Armcor XCC User manual

Armcor XCC Installation Manual 1
XCC – Ceiling Mount Fan Coil Unit
XCC 300 – XCC 1200
Installation and
Operation Manual

Armcor XCC Installation Manual 2
The XCC series is a low profile heat recovery unit with
the addition of an add-on-coil. Designed for installation
in a roof space, these ERV units utilize the Xchange
plate heat exchanger with either enthalpy or sensible
media. This series is available with hot water, chilled
water or DX coils which are designed to match with
standard commercially available condensors. EC Plug
Fans and in-built panel filters are standard.
Every proposed installation must be subject to an
engineered design by a mechanical services consultant.
Armcor Air Solutions is not responsible for performance
of equipment in applications for which the equipment
was not designed or specified.
1. Equipment
Application
/ 1. Equipment Application

Armcor XCC Installation Manual 3
2. Safety
Considerations
Warning
Improper installation, service, maintenance or
use can cause explosion, fire, electrical shock or
other conditions, which may cause personal injury
or property damage and will void the warranty.
Check with Armcor Air Solutions for any information
required on this equipment.
Danger
Electrical shock can cause personal injury or death.
Before performing any work on this equipment, the
electrical supply must be turned o to avoid the
possibility of shock, injury or damage to the equipment.
There may be more than one power supply circuit.
Installation by Authorised Personnel
—Only trained and qualified personnel should install, repair or service heat
recovery and/or air handling equipment.
—Installing and servicing equipment can be hazardous due to electrical and
mechanical components.
—When working on equipment, observe precautions in all literature, tags
and labels attached to or shipped with the unit. Follow all safety codes and
guidelines. Wear work gloves, safety goggles and protective clothing.
—All work must comply with relevant SAA wiring rules and local authority
codes. Installers must ensure that allstatutory regulations and by laws have
been addressed.
—Installers must ensure that the structures built to support the equipment
have been suitably constructed for the purpose, all safety precautions
have been applied prior to installation, and all preparation work has been
suitably sized and installed for its purpose.
/ 2. Safety Considerations

Armcor XCC Installation Manual 4
It is important that the selected location for the
equipment is suitable and can adequately accommodate
the unit physical size, the unit weight and has safe
and suitable access for correct operation and future
maintenance requirements.
Minimum Access Requirements for Maintenance
—The unit must be mounted so that sucient space is allowed for installation and
service access.
—Maintenance personnel need to gain access to all parts of the unit and be able
to remove components such as fans and filters via access doors as required.
—Unless otherwise specified the following minimum access should be available:
– 800mm clearance for electrical connections
– 1200mm for all access doors on the unit or if no access door is provided 1200mm
from the front of the unit.
Noise Levels
—Do not locate equipment adjacent to sleeping quarters unless background noise levels
have been checked and permitted by the appropriate authority.
—It is recommended that rubber supporting or vibration absorbing pads be used to
support the unit to minimise any vibration being transmitted into the building structure.
We recommend wae pad to be used under the base frame and flexible couplings be
fitted to the supply and return ducts to reduce any vibration transfer.
Fresh Air Inlet and Exhaust Air Outlet
—The location of the fresh air inlets must adhere to the Australian Standards 1668.2.
—The fresh air intake should be positioned clear of any objects which could obstruct the
airflow and be a minimum distance of 6 metres from any exhaust discharge ducts from
this unit or any other adjacent equipment. Refer to Australian Standards AS 1668.2.
—The fresh air inlet and exhaust air outlet should be fitted with a cowl or other suitable
means of weatherproofing.
—The exhaust discharge should be directed away from any openable windows.
3.1
3.2
3.3
3. Location
of Equipment
/ 3. Location of Equipment

Armcor XCC Installation Manual 5
Drainage
—Equipment should be installed with a positive fall to ensure water drains away
freely through drain outlets. Drain lines must be as large as or larger than the fitting
to which the line is being connected.
—All condensate drains must have a ‘P” Trap Fitted and have a minimum fall of 20mm
per metre length.
—If drain lines are to be extended from the inside to the outside of the building
they must be extended beyond walls of the building to eliminate the possibility of
damage caused by drain water running down the exterior surface of the building wall.
—When a drain is exposed to freezing temperatures or subject to the formation
of condensation, the drain should be insulated.
IMPORTANT: ALL UNITS LOCATED IN PLANT ROOMS MUST HAVE DRAIN TRAYS
UNDER THE COMPLETE UNIT.
3.4
/ 3. Location of Equipment

