Heat Controller BG-123A, BG-81A, BG-101A User Manual

Download

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: BG-81A

BG-101A

BG-123A

CONTENTS

1. PREFACE

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

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

1.3 SPECIFICATIONS ..........................................3

1.4 FEATURES.....................................................4

1.5 CONTROL LOCATIONS.................................4

DISASSEMBLY INSTRUCTIONS

2.1 MECHANICAL PARTS....................................5

2.1.1 FRONT GRILLE.....................................5

2.1.2 CABINET................................................5

2.1.3 CONTROL BOX.....................................5

2.2 AIR HANDLING PARTS..................................6

2.2.1

ORIFICE, HEATER ASSY AND TURBO FAN

2.2.2 FAN........................................................6

2.2.3 SHROUD................................................7

2.3 ELECTRICAL PARTS.....................................7

2.3.1 MOTOR..................................................7

2.3.2 COMPRESSOR .....................................7

2.3.3 CAPACITOR ..........................................7

2.3.4 POWER CORD......................................8

2.3.5 THERMISTOR .......................................8

.........6

2.4 REFRIGERATION CYCLE.................................9

2.4.1 CONDENSER ......................................9

2.4.2 EVAPORATOR ....................................9

2.4.3 CAPILLARY TUBE...............................9

INSTALLATION

3.1 INSTALLATION REQUIREMENTS...............12

3.2 INSTALLATION.............................................13

3.3 PROCEDURE A............................................14

3.4 PROCEDURE B............................................15

3.5 PROCEDURE C............................................17

TROUBLESHOOTING GUIDE

4.1 OUTSIDE DIMENSIONS...............................19

4.2 PIPING SYSTEM ..........................................19

4.3 TROUBLESHOOTING GUIDE......................20

5. SCHEMATIC DIAGRAM

5.1 CIRCUIT DIAGRAM......................................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, turn off the air conditioner 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.

4. The value should be over 1MΩ.

—2—

BG-101A

—3—

1.3 SPECIFICATIONS

1.3.1FOR BG-81A/BG-101A/BG-123A

POWER SUPPLY

COOLING CAPACITY (Btu/h)

INPUT (W)

RUNNING CURRENT (A)

E.E.R (Btu/w.h)

REFRIGERANT (R-22) CHARGE(g)

OPERATING

INDOOR (°C)

TEMPERATURE

OUTDOOR (°C)

EVAPORATOR

CONDENSER

FAN, INDOOR

FAN, OUTDOOR

FAN SPEEDS, FAN/COOLING

FAN MOTOR

OPERATION CONTROL

ROOM TEMP. CONTROL

AIR DIRECTION CONTROL

CONSTRUCTION

FAN MOTOR

POWER CORD

DRAIN SYSTEM

NET WEIGHT (lbs/kg)

(W x H x D) (mm)

MODELS

REMARK

ITEMS

OPTIONAL

PART

LOUVERED-FIN TYPE

BG-81A

1Ø, 115V, 60Hz

9,800 11,500/11,200 8,000

1,110 1,310/1270 830

10.2 6.0/6.4 7.5

8.8 8.8/8.8 9.6

470g(16.6OZ) 485g(17.1OZ) 545g(19.2OZ)

3 ROW 12STACKS 2ROW12STACKS

1ROW 17STACKS, L-BENDING TYPE

PROPELLER TYPE FAN WITH SLINGER-RING

VERTICAL LOUVER(RIGHT & LEFT)

HORIZONTAL LOUVER(UP & DOWN)

BG-123A

1Ø, 115V, 60Hz1Ø, 230/208V, 60Hz

26.7(DB) 19.4(WB)

35(DB) 23.9(WB)

TURBO FAN

3/3

4POLES

ELECTRIC

THERMISTOR

PROTECTOR COMPRESSOR

DIMENSION (inch)

SLEEVE DIMESION (inch)

SLEEVE DEPTH (inch)

WITH FRONT GRILLE (mm)

TOP-DOWN

EXTERNAL OVERLOAD PROTECTOR

INTERNAL THERMAL PROTECTOR

2.3m (3WIRES WITH GROUNDING)

ATTACHMENT PLUG(CORD-CONNECTED TYPE, LCDI)

SPLASHED BY FAN SLINGER

78/35 80/36 73/33

24 x 1413/32 x 20 3/32

610 x 366 x 499

257/8 x 15 17/32 x 1623/32

656 x 394 x 425

201/2

521

1.4 FEATURES

PULL OPEN / PUSH CLOSE

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

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

MODE

TIMER

POW

FAN

SPEED

Fan

Energy Saver

Cool

Timer

TEMP

F1 LOW F2 MED F3 HIGH

MODE

TIMER

POWER

FAN

SPEED

Fan

Energy Saver

Cool

Timer

TEMP

F1 LOW F2 MED

F3 HIGH

FAN SPEED

Fan

Cool

Timer

TEMP

MODE TIMER POWER

FAN SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

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 DE

TIM

W ER

FAN SPEED

Fan

Energy Saver

Cool

Tim

TEMP

F1 LOW F2 MED F3 HIGH

MODE

TIMER

POWER

FAN

SPEED

Fan

ergy

Saver

Cool

Timer

TEMP

1 LO

F2 MED

F3 H

M OD

TIMER

W ER

FAN SPEED

Fan

E nergy Saver

C ool

Tim

e r

TEMP

F1 LOW F2 MED F3 HIGH

M O DE

TIM

POW

FAN SPEED

Fan

Energy Saver

Cool

Tim

TEMP

F1 LOW F2 MED F3 HIGH

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

MODE

TIMER

POWER

FAN

SPEED

Fan

Energy Saver

Cool

Timer

TEMP

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

. 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.

