Magic Aire HCA, HCA 06, HCA 08, HCA 04, HCA 12 Installation, Operation And Maintenance Manual

Magic Aire HCA Series units
are direct drive High Efficien­cy Horizontal Air Handlers
delivering nominal airflows of
400 to 4000cfm and nominal
cooling capacities of 1/2 to 10
tons. Units may be specified

with chilled water or DX cooling coils and
hot water or steam heating coils to meet
space cooling loads or heating loads or
both.

How to Use this Manual:

This manual gives instructions regarding in­stallation, operation and maintenance for the
HCA Series air handling units. For more in­formation refer to:

Catalog brochure for unit dimensions,
options, guide specifications and perfor­mance information.
New Magic 4 software for faster selection
of new equipment.
Website www.magicaire.com for re­placement parts guide, software down­loads, product data and contact info for
your local Magic Aire representative.
Replacement Parts – Identify parts
needed using the replacement parts
guide available at www.magicaire.com.

HCA Series Air Handler

Installation, Operation and Maintenance

Manual

GENERAL

Installation and maintenance are to be per­formed only by qualified personnel who are fa­miliar with local codes and regulations and are
experienced with HVAC equipment of this type.

WARNING: Sharp edges, coil surfaces
and rotating fans are a potential injury
hazard – avoid contact.

WARNING: Hazardous voltage – Discon­nect and Lock Out all incoming power
sources before servicing or installing unit.
ELECTRIC SHOCK CAN CAUSE DEATH.

Use these instructions in conjunction with
other appropriate instructions, including but
not limited to those instructions supplied with
the outdoor unit (if applicable). Installation
must comply with all applicable local codes.

SAFETY WARNING:

Installer should pay particular attention to the
following words:
NOTE–intended to clarify or make installation
easier.
CAUTION–given to prevent equipment dam­age.
WARNING–to alert installer that personal inju-

ry and/or equipment damage may result if in­stallation procedure is not properly followed.

WARNING: This equipment may be in­stalled well above finished floor—Use ex­treme caution when working at heights.

UNPACKING-CHECK FOR DAMAGE!

Immediately inspect each unit for dam­age upon receipt.

• Inspect units for external and concealed

damage immediately.

• File any damage claims in accordance

with Magic Aire Freight Damage Policy
and Terms and Conditions (available at

www.magicaire.com).

• Do not repair damaged units without

written authorization.

• Protect stored units from damage.

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HCA Series Air Handler

Installation, Operation and Maintenance

Manual

Installaon, Start-Up

and Service

Instrucons

Topic Page

Warranty Registration Form
SAFETY CONSIDERATIONS

UNPACKING-Remove Shipping Screws
PREINSTALLATION

Rigging
Unit Weight Calculation
INSTALLATION
Unit Suspension
External Vibration Isolators
Ductwork
Electrical
Service Clearance
Condensate Drain
Steam Coil Piping Recommendations
Coil Freeze-Up Protection
Refrigerant Piping, Direct Expansion (DX) Coils
START-UP
SERVICE
Water Quality Guidelines
Physical Data
Dimensional Drawings

27

1,4

4
5

5
5

6-18

6-7

7
8

9-11

12
13

14-16

16

17-18

19

20-23

24
25
26

035-000049-001 Page 3 HCA IOM 1.1 8-28-2017

DANGER

UNPACKING-CAUTION!

NEVER enter an enclosed fan cabinet or reach into
a unit while the fan is running.
LOCK OPEN AND TAG the fan motor power dis­connect switch before working on a fan. Take fuses
with you and note removal on tag. Electric shock
can cause personal injury or death.
LOCK OPEN AND TAG the electric heat coil power
disconnect switch before working on or near heat­ers.
Failure to follow these warnings could lead to per­sonal injury or death.

WARNING

CHECK the assembly and component weights to
be sure that the rigging equipment can handle
them safely.
Note also, the centers of gravity and any specific
rigging instructions.
CHECK for adequate ventilation so that fumes
will not migrate through ductwork to occupied
spaces when welding or cutting inside air­handling unit cabinet or plenum.
WHEN STEAM CLEANING COILS be sure that
the area is clear of personnel.
DO NOT attempt to handle access covers and
removable panels on outdoor units when winds
are strong or gusting until you have sufficient help
to control them. Make sure panels are properly
secured while repairs are being made to a unit.
DO NOT remove access panel fasteners or open
access doors until fan is completely stopped.
Pressure developed by a moving fan can cause
excessive force against the panel which can in­jure personnel.
DO NOT work on dampers until their operators
are disconnected.
BE SURE that fans are properly grounded before
working on them.
Failure to follow these warnings could result in
personal injury or equipment damage.

After removing the outer packaging,

REMOVE RED BLOWER SHIPPING

SCREWS

from the blower discharge flanges (Fig.1)
and blower supports (Fig. 2). These screws
stabilize the fan assembly during shipping
and need to be removed.

CAUTION! Not removing red shipping
screws can result in unsatisfactory vibration
or blower noise.

Figure 1

Remove Red Shipping Screws

(4 per blower discharge—single discharge

shown)

Figure 2

Remove Red Shipping Screws–

Blower (1ea per side, 2ea total)

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PREINSTALLATION

Std

High

1R2R4R6RSteam

Component Weights (lbs)

1. Check items received against packing list.

2. Do not stack unit components or accessories
during storage. Stacking can cause damage or
deformation.

3. If unit is to be stored for more than 2 weeks pri­or to installation, observe the following precau­tions:

a. Choose a dry storage site that is reasona-

bly level and sturdy to prevent undue
stress or permanent damage to the unit
structure or components. Do not store unit
on vibrating surface. Damage to stationary
bearings can occur. Set unit off ground if in
heavy rain area.

b. Remove all fasteners and other small parts

from jobsite to minimize theft. Tag and
store parts in a safe place until needed.

c. Cover entire unit with a tarp or plastic cov-

erall. Extend cover under unit if stored on
ground. Secure cover with adequate tie­downs or store indoors. Be sure all coil
connections have protective shipping caps.

d. Monthly — Remove tarp from unit, enter

fan section through access door or through
fan inlet, and rotate fan and motor slowly
by hand to redistribute the bearing grease

and to prevent bearing corrosion.
Rigging — Do not remove shipping skids or protec­tive covering until unit is ready for final placement.
Use slings and spreader bars as applicable to lift
unit. Do not lift unit by coil connections or headers.

Do not remove protective caps from coil piping
connections until ready to connect piping.
Do not remove protective cover or grease from
fan shaft until ready to install sheave.
Lay rigid temporary protection such as plywood
walkways in unit to prevent damage to insula­tion or bottom panel during installation.

WARNING-AUXILIARY DRAIN PAN
RECOMMMENDED:

This product has an auxiliary condensate drain
which should be piped to a condensate overflow
sensor or safe drain location or both to protect the
equipment and property from damage in the case
of condensate overflow.

In addition, the International Mechanical Code
(IMC) section 307.2.3 requires the use of auxiliary
drain pans. Many municipalities have adopted this
code.

