Armstrong World Industries HWC PREMIER 302, HWC PREMIER 123, HWC PREMIER 183, HWC PREMIER 243, HWC PREMIER 203 User Manual

...

Service Reference Manual

HWC Thru-the-Wall Units

Models:

HWC Premier 122, 182, 242, 302 123, 183, 243, 303

Armstrong Air Conditioning Inc.

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 Armstrong Air Conditioning Inc., 421 Monroe Street, Bellevue, Ohio USA 44811. Telephone: 419483-4840 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 notice. Armstrong Air Conditioning 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 information in this manual. For the most current information, please contact the Ar mstrong Customer Service Department.

This document is confidential. All information within is the sole property of Armstrong Air Conditioning 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 necessary to safely install, repair, adjust and maintain the Magic-Pak units and components described within.

SRM-HW/HWC 8/99

Service Reference Manual TABLE OF CONTENTS

1 - Specifications

2 - Sequence of Operations

3 - Unit Tear Down

4 - Component Location Illustrations

5 - Unit Components

6 - Installation

7 - Accessories

8 - Parts Lists

9 - Troubleshooting/Performance/

Charge Weights

Go to: If you need information on:

Section 1 Perf ormance, electrical data and cabinet dimensions. Section 2 Sequence of operation descriptions with accompanying schematics. Section 3 Complete description of unit disassembly . Section 4 Locations of major components of HW/HWC models. Section 5 Illustrations and specifications for individual components including valv es ,

blowers, ignition controls and b lo wer control boards .

SRM-HW/HWC 8/99

Section 6 Installation requirements and startup guidelines. Section 7 Complete listing of all Armstrong accessories available, including wall

sleeves, louvers and gas conversion kits. Section 8 Complete service parts lists for all HW and HWC models. Section 9 System check and troubleshooting procedures .

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

HW/HWC ............................................ 1-4

Physical and Electrical ................................ 1-4

Performance Ratings .................................. 1-4

Blower Performance ................................... 1-6

Dimensions ................................................ 1-6

Wall Sleeve................................................ 1-7

1-1

SRM-HW/HWC 8/99

SPECIFICATIONS Magic-Pak: HW/HWC

1-2

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 64HW

Model Number Guide

HW/HWC Models

26 H W C 12 2 -- 2A

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) A = Month (see list below) 12345 = Sequential Number

A = Jan B = Feb C = Mar D = Apr E = May F = June G = July H = Aug J = Sept K = Oct L = Nov M = Dec

SRM-HW/HWC 8/99

Service Reference Manual SPECIFICATIONS

Summary of Model Revisions/Variations

Table 1-1 Heating Configurations of HW/HWC Units

1-3

ledoMnoitarugifnoCEUFAlortnoCrewolB/noitingI

1-)303,342,381,321(CWH)llA(

9-WH)llA(ylnOtaeHsaG087901lortnoCrewolB/noitingInoitanibmoChceTUISD

)203,242,281,221(CWH)llA(

5-,6-,7-,8-,9-,01-,11-

)203,242,281,221(CWH)llA(

1-,2-,3-,4-

/taeHsaG

087901lortnoCrewolB/noitingInoitanibmoChceTUISD

looCcirtcelE

Table 1-2 Cooling Configurations of HWC Units

ledoMnoitarugifnoCegannoTREES*epyTrosserpmoCeciveDgnireteM

1-321CWH)llA(looCcirtcelE/taeHsaG17.9yratoRhesmuceTreirDretliF/ebuTyrallipaC

1-381CWH)llA(looCcirtcelE/taeHsaG5.17.9

noitingI

epyT

D1642notirTlawneF:lortnoCnoitingI

,104C4HCBItfarctaeH:lortnoCrewolB

0101hceTUro8400B029atledirT

92-50lawneF:lortnoCnoitingI

,104C4HCBItfarctaeH:lortnoCrewolB

0101hceTUro8400B029atledirT

hesmuceT

gnitacorpiceR

ISD

reirDretliF/ebuTyrallipaC

1-342CWH)llA(looCcirtcelE/taeHsaG27.9llorcSdnalepoCreirDretliF/ebuTyrallipaC 1-303CWH)llA(looCcirtcelEtaeHsaG5.27.9llorcSdnalepoCreirDretliF/ebuTyrallipaC

-,11-281CWH)llA(

6-,7-,9

9-,11-242CWH)llA(looCcirtcelE/taeHsaG27.9llorcSdnalepoCreirDretliF/ebuTyrallipaC

-,01-221CWH)llA(

1-,3-,4-,5-,8

-,01-242CWH)llA(

1-,3-,4-,5-,8

9-203CWH)llA(looCcirtcelE/taeHsaG5.25.9llorcSdnalepoCreirDretliF/ebuTyrallipaC

,5-,8-281CWH)llA(

2-,3-,4-

,5-,8-203CWH)llA(

1-,3-,4-

1-281CWH)llA(looCcirtcelE/taeHsaG5.15.9llorcSdnalepoCreirDretliF/ebuTyrallipaC

* For more information on the compressors used in HWC units, see the Unit Components section, beginning on page 5-28.

