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

Copyright © 1998

Armstrong Air Conditioning Inc.

All rights reserved.

Disclaimer

This manual presents information and guidelines for proper installation, adjustment, operation and maintenance of Armstrong Magic-Pak HW/HWC Thru-the-Wall units. Read this manual before attempting assembly, installation, start-up, adjustment or operation of the unit. If you have any questions about the operation of the unit or a particular safety device, call or write Armstrong Air Conditioning Inc., 421 Monroe Street, Bellevue, Ohio USA 44811. Telephone: [phone] Fax: [phone]

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 Armstrong 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
		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	Performance, 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 valves,
		blowers, ignition controls and blower control boards.
	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.

SRM-HW/HWC 8/99

Service Reference Manual

SPECIFICATIONS

1-1

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

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

HW/HWC-SRM

8/99

Service Reference Manual

SPECIFICATIONS

1-3

Summary of Model Revisions/Variations

Table 1-1 Heating Configurations of HW/HWC Units

	Model	Configuration	AFUE	Ignition/Blower Control	Ignition
					Type
	(All) HWC (123, 183, 243, 303) -1	Gas Heat/	80	UTech Combination Ignition/Blower Control 1097	DSI
		Electric Cool
	(All) HW -9	Gas Heat Only	80	UTech Combination Ignition/Blower Control 1097	DSI
	(All) HWC (122, 182, 242, 302)	Gas Heat/		Ignition Control: Fenwal Triton 2461D
			80	Blower Control: Heatcraft IBCH4C401,	DSI
	-11, -10, -9, -8, -7, -6, -5	Electric Cool
				Tridelta 920B0048 or UTech 1010
	(All) HWC (122, 182, 242, 302)	Gas Heat/		Ignition Control: Fenwal 05-29
			80	Blower Control: Heatcraft IBCH4C401,	DSI
	-4, -3, -2, -1	Electric Cool
				Tridelta 920B0048 or UTech 1010

Table 1-2 Cooling Configurations of HWC Units

	Model	Configuration	Tonnage	SEER	Compressor Type*	Metering Device
	(All) HWC 123-1	Gas Heat/Electric Cool	1	9.7	Tecumseh Rotary	Capillary Tube/Filter Drier
	(All) HWC183-1	Gas Heat/Electric Cool	1.5	9.7	Tecumseh	Capillary Tube/Filter Drier
					Reciprocating
	(All) HWC 243-1	Gas Heat/Electric Cool	2	9.7	Copeland Scroll	Capillary Tube/Filter Drier
	(All) HWC 303-1	Gas HeatElectric Cool	2.5	9.7	Copeland Scroll	Capillary Tube/Filter Drier
	(All) HWC 182-11, -	Gas Heat/Electric Cool	1.5	9.7	Tecumseh	Capillary Tube/Filter Drier
	9, -7, -6				Reciprocating
	(All) HWC 242-11, -9	Gas Heat/Electric Cool	2	9.7	Copeland Scroll	Capillary Tube/Filter Drier
	(All) HWC 122-10, -	Gas Heat/Electric Cool	1	9.7	Tecumseh Rotary	Capillary Tube/Filter Drier
	8, -5, -4, -3, -1
	(All) HWC 242-10, -	Gas Heat/Electric Cool	2	9.7	Copeland Scroll	Capillary Tube/Filter Drier
	8, -5, -4, -3, -1
	(All) HWC 302-9	Gas Heat/Electric Cool	2.5	9.5	Copeland Scroll	Capillary Tube/Filter Drier
	(All) HWC 182-8, -5,	Gas Heat/Electric Cool	1.5	9.7	Tecumseh Rotary	Capillary Tube/Filter Drier
	-4, -3, -2
	(All) HWC 302-8, -5,	Gas Heat/Electric Cool	2.5	9.5	Copeland Scroll	Capillary Tube/Filter Drier
	-4, -3, -1
	(All) HWC 182-1	Gas Heat/Electric Cool	1.5	9.5	Copeland Scroll	Capillary Tube/Filter Drier

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

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
					Max.	Comp.	Comp.	O.D.		Outside		Indoor
			Normal	Min.						Fan		Wheel	Blower	Refrig.
		Voltage/			Fuse/HACR	Rated	Locked	Fan	Nom.		Rated				Weight
	Model		Voltage	Circuit						Rated		dia. x	Rated	Charge
		Hz/Phase			Brkr.	Load	Rotor	Dia.	RPM		HP				(lbs.)
			Range	Ampacity						Load		width	HP	(oz.)
					(amps)	(amps)	(amps)	(in.)
										(amps)		(in.)
	26HWC122/123	208-230/60/1	197-253	8.3	15	5.0	26.3	18	1075	0.9	1/8	10 X 4	1/6	42	325
	38HWC122/123	208-230/60/1	197-253	8.3	15	5.0	26.3	18	1075	0.9	1/8	10 X 4	1/6	42	325
	38HWC182/183	208-230/60/1	197-253	13.6	20	8.3	45.0	18	1075	0.9	1/8	10 X 4	1/3	56	350
	51HWC182/183	208-230/60/1	197-253	13.6	20	8.3	45.0	18	1075	0.9	1/8	10 X 4	1/3	56	350
	64HWC182/183	208-230/60/1	197-253	13.6	20	8.3	45.0	18	1075	0.9	1/8	10 X 4	1/3	56	350
	36HWC242/243	208-230/60/1	197-253	18.6	25	11.6	62.5	18	1075	1.8	1/4	10 X 4	1/3	58	360
	51HWC242/243	208-230/60/1	197-253	18.6	25	11.6	62.5	18	1075	1.8	1/4	10 X 4	1/3	58	360
	64HWC242/243	208-230/60/1	197-253	18.6	25	11.6	62.5	18	1075	1.8	1/4	10 X 4	1/3	58	360
	51HWC302	208-230/60/1	197-253	22.4	30	14.6	76.0	18	1075	1.8	1/4	10 X 4	1/3	59	380
	64HWC302	208-230/60/1	197-253	22.4	30	14.6	76.0	18	1075	1.8	1/4	10 X 4	1/3	59	380
	51HWC303	208-230/60/1	197-253	21.9	30	14.1	73.0	18	1075	1.8	1/4	10 X 4	1/3	59	380
	64HWC303	208-230/60/1	197-253	21.9	30	14.1	73.0	18	1075	1.8	1/4	10 X 4	1/3	59	380

