SAMSUNG APH450PG0K Service Manual

PACKAGED AIR CONDITIONER

A P H 4 5 0 P G

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

Printed in Korea. Code No. DB81-10147A(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

Model APH450PG

ITEM Indoor unit Outdoor unit

Power source Capacity (Cooling/Heating) Aux. heater Power consumption E.E.R (Cooling/Heating) Running current (C/H) Noise level (C/H) Moisture removal Air circulation Dimension Width (Net/Packed) Height

Depth Weight(Net/Packed) Piping box Refrigerant type Refrigerant quantity

ø/V/Hz

kcal/h BTU/h

Watt/h

kcal/Wh

dBA

l/hr

m3/h

mm mm mm

3 / 380 / 50

11,250 / 12,200

45,000 / 48,800

3,000

5,000 / 4,700

2.25 / 2.60 9 / 8.7

53 / 54 63

5.8

1,920 4,800

590 / 704 930 / 1,200

1,810 / 1,925 1,240 / 1,370

420 / 600 385 / 540

75 / 85 123 / 133

R-22

4.8 Compressor type Protective device

Refrigerant piping size Drain piping size Loading Q’ty (20’/40’)

Note: (1) The data are measured at the following conditions.

Indoor air temperature DB

Outdoor air temperature DB

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Reciprocating

Internal thermostat (CM)

High pressure switch

inch

set

Cooling Heating

27.0˚C(80.6˚F) 20.0˚C(68.0˚F)

19.0˚C(66.2˚F) 12.0˚C(53.6˚F)

35.0˚C(95.0˚F) 7.0˚C(44.6˚F)

24.0˚C(75.2˚F) 6.0˚C(42.8˚F)

Gas : 3/4”, Liquid : 3/8”

I.D 18 I.D 16

12 / 24

APH450PG

2-1

2-2 Dimensions

420

Unit : mm

385

2-2

930

590

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3. Operating instructions and Installation

3-1 Operating Instructions

Operation Main switch operation

Operation of remote

controller

Function selection Auto cool mode

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

Cool mode

Heat mode

Fan mode

Fan speed

selector mode

Airflow selector

mode

Manual 3-step

Auto

Left-right turn

Operation of auto cool, auto heat, cool, heat, fan Operation of turbo, cool, heat, 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

Convenience function

LED display

function

Turbo operation

Convenience reservation

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

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

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

Auto cool, auto heat, cool, heat, turbo, fan lamp

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3-1

3-2 Key type and functions

3-2-1 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.

Brief reservation The hours of 1,2,3,4 and 5 is selected whenever one time of on is performed. TACT

Heater on/off selection If the switch is selected to the on direction, the heater is operating at the heater SLIDE

operation condition. The heater is not operating when the switch is selected to the off position.

* Operating functions

Fan Speed

adjustment

Time/Temperature Selection

3-2

Fan Speed display

Time/Temperature display

Time or Temperature adjustment

Operating Light

Operating

Mode Selection

Remote control Sensor

Timer adjustment

On/Off Button

Power Light

Auxiliary Heater Switch (option)

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3-3 Accessory Parts List

3-3-1 Connection Parts 3-3-2 Others

No.

Connecting pipe

Heater cable (3 strand)

Protection tube

Connecting wire (7 strand)

Wire of sensor (2 strand)

Power cable

Drain hose

Finishing tape

Part Name Q’ty Remarks

3/8”

(ø9.52mm)

3/4”

(ø19.05mm)

Option

(Piping box)

Piping box

No.

Leg holder for indoor unit

Screw

Cable clamp

Indoor unit fixing holder

4 1

Leg holder for outdoor unit

Insulation rubber bottom

Cable tie

Putty

Pipe band

Rubber cabi slot

Part Name Q’ty Remarks

TH M4 X 12 TH M4 X 25

12N

8N 6N

Piping box

4 4

Option(Piping box) 3 1

Piping box

Insulation tape

Insulation tube for indoor unit piping connection

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Rubber cabi hole

Drain plug out

12 1

3-3

3-4 Installation

3-4-1 Selection of Installation Place

3-4-1(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

3-4-1(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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Operating instructions and Installation

3-4-2 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

3phase 4wires 380V

50 A 25A 25 A

2.5 mm

0.75 mm

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 380V

342V ~ 418V

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.

3 . Connect electric wires to each terminal on indoor and outdoor unit re s p e c t i v e l y.

