Armstrong World Industries 203, 243, 302, 242, 122, 123, 182, 183

INSTALLATION

Magic-Pak: HW/HWC

6-2

Installation and Operation in Extremely
Cold Weather Areas	6-15

SRM-HW/HWC

8/99

Image 109

Armstrong World Industries 203, 243, 302, 242, 122, 123, 182, 183 Installation and Operation in Extremely Cold Weather Areas

Contents

Models HWC Premier 122, 182, 242, 302 123, 183, 243 Service Reference Manual Disclaimer Table of Contents Heating Configuration Table Cooling Configuration Table Specifications Model Number Guide Models Covered By This ManualProduct Serial Numbers, Beginning Cooling Configurations of HWC Units Heating Configurations of HW/HWC UnitsSummary of Model Revisions/Variations Physical and Electrical Physical and Electrical Specifications HWC UnitsPerformance Ratings Performance Ratings HWC122/123 Performance Ratings HWC182/183 Performance RatingsPerformance Ratings HWC242/243 Performance Ratings HWC302/303 Blower Performance HWC Units Blower Performance Wall Sleeve all measurements in inches Service Reference Manual Dimensions HWC123,183,243,303 Sequence of OperationHW Heating Only Utec 1097 Spark Ignition System HWC122,182,242,302 Fenwal 2461D Ignition Control HW Heating Only Fenwal 05-29 Ignition Control HWC122,182,242,302 Fenwal 05-29 Ignition ControlHWC123,183,243,303 Low Ambient Control HWC122,182,242,302 Blank United Technologies 1097 Spark Ignition System Connection Diagram Refer to Figure Simplified Sequence HWC123,183, 243Detailed Sequence follows L2 Power L1 PowerLine Voltage Low Voltage 24 VAC LIMIT/ROLLOUT Opens Failed Flame SENSE/TRIAL for Ignition FAN on HW Heating Only Simplified Sequence HW w/UTEC 1097 Board At pin 6 of the 6-pin ignition wire harness LIMIT/ROLLOUT Opens Failed Flame SENSE/TRIAL for Ignition Blank Fenwal Triton 2461D DSI Ignition Control HWC122, 182, 242 Refer to Figure 2 on the contactor Second black wireTerminal R on the blower control board Limit Opens FAN on Blank #39247D2 Simplified Sequence HW w/Fenwal 2461D Board Terminal on the blower control board Low Voltage 24 VAC First black wire 1 on the ignition control Limit Opens Only Fenwal 05-29 Ignition Control Refer to Figure Power Limit Opens FAN on Blank Circuits Energized Simplified Sequence HW w/Fenwal 05-29 Board Circulating air blower capacitor terminal Second black wire First black wire 1 on the ignition moduleTerminal L-1 on the blower control board Low Voltage 24 VAC Flame Sense HWC123, 183, 243, 303 Low Ambient HWC123,183, 243 Low Ambient Model HWC122, 182, 242, 302 Low Ambient HWC122,182, 242 Low Ambient Model Unit Tear Down Chassis Removal Evaporator Blower Assembly RemovalHeating Section Cooling Section Induced Draft Combustion Blower Removal Heat Exchanger Removal Unit Tear Down Chassis Removal 63 5/8 I.D Evaporator Blower Assembly Removal Component Location Illustrations Service Reference Manual Component Location Illustrations HW/HWC123,183,243,303 HW/HWC122, 182, 242 HW/HWC Panels HW/HWC Exterior Louver/Grill Panel HWC Chassis Assembly Armstrong P/N 03982D004 Armstrong P/N Band Armstrong P/N 07407B000 Arms Armstrong P/N 07408B004 10.75 x63 5/8 16.5 x 25 x Unit Components Unit Components Transformer *1 Transformer Specifications24 VAC Secondary 208/240 VAC White-Rodgers 25K49-120 Gas Valves *7 Honeywell 8105 Series Gas Valve Specifications 24VAC Heatcraft Blower Control Board IBC-H4C401 Ignition Controls *24 Ignition Control SpecificationsFenwal Triton 2461D Triton 2461D Diagnostic Flash Code Diagnostics Fenwal Triton 2461D Fenw Integrated Blower/Ignition Control *24 Integrated Control SpecificationsUnited Technologies Model United Technologies Model 1097-400-1 Fan On Delay Heat ModeFan Off Delay Induced Draft Blower *63 Induced Draft Blower Specifications Burners *34 Burner Specifications 11 Inshot Burners Flame Carryover Problems Manifold Orifices *13 Manifold Orifice Specifications Contactor *278 Contactor Specifications 15 Camstat Main Limit Switch Main High Limit Switch *52 17 Flame Rollout Switch Flame Rollout Switch *55 Pressure Switch Specifications Pressure Switch *57 Pressure Switches Pressure Switch Problems Blocked Intake Blocked Flue Terminology What Is Needed for the Tests Word About the Switch Open Value Word About the Switch Closed ValueProcedure for Checking Pressure Switch 20 Incline Manometer Connection Compressors *262 Compressor Specifications on next RLA LRA Manufacturer Tecumseh Tecumseh Rotary Compressor SpecificationsTop View