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