Heat Controller Comfort-Aire BD-101, Service Manual

Page 1: ...t Contact a qualified sevice technician for installation repair and maintenance of this unit The appliance is not intended for use by young children or those who require supervision Young children should be supervised to ensure that they do not play with the appliance HEAT CONTROLLER INC Models BD 81 BD 101 BD 123 BDE 103 BDE 123 ...

Page 2: ...IAGRAM 29 6 EXPLODED VIEW 31 7 REPLACEMENT PARTS LIST 32 1 PREFACE This SERVICE MANUAL provides various service information including the mechanical and electrical parts etc This room air conditioner was manufactured and assembled under a strict quality control system The refrigerant is charged at the factory Be sure to read the safety precautions prior to servicing the unit 1 1 SAFETY PRECAUTIONS...

Page 3: ...M TEMP CONTROL THERMISTOR VERTICAL LOUVER RIGHT LEFT HORIZONTAL LOUVER UP DOWN CONSTRUCTION TOP DOWN COMPRESSOR FAN MOTOR INTERNAL THERMAL PROTECTOR 1 6m 3WIRE WITH GROUNDING ATTACHMENT PLUG CORD CONNECTED TYPE DRAIN SYSTEM SPLASHED BY FAN SLINGER NET WEIGHT lbs kg 72 33 79 36 DIMENSION inch W x H x D mm SLEEVE DIMESION inch W x H x D mm SLEEVE DEPTH inch WITH FRONT GRILLE mm MODELS BD 81 BD101 RE...

Page 4: ... 208 230V 60Hz 11 400 11 700 1 200 1 230 6 2 5 8 9 5 26 7 DB 19 4 WB 35 DB 23 9 WB 465 16 4 OZ 2 ROW 11 STACKS 2 ROW 17 STACKS L BENDED TYPE TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 3 3 6 POLES ELECTRIC THERMISTOR VERTICAL LOUVER RIGHT LEFT HORIZONTAL LOUVER UP DOWN TOP DOWN EXTERNAL OVERLOAD PROTECTOR INTERNAL THERMAL PROTECTOR 1 6m 3 WIRE WITH GROUDING ATTACHMENT PLUG CORD CONNECTED TYPE S...

Page 5: ...2 4 7 6 2 5 8 9 5 9 5 9 200 11 200 2 900 3 500 14 0 15 3 26 7 DB 19 4 WB 35 DB 23 9 WB 21 1 DB 15 6 WB 8 3 DB 6 1 WB 440 15 5 OZ 465 16 4 OZ 2 ROW 12 STACKS 2 ROW 11 STACKS 2 ROW 17 STACKS L BENDED TYPE TURBO FAN PROPELLER TYPE FAN WITH SLINGER RING 1 2 2 6 POLES ROTARY SWITCH THERMOSTAT VERTICAL LOUVER RIGHT LEFT HORIZONTAL LOUVER UP DOWN TOP DOWN 3 5KW 208 230V EXTERNAL OVERLOAD PROTECTOR INTERN...

Page 6: ...eded TIMER SHUT OFF TIME You will usually use shut off time while you sleep With unit 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 2 F after another 30 min Every time you push Timer button it advances the Timer setting as follows 1 Hour 2 Hours 12 Hours maximum START TIME With unit not run...

Page 7: ... 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 ...

Page 8: ...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 Refe...

Page 9: ...fice See Fig 5 8 Using handheld pliers remove the clamp which secures the turbo fan See Fig 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 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 th...

Page 10: ...ry 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 compone...

Page 11: ...nd specified cord 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 procedures above 2 3 6 ROTARY SWITCH 1 Remove the control box Refer to sectio...

Page 12: ...e 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 the notes on pages 13 14 See Fig 17 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...

Page 13: ...ifold connection 5 The system is now ready for final charging 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 a...

Page 14: ...or proof seal Leak detector Tubing cutter Hand Tools to remove components Service valve A COMPOUND GAUGE EVAPORATOR LOW PRESSURE SIDE COMPRESSOR CAPILLARY TUBE CONDENSER HIGH PRESSURE SIDE SEE INSETS BELOW MANIFOLD GAUGE B Figure 18A Pulling Vacuum Figure 18B Charging A B EXTERNAL VACUUM PUMP A CHARGING CYLINDER LOW HI B C ...