Side View 22 Tecumseh Reciprocating Compressor Tecumseh Reciprocating Compressor Specifications Manufacturer Copeland Copeland Compressor SpecificationsLayout 24 Copeland Compressor Side View Drier-Filters *301 10 Drier-Filter Specifications Armstrong Part Number HWC Capillary Tubes *256 HWC Capillary Tube Specification Tables 26 43267-001 Capillary Tubes 30 43281-001 Capillary Tubes 34 39102B001 Capillary Tubes 12 39102B001 Specifications 13 Capacitor Ratings Armstrong Capacitors *271Volts Dual Single 15 Condenser Fan Motor Specifications 14 Evaporator Blower Motor SpecificationsEvaporator Blower Motor Indoor Blower *69 Condenser Fan Motor Outdoor Motor *267 16 Run Capacitor Ratings Capacitors-Run *86Armstrong Rating 37 Fan Blades HWC Models 122, 182 & 123 Fan Blades *268 38 Fan Blades HWC Models 242, 302 & 243 39 Exterior Grill Panels Exterior Grill Panels Not Listed in the Parts Lists Installation Installation and Operation in Extremely Cold Weather Areas Location HW/HWC Installation and Maintenance Instructions Installation HW/HWC Installation Installing With a Wall Sleeve Installing Without a Wall Sleeve Condensate Drain HWC Models HWC Drain Installation Required Clearances for Direct Vent Terminals Removal of Unit from Common Venting System NOx Insert Removal Gas Supply Piping HW/HWC Minimum Required Surface Area for Disposable Temperature RiseFilters Pressure Regulator High Altitude Adjustments U.S. Installa- tions Adjustments Cooling Section HWC modelsHigh Altitude Adjustments Canadian Instal- lations Cubic Feet Per Revolution 3600 Heating Installation and Operation in Extremely Cold Weather Areas HW/HWC Accessory Kit Index Accessories Intended as a general guide only, for use by qualified Components and accessories. These instructions shouldPersonnel, and do not supersede any national or local Codes in any way CA-239 Wall Sleeve Kit Wall Sleeve Assembly CA-239 Wall Sleeve Kit Assembly CA-239 Parts List Recessed Wall Sleeve Installation Wall Sleeve Installation Weather Sealing Magic-Pak Installation A242-1 Wall Sleeve Adaptor Kit Wall Sleeve Adaptor Kit Assembly Attachment to HW/HWC Installing the HW/HWC Unit A242-1 Wall Sleeve Adaptor Kit Assembly A242-1 Parts List Installation AssemblyALVR42 Architectural Aluminum Louver Facade Alvr Architectural Aluminum Extended Louver 34961A001 Compressor Vibration Isolator Kit 34961A001 Parts List ALPKT389-2 L.P. Gas Conversion Kit ALPKT389-2 Parts ListALPKT389-2 Orifices AHALT390-1 High Altitude Kit AHALT390-1 Parts ListRegulator Natural Gas Regulator Propane Accessories ATIMR466-1 Short Cycle Protector Kit ATIMR466-1 Parts List ADAPT420-2 Chassis Conversion Kit 10 ADAPT420-2 Parts List Fenwal Triton Ignition Control Kit 11 Triton Ignition Control Kit Parts List TL109 Burner Tray TL109 Burner Tray Kit AMUFFKT494-1 Discharge Muffler Kit AMUFFKT494-1 Kit Discharge Muffler Installation HW-1 HWA-9 HWC123, 183, 243, 303S-1 Parts ListsHWC123, 183, 243, 303H-1 HWC3-A-1 HWC3-A-1 COMPRESSOR-AW501ET-089-A4 HWC182-242A-11 HWC182-242A-11 HWC122-242A-10 Revised HWC122-242A-10 26HWC122A-10 38HWC122A-10 38HWC242A-10 HWC182-9 HWC182-9 HWC242-302-9 HWC242-302-9 HWC-8 HWC-8cont REC Stocking Service Level COMP-ZR28K1-PFV HWC-6/7 HWC-6/7 HWC-5 HWC-5cont 64HWC302-5A Last letter of the Model # is the Service Level 64HWC302-5 a Last letter of the Model # is the Service Level HWC-4 HWC-4cont Capacitor 25/5 MFD@370VAC HWC-3 HWC-3cont 64HWC302-3A Last letter of the Model # is the Service Level CAP Tube Assy HWC-2 HWC-2cont HWC-1 HWC-1cont Coil Outdoor HW-1 HW-1cont HWA-9 HWA-9cont HWC3-S-1 HWC3-S-1 RELAY-CONDENSER FAN Motor HWC3-H-1 HWC3-H-1 COMPRESSOR-AW501ET-089-A4 Troubleshooting Troubleshooting Performance Charge WeightsPerformance Tests Installed Performance Tests Bench Tested Performance Initial Testing TroubleshootingFurther Testing Compressor Checkout Example #1 Checking Windings Checking the Thermal Overload Device Example #2 Troubleshooting Magic-Pak HW/HWC Capacitor Checkout Capacitor Testing Troubleshooting Example Determining Capacitance MFD Rating with a Test Cord HWC122 Performance Test Chassis Installed Performance Tests Chassis Installed in UnitHWC182 Performance Test Chassis Installed Performance Checkout HWC302 Performance Test Chassis Installed HWC242 Performance Test Chassis Installed Ambient Temperature Chassis Bench Test 70 80 Ambient Temperature Chassis Bench TestHWC Refrigerant Charge Weights Performance Tests Chassis Bench Tested