Manuals / Armstrong World Industries / Household Appliance / Air Conditioner

Armstrong World Industries 242, 243, 302 Unit Tear Down, Service Reference Manual, Heating Section

Models: 183 182 203 123 122 242 302 243

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Service Reference Manual

UNIT TEAR DOWN

3-1

Section 3 - Unit Tear Down

Heating Section

Heat Exchanger Removal	3-2
Induced Draft Blower Removal	3-2

Cooling Section

Chassis Removal	3-4
Evaporator Blower Assembly Removal	3-6

SRM-HW/HWC 8/99

Page 50

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Armstrong World Industries 242, 243, 302, 122, 123 Unit Tear Down, Service Reference Manual, Heating Section, Cooling Section

Contents

Models HWC Premier 122, 182, 242, 302 123, 183, 243 Service Reference ManualHWC Thru-the-Wall Units Disclaimer TABLE OF CONTENTS Section 1 - Specifications Product Serial Numbers, Beginning Models Covered By This ManualModel Number Guide HW/HWC ModelsSPECIFICATIONS Summary of Model Revisions/VariationsService Reference Manual Table 1-1 Heating Configurations of HW/HWC UnitsPerformance Ratings HW/HWCPhysical and Electrical Performance Ratings continued Service Reference ManualSPECIFICATIONS Performance Ratings - HWC182/183RETURN AIR OPENING ON BOTTOM 6 x Blower Performance¾ DUCT CONNECTION FLANGE Model12 1 Flanges may be assembled 1 or 33 4 from this side of the sleeve Wall Sleeve all measurements in inches1 or 3 3 15 or 121 Section 2 - Sequence of Operation PRESSURE SWITCH OPENS BLOCKED FLUESPECIFICATIONS BLANK PAGE Service Reference ManualSEQUENCE OF OPERATIONS FIGURE 2-1 Connection Diagram HWC123, 183, 243w/United Technologies 1097 Spark Ignition System DIAGNOSTICSFLAME SENSE Simplified Sequence - HWC123,183, 243CALL FOR HEAT CALL FOR COOLINGL2 Power POWER Line VoltageL1 Power Low Voltage 24 VACPRESSURE SWITCH OPENS BLOCKED FLUE LIMIT/ROLLOUT OPENSCALL FOR COOLING Line Voltage “off” delayFAILED FLAME SENSE/TRIAL FOR IGNITION Low Voltage6. After the 90-second delay, the ignition control de- energizes the cooling speed relay and the circulat- ing air blower stops FAN ONDIAGNOSTICS HW Heating OnlyConnection Diagram w/United Technologies 1097 Spark Ignition SystemFAN ON Simplified Sequence - HW w/UTEC 1097 BoardCALL FOR HEAT L2 Power POWER Line VoltageL1 Power 3. At the circulating air blower capacitor terminalSEQUENCE OF OPERATIONS Service Reference ManualPRESSURE SWITCH OPENS BLOCKED FLUE LIMIT/ROLLOUT OPENSFAILED FLAME SENSE/TRIAL FOR IGNITION SPECIFICATIONSMagic-Pak HW/HWC FAN ONBLANK PAGE Service Reference ManualSEQUENCE OF OPERATIONS FIGURE 2-3 Connection Diagram HWC122, 182, 242w/Fenwal Triton 2461D DSI Ignition Control 1. A call for cooling closes the circuit from R to Y and G CALL FOR HEATCALL FOR COOLING FAN ONSecond black wire POWER Line VoltageFirst black wire 1. L-1 on the ignition control 2. L-1 on the contactor 3. L-1 on the blower control boardLIMIT OPENS PRESSURE SWITCH OPENS BLOCKED FLUEROLLOUT SWITCH ACTIVATED CALL FOR COOLING Line VoltageFAN ON Low Voltage SPECIFICATIONSMagic-Pak HW/HWC BLANK PAGE