Samsung AP500PF User manual

SERVICE Manual
CONTENTSAIR CONDITIONER
1. Precautions
2.ProductSpecifications
3. OperatingInstructions and
Installation
4.Disassembly and Reassembly
5. Troubleshooting
6. Exploded Views andParts List
7. BlockDiagrams
8. PCBDiagrams
9. Wiring Diagrams
10. Schematic Diagrams
ROOM AIR CONDITIONER
AP500PF

1) Turn off the the power.
Be sure to turn off the power before attempting to repair the
unit such as the disassembly of the unit.
2) Be careful of electric shock
When checking the circuit with the power connected in
unavoidable circumstances, take special care not to touch the
live parts. There is a danger of electric shock.
3) Use of appropriate parts
Be sure to use the genuine parts of the relevant model when it
is necessary to replace parts. (Replace parts instead of repair-
ing with regard to the malfunctioning of electric contact areas.
Never attempt to modify the unit. It is extremely dangerous
for the consumer to attempt to repair the unit on his(her)
own.)
4) Use of proper tools
Use appropriate tools for repair, and use measuring equip-
ment after accurate calibration. Using worn tools may result
in problems, including poor contact and poor connection.
5) Avoid damage to electric wire or electric cord.
Check the electric cord or electric wire for any damage during
repair.
Be sure to replace it if damaged.
6) Avoid intermediate connection of the electric cord.
Never attempt to make an intermediate connection by cutting
the middle area of the electric cord or make a connection to
the power receptacle as it is very dangerous, causing problems
or fire.
7) Checking of insulation
Be sure to check the insulation resistance after completion of
the assembly work.
(Check whether the insulation resistance of the electric wire
and grounding terminal is over 30MΩby using the insulation
resistance tester, and then connect the power source.)
8) Checking of grounding
Check the grounding condition, and perform repair if poorly
grounded.
9) Checking of installation condition
Check the installation condition of the unit, and perform
repair if there is any defective area.
If the unit remains in an unstable installing condition, install it
at a new site.
10) Be careful of children
As the repair of the unit involves a lot of dangerous elements,
do not allow children to approach nearby during repair work.
Samsung Electronics 1-1
1. Precautions
Turn off the sub power switch separately installed.
No connection with the power receptacle
Upon completion of the repair, clean the air
conditioner and surrounding area, and
inform the customer of completion of the repair.
Cleaning

Samsung Electronics 2-1
2. Product Specifications
2-1 Table
590 x 1810 x 400
704 x 1925 x 600
930 x 1240 x 385
1200 x 1370 x 540
760 x 165 x 760
75
83
104
114
17
50,000
5,100
16/9.5A
9.8
56
55
54
53
65
4 x 30
WAVE 1.7
ø1.2
6P
450VAC, 6µF
1000
950
900
850
SIROCCO
220V, 6RPM
250V,5A
2 x 24, 2EA
WAVE 1.7
3800
COPELAND
CRL3-0351
Recipro
450VAC, 40µF
-
8P
4µF
750
PROPELLER
3/8 inch
3/4 inch
Size
Weight
Electric
characteristics
Indoor unit
Outdoor unit
mm
mm
mm
mm
mm
kg
kg
kg
kg
kg
BTU/h
W
A
BTU/Wh
dB
dB
dB
dB
dB
Row x Step
Turbo
High
Medium
Low
V/A
Row x Step
g
Width x Height x Depth
Width x Height x Depth
Width x Height x Depth
Width x Height x Depth
Width x Height x Depth
Turbo
High
Medium
Low
Construction
Fin
Capillary tube
No. of polarities
Capacitor
RPM
Type
Construction
Fin
Maker
Model
Type
Capacitor
OLP
No. of polarities
Capacitor
RPM
Type
High pressure side
Low pressure side
Unit
Packed
Unit
Packed
Packed
Unit
Packed
Unit
Packed
Packed
Indoor unit
Outdoor unit
Indoor unit
Indoor unit
Outdoor unit
Piping
Piping
Outdoor unit
1. Cooling capacity
2. Power consumption(Cooling)
3. Current consuption(Cooling)
4. E.E.R
5. Noise (Cooling/
Heating)
1. Evaporator
2. Blower motor
3. Blower
4. Motor swing
5. Fuse
1. Condenser
2. Refrigerant volume
3. Compressor
4. Fan motor
5. Fan
6. Service v/v
Model AP500PF
ITEM

