Panasonic CW-XC143HU, CW-XC123HU, CW-XC118HU, CW-XC103HU Service Manual

Service Manual

Room Air Conditioner

CW -XC103HU CW -XC118HU CW -XC123HU CW -XC143HU

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. RAC0209003C1 E9

—2—

1. PREFACE

1.1 SAFETY PRECAUTIONS................................2

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

1.3 FEATURES......................................................4

DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS ....................................6

2.1.1 FRONT GRILLE .....................................6

2.1.2 CABINET................................................6

2.1.3 CONTROL BOX .....................................6

2.2 AIR HANDLING PARTS..................................7

2.2.1 AIR GUIDE AND BLOWER....................7

2.2.2 FAN ........................................................7

2.2.3 SHROUD................................................8

2.3 ELECTRICAL PARTS......................................8

2.3.1 OVERLOAD PROTECTOR ....................8

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

2.3.3 CAPACITOR...........................................9

2.3.4 POWER CORD ......................................9

2.3.5 THERMOSTAT.......................................9

2.3.6 SYNCHRONOUS MOTOR.....................9

2.3.7 MOTOR ................................................10

2.4 REFRIGERATION CYCLE ............................10

2.4.1 CONDENSER.......................................10

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

2.4.3 CAPILLARY TUBE ...............................11

INSTALLATION

3.1 SELECT THE BEST LOCATION...................13

3.2 CHECK OF INSTALLATION..........................13

3.3 HOW TO DRAIN............................................13

3.4 HOW TO INSTALL ........................................14

3.4.1 WHEN USING GASKET.......................14

3.4.2 WHEN USING INSTALLATION KITS...14

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS...............................17

4.2 PIPING SYSTEM...........................................18

4.3 TROUBLESHOOTING GUIDE ......................19

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM ......................................27

5.2 ELECTRONIC CONTROL DEVICE...............28

5.3

COMPONENTS LOCATION(FOR MAIN P.C.B ASM)

...29

5.4

COMPONENTS LOCATION(FOR DISPLAY P.C.B ASM)

...30

6. EXPLODED VIEW..................................31

7. REPLACEMENT PARTS LIST........33

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 SAFETY PRECAUTIONS

1. When servicing the unit, set the POWER 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.

CONTENTS

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POWER SUPPLY Ø, V, Hz COOLING CAPACITY Btu/h. POWER INPUT W RUNNING CURRENT A EER Btu/h.W OPERATING INDOOR °F(°C) CONDITION OUTDOOR °F(°C) REFREIGERANT (R-22) CHARGE EVAPORATOR CONDENSER

FAN

INDOOR

OUTDOOR

FAN SPEED

FAN/COOLING FAN MOTOR OPERATION CONTROL ROOM TEMP. CONTROL AIR DIRECTION VERTICAL CONTROL

HORIZONTAL

CONSTRUCTION

PROTECTOR

COMPRESSOR

FAN MOTOR

POWER CORD

DRAIN SYSTEM NET WEIGHT lbs(kg) DIMENSION(W*H*D) inch(mm)

1, 115, 60

9,800 11,800 12,000 13,800

910 1,090 1,110 1,280

8.4 10.0 10.2 11.8

10.8 10.8 10.8 10.8 DB : 80(26.7) WB : 67(19.4)

DB : 95(35) WB : 75(23.9)

490g(17.3 oz) 500g(17.6 oz) 500g(17.6 oz) 530g(18.7 oz)

2 ROW 16 STACKS,SLIT-FIN TYPE

2 ROW 13 STACKS,SLIT-FIN TYPE

2 ROW 18 STACKS,LOUVERED-FIN TYPE

2 ROW 17 STACKS,LOUVERED-FIN TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

3/3

6 POLES

REMOTE CONTROLLER

THERMISTOR

MANUAL

AUTO MANUAL AUTO

SLIDE IN-OUT CHASSIS

OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

3 WIRE WITH GROUNDING

ATTACHMENT PLUG (CORD-CONNECTED TYPE)

DRAIN PIPE OR SPLASHED BY FAN SLINGER

95(43) 100(45) 115(52)

23 5/8*14 31/32*22 5/16 (600*380*567)

CW-XC103HU CW-XC118HU CW-XC123HU CW-XC143HU

MODELS

ITEMS

1.2 SPECIFICATIONS

* DB:Dry Bulb **

WB:Wet Bulb

❈ The specifications will be changed without notice for further improvement.

