Panasonic Inverter Air Conditioner R410A Technical Data And Service Manual

							1-115
1. Specifications
7-22. Precautions
  Request that the customer be present at the time the test run is performed. Explain the Operating Instructions to
the customer, and then have the customer actually operate the system.
  Be sure to pass the manual and warranty certi cate to the customer.
  Verify that the AC 208 / 230 V wiring is not connected to the terminal plate which is used to connect the inter-unit
control wiring.
* If AC 208 / 230 V is accidentally applied to this terminal plate, the fuse (0.5A for both indoor and outdoor units) on
the inter-unit control PCB will be tripped in order to protect the PCB. Correct the wiring connections, then
disconnect the 2P connectors (indoor unit: blue, OC, CN40; outdoor unit: blue, OC) which are connected
to the PCB and connect the other 2P connectors (indoor unit: brown, EMG, CN44; outdoor unit: brown, EMG).
(See the  gure below.)
If operation is still not possible with the brown connectors connected, cut the varistor (black) (for both the indoor
and outdoor units).
(Be sure to turn OFF the power before performing this work.)
B C P l o r t n o c t i n u r o o d t u O B C P l o r t n o c t i n u r o o d n I
Varistor (black)Fuse
0.5A
Serial 1 connector (blue)
Serial 2 connector (brown) 
Varistor (black)
VA0022P connector (brown) 2P connector (blue)
Fuse
0.5A
CHK (2P plug)
SW103TEST
OFF
ON
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							1-116
1. Specifications
7-23. When Setting Indoor Unit Control PCB Switch for Wall Mounted Indoor Unit
When using both the wired and wireless remote controller, refer to the procedure below.
  If this setting is not made correctly an alarm will occur. (The operation lamp on the display blinks.)
  This setting is not necessary for the case of using wireless remote controller only.
  The slide switch setting at the time of factory shipment for model K1 type is “B.”
  When using wired remote controller as “sub”, to set its
data to “sub” in remote controller setting mode.
  When using wireless remote controller as “sub”, set the
switch on the indoor unit control PCS to A.
 S-26PK1U6
A
Nos. 1, 2 OFF, No. 3 ON.
B
Nos. 1, 2, 3 all OFF
When using
wireless
remote
controller
as “main”
When using
wireless
remote
controller
as “sub”
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							1-117
1. Specifications
7-24.  Diagnosis TableWired remote 
Cause
E 0 1
E 0 2
E 0 9
E 1 4
E 0 4
E 0 6
E 1 5
E 1 6
E 2 0
P 0 5
L 0 2
P 0 9
 dis
played
L 0 7
 displayed
Indoor unit 
1:1 connection (single type)
Nothing is
displayedNothing is
displayed
 displayed
 displayedOperating lamp
is blinking.
 displayed
 displayed
 displayed
 displayed
 displayed
 displayed
 displayed
 displayed
 displayed
displayed
L 1 3
Standby lamp
is blinking.Operation lamp and
Standby lamp are 
blinking alternately.
Both the Operation
lamp and Standby 
lamp are blinking
together.
Timer lamp and
Standby lamp are 
blinking alternately.Remote controller is not connected correctly.
Indoor unit power is not ON.
Automatic address setting has not been
completed.
Inter-unit control wiring is cut or is not
connected correctly.
Remote controller is not connected correctly 
(remote controller receiving failure).
Remote controller is not connected correctly 
(failure in transmission from remote controller
to indoor unit).
Indoor-outdoor inter-unit wiring is not
connected correctly.
Indoor unit capacity is too low.
Indoor unit capacity is too high.
No serial signal is being received at all from 
the indoor units.
Inter-unit circuit or open phase in the outdoor
unit power
Insufficient gas
Indoor-outdoor unit type mismatch
The indoor unit ceiling panel connector is not
connected correctly.Group connection
Remote controller is not connected with 
indoor unit correctly
Indoor unit power is not ON.
Automatic address setting has not been
completed.
Inter-unit control wiring is cut or is not
connected correctly.
