Armstrong World Industries Hwc Premier 183 Users Manual TOC

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Service Reference Manual
HWC Thru-the-Wall Units
Models:
HWC Premier
122, 182, 242, 302
123, 183, 243, 303

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 Armstrong Customer
Service Department.

SRM-HW/HWC 8/99

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.

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

SRM-HW/HWC 8/99

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.

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

SRM-HW/HWC 8/99

Physical and Electrical ................................
Performance Ratings ..................................
Blower Performance ...................................
Dimensions ................................................
Wall Sleeve ................................................

1-4
1-4
1-6
1-6
1-7

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

2 --

26 = Rated Input BTU/Hr x 1000
H = Gas Heat
W = Thru-the-Wall
C = Cooling
12 = Nominal Cooling BTU/Hr x 1000
2 = Cooling Efficiency 2 - 9.7 SEER
2A = Revision Code

Product Serial Numbers, Beginning 1993
84

12345

84 = Armstrong Factory Number
95 = Year (ex: 1995)
A = Month (see list below)
12345 = Sequential Number
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

A = Jan

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/
Electric Cool

UTech Combination Ignition/Blower Control 1097

DSI

(All) HW -9

Gas Heat Only

UTech Combination Ignition/Blower Control 1097

DSI

(All) HWC (122, 182, 242, 302)
-11, -10, -9, -8, -7, -6, -5

Gas Heat/
Electric Cool

Ignition Control: Fenwal Triton 2461D
Blower Control: Heatcraft IBCH4C401,
Tridelta 920B0048 or UTech 1010

DSI

(All) HWC (122, 182, 242, 302)
-4, -3, -2, -1

Gas Heat/
Electric Cool

Ignition Control: Fenwal 05-29
Blower Control: Heatcraft IBCH4C401,
Tridelta 920B0048 or UTech 1010

DSI

Table 1-2 Cooling Configurations of HWC Units
Model

Configuration

Tonnage

SEER

Compressor Type*

Metering Device

(All) HWC 123-1

Gas Heat/Electric Cool

9.7

Tecumseh Rotary

Capillary Tube/Filter Drier

(All) HWC183-1

Gas Heat/Electric Cool

1.5

9.7

Tecumseh
Reciprocating

Capillary Tube/Filter Drier

(All) HWC 243-1

Gas Heat/Electric Cool

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, 9, -7, -6

Gas Heat/Electric Cool

1.5

9.7

Tecumseh
Reciprocating

Capillary Tube/Filter Drier

(All) HWC 242-11, -9

Gas Heat/Electric Cool

9.7

Copeland Scroll

Capillary Tube/Filter Drier

(All) HWC 122-10, 8, -5, -4, -3, -1

Gas Heat/Electric Cool

9.7

Tecumseh Rotary

Capillary Tube/Filter Drier

(All) HWC 242-10, 8, -5, -4, -3, -1

Gas Heat/Electric Cool

9.7

Copeland Scroll

Capillary Tube/Filter Drier

(All) HWC 302-9

Gas Heat/Electric Cool

2.5

9.5

Copeland Scroll

Capillary Tube/Filter Drier

(All) HWC 182-8, -5,
-4, -3, -2

Gas Heat/Electric Cool

1.5

9.7

Tecumseh Rotary

Capillary Tube/Filter Drier

(All) HWC 302-8, -5,
-4, -3, -1

Gas Heat/Electric Cool

2.5

9.5

Copeland Scroll

Capillary Tube/Filter Drier

(All) HWC 182-1

Gas Heat/Electric Cool

1.5

9.5

Copeland Scroll

Capillary Tube/Filter Drier

SRM-HW/HWC 8/99

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

SPECIFICATIONS

Magic-Pak: HW/HWC

1-4

HW/HWC
Physical and Electrical
Table 1-3

Physical and Electrical Specifications - HWC Units

Model

Voltage/
Hz/Phase

Normal
Voltage
Range

Min.
Circuit
Ampacity

Max.
Fuse/HACR
Brkr.
(amps)

Comp.
Rated
Load
(amps)

Comp.
Locked
Rotor
(amps)

O.D.
Fan
Dia.
(in.)

Nom.
RPM

Outside
Fan
Rated
Load
(amps)

Rated
HP

Indoor
Wheel
dia. x
width
(in.)

Blower
Rated
HP

Refrig.
Charge
(oz.)

Weight
(lbs.)

26HWC122/123

208-230/60/1

197-253

8.3

5.0

26.3

1075

0.9

1/8

10 X 4

1/6

325

38HWC122/123

208-230/60/1

197-253

8.3

5.0

26.3

1075

0.9

1/8

10 X 4

1/6

325

38HWC182/183

208-230/60/1

197-253

13.6

8.3

45.0

1075

0.9

1/8

10 X 4

1/3

350

51HWC182/183

208-230/60/1

197-253

13.6

8.3

45.0

1075

0.9

1/8

10 X 4

1/3

350

64HWC182/183

208-230/60/1

197-253

13.6

8.3

45.0

1075

0.9

1/8

10 X 4

1/3

350

36HWC242/243

208-230/60/1

197-253

18.6

11.6

62.5

1075

1.8

1/4

10 X 4

1/3

360

51HWC242/243

208-230/60/1

197-253

18.6

11.6

62.5

1075

1.8

1/4

10 X 4

1/3

360

64HWC242/243

208-230/60/1

197-253

18.6

11.6

62.5

1075

1.8

1/4

10 X 4

1/3

360

51HWC302

208-230/60/1

197-253

22.4

14.6

76.0

1075

1.8

1/4

10 X 4

1/3

380

64HWC302

208-230/60/1

197-253

22.4

14.6

76.0

1075

1.8

1/4

10 X 4

1/3

380

51HWC303

208-230/60/1

197-253

21.9

14.1

73.0

1075

1.8

1/4

10 X 4

1/3

380

64HWC303

208-230/60/1

197-253

21.9

14.1

73.0

1075

1.8

1/4

10 X 4

1/3

380

Performance Ratings
Table 1-4

Performance Ratings - HWC122/123
Outdoor Air Temperature Entering Outdoor Coil
95°

85°
Enter.
Wet
Bulb

63°

67°

71°

105°

115°

Total
Air
Vol.
(CFM)

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
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

450

12800

820

.82

.97

1.00

12200

910

.85

1.00

11600

1000

.87

1.00

11000

1090

.90

1.00

500

13100

820

.87

1.00

12400

910

.90

1.00

11800

1000

.92

1.00

11200

1090

.95

1.00

400

13400

820

.59

.74

.89

12700

910

.60

.76

.91

12100

1010

.62

.79

1.00

11500

1110

.63

.81

.96

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

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.
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
95°

85°
Enter.
Wet
Bulb

63°

67°

71°

Total
Air
Vol.
(CFM)

Total
Cooling
Capacity
(Btuh)

550

18400

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

1370

.75

.90

1.00

17100

105°

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

1470

.78

.92

1.00

15700

115°

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

1550

.82

.96

1.00

14400

1640

.86

.96

1.00

600

18700

1380

.78

.93

1.00

17400

1480

.81

.96

1.00

16000

1560

.85

1.00

14600

1650

.89

1.00

650

18900

1390

.81

.96

1.00

17600

1490

.84

.99

1.00

16200

1570

.88

1.00

14800

1660

.92

1.00

550

19800

1410

.58

.72

.87

18500

1510

.59

.74

.89

17100

1600

.62

.78

.94

15600

1700

.64

.80

.96

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

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

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

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
95°

85°
Enter.
Wet
Bulb

63°

67°

71°

Total
Air
Vol.
(CFM)

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

105°
S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

115°
Comp.
Watts
Input

S/T at
75°
Dry
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

800

24700

1870

.78

.93

1.00

23600

2110

.80

.94

1.00

22200

2380

.82

.99

1.00

21300

2710

.84

1.00

900

25200

1880

.82

.98

1.00

24100

2120

.85

.99

1.00

22600

2390

.87

1.00

21700

2720

.89

1.00

700

25900

1890

.57

.71

.85

24700

2130

.58

.72

.86

23600

2400

.59

.75

.91

22400

2750

.60

.76

.92

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

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
95°

85°
Enter.
Wet
Bulb

63°

SRM-HW/HWC 8/99

67°

71°

105°

115°

Total
Air
Vol.
(CFM)

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
Bulb

Total
Cooling
Capacity
(Btuh)

Comp.
Watts
Input

S/T at
75°
Dry
Bulb

S/T at
80°
Dry
Bulb

S/T at
85°
Dry
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

850

28900

2160

.74

.87

1.00

27600

2400

.76

.90

1.00

26400

2680

.77

.93

1.00

25100

3000

.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

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

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

Blower Speed

Model

HWC122/123

HWC182,242,302
HWC183,243,303

Dimensions

0.2

0.3

0.4

0.5

650

615

575

540

Med

475

450

425

400

Low

415

405

390

380

875

825

775

725

Med

850

805

760

710

Low

630

605

575

550

(all measurements in inches)
SUPPLY AIR DUCT CONNECTION
LOW VOLTAGE
8" x 16"
THERMOSTAT CONNECTIONS
HIGH VOLTAGE
JUNCTION BOX
4" x 4" x 2"

¾" DUCT CONNECTION FLANGE

GAS LINE
CONNECTION

Measurements from Side and
Top to Center of Vent Outlet
1
4 2"

43 1/8

3
6 4"

7 16

27 /7 "
8

SRM-HW/HWC 8/99

RETURN AIR OPENING ON BOTTOM
6" x 22"

Service Reference Manual

SPECIFICATIONS
1-7

Dimensions (cont.)
1

13 3/8
8

Supply
Line Voltage
Box

Low
Voltage

43 1/8

Supply 8
2 7/8 4
1 3/4
3

½ Gas Inlet

Return
2 7/8

Wall Sleeve

22
27 7/8

(all measurements in inches)
1 or 3 3 4
15 or 12 1 4

45
2

12 1 2"

SRM-HW/HWC 8/99

Flanges may be assembled
1" or 3 3 4" from this side of the sleeve

29 7/16

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

SRM-HW/HWC 2/99

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

SRM-HW/HWC 2/99

Service Reference Manual

SEQUENCE OF OPERATIONS
2-3

SRM-HW/HWC 2/99

BLANK PAGE

SPECIFICATIONS

Magic-Pak: HW/HWC

2-4

HWC123, 183, 243, 303
(w/United Technologies 1097 Spark Ignition System)

CONNECTION DIAGRAM
CIRCUITS ENERGIZED

}

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

OPERATING MODE
HEATING
COOLING
FAN

YELLOW
RED

CIRCUIT
R-W
R-G-Y
R-G

BLUE

LINE VOLTAGE-FACTORY
LINE VOLTAGE-FACTORY WHEN USED
LINE VOLTAGE-FIELD
LOW VOLTAGE-FACTORY
LOW VOLTAGE-FIELD

BLACK

4
5

VIOLET

WHT

IGNITION
CONTROL

PRESSURE
SWITCH

4 5 6
RED

ELECTRODE

GND

GREEN

ORN

RED

BLUE

MANUAL RESET
LIMIT SWITCH

YELLOW

ORN

ORN
AUTO RESET
LIMIT SWITCH

THERMOSTAT

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

1 2 3

GAS
VALVE BLUE

VIOLET

}

FLAME ROD

24VAC

BLACK

HEAT

UNUSED

COOL
BLACK
L1
Y C W G R

CMB

WHITE

RED

GREEN

BLACK

COMBUSTION
BLOWER

RED
BLACK

CONDENSER FAN
VIOLET

TRANSFORMER

BLACK

CAPACITOR-RUN

BLUE
RED

CONNECTOR BLOCK
EVAP. MOTOR SPEED CONNECTIONS
MODELS
HEATING
COOLING
26HWC123 LOW (RED)
MED (BLUE)
38HWC123 HIGH(BLACK) MED (BLUE)
38HWC183 LOW (RED)
LOW (RED)*
51HWC183 MED (BLUE) LOW (RED)
64HWC183 HIGH(BLACK) LOW (RED)
38HWC243 LOW (RED)
MED (BLUE)
51HWC243 MED (BLUE) MED (BLUE)*
64HWC243 HIGH(BLACK) MED (BLUE)
51HWC303 MED (BLUE) HIGH(BLACK)
64HWC303 HIGH(BLACK) HIGH(BLACK)*

BROWN
COM

FAN
HERM

YELLOW

COMP
R

BLK

BLACK

208 V

240 V

BLK

RED

CONTACTOR

RED D

RED
SEE CHART
FOR WIRING
BLACK

YELLOW
BROWN

BLOWER
MOTOR

BLUE
RED

BLOWER
CONTROL

H
M

* JUMPER REQUIRED

L
BLUE

CAPACITOR
BLOWER
YELLOW

#45004-1
DIAGNOSTICS
The following blower/ignition control board
LED codes will indicate normal or abnormal
operations:

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 2-36.

Connection Diagram

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)

SRM-HW/HWC 2/99

FIGURE 2-1

SLOW FLASH

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.

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.

FLAME SENSE

SRM-HW/HWC 2/99

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).

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 6pin 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

1. The combustion blower relay energizes, sending
L1 power to CMB BLWR terminal on the ignition

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 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

The ignition control receives a signal from the R-W
circuit indicating a call for heat.

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.

Service Reference Manual

SEQUENCE OF OPERATIONS
2-7

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 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.

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 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.

LIMIT/ROLLOUT OPENS

SRM-HW/HWC 2/99

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.

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 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

Magic-Pak: HW/HWC

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-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 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.

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

SRM-HW/HWC 2/99

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.

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.

SRM-HW/HWC 2/99

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.

SPECIFICATIONS

Magic-Pak: HW/HWC

2-10

HW (Heating Only)
(w/United Technologies 1097 Spark Ignition System)

CONNECTION DIAGRAM

}

208/230-1-60
POWER SUPPLY

COPPER CONDUCTORS
ONLY

CIRCUITS ENERGIZED

WIRE NUT

OPERATING MODE
HEATING
COOLING
FAN

YELLOW
RED

LINE VOLTAGE-FACTORY
LINE VOLTAGE-FACTORY WHEN USED
LINE VOLTAGE-FIELD
LOW VOLTAGE-FACTORY
LOW VOLTAGE-FIELD

BLUE
BLACK

GND

ORANGE

Y
W

}

THERMOSTAT

FLAME ROD

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

GREEN
RED

BLUE

MANUAL RESET
LIMIT SWITCH

YELLOW

VOILET

ORANGE

WHT
24VAC

4 5 6
1 2 3

RED

ELECTRODE

IGNITION
CONTROL

GAS
VALVE BLUE

ORANGE
AUTO RESET
LIMIT SWITCH

HEAT

VOILET

UNUSED

PRESSURE
SWITCH

BLACK

COOL

CNB Y C W G R

WHITE

RED

GREEN

BLACK

COMBUSTION
BLOWER

CIRCUIT
R-W
R-G-Y
R-G

BLACK

CONNECTOR
BLOCK

RED

YELLOW
208 V

EVAP. MOTOR
SPEED CONNECTIONS

240 V

MODELS
26HW
38HW
51HW
64HW

TRANSFORMER

BLUE
RED

HEATING
LOW (RED)
HIGH (BLACK)
MED (BLUE)
HIGH (BLACK)

SEE
CHART
FOR WIRING
BLACK

YELLOW
BROWN
CAPACITOR
BLOWER

BLOWER
MOTOR

BLUE
RED

#45008-2

H
M

L
TERMINAL BLOCK

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

Connection Diagram

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)

SRM-HW/HWC 2/99

FIGURE 2-2

SLOW FLASH

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.

SRM-HW/HWC 2/99

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

Detailed Sequence follows

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.

SRM-HW/HWC 2/99

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.

Service Reference Manual

SEQUENCE OF OPERATIONS
2-13

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.

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: 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.

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

LIMIT/ROLLOUT OPENS

SRM-HW/HWC 2/99

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.

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.
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

Magic-Pak: HW/HWC

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-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 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.

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.

FAN ON

SRM-HW/HWC 2/99

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.

Service Reference Manual

SEQUENCE OF OPERATIONS
2-15

SRM-HW/HWC 2/99

BLANK PAGE

SPECIFICATIONS

Magic-Pak: HW/HWC

2-16

HWC122, 182, 242, 302
(w/Fenwal T
riton 2461D DSI Ignition Contr
ol)
Triton
Control)

CIRCUITS ENERGIZED
OPERATING MODE

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

BLACK
BLACK

BLUE
BLUE

LIMIT
SWITCH

WHITE

GAS
VALVE

V2
IGNITION
CONTROL GND

PRESSURE
SWITCH

WHITE

Y
G

THERMOSTAT

BROWN

BLACK
BLACK

GREEN
WHITE
RED
YELLOW
BLUE

COMBUSTION
BLOWER

BLACK
BLACK

RED

GREEN

ELECTRODE
CABLE

WHITE

ORN
ORN

MANUAL
RESET

WHITE

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

RED

PINK
TH
P.SW
V1
IND
L1
24VAC

CIRCUIT
R-W
R-G-Y
R-G

HEATING
COOLING
FAN

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

CONNECTOR
BLOCK

BLACK

BROWN

COM

YELLOW

HERM

S
R

BLACK

CONTACTOR

RED

BLACK

RED

CAPACITY
BLOWER

BLOWER
MOTOR

H
L1

C
R
W
G

SEE TABLE

BLUE

BLK

BROWN

BLK

BLK
BLUE
RED

YEL

BLOWER
CONTROL

YEL

RED

SEE TABLE
FOR WIRING

208V
240V

TRANSFORMER
BLUE
RED
BLK

YEL

CONTR

YEL

LOAD

COMP T’STAT
(IF USED)

BLUE
WHITE
GREEN

RED

FAN

BLUE

CONDENSER FAN
VIOLET
BLACK
CAPACITOR-RUN

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

*
*
*

COM

TIME DELAY
(IF USED)

#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.

Connection Diagram

SRM-HW/HWC 2/99

FIGURE 2-3

Service Reference Manual

SEQUENCE OF OPERATIONS
2-17

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

SRM-HW/HWC 2/99

Refer to Figure 2-3
CALL FOR HEAT

CALL FOR COOLING

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.

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.
2.
3.

When the thermostat switch is moved to the “FAN
ON” position, the circuit between R and G closes.
The 24-volt signal from G goes to the blower control
board which starts the timer.
Fifteen seconds after terminal G on the blower
control board energizes (or immediately after - see
note below), the circulating air blower starts.
When terminal G on the blower control board 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.

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:

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.
SRM-HW/HWC 2/99

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.

Service Reference Manual

SEQUENCE OF OPERATIONS
2-19

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.

SRM-HW/HWC 2/99

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.

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.

SRM-HW/HWC 2/99

Service Reference Manual

SEQUENCE OF OPERATIONS
2-21

SRM-HW/HWC 2/99

BLANK PAGE

SPECIFICATIONS

Magic-Pak: HW/HWC

2-22

HW (Heating Only)
(w/Fenwal Triton 2461D DSI Ignition Control)

CIRCUITS ENERGIZED
OPERATING MODE

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

PINK

BROWN

WHITE
ORANGE

BLUE
BLUE

V2
GND

BLACK
BLACK

PRESSURE
SWITCH

LIMIT
SWITCH

W
Y
G

W
Y

GREEN
WHITE
RED
YELLOW
BLUE

RED

GREEN

ELECTRODE
CABLE

GAS
VALVE

WHITE

ORANGE

WHITE

BLACK
BLACK

TH
P.SW
V1
IND
L1
24VAC

MANUAL
RESET

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

WHITE
RED

IGNITION
CONTROL

CIRCUIT
R-W

HEATING

COMBUSTION
BLOWER

BLACK
BLACK

THERMOSTAT

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

BLUE

BLACK
BLUE
RED

YELLOW
BROWN
CAPACITOR
BLOWER

BLOWER
MOTOR

BLACK

TRANSFORMER
L1
H

BLOWER
R

208

240

BLUE

SEE CHART
FOR WIRING

BLOWER
CONTROL

GREEN
WHITE
RED

YELLOW

MOTOR SPEED CONNECTIONS
HEATING
MODELS
LOW (RED)
26HW
HIGH (BLACK)
38HW
MED (BLUE)
51HW
HIGH (BLACK)
64HW

WHITE
RED

#39247D2

Connection Diagram

SRM-HW/HWC 2/99

FIGURE 2-4

Service Reference Manual

SEQUENCE OF OPERATIONS
2-23

Simplified Sequence - HW (w/Fenwal 2461D Board)
Refer to Figure 2-4
CALL FOR HEAT

SRM-HW/HWC 2/99

1. A call for heat closes the circuit between R and W
on the thermostat. This sends a 24-volt signal to the
white wire on the unit.
2. The 24-volt signal energizes terminal TH on the
ignition control and the W terminal on the blower
control board.
3. With the TH terminal energized, the ignition control
closes an internal relay. This sends line voltage
from terminal IND to the induced draft blower,
starting the inducer.
4. After a pre-purge cycle of approximately 30 seconds, the ignition control makes a trial for ignition.
Terminal V1 energizes at this time, opening the gas
valve. The ignition control initiates a spark at the
burner to light the main burners.
5. The trial for ignition lasts seven seconds, at which
time the ignition control stops sparking. The ignition
control looks at the flame sense to determine if the
main burners have ignited. If flame sense is not
proven, the ignition control goes through another
pre-purge cycle (approximately 30 seconds) and
makes another trial for ignition. It does this three
times. If the three trials for ignition fail, the ignition
control locks out for approximately 60 minutes.
After 60 minutes, the ignition control again makes
three trials for ignition. This continues as long as
there is a call for heat from the thermostat.
6. When W energizes, the blower control board starts
a countdown to fan “on”. Approximately 60 seconds
after the thermostat initiates a call for heat, the
circulating air blower starts.
7. The unit continues to operate as long as there is a
call for heat from the thermostat.
8. When the heat call is satisfied, the circuit between R
and W is interrupted. With the white wire deenergized, the ignition control interrupts the 24-volt
signal to the gas valve. This closes the gas valve
immediately and opens the internal relay that deenergizes terminal IND. The induced draft blower
shut downs several seconds later.
9. The W terminal on the blower control board deenergizes. This causes the blower control board to
start a countdown to blower “off”. Approximately 90
seconds later, the circulating air blower shuts down.
This completes the heating cycle.

Detailed Sequence follows

SPECIFICATIONS

Magic-Pak: HW/HWC

2-24

Detailed Sequence - HW
(w/Fenwal Triton 2461D Ignition Control)
Refer to Figure 2-4
POWER
Line Voltage
When the service disconnect switch is closed, power is
sent to the unit (unit in standby, no signal from thermostat). Power (208 - 230 volts A/C) is supplied to the two
black wires located in the junction block on top of the
unit.
Line voltage will be present at the following locations:
First black wire
1. L-1 on the ignition control
2. Terminal on the transformer marked 208V or
240V (whichever is being used)
3. Common terminal on the blower capacitor
Second black wire
1. Supplies power to the one side of the induced
draft blower
2. Common terminal on the transformer
3. L terminal on the blower control board
Low Voltage (24 VAC)
With the unit at rest (no call from the thermostat), 24
volts A/C will be found at the following points:
1.
2.
2.
3.

Red wire exiting the top of the unit
Terminal marked NO on the limit switch
Terminal marked 24VAC on the ignition control
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:

Low Voltage
The following is the sequence of operation for the low
voltage side of the unit on a heat call:
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.
3. The 24-volt signal is sent from the C terminal
(brown wire) on the limit switch to terminal TH on
the ignition control. This causes the ignition
control to close the line voltage relay, starting the
induced draft blower. When the induced draft
blower comes up to speed and creates enough
negative pressure, the pressure switch closes.
4. With the pressure switch closed, the 24-volt signal
goes to the rollout switch located over the burners.
5. The 24-volt signal from the rollout switch goes to
the terminal marked P.SW on the ignition control,
causing the ignition control to make a trial for
ignition (sparking). Terminal V1 on the ignition
control also energizes at this time, causing the gas
valve to open.
6. At the same time that the C terminal on the limit
switch energizes, a 24-volt signal is also sent to the
W terminal on the blower control board. This
starts the timer on the blower control board.
Approximately 30 seconds after the main burners
ignite, the blower control board closes a relay;
this sends line voltage to the circulating air
blower, starting the blower.
7. As long as W (white wire) is energized, the unit
continues to operate.
8. When the heat call is satisfied, the circuit between R
and W is interrupted.

SRM-HW/HWC 2/99

1. Terminal TH on the ignition control energizes,
causing a relay in the ignition control to close.
This sends line voltage to terminal IND on the
ignition control, causing the induced draft
blower to start.
2. When W is energized, a 24-volt signal is also sent
to the W terminal on the blower control board.
Approximately 60 seconds after W terminal ener-

gizes, the timer on the blower control board
closes the heat speed relay on the board. This
sends line voltage to the H terminal on the blower
control board, which starts the circulating air
blower.
3. The induced draft blower and the circulating air
blower continue to operate as long as W is energized.
4. When W de-energizes, a relay in the ignition
control opens. Terminal IND de-energizes and the
induced draft blower shuts down. Approximately
90 seconds later, the circulating air blower also
shuts down.

Service Reference Manual

SEQUENCE OF OPERATIONS
2-25

9. When W de-energizes, the gas valve immediately
shuts down and the induced draft blower also
stops after several seconds.
10. The blower control board starts a countdown to
blower “off”. Approximately 90 seconds later, the
circulating air blower shuts down.

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
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 circuit between terminals C
and NC on the limit switch opens. This closes the
circuit between terminals C and NO on the limit
switch, interrupting the 24-volt signal to the pressure switch and the rollout switch and causing
terminal P.SW on the ignition control to deenergize. The gas valve immediately closes, as
there is no longer a 24-volt signal at terminal V1 on
the ignition control. With 24 volts still going to the
blower control board and terminal TH on the
ignition control, the circulating air blower and
induced draft blower continue to run.
2. The circulating air blower and the induced draft
blower continue to run as long as there is a call for
heat from the thermostat or the limit switch
remains open.
3. When the limit switch senses that the temperature
in the unit is low enough, the circuit between C and
NO opens and the circuit between C and NC
closes.
4. With the limit switch closed, the unit again makes
a trial for ignition and returns to normal operation.

SRM-HW/HWC 2/99

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 coming from
terminal NC on the limit switch. Terminal P.SW on
the ignition control de-energizes, as does terminal
V1. With loss of the 24-volt signal to the gas valve,
the valve closes immediately.
2. Terminals TH on the ignition control and W on the
blower control board remain energized. The
induced draft blower and the circulating air
blower continue to run.
3. When the pressure switch senses that there is
enough negative pressure within the flue, it will
again close the circuit between the limit switch and
terminal P.SW on the ignition control.
4. The unit makes a trial for ignition and returns to
normal operation.

1. If the conditions in the burner compartment cause
the rollout switch to trip, the contacts on the switch
open. This interrupts the 24-volt signal going to
terminal P.SW on the ignition control, causing
terminal V1 on the ignition control to de-energize.
This interrupts the 24-volt signal to the gas valve
and immediately closes it. Since terminal TH on the
ignition control and W on the blower control
board remain energized, the induced draft
blower and the circulating air blower continue to
run.
2. The 24-volt signal to the ignition control can only
be restored if the rollout switch is manually reset.
3. Once the cause of the rollout switch being tripped
has been determined, the switch can be reset.
4. With the rollout switch reset, terminal P.SW on the
ignition control again energizes. The ignition
control makes a trial for ignition and operation
returns to normal.

SPECIFICATIONS

Magic-Pak: HW/HWC

2-26

HWC122, 182, 242, 302
(w/Fenwal 05-29 Ignition Contr
ol)
Control)

CIRCUITS ENERGIZED
OPERATING MODE

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

WHITE

LIMIT
SWITCH

WHITE

FLAME
SENSOR

WHITE

MANUAL
RESET

PRESSURE
SWITCH

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

RED

BLUE
BLUE

BLACK
BLACK

V1
P.SW
S1
TS
IND
L1
V2

ORANGE
ORANGE

IGNITION
CONTROL

GAS
VALVE

CIRCUIT
R-W
R-G-Y
R-G

HEATING
COOLING
FAN

WHITE

Y
G

BROWN

GND

COMBUSTION
BLOWER

BLACK
BLACK

CONNECTOR
BLOCK

GREEN
WHITE
RED
YELLOW
BLUE

GREEN

RED

ELECTRODE
CABLE

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

BLACK

BROWN

YELLOW

HERM

BLACK

S
R

RED

BLOWER
CONTROL

CAPACITY
BLOWER

H
L1

BLOWER
MOTOR

C
R
W
G

BLUE

BLK

BROWN

BLK

BLK
BLUE
RED

YEL

BLACK

240V

BLUE
RED
BLK

COMP T’STAT
(IF USED)

SEE TABLE

208V

TRANSFORMER

YEL

RED

RED
SEE TABLE
FOR WIRING

BLACK

CONTACTOR

YEL

TIME DELAY
(IF USED)

RED

FAN
COM

BLUE

CONDENSER FAN
VIOLET
BLACK
CAPACITOR-RUN

JUMPER REQUIRED

*
*
*

#39007D4

WHITE
GREEN

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.

Connection Diagram

SRM-HW/HWC 2/99

FIGURE 2-5

Service Reference Manual

SEQUENCE OF OPERATIONS
2-27

Simplified Sequence - HWC122, 182, 242, 302
(w/Fenwal 05-29 Ignition Control)
Refer to Figure 2-5
CALL FOR HEAT

CALL FOR COOLING

1. The thermostat energizes the R-W circuit, sending a
24-volt signal to the W wire at the unit.
2. The 24-volt signal is sent to the ignition control,
closing the combustion blower relay and causing the
combustion blower to run.
3. The 24-volt signal is also sent to the blower control
board, starting a 30-second circulation air blower
“on” delay.
4. As the combustion blower reaches full speed, it
closes the pressure switch.
5. A 24-volt signal is sent from the pressure switch to
the ignition control. Following a 30-second prepurge delay, this signal energizes the spark terminal.
6. The gas valve solenoid energizes at the same time
as the spark terminal, causing the gas valve to open
and the burners to light.
7. The spark ignitor continues to spark for approximately six seconds or until flame is sensed by the
flame sensor electrode.
8. The unit will operate normally until the R-W circuit is
de-energized by the thermostat, interrupting the 24volt signal to the unit.
9. When the signal is interrupted, the gas valve deenergizes and closes immediately.
10. The combustion blower relay de-energizes several
seconds later, causing the combustion blower to
stop.
11. The blower control board starts a 90-second
circulating air blower “off” delay.
12. Following the 90-second delay, the circulating air
blower stops.

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 15 seconds later (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 blower turns off
after 90 seconds (see note below).

FLAME SENSE

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 blower turns off after 90 seconds
(see note below).

