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Ariston K3E1/IR Oven User Manual

1. Im II mim Y I cay Refer to the Component Location Illustrations section beginning on page 4 1 for further detail of the exterior grill panels and other panels FIGURE 5 39 Exterior Grill Panels SRM HW HWC 2 99 SRM HW HWC 8 99 Service Reference Manual INSTALLATION Section 6 Installation MM Pn 6 3 Installing With Wall Sleeve 6 5 Installing Without Wall Sleeve 6 6 SUDDOFPU 6 6 Condensate Drain
2. A SWTCH ROLLOUTRED A 20 21 24 34 8 8 8 8 40 46 47 52 54 55 PARTS LISTS MAGIC PAK HW HWC HWC 5 cont pM TO SELECT PART Last letter of the Model is the Service Level 64HWC302 5A First find Model 64HWC302 5 Then match Service Level for desired part gt REPART a PART DESCRIPTION SWITCH PRESS GREEN eem uomine 38HWC242 5 51HWC242 4 64HWC242 A LE EL LLL d PPE LLL ELIT 1 A 1 74 39010B001 ASSY BLOWER HOUSING 392320001 CAPACITOR 4 MFD 370V 392320004 CAPACITOR 7 5 MFD 370V 39007D005 LABEL WIRING DIAGRAM 255 389808001 COIL INDOOR 255 40648 001 COIL INDOOR 26 27 28 30 ENNMEEEEEEGBSSESNEBEOHSEEBEE ELO 66 8 OMH MH INHS gt gt service cever _ o ea awers sesso abs UE ser 59 sso4eeno 71 0740792000 CECI 73 74 1300108001 1 6 302320004 24 402218001 125 396058001 126 390808001 her 061818046 128 061328001 90 390070008 250 250 38
3. esos 1 o fessos s esos a s esso bs ooo pala be eorr a _ be oso sssewereeenrenneen m pee wenn S s peor sr mor p wem 51HWC182 6 64HWC182 6 REC STOCKING PART 38HWC182 7 SERVICE LEVEL 8 17 PARTS LISTS MAGIC PAK HW HWC HWC 6 7 cont anas TO SELECT PART Last letter of the Model is the Service Level 64HWC182 6A 8 18 First find Model 64HWC182 6 Then match Service Level for desired part gt REF PART DESCRIPTION 10 z won m pese wenmoe p omo assrecowenvousns bs oae ar nee assrwncnamessrevais A assvownenamvessune 06131B046 FILTER 16 5 X 25 X 50 a sso monns a so anon own s rs ERVICE LEVEL 1HWC182 6 4HWC182 6 REC STOCKING PART 8HWC182 7 gt gt 26 27 O k i k
4. s as s ewe wwowwmesueno j momo jones mes f memo pr moworon monens el REC STOCKING PART SERVICE LEVEL 26HWC122A 10 38HWC122A 10 38HWC242A 10 8 7 PARTS LISTS MAGIC PAK HW HWC 122 242 10 cont E TO SELECT PART Last letter of the Model is the Service Level 38HWC242A 10A First find Model 38HWC242A 10 Then match Service Level for desired part v meme m jwenaows p semwem assensiveowennousns we bs seam b seu owworoe swoasewc we emen aa a a som esterne warvessiowen ae i s FILTER 165 X25 X 50 e mers ase em mem Pe em es mme fooro es sera estuevowe we we sers bs sss we as a a bw amem emen _ es mmm foen mem auem _ bs e
5. 67 268 278 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS 8 19 HWC 5 TO SELECT PART Last letter of the Model is the Service Level 64HWC302 5A First find Model 64HWC302 5 Then match Service Level for desired part gt REF PART DESCRIPTION 1 TRANSFORMER 39029B002 CONTROL BLOWER CENTER VALVE GAS 1 MANIFOLD 3 CELL 1 MANIFOLD 4 CELL 1 MANIFOLD 5 CELL MANIFOLD 6 CELL ORIFICE 52 ORIFICE 53 ORIFICE 54 ELECTRODE WIRE ELECTRODE CONTROL IGNITION ASSY BURNER ASSY HEAT EXCHANGER ASSY HEAT EXCHANGER ASSY HEAT EXCHANGER ASSY HEAT EXCHANGER TURBULATOR GASKET FLUE COVER GASKET FLUE COL END CONTROL LIMIT 39113B001 GASKET LIMIT SWITCH 37520B004 SWITCH ROLLOUT RED G Co 3 3 3 3 EE ELE Fe eres epe lt ogl z le olw F O ae gt olf clo TRANSFORMER CONTROLBLOWERCENTER IVAVEGAS MANFOLD3CELL MANFOLD4 CELL MANFOLDSCELL A MANFOLD6CELL omFICE amp 2 ORIFICE J electrode WREELECTRODE CONTROLIGNTION A JAssyBURNER A ASSYHEAT EXCHANGER A JASSYHEATEXCHANGER A ASSY HEAT EXCHANGER EXCHANGER TURBULATOR IGASKEFRLUECOVER A GASKETFLUECOLEND A
6. e wm wemmown b f A ss ww wewsoacran se owes l PP ws fecoon s fso eoc m 27 gt wen swoerwoosswmon me foer sme 38HWC182 2 51HWC182 2 EE E EE E E mmm REC STOCKING PART SERVICE LEVEL m 390598002 DRIER 38065A001 RELAY TIME DELAY PARTS LISTS MAGIC PAK HW HWC HWC 1 TO SELECT PART Last letter of the Model is the Service Level 64HWC302 1A First find Model 64HWC302 1 Then match Service Level for desired part ea heo b U 5 rene som see camcn sme sonar mmm famoss ie oreo oom fa we orem gt cow bs oem connor LLL ITT mee mem TITI onere one eese T orm one sese noone _ omoes onrice sree bs osos gt oom L ta PL ene
7. 3 4 Evaporator Blower Assembly Removal 3 6 3 2 UNIT TEAR DOWN Magic Pak HW HWC 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 the heating function controls burners switches etc The total heating section is not removable as a complete unit The heat exchanger may be removed separately for service see below The cooling section is located in the lower half of the unit It contains the compressor coils and motors that make up the refrigeration system The cooling section is referred to as the chassis of the cooling system The chassis is removable as a complete unit Removal of the chassis allows service to be performed away from the job site thus allowing a spare chassis to be installed to reduce downtime at a residence Bench tests may be performed on chassis See the Performance Test section beginning on page 9 11 for chassis performance data of both bench tested and installed units Heating Section Heat Exchanger Removal The heat exchanger may be removed from the unit through the front side Refer to the following directions and Figure 3 1 To remove the heat exchanger Disconnect all power to the unit Shut off and disconnect the gas supply Open the burner access panel Remove the burner tray and the gas valve Remove t
8. o REF PART 4 PART DESCRIPTION 256 390588001 ASSY CAP TUBE w 256 390588002 ASSY CAP TUBE 256 390588003 ASSY CAP TUBE EN 256 40650 001 ASSY CAP TUBE a 262 35136 001 COMP ZR28K1 PFV 262 351366005 COMP ZR23K1 PFV 262 39008 001 147 002 4 262 39008 002 COMP RK233ET 009 A4 267 41254 001 MOTOR 1 4 HP 1 PHASE 267 41282 001 MOTOR 1 8 HP 1 PHASE 268 390628001 BLADE FAN 268 390858001 BLADE FAN 269 039820004 BRACKET MOTOR SUPPORT 285140002 25 5 MFD 370 285140003 CAPACITOR 30 5 MFD 370 385140004 CAPACITOR 35 5 MFD 370 VAC 278 07535 001 CONTACTOR 40715 001 RELAY TIME DELAY gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt eve _ IE LL ves de 38HWC122 8 et ecse L sewenseee 38HWC242 8 fet ef LL I seweszee eese 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS HWC 6 7 ur TO SELECT PART Last letter of the Model is the Service Level 64HWC182 6A First find Model 64HWC182 6 Then match Service Level for desired part I p eme s omen
9. 44358 2 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual HWC122 182 242 302 Low Ambient Model Refer to Figure 2 8 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 sequence of operation during a cooling call is modified when outdoor temperatures fall below the normal operating range The switch will interrupt the operation of the outdoor cooling fan when the temperature of the liquid line coming in from the outdoor coil falls below 55 F When the temperature of the liquid line rises to 95 F the switch will close and the outdoor fan will resume opera tion The low ambient switch does not affect any other facet of the operation of the unit To see simplified and detailed sequences of operation for the HWC122 182 242 302 models equipped with the Fenwal Triton 2461D DSI Ignition Control refer to pages 2 17 to 2 20 To see simplified and detailed sequences of operation for the HWC122 182 242 302 models equipped with the Fenwal 05 29 Ignition Control refer to pages 2 27 to 2 30 SEQUENCE OF OPERATIONS 2 39 SRM HW HWC 8 99 Service Reference Manual UNIT TEAR DOWN Section 3 Unit Tear Down Heating Section Heat Exchanger Remowval 3 e Induced Draft Blower Removal 3 e Cooling Section Chassis Removal
10. 6 7 RN EE 6 7 Removal of Unit from Common Venting System 6 9 Gas Connections 6 9 Electrical Connections 6 11 Thermostat 6 12 Supply and Return Ducts 6 12 Air Filter 6 13 Adjustments Heating Section 6 13 Adjustments Cooling Section 6 14 6 14 Limit Control 6 14 High Altitude Adjustments U S 6 14 High Altitude Adjustments Canada 6 14 6 1 6 2 INSTALLATION Magic Pak HW HWC Installation and Operation in Extremely Cold Weather Areas 6 15 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual IMPORTANT READ THIS FIRST INSTALLATION 6 3 Installation Information in this section is provided for the convenience of the service technician for the purpose of evaluating the installation during service and troubleshooting It does not take the place of the complete Arm strong Installation and Maintenance Instructions that are shipped with every Magic Pak unit If you are installing an Armstrong product and need a copy of the Installation and Maintenance Instructions consult the table below and contact the Armstrong factory TABLE 6 1 HW HWC Installation and Mainte
11. R E en NOTE de IF ANY OF THE ORIGINAL S WIRES ARE REPLACED THE m SAME SIZE AND TYPE WIRE lt MUST BE USED gt AUTORESET MANUAL RESET LIMITSWITCH LIMIT SWITCH CONDENSER FAN VIOLET BLUE CONNECTOR BLOCK TRANSFORMER CAPAGITORERUN BROWN BLACK 6666600 EVAP MOTOR SPEED CONNECTIONS Bk MODELS HEATING COOLING FAN BLACK 208 V 26HWC123 LOW RED BLUE COM HERM YELLOW 240V 38HWC123 HIGH BLACK MED BLUE O S COMP BLK 38HWC183 LOW RED LOW RED R 51HWC183 MED BLUE LOW RED RED 64HWC183 HIGH BLACK LOW RED m mE 38HWC243 LOW RED MED BLUE FOR WIRING BLOWER 51HWC243 MED BLUE MED BLUE CONTROL 64HWC243 HIGH BLACK BLUE BLACK 51HWC303 MED BLUE HIGH BLACK 64HWC303 HIGH BLACK HIGH BLACK BROWN MOTOR JUMPER REQUIRED EN 45004 1 DIAGNOSTICS The following blower ignition control board LED codes will indicate normal or abnormal operations SLOW FLASH Normal Operation No Call for Heat Note On units that are equipped with a low ambient switch designated with an SA in the model number sequence of operation during cooling call is modified when outdoor temperatures fall below the ies a normal operating range For more information on the low ambient 3 FLASH Pressure Swi
12. airs me S ooo S gt weno coco f fs es cmo o sarsa ow messen Li me ese LL LI Li eom SE S fat ope ser sso won eee ze mom L LL memo uer S aracrerworonsurrom REC STOCKING PART SERVICE LEVEL TE 38HWC182 4 E 51HWC182 4 BS 64HWC182 4 AERE 51HWC302 4 64HWC302 4 8 24 PARTS LISTS MAGIC PAK HW HWC HWC 4 cont 12099 TO SELECT PART Last letter of the Model is the Service Level 38HWC182 4A First find Model 38HWC182 4 Then match Service Level for desired part IREF PART 4 DESCRIPTION REC STOCKING PART 51HWC182 4 64HWC182 4 51HWC302 4 64HWC302 4 SERVICE LEVEL 38HWC182 4 e mer owmemmewoemwc Eri ssis 282 seo ReLa TME DELAY por asos9B002 por omer TAT 4 1 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS 8 25 HWC 3 SELECT PART Last letter of the Model is the Service Level 64HWC302 3A First find Model
13. gt m PARTS LISTS REVISED 1 20 98 E EEEEEEEEEEEEEEEE E mm 8 11 PARTS LISTS MAGIC PAK HW HWC HWC242 302 9 e TO SELECT PART Last letter of the Model is the Service Level 64HWC302A 9A 8 12 First find Model 64HWC302A 9 Then match Service Level for desired part CIC INC TI T 2 MN t erem e s sss pep pe 1 m erem wa S LL hs moms s moms _ mens assewaurnenrexcrancer e own r r hs s wwe fp ef s mem 1 ca cm REC STOCKING PART SERVICE LEVEL TT 51HWC242A 9 REN 64HWC242A 9 HAR 51HWC302A 9 REN 64HWC302A 9 41144 001 BLOWER INDUCED DRAFT 1 1 t 39046B001 MOTOR 1 3 HP 1 PHASE 074088004 ARM MOTOR MOUNTING 348338001 WHEEL BLOWER 5390108001 ASSEMBLY BLOWER HOUSING 07407B000 BAND MOTOR MOUNTING Te a 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS HWC242 302 9 cont SELECT PART Las
14. WARNING Never try to adjust a pressure switch or jumper the switch to allow the furnace to operate Doing so could allow the furnace to operate under hazardous conditions potentially causing property damage personal injury or death 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 calibrated open setting of the pressure switch Potential Causes Rodents Spiders Nest building in the intake opening Debris or trash that has been pulled into the intake opening Symptoms Excessive negative pressure in the burner box area The furnace cycles on and off quite frequently typically within 60 seconds or so inability of unit to stay on for a complete call for heat For a blocked intake or blocked flue connect the incline manometer as shown on in Figure 5 20 on page 5 27 for the specific model groups 5 24 UNIT COMPONENTS Magic Pak HW HWC Blocked Flue Blocked flue is any condition that blocks or restricts the flue vent pipe to a point where the pressure fall reaches the calibrated open setting of the pressure switch Potential Causes Rodents Spiders Nest building in the flue pipe Outlet screens with excessive restriction High wind conditions exceeding 40 mph Symptoms Low negative pressure on the induced draft combustion blower The unit cycles on
15. tubes together with masking tape 14 74 13 13 Ref 75 Rad Typ 3 500 Diameter 3 00 Mandrel 53025B025 2 9 voe Rad I S Typ 75 FIGURE 5 30 43281 001 Capillary Tubes 5302 025 2 FIGURE 5 32 40652 001 Capillary Tubes 750 Rad Ww Typical 1 28 N gt 50 13 UNIT COMPONENTS 5 37 12 22 13 5302B025 2 Req d 250 Rad 1 6 Typical Y 75 750 Rad Typical 50 13 3 688 Diameter 3 Turns 5302B025 2 Reqd FIGURE 5 33 39103B001 Capillary Tubes UNIT COMPONENTS Magic Pak HW HWC 5 38 Notes All bends 90 unless otherwise noted Do not kink or flatten during forming Tape tubes together with masking tape TABLE 5 12 391028001 Specifications 2 79 25 Rad 1 6 Typ 9 A Diameter Turns FIGURE 5 34 391028001 Capillary Tubes 75 Rad Typ Mm 1 55 f i 43 2 50 3 30 gt 2 844 Diameter 3 Turns 53205B025 2 Reqd C ous A MS 1 lt 2 03 FIGURE 5 35 39298B001 Capillary Tubes 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 39 Capacitors 271 TABLE 5 13 Capacitor Ratings Armstrong Rating P N MFD Volts
16. STOCKING PART SSC SERVICE LEVEL memes 182 1 AERE EE 38HWC242 1 mns emere 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS 8 31 HWC 1 cont 1 TO SELECT PART Last letter of the Model is the Service Level 64HWC302 1A First find Model 64HWC302 1 Then match Service Level for desired part lt lt o0 REF PART PART DESCRIPTION 38 38977B001 GASKET FLUE FRONT FLUE FRONT FLUE FRONT 38978B001 GASKET FLUE SIDE m 47 390068001 BURNER END SHOT 48 388328001 MANIFOLD GAS mE 48 388328002 MANIFOLD GAS SU aE 48 388328003 MANIFOLD GAS TT y 38832B004 MANIFOLD GAS RETE 55 39086B001 SWITCH PRESSURE sl mz uE 39086B002 SWITCH N O PRESSURE ss sem noue seme swTo noro s som sangs ESE essere rs sene E pb bbb ss sem uon re ss cem poen vase s reos meson s seo muon uam T s s s s s s s ser enc
17. The blower starts in approximately 60 seconds 4 The 24 volt signal sent to the TS terminal closes a relay in the ignition control This starts the induced draft blower by energizing terminal IND on the ignition control 5 Asthe induced draft blower comes up to speed and creates enough negative pressure the pres sure switch closes The 24 volt signal is sent from the pressure switch to one side of the Normally Closed manual reset rollout switch If the rollout switch is closed the 24 volt signal is passed through the switch to the P SW terminal on the ignition control This initiates a 30 second pre purge period 6 After the 30 second pre purge period a trial for ignition starts by energizing the spark terminal and the V1 terminal simultaneously The 24 volt signal from V1 energizes the gas valve solenoid causing it to open These actions cause the burners to light 7 After the burners are lit a flame sense is picked up by the flame sense rod located at the opposite end of the burner rack from the spark electrodes The flame sense signal is sent to the S1 terminal of the ignition control The unit continues to operate as long as W is energized 8 When the call for heat is satisfied the circuit be tween R and W is interrupted de energizing W 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual 9 With W de energized the gas valve closes immedi ately and the induced draft blower stops several seconds l
18. ors ja oo mo 26HWC122 1 efe ewes CLAN SECEDE gt gt ELLE ELI ome alala T P PARTS LISTS MAGIC PAK HW HWC 8 32 REVISED HWC 1 cont peus TO SELECT PART Last letter of the Model is the Service Level 64HWC302 1A First find Model 64HWC302 1 Then match Service Level for desired part lt T z o m REF PART PART DESCRIPTION 389828001 COIL OUTDOOR m 38983B001 COIL OUTDOOR D 38984B001 COIL OUTDOOR N 35658B001 CONTACTOR 35136C001 COMPRESSOR 3 gt 9 2 amp N 1 1 1 1 Er seco mozo amacrer snc eem m poer E sre mereces emer esee pem 390598003 FILTER DRIER 38065 001 RELAY TIME DELAY 1 EEELEIELELEELLLIELLI sel s e eNe a aa e i L
19. 64HWC302 3 Then match Service Level for desired part rer panty sawam CENTER BLO CONT juae _ i E lt a x o o a serve cever 11 1 1 Co E Co c 20 34 38 38 38 38 52 S P i P no s 1 1 1 ESSET n pan e LL IL e mensem skeis E sj s s aaa alaa JA deea e a a A e e faw Elek T da elk LI eee 54 PARTS LISTS MAGIC PAK HW HWC HWC 3 cont 5 TO SELECT PART Last letter of the Model is the Service Level 64HWC302 3A First find Model 64HWC302 3 Then match Service Level for desired part gt REF PART PART DESCRIPTION sma sr swrcawo pressure s smesso sommo mese s sensor aowenmouceoomer gt e pes uror 7 fale mro woes aloe 23 ro weer wemmoe mese eusnemons DT sumo fermeron sumo T essor DD reran E
20. LINE VOLTAGE FACTORY WHEN USED LINE VOLTAGE FIELD LOW VOLTAGE FACTORY LOW VOLTAGE FIELD ELECTRODE 31IHM COMBUSTION BLOWER BLACK WHEN USED O o IGNITION WHITE CONTROL VIOLET J FLAME ROD THERMOSTAT 9v 18 IF ANY OF THE ORIGINAL WIRES ARE REPLACED THE SAME SIZE AND TYPE WIRE MUST BE USED amp Gi RED N GAS VALVE BLUE E ORANGE a HOLIMS 3unsSdud 5 m L o m m z AUTO RESET MANUAL RESET LIMIT SWITCH LIMIT SWITCH 0 1 CORANGE nr MOTI3A CONNECTOR BLOCK ERN EVAP MOTOR SPEED CONNECTIONS MODELS HEATING COOLING EN YELLOW TRANSFORMER 208V 240 BLK CONTACTOR FAN RELAY OOTO 26HWC123SA LOW RED MED BLUE 38HWC123SA HIGH BLACK MED BLUE 38HWC183SA LOW RED LOW RED 51HWC183SA MED BLUE LOW RED 64HWC183SA HIGH BLACK LOW RED 38HWC243SA LOW RED MED BLUE 51HWC243SA MED BLUE MED BLUE 64HWC243SA HIGH BLACK BLUE 51HWC303SA MED BLUE HIGH BLACK 64HWC303SA HIGH BLACK HIGH BLACKJ JUMPER REQUIRED CONDENSER FAN VIOLET CAPACITOR RUN 45005 2 CHART FOR WIRING YELLOW DIAGNOSTICS OBLOWERO
21. Installation The ALVR42 is designed to be fastened to the finish wall support wall or wall sleeve using field supplied materials and techniques Whenever installing a louver facade of any type special considerations must be made for proper drainage and air circulation The drain holes of the wall sleeve and the unit must never be obstructed 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 1 11 The louver will fit directly against the front of the unit However the lower lip of the unit will protrude into the louver The louver must be positioned to accommodate the protruding lower lip The louver must be caulk sealed on all four sides and field supplied flashing should be installed across the bottom of the louver This will prevent water runoff directly onto the finish wall 28 875 500 x 375 x 28 875 13 831 Polyether Gasket 1 225 el T 1 225 Typ 13 831 Gasket 45 000 FIGURE 7 3 ALVR Architectural Aluminum Extended Louver 1 12 ACCESSORIES Magic Pak HW HWC 34961A001 Compressor Vibration Isolator Kit The 349614001 spring grommet kit is designed to isolate vibrations common to most compressors away from the base of Magic Pak units and building walls Some types of wall construction will be especially susceptible to vibration transmissions In these insta
22. 2 14 FAN ON Z ascertain aa 2 14 122 182 242 302 w Fenwal 24610 Ignition Control 2 16 Simplified Sequence 2 17 Detailed Sequence 2 18 2 18 CALL FOR 2 18 LIMIT OPENS 2 19 PRESSURE SWITCH OPENS BLOCKED FLUE 2 19 ROLLOUT SWITCH ACTIVATED 2 19 CALL FOR COOLING decade org ulis 2 19 FAN ON Z discoteca 2 20 HW Heating Only w Fenwal 24610 Ignition Control 2 22 Simplified Sequence 2 23 Detailed Sequence 2 24 POWER d a rad 2 24 GALL FOR HEAT beoe 2 24 LIMIT OPENS 2 25 PRESSURE SWITCH OPENS BLOCKED FLUE 2 25 ROLLOUT SWITCH ACTIVATED 2 25 2 2 SPECIFICATIONS Magic Pak HW HWC HWC122 182 242 302 w Fenwal 05 29 Ignition Control 2 26 Simplified Sequence 2 27 Detailed Sequence 2 28 gt assistant Qh uei pL Eod 2 28 GALILEO HEA ER DR 2 28 FLAME SENSE 2 29
23. TABLE 7 3 A242 1 Parts List Part Quantity 1 Front Panel Rear Panel 2 8 7 Screws in each rear corner bx Right Side Rear E Pd E Right Side Panel 8 x 1 2 Screw 1 4 x 3 4 Screw 1 2 48 x Screws 1 4 Flat Washer in each side Left Side Panel Flat Washer HW HWC Unit P Screws that are removed and reinserted to attach adapter kit to HW HWC unit both sides AN MM NS FIGURE 7 2 A242 1 Wall Sleeve Adaptor Kit Assembly 1 10 ACCESSORIES Magic Pak HW HWC ALVR4e Architectural Aluminum Louver Facade In many applications architects and installers will choose to use facades over the front of Magic Pak units Often this is done to improve the appearance of a building Properly constructed louver facades may also provide some degree of weather protection and sound deflection Louver facades can be designed by engineers and architects and inte grated into the building construction by contractors in the field However research and testing has shown that many designs may actually diminish the performance of the Magic Pak units and in some cases even damage them For these reasons Armstrong approved the ALVR42 architectural alumi num louver facade kit The instructions provided with the kit
24. 2 This circuit energizes whenever line voltage power is supplied to the unit 3 If the circuit is interrupted by either switch opening the 24 volt signal to pin 1 of the 6 pin ignition wire harness de energizes 4 This causes the combustion blower relay to energize sending L1 power to the CMB BLWR terminal on the ignition control It also causes the circulating air blower heat speed relay to ener gize sending L1 power to the ACB HEAT terminal on the ignition control This causes both blowers to start immediately 5 Theignition control lockouts the spark ignition cable terminal and pin 4 of the 6 pin ignition wire harness until the 24 volt signal is restored at pin 1 of the 6 pin ignition wire harness 6 Thecirculating air blower and the combustion blower are energized until the 24 volt signal is restored at pin 1 of the 6 pin ignition wire harness SEQUENCE OF OPERATIONS 2 7 The green ignition control LED shows a 4 flash fault code indicating limit switch rollout switch open 8 When the 24 volt signal is restored at pin 1 of the 6 pin ignition wire harness the ignition control starts a 5 second combustion blower post purge delay and a 120 second circulating air blower off delay 9 Once the delays have timed out both blowers stop and the green LED flashes a consistent slow flash if no heat call is present A consistent fast flash appears if there is a call for heat Note The limit switch resets automaticall
25. 2 29 ROLLOUT SWITCH 2 29 CALL FOR COOLING rr d 2 29 TNT ON T nS 2 30 HW Heating Only w Fenwal 05 29 Ignition Control 2 32 Simplified Sequence 2 33 Detailed Sequence 2 34 2 34 CALL FOR HEAT 2 34 FLAME SENSE 2 35 LIMIT OPENS 2 35 ROLLOUT SWITCH ACTIVATED 2 35 HWC123 183 243 303 w Low Ambient Control 2 36 HWC122 182 242 302 w Low Ambient Control 2 38 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual SEQUENCE OF OPERATIONS BLANK PAGE 2 3 SPECIFICATIONS Magic Pak HW HWC HWC123 183 243 303 w United Technologies 1097 Spark Ignition System 2 4 CIRCUITS ENERGIZED POWER SUPPLY ONLY T AENHNG SEC COOLING R G Y x FAN R G 11 r aa LINE VOLTAGE FACTORY LINE VOLTAGE FACTORY WHEN USED DT ELECTRODE COMBUSTION LOW VOLTAGE FIELD KNEES 97 THERMOSTAT
26. 4 Atpin 6 of the 6 pin ignition wire harness 5 Through the auto reset limit switch and the manual reset rollout switch to pin 1 of the 6 pin ignition wire harness Note While the unit is at rest the green LED shows consistent slow flash This indicates normal operation system at rest standby mode CALL FOR HEAT Line Voltage The ignition control receives a signal from the R W circuit indicating a call for heat 1 The combustion blower relay energizes sending L1 power to CMB BLWR terminal on the ignition control This causes the combustion blower to start 2 Asthe 24 volt signal is sent to pin 4 of the 6 pin ignition wire harness by the ignition control a 30 second circulating air blower delay starts After the delay the ignition control energizes the heat speed blower relay This sends L1 power to the ACB HEAT terminal on the ignition control L1 power is then sent to the circulating air blower terminal block where it is connected to the blower motor starting the circulating air blower The combustion blower and the circulating air blower continue to run until the R W circuit is interrupted After a 5 second post purge delay the CMB BLWR terminal on the ignition control de energizes This interrupts L1 power to the combus tion blower After a 120 second circulating air blower off delay the ACB HEAT terminal de energizes This interrupts L1 to the circulating air blower As L1 power is interrupted
27. Enter Prae Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid DB WB Temp Temp Temp Pressure Temp Temp Pressure Temp 550 80 49 48 106 84 50 ti4 86 51 123 754634 600 82 54 96 50 106 86 51 114 88 52 123 650 so 9 85 52 16 88 52 114 90 54 124 550 86 62 98 53 106 90 54 1145 92 55 124 80767 600 87 67 98 89 58 107 9 54 16 94 56 125 650 9 72 9 62 107 o3 5 116 95 56 125 550 91 73 99 9 64 107 9 5 97 58 125 85771 600 93 78 99 95 70 108 97 117 99 59 126 eso 95 99 97 74 99 66 117 60 126 Based on a normally installed cooling chassis TROUBLESHOOTING Magic Pak HW HWC 9 10 Performance Tests Chassis Installed in Unit cont TABLE 9 3 HWC242 Performance Test Chassis Installed Outdoor Air Temperature Entering Outdoor Coil Based on a normally installed cooling chassis TABLE 9 4 02 Performance Test Chassis Installed Outdoor Air Temperature Entering Outdoor Coil Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid Pressure Temp Temp Pressure Temp
28. Model JBIMI37NS Armstrong P N 41144 001 208 240VAC 60 Hz Single Phase 55 FLA 3000 RPM 031 HP Rotation CW LE Continuous Duty Features Ball Bearing Stainless Steel Shaft Motor Grounded to Blower Housing 32 Extension Barbed Tube for 096 005 1 0 Pressure Tap FIGURE 5 9 Magnetek JBIMI37NS Induced Draft Blower 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 15 Burners 34 The Magic Pak HW and HWC units covered in this manual use a burner design called the inshot type No adjustment is provided for primary or secondary air For best operation keep the burners clean Use the correct orifice size and adjust the manifold pressure for the fuel being used and the operating altitude Burner Specifications Manufacturer Beckett Gas Model 086 Armstrong P N 41948 001 Burner Dimensions 4 50 x 2 48 Burner Carryover Gap 025 002 Burners D _ FIGURE 5 10 Typical Burner Arrangement 5 16 025 gap 002 UNIT COMPONENTS Flame Exit for flame carryover Gap 025 002 Magic Pak HW HWC Flame Carryover Problems During ignition the flame must travel uninterrupted from one burner to the rest of the burners Causes Carryover wing on burner is plugged with insects or debris Improper gap setting on wings Incorrect gas pressure The burner wing has a specified gap typically 0 025 0
29. Temp Pressure Temp Temp Pressure Temp Temp 75963 850 78 51 100 79 47 48 120 48 129 955 so 57 ioo e 48 ht 49 160 83 so 12130 775 62 402 84 si 585 82 52 80 67 925 8 7 102 87 eo 112 54 121 89 53 131 775 8 72 103 90 63 112 92 55 93 55 132 859 71 850 91 77 104 92 69 13 94 61 123 95 57 133 925 93 82 104 94 72 113 128 97 58 133 Based on a normally installed cooling chassis 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual Performance Tests Chassis Bench Tested TABLE 9 5 70 80 Ambient Temperature Chassis Bench Test Chassis Ambient Disch isch Liquid iqui Suction Model Temp Pressure Pressure Pressure DB WB COEM 175 psi 170 psi 182 183 200 psi 190 psi 242 243 205 psi 99 200 psi 302 303 205 psi 200 psi TABLE 9 6 95 Ambient Temperature Chassis Bench Test Chassis Disch isch Liquid iqui Suction Model Temp Pressure Pressure Pressure DB WB TROUBLESHOOTING Suction Total Comp Subcoolin Temp Amps sH i wwe z e zas ole seme mm oe mmm m ese sv e sos ne s wow wo vr mom we eem 9 gt
30. smonomese Eo sowas 1 esse pLowenwpucedorarT swrcinoor 1 14 7 1 rg rti rg m emm pep fearon L L m mem porone _ o oone S ororo lomoworomnowmme feee m wem b sme w www wancos ed Pe LH EET 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual HWA 9 TO SELECT PART Last letter of the Model is the Service Level 64HWA 9A First find Model 64HWA 9 Then match Service Level for desired part IREF PART PART DESCRIPTION REC STOCKING PART SERVICE LEVEL PARTS LISTS REVISED 4 26 99 51HWA 9 eme mese 7 eere a ads fap vemos peas f uron Pew ua sew oweeszwswwros ew ses eem uen es _ ew Dee n m ewe ees women T 13 13 Em Em Em Em Em E
