Heat Controller BG-103A User manual

Service Manual

CAUTION

-Before servicing the unit, read the "safety precautions" in this manual.

-Only for authorized service personnel.

Through-The-Wall

Air Conditioning

HEAT CONTROLLER, INC.

Model: BG-103A

—2—

1. PREFACE

1.1 SAFETY PRECAUTIONS ...............................2

1.2 INSULATION RESISTANCE TEST.................2

1.3 SPECIFICATIONS ..........................................3

1.4 FEATURES.....................................................4

1.5 CONTROL LOCATIONS.................................4

DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS....................................5

2.1.1 FRONT GRILLE.....................................5

2.1.2 CABINET................................................5

2.1.3 CONTROL BOX.....................................5

2.2 AIR HANDLING PARTS..................................6

2.2.1 ORIFICE AND TURBO FAN

................. 6

2.2.2 FAN........................................................6

2.2.3 SHROUD................................................7

2.3 ELECTRICAL PARTS.....................................7

2.3.1 MOTOR..................................................7

2.3.2 COMPRESSOR .....................................7

2.3.3 CAPACITOR ..........................................7

2.3.4 POWER CORD......................................8

2.3.5 THERMISTOR .......................................8

2.4 REFRIGERATION CYCLE.................................9

2.4.1 CONDENSER ......................................9

2.4.2 EVAPORATOR ....................................9

2.4.3 CAPILLARY TUBE...............................9

INSTALLATION

3.1 INSTALLATION REQUIREMENTS...............12

3.2 INSTALLATION.............................................13

3.3 PROCEDURE A............................................14

3.4 PROCEDURE B............................................15

3.5 PROCEDURE C............................................17

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS...............................19

4.2 PIPING SYSTEM ..........................................19

4.3 TROUBLESHOOTING GUIDE......................20

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM......................................25

6. EXPLODED VIEW..................................26

7. REPLACEMENT PARTS LIST .......27

1. PREFACE

This SERVICE MANUAL provides various service information, including the mechanical and electrical

parts etc. This room air conditioner was manufactured and assembled under a strict quality control system.

The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.

1.1 SAFETY PRECAUTIONS

1. When servicing the unit, turn off the air conditioner

and unplug the power cord.

2. Observe the original lead dress.

If a short circuit is found, replace all parts which

have been overheated or damaged by the short

circuit.

3. After servicing the unit, make an insulation

resistance test to protect the customer from being

exposed to shock hazards.

1.2

INSULATION RESISTANCE TEST

1. Unplug the power cord and connect a jumper

between 2 pins (black and white).

2. The grounding conductor (green or green & yellow)

is to be open.

3. Measure the resistance value with an ohm meter

between the jumpered lead and each exposed

metallic part on the equipment.

4. The value should be over 1M.

CONTENTS

—3—

1.3 SPECIFICATIONS

1.3.1 FOR BG-103A

POWER SUPPLY

COOLING CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT (A)

E.E.R (Btu/W.h)

OPERATING INDOOR(°C)

TEMPERATURE OUTDOOR(°C)

REFRIGERANT (R-22) CHARGE (g)

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

FAN SPEED (FAN/COOLING/HEATING)

FAN MOTOR

OPERATION CONTROL

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

CONSTRUCTION

PROTECTOR COMPRESSOR

FAN MOTOR

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

DIMENSION (inch)

(W x H x D) (mm)

SLEEVE DIMENSION (inch)

(W x H x D) (mm)

SLEEVE DEPTH (inch)

WITH FRONT GRILLE (mm)

BG-103A REMARK

Model

Items

1Ø, 230/208V, 60Hz

10,500 / 10,000

1,230 / 1,170

5.7 / 6.0

8.5 / 8.5

26.7(DB) 19.4(WB)

35(DB) 23.9(WB)

475g(16.8OZ)

3ROW 12STACKS

2ROW 17STACKS, L-BENDING TYPE

LOUVERED-FIN TYPE

TURBO FAN

PROPELLER TYPE FAN WITH SLINGER-RING

3/3

4POLES

ELECTRIC

THERMISTOR

VERTICAL LOUVER(RIGHT & LEFT)