Magic Aire holds that this practice represents the
standard for professional installation whether or not
this code has been adopted in a specific municipal­ity or territory. As such, water damages that would
have been prevented had an auxiliary pan been
deployed will not be considered for compensation.
This position is taken regardless of whether the
source of the moisture was specified as a potential
failure mode in the applicable building code or not.
A freeze burst, cracked drain pan, failed weld, or
corrosion induced leak are some of the potential
failure modes that are mitigated when an auxiliary
pan is properly installed. Professional installers
recognize the value of protecting customer assets
against foreseeable events. Customers who
choose to avoid the cost of common protective
measures waive their right to seek damages when
those foreseeable events occur. If the product is
located above a living space or where damage
may result from condensate overflow, install a wa­tertight pan of corrosion-resistant metal beneath
the unit to catch over-flow which may result from
clogged drains or from other reasons. Provide
proper drain piping for this auxiliary pan. Consult
local codes for additional precautions before instal­lation.

UNIT WEIGHT CALCULATION

MotorSize

Coil Weight, Dry

Cabinet

04 92 15 15 10 10 18 23 13
06 93 15 15 12 12 22 27 15
08 125 18 20 16 16 30 50 20
12 141 18 20 20 20 40 59 25
16 160 20 25 25 25 50 77 31
20 192 20 25 31 31 62 81 39
30 383 30 35 n/a 42 84 102 53
40 414 40 45 n/a 54 108 143 68

Table 1 — Unit Dry Weight

Calculation Procedure:

1. Calculate coil water weight for
each water coil using the following
formula:

Water Weight =
Coil Volume (gal) x 8.345lb/gal
(volume is from Physical Data
table)

2. Calculate dry weight:
Cabinet Dry Weight

+Motor Weight
+Dry Coil Weight (coil 1)
+Dry Coil Weight (coil 2)
= Total Unit Dry Weight

3. Calculate total weight:
Total Unit Dry Weight

+Water Weight (coil 1)
+ Water Weight (coil 2)
= Total Unit Installed Weight

035-000049-001 Page 5 HCA IOM 1.1 8-28-2017

UNIT SUSPENSION

Ceiling Suspension: Acceptable forms of unit
suspension are shown in Fig. 3, 4 and 5. Figure
3 shows suspension rods run through the knock­outs in top and bottom of the unit. Use strut ma­terial and hardware at bottom as shown in the
details. Figure 4 shows field-supplied platform
mount. Units can also be supported by suspend­ing the unit from crossbeams at the front and
rear (Figure 5).

Size suspension rods to support the weight.
Size any beam members to insure that they are
adequate for a safe installation. Ensure that
suspension rods are secured to adequately sup-

1

port the unit and that the rods extend entirely
through their associated fasteners.

It is recommended that framing be construct­ed from structural steel or formed-strut mate­rials.

With Mixing Boxes: HCA units sizes 30-40
with mixing boxes should be supported with
crossbeams at each end of the unit and at the
duct connection side of the mixing box. Sizes
04-20 with mixing box—no additional support
is required.

WARNING! INSURE THAT UNIT IS ADE­QUATELY SUPPORTED FROM STRUC­TURE TO PREVENT DAMAGE OR INJURY
CAUSED BY FALLING EQUIPMENT! If un­certain about how to connect to the struc­ture, consult a qualified structural engi­neer.

Fig. 3

Ceiling Suspension—

Rods Through Unit

NOTES:

1. INSTALLATION MATERIALS
ARE FIELD-SUPPLIED AND
INSTALLED.

2. INSURE BUILDING STRUCTURE IS ADEQUATE FOR
SUPPORTING THE EQUIPMENT.

3. INSURE AT LEAST 3 FULL THREADS ARE EXPOSED
THROUGH EACH NUT WHEN LEVELING THE AHU.

4. USE NUT, WASHER, AND LOCK WASHER. ALTER­NATE: NYLOCK NUT MAY BE USED INSTAD OF

STANDARD NUT AND LOCK WASHER. WARNING!

DO NOT OMIT LOCK WASHER OR NYLOCK NUT!

035-000049-001 Page 6 HCA IOM 1.1 8-28-2017

UNIT SUSPENSION (CONT’D)

Floor mounting: Unit may be mounted on a
housekeeping pad, floor or platform. CAUTION!

Make sure to allow enough elevation to permit
construction of the condensate trap.

Vibration Isolators: (field supplied) If required,

install isolators in the suspension rod system.
Allow clearance as needed between isolators and
unit.

Fig. 4

Ceiling Suspension—

Platform Mount

WARNING! INSURE THAT UNIT IS ADE­QUATELY SUPPORTED FROM STRUCTURE
TO PREVENT DAMAGE OR INJURY CAUSED
BY FALLING EQUIPMENT! If uncertain about
how to connect to the structure, consult a
qualified structural engineer.

Fig. 5

Ceiling Suspension—

Crossbeam Mount

035-000049-001 Page 7 HCA IOM 1.1 8-28-2017

INSTALLATION—DUCTWORK

DUCTWORK CONNECTIONS

Install supply and return ductwork to the
unit as required for the application. Note
that free discharge or free return is ac­ceptable.

Return Ductwork: Install return ductwork
by attaching one side of a field-provided
flexible duct connector to the duct flange
on the return side of the unit (filter side).
Attach the other side of the flexible duct
connector to the return ductwork. Seal the
connections using duct mastic or HVAC
tape.

Supply Ductwork—Unit Sizes 04-20: Install
supply ductwork by attaching one side of a field­provided flexible duct to the fan discharge duct
collar on the front of the unit. Attach the other
side to the supply ductwork. Seal the connec­tions using duct mastic or HVAC tape. Refer to
Figure 6.

NOTE: It is acceptable to omit the flexible duct
connectors, but this may allow normal operating
vibration or noise to transfer through the duct
system leading to customer complaints.

Fig. 6 — HCA size 04 to 20

Duct Connections

Size all ductwork according to SMACNA and
ASHRAE duct design standards.

MIXING BOX INSTALLATION

Mixing box accessory connects to the return (air
inlet) flange on the rear of the unit. Refer to
Mixing Box Installation Instructions (available at
www.magicaire.com) for detailed instructions for
installation along with economizer controls and
damper installation.

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INSTALLATION-ELECTRICAL

DANGER

WARNING: Hazardous voltage. Only qualified
personnel must install the electrical service. Dis­connect and Lock Out all incoming power sources
before connecting to electrical service.

WARNING: This appliance must be permanently
grounded in accordance with the National Electrical
Code and local code requirements.

WARNING: For use with copper conductors only.

INSTALLATION-ELECTRICAL

Typical wiring diagrams are shown on the fol­lowing pages FOR REFERENCE. Always re­fer to the wiring diagram on the air handling unit
for actual wiring.

Connect electrical service to unit. Refer to unit
wiring diagram. NOTE: CHECK MOTOR RAT­ING PLATE FOR CORRECT LINE VOLTAGE.
For power supply connection, route field power
wiring to Motor Start/Stop Station (MSS) dis­connect switch (if provided) or motor leads in
the junction box (j-box).

DANGER

NEVER enter an enclosed fan cabinet or reach into
a unit while the fan is running.
LOCK OPEN AND TAG the fan motor power dis­connect switch before working on a fan. Take fuses
with you and note removal on tag. Electric shock
can cause personal injury or death.
LOCK OPEN AND TAG the electric heat coil power
disconnect switch before working on or near heat­ers.
Failure to follow these warnings could lead to per­sonal injury or death.

Refer to nameplate FLA, maximum overcurrent
protection device (MOPD) and minimum circuit
ampacity (MCA). Also refer to wiring diagram
affixed to unit to make control and power wiring
connections.

NOTE: Installer is responsible for power wiring
and branch circuit overcurrent protection.

NOTE: Motor provided has internal thermal
overload protection. Units ordered Factory
Electric Heat include fan relay or contactor and
disconnect switch located inside the electric
heat control box.

