HEAT CONTROLLER, INC.
Through-The-Wall
Air Conditioning
Model: BG-103A
Service Manual
CAUTION
-Before servicing the unit, read the "safety precautions" in this manual.
-Only for authorized service personnel.
1.3 SPECIFICATIONS
1.3.1 FOR BG-103A
Model
BG-103A
REMARK
Items
1Ø, 230/208V, 60Hz
POWER SUPPLY
10,500 / 10,000
COOLING CAPACITY
INPUT
(Btu/h)
1,230 / 1,170
(W)
5.7 / 6.0
8.5 / 8.5
RUNNING CURRENT
E.E.R
(A)
(Btu/W.h)
INDOOR(°C)
OUTDOOR(°C)
26.7(DB) 19.4(WB)
OPERATING
35(DB) 23.9(WB)
TEMPERATURE
475g(16.8OZ)
REFRIGERANT (R-22) CHARGE (g)
EVAPORATOR
3ROW 12STACKS
2ROW 17STACKS, L-BENDING TYPE
TURBO FAN
LOUVERED-FIN TYPE
CONDENSER
FAN, INDOOR
PROPELLER TYPE FAN WITH SLINGER-RING
3/3
FAN, OUTDOOR
FAN SPEED (FAN/COOLING/HEATING)
FAN MOTOR
4POLES
ELECTRIC
OPERATION CONTROL
ROOM TEMP. CONTROL
AIR DIRECTION CONTROL
THERMISTOR
VERTICAL LOUVER(RIGHT & LEFT)
HORIZONTAL(UP & DOWN)
TOP-DOWN
CONSTRUCTION
EXTERNAL OVERLOAD PROTECTOR
INTERNAL THERMAL PROTECTOR
1.4m (3WIRES WITH GROUNDING)
ATTACHMENT PLUG(CORD-CONNECTED TYPE, LCDI)
SPLASHED BY FAN SLINGER
80/36
PROTECTOR
COMPRESSOR
FAN MOTOR
POWER CORD
DRAIN SYSTEM
NET WEIGHT
(lbs/kg)
(inch)
(mm)
(inch)
(mm)
(inch)
(mm)
24 x 14 13/32 x 20 3/32
DIMENSION
610 x 366 x 499
(W x H x D)
25 7/8 x 15 17/32 x 16 23/32
656 x 394 x 425
SLEEVE DIMENSION
(W x H x D)
SLEEVE DEPTH
WITH FRONT GRILLE
20 1/2
521
—3—
1.4 FEATURES
• Designed for cooling only.
• Side air-intake, side cooled-air discharge.
• Built in adjustable THERMISTOR and 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
FAN SPEED
• Every time you push this button, it advances the setting as follows: {High ¡ Low ¡ Med ¡ High}
REMOTE CONTROL SIGNAL RECEIVER
'
Cool
F
F1 LOW
F2 MED
F3 HIGH
TEMPERATURE SETTING
Energy
Saver
• Use this button to automatically control the temperature of the room.
The temperature can be set within a range of 60°F to 86°F by increments of
1°F.
Fan
TEMP
Timer
• The setting appears in the display.
FAN
MODE
TIMER
POWER
POWER
SPEED
• To turn the air conditioner ON, push this button.
To turn the air conditioner OFF, push the button again.
• This button takes priority over any other button.
• When you first turn it on, the unit is in cool mode, High fan speed,
Temperature setting at 72°F.
TIMER
- SHUT-OFF TIME
• You will usually use shut-off time while you sleep.
• If unit is running, use Timer to set number of hours until shut-off.
• For your sleeping comfort, once Time is set, the Temperature setting will raise 2°F after 30 min., and once again after another 30 min.
• Push Timer button to advance setting from 1Hour ¡ 2Hours ¡ ... ¡ 12Hours maximum.
- START TIME
• If unit is off, use Timer to set number of hours before unit starts.
