HEAT CONTROLLER, INC.
Through-The-Wall
Air Conditioner
MODELS: BDE-103-A
BDE-123-A
S ervice M anual
CAUTION
-Before servicing the unit, read the "safety precautions" in this manual.
-Only for authorized service personnel.
1.3 SPECIFICATIONS
1.3.1 FOR BDE-103-A/BDE-123-A
MODELS
ITEMS
BDE-103-A
BDE-123-A
REMARK
1Ø, 208/ 230V, 60Hz
POWER SUPPLY
9,800/10,000
1,040/1,060
5.2/4.7
11,400/11,700
1,210/1,250
6.2/5.8
CAPACITY
INPUT
(Btu/h)
(W)
COOLING
HEATING
RUNNING CURRENT (A)
9.4
9.4
E.E.R.
(Btu/W.h)
(Btu/h)
(W)
9,200/11,200
2,900/3,500
14.0/15.3
CAPACITY
INPUT
RUNNING CURRENT (A)
26.7 (DB) 19.4 (WB)
35 (DB) 23.9 (WB)
21.1 (DB) 15.6 (WB)
INDOOR (°C)
COOLING
OPERATING
TEMPERA-
TURE
OUTDOOR (°C)
INDOOR (°C)
HEATING
8.3 (DB)
440(15.5 OZ)
2 ROW 12 STACKS
2 ROW 17 STACKS, L-BENDED TYPE
6.1 (WB)
470(16.6 OZ)
3 ROW 12 STACKS
OUTDOOR (°C)
REFRIGERANT (R-22) CHARGE(g)
EVAPORATOR
LOUVERED-
FIN TYPE
CONDENSER
TURBO FAN
PROPELLER TYPE FAN WITH SLINGER-RING
1/ 2/ 2
FAN, INDOOR
FAN, OUTDOOR
FAN SPEEDS (FAN/COOLING/HEATING)
FAN MOTOR
6 POLES
ROTARY SWITCH
OPERATION CONTROL
ROOM TEMP. CONTROL
THERMOSTAT
VERTICAL LOUVER (RIGHT & LEFT)
HORIZONTAL LOUVER (UP & DOWN)
TOP-DOWN
AIR DIRECTION CONTROL
CONSTRUCTION
ELECTRIC HEATER
COMPRESSOR
3.5KW, 230V
EXTERNAL OVERLOAD PROTECTOR
INTERANL THERMAL PROTECTOR
FUSE LINK, BIMETAL THERMOSTAT
1.6m (3 WIRE WITH GROUDING)
ATTACHMENT PLUG (CORD-CONNECTED TYPE)
SPLASHED BY FAN SLINGER
PROTECTOR
FAN MOTOR
ELECTRIC HEATER
POWER CORD
DRAIN SYSTEM
80/36
81/37
NET WEIGHT
(lbs/kg)
(inch)
(mm)
(inch)
(mm)
(inch)
(mm)
21
13
21
24 /32 x 14 /32 x 19 /32
626 x 366 x 499
DIMENSION
(W x H x D)
7
17
23
25 /8 x 15 /32 x 16 /32
SLEEVE DIMESION
(W x H x D)
OPTIONAL
PART
656 x 394 x 425
20
SLEEVE DEPTH
WITH FRONT GRILLE
510
—3—
1.4 FEATURES
• Designed for cooling only.
• Side air-intake, side cooled-air discharge.
• Built in adjustable THERMOSTAT.
• Washable one-touch filter.
• Powerful and quiet cooling.
• Top-down chassis for the simple installation and service.
• 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.
Low Fan - Low speed fan operation without cooling.
High Cool - Cooling with high speed fan operation.
Med Cool - Cooling with med speed fan operation.
Low Cool - Cooling with low speed fan operation.
Med
Fan
High
Cool
Low
Fan
Med
Cool
Low Cool
Thermostat
5
4
6
This automatically controls the temperature of the indoor air.
Turn the knob so that arrow points to the larger marks for
greater cooling. Point the arrow to the smaller marks for more moderate cooling.
(i.e. the higher number, the greater cooling)
3
2
7
8
1
9
• VENTILATION
The ventilation lever is located in the right of the air
discharge.
The ventilation lever must be in the CLOSE position in
order to maintain the best cooling conditions.
When fresh air is necessary in the room, set the ventilation
lever to the OPEN position.
