magicpac HWC9 Installation Manual
INSTALLATION INSTRUCTIONS
HWC9 V-Series
This manual must be left with the homeowner for future reference.
This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to
the potential for personal injury or death.
TM
Models
Table of Contents
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must be
performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
WARNING
Do not store combustible materials near the furnace or
warm air ducts. The material may ignite by spontaneous
combustion creating a re hazard.
WARNING
Unit Dimensions ..........................................................2
Installation ...................................................................3
Electrical Connections .................................................9
Start-Up .....................................................................13
Operation ...................................................................13
Maintenance ..............................................................14
Wiring Diagrams ........................................................20
WARNING
For your safety, do not store or use gasoline or other
ammable vapors and liquids in the vicinity of this or any
other appliance. Such actions could result in property
damage, personal injury, or death.
These units are not approved for mobile home
applications. Such use could result in property damage,
personal injury, or death.
Installation shall be made in accordance with the
requirements of the local utility and other authorities
CAUTION
If these instructions are not followed exactly, a re
or explosion may result causing property damage,
personal injury, or loss of life.
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
Check that equipment complies with all applicable building codes, laws, and regulations for its intended use prior to installation.
507389-03 Issue 2110
having jurisdiction, or with the National Fuel Gas
Code, ANSI Z223.1 (latest edition) and the National
Electrical Code. Any alteration of internal wiring will void
certication and warranties.
*P507389-03*
CAUTION
(P) 507389-03
Page 1 of 22
27-7/8
Unit Dimensions
Line Voltage
Box
Low
Voltage
Supply
1/2 Gas Inlet
161
Supply
1-1/2
2-3/4
1-3/4
8
13-3/8
81
Supply
Condensate
18-1/4
2
Drain
(HWC9 Only)
2
43-3/16
Return
2-7/8
Page 2 of 22 507389-03Issue 2110
22
61
Return
29-7/16
Installation
General
These instructions must be hung on or near the furnace in
a conspicuous place.
The MagicPak All-In-One™ HVAC system model HWC9
V-Series™ units are self-contained, gas-red heating with
electric cooling models. The unit design has been certied
by Intertek Testing Services for compliance with the latest
edition of the American National Standard – ANSI Z21.47/
National Standard of Canada – CAN/CGA-2.3 for direct
vent central furnaces. The HWC9 models are certied
to be in compliance with the latest edition of A.H.R.I.
Standard 210/240. All models are design certied for
heating operation when red with natural or propane gas.
These installation instructions are intended as a general
guide only, for use by an experienced, qualied contractor.
Inspection
The unit is shipped in one package, completely assembled
and wired. The Evaporator drain tubing is in the cooling
compartment behind the lter access panel. Fittings for
furnace condensate drainage are located in the hardware
kit bag.
If any damage is found, proper notation should be made on
the carrier’s freight bill. Damage claims should be led with
the carrier as quickly as possible.
Check the rating plate to conrm heating and cooling
capacities. The unit should be operated only with the type
of gas and electrical supply noted on the rating plate.
NOTE: Remove the chassis hold down shipping bracket
before installation. These brackets are located on the
outdoor side of the unit below the louver panels.
Location
The design is certied for indoor installation only. The
interior portions of the unit may be surrounded by a closet
with minimum clearances to combustible material of 0”
sides, 2” top, and 1” front and plenum. Adequate clearance
must be provided to install gas line union and manual
shuto valve , condensate drain connections as well as
providing accessibility for eld wiring.
NOTE: Approximately 2” of clearance is required if using
side exit furnace condensate drain connection. 2” to 4” of
clearance (depending on choice of ttings) is required if
using front exit furnace condensate drain connection. Do
not install directly on carpeting, tile, or other combustible
material other than wood ooring.
The grille side of the unit may be ush 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.
If the unit is to be enclosed, provisions should be made
allowing access to the indoor side of the unit for changing
lters and for inspection. At least 29” of unobstructed space
should be provided in front of the indoor side, whether
enclosed or not, to permit removal of the cooling chassis
should repairs or inspection be required.
If the unit is installed in a residential garage, it must be
located or protected to avoid physical damage by vehicles.
Unit must be installed so the burners and ignition source
are not less than 18” (457 mm) above the oor. This unit
must be installed so that no electrical components are
exposed to water.
WARNING
In the State of Massachusetts:
This product must be installed by a licensed Plumber
or Gas Fitter. When exible connectors are used, the
maximum length shall not exceed 36”. When lever-type
gas shutos are used, they shall be T-handle type.