31. the resistance of the entire motor windings circuit is not equal to the sum of C to S and C to R A short between the windings of the start and run coils would reduce the length of the wire being measured and would result in less resistance between the two points Instead of measuring the resistance from S to C to R the resistance is actually being measured through an internal short in the windings to the R terminal bypassing the C terminal This results in a lower resistance reading and indicates that the compressor has failed and the windings are shorted Checking the Thermal Overload Device If during the time that resistance was being checked in the previous test infinity was ever registered meter indicated no continuity the assump tion could be made that there is an open winding or a break in the wires of the winding This may indicate that the windings had burned out and that the compressor had failed In the motor windings there is a thermal overload device This device is designed to open if the internal temperature of the windings exceed a preset limit Since the resistance reading of a winding where the thermal overload device has opened would show no resistance the assumption would most likely be made that the winding was burned out This is where the temperature of the compressor as noted in the touch test becomes very important If at the time of the touch test the compressor was found to be very hot then the
32. 0 112 302 1 to 3 39057B001 390598003 39103B001 39298B001 053028025 0 054 0 106 302 4 to 8 40650 001 39059B003 40652 001 40651 001 05302B025 0 054 0 106 302 9 43375 001 39059 003 43281 001 43280 001 05302 025 0 054 0 106 All part numbers provided are Armstrong part numbers See page 5 34 for drier information See the figures beginning on page 5 36 for detailed drawings of the capillary tubes UNIT COMPONENTS 5 36 Notes All bends 90 unless otherwise noted Do not kink or flatten during forming Tape tubes together with masking tape 14 00 11 89 Ref 5302B001 2 Reqd 73 Ret 178 FIGURE 5 26 43267 001 Capillary Tubes 9 00 Ref 6 50 Ref 3 500 Diameter 1 Turn 2 875 Diameter Mandrel 5302B024 3 Reqd FIGURE 5 28 43267 003 Capillary Tubes Magic Pak HW HWC 7 25 Ref 6 75 Ref 75 Rad Typ 3 500 Diameter 1 Turn 2 875 Diameter Mandrel 5302B025 3 Reqd FIGURE 5 27 43267 002 Capillary Tubes 15 86 9 00 Ref 53028025 2 2 62 2 500 Diameter 2 Turns 2 125 Mandrel FIGURE 5 29 43280 001 Capillary Tubes Fi 5 25 Ref 5 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual Notes All bends 90 unless otherwise noted Do not kink or flatten during forming
33. 2 L 10n the contactor 3 L 10n the blower control board 4 Terminal on the transformer marked 208V or 240V whichever is being used Second black wire Supplies power to the induced draft blower L 2 on the contactor Common terminal on the transformer T 2 on the contactor Red wire on the R terminal of the compressor Red wire to the common terminals on the capaci tors oo Low Voltage 24 VAC With the unit at rest no call from the thermostat 24 volts A C will be found at these points 1 Red wire exiting the top of the unit 2 Terminal marked 24 VAC on the ignition control 3 Terminal R on the blower control board CALL FOR HEAT Line Voltage The thermostat closes the circuit between R and W The following is the sequence of operation for the line voltage side of the unit 1 Terminal TH 24 volt energizes on the ignition control causing the relay in the ignition control to close This sends line voltage to the terminal marked IND causing the induced draft blower to start 2 When W energizes a 24 volt signal is also sent to the W terminal on the blower control board The 24 volt signal to the blower control board starts the timer on the board After 60 seconds the heat speed relay on the blower control board closes This sends line voltage from the terminal marked HEAT to the circulating air blower starting the blower The induced draft blower and the circu lating air blower continue to o
34. 320308003 380308004 13 990808005 _ 9 aeneo queso 24 144900001 aoe 36 Ho 46 389778001 52 401548007 55 szs20B004 55 375208005 57 144819010 anseo 63 PARTS LISTS MAGIC PAK HW HWC HWC3 S 1 cont TO SELECT PART Last letter of the Model is the Service Level 64HWC303SA 1A 1 First find Model 64HWC303SA 1 Then match Service Level for desired part gt gt o 2 IREF PART PART DESCRIPTION 7 69 390458001 MOTOR 1 6 HP 1 PHASE 69 390468001 MOTOR 1 3 HP 1 PHASE 074078000 BAND MOTOR MOUNTING 074088004 MOUNTING NE 348338001 WHEEL BLOWER um 5390108001 ASSEMBLY BLOWER HOUSING 86 34001D001 CAPACITOR 4 MFD 370 VAC PES 86 34001D004 CAPACITOR 7 5 MFD 370 VAC Eg 1 lt scm 2 lt lt lt lt lt z QO 9 215 8 8 8181 815 5 5 5 516 I L qutt PEPE EERE ET 1 1 EE EN 51HWC243SA esee rr aso sstumme mision FILTER 16 5 X 25 X 50 55 a mess
35. 64HW Model Number Guide 26 H 12 2 26 Rated Input BTU Hr x 1000 H Gas Heat W Thru the Wall C Cooling 12 Nominal Cooling BTU Hr x 1000 2 Cooling Efficiency 2 9 7 SEER 2A Revision Code Product Serial Numbers Beginning 1993 84 95 A 12345 84 Armstrong Factory Number 95 Year ex 1995 Month see list below 12345 Sequential Number Jan Feb D Apr E May June July H Aug J Oct L Nov M Dec 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual SPECIFICATIONS 1 3 Summary of Model Revisions Variations Table 1 1 Heating Configurations of HW HWC Units Configuration Ignition Blower Control Ignition Type HWC 123 183 243 303 1 225 Heat UTech Combination Ignition Blower Control 1097 Electric Cool All HW 9 Gas Heat Only UTech Combination Ignition Blower Control 1097 HWC 122 182 242 302 Gas DSI DSI Ignition Control Fenwal Triton 24610 Blower Control Heatcraft 4 401 DSI Teque ei eom Econo ee Tridelta 92080048 or UTech 1010 DSI Ignition Control Fenwal 05 29 All HWC 122 182 242 302 Gas Heat Blower Control Heatcraft 4 401 E 4 3 1 Electric Cool Tridelta 92080048 or UTech 1010 Table 1 2 Cooling Configurations of HWC Units Configuration Tonnage SEER Compressor Type Metering Device All HWC 123 1 Gas Heat Electr
36. Are they pitted or corroded to the point where they no longer conduct electricity sthe capacitor in good condition Does it have the correct rating for the application Using a meter determine if it still has the correct capacitance e last of these initial tests to do is a touch test This should be done very carefully as the compressor can become very hot in certain situations This information may be helpful if further tests are needed to determine the condition of the compressor Further Testing Use extreme caution when conducting the following tests The power must be turned off before continuing with the testing Checking Continuity 1 Remove wires from the fusite plug in the compressor recording the location of each wire as it is removed If a wire is misplaced when the test is complete serious damage could be done to the compressor 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual TROUBLESHOOTING 2 Set an ohm meter to the lowest possible setting On a note pad write the following to ground S to ground and R to ground 3 Using the ohm meter check for continuity between C terminal on the fusite plug and the case of the compressor a spot may have to be cleaned on the compressor to get a good reading Record what was observed on the note pad next to the heading C to ground Do the same to the other two terminals and record the findings in the proper places 4 If any si
37. FIRME u IEEE al ifr mew T sf re TI conmo 1 1 lt eo x o a 1 1 1 EEERELEEL 1444 1 41 LL menn 1 sc sas ELIT i E mense msn mene FII EI mne pp mensem m 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS 8 27 HWC 3 cont pw TO SELECT PART Last letter of the Model is the Service Level 64HWC302 3A First find Model 64HWC302 3 Then match Service Level for desired part gt DESCRIPTION FILTER DRIER 38HWC242 3 51HWC242 3 64HWC242 3 1 sr mna e esso 110 1 1 _ weisse 4414 4411 E LL l el gt gt sveve LL b La 271 271 271 301 301 301 PARTS LISTS MAGIC PAK HW HWC HWC 2 TO SELECT PART Last letter of the Mode
38. LOW VOLTAGE FACTORY WHEN USED ms m LIMIT Io LOW VOLTAGE FIELD rag vi m MANGAL SWITCH m PSWO WHITE OCTO 9 WHITE TS SENSOR z z 0 But Rue acr E Ree X INDO I I THERMOSTAT PRESSURE q enmar 119 Qe 9 CONTROL bicis cm inc ond BLACK IF ANY OF THE ORIGINAL O WIRES REPLACED ELECTRODE a cence TION w E 5 d THE SAME SIZE AND TYPE CABLE WIRE MUST USED BLACK Siem cim YELLOW E SEE CHART CONTROL 027 MOTOR SPEED CONNECTIONS FOR WIRING C 0240 m Dm m MODELS KEATING TRANS 26HW RED BLACK FORMER 38HW HIGH BLACK YELLOW 51HW l SW FIGH BLACI BLOWER WHITE CAPACITOR BLOWER BLOWER MOTOR RED 3924701 FIGURE 2 6 Connection Diagram 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual SEQUENCE OF OPERATIONS Simplified Sequence HW w Fenwal 05 29 Board Refer to Figure 2 6 CALL FOR HEAT 1 The indoor thermostat calls for heat by energizing the R W circuit 2 This sends a 24 volt signal to the ignition control causing the induced draft blower to run 3 24 volt signal is also sent to the blower control board at this time starting a 60 second circulating air blower delay The circulating air bl
39. SEQUENCE OF OPERATIONS 2 31 SPECIFICATIONS 2 38 Magic Pak HW HWC 122 182 242 302 Low Ambient CIRCUITS ENERGIZED OPERATING MODE CIRCUIT 208 230 1 60 N COPPER CONDUCTORS POWER SUPPLY ONLY R FAN G LINE VOLTAGE FACTORY LINE VOLTAGE FACTORY WHEN USED Fa LINE VOLTAGE FIELD IGNITION LOW VOLTAGE FACTORY e LOW VOLTAGE FIELD PSWO e INDO PE PRESSURE THERMOSTAT els oe BLUE 8 vac EIL SI GND NOTE D IF ANY OF THE ORIGINAL WIRES ARE REPLACED dd m THE SAME SIZE AND WIRE MUST USED z mz BLACK CONNECTOR BLOCK BLACK RELAY FAN CONTROL SEE TABLE w FOR WIRING gt EVAPORATOR MOTOR Q SPEED CONNECTIONS CAPACITOR BLOWER BLOWER MOTOR SEE TABLE FIGURE 2 8 Connection Diagram MODELS HEATING COOLING 26HWC122 LOW RED MED BLUE 38HWC122 HIGH BLK MED BLUE 38HWC182 LOW RED LOW RED 82 MED BLUE LOW RED 64HWC182 HIGH BLK LOW RED 38HWC242 LOW RED MED BLUE 51HWC242 MED BLUE MED BLUE 64HWC242 HIGH BLK MED BLUE 51HWC302 MED BLUE HIGH 64HWC302 HIGH HIGH BLK JUMPER REQUIRED
40. TABLE 5 1 Triton 2461D Diagnostic Flash Code This code is used for up to four seconds at startup each time the control is powered to indicate that the control is performing a self diagnostic check If a problem is detected the STEADY ON NAME ue self diagnosis will repeat for a total of five times which equals twenty seconds If LED is on steady for 20 seconds this indicates a control failure Indicates an air flow fault Used only on models with a pressure switch input PSW This code is active only if the PSW input is in the improper state after a predetermined time delay For example If the PSW input was powered when the call for heat begins closed contacts ONE FLASH the control will allow a fixed time for the PSW input to go off otherwise the LED flash will commence Conversely if he PSW input is not powered within a fixed delay time after the inducer motor is energized the LED flash will commence If the PSW input is removed during a heating cycle power will be removed from the gas valve immediately If the PSW power input is not reapplied within a fixed time the LED flash will commence Indicates a flame detected out of sequence or with no call for heat LED will flash twice as TWO soon as flame is detected out of sequence and continue as long as the flame is present FLASHES Controls with an inducer control circuit will also power the inducer circuit when flame is detected out of sequence Indicates ignition lockout
41. circulating air blower is energized The unit will continue to operate normally until the R W circuit is interrupted When the heat call is satisfied the thermostat will interrupt the R W circuit This causes the 24 volt signal to the white wire in the unit to be de ener gized 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual 12 13 14 15 The gas valve closes immediately as 24V through pin 4 of the 6 pin ignition wire harness is de energized by the ignition control The ignition control initiates a 120 second circu lating air blower off delay and 5 second com bustion blower post purge delay After 5 seconds the combustion blower shuts off After 120 seconds the circulating air blower shuts off and the system returns to standby mode Note During a call for heat the green LED shows consistent fast flash as long as the R W circuit is closed When the R W circuit is interrupted indicating the heat call has been satisfied the green LED returns to a consistent slow flash LIMIT ROLLOUT OPENS In all modes of operation 24VAC is supplied to the ignition control 24VAC hot terminal and is passed through the ignition control to pin 6 of the 6 pin ignition wire harness 1 A 24 volt signal is sent from pin 6 of the 6 pin ignition wire harness to one side of the Normally Closed manual reset rollout switch across the rollout switch to one side of the Normally Closed auto reset limit switch an
42. m pesw p sme bo soesooow eneo 1 1 REC STOCKING PART SERVICE LEVEL 38HWC1824A 11 38HWC242A 11 PARTS LISTS MAGIC PAK HW HWC 1 82 242 11 cont ps TO SELECT PART Last letter of the Model is the Service Level 38HWC242A 11A First find Model 38HWC242A 11 Then match Service Level for desired part gt IREF PART PART DESCRIPTION ras FILTER 16 5 X 25 X 50 ET E M E REC STOCKING PART SERVICE LEVEL 38HWC1824A 11 38HWC242A 11 255 267 sse serons sse serons 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS HWC122 242A 10 p TO SELECT PART Last letter of the Model is the Service Level 38HWC242A 10A First find Model 38HWC242A 10 Then match Service Level for desired part EIE lt mmmo s sese cowmocmowencees e wwes ff ww _ eere wr nsf s is onricewsenaruraccas Emri m esteem sewn b exon B meeerueseen e s s as afr
43. oowourooon sese EET E essen Soora foram L PL PLLPLLLITL sss oaa essor IET EET TET DI s seras pesce eren ss seras ss seras E i seen Taf L EI 1 1 ES EJ 1 1 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS 8 39 HWC3 S 1 cont 5 SELECT PART Last letter of the Model is the Service Level 64HWC303SA 1A First find Model 1 64HWC303SA 1 Then match Service Level for desired part lt 2 lt o REF PART PART DESCRIPTION oc 351256009 COMPRESSOR AW501ET 089 A4 39008C001 COMPRESSOR RK147ET 002 A4 42811 005 COMPRESSOR ZR24KC PF V 130 42811 006 COMPRESSOR ZR28KC PFV 130 mn 67 41254 001 MOTOR 1 4 HP 1 PHASE 67 41282 001 MOTOR 1 8 HP 1 PHASE 68 390628001 BLADE FAN 68 390858001 BLADE FAN m 69 039820004 SUPPORT 71 385140002 CAPACITOR 25 5 MFD 370 VAC 71 385140004 CAPACITOR 35 5 MFD 370 VAC 76 42725 001 PLUG COMPRESSOR ES 78 07525 001 CONTACTOR 80 074898007 RELAY CONDENSER FAN MOTOR 91 363278007 SWITCH CONDENSER FAN ES 01 390
44. 002 Burners FIGURE 7 5 TL109 Burner Tray lt 66 8 SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 1 21 AMUFFKT494 1 Discharge Muffler Kit In the event that during operation an unacceptable noise occurs a muffler kit AMUFFKT494 1 may be installed in the discharge line The cham ber of the muffler acts as a sound absorbing chamber reducing compres Sor pulsation noises AMUFFKT494 1 is designed to be used only with HWC182 units p Discharge Line to Condenser Coil Discharge Muffler FIGURE 7 6 AMUFFKT494 1 Kit Discharge Muffler Installation SRM HW HWC 8 99 Service Reference Manual PARTS LISTS Section 8 Parts Lists HWC 123 183 243 303 1 HWC1882 P242 11 HWC122 242 10 HWC242 302 9 HWC122 182 242 302 8 HWC182 6 7 HWC122 282 242 302 5 HWC1892 302 4 HWC122 182 242 302 3 HWC182 2 HWC122 182 242 302 1 vido eda dnd HWC123 183 243 303S 1 Low HWC123 183 243 303H 1 High Altitude 8 1 PARTS LISTS MAGIC PAK HW HWC HWC3 A 1 TO SELE
45. 1 a BN 385140011 45 5 385140012 55 7 5 Dual Single 38514D013 60 7 5 FIGURE 5 36 Capacitors 5 40 UNIT COMPONENTS Magic Pak HW HWC Evaporator Blower Motor Indoor Blower 69 TABLE 5 14 Evaporator Blower Motor Specifications Armstrong FLA of Capacitor P N v hz ph Speeds 1 1 39045B001 208 230 60 1 1000 4 370 2 3 39046B001 208 230 60 1 1120 1 3 7 5 370 Notes capacitor ratings may vary Always check FLA and capacitor ratings on the motor data plate Motor diameter 5 70 shaft size 50 rotatin CW lead end See parts list for correct selection of motor and capacitor Condenser Fan Motor Outdoor Motor 267 TABLE 5 5 Condenser Fan Motor Specifications Armstrong FLA of Capacitor P N v hz ph Speeds 1 8 9 9 41254 001 18 1075 1 14 5 370 208 230 60 1 Notes capacitor ratings may vary Always check FLA and capacitor ratings on the motor data plate Motor diameter 5 70 shaft size 50 rotatin CW lead end See parts list for correct selection of motor and capacitor 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS Capacitors Run 86 TABLE 5 16 Armstrong P N 34001D001 34001D002 340010003 340010004 340010005 340010006 340010007 340010008 340010009 340010010 340010011 340010012 340010013 340010014 340010015 340010016 340010017 3400100
46. 208 230 60 1 13 6 208 230 60 1 13 6 208 230 60 1 18 6 208 230 60 1 18 6 208 230 60 1 18 6 Voltage Hz Phase A 1 8 5 0 26HWC122 123 A 1 8 a e 38HWC122 123 1 8 a 38HWC182 183 1 8 a 51HWC182 183 1 8 a 64HWC182 183 1 4 51HWC302 208 230 60 1 22 4 30 14 76 0 1 4 36HWC242 243 o a 51HWC242 243 64HWC242 243 a a a a 2 zr Performance Ratings Table 1 4 Performance Ratings HWC122 123 Cooling Cooling Cooling 5 71 450 4400 830 3700 920 42 78 Note All values are gross capacities and do not include blower motor heat deduction 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual SPECIFICATIONS 1 5 Performance Ratings continued Table 1 5 Performance Ratings HWC182 183 Total Total Total Cooling 9 Cooling Cooling Cooling Capacity Capacity Capacity Capacity Note All values are gross capacities and do not include blower motor heat deduction Table 1 6 Performance Ratings HWC242 243 Total Total Cooling I Cooling y Cooling Btuh GEJ
47. 24 volt signal going to terminal P SW on the ignition control causing terminal V1 on the ignition control to de energize This interrupts the 24 volt signal to the gas valve and immediately closes it Since terminal TH on the ignition control and W on the blower control board remain energized the induced draft blower and the circulating air blower continue to run The 24 volt signal to the ignition control can only be restored if the rollout switch is manually reset Once the cause of the rollout switch being tripped has been determined the switch can be reset With the rollout switch reset terminal P SW on the ignition control again energizes The ignition control makes a trial for ignition and operation returns to normal SPECIFICATIONS HWC122 182 242 302 w Fenwal 05 29 Ignition Control 208 230 1 60 N COPPER CONDUCTORS POWER SUPPLY ONLY teng o S 2 r j gt 0 E n IGNITION MANUAL 9 vi RESET CONTROL WHITE BESET SWITCH OO Sio WHITE FLAME Z PRESSURE INDO m SWITCH ELECTRODE CABLE Magic Pak HW HWC CIRCUITS ENERGIZED OPERATING MODE CIRCUIT HEATING R W COOLING R G Y FAN R G LINE VOLTAGE FACTORY m LINE VOLTAGE FACTORY WHEN USED m LINE VOLTAGE FIELD LOW VOLTAGE FACTORY LOW VOLTAGE FIELD WHITE NOTE IF ANY OF THE ORIGINAL WIRES ARE REPLACED D THE SAME SIZE AND TY
48. 3 FILTER RETAINER ARMSTRONG P N 38072B001 FILTER STOP ARMSTRONG P N 38703B001 EVAPORATOR DRAIN TUBE CONNECTION FILTER 127 SIZE 63 5 8 FILTER RETAINER 16 5 x 25 x 50 ARMSTRONG P N 380728001 ARMSTRONG P N 06131B046 NOTE WHEN USING A REPLACEMENT FILTER WITH REQUIRES 5 8 1 0 DRAIN HOSE A MANUFACTURED FRAME THE DIMENSIONS ARMSTRONG P N 03613A001 NOT SHOWN MAY NEED TO BE REDUCED FOR PROPER FIT TAKE AND RECORD MEASUREMENTS FOR PROPER FIT FIGURE 4 7 The numbers in parentheses in the drawing above refer to the section number each part is assigned These num bers are provided here to aid in locating the parts in the Parts List section found beginning on page 8 1 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS Section 5 Unit Components Transformer 5 3 Gas Valves 5 4 White Rodgers 25K49 5 4 Honeywell 8105 5 5 Blower Control Boards 5 6 United Technologies Model 1010 611 5 6 Heatcraft Model IBC H4C401 5 7 Ignition Controls 5 8 Fenwal Triton 2461D 5 8 Fenwal 05 29 DSI 5 10 Induced Draft Blower 5 14 BurnerS 5 15
49. 3 Terminal R on the blower control board CALL FOR HEAT Line Voltage The thermostat closes the circuit between R and W The following is the sequence of operation for the line voltage side of the unit 1 Terminal TS 24 volt energizes on the ignition control causing a relay in the ignition control to close This sends line voltage to the terminal marked IND causing the induced draft blower to start 2 WhenW is energized a 24 volt signal is also sent to the W terminal on the blower control board The 24 volt signal starts the timer on the blower con trol board After 60 seconds the heat speed relay on the blower control board closes This sends line voltage from the terminal marked HEAT to the circulating air blower starting the blower The induced draft blower and the circulating air blower continue to operate until the heat call is satisfied interrupting the circuit between R and W The W terminal de energizes causing the blower relay to open approximately 90 seconds later This interrupts the line voltage to the circulating air blower and the blower shuts down Low Voltage 1 call for heat closes the circuit the thermostat between R and W sending a 24 volt signal to the white wire on the unit 2 The white wire goes to the C terminal on the limit switch ignition control terminal TS and terminal W on the blower control board 3 When W energizes the timer starts a countdown to circulating air blower
50. ARM MOTOR MOUNTING 39046B001 71 07407B000 72 07408B004 73 34833B001 WHEEL BLOWER ASSY BLOWER HOUSING CAPACITOR 4 MFD 370V 74 1390108001 39232D001 392320004 CAPACITOR 7 5 MFD 370V 24 42268 001 ASSY WIRE HARNESS UPPER 25 396058001 ASSY WIRE HARNESS LOWER gt gt service reve 26 39080B001 VALVE GAS SHUT OFF 27 06131 046 FILTER 16 5 X 25 X 5 ROD FILTER LABEL WIRING DIAGRAM 28 06132B001 30 39007D005 250 38982B001 COIL OUTDOOR 250 38983B001 COIL OUTDOOR 250 40649 001 COIL OUTDOOR 250 41114 001 COIL OUTDOOR 255 389798001 COIL INDOOR mE 255 389808001 COIL INDOOR 255 40648 001 COIL INDOOR 57 390458001 9046800 72 7408800 sesso 74 1390109001 46 392320004 124 42268 001 pes 386088001 28 200808001 27 001318046 061328001 180 390070005 250 389628007 250 389638001 250 neieom Een 255 6960800 255 0646001 _ PARTS LISTS 8 15 REVISED 1 20 98 8 gt LLLI L LL E BEES EGER ETE TT PARTS LISTS MAGIC PAK HW HWC 8 16 REVISED HWC 8 cont 1 20 98 TO SELECT PART Last letter of the Model is the Service Level 64HWC302 8A First find Model 64HWC302 8 Then match Service Level for desired part lt 2 lt
51. Charge Weights TABLE 9 7 HWC Refrigerant Charge Weights 9 11
52. Tests Bench Tested 9 11 Charge Weights 9 11 9 1 9 2 TROUBLESHOOTING Magic Pak HW HWC 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 a determination on the condition of the compressor is made This section has been organized so that the simplest checks are done first followed by the more detailed tests if necessary WARNING Use extreme caution when performing maintenance or troubleshooting operations Electrical shock could cause personal injury or death Initial Testing If a compressor failure is suspected several simple checks should be done initially to make sure that the right course of action is being taken The following is a list of items and points that should be looked at before a determination is made of the condition of the compressor e 15 correct voltage available at the unit Using a volt ohm meter check the voltage and compare with the voltage specified by the manufacturer found on the data plate on the unit Many compres Sors are replaced only to find later that there was either no power or incorrect power available to the unit Is the contactor closing Check to make sure that there is 24 volts at the coil side of the contactor Check to make sure the points in the contactor are in good condition
53. UNIT COMPONENTS 5 5 Honeywell 8105 Series Gas Valve Specifications Manufacturer Honeywell Model VR8105M8202 Armstrong P N 44987 001 Dimensions 2 70 W x 4 75 L Nominal Operating Currents 25 VAC 60Hz 5A Regulator Setting 3 50 3 W C Pipe Size 50 Inlet x 375 Outlet Valve Amp Draw 5 1 Drop Capacity 85 000 Btuh Max Regulator Capacity 120 000 Btuh Temperature Rating 40 F to 175 F Main Valve Terminal Hot Main Valve Common Terminal FIGURE 5 3 Honeywell Gas Valve Reference Tube Vent Manifold Pressure Adjustment BN 8 NPT Outlet Pressure Tap On Off Switch UNIT COMPONENTS Magic Pak HW HWC 5 6 Blower Control Boards 5 A separate blower control board is used in the Magic Pak HW HWC models that do not use integrated ignition blower control boards Blower control boards from two different manufacturers are used in these HW and HWC units The two blower control boards are explained in detail in the following pages United Technologies Model 1010 611 Blower Control Board Specifications Manufacturer United Technologies Model 1010 611 Armstrong P N 39029B002 Operating Voltage 18 30VAC 60 Hz 60 Hz Power Requirement 4 VA max Operating Temperature 40 F to 170 F Wiring Connections All Male 250 x 032 Quick Connect Tabs Performance Specifications all timings 1 second Heating On Delay Timing 60 seconds Off Delay Timing 90
54. W When the call for heat is satisfied the 24 volt signal between R and W discontinues When W de energizes the power to the induced draft blower and the gas valve is interrupted The 24 volt signal to the blower control board is also interrupted causing the module to start the countdown to blower off approximately 90 seconds 9 Ifatany time during call for heat the limit switch opens the 24 volt signal to the white wire going to terminal P SW on the ignition control is interrupted This de energizes the gas valve immediately The circulating air blower and the induced draft blower continue to run When the unit cools down enough for the limit switch to close the 24 volt signal is again sent to the P SW terminal on the ignition control With terminal P SW energized the ignition control again makes a trial for ignition and relights the burners CALL FOR COOLING 1 call for cooling closes the circuit from to Y and G 2 A24 volt signal is sent to blower control board terminal G and to the compressor contactor The contactor closes sending line voltage to the com pressor and the outdoor condenser fan 3 With a 24 volt signal at terminal G on the blower control board the circulating air blower starts in cooling speed approximately 15 seconds later or immediately see note below 4 When the cooling call is completed G and Y de energize The contactor opens immediately stop ping the compressor and the outdoor
55. an off delay of 90 seconds Tridelta blower control boards have no on time delay and 60 130 second off delay 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual BLANK PAGE SEQUENCE OF OPERATIONS 2 21 SPECIFICATIONS Magic Pak HW HWC 2 22 HW Heating Only w Fenwal Triton 24610 DSI Ignition Control CIRCUITS ENERGIZED OPERATING MODE CIRCUIT 208 230 1 60 COPPER CONDUCTORS HEATING R W POWER SUPPLY ONLY Way LINE VOLTAGE FACTORY LINE VOLTAGE FACTORY WHEN USED LINE VOLTAGE FIELD LOW VOLTAGE FACTORY anne LOW VOLTAGE FACTORY WHEN USED IGNITION fa LOW VOLTAGE FIELD CONTROL _ THO PSWO __ V104 E EEE INDO TUN D 110 Be s THERMOSTAT 2105 24 gt gt o ATA V2 OF Qd NOTE lt zo IF ANY OF THE ORIGINAL E s WIRES ARE REPLACED THE SAME SIZE AND WIRE MUST USED YELLOW MOTOR SPEED CONNECTIONS BLOWER MODELS HEATING SEE CHART CONTROL BLACK m m 26HW LOW RED FORWIRING lt 03240 38HW HIGH BLACK PRANS ae 51HW MED BLUE LN YELLOW BLACK O 64HW HIGH BLACK BLUES B BROWN RED BLOWER WHITE CAPACITOR BLOWER ONR RED 39247D2 FIGURE 2 4 Connection Diagram 66 2 OMH MH INHS SR
56. apply to 12 18 24 and 30 or 121 181 241 and 301 units 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 1 3 CA 239 Wall Sleeve Kit The CA 239 wall sleeve kit is designed to facilitate the installation of Magic Pak units by providing an accurate opening to properly accept a Magic Pak unit During the construction of a building the wall sleeve allows for the unit to remain off site until the construction is completed The wall sleeve is comprised of four assemblies top bottom and left and right sides which assemble easily to form a correctly sized rectangular box to receive a Magic Pak unit When installed and securely fastened to the supporting wall the wall sleeve provides easy access to the finish wall for weather sealing The wall sleeve must always be fastened to the supporting wall and never to the finished wall Inspection of Shipment Upon receipt of equipment carefully inspect it for possible shipping damage If damage is found it should be noted on the carrier s freight bill Damage claims should be filed with the carrier immediately Claims of shortages should be filed with the seller within five days Wall Sleeve Assembly To assemble the wall sleeve refer to the following directions and Figure 7 1 on page 7 4 1 Slide top panel over side panels until retaining clips are engaged in slotted openings 2 Place side and top assembly down with the front flange against floor a
57. burner rack from the spark electrodes The flame sense signal is sent to the S1 terminal of the ignition control The unit continues to operate as long as W is energized 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual 8 When the call for heat is satisfied the circuit be tween R and W is interrupted de energizing W 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 blower off delay Approximately 90 seconds later the blower stops FLAME SENSE 1 During a call for heat the spark terminal is ener gized and the gas valve is opened to light the burners 2 The ignition control energizes the spark terminal and the gas valve for approximately six seconds If a flame is not sensed in this time period the igni tion control de energizes the spark terminal and the gas valve This causes the gas valve to close and the burners to shut off 3 Since the 24 volt signal has been sent to the blower control board the circulating air blower times on in approximately 60 seconds 4 The induced draft blower continues to run for approximately 30 seconds then another trial for ignition begins 5 The ignition control runs three trials for ignition If a flame is not sensed during these three trials the ignition control will lockout 6 Thecirculating air blower continues to run until the R W circuit at the
