Heat Controller RG-51G User manual

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com

SERVICE MANUAL

Room Air Conditioner

with R-410A:

RG-51G

Beforeusingyourairconditioner,pleaseread

thismanualcarefullyandkeepitforfuturereference.

WINDOW/WALL TYPE

ROOM AIRCONDITIONER

RG-51G Service Manual Room Air Conditioner with R-410A Heat Controller, Inc.

1.PRECAUTIONS..........................................................................................................2

1.1 Safety precautions.............................................................................................2

1.2 Warning .............................................................................................................2

1.3 Caution ..............................................................................................................2

2. FEATURES AND PANEL...........................................................................................2

2.1 Features.............................................................................................................2

2.2 Control panel illustration ....................................................................................3

POWER .........................................................................................................................4

COOL MODE.................................................................................................................4

FAN MODE .................................................................................................................... 4

THERMOSTAT...............................................................................................................4

3. UNIT DIMENSIONS...................................................................................................5

3.1 Unit dimensions..................................................................................................5

4. OPERATION LIMITS .................................................................................................6

4.1 Cooling operation ...............................................................................................6

5. PROTECTION FUNCTIONS ..................................................................................... 6

6. COMPONENT OPERATION & TESTING..................................................................7

7. WIRING DIAGRAM..................................................................................................12

8. TROUBLESHOOTING............................................................................................. 13

8.1 Flow Chart.........................................................................................................13

8.2 General Troubleshooting...................................................................................16

Table of Contents

Heat Controller, Inc. Room Air Conditioner with R-410A RG-51G Service Manual

1.PRECAUTIONS

1.1 Safety precautions

• To prevent injury to the user or property damage, the following instructions must be followed.

• Incorrect operation due to ignoring instruction will cause harm or damage.

• Beforeservicingunit,besuretoreadthisservicemanualrst.

1.2 Warning

• Do not use damaged power cords, plugs, or a loose socket.

• Always use the power plug and socket with a ground terminal.

• Do not modify or extend the power cord.

• Do not turn the air-conditioner ON or OFF by plugging or unplugging the power plug.

• Use a dedicated power outlet for this appliance.

• Grasp the plug to remove the cord from the outlet. Do not touch it with wet hands.

• Do not place a heater or any other appliance near the power cable.

• Do not allow water to run into electrical parts.

• Donotstoreoruseammablegasorcombustiblesneartheairconditioner.

• Unplug the unit if strange sounds, odors, or smoke comes from it.

1.3 Caution

• Use a soft cloth to clean the unit. Do not use harsh detergents, solvents, etc.

• Donottouchthemetalpartsoftheproductwhenremovingtheairlter.Theyareverysharp.

• Do not step on or put anything on the air conditioner.

• Do not insert hands or other objects through the air inlet or outlet while the air conditioner is plugged in.

2. FEATURES AND PANEL

2.1 Features

• Powerful cooling.

• Slide-in and slide-out chassis for the simple installation and service (on some models).

• Washableone-touchlterandeasyremovablefrontpanel.

• Super compact design.

• Reliableandefcientrotarycompressor.

• Fresh air ventilation door (on some models).

• Three minute time delay safety for compressor.

• Silverionlter(optional).

RG-51G Service Manual Room Air Conditioner with R-410A Heat Controller, Inc.

2.2 Control panel illustration

RG-51G Series

Note: The controls featured above are

representative of many available models. Your

model may offer slightly different features.

Heat Controller, Inc. Room Air Conditioner with R-410A RG-51G Service Manual

POWER:

• Rotate the knob to any position except the OFF position to start the unit. To turn off the unit, rotate the knob

to the OFF position.

COOL MODE:

• The desired cool setting is selected by rotating the knob to the right to the appropriate location.

• MAX COOLhasmaximumcoolingeffectandairow.

• MIN COOLhasminimumcoolingeffectandairow.

FAN MODE:

Rotate the knob to the left to select your choice of fan speeds for air circulation.

Note: When selecting a fan speed, the compressor will not run.

THERMOSTAT

The thermostat is used to set the desired room temperature when the unit is being operated in the COOL MODE.

To set the desired room temperature, rotate the thermostat switch to the desired setting. After the set temperature

is achieved, the thermostat will automatically start and stop the compressor in order to maintain the desired set

temperature.

Rotate the thermostat selector counter clockwise for higher cool settings. Higher cool settings will provide lower

room temperature. Rotate the thermostat selector clockwise for lower cool settings. Lower cool settings will provide

higher room temperature.

RG-51G Service Manual Room Air Conditioner with R-410A Heat Controller, Inc.

3. UNIT DIMENSIONS

3.1 Unit dimensions

SERIES A (inch/mm) B (inch/mm) C (inch/mm)

RG-51G 16 1/4” / 412 12 5/16” / 312 13 3/4” / 350

Heat Controller, Inc. Room Air Conditioner with R-410A RG-51G Service Manual

4. OPERATION LIMITS

4.1 Cooling operation

Outdoor unit air temp DB

5. PROTECTION FUNCTION

• Compressor restart time delay

The compressor has an automatic 3 minute time delayed start if the unit is turned off and on quickly, to

prevent pressure imbalance of cooling system from resulting in a locked motor on the compressor.

Indoor air temp DB

Note: The chart is the result from the continuous operation under constant air

temperature conditions. However, excludes the initial pull-down stage.

RG-51G Service Manual Room Air Conditioner with R-410A Heat Controller, Inc.

6. COMPONENT OPERATION & TESTING

WARNING:

DISCONNECT THE POWER CORD FROM THE POWER PLUG BEFORE SERVICING OR TESTING.