• Push Timer button to advance setting from 1Hour ¡ 2Hours ¡ ... ¡ 12Hours maximum.
MODE
-
Push this button to shift mode of operation from COOL ¡ ENERGY SAVER ¡ FAN.
- COOL:
• Fan runs continually for normal cooling operation.
- ENERGY SAVER:
• The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and the unit will check the room air
temperature to determine if cooling is needed.
- FAN:
• Fan-only operation.
• VENTILATION
Push the lever to the "CLOSE" position to cool, heat or recirculate room air only.
Pull the lever to the "OPEN" position to exhaust smoke or stale air from the room.
This feature is best used in conjunction with the FAN ONLY position.
CAUTION
When the air conditioner has been operating in the
cooling and is turned off or set to the fan only position,
wait at least 3 minutes before resetting to the cooling
operation again.
PULL OPEN / PUSH CLOSE
—4—
2. DISASSEMBLY INSTRUCTIONS
— Prior to disassembling the unit, make sure that the POWER is off and the power cord is unplugged from the
wall receptacle.
2.1 MECHANICAL PARTS
'
F
W
LO
D
F1 ME
F3
F
2
H
I
G
ool
EMP
N
R
E
C
T
y
W
O
P
n
e
rg
e
r
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a
v
S
er
Tim
n
A
PEE
Fa
F
S
D
R
E
M
TI
E
D
O
M
2.1.1 FRONT GRILLE
1. Open the inlet grille downward.
2. Remove the screw which fastens the front grille.
3. Pull the front grille from the right side.
4. Remove the front grille. (See Fig. 1)
5. Re-install the component by referring to the
removal procedure.
Cool
F
1
L
O
W
'
F
F2 MED
F3 HIGH
Energy
Saver
Fan
TEMP
Timer
F
AN
MODE
TIMER
POWER
SPEED
Figure 1
2.1.2 CABINET
1. After disassembling the FRONT GRILLE, remove
the 6 screws which fasten the cabinet at the both
sides and the top. (See Fig. 2)
Keep these for later use.
C
o
o
l
E
S
n
er
g
y
av
er
F
a
n
F1
LO
F2
W
ME
F3
D
H
IG
H
T
im
e
'
r
F
M
O
D
TEMP
E
T
IM
E
R
F
A
SPEED
N
P
O
W
E
R
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)
C
o
o
l
Ener
Sa
gy
ver
F
a
n
F
1
M
L
F
O
W
2
F
E
D
3
H
IG
H
T
im
e
'
r
F
MODE
T
E
M
P
TIMER
F
E
A
S
N
P
E
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)
WER
Figure 3
(Refer to the circuit diagram found on pages 25 in
this manual and on the control box.)
—5—
2.2 AIR HANDLING PARTS
2.2.1 ORIFICE, 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)
Cool
E
S
ne
rg
y
av
er
Fa
n
F1
LO
F2
W
M
F3
ED
H
IG
H
Time
r
'
F
M
O
D
T
E
E
M
P
TI
M
E
R
F
E
A
S
N
P
E
D
P
O
W
E
R
4. Move the evaporator sideward carefully.
Figure 4
5. Remove the orifice. (See Fig. 5)
C
o
o
l
E
S
ne
rg
y
av
er
an
F
F1
LO
F2
W
M
F3
ED
HIG
H
T
im
er
'
F
M
O
D
T
EMP
E
T
IM
E
R
F
E
A
S
N
P
E
D
P
O
W
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R
Figure 5
8. Using handheld pliers, remove the clamp which
secures the turbo fan. (See Fig. 6)
C
o
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l
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S
ne
rg
y
av
er
an
F
F1
F3 ME
HIG
F
2
L
O
W
D
H
T
im
er
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F
M
O
D
T
E
EM
P
T
IM
E
R
F
E
A
E
S
N
P
D
P
O
W
E
R
Figure 6
9. Remove the turbo fan with pliers or your hand,
without touching blades. (See Fig. 7)
10. Re-install the components by referring to the
removal procedures, above.
