Heat Controller BG-101G Service Manual Download

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Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • (517)787-2100 • www.heatcontroller.com

SERVICE MANUAL

Thru-the-Wall Series with R-410A

BG-81G

BG-101G

BG-103G

BG-123G

BGE-103G

BGE-123G

BG-143G

Summary of Contents for BG-101G

Page 1: ...Heat Controller Inc 1900 Wellworth Ave Jackson MI 49203 517 787 2100 www heatcontroller com SERVICE MANUAL Thru the Wall Series with R 410A BG 81G BG 101G BG 103G BG 123G BGE 103G BGE 123G BG 143G ...

Page 2: ...TING 9 6 1 COMPRESSORS 9 6 2 FAN MOTOR 11 6 3 CAPACITOR RUN 11 6 4 THERMOSTAT ADJUSTMENT 12 6 5 HEATING ELEMENT See Figure 6 12 6 6 VALVE DRAIN PAN see Figure 7 13 6 7 SEALED REFRIGERATION SYSTEM REPAIRS 13 7 WIRING DIAGRAM 15 8 TROUBLESHOOTING 17 8 1 Flow Chart 17 8 2 General Troubleshooting 27 8 3 Troubleshooting Cooling 30 8 4 Troubleshooting Heating Cooling Electric Heater Models 32 9 INSTALLA...

Page 3: ... 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 s...

Page 4: ...tart 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 tem...

Page 5: ...matically 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 coo...

Page 6: ...n 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 ...

Page 7: ...3 UNIT DIMENSION 3 1 Unit dimension 4 OPERATION LIMITS 4 1 Cooling operation Outdoor unit air temp DB Indoor air temp DB Service Manual Room Air Conditioner with R 410A Heat Controller Inc 6 ...

Page 8: ...ull down stage is not included 4 2 Electric heating operation Indoor air temp DB Outdoor air temp DB Note The chart is the result from the continuous operation under constant air temperature conditions However the initial pull down stage is not included Service Manual Room Air Conditioner with R 410A Heat Controller Inc 7 ...

Page 9: ...e 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 s...

Page 10: ...re 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...

Page 11: ...pressor 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 ...

Page 12: ...bes 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 ...

Page 13: ...d 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 Th...

Page 14: ...ure 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...

Page 15: ...m 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 h...

Page 16: ...ubleshooting 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 wi...

Page 17: ...all these features accordingly it will slightly differ from your wiring diagram in these optional features area Refer to the actual wiring diagram included wit your unit Wiring Diagram For TTW Cooling only models Wiring Diagram For TTW Cooling and Heating models Service Manual Room Air Conditioner with R 410A Heat Controller Inc 16 ...

Page 18: ...1 C 90 F or lower than 16 C 60 F Replace the control board Check the resistance of room temperature sensor according to the characteristic table 8 TROUBLESHOOTING In general problems are classified by three types One is called Starting Failure which is caused from an electrical defect another is ineffective Air Conditioning caused by a defect in the refrigeration circuit and improper application a...

Page 19: ... Check whether the failure button is locked by button holder Yes Replace with new batteries No Check the wiring No Check whether the transformer damaged open circuit or short circuit Yes Replace the transformer No Check whether other modes work normally Replace the display board Replace the main control board Check whether the buttons on the unit work normally Yes Replace the remote controller No ...

Page 20: ...ow me mode doesn t work Check the power supply Press follow me button several times and check whether this mode can work Pay attention to the position of Remote controller Check w hether other functions of r emote work or not Replace the display board Replace the main control board Check the batteries Replace it if failed Replace the remote controller No No No Yes No No No No No Yes No Service Man...

Page 21: ...temperature is too low Check whether the indoor dust filter is too dirty Check whether there is too much water on the chassis Check the wiring of pipe temperature sensor Check the pipe temperature sensor Replace the pipe temperature sensor Replace the main control board No No No Service Manual Room Air Conditioner with R 410A Heat Controller Inc 20 ...

Page 22: ...in the cool mode and 26 F 17 C Then check the output of relay and replace the PCB if failed Check whether the external protector works normally 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 Comparing with compressor specification check the resistance of compressor Replace the compressor No Check whether the indoor tempera...

Page 23: ...otor 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 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 No No No No No Service Manual Room Air Co...

Page 24: ... not replace the transformer Replace the PCB The compressor doesn t stop after the set temperature is reached Check the wiring Check whether the unit can turn off using the remote controller Check whether all te mperature sensors a re n ormal comparing with the resistance table If not replace the sensor Replace the PCB No No No No No No Service Manual Room Air Conditioner with R 410A Heat Controll...

Page 25: ...ontroller Replace if failed The compressor cycles on off frequently Check whether the airflow is blocked Check if the fan motor isn t working Check whether capacitor of compressor is working normally Check whether the relay of compressor on PCB works normally Replace the PCB Check whether the capillary tube is blocked Replace the capillary Replace the compressor No No No No No No No No No No No Se...

Page 26: ...k whether the foam of evaporator base is damaged Check whether the drain passage of evaporator is blocked Replace if failed Temperature controller interrupts frequently Check whether the set temperature is reached Check the wiring Check whether the compressor is in the protection mode or 3 minute time delay Check the specification of temperature controller Replace if failed No No No No No No No No...

Page 27: ...ic Heater Check the mode Check whether the airflow speed is too low Check the specification of PTC heater Check the heat load of the room Fan motor speed can t change Mechanical Control Check whether the selector is damaged 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 Check the resistance of fan motor and replace if fai...

Page 28: ...tor if motor shaft do not rotate Check voltage Call an electrician if not within limits Test capacitor Replace if not within 10 of manufacturer s rating Check bearings Replace the motor if the fan blade cannot rotate freely Fan motor runs intermittently Cycles on overload Pay attention to any change from high speed to low speed Replace the motor if the speed does not change Fan Replace the fan if ...

Page 29: ...ube and ensure the evaporating temperature is appropriate if the evaporator is frosted Replace if blocked Repair joint if leaking Compressor The inlet and outlet valve of the 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 Heat s...

Page 30: ...ct Main switch failure Check and replace the main switch if failed Capacitor Discharge capacitor before testing Check the capacitor Replace if not within 10 of manufacturer s rating Replace if shorted open or damaged Thermostat Check the thermostat setting if not at the coolest in cooling mode or the warmest in heating mode Try adjusting these settings Compressor will not run while fan motor runs ...

Page 31: ...inoperative Broken loose or incorrect wiring Refer to applicable wiring diagram Open capacitor Test capacitor and replace if inoperative Fan speed switch open Test switch and replace if inoperative Fan motor does not run Inoperative fan motor Test fan motor and replace if inoperative Be sure internal overload has had time to reset Undersized unit Refer to Sizing Charts Thermostat open or inoperati...

Page 32: ... 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 Inoperative fan motor Test fan motor and replace if inoperative Evaporator coil freezes up Partially restricted capillary De ice coil Check temperature differential across coil Touch test coil return bends for same tempe...

Page 33: ...pen or shorted element Check amperage draw of heater Fan Operates heating element does not come on Loose connections Tighten all terminals Restricted filter Clean as recommended in Owner s Manual Cycling high limit control 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 Heating inadequate Exhaust or fresh air door open Check...

Page 34: ...speed Loose connections Check all connections Check voltage to fan motor Fuse link 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 Unit does not heat Heat relay or heater contactor coil open Defective coil Test coil for continuity Service Manua...

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Page 36: ...04 2009 03 2010 ...

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