Panasonic Cs W7ckp Cs W9ckp Cs W7ckp Series Repair Manual

							Precau tions
 • Be sure to read the instructions for the vacuum pump,
vacuum pump adaptor and manifold gauge prior to use,
and follow the instructions carefully.
 • Make sure that the vacuum pump is filled with oil up to
the designa ted line on the oil gauge.
 • The gas pressure back flow prevention valve on the
charging hose is generally open during use.When you
are removing the charging hose from the service port, it
will come off moreeasily if you close this valve.
Fig. 12 Vacuum pump air purging configuration
 b. Copper pipes
Use only copper pipes with the thickness given in table 10, and with minimal impurities. Becaus e the surface of the pipe is
expose d, you should take special care, and also take measures such as marking the pipes to make sure they areeasily
distinguished from other piping materials, to prevent mistaken use.
 3. Precautions during refrigerant piping work
Take the followin g precautions on-site when connecting pipes. (Keep in mind that the need to control the entry of moisture and
dust is even more important that in conventional piping).
 a. Keep the open ends of all pipes sealed until connection with AC equipment is complete.
 b. Take special care when doing piping work on rainy days. The entering of moisture will degrade the refrigerating machine oil,
and lead to malfunctions in the equipment.
 c. Complete all pipe connections in as short a time as possible. If the pipe must be left standing for a long time after removing
the seal, it must be thoroughly purged with nitrogen, or dried with a vacuum pump.
11.4. INSTALLATION, TRANSFERRING, SERVICING
11.4.1. Inspecting Gas Leaks with a VacuumPump for New Installations (Using New
Refrigerant Piping)
 1. From the viewpoint of protecting the global environment, please do not release refrigerant into the atmosphere.
 a. Connec t the projecting side (pin-pushing side) of the charging hose for the manifold gauge to the service port of the 3-way
valve. (1)
 b. Fully open the handle Lo of the manifold gauge and run the vacuum pump. (2) (If the needle of the low-pressure gauge
instantly reaches vacuum, re-check step a).)
 c. Continu e the vacuum process for at least 15 minutes, then check to make sure the low-pressure gauge has reached -0.1
MPa (-76 cmHg). Once the vacuum process has finished ,fully close the handle Lo of the manifold gauge and stop the
vacuum pump operation, then remove the charging hose that is connected to the vacuum pump adaptor. (Leave the unit in
that conditio n for 1-2 minutes, and make sure that the needle of the manifold gauge does not return.) (2) and (3)
 d. Turn the valve stem of the 2-way valve 90 counter-clockwise to open it, then, after 10 seconds, close it and inspect for a gas
leak (4)
 e. Remove the charging hose from the 3-way valve service port, then open both the 2-way valve and 3-way valve. (1) (4) (Turn
the valve stem in the counter-clockwise direction until itgently makes contact. Do not turn it forcefully).
 f. Tighten the service port cap with a torque wrench (18 N.m (1.8 kgf.m)). (5) Then tighten the 2-way valve and 3-way valve
caps with a torque wrench (42 N.m (4.2 kgf.m)) or (55 N.m (5.5 kgf.m)).
 g. After attaching each of the caps, inspect for a gas leak around the cap area. (5) (6)
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							11.4.2. Transferring (Using New Refrigerant Piping)
 1. Removing the unit
 a. Collecting the refrigerant into the outdoor unit by pumping down
The refrigerant can be collected into the outdoor unit (pumping down) by pressing the TEST RUN button, even when the
temperature of the room is low.
 • Check to make sure that the valve stems of the 2-way valve and 3-way valve have been opened by turning them counter-
clockwise. (Remove the valve stem caps and check to see that the valve stems arefully opened position . Always use
a hex wrench (with 4-mm opposin g sides) to operate the valve stems.)
 • Press the TEST RUN button on the indoor unit, and allow preliminary for 5-6 minutes. (TEST RUN mode)
 • After stopping the operation, let the unit sit for about 3 minutes, then close the 2-way valve by turning the valve stem in
the clockwise direction.
 • Press the TEST RUN button on the indoor unit again, and after 2-3 minutes of operation, turn the valve stem of the 3-
way valve quickly in the clockwise direction to close it, then stop the operation.