58. chassis come with a pre charged chassis assembly The chassis 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 the performance measurements will be affected due to the change in static pressures recirculated air excessive temperatures and equal ambient temperatures from indoor to outdoor Two sets of tables are provided in this section to address these issues Tables 9 1 to 9 4 are to be used when the chassis is still installed in the complete unit Tables 9 5 and 9 6 are to be used when the chassis is run independently outside of the unit Note Pressures may vary 10 psi Temperatures may vary 2 3 Performance Tests Chassis Installed in Unit TABLE 9 1 HWC122 Performance Test Chassis Installed Outdoor Air Entering Outdoor Coil Suction Suction Liquid Suction Suction Pre Pen Suction Suction Liquid Pressure Temp Temp Pressure Temp Temp Pressure Temp Temp Pressure Temp Temp 84 50 107 85 5 117 5 1071 52 52 107 89 53 117 54 107 93 5 117 57 107 9 56 117 56 108 96 57 17 65 90 108 98 58 117 Based on a normally installed cooling chassis TABLE 9 2 HWCt182 Performance Test Chassis Installed Outdoor Air amr Entering Outdoor Coil
59. cooling fan When G de energizes the timer to turn off the circulating air blower starts The circulating air blower turns off after 90 seconds see note below FAN ON 1 When the thermostat switch is moved to the FAN position the circuit between R and G closes 2 The 24 volt signal from G goes to the blower control board which starts the timer 3 Fifteen seconds after terminal G on the blower control board energizes or immediately after see note below the circulating air blower starts 4 When terminal on the blower control board de energizes the timer to turn off the circulating air blower starts The circulating air blower turns off after 90 seconds see note below Note Heatcraft blower control boards have a G delay of 15 seconds and an off delay of 90 seconds Tridelta blower control boards have no on time delay and a 60 130 second off delay Detailed Sequence follows 2 18 SPECIFICATIONS Magic Pak HW HWC Detailed Sequence HWC122 182 242 302 w Fenwal Triton 24610 DSI Ignition Control Refer to Figure 2 3 POWER Line Voltage When the service disconnect switch is closed power is sent to the unit unit in standby no signal from the thermostat Power 208 230 volts A C is supplied to both black wires located in the junction block on top of the unit Line voltage will be present at the following locations First black wire 1 L 1 on the ignition control
60. description of unit disassembly Locations of major components of HW HWC models Illustrations and specifications for individual components including valves blowers ignition controls and blower control boards Installation requirements and startup guidelines Complete listing of all Armstrong accessories available including wall Sleeves louvers and gas conversion kits Complete service parts lists for all HW and HWC models System check and troubleshooting procedures 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 1 3 Heating Configuration Table 1 3 Cooling Configuration Table 1 3 HWS ING 1 4 Physical and Electrical 1 4 Performance Ratings 1 4 Blower Performance 1 6 Dimensions 1 6 Wall Sleeve 1 7 1 1 1 2 SPECIFICATIONS Magic Pak HW HWC Models Covered By This Manual HWC Gas Heating Electric Cooling Units HW122 123 HW182 183 HW242 243 HW302 303 HW Gas Heating Only Units 26HW 38HW 51HW
61. easily during testing Balance and zero the manometer according to the manufacturer s instructions 2 Insert atest line with tee between the pressure switch and blower One piece of the tubing connects the pressure switch to the fitting at the back side of the induced draft blower housing Connect the tee to the manometer as shown in Figure 5 20 Note Always keep the pressure switch in the circuit when measuring Switches incorporate internal bleeds to keep moisture out of the pressure switch line 3 Using Table 5 4 on page 5 22 and the formula provided above calculate the close value for the switch being worked with 4 Startthe furnace to call for heat Observe the manometer reading increase increasing pressure rise as the induced draft blower comes up to speed Ignition should start at a reading that is approxi mately the Close value that was earlier determined for the specific switch in Step 3 5 With the furnace running in the full heat cycle observe the pressure reading Note this reading and compare it to the Open value shown for that switch in Table 5 4 on page 5 22 Using Armstrong P N 44819 005 pressure switch for an example the reading on pressure fall when the contacts open can be between 0 54 W C and 0 66 W C 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 27 Induced Draft Blower Pressure Switch 1 8 Tee z Tee installed for test purposes only FIG
62. is made in which it is more desirable to mount the filter exterior to the unit in the return duct work or elsewhere the permanent filer can be used or replaced with a disposable filter If a disposable filter is used refer to Table 6 4 when sizing the disposable filter TABLE 6 4 Minimum Required Surface Area for Disposable Filters Adjustments Heating Section Temperature Rise At the time of installation the temperature rise must be adjusted to be within the range specified on the unit rating plate Pressure Regulator The gas input must not exceed the figures shown on the rating plate The unit is equipped for rated inputs with manifold pressures of 3 5 W C for natural gas and 10 0 W C for propane The manifold pressure can be measured by removing the pipe plug in the automatic gas valve Connect a water manometer and measure the pressure Only small variations in gas input may be made by adjusting the regulator In no case should the final manifold pressure vary more than 0 3 W C for natural gas or 0 7 W C for propane 6 14 INSTALLATION Magic Pak HW HWC To adjust the regulator turn the adjusting screw on the regulator clock wise to increase pressure and input or counterclockwise to decrease pressure and input For natural gas installations check the burner rate by observing the gas meter making sure that all other gas appliances are turned off The test hand on the meter should be timed for at leas
63. part lt L PART PART DESCRIPTION 5 35125C009 COMPRESSOR AWSO1ET 089 A4 aM 39008 001 COMPRESSOR RK147ET 002 A4 EE TT 42811 005 COMPRESSOR ZR24KC PFV 130 fal 42811 006 COMPRESSOR ZR28KC PFV 130 eee 41254 001 MOTOR 1 4 HP 1 PHASE P fat fafa socer meme sf a 2 E D T pr T L b ronem prenne ones 8 4 REC STOCKING PART gt gt SERVICE LEVEL 26HWC1234A 1 EN 38HWC1234A 1 38HWC1834A 1 64HWC243A 1 51HWC303A 1 64HWC303A 1 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS HWC182 242A 11 TO SELECT PART Last letter of the Model is the Service Level 38HWC242A 11A First find Model 38 242 11 Then match Service Level for desired part A E i emm mase e murmu oor ames be o sno s mem swonmnessunene wem uronwore mese 7 gt wes 1 8 a a
64. seconds Cooling On Delay Timing 15 seconds Off Delay Timing 90 seconds Heating and Cooling Output Rating 12 F L A 30 L R A at 120VAC for 100 000 Cycles 10 F L A 30 L R A at 240VAC for 100 000 Cycles Both heat and cool outputs cannot be energized simultaneously L1 Line Voltage COOL Cool Speed L1 Power Out NOW Heat Speed L1 Power Out w 24VAC Heat NE G 24VAC Fan Call Fan On Dumb Terminals Cooling Call Fan Auto Park 27 24VAC Common EUN N FIGURE 5 4 United Technologies Blower Control Board 1010 611 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 7 Heatcraft Model IBC H4C401 Blower Control Board Specifications Manufacturer United Technologies Model 1010 611 Armstrong P N 39029B002 Operating Voltage 18 30VAC 60 Hz 60 Hz Power Requirement 4 VA max Operating Temperature 40 F to 170 F Wiring Connections All Male 250 x 032 Quick Connect Tabs Performance Specifications all timings 1 second Heating On Delay Timing 60 seconds Off Delay Timing 90 seconds Cooling On Delay Timing 15 seconds Off Delay Timing 90 seconds Heating and Cooling Output Rating 12 F L A 30 L R A at 120VAC for 100 000 Cycles 10 F L A 30 L R A at 240VAC for 100 000 Cycles Both heat and cool outputs cannot be energized si
65. should serve as a general guide for installation of the kit For guidelines on designing louver facades refer to the Magic Pak Application Manual Armstrong P N MPA 100 The ALVR42 is designed to be integrated into the construction of the finish wall or secured directly to the finish wall Therefore actual installa tion of the louvers will vary depending on the type of finish wall it is applied to The ALVR42 kit is available is many different colors to match finish walls Color matching services are also available For more information con cerning color matching please contact your supplier or Armstrong Assembly The ALVR42 kit consists of two sections of louver fins The top section is composed of fins angled approximately 30 upward while the bottom section consists of fins angled approximately 30 downward see Figure 7 3 This design allows flue gases and condenser discharge air to be circulated away from the condenser inlet and burner compartment fresh air intake There is also a sealing gasket between the two louver sections to allow for separation of inlet and discharge air when the louver is secured directly to the front of the unit When the louver is secured away from the unit a separation bracket sealed to the unit and then to the louver kit must be field fabricated and installed The ALVR42 louver is 45 tall to accommodate proper drainage of the unit and wall sleeve and proper discharge of condenser air and flue gases
66. the following directions and Figure 6 1 on page 6 5 for guidance in installing the unit without a wall sleeve 1 Measure the size of the unit and provide an opening in an outside wall that will accept the unit Local ordinances may require a steel lintel to support the wall above the opening The opening must be square in all four corners 2 Position the unit so that the grilles on the outside face of the unit are flush or extend beyond the face of the exterior wall but not recessed more than 2 from the face of the building Provide a support under the unit inside the building Make sure that the inside support does not block the return air The unit should be installed level or pitched slightly to the outside of the building so that rain water will drain away 3 Sealthe space between the unit and building opening using a non hardening caulking compound The seal must be weathertight to prevent entrance of moisture and water into the building Make sure the drain holes in the base are not plugged with caulking Support In general the wall sleeves will support the Magic Pak HW HWC units on any wall The wall however must be adequate to support the unit Otherwise one must provide additional support between the unit and the floor The center of gravity is between the bottom return air opening rear flange and the wall sleeve When additional support for the unit is desir able it should be near this center of gravity and applied even
67. 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 could be caused by a defective or incorrect capacitor Motor overheating internal thermal overload tripped Motor refuses to start Intermittent problems with blown fuses or breaker tripped High electrical consumption Motor rotates in the wrong direction e Contactor overheating or melted contacts Motor vibration Any one of the above faults could be attributed to the capacitor There fore the capacitor must be checked out before a determination is made of the problem In the past the old method of swinging the meter needle to tell if the capacitor was good or not could be used When the terminal of the capacitor was touched with the meter probes the meter needle would swing over than back to zero If it didn t it could be assumed that the capacitor had failed There are many problems with this technique Swinging the meter needle only proves that the capacitor will take a charge but not how much of a charge In some cases when a capacitor starts to break down it still will take a charge but the number of electrons that it can hold is greatly reduced The capacitor must take the correct charge as originally designed so that the motor will work as it should A much more accurate method must be used to determine the condition of the capacitor before the decision on
68. 02 which must carry gas and a small flame to allow flame carryover from one burner to the next Check the gap settings on all burners Smooth end slips into burner Threads into manifold Orifice Gas Entry FIGURE 5 11 Inshot Burners FIGURE 5 12 Burner Wing Gap 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS Manifold Orifices 13 TABLE 5 3 Manifold Orifice Specifications Armstrong Hole Diameter Drill Size inches 39030B001 39030B002 390308009 A E a 39030B010 39030B011 390308012 e 390308013 390308014 o 9 e 39030B015 39030B016 39030B017 39030B018 39030B019 Hole Diameter FIGURE 5 13 Manifold Orifice 9 17 5 18 UNIT COMPONENTS Magic Pak HW HWC Contactor 278 Contactor Specifications Manufacturer Honeywell Model 8242 1008 Armstrong P N 7535C001 Single phase Single pole 25 F L A 125 L R A Coil 24VAC 50 60 Hz Line Voltage 240 277 Coil Resistance at 70 F 8 10 ohms Low Voltage Coil Terminals Open Contact Closed Contact FIGURE 5 14 Honeywell Contactor Model R8242A 1008 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 19 Main High Limit Switch 52 A Normally Closed control that opens if abnormally high circulating air temperatures o
69. 120 second circulating air blower off delay starts After the elapsed time the circulating air blower stops FAN ON 1 When the thermostat is switched to the FAN ON position a 24 volt signal is sent to the ignition control 2 The ignition control immediately energizes the cooling speed of the circulating air blower 3 Thecirculating air blower runs in the cooling speed until the thermostat fan switch is moved back to the AUTO position At this time the circulating air blower stops During the call for FAN ON the circulating air blower heat speed will not be energized by the ignition control unless the limit switch circuit is interrupted Detailed Sequence follows 2 12 SPECIFICATIONS Magic Pak HW HWC Detailed Sequence HW w UTEC 1097 Board Refer to Figure 2 2 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 Atthe transformer terminal marked 208 240V L2 Power 1 Through the L2 black lead to the induced draft blower 2 Transformer common terminal 3 Atthe circulating air blower capacitor terminal Low Voltage 24 VAC With the unit at rest no call from the thermostat 24 volts A C will be present 1 Atthe transformer 24V terminal 2 Atthe 24VAC hot terminal on the ignition control 3 Atpin 5 of the 5 pin thermostat harness red wire pin
70. 18 340010024 340010025 340010026 340010027 340010028 340010029 340010030 340010031 340010032 340010033 Capacitor Ratings Volts 4 E 1 5 0 5 5 18 EN 370 370 370 370 370 440 370 370 1 440 2 440 2 370 2 440 3 440 3 370 3 440 370 440 440 1 370 2 370 3 370 1 440 2 370 2 370 3 370 3 370 370 5 40 4 8 41 UNIT COMPONENTS Magic Pak HW HWC 5 42 Fan Blades 268 Notes 1 26 Pitch 5 Blades 2 Material 24 Ga Galvalume 3 Set Screw 2 5 16 24 x 5 8 long square head cup point 3 79 09 5002 I Diameter Bore 1 E 4 AIR FLOW FIGURE 5 37 Fan Blades HWC Models 122 182 amp 123 183 66 2 OMH MH INHS SRM HW HWC 2 99 UNIT COMPONENTS Service Reference Manual 5 43 Notes 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 3 59 09 N e Q 18 00 06 1 1 1 1 1 _ 5002 5019 Diameter Bore FIGURE 5 38 Fan Blades HWC Models 242 302 amp 243 303 HW HWC Magic Pak UNIT COMPONENTS 9 44 Exterior Grill Panels Not Listed in the Parts Lists Armstrong P N 03545C000 Armstrong P N 03551D100 Lower Grill Panel zi Upper Louver Panel
71. 2 The plastic drain connection is provided so that it may be disconnected from the permanent drain tubing in the building in the event it becomes necessary to remove the cooling chassis assembly The drain line should pitch gradually downward at least 1 per 10 feet of horizontal run to the open drain trap Be certain that the plastic drain tube has free drainage and is not crimped or flattened at any bend Drain Pan LE NECARE Top of Drain Tube Alternative Method m 2h Must be Below T H Bottom of Drain Pan To Open Drain Trap gt i AC Drain Tube Pitch 1 for Return Air Duct ET every 10 ft Installer Supplied 5 8 I D Plastic Tube Furnished Open Drain Trap FIGURE 6 2 HWC Drain Installation Venting The venting system is an integral part of the appliance The venting system must not be modified or added on to HW HWC units are direct vent forced air central furnaces which draw fresh air from outside through a combustion air opening beneath the vent into the combustion chamber The combustion products are then drawn out of the heat exchanger by an exhaust fan and are forced to the out doors No special provisions are required for supplying combustion air The vent outlet must not be altered or extended in any way This appliance should be installed in a location such that the vent system complies with the National Fuel Gas Code Z223 1 or CAN CGA B149 1 amp 2 INSTA
72. 24 volt signal to the pressure switch and also de energizes terminal P SW on the ignition control The gas valve closes immediately as the 24 volt signal to terminal P SW is no longer present The induced draft blower and the circulating air blower continue to run Power to blower control board terminal W is maintained The blower continues to run until the limit switch closes or the heat call at the thermostat is satisfied 2 When the limit switch senses that the tempera tures in the unit are normal the contacts between terminals C and NO open the contacts between terminals C and NC close and the operation of the unit returns to normal SEQUENCE OF OPERATIONS PRESSURE SWITCH OPENS BLOCKED FLUE 1 If blockage of the flue occurs negative pressure in the induced draft blower is reduced the set point of the pressure switch the contacts open This interrupts the 24 volt signal to terminal P SW on the ignition control The gas valve closes immediately as a relay in the ignition control opens and interrupts the signal to terminal V2 of the ignition control 2 Terminal W on the blower control board stays energized and the circulating air blower contin ues to run If negative pressure is restored the pressure switch closes and sends a 24 volt signal to the P SW terminal on the ignition control The ignition control makes a trial for ignition again and the operation returns to normal ROLLOUT SWITCH ACTIVATED 1 If conditio
73. 3 lt 5 lt PPS SSS SS SS SSS Sea Y ECCE 22 lt 27 gt lt 2976 gt Wall Sleeve all measurements in inches 15 or 12 gt lor 34 gt 2 lt 16 gt L A 45 2 29 lt 12 5 Flanges may be assembled 1 or 524 from this side of the sleeve SRM HW HWC 2 99 Service Reference Manual SEQUENCE OF OPERATIONS Section 2 Sequence of Operation HWC123 183 243 303 2 4 Simplified Sequence 2 5 Detailed Sequence 2 6 POWERS 2 6 CALL FOR HEAT dede reor p bee 2 6 LIMIT ROLLOUT 2 7 PRESSURE SWITCH OPENS BLOCKED FLUE 2 7 FAILED FLAME SENSE TRIAL FOR IGNITION 2 8 CALL FOR COOLING diti org ebore 2 8 FAN OBSS editos bois dept tap turpe 2 9 HW Heating Only w UTEC 1097 Spark Ignition System 2 10 Simplified Sequence 2 11 Detailed Sequence 2 12 tt cla AE LOU 2 12 GALL FOR HEAD a ann 2 12 LIMIT ROLLOUT OPENS 2 13 PRESSURE SWITCH OPENS BLOCKED FLUE 2 13 FAILED FLAME SENSE TRIAL FOR IGNITION
74. 30 chassis This kit cannot be used to replace an HWC181 241 or 301 TABLE 7 10 ADAPT420 2 Parts List Installation Instructions Center Rear Panel 4 Filter Access Panel Support Foam Sealing Tape 12 inches Wiring Diagram Labels When replacing the old chassis the new chassis must have the same nominal cooling capacity If the nominal cooing capacity of the new chassis is larger than the original both the appliance internal line voltage wire and the field wiring must be checked for proper size The fuse and or breaker size must also be checked 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 1 19 Fenwal Triton Ignition Control Kit This kit enables the Fenwal Triton local sense one hour retry direct spark ignition DSI control to be used as a service parts replacement for earlier versions of Fenwal DSI controls used on HW HWC models The operation and features of this ignition control differ from the other types of DSI controls used These features include Longer trial for ignition 15 seconds nominal One hour retry feature if main burner operation is not proved after three trials for ignition control goes into lockout for one hour then automatically initiates another ignition sequence will repeat as long as call for heat exists Senses flame through spark electrode local flame sense instead of through a separate flame sensor remote flame sense Diagnostic LED indicates cer
75. 3545C000 EXTERIOR LOWER GRILL PANEL ARMSTRONG P N 03551D100 CONDENSER AIR FLOW INLET FIGURE 4 4 SIDE VIEW LOUVERS POINT UPWARD AT 45 ANGLE GRILL IS FLAT WITH RECTANGULAR OPENINGS Note Panels found in the drawing above are not listed in the Parts List section that begins on page 8 1 COMPONENT LOCATION ILLUSTRATIONS Magic Pak HW HWC 4 6 HWC Chassis Assembly EVAPORATOR BLOWER MOTOR 69 COMPRESSOR CONTACTOR 278 COMPRESSOR CAPACITOR 271 ARMSTRONG P N 03575 001 N 75 CONDENSING FAN CONDENSER FAN 267 268 CAPACITOR 271 wy Ss CONDENSING COIL 250 CAPILLARY TUBE BLOWER CONTROL BOARD 5 amp s 5 HE lt ARMSTRONG P N 39029B002 Zag SSS METERING DEVICE 256 FILTER RETAINER 57 lt FILTER DRIER DISTRIBUTOR 301 ARMSTRONG P N 38072B001 yx n 12 ARMSTRONG P N 39059B001 LOW VOLTAGE PA L 18 24 ARMSTRONG P N 39059B002 ARMSTRONG P N 39370B001 FILTER STOP ARMSTRONG P N 38073B001 FILTER SIZE 16 5 X 25 5 X 5 EVAPORATOR 255 SUCTION LINE PORT DISCHARGE LINE PORT COMPRESSOR 262 FILTER RETAINER EVAPORATOR DRAIN PAN ARMSTRONG P N 38072B001 ARMSTRONG P N 38918B001 FIGURE 4 5 The numbers in parentheses in the drawing above refer to the section number each part is assigned These num bers are provided here to aid in locating the parts in the Parts List section found beginning on page 8 1 66 2 OMH MH INH
76. 38514D004 2 45 1 17 Mineral 200 Viscosity 75 3 4 50 1 2 12 208 230 1 ola s oO N N fo UNIT COMPONENTS Magic Pak HW HWC 5 30 Manufacturer Tecumseh TABLE 5 6 Tecumseh Rotary Compressor Specifications Supplier Model Supplier B M Cap Req d 39008C001 512 RK147ET 002 A4 47ET 002 A4 10 62 62 10 06 06 500 8 56 56 25 370 39008C002 RKA5518EXD RK233ET 009 M 11 50 10 94 25 370 All measurements in inches unless otherwise specified FIGURE 5 21 Tecumseh Rotary Compressor 75 Diameter Holes Top View 6 315 D Copper Discharge Tube C 1 0 Copper Suction Tube 43 50 Deep Side View 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 31 Manufacturer Tecumseh TABLE 5 7 Tecumseh Reciprocating Compressor Specifications Armstrong Supplier Model Supplier Crankcase Cap 35125009 AWF5517EXN AWF5517EXN AW501ET 089 A4 AW501ET 089 A4 089 A4 208 230 208 230 35 MFD 35 MFD 370V 35 MFD 370V lt 938 753 756 1 0 Copper Suction Tube 12 647 12 753 378 381 I D Copper Discharge Tube E 7 475 7
77. 4500 feet a high altitude kit as supplied by the manufacturer must be used see page 7 15 TABLE 7 5 ALPKT389 2 Parts List Part Quantity Adapter Kit for White Rodgers 25K Gas Valve 65 Main Burner Orifices 64 Main Burner Orifices 62 Main Burner Orifices Gas Valve Conversion Label Although the equipment is suitable for operation with propane gas after the conversion kit has been installed certain precautions must be observed because of the distinct burning characteristics of propane gas The following problems may be encountered 1 Burning back at the orifices with a loud roar 2 Loud popping upon extinction of the burner 3 Flame rollout at the time of the ignition These problems can be caused by 1 Low gas pressure 2 Improper air adjustment 3 Incorrect burning rate The furnace has a regulator in the gas valve A regulator is also required on the propane tank Another regulator may be required at the house or the unit The minimum permissible gas supply pressure to the furnace is 11 W C for the purpose of input adjustment The maximum permissible gas pressure to the gas valve is 14 W C 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 1 15 AHALTS90 1 High Altitude Kit The AHALT390 1 kit contains the following parts to convert the 26 38 51 and 64HW HWC series units to high altitude for natural or propane gas If the field conversion is for high altitude propane gas be su
78. 525 Between Centers of Holes 750 760 Diameter 4 Holes Side View FIGURE 5 22 Tecumseh Reciprocating Compressor UNIT COMPONENTS Magic Pak HW HWC 5 32 Manufacturer Copeland TABLE 5 8 Copeland Compressor Specifications Armstrong Supplier Model Cap Req d P N Number 98 VAC 351366001 ZR28K1 PFV 14 06 14 31 13 32 7727795 7727795 95 35870 All measurements in inches unless otherwise specified 18 Ga Thermal Protector Leads 12 13 Long 500 1 0 Copper Discharge Tube 750 1 0 Copper Plated Steel Suction Tube C D Side View 7 50 c Between Centers of Holes 65 Diameter 4 Holes Typical T Box FIGURE 5 23 Copeland Compressor Layout 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 33 Manufacturer Copeland TABLE 5 9 Copeland Compressor Specifications Armstrong Supplier Model Rating Cap Req d 2 VAC 42811 005 005 ZR24KC PFV 130 PFV 130 208 230 1 60 1 60 14 1421 1445 45 13 32 32 9 63 63 8 53 8 77 53 8 77 547 47 35970 42811 006 ZR28KC PFV 130 208 230 1 60 14 21 14 45 13 32 35 370 All measurements in inches unless otherwise specified 9 41 9 790 Dia 4 7 50 4 Holes Typ pd Top View 500 I D C
79. 59B001 FILTER DRIER ES 390598002 FILTER DRIER 01 39059B003 FILTER DRIER 7 287 E Ez got gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt snee eve 11 eewesesss PARTS LISTS MAGIC PAK HW HWC 1 m TO SELECT PART Last letter of the Model is the Service Level 64HWC303HA 1A 8 10 1 First find Model 64HWC303HA 1 Then match Service Level for desired part 5 s VANEGASHONEWWEL 11 TA 11 j qp 1 11 j p op 4 13 somos omeesoema cas faf e 6 s Jonne aea 445 4 8 8 oas 5 a sj eb 24 ascend e A mem umen 5 5 seo FR Jassemavnearexchancer ipti ro ss ns 1 64HWC303HA D seo al L hs perso a ss msn sonores E E e E LLL 55 375208005 SWITCH ROLLOUTGREEN fala NINE
80. 6 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual SEQUENCE OF OPERATIONS 2 17 Simplified Sequence HWC122 182 242 302 w Fenwal Triton 24610 DSI Ignition Control Refer to Figure 2 3 CALL FOR HEAT 1 for heat closes the circuit between wires red and W white on the unit s thermostat connec tions 2 Alow voltage 24 volts signal is sent to the ignition control closing a relay which sends line voltage to the induced draft blower At the same time a 24 volt signal is also sent to the blower control board This causes the blower control board to begin the countdown to closing the relay that starts the circulating air blower 3 After the induced draft blower creates enough negative pressure the pressure switch closes 4 When the pressure switch closes the 24 volt signal is sent to the ignition control This starts a 30 second pre purge countdown after which a trial for ignition is made 5 Atthe same time that the trial for ignition is made the gas valve energizes and gas flows to the burners 6 With the burners in operation the trial for ignition continues for seven seconds At the end of this time the ignition control stops sparking 7 Approximately 30 seconds after the burners ignite the timer on the blower control board closes a relay sending line voltage to and starting the circulating air blower 8 Theunit continues to operate as long as there is a 24 volt signal between R and
81. 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS HWC3 H 1 cont TO SELECT PART Last letter of the Model is the Service Level 64HWC303HA 1A First find Model 64HWC303HA 1 Then match Service Level for desired part lt lt lt lt lt lt lt I I L I CN TT T T T T N N O O O O O O O s REF PART PART DESCRIPTION 25 69 39045 001 MOTOR 1 6 1 PHASE n ssa rores seems ose emus ms es ie NESE EVEN EVEN EV EE 74 39010B001 ASSEMBLY BLOWER HOUSING sam ouncronawroommme DE TL I 86 340010004 CAPACITOR 7 5 MFD 370 VAC P fal tp tl iv aseo enun EVEN 45001 001 ASSEMBLY WIRE HARNESS UPPER 1 t ij n n ng 45002 001 ASSEMBLY WIRE HARNESS LOWER EA p t t t t 1 n lt x o a ree Jerem pp Fe eee EL m eee s oem smaris s aseo osos L sere assvcar ruse wrurenoner 1 jes siero assvcar ruse wrurenoner al assvca
