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BG-103A
User Manual
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Heat Controller BG-103A User Manual

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HEAT CONTROLLER, INC.
Through-The-Wall
Air Conditioning
Model: BG-103A
Service Manual
CAUTION
-Before servicing the unit, read the "safety precautions" in this manual.
-Only for authorized service personnel.
1.3 SPECIFICATIONS
1.3.1 FOR BG-103A
Items
Model
BG-103A REMARK
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
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
TURBO FAN
PROPELLER TYPE FAN WITH SLINGER-RING
3/3
4POLES
ELECTRIC
THERMISTOR
LOUVERED-FIN TYPE
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)
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 7/8 x 15 17/32 x 16 23/32
656 x 394 x 425
20 1/2
521
—3—
1.4 FEATURES
PULL OPEN / PUSH CLOSE
MODE TIMER POWER
FAN
SPEED
Fan
Energy
Saver
Cool
Timer
TEMP
'
F
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}
• 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.
CAUTION
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.
—4—
2. DISASSEMBLY INSTRUCTIONS
M O
D E
T I M
E R
P O
W E R
FAN
SPEED
F a n
E n e
r g
y S a v
e
r
C
o
o
l
T i m
e r
TEMP
'
F
F 1 L O W
F2 ME D
F 3 H IG H
MODE
TIMER
POWER
F A
N
S
P E
E D
F a
n
Energy Saver
C
o o
l
T im
e r
T E
M P
'
F
F 1 L
O W
F 2 M
E D
F
3 H I G
H
M
O
D
E
T
I
M
E
R
P
O
W
E
R
F
A
N
S
PEE
D
Fa
n
E
n
e
r
g
y
S
a
v
e
r
C
o
ol
Tim
er
T
E
MP
'
F
F
1
L
O
W
F
2
M
E
D
F
3
H
I
G
H
MODE TIMER POWER
FAN SPEED
Fan
Energy
Saver
Cool
Timer
TEMP
'
F
F1 LOW F2 MED F3 HIGH
— Prior to disassembling the unit, make sure that the POWER is off and the power cord is unplugged from the
wall receptacle.
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.
Figure 1
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 25 in
this manual and on the control box.)
Figure 2
Figure 3
—5—
2.2 AIR HANDLING PARTS
M O D
E
T
I M E
R
P O W
E R
F A
N S P
E
E
D
F
a n
E
n e r g
y
S
a v e r
C o
o l
T i m
e r
T
EM P
'
F
F 1 L O W
F
2 M E D
F
3 H I G H
M O
D E
T
I M E
R
P O
W E
R
F
A
N S
P
E
E
D
Fan
E
n e r g
y
S
a v e
r
Cool
Time
r
T E M P
'
F
F 1 L O W
F 2 M E D
F 3 H IG H
M O D
E
T
I M E
R
P O W
E R
FA
N S P
E
E
D
F
a n
E
n e r g
y
S
a v e r
C o
o l
T i m
e r
T
EMP
'
F
F1 L O W
F
2 M E D
F
3 H I G H
M O D
E
T
I M E
R
P O W
E R
F
A
N S P
E
E
D
F
a n
E
n e r g
y
S
a v e r
C o
o l
T i m
e r
TEM
P
'
F
F 1 L O W
F
2 M E D
F
3 H I G H
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)
Figure 4
Figure 5
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.
Figure 6
Figure 7
Figure 8
—6—
2.2.3 SHROUD
M
O
DE
TIM
ER
P
O W
E
R
FAN
SPEED
F a
n
E
n e
rg
y S a
v
e
r
C
o
o l
T
i m
e r
TE
M
P
'
F
F1 LOW F2 MED
F3 HIGH
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 Freon 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.
TM
Figure 9
Figure 10
Figure 11
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.
