Samsung AS12AAMC User manual

SERVICE Manual
CONTENTSAIR CONDITIONER
1. Installation
2. Disassembly and Reassembly
3. Troubleshooting
4. Exploded Views and Parts List
5. Refrigerating Cycle Block Diagrams
6. Wiring Diagrams
7. Schematic Diagrams
ROOM AIR CONDITIONER
INDOOR UNIT
AS12AA(B)MC OUTDOOR UNIT US12AA(B)MC
E DB98-05495A(1)
DB98-05495A(1)-co 3/21/02 4:27 PM Page 1

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 64~78kg/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
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Index

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 cable.
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 enter-
ing.
Relocation of the air conditioner
5. Disconnect the pipe connected to the out-
door unit.
At this time, cover the valve of the out-
door 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 2-way valve and the 3-way 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 2-way valve 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.
2-Way Valve
3-Way Valve
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Index

3
2. Disassembly and Reassembly
2-1 Indoor Unit
Stop operation of the air conditioner and remove the power cable before repairing the unit.
No Parts Procedure Remark
Front Grille1 1) Stop the air conditioner operation and block the
main power.
2) Separate tape of front panel upper.
3) Contract the second finger to the left, and right
handle and pull to open the inlet grille.
4) Take the left and right filter out.
5) Loosen one of the right fixing screw and sepa-
rate the terminal cover.
6) Loosen three fixing screws of front grille.
7) Pull the upper left and right of discharge softly
for the outside cover to be pulled out.
8) Pull softly the lower part of discharge and push
it up.
Caution;
Assemble the front panel and fix the
hooks of left and right.
*Taking off the deodorizing filter.
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Index

4
No Parts Procedure Remark
Electrical Parts
(Main PCB)
Ass’y Tray Drain.
Heat Exchanger
Fan Motor and
Cross Fan
2
3
4
5
1) Do “1”above.
2) Take all the connector of PCB upper side out.
(Inclusion Power cord)
3) Separate the outdoor unit connection wire from
the terminal block.
4) If pulling the Main PCB up. it will be taken out.
1) Do “1”, “2”, above.
Separate the drain hose from the extension
drain hose.
2) Pull tray drain out from the back body.
1) Do “1” and “2”, “3”, above.
2) Loosen two fixing earth screws of right side.
3) Separate the connection pipe.
4) Separate the holder pipe at the rearside.
5) Loosen the three fixing screws of right and left
side.
6) Lifting the heat exchanger up a little to push the
up side for separation from the indoor unit.
1) Do “1” “2” ”3” “4”, above.
2) Loosen the fixing two screws and separate the
motor holder.
3) Loosen the fixing screw of fan motor.
(By use of M3 wrench)
4) Separate the fan motor from the fan.
5) Separate the fan from the left holder bearing.
DB98-05495A(1)-1 3/21/02 4:27 PM Page 4
Index

2-2 Outdoor Unit
■US12AA(B)MC
No Parts Procedure Remark
Common Work 1) Loosen the fixing one screws and separate the
COVER TERMINAL.
2) Loosen the fixing one screws and seperate the
cover control.
3) Separate the connection wire from the terminal
block.
4) Loosen 13 fixing screws and separate the cabi
front.
5) Loosen the one fixing screw of Ass'y E-part.
6) Loosen 4 fixing screws and separate the cabi
side.
1
5
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Index

6
No Parts Procedure Remark
Fan and Motor
Heat Exchanger
Compressor
2
3
4
1) Do “1”, above.
2) Remove the nut flange (Turn to the right to
remove, as it is a left hand screw).
3) Separate the fan.
4) Loosen four fixing screws to separate the motor.
5) Loosen five fixing screws and seperate the
motor bracket from. the base.
1) Do “1”,“2”, above.
2) Loosen two fixing screws of left and right side.
3) Disassemble the inlet and outlet pipe by weld-
ing.
4) Separate the heat exchanger.
1) Do “1”,“2”,“3”, above.
2) Open the terminal cover of compressor and
unscrew the connection terminal.
3) Disassemble the inlet and outlet pipe of com-
pressor by welding.
4) Loosen the three bolts of the lower part.
5) Separate the compressor.
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Index