C
o
o
l
E
S
ne
rg
y
av
er
an
F
F1
F
2
L
O
W
F
3
M
E
D
HIG
H
T
im
er
'
F
M
O
D
TEM
N
E
P
T
IM
E
R
F
E
A
E
S
P
D
P
O
W
E
R
Figure 7
2.2.2 FAN
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the brace.
(Refer to section 2.2.1)
3. Remove the 7 screws which fasten the condenser.
4. Move the condenser sideways carefully.
5. Using handheld pliers, remove the clamp which
secures the fan.
6. Remove the fan. (See Fig. 8)
7. Re-install the components by referring to the
removal procedures, above.
Figure 8
—6—
2.2.3 SHROUD
1. Remove the fan. (Refer to section 2.2.2)
2. Remove the shroud. (See Fig. 9)
3. Re-install the components by referring to the
removal procedures, above.
2.3 ELECTRICAL PARTS
2.3.1 MOTOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the clamp cord and disconnect the wire
housing in control box. (Refer to 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 procedures, above.
2.3.2 COMPRESSOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Discharge the refrigerant system using a FreonTM
Recovery System.
Figure 10
If there is no valve to attach the recovery system
to, 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.
7. Re-install the components by referring to the
removal procedures, above.
Figure 11
2.3.3 CAPACITOR
1. Remove the control box. (Refer to section 2.1.3)
2. Remove the 1 screw
3. Open the control box
4. Disconnect all the leads on the capacitor terminals.
5. Re-install the components by referring to the
removal procedures, above.
C
o
o
l
E
S
n
a
e
v
rg
e
y
r
F
a
n
F1 LO
W
F2 MED
F3 HIGH
T
i
m
e
'
r
F
M
O
DE
TE
M
P
TIM
ER
FA
SPEE
N
D
P
O
W
E
R
Figure 12
—7—
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 Base
pan.
4. Disconnect 2 receptacles.
5. Remove a screw which fastens the clip cord.
6. Pull the power cord. (See Fig. 13)
7. Re-install the components by referring to the
removal procedure, above.
(Use only one ground-marked hole, , for ground
connection.)
8. If the supply cord of this appliance is damaged, it
must be replaced with the factory-authorized and
specified cord.
Figure 13
C
ool
Ener
Sa
gy
ver
Fa
n
F1 LO
F2 MED
F3 HIGH
W
2.3.5 THERMISTOR
Tim
er
'
F
MODE
TEMP
TIMER
1. Remove the control box. (Refer to section 2.1.3)
2. Unfold the control box. (Refer to section 2.3.3)
3. Disconnect all the leads of thermistor terminals.
4. Remove the thermistor. (See Fig. 14)
5. Re-install the components by referring to the
removal procedures, above.
FA
N
SPEED
PO
WER
Figure 14
—8—
2.4 REFRIGERATION CYCLE
CAUTION
TM
Discharge the refrigerant system using a 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.
(Refer to section 2.2.1)
3. Remove the 7 screws which fasten the condenser.
4. After discharging the refrigerant completely into a
FreonTM Recovery System, unbraze the
interconnecting tube at the condenser
connections.
5. Remove the condenser.
6. Re-install the components by referring to the notes
(See Fig. 15)
Figure 15
2.4.2 EVAPORATOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Discharge the refrigerant completely – into a
FreonTM Recovery System.
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.
C
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o
l
E
S
n
a
e
v
rg
y
e
r
F
a
n
F1
LO
W
F
2
M
E
F3
D
HIGH
T
im
e
'
r
F
M
O
D
E
TEMP
N
T
IM
E
R
F
EED
A
SP
P
O
W
E
R
5. Remove the evaporator.
6. Re-install the components by referring to the notes
(See Fig. 16)
Figure 16
2.4.3 CAPILLARY TUBE
1. Remove the cabinet. (Refer to section 2.1.2)
2. After discharging the refrigerant completely – into
a FreonTM Recovery System, unbraze the
interconnecting tube at the capillary tube.
