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Panasonic CS-A181KE, Service Manual, Page: 2 / 50

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MAC9512086C2

CS-A181KE

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 dealt with
in this service information by anyone else could result in serious injury or death.

• High Efficiency

• High Efficiency Airflow Circuit

• Compact Design

• Removable and Washable

Front Panel

• Auto Restart after Power Failure

• Long Piping up to 25m

• Deodorizing Air Filter

• Deodorizing Control during

operation

Features

PRECAUTION OF LOW TEMPERATURE

In order to avoid frostbite, be assured of no refrigerant leakage during the installation or repairing of refrigeration circuit.

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6/21/00, 9:54 AM

1

Summary of Contents for CS-A181KE

Page 1: ...2 Installation Information 23 24 3 way Valves 25 31 Servicing Information 32 35 Troubleshooting Guide 36 37 Technical Data 38 40 Exploded View 41 43 Replacement Parts List 42 44 Electronic Parts List 45 46 CS A181KE CU A181KE CS A241KE CU A241KE ORDER NO MAC9811041C2 1999 Matsushita Air Conditioning Corp Sdn Bhd 183914D All rights reserved Unauthorized copying and distribu tion is a violation of l...

Page 2: ...enced professional technicians Any attempt to service or repair the product or products dealt with in this service information by anyone else could result in serious injury or death High Efficiency High Efficiency Airflow Circuit Compact Design Removable and Washable Front Panel Auto Restart after Power Failure Long Piping up to 25m Deodorizing Air Filter Deodorizing Control during operation Featu...

Page 3: ... Mode MODE TIME Time Timer Setting Hours and minutes setting Clock Setting Current time setting Sleep Mode Operation OFF ON SLEEP Indoor Fan Speed Selection FAN SPEED h j k Low Speed l h j k Medium Speed lll h j k High Speed lllll AUTOFAN Automatic Fan Speed SWING Automatic Airflow Direction Control MANUAL Airflow Direction Manual Control Airflow Direction Control 24 hour OFF ON Real Timer Setting...

Page 4: ...izontal airflow Airflow Direction Control The indoor fan stops until the indoor heat exchanger temperature over 30 C The indoor fan operates at SLo and Lo when indoor heat exchanger temperature reaches 30 C 42 C Hot start is completed when indoor heat exchanger reaches 42 C Auto Operation Switch Used when the remote control cannot be used AUTO OFF ON Remote Control Signal Receiving Sound Control I...

Page 5: ...i speed when outdoor temperature reaches to 31 C Lo speed when outdoor temperature reaches to 29 C For Heating Operation Hi speed when outdoor temperature reaches to 13 5 C Lo speed when outdoor temperature reaches to 15 5 C For Over heating Protection the Fan is switched ON or OFF depending on the piping temperature and the outdoor tem perature Overload Protector Inner protector Compressor Fan Mo...

Page 6: ...00 17 600 6 20 6 05 21 100 20 600 2 9 6 1 Single 240 220 50 Cooling 11 2 395 Heating 11 6 409 Cooling 12 4 437 Heating 12 9 455 Cooling 13 7 480 Heating 14 2 500 Cooling 11 8 416 Heating 12 2 430 Cooling High 43 43 Low 38 38 Cooling High 56 54 Heating High 42 42 Low 38 38 Heating High 57 55 Cooling 2 12 1 98 Heating 2 19 2 04 Cooling 10 9 10 0 Heating 11 2 10 2 Cooling 2 45 2 60 Heating 2 83 2 97 ...

Page 7: ...ize W H L CS A181KE Evaporator Copper Aluminium Slot Fin 2 14 21 732 294 25 4 Electronic Control P P Honeycomb µF VAC µF VAC Specifications are subject to change without notice for further improvement Unit mm cm3 g oz mm s min mm 769 2 732 9 CU A181KE Condenser Copper Aluminium Corrugated Fin 2 26 14 660 4 44 Capillary Tube SUNISO 4GDID or ATMOS M60 700 1 590 56 1 Inner Protector Cooling 690 Heati...