7
3. Troubleshooting
3-1 Items to be checked first
1) The input voltage should be rating voltage ±10% range.
The airconditioner may not operate properly if the voltage is out of this range.
2) Is the link cable linking the indoor unit and the outdoor unit linked properly?
The indoor unit and the outdoor unit shall be linked by 4 cables.
Check the terminals if the indoor unit and outdoor unit are properly linked by the same number of
cables.
Otherwise the airconditioner may not operate properly.
3) When a problem occurs due to the contents illustrated in the table below it is a symptom not related to
the malfunction of the airconditioner.
4) Indoor unit observes operation condition of the air conditioner, and displays self diagnosis details on
the display panel.
NO Operation of air conditioner
1 The STD operation indication LED blinks when a
power plug of the indoor unit is plugged in for the first time.
2 In a COOL operation mode, the compressor does not
operate at a room temperature higher than the setting
temperature that the IN DOOR FAN should operate.
3 Fan speed setting is not allowed in AUTO or DRY mode.
4 Compressor stops operation intermittently in DRY mode.
5 Timer LED only of the indoor unit lights up and the
air conditioner does not operate.
6 The compressor stops intermittently in a COOL mode or DRY
mode, and fan speed of the indoor unit decreases.
It indicates power is on. The LED stops blinking if the operation
ON/OFF button on the remote control unit is pushed.
In happens after a delay of 3 minutes when the compressor is reop-
erated. The same phenomenon occurs when a power is on.
As a phenomenon that the compressor is reoperated after a delay of
3 minutes, the indoor fan is adjusted automatically with reference
to a temperature of the air blew
The speed of the indoor fan is set to LL in DRY mode.
Fan speed is 5 steps is selected automatically in AUTO mode.
Compressor operation is controlled automatically in DRY mode
depending on the room temperature and humidity.
Timer is being activated and the unit is in ready mode.
The unit operates normally if the timer operation is cancelled.
The compressor stops intermittently or the fan speed of the indoor
unit decreases to prevent inside/outside air frozen depending on the
inside/outside air temperature.
Explanation
NO Display
1 STD LED blinking (1Hz)
2 TIMER LED blinking (1Hz)
3 STD and TIMER LED blinking (1Hz)
4 NATURE LED blinking (1Hz)
Restore from power failure (input initial power)
Indoor unit Room sensor Error (open or short)
Indoor unit heat exchanger temperature sensor Error (open or short)
Indoor fan malfunctioning (for spead is Below 450rpm)
Self Diagnosis
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Index

8
3-2 Fault Diagnosis by Symptom
3-2-1 No Power (completely dead)-Initial diagnosis
1) Checklist :
(1) Is input voltage normal?
(2) Is AC power linked correctly?
(3) Is output voltage of DC regulator IC KA78L05 (IC02) normal? (4.5VDC-5.5VDC)
2) Troubleshooting procedure
Replace PCB
display
Is DC voltage of PCB
display normal?
Remove power cord and plug in
again in approx. 5 seconds
Is operation lamp blinking?
Does operation start when
ON/OFF button on the remote
controller unit pushed?
Is transmission display of the
remote controller unit blinking?
Is "beep"sound heard from the main
unit?
Is DC voltage of the PCB module
normal?
Are voltages of #33 (compressor),
of the micom normal? 5VDC
Is voltage of #32 (indoor fan) of the
micom normal?
Is voltage at #10 terminal of the Micom normal?
0VDC
Is voltage at #9 terminal of the Micom normal?
5VDC
Is rating voltage ±10% range
applied to the primary side(~,~)
of the “BD71”
•Check linkage between
power cord and
terminal tap
•Check fuse
Is 325VDC appear in the
secondary side (+, -)
of “BD71”
Replace
SMPS PARTS
YES
NO YES
NO
YES
YES
YES
NO
YES
YES
YES
DC5V
10ms
10ms
250ns
NO
NO
OK
YES
YES
YES
YES
NO
NO
YES Normal
Refer to remote control
unit fault diagnosis
Replace PCB
module.
Is output voltage of ICO2 normal?
Check connections
compressor
and indoor fan.
Are voltages at RY71(Compressor)
normal? DC12V
Is voltage at SS71(indoor fan)
Replace
RY71 and
SS71
NO
NO
NO
Is voltage output terminal of
PC814(PC02) normal?
Replace ICO2
CheckPCBpattern.
ReplacemainPCB.
Replace PC814(pc02)
Replace
micom
Is voltage at #3 terminal of the micom
normal?
Are voltage at #11 and #12 of the
micom normal?
NO
NO NO
YESNO
NO
NO
YES
OK
Is operation normal?
Replace resonator (X301)
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Index

