Manuals / Armstrong World Industries / Household Appliance / Air Conditioner

Armstrong World Industries 122, 243, 302, 242, 123, 203, 182, 183 manual Table Of Contents

Models: 183 182 203 123 122 242 302 243

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	Service Reference Manual		TABLE OF CONTENTS
		TABLE OF CONTENTS
		TABLE OF CONTENTS
		1	- Specifications
		2	- Sequence of Operations
		3	- Unit Tear Down
		4	- Component Location Illustrations
		5	- Unit Components
		6	- Installation
		7	- Accessories
		8	- Parts Lists
		9	- Troubleshooting/Performance/
			Charge Weights
	Go to:	If you need information on:

	Section 1	Performance, electrical data and cabinet dimensions.
	Section 2	Sequence of operation descriptions with accompanying schematics.
	Section 3	Complete description of unit disassembly.
	Section 4	Locations of major components of HW/HWC models.
	Section 5	Illustrations and specifications for individual components including valves,
		blowers, ignition controls and blower control boards.
	Section 6	Installation requirements and startup guidelines.
	Section 7	Complete listing of all Armstrong accessories available, including wall
		sleeves, louvers and gas conversion kits.
	Section 8	Complete service parts lists for all HW and HWC models.
	Section 9	System check and troubleshooting procedures.

SRM-HW/HWC 8/99

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Armstrong World Industries 122, 243, 302, 242, 123, 203, 182, 183 manual Table Of Contents

Contents

Service Reference Manual HWC Thru-the-Wall UnitsModels HWC Premier 122, 182, 242, 302 123, 183, 243 Disclaimer TABLE OF CONTENTS Section 1 - Specifications HW/HWC Models Models Covered By This ManualModel Number Guide Product Serial Numbers, BeginningTable 1-1 Heating Configurations of HW/HWC Units Summary of Model Revisions/VariationsService Reference Manual SPECIFICATIONSHW/HWC Physical and ElectricalPerformance Ratings Performance Ratings - HWC182/183 Service Reference ManualSPECIFICATIONS Performance Ratings continuedModel Blower Performance¾ DUCT CONNECTION FLANGE RETURN AIR OPENING ON BOTTOM 6 xWall Sleeve all measurements in inches 1 or 3 3 15 or 12112 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 Service Reference Manual SEQUENCE OF OPERATIONSBLANK PAGE DIAGNOSTICS HWC123, 183, 243w/United Technologies 1097 Spark Ignition System FIGURE 2-1 Connection DiagramCALL FOR COOLING Simplified Sequence - HWC123,183, 243CALL FOR HEAT FLAME SENSELow Voltage 24 VAC POWER Line VoltageL1 Power L2 PowerLIMIT/ROLLOUT OPENS PRESSURE SWITCH OPENS BLOCKED FLUELow Voltage “off” delayFAILED FLAME SENSE/TRIAL FOR IGNITION CALL FOR COOLING Line VoltageFAN ON 6. After the 90-second delay, the ignition control de- energizes the cooling speed relay and the circulat- ing air blower stopsw/United Technologies 1097 Spark Ignition System HW Heating OnlyConnection Diagram DIAGNOSTICSSimplified Sequence - HW w/UTEC 1097 Board CALL FOR HEATFAN ON 3. At the circulating air blower capacitor terminal POWER Line VoltageL1 Power L2 PowerLIMIT/ROLLOUT OPENS Service Reference ManualPRESSURE SWITCH OPENS BLOCKED FLUE SEQUENCE OF OPERATIONSFAN ON SPECIFICATIONSMagic-Pak HW/HWC FAILED FLAME SENSE/TRIAL FOR IGNITIONService