Manuals / Armstrong World Industries / Household Appliance / Air Conditioner

Armstrong World Industries 302 Contactor Specifications, 14 Honeywell Contactor Model R8242A-1008

Models: 183 182 203 123 122 242 302 243

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UNIT COMPONENTS

Magic-Pak: HW/HWC

5-18

Contactor (*278)

Contactor Specifications

Manufacturer: Honeywell

Model: R8242A-1008

Armstrong P/N 7535C001

Single-phase, Single-pole, 25 F.L.A., 125 L.R.A

Coil: 24VAC, 50/60 Hz

Line Voltage: 240/277

Coil Resistance at 70°F: 8 - 10 ohms

Open Contact

Low Voltage

Coil Terminals

Closed Contact

FIGURE 5-14 Honeywell Contactor Model R8242A-1008

SRM-HW/HWC

2/99

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Armstrong World Industries 302, 243, 122, 123, 203, 182, 183 Contactor Specifications, 14 Honeywell Contactor Model R8242A-1008

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 Model Number Guide Models Covered By This ManualProduct Serial Numbers, Beginning HW/HWC ModelsService Reference Manual Summary of Model Revisions/VariationsSPECIFICATIONS Table 1-1 Heating Configurations of HW/HWC UnitsHW/HWC Physical and ElectricalPerformance Ratings SPECIFICATIONS Service Reference ManualPerformance Ratings continued Performance Ratings - HWC182/183¾ DUCT CONNECTION FLANGE Blower PerformanceRETURN AIR OPENING ON BOTTOM 6 x ModelWall 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 w/United Technologies 1097 Spark Ignition System HWC123, 183, 243FIGURE 2-1 Connection Diagram DIAGNOSTICSCALL FOR HEAT Simplified Sequence - HWC123,183, 243FLAME SENSE CALL FOR COOLINGL1 Power POWER Line VoltageL2 Power Low Voltage 24 VACLIMIT/ROLLOUT OPENS PRESSURE SWITCH OPENS BLOCKED FLUEFAILED FLAME SENSE/TRIAL FOR IGNITION “off” delayCALL FOR COOLING Line Voltage Low VoltageFAN ON 6. After the 90-second delay, the ignition control de- energizes the cooling speed relay and the circulat- ing air blower stopsConnection Diagram HW Heating OnlyDIAGNOSTICS w/United Technologies 1097 Spark Ignition SystemSimplified Sequence - HW w/UTEC 1097 Board CALL FOR HEATFAN ON L1 Power POWER Line VoltageL2 Power 3. At the circulating air blower capacitor terminalPRESSURE SWITCH OPENS BLOCKED FLUE Service Reference ManualSEQUENCE OF OPERATIONS LIMIT/ROLLOUT OPENSMagic-Pak HW/HWC SPECIFICATIONSFAILED FLAME SENSE/TRIAL FOR IGNITION FAN ONService Reference Manual SEQUENCE OF OPERATIONSBLANK PAGE HWC122, 182, 242 w/Fenwal Triton 2461D DSI Ignition ControlFIGURE 2-3 Connection Diagram CALL FOR COOLING CALL FOR HEAT1. A call for cooling closes the circuit from R to Y and G FAN ONFirst black wire 1. L-1 on the ignition control POWER Line VoltageSecond black wire 2. L-1 on the contactor 3. L-1 on the blower control boardROLLOUT SWITCH ACTIVATED PRESSURE SWITCH OPENS BLOCKED FLUELIMIT OPENS CALL FOR COOLING Line VoltageSPECIFICATIONS Magic-Pak HW/HWCFAN ON Low Voltage Service Reference Manual SEQUENCE OF OPERATIONSBLANK PAGE HW Heating Only FIGURE 2-4 Connection Diagramw/Fenwal Triton 2461D DSI Ignition Control #39247D2CALL FOR HEAT Simplified Sequence - HW w/Fenwal 2461D BoardFirst black wire 1. L-1 on the ignition control POWER Line VoltageSecond black wire 3. L terminal on the blower control board Low Voltage 24 VACPRESSURE SWITCH OPENS BLOCKED FLUE Service Reference ManualROLLOUT SWITCH ACTIVATED SEQUENCE OF OPERATIONSw/Fenwal 05-29 Ignition Control FIGURE 2-5 Connection DiagramHWC122, 