How to fix a mini split AC that is displaying an overload error

So, your mini split AC is flashing an “overload error” and you’re scratching your head? Don’t sweat it, it’s usually not as bad as it seems. This error typically means a part is pulling too much current or working harder than it should. The good news? You can often sort it out with some basic troubleshooting. We’ll explain what an overload error really means, why it might pop up, and how you can fix it safely. Plus, we’ve got some tips on testing electrical components and motors to get your unit humming again.

The info in this article might not match your exact appliance model. We aim to give helpful advice for all sorts of DIY appliance fixes, but different models and setups can mean different troubleshooting steps, error codes, parts, and so on. To get the most accurate guidance, we strongly suggest checking the manufacturer’s docs for your specific appliance model or reach out to us if you’ve got any questions.

What does an overload error mean?

When your mini split AC throws up an overload error, it’s a signal that something, usually an electrical or mechanical part, is under more stress than it can handle. Modern mini splits keep an eye on things like voltage, current draw, and temperatures using sensors and circuit boards. If any of these readings go haywire, the system sounds the alarm to prevent further damage.

These overload situations often involve the compressor or fan motors because they rely on steady power to do their job. Problems like a busted capacitor, dodgy wiring, or just wear and tear can cause an “overload” scenario. The error code is your unit’s way of saying, “Hey, something’s off, and I need a checkup.” Luckily, you can often figure out what’s wrong at home if you know how to test and fix the right parts.

Common causes of overload errors

Your mini split system might seem complex, but when it comes to overload errors, there are a few common troublemakers. A failing capacitor is a big one, it helps the motors start and run at the correct voltage. Another possibility is the compressor drawing too many amps due to mechanical strain, low refrigerant levels, or blocked airflow. Damaged fan motors or control boards can also trigger overload conditions.

Improper use or a botched installation can overwork components too. If your unit’s always running in extreme temperatures or the outdoor unit’s clogged with debris, the compressor might overheat. Over time, that overheating can cause damage, leading to those pesky overload errors cropping up again and again. Understanding these issues helps you pinpoint the problem before you spend time or money replacing parts that might not need it.

How to diagnose mini split overload errors

Figuring out an overload error is a mix of observation, testing, and careful handling of electrical parts. Here’s a step-by-step guide you can follow if your mini split AC is showing an overload error code. Remember to turn off the power to your unit before checking anything, and handle all components with care. If you’re not sure how to find or access certain parts, check the manufacturer’s docs for your model. If you’re unsure of your specific model, swing by our resource on how to find your appliance’s model number before you dive in.

Step 1: Confirm your model and gather information

• Find the data plate or label on your mini split AC. It’ll have the model number and important electrical specs.
• If you need help figuring out your model number, see how to find your appliance’s model number for a step-by-step guide.
• Keep your user manual or manufacturer docs handy so you understand the specific overload error code your brand uses.

This info helps you interpret test readings and confirm part compatibility if you need replacements.

Step 2: Check power supply and wiring

1. Turn off the AC at the breaker panel to avoid any electrical shocks.
2. Take a good look at all the wiring connections on both the indoor and outdoor units. You’re looking for exposed wires, discoloration, or signs of melted insulation.
3. Tighten any loose screw terminals, poor connections can cause voltage drops and overload errors.
4. If you spot major damage, you might need to replace the wires or terminals. Make sure any new wires match the correct gauge and type as specified in your system’s docs.

Step 3: Test electrical components with a multimeter

1. Start by checking the capacitor(s) in your mini split AC. They help your fan motor or compressor run properly. Remove the capacitor from the circuit and discharge it safely before testing.
2. Set your multimeter to the right capacitance setting or use the capacitor test mode if your meter has one. Compare your reading with the capacitor’s rated specs. If it’s way off or the capacitor’s swollen, it’s probably time to replace it.
3. Look over the control board for burnt traces, blackened components, or any visible shorts. These issues can overload parts of the mini split’s electrical system. If you find obvious damage, you might need a new board.
4. Check the wiring harnesses connected to the control board. A loose harness can cause intermittent connections and lead to overload error codes.

Step 4: Examine fan motors

1. Most mini-split systems have at least two fan motors, one for the indoor unit’s blower and one for the outdoor unit’s condenser fan.
2. Check each motor for signs of overheating, like discoloration on the casing or a burnt smell.
3. Use a multimeter to measure the resistance of the motor windings and make sure they’re within the manufacturer’s recommended range. If the windings show open circuits, shorts, or resistance readings way off from what’s specified, the motor might be failing and pulling too much current.
4. Spin the fan blades by hand to see if there’s any unusual resistance or wobbling, which could point to a bearing issue or obstruction. A fan that doesn’t spin freely can strain the motor and cause overload errors.

Step 5: Check the compressor

The compressor is the heart of your mini split system, and it can cause overload errors if it’s damaged, low on refrigerant, or struggling against a clogged coil. Working on the compressor requires caution because it usually operates under higher voltages and involves the refrigerant circuit. If you prefer to stick to electrical checks, you can still do some basic troubleshooting:

1. Use your multimeter to measure the resistance of the compressor terminals. You’re looking for stable readings that match the norms for your specific compressor. If you get a reading that indicates a short or open circuit, or resistance way different from normal, the compressor might be faulty.
2. Check the compressor capacitor if there’s one. Some mini splits have specific start or run capacitors for the compressor. A failing capacitor can prevent the compressor from running right and trigger overload errors.
3. Make sure the outdoor coil is free of dirt, leaves, or other debris. Restricted airflow can cause the compressor to overheat.

More resources

When you need quality replacement parts and extra resources, check out AppliancePartsPros.com. We’ve got a huge inventory of original parts for various air conditioner makes and models, and you can find even more repair help on related topics. If you have questions about your specific unit or want guidance on troubleshooting steps, feel free to reach out through our contact page. We’re happy to point you in the right direction.

We also invite you to follow us on social media. Find us on Facebook and Twitter for more appliance repair tips, product updates, and helpful videos. For additional assistance or to place an order, contact us at AppliancePartsPros.com. We’re here to help you get your mini split AC back in action and keep it running for the long haul.