Dixell/Copeland AL05 Error Code

What does Dixell/Copeland AL05 mean?

On the Dixell IC100CX iChill controller, AL05 sets the maximum number of water flow switch alarm events allowed within one hour before the controller switches to manual reset mode and stops the water pump. Once the AL05 count is reached, the 'Flow!' icon illuminates on the display and remains lit even after the alarm condition clears, requiring manual intervention through the function menu to restore automatic operation.

Symptoms

• Water flow alarm trips multiple times within one hour.
• After reaching the AL05 count, the 'Flow!' icon remains lit permanently on the display.
• Water pump stops and does not restart automatically.
• Manual reset required through the IC100CX function menu to restore pump and compressor operation.

Common causes

• Air in the evaporator water circuit causing intermittent flow switch trips.
• Partially blocked evaporator water strainer reducing flow intermittently near the flow switch threshold.
• Flow switch calibrated too close to actual operating flow rate — minor flow variations trigger the switch.
• Evaporator water pump cavitating or worn, producing variable flow output.
• AL04 delay time too short relative to normal pump startup transients, resulting in nuisance trips that accumulate toward AL05 count.

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Diagnostic steps

1. Perform manual reset

   Access the function menu on the IC100CX and perform the manual reset procedure to clear the AL05 lockout. The 'Flow!' icon will remain if the flow condition is still active.

2. Inspect evaporator water strainer

   Check and clean the evaporator water circuit strainer/filter. A blocked strainer is the most common cause of repeated flow alarms. Clean per the maintenance schedule.

3. Bleed air from the evaporator water circuit

   Open air vents at the highest points in the circuit. Confirm system pressure and fill level are correct. Air causes intermittent flow switch activation.

4. Check flow switch calibration

   Verify the flow switch setpoint matches the minimum required flow for the evaporator. A switch set at too high a flow threshold trips during normal low-load operation.

5. Verify AL04 delay time

   AL04 sets the flow alarm bypass period after pump startup. Confirm AL04 is long enough for the pump to establish stable flow before the flow switch is checked.

When to call a professional

If the water pump repeatedly fails to maintain flow despite a clean strainer and purged circuit, a licensed HVAC/R technician should assess pump performance, impeller condition, and system hydraulic balance. Repeated AL05 lockouts risk evaporator freeze-up if the anti-freeze function is insufficient.