Magic Aire DV SERIES Bedienungsanleitung

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DV SERIES

Generation B

Magic Aire Fan Coil Unit – Sizes 04 through 10

Installation, Operation and Maintenance Manual

The Magic Aire®Fan Coil Unit is

designed for use in any air distribu-

tion system. It is easily adaptable to

most types of existing or new forced-

air heating systems, or it can be in-

stalled in an independent air cooling

system.

GENERAL

Immediately inspect each unit

for damage upon receipt. File any

damage claims with the freight carri-

er. Protect stored units from dam-

age. Do not stack more than two

high.

Use these instructions in conjunction

with other appropriate instructions,

including but not limited to those in-

structions supplied with the outdoor

unit (if applicable). Installation must

comply with all applicable local

codes.

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 injury and/or

equipment damage may re-

sult if installation procedure

is not properly followed.

EXISTING DUCT WORK

The previously installed air distribution system

for heating requires close inspection to determine

its suitability for cooling. In general, heating sys-

tems designed for outside temperatures of zero

degrees or lower will need no alteration when used

for cooling. However, in southern sections of the

country, the existing heating duct work may have

to be modified to provide better air distribution and

insulation for cooling.

DUCT INSULATION AND VAPOR PROOFING

Properly 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 protect

against heat gain. However, depending on the

specific installation, it may be desirable to add to

the insulation.

All externally insulated duct work must have an

adequate vapor seal for summer operation. This is

particularly important where the duct is exposed to

highly 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 and

subsequent loss of its insulating value.

NOTE: Consult a qualified insulation contractor

to insure your system is properly insulated.

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Topic Page

SAFETY CONSIDERATIONS 1, 5

UNPACKING 1

INSTALLATION 5

Pre-installation 5

Floor Mounting 5

Ductwork 6

Condensate Drain 6

Refrigerant/Chilled Water Piping 6

Freeze Protection 6

Auxiliary Drain Pan 6

Refrigerant Connections, TXV or Orifice 7

Electrical 8-11

DIMENSIONAL DRAWINGS 12-13

STARTUP REPORT 15

Installation, Start-Up

and Service

Instructions

DV Series Air Handling Unit

Installation, Operation and Maintenance

Manual

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INSTALLATION

1. Remove all packing and foreign material

from unit.

2. Check blower wheel for free rotation.

3. Check copper lines, coil etc for internal or

hidden damage. Maintain caps and plugs

until ready for connection to system.

4. In an attic installation where unit is resting

on the attic floor, a suitable isolation pad or

other vibration isolation should be provided

to minimize equipment sound transmission

to the living area.

5. The fan coil requires service clearances as

shown in Figures 8 and 9. Units are ap-

proved for 0” (zero inches) of clearance.

Units are designed for vertical (upflow or

downflow) airflow discharge only.

6. Mount unit on accessory legs (leg kit ac-

cessory) or field-provided stand. WARN-

ING! Make sure to allow at least 4.5”

below the unit for the condensate drain

trap!

7. Mount Install condensate drain. See sec-

tion “CONDENSATE DRAIN”.

8. Attach discharge and return ductwork. See

section “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’s

recommendations.

10. Connect chilled water supply and return

piping to unit (Chilled Water coil).

CAUTION: Protect cabinet and internal

piping by wrapping each pipe with a wet

cloth while brazing.

WARNING: Disconnect and Lock Out all

incoming power sources before connecting

to electrical service.

Attach L1 and L2 to motor neutral and

speed wire lead leads as shown on wiring

diagram on unit front panel. Refer to

nameplate for FLA, MCA and MOPD.

Units with field installed electric heater ac-

cessory may be equipped with fan relay.

The unit should be supported by a suitable

floor surface. Unit is not intended to be

suspended from a ceiling or roof deck.

WARNING: Insure that supporting

structure is adequate for the loads

being applied. Consult structural de-

sign professional if required.

Before installing any unit, the installer must

determine that the weight of the unit can be

safely supported by the floor joists, rafters,

ceiling, etc. Care should be taken to insure

that floor stand or other mounting surface is

located so as to not block the access doors,

interfere with the electrical, mechanical, or

drain functions of the units.