Performance Ratings

Table 1-4			Performance Ratings - HWC122/123
										Outdoor Air Temperature Entering Outdoor Coil
					85°					95°					105°					115°
Enter.	Total		Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at
	Air		Cooling		75°	80°	85°	Cooling		75°	80°	85°	Cooling		75°	80°	85°	Cooling		75°	80°	85°
Wet				Watts					Watts					Watts					Watts
	Vol.		Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry
Bulb				Input					Input					Input					Input
	(CFM)		(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb
	400		12600	820	.78	.92	1.00	12000	910	.80	.95	1.00	11400	1000	.82	.95	1.00	10800	1090	.85	1.00	1.00
63°
	450		12800	820	.82	.97	1.00	12200	910	.85	1.00	1.00	11600	1000	.87	1.00	1.00	11000	1090	.90	1.00	1.00
	500		13100	820	.87	1.00	1.00	12400	910	.90	1.00	1.00	11800	1000	.92	1.00	1.00	11200	1090	.95	1.00	1.00
	400		13400	820	.59	.74	.89	12700	910	.60	.76	.91	12100	1010	.62	.79	1.00	11500	1110	.63	.81	.96
67°
	450		13600	820	.62	.78	.94	12900	910	.64	.80	.97	12300	1010	.65	.83	1.00	11700	1110	.67	.86	1.00
	500		13900	820	.65	.82	.99	13200	910	.67	.84	1.00	12600	1010	.69	.88	1.00	11900	1110	.70	.91	1.00
	400		14200	830	.40	.56	.72	13500	920	.40	.57	.74	12800	1020	.41	.58	.76	12100	1120	.41	.59	.78
71°
	450		14400	830	.42	.59	.76	13700	920	.42	.60	.78	13000	1020	.43	.62	.80	12300	1120	.43	.63	.82
	500		14700	830	.44	.62	.80	14000	920	.44	.63	.82	13300	1020	.45	.65	.84	12600	1120	.45	.66	.87

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

HW/HWC-SRM

8/99

SRM-HW/HWC 8/99

Service Reference Manual

SPECIFICATIONS

1-5

Performance Ratings (continued)

Table 1-5			Performance Ratings - HWC182/183
										Outdoor Air Temperature Entering Outdoor Coil
					85°					95°					105°					115°
Enter.	Total		Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at
	Air		Cooling		75°	80°	85°	Cooling		75°	80°	85°	Cooling		75°	80°	85°	Cooling		75°	80°	85°
Wet				Watts					Watts					Watts					Watts
	Vol.		Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry
Bulb				Input					Input					Input					Input
	(CFM)		(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb
	550		18400	1370	.75	.90	1.00	17100	1470	.78	.92	1.00	15700	1550	.82	.96	1.00	14400	1640	.86	.96	1.00
63°
	600		18700	1380	.78	.93	1.00	17400	1480	.81	.96	1.00	16000	1560	.85	1.00	1.00	14600	1650	.89	1.00	1.00
	650		18900	1390	.81	.96	1.00	17600	1490	.84	.99	1.00	16200	1570	.88	1.00	1.00	14800	1660	.92	1.00	1.00
	550		19800	1410	.58	.72	.87	18500	1510	.59	.74	.89	17100	1600	.62	.78	.94	15600	1700	.64	.80	.96
67°
	600		20100	1420	.60	.75	.90	18800	1520	.62	.77	.93	17400	1610	.64	.81	.98	15900	1710	.66	.83	1.00
	650		20400	1430	.62	.78	.93	19000	1530	.64	.80	.96	17600	1620	.66	.84	1.00	16100	1720	.68	.86	1.00
	550		21200	1450	.40	.55	.69	19700	1550	.40	.56	.72	18300	1650	.41	.58	.75	16700	1750	.41	.60	.78
71°
	600		21500	1460	.42	.57	.72	20000	1560	.42	.59	.75	18600	1660	.43	.61	.78	17000	1760	.43	.62	.81
	650		21800	1470	.43	.59	.74	20300	1570	.43	.60	.78	18800	1670	.44	.63	.81	17200	1770	.44	.64	.84

