Panasonic Cs W34bd2p Cs W43bd2p Series Repair Manual

							 1 SERVICE INFORMATION 2
 2 FEATURES 
3
 3 SPECIFICATION (HEAT PUMP TYPE) 
9
 4 SPECIFICATION (COOLING ONLY TYPE) 
14
 5 TECHNICAL DRAWING 
20
 6 CIRCUITDIAGRAM 
26
 7 OPERATING INSTRUCTION 
42
 8 REFRIGERATION CYCLE 
44
 9 OPERATIO N RANGE 
47
 10  PIPE LENGTH 
48
 11  OPERATING CHARACTERISTIC 
50
 12  FAN PERFORMANCE 
51
 13  SAFETYDEVICE 
54
 14  COMPONENT SPECIFICATION 
55
© 2002 Matsushita Air-Conditioning Corp. Sdn. Bhd.
(183914D). All rights reserved. Unauthorized copying
and distribution is a violation of law.
CS-W24BD2P CU-W24BBP5
CS-W28BD2P CU-W28BBP5
CS-W28BD2P CU-W28BBP8
CS-W34BD2P CU-W34BBP8
CS-W43BD2P CU-W43BBP8
CS-W24BD2P CU-V24BBP5
CS-W24BD2P CU-V24BBP8
CS-W28BD2P CU-V28BBP5
CS-W28BD2P CU-V28BBP8
CS-W34BD2P CU-V34BBP8
CS-W43BD2P CU-V43BBP8
 15  CAPACITY AND POWERCONSUMPTION 57
 16  DISCHARGE AND SUCTION PRESSURE 
60
 17  SOUNDDATA 
61
 18  TWIN OPERATIO N 
66
 19  WIRING MISTAKE PREVENTION 
71
 20  TEST OPERATIO N AND SELF DIAGNOSIS 
72
 21  SETTING OF SAVEENERGY AND THERMISTOR SWITCH 
76
 22  GROUP CONTROL 
77
 23  TROUBLE SHOOTING  
78
 24  EMERGENCY OPERATIO N 
84
 25  CONTROL 
85
 26  INSTALLA TION (INDOOR UNIT) 
96
 27  INSTALLA TION (OUTDOOR UNIT) 
108
 28  REPLACEMENT PARTS 
120
AIR CONDITIONER
CONTENTS
 Page  Page
ORDER NO. MAC0201010C2 
						

							1 SERVICE INFORMATION
Notice of Address setting for NEW Cassette / NEW Outdoor Unit.
The new Ceiling / New Outdoor models are possible to have address setting fortwin / triplecontrol or group control by
automatic when main powersupply is switched on.
(Manual address setting is also possible by using Dip switch on Indoor unit P.C. board.) However,this address setting isonly
possible when made proper wiring connection and also Indoor unit should be original virgin unit
.
1.1. Example of trouble at test operation
If found out as following phenomenon at test operation on site, it may have possibility of wrong address setting.
Theref ore, please ensure of the address setting.
 1. LCD display of wiredremote control had not illuminate although the main powersupply switch is ‘on’.
 2. LCD display had indicated as normal illumination when power supply switch is ‘on’, however outdoo r unit cannot be operated.
(But, it is necessary to take 3 to 5 minutes for outdoor unit to start from the timing of remote control ON/OFF switch is ‘on’.)
 3. P.C. board had memorized wrong setting information.
 a. If main power supply is switched ‘on’ with the wrong connection.
 b. Whenchanging the connection or combination of units due to re-installation etc.
 
    • 
• •  • 
W hen changing the system from twin to triple (triple to twin).
 
    • 
• •  • 
W hen changing the system from group control to normal one to one system.
 
    • 
• •  • 
W hen making the replacement of units as master and slave etc.
1.2. Caution of test operation
Do not touch the remote control switch and do not change any wirings for one minute when the main powersupply switch is ‘on’.
(Because the unit is having automatic address setting during the first one minute.)
1.3. Caution during automatic address setting
When mainpower supply switch is ‘on’, the P.C. board willautomatically memorized the connecting system.
Consequently , when initial power supply is ‘on’, there will not be interchangeability of units even of the same type and same
capacity unit. Theref ore unable to connect the unit to anothe r system.
2 
						

