Manuals / Armstrong World Industries / Household Appliance / Air Conditioner

Armstrong World Industries 123, 243, 302, 242, 122, 203, 182 Service Reference Manual, Unit Tear Down

Models: 183 182 203 123 122 242 302 243

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Service Reference Manual

UNIT TEAR DOWN

3-3

PLATE MOUNTING

SCREWS

INDUCED DRAFT BLOWER/

COMBUSTION BLOWER

HEAT EXCHANGER

FRONT HEAT

SECTION PANEL

GAS VALVE

HEATING SECTION

VESTIBULE PANEL

CONTROL SECTION

BURNER TRAY

COOLING SECTION

BURNER ACCESS PANEL

FILTER ACCESS DOOR

Figure 3-1

SRM-HW/HWC 8/99

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Armstrong World Industries 123, 243, 302 Service Reference Manual, Unit Tear Down, Burner Access Panel Filter Access Door

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 Models Covered By This Manual Model Number GuideProduct Serial Numbers, Beginning HW/HWC ModelsSummary of Model Revisions/Variations Service Reference ManualSPECIFICATIONS Table 1-1 Heating Configurations of HW/HWC UnitsPhysical and Electrical HW/HWCPerformance Ratings Service Reference Manual SPECIFICATIONSPerformance Ratings continued Performance Ratings - HWC182/183Blower Performance ¾ DUCT CONNECTION FLANGERETURN 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 Section 2 - Sequence of Operation PRESSURE SWITCH OPENS BLOCKED FLUESPECIFICATIONS SEQUENCE OF OPERATIONS Service Reference ManualBLANK PAGE HWC123, 183, 243 w/United Technologies 1097 Spark Ignition SystemFIGURE 2-1 Connection Diagram DIAGNOSTICSSimplified Sequence - HWC123,183, 243 CALL FOR HEATFLAME SENSE CALL FOR COOLINGPOWER Line Voltage L1 PowerL2 Power Low Voltage 24 VACPRESSURE SWITCH OPENS BLOCKED FLUE LIMIT/ROLLOUT OPENS“off” delay FAILED FLAME SENSE/TRIAL FOR IGNITIONCALL FOR COOLING Line Voltage Low Voltage6. After the 90-second delay, the ignition control de- energizes the cooling speed relay and the circulat- ing air blower stops FAN ONHW Heating Only Connection DiagramDIAGNOSTICS w/United Technologies 1097 Spark Ignition SystemCALL FOR HEAT Simplified Sequence - HW w/UTEC 1097 BoardFAN ON POWER Line Voltage L1 PowerL2 Power 3. At the circulating air blower capacitor terminalService Reference Manual PRESSURE SWITCH OPENS BLOCKED FLUESEQUENCE OF OPERATIONS LIMIT/ROLLOUT OPENSSPECIFICATIONS Magic-Pak HW/HWCFAILED 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 HEAT CALL FOR COOLING1. A call for cooling closes the circuit from R to Y and G FAN ONPOWER Line Voltage First black wire 1. L-1 on the ignition controlSecond black wire 2. L-1 on the contactor 3. L-1 on the blower control boardPRESSURE SWITCH OPENS BLOCKED FLUE ROLLOUT SWITCH ACTIVATEDLIMIT OPENS CALL FOR COOLING Line VoltageMagic-Pak HW/HWC SPECIFICATIONSFAN ON Low Voltage SEQUENCE OF OPERATIONS Service Reference ManualBLANK PAGE FIGURE 2-4 Connection Diagram HW Heating Onlyw/Fenwal Triton 2461D DSI Ignition Control #39247D2Simplified Sequence - HW w/Fenwal 2461D Board CALL FOR HEATPOWER Line Voltage First black wire 1. L-1 on the ignition controlSecond black wire 3. L terminal on the blower control board Low Voltage 24 VACService Reference Manual PRESSURE SWITCH OPENS BLOCKED FLUEROLLOUT SWITCH ACTIVATED SEQUENCE OF OPERATIONSFIGURE 2-5 Connection Diagram w/Fenwal 05-29 Ignition ControlHWC122, 182, 242 Service Reference Manual SEQUENCE OF OPERATIONSRefer to Figure CALL FOR HEATPOWER Line Voltage First black wire 1. L-1 on the ignition moduleSecond