035-000049-001 Page 9 HCA IOM 1.1 8-28-2017

INSTALLATION-ELECTRICAL (cont’d)

TYPICAL WIRING DIAGRAMS—

Control Option “C”

Four User-Adjustable Speeds

NOTES:

1. This diagram represents the factory-installed
electrical option with 4 user-adjustable speeds.

2. Typical wiring is shown. For exact wiring, refer
to the wiring diagram provided with the unit.

3. Field wiring includes power wiring (upper left
hand corner) and low voltage control wiring
(terminal block TB1).

4. Units ordered for 208V-240V voltage selection
are factory wired for 240V. Field may rewire
transformer primary tap for operation at 208V.

5. Selection of field provided and installed electri­cal components is the responsibility of the in­staller, including branch circuit protection and
wiring.

6. To start the fan, connect R and G1 or G2 or G3
to energize fan at each respective speed. Add
connection to terminal “FLO4” on the control
board (EVOECM-4SPD) to enable a fourth
speed. Adjust each fan speed using potentiom­eter control on the control board. Speed adjust­ments can be made while the fan is running.

WARNING: Hazardous voltage!

7. The control power (R and C at terminal
block TB1) can be used to power a stand­ard 24VAC thermostat , DX relay and up to
2ea control valves. NOTE: Factory trans­former is 40VA, so use caution when con­necting multiple loads to the 24VAC control
circuit.

8. Optional condensate switch (CNS) factory
option interrupts 24VAC to thermostat (R)
and controls when water level rises to pre­set sensor level in the drain pan.

9. Optional current switch (CRS) factory op­tion makes upon current flow to the motor.
Utilize as a dry contact for control system
alarms as needed.

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INSTALLATION-ELECTRICAL (cont’d)

0-10VDC Signal Fan Speed Control

TYPICAL WIRING DIAGRAMS—

Control Option “E”

Variable Speed

NOTES:

1. This diagram represents the factory-installed
electrical option with constant CFM control us­ing the pressure transducer mounted inside the
unit. Control loop logic is contained in the VFD
programming. VFD keypad is mounted on out­side of unit.

2. Typical wiring is shown. For exact wiring, refer
to the wiring diagram provided with the unit.

3. Field wiring includes power wiring (upper left
hand corner) and low voltage control wiring
(terminal block TB1).

4. Units ordered for 208V-240V voltage selection
are factory wired for 240V. Field may rewire
motor and transformer primary tap for opera­tion at 208V.

5. Selection of field provided and installed electri­cal components is the responsibility of the in­staller, including branch circuit protection and
wiring.

6. To start the fan, apply 2.0VDC to + (plus)
and—(minus) terminals. Fan speed is variable
from 2.0VDC (minimum speed) to 10.0VDC
(maximum speed).

7. The control power (R and C at terminal
block TB1) can be used to power a stand­ard 24VAC thermostat , DX relay and up to
2ea control valves. NOTE: Factory trans­former is 40VA, so use caution when con­necting multiple loads to the 24VAC con­trol circuit.

8. Optional condensate switch (CNS) factory
option interrupts 24VAC to thermostat (R)
and controls when water level rises to pre­set sensor level in the drain pan.

9. Optional current switch (CRS) factory op­tion makes upon current flow to the motor.
Utilize as a dry contact for control system
alarms as needed.

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SIZE

SERVICE CLEARANCES

CONTROL BOX

HC

UNIT

A B C D E

DIMENSIONS

04,06 18 36 4 30 26
08,12 20 36 4 36 31
16,20 23 36 4 30 38

CONTROL BOX
CLEARANCE

NOTES:

1. NOT TO SCALE. REFER TO CATALOG DRAWINGS FOR UNIT
OUTLINE DIMENSIONS.

2. MOTOR IS LOCATED ON THE SAME SIDE AS COOLING COIL
CONNECTION (UNIT WITH 2 COILS) OR 2-PIPE/HEATING COIL CON­NECTION (UNIT WITH SINGLE COIL).

3. ALLOW CLEARANCE FOR FIELD PIPING AS REQUIRED BY THE
PROJECT REQUIREMENTS. CONNECTIONS MAY BE ON ONE SIDE
OR ON BOTH SIDES.

4. REFER TO INSTALLATION INSTRUCTIONS FOR UNIT HANGING
(SUSPENSION) REQUIREMENTS.

5. COIL, DRAINPAN OR BLOWER REPLACEMETN REQUIRES UNIT
TO BE REMOVED TO FLOOR FOR SAFE WORKING CONDITION.
ALLOW FULL WIDTH OF UNIT FOR COIL REMOVAL. REFER TO
SERVICE INSTRUCTIONS.

6. ALLOW ADEQUATE DEPTH FOR CONDENSATE DRAIN TRAP.
REFER TO INSTALLATION INSTRUCTIONS FOR TRAP REQUIRE­MENTS.

035-000049-001 Page 12 HCA IOM 1.1 8-28-2017

Fig. 7 — Condensate

Drain

INSTALLATION

Condensate Drain — Install a trapped condensate

drain line at unit drain connection. HCA units have a 3/4
in. FPT condensate drain connection, or alternately a
3/4” male PVC pipe outlet for the condensate drain con­nection.

WARNING! To prevent excessive build-up of conden­sate in drain pan, adequate trap clearance (trap depth)
must be provided beneath the unit as indicated in Fig. 6.

Measure maximum design negative static pressure up­stream from the fan. Referring to Fig. 7, height “H” must
be 1” larger than the fan inlet static pressure Iinches
w.g.) at the design operating conditions. Prime enough
water in trap to prevent losing seal when starting up the
unit. After the fan is running with the design fan inlet
(negative) pressure, the elevation of the water on the
unit side of the trap will be 1” below the drain invert.

Provide freeze-up protection as required to insure relia­ble condensate drainage. Freeze protection measures
are customer-supplied and installed.

Water Coil Piping Recommendations

Water coils are piped by connecting the supply
at the bottom and the return at the top. This is
“counterflow” piping arrangement and is nec­essary to achieve rated thermal performance.

CAUTION! Piping the other way
(parallel) will result in reduced thermal
performance!

Coil Venting: Water coils are not provided with
venting devices. Insure that the circulating
water system has proper air venting capability.
If vents are required at the coil, install them in
the field piping attached to the return (upper)
connection.

035-000049-001 Page 13 HCA IOM 1.1 8-28-2017

Steam Coil Piping Recommendations

GENERAL — Use straps around the coil casing to lift
and place the coil.

CAUTION

To prevent damage to the coil or coil headers: Do not
use the headers to lift the coil. Support the piping

and coil connections independently. Do not use the coil
connections to support piping. When tightening coil
connections, use a backup wrench on the coil connec­tion stub-out.

NOTE: Piping should be installed by a qualified install­er familiar with the type of piping to be installed. Per­form piping to industry best practices.

STEAM COILS — Position the steam supply connec­tion at the top of the coil, and the return (condensate)
connection at the bottom.
Figure 8 illustrates the normal piping components
and the suggested locations for high, medium, or low­pressure steam coils. The low-pressure application
(zero to 15 psig) can dispense with the ¼-in. petcock
for continuous venting located above the vacuum
breaker (check valve).
Note the horizontal location of the 15-degree check
valve, and the orientation of the gate/pivot. This valve
is intended to relieve any vacuum forming in the con­densate outlet of a condensing steam coil, and to seal
this port when steam pressure is again supplied to the
coil. It must not be installed in any other position, and
should not be used in the supply line.
For coils used in tempering service, or to preheat
outside air, install an immersion thermostat in the con­densate line ahead of the trap. This will shut down the
supply fan and close the outdoor damper whenever the
condensate falls to a predetermined point, perhaps 120
F.
NOTE: DO NOT use an immersion thermostat to over­ride a duct thermostat and open the steam supply
valve. For vacuum return systems, the vacuum break­ing check valve would be piped into the condensate
line between the trap and the gate valve instead of
open to the atmosphere.