Figure 12
—7—
2.3.4 POWER CORD
MODE
TIMER
POWER
FAN
SPEED
Fan
Energy Saver
C
ool
Tim
er
TEMP
'
F
F1 LOW F2 MED
F3 HIGH
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.
Figure 13
Figure 14
—8—
2.4 REFRIGERATION CYCLE
M
O D
E
T
I M E
R
P O W
E R
FAN SP EED
F
a n
E n
e r g
y
S
a v e r
C o
o l
T
im e
r
TEMP
'
F
F 1 L OW
F
2 ME D
F3
HIGH
CAUTION
Discharge the refrigerant system using a Freon Recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before
TM
venting the Freon
. Leave the valve in place
after servicing the system.
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 FreonTMRecovery 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 FreonTMRecovery 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)
TM
Figure 15
Figure 16
2.4.3 CAPILLARY TUBE
1. Remove the cabinet. (Refer to section 2.1.2)
2. After discharging the refrigerant completely – into a FreonTMRecovery System, unbraze the interconnecting tube at the capillary tube.
3. Remove the capillary tube.
4.
Re-install the components by referring to the notes.
—9—
NOTES
— Replacement of the refrigeration cycle.
1. When replacing the refrigeration cycle, be sure to
discharge the refrigerant system using a Freon
TM
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.
CAUTION
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.
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.
2)
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.
—10—
Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pinch-off tool
A
COMPOUND GAUGE
EVAPORATOR (LOW PRESSURE SIDE)
COMPRESSOR
CAPILLARY TUBE
CONDENSER (HIGH PRESSURE SIDE)
SEE INSETS
BELOW
MANIFOLD
GAUGE
B
A
B
EXTERNAL VACUUM PUMP
capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve.
LOW
B
HI
A
CHARGING CYLINDER
C
Figure 17A-Pulling Vacuum
Figure 17B-Charging
—11—
—12—
3. INSTALLATION
3.1 INSTALLATION REQUIREMENTS
If you use an existing wall sleeve, you should measure its
dimensions. Install the new air conditioner according to these installation instructions to achieve the best performance. All wall sleeves used to mount the new air conditioner must be in good structural condition and have a compatible rear grille in order to securely attach the new air conditioner. (FIG. 18A) With the FRIEDRICH USC sleeve, you can maintain the best performance of the new air conditioner. (FIG. 18B)
ELECTRICAL SERVICE
Check your available electrical service. The power supply available must be the same as that shown on the unit nameplate (found on left side of cabinet).
All models are equipped with a 3-prong service plug to provide proper service and safe positive grounding. Do not change plug in any way. Do not use an adapter plug. If your present wall outlet does not match your plug, call a qualified electrician to make the necessary corrections. SAVE CARTON for storage and this OWNER'S MANUAL for future reference. The carton is the best way to store unit during winter or when not in use.
INSTALLATION HARDWARE
15-17/32" (394 mm)
16-23/32" (425 mm)
25-7/8"
(656 mm)
aluminum metal grille
20-3/32"
(511 mm)
Air Conditioner
24"(610 mm)
14-13/32" (366 mm)
18-15/32"(468 mm)
FIG. 18A
1
8
9
ITEM NAME OF PARTS Q'TY
PLASTIC GRILLE 1 VERTICAL INSULATION STRIP 1 AROUND INSULATION STRIPS 2 HORIZONTAL INSULATION STRIP 1 SUPPORT BLOCK 2 BAFFLE 1 TRIM FRAME 2 SHIM 2 PLASTIC NUTS AND WASHER SCREWS
3
2 4
5
2 Size options
6
7
2 Size options
4
FRIEDRICH USC Wall Sleeve
FIG. 18B
CAUTION
REQUIRED TOOLS:
• Tight Fitting gloves
• Standard screwdriver
• Phillips screwdriver
• Pliers
• Sharp knife
• 3/8-inch open end
wrench or adjustable wrench
• 1/4-inch hex socket and ratchet
• Tape measure
• Electric drill
• 1/4-inch drill bit
3.2 INSTALLATION
1/4"
Wall Sleeve
FRONT
UNIT
SHIM PLACEMENT UNIT INSTALLATION
1" high
3
/4" High
Shim
6" 6"
CAUTION
Installing the FRIEDRICH USC sleeve ensures optional performances of the unit.
