Quality / Service Technical Reference
Error 95 - Burnt Compressor Wiring
Affected models: AOTG30LFTC and AOTG24LATC
A quality assurance investigation was completed following reports of Error 95 and burnt compressor wiring. In the reported cases, replacement of the compressor resolved the fault.
Affected Units
| Model | Quantity | Serial Numbers |
|---|---|---|
| AOTG30LFTC | 5 units | T007720, T011800, T011425, T018491, T020367 |
| AOTG24LATC | 1 unit | Unknown |
Reported Problem
Error 95 was displayed. Technical inspection found burnt compressor wiring. After replacing the compressor, the error was cleared.
Factory Record Investigation
The manufacturing records for the affected units were reviewed.
Finding: There was no repair history recorded in the factory manufacturing records.
Returned Sample Investigation
The returned compressor wiring and terminal condition were inspected, including the burnt red wire and the black and white wire terminals.
- The black and white wire terminal dimensions were found to be normal.
- Ultimate tensile strength of the black and white wire terminals was 200 N or more.
- No terminal pull-out was identified.
- The actual terminal where the burnout originated was not available in the returned sample.
Stock Wire Investigation
FGT stock of wire part number 9707837032 was checked.
| Check | Result |
|---|---|
| Terminal dimensions | Normal |
| Ultimate tensile strength | n=10 tested at 200 N with no pull-out |
| Stock quantity checked | 50 pieces |
Wire Supplier Manufacturing Check
The wire manufacturer, Thai Lustar, was also reviewed.
- The terminal being used was confirmed to be the correct terminal.
- Terminal tensile strength was consistent with the normal specification.
- FGL reviewed the manufacturing process and confirmed that a work instruction was in place.
- The process was checked on 12 September 2014 and was found to be operating correctly at that time.
Suspected Cause
The investigation concluded that the most likely mechanism was a poor electrical connection at the compressor terminal or wire connection.
A poor connection can increase electrical resistance. Over extended operation, the increased resistance can generate heat and result in terminal or wire burnout.
Important: The exact root cause could not be confirmed because the terminal at the actual burnout point was not available for examination.
Possible Causes Identified
- The terminal may not have been inserted fully.
- The terminal may have been inserted incorrectly or inconsistently.
- The terminal crimping/caulking may have been poor.
Corrective Action
- An assembly instruction was created.
- Factory workers were retrained using the new assembly instruction.
- The manufacturing process was updated to address the risk.
Product Action
| Product Status | Action |
|---|---|
| Already installed | Address as required on a case-by-case basis. |
| Stock product | No action specified. The issue was considered unlikely to occur frequently. |
| Current manufacture | Corrective action implemented in production. |
Service Guidance
- For Error 95 complaints on affected models, inspect the compressor wiring and terminals for signs of overheating, discolouration or burning.
- Check that compressor terminals are fully inserted and secure.
- Inspect terminal crimping and wire condition before replacing major components.
- Where a burnt connection is found, retain the affected wire and terminal where practical for technical analysis.
- Record the model, serial number and location of the failed connection when escalating the case.
Safety: Isolate electrical supply before inspecting compressor terminals or wiring. Electrical testing and repairs must only be completed by suitably qualified personnel.