Armcor XCC Installation Manual 6
Unpacking and Inspection
—The unit should be inspected upon delivery for possible external damage incurred
during transport. If damage is evident it should be noted on the freight docket and
contact is to be made with the Armcor Air Solutions sales oce. A claim should be
lodged with the shipping company within 3 days if goods are damaged or incomplete.
No claims will be recognised after this date.
—IF MAJOR DAMAGE IS APPARENT, DO NOT LIFT UNIT ON TO SITE WITHOUT PRIOR
APPROVAL FROM ARMCOR.
—The unit was tested and inspected prior to packing and was in perfect condition at
the time at time of despatch.
—Check unit rating plate to ensure the correct unit matches the job specifications.
Unit Handling
—Protective crating or packaging and the pallets should not be removed until the unit is
at the point of installation.
—When removing packaging or crating, be careful not to damage, scratch or dent the unit.
—After removal of packaging, all removable access panels should be opened to inspect
for unit internal damage.
4.1
4.2
4. Installation
Instructions
/ 4. Installation Instructions

Armcor XCC Installation Manual 7
Lifting with a Crane
—SAFETY – when installing or working on equipment, always adhere to safety codes
and guidelines. Wear safety goggles, work gloves, work boots and protective clothing.
—All external units are provided with substantial lifting lugs on each corner at the base
frame. NOTE – All units should be lifted into position using SLINGS and not CHAINS.
(Chains may damage exterior finish on the fan unit).
—Where units have to be craned into position, installers must check unit weight is
within the safe tolerance of the working capacity of the crane.
—Prepare for lifting with spreaders as you would do with lifting air conditioning equipment.
—When lifting equipment never stand under the load.
—Beware of lifting equipment on to roof areas in windy conditions. Only lift when
weather conditions are favourable.
Lifting with a Forklift
—Exercise extreme caution when lifting with a forklift. Do not exceed the height limit
of the forklift and never allow the forklift forks to make contact directly with the bottom
panel of the unit.
—Make careful consideration of the unit’s centre of gravity and distribute the weight
equally on both forks. Test load to see if the weight is equally distributed. Do this
by lifting the unit a few centimetres o the ground level and checking stability before
lifting any further or before transporting the unit.
Suspending the Unit
—Before suspending the unit, check the supporting beams have sucient load carrying
capacity to support the weight of the unit. Equipment is supplied with brackets to
support the unit.
—We recommend that all ceiling mounted units be suspended or supported with suitable
mounting springs to eliminate the transmission of vibration.
4.4
4.5
/ 4. Installation Instructions
4.3

Armcor XCC Installation Manual 8
Ductwork
—Air distribution ductwork must be designed to allow for the specified air flow without
excessive pressure levels. The unit should be situated as close as possible to the point
of use to prevent unnecessary long runs of ductwork.
—Sheetmetal ductwork is recommended for use with all Armcor Air Solutions equipment.
—Ducts should be insulated in accordance with BCA Section J-5.
—Fan inlet conditions can aect the fan performance, particularly where duct bends
cause a non-uniform flow and swirl at the inlet. To reduce losses due to fan systems
eect, adequate length of straight duct between any elbow and the fan inlet should
be provided or turning vanes used in the elbow.
—Poor fan outlet conditions will also aect the fan performance. We recommend a
minimum of 1000mm of straight duct directly after the fan outlet.
Filters
—50mm panel filters are a minimum recommendation for all equipment.
—Filters must be fitted to fresh air and/or return air. Where there is no provision
for filters within the unit, the installing contractor is responsible to incorporate filters
in the ductwork system external to the unit.
—It is recommended that temporary disposable filters are used during construction
and commissioning.
—Where a Heat Exchanger is incorporated in the equipment, warranty is void if filters
are not fitted.
IMPORTANT: NEVER OPERATE A UNIT WITHOUT FILTERS FITTED TO THE
RETURN AND FRESH AIR INTAKES.
Electrical Requirements
—The power requirement and voltage are detailed on the equipment technical
specifications (available on our website www.armcor.com.au) and are on the
identification/serial no. plate attached to each unit.
—An electrical diagram is attached to the electrical box on the unit.
5.1
5.2
5.3
5. Equipment
Connections
/ 5. Equipment Connections