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

Table 1-6			Performance Ratings - HWC242/243
										Outdoor Air Temperature Entering Outdoor Coil
					85°					95°					105°					115°
Enter.	Total		Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at
	Air		Cooling		75°	80°	85°	Cooling		75°	80°	85°	Cooling		75°	80°	85°	Cooling		75°	80°	85°
Wet				Watts					Watts					Watts					Watts
	Vol.		Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry
Bulb				Input					Input					Input					Input
	(CFM)		(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb
	700		24300	1870	.74	.88	1.00	23200	2110	.76	.89	1.00	21800	2380	.78	.94	1.00	21000	2710	.80	.95	1.00
63°
	800		24700	1870	.78	.93	1.00	23600	2110	.80	.94	1.00	22200	2380	.82	.99	1.00	21300	2710	.84	1.00	1.00
	900		25200	1880	.82	.98	1.00	24100	2120	.85	.99	1.00	22600	2390	.87	1.00	1.00	21700	2720	.89	1.00	1.00
	700		25900	1890	.57	.71	.85	24700	2130	.58	.72	.86	23600	2400	.59	.75	.91	22400	2750	.60	.76	.92
67°
	800		26300	1890	.60	.75	.90	25100	2130	.61	.76	.91	24000	2400	.62	.79	.96	22800	2750	.63	.80	.97
	900		26800	1900	.63	.79	.95	25600	2140	.64	.80	.96	24500	2410	.66	.84	1.00	23200	2760	.67	.85	1.00
	700		27300	1910	.40	.55	.69	26100	2150	.40	.55	.70	24900	2430	.40	.56	.72	23700	2770	.40	.57	.74
71°
	800		27700	1910	.42	.58	.73	26500	2150	.42	.58	.74	25300	2430	.42	.59	.76	24100	2770	.42	.60	.78
	900		28300	1920	.44	.61	.77	27000	2160	.44	.61	.78	25800	2440	.44	.62	.80	24600	2780	.44	.63	.82

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
					85°					95°					105°					115°
Enter.	Total		Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at	Total	Comp.	S/T at	S/T at	S/T at
	Air		Cooling		75°	80°	85°	Cooling		75°	80°	85°	Cooling		75°	80°	85°	Cooling		75°	80°	85°
Wet				Watts					Watts					Watts					Watts
	Vol.		Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry	Capacity		Dry	Dry	Dry
Bulb				Input					Input					Input					Input
	(CFM)		(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb	(Btuh)		Bulb	Bulb	Bulb
	775		28500	2150	.72	.84	.97	27300	2390	.73	.87	1.00	26100	2670	.74	.89	1.00	24800	2990	.76	.90	1.00
63°
	850		28900	2160	.74	.87	1.00	27600	2400	.76	.90	1.00	26400	2680	.77	.93	1.00	25100	3000	79	.93	1.00
	925		29300	2170	.77	.90	1.00	28000	2410	.79	.93	1.00	26800	2690	.80	.96	1.00	25400	3010	.82	.96	1.00
	775		30400	2190	.56	.69	.82	29000	2440	.57	.71	.84	27800	2720	.58	.73	.88	26400	3050	.59	.73	.88
67°
	850		30800	2200	.58	.71	.85	29400	2450	.59	.73	.87	28100	2730	.60	.75	.91	26700	3060	.61	.76	.91
	925		31200	2210	.60	.73	.87	29800	2460	.61	.76	.90	28500	2740	.62	.78	.94	27100	3070	.63	.79	.94
	775		32200	2220	.40	.54	.68	30800	2480	.41	.55	.69	29300	2760	.41	.56	.71	28000	3090	.42	.57	.73
71°
	850		32600	2230	.41	.56	.70	31200	2490	.42	.57	.71	29700	2770	.42	.58	.73	28300	3100	.43	.59	.75
	925		33000	2240	.42	.57	.72	31600	2500	.43	.58	.73	30100	2780	.43	.60	.76	28700	3110	.45	.61	.78

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

		SPECIFICATIONS						Magic-Pak: HW/HWC
1-6
		Blower Performance
		Table 1-8 Blower Performance - HWC Units
		Model	Blower Speed			CFM @ ext. static pressure - in. w.c. with filter(s)
					0.2		0.3	0.4		0.5
			Hi		650		615	575		540
		HWC122/123
			Med		475		450	425		400
			Low		415		405	390		380
			Hi		875		825	775		725
		HWC182,242,302
			Med		850		805	760		710
		HWC183,243,303
			Low		630		605	575		550

Dimensions (all measurements in inches)

SUPPLY AIR DUCT CONNECTION

8" x 16" LOW VOLTAGE THERMOSTAT CONNECTIONS

	HIGH VOLTAGE
¾" DUCT CONNECTION FLANGE	JUNCTION BOX
	4" x 4" x 2"

GAS LINE

CONNECTION

Measurements from Side and Top to Center of Vent Outlet

41 2"

634"

" /8 1

43

27	7
	/8"

RETURN AIR OPENING ON BOTTOM 6" x 22"

"

7/16 29

HW/HWC-SRM

8/99

Service Reference Manual

SPECIFICATIONS

1-7

Dimensions (cont.)

	1		1	133/8
		16		8
		Supply
Line Voltage
Box	Low
	Voltage		43 1/8
Supply	8
	2 7/8 4
½ Gas Inlet	1 3/4
	3	Return

2	/								22						1
	78																				6
								27 7/8																				29 7/16

Wall Sleeve (all measurements in inches)

1 or 3 3 4

15 or 1214

2

16

45

2

29

12 1 2"

Flanges may be assembled

1" or 33 4" from this side of the sleeve

SRM-HW/HWC 8/99

SRM-HW/HWC 2/99

Service Reference Manual

SEQUENCE OF OPERATIONS

2-1

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

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

SPECIFICATIONS

Magic-Pak: HW/HWC

2-2

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

HW/HWC-SRM

2/99

Service Reference Manual

SEQUENCE OF OPERATIONS

2-3

BLANK PAGE

SRM-HW/HWC 2/99

SPECIFICATIONS

Magic-Pak: HW/HWC

2-4

HWC123, 183, 243, 303

(w/United Technologies 1097 Spark Ignition System)