looCcirtcelE/taeHsaG5.17.9

looCcirtcelE/taeHsaG17.9yratoRhesmuceTreirDretliF/ebuTyrallipaC

looCcirtcelE/taeHsaG27.9llorcSdnalepoCreirDretliF/ebuTyrallipaC

looCcirtcelE/taeHsaG5.17.9yratoRhesmuceTreirDretliF/ebuTyrallipaC

looCcirtcelE/taeHsaG5.25.9llorcSdnalepoCreirDretliF/ebuTyrallipaC

hesmuceT

gnitacorpiceR

reirDretliF/ebuTyrallipaC

SRM-HW/HWC 8/99

SPECIFICATIONS Magic-Pak: HW/HWC

1-4

HW/HWC

Physical and Electrical

Table 1-3 Physical and Electrical Specifications - HWC Units

ledoM

/egatloV

esahP/zH

lamroN

egatloV

egnaR

.niM

tiucriC

yticapmA

321/221CWH621/06/032-802352-7913.8510.53.628157019.08/14X016/124523 321/221CWH83 1/06/032-802 352-791 3.8 51 0.5 3.62 81 5701 9.0 8/1 4X01 6/1 24 523 381/281CWH831/06/032-802352-7916.31023.80.548157019.08/14X013/165053 381/281CWH15 1/06/032-802 352-791 6.31 02 3.8 0.54 81 5701 9.0 8/1 4X01 3/1 65 053 381/281CWH461/06/032-802352-7916.31023.80.548157019.08/14X013/165053 342/242CWH63 1/06/032-802 352-791 6.81 52 6.11 5.26 81 5701 8.1 4/1 4X01 3/1 85 063 342/242CWH151/06/032-802352-7916.81526.115.268157018.14/14X013/185063

342/242CWH46 1/06/032-802 352-791 6.81 52 6.11 5.26 81 5701 8.1 4/1 4X01 3/1 85 063 203CWH151/06/032-802352-7914.22036.410.678157018.14/14X013/195083 203CWH46 1/06/032-802 352-791 4.22 03 6.41 0.67 81 5701 8.1 4/1 4X01 3/1 95 083 303CWH151/06/032-802352-7919.12031.410.378157018.14/14X013/195083 303CWH46 1/06/032-802 352-791 9.12 03 1.41 0.37 81 5701 8.1 4/1 4X01 3/1 95 083

Performance Ratings

.xaM

RCAH/esuF

.rkrB

)spma(

.pmoC

detaR

daoL

)spma(

.pmoC

.D.O

dekcoL

naF

rotoR

)spma(

.moN

.aiD

MPR

).ni(

edistuO

naF

detaR

daoL

detaR

)spma(

roodnI

leehW

x.aid

htdiw

rewolB

detaR

.girfeR

egrahC

).zo(

thgieW

).sbl(

).ni(

Table 1-4 Performance Ratings - HWC122/123

Outdoor Air Temperature Entering Outdoor Coil

85°

latoT

Enter.

Wet

Bulb

63°

67°

71°

latoT

riA

0040062102887.29.00.10002101908.59.00.100411000128.59.00.100801090158.00.100.1

0540082102828.79.00.10022101958.00.100.100611000178.00.100.100011090109.00.100.1

0050013102878.00.100.10042101909.00.100.100811000129.00.100.100211090159.00.100.1

0040043102895.47.98.0072101906.67.19.00121010126.97.00.100511011136.18.69.

0540063102826.87.49.0092101946.08.79.00321010156.38.00.100711011176.68.00.1

0050093102856.28.99.0023101976.48.00.100621010196.88.00.100911011107.19.00.1

0040024103804.65.27.0053102904.75.47.00821020114.85.67.00121021114.95.87.

0540044103824.95.67.0073102924.06.87.00031020134.26.08.00321021134.36.28.

0050074103844.26.08.0004102944.36.28.00331020154.56.48.00621021154.66.78.

gnilooC

.loV

yticapaC

)MFC(

)hutB(

taT/S

.pmoC

°57

sttaW

tupnI

°08

yrD

bluB

latoT

°58

yrD

bluB

gnilooC

yticapaC

)hutB(

Note: All values are gross capacities and do not include blower motor heat deduction.

95° 105° 115°

taT/S

.pmoC

°57

sttaW

yrD

tupnI

bluB

taT/S

°08

°58

yrD

bluB

latoT

gnilooC

yticapaC

)hutB(

taT/S

.pmoC

°57

sttaW

tupnI

°08

yrD

bluB

latoT

°58

yrD

bluB

gnilooC

yticapaC

)hutB(

taT/S

.pmoC

°57

sttaW

yrD

tupnI

bluB

taT/S

°08

°58

yrD

bluB

SRM-HW/HWC 8/99

Service Reference Manual SPECIFICATIONS

Performance Ratings (continued)

Table 1-5 Performance Ratings - HWC182/183

Outdoor Air Temperature Entering Outdoor Coil

85°

Enter.

Wet

Bulb

63°

67°

71°

latoT

riA

05500481073157.09.00.100171074187.29.00.100751055128.69.00.100441046168.69.00.1

00600781083187.39.00.100471084118.69.00.100061065158.00.100.100641056198.00.100.1

05600981093118.69.00.100671094148.99.00.100261075188.00.100.100841066129.00.100.1

05500891014185.27.78.00581015195.47.98.00171006126.87.49.00651007146.08.69.

00600102024106.57.09.00881025126.77.39.00471016146.18.89.00951017166.38.00.1

05600402034126.87.39.00091035146.08.69.00671026166.48.00.100161027186.68.00.1

05500212054104.55.96.00791055104.65.27.00381056114.85.57.00761057114.06.87.

00600512064124.75.27.00002065124.95.57.00681066134.16.87.00071067134.26.18.

05600812074134.95.47.00302075134.06.87.00881076144.36.18.00271077144.46.48.

gnilooC

.loV

yticapaC

)MFC(

)hutB(

taT/S

.pmoC

°57

sttaW

tupnI

°08

yrD

bluB

latoT

°58

yrD

bluB

gnilooC

yticapaC

)hutB(

latoT

Note: All values are gross capacities and do not include blower motor heat deduction.

