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Heat Controller BDE-103-A manual

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Table of contents for the manual

  • Page 1

    Through-The-Wall Air Conditioner Service Manual CAUTION -Before servicing the unit, read the "safety precautions" in this manual. -Only for authorized service personnel. HEA T CONTR OLLER, INC. MODELS: BDE-103-A BDE-123-A[...]

  • Page 2

    —2— 1. PREF A CE 1.1 SAFETY PRECAUTIONS ...............................2 1.2 INSULATION RESISTANCE TEST.................2 1.3 FEATURES .....................................................4 1.4 CONTROL LOCATIONS .................................4 2. DISASSEMBL Y INSTR UCTIONS 2.1 MECHANICAL PARTS ....................................6 2.1.1 FRON[...]

  • Page 3

    —3— 1.3 SPECIFICA TIONS 1.3.1 FOR BDE-103-A/BDE-123-A REMARK POWER SUPPLY CAPACITY (Btu/h) INPUT (W) RUNNING CURRENT (A) E.E.R. (Btu/W.h) CAPACITY (Btu/h) INPUT (W) RUNNING CURRENT (A) INDOOR (°C) OUTDOOR (°C) INDOOR (°C) OUTDOOR (°C) REFRIGERANT (R-22) CHARGE(g) EVAPORATOR CONDENSER FAN, INDOOR FAN, OUTDOOR FAN SPEEDS (FAN/COOLING/HEATING)[...]

  • Page 4

    1.4 FEA TURES • Designed for cooling only. • Powerful and quiet cooling. • Top-down chassis for the simple installation and service. 1.5 CONTR OL LOCA TIONS 1.5.1 COOLING ONL Y MODEL • OPERA TION • VENTILA TION The ventilation lever is located in the right of the air discharge. The ventilation lever must be in the CLOSE position in order [...]

  • Page 5

    1.5.2 COOLING AND HEA TING MODEL • OPERA TION — 5 — 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. Turn the Temperature Knob to the desired setting. The central position is a normal setting for average cond[...]

  • Page 6

    — 6 — 2.1 MECHANICAL P AR TS 2.1.1 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. 1) 5. Re-install the component by referring to the removal procedure. 2.1.2 CABINET 1. After disassembling the FRONT [...]

  • Page 7

    Figure 7 — 7 — 2.2 AIR HANDLING P AR TS 2.2.1 ORIFICE, HEA TER ASSY AND TURBO F AN 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 2 te[...]

  • Page 8

    — 8 — 2.2.3 SHROUD 1. Remove the fan. (Refer to section 2.2.2) 2. Remove the screw which fasten the shroud. 3. Remove the shroud. (See Fig. 9) 4. Re-install the component by referring to the removal procedure, above. 2.3 ELECTRICAL P AR TS 2.3.1 MO T OR 1. Remove the cabinet. (Refer to section 2.1.2) 2. Remove the clamp cord and disconnect a wi[...]

  • Page 9

    — 9 — 2.3.4 PO WER CORD 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 control box. 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 component by referring to the [...]

  • Page 10

    — 10 — 2.4 REFRIGERA TION CYCLE 2.4.1 CONDENSER 1. Remove the cabinet. (Refer to section 2.1.2) 2. Remove the brace and the shroud cover. (Refer to section 2.2.1) 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 conden[...]

  • Page 11

    — 11 — — 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 Freon TM . Leave the valve in place after servicing the system. 2. Af[...]

  • Page 12

    — 12 — 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 M[...]

  • Page 13

    — 13 — 3. INST ALLA TION 3.1 HO W T O INST ALL THE UNIT For existing sleeve, you should measure the wall sleeve dimensions. You can install the new air conditioner according to these installation instructions to achieve the best performence. All wall sleeves used to mount the new air conditioner must be in good structural condition and have the[...]

  • Page 14

    — 14 — 3.2 INST ALLA TION KITS CONTENTS Air Conditioner 1 2 Slee ve Assemb ly (optional, including e xpanded aluminum metal grille) 1 Insulation F ront (1 ea) 3 Insulation V er tical (4 ea) (Adhesive bac ked) 4 Suppor t Bloc k (4 ea) (Adhesive bac ked) 5 Baffle (2 ea) (Plastic sheet) 2 Insulation Horizontal (2 ea) (Adhesive bac ked) Louvered Gr[...]

