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Armstrong World Industries 302 manual

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Table of contents for the manual

  • Page 1

    Ser vice Refer ence Manual HWC Thru-the-Wall Units Models: HWC Premier 122, 182, 242, 302 123, 183, 243, 303[...]

  • Page 2

    SRM-HW/HWC 8/99 Cop yr ight © 1998 Ar mstrong Air Conditioning Inc. All rights reser v ed. Disclaimer This manual presents inf ormation and guidelines for proper installation, adjustment, operation and maintenance of Armstrong Magic-Pak HW/HWC Thru-the-Wall units . Read this manual bef ore attempting assembly , installation, star t-up , adjustment[...]

  • Page 3

    Service Refer ence Manual T ABLE OF CONTENTS SRM-HW/HWC 8/99 T ABLE OF CONTENTS 1 - Specifications 2 - Sequence of Operations 3 - Unit T ear Down 4 - Component Location Illustrations 5 - Unit Components 6 - Installation 7 - Accessories 8 - Par ts Lists 9 - T r oubleshooting/Per formance/ Char ge Weights Go to: If you need information on: Section 1 [...]

  • Page 4

    1-1 SRM-HW/HWC 8/99 Service Refer ence Manual SPECIFICA TIONS Section 1 - Specifications Models Cover ed By This Manual ............ 1-2 Model Number Guide ............................ 1-2 Pr oduct Serial Numbers (Beginning 1993) ................................. 1-2 Summar y of Model Revisions/V ariations 1-3 Heating Configuration T able .........[...]

  • Page 5

    1-2 SPECIFICA TIONS Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Models Cover ed 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 64HW Model Number Guide 26 = Rated Input BTU/Hr x 1000 H = Gas Heat W = Thr u-the-W all C = Cooling 12 = Nominal Cooling BTU/Hr x 1000 2 = Coo[...]

  • Page 6

    1-3 SRM-HW/HWC 8/99 Service Refer ence Manual SPECIFICA TIONS Summar y of Model Revisions/V ariations * For more inf or mation on the compressors used in HWC units, see the Unit Components section, beginning on page 5-28. T able 1-1 Heating Configurations of HW/HWC Units T able 1-2 Cooling Configurations of HWC Units l e d o Mn o i t a r u g i f n [...]

  • Page 7

    1-4 SPECIFICA TIONS Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Physical and Electrical HW/HWC Per formance Ratings T able 1-3 Physical and Electrical Specifications - HWC Units l e d o M / e g a t l o V e s a h P / z H l a m r o N e g a t l o V e g n a R . n i M t i u c r i C y t i c a p m A . x a M R C A H / e s u F . r k r B ) s p m a ( . p m o C d e t a [...]

  • Page 8

    1-5 SRM-HW/HWC 8/99 Service Refer ence Manual SPECIFICA TIONS Per formance Ratings (continued) T able 1-5 P erformance Ratings - HWC182/183 T able 1-6 P erformance Ratings - HWC242/243 T able 1-7 P erformance Ratings - HWC302/303 Note: All values are gross capacities and do not include b lower motor heat deduction. Enter . Wet Bulb 63° 67° 71° O[...]

  • Page 9

    1-6 SPECIFICA TIONS Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Dimensions (all measur ements in inches) Blower Per for mance Model Blower Speed CFM @ ext. static pressure - in. w .c. with filter(s) 0.2 0.3 0.4 0.5 HWC122/123 HWC182,242,302 HWC183,243,303 SUPPL Y AIR DUCT CONNECTION 8" x 16" LOW V OL T AGE THERMOST A T CONNECTIONS HIGH VOL T AGE JU[...]

  • Page 10

    1-7 SRM-HW/HWC 8/99 Service Refer ence Manual SPECIFICA TIONS W all Sleeve (all measurements in inches) 22 16 8 6 Return Supply 1 1 1 Supply Low Vo l t a g e Line V oltage Box ½ Gas Inl et 3 8 4 1 3 / 4 2 7 / 8 13 3 / 8 43 1 / 8 27 7 / 8 29 7 / 16 2 7 / 8 Dimensions (cont.) 29 16 45 2 2 1 or 3 3 4 Flanges may be assembled 1" or 3 from this si[...]

  • Page 11

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-1 SRM-HW/HWC 2/99 Section 2 - Sequence of Operation HWC123,183,243,303 ........................ 2-4 Simplified Sequence ........................................ 2-5 Detailed Sequence .......................................... 2-6 PO WER .............................................................[...]

  • Page 12

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-2 SRM-HW/HWC 2/99 HWC122,182,242,302 (w/Fenwal 05-29 Ignition Contr ol) ....... 2-26 Simplified Sequence ...................................... 2-27 Detailed Sequence ........................................ 2-28 PO WER .................................................................... 2-28 CALL FOR HEA T .....[...]

  • Page 13

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-3 SRM-HW/HWC 2/99 BLANK P A GE[...]

  • Page 14

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-4 SRM-HW/HWC 2/99 FIGURE 2-1 Connection Diagram GREEN BLACK BLK M ORN ORN VIOLET RED BLUE WHT RED BLACK BLUE YELLOW WHITE GREEN RED FLAME ROD ELECTRODE 4 6 2 R G W C Y BLACK BLACK BLA CK GAS VA LVE MANUAL RESET LIMIT SWITCH COMBUSTION BLOWER RED BLUE YELLOW RED YELLOW D 208 V RED BLUE 240 V CAP ACITOR CAP ACITOR [...]

  • Page 15

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-5 SRM-HW/HWC 2/99 Simplified Sequence - HWC123,183, 243, 303 Refer to Figur e 2-1 • 208/230V pow er is supplied to the junction box on top of the unit • 24V power is supplied from the unit tr ansf ormer to the thermostat CALL FOR HEAT 1. The thermostat closes the R-W circuit, sending a 24-volt[...]

  • Page 16

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-6 SRM-HW/HWC 2/99 Detailed Sequence - HWC123, 183, 243, 303 Refer to Figur e 2-1 POWER Line V oltage With the unit at rest (no call from the thermostat ), line voltage will be present: L1 Power 1. Through the L1 b lac k lead to the L1 terminal on the ignition control 2. At the L1 contactor terminal 3. At the tran[...]

  • Page 17

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-7 SRM-HW/HWC 2/99 9. After 30-second “on” dela y , the circulating air blower rela y energiz es the heat terminal and the circulating air blower is energized. 10. The unit will continue to operate nor mally until the R-W circuit is interr upted. 11. When the heat call is satisfied, the thermos[...]

  • Page 18

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-8 SRM-HW/HWC 2/99 8. The 24-volt signal will only be supplied to the limit switch circuit through pin 6 of the 6-pin ignition wire har ness and to the pr essure s witch circuit through pin 2 of the 6-pin ignition wire harness. 9. The system will repeat this sequence until the pressure s witch closes and the 24-v [...]

  • Page 19

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-9 SRM-HW/HWC 2/99 6. After the 90-second dela y , the ignition control de- energizes the cooling speed rela y and the cir culat- ing air blower stops . FAN ON 1. When the thermostat is switched to the “F AN ON” position, the R-G circuit sends a 24-volt signal to pin 4 of the 5-pin thermostat h[...]

  • Page 20

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-10 SRM-HW/HWC 2/99 #45008-2 HIGH (BLACK) 64HW MED (BLUE) 51HW HIGH (BLACK) 38HW LOW (RED) LOW (RED) 26HW HEA TING HEA TI NG MODELS EV AP . MOT OR SPEED CONNECTIONS EV AP . MOT OR SPEED CONNECTIONS GREEN M ORANGE ORANGE VOI LE T VOI LE T RED BLUE WHT RED BLACK BLUE YELLOW WHITE GREEN RED FLAME ROD ELECTRODE 4 5 6 [...]

  • Page 21

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-11 SRM-HW/HWC 2/99 Simplified Sequence - HW (w/UTEC 1097 Boar d) Refer to Figur e 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 dr aft blo w er to star t, which closes the pressure s [...]

  • Page 22

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-12 SRM-HW/HWC 2/99 Detailed Sequence - HW (w/UTEC 1097 Boar d) Refer to Figur e 2-2 POWER Line V oltage With the unit at rest (no call from the thermostat ), line voltage will be present: L1 Power 1. Through the L1 b lac k lead to the L1 terminal on the ignition control 2. At the transformer terminal marked 208-2[...]

  • Page 23

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-13 SRM-HW/HWC 2/99 12. The gas valve closes immediately as 24V through pin 4 of the 6-pin ignition wire harness is de- energized b y the ignition control . 13. The ignition control initiates a 120-second circu- lating air blower “off ” dela y and 5-second com- bustion blower post-purge dela y [...]