Service Reference ManualSEQUENCE OF OPERATIONS w/Fenwal Triton 2461D DSI Ignition Control FIGURE 2-4 Connection DiagramHW Heating Only #39247D2Simplified Sequence - HW w/Fenwal 2461D Board CALL FOR HEATSecond black wire POWER Line VoltageFirst black wire 1. L-1 on the ignition control 3. L terminal on the blower control board Low Voltage 24 VACROLLOUT SWITCH ACTIVATED Service Reference ManualPRESSURE SWITCH OPENS BLOCKED FLUE SEQUENCE OF OPERATIONSHWC122, 182, 242 w/Fenwal 05-29 Ignition ControlFIGURE 2-5 Connection Diagram Refer to Figure Service Reference ManualSEQUENCE OF OPERATIONS CALL FOR HEATSecond black wire POWER Line VoltageFirst black wire 1. L-1 on the ignition module 2. L-1 on the contactor 3. L-1 on the blower control boardFLAME SENSE PRESSURE SWITCH OPENS BLOCKED FLUEROLLOUT SWITCH ACTIVATED LIMIT OPENSLow Voltage SPECIFICATIONSMagic-Pak HW/HWC FAN ON Low VoltageBLANK PAGE Service Reference ManualSEQUENCE OF OPERATIONS HW Heating Only FIGURE 2-6 Connection DiagramSWITCH w/Fenwal 05-29 Ignition ControlSimplified Sequence - HW w/Fenwal 05-29 Board CALL FOR HEAT3. Circulating air blower capacitor terminal Second black wire POWER Line VoltageFirst black wire 1. L-1 on the ignition module 3. Terminal L-1 on the blower control board Low Voltage 24 VACROLLOUT SWITCH ACTIVATED Service Reference ManualPRESSURE SWITCH OPENS BLOCKED FLUE SEQUENCE OF OPERATIONSDIAGNOSTICS HWC123, 183, 243, 303 Low AmbientFIGURE 2-7 Connection Diagram w/United Technologies 1097 Spark Ignition SystemHWC123,183, 243 Low Ambient Model HWC122, 182, 242, 302 Low Ambient FIGURE 2-8 Connection DiagramSEQUENCE OF OPERATIONS HWC122,182, 242 Low Ambient ModelService Reference Manual Refer to FigureUNIT TEAR DOWN Section 3 - Unit Tear DownService Reference Manual Heating SectionMagic-Pak HW/HWC UNIT TEAR DOWNUNIT TEAR DOWN Heating SectionUNIT TEAR DOWN Service Reference ManualBURNER ACCESS PANEL FILTER ACCESS DOOR PLATE MOUNTING SCREWS INDUCED DRAFT BLOWER COMBUSTION BLOWERMagic-Pak HW/HWC L1/L2 WIRES RIGHT SIDE CHASSIS SCREW HOLD DOWN SCREWS FILLER PANELUNIT TEAR DOWN Cooling SectionPERMAGUM SEAL CHASSIS SHOWN PARTIALLY REMOVED LOW VOLTAGE MOLEX PLUGEVAPORATOR DRAIN TUBE CONNECTIONCONTROL PANEL SCREWS 3-6 Evaporator Blower Assembly RemovalMOUNTING SCREWS EVAPORATOR BLOWER ASSEMBLY R CHASSIS BASE PERMAGUM SEAL BETWEEN BASE RAIL AND CHASSIS BASESection 4 - Component Location Illustrations HW/HWC123,183,243,303 HW/HWC122, 182 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONSTOP PANEL ASSEMBLY ARMSTRONG P/N 03455D007 INSPECTION WINDOW HW/HWC - PanelsHEAT EXCHANGER ACCESS PANEL ARMSTRONG P/N 38782D001 ARMSTRONG P/N 03551D100 COOLING CONTROL ACCESS PANELARMSTRONG P/N 03545C000 LOUVERS POINT UPWARD HW/HWC Exterior Louver/Grill PanelCONDENSER AIR FLOW OUTLET EXTERIOR UPPER LOUVER PANEL EXTERIOR LOWER GRILL PANELAT 45 ANGLE ARMSTRONG P/N 03551D100HWC Chassis Assembly CONDENSER MOTOR *267 12-18 ARMSTRONG P/N 24-30 ARMSTRONG P/N HWC Chassis Assembly - Top ViewSEE FIGURE 4-7 FOR CIRCULATING AIR BLOWER COMPONENTS CONDENSER FAN MOTOR BRACKET *269 ARMSTRONG