—4—

1.3 FEATURES

■ VENTILATION

■ CW-XC118HU

OPERATION BUTTON

To turn the air conditioner ON, push the button. To turn the air conditioner OFF, push the button again. This button takes priority over any other buttons. When you first turn it on, the air conditioner is on the High cool mode and the temp. at 72°F (22°C).

OPERATION MODE SELECTION BUTTON

Every time you push this button, it will toggle between COOL and FAN.

FAN SPEED SELECTION BUTTON

Every time you push this button, it is set as follows. [High(F3) → Low(F1) → Med(F2) → High(F3) →...]

ROOM TEMPERATURE SETTING BUTTON

This button can automatically control the temperature of theroom.Thetemperaturecanbesetwithinarangeof 60°F to 86°F by 1°F (16°C to 30°C by 1°C). Select the lower number for lower temperature of the room.

ON/OFF TIMER BUTTON

You can set the time when the unit will turn on or turn off automatically by pressing the timer button. If the unit is operating, this button controls the time it will be turned off. If the unit is off state, this button controls the time it will start. Every time you push this button, the remaining time will be set as follows.

- Stopping operation

• (1Hour → 2Hours → 3Hours → 4Hours → 5Hours → 6Hours → 7Hours → 8Hours → 9Hours → 10Hours → 11Hours → 12Hours → 0Hour → 1Hour → 2Hours →... )

•

The Setting Temperature will be raised by 2°F(1°C) 30min. later and by 2°F(1°C) after another 30 min.

- Starting operation

•

(1Hour → 2Hours → 3Hours → 4Hours → 5Hours → 6Hours → 7Hours → 8Hours → 9Hours → 10Hours → 11Hours → 12Hours → 0Hour → 1Hour → 2Hours → ... )

REMOTE CONTROL SIGNAL RECEIVER

Precaution: The Remote Control unit will not function properly if strong light strikes the sensor window of the air

conditioner or if there are obstacles between the Remote Control unit and the air conditioner.

REMOTE CONTROL

DISPLAY

The ventilation lever must be in the CLOSE position in order to maintain the best cooling conditions. When fresh air is necessary in the room, set the ventilation lever to the OPEN position. The damper is opened and room air is drawn out.

NOTE: Before using the ventilation feature, and prior to installing the front grille, pull down part

until level with part .

Part

VENTCLOSE

OPEN

OPERATION

TEMP

TIMER

MODE FAN SPEED

1 5

—5—

■ CW-XC103HU, CW-XC123HU, CW-XC143HU

OPERATION BUTTON

OPERATION MODE SELECTION BUTTON

Every time you push this button, it will toggle between COOL, FAN.

ROOM TEMPERATURE SETTING BUTTON

This button can automatically control the temperature of the room. The temperature can be set within a range of 60°Fto 86°Fby1°F(16°Cto30°Cby1°C). Select the lower number for lower temperature of the room.

FAN SPEED SELECTION BUTTON

Every time you push this button, it is set as follows. [High(F3) → Low(F1) → Med(F2) → High(F3) →...]

ON/OFF TIMER BUTTON

- Stopping operation (1Hour → 2Hours → 3Hours → 4Hours → 5Hours → 6Hours → 7Hours → 8Hours → 9Hours → 10Hours → 11Hours → 12Hours → 0Hour → 1Hour → 2Hours →... ) The Setting Temperature will be raised by 2°F(1˚C) 30min. later and by 2°F(1˚C) after another 30 min.

- Starting operation (1Hour → 2Hours → 3Hours → 4Hours → 5Hours → 6Hours → 7Hours → 8Hours → 9Hours → 10Hours → 11Hours → 12Hours → 0Hour → 1Hour → 2Hours → ... )

AIR SWING BUTTON

This button can automatically control the air flow direction.

ECONOMY BUTTON

If you push this button, the fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and check the room air temperature to determine if cooling is necessary.

REMOTE CONTROL SIGNAL RECEIVER

Precaution: The Remote Control unit will not function properly if strong light strikes the sensor window of the air

conditioner or if there are obstacles between the Remote Control unit and the air conditioner.

REMOTE CONTROL

DISPLAY

OPERATION

TEMP

TIMER

MODE

ECONOMY

AIR

SWING

FAN SPEED

1 3 6

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2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Open the lnlet grille upward .

