Magic-Pak HWC8-12 User manual
Page 1 of 18507388-01 Issue 1504
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
If these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal
injury, or loss of life.
CAUTION
These units are not approved for mobile home applicaons.
Such use could result in property damage, personal injury,
or death.
WARNING
Do not store combusble materials near the furnace or
warm air ducts. The material may ignite by spontaneous
combuson creang a re hazard.
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.
WARNING
Installaon shall be made in accordance with the requirements of the local ulity and other authories having jurisdicon, or with
the Naonal Fuel Gas Code, ANSI Z223.1 (latest edion) and the Naonal Electrical Code in the United States or CAN/CGA-B149.1 &
.2 and the Canadian Electrical Code CSA C22.1 Part 1 (latest edion) in Canada. Any alteraon of internal wiring will void cercaon
and warranes.
CAUTION
Save these instrucons for future reference
HWC8 V-SeriesTM Models
INSTALLATION INSTRUCTIONS
TABLE OF CONTENTS
INSTALLATION.................................................................2
START-UP ........................................................................9
OPERATION...................................................................10
MAINTENANCE .............................................................10
WIRING DIAGRAMS ......................................................16
Manufactured By
Allied Air Enterprises LLC
A Lennox International Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
*P507388-01*
*P507388-01*
Page 2 of 18 507388-01Issue 1504
clearances to combusble material held to 0” sides, 2” top, and
1” front and plenum. Adequate clearance must be provided to
install the union and manual shuto valve as well as providing
accessibility for eld wiring. Do not install directly on carpeng,
le, or other combusble 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 locang 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
inspecon. 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 inspecon be
required.
If the unit is installed in a residenal garage, it must be located
or protected to avoid physical damage by vehicles. Unit must be
installed so the burners and ignion 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 locaon 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 Naonal Fuel Gas
Code Z223.1 or CAN/CGA-B149.1 & .2.
2. For U.S. installaons, the vent system shall terminate a
minimum horizontal clearance of 4’ from electric meters,
regulators, and relief equipment. For installaons in Canada,
refer to the current CAN/CGA-B149.1 & .2 or with the
authories having local jurisdicon.
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.
INSTALLATION
General
These instrucons must be hung on or near the furnace in a
conspicuous place.
The HWC8 V-Series™ units are self-contained, gas-red heang
with electric cooling models. The unit design has been cered by
Intertek Tesng Services for compliance with the latest edion of
the American Naonal Standard – ANSI Z21.47/Naonal Standard
of Canada – CAN/CGA-2.3 for direct vent central furnaces. The
HWC8 models are cered to be in compliance with the latest
edion of A.H.R.I. Standard 390. All models are design cered
for heang operaon when red with natural or propane gas.
These installaon instrucons 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 notaon should be made on the
carrier’s freight bill. Damage claims should be led with the
carrier as quickly as possible.
Check the rang plate to conrm heang and cooling capacies.
The unit should be operated only with the type of gas and
electrical supply noted on the rang plate.
IMPORTANT: Remove the chassis hold down shipping bracket
before installaon. These brackets are located on the outdoor
side of the unit below the louver panels.
Location
The design is cered for indoor installaon only. The interior
portions of the unit may be surrounded by a closet with
In the State of Massachuses:
This product must be installed by a licensed Plumber or Gas
Fier. 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.
WARNING
Install operate and maintain unit in accordance with
manufacturer’s instrucons. The State of California has
determined that this product may contain or produce
chemicals, in very low doses, which may cause serious
illness or death. it may also cause cancer, birth defects or
reproducve harm.
WARNING
Page 3 of 18507388-01 Issue 1504
The sleeve is not intended as the sole support for the unit.
An addional support must be provided near the return
opening on the unit for adequate support. The use of
vibraon isolaon material between the unit and the support
is recommended.
CAUTION
•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 filters 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 installaon instrucons packed with the wall sleeve
and Figure 1 for guidance in assembly and mounng using a
wall sleeve.
Make sure the gaskets aached to the sleeve are not damaged.
Page 4 of 18 507388-01Issue 1504
Figure 1
HWC Installaon
Plywood
28" Min.
Wall Sleeve
Vibration Isolating Material
FLO
O
R
6 x 22 Minimum Opening
to Align with Return Air
Opening in Unit.