CONNECTION DIAGRAM

CIRCUITS ENERGIZED

208/230-1-60

COPPER CONDUCTORS

OPERATING MODE

CIRCUIT

POWER SUPPLY

ONLY

HEATING

R-W

}

YELLOW

COOLING

R-G-Y

RED

FAN

R-G

BLUE

BLACK

LINE VOLTAGE-FACTORY

LINE VOLTAGE-FACTORY WHEN USED

BLACK

GREEN RED

WHITE

2

CY

BLACK L1

COOL

UNUSED HEAT

LINE VOLTAGE-FIELD

COMBUSTION

CMB

ELECTRODE

LOW VOLTAGE-FACTORY

LOW VOLTAGE-FIELD

BLOWER

1

R

R

G

G

BLACK

BLACK

BLACK BLACK

PRESSURE SWITCH

3

RGW

24VAC

THERMOSTAT

Y

Y

4

IGNITION

WHT

W

W }

5

CONTROL

FLAME ROD

VIOLET

RED

4

5 6

GND

NOTE:

1

2

3

GAS

IF ANY OF THE ORIGINAL

WIRES ARE REPLACED, THE

VALVE BLUE

VIOLET

GREEN

SAME SIZE AND TYPE WIRE

ORN

BLUE

YELLOW

RED

MUST BE USED.

ORN

AUTO RESET

MANUAL RESET

LIMIT SWITCH

LIMIT SWITCH

ORN

RED

BLACK

CONDENSER FAN

VIOLET

BLUE

CONNECTOR BLOCK

TRANSFORMER

RED

CAPACITOR-RUN

BLACK

EVAP. MOTOR SPEED CONNECTIONS

BROWN

MODELS

HEATING

COOLING

BLK

FAN

BLACK

26HWC123

LOW (RED)

MED (BLUE)

208 V

COM

HERM

YELLOW

C

240 V

38HWC123

HIGH(BLACK) MED (BLUE)

S

COMP

BLK

38HWC183

LOW (RED)

LOW (RED)*

RED

R

CONTACTOR

51HWC183

MED (BLUE)

LOW (RED)

RED

64HWC183

HIGH(BLACK) LOW (RED)

RED

SEE CHART

T1

L1

38HWC243

LOW (RED)

MED (BLUE)

D

FOR WIRING

BLOWER

51HWC243

MED (BLUE)

MED (BLUE)*

CONTROL

T2

L2

64HWC243

HIGH(BLACK) MED (BLUE)

BLACK

51HWC303

MED (BLUE)

HIGH(BLACK)

YELLOW

H

BLUE

64HWC303

HIGH(BLACK) HIGH(BLACK)*

BLOWER

M

BROWN

RED

*JUMPER REQUIRED

MOTOR

L

CAPACITOR

BLUE

BLOWER

YELLOW

#45004-1

				DIAGNOSTICS
				The following blower/ignition control board
				LED codes will indicate normal or abnormal
				operations:
				SLOW FLASH	Normal Operation, No
					Call for Heat
	Note: On units that are equipped with a low ambient switch (designated			FAST FLASH	Normal Operation, Call for
	with an “SA” in the model number), sequence of operation during				Heat
				2 FLASH	System Lockout - Failed to
	cooling call is modified when outdoor temperatures fall below the
					Detect or Sustain Flame
	normal operating range. For more information on the low ambient			3 FLASH	Pressure Switch Open or
	switch equipped version of this unit, see the section beginning on
					Closed
	page 2-36.			4 FLASH	High Limit or Rollout
					Switch Open
				5 FLASH	Flame Sensed and Gas
					Valve Not Energized
				STEADY	Internal Failure
					(Micro-controller Failure;
					Self-check)
	FIGURE 2-1 Connection Diagram

HW/HWC-SRM

2/99

Service Reference Manual

SEQUENCE OF OPERATIONS

2-5

Simplified Sequence - HWC123,183, 243, 303

Refer to Figure 2-1

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

•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 blower, causing the pressure switch to close.

3.The combustion blower runs for 30 seconds as a pre-purge to trial for ignition.

4.The ignition control energizes the spark ignition and opens the gas valve, causing the burners to light. When the gas valve energizes, a 30-second circulating air blower “on” delay begins.

5.Flame sense is sent to the ignition control through the flame sensor and flame sense wire.

6.After the 30-second delay, the circulating air blower energizes and runs until the heat call is satisfied.

7.When the heat call is satisfied, the gas valve deenergizes. This shuts down the burners.

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

9.After the delay times elapse, the combustion blower and the circulating air blower stop.

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 lockout.

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

CALL FOR COOLING

1.The thermostat energizes the R, Y and G circuit, sending a 24-volt signal to the cooling contactor and the ignition control to start the cooling sequence.

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 “AUTO” position.

SRM-HW/HWC 2/99

Detailed Sequence follows

SPECIFICATIONS

Magic-Pak: HW/HWC

2-6

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:

1.From the transformer 24V terminal to pin 4 of the 6-pin chassis low voltage harness

2.From pin 4 of the chassis low voltage harness to the

24VAC hot terminal on the ignition control

3.From 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

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 30second circulating air blower “on” delay starts. After the delay, the ignition control energizes the heat speed blower relay. This sends L1 power to the

ACB HEAT terminal on the ignition control.

3.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 delay, the

CMB BLWR terminal on the ignition control deenergizes. This interrupts L1 power to the combustion blower. After a 120-second circulating air blower “off” delay, the ACB HEAT terminal deenergizes. This interrupts L1 to the circulating air blower. As L1 power is interrupted, the blowers shut off.

Low Voltage

1.A call for heat closes the R-W circuit, sending a 24volt signal to the low voltage white wire in the unit.

