Page 2 - Armstrong Air Conditioning Inc.; Disclaimer
SRM-HW/HWC 8/99 Copyright © 1998 Armstrong Air Conditioning Inc. All rights reserved. Disclaimer This manual presents information and guidelines for proper installation, adjustment, operationand maintenance of Armstrong Magic-Pak HW/HWC Thru-the-Wall units. Read this manualbefore attempting assembly...
Page 3 - TABLE OF CONTENTS; - Sequence of Operations; If you need information on:
Service Reference Manual TABLE OF CONTENTS SRM-HW/HWC 8/99 TABLE OF CONTENTS 1 - Specifications 2 - Sequence of Operations 3 - Unit Tear Down 4 - Component Location Illustrations 5 - Unit Components 6 - Installation 7 - Accessories 8 - Par ts Lists 9 - Tr oubleshooting/Per for mance/ Char ge Weights...
Page 4 - Section 1 - Specifications; Summary of Model Revisions/Variations 1-3
1-1 SRM-HW/HWC 8/99 Service Reference Manual SPECIFICATIONS Section 1 - Specifications Models Covered By This Manual ............ 1-2 Model Number Guide ............................ 1-2 Product Serial Numbers(Beginning 1993) ................................. 1-2 Summary of Model Revisions/Variations...
Page 5 - SPECIFICATIONS; Models Covered By This Manual; HWC Gas Heating/Electric Cooling Units; Model Number Guide; 4 = Armstrong Factory Number
1-2 SPECIFICATIONS Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Models Covered By This Manual HWC Gas Heating/Electric Cooling Units HW122, 123HW182,183HW242, 243HW302, 303 HW Gas Heating Only Units 26HW38HW51HW64HW Model Number Guide 26 = Rated Input BTU/Hr x 1000 H = Gas Heat W = Thru-the-Wall C = Cooling 12...
Page 6 - Summary of Model Revisions/Variations; Heating Configurations of HW/HWC Units; if
1-3 SRM-HW/HWC 8/99 Service Reference Manual SPECIFICATIONS Summary of Model Revisions/Variations * For more information on the compressors used in HWC units, see the Unit Components section, beginning on page 5-28. Table 1-1 Heating Configurations of HW/HWC Units Table 1-2 Cooling Configurations of...
Page 7 - Physical and Electrical; Physical and Electrical Specifications - HWC Units
1-4 SPECIFICATIONS Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Physical and Electrical HW/HWC Performance Ratings Table 1-3 Physical and Electrical Specifications - HWC Units l e d o M / e g a tl o V e s a h P / z H l a m r o N e g a tl o V e g n a R . n i M ti u c r i C y ti c a p m A . x a M R C A H / e s u...
Page 9 - Dimensions; Blower Performance - HWC Units; Measurements from Side and
1-6 SPECIFICATIONS Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Dimensions (all measurements in inches) Blower Performance Model Blower Speed CFM @ ext. static pressure - in. w.c. with filter(s) 0.2 0.3 0.4 0.5 HWC122/123 HWC182,242,302HWC183,243,303 SUPPLY AIR DUCT CONNECTION 8" x 16" LOW VOLTAGE THER...
Page 10 - Wall Sleeve; Flanges may be assembled
1-7 SRM-HW/HWC 8/99 Service Reference Manual SPECIFICATIONS Wall Sleeve (all measurements in inches) 22 16 8 6 Return Supply 1 1 1 Supply Low Voltage Line Voltage Box ½ Gas Inlet 3 8 4 1 3 / 4 2 7 / 8 13 3 / 8 43 1 / 8 27 7 / 8 29 7 / 16 2 7 / 8 Dimensions (cont.) 29 16 45 2 2 1 or 3 3 4 Flanges may...
Page 11 - Section 2 - Sequence of Operation
Service Reference Manual SEQUENCE OF OPERATIONS 2-1 SRM-HW/HWC 2/99 Section 2 - Sequence of Operation HWC123,183,243,303 ........................ 2-4 Simplified Sequence ........................................ 2-5Detailed Sequence .......................................... 2-6 POWER ..................
Page 13 - BLANK PAGE
Service Reference Manual SEQUENCE OF OPERATIONS 2-3 SRM-HW/HWC 2/99 BLANK PAGE
Page 14 - Connection Diagram; outdoor; temperatures fall below the
SPECIFICATIONS Magic-Pak: HW/HWC 2-4 SRM-HW/HWC 2/99 FIGURE 2-1 Connection Diagram GREEN BLA C K BLK M ORN ORN VIOLET RED BLUE WHT RED BLACK BLUE YELLOW WH IT E GREEN RED FLAME ROD ELECTRODE 4 6 2 R G W C Y BLA C K BLA C K BLA C K GAS VALVE MANUAL RESET LIMIT SWITCH COMBUSTION BLOWER RED BLUE YELLO ...
Page 15 - CALL FOR HEAT; After 90 seconds, the circulating air blower stops.; FAN ON; Detailed Sequence follows
Service Reference Manual SEQUENCE OF OPERATIONS 2-5 SRM-HW/HWC 2/99 Simplified Sequence - HWC123,183, 243, 303 Refer to Figure 2-1 • 208/230V power is supplied to the junction box ontop of the unit • 24V power is supplied from the unit transformer tothe thermostat CALL FOR HEAT 1. The thermostat clo...
Page 16 - POWER
SPECIFICATIONS Magic-Pak: HW/HWC 2-6 SRM-HW/HWC 2/99 Detailed Sequence - HWC123, 183, 243, 303 Refer to Figure 2-1 POWER Line Voltage With the unit at rest (no call from the thermostat ), line voltage will be present: L1 Power 1. Through the L1 black lead to the L1 terminal on the ignition control 2...
