Samsung AW0503B User manual

SERVICE Manual
CONTENTSAIR CONDITIONER
11. Precautions
12. Product Specifications
13. Installation and Operating
Instructions
14. Disassembly and Reassembly
15. Troubleshooting
16. Exploded Views and Parts List
17. Block Diagram
18. PCB Diagram
19. Wiring Diagram
10. Schematic Diagram
DB98_04511A(2)-CO 2/18/03 4:08 PM Page 3
ROOM AIR CONDITIONER
AW0503B AW0505B
AW0603B AW0605B
AW0803B AW0805B
AW1003B AW1005B
AW1203B AW1205B
AW1403B
AW1803B AW1805B

1. Precautions
Samsung Electronics 1-1
1. Precautions
1. Warning: Prior to repair, disconnect the
power cord from the circuit breaker.
2. Use proper parts: Use only exact
replacement parts. (Also, we recommend
replacing parts rather than repairing them.)
3. Use the proper tools: Use the proper tools
and test equipment, and know how to use
equipment may cause problems later-
intermittent contact, for example.
4. Power Cord: Prior to repair, check the
power cord and replace it if necessary.
5. Avoid using an extension cord, and avoid
tapping into a power cord. This practice
may result in malfunction or fire.
6. After completing repairs and reassembly,
check the insulation resistance.
Procedure: Prior to applying power, measure
the resistance between the power cord and the
ground terminal. The resistance must be
greater than 30 megaohms.
7. Make sure that the grounds are adequate.
8. Make sure that the installation conditions
are satisfactory.
Relocate the unit if necessary.
9. Keep children away from the unit while it is
being repaired.
10. Be sure to clean the unit and its surrounding
area.
Fig. 1-1 Avoid Dangerous Contact
Fig. 1-2 No Tapping and No Extension Cords
Fig. 1-3 No Kids Nearby!
Fig. 1-4 Clean the Unit
DB98_04511A(2)-1 2/18/03 4:09 PM Page 1-1

2.Product Specifications
2-1 Table
Item Unit of
Measure AW0503B AW0505B AW0603B AW0605B
Type WINDOW
Dimension:
(Width×Height×Depth) mm 424×310×326
Voltage Volt 115
Phase - SINGLE
Frequency Hz 60
Operation Current A 4.8 4.8 5.7 5.7
Power Consumption W 530 530 630 630
Refrigerant Type FREON R22
Refrigerant Change g 310 300 300 300
Capacity BTU/h 5200 5200 6100 6100
EER BTU/h.W 9.8 9.8 9.7 9.7
Net Weight Kg 18.5 18.5 19 19
Condenser Row 2×15 2×15 2×15 2×15
Condenser Fan Type Propeller Fan
Evaporator Row 2×10 2×10 2×10 2×10
Evaporator Fan Type Blower
Fan Motor MODEL YSLA-30-6-0005 YSLA-30-6-0005 YSLA-30-6-0005 YSLA-30-6-0005
Compressor(Rotary) MODEL 2R7S126BUC 39A050HSAKA 39A062HSAKA 39A062HSAKA
Overload Protect - MRA99811-9201 KA-122-LBDN61K KA-122-LLCN00B KA-122-LLCN00B
Compressor Capacitor μF/VAC 35/270 35/270 40/270 40/270
Fan Motor Capacitor μF/VAC 3.5/270 3.5/270 3.5/27 3.5/27
Fan Speed RPM 1060/1010/960 1060/1010/960 1060/1010/960 1060/1010/960
Thermo Control - THERMISTOR
Samsung Electronics 2-1

2-1 Table(CONT.)
Item Unit of
Measure AW0803B AW0805B REMARK
Type WINDOW WINDOW
Dimension:
(Width×Height×Depth) mm 500×355×461 500×355×461
Voltage Volt 115 115
Phase - SINGLE SINGLE
Frequency Hz 60 60
Operation Current A 7.4 7.4
Power Consumption W 820 820
Refrigerant Type FREON R22 R22
Refrigerant Change g 320 320
Capacity BTU/h 8000 8000
EER BTU/h.W 9.8 9.8
Net Weight Kg 26.5 26.5
Condenser Row 2×16(L-Bending) 2×16(L-Bending)
Condenser Fan Type Propeller Fan Propeller Fan
Evaporator Row 2×11 2×11
Evaporator Fan Type Blower Blower
Fan Motor MODEL YSK40-6S-1 YSK40-6S-1
Compressor(Rotary) MODEL 44A080HUAEB 44A080HUAEB
Overload Protect - KA-122LFGN17K KA-122LFGN17K
Compressor Capacitor μF/VAC 45/370 45/370
Fan Motor Capacitor μF/VAC 8/450 8/450
Fan Speed RPM 1030/980/920 1030/980/920
Thermo Control - THERMISTOR
2-2 Samsung Electronics