Fig. 8 — Low, Medium or High

Pressure Coil Piping

NOTES:

1. Flange or union is located to facilitate coil
removal.

2. Flash trap may be used if pressure differen­tial between steam and condensate return
exceeds 5 psi.

3. Dirt leg may be replaced with a strainer. If
so, tee on drop can be replaced by a reduc­ing ell.

4. The petcock is not necessary with a bucket
trap or any trap which has provision for
passing air. The great majority of high or
medium pressure returns end in hot wells or
deaerators which vent the air.

Figure 9 illustrates the typical piping at the end of every
steam supply main. Omitting this causes many field
problems and failed coils.

Figure 10 shows the typical field piping of multiple
coils. Use this only if the coils are the same size and
have the same pressure drop. If this is not the case, an
individual trap must be provided for each coil.

Figure 11 shows a multiple coil arrangement applied to
a gravity return, including the open air relief to the at­mosphere, which DOES NOT replace the vacuum
breakers.

Figure 12 illustrates the basic condensate lift piping.

Fig. 9 — End of Steam Supply

Main Piping Detail

035-000049-001 Page 14 HCA IOM 1.1 8-28-2017

Steam Coil Piping Recommendations (Cont’d)

NOTES (Figure 9):

1. A bypass is necessary around trap and valves
when uninterrupted operation is necessary.

2. Bypass to be the same size as trap orifice but nev­er less than 1/2 inch.

Fig. 10 — Multiple Coil High Pressure Piping

Fig. 11 — Multiple Coil Low Pressure

Piping Gravity Return

NOTES:

1. Flange or union is located to facilitate coil re­moval.

2. When control valve is omitted on multiple coils
in parallel air flow.

3. When a bypass with control is required.

4. Coils with different pressure drops require in-

dividual traps. This is often caused by varying
air velocities across the coil bank.

NOTES:

1. Flange or union is located to facilitate coil re­moval.

2. When a bypass with control is required.

3. Flash trap can be used if pressure differential
between supply and condensate return exceeds
5 psi.

4. Coils with different pressure drops require indi­vidual traps. This is often caused by varying air
velocities across the coil bank.

5. Dirt leg may be replaced with a strainer. If so,
tee on drop can be replaced by a reducing ell.

6. The petcock is not necessary with a bucket trap
or any trap which has provision for passing air.
The great majority of high pressure return mains
terminate in hot wells or deaerators which vent
the air.

NOTES:

1. Flange or union is located to facilitate coil removal.

2. To avoid water hammer, drain coil before admitting steam.

3. Do not exceed one foot of lift between trap discharge and return
main for each pound of pressure differential.

4. Do not use this arrangement for units handling outside air.

Fig. 12 — Multiple Coil Low Pressure Piping

Gravity Return

035-000049-001 Page 15 HCA IOM 1.1 8-28-2017

Steam Coil Piping Recommendations (Cont’d)

Following the piping diagrams in Fig. 8-12, make all
connections while observing the following precau­tions:

• Install a drip line and trap on the pressure side of
the inlet control valve. Connect the drip line to the
return line downstream of the return line trap.

• To prevent scale or foreign matter from entering
the control valve and coil, install a 3/32-in. mesh
strainer in the steam supply line upstream from the
control valve.

• Provide air vents for the coils to eliminate noncon­densable gases.

• Select a control valve according to the steam load,
not he coils supply connection size. Do not use an
oversized control valve.

• Do not use bushings that reduce the size of the
header return connection. The return connection
should be the same size as the return line and re­duced only at the downstream trap.

• To lift condensate above the coil return line into
overhead steam mains, or pressurized mains, install
a pump and receiver between the condensate trap
and the pressurized main. Do not try to lift conden­sate with modulating or on-and-off steam control
valves. Use only
15-degree check valves, as they open with a lower
water head. Do not use 45-degree or vertical-lift
check valves.

• Use float and thermostatic traps. Select the trap
size according to the pressure difference between
the steam supply main and the return main.

• Load variations can be caused by uneven inlet air
distribution or temperature stratification.

• Drain condensate out of coils completely at the end
of the heating season to prevent the formation of
acid.

Coil Freeze-Up Protection

STEAM COILS — When used for preheating out­door air in pressure or vacuum systems, an immer­sion thermostat to control outdoor-air damper and
fan motor is recommended. This control is actuated
when steam supply fails or condensate temperature
drops below an established level, such as 120 to
150 F. A vacuum breaker should also be used to
equalize coil pressure with the atmosphere when
steam supply throttles close. Steam should not be
modulated when outdoor air is below 40 F.
On low-pressure and vacuum steam-heating sys­tems, the thermostat may be replaced by a conden­sate drain with a thermal element. This element
opens and drains the coil when condensate temper­ature drops below 165 F. Note that condensate
drains are limited to 5 psig pressure.
INNER DISTRIBUTING TUBE STEAM COILS —
The inner distributing tube (IDT) steam coil used in
the HHA air handling units has an inner tube pierced
to facilitate the distribution of the steam along the
tube's length. The outer tubes are expanded into
plate fins. The completed assembly includes the
supply and condensate header and side casings
which are built to slant the fin/tube bundle back to­ward the condensate header. The slanting of the

assembly ensures that condensate will flow
toward the drains. This condensate must be
removed through the return piping to prevent
premature failure of the coil. The fin/tube bun­dle is slanted vertically for horizontal airflow
coils, and horizontally for vertical airflow coils.
IDT Steam Coil Piping — The following piping
guidelines will contribute to efficient coil oper­ation and long coil life:

1. Use full size coil outlets and return piping
to the steam trap. Do not bush return out­let to the coil. Run full size to the trap,
reduce at the trap.

2. Use float and thermostatic (F & T) traps
only for condensate removal. Trap size
selection should be based on the differ­ence in pressure between the steam sup­ply main and the condensate return main.
It is good practice to select a trap with 3
times the condensate rating of the coil to
which it is connected.

3. Use thermostatic traps for venting only.

4. Use only 1/2-in., 15-degree swing check
valves installed horizontally, piped open
to atmosphere, and located at least 12 in.
above the condensate outlet. Do not use
45-degree, vertical lift and ring check
valves.

5. The supply valve must be sized for the
maximum anticipated steam load.

6. Do not drip steam mains into coil sec­tions. Drip them on the pressure side of
the control valve and trap them into the
return main beyond the trap for the coil.

7. Do not use a single trap for two or more
coils installed in series. Where two or
more coils are installed in a single bank,
in parallel, the use of a single trap is per­missible, but only if the load on each coil
is equal. Where loads in the same coil
bank vary, best practice is to use a sepa­rate trap for each coil. Variation in load on
different coils in the same bank may be
caused by several factors. Two of the
most common are uneven airflow distribu­tion across the coil and stratification of
inlet air across the coil.

8. Do not try to lift condensate above the coil
return into an overhead main, or drain into
a main under pressure with a modulating
or on/off steam control valves. A pump
and receiver should be installed between
the coil condensate traps and overhead
mains and return mains under pressure.