Page 18 - FAILED FLAME SENSE/TRIAL FOR IGNITION
SPECIFICATIONS Magic-Pak: HW/HWC 2-8 SRM-HW/HWC 2/99 8. The 24-volt signal will only be supplied to the limit switch circuit through pin 6 of the 6-pin ignition wire harness and to the pressure switch circuit through pin 2 of the 6-pin ignition wire harness. 9. The system will repeat this sequence u...
Page 26 - (w/Fenwal Triton 2461D DSI Ignition Contr; temperatures fall
SPECIFICATIONS Magic-Pak: HW/HWC 2-16 SRM-HW/HWC 2/99 FIGURE 2-3 Connection Diagram #39007D5 HWC122, 182, 242, 302 (w/Fenwal T (w/Fenwal T (w/Fenwal T (w/Fenwal T (w/Fenwal Triton 2461D DSI Ignition Contr riton 2461D DSI Ignition Contr riton 2461D DSI Ignition Contr riton 2461D DSI Ignition Contr ri...
Page 27 - CALL FOR COOLING; blower control boards have a G “on”; Tridelta; blower control boards have no
Service Reference Manual SEQUENCE OF OPERATIONS 2-17 SRM-HW/HWC 2/99 Detailed Sequence follows CALL FOR COOLING 1. A call for cooling closes the circuit from R to Y andG. 2. A 24-volt signal is sent to blower control boardterminal G and to the compressor contactor. Thecontactor closes, sending line ...
Page 29 - LIMIT OPENS
Service Reference Manual SEQUENCE OF OPERATIONS 2-19 SRM-HW/HWC 2/99 LIMIT OPENS If the limit switch opens for any reason during a call for heat, the following happens: 1. If the limit switch senses that the temperature in the unit is too high, the contacts between terminals C and NC on the limit sw...
Page 39 - FLAME SENSE
Service Reference Manual SEQUENCE OF OPERATIONS 2-29 SRM-HW/HWC 2/99 9. With W de-energized, the gas valve closes immedi- ately and the induced draft blower stops several seconds later. 10. The blower control board starts a 90-second circulating air blower “off ” delay. Approximately 90 seconds late...
Page 40 - Low Voltage
SPECIFICATIONS Magic-Pak: HW/HWC 2-30 SRM-HW/HWC 2/99 3. The unit continues cooling as long as both Y and G are energized. When the cooling call is satisfied,the circuit between Y , G and R is interrupted. The contactor immediately opens, interrupting power to the compressor and the outdoor cooling ...
Page 47 - temperatures fall below the normal operating
Service Reference Manual SEQUENCE OF OPERATIONS 2-37 SRM-HW/HWC 2/99 HWC123,183, 243, 303Low Ambient Model Refer to Figure 2-7 The low ambient switch is designed to allow the opera-tion of the air conditioning unit below the normal operat-ing range. On units equipped with this switch, sequenceof ope...
Page 50 - Section 3 - Unit Tear Down; Heating Section
Service Reference Manual UNIT TEAR DOWN 3-1 SRM-HW/HWC 8/99 Section 3 - Unit Tear Down Heating Section Heat Exchanger Removal ............................ 3-2Induced Draft Blower Removal ..................... 3-2 Cooling Section Chassis Removal ........................................ 3-4Evaporator ...
Page 51 - UNIT TEAR DOWN; heating section; Heat Exchanger Removal:
3-2 UNIT TEAR DOWN Magic-Pak: HW/HWC SRM-HW/HWC 8/99 UNIT TEAR DOWN HWC units are comprised of two major sections. The heating section is located in the top half of the unit. It contains the heat exchanger and the majority of the components associated with theheating function: controls, burners, swi...
Page 53 - To remove the cooling chassis:
3-4 UNIT TEAR DOWN Magic-Pak: HW/HWC SRM-HW/HWC 8/99 FILLER PANEL HOLD DOWN SCREWS L1/L2 WIRES 6-PIN LOW VOLTAGE MOLEX PLUG RIGHT SIDE CHASSIS SCREW Figure 3-2 Cooling Section Chassis Removal: The cooling chassis may be removed from behind the filter access door.Refer to the following directions and...
Page 54 - PERMAGUM SEAL
Service Reference Manual UNIT TEAR DOWN 3-5 SRM-HW/HWC 8/99 EVAPORATOR BLOWER MOTOR COMPRESSOR EVAPORATOR DRAIN PAN EVAPORATOR EVAPORATOR DRAIN TUBE CONNECTION Figure 3-3 LOW VOLTAGEMOLEX PLUG PERMAGUM SEAL EVAPORATOR DRAIN TUBE CONNECTION DRAIN HOSE (NOT PICTURED) ARMSTRONG P/N 03613A001 17" LO...
Page 55 - Evaporator Blower Assembly Removal:
3-6 UNIT TEAR DOWN Magic-Pak: HW/HWC SRM-HW/HWC 8/99 R O T A T IO N MOUNTING SCREWS EVAPORATOR BLOWER ASSEMBLY CONTROL PANEL SCREWS CHASSIS BASE PERMAGUM SEAL (BETWEEN BASE RAIL AND CHASSIS BASE) Figure 3-5 Evaporator Blower Assembly Removal: The evaporator blower assembly is removable as one comple...
Page 56 - Section 4 - Component Location
4-1 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS SRM-HW/HWC 2/99 Section 4 - Component Location Illustrations HW/HWC(3) Unit ................................. 4-2 HW/HWC(2) Unit ................................. 4-3 HW/HWC - Panels ................................ 4-4 HW/HWC - Exterior ...
