Panasonic Cs A7dkd Cs A9dkd Cs A12dkd Repair Manual

							 2. Set the vertical airflow direction louver to the horizontal
position.
 3. Slide down the 2 caps on the front grille as shown in the
illustration at right, and then remove the 2 mounting screws.
 4. Pull the lower section of the front grille towards you to
remove the front grille.
When reinstalling the front grille, first set the vertical
airflow direction louver to the horizontal position and
then carry out above steps 2 -3 in the reverse order.
AUTO SWITCH OPERATION
The below operations will be performed by pressing the
“AUTO” switch.
 1. AUTO OPERATION MODE
The Auto operation will be activated immediately once the
Auto Switch is pressed.
 2. TEST RUN OPERATION (FOR PUMP DOWN/SERV ICING
PURPOSE)
The Test Run operation will be activated if the Auto Switch
is pressed continuously for more than 5 sec. to below 10
sec. A “pep” sound will occur at the fifth sec., in order to
identify the starting ofTest Run operation
 3. REMOTE CONTROLLER RECEIVING SOUND ON/OFF
The ON/OFF of Remote Controller receiving sound can be
change over by the following steps:
a) Release the Auto Switch after Test Run operation is
activated.
b) Then, within 20 sec. after (a), press Auto Switch for more
than 5 sec..A “beep” “beep” sound will occur at the fifth
sec., then release the Auto Switch.
c) Within 20 sec. after (b), press Auto Switch again.
Everytime Auto Switch is pressed (within 20 sec. interval),
remote controller receiving soundstatus will be reversed
between ON and OFF.
Long “beep” sound indicates that remote controller
receiving sound is OFF.
Short “beep” sound indicates that remote controller
receiving sound is ON.
10.6. Outdoor unit
10.6.1. SELECT THE BEST LOCATION
(Refer to “Select the best location”
section)
10.6.2. INSTALL THE OUTDOOR UNIT
 • After selecting the best location, start installation according
to Indoor/Outdoor Unit Installation Diagram.
 1. Fix the unit on concreteor rigid frame firmly and horizontally
by bolt nut. (ø10 mm).
 2. When installing at roof, please consider strong wind and
earthquake. Please fasten theinstallation standfirmly with
bolt or nails.
10.6.3. CONNECTING THE PIPING
Connecting The Piping To Indoor Unit
Please make flare after inserting flare nut (locate at joint portion
of tube assembly) onto the copper pipe. (In case of using long
piping)
Connect the piping
 • Align the center of piping and sufficiently tighten the flare
nut with fingers.
 • Further tighten the flare nut with torque wrench in specified
torque as stated in the table.
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							MODELPiping size (Torque)
GasLiquid
C7DK, C9DK, A7DK, A9DK3/8” (42 N.m)1/4” (18 N.m)
C12DK, A12DK1/2” (55 N.m)1/4” (18 N.m)
Connecting The Piping To Outdoor Unit
Decide piping length and then cut by using pipe cutter. Remove
burrs from cut edge. Make flare after inserting the flare nut
(located at valve) onto the copper pipe.
Align center of piping to valves and then tighten with torque
wrench to the specified torque as stated in the table.
CUTTING AND FLARING THE PIPING
 1. Please cut using pipe cutter and then remove the burrs.
 2. Remove the burrs by using reamer. If burrs is not
removed, gas leakage may be caused.
Turn the piping end down to avoid the metal powder
entering the pipe.
 3. Please make flare after inserting the flare nut onto the
copper pipes.
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							10.6.4. EVACUATION OF THE EQUIPMENT
WHEN INSTALLING AN AIR CONDITIONER, BE SURE TO EVACUATE THE AIR INSIDE THE INDOOR UNIT AND PIPES in the
following procedure.
 1. Connect a charging hose with a push pin to the Low andHigh side of a charging set andthe service port ofthe 3-wayvalve.
 • Be sure to connect the end of the charginghose with the push pin to the service port.
 2. Connect the center hose of the charging set to a vacuum pump.
 3. Turn on the power switch of the vacuum pump and make sure that the needle in the gauge moves from 0 cmHg (0 MPa) to
-76 cmHg (-0.1 MPa). Thenevacuate the air approximately ten minutes.
 4. Close the low side valve of the charging set and turn off the vacuum pump. Make sure that the needle in the gauge does not
move after approximately five minutes.
Note: BE SURE TO FOLLOW THIS PROCEDURE IN ORDER TO AVOID REFRIGERANT GAS LEAKAGE.
 5. Disconnect the charging hose from the vacuum pumpand from the service portof the3-way valve.
 6. Tighten the service port capsof the 3-wayvalve at torque of 18 N.m with a torque wrench.
 7. Remove the valve caps of both ofthe 2-wayvalve and3-way valve.Position both of the valves to “OPEN” using a hexagonal
wrench (4 mm).