Page 8: ...1 800 7 80 7 55 26 600 25 700 3 8 8 0 Single 240 220 50 Cooling 13 1 462 Heating 14 1 497 Cooling 14 3 504 Heating 15 4 542 Cooling 15 7 550 Heating 16 9 600 Cooling 14 3 504 Heating 15 4 542 Cooling High 47 47 Low 41 41 Cooling High 61 59 Heating High 46 46 Low 41 41 Heating High 62 60 Cooling 2 86 2 67 Heating 2 96 2 74 Cooling 14 0 13 2 Heating 14 3 13 5 Cooling 2 26 2 40 Heating 2 64 2 76 66 C...

Page 9: ...ial Fin Type Row Stage FPI Size W H L µF VAC µF VAC Specifications are subject to change without notice for further improvement 769 2 732 9 CS A241KE Evaporator Copper Aluminium Slot Fin 2 14 21 732 294 25 4 Electronic Control P P Honeycomb CU A241KE Condenser Copper Aluminium Corrugated Fin 2 26 16 660 4 44 Capillary Tube SUNISO 4GDID or ATMOS M60 1 130 1 770 62 5 Inner Protector Cooling 700 Heat...

Page 10: ...n ports 980 290 195 59 direction Air intake Air outlet direction Left piping hole Right piping hole 6 Lower piping hole 52 60 165 2 100 Approx Front View Top View Side View 48 5 39 892 49 276 7 59 5 165 100 100 Slot 2 places Slot 2 places Indoor unit external dimensions line Installation plate Left piping hole Arrow Arrow Centre Right piping hole Installation plate positioning gauge 350 7 561 13 5...

Page 11: ... at gas side 22 106 5 100cm 10cm 10cm Required space for installation Anchor bolt pitch 330 x 540 Unit mm COOLING HEATING PROCESS STRAINER 3 WAY VALVE 3 WAY VALVE INDOOR UNIT OUTDOOR UNIT HEAT EXCHANGER EVAPORATOR SENSOR SENSOR PIPE TEMP CAPILLARY TUBE CHECK VALVE COMPRESSOR OIL SEPARATOR HEAT EXCHANGER CONDENSER 4 WAY VALVE ACCUMULATOR SUB TEMP PIPE SENSOR ONLY OIL V SENSOR INTAKE AIR TEMP INTAKE...

Page 12: ...LER 4 4 3 3 TRANSFORMER2 FUSE 3 15A FUSE 3 15A ZNR2 RY HOT ZNR1 COMP F M RY V RY OFF RY DEICE 2 WAY TRANSFORMER1 RY H L TRANS FORMER 4 WAY VALVE VALVE CU A241K ONLY O L P P C B RECEIVER SENSOR 6C S M INDICATORS 5C 4C SENSOR 4C ZNR3 ZNR4 3 15A FUSE 3C F M ELECTRONIC CONTROLLER THERMAL FUSE 102 C Indicates the number of core wires Example 6C 6 core wires C Indicates the electronic control unit MAIN ...

Page 13: ...TDOOR UNIT BRW BLU RED INDOOR UNIT TERMINAL RED GRY HOT2 BLK HOT1 RED DEICE GRY ELECTRONIC COMPRESSOR V BLU 2 WAY VALVE COIL BLU BLK WHT HOT RED BLUE YELLO TRADE M COMPRESSOR 3 2 1 WHT WHT WHT CN DISP WHT 3 1 113 C THERMAL FUSE CN FUSE1 BLU TEMP O L P ZNR4 T 3 15A L 250V FUSE ZNR WHT YLW BLU ZNR3 FM2 ORG FM1 BRW CONTROLLER 2 4 3 3 2 1 2 1 2 3 4 6 5 T BLK AC BRW COMP BLK CN FUSE2 REMOTE SW1 5 4 3 2...

