010-200021-000 Page 1 DHB IOM 1.3 08-15-2012

AIR HANDLERS AND FANCOILS

t ĂƌƌĂŶƚLJ�ZĞŐŝƐƚƌĂƟŽŶ�ĂŶĚ�̂ ƚĂƌƚ-up Report

Warranty Registration Form: Completeand submit this form within ten (10) days ofstart-up to comply with the terms of theMagic Aire warranty. Form must be com-pleted to clearly indicate startup for eachunit being registered.

Mail form(s) to Magic AireWarranty Department501 Galveston St.

Wichita Falls, TX, 76301 orEmail customer.service@MagicAire.com

STARTUP REPORT

Group Checklist Item Yes No

Ele

ctric

al/O

pera

tion

al

Have red shipping screws been removed from blower discharge?

Does electrical service correspond to unit nameplate?

-Nameplate Supply Voltage/PhaseVoltage:

Phase:

-Nameplate Rated FLA motor current (Amps).Actual Motor Current:

Does all field wiring conform to unit wiring diagram?

Is field-provided freeze protection present? (for DX and hydroniccoils)

Is fan wheel turning the correct direction?

Are mixing box dampers operating properly?

Is the filter clean?

Stru

ctu

ral

Is unit properly supported?

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 recommend-ed by IOM and Int’l Mech’l Code? (not required for valid warranty)

DX

Syste

ms

Is expansion valve bulb properly installed and insulated?

Is Heat Pump Bypass Kit (HPK) present if required?

Has the DX system been charged with refrigerant according to thecondensing unit manufacturer’s instructions?

Pip

ing

Ch

eck

Is unit piping correct and insulated to prevent condensation?

Are the control valve packages piped correctly?

Are Valve packages properly insulated?

Are there any leaks detected?

-interior to unit?

-at unit piping connections?

-at valve packages or other piping modified in the installation?

Job Name City

Sales Order # Unit Tag

Model Number Serial Number

Installer Quantity of Units

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DHB SERIESMagic Aire Fan Coil Unit – Sizes 04 through 10

Installation, Operation and Maintenance Manual

The Magic Aire® Fan Coil Unit isdesigned for use in any air distribu-tion system. It is easily adaptable tomost types of existing or new forced-air heating systems, or it can be in-stalled in an independent air coolingsystem.

GENERALImmediately inspect each unit

for damage upon receipt. File anydamage claims with the freight carri-er. Protect stored units from dam-age. Do not stack more than twohigh.

Use these instructions in conjunctionwith other appropriate instructions,including but not limited to those in-structions supplied with the outdoorunit (if applicable). Installation mustcomply with all applicable localcodes.

Pay particular attention to thefollowing words:NOTE–intended to clarify ormake installation easier.CAUTION–given to preventequipment damage.WARNING–to alert installer

that personal injury and/or

equipment damage may re-

sult if installation procedure

is not properly followed.

EXISTING DUCT WORKThe previously installed air distribution system

for heating requires close inspection to determineits suitability for cooling. In general, heating sys-tems designed for outside temperatures of zerodegrees or lower will need no alteration when usedfor cooling. However, in southern sections of thecountry, the existing heating duct work may haveto be modified to provide better air distribution andinsulation for cooling.

DUCT INSULATION AND VAPOR PROOFINGProperly installed heating supply ducts should

already have adequate insulation against exces-sive heat loss. This same insulation should there-fore be satisfactory in the summer to protectagainst heat gain. However, depending on thespecific installation, it may be desirable to add tothe insulation.

All externally insulated duct work must have anadequate vapor seal for summer operation. This isparticularly important where the duct is exposed tohighly humid conditions in such places as attic,vented crawl spaces, unconditioned basements,and utility rooms. The vapor seal prevents conden-sation of moisture in the insulating material andsubsequent loss of its insulating value.

NOTE: Consult a qualified insulation contractorto insure your system is properly insulated.

INSTALLATION1. Remove all packing and foreign material from

unit.2. Check blower wheel for free rotation. RE-

MOVE 2ea RED SHIPPING SCREWS (SeeFigure 1).

3. Check copper lines, coil etc for internal or hid-den damage. Maintain caps and plugs untilready for connection to system.

Figure 1Blower Ship-ping Screws

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4. In an attic installation where unit is restingon the attic floor, a suitable isolation pad orother vibration isolation should be providedto minimize equipment sound transmissionto the living area.

5. The fan coil requires service clearances asindicated in Figure 6. Units are approvedfor 0” (zero inches) of clearance. Units aredesigned for horizontal airflow dischargeonly.

6. Units may be installed with access panelon top – refer to section “TOP ACCESS”.

7. Install condensate drain. See section“CONDENSATE DRAIN”.

8. Attach discharge and return ductwork. Seesection “Placing Unit in Ductwork.”

9. Connect refrigerant liquid and suction pip-ing to unit (DX coil). NOTE: Size and in-stall per condensing unit manufacturer’srecommendations.

10. Connect chilled water supply and returnpiping to unit (Chilled Water coil).CAUTION: Protect cabinet and internalpiping by wrapping each pipe with a wetcloth while brazing.