 8. Mount valve caps onto the2-wayvalve and the3-way valve.
 • 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 take the following measure:
 • If the leak stops when the piping connections are tightened further, continue working from step 3.
 • If the leak does not stop when the connections are retightened, repair the location of leak.
 • Do not release refrigerant during piping work for installation and reinstallation. Take care of the liquid refrigerant, it may cause
frostbite.
10.6.5. CONNECT THE CABLE TO THE OUTDOOR UNIT
 1. Remove the control board cover from the unit by loosening the screw.
 2. Connecting cable between indoor unit and outdoor unit shall be approved polychloroprene sheathed 3 (C7DK, C9DK, C12DK)
or 5 (A7DK, A9DK, A12DK) × 1.5 mm
2flexible cord, typedesignation 245 IEC 57 or heavier cord.
 3. Secure the cable onto the control board with the holder (clamper).
 4. Attach the control board cover back to the original position with the screw.
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							DISPOSAL OFOUTDOOR UNITDRAIN WATER
 • If the drain elbow is used, the unit should be placed on a
stand which is taller than 3cm.
 • If the unit is used in an area where temperature falls below
0° C for 2 or 3 days in succession, it is recommended not to
use a drain elbow, for the drain water freezes and the fan
will not rotate.
CHECK THEDRAINAGE
 • Open front panel and remove air filters.
(Drainage checking can be carriedout without removing the
front grille.)
 • Pour a glass of water into the drain tray-styrofoam.
 • Ensure that water flows out from drain hose of the indoor
unit.
EVALUATION OF THEPERFORMANCE
 • Operate the unit at cooling operation mode for fifteen
minutes or more.
 • Measure the temperature of the intake and discharge air.
 • Ensure the difference between the intake temperature and
the discharge is more than 8°C.
10.6.6. PIPE INSULATION
 1. Please carry out insulation at pipe connection portion as mentioned in Indoor/Outdoor Unit Installation Diagram. Please wrap
the insulated piping end to prevent water from going inside the piping.
 2. If drain hose or connecting piping is in the room (where dew may form), please increase the insulation by using POLY-E FOAM
with thickness 6 mm or above.
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							CHECK ITEMS
Is there any gas leakage at flare nut connections?
Has the heat insulation been carried out at flare nut
connection?
Is the connecting cable being fixed to terminal board firmly?
Is the connecting cable being clamped firmly?
Is the drainage OK?
(Refer to “Check the drainage” section)
Is the earth wire connection properly done?
Is the indoor unit properly hooked to the installation plate?
Is the power supplyvoltage complied with rated value?
Is there any abnormal sound?
Is the cooling operation normal?
Is the thermostat operation normal?
Is the remote control’s LCD operation normal?
Is the super alleru-buster filter installed?
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							11 2-way, 3-way Valve
2-way Valve (Liquid Side)3-way Valve (Gas Side)
WorksShaft PositionShaft PositionService Port
ShippingCloseCloseClose
(With valve cap)(With valve cap)(With cap)
EvacuationCloseCloseOpen
(Installation and(Counter-Clockwise)(Clockwise)(Push-pin)
Re-installation)
OperationOpenOpenClose
(With valve cap)(With valve cap)(With cap)
Pumping downCloseOpenOpen
(Transferring)(Clockwise)(Counter-Clockwise)(Connected manifo ld
gauge)
EvacuationOpenOpenOpen
(Servicing)With vacuumpump
Gas chargingOpenOpenOpen
(Servicing)(Withchargingcylinder)
Pressure checkOpen
(Servicing)OpenOpen(Connected manifo ld
gauge)
Gas releasingOpen
(Servicing)OpenOpen(Connected manifo ld
gauge)
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							Required tools: hexagonal wrench, adjustable wrench, torque
wrenches, wrench to hold the joints and gas leak detector.
The additional gas for air purging has been charged in the
outdoor unit.
However, if the flare connections have not been done correctly
and there gas leaks, a gas cylinder and the charge set will be
needed.
 1. Recheck the piping connections.
 2. Open thevalve stemof the2-wayvalvecounter-
clockwise approximately 90°, wait 10 seconds, and
then set it to closed position.
 • Be sure to use a hexagonal wrench to operate the valve
stem.
 3. Check for gas leakage.
 • Check the flare connection for gas leakage.
 4. Purge the air from the system
 • Set the 2-way valve to the open position and remove the
cap from the3-wayvalve’s service port.
 • Using the hexagonal wrench to press the valve core pin,
discharge for three seconds and then wait for one
minute.
Repeat this three times.
