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HEAT CONTROLLER, INC.
Through-The-Wall
Air Conditioning
Model: BG-103A
Service Manual
CAUTION
-Before servicing the unit, read the "safety precautions" in this manual.
-Only for authorized service personnel.
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CONTENTS 2.4 REFRIGERATION CYCLE.................................9 1. PREFACE 2.4.1 CONDENSER ......................................9 1.1 SAFETY PRECAUTIONS ...............................2 2.4.2 EVAPORATOR ....................................9 1.2 INSULATION RESISTANCE TEST.................2 2.4.3 CAPILLARY TUBE...............................9 1.3 SPECIFICATIONS ..........................................3 1.4 FEATURES .....................................................4 3. INSTALLATION 1.5 CO
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1.3 SPECIFICATIONS 1.3.1 FOR BG-103A Model BG-103A REMARK Items 1Ø, 230/208V, 60Hz POWER SUPPLY 10,500 / 10,000 COOLING CAPACITY (Btu/h) INPUT (W) 1,230 / 1,170 5.7 / 6.0 RUNNING CURRENT (A) E.E.R (Btu/W.h) 8.5 / 8.5 26.7(DB) 19.4(WB) OPERATING INDOOR(°C) TEMPERATURE OUTDOOR(°C) 35(DB) 23.9(WB) 475g(16.8OZ) REFRIGERANT (R-22) CHARGE (g) 3ROW 12STACKS EVAPORATOR 2ROW 17STACKS, L-BENDING TYPE LOUVERED-FIN TYPE CONDENSER TURBO FAN FAN, INDOOR FAN, OUTDOOR PROPELLER TYPE FAN WITH SLINGER-RING 3/3 FA
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1.4 FEATURES • Designed for cooling only. • Side air-intake, side cooled-air discharge. • Built in adjustable THERMISTOR and THERMOSTAT. • Powerful and quiet cooling. • Top-down chassis for the simple installation and service. • Washable one-touch filter. • Compact size. 1.5 CONTROL LOCATIONS 1.5.1 COOLING ONLY MODEL • OPERATION FAN SPEED • Every time you push this button, it advances the setting as follows: {High Low Med High} REMOTE CONTROL SIGNAL RECEIVER ' Cool F F1 LOW F2 MED F3 HIGH
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C l ' oo F F2 1 3L ME H OIG W DH F En S earv ge yr F Fan TEMP Timer MODE TIMER FAN POWER SPEED Cool F1 LOW 'F F F2 3 M HE IG DH Ener Saver gy Fan Timer TEMP MODE TIMER FAN POWER SPEED 2. DISASSEMBLY INSTRUCTIONS — 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
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Cool F1 LO W ' F En erg y F F 2 3 M H IG ED H Saver Fan Timer TEMP MODE TIMER FAN POWER SPEED Coo l F1 LOW 'F Energy F F 2 3 M H I E G DH Saver Fan T imer TEMP MODE TIMER FAN POWER SPEED Cool F1 LOW ' F Energy F F2 3 M H E G IDH Saver Fan Timer TEMP MODE TIMER FAN POWER SPEED ' EC no ero gly F F F 1 2 3 L M H OE W IG DH F Saver Fan Timer TEMP FAN MODE TIMER SPEED POWER 2.2 AIR HANDLING PARTS 2.2.1 ORIFICE, AND TURBO FAN 1. Remove the front grille. (Refer to section 2.1.1) 2. Remove the cabine
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Cool 'F F1 LO F2 MED W Energy F3 HIGH Saver Fan TEMP Timer FAN MODE TIMER SPEED POWER 2.2.3 SHROUD 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) Figure 9 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. Remo
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Cool 'F F1 LOW F2 MED Energy F3 HIGH Saver Fan TEMP Timer FAN MODE TIMER POWER SPEED 2.3.4 POWER 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 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
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Cool 'F Energy F F F3 1 2 ME LHIGH OW D Saver Fan Timer TEMP FAN MODE TIMER SPEED POWER 2.4 REFRIGERATION CYCLE CAUTION TM Discharge the refrigerant system using a Freon Recovery System. If there is no valve to attach the recovery system, install one (such as a WATCO A-1) before TM venting the Freon . Leave the valve in place after servicing the system. 2.4.1 CONDENSER 1. Remove the cabinet. (Refer to section 2.1.2) 2. Remove the brace. (Refer to section 2.2.1) 3. Remove the 7 screws which fast
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NOTES — Replacement of the refrigeration cycle. 1. When replacing the refrigeration cycle, be sure to 6. Recharge as follows : TM discharge the refrigerant system using a Freon 1) Refrigeration cycle systems are charged from the recovery System. High-side. If the total charge cannot be put If there is no valve to attach the recovery system, in the High-side, the balance will be put in the install one (such as a WATCO A-1) before venting suction line through the access valve which you TM the F
