Samsung AP500PF User manual

SERVICE Manual
CONTENTSAIR CONDITIONER
1. Installation
2. Operating instructions and Installation
3. Disassembly and reassembly
4. Troubleshooting
5. Exploded Views and Parts List
6. Refrigerating Cycle Block Diagram
7. PCB Diagrams
8. Wiring Diagrams
9. Schematic Diagrams
FLOOR STANDING TYPE AIR CONDITIONER
AP500PF
E DB68-00101A(3)

1
1. Installation
1-1 Refrigerant Refill Procedure
Refill an air-conditioner with refrigerant when refrigerant has been leaked at installing or using
1. Purge air(for new installation only).
3. Connect the tank to refill with Refrigerant
4. Set the unit to cool operation mode.
7. Stop operation of the air conditioner.
9. Close the cap of each valve.
2. Turn the 3-way valve clockwise to close, connect the
pressure gauge(low pressure side) to the service valve,
and open the 3-way valve again.
5. Check the pressure indicated by the pressure gauge(low
pressure side).
* Standard pressure is should be 4.5~5.5kg/cm2in a
regular, high operation mode.
6. Open the refrigerant tank and fill with refrigerant until
the rated pressure is reached.
* It is recommended not to pour the refrigerant in too
quickly, but gradually while operating a pressure valve.
8. Close the 3-way valve, disconnect the pressure gauge,
and open the 3-way valve again.
R-22
Suspension hook
High
pressure
gauge
Hand
wheel
Finger tight
fittings
Connected to
high pressure
side
Charging
line
For mounting
other and of
hose when
not in use
Compound
gauge

2
1-2 “Pump down” Procedure
Relocation of the air conditioner
• Refer to this procedure when the unit is
relocated.
1. Carry out the pump down procedure
(refer to the details of 'pump down').
2. Remove the power cord.
3. Disconnect the assembly cable from the
indoor and outdoor units.
4. Remove the flare nut connecting the
indoor unit and the pipe.
At this time, cover the pipe of the indoor
unit and the other pipe using a cap or
vinyl plug to avoid foreign material
entering.
5. Disconnect the pipe connected to the
outdoor unit.
At this time, cover the valve of the
outdoor unit and the other pipe using
a cap or vinyl plug to avoid foreign
material entering.
6. Make sure you do not bend the connection
pipes in the middle and store together
with the cables.
7. Move the indoor and outdoor units to a
new locatioon.
8. Remove the mounting plate for the indoor
unit and move it to a new location.
Pump down' shall be carried out when an evaporator is replaced or when the unit is relocated in
another area.
1. Remove the caps from the each valve.
3. Set the unit to cool operation mode (Check if the compressor
is operating.)
5 When the pressure gauge indicates "0" turn the 3-way
valve clockwise to close.
4. Turn the left side valve(A) clockwise to close.
6. Stop operation of the air conditioner.
7. Close the cap of each valve.
2 Turn the 3-way valve clockwise to close and connect a pres-
sure gauge(low pressure side) to the service valve, and open
the 3-way valve again.
(A)
(B)

3
2. Operating instructions and Installation
2-1 Operating Instructions
2-1-1 Control system chart
Operation Main switch operation
Operation of remote
controller
Operation of auto, cool and fan
Operation of turbo, auto, cool, and fan
Function selection Auto mode
Cool mode
Fan mode
Manual 3-step
Auto
Left-right turn
Turbo operation
Convenience reservation
“E1”
Function selector
Control of fan motor step according to current temperature
Operation of indoor fan motor only
High, medium, low
Control of fan motor step according to current temperature
Turbo-operating compressor and powerful operating fan
motor(30minutes)
Reserve function which is off after on time of 1, 2, 3, 4, or
5 hours
Displayed at the time of indoor temperature sensor open
or short
Auto, cool, fan lamp
Selection of fan speed Low, medium, high lamp
Selection of airflow Left-right lamp
Current temperature Indoor temperature display
Desired temperature Desired temperature display
Fan speed diagram Low, medium, high, turbo lamp
Convenience reservation Reserve lamp and reserve time display
Current time Current time display
Control of cool according to the difference between current
and desired temperature
Fan speed
selector mode
Airflow selector
mode
Convenience function
Self-diagnosis
function
LED display
function