black wire 2. L-1 on the contactor 3. L-1 on the blower control boardPRESSURE SWITCH OPENS BLOCKED FLUE ROLLOUT SWITCH ACTIVATEDFLAME SENSE LIMIT OPENSSPECIFICATIONS Magic-Pak HW/HWCLow Voltage FAN ON Low VoltageSEQUENCE OF OPERATIONS Service Reference ManualBLANK PAGE FIGURE 2-6 Connection Diagram SWITCHHW Heating Only w/Fenwal 05-29 Ignition ControlSimplified Sequence - HW w/Fenwal 05-29 Board CALL FOR HEATPOWER Line Voltage First black wire 1. L-1 on the ignition module3. Circulating air blower capacitor terminal Second black wire 3. Terminal L-1 on the blower control board Low Voltage 24 VACService Reference Manual PRESSURE SWITCH OPENS BLOCKED FLUEROLLOUT SWITCH ACTIVATED SEQUENCE OF OPERATIONSHWC123, 183, 243, 303 Low Ambient FIGURE 2-7 Connection DiagramDIAGNOSTICS w/United Technologies 1097 Spark Ignition SystemHWC123,183, 243 Low Ambient Model HWC122, 182, 242, 302 Low Ambient FIGURE 2-8 Connection DiagramHWC122,182, 242 Low Ambient Model Service Reference ManualSEQUENCE OF OPERATIONS Refer to FigureSection 3 - Unit Tear Down Service Reference ManualUNIT TEAR DOWN Heating SectionUNIT TEAR DOWN UNIT TEAR DOWNMagic-Pak HW/HWC Heating SectionService Reference Manual BURNER ACCESS PANEL FILTER ACCESS DOORUNIT TEAR DOWN PLATE MOUNTING SCREWS INDUCED DRAFT BLOWER COMBUSTION BLOWERL1/L2 WIRES RIGHT SIDE CHASSIS SCREW HOLD DOWN SCREWS FILLER PANEL UNIT TEAR DOWNMagic-Pak HW/HWC Cooling SectionCHASSIS SHOWN PARTIALLY REMOVED LOW VOLTAGE MOLEX PLUG EVAPORATOR DRAINPERMAGUM SEAL TUBE CONNECTION3-6 Evaporator Blower Assembly Removal MOUNTING SCREWS EVAPORATOR BLOWER ASSEMBLY RCONTROL PANEL SCREWS 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 ILLUSTRATIONSHW/HWC - Panels HEAT EXCHANGER ACCESS PANEL ARMSTRONG P/N 38782D001TOP PANEL ASSEMBLY ARMSTRONG P/N 03455D007 INSPECTION WINDOW ARMSTRONG P/N 03551D100 COOLING CONTROL ACCESS PANELHW/HWC Exterior Louver/Grill Panel CONDENSER AIR FLOW OUTLET EXTERIOR UPPER LOUVER PANELARMSTRONG P/N 03545C000 LOUVERS POINT UPWARD EXTERIOR LOWER GRILL PANELAT 45 ANGLE ARMSTRONG P/N 03551D100HWC Chassis Assembly HWC Chassis Assembly - Top View SEE FIGURE 4-7 FOR CIRCULATING AIR BLOWER COMPONENTSCONDENSER MOTOR *267 12-18 ARMSTRONG P/N 24-30 ARMSTRONG P/N CONDENSER FAN MOTOR BRACKET *269 ARMSTRONG P/N 03982D004 FAN SHROUDHWC Chassis Assembly Circulating Air Blower Partially Removed BLOWER HOUSING *74 ARMSTRONG P/N 39010B001BLOWER WHEEL *73 ARMSTRONG P/N 34833B001 10.75 x SEE FIGURE FOR FAN CONDENSING PARTSSection 5 - Unit Components UNIT COMPONENTS Unit Components Transformer SpecificationsFIGURE 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 L1 Power Out FIGURE 5-4 United Technologies Blower Control BoardFan Call Fan On Cooling Call Fan Auto5-7 Heatcraft Model IBC-H4C401 FIGURE 5-5 Heatcraft Blower Control Board IBC-H4C401FENW Ignition Control SpecificationsFIGURE 5-6 Fenwal Triton 2461D Ignition Control Diagnostics Fenwal Triton 2461D Triton 2461D Diagnostic Flash CodeFENW Ignition Control SpecificationsFIGURE 5-7 Fenwal 05-29 Ignition Control Integrated Control Specifications FIGURE 5-8 United Technologies Model 1097 Integrated ControlDiagnostics United Technologies UTech Model 1097 Diagnostic Flash CodeQuick Connect Terminal Descriptions Molex/Amp Plug-in DescriptionFan On Delay Fan Off Delay5-13 United Technologies Model 1097-400-1 contInduced Draft Blower Specifications FIGURE 5-9 Magnetek JBIMI37NS Induced Draft BlowerBurner Carryover Gap 025 +/-.002 