If you decide to keep the existing wall sleeve, you have to redirect the louvers at the back of the wall sleeve. Refer to FIG. 23 on p15. The use of pliers is recommended. If you DO NOT redirect, you run the risk of poor performance or premature product failure. This is not covered under the terms of the FRIEDRICH warranty.
• Pick a location which will allow the conditioned air to blow into the area you want. Good installation with special attention to the proper position of the unit will lessen the chance that service will be needed.
ITEMS IN INSTALLATION HARDWARE
You may not need all parts in the kit. Discard unused parts
ITEM (inches) Qty.
Plastic grille 26 Vertical insulation strip 15
Around Insulation Strips
Support Block 1 Baffle Shim 11 Trim Frame 2 Washer Screw 4 Nuts(Plastic) 4 Grille Rear 1
3
9
1
67
27
59
3
/
4
14 x
13
/
x 16
4
/
x 1
16
/
x 1
8
/
32
x 1
1
4
/
16
1
/
3
/
8
3
/
8
3
x 1
3
/
x 4
8
/
x
2
x 1 x
2
3
/
x 1
8
25
/
x
32
3
/
x 1
8
5
/
16
1
/
8
3
/
4
1 1 1
/
8
1
2 1 2
HOW TO INSTALL
Before installing the unit, identify the existing wall sleeve
1
from the list below.
NOTE: All wall sleeves used to mount the new Air Conditioner must be in sound structural condition and have a rear grille that securely attaches to sleeve, or rear flange that serves as a stop for the Air Conditioner.
Remove old air conditioner from existing wall sleeve.
2
Clean the interior of an existing sleeve. (Do not disturb seals.)
3
Wall sleeve must be securely fastened in wall before installing the air conditioner. Use the nails or screws
4
through sleeve into wall, if needed. Repaint sleeve if needed.
Prepare the wall sleeve for installation of the unit. If you plan to use your existing wall sleeve, and it is not
5
FRIEDRICH, use procedure B or C below.
Procedure Brand
A(page 16)
FRIEDRICH USC 16-23/32 White-Westinghouse Frigidaire Carrier
B
(pages 17~18)
(52F series) General Electric /Hotpoint
Depth(inches)
16, 17-1/2
or 22
16-7/8
Whirlpool 17-1/8 or 23 Carrier (51S series)
C
(pages 19)
Install new unit into wall sleeve.
6
Fedders/Emerson 16-3/4 Friedrich WSC or 19-3/4 Emerson/Fedders 15
18-5/8
CAUTION: When installation is completed, replacement unit MUST have a rearward slope as shown. To achieve 1/4" slope, remove the backing from the 11-13/16" shim strips and attach them as shown below in Fig. 19. Place the higher portion of shim to the front of the rib on base of wall sleeve.
Brand
Wall Sleeve Dimensions (inches)
Width Height Depth White-Westinghouse Frigidaire
25-1/2 15-1/4 Carrier (52F series) General Electric /Hotpoint
26 15-5/8 16-7/8
Whirlpool 25-7/8 16-1/2
Fedders/Emerson Friedrich WSC or 19-3/4
27 16-3/4
FRIEDRICH USC 25-7/8 15-17/32 16-23/32 Emerson/Fedders 26-3/4 15-3/4 15 Carrier (51S Series) 25-3/4 16-7/8 18-5/8
16, 17-1/2
or 22
17-1/8
or 23
16-3/4
FIG. 19
—13—
PROCEDURE
If you are using the new sleeve (optionally
A
suppliedwithyourunit),skiptostep3. Otherwise, install the plastic grille from the kit. Cut the plastic grille to 25-1/2" wide and 15-1/4" high. Place the plastic grille to the inside of the wall sleeve at the rear flange.