3. Remove the capillary tube.
4. Re-install the components by referring to the notes.
—9—
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. 17B.
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.
17A.
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. 17B.
Open valve C.
Discharge the line at the manifold connection.
5) The system is now ready for final charging.
—10—
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 17A-Pulling Vacuum
Figure 17B-Charging
—11—
3. INSTALLATION
3.1 INSTALLATION REQUIREMENTS
INSTALLATION HARDWARE
If you use an existing wall sleeve, you should measure its
dimensions.
2
4
1
5
Install the new air conditioner according to these installation
instructions to achieve the best performance. All wall sleeves
used to mount the new air conditioner must be in good
structural condition and have a compatible rear grille in order
to securely attach the new air conditioner. (FIG. 18A)
With the FRIEDRICH USC sleeve, you can maintain the
best performance of the new air conditioner. (FIG. 18B)
2 Size options
6
8
3
9
7
2 Size options
20-3/32"
(511 mm)
24"(610 mm)
ITEM
NAME OF PARTS
PLASTIC GRILLE
VERTICAL INSULATION STRIP
AROUND INSULATION STRIPS
HORIZONTAL INSULATION STRIP
SUPPORT BLOCK
BAFFLE
TRIM FRAME
SHIM
Q'TY
1
1
2
1
2
1
2
2
4
14-13/32"
(366 mm)
18-15/32"(468 mm)
Air Conditioner
FIG. 18A
PLASTIC NUTS AND WASHER SCREWS
25-7/8"
(656 mm)
CAUTION
To avoid risk of personal injury, property damage, or
product damage due to the weight of this device and sharp
edges that may be exposed:
15-17/32"
(394 mm)
• Air conditioners covered in this manual pose an
excessive weight hazard. Two or more people are
aluminum metal grille
16-23/32"
(425 mm)
needed
to
move
and
install
the
unit.
To prevent injury or strain, use proper lifting and carrying
techniques when moving unit.
FRIEDRICH USC Wall Sleeve
FIG. 18B
• Carefully inspect location where air conditioner will be
installed. Be sure it will support the weight of the unit
over an extended period of time.
ELECTRICAL SERVICE
• Handle air conditioner with care. Wear protective gloves
whenever lifting or carrying the unit. AVOID the sharp
metal fins of front and rear coils.
Check your available electrical service. The power supply
available must be the same as that shown on the unit
nameplate (found on left side of cabinet).
• Make sure air conditioner does not fall during installation.
All models are equipped with a 3-prong service plug to
provide proper service and safe positive grounding. Do not
change plug in any way. Do not use an adapter plug. If your
present wall outlet does not match your plug, call a qualified
electrician to make the necessary corrections. SAVE
CARTON for storage and this OWNER'S MANUAL for future
reference. The carton is the best way to store unit during
winter or when not in use.
REQUIRED TOOLS:
• 3/8-inch open end
wrench or adjustable
wrench
• 1/4-inch hex socket
and ratchet
• Tape measure
• Electric drill
• Tight Fitting gloves
• Standard screwdriver
• Phillips screwdriver
• Pliers
• Sharp knife
• 1/4-inch drill bit
—12—
NOTE: All wall sleeves used to mount the new Air
Conditioner must be in sound structural condition and have a
rear grille that securely attaches to sleeve, or rear flange that
serves as a stop for the Air Conditioner.
3.2 INSTALLATION
CAUTION
Installing the FRIEDRICH USC sleeve ensures
optional performances of the unit.
Remove old air conditioner from existing wall sleeve.
2
If you decide to keep the existing wall sleeve, you have
to redirect the louvers at the back of the wall sleeve.
Refer to FIG. 23 on p15. The use of pliers is
recommended. If you DO NOT redirect, you run the risk
of poor performance or premature product failure. This
is not covered under the terms of the FRIEDRICH
warranty.
