Panasonic Cs Xc9ckh Cs Xc12ckh Series Repair Manual

							Applicable piping kit
CZ-3F5, 7AEN (XC9CK)
CZ-4F5, 7, 10AN (XC12CK)
SELECT THE BEST LOCATION
INDOOR UNIT
 • There should not be any heat source or steam near the
unit.
 • There should not be any obstacles blocking the air
circulation.
 • A place where air circulation in the room is good.
 • A place where drainage can be easily done.
 • A place where noise prevention is taken into
consideration.
 • Do not install the unit near the doorway.
 • Ensure the spaces indicated by arrows from the wall,
ceiling, fence or other obstacles.
 • Recommended installation height for indoor unit shall be
at least 2.3 m.
OUTDOOR UNIT
 • If an awning is built over the unit to prevent direct
sunlight or rain, be careful that heat radiation from the
condenser is not obstructed.
 • There should not be any animal or plant which could be
affected by hot air discharged.
 • Keep the spaces indicated by arrows from wall, ceiling,
fence or other obstacles.
 • Do not place any obstacles which may cause a short
circuit of the discharged air.
 • If piping length is over the common length, additional
refrigerant should be added as shown in the table.
Indoor/Outdoor Unit Installation Diagram
 • This illustration is forexplanationpurposesonly.
The indoor unit will actually face a differentway. Attached accessories
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							10.2.1. SELECT THE BEST LOCATION
(Refer to “Select the best location”
section)
10.2.2. HOW TO FIX INSTALLATION
PLATE
The mounting wall is strong and solid enough to prevent it from
the vibration.
The centre of installation plate should be at more than 450 mm
at right and left of the wall.
The distance from installation plate edge to ceiling should more
than 67 mm.
From installation plate left edge to unit’s left side is 47 mm.
From installation plate right edge to unit’s right is 73 mm.
:
:
:For left side piping, piping connection for liquid should be
about 14 mm from this line.
For left side piping, piping connection for gas should be
about 56 mm from this line.
For left side piping, piping connecting cable should be
about 785 mm from this line.
 1. Mount the installation plate on the wall with 5 screws or
more.
(If mounting the unit onthe concrete wall,consider using
anchor bolts.)
 • Always mountthe installation plate horizontally by
aligning the marking-off line with the thread and using a
level gauge.
 2. Drill the piping plate hole with ø70 mm hole-core drill.
 • Line according to the arrows marked on the lower left
and right side of the installation plate. The meeting point
of the extended line is the centre of the hole. Another
method is by putting measuring tape at position as
shown in the diagram above. The hole centre is
obtained by measuring thedistance namely 150 mm
and 125 mm for left and right hole respectively.
 • Drill the piping hole at either the right or the left and the
hole should be slightly slanted to the outdoor side.
10.2.3. TO DRILL A HOLE IN THE WALL
AND INSTALL A SLEEVE OF
PIPING
 1. Insert the piping sleeve to the hole.
 2. Fix the bushing to the sleeve.
 3. Cut the sleeve until it extrudes about 15 mm from the wall.
CautionWhen the wall ishollow, please be sure to use the
sleeve for tubeass’y to prevent dangers caused by
mice biting the connecting cable.
 4. Finish by sealing thesleeve withputty orcaulking
compound at the final stage.
10.2.4. INDOOR UNIT INSTALLATION
 1. For the right rear piping
 2. For the right and right bottom piping
10.2. INDOOR UNIT
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							 3. For the embedded piping
(This can be used for left rear piping & left bottom piping also.)
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							10.2.5. CONNECT THE CABLE TO THE
INDOOR UNIT
 1. The inside and outside connecting cable can be connected
without removing the front grille.
 2. Connecting cable between indoor unit and outdoor unit
shall be approved polychloroprene sheathed 5 (XC9CK,
XC12CK) × 1.5 mm
2flexible cord, typedesignation 245 IEC
57 or heavier cord.
 • Ensure the color of wires of outdoor unit and the
terminal Nos. are the same to the indoor’s respectively.
 • Earth lead wire shall be longer than the other lead wires
as shown in the figure forthe electrical safetyin case of
the slipping out of the cord from the anchorage.
 • Secure the cable onto the control board with the holder
(clamper).
INSTALLATION OF AIRPURIFYING FILTER
 1. Open the front panel.
 2. Remove the air filters.
 3. Put air purifying filter into place as shown in illustration
below.