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

Cool

Timer

TEMP

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

O D E

IM E

P O W

E R

FAN SPEED

Fan

Energy Saver

Cool

Timer

TEMP

F1 LOW F2 MED 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

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)

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.

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

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.

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

COMPOUND GAUGE

EVAPORATOR (LOW PRESSURE SIDE)

COMPRESSOR

CAPILLARY TUBE

CONDENSER (HIGH PRESSURE SIDE)

SEE INSETS

BELOW

MANIFOLD

GAUGE

EXTERNAL VACUUM PUMP

capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve.

LOW

CHARGING CYLINDER

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

To avoid risk of personal injury, property damage, or product damage due to the weight of this device and sharp edges that may be exposed:

• 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.

• Carefully inspect location where air conditioner will be installed. Be sure it will support the weight of the unit over an extended period of time.

• Handle air conditioner with care. Wear protective gloves whenever lifting or carrying the unit. AVOID the sharp metal fins of front and rear coils.

• Make sure air conditioner does not fall during installation.

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

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

2 4

2 Size options

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

CAUTION

Installing the Heat Controller 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 Heat Controller 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

Horizontal Insulation Strip 23

Support Block 1 Baffle Shim 11 Trim Frame 2 Washer Screw 4 Nuts(Plastic) 4 Grille Rear 1

14 x

x 16

x 1

/32 x 1

x 1

x 4

x 1 x

x 1

/16 1

1 1 1

2 1 2

HOW TO INSTALL

Before installing the unit, identify the existing wall sleeve

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.

Clean the interior of an existing sleeve. (Do not disturb seals.)

Wall sleeve must be securely fastened in wall before installing the air conditioner. Use the nails or screws

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

FRIEDRICH, use procedure B or C below.

Procedure Brand

A(page 16)

FRIEDRICH USC 16-23/32 White-Westinghouse Frigidaire Carrier

(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)

(pages 19)

Install new unit into wall sleeve.

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

White-Westinghouse Frigidaire Carrier (52F series) General Electric /Hotpoint

Whirlpool 25-7/8 16-1/2

Fedders/Emerson Friedrich WSC or 19-3/4

Wall Sleeve Dimensions (inches)

Width Height Depth

25-1/2 15-1/4

16, 17-1/2

or 22

26 15-5/8 16-7/8

17-1/8

or 23

27 16-3/4

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

—13—

1" high

Shim

6" 6"

SHIM PLACEMENT UNIT INSTALLATION

FRONT

1/4"

/4" High

UNIT

Wall Sleeve

FIG. 19

PROCEDURE

If you are using the new sleeve (optionally

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

and attach that totheinsiderightofthesleeveasshown below. Remove the backing from the Around Insulation strip 67

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

4 5

FIG.23

• 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

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 8. 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

and attach that to the inside right of the sleeve as shown below. Remove the backing from the Around Insulation strip 67

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,

FIG.25

FIG. 27

FIG. 26

FIG.24

Depth"D" of the existing wall sleeve (inches)

Length "A"

(inches)

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

1-3/4

18 D 18-5/

18-5/

D 19-3/

9 1/2"6"

Indoor Outdoor

19-3/4 D 22

60°

Rear Louvers

(Top View)

60°

Indoor Outdoor

9 1/2"6"

Around Insulation

Vertical Insulation

Bracket Bracket

Length "A"

(inches)

1-3/4

Depth"D" of the existing wall sleeve (inches)

18 D 18-5/

18-5/

19-3/4 D 22

D 19-3/

Support Block

Baffle

—15—

PROCEDURE B CONTINUED

Wall

Sleeve

Baffle

(

)

Front

Support Block

Remove the backing from the support blocks and attach

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.

Assemble trim as described in Step 6,

Procedure A.

FIG. 29

CAUTION

• 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

1-3/4

18 D 18-5/8

18-5/

D 19-3/

19-3/4 D 22

3.5 PROCEDURE C

Wall

Sleeve

Baffle

Front

Support Block

Bracket Bracket

Rear Louvers

(Top View)

60°

8 1/2"

Indoor Outdoor

Around Insulation

Horizontal Insulation

Redirect the louvers at the back of the wall sleeve to 60°

angle as shown in the FIG 30. The use of pliers is recommended.

Remove the backing from the Horizontal Insulation strip

x 1

and attach that to the inside right of the

sleeve as shown below. Remove the backing from the

Around Insulation strip 59

x 1

and attach that

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

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

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

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—

1" high

/4" High

CAUTION

Parts and Installation

PROCEDURE C CONTINUED

To achieve rearward slope for unit draining, remove the backing from the 11

"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

Assemble trim as described in Step 6,

Procedure A.

FIG. 36

6" 6"

Shim (2EA)

FIG. 37

• 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-

/32"

(366mm)

MODE TIMER POWER

FAN

SPEED

Fan

Energy

Saver

Cool

Timer

TEMP

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.

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-81A/BG-101A/BG-123A

—25—

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.: 3828A20294V

04/18/07

Heat Controller BG-123A, BG-81A, BG-101A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual