SAMSUNG AQ09A1VE Service Manual

ROOM AIR CONDITIONER

INDOOR UNIT AQ07A1VE AQ09A1VE/B AQ12A1VE/B

SERVICE

OUTDOOR UNIT UQ07A1VE UQ09A1VE/B UQ12A1VE/B

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. DB81-10197A(1)

1. Precautions

1 . Warning: Prior to re p a i r, disconnect the

power cord from the circuit bre a k e r.

2 . Use proper parts: Use only exact re p l a c e-

ment parts. (Also, we recommend re p l a c i n g parts rather than repairing them.)

3 . Use the proper tools: Use the proper tools

and test equipment, and know how to use them. Using defective tools or test equipment may cause problems later- i n t e r m i t t e n t contact, for example.

4 . Power Cord: Prior to re p a i r, 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 re a s s e m b l y,

check the insulation resistance. Pro c e d u re : Prior to applying power, measure the re s i stance between the power cord and the g round terminal. The resistance must be g reater than 30 megohms.

Fig. 1-1 Avoid Dangerous Contact

Fig. 1-2 No Tapping and No Extension Cords

7 . Make sure that the grounds are adequate.

8 . Make sure that the installation conditions

a re satisfactory. Relocate the unit if necess a r y.

9 . Keep children away from the unit while it is

being re p a i re d .

1 0 . Be sure to clean the unit and its surro u n d-

ing are a .

Fig. 1-3 No Kids Nearby!

Fig. 1-4 Clean the Unit

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1-1

M E M O

1-2

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2-2 Dimensions

2-2-1 Indoor Unit

Air out

(Front view) (Remote control)

Air in

2-2-1 Outdoor Unit

(Rear view)

(Front view)

Installation plate

600

(Rear view)

2-2

720 145 55 765

245

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2-3 Refrigerating Cycle Block Diagram

INDOOR UNIT

Heat exchanger (Evaporator)

OUTDOOR UNIT

Capillary tube

Liquid side

Gas side

2-way valve

3-way valve

Check valve

Capillary tube

Compressor

Heat exchanger (Condenser)

4-way valve

Cooling Heating Gas leak check point

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M E M O

2-4

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3. Operating Instructions and Installation

3-1 Operating Instructions

3-1-1 Name & Function of Key in remote controller

NAMED OF KEY 1 2

MODE

4 5

TURBO

OFF

(UP)

(DOWN)

On/Off Button. Use this button to start and stop air conditioner. Temp. up button. If the button is pressed once,

the setting temperature is increased by 1°C Temp. up button. If the button is pressed once,

the setting temperature is decreased by 1°C

Each time you press this button,

MODE is changed in the following order.

Use this button to provide heavy duty cooling & Heating for 30 minutes. Set up the reserve or cancel the timer on and timer off quickly

Use this button for sleep operation. (The SLEEP mode can be selected at COOL and HEAT mode.)

Adjusts air flow vertically.

Each time you press this button, FAN SPEED is changed in the following order.

FUNCTION OF KEY

: Auto Mode : Fan Only : Cool Mode : Heat Mode : Dry Mode

C O

V E R

11 12 13

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E R

ON TIMER OFF TIMER

SET CANCEL

TIME

(UP)

(DOWN)

Set up the time that operation start. Set up the time that operation stop.

Use this button to reserve the timer on. Use this button to reserve or cancel the timer on and timer off.

If the button is pressed once, the time increase by one minute during the time set mode, and ten minutes during the timer set mode.

If the button is pressed once, the time decrease by one minute during the time set mode, and ten minutes during the timer set mode.

Without regard to ON/OFF condition in remote controller, use this button to set current time. Adjust the current time using button. (Data can be transmitted after setting up the time)

3-1

Operating Instructions and Installation

3-1-1 Name & Function of Key in remote controller

1. A U TO MODE : In this mode, operation mode(COOL, HEAT, DRY) is selected automatically by the room temperature of initial o p e r a t i o n .

Room Temp Tr≥ 21°C+∆T 21°C +∆T>Tr

∆T= -1°, -2°C, 0°C+1°C+2°C ∆T is controlled by setting temperature

up/down key of remote contro l l e r

2. C O O L MODE : The unit operates accord i n g to the diff e rence between the setting and room temperature. (18°C~30°C)

3. H E AT MODE : The unit operates accord i n g to the diff e rence between the setting and room temperature.(16°C~30°C) * P revention against cold wind : For about 3~5 minutes after initial operation, thermo c o n t rol or “de-ice”, the indoor fan will either not operate or operate very slowly(510 rpm), then switch to the selected fan speed. This period is to allow the indoor unit's heat-exchanger to prewarm before emitting warm air. *High temperature release function : The outdoor unit for and compressor ON/OFF c o n t rol for safety operation, when the overheat is heat exchanger of indoor unit. *De-ice : Deicing operation is controlled by indoor unit's heat exchanger temperature and accumulating time of compre s s o r ' s o p e r a t i o n . De-ice end by sensing of the pro c e s s i n g time by de-ice Condition.

Cool Operation (Set Temp:AUTO SETTING)

Heat Operation (Set Temp : 22°C+∆T)

Operation Type

4. D RY MODE : Has 3 states, each determined by room temperature . The unit operates in DRY m o d e . *Co m p ressor ON/OFF Time is contro l l e d compulsorily(can not set up the fan speed, always bre e z e ) . * P rotective function : Low temperature release. (Prevention against fre e z e )

5. TURBO MODE : This mode is available in A U TO, COOL, HEAT, DRY, FAN MODE. When this button is pressed at first, the air conditioner is operated “powerful” state for 30 minutes re g a rdless of the set temperat u re, room temperature . When this button is pressed again, or when the operating time is 30 minutes, turbo operation mode is canceled and returned to the previous mode. *But, if you press the TURBO button in DRY or FAN mode that is changed with A U TO mode automatically.

6 . S L E E P MODE : Sleep mode is available

only in COOL or HEAT mode. The operation will stop after 6 hours. *In COOL mode : The setting temperature is automatically raised by 1°C each 1hour When the temperature has been raised by total of 2°C, that temperature is maint a i n e d . *In HEAT mode : The setting temperature is automatically droped by 1°C each 1hour. When the temperature has been droped by total of 2°C, that temperature is maint a i n e d .

7. FAN SPEED : Manual (3 step), Auto (4 step) Fan speed automatically varies depending on both the diff e rence between setting and the room temperature .

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Operating Instructions and Installation

8 . C O M P U L S O RY O P E R ATION :

For operating the air conditioner without the remote contro l l e r. * A U TO : The operating is the same function that A U TO MODE in the remote cont ro l l e r.

9 . SWING : BLADE-H is rotated vertically by

the stepping motor. *Memory louver : When ON/OFF button is p ressed at stop state, the BLADE-H re t u r n s to its original location which is operating state before stop *Swing Set : Press the button under the remote control is displayed on LCD the , and the blades move up and down, about 43°. If the one more time press the button, blatles location is stop.

1 0 . Quick OFF TIMER: OFF timer (quick timer)

allows reservation or cancel the timer on and timer off quickly When OFF timer button is pressed at operating state, LCD displays the polling state s e q u e n t i a l l y. The LCD also displays the time re m a i n i n g .

OFF TIMER : The air Conditioner is turned OFF at a specified time using .

OFF TIMER

*ON TIMER : Only timer LED lights on. *OFF TIMER : Both timer and operation LED lights on. *3 minutes delay timer.

1 2 . SELF Diagnosis

LED DISPLAY

o p e r-

T I M E R

a t i o n

FA N

Tu r b o

Check Point

I n t e r ruption of electric power and Power on. Abnormal condition of the room sensor. Abnormal condition of the indoor unit's heat exchanger sensor.

Indoor unit fan motor lock.

L E D

b l i n k i n g

: LED off

1 3 . BUZZER SOUND : Whenever the ON/OFF

button is pressed or whenever change occurs to the condition which is set up or select, the compulsory operation mode, buzzer is sounded "beep"

11 . 24-Hour ON/OFF Real Setting Ti m e r. : The

air conditioner is turned ON at a specified time using .

ON TIMER

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3-2 Installation

3-2-1 Selecting Area for Installation

Select an area for installation that is suitable to the customer's needs.

3-2-1(a) Indoor Unit

1 . Make sure that you install the indoor unit in

an area providing good ventilation. It must not be blocked by an obstacle affecting the airflow near the air inlet and the air outlet.

2 . Make sure that you install the indoor unit in

an area allowing good air handling and endurance of vibration of the indoor unit.

3. Make sure that you install the indoor unit in an area where there is no source of heat or vapor nearby.

4 . Make sure that you install the indoor unit in

an area from which hot or cool air is spre a d evenly in a ro o m .

5 . Make sure that you install the indoor unit in

an area away from TVs, audio units, cordless phones, fluorescent lighting fixture s and other electrical appliances (at least 1 m e t e r ) .

6 . Make sure that you install the indoor unit in

an area which provides easy pipe connection with the outdoor unit, and easy drainage for condensed water.

(Fix the unit firmly if it is mounted in a

high place.)

3 . Make sure that you install the outdoor unit

in area providing good ventilation and which is not dusty. It must not be blocked by any obstacle affecting the airflow near the air inlet and the air outlet.

