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BG-101G
User Manual
36 pgs2.08 Mb0

Heat Controller BG-101G, BG-123G, BG-103G, BG-81G, BG-143G User Manual

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SERVICE MANUAL
Thru-the-Wall Series with R-410A
BG-81G BG-101G BG-103G BG-123G
BGE-103G BGE-123G
BG-143G
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
Table of Contents
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
1
1. PRECAUTION ........................................................................................................................2
1.1 Safety precaution ...........................................................................................................2
1.3 Caution ..........................................................................................................................2
2. FEATURES AND PANEL .......................................................................................................3
2.2 Control panel illustration ................................................................................................3
3. UNIT DIMENSION ..................................................................................................................6
3.1 Unit dimension: ..............................................................................................................6
4. OPERATION LIMITS ..............................................................................................................6
4.1 Cooling operation ..........................................................................................................6
4.2 Electric heating operation ..............................................................................................7
5. PROTECTION FUNCTION ....................................................................................................8
5.1 Symbol & Meaning ........................................................................................................8
5.2 Protection Function ........................................................................................................8
6. COMPONENT OPERATION & TESTING ..............................................................................9
6.1 COMPRESSORS ..........................................................................................................9
6.2 FAN MOTOR ...............................................................................................................11
6.3 CAPACITOR, RUN ......................................................................................................11
6.4 THERMOSTAT ADJUSTMENT ....................................................................................12
6.5 HEATING ELEMENT - See Figure 6 ...........................................................................12
6.6 VALVE, DRAIN PAN (see Figure 7) .............................................................................13
6.7 SEALED REFRIGERATION SYSTEM REPAIRS ........................................................13
7. WIRING DIAGRAM ..............................................................................................................15
8. TROUBLESHOOTING .........................................................................................................17
8.1 Flow Chart ...................................................................................................................17
8.2 General Troubleshooting .............................................................................................27
8.3 Troubleshooting Cooling ..............................................................................................30
8.4 Troubleshooting Heating (Cooling/Electric Heater Models) .........................................32
9. INSTALLATION ACCESSORY LIST ...................................................................................34
10. CHARACTERISTIC OF TEMPERATURE SENSOR .........................................................34
1. PRECAUTION
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
2
1.1 Safety precaution
To prevent injury to the user and property damage, the following instructions must be followed.
Incorrect operation may cause harm or damage.
Before servicing unit, be sure to read this service manual.
1.2 Warning
Do not use damaged power cords, plugs, or a loose socket.
Always use the power plug and socket with the 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 other appliance near the power cable.
Do not allow water to run into electrical parts.
Do not store or use flammable 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 filter. 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
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
3
2.1 Features
Slide-in and Top-out chassis for simple installation and service (on some models).
Washable one-touch filter and easy access panel.
Super compact design.
Reliable and efficient rotary compressor.
Fresh air switch (on some models).
Anti-freezing control in cooling mode. Prevents water from freezing on evaporator by
sensing the evaporator pipe temperature in cooling mode.
Auto-restart function.
Time delay safety for compressor. Restart approx. 3 minutes after the power failure.
Auto mode in heating mode. Operation mode can be automatically set by the room
temperature.
Sleep mode.
Self-diagnosis function.
Filter check sensor after 250 hours.
Auto cool function.
Follow me function (optional).
Ionizer function (optional).
Silver ion filter (optional).
Alternate between Celsius or Fahrenheit temperature display units
24 hours timer function.
Energy saver.
2.2 Control panel illustration
Control panel for cooling only models:
B Panel
Control panel for cooling and heating models:
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
4
B Panel
Note: The control panels above are representative of many available models. Your model
may be slightly different.
On/Off (On and Off):
Press this button once to start the unit, press again to stop.
FAN:
Press this button to select appropriate fan speed.
Fan Speed mode has four options - Auto, Low, Med or High. Each time the button is pressed,
the fan speed mode is shifted.
TEMPRATURE UP AND DOWN:
Press the Up(▲)or Down(▼) buttons to change temperature setting.
Press the Up(▲) button to increase the set (operating) temperature of the unit.
Press the Down(▼) button to decrease the set (operating) temperature of the unit.
Press or hold either button until the desired temperature is displayed. This temperature will be
automatically maintained anywhere between 62°F (17°C
) and 86°F (30°C).
MODE:
Pr
ess this button to select operation mode.
