Heat Controller BG-103A manual

Service Manual CAUTION -Before servicing the unit, read the "safety precautions" in this manual. -Only for authorized service personnel. Thr ough-The-W all Air Conditioning HE A T CONT R OLLER, INC. Model: BG- 103A[...]

—2— 1. PREF A CE 1.1 SAFETY PRECAUTIONS ...............................2 1.2 INSULATION RESISTANCE TEST.................2 1.3 SPECIFICATIONS ..........................................3 1.4 FEATURE S ..................................................... 4 1.5 CONTROL LOCATION S ................................. 4 2. DISASSEMBL Y INSTR UCTIONS 2.[...]

—3— 1.3 SPECIFICA TIONS 1.3.1 FOR BG-10 3A POWER SUPPLY COOLING CAPACITY (Btu/h) INPUT (W) RUNNING CURRENT (A) E.E.R (Btu/W.h) OPERATING INDOOR( ° C) TEMPERATURE OUTDOOR( ° C) REFRIGERANT (R-22) CHARGE (g) EVAPORATOR CONDENSER FAN, INDOOR FAN, OUTDOOR FAN SPEED (FAN/COOLING/HEATING) FAN MOTOR OPERATION CONTROL ROOM TEMP. CONTROL AIR DIRECTION[...]

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 • Side air-intake, side cooled-air discharge. • Built in adjustable THERMISTOR and THERMOSTAT. • Washable one-touch filter. • Compact size[...]

— 5 — 2.1 MECHANICAL P ARTS 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, rem[...]

Figure 7 — 6 — 2.2 AIR HANDLING P ARTS 2.2.1 ORIFICE, 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 orifice. (See Fig.[...]

— 7 — 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 P ARTS 2.3.1 MO T OR 1. Remove the cabinet. (Refer to section 2.1.2) 2. Remove the clamp cord and disconnect the wire housing in control box. (Refer to secti[...]

— 8 — 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 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 re[...]

— 9 — 2.4 REFRIGERA TION CYCLE 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 fasten the condenser. 4. After discharging the refrigerant completely into a Freon TM Recovery System, unbraze the interconnecting tube at the condenser connections. 5. Remove [...]

— 1 0 — — 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. A[...]

— 1 1 — 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 [...]

— 1 2 — 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 comp[...]

— 1 3 — 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 INSTALLATION HARDWARE You may not need all parts in the kit. Discard unused parts HO W T O IN[...]

P R OCEDURE If you are using the new sleeve (optionally A s u pplie d w it h y o u r unit),sk i p t o ste p 3 . Otherwise, install the plastic grille from the kit. Cut the plastic grille to 25-1/2" wide and 15-1/4" high. Place the plastic grille to the inside of the wall sleeve at the rear flange. Fasten the 4 washer screws to secure the [...]

— 1 5 — PR OCEDURE B Redirect the louvers at the back of the wall sleeve to 60 ° angle as shown in the FIG 24 . 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 25-1[...]

— 1 6 — PR OCEDURE B CONTINUED Remove the backing from the support blocks and attach them to the inside of the wall sleeve as shown FIG 29 . Slide the baffle into slots of the support blocks. Install the new unit into the wall sleeve. Assemble trim as described in Step 6, Procedure A. 8 W all W all Sleev e Baffle ( 7 3 / 32 " ) F ront Supp[...]

— 1 7 — Depth"D" of the e xisting wall slee v e (inches) Length "A" (inches) Suppor t Block Baffle A A 3 / 4 1- 3 / 4 4 18 D 18- 5 / 8 18- 5 / 8 D 19- 3 / 4 19- 3 / 4 D 22 FIG. 3 4 3.5 PR OCEDURE C Redirect the louvers at the back of the wall sleeve to 60 ° angle as shown in the FIG 3 0 . The use of pliers is recommended. I[...]

— 1 8 — 7 1" high 3 / 4 " High Shim (2EA) 6" 6" FIG. 3 7 • Air conditioners covered in this manual pose an excessive weight hazard. Two or more people are needed to move and install the unit. To prevent injury or strain, use proper lifting and carrying techniques when moving unit. • When handling the air conditioner, be [...]

— 19 — 4. TR OUBLESHOO TING GUIDE 4.1 OUTSIDE DIMENSIONS 20- 3 / 32 " (499mm) 24" (610mm) 14- 13 / 32 " (366mm) MODE TIMER POWER FAN SPEED Fan Energy Saver Cool Timer TEMP ' F F1 LOW F2 MED F3 HIGH 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 Foll[...]

— 2 0 — 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[...]

— 2 1 — 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 start. 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[...]

— 2 — 2 2 — 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 identifica[...]

— 2 3 — 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. C[...]

— 2 4 — 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.[...]

— 2 5 — 5. SCHEMA TIC DIA GRAM 5.1 CIRCUIT DIA GRAM • MODEL : BG-10 3 A[...]

— 2 6 — 6. EXPLODED VIEW • MODEL : BG-10 3 A 567502 554160 550140 359012 352380 346811 349600 554031 149980 352115 35211A 130410 435300 43530 0A 147582 A 147581 135303 152302 147582 B 135312 349480 352113 552113 W48602 354210 731273 E C B 567480 267110 W0CZZ 249950 238310 237200 A C 264110 M O E D M I T R E W O P R E N A F D E E P S Fa n y g [...]

—27— 7. REPLACEMENT PARTS LIST MODEL: BG-103A 130410 3041A10064C BASE ASSEMBLY,SINGLE 1 EA 131400 3090A20017D CABINET 1 EA 135303 3530A10272A GRILLE,INLET 1 EA 135312 3531A18004D GRILLE ASSEMBLY,FRONT 1 EA 147581 4758A20058A LOUVER,HORIZONTAL 1 EA 147582 A 4758A30045A LOUVER,VERTICAL 2 EA 147582 B 4758A30045B LOUVER,VERTICAL 4 EA 149980 4998A20[...]

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.:3828A20294W Printed in Korea[...]