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: BGE-103A
BGE-123A
Air Conditioner Service Manual
TABLE OF CONTENTS
Safety Precautions..........................................................................................................................................3
Installation.......................................................................................................................................................7
Installation requirements ...........................................................................................................................7
Installation..................................................................................................................................................8
How to Install..............................................................................................................................................8
Procedure A ...............................................................................................................................................9
Procedure B .............................................................................................................................................11
Procedure C.............................................................................................................................................12
Operating Instructions .................................................................................................................................14
Controls....................................................................................................................................................14
Remote control.........................................................................................................................................15
How to insert batteries .............................................................................................................................16
Ventilation Control....................................................................................................................................16
Air Direction..............................................................................................................................................16
Disassembly instructions.............................................................................................................................17
Mechanical Parts......................................................................................................................................17
Air Handling Parts ....................................................................................................................................18
Electrical Parts .........................................................................................................................................19
Refrigeration Cycle...................................................................................................................................21
Schematic Diagram.......................................................................................................................................24
Wiring Diagram.........................................................................................................................................24
Troubleshooting Guide.................................................................................................................................25
Piping System ..........................................................................................................................................25
Troubleshooting Guide .............................................................................................................................26
Room Air Conditioner Voltage Limits........................................................................................................29
Product specifications..................................................................................................................................31
2 Room Air Conditioner
Service Manual 3
Safety Precautions
Safety Precautions
To prevent injury to the user or other people and property damage, the following instructions must
be followed.
■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is
classified by the following indications.
■ Meanings of symbols used in this manual are as shown below.
WARNING
CAUTION
This symbol indicates the possibility of death or serious injury.
This symbol indicates the possibility of injury or damage to property only.
WARNING
■ Installation
Don’t use a power cord, a plug
or a loose socket which is damaged.
• Otherwise, it may cause a fire or
electrical shock.
Always plug into a gr ounded
outlet.
• Otherwise, it may cause a fire or
electrical shock.
Do not modify or extend the
power cord length.
• It will cause electric shock or fire
due to heat generation.
Do not disassemble or modify
products.
• It may cause failure and electric
shock.
Be caution when unpacking and
installing.
• Sharp edges may cause injury.
Do not use the power cord near flammable gas or combustibles such as
gasoline, benzene, thinner, etc.
• It may cause explosion or fire.
Be sure not to do.
Be sure to follow the instruction.
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4 Room Air Conditioner
Safety Precautions
■ Operation
Do not place heavy object on the
power cord and take care so that
the cord should not be pressed.
• There is danger of fire or electric
shock.
Do not share the outlet with
other appliances.
• It will cause electric shock or fire
due to heat generation.
Take the power plug out if necessary, holding the head of the plug
and do not touch it with wet hands.
• Otherwise, it may cause a fire or
electrical shock.
Do not place the power cord
near a heater.
• It may cause fire and electric
shock.
Do not allow water to run into
electric parts.
• It will cause failure of machine or
electric shock.
Use a soft cloth to clean. Do not
use wax, thinner, or a strong
detergent.
• The appearance of the air conditioner may deteriorate, change
color, or develop surface flaws.
Unplug the unit if strange
sounds, odors, or smoke come
from it.
• Otherwise it may cause fire and
electric shock accident.
Do not open the suction inlet
grill of the product during operation.
• Otherwise, it may electrical
shock and failure.
If water enters the product, turn off the the
power switch of the main body of appliance.
Contact service center after taking the
power-plug out from the socket.
Ventilate the room well when
using this appliance together
with a stove, etc.
• An oxygen shortage may occur.
Turn off the power and breaker
firstly when cleansing the unit.
• Since the fan rotates at high speed
during operation, it may cause
injury.
Turn off the main power switch
when not using it for a long
time.
• Prevent accidental startup and the
possibility of injury.
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Service Manual 5
Safety Precautions
Do not operate or stop the unit
by inserting or pulling out the
power plug.
• It will cause electric shock or fire
due to heat generation.
Do not damage or use an
unspecified power cord.
• It will cause electric shock or fire.
Do not operate with wet hands
or in damp environment.
• It will cause electric shock.
Hold the plug by the head when
taking it out.
• It may cause electric shock and
damage.
