Heat Controller BD-81, BDE-103, BD-123, BDE-123, BD-101 User Manual
Through-The-Wall
Air Conditioning
Important Information
• Please read carefully and thoroughly this manual before operating this unit.
• Contact a qualified sevice technician for installation, repair and maintenance of this unit.
• The appliance is not intended for use by young children or those who require supervision.
• Y oung children should be supervised to ensure that they do not play with the appliance.
HEAT CONTROLLER, INC.
Models: BD-81
BD-101
BD-123
BDE-103
BDE-123
—2—
1. PREFACE
1.1 SAFETY PRECAUTIONS ...............................2
1.2 INSULATION RESISTANCE TEST.................2
1.3 SPECIFICATIONS ..........................................3
1.4 FEATURES.....................................................6
1.5 CONTROL LOCATIONS.................................6
2.
DISASSEMBLY INSTRUCTIONS
2.1 MECHANICAL PARTS....................................8
2.1.1 FRONT GRILLE.....................................8
2.1.2 CABINET................................................8
2.1.3 CONTROL BOX.....................................8
2.2 AIR HANDLING PARTS..................................9
2.2.1
ORIFICE, HEATER ASSY AND TURBO FAN
.........9
2.2.2 FAN........................................................9
2.2.3 SHROUD..............................................10
2.3 ELECTRICAL PARTS...................................10
2.3.1 MOTOR................................................10
2.3.2 COMPRESSOR...................................10
2.3.3 CAPACITOR........................................10
2.3.4 POWER CORD....................................11
2.3.5 THERMOSTAT ....................................11
2.3.6 ROTARY SWITCH...............................11
2.4 REFRIGERATION CYCLE............................12
2.4.1 CONDENSER......................................12
2.4.2 EVAPORATOR....................................12
2.4.3 CAPILLARY TUBE...............................12
3.
INSTALLATION
3.1 INSTALLATION REQUIREMENTS...............15
3.2 INSTALLATION.............................................16
3.3 PROCEDURE A............................................17
3.4 PROCEDURE B............................................18
3.5 PROCEDURE C............................................20
3.4 ELECTRICAL REQUIREMENTS..................22
3.4.1
ELECTRICAL DATA(FOR 115V MODEL)
.....22
3.4.2
ELECTRICAL DATA(FOR 230V/208 MODEL)
......22
3.4.3 ELECTRICAL SAFETY........................22
4.
TROUBLESHOOTING GUIDE
4.1 OUTSIDE DIMENSIONS...............................23
4.2 PIPING SYSTEM ..........................................23
4.3 TROUBLESHOOTING GUIDE......................24
5. SCHEMATIC DIAGRAM
5.1 CIRCUIT DIAGRAM......................................29
6. EXPLODED VIEW..................................31
7. REPLACEMENT PARTS LIST.......32
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, set the ROTARY SWITCH
or POWER SWITCH to OFF(O) 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 at all the positions
(except OFF or O) of the ROTARY SWITCH or
POWER SWITCH.
4. The value should be over 1MΩ.
CONTENTS
—3—
1.3 SPECIFICATIONS
1.3.1 FOR BD-81/BD-101
POWER SUPPLY
1Ø, 115V, 60Hz
COOLING CAPACITY (Btu/h) 8,000 10,000
INPUT (W) 800 1,050
RUNNING CURRENT (A) 7.5 9.8
E.E.R (Btu/w.h) 10.0 9.5
REFRIGERANT (R-22) CHARGE(g) 380(13.2 OZ) 410(14.5 OZ)
INDOOR (°C) 26.7(DB) 19.4(WB)
OUTDOOR (°C) 35(DB) 23.9(WB)
EVAPORATOR 2 ROW 12 STACKS
CONDENSER
FAN, INDOOR TURBO FAN
FAN, OUTDOOR PROPELLER TYPE FAN WITH SLINGER-RING
