of the motor leads (red, black, white) and the motor frame. All values must be
outside of top of the range of the ohmmeter. Otherwise, the motor is defective. Do not continue
with testing, the checker could be damaged.
Use an ohmmeter to check the resistance between each motor power connections (red, black,
white) - must not show measurable resistance. Otherwise, the motor is defective. Do not
continue with testing, the checker could be damaged.
Connect the motor to the checker. During the connecting, the checker must be switched off by
main switch and the function switcher in position 0!
CAUTION
Plug the motor connector to the mating connector in connector box. Attention! Connectors of
certain motor types have colour coding in reverse order. Make sure that the colour of cable
wire matches the colour coding of engine connector; otherwise the engine and the checker can
be damage.
AUTO test: Turn on the main switch and then the function switcher to TEST mode. The motor spins
continuously and then reduces speed to zero. During the test, the LED flashes in red and green
alternately. Keep checking if the motor does not have any vibration, or unusual noises. If the LED after
the test is lit in solid green, the engine is electrically fine. If the LED is lit in solid red or flashing red, the
engine is faulty. If the automatic test is successful, the engine can be tested in a manual mode.
MANUAL test: Change the function switcher to MAN. In this mode, you can increase or decrease the
speed by control manual settings. Test the motor gradually throughout of his speed range. If the
engine does not respond correctly, or LED lights up red, the engine is defective.
DC MOTOR CHECKER
WARNING
- During the test, the motor must be properly fixed to avoid any personal injury or material damage.
- And also do not touch the connectors! There is high voltage and a danger of electric shock.
- Tester may use only competent person which is able to work with electrical equipment.
CAUTION
The engine must be loaded during the test, if possible with the original fan rotor (propeller). Unloaded
motor may (depending on type) show during acceleration twitching, irregular operation, vibration or
engine can be evaluated by tester as faulty.
ERROR TABLE
Red blinking
2x breakdown of DC voltage into +15V power
supply
3x breakdown of DC voltage into PWM outlet
4x breakdown of DC voltage into PULSE outlet
5x low voltage + 15V is less than 14V
6x voltage +350V is less than 200V
7x overload of PWM
8x exceeded the current limit
STEPPER MOTOR CHECKER
Functionality testing of motors of electronic expansion valve (EEV) and also the louver stepper motors.
The connector box
1. Testing and adjusting the position of
stepper motors:
- Connect the stepper motor to the checker
and turn on the main switch ON.
Louver motor
LCD display
- Press the button FN and select function
EL.CHECK, press +, then checker will
automatically check all four motor windings.
The result is displayed on the
LCD display. Any significant
difference between the four
results means that EEV is faulty.
Function selection
The manual control
Main switch
Power lead
2. Monitoring the operation of stepper
motors controlled by PCB unit:
- Press the button FN and select function
MANUAL or FAST. Use the buttons + and – to
manually control motorized rotating in both
directions (e.g. close and opening EEV).Check
if the motor rotates correctly.
Control PCB
- Turn off power to the unit.
- Disconnect the stepper motor connector from
PCB and connect instead the flat cable
connector from the connector box.
- Cable of stepper motor is connected to
corresponding connector in connector box.
- Power ON the unit and the checker.
- Press the button FN and select function
AUTO. Now is possible to
see and track the number
of pulses of the stepper
motor controlled by the
unit. If you need to open or close EEV more,
please use for it the buttons + and - During the monitoring is also possible to see
status of the excitation pulses (- - - -) but in
case of any prohibited pulse combination, the
checker will display symbol E.
EEV
STEPPER MOTOR CHECKER
Schematic view of individual checker screens with detail explanation.
Select function by button FN
In case of connection n.2 (monitoring), press the button
FN and select function AUTO. Now is possible to see and
track the number of pulses of the stepper motor controlled
by the unit. If you need to open or close EEV more, please
use for it the buttons + and -
The manual opening
or closing of EEV
The fast manual
opening or closing of
EEV
In case of connection n.1, choose
the function EL.CHECK, press +,
then checker will automatically
check all four motor windings. The
result is displayed on the LCD
display. Any significant difference
between the four results means
that EEV is faulty.
In the case of display
winding is interrupted
----
In the case of display
winding is shorted
XXXX
SIMULATOR CHECKER
Simulator of indoor and outdoor unit, communication monitoring
Testing of inverter outdoor units by simulations of the indoor unit (possible use with LOGGER)
- Turn off power supply of outdoor unit.
- From the terminal, designed for connecting cable, disconnect the communication cable.
- Connect the tester to the outdoor unit through a terminal intended for the connection cable.
- On the tester set the function switcher to INDOOR position.
- Turn on power of outdoor unit and in the menu set the right model of the unit (or type
of communication AOYA, AOYD, AOYR, AOY, DX)
- Now the outdoor unit can be controlled by SIMULATOR CHECKER
Black (L)
White (N)
Red (C)
To indoor unit
Outdoor unit
terminal
Power supply cable
Testing of indoor unit by simulation of outdoor unit (possibility use with LOGGER)
Turn off power supply of outdoor unit.