The damper is opened and room air is exhausted outside.
PULL OPEN / PUSH CLOSE
• ENERGY SAVER (optional)
On : Both the fan and the compressor turn on and turn off
together while operation knob is set to the Cool
position.
Energy Saver
You can get the more economical operation.
Off
On
Off : The fan runs constantly while operation knob is set to
the Cool position.
You can access the Energy Saver switch when you open
the inlet grille.
—4—
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 setting, if necessary, in
accordance with your temperature preference.
The thermostat automatically controls cooling or heating, but the fan runs
continuously whenever the air conditioner is in operation. If the room is too warm,
turn the thermostat control clockwise. If the room is too cool, turn the thermostat
control counterclockwise.
CAUTION
When the air conditioner has been performed its cooling
or heating operation and is turned off or set to the fan
position, wait at least 3 minutes before resetting to the
cooling operation again.
• HEAT PUMP MODELS
When the outdoor temperature is lower than
-4°C (24°F), the electric heater will turn on instead of the
heat pump.
A slight heat 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.
—5—
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 which fasten the cabinet at the both
sides and the top. (See Fig. 2)
Keep these for later use.
Figure 2
2.1.3 CONTROL BOX
1. Remove the front grille. (Refer to section 2.1.1)
2. Remove the screw which fasten the control
box. (See Fig. 3)
3. Pull the control box from the barrier.(See Fig.3)
4. Discharge the capacitor by placing a 20,000 ohm
resistor across the capacitor terminals.
5. Disconnect two wire housings in the control box.
6. Pull the control box forward completely.
7. Re-install the components by referring to the
removal procedure. (See Fig. 3)
(Refer to the circuit diagram found on pages
26~27 in this manual and on the control box.)
Figure 3
—6—
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
(See Fig. 5, at Electric Heater Model only)
6. Remove the 4 screws which fasten the orifice.
(See Fig. 5)
Figure 4
7. Remove the orifice. (See Fig. 5)
Figure 5
8. Remove the clamp which secures the turbo fan
with plier. (See Fig. 6)
Figure 6
9. Remove the turbo fan with plier or your hand
without touching blades. (See Fig. 7)
10. Re-install the components by referring to the
removal procedure, above.
Figure 7
2.2.2 FAN
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the brace and shroud cover.
(Refer to section 2.2.1)
3. Remove the 6 screws which fasten the condenser.
4. Move the condenser sideways carefully.
5. Remove the clamp which secures the fan.
6. Remove the fan. (See Fig. 8)
7. Re-install the components by referring to the
removal procedure, above.
Figure 8
—7—
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)
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 the 4 or 2 screws which fasten the motor.
(See Fig. 10)
Figure 9
6. Remove the motor.
7. Re-install the components by referring to the
removal procedure, above.
Figure 10
2.3.2 COMPRESSOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Discharge the refrigerant system using FreonTM
Recovery System.
If there is no valve to attach the recovery system,
install one (such as a WATCO A-1) before venting
the FreonTM . Leave the valve in place after
servicing the system.
3. Disconnect the 3 leads from the compressor.
4. After purging the unit completely, unbraze the
suction and discharge tubes at the compressor
connections.
5. Remove the 3 nuts and the 3 washers which
fasten the compressor. (See Fig. 11)
6. Remove the compressor.
Figure 11
7. Re-instill the components by referring to the
removal procedure, above.
2.3.3 CAPACITOR
1. Remove the control box. (Refer to section 2.1.3)
2. Remove knobs and the tips which fasten the
display panel.
3. Disconnect the 2 leads from the rocker switch and
remove the panel (Energy saver model only).
4. Remove 2 screws and unfold the control box.
(See Fig. 12)
5. Remove the Rotary Switch.
6. Remove the screw and the clamp which fastens
the capacitor. (See Fig. 12)
7. Disconnect all the leads of capacitor terminals.
8. Re-install the components by referring to the
removal procedure, above.
Figure 12
—8—
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
connection.)
for ground
8. If the supply cord of this appliance is damaged, it
must be replaced by the special cord.
(The special cord means the cord which has the
same specification marked on the supply cord
fitted to the unit.)
