Panasonic GS-G90KE Service Manual

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Service Manual

CS-G90KE / CU-G90KE

CS-G120KE / CU-G120KE

Contents

Features .......................................................... 1

Functions ................................................... 2 - 6

Product Specifications ............................. 7 - 10

Dimensions ............................................ 11 - 12

Refrigeration Cycle Diagram ......................... 13

Block Diagram ............................................... 14

Wiring Diagram ...................................... 15 - 16

Operation Details ................................... 17 - 48

Installation Information .......................... 49 - 50

Servicing Information ............................. 51 - 62

Technical Data ....................................... 63 - 64

Exploded View ......................................... 65, 67

Replacement Parts List ........................... 66, 68

Electronic Parts List ............................... 69 - 70

ORDER NO. MAC9609040C2

Room Air Conditioners

tion is a violation of law.

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Summary of Contents for Panasonic GS-G90KE

Page 1: Table Of Contents
ORDER NO. MAC9609040C2 Service Manual Room Air Conditioners CS-G90KE / CU-G90KE CS-G120KE / CU-G120KE Contents Features ............1 Functions ........... 2 – 6 Product Specifications ......7 – 10 Dimensions ..........11 – 12 Refrigeration Cycle Diagram ......13 Block Diagram ..........14 Wiring Diagram ........
Page 2: Features
CS-G90KE WARNING This service information is designed for experienced repair technicians only and is not designed for use by the general public. It does not contain warnings or cautions to advise non-technical individuals of potential dangers in attempting to service a product. Products powered by electricity should be serviced or repaired only by experienced professional technicians.
Page 3: Functions
CS-G90KE Functions Remote Control OFF / ON TEMP. Operation OFF / ON Room Temperature Setting • Temperature Setting (16˚C to 30˚C). MODE Operation Mode Selection ON-TIMER OFF-TIMER Timer Operation Selection • Automatic Operation Mode • Heating Operation Mode HEAT • 24-hour, OFF / ON Real Timer Setting. •...
Page 4 CS-G90KE Functions Indoor Unit FOR ALL OPERATIONS POWER L Power Switch OFF / ON L L L L L Power Monitor Display * * * * * • Lights up during compressor operation. AUTO OFF / ON Automatic Operation Switch Operation Mode •...
Page 5 CS-G90KE CS-G90KE CS-G90KE Functions Functions Functions Outdoor Unit COOLING/SOFT DRY OPERATION HEATING OPERATION AUTOMATIC OPERATION Outdoor Fan Motor Low Frequency Operation Deodorizing Control * * * * * Anti-Cold Draft Control * * * * * Room Temperature Control * * * * * Protection * * * * * •...
Page 6 CS-G90KE CS-G90KE CS-G90KE Product Specifications Product Specifications Product Specifications Unit CS-G90KE CU-G90KE CS-G120KE CU-G120KE Unit Unit CS-G90KE CU-G90KE Heat Evaporator Description Condenser 3.45 (1.06 - 3.85) 2.6 (0.88 - 2.90) Cooling Capacity Cooling Capacity Exchanger Tube material Copper Copper Btu/h 8,800 (3,000 - 9,900) 11,700 (3,600 - 13,100) Btu/h...
Page 7: Product Specifications
CS-G90KE Product Specifications Unit CU-G120KE CS-G120KE Description Evaporator Condenser Heat Tube material Copper Copper Exchanger Fin material Aluminium Aluminium Fin Type Slit Fin Corrugated Fin Row / Stage (Plate fin configuration, forced draft) 2/12 2/19 Size (W × H × L) 646.2 ×...
