Allied Air Enterprises MAGIC-PAK User Manual
V-SERIES™ APPLICATION GUIDE
ARCHITECTS • ENGINEERS • BUILDERS
TABLE OF CONTENTS
1. PURPOSE OF THIS MANUAL
2. MAGIC-PAK: DESIGNED AND BUILT FOR EVERY
STAGE OF DEVELOPMENT
2.1 TOTALLY PACKAGED HVAC SYSTEM PROVIDES
INDIVIDUAL COMFORT CONTROL
2.2 SLIDE-OUT COOLING CHASSIS
2.3 HERMETICALLY SEALED REFRIGERATION SYSTEM
2.4 INTERCHANGEABLE WITH EARLIER MODELS
2.5 GAS AND ELECTRIC ALTERNATIVES
8. OUTSIDE DECORATIVE FACADES, GRILLES OR
LOUVERS
8.1 GRILLE AND LOUVER FURNISHED ON MAGIC-PAK
8.2 OUTSIDE APPEARANCE VARIATIONS
8.3 CONSIDERATIONS FOR CUSTOM LOUVERS
8.4 CONTROL OF SOUND WITH LOUVERED GRILLES
9. CONDENSATE
9.1 CONDENSATE DRAIN
9.2 HIGH EFFICIENCY UNITS
3. UNIT LOCATION
3.1 GENERAL CONSIDERATIONS
3.2 SOUND CONSIDERATIONS
3.3 ACCESSIBILITY
3.4 VENT LOCATION FOR GAS MODELS
4. WALL SLEEVES
4.1 INSTALLATION
4.2 RECESSED SLEEVES
4.3 WEATHER-PROOFING WALL SLEEVES
5. TYPES OF WALL CONSTRUCTION
5.1 SUPPORT
5.2 WOOD-FRAME WALLS
5.3 CEMENT BLOCK WALLS
5.4 POURED CONCRETE WALLS
5.5 METAL STUDS
6. NOISE TRANSMISSION
6.1 VIBRATION TRANSMISSION
6.2 RADIATED SOUND AND RESONANT SURFACES
OR OBJECTS
6.3 CLEARANCES
6.4 DETERMINATION OF SOUND RATING VALUES
6.5 AIR NOISE
6.5.1. SUPPLY-AIR DUCT SYSTEM
6.5.2. RETURN-AIR DUCT SYSTEM
10. ELECTRICAL SERVICE WIRING
11. AIR FILTER
12. SPECIAL CONSIDERATION FOR GAS UNITS
NOTES
7. INFILTRATION
7.1 WATER INFILTRATION
7.2 AIR INFILTRATION
7.3 INTRODUCTION OF VENTILATION AIR
7.4 SEALING RETURN-AIR DUCTS
7.5 SEALING WALL SLEEVE
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For over 50 years, the
Magic-Pak concept of providing
heating and cooling in high-rise
condominiums and apartment
buildings has proven increasingly
popular among building designers
and mechanical contractors.
1. PURPOSE OF THIS MANUAL
This manual provides assistance to architects and design engineers who are considering the use
of Magic-Pak heating and cooling equipment in multi-dwelling buildings.
This document conveys some of the experience gained over many decades, and includes some
of the most successful and economical installation practices for Magic-Pak units.
Building structure heat loss and heat gain, duct sizing, gas supply mains and riser sizing, and
electrical-supply wiring should be determined for the building by a qualied Professional
Engineer familiar with the applicable local building code requirements for the type of occupancy.
2. MAGIC-PAK: DESIGNED AND BUILT FOR
DESIGNERS AND BUILDERS
2.1 TOTALLY PACKAGED HVAC SYSTEM PROVIDES INDIVIDUAL COMFORT CONTROL
The Magic-Pak concept provides all the practical benets of a split system, plus a heating
system, without the expense and complications of split-system units. Magic-Pak provides a
ducted, single-package, combination heating-and-cooling unit for each individual suite that
is reliable, easy to install and inexpensive to maintain. Just as important, it allows individual
metering and control for each unit.
Over these years with literally
hundreds of thousands of units
installed throughout the United
States and Canada, we have
compiled comprehensive practical
experience for varying types of
building construction and operating
conditions.
Occupants can have heating or air conditioning any time of the year according to the outdoor
temperature. A cold day in June, heating; a hot day in January, cooling. This is exibility you may
not get from some central systems.
2.2 SLIDE-OUT COOLING CHASSIS
The slide-out cooling chassis is unique to Magic-Pak units and is a chief contributor to the
ever-increasing popularity of the product. If service is required, any cooling chassis may be
replaced with another in minutes. In fact, building maintenance personnel can easily perform
this function without the refrigeration training or trade credentials often required to work on
refrigeration systems.