""
Figure 2
HWC Evaporator Condensate Drain Installaon
Drain Pan
Open Drain Trap
Return
Air Duct
To Open
Drain Trap
Alternative
Method
5/8
" I . D.
Plastic Tube
(Supplied)
Top of Drain Tube
Must be Below
Bottom of Drain Pan
Drain Tube - Pitch 1"
for every 10 ft.
(Field Supplied)
Evaporator Condensate Drain
Install the plasc drain tube (furnished) over the 5/8” O.D. ng
in the center of the Evaporator condensate pan. Connect other
end of the drain tube to the open trap (see Figure 2). The plasc
drain connecon 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 plasc drain tube has free drainage and is not
crimped or aened at any bend.
Seal the space between the wall sleeve and the building opening
with non-hardening caulking compound. The seal must be
weatherght to prevent entrance of moisture and water into
the building.
Assure that the unit is completely seated against the gaskets on
the wall sleeve.
Installing Without a Wall Sleeve
Refer to the following direcons and Figure 1 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. Posion the unit so that the grilles on the outside face of the
unit are ush 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 non-hardening caulking compound. The seal must be
weatherght to prevent entrance of moisture and water into
the building. Make sure the drain holes in the base are not
plugged with caulking.
COMBUSTION AIR
This unit is a direct - vent furnace which obtains all air needed
for combuson from outdoors.
Page 5 of 18507388-01 Issue 1504
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 lighng instrucons, place the unit being
inspected in operation. Adjust the thermostat so the
appliance will operate connuously.
5. Test for spillage at the dra control relief opening aer 5
minutes of main burner operaon. Use the ame of a match
or candle.
6. Follow the preceding steps for each appliance connected to
the common venng system.
7. Aer it has been determined that each appliance remaining
connected to the common venng system properly vents
when tested as outlined above, return doors, windows,
exhaust fans, replace dampers, and any other fuel burning
appliance to their previous condion of use.
8. If improper venng is observed during any of the above tests,
the common venng system must be corrected. See Naonal
Fuel Gas Code, ANSI Z223.1 (latest edion) or CAN/CGA
B149.1 & .2 Canadian Installaon Codes to correct improper
operaon of common venng system.
Gas Connecons
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 ulity or Naonal Fuel Gas
Code for complete details on special requirements in sizing gas
piping.
The units supplied for operaon with natural gas contain a
gas regulator which must be operated with inlet gas pressures
specied on the rang plate. If gas line pressure exceeds this
gure, an addional 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 operaon 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.
Venting
The venng system is an integral part of the appliance. The
venng system must not be modied or added on to.
The unit contains a combuson inducer. The inducer draws
the combuson products out of the heat exchanger together
with diluon air and forces the mixture from the unit to the
outside. No special provisions are required for supplying air for
combuson, nor is a chimney required.
The vent outlet must not be altered or extended.
The venng system is designed for proper operaon under all
weather condions and for winds up to 31 m.p.h.
Removal of Unit from Common Venng System
When an exisng furnace is removed from a common venng
system serving other appliances, the venng system is likely to be
too large to properly vent the remaining aached appliances. The
following test should be conducted with each appliance while
the other appliances connected to the common venng system
are not in operaon.
1. Seal any unused openings in the common venng system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restricon, leakage, corrosion, or other deciencies which
could cause an unsafe condion.
3. Insofar as is praccal, close all building doors and windows
between the space in which the appliances remaining
connected to the common venng system are located and
other spaces in the building. Turn on clothes dryers and any
appliance not connected to the common venng system.
Insufficient 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
WARNING
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.
CAUTION
Page 6 of 18 507388-01Issue 1504
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 must be ght and non-hardening. Pipe compound
resistant to propane must be used.
Electrical Connecons
All wiring must be done in accordance with the National
Electrical Code, ANSI/NFPA No. 70 (latest edion); Canadian
Electrical Code Part 1, CSA C22.1 (latest edion); or local codes,
where they prevail. Any alteraon of internal wiring will void
cercaon and warranty.
The rang plate indicates the operang voltage, phase, minimum
circuit ampacity, maximum fuse size, and minimum voltage. Units
must never be installed where voltage exceeds 10% over the
voltage indicated on the rang 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
connecon on unit transformer from 240 volt terminal to 208
volt terminal as shown on the wiring diagram.
Failure of the compressor as a result of operaon on improper
voltage voids the compressor replacement warranty.
