Troubleshooting service
Contents
1. 2 Check the pressure sensor 3 Test of the PCB 4 Test of the PCB ERROR LIST OF POSSIBLE ERRORS WITH RELATIVE CAUSES AND POSSIBLE SOLUTIONS Valid for Low Voltage firmware gt V 4 0 CODE DISPLAYED FAULT TYPE HYDRAULIC SYSTEM CAUSE DIAGNOSIS SOLUTION EXPLANATION CONDITIONS NC No current No Current 1 Missing wiring of one or more output 1 Connect all the conductors of the motor conductor to the motor 2 HV hardware problem 2 Test ofthe PCB HL Hot liquid Hot liquid 1 Too high fluid temperature 1A Check the temperature of the inlet water 1B Check the ambient temperature EY Anticycling Error detected from Anti Ciclycal startings of the Protection intervention of the cyclical pro It may be caused from leakages in the system Check the Cycling algorythm pump 40 consecutive starting with the fol lowing characteristics of periodicity Ton lt 60 sec Toff lt 300 sec tollerances between cycles5 sec tection on the starting of the pump tight of the hydraulic connections and the proper work of the check valve The anti cycling mode can be used in smart mode or disabled RESOLUTION OF OTHER PROBLEMS Valid for Low Voltage firmware gt V 4 0 Unusual Start Stop of The pump try to The pump is not able to read the flow The pressure sensor is not able to read a flow No corrective action possible a single pump stop while the flow because the flow is to small lt 2 l min data lo2. Troubleshooting service ERROR LIST OF POSSIBLE ERRORS WITH RELATIVE CAUSES AND POSSIBLE SOLUTIONS Valid for Low Voltage firmware gt V 4 0 CODE DISPLAYED FAULT TYPE HYDRAULIC SYSTEM CAUSE DIAGNOSIS SOLUTION EXPLANATION CONDITIONS E0 Internal error LV LE 0 Stack Overflow Firmware problem LV Firmware update LV Report to the electronic R amp D El Internal error LV LE 1 Overrun_50uS Firmware problem LV Firmware update LV Report to the electronic R amp D E2 Internal error LV LE 2 Overrun _200us Firmware problem LV Firmware update LV Report to the electronic R amp D E3 Internal error LV LE 3 Overrun_5ms Firmware problem LV Firmware update LV Report to the electronic R amp D E4 Internal error LV LE 4 Bad_Protocol_Ver Incompatibility between HV ed LV firmware Check the installed LV firmware version Verfy the proper sion functioning of the HV part and the version of the software E5 Internal error LV LE 5 Bad_Setup_Mi 1 Hardware not supported by low voltage 1 Install the correct LV firmware related to the hardware smatch firmware 2 HV firmware compiled for a different 2 Install the correct HV and LV firmware related to the hardware from the low voltage firmware hardware E6 Internal error HV LE 0 Stack Overrun Firmware problem LV Firmware update HV Report to the electronic R amp D E7 Internal error HV LE 1 Int_PWMTimer_ Firmware problem LV Firmware update HV Report to the electronic R
3. Test the PCB error supply S_ V5 or 5V 2 Overload of S_ V5 o 5V 2 Test the PCB 3 Fault on the measuring circuit of power 3 Test the PCB supply S_ V5 o 5V v4 Power supply Vauxl 1 Error on the circuit which generate power 1 Test the PCB error supply S_ V5_HV or 5V_HV 2 Overload of S_ V5_HV or 5V_HV 2 Test the PCB 3 Fault on the measuring circuit of power 3 Test the PCB supply S_ V5_HV or 5V_HV V5 Power supply Vaux2 Power supply overlo 1 5V of the low voltage PCB out of the 1 Fault on the 5V generation circuit Test the PCB error ad on the sensors V5_S acceptable range 2 5V power supply not correctly readed 2 Fault on the 5V reading circuit 5V Test the PCB 3 Firmware with acceptable tolerances are 3 Report to the electronic R amp D not adequate 4 Faulty pressure sensor 4 Replace the pressure sensor 5 Faulty flow sensor 5 Replace the flow sensor 6 Faulty cable of pressure sensor 6 Replace the pressure sensor cable 7 Overload of power supply 5V_S 7 Test the PCB 8 Fault on the measure circuit of 5V_S 8 Test the PCB OT Overtemperature Heatsink Overtemp Overtemperature on the dissipator 1 Bad thermal contact between the dissipa tor and the final 1 Dismantle and check the thermical contact 2 Operation in excessively unfavorable environmental conditions 2 Check water and air temperature 3 Fault on the thermical detecting circuit of the dissipator 3 Test the PCB ERROR L