SUSPENDING THE UNIT FROM A STRUC-TURE

WARNING: Insure that supportingstructure is adequate for the loads be-ing applied. Consult structural designprofessional if required.

The unit may be supported from the floor or itmay be suspended.

All suspension hardware is to be fieldprovided and installed. DO NOT attempt tohang unit from the top.

Before installing any unit, the installermust determine that the weight of the unitcan be safely supported by the floor joists,rafters, ceiling, etc. Care should be taken toinsure that suspension rods and other hard-ware be located so as to not block the ac-cess doors, interfere with the electrical, me-chanical, or drain functions of the units.

Unit may be suspended using all-thread rodin two ways:

PLACING UNIT IN DUCTWORK1. Use flexible duct connectors to supply and

return connections to minimize sound trans-mission from unit to ductwork.

2. When the connecting return air duct is small-er than the coil inlet opening, construct thetransition piece so that the vertical and hori-zontal dimensions of the transition piece donot increase more then one inch for everyseven inches of length of the transition piece.

3. Provide at least three feet of straight ductwork preceding the coil inlet.

4. Install unit so that the entering chilled water ison the leaving air side of the coil (Chilled Wa-ter coil). Refrigerant coils are supplied in theproper orientation. NOTE: If reversed, capaci-ty will be reduced.

5. Install unit so that it pitches slightly –(1/8inch) – toward the condensate drain openingthat is to be used.

SOUND PERFORMANCEThe sound level can be reduced by use of

flexible connections in the duct system nearthe outlet of the Fan-Coil Unit.

CONDENSATE DRAINProvide condensate drain piping material

and size per local code requirements. Pro-vide P-trap with minimum seal of 4.0 inches.Insure that P-trap is installed below the drainelevation to allow pan to drain fully. Pitchdrain piping downward with minimum slope of1/8” per foot, or minimum required by code.NOTE: Failure to provide proper conden-sate drain trap may lead to condensateoverflow and property damage and to un-acceptable IAQ conditions. Auxiliarydrain pan is recommended to preventproperty damage in the event of blockeddrainage system piping.

WARNING-AUXILIARY DRAIN PANRECOMMMENDED: Many municipalitieshave adopted building codes that require the

use of auxiliary drain pans. Magic Aireholds that this practice represents the stand-ard for professional installation whether or notsuch codes exist in a specific municipality orterritory. As such, water damages that wouldhave been prevented had an auxiliary panbeen deployed will not be considered for com-

TOP ACCESSTo change the cabinet to top access, removethe four screws in the coil panel on both thecoil connection side and the opposite side.Slide the coil and drain pan out of the unitcabinet. Turn the unit cabinet over and re-insert the coil and drain pan. Re-install thecoil stub-out panel and the panel on the op-posite side.

1. Use knockouts in top and bottom panel toroute all-thread all the way through unit. Usehex nut and fender washer under bottompanel to support unit.

2. Support unit on two lengths of unistrut thatspan front to back or side to side. Supportunistrut using all-thread rod or other means.

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INSTALLATION OF CHILLED WATERLINES (with Chilled Water Coils)1. If the Fan Coil Unit is located where thecoil is subject to freezing during wintermonths, protect the coil from freezing. Thecoil can be protected by:

A. Use of glycol cooling fluid, and/orB. Circulation of warm air over the coil.

CAUTION: Draining the system maynot protect the coil from freezing. However, the system must be drained whenglycol has not been added, for minimalprotection.

INSTALLATION OF REFRIGERANT LINESSize and install refrigerant lines in accordance withthe condensing unit manufacturer’s instructions.REFRIGERANT PIPING AT THE UNIT: InstallTXV sensing bulb 7 diameters downstream from themanifold on a horizontal section of the suction linein the 3-o'clock or 9-clock position. Insulate thesensing bulb thoroughly so that it receives a goodtemperature signal from the gas in the suction line.For 7/8" O.D. and larger suction lines, use 4-o'clockor 8-o'clock position. Alternately, the sensing bulbmay be located on a descending vertical section ofthe suction line.NOTE: Units with coil “less TXV” are shipped with3/8” Chatleff male refrigerant distributor and with nutand liquid line stubout (3/8” copper tube). On a“less TXV” coil THERE IS NO PISTON METERINGDEVICE PRESENT except with the R-22 “orifice”option. The customer may size, select and fieldinstall a piston to provide metering without a TXV.For best results, use of the factory TXV is recom-mended. Field installable TXV is available as anaccessory.FIELD INSTALLED TXV (Fig 3): Install TXV bythreading on to the distributor. Remove piston fromdistributor, if present. Make sure Teflon gasket (refFig. 2) is present and in good condition, at the dis-tributor and on the TXV. Connect equalizer line toschrader valve connection at the coil.

pensation. This position is taken regardless ofwhether the source of the moisture was speci-fied as a potential failure mode in the applicablebuilding code or not. A freeze burst, crackeddrain pan, failed weld, or corrosion induced leakare some of the potential failure modes that aremitigated when an auxiliary pan is properly in-stalled. Professional installers recognize thevalue of protecting customer assets againstforeseeable events. Customers who choose toavoid the cost of common protective measureswaive their right to seek damages when thoseforeseeable events occur. If the Fan-Coil islocated above a living space or where damagemay result from condensate overflow, install awatertight pan of corrosion-resistant metal be-neath the unit to catch over-flow which mayresult from clogged drains or from other rea-sons. Provide proper drain piping for this auxil-iary pan. Consult local codes for additional pre-cautions before installation.