HORIZONTAL(UP & DOWN)

TOP-DOWN

EXTERNAL OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

1.4m (3WIRES WITH GROUNDING)

ATTACHMENT PLUG(CORD-CONNECTED TYPE, LCDI)

SPLASHED BY FAN SLINGER

80/36

24 x 14 13/32 x 20 3/32

610 x 366 x 499

25 7/8x 15 17/32 x 16 23/32

20 1/2

656 x 394 x 425

521

1.4 FEATURES

• Designed for cooling only.

• Powerful and quiet cooling.

• Top-down chassis for the simple installation and service.

1.5 CONTROL LOCATIONS

1.5.1 COOLING ONLY MODEL

• OPERATION

• Side air-intake, side cooled-air discharge.

• Built in adjustable THERMISTOR and THERMOSTAT.

• Washable one-touch filter.

• Compact size.

• VENTILATION

Push the lever to the "CLOSE" position to cool, heat or recirculate room air only.

Pull the lever to the "OPEN" position to exhaust smoke or stale air from the room.

This feature is best used in conjunction with the FAN ONLY position.

—4—

PULL OPEN / PUSH CLOSE

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

REMOTE CONTROL SIGNAL RECEIVER

POWER

MODE

Push this button to shift mode of operation from COOL → ENERGY SAVER → FAN.

- COOL:

•Fan runs continually for normal cooling operation.

- ENERGY SAVER:

•The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and the unit will check the room air

temperature to determine if cooling is needed.

- FAN:

•Fan-only operation.

TIMER

- SHUT-OFF TIME

•You will usually use shut-off time while you sleep.

•If unit is running, use Timer to set number of hours until shut-off.

•For your sleeping comfort, once Time is set, the Temperature setting will raise 2°F after 30 min., and once again after another 30 min.

•Push Timer button to advance setting from 1Hour →2Hours → ... → 12Hours maximum.

- START TIME

•If unit is off, use Timer to set number of hours before unit starts.

•Push Timer button to advance setting from 1Hour →2Hours → ... → 12Hours maximum.

TEMPERATURE SETTING

•Use this button to automatically control the temperature of the room.

The temperature can be set within a range of 60°F to 86°F by increments of

1°F.

•The setting appears in the display.

•To turn the air conditioner ON, push this button.

To turn the air conditioner OFF, push the button again.

•This button takes priority over any other button.

•When you first turn it on, the unit is in cool mode, High fan speed,

Temperature setting at 72°F.

FAN SPEED

•Every time you push this button, it advances the setting as follows:

{High →Low →Med →High}

When the air conditioner has been operating in the

cooling and is turned off or set to the fan only position,

wait at least 3 minutes before resetting to the cooling

operation again.

CAUTION

—5—

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Open the inlet grille downward.

2. Remove the screw which fastens the front grille.

3. Pull the front grille from the right side.

4. Remove the front grille. (See Fig. 1)

5. Re-install the component by referring to the

removal procedure.

2.1.2 CABINET

1. After disassembling the FRONT GRILLE, remove

the 6 screws which fasten the cabinet at the both

sides and the top. (See Fig. 2)

Keep these for later use.

2.1.3 CONTROL BOX

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the screw which fasten the control

box. (See Fig. 3)

3. Pull the control box from the barrier.(See Fig.3)

4. Discharge the capacitor by placing a 20,000 ohm

resistor across the capacitor terminals.

5. Disconnect two wire housings in the control box.

6. Pull the control box forward completely.

7. Re-install the components by referring to the

removal procedure. (See Fig. 3)

(Refer to the circuit diagram found on pages 25in

this manual and on the control box.)

2. DISASSEMBLY INSTRUCTIONS

—Prior to disassembling the unit, make sure that the POWER is off and the power cord is unplugged from the

wall receptacle.

MODETIMERPOWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

Figure 1

Figure 2

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

MODETIMERPOWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

Figure 3

Figure 7

—6—

2.2 AIR HANDLING PARTS

2.2.1 ORIFICE, AND TURBO FAN

1. Remove the front grille. (Refer to section 2.1.1)

2. Remove the cabinet. (Refer to section 2.1.2)

3. Remove the 2 screws which fasten the

evaporator at the left side and the right side.

(See Fig. 4)

4. Move the evaporator sideward carefully.

5. Remove the orifice. (See Fig. 5)

8. Using handheld pliers, remove the clamp which

secures the turbo fan. (See Fig. 6)

9. Remove the turbo fan with pliers or your hand,

without touching blades. (See Fig. 7)

10. Re-install the components by referring to the

removal procedures, above.

2.2.2 FAN

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the brace.

(Refer to section 2.2.1)

3. Remove the 7 screws which fasten the condenser.

4. Move the condenser sideways carefully.

5. Using handheld pliers, remove the clamp which

secures the fan.

6. Remove the fan. (See Fig. 8)

7. Re-install the components by referring to the

removal procedures, above.

MODETIMERPOWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

MODETIMERPOWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

MODETIMERPOWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

Figure 4

Figure 5

Figure 6

MODETIMERPOWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

Figure 8

—7—

2.2.3 SHROUD

1. Remove the fan. (Refer to section 2.2.2)

2. Remove the shroud. (See Fig. 9)

3. Re-install the components by referring to the

removal procedures, above.

2.3 ELECTRICAL PARTS

2.3.1 MOTOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the clamp cord and disconnect the wire

housing in control box. (Refer to section 2.1.3)

3. Remove the turbo fan. (Refer to section 2.2.2)

4. Remove the fan. (Refer to section 2.2.2)

5. Remove the 4 or 2 screws which fasten the motor.

(See Fig. 10)

6. Remove the motor.

7. Re-install the components by referring to the

removal procedures, above.

2.3.2 COMPRESSOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Discharge the refrigerant system using a FreonTM

Recovery System.

If there is no valve to attach the recovery system

to, install one (such as a WATCO A-1) before

venting the FreonTM . Leave the valve in place after

servicing the system.

3. Disconnect the 3 leads from the compressor.

4. After purging the unit completely, unbraze the

suction and discharge tubes at the compressor

connections.

5. Remove the 3 nuts and the 3 washers which

fasten the compressor. (See Fig. 11)

6. Remove the compressor.

7. Re-install the components by referring to the

removal procedures, above.

2.3.3 CAPACITOR

1. Remove the control box. (Refer to section 2.1.3)

2. Remove the 1 screw

3. Open the control box

4. Disconnect all the leads on the capacitor terminals.

5. Re-install the components by referring to the

removal procedures, above.

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

Figure 9

Figure 10

Figure 11

Figure 12

—8—

2.3.4 POWER CORD

1. Remove the control box. (Refer to section 2.1.3)

2. Unfold the control box. (Refer to section 2.3.3)

3. Disconnect the grounding screw from the Base

pan.

4. Disconnect 2 receptacles.

5. Remove a screw which fastens the clip cord.

6. Pull the power cord. (See Fig. 13)

7. Re-install the components by referring to the

removal procedure, above.

(Use only one ground-marked hole, , for ground

connection.)

8. If the supply cord of this appliance is damaged, it

must be replaced with the factory-authorized and

specified cord.

2.3.5 THERMISTOR

1. Remove the control box. (Refer to section 2.1.3)

2. Unfold the control box. (Refer to section 2.3.3)

3. Disconnect all the leads of thermistor terminals.

4. Remove the thermistor. (See Fig. 14)

5. Re-install the components by referring to the

removal procedures, above.

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1 LOW

F2 MED

F3 HIGH

Figure 13

Figure 14

—9—

2.4 REFRIGERATION CYCLE

2.4.1 CONDENSER

1. Remove the cabinet. (Refer to section 2.1.2)

2. Remove the brace.

(Refer to section 2.2.1)

3. Remove the 7 screws which fasten the condenser.

4. After discharging the refrigerant completely into a

FreonTM Recovery System, unbraze the

interconnecting tube at the condenser

connections.