 5. Use torque wrench to tightenthe service port cap to a
torque of 1.8 kg.m. (18 N.m).The air in the indoor unit and in the piping must be purged. If air
remains in the refrigeration pipings, it will affect the
compressor, reduce the coolingcapacity, and could lead to a
malfunction.
 6. Set the 3-wayvalve to theopened position.
 7. Mount thevalve stemnuts to the2-way and 3-way
valves.
 8. Check for gas leakage.
 • At this time, especially check for gas leakage from the 2-
way and 3-way’s stem nuts,and from the service port
cap.
CautionIf gas leakage is discovered in step (3) above, take
the following measures:
Tighten the piping connections. If the leaks stop,
continue working from step (4).
If the gas leaks do not stop when the connections are
retightened, repair the location of the leak, discharge
all of the gas through the service port, and then
recharge with the specified amount of gas from a gas
cylinder.
11.1. Air Purging of the Piping and Indoor Unit
11.1.1. Air purging (Installation)
Service port cap
Be sure, using a torque wrench to tighten the service port cap (after using the service port), so that it prevents the gas
leakage from the refrigeration cycle.
Procedure:
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							 1. Confirm that both the 2-way and 3-wayvalves are set to
the opened position.
 • Remove the valve stem caps and confirm that the valve
stems are in the opened position.
 • Be sure to use a hexagonal wrench to operate the valve
stems.
 2. Operate the unit for 10 to 15 minutes.
 3. Stop operation and wait for 3 minutes, then connect the
charge set to the service port of the 3-wayvalve.
 • Connect the charge hose with the push pin to the Gas
service port.
 4. Air purging of the charge hose.
 • Open the low-pressure valveon the charge set slightly
to purge air from the charge hose. 5. Set the 2-wayvalve to theclose position.
 6. Operate the air conditioner at the cooling cycle and
stop it when the gauge indicates 1 kg/cm
2G (0.1 MPa).
 7. Immediately set the 3-wayvalve to theclosed position.
 • Do this quickly so that the gauge ends up indicating 3 to
5 kg/cm
2G (0.3 to 0.5 MPa).
 8. Disconnect the charge set, and mount the 2-way and 3-
way valve’s stemnuts and the service port caps.
 • Use a torque wrench to tighten the service port cap to a
torque of 1.8 kg.m (18 N.m).
 • Be sure to check for gas leakage.
11.1.2. Pumping down (Re-installation)
Procedure:
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							11.1.3. Re-air purging (Re-installation)
 1. Confirm that both the 2-way and 3-wayvalves are set to
the closed position.
 2. Connect the charge set and a charging cylinder to the
service port of the 3-wayvalve.
 • Leave the valve on the charging cylinder closed.
 3. Air purging.
 • Open the valves on the charging cylinder and the
charge set. Purge the air by loosening the flare nut on
the 2-wayvalve approximately 45° for 3seconds then
closing it for 1 minute; repeat 3 times.
 • After purging the air, use a torque wrench to tighten the
flare nut onthe 2-wayvalve.
 4. Check for gas leakage.
 • Check the flare connections for gas leakage. 5. Discharge the refrigerant.
 • Close the valve on the charging cylinder and discharge
the refrigerant until the gauge indicates 3 to 5 kg/cm
2G
(0.3 to 0.5 MPa)
 6. Disconnect the charge set and the charging cylinder,
and set the 2-way and 3-wayvalves tothe open
position.
 • Be sure to use a hexagonal wrench to operate the valve
stems.
 7. Mount thevalve stemnuts and the service port cap.
 • Be sure to use a torque wrench to tighten the service
port cap to a torque 1.8 kg.m (18 N.m).
 • Be sure to check for gas leakage.
Procedure:
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							(Gas leakage)
 1. Confirm that both the 2-way and 3-wayvalves are set to
the open position.
 2. Connect the charge set tothe 3-way valve’s service
port.
 • Leave the valve on the charge set closed.
 • Connect the charge hose with the push pin to the
service port.
 3. Open the valves(Low side) on the charge set and
discharge the refrigerant until the gauge indicates 0.5
to 1 kg/cm
2G (0.05 to 0.1 MPa).
 • If there is no air in the refrigeration cycle [ the pressure
when the air conditioner is not running is higher than 1
kg/cm
2G (0.1 MPa) ], discharge the refrigerant until the
gauge indicates 0.5 to 1 kg/cm2G (0.05 to 0.1 MPa). If
this is the case, it will not be necessary to apply a
evacuation.
 • Discharge the refrigerant gradually; if it is discharged
too suddenly, the refrigeration oil will be discharged.
11.1.4. Balance refrigerant of the 2-way, 3-way valves
Procedure:
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