Page 8: Dimensions
CS-G90KE Dimensions CS-G90KE / CS-G120KE <Front View> Air intake direction 2100 Air outlet direction Left piping hole Right piping hole <Back View> Installation plate hooks Remote control transmitter Liquid Drain ports side side (410) (45) Relative position between the indoor unit and the installation plate <Front View> Slot (2 places) Slot (2 places) Centre notch...
Page 9: Refrigeration Cycle Diagram
CS-G90KE Refrigeration Cycle Diagram CS-G90KE / CU-G90KE CS-G120KE / CU-G120KE INDOOR OUTDOOR CHECK VALVE HEAT EXCHANGER TEMP. 2-WAY SENSOR VALVE INTAKE AIR TEMP. OUTDOOR AIR HEAT SENSOR TEMP. EXCHANGER SENSOR TEMP. SENSOR HEAT EXCHANGER (EVAPORATOR) HEAT EXCHANGER (CONDENSER) 4-WAY VALVE 3-WAY VALVE COMPRESSOR...
Page 10: Block Diagram
CS-G90KE Block Diagram – 14 –...
Page 11: Wiring Diagram
CS-G90KE Wiring Diagram CS-G90KE / CU-G90KE 230V 50Hz MOTOR 5 3 1 POMP DOWN SWITCH AUTO Y B R (TEXT RUN) SWITCH CN-MTR(G) WIRELESS REMOTE ELECTRONIC CONTROLLER CONTROL FUSE (3.15A) ELECTRONIC CONTROLLER (RECEIVER) CN-RCV(W) COIL REMARKS: : BLUE : BROWN SENSOR (HEAT EXCHANGER TEMP.) : BLACK...
Page 12 CS-G90KE Wiring Diagram CS-G120KE / CU-G120KE 230V 50Hz MOTOR 5 3 1 POMP DOWN SWITCH AUTO Y B R (TEXT RUN) SWITCH CN-MTR(G) WIRELESS REMOTE ELECTRONIC CONTROLLER CONTROL FUSE (3.15A) ELECTRONIC CONTROLLER (RECEIVER) CN-RCV(W) COIL REMARKS: : BLUE SENSOR (HEAT EXCHANGER TEMP.) : BROWN SENSOR : BLACK...
Page 13: Operation Details
CS-G90KE Operation Details A. FUNCTIONS 1. TEMPERATURE SHIFT Once the operation starts, the remote control setting temperature will be shifted internally based on the setting fan speed and outdoor air temperature. In addition, if Sleep Mode or Powerful Mode are set, the temperature shift will be carried out.
Page 14 CS-G90KE Operation Details 2. COOLING OPERATION A. Room Temperature Control (i) When the remote control setting temperature is less than 24°C. Cooling Compressor Operation Frequency (Hz) Intake air temp. – 83 (Fc max) or 72 83 (Fc max) or 72 94 (Fc max) or 78 94 (Fc max) or 78 +1.5...
Page 15 CS-G90KE Operation Details B. Deodorizing Control • This control is available during automatic fan speed for Cooling and Soft Dry Operation. It is not available during anti-freezing control. Deodorizing Status 6, 7, 6, 7,… Compressor Time (second) ……… Fan Speed Auto ………...
Page 16 CS-G90KE Operation Details 3. SOFT DRY OPERATION A. Room Temperature Control At the start of operation, cooling operation is running until the intake air temperature is 0.5°C higher than internal setting temperature, then the operation will shift to Soft Dry with indoor fan speed SLo. Soft Dry Compressor Operation Frequency (Hz) Intake air temp.
Page 17 CS-G90KE Operation Details B. Deodorizing Control • This control is available during automatic fan speed for Cooling and Soft Dry Operation. It is not available during anti-freezing control. Deodorizing Status 6, 7, 6, 7,… Compressor Time (second) ……… Fan Speed ………...
Page 18 CS-G90KE Operation Details 4. HEATING OPERATION A. Room Temperature Control • During heating operation, the room temperature control depends on intake air temperature and internal setting temperature. Basically it can be divided into 2 periods as shown below: Stabilized Intake air temp. – internal setting temp. 0°C period –1.5°C...