Figure 13
2.3.5 THERMOSTAT
1. Remove the control box. (Refer to section 2.1.3)
2. Unfold the control box. (Refer to section 2.3.3)
3. Remove the 2 screws which fasten the thermostat.
4. Disconnect all the leads of thermostat terminals.
5. Remove the thermostat. (See Fig. 14)
6. Re-install the components by referring to the
removal procedure, above.
Figure 14
2.3.6 ROTARY SWITCH
1. Remove the control box. (Refer to section 2.1.3)
2. Unfold the control box. (Refer to section 2.3.3)
3. Remove 2 screws which fasten the rotary switch.
4. Disconnect all the leads of the rotary switch
terminals.
5. Remove the rotary switch. (See Fig. 15)
6. Re-install the components by referring to the
above removal procedure, above.
Figure 15
—9—
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,
unbraze the interconnecting tube at the condenser
connections.
Figure 16
5. Remove the condenser.
6. Re-install the components by referring to notes.
(See Fig. 16)
2.4.2 EVAPORATOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Discharge the refrigerant completely.
3. Remove the 2 screws which fasten the evaporator
at the left side and the right side.
4. Move the evaporator sideward carefully and then
unbraze the interconnecting tube at the evaporator
connectors.
5. Remove the evaporator.
6. Re-install the components by referring to notes.
(See Fig. 17)
Figure 17
2.4.3 CAPILLARY TUBE
1. Remove the cabinet. (Refer to section 2.1.2)
2. After discharging the refrigerant completely,
unbraze the interconnecting tube at the capillary
tube.
3. Remove the capillary tube.
4. Re-install the components by referring to notes.
—10—
NOTES
— Replacement of the refrigeration cycle.
1. When replacing the refrigeration cycle, be sure to
discharge the refrigerant system using a FreonTM
recovery System.
6. Recharge as follows :
1) Refrigeration cycle systems are charged from the
High-side. If the total charge cannot be put
in the High-side, the balance will be put in the
suction line through the access valve which you
installed as the system was opened.
2) Connect the charging cylinder as shown in Fig. 18B.
With valve C open, discharge the hose at the
manifold connection.
3) Open valve A and allow the proper charge to
enter the system. Valve B is still closed.
4) If more charge is required, the high-side will not
take it. Close valve A.
5) With the unit running, open valve B and add the
balance of the charge.
a. Do not add the liquid refrigerant to the Low-
side.
b. Watch the Low-side gauge; allow pressure to
rise to 30 lbs.
c. Turn off valve B and allow pressure to drop.
d. Repeat steps B and C until the balance of the
charge is in the system.
If there is no valve to attach the recovery system,
install one (such as a WATCO A-1) before venting
the FreonTM. Leave the valve in place after
servicing the system.
2. After discharging the unit completely, remove the
desired component, and unbrace the pinch-off
tubes.
3. Solder service valves into the pinch-off tube ports,
leaving the valves open.
4. Solder the pinch-off tubes with Service valves.
5. Evacuate as follows.
1) Connect the vacuum pump, as illustrated Fig.
18A.
2) Start the vacuum pump, slowly open manifold
valves A and B with two full turns
counterclockwise and leave the valves closed.
The vacuum pump is now pulling through valves
A and B up to valve C by means of the manifold
and entire system.
6) When satisfied the unit is operating correctly,
use the pinch-off tool with the unit still running
and clamp on to the pinch-off tube. Using a tube
cutter, cut the pinch-off tube about 2 inches from
the pinch-off tool. Use sil-fos solder and solder
pinch-off tube closed. Turn off the unit, allow it to
set for a while, and then test the leakage of the
pinch-off connection.
CAUTION
If high vacuum equipment is used, just crack
valves A and B for a few minutes, then open
slowly with the two full turns counterclockwise.
This will keep oil from foaming and being
drawn into the vacuum pump.
3) Operate the vacuum pump for 20 to 30 minutes,
until 600 microns of vacuum is obtained. Close
valves A and B, and observe vacuum gauge for
a few minutes. A rise in pressure would
indicate a possible leak or moisture remaining in
the system. With valves A and B closed, stop
the vacuum pump.
4) Remove the hose from the vacuum pump and
place it on the charging cylinder. See Fig. 18B.
Open valve C.
Discharge the line at the manifold connection.
5) The system is now ready for final charging.
—11—
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.
