Panasonic CS-PS9PKV Service Manual Download

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WARNING

15. Disassembly and Assembly Instructions

High Voltage is generated in the electrical parts area by the capacitor. Ensure that the capacitor has discharged sufficiently before proceeding with
repair work. Failure to heed this caution may result in electric shocks.

15.1 CS-PS9/12PKV

15.1.1 Indoor Electronic Controllers, Cross Flow Fan and Indoor Fan Motor Removal

Procedures

15.1.1.1 To remove front grille

Figure 1

15.1.2 To remove electronic controller

Figure 2

Summary of Contents for CS-PS9PKV

Page 1: ...or repairing of refrigerant circuit 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...

Page 2: ...uto Restart Control 51 11 7 Indication Panel 51 11 8 ECONAVI AUTO COMFORT Operation 52 12 Protection Control 56 12 1 Restart Control Time Delay Safety Control 56 12 2 30 Seconds Forced Operation 56 12...

Page 3: ...mmended to install with Earth Leakage Circuit Breaker ELCB or Residual Current Device RCD Otherwise it may cause electrical shock and fire in case equipment breakdown or insulation breakdown 10 Do not...

Page 4: ...for maintenance 6 Pb free solder has a higher melting point than standard solder typically the melting point is 50 F 70 F 30 C 40 C higher Please use a high temperature solder iron In case of the sol...

Page 5: ...Type Hermetic Motor Rotary Hermetic Motor Rotary Motor Type Brushless 6 poles Brushless 6 poles Output Power W 650 650 Indoor Fan Type Cross flow fan Cross flow fan Material ASG20K1 ASG20K1 Motor Typ...

Page 6: ...ated Aluminium Pre coated Fin Type Slit Fin Slit Fin Row x Stage x FPI 2 x 15 x 17 2 x 15 x 17 Size W x H x L mm 610 x 315 x 25 4 610 x 315 x 25 4 Outdoor Heat Exchanger Fin Material Aluminium Blue co...

Page 7: ...w fan Cross flow fan Material ASG30K1 ASG30K1 Motor Type DC Transistor 8 poles DC Transistor 8 poles Input Power W 94 8 94 8 Output Power W 40 40 Speed Lo rpm 930 960 Me rpm 1110 1140 Hi rpm 1300 1330...

Page 8: ...15 x 25 4 Outdoor Heat Exchanger Fin Material Aluminium Blue coated Aluminium Blue coated Fin Type Slit Fin Slit Fin Row x Stage x FPI 2 x 24 x 17 1 x 31 x 19 Size W x H x L mm 25 4 x 504 x 693 4 713...

Page 9: ...9 3 Location of Controls and Components 3 1 Indoor Unit 3 2 Outdoor Unit 3 3 Remote Control...

Page 10: ...10 4 Dimensions 4 1 Indoor Unit 4 1 1 CS PS9PKV CS PS12PKV...

Page 11: ...11 4 1 2 CS PS18PKV CS PS24PKV...

Page 12: ...12 4 2 Outdoor Unit 4 2 1 CU PS9PKV 4 2 2 CU PS12PKV CU PS18PKV...

Page 13: ...13 4 2 3 CU PS24PKV...

Page 14: ...14 5 Refrigeration Cycle Diagram 5 1 CS PS9PKV CU PS9PKV CS PS12PKV CU PS12PKV...

Page 15: ...15 5 2 CS PS18PKV CU PS18PKV CS PS24PKV CU PS24PKV...

Page 16: ...16 6 Block Diagram 6 1 CS PS9PKV CU PS9PKV...

Page 17: ...17 6 2 CS PS12PKV CU PS12PKV...

Page 18: ...18 6 3 CS PS18PKV CU PS18PKV...

Page 19: ...19 6 4 CS PS24PKV CU PS24PKV...

Page 20: ...20 7 Wiring Connection Diagram 7 1 Indoor Unit 7 1 1 CS PS9PKV CS PS12PKV Resistance of Fan Motor Windings MODEL CS PS9PKV CS PS12PKV CONNECTION CWA921443 YELLOW BLUE 382 0 RED YELLOW 226 8...

