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Magic Aire HHA Series units are
direct drive High Static Horizontal
Air Handlers delivering nominal
airflows of 300 to 5000cfm 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 heat-
ing loads or both.
How to Use this Manual:
This manual gives instructions regarding instal-
lation, operation and maintenance for the HHA
Series air handling units. For more information
refer to:
Catalog brochure for unit dimensions, op-
tions, guide specifications and performance
information.
New Magic 4 software for faster selection
of new equipment.
Website
www.magicaire.com
ment parts guide, software downloads,
product data and contact info for your local
Magic Aire representative.
Replacement Parts – Identify parts need-
ed using the replacement parts guide avail-
able at www.magicaire.com.
Use these instructions in conjunction with other
appropriate instructions, including but not lim-
ited to those instructions supplied with the out-
door unit (if applicable). Installation must com-
ply with all applicable local codes.
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 in-
jury and/or equipment damage may result if
installation procedure is not properly followed.
035-000029-001
Installation, Operation and Maintenance
Dangerous voltage is present when input power is
connected. After disconnecting power supply
wait at least 5 minutes before performing any
maintenance.
GENERAL
Installation and maintenance are to be performed
only by qualified personnel who are familiar with
local codes and regulations and are experienced
for replace-
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.
Immediately inspect each unit for damage up-
on receipt.
Inspect units for external and concealed dam-
age 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.
Page 1
HHA Series
Air Handler
Manual
DANGER
VFD Energy Stored!
UNPACKING-CHECK FOR DAMAGE!
HHA IOM 1.4 10/11/2021
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Table of Contents
Related Manuals for Magic Aire HHA Series
Summary of Contents for Magic Aire HHA Series
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Page 1: Safety Considerations
HHA Series Air Handler Installation, Operation and Maintenance Manual Magic Aire HHA Series units are direct drive High Static Horizontal Air Handlers delivering nominal airflows of 300 to 5000cfm and nominal cooling capacities of 1/2 to 10 tons. Units may be specified... - Page 2 THIS PAGE INTENTIONALLY LEFT BLANK 035-000029-001 Page 2 HHA IOM 1.4 10/11/2021...
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Page 3: Table Of Contents
HHA Series Air Handler Installation, Operation and Maintenance Manual Table of Contents Topic Page SAFETY CONSIDERATIONS UNPACKING-Remove Shipping Screws PREINSTALLATION Rigging Unit Weight Calculation Unit Suspension External Vibration Isolators 6 - 7 INSTALLATION Electrical 8 - 23 Service Clearance 24 - 25... -
Page 4: Unpacking-Remove Shipping Screws
DANGER UNPACKING-CAUTION! NEVER enter an enclosed fan cabinet or reach into After removing the outer packaging, a unit while the fan is running. LOCK OPEN AND TAG the fan motor power dis- REMOVE RED BRACKET SCREWS connect switch before working on a fan. Take fuses with you and note removal on tag. -
Page 5: Preinstallation
Set unit off ground if in heavy rain area. Magic Aire holds that this practice repre- b. Remove all fasteners and other small sents the standard for professional installa- parts from jobsite to minimize theft. Tag... -
Page 6: Unit Suspension
UNIT SUSPENSION WARNING! INSURE THAT UNIT IS ADE- Ceiling Suspension: Acceptable forms of unit sus- QUATELY SUPPORTED FROM STRUCTURE pension are shown in Fig. 3, 4, 5a and 5b. A field- TO PREVENT DAMAGE OR INJURY CAUSED supplied platform mount is recommended, espe- BY FALLING EQUIPMENT! If uncertain about cially for larger unit sizes. - Page 7 UNIT SUSPENSION (cont’d) Fig. 5b—Ceiling Suspension– HHA30/40—Hanging Brackets 035-000029-001 Page 7 HHA IOM 1.4 10/11/2021...
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Page 8: Installation
INSTALLATION-ELECTRICAL DANGER 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- VFD Energy Stored! connect switch before working on a fan. Take Dangerous voltage is present when input power is fuses with you and note removal on tag. - Page 9 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “A”, 4-20mA Fan Speed Control 208/230V—1ø NOTES: 1. This diagram represents the factory-installed electrical option with 4-20mA field signal input for fan speed control. Includes VFD keypad mounted on outside of unit. 2. Typical wiring is shown. For exact wiring, refer to the wiring diagram provided with the unit. 3.
