SAMSUNG AP500PF0K Service Manual

ROOM AIR CONDITIONER

A P 5 0 0 P F

SERVICE

Manual

CONTENTSAIR CONDITIONER

1. Pre c a u t i o n s

2. Product Specifications

3. Operating Instructions and

I n s t a l l a t i o n

4. Disassembly and Reassembly

5. Tro u b l e s h o o t i n g

6. Exploded Views and Parts List

7. Block Diagrams

8. PCB Diagrams

9. Wiring Diagrams

10. Schematic Diagrams

© Samsung Electronics Co., Ltd. APR. 1998.

Printed in Korea.
Code No. DB81-10133A(1)

1. Precautions

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 repair­ing 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 equip­ment 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 30MΩ by 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.

Turn off the sub power switch separately installed.

No connection with the power receptacle

Cleaning

Upon completion of the repair, clean the air
conditioner and surrounding area, and
inform the customer of completion of the repair.

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1-1

M E M O

1-2

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2. Product Specifications

2-1 Table

ITEM

Size

Weight

Electric

characteristics

Indoor unit

Outdoor unit

Indoor unit

Outdoor unit

Piping

Indoor unit

Outdoor unit

Piping

1. Cooling capacity

2. Power consumption(Cooling)

3. Current consuption(Cooling)

4. E.E.R

5. Noise

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

Unit
Packed
Unit
Packed
Packed
Unit
Packed
Unit
Packed
Packed

Indoor unit

(Cooling/

Heating)

Outdoor unit

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

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

Model

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

AP500PF

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

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2-1

2-2 Dimensions

400

Unit : mm

385

2-2

930

590

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3. Operating instructions and Installation

3-1 Operating Instructions

3-1-1 Control system chart

Operation Main switch operation

Operation of remote

controller

Function selection Auto mode

Cool mode

Fan mode

Fan speed

selector mode

Airflow selector

mode

Convenience function

Manual 3-step

Auto

Left-right turn

Turbo operation

Operation of auto, cool and fan

Operation of turbo, auto, cool, and fan

C o n t rol of fan motor step according to current temperature
C o n t rol of cool according to the diff e rence between curre n t

and desired temperature

Operation of indoor fan motor only

High medium, low

C o n t rol of fan motor step according to current temperature

Turbo-operating compressor and powerful operating fan
m o t o r ( 3 0 m i n u t e s )

Self-diagnosis

function

LED display

function

Convenience reservation

“E1”

Function selector
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

R e s e rve function which is off after on time of 1, 2, 3, 4, or 5

h o u r s

Displayed at the time of indoor temperature sensor open
or short

Auto, cool, fan lamp

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3-1

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

Button for speed selection: When pre s s i n g
the button, the mode is selected in the
o rder of high-medium-low.

Display change button: When the button is pressed, cur­rent time and temperature are displayed continuously.

3-2

Fan display: The fan is dis­played in the order of turbo,
high, medium, and low.

Time and temperature display:
C u rrent time, re s e rve time, and
t e m p e r a t u re are displayed.

Up/down button: It can regulate curre n t

time and desired temperature .

Cool display: The door tempera­t u re is sensed and the button is
lighted when cooling is begun.

Function selector button: when pressing the button, the mode
can be selected repeatedly in the order of auto-cool-fan.

Left-right turn
d i s p l a y.

Function selector dis­play: Current mode of
operation display.

Sensor to perceive re m o t e
c o n t roller: It can re c e i v e
o rders from remote contro l l e r. O n / o ff button.

Convenience re s e rv e
button: It can stop the
operation automatically.

R e s e rve display:
Convenience re s e rv e

operation is perc e i v e d

when ord e red to do so.

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Operation display lamp:
When the power is first
applied, the lamp will
blink, but will turn on
when operation begins.

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

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3-3

3-2 Installation

3-2-1 Selection of Installation Place

3-2-1(a) Indoor Unit

• Install the unit at a place close to the wall facing the outside
as it is necessary to perform piping connection with the out-

Top view

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.

Above 50cm

• 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.