Page 15: ...Size options 2 Size options 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 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 Carefully inspect...

Page 16: ...ard slope as shown ITEM inches Qty Plastic grille 263 4 x 161 2 1 Horizontal Insulation Strips 13 8 x 5 8 x 273 16 1 13 8 x 13 8 x 273 16 1 Around Insulation Strips 13 8 x 3 4 x 611 2 1 13 8 x 13 8 x 611 2 1 Support Block 13 4 x 13 8 x 45 16 2 Baffle 14 x 41 2 x 1 8 1 Shim 13 x 1 x 3 4 2 Trim Frame 2 Washer Screw 4 Nuts Plastic 4 1 2 3 4 5 6 1 4 Wall Sleeve FRONT UNIT FIG 20 We strongly recommend ...

Page 17: ... 8 x 273 16 and attach that to the inside bottom of the sleeve as shown below Remove the backing from the Around Insulation strip 13 8 x 3 4 x 611 2 and attach that to the inside front of the sleeve as shown below Install the new unit into the wall sleeve To assemble trim snap the tab of each piece into the slot of the other piece as shown below Slide trim over the front of the air conditioner unt...

Page 18: ...al Insulation strip 13 8 x 5 8 x 273 16 and attach that to the inside bottom of the sleeve as shown below Remove the backing from the Around Insulation strip 13 8 x 3 4 x 611 2 and attach that to the inside front of the sleeve as shown below If the depth of your existing wall 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...

Page 19: ...Trim 2 ea Wall FIG 31 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...

Page 20: ...cking from the Horizontal Insulation strip 13 8 x 13 8 x 273 16 and attach that to the inside bottom of the sleeve as shown below Remove the backing from the Around Insulation strip 13 8 x 13 8 x 611 2 and attach that to the inside front of the sleeve as shown below 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 acco...

Page 21: ...r the front of the air conditioner until trim is flush with sleeve as shown below 8 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 rea...

Page 22: ...sh to use an extension cord use a CSA certified UL listed 3 wire grounding extension cord rated 15A 125V 3 4 1 ELECTRICAL DATA FOR 115V MODEL 3 4 2 ELECTRICAL DATA FOR 230 208V MODEL 3 4 3 ELECTRICAL SAFETY All wiring should be made in accordance with local electrical codes and regulations NOTE Aluminum house wiring may pose special problems Consult a qualified electrician IMPORTANT GROUNDING INST...

Page 23: ...em Refer to Fig 41 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle MOTOR COMPRESSOR OIL LIQUID REFRIGERANT CAPILLARY TUBE OUTSIDE COOLING AIR FOR REFRIGERANT PASS THROUGH SUCTION LIME COOL LOW PRESSURE VAPOR COOLED AIR COMPLETE LIQUID BOIL OFF POINT LIQUID PRESSURE DROP ROOM AIR HEAT LOAD VAPOR INLET HOT DISCHARGED AIR LIQUID OUTLET HIGH PRESSURE VAPOR LIQUID...

Page 24: ...heck gas leakage Repair gas leak Replacement of unit if the unit is beyond repair Satisfactory operation with temperature difference of inlet outlet air 44 6 50 F Check heat load increase Unexpected residue Overloaded Circuit Check inside gas pressure Adjusting of refrigerant charge Malfunction of compressor Replacement of compressor Check cold air circulation for smooth flow Dirty indoor coil Hea...

Page 25: ...lation Replacement of fan motor Regular but fails to start Replacement of compressor locking of rotor metal Improper thermostat setting Loose terminal connection Improper wiring Irregular motor resistance Irregular motor insulation Replacement of compressor Motor damaged Drop in power voltage Check capacitor Replacement Only compressor fails to start Defective compressor capacitor Check power sour...

Page 26: ... bearings if motor shaft will not rotate replace the motor 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 Check grommets if worn or missing replace them If cracked out of balance...

Page 27: ...n 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 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 Check the compressor ov...