3-2-2 When the Indoor Unit Fan Does Not Operate. (Initial Diagnosis)
9
1) Checklist :
(1) Is the indoor unit fan motor properly connected with the connector (CN72)?
(2) Is the AC voltage correct?
(3) Is HALL IC in indoor fan motor properly connected with the connector (CN42)?
(4) Is the running capacitor (CR71) properly connected with PCB board?
2) Troubleshooting procedure
After unplugging out the power cord should
be reconnected within five seconds.
Does the STD lamp(Green) blink?
Does the Solid State Relay(SS71) work
properly?
Is the supply voltage of the fan
motor sufficient?
Test rod location
PCB CN72 Condition
Fan operate about AC 180V
Normal
voltage
pin #3 and #5
YES
YES
YES
NO
NO
NO
Check as in the procedure “NO power parts” Refer tp
page 8.
Microcomputer is out of order.
PCB is
out of order. PCB should be
replaced.
Replace MFC
Fan motor
should be replaced.
Fan motor
is out of order.
MF-C is out of order
YES
-
Test rod location
+
SS71- SS71- 12V
Normal
Voltage
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Index

10
3-2-3 When the Outdoor Unit Does Not Operate. (Initial Diagnosis)
1) Checklist :
(1) Is input voltage normal?
(2) Is the set temperature of the remote control higher than room temperature in COOL mode?
(3) Is the POWER IN connector (CN71) linked correctly?
(4) Is the outdoor unit properly connected with the TERMINAL BLOCK connector((N1), 1)?
2) Troubleshooting procedure
After unplugging out the power cord should be
reconnected within five seconds.
Does the STD lamp blink
YES
YES
NO
NO
NO
NO
YES
YES
Outdoor unit is
out of order.
Power relay is
out of order Power relay should be replaced.
PCB should be
checked.
Microcomputer is
out of order.
PCB should be checked.
Room temperature sensor is
out of order
Check as in the procedure "No Power parts"
Refer to page 8.
Is the room sensor normal register?
10°C 20°C 30°C
17.96kΩ12.09kΩ8.3kΩ
Does the timer lamp blink during operation ?
Is the power relay RY71 operated by adjusting the room
temperature?
Is rating voltage ±10% range applied relay between Terminal block
NO(N1) and No. 1
Test rod location Normal
+ - Condition Voltage
IC4 Pin No.33 GND RY71 ON DC 4.8V
#
!
!
@
#
@
NO
YES
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Index

11
3-2-4 When the UP/DOWN Louver Motor Does Not Operate. (Initial Diagnosis)
1) Checklist :
(1) Is input voltage normal?
(2) Is the UP/DOWN louver motor properly connected with the connector (CN61)?
2) Troubleshooting procedure
3-2-5 In the mode, when there is no cool air current. Check this first;
(1) Is the set temperature of Remote Control lower than room temperature in Cool mode?
(2) Is the Indoor PCB properly connected with the CN71 connector?
Remove power cord and plug in again in approx. 5 seconds.
Is STD lamp blinking?
Does operation start when swing button of the remote
control unit pushed?
Voltage at pin #58-#61 of micom (ICO4)
change?(Squarewave)
Volatge at pin #13 ~ #16 of IC06 (ULN2003A)
change?(Squarewave)
UP/DOWN louver motor is faulty.
Driver IC06 (ULN2003A) is faulty.
Micom (IC04) is faulty.
Normal
Check as in the procedure "No Power
parts". Refer to page 8.
YES
YES
YES
NO
NO
NO
YES
YES
After training on, the Cooling operation should
start in five minutes.
Is the number #33 of Micom (IC04) DC 5.0 V?
Is the number checking #10 of IC06 (ULN2003A) LOW?
RY7I or Cable Check.
NO
YES
YES
NO
NO
YES Normal
Abnormal Micom
Abnormal IC06
PCB should be replaced.
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Index

12
3-2-5 If Operation By Remote Control Unit Is Impossible. (Initial Diagnosis)
1) Troubleshooting procedure
Remove power cord and plug in again approx. 5 Seconds
Is operation lamp blinking? Check as in the procedure “NO Power
parts”. Refer to page 8.
Normal
Replace battery.
LCD is faulty.
Replace button.
Micom is faulty.
Receiver module is faulty.
Q601(C4375Y) or Q602(C1623Y) is faulty.
IR LED(CL-1L5EU) is faulty.
“ “ sound heard from the indoor unit when ON/OFF
button on the remote control unit pushed?
Voltage of battery less than 2.5V (Remote Control Unit)?
LCD display status of REMOCON normal?
Voltage at PIN #30 of Remocon Micom change?
Voltage at collecter of Q601 or Q602 change?
Voltage at pin #26 of micom (IC04) change (INDOOR UNIT)?
Micom (IC04) is faulty.
Transmission display lamp ( ) blinking when
ON/OFF button on the remote control unit pushed?
YES
NO
YES
YES
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
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Index