Side view

Above 20cm

3-2-1(b) Outdoor Unit

• 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 re q u i res special
m a i n t e n a n c e . )

• A place where the discharge air and noise of the outdoor unit do not disturb the neighborh o o d .
(Take special care not to cause any inconvenience to your neighbors when installing the unit on

the borderline with your neighborh o o d . )

• 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 build­ing.
The outdoor unit may fall down, causing severe personal or property damage or loss.

Above 100cm

* 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 ro a d .

Wall

2. Install the unit so that the air outlet faces toward the wall
at a place such as rooftop, which may be subjected to
s t rong wind.

* The outdoor unit should be installed in accordance with the service space.

Above 15cm

Above 50cm

Above 15cm

Space for piping

and wiring

The air inlet faces toward the wall.

Above 15cm

The air outlet faces toward the wall.

3-4

Strong wind

Roof top

Above 50cm

Space for piping

and wiring

Above 30cm

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Installation Method

3-2-2 Electrical Work

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 circ u i t .

• Be sure to install circuit breaker (separately purchased by the user).

• Be sure to connect the grounding wire .

Electric power spec

Power
Ampere of breaker
Knife switch

Switch
Fuse

Size of grounding wire
Min. size of electric wires from/to

the indoor/outdoor unit
Size of electric input wires

3phase 3wires 220V / 3phase 4wires 380V

50 A
30A
30 A

2

2.0 mm

0.75 mm

5.5 / 3.5 mm

2

2

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

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3-5

Installation Method

3-2-2(a) When connecting 3Phase 4wires 380V AC

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 re s p e c t i v e l y.
(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 re s p e c t i v e l y.

OUTDOOR SIDE

Power terminals on the outdoor unit

Knife switch or

automatic circuit

breaker

Red

White

Black

Green

Electric input wires

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.

Red

White

Black

Indoor / outdoor unit

connecting wire

3-6

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Installation Method

3-2-2(b) When connecting 3Phase 3wires 220V AC

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
re s p e c t i v e l y.

(Input wires are purchased by the user separately. )

3. Connect electric wires (red, white, black) to each terminal (red, white, black) on indoor and out­door unit re s p e c t i v e l y.

OUTDOOR SIDE

Power terminals on the outdoor unit

Knife switch or

automatic circuit

breaker

Red

White

Black

Red

White

Black

Electric input wires

Indoor / outdoor unit

connecting wire

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3-7

Installation Method

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.

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).

Outdoor

unit

Indoor

unit

Indoor

Outdoor

unit

3. Install the high pre s s u re pipe to the heat exchanger liquid pipe, and the low pre s s u re pipe to the
heat exchanger gas pipe respectively using the flare nut, taking care not to cause any leakage of
re f r i g e r a n t .

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 pre­vent 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 com­p l e t e d .

Outdoor unit

checking area

Indoor unit
checking area

unit

3-8

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3-2-3(b) Connection of Refrigerant Piping

Flare Processing

1. Cut the pipe using the pipe cutter.

Oblique Roughness Burr

2. Insert the flare nut into the pipe, and then perform the flare pro c e s s i n g .

Installation Method

Outer Diameter

ø 9.52mm

ø 19.05 mm

A ( out / in)

1.7 / 1.0 (mm)

2.2 / 1.5 (mm)

• Unproper flaring

Inclined Surface

damaged

Cracked Uneven

thickness

Pipe Bending

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 diff i c u l t .

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 distor­tion, and secure a minimum bending radius of more than 100mm.

Spring

Tightening of Connection Parts

• 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 .

ø 9.52mm

ø 19.05mm

Tightening Torque

400 kg • cm
700kg • cm

Final Torque
450 kg • cm
750kg • cm

RemarksOuter Diameter

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3-9

Installation Method

3-2-3(c) Drilling a Hole in the Wall

• 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.

3-2-3(d) Drain Hose

Less than

ø70mm

150mm

• Extend the drain hose to the drain hose connect­ed 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 out­w a rd l y.

Drain pan

Band

Drain hose

Insulation

Indoor and
outdoor
connection

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.)

Piping Material
Insulator

Vinyl Chloride(Outer diameter ø 16mm)
Foamed Polyethylene

3-2-3(e) Rat-prevention Cover

• 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)

3-10

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