Heat Controller Inc Air Conditioner BG 81G User Manual

SERVICE MANUAL  
Thru-the-Wall Series with R-410A  
BG-81G  
BG-101G  
BG-103G  
BG-123G  
BGE-103G  
BGE-123G  
BG-143G  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
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.  
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Room Air Conditioner with R-410A  
Heat Controller, Inc.  
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  
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Room Air Conditioner with R-410A  
Heat Controller, Inc.  
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.  
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Heat Controller, Inc.  
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.  
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Room Air Conditioner with R-410A  
Heat Controller, Inc.  
3. UNIT DIMENSION  
3.1 Unit dimension:  
4. OPERATION LIMITS  
4.1 Cooling operation  
Outdoor unit air temp DB  
Indoor air temp DB  
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Room Air Conditioner with R-410A  
Heat Controller, Inc.  
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.  
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Room Air Conditioner with R-410A  
Heat Controller, Inc.  
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.  
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Heat Controller, Inc.  
Fault Code  
Defect code  
Defect explanation  
Ed  
Evaporator de-frosting defect.  
Indoor ambient temperature sensor failure in heating, cooling, dry and auto  
mode.  
AS  
HS  
LO  
HI  
DAHT sensor failure in heating mode.  
Sensor disconnection malfunction in fan only mode  
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  
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Heat Controller, Inc.  
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  
circuit to the common motor terminal.  
Figure 3: External overload  
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.  
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Heat Controller, Inc.  
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.  
Figure 4: Internal overload  
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  
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.)  
Figure 5: Run capacitor  
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  
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Heat Controller, Inc.  
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.  
Should the fan motor fail or filter become clogged, the high limit  
Figure 6: Heating element  
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.  
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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  
drain valve is installed over a drain opening in the Chassis.  
Figure 7: Drain pan valve  
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.  
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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  
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Heat Controller, Inc.  
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.  
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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:  
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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  
Display keeps showing "AS" or "HS".  
Yes  
Correct or repair the wires.  
Check the wiring.  
No  
Yes  
Check the resistance of room temperature sensor,  
Replace the room temperature sensor.  
according to the characteristic table.  
No  
Replace the main control board.  
Display keeps showing "LO" or "HI".  
Check whether the room ambient temperature is over 31C (90F) or lower than 16C (60F).  
No  
Yes  
Check the resistance of room temperature sensor,  
according to the characteristic table.  
Replace the room temperature sensor.  
No  
Replace the control board.  
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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.  
Check the power supply.  
No  
Check whether the voltage of battery is lower than 2.2V.  
No  
Check whether the failure button is locked by button holder.  
No  
Check whether the buttons on the unit work normally.  
Yes  
Replace with new batteries.  
Yes  
Replace the remote controller.  
No  
Check the wiring.  
No  
Yes  
Check whether the transformer damaged  
(open circuit or short circuit).  
Replace the transformer.  
No  
Check whether other modes work normally.  
No  
Replace the display board.  
No  
Replace the main control board.  
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Operation panel doesn’t work.  
Check the power supply.  
No  
Press the "LED" button of remote controller several times and  
check whether the problem stops.  
No  
Check the wiring of display board.  
No  
Yes  
Repair the wiring.  
Replace the display board.  
No  
Replace the main control board.  
Follow me mode doesn’t work.  
Check the power supply.  
No  
Press "follow me" button several times and check whether this mode can work.  
(Pay attention to the position of Remote controller)  
No  
Yes  
Check w hether other functions of r emote  
work or not.  
Check the batteries. Replace it if failed.  
No  
Replace the remote controller.  
No  
Replace the display board.  
No  
Replace the main control board.  
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Display keeps showing "Ed".  
Check whether the evaporator frosts.  
No  
Check whether the indoor air inlet is blocked.  
No  
Check whether the indoor ambient temperature is too low.  
No  
Check whether the indoor dust filter is too dirty.  
No  
Check whether there is too much water on the chassis.  
No  
Check the wiring of pipe temperature sensor.  
No  
Check the pipe temperature sensor.  
Replace the main control board.  
Replace the pipe temperature sensor.  
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Compressor doesn’t work.  