							2.1. Variety of excellent features
2.1.1. Compact design
 
    • 
• •  • 
The height is only 29cm (2.5 HP model and 3 HP model)
and can be installe d even where the space is limited.
2.1.2. Automatic restart function
 
    • 
• •  • 
W hen the electric power comes back after a power failure,
the unit itself automatically restarts the operation in the pre-
failure mode.
2.1.3. Auto fanmode (indoor unit)
 
    • 
• •  • 
Auto fan mode is added beside s Hi, Me and Lo.
It automatically adjusts the fan speed according to the
indoor temperature.
2.1.4. Dry mode function
 
    • 
• •  • 
Dry mode can make a comfortable indoor environment
during wet season.
2.1.5. Quiet operation
 
    • 
• •  • 
The sound level is as low as 42db (A) for 3 HP model and
suitable for offices , shops, homes etc., where quiet
operation is essential.
2.1.6. Low ambient cooling operation
 
    • 
• •  • 
Cooling is possible to temperature as low as -5°C
2.1.7. Automatic changeover function
(heat pump models)
 
    • 
• •  • 
The unit automatically switches between cooling and
heating in accordance with operating load in order to
maintain a comfortable indoor temperature.
2.1.8. Hot start system
(heat pump model)
2 FEATURES
3 
						

							[Product features]
2.2.1. Low-noise design improves in
surrounding areas
 1. The noise-suppressing winglet fan is a result of new
research into vane design theory. The unique curved shape
suppresses the generation of vortexes, thus reduces air
flow noise.
 2. The adoption of double -orifice rings reduces air passage
resistance.
 3. Strengthening of the noise insulation materials in the
compressor and the sealing-in of mechanical noise allows
vibration noise to be greatly enclosed and suppressed.
 4. The heat exchan ger has an L-shaped design to allow air to
flow more smoothly.
 5. Noise is automatically reduced further during night time
operation with lower outdoor air temperatures.
2.2.2. Automatic restart function
When theelectric power resumes after a power failure, the unit
will automatically restarts the operation in the pre-failure mode.
2.2.3. Low ambient cooling operation
Cooling operation is possible at outdoor temperature of -5°C.
2.2. New low-noise outdoor units
2.3. Greatly improved workability increases system renewal capability
4 
						

							2.3.1. Pipes that are one size larger can
also be connected for renewal
 
    • 
• •  • 
If renewing the system, existing refrigerant pipes can be
utilized so that only the indoor units need to be replaced.
 
    • 
• •  • 
For example, liquid and gas pipesfrom 10years ago can be
connected to current pipes with the same size for one size
larger. Effective utilization of materials reduces working
time and trouble. (Adaptor sockets are not supplie d.)
2.3.2. Additional refrigerant charging
unnecessary for 30 m
 
    • 
• •  • 
All models do not require any additio nal charging of
refrigerant for 30 m of pipe length. This makes installa tion
much easier.
2.3.3. Drain water dripping-prevention
structure
 
    • 
• •  • 
The base of the outdoo r unit is provided with a single drain
hole in order to prevent drain water from leaking out of the
unit. Body connecting a drain elbow and a discharge pipe,
water leakages can be prevented even when the unit is
installe d against a wall.
2.3.4. Space saving design allows units
to be installed side by side
continuously
 
    • 
• •  • 
Servicing after installa tion can be carried-out by removing
the front covers.
2.3.5. Easy test operation
 
    • 
• •  • 
Test operation can be carried out for both indoor and
outdoor units.
2.3.6. Long pipe design
Max piping length: 50 (m)24BB~43BB
Height difference/equivalent pipe length30/50
2.3.7. Internal pipe connection
 
    • 
• •  • 
Pipes are connected inside the units (inside the side
covers), making the final appearance more attractive.
 
    • 
• •  • 
Pipes can be diverted outward in any of four directions
(forward, right, down, rear).
 
    • 
• •  • 
Small liquid pipe diameters of 9.52mm for 43BB model,
making installa tion work much easier.




 

Liquid-side pipe diameters (mm): 9.52 (43BB~50BB
models)
2.3.8. Centralized draining method
 
    • 
• •  • 
Even when multiple outdoo r units are installe d to a wall, the
drain outlets can be concentrated into a single drain pipe.
This makes installa tion easier and also improve
appearance.
2.4. A brand-new control method
using the latest in technology
2.4.1. Powersupplywiring is also easier
Power supply wiring and other wiring tasks can be carried out
more easily.
 
