Unit Tear Down, Heating Section | Armstrong World Industries 242

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

Image 50

Armstrong World Industries 242, 243, 302, 122, 123, 203, 182, 183 manual Unit Tear Down, Heating Section, Cooling Section

Contents

Service Reference Manual Models HWC Premier 122, 182, 242, 302 123, 183, 243 Disclaimer Table of Contents Specifications Heating Configuration Table Cooling Configuration Table Product Serial Numbers, Beginning Models Covered By This ManualModel Number Guide Summary of Model Revisions/Variations Heating Configurations of HW/HWC UnitsCooling Configurations of HWC Units Performance Ratings Physical and Electrical Specifications HWC UnitsPhysical and Electrical Performance Ratings HWC122/123 Performance Ratings HWC242/243 Performance RatingsPerformance Ratings HWC182/183 Performance Ratings HWC302/303 Blower Performance Blower Performance HWC Units Service Reference Manual Dimensions Wall Sleeve all measurements in inches HW Heating Only Utec 1097 Spark Ignition System Sequence of OperationHWC123,183,243,303 HWC122,182,242,302 Fenwal 2461D Ignition Control HWC123,183,243,303 Low Ambient Control HWC122,182,242,302 HWC122,182,242,302 Fenwal 05-29 Ignition ControlHW Heating Only Fenwal 05-29 Ignition Control Blank Connection Diagram United Technologies 1097 Spark Ignition System Detailed Sequence follows Simplified Sequence HWC123,183, 243Refer to Figure Line Voltage L1 PowerL2 Power 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 HWC122, 182, 242 Fenwal Triton 2461D DSI Ignition Control Refer to Figure Terminal R on the blower control board Second black wire2 on the contactor Limit Opens FAN on Blank #39247D2 Simplified Sequence HW w/Fenwal 2461D Board First black wire 1 on the ignition control Terminal on the blower control board Low Voltage 24 VAC Limit Opens Fenwal 05-29 Ignition Control Only Refer to Figure Power Limit Opens FAN on Blank Circuits Energized Simplified Sequence HW w/Fenwal 05-29 Board Terminal L-1 on the blower control board Low Voltage 24 VAC First black wire 1 on the ignition moduleCirculating air blower capacitor terminal Second black wire 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 Heating Section Chassis Removal Evaporator Blower Assembly RemovalUnit Tear Down Cooling Section Heat Exchanger Removal Induced Draft Combustion Blower Removal Unit Tear Down Chassis Removal 63 5/8 I.D Evaporator Blower Assembly Removal Service Reference Manual Component Location Illustrations 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 Armstrong P/N 03982D004 63 5/8 10.75 xBand Armstrong P/N 07407B000 Arms Armstrong P/N 07408B004 16.5 x 25 x Unit Components Unit Components 24 VAC Secondary Transformer SpecificationsTransformer *1 208/240 VAC Gas Valves *7 White-Rodgers 25K49-120 Gas Valve Specifications Honeywell 8105 Series 24VAC Heatcraft Blower Control Board IBC-H4C401 Fenwal Triton 2461D Ignition Control SpecificationsIgnition Controls *24 Diagnostics Fenwal Triton 2461D Triton 2461D Diagnostic Flash Code Fenw United Technologies Model Integrated Control SpecificationsIntegrated Blower/Ignition Control *24 United Technologies Model 1097-400-1 Fan Off Delay Heat ModeFan On Delay Induced Draft Blower Specifications Induced Draft Blower *63 Burner Specifications Burners *34 Flame Carryover Problems 11 Inshot Burners Manifold Orifice Specifications Manifold Orifices *13 Contactor Specifications Contactor *278 Main High Limit Switch *52 15 Camstat Main Limit Switch Flame Rollout Switch *55 17 Flame Rollout Switch Pressure Switch *57 Pressure Switch Specifications Pressure Switch Problems Pressure Switches Blocked Intake Blocked Flue What Is Needed for the Tests Terminology Procedure for Checking Pressure Switch Word About the Switch Closed ValueWord About the Switch Open Value 20 Incline Manometer Connection Compressor Specifications on next Compressors *262 RLA LRA Top View Tecumseh Rotary Compressor SpecificationsManufacturer Tecumseh Side View Tecumseh Reciprocating Compressor Specifications 22 Tecumseh Reciprocating Compressor