FAN SPEEDS, FAN/COOLING 3/3
FAN MOTOR 6 POLES
OPERATION CONTROL ELECTRIC
ROOM TEMP. CONTROL THERMISTOR
VERTICAL LOUVER(RIGHT & LEFT)
HORIZONTAL LOUVER(UP & DOWN)
CONSTRUCTION TOP-DOWN
COMPRESSOR
FAN MOTOR INTERNAL THERMAL PROTECTOR
1.6m (3WIRE WITH GROUNDING)
ATTACHMENT PLUG(CORD-CONNECTED TYPE)
DRAIN SYSTEM SPLASHED BY FAN SLINGER
NET WEIGHT (lbs/kg) 72/33 79/36
DIMENSION (inch)
(W x H x D) (mm)
SLEEVE DIMESION (inch)
(W x H x D) (mm)
SLEEVE DEPTH (inch)
WITH FRONT GRILLE (mm)
MODELS
BD-81 BD101
REMARK
ITEMS
AIR DIRECTION CONTROL
PROTECTOR
POWER CORD
OPERATING
TEMPERATURE
LOUVEREDFIN TYPE
OPTIONAL
PART
2 ROW 17 STACKS, L-BENDED TYPE
EXTERNAL OVERLOAD PROTECTOR
2421/
32 x 14
13
/
32 x 19
21
/
32
626 x 366 x 499
257/8 x 15
17
/32 x 16
23
/32
656 x 394 x 425
20
510
—4—
1.3.2 FOR BD-123
REMARK
POWER SUPPLY
COOLING CAPACITY (Btu/h)
INPUT (W)
RUNNING CURRENT
(A)
E.E.R. (Btu/W.h)
INDOOR (°C)
OUTDOOR (°C)
REFRIGERANT (R-22) CHARGE(g)
EVAPORATOR
CONDENSER
FAN, INDOOR
FAN, OUTDOOR
FAN SPEEDS (FAN/COOLING/HEATING)
FAN MOTOR
OPERATION CONTROL
ROOM TEMP. CONTROL
CONSTRUCTION
COMPRESSOR
FAN MOTOR
DRAIN SYSTEM
NET WEIGHT (lbs/kg)
DIMENSION (inch)
(W x H x D) (mm)
SLEEVE DIMESION (inch)
(W x H x D) (mm)
SLEEVE DEPTH (inch)
WITH FRONT GRILLE (mm)
1Ø, 208/ 230V, 60Hz
11,400/11,700
1,200/1,230
6.2/5.8
9.5
26.7 (DB) 19.4 (WB)
35 (DB) 23.9 (WB)
465(16.4 OZ)
2 ROW 11 STACKS
2 ROW 17 STACKS, L-BENDED TYPE
TURBO FAN
PROPELLER TYPE FAN WITH SLINGER-RING
3/3
6 POLES
ELECTRIC
THERMISTOR
VERTICAL LOUVER (RIGHT & LEFT)
HORIZONTAL LOUVER (UP & DOWN)
TOP-DOWN
EXTERNAL OVERLOAD PROTECTOR
INTERNAL THERMAL PROTECTOR
1.6m (3 WIRE WITH GROUDING)
ATTACHMENT PLUG (CORD-CONNECTED TYPE)
SPLASHED BY FAN SLINGER
80/37
2421/
32 x 14
13
/
32 x 19
21
/
32
626 x 366 x 499
257/
8
x 15
17
/32
x 16
23
/32
656 x 394 x 425
20
510
MODELS
ITEMS
OPERATING
TEMPERA-TURE
AIR DIRECTION CONTROL
POWER CORD
PROTECTOR
LOUVEREDFIN TYPE
BD-123
OPTIONAL
PART
REMARK
POWER SUPPLY
CAPACITY (Btu/h)
INPUT (W)
RUNNING CURRENT
(A)
E.E.R. (Btu/W.h)
CAPACITY (Btu/h)
INPUT (W)
RUNNING CURRENT
(A)
INDOOR (°C)
OUTDOOR (°C)
INDOOR (°C)
OUTDOOR (°C)
REFRIGERANT (R-22) CHARGE(g)
EVAPORATOR
CONDENSER
FAN, INDOOR
FAN, OUTDOOR
FAN SPEEDS (FAN/COOLING/HEATING)
FAN MOTOR
OPERATION CONTROL
ROOM TEMP. CONTROL
CONSTRUCTION
ELECTRIC HEATER
COMPRESSOR
FAN MOTOR
ELECTRIC HEATER
DRAIN SYSTEM
NET WEIGHT (lbs/kg)
DIMENSION (inch)
(W x H x D) (mm)
SLEEVE DIMESION (inch)
(W x H x D) (mm)
SLEEVE DEPTH (inch)
WITH FRONT GRILLE (mm)
—5—
1.3.3 FOR BDE-103/BDE-123
1Ø, 208/ 230V, 60Hz
9,800/10,000 11,400/11,700
1,030/1,050 1,200/1,230
5.2/4.7 6.2/5.8
9.5 9.5
9,200/11,200
2,900/3,500
14.0/15.3
26.7 (DB) 19.4 (WB)
35 (DB) 23.9 (WB)
21.1 (DB) 15.6 (WB)
8.3 (DB) 6.1 (WB)
440(15.5 OZ) 465(16.4 OZ)
2 ROW 12 STACKS 2 ROW 11 STACKS
2 ROW 17 STACKS, L-BENDED TYPE
TURBO FAN
PROPELLER TYPE FAN WITH SLINGER-RING
1/ 2/ 2
6 POLES
ROTARY SWITCH
THERMOSTAT
VERTICAL LOUVER (RIGHT & LEFT)
HORIZONTAL LOUVER (UP & DOWN)
TOP-DOWN
3.5KW, 208/230V
EXTERNAL OVERLOAD PROTECTOR
INTERNAL THERMAL PROTECTOR
FUSE LINK, BIMETAL THERMOSTAT
1.6m (3 WIRE WITH GROUDING)
ATTACHMENT PLUG (CORD-CONNECTED TYPE)
SPLASHED BY FAN SLINGER
80/36 81/37
2421/32 x 1413/32 x 1921/32
626 x 366 x 499
257/8 x 15
17
/32 x 16
23
/32
656 x 394 x 425
20
510
MODELS
ITEMS
OPERATING
TEMPERATURE
AIR DIRECTION CONTROL
POWER CORD
PROTECTOR
HEATING
COOLING
COOLING
HEATING
LOUVEREDFIN TYPE
BDE-103 BDE-123
OPTIONAL
PART
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
• 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.