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INSTALLATION OF CHILLED WATER LINES

(with Chilled Water Coils)

1. If the Fan Coil Unit is located where the

coil is subject to freezing during winter months,

protect the coil from freezing. The coil can be

protected by:

A. Use of glycol cooling fluid, and/or

B. Circulation of warm air over the coil.

CAUTION: Draining the system may

not protect the coil from freezing. How

ever, the system must be drained when

glycol has not been added, for minimal

protection.

2. Whenever glycol is added for the heating

season, the system may have to be flushed

prior to the start of the next cooling season

because of capacity loss due to glycol.

3. Insulate chilled water piping with good quali-

ty insulation material with vapor barrier that is

continuous up to the unit casing.

CONDENSATE DRAIN

Provide condensate drain piping material and

size per local code requirements. Provide P-trap

with minimum seal of 4.0 inches. Insure that P-

trap is installed below the drain elevation to allow

pan to drain fully. Pitch drain piping downward

with minimum slope of 1/8” per foot, or minimum

required by code. NOTE: Failure to provide

proper condensate drain trap may lead to

condensate overflow and property damage

and to unacceptable IAQ conditions. Auxilia-

ry drain pan is recommended to prevent prop-

erty damage in the event of blocked drainage

system piping.

WARNING-AUXILIARY DRAIN PAN

RECOMMMENDED: Many municipalities have

adopted building codes that require the use of

auxiliary drain pans. Magic Aire holds that this

practice represents the standard for professional

installation whether or not such codes exist in a

specific municipality or territory. As such, water

damages that would have been prevented had

an auxiliary pan been deployed will not be con-

sidered 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 in-

duced leak are some of the potential failure

modes that are mitigated when an auxiliary pan

is properly installed. Professional installers rec-

ognize 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 Fan

-Coil is located above a living space or where

damage may result from condensate overflow,

FREEZE PROTECTION

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 in-

stalled and include but are not limited to low

-limit thermostats, automatic temperature

controls, and use of glycol based heat

transfer fluids. See also section

“CONDENSATE DRAIN”.

Refrigerant coils may form ice (“freezing”)

under certain non-standard operating condi-

tions. Magic Aire recommends use of a

field-provided and installed low limit thermo-

stat on DX coils to prevent damage and

adverse operation caused by coil icing.

WARNING

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 be-

fore installation.

SUPPLY AND RETURN DUCTWORK

1. 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 the

transition piece so that the vertical and hori-

zontal dimensions of the transition piece do

not increase more then one inch for every

seven inches of length of the transition piece.

3. For best performance, provide at least three

feet of straight duct work preceding the coil

inlet.

4. Install unit so that the entering chilled water is

on the leaving air side of the coil (Chilled Wa-

ter coil). Refrigerant coils are supplied in the

proper orientation. NOTE: If reversed, capaci-

ty will be reduced.

5. Install unit so that it pitches slightly –(1/8

inch) – toward the condensate drain opening

that is to be used.

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INSTALLATION OF REFRIGERANT LINES

Size and install refrigerant lines in accordance

with the condensing unit manufacturer’s instruc-

tions.

REFRIGERANT PIPING AT THE UNIT: Install

TXV sensing bulb 7 diameters downstream from

the manifold on a horizontal section of the suction

line in the 3-o'clock or 9-clock position. Insulate

the sensing bulb thoroughly so that it receives a

good temperature signal from the gas in the suc-

tion line. For 7/8" O.D. and larger suction lines,

use 4-o'clock or 8-o'clock position. Alternately,

the sensing bulb may be located on a descending

vertical section of the suction line.

NOTE: Units with coil “less TXV” are shipped

with 3/8” Chatleff male refrigerant distributor and

with nut and liquid line stubout (3/8” copper tube).

NOTE: On a “less TXV” coil THERE IS NO PIS-

TON METERING DEVICE PRESENT except with

the R-22 “orifice” option. The customer may size,

select and field install a piston to provide metering

without a TXV. For best results, use of the facto-

ry TXV is recommended. Field installable TXV is

available as an accessory.

