Panasonic Cs W7ckp Cs W9ckp Cs W7ckp Series Repair Manual

							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.
10.3.4. (a)EVACUATION OF THE EQUIPMENT (FOR EUROPE & OCEANIA DESTINATION)
WHENINSTAL LING AN AIR CONDITIONER, BE SURE TO EVACU ATE THE AIR INSIDE THE INDOOR UNIT AND PIPES in the
followin g procedure.
 1. Connec t a charging hose with a push pin to the Low and High side 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. Connec t the center hose of the charging set to a vacuum pump with check valve, or vacuum pump and vacuum pump adaptor.
 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). Then evacuate 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 LEAKA GE.
 5. Disconnect the charging hose from the vacuum pump and from the service port of the 3-way valve.
 6. Tighten the service port caps of the 3-way valve at torque of 18 N.m with a torque wrench.
 7. Remove the valve caps of both of the 2-way valve and 3-way valve. Position both of the valves to“OPEN”using a hexagonal
wrench (4mm).
 8. Mount valve caps onto the 2-way valve and the 3-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.
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							(1)*
*Connect the manifold gauge to the service port of 3-way
valve.
Measure the pressure.(2)*
*Keep it for 5-10 minutes.
Ensure that the pressure indicated on the gauge is the
same as that of measured during the first time.
10.3.5. (b) AIR PURGING OF THE PIPING AND INDOOR UNIT
The remaining air in the Refrigeration cycle which contains moisture may cause malfunction on the compressor.
 1. Remove the caps from the 2-way and 3-way valves.
 2. Remove the service-port cap from the 3-way valves.
 3. To open the valve, turn the valve stem of 2-way valve counter-clockwise approx. 90°and hold it there for ten seconds, then
close it.
 4. Check gas-leakage of the connecting portion of the pipings.
For the left pipings, refer to item 4(A).
 5. To open 2-way valve again, turn the valve stem counter-clockwise until it stops.
4(A). Checking gas leakage for the left piping.
10.3.6. CONNECT THECABLE TO THEOUTDOOR UNIT
 1. Remove the control board cover from the unit by looseni ng the screw.
 2. Connec ting cable between indoor unit and outdoor unit shall be approved polychl oroprene sheathed 3 (C7CK, C9CK, C12CK ,
V7CK, V9CK, V12CK ) or 5 (A7CK, A9CK, A12CK ,W7CK, W9CK, W12CK)×1.5 mm
2flexible cord, type designa tion 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.
10.3.7. PIPEINSULATION
 1. Please carry out insulation at pipe connection portion as mentioned in Indoor/Outdoo r Unit Installation Diagram. Please wrap
the insulate d 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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							DISPOSAL OF OUTDOOR UNITDRAIN WATER
 • If a drain elbow is used, the unit should be placed on a
stand which is taller than 3 cm.
 • If the unit is used in an area where temperature falls below
0°C for 2 or 3 days in succession, it isrecommended not to
use a drain elbow, for the drain water freezes and the fan
will not rotate.
CHECK THE DRAINAGE
 • Open front panel and remove air filters.
(Drainage checking can be carried out 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 THE PERFORMANCE
 • Operate the unit at cooling operation mode for fifteen
minutes or more.
 • Measure the temperature of the intake and discharge air.
 • Ensure the differen ce between the intake temperature and
the discharge is more than 8°C.
NOTE:These equipment shall be connected to a suitable mains network
with a main impedance less than the following:
CS-A9CKP / CU-A9CKP5: 0.46
Ω
CS-C12CKP / CU-C12CKP5: 0.47
Ω
CS-A12CKP / CU-A12CKP5: 0.47
Ω
CS-V12CKP / CU-V12CKP5: 0.45
Ω
CS-W12CKP / CU-W12CKP5: 0.45
Ω
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 supply voltage 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 air purifying filter installed?
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							11 Installation and Servicing Air Conditioner Using R410A
11.1. OUTLINE
11.1.1. About R410ARefrigerant
 1. Converting air conditio ners to R410A
Since it was declared in1974 that chlorofluoroca rbons (CFC), hydro chlorofluoroca rbons (HCFC) and other substances pose a
destructive danger to the ozone layer in the earth´s upper stratosphere (20 to 40 km above the earth), measures have been
taken around the world to prevent this destruction.
The R22 refrigerant which has conventionally been used in ACs is an HCFC refrigerant and, therefore, possesses this ozone-
destroying potential. International regulations (the Montreal Protocol Ozone-Damaging Substances) and the domestic laws of
various countries call for the early substitution of R22 by a refrigerant which will not harm the ozone layer.