2.3 HERMETICALLY SEALED REFRIGERATION SYSTEM
The hermetically sealed refrigeration system is another feature of the Magic-Pak’s slide out
refrigeration chassis. The system is completely factory-built, checked for leaks with sensitive
electronic equipment, and thoroughly performance tested before placement in any unit. This
comprehensive testing eliminates the need for highly trained personnel at the time of installation
or start up.
2.4 INTERCHANGEABLE WITH EARLIER MODELS
Another advantage of the slide-out chassis is the one that eliminates concerns of obsolescence.
Replacement chassis are only available for units going back to 3rd version units. The chassis
built today include modern techno logy in heat transfer surface and compressor design for higher
efciencies, but the chassis will still t the older Magic-Pak models. For more information,
contact application specialist.
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Dedication to this interchangeability with earlier models is basic to the Magic-Pak concept of
today and insures that these units will never become “orphans” in the future.
2.5 GAS AND ELECTRIC ALTERNATIVES
22
27-7/8
29
7
/
16
13-3/8
43-3/16
18
2
7
/
8
161
61
81
2 3/4
1-3/4
8
2
Supply
Supply
Return
Return
1/2 Gas Inlet
Low
Voltage
Line Voltage
Box
Supply
11/
2
Condensate
Drain
HWC9
Only
1
/
4
2
Magic-Pak offers a variety of heat sources to best suit the geographic area or local energy costs.
All are ducted, through-the -wall units which have no need for chimney/vent pipe.
HWC -Gas Heating, Electric Cooling:
Depending on energy cost in your area, gas heating could maximize applications where gas
is available. Magic-Pak is classied as a direct vent application which uses only outside air for
combustion. This allows the built-in power vent to eliminate the need for a chimney.
Fig 1. HWC V-Series Model
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EWC - Electric Heating
7
Electric heating and cooling is an alternative solution when gas is not available, or in milder
geographies.
Line Voltage
Box
Low
Voltage
1-3/4
Supply
11/
2 3/4
2
8
27/
8
1
161
Supply
1
/
4
18
43-3/16
Return
7
8
/
2
22
13-3/8
81
61
Fig 2. EWC V-Series Model
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3. UNIT LOCATION
MAGIC-PAK
Figure 3. Condominium with Magic-Pak on exterior wall
3.1 GENERAL CONSIDERATIONS
A building wall should be no closer to an opposite building wall than two feet for every oor or
Magic-Pak unit in a vertical array facing the wall. For example, a one-story building with a Magic-
Pak unit should be a minimum of 2 ft. 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 ft. apart.
Magic-Pak units should be installed
in an exterior building wall that
is clear of obstructions which
might impede the free intake and
discharge of condenser air.
A six-story building with six Magic-Pak units in a vertical array should be at least 12 ft. from
the opposite building wall, and if that building wall also contains Magic-Pak units, the buildings
should be at least 24 ft. apart.
Buildings taller than six stories need not exceed the separation needed for six-story buildings.
If three or more adjacent walls form an air shaft with Magic-Pak units facing each other in each
wall, the separation between opposite walls should be increased by 20%.
These “rules-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 application
specialist about desired alternatives. In colder climates, the location of a unit should be
considered due to possible frost back-up.
Buildings that are designed with the utility closet next to each other, or stacked, need to have
a minimum horizontal clearance of 12” between units and a vertical clearance of 60” between
units (see Fig. 4).
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Fig 4: Building Clearance Needed
3.2 SOUND CONSIDERATIONS
It should be mentioned that any time a hard surface or wall faces a unit, the sound emanating
from that unit can be reected by the opposite wall. If the two walls are not parallel, the sound
may be somewhat dispersed, but in general it is preferable to locate Magic-Pak units in a wall
with as much clear distance to the nearest wall or reecting surface as is practical.
Units located in walls forming an air shaft or conned courtyard are not as desirable (from a
sound standpoint) as units located in the outer perimeter walls of a building.
Similarly, if the unit is to be installed in a wall at right angles to a wall containing a window, at
least 6 ft. of separation be tween the closest point of glass to the unit should be maintained in
order to minimize sound transmission through the window.
If, however, such a location is unavoidable contact the application specialist. For suggestions on
how others have succeeded in overcoming the challenges.
3.3 ACCESSIBILITY
An important consideration when selecting a suitable location is accessibility for chassis removal.