Clean the interior of an existing sleeve.
(Do not disturb seals.)
3
Wall sleeve must be securely fastened in wall before
installing the air conditioner. Use the nails or screws
through sleeve into wall, if needed. Repaint sleeve if
needed.
4
Prepare the wall sleeve for installation of the unit. If you
plan to use your existing wall sleeve, and it is not
FRIEDRICH, use procedure B or C below.
• Pick a location which will allow the conditioned air to blow
into the area you want. Good installation with special
attention to the proper position of the unit will lessen the
chance that service will be needed.
5
Procedure
Brand
Depth(inches)
A(page 16)
FRIEDRICH USC
White-Westinghouse
Frigidaire Carrier
(52F series)
General Electric
/Hotpoint
16-23/32
ITEMS IN INSTALLATION HARDWARE
You may not need all parts in the kit. Discard unused parts
16, 17-1/2
or 22
ITEM (inches)
Qty.
1
1
1
1
1
2
1
2
B
Plastic grille
263/ x 161/
2
4
(pages 17~18)
16-7/8
Vertical insulation strip
159/16 x 13/ x 13/
8
8
671/ x 13/ x 25
/
8
8
32
Whirlpool
17-1/8 or 23
Around Insulation Strips
5927/32 x 13/ x 13/
8
8
Carrier (51S series)
Fedders/Emerson
Friedrich WSC
Emerson/Fedders
18-5/8
16-3/4
or 19-3/4
15
Horizontal Insulation Strip
Support Block
Baffle
237/32 x 13/ x 13/16
8
C
13/ x 13/ x 45/
4
8
16
(pages 19)
14 x 41/2 x 1/
8
Shim
1113
/
16 x 1 x 3
/
4
Trim Frame
Washer Screw
Nuts(Plastic)
Grille Rear
2
4
4
1
Install new unit into wall sleeve.
6
CAUTION: When installation is completed, replacement unit
MUST have a rearward slope as shown. To achieve 1/4"
slope, remove the backing from the 11-13/16" shim strips and
attach them as shown below in Fig. 19. Place the higher
portion of shim to the front of the rib on base of wall sleeve.
HOW TO INSTALL
Before installing the unit, identify the existing wall sleeve
from the list below.
1
Wall Sleeve Dimensions (inches)
Brand
1" high
3
/ " High
4
Width
Height
Depth
White-Westinghouse
Frigidaire
Carrier (52F series)
General Electric
/Hotpoint
UNIT
Wall Sleeve
16, 17-1/2
or 22
25-1/2
15-1/4
26
25-7/8
27
15-5/8
16-1/2
16-3/4
16-7/8
FRONT
1/4"
Shim
17-1/8
or 23
16-3/4
or 19-3/4
16-23/32
15
Whirlpool
Fedders/Emerson
Friedrich WSC
FRIEDRICH USC
Emerson/Fedders
Carrier (51S Series)
6"
6"
SHIM PLACEMENT
UNIT INSTALLATION
25-7/8
26-3/4
25-3/4
15-17/32
15-3/4
16-7/8
FIG. 19
18-5/8
—13—
PROCEDURE A
Install the new unit into the wall sleeve.
If you are using the new sleeve (optionally
4
5
1
supplied with your unit),skip to step 3.
Toassembletrim,tpthetabofeachpiece
Otherwise, install the plastic grille from the kit.
Cut the plastic grille to 25-1/2" wide and
15-1/4" high. Place the plastic grille to the
inside of the wall sleeve at the rear flange.
into the slot of the other piece as shown below.
Slide trim over the front of the air conditioner
until trim is flush with sleeve as shown below.
FIG.20
Fasten the 4 washer screws to secure the grille
to the wall sleeve. If you need plastic nuts to
Trim (2 ea)
2
mount plastic grille to the inside of the wall
sleeve, there are plastic nuts in the installation
kit. The nuts are installed from the inside of the
sleeve and are pressing into the square holes
of the rear flanges.Fasten the bracket to the
upside of the wall sleeve using the washer
screw. The bracket prevents the unit from
leaving the sleeve.