 • In ACs, the HFC refrigerant which has become the mainstream alternative called R410A .Compared with R22, the pressure
of R410A is approximately 1.6 times as high at the same refrigerant temperature, but the energy efficien cy is about the
same. Consisting of hydrogen (H), fluorine (F) and carbon (C), R410A is an HFC refrigerant. Anothe r typical HFC refrigerant
is R407C. While theenergy efficien cy of R407C is some what inferior to that of R410A , it offers the advantage of having
pressure characteristics which are about the same as those of R22, and is used mainly in packaged ACs.
 2. The characteristics of HFC (R410A) refrigerants
 a. Chemical characteristics
The chemical characteristics of R410A are similar to those of R22 in that both are chemicallystable, non-flammable
refrigerants with low toxicity.
However, just like R22, the specific gravity of R410A gas is heavier than that of air. Becaus e of this, it can cause anoxygen
deficien cy if it leaks into a closed room since it collects in the lower area of the room. It also generates toxic gas when it is
directly expose d to a flame, so it must be used in awell ventilated environment where it will not collect.
Table 1 Physical comparison of R410A and R22R410AR22
Composition (wt%)R32/R125 (50/50)R22 (100)
Boiling point (°C)-51.4-40.8
Vaporizing pressure (25°C)1.56 Mpa (15.9 kgf/cm2)0.94 Mpa (9.6 kgf/cm2)
Saturated vapor density64.0 kg/m344.4 kg/m3
FlammabilityNon-flammableNon-flammable
Ozone-destroying point (ODP)00.005
Global-warming point (GWP)17301700
 b. Compositional change (pseudo-azeotropic characteristics)
R410A is a pseudo -azeotropic mixture comprising the two components R32 and R125. Multi-component refrigerants with
these chemical characteristics exhibit little compositional change evenfrom phase changes due to vaporization 9or
conden sation), which means that there is little change in the circulating refrigerant composition even when the refrigerant
leaks from the gaseous section of the piping.
Accordingly, R410A can be handle d in almost the same manner as the single-component refrigerant R22. However, when
charging, because there is a slight change in composition between the gas phase and the liquid phase inside a cylinde r or
other container, charging should basically begin with the liquid side.
 c. Pressure characteristics
As seen in Table 2, the gas pressure of R410A is approximately 1.6 times as high as that of R22 at the same refrigerant
temperature, which means that special R410A tools and materials with high-pressure specific ations must be used for all
refrigerant piping work and servicing.
Table 2 Comparison of R410A and R22 saturated vapor density
Unit: MPa
Refrigerant Temperature (°C)R410AR22
-200.300.14
00.700.40
201.350.81
402.321.43
603.732.33
654.152.60
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							 d. R410A refrigerating machine oil
Conventionally , mineral oil or a synthet ic oil such as alkylbe nzene has been used for R22 refrigerating machine oil. Becaus e
of the poor compatibility between R410A and conventional oils like mineral oil, however, there is a tendency for the
refrigerating machine oil to collect in the refrigerating cycle. For this reason, polyest er and other synthet ic oils which have
a high compatibility with R410A are used as refrigerating machine oil.
Becaus e of the high hygroscopic property of synthet ic oil, more care must be taken in its handlin g than was necessary with
conventional refrigerating machine oils. Also, these synthet ic oils will degrade if mixed with mineral oil or alkylbe nzene,
causing clogging in capillary tubes or compressor malfunction. Do not mix them under any circumstances.
11.1.2. Safety Measure When Installing / Receiving Refrigerant Piping
Cause the gas pressure of R410A is approximately 1.6 times as high as that of R22, a mistake in installation or servicing could
result in a major acciden t. It is essential that you use R410a tools and materials, and that you observe the followin g precautions
to ensure safety.
 1. Do not use any refrigerant other than R410A in ACs that have been used with R410A .
 2. If any refrigerant gas leaks while you are working, ventilate the room. Toxic gas may be generated if refrigerant gas is expose d
to a direct flame.
 3. When installin g or transferring an AC, do not allow any air or substance other than R410A to mix into the refrigeration cycle. If
it does, the pressure in the refrigeration cycle can become abnormally high, possibly causing an explosi onand/or injury.
 4. After finishin g the installation, check to make sure there is no refrigerant gas leaking.
 5. When installin g or transferring an AC, follow the instructions in the installation instructions carefully. Incorrect installation can
result in an abnormal refrigeration cycle or water leakage, electric shock, fire, etc.