SRM-HW/HWC 2/99

1. After the spark electrode has lit the main burners,
the ignition control waits approximately six seconds
for a flame sense signal.
2. If a flame sense signal is not received after approximately six seconds, the ignition control de-energizes the spark terminal and gas valve.
3. The thermostat R-W circuit sends a 24-volt signal to
the blower control board, starting the circulating air
blower (after a 30-second delay).
4. The unit initiates three trials for ignition (flame
sense) before system lockout.

Detailed Sequence follows

SPECIFICATIONS

Magic-Pak: HW/HWC

2-28

Detailed Sequence - HWC122, 182, 242, 302
(w/Fenwal 05-29 Ignition Control)
Refer to Figure 2-5
POWER
Line Voltage
When the service disconnect switch is closed, power is
sent to the unit (unit in standby, no signal from the
thermostat). Power (208 - 230 volts A/C) is supplied
to both black wires located in the junction block on top
of the unit.
Line voltage will be present at the following locations:
First black wire
1. L-1 on the ignition module
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 24VAC on the ignition control
3. Terminal R on the blower control board

CALL FOR HEAT
Line Voltage
The thermostat closes the circuit between R and W.
The following is the sequence of operation for the line
voltage side of the unit:

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 TS and terminal
W on the blower control board.
3. When W energizes, the timer starts a countdown to
circulating air blower “on”. The blower starts in
approximately 60 seconds.
4. The 24-volt signal sent to the TS terminal closes a
relay in the ignition control. This starts the
induced draft blower by energizing terminal IND
on the ignition control.
5. As the induced draft blower comes up to speed
and creates enough negative pressure, the pressure switch closes. The 24-volt signal is sent from
the pressure switch to one side of the Normally
Closed manual reset rollout switch. If the
rollout switch is closed, the 24-volt signal is
passed through the switch to the P.SW terminal on
the ignition control. This initiates a 30-second prepurge period.
6. After the 30-second pre-purge period, a trial for
ignition starts by energizing the spark terminal and
the V1 terminal simultaneously. The 24-volt signal
from V1 energizes the gas valve solenoid, causing
it to open. These actions cause the burners to light.
7. After the burners are lit, a flame sense is picked up
by the flame sense rod located at the opposite
end of the burner rack from the spark electrodes.
The flame sense signal is sent to the S1 terminal of
the ignition control. The unit continues to operate
as long as W is energized.
8. When the call for heat is satisfied, the circuit between R and W is interrupted, de-energizing W.

SRM-HW/HWC 2/99

2. When W is energized, a 24-volt signal is also sent to
the W terminal on the blower control board. The
24-volt signal starts the timer on the blower control 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.

Service Reference Manual

SEQUENCE OF OPERATIONS
2-29

9. With W de-energized, the gas valve closes immediately and the induced draft blower stops several
seconds later.
10. The blower control board starts a 90-second
circulating air blower “off” delay. Approximately
90 seconds later, the blower stops.

FLAME SENSE
1. During a call for heat, the spark terminal is energized and the gas valve is opened to light the
burners.
2. The ignition control energizes the spark terminal
and the gas valve for approximately six seconds. If
a flame is not sensed in this time period, the ignition control de-energizes the spark terminal and
the gas valve. This causes the gas valve to close
and the burners to shut off.
3. Since the 24-volt signal has been sent to the
blower control board, the circulating air blower
times “on” in approximately 60 seconds.
4. The induced draft blower continues to run for
approximately 30 seconds, then another trial for
ignition begins.
5. The ignition control runs three trials for ignition. If
a flame is not sensed during these three trials, the
ignition control will lockout.
6. The circulating air blower continues to run until
the R-W circuit at the thermostat is interrupted.
7. The ignition control remains in lockout until 24-volt
power to the ignition control is reset.

LIMIT OPENS

SRM-HW/HWC 2/99

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 blower
continues to run until the limit switch closes or the
heat call at the thermostat is satisfied.
2. When the limit switch senses that the temperatures in the unit are normal, the contacts between
terminals C and NO open, the contacts between
terminals C and NC close and the operation of the
unit returns to normal.

PRESSURE SWITCH OPENS (BLOCKED FLUE)
1. If blockage of the flue occurs, 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 a relay in the ignition control
opens and interrupts the signal to terminal V2 of the
ignition control.
2. Terminal W on the blower control board stays
energized and the circulating air blower continues to run. If negative pressure is restored, the
pressure switch closes and sends a 24-volt signal
to the P.SW terminal on the ignition control. The
ignition control makes a trial for ignition again and
the operation returns to normal.

ROLLOUT SWITCH ACTIVATED
1. If conditions in the burner compartment cause the
rollout switch to trip, the contacts on the switch
open, interrupting the 24-volt signal going to 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.
2. The reason the rollout switch was tripped must be
determined before any 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.

SPECIFICATIONS

Magic-Pak: HW/HWC

2-30
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, the cooling speed relay opens and the
circulating air blower shuts down (see note at the
end of this section).

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.
After approximately 15 seconds, the relay closes
(see note at the end of this section). This sends line
voltage to the COOLING speed terminal on the
board, which starts the circulating air blower.
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 deenergize. The contactor opens immediately,
causing the compressor and the outdoor cooling
fan to stop.
5. The circulating air blower stops approximately 90
seconds after the G terminal on the blower control
board de-energizes (see note at the end of this
section).

FAN ON
Low Voltage

SRM-HW/HWC 2/99

1. When the switch on the thermostat is moved to the
“FAN ON” position, a 24-volt signal is sent to the G
terminal on the blower control board.
2. With G energized, the blower control board starts
a countdown to fan “on”. Approximately 15 seconds
later (or immediately - see note at the end of this
section), the fan starts.
3. The blower control board closes a relay on the
board, sending line voltage to the terminal on the
board marked COOL. This starts the circulating
air blower.
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 at the end of this section). This interrupts
the power to and stops the circulating air blower.

Service Reference Manual

SEQUENCE OF OPERATIONS
2-31

SRM-HW/HWC 2/99

BLANK PAGE

SPECIFICATIONS

Magic-Pak: HW/HWC

2-32

HW (Heating Only)
(w/Fenwal 05-29 Ignition Control)

CIRCUITS ENERGIZED
OPERATING MODE

BROWN
MANUAL
RESET

WHITE
WHITE FLAME

LIMIT
SWITCH
NC

PRESSURE
SWITCH

WHITE

SENSOR

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

WHITE
RED

BLUE
BLUE

ORANGE
ORANGE

BLACK
BLACK

V1
P.SW
S1
TS
IND
L1
IGNITION V2
CONTROL

GAS
VALVE

Y
G

GND

BLACK
BLACK

GREEN
WHITE
RED
YELLOW
BLUE

GREEN

RED

ELECTRODE
CABLE

CIRCUIT
R-W

HEATING

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

COMBUSTION
BLOWER

BLACK
BLACK

THERMOSTAT

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

BLUE

BLACK
BLUE
RED

YELLOW
BROWN
CAPACITOR
BLOWER

BLOWER
CONTROL

BLOWER
MOTOR

BLACK
TRANSFORMER

L1
H

BLOWER
R

208

240

BLUE

SEE CHART
FOR WIRING

GREEN
WHITE
RED

YELLOW

MOTOR SPEED CONNECTIONS
HEATING
MODELS
LOW (RED)
26HW
HIGH (BLACK)
38HW
MED (BLUE)
51HW
HIGH (BLACK)
64HW

WHITE
RED

#39247D1

Connection Diagram

SRM-HW/HWC 2/99

FIGURE 2-6

Service Reference Manual

SEQUENCE OF OPERATIONS
2-33

Simplified Sequence - HW (w/Fenwal 05-29 Board)
Refer to Figure 2-6
CALL FOR HEAT

SRM-HW/HWC 2/99

1. The indoor thermostat calls for heat by energizing
the R-W circuit.
2. This sends a 24-volt signal to the ignition control,
causing the induced draft blower to run.
3. A 24-volt signal is also sent to the blower control
board at this time, starting a 60-second circulating
air blower “on” delay. The circulating air blower
starts 60 seconds after the initial call for heat.
4. The induced draft blower causes the pressure
switch to close which starts a 30-second pre-purge.
After the pre-purge period, the burners ignite.
5. The unit operates in the heating mode until the
indoor thermostat setting is reached and the R-W
circuit is interrupted.
6. When the R-W circuit is interrupted, the 24-volt
signal to the ignition control and the signal to the
blower control board are interrupted.
7. The induced draft blower stops within several
seconds and a 90-second circulating air blower “off”
delay starts. Following the delay period, the circulating air blower shuts off.

Detailed Sequence follows

SPECIFICATIONS

Magic-Pak: HW/HWC

2-34

Detailed Sequence - HW
(w/Fenwal 05-29 Ignition Control)
Refer to Figure 2-6
POWER
Line Voltage
When the service disconnect switch is closed, power is
sent to the unit (unit in standby, no signal from the
thermostat). Power (208 - 230 volts A/C) is supplied
to both black wires located in the junction block on top
of the unit.
Line voltage will be present at the following locations:
First black wire
1. L-1 on the ignition module
2. Terminal on the transformer marked 208V or
240V (whichever is being used)
3. Circulating air blower capacitor terminal
Second black wire
1. Supplies power to the induced draft blower
2. Common terminal on the transformer
3. Terminal L-1 on the blower control board
Low Voltage (24 VAC)
With the unit at rest (no call from the thermostat), 24
volts A/C will be found at these points:
1.
2.
3.
4.

Red wire exiting the top of the unit
Terminal R on the blower control board
Terminal NO on the limit switch
Terminal on the transformer marked 24V

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:

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 TS and terminal
W on the blower control board.
3. When W energizes, the timer starts a countdown to
circulating air blower “on”. The blower starts in
approximately 60 seconds.
4. The 24-volt signal sent to the TS terminal closes a
relay in the ignition control. This starts the
induced draft blower by energizing terminal IND
on the ignition control.
5. As the induced draft blower comes up to speed
and creates enough negative pressure, the pressure switch closes. The 24-volt signal is sent from
the pressure switch to one side of the Normally
Closed manual reset rollout switch. If the
rollout switch is closed, the 24-volt signal is
passed through the switch to the P.SW terminal on
the ignition control. This initiates a 30-second
pre-purge period.
6. After the 30-second pre-purge period, a trial for
ignition starts by energizing the spark terminal and
the V1 terminal simultaneously. The 24-volt signal
from V1 energizes the gas valve solenoid, causing
it to open. These actions cause the burners to light.
7. After the burners are lit, a flame sense is picked up
by the flame sense rod located at the opposite
end of the burner rack from the spark electrodes.
The flame sense signal is sent to the S1 terminal of
the ignition control. The unit continues to operate
as long as W is energized.

SRM-HW/HWC 2/99

1. Terminal TS (24-volt) energizes on the ignition
control, causing a relay in the ignition control to
close. This sends line voltage to the terminal
marked IND, causing the induced draft blower to
start.
2. When W is energized, a 24-volt signal is also sent
to the W terminal on the blower control board.
The 24-volt signal starts the timer on the blower
control board. After 60 seconds, the relay on the

blower control board closes. This sends line
voltage from the terminal marked L-1 to the terminal
marked H on the blower control board, starting
the circulating air blower. The induced draft
blower and the circulating air blower continue to
operate until the heat call is satisfied, interrupting
the circuit between R and W. The ignition control
de-energizes the induced draft blower relay,
interrupting L-1 power to the induced draft blower.
The induced draft blower stops several seconds
later. The W terminal on the blower control board
de-energizes, starting a 90-second blower “off”
delay. This interrupts the line voltage to the circulating air blower and after 90 seconds, the blower
shuts down.

Service Reference Manual

SEQUENCE OF OPERATIONS
2-35

8. When the call for heat is satisfied, the circuit between R and W is interrupted, de-energizing W.
9. With W de-energized, the gas valve closes immediately and the induced draft blower stops several
seconds later.
10. The blower control board starts a 90-second
blower “off” delay. Approximately 90 seconds later,
the blower stops.

FLAME SENSE
1. During a call for heat, the spark terminal is energized and the gas valve is opened to light the
burners.
2. The ignition control energizes the spark terminal
and the gas valve for approximately six seconds. If
a flame is not sensed in this time period, the ignition control de-energizes the spark terminal and
the gas valve. This causes the gas valve to close
and the burners to shut off.
3. Since the 24-volt signal has been sent to the
blower control board, the circulating air blower
times on in approximately 60 seconds.
4. The induced draft blower continues to run for
approximately 30 seconds, then another trial for
ignition begins.
5. The ignition control runs three trials for ignition. If
a flame is not sensed during these three trials, the
ignition control will lockout.
6. The circulating air blower continues to run until
the R-W circuit at the thermostat is interrupted.
7. The ignition control remains in lockout until 24-volt
power to the ignition control is reset.

LIMIT OPENS

SRM-HW/HWC 2/99

SPECIFICATIONS

Magic-Pak: HW/HWC

2-36

HWC123, 183, 243, 303 Low Ambient
(w/United Technologies 1097 Spark Ignition System)

CONNECTION DIAGRAM
CIRCUITS ENERGIZED
208/230-1-60 COPPER CONDUCTORS
POWER SUPPLY
ONLY

OPERATING MODE
HEATING
COOLING
FAN

}

YELLOW
RED
BLUE
BLACK

COOL

BLACK
(WHEN USED)

WHITE

IGNITION
CONTROL
4 5 6
1 2 3

RED

LINE VOLTAGE-FACTORY
LINE VOLTAGE-FACTORY WHEN USED
LINE VOLTAGE-FIELD
LOW VOLTAGE-FACTORY
LOW VOLTAGE-FIELD

ELECTRODE

GND

24VAC

Y C W G R

PRESSURE
SWITCH

BLACK

VIOLET

UNUSED
HEAT

CNB

WHITE

RED

GREEN

BLACK

COMBUSTION
BLOWER

RED

BLUE

YELLOW

ORANGE

THERMOSTAT

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

GREEN

ORANGE

ORANGE
AUTO RESET
MANUAL RESET
LIMIT SWITCH
LIMIT SWITCH

}

FLAME ROD

GAS
VALVE BLUE

VIOLET

CIRCUIT
R-W
R-G-Y
R-G

RED
BLACK

FAN CONTROL
BLK

FAN RELAY
208 V

BLACK

CONDENSER FAN

CONTACTOR
BLACK

BROWN

FAN
COM

240 V

BLK

VIOLET
CAPACITOR-RUN

YELLOW

S COMP

HERM

BLACK

RED

CONNECTOR
BLOCK

BLUE
RED

TRANSFORMER

YELLOW

EVAP. MOTOR SPEED CONNECTIONS
MODELS
HEATING
COOLING
26HWC123SA LOW (RED)
MED (BLUE)
38HWC123SA HIGH(BLACK) MED (BLUE)
38HWC183SA LOW (RED)
LOW (RED)*
51HWC183SA MED (BLUE) LOW (RED)
64HWC183SA HIGH(BLACK) LOW (RED)
MED (BLUE)
38HWC243SA LOW (RED)
51HWC243SA MED (BLUE) MED (BLUE)*
64HWC243SA HIGH(BLACK) MED (BLUE)
51HWC303SA MED (BLUE) HIGH(BLACK)
64HWC303SA HIGH(BLACK) HIGH(BLACK)*

*JUMPER REQUIRED
BLUE

#45005-2

YELLOW
SEE
CHART
FOR WIRING
BLACK

YELLOW
BROWN
CAPACITOR
BLOWER

BLUE
RED

DIAGNOSTICS

H
M
L
TERMINAL
BLOCK

Connection Diagram

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)

SRM-HW/HWC 2/99

FIGURE 2-7

BLOWER
MOTOR

Service Reference Manual

SEQUENCE OF OPERATIONS
2-37

HWC123,183, 243, 303
Low Ambient Model
Refer to Figure 2-7
The low ambient switch is designed to allow the operation of the air conditioning unit below the normal operating range. On units equipped with this switch, sequence
of operation during a cooling call is modified when
outdoor temperatures fall below the normal operating
range.
The switch will interrupt the operation of the outdoor
cooling fan when the temperature of the liquid line
coming in from the outdoor coil falls below 55° F. When
the temperature of the liquid line rises to 95° F, the
switch will close and the outdoor fan will resume operation.
The low ambient switch does not affect any other facet
of the operation of the unit.

SRM-HW/HWC 2/99

To see simplified and detailed sequences of operation
for the HWC123, 183, 243, 303 models, refer to pages
2-5 to 2-9.

SPECIFICATIONS

Magic-Pak: HW/HWC

2-38

HWC122, 182, 242, 302 Low Ambient

CIRCUITS ENERGIZED
OPERATING MODE

WHITE

PRESSURE
SWITCH

WHITE

W
Y
G

W THERMOSTAT
Y
G

BROWN
COMBUSTION
BLOWER

BLACK
BLACK

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

GREEN
WHITE
RED
YELLOW
BLUE

GREEN

RED

BLACK
BLACK

BLUE
BLUE

V2
GND
ELECTRODE
CABLE

GAS
VALVE

RED

WHITE
ORN
ORN

MANUAL
RESET

WHITE

TH
P.SW
VI
IND
L1
24VAC

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

LIMIT
SWITCH

PINK
IGNITION
CONTROL

CIRCUIT
R-W
R-G-Y
R-G

HEATING
COOLING
FAN

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

BLACK
BLACK
BLACK

CONNECTOR
BLOCK

CONDENSER FAN
VIOLET
CAPACITOR-RUN

BLACK
BLACK

FAN
RELAY

CONTACTOR

C
S

HERM

BLACK
RED

BRN
CAPACITOR
BLOWER

BLOWER
MOTOR

C
H
L1

BLACK

BLK
BLU
RED

1
BLACK
BLACK

208V

C
R
W
G

SEE TABLE

BLUE

BLUE
RED
YELLOW

YELLOW
WHITE
GREEN

24V

FAN
CONTROL
BLACK

240V

TRANSFORMER

SEE TABLE
FOR WIRING

YEL

BLACK

RED

BROWN
YELLOW

BLUE

FAN
COM

JUMPER REQUIRED

*
*
*

#44358-2

Connection Diagram

SRM-HW/HWC 2/99

FIGURE 2-8

Service Reference Manual

SEQUENCE OF OPERATIONS
2-39

HWC122,182, 242, 302
Low Ambient Model
Refer to Figure 2-8
The low ambient switch is designed to allow the operation of the air conditioning unit below the normal operating range. On units equipped with this switch, sequence
of operation during a cooling call is modified when
outdoor temperatures fall below the normal operating
range.
The switch will interrupt the operation of the outdoor
cooling fan when the temperature of the liquid line
coming in from the outdoor coil falls below 55° F. When
the temperature of the liquid line rises to 95° F, the
switch will close and the outdoor fan will resume operation.
The low ambient switch does not affect any other facet
of the operation of the unit.
To see simplified and detailed sequences of operation
for the HWC122, 182, 242, 302 models equipped with
the Fenwal Triton 2461D DSI Ignition Control, refer to
pages 2-17 to 2-20.

SRM-HW/HWC 2/99

To see simplified and detailed sequences of operation
for the HWC122, 182, 242, 302 models equipped with
the Fenwal 05-29 Ignition Control, refer to pages 2-27 to
2-30.

Service Reference Manual

UNIT TEAR DOWN
3-1

Section 3 - Unit Tear Down
Heating Section
Heat Exchanger Removal ............................ 3-2
Induced Draft Blower Removal ..................... 3-2

Cooling Section

SRM-HW/HWC 8/99

Chassis Removal ........................................ 3-4
Evaporator Blower Assembly Removal .......... 3-6

UNIT TEAR DOWN

Magic-Pak: HW/HWC

3-2

UNIT TEAR DOWN
HWC units are comprised of two major sections.
The heating section is located in the top half of the unit. It contains the
heat exchanger and the majority of the components associated with the
heating function: controls, burners, switches, etc.... The total heating
section is not removable as a complete unit. The heat exchanger may be
removed separately for service (see below).
The cooling section is located in the lower half of the unit. It contains
the compressor, coils and motors that make up the refrigeration system.
The cooling section is referred to as the “chassis” of the cooling system.
The chassis is removable as a complete unit. Removal of the chassis
allows service to be performed away from the job site, thus allowing a
spare chassis to be installed to reduce downtime at a residence. Bench
tests may be performed on chassis. See the Performance Test section
beginning on page 9-11 for chassis performance data of both bench
tested and installed units.

Heating Section
Heat Exchanger Removal:
The heat exchanger may be removed from the unit through the front side.
Refer to the following directions and Figure 3-1.
To remove the heat exchanger:
1.
2.
3.
4.
5.
6.
7.

Disconnect all power to the unit.
Shut off and disconnect the gas supply.
Open the burner access panel.
Remove the burner tray and the gas valve.
Remove the front heat section panel.
Remove the vestibule panel.
Remove the heat exchanger.

Induced Draft (Combustion) Blower Removal:
Refer to the following directions and Figure 3-1.
To remove the induced draft blower:
1.
2.
3.
4.

Disconnect all power to the unit.
Shut off and disconnect the gas supply.
Remove the plate mounting screws.
Slide the induced draft blower out.

SRM-HW/HWC 8/99

Service Reference Manual

UNIT TEAR DOWN
3-3

PLATE MOUNTING
SCREWS
INDUCED DRAFT BLOWER/
COMBUSTION BLOWER
HEAT EXCHANGER
FRONT HEAT
SECTION PANEL
GAS VALVE
HEATING SECTION

VESTIBULE PANEL
CONTROL SECTION
BURNER TRAY

COOLING SECTION

BURNER ACCESS PANEL
FILTER ACCESS DOOR

SRM-HW/HWC 8/99

Figure 3-1

UNIT TEAR DOWN

Magic-Pak: HW/HWC

3-4

Cooling Section
Chassis Removal:
The cooling chassis may be removed from behind the filter access door.
Refer to the following directions and Figures 3-1 to 3-4.
To remove the cooling chassis:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Disconnect all power to the unit.
Shut off and disconnect the gas supply.
Remove the filter access door (Figure 3-1).
Disconnect L1 and L2 from the compressor contactor (Figure 3-2).
Disconnect the 6-pin low voltage molex plug (Figure 3-2).
Remove the filler panel by removing the four hold down screws
(Figure 3-2).
Remove the right side chassis screw (Figure 3-2).
Remove the permagum seal on the base rails of the chassis (Figure
3-4).
Disconnect the drain tube from the evaporator drain pan (Figure 3-3).
Remove the chassis from the front of the unit, pulling it toward
yourself (Figure 3-4).

L1/L2 WIRES
RIGHT SIDE
CHASSIS SCREW
HOLD DOWN
SCREWS

FILLER PANEL
6-PIN
LOW VOLTAGE
MOLEX PLUG

Figure 3-2
SRM-HW/HWC 8/99

Service Reference Manual

UNIT TEAR DOWN
3-5

EVAPORATOR BLOWER MOTOR

Figure 3-3

EVAPORATOR

COMPRESSOR

EVAPORATOR DRAIN
TUBE CONNECTION
EVAPORATOR DRAIN PAN

CHASSIS SHOWN
PARTIALLY REMOVED

LOW VOLTAGE
MOLEX PLUG

Figure 3-4

SRM-HW/HWC 8/99

EVAPORATOR DRAIN
TUBE CONNECTION

PERMAGUM SEAL

DRAIN HOSE (NOT PICTURED)
ARMSTRONG P/N 03613A001
17" LONG
.63" (5/8") I.D.
.13" WALL THICKNESS

UNIT TEAR DOWN

Magic-Pak: HW/HWC

3-6
Evaporator Blower Assembly Removal:
The evaporator blower assembly is removable as one complete section.
To remove the assembly, the chassis must be removed first (see page 34). Refer to the following directions and Figure 3-5.
To remove the evaporator blower assembly:
1.
2.
3.
4.
5.

Remove the four mounting screws from the blower assembly.
Remove the four control panel screws.
Slide control panel toward yourself about 1".
Disconnect the electrical wiring to the motor.
Pull blower assembly up and out from chassis.

MOUNTING SCREWS
EVAPORATOR BLOWER
ASSEMBLY

ION
TAT
RO

CONTROL PANEL
SCREWS

Figure 3-5

CHASSIS BASE

PERMAGUM SEAL
(BETWEEN BASE RAIL AND CHASSIS BASE)

SRM-HW/HWC 8/99

Service Reference Manual

COMPONENT LOCATION ILLUSTRATIONS
4-1

Section 4 - Component Location
Illustrations
HW/HWC(3) Unit ................................. 4-2
HW/HWC(2) Unit ................................. 4-3
HW/HWC - Panels................................ 4-4
HW/HWC - Exterior Louver/Grill Panel .. 4-5
HWC Chassis Assembly ........................ 4-6
HWC Chassis Assembly - Top View ......... 4-7

SRM-HW/HWC 2/99

HWC Chassis Assembly Circulating Air Blower Partially Removed 4-8

COMPONENT LOCATION ILLUSTRATIONS

Magic-Pak: HW/HWC

4-2

HW/HWC123,183,243,303

IGNITION/BLOWER CONTROL BOARD (*24)
UNITED TECHNOLOGIES 1097-83-400A/1097-400-I (DSI)*
ARMSTRONG P/N 44990-001

MAIN LIMIT SWITCH (*52)
ARMSTRONG P/N 40154B007

GAS VALVE
HONEYWELL VR8105M8202
ARMSTRONG P/N 44987-001

HEATING SECTION

CONTROL SECTION

PRESSURE SWITCH (*57)

COOLING SECTION

BURNER TRAY

* SEE COMPONENT SECTION FOR FURTHER
DETAIL OF IGNITION/BLOWER CONTROL

FIGURE 4-1

The numbers in parentheses in the drawing above refer to the section number each part is assigned. These numbers are provided here to aid in locating the parts in the Parts List section found beginning on page 8-1.

SRM-HW/HWC 2/99

Service Reference Manual

COMPONENT LOCATION ILLUSTRATIONS
4-3

HW/HWC122, 182, 242, 302

FENWAL IGNITION CONTROL - 2 MODELS (*24)
FENWAL TRITON 2461D 900-227 - ARMSTRONG P/N 43110-002
FENWAL 05-29 - ARMSTRONG P/N 39048B001
(SEE NOTE BELOW)
MAIN LIMIT
SWITCH (*52)
FLUE BOX

INDUCED DRAFT BLOWER/
COMBUSTION BLOWER (*63)
ARMSTRONG P/N 41144-001
GAS VALVE (*7)
WHITE RODGERS 25K49-120
ARMSTRONG P/N 43108-001
COMBUSTION AIR INLET (5")

HEATING SECTION
BURNER COVER
BURNER TRAY ASSEMBLY
BECKETT BURNER MODELS:
TL109A-26K
TL109B-38K
TL109C-51K
TL109D-64K

CONTROL SECTION

COOLING SECTION

INDIVIDUAL BURNERS (*34)
BECKETT - ARMSTRONG P/N 41948-001
ARMSTRONG - ARMSTRONG P/N 39006B001
FLAME ROLLOUT SWITCH (*55)
PRESSURE SWITCH (*57)
NOTE:
SEE COMPONENT SECTION FOR FURTHER
DETAIL OF IGNITION/BLOWER CONTROL MODELS

FIGURE 4-2

SRM-HW/HWC 2/99

COMPONENT LOCATION ILLUSTRATIONS

Magic-Pak: HW/HWC

4-4

HW/HWC - Panels

HEAT EXCHANGER ACCESS PANEL
ARMSTRONG P/N 38782D001

TOP PANEL ASSEMBLY
ARMSTRONG P/N 03455D007
INSPECTION WINDOW
ARMSTRONG P/N 38092A002

SIDE PANEL
ARMSTRONG P/N 38769D001

UPPER LOUVER PANEL
ARMSTRONG P/N 03545C000

LOWER GRILL
PANEL
ARMSTRONG
P/N 03551D100
COOLING CONTROL
ACCESS PANEL
ARMSTRONG P/N 03938C004

HEATING COMPARTMENT DOOR
ARMSTRONG P/N 38987B004

DOOR HANDLE
ARMSTRONG
P/N 37701B001
SIDE PANEL
ARMSTRONG P/N 38769D002

FILTER ACCESS DOOR
ARMSTRONG P/N 38785D001
(FILTER - 16.5" x 25" x .50"
ARMSTRONG P/N 06131B046)

UNIT BASE SECTION*
ARMSTRONG P/N 34805B003

UNIT BASE SECTION*
ARMSTRONG P/N 38771D101
* THE BASE PAN ASSEMBLY CONSISTS OF 2 SECTIONS

FIGURE 4-3

Note: Panels and other associated parts found in the drawing above are not listed in the Parts List section that
begins on page 8-1.
SRM-HW/HWC 2/99

Service Reference Manual

COMPONENT LOCATION ILLUSTRATIONS
4-5

HW/HWC Exterior Louver/Grill Panel

SIDE VIEW
CONDENSER
AIR FLOW
OUTLET

EXTERIOR UPPER LOUVER PANEL
ARMSTRONG P/N 03545C000

LOUVERS POINT UPWARD
AT 45° ANGLE

EXTERIOR LOWER GRILL PANEL
ARMSTRONG P/N 03551D100

CONDENSER
AIR FLOW
INLET

GRILL IS FLAT WITH
RECTANGULAR OPENINGS

FIGURE 4-4

SRM-HW/HWC 2/99

Note: Panels found in the drawing above are not listed in the Parts List section that begins on page 8-1.