507389-03 Issue 2110 Page 3 of 22
This appliance should be installed in a location such that
the vent outlet is located in the following manner:
1. Distances to windows that open, building openings, or
public walkways should be consistent with the National
Fuel Gas Code Z223.1 or CAN/CGA-B149.1 & .2.
2. For U.S. installations, the vent system shall terminate
a minimum horizontal clearance of 4’ from electric
meters, regulators, and relief equipment. For
installations in Canada, refer to the current CAN/
CGA-B149.1 & .2 or with the authorities having local
jurisdiction.
3. Flue products will not cause degradation to building
materials.
This furnace design is not listed for installation in mobile
homes, recreational vehicles, or outdoors.
Use of Furnace as a Construction Heater
Allied Air does not recommended the use of these units
as a construction heater during any phase of construction.
Very low return air temperature, harmful vapors and
operation of the unit with clogged or misplaced lters will
damage the unit.
Units may be used for heating of buildings or structures
under construction, if the following conditions are met:
• The unit must be permanently installed per these
installation instructions.
• A room thermostat must control the furnace. The use
of xed jumpers that will provide continuous heating is
not allowed.
• The return air duct must be provided and sealed to the
furnace.
• Return air temperature range between 60°F (16°C)
and 80°F (27°C) must be maintained.
• Air lters must be installed in the system and must be
maintained during construction.
• Air lters must be replaced upon construction
completion.
• The input rate and temperature rise must be set per
the furnace rating plate.
• One hundred percent (100%) outdoor air must be
provided for combustion air requirements during
construction.
• The furnace heat exchanger, components, duct
system, air lters and evaporator coils must be
thoroughly cleaned following nal construction clean-
up.
• All furnace operating conditions (including ignition,
input rate, temperature rise and venting) must be
veried according to these installation instructions.
Installing with a Wall Sleeve
Refer to the installation instructions packed with the wall
sleeve and Figure 1 for guidance in assembly and mounting
using a wall sleeve.
• 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 weather-tight to prevent entrance of
moisture and water into the building.
• Assure that the unit is completely seated against the
gaskets on the wall sleeve.
• Slide the unit into the sleeve. When properly nested,
the angle on top of the unit should line up with the top
ange of the sleeve and should almost touch. Fasten
the unit to the sleeve with ve screws furnished with
the sleeve.
CAUTION
The sleeve is not intended as the sole support for the
unit. An 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.
Wall Sleeve
.
n
" Mi
8
2
F
LO
O
R
Plywood
Figure 1. HWC Installation
Page 4 of 22 507389-03Issue 2110
""
6 x 22 Minimum Opening
to Align with Return Air
Opening in Unit.
Vibrat ion Isol ating Mater ial
Evaporator Condensate Drain
Install the plastic drain tube (furnished) over the 5/8” O.D.
tting in the center of the Evaporator condensate pan.
Connect other end of the drain tube to the open trap (see
Figure 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’ of horizontal run to the open drain trap.
Be certain that the plastic drain tube has free drainage and
is not crimped or attened at any bend.
Drain Pan
Alternative
Method
To Open
Drain Trap
Return
Air Duct
" I .D.
5/8
Plastic Tube
(Suppli ed)
Top of Drain Tube
Must be Below
Bottom of Drain Pan
Drain Tube - Pit ch 1"
for every 10 ft .
(Field Supplied)
Open Drain Trap
Figure 2. HWC Evaporator Condensate Drain
Installation
Furnace Condensate Drain
The HWC9 furnace is provided with an internal condensate
drain and drain tting. A street elbow, a hose barb and a
spigot adapter for connection to the drain tting are factorysupplied in the manual bag. All other piping is eld-supplied
to suit the installation and local codes.
If the furnace is installed in an unconditioned space, the
condensate drain elbow outside the unit cabinet must
have heat tape suitable for PVC pipe installed, and the
elbow insulated. This heat tape and insulation are eld-
supplied from standard hardware items that are available
locally, and they must be installed in accordance with the
instructions provided by their manufacturers.
Units are shipped with the drain tting installed for side-exit
condensate drainage. The drain tting can be repositioned
for front-exit condensate drainage if desired. Do not
relocate or remove the internal condensate trap.
If unit will be started immediately upon completion of
installation, the drain must be primed as described in the
procedure outlined in the “Start-up” section.
Field-installed piping from the furnace must slope downward
a minimum of 1/2” per foot toward the oor drain.