    • 
• •  • 
Twin non-polar wires used to connect indoor and outdoo r
units.
 
    • 
• •  • 
Adoption of connection error prevention circuits for drives
wires and signal wires. If a connection error is made, the
relay does not operate and current does not flow to the
circuit boards.
5 
						

							2.4.2. Separate indoor/outdoor unit
power supplies
The power supply can be connected to (1) just the outdoo r
units, or (2) to both indoor and outdoor units.
2.4.5. Twin operation
 
    • 
• •  • 
Simultaneous air conditioning of wide spaces and corners is
possible. Indoor units of different horsepowers and models
can even be used in combination.
 
    • 
• •  • 
Master unit and slave-units can be set automatically in twin
systems. No address setting is necessary.
 
    • 
• •  • 
Multiple indoor units can be operated simultaneousl y with a
single remote control. Note that individual operation is not
possible.
2.4.3. Automatic settinginitialization
function (Remote control and
Indoor unit)
In accordance with the indoor and outdoor units connected and
the connection methods, conditions such as the configuration
(twin or triple format) and remote-control functions such as
cooling only or heat pump model are automatically detected
and set instantly.
2.5. New refrigerant Series [R407C]
pipe installation
2.5.1. Procedure
 
    • 
• •  • 
The new refrigerant (R407C) has a different composition to
the previously-used refrigerant (R22), so some contents
and method of pipe installa tion and charging work are
different from before. Care should be taken whencarrying
out this work.
2.5.2. Installation and precautions
2.5.2.1. Before installation
 1. Determine the installa tion division.
 2. Check the refrigerant to be used.
 
    • 
• •  • 
Check that the refrigerant is R407C .
 
    • 
• •  • 
Check that the gauge pressure is at a maximum of 3.3
MPa.
 3. Make a drawing of the Installation.
2.5.2.2. Installation
 1. Install the sleeve and the insert.
 2. Install the indoor unit.
 3. Install the refrigerant piping.
 
    • 
• •  • 
Pipe materials
 
    • 
• •  • 
Refrigerant pipes which were previously used to carry
R22 must not be re-used. If replacing the indoor and
outdoo r units, be sure to replace all refrigerant pipes
also.
 
    • 
• •  • 
Check the pipe thickness.
 
    • 
• •  • 
Clean the inside of the pipes.
2.4.4. Group control equipment
6 
						

							 
    • 
• •  • 
W hen storing pipes, seal both ends of the pipes and
store them indoors to prevent water, dust and other
foreign particles from getting inside.
 
    • 
• •  • 
Take care not to let any foreign particles (oxide scales,
water or dirt) get inside the refrigerant lines (same as for
R22).


Refrigerant pipe storing
LocationInstallation periodStoring method
Outdoors1 month or morePinching
Less than 1 monthPinching or taping
IndoorsAny
 
    • 
• •  • 
Pinching method
Close off the ends of the pipes with pliers or similar tool
and seal the openin g by brazing.
 
    • 
• •  • 
Taping method
Wind PVCtape around the ends of the pipes to seal the
openin gs.
 
    • 
• •  • 
Do not work for refrigerant piping on outdoo r on rainy
days.
 
    • 
• •  • 
Seal by brazing.
 
    • 
• •  • 
Be sure to use only a non-oxidizing brazing material.
(Use nitrogen. Anti-oxidants cannot be used.)
 
    • 
• •  • 
W hen brazing pipes together, or when brazing copper
pipes and copper joints, use a brazing material (Bcup-3)
which does not require flux.
 
    • 
• •  • 
Flare processing and ester oil.
 
    • 
• •  • 
Sealing can be improved by applyin g ester oil or mineral
oil (the minimum amoun t necessary) to flares and flange
connections.
 
    • 
• •  • 
Due to the high hygroscopic tenden cy for ester oil, do
not mix or use any other impurities. (This can cause
deterioration of the compressor oil and problems with
the compressor.)
 
    • 
• •  • 
After preparing the refrigerant pipes, close both ends of
the pipes by brazing if not immediately connectingthem.
 
    • 
• •  • 
A torque wrench must be used.
 4. Install the drain pipe.
 5. Install the ducts. 6. Insulate against heat.
 7. Carry out the electrical work.
 