  • Page 24

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-14 SRM-HW/HWC 2/99 FAILED FLAME SENSE/TRIAL FOR IGNITION When the pressur e switch closes and a 24-v olt signal is sent to pin 5 of the 6-pin ignition wire har ness , the spark ignition cable terminal and pin 4 of the 6-pin ignition wire harness energize. 1. As spar k v oltage is supplied to the ignitor elec- tro[...]

  • Page 25

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-15 SRM-HW/HWC 2/99 BLANK P A GE[...]

  • Page 26

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-16 SRM-HW/HWC 2/99 FIGURE 2-3 Connection Diagram #39007D5 HWC122, 182, 242, 302 (w/Fenwal T (w/Fenwal T (w/Fenwal T (w/Fenwal T (w/Fenwal T riton 2461D DSI Ignition Contr riton 2461D DSI Ignition Contr riton 2461D DSI Ignition Contr riton 2461D DSI Ignition Contr riton 2461D DSI Ignition Contr ol) ol) ol) ol) ol)[...]

  • Page 27

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-17 SRM-HW/HWC 2/99 Detailed Sequence follows CALL FOR COOLING 1. A call for cooling closes the circuit from R to Y and G. 2. A 24-volt signal is sent to b lo wer control board ter minal G and to the compressor contactor . The contactor closes, sending line v oltage to the com- pressor and the outd[...]

  • Page 28

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-18 SRM-HW/HWC 2/99 Detailed Sequence - HWC122, 182, 242, 302 (w/Fenwal T riton 2461D DSI Ignition Contr ol) Refer to Figur e 2-3 POWER Line V oltage When the ser vice disconnect s witch is closed, po wer is sent to the unit (unit in standby , no signal from the thermostat ). P ower (208 - 230 v olts A/C) is suppl[...]

  • Page 29

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-19 SRM-HW/HWC 2/99 LIMIT OPENS If the limit switch opens f or an y reason during a call for heat, the follo wing happens: 1. If the limit switch senses that the temper ature in the unit is too high, the contacts between terminals C and NC on the limit s witch open and the con- tacts between C and [...]

  • Page 30

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-20 SRM-HW/HWC 2/99 5. The circulating air blower shuts off appro ximately 90 seconds after G terminal on the blower control board is de-energized (see note belo w). FAN ON Low Voltage 1. When the switch on the thermostat is mo v ed to the “F AN ON” position, a 24-v olt signal is sent to G . 2. With G energize[...]

  • Page 31

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-21 SRM-HW/HWC 2/99 BLANK P A GE[...]

  • Page 32

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-22 SRM-HW/HWC 2/99 #39247D2 HW (Heating Only) (w/Fenwal T riton 2461D DSI Ignition Contr ol) CIRCUITS ENERGI ZED OPERA T ING MODE CIRCUIT HEA T ING R-W LINE VOL T AGE - F ACTOR Y LINE VOL T AGE - F ACT OR Y ( WHEN USED) LINE VOL T AGE - FIELD LOW V OL T AGE - F ACTOR Y LOW V OL T AGE - FIELD LOW V OL T AGE - F AC[...]

  • Page 33

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-23 SRM-HW/HWC 2/99 Simplified Sequence - HW (w/Fenwal 2461D Boar d) Refer to Figur e 2-4 CALL FOR HEAT 1. A call for heat closes the circuit betw een R and W on the thermostat. This sends a 24-volt signal to the white wire on the unit. 2. The 24-volt signal energiz es terminal TH on the ignition c[...]

  • Page 34

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-24 SRM-HW/HWC 2/99 Detailed Sequence - HW (w/Fenwal T riton 2461D Ignition Contr ol) Refer to Figur e 2-4 POWER Line V oltage When the ser vice disconnect s witch is closed, po wer is sent to the unit (unit in standby , no signal from thermo- stat ). P ower (208 - 230 v olts A/C) is supplied to the two blac k wir[...]

  • Page 35

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-25 SRM-HW/HWC 2/99 9. When W de-energiz es , the gas valve immediately shuts down and the induced dr aft blower also stops after sev er al seconds . 10. The blower control board star ts a countdo wn to blo w er “off ”. Appro ximately 90 seconds later , the circulating air blower shuts down. LI[...]

  • Page 36

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-26 SRM-HW/HWC 2/99 #39007D4 FIGURE 2-5 Connection Diagram HWC122, 182, 242, 302 (w/Fenwal 05-29 Ignition Contr (w/Fenwal 05-29 Ignition Contr (w/Fenwal 05-29 Ignition Contr (w/Fenwal 05-29 Ignition Contr (w/Fenwal 05-29 Ignition Contr ol) ol) ol) ol) ol) 208/230-1-60 PO W ER SUPPL Y COPPER CONDUCT ORS ONL Y GAS V[...]

  • Page 37

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-27 SRM-HW/HWC 2/99 Simplified Sequence - HWC122, 182, 242, 302 (w/Fenwal 05-29 Ignition Contr ol) Refer to Figur e 2-5 CALL FOR COOLING 1. A call for cooling closes the circuit from R to Y and G. 2. A 24-volt signal is sent to b lo wer control board ter minal G and to the compressor contactor . Th[...]

  • Page 38

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-28 SRM-HW/HWC 2/99 Detailed Sequence - HWC122, 182, 242, 302 (w/Fenwal 05-29 Ignition Contr ol) Refer to Figur e 2-5 POWER Line V oltage When the ser vice disconnect s witch is closed, po wer is sent to the unit (unit in standby , no signal from the thermostat ). P ower (208 - 230 v olts A/C) is supplied to both [...]

  • Page 39

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-29 SRM-HW/HWC 2/99 9. With W de-energiz ed, the gas valve closes immedi- ately and the induced draft blower stops se v eral seconds later . 10. The blower control board starts a 90-second circulating air blower “off ” dela y . Appro ximately 90 seconds later , the b lo wer stops . FLAME SENSE [...]

  • Page 40

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-30 SRM-HW/HWC 2/99 3. The unit continues cooling as long as both Y and G are energized. When the cooling call is satisfied, the circuit between Y , G and R is interrupted. The contactor immediately opens, interrupting power to the compressor and the outdoor cooling fan . 4. With the low v oltage signal to termina[...]

  • Page 41

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-31 SRM-HW/HWC 2/99 BLANK P A GE[...]

  • Page 42

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-32 SRM-HW/HWC 2/99 #39247D1 HW (Heating Only) (w/Fenwal 05-29 Ignition Contr ol) C CIRCUI TS ENERGIZED OPERA TI NG MODE CIRCUI T HEA TI NG R-W LINE VOL T AGE - F ACT OR Y LINE VO L T AGE - F ACT OR Y (WHEN USED) LINE VOL T AGE - FIELD LOW V OL T AGE - F ACTOR Y LOW V OL T AGE - FIELD LOW V OL T AGE - F ACT OR Y ([...]

  • Page 43

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-33 SRM-HW/HWC 2/99 Simplified Sequence - HW (w/Fenwal 05-29 Boar d) Refer to Figur e 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 blo w er to run. 3. A 24-volt signal is al[...]

  • Page 44

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-34 SRM-HW/HWC 2/99 Detailed Sequence - HW (w/Fenwal 05-29 Ignition Contr ol) Refer to Figur e 2-6 POWER Line V oltage When the ser vice disconnect s witch is closed, po wer is sent to the unit (unit in standby , no signal from the thermostat ). P ower (208 - 230 v olts A/C) is supplied to both blac k wires locate[...]

  • Page 45

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-35 SRM-HW/HWC 2/99 8. When the call f or heat is satisfied, the circuit be- tween R and W is interrupted, de-energizing W . 9. With W de-energiz ed, the gas valve closes immedi- ately and the induced draft blower stops se v eral seconds later . 10. The blower control board starts a 90-second blo w[...]

  • Page 46

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-36 SRM-HW/HWC 2/99 #45005-2 GREEN BLACK BLK M ORANGE VIOLET RED BLUE WHITE RED BLACK BLUE YELLOW WHITE GREEN RED FLAME ROD ELECTRODE 4 5 6 3 2 1 R G W C Y BLACK BLA CK GAS VA LVE MANUAL RESET LIMIT SWITCH COMBUSTION BLOWER BLUE YELLOW RED YELLOW 208 V RED BLUE 240 V CAP ACITOR BLOWER 208/230-1-60 POW ER SUPPL Y C[...]

  • Page 47

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-37 SRM-HW/HWC 2/99 HWC123,183, 243, 303 Low Ambient Model Refer to Figur e 2-7 The low ambient s witch is designed to allo w the opera- tion of the air conditioning unit below the normal operat- ing range. On units equipped with this s witch, sequence of operation during a cooling call is modified[...]