4. supply 1 Check the power supply distribution ERROR LIST OF POSSIBLE ERRORS WITH RELATIVE CAUSES AND POSSIBLE SOLUTIONS Valid for Low Voltage firmware gt V 4 0 CODE DISPLAYED FAULT TYPE HYDRAULIC SYSTEM CAUSE DIAGNOSIS SOLUTION EXPLANATION CONDITIONS OC Overcurrent OC Blocked motor or 1 Too high power absorption from the 1 Check and replace the damaged components impeller motor 2 Hardware problem on the output circuit 2 Test of the PCB reading PH Hot pump Hot pump Overheating of the pump Alarm displayed Wait for the automatical reset check the addendum Avoid when the pump run for more than 5 minutes the working in manual mode without flow without any flow Not necessary due to a overheating of the windings BL Dry running BL Lack of water in the 1 Dry running 1 Prime the pump impellers Flow 0 l min Diffe rent system pressure from what displayed from e sybox 2 Faulty pressure sensor 2 Check the pressure sensor Flow gt 2 l min Mea sured flow 0 l min Measured pressure lt setpoint RP 3 Faulty flow sensor 3 Check the flow sensor 4 Hardware problem on the pressure or flow reading circuit 4 Test of the PCB BP1 Press Sens BP1 Pressure sensor 1 1 Real missing pressure sensor 1 Connect the sensor 2 Faulty pressure sensor 3 Problem with the reading of the pressure sensor signal 4 Problem on the pressure sensor power supply
5. IST OF POSSIBLE ERRORS WITH RELATIVE CAUSES AND POSSIBLE SOLUTIONS Valid for Low Voltage firmware gt V 4 0 CODE DISPLAYED FAULT TYPE HYDRAULIC SYSTEM CAUSE DIAGNOSIS SOLUTION EXPLANATION CONDITIONS PB Power supply Bad Power Supply Poer supplly out of range Power supply lt 185 1 Too low power supply VAC Power supply gt 270 VAC 2 Too high power supply 1 Check the power supply Power supply with 3 Too long electrical line or undersized 2 Check the power supply pump off gt 185 VAC conductors e lt 270VAC After the 4 Fault on the reading circuit of the input 3 Check the sizing of the electrical line and the voltage drop starting ofthe motor voltage become lt 185 VAC LP Low voltage LOW Voltage Low power supply on the DC bus 4 Test ofthe PCB Power supply gt 177 VAC 1 Fault on the soft start circuit or on the rectifier bridge Power supply with 2 High line resistance 1 Test of the PCB pump off gt 177 VAC After the starting of the motor become lt 177 VAC Input power supply lt 3 Too low power supply 2 Check the sizing of the electrical line and the voltage drop 177 VAC Power supply gt 177 VAC 4 Fault on power supply reading circuit 3 Check the power supply distribution e lt 275VAC of DC bus HP High voltage High Voltage High power supply on the DC bus 4 Test of the PCB Power supply gt 275 VAC 1 Too high power supply 2 Fault on the reading circuit of DC bus power
6. T OF GP AND GI GAINS SINGLE PHASE INVERTER WIRED ON A THREE PHASE INE An inverter without PFC absorb an impulsive current in correspondene of the AC voltage s picks If Lead GP to the minimum more than one inverter are wired on a three phase line distributing them on the three phases to balance Open a small levy and give it small perturbations While checking a manometer the load it creates a current imbalance on the neutral wire the sum of the three currents doesn t vanish increase Gl as long as the first oscillations due to the perturbations start because of the non sinusoidal nature of the absorbtion and the currents close themselves to the neutral The GI gain to set is of the value that you have found at the previous step The result is that you can find on the neutral the sum of the three phase currents After have set Gl increase GP as long as the first oscillations start and set GP at 14 of the value that you have found during the first oscillations PFC Power Factor Correction it s an active or passive electronic system inserted between the electrical distribution and an eletric electhronic device Normally it s on the input stage inside the device It serves to see to the distribution a resistive sinu soidal current consumption by the device It corrects the non linear absorption impulsive absorption or armonics presence 30