182, 242 SEQUENCE OF OPERATIONS Service Reference ManualRefer to Figure CALL FOR HEATFirst black wire 1. L-1 on the ignition module POWER Line VoltageSecond black wire 2. L-1 on the contactor 3. L-1 on the blower control boardROLLOUT SWITCH ACTIVATED PRESSURE SWITCH OPENS BLOCKED FLUEFLAME SENSE LIMIT OPENSMagic-Pak HW/HWC SPECIFICATIONSLow Voltage FAN ON Low VoltageService Reference Manual SEQUENCE OF OPERATIONSBLANK PAGE SWITCH FIGURE 2-6 Connection DiagramHW Heating Only w/Fenwal 05-29 Ignition ControlCALL FOR HEAT Simplified Sequence - HW w/Fenwal 05-29 BoardFirst black wire 1. L-1 on the ignition module POWER Line Voltage3. Circulating air blower capacitor terminal Second black wire 3. Terminal L-1 on the blower control board Low Voltage 24 VACPRESSURE SWITCH OPENS BLOCKED FLUE Service Reference ManualROLLOUT SWITCH ACTIVATED SEQUENCE OF OPERATIONSFIGURE 2-7 Connection Diagram HWC123, 183, 243, 303 Low AmbientDIAGNOSTICS w/United Technologies 1097 Spark Ignition SystemHWC123,183, 243 Low Ambient Model FIGURE 2-8 Connection Diagram HWC122, 182, 242, 302 Low AmbientService Reference Manual HWC122,182, 242 Low Ambient ModelSEQUENCE OF OPERATIONS Refer to FigureService Reference Manual Section 3 - Unit Tear DownUNIT TEAR DOWN Heating SectionUNIT TEAR DOWN UNIT TEAR DOWNMagic-Pak HW/HWC Heating SectionBURNER ACCESS PANEL FILTER ACCESS DOOR Service Reference ManualUNIT TEAR DOWN PLATE MOUNTING SCREWS INDUCED DRAFT BLOWER COMBUSTION BLOWERUNIT TEAR DOWN L1/L2 WIRES RIGHT SIDE CHASSIS SCREW HOLD DOWN SCREWS FILLER PANELMagic-Pak HW/HWC Cooling SectionEVAPORATOR DRAIN CHASSIS SHOWN PARTIALLY REMOVED LOW VOLTAGE MOLEX PLUGPERMAGUM SEAL TUBE CONNECTIONMOUNTING SCREWS EVAPORATOR BLOWER ASSEMBLY R 3-6 Evaporator Blower Assembly RemovalCONTROL PANEL SCREWS CHASSIS BASE PERMAGUM SEAL BETWEEN BASE RAIL AND CHASSIS BASESection 4 - Component Location Illustrations HW/HWC123,183,243,303 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS HW/HWC122, 182HEAT EXCHANGER ACCESS PANEL ARMSTRONG P/N 38782D001 HW/HWC - PanelsTOP PANEL ASSEMBLY ARMSTRONG P/N 03455D007 INSPECTION WINDOW ARMSTRONG P/N 03551D100 COOLING CONTROL ACCESS PANELCONDENSER AIR FLOW OUTLET EXTERIOR UPPER LOUVER PANEL HW/HWC Exterior Louver/Grill PanelARMSTRONG P/N 03545C000 LOUVERS POINT UPWARD EXTERIOR LOWER GRILL PANELAT 45 ANGLE ARMSTRONG P/N 03551D100HWC Chassis Assembly SEE FIGURE 4-7 FOR CIRCULATING AIR BLOWER COMPONENTS HWC Chassis Assembly - Top ViewCONDENSER MOTOR *267 12-18 ARMSTRONG P/N 24-30 ARMSTRONG P/N CONDENSER FAN MOTOR BRACKET *269 ARMSTRONG P/N 03982D004 FAN SHROUDBLOWER HOUSING *74 ARMSTRONG P/N 39010B001 HWC Chassis Assembly Circulating Air Blower Partially RemovedBLOWER WHEEL *73 ARMSTRONG P/N 34833B001 10.75 x SEE FIGURE FOR FAN CONDENSING PARTSSection 5 - Unit Components UNIT COMPONENTS Transformer Specifications Unit ComponentsFIGURE 5-1 24-volt Transformer Typical Configuration 24 VAC SecondaryFIGURE 5-2 White-Rodgers Gas Valve Gas Valve Specifications 5-5 Honeywell 8105 SeriesFIGURE 5-3 Honeywell Gas Valve FIGURE 5-4 United Technologies Blower Control Board L1 Power OutFan Call Fan On Cooling Call Fan AutoFIGURE 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 SpecificationsUTech Model 1097 Diagnostic Flash Code Diagnostics United TechnologiesQuick Connect Terminal Descriptions Molex/Amp Plug-in DescriptionFan Off Delay Fan On Delay5-13 United Technologies Model 1097-400-1 contFIGURE 5-9 