  • Page 48

    SPECIFICA TIONS Magic-Pak: HW/HWC 2-38 SRM-HW/HWC 2/99 #44358-2 HWC122, 182, 242, 302 Low Ambient LINE VOL T AGE - F ACTOR Y LINE VOL T AGE - F ACTOR Y ( WHEN USED) LINE VOL T AGE - FIELD LOW V OL T AGE - F A CT OR Y LOW VOL T AGE - FIELD CIRCUITS ENERGI ZED OPERA TING MODE CIRCUI T HEA T ING COOLING FA N R-W R-G-Y R-G 208/230-1-60 PO W ER SUPPL Y [...]

  • Page 49

    Service Refer ence Manual SEQUENCE OF OPERA TIONS 2-39 SRM-HW/HWC 2/99 The low ambient s witch is designed to allo w the opera- tion of the air conditioning unit below the normal operat- ing range. On units equipped with this s witch, sequence of operation during a cooling call is modified when outdoor temperatures f all below the normal operating [...]

  • Page 50

    Service Refer ence Manual UNIT TEAR DOWN 3-1 SRM-HW/HWC 8/99 Section 3 - Unit T ear Down Heating Section Heat Exchanger Removal ............................ 3-2 Induced Draft Blower Removal ..................... 3-2 Cooling Section Chassis Removal ........................................ 3-4 Evaporator Blower Assembly Removal .......... 3-6[...]

  • Page 51

    3-2 UNIT TEAR DOWN Magic-Pak: HW/HWC SRM-HW/HWC 8/99 UNIT TEAR DOWN HWC units are comprised of two major sections. The heating section is located in the top half of the unit. It contains the heat e xchanger and the majority of the components associated with the heating function: controls , b urners, s witches, etc.... The total heating section is n[...]

  • Page 52

    Service Refer ence Manual UNIT TEAR DOWN 3-3 SRM-HW/HWC 8/99 Figure 3-1 INDUCED DRAFT BLOWER/ COMBUSTION BLOWER HEA TING SECTI ON CONTROL SECTION COOLING SECTI ON HEA T EXCHANGER VESTIBULE P ANEL BURNER ACCESS P ANEL FIL TER ACCESS DOOR PLA TE MOUNTING SCREWS BURNER TRA Y GAS V AL VE FRONT HEA T SECTION P ANEL[...]

  • Page 53

    3-4 UNIT TEAR DOWN Magic-Pak: HW/HWC SRM-HW/HWC 8/99 FILLER P ANEL HOLD DOWN SCREWS L1/L2 WIRES 6-PIN LOW VO L T AGE MOLEX PLUG RIGHT SIDE CHASSIS SCREW Figure 3-2 Cooling Section Chassis Removal: The cooling chassis ma y be remov ed from behind the filter access door . Ref er to the f ollo wing directions and Figures 3-1 to 3-4. T o remov e the co[...]

  • Page 54

    Service Refer ence Manual UNIT TEAR DOWN 3-5 SRM-HW/HWC 8/99 EV APORA TOR BLOWER MO TOR COMPRESSOR EV APORA TOR DRAIN P AN EV APORA TOR EV APORA TOR DRAIN TUBE CONNECTION Figure 3-3 LOW V OL T AGE MOLEX PL UG PERMAGUM SEAL EV APORA TOR DRAIN TUBE CONNECTION DRAIN HOSE (NOT PICTURED) ARMSTRONG P/N 03613A001 17" LONG .63" (5 /8") I.D .[...]

  • Page 55

    3-6 UNIT TEAR DOWN Magic-Pak: HW/HWC SRM-HW/HWC 8/99 R O T A T I O N MOUNTING SCREWS EV APORA TOR BLOWER ASSEMBL Y CONTROL P ANEL SCREWS CHASSIS BASE PERMAGUM SEAL (BETWEEN BASE RAIL AND CHASSI S BASE) Figure 3-5 Evaporator Blower Assembly Removal: The ev apor ator blo w er assembly is remo v ab le as one complete section. T o remov e the assemb ly[...]

  • Page 56

    4-1 Service Reference Manual COMPONENT LOCA TION ILLUSTRA TIONS SRM-HW/HWC 2/99 Section 4 - Component Location Illustrations HW/HWC(3) Unit ................................. 4-2 HW/HWC(2) Unit ................................. 4-3 HW/HWC - Panels ................................ 4-4 HW/HWC - Exterior Louver/Grill Panel .. 4-5 HWC Chassis Assembly .[...]

  • Page 57

    4-2 COMPONENT LOCA TION ILLUSTRA TIONS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 HW/HWC123,183,243,303 FIGURE 4-1 IGNITI ON/BLOWER CONTROL BOARD (*24) UNITED TECHNOLOGIES 1097-83- 400A/1097-400-I ARMSTRONG P/N 44990-001 (DS I)* MA IN LIM IT SW ITC H (*52 ) ARMSTRONG P/N 40154B007 GAS V AL VE HONEYWELL VR8105M8202 ARMSTRONG P/N 44987-001 PRESSURE SWITCH (*5[...]

  • Page 58

    4-3 Service Reference Manual COMPONENT LOCA TION ILLUSTRA TIONS SRM-HW/HWC 2/99 HW/HWC122, 182, 242, 302 FENWAL IGNITION CONTROL - 2 MODELS (*24) FENWAL TRIT ON 2461D 900-227 - ARMSTRONG P/N 43110- 002 FENWAL 05-29 - ARMSTRONG P/N 39048B001 (SEE NOTE BELOW) FLUE BOX MAIN LIMIT SW ITCH (*5 2) INDUCED DRAFT BLOWER/ COMBUSTION BLOWER (*63) ARMSTRONG P[...]

  • Page 59

    4-4 COMPONENT LOCA TION ILLUSTRA TIONS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 SIDE P ANEL ARMSTRONG P/N 38769D001 HEA T EXCHANGER ACCESS P ANEL ARMSTRONG P/N 38782D001 TOP P ANEL ASSEMBL Y ARMSTRONG P/N 03455D007 INSPECTION WI NDOW ARMSTRONG P/N 38092A002 UPPER LOUVER P ANEL ARMSTRONG P/N 03545C000 LOWER GRILL PA N E L ARMSTRONG P/N 03551D100 DOOR HANDL[...]

  • Page 60

    4-5 Service Reference Manual COMPONENT LOCA TION ILLUSTRA TIONS SRM-HW/HWC 2/99 HW/HWC Exterior Louver/Grill Panel CONDENSER AIR FLOW OUTLET EXTERIOR UPPER LOUVER P ANEL ARMSTRONG P/N 03545C000 EXTERIOR LOWER GRILL P ANEL ARMSTRONG P/N 03551D100 CONDENSER AIR FLOW INLE T SIDE VIEW LOUVERS POINT UPWARD A T 45° ANGLE GR ILL IS F LA T WITH RECT ANGUL[...]

  • Page 61

    4-6 COMPONENT LOCA TION ILLUSTRA TIONS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 HWC Chassis Assembly EV APORA TOR BLOWER MOT OR (* 69) COMPRESSOR CONT A CTOR (*278) ARMSTRONG P/N 03575C001 CONDENSING FAN SHROUD CONDENSER F AN (*267, 268) CONDENSING COIL (* 250) CAPILLARY TUBE METERING DEVICE (* 256) FIL TER D RIER /DIST RIBU TO R (*30 1) (12) ARM STRONG P[...]

  • Page 62

    4-7 Service Reference Manual COMPONENT LOCA TION ILLUSTRA TIONS SRM-HW/HWC 2/99 SEE FIGURE 4-7 FOR CIRCULA TI NG AIR BLOWER COMPONENTS CONDENSER MO TOR (*267) (12-1 8) ARMSTRONG P/N 41282-001 (24-30) ARM STRONG P/N 41254-001 CONDENSER F AN MO TOR BRA CKET (*269) ARMSTRONG P/N 03982D004 F AN SHROUD F AN BLADE (*268) (12-1 8) ARMSTRONG P/N 39085B001 [...]

  • Page 63

    4-8 COMPONENT LOCA TION ILLUSTRA TIONS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 BLOWER WHEEL (*73) ARMSTRONG P/N 34833B001 10.75" x 4" CIRCULA TI NG AIR BLOWER MO TOR (*69) (12) ARM STRONG P/N 39045B001 (24-30) 39046B001 MO TOR M OUNTING BRACKET (*71, 72) BAND - ARMSTRONG P/N 07407B000 (1) ARMS - ARMSTRONG P/N 07408B004 (3) BLO WE R HO USIN G (*[...]