Burners Burner SpecificationsFIGURE 5-10 Typical Burner Arrangement Flame Carryover Problems 5-16FIGURE 5-11 Inshot Burners FIGURE 5-12 Burner Wing GapService Reference Manual TABLE 5-3 Manifold Orifice SpecificationsUNIT COMPONENTS Manifold Orifices *13Contactor Specifications FIGURE 5-14 Honeywell Contactor Model R8242A-1008FIGURE 5-16 Main Limit Switch FIGURE 5-15 Camstat Main Limit Switch3.05 +/-.05 FIGURE 5-17 Flame Rollout Switch Pressure Switch Specifications FIGURE 5-18 Pressure SwitchUNIT COMPONENTS Pressure SwitchesMagic-Pak HW/HWC Blocked Intake Magic-Pak HW/HWC UNIT COMPONENTSBlocked Flue What Is Needed for the Tests pressureRise” “PressureA Word About the “Switch Open” Value A Word About the “Switch Closed” ValueProcedure for Checking Pressure Switch FIGURE 5-20 Incline Manometer Connection TABLE 5-5 Compressor Specifications continued on next page UNIT COMPONENTSMagic-Pak HW/HWC Compressors *262Service Reference Manual UNIT COMPONENTSTABLE 5-6 Tecumseh Rotary Compressor Specifications A B DFIGURE 5-21 Tecumseh Rotary Compressor Top ViewTABLE 5-7 Tecumseh Reciprocating Compressor Specifications Side View FIGURE 5-22 Tecumseh Reciprocating CompressorAW501ET-089-A4 750 /.760 DiameterTABLE 5-8 Copeland Compressor Specifications A B CSide View FIGURE 5-23 Copeland CompressorTABLE 5-9 Copeland Compressor Specifications A B E C DTop View Top ViewTABLE 5-10 Drier-Filter Specifications Armstrong Part NumberSupplier Supplier Part NumberAll part numbers provided are Armstrong part numbers HWC Capillary Tube Specification TablesSee page 5-34 for drier information All bends 90 unless otherwise noted Do not kink or flatten during formingTape tubes together with masking tape FIGURE 5-26 43267-001 Capillary TubesFIGURE 5-30 43281-001 Capillary Tubes FIGURE 5-31 40651-001 Capillary TubesFIGURE 5-32 40652-001 Capillary Tubes FIGURE 5-33 39103B001 Capillary TubesTABLE 5-12 39102B001 Specifications UNIT COMPONENTSMagic-Pak HW/HWC FIGURE 5-34 39102B001 Capillary TubesTABLE 5-13 Capacitor Ratings ArmstrongRating VoltsTABLE 5-14 Evaporator Blower Motor Specifications TABLE 5-15 Condenser Fan Motor SpecificationsUNIT COMPONENTS Magic-Pak HW/HWCService Reference Manual UNIT COMPONENTSCapacitors-Run *86 TABLE 5-16 Run Capacitor RatingsAIR FLOW FIGURE 5-37 Fan Blades - HWC Models 122, 182 & 123AIR FLOW 1. 24 Pitch, 3 Blades 2. Material 24 Ga. Galvalume3. 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 Installation and Operation in ExtremelyMagic-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% 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 TABLE 6-2 HW/HWC Installation and Maintenance Instructions UnitsClearance 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 Temperature Rise Minimum Required Surface Area for DisposableFilters Pressure RegulatorBTU/HR Cubic Feet Per RevolutionX 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 Section 7 - Accessories Service Reference ManualHW/HWC Accessory Kit Index ACCESSORIESAccessories ACCESSORIESMagic-Pak HW/HWC components and accessories. These instructions shouldService Reference Manual ACCESSORIESCA-239 Wall Sleeve Kit Inspection of ShipmentACCESSORIES CA-239 Parts ListFIGURE 7-1 CA-239 Wall Sleeve Kit Assembly Magic-Pak HW/HWCService Reference Manual ACCESSORIES7-5 Wall Sleeve Installation Recessed Wall Sleeve InstallationACCESSORIES 7-6 Magic-Pak InstallationMagic-Pak HW/HWC Weather SealingService Reference Manual ACCESSORIESA242-1 Wall