4
2-1-2 Key type and functions
2-1-2(a) PANEL key type and functions
Key name Key operating function Key type
On/off Start and stop of operation TACT
- ON 1 time = operation start, ON again = operation stop.
- No continued operation
Mode selection Change of the operation mode TACT
- Each time the button is pressed(ON), the mode is changed in the following order:
“auto cool fan”(standard=auto)
- No continued operation
Fan speed Setting of the indoor fan motor speed TACT
selection - Each time the button is pressed ON, the mode is changed in the following order:
“low medium high”(standard=high)
Temperature(time) Increase the desired temperature(current time) TACT
setting(up) - Temperature: When pressing the button(UP) one time,
the desired temperature is increased by the unit of 1°C.(18°C- 30°C)
- Time: When pressing the button(UP) one time, the time is increased by 1 minute.
If the “UP” button is pressed continuously, the time is increased by 10 minutes.
- One short, and continued operation
Temperature(time) Decrease the desired temperature (current time) TACT
setting(down) - Temperature: When pressing the button(DOWN) one time,
the desired temperature is decreased by the unit of 1°F. (65°F- 86°F),(1°C.(18°C- 30°C))
- Time: When pressing the button(DOWN) one time, the time is decreased by 1 minute.
If the “DOWN” button is pressed continuously, the time is decreased by 10 minutes.
- One short, and continued operation
TIME/TEMP. The temperature and current time can be changed. TACT
SELECTION - If the key is pressed 1 time, current temperature
and desired temperature are displayed.
- If the key is pressed again, current time is displayed.
←
←←
←
* Operating functions
Buttonforspeedselection:Whenpressing
thebutton,themodeisselectedinthe
orderofhigh-medium-low.
Displaychangebutton:Whenthebuttonispressed,
currenttimeandtemperaturearedisplayedalternately. Up/down button: It can regulate current
timeanddesiredtemperature. Functionselectorbutton:whenpressingthebutton,themode
canbeselectedrepeatedlyintheorderofauto-cool-fan.
Conveniencereserve
button:Itcanstopthe
operationautomatically. Reserve display:
Conveniencereserve
operationisperceived
whenorderedtodoso.
Operationdisplaylamp:
Whenthepowerisfirst
applied,thelampwill
blink,butwillturnon
whenoperationbegins.
Fandisplay:Thefanisdis-
playedintheorderofturbo,
high,medium,andlow.
Time and temperature display:
Currenttime,reservetime,and
temperaturearedisplayed.
Cooldisplay:Thedoortempera-
tureissensedandthebuttonis
lightedwhencoolingisbegun. Left-rightturn
display.
Functionselectordis-
play:Currentmodeof
operationdisplay.
Sensortoperceiveremote
controller:Itcanreceive
ordersfromremotecontroller. On/off button.

5
2-1-2(b) LED display operating spec.
Lamp name Operating spec.
Operation lamp - When the power is applied, the lamp goes on and off in an interval of 0.5
seconds.
- If the operation is changed to “on”, the lamp stops turning on and off and
continues to remain on.
- If the operation is changed to “off”, then LED off.
Cool lamp - When the compressor is activated: ON
- When the compressor is stopped: OFF
Timer lamp - During reservation: ON
- Reservation ended or cancelled: OFF
Reservation-timer - During reservation-timer display: ON
lamp - During current time and temperature: OFF
Current temperature - During current temperature display : ON
lamp - During current time and reserve time display: OFF
Desired temperature - During desired temperature display: ON
lamp - During current time and reserve time display: OFF
Fan speed display - During on operation: ON
lamp - During off operation: OFF
Current time lamp - During current time display: ON
- During reserve time and temperature display: OFF
Turbo lamp - During turbo operation: ON
- During turbo operation is ended or cancelled: OFF
Fan speed selector - Low: 2 lines ON
lamp - Medium: 4 lines ON
- High: 5 lines ON
- Turbo: 6 lines ON
Left-right lamp - During left-right turn operation: ON
- During left-right turn ends: OFF
Auto lamp - During auto operation: ON
- Other modes: OFF
Cool lamp - During cool operation: ON
- Other modes: OFF
Fan lamp - During fan operation: ON
- Other modes: OFF

6
3. Disassembly and reassembly
3-1 Indoor unit
No Parts Procedure Remark
Indoor unit
Inlet grille
Main PCB
!
@
#
1) Open the inlet grille and remove the
connection ring.
1) Separate the PCB connect wire after
separating the control box cover.
2) Separate the connection wire to separate the
front cover and duct.
3) The main PCB should be separated by turn over
the mountain tab.