  • Page 64

    Service Reference Manual UNIT COMPONENTS 5-1 SRM-HW/HWC 2/99 Section 5 - Unit Components T ransformer ........................................ 5-3 Gas V alves ........................................... 5-4 White-Rodgers 25K49 ................................ 5-4 Honeywell 8105 ......................................... 5-5 Blower Contr ol Boards ..[...]

  • Page 65

    5-2 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 HWC Capillar y T ubes .......................... 5-35 Capacitors ......................................... 5-39 Evaporator Blower Motor ................... 5-40 Condenser Fan Motor ......................... 5-40 Capacitors-Run .................................. 5-41 Fan Blades ..................[...]

  • Page 66

    Service Reference Manual UNIT COMPONENTS 5-3 SRM-HW/HWC 2/99 Unit Components This section provides a brief description of the most impor tant compo- nents within the Magic-P ak HW/HWC units . The information presented here is not intended to take the place of the instructions and printed literature pack ed with each component b y the original manuf[...]

  • Page 67

    5-4 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Gas V alves (*7) Gas V alve Specifications Manuf acturer : White-Rodgers Model: 25K49-120 Armstrong P/N 43108-001 Dimensions: 1.97" W x 5.31" L Nominal Operating Currents: 25V A C/60Hz/.5A Regulator set at 3.50 +/– .02” W .C . at 55.6 cubic Ft./Hr of air at standard conditions (wit[...]

  • Page 68

    Service Reference Manual UNIT COMPONENTS 5-5 SRM-HW/HWC 2/99 Honeywell 8105 Series Gas V alve Specifications Manuf acturer: Hone yw ell Model: VR8105M8202 Armstrong P/N 44987-001 Dimensions: 2.70" W x 4.75" L Nominal Operating Currents: 25V AC/60Hz/.5A Regulator Setting: 3.50 +/– .3" W .C. Pipe Size: .50" Inlet x .375" Ou[...]

  • Page 69

    5-6 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Blower Contr ol Boar ds (*5) A separate blo w er control board is used in the Magic-P ak HW/HWC models that do not use integrated ignition/b lo wer control boards. Blower control boards from two diff erent manuf acturers are used in these HW and HWC units. The two b lo wer control boards are e x[...]

  • Page 70

    Service Reference Manual UNIT COMPONENTS 5-7 SRM-HW/HWC 2/99 Heatcraft Model IBC-H4C401 Blower Control Board Specifications Manuf acturer: United T echnologies Model: 1010-611 Armstrong P/N 39029B002 Operating V oltage: 18-30V AC 60 Hz 60 Hz P o w er Requirement: 4 V A max. Operating T emperature: – 40°F to +170°F Wiring Connections: All Male .[...]

  • Page 71

    5-8 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Ignition Contr ols (*24) FENW AL ® ¨ V2 GND FC- CA UTION: HIGH VO L T AGE DISCONNECT W IRING BEFORE SER VICI NG FC+ 24 VAC L1 IND V1 PSW TH Fenwal T riton 2461D Ignition Control Specifications Manuf acturer: F enwal Model: T riton 2461D Armstrong P/N 43110-002 Pre-purge: 30 seconds Ignition: 1[...]

  • Page 72

    Service Reference Manual UNIT COMPONENTS 5-9 SRM-HW/HWC 2/99 Diagnostics (Fenwal T riton 2461D) 1. Diagnostic LED flash rate is 1/4 second “ON”, 1/4 second “OFF” f ollow ed by up to f our seconds “OFF” before repeating the code . 2. Only one code is displa y ed at a time . 3. During a “STEAD Y ON” code , the LED ma y b link off mome[...]

  • Page 73

    5-10 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Fenwal 05-29 DSI G N D V2 T2 S1 V1 P. SW L1 IND FENW AL ® Seri es 05-29 DSI CAUTION HIGH VOL TAG E A UT OMATIC I GNITION SYSTEM FIGURE 5-7 Fenwal 05-29 Ignition Control Ignition Control Specifications Manuf acturer: F enwal Model: 05-29 DSI Armstrong P/N 39048B001 Relative Humidity Rating: 5 t[...]

  • Page 74

    Service Reference Manual UNIT COMPONENTS 5-11 SRM-HW/HWC 2/99 Integrated Blower/Ignition Contr ol (*24) United T echnologies Model 1097-400-1 The integrated control combines the actions and purposes of the indi- vidual ignition and blo wer control boards f ound on other units. It automati- cally monitors and controls the operation of the gas burner[...]

  • Page 75

    5-12 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 T ABLE 5-2 UT ech Model 1097 Diagnostic Flash Code United T echnologies Model 1097-400-1 (cont.) Quick Connect T erminal Descriptions 1 24V AC HO T - from T ransformer 2 GROUND = 24V AC Return 4 CMB BL WR = Comb ustion Blow er (Line V oltage) 5 L1 = Line V oltage 9 ACB COOL = Air Circulating Bl[...]

  • Page 76

    Service Reference Manual UNIT COMPONENTS 5-13 SRM-HW/HWC 2/99 United T echnologies Model 1097-400-1 (cont.) Heat Mode Pre-purge 30 seconds Inter-purge 30 seconds P ost-purge 5 seconds T rial Time 10 seconds # of T rials 3 Board to reset from lock out after 60 min utes. F an On Delay Cool 5 seconds (fixed) Heat 30 seconds (fixed) F an Off Delay Cool[...]

  • Page 77

    5-14 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Induced Draft Blower (*63) The induced draft b lo wer is also ref erred to as a “comb ustion” b lo w er , since its purpose is to establish flow of comb ustion air through the heat e xchanger . Mounted at the outlet of the secondar y heat e xchanger , the blo w er establishes a negativ e pr[...]

  • Page 78

    Service Reference Manual UNIT COMPONENTS 5-15 SRM-HW/HWC 2/99 Burners (*34) The Magic-P ak HW and HWC units co v ered in this man ual use a b urner design called the “inshot” type. No adjustment is pro vided f or primary or secondar y air . F or best operation, keep the b urners clean. Use the correct orifice size and adjust the manifold pressu[...]

  • Page 79

    5-16 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Flame Carr yover Problems During ignition, the flame must trav el uninterrupted from one burner to the rest of the burners. Causes: • Carr y o v er “wing” on bur ner is plugged with insects or debris • Improper gap setting on wings • Incorrect gas pressure The burner wing has a specif[...]

  • Page 80

    Service Reference Manual UNIT COMPONENTS 5-17 SRM-HW/HWC 2/99 Manifold Orifices (*13) Hole Diameter FIGURE 5-13 Manifold Orifice T ABLE 5-3 Manifold Orifice Specifications g n o r t s m r A N / P r e t e m a i D e l o H e z i S l l i r D r e t e m a i D e l o H ) s e h c n i ( 1 0 0 B 0 3 0 9 3k n a l Bk n a l B 2 0 0 B 0 3 0 9 31 50 7 6 0 . 3 0 0 [...]

  • Page 81

    5-18 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Contactor (*278) L1 L2 T1 T2 Open Contact Closed Contact Low V olt age Co il T er m inals FIGURE 5-14 Honeywell Contactor Model R8242A-1008 Contactor Specifications Manuf acturer: Hone ywell Model: R8242A-1008 Armstrong P/N 7535C001 Single-phase, Single-pole, 25 F .L.A., 125 L.R.A Coil: 24V AC [...]

  • Page 82

    Service Reference Manual UNIT COMPONENTS 5-19 SRM-HW/HWC 2/99 Main (High) Limit Switch (*52) A Normally Closed control that opens if abnor mally high circulating air temperatures occur . It is an automatic reset control. Note: Sev eral diff erent main limit s witches are used. Refer to the parts list for the correct limit switch. N.O . (Nor m ally [...]

  • Page 83

    5-20 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Flame Rollout Switch (*55) A Normally Closed switch that opens when abnor mal temperatures occur in the burner area, caused by a restricted heat exchanger , causing main burner flame to “roll out” into the v estib ule area. T o reset the s witch, push the b utton on top . The button is a di[...]

  • Page 84

    Service Reference Manual UNIT COMPONENTS 5-21 SRM-HW/HWC 2/99 Pr essure Switch (*57) These are Normally Open switches that react to a diff erence in pressure on an internal diaphragm. It will not allow ignition to start if the induced draft blo w er cannot produce sufficient negativ e pressure relativ e to atmospheric pressure or pressure in a seal[...]