A separate electric line with wire having a temperature rang of
60°C should be run directly from the main supply panel to the
leads in the unit. Refer to the rang 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 Naonal Electrical Code, ANSI/NFPA No. 70 (latest
The furnace must be isolated from the gas supply piping
system by closing the individual manual shutoff valve
during any pressure tesng 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 overring of the burners and
improper burner operaon. This acon may produce a
high concentraon of carbon monoxide which can result
in asphyxiaon.
WARNING
Figure 3
Gas Supply Piping
Leak Check
After gas piping is completed, carefully check all piping
connecons (factory and eld installed) for gas leaks. Use a leak
detecng soluon or other preferred means.
NOTE: If emergency shutoff is necessary, shut off the main
manual gas valve and disconnect the main power to the
furnace. The installer should properly label these devices.
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.
CAUTION
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
Electrostatic discharge can affect electronic components.
Take precautions during furnace installation and service
to protect the furnace’s electronic controls. Precautions
will help to avoid control exposure to electrostatic
discharge by putting the furnace, the control and
the technician at the same electrostatic potential.
Neutralize electrostatic charge by touching hand and
all tools on an unpainted unit surface, such as the gas
valve or blower deck, before performing any service
procedure.
CAUTION
Compounds used on threaded joints of gas piping must
be resistant to the actions of liquied petroleum gases.
IMPORTANT
Never use a ame to check for gas leaks. Explosion causing
injury or death may occur.
CAUTION
Page 7 of 18507388-01 Issue 1504
edion) for installaons in the U.S. or the Canadian Electrical
Code Part 1, CSA C22.1 (latest edion) for installaons in Canada.
See rang plate for correct wire ampacity for the cooling chassis
required, and size wire accordingly.
Thermostat
Install the thermostat according to the direcons furnished with
it. The thermostat must be located on an inside wall where it will
not be aected by dras, 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 aached
to the unit. The heat ancipator seng is 0.50 amp.
Air Filter
All indoor return air must be ltered. A permanent-type lter is
furnished with the unit, located directly behind the access panel.
Removing the panel permits access to the lter. See Figure 3.
If an installaon is made in which it is more desirable to mount the
lter exterior to the unit, in the return duct work or elsewhere, the
permanent lter can be used or replaced with a disposable lter.
If a disposable lter is used, refer to the informaon provided in
Table 1 when sizing the disposable lter.
Supply and Return Duct(s)
Provide duct(s) sized suciently to handle the larger of the air
volumes for heang or cooling provided by this model.
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.
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 boom of the unit and ange the duct over the
exisng anges around the opening inside the unit. Make sure
that all sides of the duct are anged over to permit removal of
the cooling chassis if required. Use a exible connecon to aach
the remainder of the return duct. The return duct should be
sealed to the unit casing and must terminate outside the space
containing the furnace.
x3600 x
=Cubic Feet Per RevoluonBTU/HR
INPUT # Seconds Per Revoluon
Heang
Value
Adjustments – Heang Secon
Temperature Rise
At me of installaon, the temperature rise must be adjusted to
be within the range specied on the unit rang plate. See table 2.
Pressure Regulator
he gas input must not exceed the gures shown on the rang plate.
The unit is equipped for rated inputs with manifold pressures of:
3.5” W.C. for natural gas and 10.5” W.C. for propane.
The manifold pressure can be measured by removing the pipe
plug in the automac gas valve. Connect a water manometer and
measure the pressure.
Only small variaons in gas input may be made by adjusng the
regulator. In no case should the nal manifold pressure vary
more than 0.3” W.C. for natural gas or 0.7” W.C. for propane.
To adjust the regulator, turn the adjusng screw on the regulator
clockwise to increase pressure and input or counterclockwise to
decrease pressure and input.
For natural gas installaons, check the burner rate by observing
the gas meter (making sure that all other gas appliances are
turned o). The test hand on the meter should be med for
at least one revoluon. Note the number of seconds for one
revoluon.
Adjustments – Cooling Secon (HWC models)
No adjustments are required or should be aempted 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.
Cooling chassis is charged with R410A refrigerant.
Pressure Regulator
Model
Number
Filter Area
(sq. in.)