Fasten the 4 washer screws to secure the grille to the wall sleeve. If you need plastic nuts to mount plastic grille to the inside of the wall sleeve, there are plastic nuts in the installation kit. The nuts are installed from the inside of the sleeve and are pressing into the square holes of the rear flanges.Fasten the bracket to the upside of the wall sleeve using the washer screw. The bracket prevents the unit from leaving the sleeve.
Remove the backing from the Vertical Insulation strip 15
9
/
16
x1
3
/
8
x1
3
/
8
and attach that totheinsiderightofthesleeveasshown below. Remove the backing from the Around Insulation strip 67
1
/
8
x1
3
/
8
x
25
/
32
and attach that to the inside front of the sleeve as shown below.
FIG.20
FIG. 22
FIG.21
Fasten the screws and the bracket
1
2
3
4 5
FIG.23
• Air conditioners covered in this manual pose an excessive weight hazard. Two or more people are needed to move and install the unit. To prevent injury or strain, use proper lifting and carrying techniques when moving unit.
• When handling the air conditioner, be careful to avoid cuts from sharp metal fins on front and rear coils.
• Make sure air conditioner does not fall during removal.
• If unit does not operate after installation check, to be sure the circuit interrupter has not been tripped. Refer to the Troubleshooting guide for reset procedure.
CAUTION
Install the new unit into the wall sleeve.
Toassembletrim,tpthetabofeachpiece into the slot of the other piece as shown below. Slide trim over the front of the air conditioner until trim is flush with sleeve as shown below.
Bracket Bracket
or
Trim (2 ea)
Wall
Indoor Outdoor
Around Insulation
9 1/2"6"
—14—
PROCEDURE B
Redirect the louvers at the back of the wall
sleeve to 60° angle as shown in the FIG 24. The
use of pliers is recommended.
If the wall sleeve already has a rear grille, skip to step 4. If the wall sleeve does not have a rear grille or louvered panel, install the plastic grille from the kit. Cut the plastic grille to 25-1/2" wide and 15-1/4" high. Place the plastic grille to the inside of the wall sleeve at the rear flange.
Fasten the 4 washer screws to secure the grille to the wall sleeve. If you need plastic nuts to mount plastic grille to the inside of the wall sleeve, there are plastic nuts in the installation kit. The nuts are installed from the inside of the sleeve and are pressed into the square holes of the rear flanges.Fasten the bracket to the upside of the wall sleeve using the washer screw. The bracket prevents the unit from leaving the sleeve.
Remove the backing from the Vertical Insulation strip 15
9
/
16
x1
3
/
8
x1
3
/
8
and attach that to the inside right of the sleeve as shown below. Remove the backing from the Around Insulation strip 67
1
/
8
x1
3
/
8
x
25
/
32
and attach that to the
inside front of the sleeve as shown below.
If the depth of your existing wall sleeve is less than or equal to 18", skip to step 7. Otherwise,
1
4
2
3
FIG.25
FIG. 27
FIG. 26
FIG.24
Depth"D" of the existing wall sleeve (inches)
Length "A"
(inches)
5
Place the plastic grille
Fasten the screws and the bracket
cut the baffles and the support blocks according to length "A" in the table below.