COMPOUND GAUGE
CONDENSER
(HIGH PRESSURE SIDE)
MANIFOLD
GAUGE
A
B
CAPILLARY TUBE
SEE INSETS
BELOW
EVAPORATOR
(LOW PRESSURE SIDE)
COMPRESSOR
HI
LOW
A
B
A
B
EXTERNAL
VACUUM PUMP
CHARGING
CYLINDER
C
Figure 18A-Pulling Vacuum
Figure 18B-Charging
—12—
Dimension of air conditioner
3. INSTALLATION
3.1 HOW TO INSTALL THE UNIT
24-21/32"
(626 mm)
CAUTION
• There are sharp edges that can cause serious cuts.
• When lifting the air conditioner, it is HEAVY.
Use 2 peoples to lift.
14-13/32"
(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
wall sleeves used to mount the new air conditioner must be in
good structural condition and have the rear grille that securely
attaches to the sleeve or the flange of the sleeve to secure the
new air conditioner.
18"(458 mm)
19-21/32"
(499 mm)
Dimension of sleeve assembly (optional)
• To avoid vibration and noise, make sure the unit is installed
securely and firmly.
25-7/8"
(656 mm)
15- 17/32"
(394 mm)
16-23/32"
(425 mm)
A. BEFORE ATTACHING THE FRONT
GRILLE TO THE CABINET, IF YOU WANT
TO PULL OUT THE FILTER UPWARD;
1. There should be no obstacle, like a fence, within 20" which
might restrict heat radiation from the condenser.
INSULATION
SLEEVE
WALL
WALL
COOLED
HEAT
RADIATION
AIR
2. To prevent reducing performance, install the unit so that
louvers of the cabinet are not blocked.
INTAKE
AIR
1/4" Bubble
of the level
B. IF YOU WANT TO PULL OUT THE FILTER
DOWNWARD;
Over 20"
The grille is already designed for that way.
1. Install the unit a little obliquely outward not to leak the
condensed water into the room (about 1/2" or 1/4" bubble
with level).
1/4" Bubble
2. Install the unit with its bottom portion 30~60" above the floor
level.
3. The power cord must be connected to an independent
circuit. The green wire must be grounded.
Level
—13—
3.2 INSTALLATION KITS CONTENTS
1 Insulation Front (1 ea)
2 Insulation Horizontal (2 ea)
(Adhesive backed)
82-11/16"
(2,100 mm)
26-3/8"
(670 mm)
Sleeve Assembly
(optional, including expanded
aluminum metal grille)
3 Insulation Vertical (4 ea) 4 Support Block (4 ea) 5 Baffle (2 ea)
Louvered Grille
(optional)
(Adhesive backed)
(Adhesive backed)
(Plastic sheet)
2
14"
(355 mm)
Air Conditioner
1
3
4
5
Trim (2 ea)
—14—
3.3 SUGGESTED TOOL REQUIREMENTS
SCREWDRIVER(+, -), RULER, KNIFE, HAMMER, PENCIL, LEVEL
3.3.1 PREPARATION OF SLEEVE
Width of the existing
wall sleeve
A
B
25-1/2"(648 mm)
25-3/4"(654 mm)
26" (660 mm)
26-3/4"(680 mm)
27" (686 mm)
2-3/4" (70 mm) 4-3/4" (120 mm)
2-3/4" (70 mm) 5" (130 mm)
1. Remove the old air conditioner from the wall sleeve and
prepare the wall sleeve.
Clean the interior of the sleeve (do not disturb the insulation
or seals).
The wall sleeve must be fastened in the wall securely before
installing the new air conditioner.
3"
(75 mm) 5" (130 mm)
3-1/4" (80 mm) 5-1/2" (140 mm)
3-1/2" (90 mm) 5-1/2" (140 mm)
2. Prepare the wall sleeve for installation of the new unit
according to the following installation procedures. Before
you prepare the wall sleeve, you should check the wall
sleeve dimensions.
1
/
2
"
1-1/4
(32 mm)
"
A
(12 mm)
B
45~60°
45~60°
45~60°
3. Redirect the louvers at the back of the wall sleeves as
following A and B lengths in the below table.
Wall Top view of the wall sleeve Wall
Insulation
4. Sleeve (up to 18 inches deep)
When the depth of your existing sleeve is deeper than 18",
please skip to step 5.
Horizontal
(2 ea)
Wall
Remove the backing from horizontal insulation and attach
them to the inside of the wall sleeve as shown below.
