Comfort-aire BHD-252 Heat Controller Dehumidifier Owner’s Manual

BHD-252 Heat Controller Dehumidifier
Owner’s Manual

BHD-252 Heat Controller Dehumidifier

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HEAT CONTROLLER, INC.
Dehumidifier

Service Manual

CAUTION
-Before servicing the unit, read the “safety precautions” in this manual.
-Only for authorized service personnel.

PREFACE

This Service Manual provides various service information, including the mechanical and electrical parts.
This dehumidifier was manufactured and assembled under the strict quality control procedures.
The refrigerant is charged at the factory. Be sure to read the safety precaution prior to servicing the unit.
1.1 SAFETY PRECAUTIONS

• Disconnect the power supply before servicing or replacing any component.
• Do not cut off the grounding prong or alter the plug in any manner.

1.2 FEATURES AND DIMENSIONS
1.2.1 FEATURES

• Quiet operation
• High efficiency
• Adjustable humidistat
• Automatic defrost
• Automatic shut-off
• Bucket-full indicator light
• Easy roll casters
• Removable & large capacity bucket.
• Washable air filter
• Two-speed fan
• Drain hose connection.
•  Low temperature operation

1.2.2 DIMENSIONS (mm/in) 1.3 SPECIFICATIONS

Rating:7W/90mA
COMPRESSOR MODEL No.| NR45HAEG| GA066PAB
PROTECTOR| OVERLOAD PROTECTOR FOR COMPRESSOR
| INTERNAL PROTECTOR(FUSE)FOR MOTOR
CAPACITOR| | 25pF,370VAC
MOTOR ASSEMBLY,SINGLE| Shaded pdemoW2WIteasi ablinille| Shaded pcle heta,77/111AATSI cutd266’FV1130%
SWITCH ASSEMBLY,MICRO| 15A/250VAC
OUTSIDED MENSIONS WxHxD,mm(in)| 385X540X340(15 5/32 x 21 1/4 x 13 3/8)
NET WEIGHT,kg| 18| 121

*NOTE: Specifications are subject to minor change without notice for further improvement.
1.4 CONTROL TYPE 1.5 HOW TO OPERATE DEHUMIDIFIER
1.5.1 HOW DOES THE DEHUMIDIFIER WORK?
Moist, humid air is drawn over a cold refrigerated dehumidifying coil. Moisture in the air condenses on this coil and drains into a bucket (or through the bucket into a hose and drain).
Dry, clean air is drawn over the condenser where it is actually heated several degrees and discharged out the rear grill into the room. (See Figure 3)

• It is normal for the surrounding air to become slightly warmer as the dehumidifier operates.
  This warming effect further reduces the relative humidity of the surrounding air.

1.5.2 LOCATION FOR THE DEHUMIDIFIER
Allow at least 30 cm of space on all sides of the unit for good air circulation. (See Figure 4)

• The dehumidifier must be operated in an enclosed area to be most effective.
• Close all doors, windows and other outside openings to the room.

Place the dehumidifier in a location that does not restrict air flow into the front grille or out the rear grille.
The operation of dehumidifier in a basement will have little or no effect in drying an adjacent enclosed storage area, such as a closet, unless there is adequate circulation of air in and out of the area.
1.5.3 MICRO SWITCH
The micro switch assembly, which is located on the drain pan of inside unit, automatically shuts off the dehumidifier when the bucket is full (note, the Auto Shut Off lights, to indicate bucket must be emptied). The bucket replaces in its place, the unit again turns itself on.
1.5.4 AUTO DEFROST
When frost builds up on the cooling coils, the unit will automatically cycle off until the frost disappears. The fan continues to run.
NOTE: The unit will not operate satisfactorily if the room temperature is below 18˚C. If the dehumidifier is operated in low temperature conditions frost can form in the evaporator coil and the unit will cycle ON/OFF
repeatedly. In this case, please check your room temperature conditions and stop the unit.
NOTE: The low temperature operation feature in the BHD-252 and BHD-652 models will continuously cycle up to a temperature of 6°C.
1.5.5 HUMIDITY CONTROLLER
1.5.5.1 Mechanical Type
The humidity control can be set anywhere between Off and Max for normal operation.
If you need more dehumidification, turn the Humidity Control toward Max. If you need less dehumidification, turn the Humidity Control toward Off.
The relative humidity range is from 20% to 80%. (See Figure 5)
Turn the Humidity Control to Off to stop the unit manually. 1.5.5.2 Electronic Type
The humidity control can be set ‘on’ or 35%-70% RH(Relative Humidity) for normal operation. (See Figure 6) If you need drier air, press the Humidity Control button. If you need moister air, press the Humidity Control button.
Press the Power button to stop the unit manually. 1.5.6 DRYER
Dryer is used to prevent capillary blockage from moisture in the refrigerant system and H/E, condenser and evaporator.
Also, dryer is used to remove corrosion of the components.
NOTE: When dryer is replaced, proper injection to capillary is needed. On opening the dryer, it should be welded instantly. The oxidization of dryer inside and all tubes inside after welding can be prevented.