HWC8-12 300
HWC8-18 480
HWC8-24 480
HWC8-30 480
Minimum Required Surface Area
for Disposable Filters
Table 1
Page 8 of 18 507388-01Issue 1504
SCFM
Temp
Rise
(F°)
SCFM
Temp
Rise
(F°)
SCFM
Temp
Rise
(F°)
SCFM
Temp
Rise
(F°)
208 365 49 340 53 315 N/A 285 N/A
230 425 42 405 44 380 47 350 51
208 445 40 415 43 390 46 365 49
230 515 35 485 37 455 39 430 42
208 620 29 585 31 555 32 520 34
230 685 26 650 28 610 29 570 31
208 365 N/A 340 N/A 315 N/A 285 N/A
230 425 63 405 N/A 380 N/A 350 N/A
208 445 60 415 65 390 N/A 365 N/A
230 515 52 485 55 455 59 430 62
208 620 43 585 46 555 48 520 52
230 685 39 650 41 610 44 570 47
208 480 N/A 465 N/A 450 N/A 435 N/A
230 610 44 590 45 565 47 535 50
208 750 36 715 38 685 39 655 41
230 810 33 770 35 735 37 700 38
208 860 31 815 33 770 35 735 37
230 880 30 835 32 790 34 750 36
208 480 N/A 465 N/A 450 N/A 435 N/A
230 610 59 590 61 565 63 535 N/A
208 750 48 715 50 685 52 655 55
230 810 44 770 46 735 49 700 51
208 860 42 815 44 770 46 735 49
230 880 41 835 43 790 45 750 48
208 480 N/A 465 N/A 450 N/A 435 N/A
230 610 73 590 N/A 565 N/A 535 N/A
208 750 60 715 63 685 65 655 68
230 810 55 770 58 735 61 700 64
208 860 52 815 55 770 58 735 61
230 880 51 835 54 790 57 750 60
TAP 1 (HEAT) 208 or 230 735 49 700 51 670 53 640 56
TAP 2 (HEAT) * 208 or 230 825 43 795 45 770 46 745 48
TAP 3 (HEAT) 208 or 230 895 40 865 41 840 43 810 44
TAP 4 (COOL) 208 or 230 800 765 735 715
TAP 5 (COOL) 208 or 230 880 845 820 795
TAP 1 (HEAT) 208 or 230 735 61 700 64 670 67 640 70
TAP 2 (HEAT) * 208 or 230 825 54 795 56 770 58 745 60
TAP 3 (HEAT) 208 or 230 895 50 865 52 840 53 810 55
TAP 4 (COOL) 208 or 230 800 765 735 715
TAP 5 (COOL) 208 or 230 880 845 820 795
55 40
LOW
0.1 " w.c. 0.2 " w.c. 0.3 " w.c. 0.4 " w.c.
Model
Rise
Range
(F°)
Mid
Rise
(F°)
Indoor Blower
Speed
HWC8(R/N)360912A 35
Unit
Voltage
(V)
-
LOW
MED
HWC8(R/N)240912A 25
-
MED *
HIGH
-
65 50
HIGH *
HWC8(R/N)360918A
HWC8(R/N)360924A
25
LOW
55 40
LOW
MED *
HIGH
LOW
HWC8(R/N)480918A
HWC8(R/N)480924A
35 - 65 50
75 60
MED *
HIGH
HIGH *
60
HWC8(R/N)600918A
HWC8(R/N)600924A
45 -
HWC8(R/N)480930A 30 -
HWC8(R/N)600930A -
AIRFLOWS AND HEATING TEMPERATURE RISES
AS A FUNCTION OF EXTERNAL STATIC PRESSURE
N/A: Do not operate unit in heating mode using this blower speed at this external static pressure. Outside of temperature rise range.
* : As shipped speed for heating operation
Table 2
75 60
45
45
MED
Table 2
Page 9 of 18507388-01 Issue 1504
Blower
The unit contains a direct-drive, mulspeed blower. The proper
speeds have been preset at the factory for heang and cooling.
Refer to the wiring diagram for recommended
heang/cooling speeds for specic models. Direct-drive blower
motors are permanently lubricated and do not require oiling.
Limit Control
A xed temperature limit control is provided which will shut
o the gas to the main burners if the unit is overheated for any
reason. The control must not be adjusted or relocated.
