Models HWC Premier 122, 182, 242, 302 123, 183, 243
Service Reference Manual
HWC Thru-the-Wall Units
Disclaimer
TABLE OF CONTENTS
Section 1 - Specifications
HW/HWC Models
Models Covered By This Manual
Model Number Guide
Product Serial Numbers, Beginning
Table 1-1 Heating Configurations of HW/HWC Units
Summary of Model Revisions/Variations
Service Reference Manual
SPECIFICATIONS
Performance Ratings
HW/HWC
Physical and Electrical
Performance Ratings - HWC182/183
Service Reference Manual
SPECIFICATIONS
Performance Ratings continued
Model
Blower Performance
¾ DUCT CONNECTION FLANGE
RETURN AIR OPENING ON BOTTOM 6 x
12 1 Flanges may be assembled 1 or 33 4 from this side of the sleeve
Wall Sleeve all measurements in inches
1 or 3 3 15 or 121
PRESSURE SWITCH OPENS BLOCKED FLUE
Section 2 - Sequence of Operation
SPECIFICATIONS
BLANK PAGE
Service Reference Manual
SEQUENCE OF OPERATIONS
DIAGNOSTICS
HWC123, 183, 243
w/United Technologies 1097 Spark Ignition System
FIGURE 2-1 Connection Diagram
CALL FOR COOLING
Simplified Sequence - HWC123,183, 243
CALL FOR HEAT
FLAME SENSE
Low Voltage 24 VAC
POWER Line Voltage
L1 Power
L2 Power
LIMIT/ROLLOUT OPENS
PRESSURE SWITCH OPENS BLOCKED FLUE
Low Voltage
“off” delay
FAILED FLAME SENSE/TRIAL FOR IGNITION
CALL FOR COOLING Line Voltage
FAN ON
6. After the 90-second delay, the ignition control de- energizes the cooling speed relay and the circulat- ing air blower stops
w/United Technologies 1097 Spark Ignition System
HW Heating Only
Connection Diagram
DIAGNOSTICS
FAN ON
Simplified Sequence - HW w/UTEC 1097 Board
CALL FOR HEAT
3. At the circulating air blower capacitor terminal
POWER Line Voltage
L1 Power
L2 Power
LIMIT/ROLLOUT OPENS
Service Reference Manual
PRESSURE SWITCH OPENS BLOCKED FLUE
SEQUENCE OF OPERATIONS
FAN ON
SPECIFICATIONS
Magic-Pak HW/HWC
FAILED FLAME SENSE/TRIAL FOR IGNITION
BLANK PAGE
Service Reference Manual
SEQUENCE OF OPERATIONS
FIGURE 2-3 Connection Diagram
HWC122, 182, 242
w/Fenwal Triton 2461D DSI Ignition Control
FAN ON
CALL FOR HEAT
CALL FOR COOLING
1. A call for cooling closes the circuit from R to Y and G
2. L-1 on the contactor 3. L-1 on the blower control board
POWER Line Voltage
First black wire 1. L-1 on the ignition control
Second black wire
CALL FOR COOLING Line Voltage
PRESSURE SWITCH OPENS BLOCKED FLUE
ROLLOUT SWITCH ACTIVATED
LIMIT OPENS
FAN ON Low Voltage
SPECIFICATIONS
Magic-Pak HW/HWC
BLANK PAGE
Service Reference Manual
SEQUENCE OF OPERATIONS
#39247D2
FIGURE 2-4 Connection Diagram
HW Heating Only
w/Fenwal Triton 2461D DSI Ignition Control
CALL FOR HEAT
Simplified Sequence - HW w/Fenwal 2461D Board
3. L terminal on the blower control board Low Voltage 24 VAC
POWER Line Voltage
First black wire 1. L-1 on the ignition control
Second black wire
SEQUENCE OF OPERATIONS
Service Reference Manual
PRESSURE SWITCH OPENS BLOCKED FLUE
ROLLOUT SWITCH ACTIVATED
HWC122, 182, 242
w/Fenwal 05-29 Ignition Control
FIGURE 2-5 Connection Diagram