- Page 10 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “A”, 4-20mA Fan Speed Control 277V—1ø NOTES: 1. This diagram represents the factory-installed electrical option with 4-20mA field signal input for fan speed control. Includes VFD keypad mounted on outside of unit. 2. Typical wiring is shown. For exact wiring, refer to the wiring diagram provided with the unit. 3.
- Page 11 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “A”, 4-20mA Fan Speed Control 208/240V—3ø NOTES: 1. This diagram represents the factory-installed electrical option with 4-20mA field signal input for fan speed control. Includes VFD keypad mounted on outside of unit. 2. Typical wiring is shown. For exact wiring, refer to the wiring diagram provided with the unit. 3.
- Page 12 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “A”, 4-20mA Fan Speed Control 480V—3ø NOTES: 1. This diagram represents the factory-installed electrical option with 4-20mA field signal input for fan speed control. Includes VFD keypad mounted on outside of unit. 2. Typical wiring is shown. For exact wiring, refer to the wiring diagram provided with the unit. 3.
- Page 13 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “A”, 4-20mA Fan Speed Control 208/230V—3ø with UV light option NOTES: 1. This diagram represents the factory-installed electrical option with 4-20mA field signal input for fan speed control. Includes VFD keypad mounted on outside of unit. Includes UVC light option with door switches to protect workers from harmful high energy UVC exposure that can damage skin and eyes.
- Page 14 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “B”, Manual Fan Speed Control 208/230V—1ø NOTES: 1. This diagram represents the factory-installed electrical option with manual fan speed control using the VFD keypad mounted on outside of unit. 2. Typical wiring is shown. For exact wiring, refer to the wiring diagram provided with the unit. 3.
- Page 15 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “B”, Manual Fan Speed Control 277V—1ø NOTES: 1. This diagram represents the factory-installed electrical option with manual fan speed control using the VFD keypad mounted on outside of unit. 2. Typical wiring is shown. For exact wiring, refer to the wiring diagram provided with the unit. 3.
- Page 16 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “B”, Manual Fan Speed Control 208/230V—1ø with UV Light Op on NOTES: 1. This diagram represents the factory-installed electrical option with manual fan speed control using the VFD keypad mounted on outside of unit. Includes UVC light option with door switches to protect work- ers from harmful high energy UVC exposure that can damage skin and eyes.
- Page 17 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “B”, Manual Fan Speed Control ø 208/240V—3 NOTES: 1. This diagram represents the factory-installed electrical option with manual fan speed control using the VFD keypad mounted on outside of unit. 2. Typical wiring is shown. For exact wiring, refer to the wiring diagram provided with the unit. 3.
- Page 18 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “B”, Manual Fan Speed Control ø 480V—3 NOTES: 1. This diagram represents the factory-installed electrical option with manual fan speed control using the VFD keypad mounted on outside of unit. 2. Typical wiring is shown. For exact wiring, refer to the wiring diagram provided with the unit. 3.
- Page 19 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “B”, Manual Fan Speed Control ø with UV Light Op on 480V—3 NOTES: 1. This diagram represents the factory-installed electrical option with manual fan speed control using the VFD keypad mounted on outside of unit. Includes UVC light option with door switches to protect work- ers from harmful high energy UVC exposure that can damage skin and eyes.
- Page 20 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “D”, Constant CFM Control 208/230V—1ø NOTES: 1. This diagram represents the factory-installed electrical option with constant CFM control using the pres- sure transducer mounted inside the unit. Control loop logic is contained in the VFD programming. VFD keypad is mounted on outside of unit.
- Page 21 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “D”, Constant CFM Control 277V—1ø NOTES: 1. This diagram represents the factory-installed electrical option with constant CFM control using the pres- sure transducer mounted inside the unit. Control loop logic is contained in the VFD programming. VFD keypad is mounted on outside of unit.
- Page 22 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “D”, Constant CFM Control 208/230V—3ø NOTES: 1. This diagram represents the factory-installed electrical option with constant CFM control using the pres- sure transducer mounted inside the unit. Control loop logic is contained in the VFD programming. VFD keypad is mounted on outside of unit.