 6. Do not perform any alterations on the AC unit under any circumstances. Have all repair work done by a specialist. Incorrect
repairs can result in an water leakage, electric shock, fire, etc.
11.2. TOOL FOR INSTALLING / SERVICING REFRIGERANT PIPING
11.2.1. Necessary Tools
In order to prevent an R410A ACfrom mistakenly being charged with any other refrigerant, the diameter of the 3-way valve service
port on the outdoor unit has been changed. Also, to increase its ability to withstand pressure, the opposin g dimensions have been
changed for the refrigerant pipe flaring size and flare nut. Accordingly, when installin g or servicing refrigerant piping, youmust have
both the R410A and ordinary tools listed below.
Table 3 Tools for installation, transferring or replacementType of workOrdinary toolsR410A tools
FlaringFlaring tool (clutch type), pipe cutter,
reamerCopper pipe gauge for clearance
Adjustment, flaring tool (clutch type)*1)
Bending, connecting pipesTorque wrench (nominal diameter 1/4,
3/8,1/2) Fixed spanner (opposing sides 12
mm, 17 mm, 19 mm) Adjustable wrench,
Spring bender
Air purgingVacuum pump Hexagonal wrench
(opposing sides 4 mm)Manifold gauge, charging hose, vacuum
pump adaptor
Gas leak inspectionGas leak inspection fluid or soapy waterElectric gas leak detector for HFC
refrigerant*2)
*1) You can use the conventional (R22) flaring tool. If you need to buy a new tool, buy the R410A type.
*2) Use when it is necessary to detect small gas leaks.
For other installation work, you should have the usual tools, such as screwdrivers (+,-), a metal-cutting saw, an electrical drill, a hole
core drill (65 or 70 dia.), a tape measure, a level, a thermometer, a clamp meter, an insulation tester, a voltmeter, etc.
Table 4 Tools for servingType of workOrdinary toolsR410A tools
Refrigerant chargingElectronic scale for refrigerant charging
Refrigerant cylinder Charging orifice and
packing for refrigerant cylinder
Brazing (Replacing refrigerating cycle
part*1)Nitrogen blow set (be sure to use nitrogen
blowing for all brazing), and brazing), and
brazing machine
*1) Always replace the dryer of the outdoor unit at thesame time. The replacement dryer is wrapped in a vacuum pack. Replace
it last among the refrigerating cycle parts. Start brazing as soon as you have opened the vacuum pack, and begin the vacuuming
operation within 2 hours.
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							11.2.2. R410ATools
 1. Cooper tube gauge for clearance adjustment
(used when flaring with the conventional flaring tool (clutch
type))
 • This gauge makes iteasy to set the clearance for the
copper tube to 1.0-1.5 mm from the clamp bar of the
flaring tool.
 2. Flaring tool (clutch type)
 • In the R410A flaring tool, the receiving hole for the
clamp bar is enlarged so the clearance from the clamp
bar can be set to 0-0.5 mm, and the spring inside the
tool is strengthened to increase the strength of the pipe-
expand ing torque. This flaring tools can also be used
with R22 piping, so we recommend that you select it if
you are buying a new flaring tool.
 3. Torque wrenches
 4. Manifo ld gauge
Fig. 1 Copper tube gauge for clearance adjustment
Fig. 2 Flaring tool (clutch type)
Fig. 3 Torque wrenches
Table 5
Conventional wrenchesR410A wrenches
For 1/4 (opposite side x torque)17 mm x 18 N.m (180 kgf.cm)17 mm x 18 N.m (180 kgf.cm)
For 3/3 (opposite side x torque)22 mm x 42 N.m (180 kgf.cm)22 mm x 42 N.m (180 kgf.cm)
For 1/2 (opposite side x torque)24 mm x 55 N.m (180 kgf.cm)26 mm x 55 N.m (180 kgf.cm)
 • Because the pressure is higher for the R410A type, the conventional type cannot be used.
Table 6 Difference between R410A and conventional high / low-pressure gaugesConventional wrenchesR410A wrenches
High-pressure gauge (red)-76 cmHg - 35 kgf/cm3-0.1 - 5.3 Mpa -76 cmHg - 53 kgf/cm3
High-pressure gauge (blue)-76 cmHg - 17 kgf/cm3-0.1 - 3.8 Mpa -76 cmHg - 38 kgf/cm3
 • The shape of the manifold ports has been changed to prevent the possibility of mistakenly charging with another type of
refrigerant.