Page 21: ...21 7 1 2 CS PS18PKV CS PS24PKV...

Page 22: ...2 1 CU PS9PKV Resistance of Compressor Windings Resistance of Fan Motor Windings MODEL CU PS9PKV MODEL CU PS9PKV CONNECTION 5RS092XCE21 CONNECTION CWA951734 U V 1 152 YELLOW BLUE 338 0 U W 1 152 RED Y...

Page 23: ...2PKV Resistance of Compressor Windings Resistance of Fan Motor Windings MODEL CU PS12PKV MODEL CU PS12PKV CONNECTION 5RS092XCD21 CONNECTION CWA951466 U V 1 152 YELLOW BLUE 262 7 U W 1 152 RED YELLOW 2...

Page 24: ...24 7 2 3 CU PS18PKV Resistance of Compressor Windings MODEL CU PS18PKV CONNECTION 5RD132XDA21 U V 1 152 U W 1 152 V W 1 152...

Page 25: ...24PKV Resistance of Compressor Windings Resistance of Fan Motor Windings MODEL CU PS24PKV MODEL CU PS24PKV CONNECTION 5RD132XBA21 CONNECTION CWA951762 U V 1 897 YELLOW BLUE 75 0 U W 1 907 RED YELLOW 7...

Page 26: ...26 8 Electronic Circuit Diagram 8 1 Indoor Unit 8 1 1 CS PS9PKV CS PS12PKV...

Page 27: ...27 8 1 2 CS PS18PKV CS PS24PKV...

Page 28: ...28 8 2 Outdoor Unit 8 2 1 CU PS9PKV...

Page 29: ...29 8 2 2 CU PS12PKV...

Page 30: ...30 8 2 3 CU PS18PKV...

Page 31: ...31 8 2 4 CU PS24PKV...

Page 32: ...32 9 Printed Circuit Board 9 1 Indoor Unit 9 1 1 Main Printed Circuit Board 9 1 1 1 CS PS9PKV CS PS12PKV...

Page 33: ...33 9 1 1 2 CS PS18PKV CS PS24PKV 9 1 2 Indicator and Receiver Printed Circuit Board...

Page 34: ...34 9 1 3 Comparator Printed Circuit Board 9 1 4 Human Activity Sensor Printed Circuit Board...

Page 35: ...35 9 2 Outdoor Unit 9 2 1 Main Printed Circuit Board 9 2 1 1 CU PS9PKV...

Page 36: ...36 9 2 1 2 CU PS12PKV...

Page 37: ...37 9 2 1 3 CU PS18PKV...

Page 38: ...38 9 2 1 4 CU PS24PKV...

Page 39: ...39 9 2 2 Noise Filter Printed Circuit Board 9 2 2 1 CU PS9PKV...

Page 40: ...ed installation height for indoor unit shall be at least 2 5 m 10 1 2 Outdoor Unit If an awning is built over the unit to prevent direct sunlight or rain be careful that heat radiation from the conden...

Page 41: ...he marking off line with the thread and using a level gauge 2 Drill the piping plate hole with 70 mm hole core drill o Line according to the left and right side of the installation plate The meeting p...

Page 42: ...2 3 Indoor Unit Installation 10 2 3 1 For the right rear piping 10 2 3 2 For the right and right bottom piping 10 2 3 3 For the embedded piping This can be used for left rear piping and bottom piping...

Page 43: ...indoor unit and outdoor unit shall be approved polychloroprene sheathed 4 x 1 5 mm2 1 0 1 5HP or 4 x 2 5 mm2 2 0 2 5HP flexible cord type designation 245 IEC 57 or heavier cord Do not use joint conne...

Page 44: ...hown in the figure for the electrical safety in case of the slipping out of the cord from the anchorage 10 2 5 Wire Stripping And Connecting Requirement 10 2 6 Cutting and flaring the piping 1 Please...