- Page 23 INSTALLATION-ELECTRICAL (cont’d) TYPICAL WIRING DIAGRAMS— Control Option “D”, Constant CFM Control 460V—3ø NOTES: 1. This diagram represents the factory-installed electrical option with constant CFM control using the pres- sure transducer mounted inside the unit. Control loop logic is contained in the VFD programming. VFD keypad is mounted on outside of unit.
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Page 24: Service Clearance
Service Clearances Arrangement B (No integral Final Filter) 035-000029-001 Page 24 HHA IOM 1.4 10/11/2021... - Page 25 Service Clearances Arrangement D (with integral HEPA Filter) 035-000029-001 Page 25 HHA IOM 1.4 10/11/2021...
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Page 26: Condensate Drain
INSTALLATION-Piping CAUTION Water Coil Piping Recommendations Water coils are piped by connecting the supply at the bottom and the return at To prevent damage to the coil or coil headers: the top. This is “counterflow” piping ar- Do not use the headers to lift the coil. rangement and is necessary to achieve ... -
Page 27: Steam Coil Piping Recommendations
INSTALLATION-Piping (cont’d) Steam Coil Piping Recommendations GENERAL — Use straps around the coil casing to lift and place the coil. NOTE: Piping should be installed by a qualified installer familiar with the type of piping to be in- stalled. Perform piping to industry best practices. STEAM COILS —... - Page 28 INSTALLATION-Piping (cont’d) Fig. 10 — Multiple Coil Low Pressure Piping Gravity Return NOTES: 1. Flange or union is located to facilitate coil re- moval. Fig. 9 — Multiple Coil High Pressure Piping 2. When control valve is omitted on multiple coils in parallel air flow.
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Page 29: Coil Freeze-Up Protection
INSTALLATION-Piping (cont’d) Following the piping diagrams in Fig. 7-11, steam along the tube's length. The outer tubes make all connections while observing the fol- are expanded into plate fins. The completed lowing precautions: assembly includes the supply and condensate • Install a drip line and trap on the pressure header and side casings which are built to slant side of the inlet control valve. -
Page 30: Refrigerant Piping, Direct Expansion (Dx) Coils
INSTALLATION-Piping (cont’d) SUCTION PIPING — Connect suction piping as shown in Fig. 12 for face split coil. NOTE: IDT coils must be installed with the tubes draining toward the header end of the coil. The IDT steam coils are pitched toward the header end as installed in the unit. - Page 31 INSTALLATION-Piping (cont’d) EXPANSION VALVE PIPING — Distributor nozzles and expansion valves sized for acceptable per- formance for a range of conditions are factory supplied. Use the AHU (air-handling unit) selection program in the electronic catalog to select optimal nozzle sizes. Circuiting selection should result in a circuit loading of 0.8 to 2.0 tons per circuit at design load.
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Page 32: Apd Gauge Option
INSTALLATION—FACTORY OPTIONS Final (HEPA) Filter APD Gauge Option— See Figure 14. Units provided with the final filter APD gauge option have tubing routed internally from static pressure ports across the HEPA filter. The static ports (see Figure 15) allow the gauge to measure the air pres- sure drop (APD) across the HEPA filter. -
Page 33: Static Pressure Ports Option
INSTALLATION—FACTORY OPTIONS Static Pressure Ports Option— See Figure 16. Units provided with the “static ports” option have 4ea static pressure taps to allow connection to field APD gauges or other de- vices to monitor filter loading. The taps have factory tubing routed to a gauge block on the side of the unit. -
Page 34: Filter Pressure Drop Tables
TABLE 2 FILTER APD TABLES Filter Air Pressure Drop 2" and 4" Pre-Filters HHA Unit Size CFM 04/06 2.25 0.04 0.04 0.08 04/06 2.25 0.06 0.06 0.12 04/06 2.25 0.08 0.08 0.16 04/06 2.25 0.10 0.11 0.21 04/06 2.25 0.12 0.14 0.26 04/06... -
Page 35: Start-Up
2. If damper actuator provided, insure that actuator terms of the Magic Aire warranty. opens the damper when the fan turns on, and closes when fan stops. Test mixing box controls to make... -
Page 36: Fan Curves
Model HHA Critical Environment AHU Fan Curves—Sizes 04-12 Legend Note: Coil air pressure drop not included. Refer to New Magic 4 software for coil capacity and complete static pres- sure calculation. 035-000029-001 Page 36 HHA IOM 1.4 10/11/2021... - Page 37 Model HHA Critical Environment AHU Fan Curves—Sizes 16-25 Legend Note: Coil air pressure drop not included. Refer to New Magic 4 software for coil capacity and complete static pres- sure calculation. 035-000029-001 Page 37 HHA IOM 1.4 10/11/2021...