Wall
Bracket
Bracket
FIG.23
or
Fasten the screws and the bracket
FIG.21
CAUTION
Remove the backing from the Vertical
• Air conditioners covered in this manual pose an
excessive weight hazard. Two or more people are
needed to move and install the unit.
To prevent injury or strain, use proper lifting and
carrying techniques when moving unit.
• When handling the air conditioner, be careful to avoid
cuts from sharp metal fins on front and rear coils.
3
Insulation strip 159/16 x 13/ x 13/ and attach that
8
8
to the inside right of the sleeve as shown
below. Remove the backing from the Around
Insulation strip 671/ x 13/ x 25/32 and attach that
8
8
to the inside front of the sleeve as shown
below.
Indoor
Outdoor
• Make sure air conditioner does not fall during
removal.
• If unit does not operate after installation check, to be
sure the circuit interrupter has not been tripped. Refer
to the Troubleshooting guide for reset procedure.
9 1/2"
6"
FIG. 22
—14—
Remove the backing from the Vertical Insulation
strip 159/16 x 13/8 x 13/8 and attach that to the
inside right of the sleeve as shown below.
Remove the backing from the Around Insulation
strip 671/8 x 13/8 x 25/32 and attach that to the
inside front of the sleeve as shown below.
PROCEDURE B
4
Redirect the louvers at the back of the wall
1
sleeve to 60° angle as shown in the FIG 24. The
use of pliers is recommended.
7 3/
"
32
Indoor
Outdoor
60°
60°
Rear Louvers
(Top View)
9 1/2"
6"
FIG.24
FIG. 27
If the wall sleeve already has a rear grille, skip
to step 4. If the wall sleeve does not have a rear
grille or louvered panel, install the plastic grille
from the kit. Cut the plastic grille to 25-1/2" wide
and 15-1/4" high. Place the plastic grille to the
inside of the wall sleeve at the rear flange.
If the depth of your existing wall sleeve is less
than or equal to 18", skip to step 7. Otherwise,
2
5
cut the baffles and the support blocks according
to length "A" in the table below.
A
Length "A"
(inches)
Depth"D" of the existing
wall sleeve (inches)
Support
Block
3/4
1-3/4
4
18
D
18-5/8
19-3/4
22
18-5/8
D
Baffle
19-3/4
D
A
FIG. 28
Place the plastic grille
FIG.25
Fasten the 4 washer screws to secure the grille
to the wall sleeve. If you need plastic nuts to
mount plastic grille to the inside of the wall
sleeve, there are plastic nuts in the installation
kit. The nuts are installed from the inside of the
sleeve and are pressed into the square holes of
the rear flanges.Fasten the bracket to the
upside of the wall sleeve using the washer
screw. The bracket prevents the unit from
leaving the sleeve.
3
Bracket
Bracket
or
FIG. 26
Fasten the screws and the bracket
—15—
PROCEDURE B CONTINUED
Remove the backing from the support blocks and attach
them to the inside of the wall sleeve as shown FIG 29.
Slide the baffle into slots of the support blocks.
6
(
7 3
/
")
32
Wall
Wall
Sleeve
Baffle
Front
Support
Block
FIG. 29
Install the new unit into the wall sleeve.
7
8
Assemble trim as described in Step 6,
Procedure A.
CAUTION
• Air conditioners covered in this manual pose an
excessive weight hazard. Two or more people are
needed to move and install the unit.
To prevent injury or strain, use proper lifting and carrying
techniques when moving unit.
• When handling the air conditioner, be careful to avoid
cuts from sharp metal fins on front and rear coils.
• Make sure air conditioner does not fall during removal.
• If unit does not operate after installation check, to be sure
the circuit interrupter has not been tripped. Refer to the
Troubleshooting guide for reset procedure.