2.The 24-volt signal is received at pin 3 of the 5-pin thermostat harness on the ignition control.

3.The 24-volt signal causes the combustion blower relay to close, causing the combustion blower to run. At this time, a 24-volt signal is also sent out through pin 2 of the 6-pin ignition wire harness.

4.The 24-volt signal from pin 2 of the 6-pin ignition wire harness energizes one side of the Normally Open pressure switch. As the induced draft blower reaches full speed, the pressure switch closes and a 24-volt signal is sent to pin 5 of the 6- pin ignition wire harness.

5.When the 24-volt signal is received at pin 5 of the 6- pin ignition wire harness, the ignition control starts a 30-second pre-purge delay.

6.After the 30-second pre-purge, the ignition control initiates a trial for ignition. The spark ignition cable terminal and pin 4 of the 6-pin ignition wire harness energize simultaneously.

7.When the 24-volt signal is present at pin 4 of the 6- pin ignition wire harness, the ignition control starts a 30-second circulating air blower “on” delay.

8.The 24-volt signal from pin 4 of the 6-pin ignition wire harness is received at the gas valve, causing it to open and the burners to ignite.

HW/HWC-SRM

2/99

SRM-HW/HWC 2/99

Service Reference Manual

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-ener- gized.

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 circulating air blower “off” delay and 5-second combustion blower post-purge delay.

14.After 5 seconds, the combustion blower shuts off.

15.After 120 seconds, the circulating air blower shuts off and the system returns to standby mode.

Note: During a call for heat, the green LED shows consistent fast flash (as long as the R-W circuit is closed). When the R-W circuit is interrupted (indicating the heat call has been satisfied), the green LED returns to a consistent slow flash.

LIMIT/ROLLOUT OPENS

In all modes of operation, 24VAC is supplied to the ignition control 24VAC hot terminal and is passed through the ignition control to pin 6 of the 6-pin ignition wire harness.

1.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 voltage power is supplied to the unit.

3.If the circuit is interrupted by either switch opening, the 24-volt signal to pin 1 of the 6-pin ignition wire harness de-energizes.

4.This causes the combustion blower relay to energize, sending L1 power to the CMB BLWR terminal on the ignition control. It also causes the circulating air blower heat speed relay to 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.

SEQUENCE OF OPERATIONS

2-7

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

8.When the 24-volt signal is restored at pin 1 of the 6- pin ignition wire harness, the ignition control starts a 5-second combustion blower post-purge delay and a 120-second circulating air blower “off” delay.

9.Once the delays have timed out, both blowers stop and the green LED flashes a consistent slow flash if no heat call is present. (A consistent fast flash appears if there is a call for heat.)

Note: The limit switch resets automatically when temperatures are acceptable, but the rollout switch must be manually reset by pushing in on the small button on top of the switch.

The reason why the switches opened must be determined before any corrective action is taken.

PRESSURE SWITCH OPENS (BLOCKED FLUE)

When the R-W circuit is energized, a 24-volt signal is sent to the ignition control. This starts the call for heat.

1.The 24-volt signal from the R-W circuit energizes the combustion blower relay, sending L1 power to the CMB BLWR terminal on the ignition control. This starts the ignition control.

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

3.When the combustion blower causes the pressure switch to close, a 24-volt signal is sent across the switch to pin 5 of the 6-pin ignition wire harness. The 24-volt signal energizes at pin 5 and the ignition sequence continues.

4.If the combustion blower fails to close the pressure 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 power to the CMB BLWR terminal on the ignition control.

7.The combustion blower remains de-energized for approximately six minutes. During this 6-minute lockout, the green LED flashes three times (indicating pressure switch fault—open or closed).

SPECIFICATIONS

2-8

8.The 24-volt signal will only be supplied to the limit switch circuit through pin 6 of the 6-pin ignition wire harness and to the pressure switch circuit through pin 2 of the 6-pin ignition wire harness.

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.

FAILED FLAME SENSE/TRIAL FOR IGNITION

When the pressure switch closes and a 24-volt signal is sent to pin 5 of the 6-pin ignition wire harness, the spark ignition cable terminal and pin 4 of the 6-pin ignition wire harness energize.

1.As spark voltage is supplied to the ignitor electrodes, 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 ignition 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 delay is timed out, the circulating air blower starts.

6.After the spark ignition cable terminal de-ener- gizes, 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 above 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.

Magic-Pak: HW/HWC

CALL FOR COOLING

Line Voltage

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

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 power 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 thermostat, 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 deenergized. This interrupts L1 power to the compressor and condenser fan motors, stopping both.

7.The ignition control starts a 90-second circulating 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 circulating air blower “on” delay.

4.After the 5-second delay, the ignition control energizes the cooling speed relay and the circulating 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.

HW/HWC-SRM

2/99

Service Reference Manual

SEQUENCE OF OPERATIONS

2-9

6.After the 90-second delay, the ignition control deenergizes the cooling speed relay and the circulating 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 “AUTO”, interrupting the R-G circuit.

Note: With the thermostat in the “FAN ON” position during heat call, ignition control will not energize the heat speed relay. The circulating air blower continues to run in cooling speed unless the limit switch circuit opens, which would cause the heat speed relay and the induced draft blower relay to become energized. This would de-energize the cooling speed relay until either the limit switch circuit is closed or the thermostat is switched to the “AUTO” position.