7
No Parts Procedure Remark
Front cabi
Plate top
$
%
1) The front cabi should be separated by giving
strength downward after loosening 2 screws at
the lower end.
1) The plate top should be separated by loosening
screws.

8
No Parts Procedure Remark
Ass’y grille out
Ass’y duct
^
&
1) First loosen screws at left and right sides of
grille out.
2) Then the ass’y grille out should be separated
by giving strength upward (↑).
1) First loosen the 4 screws at left and right sides.
2) Then the ass’y duct should be separated by
lifting it.

9
No Parts Procedure Remark
Evaporator
*1) First separate the cover after loosening the
screws fixed at evap cover R.
2) Ten separate the 3 screws fixed at cabinet BKT
of evaporator BKT.
3) Evaporator should be separated by flinging
ahead.

10
No Parts Procedure Remark
Motor
(1) When the ass’y duct should be separated from
the motor, the 2 bracket should be separated
first.
2) Then the bolts fixed at the blower and motor
shaft should be separated.
3) Then the screws binding the holder top blower
and duct should be separated.
4) The duct of one side should be separated as
the picture shows after loosening the upper
binder.
5) The binder of the motor and the duct should be
separated.

11
No Parts Procedure Remark
Panel PCB
)
6) Then the motor should be separated.
7) The bracket fixed at the motor should be
separated.
1) Should be separated after loosening the
insulating material and binders at the back
of the front side.

12
3-2 Outdoor Unit
No Parts Procedure Remark
Outdoor unit
Control box
!
@
1) Packaged air conditioner outdoor unit
2) The binders of the front side should be
separated.
3) The flank and the binders should be separated
from each other.
1) Connect distributed wires in the control box.

13
4. Troubleshooting
4-1 Items to be checked first
4-2 Self-diagnosis and corrective actions
1) Is the supply voltage appropriate?
The supply voltage: should be AC 187V-AC 253V/60Hz
2) Is the connecting wire between the indoor unit and outdoor unit appropriate?
The indoor unit and outdoor unit should be connected with each other by 3 cables.
Be sure to check whether the cables for the indoor unit and outdoor unit are securely connected by
the same terminal number.
3) When any claim occurs according to the contents of the table below, it is not related the trouble of
the air-conditioner at all.
Troubleshooting
First, Items to be checked first
Second, Check the corrective actions in the case of occurrence of self-diagnosis mode
Third, When the trouble is not related to the 1st or 2nd items above, check the troubled area in
detail in accordance with the fault analysis method by symptom.
Temperature
No. Cause Corrective actions
display
1 E1 - Room temperature sensor short - Replace the room temperature sensor
- Room temperature sensor open - Check the main PCB pattern and components
- for short or open
No. Operation of air-conditioner Description
1 The compressor does not operate when the When restarting the compressor, the operation of the compressor is
desired temperature is set at a lower delayed for 3 minutes to protect the compressor.
level than the room temperature. Normal operation is possible only after an elapse of 3 minutes,
even when applying the initial power.
2 The fan speed cannot be controlled The fan speed is automatically set at the
during auto or turbo operation. MICOM during auto and turbo operation.
3 The temperature is not set during auto, The desired temperature is automatically set at the MICOM
fan or turbo operation. during auto and turbo operation.
The fan operation circulates the room air without temperature control.