Wall Sleeve
Front
A
Remove the backing from insulation vertical and attach them
to the inside of the wall sleeve, as shown below.
B
Wall
Wall Sleeve
Front
C
5. Sleeve (18~22 inches deep)
When the depth of your existing sleeve is not deeper than
18", please skip to step 6.
Cut the baffles and the support blocks as following C length
in the below table.
Depth of the existing
wall sleeve
C
Support
Block
18-5/8" (473 mm)
19-3/4" (502 mm)
/
4"
(20 mm)
3
1-3/4" (45 mm)
4"
Baffle
22"
(559 mm)
(100 mm)
C
—15—
A+1/4"
(6 mm)
Remove the backing from vertical and horizontal insulation and
attach them to the inside of the wall sleeve as shown below.
Remove the backing from the support blocks and attach them
to the inside of the wall sleeve as shown below. Slide the
baffles in the slots of the support blocks.
B+1/4"
(6 mm)
Wall
Insulation
Horizontal
Wall
Sleeve
Insulation
Vertical
Front
3.3.2 UNIT INSTALLATION
A
1. Remove the backing from vertical insulation and attach them
to the back of the unit as shown below.
B
Vertical
Insulation
2. Install the new unit into the wall sleeve.
3. Insert front insulation between the wall sleeve and the unit.
A flat-bladed screwdriver or putty knife is recommended.
Wall
Wall Sleeve
Front
Wall
4. To assemble trim, insert the snaps into the slots of others.
To install trim to the sleeve, slide the trim through the unit
until it is flush with the wall sleeve.
Trim (2 ea)
—16—
4. TROUBLESHOOTING GUIDE
4.1 OUTSIDE DIMENSIONS
24-21/32"
19-21/32"
(626mm)
(499mm)
4.2 PIPING SYSTEM
CONDENSER COILS
FAN
CAPILLARY TUBE
COMPRESSOR
MOTOR
TURBO FAN
EVAPORATOR COILS
: REFRIGERANT FLOW
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 LIME
COOL LOW PRESSURE VAPOR
HOT
DISCHARGED
AIR
COMPLETE LIQUID
BOIL OFF POINT
COOLED
AIR
ROOM AIR HEAT LOAD
OUTSIDE COOLING
AIR FOR REFRIGERANT
PASS THROUGH
MOTOR
COMPRESSOR
OIL
LIQUID
PRESSURE
DROP
LIQUID OUTLET
HIGH PRESSURE VAPOR
(LIQUID REFRIGERANT)
LIQUID PEFRIGERANT
CAPILLARY TUBE
LOW PRESSURE VAPOR
Figure 19
—17—
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
for smooth flow.
Check of outdoor coil
(heat exchanger) & the fan
operation.
Check heat load increase.
Unexpected residue
Overloaded Circuit
Dirty indoor coil
(Heat exchanger)
Check gas leakage.
Repair gas leak.
Malfunction of fan
Check of inside gas
pressure.
Clogged of air filter
Obstruction at air outlet
Replacement of unit if the
unit is beyond repair.
Adjusting of refrigerant
charge
Stop of auto air-swing
Correct above trouble
Malfunction of compressor
Replacement of
compressor
Check clogging in
refrigeration circuit.
Satisfactory operation with
temperature difference of
inlet & outlet air ; 44.6~50˚F
Repair clogging in
refrigeration circuit.
—18—
Fails to Start
Check of power source.
Check of circuit breaker
and fuse.
Check of control switch
setting.
Gas leakage of feeler bulb
of thermostat
Check of control switch.
Only compressor fails to
start.
Only fan fails to start.
Improper wiring.
Drop of power voltage.
Improper thermostat setting
Defect of fan motor
capacitor.
Defect of compressor
capacitor.
Loose terminal connection.
Improper wiring
Irregular motor resistance
(
).
Irregular motor insulation
).
Check capacitor.
Replacement.
(
Replacement of fan motor
Regular but fails to start
Irregular motor resistance ( )
Irregular motor insulation ( )
Replacement of compressor
(locking of rotor, metal)
Replacement of compressor
(Motor damaged)
—19—
COMPLAINT
CAUSE
REMEDY
Fan motor will not run.
No power
Check voltage at outlet. Correct if none.
Power supply cord
Rotary switch
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.