82. 7 10 34961A001 Vibration Isolator 7 12 ALPKT389 2 L P Gas Conversion Kit 7 14 AHALT390 1 High Altitude Kit 7 15 ATIMR466 1 Nuisance Blower Repair Kit 7 17 ADAPT420 2 Chassis Conversion Kit 7 18 Fenwal Triton Ignition Control Kit 7 19 TL109 Burner Tray Kits 7 20 AMUFFKT494 1 Tecumseh AW Model Compressor Sound Reduction Kit 7 21 ACCESSORIES Magic Pak HW HWC 1 2 Accessories There are a number of accessories available to increase the performance or versatility of the Armstrong Magic Pak HW HWC units This section provides a general description of each Note Complete instructions are packaged with each kit or its components and accessories These instructions should be read carefully prior to installation The instructions are intended as a general guide only for use by qualified personnel and do not supersede any national or local codes in any way TABLE 7 1 HW HWC Accessory Kit Index CA 239 All HW HWC Models 242 1 HW HWC Models ALVR42 HW HWC Models 34961A001 HW HWC Models ALPKT389 2 26 38 51 64HW HWC Models AHALT390 1 26 38 51 64HW HWC Models ATIMR466 1 All HW HWC Series 2 Models ADAPT420 2 All HW HWC Models 43110 001 HW HWC Series 2 Models Does not apply to 121 181 241 and 301 48 tall series units use sleeve 241 Does not
83. 9888001 250 40649001 250 meom 255 255 255 0648001 SRM HW HWC 8 99 Service Reference Manual PARTS LISTS 8 21 HWC 5 cont SELECT PART Last letter of the Model is the Service Level 64HWC302 5A First find Model 64HWC302 5 Then match Service Level for desired part gt E 2 o IREFIPART PART DESCRIPTION 256 390588001 ASSY CAP TUBE mE 256 390588002 ASSY CAP TUBE 256 390588003 ASSY CAP TUBE 256 40650 001 ASSY CAP TUBE 1 1 _ za oossoo foroen T am oem 282 40715 001 RELAY TIME DELAY 2 2 71 71 71 le e EZ ee ee a E E E mess _ 1 L L A Pie Ee Pe menm ee esso l A e e e lL d femos PARTS LISTS MAGIC PAK HW HWC 4 um TO SELECT PART Last letter of the Model is the Service Level 38HWC182 4A First find Model 38HWC182 4 Then match Service Level for desired part meme mesowem eN s menm 7 mew A a 5 once A rs
84. BLUE The following blower ignition control board BROWN MOTOR NERA LED codes will indicate normal or abnormal j operations TERMINAL BLOWER BLOCK SLOW FLASH Normal Operation No Call for Heat FAST FLASH Normal Operation Call for Heat 2 FLASH System Lockout Failed to Detect or Sustain Flame 3 FLASH Pressure Switch Open or Closed 4 FLASH High Limit or Rollout Switch Open 5 FLASH Flame Sensed and Gas Valve Not Energized STEADY Internal Failure Micro controller Failure Self check FIGURE 2 7 Connection Diagram 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual HWC123 183 243 303 Low 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 sequence of operation during a cooling call is modified when outdoor temperatures fall below the normal operating range The switch will interrupt the operation of the outdoor cooling fan when the temperature of the liquid line coming in from the outdoor coil falls below 55 F When the temperature of the liquid line rises to 95 F the switch will close and the outdoor fan will resume tion The low ambient switch does not affect any other facet of the operation of the unit To see simplified and detailed sequences of operation for the HWC123 183 243 303 models refer to pages 2 5 to 2 9
85. BLY WIRE HARNESS UPPER 45002 001 ASSEMBLY WIRE HARNESS LOWER FILTER 16 5 X 25 X 50 3 LABEL WIRING DIAGRAM 250 COIL OUTDOOR 250 COIL OUTDOOR 250 COIL OUTDOOR 250 41114 001 COIL OUTDOOR 73 74 2 2 2 8 5 7 0 255 389798001 COIL INDOOR 255 COIL INDOOR 255 COIL INDOOR 256 ASSY CAP TUBE W FILTER DRIER 256 ASSY CAP TUBE W FILTER DRIER 256 ASSY CAP TUBE W FILTER DRIER 256 543375 001 ASSY CAP TUBE W FILTER DRIER lt 2 x o a E E 2 9 gt ES EX Ex E EX EX EX EX ES EX EN EX LY EJ p 1 1 N e O O 10 33313 ES CUE Ex P es aa ie Pitt NI Pitt PL tt lt EJ Er Ei El PARTS LISTS 8 3 REVISED 4 26 99 51HWC303A 1 51HWC243A 1 64HWC243A 1 38HWC243A 1 Ea fa fa l IILI Te 1 ele esan PARTS LISTS MAGIC PAK HW HWC HWC3 A 1 cont 5 SELECT PART Last letter of the Model is the Service Level 64HWC303A 1A First find Model 64HWC303A 1 Then match Service Level for desired
86. CT PART Last letter of the Model is the Service Level 64HWC303A 1A First find Model 64HWC303A 1 Then match Service Level for desired part gt REF PART PART DESCRIPTION ET lt x o o o a DODE 1 1 1 1 1 1 1 1 oa E 38 8 8 41144 001 BLOWER INDUCED DRAFT 55 55 7 63 all deel LT lela 11 lewa 66 8 OMH MH INHS sas F IS emere a e ai SL LL LL eme ael ae ae e e ETT UY 77 13 EH CH 57 CH SRM HW HWC 8 99 Service Reference Manual 1 cont TO SELECT PART Last letter of the Model is the Service Level 64HWC303A 1A First find Model 64HWC303A 1 Then match Service Level for desired part gt Remp pant Desom Ton ss onem mese MOTOR 1 3 HP 1 PHASE ARM MOTOR MOUNTING WHEEL BLOWER ASSEMBLY BLOWER HOUSING CAPACITOR 4 MFD 370 VAC CAPACITOR 7 5 MFD 370 VAC 11 BOARD TERMINAL 4 45001 001 ASSEM
87. ET LIMIT SWITCH SWITCH ROLLOUT RED 57 43336 010 SWITCH PRESSURE RED 1 63 41144 001 BLOWER INDUCED DRAFT 69 390468001 MOTOR 1 3 HP 1 PHASE gt gt gt 46 389778001 gt gt gt gt gt gt gt gt gt gt gt gt 47 38978B001 mmimimi mi mimimimiy mmsijmmijm ydm Jg dg m m 2 01150A008 4 39113B001 E 5 37520 004 gt gt gt gt P m rm 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual HWC1 82 9 cont TO SELECT PART Last letter of the Model is the Service Level 64HWC182A 9A First find Model 64HWC182A 9 Then match Service Level for desired part PART DESCRIPTION 07407B000 BAND MOTOR MOUNTING 07408 004 ARM MOTOR MOUNTING 34833 001 WHEEL BLOWER 74 5390108001 ASSY BLOWER HOUSING 86 5392320004 CAPACITOR 7 5 MFD 370VAC ED ASSY WIRE HARNESS UPPER ASSY WIRE HARNESS LOWER x VALVE GAS SHUT OFF FILTER 16 5 X 25 X 50 ED pee uerus een T _ p A REC STOCKING PART SERVICE LEVEL gt gt gt gt m mi mi m mmm gt Ie pum pe j gt gt gt gt gt gt gt gt m co rm gt gt gt gt gt
88. FIGURE 6 3 Required Clearances for Direct Vent Terminals 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual INSTALLATION 6 9 Removal of Unit from Common Venting System When an existing furnace is removed from a common venting system serving other appliances the venting system is likely to be too large to properly vent the remaining attached appliances The following test should be conducted with each appliance while the other appliances connected to the common venting system are not in operation 1 Sealany unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condi tion 3 Insofar as is practical close all building doors and windows between the space in which the appliances remaining connected to the common venting system are located and other spaces in the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Following the lighting instructions place the unit being inspected in operation Adjust the thermostat so the appliance will operate continuously 5 Testfor spillage at the draft control relief opening after five min
89. H amp z c LOW VOLTAGE FIELD ORN noo U Gas WHITE Lio VALVE 24 o IGNITION v2 BLUE L CONTROLOGND Qj NOTE COMBUSTION lt IF ANY OF THE ORIGINAL o ELECTRODE m BLOWER PE WIRES ARE REPLACED CABLE THE SAME SIZE AND TYPE m O Im TS me WIRE MUST BE USED CONNECTOR BLOCK se BLACK UNT EIS TTE ws vs EVAPORATOR MOTOR Ja SPEED CONNECTIONS m 9 MODELS HEATING COOLING BLACK AD 26HWC122 LOW RED MED BLUE BLACK 38HWC122 HIGH BLK MED BLUE Q 38HWC182 LOW RED LOW RED 8 208y 51HWC182 BLUE LOW RED x RE oA0V 64HWC182 HIGH BLK LOW RED TRANS 38HWC242 LOW RED MED BLUE vi 51HWC242 MED BLUE MED BLUE BLUE 64HWC242 HIGH BLK MED BLUE Lau A A 51HWC302 MED BLUE HIGH BLK 64HWC302 HIGH BLK HIGH BLK JUMPER REQUIRED BLK YEL CONTR YEL LOAD BLOWER MOTOR COMP STAT BLUE tow TIME DELAY WHITE IF USED SEE TABLE GREEN 3900705 Note On units that are equipped with a low ambient switch designated with an SA in the model number sequence of operation during cooling call is modified when outdoor temperatures fall below the normal operating range For more information on the low ambient switch equipped version of this unit see the section beginning on page 2 38 FIGURE 2 3 Connection Diagram 6
90. ING SECTION lt BURNER TRAY SEE COMPONENT SECTION FOR FURTHER DETAIL OF IGNITION BLOWER CONTROL FIGURE 4 1 The numbers in parentheses in the drawing above refer to the section number each part is assigned These num bers are provided here to aid in locating the parts in the Parts List section found beginning on page 8 1 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS 4 3 HW HWC122 182 242 302 FENWAL IGNITION CONTROL 2 MODELS 24 FENWAL TRITON 2461D 900 227 ARMSTRONG P N 43110 002 FENWAL 05 29 ARMSTRONG P N 39048 001 SEE NOTE BELOW MAIN LIMIT SWITCH 52 INDUCED DRAFT BLOWER FLUE BOX COMBUSTION BLOWER 63 ARMSTRONG P N 41144 001 mE 229172 GAS VALVE 7 py WHITE RODGERS 25K49 120 ARMSTRONG P N 43108 001 0 COMBUSTION AIR INLET 5 HEATING SECTION P N BURNER COVER D BURNER TRAY ASSEMBLY N J BECKETT BURNER MODELS CONTROL SECTION EA 2 TL109A 26K 7 T TL109B 38K TL109C 51K TL109D 64K COOLING SECTION INDIVIDUAL BURNERS 534 BECKETT ARMSTRONG P N 41948 001 ARMSTRONG ARMSTRONG P N 39006B001 4 FLAME ROLLOUT SWITCH 55 PRESSURE SWITCH 57 NOTE SEE COMPONENT SECTION FOR FURTHER DETAIL OF IGNITION BLOWER CONTROL MODELS FIGURE 4 2 The numbers in parentheses in the drawing above refer to the section num
91. LLATION 10 000 50 000 Btu hr Magic Pak HW HWC Special provisions must be made concerning the location of the vent termination with relation to building air inlets A building air inlet is consid ered to be any door moveable window gravity fresh air inlet or other opening where fresh outdoor air can be brought into the building See Table 6 2 for the clearances required TABLE 6 2 HW HWC Installation and Maintenance Instructions 51 64HW HWC 12 Inches The vent system must also terminate at least 3 feet above any forced air inlet within 10 feet of it These clearances do not apply to the combustion air inlet of the appliance because the combustion air does not enter the air of the building Clearance to windows applies to openable windows and not to windows constructed only of glass with no movable parts such as picture windows The vent system must terminate a minimum horizontal distance of 4 feet away from public walkways electrical meters regulators and relief equipment The venting system is designed for proper operation under all weather conditions and for winds up to 40 m p h Figure 6 3 shows the required clearances of direct vent to building air inlets 7 D E 4 x Z i UM Less th Direct Vent Terminal PC m Z E P T4 1 Direct Vent Ec P d Terminal LS Forced Air Inlet E hc Direct Vent Terminal ba more than 50 000 Btu hr
92. M HW HWC 2 99 Service Reference Manual SEQUENCE OF OPERATIONS 2 23 Simplified Sequence HW w Fenwal 2461D Board Refer to Figure 2 4 CALL FOR HEAT 1 call for heat closes the circuit between R and W on the thermostat This sends a 24 volt signal to the white wire on the unit 2 The 24 volt signal energizes terminal TH on the ignition control and the W terminal on the blower control board 3 With the TH terminal energized the ignition control closes an internal relay This sends line voltage from terminal IND to the induced draft blower starting the inducer 4 After a pre purge cycle of approximately 30 sec ondas the ignition control makes a trial for ignition Terminal V1 energizes at this time opening the gas valve The ignition control initiates a spark at the burner to light the main burners 5 The trial for ignition lasts seven seconds at which time the ignition control stops sparking The ignition control looks at the flame sense to determine if the main burners have ignited If flame sense is not proven the ignition control goes through another pre purge cycle approximately 30 seconds and makes another trial for ignition It does this three times If the three trials for ignition fail the ignition control locks out for approximately 60 minutes After 60 minutes the ignition control again makes three trials for ignition This continues as long as there is a call for heat from the thermostat 6 When W ener
93. MH MH INHS SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 1 5 Wall Sleeve Installation The wall sleeve can be installed from either the inside or the outside of the building In any case proper considerations must be made for final weather sealing of the wall sleeve and the Magic Pak unit Whether installing from the inside or outside of a building the wall sleeve may be secured to the supporting wall through the top and side support angles or directly through the wall sleeve side panels When securing the wall sleeve directly through the side panels the top and side angle supports are often used as stops to assure proper alignment before final securing of the wall sleeve is accomplished The top and side support angles can be adjusted to allow the unit to protrude through the outside of the supporting wall by 1 or 3 3 4 inches This will also change the depth that the unit protrudes through the inside wall This adjustment is designed to allow for final sealing of the wall sleeve to various finish types The top and side support angles can be removed altogether and the wall sleeve secured directly through the side panels provided that the installer performs a proper alignment of the wall sleeve A WARNING The further the wall sleeve is extended past the finished wall the more difficult it becomes to accom plish final sealing from the inside of the building Adequate safety precautions must be considered to
94. Magic Pak units in a vertical array should be at least 12 from the opposite building wall and if that building wall also contains Magic Pak units the building should be at least 24 apart Buildings taller than six stories need not exceed the separation needed for six story buildings 6 4 INSTALLATION Magic Pak HW HWC 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 These rule of thumb dimensions are intended to minimize possibilities for recirculation of condenser air or interaction between units However these numbers are not exact for every application and other consider ations might suggest that the designer consult the factory about desired alternatives The grille side of the unit may be flush with or extend beyond the face of the exterior wall but should not be recessed more than 2 from the face of the building and should not be obstructed with trees landscape materi als or building structure There is no minimum clearance required on locating the unit to an interior corner of a building Due to the through the wall design HW HWC units will always have some portion of the unit cabinet extending into the interior of the building The amount of cabinet exposed to the interior will depend on the wall thick ness and the depth the unit is installed into the wall Often mechanical ro
95. Manifold Orifices 5 17 Contactor 5 18 Main High Limit Switch 5 19 Flame Rollout Switch 5 20 Pressure Switch 5 21 Pressure Switch Problems 5 23 Checking Pressure Switch Operation 5 24 Compressors 5 28 Tecumseh uiii orsa ve Vus Ren EA aea ER xa 5 30 ome rm 5 32 Drier Filters rrr n 5 34 5 2 UNIT COMPONENTS Magic Pak HW HWC HWC Capillary Tubes 5 35 Gapacitors u u u ERR 5 39 Evaporator Blower Motor 5 40 Condenser Fan Motor 5 40 Capacitors Run 5 41 Fan Blades 52 5 42 Exterior Grill Panels 5 44 66 2 OMH MH IWNHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS Unit Components This section provides a brief description of the most important compo nents within the Magic Pak HW HWC units The information presented here is not intended to take the place of the instructions and printed literature packed with each component by the original manufacturer The section number for each component is listed in parentheses following the component name This number refers to the section number a
96. PE m WIRE MUST BE USED 2 NOTI3A S BLACK mm C Soviacron BLACK gt TRANS m BLE SLOWER FORMER 55555 EL JURED BROWN lt o L1 BLOWER MOTOR E COMP T STAT TIME DELAY IF USED IF USED SEE TABLE WHITE EVAPORATOR MOTOR SPEED CONNECTIONS MODELS HEATING COOLING 26HWC122 LOW RED BLUE 38HWC122 HIGH BLK BLUE 38HWC182 LOW RED LOW RED 51HWC182 MED BLUE LOW RED 64HWC18 2 HIGH BLK LOW RED 38HWC242 LOW RED MED BLUE 51HWC242 MED BLUE MED BLUE 64HWC242 HIGH BLK MED BLUE 51HWC302 MED BLUE HIGH BLK 64HWC302 HIGH BLK HIGH BLK JUMPER REQUIRED 39007D4 Note On units that are equipped with a low ambient switch designated with an SA in the model number sequence of operation during cooling call is modified when outdoor temperatures fall below the normal operating range For more information on the low ambient switch equipped version of this unit see the section beginning on page 2 38 FIGURE 2 5 Connection Diagram 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual Simplified Sequence HWC122 182 242 302 w Fenwal 05 29 Ignition Control Refer to Figure 2 5 CALL FOR HEAT 1 2 10 11 12 The thermostat energizes the R W circuit send
97. S SRM HW HWC 2 99 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS 4 7 HWC Chassis Assembly View b SEE FIGURE 4 7 FOR CIRCULATING AIR BLOWER COMPONENTS TITIT IL 12 18 ARMSTRONG P N 41282 001 24 30 ARMSTRONG P N 41254 001 7 CONDENSER MOTOR 267 CONDENSER FAN MOTOR BRACKET 269 ARMSTRONG P N 03982D004 O O FAN SHROUD FAN BLADE 268 12 18 ARMSTRONG P N 39085B001 3 BLADE 24 PITCH 18 24 30 ARMSTRONG P N 390628001 5 BLADE 26 PITCH 18 On FIGURE 4 6 The numbers in parentheses in the drawing above refer to the section number each part is assigned These num bers are provided here to aid in locating the parts in the Parts List section found beginning on page 8 1 COMPONENT LOCATION ILLUSTRATIONS HW HWC 4 8 HWC Chassis Assembly Circulating Air Blower Partially Removed BLOWER WHEEL 73 ARMSTRONG P N 348338001 id ioc SEE FIGURE 4 6 FOR FAN CONDENSING p PARTS CIRCULATING AIR BLOWER MOTOR 69 12 ARMSTRONG P N 39045B001 24 30 39046B001 BLOWER HOUSING 74 ARMSTRONG P N 39010B001 MOTOR MOUNTING BRACKET 71 72 BAND ARMSTRONG P N 07407B000 1 ARMS ARMSTRONG P N 07408B004
98. Service Reference Manual HWC Thru the Wall Units Models HWC Premier 122 182 242 302 123 183 243 303 ARMSTRONG Air Conditioning Inc A LENNOX International Inc Company 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 operation and maintenance of Armstrong Magic Pak HW HWC Thru the Wall units Read this manual before attempting assembly installation start up adjustment or operation of the unit If you have any questions about the operation of the unit or a particular safety device call or write Arm strong Air Conditioning Inc 421 Monroe Street Bellevue Ohio USA 44811 Telephone 419 483 4840 Fax 419 483 3557 The documentation and drawings contained in this manual are intended as a general guide and may not reflect exactly the current designs or all of the options available to our customers Please call or write Armstrong Air Conditioning Inc regarding specific details of a particular furnace model configuration or installation The information and specifications contained in this manual are subject to change without no tice Armstrong Air Cond
99. T Air Circulating Blower Heat Speed Line Voltage 11 UNUSED Park 12 FLAME Flame Probe CO OQ S Molex Amp Plug in Description Roll out Switch Return Hi Limit Return Pressure Switch Out Gas Valve Common Gas Valve Out Pressure Switch Return Roll out Switch Out Q N Thermostat Input 24VAC to Thermostat RED Manual Fan Input from Thermostat GREEN Heat Demand Input from Thermostat WHITE Common Ground to Thermostat Cool Demand Input from Thermostat YELLOW Ozom 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 13 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 Heat 30 seconds fixed Fan Off Delay Cool 90 seconds fixed Heat 120 seconds fixed 9 14 UNIT COMPONENTS Magic Pak HW HWC 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 heat exchanger Mounted at the outlet of the secondary heat exchanger the blower establishes a negative pressure within the heat exchanger and exhausts the flue products outside the structure Blower motors operate at a fixed speed Induced Draft Blower Specifications Manufacturer Magnetek
100. URE 5 20 Incline Manometer Connection Incline Manometer UNIT COMPONENTS Magic Pak HW HWC 5 28 Compressors 262 TABLE 5 5 Compressor Specifications continued on next page Compressor Type Compressor B M Armstrong Tecumseh Only P N 42811 005 3 42811 006 4 35125C009 5 42811 005 6 39008 001 7 35136C005 8 42811 006 9 39008 002 10 35136C001 11 35136C004 12 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 29 Voltage 1 208 230 1 Run Armstrong Winding Cil Suction Discharge 25 370 38514D002 Mineral 200 Viscosity 50 1 2 315 5 16 2 208 230 1 35 370 38514D004 Mineral 200 Viscosity 753 3 4 378 3 8 N A N A N A 1 35 370 385140004 2 45 1 17 Mineral 200 Viscosity 25 75 3 4 50 1 2 1 35 440 385140010 2 74 93 Mineral 200 Viscosity 38 75 3 4 50 1 2 208 230 1 4 208 230 1 5 208 230 1 35 370 385140004 Mineral 200 Viscosity 753 3 4 378 3 8 7 25 370 38514D002 NA Mineral 200 Viscosity 50 1 2 315 5 16 7 7 208 230 1 8 208 230 1 1 30 370 385140003 3 03 98 260z 75 3 4 50 1 2 35 440 38514D010 2 74 93 50 1 2 25 370 385140002 315 5 16 1 35 370 38514D004 26 oz 75 8 4 50 1 2 9 208 230 1 8 13 2 15 10 208 230 1 5 11 208 230 1 35 370
101. a Em Ea Em CETT ER EE PB PARTS LISTS MAGIC PAK HW HWC HWA 9 cont ppm TO SELECT PART Last letter of the Model is the Service Level 64HWA 9A a i First find Model 64HWA 9 Then match Service Level for desired part rara je eevee uon ese nee i eese P omes mes swacronwcames a 3 messe wenaoes 3 senos A enn Y pese usarse 16 5 25 50 e eos femen L REC STOCKING PART SERVICE LEVEL m EE ELE TET 1 gt lt lt E I y 10 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS 8 37 HWC3 S 1 p TO SELECT PART Last letter of the Model is the Service Level 64HWC303SA 1A First find Model 64HWC303SA 1 Then match Service Level for desired part gt REF PART 4 PART DESCRIPTION 7 7 44987 001 VALVE GAS HONEYWELL At Bao i ena 1 Ka 8 8 8 55 55 57 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt service a Hlal Hls 0 11 L ele 42074008 LM
102. a we n epal e e ow om Note All values are gross capacities and do not include blower motor heat deduction Table 1 7 Performance Ratings HWC302 303 Total Total Total Total Cooling d Cooling Cooling Cooling Capacity Capacity Capacity Capacity Btuh Btuh 775 67 850 925 775 71 850 925 Note values are gross capacities and do not include blower motor heat deduction SPECIFICATIONS Magic Pak HW HWC 1 6 Blower Performance Table 1 8 Blower Performance HWC Units ext static pressure in w c with filter s HWC182 242 302 HWC183 243 303 Dimensions all measurements in inches SUPPLY AIR DUCT CONNECTION 8 x16 LOW VOLTAGE THERMOSTAT CONNECTIONS HIGH VOLTAGE JUNCTION BOX 4 x 4 x 2 34 DUCT CONNECTION FLANGE GAS LINE CONNECTION Measurements from Side and Top to Center of Vent Outlet 43 RETURN AIR OPENING ON BOTTOM 6 x 22 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual Dimensions cont SPECIFICATIONS 1 7 1 gt 4 16 gt 1 gt e Supply Line Voltage Low Voltage 45 Supply 8 K y y y 2p Gas Inlet 175
103. after all ignition tries have been completed This code will continue THREE FLASHES as long as the call for heat remains On models equipped with one hour automatic reset the code will stop when a new ignition attempt begins 5 10 UNIT COMPONENTS Magic Pak HW HWC Fenwal 05 29 DSI Ignition Control Specifications Manufacturer Fenwal Model 05 29 DSI Armstrong P N 39048B001 Relative Humidity Rating 5 to 9096 RH at 95 F Flame Current 3 mA min Spark Gap 1 8 Trial for Ignition 6 8 seconds Pre purge 30 seconds Input 24VAC from TS and P SW to ground Gas Valve Contacts 24VAC 600 mA max Blower Output Relay between L1 and IND 10 A at 250VAC Ambient 40 F to 150 F FIGURE 5 7 Fenwal 05 29 Ignition Control 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 11 Integrated Blower lgnition 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 and controls the operation of the gas burners gas valve induced draft blower and circulating blower The control has a built in diagnostic function quick gas valve shutoff and automatic ignition retry when it detects that a fault condition has been corrected If a fault is detected the controls goes into fault mode and flashes the single LED indicator at a pres
104. all It is recommended that vibration isolation pads be installed evenly spaced across the outer edge of the bottom panel of the wall sleeve The vibration isolator pads should be approximately 4 x 4 x 7 8 and con structed of one piece of cork rubber with pieces of neoprene rubber adhered to the top and bottom Once the wall sleeve is properly secured to the supporting wall and the vibration isolators are in place the Magic Pak unit can be slid into the wall sleeve The unit must be slid completely forward so that the outer edges of the unit touch the inside flanges of the wall sleeve The unit can then be secured to the wall sleeve by bolting the top flange of the unit to the top turned down flange of the wall sleeve with 1 4 x 3 4 bolts and washers Note In applications where vibration isolation is of particular importance rubber grommets Armstrong P N 9015 can be inserted between the top flanges The wall sleeve alone is not adequate support for the full weight of the Magic Pak unit Additional field fabricated support must be provided between the rear flange of the return opening and the wall sleeve The use of vibrator isolator pads is required between the unit and the support and between the floor and the support Please refer to installation instructions and application manual for details on field fabricated additional supports Weather Sealing After assembling the wall sleeve it is recommended that all panel con ne
105. and off quite frequently typically coming back on within 60 seconds Inability of unit to stay on for a complete call for heat Units cycling on pressure switch re ignite sooner than a main limit switch can reset Tip With all wiring connected and unit running use your volt meter across the pressure switch terminals No voltage reading switch closed Voltage present switch open Checking Pressure Switch Operation Itis easy to check a pressure switch as it operates within the overall system These test procedures make it possible to pinpoint the opening and closing actions of the pressure switch WARNING DO NOT try to repair a pressure switch Use an identical replacement The use of an improperly repaired or malfunctioning pressure switch could result in property damage personal injury or death WARNING Never try to adjust a pressure switch or jumper the switch to allow the furnace to operate Doing so could allow the furnace to operate under hazardous conditions potentially causing property damage personal injury or death 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 25 What Is Needed for the Tests e 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 installed in the unit Look for the Armstrong part number stamped on the meta
106. arting the blower 7 Aslong as W white wire is energized the unit continues to operate 8 When the heat call is satisfied the circuit between and W is interrupted 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual 9 When W de energizes the gas valve immediately shuts down and the induced draft blower also stops after several seconds 10 The blower control board starts a countdown to blower off Approximately 90 seconds later the circulating air blower shuts down LIMIT OPENS If the limit switch opens for any reason during a call for heat the following happens 1 Ifthe limit switch senses that the temperature in the unit is too high the circuit between terminals C and NC on the limit switch opens This closes the circuit between terminals C and NO on the limit switch interrupting the 24 volt signal to the pres sure switch and the rollout switch and causing terminal P SW on the ignition control to de energize The gas valve immediately closes as there is no longer a 24 volt signal at terminal V1 on the ignition control With 24 volts still going to the blower control board and terminal TH on the ignition control the circulating air blower and induced draft blower continue to run 2 Thecirculating air blower and the induced draft blower continue to run as long as there is a call for heat from the thermostat or the limit switch remains open 3 When the limit switch senses that the temperature i
107. ater 10 The blower control board starts a 90 second circulating air blower off delay Approximately 90 seconds later the blower stops FLAME SENSE 1 During a call for heat the spark terminal is ener gized and the gas valve is opened to light the burners 2 The ignition control energizes the spark terminal and the gas valve for approximately six seconds If a flame is not sensed in this time period the igni tion control de energizes the spark terminal and the gas valve This causes the gas valve to close and the burners to shut off 3 Since the 24 volt signal has been sent to the blower control board the circulating air blower times on in approximately 60 seconds 4 The induced draft blower continues to run for approximately 30 seconds then another trial for ignition begins 5 ignition control runs three trials for ignition If a flame is not sensed during these three trials the ignition control will lockout 6 Thecirculating air blower continues to run until the R W circuit at the thermostat is interrupted 7 Theignition control remains in lockout until 24 volt power to the ignition control is reset LIMIT OPENS If the limit switch opens for any reason during a call for heat the following happens 1 Ifthe limit switch senses that the temperature in the unit is too high the contacts between terminals C and NC on the limit switch open and the con tacts between C and NO close This interrupts the