Piping for Side-Exit Condensate Drain
Determine whether the installation better suits a side-exit or
a front-exit furnace condensate drain. For side condensate
drain, see Figure 3 for component locations and additional
details. A 2” clearance to the cabinet side is required for
service access to the condensate drain tting when using
the side location.
1. Install the factory-supplied street elbow to the drain
tting by threading into place. Use a thread sealant
suitable for PVC; do not use thread tape.
2. Use the appropriate primer and solvent cement to
bond eld-supplied drain line piping or ttings to the
PVC street elbow. Do not use copper tubing or existing
copper condensate lines for drain line.
3. Route the piping to an open oor drain. Do not connect
directly to evaporator condensate drain line.
Side Panel
Upper Drain Hose
(from Collector Box)
Lower Drain Hose
(to drain tting)
Condensate
Trap
Drain Fitting
Install threaded street elbow into
drain tting. Solvent weld piping to
street elbow.
Figure 3. Furnace Condensate Drain Component Locations - Side Exit
507389-03 Issue 2110 Page 5 of 22
Condensate
Trap
Install threaded hose barb or
threaded spigot adapter into
drain tting
Threaded
Hose Barb
Side Panel
Upper Drain Hose
(from Collector Box)
Lower Drain Hose
(to drain tting)
Drain Fitting
(repositioned to front)
Grommet Plug
(remove from access panel
and use here)
5/8” ID Tubing
(eld provided)
Figure 4. Furnace Condensate Drain Component Locations - Front Exit
Piping for Front-Exit Condensate Drain
For front condensate drain, see Figure 4 for component
locations and additional details. Use the factory-supplied
hose barb with eld-supplied exible tubing or spigot and
hose coupling for these installations. A 2” or 4”(depending
of choice of ttings) clearance to the cabinet front is
required for service access when using the front location.
The modications necessary to convert to front-exit
condensate drain are:
1. Disconnect the lower drain hose from the drain tting.
2. Remove the screw securing the drain tting to the
division panel.
3. Remove the drain tting and rotate it so that it faces
the front of the furnace.
4. Replace the securing screw.
5. Disconnect lower drain hose from drain trap and rotate
the hose so that the angled end will connect to the
drain tting in its new orientation.
Spigot adapter with hose coupling
and clamps
6. Reconnect the lower drain hose to the drain trap and
drain tting. Verify hose level to allow drainage.
7. Remove the grommet plug from the front access panel
and insert it into the oval opening in the side panel.
8. Remove the perforated insulation from inside the front
access panel around the oval opening. Be sure the
area is clean and free of insulation and glue, as it will
be used as a sealing surface for the drain tting gasket.
9. Prior to setting the unit into operation, replace the
access panel.
10. Install the factory-supplied hose barb or spigot adapter
to the drain tting by threading into place. Use a thread
sealant suitable for PVC; do not use thread tape.
11. For the hose barb tting, ax a suitable length of
exible tubing and route to an open oor drain. Secure
the end of the tubing to the drain. Do not connect
directly to evaporator condensate drain line.
Page 6 of 22 507389-03Issue 2110
12. For the spigot adapter, attach the provided rubber
coupling and then route 3/4” PVC pipping to an open
oor drain. Do not connect directly to evaporator
condensate drain line.
Combustion Air
This unit is a direct-vent furnace which obtains all air
needed for combustion from outdoors.
WARNING
Insucient combustion air can cause headaches,
nausea, dizziness or asphyxiation. It will also cause
excess water in the heat exchanger resulting in rusting
and premature heat exchanger failure. Excessive
exposure to contaminated combustion air will result
in safety and performance related problems. Avoid
exposure to the following substances in the combustion
air supply:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine base swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
Venting
The venting system is an integral part of the appliance.
The venting system must not be modied or added on
to.
The unit contains a combustion inducer. The inducer
draws the combustion products out of the heat exchanger
and forces them from the unit to the outside. No special
provisions are required for supplying air for combustion,
nor is a chimney required.
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 deciencies
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 replace 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
5 minutes of main burner operation. Use the ame 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, replace 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
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 vent outlet must not be altered or extended.
The venting system is designed for proper operation under
all weather conditions and for winds up to 31 m.p.h.
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
507389-03 Issue 2110 Page 7 of 22
The units supplied for operation with natural gas contain
a gas regulator which must be operated with inlet gas
pressures specied on the rating plate. If gas line pressure
exceeds this gure, an additional high pressure regulator
must be installed to reduce this pressure.
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 13” W.C.
maximum. A regulator is also required on the propane tank.
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