7. amp D Overrun E8 Internal error HV LE 2 Int_250us_Overrun Firmware problem LV Firmware update HV Report to the electronic R amp D E9 Internal error HV LE 3 Int_5ms_Overrun Firmware problem LV Firmware update HV Report to the electronic R amp D E10 Internal error HV LE 4 Synchronization 1 uP HV with test firmware 1 HV firmware update Lost 2 Firmware problem LV 2 HV firmware update 3 Problem with the syncronism generation 3 Check the weldings the electronic tracks and the syncro system nism generation system components Ell Internal error HV LE 5 BadRx_LV 1 HV or LV firmware system 1 HW and or LW firmware update 2 uP HV with test firmware 2 HV firmware update 3 hardware problem between HV LV 3 Test of the PCB comunication El2 Internal error HV LE 6 Invalid HV_LV_ Different version between HV LV firmware HW and or LW firmware update Config ERROR LIST OF POSSIBLE ERRORS WITH RELATIVE CAUSES AND POSSIBLE SOLUTIONS Valid for Low Voltage firmware gt V 4 0 CODE DISPLAYED FAULT TYPE HYDRAULIC SYSTEM CAUSE DIAGNOSIS SOLUTION EXPLANATION CONDITIONS E13 Internal error HV LE 7 Setup_Mismatch HV firmware compiled for a different har Check the compatibility between LV HW firmware and the dware from the low voltage firmware mounted hardware E14 Errore int HV LE 8 Proto_mismatch Incompatibility between HV ed LV software HW and or LW firmware update E15 Internal erro
8. atically occurs after 15 minutes VD Power supply VDC_Overvoltage 1 Faulty Overtemperature detecting circuit 1 Test the PCB error 2 HV PCB with sizing problems of over vol 2 Report to the electronic R amp D tage detect circuit on the electrolytic PD Internal error Power_Down low absolute 1 Excessive lowering of nthe power supply 1A Bad delivery of the power supply voltage 1B Wrong sizing of the powersupply line No click noise from any 2 The soft start relee is not closing 2 Test the PCB relee after the switch on 3 Fault on the short circuit of the electrolytic 3 Test the PCB detecting sytem vo Power supply HV_V18 1 Problem on the regulator wich generate 1 Test the PCB error V18 2 High resistance 3 Overload on the V18 4 Fault on the measuring circuit of V18 PCB PCB PCB 2 Test the 3 Test the 4 Test the ERROR LIST OF POSSIBLE ERRORS WITH RELATIVE CAUSES AND POSSIBLE SOLUTIONS Valid for Low Voltage firmware gt V 4 0 CODE DISPLAYED FAULT TYPE HYDRAULIC SYSTEM CAUSE DIAGNOSIS SOLUTION EXPLANATION CONDITIONS vi Power supply LV_7V5 1 Error on the circuit which generate power 1 Test the PCB error supply S_ 7V5FLB or 7V5FLB 2 Overload of S_ 7V5FLB o 7V5FLB 2 Test the PCB 3 Fault on the measuring circuit of power 3 Test the PCB supply S_ 7V5FLB or 7V5FLB v2 Power supply LV_5V 1 Error on the circuit which generate power 1
9. ave with FW lt 4 0 Stepl e Sybox Master with FW gt 4 0 e sybox Slave Perform the association between the devices Hold the key 25 FIRMWARE SEMI AUTOMATIC UPDATE News of V firmware 4 0 SEMI AUTOMATIC UPDATE Shut off the e Sqybox and wait for the display shutdown Turn on the pump holding the keys MODE and at the same as long as this update screen doesn t appear 26 FIRMWARE SEMI AUTOMATIC UPDATE News of V firmware 4 0 SEMI AUTOMATIC UPDATE Requirements Master with FW gt 4 0 Slave with FW lt 4 0 The programming starts Wait until the end of the process and for the pumps restart 27 ADDENDUM In the following addendum you can find a set of instructions warning and notions in separed squares with non related contens that are references for previous pages BLOCKING ERRORS RESET Automatic when the causes disappear Automatic when the causes disappear OT Block due to overtemperature of power terminals TE It s restored when the temperature of the power terminals goes again under 75 C gt 85 C Supply voltage out of range Vin lt 185V Vin gt 270V Automatic when the causes disappear when Vin goes up to 190V or under 265V with a break of at least 1 min Block due to low DC bus s voltage lower than 200VDC It s restored when the voltage goes up to 250VDC HP Block due to high DC bus s voltage higher than 390VDC It s restored when the vo