CIRCUIT DIAGRAM

• MODEL : BHD-252

NO| DESCRIPTION| PART NO| Q’TY
PER SET| RE MARKS
---|---|---|---|---
BHD-252
1| POWER CORD ASSEMBLY| 6411A20044B| 1| S
2| MOTOR ASSEMBLY| 4681A20040N| 1| S
3| PTC ASSEMBLY| 6748C-0003C| 1| S
4| COMPRESSOR, SET| 5416A20009A| 1| S
5| OLP| 6750C-0005M| 1| S
6| PWB(PCB) ASSEMBLY, DISPLAY| 6871A20600B| 1|
7| SENSOR ASSEMBLY| 6877A30013L| 1| S
8| SWITCH ASSEMBLY, MICRO| 6600A30003C| 1| S
9| PWB(PCB) ASSEMBLY, MAIN| 6871A20888E| 1| S

S: SERVICE PARTS A: ALTERNATE PARTS N: NOT SERVICE PARTS
• MODEL : BHD-652

BHD-652
1| POWER CORD ASSEMBLY| 6411A20044B| 1| S
2| MOTOR ASSEMBLY| 4681A20040L| 1| S
3| CAPACITOR| OCZZA20005U| 1| S
4| COMPRESSOR, SET| TBZ30503801| 1| S
5| OLP.| 6750U-L047A| 1| S
6| PWB(PCB) ASSEMBLY, DISPLAY| 6871A20600B| 1| S
7| SENSOR ASSEMBLY| 6877A30013L| 1| S
8| SWITCH ASSEMBLY, MICRO| 6600A30003C| 1| S
9| PWB(PCB) ASSEMBLY, MAIN| 6871A20888E| 1| S
10| COIL ASSEMBLY, SOLENOID| 6421A90001H| 1| S

S: SERVICE PARTS A: ALTERNATE PARTS N: NOT SERVICE PARTS

DISASSEMBLY INSTRUCTIONS

3.1 MECHANICAL PARTS
3.1.1 BUCKET AND AIR FILTER

1. Turn the Humidity Control off(Mechanical type) or press the power button off. (Electronic type)
2. Disconnect the power supply.
3. Remove the bucket. (See Figure 8)
4. Pull out the air filter. (See Figure 9)

3.1.2 FRONT CASE AND REAR GRILLE

1. Remove 2 screws which fasten the front grille.
2. Pull the front grille forward and upward. (See Figure 10)
3. Remove 6 screws that secure the rear grille.
4. Remove the rear grille. (See Figure 11)

3.1.3. CABINET AND CONTROL BOX

1. Remove the Bucket, the Air filter and Front grille according to the procedure above.
2. Remove 1 screws that fasten Control box. (See Figure 12)
3. Remove 9 screws on all sides of the cabinet.
4. Lift the Cabinet from the base.(See Figure 12)
5. Remove a screw fasten the earth wire on the inside of control box.
6. Remove 1 screw that fasten control box and unhook control box from hook on the shroud. (See Figure 13)

3.2 CONTROL PARTS
3.2.1 POWER CORD ASSEMBLY

1. After opening the control box, remove the screw that holds the ground wire. (See Figure 14)
2. Disconnect the remaining leads of the power cord from the PWB(PCB) ASSEMBLY, MAIN, then remove it from the control box.

3.2.2 SENSOR ASSEMBLY

1. Disconnect the sensor assembly from the PWB(PCB) ASSEMBLY, MAIN.
2. Remove the screw which fastens the humidity sensor. (See Figure 15)
3. Remove the thermistor from the holder. (See Figure 15)
4. Disconnect the switch wires from the micro switch assembly. (See Figure 15)

3.2.3 PWB(PCB) ASSEMBLY, MAIN

1. Disconnect all leads of the motor and the compressor from PWB(PCB) ASSEMBLY, MAIN.
2. Remove the screw which fastens the PWB(PCB) ASSEMBLY, MAIN and pull it out after unhooking from 2 rectangular holes of the control box (lower). (See Figure 16)

3.2.4 CAPACITOR

1. Remove the screw that fastens the capacitor. (See Figure 16)
2. Disconnect all leads from the capacitor and then remove it from control box.