COMPONENT LOCATION ILLUSTRATIONS

Magic-Pak: HW/HWC

4-6

HWC Chassis Assembly

EVAPORATOR BLOWER MOTOR (*69)
COMPRESSOR CAPACITOR (*271)

COMPRESSOR CONTACTOR (*278)
ARMSTRONG P/N 03575C001
CONDENSING FAN SHROUD

CONDENSING FAN
CAPACITOR (*271)

CONDENSER FAN (*267, 268)
CONDENSING COIL (*250)
CAPILLARY TUBE
METERING DEVICE (*256)

BLOWER CONTROL BOARD (*5)
ARMSTRONG P/N 39029B002
FILTER RETAINER
ARMSTRONG P/N 38072B001

FILTER DRIER/DISTRIBUTOR (*301)
(12) ARMSTRONG P/N 39059B001
(18-24) ARMSTRONG P/N 39059B002
(30) ARMSTRONG P/N 39059B003

LOW VOLTAGE
CONTROL TRANSFORMER (*1)
ARMSTRONG P/N 39370B001

SUCTION LINE/PORT

FILTER STOP
ARMSTRONG P/N 38073BOO1
FILTER SIZE 16.5" X 25.5" X .5"
EVAPORATOR (*255)

DISCHARGE LINE/PORT
COMPRESSOR (*262)

FILTER RETAINER
EVAPORATOR DRAIN PAN ARMSTRONG P/N 38072B001
ARMSTRONG P/N 38918B001

FIGURE 4-5

SRM-HW/HWC 2/99

Service Reference Manual

COMPONENT LOCATION ILLUSTRATIONS
4-7

HWC Chassis Assembly - Top View

SEE FIGURE 4-7 FOR
CIRCULATING AIR BLOWER
COMPONENTS

CONDENSER MOTOR (*267)
(12-18) ARMSTRONG P/N 41282-001
(24-30) ARMSTRONG P/N 41254-001

CONDENSER FAN MOTOR BRACKET (*269)
ARMSTRONG P/N 03982D004

FAN SHROUD

FAN BLADE (*268)
(12-18) ARMSTRONG P/N 39085B001 (3 BLADE/24° PITCH/18”)
(24-30) ARMSTRONG P/N 39062B001 (5 BLADE/26° PITCH/18”)

FIGURE 4-6

SRM-HW/HWC 2/99

FIGURE 3-7

TOP VIEW — HWC CHASSIS ASSEMBLY

COMPONENT LOCATION ILLUSTRATIONS

Magic-Pak: HW/HWC

4-8

HWC Chassis Assembly Circulating Air Blower Partially Removed
BLOWER WHEEL (*73)
ARMSTRONG P/N 34833B001
10.75" x 4"

ION
TAT
RO

CIRCULATING AIR BLOWER MOTOR (*69)
(12) ARMSTRONG P/N 39045B001
(24-30) 39046B001
MOTOR MOUNTING BRACKET (*71, 72)
BAND - ARMSTRONG P/N 07407B000 (1)
ARMS - ARMSTRONG P/N 07408B004 (3)

SEE FIGURE 4-6
FOR FAN CONDENSING
PARTS

BLOWER HOUSING (*74)
ARMSTRONG P/N 39010B001

FILTER RETAINER
ARMSTRONG P/N 38072B001

FILTER STOP
ARMSTRONG P/N 38703B001

FILTER (*127) SIZE
16.5" x 25" x .50"
ARMSTRONG P/N 06131B046

EVAPORATOR DRAIN
TUBE CONNECTION
.63" (5/8")*

FILTER RETAINER
ARMSTRONG P/N 38072B001
NOTE:

* REQUIRES (5/8") I.D. DRAIN HOSE
ARMSTRONG P/N 03613A001 (NOT SHOWN)

WHEN USING A REPLACEMENT FILTER WITH
A MANUFACTURED FRAME, THE DIMENSIONS
MAY NEED TO BE REDUCED FOR PROPER FIT.
TAKE AND RECORD MEASUREMENTS FOR
PROPER FIT.

FIGURE 4-7
The numbers in parentheses in the drawing above refer to the section number each part is assigned. These numbers are provided here to aid in locating the parts in the Parts List section found beginning on page 8-1.
SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-1

Section 5 - Unit Components
Transformer ........................................ 5-3
Gas Valves ........................................... 5-4
White-Rodgers 25K49 ................................ 5-4
Honeywell 8105 ......................................... 5-5

Blower Control Boards ......................... 5-6
United Technologies Model 1010-611 .......... 5-6
Heatcraft Model IBC-H4C401 ..................... 5-7

Ignition Controls .................................. 5-8
Fenwal Triton 2461D.................................. 5-8
Fenwal 05-29 DSI .................................... 5-10

Integrated Blower/Ignition Controls .... 5-11
Induced Draft Blower .......................... 5-14
Burners ............................................. 5-15
Manifold Orifices ................................ 5-17
Contactor .......................................... 5-18
Main (High) Limit Switch ..................... 5-19
Flame Rollout Switch .......................... 5-20
Pressure Switch ................................ 5-21
Pressure Switch Problems ........................ 5-23
Checking Pressure Switch Operation.......... 5-24

Compressors ..................................... 5-28
Tecumseh ................................................ 5-30
Copeland ................................................. 5-32

SRM-HW/HWC 2/99

Drier-Filters ....................................... 5-34

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-2

HWC Capillary Tubes .......................... 5-35
Capacitors ......................................... 5-39
Evaporator Blower Motor ................... 5-40
Condenser Fan Motor ......................... 5-40
Capacitors-Run .................................. 5-41
Fan Blades ......................................... 5-42
Exterior Grill Panels ........................... 5-44

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-3

Unit Components
This section provides a brief description of the most important components within the Magic-Pak HW/HWC units. The information presented
here is not intended to take the place of the instructions and printed
literature packed with each component by the original manufacturer. The
section number for each component is listed in parentheses following the
component name. This number refers to the section number assigned to
each part in the Parts List section beginning on page 8-1.

Transformer (*1)
The transformer supplies 24 VAC from its secondary winding to operate
the blower control board, gas valve and ignition control depending on the
particular model. Transformers are typically rated at 40 VA, 50/60 Hz.

Transformer Specifications
Manufacturer: Basler Electric
Model: 31264-GEK
Armstrong P/N 39370B001
Primary: 208/240V
Secondary: 24V
Rating: 40VA
Dimensions: 2.28" W x 1.94" H x 3.12" D
Base - 3.25" W (2.81" between I.D. of holes)

.19" x .020"
Quick Connect
Terminals

24 VAC
Secondary

0V
24

M
CO

8V
20

.188" Diameter Holes

208/240 VAC
Primary

.25" x .032"
Quick Connect
Terminals

Note: Secondary leads may exit from top of transformer.

SRM-HW/HWC 2/99

FIGURE 5-1

24-volt Transformer (Typical Configuration)

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-4

Gas Valves (*7)
White-Rodgers 25K49-120
Gas Valve Specifications
Manufacturer: White-Rodgers
Model: 25K49-120
Armstrong P/N 43108-001
Dimensions: 1.97" W x 5.31" L
Nominal Operating Currents: 25VAC/60Hz/.5A
Regulator set at 3.50 +/– .02” W.C. at 55.6 cubic Ft./Hr of air at
standard conditions (with valve in vertical position, inlet up).

3/8" - 18 N.P.T.
Outlet

1/8" - 27 N.P.T.
Pipe Plug
3/8" - 18 N.P.T.
Inlet

FIGURE 5-2

White-Rodgers Gas Valve

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-5
Honeywell 8105 Series
Gas Valve Specifications
Manufacturer: Honeywell
Model: VR8105M8202
Armstrong P/N 44987-001
Dimensions: 2.70" W x 4.75" L
Nominal Operating Currents: 25VAC/60Hz/.5A
Regulator Setting: 3.50 +/– .3" W.C.
Pipe Size: .50" Inlet x .375" Outlet
Valve Amp Draw: .5 A
1" Drop Capacity: 85,000 Btuh
Max. Regulator Capacity: 120,000 Btuh
Temperature Rating: – 40°F to +175°F

Main Valve Terminal (Hot)
Main Valve Common Terminal

FIGURE 5-3

Honeywell Gas Valve

FLOW

Reference Tube Vent
Manifold Pressure Adjustment
1/8" NPT Outlet Pressure Tap
1/8" NPT Inlet Pressure Tap

FLOW
ON

SRM-HW/HWC 2/99

OFF

On/Off Switch

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-6

Blower Control Boards (*5)
A separate blower control board is used in the Magic-Pak HW/HWC
models that do not use integrated ignition/blower control boards. Blower
control boards from two different manufacturers are used in these HW
and HWC units. The two blower control boards are explained in detail in
the following pages.

United Technologies Model 1010-611
Blower Control Board Specifications
Manufacturer: United Technologies
Model: 1010-611
Armstrong P/N 39029B002
Operating Voltage: 18-30VAC 60 Hz
60 Hz Power Requirement: 4 VA max.
Operating Temperature: – 40°F to +170°F
Wiring Connections: All Male .250" x .032" Quick Connect Tabs
Performance Specifications (all timings +/– 1 second):
Heating: On Delay Timing - 60 seconds
Off Delay Timing - 90 seconds
Cooling: On Delay Timing - 15 seconds
Off Delay Timing - 90 seconds
Heating and Cooling Output Rating:
12 F.L.A., 30 L.R.A. at 120VAC for 100,000 Cycles
10 F.L.A., 30 L.R.A. at 240VAC for 100,000 Cycles
Both heat and cool outputs cannot be energized simultaneously.

9840A

L1
COOL
HEAT

24VAC Power

Cool Speed
L1 Power Out
Heat Speed
L1 Power Out

W
M1

24VAC Heat Call
G

Fan Call (Fan On)
24VAC Cooling
Call (Fan Auto)

L1 Line Voltage

24VAC Common

FIGURE 5-4

Dumb Terminals
(Park)

39029B002
1010-83-611A

United Technologies Blower Control Board 1010-611
SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-7
Heatcraft Model IBC-H4C401
Blower Control Board Specifications
Manufacturer: United Technologies
Model: 1010-611
Armstrong P/N 39029B002
Operating Voltage: 18-30VAC 60 Hz
60 Hz Power Requirement: 4 VA max.
Operating Temperature: – 40°F to +170°F
Wiring Connections: All Male .250" x .032" Quick Connect Tabs
Performance Specifications (all timings +/– 1 second):
Heating: On Delay Timing - 60 seconds
Off Delay Timing - 90 seconds
Cooling: On Delay Timing - 15 seconds
Off Delay Timing - 90 seconds
Heating and Cooling Output Rating:
12 F.L.A., 30 L.R.A. at 120VAC for 100,000 Cycles
10 F.L.A., 30 L.R.A. at 240VAC for 100,000 Cycles
Both heat and cool outputs cannot be energized simultaneously.

Cool Speed
L1 Power Out
Heat Speed
L1 Power Out

Dumb Terminal
(Park)

39029B002

HEAT

L1 Line Voltage

COOL
L1

Dumb Terminal
(Park)

HEATCRAFT
M1

24 VAC Heat Call
24 VAC Common

FIGURE 5-5

SRM-HW/HWC 2/99

24 VAC (Fan On/Cooling Fan Auto)
24 VAC Power

Heatcraft Blower Control Board IBC-H4C401

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-8

Ignition Controls (*24)
Fenwal Triton 2461D
Ignition Control Specifications
Manufacturer: Fenwal
Model: Triton 2461D
Armstrong P/N 43110-002
Pre-purge: 30 seconds
Ignition: 15 seconds
Input: 24VAC, 50/60 Hz 300 mA
Valve: 24VAC, 2.0 A max.
Inducer: 120VAC, 3.0 A or 240VAC, 1.5 A, 1/4 HP
Ambient: – 40°F to +160°F
ANSI Z21.20-1993 CAN/CSA-C22.2 No. 199-M89

FC-

FC+

FENWAL ®

CAUTIO
N: HIGH
VOLTAG
E DISC
V2
ONNEC
24
T WIRIN
GND
G BEFO
VAC
RE SER
L1
VICING
IND

V1 PS
W TH

FIGURE 5-6

Fenwal Triton 2461D Ignition Control

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-9
Diagnostics (Fenwal Triton 2461D)
1. Diagnostic LED flash rate is 1/4 second “ON”, 1/4 second “OFF”
followed by up to four seconds “OFF” before repeating the code.
2. Only one code is displayed at a time.
3. During a “STEADY ON” code, the LED may blink off momentarily.
4. Diagnostic codes may be reset by removing the power from the
control for three seconds, then reapplying power. (Cycle thermostat
“OFF” for three seconds, then back “ON”.)
The following ignition control board LED codes indicate normal or
abnormal operations:

TABLE 5-1

Triton 2461D Diagnostic Flash Code

This code is used for up to four seconds at startup each time the control is powered to
indicate that the control is performing a self diagnostic check. If a problem is detected, the
STEADY ON
self diagnosis will repeat for a total of five times which equals twenty seconds. If LED is on
steady for 20 seconds, this indicates a control failure.

SRM-HW/HWC 2/99

Indicates an air flow fault. Used only on models with a pressure switch input (PSW). This
code is active only if the PSW input is in the improper state after a predetermined time delay.
For example: If the PSW input was powered when the call for heat begins (closed contacts),
the control will allow a fixed time for the PSW input to go off otherwise the LED flash will
ONE FLASH
commence. Conversely, if he PSW input is not powered within a fixed delay time after the
inducer motor is energized, the LED flash will commence. If the PSW input is removed
during a heating cycle, power will be removed from the gas valve immediately. If the PSW
power input is not reapplied within a fixed time, the LED flash will commence.
TWO
FLASHES

Indicates a flame detected out of sequence or with no call for heat. LED will flash twice as
soon as flame is detected out of sequence and continue as long as the flame is present.
Controls with an inducer control circuit will also power the inducer circuit when flame is
detected out of sequence.

THREE
FLASHES

Indicates ignition lockout after all ignition tries have been completed. This code will continue
as long as the call for heat remains. On models equipped with one hour automatic reset, the
code will stop when a new ignition attempt begins.

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-10
Fenwal 05-29 DSI

Ignition Control Specifications
Manufacturer: Fenwal
Model: 05-29 DSI
Armstrong P/N 39048B001
Relative Humidity Rating: 5 to 90% RH at 95°F
Flame Current: 3 mA min.
Spark Gap: 1/8"
Trial for Ignition: 6.8 seconds
Pre-purge: 30 seconds
Input: 24VAC from TS and P.SW to ground
Gas Valve Contacts: 24VAC, 600 mA max.
Blower Output: Relay between L1 and IND, 10 A at 250VAC
Ambient: – 40°F to +150°F

FENW ®
AL
Series

0
AUT O
MATIC 5-29 DSI
IGNIT
ION S
YSTE
M

CAUT
IO
HIGH N
VOL T
AGE

G
N
D

FIGURE 5-7

IND

P.
SW

Fenwal 05-29 Ignition Control

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-11

Integrated Blower/Ignition Control (*24)
United Technologies Model 1097-400-1
The integrated control combines the actions and purposes of the individual ignition and blower control boards found on other units. It automatically monitors and controls the operation of the gas burners, gas valve,
induced draft blower and circulating blower.
The control has a built-in diagnostic function, quick gas valve shutoff and
automatic ignition retry when it detects that a fault condition has been
corrected. If a fault is detected, the controls goes into fault mode and
flashes the single LED indicator at a preset rate for that particular fault
condition. (See Diagnostic Flash Code found in Table 4-1 on page 4-8 or
Diagnostic Indicator code printed on unit label.)
Integrated Control Specifications
Manufacturer: United Technologies
Model: 1097-400-1
Armstrong P/N 44990-001
Operating Temperature: – 40°F to +175°F
Timing Tolerance: +/– 10%
Input Voltage: 18-30VAC, 50/60 Hz
Combustion Blower: 1/8 HP @ 120/240VAC
Circulating Blower: 1/2 HP @ 120VAC, 1 HP @ 240VAC
Gas Valve: 24VAC, 60 Hz, 1.0 A

FLAME

24VAC

GROUND

UNUSED

ACB
HEAT
ACB
COOL

CMB

BL WR

SRM-HW/HWC 2/99

FIGURE 5-8

G R
C W

United Technologies Model 1097 Integrated Control

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-12
Diagnostics (United Technologies 1097-400-1)
The following blower/ignition control board LED codes indicate normal or
abnormal operations:
TABLE 5-2

UTech Model 1097 Diagnostic Flash Code

SLOW FLASH

Normal Operation, No Call for Heat

FAST FLASH

Normal Operation, Call for Heat

2 FLASH

System Lockout - Failed to Detect or Sustain Flame

3 FLASH

Pressure Switch Open or Closed

4 FLASH

High Limit or Rollout Switch Open

5 FLASH

Flame Sensed and Gas Valve Not Energized

STEADY

Internal Failure (Micro-controller Failure; Self-check)

United Technologies Model 1097-400-1 (cont.)
Quick Connect Terminal Descriptions
1
2
4
5
9
10
11
12

24VAC HOT - from Transformer
GROUND = 24VAC Return
CMB BLWR = Combustion Blower (Line Voltage)
L1 = Line Voltage
ACB COOL = Air Circulating Blower Cool Speed (Line Voltage)
ACB HEAT = Air Circulating Blower Heat Speed (Line Voltage)
UNUSED (Park)
FLAME = Flame Probe

Molex/Amp Plug-in Description
1
2
3
4
5
6

Roll-out Switch Return
Hi Limit Return/Pressure Switch Out
Gas Valve Common
Gas Valve Out
Pressure Switch Return
Roll-out Switch Out

Thermostat Input
24VAC to Thermostat (RED)
Manual Fan Input from Thermostat (GREEN)
Heat Demand Input from Thermostat (WHITE)
Common Ground to Thermostat
Cool Demand Input from Thermostat (YELLOW)

SRM-HW/HWC 2/99

R
G
W
C
Y

Service Reference Manual

UNIT COMPONENTS
5-13
United Technologies Model 1097-400-1 (cont.)
Heat Mode
Pre-purge
Inter-purge
Post-purge
Trial Time
# of Trials

30 seconds
30 seconds
5 seconds
10 seconds
3

Board to reset from lockout after 60 minutes.

Fan On Delay
Cool
Heat

5 seconds (fixed)
30 seconds (fixed)

Fan Off Delay

SRM-HW/HWC 2/99

Cool
Heat

90 seconds (fixed)
120 seconds (fixed)

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-14

Induced Draft Blower (*63)
The induced draft blower is also referred to as a “combustion” blower,
since its purpose is to establish flow of combustion air through the heat
exchanger. Mounted at the outlet of the secondary heat exchanger, the
blower establishes a negative pressure within the heat exchanger and
exhausts the flue products outside the structure.
Blower motors operate at a fixed speed.

Induced Draft Blower Specifications
Manufacturer: Magnetek
Model: JBIMI37NS
Armstrong P/N 41144-001
208/240VAC, 60 Hz, Single Phase, .55 FLA, 3000 RPM, .031 HP
Rotation CW LE
Continuous Duty
Features: Ball Bearing; Stainless Steel Shaft;
Motor Grounded to Blower Housing

.32" Extension Barbed Tube
for .096" (+/.005") I.D.
Pressure Tap

FIGURE 5-9

Magnetek JBIMI37NS Induced Draft Blower

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-15

Burners (*34)
The Magic-Pak HW and HWC units covered in this manual use a burner
design called the “inshot” type. No adjustment is provided for primary or
secondary air. For best operation, keep the burners clean. Use the
correct orifice size and adjust the manifold pressure for the fuel being
used and the operating altitude.

Burner Specifications
Manufacturer: Beckett Gas
Model: AR086
Armstrong P/N 41948-001
Burner Dimensions: 4.50" x 2.48"

Burner Carryover Gap
.025" (+/.002")

Burners

SRM-HW/HWC 2/99

FIGURE 5-10 Typical Burner Arrangement

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-16
Flame Carryover Problems
During ignition, the flame must travel uninterrupted from one burner to the
rest of the burners.
Causes:
•
•
•

Carryover “wing” on burner is plugged with insects or debris
Improper gap setting on wings
Incorrect gas pressure

The burner wing has a specified gap (typically 0.025" +/– .002"), which
must carry gas and a small flame to allow flame carryover from one
burner to the next. Check the gap settings on all burners.

Smooth end slips
into burner

Flame Exit

Threads
into manifold

.025" gap (+/ .002")
for flame carryover

Orifice
Gas Entry

FIGURE 5-11

Inshot Burners

Gap = .025" +/– .002"

Armstrong P/N: 41948-001

FIGURE 5-12 Burner Wing Gap

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-17

Manifold Orifices (*13)
TABLE 5-3

Manifold Orifice Specifications

Armstrong
P/N

Hole Diameter
Drill Size

Hole Diameter
(inches)

39030B001

Blank

39030B002

.0670

39030B003

.0635

39030B004

.0595

39030B005

.0550

39030B006

.0390

39030B007

.0380

39030B008

.0370

39030B009

.0860

39030B010

.0785

39030B011

.0520

39030B012

.0465

39030B013

.0350

39030B014

.0360

39030B015

.1040

39030B016

.0960

39030B017

.0980

39030B018

.0890

39030B019

.0935

Hole Diameter

SRM-HW/HWC 2/99

FIGURE 5-13 Manifold Orifice

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-18

Contactor (*278)
Contactor Specifications
Manufacturer: Honeywell
Model: R8242A-1008
Armstrong P/N 7535C001
Single-phase, Single-pole, 25 F.L.A., 125 L.R.A
Coil: 24VAC, 50/60 Hz
Line Voltage: 240/277
Coil Resistance at 70°F: 8 - 10 ohms

Low Voltage
Coil Terminals

Open Contact

T1
T2
Closed Contact

FIGURE 5-14 Honeywell Contactor Model R8242A-1008

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-19

Main (High) Limit Switch (*52)
A Normally Closed control that opens if abnormally high circulating air
temperatures occur. It is an automatic reset control.
Note: Several different main limit switches are used. Refer to the parts
list for the correct limit switch.

Common Terminal

Camstat Model L59-7B-220-30
Armstrong P/N: 01150A008
Setting: 220°F

N.C. (Normally Closed)
Terminal
N.O. (Normally Open)
Terminal
FIGURE 5-15 Camstat Main Limit Switch

3.05
" (+/
.05")
Manufacturer P/N: INT17L-2107
Armstrong P/N: 40154B007
Open Setting: 190°F
Closed Setting: 160°F

SRM-HW/HWC 2/99

FIGURE 5-16 Main Limit Switch

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-20

Flame Rollout Switch (*55)
A Normally Closed switch that opens when abnormal temperatures occur
in the burner area, caused by a restricted heat exchanger, causing main
burner flame to “roll out” into the vestibule area.
To reset the switch, push the button on top. The button is a different color
from the body.

Reset Button

Cutout Temperature:
Marked on body of switch
Nominal Switch Contact Rating:
15 A @ 120VAC

FIGURE 5-17 Flame Rollout Switch

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-21

Pressure Switch (*57)
These are Normally Open switches that react to a difference in pressure
on an internal diaphragm. It will not allow ignition to start if the induced
draft blower cannot produce sufficient negative pressure relative to
atmospheric pressure or pressure in a sealed burner box. Its electrical
contacts will open in reaction to inadequate negative pressure resulting
from excessive venting system restriction or a failed induced draft blower,
thus providing protection from a change in safe, stable furnace operation.
The Armstrong part number is stamped on the body of the switch. A label
on the switch carries the manufacturer’s model number. Always verify the
proper switch number from the parts list.

Normally Open
Terminal
Connect to Port on
Induced Draft Blower
Common Terminal

SRM-HW/HWC 2/99

Pressure Switch Specifications
Manufacturer: Tridelta Industries
Electrical Rating:
SPDT Elec. Load: 28 VA Pilot Duty @ 24VAC
3 FLA, 18 LRA @ 24VAC
SPST Elec. Load: 5 A Resistive @ 24VAC
Electrical Switch: Single Pole, Normally Open, Snap
Acting Contacts
Electrical Connectors: Common (C), Normally Open
(NO) 1/4" x .032" thick quick connect terminals
Maximum Pressure: 3" W.C.
Operating Temperature Range: – 40° to 190°F
Sample Line Connector: Negative; barb type for use with
3/16" or 1/4" I.D. tubing with .016" +/– .004" bleed hole

Electrical Switch

FIGURE 5-18 Pressure Switch

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-22
TABLE 5-4

Pressure Switches

Armstrong
P/N

Vendor

Model Number

Switch Opens
(inches W.C.)

Color
Code

41862-001

Tridelta Industries

FS6080A-1889

.40

Red

41862-002

Tridelta Industries

FS6080A-1891

.27

Green

41862-003

Tridelta Industries

FS6080A-1890

.45

White

44819-001

Tridelta Industries

PPS10090-2614

.25 +/– .05

Purple

44819-002

Tridelta Industries

PPS10090-2615

.35 +/– .05

Blue

44819-003

Tridelta Industries

PPS10090-2616

.45 +/– .05

Pink

44819-004

Tridelta Industries

PPS10090-2617

.55 +/– .05

Red

44819-005

Tridelta Industries

PPS10090-2618

.60 +/– .06

Green

44819-006

Tridelta Industries

PPS10090-2619

.70 +/– .06

White

44819-007

Tridelta Industries

PPS10090-2620

.80 +/– .07

Gray

44819-008

Tridelta Industries

PPS10090-2621

.50+/– .05

Red

44819-009

Tridelta Industries

PPS10090-2622

.30 +/– .05

Orange

44819-010

Tridelta Industries

PPS10090-2623

.10 +/– .05

Yellow

44819-011

Tridelta Industries

PPS10090-2624

.40 +/– .05

Light Blue

44819-012

Tridelta Industries

PPS10090-2625

.65 +/– .05

Brown

Pressure Switch Problems
The negative pressure developed in the combustion chamber is directly
related to airflow. During furnace operation, the switch will react to
conditions that reduce airflow, such as: blocked or restricted intake
(combustion air piping), blockage of vent (flue) piping, blockage of the
condensate drain piping, plugged pressure tap ports, leaking hoses or a
failure of the induced draft blower motor.
If the pressure switch has already been replaced and problems are still
being experienced, follow the procedure, Checking Pressure Switch
Operation (found on page 5-24).
If the measured static pressure reading does not meet the switch specifications, check these items:
1. Pressure switch hose/tubing for cracks or loose connections
2. Induced draft blower wheel for corrosion or loose blades
3. Induced draft blower for tight bearings or loose inducer wheel

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-23
The measured static pressure reading should be compared to the pressure switch specifications. If the measured static pressure meets or
exceeds the specifications and switch contacts will not transfer, check the
following items:
•
•
•
•

Switch out of calibration
Defective pressure switch
Moisture in pressure switch tubing
Incorrect switch installed

WARNING
DO NOT try to repair a pressure switch. Use an
identical replacement. The use of an improperly
repaired or malfunctioning pressure switch could
result in property damage, personal injury or death.

WARNING
Never try to adjust a pressure switch or jumper the
switch to allow the furnace to operate. Doing so
could allow the furnace to operate under hazardous
conditions, potentially causing property damage,
personal injury or death.
Blocked Intake
Blocked intake is any condition that blocks or restricts the flow of intake
(combustion) air to a point where the pressure fall reaches the calibrated
open setting of the pressure switch.
Potential Causes:
•
•
•
•

Rodents
Spiders
Nest building in the intake opening
Debris or trash that has been pulled into the intake opening

Symptoms:
•
•

Excessive negative pressure in the burner box area. The furnace
cycles on and off quite frequently, typically within 60 seconds or so.
Inability of unit to stay on for a complete call for heat.

SRM-HW/HWC 2/99

For a blocked intake or blocked flue, connect the incline manometer as
shown on in Figure 5-20 on page 5-27 for the specific model groups.

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-24
Blocked Flue
Blocked flue is any condition that blocks or restricts the flue (vent) pipe to
a point where the pressure fall reaches the calibrated open setting of the
pressure switch.
Potential Causes:
•
•
•
•
•

Rodents
Spiders
Nest building in the flue pipe
Outlet screens with excessive restriction
High wind conditions exceeding 40 mph

Symptoms:
•

•

Low negative pressure on the induced draft (combustion) blower. The
unit cycles on and off quite frequently, typically coming back on within
60 seconds.
Inability of unit to stay on for a complete call for heat.

Units cycling on pressure switch re-ignite sooner than a main limit switch
can reset.
Tip: With all wiring connected and unit running, use your volt meter
across the pressure switch terminals. No voltage reading = switch closed.
Voltage present = switch open.

Checking Pressure Switch Operation
It is easy to check a pressure switch as it operates within the overall
system. These test procedures make it possible to pinpoint the opening
and closing actions of the pressure switch.

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-25
What Is Needed for the Tests
•
•

•
•

A good general-purpose incline manometer with a range of 0 - 3"
W.C. (Dwyer 1227 or equivalent).
Use the parts list to verify that the proper pressure switch is installed
in the unit. Look for the Armstrong part number stamped on the
metal housing. A label on the housing shows the manufacturer’s
model number.
Find the Switch Open value for the pressure switch in Table 5-4 on
page 22.
Assorted lengths of plastic tubing and tees to make the connections
to the manometer including the following: 1/8" I.D. high temperature
silicone tubing, 1/4" I.D. vinyl tubing, 1/8" tee and 1/4" tee.

Note: For each procedure, the schematic shows the original factory
tubing with solid black lines. The tees to be installed for pressure
sampling are shown within the dashed circles.
Terminology
Terms related to pressure switch operation and incline manometer testing
are shown below in Figure 5-19.

A
-1"
0
1"
2"
3"

“Nega
tive” p
ressu
“Posit
re
ive” pr
essur
e
“Pres
sure R
ise”
“Pres
sure F
all”

SRM-HW/HWC 2/99

FIGURE 5-19 Incline Manometer

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-26
A Word About the “Switch Closed” Value
Switch Closed is the pressure at which the contacts close as the induced
draft blower comes up to speed. It is calculated by adding – 0.1" W.C. to
the sum of the switch’s Open value and its upper tolerance.
For example, for a Armstrong P/N 44819-005 switch:
– 0.1" + (– .60" + – .06") = – 0.76" W.C.
On a system operating correctly, it is likely that the manometer reading
will go to a value that is more than enough to close the switch.
A Word About the “Switch Open” Value
Switch Open is the pressure at which the contacts open as the negative
pressure decreases (pressure fall).
Procedure for Checking Pressure Switch
1. Position the manometer so it can be watched easily during testing.
Balance and zero the manometer according to the manufacturer’s
instructions.
2. Insert a test line with tee between the pressure switch and blower.
One piece of the tubing connects the pressure switch to the fitting at
the back side of the induced draft blower housing. Connect the tee to
the manometer as shown in Figure 5-20.
Note: Always keep the pressure switch in the circuit when measuring.
Switches incorporate internal bleeds to keep moisture out of
the pressure switch line.
3. Using Table 5-4 on page 5-22 and the formula provided above,
calculate the close value for the switch being worked with.
4. Start the furnace to call for heat. Observe the manometer reading
increase (increasing pressure rise) as the induced draft blower
comes up to speed. Ignition should start at a reading that is approximately the Close value that was earlier determined for the specific
switch in Step 3.
5. With the furnace running in the full heat cycle, observe the pressure
reading. Note this reading and compare it to the Open value shown
for that switch in Table 5-4 on page 5-22.
Using Armstrong P/N 44819-005 pressure switch for an example, the
reading on pressure fall when the contacts open can be between – 0.54"
W.C. and – 0.66" W.C.

