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HEAT CONTROLLER, INC.
Through-The-Wall
Air Conditioner
MODELS: BDE-103-A
BDE-123-A
Service Manual
CAUTION
-Before servicing the unit, read the "safety precautions" in this manual.
-Only for authorized service personnel.
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CONTENTS 1. PREFACE 1.1 SAFETY PRECAUTIONS ...............................2 2.4 REFRIGERATION CYCLE............................10 1.2 INSULATION RESISTANCE TEST.................2 2.4.1 CONDENSER ......................................10 1.3 FEATURES .....................................................4 2.4.2 EVAPORATOR ....................................10 1.4 CONTROL LOCATIONS.................................4 2.4.3 CAPILLARY TUBE...............................10 2. DISASSEMBLY INSTRUCTIONS 3.
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1.3 SPECIFICATIONS 1.3.1 FOR BDE-103-A/BDE-123-A MODELS BDE-103-A BDE-123-A REMARK ITEMS POWER SUPPLY 1Ø, 208/ 230V, 60Hz CAPACITY (Btu/h) 9,800/10,000 11,400/11,700 INPUT (W) 1,040/1,060 1,210/1,250 COOLING RUNNING CURRENT (A) 5.2/4.7 6.2/5.8 E.E.R. (Btu/W.h) 9.4 9.4 CAPACITY (Btu/h) 9,200/11,200 HEATING 2,900/3,500 INPUT (W) 14.0/15.3 RUNNING CURRENT (A) 26.7 (DB) 19.4 (WB) INDOOR (°C) COOLING OPERATING OUTDOOR (°C) 35 (DB) 23.9 (WB) TEMPERA- INDOOR (°C) 21.1 (DB) 15.6 (WB) TURE HE
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r e l o o C 1.4 FEATURES • Designed for cooling only. • Side air-intake, side cooled-air discharge. • Built in adjustable 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 Operation Off - Turns air conditioner off. Off Med Fan - Med speed fan operation without cooling. Med High Fan Cool Low Fan - Low speed fan operation without cooling. High
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1.5.2 COOLING AND HEATING MODEL • OPERATION OFF - Turns the air conditioner off. FAN ONLY - The low fan speed operation without cooling/heating. LOW COOL - Cooling with the low speed fan operation. HIGH COOL - Cooling with the high speed fan operation. LOW HEAT - Heating with the low speed fan operation. HIGH HEAT - Heating with the high speed fan operation. Turn the Temperature Knob to the desired setting. The central position is a normal setting for average conditions. You can change this sett
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2. DISASSEMBLY INSTRUCTIONS — Before the following disassembly, POWER SWITCH is set to OFF and disconnected the power cord. 2.1 MECHANICAL PARTS 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. Figure 1 2.1.2 CABINET 1. After disassembling the FRONT GRILLE, remove the 9 screws w
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2.2 AIR HANDLING PARTS 2.2.1 ORIFICE, HEATER ASSY 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 2 terminals carefully Figure 4 (See Fig. 5, at Electric Heater Model only) 6. Remove the 4 screws which fasten the orifice. (See Fig. 5) 7. Remove the orifice. (See Fig. 5) Fi
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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 PARTS 2.3.1 MOTOR 1. Remove the cabinet. (Refer to section 2.1.2) Figure 9 2. Remove the clamp cord and disconnect a 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
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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 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 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 b
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2.4 REFRIGERATION CYCLE CAUTION TM Discharge the refrigerant system using 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 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, Fig
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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 18A-Pulling Vacuum Figure 18B-Charging —12— 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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Dimension of air conditioner 3. INSTALLATION 3.1 HOW TO INSTALL THE UNIT 21 24- /32" (626 mm) CAUTION • There are sharp edges that can cause serious cuts. • When lifting the air conditioner, it is HEAVY. 13 14- /32" Use 2 peoples to lift. (366 mm) 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 18"(458 mm) wall sleeves used to mount the new air conditione
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3.2 INSTALLATION KITS CONTENTS 1 Insulation Front (1 ea) 2 Insulation Horizontal (2 ea) (Adhesive backed) 11 3 82- /16" 26- /8" Sleeve Assembly (2,100 mm) (670 mm) (optional, including expanded aluminum metal grille) 3 Insulation Vertical (4 ea) 4 Support Block (4 ea) 5 Baffle (2 ea) Louvered Grille (Adhesive backed) (Adhesive backed) (Plastic sheet) (optional) 2 14" (355 mm) Air Conditioner 1 3 4 Trim (2 ea) 5 —14—
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3.3 SUGGESTED TOOL REQUIREMENTS SCREWDRIVER(+, -), RULER, KNIFE, HAMMER, PENCIL, LEVEL 3.3.1 PREPARATION OF SLEEVE Width of the existing A B wall sleeve 1 3 3 25- /2" (648 mm) 2- /4" (70 mm) 4- /4" (120 mm) 1. Remove the old air conditioner from the wall sleeve and prepare the wall sleeve. 3 3 25- /4" (654 mm) 2- /4" (70 mm) 5" (130 mm) Clean the interior of the sleeve (do not disturb the insulation 26" (660 mm) 3" (75 mm) 5" (130 mm) or seals). 3 1 1 The wall sleeve must be fastened in the wall
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1 A+ /4" Remove the backing from vertical and horizontal insulation and (6 mm) attach them to the inside of the wall sleeve as shown below. 1 B+ /4" Remove the backing from the support blocks and attach them (6 mm) to the inside of the wall sleeve as shown below. Slide the Wall baffles in the slots of the support blocks. Insulation Horizontal Wall Sleeve Insulation Vertical Front 3.3.2 UNIT INSTALLATION A 1. Remove the backing from vertical insulation and attach them B to the back of the unit as
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4. TROUBLESHOOTING GUIDE 4.1 OUTSIDE DIMENSIONS 21 21 24- /32" 19- /32" (499mm) (626mm) 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. 19 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle. ROOM AIR CONDITIONER CYCLE OF REFRIGERATION EVAPORATOR COILS CONDENSER COILS VAPOR INLET SUCTION
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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 of cold air circulation Check of outdoor coil Check heat load increase. for smooth flow. (heat exchanger) & the fan operation. Unexpected residue D
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Fails to Start Check of power source. Check of circuit breaker and fuse. Check of control switch Gas leakage of feeler bulb setting. of thermostat Check of control switch. Only compressor fails to Only fan fails to start. start. Improper wiring. Drop of power voltage. Improper thermostat setting Defect of fan motor capacitor. Defect of compressor capacitor. Loose terminal connection. Irregular motor resistance ( ). Check capacitor. Irregular motor insulation ( ). Improper wiring Replaceme
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COMPLAINT CAUSE REMEDY Fan motor will not run. No power Check voltage at outlet. Correct if none. Power supply cord Check voltage to rotary switch. If none, check power supply cord. Replace cord if circuit is open. Rotary switch Check switch continuity. Refer to wiring diagram for terminal identification. Replace switch if defective. Wire disconnected or Connect wire. Refer to wiring diagram for terminal connection loose identification. Repair or replace loose terminal. Capacitor (Discharge Test