Check whether the indoor temperature is lower than 59F (15°C).  
No  
Check the power supply.  
No  
Check whether the voltage is too high or too low.  
No  
Check the wiring.  
No  
Check whether the compressor is in overload protection mode.  
No  
Check whether the relay of compressor in PCB works normally (Start the unit, wait 3 minutes  
for the compressor to turn on, and set the unit in the cool mode and 26F (17C). Then check the  
output of relay and replace the PCB if failed.  
No  
Remove t he overl oad p rotector a nd cool t o  
normal temperature. Then che ck whether it is  
open circuit. Replace if failed.  
Check whether the external  
protector works normally.  
Comparing with compressor specification, check the resistance of compressor.  
No  
Replace the compressor.  
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The fan motor doesn’t work.  
Check the power supply.  
Check whether the indoor (outdoor) fan is locked.  
No  
Check the wiring.  
No  
Check whether the relays on PCB for motor work normally.  
No  
No  
Comparing w ith f an m otor spec ification, check  
the resistance of fan motor.  
Replace the fan motor.  
Cooling mode doesn’t work or not cooling not enough.  
Check the operation mode.  
Check the set temperature.  
Check whether the filter is dirty/clogged.  
No  
Start t he unit in t he cool m ode and check w hether the  
temperature of compressor’s discharge pipe is between 176°F  
(80℃) to 194°F (90). If no, recharge refrigerant.  
Replace the capillary tube.  
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The air conditioner doesn’t work.  
Check the power supply.  
No  
Check the wiring.  
No  
Check whether the transformer has failed. Measure the output voltage of transformer and  
check whether it is the range from +5V to 12V. If not, replace the transformer.  
No  
Replace the PCB.  
The compressor doesn’t stop, after the set temperature is reached.  
Check the wiring.  
No  
Check whether the unit can turn off using the remote controller.  
No  
Check whether all te mperature sensors a re n ormal, comparing  
with the resistance table. If not, replace the sensor.  
No  
Replace the PCB.  
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The compressor cycles on/off frequently.  
Check whether the airflow is blocked.  
No  
Check if the fan motor isn’t working.  
No  
Check whether capacitor of compressor is working normally.  
No  
Check whether the relay of compressor on PCB works normally.  
No  
Replace the PCB.  
No  
Check whether the capillary tube is blocked.  
No  
Replace the capillary.  
No  
Replace the compressor.  
Temperature controller doesn’t work or is unstable.  
Check whether the set temperature is reached.  
No  
Test the several higher temperature set points and check whether unit works normally.  
No  
Check the wiring.  
No  
Check whether the unit is correctly installed.  
No  
Check the temperature controller. Replace if failed.  
24  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
Water drips from the unit.  
Check whether the ambient humidity is too high.  
No  
Check whether the indoor outlet airflow foam is wet if water is dripping from the louvers.  
No  
Check whether the unit is correctly installed.  
No  
Check whether the air outlet foam is installed normally.  
No  
Check whether the foam of evaporator base is damaged.  
No  
Check whether the drain passage of evaporator is blocked. Replace if failed.  
Temperature controller interrupts frequently.  
Check whether the set temperature is reached.  
No  
Check the wiring.  
No  
Check whether the compressor is in the protection mode or 3 minute time delay.  
No  
Check the specification of temperature controller. Replace if failed  
25  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
Not heating or not heating enough. (Cooling and Electric Heater)  
Check the mode.  
No  
Check whether the airflow speed is too low.  
No  
Check the heat load of the room.  
No  
Check the specification of PTC-heater.  
Fan motor speed can’t change. (Electric Control)  
Check the wiring.  
No  
Check the capacitor of fan motor. Replace if failed.  
No  
Replace the PCB.  
No  
Check the resistance of fan motor and replace the motor if failed.  
Fan motor speed can’t change. (Mechanical Control)  
Check whether the selector is damaged.  
No  
Check whether the ca pacitor of fan motor is in the rang e from 95 % to  
105% of rated capacity. Replace the capacitor if failed.  
No  
Check the resistance of fan motor and replace if failed.  
26  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
8.2 General Troubleshooting  
PROBLEM P  
OSSIBLE CAUSE  
REMARK  
Check voltage at electrical outlet. Correct if  
none.  