    • 
• •  • 
Connecting cables and power cables.
 8. Make all necessary settings.
 9. Prepare the outdoor unit foundation.
 10. Install the outdoor unit.
 11. Air-tightness test.
For the final check, there should be no pressure drop when
3.3 MPa is applied for 24 hours.
 12. Vacuum drying.
Vacuum draw time60 min. or more
* Vacuum pump capacity 60 l/min. or higher
 
    • 
• •  • 
Drawing the vacuum will remove any moisture.
 
    • 
• •  • 
The pressure after vacuum drawing should be 755
mmHg or less.
 
    • 
• •  • 
Use a special vacuum pump (with backflow-prevention
mechanism).
 
    • 
• •  • 
Gas must never be used for air purging.
 13. Additio nal refrigerant charging.
 
    • 
• •  • 
Check that refrigerant volume is correct.
 
    • 
• •  • 
Be sure to charge refrigerant in liquid state.
 
    • 
• •  • 
Always charge in liquid state.
When therefrigerant is charged from thecylinde r, the
composition may change greatly (compounds which do
not easily evaporate may remain inside the cylinde r), so
the refrigerant must always be charged in a liquid state.
(It is recommended that a manifo ld with sight glass be
used.)


Boiling point at normal atmospheric pressure
(reference)
RefrigerantHFC32HFC125HFC134a
Boiling point-52°C-49°C-26°C
 
    • 
• •  • 
Use a special gauge manifo ld and charging hose.
 
    • 
• •  • 
If refrigerant leaks occur, replace all of the refrigerant
(same as for R22).
 
    • 
• •  • 
Note that a R22 leak detector cannot be use to detect
leaks.
 
    • 
• •  • 
Refer to the Installation Instructions include d for the
correct charging amoun t.
 
    • 
• •  • 
Make a note of additio nal refrigerant charging amoun ts
in the record table.
7 
						

							 14. Test operation and adjustment.
 15. Organize documentatio n before handover.
 16. Hando ver and explan ation of operation.
 
    • 
• •  • 
Ventilation of closed rooms
R407C is a non-fla mmable refrigerant with low toxicity ,but in the gas state its specific gravity is heavier than
that of air, and so if leaks occur in a closed room,
suffoca tion may occur. Toxic gases may also be
generated if it comes into direct contact with flames, so
adequate ventilation must be provided.
8 
						

							3 SPECIFICATION (HEAT PUMP TYPE)
3.1. CS-W24BD2P / CU-W24BBP5
ITEM / MODELIndoor UnitOutdoor unit
Main BodyCS-W24BD2PCU-W24BBP5
Cooling CapacitykW6.30
(BTU/h)(21,500)
Heating CapacitykW7.10
(BTU/h)(24,200)
Refrigerant Charge-lessm30
Standard Air Volume for High Speedm3/minHi 18
cfmHi 636
External Static PressuremmAqHi 10-
PaHi 98
Air InletBackward SuctionBack sided Suction
Air OutletFront blow-outFront blow-out
Outside Dimension (H x W x D)mm290 x (1000 + 100) x 500900 x 900 x 320
Net Weightkg (lbs)43 (95)81 (179)
Piping
ConnectionRefrigerantGasmm (inch)O.D Ø 15.88 (5/8) Flared Type
Liquidmm (inch)O.D Ø 6.35 (1/4) Flared Type
DrainmmFemale screw RC1 (PT1)I.DØ 20 x 1
CompressorType, Number of Set-Hermetic-1 (Rotary), 1
Starting Method-Direct on-line starting
MotorType-2-pole single phase induction motor
Rated OutputkW-1.9
FanType, Number of SetSirocco fanProp. fan
Air Volume ControlThree-Step and Auto mode-
(Remote Control)
MotorType4-pole single phase induction motor6-pole single phase induction motor
Rated OutputkW0.150.05
Air-heat ExchangerLouvre-fin typeX-Louvre-fintype
Refrigerant ControlCapillary tubeCapillary tube
Refrigerant Oil (Charged)L-MEL56 (1.3)
Refrigerant (Charged)kg (oz)-R407C 2.8 (99)
Running
AdjustmentControl SwitchWired RemoteControl-
Room Temperatu reThermosta t (Main Body)-
Safety DevicesInternal protector for compressor, Internal thermostat for F.M, Crankcase
heater, High pressure switch, Current Transformer
Noise LeveldB (A)Hi 40 Lo 36Cooling 52, Heating 53
Power level dBHi 55 Lo 51Cooling 65, Heating 66
 1. Coolin g capacities are based on indoor temp. 27°C D.B. (80.6°F D.B.), 19.0°CW.B.(66.2°F W.B.) and outdoor air temp. 35°C
D.B. (95°F D.B.), 24°CW.B.(75.2°F W.B.)
 2. Heating capacities are based on indoor temp. 20°C D.B. (68.0°F D.B.) and outdoor air temp. 7°C D.B. (44.6°F D.B.), 6°CW.B.
(42.8°F D.B.)
ELECTRICAL DATA (50Hz)
MODEL / ITEMCS-W24BD2P/CU-W24BBP5
Condition by JIS B 8615
VoltsV220230240
PhaseSingleSingleSingle
Input PowerkWCool2.562.562.56
Heat2.602.602.60
Running CurrentACool11.711.210.8
Heat11.911.410.9
Starting CurrentA646668
Power Factor%Cool999999
Heat999999
*Power Factor means total figure of compressor, indoor fan motor and outdoor fan motor.
PanasonicPower sourceAC, 1~220V, 230V, 240V 50Hz
9 
						