CALL FOR HEAT
Service Reference Manual
SEQUENCE OF OPERATIONS
Refer to Figure
2. L-1 on the contactor 3. L-1 on the blower control board
POWER Line Voltage
First black wire 1. L-1 on the ignition module
Second black wire
LIMIT OPENS
PRESSURE SWITCH OPENS BLOCKED FLUE
ROLLOUT SWITCH ACTIVATED
FLAME SENSE
FAN ON Low Voltage
SPECIFICATIONS
Magic-Pak HW/HWC
Low Voltage
BLANK PAGE
Service Reference Manual
SEQUENCE OF OPERATIONS
w/Fenwal 05-29 Ignition Control
FIGURE 2-6 Connection Diagram
SWITCH
HW Heating Only
CALL FOR HEAT
Simplified Sequence - HW w/Fenwal 05-29 Board
3. Terminal L-1 on the blower control board Low Voltage 24 VAC
POWER Line Voltage
First black wire 1. L-1 on the ignition module
3. Circulating air blower capacitor terminal Second black wire
SEQUENCE OF OPERATIONS
Service Reference Manual
PRESSURE SWITCH OPENS BLOCKED FLUE
ROLLOUT SWITCH ACTIVATED
w/United Technologies 1097 Spark Ignition System
HWC123, 183, 243, 303 Low Ambient
FIGURE 2-7 Connection Diagram
DIAGNOSTICS
HWC123,183, 243 Low Ambient Model
FIGURE 2-8 Connection Diagram
HWC122, 182, 242, 302 Low Ambient
Refer to Figure
HWC122,182, 242 Low Ambient Model
Service Reference Manual
SEQUENCE OF OPERATIONS
Heating Section
Section 3 - Unit Tear Down
Service Reference Manual
UNIT TEAR DOWN
Heating Section
UNIT TEAR DOWN
UNIT TEAR DOWN
Magic-Pak HW/HWC
PLATE MOUNTING SCREWS INDUCED DRAFT BLOWER COMBUSTION BLOWER
Service Reference Manual
BURNER ACCESS PANEL FILTER ACCESS DOOR
UNIT TEAR DOWN
Cooling Section
L1/L2 WIRES RIGHT SIDE CHASSIS SCREW HOLD DOWN SCREWS FILLER PANEL
UNIT TEAR DOWN
Magic-Pak HW/HWC
TUBE CONNECTION
CHASSIS SHOWN PARTIALLY REMOVED LOW VOLTAGE MOLEX PLUG
EVAPORATOR DRAIN
PERMAGUM SEAL
CHASSIS BASE PERMAGUM SEAL BETWEEN BASE RAIL AND CHASSIS BASE
3-6 Evaporator Blower Assembly Removal
MOUNTING SCREWS EVAPORATOR BLOWER ASSEMBLY R
CONTROL PANEL SCREWS
Section 4 - Component Location Illustrations
HW/HWC123,183,243,303
Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS
HW/HWC122, 182
ARMSTRONG P/N 03551D100 COOLING CONTROL ACCESS PANEL
HW/HWC - Panels
HEAT EXCHANGER ACCESS PANEL ARMSTRONG P/N 38782D001
TOP PANEL ASSEMBLY ARMSTRONG P/N 03455D007 INSPECTION WINDOW
EXTERIOR LOWER GRILL PANELAT 45 ANGLE ARMSTRONG P/N 03551D100
HW/HWC Exterior Louver/Grill Panel
CONDENSER AIR FLOW OUTLET EXTERIOR UPPER LOUVER PANEL
ARMSTRONG P/N 03545C000 LOUVERS POINT UPWARD
HWC Chassis Assembly
CONDENSER FAN MOTOR BRACKET *269 ARMSTRONG P/N 03982D004 FAN SHROUD
HWC Chassis Assembly - Top View
SEE FIGURE 4-7 FOR CIRCULATING AIR BLOWER COMPONENTS
CONDENSER MOTOR *267 12-18 ARMSTRONG P/N 24-30 ARMSTRONG P/N
FOR FAN CONDENSING PARTS
HWC Chassis Assembly Circulating Air Blower Partially Removed
BLOWER HOUSING *74 ARMSTRONG P/N 39010B001
BLOWER WHEEL *73 ARMSTRONG P/N 34833B001 10.75 x SEE FIGURE
Section 5 - Unit Components
UNIT COMPONENTS
24 VAC Secondary
Unit Components
Transformer Specifications
FIGURE 5-1 24-volt Transformer Typical Configuration
