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035-000049-001 

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HCA IOM 1.1 8-28-2017 

SERVICE 

General 

1.  Place a suitable walkway to protect floor insula-

tion whenever entering the fan section. 

2.  Review Safety Considerations at beginning of 

these instructions. Good safety habits are im-
portant tools when performing service proce-
dures. 

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 har-

ness(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 mo-

tor (or new impeller on motor):    

Fan System Periodic Maintenance 

1.  Magic Aire strongly recommends use of a Pre-

ventive 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 neces-

sary to prevent imbalance due to ingress of 
dirt.   

2.  Clean the fan’s flow area - maintenance inter-

val in accordance with the degree of contami-
nation.  

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 water-

spray for cleaning - particularly when the fan 
is running. 

WARNING!  Wet cleaning under volt-
age 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 con-
densate line is plugged. 

Winter Shutdown (Chilled Water Coil Only) 

ANTIFREEZE METHODS OF COIL PROTEC-
TION 
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 res-
ervoir. Connect a self-priming reversible pump 
between the low header connection and the res-
ervoir. 

Method II 

— Make connection to auxiliary drain 

valves. 
4.  Fill reservoir with any inhibited antifreeze ac-

ceptable 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 circu-
late solution through coil for 15 minutes or 
until concentration is satisfactory. 

7.  Remove upper line from reservoir to reversi-

ble 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 aux-

iliary 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. 

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 dis-
connect switch before working on a fan. Take fus-
es with you and note removal on tag. Electric 
shock can cause personal injury or death. 
LOCK OPEN AND TAG the electric heat coil pow-
er disconnect switch before working on or near 
heaters. 
Failure to follow these warnings could lead to per-
sonal injury or death. 

Summary of Contents for HCA 04

Page 1: ...ARNING 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 fini...

Page 2: ...035 000049 001 Page 2 HCA IOM 1 1 8 28 2017 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 3: ...G Remove Shipping Screws 4 PREINSTALLATION 5 Rigging 5 Unit Weight Calculation 5 INSTALLATION 6 18 Unit Suspension 6 7 External Vibration Isolators 7 Ductwork 8 Electrical 9 11 Service Clearance 12 Co...

Page 4: ...ampers 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 DANGER...

Page 5: ...l 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...

Page 6: ...ming be construct ed from structural steel or formed strut mate rials 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 d...

Page 7: ...JURY CAUSED BY FALLING EQUIPMENT If uncertain about how to connect to the structure consult a qualified structural engineer Floor mounting Unit may be mounted on a housekeeping pad floor or platform C...

Page 8: ...side of a field provided flexible duct to the fan discharge duct collar on the front of the unit Attach the other side to the supply ductwork Seal the connec tions using duct mastic or HVAC tape Refe...

Page 9: ...WARNING For use with copper conductors only INSTALLATION ELECTRICAL INSTALLATION ELECTRICAL Typical wiring diagrams are shown on the fol lowing pages FOR REFERENCE Always re fer to the wiring diagram...

Page 10: ...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 four...

Page 11: ...components is the responsibility of the in staller 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...

Page 12: ...S 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...

Page 13: ...vent 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...

Page 14: ...nto the condensate line between the trap and the gate valve instead of open to the atmosphere Figure 9 illustrates the typical piping at the end of every steam supply main Omitting this causes many fi...

Page 15: ...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 Fig 10 Multiple Coil High P...

Page 16: ...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 to ward the co...

Page 17: ...ions 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 SUCTION...

Page 18: ...o 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 un lo...

Page 19: ...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...

Page 20: ...use any aggressive paint solvent cleaning agents when cleaning 5 Never use a high pressure cleaner or water spray for cleaning particularly when the fan is running WARNING Wet cleaning under volt age...

Page 21: ...prevent the formation and build up of acids There are additional precautions and control strate gies as found in various catalogues and in the ASHRAE Fundamentals Handbook when the enter ing air tempe...

Page 22: ...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 SERVICE Coil Drainpan Removal and Reinstallatio...

Page 23: ...il panel Figure 23 and 24 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...

Page 24: ...nation 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 wa...

Page 25: ...mary Auxiliary cu in note 2 Hot Water 1 row gal Hot Water 2 row gal Coil Face Area Pre Filter 12 x 24 16 x 32 3 Not all combinations equaling 10 rows are allowed Please refer to New Magic 4 Software f...

Page 26: ...035 000049 001 Page 26 HCA IOM 1 1 8 28 2017...

Page 27: ...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 recomm...

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Page 29: ...035 000049 001 Page 29 HCA IOM 1 1 8 28 2017 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 30: ...035 000049 001 Page 30 HCA IOM 1 1 8 28 2017 HCA Series Air Handler Installation Operation and Maintenance Manual...

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