Heat Controller BG-81G User manual

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com
SERVICE MANUAL
Thru-the-Wall Series with R-410A
BG-81G
BG-101G
BG-103G
BG-123G
BGE-103G
BGE-123G
BG-143G

1. PRECAUTION........................................................................................................................2
1.1 Safety precaution...........................................................................................................2
1.2 Warning .........................................................................................................................2
1.3 Caution ..........................................................................................................................2
2. FEATURES AND PANEL.......................................................................................................3
2.1 Features ........................................................................................................................3
2.2 Control panel illustration ................................................................................................3
3. UNIT DIMENSION..................................................................................................................6
3.1 Unit dimension:..............................................................................................................6
4. OPERATION LIMITS..............................................................................................................6
4.1 Cooling operation ..........................................................................................................6
4.2 Electric heating operation ..............................................................................................7
5. PROTECTION FUNCTION ....................................................................................................8
5.1 Symbol & Meaning ........................................................................................................8
5.2 Protection Function........................................................................................................8
6. COMPONENT OPERATION & TESTING..............................................................................9
6.1 COMPRESSORS ..........................................................................................................9
6.2 FAN MOTOR ...............................................................................................................11
6.3 CAPACITOR, RUN ......................................................................................................11
6.4 THERMOSTAT ADJUSTMENT....................................................................................12
6.5 HEATING ELEMENT - See Figure 6 ...........................................................................12
6.6 VALVE, DRAIN PAN (see Figure 7).............................................................................13
6.7 SEALED REFRIGERATION SYSTEM REPAIRS........................................................13
7. WIRING DIAGRAM..............................................................................................................15
8. TROUBLESHOOTING.........................................................................................................17
8.1 Flow Chart ...................................................................................................................17
8.2 General Troubleshooting .............................................................................................27
8.3 Troubleshooting Cooling..............................................................................................30
8.4 Troubleshooting Heating (Cooling/Electric Heater Models).........................................32
9. INSTALLATION ACCESSORY LIST ...................................................................................34
10. CHARACTERISTIC OF TEMPERATURE SENSOR .........................................................34
Table of Contents
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
1

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.
Do not turn the air-conditioner ON or OFF by plugging or unplugging the power plug.
Use a dedicated power outlet for this appliance.
Grasp the plug to remove the cord from the outlet. Do not touch it with wet hands.
Do not place a heater or other appliance near the power cable.
Do not allow water to run into electrical parts.
Do not store or use flammable gas or combustibles near the air conditioner.
Unplug the unit if strange sounds, odors, or smoke comes from it.
1.3 Caution
Use a soft cloth to clean the unit. Do not use harsh detergents, solvents, etc.
Do not touch the metal parts of the product when removing the air filter. They are very sharp.
Do not step on or put anything on the air conditioner
Do not insert hands or other objects through the air inlet or outlet while the air conditioner is plugged in.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
2

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.
Auto-restart function.
Time delay safety for compressor. Restart approx. 3 minutes after the power failure.
Auto mode in heating mode. Operation mode can be automatically set by the room
temperature.
Sleep mode.
Self-diagnosis function.
Filter check sensor after 250 hours.
Auto cool function.
Follow me function (optional).
Ionizer function (optional).
Silver ion filter (optional).
Alternate between Celsius or Fahrenheit temperature display units
24 hours timer function.
Energy saver.
2.2 Control panel illustration
Control panel for cooling only models:
B Panel
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
3

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,
the fan speed mode is shifted.
TEMPRATURE UP AND DOWN:
Press the Up(▲)or Down(▼) buttons to change temperature setting.
Press the Up(▲) button to increase the set (operating) temperature of the unit.
Press the Down(▼) button to decrease the set (operating) temperature of the unit.
Press or hold either button until the desired temperature is displayed. This temperature will be
automatically maintained anywhere between 62°F (17°C) and 86°F(30°C).
MODE:
Press this button to select operation mode.
Each time you press the button, the operation mode is selected in a sequence that goes from
Auto, Cool, Dry and Fan for cooling only models. and Auto, Cool, Dry, Heat and Fan for electric
heating models.
ENERGY SAVER:
Press this button to activate energy saving. This feature can only function in cooling mode.
SLEEP:
Press this button to save energy and create a more comfortable environment when sleeping. In
this function, the setting temperature will increase by 2° F degrees 30 minutes after the mode is
selected. The temperature will then continue to increase by another 2° F degrees after every 30
minutes. After 7 hours, the unit return to the originally programmed settings. The Sleep mode
program can be cancelled at any time during operation by again pressing the Sleep button.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
4