No power  
Check voltage at the power cord terminal.  
Replace the power cord if none.  
Connect wire. Refer to wiring diagram for  
terminal identification. Repair or replace  
loose terminal.  
Power supply cord  
Wire disconnected or  
connection loose  
Fan motor doesn’t  
run.  
Main switch failure  
Check and replace the main switch if failure.  
Test capacitor. Replace if not within +/-10%  
of manufacturer's rating. Replace if  
shorted, open or damaged.  
Capacitor (Discharge  
capacitor before testing)  
Fan blade hitting shroud or blower hitting  
scroll. Realign assembly. Check fan motor  
bearings. Replace the motor if motor shaft  
do not rotate.  
Will not rotate  
Check voltage. Call an electrician if not  
within limits.  
Test capacitor. Replace if not within +/-10%  
of manufacturer's rating.  
Fan motor runs  
intermittently  
Cycles on overload.  
Check bearings. Replace the motor if the  
fan blade cannot rotate freely.  
Pay attention to any change from high  
speed to low speed. Replace the motor if  
the speed does not change.  
Replace the fan if cracked, out of balance,  
or partially missing.  
Fan  
Replace the blower if cracked, out of  
balance, or partially missing.  
Blower  
Fan motor noise.  
Loose screws  
Tighten them.  
Replace the motor if knocking sounds continue  
when running or loose, or the motor hums or  
noise appears to be internal while running.  
Worn bearings  
Thermostat  
Compressor does  
not to stop although  
room temperature  
has reached set  
temperature.  
Check and replace the thermostat.  
27  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
PROBLEM P  
OSSIBLE CAUSE  
REMARK  
Clean or replace if restricted.  
Close if open.  
Air filter  
Vent door  
Determine if the unit is properly sized for  
the area to be cooled or heated.  
Unit undersized  
Condenser and Evaporator Clean if restricted.  
Check the fan capacitor and replace if not  
Fan motor  
within +/-10% of manufacturer’s rating.  
Take proper measures to make sure doors  
and windows are sealed well.  
Room structure  
Clean or remove if any barrier is found to  
block the inlet/outlet wind flow of the unit  
(drapes, shrubs, etc.).  
Air flow  
Add a awning if the unit is exposed to direct  
sunlight or move the unit to another window  
that’s not exposed to direct sunlight.  
Check the tubes for leakage. Reclaim the  
refrigerant, correct the leakage points and  
recharge.  
Sunlight  
Refrigerant loss  
Insufficient cooling  
or heating.  
Regulate the flow of capillary tube and  
ensure the evaporating temperature is  
appropriate, if the evaporator is frosted.  
Replace if blocked. Repair joint if leaking.  
The inlet and outlet valve of the  
Capillary tube  
Compressor  
compressor may be damaged, making the  
low pressure connected with the high  
pressure. The refrigerating system can not  
produce high pressure and low pressure.  
Replace the compressor after checking for  
the reason of failure.  
Reduce if too many (dryers, electric  
heaters, small appliances, etc.)  
Heat sources  
Drainage  
If drainage is blocked it will increase the  
efficiency in cooling mode, but will cause  
the condenser to frost in heating mode.  
Remove any obstacles.  
If the amount of the refrigerant is too large,  
making the compressor load too large.  
Reclaim and recharge the refrigerant after  
checking for the reason of failure.  
The compressor is seized. Replace after  
checking for the reason of failure.  
Refrigerant  
Stop instantly after  
startup.  
Compressor  
28  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
PROBLEM P  
OSSIBLE CAUSE  
REMARK  
Check the voltage. Call an electrician if not  
within correct limits of +/- 10% of nominal  
voltage rating required.  
No power  
Wiring  
Check terminals. Repair and correct if loose.  
Check and adjust the thermostat.  
Temperature setting  
Main switch setting  
No cooling or  
heating.  
Check and adjust the main switch setting.  
Check the resistance of reversing valve wire.  
Replace the wire if short, open or damaged.  
If the reversing valve is blocked, the heating  
mode will not operate. Replace the reversing  
valve after checking the reason for failure.  