- Page 38 Model HHA Critical Environment AHU Fan Curves—Sizes 30-40 Legend Note: Coil air pressure drop not included. Refer to New Magic 4 software for coil capacity and complete static pressure calculation. 035-000029-001 Page 38 HHA IOM 1.4 10/11/2021...
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Page 39: Service - Periodic Maintenance & Replacement
DANGER MOTOR MOUNTING NEVER enter an enclosed fan cabinet or reach BOLTS MOUNTING into a unit while the fan is running. PLATE 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. - Page 40 DETERGENT — Spray mild detergent solu- Fan System Periodic Maintenance tion on coils with garden-type sprayer. Rinse 1. Magic Aire strongly recommends use of a with fresh water. Check to ensure condensate Preventive Maintenance program to insure line is free. Excess water from cleaning may that the unit operates safely and efficiently.
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Page 41: Coil
SERVICE—Winter Shutdown (cont’d) Method II — Make connection to auxiliary drain 8. Check operation of the thermal protection de- valves. vices used for freeze-up protection. 4. Fill reservoir with any inhibited antifreeze 9. Steam or condensate should not be allowed to acceptable to code and underwriter authori- remain in the coil during the off season. - Page 42 SERVICE-Coil Removal and Reinstallation Procedure CAUTION To prevent damage to the coil or coil headers: Do not use the headers to lift the coil. Use straps around the coil casing to lift and place the coil. Support the piping and coil connections independent- ly.
- Page 43 SERVICE-Coil Removal and Reinstallation Procedure (cont’d) Remove all fasteners Remove all fasteners Pull out the insulation indicated on the image indicated on the image Figure 26 Figure 27 Figure 28 Pull coil from opposite Push coil from this end Remove the fasteners side (Do not pull by the (If necessary, carefully indicated on the image...
- Page 44 SERVICE-Coil Removal and Reinstallation Procedure (cont’d) Remove all fasteners Remove the remaining Displace the top of the indicated on the image fasteners left on the module from both end plates corners Figure 32 Figure 33 Figure 34 Remove the fasteners Remove all fasteners Pull out the corners.
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Page 45: Uv Light
SERVICE– UVC Light Option UVC Light Emitter must be replaced every 12 months to maintain reliable germicidal control. 035-000029-001 Page 45 HHA IOM 1.4 10/11/2021... -
Page 46: Vfd Parameters
SERVICE-VFD Parameters DANGER DANGER NEVER enter an enclosed fan cabinet or reach into a unit while the fan is running. VFD Energy Stored! LOCK OPEN AND TAG the fan motor power dis- Dangerous voltage is present when input power is connect switch before working on a fan. - Page 47 SERVICE-VFD Parameters—Cont’d Table 2—VFD Parameters—Control (digit 17) Option A, B, C (Keypad or 4-20mA control signal) Control Option (Digit 17) Parameter Index Parameter Function Setting 1611 Parameter View 3 (Long View) (ACS310-320) Parameter View – Menu PAr S/ PAr L PAr L (Long View) (ACS55 ONLY) ...
- Page 48 SERVICE-VFD Parameters—Cont’d Table 3—VFD Parameters—Control (digit 17) Option D (Constant CFM control) Parameter Index Parameter Function Setting 1611 Parameter View 3 (Long View) 9902 Application Macro 1 (HVAC Default) 9905 Motor Nom Voltage 230 or 460 (see Nameplate) 9906 Motor Nominal Current SEE MOTOR TABLE (PG 49) 9908 Motor Nominal Speed...
- Page 49 SERVICE-VFD Parameters—Cont’d Table 3 (Continued) VFD Parameters—Control (digit 17) Option D (Constant CFM control) Parameter Index Parameter Function Setting 4001 PID GAIN 4002 PID INTEGRATE 4005 ERROR VALUE INVERTED 0 (No) 4006 UNITS 58 (in H20) 4007 UNIT SCALE 2 (2 DEC) 4008 0% VALUE 0.0 (in H20)
- Page 50 SERVICE-VFD Parameters—Cont’d Table 4b— All Control Options—Set Point Table Freq @ 0 ESP (Hz) SET POINT Unit Model (PARAMETER 4011) +/- 10% HHA04B* HHA04D* HHA06B* HHA06D* HHA08B* HHA08D* HHA12B* 10.0 HHA12D* HHA16B* HHA16D* HHA20B* HHA20D* HHA25B* HHA25D* HHA30B* HHA30D* HHA40B* HHA40D* 035-000029-001 Page 50...
