magicpak EWC Installation Instructions Manual

Refrigerant detection kit

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Installation Instructions for Refrigerant Detection Kit
©2025
West Columbia, South Carolina, USA
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must be
performed by a licensed professional HVAC installer or
equivalent or service agency.
CAUTION
As with any mechanical equipment, contact with sharp
sheet metal edges can result in personal injury. Take
care while handling this equipment and wear gloves and
protective clothing.
WARNING
Electric Shock Hazard. Can cause injury or
death. Unit must be properly grounded in
accordance with national and local codes.
Line voltage is present at all components when
unit is not in operation on units with single-
pole contactors. Disconnect all remote electric
power supplies before opening access panel.
Unit may have multiple power supplies.
CAUTION
Refrigerant Detection System installed. Unit must be
powered except for service.
WARNING
RISK OF ELECTRIC SHOCK. CAN CAUSE INJURY OR
DEATH: System contains two independent protective
earthing (grounding) terminals which both shall be
properly connected and secured.
WARNING
If this appliance is conditioning a space with an area
smaller than TAmin, then that space must be without
continuously operating open flames (e.g. an operating
gas appliance) or other potential ignition sources (e.g.
an operating electric heater or similar hot surface). A
flame-producing device may be installed in the same
space if the device is provided with an effective flame
arrest system.
508706-01
HWC8, HWC9 & EWC
RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE
Charge (lb)
Charge (kg)
Minimum Conditioned
Area (ft2)
Minimum Conditioned
Area (m2)
Equipment shall be labeled stating that it has been
decommissioned and emptied of refrigerant. The label
shall be dated and signed. For appliances containing
flammable refrigerants, ensure that there are labels on
the equipment stating the equipment contains flammable
refrigerant.
Auxiliary devices which may be a potential ignition
source shall not be installed in the duct work. Examples
of such potential ignition sources are hot surfaces with
a temperature exceeding 700°C and electric switching
devices.
For appliances using A2L refrigerants connected via
an air duct system to one or more rooms, only auxiliary
devices approved by the appliance manufacturer or
declared suitable with the refrigerant shall be installed in
connecting ductwork.
Any service personnel installing, decommissioning, or
performing maintenance on the unit must be properly
trained with A2L refrigerants.
RDS system requires 3 VA additional loading on low
voltage transformer.
*P508706-01*
Issue 2515
TAmin Table
< 4
4
6
< 1.8
1.8
2.7
N/A*
60
90
N/A*
5.6
8.4
CAUTION
WARNING
WARNING
CAUTION
IMPORTANT
(P) 508706-01
508706-01
04/2025
8
10
3.6
4.5
120
150
11.2
14.0
Page 1 of 13

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Summarization of Contents

Safety Warnings and Precautions
General Installation and Service Safety
Improper installation or service can cause damage or injury. Must be performed by licensed professionals.
Electrical Safety
Risk of electric shock. Unit must be properly grounded; disconnect power before access.
Flammable Refrigerant Handling
Avoid ignition sources in conditioned spaces with flammable refrigerants; use trained personnel.
System Operational Cautions
RDS unit must stay powered; check transformer loading; avoid ignition sources in ductwork.
General Information and System Purpose
System Overview and Functionality
The RDS kit ensures safe operation of HVAC systems with low GWP A2L refrigerant, activating the blower and interrupting ignition sources.
Refrigerant Charging Procedures
Follow specific requirements for refrigerant charging, including contamination prevention and system earthing.
Refrigerant System Handling and Safety
Ignition Source Prohibition
Do not use potential ignition sources for refrigerant detection; use approved electronic detectors.
Refrigerant Circuit Repair Procedures
Follow best practices for flammable refrigerants, including safe recovery, purging, and evacuation.
Operating Environment Specifications
Details the temperature and humidity ranges for the Refrigerant Detection Kit's operation.
Installation Procedures
Sensor Part Number Verification
Verify the refrigerant detection system sensor's part number (107648-01) for proper control board function.
Mounting Methods and Location
Mount the RDS board to side drywall or duct within 48 inches; avoid secondary drain pans.
Bracket and Sensor Installation
Bracket Identification
Identify the sensor bracket part number (628100-01) and follow bending instructions for assembly.
Condensate Safety Switch Integration
Float Switch Wiring
Wire the float switch between the thermostat and RDS board, ensuring the board remains powered.
Sensor Bracket Mounting
Install the sensor bracket into the cabinet along the inlet duct, below the unit chassis.
Making Electrical Connections
Wire Harness Connections
Connect thermostat, mitigation board, float switch, and sensor harnesses to the RDS board.
Cable Routing and Grommets
Route cables through grommets, ensuring a drip loop and secure connections to the RDS board.
RDS Control Board Modes and Diagnostics
Operating Modes Explained
Details the Initializing, Normal, Refrigerant Detected, and Fault modes of the RDS control board.
LED Diagnostic Codes
Explains the LED indicators for various states like Initializing, Monitoring, Refrigerant Detected, and Fault/Service.
Diagnostic Codes and Troubleshooting
Red LED Diagnostic Codes
Lists red LED flashes, their causes (e.g., sensor fault, comms issue), and required actions.
Test Button Functionality
Test Button Operations
Describes how to use the Test/Reset button for functions like triggering detection response or resetting the board.
Test Button Functions and Thermostat Compatibility
Additional Button Actions
Details specific Test button functions like skipping pre-purge or resetting controls in various states.
Thermostat Compatibility Check
Procedure to verify thermostat compatibility by checking setpoint retention after a power cycle.
System Application Notes
Zone Systems and External Alarms
Describes RDS interaction with zone dampers and external alarm triggering.
Start-Up Test Procedures
Cooling Demand Test
Simulate cooling demand and use the test button to verify refrigerant detection response.
Heating Demand Test
Simulate heating demand and use the test button to verify leak detection response.
Diagnostic Codes Summary
LED Status Indicators
Summarizes LED diagnostic codes for Initializing, Monitoring, Refrigerant Detected, and Fault/Service states.
Troubleshooting Red LED Codes
Red Flash Code Actions
Lists red LED flashes, their causes (e.g., sensor fault, float switch alarm), and troubleshooting steps.
Label Installation Guidelines
Warning Label Placement
Apply all required warning labels to the plenum and coil front panel during initial installation.
Decommissioning Procedures
Pre-Decommissioning Checks
Ensure technician familiarity, electrical isolation, PPE, and recovery equipment before starting.
Refrigerant Recovery Steps
Follow safe practices for pumping down, recovering refrigerant, and handling cylinders.
Sensor Maintenance Schedule
Routine Sensor Checks
Check sensor opening, cable condition, and avoid abrasive cleaners or vacuuming.

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