13
3-3 Set up the Model option
• It is necessary to set up option code after replacing the main-PCB as a service parts.
Make sure that you can set up the option of code the remote controller after you replace the main
PBA otherwise, the unit won’t be working properly and all LED lamps on display will be flickering.
Step 1 : Preparing the remocon to main PCB option set
1st Remove the battery from the remocon.
2nd Press the temperature raise/down button simultaneously
and insert the battery again.
3rd Make sure the remocon display shown as .
Step 2 : Second stage preparation of the remocon option set.
The Method for Setting up the model option with remocon
❈Note ; In case the wrong letter has been selected, continue to press the button until the correct letter appears.
1st If the first stage number “ ” appears on the display, proceed to the second stage.
2nd Every time the !and &button, “ ” and “ ” each continue to appear.
3rd Whenever pressing the @, #, $, %, ^, *, (, ), 1, 2button, the number increase from
0~9(0123456789) and A, b, C, d, E, F each time.
! If the first number is , it is correct otherwise press until
appear.
@ When pressing the button ~ appear on the display,
select one of them.
# When pressing the button ~ appear on the display,
select one of them.
$ When pressing the button ~ appear on the display,
select one of them.
% When pressing the button ~ appear on the display,
select one of them.
^ When pressing the button ~ appear on the display,
select one of them.
DB98-05495A(1)-1 3/21/02 4:28 PM Page 13
Index

14
! If the first number is , it is correct otherwise press until
appear.
@ When pressing the button ~ appear on the display,
select one of them.
# When pressing the button ~ appear on the display,
select one of them.
$ When pressing the button ~ appear on the display,
select one of them.
% When pressing the button ~ appear on the display,
select one of them.
^ When pressing the button ~ appear on the display,
select one of them.
Step 3 : Reconfirming option set after completion
(in case of ex. 000000-1700b7)
After pressing selector for the mode, the display shown as .
After pressing selector for the mode, the display shown as .
Step 4 : Pressing the ON/OFF button ( )
When pressing the operation ON/OFF key with the direction of remote controller for unit,
the sound “Ding” or “Diriring” is heard and the first LED lamp on the left side is flickering
at the same time, then the input of option is completed. (If the diriring sound isn’t heard, try
again pressing the ON/OFF button.)
Step 5 : Unit operation test-run
First, Remove the battery from the remote controller.
Second, Re-insert the battery into the remote controller.
Third, Press ON/OFF key with the direction of remote controller for set.
• Error Mode
1st If all lamps of indoor unit are flickering, Plug out and plug in again and pressing ON/OFF key to retry.
2nd If the unit is not working properly or all lamps are continuously flickering after setting the option code, see
if the correct option code is set up for it’s model.
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Index

15
<Table of the option code>
MODEL
AS12AAMC
AS12ABMC
OPTION CODE
010000-170340
000000-017340
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Index

16
4. Exploded Views and Parts List
4-1 Indoor Unit
17
16
14
22
9
7
21
3
4
5
6
19
20
8
12
25
13-4
23
13-3
13-2
13
13-1 11
10
2
1
15
18-1
18-5
18-4
18 18-618-6-1
18-2
18-3
24
DB98-05495A(1)-2 3/21/02 4:28 PM Page 16
Index