108. ay the ignition control energizes the cooling speed relay and the circulat ing air blower starts When the cooling call is satisfied the thermostat interrupts the R Y and G circuit The contactor de energizes immediately causing the compressor and the condenser fan to stop The ignition control starts a 90 second circulating air blower off delay 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual 6 After the 90 second delay the ignition control de energizes the cooling speed relay and the circulat ing air blower stops FAN ON 1 When the thermostat is switched to the FAN ON position the R G circuit sends a 24 volt signal to pin 4 of the 5 pin thermostat harness The 24 volt signal energizes the cooling speed relay sending L1 power to the ACB COOL terminal of the ignition control L1 power is sent to the circulating air blower terminal block causing the circulating air blower to run in cooling speed The circulating air blower continues to run in cooling speed until the thermostat is switched to AUTO interrupting the R G circuit Note With the thermostat in the FAN ON position during heat call ignition control will not energize the heat speed relay The circulating air blower continues to run in cooling speed unless the limit switch circuit opens which would cause the heat speed relay and the induced draft blower relay to become energized This would de energize the cooling speed rel
109. ay until either the limit switch circuit is closed or the thermostat is switched to the AUTO position SEQUENCE OF OPERATIONS 2 9 SPECIFICATIONS Magic Pak HW HWC HW Heating Only w United Technologies 1097 Spark Ignition System 2 10 WIRE NUT CIRCUITS ENERGIZED OPERATING MODE CIRCUIT 208 230 1 60 COPPER CONDUCTORS HEATING R W POWER SUPPLY ONLY SENS jM RED BLUE BLACK LINE VOLTAGE FACTORY LINE VOLTAGE FACTORY WHEN USED m LINE VOLTAGE FIELD LOW VOLTAGE FACTORY 1 N o LOW VOLTAGE FIELD B COMBUSTION als 5 95 2 i BLOWER x Po lt E9599 6 a as THERMOSTAT IGNITION WHT u T FLAMEROD ox DOR GND 8 RED NOTE 95 BLUE EH IF ANY OF THE ORIGINAL oTm ALVE GREEN WIRES ARE REPLACED THE VOILET E gt SAME SIZE AND TYPE WIRE ORANGE MUST BE USED AUTO RESET MANUAL RESET 5 LIMIT SWITCH LIMIT SWITCH O 7 ORANGE CONNECTOR BLOCK EVAP MOTOR 208V 240V SPEED CONNECTIONS MODELS HEATING TRANSFORMER LOW RED 38HW HIGH BLACK 51HW MED BLUE 64HW HIGH BLACI SEE CHART FOR WIRING 45008 2 CAPACITOR TERMINAL BLOCK BLOWER DIAGNOSTICS The following blower ignitio
110. ber each part is assigned These num bers are provided here to aid in locating the parts in the Parts List section found beginning on page 8 1 COMPONENT LOCATION ILLUSTRATIONS Magic Pak HW HWC 4 4 HW HWC Panels TOP PANEL ASSEMBLY HEAT EXCHANGER ACCESS PANEL ARMSTRONG P N 034550007 ARMSTRONG P N 38782D001 INSPECTION WINDOW SIDE PANEL ARMSTRONG P N 38092A002 ARMSTRONG P N 387690001 UPPER LOUVER PANEL ARMSTRONG P N 03545C000 LOWER GRILL PANEL ARMSTRONG P N 03551D100 ean VA COOLING CONTROL ACCESS PANEL ARMSTRONG P N 03938C004 HEATING COMPARTMENT DOOR ARMSTRONG P N 38987B004 DOOR HANDLE ARMSTRONG P N 37701 001 SIDE PANEL ARMSTRONG P N 38769D002 FILTER ACCESS DOOR ARMSTRONG P N 38785D001 FILTER 16 5 x 25 x 50 ARMSTRONG P N 06131B046 _ UNIT BASE SECTION ARMSTRONG P N 34805B003 UNIT BASE SECTION ARMSTRONG P N 38771D101 THE BASE PAN ASSEMBLY CONSISTS OF 2 SECTIONS FIGURE 4 3 Note Panels and other associated parts found in the drawing above are not listed in the Parts List section that begins on page 8 1 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS 4 5 HW HWC Exterior Louver Grill Panel CONDENSER AIR FLOW OUTLET EXTERIOR UPPER LOUVER PANEL ARMSTRONG P N 0
111. ccur It is an automatic reset control Note Several different main limit switches are used Refer to the parts list for the correct limit switch Common Terminal Camstat Model L59 7B 220 30 Armstrong P N 01150A008 Setting 220 F N C Normally Closed 7 Terminal N O Normally Open Terminal FIGURE 5 15 Camstat Main Limit Switch Manufacturer P N INT17L 2107 Armstrong P N 40154B007 Open Setting 190 F Closed Setting 160 F FIGURE 5 16 Main Limit Switch UNIT COMPONENTS Magic Pak HW HWC Flame Rollout Switch 55 A Normally Closed switch that opens when abnormal temperatures occur in the burner area caused by a restricted heat exchanger causing main burner flame to roll out into the vestibule area To reset the switch push the button on top The button is a different color from the body Reset Button Cutout Temperature Marked on body of switch Nominal Switch Contact Rating 15 120 FIGURE 5 17 Flame Rollout Switch 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 21 Pressure Switch 57 These are Normally Open switches that react to a difference in pressure an internal diaphragm It will not allow ignition to start if the induced draft blower cannot produce sufficient negative pressure relative to atmospheric pressure or pressure in a sealed burner box Its electrical contacts will open in reaction to inadequa
112. ctions and joints be sealed with caulk to prevent water and wind infiltration into the building Once the Magic Pak is installed and secured to the wall sleeve it is important to seal any gaps between the wall sleeve and the unit with caulk This includes both sides top and bottom Sealing these gaps will prevent water and wind from leaking into the building between the unit and wall sleeve The outside of the wall sleeve must also be sealed with caulk on all four sides whether it is installed recessed or protruding 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual ACCESSORIES A242 1 Wall Sleeve Adaptor Kit The A242 1 wall sleeve adaptor kit is designed to allow for the installation of current 43 tall HW HWC units into 48 tall wall sleeves CA241 wall sleeve kits The CA241 wall sleeve kits were designed for use with HW HWC121 181 241 and 301 units manufactured during the late 1980 s HW HWC series 1 units were approximately 48 tall If replacement of the wall sleeve is not feasible use of the A 242 1 adaptor kit creates an insulated block off panel at the top portion of the 241 wall sleeve The adaptor kit also allows for easy mounting of the HW HWC unit to the taller sleeve Whenever it is necessary to convert a CA241 wall sleeve to current unit dimensions use of the A242 1 adaptor kit is required Inspection of Shipment Upon receipt of equipment carefully inspect it for possible shipping
113. d across the limit switch to pin 1 of the 6 pin ignition wire harness This circuit energizes whenever line voltage power is supplied to the unit If the circuit is interrupted by either switch opening the 24 volt signal to pin 1 of the 6 pin ignition wire harness de energizes This causes the combustion blower relay to energize sending L1 power to the CMB BLWR terminal on the ignition control It also causes the circulating air blower heat speed relay to ener gize sending L1 power to the ACB HEAT terminal on the ignition control This causes both blowers to start immediately The ignition control lockouts the spark ignition cable terminal and pin 4 of the 6 pin ignition wire harness until the 24 volt signal is restored at pin 1 of the 6 pin ignition wire harness The circulating air blower and the combustion blower are energized until the 24 volt signal is restored at pin 1 of the 6 pin ignition wire harness The green ignition control LED shows a 4 flash fault code indicating limit switch rollout switch open When the 24 volt signal is restored at pin 1 of the 6 pin ignition wire harness the ignition control starts a 5 second combustion blower post purge delay and a 120 second circulating air blower off delay SEQUENCE OF OPERATIONS 2 13 9 Once the delays have timed out both blowers stop and the green LED flashes a consistent slow flash if no heat call is present A consistent fast flash appears if there is a call for h
114. d on the aluminum sheets used to make up its internal parts The electrons that are supplied to the capacitor are stored in this layer of oxide But by doing this nature is being forced to do something that it doesn t want to do Nature likes to be in equilibrium The fact that nature prefers to return to a steady state is the idea behind the use of capacitors By storing a fixed amount of energy in the capacitor it provides the reserve of extra power needed to start and run a motor Without this energy source motors would have to be much bigger and more complex WARNING A capacitor can store a charge for a considerable length of time after the power has been turned off This charge can be very dangerous An electrolytic capacitor charged with only 10 or 15 volts can melt the tip of the end of a screwdriver when placed across the terminals A high voltage capacitor can store a charge that could be lethal Never touch the terminals of a capacitor without first discharging it Capacitor Testing Capacitors are an integral part of the system and must be checked along with the motor when a problem occurs Check to make sure that the capacitor is correctly rated for the applica tion Confirm that the right capacitor is being used for the application 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual TROUBLESHOOTING 9 7 The following information is found on a capacitor the MFD microfarad rating and the
115. damage If damage is found it should be noted on the carrier s freight bill Damage claims should be filed with the carrier immediately Claims of shortages should be filed with the seller within five days Wall Sleeve Adaptor Kit Assembly Once assembled the A242 1 adaptor kit will form a rectangular box approximately 4 7 8 tall with approximately 7 8 overlapping the front and side of the top panel of the HW HWC unit see Figure 7 2 on page 7 9 To assemble the adaptor kit 1 Settop flanges of side and front panels on the floor or ground so that they are resting flat The screw holes through the side flanges of front panel should align with the pilot holes in side panel 2 Fasten two 8 x 1 2 screws in each side 3 Place rear panel against the rear flanges of the side panels The screw holes of the rear panel should align with the pilot holes in the side panel rear flanges 4 The top and bottom flanges of the rear panel should be facing the front panel The five 1 4 pilot holes should be positioned towards the bottom of the kit and the five oval screw holes should be positioned towards the top of the kit 5 Fasten two 8 x 1 2 screws at each end of the rear panel 1 1 1 8 ACCESSORIES Magic Pak HW HWC 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 pa
116. dicates normal operation system at rest standby mode CALL FOR HEAT Line Voltage The ignition control receives a signal from the R W circuit indicating a call for heat 1 The combustion blower relay energizes sending L1 power to CMB BLWR terminal on the ignition control This causes the combustion blower to start by completing the line voltage circuit through the L2 wire connection in the unit 2 Asthe 24 volt signal is sent to pin 4 of the 6 pin ignition wire harness by the ignition control a 30 second circulating air blower delay starts After the delay the ignition control energizes the heat speed blower relay This sends L1 power to the ACB HEAT terminal on the ignition control 3 11 power is then sent to the circulating air blower terminal block where it is connected to the blower motor The circulating air blower starts by completing the L1 L2 circuit through the L2 connec tion at the blower motor capacitor 4 The combustion blower and the circulating air blower continue to run until the R W circuit is interrupted After a 5 second post purge delay the CMB BLWR terminal on the ignition control de energizes This interrupts L1 power to the combus tion blower After a 120 second circulating air blower off delay the ACB HEAT terminal de energizes This interrupts L1 to the circulating air blower As L1 power is interrupted the blowers shut off Low Voltage 1 for heat closes the R W c
117. e circulating air blower is energized 10 The unit will continue to operate normally until the R W circuit is interrupted 11 When the heat call is satisfied the thermostat will interrupt the R W circuit This causes the 24 volt signal to the white wire in the unit to be de ener gized 12 The gas valve closes immediately as 24V through pin 4 of the 6 pin ignition wire harness is de energized by the ignition control 13 The ignition control initiates a 120 second circu lating air blower off delay and 5 second com bustion blower post purge delay 14 After 5 seconds the combustion blower shuts off 15 After 120 seconds the circulating air blower shuts off and the system returns to standby mode Note During a call for heat the green LED shows consistent fast flash as long as the R W circuit is closed When the R W circuit is interrupted indicating the heat call has been satisfied the green LED returns to a consistent slow flash LIMIT ROLLOUT OPENS In all modes of operation 24VAC is supplied to the ignition control 24VAC hot terminal and is passed through the ignition control to pin 6 of the 6 pin ignition wire harness 1 24 signal is sent from pin 6 of the 6 pin ignition wire harness to one side of the Normally Closed manual reset rollout switch across the rollout switch to one side of the Normally Closed auto reset limit switch and across the limit switch to pin 1 of the 6 pin ignition wire harness
118. e T2 terminal becomes energized L1 power is sent to the compressor COMMON terminal and the condenser fan This energizes the compressor and condenser fan motors When pin 1 Y terminal of the 5 pin thermostat harness receives a 24 volt signal from the thermo stat a 5 second circulating air blower delay starts After the 5 second delay the ignition control energizes the cooling speed relay This sends L1 power to the ACB COOL terminal of the ignition control L1 power is sent to the circulating air blower terminal block energizing the circulating air blower motor When the R Y and G circuit is interrupted by the thermostat the contactor is immediately de energized This interrupts L1 power to the com pressor and condenser fan motors stopping both The ignition control starts a 90 second circulat ing air blower off delay after which the ACB COOL terminal de energizes This interrupts L1 power to the circulating air blower motor causing it to stop Low Voltage 1 The thermostat energizes the R Y and G circuit sending a 24 volt signal to the contactor coil and to pin 1 of the 5 pin thermostat harness connected to the ignition control The contactor closes immediately upon receiving the 24 volt signal causing the compressor and condenser fan motors to start The 24 volt signal is also sent to pin 1 of the 5 pin thermostat harness initiating a 5 second circulat ing air blower on delay After the 5 second del
119. e avoided if for no other reason than to keep the air filter accessible for easy and timely cleaning by the occupants or maintenance personnel 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual INSTALLATION 6 5 Installing With a Wall Sleeve CAUTION The sleeve is not intended as the sole support for the unit Additional support must be provided near the return opening on the unit for adequate support The use of vibration isolation material between the unit and the support is recommended Refer to the installation instructions packed with the wall sleeve and Figure 6 1 for guidance in assembly and mounting using a wall sleeve See also the Accessories section beginning on page 7 3 for further details on wall sleeve installations Refer to page 6 6 for information concerning additional support under the HW HWC unit Make sure the gaskets attached to the sleeve are not damaged Seal the space between the wall sleeve and the building opening with non hardening caulking compound The seal must be weathertight to prevent entrance of moisture and water into the building Assure that the unit is completely seated against the gaskets on the wall sleeve Wall Sleeve 6 X 22 Minimum Opening to Align with Return Air Opening In Unit Vibration Isolating Material FIGURE 6 1 HW HWC Installation INSTALLATION Magic Pak HW HWC Installing Without a Wall Sleeve Refer to
120. e ignition control The gas valve closes immediately as the relay in the ignition control opens and interrupts the signal to terminal V2 of the ignition control 2 Terminal W on the blower control board stays energized and the circulating air blower contin ues to run If the negative pressure is restored the pressure switch closes and sends a 24 volt signal to the P SW terminal on the ignition control The ignition control makes a trial for ignition again and operation returns to normal Note If the P SW and TH terminals energize at the same time the ignition control will not respond A pressure switch being stuck closed is an example of what would cause this to happen ROLLOUT SWITCH ACTIVATED 1 Ifthe conditions in the burner compartment cause the rollout switch to trip the contacts on the switch open interrupting the 24 volt signal going to termi nal P SW on the ignition control This causes the ignition control to de energize terminal V1 interrupting the 24 volt signal to the gas valve and immediately closing it SEQUENCE OF OPERATIONS 2 19 The reason the rollout switch was tripped must be determined before corrective action is taken The signal to terminal P SW can only be restored if the rollout switch is reset which can only be done manually The W terminal on the blower control board remains energized and the circulating air blower continues to operate Once the rollout switch is reset the operation of the unit r
121. e jumper and record the readings Using the calculator divide the amp meter reading by ten the number of loops in one of the test leads This is the correct amp reading which is needed to finish the calculations This information and the voltage at the outlet is all that is needed to calculate the capacitance of the capacitor 2650 x Amps Capacitance Volts In the following calculation a constant multiplier 2650 is used for 60 Hz electrical systems 2650 x 1 Amp 115 Volts 23 MFD Example This calculation provides the actual capacitance of the capacitor Com pare this reading to the listed rating on the capacitor It should be within 10 of the actual capacitor rating If it does not fall within this range the capacitor is defective and should be replaced The capacitor should always be checked before replacing an electric motor Eliminate the capacitor as a possible cause of the problems before the decision is made to replace the motor A good practice is also to replace the capacitor whenever a motor is replaced as the capacitor does have a service life cycle The capacitor is a very important part of the motor electrical system Always check the capacitor along with the motor when a fault is noted For 50 Hz electrical systems use 3180 as the constant multiplier 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual TROUBLESHOOTING 9 9 Performance Performance Checkout HW HWC
122. eat Note The limit switch resets automatically when temperatures are acceptable but the rollout switch must be manually reset by pushing in on the small button on top of the switch The reason why the switches opened must be determined before any corrective action is taken PRESSURE SWITCH OPENS BLOCKED FLUE When the R W circuit is energized a 24 volt signal is sent to the ignition control This starts the call for heat 1 The 24 volt signal from the R W circuit energizes the combustion blower relay sending L1 power to the CMB BLWR terminal on the ignition control This starts the ignition control 2 Atthe same time the combustion blower relay energizes the 24 volt signal is sent to pin 2 of the 6 pin ignition wire harness and from pin 2 to one side of the Normally Open pressure switch 3 combustion blower causes the pressure switch to close a 24 volt signal is sent across the Switch to pin 5 of the 6 pin ignition wire harness The 24 volt signal energizes at pin 5 and the ignition sequence continues 4 Ifthe combustion blower fails to close the pres sure switch the 24 volt signal is not sent to pin 5 of the 6 pin ignition wire harness and the ignition control does not initiate a 30 second pre purge delay 5 No signal is sent to the spark ignition cable terminal on the ignition control or to the gas valve through pin 4 of the 6 pin ignition wire harness 6 The combustion blower continues to run for 60
123. edi ately and the induced draft blower shuts down several seconds later 9 The blower control board starts a countdown to blower off Approximately 90 seconds later the blower shuts down 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual LIMIT OPENS If the limit switch opens for any reason during a call for heat the following happens 1 Ifthe limit switch senses that the temperature in the unit is too high the contacts between terminals C and NC on the limit switch open and the con tacts between C and NO close This interrupts the 24 volt signal to the pressure switch and also de energizes terminal P SW on the ignition control The gas valve closes immediately as the 24 volt signal to terminal P SW is no longer present The induced draft blower and the circulating air blower continue to run Power to blower control board terminal W is maintained The blowers continue to run until the limit switch closes or the heat call at the thermostat is satisfied 2 When the limit switch senses that temperatures in the unit are normal the contacts between terminals C and NO open the contacts between terminals C and NC close and operation of the unit returns to normal PRESSURE SWITCH OPENS BLOCKED FLUE 1 If blockage of the flue occurs the negative pressure in the induced draft blower is reduced the set point of the pressure switch the contacts open This interrupts the 24 volt signal to terminal P SW on th
124. er spacer the compressor mounting legs 6 Insert the bottom rubber spacer into the bottom of the spring and slide the spring between the upper spacer and chassis base 7 Insert the metal sleeve through the top of the upper spacer spring and lower spacer 8 Re install the bolts removed in step 1 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 1 13 Use of spray lubricant or liquid soap will aid in the installation of rubber parts Compressor belly is rounded and can be rocked on the belly support It is easiest to install one spring grommet at a time Start with the most difficult to access compressor mounting leg and work in a crisscross pattern from back to front Compressor mounting bolts should be tightened down so that the metal sleeve is secured fast to the chassis base and bolt head Before securing the final bolt make sure that the wooden block or material supporting the belly of the compressor has been removed TABLE 7 4 34961A001 Parts List Quantity Upper Rubber Spacer 4 Lower Rubber Spacer 4 Spring 4 Metal Sleeve 4 ACCESSORIES 1 14 TABLE 7 6 ALPKT389 2 Orifices Propane Orifice Size 26HW HWC 51HW HWC 64HW HWC 38HW HWC Magic Pak HW HWC 89 2 L P Gas Conversion Kit ALPKT389 2 kit contains the following parts to convert the 26 38 51 and 64HW HWC series gas furnace from natural gas to propane gas For altitudes from 2000
125. et rate for that particular fault condition See Diagnostic Flash Code found in Table 4 1 on page 4 8 or Diagnostic Indicator code printed on unit label Integrated Control Specifications Manufacturer United Technologies Model 1097 400 1 Armstrong P N 44990 001 Operating Temperature 40 F to 175 F Timing Tolerance 10 Input Voltage 18 30VAC 50 60 Hz Combustion Blower 1 8 HP 120 240 Circulating Blower 1 2 HP 120VAC 1 HP 240 Gas Valve 24VAC 60 Hz 1 0A FIGURE 5 8 United Technologies Model 1097 Integrated Control 5 12 UNIT COMPONENTS Magic Pak HW HWC Diagnostics United Technologies 1097 400 1 The following blower ignition control board LED codes indicate normal or abnormal operations TABLE 5 2 UTech Model 1097 Diagnostic Flash Code SLOW FLASH Normal Operation No Call for Heat FAST FLASH Normal Operation Call for Heat 2 FLASH System Lockout Failed to Detect or Sustain Flame 3 FLASH Pressure Switch Open or Closed 4 FLASH High Limit or Rollout Switch Open 5 FLASH Flame Sensed and Gas Valve Not Energized STEADY Internal Failure Micro controller Failure Self check United Technologies Model 1097 400 1 cont Quick Connect Terminal Descriptions 24VAC HOT from Transformer GROUND 24VAC Return CMB BLWR Combustion Blower Line Voltage L1 Line Voltage ACB COOL Air Circulating Blower Cool Speed Line Voltage 10 ACB HEA
126. eturns to normal CALL FOR COOLING Line Voltage On a call for cooling the thermostat closes the circuit between Y G and R 1 With Y energized the contactor closes This sends line voltage to compressor terminal C causing the compressor to start The outdoor fan also starts drawing air through the outdoor coil Terminal G on the blower control board also energizes at the same time as Y This starts the timer on the blower control board Approximately 15 seconds later or immediately see note on page 2 20 the terminal marked COOL energizes This sends line voltage to the circulating air blower starting the blower 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 fan With the low voltage signal to terminal G on the blower control board interrupted the board starts a countdown to blower off After approximately 90 seconds see note on page 2 20 the cooling speed relay opens and the circulating air blower shuts down Low Voltage 1 2 On a call for cooling the thermostat closes the circuit between R and terminals G and Y The 24 volt signal energizes terminal G on the blower control board starting the fan timer Approximately 15 seconds later or immediately see note on page 2 20 the relay closes Thi
127. gizes the blower control board starts a countdown to fan on Approximately 60 seconds after the thermostat initiates a call for heat the circulating air blower starts 7 Theunit continues to operate as long as there is a call for heat from the thermostat 8 When the heat call is satisfied the circuit between R and W is interrupted With the white wire de energized the ignition control interrupts the 24 volt signal to the gas valve This closes the gas valve immediately and opens the internal relay that de energizes terminal IND The induced draft blower shut downs several seconds later 9 TheW terminal on the blower control board de energizes This causes the blower control board to start a countdown to blower off Approximately 90 seconds later the circulating air blower shuts down This completes the heating cycle Detailed Sequence follows 2 24 SPECIFICATIONS Detailed Sequence HW Magic Pak HW HWC w Fenwal Triton 24610 Ignition Control Refer to Figure 2 4 POWER Line Voltage When the service disconnect switch is closed power is sent to the unit unit in standby no signal from thermo stat Power 208 230 volts A C is supplied to the two black wires located in the junction block on top of the unit Line voltage will be present at the following locations First black wire 1 L 10nthe ignition control 2 Terminal on the transformer marked 208V or 240V whichever is being used 3 Co
128. gn of continuity between any of the terminals and ground was observed recheck the terminal to confirm that the readings were correct Any indication of continuity between any of the terminals and ground would point to an internal winding being shorted to the compressor case This suggests that the compressor has an internal failure and it would need to be replaced 5 If no continuity is noted between any of the terminals and ground the compressor must be checked out further Checking Windings The following test is used to check the condition of the internal start and run windings 1 Write the following down C to S C to and 5 to 2 Using the volt ohmmeter measure the resistance between terminals C and S Record the findings on the note pad in the correct place Measure and record the resistance between the remaining terminals in the same manner The following examples show how this information can be used to deter mine if there is an internal failure Example 1 C to S Common through Start Windings 3 5 ohms C to R Common through Run Windings 1 5 ohms S to R Start Windings through Common and Run Windings 5 0 ohms A resistance measurement between C to S shows that there is continuity between the common and start terminals The reading between terminals C and R proves that there is continuity between the terminals through the windings The resistance recorded between S and R is actually a reading of the en