  • Page 85

    5-22 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 T ABLE 5-4 Pressur e Switches Pressur e Switch Problems The negative pressure de v eloped in the comb ustion chamber is directly related to airflow . During furnace operation, the switch will react to conditions that reduce airflow , such as: b loc k ed or restricted intake (combustion air pipi[...]

  • Page 86

    Service Reference Manual UNIT COMPONENTS 5-23 SRM-HW/HWC 2/99 Blocked Intake Block ed intak e is any condition that b loc ks or restricts the flow of intake (combustion) air to a point where the pressure f all reaches the calibrated open setting of the pressure s witch. P otential Causes: • Rodents • Spiders • Nest building in the intak e ope[...]

  • Page 87

    5-24 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Blocked Flue Block ed flue is an y condition that b loc ks or restricts the flue (vent) pipe to a point where the pressure f all reaches the calibr ated open setting of the pressure switch. P otential Causes: • Rodents • Spiders • Nest building in the flue pipe • Outlet screens with exc[...]

  • Page 88

    Service Reference Manual UNIT COMPONENTS 5-25 SRM-HW/HWC 2/99 What Is Needed for the T ests • A good general-purpose incline manometer with a range of 0 - 3" W .C . (Dwyer 1227 or equivalent). • Use the par ts list to v erify that the proper pressure s witch is installed in the unit. Look for the Armstrong par t number stamped on the metal[...]

  • Page 89

    5-26 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 A Wor d About the “Switch Closed” V al ue Switch Closed is the pressure at which the contacts close as the induced draft blo w er 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. F or e xample , f or a Armstr[...]

  • Page 90

    Service Reference Manual UNIT COMPONENTS 5-27 SRM-HW/HWC 2/99 0 -1" 1" 2" 3" Pressure Swit ch 1/8" T ee Induced Draft Bl o w er BA Incli ne M anom eter = T ee install ed f or test pur poses only FIGURE 5-20 Incline Manometer Connection[...]

  • Page 91

    5-28 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Compr essors (*262) 1 2 3 4 5 6 7 8 9 10 11 12 T ABLE 5-5 Compressor Specifications (continued on next page) l e d o Me p y T r o s s e r p m o C r o s s e r p m o C l e d o M M / B ) y l n O h e s m u c e T ( g n o r t s m r A N / P 1 - 3 2 1 C W H ) l l A (y r a t o R h e s m u c e TD X E 2 1[...]

  • Page 92

    Service Reference Manual UNIT COMPONENTS 5-29 SRM-HW/HWC 2/99 1 2 3 4 5 6 7 8 9 10 11 12 e g a t l o Ve s a h PA L RA R L n u R . p a C g n o r t s m r A N / P g n i d n i W R / S . s e R e p y T l i O l i O e g r a h C n o i t c u S e n i L e g r a h c s i D e n i L 0 3 2 / 8 0 21 3 . 6 20 7 3 / 5 22 0 0 D 4 1 5 8 3A / Ny t i s o c s i V 0 0 2 l a[...]

  • Page 93

    5-30 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 A B C D I.D . Copper T ube .(43 - .50 " Suction " Deep) .315 I.D .Copper T ube " Discharge .75 Dia m eter H o le s " C S R Manufactur er: T ecumseh All measurements in inches unless otherwise specified. Side View T op View T ABLE 5-6 T ecumseh Rotary Compressor Specification[...]

  • Page 94

    Service Reference Manual UNIT COMPONENTS 5-31 SRM-HW/HWC 2/99 T ABLE 5-7 T ecumseh Reciprocating Compressor Specifications Manufacturer: T ecumseh .753"/. 756" I.D . Copper T ube Suction 12.647" 12.753” .378"/. 381" I.D . Copper T ube Discharge 7.475" 7.525" (Between Centers of Holes) .750 /.760 Diameter (4 Ho l[...]

  • Page 95

    5-32 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Manufactur er: Copeland A B CD .500" I. D . Copper T ube Dischar ge .750" I. D . Copper -Plated Steel T ube Suction 18 Ga. Ther mal Protect or Leads (12.13" Long) 7.50 " (Between Centers of Holes) .765 Diameter (4 Holes) " FIGURE 5-23 Copeland Compressor Side View C R S[...]

  • Page 96

    Service Reference Manual UNIT COMPONENTS 5-33 SRM-HW/HWC 2/99 Manufacturer: Copeland C S R T 1 T 3 T 2 9.41 /9.62 "" 7.50 " (T yp.) 7.50 " (T yp.) .750 Dia. (4 Ho le s ) " A B C D .500" I. D . Copper Discharge Fit ting .750" I. D . Copper- Plated Steel Suct ion Fitti ng E FIGURE 5-24 Copeland Compressor Side View [...]

  • Page 97

    5-34 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Drier -Filters (*301) .314" .317" 4.38" +/– . 13" 1.00 " B - # Holes A - I.D . I.D . FIGURE 5-25 Drier -Filter Armstrong P art Number 39059B001 39059B002 39059B003 A B .108" .111" .114" .117" .108" .111" 2 3 4 T ABLE 5-10 Drier -Filter Sp[...]

  • Page 98

    Service Reference Manual UNIT COMPONENTS 5-35 SRM-HW/HWC 2/99 HWC Capillar y T ubes (*256) * All par t numbers pro vided are Armstrong par t numbers. ** See page 5-34 f or drier information. *** See the figures beginning on page 5-36 for detailed dr awings of the capillary tubes. T ABLE 5-11 HWC Capillary T ube Specification T ables* s l e d o Mr e[...]

  • Page 99

    5-36 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 30° .75" .25" Rad. I.S. T yp . .13" .08" 3.81" Ref. 6.00" 11.89" Ref. 14.00" 1.00 Rad. T yp . " 5302B001 - 2 Req’d 14.88" 12.77" Ref. 1.78" .73" Ref. 3.500 Diameter 1T u r n 2.875 Diameter Mandrel " " 30° .75" .[...]

  • Page 100

    Service Reference Manual UNIT COMPONENTS 5-37 SRM-HW/HWC 2/99 30° 4.25" Ref. 6.16" .13" T yp. .12" T yp. 13.13" Ref. 14.74" 3.500" Diameter 1T u r n 3.00" Mandrel 11.00" Ref. 12.91" .25" Rad. I.S. T yp. 53025B025 - 2 Req’d .75" T yp. .75" Rad. T yp . 10.70 " 1.446 Diameter &qu[...]

  • Page 101

    5-38 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 A - Diameter B - T urns 4.64" 6.76" .75" 1.25" C - D Req’d .75" 2.79" .13" .25" Rad. I.S. T yp. .08" 30° 5.42" 2.844" Diameter 3 T ur ns 53205B025 - 2 Req’d 7.00" 3.30" 7.43" 2.50" .75" Rad. T yp. 1.55" .7[...]

  • Page 102

    Service Reference Manual UNIT COMPONENTS 5-39 SRM-HW/HWC 2/99 Capacitors (*271) FIGURE 5-36 Capacitors Dual Single Armstrong P/N Rating V olts MFD T ABLE 5-13 Capacitor Ratings 1 0 0 D 4 1 5 8 35 / 0 20 7 3 2 0 0 D 4 1 5 8 35 / 5 20 7 3 3 0 0 D 4 1 5 8 35 / 0 30 7 3 4 0 0 D 4 1 5 8 35 / 5 30 7 3 5 0 0 D 4 1 5 8 35 / 0 40 7 3 6 0 0 D 4 1 5 8 35 / 0 [...]

  • Page 103

    5-40 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Evaporator Blower Motor - Indoor Blower (*69) • FLA and capacitor ratings ma y v ary . Alw a ys chec k FLA and capacitor ratings on the motor data plate . • Motor diameter - 5.70", shaft size - .50", rotatin - CW lead end • See par ts list f or correct selection of motor and cap[...]

  • Page 104

    Service Reference Manual UNIT COMPONENTS 5-41 SRM-HW/HWC 2/99 Capacitors-Run (*86) Armstrong P/N Rating V olts MFD T ABLE 5-16 Run Capacitor Ratings 1 0 0 D 1 0 0 4 34 0 7 3 2 0 0 D 1 0 0 4 35 0 7 3 3 0 0 D 1 0 0 4 36 0 7 3 4 0 0 D 1 0 0 4 35 . 70 7 3 5 0 0 D 1 0 0 4 38 0 7 3 6 0 0 D 1 0 0 4 38 0 4 4 7 0 0 D 1 0 0 4 30 10 7 3 8 0 0 D 1 0 0 4 35 . 2[...]