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 button to confirm that the filter has been cleaned and the
light will go off.
FOLLOW ME (OPTIONAL):
Press the button on the remote controller to activate this feature, which serves as a remote
thermostat allowing for the precise temperature control at its location, rather than using the
thermostat sensor in the unit’s display.
Clean Air (OPTIONAL):
Press this button to start the Clean Air feature, press again to stop.
When this feature is started, the Ionizer is energized to generate abundant anions to fill the
room with refreshing and natural air.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
5

3. UNIT DIMENSION
3.1 Unit dimension:
4. OPERATION LIMITS
4.1 Cooling operation
Outdoor unit air temp DB
Indoor air temp DB
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
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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.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
7

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 in cooling or dry mode
Anti-freezing function is activated according to TE.
If TE is lower than 33.8°F (1℃) for 14 minutes, the evaporator anti-freezing protection will be
activated. The compressor will turn off for 5 minutes. 5 minutes later, if the evaporator pipe
temperature is still lower than 33.8°F (1℃), the compressor remain off; when it gets higher
than 33.8°F (1℃), the compressor will restart and the antifreeze function will be cancelled.
Note:If the compressor stops operation, the time will be cleared.
If the fan motor turns to High speed or the indoor ambient temperature gets over 78.8°F
(26℃), the time will keep inactive, not be cleared.
 Anti-frosting protection and defect at cooling or dry mode
After compressor runs for 3 minutes, if TE is less than 5°F (-15℃) for the subsequent 3
minutes, the anti-frosting protection will be activated and the compressor will stop for the
following 6 minutes. After that time, if the condition for de-frosting function is met again in the
following 10 minutes while the compressor is operating, the unit will display ‘Ed’ to indicate that
the unit is in the defrost mode defect. The compressor and fan motor will turn OFF
Note: The Defect display can be cancelled only by pressing the ON/OFF button on the unit
or the remote controller.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
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 Fault Code
Defect code Defect explanation
Ed Evaporator de-frosting defect.
AS Indoor ambient temperature sensor failure in heating, cooling, dry and auto
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 OR
TESTING.
6.1 COMPRESSORS
Compressors are single phase, 115 or 230/208 volt, depending on the model number. All
compressor motors are permanent split capacitor type using only a running capacitor across
the start and run terminal.
All compressors are internally spring mounted and externally mounted on rubber isolators.
COMPRESSOR WINDING TEST (See Figure 1)
Remove compressor terminal box cover and disconnect
wires from terminals. Using an ohmmeter, check
continuity across the following:
1. Terminal "C" and "S" - no continuity
- open winding - replace compressor.
2. Terminal "C" and "R" - no continuity
- open winding - replace compressor.
3. Terminal "R" and "S" - no continuity
- open winding - replace compressor. Figure 1: Compressor winding test
GROUND TEST
Use an ohmmeter set on its highest scale. Touch
one lead to the compressor body (clean point of
contact as a good connection is a must) and the
other probe in turn to each compressor terminal
(see Figure 2.) If a reading is obtained, the
compressor is grounded and must be replaced. Figure 2: Typical ground test
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
9

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 performance test.”
If test shows:
A. Below normal high side pressure.
B. Above normal low side pressure.
C. Low temperature difference across coil.
The compressor valves are faulty - replace the compressor.
THERMAL OVERLOAD (External)
Some compressors are equipped with an external overload which
is located in the compressor terminal box adjacent to the
compressor body (see Figure 3.) The overload is wired in series
with the common motor terminal. The overload senses both major
amperage and compressor temperature. High motor temperature
or amperage heats the disc causing it to open and break the
circuittothecommonmotorterminal. Figure3:Externaloverload
Heat generated within the compressor shell is usually due to:
1. High amperage.
2. Low refrigerant charge.
3. Frequent recycling.
4. Dirty condenser.
TERMINAL OVERLOAD – TEST (Compressor - External Type)
1. Remove overload.
2. Allow time for overload to reset before attempting to test.
3. Apply ohmmeter probes to terminals on overload wires. There should be continuity through
the overload.
TERMINAL OVERLOAD (Internal)
Some model compressors are equipped with an internal overload. The overload is embedded
in the motor windings to sense the winding temperature and/or current draw. The overload is
connected in series with the common motor terminal.
Should the internal temperature and/or current draw become excessive, the contacts in the
overload will open, turning off the compressor. The overload will automatically reset, but may
require several hours before the heat is dissipated.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
10