9. Use a strainer (3/32-in. mesh) on the
steam supply side, as shown in the piping
diagrams, to avoid collection of scale or
other foreign matter in the inner tube dis­tributing orifices.

NOTE: IDT coils must be installed with the
tubes draining toward the header end of the
coil. The IDT steam coils are pitched toward
the header end as installed in the unit.

10. Ensure the AHU (air-handling unit) is in-

035-000049-001 Page 16 HCA IOM 1.1 8-28-2017

stalled level to maintain the inherent slope.
Also ensure the unit is installed high enough
to allow the piping to be installed correctly,
especially the traps which require long drip
legs.

11. Do not fail to provide all coils with the proper
air vents to eliminate noncondensable gas­ses.

12. Do not support steam piping from the coil
units. Both mains and coil sections should
be supported separately.

IDT Steam Coil Installation — Refer to drawings
to position the coils properly with regard to the
location of the supply and return connections.
Ensure that the IDT coil is pitched with the tubes
draining toward the header. The AHUs provide
proper coil pitch when the AHU is installed level.
Refer to schematic piping diagrams and piping
connection notes for the recommended piping
methods.

SUCTION PIPING — Connect suction piping as shown
in Fig. 13 for face split coil.

Fig. 13 — Face Split Coil Suction Line Piping

(TXV — Thermostatic Expansion Valve)

Refrigerant Piping, Direct-Expansion (DX)
Coils —

Direct-expansion coils are divided into 1 or 2 splits
depending upon the unit size and coil circuiting.
Each split requires its own distributor nozzle, ex­pansion valve, and suction piping. Suction con­nections are on the air entering side when the coil
is properly installed. Matching distributor connec­tions for each coil split are on the air leaving side.
See unit label or certified drawing to assure con­nection to matching suction and liquid connec­tions.
The lower split of face split coils should be first on,
last off (Fig. 13).
Row split coils utilize special intertwined circuits;
either split of these row split coils can be first on,
last off.

CAUTION

Direct-expansion coils are shipped pressurized
with dry nitrogen. Release pressure from each
coil split through valves in protective caps before
removing caps.

Do not leave piping open to the atmosphere un­necessarily. Water and water vapor are detri­mental to the refrigerant system. Until the piping
is complete, recap the system and charge with
nitrogen at the end of each workday. Clean all
piping connections before soldering joints.

Failure to follow these procedures could result in
personal injury or equipment damage.

Suction line from coil connection to end of the 15­diameter-long riser should be same tube size as coil
connection to ensure proper refrigerant velocity.
Size remaining suction line to compressor for a
pressure drop equivalent to 2.0 F. This will provide a
total suction line header pressure drop equivalent to
approximately 2.5 F. Refer to Fig. 14 for piping risers
to the compressor.
To minimize the possibility of flooded starts and com­pressor damage during prolonged light load operation,
install an accumulator in the suction line or a solenoid
in the liquid line of last-on, first off split in row-split ap­plications.

Fig. 14 — Suction Line Riser Piping

035-000049-001 Page 17 HCA IOM 1.1 8-28-2017

Refrigerant Piping, Direct-Expansion (DX) Coils
(Cont’d)

EXPANSION VALVE PIPING — Distributor nozzles and
expansion valves sized for acceptable performance for a
range of conditions are factory supplied. Use the AHU (air­handling unit) selection program in the electronic catalog to
select optimal nozzle sizes.
Circuiting selection should result in a circuit loading of 0.8
to 2.0 tons per circuit at design load. Circuit loading must
be evaluated at minimum load to ensure that it does not
drop below 0.6 tons per circuit. Solenoid valves may be
used, if necessary, to shut off the refrigerant supply to indi­vidual expansion valves to maintain adequate coil circuit
loading.
Compressor minimum unloading and TXV quantity is nec­essary to determine minimum tonnage per circuit.
Minimum Unloading Equation:

Example:
Condensing Unit: 38ARS012
Minimum Unloading: 33%
Coil: 6 row, 11 FPI, Half Circuit
Coil Tons per Circuit: 1.68
Total TXVs: 2
In the first example we will determine the tons per circuit
when both TXVs are active and the compressor is unload­ed to its minimum of 33%

There are three different options to control
tons per circuit when using an unloading
compressor. The first is to use drop solenoid
valve control as illustrated above and let the
suction cutoff unloaders “ride” with the load.
The second is to use drop solenoid valve
control as illustrated above with electric un­loaders and let the control algorithm deter­mine the combination of solenoid valves and
unloaders to limit tons per circuit to accepta­ble limits. The third is to limit the minimum
amount of unloading so that tons per circuit
is within acceptable limits.
TXV SENSING BULB—sensing bulb for
TXV is shipped coiled up inside cabinet.
Remove coil connection panel, route sens­ing bulb out through suction line hole in pan­el, reinstall panel. Locate sensing bulb on
horizontal section of suction line , and attach
to tubing using copper plated strap. Attach
sensing bulb between but no lower than the
2-o’clock and 10-o’clock positions. Make
sure that there is good contact between the
bulb cylinder and tubing. INSULATE the
sensing bulb to insure that it reads the tem­perature of the suction line. For dual-circuit
DX coils, make sure to locate the sensing
bulb on the correct suction line.

Electrical Installation

WARNING

To avoid possible injury or death due to
electrical shock, open the power supply dis­connect switch and secure it in an open po­sition during installation.

= .55 tons per circuit at minimum unloading UNACCEPTA­BLE

All field-installed wiring, including the electri-

If we install a liquid line solenoid valve before one of the
TXVs and close it so that only one TXV is active when the
compressor is unloaded to its minimum of 33%, we see the
following:

cal ground, MUST comply with the National
Electrical Code (NEC) as well as applicable
local codes. In addition, all field wiring must
conform to the Class II temperature limita­tions described in the NEC.
Refer to factory wiring diagrams installed in
the unit.

CAUTION

Use only copper conductors for field

= 1.10 tons per circuit at minimum unloading ACCEPTABLE

-installed electrical wiring. Unit ter­minals are not designed to accept
other types of conductors.

035-000049-001 Page 18 HCA IOM 1.1 8-28-2017

START-UP

Pre-Startup

BUILDING ENVELOPE—All building windows and
doors should be installed and closed before starting
unit. During summer construction, avoid unit sweating
by allowing for gradual pull down: use elevated chilled
water temperature, reduce chilled water flow rate
(gpm), use maximum available airflow.
HEATING FLUID TEMPERATURE-Maximum entering
water temperature is 180°F, unless nameplate indicates
200°F. CAUTION: If unit is marked for 200°F maxi­mum entering water temperature, customer must en­sure that water vaporization does not occur especially
at higher elevations when entering water temperatures
are greater than 190°F.
TEMPERATURE CONTROLS-Check that unit or wall
mounted thermostat or field-supplied controller is con­nected to the unit.
OUTSIDE AIR AND FREEZE PROTECTION-

WARNING: Insure that the unit is protected against
freezing conditions Failure to provide freeze pro­tection may result in equipment or property dam­age. Freeze protection measures are customer-

provided and installed and include but are not limited to
low-limit thermostats, automatic temperature controls,
and use of glycol based heat transfer fluids (see section
FREEZE PROTECTION OF WATER PIPING).