  • Page 105

    5-42 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Fan Blades (*268) 18.00 +/ .06 " " AIR FLO W Rota tion Diameter Bore .5002" .5019" 3.79 +/ .09 " " Notes: 1. 26° Pitch, 5 Blades 2. Material: 24 Ga. Galvalume 3. Set Screw: (2) 5/16"-24 x 5/8" long square head, cup point FIGURE 5-37 F an Blades - H[...]

  • Page 106

    Service Reference Manual UNIT COMPONENTS 5-43 SRM-HW/HWC 2/99 18.00 +/ .06 " " AIR FLO W Rota tion Diameter Bore .5002" .5019" 3.59 +/ .09 " " Notes: 1. 24° Pitch, 3 Blades 2. Mater ial: 24 Ga. Galv alume 3. Set Screw: (2) 5/16"-24 x 5/8" long square head, cup point FIGURE 5-38 F an Blades - HWC Models[...]

  • Page 107

    5-44 UNIT COMPONENTS Magic-Pak: HW/HWC SRM-HW/HWC 2/99 Low er Grill P anel Ar mstrong P/N 03551D100 Upper Louver P anel Ar mstrong P/N 03545C000 Exterior Grill Panels (Not Listed in the Par ts Lists) Ref er to the Component Location Illustrations section beginning on page 4-1 f or fur ther detail of the e xterior grill panels and other panels. FIGU[...]

  • Page 108

    Service Refer ence Manual INST ALLA TION 6-1 SRM-HW/HWC 8/99 Section 6 - Installation Location .............................................. 6-3 Installing W ith W all Sleeve .................... 6-5 Installing W ithout Wall Sleeve ............... 6-6 Suppor t ............................................... 6-6 Condensate Drain ...................[...]

  • Page 109

    6-2 INST ALLA TION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Installation and Operation in Extr emely Cold Weather Areas ........................... 6-15[...]

  • Page 110

    Service Refer ence Manual INST ALLA TION 6-3 SRM-HW/HWC 8/99 Installation Inf ormation in this section is provided f or the con v enience of the service technician, for the purpose of ev aluating the installation during ser vice and troubleshooting. It does not take the place of the complete Arm- strong Installation and Maintenance Instructions tha[...]

  • Page 111

    6-4 INST ALLA TION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 If three or more adjacent walls f orm an air shaft with Magic-P ak HW/HWC units facing each other in each w all, the separ ation between opposite walls should be increased b y 20%. These “rule-of-thumb” dimensions are intended to minimiz e possibilities f or recirculation of condenser air , o[...]

  • Page 112

    Service Refer ence Manual INST ALLA TION 6-5 SRM-HW/HWC 8/99 Installing W ith a Wall Sleeve FIGURE 6-1 HW/HWC Installation Ref er to the installation instructions pack ed with the wall slee v e and Figure 6-1 for guidance in assemb ly and mounting using a w all slee v e . See also the Accessories section beginning on page 7-3 for fur ther details o[...]

  • Page 113

    6-6 INST ALLA TION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Installing W ithout a Wall Sleeve Ref er to the f o llowing directions and Figure 6-1 on page 6-5 f or guidance in installing the unit without a wall slee v e: 1. Measure the size of the unit and provide an opening in an outside wall that will accept the unit. Local ordinances ma y require a stee[...]

  • Page 114

    Service Refer ence Manual INST ALLA TION 6-7 SRM-HW/HWC 8/99 Condensate Drain (HWC Models) Install the plastic drain tube (furnished) ov er the 5/8" O .D . fitting w elded to the center of the condensate pan. Connect the other end of the drain tube to the open trap (see Figure 6-2). The plastic drain connection is provided so that it ma y be d[...]

  • Page 115

    6-8 INST ALLA TION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 The vent system m ust also terminate at least 3 feet abo v e any f orced 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 b uilding. Clearance to windo ws applies to openab le window[...]

  • Page 116

    Service Refer ence Manual INST ALLA TION 6-9 SRM-HW/HWC 8/99 Removal of Unit fr om Common V enting System When an e xisting furnace is remov ed from a common v enting system serving other appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. The f ollo wing test should be conducted with each ap[...]

  • Page 117

    6-10 INST ALLA TION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Low NO I nser t x FIGURE 6-4 NO x Insert Removal Ne v er use a flame to check f or gas leaks. Explosion causing injury or death may occur . W ARNING Units f or oper ation with propane must be con v er ted with a kit supplied b y the manuf acturer and require f or operation an inlet pressure of 1[...]

  • Page 118

    Service Refer ence Manual INST ALLA TION 6-11 SRM-HW/HWC 8/99 Electrical Connections All wiring must be done in accordance with the National Electrical Code, ANSI/NFP A No. 70 (latest edition); Canadian Electrical Code P art 1, CSA C22.1 (latest edition); or local codes, where they prevail. Any alter ation of internal wiring will void certification[...]

  • Page 119

    6-12 INST ALLA TION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 T ABLE 6-3 Minimum Cir cuit Ampacity See T able 6-3 and the Specifications section beginning on page 1-1 f or correct wire ampacity f or the cooling chassis required, and siz e the wire accordingly . F or HW (heating only units): When sizing wire , keep in mind that an air conditioning chassis m[...]

  • Page 120

    Service Refer ence Manual INST ALLA TION 6-13 SRM-HW/HWC 8/99 inside the unit. Make sure that all sides of the duct are flanged ov er to permit removal of the cooling chassis if required. Use a flexib le connec- tion to attach the remainder of the return duct. The retur n duct should be sealed to the unit casing and terminate outside the space cont[...]

  • Page 121

    6-14 INST ALLA TION Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Adjustments - Cooling Section (HWC models) No adjustments are required or should be attempted regarding any of the components of the cooling chassis. The chassis should be chec k ed to see that none of the wiring is loose or missing. Blower The unit contains a direct-drive , multispeed b lower .[...]

  • Page 122

    Service Refer ence Manual INST ALLA TION 6-15 SRM-HW/HWC 8/99 Installation and Operation in Extr emely Cold W eather Ar eas In areas where e xtremely cold (below – 20°F) outdoor temper atures can be e xpected, some additional installation and operating precautions should be taken. The f o llo wing precautions are taken to pre v ent possib le ven[...]

  • Page 123

    Service Refer ence Manual ACCESSORIES 7-1 SRM-HW/HWC 8/99 Section 7 - Accessories HW/HWC Accessor y Kit Index .............. 7-2 CA-239 Wall Sleeve Kit ................................... 7-3 A242-1 Wall Sleeve Adaptor Kit ...................... 7-7 AL VR42 Architectural Louver Facade ............. 7-10 34961A001 V ibration Isolator ...............[...]

  • Page 124

    7-2 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Accessories There are a number of accessories av ailable to increase the perf ormance or versatility of the Armstrong Magic-P ak 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 instruct[...]

  • Page 125

    Service Refer ence Manual ACCESSORIES 7-3 SRM-HW/HWC 8/99 CA-239 Wall Sleeve Kit The CA-239 wall slee v e kit is designed to f acilitate the installation of Magic-P ak units b y providing an accurate opening to properly accept a Magic-P ak unit. Dur ing the construction of a building, the w all slee ve allows f or the unit to remain off-site until [...]

  • Page 126

    7-4 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 T op P anel F ront of Sleev e Suppor t Angle - 8 H oles Squari ng Braces Left Si de P anel Bottom P anel Suppor t Angle - 2 Sides FIGURE 7-1 CA-239 W all Sleeve Kit Assembly T ABLE 7-2 CA-239 P arts List Assembled Wall Slee v e Dimensions: 45" high x 29" wide x 12.5" deep n o i t p i [...]

  • Page 127

    Service Refer ence Manual ACCESSORIES 7-5 SRM-HW/HWC 8/99 Wall Sleeve Installation The wall slee v e can be installed from either the inside or the outside of the building. In any case , proper considerations must be made f or final weather sealing of the w all slee ve and the Magic-P ak unit. Whether installing from the inside or outside of a buil[...]

  • Page 128

    7-6 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Magic-Pak Installation Before installing the Magic-P ak unit in the wall slee v e, it is impor tant to consider the possibility of sound and vibration transmission through the wall. It is recommended that vibration isolation pads be installed e venly spaced across the outer edge of the bottom panel [...]

  • Page 129

    Service Refer ence Manual ACCESSORIES 7-7 SRM-HW/HWC 8/99 A242-1 Wall Sleeve Adaptor Kit The A242-1 wall slee v e adaptor kit is designed to allow f or the installation of current 43" tall HW/HWC units into 48" tall wall slee v es (CA241 wall sleev e kits). The CA241 wall slee v e kits were designed f or use with HW/ HWC121, 181, 241 and [...]