When gas leaks, open the window for ventilation before operating the unit.
• Otherwise, it may cause explosion, and a fire.
Never touch the metal parts of
the unit when removing the filter.
• They are sharp and may cause
injury.
Install the product so that the noise or hot wind
from the outdoor unit may not cause any damage
to the neighbors.
• Otherwise, it may cause dispute with the neighbors.
Keep level parallel in installing the product.
• Otherwise, it may cause vibration or water leakage.
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CAUTION
■ Installation
6 Room Air Conditioner
Safety Precautions
Do not put a pet or house plant
where it will be exposed to
direct air flow.
• It may cause injury.
Do not block the inlet or outlet
of air flow.
• It may cause product failure.
Use a soft cloth to clean. Do not
use wax, thinner, or a strong
detergent.
• The appearance of the air condi-
tioner may deteriorate, change
color, or develop surface flaws.
Do not step on the indoor/outdoor unit and do not put anything on it.
• It may cause an injury through
dropping of the unit or falling
down.
Always insert the filter securely.
Clean it every two weeks.
• Operation without filters will cause
failure.
Do not drink water drained from
air conditioner.
• It contains containments and will
make you sick.
Be cautious not to touch the
sharp edges when installing.
• It may cause injury.
Avoid excessive cooling and
perform ventilation sometimes.
• Otherwise, it may do harm to
your health.
Do not insert the hands or bars
through the air inlet or outlet
during operation.
• Otherwise, it may cause personal injury.
■ Operation
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Service Manual 7
Installation
Installation
Remove packing sheet from the back of the sleeve,
and packing corner and blue tape from the air conditioner.
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 rear
grille to securely attach the new air conditioner.
(FIG. 1)
With the HCI sleeve(optionally supplied with your
unit), you can maintain the best performance of the
new air conditioner. (FIG. 2)
21
/32"
19-
(499 mm)
24-21/32"
(626 mm)
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14-13/32"
(366 mm)
INSTALLATION HARDWARE
1
2
4
2 Size options
7
8
3
5
6
2 Size options
ITEM NAME OF PARTS Q'TY
1 PLASTIC GRILLE 1
2 HORIZONTAL INSULATION STRIPS 2
3 AROUND INSULATION STRIPS 2
4 SUPPORT BLOCK 2
5 BAFFLE 1
6 TRIM FRAME 2
7 SHIM 2
8 PLASTIC NUTS AND WASHER SCREWS 4
Air Conditioner
Expanded
aluminum metal grille
LGE Wall Sleeve
18"(458 mm)
25-7/8"
(656 mm)
15-17/32"
(394 mm)
16-23/32"
(425 mm)
FIG. 1
FIG. 2
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.
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.
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
NOTICE
8 Room Air Conditioner
Installation
Installation
FIG. 3
We strongly recommend the removal of the old wall
sleeve and the installation of a new HCI Wall Sleeve.
If you decide to keep the existing wall sleeve, you have
to redirect the louvers at the back of the wall sleeve illustration. The use of pliers is recommended. If you DO
NOT redirect, you run the risk of poor performance or
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)
Plastic grille 263/4 x 161/2 1
Horizontal Insulation Strips
Around Insulation Strips
Support Block 13/4 x 1 3/8 x 45/16 2
Baffle 14 x 41/2 x 1/8 1
Shim 13 x 1 x 3/4 2
Trim Frame 2
Washer Screw 4
Nuts(Plastic) 4
13/8 x 5/8 x 273/16 1
13/8 x 1 3/8 x 27 3/16 1
13/8 x 3/4 x 611/2 1
13/8 x 1 3/8 x 61 1/2 1
Qty.
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,
2. Remove old air conditioner from existing wall
sleeve.
3. Clean the interior of an existing sleeve.
(Do not disturb seals.)
4. 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.
5. Prepare the wall sleeve for installation of the unit. If
you plan to use your existing wall sleeve, and it is
not LGE, use procedure B or C below.
