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