Each time you press the button, the operation mode is selected in a sequence that goes from
Auto, Cool, Dry and Fan for cooling only models. and Auto, Cool, Dry, Heat and Fan for electric
heating models.
ENERGY SAVER:
Press this button to activate energy saving. This feature can only function in cooling mode.
SLEEP:
Press this button to save energy and create a more comfortable environment when sleeping. In
this function, the setting temperature will increase by 2° F degrees 30 minutes after the mode is
selected. The temperature will then continue to increase by another 2° F degrees after every 30
minutes. After 7 hours, the unit return to the originally programmed settings. The Sleep mode
program can be cancelled at any time during operation by again pressing the Sleep button.
TIMER:
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
5
Press this button to set the time for unit starting or stopping.
Press or hold the Up (▲) / Down (▼) to set the timer time.
Turning the unit ON or OFF at any time will cancel the Auto Start/Stop function.
CHECK FILTER:
This feature is a reminder to clean the Air Filter for more efficient operation. The “CHECK
FILTER” light will illuminate after 250 hours of operation.
After the filter is cleaned, press this button to confirm that the filter has been cleaned and the
light will go off.
FOLLOW ME (OPTIONAL):
Press the button on the remote controller to activate this feature, which serves as a remote
thermostat allowing for the precise temperature control at its location, rather than using the
thermostat sensor in the unit’s display.
Clean Air (OPTIONAL):
Press this button to start the Clean Air feature, press again to stop.
When this feature is started, the Ionizer is energized to generate abundant anions to fill the
room with refreshing and natural air.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
6
3. UNIT DIMENSION
3.1 Unit dimension:
4. OPERATION LIMITS
4.1 Cooling operation
Outdoor unit air temp DB
Indoor air temp DB
Note: The chart is the result from the continuous operation under constant air
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
7
temperature conditions. However, the initial pull-down stage is not included.
4.2 Electric heating operation
Indoor air temp DB
Outdoor air temp DB
Note: The chart is the result from the continuous operation under constant air
temperature conditions. However, the initial pull-down stage is not included.
5. PROTECTION FUNCTION
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
8
5.1 Symbol & Meaning
TA: Indoor ambient temperature;
TE: Indoor evaporator temperature;
TS: Setting temperature through the remote controller.
5.2 Protection Function
3 minute compressor time delay
The compressor will wait for 3 minutes before restarting, so as to prevent the pressure
imbalance in refrigerant system from resulting in compressor rotor locking.
Anti-freezing protection in cooling or dry mode
Anti-freezing function is activated according to TE.
If TE is lower than 33.8°F (1℃) for 14 minutes, the evaporator anti-freezing protection will be
activated. The compressor will turn off for 5 minutes. 5 minutes later, if the evaporator pipe
temperature is still lower than 33.8°F (1℃), the compressor remain off; when it gets higher
than 33.8°F (1℃), the compressor will restart and the antifreeze function will be cancelled.
: If the compressor stops operation, the time will be cleared.
Note
If the fan motor turns to High speed or the indoor ambient temperature gets over 78.8°F
(26℃), the time will keep inactive, not be cleared.
Anti-frosting protection and defect at cooling or dry mode After compressor runs for 3 minutes, if TE is less than 5°F (-15℃) for the subsequent 3
minutes, the anti-frosting protection will be activated and the compressor will stop for the
following 6 minutes. After that time, if the condition for de-frosting function is met again in the
following 10 minutes while the compressor is operating, the unit will display ‘Ed’ to indicate that
the unit is in the defrost mode defect. The compressor and fan motor will turn OFF
Note: The Defect display can be cancelled only by pressing the ON/OFF button on the unit
or the remote controller.
Fault Code
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
9
Defect code Defect explanation
Ed
AS
HS LO
HI
Evaporator de-frosting defect.
Indoor ambient temperature sensor failure in heating, cooling, dry and auto
mode.
DAHT sensor failure in heating mode.
Sensor disconnection malfunction in fan only mode
Sensor short circuit malfunction in fan only mode
6. COMPONENT OPERATION & TESTING
WARNING: DISCONNECT THE POWER CORD FROM THE POWER PLUG BEFORE SERVICING OR TESTING.
6.1 COMPRESSORS
Compressors are single phase, 115 or 230/208 volt, depending on the model number. 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. Figure 1: Compressor winding test
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. Figure 2: Typical ground test
CHECKING COMPRESSOR EFFICIENCY
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
10
The reason for compressor inefficiency 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 process tube.
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.
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 major
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. Figure 3: External overload
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.
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