129. he front heat section panel Remove the vestibule panel Remove the heat exchanger plo Pe o mw Induced Draft Combustion Blower Removal Refer to the following directions and Figure 3 1 To remove the induced draft blower Disconnect all power to the unit Shut off and disconnect the gas supply Remove the plate mounting screws Slide the induced draft blower out Boom 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual UNIT TEAR DOWN 3 3 PLATE MOUNTING SCREWS 0 i HEAT a 2 INDUCED DRAFT BLOWER COMBUSTION BLOWER FRONT HEAT SECTION PANEL i 4 HEATING SECTION lt N N x CONTROL SECTION lt 224 RN lt o c m 2 gt 2 m r BURNER TRAY COOLING SECTION lt BURNER ACCESS PANEL FILTER ACCESS DOOR Figure 3 1 3 4 UNIT TEAR DOWN Magic Pak HW HWC Cooling Section Chassis Removal The cooling chassis may be removed from behind the filter access door Refer to the following directions and Figures 3 1 to 3 4 To remove the cooling chassis oosomc oN Disconnect all power to the unit Shut off and disconnect the gas supply Remove the filter access door Figure 3 1 Disconnect L1 and L2 from the comp
130. he unit The use of a union located upstream of the controls is recommended between the controls and the manual shutoff valve This will facilitate removal of controls and manifold See Figure 6 5 for recommended placement of the union Provide a drip leg in the supply piping located exterior to the unit Piping must be tight and non hardening Pipe compound resistant to propane must be used Manual Shutoff Valve w 1 8 NPT plugged tapping accessible for test gauge connection field supplied Ground Joint Union field supplied Drip Leg field supplied Access Panels to Controls and Burners Access Panel To Filter FIGURE 6 5 Gas Supply Piping Electrical Connections All wiring must be done in accordance with the National Electrical Code ANSI NFPA No 70 latest edition Canadian Electrical Code Part 1 CSA C22 1 latest edition or local codes where they prevail Any alteration of internal wiring will void certification and warranty The rating plate indicates the operating voltage phase ampacity maxi mum fuse size and minimum voltage Units must never be installed where voltage exceeds 10 over the voltage indicated on the rating plate Units are factory wired for a 230 volt power supply If power supply is 208 volts it will be necessary to change a wire connec tion on unit transformer from 240 volt terminal to 208 volt termi nal as shown on the wiring diagram Failure of the compressor as a result of operation
131. i EX DA REE uoo mz 4 4 8 61 4 sesonooe assvnearexcHancer Jaji assvnearexchancer ata al 1 1 14 pe 89990012 al tet 1 40 wrsuaron 445 6 456 5 sis 54 8 14 64HWC242 8 38HWC242 8 51HWC242 8 lt x o a TES SERVICE LEVEL ELI 26HWC122 8 SERES 38HWC122 8 EBENE SCC EL CEE O 5 111 1 1 1 1 1 1 1 1 1 1 2 1 391198001 SWITCH E 1 4 375208004 SWITCHROLOUTRED 375208005 SWITOHROLLOUTGREEN PEELE LL Sea p e em 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual HWC 8 cont TO SELECT PART Last letter of the Model is the Service Level 64HWC302 8A First find Model 64HWC302 8 Then match Service Level for desired part REF PART 4 DESCRIPTION 57 41862 002 SWITCH PRESS GREEN 63 41144 001 BLOWER INDUCED DRAFT 39045B001 MOTOR 1 6 HP 1 PHASE MOTOR 1 3 HP 1 PHASE BAND MOTOR MOUNTING
132. i L A A T T e fewo iL eh IL LL 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS REVISED 1 20 98 TO SELECT PART Last letter of the Model is the Service Level 64HW 1A First find Model 64HW 1 Then match Service Level for desired part meme L b mee _ wwe weaemoe mee omesmoce L L 5 mosso b mee wwonme m mese ferec LESE m mm L L forces e s forces e soon forces L mee m mmo urea LL LL m pmmow LL 1 m mee L meme erm sts ff mene oascerawesoe s meme m meme L LL L m meme mone L LI m woes e LL LI REC STOCKING PART SERVICE LEVEL PARTS LISTS MAGIC PAK HW HWC HW 1 cont TO SELECT PART Last letter of the Model st is the Service Level 64HW 1A 8 34 A First find Model 64HW 1 Then match Service Level for desired part REC STOCKING PART SERVICE LEVEL
133. ic Cool Tecumseh Rotary Capillary Tube Filter Drier 7 Al HWC183 1 Gas Heat Electric Cool 7 Tecumeeh Capillary Tube Filter Drier Reciprocating All HWC 243 1 Gas Heat Electric Cool Copeland Scroll Capillary Tube Filter Drier All HWC 303 1 Gas HeatElectric Cool Copeland Scroll Capillary Tube Filter Drier All 182 11 Gas Heat Electric Cool Tecumseh Capillary Tube Filter Drier 9 7 6 Reciprocating All HWC 242 11 9 Gas Heat Electric Cool Copeland Scroll Capillary Tube Filter Drier Tecumseh Rotary Capillary Tube Filter Drier Copeland Scroll Capillary Tube Filter Drier All HWC 242 10 8 5 4 3 1 Gas Heat Electric Cool All HWC 302 9 Gas Heat Electric Cool All HWC 182 8 5 Gas Heat Electric Cool of ae All 2 gt Gas Heat Electric Cool All 182 1 Gas Heat Electric Cool For more information on the compressors used in HWC units see the Unit Components section beginning on page 5 28 Copeland Scroll Capillary Tube Filter Drier Tecumseh Rotary Capillary Tube Filter Drier Copeland Scroll Capillary Tube Filter Drier Copeland Scroll Capillary Tube Filter Drier Mem SPECIFICATIONS Magic Pak HW HWC 1 4 HW HWC Physical and Electrical Table 1 3 Physical and Electrical Specifications HWC Units Max Outside Normal Min I sai Fan Voltage Circuit Rated Range Ampacity Brit Load amps 208 230 60 1 8 3 208 230 60 1 8 3 208 230 60 1 13 6
134. ine voltage to the circu lating air blower and after 90 seconds the blower shuts down Low Voltage 1 call for heat closes the circuit the thermostat between R and W sending a 24 volt signal to the white wire on the unit 2 The white wire goes to the C terminal on the limit switch ignition control terminal TS and terminal W on the blower control board 3 When W energizes the timer starts a countdown to circulating air blower The blower starts in approximately 60 seconds 4 The 24 volt signal sent to the TS terminal closes a relay in the ignition control This starts the induced draft blower by energizing terminal IND on the ignition control 5 Asthe induced draft blower comes up to speed and creates enough negative pressure the pres sure switch closes The 24 volt signal is sent from the pressure switch to one side of the Normally Closed manual reset rollout switch If the rollout switch is closed the 24 volt signal is passed through the switch to the P SW terminal on the ignition control This initiates a 30 second pre purge period 6 After the 30 second pre purge period a trial for ignition starts by energizing the spark terminal and the V1 terminal simultaneously The 24 volt signal from V1 energizes the gas valve solenoid causing it to open These actions cause the burners to light 7 After the burners are lit a flame sense is picked up by the flame sense rod located at the opposite end of the
135. ing a 24 volt signal to the W wire at the unit The 24 volt signal is sent to the ignition control closing the combustion blower relay and causing the combustion blower to run The 24 volt signal is also sent to the blower control board starting a 30 second circulation air blower on delay As the combustion blower reaches full speed it closes the pressure switch A 24 volt signal is sent from the pressure switch to the ignition control Following a 30 second pre purge delay this signal energizes the spark termi nal The gas valve solenoid energizes at the same time as the spark terminal causing the gas valve to open and the burners to light The spark ignitor continues to spark for approxi mately six seconds or until flame is sensed by the flame sensor electrode The unit will operate normally until the R W circuit is de energized by the thermostat interrupting the 24 volt signal to the unit When the signal is interrupted the gas valve de energizes and closes immediately The combustion blower relay de energizes several seconds later causing the combustion blower to stop The blower control board starts a 90 second circulating air blower off delay Following the 90 second delay the circulating air blower stops FLAME SENSE 1 After the spark electrode has lit the main burners the ignition control waits approximately six seconds for a flame sense signal If a flame sense signal is not received after app
136. ion the ignition control de energizes the spark ignition cable terminal and pin 4 of the 6 pin ignition wire harness This causes the gas valve to close and the elec trode spark to stop Once the 24 volt signal is sent to pin 4 of the 6 pin ignition wire harness a 30 second circulating air blower on delay starts After the delay is timed out the circulating air blower starts After the spark ignition cable terminal de ener gizes the ignition control initiates a 30 second combustion blower inter purge delay After 30 second inter purge the ignition control energizes the spark ignition cable terminal and pin 4 of the 6 pin ignition wire harness If the flame sense signal is received at the flame terminal of the ignition control the unit continues heat call If the flame sense signal is not received the system goes through three trials following the above sequence After three trials the system goes into lockout and only the limit switch circuit and pressure switch circuit remain energized during the 60 minute lockout period If the flame sense is lost during the heat cycle the gas valve de energizes immediately and the System goes into the trial sequence FAN ON 1 When the thermostat is switched to the ON position the R G circuit sends a 24 volt signal to pin 4 of the 5 pin thermostat harness The 24 volt signal energizes the cooling speed relay sending L1 power to the ACB COOL terminal of the ignition co
137. ircuit sending 24 volt signal to the low voltage white wire in the unit 2 The 24 volt signal is received at pin 3 of the 5 pin thermostat harness on the ignition control 3 The 24 volt signal causes the combustion blower relay to close causing the combustion blower to run At this time 24 volt signal is also sent out through pin 2 of the 6 pin ignition wire harness 4 The 24 volt signal from pin 2 of the 6 pin ignition wire harness energizes one side of the Normally Open pressure switch As the induced draft blower reaches full speed the pressure switch closes and a 24 volt signal is sent to pin 5 of the 6 pin ignition wire harness 5 When the 24 volt signal is received at pin 5 of the 6 pin ignition wire harness the ignition control starts a 30 second pre purge delay 6 After the 30 second pre purge the ignition control initiates a trial for ignition The spark ignition cable terminal and pin 4 of the 6 pin ignition wire harness energize simultaneously 7 When the 24 volt signal is present at pin 4 of the 6 pin ignition wire harness the ignition control starts a 30 second circulating air blower on delay 8 The 24 volt signal from pin 4 of the 6 pin ignition wire harness is received at the gas valve causing itto open and the burners to ignite 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual 9 After 30 second delay the circulating air blower relay energizes the heat terminal and th
138. itioning Inc reserves the right to change such specifications at any time without incurring obligation Every effort has been made to ensure the accuracy of the informa tion in this manual For the most current information please contact the Armstrong Customer Service Department This document is confidential All information within is the sole property of Armstrong Air Condi tioning Inc and is loaned for mutual assistance It may not be used for any purpose other than originally intended without prior written consent of Armstrong It is not intended for use by homeowners or as a guide for do it yourself projects It provides specialized information for use by qualified service personnel who have the proper equipment training and experience neces sary to safely install repair adjust and maintain the Magic Pak units and components described within SRM HW HWC 8 99 Service Reference Manual Go to Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 TABLE OF CONTENTS TABLE OF CONTENTS 1 Specifications Sequence of Operations Unit Tear Down Component Location Illustrations Unit Components o a N Installation 7 Accessories Parts Lists 9 Troubleshooting Performance Charge Weights If you need information on Performance electrical data and cabinet dimensions Sequence of operation descriptions with accompanying schematics Complete
139. its condition can be made The best method is to use a meter that is capable of reading capacitance This gives a very accurate indication of the condition of the capacitor If a meter that is able to do this is not available then another way to deter mine the condition of the capacitor must be found In order to do this several things will be needed a volt ohm meter an amp meter and a calculator A set of test leads will also need to prepared to do this test Make the test leads with a loop 10 loops in one of the leads The ten loops in the lead will cause the amp meter reading to be multiplied by ten This will make it much easier to read very low amp meter readings and will be helpful when doing the following test Connect the alligator clips of the test leads to the terminals on the capaci tor Hook the amp meter through the 10 loops of wire on the test lead see Figure 9 1 on page 9 8 TROUBLESHOOTING Magic Pak HW HWC Ammeter 10 Loops DOSE Capacitor Voltage Voltmeter V 30 B Tested Source FIGURE 9 1 Determining Capacitance MFD Rating with a Test Cord Before starting the test take a reading of the line voltage at the outlet that will 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 the amp meter CAUTION there is only approximately ten seconds to do this or the capacitor could be damaged Unplug th
140. k ignition cable terminal and pin 4 of the 6 pin ignition wire harness This causes the gas valve to close and the elec trode spark to stop Once the 24 volt signal is sent to pin 4 of the 6 pin ignition wire harness a 30 second circulating air blower on delay starts After the delay is timed out the circulating air blower starts After the spark ignition cable terminal de ener gizes the ignition control initiates a 30 second combustion blower inter purge delay After 30 second inter purge the ignition control energizes the spark ignition cable terminal and pin 4 of the 6 pin ignition wire harness If the flame sense signal is received at the flame terminal of the ignition control the unit continues heat call If the flame sense signal is not received the system goes through three trials following the above sequence After three trials the system goes into lockout and only the high limit switch circuit and pressure switch circuit remain energized during the 60 minute lockout period If the flame sense is lost during the heat cycle the gas valve de energizes immediately and the System goes into the trial sequence Magic Pak HW HWC CALL FOR COOLING Line Voltage 1 L2 power passes through the fixed closed L2 T2 terminals on the contactor to the RUN terminal of the compressor and the COMMON terminal of the capacitor L1 power is sent to the L1 terminal of the contactor When the Y signal energizes the contactor th
141. l is the Service Level 64HWC182 2A First find Model 64HWC182 2 Then match Service Level for desired part EIE woe wareno 5 wem a mem efa ome commorans fa e oem sson m wwe a s forsone comer e oso mee couwooor omoes ores m wmm meos b omo mew Ta mene wem b rrr enserrer b mem oewermuesoe a 2 mem aurneneno anor a 4 moe T 4 mew 4 mrono a ome suono rese wem uomo REC STOCKING PART SERVICE LEVEL s MES Ed n 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS HWC 2 cont po TO SELECT PART Last letter of the Model is the Service Level 64HWC182 2A First find Model 64HWC182 2 Then match Service Level for desired part wem s sss so wwe unn s verses oes smweworonwonms
142. l automatically de energizes the combustion blower relay This interrupts L1 power to the CMB BLWR terminal on the ignition control 7 The combustion blower remains de energized for approximately six minutes During this 6 minute lockout the green LED flashes three times indicat ing pressure switch fault open or closed SPECIFICATIONS 2 8 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 The system will repeat this sequence until the pressure switch closes and the 24 volt signal is restored at pin 5 of the 6 pin ignition wire harness FAILED FLAME SENSE TRIAL FOR IGNITION When the pressure switch closes and a 24 volt signal is sent to pin 5 of the 6 pin ignition wire harness the spark ignition cable terminal and pin 4 of the 6 pin ignition wire harness energize 1 10 As spark voltage is supplied to the ignitor elec trodes the gas valve opens and this causes the burners to ignite The ignition control continues to energize spark voltage until a flame sense signal is supplied to the flame terminal on the ignition control If a flame sense signal is not received at the flame terminal on the ignition control the spark igni tion cable terminal remains energized for 10 seconds After the 10 second trial for ignition the ignition control de energizes the spar
143. l housing A label on the housing shows the manufacturer s model number Find the Switch Open value for the pressure switch in Table 5 4 on page 22 Assorted lengths of plastic tubing and tees to make the connections to the manometer including the following 1 8 1 0 high temperature silicone tubing 1 4 1 0 vinyl tubing 1 8 tee and 1 4 tee Note For each procedure the schematic shows the original factory tubing with solid black lines The tees to be installed for pressure sampling are shown within the dashed circles Terminology Terms related to pressure switch operation and incline manometer testing are shown below in Figure 5 19 FIGURE 5 19 Incline Manometer UNIT COMPONENTS Magic Pak HW HWC A Word About the Switch Closed Value Switch Closed is the pressure at which the contacts close as the induced draft blower comes up to speed It is calculated by adding 0 1 W C to the sum of the switch s Open value and its upper tolerance For example for a Armstrong P N 44819 005 switch 0 1 60 06 0 76 On a system operating correctly it is likely that the manometer reading will go to a value that is more than enough to close the switch A Word About the Switch Open Value Switch Open is the pressure at which the contacts open as the negative pressure decreases pressure fall Procedure for Checking Pressure Switch 1 Position the manometer so it can be watched
144. lowing directions and Figure 3 5 To remove the evaporator blower assembly Remove the four mounting screws from the blower assembly Remove the four control panel screws Slide control panel toward yourself about 1 Disconnect the electrical wiring to the motor Pull blower assembly up and out from chassis MOUNTING SCREWS EVAPORATOR BLOWER LA oN ASSEMBLY Y E CONTROL PANEL SCREWS Figure 3 5 BETWEEN BASE RAIL AND CHASSIS BASE 66 8 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual COMPONENT LOCATION ILLUSTRATIONS Section 4 Component Location Illustrations HW HWC 3 Unit 4 2 HW HWC 2 Unit 4 3 HW HWC 4 4 HW HWC Exterior Louver Grill Panel 4 5 HWC Chassis Assembly 4 6 HWC Chassis Assembly Top View 4 7 HWC Chassis Assembly Circulating Air Blower Partially Removed 4 8 4 1 COMPONENT LOCATION ILLUSTRATIONS Magic Pak HW HWC 4 2 HW HWC123 183 243 303 IGNITION BLOWER CONTROL BOARD 24 UNITED TECHNOLOGIES 1097 83 400 1097 400 1 DSI ARMSTRONG P N 44990 001 MAIN LIMIT SWITCH 52 ARMSTRONG P N 40154B007 GAS VALVE HONEYWELL VR8105M8202 HEATING SECTION lt ARMSTRONG P N 44987 001 CONTROLSECTION PRESSURE SWITCH 57 d 4 COOL
145. ly across the bottom of the unit through adjustable legs to the floor A supplementary support can be made for this purpose It should consist of two steel channels 28 long one placed under the unit and one on the floor They are separated by 3 4 pipe and all thread rod with nuts and washers to provide the adjustment pressure Vibration isolation blocks or pads are also required to minimize transmission of vibration into the floor Even though the wall may be adequate to support the unit experience has shown the desirability of supplementary support to reduce the possibility of vibration being transmitted into the wall and to other parts of the structure Two 1 diameter holes are located near the front of the Magic Pak HW HWC units on either side of the return air opening These holes are intended to allow a condensate drain tube to exit the return air duct cavity whenever a closed return duct and flexible collar are used These should not be used to support the unit The sheet metal in the cabinet in this area is not heavy enough to act as a support without distorting and interfering with proper retention of the filter access cover 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual INSTALLATION 6 7 Condensate Drain HWC Models Install the plastic drain tube furnished over the 5 8 O D fitting welded to the center of the condensate pan Connect the other end of the drain tube to the open trap see Figure 6
146. m meme m mese m mesmo ea p meme m common b mon umenmosor m meom m memo S m meme umano E meme ersero a s pm E memes cocum s sua 57 390898001 SWITCH N O PRESSURE 6 390058001 BLOWER INDUCED DRAFT A STOCKING PART SERVICE LEVEL peewee peel leet tee ele seeds 444454 5 4 III 2 leer Jel eal jee la eer Te IE Ie 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS HWC 4 cont poe TO SELECT PART Last letter of the Model is the Service Level 38HWC182 4A First find Model 38HWC182 4 Then match Service Level for desired part REF PART PART DESCRIPTION moe wow wee J s wem sens amaonauonme mopeme wma p wow LE sf fs pop pe amem FILTER 16 5 X 25 X 50 EXEXEHESESEZE omms m mew
147. mmon terminal on the blower capacitor Second black wire 1 Supplies power to the one side of the induced draft blower 2 Common terminal on the transformer 3 L terminal on the blower control board Low Voltage 24 VAC With the unit at rest no call from the thermostat 24 volts A C will be found at the following points 1 Red wire exiting the top of the unit 2 Terminal marked NO on the limit switch 2 Terminal marked 24VAC on the ignition control 3 Terminal R on the blower control board CALL FOR HEAT Line Voltage The thermostat closes the circuit between R and W The following is the sequence of operation for the line voltage side of the unit 1 Terminal TH on the ignition control energizes causing a relay in the ignition control to close This sends line voltage to terminal IND on the ignition control causing the induced draft blower to start 2 When Wis energized a 24 volt signal is also sent to the W terminal on the blower control board Approximately 60 seconds after W terminal ener gizes the timer on the blower control board closes the heat speed relay on the board This sends line voltage to the H terminal on the blower control board which starts the circulating air blower 3 The induced draft blower and the circulating air blower continue to operate as long as W is ener gized 4 When W de energizes a relay in the ignition control opens Terminal IND de energizes and the induced draft blower sh
148. multaneously Cool Speed L1 Power Out Heat Speed L1 Power acl L1 Line Voltage Em 42 Dumb Terminal 4 Dumb Terminal fe Park Park m Voi y 24 Heat F M Fan On Cooling Fan Auto 24 VAC Common 24 VAC Power FIGURE 5 5 Heatcraft Blower Control Board IBC H4C401 UNIT COMPONENTS Magic Pak HW HWC Ignition Controls 24 Fenwal Triton 2461D Ignition Control Specifications Manufacturer Fenwal Model Triton 24610 Armstrong P N 43110 002 Pre purge 30 seconds Ignition 15 seconds Input 24VAC 50 60 Hz 300 mA Valve 24VAC 2 0 A max Inducer 120VAC 3 0 A or 240VAC 1 5 A 1 4 HP Ambient 40 F to 160 F ANSI Z21 20 1993 CAN CSA C22 2 No 199 M89 FIGURE 5 6 Fenwal Triton 2461D Ignition Control 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 9 Diagnostics Fenwal Triton 24610 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 code the LED may blink off momentarily 4 Diagnostic codes may be reset by removing the power from the control for three seconds then reapplying power Cycle thermostat OFF for three seconds then back ON The following ignition control board LED codes indicate normal or abnormal operations
149. n control board LED codes will indicate normal or abnormal operations SLOW FLASH Normal Operation No Call for Heat FASTFLASH Normal Operation Call for Heat 2 FLASH System Lockout Failed to Detect or Sustain Flame 3 FLASH Pressure Switch Open or Closed 4 FLASH High Limit or Rollout Switch Open 5 FLASH Flame Sensed and Gas Valve Not Energized STEADY Internal Failure Micro controller Failure Self check FIGURE 2 2 Connection Diagram 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual SEQUENCE OF OPERATIONS 2 11 Simplified Sequence HW w UTEC 1097 Board Refer to Figure 2 2 CALL FOR HEAT 1 The indoor thermostat energizes the R W circuit sending a 24 volt signal to the ignition control 2 The 24 volt signal causes the induced draft blower to start which closes the pressure switch 3 Once the pressure switch closes a 30 second induced draft blower pre purge starts 4 After the 30 second induced draft blower pre purge the gas valve opens and the burners ignite This starts a 30 second circulating air blower delay 5 Theunit continues to operate in the heat mode until the indoor thermostat setting is reached At that time the R W circuit is interrupted 6 The 24 volt signal to the ignition control is inter rupted causing the gas valve to close and the burners to shut down 7 5 post purge starts and following that the induced draft blower stops 8 A
150. n the unit is low enough the circuit between C and NO opens and the circuit between C and NC closes 4 With the limit switch closed the unit again makes a trial for ignition and returns to normal operation PRESSURE SWITCH OPENS BLOCKED FLUE 1 If blockage of the flue occurs the negative pressure in the induced draft blower is reduced Atthe set point of the pressure switch the contacts open This interrupts the 24 volt signal coming from terminal NC on the limit switch Terminal P SW the ignition control de energizes as does terminal V1 With loss of the 24 volt signal to the gas valve the valve closes immediately 2 Terminals TH on the ignition control and W on the blower control board remain energized The induced draft blower and the circulating air blower continue to run 3 When the pressure switch senses that there is enough negative pressure within the flue it will again close the circuit between the limit switch and terminal P SW on the ignition control 4 The unit makes a trial for ignition and returns to normal operation SEQUENCE OF OPERATIONS 2 25 Note If the P SW and TH terminals energize at the same time the ignition control will not respond A pressure switch being stuck closed is an example of what would cause this to happen ROLLOUT SWITCH ACTIVATED 1 If the conditions in the burner compartment cause the rollout switch to trip the contacts on the switch open This interrupts the
151. nance Instructions Armstrong Publication Description P N All HWC 123 183 243 303 1 45042 099 2 99 amp HW 9 w UTech 1097 Board All HWC 122 182 243 303 39025G097 7 97 11 10 9 8 7 6 5 amp HW w Fenwal 2461D Board All HWC 122 182 243 303 39025G094 4 3 2 1 amp HW w Fenwal 05 29 Board Location Magic Pak HW HWC units are designed and certified for through the wall installations only and must not be installed in any other type of applica tion The interior portions of the unit may be surrounded by a closet with clearances to combustible material held to 0 at sides 2 top and 1 front and plenum Adequate clearance must be provided to install the union and manual shutoff valve as well as providing accessibility to the field wiring junction box Do not install directly on carpeting tile or other combustible material other than wood flooring Magic Pak HW HWC units should be installed in an outside building wall that is clear of obstructions which might impede the free intake and discharge of condenser air A building wall should be no closer to an opposite building wall than 2 for every floor or Magic Pak unit in a vertical array facing the wall For example a one story building with a Magic Pak HW HWC unit should a minimum of 2 from the wall facing the unit and if the facing wall also has a Magic Pak unit the two walls should be at least 4 apart A six story building with six
152. nces installers and building designers must make special considerations for isolating vibration Designing and constructing walls and wall openings in a particular manner to isolate vibration transmission is the recommended procedure for dealing with these instances However if further vibration isolation is necessary the 34961A001 compressor vibration isolator kit should be used For instructions and recommendations on designing and constructing walls and wall openings refer to the Magic Pak Application Manual Installation The Magic Pak cooling chassis must be removed from the cabinet to perform the following installation procedures Refer to the Chassis Removal section beginning on page 3 4 for instructions on proper chassis removal To install the 34961 1 kit 1 Remove the factory installed compressor mounting leg bolts from the base of the compressor 2 Liftthe compressor of the base of the chassis by inserting a large screwdriver or pry bar under the belly of the compressor 3 Support the compressor by sliding 3 4 to 1 1 4 thick wooden block or suitable material underneath the compressor belly The copper refrigerant tubing connected to the compressor will have some free movement However be careful not to kink or damage the tubing Loss of refrigerant or lack of proper unit performance may result 4 Remove the factory installed rubber grommets from the compressor mounting legs 5 Install the top rubb