  • Page 130

    7-8 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Attachment to HW/HWC After assembling the kit, it is ready to be attached to the top of the HW/ HWC unit. T o attach the kit to the HW/HWC unit: 1. Remov e the two front scre ws (each side) that f asten the top panel side flanges to the side panels on each side of the HW/HWC unit. 2. Place the adapt[...]

  • Page 131

    Service Refer ence Manual ACCESSORIES 7-9 SRM-HW/HWC 8/99 (2) #8 x ½" Sc rew s in each rear cor ner (2) #8 x ½" Sc rew s in each side Right Si de F ront 1/4" x ¾" Screw ¼" Flat W asher HW/HWC Unit Rear Left Si de Screws that are remov ed and reinser ted t o attach adapter kit to HW/HWC unit ( both sides) FIGURE 7-2 A242[...]

  • Page 132

    7-10 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 AL VR42 Ar chitectural Aluminum Louver Facade In many applications, architects and installers will choose to use f acades ov er the front of Magic-P ak units. Often this is done to improv e the appearance of a b uilding. Properly constructed louver f acades ma y also provide some degree of w eather[...]

  • Page 133

    Service Refer ence Manual ACCESSORIES 7-11 SRM-HW/HWC 8/99 The louver will fit directly against the front of the unit. Howe v er , the lo wer lip of the unit will protrude into the louver . The louv er must be positioned to accommodate the protruding lower lip . The louver must be caulk sealed on all f our sides and field-supplied flashing should b[...]

  • Page 134

    7-12 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 34961A001 Compr essor Vibration Isolator Kit The 34961A001 spring/grommet kit is designed to isolate vibrations common to most compressors aw a y from the base of Magic-P ak units and building w alls. Some types of wall construction will be especially susceptible to vibration transmissions. In thes[...]

  • Page 135

    Service Refer ence Manual ACCESSORIES 7-13 SRM-HW/HWC 8/99 Use of spra y lubricant or liquid soap will aid in the installation of rubber par ts . Compressor belly is rounded and can be “roc k ed” on the belly suppor t. It is easiest to install one spring grommet at a time. Star t with the most difficult to access compressor mounting leg and wor[...]

  • Page 136

    7-14 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 ALPKT389-2 L.P . Gas Conversion Kit The ALPKT389-2 kit contains the follo wing par ts to con vert the 26, 38, 51 and 64HW/HWC series gas fur nace from natural gas to propane gas. For altitudes from 2000 - 4500 feet, a high altitude kit as supplied b y the manuf acturer must be used (see page 7-15).[...]

  • Page 137

    Service Refer ence Manual ACCESSORIES 7-15 SRM-HW/HWC 8/99 AHAL T390-1 High Altitude Kit The AHAL T390-1 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 conv ersion is f or high altitude propane gas, be sure to install the appropriate gas valv e conv ersi[...]

  • Page 138

    7-16 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 x 3600 x = Cubic Feet Per Revolution BTU/HR INPUT # Seconds Per Revolution Heating V alue The heating value of y our gas can be obtained from y our local utility . With proper manifold pressure achie v ed, cycle main burners on and off . Ignition and extinction should be smooth and quiet. Bur ning [...]

  • Page 139

    Service Refer ence Manual ACCESSORIES 7-17 SRM-HW/HWC 8/99 A TIMR466-1 Shor t Cycle Pr otector Kit The A TIMR466-1 Shor t Cycle Protector Kit helps guard against compres- sor f ailure due to repeated, shor t inter v al on/off cycles . It is also ref erred to as the Nuisance Blow er Operation Repair Kit. The kit is designed to be used in conjunction[...]

  • Page 140

    7-18 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 ADAPT420-2 Chassis Conversion Kit The AD APT420-2 kit w as designed to retrofit an HWC122, 182, 242 or 302 chassis onto a cabinet originally equipped with an HWC12, 18, 24 or 30 chassis. This kit cannot be used to replace an HWC181, 241 or 301. When replacing the old chassis, the new chassis must h[...]

  • Page 141

    Service Refer ence Manual ACCESSORIES 7-19 SRM-HW/HWC 8/99 Fenwal T riton Ignition Contr ol Kit This kit enables the F enw al “T riton” local sense, one-hour retry , direct spark ignition (DSI) control to be used as a ser vice par ts replacement f or earlier versions of F enwal DSI controls used on HW/HWC models . The operation and f eatures of[...]

  • Page 142

    7-20 ACCESSORIES Magic-Pak: HW/HWC SRM-HW/HWC 8/99 TL109 Burner T ray Kit The TL109 Burner T ray Kit is designed f or use in HW/HWC’ s that were originally equipped with single por t inshot burners. F our kits are a v ailable , one for each natur al gas heating input rating as f ollows: • 26,000 BTUH (3 main bu r ners) • 38,000 BTUH (4 main b[...]

  • Page 143

    Service Refer ence Manual ACCESSORIES 7-21 SRM-HW/HWC 8/99 Discharge Mu ffler Discharge Line t o Condenser Coil FIGURE 7-6 AMUFFKT494-1 Kit Discharge Muffler Installation AMUFFKT494-1 Dischar ge Muffler Kit In the ev ent that during operation an unacceptab le noise occurs, a muffler kit (AMUFFKT494-1) ma y be installed in the discharge line*. The c[...]

  • Page 144

    8-1 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS Section 8 - Par ts Lists HWC123, 183, 243, 303-1 .................. 8-2 HWC182, 242-11 ................................ 8-5 HWC122, 242-10 ................................ 8-7 HWC182-9 ........................................ 8-10 HWC242, 302-9 ................................ 8-12 HWC122, 1[...]

  • Page 145

    8-2 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC303A-1 A First find Model #. ------------------------------------------------ > 64HWC303A-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51HWC183A-1 (*)[...]

  • Page 146

    8-3 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC303A-1 A First find Model #. ------------------------------------------------ > 64HWC303A-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51HWC183A-1[...]

  • Page 147

    8-4 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC303A-1 A First find Model #. ------------------------------------------------ > 64HWC303A-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51HWC183A-1 (*)[...]

  • Page 148

    8-5 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Level. 38HWC242A-11 A First find Model #. -------------------------------------------------------------- > 38HWC242A-11 (*) Then match Ser vice Le v el f or desired part . --------------------[...]

  • Page 149

    8-6 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Level. 38HWC242A-11 A First find Model #. -------------------------------------------------------------- > 38HWC242A-11 (*) Then match Ser vice Le v el f or desired par t. --------------------------[...]

  • Page 150

    8-7 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS HWC122-242A-10 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 38HWC242A-10 A First find Model #. -------------------------------------------------------------- > 38HWC242A-10 (*) Then match Ser vice Le v el f or desired part . --------------------[...]

  • Page 151

    8-8 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 HWC122-242A-10 (cont.) REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Level. 38HWC242A-10 A First find Model #. -------------------------------------------------------------- > 38HWC242A-10 (*) Then match Ser vice Le v el f or desired part . -------------------[...]

  • Page 152

    8-9 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS HWC122-242A-10 (cont.) REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 38HWC242A-10 A First find Model #. -------------------------------------------------------------- > 38HWC242A-10 (*) Then match Ser vice Le v el f or desired par t. ----------[...]

  • Page 153

    8-10 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC182A-9 A First find Model #. -------------------------------------------------------------- > 64HWC182A-9 (*) Then match Ser vice Le v el f or desired part . --------------------------[...]

  • Page 154

    8-11 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Level. 64HWC182A-9 A First find Model #. -------------------------------------------------------------- > 64HWC182A-9 (*) Then match Ser vice Le v el f or desired part . ---------------------[...]

  • Page 155

    8-12 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC302A-9 A First find Model #. -------------------------------------------------------------- > 64HWC302A-9 (*) Then match Ser vice Le v el f or desired part . --------------------------[...]

  • Page 156

    8-13 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC302A-9 A First find Model #. -------------------------------------------------------------- > 64HWC302A-9 (*) Then match Ser vice Le v el f or desired part . --------------------[...]

  • Page 157

    8-14 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC302-8 A First find Model #. ------------------------------------------------ > 64HWC302-8 (*) Then match Ser vice Le v el f or desired par t. ---------------- > SERVICE LEVEL = * [...]

  • Page 158

    8-15 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC302-8 A First find Model #. ------------------------------------------------ > 64HWC302-8 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVE[...]

  • Page 159

    8-16 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC302-8 A First find Model #. ------------------------------------------------ > 64HWC302-8 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * [...]

  • Page 160

    8-17 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC182-6 A First find Model #. -------------------------------------------------------------- > 64HWC182-6 (*) Then match Ser vice Le v el f or desired part . --------------------[...]