Page 14: ...ill start automatically if it has stopped for 7 minutes even if the room temperature is below the compressor ON temperature Time Delay Safety Control 3 minutes 7 minutes Time Saved Control Anti Freezing Control If the temperature of the indoor heat exchanger falls continously below 2 C for 4 minutes the compressor turns off to protect the indoor heat exchanger from freezing The fan speed setting r...

Page 15: ...escription of operation d g Time Delay Safety Control waiting for 3 minutes g h 60 sec Forced Operation h o 7 min Time Saved Control q t Anti Freezing Control v y Outdoor Fan Control Indoor Fan Comp SLo SLo SLo SLo ON ON OFF stop stop stop 30 stop 30 160 1 40 40 20 2 a b c d e f g h i j k l m n o p q r s t u v w x y z Basic Time Compressor Indoor Fan Outdoor Fan Operation LED 4 Way Valve 2 Way Val...

Page 16: ...ture Indoor Fan Compressor and Outdoor Fan Stop for 6 minutes Once the compressor stops it will not start for 3 minutes during Cooling operation Same as Anti Freezing Control for Cooling Mode operation For Soft Dry region 6 minutes waiting is valid during compressor stops When Automatic Fan Speed is selected at Remote Control during Soft Dry Operation Fan speed rotates at SLo speed Deodorizing Con...

Page 17: ...ed Operation q t Anti Freezing Control Operation Stop a b c d e f g h i j k l m n o p q r s t u v Basic Time Compressor Indoor Fan Outdoor Fan Operation LED 4 Way Valve 2 Way Valve A241K 1 1 1 1 6 6 6 6 4 1 Cooling ON Cooling OFF Soft Dry OFF ON 1 5 C 1 0 C SLo SLo SLo SLo SLo SLo SLo SLo SLo SLo SLo SLo 6 Intake Air Temperature Set Temp Indoor Heat Exchanger Temp 10 C 2 C ...

Page 18: ...minutes waiting 4 way Valve Control 4 way valve ON during Heating operation except deicing operation When the unit is switched to OFF during Heating operation 4 way valve stays at Heating position for 5 minutes Hot Start Control When Heating operation starts Indoor Fan will not start until the indoor heat exchanger reaches 30 C as diagram shown Hot Start is completed when indoor heat exchanger rea...

Page 19: ...en Automatic Fan Speed is selected at Remote Control during heating operation Fan speed rotates in the range of Me SLo according to the heat exchanger temperature Automatic Fan Speed Mode Heating Operation Time Diagram Description of operation a c Hot start Indoor fan OFF c d Hot start Indoor fan SLo h k o s Indoor fan control controlled during thermostat OFF Blinking Operation Stop Operation or S...

Page 20: ...fter compressor starts for 1 minutes deicing starts Deicing ends when a 12 minutes after deicing operation starts b The outdoor piping temperature rises to about 12 C After deicing operation compressor stops for 30 seconds and 4 way valve stays at cooling position for 10 seconds a Normal Deicing Time Diagram Description of operation a c Deicing operation judging condition established c f Deicing o...

Page 21: ...le the air conditioner is operating operation will continue If current operation is in Cooling Mode including the operation which is a part of Soft Dry Mode operation it will be maintained for 20 seconds at SLo fan speed Then the selected operation mode will continue f Room temperature adjustment The following are added to the setting temperature specified as above g If the value for R72 is change...

Page 22: ...perature will be risen by 2 C at the start of operation and by 3 C one hour later The operation will stop after 8 hours When using together with the Timer the ON Timer has priority 6 Auto Restart Control If there is a power failure operation will be automatically restarted when the power is resumed It will start with previous operation mode and airflow direction Time Delay Safety Control is valid ...

Page 23: ...on louver move up and down in the range shown in the diagram The louver can be stopped by releasing the button at the desired louver position When the remote control is used to stop the opera tion the discharge vent is closed with airflow direction louver When the Delayed ON Timer is set by using the remote control the unit will start operate slightly before the set time so that the room will reac...

