SAMSUNG AP500PF0K Service Manual

ROOM AIR CONDITIONER

AP500PF

SERVICE Manual

AIR CONDITIONER

CONTENTS

1. Precautions

2. Product Specifications

3. Operating Instructions and

Installation

4. Disassembly and Reassembly

5. Troubleshooting

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.

Samsung Electronics	1-1

M E M O

1-2	Samsung Electronics

2. Product Specifications

2-1 Table

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

Samsung Electronics

2-1

2-2 Dimensions

400

Unit : mm

385

930

590

2-2	Samsung Electronics

3. Operating instructions and Installation

3-1 Operating Instructions

3-1-1 Control system chart

	Operation			Main switch operation		Operation of auto, cool and fan
				Operation of remote		Operation of turbo, auto, cool, and fan
				controller
	Function selection			Auto mode		Control of fan motor step according to current temperature
				Cool mode		Control of cool according to the difference between current
						and desired temperature
				Fan mode		Operation of indoor fan motor only
	Fan speed			Manual 3-step		High medium, low
	selector mode
				Auto		Control of fan motor step according to current temperature

Airflow selector mode

Convenience function

Self-diagnosis

function

Left-right turn

Turbo operation

Convenience reservation

“E1”

Turbo-operating compressor and powerful operating fan motor(30minutes)

Reserve function which is off after on time of 1, 2, 3, 4, or 5 hours

Displayed at the time of indoor temperature sensor open or short

LED display			Function selector		Auto, cool, fan lamp
function
			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

Samsung Electronics

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 pressing	Fan display: The fan is dis-	Time and temperature display:	Cool display: The door tempera-	Left-right turn	Function selector dis-
the button, the mode is selected in the	played in the order of turbo,	Current time, reserve time, and	ture is sensed and the button is		play: Current mode of
order of high-medium-low.	high, medium, and low.	temperature are displayed.	lighted when cooling is begun.	display.	operation display.

Sensor to perceive remote
controller: It can receive
orders from remote controller.	On/off button.

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

Up/down button: It can regulate current time and desired temperature.

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

Convenience reserve button: It can stop the operation automatically.

Reserve display: Convenience reserve operation is perceived when ordered to do so.

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

3-2	Samsung Electronics

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

Samsung Electronics

3-3

Above 100cm

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	Top view
	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	Above 50cm
	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.)	Side view
	• Avoid a place near the door which is frequented by people.
	• Avoid a place subject to direct sunlight.	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 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 building.

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

*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.

Strong wind

Wall

Roof top

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

Above 15cm			Above 50cm
	Above 50cm		Space for piping
			and wiring
	Space for piping	Above 15cm	Above 30cm
Above 15cm
	and wiring	The air outlet faces toward the wall.
The air inlet faces toward the wall.

3-4	Samsung Electronics

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 circuit.

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

•Be sure to connect the grounding wire.

Electric power spec

	Power		3phase 3wires 220V / 3phase 4wires 380V
	Ampere of breaker		50 A
	Knife switch	Switch	30 A
		Fuse	30 A
	Size of grounding wire		2.0 mm2
	Min. size of electric wires from/to		0.75 mm2
	the indoor/outdoor unit
	Size of electric input wires		5.5 / 3.5 mm2

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	198V ~ 242V
Applicable voltage 380V	342V ~ 418V

Samsung Electronics

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 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 outdoor unit respectively.

		OUTDOOR SIDE
		Power terminals on the outdoor unit
Knife switch or
		Red	White	Black
automatic circuit
	Red
breaker		White
		Black
		Green
	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.

3-6	Samsung Electronics

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 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 outdoor unit respectively.

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

Samsung Electronics

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
unit

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 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 completed.

Outdoor unit checking area

Indoor unit checking area

3-8	Samsung Electronics

Installation Method

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 processing.

Outer Diameter	A ( out / in)
ø 9.52mm	1.7 / 1.0 (mm)
ø 19.05 mm	2.2 / 1.5 (mm)

• Unproper flaring

Inclined	Surface	Cracked	Uneven
	damaged		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 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 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.

Outer Diameter	Tightening Torque	Final Torque	Remarks
ø 9.52mm	400 kg • cm	450 kg • cm
ø 19.05mm	700kg • cm	750kg • cm

Samsung Electronics

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.

ø70mm

Less than 150mm

3-2-3(d) Drain Hose

•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 outwardly.

Piping Material	Vinyl Chloride(Outer diameter ø 16mm)
Insulator	Foamed Polyethylene

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.)

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	Samsung Electronics