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-27

Induced Draft Blower

Pressure Switch

1/8" Tee

A
-1"
0
1"
2"
3"

= Tee installed for test
purposes only

Incline Manometer

SRM-HW/HWC 2/99

FIGURE 5-20 Incline Manometer Connection

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-28

Compressors (*262)

TABLE 5-5 Compressor Specifications (continued on next page)
Model

Compressor Type

Compressor
Model

B/M
(Tecumseh Only)

Armstrong
P/N

(All) HWC123-1

Tecumseh Rotary

RKA5512EXD

RK147-ET-002-A4

39008C001

(All) HWC183-1

Tecumseh Recriprocating

AWF5517EXN

AW501-ET-089-A4

35125C009

(All) HWC243-1

Copeland Scroll

ZR24KC PFV-130

42811-005

(All) HWC303-1

Copeland Scroll

ZR28KC PFV-130

42811-006

(All) HWC182-11, -9, -7, -6

Tecumseh Recriprocating

AWF5517EXN

AW501-ET-089-A4

35125C009

(All) HWC242-11, -9

Copeland Scroll

ZR24KC PFV-130

42811-005

(All) HWC122-10, -8, -5, -4, -3, -1

Tecumseh Rotary

RKA5512EXD

RK147-ET-002-A4

39008C001

(All) HWC242-10, -8, -5, -4, -3, -1

Copeland Scroll

ZR23K1 PFV

35136C005

(All) HWC302-9

Copeland Scroll

ZR28KC PFV-130

42811-006

(All) HWC182-8, -5, -4, -3, -2

Tecumseh Rotary

RKA5518EXD

RK233-ET-009-A4

39008C002

(All) HWC302-8, -5, -4, -3, -1

Copeland Scroll

ZR28K1 PFV

35136C001

(All) HWC182-1

Copeland Scroll

ZR18K1 PFV

35136C004

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-29

SRM-HW/HWC 2/99

Voltage

Phase RLA

LRA

Run
Cap.

Armstrong Winding
P/N
Res. S/R

Oil Type

Oil
Charge

Suction
Line

Discharge
Line

208/230

26.3

25/370 38514D002

N/A

Mineral 200 Viscosity

12 oz.

.50 (1/2)"

.315 (5/16)"

208/230

48.3

35/370 38514D004

N/A

Mineral 200 Viscosity

32 oz.

.753 (3/4)"

.378 (3/8)"

208/230

13.2

59.0

35/370 38514D004 2.45/1.17

Mineral 200 Viscosity

25 oz.

.75 (3/4)"

.50 (1/2)"

208/230

15.7

73.0

35/440 38514D010

2.74/.93

Mineral 200 Viscosity

38 oz.

.75 (3/4)"

.50 (1/2)"

208/230

48.3

35/370 38514D004

N/A

Mineral 200 Viscosity

32 oz.

.753 (3/4)"

.378 (3/8)"

208/230

59.0

35/370 38514D004 2.45/1.17

Mineral 200 Viscosity

25 oz.

.75 (3/4)"

.50 (1/2)"

208/230

26.3

25/370 38514D002

N/A

Mineral 200 Viscosity

12 oz.

.50 (1/2)"

.315 (5/16)"

208/230

12.9

62.5

30/370 38514D003

3.03/.98

Mineral 200 Viscosity

26 oz.

.75 (3/4)"

.50 (1/2)"

208/230

15.7

73.0

35/440 38514D010

2.74/.93

Mineral 200 Viscosity

38 oz.

.75 (3/4)"

.50 (1/2)"

208/230

45.0

25/370 38514D002

N/A

Mineral 200 Viscosity

12 oz.

.63 (5/8)"

.315 (5/16)"

208/230

15.0

76.0

35/370 38514D004

2.53/.77

Mineral 200 Viscosity

26 oz.

.75 (3/4)"

.50 (1/2)"

208/230

10.7

50.0

25/370 38514D002 4.91/1.29

Mineral 200 Viscosity

24 oz.

.75 (3/4)"

.50 (1/2)"

13.2

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-30
Manufacturer: Tecumseh
TABLE 5-6

Tecumseh Rotary Compressor Specifications

Armstrong P/N

Supplier Model
Number

Supplier B/M
Number

Cap. Req'd
MDF-VAC

Oil
(oz.)

39008C001

RKA5512EXD

RK147ET-002-A4

10.62

10.06

.500

8.56

25/370

39008C002

RKA5518EXD

RK233ET-009-A4

11.50

10.94

.630

8.78

25/370

All measurements in inches unless otherwise specified.

FIGURE 5-21 Tecumseh Rotary Compressor

.75" Diameter Holes

Top View

A
B

.315" I.D.Copper
Discharge Tube

C
I.D. Copper Suction Tube
.(43" - .50" Deep)

D
Side View
SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-31
Manufacturer: Tecumseh

TABLE 5-7

Tecumseh Reciprocating Compressor Specifications

Armstrong
P/N

Supplier Model
Number

35125C009

AWF5517EXN

Supplier B/M
Number

Voltage

Hz.

Crankcase
Heater

L.R.A.

P.H.

Cap.
Req'd

AW501ET-089-A4 208/230

48.3

35 MFD @ 370V

9.38"

.753"/.756" I.D.
Copper Suction Tube

12.647"
12.753”

.378"/.381" I.D. Copper Discharge Tube

7.475"
7.525"
(Between Centers of Holes)

.750"/.760" Diameter
(4 Holes)

Side View

SRM-HW/HWC 2/99

FIGURE 5-22 Tecumseh Reciprocating Compressor

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-32
Manufacturer: Copeland
TABLE 5-8

Copeland Compressor Specifications

Armstrong
P/N

Supplier Model
Number

Cap. Req'd
MFD-VAC

35136C001

ZR28K1-PFV

14.06/14.31

13.32

7.72/7.95

9.63

35/370

All measurements in inches unless otherwise specified.

18 Ga. Thermal Protector Leads
(12.13" Long)
.500" I.D. Copper Discharge Tube

.750" I.D. Copper-Plated Steel Suction Tube

D
Side View

7.50"
(Between Centers of Holes)

.765" Diameter (4 Holes)

T1 C

S
T2
T3

Typical T’Box
Layout

FIGURE 5-23 Copeland Compressor

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-33
Manufacturer: Copeland

TABLE 5-9

Copeland Compressor Specifications

Armstrong
P/N

Supplier Model
Number

Rating
Voltage-PH-Hz

42811-005

ZR24KC-PFV-130

208/230-1-60

14.21/14.45

13.32

9.63 8.53/8.77 5.47

35/370

42811-006

ZR28KC-PFV-130

208/230-1-60

14.21/14.45

13.32

9.63

35/370

Cap. Req'd
MFD-VAC

7.97

6.52

All measurements in inches unless otherwise specified.

9.41"/9.62"
7.50"

.750" Dia.
(4 Holes)

(Typ.)

7.50"
(Typ.)

Top View
C
T1
R

S
T2
T3

.500" I.D. Copper
Discharge Fitting

Top View

.750" I.D. Copper-Plated
Steel Suction Fitting

A
B
C

E
D

FIGURE 5-24 Copeland Compressor

SRM-HW/HWC 2/99

Side View

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-34

Drier-Filters (*301)
TABLE 5-10

Drier-Filter Specifications

Armstrong Part Number

Supplier

Supplier Part Number

Spinco

100307-1

Parker

032151-00

.108"
.111"

Spinco

100307-2

Parker

032150-00

.114"
.117"

Spinco

100307-3

Parker

032181-00

.108"
.111"

39059B001

39059B002

39059B003

A - I.D.

4.38" +/– .13"
.314"
I.D.
.317"

B - # Holes
1.00"

FIGURE 5-25 Drier-Filter

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-35

HWC Capillary Tubes (*256)
TABLE 5-11

HWC Capillary Tube Specification Tables*

Models

Assy. + Drier

Drier Only**

Cap. Tubes Only***

Ind. Cap.
Tube

Cap.
I.D.

Cap.
O.D.

Cap.
Length

#
Tubes

123-1

43271-001

39059B001

43267-001

05302B001

0.054"

0.106"

35"

183-1

43271-002

39059B002

43267-002

05302B025

0.054"

0.106"

44"

243-1

43271-003

39059B002

43267-003

05302B024

0.059"

0.112"

46"

303-1

43375-001

39059B003

43281-001, 43280-001

05302B025

0.054"

0.106"

44"

122-10

43271-001

39059B001

43267-001

05302B001

0.054"

0.106"

35"

122-1 to -8

39058B001

39059B001

39102B001

05302B001

0.054"

0.106"

35"

182-1 to -9

39058B002

39059B002

39102B002

05302B025

0.054"

0.106"

44"

242-4 to -8

39058B003

39059B002

39102B003

05302B024

0.059"

0.112"

46"

242-9 to -11

43271-003

39059B002

43267-003

05302B024

0.059"

0.112"

46"

302-1 to -3

39057B001

39059B003

39103B001, 39298B001

05302B025

0.054"

0.106"

44"

302-4 to -8

40650-001

39059B003

40652-001, 40651-001

05302B025

0.054"

0.106"

44"

302-9

43375-001

39059B003

43281-001, 43280-001

05302B025

0.054"

0.106"

44"

SRM-HW/HWC 2/99

* All part numbers provided are Armstrong part numbers.
** See page 5-34 for drier information.
*** See the figures beginning on page 5-36 for detailed drawings of the capillary tubes.

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-36
Notes:
• All bends 90° unless otherwise noted.
• Do not kink or flatten during forming.
• Tape tubes together with masking tape.

14.00"

15.60"

11.89" Ref.

6.75" Ref.

7.25" Ref.

1.00" Rad. Typ.

.75" Rad. Typ.

6.00"
.13"
.25" Rad.
I.S. Typ.

.08"

14.88"

5.43"
.13"

3.81"
Ref.

.75"

.25" Rad.
I.S. Typ.

3.500" Diameter
1 Turn
2.875" Diameter Mandrel

12.82"

.12"
.75"

30°
12.77"
Ref.

3.50"
Ref.

30°
10.88"
Ref.

5302B001 - 2 Req’d

5302B025 - 3 Req’d

.13"
.12"
.75"

.73"
Ref.

30°

1.78"

FIGURE 5-26 43267-001 Capillary Tubes

FIGURE 5-27 43267-002 Capillary Tubes

17.11"
9.00" Ref.

15.86"

6.50" Ref.

9.00" Ref.

5.25" Ref.

.75" Rad. Typ.
5.57"
.13"
3.500" Diameter
1 Turn
2.875" Diameter Mandrel

13.19"

.25" Rad.
I.S. Typ.

.12"
.75"

5302B025
2 Req’d

3.63"
Ref.

.75" Typ.

.12"
Typ.

2.62"
Ref.

5302B024 - 3 Req’d

4.23"

4.38"
Ref.

2.500" Diameter
2 Turns
2.125" Mandrel

30°
11.25"
Ref.

.75" Rad.
Typ.

.250" Rad.
Typ.

5.46"
.13" Typ.

130°
.75" Ref.

.13"

30°

.12"
.75"
30°

FIGURE 5-29 43280-001 Capillary Tubes

SRM-HW/HWC 2/99

FIGURE 5-28 43267-003 Capillary Tubes

Service Reference Manual

UNIT COMPONENTS
5-37

Notes:
• All bends 90° unless otherwise noted.
• Do not kink or flatten during forming.
• Tape tubes together with masking tape.

1.25
Turns

10.70"

14.74"
13.13" Ref.

1.446" Diameter
.75" Rad. Typ.
3.500" Diameter
1 Turn
3.00" Mandrel

4.25"
Ref.
.13" Typ.

6.16"

12.22" +/ .13"

12.91"

5302B025 - 2 Req’d

.12" Typ.

16.40"

11.00"
Ref.

.250"
Rad. I.S.
Typical

30°

.08"

53025B025 - 2 Req’d

.75"
30°
.13"
.25" Rad. I.S. Typ.

.750" Rad.
Typical

.75" Typ.

.50" +/– .13"
1.28"

FIGURE 5-30 43281-001 Capillary Tubes

10.70"
50°

.75"
.250" Rad. I.S.
Typical

FIGURE 5-31 40651-001 Capillary Tubes

.75"

1.25
Turns

1.55"

3.81"
.08"

.75" Rad.

2.25"
3.05"

3.196" Diameter

3.60"

2.73"

3.688" Diameter
3 Turns

5302B025 - 2 Req’d
16.40"

.08"
30°

.750" Rad.
Typical
.50" +/– .13"

SRM-HW/HWC 2/99

1.28"

FIGURE 5-32 40652-001 Capillary Tubes

.13"
5302B025 -2 Req’d

.25" Rad. I.S. Typ.
2.50"

.75"

FIGURE 5-33 39103B001 Capillary Tubes

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-38
Notes:
• All bends 90° unless otherwise noted.
• Do not kink or flatten during forming.
• Tape tubes together with masking tape.
TABLE 5-12

.75"

39102B001 Specifications

Armstrong P/N

39102B001

3.530"

5302B001

39102B002

3.281"

5302B025

39102B003

3.500"

5302B024

2.79"
.25" Rad. I.S. Typ.
C - D Req’d

.13"
30°

5.42"

.08"

1.25"
.75"

A - Diameter
B - Turns

4.64"

6.76"

FIGURE 5-34 39102B001 Capillary Tubes

.75" Rad. Typ.

7.43"

7.00"

.75"
1.55"

2.50"

3.30"
2.844" Diameter
3 Turns

53205B025 - 2 Req’d

.75"
30°

.50"

.08"

2.03"

SRM-HW/HWC 2/99

FIGURE 5-35 39298B001 Capillary Tubes

Service Reference Manual

UNIT COMPONENTS
5-39

Capacitors (*271)

SRM-HW/HWC 2/99

TABLE 5-13

Capacitor Ratings
Rating

Armstrong
P/N

MFD

Volts

38514D001

20/5

370

38514D002

25/5

370

38514D003

30/5

370

38514D004

35/5

370

38514D005

40/5

370

38514D006

40/5

440

38514D007

40/7.5

440

38514D008

45/7.5

440

38514D009

35/7.5

440

38514D010

35/5

440

38514D011

45/5

370

38514D012

55/7.5

440

38514D013

60/7.5

370

38514D014

80/7.5

370

38514D015

45/5

440

38514D016

60/5

370

38514D017

80/5

370

38514D018

50/5

370

38514D019

50/7.5

440

38514D020

55/5

370

38514D021

70/5

370

38514D022

60/5

440

Dual

Single

FIGURE 5-36 Capacitors

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-40

Evaporator Blower Motor Indoor Blower (*69)
TABLE 5-14

Evaporator Blower Motor Specifications

Armstrong
P/N

FLA
(v/hz/ph)

RPM

# of
Speeds

Capacitor

39045B001

1.1
(208-230/60/1)

1000

1/6

4/370

39046B001

2.3
(208-230/60/1)

1120

1/3

7.5/370

Notes:
• FLA and capacitor ratings may vary. Always check FLA and
capacitor ratings on the motor data plate.
• Motor diameter - 5.70", shaft size - .50", rotatin - CW lead end
• See parts list for correct selection of motor and capacitor.

Condenser Fan Motor Outdoor Motor (*267)
TABLE 5-15

Condenser Fan Motor Specifications

Armstrong
P/N

FLA
(v/hz/ph)

RPM

# of
Speeds

Capacitor

39044B001

1.8
(208-230/60/1)

1075

1/4

5/370

39084B001

.9
(208-230/60/1)

1075

1/8

5/370

41282-001

.9
(208-230/60/1)

1075

1/8

5/370

41254-001

1.8
(208-230/60/1)

1075

1/4

5/370

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-41

Capacitors-Run (*86)

SRM-HW/HWC 2/99

TABLE 5-16

Run Capacitor Ratings
Rating

Armstrong
P/N

MFD

Volts

34001D001

370

34001D002

370

34001D003

370

34001D004

7.5

370

34001D005

370

34001D006

440

34001D007

370

34001D008

12.5

370

34001D009

440

34001D010

440

34001D011

370

34001D012

440

34001D013

440

34001D014

370

34001D015

440

34001D016

370

34001D017

440

34001D018

440

34001D024

370

34001D025

370

34001D026

370

34001D027

440

34001D028

370

34001D029

370

34001D030

370

34001D031

370

34001D032

370

34001D033

440

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-42

Fan Blades (*268)

Notes:
1. 26° Pitch, 5 Blades
2. Material: 24 Ga. Galvalume
3. Set Screw: (2) 5/16"-24 x 5/8" long square head, cup point

3.79" +/ .09"

18.00" +/ .06"

.5002"
Diameter Bore
.5019"

Rotation

AIR FLOW

FIGURE 5-37 Fan Blades - HWC Models 122, 182 & 123, 183

SRM-HW/HWC 2/99

Service Reference Manual

UNIT COMPONENTS
5-43

Notes:
1. 24° Pitch, 3 Blades
2. Material: 24 Ga. Galvalume
3. Set Screw: (2) 5/16"-24 x 5/8" long square head, cup point

3.59" +/ .09"

18.00" +/ .06"

.5002"
Diameter Bore
.5019"

Rotation

AIR FLOW

SRM-HW/HWC 2/99

FIGURE 5-38 Fan Blades - HWC Models 242, 302 & 243, 303

UNIT COMPONENTS

Magic-Pak: HW/HWC

5-44

Exterior Grill Panels
(Not Listed in the Parts Lists)

Upper Louver Panel
Armstrong P/N 03545C000

Lower Grill Panel
Armstrong P/N 03551D100

Refer to the Component Location Illustrations section beginning on page
4-1 for further detail of the exterior grill panels and other panels.

FIGURE 5-39 Exterior Grill Panels

SRM-HW/HWC 2/99

Service Reference Manual

INSTALLATION
6-1

Section 6 - Installation
Location .............................................. 6-3
Installing With Wall Sleeve.................... 6-5
Installing Without Wall Sleeve ............... 6-6
Support............................................... 6-6
Condensate Drain ................................. 6-7
Venting ............................................... 6-7
Removal of Unit from Common
Venting System .................................... 6-9
Gas Connections .................................. 6-9
Electrical Connections ........................ 6-11
Thermostat ....................................... 6-12
Supply and Return Ducts .................... 6-12
Air Filter ........................................... 6-13
Adjustments (Heating Section) ............ 6-13
Adjustments (Cooling Section) ............. 6-14
Blower .............................................. 6-14
Limit Control ..................................... 6-14

SRM-HW/HWC 8/99

High Altitude Adjustments (U.S.) ......... 6-14
High Altitude Adjustments (Canada)..... 6-14

INSTALLATION

Magic-Pak: HW/HWC

6-2

Installation and Operation in Extremely
Cold Weather Areas ........................... 6-15

SRM-HW/HWC 8/99

Service Reference Manual

INSTALLATION
6-3

Installation

IMPORTANT:
READ THIS FIRST

Information in this section is provided for the convenience of the service
technician, for the purpose of evaluating the installation during service
and troubleshooting. It does not take the place of the complete Armstrong Installation and Maintenance Instructions that are shipped with
every Magic-Pak unit. If you are installing an Armstrong product and
need a copy of the Installation and Maintenance Instructions, consult the
table below and contact the Armstrong factory.
TABLE 6-1

HW/HWC Installation and Maintenance Instructions

Armstrong
Publication
P/N

Date

Description

45042B099

2/99

(All) HWC (123, 183, 243, 303)-1
& HW -9 w/UTech 1097 Board

39025G097

7/97

(All) HWC (122, 182, 243, 303)
-11, -10, -9, -8, -7, -6, -5 & HW
w/Fenwal 2461D Board

39025G094

7/94

(All) HWC (122, 182, 243, 303)
-4, -3, -2, -1 & HW
w/Fenwal 05-29 Board

Location
Magic-Pak HW/HWC units are designed and certified for through-the-wall
installations only and must not be installed in any other type of application. The interior portions of the unit may be surrounded by a closet with
clearances to combustible material held to 0" at sides, 2" top and 1" front
and plenum. Adequate clearance must be provided to install the union
and manual shutoff valve as well as providing accessibility to the field
wiring junction box. Do not install directly on carpeting, tile or other
combustible material other than wood flooring.
Magic-Pak HW/HWC units should be installed in an outside building wall
that is clear of obstructions which might impede the free intake and
discharge of condenser air.
A building wall should be no closer to an opposite building wall than 2' for
every floor or Magic-Pak unit in a vertical array facing the wall. For
example, a one-story building with a Magic-Pak HW/HWC unit should be
a minimum of 2' from the wall facing the unit, and if the facing wall also
has a Magic-Pak unit, the two walls should be at least 4' apart.
A six-story building with six Magic-Pak units in a vertical array should be
at least 12' from the opposite building wall, and if that building wall also
contains Magic-Pak units, the building should be at least 24' apart.

SRM-HW/HWC 8/99

Buildings taller than six stories need not exceed the separation needed
for six-story buildings.

INSTALLATION

Magic-Pak: HW/HWC

6-4
If three or more adjacent walls form an air shaft with Magic-Pak HW/HWC
units facing each other in each wall, the separation between opposite
walls should be increased by 20%.
These “rule-of-thumb” dimensions are intended to minimize possibilities
for recirculation of condenser air, or interaction between units. However,
these numbers are not exact for every application, and other considerations might suggest that the designer consult the factory about desired
alternatives.
The grille side of the unit may be flush with, or extend beyond, the face of
the exterior wall, but should not be recessed more than 2" from the face
of the building and should not be obstructed with trees, landscape materials or building structure.
There is no minimum clearance required on locating the unit to an interior
corner of a building.
Due to the through-the-wall design, HW/HWC units will always have some
portion of the unit cabinet extending into the interior of the building. The
amount of cabinet exposed to the interior will depend on the wall thickness and the depth the unit is installed into the wall.
Often mechanical rooms and closets are designed into the building
structure to accommodate the interior portions and duct connections.
These rooms or closets must allow ample clearance for regular service
and maintenance.
A 30" wide minimum clearance opening is required in front of the filter
access door. This will allow for easy removal of the door and replacement
of the filter. Electrical conduit, gas lines, duct work and building structures
places within this opening will complicate removal of the filter access door
that may result in a lack of proper maintenance and diminished performance.
The cooling section of an HWC unit is built on a sliding chassis that can
only be removed through the filter access door. Any service that must be
done to the condenser section, evaporator fan or refrigeration circuit
requires removal of the chassis from the unit. Therefore, a 30" horizontal
minimum clear opening is required in front of the filter access door to
facilitate removal of the entire cooling chassis.
It is recommended that the doorway to any closet or room containing a
Magic-Pak HW/HWC unit be a minimum of 36" wide to allow some
tolerance for chassis removal and service.
If the unit is installed in a residential garage, it must be located or protected to avoid physical damage by vehicles. This unit must be installed
so that no electrical components are exposed to water.
Installing units in a relatively inaccessible location for easy chassis
removal should be avoided, if for no other reason than to keep the air filter
accessible for easy and timely cleaning by the occupants or maintenance
personnel.
SRM-HW/HWC 8/99

Service Reference Manual

INSTALLATION
6-5

Installing With a Wall Sleeve
CAUTION
The sleeve is not intended as the sole support for the
unit. Additional support must be provided near the
return opening on the unit for adequate support. The
use of vibration isolation material between the unit and
the support is recommended.
Refer to the installation instructions packed with the wall sleeve and
Figure 6-1 for guidance in assembly and mounting using a wall sleeve.
See also the Accessories section beginning on page 7-3 for further
details on wall sleeve installations.
Refer to page 6-6 for information concerning additional support under the
HW/HWC unit.
Make sure the gaskets attached to the sleeve are not damaged.
Seal the space between the wall sleeve and the building opening with
non-hardening caulking compound. The seal must be weathertight to
prevent entrance of moisture and water into the building.
Assure that the unit is completely seated against the gaskets on the wall
sleeve.

Wall Sleeve

6" X 22" Minimum Opening to
Align with Return Air Opening
In Unit.

in.
"M
8
2

Vibration Isolating Material

FLO
OR

SRM-HW/HWC 8/99

Plywood

FIGURE 6-1

HW/HWC Installation

INSTALLATION

Magic-Pak: HW/HWC

6-6

Installing Without a Wall Sleeve
Refer to the following directions and Figure 6-1 on page 6-5 for guidance
in installing the unit without a wall sleeve:
1. Measure the size of the unit and provide an opening in an outside
wall that will accept the unit. Local ordinances may require a steel
lintel to support the wall above the opening. The opening must be
square in all four corners.
2. Position the unit so that the grilles on the outside face of the unit are
flush or extend beyond the face of the exterior wall, but not recessed
more than 2" from the face of the building. Provide a support
under the unit, inside the building. Make sure that the inside
support does not block the return air. The unit should be installed
level or pitched slightly to the outside of the building so that rain water
will drain away.
3. Seal the space between the unit and building opening using a nonhardening caulking compound. The seal must be weathertight to
prevent entrance of moisture and water into the building. Make sure
the drain holes in the base are not plugged with caulking.

Support
In general, the wall sleeves will support the Magic-Pak HW/HWC units on
any wall. The wall, however, must be adequate to support the unit.
Otherwise, one must provide additional support between the unit and the
floor. The center of gravity is between the bottom return-air opening rear
flange and the wall sleeve. When additional support for the unit is desirable, it should be near this center of gravity and applied evenly across the
bottom of the unit through adjustable legs to the floor.
A supplementary support can be made for this purpose. It should consist
of two steel channels, 28" long, one placed under the unit and one on the
floor. They are separated by 3/4" pipe and “all-thread” rod, with nuts and
washers, to provide the adjustment pressure. Vibration-isolation blocks or
pads are also required to minimize transmission of vibration into the floor.
Even though the wall may be adequate to support the unit, experience
has shown the desirability of supplementary support to reduce the
possibility of vibration being transmitted into the wall and to other parts of
the structure.
Two 1" diameter holes are located near the front of the Magic-Pak HW/
HWC units, on either side of the return-air opening. These holes are
intended to allow a condensate drain tube to exit the return-air duct cavity
whenever a closed return duct and flexible collar are used. These
should not be used to support the unit. The sheet metal in the
cabinet in this area is not heavy enough to act as a support without
distorting and interfering with proper retention of the filter access cover.

SRM-HW/HWC 8/99

Service Reference Manual

INSTALLATION
6-7

Condensate Drain (HWC Models)
Install the plastic drain tube (furnished) over the 5/8" O.D. fitting welded to
the center of the condensate pan. Connect the other end of the drain
tube to the open trap (see Figure 6-2). The plastic drain connection is
provided so that it may be disconnected from the permanent drain tubing
in the building in the event it becomes necessary to remove the cooling
chassis assembly.
The drain line should pitch gradually downward at least 1" per 10 feet of
horizontal run to the open drain trap.
Be certain that the plastic drain tube has free drainage and is not crimped
or flattened at any bend.

Drain Pan
Top of Drain Tube
Must be Below
Bottom of Drain Pan

Alternative Method
To Open Drain Trap

Drain Tube - Pitch 1" for
every 10 ft. (Installer
Supplied)

Return Air Duct
5/8" I.D.
Plastic Tube
(Furnished)

FIGURE 6-2

Open Drain Trap

HWC Drain Installation

Venting
The venting system is an integral part of the appliance. The
venting system must not be modified or added on to.
HW/HWC units are direct vent forced air central furnaces which draw
fresh air from outside through a combustion air opening beneath the vent
into the combustion chamber. The combustion products are then drawn
out of the heat exchanger by an exhaust fan and are forced to the outdoors.
No special provisions are required for supplying combustion air.
The vent outlet must not be altered or extended in any way.

SRM-HW/HWC 8/99

This appliance should be installed in a location such that the vent system
complies with the National Fuel Gas Code Z223.1 or CAN/CGA-B149.1 &
.2.

INSTALLATION

Magic-Pak: HW/HWC

6-8
Special provisions must be made concerning the location of the vent
termination with relation to building air inlets. A building air inlet is considered to be any door, moveable window, gravity fresh air inlet or other
opening where fresh outdoor air can be brought into the building. See
Table 6-2 for the clearances required.
TABLE 6-2

HW/HWC Installation and Maintenance Instructions
Units

Clearance

26, 38HW/HWC

9 Inches

51, 64HW/HWC

12 Inches

The vent system must also terminate at least 3 feet above any forced air
inlet within 10 feet of it.
These clearances do not apply to the combustion air inlet of the appliance
because the combustion air does not enter the air of the building.
Clearance to windows applies to openable windows and not to windows
constructed only of glass with no movable parts such as picture windows.
The vent system must terminate a minimum horizontal distance of 4 feet
away from public walkways, electrical meters, regulators and relief
equipment.
The venting system is designed for proper operation under all weather
conditions and for winds up to 40 m.p.h.
Figure 6-3 shows the required clearances of direct vent to building air
inlets.

Direct Vent Terminal
10,000 - 50,000 Btu/hr

Less than
10'

12
"m
in

in
3' m

12"
in
"m
12

Forced Air Inlet
Direct Vent Terminal
more than 50,000 Btu/hr

Required Clearances for Direct Vent Terminals

SRM-HW/HWC 8/99

FIGURE 6-3

Direct Vent
Terminal

Service Reference Manual

INSTALLATION
6-9

Removal of Unit from Common Venting
System
When an existing furnace is removed from a common venting system
serving other appliances, the venting system is likely to be too large to
properly vent the remaining attached appliances. The following test
should be conducted with each appliance while the other appliances
connected to the common venting system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal
pitch and determine there is no blockage or restriction, leakage,
corrosion or other deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows between
the space in which the appliances remaining connected to the
common venting system are located and other spaces in the building.
Turn on clothes dryers and any appliance not connected to the
common venting system. Turn on exhaust fans, such as range hoods
and bathroom exhausts, so they will operate at maximum speed. Do
not operate a summer exhaust fan. Close fireplace dampers.
4. Following the lighting instructions, place the unit being inspected in
operation. Adjust the thermostat so the appliance will operate
continuously.
5. Test for spillage at the draft control relief opening after five minutes of
main burner operation. Use the flame of a match or candle.
6. Follow the preceding steps for each appliance connected to the
common venting system.
7. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as
outlined above, return doors, windows, exhaust fans, fireplace
dampers and any other fuel burning appliance to their previous
condition of use.
8. If improper venting is observed during any of the above tests, the
common venting system must be corrected. See National Fuel
Gas Code, ANSI Z223.1 (latest edition) or CAN/CGA B149.1 & .2
Canadian Installation Codes to correct improper operation of
common venting system.

Gas Connections

SRM-HW/HWC 8/99

The gas line to the unit should be adequately sized to prevent undue
pressure drop and should never be smaller than the manual valve used.
Consult the local utility or National Fuel Gas Code for complete details on
special requirements in sizing gas piping.
The units supplied for operation with natural gas contain a gas regulator
which must be operated with inlet gas pressures specified on the rating
plate. If gas line pressure exceeds this figure, an additional high pressure
regulator must be installed to reduce this pressure.

INSTALLATION

Magic-Pak: HW/HWC

6-10
Units for operation with propane must be converted with a kit supplied by
the manufacturer and require for operation an inlet pressure of 11" W.C.
minimum and 14" W.C. maximum. A regulator is also required on the
propane tank.
When converting a low NOx unit (designated by an L in the model number) to propane, the NOx inserts must be removed. After removing
the burners, remove the screw holding each insert and pull the insert from
the combustion chamber (see Figure 6-4). The screws must be reinstalled in the vest panel after the inserts are removed.

Low NOx Insert

FIGURE 6-4

NOx Insert Removal

WARNING
Never use a flame to check for gas leaks. Explosion
causing injury or death may occur.