Check voltage. Call Supply Authority if not  
within limits of +/- 10% of nominal voltage  
rating required.  
Reversing valve wire  
Reversing valve  
Voltage  
Wiring  
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.  
Compressor will not Main switch failure  
run while fan motor  
Check and replace the main switch if failed.  
Check the capacitor.  
runs.  
Capacitor (Discharge  
Replace if not within +/-10% of  
capacitor before testing)  
manufacturer’s rating. Replace if shorted,  
open, or damaged.  
Check the thermostat setting if not at the  
coolest (in cooling mode) or the warmest (in  
heating mode). Try adjusting these settings.  
Check the compressor for open circuit or  
ground. If open or grounded, replace the  
compressor.  
Thermostat  
Compressor  
If copper tubing is rubbing against the cabinet  
and vibrating while operating, remove the  
cabinet and carefully rearrange tubing to not  
contact cabinet, compressor, shroud and barrier.  
The input power supply voltage is too low or  
not within +/- 10% of nominal voltage rating  
required. Call an electrician if not within limits.  
When the outdoor temperature is too high,  
the compressor will go into a protection  
mode or 3 minute time delay.  
Excessive noise.  
Copper tubing  
Power supply  
The unit starts and  
stops frequently.  
Outdoor temperature  
29  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
8.3 Troubleshooting Cooling  
PROBLEM  
POSSIBLE CAUSE  
Low voltage.  
TO CORRECT  
Compressor  
does not run.  
Check for voltage at compressor. 115 volt  
and 230 volt units will operate at 10%  
voltage variance  
Thermostat not set cold enough  
or inoperative.  
Set thermostat to coldest position. Test  
thermostat and replace if inoperative.  
Compressor hums but cuts off on Hard start compressor. Direct test  
overload.  
compressor. If compressor starts, add  
starting components.  
Open or shorted compressor  
windings.  
Check for continuity and resistance.  
Open overload.  
Test overload protector and replace if  
inoperative.  
Test capacitor and replace if inoperative.  
Test for continuity in all positions.  
Replace if inoperative.  
Open capacitor.  
Inoperative system switch.  
Broken, loose or incorrect wiring. Refer to appropriate wiring diagram to check  
wiring.  
Fan motor  
Inoperative system switch.  
Test switch and replace in inoperative.  
does not run.  
Broken, loose or incorrect wiring. Refer to applicable wiring diagram.  
Open capacitor.  
Test capacitor and replace if inoperative.  
Test switch and replace if inoperative.  
Test fan motor and replace if inoperative.  
(Be sure internal overload has had time to  
reset.)  
Fan speed switch open.  
Inoperative fan motor.  
Does not  
Undersized unit.  
Refer to Sizing Charts.  
cool, or cools  
only slightly.  
Thermostat open or inoperative.  
Set to coldest position. Test thermostat and  
replace if necessary.  
Dirty filter.  
Clean as recommended in Owner’s Manual.  
Use steam or detergents to clean.  
Dirty or plugged condenser or  
evaporator coil.  
Poor air circulation in area being Adjust discharge air louvers. Use high fan  
cooled.  
speed.  
Fresh air or exhaust air door  
open on applicable models.  
Low capacity – undercharge.  
Compressor not pumping  
properly.  
Close doors. Instruct customer on use of this  
feature.  
Check for leak and make repair.  
Check amperage draw against nameplate. If  
not conclusive, make pressure test.  
30  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
PROBLEM  
POSSIBLE CAUSE  
TO CORRECT  
Unit does  
not run.  
Fuse blown or circuit tripped.  
Replace fuse, reset breaker. If repeats,  
check fuse or breaker size. Check for shorts  
in unit wiring and components.  
Power cord not plugged in.  
System switch in "Off" position.  
Inoperative system switch.  
Set switch correctly.  
Test for continuity in each switch position.  
Check wiring and connections.  
Loose or disconnected wiring at Reconnect per wiring diagram.  
switch or other components.  
Thermostat  
does not  
Thermostat contacts stuck.  
Replace thermostat.  
Thermostat set at coldest point.  
Turn to higher temperature setting to see if  
the unit cycles off.  
turn unit off.  
Incorrect wiring.  
