Panasonic CW-XC244HU User Manual

Service Manual

Room Air Conditioner

CW -XC184HU
CW -XC244HU

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.

© 2003 Matsushita Electric Industrial co., Ltd.
All rights reserved. Unauthorized copying and
distribution is violation of law.

R

ORDER NO. RAC0310006C1
E9

—2—

1. PREFACE

1.1 SAFETY PRECAUTIONS................................................................................................................................3

1.2 INSULATION RESISTANCE TEST.................................................................................................................3

1.3 SPECIFICATIONS...........................................................................................................................................3

1.4 ABOUT THE CONTROLS ON THE AIR CONDITIONER...............................................................................4

2.

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 COVER (AT THE TOP)..........................................................................................................................7

2.2.2 TURBO...................................................................................................................................................7

2.2.3 FAN........................................................................................................................................................7

2.2.4 SHROUD................................................................................................................................................8

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

2.3.1 MOTOR..................................................................................................................................................8

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

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

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

2.3.5 THERMISTOR........................................................................................................................................9

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

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

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

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

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

3.

INSTALLATION

3.1 HOW TO INSTALL THE UNIT.......................................................................................................................13

3.2

HOW TO USE THE REVERSIBLE INLET GRILLE

..................................................................................................................

13

3.3 WINDOW REQUIREMENTS.........................................................................................................................14

3.4 INSTALLATION KITS CONTENTS...............................................................................................................14

3.5 SUGGESTED TOOL REQUIREMENTS.......................................................................................................15

3.6 CABINET INSTALLATION ............................................................................................................................16

4.

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS...............................................................................................................................18

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

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

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM......................................................................................................................................28

5.2 ELECTRONIC CONTROL DEVICE ..............................................................................................................29

5.3

COMPONENTS LOCATION(FOR MAIN P.C.B ASM

).......................................................................................................30

5.4

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

.......................................................................................................30

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

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

CONTENTS

—3—

1.1 SAFETY PRECAUTIONS

1. When servicing, set the POWER of CONTROL BOARD
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.

1.2

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.

4. The value should be over 1 MΩ.

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.

1.3 SPECIFICATIONS

* DB:Dry Bulb

**

WB:Wet Bulb

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

CW-XC184HU CW-XC244HU

POWER SUPPLY Ø, V, Hz
COOLING CAPACITY Btu/h.
POWER INPUT W
RUNNING CURRENT A
EER Btu/h.W
REFREIGERANT (R-22) CHARGE
OPERATING

INDOOR °F(°C)

TEMPERATURE

OUTDOOR

°F(°C)
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, 208/230, 60

17,800/17,300 23,500/23,000

1,660/1,620 2,500/2,450

7.4/7.9 11.2/12.0

10.7/10.7 9.4/9.4

780g (27.5 oz) 980g (34.6oz)

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

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

3 ROW 15 STACKS, SLIT-FIN TYPE

2 ROW 19 STACKS, LOUVERED-FIN TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

3/3

6 POLES

REMOTE CONTROL

THERMISTOR

MANUAL

AUTO

SLIDE IN-OUT CHASSIS

INTERNAL OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

1.6m(63") (3WIRE WITH GROUNDING)

ATTACHMENT PLUG(CORD-CONNECTED TYPE)

DRAIN PIPE OR SPLASHED BY FAN SLINGER

123(55) 146(66)

26 * 1627/

32 * 26

17

/

32 (660 * 428 * 675) 26 * 16

27

/

32 * 30

17

/

32 (660 * 428 * 770)

MODELS

ITEMS

1.4 ABOUT THE CONTROLS ON THE AIR CONDITIONER

Models: CW-XC184HU, CW-XC244HU

—4—

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, ECONOMY, FAN, DRY.

ROOM TEMPERATURE SETTING BUTTON

This button can automatically control the temperature of
the room. The temperature can be set within a range of
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.

FAN SPEED SELECTION BUTTONS

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

ECONOMY

• 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 to
determine if cooling is needed.

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 in 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

• Every time you push this button, when the air
conditioner is operating, timer is set as follows.
(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

• Every time you push this button, when the air
conditioner is not operating, timer is set as follows.
(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.

