Magic Aire DV SERIES User manual

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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
1/3
4.3
4.3
3
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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Figure 7
ECM Motor Option-
Control Box Connections
Terminal Block “TB1”
Terminal Block “TB2”

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Figure 8
Unit Dimensions
(Upflow)

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Figure 9
Unit Dimensions
(Downflow)

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AIR HANDLERS AND FAN
COILS
t ĂƌƌĂŶƚLJZĞŐŝƐƚƌĂƟŽŶĂŶĚ^ƚĂƌƚ-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 com-
pleted to clearly indicate startup for each
unit being registered.
Mail Form(s) to Magic Aire
Warranty Department
501 Galveston St.
Wichita Falls, TX, 76301 or
Email [e-mail]
STARTUP REPORT
Group Checklist Item Yes No
Electrical/Operational
Does electrical service correspond to unit nameplate?
-Nameplate Supply Voltage/Phase Voltage:
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 hydronic coils)
Is fan wheel turning the correct direction?
Are mixing box dampers operating properly?
Is the filter clean?
Structural
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 recommended
by the installation manual? (not required for valid warranty)
DX Systems
Is expansion valve bulb properly installed and insulated?
Is equalizer line connected to the suction line Schrader valve (or to
suction line if field-provided TXV)?
Has the DX system been charged with refrigerant according to the
condensing unit manufacturer’s instructions?
Piping Check
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?
-in the interior of the 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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DV Series Air Handling Unit
Installation, Operation and Maintenance Manual