FIG. 28
Around Insulation
Vertical Insulation
3
/4
1-3/4
4
18 D 18-5/
8
18-5/
8
D 19-3/
4
9 1/2"6"
Indoor Outdoor
19-3/4 D 22
60°
60°
Rear Louvers
Rear Louvers
(Top View)
(Top View)
3
3
7
7
/
"
/
"
32
32
60°
60°
Indoor Outdoor
9 1/2"6"
Around Insulation
Vertical Insulation
Bracket Bracket
or
4
Length "A"
(inches)
3
/4
1-3/4
4
Depth"D" of the existing wall sleeve (inches)
18 D 18-5/
18-5/
8
19-3/4 D 22
8
D 19-3/
A
A
Support Block
Baffle
—15—
PROCEDURE B CONTINUED
Wall
Wall
Sleeve
Baffle
(
7
3
/
32
"
)
Front
Support Block
Remove the backing from the support blocks and attach
6
them to the inside of the wall sleeve as shown FIG 29. Slide the baffle into slots of the support blocks.
Install the new unit into the wall sleeve.
7
Assemble trim as described in Step 6,
8
Procedure A.
FIG. 29
CAUTION
• Air conditioners covered in this manual pose an excessive weight hazard. Two or more people are needed to move and install the unit. To prevent injury or strain, use proper lifting and carrying techniques when moving unit.
• When handling the air conditioner, be careful to avoid cuts from sharp metal fins on front and rear coils.
• Make sure air conditioner does not fall during removal.
• If unit does not operate after installation check, to be sure
the circuit interrupter has not been tripped. Refer to the Troubleshooting guide for reset procedure.
—16—
Depth"D" of the existing wall sleeve (inches)
Length "A"
(inches)
Support Block
Baffle
A
A
3
/4
1-3/4
4
18 D 18-5/8
18-5/
8
D 19-3/
4
19-3/4 D 22
3.5 PROCEDURE C
Wall
Wall
Sleeve
Baffle
Front
Support Block
(7
3
/
32
")
or
Bracket Bracket
Rear Louvers
(Top View)
60°
7
13
/
16
"
60°
5
8 1/2"
Indoor Outdoor
Around Insulation
Horizontal Insulation
Redirect the louvers at the back of the wall sleeve to 60°
1
angle as shown in the FIG 30. The use of pliers is recommended.
Remove the backing from the Horizontal Insulation strip
4
7
3
23
/
x 1
32
3
/
/
x 1
8
and attach that to the inside right of the
16
sleeve as shown below. Remove the backing from the
27
3
Around Insulation strip 59
/
x 1
32
3
/
/
x 1
and attach that
8
8
to the inside front of the sleeve as shown below.
FIG. 30
If the wall sleeve already has a rear grille, skip to step 4. If the
2
wall sleeve does not have a rear grille or louvered panel, install the plastic grille from the kit. Cut the plastic grille to 26-1/2" wide and 15-1/2" high or to the sleeve dimensions. Place the plastic grille to the inside of the wall sleeve at the rear flange.
Place the plastic grille
Fasten the 4 washer screws to secure the grille to the
3
wall sleeve. If you need plastic nuts to mount plastic grille
FIG. 31
to the inside of the wall sleeve, there are plastic nuts in the installation kit. The nuts are installed from the inside of the sleeve and are pressed into the square holes of the rear flanges. Fasten the bracket to the upside of the wall sleeve using the washer screw. The bracket prevents the unit from leaving the sleeve.
If the depth of your existing sleeve is less than or equal to 18”, skip to step 7. Otherwise, cut the baffles and the support blocks according to Length "A" in the table below.
Remove the backing from the support blocks and attach
6
them to the inside of the wall sleeve as shown FIG 35. Slide the baffle into slots of the support blocks
FIG. 33
FIG. 34
Fasten the screws and the bracket
FIG. 35
FIG. 32
—17—
7
1" high
3
/4" High
CAUTION
Parts and Installation
PROCEDURE C CONTINUED
To achieve rearward slope for unit draining, remove the backing from the 11
13
/
16
"shim
strips and attach them as shown below in Fig.
37. The higher portion of shim is to be placed in front of the rib on the base of wall sleeve.
Install the new unit into the wall sleeve
8
9
Assemble trim as described in Step 6,
Procedure A.