Reference Manual SEQUENCE OF OPERATIONSBLANK PAGE HWC122, 182, 242 w/Fenwal Triton 2461D DSI Ignition ControlFIGURE 2-3 Connection Diagram FAN ON CALL FOR HEATCALL FOR COOLING 1. A call for cooling closes the circuit from R to Y and G2. L-1 on the contactor 3. L-1 on the blower control board POWER Line VoltageFirst black wire 1. L-1 on the ignition control Second black wireCALL FOR COOLING Line Voltage PRESSURE SWITCH OPENS BLOCKED FLUEROLLOUT SWITCH ACTIVATED LIMIT OPENSSPECIFICATIONS Magic-Pak HW/HWCFAN ON Low Voltage Service Reference Manual SEQUENCE OF OPERATIONSBLANK PAGE #39247D2 FIGURE 2-4 Connection DiagramHW Heating Only w/Fenwal Triton 2461D DSI Ignition ControlCALL FOR HEAT Simplified Sequence - HW w/Fenwal 2461D Board3. L terminal on the blower control board Low Voltage 24 VAC POWER Line VoltageFirst black wire 1. L-1 on the ignition control Second black wireSEQUENCE OF OPERATIONS Service Reference ManualPRESSURE SWITCH OPENS BLOCKED FLUE ROLLOUT SWITCH ACTIVATEDw/Fenwal 05-29 Ignition Control FIGURE 2-5 Connection DiagramHWC122, 182, 242 CALL FOR HEAT Service Reference ManualSEQUENCE OF OPERATIONS Refer to Figure2. L-1 on the contactor 3. L-1 on the blower control board POWER Line VoltageFirst black wire 1. L-1 on the ignition module Second black wireLIMIT OPENS PRESSURE SWITCH OPENS BLOCKED FLUEROLLOUT SWITCH ACTIVATED FLAME SENSEFAN ON Low Voltage SPECIFICATIONSMagic-Pak HW/HWC Low VoltageService Reference Manual SEQUENCE OF OPERATIONSBLANK PAGE w/Fenwal 05-29 Ignition Control FIGURE 2-6 Connection DiagramSWITCH HW Heating OnlyCALL FOR HEAT Simplified Sequence - HW w/Fenwal 05-29 Board3. Terminal L-1 on the blower control board Low Voltage 24 VAC POWER Line VoltageFirst black wire 1. L-1 on the ignition module 3. Circulating air blower capacitor terminal Second black wireSEQUENCE OF OPERATIONS Service Reference ManualPRESSURE SWITCH OPENS BLOCKED FLUE ROLLOUT SWITCH ACTIVATEDw/United Technologies 1097 Spark Ignition System HWC123, 183, 243, 303 Low AmbientFIGURE 2-7 Connection Diagram DIAGNOSTICSHWC123,183, 243 Low Ambient Model FIGURE 2-8 Connection Diagram HWC122, 182, 242, 302 Low AmbientRefer to Figure HWC122,182, 242 Low Ambient ModelService Reference Manual SEQUENCE OF OPERATIONSHeating Section Section 3 - Unit Tear DownService Reference Manual UNIT TEAR DOWNHeating Section UNIT TEAR DOWNUNIT TEAR DOWN Magic-Pak HW/HWCPLATE MOUNTING SCREWS INDUCED DRAFT BLOWER COMBUSTION BLOWER Service Reference ManualBURNER ACCESS PANEL FILTER ACCESS DOOR UNIT TEAR DOWNCooling Section L1/L2 WIRES RIGHT SIDE CHASSIS SCREW HOLD DOWN SCREWS FILLER PANELUNIT TEAR DOWN Magic-Pak HW/HWCTUBE CONNECTION CHASSIS SHOWN PARTIALLY REMOVED LOW VOLTAGE MOLEX PLUGEVAPORATOR DRAIN PERMAGUM SEALCHASSIS BASE PERMAGUM SEAL BETWEEN BASE RAIL AND CHASSIS BASE 3-6 Evaporator Blower Assembly RemovalMOUNTING SCREWS EVAPORATOR BLOWER ASSEMBLY R CONTROL PANEL SCREWSSection 4 - Component Location Illustrations HW/HWC123,183,243,303 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS HW/HWC122, 182ARMSTRONG P/N 03551D100 COOLING CONTROL ACCESS PANEL HW/HWC - PanelsHEAT EXCHANGER ACCESS PANEL ARMSTRONG P/N 38782D001 TOP PANEL ASSEMBLY ARMSTRONG P/N 03455D007 INSPECTION WINDOWEXTERIOR