  • Page 161

    8-18 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC182-6 A First find Model #. -------------------------------------------------------------- > 64HWC182-6 (*) Then match Ser vice Le v el f or desired part . ----------------------------[...]

  • Page 162

    8-19 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC302-5 A First find Model #. ------------------------------------------------ > 64HWC302-5 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVE[...]

  • Page 163

    8-20 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC302-5 A First find Model #. ------------------------------------------------ > 64HWC302-5 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51[...]

  • Page 164

    8-21 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC302-5 A First find Model #. ------------------------------------------------ > 64HWC302-5 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVE[...]

  • Page 165

    8-22 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 38HWC182-4 A First find Model #. -------------------------------------------------------------- > 38HWC182-4 (*) Then match Ser vice Le v el f or desired part . ----------------------------[...]

  • Page 166

    8-23 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Level. 38HWC182-4 A First find Model #. -------------------------------------------------------------- > 38HWC182-4 (*) Then match Ser vice Le v el f or desired par t. -----------------------[...]

  • Page 167

    8-24 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 38HWC182-4 A First find Model #. -------------------------------------------------------------- > 38HWC182-4 (*) Then match Ser vice Le v el f or desired part . ----------------------------[...]

  • Page 168

    8-25 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC302-3 A First find Model #. ------------------------------------------------ > 64HWC302-3 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVE[...]

  • Page 169

    8-26 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC302-3 A First find Model #. ------------------------------------------------ > 64HWC302-3 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * [...]

  • Page 170

    8-27 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC302-3 A First find Model #. ------------------------------------------------ > 64HWC302-3 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL [...]

  • Page 171

    8-28 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC182-2 A First find Model #. -------------------------------------------------------------- > 64HWC182-2 (*) Then match Ser vice Le v el f or desired part . ----------------------------[...]

  • Page 172

    8-29 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Level. 64HWC182-2 A First find Model #. -------------------------------------------------------------- > 64HWC182-2 (*) Then match Ser vice Le v el f or desired par t. -----------------------[...]

  • Page 173

    8-30 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC302-1 A First find Model #. ------------------------------------------------ > 64HWC302-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51HWC182-1 (*) 6[...]

  • Page 174

    8-31 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC302-1 A First find Model #. ------------------------------------------------ > 64HWC302-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL [...]

  • Page 175

    8-32 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC302-1 A First find Model #. ------------------------------------------------ > 64HWC302-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51HWC182-1 (*) 6[...]

  • Page 176

    8-33 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REVISED 1-20-98 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HW -1 A First find Model #. -------------------------------------------------------------- > 64HW -1 (*) Then match Ser vice Le v el f or desired part . ----------------------------[...]

  • Page 177

    8-34 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REVISED 1-20-98 HW -1 (cont.) REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HW -1 A First find Model #. -------------------------------------------------------------- > 64HW -1 (*) Then match Ser vice Le v el f or desired part . ------------------[...]

  • Page 178

    8-35 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS HW A-9 REVISED 4-26-99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Level. 64HW A-9 A First find Model #. -------------------------------------------------------------- > 64HW A-9 (*) Then match Ser vice Le v el f or desired part . --------------------[...]

  • Page 179

    8-36 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 HW A-9 (cont.) REVISED 4-26-99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Level. 64HW A-9 A First find Model #. -------------------------------------------------------------- > 64HW A-9 (*) Then match Ser vice Le v el f or desired part . ------------------[...]

  • Page 180

    8-37 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS HWC3-S-1 REVISED 4-26-99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC303SA-1 A First find Model #. ------------------------------------------------ > 64HWC303SA-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > S[...]

  • Page 181

    8-38 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC303SA-1 A First find Model #. ------------------------------------------------ > 64HWC303SA-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51HWC183SA-1 ([...]

  • Page 182

    8-39 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC303SA-1 A First find Model #. ------------------------------------------------ > 64HWC303SA-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51HWC183[...]

  • Page 183

    8-40 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 HWC3-H-1 REVISED 4-26-99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC303HA-1 A First find Model #. ------------------------------------------------ > 64HWC303HA-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE[...]

  • Page 184

    8-41 SRM-HW/HWC 8/99 Service Reference Manual P ARTS LISTS REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Service Lev el. 64HWC303HA-1 A First find Model #. ------------------------------------------------ > 64HWC303HA-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51HWC183[...]

  • Page 185

    8-42 P ARTS LISTS MAGIC-P AK: HW/HWC SRM-HW/HWC 8/99 REC STOCKING P ART T O SELECT P AR T # Last letter of the Model # is the Ser vice Le v el. 64HWC303HA-1 A First find Model #. ------------------------------------------------ > 64HWC303HA-1 (*) Then match Ser vice Le v el f or desired part . ---------------- > SERVICE LEVEL = * 51HWC183HA-1[...]

  • Page 186

    Service Refer ence Manual TROUBLESHOOTING 9-1 SRM-HW/HWC 8/99 Section 9 - T r oubleshooting/ Per for mance/ Char ge W eights T roubleshooting ................................... 9-2 Compr essor Checkout ................................ 9-2 Capacitor Checkout .................................... 9-6 Per formance .....................................[...]

  • Page 187

    9-2 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 T r oubleshooting Compr essor Checkout The objective of this section is to help in diagnosing compressor prob- lems. It presents a ser ies of tests that should be conducting bef ore a determination on the condition of the compressor is made. This section has been organized so that the simplest c[...]

  • Page 188

    Service Refer ence Manual TROUBLESHOOTING 9-3 SRM-HW/HWC 8/99 2. Set an ohm meter to the low est possib le setting. On a note pad, write the follo wing: “C to ground”, “S to g round” and “R to ground. ” 3. Using the ohm meter , chec k f or continuity betw een C terminal on the fusite plug and the case of the compressor (a spot may ha v [...]

  • Page 189

    9-4 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 When the resistance of “C to S” is added to the resistance of “C to R”, the combination is the total resistance of the entire motor windings circuit. 2. Compare the total to the reading tak en between “S to R. ” If the windings are in good condition, the sum of “C to S” and “C [...]

  • Page 190

    Service Refer ence Manual TROUBLESHOOTING 9-5 SRM-HW/HWC 8/99 ov erload protector has opened. Before the compressor can be con- demned as having a b urned out star t or run winding, it must be deter- mined that the ov erload switch is in f act closed. It may tak e se veral hours f or the compressor to cool do wn enough to guarantee that the s witch[...]

  • Page 191

    9-6 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Capacitor Checkout Before starting the check out of the capacitor , it is impor tant to understand what a capacitor is, how it w orks 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 giv e up its e[...]

  • Page 192

    Service Refer ence Manual TROUBLESHOOTING 9-7 SRM-HW/HWC 8/99 The f ollowing inf or mation is f ound on a capacitor: the MFD (microf ar ad rating) and the working voltage . Compare this to the rating plate on the motor or the inf ormation provided with the unit. The fo llowing are some of the prob lems that could be caused b y a def ectiv e or inco[...]

  • Page 193

    9-8 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Before starting the test, take a reading of the line v oltage at the outlet that will be used. Double chec k the connections , making sure that the amp meter is on. Plug the test leads into the wall outlet. W ait a f e w seconds and read the amp meter ( CAUTION: there is only appro ximately ten [...]

  • Page 194

    Service Refer ence Manual TROUBLESHOOTING 9-9 SRM-HW/HWC 8/99 Per formance Per formance Checkout HW/HWC chassis come with a pre-charged chassis assembly . The chassis assembly is designed in a w a y that the unit ma y be run indepen- dently of the HWC unit. When the chassis is run on a floor or bench, the perf ormance measurements will be affected [...]

  • Page 195

    9-10 TROUBLESHOOTING Magic-Pak: HW/HWC SRM-HW/HWC 8/99 Perfor mance T ests (Chassis Installed in Unit) - cont. T otal Air V ol. (CFM) Enter . DB/WB Suction Pressure Suction Te m p . Liquid Te m p . Suction Pressure Suction Te m p . Liquid Te m p . Suction Pressure Suction Te m p . Liquid Te m p . Suction Pressure Suction Te m p . Liquid Te m p . Ou[...]

  • Page 196

    Service Refer ence Manual TROUBLESHOOTING 9-11 SRM-HW/HWC 8/99 Perfor mance T ests (Chassis Bench T ested) T ABLE 9-6 95° Ambient T emperature Chassis Bench T est T ABLE 9-5 70 - 80° Ambient T emperature Chassis Bench T est s i s s a h C l e d o M t n e i b m A . p m e T B W / B D . h c s i D e r u s s e r P . h c s i D . p m e T d i u q i L e r [...]