Samsung AS24A2RC 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. PCB Diagrams
7. Wiring Diagrams
8. Schematic Diagrams
ROOM AIR CONDITIONER
INDOOR UNIT
AS24A2RC
AS18A6RC
OUTDOOR UNIT
US24A2RC
US18A6RC
E DB81-00189A(2)
1-00189A(2)-CO 3/16/01 1:51 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 4.5~5.5kg/cm2in a
reqular, 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
1-00189A(2) 3/14/01 4:24 PM Page 1

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 enter-
ing.
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 pressure gauge(low pressure side) to the service valve,
and open the 3-way valve again.
2-Way Valve
3-Way Valve
1-00189A(2) 3/14/01 4:24 PM Page 2

3
2. Disassembly and Reassembly
2-1 Indoor Unit
Stop operation of the air conditioner and remove the power cord before repairing the unit.
No Parts Procedure Remark
!Front Grille 1) Stop the air conditioner operation and block the
main power.
2) Seperate 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 seper-
ate the terminal cover.
6) Loosen three fixing screws of front grille.
7) Pull the upper left, right and Center 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, right and Center
* Take the Deodorizing and Electrostatic filter
out. (Optional)
1-00189A(2) 3/14/01 4:25 PM Page 3

4
No Parts Procedure Remark
Ass’y Tray Drain.
Electrical Parts
(Main PCB)
Heat Exchanger
1) Do “1” above.
Separate the drain hose from the extension
drain hose.
2) Take the display PCB out.
(Center of indoor unit)
3) Loosen two fixing screws of left and right
4) Pull tray drain out from the back body.
1) Do “1”, “2”, 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.
(Separate the TRANS hook. it before).
1) Do “1” and “2”, “3”, above
2) Loosen two fixing earth screws of right side.
3) Separate the connection pipe.
4) Separate the bush body at the upper side and
holder at the rear side.
5) Loosen the two fixing screws of left side.
6) Lifting the heat exchanger up a little to push the
up side for separation from the indoor unit.
@
#
$
1-00189A(2) 3/14/01 4:25 PM Page 4

5
No Parts Procedure Remark
Fan Motor and
Cross Fan 1) Do “1” “2” ”3” “4”, above.
2) Loosen the fixing three 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.
%
1-00189A(2) 3/14/01 4:25 PM Page 5

6
2-2 Outdoor Unit
No Parts Procedure Remark
Cabinet
Fan Motor &
Propeller Fan
1) Turn off the unit and remove the power cable
2) Remove the top cover.
3) Remove the control box cover.
4) Unplug the ass'y cable.
5) Remove the cabi-side.
6) Remove the cabi-front.
* When you assemble the parts, check if the
each parts and electric connectors are fixed
firmly.
1) Do Procedure 1 above.
2) Remove the nut flange.
(Turn to the right to remove as it is a left turned
screw)
3) Disassemble the propeller fan.
!
@
1-00189A(2) 3/14/01 4:25 PM Page 6

7
3. Troubleshooting
3-1 Items to be checked first
1) The input voltage should be rating voltage 610% 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 6 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 INDOOR FAN should operate.
3 Fan speed setting is not allowed in AUTO or DRY mode.
4 Compressor stops operation intermittently in DRY mode.
5 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
reoperated. 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.
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 BIO LED blinking (1Hz)
5 STD, BIO and TIMER LED blinking(1Hz)
6 All 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)
EEPROM Error
Option Erro (option wasn’t setup or option data error)
Self Diagnosis
1-00189A(2) 3/14/01 4:25 PM Page 7