Page 45: ...ssembly 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 wr...

Page 46: ...g 0 MPa to 76 cmHg 0 1 MPa Then evacuate the air approximately ten minutes 4 Close the Low side valve of the charging set and turn off the vacuum pump Make sure that the needle in the gauge does not m...

Page 47: ...board with the holder clamper 4 Attach the control board cover back to the original position with the screw 5 For wire stripping and connection requirement refer to instruction 10 2 4 of the indoor u...

Page 48: ...2 Cooling Operation 11 1 2 1 Thermostat control Compressor is OFF when intake Air Temperature Internal Setting Temperature 0 5 C Compressor is ON after waiting for 3 minutes if the Intake Temperature...

Page 49: ...ately after the fan motor is started feedback control is performed once every second o During fan motor on if fan motor feedback 2550 rpm or 50 rpm continuously for 10 seconds the fan motor error coun...

Page 50: ...rol the vane will shift to close position Manual vertical airflow direction can be set using remote control the angles of the vane are as stated above and the positions of the vane are as figure below...

Page 51: ...ation of air conditioner the compressor will re operate within three to four minutes There are 10 patterns to be selected randomly after power supply resumes This control is not applicable during OFF...

Page 52: ...NAVI AUTO COMFORT Sensor power ON and end after 30 seconds Control content Judge ECONAVI AUTO COMFORT Sensor power level every 100ms Abnormal Judgment condition When ECONAVI AUTO COMFORT Sensor has co...

Page 53: ...ted in order to provide comfort and energy saving ECONAVI Start condition Press ECONAVI button ECONAVI Stop condition Press ECONAVI button again OFF Timer activates Press OFF ON button to turn off the...

Page 54: ...AVI AUTO COMFORT cannot be operated at the same time ECONAVI AUTO COMFORT sensor initialized time is 70 seconds from power supplied to ECONAVI AUTO COMFORT sensor or 70 seconds from the operation star...

Page 55: ...D start blinking ECONAVI AUTO COMFORT sensor operation stops but the unit operates as normal and ECONAVI AUTO COMFORT sensor abnormal code is memorized the 4 times counter is ignored The blinking of E...

Page 56: ...creased If the running current does not exceed X value for 5 seconds the frequency instructed will be increased However if total outdoor unit running current exceeds Y value compressor will be stopped...

Page 57: ...s 30 5 C Remote Control setting 16 C and Hi Fan Speed Control contents o Compressor stops and restart after 3 minutes o If the conditions above happened 2 times within 20 minutes the unit will Stop op...

Page 58: ...or Compressor stops for freeze prevention control o Either one of the conditions above occurs 5 times in 60 minutes Control contents o Operation stops o Timer LED blinks and H99 indicated 12 13 Dew P...

Page 59: ...d be selected The indoor unit will only operate when received signal with same transmission code from remote control This could prevent signal interference when there are 2 or more units installed nea...

Page 60: ...on unit a beep sound is heard as confirmation of transmission code change 13 2 2 RESET RC Button To clear and restore the remote control setting to factory default o Press once to clear the memory 13...

Page 61: ...Mpa kg cm 2 G Outlet air Temperature C Cooling Mode 0 9 1 2 9 12 12 16 Condition Indoor fan speed High Outdoor temperature 35 C at cooling mode Compressor operate at rated frequency Different in the i...

Page 62: ...w Pressure High Pressure Electric current during operation Insufficient refrigerant gas leakage Clogged capillary tube or strainer Short circuit in the indoor unit Heat radiation deficiency of the out...

Page 63: ...2 3 To Display Memorized Error Code Protective Operation 1 Turn power on 2 Press the CHECK button on the remote control 3 will be displayed on the remote control display Note Display only for No sign...

Page 64: ...Fan Motor H98 Indoor temperature rise abnormality Air filter dirty Air circulation short circuit H99 Indoor heat exchanger freeze prevention protection Insufficient refrigerant Air filter dirty F11 4...

