Panasonic GS-G90KE User manual

ServiceManual
Room Air Conditioners
CS-G90KE / CU-G90KE
CS-G120KE / CU-G120KE
 1996 Matsushita Air-Conditioning Corp. Sdn. Bhd.
All rights reserved. Unauthorized copying and distribu-
tion is a violation of law.
ORDER NO. MAC9609040C2
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
Untitled-2 6/29/00, 10:40 AM1

– 1 –
CS-G90KE
Features
WARNING
Thisserviceinformationisdesigned forexperienced repair techniciansonly andis notdesigned foruse bythe generalpublic. Itdoes notcontain
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. Any attempt to service or repair the product or products dealt with
in this service information by anyone else could result in serious injury or death.
!
• Product
– Powerful Mode for quick cool/heat
– Compressor operating frequency control to maintain
desired room temperature
– Automatic Restart after power failure
– Battery weak indication mark at remote control
– Washable front panel
– Power Monitor Display
• Serviceability
– Self diagnosis
– TestRunatbothCoolingandHeatingratedfrequency
• Quality Improvement
– High power supply voltage protection
– Low power supply voltage protection
– Gas leakage detection
Untitled-1 6/29/00, 10:39 AM1

– 2 –
MAC9609040C2
CS-G90KE
Remote Control
Functions
Operation OFF / ON Room Temperature Setting
TEMP.
• Temperature Setting (16˚C to 30˚C).
Operation Mode Selection
•aAutomatic Operation Mode
•HEAT Heating Operation Mode
•COOL Cooling Operation Mode
•DRY Soft Dry Operation Mode
•FAN Fan Operation Mode
MODE
OFF / ON
L
Powerful Mode Operation
POWERFUL
Indoor Fan Speed Selection
FAN SPEED
•h j k Low
l
•h j k Medium–
ll
•h j k Medium
lll
•h j k Medium+
llll
•h j k High
lllll
•AUTO FAN Automatic Fan Speed
• Automatic Airflow Direction
Control
• Airflow Direction Manual Control
Airflow Direction Control
AIR
SWING
AIR
SWING
a
AIR
SWING
Time / Timer Setting
• Hours and minutes setting.
Clock Setting
• Current time setting.
Sleep Mode Operation OFF / ON
SLEEP
• 24-hour, OFF / ON Real Timer Setting.
ON-TIMER
OFF-TIMER Timer Operation Selection
SET
CANCEL Timer Operation Set / Cancel
• ON Timer and OFF Timer setting and
cancellation.
∨
∧
CLOCK
Battery Indication
• Battery mark “
%
” blinks when the batteries
should be replaced.
Untitled-1 6/29/00, 10:39 AM2

– 3 –
CS-G90KE
Functions
Indoor Unit
Power Switch OFF / ON LL
LL
LPower Monitor Display **
**
*
• Lights up during compressor operation.
Automatic Operation Switch
• Used when the remote control cannot be
used.
Remote Control Signal Receiving
Sound Control OFF/ON **
**
*
• It can be controlled by pressing Automatic
Operation Switch for 10 seconds.
Test Run Operation
• Used when test running or servicing.
• Compressor operation: rated frequency
Cooling: 72Hz (CS-G90KE), 78Hz (CS-G120KE)
Heating: 92Hz (CS-G90KE), 98Hz (CS-G120KE)
Operation Mode
• Automatic, Heating, Cooling, Soft Dry and
Fan Operation.
Automatic Restart Control **
**
*
• Operation is restarted after power failure at
previous setting mode.
POWER L
AUTO
OFF / ON
TEST RUN
OFF / ON
Operation Indication Lamps
•POWER (Red) – Lights up in operation,
blinks in Automatic
Operation judging and
Hot Start operation.
•TIMER (Orange) – Lights up in Timer
Setting.
Blinks in Self Diagnosis
Control.
•SLEEP (Orange) – Lights up in Sleep Mode
Operation.
Sleep Operation Mode **
**
*
Timer Operation **
**
*
Powerful Mode **
**
*
• For quick cooling or heating
Indoor Fan Speed Control **
**
*
Airflow Direction Control **
**
*
FOR ALL OPERATIONS
Untitled-1 6/29/00, 10:39 AM3