8
3-2 Fault Diagnosis by Symptom
3-2-1 No Power(completely dead)-Initial diagnosis
1) Checklist :
(1) Is input voltage normal? (rating voltage ±10% range)
(2) Is AC power linked correctly?
(3) Are connections between primary side, secondary side of the power transformer and PCB good.
(4) Is input voltage of DC regulator IC KA7805 (IC02) normal? (11VDC-12.5VDC)
(5) Is output voltage of DC regulator IC KA7805 (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
run/stop 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 #8 (compressor), and#6
(outdoor fan) of the micom normal? ; 5VDC
Is voltage of #60 (indoor fan) of the micom
normal?
Is voltage at #33 terminal of the Micom normal?
; 0VDC
Is voltage at #18 terminal of the Micom normal?
; 5VDC
Is the rating Voltage ±10%
range applied to the
between #1 and #3 of CN78
•Check linkage between
power cord and
terminal tap
•Check fuse
Is 11~12.5VDC appear in
the input side of the DC
regulator IC KA7805(IC02)?
refer to
replace
PCB module
YES
NO YES
NO
YES
YES
YES
NO
YES
YES
YES
DC5V
10ms
10ms
100ns
NO
NO
OK
YES
YES
YES
YES
NO
NO
YES Normal
Refer to remote control
unit fault diagnosis
Refer to Replace PCB
module.
Is output voltage of ICO2 normal?(DC5V)
Check connections
compressor, outdoor
fan and indoor fan.
Are voltages at RY71(Compressor)
and RY72 (Outdoor fan) normal? ; DC12V
Is voltage at SS71(indoor fan)
Replace
RY71, RY72
and SS71
NO
NO
NO
Is voltage output terminal of
D101~D105(IN4007) normal?
Replace ICO2
RefertoreplacePCB
module
Replace IN4007
Replace
micom
Is voltage at #52 terminal of the micom
normal?
Are voltage at #48 and #49 of the
micom normal?
NO
NO NO
YESNO
NO
NO
YES
OK
Is operation normal?
Replace resonator (X501)
1-00189A(2) 3/14/01 4:25 PM Page 8

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 (CN73)?
(2) Is the AC voltage correct?
(3) Is HALL IC in indoor fan motor properly connected with the connector (CN43)?
(4) Is the running capacitor properly connected with the solder part of the PCB?
2) Troubleshooting procedure
After unplugging out the power cord should
be reconnected within five seconds.
Does the operating lamp(Green) blink?
Does the Solid State Relay(SS71) work
properly?
Is the supply voltage of the fan
motor sufficient?
Test rod location
PCB CN73
pin3, pin5
Condition
Fan operate = AC 180V
Normal
voltage
YES
YES
YES
NO
NO
NO
Check as in the procedur “NO power parts” Refer to
page 8.
Microcomputer is out of order.
PCB is
out of order. Refer to replace
PCB module
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
..
1-00189A(2) 3/14/01 4:25 PM Page 9

10
3-2-3 When the Outdoor Unit Does Not Operate. (Initial Diagnosis)
1) Checklist :
(1) Is input voltage normal?(rating voltage ±10% range)
(2) Is the set temperature of the remote control higher than room temperature in COOL mode?
(3) Is the POWER IN connector (CN78) linked correctly?
(4) Is the outdoor unit properly connected with the TERMINAL BLOCK connector(5P)?
2) Troubleshooting procedure
After unplugging out the power cord should be recon-
nected within five seconds.
Does the operating lamp blink
YES
YES
YES
NO
NO
NO
①③
③
②
②
①
①
NO
YES
NO
Outdoor unit is
out of order.
Power relay is
out of order Power relay should be replaced.
Refer to replace
PCB module
PCB is out of order.
PCB and
Room tem-
perature
sensorshould
be checked.
Room temperature sensor is
out of order
Check as in the procedure "No Power parts"
Refer to page 8.
YES
Is the room sensor normal register?
(25°C →10KΩ)
50˚F 68˚F 86˚F
17.96k Ω12.09k Ω8.3k Ω
Does the timer lamp blink during operation ?
Is the power relay RY71 operated by adjusting the room
temperature?
Is the rating Voltage ±10% range applied relay between CN78 ①
and ③.
Test rod location Normal
+ - Condition Voltage
IC06 Pin #6 GND RY71 ON DC 4.8V
1-00189A(2) 3/14/01 4:26 PM Page 10

11
3-2-4 When the UP/DOWN Louver Motor Does Not Operate. (Initial Diagnosis)
1) Checklist :
(1) Is input voltage normal? (rating voltage ±10% range)
(2) Is the UP/DOWN louver motor properly connected with the connector (CN61)?
2) Troubleshooting procedure
Remove power cord and plug in again in approx. 5 seconds.
Is operating lamp blinking?
Does operation start when swing button of the remote
control unit pushed?
Voltage at pin #1-#4 of micom (ICO4)
change?(Squarewave)
Volatge at pin #16, #15 of IC06, #10, #11 of IC05 (KID65003)
change?(Squarewave)
UP/DOWN louver motor is faulty.
Driver IC05 (KID65003) is faulty.
Micom (IC04) is faulty.
Normal
Check as in the procedure "No Power
parts". Refer to page 8.
N
Y
N
N
N
Y
Y
Y
1-00189A(2) 3/14/01 4:26 PM Page 11