95° 105° 115°

taT/S

.pmoC

°57

sttaW

tupnI

°08

yrD

bluB

latoT

°58

yrD

bluB

gnilooC

yticapaC

)hutB(

taT/S

.pmoC

°57

sttaW

tupnI

°08

yrD

bluB

latoT

°58

yrD

bluB

gnilooC

yticapaC

)hutB(

taT/S

.pmoC

°57

sttaW

yrD

tupnI

bluB

1-5

taT/S

°08

°58

yrD

bluB

Table 1-6 Performance Ratings - HWC242/243

Outdoor Air Temperature Entering Outdoor Coil

95° 105° 115°

taT/S

.pmoC

°57

sttaW

yrD

tupnI

bluB

taT/S

°08

°58

yrD

bluB

Enter.

Wet

Bulb

63°

67°

71°

85°

latoT

riA

00700342078147.88.00.100232011267.98.00.100812083287.49.00.100012017208.59.00.1

00800742078187.39.00.100632011208.49.00.100222083228.99.00.100312017248.00.100.1

00900252088128.89.00.100142021258.99.00.100622093278.00.100.100712027298.00.100.1

00700952098175.17.58.00742031285.27.68.00632004295.57.19.00422057206.67.29.

00800362098106.57.09.00152031216.67.19.00042004226.97.69.00822057236.08.79.

00900862009136.97.59.00652041246.08.69.00542014266.48.00.100232067276.58.00.1

00700372019104.55.96.00162051204.55.07.00942034204.65.27.00732077204.75.47.

00800772019124.85.37.00562051224.85.47.00352034224.95.67.00142077224.06.87.

00900382029144.16.77.00072061244.16.87.00852044244.26.08.00642087244.36.28.

gnilooC

.loV

yticapaC

)MFC(

)hutB(

taT/S

.pmoC

°57

sttaW

tupnI

°08

yrD

bluB

latoT

°58

yrD

gnilooC

bluB

yticapaC

)hutB(

Note: All values are gross capacities and do not include blower motor heat deduction.

Table 1-7 Performance Ratings - HWC302/303

Outdoor Air Temperature Entering Outdoor Coil

95° 105° 115°

taT/S

.pmoC

°57

sttaW

yrD

tupnI

bluB

taT/S

°08

°58

yrD

bluB

Enter.

Wet

Bulb

63°

67°

71°

85°

latoT

riA

57700582051227.48.79.00372093237.78.00.100162076247.98.00.100842099267.09.00.1

05800982061247.78.00.100672004267.09.00.100462086277.39.00.10015200039739.00.1

52900392071277.09.00.100082014297.39.00.100862096208.69.00.100452010328.69.00.1

57700403091265.96.28.00092044275.17.48.00872027285.37.88.00462050395.37.88.

05800803002285.17.58.00492054295.37.78.00182037206.57.19.00762060316.67.19.

52900213012206.37.78.00892064216.67.09.00582047226.87.49.00172070336.97.49.

57700223022204.45.86.00803084214.55.96.00392067214.65.17.00082090324.75.37.

05800623032214.65.07.00213094224.75.17.00792077224.85.37.00382001334.95.57.

52900033042224.75.27.00613005234.85.37.00103087234.06.67.00782011354.16.87.

gnilooC

.loV

yticapaC

)MFC(

)hutB(

taT/S

.pmoC

°57

sttaW

tupnI

°08

yrD

bluB

latoT

°58

yrD

bluB

gnilooC

yticapaC

)hutB(

latoT

gnilooC

yticapaC

)hutB(

latoT

gnilooC

yticapaC

)hutB(

taT/S

.pmoC

°57

sttaW

tupnI

.pmoC

sttaW

tupnI

°08

yrD

bluB

taT/S

°57

°08

yrD

bluB

latoT

°58

yrD

bluB

°58

yrD

bluB

gnilooC

yticapaC

)hutB(

taT/S

latoT

gnilooC

yticapaC

)hutB(

taT/S

.pmoC

°57

sttaW

yrD

tupnI

bluB

taT/S

.pmoC

°57

sttaW

yrD

tupnI

bluB

taT/S

°08

°58

yrD

bluB

taT/S

°08

°58

yrD

bluB

Note: All values are gross capacities and do not include blower motor heat deduction.

SRM-HW/HWC 8/99

SPECIFICATIONS Magic-Pak: HW/HWC

1-6

Blower Performance

Table 1-8 Blower Performance - HWC Units

Model

HWC122/123

HWC182,242,302 HWC183,243,303

Blower Speed

0.2 0.3 0.4 0.5

iH056516575045

deM574054524004

woL514504093083

iH 578 528 577 527

deM 058 508 067 017

woL 036 506 575 055

CFM @ ext. static pressure - in. w.c. with filter(s)

Dimensions (all measurements in inches)

SUPPLY AIR DUCT CONNECTION

8" x 16"

¾" DUCT CONNECTION FLANGE

LOW VOLTAGE

THERMOSTAT CONNECTIONS

HIGH VOLTAGE

JUNCTION BOX

4" x 4" x 2"

Measurements from Side and

Top to Center of V ent Outlet

GAS LINE CONNECTION

RETURN AIR OPENING ON BOTTOM

6" x 22"

SRM-HW/HWC 8/99

Service Reference Manual SPECIFICATIONS

Dimensions (cont.)

