Heat Controller BDE-123-A, BDE-103-A User Manual

Through-The-Wall

Air Conditioner

Service Manual

CAUTION

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

-Only for authorized service personnel.

HEAT CONTROLLER, INC.

MODELS: BDE-103-A

BDE-123-A

—2—

1. PREFACE

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

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

1.3 FEATURES.....................................................4

1.4 CONTROL LOCATIONS.................................4

DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS....................................6

2.1.1 FRONT GRILLE.....................................6

2.1.2 CABINET................................................6

2.1.3 CONTROL BOX.....................................6

2.2 AIR HANDLING PARTS..................................7

2.2.1

ORIFICE, HEATER ASSY AND TURBO FAN

.........7

2.2.2 FAN........................................................7

2.2.3 SHROUD................................................8

2.3 ELECTRICAL PARTS.....................................8

2.3.1 MOTOR..................................................8

2.3.2 COMPRESSOR.....................................8

2.3.3 CAPACITOR..........................................8

2.3.4 POWER CORD......................................9

2.3.5 THERMOSTAT ......................................9

2.3.6 ROTARY SWITCH.................................9

2.4 REFRIGERATION CYCLE............................10

2.4.1 CONDENSER......................................10

2.4.2 EVAPORATOR....................................10

2.4.3 CAPILLARY TUBE...............................10

INSTALLATION

3.1 HOW TO INSTALL THE UNIT ......................13

3.2 INSTALLATION KITS CONTENTS...............14

3.3 SUGGESTED TOOL REQUIREMENTS.......15

3.3.1 PREPARATION OF SLEEVE ..............15

3.3.2 UNIT INSTALLATION..........................16

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS...............................17

4.2 PIPING SYSTEM ..........................................17

4.3 TROUBLESHOOTING GUIDE......................18

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM......................................23

6. EXPLODED VIEW..................................24

7. REPLACEMENT PARTS LIST.......25

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.

4. The value should be over 1MΩ.

CONTENTS

—3—

1.3 SPECIFICATIONS

1.3.1 FOR BDE-103-A/BDE-123-A

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)

1Ø, 208/ 230V, 60Hz

9,800/10,000 11,400/11,700

1,040/1,060 1,210/1,250

5.2/4.7 6.2/5.8

9.4 9.4 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) 470(16.6 OZ)

2 ROW 12 STACKS 3 ROW 12 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, 230V

EXTERNAL OVERLOAD PROTECTOR

INTERANL 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

/32 x 1413/32 x 1921/32

626 x 366 x 499

257/8 x 15

/32 x 16

/32

656 x 394 x 425

510

MODELS

ITEMS

OPERATING TEMPERATURE

AIR DIRECTION CONTROL

POWER CORD

PROTECTOR

HEATING

COOLING

HEATING

LOUVEREDFIN TYPE

BDE-103-A BDE-123-A

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

The ventilation lever is located in the right of the air discharge. The ventilation lever must be in the CLOSE position in order to maintain the best cooling conditions. When fresh air is necessary in the room, set the ventilation lever to the OPEN position. The damper is opened and room air is exhausted outside.

• ENERGY SAVER (optional)

On : Both the fan and the compressor turn on and turn off

together while operation knob is set to the Cool position. You can get the more economical operation.

Off : The fan runs constantly while operation knob is set to

the Cool position.

You can access the Energy Saver switch when you open the inlet grille.

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

• Built in adjustable THERMOSTAT.

• Washable one-touch filter.

• Compact size.

—4—

PULL OPEN / PUSH CLOSE

Off On

Energy Saver

Med

Fan

Off

Low

Fan

High

Cool

Med Cool

Low Cool

Operation

Thermostat

Off - Turns air conditioner off. Med Fan - Med speed fan operation without cooling. Low Fan - Low speed fan operation without cooling. High Cool - Cooling with high speed fan operation. Med Cool - Cooling with med speed fan operation. Low Cool - Cooling with low speed fan operation.

This automatically controls the temperature of the indoor air. Turn the knob so that arrow points to the larger marks for greater cooling. Point the arrow to the smaller marks for more moderate cooling. (i.e. the higher number, the greater cooling)

1.5.2 COOLING AND HEATING MODEL

• OPERATION

—5—

A slight heat 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.

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.

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.

When the air conditioner has been performed its cooling or heating operation and is turned off or set to the fan position, wait at least 3 minutes before resetting to the cooling operation again.

CAUTION

• HEAT PUMP MODELS

When the outdoor temperature is lower than

-4°C (24°F), the electric heater will turn on instead of the heat pump.

—6—

2.1 MECHANICAL PARTS

2.1.1 FRONT GRILLE

1. Open the inlet grille upward or 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 26~27 in this manual and on the control box.)

2. DISASSEMBLY INSTRUCTIONS

— Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord.

Figure 1

Figure 2

Figure 3

Figure 7

—7—

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, at Electric Heater Model only)

6. Remove the 4 screws which fasten the orifice. (See Fig. 5)

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

8. Remove the clamp which secures the turbo fan with plier. (See Fig. 6)

9. Remove the turbo fan with plier or your hand without touching blades. (See Fig. 7)

10. Re-install the components by referring to the removal procedure, 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. Remove the clamp which secures the fan.

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

7. Re-install the components by referring to the

removal procedure, above.

Figure 4

Figure 5

Figure 6

Figure 8

—8—

2.2.3 SHROUD

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

2. Remove the screw which fasten the shroud.

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

4. Re-install the component by referring to the

removal procedure, 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 a 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 procedure, above.

2.3.2 COMPRESSOR

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

2. Discharge the refrigerant system using Freon

Recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before venting the Freon

. 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-instill the components by referring to the

removal procedure, 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 of capacitor terminals.

8. Re-install the components by referring to the

removal procedure, above.

Figure 9

Figure 10

Figure 11

Figure 12

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