FIGURE 5-2 White-Rodgers Gas Valve
FIGURE 5-3 Honeywell Gas Valve
Gas Valve Specifications
5-5 Honeywell 8105 Series
Cooling Call Fan Auto
L1 Power Out
FIGURE 5-4 United Technologies Blower Control Board
Fan Call Fan On
FIGURE 5-5 Heatcraft Blower Control Board IBC-H4C401
5-7 Heatcraft Model IBC-H4C401
FIGURE 5-6 Fenwal Triton 2461D Ignition Control
Ignition Control Specifications
FENW
Triton 2461D Diagnostic Flash Code
Diagnostics Fenwal Triton 2461D
FIGURE 5-7 Fenwal 05-29 Ignition Control
Ignition Control Specifications
FENW
FIGURE 5-8 United Technologies Model 1097 Integrated Control
Integrated Control Specifications
Molex/Amp Plug-in Description
Diagnostics United Technologies
UTech Model 1097 Diagnostic Flash Code
Quick Connect Terminal Descriptions
United Technologies Model 1097-400-1 cont
Fan On Delay
Fan Off Delay
5-13
FIGURE 5-9 Magnetek JBIMI37NS Induced Draft Blower
Induced Draft Blower Specifications
FIGURE 5-10 Typical Burner Arrangement
Burner Specifications
Burner Carryover Gap 025 +/-.002 Burners
FIGURE 5-12 Burner Wing Gap
Flame Carryover Problems
5-16
FIGURE 5-11 Inshot Burners
Manifold Orifices *13
Service Reference Manual
TABLE 5-3 Manifold Orifice Specifications
UNIT COMPONENTS
FIGURE 5-14 Honeywell Contactor Model R8242A-1008
Contactor Specifications
3.05 +/-.05
FIGURE 5-15 Camstat Main Limit Switch
FIGURE 5-16 Main Limit Switch
FIGURE 5-17 Flame Rollout Switch
FIGURE 5-18 Pressure Switch
Pressure Switch Specifications
Magic-Pak HW/HWC
Pressure Switches
UNIT COMPONENTS
Blocked Intake
Blocked Flue
UNIT COMPONENTS
Magic-Pak HW/HWC
“Pressure
What Is Needed for the Tests
pressure
Rise”
Procedure for Checking Pressure Switch
A Word About the “Switch Closed” Value
A Word About the “Switch Open” Value
FIGURE 5-20 Incline Manometer Connection
Compressors *262
TABLE 5-5 Compressor Specifications continued on next page
UNIT COMPONENTS
Magic-Pak HW/HWC
UNIT COMPONENTS
Service Reference Manual
Top View
TABLE 5-6 Tecumseh Rotary Compressor Specifications
A B D
FIGURE 5-21 Tecumseh Rotary Compressor
750 /.760 Diameter
TABLE 5-7 Tecumseh Reciprocating Compressor Specifications
Side View FIGURE 5-22 Tecumseh Reciprocating Compressor
AW501ET-089-A4
FIGURE 5-23 Copeland Compressor
TABLE 5-8 Copeland Compressor Specifications
A B C
Side View
Top View
TABLE 5-9 Copeland Compressor Specifications
A B E C D
Top View
Supplier Part Number
TABLE 5-10 Drier-Filter Specifications
Armstrong Part Number
Supplier
See page 5-34 for drier information
HWC Capillary Tube Specification Tables
All part numbers provided are Armstrong part numbers
FIGURE 5-26 43267-001 Capillary Tubes
All bends 90 unless otherwise noted
Do not kink or flatten during forming
Tape tubes together with masking tape
FIGURE 5-33 39103B001 Capillary Tubes
FIGURE 5-30 43281-001 Capillary Tubes
FIGURE 5-31 40651-001 Capillary Tubes
FIGURE 5-32 40652-001 Capillary Tubes
FIGURE 5-34 39102B001 Capillary Tubes