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.
N
Y
Y
N
N
N
N
N
Y
Y
Y
Y
Y
N
N
Y
Transmission display lamp ( ) blinking when ON/OFF
button on the remote control unit pushed?
1-00189A(2) 3/14/01 4:26 PM Page 12

13
3-3 Replace PCB module
3-3-1 Replace PCB module
Remove power cord
Replace the PCB module
Check the connection and plug in
Refer to set up the Model option
Does al display lamp blink or STD lamp blink?
YES
NO Replace another PCB module
1-00189A(2) 3/14/01 4:26 PM Page 13

14
4. Exploded Views and Parts List
4-1 Indoor Unit
1-1
2
3-3
3-2
3
3-1
4
1-2
7-2
7-1
20
5
12 11
16
17
18
19
14
6-1 6
10
10-2
10-1
10-3
15
7
8
9
13
13-2
13-1 13-3
1
1-00189A(2) 3/14/01 4:26 PM Page 14

15
■Parts List (Cooling Only)
No.
1
1-1
1-2
2
3
3-1
3-2
3-3
4
5
6
6-1
7
7-1
7-2
8
9
10
10-1
10-2
10-3
11
12
13
13-1
13-2
13-3
14
15
16
17
18
19
20
CODE NO
DB92-00035A
DB64-00127A
DB64-00130A
DB63-30150C
DB74-10101C
DB61-10164B
DB74-10082A
DB74-10081A
DB63-00091A
DB70-00116A
DB93-00311C
DB63-00115A
DB94-00029G
DB31-10153B
DB66-00104A
DB75-40087G
DB75-40087F
DB67-30089E
DB90-00140K
DB61-00209A
DB65-10108A
DB65-00039B
DB31-10151D
DB94-00040J
DB90-40135D
DB94-00074A
DB61-40244A
DB94-40007A
PD-TQ24A1R-01
DB32-00027B
DB-61-10163A
DB94-20037H
DB90-00163A
DB70-10663A
DB63-00227A
ASS´Y FRONT PANEL
GRILLE AIR INLET
PANEL FRONT
GUARD AIR FILTER
CLEANER FILTER ASS’Y
CASE CLEANER FILTER
DEODORIZING FILTER
CLEANER FILTER
COVER TERMINAL
PLATE-TERMINAL BLOCK
ASS´Y PCB DISPLAY
COVER DISPLAY
ASS´Y TRAY DRAIN
ASS´Y STEPPING MOTOR
BLADE-H
ASS´Y EVAP
ASS´Y EVAP
ASS’Y SPACER
ASS´Y HOLDER MOTOR
HOLDER MOTOR
CLIP EARTH WIRE
TERMINAL BLOCK ASS´Y
MOTOR FAN IN
ASS´Y C-F-FAN
ASS´Y HOLDER BEARING
RUBBER BEARING
HOLDER BEARING
BEARING
ASS´Y MAIN PCB
ASS´Y THERMISTOR
CASE CONTROL
ASS’Y BACK BODY
HOLDER PIPE
PLATE HANGER
COVER-TERMINAL BLOCK
ASS’Y
HIPS
HIPS
PP
ASS’Y
PP
POLYESTER/CARBON
POLYESTER/COTTON
ABS(V0)
SGCC-NI
ASS’Y
ABS(BLK)
ASS’Y
STEPPING
ABS
PLATE1.2(5/8”)
SLIT1.5(1/2”)
PVC
ASS’Y
PP
SECC
6P, 25A
IC-9430SKC7B
ø95 x L
ASS’Y
CR
PP
PG5
PD-TQ24A1R
103AT
ABS(VO)
HIPS
PP
SGCC-M
ABS
1
1
1
2
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
1
1
1
1
1
1
1
1
2
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
1
1
1
1
1
Description Specification Remark
Q’TY
AS24A2RC AS18A6RC
1-00189A(2) 3/14/01 4:26 PM Page 15

1
2
3
4
7
16
6
5
8
18
13
12
13-1
15-1
15-2
15-3
15-5
15
15-4
15-6 14-2
10
9
14-1
14
12-2
12-1
11
16
4-2 Outdoor Unit
4-2-1 24K BTU
17-1 17-2
17
1-00189A(2) 3/14/01 4:26 PM Page 16