• Side air-intake, side cooled-air discharge.
• Built in adjustable THERMISTOR and THERMOSTAT.
• Washable one-touch filter.
• Compact size.
—6—
PULL OPEN / PUSH CLOSE
REMOTE CONTROL SIGNAL RECEIVER
POWER
MODE
-
Every time you push this button, the air conditioner alternates between COOL, MONEY SAVER
®
and FAN.
- MONEY 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 to determine if cooling is needed.
TIMER
- SHUT-OFF TIME
• You will usually use shut-off time while you sleep.
• With unit 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 2°F
after another 30 min.
• Every time you push Timer button, it advances the Timer
setting as follows: 1 Hour
→
2 Hours
→
....
→
12 Hours
maximum.
- START TIME
• With unit not running, use Timer to set number of hours
before unit starts.
• Every time you push Timer button, it advances the Timer
setting as follows: 1 Hour
→
2 Hours
→
.....
→
12 Hours
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.
• 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, at High
fan speed, and set at a temperature setting of 72°F.
FAN SPEED
• Every time you push this button, it advances the setting as
follows:
{High → Low → Med → High}
1.5.2 COOLING AND HEATING MODEL
• OPERATION
—7—
A slight burning odor may come from the unit
when first switching to HEAT after the cooling
season is over. This odor, caused by fine dust
particles on the heater, will disappear quickly.
This is normal operation.
Off - Turns the air conditioner off.
Fan Only - The low fan speed operation without cooling (heating).
Low Cool - Cooling with the low speed fan operation.
High Cool - Cooling with the high speed fan operation.
Low Heat - Heating with the low speed fan operation.
High Heat - Heating with the high speed fan operation.
Turn the Temperature Knob to the desired setting. The central position is a normal
setting for average conditions. You can change this setting, if necessary, in
accordance with your temperature preference.
The thermostat automatically controls cooling or heating, but the fan runs
continuously whenever the air conditioner is in operation. If the room is too warm,
turn the thermostat control clockwise. If the room is too cool, turn the thermostat
control counterclockwise.
When the air conditioner has been operating in the
cooling or heating mode and is turned off or set to the fan
only position, wait at least 3 minutes before resetting to
the cooling operation again.
CAUTION
—8—
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 9 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
29~30 in this manual and on the control box.)
2. DISASSEMBLY INSTRUCTIONS
— Prior to disassembling the unit, make sure that the POWER switch is set to OFF and the power cord is
unplugged from the wall receptacle.
Figure 1
Figure 2
Figure 3
Figure 7
—9—
2.2 AIR HANDLING PARTS
2.2.1 ORIFICE, HEATER ASSY 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 2 terminals carefully
(See Fig. 5, Electric Heater Model only)
6. Remove the 4 screws which fasten the orifice.
(See Fig. 5)
7. 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 and shroud cover.
(Refer to section 2.2.1)
3. Remove the 6 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.
Figure 4
Figure 5
Figure 6
Figure 8
—10—
2.2.3 SHROUD
1. Remove the fan. (Refer to section 2.2.2)
2. Remove the screw which fastens the shroud.
3. Remove the shroud. (See Fig. 9)
4. 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 Freon
TM
Recovery System.
If there is no valve to attach the recovery system
to, install one (such as a WATCO A-1) before
venting the Freon
TM
. 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 knobs and the tips which fasten the
display panel.
3. Disconnect the 2 leads from the rocker switch and
remove the panel (Energy saver model only).
4. Remove 2 screws and unfold the control box.
(See Fig. 12)
5. Remove the Rotary Switch.
6. Remove the screw and the clamp which fastens
the capacitor. (See Fig. 12)
7. Disconnect all the leads on the capacitor terminals.
8. Re-install the components by referring to the
removal procedures, above.
Figure 9
Figure 10
Figure 11
Figure 12
—11—
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 control
box.
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 THERMOSTAT
1. Remove the control box. (Refer to section 2.1.3)
2. Unfold the control box. (Refer to section 2.3.3)
3. Remove the 2 screws which fasten the thermostat.
4. Disconnect all the leads of thermostat terminals.
5. Remove the thermostat. (See Fig. 14)
6. Re-install the components by referring to the
removal procedures, above.
2.3.6 ROTARY SWITCH
1. Remove the control box. (Refer to section 2.1.3)
2. Unfold the control box. (Refer to section 2.3.3)
3. Remove 2 screws which fasten the rotary switch.
4. Disconnect all the leads of the rotary switch
terminals.
5. Remove the rotary switch. (See Fig. 15)
6. Re-install the components by referring to the
removal procedure, above.
Figure 13
Figure 14
Figure 15
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