High Altude Adjustments (U.S. Installaons)
Rangs shown on the rang plate are for elevaons up to 2000
feet. For elevaons above 2000 feet, rangs should be reduced at
a rate of 4% for each 1000’ above sea level. Refer to the Naonal
Fuel Gas Code Z223.1 (latest edion) for further explanaon.
High Altude Adjustments (Canadian Installaons)
High altude conversions may be made by the manufacturer’s
authorized representave, in accordance with the requirement
of the manufacturer, provincial, or territorial authories having
jurisdicon, and in accordance with the requirements of CAN/CGA
B149.1 or B149.2 Installaon Code. A high altude conversion kit,
available from the manufacturer and approved for this purpose,
must be used.
Installaon and Operaon in Extremely Cold Weather Areas
In areas where extremely cold (below – 20°F) outdoor temperatures
can be expected, some additional installation and operating
precauons should be taken. The following precauons 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 stac pressure ranges specied on the rang
plate. Depending on specic model, it may be possible to
change to a lower heang 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.
3. Keep the outside louver grille as free as possible of any ice
that may form and obstruct the ue outlet.
START-UP
For Your Safety Read Before Lighng
If you do not follow these instrucons exactly, a re or
explosion may result causing property damage, personal
injury, or loss of life.
WARNING
This furnace is equipped with a direct ignion control. Do
not aempt to manually light the burners.
CAUTION
To Shut Down Main Burners
1. Turn o electrical power to unit.
2. Move the ON/OFF switch to the “OFF” posion
(see Figure 4).
To Light Main Burners
1. Turn o electrical power to unit.
2. Turn the thermostat to lowest seng.
3. Move the gas valve ON/OFF switch to the “ON” posion (see
Figure 4).
4. Turn on electrical power to the unit.
5. Set the room thermostat to the desired temperature.
(If the thermostat “set” temperature is above room
temperature aer the pre-purge me expires, main burners
will light.)
Gas Valve
Figure 4
Gas Inlet
ON/OFF
SWITCH
Gas Inlet
Pressure
test tap
Regulator
adjustment
Screw
(Under Cap)
Gas manifold
Pressure test
tap
Page 10 of 18 507388-01Issue 1504
OPERATION
Operaon of the unit is automac and will provide heang and
cooling depending on the seng of the thermostat.
Heang
1. Turn on main power supply.
2. Open manual gas shuto valve.
3. Set thermostat system to “HEAT”.
4. Set thermostat to temperature desired.
Cooling
1. Turn on main power supply.
2. Set thermostat system switch to “COOL”.
3. Set thermostat to temperature desired.
Heang Sequence of Operaon
1. Thermostat calls for heat.
2. Combuson blower starts and proper air ow is proven by
the pressure switch closing.
3. Blower connues to operate for 30 seconds prior to the
burners lighng.
4. Ignion control begins spark and opens gas valve. The
burners are lit. Ignion is proved through the ame sensor.
5. Circulang air blower starts 30 seconds aer the burners
light.
6. When the thermostat is sased, the burners and combuson
blower shut o.
7. Circulang air blower will shut o 120 seconds later.
If the burners should fail to ignite, the ignion control will try to
ignite the burners a total of three mes. Should the burners fail
to ignite within the three trials for ignion, the ignion control
will lock out for 1 hour before beginning another ignion cycle.
To reset the control, turn the thermostat down or o for 10
seconds and then set to desired seng. At this me, the ignion
sequence will try again.
Blower Control
The blower will start approximately 30 seconds after the
burners ignite and will stop approximately 120 seconds aer the
thermostat is sased. The me delay is preset at the factory
and ming can not be adjusted.
Cooling Sequence of operaon
When the thermostat system switch is set for “COOL”, the blower
will start 5 seconds aer the thermostat calls for cooling and will
stop 90 seconds aer the thermostat is sased.
Connuous Fan Operaon
Connuous operaon of the air handling blower will be obtained
if the thermostat fan switch is set to “ON”. With the thermostat
fan switch set to “AUTO”, the air handling blower will cycle
corresponding with the thermostat cycling.
To Shut Down Unit
For temporary or short periods of shutdown, set the thermostat
system switch to “OFF”. For a prolonged period of shutdown, set
the thermostat system switch to “OFF” and turn o the electrical
power supply and the gas supply to the unit.
The HWC8 burner & manifold assembly, combuson inducer
assembly, and ignition control board mounting are newly
designed for improved service access over previous models. Refer
to Figure 5 for heang cabinet component layout.