3.2.5 MICRO SWITCH ASSEMBLY

1. Turn the nut counterclockwise and pull out the micro switch from the drain pan. (See Figure 17)

3.2.6 COIL ASSEMBLY, SOLENOID

1. Disconnect the housing of the COIL ASSEMBLY, SOLENOID from the PCB(PWB) ASSEMBLY, MAIN.
2. Remove the screw that fastens the COIL ASSEMBLY, SOLENOID. (See Figure 18)
3.  Pull it out upwards.

3.2.7 CONTROL PANEL

1. Disconnect the housing of the PWB(PCB) ASSEMBLY, DISPLAY from PWB(PCB) ASSEMBLY, MAIN (3.1.3).
2.  Remove 6 screws that secure the PWB(PCB) ASSEMBLY, DISPLAY to the display cover.

3.2.8 FAN AND MOTOR

1. Turn the nut left and full out the Fan by hands carefully.
2. Remove 2 screws that fasten Heat Exchange.
3. Lift the H/E and open the H/E around 45 degree clockwise carefully. (See Figure 20)
4. Unfasten 3 screws that secure the Motor and earth wire. (See Figure 21)
5. Remove the Motor.

3.2.9 SHROUD AND DRAIN PAN

1. Discharge the refrigerant by using a refrigerant Recovery System.
2. After purging the unit completely, unbrace the Discharge and the Suction tube connected compressor carefully.
3. Remove 2 screws that fasten the H/E.
4. Unfasten 2 screws that secure the shroud on the sides and then lift shroud from the drain pan. (See Figure 22)
5. Unfasten 2 screws that secure the drain pan to base pan. (See Figure 23)
6. Pull the drain pan backward then take it up from the base. (See Figure 23)

3.3 REFRIGERATING CYCLE
3.3.1 CONDENSER, EVAPORATOR AND
CAPILLARY TUBE

1. Remove the insulation on the Heater/Evaporator (H/E) assembly
2. Pierce the pinch-off tube to discharge the refrigerant, using a refrigerant recovery system.
3. After discharging the refrigerant completely, remove 2 screws between the housing assembly and the H/E. (See Figure 24)
4. Lift the H/E and open the H/E around 45 degree counterclockwise carefully.
5. Unbraze each of interconnecting tubes of the evaporator and condenser carefully.
6. Remove the H/E assembly from the orifice. (See Figure 25)
7. Unbraze the capillary tube at the connections of the condenser and evaporator. (See Figure 26)
8. Remove 4 screws between the condenser and evaporator. (See Figure 26)

3.3.2 PTC OR OVERLOAD PROTECTOR (OLP) FOR RECIPROCATING COMPRESSOR (BHD-252)

1. Discharge the refrigerant by using a refrigerant Recovery System.
2.  After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections.
3. Remove the screw or nut which fastens the erminal cover
4. Disconnect the lead wire from the overload protector or PTC assembly.
5. Remove the overload protector(OLP) or PTC assembly. (See Figure 27)

3.3.3 COMPRESSOR (BHD-652)

1. Discharge the refrigerant by using a refrigerant Recovery System.
2. After purging the unit completely, unbraze the suction and discharge tubes at the compressor connections.
3. Remove the nuts and washers which fasten the compressor. (See Figure 28)
4. Remove the compressor. (See Figure 28)

3.4 HOW TO REPLACE THE REFRIGERATION SYSTEM

1. When replacing a refrigeration component, be sure to discharge the refrigerant system by using a refrigerant recovery system.
2. After discharging the unit completely, remove the desired component, and unbraze 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. After doing the above procedures, the valve must be closed and left in place on the system for any subsequent procedures.
6. Evacuate as follows.

1. Connect the vacuum pump, as illustrated in Figure 30A.
2. Start the vacuum pump, slowly open manifold valves A and B two full turns counterclockwise and leave the valves open.
   The vacuum pump is now pulling through valves A and B to valve C by means of the manifold and entire system.
   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 are 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 Figure 30B. Open valve C.
   Discharge the line at the manifold connection.
5. The system is now ready for final charging.

7. 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 Figure 30B. 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 Lowside.
   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.
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.