2-1 Table(CONT.)
Item Unit of
Measure AW1003B AW1005B AW1203B AW1205B
Type WINDOW
Dimension:
(Width×Height×Depth) mm 560×411×548
Voltage Volt 115
Phase - SINGLE
Frequency Hz 60
Operation Current A 9.2 9.2 11.3 11.3
Power Consumption W 1040 1040 1240 1240
Refrigerant Type FREON R22
Refrigerant Change g 390 390 560 560
Capacity BTU/h 10200 10200 12400 12400
EER BTU/h.W 9.8 9.8 9.8 9.8
Net Weight Kg 37 37 38.5 38.5
Condenser Row 2×17(L-Bending) 2×17(L-Bending) 3×17(L-Bending) 3×17(L-Bending)
Condenser Fan Type Propeller Fan
Evaporator Row 2×12 2×12 2×10(φ9.52) 2×10(φ9.52)
Evaporator Fan Type Blower
Fan Motor MODEL YGN60-6B-2 YGN60-6B-2 YGN60-6B-1 YGN60-6B-1
Compressor(Rotary) MODEL 2P16S126B1G 2P16S126B1G 2P18S126B1H 2P18S126B1H
Overload Protect - MRA98695 MRA98695 MRA98896-9200 MRA98896-9200
Compressor Capacitor μF/VAC 45/370 45/370 45/370 45/370
Fan Motor Capacitor μF/VAC 15/250 15/250 15/250 15/250
Fan Speed RPM 930/890/850 930/890/850 900/850/800 900/850/800
Thermo Control - THERMISTOR
Samsung Electronics 2-3

2-1 Table(CONT.)
Item Unit of
Measure AW1403B AW1803B AW1805B
Type WINDOW
Dimension:
(Width×Height×Depth) mm 620×425×640
Voltage Volt 115 230/208
Phase - SINGLE
Frequency Hz 60
Operation Current A 12.0 8.2/8.8 8.2/8.8
Power Consumption W 1400 1850/1800 1850/1800
Refrigerant Type FREON R22
Refrigerant Change g 580 700 700
Capacity BTU/h 14000 17900/17400 17900/17400
EER BTU/h.W 10.0 9.7/9.7 9.7/9.7
Net Weight Kg 48.0 54.5 54.5
Condenser Row 2×19(L-Bending) 2×19(L-Bending) 2×19(L-Bending)
Condenser Fan Type Propeller Fan
Evaporator Row 2×11(φ9.52) 3×11(φ9.52) 3×11(φ9.52)
Evaporator Fan Type Blower
Fan Motor MODEL YGN59-6B YSK160-6A-3 YSK160-6A-3
Compressor(Rotary) MODEL 44B135HX1EL 48D180IU1EQ 48D180IU1EQ
Overload Protect - MRA98693-12007 MRA12046-12007 MRA12046-12007
Compressor Capacitor μF/VAC 50/370 35/450 35/450
Fan Motor Capacitor μF/VAC 15/450 6/450 6/450
Fan Speed RPM 900/850/800 1050/1000/960 1050/1000/960
Thermo Control - THERMISTOR
2-4 Samsung Electronics

Samsung Electronics 2-5
2-2-1 Main Unit
2-2 Dimensions
DB98-04512A(2)_1 2/19/03 10:44 AM Page 2-3
Width
Height
Height
Front view Side view Front viewFront view
(Unit : mm)
Side viewSide view
Front view
Depth
(Unit : mm)(Unit : mm)
Side view
(Unit : mm)
Model Name Width Height Depth
AW0503B AW0505B 424 310 326
AW0603B AW0605B
AW0803B 500 355 461
AW0805B
AW1003B AW1005B 560 411 548
AW1203B AW1205B
AW1403B 620 425 640
AW1803B AW1805B
Timer setting button
Temperature
adjustment buttons
Fan speed
adjustment buttons
On/Off button
Sleep timer setting
button
Mode selection
buttons
Energy Saver button
2-2-2 Remote Control