Wire disconnected or
connection loose
Connect wire. Refer to wiring diagram for terminal
identification. Repair or replace loose terminal.
Capacitor (Discharge
Test capacitor.
capacitor before testing.)
Replace if not within ±10% of manufacturer's
rating. Replace if shorted, open, or damaged.
Will not rotate
Fan blade hitting shroud or blower wheel hitting
scroll. Realign assembly.
Units using slinger ring condenser fans must
have 1/4 to 5/16 inch clearance to the base. If it is
hitting the base, shim up the bottom of the fan
motor with mounting screw(s).
Check fan motor bearings; if motor shaft will not
rotate, replace the motor.
Fan motor runs
intermittently
Revolves on overload.
Check voltage. See limits on this page. If not within
limits, call an electrician.
Test capacitor.
Check bearings. Does the fan blade rotate freely?
If not, replace fan motor.
Pay attention to any change from high speed to
low speed. If the speed does not change, replace
the motor.
Fan motor noise.
Grommets
Fan
Check grommets; if worn or missing, replace them.
If cracked, out of balance, or partially missing,
replace it.
Turbo fan
If cracked, out of balance, or partially missing,
replace it.
Loose set screw
Worn bearings
Tighten it.
If knocking sounds continue when running or
loose, replace the motor. If the motor hums or
noise appears to be internal while running,
replace motor.
—20—
COMPLAINT
CAUSE
REMEDY
Compressor will not run,
but fan motor runs.
Voltage
Wiring
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. Check wire
locations. If not per wiring diagram, correct.
Rotary
Check for continuity, refer to the wiring diagram
for terminal identification. Replace the switch if
circuit is open.
Thermostat
Check the position of knob If not at the coldest
setting, advance the knob to this setting and
restart unit.
Check continuity of the thermostat. Replace
thermostat if circuit is open.
Capacitor (Discharge
capacitor before
servicing.)
Check the capacitor.
Replace if not within ±10% of manufacturers
rating. Replace if shorted, open, or damaged.
Check the compressor for open circuit or
ground. If open or grounded, replace the
compressor.
Compressor
Overload
Check the compressor overload, if externally
mounted. Replace if open. (If the compressor
temperature is high, remove the overload, cool it,
and retest.)
ROOM AIR CONDITIONER VOLTAGE LIMITS
NAME PLATE RATING
MINIMUM
MAXIMUM
126.5V
253V
115V
103.5V
187V
208/230V
—21—
REMEDY
COMPLAINT
CAUSE
Compressor cycles
on overload.
Voltage
Check the voltage. See the limits on the preced-
ing page. If not within limits, call an electrician.
Overload
Check overload, if externally mounted.
Replace if open. (If the compressor temperature
is high, remove the overload, cool, and retest.)
Fan motor
If not running, determine the cause. Replace if
required.
Condenser air flow
restriction
Remove the cabinet. inspect the interior surface
of the condenser; if restricted, clean carefully
with a vacuum cleaner (do not damage fins) or
brush. Clean the interior base before
reassembling.
Condenser fins
(damaged)
If condenser fins are closed over a large area
on the coil surface, head pressures will increase,
causing the compressor to cycle. Straighten the
fins or replace the coil.
Capacitor
Test capacitor.
Wiring
Refrigerating system
Air filter
Check the terminals. If loose, repair or replace.
Check the system for a restriction.
If restricted, clean of replace.
Insufficient cooling or
heating
Exhaust damper door
Unit undersized
Close if open.
Determine if the unit is properly sized for the area to
be cooled.
Excessive noise.
Blower or fan
Copper tubing
Check the set screw or clamp. If loose or missing,
correct. If the blower or fan is hitting air guide,
rearrange the air handling parts.
Remove the cabinet and carefully rearrange tubing
not to contact cabinet, compressor, shroud, and
barrier.
—22—
5. SCHEMATIC DIAGRAM
5.1 CIRCUIT DIAGRAM
• MODEL : BDE-103-A/BDE-123-A
POWER INPUT
GN/YL
1
3
BK(BR)
(Plain)
WH(BL)
(Ribbed)
ROTARY SWITCH
8
6
4
2
RD
BL
7
1
BL
BK
L
2
H
BK
MOTOR
OR(BR)
CAPACITOR
F
YL
YL
OR(BR)
C
THERMOSTAT
WH
BK
4
5
C
H
L
C
H
BK
RD
BK
RD
R
S
7
COMP
BL
BL
BR(YL)
C
O.L.P
RD
RD
6
8
FUSE LINK
HEATER
BI-METAL
THERMOSTAT
WIRING DIAGRAM
3854AR3563D
PART NO.