2. Whenever glycol is added for the heating season,the system may have to be flushed prior to the start ofthe next cooling season because of capacity loss dueto glycol.3. Insulate chilled water piping with good quality insu-lation material with vapor barrier that is continuous upto the unit casing.

Figure 2Orifice Metering Option

Figure 3TXV Installation

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Figure 4PSC Motor Option

Unit Wiring

ELECTRICAL CONNECTIONS

PSC MOTOR: Figure 4 illustrates the internalwiring for the unit. The utility box is mounted onthe coil connection side of the unit. All leads passthrough a strain relief where they enter the utilitybox. Wiring within the cabinet has been positivelylocated and supported so that it does not passover sharp metal edges or come in contact withmoving parts. After servicing, properly positionelectrical leads in their original supports.

ECM MOTOR: Figure 7 indicates the internalwiring for the unit. The electrically commutatedmotor (ECM) has 5 discrete speed settings thatcan be adjusted. The single fan relay allows thethermostat to activate one of the 5 fan speeds.The 24VAC, 40VA control transformer allows theunit to power a thermostat and up to two waterflow control valves. See also Figure 9.

WARNING: CHECK MOTOR RATINGPLATE FOR CORRECT LINE VOLTAGE.This appliance must be permanently ground-ed in accordance with the National ElectricalCode and local codes and ordinances.

NOTE: Reference Figures 5 and 6 for accessto motor and electrical components.

Voltage Phase HP FLA

115 1/10 2.1 2.6

DHB04 208-230 1 1/10 0.8 1.0 15

277 1/6 0.9 1.1

115 2.7 3.4

DHB06 208-230 1 1/6 1.0 1.3 15

277 0.9 1.1

115 4.1 5.1

DHB08 208-230 1 1/4 1.3 1.6 15

277 2.0 2.5

115 6.9 8.6

DHB10 208-230 1 1/3 2.2 2.8 15

277 2.4 3.0

Notes:

1.MCA = Minimum Circuit Ampacity

2.MOPD = Maximum Overcurrent Protective Device, in amps.

3.FLA = Full Load Amps

4.HP = Motor nominal horsepow er.

5.All motors are 60Hz.

6.Use minimum w ire size #14 AWG 75C w ire at unit.

ELECTRICAL DATA - DHB with PSC MOTOR

ModelMotor

MCA MOPD

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Figure 5Access Panels Removed

(ECM Motor option shown)

Figure 6ECM Motor-Connection Detail

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ECM APPLICATION GUIDELINESDHB units with ECM-VE motor have 5 pre-programmed speeds to choose from. Whichspeed is active is selected using the terminalblock.

How it works: Airflow, RPM and static pres-sure is similar to a PSC motor but more sta-ble and much more efficient.1. As system static pressure goes up, RPM

goes up and CFM goes down.2. At around 1050rpm, as SP increases,

CFM decreases rapidly down to zero at1200rpm.

How to select the fan speed:1. Use the airflow tables to locate the de-

sired operating point.2. Identify the corresponding tap number

from the table.3. Move Violet wire (504) to the matching

connection on terminal block TB2.

How to integrate with 24V thermostat:Connect R, C and G connections on terminalblock TB1 to matching connections on ther-mostat. Energizing the G connection will startthe fan.

Figure 7ECM Motor Option

Unit Wiring

115V 208-230V

DHB04 All 1/3 2.4 1.7

DHB06 All 1/3 3.3 2.3

DHB08 All 1/3 3.3 2.3

DHB104R, 6R

Hydronic1/2 4.9 3.5

DHB10

4R DX

(R22 and

R410A)

1/2 5.8 4.1

Notes:

2. Overload Protection: ECM-VE motor is

electronically protected.

3. Locked Rotor Amps: If motor speed decreases

below a programmed stall speed, the motor will shut

down and after a delay period, the control will attempt

to restart the motor. Starting current is limited to

significantly less than full load current.

4. Agency Listings for the motor: UL File: E100625

Vol. 9 for Motor, Vol. 7 Sect. 14 for Control; CSA File:

LR80176

ELECTRICAL DATA - DHB with ECM-VE MOTOR

Unit Size Motor hpMotor FLA

Coil

1. Motor is Genteq X-13 or equivalent.

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Airflow Table-ECM Motor

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Airflow Table-ECM Motor

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Airflow Table-ECM Motor

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Airflow Table-ECM Motor

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Figure 8Service Clearances

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Figure 9ECM Motor Option-

Control Box Connections

Terminal Block “TB1”

Terminal Block “TB2”