14
4-3 Fault Diagnosis by Symptom
4-3-1 No power (no display)
1) Checkpoints
(1) Is the voltage of the power source normal?(AC 187V - AC 253V)
(2) Is the power line in good contact?
(3) Check the power fuse(F701, F702) and PCB fuse(F101) for open.
(4) Are the primary and secondary sides of the power-trans in good contact with the connector?
(5) Is the output voltage of REG1(KA7812) normal?(DC 11.5V - DC 12.5V)
(6) Is the output voltage of REG2(KA 7805) normal?(DC 4.5V - DC 5.5V)
2) Checking procedures(after checking the checkpoints of clause 1)
N
N
Y
Y
Y
Y
Y
N
N
Y
N
N
Turn off the power, and then turn it on in 5 seconds.
Is the voltage or the power trans AC 18V-21V secondary side(CN11)
normal?
Is the output voltage of REG1 and REG2 normal? (REG1=12V, REG2=5V)
Is the output wave at the MICOM(IC1) pin (No. 33~40) a
square wave?
Is the output wave at IC4 pin No. 13~18 a square wave?
Is the harness between the main PCB and panel PCB well connected?
LED display or panel PCB defective.
Is the room temperature displayed on the temperature indicator,
the display lamp turned on, and the panel shutter down when
pressing the on/off button. Then it is normal operation.
Check and replace the power trans.
Remove the shorted parts of the
power terminal.
Replace the defective parts.
(D101-104, REG1, REG2)
Check and replace the MICOM(IC1).
Check and replace the IC4.
Reassemble or replace the harness
after checking it.

15
4-3-2 When the indoor fan motor does not operate.
1) Checkpoints
(1) Is the voltage of the power source normal?(AC 187V-AC 253V)
(2) Is the indoor fan connector (CN71) in good contact?
(3) Is the starting condensor of the fan motor in good contact with the terminal?
(4) Is the resistance at both ends of the relay coil approximately 400Ω?
2) Checking procedures(after checking the checkpoints of clause 1)
Y
Y
N
N
N
N
N
N
Y
Y
YY
N
Turn off the power, and then turn it on in 5 seconds.
Then the indoor fan motor is normal.
Then the relay is normal.
Then check and replace
the IC3.
Then check and replace the
MICOM(IC1).
Then check the wiring harness for open.
Is it low when checking the
output wave for each airflow
at the IC3 pin No. 11, 12,
and 13?
Then replace the relay when
resistance is 0Ωor ∞.
Check the resistance
level after turning
off the power.
Operate the on/off button, and operation mode key,
and place it in the “FAN” position.
Does the airflow volume of the indoor fan motor change when
converting into high, medium, and low by the FAN speed key?
Do the RY3(high), RY4(medium), and RY5(low) operate when
converting into high medium and low by the FAN speed key.
Is the resistance at both ends of the relay(RY 3, 4, 5) coil
approximately 400Ω?
Is it “high” when checking the output wave for airflow at the
MICOM(IC1) pin No. 54, 55, and 56?
Is the voltage at both ends of the relay for each airflow at the
time of selecting the fan speed(high/medium/low) DC 12V?
Is the voltage at both ends of indoor fan motor AC 187V ~ AC 253V?
Check and replace the indoor fan motor.

4-3-3 When the compressor does not operate
16
1) Checkpoints
(1) Is the voltage of the power source normal?(AC 187V - AC 253V)
(2) Is the desired temperature set at a higher level than the current temperature at the time of
“Cool” operation?
(3) Is the power-in good contact with the comp. connector(GT 1, 2, 3)?
(4) Check the wirings of the outdoor and indoor unit for a wrong connection or poor contact.
(5) Isn’t the compressor in a 3-minute stand-by state?
2) Checking procedures(after checking the checkpoints of clause 1)
Y
N
N
N
Y
Y
Y
Y
N
N
N
Y
Y
N
Turn off the power, and then turn it on in 5 seconds.
Then the compressor and relay are normal.
Replace the relay when the
resistance is 0Ωor ∞.
Then check and replace the
MICOM (IC1).
Then check and
replace the IC 3
Is it “low” when checking
the output wave of the IC 3
No. 16.
Check and measure
the resistance value
after turning off the
power.
Check whether the relay(RY1) is turned on and the compressor is
operated in 3 minutes after starting the “COOL” operation by activat-
ing the on/off button and operation made key.
Is the resistance at both ends of the relay(RY 1) coil approximately 400Ω?
Is it “high” when checking the output wave of the MICOM
(IC1) pin No. 6?
Is the voltage at both ends of the relay(RY1) coil DC 12V?
Is the voltage at both ends of the electronic contactor coil
AC 187V ~ AC 253V?
Replace the compressor.
Then check and replace the
electronic contactor
Then check the wiring of indoor unit and Then
check the wiring of outdoor unit short or open.
Is the voltage at both ends of the electronic contactor terminal
AC 187V ~ AC 253V?