REMOTE CONTROL SIGNAL RECEIVER

DRY

When this unit is in dry mode, the fan rotates in low
speed. The fan stops when the compressor stops
cooling.
Approximately every 3 minutes the fan will turn on and
the unit checks the room air temperature to set itself.

7

7

6

6

8

8

9

9

Precaution: The Remote Controller 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.

OPERATION

TEMP

TIMER

AIR

SWING

MODE

ECONOMY

FAN SPEED

1

6

2 4
5

3

7

2 6

1

8

4 7

3

—5—

ADDITIONAL CONTROLS AND IMPORTANT INFORMATION.

• VENTILATION

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 .

• AIR DIRECTION

The direction of air can be controlled wherever you want to cool by
adjusting the horizontal louver and the vertical louver.

• VERTICAL AIR-DIRECTION CONTROL

The vertical air direction is adjusted by rotating the
horizontal louver forward or backward manually.

The horizontal air direction is adjusted by rotating the
vertical louver right or left by Remote Controller.

•

HORIZONTAL AIR-DIRECTION CONTROL

• HOW TO SECURE THE DRAIN PIPE

In humid weather, excess water may cause the BASE PAN to overflow.
To drain the water, remove the DRAIN CAP and secure the DRAIN PIPE
to the rear hole of the BASE PAN. Press the drain pipe into the hole by
pushing down and away from the fins to avoid injury. (See Fig.1)

Optional(CW3H02502C)

1. Remove the rubber plug and slide the chassis out from the cabinet.
(See Fig.2)

2. Install the drain pan over the corner of the cabinet where you removed
the plug with 4 (or 2) screws.(See Fig.3)

3. Connect the drain hose to the outlet located at the bottom of the drain
pan. You can purchase the drain hose or tubing locally to satisfy your
particular needs. (Drain hose is not supplied). (See Fig.3)

4. Select the most appropriate connection from among the figures to the
right (by considering the hole of the unit) to fit drain pan to your own
unit. (See Fig.3)

5. Slide the chassis back into the cabinet. Reinstall the cabinet screws.
Secure the cabinet to chassis by using screws. (See Fig.4)

VENTCLOSE

OPEN

Part

A

Part

B

Drain pipe

Drain cap

Fig. 4

Fig. 3

Fig. 2

O

F
F
/
O

N

O
P
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R
A

T
I
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N

T
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P

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HI
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m
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Remove the

rubber plug

O

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O

N

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N

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P

/

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ET

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s

s

R

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m

o

t

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C

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n

t

r

o

l

DRAIN HOSE
Inside diameter 17mm (5/8")

DRAIN
PAN

CABINET

SCREW

—6—

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Open the inlet grille upward or downward.

2. Remove the screw which fastens the front grille.

3. Pull the front grille from the right side.

4. Remove the front grille. (See Fig. 1)

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

NOTE: Mark ∆ of inlet grille means opening direction.

2.1.2 CABINET

1. After disassembling the FRONT GRILLE, remove
the screws which fasten the cabinet at both sides.
Keep these for later use.

2. Remove the two screws which fasten the cabinet
at back. (See Fig. 2)

3. Pull the base pan forward.

2.1.3 CONTROL BOX

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

2. Pull the base pan forward so that you can remove
the 2 screws which fasten the cover control at the
right side. (See Fig. 3)

3. Remove the 3 screws which fasten the control
box. (See Fig. 3)

4. Discharge the capacitor by placing a 20,000 ohm
resistor across the capacitor terminals.

5. Disconnect two wire housings in the control box.

6. Pull the control box forward completely.

7. Re-install the components by referring to the
removal procedure. (See Fig. 3)
(Refer to the circuit diagram found on page 28 in
this manual and on the control box.)