Page 57 - COMPONENT LOCATION ILLUSTRATIONS
4-2 COMPONENT LOCATION ILLUSTRATIONS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 HW/HWC123,183,243,303 FIGURE 4-1 IGNITION/BLOWER CONTROL BOARD (*24) UNITED TECHNOLOGIES 1097-83-400A/1097-400-I ARMSTRONG P/N 44990-001 (DSI)* MAIN LIMIT SWITCH (*52)ARMSTRONG P/N 40154B007 GAS VALVEHONEYWELL VR8105M8202ARMSTRON...
Page 60 - SIDE VIEW
4-5 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS SRM-HW/HWC 2/99 HW/HWC Exterior Louver/Grill Panel CONDENSER AIR FLOW OUTLET EXTERIOR UPPER LOUVER PANEL ARMSTRONG P/N 03545C000 EXTERIOR LOWER GRILL PANEL ARMSTRONG P/N 03551D100 CONDENSER AIR FLOW INLET SIDE VIEW LOUVERS POINT UPWARDAT ...
Page 61 - HWC Chassis Assembly
4-6 COMPONENT LOCATION ILLUSTRATIONS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 HWC Chassis Assembly EVAPORATOR BLOWER MOTOR (*69) COMPRESSOR CONTACTOR (*278) ARMSTRONG P/N 03575C001 CONDENSING FAN SHROUD CONDENSER FAN (*267, 268) CONDENSING COIL (*250) CAPILLARY TUBEMETERING DEVICE (*256) FILTER DRIER/DISTR...
Page 62 - TOP VIEW — HWC CHASSIS ASSEMBLY; HWC Chassis Assembly - Top View
4-7 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS SRM-HW/HWC 2/99 SEE FIGURE 4-7 FORCIRCULATING AIR BLOWERCOMPONENTS CONDENSER MOTOR (*267)(12-18) ARMSTRONG P/N 41282-001(24-30) ARMSTRONG P/N 41254-001 CONDENSER FAN MOTOR BRACKET (*269)ARMSTRONG P/N 03982D004 FAN SHROUD FAN BLADE (*268) ...
Page 64 - Section 5 - Unit Components
Service Reference Manual UNIT COMPONENTS 5-1 SRM-HW/HWC 2/99 Section 5 - Unit Components Transformer ........................................ 5-3 Gas Valves ........................................... 5-4 White-Rodgers 25K49 ................................ 5-4Honeywell 8105 ...........................
Page 65 - UNIT COMPONENTS
5-2 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 HWC Capillary Tubes .......................... 5-35 Capacitors ......................................... 5-39 Evaporator Blower Motor ................... 5-40 Condenser Fan Motor ......................... 5-40 Capacitors-Run ........................
Page 66 - Unit Components; Note: Secondary leads may exit from top of transformer.; Primary; Quick Connect; Transformer Specifications
Service Reference Manual UNIT COMPONENTS 5-3 SRM-HW/HWC 2/99 Unit Components This section provides a brief description of the most important compo-nents within the Magic-Pak HW/HWC units. The information presentedhere is not intended to take the place of the instructions and printedliterature packed...
Page 67 - Gas Valve Specifications; White-Rodgers Gas Valve
5-4 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Gas Valves (*7) Gas Valve Specifications Manufacturer: White-RodgersModel: 25K49-120Armstrong P/N 43108-001Dimensions: 1.97" W x 5.31" LNominal Operating Currents: 25VAC/60Hz/.5ARegulator set at 3.50 +/– .02” W.C. at 55.6 cubic Ft./Hr of ...
Page 68 - Main Valve Common Terminal; /8 NPT Inlet Pressure Tap; FLOW; /8 NPT Outlet Pressure Tap
Service Reference Manual UNIT COMPONENTS 5-5 SRM-HW/HWC 2/99 Honeywell 8105 Series Gas Valve Specifications Manufacturer: HoneywellModel: VR8105M8202Armstrong P/N 44987-001Dimensions: 2.70" W x 4.75" LNominal Operating Currents: 25VAC/60Hz/.5ARegulator Setting: 3.50 +/– .3" W.C.Pipe Size...
Page 69 - 4VAC Heat Call; Blower Control Board Specifications; Off Delay Timing - 90 seconds; United Technologies Blower Control Board 1010-611
5-6 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Blower Control Boards (*5) A separate blower control board is used in the Magic-Pak HW/HWCmodels that do not use integrated ignition/blower control boards. Blowercontrol boards from two different manufacturers are used in these HWand HWC units. T...
Page 70 - Heatcraft Blower Control Board IBC-H4C401
Service Reference Manual UNIT COMPONENTS 5-7 SRM-HW/HWC 2/99 Heatcraft Model IBC-H4C401 Blower Control Board Specifications Manufacturer: United TechnologiesModel: 1010-611Armstrong P/N 39029B002Operating Voltage: 18-30VAC 60 Hz60 Hz Power Requirement: 4 VA max.Operating Temperature: – 40°F to +170°...
Page 71 - FENWAL; Ignition Control Specifications
5-8 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Ignition Controls (*24) FENWAL ® ¨ V2 GND FC- CAUTION: HIGH VOLTA GE DISCONNECT WIRING BEFORE SER VICING FC+ 24 VAC L1 IND V1 PSW TH Fenwal Triton 2461D Ignition Control Specifications Manufacturer: FenwalModel: Triton 2461DArmstrong P/N 43110-00...
Page 72 - Only one code is displayed at a time.; Triton 2461D Diagnostic Flash Code
Service Reference Manual UNIT COMPONENTS 5-9 SRM-HW/HWC 2/99 Diagnostics (Fenwal Triton 2461D) 1. Diagnostic LED flash rate is 1/4 second “ON”, 1/4 second “OFF”followed by up to four seconds “OFF” before repeating the code. 2. Only one code is displayed at a time. 3. During a “STEADY ON” code, the L...