Procedure Brand
A LGE 16-23/32
White-Westinghouse
Frigidaire Carrier
(52F series)
B
C
6. Install new unit into wall sleeve.
General Electric
/Hotpoint
Whirlpool 17-1/8 or 23
Carrier (51S series)
Fedders/Emerson
Emerson/Fedders 15
Friedrich 16-3/4
Depth(inches)
16, 17-1/2
or 22
16-7/8
18-5/8
16-3/4
or 19-3/4
How to Install
1. Identify the existing wall sleeve before installing the
unit from the listed below.
Brand
White-Westinghouse
Frigidaire
Carrier (52F series)
General Electric
/Hotpoint
Whirlpool 25-7/8 16-1/2
Fedders/Emerson 27 16-3/4
LGE 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
Friedrich 27 16-3/4 16-3/4
Wall Sleeve Dimensions (inches)
Width Height Depth
25-1/2 15-1/4
26 15-5/8 16-7/8
16, 17-1/2
or 22
17-1/8
or 23
16-3/4
or 19-3/4
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. 3.
Place the higher portion of shim to the front of the rib
on base of wall sleeve.
1" high
Shim
6" 6"
SHIM PLACEMENT UNIT INSTALLATION
FRONT
1/4"
3
/4" High
UNIT
Wall Sleeve
Service Manual 9
Installation
Procedure A
1. If you are using the new sleeve (optionally supplied
with your unit),skip to step 3. Otherwise, install the
plastic grille from the kit. Cut the plastic grille to 251/2" wide and 15-1/4" high. Place the plastic grille to
the inside of the wall sleeve at the rear flange.
2. 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.
3. Remove the backing from the Horizontal Insulation
strip 1
3
/
8
x
3
/
8
8 x 27
3
/
16
and attach that to the inside
bottom of the sleeve as shown below. Remove the
backing from the Around Insulation strip 1
3
/
8
x
3
/
4
x
61
1
/
2
and attach that to the inside front of the sleeve
as shown below.
4. Install the new unit into the wall sleeve.
FIG. 4
Around Insulation
Horizontal Insulation
FIG. 6
or
FIG. 5
Wall
Trim (2 ea)
M
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P
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FAN
SPEED
F
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F
1
L
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W
F
2
H
I
G
H
• 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.
FIG. 7
5. To assemble trim, snap the tab of each piece 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.
10 Room Air Conditioner
Installation
Procedure B
1. 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.
2. 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.
3. 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.
4. Remove the backing from the Horizontal Insulation
strip 1
3
/
8
x
5
/
8
x 27
3
/
16
and attach that to the inside bottom of the sleeve as shown below. Remove the
backing from the Around Insulation strip 1
3
/
8
x
3
/
4
x
61
1
/
2
and attach that to the inside front of the sleeve
as shown below.
5.If the depth of your existing wall sleeve is less than
or equal to 18", skip to step 6. Otherwise, cut the
baffles and the support blocks according to length
Rear Louvers
(Top View)
60°
60°
7
5
/
16
"
FIG. 8
FIG. 9
Place the plastic grille
or
FIG. 10
Fasten the screws
Around Insulation
Horizontal Insulation
FIG. 11
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
FIG. 12
"A" in the table below.
Service Manual 11
Installation
6. Remove the backing from the support blocks and
attach them to the inside of the wall sleeve as
shown FIG 13. Slide the baffle into slots of the support blocks.
7.Install the new unit into the wall sleeve.
8.To assemble trim, snap the tab of each piece 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.
Wall
Wall
Sleeve
Baffle
(7
5
/
16
")
Front
Support
Block
FIG. 13
Wall
Trim (2 ea)
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1
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2
H
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FIG. 14
• 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.
12 Room Air Conditioner
Installation
Procedure C
1. Redirect the louvers at the back of the wall sleeve to
60° angle as shown in the FIG 15. The use of pliers
is recommended.
2. 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. Place the plastic grille to the inside of the wall
sleeve at the rear flange.
3. 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.
4. Remove the backing from the Horizontal Insulation
strip 1
3
/
8
x 1
3
/
8
x 27
3
/
16
and attach that to the inside
bottom of the sleeve as shown below. Remove the
backing from the Around Insulation strip 1
3
/
8
x 1
3
/
8
x
61
1
/
2
and attach that to the inside front of the sleeve
as shown below.
5. 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.
