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Heat Controller BD-81 manual

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Table of contents for the manual

  • Page 1

    Through-The-Wall Air Conditioning Impor tant Information • Please read carefully and thor oughly this manual before operating this unit. • Contact a qualified sevice technician for installation, repair and maintenance of this unit. • The appliance is not intended for use by young children or those who r equire supervision. • Y oung childr e[...]

  • Page 2

    —2— 1. PREF A CE 1.1 SAFETY PRECAUTIONS ...............................2 1.2 INSULATION RESISTANCE TEST.................2 1.3 SPECIFICATIONS ..........................................3 1.4 FEATURES .....................................................6 1.5 CONTROL LOCATIONS .................................6 2. DISASSEMBL Y INSTR UCTIONS 2.1 ME[...]

  • Page 3

    —3— 1.3 SPECIFICA TIONS 1.3.1 FOR BD-81/BD-101 POWER SUPPLY 1Ø, 115V, 60Hz COOLING CAPACITY (Btu/h) 8,000 10,000 INPUT (W) 800 1,050 RUNNING CURRENT (A) 7.5 9.8 E.E.R (Btu/w.h) 10.0 9.5 REFRIGERANT (R-22) CHARGE(g) 380(13.2 OZ) 410(14.5 OZ) INDOOR (°C) 26.7(DB) 19.4(WB) OUTDOOR (°C) 35(DB) 23.9(WB) EVAPORATOR 2 ROW 12 STACKS CONDENSER FAN, I[...]

  • Page 4

    —4— 1.3.2 FOR BD-123 REMARK POWER SUPPLY COOLING CAPACITY (Btu/h) INPUT (W) RUNNING CURRENT (A) E.E.R. (Btu/W.h) INDOOR (°C) OUTDOOR (°C) REFRIGERANT (R-22) CHARGE(g) EVAPORATOR CONDENSER FAN, INDOOR FAN, OUTDOOR FAN SPEEDS (FAN/COOLING/HEATING) FAN MOTOR OPERATION CONTROL ROOM TEMP. CONTROL CONSTRUCTION COMPRESSOR FAN MOTOR DRAIN SYSTEM NET [...]

  • Page 5

    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) FAN MOTOR OPERATION CONTROL ROOM TEMP. CONTROL CONSTRUCTI[...]

  • Page 6

    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 Push the lever to the "CLOSE" position to cool, heat or recirculate room air only. Pull the lever to the "OPEN&quo[...]

  • Page 7

    1.5.2 COOLING AND HEA TING MODEL • OPERA TION — 7 — A slight burning 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 normal operation. Off - Turns the air conditioner off. Fan Only - The low fan speed operation wi[...]

  • Page 8

    — 8 — 2.1 MECHANICAL P AR TS 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 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 GRILLE, re[...]

  • Page 9

    Figure 7 — 9 — 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 10

    — 10 — 2.2.3 SHROUD 1. Remove the fan. (Refer to section 2.2.2) 2. Remove the screw which fastens the shroud. 3. Remove the shroud. (See Fig. 9) 4. Re-install the components by referring to the removal procedures, 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 [...]

  • Page 11

    — 11 — 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 components by referring to th[...]

  • Page 12

    — 12 — 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 into a Freon TM Recovery System, unbraze the interconnecting tube at the condenser c[...]

  • Page 13

    — 13 — — 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 14

    — 14 — 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 15

    — 15 — 3. INST ALLA TION 3.1 INST ALLA TION 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 compa[...]

  • Page 16

    — 16 — 3.2 INST ALLA TION • 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 INST ALLA TION HARD W ARE You may not need all parts in the kit. Discard unused parts HO W T O[...]

  • Page 17

    — 17 — 3.3 PR OCEDURE A If you are using a new USC sleeve in conjunction with your unit, skip to step 3. Otherwise, install the plastic grille from the kit. Cut the plastic grille to fit the rear opening of the existing sleeve. Place the plastic grille to the inside of the wall sleeve at the rear flange. Fasten the 4 washer screws to secure the[...]

  • Page 18

    — 18 — 3.4 PR OCEDURE B Redirect the louvers at the back of the wall sleeve to 60 ° angle as shown in the FIG 25. The use of pliers is recommended. 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[...]

  • Page 19

    — 19 — PR OCEDURE B 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. 8 T r im (2 ea) W all FIG. 31 • Air conditioners co vered in this man ual pose an e xcessive w eight hazard. T wo or more people are [...]

  • Page 20

    — 20 — 3.5 PR OCEDURE C Redirect the louvers at the back of the wall sleeve to 60 ° angle as shown in the FIG 32. The use of pliers is recommended. 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[...]