Page 65: ...transmission is checked whether it is normal Malfunction Caused Faulty indoor unit PCB Faulty outdoor unit PCB Indoor unit outdoor unit signal transmission error due to wrong wiring Indoor unit outdo...

Page 66: ...re interconnected Malfunction Caused Wrong models interconnected Wrong indoor unit or outdoor unit PCBs mounted Indoor unit or outdoor unit PCBs defective Indoor outdoor unit signal transmission error...

Page 67: ...tion Decision Conditions During startup and operation of cooling and heating the temperatures detected by the indoor intake air temperature sensor are used to determine sensor errors Malfunction Cause...

Page 68: ...Decision Conditions During startup and operation of cooling and heating the temperatures detected by the outdoor compressor temperature sensor are used to determine sensor errors Malfunction Caused F...

Page 69: ...ons A current transformer CT is detected by checking the compressor running frequency rated frequency and CT detected input current less than 1 14A for continuously 20 seconds Malfunction Caused CT de...

Page 70: ...termine abnormal fan motor feedback of rotation 2550rpm or 50rpm Malfunction Caused Operation stops due to short circuit inside the fan motor winding Operation stops due to breaking of wire inside the...

Page 71: ...Decision Conditions During startup and operation of cooling and heating the temperatures detected by the indoor heat exchanger temperature sensor are used to determine sensor errors Malfunction Caused...

Page 72: ...tion Decision Conditions During startup and operation of cooling and heating the temperatures detected by the outdoor air temperature sensor are used to determine sensor errors Malfunction Caused Faul...

Page 73: ...tion Decision Conditions During startup and operation of cooling and heating the temperatures detected by the outdoor pipe temperature sensor are used to determine sensor errors Malfunction Caused Fau...

Page 74: ...lfunction Decision Conditions The supply power is detected for its requirement by the indoor outdoor transmission Malfunction Caused Wrong models interconnected Wrong indoor unit and outdoor unit PCBs...

Page 75: ...ration is used to determine abnormal fan motor Malfunction Caused Operation stops due to short circuit inside the fan motor winding Operation stops due to breaking of wire inside the fan motor Operati...

Page 76: ...uring heating operation the temperature detected by the indoor pipe temperature sensor is above 60 C Malfunction Caused Clogged air filter of the indoor unit Dust accumulation on the indoor unit heat...

Page 77: ...n control takes place when indoor pipe temperature is lower than 2 C Malfunction Caused Clogged air filter of the indoor unit Dust accumulation on the indoor unit heat exchanger Air short circuit Dete...

Page 78: ...unction Decision Conditions When cooling operation when indoor pipe temperature or indoor heat exchanger temperature sensor is above 45 C Malfunction Caused Faulty connector connection Faulty indoor p...

Page 79: ...eration of cooling and heating when Power Factor Correction PFC protection circuitry at the outdoor unit main PCB senses abnormal high DC voltage level Malfunction Caused DC voltage peak due to power...

Page 80: ...cooling and heating operation running current 0 65A I 1 65A During cooling indoor intake indoor pipe 4 C Malfunction Caused Refrigerant shortage refrigerant leakage Poor compression performance of com...

Page 81: ...lfunction Decision Conditions A compressor rotation failure is detected by checking the compressor running condition through the position detection circuit Malfunction Caused Compressor terminal disco...

Page 82: ...detected by the outdoor pipe temperature sensor Malfunction Caused Outdoor pipe temperature rise due to short circuit of hot discharge air flow Outdoor pipe temperature rise due to defective of outdo...

Page 83: ...ture data 100 C is detected by the IPM temperature sensor Malfunction Caused IPM overheats due to short circuit of hot discharge air flow IPM overheats due to defective of outdoor fan motor IPM overhe...

Page 84: ...n of cooling and heating when compressor tank temperature data 112 C is detected by the compressor tank temperature sensor Malfunction Caused Refrigerant shortage refrigerant leakage 2 3 way valve clo...