TABLE 5-12 39102B001 Specifications
UNIT COMPONENTS
Magic-Pak HW/HWC
Volts
TABLE 5-13 Capacitor Ratings
Armstrong
Rating
Magic-Pak HW/HWC
TABLE 5-14 Evaporator Blower Motor Specifications
TABLE 5-15 Condenser Fan Motor Specifications
UNIT COMPONENTS
TABLE 5-16 Run Capacitor Ratings
Service Reference Manual
UNIT COMPONENTS
Capacitors-Run *86
FIGURE 5-37 Fan Blades - HWC Models 122, 182 & 123
AIR FLOW
18.00 + 5002 5019 Diameter Bore Rotation
AIR FLOW
1. 24 Pitch, 3 Blades 2. Material 24 Ga. Galvalume
3. Set Screw 2 5/16-24 x 5/8 long square head, cup point
FIGURE 5-39 Exterior Grill Panels
Upper Louver Panel Armstrong P/N 03545C000 Lower Grill Panel
Armstrong P/N 03551D100
Section 6 - Installation
Cold Weather Areas
INSTALLATION
Installation and Operation in Extremely
Magic-Pak HW/HWC
IMPORTANT READ THIS FIRST
Installation
HW/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 Installation
Refer 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 Instructions
Units
Clearance
1. 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 Rise
Minimum Required Surface Area for Disposable
Filters
Heating
BTU/HR
Cubic Feet Per Revolution
X 3600
In 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 - Accessories
Service Reference Manual
HW/HWC Accessory Kit Index
components and accessories. These instructions should
Accessories
ACCESSORIES
Magic-Pak HW/HWC
Inspection of Shipment
Service Reference Manual
ACCESSORIES
CA-239 Wall Sleeve Kit
Magic-Pak HW/HWC
ACCESSORIES
CA-239 Parts List
FIGURE 7-1 CA-239 Wall Sleeve Kit Assembly
Recessed Wall Sleeve Installation
Service Reference Manual
ACCESSORIES
7-5 Wall Sleeve Installation
Weather Sealing
ACCESSORIES
7-6 Magic-Pak Installation
Magic-Pak HW/HWC
Inspection of Shipment
Service Reference Manual
ACCESSORIES
A242-1 Wall Sleeve Adaptor Kit
7-8 Attachment to HW/HWC
ACCESSORIES
Installing the HW/HWC Unit
Magic-Pak HW/HWC
FIGURE 7-2 A242-1 Wall Sleeve Adaptor Kit Assembly
Service Reference Manual
ACCESSORIES
TABLE 7-3 A242-1 Parts List
ALVR42 Architectural Aluminum Louver Facade
ACCESSORIES
Magic-Pak HW/HWC
FIGURE 7-3 ALVR Architectural Aluminum Extended Louver
Service Reference Manual
ACCESSORIES
34961A001 Compressor Vibration Isolator Kit
ACCESSORIES
Magic-Pak HW/HWC
34961A001 Parts List
Service Reference Manual
ACCESSORIES
ALPKT389-2 L.P. Gas Conversion Kit
ACCESSORIES
ALPKT389-2 Parts List
Magic-Pak HW/HWC
AHALT390-1 High Altitude Kit
Service Reference Manual
ACCESSORIES
AHALT390-1 Parts List
High
AHALT390-1 Orifices
Normal
High
ATIMR466-1 Parts List
Time Delay Relay
Service Reference Manual
ACCESSORIES
ADAPT420-2 Chassis Conversion Kit
ACCESSORIES
TABLE 7-10 ADAPT420-2 Parts List
Magic-Pak HW/HWC
Fenwal Triton Ignition Control Kit
Service Reference Manual
ACCESSORIES
TABLE 7-11 Triton Ignition Control Kit Parts List
Burner Carryover Gap 025 +/.002 Burners
ACCESSORIES
Magic-Pak HW/HWC
TL109 Burner Tray Kit
AMUFFKT494-1 Discharge Muffler Kit