Line Voltage

Box

Supply

½ Gas Inlet

Supply

Low

Voltage

Return

1-7

Wall Sleeve (all measurements in inches)

1 or 3

15 or 12

SRM-HW/HWC 8/99

Flanges may be assembled

1" or 3 from this side of the sleeve

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

POWER ...................................................................... 2-6

CALL FOR HEAT ........................................................ 2-6

LIMIT/ROLLOUT OPENS ........................................... 2-7

PRESSURE SWITCH OPENS (BLOCKED FLUE)..... 2-7

FAILED FLAME SENSE/TRIAL FOR IGNITION......... 2-8

CALL FOR COOLING................................................. 2-8

FAN ON....................................................................... 2-9

HW (Heating Only) (w/UTEC 1097 Spark Ignition System) 2-10

Simplified Sequence ...................................... 2-11

Detailed Sequence ........................................ 2-12

POWER .................................................................... 2-12

CALL FOR HEAT ...................................................... 2-12

LIMIT/ROLLOUT OPENS ......................................... 2-13

PRESSURE SWITCH OPENS (BLOCKED FLUE)... 2-13

FAILED FLAME SENSE/TRIAL FOR IGNITION....... 2-14

FAN ON..................................................................... 2-14

2-1

HWC122,182,242,302

(w/Fenwal 2461D Ignition Control) ..... 2-16

Simplified Sequence ...................................... 2-17

Detailed Sequence ........................................ 2-18

POWER .................................................................... 2-18

CALL FOR HEAT ...................................................... 2-18

LIMIT OPENS ........................................................... 2-19

PRESSURE SWITCH OPENS (BLOCKED FLUE)... 2-19

ROLLOUT SWITCH ACTIVATED.............................. 2-19

CALL FOR COOLING............................................... 2-19

FAN ON..................................................................... 2-20

HW (Heating Only)

(w/Fenwal 2461D Ignition Control) ..... 2-22

Simplified Sequence ...................................... 2-23

Detailed Sequence ........................................ 2-24

POWER .................................................................... 2-24

CALL FOR HEAT ...................................................... 2-24

LIMIT OPENS ........................................................... 2-25

PRESSURE SWITCH OPENS (BLOCKED FLUE)... 2-25

ROLLOUT SWITCH ACTIVATED.............................. 2-25

SRM-HW/HWC 2/99

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

POWER .................................................................... 2-28

CALL FOR HEAT ...................................................... 2-28

FLAME SENSE......................................................... 2-29

LIMIT OPENS ........................................................... 2-29

ROLLOUT SWITCH ACTIVATED.............................. 2-29

CALL FOR COOLING............................................... 2-29

FAN ON..................................................................... 2-30

HW (Heating Only)

(w/Fenwal 05-29 Ignition Control) ....... 2-32

Simplified Sequence ...................................... 2-33

Detailed Sequence ........................................ 2-34

POWER .................................................................... 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

SRM-HW/HWC 2/99

Service Reference Manual SEQUENCE OF OPERATIONS

BLANK PAGE

2-3

SRM-HW/HWC 2/99

2-4

SPECIFICATIONS Magic-Pak: HW/HWC

HWC123, 183, 243, 303

(w/United Technologies 1097 Spark Ignition System)

208/230-1-60

POWER SUPPLY

}

BLACK

CAPACITOR-RUN

FAN

COM HERM

RED

YELLOW

BROWN

CAPA CIT ORCAPA CIT OR

BLOWER

COPPER CONDUCTORS

VIOLET

BROWN

YELLOWYELLOW

RED

BLOWER

MOTOR

ONLY

BLACK BLACK

COMBUSTION

BLOWER

BLACK

CONDENSER FANCONDENSER FAN

SEE

FORWIRING

SWITCH

CHARTCHART

BLACK BLUEBLUE RED

VIOLET

PRESSURE

VIOLET

AUTO RESET

LIMIT SWITCH

COMP

H M L

RED

GAS

VALVE

ORN

BLACK

BLOWER

CONTROL

GREEN

WHITE

RED

BLUE

MANUAL RESET

LIMIT SWITCH

BLACK

RED

CONNECTION DIAGRAMCONNECTION DIAGRAM

YELLOW RED BLUE

COOL

HEAT

IGNITION

CONTROLCONTROL

ORN

208 V

CONTACTOR

BLACK

UNUSED

24VAC

GND

RED

BLACK

TRANSFORMERTRANSFORMER

240 V

BLK

ELECTRODE

WHT

FLAME ROD

GREEN

BLK

BLUE

YELLOW

CMB

1 2 3 4 5

BLACK

RGWCY

4 1

BLUE RED

CIRCUITS ENERGIZED

OPERATING MODE CIRCUIT

HEATING R-W

COOLING R-G-Y

FAN R-G

LINE VOLT A GE-FACTORY LINE VOLTAGE-FA CTORYWHEN USED LINE VOLTAGE-FIELD LOWVOLTAGE-FACTORY LOWVOLTAGE-FIELD

R G Y

NOTE:

IF ANY OF THE ORIGINAL WIRES ARE REPLACED,THE

BLUE

YELLOW

RED

SAME SIZE AND TYPE WIRE MUST BE USED.