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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. Figure 17A-Pulling Vacuum Figure 17B-Charging —11— COMPOUND GAUGE CONDENSER (HIGH PRESSURE SIDE) MANIFOLD GAUGE B A CAPILLARY TUBE SEE INSETS BELOW EVAPORATOR (LOW PRESSURE SIDE) COMPRESSOR LOW HI A B B A EXTERNAL VACUUM PUMP CHARGING CYLINDER C
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3. INSTALLATION INSTALLATION HARDWARE 3.1 INSTALLATION REQUIREMENTS If you use an existing wall sleeve, you should measure its 2 4 1 dimensions. 5 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 2 Size options 6 structural condition and have a compatible rear grille in order 8 to securely attach the new air conditioner. (FIG. 18A) With the FRIEDRICH USC sleeve, yo
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NOTE: All wall sleeves used to mount the new Air 3.2 INSTALLATION Conditioner must be in sound structural condition and have a CAUTION rear grille that securely attaches to sleeve, or rear flange that serves as a stop for the Air Conditioner. Installing the FRIEDRICH USC sleeve ensures Remove old air conditioner from existing wall sleeve. optional performances of the unit. 2 If you decide to keep the existing wall sleeve, you have Clean the interior of an existing sleeve. to redirect the louver
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PROCEDURE A If you are using the new sleeve (optionally Install the new unit into the wall sleeve. 4 1 supplied with your unit),skip to step 3. Toassembletrim,tpthetabofeachpiece Otherwise, install the plastic grille from the kit. 5 into the slot of the other piece as shown below. Cut the plastic grille to 25-1/2" wide and 15-1/4" high. Place the plastic grille to the Slide trim over the front of the air conditioner until trim is flush with sleeve as shown below. inside of the wall sleeve at the
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Remove the backing from the Vertical Insulation PROCEDURE B 4 9 3 3 strip 15 / x1 / x1 / and attach that to the 16 8 8 Redirect the louvers at the back of the wall inside right of the sleeve as shown below. 1 sleeve to 60° angle as shown in the FIG 24. The Remove the backing from the Around Insulation use of pliers is recommended. 1 3 25 strip 67 / x 1 / x / and attach that to the 8 8 32 inside front of the sleeve as shown below. 3 3 7 7 // " " Indoor Indoor Outdoor Outdoor 32 32 60 60°° 60 60°
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PROCEDURE B CONTINUED Remove the backing from the support blocks and attach 6 them to the inside of the wall sleeve as shown FIG 29. Slide the baffle into slots of the support blocks. 3 (7 / ") 32 Wall Wall Baffle Sleeve Front Support Block FIG. 29 Install the new unit into the wall sleeve. 7 Assemble trim as described in Step 6, 8 Procedure A. CAUTION • Air conditioners covered in this manual pose an excessive weight hazard. Two or more people are needed to move and install the unit. To preve
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Remove the backing from the Horizontal Insulation strip 3.5 PROCEDURE C 4 7 3 3 23 / x 1 / x 1 / and attach that to the inside right of the 32 8 16 Redirect the louvers at the back of the wall sleeve to 60° sleeve as shown below. Remove the backing from the 1 27 3 3 angle as shown in the FIG 30. The use of pliers is Around Insulation strip 59 / x 1 / x 1 / and attach that 32 8 8 recommended. to the inside front of the sleeve as shown below. 13 7 / " 16 Indoor Outdoor 60° 60° Rear Louvers Around
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Parts and Installation PROCEDURE C CONTINUED CAUTION To achieve rearward slope for unit draining, 7 13 • Air conditioners covered in this manual pose an remove the backing from the 11 / "shim 16 excessive weight hazard. Two or more people are strips and attach them as shown below in Fig. 37. The higher portion of shim is to be placed needed to move and install the unit. in front of the rib on the base of wall sleeve. To prevent injury or strain, use proper lifting and carrying techniques when mo
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4. TROUBLESHOOTING GUIDE 4.1 OUTSIDE DIMENSIONS 3 24" 20- /32" (499mm) (610mm) Cool F1 LOW 'F F3 HIGH F2 MED Ener Saver gy Fan Timer TEMP MODE TIMER FAN POWER SPEED 4.2 PIPING SYSTEM CONDENSER COILS FAN CAPILLARY TUBE MOTOR COMPRESSOR TURBO FAN EVAPORATOR COILS 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. ROOM AIR CONDITIONE
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4.3 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 cold air circulation Check outdoor coil Check heat load increase. for smooth flow. (heat exchanger) & the fan operation. Unexpected residue Dirty i