2. Remove the screw which fastens the front grille.

3. Pull the front grille from the right side.

4. Remove the front grille.

5. Re-install the component by referring to the removal procedure, above.(See Figure 1)

2.1.2 CABINET

1. After disassembling the FRONT GRILLE, remove the 2 screws which fasten the cabinet at both sides.

2. Remove the 2 screws which fasten the cabinet at back.

3. Pull the base pan forward. (See Figure 2)

4. Remove the cabinet.

5. Re-install the component by referring to the removal procedure, above.

2.1.3 CONTROL BOX

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

2. Remove the cabinet. (Refer to section 2.1.2)

3. Remove the 2 screws which fasten the control box cover.

4. Remove two housings which connect compressor wire and motor wire in the control box.

5.Discharge the capacitor by placing a 20,000 ohmresistor across the capacitor terminals.

6. Remove the 2 screws which fasten the control box.

7. Pull the control box forward completely.

8. Re-install the components by referring to the removal procedure, above. (See Figure 3) (Refer to the circuit diagram found on pages 34~37 in this manual and on the control box.)

2. DISASSEMBLY INSTRUCTIONS

— Before the following disassembly, POWER SWITCH set to OFF and disconnect the power cord.

Figure 1

Figure 3

Figure 2

—7—

2.2 AIR HANDLING PARTS

2.2.1 AIR GUIDE AND BLOWER

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

2. Remove the cabinet. (Refer to section 2.1.2)

3. Remove the control box. (Refer to section 2.1.3)

4. Remove the 4 screws which fasten the brace.

5. Remove the brace.

6. Remove the 2 screws which fasten the evaporator.

7. Move the evaporator forward and pulling it upward slightly. (See Figure 4)

8. Move the evaporator to the left carefully.

9. Pull out the hook of orifice by pushing the tabs and remove it. (See Figure 5)

10.Remove the clamp with a hand plier which

secures the blower.

11. Remove the blower.

12. Remove the 4 screws which fasten the air guide

from the barrier.

13. Move the air guide backward, pulling out from the

base pan.

14. Re-install the components by referring to the

removal procedure, above.

2.2.2 FAN

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

2. Remove the brace (Refer to section 2.2.1)

3. Remove the 4 screws which fasten the condenser.

4. Move the condenser to the left carefully.

5. Remove the clamp which secures the fan.

6. Remove the fan. (See Figure 7)

7. Re-install by referring to the removal procedure.

Figure 4

Figure 5

Figure 6

Figure 7

—8—

2.2.3 SHROUD

1. Remove the fan. (Refer to section 2.2.2)

2. Remove the screw which fastens the shroud.

3. Remove the shroud. (See Figure 8)

4. Re-install the component by referring to the removal procedure, above.

2.3 ELECTRICAL PARTS

2.3.1 OVERLOAD PROTECTOR

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

2. Remove the nut which fastens the terminal cover.

3. Remove the terminal cover. (See Figure 9)

4. Remove all the leads from the overload protector.

5. Remove the overload protector.

6. Re-install the component by referring to the removal procedure, above.

2.3.2 COMPRESSOR

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

2. Discharge the refrigerant system using a Freon

Recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the Freon

. Leave the valve in place after

servicing the system.

3. Remove the overload protector. (Refer to section

2.3.1)

4. After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections.

5. Remove the 3 nuts and the 3 washers which fasten the compressor.

6. Remove the compressor. (See Figure 10)

7. Re-install the components by referring to the removal procedure, above.

Figure 8

Figure 9

Figure 10

—9—

2.3.3 CAPACITOR

1. Remove the control box. (Refer to section 2.1.3)

2. Remove the knobs and the screw which fasten control panel from control box.

3. Remove the screw which located in the front.

4. Open the bottom side of control box.

5. Remove the screw and the clamp which fastens the capacitor.

6. Disconnect all the leads of capacitor terminals.

7. Re-install the components by referring to the removal procedure, above. (See Figure 11)

2.3.4 POWER CORD

1. Remove the control box. (Refer to section 2.1.3)

2. Open the control box. (Refer to section 2.3.3)

3. Disconnect the grounding screw from the control box.

4. Disconnect the 2 receptacles.

5. Remove a screw which fastens the clip cord. (See Figure 12)

6. Remove the power cord.

7. Re-install the component by referring to the above removal procedure, above. (Use only one ground-marked hole for ground connection.)

8. If the supply cord of this appliance is damaged, it must be replaced by the special cord. (The special cord means the cord which has the same specification marked on the supply cord attached at the unit.)