2-2 Samsung Electronics
Unit : mm
400
590 930
385
2-2 Dimensions

Samsung Electronics 3-1
3. Operating instructions and Installation
3-1 Operating Instructions
3-1-1 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 offan motor step according to current temperature
Operationof indoor fan motoronly
High medium,low
Control of fan motor stepaccordingto current temperature
Turbo-operatingcompressorandpowerfuloperatingfan
motor(30minutes)
Reserve functionwhichisoffafter 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 differencebetweencurrent
anddesired temperature
Fan speed
selector mode
Airflow selector
mode
Convenience function
Self-diagnosis
function
LED display
function

Samsung Electronics
3-2
3-1-2 Key type and functions
3-1-2(a) PANEL key type and functions
Key name Key operating function Key type
On/off Start and end of operation TACT
- ON 1 time = operation start, ON again = operation end.
- 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(ON) one time,
the desired temperature is increased by the unit of 1°C.(18°C- 30°C)
- Time: When pressing the button(ON) one time, the time is increased by 1 minte.
If the “on” 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(ON) one time,
the desired temperature is decreased by the unit of 1°C. (18°c- 30°C)
- Time: When pressing the button(ON) one time, the time is decreased by 1 minute.
If the “on” button is pressed continuously, the time is decreased by 10 minutes.
- One short, and continued operation
Change of display The temperature and current time can be changed. TACT
- If the “on” key is pressed 1 time, current temperature
and desired temperature are displayed.
- If the “on” key is pressed 1 time, current time is displayed.
* Operating functions
Buttonforspeedselection:Whenpressing
thebutton,themodeis selectedinthe
orderofhigh-medium-low.
Displaychangebutton:Whenthebuttonispressed,cur-
renttimeandtemperaturearedisplayedcontinuously. Up/downbutton:Itcanregulatecurrent timeanddesiredtemperature. Functionselectorbutton:whenpressingthebutton,themode canbeselectedrepeatedlyintheorderofauto-cool-fan.
Conveniencereserve
button:Itcanstopthe
operationautomatically. Reservedisplay:
Conveniencereserve
operationisperceived
whenorderedtodoso.
Operationdisplaylamp:
Whenthepowerisfirst
applied,thelampwill
blink,butwillturnon
whenoperationbegins.
Fandisplay:Thefanisdis-
playedintheorderofturbo,
high,medium, andlow.
Timeandtemperaturedisplay:
Currenttime,reservetime,and
temperaturearedisplayed.
Cooldisplay:Thedoortempera-
tureissensedandthebuttonis
lightedwhencoolingisbegun. Left-rightturn
display.
Functionselectordis-
play:Currentmodeof
operationdisplay.
Sensortoperceive remote
controller: It canreceive
ordersfrom remotecontroller.On/offbutton.

Samsung Electronics 3-3
3-1-2(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 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

3-4 Samsung Electronics
3-2 Installation
3-2-1 Selection of Installation Place
3-2-1(a) Indoor Unit
3-2-1(b) Outdoor Unit
*If there is any unavoidable reason to install the unit at such
a place, take the following measures against the wind;
1. When installing the unit at a roadside concentrated with
buildings, install it parallel with the road.
2. Install the unit so that the air outlet faces toward the wall
at a place such as rooftop, which may be subjected to
strong wind.
* The outdoor unit should be installed in accordance with the service space.
•Place free from the risk of combustible gas leakage.
•Place which can bear the weight of the unit.
•Place which can bear the fixing strength of the outdoor unit.
•Avoid a place subject to oil (including machine oil).
•Avoid a saline place.
•Avoid a place subject to sulfide gas (hot spring zone).
(When installing the unit at such special environmental
conditions, it may cause machine trouble. When it is
unavoidable to use such places. It requires special
maintenance.)
• A place where the discharge air and noise of the outdoor unit do not disturb the neighborhood.
(Take special care not to cause any inconvenience to your neighbors when installing the unit on
the borderline with your neighborhood.)
• A place where strong wind does not head against the air outlet of the outdoor unit.
(If a strong wind heads directly against the air outlet at the time of cool operation, a safety device
can be operated.)
•Do not install the outdoor unit at an unstable place such as outer wall of an apartment or build-
ing.
The outdoor unit may fall down, causing severe personal or property damage or loss.
•Install the unit at a place close to the wall facing the outside
as it is necessary to perform piping connection with the out-
door unit.
- It is effective to install the unit at a window side to ensure
uniform distribution of indoor temperature.
•Install the unit at a place where there is no obstacle against
the wind around the air inlet and air outlet.
• Install the unit horizontally at a stable, rigid place.
(When installing the unit at a place subjected to vibration,
noise may occur.)
•Avoid a place near the door which is frequented by people.
•Avoid a place subject to direct sunlight.
Above 15cm
Above 15cm
Above 50cm
Above 15cm
Above 50cm
Above 30cm
The air inlet faces toward the wall. The air outlet faces toward the wall.
Space for piping
and wiring
Space for piping
and wiring
Wall Strong wind
Roof top
Above 50cm
Above 100cm
Above 20cm
Top view
Side view