MAC9609040C2
CS-G90KE
CS-G90KE
CS-G90KE
Deodorizing Control **
**
*
Sensible Heat Control **
**
*
Anti-Fog Discharge Control **
**
*
Anti-Dew Formation Control **
**
*
Anti-Freezing Control **
**
*
Quiet Operation **
**
*
Anti-Cold Draft Control **
**
*
Hot Start **
**
*
Intake Air Temperature Control **
**
*
High Pressure Control **
**
*
Functions Functions
– 4 – – 5 – – 6 –
Room Temperature Control **
**
*
COOLING/SOFT DRY OPERATION HEATING OPERATION
FAN OPERATION
AUTOMATIC OPERATION
Outdoor Fan Motor
Time Delay Safety Control **
**
*
Forced Operation 30 seconds **
**
*
High Pressure Control **
**
*
(For Cooling/Soft Dry)
DC Peak **
**
*
DC Reset **
**
*
Total Running Current Control **
**
*
Compressor Overheating
Protection **
**
*
Power Transistor Overheating
Protection **
**
*
• 6 poles induction motor, 1 speed.
*Details can be refered to OPERATION
DETAIL in this manual.
Low Frequency Operation
Protection **
**
*
Minimum Frequency Operation
Protection **
**
*
Outdoor Air Temperature
Control **
**
*
• Detect outdoor ambient temperature
and limits compressor operating
frequency
Functions
Outdoor Unit
Operation Mode
Cooling
Soft Dry
Heating
CS-G90KE
25 – 83 Hz
25 – 36 Hz
25 – 118 Hz
CS-G120KE
25 – 94 Hz
25 – 38 Hz
25 – 118 Hz
Compressor Operation Frequency
Temperature Shift **
**
*
Self Diagnosis **
**
*
Low Pressure Control **
**
*
(Gas Leakage Detection)
High Power Supply Voltage
Protection **
**
*
Indoor Power Relay Control **
**
*
Untitled-3 6/29/00, 10:44 AM4