Remote controller is not connected with 
indoor unit correctly
Remote controller is not connected with 
indoor unit correctly
Same as at left
Indoor-outdoor inter-unit wiring is cut or 
is not connected correctly.
Same as at left
Reversed phase or open phase in the 
3-phase power at one of the outdoor
units in the group
Same as at left
Ceiling panel connector at one of the 
indoor units in the group is not
connected correctly.
Simultaneous-operation multi system
(flexible combination)
Same as at left
Same as at left
Same as at left
Control wiring for group control is cut or 
is not connected correctly.
Same as at left
Same as at left
Same as at left
Reversed phase or open phase in the 
outdoor unit 3-phase power
Same as at left
Control wiring for group control
 is connected
to the indoor unit, however it is set for individual
operation.
Indoor unit ceiling panel connector is not
connected correctly.Control by main-sub
remote controllers
Same as at left
Same as at left
Same as at left
2 remote controllers are 
set as the main remote 
controller.Same as at left
Same as at left
Same as at left
Same as at left
Same as at left
Same as at left
Same as at left
receiver lamp spcontroller dilay
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							1-118
1. Specifications
1-13.  HOW TO PROCESS TUBING 8. HOW TO INSTALL THE TIMER WIRED REMOTE CONTROLLER
The liquid tubing side is connected by a flare nut, and Refer to the Instraction Manual attaehed to the Timer Remote Controller.
the gas tubing side is connected by brazing.
1. Connecting the Refrigerant Tubing
Use of the Flaring Method
Many conventional split system air conditioners employ 
the flaring method to connect refrigerant tubes which run 
between indoor and outdoor units. In this method, the 
copper tubes are flared at each end and connected with 
flare nuts.
Flaring Procedure with a Flare Tool
(1)
cutter. It is recommended to cut approx. 12 – 20 in. 
longer than the tubing length you estimate.
(2)Cut the copper tube to the required length with a tube 
Remove burrs at each end of the copper tubing with 
a tube reamer or file. This process is important and 
should be done carefully to make a good flare. Be sure 
to keep any contaminants (moisture, dirt, metal filings, 
etc.) from entering the tubing. (Figs. 1-110 and 1-111)
(3)
mount it on the copper tube.
(4)Remove the flare nut from the unit and be sure to 
Make a flare at the end of the copper tube with a flare 
tool. (Fig. 1-112)
NOTE
NOTE
When reaming, hold the tube end downward and be sure 
that no copper scraps fall into the tube. (Fig. 1-111)
NOTE
A good flare should have the following characteristics:
 
inside surface is glossy and smooth
 
edge is smooth
tapered sides are of uniform lengthFig. 1-110
Fig. 1-111
Fig. 1-112
Deburring
BeforeAfter
Reamer Copper
tubing
Flare toolFlare nut
Copper
tubing
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							1-119
1. Specifications
Caution Before Connecting Tubes Tightly
(1) Apply a sealing cap or water-proof tape to prevent dust or water from
entering the tubes before they are used.
(2) Be sure to apply refrigerant lubricant to the matching surfaces of the
 are and union before connecting them together. This is effective for
reducing gas leaks. (Fig. 1-113)
(3) For proper connection, align the union tube and  are tube straight with
each other, then screw on the  are nut lightly at  rst to obtain a smooth
match. (Fig. 1-114)
 Adjust the shape of the liquid tube using a tube bender at the installation
site and connect it to the liquid tubing side valve using a  are.
Cautions During Brazing
Replace air inside the tube with nitrogen gas to prevent copper
oxide  lm from forming during the brazing process. (Oxygen,
carbon dioxide and Freon are not acceptable.)
Do not allow the tubing to get too hot during brazing. The nitrogen
gas inside the tubing may overheat, causing refrigerant system
valves to become damaged. Therefore allow the tubing to cool
when brazing.
Use a reducing valve for the nitrogen cylinder.
Do not use agents intended to prevent the formation of oxide  lm.