Installation Method
3-5
Samsung Electronics
3-2-2 Electrical Work
Power
Ampere of breaker
Knife switch
Size of grounding wire
Min. size of electric wires from/to
the indoor/outdoor unit
Size of electric input wires
Switch
Fuse
3phase 3wires 220V / 3phase 4wires 380V
50 A
30A
30 A
2.0 mm2
0.75 mm2
5.5 / 3.5 mm2
The electrical work should be performed by a specialist qualified for the work.
• Use the three phase power supply, and be sure to install the sub power distributing board for
exclusive use with the unit(separately purchased by the user).
* Avoid octopus-type wiring as it can cause a drop in voltage, thus resulting in poor performance
of the automatic control circuit.
• Be sure to install circuit breaker (separately purchased by the user).
• Be sure to connect the grounding wire.
Electric power spec
CAUTION
• Be sure to use the wires, and switches or fuses of power distribution board are qualified
and fulfill the specification.
• Be sure to install knife switch or circuit breaker on the power distribution board.
• The electrical and grounding work should be performed as per “ technical specification
of electrical facilities ” and “ specification of internal wiring ”.
• Be sure to connect main electrical input wires with bolted connectors using compressed terminal.
Applicable voltage 220V
Applicable voltage 380V 198V ~ 242V
342V ~ 418V

Installation Method
3-6 Samsung Electronics
1. Remove cover of electric box on side panel of outdoor unit.
2. Connect electric input wires (R,S,T,N) to each terminal (R,S,T,N) of the electric box on outdoor
unit respectively.
(Input wires are purchased by the user separately.)
3. Connect electric wires (red, white, black) to each terminal (red, white, black) on indoor and out-
door unit respectively.
OUTDOOR SIDE
Power terminals on the outdoor unit
Red Red
White
Black
Black
Green
Knife switch or
automatic circuit
breaker
Electric input wires Indoor / outdoor unit
connecting wire
CAUTION
• Be sure to connect electrical wires correctly, if not it can cause a trouble.
* Be sure to fix wires from/to the indoor and outdoor unit on the piping insulated.
Avoid wires contact to bare pipe or valve directly without any insulated spacer.
3-2-2(a) When connecting 3Phase 4wires 380V AC
White

Installation Method
3-7
Samsung Electronics
OUTDOOR SIDE
Power terminals on the outdoor unit
Red Red
White
Black
Black
Knife switch or
automatic circuit
breaker
Electric input wires Indoor / outdoor unit
connecting wire
1. Remove cover of electric box on side panel of outdoor unit.
2. Connect electric input wires (R,S,T) to each terminal (R,S,T) of the electric box on outdoor unit
respectively.
(Input wires are purchased by the user separately.)
3. Connect electric wires (red, white, black) to each terminal (red, white, black) on indoor and out-
door unit respectively.
3-2-2(b) When connecting 3Phase 3wires 220V AC
White

Installation Method
3-8 Samsung Electronics
3-2-3 Installation Method
3-2-3(a) Installation Procedures
1. Open the inlet grille, and remove the flare nut.
2. Bend the connection pipe to an appropriate length using the spring bender depending
upon the installation place.
- Allowable pipe length : Maximum 25m
- Allowable pipe drop distance : Maximum 15m
- Make no more than ten bending points on the pipe
• When the pipe length is in excess of the standard pipe length of 5m, add the refrigerant
(R-22) of 50g for each additional 1m.
3. Install the high pressure pipe to the heat exchanger liquid pipe, and the low pressure pipe to the
heat exchanger gas pipe respectively using the flare nut, taking care not to cause any leakage of
refrigerant.
4. Be sure to insulate the pipe with appropriate insulation material.
5. Insert the drain hose into the drain pipe, and connect them by tying them to the cable tie to pre-
vent any water leakage.
6. After completion of the installation, check the connecting area for any gas leakage.
7. Wind a finish tape when the wiring of the refrigerant pipe, the unit, and the drain piping are com-
pleted.
Outdoor
unit
Outdoor
unit
Indoor
unit
Indoor
unit
Outdoor unit
checking area
Indoor unit
checking area
CAUTION
• If the pipe is lengthened, the performance of the unit is degraded, and the service life is shortened.
Therefore, the pipe length should be as short as possible (less then 15m).