17
Q’TY
■Parts List
CODE NO
No. Description REMARK
AS12AA(B)MC
1
2
3
4
5
6
7
8
9
10
11
12
13
13-1
13-2
13-3
13-3-1
13-3-2
13-4
14
15
16
17
18
18-1
18-2
18-3
18-4
18-5
18-6
18-6-1
19
20
21
22
23
24
25
DB64-00085A
DB63-00064B
DB95-00287K
DB63-00067A
DB92-00031L
DB67-00051A
DB67-00032A
DB63-00083A
DB94-00020A
DB60-20011A
DB31-00071B
DB32-00020A
DB93-00458C
DB93-01018A
DB65-00079A
DB93-00268A
2202-000780
DB32-00037A
DB39-00147A
DB94-00056E
DB94-00104A
DB61-00165A
DB70-00036A
DB94-00058F
DB94-00062E
DB66-00127B
DB66-00128A
DB66-00128B
DB63-00082A
DB95-20138A
DB31-10129A
DB61-40251A
DB67-60030A
DB96-01443A
DB94-40003A
DB93-00861A
DB70-00114A
DB63-00226A
GRILLE AIR INLET
GUARD-AIR FILTER
FILTER CLEANER ASS´Y
COVER TEMINAL
ASS´Y PANEL
SPACER EVAP LOW
SPACER EVAP UP
COVER U BEND
ASS´Y FAN CROSS
BOLT SPECIAL
MOTOR FAN IN
THERMISTOR WIRE ASS´Y
ASS’Y CONTROL IN
ASS´Y PCB MAIN
TERMINAL BLOCK ASS´Y
ASS´Y PCB DISPLAY
C CERAMIC,MLC-AXIAL
MODULE REMOCON
CONNECT WIRE PCB
ASS´Y BACK BODY(RIGHT SIDE)
ASS´Y HOLDER MOTOR
HOLDER PIPE
PLATE HANGER
ASS´Y TRAY DRAIN(RIGHT SIDE)
ASS´Y DRAIN HOSE
BLADE H
BLADE V,A
BLADE V,B
SCREEN SAFETY WIRE
ASS´Y MOTOR STEPPING
MOTOR STEPPING; GSP 24RW
HOLDER SENSOR
SPRING SENSOR
ASS’Y CYCLE IN(EVAPORATOR)
ASS´Y BEARING
ASS´Y REMOCON
PLATE-KNOCKOUT
COVER TERMINAL BLOCK
1
2
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
6
1
1
1
1
1
1
1
1
1
1
DB98-05495A(1)-2 3/21/02 4:28 PM Page 17
Index

18
4-2 Outdoor Unit
20
19
4
2
1
9
3
8-6
12
14
13
17
16
8-5
15
5
6
22
10
11
18
21
7
8-7
88-1
8-3
8-4 8-2
■ US12AA(B)MC
DB98-05495A(1)-2 3/21/02 4:28 PM Page 18
Index

19
DB63-00385A
DB60-30020A
DB67-50063A
DB31-10058C
DB90-00633E
DB90-00687D
DB61-00887A
DB93-00424H
2501-001237
2301-001375
DB65-40074A
DB93-00423A
DB35-00015H
DB67-60020A
DB94-00163A
DB62-00975B
DB62-00974A
48D135TU1EL
DB73-00067A
DB60-30028A
DB63-20002A
DB63-10165D
DB60-30018A
DB96-01457J
DB96-01533A
DB90-00634B
DB61-00802A
DB63-10443C
1
2
3
4
5
6
7
8
8-1
8-2
8-3
8-4
8-5
8-6
9
10
11
12
13
14
15
16
17
18
19
20
21
22
GUARD FAN
NUT FLANGE
PROPELLER-FAN
MOTOR FAN OUT
ASS´Y CABI FRONT
ASS´Y BASE OUT
BRACKET-VALVE
ASS´Y CONTROL OUT
CAPACITOR COMP
CAPACITOR MOTOR
TERMINAL BLOCK
ASS’Y LEAD WIRE
O L P
O L P SPRING
ASS´Y-PARTITION
ASS´Y SUCTION
TUBE-DISCHARGE
COMPRESSOR
GROMMET-ISOLATOR
NUT-WASHER
GASKET
COVER TERMINAL
NUT-FLANGE
ASS´Y CAPILLARY
ASS´Y COND
ASS’Y-CABI SIDE
BRACKET-MORTOR
HANDLE CABI,RH
HSER, CD 2.0
2C SM20C M6 NTR
AS+G/F, ø405
220/240V, 60/50HZ
ASS’Y
ASS’Y
SECC-P
ASS’Y
35µF 450VAC
1.5µF 450VAC
5P DFT-20A
ASS’Y
RAC12074-9622
STS304
ASS’Y
ASS’Y
ASS’Y
208-230V~/60Hz
NR
HEX 2C MB ZPC
EPDM
PBT
M5, SM20C
ASS’Y(1.7x800)
ASS’Y
ASS’Y
SGCC-M
ABS
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
1
1
1
1
1
1
1
1
■Parts List (OUTDOOR UNIT)
No. CODE NO Description Specification Remark
Q’TY
US12AA(B)MC
DB98-05495A(1)-2 3/21/02 4:28 PM Page 19
Index