Layout Copeland Compressor SpecificationsManufacturer Copeland 24 Copeland Compressor Side View 10 Drier-Filter Specifications Armstrong Part Number Drier-Filters *301 HWC Capillary Tube Specification Tables HWC Capillary Tubes *256 26 43267-001 Capillary Tubes 30 43281-001 Capillary Tubes 12 39102B001 Specifications 34 39102B001 Capillary Tubes Volts Capacitors *27113 Capacitor Ratings Armstrong Dual Single Evaporator Blower Motor Indoor Blower *69 14 Evaporator Blower Motor Specifications15 Condenser Fan Motor Specifications Condenser Fan Motor Outdoor Motor *267 Armstrong Rating Capacitors-Run *8616 Run Capacitor Ratings Fan Blades *268 37 Fan Blades HWC Models 122, 182 & 123 38 Fan Blades HWC Models 242, 302 & 243 Exterior Grill Panels Not Listed in the Parts Lists 39 Exterior Grill Panels Installation Installation and Operation in Extremely Cold Weather Areas HW/HWC Installation and Maintenance Instructions Location Installation Installing With a Wall Sleeve HW/HWC Installation Installing Without a Wall Sleeve HWC Drain Installation Condensate Drain HWC Models Required Clearances for Direct Vent Terminals Removal of Unit from Common Venting System NOx Insert Removal Gas Supply Piping HW/HWC Filters Temperature RiseMinimum Required Surface Area for Disposable Pressure Regulator High Altitude Adjustments Canadian Instal- lations Adjustments Cooling Section HWC modelsHigh Altitude Adjustments U.S. Installa- tions Cubic Feet Per Revolution 3600 Heating Installation and Operation in Extremely Cold Weather Areas Accessories HW/HWC Accessory Kit Index Personnel, and do not supersede any national or local Components and accessories. These instructions shouldIntended as a general guide only, for use by qualified Codes in any way Wall Sleeve Assembly CA-239 Wall Sleeve Kit CA-239 Parts List CA-239 Wall Sleeve Kit Assembly Wall Sleeve Installation Recessed Wall Sleeve Installation Magic-Pak Installation Weather Sealing Wall Sleeve Adaptor Kit Assembly A242-1 Wall Sleeve Adaptor Kit Installing the HW/HWC Unit Attachment to HW/HWC A242-1 Parts List A242-1 Wall Sleeve Adaptor Kit Assembly ALVR42 Architectural Aluminum Louver Facade AssemblyInstallation Alvr Architectural Aluminum Extended Louver 34961A001 Compressor Vibration Isolator Kit 34961A001 Parts List ALPKT389-2 Orifices ALPKT389-2 Parts ListALPKT389-2 L.P. Gas Conversion Kit Regulator Natural Gas AHALT390-1 Parts ListAHALT390-1 High Altitude Kit Accessories Regulator Propane ATIMR466-1 Parts List ATIMR466-1 Short Cycle Protector Kit 10 ADAPT420-2 Parts List ADAPT420-2 Chassis Conversion Kit 11 Triton Ignition Control Kit Parts List Fenwal Triton Ignition Control Kit TL109 Burner Tray Kit TL109 Burner Tray AMUFFKT494-1 Kit Discharge Muffler Installation AMUFFKT494-1 Discharge Muffler Kit HWC123, 183, 243, 303H-1 Parts ListsHW-1 HWA-9 HWC123, 183, 243, 303S-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 REC Stocking Service Level HWC-8cont COMP-ZR28K1-PFV HWC-6/7 HWC-6/7 HWC-5 64HWC302-5A Last letter of the Model # is the Service Level HWC-5cont 64HWC302-5 a Last letter of the Model # is the Service Level HWC-4 HWC-4cont Capacitor 25/5 MFD@370VAC HWC-3 64HWC302-3A Last letter of the Model # is the Service Level HWC-3cont 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 Performance Tests Installed Performance Tests Bench Tested Troubleshooting Performance Charge WeightsTroubleshooting Performance Further Testing TroubleshootingInitial Testing Compressor Checkout Checking Windings Example #1 Example #2 Checking the Thermal Overload Device Troubleshooting Capacitor Testing Magic-Pak HW/HWC Capacitor Checkout Troubleshooting Determining Capacitance MFD Rating with a Test Cord Example HWC182 Performance Test Chassis Installed Performance Tests Chassis Installed in UnitHWC122 Performance Test Chassis Installed Performance Checkout HWC242 Performance Test Chassis Installed HWC302 Performance Test Chassis Installed HWC Refrigerant Charge Weights 70 80 Ambient Temperature Chassis Bench TestAmbient Temperature Chassis Bench Test Performance Tests Chassis Bench Tested