5. Remove the condenser.

6. Re-install the components by referring to the notes

(See Fig. 15)

2.4.2 EVAPORATOR

1. Remove the cabinet. (Refer to section 2.1.2)

2. Discharge the refrigerant completely –into a

FreonTM Recovery System.

3. Remove the 2 screws which fasten the evaporator

at the left side and the right side.

4. Move the evaporator sideward carefully and then

unbraze the interconnecting tube at the evaporator

connectors.

5. Remove the evaporator.

6. Re-install the components by referring to the notes

(See Fig. 16)

2.4.3 CAPILLARY TUBE

1. Remove the cabinet. (Refer to section 2.1.2)

2. After discharging the refrigerant completely –into

a FreonTM Recovery System, unbraze the

interconnecting tube at the capillary tube.

3. Remove the capillary tube.

Re-install the components by referring to the notes.

Figure 15

Figure 16

MODETIMERPOWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

F1LOW

F2MED

F3HIGH

Discharge the refrigerant system using a FreonTM

Recovery System.

If there is no valve to attach the recovery system,

install one (such as a WATCO A-1) before

venting the FreonTM. Leave the valve in place

after servicing the system.

CAUTION

—10—

—Replacement of the refrigeration cycle.

1. When replacing the refrigeration cycle, be sure to

discharge the refrigerant system using a FreonTM

recovery System.

If there is no valve to attach the recovery system,

install one (such as a WATCO A-1) before venting

the FreonTM. Leave the valve in place after

servicing the system.

2. After discharging the unit completely, remove the

desired component, and unbrace the pinch-off

tubes.

3. Solder service valves into the pinch-off tube ports,

leaving the valves open.

4. Solder the pinch-off tubes with Service valves.

5. Evacuate as follows.

1) Connect the vacuum pump, as illustrated Fig.

17A.

2) Start the vacuum pump, slowly open manifold

valves A and B with two full turns

counterclockwise and leave the valves closed.

The vacuum pump is now pulling through valves

A and B up to valve C by means of the manifold

and entire system.

3) Operate the vacuum pump for 20 to 30 minutes,

until 600 microns of vacuum is obtained. Close

valves A and B, and observe vacuum gauge for

a few minutes. A rise in pressure would

indicate a possible leak or moisture remaining in

the system. With valves A and B closed, stop

the vacuum pump.

4) Remove the hose from the vacuum pump and

place it on the charging cylinder. See Fig. 17B.

Open valve C.

Discharge the line at the manifold connection.

5) The system is now ready for final charging.

6. Recharge as follows :

1) Refrigeration cycle systems are charged from the

High-side. If the total charge cannot be put

in the High-side, the balance will be put in the

suction line through the access valve which you

installed as the system was opened.

Connect the charging cylinder as shown in Fig. 17B.

With valve C open, discharge the hose at the

manifold connection.

3) Open valve A and allow the proper charge to

enter the system. Valve B is still closed.

4) If more charge is required, the high-side will not

take it. Close valve A.

5) With the unit running, open valve B and add the

balance of the charge.

a. Do not add the liquid refrigerant to the Low-

side.

b. Watch the Low-side gauge; allow pressure to

rise to 30 lbs.

c. Turn off valve B and allow pressure to drop.

d. Repeat steps B and C until the balance of the

charge is in the system.

6) When satisfied the unit is operating correctly,

use the pinch-off tool with the unit still running

and clamp on to the pinch-off tube. Using a tube

cutter, cut the pinch-off tube about 2 inches from

the pinch-off tool. Use sil-fos solder and solder

pinch-off tube closed. Turn off the unit, allow it to

set for a while, and then test the leakage of the

pinch-off connection.

NOTES

If high vacuum equipment is used, just crack

valves A and B for a few minutes, then open

slowly with the two full turns counterclockwise.

This will keep oil from foaming and being

drawn into the vacuum pump.

CAUTION

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