153. nd 14 W C maximum A regulator is also required on the propane tank When converting a low NO unit designated by an L in the model num ber to propane the NO inserts must be removed After removing the burners remove the screw holding each insert and pull the insert from the combustion chamber see Figure 6 4 The screws must be rein stalled in the vest panel after the inserts are removed bddddd Low NO Insert FIGURE 6 4 NO Insert Removal WARNING Never use a flame to check for gas leaks Explosion causing injury or death may occur WARNING The furnace must be isolated from the gas supply piping system by closing the individual manual shutoff valve during any pressure testing of gas supply piping system at test pressures equal to or less than 1 2 psig or 14 W C If the piping system is to be tested at pressures in excess of 1 2 psig the furnace and its individual shutoff valve must be disconnected from the gas supply piping system The gas valve supplied with this furnace is rated at 1 2 psig Any higher pressure may rupture the pressure regulator diaphragm which will cause over firing of the burners and improper burner operation This action may produce a high concentration of carbon monoxide which can result in asphyxiation 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual INSTALLATION 6 11 A manual shutoff valve must be located outside t
154. nd slide bottom panel into side panel slip strips until tabs on bottom panels are locked in place 3 Attach squaring braces to top and side panels using existing holes Do not remove braces until wall sleeve is secured to building 4 Attach the support angles to top and side panels using the 8 x 3 8 screws provided Two sets of holes are provided in the panels for attaching the support angles The row of holes nearest the front of sleeve will locate the support angles for 1 spacing and the second set of holes will locate the angles for 3 3 4 spacing 5 Wall sleeve must be square in opening before securing sleeve to building This is required to assure Magic Pak unit will slide into the sleeve 6 Caulk all seams where bottom panel joins to side panels including the front corners of bottom panel and the top of side panel slip joints Caulk sealing is best accomplished after the wall sleeve is assembled but before it is placed in the wall opening ACCESSORIES Magic Pak HW HWC 1 4 TABLE 7 2 CA 239 Parts List Assembled Wall Sleeve Dimensions 45 high x 29 wide x 12 5 deep Right Side Panel Support Angle 8 Holes Left Side Panel Top Panel Squaring Braco 2 peg 2 1 4 x 3 4 Screw 5 8 x 3 8 Screw 1 4 Flat Washer Side Support Angle Top Support Angle Squaring Braces Support Angle 2 Sides FIGURE 7 1 CA 239 Wall Sleeve Kit Assembly 66 8 O
155. nel side flanges to the side panels on each side of the HW HWC unit 2 Place the adaptor kit on top of the HW HWC unit The five pilot holes positioned towards the bottom of the kit s rear panel should align with the five oval screw holes in the HW HWC mounting bracket see Figure 7 2 3 Fasten the five 1 4 x 3 4 screws and washers through the unit mounting bracket to the kit pilot holes 4 Align the kit side panel oval screw holes to the screw holes in the side of the HW HWC unit 5b Re fasten the screws that were removed in step 1 Installing the HW HWC Unit After the adaptor kit is fastened to the HW HWC unit the unit is ready to be slid into the wall sleeve The top flange of the adaptor kit is designed to overlap the top of the wall sleeve The five 1 4 x 3 4 mounting screws included with the wall sleeve kit can be fastened through the top flange of the kit into the turned down flange of the wall sleeve The HW HWC unit must be slid all the way forward so that the outer edges of the adaptor kit and HW HWC unit are touching the outer flanges of the wall sleeve HW HWC unit and wall sleeve must be weather sealed according to the wall sleeve kit instructions unit installation instructions or unit applica tion manual For further information on installing HW HWC units refer to the Installa tion section beginning on page 6 1 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 1 9
156. ns in the burner compartment cause the rollout switch to trip the contacts on the switch open interrupting the 24 volt signal going to termi nal P SW on the ignition control This causes the ignition control to de energize terminal V1 interrupting the 24 volt signal to the gas valve and immediately closing it 2 Thereason the rollout switch was tripped must be determined before any corrective action is taken 3 Thesignal to terminal P SW can only be restored if the rollout switch is reset which can only be done manually The W terminal on the blower control board remains energized and the circulating air blower continues to operate Once the rollout switch is reset the operation of the unit returns to normal CALL FOR COOLING Line Voltage On a call for cooling the thermostat closes the circuit between Y G and R 1 With Y energized the contactor closes This sends line voltage to compressor terminal C causing the compressor to start The outdoor fan also starts drawing air through the outdoor coil 2 Terminal G on the blower control board also energizes at same time as Y This starts the timer on the blower control board Approximately 15 seconds later or immediately see note on page 2 30 the terminal marked COOL energizes This sends line voltage to the circulating air blower starting the blower 2 30 SPECIFICATIONS The unit continues cooling as long as both Y and G are energized When the cooling call is
157. ns running in cooling speed until the thermostat is switched to the AUTO position Detailed Sequence follows 2 B SPECIFICATIONS Magic Pak HW HWC 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 Atthe L1 contactor terminal 3 Atthe transformer terminal marked 208 240V L2 Power 1 Through the L2 black lead to the induced draft blower At the L2 contactor terminal A transformer common terminal At the T2 contactor terminal At the R terminal of the compressor At the capacitor common terminals oo RON Low Voltage 24 VAC With the unit at rest no call from the thermostat 24 volts A C will be present 1 From the transformer 24V terminal to pin 4 of the 6 pin chassis low voltage harness 2 From pin 4 of the chassis low voltage harness to the 24VAC hot terminal on the ignition control 3 From 24VAC hot terminal to pin 5 of the 5 pin thermostat harness internal to board 4 From 24VAC hot terminal also to pin 6 of the 6 pin ignition wire harness 5 From pin 6 of the ignition wire harness through the auto reset limit switch and the manual reset rollout switch to pin 1 of the 6 pin ignition wire harness Note While the unit is at rest the green LED shows consistent slow flash This in
158. ntrol L1 power is sent to the circulating air blower terminal block causing the circulating air blower to run in cooling speed Magic Pak HW HWC 4 Thecirculating air blower continues to run in cooling speed until the thermostat is switched to AUTO interrupting the R G circuit Note With the thermostat in the FAN ON position during heat call ignition control will not energize the heat speed relay The circulating air blower continues to run in cooling speed unless the limit switch circuit opens which would cause the heat speed relay and the induced draft blower relay to become energized This would de energize the cooling speed relay until either the limit switch circuit is closed or the thermostat is switched to the AUTO position 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual BLANK PAGE SEQUENCE OF OPERATIONS 2 15 SPECIFICATIONS Magic Pak HW HWC HWC122 182 242 302 w Fenwal Triton 24610 DSI Ignition Control 2 16 CIRCUITS ENERGIZED OPERATING MODE CIRCUIT 208 230 1 60 COPPER CONDUCTORS HEATING POWER SUPPLY ONLY COOLING R G Y FAN R G T LINE VOLTAGE FACTORY m I LINE VOLTAGE FACTORY WHEN USED 1 1 PINK LINE VOLTAGE FIELD THO MANUAL LIMIT LOW VOLTAGE FACTORY WHITE BESET sWwiTC
159. ntrol board starts a countdown to fan on Approximately 15 seconds later or immediately see note at the end of this section the fan starts The blower control board closes a relay on the board sending line voltage to the terminal on the board marked COOL This starts the circulating air blower When the switch at the thermostat is moved to the OFF position the 24 volt signal to the blower control board is interrupted With no signal at the G terminal the blower control board starts a countdown to fan off Approximately 90 seconds later a relay on the blower control board opens see note at the end of this section This interrupts the power to and stops the circulating air blower Magic Pak HW HWC Note Heatcraft blower control boards have a G on delay of 15 seconds and an off delay of 90 seconds Tridelta blower control boards have no on time delay and a 60 130 second off delay 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual BLANK PAGE SEQUENCE OF OPERATIONS 2 31 SPECIFICATIONS Magic Pak HW HWC 2 32 HW Heating Only w Fenwal 05 29 Ignition Control CIRCUITS ENERGIZED OPERATING MODE CIRCUIT 208 230 1 60 N COPPER CONDUCTORS HEATING FEW POWER SUPPLY ONL LINE VOLTAGE FACTORY E 21 LINE VOLTAGE FACTORY WHEN USED 9 5 VALVE w LINE VOLTAGE FIELD gt mc LOW VOLTAGE FACTORY 5 gt E c BONN 9
160. o turn off the circulating air blower starts The blower turns off after 90 seconds see note below Note Heatcraft blower control boards have a G delay of 15 seconds and an off delay of 90 seconds Tridelta blower control boards have no on time delay and 60 130 second off delay Detailed Sequence follows 2 28 SPECIFICATIONS Magic Pak HW HWC Detailed Sequence HWC122 182 242 302 w Fenwal 05 29 Ignition Control Refer to Figure 2 5 POWER Line Voltage When the service disconnect switch is closed power is sent to the unit unit in standby no signal from the thermostat Power 208 230 volts A C is supplied to both black wires located in the junction block on top of the unit Line voltage will be present at the following locations First black wire 1 L 10nthe ignition module 2 L 10n the contactor 3 L 10n the blower control board 4 Terminal on the transformer marked 208V or 240V whichever is being used Second black wire Supplies power to the induced draft blower L 2 on the contactor Common terminal on the transformer T 2 on the contactor Red wire on the R terminal of the compressor Red wire to the common terminals on the capaci tors Qr co Low Voltage 24 VAC With the unit at rest no call from the thermostat 24 volts A C will be found at these points 1 Red wire exiting the top of the unit 2 Terminal marked 24VAC on the ignition control
161. oltage 24 VAC With the unit at rest no call from the thermostat 24 volts A C will be found at these points Red wire exiting the top of the unit Terminal R on the blower control board Terminal NO on the limit switch Terminal on the transformer marked 24V Bom CALL FOR HEAT Line Voltage The thermostat closes the circuit between R and W The following is the sequence of operation for the line voltage side of the unit 1 Terminal TS 24 volt energizes on the ignition control causing a relay in the ignition control to close This sends line voltage to the terminal marked IND causing the induced draft blower to start 2 When Wis energized a 24 volt signal is also sent to the W terminal on the blower control board The 24 volt signal starts the timer on the blower control board After 60 seconds the relay on the blower control board closes This sends line voltage from the terminal marked L 1 to the terminal marked H on the blower control board starting the circulating air blower The induced draft blower and the circulating air blower continue to operate until the heat call is satisfied interrupting the circuit between R and W The ignition control de energizes the induced draft blower relay interrupting L 1 power to the induced draft blower The induced draft blower stops several seconds later The W terminal on the blower control board de energizes starting a 90 second blower off delay This interrupts the l
162. olution x 3600 x Heating INPUT Seconds Per Revolution Value The heating value of your gas can be obtained from your local utility With proper manifold pressure achieved cycle main burners on and off Ignition and extinction should be smooth and quiet Burning back at the orifice or flame popping back to the orifice can be corrected by adjusting the air shutter to soften the flame Regulator Propane The furnace has a regulator in the gas valve A regulator is also required on the propane tank Another regulator may be required at the house or the unit The minimum permissible gas supply pressure to the furnace is 11 W C for the purpose of input adjustment If at any time ignition is slow and the burner does not seem to be ing correctly check manifold pressure It should be between 10 to 10 5 W C The furnace is designed to obtain rated input at 10 0 W C To check this pressure 1 Turn off the gas valve 2 Remove the plug on the valve 3 Install a water manometer Turn gas valve ON If manifold pressure must be adjusted remove from pressure regulator and turn adjustment screw clockwise to increase pressure counterclockwise to reduce pressure After checking pressure turn gas off remove the manometer fitting and replace the pipe plug and regulator cap Put furnace in operation and leak check plug for leaks using a soapy solution With proper manifold pressure achieved cycle main burne
163. oms and closets are designed into the building structure to accommodate the interior portions and duct connections These rooms or closets must allow ample clearance for regular service and maintenance A 30 wide minimum clearance opening is required in front of the filter access door This will allow for easy removal of the door and replacement of the filter Electrical conduit gas lines duct work and building structures places within this opening will complicate removal of the filter access door that may result in a lack of proper maintenance and diminished perfor mance The cooling section of an HWC unit is built on a sliding chassis that can only be removed through the filter access door Any service that must be done to the condenser section evaporator fan or refrigeration circuit requires removal of the chassis from the unit Therefore a 30 horizontal minimum clear opening is required in front of the filter access door to facilitate removal of the entire cooling chassis It is recommended that the doorway to any closet or room containing Magic Pak HW HWC unit be a minimum of 36 wide to allow some tolerance for chassis removal and service If the unit is installed in a residential garage it must be located or pro tected to avoid physical damage by vehicles This unit must be installed 50 that no electrical components are exposed to water Installing units in a relatively inaccessible location for easy chassis removal should b
164. on improper voltage voids the compressor replacement warranty A separate electric line with wire having a temperature rating of 60 C should be run directly from the main supply panel to the leads in the unit Refer to the rating plate located on the unit for proper fuse or breaker size Make sure the unit is electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA No 70 latest edition for installations in the U S or the Canadian Electrical Code Part 1 CSA C22 1 latest edition for installations in Canada 6 12 INSTALLATION Magic Pak HW HWC See Table 6 3 and the Specifications section beginning on page 1 1 for correct wire ampacity for the cooling chassis required and size the wire accordingly For HW heating only units When sizing wire keep in mind that an air conditioning chassis may be added in the future TABLE 6 3 Minimum Circuit Ampacity Clg Chassis Model Min Circuit Ampacity 18A 16 24A 24 30A 27 241 21 301 23 6 122 123 8 3 182 183 13 6 Rotary 15 4 Scroll 242 243 18 6 302 303 22 4 Thermostat Install the thermostat according to the directions furnished with it The thermostat must be located on an inside wall where it will not be affected by drafts sunlight or any other heat producing appliances Connect the thermostat wires to the low voltage leads on top of the unit following the wiring diagram attached
165. opper Discharge Fitting il Top View p 750 1 0 Copper Plated Steel Suction Fitting qr mE lt O lt UJ FIGURE 5 24 Copeland Compressor Side View UNIT COMPONENTS Magic Pak HW HWC 5 34 Drier Filters 301 TABLE 5 10 Drier Filter Specifications Armstrong Part Number Supplier Supplier Part Number B 39059B001 39059B002 39059B003 4 38 13 A 1 0 314 B 4 Holes ll 1 C FIGURE 5 25 Drier Filter 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS HWC Capillary Tubes 256 TABLE 5 11 HWC Capillary Tube Specification Tables xx Ind Cap Cap Cap Cap 123 1 43271 001 390598001 43267 001 053028001 0 054 0 106 183 1 43271 002 390598002 43267 002 053028025 0 054 0 106 243 1 43271 003 390598002 43267 003 053028024 0 059 0 112 303 1 43375 001 390598003 43281 001 43280 001 053028025 0 054 0 106 122 10 43271 001 390598001 43267 001 053028001 0 054 0 106 122 1 to 8 39058B001 39059B001 39102B001 05302B001 0 054 0 106 182 1 to 9 390588002 39059B002 39102B002 05302B025 0 054 0 106 242 4 to 8 39058B003 39059B002 39102B003 053028024 0 059 0 112 242 9 to 11 43271 003 39059B002 43267 003 05302B024 0 059
166. ower off delay start 9 Afterthe delay times elapse the combustion blower and the circulating air blower stop FLAME SENSE 1 Afterthe burners have been lit the ignition control starts a 10 second trial for ignition delay 2 If after 10 seconds a flame has not been sensed by the ignition control the ignition control de energizes the gas valve and the spark ignitor 3 Theunitinitiates three trials for ignition flame sense before system lockout 4 System lockout lasts 60 minutes or until power is reset to unit whichever comes first CALL FOR COOLING 1 The thermostat energizes the R Y and G circuit sending a 24 volt signal to the cooling contactor and the ignition control to start the cooling sequence The contactor closes immediately causing the compressor and the condenser fan to run The 24 volt Y signal starts a 5 second circulating air blower on delay After 5 seconds the circulating air blower starts and runs until the R Y and G circuit is interrupted by the thermostat When the R Y and G circuit is interrupted the cooling contactor immediately de energizes This causes the compressor and the condenser fan to stop The ignition control starts a 90 second circulating air blower off delay After 90 seconds the circulating air blower stops FAN ON 1 The thermostat energizes the R G circuit causing the circulating air blower to energize in cooling speed The circulating air blower remai
167. ower starts 60 seconds after the initial call for heat 4 The induced draft blower causes the pressure switch to close which starts a 30 second pre purge After the pre purge period the burners ignite 5 Theunit operates in the heating mode until the indoor thermostat setting is reached and the R W circuit is interrupted 6 When the R W circuit is interrupted the 24 volt signal to the ignition control and the signal to the blower control board are interrupted 7 Theinduced draft blower stops within several seconds and a 90 second circulating air blower off delay starts Following the delay period the circu lating air blower shuts off Detailed Sequence follows 2 34 SPECIFICATIONS Detailed Sequence HW Magic Pak HW HWC w Fenwal 05 29 Ignition Control Refer to Figure 2 6 POWER Line Voltage When the service disconnect switch is closed power is sent to the unit unit in standby no signal from the thermostat Power 208 230 volts A C is supplied to both black wires located in the junction block on top of the unit Line voltage will be present at the following locations First black wire 1 L 10nthe ignition module 2 Terminal on the transformer marked 208V or 240V whichever is being used 3 Circulating air blower capacitor terminal Second black wire 1 Supplies power to the induced draft blower 2 Common terminal on the transformer 3 Terminal L 1 on the blower control board Low V
168. perate until the heat call is satisfied interrupting the circuit between R and W The W terminal de energizes causing the blower relay to open approximately 90 seconds later This interrupts the line voltage to the circulat ing air blower and the blower shuts down Low Voltage 1 call for heat closes the circuit the thermostat between R and W sending a 24 volt signal to the white wire on the unit 2 The white wire goes to the C terminal on the limit switch ignition control terminal TH and terminal W on the blower control board 3 When W energizes the timer starts a countdown to blower The blower starts in approximately 60 seconds 4 The 24 volt signal sent to terminal TH closes the relay in the ignition control This starts the induced draft blower by energizing terminal IND on the ignition control 5 Asthe induced draft blower comes up to speed and creates enough negative pressure the pres sure switch closes The 24 volt signal from the pressure switch energizes terminal P SW causing the ignition control to start a trial for ignition sparking 6 Asthe trial for ignition starts the V1 terminal on the ignition control energizes At the same time a 24 volt signal is sent to the gas valve opening the valve The unit continues to operate as long as W is energized 7 When call for heat is satisfied the circuit be tween R and W is interrupted 8 With W de energized the gas valve closes imm
169. protect personnel Whether installing from the inside or the outside of the building the wall sleeve should extend at least 3 8 1 beyond the finished wall to allow for proper weather sealing When installing during wall construction consid eration must be made to allow for final weather sealing to the type of finish wall that will be constructed later Recessed Wall Sleeve Installation In some applications the thickness of the wall or architectural design will dictate that the wall sleeve be recessed in the finished wall This can be done but it is not recommended if the wall opening is required to be the same size as the wall sleeve opening Recessed installation can be done if the wall opening is 2 larger verti cally than the wall sleeve The wall sleeve may then be placed on a sill 2 higher than the bottom of the finished wall opening The sill must be recessed 3 8 1 inside of the outer edge of the wall sleeve This permits weather sealing of the bottom edge without plugging the drain holes in the bottom of the wall sleeve The top of the finished wall opening should extend above the top of the wall sleeve by a dimension equal to or greater than the dimension that the wall sleeve is recessed 7 6 ACCESSORIES Magic Pak HW HWC Magic Pak Installation Before installing the Magic Pak unit in the wall sleeve it is important to consider the possibility of sound and vibration transmission through the w
170. r ruse wrurenorer al L ala bs sere assvonr ruse wrurenoner at L L LL 8 41 REVISED 4 26 99 1 9 lt I O z I co PARTS LISTS MAGIC PAK HW HWC HWCS3 H 1 cont onus TO SELECT PART Last letter of the Model is the Service Level 64HWC303HA 1A First find Model 64HWC303HA 1 Then match Service Level for desired part REF PART PART DESCRIPTION ase CONPRESSOR 8 40 1 REC STOCKING PART SERVICE LEVEL lt I N N memes mem at pee smesbor TAL ttt titi 269 039820004 support 1 271 aest4D004 capacitor sse al 27e 42725001 Puecowmesson Pn Em eco d eremo misa ea seems umen nen yq qq lt I I co 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual TROUBLESHOOTING Section 9 Troubleshooting Performance Charge Weights Troubleshooting 9 2 Compressor Checkout 9 2 Capacitor Checkout 9 6 Performance 9 9 Performance Tests Installed 9 9 Performance
171. re is a good chance that the thermal 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual TROUBLESHOOTING 9 5 overload protector has opened Before the compressor can be con demned as having a burned out start or run winding it must be deter mined that the overload switch is in fact closed It may take several hours for the compressor to cool down enough to guarantee that the switch has closed After enough time has elapsed for the switch to close the resis tance between each of the terminals should be measured It may be found that with the overload switch closed the compressor checks out electrically sound If this is the case then other possibilities have to be looked at as to what caused the compressor to overheat There are several reasons why a compressor would overheat Ifthe capacitor was incorrect or failing the amp draw current flow would be increased This could cause the motor to heat up very rapidly activating the thermal overload protection device This would interrupt power and protect the motor windings from damage A loss of charge could also cause the operating temperature of the compressor to rise and open the thermal overload switch Restricted airflow through the coil could also cause the operating temperature of the unit to rise It is important to perform these checks before making a decision as to the condition of the compressor An open thermal overload device in a motor doe
172. re to install the appropriate gas valve conversion kit see page 7 14 TABLE 7 7 AHALT390 1 Parts List Gy 5 _ 5 Regulator Natural Gas The minimum permissible gas supply pressure is 5 0 W C for purpose of input adjustment Gas input must never exceed the input capacity shown on the rating plate The furnace is equipped for rated inputs with manifold pressure of 3 5 W C for natural gas Only small variations in gas input may be made by adjusting the regulator In no case should the final manifold pressure vary more than 0 3 W C from the specified pressure To check this pressure 1 Turn off the gas valve 2 Remove the plug on the valve marked OUTLET PRESSURE 3 Install a water manometer Turn gas valve ON If manifold pressure must be adjusted remove from pressure regulator and turn adjustment screw clockwise to increase pressure counterclockwise to reduce pressure After checking pressure turn gas off remove the manometer fitting and replace the pipe plug and regulator cap Put furnace in operation and leak check plug for leaks using a soapy solution Check the furnace rate by observing the gas meter when available making sure all other gas appliances are turned off The test hand on the meter should be timed for at least one revolution Note the number of seconds for one revolution 1 16 ACCESSORIES Magic Pak HW HWC BTU HR _ Cubic Feet Per Rev
173. ressor contactor Figure 3 2 Disconnect the 6 pin low voltage molex plug Figure 3 2 Remove the filler panel by removing the four hold down screws Figure 3 2 Remove the right side chassis screw Figure 3 2 Remove the permagum seal on the base rails of the chassis Figure 3 4 Disconnect the drain tube from the evaporator drain pan Figure 3 3 Remove the chassis from the front of the unit pulling it toward yourself Figure 3 4 RIGHT SIDE CHASSIS SCREW HOLD DOWN d p L1 L2 WIRES SCREWS o d FILLER PANEL 6 PIN LOW VOLTAGE MOLEX PLUG Figure 3 2 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual UNIT TEAR DOWN 3 5 EVAPORATOR BLOWER MOTOR N 24 1 ON Figure 3 3 EVAPORATOR DRAIN TUBE CONNECTION EVAPORATOR DRAIN PAN CHASSIS SHOWN PARTIALLY REMOVED LOW VOLTAGE MOLEX PLUG Figure 3 4 EVAPORATOR DRAIN TUBE CONNECTION PERMAGUM SEAL DRAIN HOSE NOT PICTURED ARMSTRONG P N 03613A001 17 LONG 63 5 8 1 0 13 WALL THICKNESS UNIT TEAR DOWN Magic Pak HW HWC Evaporator Blower Assembly Removal The evaporator blower assembly is removable as one complete section To remove the assembly the chassis must be removed first see page 3 4 Refer to the fol
174. roxi mately six seconds the ignition control de ener gizes the spark terminal and gas valve The thermostat R W circuit sends a 24 volt signal to the blower control board starting the circulating air blower after a 30 second delay The unit initiates three trials for ignition flame sense before system lockout SEQUENCE OF OPERATIONS 2 27 CALL FOR COOLING A call for cooling closes the circuit from R to Y and G A 24 volt signal is sent to blower control board terminal G and to the compressor contactor The contactor closes sending line voltage to the com pressor and the outdoor condenser fan With a 24 volt signal at terminal G on the blower control board the circulating air blower starts in cooling speed 15 seconds later see note below When the cooling call is completed G and Y de energize The contactor opens immediately stop ping the compressor and the outdoor cooling fan When G de energizes the timer to turn off the circulating air blower starts The blower turns off after 90 seconds see note below FAN ON When the thermostat switch is moved to the FAN position the circuit between R and G closes The 24 volt signal from G goes to the blower control board which starts the timer Fifteen seconds after terminal G on the blower control board energizes or immediately after see note below the circulating air blower starts When terminal G on the blower control board de energizes the timer t