Page 19 CS-G90KE Operation Details CS-G120KE Heating Operation Compressor Operation Frequency (Hz) Transition Period Stabilized Period Remote Control Setting Temp. 16°C ~ 30°C 16°C ~ 20°C 21°C ~ 25°C 26°C ~ 30°C Intake air temperature – Internal setting temperature Comp Off Comp Off Comp Off Comp Off Comp Off...
Page 20 CS-G90KE Operation Details CS-G120KE Heating Operation Compressor Operation Frequency (Hz) Transition Period Stabilized Period Remote Control Setting Temp. 16°C ~ 30°C 16°C ~ 20°C 21°C ~ 25°C 26°C ~ 30°C Intake air temperature – Internal setting temperature Comp Off Comp Off Comp Off Comp Off Comp Off...
Page 21 CS-G90KE Operation Details B. Anti Cold Draft Control (i) Indoor Fan Control Indoor fan speed and airflow direction varies in accordance to the indoor heat exchanger temperature as shown below: a. Manual Fan speed control (Manual Airflow Direction Control) (Auto Airflow Direction Control) Min Me Min Me 58°C...
Page 22 CS-G90KE Operation Details (ii) Hot Start • At the start of heating operation, the indoor fan stops and compressor operates at Fhmax frequency (118Hz). This is to heat up the indoor heat exchanger in order to avoid cold air discharged. •...
Page 23 CS-G90KE Operation Details Deice Operation Time Chart Outdoor Heat Exchanger Temperature (°C) Deice Operation Ending Signal 30 sec 30 sec Deice max 11 min Heating Heating Operation Operation –6 Deice Operation –7 Starting Signal –9 –11 Compressor operating 75Hz (CU-G90KE) Free 55Hz 118Hz...
Page 24 CS-G90KE Operation Details 5. FAN OPERATION This operation is to enable the fan operation without compressor running. Timer operation is valid for fan operation. 6. AUTOMATIC OPERATION When the Automatic mode is selected, the operation mode is decided in accordance to remote control setting temperature, intake air temperature and outdoor air temperature.
Page 25 CS-G90KE Operation Details (b) When the remote control setting temperature is 25°C. Soft Dry Cool -ing Intake Air Temp. Heating (°C) Outdoor Air Temp Setting Temp (°C) 18 and below 19 ~ 22 23 ~ 26 27 and above (c) When the remote control setting temperature is 30°C. Soft Dry Cool -ing...
Page 26 CS-G90KE Operation Details • When the operation mode is changed over, the value for t1, t2 and t3 are shifted as follows: Cooling/Soft dry → Heating : –2°C Heating → Cooling/Soft dry : +2°C • When the indoor intake air temperature is lower than 16°C, heating operation is immediately started. •...
Page 27 CS-G90KE MEMO – 31 –...
Page 28 CS-G90KE CS-G90KE – 33 – – 32 –...
Page 29 CS-G90KE CS-G90KE – 34 – – 35 –...
Page 30 CS-G90KE Operation Details (a) Cooling Automatic Fan Speed The Automatic Fan Speed for cooling operation is shown as below: (i) When Automatic Fan Speed is selected Fan No. 15 Fan No. 13 Fan No. 11 sec. 80 sec. (ii) When Automatic Fan Speed and Powerful Mode are selected Fan No.
Page 31 CS-G90KE Operation Details (c) Cooling Operation at SHi Speed During Cooling operation, Indoor Fan speed is set at SHi when the following conditions occur: • Outside air temperature is 30°C or above • Compressor operates at 72Hz (CU-G90KE) or 78Hz (CU-G120KE) and above •...
Page 32 CS-G90KE Operation Details 9. AIRFLOW DIRECTION • Blade angle setting (Upper limit reference) Blade angle Operation 14° Heating Airflow direction auto Indoor heat exchanger temperature 61° 0° Airflow direction manual – 29.4° – 0° 18° 45.1° 61° Cooling Airflow direction auto –...
Page 33 CS-G90KE Operation Details (b) Airflow Direction Auto By setting the airflow direction to AUTO, the blade swings up and down from 0°-37° during Cooling and Soft Dry operation. During Heating operation, the blade angle will shift according to the indoor heat exchanger temperature as shown below: Zone A 58°C...
