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Armstrong World Industries 302, 243, 242 manual Service Reference Manual, HWC Thru-the-Wall Units

Models: 183 182 203 123 122 242 302 243

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Service Reference Manual

HWC Thru-the-Wall Units

Models:

HWC Premier

122, 182, 242, 302 123, 183, 243, 303

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Armstrong World Industries 302, 243, 242, 122, 123, 203, 182, 183 manual Service Reference Manual, HWC Thru-the-Wall Units

Contents

HWC Thru-the-Wall Units Service Reference ManualModels HWC Premier 122, 182, 242, 302 123, 183, 243 Disclaimer TABLE OF CONTENTS Section 1 - Specifications Model Number Guide Models Covered By This ManualProduct Serial Numbers, Beginning HW/HWC ModelsService Reference Manual Summary of Model Revisions/VariationsSPECIFICATIONS Table 1-1 Heating Configurations of HW/HWC UnitsPhysical and Electrical HW/HWCPerformance Ratings SPECIFICATIONS Service Reference ManualPerformance Ratings continued Performance Ratings - HWC182/183¾ DUCT CONNECTION FLANGE Blower PerformanceRETURN AIR OPENING ON BOTTOM 6 x Model1 or 3 3 15 or 121 Wall Sleeve all measurements in inches12 1 Flanges may be assembled 1 or 33 4 from this side of the sleeve PRESSURE SWITCH OPENS BLOCKED FLUE Section 2 - Sequence of OperationSPECIFICATIONS SEQUENCE OF OPERATIONS Service Reference ManualBLANK PAGE w/United Technologies 1097 Spark Ignition System HWC123, 183, 243FIGURE 2-1 Connection Diagram DIAGNOSTICSCALL FOR HEAT Simplified Sequence - HWC123,183, 243FLAME SENSE CALL FOR COOLINGL1 Power POWER Line VoltageL2 Power Low Voltage 24 VACLIMIT/ROLLOUT OPENS PRESSURE SWITCH OPENS BLOCKED FLUEFAILED FLAME SENSE/TRIAL FOR IGNITION “off” delayCALL FOR COOLING Line Voltage Low VoltageFAN ON 6. After the 90-second delay, the ignition control de- energizes the cooling speed relay and the circulat- ing air blower stopsConnection Diagram HW Heating OnlyDIAGNOSTICS w/United Technologies 1097 Spark Ignition SystemCALL FOR HEAT Simplified Sequence - HW w/UTEC 1097 BoardFAN ON L1 Power POWER Line VoltageL2 Power 3. At the circulating air blower capacitor terminalPRESSURE SWITCH OPENS BLOCKED FLUE Service Reference ManualSEQUENCE OF OPERATIONS LIMIT/ROLLOUT OPENSMagic-Pak HW/HWC SPECIFICATIONSFAILED FLAME SENSE/TRIAL FOR IGNITION FAN ONSEQUENCE OF OPERATIONS Service Reference ManualBLANK PAGE w/Fenwal Triton 2461D DSI Ignition Control HWC122, 182, 242FIGURE 2-3 Connection Diagram CALL FOR COOLING CALL FOR HEAT1. A call for cooling closes the circuit from R to Y and G FAN ONFirst black wire 1. L-1 on the ignition control POWER Line VoltageSecond black wire 2. L-1 on the contactor 3. L-1 on the blower control boardROLLOUT SWITCH ACTIVATED PRESSURE SWITCH OPENS BLOCKED FLUELIMIT OPENS CALL FOR COOLING Line VoltageMagic-Pak HW/HWC SPECIFICATIONSFAN ON Low Voltage SEQUENCE OF OPERATIONS Service Reference ManualBLANK PAGE HW Heating Only FIGURE 2-4 Connection Diagramw/Fenwal Triton 2461D DSI Ignition Control #39247D2CALL FOR HEAT Simplified Sequence - HW w/Fenwal 2461D BoardFirst black wire 1. L-1 on the ignition control POWER Line