CONNECTORCONNECTOR

BLOCKBLOCK

EVAP. MOTOR SPEED CONNECTIONSEVAP.MOTOR SPEED CONNECTIONS

JUMPER REQUIRED

R G Y

}

THERMOST AT

COOLINGCOOLINGHEATINGHEATINGMODELSMODELS MED (BLUE)MED (BLUE)LOW (RED)26HWC12326HWC123 MED (BLUE)MED (BLUE)HIGH(BLACK)HIGH(BLACK)38HWC12338HWC123 LOW (RED)LOW (RED)LOW (RED)38HWC183 LOW (RED)LOW (RED)MED (BLUE)51HWC18351HWC183 LOW (RED)LOW (RED)HIGH(BLACK)HIGH(BLACK)64HWC18364HWC183 MED (BLUE)MED (BLUE)LOW (RED)38HWC24338HWC243 MED (BLUE)MED (BLUE)MED (BLUE)51HWC24351HWC243 MED (BLUE)MED (BLUE)HIGH(BLACK)HIGH(BLACK)64HWC24364HWC243 HIGH(BLACK)MED (BLUE)51HWC30351HWC303 HIGH(BLACK)HIGH(BLACK)HIGH(BLACK)64HWC30364HWC303

#45004-1

Note: On units that are equipped with a low ambient switch (designated

with an “SA” in the model number), sequence of oper ation during cooling call is modified when outdoor temperatures fall below the normal operating range. F or more inf ormation on the low ambient switch equipped version of this unit, see the section beginning on page 2-36.

FIGURE 2-1 Connection Diagram

The following blower/ignition control board

DIAGNOSTICS

LED codes will indicate normal or abnormal operations:

SLOW FLASH Normal Operation, No

FAST FLASH Normal Operation, Call for

2 FLASH System Lockout - Failed to

3 FLASH Pressure Switch Open or

4 FLASH High Limit or Rollout

5 FLASH Flame Sensed and Gas

STEADY Internal Failure

Call for Heat

Heat

Detect or Sustain Flame

Closed

Switch Open

Valve Not Energized

(Micro-controlle r Failure; Self-check)

SRM-HW/HWC 2/99

Service Reference Manual SEQUENCE OF OPERATIONS

Simplified Sequence - HWC123,183, 243, 303

Refer to Figure 2-1

2-5

• 208/230V power is supplied to the junction box on top of the unit

• 24V 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 b low er, causing the pressure switch to close.

3. The combustion blow er runs f or 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 b urners to light. When the gas valve energizes , a 30-second circulating air blower “on” dela y 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 deenergizes. This shuts down the burners.

8. A 5-second combustion blow er post-purge dela y and a 120-second circulating air blower “off” delay start.

9. After the delay times elapse, the combustion b lo w er and the circulating air blower stop .

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.

2. The contactor closes immediately, causing the compressor and the condenser fan to run.

3. The 24-volt Y signal starts a 5-second circulating air blower “on” delay .

4. After 5 seconds, the circulating air blower starts and runs until the R, Y and G circuit is interrupted by the thermostat.

5. 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.

6. The ignition control starts a 90-second circulating air blower “off” delay.

7. 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.

2. The circulating air blower remains running in cooling speed until the thermostat is switched to the “A UTO” position.

FLAME SENSE

1. After the 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. The unit initiates three trials for ignition (flame sense) before system lock out.

4. System lockout lasts 60 minutes or until po wer is reset to unit (whichever comes first).

SRM-HW/HWC 2/99

Detailed Sequence follows

2-6

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. At the L1 contactor terminal

3. At the transformer terminal marked 208-240V

L2 Power

1. Through the L2 black lead to the induced draft

blower

2. At the L2 contactor terminal

3. A transformer common terminal

4. At the T2 contactor terminal

5. At the R terminal of the compressor

6. At the capacitor common terminals

Low Voltage (24 VAC)

With the unit at rest (no call from the thermostat), 24 volts A/C will be present:

control. This causes the combustion blower to start by completing the line voltage circuit through the L2 wire connection in the unit.

2. As the 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 “on” dela y 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. L1 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 connection 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 dela y, the CMB BLWR terminal on the ignition control deenergizes. This interrupts L1 pow er 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 pow er is interrupted, the blo wers

shut off.

Low Voltage

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 v oltage harness to the 24VAC hot terminal on the ignition control

3. From the 24VAC hot terminal to pin 5 of the 5-pin thermostat harness (internal to board)

4. From the 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 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

1. A call for heat closes the R-W circuit, sending a 24volt signal to the low v oltage 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, a 24-v olt 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 6pin ignition wire harness.

5. When the 24-volt signal is received at pin 5 of the 6pin 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 6pin 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 it to open and the burners to ignite.

SRM-HW/HWC 2/99

Service Reference Manual SEQUENCE OF OPERATIONS

9. After 30-second “on” delay, the circulating air blower relay energizes the heat terminal and the 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-energized.

12. The gas valve closes immediately as 24V through pin 4 of the 6-pin ignition wire harness is deenergized 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, 24V AC 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 and across the limit switch to pin 1 of the 6-pin ignition wire harness.

2. This circuit energizes whenever line v oltage po wer 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 energize, sending L1 power to the ACB HEAT terminal on the ignition control. This causes both blowers to start immediately.

5. 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.

6. 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.

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 6pin 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 hav e timed out, both b low ers 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 automatically when

temperatures are acceptable, b ut 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. At the same time the combustion blower relay energizes, the 24-volt signal is sent to pin 2 of the 6pin 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. If the 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 seconds. After 60 seconds, the ignition control automatically de-energizes the combustion

blower relay. This interrupts L1 pow er 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 (indicating pressure switch fault—open or closed).

2-7

SRM-HW/HWC 2/99

2-8

SPECIFICATIONS Magic-Pak: HW/HWC

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-v olt 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-v olt 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. As spark voltage is supplied to the ignitor elec- trodes, the gas valve opens and this causes the burners to ignite.

2. The ignition control continues to energize spark voltage until a flame sense signal is supplied to the flame terminal on the ignition control.

3. 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.

4. After the 10-second trial for ignition, 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 electrode spark to stop.

5. 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 dela y is timed out, the circulating air blower starts.

