Summary of the content on the page No. 1
SERVICE MANUAL
Thru-the-Wall Series with R-410A
BG-81G
BG-101G
BG-103G
BG-123G
BGE-103G
BGE-123G
BG-143G
Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com
Summary of the content on the page No. 2
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. Table of Contents 1. PRECAUTION ........................................................................................................................2 1.1 Safety precaution ...........................................................................................................2 1.2 Warning .........................................................................................................................2 1.3 Cautio
Summary of the content on the page No. 3
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. 1. PRECAUTION 1.1 Safety precaution To prevent injury to the user and property damage, the following instructions must be followed. Incorrect operation may cause harm or damage. Before servicing unit, be sure to read this service manual. 1.2 Warning Do not use damaged power cords, plugs, or a loose socket. Always use the power plug and socket with the ground terminal. Do not modify or extend the power cord
Summary of the content on the page No. 4
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. 2. FEATURES AND PANEL 2.1 Features Slide-in and Top-out chassis for simple installation and service (on some models). Washable one-touch filter and easy access panel. Super compact design. Reliable and efficient rotary compressor. Fresh air switch (on some models). Anti-freezing control in cooling mode. Prevents water from freezing on evaporator by sensing the evaporator pipe temperature in cooling mode.
Summary of the content on the page No. 5
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. Control panel for cooling and heating models: B Panel Note: The control panels above are representative of many available models. Your model may be slightly different. On/Off (On and Off): Press this button once to start the unit, press again to stop. FAN: Press this button to select appropriate fan speed. Fan Speed mode has four options - Auto, Low, Med or High. Each time the button is pressed
Summary of the content on the page No. 6
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. TIMER: Press this button to set the time for unit starting or stopping. Press or hold the Up ( ▲) / Down ( ▼) to set the timer time. Turning the unit ON or OFF at any time will cancel the Auto Start/Stop function. CHECK FILTER: This feature is a reminder to clean the Air Filter for more efficient operation. The “CHECK FILTER” light will illuminate after 250 hours of operation. After the filter is cleaned, press this b
Summary of the content on the page No. 7
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. 3. UNIT DIMENSION 3.1 Unit dimension: 4. OPERATION LIMITS 4.1 Cooling operation Outdoor unit air temp DB Indoor air temp DB 6
Summary of the content on the page No. 8
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. Note: The chart is the result from the continuous operation under constant air temperature conditions. However, the initial pull-down stage is not included. 4.2 Electric heating operation Indoor air temp DB Outdoor air temp DB Note: The chart is the result from the continuous operation under constant air temperature conditions. However, the initial pull-down stage is not included. 7
Summary of the content on the page No. 9
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. 5. PROTECTION FUNCTION 5.1 Symbol & Meaning TA: Indoor ambient temperature; TE: Indoor evaporator temperature; TS: Setting temperature through the remote controller. 5.2 Protection Function 3 minute compressor time delay The compressor will wait for 3 minutes before restarting, so as to prevent the pressure imbalance in refrigerant system from resulting in compressor rotor locking. Anti-freezing protection
Summary of the content on the page No. 10
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. Fault Code Defect code Defect explanation Ed Evaporator de-frosting defect. Indoor ambient temperature sensor failure in heating, cooling, dry and auto AS mode. HS DAHT sensor failure in heating mode. LO Sensor disconnection malfunction in fan only mode HI Sensor short circuit malfunction in fan only mode 6. COMPONENT OPERATION & TESTING WARNING: DISCONNECT THE POWER CORD FROM THE POWER PLUG BEFORE SERVICING
Summary of the content on the page No. 11
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. CHECKING COMPRESSOR EFFICIENCY The reason for compressor inefficiency is normally due to broken or damaged suction and/or discharge valves, reducing the ability of the compressor to pump refrigerant gas. This condition can be checked as follows: 1. Install a piercing valve on the suction and discharge or liquid process tube. 2. Attach gauges to the high and low sides of the system. 3. Start the system and run a “cooling
Summary of the content on the page No. 12
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. CHECKING THE INTERNAL OVERLOAD (see Figure 4.) 1. With no power to unit, remove the leads from the compressor terminals. 2. Using an ohmmeter, test continuity between terminals C-S and C-R. If not continuous, the compressor overload is open and the compressor must be replaced. Figure 4: Internal overload 6.2 FAN MOTOR A single phase permanent split capacitor
Summary of the content on the page No. 13
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. compressor (HERM) terminal. A satisfactory capacitor will cause a deflection on the pointer, then gradually move back to infinity. 4. Reverse the leads of the probe and momentarily touch the capacitor terminals. The deflection of the pointer should be two times that of the first check if the capacitor is good. 5. Repeat steps 3 and 4 to check fan motor capacitor. NOTE: A shorted capacitor will indicate a low resistance a
Summary of the content on the page No. 14
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. 6.6 VALVE, DRAIN PAN (see Figure 7) During the cooling mode of operation, condensate which collects in the drain pan is picked up by the condenser fan blade and sprayed onto the condenser coil. This assists in cooling the refrigerant plus evaporating the water. During the heating mode of operation, it is necessary that water be removed to prevent it from freezing due to cold outside temperatures. This could cause the
Summary of the content on the page No. 15
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. HERMETIC COMPONENT REPLACEMENT The following procedure applies when replacing components in the sealed refrigeration circuit or repairing refrigerant leaks. (Compressor, condenser, evaporator, capillary tube, refrigerant leaks, etc.) 1. Recover the refrigerant from the system at the process tube located on the high side of the system by installing a line tap on the process tube. Apply gauge from process tube to EPA
Summary of the content on the page No. 16
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. side in small increments while operating the unit. 12. Restart unit several times after allowing pressures to stabilize. Pinch off process tubes, cut and solder the ends. Remove pinch off tool, and leak check the process tube ends. SPECIAL PROCEDURE IN THE CASE OF COMPRESSOR MOTOR BURNOUT 1. Recover all refrigerant and oil from the system. 2. Remove compressor, capillary tube and filter drier from the system. 3. Flush
Summary of the content on the page No. 17
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. 7. WIRING DIAGRAM The wiring diagrams listed below are representative of models deployed with full features. Your model may not offer all these features, accordingly it will slightly differ from your wiring diagram in these optional features area. Refer to the actual wiring diagram included wit your unit. Wiring Diagram For TTW Cooling only models: Wiring Diagram For TTW Cooling and Heating models: 16
Summary of the content on the page No. 18
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. 8. TROUBLESHOOTING In general, problems are classified by three types. One is called Starting Failure which is caused from an electrical defect, another is ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application, and the other is called Structure Damage. 8.1 Flow Chart Display keeps showing "AS" or "HS". Yes Correct or repair the wires. Check the wiring. No
Summary of the content on the page No. 19
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. The "filter check" lamp is on. Press "filter check" button several times and check whether the problem stops. No Replace the main control board. Button of remote controller doesn’t work. Check the power supply. No Yes Check whether the voltage of battery is lower than 2.2V. Replace with new batteries. No Check whether the failure button is locked by button holder. No Yes
Summary of the content on the page No. 20
Service Manual Room Air Conditioner with R-410A Heat Controller, Inc. Operation panel doesn’t work. Check the power supply. No Press the "LED" button of remote controller several times and check whether the problem stops. No Yes Check the wiring of display board. Repair the wiring. No Replace the display board. No Replace the main control board. Follow me mode doesn’t work. Check the power supply. No Press "follow me" button seve