Page 24: ...from the condenser is not obstructed There should not be any animal or plant which could be affected by hot air discharged Keep the spaces indicated by arrows from wall ceiling fence or other obstacles Do not place any obstacles which may cause a short circuit of the discharged air If piping length is over 10m additional refrigerant should be added as shown in the table No 1 2 3 4 5 Accessories pa...

Page 25: ...he drainage test remove the air filters and pour water into the heat exchanger Connecting cable 3 CORE WIRE 2 5 mm2 Locally approved cable Vinyl tape Narrow This illustration is for explanation purposes only The indoor unit will actually face a different way Air purifying filter 8 Left and right are identical Bushing Sleeve Putty Gum Type Sealer 5 cm or more 5 cm or more 100 cm or more 10 cm or mo...

Page 26: ...ted manifold gauge Open Connected manifold gauge Open Connected manifold gauge Open Connected manifold gauge Open Connected manifold gauge Works Shipping Evacuation Installation and Re installation Operation Pumping down Transferring Evacuation Servicing Gas charging Servicing Pressure check Servicing Gas releasing Servicing Valve cap Shaft Position Closed With valve cap Closed Clockwise Open With...

Page 27: ...ay valves 6 Tighten the service port caps of both the 3 way valves at a torque of 18 N m with a torque wrench 7 Remove the valve caps of both the 3 way valves Position both of the valves to open using a hexagonal wrench 4 mm 8 Mount valve caps onto both of the 3 way valves Be sure to check for gas leakage Caution If gauge needle does not move from 0 cmHg 0 MPa to 76 cmHg 0 1 MPa in step 3 above ta...

Page 28: ... at the cooling cycle and stop it when the gauge indicates 0 kg cm2 G 0 MPa If the unit cannot be operated at the cool condition weather is rather cool press the Pump Down Switch on the Indoor unit So that the unit can be operated 7 Immediately set the gas side 3 way valve to the close position Do this quickly so that the gauge ends up indicating 1 to 3 kg cm2 G 0 1 MPa to 0 3 MPa 8 Use refrigeran...

Page 29: ...ves to open using a hexagonal wrench 4 mm 9 Mount valve caps onto the 3 way valves Procedure 1 Connect a charging hose with a push pin to the Low and High sides of a charging set and the service port of the 3 way valve Be sure to connect the end of the charging hose with the push pin to the service port 2 Connect the centre hose of the charging set to a vacuum pump 3 Turn on the power switch of th...

Page 30: ...rvice port Confirm whether the pressure indicates more than 0 1 MPa 1 kg cm2 G 3 Connectthechargeset scentrehosetorefrigerant reclaiming equipment 4 Open the valve Low side on the charge set and loosen the hose connected with the Refrigerant Reclaiming Equipment to purge the air from the hose 5 Turnonrefrigerantreclaimingequipmenttocollect the refrigerant until the needle indicates 0 no refrigeran...

Page 31: ...rn on the vaccuum pump to evacuate the unit Confirm that the gauge needle has moved toward 76 cmHg 0 1 MPa Apply the vacuum for approximately 1 hour vaccuum of 4 mmHg or less 3 Close the valves Low side and High side on the charge set turn off the vacuum pump and confirm that the gauge needle does not move approxi mately 5 minutes after the vacuum pump is turned off 4 Disconnect the charge hose fr...

Page 32: ... Be sure to open only the High side valve on the charge set to charge the system from the liquid side high presure pipe If the system cannot be charged with the specified amount of refrigerant operate the compressor until the specifiedamountcanbecharged andthenclosethevalve at the bottom of the charge cylinder 4 Immediately disconnect the charge hoses from both 3 way valve service ports Indoor uni...

Page 33: ...and connector CN STM GREEN of stepping motor from the electronic controller Release the earthwire YELLOW GREEN fromthecontrolboard terminal and sensors from its holders Refer Fig 2 2 Remove the Control Board As shown in Fig 3 remove the 3 screws and release the tab at the top of Control Board Pull the Control Board forward slightly Caution RemovalofDischargeGrillebeforeremoving the control board i...