SRM-HW/HWC 2/99

SPECIFICATIONS

Magic-Pak: HW/HWC

2-10

HW (Heating Only)

(w/United Technologies 1097 Spark Ignition System)

CONNECTION DIAGRAM

WIRE NUT

CIRCUITS ENERGIZED

OPERATING MODE

CIRCUIT

208/230-1-60

COPPER CONDUCTORS

HEATING

R-W

POWER SUPPLY

ONLY

YELLOW

COOLING

R-G-Y

}

RED

FAN

R-G

BLUE

LINE VOLTAGE-FACTORY

BLACK

LINE VOLTAGE-FACTORY WHEN USED

LINE VOLTAGE-FIELD

BLACK

RED

GREEN

WHITE

Y

L1

COOL

HEAT

UNUSED

LOW VOLTAGE-FACTORY

COMBUSTION

CNB

ELECTRODE

LOW VOLTAGE-FIELD

BLOWER

1

R

R

2

C

G

G

THERMOSTAT

BLACK BLACK

R G W

BLACK BLACK

PRESSURE SWITCH

3

24VAC

VALVE BLUE

WIRES ARE REPLACED, THE

Y

Y

4

IGNITION

WHT

W

W }

5

CONTROL

FLAME ROD

VOILET

RED

4

5 6

GND

1

2 3

NOTE:

GAS

ORANGE

BLUE

YELLOW

RED

IF ANY OF THE ORIGINAL

VOILET

GREEN

SAME SIZE AND TYPE WIRE

ORANGE

MUST BE USED.

AUTO RESET

MANUAL RESET

LIMIT SWITCH

LIMIT SWITCH

ORANGE

BLACK

CONNECTOR

RED

BLOCK

YELLOW

EVAP. MOTOR

208 V

240 V

SPEED CONNECTIONS

MODELS

HEATING

TRANSFORMER

26HW

LOW (RED)

38HW

HIGH (BLACK)

BLUE

51HW

MED (BLUE)

64HW

HIGH (BLACK)

RED

SEE

CHART

FOR WIRING

#45008-2

YELLOW

BLACK

H

BLOWER

BLUE

M

BROWN

MOTOR

RED

L

CAPACITOR

TERMINAL BLOCK

BLOWER

DIAGNOSTICS

The following blower/ignition control board LED codes will indicate normal or abnormal operations:

SLOW FLASH	Normal Operation, No
	Call for Heat
FAST FLASH	Normal Operation, Call for
	Heat
2 FLASH	System Lockout - Failed to
	Detect or Sustain Flame
3 FLASH	Pressure Switch Open or
	Closed
4 FLASH	High Limit or Rollout
	Switch Open
5 FLASH	Flame Sensed and Gas
	Valve Not Energized
STEADY	Internal Failure
	(Micro-controller Failure;
	Self-check)

FIGURE 2-2 Connection Diagram

HW/HWC-SRM

2/99

Service Reference Manual

SEQUENCE OF OPERATIONS

2-11

Simplified Sequence - HW (w/UTEC 1097 Board)

Refer to Figure 2-2

CALL FOR HEAT

1.The indoor thermostat energizes the R-W circuit, sending a 24-volt signal to the ignition control.

2.The 24-volt signal causes the induced draft blower to start, which closes the pressure switch.

3.Once the pressure switch closes, a 30-second induced draft blower pre-purge starts.

4.After the 30-second induced draft blower pre-purge, the gas valve opens and the burners ignite. This starts a 30-second circulating air blower “on” delay.

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.

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 moved back to the “AUTO” position. At this time, the circulating air blower stops.

During the call for “FAN ON”, the circulating air blower heat speed will not be energized by the ignition control unless the limit switch circuit is interrupted.

SRM-HW/HWC 2/99

Detailed Sequence follows

SPECIFICATIONS

Magic-Pak: HW/HWC

2-12

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 30second circulating air blower “on” delay starts. After the delay, the ignition control energizes the heat speed blower relay. This sends L1 power to the ACB HEAT terminal on the ignition control.

3.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.

4.The combustion blower and the circulating air blower continue to run until the R-W circuit is interrupted. After a 5-second post-purge delay, the

CMB BLWR terminal on the ignition control deenergizes. This interrupts L1 power to the combustion blower. After a 120-second circulating air blower “off” delay, the ACB HEAT terminal deenergizes. This interrupts L1 to the circulating air blower. As L1 power is interrupted, the blowers shut off.

Low Voltage

1.A call for heat closes the R-W circuit, sending a 24volt signal to the low voltage white wire in the unit.

2.The 24-volt signal is received at pin 3 of the 5-pin thermostat harness on the ignition control.

3.The 24-volt signal causes the combustion blower relay to close, causing the combustion blower to run. At this time, a 24-volt signal is also sent out through pin 2 of the 6-pin ignition wire harness.

4.The 24-volt signal from pin 2 of the 6-pin ignition wire harness energizes one side of the Normally Open pressure switch. As the induced draft blower reaches full speed, the pressure switch closes and a 24-volt signal is sent to pin 5 of the 6- pin ignition wire harness.

5.When the 24-volt signal is received at pin 5 of the 6- pin ignition wire harness, the ignition control starts a 30-second pre-purge delay.

6.After the 30-second pre-purge, the ignition control initiates a trial for ignition. The spark ignition cable terminal and pin 4 of the 6-pin ignition wire harness energize simultaneously.

7.When the 24-volt signal is present at pin 4 of the 6- pin ignition wire harness, the ignition control starts a 30-second circulating air blower “on” delay.

8.The 24-volt signal from pin 4 of the 6-pin ignition wire harness is received at the gas valve, causing 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-ener- gized.

HW/HWC-SRM

2/99

SRM-HW/HWC 2/99

Service Reference Manual

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 circulating air blower “off” delay and 5-second combustion blower post-purge delay.

14.After 5 seconds, the combustion blower shuts off.