Page 85: ...rent Control is detected by checking the input current value being detected by current transformer CT with the compressor running Malfunction Caused Over current due to compressor failure Over current...

Page 86: ...door unit PCB Troubleshooting Checking the power transistor Never touch any live parts for at least 10 minutes after turning off the circuit breaker If unavoidable necessary to touch a live part make...

Page 87: ...the capacitor has discharged sufficiently before proceeding with repair work Failure to heed this caution may result in electric shocks 15 1 CS PS9 12PKV 15 1 1 Indoor Electronic Controllers Cross Fl...

Page 88: ...88 Figure 3 Figure 4 15 1 3 To remove discharge grille Figure 5 11 Pull out to remove the drain hose from the discharge grille 12 Then pull the discharge grille downward gently to dismantle it...

Page 89: ...and indoor fan motor Figure 7 Figure 8 16 Remove the bearing by pulling it out gently 15 Remove the screw from the evaporator 14 Remove the screw that holding the cross flow fan and fan motor axis 13...

Page 90: ...val of cross flow fan Reminder To reinstall the fan motor adjust the fan motor connector to 45 towards you before fixing control board 18 Remove the cross flow fan from the unit by pulling it to the l...

Page 91: ...charged sufficiently before proceeding with repair work Failure to heed this caution may result in electric shocks 15 2 CS PS18 24PKV 15 2 1 Indoor Electronic Controllers Cross Flow Fan and Indoor Fan...

Page 92: ...92 Figure 13 Figure 14 15 2 3 To remove discharge grille Figure 15 15 2 4 To remove control board Figure 16...

Page 93: ...93 15 2 5 To remove cross flow fan and indoor fan motor Figure 17 Figure 18 Figure 19...

Page 94: ...94 Figure 20...

Page 95: ...00 15 800 16 000 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Outdoor Temperature C Outdoor Air Temperature C 220 2 000 2 200 2 400 2 600 2 800 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Cooling Capacity...

Page 96: ...100 15 200 15 300 3 4 5 6 7 8 9 10 11 12 13 14 15 Outdoor Temperature C Piping Length m 220 2 400 2 500 2 600 2 700 3 4 5 6 7 8 9 10 11 12 13 14 15 Cooling Capacity kW Piping Length m 3 340 3 360 3 38...

Page 97: ...40 41 42 43 Outdoor Temperature C Outdoor Air Temperature C 220 2 600 2 700 2 800 2 900 3 000 3 100 3 200 3 300 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Cooling Capacity kW Outdoor Air Temperature C...

Page 98: ...5 900 3 4 5 6 7 8 9 10 11 12 13 14 15 Outdoor Temperature C Piping Length m 220 2 900 2 950 3 000 3 050 3 100 3 150 3 200 3 4 5 6 7 8 9 10 11 12 13 14 15 Cooling Capacity kW Piping Length m 3 920 3 94...

Page 99: ...door Temperature C Outdoor Air Temperature C 220 4 500 4 700 4 900 5 100 5 300 5 500 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Cooling Capacity kW Outdoor Air Temperature C 6 200 6 400 6 600 6 800 7 0...

Page 100: ...1 12 13 14 15 16 17 18 19 20 Outdoor Temperature C Piping Length m 220 4 950 5 000 5 050 5 100 5 150 5 200 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Cooling Capacity kW Piping Length m 6 600 6 70...

Page 101: ...41 42 43 Outdoor Temperature C Outdoor Air Temperature C 220 5 200 5 400 5 600 5 800 6 000 6 200 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Cooling Capacity kW Outdoor Air Temperature C 7 500 8 000 8 5...

Page 102: ...7 8 9 10 11 12 13 14 15 16 17 18 19 20 Outdoor Temperature C Piping Length m 220 5 600 5 700 5 800 5 900 6 000 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Cooling Capacity kW Piping Length m 8 100...

Page 103: ...and Replacement Parts List 17 1 Indoor Unit 17 1 1 CS PS9PKV CS PS12PKV Note The above exploded view is for the purpose of parts disassembly and replacement The non numbered parts are not kept as sta...