Samsung Electronics 3-1
3. Installation and Operating Instructions
3-1 Installation
3-1-1 Selecting Area for Installation
1. Make sure that you install the unit in an area
providing good ventilation. The air conditioner
must not be blocked by any obstacle affecting the
air flow near the air inlet and air outlet.
2. Make sure that you install the unit in an area that
allow good air handling. The installation area
must be able to endure vibration from the unit.
3. Make sure that you install the unit away from
heat or vapor.
4. Make sure that you install the unit in an area
which is cool and has adequate space.
5. Make sure that you install the unit in an area
away from TVs, audio units, cordless phones,
fluorescent lighting fixtures and other electrical
appliances (obtain a clearance of at least one
meter).
6. Make sure that you install the unit in an area
which provides easy drainage for condensed
water.
7. Make sure that you install the unit in an area not
exposed to rain or direct sunlight.
(Install a separate sunblind if exposed to direct
sunlight.)
8. Make sure that you install the unit in an area
allowing good air movement. Do not install it in
a space that would cause noise amplification of
noise.
9. Fix the unit firmly if mounted in a high place.
Caution:
Do not use the air conditioner in the following environments : greasy areas (including areas near
machines), or marine areas. Contact your local dealer for advice.
DB98_04511A(2)-1 2/18/03 4:09 PM Page 3-1

3-2 Function Description
3-2-1 Cooling operation mode
The compressor is turned on and off according to the ambient temperature and set temperature.
1) Compressor on and off control
• Compressor on and off control according to the ambient temperature
*The compressor is turned off when "ambient temperature = set temperature
*The compressor is turned on when "ambient temperature = set temperature +1˚C"
2) Default value after power reset ➔set temperature = 24˚C
Fan speed = High
3) Set temperature indicating (setting) range : 1˚C interval from 18˚C to 30˚C.
3-2-2 Fan operation mode
1) If "Fan operation mode" signal is received from remocon or panel.
➔ the compressor is immediately turned off and only fan motor is operated at set blowing speed.
➔ it changes such as "High ➔Med ➔Low ➔ High"( if Fan speed is selected).
2) The initial Fan motor speed is set to "High".
3) The set temperature can not be indicated and set.
3-2-3 Energy saver operation mode
*If the compressor turn off at the cooling operation, the fan motor turn off after operation during the fixation
time only, and operation that energy saver by turn off the fixation time only, and operation that energy saver
by turn off the motor continuously before the condition of the compressor on.
*The fan motor is not operated at flow wind operation.
*Energy saver operation specification at the cooling operation.
1) Fan motor control in compressor on : operate with setting wind speed
2) Fan motor control in compressor off : After compressor off, the fan motor is operated breeze for 2 minutes
and then it turn off.
3) After the fan motor off, the compressor and fan motor is operated normally when the compressor on.
3-2 Samsung Electronics
DB98_04511A(2)-1 2/18/03 4:09 PM Page 3-2
Temperature/Timer
settings
Temperature adjustment
buttons
On/Off button
Mode selection button
(Cool,Fan, Dry)
Sleep timer setting button
Timer setting button
Fan speed adjustment button Remote control
Energy Saver button
Fan Speed
Mode
Cool/Dry/Fan
E.Saver
Sleep
Timer
Temp.
Power

Samsung Electronics 3-3
3-2-4 Sleep operation mode
1) Enable to sleep operation only when cooling operation.
2) First, 7-SEG LED DISPLAY"SLEEP" while 15 second, Second, 7-SEG LED DISPLAY"8Hr"
And, automatically SET OFF after operated while 8 Hour
3) If sleep operation, setting Temperature rise 1˚C after 1 Hour
4) ON TIMER operation, not operation, ENERGY SAVER operation, not sleep operation.
3-2-5 Dry operation mode
Same as Cool operation mode.
3-2-6 LED display indication in case of error detection
ERROR OPERATION
ROOM THERMISTOR
(OPEN or SHORT)
7-SEG
LED DISPLAY
E1 displayed
1) Set operation in case of error occurrence.
• Malfunction of each temperature sensor (open, short)
- Error mode display, warning sound.
- The operation status is off.
Installation and Operating Instructions
DB98_04511A(2)-1 2/18/03 4:09 PM Page 1

MEMO
3-4 Samsung Electronics
DB98_04511A(2)-1 2/18/03 4:09 PM Page 2

Samsung Electronics 4-1
4. Disassembly and Reassembly
4-1 Compressor Replacement Flow Chart
Locate cause of defect
Release refrigerant
Disconnect electrical wiring
from compressor
Cut refrigerant lines
from compressor
Plug disconnected lines
Replace compressor
Inspect electrical
wiring for defects,
and terminals for
correct and secure
connections
Solder discharge line
Corrective action
Check refrigerant oil level
Add oil as necessary
Solder suction line Use nitrogen gas
Perform soldering function
Fill system with
nitrogen gas
Check for leakage
Pinch and braze filling tube
Recharge system
Evacuate system
Release nitrogen gas?
Low oil level? N
Y
Y
N
N
Y
Leakage?
Problem?
DB98_04511A(2)-1 2/18/03 4:09 PM Page 3