Refer to appropriate wiring diagram.  
Unit undersized for area to be Refer to Sizing Chart.  
cooled.  
Evaporator  
coil freezes  
up.  
Dirty filter.  
Clean as recommended in Owner’s Manual.  
Restricted air flow.  
Check for dirty or obstructed coil - clean as  
required or remove obsticales.  
Inoperative thermostat.  
Test for shorted thermostat or stuck  
contacts.  
Short of refrigerant.  
De-ice coil and check for leak.  
Test fan motor and replace if inoperative.  
Inoperative fan motor.  
Partially restricted capillary.  
De-ice coil. Check temperature differential  
across coil. Touch test coil return bends for  
same temperature. Test for low running  
current.  
Compressor Excessive heat load.  
runs  
Unit undersized. Test cooling performance  
of unit. Replace with larger unit.  
continually,  
does not  
Restriction in line.  
Check for partially iced coil. Check  
temperature split across coil.  
cycle off.  
Refrigerant leak.  
Check for oil at silver soldered connections.  
Check for partially iced coil. Check split across  
coil. Check for low running amperage.  
Check operation of thermostat. Replace if  
contacts remain closed.  
Thermostat contacts stuck  
Thermostat incorrectly wired.  
Refer to appropriate wiring diagram.  
31  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
PROBLEM  
POSSIBLE CAUSE  
TO CORRECT  
Compressor Overload inoperative. Opens too  
Check operation of unit. Replace overload if  
system operation is satisfactory.  
attempts to  
start, or runs  
for short  
soon.  
Compressor attempts to start  
before system pressures are  
equalized.  
Allow a minimum of 2 minutes for pressures  
to equalize before attempting to restart.  
periods only.  
Cycles on  
overload.  
Low or fluctuating voltage.  
Check voltage with unit operating. Check for  
other appliances on circuit. Air conditioner  
should be on separate circuit for proper  
voltage, and be fused separately.  
8.4 Troubleshooting Heating (Cooling/Electric Heater Models)  
PROBLEM P  
Fan  
OSSIBLE CAUSE  
TO CORRECT  
Heater relay or contactor coil open. Check continuity of coil. Inspect, test  
continuity with ohmmeter.  
Operates –  
heating  
Heater relay or contactor stuck  
open, pitted or burned.  
High limit control open.  
Open thermal fuse.  
Check continuity – if open, replace.  
element does  
not come on.  
Check continuity. Check reason for failure.  
Check voltage across heater terminals.  
Check amperage draw of heater.  
Open or shorted element.  
Loose connections.  
Tighten all terminals.  
Heating  
Restricted filter.  
Clean as recommended in Owner’s Manual.  
Control is set to open at 155°F± 5°F (68.3°C  
+/- 15°C) and close at 130°F± 8°F (54.4°C +/-  
13°C). If cycling prematurely, replace control.  
Check position of fresh air door control slide.  
Adjust cable if door does not close properly.  
Check continuity of fan relay.  
inadequate.  
Cycling high limit control.  
Exhaust or fresh air door open.  
Fan operates Fan relay contacts open.  
in "Constant"  
NOTE: Some models have fan relay energized  
during heating cycle while others do not.  
Check connections on system switch and  
fan relay.  
speed, but  
not in "Auto"  
Inoperative system switch.  
Loose connection.  
Check connections on system switch and  
fan relay.  
Long "off"  
and "on"  
cycles.  
Heat anticipator (resistor)  
shorted.  
Disconnect power to unit. Remove resistor  
from thermostat bulb block. Plug in unit and  
allow to operate. Feel resistor for heat. If no  
heat is felt, replace resistor.  
Defective temperature sensor.  
Replace temp. sensor and check operation.  
32  
Service Manual  
Room Air Conditioner with R-410A  
Heat Controller, Inc.  
PROBLEM  
POSSIBLE CAUSE  
Defective motor.  
Open or shorted capacitor.  
TO CORRECT  
Check and replace.  
Replace capacitor and check.  
Fan motor  
does not  
operate in  
"Constant"  
speed or  
Condenser fan frozen to Chassis. Check if drain pan valve is open. If not,  
replace.  
Loose connections.  