6. Remove the backing from the support blocks and
attach them to the inside of the wall sleeve as
shown FIG 20. Slide the baffle into slots of the support blocks
FIG. 16
or
FIG. 17
Rear Louvers
(Top View)
60°
7
13
/
16
"
60°
FIG. 15
Place the plastic grille
Fasten the screws
Around Insulation
Horizontal Insulation
FIG. 18
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
Wall
Wall
Sleeve
Baffle
Front
Support
Block
(
7
13
/
16
"
)
FIG. 20
FIG. 19
Service Manual 13
Installation
7. Remove the backing from the 13" shim strips and
attach them as shown below in Fig. 22. The higher
portion of shim is to be placed in front of the rib on
the base of wall sleeve.
8. Install the new unit into the wall sleeve
FIG. 21
1" high
3
/4" High
FIG. 22
Wall
Trim (2 ea)
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2
H
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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.
Shim (2EA)
6" 6"
9. To assemble trim, snap the tab of each piece 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.
14 Room Air Conditioner
Operating Instructions
Operating Instructions
Controls
The controls will look like one of the following.
MODE TIMER POWER
FAN
SPEED
Fan
Heat
Energy
Saver
Cool
Timer
TEMP
'
F
F1 LOW
F2 HIGH
REMOTE CONTROL SIGNAL
RECEIVER
POWER
MODE
-
Push this button to shift mode of operation from COOL → ENERGY SAVER → FAN → HEAT
- 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.
- HEAT:
• Fan runs continually for normal heating 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.
FAN SPEED
• Every time you push this button, it advances the setting as follows:
{High[ F2 ] → Low[ F1 ] → High[ F2 ]}
AUTO RESTART
When power is restored after an electrical power failure, the unit will begin to run at its last setting.
Service Manual 15
Operating Instructions
Remote control
The remote control and control panel will look like one of the following pictures.
Power
Temp
Fan Speed
Timer Mode
POWER
• 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.
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.
FAN SPEED
• Every time you push this button it advances the setting as follows:
{High[ F2 ] → Low[ F1 ] → High[ F2 ]}
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 of hours before unit starts.
• Push Timer button to advance setting from 1Hour
→ 2Hours → ... →
12Hours maximum.
MODE
- Push this button to shift mode of operation from COOL → ENERGY SAVER → FAN → Heat.
- 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.
- HEAT:
• Fan runs continually for normal heating operation.
When the air conditioner has been performed its cooling or
heating operation and is turned off or set to the fan position, wait at least 3 minutes before resetting to the cooling
operation again.
A slight heat odor may come from the unit when
first switching to HEAT after the cooling season is
over. This odor, caused by fine dust particles on
the heater, will disappear quickly. This is harmless.
16 Room Air Conditioner
Operating Instructions
How to insert Batteries
1. Remove the cover from the back of the remote
controller.
2. Insert two batteries.
• Be sure that the (+) and (-) directions are correct.
• Be sure that both batteries are new.
3. Re-attach the cover.
• Do not use rechargeable batteries.
Such batteries differ from standard
dry cells in shape, dimensions, and
performance.
• Remove the batteries from the
remote controller if the air conditioner
is not going to be used for an extended length of time.
Ventilation Control
Air Direction
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.
The direction of air can be controlled by adjusting the horizontal and vertical louvers.
• HORIZONTAL AIR-DIRECTION CONTROL
The horizontal air direction is adjusted by moving the vertical louver.
The lever for the vertical louver is located in the right and left side of the
air discharge.
• VERTICAL AIR-DIRECTION CONTROL
The vertical air direction is adjusted by moving the horizontal louver.
M
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1
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2
H
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PULL OPEN / PUSH CLOSE
M
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SPEE
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F2 HI
GH
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Service Manual 17
Disassembly Instructions
Disassembly Instructions
Mechanical Parts
— Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord.
1.
FRONT GRILLE
1. Open the inlet grille upward or downward.
2. Remove the screw which fastens the front grille.
3. Pull the front grille from the right side.
4. Remove the front grille. (See Fig. 24)
5. Re-install the component by referring to the
removal procedure.
2. CABINET
1. After disassembling the FRONT GRILLE, remove the 9
screws which fasten the cabinet at the both sides and the
top. (See Fig. 25)
Keep these for later use.
