Panasonic Cw-c53gk, Cw-c53hu Owner's Manual

Service Manual

Room Air Conditioner

CW -C53GK CW -C53HU

WARNING

This service information is designed for experienced repair technicians only and is not designed for use by the general public. It does not contain warnings or cautions to advise non-technical individuals of potential dangers in attempting to service a product. Products powered by electricity should be serviced or repaired only by experienced professional technicians. Any attempt to service or repair the product or products deal with in this service information by anyone else could result in serious injury or death.

ORDER NO. RAC0209001C1 E9

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CONTENTS

1. PREFACE ...................................................................................................................................................3

1.1 FEATURES.....................................................................................................................................................3

1.2 SPECIFICATIONS .........................................................................................................................................3

1.3 LOCATIONS OF CONTROLS .......................................................................................................................4

1.4 SAFETY PRECAUTIONS ..............................................................................................................................4

1.5 INSULATION RESISTANCE TEST ................................................................................................................4

2. DISASSEMBLY INSTRUCTIONS ................................................................................................5

2.1 MECHANICAL PARTS ..................................................................................................................................5

2.1.1 FRONT GRILLE ....................................................................................................................................5

2.1.2 CABINET................................................................................................................................................5

2.1.3 CONTROL BOARD................................................................................................................................5

2.2 AIR HANDLING PARTS ................................................................................................................................6

2.2.1 AIR GUIDE UPPER ..............................................................................................................................6

2.2.2 ORIFICE, TURBO FAN AND FAN .........................................................................................................6

2.2.3 MOTOR..................................................................................................................................................7

2.2.4 AIR GUIDE.............................................................................................................................................7

2.3 ELECTRICAL PARTS ....................................................................................................................................7

2.3.1 OVERLOAD PROTECTOR ...................................................................................................................7

2.3.2 COMPRESSOR .....................................................................................................................................8

2.3.3 CAPACITOR ..........................................................................................................................................8

2.3.4 THERMOSTAT .......................................................................................................................................8

2.3.5 ROTARY SWITCH..................................................................................................................................8

2.3.6 POWER CORD .....................................................................................................................................9

2.4 REFRIGERANT CYCLE ................................................................................................................................9

2.4.1 CONDENSER .......................................................................................................................................9

2.4.2 EVAPORATOR ....................................................................................................................................10

2.4.3 CAPILLARY TUBE ..............................................................................................................................10

3. INSTALLATION ....................................................................................................................................12

3.1 SELECT THE BEST LOCATION .................................................................................................................12

3.2 HOW TO INSTALL .......................................................................................................................................12

3.3 ELECTRICAL DATA .....................................................................................................................................15

4. TROUBLESHOOTING GUIDE ....................................................................................................

4.1 OUTSIDE DIMENSIONS..............................................................................................................................15

4.2 PIPING SYSTEM ........................................................................................................................................16

4.3 TROUBLESHOOTING GUIDE ....................................................................................................................17

5. CIRCUIT DIAGRAM ...........................................................................................................................22

6. EXPLODED VIEW ..............................................................................................................................23

7. SERVICE PARTS LIST ....................................................................................................................24

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1. PREFACE

This service manual provides various service information, including the mechanical and electrical parts, etc. This room air conditioner was manufactured and assembled under a strict quality control system. The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

1.1 FEATURES

• DESIGNED FOR COOLING ONLY

• POWERFUL AND INCREDIBLE COOLING

• BUILT-IN ADJUSTABLE THERMOSTAT

• WASHABLE ONE-TOUCH FILTER

• COMPACT SIZE

1.2 SPECIFICATIONS

MODELS

ITEMS

COOLING CAPACITY (BTU/h) 5,250 5,200 POWER SUPPLY (Phase, V, Hz) 1ø, 115V, 60Hz INPUT (W) 540 480 OPERATING CURRENT (AMP.) 5.0 4.4 REFRIGERANT CONTROL CAPILLARY TUBE REFRIGERANT CHARGE (R-22) 220g(7.8 Oz) 330g(11.6 Oz) INSIDE FAN TURBO OUTSIDE FAN PROPELLER FAN WITH SLINGER RING AIR DISCHARGE 2-WAY (RIGHT AND LEFT) CHASSIS TOP-DOWN