WARNING
The furnace must be isolated from the gas supply
piping system by closing the individual manual shutoff
valve during any pressure testing of gas supply piping
system at test pressures equal to or less than 1/2 psig
or 14" W.C. If the piping system is to be tested at
pressures in excess of 1/2 psig, the furnace and its
individual shutoff valve must be disconnected from the
gas supply piping system. The gas valve supplied with
this furnace is rated at 1/2 psig. Any higher pressure
may rupture the pressure regulator diaphragm which
will cause over firing of the burners and improper
burner operation. This action may produce a high
concentration of carbon monoxide which can result in
asphyxiation.

SRM-HW/HWC 8/99

Service Reference Manual

INSTALLATION
6-11
A manual shutoff valve must be located outside the unit. The use of a
union located upstream of the controls is recommended, between the
controls and the manual shutoff valve. This will facilitate removal of
controls and manifold. See Figure 6-5 for recommended placement of the
union.
Provide a drip leg in the supply piping located exterior to the unit. Piping
must be tight and non-hardening. Pipe compound resistant to propane
must be used.
Manual Shutoff Valve w/ 1/8" NPT
plugged tapping, accessible for
test gauge connection (field-supplied)
Ground Joint Union (field-supplied)
Drip Leg (field-supplied)
Access Panels to
Controls and Burners

Access Panel To Filter

FIGURE 6-5

Gas Supply Piping

Electrical Connections
All wiring must be done in accordance with the National Electrical
Code, ANSI/NFPA No. 70 (latest edition); Canadian Electrical
Code Part 1, CSA C22.1 (latest edition); or local codes, where they
prevail. Any alteration of internal wiring will void certification and
warranty.
The rating plate indicates the operating voltage, phase, ampacity, maximum fuse size and minimum voltage. Units must never be installed
where voltage exceeds 10% over the voltage indicated on the rating plate.
Units are factory wired for a 230 volt power supply. If power
supply is 208 volts, it will be necessary to change a wire connection on unit transformer from 240 volt terminal to 208 volt terminal as shown on the wiring diagram.

SRM-HW/HWC 8/99

Failure of the compressor as a result of operation on improper
voltage voids the compressor replacement warranty.
A separate electric line with wire having a temperature rating of 60°C
should be run directly from the main supply panel to the leads in the unit.
Refer to the rating plate located on the unit for proper fuse or breaker size.
Make sure the unit is electrically grounded in accordance with local codes
or, in the absence of local codes, with the National Electrical Code, ANSI/
NFPA No. 70 (latest edition) for installations in the U.S. or the Canadian
Electrical Code Part 1, CSA C22.1 (latest edition) for installations in
Canada.

INSTALLATION

Magic-Pak: HW/HWC

6-12
See Table 6-3 and the Specifications section beginning on page 1-1 for
correct wire ampacity for the cooling chassis required, and size the wire
accordingly.
For HW (heating only units): When sizing wire, keep in mind that
an air conditioning chassis may be added in the future.
TABLE 6-3

Minimum Circuit Ampacity

Clg. Chassis Model

Min. Circuit Ampacity

18A

24A

30A

181

13.3

241

301

23.6

122, 123

8.3

182, 183

13.6 Rotary/15.4 Scroll

242, 243

18.6

302, 303

22.4

Thermostat
Install the thermostat according to the directions furnished with it. The
thermostat must be located on an inside wall where it will not be affected
by drafts, sunlight or any other heat producing appliances. Connect the
thermostat wires to the low voltage leads on top of the unit following the
wiring diagram attached to the unit. The heat anticipator setting is 0.50
Amp.

Supply and Return Ducts
Provide ducts sized sufficiently to handle the larger of the air volumes for
heating or cooling provided by the unit.
Connect the supply duct to the top of the unit using canvas connections
or other flexible connections to prevent noise transmission into the duct
system.
The supply duct should have a removable access panel. The
opening should be accessible when the furnace is installed and
should be large enough and located such that the heat exchanger
can be inspected for leaks. The cover must be attached in such a
manner as to prevent air leaks.

SRM-HW/HWC 8/99

To connect the return duct to the system, use a straight piece of duct 22"
wide by 6" deep. Insert the duct into the return opening in the bottom of
the unit and flange the duct over the existing flanges around the opening

Service Reference Manual

INSTALLATION
6-13
inside the unit. Make sure that all sides of the duct are flanged over to
permit removal of the cooling chassis if required. Use a flexible connection to attach the remainder of the return duct. The return duct should be
sealed to the unit casing and terminate outside the space containing the
furnace.

Air Filter
All indoor return air must be filtered. A permanent-type filter is furnished
with the unit, located directly behind the access panel. Removing the
panel permits access to the filter.
If an installation is made in which it is more desirable to mount the filter
exterior to the unit, in the return duct work or elsewhere, the permanent
filter can be used or replaced with a disposable filter. If a disposable filter
is used, refer to Table 6-4 when sizing the disposable filter.
TABLE 6-4

Minimum Required Surface Area for Disposable
Filters

Model Number

Filter Area (minimum)

Supplied Filter Size

HWC122, 123

300 square inches

16.5" x 25.5" x .50"

HWC182, 183

480 square inches

16.5" x 25.5" x .50"

HWC242, 243

480 square inches

16.5" x 25.5" x .50"

HWC302, 303

480 square inches

16.5" x 25.5" x .50"

26 HW

300 square inches

16.5" x 25.5" x .50"

38 HW

300 square inches

16.5" x 25.5" x .50"

51 HW

480 square inches

16.5" x 25.5" x .50"

64 HW

480 square inches

16.5" x 25.5" x .50"

Adjustments - Heating Section
Temperature Rise
At the time of installation, the temperature rise must be adjusted to be
within the range specified on the unit rating plate.
Pressure Regulator
The gas input must not exceed the figures shown on the rating plate. The
unit is equipped for rated inputs with manifold pressures of: 3.5" W.C. for
natural gas and 10.0" W.C. for propane.

SRM-HW/HWC 8/99

The manifold pressure can be measured by removing the pipe plug in the
automatic gas valve. Connect a water manometer and measure the
pressure.
Only small variations in gas input may be made by adjusting the regulator.
In no case should the final manifold pressure vary more than 0.3"
W.C. for natural gas or 0.7" W.C. for propane.

INSTALLATION

Magic-Pak: HW/HWC

6-14
To adjust the regulator, turn the adjusting screw on the regulator clockwise to increase pressure and input or counterclockwise to decrease
pressure and input.
For natural gas installations, check the burner rate by observing the gas
meter (making sure that all other gas appliances are turned off). The test
hand on the meter should be timed for at least one revolution. Note the
number of seconds for one revolution.
BTU/HR
=
INPUT

Cubic Feet Per Revolution
# Seconds Per Revolution

X 3600 X

Heating
Value

Adjustments - Cooling Section (HWC models)
No adjustments are required or should be attempted regarding any of the
components of the cooling chassis. The chassis should be checked to
see that none of the wiring is loose or missing.

Blower
The unit contains a direct-drive, multispeed blower. The proper speeds
have been preset at the factory for heating and cooling. Refer to the
wiring diagram for recommended heating/cooling speeds for specific
models. Direct-drive blower motors are permanently lubricated and do
not require oiling.

Limit Control
A fixed-temperature limit control is provided which will shut off the gas to
the main burners if the unit is overheated for any reason. The control
must not be adjusted or relocated.

High Altitude Adjustments (U.S. Installations)
Ratings shown on the rating plate are for elevations up to 2000 feet. For
elevations above 2000 feet, ratings should be reduced at a rate of 4% for
each 1000 feet above sea level. Refer to the National Fuel Gas Code
Z223.1 (latest edition) for further explanation.

High Altitude Adjustments (Canadian Installations)
High altitude conversions may be made by the manufacturer’s authorized
representative, in accordance with the requirement of the manufacturer,
provincial or territorial authorities having jurisdiction, and in accordance
with the requirements of CAN/CGA B149.1 or B149.2 Installation Code.
A high altitude conversion kit, available from the manufacturer and
approved for this purpose, must be used (see the Accessories section
beginning on page 7-15).

SRM-HW/HWC 8/99

Service Reference Manual

INSTALLATION
6-15

Installation and Operation in Extremely Cold
Weather Areas
In areas where extremely cold (below – 20°F) outdoor temperatures can
be expected, some additional installation and operating precautions
should be taken. The following precautions are taken to prevent possible
vent system ice blockage that could result in safety shutdown of the
burners:
1. Adjust to the highest achievable temperature rise within the rise and
static pressure ranges specified on the rating plate. Depending on
specific model, it may be possible to change to a lower heating blower
speed tap to get a higher temperature rise. This also increases
comfort.
2. Make sure there are no leaks of outside air into the return air system.

SRM-HW/HWC 8/99

3. Keep the outside louver grille as free as possible of any ice that may
form and obstruct the flue outlet.

Service Reference Manual

ACCESSORIES
7-1

Section 7 - Accessories
HW/HWC Accessory Kit Index .............. 7-2
CA-239 Wall Sleeve Kit ................................... 7-3
A242-1 Wall Sleeve Adaptor Kit ...................... 7-7
ALVR42 Architectural Louver Facade ............. 7-10
34961A001 Vibration Isolator ...................... 7-12
ALPKT389-2 L.P. Gas Conversion Kit ............. 7-14
AHALT390-1 High Altitude Kit ....................... 7-15
ATIMR466-1 Nuisance Blower Repair Kit ........ 7-17
ADAPT420-2 Chassis Conversion Kit .............. 7-18
Fenwal Triton Ignition Control Kit .................. 7-19
TL109 Burner Tray Kits ................................ 7-20

SRM-HW/HWC 8/99

AMUFFKT494-1 Tecumseh “AW” Model
Compressor Sound Reduction Kit ................... 7-21

ACCESSORIES

Magic-Pak: HW/HWC

7-2

Accessories
There are a number of accessories available to increase the performance
or versatility of the Armstrong Magic-Pak HW/HWC units. This section
provides a general description of each.
Note: Complete instructions are packaged with each kit or its
components and accessories. These instructions should
be read carefully prior to installation. The instructions are
intended as a general guide only, for use by qualified
personnel, and do not supersede any national or local
codes in any way.

TABLE 7-1

HW/HWC Accessory Kit Index

PART NUMBER

DESCRIPTION

UNIT MODELS

CA-239

Knocked Down Wall Sleeve Kit*

All HW/HWC Models

A242-1

Wall Sleeve Adaptor Kit

All HW/HWC Models

ALVR42

Architectural Extruded Aluminum Louver Facade*

All HW/HWC Models

34961A001

Compressor Vibration Isolator/Spring In Grommet Kit

All HW/HWC Models

ALPKT389-2

L.P. Gas Conversion Kit**

26, 38, 51, 64HW/HWC Models

AHALT390-1

High Altitude Conversion Kit**

26, 38, 51, 64HW/HWC Models

ATIMR466-1

Nuisance Blower Operation Repair Kit

All HW/HWC Series 2 Models

ADAPT420-2

Chassis Conversion Kit

All HW/HWC Models

43110-001

Ignition Control Conversion Kit

All HW/HWC Series 2 Models

TL109A

Burner Tray Assembly Kit

26HW/HWC

TL109B

Burner Tray Assembly Kit

38HW/HWC

TL109C

Burner Tray Assembly Kit

51HW/HWC

TL109D

Burner Tray Assembly Kit

64HW/HWC

AMUFFKT494-1

Tecumseh 'AW' Model Compressor Sound Reduction Kit

HWC182

* Does not apply to 121, 181, 241 and 301 (48" tall series units use sleeve CA241).
** Does not apply to 12, 18, 24 and 30 or 121, 181, 241 and 301 units.

SRM-HW/HWC 8/99

Service Reference Manual

ACCESSORIES
7-3

CA-239 Wall Sleeve Kit
The CA-239 wall sleeve kit is designed to facilitate the installation of
Magic-Pak units by providing an accurate opening to properly accept a
Magic-Pak unit. During the construction of a building, the wall sleeve
allows for the unit to remain off-site until the construction is completed.
The wall sleeve is comprised of four assemblies (top, bottom and left and
right sides) which assemble easily to form a correctly sized rectangular
box to receive a Magic-Pak unit.
When installed and securely fastened to the supporting wall, the wall
sleeve provides easy access to the finish wall for weather sealing.
The wall sleeve must always be fastened to the supporting wall
and never to the finished wall.
Inspection of Shipment
Upon receipt of equipment, carefully inspect it for possible shipping
damage. If damage is found, it should be noted on the carrier’s freight bill.
Damage claims should be filed with the carrier immediately. Claims of
shortages should be filed with the seller within five days.

Wall Sleeve Assembly
To assemble the wall sleeve, refer to the following directions and Figure 71 on page 7-4.
1. Slide top panel over side panels until retaining clips are engaged in
slotted openings.
2. Place side and top assembly down with the front flange against floor
and slide bottom panel into side panel slip strips until tabs on bottom
panels are locked in place.
3. Attach squaring braces to top and side panels using existing holes.
(Do not remove braces until wall sleeve is secured to building.)
4. Attach the support angles to top and side panels using the #8 x 3/8"
screws provided. Two sets of holes are provided in the panels for
attaching the support angles. The row of holes nearest the front of
sleeve will locate the support angles for 1" spacing and the second
set of holes will locate the angles for 3-3/4" spacing.
5. Wall sleeve must be square in opening before securing sleeve
to building. This is required to assure Magic-Pak unit will slide into
the sleeve.

SRM-HW/HWC 8/99

6. Caulk all seams where bottom panel joins to side panels including the
front corners of bottom panel and the top of side panel slip joints.
Caulk sealing is best accomplished after the wall sleeve is assembled
but before it is placed in the wall opening.

ACCESSORIES

Magic-Pak: HW/HWC

7-4

TABLE 7-2

CA-239 Parts List

Description

Quantity

Top Panel

Bottom Panel

Right Side Panel

Left Side Panel

Squaring Brace

1/4" x 3/4" Screw

#8 x 3/8" Screw

1/4" Flat Washer

Side Support Angle

Top Support Angle

Assembled Wall Sleeve Dimensions: 45" high x 29" wide x 12.5" deep

Top Panel

Support Angle - 8 Holes

Front of
Sleeve

Left Side
Panel

Squaring
Braces

Support Angle - 2 Sides

Bottom Panel

FIGURE 7-1

CA-239 Wall Sleeve Kit Assembly
SRM-HW/HWC 8/99

Service Reference Manual

ACCESSORIES
7-5
Wall Sleeve Installation
The wall sleeve can be installed from either the inside or the outside of
the building. In any case, proper considerations must be made for final
weather sealing of the wall sleeve and the Magic-Pak unit.
Whether installing from the inside or outside of a building, the wall sleeve
may be secured to the supporting wall through the top and side support
angles or directly through the wall sleeve side panels. When securing the
wall sleeve directly through the side panels, the top and side angle
supports are often used as “stops” to assure proper alignment before final
securing of the wall sleeve is accomplished.
The top and side support angles can be adjusted to allow the unit to
protrude through the outside of the supporting wall by 1" or 3-3/4" inches.
This will also change the depth that the unit protrudes through the inside
wall. This adjustment is designed to allow for final sealing of the wall
sleeve to various finish types.
The top and side support angles can be removed altogether and the wall
sleeve secured directly through the side panels, provided that the installer
performs a proper alignment of the wall sleeve.

WARNING
The further the wall sleeve is extended past the
finished wall the more difficult it becomes to accomplish final sealing from the inside of the building.
Adequate safety precautions must be considered to
protect personnel.
Whether installing from the inside or the outside of the building, the wall
sleeve should extend at least 3/8" - 1" beyond the finished wall to allow for
proper weather sealing. When installing during wall construction, consideration must be made to allow for final weather sealing to the type of
finish wall that will be constructed later.
Recessed Wall Sleeve Installation
In some applications, the thickness of the wall or architectural design will
dictate that the wall sleeve be recessed in the finished wall. This can be
done, but it is not recommended if the wall opening is required to be the
same size as the wall sleeve opening.
Recessed installation can be done if the wall opening is 2" larger vertically than the wall sleeve. The wall sleeve may then be placed on a sill 2"
higher than the bottom of the finished wall opening.

SRM-HW/HWC 8/99

The sill must be recessed 3/8" - 1" inside of the outer edge of the wall
sleeve. This permits weather sealing of the bottom edge without plugging
the drain holes in the bottom of the wall sleeve.
The top of the finished wall opening should extend above the top of the
wall sleeve by a dimension equal to or greater than the dimension that the
wall sleeve is recessed.

ACCESSORIES

Magic-Pak: HW/HWC

7-6
Magic-Pak Installation
Before installing the Magic-Pak unit in the wall sleeve, it is important to
consider the possibility of sound and vibration transmission through the
wall. It is recommended that vibration isolation pads be installed evenly
spaced across the outer edge of the bottom panel of the wall sleeve. The
vibration isolator pads should be approximately 4" x 4" x 7/8" and constructed of one piece of cork rubber with pieces of neoprene rubber
adhered to the top and bottom.
Once the wall sleeve is properly secured to the supporting wall and the
vibration isolators are in place, the Magic-Pak unit can be slid into the wall
sleeve. The unit must be slid completely forward so that the outer edges
of the unit touch the inside flanges of the wall sleeve. The unit can then
be secured to the wall sleeve by bolting the top flange of the unit to the
top turned-down flange of the wall sleeve with 1/4" x 3/4" bolts and
washers.
Note: In applications where vibration isolation is of particular importance,
rubber grommets (Armstrong P/N 9015A) can be inserted between
the top flanges.
The wall sleeve alone is not adequate support for the full weight of the
Magic-Pak unit. Additional, field-fabricated support must be provided
between the rear flange of the return opening and the wall sleeve.
The use of vibrator isolator pads is required between the unit and the
support and between the floor and the support.
Please refer to installation instructions and application manual for details
on field-fabricated additional supports.

Weather Sealing
After assembling the wall sleeve, it is recommended that all panel connections and joints be sealed with caulk to prevent water and wind
infiltration into the building.
Once the Magic-Pak is installed and secured to the wall sleeve, it is
important to seal any gaps between the wall sleeve and the unit with
caulk. This includes both sides, top and bottom. Sealing these gaps will
prevent water and wind from leaking into the building between the unit
and wall sleeve.
The outside of the wall sleeve must also be sealed with caulk on all four
sides whether it is installed recessed or protruding.

SRM-HW/HWC 8/99

Service Reference Manual

ACCESSORIES
7-7

A242-1 Wall Sleeve Adaptor Kit
The A242-1 wall sleeve adaptor kit is designed to allow for the installation
of current 43" tall HW/HWC units into 48" tall wall sleeves (CA241 wall
sleeve kits). The CA241 wall sleeve kits were designed for use with HW/
HWC121, 181, 241 and 301 units manufactured during the late 1980’s.
The HW/HWC series 1 units were approximately 48" tall.
If replacement of the wall sleeve is not feasible, use of the A-242-1
adaptor kit creates an insulated block-off panel at the top portion of the
CA241 wall sleeve.
The adaptor kit also allows for easy mounting of the HW/HWC unit to the
taller sleeve.
Whenever it is necessary to convert a CA241 wall sleeve to current unit
dimensions, use of the A242-1 adaptor kit is required.
Inspection of Shipment
Upon receipt of equipment, carefully inspect it for possible shipping
damage. If damage is found, it should be noted on the carrier’s freight bill.
Damage claims should be filed with the carrier immediately. Claims of
shortages should be filed with the seller within five days.

Wall Sleeve Adaptor Kit Assembly
Once assembled, the A242-1 adaptor kit will form a rectangular box
approximately 4-7/8" tall with approximately 7/8" overlapping the front and
side of the top panel of the HW/HWC unit (see Figure 7-2 on page 7-9).
To assemble the adaptor kit:
1. Set top flanges of side and front panels on the floor or ground so that
they are resting flat. The screw holes through the side flanges of front
panel should align with the pilot holes in side panel.
2. Fasten two #8 x 1/2" screws in each side.
3. Place rear panel against the rear flanges of the side panels. The
screw holes of the rear panel should align with the pilot holes in the
side panel rear flanges.
4. The top and bottom flanges of the rear panel should be facing the
front panel. The five 1/4" pilot holes should be positioned towards the
bottom of the kit and the five oval screw holes should be positioned
towards the top of the kit.

SRM-HW/HWC 8/99

5. Fasten two #8 x 1/2" screws at each end of the rear panel.

ACCESSORIES

Magic-Pak: HW/HWC

7-8
Attachment to HW/HWC
After assembling the kit, it is ready to be attached to the top of the HW/
HWC unit. To attach the kit to the HW/HWC unit:
1. Remove the two front screws (each side) that fasten the top panel
side flanges to the side panels on each side of the HW/HWC unit.
2. Place the adaptor kit on top of the HW/HWC unit. The five pilot holes
positioned towards the bottom of the kit’s rear panel should align with
the five oval screw holes in the HW/HWC mounting bracket (see
Figure 7-2).
3. Fasten the five 1/4" x 3/4" screws and washers through the unit
mounting bracket to the kit pilot holes.
4. Align the kit side panel oval screw holes to the screw holes in the side
of the HW/HWC unit.
5. Re-fasten the screws that were removed in step 1.

Installing the HW/HWC Unit
After the adaptor kit is fastened to the HW/HWC unit, the unit is ready to
be slid into the wall sleeve.
The top flange of the adaptor kit is designed to overlap the top of the wall
sleeve. The five 1/4" x 3/4" mounting screws included with the wall sleeve
kit can be fastened through the top flange of the kit into the turned-down
flange of the wall sleeve.
The HW/HWC unit must be slid all the way forward so that the outer
edges of the adaptor kit and HW/HWC unit are touching the outer flanges
of the wall sleeve.
The HW/HWC unit and wall sleeve must be weather sealed according to
the wall sleeve kit instructions, unit installation instructions or unit application manual.
For further information on installing HW/HWC units, refer to the Installation section beginning on page 6-1.

SRM-HW/HWC 8/99

Service Reference Manual

ACCESSORIES
7-9

TABLE 7-3

A242-1 Parts List

Part

Quantity

Front Panel

Rear Panel

Right Side Panel

Left Side Panel

#8 x 1/2" Screw

1/4" x 3/4" Screw

1/4" Flat Washer

(2) #8 x ½" Screws
in each rear corner
Right Side
Rear

(2) #8 x ½" Screws
in each side
Left Side

Front

1/4" x ¾" Screw

¼" Flat Washer

HW/HWC Unit

SRM-HW/HWC 8/99

Screws that are removed
and reinserted to attach adapter kit
to HW/HWC unit (both sides)

FIGURE 7-2

A242-1 Wall Sleeve Adaptor Kit Assembly

ACCESSORIES

Magic-Pak: HW/HWC

7-10

ALVR42 Architectural Aluminum Louver
Facade
In many applications, architects and installers will choose to use facades
over the front of Magic-Pak units. Often this is done to improve the
appearance of a building. Properly constructed louver facades may also
provide some degree of weather protection and sound deflection.
Louver facades can be designed by engineers and architects and integrated into the building construction by contractors in the field. However
research and testing has shown that many designs may actually diminish
the performance of the Magic-Pak units and in some cases even damage
them.
For these reasons, Armstrong approved the ALVR42 architectural aluminum louver facade kit. The instructions provided with the kit should serve
as a general guide for installation of the kit. For guidelines on designing
louver facades, refer to the Magic-Pak Application Manual (Armstrong
P/N MPA-100).
The ALVR42 is designed to be integrated into the construction of the
finish wall or secured directly to the finish wall. Therefore, actual installation of the louvers will vary depending on the type of finish wall it is
applied to.
The ALVR42 kit is available is many different colors to match finish walls.
Color matching services are also available. For more information concerning color matching, please contact your supplier or Armstrong.

Assembly
The ALVR42 kit consists of two sections of louver fins. The top section is
composed of fins angled approximately 30° upward while the bottom
section consists of fins angled approximately 30° downward (see Figure
7-3). This design allows flue gases and condenser discharge air to be
circulated away from the condenser inlet and burner compartment fresh
air intake.
There is also a sealing gasket between the two louver sections to allow
for separation of inlet and discharge air when the louver is secured
directly to the front of the unit. When the louver is secured away from the
unit, a separation bracket sealed to the unit and then to the louver kit
must be field-fabricated and installed.
The ALVR42 louver is 45" tall to accommodate proper drainage of the unit
and wall sleeve and proper discharge of condenser air and flue gases.

Installation
The ALVR42 is designed to be fastened to the finish wall, support wall or
wall sleeve using field-supplied materials and techniques.

SRM-HW/HWC 8/99

Whenever installing a louver facade of any type, special considerations
must be made for proper drainage and air circulation. The drain holes of
the wall sleeve and the unit must never be obstructed.

Service Reference Manual

ACCESSORIES
7-11
The louver will fit directly against the front of the unit. However, the lower
lip of the unit will protrude into the louver. The louver must be positioned
to accommodate the protruding lower lip.
The louver must be caulk sealed on all four sides and field-supplied
flashing should be installed across the bottom of the louver. This will
prevent water runoff directly onto the finish wall.

28.875"
13.831"

13.831"

.500" x .375" x 28.875"
Polyether Gasket
1.225"
Typ.
1.225"
Typ.
.775"
Typ.

Gasket

45.000"

SRM-HW/HWC 8/99

FIGURE 7-3

ALVR Architectural Aluminum Extended Louver

ACCESSORIES

Magic-Pak: HW/HWC

7-12

34961A001 Compressor Vibration Isolator
Kit
The 34961A001 spring/grommet kit is designed to isolate vibrations
common to most compressors away from the base of Magic-Pak units
and building walls.
Some types of wall construction will be especially susceptible to vibration
transmissions. In these instances, installers and building designers must
make special considerations for isolating vibration.
Designing and constructing walls and wall openings in a particular
manner to isolate vibration transmission is the recommended procedure
for dealing with these instances. However, if further vibration isolation is
necessary, the 34961A001 compressor vibration isolator kit should be
used.
For instructions and recommendations on designing and constructing
walls and wall openings, refer to the Magic-Pak Application Manual.

Installation
The Magic-Pak cooling chassis must be removed from the cabinet to
perform the following installation procedures. Refer to the Chassis
Removal section beginning on page 3-4 for instructions on proper chassis
removal.
To install the 34961A001 kit:
1. Remove the factory-installed compressor mounting leg bolts from the
base of the compressor.
2. Lift the compressor of the base of the chassis by inserting a large
screwdriver or pry bar under the belly of the compressor.
3. Support the compressor by sliding a 3/4" to 1-1/4" thick wooden block
or suitable material underneath the compressor belly.
The copper refrigerant tubing connected to the compressor will
have some free movement. However, be careful not to kink or
damage the tubing. Loss of refrigerant or lack of proper unit
performance may result.
4. Remove the factory-installed rubber grommets from the compressor
mounting legs.
5. Install the top rubber spacer in the compressor mounting legs.
6. Insert the bottom rubber spacer into the bottom of the spring and
slide the spring between the upper spacer and chassis base.
7. Insert the metal sleeve through the top of the upper spacer, spring
and lower spacer.
SRM-HW/HWC 8/99

8. Re-install the bolts removed in step 1.

Service Reference Manual

ACCESSORIES
7-13
Use of spray lubricant or liquid soap will aid in the installation of rubber
parts.
Compressor belly is rounded and can be “rocked” on the belly support. It
is easiest to install one spring grommet at a time. Start with the most
difficult to access compressor mounting leg and work in a crisscross
pattern from back to front.
Compressor mounting bolts should be tightened down so that the metal
sleeve is secured fast to the chassis base and bolt head. Before securing
the final bolt, make sure that the wooden block or material supporting the
belly of the compressor has been removed.

SRM-HW/HWC 8/99

TABLE 7-4

34961A001 Parts List

Part

Quantity

Upper Rubber Spacer

Lower Rubber Spacer

Spring

Metal Sleeve

ACCESSORIES

Magic-Pak: HW/HWC

7-14

ALPKT389-2 L.P. Gas Conversion Kit
The ALPKT389-2 kit contains the following parts to convert the 26, 38, 51
and 64HW/HWC series gas furnace from natural gas to propane gas. For
altitudes from 2000 - 4500 feet, a high altitude kit as supplied by the
manufacturer must be used (see page 7-15).
TABLE 7-5

ALPKT389-2 Parts List
Part

Quantity

Conversion Plate

Gas Conversion Label

Air Shutter Adjustment Label

Installation Instructions

Adapter Kit for White-Rodgers 25K Gas Valve

#65 Main Burner Orifices

#64 Main Burner Orifices

#62 Main Burner Orifices

Gas Valve Conversion Label

Although the equipment is suitable for operation with propane gas (after
the conversion kit has been installed), certain precautions must be
observed because of the distinct burning characteristics of propane gas.
The following problems may be encountered:
TABLE 7-6

ALPKT389-2 Orifices
1. Burning back at the orifices with a loud roar

Model

Propane Orifice Size

26HW/HWC

#65

2. Loud popping upon extinction of the burner

38HW/HWC

#64

3. Flame rollout at the time of the ignition

51HW/HWC

#62

These problems can be caused by:

64HW/HWC

#62

1. Low gas pressure
2. Improper air adjustment
3. Incorrect burning rate
The furnace has a regulator in the gas valve. A regulator is also required
on the propane tank. Another regulator may be required at the house or
the unit.
The minimum permissible gas supply pressure to the furnace is 11" W.C.
for the purpose of input adjustment. The maximum permissible gas
pressure to the gas valve is 14" W.C.

SRM-HW/HWC 8/99

Service Reference Manual

ACCESSORIES
7-15

AHALT390-1 High Altitude Kit
The AHALT390-1 kit contains the following parts to convert the 26, 38, 51
and 64HW/HWC series units to high altitude for natural or propane gas. If
the field conversion is for high altitude propane gas, be sure to install the
appropriate gas valve conversion kit (see page 7-14).
TABLE 7-7

AHALT390-1 Parts List

Part

Quantity

Installation Instructions

High Altitude Conversion Plate

Air Shutter Adjustment Label

Burner Orifices #55 (Natural Gas)

Burner Orifices #54 (Natural Gas)

Burner Orifices #53 (Natural Gas)

Burner Orifices #65 (Propane Gas)

Burner Orifices #64 (Propane Gas)

Burner Orifices #63 (Propane Gas)

Regulator - Natural Gas
The minimum permissible gas supply pressure is 5.0" W.C. for purpose of
input adjustment. Gas input must never exceed the input capacity shown
on the rating plate. The furnace is equipped for rated inputs with manifold
pressure of 3.5" W.C. for natural gas. Only small variations in gas input
may be made by adjusting the regulator. In no case should the final
manifold pressure vary more than 0.3" W.C. from the specified pressure.
To check this pressure:
1. Turn off the gas valve.
2. Remove the plug on the valve marked “OUTLET PRESSURE”.
3. Install a water manometer.