3. CONTROL BOX
1. Remove the front grille. (Refer to section 1)
2. Remove the screw which fasten the control
box. (See Fig. 26)
3. Pull the control box from the barrier.(See Fig.26)
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. 26)
(Refer to the circuit diagram found on pages 24 in this
manual and on the control box.)
FIG. 24
FIG. 26
FIG. 25
M
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Fan
Energy
Saver
Cool
Timer
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E
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1
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2
M
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F
3
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MODE TIMER POWER
FAN
SPEED
Fan
Heat
Energy
Saver
Cool
Timer
TEMP
'
F
F1 LOW
F2 HIGH
MODE
TIMER
POW
ER
F
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F
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18 Room Air Conditioner
Disassembly Instructions
4. ORIFICE, HEATER ASSY AND TURBO FAN
1. Remove the front grille. (Refer to section 1)
2. Remove the cabinet. (Refer to section 2)
3. Remove the 2 screws which fasten the evaporator
at the left side and the right side.
(See Fig. 27)
4. Move the evaporator sideward carefully.
5. Remove the 2 terminals carefully
(See Fig. 28, at Electric Heater Model only)
6. Remove the 4 screws which fasten the orifice. (See
Fig. 28)
7. Remove the orifice. (See Fig. 28)
8. Remove the clamp which secures the turbo fan with
plier. (See Fig. 29)
9. Remove the turbo fan with plier or your hand without touching blades. (See Fig. 30)
10. Re-install the components by referring to the
removal procedure, above.
5. FAN
1. Remove the cabinet. (Refer to section 2)
2. Remove the brace and shroud cover.
(Refer to section 4)
3. Remove the 6 screws which fasten the condenser.
4. Move the condenser sideways carefully.
5. Remove the clamp which secures the fan.
6. Remove the fan. (See Fig. 31)
7. Re-install the components by referring to the removal
procedure, above.
Air Handling Parts
MODE
TI
MER
P
O
W
E
R
F
A
N
S
P
E
E
D
F
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P
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F
F1
L
O
W
F
2
M
E
D
F
3
H
I
G
H
FIG. 27
FIG. 28
FIG. 29
FIG. 30
FIG. 31
Service Manual 19
6. SHROUD
1. Remove the fan. (Refer to section 5)
2. Remove the screw which fasten the shroud.
3. Remove the shroud. (See Fig. 32)
4. Re-install the component by referring to the
removal procedure, above.
7. MOTOR
1. Remove the cabinet. (Refer to section 2)
2. Remove the clamp cord and disconnect a wire
housing in control box. (Refer to section 3)
3. Remove the turbo fan. (Refer to section 5)
4. Remove the fan. (Refer to section 5)
5. Remove the 4 or 2 screws which fasten the motor.
(See Fig. 33)
6. Remove the motor.
7. Re-install the components by referring to the
removal procedure, above.
8. COMPRESSOR
1. Remove the cabinet. (Refer to section 2)
2. Discharge the refrigerant system using 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 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. 34)
6. Remove the compressor.
7. Re-instill the components by referring to the
removal procedure, above.
9. CAPACITOR
1. Remove the control box. (Refer to section 3)
2. Remove a screw which fasten the display panel.
3. Remove 2 screws and unfold the control box.
(See Fig. 35)
4. Remove the screw and the clamp which fastens
the capacitor. (See Fig. 35)
5. Disconnect all the leads of capacitor terminals.
6. Re-install the components by referring to the
removal procedure, above.
Disassembly Instructions
Electrical Parts
FIG. 32
FIG. 34
FIG. 35
MODE
TIMER
POWER
FAN
SPEED
Fan
Energy
Saver
Cool
Timer
TEM
P
'
F
F1 LO
W
F2 M
ED
F
3 HIG
H
FIG. 33
20 Room Air Conditioner
Disassembly Instructions
10. POWER CORD
1. Remove the control box. (Refer to section 3)
2. Unfold the control box. (Refer to section 9)
3. Disconnect the grounding screw from the control
box.
4. Disconnect 2 receptacles.
5. Remove a screw which fastens the clip cord.
6. Pull the power cord. (See Fig. 36)
7. Re-install the component 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 by the special cord.
(The special cord means the cord which has the
same specification marked on the supply cord fitted to the unit.)