COMPRESSORS

Compressors are single phase, 115 volt, depending on the model unit. All compressor motors are permanent split

capacitor type using only a running capacitor across the start and run terminal.

All compressors are internally spring mounted and externally mounted

on rubber isolators.

COMPRESSOR WINDING TEST (See Figure 1)

Remove compressor terminal box cover and disconnect

wires from terminals. Using an ohmmeter, check

continuity across the following:

1. Terminal “C” and “S” - no continuity

- open winding - replace compressor.

2. Terminal “C” and “R” - no continuity

- open winding - replace compressor.

3. Terminal “R” and “S” - no continuity

- open winding - replace compressor.

GROUND TEST

Use an ohmmeter set on its highest scale. Touch

one lead to the compressor body (clean point of

contact as a good connection is a must) and the

other probe in turn to each compressor terminal

(see Figure 2.) If a reading is obtained, the

compressor is grounded and must be replaced.

CHECKING COMPRESSOR EFFICIENCY

Thereasonforcompressorinefciencyisnormallyduetobrokenor

damaged suction and/or discharge valves, reducing the ability of the

compressor to pump refrigerant gas.

This condition can be checked as follows:

1. Install a piercing valve on the suction and discharge or liquid lines.

2. Attach gauges to the high and low sides of the system.

3. Start the system and run a “cooling performance test.”

If test shows:

A. Below normal high side pressure.

B. Above normal low side pressure.

Figure 2: Typical ground test

Figure 1: Compressor winding test

Heat Controller, Inc. Room Air Conditioner with R-410A RG-51G Service Manual

C. Low temperature difference across coil.

The compressor valves are faulty - replace the compressor.

THERMAL OVERLOAD (External)

Some compressors are equipped with an external overload which

is located in the compressor terminal box adjacent to the

compressor body (see Figure 3.) The overload is wired in series

with the common motor terminal. The overload senses both

amperage and compressor temperature. High motor temperature

or amperage heats the disc causing it to open and break the

circuit to the common motor terminal.

Heat generated within the compressor shell is usually due to:

1. High amperage.

2. Low refrigerant charge.

3. Frequent recycling.

4. Dirty condenser.

TERMINAL OVERLOAD – TEST (Compressor - External Type)

1. Remove overload.

2. Allow time for overload to reset before attempting to test.

3. Apply ohmmeter probes to terminals on overload wires. There should be continuity through the overload.

TERMINAL OVERLOAD (Internal)

Some model compressors are equipped with an internal overload. The overload is embedded in the motor windings

to sense the winding temperature and/or current draw. The overload is connected in series with the common motor

terminal.

Should the internal temperature and/or current draw become excessive, the contacts in the overload will open,

turning off the compressor. The overload will automatically reset, but may require several hours before the heat is

dissipated.

CHECKING THE INTERNAL OVERLOAD (see Figure 4.)

1. With no power to unit, remove the leads from the compressor terminals.

2. Using an ohmmeter, test continuity between terminals C-S and C-R. If not

continuous, the compressor overload is open and the compressor must be

replaced.

FAN MOTOR

A single phase permanent split capacitor motor is used to drive the evaporator

blower and condenser fan. A self-resetting overload is located inside the motor to

protect against high temperature and high amperage conditions.

FAN MOTOR - TEST

Figure 4: Internal overload

Figure 3: External overload

RG-51G Service Manual Room Air Conditioner with R-410A Heat Controller, Inc.

1. Determine that capacitor is serviceable.

2. Disconnect fan motor wires from fan speed switch or system switch.

3. Apply “live” test cord probes on red wire and common terminal of capacitor. Motor should run at high speed.

4. Apply “live” test cord probes on white wire and common terminal of capacitor. Motor should run at low speed.

5. Apply “live” test cord probes on each of the remaining wires from the speed switch or system switch to test

intermediate speeds.

CAPACITOR, RUN

A run capacitor is wired across the auxiliary and main winding of a single phase

permanent split capacitor motor such as the compressor and fan motor. A single

capacitor can be used for each motor or a dual rated capacitor can be used for both.

The capacitor’s primary function is to reduce the line current while greatly improving

the torque characteristics of a motor. The capacitor also reduces the line current to

the motor by improving the power factor of the load. The hook-up line side of the

capacitor is marked with a red dot and is wired to the line side of the circuit (see

Figure 5.)

CAPACITOR - TEST

1. Remove capacitor from unit.

2. Check for visual damage such as bulges, cracks, or leaks.

3. For dual rated, apply an ohmmeter lead to common (C) terminal and the other probe to the compressor

(HERM)terminal.Asatisfactorycapacitorwillcauseadeectiononthepointer,thengraduallymovebackto

innity.

4.Reversetheleadsoftheprobeandmomentarilytouchthecapacitorterminals.Thedeectionofthepointer

shouldbetwotimesthatoftherstcheckifthecapacitorisgood.

5. Repeat steps 3 and 4 to check fan motor capacitor.

NOTE: A shorted capacitor will indicate a low resistance and the pointer will move to the “0” end of the

scale and remain there as long as the probes are connected. An open capacitor will show no

movement of the pointer when placed across the terminals of the capacitor.

THERMOSTAT ADJUSTMENT

No attempt should be made to adjust thermostat. Due to the sensitivity of the internal mechanism and the

sophisticated equipment required to check the calibration, it is suggested that the thermostat be replaced rather

than calibrated. Thermostat bulb must be straight to insure proper performance.

Figure 5: Run capacitor

Table of contents

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