4-2 Samsung Electronics
4-2 Checking the oil
4-2-1 Oil quality
4-2-2 Replacing and refilling the refrigerant oil
1. Change the compressor - DO NOT recharge the oil as the compressor itself is
already charged.
2. Change the condenser .... add 50cc
3. Change the evaporator .... add 50cc
4. When the refrigerant is replaced .... add 30cc oil.
5. After vacuum is completed, the oil is filled through the high pressure side.
6. In the event of a refrigerant leak, generally it is not necessary to add oil.
(Unless the oil has leaked significantly.)
Fill the transparent container with 10cc of oil, and then conduct the test.
Condition of
Refrigerant Cycle
Normal
Over-heated
Compressor Damage
Color
Straw Yellow
Brown Color
Dark Brown
Odor
No Odor
-
Pungent oil
Remarks
Return with the system
Change the oil
Change the oil
Oil Condition
DB98_04511A(2)-1 2/18/03 4:09 PM Page 4

4-3.Disassembly and Reassembly Procedure(AW0503B/AW0505B/AW0603B/AW0605B)
Stop operating the air conditioner, and pull out the power cord before repair.
No. Part Name Procedures Remarks
1 Ass’y Grille
1.Pull the Grille air inlet and Guard air filter out.
(Pull both sides of Grille air inlet forward
carefully, then take out the filter.)
2.Remove the screw fixed on the panel front.
3.Hold the lower part of panel with two hands
while pressing down on both sides of the lower
part of the cabinet, pull it forward by about
30mm,and then lift it up carefully for removal.
2 Ass’y Cabinet
1.Remove all screws on the both side of the
cabinet .
2.Take the cabinet upward.
3 Ass’y Control
1.Remove the earth screw fixed on the base.
2.Remove 3 screws fixed on the partition.
3.Remove the screw fixed for the power cord.
4.Un-connect the motor wire and comp lead
wire, then take out the control box upward.
(The picture maybe have a little
different from actual product)
Samsung Electronics 4-3

Disassembly and Reassembly Procedure(AW0503B/AW0505B/AW0603B/AW0605B)
No. Part Name Procedures Remarks
4 CASE EVAP
UP & ASSY
EVAP
1.Take the case evap up forward carefully.
(tear all the seal on it before )
2.Pull the frame up upward.
5 Blower
1.Remove all screws on the evaporator.
2.Pull the evaporator from frame low carefully.
3.Remove the nut and remove the Blower.
6 Case Cond &
Fan Propeller
& Motor Fan
1.Remove 2 screws on the rear side of the
base pan, and all screws fixed on case cond.
2.Pull up the condenser from the base pan.
3.Remove the nut and remove the Propeller
fan.
4.Remove the screw fixed on the partition and
earth screw fixed on the base pan, then take
out the motor backward.
4-4 Samsung Electronics

Disassembly and Reassembly Procedure(AW0803B/AW0805B)
Stop operating the air conditioner, and pull out the power cord before repair.
No. Part Name Procedures Remarks
1 Ass’y Grille
1.Pull the Grille air inlet and Guard air filter out.
(Pull both sides of Grille air inlet forward
carefully, then take out the filter.)
2.Remove the screw fixed on the panel front.
3.Hold the lower part of panel with two hands
while pressing down on both sides of the lower
part of the cabinet, pull it forward by about
30mm,and then lift it up carefully for removal.
2 Ass’y Cabinet
1. Remove the screws on both sides of the
cabinet to disconnect the cabinet and frame.
2. Pull the handle on the front side of the
bottom, and remove the unit from the cabinet.
3 Ass’y Control
1.Remove the earth screw fixed on the plate
evaporator
2.Remove 3 screws fixed on the partition and
plate evaporator casing.
3.Remove the screw fixed for the power cord.
4.Un-connect the motor wire and comp lead
wire, then take out the control box upward.
(The picture maybe have a little
different from actual product)
Samsung Electronics 4-5