Page 34: ...ion 4 Remove the Indoor Fan Motor Loosen the Fan Mounting Screw at the junction with Cross Flow Fan Remove the screw that hold the metal plate and remove the metal plate Pull off the Bearing at the left of the Cross Flow Fan and remove the Indoor Fan motor Fig 4 Fig 7 Fan Motor Fan mounting screw Cross Flow Fan Fig 5 Fig 6 Fan Motor Metal plate Screw Bearing ...

Page 35: ... the left side of the evaporator 3 Pull the left side of the evaporator forward slightly and remove the cross Flow Fan B Disassembly of the parts Outdoor Unit Inspection points for the Outdoor Electronic Controller 1 The Electronic Controller Can be seen by removing thecabinetTopplateandFrontplate asshowninthe Fig 10 Screws Evaporator Fig 8 Evaporator Fig 9 Cross Flow Fan Fig 10 Electronic Control...

Page 36: ... two indoor units are installed in the same room in order to prevent operating errors caused by using two remote controls set up the remote control B A switch SW1 The unit is set to A when it is shipped Reset terminal Remote Control Switch By adding a jumper wire to the remote control side and a carbon resistor 1 4 W 10 k to the indoor printed circuit board it is possible to select from 4 types of...

Page 37: ...e difference Less than 8 C at the cooling mode Less than 14 C at the heating mode Troubleshooting Guide Condition Indoor fan speed High Outdoor temperature 35 C at the cooling mode and 7 C at the heating mode Gas pressure MPa kg cm2 G 0 4 0 6 4 6 1 5 2 1 15 21 More than 8 C 15 minutes after an operation is started at the cooling mode More than 14 C 15 minutes after an operation is started at the h...

Page 38: ...is started Electric current during operation becomes approximately 20 lower than the normal value The discharge tube of the compressor becomes abnormally hot nor mally 70 to 90 C The difference between high pressure and low pressure becomes almost zero Electric current reaches a high level abnormally and the value exceeds the limit of an ammeter In some cases a breaker turns off The compressor is ...

Page 39: ...26 24 22 20 30 18 20 22 24 26 28 30 32 34 C Diff 1 5 C Cooling ON Diff 1 5 C 16 16 C Intake Air Temperature Soft Dry OFF Soft Dry ON Diff 1 0 C Thermostat Setting Remote Control 34 24 22 20 18 28 26 30 32 18 20 22 24 26 28 30 C Cooling OFF Set Temperature COMP OFF SET TEMPERATURE COMP ON diff 2 0 C 16 C Thermostat setting remote control 18 28 26 24 22 20 30 C 16 18 28 26 24 22 20 30 32 34 Intake A...

Page 40: ...gth 7 5 m 13 12 11 10 9 14 0 13 5 13 0 12 5 12 0 0 46 0 45 0 44 0 43 0 42 5 6 5 4 5 2 5 0 4 8 4 6 220V 240V I Q Current A Cooling Capacity kW LP O Outlet Gas Side Piping Pressure MPa Air Temperature C I LP Q O 6 4 2 0 2 4 6 8 OUTDOOR AIR TEMPERATURE C Condition Room temperature 20 C Heating operation High fan Piping length 7 5 m 13 12 11 10 9 44 42 40 38 36 1 8 1 7 1 6 1 5 1 4 1 3 6 0 5 5 5 0 4 5 ...

Page 41: ... Outlet Gas Side Piping Pressure MPa Air Temperature C Condition Room temperature 27 19 C Outdoor air temperature 35 24 C Cooling operation High fan I LP Q O Heating Characteristic Piping Length Characteristic Heating 6 4 2 0 2 4 6 8 OUTDOOR AIR TEMPERATURE C Condition Room temperature 20 C Heating operation High fan Piping length 7 5 m 16 15 14 13 12 11 46 44 42 40 38 36 2 2 2 0 1 8 1 6 1 4 8 0 7...

Page 42: ... 41 CS A181KE Exploded View CS A181KE CS A241KE 5 9 7 6 4 3 5 3 1 4 2 7 6 8 1 2 0 V0 V 0 V _ ...