10. ems Ongoing blocking faults Regulate the functioning in manual setting Manual disabling anabled keys and Enabled blocking functions related to the inputs E sylink not detected 13 Solutions Aligne the parameters by pressing when requested Update all the firmware see the firmware update section Remove the cause of the error and reset the E sybox Press SET to exit from the menu Enable the pump by pressing keys and together Check the right functioning of the e sylink and the inputs Check the power supply of the e sylink RESOLUTION OF OTHER PROBLEMS Valid for Low Voltage firmware gt V 4 0 Pressure regulation ressure fluctuates The hydraulic load is costant or null GP and Glare too big for the actual Lower GP e GI see addendum EM hydraulic system The malfunction appear due to a small Lower GP e GI see addendum variation of the hydraulic load ressure readed on System with e sylink On the display Regulate the functioning for the compenb No corrective action possible 36 the gauge near to the appear a remote pressure sensor sation of the friction loss pump is bigger than symbol the set point Insufficient pressure The pump don t deliver Not primed pump Prime the pump flow any flow Primed pump Wrong hydraulic connections Connect sunction and delivery as explained on the manual The pump give a lower Displayed speed 3050 rpm The pump flow request is too big the pump No cor
11. heck clean and eventually unblock the check valve 16 Entry of air ion the pipes Verifify the integrity of the sunction pipe and eventually 17 remore the entry of air The pump restart wi Leakage in the system Remove the leakage thout water demand Malfunction of the check valve Check clean and eventually unblock the check valve Expansion tank broken too high or too Check the expansion vessel loo charged Faulty pressure sensor Verify the pressure sensor After the opening of Expansion tank broken too high or too Check the expansion vessel a water demand the loo charged pressure suddenly drop and then it The inluded expansion vessel is too small Install a further expansion vessel return on the regime GP and GI are too big for the actual Increase GI e GP compatibly with the carathristics of hydraulic system the system 12 Unusual Start Stop od a booster set The pump don t start RESOLUTION OF OTHER PROBLEMS Valid for Low Voltage firmware gt V 4 0 Condition of the system Appear an E instead of the pmp adress Apper an alignment setting pop up Appeare an not aligned firmware versions pop up We are in manual menu Blinking white led System with e sylink Red led on On the display appeare the symbol of a blocking function Float F3 F4 System with e sylink Red led on On the display appeare the safety sign Possible causes Not aligned parameter Different firmware versions in the syst
12. ltage goes under 250VDC Block due to overcurrent in the electropump s motor Manual or automatic with the following timing 1 attempt every 10 mins a total of 6 attempts 1 attempt every hour a total of 24 attempts 1 attempt every 24 hours a total of 30 attempts Pump s overtemperature Automatically restored after 15 mins Ifthe pump was in running status the recovery will reset the lock and it will bring the pump in running status again but not in manual mode The user will decide the restat 29 ADDENDUM In the following addendum you can find a set of instructions warning and notions in separed squares with non related contens that are references for previous pages ERR UNLOCK Bock due to a lack of water Manual or automatic with the following timing 1 attempt every 10 mins a total of 6 attempts 1 attempt every hour a total of 24 attempts 1 attempt every 24 hours a total of 30 attempts Unexpected value on the pressure sensor It will be restored when it reads a consistent vaue Block due to an high water temperature Twater gt 65 C Restored when Twater lt 60 C Anti cycling s protection intervention 40 consecutive igni Only manual recovery tions with the following caratteristics of periodicity Ton lt 60 sec Toff lt 300 sec tolleranza tra i cicli 5 sec The anti cycling protection can be disabled or set in Smart mode not blocking mode with automatic RP lowering PROCEDURE FOR THE SE