These agents adversely affect the refrigerant and refrigerant oil,
and may cause damage or malfunctions.
2. Connecting Tubing between Indoor and Outdoor Units
(1) Tightly connect the indoor-side refrigerant tubing extended from the wall
with the outdoor-side tubing.
(2) To fasten the  are nuts, apply speci ed torque as shown at right.
   When removing the  are nuts from the tubing
connections, or when tightening them after
connecting the tubing, be sure to use 2 adjustable
wrenches or spanners. (Fig. 1-115)
If the  are nuts are over-tightened, the  are may
be damaged, which could result in refrigerant
leakage and cause injury or asphyxiation to
room occupants.
 When removing or tightening the gas tube  are
nut, use 2 adjustable wrenches together: one at
the gas tube  are nut, and one at part A.
(Fig. 1-116)
   For the  are nuts at tubing connections, be
sure to use the  are nuts that were supplied
with the unit, or else  are nuts for R410A
(type 2). The refrigerant tubing that is used
must be of the correct wall thickness as shown
in the table at right.
Because the pressure is approximately 1.6 times higher
than conventional refrigerant pressure, the use of ordinary
 are nuts (type 1) or thin-walled tubes may result in tube
rupture, injury, or asphyxiation caused by refrigerant
leakage.
   In order to prevent damage to the  are caused by
over-tightening of the  are nuts, use the table above
as a guide when tightening.
   When tightening the  are nut on the liquid tube, use an
adjustable wrench with a nominal handle length of 7-7/8 in.
Fig. 1-113
Apply refrigerant 
lubricant
Fig. 1-114
Flare nut
Union
Fig. 1-115
Indoor unit
Outdoor unitSpanner Torque wrench
Fig. 1-116
A
Tube diameter
ø1/4 (6.35 mm)
ø3/8 (9.52 mm)
ø1/2 (12.7 mm)
ø5/8 (15.88 mm)
Tightening torque
(approximate)
120 – 160 in.lbs
(140 – 180 kgf
· cm)
300 – 360 in.lbs
(340 – 420 kgf
· cm)
430 – 480 in.lbs
(490 – 550 kgf
· cm)
590 – 710 in.lbs
(680 – 820 kgf
· cm)t0.032
t0.032
t0.032
t0.04 Tube thickness
(in.)
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							1-120
1. Specifications
 Do not use a spanner to tighten the valve stem caps.
Doing so may damage the valves.
 Depending on the installation conditions, applying
excessive torque may cause the nuts to crack.
Precautions for Packed Valve Operation
   If the packed valve is left for a long time with the valve
stem cap removed, refrigerant will leak from the valve.
Therefore, do not leave the valve stem cap removed.
 Use a torque wrench to securely tighten the valve stem
cap.
   Valve stem cap tightening torque:
Charging port 70 – 85 in.lbs (80 – 100 kgf  cm)
ø3/8
(Liquid side)160 – 180 in.lbs (190 – 210 kgf  cm)
ø5/8
(Gas side)240 – 270 in.lbs (280 – 320 kgf  cm)
3. Insulating the Refrigerant Tubing
Tubing Insulation
   Thermal insulation must be applied to all unit tubing,
including the distribution joint (purchased separately).
* For gas tubing, the insulation material must be heat
  resistant to 248°F or above. For other tubing, it must be
  heat resistant to 176°F or above.
Insulation material thickness must be 13/32 in. or greater.
CAUTION
If the exterior of the outdoor unit
valves has been  nished with a
square duct covering, make sure
you allow suf cient space to
access the valves and to allow
the panels to be attached and
removed.
Taping the  are nuts
Wind the white insulation tape around the  are nuts at the
gas tube connections. Then cover up the tubing
connections with the  are insulator, and  ll the gap at the
union with the supplied black insulation tape. Finally, fasten
the insulator at both ends with the supplied vinyl clamps.
(Fig. 1-119)
Insulation material
The material used for insulation must have good insulation
characteristics, be easy to use, be age resistant, and must
not easily absorb moisture.