Sleeve Adaptor Kit Inspection of ShipmentACCESSORIES Installing the HW/HWC UnitMagic-Pak HW/HWC 7-8 Attachment to HW/HWCService Reference Manual ACCESSORIESTABLE 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 ACCESSORIES ALPKT389-2 Parts ListMagic-Pak HW/HWC ALPKT389-2 L.P. Gas Conversion KitService Reference Manual ACCESSORIESAHALT390-1 Parts List AHALT390-1 High Altitude KitAHALT390-1 Orifices NormalHigh HighTime Delay Relay Service Reference ManualACCESSORIES ATIMR466-1 Parts ListACCESSORIES TABLE 7-10 ADAPT420-2 Parts ListMagic-Pak HW/HWC ADAPT420-2 Chassis Conversion KitService Reference Manual ACCESSORIESTABLE 7-11 Triton Ignition Control Kit Parts List Fenwal Triton Ignition Control KitACCESSORIES Magic-Pak HW/HWCTL109 Burner Tray Kit Burner Carryover Gap 025 +/.002 BurnersService Reference Manual ACCESSORIESFIGURE 7-6 AMUFFKT494-1 Kit Discharge Muffler Installation AMUFFKT494-1 Discharge Muffler KitSection 8 - Parts Lists 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 HWC182-242A-11 cont SERVICE LEVEL =REC STOCKING PART First find Model #PARTS LISTS HWC122-242A-10 REVISEDPART DESCRIPTION SERVICELEVEL = HWC122-242A-10 contPART DESCRIPTION Service Reference Manual PARTS LISTSSERVICE LEVEL = HWC122-242A-10 contHWC182-9 38HWC182A-951HWC182A-9 64HWC182A-9PARTS LISTS HWC182-9 contFirst find Model # HWC242-302-9 SERVICE LEVEL =REC STOCKING PART MAGIC-PAK HW/HWCHWC242-302-9 cont PARTS LISTS51HWC242A-9 64HWC242A-9HWC-8 PARTHWC-8 cont PARTS LISTSSERVICE LEVEL PARTHWC-8 cont SERVICELEVELPART HWC-6/7 PARTS LISTSPART 38HWC182-7HWC-6/7 cont PARTS LISTSMAGIC-PAK HW/HWC PARTHWC-5 PARTS LISTSSERVICE LEVEL PARTHWC-5 cont PARTService Reference Manual PARTS LISTSHWC-5 cont PARTHWC-4 PART38HWC182-4 51HWC182-4HWC-4 cont Service Reference ManualPARTS LISTS PARTPARTS LISTS HWC-4 contMAGIC-PAK HW/HWC PARTHWC-3 PARTS LISTSSERVICE LEVEL PARTHWC-3 cont PARTPARTS LISTS SERVICE LEVELHWC-3 cont PARTHWC-2 PART38HWC182-2 51HWC182-2HWC-2 cont Service Reference ManualPARTS LISTS PARTHWC-1 PARTHWC-1 cont PARTS LISTSSERVICE LEVEL PART DESCRIPTIONPARTS LISTS HWC-1 contMAGIC-PAK HW/HWC PARTHW-1 Service Reference ManualPARTS LISTS PARTHW-1 cont PARTS LISTSMAGIC-PAK HW/HWC PARTHWA-9 PARTS LISTSPART DESCRIPTION PARTHWA-9 cont PARTS LISTSMAGIC-PAK HW/HWC PART DESCRIPTIONHWC3-S-1 Service Reference ManualPARTS LISTS SERVICE LEVEL =HWC3-S-1 cont Service Reference Manual PARTS LISTSSERVICE LEVEL = HWC3-S-1 contHWC3-H-1 HWC3-H-1 cont Service Reference ManualPARTS LISTS SERVICE LEVEL =PARTS LISTS SERVICE LEVEL =HWC3-H-1 cont MAGIC-PAK HW/HWCSection 9 - Troubleshooting Performance Charge Weights Performance Tests InstalledCompressor Checkout Capacitor Checkoutmust be turned off before continuing with the testing TroubleshootingChecking Continuity Checking Windings Example #1TROUBLESHOOTING Magic-Pak HW/HWCExample #2 Checking the Thermal Overload DeviceThere are several reasons why a compressor would overheat length of time after the power has been turned off the tip of the end of a screwdriver when placedA capacitor can store a charge for a considerable This charge can be very dangerous. An electrolyticMotor overheating internal thermal overload tripped FIGURE 9-1 Determining Capacitance MFD Rating with a Test Cord ExampleHWC122 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 Charge Weights 70 - 80 Ambient Temperature Chassis Bench Test95 Ambient Temperature Chassis Bench Test TABLE 9-7 HWC Refrigerant Charge Weights