13. nng part of the IGBT or the final stage 3 HV Firmware problem 3 Install a latest firmware if not possible report the situation to the electronic R amp D 4 Check the weldings the electronic tracks and the compo nents mounted on the output current reading circuits ERROR LIST OF POSSIBLE ERRORS WITH RELATIVE CAUSES AND POSSIBLE SOLUTIONS Valid for Low Voltage firmware gt V 4 0 CODE DISPLAYED FAULT TYPE HYDRAULIC SYSTEM CAUSE DIAGNOSIS SOLUTION EXPLANATION CONDITIONS E19 Internal error HV LE 12 Security ref HV Previous E18 safety intervention still not This error occur due to a restart after a shut off with an TE11 resetted ongoing E18 error The recovery automatically occurs after 15 minutes E20 Internal error HV LE 13 HV Internal error Safety intervention for a not expected power The recovery automatically occurs after 15 minutes consumption 1 Damaged impeller 1 Check the impellers status 2 Blocked sunction 2 Check the sunction 3 Air in the sunction 3A Ensure that no water can enter in the sunction pipe 3B Move the foot valve in a place where it can t suck air 4 HV firmware problem 4 Install a latest firmware if not possible report the situation to the electronic R amp D E21 Internal error HV LE 14 Security ref HV Previous E20 safety intervention still not This error occur due to a restart after a shut off with an IE13 resetted ongoing E20 error The recovery autom
14. r LV LE 6 BadRx_HV 1 uP HV not programmed or faulty 1 Check the red high power supply led if anyone is blinking try to reprogram the HVP 2 uP HV programmed with test software 2 Try to reprogram the HVP 3 HV and or LV firmware problem 3 HW and or LW firmware update El6 Internal error HV LE 9 Security_Internal Faulty onl uP HV Sostituire il uP HV Error ERR wrong match Sw Wrong match between HV I uP HV and LV are not able to commu 1 Test of the PCB LV x xx HV eLV nicate XXX 2 HV firmware have a different firmware 2 Check the firmware version version from what expected by the LV firmware sc Short circuit Short circuit between output Real short circuit 1 Remove the short circuit phases 2 Two phases short circuit on the motor 2 Replace the motor 3 Faulty short circuit detecting system 3 Test ofthe PCB 4 Sizing problem of the short circuit de 4 Report to electronic R amp D tecting system E17 Internal error HV LE 10 HV_EEprom_Er Impossible read or write to eeprom HV 1 Replace the eeprom HV ror 2 Hardware fault on the reading circuit of 2 Check the weldings the electronic tracks and the compo HV of the EEPROM nents mounted on the eeprom HV circuit E18 Internal error HV LE 11 HV Internal error Routine safety intervention in progress The recovery automatically occurs after 15 minutes 1 Blocked motor 1 Unblock the motor 2 HV PCB with driving problem of the IGBT bridge 2 Possible fault on the drivi
15. re 4 0 FIRMWARE MANUAL UPDATE Requirements Master with FW gt 4 0 Slave with FW lt Master Step 1 e Sybox Master with FW gt 4 0 e sybox Slave Enter the menu TECHNICAL ASSISTANCE Press the key Shut off the the e Sybox Slave and wait forthe display shutdown 19 FIRMWARE MANUAL UPDATE News of V firmware 4 0 FIRMWARE MANUAL UPDATE Turn on the power supply holding at the same time The Master startsto searcha Slave the keys MODE and as long as this update screen doesn tappear 20 FIRMWARE MANUAL UPDATE News of V firmware 4 0 FIRMWARE MANUAL UPDATE The programming starts Wait until the end of the process and for the pumps restart 21 FIRMWARE AUTOMATIC UPDATE News of V firmware 4 0 AUTOMATIC UPDATE Requirements Master with FW gt 4 0 Slave with FW gt 4 0 and FW lt Master e Sybox Masterwith FW 2 4 0 e Sybox Slave with FW gt 4 0 and lt Master Performthe association between the devices Hold the key Hold the key 22 FIRMWARE AUTOMATIC UPDATE News of V firmware 4 0 AUTOMATIC UPDATE 23 FIRMWARE AUTOMATIC UPDATE News of V firmware 4 0 AUTOMATIC UPDATE The programming starts Wait until the end of the process and for the pumps restart 24 FIRMWARE SEMI AUTOMATIC UPDATE News of V firmware 4 0 SEMI AUTOMATIC UPDATE Requirements Master with FW gt 4 0 Sl