11. THERMOSTAT
1. Remove the control box. (Refer to section 3)
2. Unfold the control box. (Refer to section 9)
3. Disconnect the theristor terminals from main
P.W.B assembly.
4. Remove the thermostat. (See Fig. 37)
5. Re-install the components by referring to the
removal procedure, above.
MODE
TIMER
POWER
FAN
SPEED
Fan
Energy
Saver
Cool
Timer
TEMP
'
F
F
1 L
O
W
F
2 M
ED
F
3 H
IG
H
MODE
TIMER
POWER
FAN
SPEED
Fan
Energy
Saver
Cool
Timer
TEMP
'
F
F
1 L
O
W
F
2 M
E
D
F
3
H
IG
H
FIG. 36
FIG. 37
Service Manual 21
Disassembly Instructions
12. CONDENSER
1. Remove the cabinet. (Refer to section 2)
2. Remove the brace and the shroud cover.
(Refer to section 4)
3. Remove the 5 screws which fasten the condenser.
4. After discharging the refrigerant completely,
unbraze the interconnecting tube at the condenser
connections.
5. Remove the condenser.
6. Re-install the components by referring to notes.
(See Fig. 38)
13. EVAPORATOR
1. Remove the cabinet. (Refer to section 2)
2. Discharge the refrigerant completely.
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 notes.
(See Fig. 39)
14. CAPILLARY TUBE
1. Remove the cabinet. (Refer to section 2)
2. After discharging the refrigerant completely,
unbraze the interconnecting tube at the capillary
tube.
3. Remove the capillary tube.
4. Re-install the components by referring to notes.
FIG. 38
FIG. 39
Refrigerating Cycle
Discharge the refrigerant system using 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 Freon
TM
. Leave the valve in place after
servicing the system.
CAUTION
M
O
D
E
T
I
M
E
R
P
O
W
E
R
F
A
N
S
P
E
E
D
Fan
Energy
Saver
Cool
Timer
T
E
M
P
'
F
F
1
L
O
W
F
2 M
ED
F
3
H
IG
H
22 Room Air Conditioner
Disassembly Instructions
— 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.
40A.
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.
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. 40B.
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. 40B.
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.
NOTICE
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.
CAUTION
Service Manual 23
Disassembly Instructions
Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pinch-off tool capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service valve.
A
COMPOUND GAUGE
EVAPORATOR
(LOW PRESSURE SIDE)
COMPRESSOR
CAPILLARY TUBE
CONDENSER
(HIGH PRESSURE SIDE)
SEE INSETS
BELOW
MANIFOLD
GAUGE
B
FIG. 40A-Pulling Vacuum
FIG 40B-Charging
A
B
EXTERNAL
VACUUM PUMP
LOW
B
HI
A
CHARGING
CYLINDER
C
24 Room Air Conditioner
Schematic Diagram
Schematic Diagram
Wiring Diagram
■ ELECTRIC HEATING MODEL
Service Manual 25
Troubleshooting Guide
Troubleshooting Guide
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.
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
FIG. 41
CONDENSER COILS
FAN
CAPILLARY TUBE
MOTOR
COMPRESSOR
TURBO FAN
EVAPORATOR COILS
: REFRIGERANT FLOW
26 Room Air Conditioner
Troubleshooting Guide
Troubleshooting Guide
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
Ineffective Cooling
Check of 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 of inside gas
pressure.
Adjusting of refrigerant
charge
Malfunction of compressor
Replacement of
compressor
Check of cold air circulation
for smooth flow.
Dirty indoor coil
(Heat exchanger)
Malfunction of fan
Clogged of air filter
Obstruction at air outlet
Correct above trouble
Stop of auto air-swing
Check clogging in
refrigeration circuit.
Repair clogging in
refrigeration circuit.
Service Manual 27
Troubleshooting Guide
Fails to Start
Check of circuit breaker
and fuse.
Gas leakage of feeler bulb
of thermostat
Check of 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 of power voltage.
Check capacitor.
Replacement.
Only compressor fails to
start.
Defect of compressor
capacitor.
Check of power source.
Check of control switch
setting.
28 Room Air Conditioner
Troubleshooting Guide
COMPLAINT CAUSE REMEDY
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).