17
■Parts List
No. CODE NO
ASS’Y WELD FRONT
ASS’Y-BASE OUT
ASS’Y-FAN
BOLT SPECIAL
MOTOR FAN OUT
ASS’Y-MOTOR B/K
PARTITION
ASS’Y-CONDENSER
COVER-CONTROL
CABI SIDE OUT
TOP COVER
COMPRESSOR
GROMMET ISOLATOR
NUT WASHER
ASS’Y SUCTION
PACKED V/V 15.88”
ASS’Y-TUBE CAPI
TUBE CAPI(C)
PACKED V/V 6.35”
ASS’Y CONTROL OUT
SWITCH MAGNET
COMPOR CAPACITOR
TERMINAL BLOCK
SPARK KILLER
FUSE
MOTOR CAPACITOR
CLOTH SOUND
NUT FLANGE 6.35”
NUT FLANGE 15.88”
TUBE-DISCHARGE
SC-90073T
SC-90073T
AS+G/F20%
M8 L25
OSME-906SRC
SGCC-M
SGCC-M
ASS’Y
ABS(V5)
SC-90073T
SC-90073T
H29B26UABCA
EPDM
M8
ASS’Y
20LT/MIN
ASS’Y
ID 1.7 x 900 x 2
6.35 INCH
ASS’Y
45CG20AGB
35µFx450VAC
8P/35A
-
2A, 250V
4µF x 450VAC
-
G3771BD
G3771BD
-
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
-
1
1
1
1
1
2
2
1
Description Specification Remark
Q’TY
US24A2RC
1
2
3
4
5
6
7
8
9
10
11
12
12-1
12-2
13
13-1
14
14-1
14-2
15
15-1
15-2
15-3
15-4
15-5
15-6
16
17-1
17-2
18
DB90-10634A
DB90-20210A
DB67-50074A
DB60-20020A
DB31-00027F
DB95-20147A
DB94-50039C
DB75-30102F
DB90-40176B
DB64-60160B
DB90-10616A
DB95-10339F
DB73-10004A
DB60-00028A
DB96-10637A
DB62-40055F
DB96-10635A
DB62-31842B
DB62-40039C
DB93-00306E
DB34-90057A
2501-001194
DB65-00040A
DB95-90026B
3601-000236
2501-000389
DB72-50622A
DB60-30010A
DB60-30010D
DB96-10670A
1-00189A(2) 3/14/01 4:26 PM Page 17

2
3
5
13-1
13
12-1
12-2
12
12-4
18
14
14-1
9
10
15-5
15-3
15-2
15-1
15-6
15-4
15
12-3
4
1
11
6
7
16
8
18
4-2-2 18K BTU
17-1 17-2
17
1-00189A(2) 3/14/01 4:26 PM Page 18

19
■Parts List
No. CODE NO
ASS’Y-CABI FRONT
ASS’Y-BASE OUT
ASS’Y-FAN
BLOT SPECIAL
MOTOR FAN OUT
ASS’Y-MOTOR B/K
PARTITION
ASS’Y-CONDENSER
COVER-CONTROL
CABI SIDE OUT
TOP COVER
COMPRESSOR
ASS’Y-SUCTION
PACKED V/V 12.7”
ASS’Y-TUBE CAPI
PACKED V/V 6.35”
ASS’Y CONTROL OUT
SWITCH MAGNET
CAPACITOR COMP
TERMINAL BLOCK
SPARK KILLER
FUSE
CAPACITOR MOTOR
CLOTH SOUND
NUT FLANGE 6.35”
NUT FLANGE 15.88”
TUBE-DISCHARGE
SC-90073T
SC-90073T
AS+G/F20%
M8L25
ASS035ZTEE
SGCC-M
SGCC-M
ASS’Y
ABS(V5)
SC-90073T
SC-90073T
48B190JV1EH
ASS’Y
10LT/MIN, 1/2”
ASS’Y
6.35 INCH
ASS’Y
45CG20ALB
40µF x 450VAC
8P, 35A
-
2A, 250V
2.5µF x 450VAC
-
C3771BD
C3771BD
-
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description Specification Remark
Q’TY
US18A6RC
1
2
3
4
5
6
7
8
9
10
11
12
13
13-1
14
14-1
15
15-1
15-2
15-3
15-4
15-5
15-6
16
17-1
17-2
18
DB90-00260A
DB90-20210B
DB67-50074A
DB60-20020A
DB31-10119C
DB95-20147A
DB94-00080A
DB75-00058B
DB90-40176B
DB64-60160B
DB90-10616D
48B190JV1EH
DB96-00504A
DB62-40022A
DB96-00502B
DB62-40039C
DB93-00416F
DB34-90057A
2501-001238
DB65-00040A
DB95-90026B
3601-000236
2501-001370
DB72-50615A
DB60-30010A
DB60-30010D
DB96-00503A
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