15.After 120 seconds, the circulating air blower shuts off and the system returns to standby mode.

Note: During a call for heat, the green LED shows consistent fast flash (as long as the R-W circuit is closed). When the R-W circuit is interrupted (indicating the heat call has been satisfied), the green LED returns to a consistent slow flash.

LIMIT/ROLLOUT OPENS

In all modes of operation, 24VAC is supplied to the ignition control 24VAC hot terminal and is passed through the ignition control to pin 6 of the 6-pin ignition wire harness.

1.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 voltage power is supplied to the unit.

3.If the circuit is interrupted by either switch opening, the 24-volt signal to pin 1 of the 6-pin ignition wire harness de-energizes.

4.This causes the combustion blower relay to energize, sending L1 power to the CMB BLWR terminal on the ignition control. It also causes the circulating air blower heat speed relay to 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 6- pin ignition wire harness, the ignition control starts a 5-second combustion blower post-purge delay and a 120-second circulating air blower “off” delay.

SEQUENCE OF OPERATIONS

2-13

9.Once the delays have timed out, both blowers stop and the green LED flashes a consistent slow flash if no heat call is present. (A consistent fast flash appears if there is a call for heat.)

Note: The limit switch resets automatically when temperatures are acceptable, but the rollout switch must be manually reset by pushing in on the small button on top of the switch.

The reason why the switches opened must be determined before any corrective action is taken.

PRESSURE SWITCH OPENS (BLOCKED FLUE)

When the R-W circuit is energized, a 24-volt signal is sent to the ignition control. This starts the call for heat.

1.The 24-volt signal from the R-W circuit energizes the combustion blower relay, sending L1 power to the CMB BLWR terminal on the ignition control. This starts the ignition control.

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

3.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.

4.If the combustion blower fails to close the pressure 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 power to the CMB BLWR terminal on the ignition control.

7.The combustion blower remains de-energized for approximately six minutes. During this 6-minute lockout, the green LED flashes three times (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.

SPECIFICATIONS

2-14

FAILED FLAME SENSE/TRIAL FOR IGNITION

When the pressure switch closes and a 24-volt signal is sent to pin 5 of the 6-pin ignition wire harness, the spark ignition cable terminal and pin 4 of the 6-pin ignition wire harness energize.

1.As spark voltage is supplied to the ignitor electrodes, 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 ignition 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 delay is timed out, the circulating air blower starts.

6.After the spark ignition cable terminal de-ener- gizes, 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 above 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.

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.

Magic-Pak: HW/HWC

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 during heat call, ignition control will not energize the heat speed relay. The circulating air blower continues to run in cooling speed unless the limit switch circuit opens, which would cause the heat speed relay and the induced draft blower relay to become energized. This would de-energize the cooling speed relay until either the limit switch circuit is closed or the thermostat is switched to the “AUTO” position.

HW/HWC-SRM

2/99

Service Reference Manual

SEQUENCE OF OPERATIONS

2-15

BLANK PAGE

SRM-HW/HWC 2/99

SPECIFICATIONS

Magic-Pak: HW/HWC

2-16

HWC122, 182, 242, 302

(w/Fenwal Triton 2461D DSI Ignition Control)

CIRCUITS ENERGIZED

208/230-1-60			COPPER CONDUCTORS
POWER SUPPLY			ONLY

OPERATING MODE	CIRCUIT
HEATING	R-W
COOLING	R-G-Y
FAN	R-G

				PINK	MANUAL			NO	RED
							LIMIT
		TH
			WHITE		RESET		SWITCH NC		C
		P.SW
			ORN
		V1			WHITE						R
			ORN					WHITE	WHITE
		IND									W
BLACK BLACK				BLUE
					BROWN
				GAS
		L1		VALVE		PRESSURE					Y
	24VAC			BLUE			SWITCH				G
	IGNITION	V2
	CONTROL	GND
		GREEN	RED	BLACK		COMBUSTION			BLUE	GREEN WHITE RED YELLOW
	ELECTRODE						BLOWER
				BLACK
	CABLE
					BLACK			CONNECTOR
					BLACK
									BLOCK
	BLACK

CONDENSER FAN

VIOLET

BLACK

BLUE

CAPACITOR-RUN

RED

FAN

BROWN

BLACK

C

T1

L1

COM

BLACK

YELLOW

S

RED

CONTACTOR

HERM

R

T2

L2

BLACK

208V

RED

240V

TRANS-

RED

SEE TABLE

YEL

FORMER

FOR WIRING

BLOWER

BLK

CONTROL

BLUE

BLUE

YEL

C

C

BLK

RED

BLUE

R

BLK

RED

H

BLK

YEL

CONTR

YEL

BROWN

W

CAPACITY

BLOWER

L1

G

COMP T’STAT

LOAD

BLUE

BLOWER

MOTOR

COM

(IF USED)

TIME DELAY

SEE TABLE

WHITE

(IF USED)

GREEN

LINE VOLTAGE - FACTORY

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

LOW VOLTAGE - FACTORY LOW VOLTAGE - FIELD

R

W THERMOSTAT

Y

G

NOTE:

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

EVAPORATOR MOTOR

SPEED CONNECTIONS

	MODELS	HEATING	COOLING
	26HWC122	LOW (RED)	MED (BLUE)
	38HWC122	HIGH (BLK)	MED (BLUE)
	38HWC182	LOW (RED)	LOW (RED)	*
	51HWC182	MED (BLUE)	LOW (RED)
	64HWC182	HIGH (BLK)	LOW (RED)
	38HWC242	LOW (RED)	MED (BLUE)
	51HWC242	MED (BLUE)	MED (BLUE)	*
	64HWC242	HIGH (BLK)	MED (BLUE)
	51HWC302	MED (BLUE)	HIGH (BLK)
	64HWC302	HIGH (BLK)	HIGH (BLK)	*
	* JUMPER REQUIRED

#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. For more information on the low ambient switch equipped version of this unit, see the section beginning on page 2-38.