  • Page 21

    — 21 — PR OCEDURE C Remove the backing from the 13" shim strips and attach them as shown below in Fig. 39. The higher portion of shim is to be placed in front of the rib on the base of wall sleeve. Install the new unit into the wall sleeve To assemble trim, snap the tab of each piece into the slot of the other piece as shown below. Slide t[...]

  • Page 22

    — 22 — Do not under any circumstances cut or remove the grounding prong from the plug. Line Cord Plug Use Wall Receptacle Power Supply Power supply cord with 3-prong grounding plug Standard 125V, 3-wire grounding receptacle rated 15A, 125V AC Parallel type Use 15 AMP time delay fuse or 15 AMP circuit breaker. Line Cord Plug Use Wall Receptacle [...]

  • Page 23

    — 23 — 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 T OR COILS FA N M OTO R : 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 [...]

  • Page 24

    — 24 — 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 25

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

  • Page 26

    — 26 — — 26 — 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 27

    — 27 — 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 28

    — 28 — 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 29

    — 29 — 5. SCHEMA TIC DIA GRAM 5.1 CIRCUIT DIA GRAM • MODEL : BD-81/BD-101/BD-123 1 3 7 4 2 6 5 WIRING DIAGRAM 3854A20407A M OTO R COMP . CAP A CITOR DC PCB ASSEMBL Y THERMIST OR AIR FIL TER ASSEMBL Y A C PCB ASSEMBL Y SWITCH H.V . ASSEMBL Y BK CN-MO TOR CN-PWR DC12V ZNR01J CN-12V CN-HVB R Y -COMP 3 4 FUSE 250V/T2A (115V/T2A) R Y -LO W R Y -ME[...]

  • Page 30

    2H00677U 2H00598F 4681A20044E 4681A20041C 6120AR2359E 2H01127D 2520UKCK2BA 2520UKHK2CA 6750U-L028A 6750U-L058A 5300A20003A — 30 — • MODEL : BDE-103/BDE-123 3854AR3563D WIRING DIA GRAM COMP MO T OR CAP A CITOR RO T AR Y SWITCH POWER INPUT 7 1 8 6 4 2 F C C H RD BL BK BL BK L H OR(BR) OR(BR) THERMOST A T WH BK YL BL RD RD YL C L H R S C BR(YL) [...]

  • Page 31

    —31— 6. EXPLODED VIEW • MODEL: BD-81/BD-101/BD-123/BDE-103/BDE-123 354210 753010 753011 349480 554031 W48602 559010 346811 349600 567502 349001 130410 352113 35211A 352115 W48602 249950 137215 149410 W0CZZ 264110 130900 135312 147581 135500 147582-2 147582-1 352390 148000 554160 550140 149980 359012 266003 269310 552111 152302 135313 E D F A [...]

  • Page 32

    G 249950 CONTROL BOX ASSY, SINGLE R 268714 PWB(PCB) ASSEMBLY, MAIN(AC) R 268712 PWB(PCB) ASSEMBLY, MAIN(DC) R 264110 POWER CORD ASSY R 263230 THERMOSTAT ASSY R W0CZZ CAPACITOR, DRAWING R 267110 REMOTE, CONTROLLER R 237200 PANEL ASSY, CONTROL R B 554160 COMPRESSOR R 550140 ISOLATOR, COMP R 567502 O.L.P R C 352113 TUBE ASSY, DISCHARGE SINGLE R 352115[...]

  • Page 33

    — 33 — G 249950 CONTROL BOX ASSY, SINGLE R 268714 RPWB(PCB) ASSEMBLY, MAIN(AC) R 268712 PWB(PCB) ASSEMBLY, MAIN(DC) R 264110 POWER CORD ASSY R 263230 THERMOSTAT ASSY R W0CZZ CAPACITOR, DRAWING R 267110 REMOTE CONTROLLER R 237200 PANEL ASSY, CONTROL R B 554160 COMPRESSOR R 550140 ISOLATOR, COMP R 567502 O.L.P R C 352113 TUBE ASSY, DISCHARGE SING[...]

  • Page 34

    — 34 — A 249950 CONTROL BOX ASSY, SINGLE R 264110 POWER CORD ASSY R 266003 SWITCH, ROTARY R 269310 THERMOSTAT ASSY R W0CZZ CAPACITOR, DRAWING R 149410 KNOB ASSY R 137215 PANEL ASSY, CONTROL R B 554160 COMPRESSOR R 550140 ISOLATOR, COMP R 567502 O.L.P R C 352113 TUBE ASSY, DISCHARGE SINGLE R 352115 TUBE ASSY, EVAPORATOR IN R 352115-1 TUBE ASST, [...]

  • Page 35

    Specifications and performance data subject to change without notice. HEA T CONTROLLER, INC. 1900 WELL WOR TH A VENUE • J ACKSON, MICHIGAN 49203 THE QU ALITY LEADER IN CONDITIONING AIR P/No.: 3828A20040D[...]