PROTECTOR

TEMPERATURE CONTROL THERMOSTAT ROTARY SWITCH

5 POSITIONS (LOW FAN, HIGH FAN, OFF, HIGH COOL, LOW COOL)

FAN MOTOR 6 POLES, 19.9W

• OVERLOAD PROTECTOR FOR COMPRESSOR

• INTERNAL PROTECTOR FOR FAN MOTOR

CW-C53GK CW-C53HU

• NOTE: Specifications are subject to minor change without notice for further improvement.

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1.3 LOCATIONS OF CONTROLS

1.4 SAFETY PRECAUTIONS

1. When servicing, set the ROTARY SWITCH to Off and unplug the power cord.

2. Observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.

3. After servicing, make an insulation resistance test to prevent the customer's exposure to shock hazards.

1.5

INSULATION RESISTANCE TEST

1. Unplug the power cord and connect a jumper between 2 pins (black and white).

2. The grounding conductor (green or green and yellow) is to be open.

3. Measure the resistance value with an ohm meter between the jumpered lead and each exposed metallic part on the equipment at all positions [except Off] of the ROTARY SWITCH.

4. The value should be over 1 MΩ.

CAUTION : After switching the air conditioner from Cool to Off or Fan, wait at least 3 minutes before switching it

back to Cool.

Off—Turns air conditioner off. High Fan

—

High speed fan operation without cooling. Low Fan—Low speed fan operation without cooling. High Cool—Cooling with high speed fan operation. Low Cool—Cooling with low speed fan operation.

This automatically controls the temperature of the indoor air. Turn the knob so that the arrow points to the larger marks for greater cooling.

Point the arrow to the smaller marks for more moderate cooling. (i.e. the higher the number, the greater the cooling)

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2. DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Disconnect the unit from source of power.

2. Remove the two knobs by pulling them off. Using a screwdriver, remove the screw that secures the front grille to control board. (See Figure 1)

3. Push the front grille up from the bottom. Pull the top of the front grille away from the cabinet as the top tabs lift out of their slots. (See Figure 2)

4. Replace the grille by placing the tabs in the slots and push the grille until it snaps into place.

2.1.2 CABINET

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to section 2.1.1)

3. Remove 9 screws that secure the cabinet to the base pan and condenser. (See figure 3)

4. Lift the cabinet from the unit.

5. Re-install by referring to the procedures above.

2.1.3 CONTROL BOARD

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove 2 screws that secure the control board to base pan and air guide. (See Figure 4)

5. Pull the control board toward yourself.

6. Disconnect one housing terminal and 3 wires for the fan motor and compressor. (See Figure 5)

7. Re-install components by referring to procedures above. (Refer to wiring diagram on page 23 in this manual or inside control board.)

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

NOTE : Controls, wires, and capacitor are now

accessible for servicing. Discharge the capacitor before servicing. See step

2.3.3 on page 8 for procedures.

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2.2 AIR HANDLING PARTS

2.2.1 AIR GUIDE UPPER

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove the control board. (Refer to Section 2.1.3)

5. Remove 2 screws that secure the air guide upper to air guide lower. (See Figure 6)

6. Lift air guide upper upward.

7. Re-install by referring to the procedures above.

2.2.2 ORIFICE, TURBO FAN AND FAN

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove the control board. (Refer to Section 2.1.3)

5. Remove the air guide upper. (Refer to Section 2.2.1)

6. Remove 2 screws that secure the base pan to condenser. (See Figure 7)

7. Remove screw that secures the shroud to channel of condenser.

8. Press the snap area of shroud with your thumbs. This allows you to remove it from the condenser.

9. Lift the compressor upward with the evaporator and condenser. (See Figure 7)

10. Remove the orfice by pushing the snap area of the air guide blower. (See Figure 8)

11. Remove the clamp springs which are clamped to the boss of fan and turbo fan by hand plier. (See Figure 9)

12. Pull the fan and turbo fan outward.

13. Remove the shroud.

14. Re-install by referring to the procedures above.

Figure 6

Figure 7

Figure 8

Figure 9

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2.2.3 MOTOR

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove the control board. (Refer to Section 2.1.3)

5. Remove the air guide upper. (Refer to Section 2.2.1)

Remove the compressor, turbo fan, fan and shroud. (Refer to

Section

2.2.2)

Remove 2 screws that secure the motor to the motor. (See figure 10)

8. Remove the motor.

Re-install by referring to the procedures above.