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							HOW TO TAKE OUT FRONT GRILLE
Please follow the steps below to take out front grille if
necessary such as when servicing.
 1. Set the vertical airflow direction louver to the horizontal
position.
 2. Slide down the two caps on the front grille as shown in the
illustration below, and then remove the two mounting
screws.
 3. 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/SE RVICING
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 pressing the“AUTO” Switch continuously
for 10 sec. and above. A “pep”, “pep” sound will occur at the
tenth sec., in order to indicate the “ON/OFF” change over of
remote control receiving sound.
10.3. OUTDOOR UNIT
10.3.1. SELECT THE BEST LOCATION
(Refer to “Select the best location”
section)
10.3.2. 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 firmlyand horizontally
by bolt nut. (ø10 mm).
 2. When installing at roof, please consider strong wind and
earthquake. Pleasefasten the installation stand firmly with
bolt or nails.
10.3.3. 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.
MODELPiping size (Torque)
GasLiquid
XC9CK3/8” (42 N.m)1/4” (18 N.m)
XC12CK1/2” (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.
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							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.
(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.
10.3.4. 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 fromthe 2-way and3-wayvalves.
 2. Remove the service-portcap from the3-wayvalves.
 3. To open the valve, turn the valvestem of 2-wayvalve 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 open2-wayvalve again, turn the valve stem counter-clockwise until it stops.
4(A). Checking gas leakage for the left piping.
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							CHECK THE DRAINAGE
 • Open front panel and remove air filters.
(Drainage checking can be carriedout without removing the
front grille.)
 • Pour a glass of waterinto the draintraystyrofo am.
 • Ensure that water flows out from drain hose of the indoor
unit.
EVALUATIONOF 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 difference between the intake temperature and
the discharge is more than 8°C.
CHECK ITEMS
Is there any gas leakage at flare nut connection?
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?
10.3.5. 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 5 (XC9CK, XC12CK) × 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.
10.3.6. 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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							10.3.7. OXYGEN TUBE CONNECTION
Precautions duringoxygen tube connection
 1. Tube allowable length and height difference is the same as
pipes.
 2. Tube should be pulled without folding it along the path of
refrigerant pipe, providing sufficient allowance and cut to
length.
 • If there is no allowance, tube length will contract when
temperature changes and it may cause trouble.
 • On the other hand, tube length used without cutting and
in the form of loop too should be avoided.
 3. When the tube is passed throught the pipe hole, it should
not form the inner wall of the pipe bends.
The tube may be pressed to the corner of the hold and
crushed.
 4. Cutting of tube should be done with cutter or knife, cutting
suface should be straight and even.
Finishing should be done and leave no scratches behind.
 5. Tube end’s last 15 mm (the section to be inserted to the
joint during connection) should be free from any damages.
 6. Take note that the inside of tube should be free from
stones, dirt, dust, and other impurities.
Oxygen tube connection
 • Insert oxygen tube into the jointsection of indoor unit till it
fullyreaches its limit (about 15 mm).
 • Insert into the joint of outdoor unit in the same manner.
 • If the insert does not fullyreach the limit, oxygen may leak
out from the joint causing abnormal noise. • In both indoor and outdoor unit, the tube inserted will be
locked inside the joint by the stopper, and the job is
complete. To make sure that it’s done properly, pull out
lightly to checkif can be removed.
Connection check
 • Do connection check after normal running of
cooling/heating/ has been confirmed during trial operation.
(You cannot do properoxygen tubeconnection check
before normal running has been confirmed during trial
operation).
 • Operate according tothe sequence listed below, and check
tube connection.
 1. Check if the cap at the air filter (right) inner area of
oxygen supply section releases air after it has been
lifted up.
( If there is no air release, the cause may be tube
collape, or the insert at join section not proper. Check
again and make correction if found not properly done.)
 2. After checking, make sure that you push down the cap
and return to its original position.
(If it is not returned to its position, it may cause
abnormal noise.)
Finishing
 • Finishing should be carried out for pipe and drain hose.
 • Refer to 10.3.6 Pipe insulation of outdoor unit.
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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 manifold
gauge)
EvacuationOpenOpenOpen
(Servicing)With vacuum pump
Gas chargingOpenOpenOpen
(Servicing)(With chargingcylinder)
Pressure checkOpen
(Servicing)OpenOpen(Connected manifold
gauge)
Gas releasingOpen
(Servicing)OpenOpen(Connected manifold
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 thecooling capacity, 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:
If the leaks stop when the piping connections are
tightened further, 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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