LOWER GRILL PANELAT 45 ANGLE ARMSTRONG P/N 03551D100 HW/HWC Exterior Louver/Grill PanelCONDENSER AIR FLOW OUTLET EXTERIOR UPPER LOUVER PANEL ARMSTRONG P/N 03545C000 LOUVERS POINT UPWARDHWC Chassis Assembly CONDENSER FAN MOTOR BRACKET *269 ARMSTRONG P/N 03982D004 FAN SHROUD HWC Chassis Assembly - Top ViewSEE FIGURE 4-7 FOR CIRCULATING AIR BLOWER COMPONENTS CONDENSER MOTOR *267 12-18 ARMSTRONG P/N 24-30 ARMSTRONG P/NFOR FAN CONDENSING PARTS HWC Chassis Assembly Circulating Air Blower Partially RemovedBLOWER HOUSING *74 ARMSTRONG P/N 39010B001 BLOWER WHEEL *73 ARMSTRONG P/N 34833B001 10.75 x SEE FIGURESection 5 - Unit Components UNIT COMPONENTS 24 VAC Secondary Unit ComponentsTransformer Specifications FIGURE 5-1 24-volt Transformer Typical ConfigurationFIGURE 5-2 White-Rodgers Gas Valve Gas Valve Specifications 5-5 Honeywell 8105 SeriesFIGURE 5-3 Honeywell Gas Valve Cooling Call Fan Auto L1 Power OutFIGURE 5-4 United Technologies Blower Control Board Fan Call Fan OnFIGURE 5-5 Heatcraft Blower Control Board IBC-H4C401 5-7 Heatcraft Model IBC-H4C401Ignition Control Specifications FENWFIGURE 5-6 Fenwal Triton 2461D Ignition Control Triton 2461D Diagnostic Flash Code Diagnostics Fenwal Triton 2461DIgnition Control Specifications FENWFIGURE 5-7 Fenwal 05-29 Ignition Control FIGURE 5-8 United Technologies Model 1097 Integrated Control Integrated Control SpecificationsMolex/Amp Plug-in Description Diagnostics United TechnologiesUTech Model 1097 Diagnostic Flash Code Quick Connect Terminal DescriptionsUnited Technologies Model 1097-400-1 cont Fan On DelayFan Off Delay 5-13FIGURE 5-9 Magnetek JBIMI37NS Induced Draft Blower Induced Draft Blower SpecificationsBurner Specifications Burner Carryover Gap 025 +/-.002 BurnersFIGURE 5-10 Typical Burner Arrangement FIGURE 5-12 Burner Wing Gap Flame Carryover Problems5-16 FIGURE 5-11 Inshot BurnersManifold Orifices *13 Service Reference ManualTABLE 5-3 Manifold Orifice Specifications UNIT COMPONENTSFIGURE 5-14 Honeywell Contactor Model R8242A-1008 Contactor SpecificationsFIGURE 5-15 Camstat Main Limit Switch FIGURE 5-16 Main Limit Switch3.05 +/-.05 FIGURE 5-17 Flame Rollout Switch FIGURE 5-18 Pressure Switch Pressure Switch SpecificationsPressure Switches UNIT COMPONENTSMagic-Pak HW/HWC Blocked Intake UNIT COMPONENTS Magic-Pak HW/HWCBlocked Flue “Pressure What Is Needed for the Testspressure Rise”A Word About the “Switch Closed” Value A Word About the “Switch Open” ValueProcedure for Checking Pressure Switch FIGURE 5-20 Incline Manometer Connection Compressors *262 TABLE 5-5 Compressor Specifications continued on next pageUNIT COMPONENTS Magic-Pak HW/HWCUNIT COMPONENTS Service Reference ManualTop View TABLE 5-6 Tecumseh Rotary Compressor SpecificationsA B D FIGURE 5-21 Tecumseh Rotary Compressor750 /.760 Diameter TABLE 5-7 Tecumseh Reciprocating Compressor SpecificationsSide View FIGURE 5-22 Tecumseh Reciprocating Compressor AW501ET-089-A4FIGURE 5-23 Copeland Compressor TABLE 5-8 Copeland Compressor SpecificationsA B C Side ViewTop View TABLE 5-9 Copeland Compressor SpecificationsA B E C D Top ViewSupplier Part Number TABLE 5-10 Drier-Filter SpecificationsArmstrong Part Number SupplierHWC Capillary Tube Specification Tables All