VoltageSecond black wire 3. L terminal on the blower control board Low Voltage 24 VACPRESSURE SWITCH OPENS BLOCKED FLUE Service Reference ManualROLLOUT SWITCH ACTIVATED SEQUENCE OF OPERATIONSFIGURE 2-5 Connection Diagram w/Fenwal 05-29 Ignition ControlHWC122, 182, 242 SEQUENCE OF OPERATIONS Service Reference ManualRefer to Figure CALL FOR HEATFirst black wire 1. L-1 on the ignition module POWER Line VoltageSecond black wire 2. L-1 on the contactor 3. L-1 on the blower control boardROLLOUT SWITCH ACTIVATED PRESSURE SWITCH OPENS BLOCKED FLUEFLAME SENSE LIMIT OPENSMagic-Pak HW/HWC SPECIFICATIONSLow Voltage FAN ON Low VoltageSEQUENCE OF OPERATIONS Service Reference ManualBLANK PAGE SWITCH FIGURE 2-6 Connection DiagramHW Heating Only w/Fenwal 05-29 Ignition ControlCALL FOR HEAT Simplified Sequence - HW w/Fenwal 05-29 BoardFirst black wire 1. L-1 on the ignition module POWER Line Voltage3. Circulating air blower capacitor terminal Second black wire 3. Terminal L-1 on the blower control board Low Voltage 24 VACPRESSURE SWITCH OPENS BLOCKED FLUE Service Reference ManualROLLOUT SWITCH ACTIVATED SEQUENCE OF OPERATIONSFIGURE 2-7 Connection Diagram HWC123, 183, 243, 303 Low AmbientDIAGNOSTICS w/United Technologies 1097 Spark Ignition SystemHWC123,183, 243 Low Ambient Model FIGURE 2-8 Connection Diagram HWC122, 182, 242, 302 Low AmbientService Reference Manual HWC122,182, 242 Low Ambient ModelSEQUENCE OF OPERATIONS Refer to FigureService Reference Manual Section 3 - Unit Tear DownUNIT TEAR DOWN Heating SectionUNIT TEAR DOWN UNIT TEAR DOWNMagic-Pak HW/HWC Heating SectionBURNER ACCESS PANEL FILTER ACCESS DOOR Service Reference ManualUNIT TEAR DOWN PLATE MOUNTING SCREWS INDUCED DRAFT BLOWER COMBUSTION BLOWERUNIT TEAR DOWN L1/L2 WIRES RIGHT SIDE CHASSIS SCREW HOLD DOWN SCREWS FILLER PANELMagic-Pak HW/HWC Cooling SectionEVAPORATOR DRAIN CHASSIS SHOWN PARTIALLY REMOVED LOW VOLTAGE MOLEX PLUGPERMAGUM SEAL TUBE CONNECTIONMOUNTING SCREWS EVAPORATOR BLOWER ASSEMBLY R 3-6 Evaporator Blower Assembly RemovalCONTROL PANEL SCREWS CHASSIS BASE PERMAGUM SEAL BETWEEN BASE RAIL AND CHASSIS BASESection 4 - Component Location Illustrations HW/HWC123,183,243,303 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS HW/HWC122, 182HEAT EXCHANGER ACCESS PANEL ARMSTRONG P/N 38782D001 HW/HWC - PanelsTOP PANEL ASSEMBLY ARMSTRONG P/N 03455D007 INSPECTION WINDOW ARMSTRONG P/N 03551D100 COOLING CONTROL ACCESS PANELCONDENSER AIR FLOW OUTLET EXTERIOR UPPER LOUVER PANEL HW/HWC Exterior Louver/Grill PanelARMSTRONG P/N 03545C000 LOUVERS POINT UPWARD EXTERIOR LOWER GRILL PANELAT 45 ANGLE ARMSTRONG P/N 03551D100HWC Chassis Assembly SEE FIGURE 4-7 FOR CIRCULATING AIR BLOWER COMPONENTS HWC Chassis Assembly - Top ViewCONDENSER MOTOR *267 12-18 ARMSTRONG P/N 24-30 ARMSTRONG P/N CONDENSER FAN MOTOR BRACKET *269 ARMSTRONG P/N 03982D004 FAN SHROUDBLOWER HOUSING *74 ARMSTRONG P/N 39010B001 HWC Chassis Assembly Circulating Air Blower Partially RemovedBLOWER WHEEL *73 ARMSTRONG P/N 34833B001 10.75 x SEE FIGURE FOR FAN CONDENSING PARTSSection 5 - Unit Components UNIT COMPONENTS Transformer Specifications Unit ComponentsFIGURE 5-1 24-volt Transformer Typical