Manuals / Armstrong World Industries / Household Appliance / Air Conditioner

Armstrong World Industries 122, 243, 302, 242, 123, 203, 182, 183 manual 17 Flame Rollout Switch

Models: 183 182 203 123 122 242 302 243

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UNIT COMPONENTS

Magic-Pak: HW/HWC

5-20

Flame Rollout Switch (*55)

A Normally Closed switch that opens when abnormal temperatures occur in the burner area, caused by a restricted heat exchanger, causing main burner flame to “roll out” into the vestibule area.

To reset the switch, push the button on top. The button is a different color from the body.

Reset Button

Cutout Temperature: Marked on body of switch Nominal Switch Contact Rating: 15 A @ 120VAC

FIGURE 5-17 Flame Rollout Switch

SRM-HW/HWC

2/99

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Armstrong World Industries 122, 243, 302, 242, 123, 203, 182, 183 manual 17 Flame Rollout Switch

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 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 SPECIFICATIONSPerformance Ratings HW/HWCPhysical and Electrical Performance Ratings - HWC182/183 Service Reference ManualSPECIFICATIONS Performance Ratings continuedModel Blower Performance¾ DUCT CONNECTION FLANGE RETURN AIR OPENING ON BOTTOM 6 x12 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 PRESSURE SWITCH OPENS BLOCKED FLUE Section 2 - Sequence of OperationSPECIFICATIONS BLANK PAGE Service Reference ManualSEQUENCE OF OPERATIONS 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 DIAGNOSTICSFAN ON Simplified Sequence - HW w/UTEC 1097 BoardCALL FOR HEAT 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 IGNITIONBLANK PAGE Service Reference ManualSEQUENCE OF OPERATIONS FIGURE 2-3 Connection Diagram HWC122, 182, 242w/Fenwal Triton 2461D DSI Ignition Control 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 OPENSFAN ON Low Voltage SPECIFICATIONSMagic-Pak HW/HWC BLANK PAGE Service Reference ManualSEQUENCE OF OPERATIONS #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 ACTIVATEDHWC122, 182, 242 w/Fenwal 05-29 Ignition ControlFIGURE 2-5 Connection Diagram 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 VoltageBLANK PAGE Service Reference ManualSEQUENCE OF OPERATIONS 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 FIGURE 5-3 Honeywell Gas Valve Gas Valve Specifications5-5 Honeywell 8105 Series 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-H4C401FIGURE 5-6 Fenwal Triton 2461D Ignition Control Ignition Control SpecificationsFENW Triton 2461D Diagnostic Flash Code Diagnostics Fenwal Triton 2461DFIGURE 5-7 Fenwal 05-29 Ignition Control Ignition Control SpecificationsFENW 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 SpecificationsFIGURE 5-10 Typical Burner Arrangement Burner SpecificationsBurner Carryover Gap 025 +/-.002 Burners 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 Specifications3.05 +/-.05 FIGURE 5-15 Camstat Main Limit SwitchFIGURE 5-16 Main Limit Switch FIGURE 5-17 Flame Rollout Switch FIGURE 5-18 Pressure Switch Pressure Switch SpecificationsMagic-Pak HW/HWC Pressure SwitchesUNIT COMPONENTS Blocked Intake Blocked Flue UNIT COMPONENTSMagic-Pak HW/HWC “Pressure What Is Needed for the Testspressure Rise”Procedure for Checking Pressure Switch A Word About the “Switch Closed” ValueA Word About the “Switch Open” Value 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 SupplierSee page 5-34 for drier information HWC Capillary Tube Specification TablesAll part numbers provided are Armstrong part numbers 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 pointFIGURE 5-39 Exterior Grill Panels Upper Louver Panel Armstrong P/N 03545C000 Lower Grill PanelArmstrong P/N 03551D100 Section 6 - Installation Cold Weather Areas INSTALLATIONInstallation and Operation in Extremely Magic-Pak HW/HWCIMPORTANT 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% 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 ListALVR42 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 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, 243MAGIC-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 = First find Model # HWC182-242A-11 contSERVICE LEVEL = REC STOCKING PARTPART DESCRIPTION HWC122-242A-10 REVISEDPARTS LISTS PART DESCRIPTION HWC122-242A-10 contSERVICELEVEL = HWC122-242A-10 cont Service Reference ManualPARTS LISTS SERVICE LEVEL =64HWC182A-9 HWC182-938HWC182A-9 51HWC182A-9First find Model # HWC182-9 contPARTS LISTS 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 LEVELPART SERVICELEVELHWC-8 cont 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 CheckoutChecking Continuity Troubleshootingmust be turned off before continuing with the testing 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 CordHWC182 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 TABLE 9-7 HWC Refrigerant Charge Weights Charge Weights70 - 80 Ambient Temperature Chassis Bench Test 95 Ambient Temperature Chassis Bench Test