part numbers provided are Armstrong part numbersSee page 5-34 for drier information FIGURE 5-26 43267-001 Capillary Tubes All bends 90 unless otherwise notedDo not kink or flatten during forming Tape tubes together with masking tapeFIGURE 5-33 39103B001 Capillary Tubes FIGURE 5-30 43281-001 Capillary TubesFIGURE 5-31 40651-001 Capillary Tubes FIGURE 5-32 40652-001 Capillary TubesFIGURE 5-34 39102B001 Capillary Tubes TABLE 5-12 39102B001 SpecificationsUNIT COMPONENTS Magic-Pak HW/HWCVolts TABLE 5-13 Capacitor RatingsArmstrong RatingMagic-Pak HW/HWC TABLE 5-14 Evaporator Blower Motor SpecificationsTABLE 5-15 Condenser Fan Motor Specifications UNIT COMPONENTSTABLE 5-16 Run Capacitor Ratings Service Reference ManualUNIT COMPONENTS Capacitors-Run *86FIGURE 5-37 Fan Blades - HWC Models 122, 182 & 123 AIR FLOW18.00 + 5002 5019 Diameter Bore Rotation AIR FLOW1. 24 Pitch, 3 Blades 2. Material 24 Ga. Galvalume 3. Set Screw 2 5/16-24 x 5/8 long square head, cup pointUpper Louver Panel Armstrong P/N 03545C000 Lower Grill Panel Armstrong P/N 03551D100FIGURE 5-39 Exterior Grill Panels Section 6 - Installation Cold Weather Areas INSTALLATIONInstallation and Operation in Extremely Magic-Pak HW/HWCInstallation HW/HWC Installation and Maintenance InstructionsIMPORTANT 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 FIGURE 6-3 Required Clearances for Direct Vent Terminals TABLE 6-2 HW/HWC Installation and Maintenance InstructionsUnits Clearance1. Seal any unused openings in the common venting system FIGURE 6-4 NOx Insert Removal FIGURE 6-5 Gas Supply Piping Minimum Circuit Ampacity Pressure Regulator Temperature RiseMinimum Required Surface Area for Disposable FiltersHeating BTU/HRCubic Feet Per Revolution X 3600In 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 ACCESSORIES Section 7 - AccessoriesService Reference Manual HW/HWC Accessory Kit Indexcomponents and accessories. These instructions should AccessoriesACCESSORIES Magic-Pak HW/HWCInspection of Shipment Service Reference ManualACCESSORIES CA-239 Wall Sleeve KitMagic-Pak HW/HWC ACCESSORIESCA-239 Parts List FIGURE 7-1 CA-239 Wall Sleeve Kit AssemblyRecessed Wall Sleeve Installation Service Reference ManualACCESSORIES 7-5 Wall Sleeve InstallationWeather Sealing ACCESSORIES7-6 Magic-Pak Installation Magic-Pak HW/HWCInspection of Shipment Service Reference ManualACCESSORIES A242-1 Wall Sleeve Adaptor Kit7-8 Attachment to HW/HWC ACCESSORIESInstalling the HW/HWC Unit Magic-Pak HW/HWCFIGURE 7-2 A242-1 Wall Sleeve Adaptor Kit Assembly Service Reference ManualACCESSORIES TABLE 7-3 A242-1 Parts ListACCESSORIES Magic-Pak HW/HWCALVR42 Architectural Aluminum Louver Facade Service Reference Manual ACCESSORIESFIGURE 7-3 ALVR Architectural Aluminum Extended Louver ACCESSORIES Magic-Pak HW/HWC34961A001 Compressor Vibration Isolator Kit Service Reference Manual ACCESSORIES34961A001 Parts List ALPKT389-2 L.P. Gas Conversion Kit ACCESSORIESALPKT389-2 Parts List Magic-Pak HW/HWCAHALT390-1 High Altitude Kit Service Reference ManualACCESSORIES AHALT390-1 Parts ListHigh AHALT390-1 OrificesNormal HighATIMR466-1 Parts List Time Delay RelayService Reference Manual ACCESSORIESADAPT420-2 Chassis Conversion Kit ACCESSORIESTABLE 7-10 ADAPT420-2 