 • Tighten the caps of the 2-way valve and 3-way valve to the stipulated torque.
 • Remove the connection pipes (liquid side and gas side).
 2. Installing the unit
Install the unit using new refrigerant piping. Follow the instructions in section 4.1 to evacuate the pipes connecting the indoor
and outdoor units, and the pipes of the indoor unit, and check for gas leaks.
11.4.3. AC Units Replacement (Using Existing Refrigerant Piping)
Whenreplacin g and R410A AC unit with another R410A AC unit, you should re-flare the refrigerant piping. Even though the
replacement AC unit uses the R410A , problems occur when, for example, either the AC unit maker or the refrigerating machine oil
is differen t.
Whenreplacin g an R22 AC unit with an R410A AC unit, the followin g checks and cleanin g procedures are necessary but are
difficult to do because of the chemical characteristics of the refrigerating machine oil (as described in items c) and d) of section
10.1.1.(2)). In this case, you should use new refrigerant piping rather than the existing piping.
 1. Piping check
Becaus e of the differen t pressure characteristics of R22 and R410A , the design pressure for the equipment is 1.6 times
differen t. the wall thickness of the pipingmust comply with that shown in Table 10, but this is noteasy tocheck. Also, even if
the thickness is correct, there may be flattene d or bent portions midway through the piping due to sharp curves. Buried sections
of the piping also cannot be checked.
 2. Pipe cleanin g
A large quantity of refrigerating machine oil (mineral oil) adheres to existing pipes due to the refrigeration cycle circulation. If the
pipes are used just as they are for the R410A cycle, the capacity will be lowered due to the incompatibility of this oil with the
R410A , or irregularities may occur in the refrigeration cycle. For this reason, the pipingmust be thoroughly cleaned , but this is
difficult with the present technology.
11.4.4. Refrigerant Compatibility (UsingR410ARefrigerant in R22 ACs and Vice Versa)
Do not operate an existing R22 AC with the new R410A refrigerant. Doing so would result in improper function ing of the equipment
or malfunction, and might lead to a major acciden t such as an explosion in the refrigerationcycle. Similarly, do not operate an
R410A AC with R22 refrigerant. The chemical reaction between the refrigerating machine oil used in R410A ACs and the chlorine
that is contained in R22 would cause the refrigerating machine oil to degrade and lead to malfunction.
11.4.5. Recharging Refrigerant During Servicing
Whenrecharging is necessary, insert the specifie d amount of new refrigerant in accordance with the followin g procedure.
 1. Connec t the charging hose to the service port of the outdoor unit.
 2. Connec t the charging hose to the vacuum pump adaptor. At this time,fully open the 2-way valve and 3-way valve.
 3. Fully open the handle Lo of themanifold gauge, turn on the power of the vacuum pump and continue the vacuum process for
at least one hour.
 4. Confirm that the low pressure gauge shows a reading of -0.1 Mpa (-76 cmHg), thenfully close the handle Lo, and turn off the
vacuum pump. Wait for 1-2 minutes, then check to make sure that the needle of the Low pressure gauge has not returned. See
Fig. 13 for the remaining steps of this procedure.
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							 5. Set the refrigerant cylinde r onto the electronic scale, then correct the hose the cylinde r and to the connection port for the
electronic scale. (1)(2)
Precau tion:
Be sure to set up the cylinde r for liquid charging. If you use a cylinde r equipped with a siphon tube, you can charge the liquid
without having to turn the cylinde r around
 6. Remove the charging hose of the manifold gauge from the vacuum pump adaptor, and connect it to the connection port of the
electronic scale. (2)(3)
 7. Open the valve of the refrigerant cylinde r, then open the charging valve slightly and close it. Next, press the check valve of the
manifold gauge and purge the air. (2)(4)(Watch the liquid refrigerant closely at this point.)
 8. After adjusting the electronic scale to zero, open the charging valve, then open the valve Lo of the manifold gauge and charge
with the liquid refrigerant. (2)(5) (Be sure to read the operating instructions for the electronic scale.)
 9. If you cannot charge the stipulated amount, operate the unit in the cooling mode while charging a little of the liquid at a time
(about 150 g/time as a guideline). If the charging amount is insuffic ient from one operation, wait about one minute, then use the
same procedure to do the liquid charging again.