Table 7 Difference between R410A and conventional manifold port sizeConventional gaugesR410A gauges
Port size7/6 UNF 20 threads1/2 UNF 20 threads
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							 5. Charging hose
 • The pressure resistance of the charging hose has been
raised to match the higher pressure of R410A . The hose
material has also been changed to suit HFC use, and
the size of the fitting has been changed to match the
manifold ports.
 6. Vacuum pump adaptor
 • W hen using a vacuum pump for R410A , it is necessary
to install an electromagnetic valve to prevent the
vacuum pump oil from flowing back into the charging
hose. The vacuum pump adaptor is installed for that
purpose. if the vacuum pump oil (mineral oil) becomes
mixed with R410A , it will damage the unit.
 7. Electric gas leak detector for HFC refrigerant
 • The leak detector and halide torch that were used with
CFC and HCFC cannot be used with R410A (because
there is no chlorine in the refrigerant).
 • The present R134a leak detector can be used, but the
detection sensitivity will be lower (setting the sensitivity
for R134a at 1, the level for R410A will drop to 0.6).
 • For detecting small amounts of gas leakage, use the
electric gas leak detector for HFC refrigerant. (Detection
sensitivity with R410A is about 23 g/year).
Fig. 4 Manifold gauge charging hose
Fig. 5 Vacuum pump adaptor
Fig. 6 Electric gas leak detector for HFC refrigerant Table 8 Difference between R410A and conventional charging hoses
Conventional hosesR410A hoses
Pressure
resistanceWorking pressure3.4 MPa (35 kgf/cm3)5.1 MPa (52 kgf/cm3)
Bursting pressure17.2 MPa (175 kgf/cm3)27.4 MPa (280 kgf/cm3)
MaterialNBR rubberHNBR rubber Nylon coating inside
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							 8. Electronic scale for refrigerant charging
 • Because of the high pressure and fast vaporizing speed
of R410A , the refrigerant cannot be held in a liquid
phase inside the charging cylinde r when charging is
done using the charging cylinde r method, causing
bubble s to form in the measurement scale glass and
making it difficult to see the reading. (Naturally, the
conventional R22 charging cylinde r cannot be used
because of the differen ces in the pressure resistance,
scale gradation, connecting port size, etc.)
 • The electronic scale has been strengthened by using a
structure in which the weight detector for the refrigerant
cylinde r is held by four supports. It is also equipped with
two connection ports, one for R22 *7/16 UNF, 20
threads) and one for R410A (1/2 UNF, 20 threads), so
it can also be used for conventional refrigerant charging.
 • There are two types of electronic scales, one for 10-kg
cylinde rs and one for 20-kg cylinde rs. (The 10-kg
cylinde r isrecommended. )
Refrigerant charging is done manually by openin g and
closing the valve.
 9. Refrigerant cylinde rs
 • The R410A cylinde rs are labeled with the refrigerant
name, and the coating color of the cylinde r protector is
pink, which is the color stipulated by ARI of the U.S.
 • Cylinder equipped with a siphon tube are available to
allow the cylinde r to stand upright for liquid refrigerant
charging.
 10. Charging orifice and packing for refrigerant cylinde rs
 • The charging orifice must match thesize of the charging
hose fitting (1/2 UNF, 20 threads).
 • The packing must also be made of an HFC-resistant
material.
Fig. 7 Electronic scale for refrigerant charging
Fig. 8 Refrigerant cylinders
Fig. 9 Charging orifice and packing
11.2.3. R410ATools Which Are Usable for R22 Models
Table 9 R410A tools which are usable for R22 modelsR410A toolsUsable for R22 models
(1)Copper tube gauge for clearance adjustmentOK
(2)Flaring tool (clutch type)OK
(3)Manifold gaugeNG
(4)Charging hoseNG
(5)Vacuum pump adaptorOK
(6)Electric gas leak detector for HFC refrigerantNG
(7)Electronic scale for refrigerant chargingOK
(8)Refrigerant cylinderNG
(9)Charging orifice and packing for refrigerant cylinderNG
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							11.3. REFRIGERANT PIPING WORK
Whenworking with refrigerant piping, the followin g points must
be carefully observed: no moisture od dust must be allowed to
enter the piping, and there must be no refrigerant leaks.
 1. Procedure and precautions for flaring work
 a. Cut the pipe
Use a pipe cutter, and cutslowly so the pipe will not be
deformed.
 b. Remove burrs and clean shavings from the cut surface
If the shape of the pipe end is poor after removing burrs,
or if shavings adhere to the flared area, it may lead to
refrigerant leaks.
To prevent this, turn the cut surface downward and
remove burrs, then clean the surface, carefully.
 c. Insert the flare nut (be sure to used the same nut that is
used on the AC unit)
 d. Flaring
Check the clamp bar and the cleanlin ess of the copper
pipe.