—16—
Remove the backing from the Horizontal Insulation strip
237/32 x 13/8 x 13/16 and attach that to the inside right of the
sleeve as shown below. Remove the backing from the
Around Insulation strip 5927/32 x 13/8 x 13/8 and attach that
to the inside front of the sleeve as shown below.
3.5 PROCEDURE C
4
Redirect the louvers at the back of the wall sleeve to 60°
angle as shown in the FIG 30. The use of pliers is
1
recommended.
7 13
/
"
16
Indoor
Outdoor
60°
60°
Rear Louvers
Around Insulation
Horizontal Insulation
(Top View)
8 1/2"
FIG. 30
FIG. 33
If the wall sleeve already has a rear grille, skip to step 4. If the
wall sleeve does not have a rear grille or louvered panel, install
the plastic grille from the kit. Cut the plastic grille to 26-1/2"
wide and 15-1/2" high or to the sleeve dimensions. Place the
plastic grille to the inside of the wall sleeve at the rear flange.
2
If the depth of your existing sleeve is less than or equal
to 18”, skip to step 7. Otherwise, cut the baffles and the
support blocks according to Length "A" in the table
below.
5
A
Length "A"
(inches)
Depth"D" of the existing
wall sleeve (inches)
Support
Block
18-5/8
3/4
1-3/4
4
18
D
18-5/8
D
19-3/4
Baffle
19-3/4
D
22
A
FIG. 34
Remove the backing from the support blocks and attach
them to the inside of the wall sleeve as shown FIG 35.
Slide the baffle into slots of the support blocks
FIG. 31
Place the plastic grille
6
Fasten the 4 washer screws to secure the grille to the
wall sleeve. If you need plastic nuts to mount plastic grille
to the inside of the wall sleeve, there are plastic nuts in
the installation kit. The nuts are installed from the inside
of the sleeve and are pressed into the square holes of
the rear flanges. Fasten the bracket to the upside of the
wall sleeve using the washer screw. The bracket
prevents the unit from leaving the sleeve.
3
(7 3/32")
Wall
Baffle
Wall
Sleeve
Front
Support
Block
Bracket
Bracket
FIG. 35
or
FIG. 32
Fasten the screws and the bracket
—17—
PROCEDURE C CONTINUED
CAUTION
To achieve rearward slope for unit draining,
remove the backing from the 1113/16" shim
7
• Air conditioners covered in this manual pose an
excessive weight hazard. Two or more people are
needed to move and install the unit.
To prevent injury or strain, use proper lifting and
carrying techniques when moving unit.
strips and attach them as shown below in Fig.
37. The higher portion of shim is to be placed
in front of the rib on the base of wall sleeve.
• When handling the air conditioner, be careful to avoid
cuts from sharp metal fins on front and rear coils.
1" high
3/4" High
• Make sure air conditioner does not fall during
removal.
FIG. 36
• If unit does not operate after installation check, to be
sure the circuit interrupter has not been tripped. Refer
to the Troubleshooting guide for reset procedure.
Shim (2EA)
6"
6"
FIG. 37
Install the new unit into the wall sleeve
8
Assemble trim as described in Step 6,
Procedure A.
9
—18—
4. TROUBLESHOOTING GUIDE
4.1 OUTSIDE DIMENSIONS
20-3/32"
24"
(610mm)
(499mm)
Cool
'
F
F1 LOW
F2 MED
F3 HIGH
Energy
Saver
Fan
TEMP
Timer
FAN
MODE
TIMER
POWER
SPEED
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. 41 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 41
—19—
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 cold air circulation
for smooth flow.
Check 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
Clogged air filter
Check inside gas pressure.
Replacement of unit if the
unit is beyond repair.
Obstruction at air outlet
Adjusting of refrigerant
charge
Stop auto air-swing
Malfunction of compressor
Correct above troubles
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.
—20—
Fails to Start
Check power source.
Check circuit breaker
and fuse.