OUTDOOR SIDE

1:Thin Brown 2:Sky 3:Brown 4:Black 5:Thin sky 6:Dark Black

Wire of sensor

Indoor/outdoor unit connecting wire

Inoor

unit

Heater cable

Power cable

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.

* Must be use the approval wire according to IEC or EN requirement.

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Knife switch or automatic circuit breaker

3-5

Operating instructions and Installation

3-4-3 Installation Method

3-4-3(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

3-6

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Operating instructions and Installation

3-4-3(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 .

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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3-7

Operating instructions and Installation

3-4-3(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.

3-4-3(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

Piping Material Insulator

it so that water can not flow outward 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.)

• In heating and deice operation, condensed water may be generated. Install drain line as following procedure.

Hole

1. Insert the drain plug into base hole.

2. And then connect drain hose to drin plug.

Vinyl Chloride(Outer diameter ø 16mm) Foamed Polyethylene

Base

Drain plug

3-4-3(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)

3-8

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Drain hose

Operating instructions and Installation

3-4-3(f) Indoor Unit

In order to install drain hose through wall, adjust height (max. 150mm) of the indoor unit using leg holder.

Fixing to the floor

• When using the leg holder of the indoor unit.

1. Lie down the unit on flat floor. 2 . Insert the leg holders into screwed holes and then

fasten them clockwise.

3 . Turn the unit right and adjust horizontal line of it.

* Mis-alignment of the unit can cause vibration and

Leg holder of the indoor unit

n o i s e .

Fixing to the wall

• When using fixing holder of the indoor unit. 1 . Fix the holder using long screw bolts on wall. 2 . Fix the unit using two screw bolts or four anchor

bolts. (Size of the screw hole on the holder is ø4.5mm

and size of the bolt is ø6mm.)

3-4-3(g) Outdoor Unit

When using the anchor bolt

1 . Fix the unit on a flat, rigid floor using the anchor bolt.

(Anchor bolt : M10 x 4 points - separately purc h a s e d )

When using the leg holder of the outdoor unit

1 . Insert the foot holder (4EA). 2 . Remove the nut fastened to the leg holder,

and then insert the leg holder into the hole of the outdoor unit leg.

3 . Fix the unit securely with the nut.

Fixing holder of the indoor unit

Anchor bolt fixing dimensions

Unit:mm A 840 B 415

Nut

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Outdoor unit leg

Leg holder

Foot holder

3-9

Operating instructions and Installation

3-4-3(h) Air Purge

• Be sure to perform the air purge of the indoor unit, and piping using the refrigerant of the outdoor unit at the time of installation.

Open the cap of the valve(B), and valve(A).

Open the valve cock of the valve(B) by

approximately 45°. After an elapse of 10 seconds, close the valve cork.

Check the connection piping for leakage.

Not

Leaking

Ieaking

• Close the nut for the connection piping again.

Proceed to h when there is no leakage.

• If it is necessary to perform repair due to continuous leakage of gas, discharge the refrigerant gas, and repair the leaking area.

Then revacuum and refill the refrigerant.

OUTDOOR UNIT

Gas side

Liquid side

Flare nut

Valve cock

Cap

Needle valve cap

* Open the needle cap of the valve(A), and press

the needle valve for 3 seconds to drain the gas out. Repeat this procedure three times.

Open the valve cock of valve(B) and

valve(A) completely.a

Close the cap of each valve.

Check the valve for leakage.

Indoor unit

Liquid side Gas side

3-Way valve

Outdoor unit

3-Way valve

3-10

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3-4-3(i) Refrigerant Charging

Air purge(at the time of new installation only)

Close the gas pipe side valve by turning it clockwise. Connect the pressure gauge to the low pressure side service valve, and then open the gas pipe side valve again.

Connect it to the refrigerant filling tank.

(Turn the tank upside down : Fill the refrigerant

in liquid form.)

Operating instructions and Installation

Start cooling operation.

Check the pressure of the pressure gauge. Check whether the low pressure side is within the range of 4.5~5.5kg/cm2G

(outside temperature 35°C).

Open the tank and refill the refrigerant until arriving at the proper pressure.

(Refill the refrigent slowly checking the pressure.)

Stop operation.

Close the gas pipe side valve, and loosen the pressure gauge connected. Then open the gas pipe side valve again.

OUTDOOR UNIT

Gas pipe side

Liquid pipe side

Tighten the cap of each valve using a specified tool.

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