							3.2. CS-W28BD2P / CU-W28BBP5
ITEM / MODELIndoor UnitOutdoor unit
Main BodyCS-W28BD2PCU-W28BBP5
Cooling CapacitykW7.10
(BTU/h)(24,200)
Heating CapacitykW8.00
(BTU/h)(27,300)
Refrigerant Charge-lessm30
Standard Air Volume for High Speedm3/minHi 20
cfmHi 706
External Static PressuremmAqHi 10-
PaHi 98
Air InletBackward SuctionBack sided Suction
Air OutletFront blow-outFront blow-out
Outside Dimension (H x W x D)mm290 x (1000 + 100) x 500900 x 900 x 320
Net Weightkg (lbs)43 (95)81 (181)
Piping ConnectionRefrigerantGasmm (inch)O.D Ø 15.88 (5/8) Flared Type
Liquidmm (inch)O.D Ø 9.52 (3/8) Flared Type
DrainmmFemale screw RC1 (PT1)I.DØ 20 x 1
CompressorType, Number of Set-Hermetic-1 (Rotary), 1
Starting Method-Direct on-line starting
MotorType-2-pole single phase induction motor
Rated OutputkW-2.0
FanType, Number of SetSirocco fanProp. fan
Air Volume ControlThree-Step and Auto mode-
(Remote Control)
MotorType4-pole single phase induction motor6-pole single phase induction motor
Rated OutputkW0.150.05
Air-heat ExchangerLouvre-fin typeX-Louvre-fintype
Refrigerant ControlCapillary tubeCapillary tube
Refrigerant Oil (Charged)L-MEL56 (1.3)
Refrigerant (Charged)kg (oz)-R407C 3.3 (116)
Running
AdjustmentControl SwitchWired RemoteControl-
Room Temperatu reThermosta t (Main Body)-
Safety DevicesInternal protector for compressor, Internal thermostat for F.M, Crankcase
heater, High pressure switch, Current Transformer
Noise LeveldB (A)Hi 41 Lo 37Cooling 53, Heating 54
Power level dBHi 56 Lo 52Cooling 66, Heating 67
 1. Coolin g capacities are based on indoor temp. 27°C D.B. (80.6°F D.B.), 19.0°CW.B.(66.2°F W.B.) and outdoor air temp. 35°C
D.B. (95°F D.B.), 24°CW.B.(75.2°F W.B.)
 2. Heating capacities are based on indoor temp. 20°C D.B. (68.0°F D.B.) and outdoor air temp. 7°C D.B. (44.6°F D.B.), 6°C W.B.
(42.8°F D.B.)
ELECTRICAL DATA (50Hz)
MODEL / ITEMCS-W24BD2P/CU-W28BBP5
Condition by JIS B 8615
VoltsV220230240
PhaseSingleSingleSingle
Input PowerkWCool2.862.862.86
Heat3.023.023.02
Running CurrentACool13.112.512.5
Heat13.813.212.7
Starting CurrentA687072
Power Factor%Cool999995
Heat999999
*Power Factor means total figure of compressor, indoor fan motor and outdoor fan motor.
PanasonicPower sourceAC, 1~220V, 230V, 240V 50Hz
10