Q'TY
RE-
NO.
DESCRIPTION
POWER CORD
PER SET MARKS
BDE-103-A
BDE-123-A
6411A20048L
2H00598F
1
2
3
4
5
6
7
8
1
1
1
1
1
1
1
1
ROTARY SWITCH
FAN MOTOR
4681A20044E
6120AR2359E
2H01127D
4681A20041M
CAPACITOR
THERMOSTAT
6750U-L028A
6750U-L039A
OVERLOAD PROTECTOR
COMPRESSOR
2520UKCK2BA
2520UKHK2AA
5300A20003A
ELECTRIC HEATER
—23—
6. EXPLODED VIEW
• MODEL: BDE-103-A/BDE-123-A
130900
135312
E
147582-1
147582-2
147581
435301
152302
135313
749180
352390
D
559011
349001
349480
753010
148000
W48602
F
753011
149980
354210
346811
554030
130410
349600
359012
249950
W48602
A
C
B
269310
266003
35211A
352113
567502
137215
554160
264110
352115
552111
W0CZZ
550140
149410
352115-1
—24—
7. REPLACEMENT PARTS LIST
• MODEL: BDE-103-A/BDE-123-A
R: Service Parts
N: Non Service parts
PART NO.
LOCATION
DESCRIPTION
REMARK
NO
.
BDE-103-A
BDE-123-A
A
249950
264110
266003
269310
W0CZZ
149410
137215
554160
550140
567502
352113
352115
35211A
552111
352390
349001
135312
135313
147581
CONTROL BOX ASSY, SINGLE
POWER CORD ASSY
SWITCH, ROTARY
4995A20408E
6411A20048L
2H00598F
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
THERMOSTAT ASSY
CAPACITOR, DRAWING
KNOB ASSY
2H01127D
6120AR2359E
4941A30005B
3721A20049H
PANEL ASSY, CONTROL
COMPRESSOR
B
C
2520UKCK2BA
2520UKHK2AA
ISOLATOR, COMP
4H00982E
O.L.P
6750U-L028A
5211A30588B
5211A20289C
5211A20498B
5211A20214L
6750U-L039A
5211A21421C
5211A29024E
5211A25028A
5210A22592L/M
TUBE ASSY, DISCHARGE SINGLE
TUBE ASSY, EVAPORATOR IN
TUBE ASSY, SUCTION SINGLE
TUBE ASSY, CAPILLARY
AIR GUIDE ASSY
D
E
5239A10002F
4900A20001A
3531A20055G
3530A20020A
4758A20008B
4758A20009A
4758A20009B
5230A20007A
5301A20011A
5300A20003A
4948A10006A
4998A10007B
DAMPER,VENTILATION
GRILLE ASSY, FRONT
GRILLE, INLET
LOUVER, HORIZONTAL
147582-1 LOUVER, VERTICAL
147582-2 LOUVER, VERTICAL
152302
753010
753011
349480
149980
346811
349600
148000
435301
354210
359012
554030
559011
W48602
130410
130900
749180
FILTER(MESH), A/C
HEATER ASSY
F
HEATER ASSY, ELECTRIC
ORIFICE
SHROUD
MOTOR ASSY, SINGLE
MOUNT, MOTOR
BRACE
4681A20044E
4681A20041M
4960A20008A
4960A20005A
4800A30002A
3530A30002A
GRILLE, REAR
EVAPORATOR ASSY, FIRST
FAN, TURBO
5421A20071E
5421A20071J
5900A20009B
CONDENSER ASSY, BENT
FAN ASSY, AXIAL
CLAMP, SPRING
BASE ASSY, SINGLE
CABINET
5403A20040M
5900AR1173A
3H02932B
5403A20040D
3041A10038D
3041A10038F
3090A20003B
4918A20001A
TRIM
—25—
Specifications and performance data subject to change without notice.
HEAT CONTROLLER, INC.
1900 WELLWORTH AVENUE • JACKSON, MICHIGAN 49203
THE QUALITY LEADER IN CONDITIONING AIR
P/No.: 3828A20040F
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