175. rs on and off Ignition and extinction should be smooth and quiet Burning back at the orifice or flame popping back to the orifice can be corrected by adjusting the air shutter to soften the flame TABLE 7 8 AHALT390 1 Orifices 26HW HWC 26 000 23 400 18 000 38HW HWC 38 000 24 200 27 000 51HW HWC 51 000 45 900 36 000 64HW HWC 64 000 57 600 45 000 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 1 17 ATIMR466 1 Short Cycle Protector Kit The ATIMR466 1 Short Cycle Protector Kit helps guard against compres sor failure due to repeated short interval on off cycles It is also referred to as the Nuisance Blower Operation Repair Kit The kit is designed to be used in conjunction with matching air conditioner or heat pumps for comfort cooling heating applications as shown in the Armstrong specification information TABLE 7 9 ATIMR466 1 Parts List Time Delay Relay Wires Installation Instructions Time Delay Relay T stat Common Load Contactor Coil High Pressure Discharge Cutout Thermostat If Used If Used Low Voltage Leads to Contactor Coil from Thermostat Discharge Thermostat If Used FIGURE 7 4 ATIMR466 1 Kit Wiring 1 18 ACCESSORIES Magic Pak HW HWC ADAPT420 2 Chassis Conversion Kit The ADAPT420 2 kit was designed to retrofit an HWC122 182 242 or 302 chassis onto a cabinet originally equipped with an HWC12 18 24 or
176. s sends line voltage to the COOLING speed terminal on the blower control board which starts the circulating air blower The signal from Y energizes the contactor starting the compressor and the outdoor cooling fan When the cooling call is satisfied both G and Y are de energized The contactor opens immediately causing the compressor and the outdoor cooling fan to stop SPECIFICATIONS Magic Pak HW HWC 2 20 5 circulating air blower shuts off approximately 90 seconds after G terminal on the blower control board is de energized see note below FAN ON Low Voltage 1 When the switch on the thermostat is moved to the FAN ON position a 24 volt signal is sent to G 2 With G energized the blower control board starts a countdown to fan on After approximately 15 seconds the fan starts see note below 3 The blower control board closes a relay on the board sending line voltage to the terminal marked COOL on the board This starts the circulating air blower 4 When the switch at the thermostat is moved to the OFF position the 24 volt signal to the blower control board is interrupted With no signal at the G terminal the blower control board starts a countdown to fan off Approximately 90 seconds later a relay on the blower control board opens see note below This interrupts the power to and stops the circulating air blower Note Heatcraft blower control boards have a G delay of 15 seconds and
177. s not mean that the motor was damaged or harmed in any way TROUBLESHOOTING Magic Pak HW HWC Capacitor Checkout Before starting the checkout of the capacitor it is important to understand what a capacitor is how it works and what its function is in relation to a motor A capacitor is a storage device similar to a battery only unlike a battery a capacitor wants to give up its energy all at once This ability to store and release energy is used to make motors run more efficiently with more power in a smaller size and to start easier There are many types of capacitors but they all serve one common purpose to store electrons Capacitance refers to the capacitor s ability to store electrons Different size capacitors hold different amounts of charge Capacitance is measured in farads A 1 farad capacitor connected to a 1 volt power supply will store 6 280 000 000 000 000 000 or 6 28 x 10 to the 18 power electrons Most capacitors store a much smaller quantity of electrons Smaller capacitors have different terms to indicate the quantity of electrons that they can store A picofarad is one trillionth of a farad a microfarad is one millionth of a farad The microfarad is the term most often used in the HVAC business this is marked on a capacitor as MFD The capacitor that is most often used in the HVAC business is known as an electrolytic capacitor The electrolytic capacitor is unique in that a thin layer of oxide is forme
178. satisfied the circuit between Y G and R is interrupted The contactor immediately opens interrupting power to the compressor and the outdoor cooling fan With the low voltage signal to terminal G on the blower control board interrupted the board starts a countdown to blower off After approximately 90 seconds the cooling speed relay opens and the circulating air blower shuts down see note at the end of this section Low Voltage 1 2 On a call for cooling the thermostat closes the circuit between R and terminals G and Y The 24 volt signal energizes terminal G on the blower control board starting the fan timer After approximately 15 seconds the relay closes see note at the end of this section This sends line voltage to the COOLING speed terminal on the board which starts the circulating air blower The signal from Y energizes the contactor starting the compressor and the outdoor cooling fan When the cooling call is satisfied both G and Y de energize The contactor opens immediately causing the compressor and the outdoor cooling fan to stop The circulating air blower stops approximately 90 seconds after the G terminal on the blower control board de energizes see note at the end of this section FAN ON Low Voltage 1 When the switch on the thermostat is moved to the FAN ON position a 24 volt signal is sent to the G terminal on the blower control board With G energized the blower co
179. seconds After 60 seconds the ignition control automatically de energizes the combustion blower relay This interrupts L1 power to the CMB BLWR terminal on the ignition control 7 The combustion blower remains de energized for approximately six minutes During this 6 minute lockout the green LED flashes three times indicat ing pressure switch fault open or closed 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 until the pressure switch closes and the 24 volt signal is restored at pin 5 of the 6 pin ignition wire harness 2 14 SPECIFICATIONS FAILED FLAME SENSE TRIAL FOR IGNITION When the pressure switch closes and a 24 volt signal is sent to pin 5 of the 6 pin ignition wire harness the spark ignition cable terminal and pin 4 of the 6 pin ignition wire harness energize 1 10 As spark voltage is supplied to the ignitor elec trodes the gas valve opens and this causes the burners to ignite The ignition control continues to energize spark voltage until a flame sense signal is supplied to the flame terminal on the ignition control If a flame sense signal is not received at the flame terminal on the ignition control the spark igni tion cable terminal remains energized for 10 seconds After the 10 second trial for ignit
180. ssen se REC STOCKING PART SERVICE LEVEL 26HWC122A 10 38HWC122A 10 38HWC242A 10 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual PARTS LISTS HWC 1 22 242 1 0 cont TO SELECT PART Last letter of the Model is the Service Level 38HWC242A 10A First find Model 38HWC242A 10 Then match Service Level for desired part CUR NCC MRNA ari owwomonzsswroesac lt a eo x o cc SERVICE LEVEL 26HWC1 22A 10 38 122 10 38HWC242A 10 8 10 PARTS LISTS MAGIC PAK HW HWC HWC182 9 um TO SELECT PART Last letter of the Model is the Service Level 64HWC182A 9A First find Model 64HWC182A 9 Then match Service Level for desired part gt PART PART DESCRIPTION VALVE GAS 43108 001 VALVE GAS MANIFOLD MANIFOLD MANIFOLD E REC STOCKING PART SERVICE LEVEL 42074 002 42074 003 42074 004 390308003 ORIFICE 52 NATURAL GAS 390308004 ORIFICE 53 NATURAL GAS ELECTRODE WIRE ELECTRODE CONTROL IGNITION BURNER 0 41957 001 1 41583 001 24 43110 001 4 41948 001 8 389990010 ASSEMBLY HEAT EXCHANGER 8 389990011 ASSEMBLY HEAT EXCHANGER 8 38999D012 ASSEMBLY HEAT EXCHANGER E C 40 538841 001 TURBULATOR GASKET FLUE COVER GASKET FLUE COL END CONTROL LIMIT GASK
181. ssigned to each part in the Parts List section beginning on page 8 1 Transformer 1 The transformer supplies 24 VAC from its secondary winding to operate the blower control board gas valve and ignition control depending on the particular model Transformers are typically rated at 40 VA 50 60 Hz Transformer Specifications Manufacturer Basler Electric Model 31264 GEK Armstrong P N 39370B001 Primary 208 240V Secondary 24V Rating 40VA Dimensions 2 28 W x 1 94 H x 3 12 D Base 3 25 W 2 81 between 1 0 of holes 19 x 020 Quick Connect Terminals 24 VAC Secondary 25 x 032 Quick Connect Terminals 188 Diameter Holes 208 240 VAC Primary Note Secondary leads may exit from top of transformer FIGURE 5 1 24 volt Transformer Typical Configuration 5 4 UNIT COMPONENTS Magic Pak HW HWC Gas Valves 7 White Rodgers 25K49 120 Gas Valve Specifications Manufacturer White Rodgers Model 25K49 120 Armstrong P N 43108 001 Dimensions 1 97 W x 5 31 L Nominal Operating Currents 25VAC 60Hz 5A Regulator set at 3 50 02 W C at 55 6 cubic Ft Hr of air at standard conditions with valve in vertical position inlet up 3 8 18 N P T Outlet 1 8 27 Pipe Plug 3 8 18 Inlet FIGURE 5 2 White Rodgers Gas Valve 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual 1 8 NPT Inlet Pressure Tap
182. t letter of the Model is the Service Level 64HWC302A 9A 8 13 First find Model 64HWC302A 9 Then match Service Level for desired part oT a a O warvessurren s mee fre i ENE FILTER 165 25 X 50 EREIERERERER sone vee wens oneran emos es mener fooro _ es como L es serro sro mee s omo apa mnan owzwecewen s oowzwecerwm L es mme uem bs menor sweerwnonsweos ownoronssswoeoas powcrn 51HWC242A 9 64HWC242A 9 51HWC302A 9 64HWC302A 9 REC STOCKING PART SERVICE LEVEL PARTS LISTS MAGIC PAK HW HWC HWC 8 m TO SELECT PART Last letter of the Model is the Service Level 64HWC302 8A First find Model 64HWC302 8 Then match Service Level for desired part aT CE 7 massa 5 3 0298002 CONTROL BLOWER CENTER z 200910001 vas e Eom m rese jwwas fa 13 omrcewe s 390808604 ones AP fas esses eere TL LL go evecrrove tt TA t io
183. t one revolution Note the number of seconds for one revolution BTU HR _ Cubic Feet Per Revolution X 3600 X Heating INPUT Seconds Per Revolution Value Adjustments Cooling Section HWC models No adjustments are required or should be attempted regarding any of the components of the cooling chassis The chassis should be checked to see that none of the wiring is loose or missing Blower The unit contains a direct drive multispeed blower The proper speeds have been preset at the factory for heating and cooling Refer to the wiring diagram for recommended heating cooling speeds for specific models Direct drive blower motors are permanently lubricated and do not require oiling Limit Control A fixed temperature limit control is provided which will shut off the gas to the main burners if the unit is overheated for any reason The control must not be adjusted or relocated High Altitude Adjustments U S Installa tions Ratings shown on the rating plate are for elevations up to 2000 feet For elevations above 2000 feet ratings should be reduced at a rate of 4 for each 1000 feet above sea level Refer to the National Fuel Gas Code Z223 1 latest edition for further explanation High Altitude Adjustments Canadian Instal lations High altitude conversions may be made by the manufacturer s authorized representative in accordance with the requirement of the manufacturer provincial or territorial authorities having jurisdic
184. tain ignition and venting system mal functions refer to control label for specific diagnostic codes Includes flame current FC test terminals TABLE 7 11 Ignition Control Kit Parts List Fenwal Triton 2461D Series Direct Spark Gas Ignition Control High Voltage Electrode Cable Wiring Label Installation Instructions May Be Pre installed on Ignition Control Terminals ACCESSORIES Magic Pak HW HWC 1 20 TL109 Burner Tray Kit The TL109 Burner Tray Kit is designed for use HW HWC s that were originally equipped with single port inshot burners Four kits are available one for each natural gas heating input rating as follows e 26 000 BTUH 3 main burners 38 000 BTUH 4 main burners e 51 000 BTUH 5 main burners e 64 000 BTUH 6 main burners Each kit includes e Anassembled burner tray including manifold natural gas orifices and 3 4 5 or 6 main burners depending on heating input rating e Athree rod combination igniter sensor Installation instructions The burner tray assembly included in this kit can be used with either the Fenwal remote sense ignition control which uses a separate flame sensor lead or the more recent Fenwal local sense ignition control which does not use a separate flame sensor lead When used with the remote sense ignition control the three rod combination igniter sensor in the kit effectively makes this a local sense system Burner Carryover Gap 025
185. tch Open or switch equipped version of this unit see the section beginning on Closed page 2 36 4 FLASH High Limit or Rollout Switch Open 5 FLASH Flame Sensed and Gas Valve Not Energized STEADY Internal Failure Micro controller Failure Self check FIGURE 2 1 Connection Diagram 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual SEQUENCE OF OPERATIONS 2 5 Simplified Sequence HWC123 183 243 303 Refer to Figure 2 1 208 230V power is supplied to the junction box on top of the unit 24 power is supplied from the unit transformer to the thermostat CALL FOR HEAT 1 The thermostat closes the R W circuit sending a 24 volt signal to the unit 2 The 24 volt signal energizes the combustion blower causing the pressure switch to close 3 The combustion blower runs for 30 seconds as a pre purge to trial for ignition 4 The ignition control energizes the spark ignition and opens the gas valve causing the burners to light When the gas valve energizes a 30 second circu lating air blower delay begins 5 Flame sense is sent to the ignition control through the flame sensor and flame sense wire 6 After the 30 second delay the circulating air blower energizes and runs until the heat call is satisfied 7 When the heat call is satisfied the gas valve de energizes This shuts down the burners 8 5 second combustion blower post purge delay and a 120 second circulating air bl
186. te negative pressure resulting from excessive venting system restriction or a failed induced draft blower thus providing protection from a change in safe stable furnace operation The Armstrong part number is stamped on the body of the switch A label on the switch carries the manufacturer s model number Always verify the proper switch number from the parts list Normally Open Terminal Connect to Port on Induced Draft Blower Common Terminal Pressure Switch Specifications Manufacturer Tridelta Industries Electrical Rating SPDT Elec Load 28 VA Pilot Duty 24 3 FLA 18 LRA 24VAC SPST Elec Load 5 A Resistive 9 24VAC Electrical Switch Electrical Switch Single Pole Normally Open Snap Acting Contacts Electrical Connectors Common C Normally Open NO 1 4 x 032 thick quick connect terminals Maximum Pressure 3 W C Operating Temperature Range 40 to 190 Sample Line Connector Negative barb type for use with 3 16 or 1 4 I D tubing with 016 004 bleed hole FIGURE 5 18 Pressure Switch UNIT COMPONENTS Magic Pak HW HWC 5 22 TABLE 5 4 Pressure Switches Armstrong Switch Opens P N Model Number inches W C 44819 007 Tridelta Industries 44819 008 Tridelta Industries PPS10090 2621 504 05 Red 44819 009 Tridelta Industries 44819 010 Tridelta Industries Pressure Switch Problems The negative pressure developed in the combustion chamber is directly related
187. terrupts the signal to terminal V2 of the ignition control 2 Terminal W on the blower control board stays energized and the circulating air blower contin ues to run If negative pressure is restored the pressure switch closes and sends a 24 volt signal to the P SW terminal on the ignition control The ignition control makes a trial for ignition again and the operation returns to normal ROLLOUT SWITCH ACTIVATED 1 If conditions in the burner compartment cause the rollout switch to trip the contacts on the switch open interrupting the 24 volt signal going to termi nal P SW on the ignition control This causes the ignition control to de energize terminal V1 interrupting the 24 volt signal to the gas valve and immediately closing it 2 Thereason the rollout switch was tripped must be determined before any corrective action is taken 3 Thesignal to terminal P SW can only be restored if the rollout switch is reset which can only be done manually The W terminal on the blower control board remains energized and the circulating air blower continues to operate Once the rollout switch is reset the operation of the unit returns to normal SPECIFICATIONS Magic Pak HW HWC HWC123 183 243 303 Low Ambient w United Technologies 1097 Spark Ignition System CIRCUITS ENERGIZED 208 230 1 60 SNCOPPER CONDUCTORS OPERATING MODE CIRCUIT POWER SUPPLY ONLY HEATING sd COOLING R G Y FAN BLUE LINE VOLTAGE FACTORY
188. the blowers shut off Low Voltage 1 2 10 11 A call for heat closes the R W circuit sending a 24 volt signal to the low voltage white wire in the unit The 24 volt signal is received at pin 3 of the 5 pin thermostat harness on the ignition control The 24 volt signal causes the combustion blower relay to close causing the combustion blower to run this time 24 volt signal is also sent out through pin 2 of the 6 pin ignition wire harness The 24 volt signal from pin 2 of the 6 pin ignition wire harness energizes one side of the Normally Open pressure switch As the induced draft blower reaches full speed the pressure switch closes and a 24 volt signal is sent to pin 5 of the 6 pin ignition wire harness When the 24 volt signal is received at pin 5 of the 6 pin ignition wire harness the ignition control starts a 30 second pre purge delay After the 30 second pre purge the ignition control initiates a trial for ignition The spark ignition cable terminal and pin 4 of the 6 pin ignition wire harness energize simultaneously When the 24 volt signal is present at pin 4 of the 6 pin ignition wire harness the ignition control starts a 30 second circulating air blower on delay The 24 volt signal from pin 4 of the 6 pin ignition wire harness is received at the gas valve causing it to open and the burners to ignite After 30 second on delay the circulating air blower relay energizes the heat terminal and the
189. thermostat is interrupted 7 The ignition control remains in lockout until 24 volt power to the ignition control is reset LIMIT OPENS If the limit switch opens for any reason during a call for heat the following happens 1 Ifthe limit switch senses that the temperature in the unit is too high the contacts between terminals C and NC on the limit switch open and the con tacts between C and NO close This interrupts the 24 volt signal to the pressure switch and also de energizes terminal P SW on the ignition control The gas valve closes immediately as the 24 volt signal to terminal P SW is no longer present The induced draft blower and the circulating air blower continue to run Power to blower control board terminal W is maintained The blower continues to run until the limit switch closes or the heat call at the thermostat is satisfied 2 When the limit switch senses that the tempera tures in the unit are normal the contacts between terminals C and NO open the contacts between terminals C and NC close and the operation of the unit returns to normal SEQUENCE OF OPERATIONS 2 35 PRESSURE SWITCH OPENS BLOCKED FLUE 1 If blockage of the flue occurs negative pressure in the induced draft blower is reduced the set point of the pressure switch the contacts open This interrupts the 24 volt signal to terminal P SW on the ignition control The gas valve closes immediately as a relay in the ignition control opens and in
190. tion and in accordance with the requirements of CAN CGA B149 1 or B149 2 Installation Code A high altitude conversion kit available from the manufacturer and approved for this purpose must be used see the Accessories section beginning on page 7 15 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual INSTALLATION 6 15 Installation and Operation Extremely Cold Weather Areas In areas where extremely cold below 209 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 1 Adjustto the highest achievable temperature rise within the rise and static pressure ranges specified on the rating plate Depending on specific model it may be possible to change to a lower heating blower speed tap to get a higher temperature rise This also increases comfort 2 Make sure there are no leaks of outside air into the return air system 3 Keep the outside louver grille as free as possible of any ice that may form and obstruct the flue outlet SRM HW HWC 8 99 Service Reference Manual ACCESSORIES 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 Louver Facade
191. tire circuit within the motor S through C to R A determination of the condition of the motor windings can be made with the information just collected The following steps show how this is done 1 Add the readings from C to S and C to R C to S 3 5 ohms C to R 1 5 ohms 5 ohms 9 4 TROUBLESHOOTING Magic Pak HW HWC When the resistance of C to S is added to the resistance of C to the combination is the total resistance of the entire motor windings circuit 2 Compare the total to the reading taken between S to R If the windings are in good condition the sum of C to S and C to R should be the same as the reading between 5 to R S through C to R In this example they are equal If the numbers are the same this suggests that the windings are intact and that there are no internal shorts between the start and run windings Example 2 In the following example the measurements taken provide different results from the earlier example These results would indicate that there is a problem with the compressor C to S Common through Start Windings 3 5 ohms C to R Common through Run Windings 1 5 ohms S to R Start Windings through Common and Run Windings 4 3 ohms Using the procedure followed in Example 1 C to S 8 5 ohms C to R 1 5 ohms 5 ohms In this example the actual reading of S to R is 4 3 ohms In comparing the readings taken the resistance measured between S to R
192. to airflow During furnace operation the switch will react to conditions that reduce airflow such as blocked or restricted intake combustion air piping blockage of vent flue piping blockage of the condensate drain piping plugged pressure tap ports leaking hoses or a failure of the induced draft blower motor If the pressure switch has already been replaced and problems are still being experienced follow the procedure Checking Pressure Switch Operation found on page 5 24 If the measured static pressure reading does not meet the switch specifi cations check these items 1 Pressure switch hose tubing for cracks or loose connections 2 Induced draft blower wheel for corrosion or loose blades 3 Induced draft blower for tight bearings or loose inducer wheel 66 2 OMH MH INHS SRM HW HWC 2 99 Service Reference Manual UNIT COMPONENTS 5 23 The measured static pressure reading should be compared to the pres sure switch specifications If the measured static pressure meets or exceeds the specifications and switch contacts will not transfer check the following items Switch out of calibration Defective pressure switch e Moisture in pressure switch tubing Incorrect switch installed WARNING DO NOT try to repair a pressure switch Use an identical replacement The use of an improperly repaired or malfunctioning pressure switch could result in property damage personal injury or death
193. to the unit The heat anticipator setting is 0 50 Amp Supply and Return Ducts Provide ducts sized sufficiently to handle the larger of the air volumes for heating or cooling provided by the unit Connect the supply duct to the top of the unit using canvas connections or other flexible connections to prevent noise transmission into the duct system The supply duct should have a removable access panel The opening should be accessible when the furnace is installed and should be large enough and located such that the heat exchanger can be inspected for leaks The cover must be attached in such a manner as to prevent air leaks To connect the return duct to the system use a straight piece of duct 22 wide by 6 deep Insert the duct into the return opening in the bottom of the unit and flange the duct over the existing flanges around the opening 66 8 OMH MH INHS SRM HW HWC 8 99 Service Reference Manual INSTALLATION 6 13 inside the unit Make sure that all sides of the duct are flanged over to permit removal of the cooling chassis if required Use a flexible connec tion to attach the remainder of the return duct The return duct should be sealed to the unit casing and terminate outside the space containing the furnace Air Filter All indoor return air must be filtered A permanent type filter is furnished with the unit located directly behind the access panel Removing the panel permits access to the filter If an installation
194. utes of main burner operation Use the flame of a match or candle 6 Follow the preceding steps for each appliance connected to the common venting system 7 Afterit has been determined that each appliance remaining con nected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other fuel burning appliance to their previous condition of use 8 If improper venting is observed during any of the above tests the common venting system must be corrected See National Fuel Gas Code ANSI 2223 1 latest edition or CAN CGA B149 1 amp 2 Canadian Installation Codes to correct improper operation of common venting system Gas Gonnections The gas line to the unit should be adequately sized to prevent undue pressure drop and should never be smaller than the manual valve used Consult the local utility or National Fuel Gas Code for complete details on special requirements in sizing gas piping The units supplied for operation with natural gas contain a gas regulator which must be operated with inlet gas pressures specified on the rating plate If gas line pressure exceeds this figure an additional high pressure regulator must be installed to reduce this pressure 6 10 INSTALLATION Magic Pak HW HWC Units for operation with propane must be converted with a kit supplied by the manufacturer and require for operation an inlet pressure of 11 W C minimum a
195. uts down Approximately 90 seconds later the circulating air blower also shuts down Low Voltage The following is the sequence of operation for the low voltage side of the unit on a heat call 1 call for heat closes the circuit the thermostat between R and W sending a 24 volt signal to the white wire on the unit 2 The white wire goes to the C terminal on the limit switch 3 The 24 volt signal is sent from the C terminal brown wire on the limit switch to terminal TH on the ignition control This causes the ignition control to close the line voltage relay starting the induced draft blower When the induced draft blower comes up to speed and creates enough negative pressure the pressure switch closes 4 With the pressure switch closed the 24 volt signal goes to the rollout switch located over the burners 5 The 24 volt signal from the rollout switch goes to the terminal marked P SW on the ignition control causing the ignition control to make a trial for ignition sparking Terminal V1 on the ignition control also energizes at this time causing the gas valve to open 6 Atthe same time that the C terminal on the limit switch energizes a 24 volt signal is also sent to the W terminal on the blower control board This starts the timer on the blower control board Approximately 30 seconds after the main burners ignite the blower control board closes a relay this sends line voltage to the circulating air blower st
196. y when temperatures are acceptable but the rollout switch must be manually reset by pushing in on the small button on top of the switch The reason why the switches opened must be determined before any corrective action is taken PRESSURE SWITCH OPENS BLOCKED FLUE When the R W circuit is energized a 24 volt signal is sent to the ignition control This starts the call for heat 1 The 24 volt signal from the R W circuit energizes the combustion blower relay sending L1 power to the CMB BLWR terminal on the ignition control This starts the ignition control 2 Atthe same time the combustion blower relay energizes the 24 volt signal is sent to pin 2 of the 6 pin ignition wire harness and from pin 2 to one side of the Normally Open pressure switch 3 When the combustion blower causes the pres sure switch to close a 24 volt signal is sent across the switch to pin 5 of the 6 pin ignition wire harness The 24 volt signal energizes at pin 5 and the ignition sequence continues 4 Ifthe combustion blower fails to close the pres sure switch the 24 volt signal is not sent to pin 5 of the 6 pin ignition wire harness and the ignition control does not initiate a 30 second pre purge delay 5 signal 1 sent to the spark ignition cable terminal on the ignition control or to the gas valve through pin 4 of the 6 pin ignition wire harness 6 The combustion blower continues to run for 60 seconds After 60 seconds the ignition contro

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