4 . Make sure that you install the outdoor unit

in area free from animals or plants.

5 . Make sure that you install the outdoor unit

in area not blocking the traff i c .

6. Make sure that you install the outdoor unit in area easy to drain condensed water fro m the indoor unit.

7. Make sure that you install the outdoor unit in area which provides easy connection within the maximum allowable length of a coolant pipe(10 meters).

Note

1. Add 10 grams of refrigerant (R-22) for every 1 meter if the pipe length exceeds the standard pipe length of 5 meters.

2. Maintain a height between the indoor and outdoor units of less than 3 meters.

8 . Make sure that you install the outdoor unit

in an area which is large enough to accommodate the measurements

shown in figure on the next page.

7. Make sure that you install the indoor unit in an area which is large enough to accomodate the measurements shown in figure on the next page.

3-2-1(b) Outdoor Unit

1 . Make sure that you install the outdoor unit

in area not exposed to the rain or direct sun l i g h t .

(Install a separate sunblind if exposed to

d i rect sun light.)

2 . Make sure that you install the outdoor unit

in area allowing good air moment, not amplifying noise or vibration, especially to avoid disturbing neighbours.

Caution :

It is harmful to the air conditioner if it is used in the following environments: greasy areas (including areas near machines), salty areas such as coast areas, areas where sulfuric gas is present such as hot spring areas. Contact your dealer for advice.

3-4

3-2-1(c) Remote Control Unit

1 . Make sure that you install the remote con-

t rol unit in an area free from obstacles such as curtains etc, which may block signals f rom the remote control unit.

2. Make sure that you install the remote cont rol unit in an area not exposed to d i rect sunlight, and where there is no sourc e of heat.

3. Make sure that you install the remote cont rol unit in an area away from TVs, audio units, cordless phones, fluorescent lighting f i x t u res and other electrical appliances (at least 1 meter).

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3-2-2 Installation diagram of indoor unit and outdoor unit

Operating Instructions and Installation

A Indoor unit gas leak test check point

Indoor unit

Piping

Tape vinyl

B Drain hose installation

Cut the piping hole sloped slightly

5 6

250mm or more

Piping may be laid to the rear, left, right or down .

Right

Rear

Down

Rear

200mm or more

Left

1 2

4 5

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Piping (Liquid) 1/4" Clamper tube

7K/9K BTU Piping(Gas)3/8” 12K BTU Piping(Gas)1/2”

Installation tube Pipe-connection

Vinyl tape Screw Putty Drain hose

6 7 8

Remote control

Remote control holder

Installation plate

3-5

Operating Instructions and Installation

3-2-2(a) Fixing the Installation Plate

(Unit : mm)

Installation plate

280

340

Pipe hole (ø65mm)

1. Determine the position of the pipe and drain hose hole using the right figure and drill the hole with an inner diameter of 65mm so that it slants slightly downwards.

2. If you are fixing the indoor unit to a… Then follow Steps…

Wall 3.

Window frame 4 to 6.

3. Fix the installation plate to the wall in a manner appropriate to the weight of the indoor unit.

If you are mounting the plate on a concrete wall with anchor bolts, the anchor bolts must not project by more than 20mm.

4. Determine the positions of the wooden uprights to be attached to the window frame.

3-2-2(b) Purging the Unit

5. Attach the wooden uprights to the window frame in a manner appropriate to the weight of the indoor unit.

6. Using tapped screws, attach the installation plate to the wooden uprights, as illustrated in the last figure opposite.

On delivery, the indoor unit is loaded with an inert gas. All this gas must therefore be purged before connecting the assembly piping. To purge the inert gas, proceed as fol lows.

Unscrew the caps at the end of each pipe.

Result : All inert gas escapes from the indoor unit.

• To prevent dirt or foreign objects from getting into

the pipes during installation, do NOT remove the caps completely until you are ready to connect the piping.

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3-2-2(c) Connecting the Assembly Cable.

The outdoor unit is powered from the indoor unit via the assembly cable. If the outdoor unit is more than five metres away from the indoor unit, the cable must first be extended to a maximum of ten m e t re s .

1 . Extend the assembly cable if necessary. 2 . Open the front grille by pulling on the tabs on the lower right and

left sides of the indoor unit.

Indoor unit

Outdoor unit

3 . Remove the screw securing the connector cover. 4 . Pass the assembly cable through the rear of the indoor unit and

connect the assembly cable to terminals 1 to 5.

• Each wire is labelled with the corresponding terminal number.

5 . Firmly fix the ass’y cable with clamp wire holder. 6 . Pass the other end of the cable through the 65mm hole in the wall.