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.
Figure4:Internaloverload
6.2 FAN MOTOR
A single phase permanent split capacitor motor is used to drive the evaporator blower and
condenser fan. A self-resetting overload is located inside the motor to protect against high
temperature and high amperage conditions.
FAN MOTOR - TEST
1. Determine that capacitor is serviceable.
2. Disconnect fan motor wires from fan speed switch or system switch.
3. Apply "live" test cord probes on Red wire and common terminal of capacitor. Motor should
run at high speed.
4. Apply "live" test cord probes on Yellow wire and common terminal of capacitor. Motor should
run at mid speed.
5. Apply "live" test cord probes on White wire and common terminal of capacitor. Motor should
run at low speed.
6. Apply "live" test cord probes on each of the remaining wires from the speed switch or
system switch to test intermediate speeds.
6.3 CAPACITOR, RUN
A run capacitor is wired across the auxiliary and main
winding of a single phase permanent split capacitor motor
such as the compressor and fan motor. A single capacitor
can be used for each motor or a dual rated capacitor can
be used for both.
The capacitor's primary function is to reduce the line
current while greatly improving the torque characteristics
of a motor. The capacitor also reduces the line current to
the motor by improving the power factor of the load. The Figure 5: Run capacitor
hook-up line side of the capacitor is marked with a red dot and is
wired to the line side of the circuit (see Figure 5.)
CAPACITOR - TEST
1. Remove capacitor from unit.
2. Check for visual damage such as bulges, cracks, or leaks.
3. For dual rated, apply an ohmmeter lead to common (C) terminal and the other probe to the
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
11

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 and the pointer will move to the "0"
end of the scale and remain there as long as the probes are connected.
An open capacitor will show no movement of the pointer when placed across the
terminals of the capacitor.
6.4 THERMOSTAT ADJUSTMENT
No attempt should be made to adjust thermostat. Due to the sensitivity of the internal
mechanism and the sophisticated equipment required to check the calibration, it is suggested
that the thermostat be replaced rather than calibrated. Thermostat bulb must be straight to
insure proper performance.
6.5 HEATING ELEMENT - See Figure 6
All electric heater models are equipped with a heating element.
The heating element contains a fuse link and a heater limit
switch. The fuse link is in series with the power supply and
will open and interrupt the power when the temperature
reaches 183.2°F (84°C) or 199.4°F (93°C) depending on series
model, or a short circuit occurs in the heating element.
Once the fuse link separates, a new fuse link must
be installed. NOTE: Always replace with the exact replacement.
The heater element has a high limit control. This control is a
bimetal thermostat mounted in the top of the heating element. Figure 6: Heating element
Should the fan motor fail or filter become clogged, the high limit
control will open and interrupt power to the heater before reaching an unsafe temperature
condition.
The control is designed to open at 104°F (40°C). Test continuity below 104°F (40°C). and for
open above 104°F (40°C)..
Press the “Mode” button, select “Heat” mode, to bring on the heating element and turn off the
compressor. The room temperature sensor will then control the cycling of the element when
the selected indoor temperature is reached.
Testing of the elements can be done using an ohmmeter across the terminals after the
connecting wires have been removed. A cold resistance reading of approximately 10.2 ohms
for the 4.7 KW heater should be registered.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
12

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
condenser fan blade to freeze in the accumulated water
and prevent it from turning.
To provide a means of draining this water, a bellows type Figure 7: Drain pan valve
drain valve is installed over a drain opening in the Chassis.
This valve is temperature sensitive and will open when the outside temperature reaches 40°F
(4.4°C). The valve will close gradually as the temperature rises above 40°F (4.4°C) to fully
close at 68°F (20°C).
6.7 SEALED REFRIGERATION SYSTEM REPAIRS
EQUIPMENT REQUIRED:
1. Voltmeter
2. Ammeter
3. Ohmmeter
4. E.P.A. Approved Refrigerant Recovery System.
5. Vacuum Pump (capable of 200 microns or less vacuum.)
6. Acetylene Welder
7. Electronic Halogen Leak Detector (G.E. Type H-6 or equivalent.)
8. Accurate refrigerant charge measuring device such as:
a. Balance Scales - 1/2 oz. accuracy
b. Charging Board - 1/2 oz. accuracy
9. High Pressure Gauge - (0 - 400 lbs.)
10. Low Pressure Gauge - (30 - 150 lbs.)
11. Vacuum Gauge - (0 - 1000 microns)
EQUIPMENT MUST BE CAPABLE OF:
1. Recovery CFC's as low as 5%.
2. Evacuation from both the high side and low side of the system simultaneously.
3. Introducing refrigerant charge into high side of the system.
4. Accurately weighing the refrigerant charge actually introduced into the system.
5. Facilities for flowing nitrogen through refrigeration tubing during all brazing processes.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
13