Check control switch
setting.
Gas leakage at feeler bulb
of thermostat
Check control switch.
Only compressor fails to
start.
Only fan fails to start.
Improper wiring.
Drop in power voltage.
Improper thermostat setting
Defect of fan motor
capacitor.
Defective 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)
—21—
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 page 27. 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.
—22—
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
—23—
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.
—24—
5. SCHEMATIC DIAGRAM
5.1 CIRCUIT DIAGRAM
• MODEL : BG-103A
—25—
6. EXPLODED VIEW
• MODEL: BG-103A
132100
E
152302
147581
147582A
135303
147582B
131400
149980
135312
346811
359012
W48602
354210
559011
435300A
435300
349480
352380
554031
349600
731273
130410
A
264110
268711B
249950
B
567480
552102
C
C
352115
567502
268711A
35211A
C
o
o
l
E
S
n
a
e
r
e
g
r
y
v
F
a
n
F
2
1
L
F
O
W
M
F
E
IG
554160
550140
3
D
H
H
T
i
m
e
'
F
r
M
O
D
E
T
E
M
P
W0CZZ
T
I
M
E
R
F
E
A
S
N
P
E
D
P
O
W
E
R
352113
552113
238310 237200
267110
—26—
7. REPLACEMENT PARTS LIST
MODEL: BG-103A
LOCATION
PART NO.
DESCRIPTION
QTY
REMARK
NO
.
130410
131400
135303
135312
147581
147582A
147582B
149980
237200
238310
249950
263230
264110
267110
268711A
268711B
346811
349480
352113
352115
35211A
352380
354210
359012
435300A
552113
550140
552102
554031
554160
559011
567502
731273
WOCZZ
W48602
435300
152302
132100
349600
3041A10064C
3090A20017D
3530A10272A
3531A18004D
4758A20058A
4758A30045A
4758A30045B
4998A20003A
3720A20251A
3831A10037F
4995A20493V
6323A20004S
6411A20048J
6711A20093A
6871A20448A
6871A01001B
4681A20041J
4948A20045A
5211A21421A
5211A29024A
5211A21420A
5238A20033A
5421A20071G
5900A20009A
3530A30015A
5211A20560H
4H00982E
BASE ASSEMBLY,SINGLE
CABINET
1
1
1
1
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
EA
GRILLE,INLET
GRILLE ASSEMBLY,FRONT
LOUVER,HORIZONTAL
LOUVER,VERTICAL
LOUVER,VERTICAL
SHROUD
PANEL,CONTROL
ESCUTCHEON
CASE ASSEMBLY,CONTROL
THERMISTOR ASSEMBLY
POWER CORD ASSEMBLY
REMOTE CONTROLLER ASSEMBLY
PCB ASSEMBLY,DISPLAY
PCB ASSEMBLY,MAIN
MOTOR,AC
ORIFICE
TUBE ASSEMBLY,DISCHARGE
TUBE ASSEMBLY,EVAPORATOR(IN)
TUBE ASSEMBLY,SUCTION
GUIDE,AIR
EVAPORATOR ASSEMBLY,FIRST
FAN,TURBO
GRILLE,REAR
TUBE ASSEMBLY,CONDENSER(OUT)
DAMPER,COMPRESSOR
TUBE,CAPILLARY BENDING
CONDENSER ASSEMBLY,BENDING
COMPRESSOR SET,CHINA
FAN ASSEMBLY,AXIAL
OVERLOAD PROTECT
INSTALL PART ASSEMBLY,SINGLE
CAPACITOR,DRAWING
CLAMP,SPRING
5210A23523A
5403A20183H
2520UCDK020
5900AR1173A
6750U-L058A
3127A20017C
6120AR2194D
3H02932B
3530A20101A
5230A20041A
3210A20075A
4960A20008A
GRILLE,REAR
FILTER,AIR
FRAME
BRACKET,MOTOR
—27—
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.:3828A20294W
Printed in Korea
|