Disassembly and Reassembly Procedure(AW0803B/AW0805B)
No. Part Name Procedures Remarks
4 CASE EVAP
UP & ASSY
EVAP
1.Take the case evap up forward carefully.
2.Remove 4 screws fixed on the plate
evaporator casing and evaporator.
5 Blower
1.Lift up the evaporator carefully.
2.Remove 2 screws on the plate evaporator
casing and partition.
3. Lift up the plate evaporator casing.
4.Remove the nut and remove the Blower.
6 Case Cond &
Fan Propeller
& Motor Fan
1.Remove 2 screws on the base pan, and all
screws fixed on case cond.
2.Pull up the condenser from the base pan.
3.Remove the nut and remove the Propeller
fan.
4.Remove the screw fixed on the partition and
earth screw fixed on the base pan, then take
out the motor backward.
4-6 Samsung Electronics

Disassembly and Reassembly Procedure(AW1003B/AW1005B/AW1203B/AW1205B/AW1403B/AW1803B/AW1805B)
Stop operating the air conditioner, and pull out the power cord before repair.
No. Part Name Procedures Remarks
1 Ass’y Grille
1.Pull the Grille air inlet and Guard air filter out.
(Pull both sides of Grille air inlet forward
carefully, then take out the filter.)
2.Remove the screw fixed on the panel front.
3.Hold the lower part of panel with two hands
while pressing down on both sides of the lower
part of the cabinet, pull it forward by about
30mm,and then lift it up carefully for removal.
2 Ass’y Cabinet
1. Remove the screws on both sides of the
cabinet to disconnect the cabinet and frame.
2. Pull the handle on the front side of the
bottom, and remove the unit from the cabinet.
3 Ass’y Control
1.Remove the earth screw fixed on the plate
evaporator
2.Remove all screws fixed on the partition and
plate evaporator casing.
3.Remove the screw fixed for the power cord.
4.Un-connect the motor wire and comp lead
wire, then take out the control box upward.
(The picture maybe have a little
different from actual product)
Samsung Electronics 4-7

Disassembly and Reassembly Procedure(AW1003B/AW1005B/AW1203B/AW1205B/AW1403B/AW1803B/AW1805B)
No. Part Name Procedures Remarks
4 CASE EVAP
UP & ASSY
EVAP
1.Take the case evap up forward carefully.
2.Remove 4 screws fixed on the plate
evaporator casing and evaporator.
5 Blower
1.Lift up the evaporator carefully.
2.Remove 2 screws on the plate evaporator
casing and partition.
3. Lift up the plate evaporator casing.
4.Remove the nut and remove the Blower.
6 Case Cond &
Fan Propeller
& Motor Fan&
Mount motor
1.Remove 2 screws on the base pan, and all
screws fixed on case cond.
2.Pull up the condenser from the base pan.
3.Remove the nut and remove the Propeller
fan.
4.Remove 4 screws fixed on the plate reinf,
then take out the case cond.
5.Remove 4 screws fixed on the mount motor
then take out the motor backward.
6.Remove 4 screws fixed on the base and
partition then remove the mount motor.
4-8 Samsung Electronics

Samsung Electronics 5-1
5. Troubleshooting
5-1 Basic Checkpoints for Troubleshooting
Check the basic checkpoints first to determine whether it is machine trouble or a problem
in the operation method. When it is not related to the basic checkpoints, perform checking
in accordance with the procedures of troubleshooting by symptom.
1) Is the voltage of the power source appropriate ?
(1) It should be within the rating voltage ±10% range.
(2) The air conditioner may not operate properly when the voltage is out of this range.
2) Is the connection with the fan motor, compressor wire, and starting condenser
appropriately made ?
3) The symptoms listed in the table below are not indicative of machine trouble.
Symptom Cause and check
No operation • Check whether there is power failure or the power plug is pulled out.
• Check whether the unit is stopped as a result of completion
of the sleep time.
• Pull out the power plug for ten seconds, and then insert it again.
Air flows, but • Check whether the Air filter is clogged with dust or is dirty.
no cooling • Check whether the desired temperature is too high. Set the desired
temperature to a lower level than the current temperature.
• Check whether it is in "FAN" mode.
The remocon does • Check whether battery is completely depleted.
not operate • Check whether the battery is properly inserted.
• Check whether the receiving window of the remocon for the assembly
main PCB is blinded.
• Check whether the remocon is affected by jamming due to a neon sign.
No temperature • Check whether the unit is in "FAN" mode.
setting (In "FAN" mode, only the current temperature is displayed, and the
desired temperature is not set.)
❈Checking and Display of Fault Area
ERROR OPERATION
ROOM THERMISTOR (OPEN OR SHORT)
ERROR OPERATION
E1 displayed
DB98_04511A(2)-2 2/18/03 4:12 PM Page 5-1