7 . Replace the connector cover, carefully tightening the scre w. 8 . Close the front grille. 9 . For further details on how to plug the other end of the assembly

cable into the outdoor unit, refer to page 12.

Operating Instructions and Installation

3-2-2(d) Installing and Connecting the Indoor Unit Drain Hose

C a re must be taken when installing the drain hose for the indoor unit to ensure that any condensa tion water is correctly drained outside.l When passing the drain hose through the 65mm hole drilled in the wall, check that none of the following situations occur.

The hose must NOT slope upw ards.

To install the drain hose, proceed as follows.

1. If necessary, connect the 2-metre extension to the drain hose. 2 . If you are using the extension, insulate the inside part of the extension drain hose with a shield.

3. Pass the drain hose under the refrigerant piping, taking care to keep the drain hose tight.

4. Pass the drain hose through the hole in the wall, making sure that it is sloping downwards, as shown in the illustrations above.

The end of the drain hose must NOT be placed in water.

Do NOT bend the hose in different directions.

Keep a clearance of at least 5cm between the end of the hose and the ground.

Do NOT place the end of the drain hose in a hollow.

Shield

Drain hose Extension drain hose

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The hose will be fixed permanently into position once the whole installation has been tested for gas leaks; refer to page 16 for further details.

3-7

Operating Instructions and Installation

3-2-2(e) Outdoor unit installation

Wiring connection

1. Remove the cover-E parts.

2. Firmly connect the cable connector in the terminal block.

3. Fasten the M4 ring terminal to the hole marked

4. Firmly fix the ass'y cable with clamp wire holder.

5. Assemble the cover-E parts.

6. To prevent the entry of water, form a trap of the ass'y cable as illustrated in the installation diagram of indoor and outdoor unit.

Cover-E parts

Screw

Installation of drain line

In heating and de-ice operation, condensed water may be generated. Install drain line as following pro c e d u re .

1 . Close Hole with Cap Drain A . 2 . Close Hole with Cap Drain B. 3 . Insert Drain plug into Hole , and then connect drain hose to drain plug.

• Inside diameter of drain hose is 18mm.

Hole

Drain Plug Cap-Drain A

Cap-Drain B

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3-2-2(f) Flare Modification

• Tools used

Flare modification procedure

Operating Instructions and Installation

1 ) Cut the pipe using a pipe cutter.

Oblique Raughness Burr

3 ) Insert a flare nut into the pipe and

modifty flare .

2 ) Remove burrs at the tip of the pipe cut.

Caution : Burrs not removed may result in

leakage of gas.

Pipe

Reamer

Outer diameter A(mm)

ø6.35mm 1.3 ø9.52mm 1.8 ø12.7mm 2.0

* Unproper flaring

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Inclined Surface

damaged

Cracked Uneven

thickness

3-9

Operating Instructions and Installation

3-2-2(g) Air-Purge Procedure

• Use the refrigerant of the outdoor unit to purge air inside indoor unit and pipe.

1. Remove the caps from the 2-way valve(B) and the 3-way valve(A).

2 Turn the 2-way valve cock approx. 45°

counterclockwise to open it. Close it about 10 seconds later.

Valve stem

3 Check refrigerant leakage of each joint parts

(A, B, C & D in right figure)

Valve stem

Stopper

not

Leaking

leaking

If leaking, tighten the flare nut one more time. If continues to leak, although the pipe fixing area has been tightened again, repair the leaking area.

4. Open the 2-way valve again.

5. Open the service valve cap of the 3-way valve and press the needle valve to discharge gas for 3 seconds and leave it for about 1 minute. Repeat the above procedure for 3 times to purge air.

6. Open the 2-way valve and 3-way valve

completely

Indoor Unit

Liquid pipe side

2-way valve 3-way valve

Gas pipe side

7. Close the cap of each valve.

8. Check each valve for leakage.

3-10

Outdoor Unit

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Operating Instructions and Installation

3-2-2(h) Refrigerant Refill

• Refill an air-conditioner with refrigerant when refrigerant has been leaked at installing or using

1. Purge air(for new installation only).

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.

Suspension hook

3. Connect the tank to refill with Refrigerant

4. Set the unit to cool operation mode.

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 refrig-

erant until the rated pressure is reached. * It is recommended not to pour the

refrigerant in too quickly, but gradually while operating a pressure valve.

Compound gauge

For mounting other and of hose when not in use

High pressure gauge

Hand wheel

Finger tight fittings

Connected to high pressure side

Charging line

7. Stop operation of the air conditioner.

8. Close the 3-way valve, disconnect the pressure gauge, and open the 3-way valve again.

9. Close the cap of each valve.

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