FIELD INSTALLED TXV—Factory Provided

(Figure 2) Install Factory TXV by threading on to

the distributor. Remove piston (if present) from

distributor. Make sure Teflon gasket (ref Fig.

1) is present and in good condition, at the distrib-

utor and on the TXV. Connect equalizer line to

schrader valve connection at the coil.

Figure 2

TXV Installation

Figure 1

Orifice Metering Option

FIELD INSTALLED TXV—Field Provided

Install field-provided TXV outside the unit cabi-

net in the liquid line. NOTE: Remove piston (if

present) from distributor. Make sure Teflon

gasket (ref Fig. 2) is present and in good condi-

tion, at the distributor. Connect equalizer line to

schrader valve connection at the coil. Use a

schrader depresser fitting or remove the schrad-

er valve body so that the equalizer line reads the

suction line pressure. It is also acceptable to

braze-in a separate equalizer connection next to

the factory connection.

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Figure 3

PSC Motor Option

Unit Wiring

ELECTRICAL CONNECTIONS

PSC MOTOR: Figure 3 illustrates the internal

wiring for the unit. The utility box is mounted on

the coil connection side of the unit. All leads pass

through a strain relief where they enter the utility

box. Wiring within the cabinet has been positively

located and supported so that it does not pass

over sharp metal edges or come in contact with

moving parts. After servicing, properly position

electrical leads in their original supports.

ECM MOTOR: Figure 6 indicates the internal

wiring for the unit. The electrically commutated

motor (ECM) has 5 discrete speed settings that

can be adjusted. The single fan relay allows the

thermostat to activate one of the 5 fan speeds.

The 24VAC, 40VA control transformer allows the

unit to power a thermostat and up to two water

flow control valves. See also Figure 8.

WARNING: CHECK MOTOR RATING

PLATE FOR CORRECT LINE VOLTAGE.

This appliance must be permanently grounded

in accordance with the National Electrical

Code and local codes and ordinances.

NOTE: Reference Figures 4 and 5 for access

to motor and electrical components.

Voltage Phase HP FLA

115 1/10 2.1 2.6

DVB04 208-230 1 1/10 0.8 1.0 15

277 1/6 0.9 1.1

115 2.7 3.4

DVB06 208-230 1 1/6 1.0 1.3 15

277 0.9 1.1

115 4.1 5.1

DVB08 208-230 1 1/4 1.3 1.6 15

277 2.0 2.5

115 6.9 8.6

DVB10 208-230 1 1/3 2.2 2.8 15

277 2.4 3.0

Notes:

1.MCA = MinimumCircuit Ampacity

2.MOPD= MaximumOvercurrent Protective Device, in amps.

3.FLA = Full Load Amps

4.HP= Motor nominal horsepower.

5.All motors are 60Hz.

6.Use minimumwire size #14 AWG75Cwire at unit.

ELECTRICAL DATA - DVB with PSC MOTOR

Model

Motor

MCA MOPD

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Figure 4

Access Panels Removed

(PSC Motor option shown)

Figure 5

ECM Motor-Connection Detail

J Box

(Replaced by control

Box with ECM option)

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ECM APPLICATION GUIDELINES

DV units with ECM motor have 5 pre-

programmed speeds to choose from. Which

speed is active is selected using the terminal

block.

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 at

1200rpm.

How to select the fan speed:

1. Use the airflow tables or New Magic 4

Software to locate the desired 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 terminal

block TB1 to matching connections on ther-

mostat. Energizing the G connection will start

the fan.

Figure 6

ECM Motor-Unit Wiring

ECM ELECTRICAL DATA

Unit Size Coil Motor

hp 115V 208-230V

DVB04 All 1/3 3.2 2.2

DVB06 All

DVB08 All

DVB10 All 1/2 6.8 4.1

Motor FLA

1/3

4.3

Notes:

1. Motor is Regal Beloit Endura Pro or equiva-

lent (formerly model “X-13”).

2. Overload Protection: ECM motor is electroni-

cally protected.

3. Locked Rotor Amps: If motor speed decreas-

es below a programmed stall speed, the mo-

tor will shut down and after a delay period, the

control will attempt to restart the motor. Start-

ing 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

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