From the terminal, designed for connecting cable, disconnect the communication cable.
Connect the tester to the indoor unit through a terminal intended for the connection cable.
On the tester set the function switcher to OUTDOOR position.
Turn on power of indoor unit and in the menu set the right model of the unit (same as for
indoor mode)
Now the indoor unit can be controlled by SIMULATOR CHECKER
Black (L)
White (N)
Red (C)
Indoor unit
terminal
Cable to outdoor unit
Monitoring of communication between indoor and outdoor unit (possibility use with LOGGER)
Turn off power supply of outdoor unit.
Connect the tester to the indoor unit through terminals, designed to connect the cable.
On the tester set the function switcher to MONITOR position
Turn on power of outdoor unit + indoor unit
Now you can monitor the communication between the indoor and outdoor unit by program
Simulator, connected to checker over the USB data cable or use a LOGGER.
Black (L)
White (N)
Red (C)
Outdoor unit
terminal
Indoor unit
terminal
Tester is possible to connect either to indoor or outdoor unit
SIMULATOR CHECKER
Description of each simulator screen with detail explanation
1. Screen of indoor unit (INDOOR mode ON)
It is possible to simulate ON / OFF or switch cooling / heating
(Next to the function which is ready to be simulate is appearing a symbol of arrow)
Exchanger temperature (+25°C)
Information about the
power request (60%)
Indoor unit
request – ON
or OFF
Unit mode - cooling or
heating (Cl/Ht)
2. Screen of outdoor unit (OUTDOOR mode ON)
It is possible to simulate a several following operations (see screens below)
Outdoor
temperature
(+25°C)
Error
simulation
Defrosting
OFF
Simulation of
Compressor
ON
Simulation of
Compressor
OFF
Defrosting
ON
3. Screen for setting a power request
If is Monitor mode active then this screen is just informative without any possible modification
Setting of power request (33%)
SIMULATOR CHECKER
Description of each simulator screen with detail explanation
4. Screen display information from controller (MONITOR mode ON)
Active only with the latest series of G model units (in all modes). While you in monitoring mode
the other available screen are - Indoor, Outdoor, power req. and type of unit. The screens
are for information only and cannot be modify (no arrow symbol)
Required temperature (+16°C)
Indoor temperate (+23°C)
Fan on the controller:
Mode on the controller:
Stop, Cool, Dry, Heat, Fan, Auto
FA(auto), FH(high),
FM(medium), FL(low),
FQ(quiet)
Outdoor temperature (+24°C)
Error Code:
Defrosting OFF
Same as error code of remote
controller
5. Screen for setting type of unit
Possible to be modify only if the INDOOR or OUTDOOR mode are active. Choose a right
model of the unit or right type of communication in case of older type of units like AOYA,
AOYD, AOYR, AOY, DX
Select a simulation of the outdoor unit (in this
case AOYG12LALL). If it is necessary to
simulate the indoor unit then must be on the
screen selected the appropriate compatible
outdoor unit.
COMUNICATION TESTER
Tester of correct unit wiring and their communication
USED FOR TESTING:
-
Connection of the power supply
The correct cable connection.
Communication between indoor and
outdoor unit in the individual directions.
The functionality of external outputs of
modules UTI-INV-xxx and UTI-EXP.
1. Test of connection and communication:
a. Connect the crocodile clip from tester to the ground terminal or ground of the IU or OU.
b. Attach the probe tip to the testing terminal.
c. Watch glow of green and red LED:
N zero terminal (white wire from the terminal to the electronics of unit):
LED is not lit
L phase (black wire):
Green and red LED lights continuously
C communication terminal (red wire):
Flashing red LED: direction from inside to outside
Flashing green LED: direction from outside to inside
2. Test of external outputs UTI-INV-xxx (ON ERR DEF) and UTI-EXP:
According to the current output either of the LED is off, or both LED lights continuously. Another way
of indication means the malfunction.
LOGGER
Recording device for communication data
The LOGGER scans the data from communication line and saves them on the SD memory card for
future analysis, the possibilities of use are following:
-
-
between indoor and outdoor unit with the connected Simulator checker (monitoring mode)
between Compressor checker and connected compressor for testing
between Simulator checker and connected indoor or outdoor unit (indoor or outdoor mode)
from connected UTI-INV-xx module
ATTENTION:
•
•
Whenever you connect the logger, either during testing or monitoring, then on the SD card is
created a file matching a given date (see picture below L130723 = July 23, 2013).
And also it should be remembered that if the logger is used a several times in one day, all the data
are always saved together into a same file!! (but displayable in the checker viewer in separated
time subfolders)
TIME SETTING
a) if it is necessary in the logger set the current time, then you need to upload on SD card a time.txt
file (could be created in windows notepad), which contains desired time and date configuration
(see figure below 240613183900 = 24.6.2013,18:39:00)
b) the next time when you are connecting the logger for testing, the time will be set automatically to
required settings
c) but it should be remembered that the LOGGER itself holds power only for two days (charging
takes in about 10 minutes after the connection) and therefore it is necessary to set the time again
as you need it
SOFTWARE for INVERTER CHECKER
SOFTWARE INSTALLATION
On the attached SD memory card can be find a INSTALL.EXE file, which is necessary for installation
of all inverter checker programs into your computer.