Check all connections. Check voltage to fan  
motor.  
"Auto” speed.  
Unit does not Fuse link.  
heat.  
Check fuse link for continuity. If defective,  
replace.  
Heating element shorted.  
Check amperage draw of element. If no  
amperage, replace.  
Incorrect wiring.  
Check voltage to element. If voltage is okay,  
check wiring.  
Heat relay or heater contactor coil Defective coil. Test coil for continuity.  
open.  
33  
Service Manual  
Heat Controller, Inc.  
9. INSTALLATION ACCESSORYRLooImSATir Conditioner with R-410A  
Part list for CD Series:  
No.  
1
Part No.  
Part Name  
Quantity  
202921890000  
201121890009  
201121890006  
201121890007  
201121890008  
Grille(Aluminum)  
Grille(plastic)  
1
1
1
2
2
2
3
Stuffer seal  
4
Trim Frame(side legs)  
Trim Frame(top & bottom legs)  
5
10. CHARACTERISTIC OF TEMPERATURE SENSOR  
Temp.°F (°C)  
14 (-10)  
16 (-9)  
Resistance KΩ  
62.2756  
58.7079  
56.3694  
52.2438  
49.3161  
46.5725  
44.0000  
41.5878  
39.8239  
37.1988  
35.2024  
33.3269  
31.5635  
29.9058  
28.3459  
26.8778  
25.4954  
24.1932  
22.5662  
21.8094  
20.7184  
19.6891  
18.7177  
17.8005  
16.9341  
16.1156  
15.3418  
Temp.°F (°C)  
62.6 (17)  
64.4 (18)  
66.3 (19)  
68 (20)  
Resistance KΩ  
14.6181  
13.918  
13.2631  
12.6431  
12.0561  
11.5000  
10.9731  
10.4736  
10.0000  
9.5507  
9.1245  
8.7198  
8.3357  
7.9708  
7.6241  
7.2946  
6.9814  
6.6835  
6.4002  
6.1306  
5.8736  
5.6296  
5.3969  
5.1752  
4.9639  
4.7625  
4.5705  
Temp.°F (°C)  
111.2 (44)  
113 (45)  
Resistance KΩ  
4.3874  
4.2126  
4.0459  
3.8867  
3.7348  
3.5896  
3.4510  
3.3185  
3.1918  
3.0707  
2.959  
18 (-8)  
114.8 (46)  
116.6 (47)  
118.4 (48)  
120.2 (49)  
122 (50)  
194. (-7)  
21.2 (-6)  
23 (-5)  
69.8 (21)  
71.6 (22)  
73.4 (23)  
75.2 (24)  
77 (25)  
25 (-4)  
26.6 (-3)  
28.4 (-2)  
30.2 (-1)  
32 (0)  
123.8 (51)  
125.6 (52)  
127.4 (53)  
129.2 (54)  
131 (55)  
78.8 (26)  
80.6 (27)  
82.4 (28)  
84.2 (29)  
86 (30)  
33.8 (1)  
35.6 (2)  
37.4 (3)  
39.2 (4)  
41 (5)  
2.8442  
2.7382  
2.6368  
2.5397  
2.4468  
2.3577  
2.2725  
2.1907  
2.1124  
2.0373  
1.9653  
1.8963  
1.830  
132.8 (56)  
134.6 (57)  
136.4 (58)  
138.2 (59)  
140 (60)  
87.8 (31)  
89.6 (32)  
91.4 (33)  
93.2 (34)  
95 (35)  
42.8 (6)  
44.6 (7)  
46.4 (8)  
48.2 (9)  
50 (10)  
141.8 (61)  
143.6 (62)  
145.4 (63)  
147.2 (64)  
149 (65)  
96.8 (36)  
98.6 (37)  
100.4 (38)  
102.2 (39)  
104 (40)  
105.8 (41)  
107.6 (42)  
109.4 (43)  
51.8 (11)  
53.6 (12)  
55.4 (13)  
57.2 (14)  
57 (15)  
150.8 (66)  
152.6 (67)  
154.4 (68)  
156.2 (69)  
158 (70)  
1.7665  
1.7055  
1.6469  
60.8 (16)  
34  
03/2010  

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