SRM-HW/HWC 8/99

Turn gas valve “ON”. If manifold pressure must be adjusted, remove cap
from pressure regulator and turn adjustment screw clockwise to increase
pressure, counterclockwise to reduce pressure. After checking pressure,
turn gas off, remove the manometer fitting and replace the pipe plug and
regulator cap. Put furnace in operation and leak check plug for leaks
using a soapy solution.
Check the furnace rate by observing the gas meter, when available,
making sure all other gas appliances are turned off. The test hand on the
meter should be timed for at least one revolution. Note the number of
seconds for one revolution.

ACCESSORIES

Magic-Pak: HW/HWC

7-16
BTU/HR Cubic Feet Per Revolution x 3600 x Heating
=
INPUT
# Seconds Per Revolution
Value
The heating value of your gas can be obtained from your local utility.
With proper manifold pressure achieved, cycle main burners on and off.
Ignition and extinction should be smooth and quiet. Burning back at the
orifice or flame popping back to the orifice can be corrected by adjusting
the air shutter to soften the flame.

Regulator - Propane
The furnace has a regulator in the gas valve. A regulator is also required
on the propane tank. Another regulator may be required at the house or
the unit.
The minimum permissible gas supply pressure to the furnace is 11" W.C.
for the purpose of input adjustment.
If at any time ignition is slow and the burner does not seem to be operating correctly, check manifold pressure. It should be between 10" to 10.5"
W.C.
The furnace is designed to obtain rated input at 10.0" W.C.
To check this pressure:
1. Turn off the gas valve.
2. Remove the plug on the valve.
3. Install a water manometer.
Turn gas valve “ON”. If manifold pressure must be adjusted, remove cap
from pressure regulator and turn adjustment screw clockwise to increase
pressure, counterclockwise to reduce pressure. After checking pressure,
turn gas off, remove the manometer fitting and replace the pipe plug and
regulator cap. Put furnace in operation and leak check plug for leaks
using a soapy solution.
With proper manifold pressure achieved, cycle main burners on and off.
Ignition and extinction should be smooth and quiet. Burning back at the
orifice or flame popping back to the orifice can be corrected by adjusting
the air shutter to soften the flame.
TABLE 7-8

AHALT390-1 Orifices
High
High
Altitude Altitude
Input
Output
Btuh
Btuh

Model
Size

Normal
Input
Btuh

26HW/HWC

26,000

23,400

18,000

38HW/HWC

38,000

24,200

27,000

51HW/HWC

51,000

45,900

36,000

64HW/HWC

64,000

57,600

45,000

Orifice Size
Natural Propane

SRM-HW/HWC 8/99

Service Reference Manual

ACCESSORIES
7-17

ATIMR466-1 Short Cycle Protector Kit
The ATIMR466-1 Short Cycle Protector Kit helps guard against compressor failure due to repeated, short interval on/off cycles. It is also referred
to as the Nuisance Blower Operation Repair Kit.
The kit is designed to be used in conjunction with matching air conditioner
or heat pumps for comfort cooling/heating applications as shown in the
Armstrong specification information.
TABLE 7-9

ATIMR466-1 Parts List

Part

Quantity

Time Delay Relay

Fastener

Wires

Installation Instructions

Time Delay
Relay
T’stat

Common

Load

Yellow

Blue
Contactor
Coil
C
High Pressure
Cutout
(If Used)

Discharge
Thermostat
(If Used)

Low Voltage Leads
to Contactor Coil
from Thermostat
Y

Discharge
Thermostat
(If Used)

SRM-HW/HWC 8/99

FIGURE 7-4

ATIMR466-1 Kit Wiring

ACCESSORIES

Magic-Pak: HW/HWC

7-18

ADAPT420-2 Chassis Conversion Kit
The ADAPT420-2 kit was designed to retrofit an HWC122, 182, 242 or
302 chassis onto a cabinet originally equipped with an HWC12, 18, 24 or
30 chassis. This kit cannot be used to replace an HWC181, 241 or 301.
TABLE 7-10

ADAPT420-2 Parts List
Part

Quantity

Installation Instructions

Filler Panel

Center Rear Panel
(Filter Access Panel Support)

Foam Sealing Tape (12 inches)

Wiring Diagram Labels

When replacing the old chassis, the new chassis must have the same
nominal cooling capacity. If the nominal cooing capacity of the new
chassis is larger than the original, both the appliance internal line voltage
wire and the field wiring must be checked for proper size. The fuse
and/or breaker size must also be checked.

SRM-HW/HWC 8/99

Service Reference Manual

ACCESSORIES
7-19

Fenwal Triton Ignition Control Kit
This kit enables the Fenwal “Triton” local sense, one-hour retry, direct
spark ignition (DSI) control to be used as a service parts replacement for
earlier versions of Fenwal DSI controls used on HW/HWC models.
The operation and features of this ignition control differ from the other
types of DSI controls used. These features include:
•

Longer trial for ignition (15 seconds nominal).

•

One-hour retry feature (if main burner operation is not proved after
three trials for ignition, control goes into lockout for one hour, then
automatically initiates another ignition sequence; will repeat as long
as call for heat exists).

•

Senses flame through spark electrode (local flame sense) instead of
through a separate flame sensor (remote flame sense).

•

Diagnostic LED indicates certain ignition and venting system malfunctions (refer to control label for specific diagnostic codes).

•

Includes flame current (FC) test terminals.

SRM-HW/HWC 8/99

TABLE 7-11

Triton Ignition Control Kit Parts List
Part

Quantity

Fenwal "Triton" 2461D Series Direct Spark Gas
Ignition Control

High Voltage Electrode Cable

Low Voltage Jumper Wire
(May Be Pre-installed on Ignition Control Terminals)

Wiring Label

Installation Instructions

ACCESSORIES

Magic-Pak: HW/HWC

7-20

TL109 Burner Tray Kit
The TL109 Burner Tray Kit is designed for use in HW/HWC’s that were
originally equipped with single port inshot burners. Four kits are available,
one for each natural gas heating input rating as follows:
•

26,000 BTUH (3 main burners)

•

38,000 BTUH (4 main burners)

•

51,000 BTUH (5 main burners)

•

64,000 BTUH (6 main burners)

Each kit includes:
•

An assembled burner tray including manifold, natural gas orifices and
3, 4, 5 or 6 main burners (depending on heating input rating

•

A three-rod combination igniter/sensor

•

Installation instructions

The burner tray assembly included in this kit can be used with either the
Fenwal remote sense ignition control (which uses a separate flame
sensor lead), or the more recent Fenwal local sense ignition control
(which does not use a separate flame sensor lead). When used with the
remote sense ignition control, the three-rod combination igniter/sensor in
the kit effectively makes this a “local sense” system.

Burner Carryover Gap
.025" (+/.002")

Burners

FIGURE 7-5

TL109 Burner Tray

SRM-HW/HWC 8/99

Service Reference Manual

ACCESSORIES
7-21

AMUFFKT494-1 Discharge Muffler Kit
In the event that during operation an unacceptable noise occurs, a muffler
kit (AMUFFKT494-1) may be installed in the discharge line*. The chamber of the muffler acts as a sound-absorbing chamber reducing compressor pulsation noises.

* AMUFFKT494-1 is designed to be used only with HWC182 units.

Discharge Line to
Condenser Coil

Discharge
Muffler

SRM-HW/HWC 8/99

FIGURE 7-6

AMUFFKT494-1 Kit Discharge Muffler Installation

Service Reference Manual

PARTS LISTS
8-1

Section 8 - Parts Lists
HWC123, 183, 243, 303-1 .................. 8-2
HWC182, 242-11 ................................ 8-5
HWC122, 242-10 ................................ 8-7
HWC182-9 ........................................ 8-10
HWC242, 302-9 ................................ 8-12
HWC122, 182, 242, 302-8 ................ 8-14
HWC182-6/7 .................................... 8-17
HWC122, 282, 242, 302-5 ................ 8-19
HWC182, 302-4 ................................ 8-22
HWC122, 182, 242, 302-3 ................ 8-25
HWC182-2 ........................................ 8-28
HWC122, 182, 242, 302--1 ............... 8-30
HW-1 ................................................ 8-33
HWA-9 .............................................. 8-35

SRM-HW/HWC 8/99

HWC123, 183, 243, 303S-1
(Low Ambient) .................................... 8-37
HWC123, 183, 243, 303H-1
(High Altitude) ................................... 8-40

PARTS LISTS

MAGIC-PAK: HW/HWC

8-2

HWC3-A-1

REVISED
4-26-99

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

26HWC123A-1(*)

38HWC123A-1(*)

38HWC183A-1(*)

51HWC183A-1(*)

64HWC183A-1(*)

38HWC243A-1(*)

51HWC243A-1(*)

64HWC243A-1(*)

51HWC303A-1(*)

64HWC303A-1(*)

TO SELECT PART #

39370B001

TRANSFORMER

44987-001

VALVE-GAS HONEYWELL

42074-001

MANIFOLD

42074-002

MANIFOLD

42074-003

MANIFOLD

42074-004

MANIFOLD

39030B003

ORIFICE #52 NATURAL GAS

39030B004

ORIFICE #53 NATURAL GAS

39030B005

ORIFICE #54 NATURAL GAS

44992-001

ELECTRODE

44993-001

WIRE-ELECTRODE

44990-001

CONTROL-IGNITION/BLOWER

41948-001

BURNER

38999D009

ASSEMBLY-HEAT EXCHANGER

38999D010

ASSEMBLY-HEAT EXCHANGER

38999D011

ASSEMBLY-HEAT EXCHANGER

38999D012

ASSEMBLY-HEAT EXCHANGER

S38841B001 TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

Last letter of the Model # is the Service Level.
64HWC303A-1A
First find Model #. ------------------------------------------------ >
64HWC303A-1(*)
Then match Service Level for desired part. ---------------- >

1
1

GASKET-FLUE COL. END

40154B007

CONTROL-LIMIT

37520B004

SWITCH-ROLLOUT RED

37520B005

SWITCH-ROLLOUTGREEN

44819-010

SWITCH-PRESSURE RED

41144-001

BLOWER-INDUCED DRAFT

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-3

HWC3-A-1

REVISED
4-26-99

(cont.)

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

26HWC123A-1(*)

38HWC123A-1(*)

TO SELECT PART #

39045B001

MOTOR 1/6 HP, 1 PHASE

39046B001

MOTOR 1/3 HP, 1 PHASE

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833-001

WHEEL-BLOWER

S39010B001 ASSEMBLY-BLOWER HOUSING

34001D001

CAPACITOR-4 MFD@370 VAC

34001D004

Last letter of the Model # is the Service Level.

38HWC183A-1(*)

51HWC183A-1(*)

64HWC183A-1(*)

38HWC243A-1(*)

51HWC243A-1(*)

64HWC243A-1(*)

51HWC303A-1(*)

64HWC303A-1(*)

64HWC303A-1A

CAPACITOR-7.5 MFD@370 VAC

111 02764B000

BOARD-TERMINAL

124 45001-001

ASSEMBLY-WIRE HARNESS UPPER

125 45002-001

ASSEMBLY-WIRE HARNESS LOWER

127 06131B046

FILTER 16.5" X 25" X .50"

130 45004-001

LABEL-WIRING DIAGRAM

250 38982B001

COIL-OUTDOOR

250 38983B001

COIL-OUTDOOR

250 40649-001

COIL-OUTDOOR

250 41114-001

COIL-OUTDOOR

255 38979B001

COIL-INDOOR

255 38980B001

COIL-INDOOR

255 40648-001

COIL-INDOOR

256 S43271-001

ASSY-CAP. TUBE W/FILTER-DRIER

256 S43271-002

ASSY-CAP. TUBE W/FILTER-DRIER

256 S43271-003

ASSY-CAP. TUBE W/FILTER-DRIER

256 S43375-001

ASSY-CAP. TUBE W/FILTER-DRIER

First find Model #. ------------------------------------------------ >
64HWC303A-1(*)

SRM-HW/HWC 8/99

Then match Service Level for desired part. ---------------- >

1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-4

HWC3-A-1

REVISED
4-26-99

(cont.)

262 39008C001

COMPRESSOR-RK147ET-002-A4

262 42811-005

COMPRESSOR-ZR24KC-PFV-130

262 42811-006

COMPRESSOR-ZR28KC-PFV-130

267 41254-001

MOTOR 1/4 HP, 1 PHASE

267 41282-001

MOTOR 1/8 HP, 1 PHASE

268 39062B001

BLADE-FAN

268 39085B001

BLADE-FAN

269 03982D004

BRACKET-MOTOR SUPPORT

271 38514D002

CAPACITOR-25/5 MFD@370 VAC

271 38514D004

CAPACITOR-35/5 MFD@370 VAC

276 42725-001

PLUG-COMPRESSOR

278 07535C001

CONTACTOR

301 39059B001

FILTER-DRIER

301 39059B002

FILTER-DRIER

301 39059B003

FILTER-DRIER

64HWC303A-1(*)

COMPRESSOR-AW501ET-089-A4

51HWC303A-1(*)

262 35125C009

64HWC243A-1(*)

PART DESCRIPTION

51HWC243A-1(*)

64HWC183A-1(*)

REF PART #

38HWC243A-1(*)

51HWC183A-1(*)

Then match Service Level for desired part. ---------------- >

38HWC183A-1(*)

64HWC303A-1(*)

38HWC123A-1(*)

First find Model #. ------------------------------------------------ >

26HWC123A-1(*)

64HWC303A-1A

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-5

HWC182-242A-11

REVISED
1-20-98

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

38HWC182A-11(*)

38HWC242A-11(*)

TO SELECT PART #

39370B001

TRANSFORMER

A-B

39029B001

CONTROL-BLOWER CENTER

A-B

43108-001

VALVE-GAS

A-B

42074-002

MANIFOLD

A-B

39030B004

ORIFICE #53 NATURAL GAS

A-B

41957-001

ELECTRODE

A-B

41583-001

WIRE-ELECTRODE

A-B

43110-001

CONTROL-IGNITION

A-B

41948-001

BURNER

A-B

38999D010

ASSEMBLY-HEAT EXCHANGER

A-B

S38841B001

TURBULATOR

A-B

38977B001

GASKET-FLUE COVER

A-B

38978B001

GASKET-FLUE COL. END

A-B

01150A008

CONTROL-LIMIT

A-B

39113B001

GASKET-LIMIT SWITCH

A-B

37520B004

SWITCH-ROLLOUT RED

A-B

43336-010

SWITCH-PRESSURE RED

A-B

41144-001

BLOWER-INDUCED DRAFT

A-B

39046B001

MOTOR 1/3 HP, 1 PHASE

A-B

07407B000

BAND-MOTOR MOUNTING

A-B

07408B004

ARM-MOTOR MOUNTING

A-B

34833B001

WHEEL-BLOWER

A-B

S39010B001

ASSY-BLOWER HOUSING

A-B

S39232D004 CAPACITOR-7.5 MFD@370 VAC

A-B

124

43109-001

A-B

Last letter of the Model # is the Service Level.
38HWC242A-11A
First find Model #. -------------------------------------------------------------- >
38HWC242A-11(*)

SRM-HW/HWC 8/99

Then match Service Level for desired part. ------------------------------ >

ASSY-WIRE HARNESS UPPER

PARTS LISTS

MAGIC-PAK: HW/HWC

8-6

HWC182-242A-11

REVISED
1-20-98

(cont.)

REF PART #

PART DESCRIPTION

SERVICE LEVEL = *

38HWC182A-11(*)

38HWC242A-11(*)

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

125

39605B001

ASSY-WIRE HARNESS LOWER

A-B

126

39080B001

VALVE-GAS SHUT-OFF

A-B

127

06131B055

FILTER 16.5" X 25" X .50"

A-B

130

39007D006

LABEL-WIRING DIAGRAM

A-B

250

38983B001

COIL-OUTDOOR

A-B

250

41114-001

COIL-OUTDOOR

A-B

255

38980B001

COIL-INDOOR

A-B

256

S43267-002

ASSY-CAPILLARY TUBE

A-B

256

S43267-003

ASSY-CAPILLARY TUBE

A-B

262

35125C009

COMP-AW501ET-089-A4

A-B

262

42811-005

COMP-ZR24KC-PFV-130

A-B

267

41254-001

MOTOR 1/4 HP, 1 PHASE

A-B

267

41282-001

MOTOR 1/8 HP, 1 PHASE

A-B

268

39062B001

BLADE-FAN

A-B

268

39085B001

BLADE-FAN

A-B

269

03982D004

BRACKET-MOTOR SUPPORT

A-B

271

38514D004

CAPACITOR-35/5 MFD@370 VAC

A-B

276

42725-001

ASSY-COMPRESSOR PLUG

A-B

278

07535C001

CONTACTOR

A-B

38HWC242A-11A
First find Model #. -------------------------------------------------------------- >
38HWC242A-11(*)
Then match Service Level for desired part. ------------------------------ >

1
1

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-7

HWC122-242A-10

REVISED
4-26-99

REC STOCKING PART

SERVICE LEVEL = *

26HWC122A-10(*)

38HWC122A-10(*)

38HWC242A-10(*)

TO SELECT PART #

39370B001

TRANSFORMER

A-B

39029B001

CONTROL-BLOWER CENTER

A-B

43108-001

VALVE-GAS

A-B

42074-001

MANIFOLD

A-B

42074-002

MANIFOLD

A-B

39030B004

ORIFICE #53 NATURAL GAS

A-B

39030B005

ORIFICE #54 NATURAL GAS

A-B

41957-001

ELECTRODE

A-B

41583-001

WIRE-ELECTRODE

A-B

43110-001

CONTROL-IGNITION

A-B

41948-001

BURNER

A-B

38999D009

ASSEMBLY-HEAT EXCHANGER

A-B

38999D010

ASSEMBLY-HEAT EXCHANGER

A-B

S38841B001 TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

Last letter of the Model # is the Service Level.
38HWC242A-10A
First find Model #. -------------------------------------------------------------- >
38HWC242A-10(*)
Then match Service Level for desired part. ------------------------------ >

SRM-HW/HWC 8/99

REF

PART #

PART DESCRIPTION

A-B

GASKET-FLUE COL. END

A-B

01150A008

CONTROL-LIMIT

A-B

39113B001

GASKET-LIMIT SWITCH

A-B

37520B004

SWITCH-ROLLOUT RED

A-B

37520B005

SWITCH-ROLLOUT GREEN

A-B

43336-010

SWITCH-PRESSURE RED

A-B

41144-001

BLOWER-INDUCED DRAFT

A-B

39045B001

MOTOR 1/6 HP, 1 PHASE

A-B

39046B001

MOTOR 1/3 HP, 1 PHASE

A-B

07407B000

BAND-MOTOR MOUNTING

A-B

1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-8

HWC122-242A-10

REVISED
4-26-99

(cont.)

SERVICE LEVEL = *

26HWC122A-10(*)

38HWC122A-10(*)

38HWC242A-10(*)

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

07408B004

ARM-MOTOR MOUNTING

A-B

34833B001

WHEEL-BLOWER

A-B

S39010B001

ASSEMBLY-BLOWER HOUSING

A-B

S39232D001

CAPACITOR-4 MFD@370 VAC

A-B

S39232D004

CAPACITOR-7.5 MFD@370 VAC

A-B

124

43109-001

ASSEMBLY-WIRE HARNESS UPPER

A-B

125

39605B001

ASSEMBLY-WIRE HARNESS LOWER

A-B

126

39080B001

VALVE-GAS SHUT-OFF

A-B

127

06131B055

FILTER 16.5" X 25" X .50"

A-B

130

39007-006

LABEL-WIRING DIAGRAM

A-B

250

38982B001

COIL-OUTDOOR

A-B

250

38983B001

COIL-OUTDOOR

A-B

255

38979B001

COIL-INDOOR

A-B

255

38980B001

COIL-INDOOR

A-B

256

S43267-001

ASSEMBLY-CAPILLARY TUBE

A-B

256

S43267-003

ASSEMBLY-CAPILLARY TUBE

A-B

262

35136C005

COMPRESSOR-ZR23K1-PFV

A-B

262

39008C001

COMPRESSOR-RK147ET-002-A4

A-B

267

41254-001

MOTOR 1/4 HP, 1 PHASE

A-B

267

41282-001

MOTOR 1/8 HP, 1 PHASE

A-B

268

39062B001

BLADE-FAN

A-B

268

39085B001

BLADE-FAN

A-B

269

03982D004

BRACKET-MOTOR SUPPORT

A-B

38HWC242A-10A
First find Model #. -------------------------------------------------------------- >
38HWC242A-10(*)
Then match Service Level for desired part. ------------------------------ >

REF

PART #

PART DESCRIPTION

1
1

1
SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-9

HWC122-242A-10

REVISED
4-26-99

(cont.)

SERVICE LEVEL = *

26HWC122A-10(*)

38HWC122A-10(*)

271

38514D002

CAPACITOR-25/5 MFD@370VAC

A-B

271

38514D003

CAPACITOR-30/5 MFD@370VAC

A-B

278

07535C001

CONTACTOR

A-B

SRM-HW/HWC 8/99

REF

PART #

PART DESCRIPTION

38HWC242A-10(*)

REC STOCKING PART

TO SELECT PART #

1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-10

HWC182-9

REVISED
1-20-98

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

38HWC182A-9(*)

51HWC182A-9(*)

64HWC182A-9(*)

TO SELECT PART #

39370B001

TRANSFORMER

A-E

39029B002

CONTROL-BLOWER CENTER

A-E

39031D001

VALVE-GAS

A-C

43108-001

VALVE-GAS

42074-002

MANIFOLD

A-E

42074-003

MANIFOLD

A-E

42074-004

MANIFOLD

A-E

39030B003

ORIFICE #52 NATURAL GAS

A-E

39030B004

ORIFICE #53 NATURAL GAS

A-E

41957-001

ELECTRODE

A-E

41583-001

WIRE-ELECTRODE

A-E

43110-001

CONTROL-IGNITION

A-E

41948-001

BURNER

A-E

38999D010

ASSEMBLY-HEAT EXCHANGER

A-E

38999D011

ASSEMBLY-HEAT EXCHANGER

A-E

38999D012

ASSEMBLY-HEAT EXCHANGER

A-E

S38841B001 TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

Last letter of the Model # is the Service Level.
64HWC182A-9A
First find Model #. -------------------------------------------------------------- >
64HWC182A-9(*)
Then match Service Level for desired part. ------------------------------ >

1
1
4

A-E

GASKET-FLUE COL. END

A-E

01150A008

CONTROL-LIMIT

A-E

39113B001

GASKET-LIMIT SWITCH

A-E

37520B004

SWITCH-ROLLOUT RED

A-E

43336-010

SWITCH-PRESSURE RED

A-E

41144-001

BLOWER-INDUCED DRAFT

A-E

39046B001

MOTOR 1/3 HP, 1 PHASE

A-E

SRM-HW/HWC 8/99

A-E

Service Reference Manual

PARTS LISTS
8-11

HWC182-9

REVISED
1-20-98

(cont.)

REF PART #

PART DESCRIPTION

SERVICE LEVEL = *

38HWC182A-9(*)

51HWC182A-9(*)

64HWC182A-9(*)

Last letter of the Model # is the Service Level.

07407B000

BAND-MOTOR MOUNTING

A-E

07408B004

ARM-MOTOR MOUNTING

A-E

34833B001

WHEEL-BLOWER

A-E

S39010B001

ASSY-BLOWER HOUSING

A-E

S39232D004

CAPACITOR 7.5 MFD@370VAC

A-E

124

43109-001

ASSY-WIRE HARNESS UPPER

A-E

125

39605B001

ASSY-WIRE HARNESS LOWER

A-E

126

39080B001

VALVE-GAS SHUT-OFF

A-E

127

06131B055

FILTER 16.5" X 25" X .50"

A-E

130

39007D006

LABEL-WIRING DIAGRAM

A-E

250

41114-001

COIL-OUTDOOR

A-E

255

38980B001

COIL-INDOOR

A-E

256

S39058B002

ASSY-CAP TUBE

A-B

256

S43627-002

ASSY-CAP TUBE

C-E

262

35125C009

COMP-AW201ET-033-A4

A-E

267

41282-001

MOTOR 1/8 HP, 1 PHASE

A-E

268

39085B001

BLADE-FAN

A-E

269

03982D004

BRACKET-MOTOR SUPPORT

A-E

271

38514D004

CAPACITOR 35/5 MFD@370VAC

A-E

278

07535C001

CONTACTOR

A-E

64HWC182A-9A
First find Model #. -------------------------------------------------------------- >
64HWC182A-9(*)
Then match Service Level for desired part. ------------------------------ >

SRM-HW/HWC 8/99

REC STOCKING PART

TO SELECT PART #

PARTS LISTS

MAGIC-PAK: HW/HWC

8-12

HWC242-302-9

REVISED
1-20-98

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

51HWC242A-9(*)

64HWC242A-9(*)

51HWC302A-9(*)

64HWC302A-9(*)

TO SELECT PART #

39370B001

TRANSFORMER

A-B

39029B002

CONTROL-BLOWER CENTER

A-B

43108-001

VALVE-GAS

A-B

42074-003

MANIFOLD

A-B

42074-004

MANIFOLD

A-B

39030B003

ORIFICE #52 NATURAL GAS

A-B

39030B004

ORIFICE #53 NATURAL GAS

A-B

41957-001

ELECTRODE

A-B

41583-002

WIRE-ELECTRODE

A-B

43110-001

CONTROL-IGNITION

A-B

41948-001

BURNER

A-B

38999D011

ASSEMBLY-HEAT EXCHANGER

A-B

38999D012

ASSEMBLY-HEAT EXCHANGER

A-B

S38841B001 TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

Last letter of the Model # is the Service Level.
64HWC302A-9A
First find Model #. -------------------------------------------------------------- >
64HWC302A-9(*)
Then match Service Level for desired part. ------------------------------ >

1
1

A-B

GASKET-FLUE COL. END

A-B

01150A008

CONTROL-LIMIT

A-B

39113B001

GASKET-LIMIT SWITCH

A-B

37520B004

SWITCH-ROLLOUT RED

A-B

41144-001

BLOWER-INDUCED DRAFT

A-B

39046B001

MOTOR 1/3 HP, 1 PHASE

A-B

07407B000

BAND-MOTOR MOUNTING

A-B

07408B004

ARM-MOTOR MOUNTING

A-B

34833B001

WHEEL-BLOWER

A-B

S39010B001 ASSEMBLY -BLOWER HOUSING

A-B

SRM-HW/HWC 8/99

A-B

Service Reference Manual

PARTS LISTS
8-13

HWC242-302-9

REVISED
1-20-98

(cont.)
REC STOCKING PART

SERVICE LEVEL = *

51HWC242A-9(*)

64HWC242A-9(*)

51HWC302A-9(*)

64HWC302A-9(*)

TO SELECT PART #

A-B

ASSY-WIRE HARNESS UPPER

A-B

39605B001

ASSY-WIRE HARNESS LOWER

A-B

126

39080B001

VALVE-GAS SHUT-OFF

A-B

127

06131B055

FILTER 16.5" X 25" X .50"

A-B

130

39007D006

LABEL-WIRING DIAGRAM

A-B

250

38983B001

COIL-OUTDOOR

A-B

250

40649-001

COIL-OUTDOOR

A-B

255

38980B001

COIL-INDOOR

A-B

255

40648-001

COIL-INDOOR

A-B

256

S43271-002

ASSY-CAPILLARY TUBE

A-B

256

S43280-001

ASSY-CAPILLARY TUBE

A-B

262

42811-005

COMP-ZR24KC-PFV-130

A-B

262

42811-006

COMP-ZR28KC-PFV-130

267

41254-001

MOTOR 1/4 HP, 1 PHASE

268

39062B001

269

Last letter of the Model # is the Service Level.
64HWC302A-9A
First find Model #. -------------------------------------------------------------- >
64HWC302A-9(*)

SRM-HW/HWC 8/99

Then match Service Level for desired part. ------------------------------ >

REF PART #

PART DESCRIPTION

S39232D004

CAPACITOR 7.5 MFD@370VAC

124

43109-001

125

A-B

BLADE-FAN

A-B

03982D004

BRACKET-MOTOR SUPPORT

A-B

271

38514D004

CAPACITOR 35/5 MFD@370VAC

A-B

276

42725-001

PLUG-COMPRESSOR

A-B

278

07535C001

CONTACTOR

A-B

PARTS LISTS

MAGIC-PAK: HW/HWC

8-14

HWC-8

REVISED
1-20-98

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

26HWC122-8(*)

38HWC122-8(*)

38HWC182-8(*)

51HWC182-8(*)

64HWC182-8(*)

38HWC242-8(*)

51HWC242-8(*)

64HWC242-8(*)

51HWC302-8(*)

64HWC302-8(*)

TO SELECT PART #

39370B001

TRANSFORMER

39029B002

CONTROL-BLOWER CENTER

39031D001

VALVE-GAS

42074-001

MANIFOLD

42074-002

MANIFOLD

42074-003

MANIFOLD

42074-004

MANIFOLD

39030B003

ORIFICE #52

39030B004

ORIFICE #53

39030B005

ORIFICE #54

41957-001

ELECTRODE

41583-001

WIRE-ELECTRODE

41582-002

CONTROL-IGNITION

41948-001

Last letter of the Model # is the Service Level.
64HWC302-8A
First find Model #. ------------------------------------------------ >
64HWC302-8(*)
Then match Service Level for desired part. ---------------- >

1
1

BURNER

38999D009

ASSY-HEAT EXCHANGER

38999D010

ASSY-HEAT EXCHANGER

38999D011

ASSY-HEAT EXCHANGER

38999D012

ASSY-HEAT EXCHANGER

38841B001

TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

GASKET-FLUE COL END

01150A008

CONTROL-LIMIT

39113B001

GASKET-LIMIT SWITCH

37520B004

SWITCH-ROLLOUT RED

37520B005

SWITCH-ROLLOUT GREEN

1
1

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-15

HWC-8

REVISED
1-20-98

(cont.)

SRM-HW/HWC 8/99

51HWC182-8(*)

64HWC182-8(*)

38HWC242-8(*)

51HWC242-8(*)

64HWC242-8(*)

51HWC302-8(*)

64HWC302-8(*)

Then match Service Level for desired part. ---------------- >

38HWC182-8(*)

64HWC302-8(*)

38HWC122-8(*)

First find Model #. ------------------------------------------------ >

1
1

26HWC122-8(*)

64HWC302-8A

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

REF PART #

PART DESCRIPTION

41862-001

SWITCH-PRESS RED

41862-002

SWITCH-PRESS GREEN

41144-001

BLOWER-INDUCED DRAFT

39045B001

MOTOR 1/6 HP, 1 PHASE

39046B001

MOTOR 1/3 HP, 1 PHASE

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

39010B001

ASSY-BLOWER HOUSING

39232D001

CAPACITOR-4 MFD@370V

39232D004

CAPACITOR-7.5 MFD@370V

124 42268-001

ASSY-WIRE HARNESS UPPER

125 39605B001

ASSY-WIRE HARNESS LOWER

126 39080B001

VALVE-GAS SHUT-OFF

127 06131B046

FILTER 16.5" X 25" X .5"

128 06132B001

ROD-FILTER

130 39007D005

LABEL-WIRING DIAGRAM

250 38982B001

COIL-OUTDOOR

250 38983B001

COIL-OUTDOOR

250 40649-001

COIL-OUTDOOR

250 41114-001

COIL-OUTDOOR

255 38979B001

COIL-INDOOR

255 38980B001

COIL-INDOOR

255 40648-001

COIL-INDOOR

1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-16

HWC-8

REVISED
1-20-98

(cont.)