It is recommended that the furnace be inspected annually by a
qualied service person.
MAINTENANCE
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in
dangerous operation, Serious injury, death or property
damage.
Improper servicing could result in dangereous operaon,
Serious injury, death or property damage
•Before servicing. disconnect all electrical power to
furnace
•When servicing controls, label all wires prior to
disconnecting reconnect wires correctly.
• Any disassembly of components containing ue
or vent gases shall be done by a qualied service
agency.
•Verify proper operation after servicing.
WARNING
Page 11 of 18507388-01 Issue 1504
Flue Collector
Box
Remove these
screws to remove
Combustion inducer
Inducer prover
switch
Loosen these screws
to remove control board
mounting bracket
Ignition
Control board
Remove these
screws to remove
Burner Assembly
Igniter
Combustion
Inducer
Gas Valve
Primary Limit
(Mounted to Vest
panel)
Gas Manifold
Flame sensor
(mounted to top of
Burner assembly)
Rollout switch
Burner & Manifold
Assembly
Figure 5
COMPONENT LAYOUT
Page 12 of 18 507388-01Issue 1504
Burner & manifold assembly
To remove the burner & manifold assembly:
1. Disconnect electrical service and turn o gas to the appliance.
2. Loosen the pipe union external to the unit and remove the
gas line to the gas valve.
3. Disconnect the orange high voltage spark wire at the ignion
control board.
4. Disconnect the white ame sensor wire at the ame sensor
on top of the burner assembly.
5. Disconnect the orange wires at the rollout switch.
6. Disconnect the red and blue wires at the gas valve.
7. Refer to Figure 6. Remove the two screws on the burner
assembly that secure it to the mounting brackets. The
mounng brackets contain pins to locate the assembly and
hold it in place aer the screws are removed. The mounng
brackets are hidden unl the burner assembly is removed.
8. First, carefully pull the burner assembly toward you unl it
is clear of the locang pins in the mounng brackets.
9. Then move the assembly away from the vest panel.
10. Finally, pull the assembly from the unit.
11. Once the burner assembly is removed, the burners can be
cleaned using a bole brush.
12. For reassembly, follow the above steps in reverse order.
Control board mounng bracket
Page 13 of 18507388-01 Issue 1504
BURNER & MANIFOLD ASSEMBLY REMOVAL
Step 7
Mounting Brackets
Step 8
Step 9
Step 10
Burner &
Manifold
Assembly
Figure 6
Page 14 of 18 507388-01Issue 1504
The control board mounng bracket is designed to be removed
to allow component access for some service procedures. The
ignion control board and the inducer prover switch are mounted
to the bracket.
1. Disconnect electrical service and turn o gas to the appliance.
2. Loosen the two screws securing the control mounng bracket
(it is not necessary to completely remove them).
3. Li the bracket clear of the screws and carefully lower the
bracket and ignion board to the boom of the compartment.
4. It may be necessary to remove the inducer prover switch
tubing at the switch.
5. For reassembly, follow the above steps in reverse order.
Igniter
The igniter can be accessed from the front of the unit without
removing any other components. To remove the igniter:
1. Disconnect electrical service and turn o gas to the appliance.
2. Disconnect the orange high voltage spark wire at the ignion
control board.
3. Remove the screw and pull the igniter out of the burner
assembly.
4. For reassembly, follow the above steps in reverse order.
Rollout switch
If for any reason the heat exchanger becomes blocked the
temperature-sensive rollout switch located beside the burners
will open and the ignion control will turn o the burners. Aer
invesgang and correcng the problem, the rollout switch must
be manually reset by pressing the buon on top of it.
The rollout switch can be accessed from the front of the unit
without removing any other components. To remove the rollout
switch:
1. Disconnect electrical service and turn o gas to the appliance.
2. Disconnect the orange leads at the rollout switch.
3. Remove the screw and slip the rollout switch from beneath
the lanced tab on the burner assembly.
4. For reassembly, follow the above steps in reverse order.
Flame sensor
1. Remove the control board mounng bracket as described
previously.
2. Remove the screw and pull the ame sensor from the top
of burner assembly.
3. For reassembly, follow the above steps in reverse order.
Primary limit switch
The primary limit will shut down the unit in case of overheang
and automacally resets when temperature falls to an acceptable
level. It is not eld adjustable
1. Remove the control board mounng bracket as described
previously.