6. After the spark ignition cable terminal de-energizes, the ignition control initiates a 30-second combustion blower inter-purge delay.

7. 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.

8. If the flame sense signal is not received, the system goes through three trials following the abov e sequence.

9. After three trials, the system goes into lockout and only the high limit switch circuit and pressure switch circuit remain energized during the 60minute lockout period.

10. If the flame sense is lost during the heat cycle, the gas valve de-energizes immediately and the system goes into the trial sequence.

CALL FOR COOLING

Line Voltage

1. L2 power passes through the fix ed closed L2-T2 terminals on the contactor to the RUN terminal of the compressor and the COMMON terminal of the capacitor.

2. L1 power is sent to the L1 terminal of the contactor. When the Y signal energizes the contactor, the T2 terminal becomes energized. L1 pow er is sent to the compressor COMMON terminal and the condenser fan. This energizes the compressor and condenser fan motors.

3. 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.

4. 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.

5. L1 power is sent to the circulating air blower terminal block, energizing the circulating air blower motor.

6. 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.

7. 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.

2. The contactor closes immediately upon receiving the 24-volt signal, causing the compressor and condenser fan motors to start.

3. 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.

4. After the 5-second delay, the ignition control energizes the cooling speed relay and the circulat- ing air blower starts.

5. 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.

SRM-HW/HWC 2/99

Service Reference Manual SEQUENCE OF OPERATIONS

6. After the 90-second delay, the ignition control deenergizes 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.

2. The 24-volt signal energizes the cooling speed relay, sending L1 power to the ACB COOL terminal of the ignition control.

3. L1 power is sent to the circulating air blower terminal block, causing the circulating air blower to run in cooling speed.

4. The circulating air blower continues to run in cooling speed until the thermostat is switched to “AUT O”, 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 “AUT O” position.

2-9

SRM-HW/HWC 2/99

2-10

SPECIFICATIONS Magic-Pak: HW/HWC

HW (Heating Only)

(w/United Technologies 1097 Spark Ignition System)

208/230-1-60

}

POWER SUPPLY

BLACK

COPPER CONDUCTORS

ONLY

BLACK BLACK

COMBUSTION

BLOWER

BLACK

VOILET

PRESSURE

SWITCH

VOILET

AUTO RESET

LIMIT SWITCH

ORANGE

YELLOW

CONNECTION DIAGRAM

CNB

1 2 3 4

RGWCY

4 1

MANUAL RESET

LIMIT SWITCH

TRANSFORMER

RED

GAS

VALVE

ORANGE

GREEN

WHITE

RED

BLUE

COOL

HEAT

IGNITION CONTROL

5 2

ORANGE

YELLOW

RED

BLUE

BLACK

UNUSED

GND

BLACK

RED

WHT

24VAC

GREEN

ELECTRODE

FLAME ROD

208 V

240 V

WIRE NUT

BLUE RED

CIRCUITS ENERGIZED

OPERATING MODE CIRCUIT

HEATING R-W

COOLING R-G-Y

FAN R-G

LINE VOLTAGE-FA CTORY LINE VOLTAGE-FACTORYWHEN USED LINE VOLTAGE-FIELD LOWVOLTAGE-FACTOR Y LOWVOLTAGE-FIELD

BLUE

YELLOW

R G

RED

NOTE:

IF ANY OF THE ORIGINAL WIRES ARE REPLACED,THE SAME SIZE AND TYPE WIRE MUST BE USED.

CONNECTOR

BLOCK

R G Y

}

EVAP. MOTOR

SPEED CONNECTIONS

51HW 64HW

HEATINGHEATINGMODELS

LOW (RED)LOW (RED)26HW

HIGH (BLACK)38HW

MED (BLUE)

HIGH (BLACK)

THERMOST AT

SEE CHART FORWIRING

CAPACITORCAPACITOR

BLOWER

YELLOW

BROWN

BLOWER

MOTOR

BLACK BLUE RED

H M

TERMINAL BLOCK

FIGURE 2-2 Connection Diagram

#45008-2

The following blower/ignition control board LED codes will indic a te n o rmal or abnormal operations:

SLOW FLASH Normal Operation, No

FAS T F L A SH Normal Operation,Call for

2 FLASH System Lockout - Failed to

3 FLASH Pressure Switch Open or

4 FLASH High Limit or Rollout

5 FLASH Flame Sensed and Gas

STEADY Internal Failure

DIAGNOSTICS

Call for Heat

Heat

Detect or Sustain Flame

Closed

Switch Open

Valve Not Energized

(Micro-controlle r Failure; Self-check)

SRM-HW/HWC 2/99

Service Reference Manual SEQUENCE OF OPERATIONS

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 blo wer 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 b urners ignite. This starts a 30-second circulating air blower “on” dela y.

5. The unit 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 interrupted, causing the gas valve to close and the burners to shut down.

7. A 5-second post-purge starts and following that the induced draft blower stops .

8. A 120-second circulating air blower “off” delay starts. After the elapsed time, the circulating air blower stops .

2-11

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. The circulating air blower runs in the cooling speed until the thermostat fan switch is mov ed bac k to the “AUT O” 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.

SRM-HW/HWC 2/99

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. At the transformer terminal marked 208-240V

L2 Power

1. Through the L2 black lead to the induced draft

blower

2. Transformer common terminal

3. At the 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. At the transformer 24V terminal

2. At the 24VAC hot terminal on the ignition control

3. At pin 5 of the 5-pin thermostat harness (red wire pin)

4. At pin 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. As the 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 “on” delay starts. After the delay, the ignition control energizes the heat speed blower rela y. This sends L1 power to the ACB HEAT terminal on the ignition control.