Page 73 - FENW; Fenwal 05-29 Ignition Control
5-10 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Fenwal 05-29 DSI G N D V2 T2 S1 V1 P. SW L1 IND FENW AL ® Series 05- 29 DSI CAUTI ON HIGH VOL TAG E AUT OMATI C IGNITI ON SYSTEM FIGURE 5-7 Fenwal 05-29 Ignition Control Ignition Control Specifications Manufacturer: FenwalModel: 05-29 DSIArmstro...
Page 74 - United Technologies Model 1097 Integrated Control
Service Reference Manual UNIT COMPONENTS 5-11 SRM-HW/HWC 2/99 Integrated Blower/Ignition Control (*24) United Technologies Model 1097-400-1 The integrated control combines the actions and purposes of the indi-vidual ignition and blower control boards found on other units. It automati-cally monitors ...
Page 75 - UTech Model 1097 Diagnostic Flash Code
5-12 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 TABLE 5-2 UTech Model 1097 Diagnostic Flash Code United Technologies Model 1097-400-1 (cont.) Quick Connect Terminal Descriptions 1 24VAC HOT - from Transformer 2 GROUND = 24VAC Return 4 CMB BLWR = Combustion Blower (Line Voltage) 5 L1 = Line Vo...
Page 76 - Heat Mode
Service Reference Manual UNIT COMPONENTS 5-13 SRM-HW/HWC 2/99 United Technologies Model 1097-400-1 (cont.) Heat Mode Pre-purge 30 seconds Inter-purge 30 seconds Post-purge 5 seconds Trial Time 10 seconds # of Trials 3 Board to reset from lockout after 60 minutes. Fan On Delay Cool 5 seconds (fixed) ...
Page 77 - Blower motors operate at a fixed speed.; Magnetek JBIMI37NS Induced Draft Blower
5-14 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Induced Draft Blower (*63) The induced draft blower is also referred to as a “combustion” blower,since its purpose is to establish flow of combustion air through the heatexchanger. Mounted at the outlet of the secondary heat exchanger, theblower...
Page 78 - Burner Specifications; Burners
Service Reference Manual UNIT COMPONENTS 5-15 SRM-HW/HWC 2/99 Burners (*34) The Magic-Pak HW and HWC units covered in this manual use a burnerdesign called the “inshot” type. No adjustment is provided for primary orsecondary air. For best operation, keep the burners clean. Use thecorrect orifice siz...
Page 79 - Flame Carryover Problems; Carryover “wing” on burner is plugged with insects or debris; Inshot Burners
5-16 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Flame Carryover Problems During ignition, the flame must travel uninterrupted from one burner to therest of the burners. Causes: • Carryover “wing” on burner is plugged with insects or debris • Improper gap setting on wings • Incorrect gas press...
Page 80 - Hole Diameter; FIGURE 5-13 Manifold Orifice; ll
Service Reference Manual UNIT COMPONENTS 5-17 SRM-HW/HWC 2/99 Manifold Orifices (*13) Hole Diameter FIGURE 5-13 Manifold Orifice TABLE 5-3 Manifold Orifice Specifications g n o r t s m r A N / P r e t e m a i D e l o H e z i S ll i r D r e t e m a i D e l o H ) s e h c n i( 1 0 0 B 0 3 0 9 3 k n a l...
Page 81 - Open Contact; Contactor Specifications
5-18 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Contactor (*278) L1 L2 T1 T2 Open Contact Closed Contact Low VoltageCoil Terminals FIGURE 5-14 Honeywell Contactor Model R8242A-1008 Contactor Specifications Manufacturer: HoneywellModel: R8242A-1008Armstrong P/N 7535C001Single-phase, Single-pol...
Page 82 - Note: Several different main limit switches are used.; Refer to the parts; Terminal; FIGURE 5-15 Camstat Main Limit Switch
Service Reference Manual UNIT COMPONENTS 5-19 SRM-HW/HWC 2/99 Main (High) Limit Switch (*52) A Normally Closed control that opens if abnormally high circulating airtemperatures occur. It is an automatic reset control. Note: Several different main limit switches are used. Refer to the parts list for ...
Page 83 - Flame Rollout Switch
5-20 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Flame Rollout Switch (*55) A Normally Closed switch that opens when abnormal temperatures occurin the burner area, caused by a restricted heat exchanger, causing mainburner flame to “roll out” into the vestibule area. To reset the switch, push t...
Page 84 - Electrical Switch; FIGURE 5-18 Pressure Switch
Service Reference Manual UNIT COMPONENTS 5-21 SRM-HW/HWC 2/99 Pressure Switch (*57) These are Normally Open switches that react to a difference in pressureon an internal diaphragm. It will not allow ignition to start if the induceddraft blower cannot produce sufficient negative pressure relative toa...
Page 85 - Pressure Switches; Pressure Switch Problems; Pressure switch hose/tubing for cracks or loose connections
5-22 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 TABLE 5-4 Pressure Switches Pressure Switch Problems The negative pressure developed in the combustion chamber is directlyrelated to airflow. During furnace operation, the switch will react toconditions that reduce airflow, such as: blocked or r...
Page 86 - Blocked Intake; WARNING
Service Reference Manual UNIT COMPONENTS 5-23 SRM-HW/HWC 2/99 Blocked Intake Blocked intake is any condition that blocks or restricts the flow of intake(combustion) air to a point where the pressure fall reaches the calibratedopen setting of the pressure switch. Potential Causes: • Rodents • Spiders...
Page 87 - Blocked Flue; Checking Pressure Switch Operation
5-24 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Blocked Flue Blocked flue is any condition that blocks or restricts the flue (vent) pipe toa point where the pressure fall reaches the calibrated open setting of thepressure switch. Potential Causes: • Rodents • Spiders • Nest building in the fl...