CAUTION
After a tube has been insulated,
never try to bend it into a narrow
curve because it can cause
the tube to break or crack.Fig. 1-117
Fig. 1-118
Fig. 1-119
Never grasp the drain or refrigerant connecting
outlets when moving the unit.
Charging port
Valve stem capValve stem
Main valvePacked valve
2 tubes arranged together
Inter-unit
control wiringGas tube
Liquid tube
Armoring tape
Insulation
Unit side
insulatorInsulation tape (white)
(supplied) Sealer (supplied)
Flare insulator (supplied)
Tube insulator
(not supplied)
Heat resistant
248°F or above
Vinyl clamps (supplied) Flare nut
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							1-121
1. Specifications
4. Taping  the Tubes
(1) At this time, the refrigerant tubes (and electrical
wiring if local codes permit) should be taped
together with armoring tape in 1 bundle. To
prevent condensation from over owing the drain
pan, keep the drain hose separate from the
refrigerant tubing.
(2) Wrap the armoring tape from the bottom of the
outdoor unit to the top of the tubing where it
enters the wall. As you wrap the tubing, overlap
half of each previous tape turn.
(3) Clamp the tubing bundle to the wall, using 1
clamp approx. each meter (3 feet). (Fig. 1-120)
NOTE
Do not wind the armoring tape too tightly since this
will decrease the heat insulation effect. Also ensure
that the condensation drain hose splits away from the
bundle and drips clear of the unit and the tubing.
5. Finishing the Installation
After  nishing insulating and taping over the tubing,
use sealing putty to seal off the hole in the wall to
prevent rain and draft from entering. (Fig. 1-121)Fig. 1-120
Fig. 1-121
Inter-unit
control wiringGas tube
Liquid tube
Armoring tape
Insulation
Tubing Apply putty here
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							1-122
1. Specifications
1-14. LEAK TEST, EVACUATION AND
     ADDITIONAL REFRIGERANT CHARGE
 Perform an air-tightness test for this package A/C.
Check that there is no leakage from any of the 
connections. Air and moisture in the refrigerant system 
may have undesirable effects as indicated below.
 pressure in the system rises
 operating current rises
 cooling (or heating) ef ciency drops
 moisture in the refrigerant circuit may freeze and block 
capillary tubing
   water may lead to corrosion of parts in the refrigerant 
system
Therefore, the indoor unit and tubing between the indoor 
and outdoor unit must be leak tested and evacuated to 
remove any noncondensables and moisture from the 
system.
 Air Purging with a Vacuum Pump (for Test Run)
Preparation
Check that each tube (both liquid and gas tubes) between 
the indoor and outdoor units has been properly connected 
and all wiring for the test run has been completed. 
Remove the valve caps from both the gas and liquid 
service valves on the outdoor unit. Note that both liquid 
and gas tube service valves on the outdoor unit are kept 
closed at this stage.
   The refrigerant charge at the time of shipment is only 
guaranteed suf cient for a tubing length of up to 100 ft.
The tubing may exceed this length, up to the maximum 
permitted length; however, an additional charge is 
necessary for the amount that the tubing exceeds 100 ft.
(No additional refrigerating machine oil is needed.)
1. Leak Test
(1) With the service valves on the outdoor unit closed,
remove the 1/4 in.  are nut and its bonnet on the gas
tube service valve. (Save for reuse.)
(2) Attach a manifold valve (with pressure gauges) and 
dry nitrogen gas cylinder to this service port with 
charge hoses.
CAUTION
Use a manifold valve for air
purging. If it is not available,
use a stop valve for this
purpose. The “Hi” knob of the
manifold valve must always be
kept closed.Fig. 1-123 Fig. 1-122
Fig. 1-124
Manifold valve
Pressure
gaugeLo Hi
Charge hose
Outdoor unit
Liquid
tube Gas
tubeNitrogen gas cylinder
(In vertical standing
position)
Close
Close Open
Cylinder
valve
Outlet
Inlet
Vacuum pump Manifold gauge
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							1-123
1. Specifications
(3) Pressurize the system up to 4.15 MPa
(42 kgf/cm2G) with dry nitrogen gas and close the
cylinder valve when the gauge reading reaches
4.15 MPa (42 kgf/cm
2G). Then, test for leaks with
liquid soap.