FIGURE 2-3 Connection Diagram

HW/HWC-SRM

2/99

Service Reference Manual

SEQUENCE OF OPERATIONS

2-17

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

Refer to Figure 2-3

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 blower control board. This causes the blower control board to begin the countdown to closing the relay that starts the circulating air blower.

3.After the induced draft blower creates enough negative pressure, the pressure switch closes.

4.When the pressure switch closes, the 24-volt signal is sent to the ignition control. This starts a 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 flows to the burners.

6.With the burners in operation, the trial for ignition continues for seven seconds. At the end of this time, the ignition control stops sparking.

7.Approximately 30 seconds after the burners ignite, the timer on the blower control board closes a relay, sending line voltage to and starting the circulating air blower.

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

9.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 blower continue to run. When the unit cools down enough for the limit switch to close, the 24-volt signal is again sent to the P.SW terminal on the ignition control. With terminal P.SW energized, the ignition control again makes a trial for ignition and relights the burners.

CALL FOR COOLING

1.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 blower control board which starts the timer.

3.Fifteen seconds after terminal G on the blower control board energizes (or immediately after - see note below), the circulating air blower starts.

4.When terminal G on the blower control board deenergizes, the timer to turn off the circulating air blower starts. The circulating air blower turns off after 90 seconds (see note below).

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

SRM-HW/HWC 2/99

Detailed Sequence follows

SPECIFICATIONS

Magic-Pak: HW/HWC

2-18

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 volts A/C) is supplied to both black wires located in the junction block on top of the unit.

Line voltage will be present at the following locations:

First black wire

1.L-1 on the ignition control

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 capacitors

Low Voltage (24 VAC)

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

1.Red wire exiting the top of the unit

2.Terminal marked 24 VAC on the ignition control

3.Terminal R on the blower control board

CALL FOR HEAT

Line Voltage

The thermostat closes the circuit between R and W.

The following is the sequence of operation for the line voltage side of the unit:

1.Terminal TH (24-volt) energizes on the ignition control, causing the relay in the ignition control to close. This sends line voltage to the terminal marked IND, causing the induced draft blower to start.

2.When W energizes, a 24-volt signal is also sent to the W terminal on the blower control board. The 24-volt signal to the blower control board starts the timer on the board. After 60 seconds, the heat speed relay on the blower control board closes. This sends line voltage from the terminal marked

HEAT to the circulating air blower, starting the blower. The induced draft blower and the circulating air blower continue to operate until the heat call is satisfied, interrupting the circuit between R and W. The W terminal de-energizes, causing the blower relay to open approximately 90 seconds later. This interrupts the line voltage to the circulating air blower and the blower shuts down.

Low Voltage

1.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 blower starts in approximately 60 seconds.

4.The 24-volt signal sent to terminal TH closes the relay in the ignition control. This starts the induced draft blower by energizing terminal IND on the ignition control.

5.As the induced draft blower comes up to speed and creates enough negative pressure, the pressure 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 continues 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 several seconds later.

9.The blower control board starts a countdown to blower “off”. Approximately 90 seconds later, the blower shuts down.

HW/HWC-SRM

2/99

SRM-HW/HWC 2/99

Service Reference Manual

LIMIT OPENS

If the limit switch opens for any reason during a call for heat, the following happens:

1.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 deenergizes terminal P.SW on the ignition control. The gas valve closes immediately, as the 24-volt signal to terminal P.SW is no longer present. The induced draft blower and the circulating air blower continue to run. Power to blower control board terminal W is maintained. The blowers continue to run until the limit switch closes or the heat call at the thermostat is satisfied.

2.When the limit switch senses that temperatures in the unit are normal, the contacts between terminals C and NO open, the contacts between terminals C and NC close and operation of the unit returns to normal.

PRESSURE SWITCH OPENS (BLOCKED FLUE)

1.If blockage of the flue occurs, the negative pressure in the induced draft blower is reduced. 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 negative pressure is restored, the pressure switch closes and sends a 24-volt signal to the P.SW terminal on the ignition control. The ignition control makes a trial for ignition again and operation returns to normal.

Note: If the P.SW and TH terminals energize at the same time, the ignition control will not respond. A pressure switch being stuck closed is an example of what would cause this to happen.

ROLLOUT SWITCH ACTIVATED

1.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.

SEQUENCE OF OPERATIONS

2-19

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 blower “off”. After approximately 90 seconds (see note on page 2-20), the cooling speed relay opens and the circulating air blower shuts down.

Low Voltage

1.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.

SPECIFICATIONS

Magic-Pak: HW/HWC

2-20

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 moved to the “FAN ON” position, a 24-volt signal is sent to G.

2.With G energized, the blower control board starts a countdown to fan “on”. After approximately 15 seconds, the fan starts (see note below).

3.The blower control board closes a relay on the board, sending line voltage to the terminal marked COOL on the board. This starts the circulating air blower.

4.When the switch at the thermostat is moved to the “OFF” position, the 24-volt signal to the blower control board is interrupted. With no signal at the

G terminal, the blower control board starts a countdown to fan “off”. Approximately 90 seconds later, a relay on the blower control board opens (see note below). This interrupts the power to and stops the circulating air blower.

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

HW/HWC-SRM

2/99