Page 88 - What Is Needed for the Tests; Note: For each procedure, the schematic shows the original factory; Terminology
Service Reference Manual UNIT COMPONENTS 5-25 SRM-HW/HWC 2/99 What Is Needed for the Tests • A good general-purpose incline manometer with a range of 0 - 3"W.C. (Dwyer 1227 or equivalent). • Use the parts list to verify that the proper pressure switch is installedin the unit. Look for the Armstr...
Page 89 - A Word About the “Switch Closed” Value
5-26 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 A Word About the “Switch Closed” Value Switch Closed is the pressure at which the contacts close as the induceddraft blower comes up to speed. It is calculated by adding – 0.1" W.C. tothe sum of the switch’s Open value and its upper toleranc...
Page 90 - FIGURE 5-20 Incline Manometer Connection
Service Reference Manual UNIT COMPONENTS 5-27 SRM-HW/HWC 2/99 0 -1" 1" 2" 3" Pressure Switch 1/8" Tee Induced Draft Blower B A Incline Manometer = Tee installed for test purposes only FIGURE 5-20 Incline Manometer Connection
Page 93 - Tube; Manufacturer: Tecumseh; Side View; il
5-30 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 A B C D I.D. Copper Tube .(43 - .50 " Suction " Deep) .315 I.D.Copper Tube " Discharge .75 Diameter Holes " C S R Manufacturer: Tecumseh All measurements in inches unless otherwise specified. Side View Top View TABLE 5-6 Tecumseh...
Page 94 - Tecumseh Reciprocating Compressor Specifications
Service Reference Manual UNIT COMPONENTS 5-31 SRM-HW/HWC 2/99 TABLE 5-7 Tecumseh Reciprocating Compressor Specifications Manufacturer: Tecumseh .753"/.756" I.D.Copper Tube Suction 12.647"12.753” .378"/.381" I.D. Copper Tube Discharge 7.475"7.525" (Between Centers of Holes...
Page 95 - Manufacturer: Copeland; FIGURE 5-23 Copeland Compressor; Typical T’Box
5-32 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Manufacturer: Copeland A B C D .500" I.D. Copper Tube Discharge .750" I.D. Copper-Plated Steel Tube Suction 18 Ga. Thermal Protector Leads (12.13" Long) 7.50 " (Between Centers of Holes) .765 Diameter (4 Holes) " FIGURE 5-23 ...
Page 96 - Discharge Fitting; FIGURE 5-24 Copeland Compressor; Copeland Compressor Specifications
Service Reference Manual UNIT COMPONENTS 5-33 SRM-HW/HWC 2/99 Manufacturer: Copeland C S R T 1 T 3 T 2 9.41 /9.62 " " 7.50 " (Typ.) 7.50 " (Typ.) .750 Dia. (4 Holes) " A B C D .500" I.D. Copper Discharge Fitting .750" I.D. Copper-Plated Steel Suction Fitting E FIGURE 5-24...
Page 97 - Armstrong Part Number
5-34 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Drier -Filters (*301) .314".317" 4.38" +/– .13" 1.00 " B - # Holes A - I.D. I.D. FIGURE 5-25 Drier-Filter Armstrong Part Number 39059B001 39059B002 39059B003 A B .108".111" .114".117" .108".111" 2 3 4 ...
Page 98 - All part numbers provided are Armstrong par t numbers.; HWC Capillary Tube Specification Tables*
Service Reference Manual UNIT COMPONENTS 5-35 SRM-HW/HWC 2/99 HWC Capillary Tubes (*256) * All part numbers provided are Armstrong par t numbers. ** See page 5-34 for drier information. *** See the figures beginning on page 5-36 for detailed drawings of the capillary tubes. TABLE 5-11 HWC Capillary ...
Page 99 - All bends 90° unless otherwise noted.
5-36 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 30° .75" .25" Rad. I.S. Typ. .13" .08" 3.81" Ref. 6.00" 11.89" Ref. 14.00" 1.00 Rad. Typ. " 5302B001 - 2 Req’d 14.88" 12.77" Ref. 1.78" .73"Ref. 3.500 Diameter 1 Turn 2.875 Diameter Mandrel ...
Page 103 - Evaporator Blower Motor Specifications; Condenser Fan Motor Specifications
5-40 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Evaporator Blower Motor -Indoor Blower (*69) • FLA and capacitor ratings may vary. Always check FLA andcapacitor ratings on the motor data plate. • Motor diameter - 5.70", shaft size - .50", rotatin - CW lead end • See par ts list for co...
Page 104 - Armstrong
Service Reference Manual UNIT COMPONENTS 5-41 SRM-HW/HWC 2/99 Capacitors-Run (*86) Armstrong P/N Rating Volts MFD TABLE 5-16 Run Capacitor Ratings 1 0 0 D 1 0 0 4 3 4 0 7 3 2 0 0 D 1 0 0 4 3 5 0 7 3 3 0 0 D 1 0 0 4 3 6 0 7 3 4 0 0 D 1 0 0 4 3 5 . 7 0 7 3 5 0 0 D 1 0 0 4 3 8 0 7 3 6 0 0 D 1 0 0 4 3 8...
Page 105 - AIR FLOW; Rotation
5-42 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Fan Blades (*268) 18.00 +/ .06 " " AIR FLOW Rotation Diameter Bore .5002".5019" 3.79 +/ .09 " " Notes: 1. 26° Pitch, 5 Blades 2. Material: 24 Ga. Galvalume 3. Set Screw: (2) 5/16"-24 x 5/8" long square head, c...