- Page 51 SERVICE-VFD Parameters—Cont’d Constant CFM Control Option With the constant CFM option the pressure transducer measures differential pressure (DP, units of in w.g.) across the fan inlet “nozzle”. The DP signal goes to the VFD which has the control logic, and the controls change fan RPM to try to maintain the DP setpoint.
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Page 52: Water Quality Guidelines
Poor cooling/heating water quality can cause serious problems. Ground source or open loop water quality varies and therefore should be tested to determine suitability for use with Magic Aire equipment. Test water for hardness, acidity and iron content before the equipment is installed. Poor water quality can cause one or more of the following problems: mineral deposits, sediment deposits or corrosion. -
Page 53: Physical Data
PHYSICAL DATA Unit Size Model HH Nominal Capacity (Tons) 12000 18000 24000 36000 Nominal Capacity (BTU/HR) 1200 Nominal Airflow (CFM) Fan Size (Plenum Fan, diameter) 9.0" Filter 2" Pleated (MERV 8) 12H x 29L 12H x 35L Quantity / Actual size 4"... - Page 54 PHYSICAL DATA Unit Size Model HH 6.25 Nominal Capacity (Tons) 48000 60000 75000 90000 120000 Nominal Capacity (BTU/HR) 1600 2000 2500 3000 4000 Nominal Airflow (CFM) 12.5" 17.7" Fan Size (Plenum Fan, diameter) Filter 2" Pleated (MERV 8) 18H x 44L 29.125H x 52.375L Quantity / Actu- 4"...
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Page 55: Dimensional Drawings
035-000029-001 Page 55 HHA IOM 1.4 10/11/2021... - Page 56 035-000029-001 Page 56 HHA IOM 1.4 10/11/2021...
- Page 57 035-000029-001 Page 57 HHA IOM 1.4 10/11/2021...
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Page 59: Uv Light Accessory
Model HHA Critical Environment AHU UV Light Option Features & Benefits UVC Light –technology with decades long anti-microbial track record Includes safety interlock switches at each door for operator safety Details Factory installed & tested. Located after first coil, above drain pan ... -
Page 60: Hepa Diffuser Accessory
Model HHA Cri cal Environment Fan Coil HEPA Diffuser Accessory Louvered Face—4-way Direc onal Features: 24” x 24” Nominal Ceiling Module size HEPA 99.99% at 0.3µm efficiency Room side replaceable filter media—does not disturb ceiling construction Gel type filter seal ... - Page 61 Model HHA Cri cal Environment Fan Coil HEPA Diffuser Accessory Perforated Face—Laminar Flow Features: 24” x 24” and 24” x 48” Nominal Ceiling Module sizes HEPA 99.99% at 0.3µm efficiency Room side replaceable filter media— does not disturb ceiling construction ...
- Page 62 Model HHA Cri cal Environment Fan Coil HEPA Diffuser Accessory Installa on Instruc ons 035-000029-001 Page 62 HHA IOM 1.4 10/11/2021...
- Page 63 THIS PAGE INTENTIONALLY LEFT BLANK 035-000029-001 Page 63 HHA IOM 1.4 10/11/2021...
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Page 64: Warranty Registration Form
(10) days of Warranty Department start-up to comply with the terms of the 501 Galveston St. Magic Aire warranty. Form must be com- Wichita Falls, TX, 76301 or pleted to clearly indicate startup for each Email customer.service@MagicAire.com... -
Page 65: Replacement Parts
Ordering Replacement Parts for your Magic Aire HHA Series Air Handler Go to: http://magicstatus.magicaire.com/ Type in Serial Number or Unit Codestring Hit Enter or click on Go The screen will display model code string, manufactured date, original purchaser, and original ship to des- tination. - Page 66 HHA Series Air Handler Installation, Operation and Maintenance Manual 035-000029-001 Page 66 HHA IOM 1.4 10/11/2021...