Precau tion:
Never use the gas side to allow a larger amount of liquid refrigerant to be charged while operating the unit.
 10. Close the charging valve, and after charging the liquid refrigerant inside the charging hose, fully close the valve Lo of the
manifold gauge, and stop the operation of the unit. (2)(5)
 11. Quickly remove the charging hose from the service port. (6) If you stopmidway through, the refrigerant that is in the cycle will
be discharged.
 12. After putting on the caps for the service port and operating valve, inspect around the caps for a gas leak. (6)(7)
Fig. 13 Re-charging refrigerant
11.4.6. Brazing
As brazing requires sophisticated techniques and experiences, it must be performed by a qualifie d person.
In order to prevent the oxide filmfrom occurring in the pipe interior during brazing, it is effective to proceed with brazingwhile letting
dry nitrogen gas (N2) flow.
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 1. Attach a reducing valve to the nitrogen gas cylinde r.
 2. Attach a reducing valve to the nitrogen gas cylinde r.
 3. Apply a seal onto the clearance between the piping and inserted pipe for the nitrogen gas in order to prevent the nitrogen gas
from flowing backward.
 4. When thenitrogen gas is flowing, be sure to keep the piping end open.
 5. Adjust the flow rate of nitrogen gas so that it is lower than 0.05 m
3/h, or 0.02 MPa (0.2 kgf/cm2) by means of the reducing valve.
 6. After taking the steps above, keep the nitrogen gas flowing until the piping cools down to a certain extent (i.e. temperature at
which pipes are touchable with finger).
 7. Completelyremove the flux after brazing.
Cautions during brazing
 1. General Caution s
 a. The brazing strength should be high as required.
 b. After operation, airtightness should be kept under pressurized conditio n.
 c. During brazing do not allow component materials to become damaged due to overheating.
 d. The refrigerant pipe work should not become blocked with scale or flux.
 e. The brazed part should not restrict the flow in the refrigerant circuit.
 f. No corrosion should occur from the brazed part.
 2. Preventing of Overheating
Due to heating, the interior and exterior surfaces of treated metal may oxidize. Especially, when the interior of the refrigerant
circuit oxidizes due to overheating, scale occurs and stays in the circuit as dust, thus exerting a fatally adverse effect. So,
make brazing at adequa te brazing temperature and with minimum of heating area.
 3. Overheating Protection
In order to prevent components near the brazed part from overheating damaged orquality deterioration due to flame or heat,
take adequa te steps for protection such as (1) by shieldin g with a metal plate, (2) by using a wet cloth, and (3) by means
of heat absorbent.
 4. Movement during Brazing
Eliminate all vibration during brazing to protect brazed joints from cracking and breakage.
 5. Oxidation Preventative
In order to improve the brazing efficien cy, various types of antioxid ant are available on themarket. However, the
constituents of these are widely varied, andsome are anticipa ted to corrode the piping materials, or adversely affect HFC
refrigerant, lubricating oil, etc. Exercise care when using an oxidatio n preventive.
11.4.7. Servicing Tips
The drier must also be replaced whenever replacing the refrigerantcycle parts. Replacing the refrigerant cycle partsfirst
before replacing the drier. The drier is supplied in a vacuum pack. Perform brazing immediately after opening the vacuum
pack, and then start the vacuumwithin two hours. In addition, the drier also needs to be replaced when the refrigerant has
leaked completely.
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							 1. The Electronic Controller, a Signal Receiver and an
Indicator (Fig. 3) can be seen by the below steps:
 • Remove the 2 caps and 2 screws at the bottom of the
Front Grille. (Fig. 1)
 • Remove the Front Grille by releasin g the 2 hooks at the
top of the Front Grille. (Fig. 1)
 • Remove the Control Board Cover by releasin g the 2
tabs at left, 1 tab on top and 1 tab at right side of the
Control Board Cover. (Fig. 2)
 2. To remove the Electronic Controller:
 • Release the Particular Piece. (Fig. 3)
 • Release the hook that hold the Electronic Controller.
