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