NOTE: THE REFRIGERANT R134a IS USED ONLY FOR THE MODEL BHD-252
NOTE: THE REFRIGERANT R410a IS USED ONLY FOR THE MODEL BHD-652.
When discharging refrigerant R134a or R410a, purging instrument should be used only for R134a or R410a respectively , without mixing that of other refrigerant.
WhencheckingtheleakageofrefrigerantR134a or R410a, leakage test tool should be used only for R134a or R410a.
The pump for discharging should be high efficiency. Final discharging value must be managed below 0.5 Torr.
Maximum water should be less than quantity 150mg in the cycle-all tubes and H/E assembly-system.
If water quantity is over 150mg, it causes acid or corrosion in the cycle system and the capillary tube to be clogged by water and harmful materials.
The model must use dryer to prevent water from overflowing.
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.

TROUBLESHOOTING GUIDE

1. Dehumidifier does not start. (Both compressor and fan motor do not operate.)| No power| Check power supply at outlet. Correct if none.
Poor plug contact at outlet.| Install plug properly or replace it.
Bucket is full.| If Auto Shut Off lights, empty the bucket and replace properly.
Humidity control is at Off position| Turn the humidity control switch toward Max.
Wire disconnected or loose| Connect wire. Refer to wiring diagram for terminal identification. Repair or replace loose terminal.
Capacitor.
(Discharge capacitor before testing.)| Test capacitor.
Replace if not within ±10% of manufacturer’s rating. Replace if shorted, open, or damaged.
2. Motor runs but compressor does not run.| Voltage (220V~240V ± 10%)| It must be between 198V and 264V. If not within limits, call an electrician
Wiring| Check the wire connections; If loose, repair or replace the terminal. If the wires are disconnected, refer to wiring diagram for identification, and replace the wires. Check the wire connections; If not according to the wiring diagram, correct the connections.
Rotary switch| Check for continuity, refer to the wiring diagram for terminal identification. Replace the switch if the circuit is open.
Defrost control| The Defrost Control senses frost build-up on the evaporator coil and automatically shuts off the compressor. The fan continues to run, drawing air across the coil, and melting the frost. When the coil is defrosted, the compressor automatically restarts, and dehumidifying resumes.
Capacitor
(Discharge capacitor before servicing.)| Check the capacitor.
Replace if not within ±10% of manufacturer’s rating. Replace if shorted, open, or damaged.
Compressor| Check the compressor for open circuit or ground. If open or grounded, replace the compressor.
Overload protector (OLP)| Check the compressor OLP if externally mounted. Replace if open. (If the compressor temperature is high, remove OLP, cool, and retest.)
3. Does not defrost control.| Defrost control is defective.| Check defrost control, replace it.
4. Insufficient dehumidification| Low relative humidity| Turn dehumidifier off.
Poor air circulation| Move dehumidifier to obtain free and unobstructed air circulation.
H/E clogged with dust and dirt| Clean evaporator and/or condenser assembly
Air filter is dirty.| Clean it.
Motor is not operating.| Check Motor, repair or replace it.
CONDITION| CAUSE| REMEDY
---|---|---
5. Noisy operating| Fan| If cracked, out of balance, or partially missing, replace it
Loose foreign material inside the housing.| Remove it.
Tube hits frame.| Adjust tubing routine carefully.
Fan blade hits frame| Check Motor Mount. If loose, tighten it.
Internal compressor noise.| Replace compressor.
Loose set screws| Tighten them.
Worn bearings of Motor Assembly| 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 assembly.
6. Water drips| The bucket is not installed properly.| The bucket should be properly positioned on the hangers of the drain pan.
Connection may be loose.| Check connection and repair.
Leak in bucket| Replace bucket.
Water drips when bucket removed for emptying.| Before removing bucket, the unit should be turned off.
Bucket overflows.| Check micro switch and float.
7. Compressor cycles on overload protector. (OLP)| High or low line voltage. (220V~240V ± 10%)| Check line voltage. It must be between

198V and 264V volts.

If intermittent, provide new supply.

Poor air circulation.| Move dehumidifier for free and unobstructed air flow.
Heat Exchange clogged with dust or dirt.| Clean dust or dirt on the Heat Exchange.
Motor| If not running, determine the cause. Replace if required.
Short circuit or ground in electrical circuit| Check electrical circuit. Repair.
Unit pressures not equalized| Allow 2 or 3 minutes for pressure to equalize before starting compressor.
Capacitor| Test the capacitor.
Wiring| Check the terminals. If loose, repair or replace.
Refrigeration system| Check the system for a restriction.
Stuck compressor| Check compressor, replace compressor
Overload protector (OLP)| Check OLP, if externally mounted. Replace if open. (If the compressor temperature is high, remove the OLP, cool, and retest.)