Page 107 - FIGURE 5-39 Exterior Grill Panels
5-44 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Lower Grill PanelArmstrong P/N 03551D100 Upper Louver PanelArmstrong P/N 03545C000 Exterior Grill Panels(Not Listed in the Parts Lists) Refer to the Component Location Illustrations section beginning on page4-1 for fur ther detail of the exterio...
Page 108 - Section 6 - Installation
Service Reference Manual INSTALLATION 6-1 SRM-HW/HWC 8/99 Section 6 - Installation Location .............................................. 6-3 Installing With Wall Sleeve .................... 6-5 Installing Without Wall Sleeve ............... 6-6 Support ................................................
Page 109 - INSTALLATION
6-2 INSTALLATION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Installation and Operation in ExtremelyCold Weather Areas ........................... 6-15
Page 110 - Installation; Location; HW/HWC Installation and Maintenance Instructions
Service Reference Manual INSTALLATION 6-3 SRM-HW/HWC 8/99 Installation Information in this section is provided for the convenience of the servicetechnician, for the purpose of evaluating the installation during serviceand troubleshooting. It does not take the place of the complete Arm-strong Install...
Page 112 - Make sure the gaskets attached to the sleeve are not damaged.; CAUTION
Service Reference Manual INSTALLATION 6-5 SRM-HW/HWC 8/99 Installing With a Wall Sleeve FIGURE 6-1 HW/HWC Installation Refer to the installation instructions packed with the wall sleeve andFigure 6-1 for guidance in assembly and mounting using a wall sleeve.See also the Accessories section beginning...
Page 113 - Provide a support; . Make sure that the inside; Support; These; The sheet metal in the
6-6 INSTALLATION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Installing Without a Wall Sleeve Refer to the following directions and Figure 6-1 on page 6-5 for guidancein installing the unit without a wall sleeve: 1. Measure the size of the unit and provide an opening in an outsidewall that will accept the uni...
Page 114 - HWC Drain Installation; Venting; No special provisions are required for supplying combustion air.
Service Reference Manual INSTALLATION 6-7 SRM-HW/HWC 8/99 Condensate Drain (HWC Models) Install the plastic drain tube (furnished) over the 5/8" O.D. fitting welded tothe center of the condensate pan. Connect the other end of the draintube to the open trap (see Figure 6-2). The plastic drain con...
Page 115 - Required Clearances for Direct Vent Terminals
6-8 INSTALLATION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 The vent system must also terminate at least 3 feet above any forced airinlet within 10 feet of it. These clearances do not apply to the combustion air inlet of the appliancebecause the combustion air does not enter the air of the building. Clearanc...
Page 116 - Seal any unused openings in the common venting system.; See National Fuel; Gas Connections
Service Reference Manual INSTALLATION 6-9 SRM-HW/HWC 8/99 Removal of Unit from Common VentingSystem When an existing furnace is removed from a common venting systemserving other appliances, the venting system is likely to be too large toproperly vent the remaining attached appliances. The following ...
Page 117 - Insert Removal; When conver ting a low NO; the NO; in the vest panel after the inserts are removed.
6-10 INSTALLATION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Low NO Insert x FIGURE 6-4 NO x Insert Removal Never use a flame to check for gas leaks. Explosioncausing injury or death may occur. WARNING Units for operation with propane must be converted with a kit supplied bythe manufacturer and require for o...
Page 118 - Gas Supply Piping
Service Reference Manual INSTALLATION 6-11 SRM-HW/HWC 8/99 Electrical Connections All wiring must be done in accordance with the National ElectricalCode, ANSI/NFPA No. 70 (latest edition); Canadian ElectricalCode Part 1, CSA C22.1 (latest edition); or local codes, where theyprevail. Any alteration o...
Page 119 - Minimum Circuit Ampacity; Thermostat
6-12 INSTALLATION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 TABLE 6-3 Minimum Circuit Ampacity See Table 6-3 and the Specifications section beginning on page 1-1 forcorrect wire ampacity for the cooling chassis required, and size the wireaccordingly. For HW (heating only units): When sizing wire, keep in mi...
Page 120 - Temperature Rise
Service Reference Manual INSTALLATION 6-13 SRM-HW/HWC 8/99 inside the unit. Make sure that all sides of the duct are flanged over topermit removal of the cooling chassis if required. Use a flexible connec-tion to attach the remainder of the return duct. The return duct should besealed to the unit ca...
Page 121 - INPUT
6-14 INSTALLATION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Adjustments - Cooling Section (HWC models) No adjustments are required or should be attempted regarding any of thecomponents of the cooling chassis. The chassis should be checked tosee that none of the wiring is loose or missing. Blower The unit co...
Page 123 - Section 7 - Accessories
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-1 SRM-HW/HWC 8/99 Section 7 - Accessories HW/HWC Accessory Kit Index .............. 7-2 CA-239 Wall Sleeve Kit ................................... 7-3 A242-1 Wall Sleeve Adaptor Kit ...................... 7-7 ALVR42 Architectural Lou...
Page 124 - A C C E S S O R I E S; Accessories; Note: Complete instructions are packaged with each kit or its; HW/HWC Accessory Kit Index
7-2 A C C E S S O R I E S M a g i c - P a k : H W / H W C SRM-HW/HWC 8/99 Accessories There are a number of accessories available to increase the performanceor versatility of the Armstrong Magic-Pak HW/HWC units. This sectionprovides a general description of each. Note: Complete instructions are pac...
Page 125 - CA-239 Wall Sleeve Kit; Inspection of Shipment; Wall Sleeve Assembly; This is required to assure Magic-Pak unit will slide into
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-3 SRM-HW/HWC 8/99 CA-239 Wall Sleeve Kit The CA-239 wall sleeve kit is designed to facilitate the installation ofMagic-Pak units by providing an accurate opening to properly accept aMagic-Pak unit. During the construction of a buildi...