3. 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.

shut off.

Low Voltage

1. A call for heat closes the R-W circuit, sending a 24volt signal to the low v oltage 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.

5. When the 24-volt signal is received at pin 5 of the 6pin 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 6pin 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 it to open and the burners to ignite.

9. After 30-second “on” delay, the circulating air

blower relay energizes the heat terminal and the 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-energized.

SRM-HW/HWC 2/99

Service Reference Manual SEQUENCE OF OPERATIONS

12. The gas valve closes immediately as 24V through pin 4 of the 6-pin ignition wire harness is deenergized 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.

9. Once the delays hav e timed out, both b low ers 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 automatically when

temperatures are acceptable, b ut the rollout switch must be manually reset by pushing in on the small button on top of the switch.

2-13

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, 24V AC 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.

2. This circuit energizes whenever line v oltage po wer 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.

5. 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.

6. 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.

7. The green ignition control LED shows a 4 flash fault code (indicating limit switch/rollout switch open).

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. At the same time the combustion blower relay energizes, the 24-volt signal is sent to pin 2 of the 6pin ignition wire harness and from pin 2 to one side of the Normally Open pressure switch.

3. If the 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.

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 seconds. After 60 seconds, the ignition control automatically de-energizes the combustion

blower relay. This interrupts L1 pow er 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 (indicating 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.

SRM-HW/HWC 2/99

2-14

SPECIFICATIONS Magic-Pak: HW/HWC

FAILED FLAME SENSE/TRIAL FOR IGNITION

When the pressure switch closes and a 24-v olt 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. As spark voltage is supplied to the ignitor elec- trodes, the gas valve opens and this causes the burners to ignite.

2. The ignition control continues to energize spark voltage until a flame sense signal is supplied to the flame terminal on the ignition control.

3. 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.

6. After the spark ignition cable terminal de-energizes, the ignition control initiates a 30-second combustion blower inter-purge delay.

8. If the flame sense signal is not received, the system goes through three trials following the abov e sequence.

9. 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.

10. If the flame sense is lost during the heat cycle, the gas valve de-energizes immediately and the system goes into the trial sequence.

4. 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

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.

2. The 24-volt signal energizes the cooling speed relay, sending L1 power to the ACB COOL terminal of the ignition control.

3. L1 power is sent to the circulating air blower terminal block, causing the circulating air blower to run in cooling speed.

SRM-HW/HWC 2/99

Service Reference Manual SEQUENCE OF OPERATIONS

2-15

BLANK PAGE

SRM-HW/HWC 2/99

2-16

SPECIFICATIONS Magic-Pak: HW/HWC

HWC122, 182, 242, 302

(w/Fenwal T(w/Fenwal T

(w/Fenwal T

(w/Fenwal T(w/Fenwal T

208/230-1-60

COPPER CONDUCTORS

POWER SUPPLY

P.S W

IND

BLACK

IGNITION

CONTROL

ELECTRODE

CABLE

BLACK

CONDENSER FAN

HERM

RED

BROWN

YEL

VIOLET

BROWN

RED

MOTOR

SEE TABLE

FORWIRING

CAPACITOR-RUN

FAN

COM

CAPACITY BLOWER

BLOWER

24VAC

YELLOW

GND

BLK BLUE RED

SEE TABLE

riton 2461D DSI Ignition Contrriton 2461D DSI Ignition Contr

riton 2461D DSI Ignition Contr

riton 2461D DSI Ignition Contrriton 2461D DSI Ignition Contr

CIRCUITS ENERGIZED

OPERATING MODE

ONLY

GREEN

BLACK

BLOWER

CONTROL

ORN ORN

H L1

WHITE

RED

BLUE

BLACK BLACK

BLACK

RED

BLK

GAS

VALVE

C R

PINK

BLUE

MANUAL

RESET

WHITE

PRESSURE

BROWN

COMBUSTION

BLACK BLACK

CONTACTOR

YEL

BLK

COMP T’STAT

(IF USED)

LIMIT

SWITCH

BLOWER

FORMER

BLUE

RED

BLK

WHITE

GREEN

WHITE

CONNECTOR

BLOCK

BLACK

TRANS-

YEL YEL

BLUE

208V

CONTR

LOAD

COM

TIME DELAY

(IF USED)

RED

WHITE

BLUE

240V

HEATING

COOLING

FAN

LINE VOLTAGE - FACTORY LINE VOLTAGE - FACTORY (WHEN USED) LINE VOLTAGE - FIELD LOWVOLTAGE - FACTORY LOWVOLTAGE - FIELD

Y G

YELLOW

GREEN

WHITE

RED

NOTE:

EVAPORATOR MOTOR

SPEED CONNECTIONS

MODELS

26HWC122 38HWC122 38HWC182

51HWC182

64HWC182 38HWC242 51HWC242 64HWC242 51HWC302 64HWC302

ol)ol)

ol)

ol)ol)

CIRCUIT

R-W

R-G-Y

R-G

R W

THERMOSTAT

Y G

IF ANY OF THE ORIGINAL WIRES ARE REPLACED , THE SAME SIZE AND TYPE WIRE MUST BE USED.

HEATING

LOW (RED) HIGH (BLK) LOW (RED) LOW (RE D )

MED (BLUE)

HIGH (BLK) LOW (RED)

MED (BLUE)

HIGH (BLK)

MED (BLUE)

HIGH (BLK)

JUMPER REQUIRED

COOLING

MED (BLUE) MED (BLUE)

LOW (RED)

LOW (RED) MED (BLUE) MED (BLUE) MED (BLUE)

HIGH (BLK) HIGH (BLK)

#39007D5

* *

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. F or more inf ormation on the low ambient s witch equipped version of this unit, see the section beginning on page 2-38.