A 30 in. wide minimum clear opening is needed in front of the unit in order to remove the
chassis. A 36 in. wide door or access covering to the enclosure is preferred as a minimum to
allow for some tolerance in locating the access door frame exactly centered on the unit ( Fig 5).
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If the unit is located in the end of a clothes closet, and it is accepted that the clothes must
be removed rst to remove the chassis, be sure that the closet door is large enough to get the
chassis out of the closet.
Also, if the Magic-Pak is installed through the side of a closet, be sure the closet is wide enough
to permit sliding the chassis all the way out before running into the opposite closet wall.
Fig 5: clearance needed for Chassis.
(Note: There are special dollies available through wholesalers that can lean the platform from
vertical to horizontal with an elevating-adjustment feature and four wheel support. These are
very useful in close quarters to provide a platform to slide the chassis onto during removal and
subsequent replacement of a chassis.)
Units in a relatively inaccessible location for easy chassis removal should be avoided if at all
possible; if for no other reason than to keep the air lter accessible for easy and timely cleaning
by the occupants or by maintenance personnel.
3.4 VENT LOCATION FOR GAS MODELS
Vent location of gas-red Magic-Pak models must comply with the latest edition of the National
Fuel Gas Code (NFPA 54/ANSI Z223.1), and local codes.
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 shutoff valve as well as providing accessibility for eld wiring. 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 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 (see Fig. 4). There is no minimum clearance required on locating
the unit to an interior corner of a building.
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“Wall sleeve” is an accessory for the
Magic-Pak units. The wall sleeve is
designed to facilitate the installation
of Magic-Pak units by providing an
accurate opening during building
construction. Units can then remain
o-site until building construction
approaches completion.
4. WALL SLEEVES
Wall Sleeve
0” X 22” Minimum
opening to Align
with return air
opening in unit
2
16
45
2
Plywood
(bottom layer)
29
Flanges may be assembled
3/4
1” or 3
” from front of sleeve
Vibration Isolating Material
(Top Layer)
1/2
12
Fig 6: Wall sleeve frame
The wall sleeve is comprised of four assemblies (top, bottom, and right and left sides see g 7).
These easily slip together on the job to form a rectangular box correctly sized to receive a Magic-
Pak unit. When in place and securely fastened, the wall sleeve opening provides easy access to
the nished wall perimeter for caulk sealing.
Magic-pak recommend that a wall sleeve be fastened into the wall opening and caulk sealed
around the outside perimeter at the building wall. In multi-story buildings, weather sealing may
be done by access through the opening in the wall sleeve later to be lled by the Magic-Pak unit.
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The weather-seal caulking is easier to perform when the sleeve protrudes beyond the nished
wall by 3/8 in. to 1 in.
Right Side Panel
Side support angle
Front of
Sleeve
Top Panel
Squaring
Braces
Top Support Angle
Left Side Panel
Bottom Panel
Fig 7: Wall sleeve assembly Fig 8:Wall sleeve dimensions
4.1 INSTALLATION
The sleeve may extend farther than 1 in. beyond the nished wall, but reaching the perimeter of
the opening from inside for sealing becomes increasingly difcult (Figs. 9 & 10)
In many high-rise construction applications, contractors insert the wall sleeves from the outside
while the wall is being constructed (Fig. 11, 12, 13). The two-sided support angles furnished with
the wall-sleeve kit should then be attached to the wall sleeve sides at a location that will exceed
the thickness of the outside nish wall by the recommended 3/8 in. to 1 in. dimension. Support
angles should not be considered ashing.
For example, if the supporting wall is concrete block with a brick facing, there is usually a space
between the block and the brick. This space dimension must be added to the width of the brick
(plus 3/8 in. to 1 in.) so that when the sleeve is inserted into the block-wall opening, up to the
angles, and fastened to the block wall before the brick is installed, the sleeve will protrude beyond
the nished brick by 3/8 in. to 1 in., as needed for caulk sealing.
The wall sleeve must be fastened to the supporting wall and not to the nished wall.
Figure 9: Wall sleeve installed from outside
angle 1
Figure 10: Wall sleeve from outside angle 2
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Figure 11 - Wall sleeve installed from outside
angle 3
Some builders will attach through the side support angles
to the support wall whether inserting the sleeve from the
outside or inside. Others will use the side angles simply as a
locating “stop” to achieve the appropriate dimension while
shooting fasteners through the sides of the wall sleeve into
the supporting wall (See Fig. 13).
The most popular method of installing the wall sleeve is from
the inside of the building with the weather seal applied from
the outside as the nish wall is applied (See Fig. 19).
Figure 13 - Fasteners shot
through wall sleeve sides into
back wall
Figure 12 - Caulk around sleeve
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