P/N 03982D004 FAN SHROUDBLOWER WHEEL *73 ARMSTRONG P/N 34833B001 10.75 x SEE FIGURE HWC Chassis Assembly Circulating Air Blower Partially RemovedBLOWER HOUSING *74 ARMSTRONG P/N 39010B001 FOR FAN CONDENSING PARTSSection 5 - Unit Components UNIT COMPONENTS FIGURE 5-1 24-volt Transformer Typical Configuration Unit ComponentsTransformer Specifications 24 VAC SecondaryFIGURE 5-2 White-Rodgers Gas Valve FIGURE 5-3 Honeywell Gas Valve Gas Valve Specifications5-5 Honeywell 8105 Series Fan Call Fan On L1 Power OutFIGURE 5-4 United Technologies Blower Control Board Cooling Call Fan Auto5-7 Heatcraft Model IBC-H4C401 FIGURE 5-5 Heatcraft Blower Control Board IBC-H4C401FIGURE 5-6 Fenwal Triton 2461D Ignition Control Ignition Control SpecificationsFENW Diagnostics Fenwal Triton 2461D Triton 2461D Diagnostic Flash CodeFIGURE 5-7 Fenwal 05-29 Ignition Control Ignition Control SpecificationsFENW Integrated Control Specifications FIGURE 5-8 United Technologies Model 1097 Integrated ControlQuick Connect Terminal Descriptions Diagnostics United TechnologiesUTech Model 1097 Diagnostic Flash Code Molex/Amp Plug-in Description5-13 Fan On DelayFan Off Delay United Technologies Model 1097-400-1 contInduced Draft Blower Specifications FIGURE 5-9 Magnetek JBIMI37NS Induced Draft BlowerFIGURE 5-10 Typical Burner Arrangement Burner SpecificationsBurner Carryover Gap 025 +/-.002 Burners FIGURE 5-11 Inshot Burners Flame Carryover Problems5-16 FIGURE 5-12 Burner Wing GapUNIT COMPONENTS Service Reference ManualTABLE 5-3 Manifold Orifice Specifications Manifold Orifices *13Contactor Specifications FIGURE 5-14 Honeywell Contactor Model R8242A-10083.05 +/-.05 FIGURE 5-15 Camstat Main Limit SwitchFIGURE 5-16 Main Limit Switch FIGURE 5-17 Flame Rollout Switch Pressure Switch Specifications FIGURE 5-18 Pressure SwitchMagic-Pak HW/HWC Pressure SwitchesUNIT COMPONENTS Blocked Intake Blocked Flue UNIT COMPONENTSMagic-Pak HW/HWC Rise” What Is Needed for the Testspressure “PressureProcedure for Checking Pressure Switch A Word About the “Switch Closed” ValueA Word About the “Switch Open” Value FIGURE 5-20 Incline Manometer Connection Magic-Pak HW/HWC TABLE 5-5 Compressor Specifications continued on next pageUNIT COMPONENTS Compressors *262Service Reference Manual UNIT COMPONENTSFIGURE 5-21 Tecumseh Rotary Compressor TABLE 5-6 Tecumseh Rotary Compressor SpecificationsA B D Top ViewAW501ET-089-A4 TABLE 5-7 Tecumseh Reciprocating Compressor SpecificationsSide View FIGURE 5-22 Tecumseh Reciprocating Compressor 750 /.760 DiameterSide View TABLE 5-8 Copeland Compressor SpecificationsA B C FIGURE 5-23 Copeland CompressorTop View TABLE 5-9 Copeland Compressor SpecificationsA B E C D Top ViewSupplier TABLE 5-10 Drier-Filter SpecificationsArmstrong Part Number Supplier Part NumberSee page 5-34 for drier information HWC Capillary Tube Specification TablesAll part numbers provided are Armstrong part numbers Tape tubes together with masking tape All bends 90 unless otherwise notedDo not kink or flatten during forming FIGURE 5-26 43267-001 Capillary TubesFIGURE 5-32 40652-001 