1. If “locking quadrant” manual damper operator pro­vided, set to desired position.

2. If damper actuator provided, insure that actuator
opens the damper when the fan turns on, and closes
when fan stops. Test mixing box controls to make sure
OA damper closes on power failure or upon activation
of customer-supplied and installed low limit thermostat
or other freeze protection device.

Start-Up Check List — Remove all construction debris
from unit interior. Remove tools and all foreign objects

before starting unit. Checklist—perform full startup
checklist located on the last page of this manual, and
submit to the factory to register the warranty.

FILTERS — Install unit filters in all filter sections. Pro­tect open filters from drywall dust and construction de­bris.
MOTOR/FAN ASSEMBLY

1. Hand turn fan to make certain it turns freely and fan

wheel does not rub the inlet ring.

2. Check fan speed with a laser-type tachometer to

confirm operating speed (access doors must be
closed to apply correct external static pressure to
the fan).

3. Check direction of rotation (see Fig. 15).

4. Check vibration. If excessive vibration occurs,

check for the following:

A. Shipping screws removed.
B. Inadequate airflow.
C. Damaged wheel.
D. Loose mounting bolts.
E. Wheel or motor out of balance.
F. External vibration isolators improperly ad-

justed.

G. Out-of-balance or corroded wheel

(rebalance or replace if necessary).

H. Accumulation of material on wheel (remove

excess material).

Fig. 15 — Fan Wheel Rotation

COILS

1. Make sure freeze protection measures are
in place to protect water coils from freezing
(see section FREEZE PROTECTION OF
WATER PIPING).

2. Make sure hydronic (water based chllled
water and hot water) systems are filled and
have air removal devices in operation.

3. For hydronic coils with 3ea connections,
make sure that the supply connection is at
the bottom (air leaving side of coil) and re­turn connection is in the middle (air entering
side of coil), and the top connection is
capped with the factory-provided cap.

Start-Up—Run Fan, Set Airflows

CONTROLS
Set up control system so that it correctly runs
the fan as needed and activates control valves
when required. Note that operating cooling with
the fan off can cause the cabinet temperature to
become too low and result in condensation in­side and outside the unit cabinet, leading to un­safe conditions. When fan is not running, cool­ing should be inactive.

START THE FAN
With 4-Speed Control:

1. Using a thermostat: Route R, C and G1
connections in the HCA control box to the
matching thermostat connections (include
G2 and G3 if required). Set thermostat to
run the fan at speed G1.

2. Without a thermostat: Jump together the R
and G1 terminals in the control box.

3. While fan is running, adjust potentiometer
marked “FLO1” that controls fan speed G1
using a small flat blade screwdriver. Repeat
for the other speeds as needed.

With 0-10VDC Control:

1. Using a thermostat: Route R, C, + (plus)
and -(minus) connections in the HCA control
box to the matching thermostat connections.
Set the thermostat to run the fan.

2. Without a thermostat: Provide a DC control
voltage across the + (plus) and — (minus)
terminals.

3. Fan starts at 2.0VDC. Fan speed varies
across available range (pre-programmed at
factory) from 2.0 VDC (minimum speed) to

10.0 VDC (maximum speed).

035-000049-001 Page 19 HCA IOM 1.1 8-28-2017

DANGER

NEVER enter an enclosed fan cabinet or reach
into a unit while the fan is running.
LOCK OPEN AND TAG the fan motor power dis­connect switch before working on a fan. Take fus­es with you and note removal on tag. Electric
shock can cause personal injury or death.
LOCK OPEN AND TAG the electric heat coil pow­er disconnect switch before working on or near
heaters.
Failure to follow these warnings could lead to per­sonal injury or death.

SERVICE

General

1. Place a suitable walkway to protect floor insula­tion whenever entering the fan section.

2. Review Safety Considerations at beginning of
these instructions. Good safety habits are im­portant tools when performing service proce­dures.

3. To make speed measurements, use a laser-style
tachometer and make sure the access doors are
closed.

Fan Motor Replacement

Shut off motor power and lock out power supply.
Procedure:

1. Disconnect motor power and control wiring har­ness(es).

2. Loosen fan inlet ring on motor side of the unit.

3. Carefully remove motor mounting bolts where
they attach to the housing. WARNING: Blower
motor/wheel assembly will fall, so be sure to fully
support the assembly before removing the bolts.

4. Remove fan motor and wheel assembly and inlet
ring from the blower housing and unit.

5. Remove the wheel from the fan motor shaft by
loosening the setscrew.

6. Before removing motor mount from motor, mark
the location of the motor mount for reference.

7. Attach new motor to existing or new wheel.
NOTE! Install blower ring BETWEEN motor and
wheel.

8. Attach existing motor mount to new motor, using
mark on old motor as a reference.

9. Install motor/wheel/ring assembly in the fan
housing. Ring is loose. Reinstall ring and motor
mount bolts.

10. Reattach motor harness to motor.

11. Return unit to serviceInstall impeller on new mo­tor (or new impeller on motor):

Fan System Periodic Maintenance

1. Magic Aire strongly recommends use of a Pre­ventive Maintenance program to insure that the
unit operates safely and efficiently.

2. Deposits of dust or other debris on the impeller
can cause vibration and premature failure. Fol-

low cleaning instructions in section “Fan
Maintenance & Cleaning”.

Fan Maintenance & Cleaning

1. Regular inspection, and cleaning is neces­sary to prevent imbalance due to ingress of
dirt.

2. Clean the fan’s flow area - maintenance inter­val in accordance with the degree of contami­nation. Verify vibration free motion.

3. The fan wheel can be cleaned with a moist
cloth.

4. Do not use any aggressive, paint solvent
cleaning agents when cleaning.

5. Never use a high-pressure cleaner or water­spray for cleaning - particularly when the fan
is running.

WARNING! Wet cleaning under volt­age may lead to electric shock and
serious injury or death!

Coil Cleaning

DETERGENT — Spray mild detergent solution on
coils with garden-type sprayer. Rinse with fresh
water. Check to ensure condensate line is free.
Excess water from cleaning may flood unit if con­densate line is plugged.

Winter Shutdown (Chilled Water Coil Only)

ANTIFREEZE METHODS OF COIL PROTEC­TION

1. Close coil water supply and return valves.

2. Drain coil as follows:
Method I — ‘Break’ flange of coupling at each
header location. Separate flange or coupling
connection to facilitate coil draining.
Method II — Open both valves to auxiliary
drain piping.

3. After coil is drained:

Method I — Connect line with a service valve and
union from upper connection to an antifreeze res­ervoir. Connect a self-priming reversible pump
between the low header connection and the res­ervoir.
Method II — Make connection to auxiliary drain
valves.

4. Fill reservoir with any inhibited antifreeze ac­ceptable to code and underwriter authority.

5. Open service valve and circulate solution for
15 minutes; then check its strength.

6. If solution is too weak, add more antifreeze
until desired strength is reached, then circu­late solution through coil for 15 minutes or
until concentration is satisfactory.

7. Remove upper line from reservoir to reversi­ble pump. Drain coil to reservoir and then
close service valve.

8. Break union and remove reservoir and its
lines.

9. Leave coil flanges or coupling open and aux­iliary drain valves open until spring.

AIR DRYING METHOD OF COIL PROTECTION
(Unit and coil must be level for this method.)

1. Close coil water supply and return main
valves.

035-000049-001 Page 20 HCA IOM 1.1 8-28-2017

SERVICE—Fan Motor Replacement (cont’d)

2. Drain coil as described in procedures for Anti­freeze Methods of Coil Protection.

3. Connect air supply or air blower to inlet header
connection and close its drain connection.

4. Circulate air and check for air dryness by hold­ing mirror in front of open vent in outlet header
drain connection. Mirror will fog if water is still
present.

