magicPak HWC8 Installation Manual
INSTALLATION INSTRUCTIONS
HWC8 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 .................................................7
Start-Up .....................................................................11
Operation ...................................................................12
Maintenance ..............................................................14
Wiring Diagrams ........................................................17
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.
507388-03 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.
*P507388-03*
CAUTION
(P) 507388-03
Page 1 of 19
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 19 507388-03Issue 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 HWC8
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 for direct vent central furnaces. The HWC8 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.
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.
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.
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.
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.
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.
2. For U.S. installations, the vent system shall terminate
a minimum horizontal clearance of 4’ from electric
meters, regulators, and relief equipment.
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.
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 held
to 0” sides, 2” top, and 1” front and plenum. Adequate
clearance must be provided to install gas line union and
manual shuto valve as well as providing accessibility for
eld wiring. Do not install directly on carpeting, tile, or other
combustible material other than wood ooring.
507388-03 Issue 2110 Page 3 of 19
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 2 for guidance in assembly and mounting
using a wall sleeve.
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
Alternati ve
Method
To Open
Drain Trap
Return
Air Duc t
5/8
" I . D.
Plasti c Tube
(Suppli ed)
Top of Drain Tube
Must be Below
Bottom of Drai n Pan
Drain Tube - Pitch 1"
for every 10 ft.
(Field Suppli ed)
Open Drain Trap
Figure 1. HWC Evaporator Condensate Drain
Installation
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.
.
n
" Mi
8
2
F
L
O
O
R
Figure 2. HWC Installation
Plywood
6 x 22 Minimum Opening
""
to Ali gn with Return Ai r
Opening in Uni t.
Vibrat ion Isolat ing Material
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 1). 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.
Page 4 of 19 507388-03Issue 2110
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
Combustion Air
This unit is a direct - vent furnace which obtains all air
needed for combustion from outdoors.
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
together with dilution air and forces the mixture from the
unit to the outside. No special provisions are required for
supplying air for combustion, nor is a chimney required.
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) 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.
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.
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.
507388-03 Issue 2110 Page 5 of 19
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.
If local codes allow use of a exible gas connector, a new
listed connector must be used. Do not use a connector
which has previously serviced another gas appliance.
CAUTION
If a exible gas connector is required or allowed by
the authority that has jurisdiction, black iron pipe shall
be installed at the gas valve and extend outside the
furnace cabinet. The exible connector can then be
added between the black iron pipe and the gas supply
line.
IMPORTANT
Compounds used on threaded joints of gas piping must
be resistant to the actions of liqueed petroleum gases.
Figure 3. Gas Supply Piping
CAUTION
Never use a ame to check for gas leaks. Explosion
causing injury or death may occur.
A manual shuto 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
shuto valve. This will facilitate removal of controls and
manifold. See Figure 3 for recommended placement of the
union.
Provide a drip leg in the supply piping located exterior
to the unit. Piping connections must be sealed with nonhardening pipe joint compound resistant to propane.
WARNING
The furnace must be isolated from the gas supply piping
system by closing the individual manual shuto 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 shuto
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-
ring of the burners and improper burner operation.
This action may produce a high concentration of carbon
monoxide which can result in asphyxiation.
Leak Check
After gas piping is completed, carefully check all piping
connections (factory and eld installed) for gas leaks. Use
a leak detecting solution or other preferred means.
NOTE: If emergency shuto is necessary, shut o the main
manual gas valve and disconnect the main power to the
furnace. The installer should properly label these devices.
CAUTION
Some soaps used for leak detection are corrosive to
certain metals. Carefully rinse piping thoroughly after
leak test has been completed. Do not use matches,
candles, ame or other sources of ignition to check for
gas leaks.
Page 6 of 19 507388-03Issue 2110
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