6" 6"
Shim (2EA)
FIG. 37
• Air conditioners covered in this manual pose an excessive weight hazard. Two or more people are needed to move and install the unit. To prevent injury or strain, use proper lifting and carrying techniques when moving unit.
• When handling the air conditioner, be careful to avoid cuts from sharp metal fins on front and rear coils.
• Make sure air conditioner does not fall during removal.
• If unit does not operate after installation check, to be sure the circuit interrupter has not been tripped. Refer to the Troubleshooting guide for reset procedure.
—18—
4. TROUBLESHOOTING GUIDE
20-3/32"
(499mm)
24"
(610mm)
14-
13
/32"
(366mm)
MODE TIMER POWER
FAN
SPEED
Fan
Energy
Saver
Cool
Timer
TEMP
'
F
F1 LOW F2 MED F3 HIGH
CONDENSER COILS
EVAPORATOR COILS
FAN
MOTOR
: REFRIGERANT FLOW
TURBO FAN
CAPILLARY TUBE
COMPRESSOR
MOTOR
COMPRESSOR
OIL
(LIQUID REFRIGERANT)
CAPILLARY TUBE
OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH
SUCTION LIME COOL LOW PRESSURE VAPOR
COOLED AIR
COMPLETE LIQUID BOIL OFF POINT
LIQUID PRESSURE DROP
ROOM AIR HEAT LOAD
VAPOR INLET
HOT DISCHARGED AIR
LIQUID OUTLET
HIGH PRESSURE VAPOR
LIQUID PEFRIGERANT
LOW PRESSURE VAPOR
ROOM AIR CONDITIONER
EVAPORATOR COILS CONDENSER COILS
CYCLE OF REFRIGERATION
4.1 OUTSIDE DIMENSIONS
4.2 PIPING SYSTEM
Following is a brief description of the important components and their functions in the refrigeration system. Refer to Fig. 41 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.
Figure 41
—19—
4.3 TROUBLESHOOTING GUIDE
Ineffective Cooling
Check outdoor coil (heat exchanger) & the fan operation.
Check gas leakage.
Repair gas leak.
Replacement of unit if the unit is beyond repair.
Satisfactory operation with temperature difference of inlet & outlet air ; 44.6~50˚F
Check heat load increase.
Unexpected residue
Overloaded Circuit
Check inside gas pressure.
Adjusting of refrigerant charge
Malfunction of compressor
Replacement of compressor
Check cold air circulation for smooth flow.
Dirty indoor coil (Heat exchanger)
Malfunction of fan
Clogged air filter
Obstruction at air outlet
Correct above troubles
Stop auto air-swing
Check clogging in refrigeration circuit.
Repair clogging in refrigeration circuit.
In general, possible trouble is classified in two causes. The one is called Starting Failure which is caused from an electrical defect, and the other is Ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application.
Unit is running but cooling is ineffective
—20—
Fails to Start
Check circuit breaker and fuse.
Gas leakage at feeler bulb of thermostat
Check control switch.
Only fan fails to start.
Improper wiring.
Defect of fan motor capacitor.
Irregular motor resistance ( ). Irregular motor insulation ( ).
Replacement of fan motor
Regular but fails to start
Replacement of compressor (locking of rotor, metal)
Improper thermostat setting
Loose terminal connection.
Improper wiring
Irregular motor resistance ( )
Irregular motor insulation ( )
Replacement of compressor (Motor damaged)
Drop in power voltage.
Check capacitor.
Replacement.
Only compressor fails to start.
Defective compressor capacitor.
Check power source.
Check control switch setting.
—21—
COMPLAINT CAUSE REMEDY
Fan motor will not run.
No power
Power supply cord
Rotary switch
Wire disconnected or connection loose
Capacitor (Discharge capacitor before testing.)
Will not rotate
Check voltage at outlet. Correct if none.
Check voltage to rotary switch. If none, check power supply cord. Replace cord if circuit is open.
Check switch continuity. Refer to wiring diagram for terminal identification. Replace switch if defective.
Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal.
Test capacitor. Replace if not within ±10% of manufacturer's rating. Replace if shorted, open, or damaged.
Fan blade hitting shroud or blower wheel hitting scroll. Realign assembly.
Units using slinger ring condenser fans must have 1/4to 5/16inch clearance to the base. If it is hitting the base, shim up the bottom of the fan motor with mounting screw(s).
Fan motor runs intermittently
Fan motor noise.
Revolves on overload.
Grommets
Fan
Turbo fan
Loose set screw
Check fan motor bearings; if motor shaft will not rotate, replace the motor.
Check voltage. See limits on page 27. If not within limits, call an electrician.
Test capacitor. Check bearings. Does the fan blade rotate freely? If not, replace fan motor.
Pay attention to any change from high speed to low speed. If the speed does not change, replace the motor.
Check grommets; if worn or missing, replace them.
If cracked, out of balance, or partially missing, replace it.
If cracked, out of balance, or partially missing, replace it.
Tighten it.
Worn bearings
If knocking sounds continue when running or loose, replace the motor. If the motor hums or noise appears to be internal while running, replace motor.
—2—22—
COMPLAINT CAUSE REMEDY
Compressor will not run, but fan motor runs.
Voltage
Wiring
Rotary
Thermostat
Capacitor (Discharge capacitor before servicing.)
Compressor
Check voltage. See the limits on the preceding. page. If not within limits, call an electrician.
Check the wire connections, if loose, repair or replace the terminal. If wires are off, refer to wiring diagram for identification, and replace. Check wire locations. If not per wiring diagram, correct.
Check for continuity, refer to the wiring diagram for terminal identification. Replace the switch if circuit is open.
Check the position of knob If not at the coldest setting, advance the knob to this setting and restart unit. Check continuity of the thermostat. Replace thermostat if circuit is open.
Check the capacitor. Replace if not within ±10% of manufacturers rating. Replace if shorted, open, or damaged.
Check the compressor for open circuit or ground. If open or grounded, replace the compressor.
Overload
Check the compressor overload, if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool it, and retest.)
ROOM AIR CONDITIONER VOLTAGE LIMITS
NAME PLATE RATING MINIMUM MAXIMUM
115V 103.5V 126.5V
208/230V 187V 253V
—23—
COMPLAINT CAUSE
REMEDY
Compressor cycles on overload.
Insufficient cooling or heating
Excessive noise.
Voltage
Overload
Fan motor
Condenser air flow restriction
Condenser fins (damaged)
Capacitor Wiring Refrigerating system Air filter Exhaust damper door Unit undersized
Blower or fan
Copper tubing
Check the voltage. See the limits on the preced­ing page. If not within limits, call an electrician.
Check overload, if externally mounted. Replace if open. (If the compressor temperature is high, remove the overload, cool, and retest.)
If not running, determine the cause. Replace if required.
Remove the cabinet. inspect the interior surface of the condenser; if restricted, clean carefully with a vacuum cleaner (do not damage fins) or brush. Clean the interior base before reassembling.
If condenser fins are closed over a large area on the coil surface, head pressures will increase, causing the compressor to cycle. Straighten the fins or replace the coil. Test capacitor. Check the terminals. If loose, repair or replace. Check the system for a restriction. If restricted, clean of replace. Close if open. Determine if the unit is properly sized for the area to be cooled. Check the set screw or clamp. If loose or missing, correct. If the blower or fan is hitting air guide, rearrange the air handling parts. Remove the cabinet and carefully rearrange tubing not to contact cabinet, compressor, shroud, and barrier.