MAC9609040C2
CS-G90KE CS-G90KE CS-G90KE
3.45 (1.06 - 3.85)
11,700 (3,600 - 13,100)
4.80 (0.98 - 6.10)
16,300 (3,300 - 20,800)
2.0
4.2
Single
230
50
Cooling ; 1.24 (0.355 - 1.53)
Heating ; 1.70 (0.34 - 2.10)
Cooling ; 5.5 (max. 6.7)
Heating ; 7.5 (max. 9.1)
Cooling ; 2.8
Heating ; 2.9
9.1
2.6 (0.88 - 2.90)
8,800 (3,000 - 9,900)
3.6 (0.78 - 4.80)
12,200 (2,600 - 16,300)
1.6
3.4
Single
230
50
Cooling ; 0.88 (0.29 - 1.01)
Heating ; 1.11 (0.275 - 1.44)
Cooling ; 4.3 (max. 4.7)
Heating ; 5.0 (max. 6.5)
Cooling ; 3.0
Heating ; 3.2
6.5
Cooling Capacity
Heating Capacity
Moisture Removal
Power Source
Airflow Method
Air Volume
Noise Level
Electrical
Data
Piping Connection Port
(Flare piping)
Pipe Size
(Flare piping)
Drain
Hose
Power Cord Length
Number of core-wire
Dimensions
Net Weight
Compressor
Air Circulation
Product Specifications
Inner diameter
Length
Input
Running Current
COP
Starting Current
Height
Width
Depth
Type
Motor Type
Rated Output
Type
Material
Motor Type
Input
Rated Output
Fan Low
Speed Medium
High (Heating)
Indoor Air (Lo)
Indoor Air (Me)
Indoor Air (Hi)
Outdoor Air
Unit
kW
Btu/h
kW
Btu/h
s/h
Pint/h
Phase
V
Cycle
OUTLET
INTAKE
m3/min (cfm)
m3/min (cfm)
m3/min (cfm)
m3/min (cfm)
dB (A)
kW
A
W/W
A
inch
inch
inch
inch
mm
m
inch (mm)
inch (mm)
inch (mm)
lb (kg)
W
W
W
rpm
rpm
rpm
CS-G90KE
SIDE VIEW
Cooling ; 6.4 (226)
Heating ; 6.4 (226)
Cooling ; 7.2 (254)
Heating ; 7.2 (254)
Cooling ; 8.3 (293)
Heating ; 9.4 (332)
–
Cooling ; High 38, Low 30
Heating ; High 39, Low 30
G ; Half Union 3/8"
L ; Half Union 1/4"
G (gas side) ; 3/8"
L (liquid side) ; 1/4"
12
0.7
2.1 m
3 core wires ×1.0 mm2
11-7/16 (290)
31-15/32 (799)
6-29/32 (175)
18 (8.0)
–
–
–
Cross-flow Fan
AS + Glass Fiber 30%
Transistor (4-poles)
–
20
1,000
1,120
1,300 (1,460)
– 7 – – 9 –
Product Specifications
Description
Tube material
Fin material
Fin Type
Row / Stage
FPI
Size (W ×H ×L)
Length
Flow Rate
Inner Diameter
Material
Style
Heat
Exchanger
Refrigerant Control Device
Refrigeration Oil
Refrigerant (R-22)
Thermostat
Protection Device
Capillary Tube
Air Filter
Capacity Control
Fan Motor Capacitor
Unit
mm
(c.c)
g (oz)
mm
s/min
mm
µF, VAC
(Plate fin configuration, forced draft)
Capillary Tube
CS-G90KE
Evaporator
Copper
Aluminium
Slit Fin
2/12
18
600 ×252 ×25.4
–
–
–
Electronic Control
–
–
–
–
P.P.
Honeycomb
–
– 8 –
Product Specifications
Inner diameter
Length
Input
Running Current
COP
Starting Current
Cooling Capacity
Heating Capacity
Moisture Removal
Power Source
Airflow Method
Air Volume
Noise Level
Electrical
Data
Piping Connection Port
(Flare piping)
Pipe Size
(Flare piping)
Drain
Hose
Power Cord Length
Number of core-wire
Dimensions
Net Weight
Compressor
Air Circulation
Height
Width
Depth
Type
Motor Type
Rated Output
Type
Material
Motor Type
Input
Rated Output
Fan Low
Speed Medium
High (Heating)
Unit
kW
Btu/h
kW
Btu/h
s/h
Pint/h
Phase
V
Cycle
OUTLET
INTAKE
m3/min (cfm)
m3/min (cfm)
m3/min (cfm)
m3/min (cfm)
dB (A)
kW
A
W/W
A
inch
inch
inch
inch
mm
m
inch (mm)
inch (mm)
inch (mm)
lb (kg)
W
W
W
rpm
rpm
rpm
Indoor Air (Lo)
Indoor Air (Me)
Indoor Air (Hi)
Outdoor Air
CS-G120KE
SIDE VIEW
Cooling ; 7.4 (261)
Heating ; 7.6 (268)
Cooling ; 8.1 (286)
Heating ; 8.3 (293)
Cooling ; 9.3 (328)
Heating ; 9.8 (346)
–
Cooling ; High 41, Low 37
Heating ; High 41, Low 37
G ; Half Union 1/2"
L ; Half Union 1/4"
G (gas side) ; 1/2"
L (liquid side) ; 1/4"
12
0.7
2.1 m
3 core wires ×1.5 mm2
11-7/16 (290)
31-15/32 (799)
6-29/32 (175)
18 (8.0)
–
–
–
Cross-flow Fan
AS + Glass Fiber 30%
Transistor (4-poles)
–
20
1,200
1,310
1,500 (1,550)
CU-G90KE
Condenser
Copper
Aluminium
Corrugated Fin
2/19
15
646.2 ×482.6 ×44
Capillary Tube
SUNISO 4GDID or
ATMOS M60 (260)
800 (28.2)
–
Electronic Control
Cooling ; 550, Heating ; 720
Cooling ; 12.5, Heating ; 5.8
Cooling ; 1.5 , Heating ; 1.2
–
1.2 µF, 400 VAC
CU-G90KE
TOP VIEW
–
–
–
23.5 (830)
Cooling ; 46
Heating ; 47
G ; 3-way valve 3/8"
L ; 2-way valve 1/4"
G (gas side) ; 3/8"
L (liquid side) ; 1/4"
–
–
–
–
19-29/32 (505)
30-23/32 (780)
9-21/32 (245)
86 (39)
Rotary (1 cylinder)
rolling piston type
Induction (2-poles)
500
Propeller Fan
AES + Glass Fiber 12%
Induction (6-poles)
34
20
–
–
675
CU-G120KE
TOP VIEW
–
–
–
26.4 (930)
Cooling ; 49
Heating ; 51
G ; 3-way valve 1/2"
L ; 2-way valve 1/4"
G (gas side) ; 1/2"
L (liquid side) ; 1/4"
–
–
–
–
19-29/32 (505)
30-23/32 (780)
9-21/32 (245)
92 (42)
Rotary (1 cylinder)
rolling piston type
Induction (2-poles)
650
Propeller Fan
AES + Glass Fiber 12%
Induction (6-poles)
70
30
–
–
780
• Specifications are subject to change without notice for further improvement.
Untitled-3 6/29/00, 10:44 AM5

