Panasonic Cs E719k Cs E919 Kcs E1219k Repair Manual

							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)
Connec t the piping
 • Align the center of piping and sufficie ntly tighten the flare
nut with fingers.
 • Further tighten the flare nut with torque wrench in specifie d
torque as stated in the table.
Connecting The Piping To Outdoor Unit
MODELPiping size (Torque)
GasLiquid
PC9CK, SC9CK,
E719K, E919K3/8”(42 N.m)1/4”(18 N.m)
PC12CK, SC12CK, E1219K1/2”(55 N.m)1/4”(18 N.m)
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 specifie d 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.
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 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.
 6. To purge the air, push the pin on the service port of 3-way valve for three seconds using with a hexagonal wrench and set it
free for one minute.
 • ·Repeat this three times.
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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K 
						

							(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.
4(A). Checking gas leakage for the left piping.
10.3.5. 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 (PC9CK, PC12C K,
SC9CK , SC12C K, E719K , E919K , E1219K )×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.
10.3.6. 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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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K 
						

							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.
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? (PC9CK,
PC12CK, E719K, E919K, E1219K)
CHECK ITEMS
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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K 
						

							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)Withvacuum pump
Gas chargingOpenOpenOpen
(Servicing)(With charging cylinder)
Pressure checkOpen
(Servicing)OpenOpen(Connected manifold
gauge)
Gas releasingOpen
(Servicing)OpenOpen(Connected manifold
gauge)
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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K 
						

							Required tools: hexagonal wrench, adjustable wrench, torque
wrenches, wrench to hold the joints and gas leak detector.
The addition al 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 cylinde r and the charge set will be
needed .
 1. Recheck the piping connec tions.
 2. Open the valvestem of the 2-wayvalve counter-
clockwise approximately 90°, wait 10second s, 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 the 3-way valve’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 tighten the 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 cooling capacity, and could lead to a
malfunction.
 6. Set the 3-way valve to the openedposition.
 7. Mount thevalvestem nuts to the 2-way and 3-way
valves .
 8. Check for gas leakage.
 • At this time, especia lly 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 refrigerationcycle.
Procedure:
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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K 
						

							 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 andwait for 3 minutes,then connec t the
charge set to the service port of the 3-way valve.
 • Connect the charge hose with the push pin to the Gas
service port.
 4. Air purging of the charge hose.
 • Open the low-pressure valve on the charge set slightly
to purge air from the charge hose. 5. Set the 2-way valve to the closeposition.
 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 the closed 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 stem nuts 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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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K 
						

							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-way valve.
 • Leave the valve on the charging cylinde r closed.
 3. Air purging.
 • Open the valves on the charging cylinde r and the
charge set. Purge the air by looseni ng the flare nut on
the 2-way valve approximately 45°for 3 seconds then
closing it for 1 minute; repeat 3 times.
 • After purging the air, use a torque wrench to tighten the
flare nut on the 2-way valve.
 4. Check for gas leakage.
 • Check the flare connections for gas leakage. 5. Discharge the refrigerant.
 • Close the valve on the charging cylinde r and discharge
the refrigerant until the gauge indicate s 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-way valves to the open
position.
 • Be sure to use a hexagonal wrench to operate the valve
stems.
 7. Mount thevalvestem nuts 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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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K 
						

							(Gas leakage)
 1. Confirm that both the 2-way and 3-wayvalves are set to
the open position.
 2. Connect the charge set to the 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 conditio ner is not running is higher than 1
kg/cm
2G (0.1 MPa) ], discharge the refrigerant until the
gauge indicate s 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 sudden ly, the refrigeration oil will be discharged.
11.1.4. Balance refrigerant of the 2-way, 3-way valves
Procedure:
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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K 
						

							(No refrigerant in the refrigeration cycle)
 1. Connect the vacuum pump to the charge set’s centre
hose.
 2. Evacuation for approximately one hour.
 • Confirm that the gauge needle has moved toward -0.1
MPa (-76 cmHg) [vacuum of 4 mmHg or less.]
 3. Close thevalve(Low side) on the charge set, turn off
the vacuum pump, and confirm that the gauge needle
does not move (approximately 5 minutes after turning
off the vacuum pump).
 4. Disconnect the charge hose from the vacuum pump.
 • Vacuum pump oil
If the vacuum pump oil becomes dirty or deplete d,
replenish as needed .
11.1.5. Evacuation (Installation)
Procedure:
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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K 
						

							11.1.6. Gas charging
(After Evacua tion)
 1. Connect the charge hose to the charging cylinder.
 • Connect the charge hose which you disconn ected from
the vacuum pump to the valve at the bottom of the
cylinde r.
 2. Purge the air from the charge hose.
 • Open the valve at the bottom of the cylinde r and press
the check valve on the charge set to purge the air (be
careful of the liquid refrigerant).
 3. Open the valve(Low side) on the charge set and charge
the systemwith liquid refrigerant.
 • If the system cannot be charged with the specifie d
amount of refrigerant, it can be charged with a little at a
time (approximately 150 g each time) while operating
the air conditio ner in the cooling cycle; however, one
time is not sufficie nt, wait approximately 1 minute and
then repeat the procedure. (pumping down-pin)
This is different from previous procedures. Because you are
charging with liquid refrigerant from the gas side, absolutely do
no attempt to charge with large amount of liquid refrigerant
while operating the air conditioner.
 4. Immediately disconnect the charge hose from the 3-
way valve’s service port.
 • Stopping partway will allow the refrigerant to be
discharged.
 • If the system has been charged with liquid refrigerant
while operating the air conditio ner, turn off the air
conditio ner before disconn ecting the hose.
 5. Mount thevalvestem caps and the service port cap.
 • Use torque wrench to tighten the service port cap to a
torque of 18 N.m.
 • Be sure to check for gas leakage.
Procedure:
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CS-E719K CU-E7 19K / CS-E919K CU-E9 19K / CS-E1219K CU-E1219 K