EXPLODED VIEWS

MODEL: BHD-252 • MODEL: BHD-652

REPLACEMENT PARTS LIST

MODEL: BHD-252

BHD-252
130410| BASE ASSEMBLY| 3041A10042C|
131400| CABINET| 3090A10042K|
135312| FRONT GRILLE,ASSEMBLY| 3531A18012V|
330870| DRAIN PAN ASSEMBLY| 3087A10019D|
148391| TANK ASSEMBLY,BUCKET| 4839A10002A|
152302| FILTER(MECH),AIR| 5230A20040A|
165010| SENSOR ASEMBLY| 6877A30013L|
249950| CONTROL BOX,ASSEMBLY| 4995A20622P|
264110| POWER CORD,ASSEMBLY| 6411A20044B|
266010| SWITCH ASSEMBLY,MICRO| 6600A30003C|
268711-1| PWB(PCB)ASSEMBLY,DISPLAY| 6871A20600B|
268711-2| PWB(PCB)ASSEMBLY,MAIN| 6871A20888E|
346811| MOTOR ASSEMBLY| 4681A20040N|
35211A| TUBE ASSEMBLY,SUCTION| 5211A10517B|
352113| TUBE ASSEMBLY,DISCHARGE| 5211A11047A|
552204| COIL ASSEMBLY,SOLENOID| 6421A90001H|
354210| EVAPORATOR,ASSEMBLY| 5421A10009P|
554030| CONDENSOR ASSEMBLY| 5403A10008A|
558511| DRIER ASSEMBLY| 5851A30001A|
554160| COMPRESSOR ,SET| 5416A20009A|
359012| FAN,TURBO| 5900A20007A|
567502| OLP| 6750C-0005M|
349600| MOUNT,MOTOR| 4960A20009B|
263230| PTC ASSEMBLY| 6748C-0003C|
436500| HANDLE| 3650A20004A|
144410| CASTER ASSEMBLY,ROLLER| 4441A30001B|
238310| ESCUTCHEON| MDD30271501|
235512| COVER ASSEMBLY,DISPLAY| 3551A20109C|
752140| HOSE,CONNECTOR| 5214A20027B|
550140| ISOLATOR,COMP| 5040AR4195A|
149980| SHROUD| 4998A10034B|
435300| REAR GRILLE| 3530A10193B|

MODEL: BHD-652

LOCATION NO.| ****

DESCRIPTION

| PART NO.| ****

REMARK

---|---|---|---
BHD-652
130410| BASE ASSEMBLY| 3041A10042A|
131400| CABINET| 3090A10042K|
135312| FRONT GRILLE,ASSEMBLY| 3531A18012X|
330870| DRAIN PAN ASSEMBLY| 3087A10019C|
148391| TANK ASSEMBLY,BUCKET| 4839A10002A|
152302| FILTER(MECH),AIR| 5230A20040A|
165010| SENSOR ASEMBLY| 6877A30013L|
W0CZZ-2| CAPACITOR| 0CZZA20005U|
249950| CONTROL BOX,ASSEMBLY| 4995A20622M|
264110| POWER CORD,ASSEMBLY| 6411A20044B|
266010| SWITCH ASSEMBLY,MICRO| 6600A30003C|
268711-1| PWB(PCB)ASSEMBLY,DISPLAY| 6871A20600B|
268711-2| PWB(PCB)ASSEMBLY,MAIN| 6871A20888E|
346811| MOTOR ASSEMBLY| 4681A20040L|
35211A| TUBE ASSEMBLY,SUCTION| 5211A11073A|
352113| TUBE ASSEMBLY,DISCHARGE| 5211A11069A|
552204| COIL ASSEMBLY,SOLENOID| 6421A90001H|
354210| EVAPORATOR,ASSEMBLY| 5421A10009N|
554030| CONDENSOR ASSEMBLY| 5403A10008A|
554160| COMPRESSOR ,SET| TBZ30503801|
359012| FAN,TURBO| 5900A20007A|
567502| OLP| 6750U-L047A|
349600| MOUNT,MOTOR| 4960A20009B|
436500| HANDLE| 3650A20004A|
144410| CASTER ASSEMBLY,ROLLER| 4441A30001B|
238310| ESCUTCHEON| MDD30271502|
235512| COVER ASSEMBLY,DISPLAY| 3551A20109C|
752140| HOSE,CONNECTOR| 5214A20027B|
550140| ISOLATOR,COMP| 4830A30005A|
149980| SHROUD| 4998A10034B|
435300| REAR GRILLE| 3530A10193B|

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.: MFL38891304

References

• Repair Your Grill: Shop Replacement Parts for 24,880 Models
• Comfort-aire Dehumidifier Parts - Select From 129 Models

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