Page 104: ...OL BOARD TOP COVER 1 CWH131467 24 INDICATOR HOLDER 1 CWD933406 25 CONTROL BOARD FRONT COVER CO 1 CWH13C1247 26 DISCHARGE GRILLE COMPLETE 1 CWE20C3236 27 BACK COVER CHASSIS 1 CWD933233 28 FULCRUM 1 CWH...

Page 105: ...CRIPTION QTY CS PS9PKV CS PS12PKV REMARK 53 C C CASE 1 CWG569891 CWG569892 56 POWER SUPPLY CORD 1 CWA20C3054 O Note All parts are supplied from PAPAMY Malaysia Vendor Code 00029488 O marked parts are...

Page 106: ...106 17 1 2 CS PS18PKV CS PS24PKV Note The above exploded view is for the purpose of parts disassembly and replacement The non numbered parts are not kept as standard service parts...

Page 107: ...OVER 1 CWH131467 24 INDICATOR HOLDER 1 CWD933406 25 CONTROL BOARD FRONT COVER CO 1 CWH13C1247 26 DISCHARGE GRILLE COMPLETE 1 CWE20C3243 27 BACK COVER CHASSIS 1 CWD933031 28 FULCRUM 2 CWH621138 29 VERT...

Page 108: ...ON QTY CS PS18PKV CS PS24PKV REMARK 53 C C CASE 1 CWG569893 CWG569894 56 POWER SUPPLY CORD 1 CWA20C2851 CWA20C2853 O Note All parts are supplied from PAPAMY Malaysia Vendor Code 00029488 O marked part...

Page 109: ...109 17 2 Outdoor Unit 17 2 1 CU PS9PKV Note The above exploded view is for the purpose of parts disassembly and replacement The non numbered parts are not kept as standard service parts...

Page 110: ...CWH151185 20 TERMINAL COVER 1 CWH171039A 21 NUT TERMINAL COVER 1 CWH7080300J 22 SENSOR COMPLETE COMP TEMP 1 CWA50C2205 O 24 SENSOR COMPLETE AIR PIPE TEMP 1 CWA50C2502 O 25 TERMINAL BOARD ASSY 1 CWA28...

Page 111: ...111 17 2 2 CU PS12PKV Note The above exploded view is for the purpose of parts disassembly and replacement The non numbered parts are not kept as standard service parts...

Page 112: ...2 20 TERMINAL COVER 1 CWH171039A 21 NUT TERMINAL COVER 1 CWH7080300J 22 SENSOR COMPLETE 1 CWA50C2205 O 24 SENSOR COMPLETE 1 CWA50C2764 O 25 TERMINAL BOARD ASSY 1 CWA28K1036J O 26 ELECTRONIC CONTROLLER...

Page 113: ...113 17 2 3 CU PS18PKV Note The above exploded view is for the purpose of parts disassembly and replacement The non numbered parts are not kept as standard service parts...

Page 114: ...H7080300J 22 SENSOR CO OUTDOOR COMP TEMP 1 CWA50C2205 O 24 SENSOR CO OUTDOOR AIR HEAT EXCHANGE TEMP 1 CWA50C2764 O 25 TERMINAL BOARD ASSY 1 CWA28K1036J O 26 ELECTRONIC CONTROLLER MAIN 1 CWA73C7960R O...

Page 115: ...115 17 2 4 CU PS24PKV Note The above exploded view is for the purpose of parts disassembly and replacement The non numbered parts are not kept as standard service part...

Page 116: ...J 22 SENSOR CO OUTDOOR COMP TEMP 1 CWA50C2185 O 27 SENSOR CO 1 CWA50C2769 O 28 REACTOR 1 G0C153J00005 O 29 TERMINAL BOARD ASSY 1 CWA28K1036J O 30 ELECTRONIC CONTROLLER MAIN 1 CWA73C7958R O 31 CONTROL...

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