Magnetek JBIMI37NS Induced Draft Blower Induced Draft Blower SpecificationsBurner Specifications Burner Carryover Gap 025 +/-.002 BurnersFIGURE 5-10 Typical Burner Arrangement 5-16 Flame Carryover ProblemsFIGURE 5-11 Inshot Burners FIGURE 5-12 Burner Wing GapTABLE 5-3 Manifold Orifice Specifications Service Reference ManualUNIT COMPONENTS Manifold Orifices *13FIGURE 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 TestsRise” “PressureA Word About the “Switch Closed” Value A Word About the “Switch Open” ValueProcedure for Checking Pressure Switch FIGURE 5-20 Incline Manometer Connection UNIT COMPONENTS TABLE 5-5 Compressor Specifications continued on next pageMagic-Pak HW/HWC Compressors *262UNIT COMPONENTS Service Reference ManualA B D TABLE 5-6 Tecumseh Rotary Compressor SpecificationsFIGURE 5-21 Tecumseh Rotary Compressor Top ViewSide View FIGURE 5-22 Tecumseh Reciprocating Compressor TABLE 5-7 Tecumseh Reciprocating Compressor SpecificationsAW501ET-089-A4 750 /.760 DiameterA B C TABLE 5-8 Copeland Compressor SpecificationsSide View FIGURE 5-23 Copeland CompressorA B E C D TABLE 5-9 Copeland Compressor SpecificationsTop View Top ViewArmstrong Part Number TABLE 5-10 Drier-Filter SpecificationsSupplier Supplier Part NumberHWC Capillary Tube Specification Tables All part numbers provided are Armstrong part numbersSee page 5-34 for drier information Do not kink or flatten during forming All bends 90 unless otherwise notedTape tubes together with masking tape FIGURE 5-26 43267-001 Capillary TubesFIGURE 5-31 40651-001 Capillary Tubes FIGURE 5-30 43281-001 Capillary TubesFIGURE 5-32 40652-001 Capillary Tubes FIGURE 5-33 39103B001 Capillary TubesUNIT COMPONENTS TABLE 5-12 39102B001 SpecificationsMagic-Pak HW/HWC FIGURE 5-34 39102B001 Capillary TubesArmstrong TABLE 5-13 Capacitor RatingsRating VoltsTABLE 5-15 Condenser Fan Motor Specifications TABLE 5-14 Evaporator Blower Motor SpecificationsUNIT COMPONENTS Magic-Pak HW/HWCUNIT COMPONENTS Service Reference ManualCapacitors-Run *86 TABLE 5-16 Run Capacitor RatingsFIGURE 5-37 Fan Blades - HWC Models 122, 182 & 123 AIR FLOW1. 24 Pitch, 3 Blades 2. Material 24 Ga. Galvalume AIR FLOW3. Set Screw 2 5/16-24 x 5/8 long square head, cup point 18.00 + 5002 5019 Diameter Bore RotationUpper Louver Panel Armstrong P/N 03545C000 Lower Grill Panel Armstrong P/N 03551D100FIGURE 5-39 Exterior Grill Panels Section 6 - Installation Installation and Operation in Extremely INSTALLATIONMagic-Pak HW/HWC Cold Weather AreasInstallation 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 Units TABLE 6-2 HW/HWC Installation and Maintenance InstructionsClearance 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 Minimum Required Surface Area for Disposable Temperature RiseFilters Pressure RegulatorCubic Feet Per Revolution BTU/HRX 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 Service Reference Manual Section 7 - AccessoriesHW/HWC Accessory Kit Index ACCESSORIESACCESSORIES AccessoriesMagic-Pak HW/HWC components and accessories. These instructions shouldACCESSORIES Service Reference ManualCA-239 Wall Sleeve Kit Inspection of ShipmentCA-239 Parts List ACCESSORIESFIGURE 7-1 CA-239 Wall Sleeve Kit Assembly Magic-Pak HW/HWCACCESSORIES Service Reference Manual7-5 Wall Sleeve Installation Recessed Wall Sleeve Installation7-6 Magic-Pak Installation ACCESSORIESMagic-Pak HW/HWC Weather SealingACCESSORIES Service Reference ManualA242-1 Wall Sleeve