Installation Method
3-9
Samsung Electronics
3-2-3(b) Connection of Refrigerant Piping
Oblique Roughness Burr
Outer Diameter
ø 9.52mm
ø 19.05 mm
• Unproper flaring
Inclined Surface
damaged Cracked Uneven thickness
A ( out / in)
1.7 / 1.0 (mm)
2.2 / 1.5 (mm)
Final Torque
450 kg • cm
750kg • cm
RemarksOuter Diameter
ø 9.52mm
ø 19.05mm
Tightening Torque
400 kg • cm
700kg • cm
Spring
1. Cut the pipe using the pipe cutter.
1. Perform bending of the pipe using the bender which has a specified bending radius.
2. Be sure to take full care to perform bending of the pipe successfully at one time.
Bending and unbending the pipe more than twice makes the bending work increasingly difficult.
3. You may use the spring inserted into the gas pipe instead of the bender to bend the pipe.
4. When you bend the pipe using the spring, hold the pipe with both hands to prevent any distor-
tion, and secure a minimum bending radius of more than 100mm.
• Align the center of the connection piping, and tighten the flare nut
by turning it with hand. Then tighten it again using the spanner in
the direction as shown in the figure.
2. Insert the flare nut into the pipe, and then perform the flare processing.
Flare Processing
Pipe Bending
Tightening of Connection Parts

Installation Method
3-10 Samsung Electronics
3-2-3(c) Drilling a Hole in the Wall
3-2-3(d) Drain Hose
3-2-3(e) Rat-prevention Cover
•Drill a hole of 70mm in diameter to the outside.
• The drilling should be done at a distance of less
than 150mm from the floor facing the indoor unit.
•Extend the drain hose to the drain hose connect-
ed to the drain pan, and fix it with the tape or a
cable tie to prevent separation. Then make a
covering of it so that water can not flow out-
wardly.
Less than
150mm
ø70mm
Drain hose Indoor and
outdoor
connection
Insulation
Drain pan
Band
Piping Material
Insulator Vinyl Chloride(Outer diameter ø 16mm) Foamed Polyethylene
• The piping of this unit can be connected to the left and rear side.
• When you hit the area for piping connection slightly with a hammer, a hole is made.
- If there is any reason to change connection, fill in hole with ruber cabi slot.
Holes for piping
connection (2 points)
CAUTION
1. As the draining is of natural drain type, make the drain hose direct downward.
2. If there is any foreign substance in the drain plate, it may clog the drain pipe.
Therefore, be sure to remove the foreign substance inside after installation.
3. After completion of installation, be sure to pour water into the drain pan,
and then check the draining condition.
(There is no problem in draining when the draining is completed within 20 seconds.)

4-1
Samsung Electronics
4. Disassembly and Reassembly
4-1 Indoor Unit
No Parts Procedure Remarks
1
2
3
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.

Disassembly and reassembly
4-2 Samsung Electronics
No Parts Procedure Remarks
4
5
Font 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 loosen-
ing screws.

Disassembly and reassembly
4-3
Samsung Electronics
No Parts Procedure Remarks
6
7
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.

Disassembly and reassembly
4-4 Samsung Electronics
No Parts Procedure Remarks
8 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.

Disassembly and reassembly
4-5
Samsung Electronics
No Parts Procedure Remarks
9 Motor 1) When the ass’y duct should be separated
from the motor, the 2 bracket should be sepa-
rated first.
2) Then the bolts fixed at the blower and motor
shaft should be separated.
3) Then the screws binding the holder top blow-
er 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.

4-6 Samsung Electronics
Disassembly and reassembly
No Parts Procedure Remarks
10 Panel PCB
6) Then the motor should be separated.
7) The bracket fixed at the motor should be sep-
arated.
1) Should be separated after loosening the insu-
lating material and binders at the back of the
front side.