Service Reference Manual
ACCESSORIES
FIGURE 7-6 AMUFFKT494-1 Kit Discharge Muffler Installation
HWC182
Section 8 - Parts Lists
PARTS LISTS
HWC123, 183, 243
MAGIC-PAK HW/HWC
HWC3-A-1
PARTS LISTS
SERVICELEVEL =
HWC3-A-1 cont
PARTS LISTS
MAGIC-PAK HW/HWC
PARTS LISTS
HWC3-A-1 cont
REC STOCKING PART
HWC182-242A-11
SERVICE LEVEL =
First find Model #
HWC182-242A-11 cont
SERVICE LEVEL =
REC STOCKING PART
PART DESCRIPTION
HWC122-242A-10 REVISED
PARTS LISTS
PART DESCRIPTION
HWC122-242A-10 cont
SERVICELEVEL =
HWC122-242A-10 cont
Service Reference Manual
PARTS LISTS
SERVICE LEVEL =
64HWC182A-9
HWC182-9
38HWC182A-9
51HWC182A-9
First find Model #
HWC182-9 cont
PARTS LISTS
MAGIC-PAK HW/HWC
HWC242-302-9
SERVICE LEVEL =
REC STOCKING PART
64HWC242A-9
HWC242-302-9 cont
PARTS LISTS
51HWC242A-9
PART
HWC-8
PART
HWC-8 cont
PARTS LISTS
SERVICE LEVEL
PART
SERVICELEVEL
HWC-8 cont
38HWC182-7
HWC-6/7
PARTS LISTS
PART
PART
HWC-6/7 cont
PARTS LISTS
MAGIC-PAK HW/HWC
PART
HWC-5
PARTS LISTS
SERVICE LEVEL
PART
HWC-5 cont
PART
Service Reference Manual
PARTS LISTS
HWC-5 cont
51HWC182-4
HWC-4
PART
38HWC182-4
PART
HWC-4 cont
Service Reference Manual
PARTS LISTS
PART
PARTS LISTS
HWC-4 cont
MAGIC-PAK HW/HWC
PART
HWC-3
PARTS LISTS
SERVICE LEVEL
PART
HWC-3 cont
PART
PARTS LISTS
SERVICE LEVEL
HWC-3 cont
51HWC182-2
HWC-2
PART
38HWC182-2
PART
HWC-2 cont
Service Reference Manual
PARTS LISTS
PART
HWC-1
PART DESCRIPTION
HWC-1 cont
PARTS LISTS
SERVICE LEVEL
PART
PARTS LISTS
HWC-1 cont
MAGIC-PAK HW/HWC
PART
HW-1
Service Reference Manual
PARTS LISTS
PART
HW-1 cont
PARTS LISTS
MAGIC-PAK HW/HWC
PART
HWA-9
PARTS LISTS
PART DESCRIPTION
PART DESCRIPTION
HWA-9 cont
PARTS LISTS
MAGIC-PAK HW/HWC
SERVICE LEVEL =
HWC3-S-1
Service Reference Manual
PARTS LISTS
HWC3-S-1 cont
HWC3-S-1 cont
Service Reference Manual
PARTS LISTS
SERVICE LEVEL =
HWC3-H-1
SERVICE LEVEL =
HWC3-H-1 cont
Service Reference Manual
PARTS LISTS
MAGIC-PAK HW/HWC
PARTS LISTS
SERVICE LEVEL =
HWC3-H-1 cont
Capacitor Checkout
Section 9 - Troubleshooting Performance Charge Weights
Performance Tests Installed
Compressor Checkout
Checking Continuity
Troubleshooting
must be turned off before continuing with the testing
Example #1
Checking Windings
Checking the Thermal Overload Device
TROUBLESHOOTING
Magic-Pak HW/HWC
Example #2
There 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 off
the tip of the end of a screwdriver when placed
A capacitor can store a charge for a considerable
Motor overheating internal thermal overload tripped
Example
FIGURE 9-1 Determining Capacitance MFD Rating with a Test Cord
HWC182 Performance Test Chassis Installed
Performance
HWC122 Performance Test Chassis Installed
TABLE 9-4 HWC302 Performance Test Chassis Installed
9-10 Performance Tests Chassis Installed in Unit - cont
HWC242 Performance Test Chassis Installed
TABLE 9-7 HWC Refrigerant Charge Weights
Charge Weights
70 - 80 Ambient Temperature Chassis Bench Test
95 Ambient Temperature Chassis Bench Test