– 10 –
MAC9509078C2
CS-G90KE
Heat
Exchanger
Refrigerant Control Device
Refrigeration Oil
Refrigeration (R-22)
Thermostat
Protection Device
Capillary Tube
Air Filter
Capacity Control
Fan Motor Capacitor
Description
Tube material
Fin material
Fin Type
Row / Stage
FPI
Size (W ×H ×L)
µF, VAC
Length
Flow Rate
Inner Diameter
Material
Style
(Plate fin configuration, forced draft)
Capillary Tube
CU-G120KE
Condenser
Copper
Aluminium
Corrugated Fin
2/19
17
646.2 ×482.6 ×44
Capillary Tube
SUNISO 4GDID or
ATMOS M60 (270)
970 (34.2)
–
Electronic Control
Cooling ; 880, Heating ; 535
Cooling ; 6.75, Heating ; 15.0
Cooling ; 1.2, Heating ; 1.6
–
–
1.5 µF, 400 VAC
Unit
mm
(c.c)
g (oz)
mm
s/min
mm
Product Specifications
CS-G120KE
Evaporator
Copper
Aluminium
Slit Fin
2/12
21
600 ×252 ×25.4
–
–
–
Electronic Control
–
–
–
–
P.P.
Honeycomb
–
• Specifications are subject to change without notice for further improvement.
Untitled-4 6/29/00, 10:47 AM10

– 11 –
CS-G90KE
Dimensions
CS-G90KE / CS-G120KE
65
122
18
799
48.5
60
290
<Front View>
175
61
34.5
52
direction
Air intake
Air outlet
direction
Left piping hole Right piping hole
290
115
55 60
2100
(45)(410)
<Back View> Installation plate hooks
Drain ports Gas
side Liquid
side
Remote control transmitter
(40) 710 (40)
276 7
(60) (110)
100 100
Slot (2 places)
Slot (2 places)
Centre notch
Indoor unit external
dimensions line
Installation plate
Left piping hole
Arrow
Arrow Centre Right piping hole
350
7
457
13.5
Relative position between the indoor unit and the installation plate <Front View>
Untitled-4 6/29/00, 10:47 AM11

– 13 –
CS-G90KE
Refrigeration Cycle Diagram
CS-G90KE / CU-G90KE
CS-G120KE / CU-G120KE
COMPRESSOR
4-WAY VALVE
C1
C3 C2
CHECK VALVE
OUTDOOR AIR
TEMP.
SENSOR
SENSOR
TEMP.
INTAKE AIR
EXCHANGER
TEMP.
SENSOR
INDOOR OUTDOOR
COOLING
HEATING
HEAT EXCHANGER
(EVAPORATOR) HEAT EXCHANGER
(CONDENSER)
2-WAY
VALVE
VALVE
3-WAY
C1, C2, C3; CAPILARRY TUBE
COMPRESSOR
TEMP.
SENSOR
TEMP.
SENSOR
HEAT
HEAT
EXCHANGER
Untitled-4 6/29/00, 10:47 AM13

– 14 –
MAC9509078C2
CS-G90KE
FUSE
(3.15A)
C-BOX
THERMAL
FUSE
99°C
102°C
FUSE
THERMAL
TERMINAL
50Hz 230V
PHASE
SINGLE
SUPPLY SWITCH RY-PWR
ELECTRONIC
CONTROLLER
ELECTRONIC
CONTROLLER
INCIDATOR
P.C.B.
RECEIVER
P.C.B.
FAN
MOTOR
STEPPING
MOTOR
3C 3C 5C
WIRELESS
REMOTE CONTROL
TRANSMITTER
11 22 33
FUSE
NOISE FILLTER
RY-PWR
ELECTRIC
RESISTOR
RY-FM
RY-HOT
FM
VALVE
4-WAY FAN
MOTOR
C-FM
CT
+
–+
–
DIODE
CU-G120KE
ONLY
CONTROLLER
ELECTRONIC
COMPRESSOR
INDOOR UNIT OUTDOOR UNIT
POWER
(20A)
Block Diagram
"C"
Indicates the electronic control unit.
Indicates the number of core wires. (Example:5C=5 core wires).
CS-G90KE / CU-G90KE CS-G120KE / CU-G120KE
Untitled-4 6/29/00, 10:47 AM14