Page 34 CS-G90KE Operation Details 11. POWERFUL MODE OPERATION When the powerful mode is selected, the internal setting temperature will shift to achieve the setting temperature quickly. (a) Cooling Operation Internal setting temperature ↓ –4°C ↑ When powerful button is pressed (b) Soft Dry Operation Internal setting temperature ↓...
Page 35 CS-G90KE Operation Details (b) Heating Operation • When the sleep button is pressed, the remote control setting temperature will decrease 2°C after 1 hour or when the remote control setting temperature is reached. After another hour, 3°C will be decreased again. Remote control setting temperature –2°C...
Page 36 CS-G90KE Operation Details 15. POWER MONITOR DISPLAY HIGH POWER MONITOR Power Monitor LED lights on when the compressor is in operation. The number of the LED lights on is in accordance to the compressor operating frequency. Display A, B A, B, C A, B, C, D A, B, C, D, E Cooling &...
Page 37 CS-G90KE Operation Details B. PROTECTION 1. PROTECTION CONTROL FOR ALL OPERATIONS Time Delay Safety Control • The compressor is not restarted for 3 minutes after stop of compressor. 30 Second Forced Operation • Once the compressor is ON, it will not turn OFF for 30 seconds. However, it is turned off by remote control or Automatic switch.
Page 38 CS-G90KE Operation Details Power Transistor Overheating Prevention Control • When the power transistor temperature rises to 110°C, the OLP goes into operation and compressor stops immediately. The compressor is restarted when the power transistor temperature decreases to 95°C after 3 minutes (Time Delay Safety Control). Compressor Overheating Prevention Control •...
Page 39 CS-G90KE Operation Details Minimum Frequency Operation Protection • When the compressor operates at less than 36 Hz (CU-G90KE) or 38 Hz (CU-G120KE) for 20 minutes, the operating frequency will increase to 36 Hz (CU-G90KE) or 38 Hz (CU-G120KE) for 2 minutes. Comp.
Page 40 CS-G90KE Operation Details 2. PROTECTION CONTROL FOR COOLING & SOFT DRY Anti-Freezing Control • When the temperature of the indoor heat exchanger becomes low, the compressor operating frequency is reduced and stopped when the temperature falls to lower than 2°C continuously for 6 minutes. This is to prevent freezing of indoor heat exchanger.
Page 41 CS-G90KE Operation Details Anti-Fog Discharge Control • The compressor operating frequency is regulated by outdoor air temperature and operation time to prevent fog discharged from indoor unit as shown in the table below. Compressor operating frequency (Hz) 0 ≤ T < 30 Operation Time, T (min) 30 ≤...
Page 42 CS-G90KE Operation Details 3. PROTECTION CONTROL FOR HEATING OPERATION Intake Air Temperature Control • When the intake air temperature is 10°C or above and remote control setting fan speed is less than Medium, the compressor operates at 92 Hz (CU-G90KE) or 98 Hz (CU-G120KE). Outdoor Air Temperature Control •...
Page 43: Installation Information
CS-G90KE Installation Information Attached accessories Accessories part Qty. Accessories part Qty. Drain elbow Installation plate Installation plate fixing screw Clamping cover of piping Remote control Vinyl tape Battery Vinyl tape Air purifying filter Accessories: Flaring piping kit CZ-3F5, 7AEN (CS-G90KE) CZ-4F5, 7AEN (CS-G120KE) SELECT THE BEST LOCATION INDOOR UNIT...