CAUTION
To avoid nitrogen entering the
refrigerant system in a liquid
state, the top of the cylinder
must be higher than the bottom
when you pressurize the
system. Usually, the cylinder is
used in a vertical standing
position.
Fig. 1-125
CAUTIONUse a cylinder speci cally
designed for use with R410A. (4) Do a leak test of all joints of the tubing (both
indoor and outdoor) and both gas and liquid
service valves. Bubbles indicate a leak. Wipe
off the soap with a clean cloth after the leak test.
(5) After the system is found to be free of leaks,
relieve the nitrogen pressure by loosening the
charge hose connector at the nitrogen cylinder.
When the system pressure is reduced to normal,
disconnect the hose from the cylinder.
2. Evacuation
Be sure to use a vacuum pump that includes a
function for prevention of back- ow, in order to
prevent back- ow of pump oil into the unit tubing
when the pump is stopped.
   Perform vacuuming of the indoor unit and tubing.
Connect the vacuum pump to the gas tube valve
and apply vacuum at a pressure of –101kPa ( –755 
mmHg, 5 Torr) or below.
Continue vacuum application for a minimum of 1
hour after the pressure reaches –101kPa ( –755 
mmHg, 5 Torr).
(1) Attach the charge hose end described in the
preceding steps to the vacuum pump to evacuate
the tubing and indoor unit. Con rm that the “Lo”
knob of the manifold valve is open. Then, run the
vacuum pump.
(2) When the desired vacuum is reached, close the
“Lo” knob of the manifold valve and turn off the
vacuum pump. Con rm that the gauge pressure is
under –101kPa ( –755 mmHg, 5 Torr) after 4 to 5
minutes of vacuum pump operation.
Manifold valve
Pressure
gaugeLo Hi
Vacuum pump
Outdoor unit
Liquid
tube Gas
tube
Close
Close Open
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							1-124
1. Specifications
CAUTION
To avoid gas from leaking
when removing the charge
hose, make sure the stem
of the gas tube is turned all
the way out (“BACK SEAT”)
position. 3. Charging Additional Refrigerant
 Charging additional refrigerant (calculated from the
liquid tube length as shown in Section 1-12. Installation
Instructions, 1. Tubing Size, Table 1-2 Tubing Data for 
Models, Amount of additional refrigerant charge) using
the liquid tube service valve. (Fig. 1-126)  
 Use a balance to measure the refrigerant accurately.
 If the additional refrigerant charge amount cannot
be charged at once, charge the remaining
refrigerant in liquid form by using the gas tube
service valve with the system in Cooling mode at
the time of test run. (Fig. 1-127)
* If an additional refrigerant charge has been
  performed, list the refrigerant tubing length and
  amount of additional refrigerant charge on the
  product label (inside the panel).
4. Finishing the Job
(1) With a hex wrench, turn the liquid tube service
valve stem counter-clockwise to fully open the
valve.
(2) Turn the gas tube service valve stem counter-clockwise
to fully open the valve.
(3) Loosen the charge hose connected to the gas
tube service port (5/16.) slightly to release the
pressure, then remove the hose.
(4) Replace the 5/16.  are nut and its bonnet on the
gas tube service port and fasten the  are nut
securely with an adjustable wrench or box wrench.
This process is very important to prevent gas from
leaking from the system.
(5) Replace the valve caps at both gas and liquid
service valves and fasten them securely.Fig. 1-126
Fi
g. 1-127
Valve
Liquid
Manifold valve
Pressure
gaugeLo Hi
Outdoor unit
Liquid
tube Gas
tube
Close
Close Close
R410A
Outdoor unit
Liquid
tube Gas
tube
Open
Open Open
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