These programs are following:
-
COMPTEST- program used for display the status information during the testing of compressor
SIMULATOR – monitoring communication data between IU a OU
UPDATER – possibility upgrade the modules or programs for INVERTER CHECKER
CHECKER viewer + FG Monitor viewer – display all saved data from testing procedures
After the installation are on your desktop also created a following data:
-
manuals (English / Czech)
CHECKER data folder (for saved files from testing)
CHECKER viewer – example of displayed saved data
Control of CHECKER viewer
(also applies to the FG Monitor viewer):
Zoom in – pressing the left mouse button and
moving the mouse cursor to right over the desired
Zoom out - pressing the left mouse button and
moving the mouse cursor to the left
Move – pressing the right mouse button and then
moving the mouse cursor
Legend - Select desired values
Focus mouse
cursor to the
appropriate place
to display values
A total of five entries stored in one
day. Three records are stored
from testing of the compressor
and two records from monitoring
of communications between the
units
UPGRADING Cable
Data cable for software upgrade of the inverter tester modules
Whenever is released a new firmware update, it is possible to do upgrade by connected upgrading
cable together with the updater program (needs internet connection). This information about UPDATE
will be send by email to all owners of inverter checker. Due to repairs and improved functionality of
INVERTER checker and programs package, this regular update is highly recommended!!
There is not any upgrade possible without a connected and properly installed UPGRADING cable!!
(Even for the programs in the PC itself)
Upgrading procedure:
1. The upgrading cable plug in to usb port on your notebook or PC and wait until is usb driver
successfully installed. (in case of any trouble with installation, it is possible download a driver
from internet server http://www.ftdichip.com/Drivers/VCP.htm).
2. Start the program Updater and if is any new update of the software on the server then you
can press the button Download to start an installation of updates for the programs in your pc.
3. Second step is to check if your module has a newest firmware already installed or not.
Connect the cable to the module which you need to upgrade (keep the top of cable as you see
on the label).
4. Press the button Connect to see what is the current firmware inside of module, if is different
compare to firmware on the server. Select the desirable FW and press the button Upgrade.
5. After the writing procedure is the module updated to latest firmware version.
CAUTION
During the firmware upgrade of the hardware device, do not disconnect the
UPGRADING cable!! This could cause irreversible damage to the updated module!!
FGMonitor
Diagnosis of SPLIT / MULTISPLIT inverter Fujitsu General units
FGMonitor is used for the diagnosis of FGL outdoor unit using a Bluetooth module and mobile phone
(tablet) with Android system. (Newer models of series G also displayed the values from indoor units)
CONTENS:
-
Bluetooth module with 6 pin connector
Connection cable from 6 to 10-pin connector
The program FGmonitor (Android version)
FEATURES AND BENEFITS:
-
The option of sending the relevant data via email from mobile
Recording of all data from the connected units
Graphical representation of saved values
View the complete history of the errors from the EEPROM
Bluetooth wireless connectivity with a range up to 20 m
Ability of comfortable finding the values which are not
normally available
INSTALLATION:
1. Upload a FGmonitor application to the mobile phone with operating system Android
(recommended version 4 and above). Before installing the application you need to allow in
mobile setting a possibility to install applications from another sources than the Android
Market. Once installation is complete, you need to start application and in FGmonitor settings
input the activation key (menu > settings > key). This key can be found printed on the side of
the Bluetooth module itself.
2. In the next step, it is necessary to connect Bluetooth module with main PCB of diagnosed
units. There are two possibilities:
a) With newer units, it is possible a direct connection with service connector (10 or 6
pin FLASH connector version is installed on the PCB from production)
b) With older units if the connector is not installed from factory, it is necessary to drill
and solder the appropriate version of the connector on the PCB at the location
specified for the service connector, as shown below (10 and 6-pin flash connector
is available on request)
CAUTION
It is necessary to keep the right connections; otherwise it could cause damage!!
3. After trouble-free installation, please switch on connected unit and start FGmonitor application
installed in the mobile phone (tablet). Bluetooth module will ask to be paired with the
appropriate mobile device. Pair key is always: 1937
4. If the previous steps have been performed correctly, FGMonitor should be ready for use.
FGMonitor - FUNCTIONS
MANAGING SESSIONS:
Choose name of related
session to be able later
identify it (customer etc.)
Record of monitoring data is
saved as long as the
FGmonitor application running
Each session is possible
to send in any time from
you mobile device
POSSIBILITY OF GRAPHICAL DISPLAY AND UPDATE:
Example of saved data
displayed in Chart
Select to display
the required data
Automatic updates
FGMonitor viewer
Data sent by emails sent for analyses can be viewed in the appropriate browser immediately after
installing the software package (install.exe), which always enclosed into the Logger SD card.
LEGEND: select the desired
values
Choice of save format:
1) Bitmap file
2) CSV file
Error history stored
in EEPROM
memory