Heat Controller Air Conditioner BDE 103 A User Manual

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.  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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—  
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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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