16. rective action possible If necessary install pressure than the set is working out of its curve further pump unit point Displayed speed lower than 3050 rpm Maximum speed limit setted is too low Increase RM up to requested performance and egual to RM Brocken impeller Check the integrity of the components The pump deliver the The hydraulic delivery is on a very Pressur loss due to the different heights If possible set up a set point that can compensate the set point pressure but different heights istead of the pump difference of height the pressure on the tap is lower Friction loss on the delivery Increase the size of the pipe Set up a lower Set point pressure allowing the e sybox to keep constant the flow Insert a remote pressure sensore for compensate the different friction losses aS Fault on the self priming valve Check the self priming valve 14 ER ES 9 Blocked sunction Rimuovere le occlusioni o Too small sunction pipe Adottare un tubo di aspirazione di diametro maggiore soo comunque mai inferiore ad 1 Obstructed impellers or hydraulic part Las ER o 34 35 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 2 The pump dont deliver the declared flow Type of problem Problem on the power supply line Differential circuit breaker intervention Differential circuit breaker intervention while the pump start to work Single phase magneto termic circuit breaker intervention Three phase
17. s magneto termic circuit breaker intervention RESOLUTION OF OTHER PROBLEMS Valid for Low Voltage firmware gt V 4 0 Three pump distriuited on the three phases Wrong class of the circuit breaker Install a CLASS A differential circuit breaker Faulty circuit breaker Install a new differentil circuit breaker Earth fault present on the pump Test the PCB and check the electrical leakage of the motor Water in the motor Check that the priming of the pump has not beel done from the shaft plug Fault or mechanical block on the motor Check the motor Water in the motor Check that the priming of the pump has not beel done from the shaft plug Too small circuit breaker Use a circuit breaker with adequate nominal current Faulty circuit breaker Replace the circuit breaker Current on the common wire With inverter Use single phases line for every single pump 61 devices the sum of the current on the com mon wire is not 0 but the sum of the three current see the addendum 15 E SYBOX FIRMWARE UPDATE News of V firmware 4 0 COMMUNICATION COMPATIBILITY BETWEEN DIFFERENT FIRMWARE VERSIONS Version E SYBOX FIRMWARE UPDATE News of V firmware 4 0 PARTICULARITY 4 0V AND SUCCEEDING Unable to update other e Sybox Requires the firmware update of all the e Sybox which are communicating Re charge user informations and settings also from previous firmware versions FIRMWARE MANUAL UPDATE News of V firmwa
18. wer than 2 l min delivering and restart right after The pump is not able to read the flow Mechanical obstacle of the pressure sensor Clean the sensor a even if the flow is solid gt 2 l min Faulty pressure sensor Replace the sensor pp Check the connection of the sensor ls The pump don t start Check the power supply ls Red led on Remove the cause of the error and reset the E sybox zo We are in manual menu Press SET to exit from the menu is Blinking white led Enable the pump by pressing keys and together ae ju TEE System with e sylink Red led on On Enabled blocking functions related to the Check the right functioning of the e sylink and the the display appeare the symbol of a inputs inputs blocking function Float F3 F4 System with e sylink Red led on On E sylink not detected Check the power supply of the e sylink the display appeare the safety sign E sylink in error status Check the manual of the e sylink Not attended readed pressure Blocked sunction Check the cause of the block on the sunction mud inverted check valve 11 RESOLUTION OF OTHER PROBLEMS Valid for Low Voltage firmware gt V 4 0 Unusual Start Stop of The pump don t stop Oscillating pressure on the water GP and Gl are too big for the actual Lower GP e GI see addendum 14 a single pump system hydraulic system The pump try to stop and then restart Leakage in the system Remove the leakage Malfunction of the check valve C
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