Page 126 - CA-239 Wall Sleeve Kit Assembly
7-4 A C C E S S O R I E S M a g i c - P a k : H W / H W C SRM-HW/HWC 8/99 Top Panel Front of Sleeve Support Angle - 8 Holes Squaring Braces Left SidePanel Bottom Panel Support Angle - 2 Sides FIGURE 7-1 CA-239 Wall Sleeve Kit Assembly TABLE 7-2 CA-239 Parts List Assembled Wall Sleeve Dimensions: 45&...
Page 127 - Wall Sleeve Installation; Recessed Wall Sleeve Installation
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-5 SRM-HW/HWC 8/99 Wall Sleeve Installation The wall sleeve can be installed from either the inside or the outside ofthe building. In any case, proper considerations must be made for finalweather sealing of the wall sleeve and the Mag...
Page 128 - Magic-Pak Installation
7-6 A C C E S S O R I E S M a g i c - P a k : H W / H W C SRM-HW/HWC 8/99 Magic-Pak Installation Before installing the Magic-Pak unit in the wall sleeve, it is impor tant toconsider the possibility of sound and vibration transmission through thewall. It is recommended that vibration isolation pads b...
Page 129 - A242-1 Wall Sleeve Adaptor Kit; Wall Sleeve Adaptor Kit Assembly; To assemble the adaptor kit:
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-7 SRM-HW/HWC 8/99 A242-1 Wall Sleeve Adaptor Kit The A242-1 wall sleeve adaptor kit is designed to allow for the installationof current 43" tall HW/HWC units into 48" tall wall sleeves (CA241 wallsleeve kits). The CA241 wall ...
Page 130 - Re-fasten the screws that were removed in step 1.; Installing the HW/HWC Unit
7-8 A C C E S S O R I E S M a g i c - P a k : H W / H W C SRM-HW/HWC 8/99 Attachment to HW/HWC After assembling the kit, it is ready to be attached to the top of the HW/HWC unit. To attach the kit to the HW/HWC unit: 1. Remove the two front screws (each side) that fasten the top panelside flanges to...
Page 131 - A242-1 Wall Sleeve Adaptor Kit Assembly
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-9 SRM-HW/HWC 8/99 (2) #8 x ½" Screwsin each rear corner (2) #8 x ½" Screws in each side Right Side Front 1/4" x ¾" Screw ¼" Flat Washer HW/HWC Unit Rear Left Side Screws that are removed and reinserted to attach a...
Page 132 - Assembly
7-10 A C C E S S O R I E S M a g i c - P a k : H W / H W C SRM-HW/HWC 8/99 ALVR42 Architectural Aluminum LouverFacade In many applications, architects and installers will choose to use facadesover the front of Magic-Pak units. Often this is done to improve theappearance of a building. Properly const...
Page 133 - ALVR Architectural Aluminum Extended Louver
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-11 SRM-HW/HWC 8/99 The louver will fit directly against the front of the unit. However, the lowerlip of the unit will protrude into the louver. The louver must be positionedto accommodate the protruding lower lip. The louver must be ...
Page 134 - Install the top rubber spacer in the compressor mounting legs.
7-12 A C C E S S O R I E S M a g i c - P a k : H W / H W C SRM-HW/HWC 8/99 34961A001 Compressor Vibration IsolatorKit The 34961A001 spring/grommet kit is designed to isolate vibrationscommon to most compressors away from the base of Magic-Pak unitsand building walls. Some types of wall construction ...
Page 137 - AHALT390-1 High Altitude Kit; Regulator - Natural Gas; To check this pressure:
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-15 SRM-HW/HWC 8/99 AHALT390-1 High Altitude Kit The AHALT390-1 kit contains the following parts to convert the 26, 38, 51and 64HW/HWC series units to high altitude for natural or propane gas. Ifthe field conversion is for high altitu...
Page 138 - Cubic Feet Per Revolution
7-16 A C C E S S O R I E S M a g i c - P a k : H W / H W C SRM-HW/HWC 8/99 x 3600 x = Cubic Feet Per Revolution BTU/HR INPUT # Seconds Per Revolution Heating Value The heating value of your gas can be obtained from your local utility. With proper manifold pressure achieved, cycle main burners on and...
Page 139 - ATIMR466-1 Short Cycle Protector Kit; Time Delay
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-17 SRM-HW/HWC 8/99 ATIMR466-1 Short Cycle Protector Kit The ATIMR466-1 Short Cycle Protector Kit helps guard against compres-sor failure due to repeated, shor t interval on/off cycles. It is also referredto as the Nuisance Blower Ope...
Page 140 - ADAPT420-2 Chassis Conversion Kit
7-18 A C C E S S O R I E S M a g i c - P a k : H W / H W C SRM-HW/HWC 8/99 ADAPT420-2 Chassis Conversion Kit The ADAPT420-2 kit was designed to retrofit an HWC122, 182, 242 or302 chassis onto a cabinet originally equipped with an HWC12, 18, 24 or30 chassis. This kit cannot be used to replace an HWC1...
Page 141 - Fenwal Triton Ignition Control Kit; Triton Ignition Control Kit Parts List
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-19 SRM-HW/HWC 8/99 Fenwal Triton Ignition Control Kit This kit enables the Fenwal “Triton” local sense, one-hour retry, directspark ignition (DSI) control to be used as a service parts replacement forearlier versions of Fenwal DSI co...
Page 142 - TL109 Burner Tray Kit; Installation instructions
7-20 A C C E S S O R I E S M a g i c - P a k : H W / H W C SRM-HW/HWC 8/99 TL109 Burner Tray Kit The TL109 Burner Tray Kit is designed for use in HW/HWC’s that wereoriginally equipped with single por t inshot burners. Four kits are available,one for each natural gas heating input rating as follows: ...