5. Allow coil to stand for a few minutes; repeat
Step 4 until coil is dry.

PIPING — Direct expansion, chilled water, and hot
water coils should always be piped for counterflow.
(Fluid should enter the coil at the leaving-air side.)
Steam coils must have the condensate connection
at bottom of coil.
To determine intervals for cleaning coils in contami­nated air operations, pressure taps should be in­stalled across the coils and checked periodically.
Abnormal air pressure drop will indicate a need for
cleaning the coils.

Steam Systems

Annual steam system maintenance should include:

1. Clean the line strainers.

2. Blow down the dirt leg.

3. Clean and check operation of steam traps.

4. Check operation of control valves.

5. Check the operation of check valves to prevent
condensate flowback.

6. Check operation of thermostatic air vents, if
used. A float and thermostatic trap will contain
a thermostatic air vent. When the bellows is
ruptured, it will fail closed.

7. Check operation of vacuum breakers.

8. Check operation of the thermal protection devic-

es used for freeze-up protection.

9. Steam or condensate should not be allowed to

remain in the coil during the off season. This will
prevent the formation and build up of acids.
There are additional precautions and control strate­gies, as found in various catalogues and in the
ASHRAE Fundamentals Handbook when the enter­ing-air temperature to the coil falls below 35 F.
These conditions occur when IDT coils are used for
pre-heat and/or face and bypass applications.
Freeze up protection:

1. Use a strainer in the supply line and the dirt leg

ahead of the trap.

2. Use a vacuum breaker in the return.

3. Do not use overhead returns from the coil. A

floodback can occur.

4. An immersion thermostat to control outdoor-air

dampers and the fan motor is recommended. This
control is activated when the steam supply fails or
the condensate temperature drops below a prede­termined temperature, usually 120 F.

5. On low pressure and vacuum systems, the im-

mersion thermostat may be replaced by a conden­sate drain with a thermal element. This element
opens and drains the coil when the condensate

temperature drops below 165 F. Note the ther­mal condensate drain is limited to 5 psig pres­sure. At greater coil pressures they will not
open.
In spite of the precautions listed above, a coil
may still freeze up. An oversize capacity coil, at
partial load, with a modulating steam control
valve will occasionally freeze. Freezing occurs
in the 20 F to 35 F range of entering-air tem­peratures. A better installation would be an un­dersize coil, with an on/off control valve with
thermostatic control in the outside air, set at 35
F air temperature, installed downstream of the
first coil; or setting the minimum steam pres­sure at 5 psig.

Filters

FILTER SECTIONS — Open or remove filter
panel to replace old filter with a new filter. See
physical data tables for filter data.

035-000049-001 Page 21 HCA IOM 1.1 8-28-2017

SERVICE-Coil & Drainpan Removal and Reinstallation Procedure

1. Perform procedure on the ground for safety. If
working at heights USE EXTREME CAUTION
observe all FALL SAFETY considerations.
Under all conditions, LOCK OUT all power
supplies before performing this procedure.

2. Isolate and drain coil from heating/cooling fluid
and/or reclaim refrigerant. Disconnect unit
from piping. Remove supply piping to allow
access into the coil section from the side. Re­fer to Service Clearance drawing to determine
required clear space.

3. Remove the flat coil stubout panel. Refer to
Figure 16 and 17. Note that there is another
coil access panel on the opposite side of the
unit.

Coil Stubout
Panel

4. Remove filter door and filter (Figure 17
and 18).

5. Remove coil retaining screws (4ea sizes
04-20, up to 6ea sizes 30-40). Screws
attach the first coil to the coil panel.
Screws are visible from the coil side
(Figure 19) and are accessible from the
filter side of the unit (Figure 20).

Filter
Door

Figure 16

Figure 19

Coil Retaining Screws

Figure 17

Coil Stubout Panel shown removed

Figure 20

Coil Retaining Screws-filter side view (filter

removed)

Figure 18

Filter removal

035-000049-001 Page 22 HCA IOM 1.1 8-28-2017

SERVICE-Coil & Drainpan Removal and Reinstallation Procedure

6. Remove top panel screws at sides and rear

(rear leg and coil panel) to allow top to be
lifted up. Front screws can remain. Remove
top filter rail. (Figure 21 and 22). WARN-

ING! Insure unit is adequately supported

before removing top panel screws!

Top Panel

Top Panel

Flange

Top Filter
Rail

Rear Leg

Figure 21

Figure 24

Figure 22

7. Remove screws at bottom of coil panel. Re­move coil panel. (Figure 23 and 24)

Plastic

Drainpan

Figure 25

Stainless

Steel

Drainpan

Figure 23

Figure26

8. Remove coils from unit along with drainpan.
Drainpan will slide out of unit (Figure 25 or

26). To remove coils and drainpan, top will
need to be lifted up as shown in Figure 21.

10. Follow instructions in reverse to
reassemble the unit.

9. At this point, the drainpan or one or more
coils may be replaced.

035-000049-001 Page 23 HCA IOM 1.1 8-28-2017

Magic Aire Water Quality Guidelines

For Heat Exchanger Coils with Copper Tubes

Introduction:

Poor cooling/heating water quality can cause serious problems. Ground source
or open loop water quality varies and therefore should be tested to determine
suitability for use with Magic Aire equipment. Test water for hardness, acidity
and iron content before the equipment is installed. Poor water quality can cause
one or more of the following problems: mineral deposits, sediment deposits or
corrosion. These problems will result in fouling, contamination or damage to
water coils and may render them inoperable or inefficient. It is the responsibility
of the customer to insure that the water quality meets or exceeds water quality
specifications prescribed in Table 1.

Table 1

Condition

pH 7 to 9
Total Hardness
Iron Oxides < 1 ppm.

Iron Bacteria No level allowable.
Brackish

Sediment/Solids

Corrosion

1

Calcium and magnesium carbonate should not exceed 20
grains per gallon (350 ppm).

Calcium or sodium chloride concentrations ≤ 125 ppm.

(Seawater is approximately 25,000 ppm)

Provide ≤ 800 micron filtration on open loop or ground

source systems.
Ammonia, Ammonium Hydroxide 0.5 ppm max.
Ammonium Chloride, Ammonium Nitrate 0.5 ppm max.
Ammonium Sulfate 0.5 ppm max.
Chlorine/Chlorides 0.5 ppm max.
Hydrogen Sulfide

2

Acceptable Level

None Allowable

NOTES:

1. If the concentration of these corrosives exceeds the maximum allowable level, then the
potential for serious corrosion problems exists.

2. Sulfides in the water quickly oxidize when exposed to air, requiring that no agitation occur as
the sample is taken. Unless tested immediately at the site, the sample will require stabilization
with a few drops of one Molar zinc acetate solution, allowing accurate sulfide determination up to
24 hours after sampling. A low pH and high alkalinity cause system problems, even when both
values are within ranges shown. The term pH refers to the acidity, basicity, or neutrality of the
water supply. Below 7.0, the water is considered to be acidic. Above 7.0, water is considered to
be basic. Neutral water contains a pH of 7.0.