Capillary Tubes FIGURE 5-30 43281-001 Capillary TubesFIGURE 5-31 40651-001 Capillary Tubes FIGURE 5-33 39103B001 Capillary TubesMagic-Pak HW/HWC TABLE 5-12 39102B001 SpecificationsUNIT COMPONENTS FIGURE 5-34 39102B001 Capillary TubesRating TABLE 5-13 Capacitor RatingsArmstrong VoltsUNIT COMPONENTS TABLE 5-14 Evaporator Blower Motor SpecificationsTABLE 5-15 Condenser Fan Motor Specifications Magic-Pak HW/HWCCapacitors-Run *86 Service Reference ManualUNIT COMPONENTS TABLE 5-16 Run Capacitor RatingsAIR FLOW FIGURE 5-37 Fan Blades - HWC Models 122, 182 & 1233. Set Screw 2 5/16-24 x 5/8 long square head, cup point AIR FLOW1. 24 Pitch, 3 Blades 2. Material 24 Ga. Galvalume 18.00 + 5002 5019 Diameter Bore RotationFIGURE 5-39 Exterior Grill Panels Upper Louver Panel Armstrong P/N 03545C000 Lower Grill PanelArmstrong P/N 03551D100 Section 6 - Installation Magic-Pak HW/HWC INSTALLATIONInstallation and Operation in Extremely Cold Weather AreasIMPORTANT READ THIS FIRST InstallationHW/HWC Installation and Maintenance Instructions 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% FIGURE 6-1 HW/HWC Installation FLOORRefer 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 Clearance TABLE 6-2 HW/HWC Installation and Maintenance InstructionsUnits 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 Filters Temperature RiseMinimum Required Surface Area for Disposable Pressure RegulatorX 3600 BTU/HRCubic Feet Per Revolution 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 HW/HWC Accessory Kit Index Section 7 - AccessoriesService Reference Manual ACCESSORIESMagic-Pak HW/HWC AccessoriesACCESSORIES components and accessories. These instructions shouldCA-239 Wall Sleeve Kit Service Reference ManualACCESSORIES Inspection of ShipmentFIGURE 7-1 CA-239 Wall Sleeve Kit Assembly ACCESSORIESCA-239 Parts List Magic-Pak HW/HWC7-5 Wall Sleeve Installation Service Reference ManualACCESSORIES Recessed Wall Sleeve InstallationMagic-Pak HW/HWC ACCESSORIES7-6 Magic-Pak Installation Weather SealingA242-1 Wall Sleeve Adaptor Kit Service Reference ManualACCESSORIES Inspection of ShipmentMagic-Pak HW/HWC ACCESSORIESInstalling the HW/HWC Unit 7-8 Attachment to HW/HWCTABLE 7-3 A242-1 Parts List Service Reference ManualACCESSORIES FIGURE 7-2 A242-1 Wall Sleeve Adaptor Kit AssemblyALVR42 Architectural Aluminum Louver Facade ACCESSORIESMagic-Pak HW/HWC FIGURE 7-3 ALVR Architectural Aluminum Extended Louver Service Reference ManualACCESSORIES 34961A001 Compressor Vibration Isolator Kit ACCESSORIESMagic-Pak HW/HWC 34961A001 Parts List Service Reference ManualACCESSORIES Magic-Pak HW/HWC ACCESSORIESALPKT389-2 Parts List ALPKT389-2 L.P. Gas Conversion KitAHALT390-1 Parts List Service Reference ManualACCESSORIES AHALT390-1 High Altitude KitHigh AHALT390-1 OrificesNormal HighACCESSORIES Time Delay RelayService Reference Manual ATIMR466-1 Parts ListMagic-Pak HW/HWC ACCESSORIESTABLE 7-10 ADAPT420-2 Parts List ADAPT420-2 Chassis Conversion KitTABLE 7-11 Triton Ignition Control Kit Parts List Service Reference ManualACCESSORIES Fenwal Triton Ignition Control KitTL109 