Panasonic Cs W7dke Cs W9dke Cs W12dke Repari Manual

							 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 R22 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 flare 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 R22 flare 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 is 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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							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)). (6)
 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 operation 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).
b. Removing the indoor and outdoor units.
 • Disconne ct the pipes and connecting electric cables from between the indoor and outdoor units.
 • Put capped flare nuts onto all of the pipe connections of the indoor and outdoor units, to make sure no dust or other
foreign matter enters.
 • Remove the indoor and outdoor units.
 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 an 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
About R410A Refrigerant
). 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.
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							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.
 5. Set the refrigerant cylinde r onto the electronic scale, then connect 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
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							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 (N
2) flow.

 1. Attach a reducing valve to the nitrogen gas cylinde r.
 2. 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.
 3. When thenitrogen gas is flowing, be sure to keep the piping end open.
 4. 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.
 5. 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).
 6. Completelyremove the flux after brazing.
Fig. 14 Prevention of Oxidation during 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. Prevention 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 damage 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. (Applicable for drier models only)
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							 • Electronic controller and Display Complete unit can be seen
by followin g the below removal procedures.
Fig. 1
 − Remove the 2 caps and 2 screws at the bottom of the
Front Grille. (Fig. 1)
Fig. 2
 − Remove the Front Grille Complete. (Fig. 2)
Fig. 3
 − Release the taps on top and on the right side of metal
plate cover. (Fig. 3)
 − Then remove the metal plate cover. (Fig. 3)
 − Remove the indicato r complete screw, and then remove
the indicato r complete. (Fig. 3)
12 Servicing Information
12.1. Distinction Of Lead Free (PbF) Printed Circuit Board
 • Printed circuit boards (manufactured) using lead free solder will have a PbF stamp on the Printed Circuit board.
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 solder iron and 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).
 • If you must use Pb solder, please completelyremove all of the Pb free solder on the pin or solder area before applyin g Pb
solder. If this is not practical, be sure to heat the Pb free solder until it melts, beforeapplyin g Pb solder.
12.2. Indoor Electronic Controllers Removal Procedures
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							Fig. 4
 − 
To remove the electronic controller.
 − 
Release CN-FM connectors. (Fig. 4)
 − 
Release CN-Sonic connector. (Fig. 4)
 − 
Release CN-FB connector. (Fig. 4)
 − 
Release CN-ION connector. (Fig. 4)
 − 
Release CN-TH connector. (Fig. 4)
 − 
Release CN-STM connector. (Fig. 4)
 − 
Release CN-REC/DISP connector. (Fig. 4)
 • 
Remove Control Board Cover
Fig. 6
 − 
Remove the screw on the left of the unit. (Fig. 6)
 − 
Pull the hook to the left and lift up the evaporator.
(Fig. 6)
 − 
Pull down the Discharge Grille Complete. (Fig. 6)
Fig. 5
 − 
Press the hook to the right then take out the PCB. (Fig.
5)
 − 
Release Ry-Pwr connector (black and brown) and Ac-
Wht connector from the PCB. (Fig. 5)
Fig. 7
Fig. 8
 − 
Remove indoor pipe sensor and air intake sensor from
the evaporator. (Fig. 7)
 − 
Remove the earth wire from the evaporator. (Fig. 7)
12.3. Indoor Fan Motor And Cross Flow Fan Removal Procedures
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							 − Release the generator complete wire (green and red).
(Fig. 8)
 − Remove 2 screws on the right and 1 screw at the left
side of the control board. (Fig. 7)
 − Press down the hook on the left side of control board.
(Fig. 7)
 − Then pull out the Control Board Completefrom the unit.
(Fig. 7)
Fig. 9
 − Remove the cross flow fan bushing from the chassis.
(Fig. 9)
 − Loosen the fan boss screw at the cross flow fan. (Fig. 9)
 • W hen the batteries are inserted for the first time or the
batteries are replaced, you may notice the indications at
remote control’s display screen blink continuously and not
function able. If this conditio n happen s, try to reset the
remote control by pushing the reset terminal with a pointing
device.
 • You may also do the reset to erase the setting at remote
control and restore back the default setting.
Fig. 10
 − Push up the evaporator and remove cross flow fan by
pulling both cross flow fan and fan motor. (Fig. 10)
12.4. Remote Control Reset
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							12.5. Auto OFF/ON Button
 • The“Auto OFF/ON Button”(behind the front grille) is used to operate the air conditio ner if remote control is misplaced or
mulfunctioning.
 • Forced cooling operation is possible by pressing the“Auto OFF/ON Button”for more than 5s where“beep”sound is heard then
release the button.
 • User able to select remote control transmission code and toggle remote control signal receiving sound under various setting
mode.
 • To enter various setting mode:
 − Press the“Auto OFF/ON Button”continuously for 5s (“beep”sound is heard) and release.
 − W ithin 20s, press the“Auto OFF/ON Button”continuously for 5s again (2“beep”sound is heard) and release.
 − Various setting mode has limit up to 20s. Then return to normal operation.
12.5.1. Toggle Remote Control Signal Receiving Sound
 • Under various setting mode, press the“Auto OFF/ON Button”to toggle the remote control sound.
 − Short“beep”: Turn ON remote control signal receiving sound.
 − Long“beep”: Turn OFF remote control signal receiving sound.
 • After“Auto OFF/ON Button”is pressed, the 20s counter for various setting mode is restarted.
12.5.2. Select Remote Control Transmission Code
 • There are 4 types of remote control transmission code could be selected and stored in EEPRO M of indoor unit. The indoor unit
will only operate when received signal with same transmission code from remote control. This could prevent signal interference
when there are 2 or more indoor unit installed nearby together.
 • To change remote control transmission code, short or open jumpers at the remote control printed circuit board.
 • Under various setting mode, after select the transmission code combination of remote control, press any button of remote
control to transmit a signal to indoor unit. The transmission code will be stored in EEPRO M.
 • After signal is received, the various setting mode is cancelled and return to normal operation.
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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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