17
4-3-4 When the Remote Controller Does not Operate
1) Checkpoint
The sounds “beep” when it receives the signal of the remote control.
2) Checking procedures
Y
N
Y
Y
Y
Y
N
N
Y
N
N
N
Turn off the power, and then turn it on in 5 seconds.
Is room temperature displayed on the temperature
indicator and does the operation start when pressing the
on/off button on the panel?
Does the indoor unit sound a “beep”, and stop when pressing
the on/off button on the remote control?
Is the panel PCB connector(CN2) properly connected to
the main PCB connector(CN91)?
Is the voltage of the battery over DC 2.5V?
Is the unit normally operated when pressing the on/off button
after replacing the remote control?
Is the receiving wave of the MICOM(IC1)
No.2 a square wave?
Check and replace the MICOM(IC1).
Then replace the receiver module.
Then replace the remote control.
Then replace the battery.
Repair and replace the panel
harness as required.
Then it is in normal operation.
Refer to the checkpoint when the
power is not supplied.

18
4-4 PCB inspection
4-4-1 Inspection precautions
4-4-2 Inspecting procedures
4-4-3 Detailed inspection procedures
1) Be sure to check whether the AC sub power switch is removed when removing the main PCB or
panel PCB.
2) Do not hold the outside of the main PCB or panel PCB with the hand or apply excessive force to it.
3) When connecting or removing the connector to the main PCB or panel PCB, do not pull the lead
wire, but hold the entire assembly with the hand.
1) When there is any trouble with the main PCB or panel PCB, check the connector for a poor
connecting and the PCB or copper-clad pattern for separation.
2) The PCB is composed of the following two parts.
• Main PCB: The main PCB is composed of the MICOM and peripheral circuit, relay drive sensor
drive circuit, DC 5V power circuit, DC 12V power circuit and buzzer drive circuit, etc.
• Panel PCB: The panel PCB is composed of the LED display key and remote control.
NO Procedures
1 Turn off the sub power switch, 1) Is the fuse blown? 1) Overvoltage?
and then check PCB fuse. 2) Indoor fan motor short?
2 1. Apply the supply voltage Check the supply voltage 1) Power cord faulty, poor connection
2. When power lamp and LED display 1) Is the voltage between both 1) of indoor and outdoor unit, fuse
operate after pressing the on/off 1) ends of the trans connector(GT4,5 1) blown, wrong wiring of power cables.
button, it is not related to items 1) AC187V ~ AC 253V? 2) Power trans faulty power circuit
1)~4). 2) The voltage between both 2) faulty.
2) terminals of the CN11 AC 18V~ 3) Power circuit faulty load short.
2) AC 21V.
3) Is the voltage between both
3) terminals of the REG1 (KA 7812)
3) out and GND DC 12V?
4) Is the voltage between both
4) terminals of the REG2 (KA7805)
4) out and GND DC 5V?
3 Set the unit to “cool” operation mode 1) The compressor does 1) The relay(RY1) for driving the
by the “on/off” button and mode 1) not operate. 1) electronic contractor does not
selector key. 1) operate.
1. Fan operation 2) Electronic contactor faulty.
2. Fan speed high, medium, low.
4 Set the unit to “fan” operation mode 1) Is AC 220V applied between the 1) Indoor fan motor faulty.
by the “on/off” button and mode 1) com terminal and the high, medium, 2) Starting condenser faulty.
selector key. 1) and low terminal at the indoor fan
1. Fan operation 1) motor connector? (when selecting
2. Fan speed high, medium, low. 1) each fan speed)
2) Indoor fan motor does not turn.

19
MEMO