Page 28: ...se causing the compressor to cycle Straighten the fins or replace the coil Test capacitor Check the terminals If loose repair or replace Check the system for a restriction If restricted clean of replace Close if open Determine if the unit is properly sized for the area to be cooled Check the set screw or clamp If loose or missing correct If the blower or fan is hitting air guide rearrange the air ...

Page 29: ... LOW RY MED RY HI CN AC DC TRANS SMPS CN AC DC CN TH1 BL RD RD BK BL R S C OLP YL OR YL F C H WH BL Ribbed BK BR Plain GN YL GN GN YL GN BK RD OR BR 6411A20028A 6411A20028C 6411A20028B 4681A20044H 4681A20044F 4681A20041C 6120AR2194F 6120AR2194K 6120AR2194D 6322AQ9189F 5416A90007D 2520UKCC2CA 2520UKHK2CA 6750A30001N 6750U L031A 6750U 058A NO 1 2 3 4 5 6 Q TY PER SET 1 1 1 1 1 1 RE MARKS DESCRIPTION...

Page 30: ... INPUT 7 1 8 6 4 2 F C C H RD BL BK BL BK L H OR BR OR BR THERMOSTAT WH BK YL BL RD RD YL C L H R S C BR YL O L P BK RD RD RD FUSE LINK BI METAL THERMOSTAT HEATER BL BK RD BL BK BR Plain WH BL Ribbed GN YL 1 3 4 5 6 8 2 7 NO 1 2 3 4 5 6 7 8 Q TY PER SET 1 1 1 1 1 1 1 1 RE MARKS DESCRIPTION POWER CORD ROTARY SWITCH FAN MOTOR CAPACITOR THERMOSTAT COMPRESSOR OVERLOAD PROTECTOR ELECTRIC HEATER PART NO...

Page 31: ...5211A 352115 W48602 249950 137215 149410 W0CZZ 264110 130900 135312 147581 135500 147582 2 147582 1 352390 148000 554160 550140 149980 359012 266003 269310 552111 152302 135313 E D F A G C B 749180 435301 F TIM ER PO WE R MO DE TE MP FA N SP EE D F1 LOW F2 MED F3 HIGH Tim er Fan Ene rgy Sav er Co ol 268714 263230 268712 237200 238310 264110 267110 W0CZZ ...

Page 32: ...00 MOUNT MOTOR R 148000 BRACE R 435301 GRILLE REAR R 354210 EVAPORATOR ASSY FIRST R 359012 FAN TURBO R 554031 CONDENSER ASSY BENT R 559010 FAN ASSY AXIAL R W48602 CLAMP SPRING R 130410 BASE ASSY SINGLE R 130900 CABINET R 749180 TRIM R 32 7 REPLACEMENT PARTS LIST MODEL BD 81 BD 101 PART NO DESCRIPTION REMARK LOCATION NO BD 81 BD 101 R Service Parts N Non Service parts 4995A10089G 4995A10089H 6871A2...

Page 33: ... FILTER MESH A C R 349480 ORIFICE R 149980 SHROUD R 346811 MOTOR ASSY SINGLE R 349600 MOUNT MOTOR R 148000 BRACE R 435301 GRILLE REAR R 354210 EVAPORATOR ASSY FIRST R 359012 FAN TURBO R 554031 CONDENSER ASSY BENT R 559010 FAN ASSY AXIAL R W48602 CLAMP SPRING R 130410 BASE ASSY SINGLE R 130900 CABINET R 749180 TRIM R MODEL BD 123 PART NO DESCRIPTION REMARK LOCATION NO BD 123 R Service Parts N Non S...

Page 34: ...R 349600 MOUNT MOTOR R 148000 BRACE R 435301 GRILLE REAR R 354210 EVAPORATOR ASSY FIRST R 359012 FAN TURBO R 554031 CONDENSER ASSY BENT R 559010 FAN ASSY AXIAL R W48602 CLAMP SPRING R 130410 BASE ASSY SINGLE R 130900 CABINET R 749180 TRIM R MODEL BDE 103 BDE 123 PART NO DESCRIPTION REMARK LOCATION NO BDE 103 BDE 123 R Service Parts N Non Service parts 4995A20131V 2H00677U 2H00598F 2H01127D 6120AR2...

Page 35: ...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 3828A20040D ...