Configuration 24 VAC SecondaryFIGURE 5-2 White-Rodgers Gas Valve 5-5 Honeywell 8105 Series Gas Valve SpecificationsFIGURE 5-3 Honeywell Gas Valve FIGURE 5-4 United Technologies Blower Control Board L1 Power OutFan Call Fan On Cooling Call Fan AutoFIGURE 5-5 Heatcraft Blower Control Board IBC-H4C401 5-7 Heatcraft Model IBC-H4C401FENW Ignition Control SpecificationsFIGURE 5-6 Fenwal Triton 2461D Ignition Control Triton 2461D Diagnostic Flash Code Diagnostics Fenwal Triton 2461DFENW Ignition Control SpecificationsFIGURE 5-7 Fenwal 05-29 Ignition Control FIGURE 5-8 United Technologies Model 1097 Integrated Control Integrated Control SpecificationsUTech Model 1097 Diagnostic Flash Code Diagnostics United TechnologiesQuick Connect Terminal Descriptions Molex/Amp Plug-in DescriptionFan Off Delay Fan On Delay5-13 United Technologies Model 1097-400-1 contFIGURE 5-9 Magnetek JBIMI37NS Induced Draft Blower Induced Draft Blower SpecificationsBurner Carryover Gap 025 +/-.002 Burners Burner SpecificationsFIGURE 5-10 Typical Burner Arrangement 5-16 Flame Carryover ProblemsFIGURE 5-11 Inshot Burners FIGURE 5-12 Burner Wing GapTABLE 5-3 Manifold Orifice Specifications Service Reference ManualUNIT COMPONENTS Manifold Orifices *13FIGURE 5-14 Honeywell Contactor Model R8242A-1008 Contactor SpecificationsFIGURE 5-16 Main Limit Switch FIGURE 5-15 Camstat Main Limit Switch3.05 +/-.05 FIGURE 5-17 Flame Rollout Switch FIGURE 5-18 Pressure Switch Pressure Switch SpecificationsUNIT COMPONENTS Pressure SwitchesMagic-Pak HW/HWC Blocked Intake Magic-Pak HW/HWC UNIT COMPONENTSBlocked Flue pressure What Is Needed for the TestsRise” “PressureA Word About the “Switch Open” Value A Word About the “Switch Closed” ValueProcedure for Checking Pressure Switch FIGURE 5-20 Incline Manometer Connection UNIT COMPONENTS TABLE 5-5 Compressor Specifications continued on next pageMagic-Pak HW/HWC Compressors *262UNIT COMPONENTS Service Reference ManualA B D TABLE 5-6 Tecumseh Rotary Compressor SpecificationsFIGURE 5-21 Tecumseh Rotary Compressor Top ViewSide View FIGURE 5-22 Tecumseh Reciprocating Compressor TABLE 5-7 Tecumseh Reciprocating Compressor SpecificationsAW501ET-089-A4 750 /.760 DiameterA B C TABLE 5-8 Copeland Compressor SpecificationsSide View FIGURE 5-23 Copeland CompressorA B E C D TABLE 5-9 Copeland Compressor SpecificationsTop View Top ViewArmstrong Part Number TABLE 5-10 Drier-Filter SpecificationsSupplier Supplier Part NumberAll part numbers provided are Armstrong part numbers HWC Capillary Tube Specification TablesSee page 5-34 for drier information Do not kink or flatten during forming All bends 90 unless otherwise notedTape tubes together with masking tape FIGURE 5-26 43267-001 Capillary TubesFIGURE 5-31 40651-001 Capillary Tubes FIGURE 5-30 43281-001 Capillary TubesFIGURE 5-32 40652-001 Capillary Tubes FIGURE 5-33 39103B001 Capillary TubesUNIT COMPONENTS TABLE 5-12 39102B001 SpecificationsMagic-Pak HW/HWC FIGURE 5-34 39102B001 Capillary TubesArmstrong TABLE 5-13 Capacitor RatingsRating VoltsTABLE 5-15 Condenser Fan Motor Specifications TABLE 5-14 Evaporator Blower Motor SpecificationsUNIT COMPONENTS Magic-Pak HW/HWCUNIT COMPONENTS Service Reference ManualCapacitors-Run *86 TABLE 5-16 Run Capacitor RatingsFIGURE 5-37 Fan Blades - HWC Models 122, 182 & 123 AIR FLOW1. 