Parts List Magic-Pak HW/HWCFenwal Triton Ignition Control Kit Service Reference ManualACCESSORIES TABLE 7-11 Triton Ignition Control Kit Parts ListBurner Carryover Gap 025 +/.002 Burners ACCESSORIESMagic-Pak HW/HWC TL109 Burner Tray KitAMUFFKT494-1 Discharge Muffler Kit Service Reference ManualACCESSORIES FIGURE 7-6 AMUFFKT494-1 Kit Discharge Muffler InstallationHWC182 Section 8 - Parts ListsPARTS LISTS HWC123, 183, 243HWC3-A-1 PARTS LISTSMAGIC-PAK HW/HWC HWC3-A-1 cont PARTS LISTSSERVICELEVEL = PARTS LISTS HWC3-A-1 contMAGIC-PAK HW/HWC HWC182-242A-11 SERVICE LEVEL =REC STOCKING PART First find Model # HWC182-242A-11 contSERVICE LEVEL = REC STOCKING PARTHWC122-242A-10 REVISED PARTS LISTSPART DESCRIPTION HWC122-242A-10 cont SERVICELEVEL =PART DESCRIPTION HWC122-242A-10 cont Service Reference ManualPARTS LISTS SERVICE LEVEL =64HWC182A-9 HWC182-938HWC182A-9 51HWC182A-9HWC182-9 cont PARTS LISTSFirst find Model # MAGIC-PAK HW/HWC HWC242-302-9SERVICE LEVEL = REC STOCKING PART64HWC242A-9 HWC242-302-9 contPARTS LISTS 51HWC242A-9PART HWC-8PART HWC-8 contPARTS LISTS SERVICE LEVELSERVICELEVEL HWC-8 contPART 38HWC182-7 HWC-6/7PARTS LISTS PARTPART HWC-6/7 contPARTS LISTS MAGIC-PAK HW/HWCPART HWC-5PARTS LISTS SERVICE LEVELPART HWC-5 contPART Service Reference ManualPARTS LISTS HWC-5 cont51HWC182-4 HWC-4PART 38HWC182-4PART HWC-4 contService Reference Manual PARTS LISTSPART PARTS LISTSHWC-4 cont MAGIC-PAK HW/HWCPART HWC-3PARTS LISTS SERVICE LEVELPART HWC-3 contPART PARTS LISTSSERVICE LEVEL HWC-3 cont51HWC182-2 HWC-2PART 38HWC182-2PART HWC-2 contService Reference Manual PARTS LISTSPART HWC-1PART DESCRIPTION HWC-1 contPARTS LISTS SERVICE LEVELPART PARTS LISTSHWC-1 cont MAGIC-PAK HW/HWCPART HW-1Service Reference Manual PARTS LISTSPART HW-1 contPARTS LISTS MAGIC-PAK HW/HWCPART HWA-9PARTS LISTS PART DESCRIPTIONPART DESCRIPTION HWA-9 contPARTS LISTS MAGIC-PAK HW/HWCSERVICE LEVEL = HWC3-S-1Service Reference Manual PARTS LISTSHWC3-S-1 cont HWC3-S-1 cont Service Reference ManualPARTS LISTS SERVICE LEVEL =HWC3-H-1 SERVICE LEVEL = HWC3-H-1 contService Reference Manual PARTS LISTSMAGIC-PAK HW/HWC PARTS LISTSSERVICE LEVEL = HWC3-H-1 contCapacitor Checkout Section 9 - Troubleshooting Performance Charge WeightsPerformance Tests Installed Compressor CheckoutTroubleshooting must be turned off before continuing with the testingChecking Continuity Example #1 Checking WindingsChecking the Thermal Overload Device TROUBLESHOOTINGMagic-Pak HW/HWC Example #2There are several reasons why a compressor would overheat This charge can be very dangerous. An electrolytic length of time after the power has been turned offthe tip of the end of a screwdriver when placed A capacitor can store a charge for a considerableMotor overheating internal thermal overload tripped Example FIGURE 9-1 Determining Capacitance MFD Rating with a Test CordPerformance HWC122 Performance Test Chassis InstalledHWC182 Performance Test Chassis Installed 9-10 Performance Tests Chassis Installed in Unit - cont HWC242 Performance Test Chassis InstalledTABLE 9-4 HWC302 Performance Test Chassis Installed TABLE 9-7 HWC Refrigerant Charge Weights Charge Weights70 - 80 Ambient Temperature Chassis Bench Test 95 Ambient Temperature Chassis Bench Test