Page 43: ...TIONS INSTALLATION PLATE BAG COMPLETE INSTALLATION SCREW AIR PURIFYING FILTER COMPLETE AIR PURIFYING FILTER NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 CS A181KE CWD50C369 CWD93956 CWA98274 CWH02C058 CWH4580304 CWH64K007 CWB30C222 CWH6002140 CWT25007 1 2 CWE20C574 CWA98267 CWH4612103 CWE24443 CWH10943 CWA28C...

Page 44: ... 43 CS A181KE Exploded View CU A181KE CU A241KE 7 4 3 5 8 3 2 1 2 4 6 7 9 1 0 6 V 9 _ 5 8 ...

Page 45: ... V COIL COMPLETE TERMINAL COVER NUT FOR TERMINAL COVER TUBE ASS Y CAPILLARY TUBE CONTROL BOARD ASS Y CAPACITOR FAN MOTOR CAPACITOR COMPRESSOR HOLDER CAPACITOR TERMINAL BOARD ASS Y ELECTRONIC CONTROLLER FUSE HOLDER FUSE SENSOR COMPLETE HOLDER SENSOR HOLDER SENSOR OVERLOAD PROTECTOR HOLDER OVERLOAD PROTECTOR CABINET FRONT PLATE COMPLETE CABINET REAR PLATE COMPLETE CABINET FRONT PLATE COMPLETE SOUND ...

Page 46: ...RATED CIRCUIT INTEGRATED CIRCUIT INTEGRATED CIRCUIT PHOTO COUPLER TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR TRANSISTOR DIODE BRIDGE DIODE BRIDGE DIODE DIODE DIODE DIODE DIODE DIODE ZENER DIODE ZNR V COIL V COIL NOISE FILTER NOISE FILTER TRANSFORMER TRANSFORMER RELAY ELECTRO MAGNETIC RELAY ELECTRO MAGNETIC SLIDE SWITCH PUSH SWITCH FUSE RESONATOR BUZZER SOUND GENER...

Page 47: ...CU A241KE ONLY A00160 A00160 A00160 A00160 A00160 CU A241KE ONLY XBA2C31TR0 A45ST4 0MGWT SYMBOL IC1 IC2 IC3 IC4 Q1 Q2 D1 D6 DB1 DB2 ZD1 ZNR2 ZNR4 T1 T2 CR1 CR2 RY HOT RY DEICE RY OFF RY H L RY V FUSE X1 DESCRIPTION NAME INTEGRATED CIRCUIT INTEGRATED CIRCUIT INTEGRATED CIRCUIT INTEGRATED CIRCUIT TRANSISTOR TRANSISTOR DIODE DIODE BRIDGE ZENAR DIODE ZNR TRANSFORMER SURGE ABSORBER SURGE ABSORBER RELAY...

Page 48: ...20 10k C23 0 022µ 10k 10k b e c Q3 UN4211 R57 5 1k C39 1000P D7 10k 10k b e c UN4211 Q13 Q14 UN4211 c e b 10k 10k UN4211 Q15 10k 10k b e c R63 10k R62 10k R61 10k D10 D9 D8 C38 1000P R60 14 7k 3 32k R59 1000P C37 D11 D12 D13 10k R64 10k R65 10k R66 R58 510k 7 5 6 C36 1000P R50 3 3k 1W 8 4 R48 620 C35 100V 10µ A54MA165TA5 X 6 D8 D13 A52MPC393C IC6 CN MTR 3 2 1 XH 3 GREEN FAN MOTOR C14 35V 2200µ C17...

Page 49: ...sec 0 sec 3 sec 30 sec When test point Short circuited How to use electronic circuit diagram Indications for resistance a K k M M W watt Not indicated 1 4W b Type Not indicated carbon resister Tolerance 5 metal oxide resister Tolerance 1 TIMER TABLE ELECTRONIC CIRCUIT DIAGRAM REMOTE CONTROL 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 ...

Page 50: ...Printed in Malaysia P990102500YW MACC ...

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