2.2.4 AIR GUIDE

1. Disconnect the unit from the power source.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove the control board. (Refer to Section 2.1.3)

5. Remove the air guide upper. (Refer to Section 2.2.1)

Remove the compressor, turbo fan, fan and shroud. (Refer to

Section

2.2.2)

Remove the motor. (Refer to

Section

2.2.3)

8. Remove 2 screws that secure the air guide to the base pan. (See Figure 11)

9. Push the air guide backward and lift it upward. (See Figure 11)

10. Re-install by referring to the procedures above.

2.3 ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

1. Remove the front grille and cabinet. (Refer to Section 2.1)

2. Remove the nut which fastens the terminal cover .

3. Remove the terminal cover.

4. Remove all the leads from the overload protector.

5. Remove the overload protector.

6. Re-install the components by referring to the removal procedure above. (See Figure 12 and 13)

Figure 10

Figure 12

Figure 13

Figure 11

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2.3.2 COMPRESSOR

1. Remove the front grille and cabinet. (Refer to Section 2.1)

2. Discharge the refrigerant by using a refrigerant recovery system.

3. Remove the overload protector. (Refer to Section 2.3.1)

4. After discharging the unit completely, unbrace the suction and discharge pipes at the compressor connections.

5. Remove 3 nuts which fasten the compressor.

6. Remove the compressor.

7. Re-install by referring to the removal procedure above. (See Figure 14)

2.3.3 CAPACITOR

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Remove the control board. (Refer to Section 2.1.3)

3. Discharge the capacitor by placing a 20 KΩ resistor across the capacitor terminals.

4. Remove the screw which fastens the capacitor clamp.

5. Remove all the leads of capacitor terminals.

6. Re-install the components by referring to the removal procedure above. (See Figure 15)

2.3.4 THERMOSTAT

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Remove the control board. (Refer to Section 2.1.3)

3. Remove 2 screws which fasten the thermostat.

4. Remove all the leads of the thermostat terminals.

5. Remove the thermostat.

6. Re-install the components by referring to the removal procedure above. (See Figure 16)

2.3.5 ROTARY SWITCH

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Remove the control board. (Refer to Section 2.1.3)

3. Remove 2 screws which fasten the rotary switch.

4. Remove all the leads of the rotary switch terminals.

5. Remove the rotary switch.

6. Re-install the components by referring to the removal procedure above. (See Figure 17)

Figure 14

Figure 15

Figure 16

Figure 17

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2.3.6 POWER CORD

1. Disconnect the unit from source of power.

2. Remove the front grille. (Refer to Section 2.1.1)

3. Remove the cabinet. (Refer to Section 2.1.2)

4. Remove a screw that secures control board to base pan. (Refer to Section 2.1.3)

5. Pulls the control board toward you.

6. Disconnect the 2 receptacles and remove the grounding screw.

7. Remove a screw securing the clip with cord to the control board.

8. Pull the power cord.

9. Re-install by referring to procedures above.

2.4 REFRIGERANT CYCLE

2.4.1 CONDENSER

1. Remove the cabinet. (Refer to Section 2.1.2)

2. Discharge the refrigerant by using a refrigerant recovery system.

3. Remove the air guide. (Refer to Section 2.2.1)

4. Remove 2 screws which fasten the condenser.

5. After discharging the refrigerant completely, unbraze the interconnecting tube at the condenser connections.

6. Remove the condenser.

7. Re-install by referring to the procedures above.

Figure 18

Figure19

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