2. Disconnect the two orange leads at the primary limit switch.
3. Remove the three screws securing the primary limit switch
to the vest panel.
4. For reassembly, follow the above steps in reverse order.
Inducer prover switch
1. Remove the control board mounng bracket as described
previously.
2. Disconnect the two purple leads at the inducer prover switch.
3. If the tubing is in place, remove it.
4. Remove the screw securing the switch to the bracket and slip
the strap end out of the hole in the bracket.
5. For reassembly, follow the above steps in reverse order.
Burner orices
Orices are threaded into the gas manifold. To remove them:
1. Remove the burner & manifold assembly as described
previously.
2. Remove the four screws securing the gas manifold to the
burner assembly.
3. Remove the orices by unscrewing them. Do not use any
pipe thread sealant during reassembly.
4. For reassembly, follow the above steps in reverse order.
Combuson inducer
The combustion inducer can be removed for inspection,
replacement, or to access the heat exchanger and ue tube
extension for cleaning. To remove the combuson inducer:
1. Remove the control board mounng bracket as described
previously.
2. Disconnect the black inducer motor leads.
Page 15 of 18507388-01 Issue 1504
3. Disconnect the inducer prover switch tubing at the switch.
4. Remove the two screws on the combuson inducer plate.
5. Pull the combuson inducer and plate toward you unl it is
free of the diluon air box that supports it. Lower the inducer
and plate and rotate to pull the assembly out of the
compartment.
6. The ue tube extension can be cleaned if necessary. Leave it
in place; do not remove it from the unit.
7. For reassembly, follow the above steps in reverse order.
Heat exchanger
The heat exchanger should be inspected periodically and cleaned
if necessary. When cleaning use a s brush with a wire handle
to remove scale and soot. To access the heat exchanger tubes
for cleaning:
1. Remove the burner & manifold assembly as described
previously.
2. Remove the combuson inducer as described previously.
3. Remove the four screws securing the diluon air box to the
ue collector box.
4. Remove the nine or twelve screws (depending on model)
securing the ue collector box to the vest panel.
5. Using the wire brush, brush out the inside of each heat
exchanger tube from the burner assembly end and from the
ue collector box end.
6. Brush out the inside of the ue collector box.
7. Brush out the inside of the ue tube extension.
8. If soot buildup is excessive, clean the combuson inducer
wheel and housing.
9. When brushing is complete, blow all brushed areas with air.
Vacuum as needed.
10. For reassembly, follow the above steps in reverse order.
Cooling Chassis
The refrigeraon system contained in the cooling chassis normally
requires no maintenance since it is a closed, self-contained
system. System is charged with R410A refrigerant. Periodic
maintenance is limited to:
• Cleaning the air lter. Follow direcons noted on the lter
and label aached to the access panel.
• Cleaning the condenser coil if covered with any foreign
material, lint, leaves, or other obstrucons.
If servicing or major repairs are required, the complete chassis
can be removed from the unit. To remove the chassis:
1. Shut o the main power supply.
2. Remove filter access panel and panel covering cooling
controls.
3. Remove drain hose from the drain pan.
4. Disconnect the plug-in electrical connections. Do not
seperate the connector by pulling on this wire; instead, grasp
the connector handle.
5. Disconnect two power leads at contactor (leads come from
Grommet in unit paron).
6. Remove screws from panel directly in front of blower and
remove panel. Also remove addional screws located near
top edge of control panel.
7. Drape power wires and wire harnesses out of cabinet and
tape to upper panel.
8. Slide out the chassis, being careful not to damage any seals
or parts. Parcular care should be taken to insure wiring is
not damaged during removal/reinstallaon process.
To reinstall the chassis, reverse the procedure outlined above.
Be sure that the chassis is inserted as far back as it will go before
replacing the screws. Side anges on the chassis must be engaged
with sealing strips on the unit sides to prevent water and air
leakage. Reconnect the wire harness, reconnect the power
leads, and replace both access panels before turning on the main
electrical power. Tubing is not to be used as a handle.
Page 16 of 18 507388-01Issue 1504
Figure 7
Page 17 of 18507388-01 Issue 1504
Figure 8
Page 18 of 18 507388-01Issue 1504
NOTES
This manual suits for next models
3
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