  • Page 15

    — 15 — 3.3.1 PREP ARA TION OF SLEEVE 1. Remove the old air conditioner from the wall sleeve and prepare the wall sleeve. Clean the interior of the sleeve (do not disturb the insulation or seals). The wall sleeve must be fastened in the wall securely before installing the new air conditioner. 2. Prepare the wall sleeve for installation of the ne[...]

  • Page 16

    — 16 — Remove the backing from vertical and horizontal insulation and attach them to the inside of the wall sleeve as shown below. Remove the backing from the support blocks and attach them to the inside of the wall sleeve as shown below. Slide the baffles in the slots of the support blocks. 3.3.2 UNIT INST ALLA TION 1. Remove the backing from [...]

  • Page 17

    — 17 — 4. TR OUBLESHOO TING GUIDE 4.1 OUTSIDE DIMENSIONS 19- 21 / 32 " (499mm) 24- 21 / 32 " (626mm) 14- 13 / 32 " (366mm) CONDENSER COILS EV APORA TOR COILS FA N M OTOR : REFRIGERANT FLOW TURBO F AN CAPILLAR Y TUBE COMPRESSOR 4.2 PIPING SYSTEM Following is a brief description of the important components and their functions in th[...]

  • Page 18

    — 18 — 4.3 TR OUBLESHOO TING 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 [...]

  • Page 19

    — 19 — Fails to Start Check of circuit break er and fuse. Gas leakage of f eeler bulb of ther mostat Check of control s witch. Only f an f ails to star t. Improper wiring. Def ect of f an motor capacitor . Irregular motor resistance ( ). Irregular motor insulation ( ). Replacement of f an motor Regular but f ails to star t Replacement of compre[...]

  • Page 20

    — 20 — — 20 — 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 identi[...]

  • Page 21

    — 21 — 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. Ch[...]

  • Page 22

    — 22 — COMPLAINT CAUSE REMEDY Check the voltage. See the limits on the preced- ing 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. [...]

  • Page 23

    — 23 — 5. SCHEMA TIC DIA GRAM 5.1 CIRCUIT DIA GRAM • MODEL : BDE-103-A/BDE-123-A 6411A20048L 2H00598F 4681A20044E 4681A20041M 6120AR2359E 2H01127D 6750U-L028A 6750U-L039A 2520UKCK2BA 2520UKHK2AA 5300A20003A 3854AR3563D WIRING DIA GRAM COMP MO TOR CAP ACIT OR RO T ARY SWITCH POWER INPUT 7 1 8 6 4 2 F C C H RD BL BK BL BK L H OR(BR) OR(BR) THER[...]

  • Page 24

    — 24 — 6. EXPLODED VIEW • MODEL: BDE-103-A/BDE-123-A 354210 753010 753011 349480 554030 W48602 559011 346811 349600 567502 349001 130410 352113 35211A 352115 352115-1 W48602 249950 137215 149410 W0CZZ 264110 130900 435301 135312 147581 147582-2 147582-1 352390 148000 554160 550140 149980 359012 266003 269310 552111 152302 135313 E D F A C B 7[...]

  • Page 25

    — 25 — 7. REPLA CEMENT P AR TS LIST • MODEL: BDE-103-A/BDE-123-A R: Service Parts N: Non Service parts A 249950 CONTROL BOX ASSY, SINGLE 4995A20408E R 264110 POWER CORD ASSY 6411A20048L R 266003 SWITCH, ROTARY 2H00598F R 269310 THERMOSTAT ASSY 2H01127D R W0CZZ CAPACITOR, DRAWING 6120AR2359E R 149410 KNOB ASSY 4941A30005B R 137215 PANEL ASSY, [...]

  • Page 26

    Specifications and performance data subject to change without notice. HEA T CONTROLLER, INC. 1900 WELL WOR TH A VENUE • JA CKSON, MICHIGAN 49203 THE QU ALITY LEADER IN CONDITIONING AIR P/No.: 3828A20040F[...]