24 Pitch, 3 Blades 2. Material 24 Ga. Galvalume AIR FLOW3. Set Screw 2 5/16-24 x 5/8 long square head, cup point 18.00 + 5002 5019 Diameter Bore RotationArmstrong P/N 03551D100 Upper Louver Panel Armstrong P/N 03545C000 Lower Grill PanelFIGURE 5-39 Exterior Grill Panels Section 6 - Installation Installation and Operation in Extremely INSTALLATIONMagic-Pak HW/HWC Cold Weather AreasHW/HWC Installation and Maintenance Instructions InstallationIMPORTANT READ THIS FIRST If three or more adjacent walls form an air shaft with Magic-Pak HW/HWC units facing each other in each wall, the separation between opposite walls should be increased by 20% FLOOR FIGURE 6-1 HW/HWC InstallationRefer to the following directions and Figure 6-1 on page 6-5 for guidance in installing the unit without a wall sleeve FIGURE 6-2 HWC Drain Installation Units TABLE 6-2 HW/HWC Installation and Maintenance InstructionsClearance FIGURE 6-3 Required Clearances for Direct Vent Terminals1. Seal any unused openings in the common venting system FIGURE 6-4 NOx Insert Removal FIGURE 6-5 Gas Supply Piping Minimum Circuit Ampacity Minimum Required Surface Area for Disposable Temperature RiseFilters Pressure RegulatorCubic Feet Per Revolution BTU/HRX 3600 HeatingIn areas where extremely cold below - 20F outdoor temperatures can be expected, some additional installation and operating precautions should be taken. The following precautions are taken to prevent possible vent system ice blockage that could result in safety shutdown of the burners Service Reference Manual Section 7 - AccessoriesHW/HWC Accessory Kit Index ACCESSORIESACCESSORIES AccessoriesMagic-Pak HW/HWC components and accessories. These instructions shouldACCESSORIES Service Reference ManualCA-239 Wall Sleeve Kit Inspection of ShipmentCA-239 Parts List ACCESSORIESFIGURE 7-1 CA-239 Wall Sleeve Kit Assembly Magic-Pak HW/HWCACCESSORIES Service Reference Manual7-5 Wall Sleeve Installation Recessed Wall Sleeve Installation7-6 Magic-Pak Installation ACCESSORIESMagic-Pak HW/HWC Weather SealingACCESSORIES Service Reference ManualA242-1 Wall Sleeve Adaptor Kit Inspection of ShipmentInstalling the HW/HWC Unit ACCESSORIESMagic-Pak HW/HWC 7-8 Attachment to HW/HWCACCESSORIES Service Reference ManualTABLE 7-3 A242-1 Parts List FIGURE 7-2 A242-1 Wall Sleeve Adaptor Kit AssemblyMagic-Pak HW/HWC ACCESSORIESALVR42 Architectural Aluminum Louver Facade ACCESSORIES Service Reference ManualFIGURE 7-3 ALVR Architectural Aluminum Extended Louver Magic-Pak HW/HWC ACCESSORIES34961A001 Compressor Vibration Isolator Kit ACCESSORIES Service Reference Manual34961A001 Parts List ALPKT389-2 Parts List ACCESSORIESMagic-Pak HW/HWC ALPKT389-2 L.P. Gas Conversion KitACCESSORIES Service Reference ManualAHALT390-1 Parts List AHALT390-1 High Altitude KitNormal AHALT390-1 OrificesHigh HighService Reference Manual Time Delay RelayACCESSORIES ATIMR466-1 Parts ListTABLE 7-10 ADAPT420-2 Parts List ACCESSORIESMagic-Pak HW/HWC ADAPT420-2 Chassis Conversion KitACCESSORIES Service Reference ManualTABLE 