Check fan motor bearings; if motor shaft will not
rotate, replace the motor.
Check voltage. See limits on this page. 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.
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.
No power
Power supply cord
Rotary switch
Wire disconnected or
connection loose
Capacitor (Discharge
capacitor before testing.)
Will not rotate
Revolves on overload.
Grommets
Fan
Turbo fan
Loose set screw
Worn bearings
Fan motor will not run.
Fan motor runs
intermittently
Fan motor noise.
Service Manual 29
Troubleshooting Guide
NAME PLATE RATING MINIMUM MAXIMUM
115V 103.5V 126.5V
208/230V 187V 253V
COMPLAINT CAUSE REMEDY
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.
Check the compressor overload, if externally
mounted. Replace if open. (If the compressor
temperature is high, remove the overload, cool it,
and retest.)
Voltage
Wiring
Rotary
Thermostat
Capacitor (Discharge
capacitor before
servicing.)
Compressor
Overload
Compressor will not run,
but fan motor runs.
ROOM AIR CONDITIONER VOLTAGE LIMITS
30 Room Air Conditioner
COMPLAINT CAUSE
REMEDY
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.
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
Compressor cycles
on overload.
Insufficient cooling or heating
Excessive noise.
Troubleshooting Guide
Service Manual 31
Product Specifications
ITEMS
COOLING
HEATING
OPERATING
TEMPERATURE
REFRIGERANT (R-22) CHARGE(g)
EVAPORATOR
CONDENSER
FAN, INDOOR
FAN, OUTDOOR
FAN SPEEDS (FAN/COOLING/HEATING)
FAN MOTOR
OPERATION CONTROL
ROOM TEMP. CONTROL
AIR DIRECTION CONTROL
CONSTRUCTION
ELECTRIC HEATER
PROTECTOR
POWER CORD
DRAIN SYSTEM
NET WEIGHT (lbs/kg)
DIMENSION
(W x H x D)
SLEEVE DIMESION
(W x H x D)
SLEEVE DEPTH
WITH FRONT GRILLE
MODELS
POWER SUPPLY
CAPACITY (Btu/h)
INPUT (W)
RUNNING CURRENT (A)
E.E.R. (Btu/W.h)
CAPACITY (Btu/h)
INPUT (W)
RUNNING CURRENT (A)
COOLING
HEATING
COMPRESSOR
FAN MOTOR
ELECTRIC HEATER
INDOOR (°C)
OUTDOOR (°C)
INDOOR (°C)
OUTDOOR (°C)
(inch)
(mm)
(inch)
(mm)
(inch)
(mm)
REMARK BGE-103A BGE-123A REMARK
1Ø, 208/ 230V, 60Hz
9,800/10,000
1,040/1,060
5.2/4.7
9.4／９．４
9,200/11,200
2,900/3,500
14.0/15.3
26.7 (DB) 19.4 (WB)
35 (DB) 23.9 (WB)
21.1 (DB) 15.6 (WB)
8.3 (DB) 6.1 (WB)
3 ROW 12 STACKS
2 ROW 17 STACKS, L-BENDED TYPE
TURBO FAN
PROPELLER TYPE FAN WITH SLINGER-RING
2 / 2 / 2
TOUCH PANEL
THERMISTOR
VERTICAL LOUVER (RIGHT & LEFT)
HORIZONTAL LOUVER (UP & DOWN)
TOP-DOWN
3.5KW, 230V
EXTERNAL OVERLOAD PROTECTOR
INTERANL THERMAL PROTECTOR
FUSE LINK, BIMETAL THERMOSTAT
1.92m (3 WIRE WITH GROUDING)
ATTACHMENT PLUG (CORD-CONNECTED TYPE)
SPLASHED BY FAN SLINGER
21/32 x 14 13/32 x 1921/32
24
626 x 366 x 499
257/8 x 1517/32 x 1623/32
656 x 394 x 425
11,200/11,500
1,270/1,310
6.4/6.0
8.8／８．８
500(17.6 OZ)465(16.40 OZ)
LOUVERED-
FIN TYPE
4 POLES6 POLES
80/36７８/3５
OPTIONA PART
20
510
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.: 3828A20040M
04/18/07
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