Be sure to sued the clamp bar to do the flaring with
accuracy. Use either an R410A flaring tool, or a
conventional flaring tool. flaring tools come in differen t
sizes, so be sure to check the size before using.When
using a conventional flaring tool, use the copper pipe
gauge for clearance adjustment, etc., to ensure the
correct A dimension (see Fig. 10)
Fig. 10 Flaring dimensions
11.3.1. Piping Materials
It is recommended that you use copper and copperalloy jointless pipes with amaximum oil adherence of 40 mg/10m. Do not used
pipes that are crushed, deformed, or discolored (especially the inside surface). If these inferior pipes are used, impurities may clog
the expans ion valves or capillaries.
Becaus e the pressure of ACs using R410A is higher than those using R22, it is essential that you select materials that are
appropriate for these standards.
The thickness of the copper tubing used for R410A is shown in Table 10. Please be aware that tubing with a thickness of only 0.7
mm is also available on the market, but this should never be used.
Table 8 Difference between R410A and conventional charging hosesSoft pipeThickness (mm)
Nominal diameterOutside diameter (mm)R410A(Reference) R22
1/46.350.800.80
3/89.520.800.80
1/212.70.800.80
11.3.2. Processing and Connecting Piping Materials
Fig. 11 Relation between the flare nut structure and flaring tool end
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							 2. Procedure and precautions for flare connection
Table 11 R410A flaring dimensionsNominal
diameterOutside
diameter
(mm)Wall thickness
(mm)A (mm)
R410A flaring
tool, clutch typeConventional flaring tool
Clutch typeWing-nuttype
1/46.350.80 - 0.51.0 - 1.51.5 - 2.0
3/89.520.80 - 0.51.0 - 1.51.5 - 2.0
1/212.700.80 - 0.51.0 - 1.52.0 - 2.5
Table 12 R410A flaring dimensionsNominal
diameterOutside
diameter
(mm)Wall thickness
(mm)A (mm)
R410A flaring
tool, clutch typeConventional flaring tool
Clutch typeWing-nuttype
1/46.350.80 - 0.50.5 - 1.01.0 - 1.5
3/89.520.80 - 0.50.5 - 1.01.0 - 1.5
1/212.700.80 - 0.50.5 - 1.01.5 - 2.0
Table 13 R410A flaring and flare nut dimensions Unit: mmNominal
diameterOutside
diameter (mm)Wall thickness
(mm)A +0, -0.4B
dimensionC
dimensionD
dimensionFlare nut
width
1/46.350.89.19.26.51317
3/89.520.813.213.59.72022
1/212.700.816.616.012.92326
Table 14 R410A flaring and flare nut dimensions Unit: mmNominal
diameterOutside
diameter (mm)Wall thickness
(mm)A +0, -0.4B
dimensionC
dimensionD
dimensionFlare nut
width
1/46.350.89.09.26.51317
3/89.520.813.013.59.72022
1/212.700.816.216.012.92024
 a. Check to make sure there are no scratches, dust, etc., on the flare and union.
 b. Align the flared surface with the axial center of the union.
 c. Use a torque wrench, and tighten to the specifie d torque. The tightening torque for R410A is the same as the conventional
torque value for R22. Be careful, because if the torque is too weak, it may lead to a gas leak. If it is too strong, it may split
the flare nut or make it impossible to remove the flare nut.
Table 15 R410A tightening torqueNominal
diameterOutside
diameter (mm)Tightening torque
N.m (kgf.cm)Torque wrench tightening torque
N.m (kgf.cm)
1/46.3514 - 18 (140 - 180)18 (180)
3/89.5233 - 42 (330 -420)42 (420)
1/212.7055 (550)55 (550)
11.3.3. Storing and managing Piping Materials
 1. Types of piping and their storage
The followin g is a general classification of the refrigerant pipe materials used for ACs.
Becaus e the gas pressure of R410A is approximately 1.6 times as high as that of R22, copper pipes with the thickness shown
in Table 10, and with minimal impurities must be used. Care must also be taken during storage to ensure that pipes are not
crushed, deformed, or scratched, and that no dust, moisture or other substance enters the pipe interior.Whenstoring sheathed
copper pipes or plain copper pipes, seal the openin gs by pinchin g or taping them securely.
 2. Makings and management
 a. Sheath ed copper pipes and copper-element pipes
Whenusing these pipes, check to make sure that they are the stipulated thickness. For flare nuts, be sure to used the same
nut that is used on the AC unit.
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