51HWC302-8(*)

64HWC302-8(*)

256 39058B002

ASSY-CAP TUBE

256 39058B003

ASSY-CAP TUBE

256 40650-001

ASSY-CAP TUBE

262 35136C001

COMP-ZR28K1-PFV

262 35136C005

COMP-ZR23K1-PFV

262 39008C001

COMP-RK147ET-002-A4

262 39008C002

COMP-RK233ET-009-A4

267 41254-001

MOTOR 1/4 HP, 1 PHASE

267 41282-001

MOTOR 1/8 HP, 1 PHASE

268 39062B001

BLADE-FAN

268 39085B001

BLADE-FAN

269 03982D004

BRACKET-MOTOR SUPPORT

271 38514D002

CAPACITOR-25/5 MFD@370 VAC

271 38514D003

CAPACITOR-30/5 MFD@370 VAC

271 38514D004

CAPACITOR-35/5 MFD@370 VAC

278 07535C001

CONTACTOR

282 40715-001

RELAY-TIME DELAY

1
1

64HWC242-8(*)

51HWC242-8(*)

Then match Service Level for desired part. ---------------- >

38HWC242-8(*)

38HWC122-8(*)

ASSY-CAP TUBE

64HWC302-8(*)

64HWC182-8(*)

26HWC122-8(*)

256 39058B001

First find Model #. ------------------------------------------------ >

51HWC182-8(*)

PART DESCRIPTION

64HWC302-8A

38HWC182-8(*)

REF PART #

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-17
REVISED
1-20-98

HWC-6/7

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

38HWC182-7(*)

51HWC182-6(*)

64HWC182-6(*)

TO SELECT PART #

39370B001

TRANSFORMER

39029B001

CONTROL-BLOWER CENTER

39031D001

VALVE-GAS

38832B002

MANIFOLD-4 CELL

38832B003

MANIFOLD-5 CELL

38832B004

MANIFOLD-6 CELL

39030B003

ORIFICE #52 NATURAL GAS

39030B004

ORIFICE #53 NATURAL GAS

39050B001

ELECTRODE

41583-001

WIRE-ELECTRODE

41582-002

CONTROL-IGNITION

39006B001

ASSY-BURNER

38999D010

ASSEMBLY-HEAT EXCHANGER

38999D011

ASSEMBLY-HEAT EXCHANGER

38999D012

ASSEMBLY-HEAT EXCHANGER

38841B001

TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

GASKET-FLUE COL. END

01150A008

CONTROL-LIMIT

39113B001

GASKET-LIMIT SWITCH

37520B004

SWITCH-ROLLOUT RED

41862-001

SWITCH-PRESS RED

41144-001

BLOWER-INDUCED DRAFT

39046B001

MOTOR 1/3 HP, 1 PHASE

07407B000

BAND-MOTOR MOUNTING

Last letter of the Model # is the Service Level.
64HWC182-6A
First find Model #. -------------------------------------------------------------- >
64HWC182-6(*)

SRM-HW/HWC 8/99

Then match Service Level for desired part. ------------------------------ >

1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-18

HWC-6/7

REVISED
1-20-98

(cont.)

REF PART #

PART DESCRIPTION

SERVICE LEVEL = *

38HWC182-7(*)

51HWC182-6(*)

64HWC182-6(*)

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL BLOWER

39010B001

ASSY-BLOWER HOUSING

39232D004

CAPACITOR 7.5 MFD@370VAC

124

40231B001

ASSY-WIRE HARNESS FEMALE

125

39605B001

ASSY-WIRE HARNESS MALE

126

39080B001

VALVE-GAS SHUT-OFF

127

06131B046

FILTER 16.5" X 25" X .50"

128

06132B001

ROD-FILTER

130

39007D005

LABEL-WIRING DIAGRAM

250

41114-001

COIL-OUTDOOR

255

38980B001

COIL-INDOOR

262

35125C009

COMP-AW5517G

267

41282-001

MOTOR 1/8 HP, 1 PHASE

268

39085B001

BLADE-FAN

269

03982D004

BRACKET-MOTOR SUPPORT

271

38514D004

CAPACITOR 35/5 MFD@370VAC

278

07535C001

CONTACTOR

64HWC182-6A
First find Model #. -------------------------------------------------------------- >
64HWC182-6(*)
Then match Service Level for desired part. ------------------------------ >

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-19

HWC-5

REVISED
1-20-98

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

26HWC122-5(*)

38HWC122-5(*)

38HWC182-6(*)

51HWC182-5(*)

64HWC182-5(*)

38HWC242-5(*)

51HWC242-4(*)

64HWC242-4(*)

51HWC302-5(*)

64HWC302-5(*)

TO SELECT PART #

39370B001

TRANSFORMER

39029B002

CONTROL-BLOWER CENTER

39031D001

VALVE-GAS

38832B001

MANIFOLD-3 CELL

38832B002

MANIFOLD-4 CELL

38832B003

MANIFOLD-5 CELL

38832B004

MANIFOLD-6 CELL

39030B003

ORIFICE #52

39030B004

ORIFICE #53

39030B005

ORIFICE #54

39050B001

ELECTRODE

41583-001

WIRE-ELECTRODE

41582-002

CONTROL-IGNITION

39006B001

Last letter of the Model # is the Service Level.
64HWC302-5A
First find Model #. ------------------------------------------------ >
64HWC302-5(*)

SRM-HW/HWC 8/99

Then match Service Level for desired part. ---------------- >

1
1

ASSY-BURNER

38999D009

ASSY-HEAT EXCHANGER

38999D010

ASSY-HEAT EXCHANGER

38999D011

ASSY-HEAT EXCHANGER

38999D012

ASSY-HEAT EXCHANGER

38841B001

TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

GASKET-FLUE COL END

01150A008

CONTROL-LIMIT

39113B001

GASKET-LIMIT SWITCH

37520B004

SWITCH-ROLLOUT RED

1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-20

HWC-5

REVISED
1-20-98

(cont.)

51HWC182-5(*)

64HWC182-5(*)

38HWC242-5(*)

51HWC242-4(*)

64HWC242-4(*)

51HWC302-5(*)

64HWC302-5(*)

Then match Service Level for desired part. ---------------- >

38HWC182-6(*)

64HWC302-5(*)

38HWC122-5(*)

First find Model #. ------------------------------------------------ >

1
1

26HWC122-5(*)

64HWC302-5A

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

REF PART #

PART DESCRIPTION

41862-001

SWITCH-PRESS RED

41862-002

SWITCH-PRESS GREEN

41144-001

BLOWER-INDUCED DRAFT

39045B001

MOTOR 1/6 HP, 1 PHASE

39046B001

MOTOR 1/3 HP, 1 PHASE

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

39010B001

ASSY-BLOWER HOUSING

39232D001

CAPACITOR-4 MFD@370V

39232D004

CAPACITOR-7.5 MFD@370V

124 40231B001

ASSY-WIRE HARNESS FEMALE

125 39605B001

ASSY-WIRE HARNESS MALE

126 39080B001

VALVE-GAS SHUT-OFF

127 06131B046

FILTER 16.5" X 25" X .5"

128 06132B001

ROD-FILTER

130 39007D005

LABEL-WIRING DIAGRAM

250 38982B001

COIL-OUTDOOR

250 38983B001

COIL-OUTDOOR

250 40649-001

COIL-OUTDOOR

250 41114-001

COIL-OUTDOOR

255 38979B001

COIL-INDOOR

255 38980B001

COIL-INDOOR

255 40648-001

COIL-INDOOR

1
1

1
SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-21

HWC-5

REVISED
1-20-98

(cont.)

51HWC302-5(*)

64HWC302-5(*)

256 39058B002

ASSY-CAP TUBE

256 39058B003

ASSY-CAP TUBE

256 40650-001

ASSY-CAP TUBE

262 35136C001

COMP-ZR28K1-PFV

262 35136C005

COMP-ZR23K1-PFV

262 39008C001

COMP-RK147ET-002-A4

262 39008C002

COMP-RK233ET-009-A4

267 41254-001

MOTOR 1/4 HP, 1 PHASE

267 41282-001

MOTOR 1/8 HP, 1 PHASE

268 39062B001

BLADE-FAN

268 39085B001

BLADE-FAN

269 03982D004

BRACKET-MOTOR SUPPORT

271 38514D002

CAPACITOR-25/5 MFD@370 VAC

271 38514D003

CAPACITOR-30/5 MFD@370 VAC

271 38514D004

CAPACITOR-35/5 MFD@370 VAC

278 07535C001

CONTACTOR

282 40715-001

RELAY-TIME DELAY

SRM-HW/HWC 8/99

1
1

64HWC242-4(*)

51HWC242-4(*)

Then match Service Level for desired part. ---------------- >

38HWC242-5(*)

38HWC122-5(*)

ASSY-CAP TUBE

64HWC302-5(*)

64HWC182-5(*)

26HWC122-5(*)

256 39058B001

First find Model #. ------------------------------------------------ >

51HWC182-5(*)

PART DESCRIPTION

64HWC302-5A

38HWC182-6(*)

REF PART #

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

PARTS LISTS

MAGIC-PAK: HW/HWC

8-22
REVISED
1-20-98

HWC-4

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

38HWC182-4(*)

51HWC182-4(*)

64HWC182-4(*)

51HWC302-4(*)

64HWC302-4(*)

TO SELECT PART #

39370B001

TRANSFORMER

39029B002

CONTROL-BLOWER CENTER

39031D001

VALVE-GAS

38832B002

MANIFOLD

38832B003

MANIFOLD

38832B004

MANIFOLD

39030B003

ORIFICE #52 NATURAL GAS

39030B004

ORIFICE #53 NATURAL GAS

39073B001

SENSOR-FLAME

39050B001

ELECTRODE

39049B001

WIRE-ELECTRODE

39049B002

WIRE-ELECTRODE

39048B001

CONTROL-IGNITION

39006B001

BURNER END SHOT

38999D002

HEAT EXCHANGER

38999D003

HEAT EXCHANGER

38999D004

HEAT EXCHANGER

S38841B001

TURBULATOR

38977B001

GASKET-FLUE FRONT

38978B001

Last letter of the Model # is the Service Level.
38HWC182-4A
First find Model #. -------------------------------------------------------------- >
38HWC182-4(*)
Then match Service Level for desired part. ------------------------------ >

1
1

GASKET-FLUE SIDE

01150A008

CONTROL-LIMIT

39113B001

GASKET-LIMIT SWITCH

37520B004

SWITCH-ROLLOUT

39089B001

SWITCH-N.O. PRESSURE

39005B001

BLOWER-INDUCED DRAFT

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-23

HWC-4

REVISED
1-20-98

(cont.)
REC STOCKING PART

SERVICE LEVEL = *

38HWC182-4(*)

51HWC182-4(*)

64HWC182-4(*)

51HWC302-4(*)

64HWC302-4(*)

TO SELECT PART #

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

39010B001

HOUSING-BLOWER

39232D004

CAPACITOR 7.5 MFD@370VAC

124

40231B001

ASSY-FEMALE RECPT.

125

390650B001

ASSY-MALE RECPT.

126

39080B001

VALVE-GAS SHUT-OFF

127

06131B046

FILTER 16.5" X 25" X .50"

128

06132B001

ROD-FILTER

130

39007D003

WIRING DIAGRAM

250

40649-001

COIL-OUTDOOR

250

41114-001

COIL-OUTDOOR

255

38980B001

COIL-INDOOR

255

40648-001

COIL-INDOOR

256

39058B002

CAP TUBE ASSY-DRIER

256

40650-001

CAP TUBE ASSY-DRIER

262

35136C001

COMPRESSOR

262

39008C002

COMPRESSOR

267

39044B001

MOTOR 1/4 HP

267

39084B001

MOTOR 1/8 HP

268

39062B001

BLADE-FAN

268

39085B001

BLADE-FAN

269

03982D004

BRACKET-MOTOR SUPPORT

Last letter of the Model # is the Service Level.
38HWC182-4A
First find Model #. -------------------------------------------------------------- >
38HWC182-4(*)

SRM-HW/HWC 8/99

Then match Service Level for desired part. ------------------------------ >

REF PART #

PART DESCRIPTION

39046B001

MOTOR 1/3 HP

07407B000

PARTS LISTS

MAGIC-PAK: HW/HWC

8-24

HWC-4

REVISED
1-20-98

(cont.)

SERVICE LEVEL = *

38HWC182-4(*)

51HWC182-4(*)

64HWC182-4(*)

271

38514D002

CAPACITOR 25/5 MFD@370VAC

271

38514D004

CAPACITOR 35/5 MFD@370VAC

278

07535C001

CONTACTOR

282

38065A001

RELAY-TIME DELAY

301

39059B002

DRIER

301

39059B003

DRIER

38HWC182-4A
First find Model #. -------------------------------------------------------------- >
38HWC182-4(*)
Then match Service Level for desired part. ------------------------------ >

64HWC302-4(*)

PART DESCRIPTION

Last letter of the Model # is the Service Level.

51HWC302-4(*)

REF PART #

REC STOCKING PART

TO SELECT PART #

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-25

HWC-3

REVISED
1-20-98

REC STOCKING PART

SERVICE LEVEL = *

26HWC122-3(*)

38HWC122-3(*)

38HWC182-3(*)

51HWC182-3(*)

64HWC182-3(*)

38HWC242-3(*)

51HWC242-3(*)

64HWC242-3(*)

51HWC302-3(*)

64HWC302-3(*)

TO SELECT PART #

39370B001

TRANSFORMER

39029B001

CENTER BLO. CONT.

39031D001

VALVE-GAS

38832B001

MANIFOLD GAS

38832B002

MANIFOLD GAS

38832B003

MANIFOLD GAS

38832B004

MANIFOLD GAS

39030B003

ORIFICE #52

39030B004

ORIFICE #53

39030B005

ORIFICE #54

39073B001

SENSOR-FLAME

39050B001

ELECTRODE-D.S.I.

39049B001

WIRE-ELECTRODE

39049B002

Last letter of the Model # is the Service Level.
64HWC302-3A
First find Model #. ------------------------------------------------ >
64HWC302-3(*)
Then match Service Level for desired part. ---------------- >

SRM-HW/HWC 8/99

REF PART #

PART DESCRIPTION

1
1

WIRE-ELECTRODE

39048B001

CONTROL-IGNITION

39006B001

BURNER END SHOT

38999D001

HEAT EXCHANGER

38999D002

HEAT EXCHANGER

38999D003

HEAT EXCHANGER

38999D004

HEAT EXCHANGER

38841B001

TURBULATOR

38977B001

GASKET FLUE FRONT

38978B001

GASKET FLUE SIDE

01150A008

CONTROL-LIMIT

39113B001

GASKET-LIMIT SWITCH

1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-26

HWC-3

REVISED
1-20-98

(cont.)

51HWC242-3(*)

64HWC242-3(*)

51HWC302-3(*)

64HWC302-3(*)

38HWC242-3(*)

PART DESCRIPTION

64HWC182-3(*)

REF PART #

51HWC182-3(*)

Then match Service Level for desired part. ---------------- >

38HWC182-3(*)

64HWC302-3(*)

38HWC122-3(*)

First find Model #. ------------------------------------------------ >

26HWC122-3(*)

64HWC302-3A

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

37520B004

SWITCH-ROLLOUT

39086B001

SWITCH N.O. PRESSURE

39086B002

SWITCH N.O. PRESSURE

39005B001

BLOWER-INDUCED DRAFT

39045B001

MOTOR 1/6 HP

39046B001

MOTOR 1/3 HP

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

39010B001

HOUSING-BLOWER

34001D001

CAPACITOR BLO 4

34001D004

CAPACITOR BLO 7.5

1
1

124 39366B001

ASSY-FEMALE RECPT.

125 39605B001

MALE RECP. ASSY

126 39080B001

VALVE-GAS SHUT-OFF

127 06131B046

FILTER-AIR

128 06132B001

ROD-FILTER

130 39007D002

LABEL-WIRING DIAGRAM

250 38982B001

COIL-OUTDOOR

250 38983B001

COIL-OUTDOOR

250 38984B001

COIL-OUTDOOR

255 38979B001

COIL-INDOOR

255 38980B001

COIL-INDOOR

255 38981B001

COIL-INDOOR

1
1

1
SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-27

HWC-3

REVISED
1-20-98

(cont.)

SRM-HW/HWC 8/99

256 39057B001

CAP TUBE ASSY

256 39058B001

CAP TUBE ASSY

256 39058B002

CAP TUBE ASSY

256 39058B003

CAP TUBE ASSY

262 35136C001

COMPRESSOR

262 35136C005

COMPRESSOR

262 39008C001

COMPRESSOR

262 39008C002

COMPRESSOR

267 39044B001

MOTOR FAN 1/4 HP

267 39084B001

MOTOR FAN 1/8 HP

268 39062B001

BLADE-FAN

268 39085B001

BLADE-FAN

269 03982D004

BRACKET-MOTOR SUPPORT

271 38514D002

CAPACITOR-25/5 MFD@370 VAC

271 38514D003

CAPACITOR-30/5 MFD@370 VAC

271 38514D004

CAPACITOR-35/5 MFD@370 VAC

278 35658B001

CONTACTOR

282 38065A001

RELAY-TIME DELAY

301 39059B001

FILTER-DRIER

301 39059B002

FILTER-DRIER

301 39059B003

FILTER-DRIER

1
1

1
1
1

64HWC302-3(*)

PART DESCRIPTION

51HWC302-3(*)

REF PART #

64HWC242-3(*)

51HWC242-3(*)

38HWC242-3(*)

64HWC182-3(*)

51HWC182-3(*)

Then match Service Level for desired part. ---------------- >

38HWC182-3(*)

64HWC302-3(*)

38HWC122-3(*)

First find Model #. ------------------------------------------------ >

26HWC122-3(*)

64HWC302-3A

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

PARTS LISTS

MAGIC-PAK: HW/HWC

8-28

HWC-2

REVISED
1-20-98

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

TO SELECT PART #

39031D001

VALVE-GAS WHITE-RODGERS

39049B001

WIRE-ELECTRODE

39049B002

WIRE-ELECTRODE

39029B001

CENTER BLO. CONT.

39048B001

CONTROL-IGNITION

39073B001

SENSOR-FLAME

39050B001

Last letter of the Model # is the Service Level.

38HWC182-2(*)

51HWC182-2(*)

64HWC182-2(*)

64HWC182-2A

ELECTRODE-D.S.I.

01150A008

CONTROL-LIMIT

36610B001

TRANSFORMER

38980B001

COIL-INDOOR

39058B002

CAP TUBE ASSY

39030B003

ORIFICE #52

39030B004

ORIFICE SPUD #53

38999D002

HEAT EXCHANGER

38999D003

HEAT EXCHANGER

38999D004

HEAT EXCHANGER

38841B001

TURBULATOR

38977B001

GASKET FLUE FRONT

38978B001

GASKET FLUE SIDE

39006B001

BURNER END SHOT

38832B002

MANIFOLD GAS

38832B003

MANIFOLD GAS

38832B004

MANIFOLD GAS

39086B001

SWITCH N.O. PRESSURE

39005B001

BLOWER I.D.

First find Model #. -------------------------------------------------------------- >
64HWC182-2(*)
Then match Service Level for desired part. ------------------------------ >

1
1
SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-29

HWC-2

REVISED
1-20-98

(cont.)
REC STOCKING PART

SERVICE LEVEL = *

38HWC182-2(*)

51HWC182-2(*)

64HWC182-2(*)

TO SELECT PART #

GASKET-LIMIT SWITCH

34001D004

CAPACITOR BLO 7.5

39046B001

MOTOR 1/3 HP

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

39010B001

HOUSING-BLOWER

39007D001

WIRING DIAGRAM

06131B046

AIR FILTER

06132B001

ROD-FILTER

250

38983B001

COIL-OUTDOOR

255

35658B001

CONTACTOR

260

39008C002

COMPRESSOR

270

38514D002

CAPACITOR 25/5

272

39044B001

MOTOR FAN 1/4 HP

273

03982D004

BRACKET MOTOR SUPPORT

279

39062B001

BLADE-FAN

290

39118B001

MALE RECP. ASSY.

328

39059B002

DRIER

348

38065A001

RELAY-TIME DELAY

Last letter of the Model # is the Service Level.
64HWC182-2A
First find Model #. -------------------------------------------------------------- >
64HWC182-2(*)

SRM-HW/HWC 8/99

Then match Service Level for desired part. ------------------------------ >

REF PART #

PART DESCRIPTION

37520B004

SWITCH ROLLOUT

39366B001

ASSY-WIRE HARNESS

39080B001

VALVE-GAS SHUT-OFF

39113B001

PARTS LISTS

MAGIC-PAK: HW/HWC

8-30

HWC-1

REVISED
1-20-98

38HWC182-1(*)

51HWC182-1(*)

64HWC182-1(*)

39049B001

WIRE-ELECTRODE

39049B002

WIRE-ELECTRODE

39029B001

CENTER BLO. CONT.

39048B002

CONTROL-IGNITION

39073B001

SENSOR-FLAME

39050B001

ELECTRODE-D.S.I.

01150A008

CONTROL-LIMIT

36610B001

TRANSFORMER

38979B001

Then match Service Level for desired part. ---------------- >

64HWC302-1(*)

38HWC122-1(*)

VALVE-GAS WHITE-RODGERS

64HWC302-1(*)

51HWC302-1(*)

26HWC122-1(*)

39031D001

First find Model #. ------------------------------------------------ >

64HWC242-1(*)

SERVICE LEVEL = *

64HWC302-1A

51HWC242-1(*)

PART DESCRIPTION

Last letter of the Model # is the Service Level.

38HWC242-1(*)

REF PART #

REC STOCKING PART

TO SELECT PART #

1
1

COIL-INDOOR

38980B001

COIL-INDOOR

38981B001

COIL-INDOOR

39057B001

CAP TUBE ASSY

39058B001

CAP TUBE ASSY

39057B002

CAP TUBE ASSY

39057B003

CAP TUBE ASSY

39030B003

ORIFICE #52

39030B004

ORIFICE SPUD #53

39030B005

ORIFICE SPUD #54

38999D001

HEAT EXCHANGER

38999D002

HEAT EXCHANGER

38999D003

HEAT EXCHANGER

38999D004

HEAT EXCHANGER

38841B001

TURBULATOR

1
1

1
4

1
5

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-31

HWC-1

REVISED
1-20-98

(cont.)

REF PART #

PART DESCRIPTION

SERVICE LEVEL = *

26HWC122-1(*)

38HWC122-1(*)

38HWC182-1(*)

51HWC182-1(*)

64HWC182-1(*)

38HWC242-1(*)

51HWC242-1(*)

64HWC242-1(*)

51HWC302-1(*)

64HWC302-1(*)

Last letter of the Model # is the Service Level.

38977B001

GASKET FLUE FRONT

38978B001

GASKET FLUE SIDE

39006B001

BURNER END SHOT

38832B001

MANIFOLD GAS

38832B002

MANIFOLD GAS

38832B003

MANIFOLD GAS

38832B004

MANIFOLD GAS

39086B001

SWITCH N.O. PRESSURE

39086B002

SWITCH N.O. PRESSURE

39005B001

BLOWER I.D.

37520B004

SWITCH-ROLLOUT

39366B001

ASSY-WIRE HARNESS

39080B001

VALVE-GAS SHUT-OFF

39113B001

64HWC302-1A
First find Model #. ------------------------------------------------ >
64HWC302-1(*)
Then match Service Level for desired part. ---------------- >

SRM-HW/HWC 8/99

REC STOCKING PART

TO SELECT PART #

1
1

GASKET-LIMIT SWITCH

34001D001

CAPACITOR BLO 4

34001D004

CAPACITOR BLO 7.5

39045B001

MOTOR 1/6 HP

39046B001

MOTOR 1/3 HP

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

39010B001

HOUSING-BLOWER

39007D001

WIRING DIAGRAM

06131B046

FILTER-AIR

06132B001

ROD-FILTER

PARTS LISTS

MAGIC-PAK: HW/HWC

8-32

HWC-1

REVISED
1-20-98

(cont.)

250 38984B001

COIL OUTDOOR

255 35658B001

CONTACTOR

260 35136C001

COMPRESSOR

260 35136C004

COMPRESSOR

260 35136C005

COMPRESSOR

260 39008C001

COMPRESSOR

270 38514D002

CAPACITOR-25/5 MFD@370 VAC

270 38514D003

CAPACITOR-30/5 MFD@370 VAC

270 38514D004

CAPACITOR-35/5 MFD@370 VAC

272 39044B001

MOTOR FAN 1/4 HP

272 39084B001

MOTOR FAN 1/8 HP

273 03982D004

BRACKET MOTOR SUP.

279 39062B001

BLADE-FAN

279 39085B001

BLADE-FAN

290 39118B001

MALE RECP. ASSY

328 39059B001

FILTER-DRIER

328 39059B002

FILTER-DRIER

328 39059B003

FILTER-DRIER

348 38065A001

RELAY-TIME DELAY

64HWC302-1(*)

COIL OUTDOOR

51HWC302-1(*)

250 38983B001

PART DESCRIPTION

64HWC242-1(*)

REF PART #

51HWC242-1(*)

Then match Service Level for desired part. ---------------- >

38HWC242-1(*)

64HWC302-1(*)

64HWC182-1(*)

38HWC122-1(*)

COIL OUTDOOR

First find Model #. ------------------------------------------------ >

51HWC182-1(*)

26HWC122-1(*)

250 38982B001

64HWC302-1A

38HWC182-1(*)

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

1
1

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-33

HW-1

REVISED
1-20-98

64HW-1A
First find Model #. -------------------------------------------------------------- >

39031D001

VALVE-GAS WHITE-RODGERS

39049B001

WIRE-ELECTRODE

39049B002

WIRE-ELECTRODE

39248B001

CENTER BLO. CONT.

39048B001

CONTROL-IGNITION

39073B001

64HW-1(*)

51HW-1(*)

PART DESCRIPTION

38HW-1(*)

REF PART #

26HW-1(*)

64HW-1(*)

SENSOR-FLAME

39050B001

ELECTRODE-D.S.I.

01150A008

CONTROL-LIMIT

39370B001

TRANSFORMER

39030B003

ORIFICE #52

39030B004

ORIFICE SPUD

39030B005

ORIFICE SPUD

38999D001

HEAT EXCHANGER

38999D002

HEAT EXCHANGER

38999D003

HEAT EXCHANGER

38999D004

HEAT EXCHANGER

38841B001

TURBULATOR

38977B001

GASKET FLUE FRONT

38978B001

GASKET FLUE SIDE

39006B001

BURNER END SHOT

38832B001

MANIFOLD GAS

38832B002

MANIFOLD GAS

38832B003

MANIFOLD GAS

38832B004

MANIFOLD GAS

Then match Service Level for desired part. ------------------------------ >

SRM-HW/HWC 8/99

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

1
1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-34

HW-1

REVISED
1-20-98

(cont.)

First find Model #. -------------------------------------------------------------- >

38HW-1(*)

51HW-1(*)

64HW-1(*)

26HW-1(*)

64HW-1A

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

SWITCH ROLLOUT

39366B001

ASSY-WIRE HARNESS

39080B001

VALVE-GAS SHUT-OFF

39113B001

GASKET-LIMIT SWITCH

34001D001

CAPACITOR BLO 4

34001D004

CAPACITOR BLO 7.5

39045B001

MOTOR 1/6 HP

39046B001

MOTOR 1/3 HP

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

39010B001

HOUSING-BLOWER

39247D001

WIRING DIAGRAM

06131B046

AIR FILTER

06132B001

ROD-FILTER

Then match Service Level for desired part. ------------------------------ >

REF PART #

PART DESCRIPTION

39086B001

SWITCH N.O. PRESSURE

39086B002

SWITCH N.O. PRESSURE

39005B001

BLOWER-INDUCED DRAFT

37520B004

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-35

HWA-9

REVISED
4-26-99

REC STOCKING PART

SERVICE LEVEL = *

26HWA-9(*)

38HWA-9(*)

51HWA-9(*)

64HWA-9(*)

TO SELECT PART #

39370B001

TRANSFORMER

44987-001

VALVE-GAS HONEYWELL

42074-001

MANIFOLD

42074-002

MANIFOLD

42074-003

MANIFOLD

42074-004

MANIFOLD

39030B003

ORIFICE #52 NATURAL GAS

39030B004

ORIFICE #53 NATURAL GAS

39030B005

ORIFICE #54 NATURAL GAS

44992-001

ELECTRODE

44993-001

WIRE-ELECTRODE

44990-001

CONTROL-IGNITION/BLOWER

41948-001

Last letter of the Model # is the Service Level.
64HWA-9A
First find Model #. -------------------------------------------------------------- >
64HWA-9(*)
Then match Service Level for desired part. ------------------------------ >

SRM-HW/HWC 8/99

REF

PART #

PART DESCRIPTION

1
1

BURNER

38999D009

ASSEMBLY-HEAT EXCHANGER

38999D010

ASSEMBLY-HEAT EXCHANGER

38999D011

ASSEMBLY-HEAT EXCHANGER

38999D012

ASSEMBLY-HEAT EXCHANGER

S38841B001 TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

1
1
1

GASKET-FLUE COL. END

40154B007

CONTROL-LIMIT

37520B004

SWITCH-ROLLOUT RED

37520B005

SWITCH-ROLLOUT GREEN

44819-010

SWITCH-PRESSURE RED

41144-001

BLOWER-INDUCED DRAFT

PARTS LISTS

MAGIC-PAK: HW/HWC

8-36

HWA-9

REVISED
4-26-99

(cont.)

PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

26HWA-9(*)

38HWA-9(*)

TO SELECT PART #

39045B001

MOTOR 1/6 HP, 1 PHASE

39046B001

MOTOR 1/3 HP, 1 PHASE

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

S39010B001 ASSEMBLY-BLOWER HOUSING

34001D001

CAPACITOR-4 MFD@370 VAC

34001D004

111

Last letter of the Model # is the Service Level.
64HWA-9A

51HWA-9(*)

64HWA-9(*)

First find Model #. -------------------------------------------------------------- >

CAPACITOR-7.5 MFD@370 VAC

02764B000

BOARD-TERMINAL

124

45001-001

ASSEMBLY-WIRE HARNESS UPPER

127

06131B046

FILTER 16.5" X 25" X .50"

130

45008-001

LABEL-WIRING DIAGRAM

64HWA-9(*)
Then match Service Level for desired part. ------------------------------ >

REF

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-37

HWC3-S-1

REVISED
4-26-99

26HWC123SA-1(*)

38HWC123SA-1(*)

38HWC183SA-1(*)

51HWC183SA-1(*)

64HWC183SA-1(*)

38HWC243SA-1(*)

51HWC243SA-1(*)

39370B001

TRANSFORMER

44987-001

VALVE-GAS HONEYWELL

42074-001

MANIFOLD

42074-002

MANIFOLD

42074-003

MANIFOLD

42074-004

MANIFOLD

39030B003

ORIFICE #52 NATURAL GAS

39030B004

ORIFICE #53 NATURAL GAS

39030B005

ORIFICE #54 NATURAL GAS

44992-001

ELECTRODE

44993-001

WIRE-ELECTRODE

44990-001

CONTROL-IGNITION/BLOWER

41948-001

First find Model #. ------------------------------------------------ >
64HWC303SA-1(*)

SRM-HW/HWC 8/99

Then match Service Level for desired part. ---------------- >

1
1

64HWC303SA-1(*)

SERVICE LEVEL = *

64HWC303SA-1A

51HWC303SA-1(*)

PART DESCRIPTION

Last letter of the Model # is the Service Level.

64HWC243SA-1(*)

REF PART #

REC STOCKING PART

TO SELECT PART #

1
1

BURNER

38999D009

ASSEMBLY-HEAT EXCHANGER

38999D010

ASSEMBLY-HEAT EXCHANGER

38999D011

ASSEMBLY-HEAT EXCHANGER

38999D012

ASSEMBLY-HEAT EXCHANGER

S38841B001 TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

1
1

GASKET-FLUE COL. END

40154B007

CONTROL-LIMIT

37520B004

SWITCH-ROLLOUT RED

37520B005

SWITCH-ROLLOUTGREEN

44819-010

SWITCH-PRESSURE RED

41144-001

BLOWER-INDUCED DRAFT

PARTS LISTS

MAGIC-PAK: HW/HWC

8-38

HWC3-S-1

REVISED
4-26-99

(cont.)

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

26HWC123SA-1(*)

38HWC123SA-1(*)

TO SELECT PART #

39045B001

MOTOR 1/6 HP, 1 PHASE

39046B001

MOTOR 1/3 HP, 1 PHASE

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

S39010B001 ASSEMBLY-BLOWER HOUSING

34001D001

CAPACITOR-4 MFD@370 VAC

34001D004

38HWC183SA-1(*)

51HWC183SA-1(*)

64HWC183SA-1(*)

38HWC243SA-1(*)

51HWC243SA-1(*)

64HWC243SA-1(*)

51HWC303SA-1(*)

64HWC303SA-1(*)

Last letter of the Model # is the Service Level.

CAPACITOR-7.5 MFD@370 VAC

111 02764B000

BOARD-TERMINAL

124 45001-001

ASSEMBLY-WIRE HARNESS UPPER

125 45002-001

ASSEMBLY-WIRE HARNESS LOWER

127 06131B046

FILTER 16.5" X 25" X .50"

130 45005-001

LABEL-WIRING DIAGRAM

250 38982B001

COIL-OUTDOOR

250 38983B001

COIL-OUTDOOR

250 40649-001

COIL-OUTDOOR

250 41114-001

COIL-OUTDOOR

255 38979B001

COIL-INDOOR

255 38980B001

COIL-INDOOR

255 40648-001

COIL-INDOOR

256 S43271-001

ASSY-CAP. TUBE W/FILTER-DRIER

256 S43271-002

ASSY-CAP. TUBE W/FILTER-DRIER

256 S43271-003

ASSY-CAP. TUBE W/FILTER-DRIER

256 S43375-001

ASSY-CAP. TUBE W/FILTER-DRIER

64HWC303SA-1A
First find Model #. ------------------------------------------------ >
64HWC303SA-1(*)
Then match Service Level for desired part. ---------------- >

1
1

1
SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-39

HWC3-S-1

REVISED
4-26-99

(cont.)

SRM-HW/HWC 8/99

262 39008C001

COMPRESSOR-RK147ET-002-A4

262 42811-005

COMPRESSOR-ZR24KC-PFV-130

262 42811-006

COMPRESSOR-ZR28KC-PFV-130

267 41254-001

MOTOR 1/4 HP, 1 PHASE

267 41282-001

MOTOR 1/8 HP, 1 PHASE

268 39062B001

BLADE-FAN

268 39085B001

BLADE-FAN

269 03982D004

BRACKET-MOTOR SUPPORT

271 38514D002

CAPACITOR-25/5 MFD@370 VAC

271 38514D004

CAPACITOR-35/5 MFD@370 VAC

276 42725-001

PLUG-COMPRESSOR

278 07535C001

CONTACTOR

280 07489B007

RELAY-CONDENSER FAN MOTOR

291 36327B007

SWITCH-CONDENSER FAN

301 39059B001

FILTER-DRIER

301 39059B002

FILTER-DRIER

301 39059B003

FILTER-DRIER

64HWC303SA-1(*)

COMPRESSOR-AW501ET-089-A4

51HWC303SA-1(*)

262 35125C009

64HWC243SA-1(*)

PART DESCRIPTION

51HWC243SA-1(*)

64HWC183SA-1(*)

REF PART #

38HWC243SA-1(*)

51HWC183SA-1(*)

Then match Service Level for desired part. ---------------- >

38HWC183SA-1(*)

64HWC303SA-1(*)

38HWC123SA-1(*)

First find Model #. ------------------------------------------------ >

26HWC123SA-1(*)

64HWC303SA-1A

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-40

HWC3-H-1

REVISED
4-26-99

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

26HWC123HA-1(*)

38HWC123HA-1(*)

38HWC183HA-1(*)

51HWC183HA-1(*)

64HWC183HA-1(*)

38HWC243HA-1(*)

51HWC243HA-1(*)

64HWC243HA-1(*)

51HWC303HA-1(*)

64HWC303HA-1(*)

TO SELECT PART #

39370B001

TRANSFORMER

44987-001

VALVE-GAS HONEYWELL

42074-001

MANIFOLD

42074-002

MANIFOLD

42074-003

MANIFOLD

42074-004

MANIFOLD

39030B004

ORIFICE #53 NATURAL GAS

39030B005

ORIFICE #54 NATURAL GAS

39030B011

ORIFICE #55 NATURAL GAS

44992-001

ELECTRODE

44993-001

WIRE-ELECTRODE

44990-001

CONTROL-IGNITION/BLOWER

41948-001

Last letter of the Model # is the Service Level.
64HWC303HA-1A
First find Model #. ------------------------------------------------ >
64HWC303HA-1(*)
Then match Service Level for desired part. ---------------- >

1
1

BURNER

38999D009

ASSEMBLY-HEAT EXCHANGER

38999D010

ASSEMBLY-HEAT EXCHANGER

38999D011

ASSEMBLY-HEAT EXCHANGER

38999D012

ASSEMBLY-HEAT EXCHANGER

S38841B001 TURBULATOR

38977B001

GASKET-FLUE COVER

38978B001

1
1

GASKET-FLUE COL. END

40154B007

CONTROL-LIMIT

37520B004

SWITCH-ROLLOUT RED

37520B005

SWITCH-ROLLOUTGREEN

44819-010

SWITCH-PRESSURE RED

41144-001

BLOWER-INDUCED DRAFT

SRM-HW/HWC 8/99

Service Reference Manual

PARTS LISTS
8-41

HWC3-H-1

REVISED
4-26-99

(cont.)

REF PART #

PART DESCRIPTION

REC STOCKING PART

SERVICE LEVEL = *

26HWC123HA-1(*)

38HWC123HA-1(*)

TO SELECT PART #

39045B001

MOTOR 1/6 HP, 1 PHASE

39046B001

MOTOR 1/3 HP, 1 PHASE

07407B000

BAND-MOTOR MOUNTING

07408B004

ARM-MOTOR MOUNTING

34833B001

WHEEL-BLOWER

S39010B001 ASSEMBLY-BLOWER HOUSING

34001D001

CAPACITOR-4 MFD@370 VAC

34001D004

38HWC183HA-1(*)

51HWC183HA-1(*)

64HWC183HA-1(*)

38HWC243HA-1(*)

51HWC243HA-1(*)

64HWC243HA-1(*)

51HWC303HA-1(*)

64HWC303HA-1(*)

Last letter of the Model # is the Service Level.

CAPACITOR-7.5 MFD@370 VAC

111 02764B000

BOARD-TERMINAL

124 45001-001

ASSEMBLY-WIRE HARNESS UPPER

125 45002-001

ASSEMBLY-WIRE HARNESS LOWER

127 06131B046

FILTER 16.5" X 25" X .50"

130 45004-001

LABEL-WIRING DIAGRAM

250 38982B001

COIL-OUTDOOR

250 38983B001

COIL-OUTDOOR

250 40649-001

COIL-OUTDOOR

250 41114-001

COIL-OUTDOOR

255 38979B001

COIL-INDOOR

255 38980B001

COIL-INDOOR

255 40648-001

COIL-INDOOR

256 S43271-001

ASSY-CAP. TUBE W/FILTER-DRIER

256 S43271-002

ASSY-CAP. TUBE W/FILTER-DRIER

256 S43271-003

ASSY-CAP. TUBE W/FILTER-DRIER

256 S43375-001

ASSY-CAP. TUBE W/FILTER-DRIER

64HWC303HA-1A
First find Model #. ------------------------------------------------ >
64HWC303HA-1(*)

SRM-HW/HWC 8/99

Then match Service Level for desired part. ---------------- >

1
1

PARTS LISTS

MAGIC-PAK: HW/HWC

8-42

HWC3-H-1

REVISED
4-26-99

(cont.)

COMPRESSOR-RK147ET-002-A4

262 42811-005

COMPRESSOR-ZR24KC-PFV-130

262 42811-006

COMPRESSOR-ZR28KC-PFV-130

267 41254-001

MOTOR 1/4 HP, 1 PHASE

267 41282-001

MOTOR 1/8 HP, 1 PHASE

268 39062B001

BLADE-FAN

268 39085B001

BLADE-FAN

269 03982D004

BRACKET-MOTOR SUPPORT

271 38514D002

CAPACITOR-25/5 MFD@370 VAC

271 38514D004

CAPACITOR-35/5 MFD@370 VAC

276 42725-001

PLUG-COMPRESSOR

278 07535C001

CONTACTOR

301 39059B001

FILTER-DRIER

301 39059B002

FILTER-DRIER

301 39059B003

FILTER-DRIER

64HWC303HA-1(*)

262 39008C001

51HWC303HA-1(*)

64HWC243HA-1(*)

COMPRESSOR-AW501ET-089-A4

51HWC243HA-1(*)

262 35125C009

38HWC243HA-1(*)

PART DESCRIPTION

64HWC183HA-1(*)

REF PART #

51HWC183HA-1(*)

Then match Service Level for desired part. ---------------- >

38HWC183HA-1(*)

64HWC303HA-1(*)

38HWC123HA-1(*)

First find Model #. ------------------------------------------------ >

26HWC123HA-1(*)

64HWC303HA-1A

SERVICE LEVEL = *

Last letter of the Model # is the Service Level.

REC STOCKING PART

TO SELECT PART #

SRM-HW/HWC 8/99

Service Reference Manual

TROUBLESHOOTING
9-1

Section 9 - Troubleshooting/
Performance/
Charge Weights
Troubleshooting ................................... 9-2
Compressor Checkout ................................ 9-2
Capacitor Checkout .................................... 9-6

Performance ........................................ 9-9
Performance Tests (Installed) ...................... 9-9
Performance Tests (Bench Tested) ............. 9-11

SRM-HW/HWC 8/99

Charge Weights ................................. 9-11

TROUBLESHOOTING

Magic-Pak: HW/HWC

9-2

Troubleshooting
Compressor Checkout
The objective of this section is to help in diagnosing compressor problems. It presents a series of tests that should be conducting before a
determination on the condition of the compressor is made. This section
has been organized so that the simplest checks are done first, followed by
the more detailed tests (if necessary).

WARNING
Use extreme caution when performing maintenance or
troubleshooting operations. Electrical shock could
cause personal injury or death.
Initial Testing
If a compressor failure is suspected, several simple checks should be
done initially to make sure that the right course of action is being taken.
The following is a list of items and points that should be looked at before a
determination is made of the condition of the compressor.

•

Is the correct voltage available at the unit? Using a volt/ohm meter,
check the voltage and compare with the voltage specified by the
manufacturer (found on the data plate on the unit). Many compressors are replaced only to find later that there was either no power or
incorrect power available to the unit.

•

Is the contactor closing? Check to make sure that there is 24 volts at
the coil side of the contactor. Check to make sure the points in the
contactor are in good condition. Are they pitted or corroded to the
point where they no longer conduct electricity?

•

Is the capacitor in good condition? Does it have the correct rating for
the application? Using a meter, determine if it still has the correct
capacitance.

•

The last of these initial tests to do is a touch test. This should be
done very carefully as the compressor can become very hot in
certain situations. This information may be helpful if further tests are
needed to determine the condition of the compressor.

Further Testing
Use extreme caution when conducting the following tests. The power
must be turned off before continuing with the testing.
Checking Continuity

SRM-HW/HWC 8/99

1. Remove wires from the fusite plug in the compressor, recording the
location of each wire as it is removed. If a wire is misplaced when the
test is complete, serious damage could be done to the compressor.

Service Reference Manual

TROUBLESHOOTING
9-3
2. Set an ohm meter to the lowest possible setting. On a note pad,
write the following: “C to ground”, “S to ground” and “R to ground.”
3. Using the ohm meter, check for continuity between C terminal on the
fusite plug and the case of the compressor (a spot may have to be
cleaned on the compressor to get a good reading.) Record what was
observed on the note pad next to the heading “C to ground”. Do the
same to the other two terminals and record the findings in the proper
places.
4. If any sign of continuity between any of the terminals and ground was
observed, recheck the terminal to confirm that the readings were
correct. Any indication of continuity between any of the terminals and
ground would point to an internal winding being shorted to the
compressor case. This suggests that the compressor has an internal
failure and it would need to be replaced.
5. If no continuity is noted between any of the terminals and ground, the
compressor must be checked out further.
Checking Windings
The following test is used to check the condition of the internal start and
run windings.
1. Write the following down: “C to S”, “C to R” and “S to R.”
2. Using the volt/ohmmeter, measure the resistance between terminals
C and S. Record the findings on the note pad in the correct place.
Measure and record the resistance between the remaining terminals
in the same manner.
The following examples show how this information can be used to determine if there is an internal failure.
Example #1
C to S (Common through Start Windings)

3.5 ohms

C to R (Common through Run Windings)

1.5 ohms

S to R (Start Windings through Common and Run Windings)

5.0 ohms

A resistance measurement between C to S shows that there is continuity
between the common and start terminals. The reading between terminals
C and R proves that there is continuity between the terminals through the
windings. The resistance recorded between S and R is actually a reading
of the entire circuit within the motor (S through C to R).
A determination of the condition of the motor windings can be made with
the information just collected. The following steps show how this is done.
1. Add the readings from “C to S” and “C to R.”

SRM-HW/HWC 8/99

C to S (3.5 ohms) + C to R (1.5 ohms) = 5 ohms

TROUBLESHOOTING

Magic-Pak: HW/HWC

9-4
When the resistance of “C to S” is added to the resistance of “C to R”,
the combination is the total resistance of the entire motor windings
circuit.
2. Compare the total to the reading taken between “S to R.” If the
windings are in good condition, the sum of “C to S” and “C to R”
should be the same as the reading between “S to R” (S through C to
R). (In this example, they are equal.)
If the numbers are the same, this suggests that the windings are intact
and that there are no internal shorts between the start and run windings.
Example #2
In the following example, the measurements taken provide different
results from the earlier example. These results would indicate that there
is a problem with the compressor.
C to S (Common through Start Windings)

3.5 ohms

C to R (Common through Run Windings)

1.5 ohms

S to R (Start Windings through Common and Run Windings)

4.3 ohms

Using the procedure followed in Example #1:
C to S (3.5 ohms) + C to R (1.5 ohms) = 5 ohms
In this example, the actual reading of “S to R” is 4.3 ohms. In comparing
the readings taken, the resistance measured between “S to R” (the
resistance of the entire motor windings circuit) is not equal to the sum of
“C to S” and “C to R.”
A short between the windings of the start and run coils would reduce the
length of the wire being measured and would result in less resistance
between the two points. Instead of measuring the resistance from “S to C
to R”, the resistance is actually being measured through an internal short
in the windings to the R terminal, bypassing the C terminal. This results
in a lower resistance reading and indicates that the compressor has failed
and the windings are shorted.
Checking the Thermal Overload Device
If during the time that resistance was being checked in the previous test
infinity was ever registered (meter indicated no continuity), the assumption could be made that there is an open winding (or a break in the wires
of the winding). This may indicate that the windings had burned out and
that the compressor had failed.

SRM-HW/HWC 8/99

In the motor windings there is a thermal overload device. This device is
designed to open if the internal temperature of the windings exceed a
preset limit. Since the resistance reading of a winding where the thermal
overload device has opened would show no resistance, the assumption
would most likely be made that the winding was burned out. This is
where the temperature of the compressor as noted in the touch test
becomes very important. If at the time of the touch test the compressor
was found to be very hot, then there is a good chance that the thermal

Service Reference Manual

TROUBLESHOOTING
9-5
overload protector has opened. Before the compressor can be condemned as having a burned out start or run winding, it must be determined that the overload switch is in fact closed. It may take several hours
for the compressor to cool down enough to guarantee that the switch has
closed. After enough time has elapsed for the switch to close, the resistance between each of the terminals should be measured. It may be
found that with the overload switch closed, the compressor checks out
electrically sound. If this is the case, then other possibilities have to be
looked at as to what caused the compressor to overheat.*
There are several reasons why a compressor would overheat.
•

If the capacitor was incorrect or failing, the amp draw (current flow)
would be increased. This could cause the motor to heat up very
rapidly, activating the thermal overload protection device. This would
interrupt power and protect the motor windings from damage.

•

A loss of charge could also cause the operating temperature of the
compressor to rise and open the thermal overload switch.

•

Restricted airflow through the coil could also cause the operating
temperature of the unit to rise.

It is important to perform these checks before making a decision as to the
condition of the compressor.

SRM-HW/HWC 8/99

An open thermal overload device in a motor does not mean that the
motor was damaged or harmed in any way.

TROUBLESHOOTING

Magic-Pak: HW/HWC

9-6

Capacitor Checkout
Before starting the checkout of the capacitor, it is important to understand
what a capacitor is, how it works and what its function is in relation to a
motor.
A capacitor is a storage device similar to a battery, only unlike a battery
a capacitor wants to give up its energy all at once. This ability to store and
release energy is used to make motors run more efficiently, with more
power in a smaller size and to start easier. There are many types of
capacitors but they all serve one common purpose, to store electrons.
Capacitance refers to the capacitor’s ability to store electrons. Different
size capacitors hold different amounts of charge.
Capacitance is measured in farads. A 1-farad capacitor connected to a
1-volt power supply will store 6,280,000,000,000,000,000, or (6.28 x 10 to
the 18th power) electrons. Most capacitors store a much smaller quantity
of electrons. Smaller capacitors have different terms to indicate the
quantity of electrons that they can store. A picofarad is one trillionth of a
farad; a microfarad is one millionth of a farad. The microfarad is the
term most often used in the HVAC business, this is marked on a capacitor
as “MFD”.
The capacitor that is most often used in the HVAC business is known as
an electrolytic capacitor. The electrolytic capacitor is unique in that a
thin layer of oxide is formed on the aluminum sheets used to make up its
internal parts. The electrons that are supplied to the capacitor are stored
in this layer of oxide. But by doing this, nature is being forced to do
something that it doesn’t want to do. Nature likes to be in equilibrium. The
fact that nature prefers to return to a steady state is the idea behind the
use of capacitors. By storing a fixed amount of energy in the capacitor, it
provides the reserve of extra power needed to start and run a motor.
Without this energy source, motors would have to be much bigger and
more complex.

WARNING
A capacitor can store a charge for a considerable
length of time after the power has been turned off.
This charge can be very dangerous. An electrolytic
capacitor charged with only 10 or 15 volts can melt
the tip of the end of a screwdriver when placed
across the terminals. A high voltage capacitor can
store a charge that could be lethal. Never touch the
terminals of a capacitor without first discharging it.
Capacitor Testing
Capacitors are an integral part of the system and must be checked along
with the motor when a problem occurs.
SRM-HW/HWC 8/99

Check to make sure that the capacitor is correctly rated for the application. Confirm that the right capacitor is being used for the application.

Service Reference Manual

TROUBLESHOOTING
9-7
The following information is found on a capacitor: the MFD (microfarad
rating) and the working voltage. Compare this to the rating plate on the
motor or the information provided with the unit.
The following are some of the problems that could be caused by a
defective or incorrect capacitor:
•

Motor overheating (internal thermal overload tripped)

•

Motor refuses to start

•

Intermittent problems with blown fuses or breaker tripped

•

High electrical consumption

•

Motor rotates in the wrong direction

•

Contactor overheating or melted contacts

•

Motor vibration

Any one of the above faults could be attributed to the capacitor. Therefore, the capacitor must be checked out before a determination is made of
the problem.
In the past, the old method of swinging the meter needle to tell if the
capacitor was good or not could be used. When the terminal of the
capacitor was touched with the meter probes, the meter needle would
swing over than back to zero. If it didn’t, it could be assumed that the
capacitor had failed. There are many problems with this technique.
Swinging the meter needle only proves that the capacitor will take a
charge, but not how much of a charge. In some cases, when a capacitor
starts to break down it still will take a charge (but the number of electrons
that it can hold is greatly reduced). The capacitor must take the correct
charge as originally designed so that the motor will work as it should. A
much more accurate method must be used to determine the condition of
the capacitor before the decision on its condition can be made.
The best method is to use a meter that is capable of reading capacitance.
This gives a very accurate indication of the condition of the capacitor. If a
meter that is able to do this is not available, then another way to determine the condition of the capacitor must be found.
In order to do this, several things will be needed: a volt ohm meter, an
amp meter and a calculator. A set of test leads will also need to prepared
to do this test. Make the test leads with a loop (10 loops) in one of the
leads. The ten loops in the lead will cause the amp meter reading to be
multiplied by “ten”. This will make it much easier to read very low amp
meter readings and will be helpful when doing the following test.

SRM-HW/HWC 8/99

Connect the alligator clips of the test leads to the terminals on the capacitor. Hook the amp meter through the 10 loops of wire on the test lead
(see Figure 9-1 on page 9-8).

TROUBLESHOOTING

Magic-Pak: HW/HWC

9-8
Ammeter
(10 Loops)

Fuse
Nominal
Voltage
Source

FIGURE 9-1

Voltmeter

Capacitor
To Be Tested

Determining Capacitance (MFD) Rating with a Test
Cord

Before starting the test, take a reading of the line voltage at the outlet that
will be used.
Double check the connections, making sure that the amp meter is on.
Plug the test leads into the wall outlet. Wait a few seconds and read the
amp meter (CAUTION: there is only approximately ten seconds to do this
or the capacitor could be damaged). Unplug the jumper and record the
readings.
Using the calculator, divide the amp meter reading by ten (the number of
loops in one of the test leads). This is the correct amp reading which is
needed to finish the calculations. This information and the voltage at the
outlet is all that is needed to calculate the capacitance of the capacitor.
2650 x Amps
Volts

= Capacitance (MFD)

In the following calculation, a constant multiplier (2650) is used for 60 Hz
electrical systems.*
2650 x 1 Amp
115 Volts

= 23 MFD

Example
This calculation provides the actual capacitance of the capacitor. Compare this reading to the listed rating on the capacitor. It should be within
+/– 10% of the actual capacitor rating. If it does not fall within this range,
the capacitor is defective and should be replaced.
The capacitor should always be checked before replacing an electric
motor. Eliminate the capacitor as a possible cause of the problems
before the decision is made to replace the motor. A good practice is also
to replace the capacitor whenever a motor is replaced, as the capacitor
does have a service life cycle. The capacitor is a very important part of
the motor electrical system. Always check the capacitor along with the
motor when a fault is noted.

SRM-HW/HWC 8/99

*For 50 Hz electrical systems, use 3180 as the constant multiplier.

Service Reference Manual

TROUBLESHOOTING
9-9

Performance
Performance Checkout
HW/HWC chassis come with a pre-charged chassis assembly. The
chassis assembly is designed in a way that the unit may be run independently of the HWC unit. When the chassis is run on a floor or bench, the
performance measurements will be affected due to the change in static
pressures, recirculated air, excessive temperatures and equal ambient
temperatures from indoor to outdoor.
Two sets of tables are provided in this section to address these issues.
Tables 9-1 to 9-4 are to be used when the chassis is still installed in the
complete unit. Tables 9-5 and 9-6 are to be used when the chassis is run
independently outside of the unit.
Note: Pressures may vary +/– 10 psi. Temperatures may vary =/– 2-3°F.

Performance Tests (Chassis Installed in Unit)
TABLE 9-1

HWC122 Performance Test (Chassis Installed)
Outdoor Air Temperature Entering Outdoor Coil
95°

85°

105°

115°

Total
Enter.
Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid
Air Vol.
DB/WB
Pressure Temp. Temp. Pressure Temp. Temp. Pressure Temp. Temp. Pressure Temp. Temp.
(CFM)
400
81
49
87
82
49
97
84
50
107
85
51
117
83
54
87
84
50
97
86
51
107
87
52
117
75°/63° 450
500
85
60
87
86
52
97
88
52
107
89
53
117
400
87
63
87
88
53
97
89
53
107
91
54
117
88
68
88
90
58
97
91
54
107
93
55
117
80°/67° 450
90
73
88
92
63
97
93
57
107
95
56
117
500
92
74
88
93
64
97
94
56
108
96
57
117
400
85°/71° 450
94
79
88
95
71
97
96
62
108
98
58
117
96
84
88
97
74
97
98
65
108
100
59
117
500

Based on a normally installed cooling chassis
TABLE 9-2

HWC182 Performance Test (Chassis Installed)
Outdoor Air Temperature Entering Outdoor Coil
95°

85°

105°

115°

SRM-HW/HWC 8/99

80°/67°

85°/71°

550
600
650
550
600
650
550
600
650

80
82
84
86
87
99
91
93
95

49
54
59
62
67
72
73
78
83

96
96
96
98
98
98
99
99
99

Based on a normally installed cooling chassis

81
83
85
88
89
91
93
95
97

48
50
52
53
58
62
64
70
74

106
106
106
106
107
107
107
108
108

84
86
88
90
91
93
95
97
99

50
51
52
54
54
57
56
63
66

114
114
114
115
116
116
116
117
117

86
88
90
92
94
95
97
99
101

51
52
54
55
56
56
58
59
60

123
123
124
124
125
125
125
126
126

TROUBLESHOOTING

Magic-Pak: HW/HWC

9-10
Performance Tests (Chassis Installed in Unit) - cont.
TABLE 9-3

HWC242 Performance Test (Chassis Installed)
Outdoor Air Temperature Entering Outdoor Coil
95°

85°

105°

115°

Total
Enter.
Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid
Air Vol.
DB/WB
Pressure Temp. Temp. Pressure Temp. Temp. Pressure Temp. Temp. Pressure Temp. Temp.
(CFM)
700
77
47
98
78
46
108
79
47
117
80
48
128
79
52
98
80
47
108
81
48
117
82
49
128
75°/63° 800
900
81
57
99
82
50
109
83
49
118
84
50
128
700
82
60
99
83
51
109
85
50
118
86
51
128
84
65
100
85
56
109
87
52
119
88
52
129
80°/67° 800
86
70
100
87
60
110
89
55
119
90
53
129
900
87
71
100
88
61
110
89
53
119
90
54
129
700
85°/71° 800
89
76
101
90
68
110
91
59
120
92
55
130
91
81
101
92
71
110
93
62
120
94
56
130
900

Based on a normally installed cooling chassis
TABLE 9-4

HWC302 Performance Test (Chassis Installed)
Outdoor Air Temperature Entering Outdoor Coil
85°

95°

105°

115°

Total
Enter.
Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid Suction Suction Liquid
Air Vol.
DB/WB
Pressure Temp. Temp. Pressure Temp. Temp. Pressure Temp. Temp. Pressure Temp. Temp.
(CFM)
775
76
46
100
77
46
110
78
46
120
79
47
129
78
51
100
79
47
110
80
48
120
81
48
129
75°/63° 850
925
80
57
100
81
49
111
82
49
120
83
50
130
775
82
60
102
84
51
111
85
51
121
87
52
131
84
65
102
85
56
112
87
52
121
88
53
131
80°/67° 850
85
70
102
87
60
112
88
54
121
89
53
131
925
89
72
103
90
63
112
92
55
122
93
55
132
775
85°/71° 850
91
77
104
92
69
113
94
61
123
95
57
133
93
82
104
94
72
113
96
64
123
97
58
133
925

Based on a normally installed cooling chassis

SRM-HW/HWC 8/99

Service Reference Manual

TROUBLESHOOTING
9-11

Performance Tests (Chassis Bench Tested)
TABLE 9-5

70 - 80° Ambient Temperature Chassis Bench Test

Chassis
Model

Ambient
Temp.
DB/WB

Disch.
Pressure

Disch.
Temp.

Liquid
Pressure

Liquid
Temp.

Suction
Pressure

Suction
Temp.

Total
Amps

Comp.
SH

Subcooling

122, 123

75°/63°

175 psi

120°

170 psi

78°

78 psi

53°

5.0

182, 183

75°/63°

200 psi

107°

190 psi

80°

82 psi

54°

8.3

242, 243

75°/63°

205 psi

99°

200 psi

81°

71 psi

50°

10.7

302, 303

75°/63°

205 psi

153°

200 psi

84°

70 psi

62°

13.5

TABLE 9-6

95° Ambient Temperature Chassis Bench Test

Chassis
Model

Ambient
Temp.
DB/WB

Disch.
Pressure

Disch.
Temp.

Liquid
Pressure

Liquid
Temp.

Suction
Pressure

Suction
Temp.

Total
Amps

Comp.
SH

Subcooling

122, 123

95°/79°

270 psi

154°

270 psi

99°

110 psi

83°

6.0

182, 183

95°/79°

310 psi

141°

305 psi

106°

110 psi

68°

10.2

242, 243

95°/79°

325 psi

153°

310 psi

114°

101 psi

69°

14.2

302, 303

95°/79°

305 psi

177°

300 psi

105°

88 psi

86°

16.4

Charge Weights

SRM-HW/HWC 8/99

TABLE 9-7

HWC Refrigerant Charge Weights

Model

Refrigerant Charge

HWC122/123

42 oz.

HWC182/183

56 oz.

HWC242/243

58 oz.

HWC302/303

59 oz.

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