Armcor XCC Installation Manual 9
5.4 Mains Power Supply and Fusing
—A single phase power supply rated at 240v (+/- 5%) 50Hz or a 3 phase power supply
rated at 415 volts is required to operate the unit within manufacturer’s tolerance.
Check the name plates for correct voltage.
—We recommend an isolator be mounted externally to the unit (not supplied) and a
suitably sized circuit breaker mounted back at the distribution board to provide local
isolation during service and maintenance periods.
—Main cables and control circuit wires are to be connected as per wiring diagram.
—All wiring must comply with relevant local wiring regulations.
—The units require a main circuit breaker or HRC fuse capable of handling the full load
of the unit and selected in accordance with SAA Wiring Rules.
—All wiring is to be independently colour coded.
—Single phase fan motors are internally protected and there is no need for
external overloads.
/ 5. Equipment Connections

Armcor XCC Installation Manual 10
6. Equipment
Layout
/ 6. Equipment Layout
Supply Air
Supply Air
Return Air
Return Air
Exhaust Air
Exhaust Air
Fresh Air
Fresh Air
Return Air Air that is drawn from conditioned area.
Exhaust Air Ducted to outside the building or into the roof space if adequate ventilation is available.
Fresh Air Use a fresh air cowl or grill to introduce fresh air.
Supply Air Connect to the Airconditioning system or directly into the conditioned area.
This option must be ordered. Adaption from standard
layout to this optional layout is NOT possible.
Drain Connection
Drain Connection
Coil Connections
Coil Connections
Standard Equipment Layout
Optional Equipment Layout

Armcor XCC Installation Manual 11/ 6. Equipment Layout
Filter and Fan Access

Armcor XCC Installation Manual 12
Maintenance
Schedule
7.
/ 7. Maintenance Schedule
7.1
7.2
7.3
General
—All Armcor equipment is designed for easy maintenance.
—Preventative maintenance programs will vary according to actual operating conditions
and location and hours of usage by the client.
—Armcor Air Solutions are pleased to provide expert advice on special service
maintenance requirements for particular installations.
IMPORTANT: Failure to carry out regular maintenance with a licensed and reputable
service company may render warranty claims invalid, if faults have been caused by
lack of proper maintenance. Armcor Air Solutions may request to see the maintenance
schedule carried out.
Monthly Maintenance Schedules
—Monthly maintenance is usually focused on air filters and visual checks to monitor
any operational deficiencies. The type of filter and frequency of cleaning should be
addressed by the installing contractor to suit the customer’s requirements.
—Filters should be inspected immediately after installation to confirm the frequency
of cleaning needed for the particular location. Regular change/clean of filters is
necessary to ensure normal operating conditions.
—Check condensate drain (if applicable) for free drainage.
Guide to How Frequency According to
Usage is Established
—Disposable Corrugated Filters. Ordinary disposable corrugated filters should last
approximately one month in normal commercial use, or longer depending on usage.
—Cleanable Filters. If filters are cleanable, they should be cleaned once a month and
the filter media should be replaced every 12 months.

Armcor XCC Installation Manual 13
7.4
7.5
Three Monthly Checks Maintenance Schedules
—Repeat the monthly schedule.
—Check blower wheels for dirt build-up and tightness on shaft.
—Check all cabinet panels for correct fitting, alignment and seals, and clean cabinets
as required. Ensure no insulation has been detached from the panels.
—All electrical terminals should be checked for tightness.
IMPORTANT – Ensure the with main switch is turned o.
—Check and clean heat exchangers, heating/cooling coils, drain trays and outlets.
(If applicable). Vacuum or brush clean as necessary.
Annual Maintenance Schedules
—Repeat monthly and three monthly checks.
—Check cabinet for any paint chips or abrasions and treat accordingly.
—Check and record the available voltage and amperage of each phase.
—Check and record the amperage of each motor against nameplate details.
—Check and record refrigerant gas pressures (if applicable).
/ 7. Maintenance Schedule

