Magic Aire HCA Series User Manual

035-000049-001 Page 1 HCA IOM 1.1 8-28-2017
How to Use this Manual:
This manual gives instructions regarding in-
stallation, operation and maintenance for the
HCA Series air handling units. For more in-
formation refer to:
Catalog brochure for unit dimensions,
options, guide specifications and perfor-
mance information.
New Magic 4 software for faster selection
of new equipment.
Website www.magicaire.com for re-
placement parts guide, software down-
loads, 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.
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.
GENERAL
Installation and maintenance are to be per-
formed only by qualified personnel who are fa-
miliar 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 – Discon-
nect and Lock Out all incoming power
sources before servicing or installing unit.
ELECTRIC SHOCK CAN CAUSE DEATH.
WARNING: This equipment may be in-
stalled well above finished floor—Use ex-
treme caution when working at heights.
SAFETY WARNING:
Installer should pay particular attention to the
following words:
NOTE–intended to clarify or make installation
easier.
CAUTION–given to prevent equipment dam-
age.
WARNING–to alert installer that personal inju-
ry and/or equipment damage may result if in-
stallation procedure is not properly followed.
HCA Series Air Handler
Installation, Operation and Maintenance
Manual
UNPACKING-CHECK FOR DAMAGE!
Immediately inspect each unit for dam-
age 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.
Magic Aire HCA Series units
are direct drive High Efficien-
cy 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.

Magic Aire HCA Series Specifications

General

Type	Horizontal or Vertical
Motor Type	PSC or ECM
Cabinet	Galvanized Steel
Insulation	1" Thick Foam Insulation
Filter Type	Washable Filters
Dimensions (H x W x D)	Varies based on model
Weight	Varies based on model

Summary

General Installation Safety

Safety Terminology and General Precautions

Defines warning terms and covers qualified personnel, sharp edges, and hazardous voltage.

Critical Installation Safety Procedures

Electrical and Fan Operation Hazards

Critical warnings about electric shock, fan operation, and heater safety.

Rigging, Handling, and Shipping Screw Removal

Safety for rigging, handling, ventilation, and blower shipping screw removal.

Unit Suspension Methods

Ceiling Suspension Techniques

Details methods for suspending units via rods, platforms, or crossbeams.

Floor Mounting and Vibration Isolation

Structural Support Safety Assurance

Emphasizes secure support and consulting engineers for safe installation.

Electrical Installation

Safety Precautions and General Wiring

Covers electrical safety warnings and general wiring connection guidance.

Service Clearances and Dimensions

Required Service Clearances

Illustrates and specifies clearances needed around the unit for service access.

Condensate Drain System

Condensate Drain Piping Details

Illustrates drain detail, dimensions, and notes for proper condensate drainage.

Condensate Drain Installation and Protection

Steam Coil Freeze-Up Protection

Protection Methods for Steam Coils

Covers protection for preheating outdoor air and using thermostats/drain elements.

IDT Steam Coil Piping Guidelines

Refrigerant Piping (DX Coils)

Suction Piping for Face Split Coils

Details suction piping connections for face split coil DX systems (Fig 13).

DX Coil Piping and Sizing

DX System Expansion Valve Piping

Expansion Valve Sizing and Control

Discusses expansion valve sizing, circuit loading, and control options.

Start-Up Procedures

Pre-Startup Checks and Preparation

Covers building envelope, fluid temperature, controls, and freeze protection.

Unit and Fan Checks

Fan Operation and Airflow Control

Controlling Fan Speed and Airflow

Details setting up controls, running the fan, and adjusting speeds for 4-speed and 0-10VDC.

Steam System Maintenance

Steam Coil Freeze-Up Prevention

Strategies to prevent freezing in steam coils, including thermostat and pressure settings.

Coil and Drainpan Removal

Coil Removal Safety and Preparation

Covers safety precautions, isolating coils, and removing access panels.

Removing Coil Retaining Screws

Water Quality Guidelines

Acceptable Water Quality Standards

Warranty Registration and Startup Report

Warranty Registration Form Completion

Startup Report Checklist

A checklist for verifying installation and operational readiness before startup.