7-11 Triton Ignition Control Kit Parts List Fenwal Triton Ignition Control KitMagic-Pak HW/HWC ACCESSORIESTL109 Burner Tray Kit Burner Carryover Gap 025 +/.002 BurnersACCESSORIES Service Reference ManualFIGURE 7-6 AMUFFKT494-1 Kit Discharge Muffler Installation AMUFFKT494-1 Discharge Muffler KitPARTS LISTS Section 8 - Parts ListsHWC123, 183, 243 HWC182PARTS LISTS HWC3-A-1MAGIC-PAK HW/HWC PARTS LISTS HWC3-A-1 contSERVICELEVEL = HWC3-A-1 cont PARTS LISTSMAGIC-PAK HW/HWC SERVICE LEVEL = HWC182-242A-11REC STOCKING PART SERVICE LEVEL = HWC182-242A-11 contREC STOCKING PART First find Model #PARTS LISTS HWC122-242A-10 REVISEDPART DESCRIPTION SERVICELEVEL = HWC122-242A-10 contPART DESCRIPTION PARTS LISTS Service Reference ManualSERVICE LEVEL = HWC122-242A-10 cont38HWC182A-9 HWC182-951HWC182A-9 64HWC182A-9PARTS LISTS HWC182-9 contFirst find Model # SERVICE LEVEL = HWC242-302-9REC STOCKING PART MAGIC-PAK HW/HWCPARTS LISTS HWC242-302-9 cont51HWC242A-9 64HWC242A-9PART HWC-8PARTS LISTS HWC-8 contSERVICE LEVEL PARTHWC-8 cont SERVICELEVELPART PARTS LISTS HWC-6/7PART 38HWC182-7PARTS LISTS HWC-6/7 contMAGIC-PAK HW/HWC PARTPARTS LISTS HWC-5SERVICE LEVEL PARTPART HWC-5 contPARTS LISTS Service Reference ManualHWC-5 cont PARTPART HWC-438HWC182-4 51HWC182-4Service Reference Manual HWC-4 contPARTS LISTS PARTHWC-4 cont PARTS LISTSMAGIC-PAK HW/HWC PARTPARTS LISTS HWC-3SERVICE LEVEL PARTPART HWC-3 contSERVICE LEVEL PARTS LISTSHWC-3 cont PARTPART HWC-238HWC182-2 51HWC182-2Service Reference Manual HWC-2 contPARTS LISTS PARTPART HWC-1PARTS LISTS HWC-1 contSERVICE LEVEL PART DESCRIPTIONHWC-1 cont PARTS LISTSMAGIC-PAK HW/HWC PARTService Reference Manual HW-1PARTS LISTS PARTPARTS LISTS HW-1 contMAGIC-PAK HW/HWC PARTPARTS LISTS HWA-9PART DESCRIPTION PARTPARTS LISTS HWA-9 contMAGIC-PAK HW/HWC PART DESCRIPTIONService Reference Manual HWC3-S-1PARTS LISTS SERVICE LEVEL =HWC3-S-1 cont PARTS LISTS Service Reference ManualSERVICE LEVEL = HWC3-S-1 contHWC3-H-1 Service Reference Manual HWC3-H-1 contPARTS LISTS SERVICE LEVEL =SERVICE LEVEL = PARTS LISTSHWC3-H-1 cont MAGIC-PAK HW/HWCPerformance Tests Installed Section 9 - Troubleshooting Performance Charge WeightsCompressor Checkout Capacitor Checkoutmust be turned off before continuing with the testing TroubleshootingChecking Continuity Example #1 Checking WindingsMagic-Pak HW/HWC TROUBLESHOOTINGExample #2 Checking the Thermal Overload DeviceThere are several reasons why a compressor would overheat the tip of the end of a screwdriver when placed length of time after the power has been turned offA capacitor can store a charge for a considerable This charge can be very dangerous. An electrolyticMotor overheating internal thermal overload tripped Example FIGURE 9-1 Determining Capacitance MFD Rating with a Test CordHWC122 Performance Test Chassis Installed PerformanceHWC182 Performance Test Chassis Installed HWC242 Performance Test Chassis Installed 9-10 Performance Tests Chassis Installed in Unit - contTABLE 9-4 HWC302 Performance Test Chassis Installed 70 - 80 Ambient Temperature Chassis Bench Test Charge Weights95 Ambient Temperature Chassis Bench Test TABLE 9-7 HWC Refrigerant Charge Weights