Burner Tray Kit ACCESSORIESMagic-Pak HW/HWC Burner Carryover Gap 025 +/.002 BurnersFIGURE 7-6 AMUFFKT494-1 Kit Discharge Muffler Installation Service Reference ManualACCESSORIES AMUFFKT494-1 Discharge Muffler KitHWC123, 183, 243 Section 8 - Parts ListsPARTS LISTS HWC182MAGIC-PAK HW/HWC HWC3-A-1PARTS LISTS SERVICELEVEL = HWC3-A-1 contPARTS LISTS MAGIC-PAK HW/HWC PARTS LISTSHWC3-A-1 cont REC STOCKING PART HWC182-242A-11SERVICE LEVEL = REC STOCKING PART HWC182-242A-11 contSERVICE LEVEL = First find Model #PART DESCRIPTION HWC122-242A-10 REVISEDPARTS LISTS PART DESCRIPTION HWC122-242A-10 contSERVICELEVEL = SERVICE LEVEL = Service Reference ManualPARTS LISTS HWC122-242A-10 cont51HWC182A-9 HWC182-938HWC182A-9 64HWC182A-9First find Model # HWC182-9 contPARTS LISTS REC STOCKING PART HWC242-302-9SERVICE LEVEL = MAGIC-PAK HW/HWC51HWC242A-9 HWC242-302-9 contPARTS LISTS 64HWC242A-9HWC-8 PARTSERVICE LEVEL HWC-8 contPARTS LISTS PARTPART SERVICELEVELHWC-8 cont PART HWC-6/7PARTS LISTS 38HWC182-7MAGIC-PAK HW/HWC HWC-6/7 contPARTS LISTS PARTSERVICE LEVEL HWC-5PARTS LISTS PARTHWC-5 cont PARTHWC-5 cont Service Reference ManualPARTS LISTS PART38HWC182-4 HWC-4PART 51HWC182-4PARTS LISTS HWC-4 contService Reference Manual PARTMAGIC-PAK HW/HWC PARTS LISTSHWC-4 cont PARTSERVICE LEVEL HWC-3PARTS LISTS PARTHWC-3 cont PARTHWC-3 cont PARTS LISTSSERVICE LEVEL PART38HWC182-2 HWC-2PART 51HWC182-2PARTS LISTS HWC-2 contService Reference Manual PARTHWC-1 PARTSERVICE LEVEL HWC-1 contPARTS LISTS PART DESCRIPTIONMAGIC-PAK HW/HWC PARTS LISTSHWC-1 cont PARTPARTS LISTS HW-1Service Reference Manual PARTMAGIC-PAK HW/HWC HW-1 contPARTS LISTS PARTPART DESCRIPTION HWA-9PARTS LISTS PARTMAGIC-PAK HW/HWC HWA-9 contPARTS LISTS PART DESCRIPTIONPARTS LISTS HWC3-S-1Service Reference Manual SERVICE LEVEL =HWC3-S-1 cont SERVICE LEVEL = Service Reference ManualPARTS LISTS HWC3-S-1 contHWC3-H-1 PARTS LISTS HWC3-H-1 contService Reference Manual SERVICE LEVEL =HWC3-H-1 cont PARTS LISTSSERVICE LEVEL = MAGIC-PAK HW/HWCCompressor Checkout Section 9 - Troubleshooting Performance Charge WeightsPerformance Tests Installed Capacitor CheckoutChecking Continuity Troubleshootingmust be turned off before continuing with the testing Checking Windings Example #1Example #2 TROUBLESHOOTINGMagic-Pak HW/HWC Checking the Thermal Overload DeviceThere are several reasons why a compressor would overheat A capacitor can store a charge for a considerable length of time after the power has been turned offthe tip of the end of a screwdriver when placed This charge can be very dangerous. An electrolyticMotor overheating internal thermal overload tripped FIGURE 9-1 Determining Capacitance MFD Rating with a Test Cord ExampleHWC182 Performance Test Chassis Installed PerformanceHWC122 Performance Test Chassis Installed TABLE 9-4 HWC302 Performance Test Chassis Installed 9-10 Performance Tests Chassis Installed in Unit - contHWC242 Performance Test Chassis Installed 95 Ambient Temperature Chassis Bench Test Charge Weights70 - 80 Ambient Temperature Chassis Bench Test TABLE 9-7 HWC Refrigerant Charge Weights