Adaptor Kit Inspection of ShipmentInstalling the HW/HWC Unit ACCESSORIESMagic-Pak HW/HWC 7-8 Attachment to HW/HWCACCESSORIES Service Reference ManualTABLE 7-3 A242-1 Parts List FIGURE 7-2 A242-1 Wall Sleeve Adaptor Kit AssemblyACCESSORIES 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 Parts List ACCESSORIESMagic-Pak HW/HWC ALPKT389-2 L.P. Gas Conversion KitACCESSORIES Service Reference ManualAHALT390-1 Parts List AHALT390-1 High Altitude KitNormal AHALT390-1 OrificesHigh HighService Reference Manual Time Delay RelayACCESSORIES ATIMR466-1 Parts ListTABLE 7-10 ADAPT420-2 Parts List ACCESSORIESMagic-Pak HW/HWC ADAPT420-2 Chassis Conversion KitACCESSORIES Service Reference ManualTABLE 7-11 Triton Ignition Control Kit Parts List Fenwal Triton Ignition Control KitMagic-Pak HW/HWC ACCESSORIESTL109 Burner Tray Kit Burner Carryover Gap 025 +/.002 BurnersACCESSORIES Service Reference ManualFIGURE 7-6 AMUFFKT494-1 Kit Discharge Muffler Installation AMUFFKT494-1 Discharge Muffler KitPARTS LISTS Section 8 - Parts ListsHWC123, 183, 243 HWC182HWC3-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 SERVICE LEVEL = HWC182-242A-11 contREC STOCKING PART First find Model #HWC122-242A-10 REVISED PARTS LISTSPART DESCRIPTION HWC122-242A-10 cont SERVICELEVEL =PART DESCRIPTION PARTS LISTS Service Reference ManualSERVICE LEVEL = HWC122-242A-10 cont38HWC182A-9 HWC182-951HWC182A-9 64HWC182A-9HWC182-9 cont PARTS LISTSFirst find Model # SERVICE LEVEL = HWC242-302-9REC STOCKING PART MAGIC-PAK HW/HWCPARTS LISTS HWC242-302-9 cont51HWC242A-9 64HWC242A-9PART HWC-8PARTS LISTS HWC-8 contSERVICE LEVEL PARTSERVICELEVEL HWC-8 contPART PARTS LISTS HWC-6/7PART 38HWC182-7PARTS LISTS HWC-6/7 contMAGIC-PAK HW/HWC PARTPARTS LISTS HWC-5SERVICE LEVEL PARTPART HWC-5 contPARTS LISTS Service Reference ManualHWC-5 cont PARTPART HWC-438HWC182-4 51HWC182-4Service Reference Manual HWC-4 contPARTS LISTS PARTHWC-4 cont PARTS LISTSMAGIC-PAK HW/HWC PARTPARTS LISTS HWC-3SERVICE LEVEL PARTPART HWC-3 contSERVICE LEVEL PARTS LISTSHWC-3 cont PARTPART HWC-238HWC182-2 51HWC182-2Service Reference Manual HWC-2 contPARTS LISTS PARTPART HWC-1PARTS LISTS HWC-1 contSERVICE LEVEL PART DESCRIPTIONHWC-1 cont PARTS LISTSMAGIC-PAK HW/HWC PARTService Reference Manual HW-1PARTS LISTS PARTPARTS LISTS HW-1 contMAGIC-PAK HW/HWC PARTPARTS LISTS HWA-9PART DESCRIPTION PARTPARTS LISTS HWA-9 contMAGIC-PAK HW/HWC PART DESCRIPTIONService Reference Manual HWC3-S-1PARTS LISTS SERVICE LEVEL =HWC3-S-1 cont PARTS LISTS Service Reference ManualSERVICE LEVEL = HWC3-S-1 contHWC3-H-1 Service Reference Manual HWC3-H-1 contPARTS LISTS SERVICE LEVEL =SERVICE LEVEL = PARTS LISTSHWC3-H-1 cont MAGIC-PAK HW/HWCPerformance Tests Installed Section 9 - Troubleshooting Performance Charge WeightsCompressor Checkout Capacitor CheckoutTroubleshooting must be turned off before continuing with the testingChecking Continuity Example #1 Checking WindingsMagic-Pak HW/HWC TROUBLESHOOTINGExample #2 Checking the Thermal Overload DeviceThere are several reasons why a compressor would overheat the tip of the end of a screwdriver when placed length of time after the power has been turned offA capacitor can store a charge for a considerable This charge can be very dangerous. An electrolyticMotor 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 70 - 80 Ambient Temperature Chassis Bench Test Charge Weights95 Ambient Temperature Chassis Bench Test TABLE 9-7 HWC Refrigerant Charge Weights