FIGURE 2-3 Connection Diagram

SRM-HW/HWC 2/99

Service Reference Manual SEQUENCE OF OPERATIONS

Simplified Sequence - HWC122,182, 242, 302 (w/Fenwal Triton 2461D DSI Ignition Control)

Refer to Figure 2-3

2-17

CALL FOR HEAT

1. A call for heat closes the circuit between wires R (red) and W (white) on the unit’s thermostat connections.

2. A low 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 24volt signal is also sent to the blow er 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 s witch closes.

4. When the pressure switch closes, the 24-v olt signal is sent to the ignition control. This starts a 30second pre-purge countdown, after which a trial for ignition is made.

5. At the same time that the trial for ignition is made, the gas valve energizes and gas flo ws to the burners.

6. With the burners in operation, the trial for ignition continues for se ven 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 rela y, sending line voltage to and starting the circulating air blower.

8. The unit continues to operate as long as there is a 24-volt signal between R and W. When the call f or heat is satisfied, the 24-volt signal between R and W discontinues. When W de-energizes, the pow er to the induced draft blow er and the gas valve is interrupted. The 24-volt signal to the blo wer control board is also interrupted, causing the module to start the countdown to blower “off” (approximately 90 seconds).

9. If at any time during a 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 b lower 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. A call for cooling closes the circuit from R to Y and G.

2. 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 compressor 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 deenergize. The contactor opens immediately, stopping the compressor and the outdoor 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 ON” position, the circuit between R and G closes.

2. The 24-volt signal from G goes to the blo wer 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 G on the blower control board deenergizes, the timer to turn off the circulating air blower starts. The circulating air blow er turns off after 90 seconds (see note below).

Note: Heatcraft blow er control boards ha v e a G “on”

delay of 15 seconds and an “off” dela y of 90 seconds. Tridelta blower control boards have no “on” time delay and a 60 -130 second “off” delay.

SRM-HW/HWC 2/99

Detailed Sequence follows

2-18

SPECIFICATIONS Magic-Pak: HW/HWC

Detailed Sequence - HWC122, 182, 242, 302 (w/Fenwal Triton 2461D 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 v olts 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 follo wing locations:

First black wire

1. L-1 on the ignition control

2. L-1 on the contactor

3. L-1 on the blower control board

4. Terminal on the transformer marked 208V or

240V (whichever is being used)

Second black wire

1. Supplies power to the induced draft blower

2. L-2 on the contactor

3. Common terminal on the transformer

4. T-2 on the contactor

5. Red wire on the R terminal of the compressor

6. Red wire to the common terminals on the capaci-

tors

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 f or 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-v olt 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 operate until the heat call is satisfied, interrupting the circuit between R and W. The W terminal de-energizes, causing the blower rela y to open appro ximately 90 seconds later. This interrupts the line v oltage to the circulat- ing air blower and the blow er shuts do wn.

Low Voltage

1. A call for heat closes the circuit in 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 “on”. The blow er 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. As the 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. As the trial for ignition starts, the V1 terminal on the ignition control energizes. At the same time, a 24volt signal is sent to the gas valve, opening the valve . The unit contin ues to operate as long as W is energized.

7. When the call for heat is satisfied, the circuit between R and W is interrupted.

8. With W de-energized, the gas valve closes immediately and the induced draft blower shuts down sever al seconds later .

9. The blower control board starts a countdown to blower “off”. Appro ximately 90 seconds later, the blower shuts do wn.

SRM-HW/HWC 2/99

Service Reference Manual SEQUENCE OF OPERATIONS

LIMIT OPENS

If the limit switch opens for an y reason during a call f or heat, the following happens:

1. If the limit switch senses that the temperature in the unit is too high, the contacts between terminals C and NC on the limit switch open and the contacts 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 negativ e pressure in the induced draft blower is reduced. At 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 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 continues to run. If the negativ e pressure is restored, the pressure switch closes and sends a 24-v olt signal to the P.SW terminal on the ignition control. The ignition control makes a trial for ignition again and operation returns to normal.

2. The reason the rollout switch was tripped must be determined before corrective action is taken.

3. 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 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 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.

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 voltage signal to terminal G on the blower control board interrupted, the board starts a countdown to blow er “off”. After appro ximately 90 seconds (see note on page 2-20), the cooling speed relay opens and the circulating air blower shuts down.

Low Voltage

2-19

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, interrupting the 24-volt signal going to terminal 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.

SRM-HW/HWC 2/99

1. On a call for cooling, the thermostat closes the circuit between R and terminals G and Y.

2. The 24-volt signal energizes terminal G on the blower control board, starting the fan “on” timer. Approximately 15 seconds later (or immediately see note on page 2-20), the relay closes. This sends line voltage to the COOLING speed terminal on the blower control board, which starts the circulating air blower.

3. The signal from Y energizes the contactor, starting the compressor and the outdoor cooling fan.

4. 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.

2-20

SPECIFICATIONS Magic-Pak: HW/HWC

5. The 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 mov ed 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 mov ed 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”. Appro ximately 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 blo wer control boards ha v e a G “on”

delay of 15 seconds and an “off” dela y of 90 seconds. Tridelta blow er control boards have no “on” time delay and a 60 -130 second “off” delay.

SRM-HW/HWC 2/99

+ 166 hidden pages

Armstrong World Industries HWC PREMIER 302, HWC PREMIER 123, HWC PREMIER 183, HWC PREMIER 243, HWC PREMIER 203 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

Section 1 - Specifications

Section 2 - Sequence of Operation