2. DISASSEMBLY INSTRUCTIONS

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

Figure 1

Figure 2

Figure 3

—7—

2.2 AIR HANDLING PARTS

2.2.1 COVER (AT THE TOP)

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

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

3. Remove 11 screws which fasten the brace and
covers.

4. Remove the covers and the brace. (See Fig. 4)

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

2.2.2 TURBO

1. Remove the cover. (Refer to section 2.2.1)

2. Remove the 3 screws which fasten the
evaporator at the left side and the top side.
(See Fig. 4)

3. Move the evaporator sideward carefully.

4. Remove the orifice from the air guide carefully.

5. Remove the clamp spring which is clamped to the
boss of turbo by hand plier. (See Fig. 5)

6. Pull the blower outward, without touching blades.
(See Fig. 6)

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

2.2.3 FAN

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

2. Remove the brace and shroud cover.
(Refer to section 2.2.1)

3. Remove the 5 screws which fasten the condenser.

4. Move the condenser sideways carefully.

5. Remove the clamp which secures the fan.

6. Remove the fan. (See Fig. 7)

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

Figure 4

Figure 5

Figure 6

Figure 7

—8—

2.2.4 SHROUD

1. Remove the fan. (Refer to section 2.2.3)

2. Remove the 2 screws which fasten the shroud.

3. Remove the shroud. (See Fig. 8)

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

2.3 ELECTRICAL PARTS

2.3.1 MOTOR

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

2. Remove the cover control and disconnect a wire
housing in control box. (Refer to section 2.1.3)

3. Remove the blower. (Refer to section 2.2.2)

4. Remove the fan. (Refer to section 2.2.3)

5. Remove the 4 screws which fasten the motor.
(See Fig. 9)

6. Remove the motor.

7. Re-install the components 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 by using a Refrigerant
Recovery System.

3. Disconnect the 3 leads from the compressor.

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. (See Fig. 10)

6. Remove the compressor.

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

2.3.3 CAPACITOR

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

2. Remove the screw which fasten the display panel.

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. (See Fig. 11)

6. Disconnect all the leads of capacitor terminals.

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

Figure 8

Figure 9

Figure 10

Figure 11

—9—

2.3.4 POWER CORD

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

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

3. Disconnect the grounding screw from the control
box.

4. Disconnect 2 receptacles.

5. Remove a screw which fastens the clip cord.

6. Pull the power cord. (See Fig. 12)

7. Re-install the component by referring to the
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
fitted to the unit.)

2.3.5 THERMISTOR

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

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

3. Disconnect the thermistor terminals from main
P.C.B assembly.

4. Remove the thermistor.

5. Re-install the components by referring to the
removal procedure above. (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 13

Figure 12

Figure 14

—10—

2.4 REFRIGERATION CYCLE

2.4.1 CONDENSER

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

2. Remove the brace and the shroud cover.
(Refer to section 2.2.1)

3. Remove the 5 screws which fasten the condenser.

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

5. Remove the condenser.

6. Re-install the components by referring to notes.
(See Fig. 15)

2.4.2 EVAPORATOR

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

2. Remove the top cover and the brace.
(Refer to section 2.2.1)

3. Discharge the refrigerant completely.

4. Remove the 3 screws which fasten the evaporator
at the left side and the top side.

5. Move the evaporator sideward carefully and then
unbraze the interconnecting tube at the evaporator
connectors.

6. Remove the evaporator.

7. Re-install the components by referring to notes.
(See Fig. 16)

2.4.3 CAPILLARY TUBE

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

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

3. After discharging the refrigerant completely,
unbraze the interconnecting tube at the capillary
tube.

4. Remove the capillary tube.

5. Re-install the components by referring to notes.

Figure 15

Figure 16

Discharge the refrigerant system using Freon

TM

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

TM

. 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

TM

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 refrigerant from unit
completely, remove the desired component, and
unbrace the pinch-off tubes.

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

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

5. Evacuate as follows.

1) Connect the vacuum pump, as illustrated Fig.

17A.

2) Start the vacuum pump, slowly open manifold

valves A and B with two full turns
counterclockwise and leave the valves closed.
The vacuum pump is now pulling through valves
A and B up to valve C (Figure 17B) by means of
the manifold and entire system.

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

until 600 microns of vacuum 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 Fig. 17B.
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 Fig. 17B.
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 30 lbs (0.2MP).
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 brazing rod and
braze 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 slightly
loosen the 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.

CAUTION

—12—

Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pinch-off tool
capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service
valve.

A

COMPOUND GAUGE

EVAPORATOR

(LOW PRESSURE SIDE)

COMPRESSOR

CAPILLARY TUBE

CONDENSER
(HIGH PRESSURE SIDE)

SEE INSETS

BELOW

MANIFOLD

GAUGE

B

Figure 17A-Pulling Vacuum

Figure 17B-Charging

A

B

EXTERNAL
VACUUM PUMP

LOW

B

HI

A

CHARGING

CYLINDER

C