Page 143 - Discharge; AMUFFKT494-1 Kit Discharge Muffler Installation; AMUFFKT494-1 Discharge Muffler Kit; * AMUFFKT494-1 is designed to be used only with HWC182 units.
S e r v i c e R e f e re n c e M a n u a l A C C E S S O R I E S 7-21 SRM-HW/HWC 8/99 Discharge Muffler Discharge Line to Condenser Coil FIGURE 7-6 AMUFFKT494-1 Kit Discharge Muffler Installation AMUFFKT494-1 Discharge Muffler Kit In the event that during operation an unacceptable noise occurs, a mu...
Page 144 - Section 8 - Parts Lists
8-1 SRM-HW/HWC 8/99 Service Reference Manual PARTS LISTS Section 8 - Parts Lists HWC123, 183, 243, 303-1 .................. 8-2 HWC182, 242-11 ................................ 8-5HWC122, 242-10 ................................ 8-7HWC182-9 ........................................ 8-10HWC242, 302-9 .....
Page 145 - PARTS LISTS; REC ST; Last letter of the Model # is the Service Level.; SERVICE LEVEL; PART DESCRIPTION; REVISED
8-2 PARTS LISTS MAGIC-PAK: HW/HWC SRM-HW/HWC 8/99 REC ST OCKING P A R T TO SELECT PART # Last letter of the Model # is the Service Level. 64HWC303A-1 A First find Model #. ------------------------------------------------ > 64HWC303A-1(*) Then match Service Level for desired part. ----------------...
Page 150 - REF
8-7 SRM-HW/HWC 8/99 Service Reference Manual PARTS LISTS HWC122-242A-10 REC ST OCKING P A R T TO SELECT PART # Last letter of the Model # is the Service Level. 38HWC242A-10 A First find Model #. -------------------------------------------------------------- > 38HWC242A-10(*) Then match Service Le...
Page 187 - TROUBLESHOOTING; Troubleshooting; Compressor Checkout; Initial Testing; Use extreme caution when conducting the following tests.; The power
9-2 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Troubleshooting Compressor Checkout The objective of this section is to help in diagnosing compressor prob-lems. It presents a series of tests that should be conducting before adetermination on the condition of the compressor is made. This sectio...
Page 188 - Checking Windings; S to R (Start Windings through Common and Run Windings)
Service Reference Manual TROUBLESHOOTING 9-3 SRM-HW/HWC 8/99 2. Set an ohm meter to the lowest possible setting. On a note pad,write the following: “C to ground”, “S to ground” and “R to ground.” 3. Using the ohm meter, check for continuity between C terminal on thefusite plug and the case of the co...
Page 189 - Checking the Thermal Overload Device
9-4 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 When the resistance of “C to S” is added to the resistance of “C to R”,the combination is the total resistance of the entire motor windingscircuit. 2. Compare the total to the reading taken between “S to R.” If thewindings are in good condition, ...
Page 190 - There are several reasons why a compressor would overheat.
Service Reference Manual TROUBLESHOOTING 9-5 SRM-HW/HWC 8/99 overload protector has opened. Before the compressor can be con-demned as having a burned out star t or run winding, it must be deter-mined that the overload switch is in fact closed. It may take several hoursfor the compressor to cool dow...
Page 191 - trillionth
9-6 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Capacitor Checkout Before starting the checkout of the capacitor, it is impor tant to understandwhat a capacitor is, how it works and what its function is in relation to amotor. A capacitor is a storage device similar to a battery, only unlike a ...
Page 192 - MFD
Service Reference Manual TROUBLESHOOTING 9-7 SRM-HW/HWC 8/99 The following information is found on a capacitor: the MFD (microfarad rating) and the working voltage . Compare this to the rating plate on the motor or the information provided with the unit. The following are some of the problems that c...
Page 193 - there is only approximately ten seconds to do this; Example; *For 50 Hz electrical systems, use 3180 as the constant multiplier.
9-8 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Before starting the test, take a reading of the line voltage at the outlet thatwill be used. Double check the connections, making sure that the amp meter is on.Plug the test leads into the wall outlet. Wait a few seconds and read theamp meter ( C...
Page 194 - Performance; Performance Checkout; Performance Tests (Chassis Installed in Unit); HWC122 Performance Test (Chassis Installed); Based on a normally installed cooling chassis; HWC182 Performance Test (Chassis Installed)
Service Reference Manual TROUBLESHOOTING 9-9 SRM-HW/HWC 8/99 Performance Performance Checkout HW/HWC chassis come with a pre-charged chassis assembly. Thechassis assembly is designed in a way that the unit may be run indepen-dently of the HWC unit. When the chassis is run on a floor or bench, theper...
Page 195 - HWC302 Performance Test (Chassis Installed); HWC242 Performance Test (Chassis Installed)
9-10 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Performance Tests (Chassis Installed in Unit) - cont. Total Air Vol. (CFM) Enter. DB/WB Suction Pressure Suction Temp. LiquidTemp. Suction Pressure Suction Temp. LiquidTemp. Suction Pressure Suction Temp. LiquidTemp. Suction Pressure Suction Tem...
Page 196 - 5° Ambient Temperature Chassis Bench Test; Charge Weights; HWC Refrigerant Charge Weights
Service Reference Manual TROUBLESHOOTING 9-11 SRM-HW/HWC 8/99 Performance Tests (Chassis Bench Tested) TABLE 9-6 95° Ambient Temperature Chassis Bench Test TABLE 9-5 70 - 80° Ambient Temperature Chassis Bench Test s i s s a h C l e d o M t n e i b m A . p m e T B W / B D . h c s i D e r u s s e r P ...
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