(Fig. 3)
 • Remove the Control Board by:-
 − Releasin g CN-REC/DISP connectors. (Fig. 4)
 − Releasin g CN-FM connectors. (Fig. 4)
 − Releasin g CN-ION connector. (Fig. 4)
 − Releasin g CN-STM connector. (Fig. 4)
 − Removing the EarthWirescrew. (Fig. 4)
 − Releasin g the Intake Air Sensor. (Fig. 4)
 − Releasin g the Piping Sensor. (Fig. 4)
Fig. 1
Fig. 2
Fig. 3
Fig. 4
12 Servicing Information
Caution: • Pb free solder has a higher melting point than standard solder; Typically the melting point is 50 - 70°F(30-40°C) higher. Please use
a high temperature soldering iron. In case of the soldering iron with temperature control, please set it to 700 ± 20°F (370 ± 10°C).
 • Pb free solder will tend to splash when heated too high (about 1100°F/600°C).
12.1. Indoor Electronic Controllers Removal Procedures
12.2. Indoor Fan Motor and Cross Flow Fan Removal Procedures
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							 − Pulling out the Drain Hose from outlet to remove the
Discharge Grille. (Fig. 5)
 − Removing the right and left screws. (Fig. 5)
 − Then remove the Control Board by pressing down the
hook at the left and pushing up the right hook. (Fig. 5)
 − Releasin g connector lead wire Ionizer. (Fig. 5)
 − Release the Fan Motor leadwire by pressing the hook at
the center of the connector. (Fig. 6)
 − Remove the screw at the Cross Flow Fan. (Fig. 7)
 − REMINDER - To reinstall the Fan Motor, adjust the
connector of the Fan Motor as shown in the Fig. 7.
Fig. 5
Fig. 6
Fig. 7
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							 − Remove the screws at the left of the Evaporator. (Fig. 8)
 − Remove the Bearing. (Fig. 9)
 − Push up the Evaporator and pull out the Cross Flow Fan
from shaft. By then, Fan Motor can be taken out. (Fig. 9)
Fig. 8
Fig. 9
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							 • Remote Control Reset
When thebatteries are inserted for the first time, or the
batteries are replaced, all the indications will blink and the
remote control might not work.
If this happen , remove the cover of the remote control and
you will find a resetting terminal, and by shorting it with a
minus screwdriver, it will return to normal.
 • Changing the wireless remote control transmission
code
When twoindoor units are installed in the same room, in
order to prevent operating errors caused by using two
remote controls, cut a jumper wire at the remote control
printed circuit board (J - A) and cut a jumper wire at the
indoor printed circuit board (JX4). It is possible to select
from 4types of transmission codes includin g one at time of
delivery conditio n (0).
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							In order to diagnose malfunctions, make sure that there are no
electrical problems before inspecting the refrigeration cycle.
Such problems include insuffic ient insulation, problem with the
power source, malfunction of a compressor and a fan.
The normal outlet air temperature and pressure of the
refrigeration cycle depend s on various conditio ns, the standard
values for them are shown in the table to the right.
13 Troubleshooting Guide
13.1. Refrigeration cycle system
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							13.1.1. Relationship between the condition of the air conditioner and pressure and
electric current
Cooling ModeHeating Mode
Condition of the air
conditonerLow PressureHigh PressureElectric current
during operationLow PressureHigh PressureElectric current
during operation
Insufficient refrigerant
(gas leakage)
Clogged capillary tube
or Strainer
Short circuit in the
indoor unit
Heat radiation
deficiency of the
outdoor unit
Inefficient compression
 • 
Carry out the measurements of pressure, electric current, and temperature fifteen minutes after an operation is started.
13.1.2. Diagnosis methods of a malfunction of a compressor and 4-way valve
Nature of faultSymptom
 • 
Electric current during operation becomes approximately 20% lower than the normal value.
Insufficient compressing of a compressor • 
The discharge tube of the compressor becomes abnormally hot (normally 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.
Locked compressor
 • 
The compressor is a humming sound.
 • 
Electric current during operation becomes approximately 80% lower than the normal value.
Insufficient switches of the 4-way valve
 • 
The temperature different between from the discharge tube to the 4-way valve and from
suction tube to the 4-way valve becomes almost zero.
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