2.3.5 THERMISTOR

1. Remove the control box. (Refer to section 2.1.3)

2. Open the control box. (Refer to section 2.3.3)

3. Disconnet the thermistor terminals from main P.W.B assembly.

4. Remove the thermistor.

5. Re-install the components by refereing to the above removal procedure. (See Figure 13)

2.3.6 SYNCHRONOUS MOTOR

1. Remove the control box. (Refer to section 2.1.3)

2. Unfold the control box. (Refer to section 2.3.3)

3. Remove the crankshaft.

4. Disconnect all the leads of the synchronous motor.

5. Remove the 2 screws which fasten the

synchronous motor. (See Fig. 14)

6. Re-install the components by referring to the

removal procedure, above.

Figure 12

Figure 11

Figure 13

Figure 14

—10—

2.3.7 MOTOR

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

2. Remove the evaporator. (Refer to section 2.2.1)

3. Remove the orifice. (Refer to section 2.2.1)

4. Remove the blower. (Refer to section 2.2.1)

5. Remove the fan. (Refer to section 2.2.2)

6. Remove the control box cover and disconnect 5 or 4 wires of motor housing. (Refer to section 2.1.3)

7. Remove the 2 or 4 screws which fasten the motor from the mount motor. (See Figure 14)

8. Remove the motor.

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

2.4 REFRIGERATING CYCLE

2.4.1 CONDENSER

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

2. Remove the 4 screws which fasten the brace.(Refer to section 2.2.1)

3. Remove the 5 screws which fasten the condenser and shroud.

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

5. Remove the condenser.

6. Re-install the component by referring to notes. (See Figure 15)

2.4.2 EVAPORATOR

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

2. Remove the 2 screws which fasten the evaporator.

3. Move the evaporator sideways carefully. (Refer to section 2.2.1)

4. After discharging the refrigerant completely, unbraze the interconnecting tube at the evaporator connections.

5. Remove the evaporator.

6. Re-install the component by referring to notes. (See Figure 16)

Figure 14

Figure 15

Figure 16

Discharge the refrigerant system using a FreonTMRecovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the FreonTM. Leave the valve in place after servicing the system.

CAUTION

—11—

— Replacement of the refrigeration cycle.

1. When replacing the refrigeration cycle, be sure to Discharge the refrigerant system using a Freon

recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the FreonTM. Leave the valve in place after servicing the system.

2. After discharging the unit completely, remove the desired component, and unbraze the pinch-off tubes.

3. Solder service valves into the pinch-off tube ports, leaving the valves open.

4. Solder the pinch-off tubes with Service valves.

5. Evacuate as follows.

1) Connect the vacuum pump, as illustrated figure

18A.

2) Start the vacuum pump, slowly open manifold

valves A and B with two full turns counterclockwise and leave the valves open. The vacuum pump is now pulling through valves A and B up to valve C by means of the manifold

and entire system.

3) Operate the vacuum pump for 20 to 30 minutes,

until 600 microns of vaccum is obtained. Close valves A and B, and observe vacuum gauge for a few minutes. A rise in pressure would indicate a possible leak or moisture remaining in the system. With valves A and B closed, stop

the vacuum pump.

4) Remove the hose from the vacuum pump and

place it on the charging cylinder. See figure 18B. Open valve C. Discharge the line at the manifold connection.

5) The system is now ready for final charging.

6. Recharge as follows :

1) Refrigeration cycle systems are charged from the High-side. If the total charge cannot be put in the High-side, the balance will be put in the suction line through the access valve which you installed as the system was opened.

2) Connect the charging cylinder as shown in figure 18B. With valve C open, discharge the hose at the manifold connection.

3) Open valve A and allow the proper charge to enter the system. Valve B is still closed.

4) If more charge is required, the high-side will not take it. Close valve A.

5) With the unit running, open valve B and add the balance of the charge.

a. Do not add the liquid refrigerant to the Low-

side.

b. Watch the Low-side gauge; allow pressure to

rise to 0.2 Mpa. c. Turn off valve B and allow pressure to drop. d. Repeat steps b. and c. until the balance of the

charge is in the system.

6) When satisfied the unit is operating correctly, use the pinch-off tool with the unit still running and clamp on to the pinch-off tube. Using a tube cutter, cut the pinch-off tube about 2 inches from the pinch-off tool. Use sil-fos solder and solder pinch-off tube closed. Turn off the unit, allow it to set for a while, and then test the leakage of the pinch-off connection.

NOTES

If high vacuum equipment is used, just crack valves A and B for a few minutes, then open slowly with the two full turns counterclockwise. This will keep oil from foaming and being drawn into the vacuum pump.

2.4.3 CAPILLARY TUBE

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

2. After discharging the refrigerant completely, unbraze the interconnecting tube at the capillary tube.(See caution above)

3. Remove the capillary tube.

4. Re-install the component by referring to notes.

CAUTION

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