Heat Controller BG-123A, BG-81A, BG-101A 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: 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—

+ 18 hidden pages