Page 44 CS-G90KE Installation Information Indoor / Outdoor unit installation diagram Length of power supply cord Piping direction Attention not to bend up drain hose (Front side) about 1.1 m about 1.8 m Right Right < < < < rear Left Left Right bottom rear Left bottom...
Page 45: Servicing Information
CS-G90KE Servicing Information A. TROUBLESHOOTING 1. RATED FREQUENCY OPERATION During troubleshooting and servicing, rated compressor operating frequency must be obtained in order to check the specification and technical data. Below are the methods used to obtain rated compressor operating specification. (a) Cooling (i) Press the Test Run button on the indoor unit.
Page 46 CS-G90KE Servicing Information 2. TROUBLESHOOTING AIR CONDITIONER Refrigeration cycle system In order to diagnose malfunctions, make sure that Normal Pressure and Outlet Air Temperature (Standard) there are no electrical problems before inspect- Gas pressure Outlet air ing the refrigeration cycle. Such problems include MPa (kg/cm temperature (°C) insufficient insulation, problem with the power source,...
Page 47 CS-G90KE Servicing Information 1. Relationship between the condition of the air conditioner and pressure and electric current Cooling Mode Heating Mode Condition of the air Electric Electric Low Pressure High Pressure Low Pressure High Pressure conditioner current during current during operation operation Insufficient refrigerant...
Page 48 CS-G90KE Servicing Information B. SELF DIAGNOSIS DISPLAY The diagnostic display can be seen on the receiver of the Front Grille. When an abnormality occurs, the unit automatically stops, and the TIMER LED blinks to indicate a malfunction. At the same time, the type of abnormality will be indicated on the receiver as shown in the diagram below. Providing this information reduces the time spent in diagnosing procedures.
Page 49 CS-G90KE Servicing Information Abnormality Temporary Diagnosis Abnormality / Protection control Primary location to verify Judgement operation display 1 min after • Internal / external cable connections Indoor / outdoor abnormal – starting operation • Indoor / Outdoor PCB communication Indoor intake air temperature •...
Page 50 CS-G90KE Servicing Information (a) Current Transformer Defective When the Current Transformer (CT) is an open circuit, total running current is less than 1.88 A and the indicated frequency is 72 Hz (CU-G90KE) or 78 Hz (CU-G120KE) or above. After 3 minutes of operation, the abnormality signal is sent from outdoor to indoor and [H16] is displayed.
Page 51 CS-G90KE Servicing Information C. REMOTE CONTROL Reset Button Remote Control Reset When the batteries are inserted for the first time, or the batteries are replaced, all the indications will blink and the remote control might not work. ¶E If this happens, remove the back cover of the REMOTE CONTROLLER ´_ remote control and you will find a resetting termi-...
Page 52 CS-G90KE Servicing Information D. DISASSEMBLY OF PARTS Earth Wire Connector Inspection points for the Indoor Electronic Controller Fan Motor 1. The Electronic Controller, a signal Receiver, a Connector power monitor, as indicator and a self diagnosis (CN-MTR) indicator display can be seen by removing the Front Grille and Control Board Cover, as shown in Electronic Controller...
Page 53 CS-G90KE Servicing Information 3. Remove the Fan Motor Fan Motor securing screw Loosen the Fan Motor securing screw at the junction with Cross Flow Fan. (Fig. 5) Fig. 5 Remove the particular piece and the Fan Motor can be taken off as shown in Fig. 6 and 7. Particular piece Fig.
Page 54 CS-G90KE Servicing Information C. Cross Flow Fan Removal Procedure 1. Remove the Indoor Fan Motor. (Refer to the removal procedure of the Indoor Fan Motor.) (Fig. 9) Fan Motor Fig. 9 2. Remove the Air Discharge Grille by taking off the screws that hold the Air Discharge Grille and then pull the Air Discharge Grille in a down and forward direction.
Page 55 CS-G90KE Servicing Information Removal Procedure of Display Electronic Controller 1. Release the Display Electronic Controller from the tab as shown in Fig. 13. 2. Move the Display Electronic Controller to the right Display Electronic and pull it towards you. Controller Fig.
Page 56 CS-G90KE Servicing Information Inspection Method for the Outdoor Unit Outdoor Electronic 1. Removal of the front panel of the outdoor unit Controller allows access to the electronic control device. (Fig. 17) Screw Cover Fig. 17 <WARNING> • Be sure to return the wiring to its original position. •...
Page 57: Technical Data
CS-G90KE Technical Data L L L L L Operation characteristics CS-G90KE / CU-G90KE • Cooling Characteristic • Piping Length Characteristic (Cooling) 230V 230V 3.75 3.70 3.65 3.60 3.55 3.50 0.62 0.60 0.58 0.56 PIPING LENGTH (m) OUTDOOR AIR TEMPERATURE (°C) [Condition] Room temperature: 27/19°C [Condition] Room temperature: 27/19°C Outdoor temperature: 35/24°C...
Page 58 CS-G90KE Technical Data L L L L L Operation characteristics CS-G120KE / CU-G120KE • Cooling Characteristic • Piping Length Characteristic (Cooling) 230V 230V 0.58 0.57 0.54 0.56 0.53 0.55 0.52 0.54 0.51 0.53 PIPING LENGTH (m) OUTDOOR AIR TEMPERATURE (°C) [Condition] Room temperature: 27/19°C [Condition] Room temperature: 27/19°C Outdoor temperature: 35/24°C...
Page 59: Exploded View
CS-G90KE Exploded View CS-G90KE / CS-G120KE "¢ & > < – 65 –...
Page 60: Replacement Parts List
CS-G90KE Replacement Parts List <Model: CS-G90KE / CS-G120KE> REMARKS DESCRIPTION & NAME CS-G90KE CS-G120KE CHASSY COMPLETE CWD50C202 FAN MOTOR CWA98244 CROSS FLOW FAN COMPLETE CWH02C053 SCREW – CROSS FLOW FAN CWH4580304 BEARING ASS’Y CWH64K007 CWB30C146 EVAPORATOR CWB30C145 CWT01C238 CWT01C237 TUBE ASS’Y COMPLETE FLARE NUT (1/4") CWH6002140 CWT25007 (1/2")
Page 61 CS-G90KE Exploded View CU-G90KE / CU-G120KE < > " & 9˚ – 67 –...
Page 62 CS-G90KE Replacement Parts List <Model: CU-G90KE / CU-G120KE> DESCRIPTION & NAME CU-G90KE CU-G120KE REMARKS CHASSY ASS’Y CWD50K622A CWD50K632A FAN MOTOR BRACKET CWD54155 CWD54K063 SCREW – FAN MOTOR BRACKET CWH4580399 FAN MOTOR CWA95341 CWA95342 SCREW – FAN MOTOR MOUNT CWH55027 CWH00K052 PROPELLER FAN NUT –...
Page 63: Electronic Parts List
CS-G90KE Electronic Parts List <Model: CWA74983> POWER PCB SYMBOL DESCRIPTION & NAME PART NO. BZ101 BUZZER A48004 D101 DIODE A54MA165TA5 D102 DIODE A54RA15–10V3 D103, D104 DIODE A54RA15–06V3 D105 DIODE A54RA15–01V3 DB101 DIODE A54D3SBA60F1 XBA2C31TRO FUSE FUSE IC101 A52C095 INTERGRATED CIRCUIT PC101, PC103 A52LP621–1B4 PHOTO COUPLER...
Page 64 CS-G90KE Electronic Parts List <Model: CWA74984 / CWA74987> OUTDOOR PCB SYMBOL DESCRIPTION & NAME PART NO. CURRENT TRANSFORMER A40260 (1.5 µF/400V) C–FM CAPACITOR A31487 (CWA74984) (1.2 µF/400V) A31476 (CWA74987) D1, D20 DIODE A54RB44–02V D2, D4 ~ D10 DIODE A54MA165TA5 DIODE A541SS136T A54RB43–O2V D11, D14, D17...
Page 65 Printed in Malaysia MACC P970102900YH...

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