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
approved gauges from process tube to EPA approved recovery system. Recover CFCs in
system to at least 5%.
2. Cut the process tube below pinch off on the suction side of the compressor.
3. Connect the line from the nitrogen tank to the suction process tube.
4. Drift dry nitrogen through the system and unsolder the more distant connection first. (Filter
drier, high side process tube, etc.)
5. Replace inoperative component, and always install a new filter drier. Drift dry nitrogen
through the system when making these connections.
6. Pressurize system to 30 PSIG with proper refrigerant and boost refrigerant pressure to 150
PSIG with dry nitrogen.
7. Leak test complete system with electric halogen leak detector, correcting any leaks found.
8. Reduce the system to zero gauge pressure.
9. Connect vacuum pump to high side and low side of system with deep vacuum hoses, or
copper tubing. (Do not use regular hoses.)
10. Evacuate system to maximum absolute holding pressure of 200 microns or less.
NOTE: This process can be sped up by use of heat lamps, or by breaking the vacuum with
refrigerant or dry nitrogen at 5,000 microns. Pressurize system to 5 PSIG and
leave a minimum of 10 minutes. Recover refrigerant, and proceed with evacuation
of a pressure of 200 microns or a minimum of 10%.
11. Break vacuum by charging system from the high side with the correct amount of refrigerant
specified. This will prevent boiling the oil out of the crankcase.
NOTE: If the entire charge will not enter the high side, allow the remainder to enter the low
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
14

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 evaporator condenser and all connecting tubing with dry nitrogen or equivalent, to
remove all contamination from system. Inspect suction and discharge line for carbon
deposits. Remove and clean if necessary.
4. Reassemble the system, including new drier strainer and capillary tube.
5. Proceed with process as outlined under hermetic component replacement.
ROTARY COMPRESSOR SPECIAL TROUBLESHOOTING AND SERVICE
Basically, troubleshooting and servicing rotary compressors is the same as on the
reciprocating compressor with only a few exceptions.
1. Because of the spinning motion of the rotary, the mounts are critical. If vibration is present,
check the mounts carefully..
2. The electrical terminals on the rotary are in a different order than the reciprocating
compressors. The terminal markings are on the cover gasket. Use your wiring diagram to
insure correct connections.
REFRIGERANT CHARGE
1. The refrigerant charge is extremely critical. Measure charge carefully - as exact as possible
to the nameplate charge.
2. The correct method for charging the a rotary compressor is to introduce liquid refrigerant
into the high side of the system with the unit off. Then start compressor and enter the
balance of the charge, gas only, into the low side.
The introduction of liquid into the low side, without the use of a capillary tube, will cause
damage to the discharge valve of the rotary compressor.
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
15

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:
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
16

Display keeps showing "AS" or "HS".
Check the wiring. Correct or repair the wires.
Check the resistance of room temperature sensor,
according to the characteristic table.
Replace the main control board.
Replace the room temperature sensor.
Display keeps showing "LO" or "HI".
Replace the room temperature sensor.
Check whether the room ambient temperature is over 31C (90F) or lower than 16C (60F).
Replace the control board.
Check the resistance of room temperature sensor,
according to the characteristic table.
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
Yes
No
Yes
No
No
Yes
No
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
17

No
No
The "filter check" lamp is on.
Press "filter check" button several times and check whether the problem stops.
Replace the main control board.
No
Button of remote controller doesn’t work.
No
Check the power supply.
Check whether the voltage of battery is lower than 2.2V.
No
Check whether the failure button is locked by button holder.
Yes
Replace with new batteries.
No
Check the wiring.
No
Check whether the transformer damaged
(
o
p
en circuit or short circuit
)
.
Ye s
Replace the transformer.
No
Check whether other modes work normally.
Replace the display board.
Replace the main control board.
Check whether the buttons on the unit work normally.
Yes
Replace the remote controller.
No
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
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Operation panel doesn’t work.
Check the power supply.
Press the "LED" button of remote controller several times and
check whether the problem stops.
Check the wiring of display board. Repair the wiring.
Replace the display board.
Replace the main control board.
Follow me mode doesn’t work.
Check the power supply.
Press "follow me" button several times and check whether this mode can work.
(Pay attention to the position of Remote controller)
Check w hether other functions of r emote
work or not.
Replace the display board.
Replace the main control board.
Check the batteries. Replace it if failed.
Replace the remote controller.
No
No
No
Yes
No
No
No
No
No
Yes
No
Service Manual
Room Air Conditioner with R-410A
Heat Controller, Inc.
19