3. To convert ppm to grains per gallon, divide by 17. Hardness in mg/l is equivalent to ppm.

035-000049-001 Page 24 HCA IOM 1.1 8-28-2017

0406081216

20

1- Row

1.58

1.79

1.50

2.39

4.03

5.00

2- Row

1.58

1.79

1.56

2.39

3.52

4.38

4- Row

1.58

1.79

2.00

3.06

4.03

5.00

6- Row

1.58

1.79

2.00

3.06

3.94

5.00

4-Row

0.875

6-Row

1.125

(note 2)

(dua l ckt)

(dua l ckt)

Unit Size

Actua l size

Note 1)

Model HCA

2" Pl ea te d (MERV 8)

4" Pl ea te d (MERV 13)

Su cti on (OD Sw e a t) 2ea

Su cti on (OD Sw e a t) 2ea

Tube)

PHYSICAL DATA

Nomi na l Capa city (Tons )
Nomi na l Capa city (BTU/H R)
Nomi na l Airfl ow (CFM)
Fa n
Fa n Si ze
Pre-Fil ter

Qua nti ty /

Coi l Fa ce Are a

Fa ce Area -Hydroni c
(s q ft.)

Fa ce Area -DX (s q ft.)
Fa ce Area -Stea m He ati ng (s q ft.)
Coi l Ro ws /FPI
Chi l le d Wate r/2-Pi p e - 4 row
Chi l le d Wate r/2-Pi p e - 6 row
Std Ca paci ty Stea m 2/8 2/8 2/6 2/6 2/6 2/6
Hi gh Capa ci ty Stea m - - 2/14 2/14 2/14 2/14
Std Ca paci ty DX
Hi gh Capa ci ty DX
Ma x Coil Rows
Coi l Conne cti ons (i n )

Chi l le d Wa te r (OD Coppe r

(See

1 1.5 2 3 4 5

12000 18000 24000 36000 48000 60000

400 600 800 1200 1600 2000

97-6T 90-6R 120-11R

12 x 24 16 x 32

1.19 1.79 2.00 3.06 4.03 5.00

1.13 1.13 1.88 2.86 3.63 4.50

4/10 4/10 4/10 4/10 4/10 4/10
6/10 6/10 6/10 6/10 6/10 6/10

3/10 3/10 3/12 3/10 3/12 3/12
6/10 6/10 6/10 6/10 6/10 6/10

10 Rows Tota l (note 1)

0.75 0.75 0.75

0.875

20 x 20

1.125

Ho t Wa ter (OD Copper Tu b e )
Ste am-Std Ca p -Sup p l y/Return (MPT)
Ste am-Hi gh Ca p-Supply/Return (MPT)

Std Ca p DX

Std Ca p DX

Hi gh Ca p DX

Hi gh Ca p DX

Conde n s ate Dra in Li ne
Prima ry & Au xi li ary
Coi l Vol u me
Hot Wa te r - 1 row (ga l)
Hot Wa te r - 2 row (ga l)
Chi l le d Wate r/2-Pi p e - 4 row (ga l)
Chi l le d Wate r/2-Pi p e - 6 row (ga l)
Std Ca paci ty DX 68 103 115 175 231 286
Hi gh Capa ci ty DX 136 205 229 350 461 573

Notes:

1. Ste a m coil s a re 1-row, 5/8" tube -i n -tube s tea m di stributi n g type con s truction. Wh e n ca l cua ti ng tota l

rows of coi l for th e uni t, thes e cou n t a s 2 rows .

2. For dua l circui t coi ls , vol u me pe r ci rcuit i s ha l f of tha t li s ted.

3. Not a ll combi na tio ns equa li ng 10 rows are a ll owe d. Pl ea se re fer to Ne w Ma gic 4 Softwa re for

pe rmi ss ibl e se l ecti ons.

Li qui d (OD Swe a t)
Su cti on (OD Sw e a t)
Li qui d (OD Swe a t) 2ea

Li qui d (OD Swe a t)
Su cti on (OD Sw e a t)
Li qui d (OD Swe a t) 2ea

(cu i n)

0.75 0.625 0.625 0.625 0.875 0.875

1.50/1.00 1.50/1.00 1.50/1.00 1.50/1.00 1.50/1.00 1.50/1.00

- - 1.50/1.00 1.50/1.00 1.50/1.00 1.50/1.00

0.375 0.375 0.375 0.375 0.375 0.625

0.625 0.625 0.75 0.75 0.75 1.125

- - 0.375 0.375 0.375 0.375

- - 0.75 0.75 0.75 0.75

0.375 0.375 0.375 0.5 0.625 0.625

0.75 0.75 0.75 0.875 0.875 1.125

- - 0.375 0.375 0.5 0.5

- - 0.75 0.75 0.875 0.875

3/4" FPT

0.1 0.2 0.2 0.3 0.5 0.6

0.3 0.3 0.3 0.7 0.7 0.9

0.5 0.6 0.6 0.8 1.1 1.4

0.8 0.9 0.8 1.3 1.7 2.1

035-000049-001 Page 25 HCA IOM 1.1 8-28-2017

035-000049-001 Page 26 HCA IOM 1.1 8-28-2017

AIR HANDLERS AND FAN

COILS

Warranty Registraon and Start-up Report

Warranty Registration Form: Complete
and submit this form within ten (10) days of
start-up to comply with the terms of the
Magic Aire warranty. Form must be com­pleted to clearly indicate startup for each

Mail form(s) to Magic Aire
Warranty Department
501 Galveston St.
Wichita Falls, TX, 76301 or

Email [e-mail]

unit being registered.

Job Name City

Sales Order # Unit Tag

Model Number Serial Number

Installer Quantity of Units

STARTUP REPORT

Group Checklist Item Yes No

Have red shipping screws been removed from pallet and blower rails?

Electrical/Operational

Does electrical service correspond to unit nameplate?

-Nameplate Supply Voltage/Phase: Rated_________ Measured___________

-Nameplate Rated FLA motor current: Rated_______ Measured__________
Does all field wiring conform to unit wiring diagram?
Is field-provided freeze protection present? (for DX and hydronic coils)
Is fan wheel turning the correct direction?
Are mixing box dampers operating properly?

Is the filter clean?
Is unit properly supported?

Structural

Is unit installed level (necessary for proper condensate drainage)?
Is properly sized condensate trap present?
Is the condensate disposal system operating correctly?
Is auxiliary external condensate drain pan installed as recommended by IOM? (not

required for valid warranty)

DX Sys-

tems

Check

Systems

Is expansion valve sensing bulb properly installed and insulated?
Is Heat Pump Bypass Kit (HPK) present if required?

Is the DX system charged per the condensing unit mfr’s instructions?
Is unit piping correct and insulated to prevent condensation?

Piping

Are the control valve packages piped correctly?
Are Valve packages properly insulated?
Are there any leaks detected: interior to unit, at connections, or at valve packages?
Have customer-provided Freeze Protection measures been taken, such as Low

Limit Thermostats and glycol (antifreeze) heat transfer fluids?

Hydronic

Does the hydronic system include a pressure relief valve or other pressure relief
device to protect the coil from operating pressures beyond the nameplate design
working pressure rating?

Are coils equipped with control valves to stop fluid flow to save energy and prevent
cabinet condensation (wild coil in cooling) when heating/cooling is not required?

035-000049-001 Page 27 HCA IOM 1.1 8-28-2017

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035-000049-001 Page 28 HCA IOM 1.1 8-28-2017

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035-000049-001 Page 29 HCA IOM 1.1 8-28-2017

HCA Series Air Handler

Installation, Operation and Maintenance
Manual

035-000049-001 Page 30 HCA IOM 1.1 8-28-2017