—24—
5. SCHEMATIC DIAGRAM
5.1 CIRCUIT DIAGRAM
• MODEL : BG-103A
—25—
—26—
6. EXPLODED VIEW
• MODEL:BG-103A
567502
554160
550140
359012
352380
346811
349600
554031
149980
352115
35211A
130410
435300
435300A
147582A
147581
135303
152302
147582B
135312
349480
352113 552113
W48602
354210
731273
E
C
B
M
O
E
D
M
I
T
R
E
W
O
P
R
E
N
A
F
D
E
E
PS
Fa
n
y
gr
e
n
E
r
ev
a
S
C
o o
l
T i
m e
r
P
M
ET
'
F
F 1L
O
W
F
2M
E D
F3
H I
G H
132100
A
264110
131400
559011
268711B
249950
567480
C
552102
268711A
W0CZZ
238310 237200
267110
7. REPLACEMENT PARTS LIST
130410 3041A10064C BASE ASSEMBLY,SINGLE 1 EA
131400 3090A20017D CABINET 1 EA
135303 3530A10272A GRILLE,INLET 1 EA
135312 3531A18004D GRILLE ASSEMBLY,FRONT 1 EA
147581 4758A20058A LOUVER,HORIZONTAL 1 EA
147582A 4758A30045A LOUVER,VERTICAL 2 EA 147582B 4758A30045B LOUVER,VERTICAL 4 EA
149980 4998A20003A SHROUD 1 EA
237200 3720A20251A PANEL,CONTROL 1 EA
238310 3831A10037F ESCUTCHEON 1 EA
249950 4995A20493V CASE ASSEMBLY,CONTROL 1 EA
263230 6323A20004S THERMISTOR ASSEMBLY 1 EA
264110 6411A20048J POWER CORD ASSEMBLY 1 EA
267110 6711A20093A REMOTE CONTROLLER ASSEMBLY 1 EA
268711A 6871A20448A PCB ASSEMBLY,DISPLAY 1 EA 268711B 6871A01001B PCB ASSEMBLY,MAIN 1 EA
346811 4681A20041J MOTOR,AC 1 EA
349480 4948A20045A ORIFICE 1 EA
352113 5211A21421A TUBE ASSEMBLY,DISCHARGE 1 EA
352115 5211A29024A TUBE ASSEMBLY,EVAPORATOR(IN) 1 EA
35211A 5211A21420A TUBE ASSEMBLY,SUCTION 1 EA
352380 5238A20033A GUIDE,AIR 1 EA
354210 5421A20071G EVAPORATOR ASSEMBLY,FIRST 1 EA
359012 5900A20009A FAN,TURBO 1 EA
435300A 3530A30015A GRILLE,REAR 1 EA
552113 5211A20560H TUBE ASSEMBLY,CONDENSER(OUT) 1 EA
550140 4H00982E DAMPER,COMPRESSOR 1 EA
552102 5210A23523A TUBE,CAPILLARY BENDING 1 EA
554031 5403A20183H CONDENSER ASSEMBLY,BENDING 1 EA
554160 2520UCDK020 COMPRESSOR SET,CHINA 1 EA
559011 5900AR1173A FAN ASSEMBLY,AXIAL 1 EA
567502 6750U-L058A OVERLOAD PROTECT 1 EA
731273 3127A20017C INSTALL PART ASSEMBLY,SINGLE 1 EA
WOCZZ 6120AR2194D CAPACITOR,DRAWING 1 EA
W48602 3H02932B CLAMP,SPRING 2 EA
435300 3530A20101A GRILLE,REAR 1 EA
152302 5230A20041A FILTER,AIR 1 EA
132100 3210A20075A FRAME 1 EA
349600 4960A20008A BRACKET,MOTOR 1 EA
PART NO.
QTY REMARK
LOCATION
NO
.
DESCRIPTION
MODEL: BG-103A
—27—
Specifications and performance data subject to change without notice.
HEAT CONTROLLER, INC.
1900 WELLWORTH AVENUE • JACKSON, MICHIGAN 49203
THE QUALITY LEADER IN CONDITIONING AIR
P/No.:3828A20294W
Printed in Korea
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