Armcor XCC Installation Manual 14
The Armcor Air Solutions Warranty Policy should be read
in conjuction with the Terms and Conditions of Sale. These
are available on our website – www.armcor.com.au.
What The Warranty Policy Covers
The standard Armcor warranty policy is a parts only warranty for a 12 month period. If any
defect in your Armcor equipment is caused by FAULTY MATERIALS within the warranty period,
starting from the date of original purchase it will be rectified or replaced without cost.
Additional labour warranty is available and must be purchased at the time of ordering
in accordance with the warranty policy.
What The Warranty Policy Does Not Cover
—Consequential damage.
—Failure to start due to voltage conditions, blown fuses or other damage cause
by inadequate or interrupted electricity supply.
—Damage caused by accident, misapplication, abuse, alteration, tampering or servicing
by anyone other than an authorized person.
—Damage resulting from incorrect installation, commissioning or use other than
in accordance with the installation and operating instructions issued by Armcor
Air Solutions.
—Damaged caused by using equipment being located in a corrosive atmosphere
or by filter neglect.
—Replacement of any worn drive belts if applicable.
—Costs incurred for regular maintenance services.
—The original service call costs in identifying a warranty claim.
—Freight and travel changes for work performed or parts supplied outside of all
capital cities in Australia.
—Field wiring, refrigerant pipe run between units, the condensation drainpipe or
other accessories.
—Any warranty work performed by Armcor Air Solutions outside of Melbourne metro
area will require the installing contractor to provide free of charge: Oxy/Acetylene
Equipment, Dry Nitrogen, Vacuum Pump, Refrigerant Gas, Reclaim Bottles, Recovery
Unit, and any other associated refrigerant tools.
8.1
8.2
8. Warranty
/ 8. Warranty

Armcor XCC Installation Manual 15
8.3
8.4
The Warranty Will Not Apply If;
—Any appliance plate is altered or removed.
—Armcor Air Solutions has not be notified within 48 hours of any fault occurring
which may require warranty work.
—Any unauthorized modification has been made to the equipment or any part has
be substituted or replaced with non-original items.
—Regular service has not been carried out by an appropriate.Armcor approved,
licenced installer.
—The unit is used other than for the heating and cooling of air for human comfort –
unless approved by Armcor Air Solutions.
—The system is installed in a mobile application (eg. caravan, boat, crane).
How to Make a Warranty Claim
Complete a warranty form available on our website www.armcor.com.au and return
the Armcor Warranty Request Form to: [e-mail]
Contact us direct by phone on 1800 244 556 or email [e-mail]
/ 8. Warranty

Armcor XCC Installation Manual 16
9. Pre-start
Checklist
/ 9. Pre-start Checklist
Unit Installation and Connections
Check that equipment is fully installed in accordance with the
installation instructions
Visually check that air flows will not be obstructed
Electrical
Visually check all field wiring
Tighten all electrical connections including all factory wiring connections
Ensure supply cable is correct size
Check the required supply voltage is available on all phases
Check overload settings are correct (if applicable)
Filters
Check that both the fresh air and return air have adequate filters
before starting unit
Starting Unit
Check Fans and Air Flows
Turn on all circuit breakers
Make sure all dampers are open
Turn on control circuit and activate fans
Turn on supply fan, run and conduct an air balance
(Fans do not require phase rotation)
Turn on exhaust fan, run and conduct an air balance
Check fan current draw for each fan individually

Armcor XCC Installation Manual 17
10. Commissioning
Checklist
/ 10. Commissioning Checklist
General
Air Filters: Overall Size and Number
Drain Pipe Traps and Vents fitted to Indoor Unit as per
Installation Instructions Y / N
Drain is Clearing Water Properly Y / N
Check Vibration of Unit OK / EXCESSIVE
Belt Tensioning Adjusted Y / N
Paint Finish Checked and Repaired Y / N
Ducting
Total Return Air Flow (Total of all inlets) (L/s)
Total System external resistance (Pa) Measured downstream of fan
outlets plus upstream of Coil(s)
Estimate of Fresh Air Make Up (% or L/s)
Electrical
Supply Voltage
Supply Fan Motor Amps
Exhaust Fan Motor Amps
Total Unit Amp
Thermostat Settings (ºC)
Thermostat Operating Correctly Y / N
Contactors & Relays Operating Correctly Y / N
All Terminals Checked for Tightness and Label signed Y / N

Armcor XCC Installation Manual 18
11. Trouble
Shooting Guide
/ 11. Trouble Shooting Guide
Problem Probable Cause Correction Method
Lock Out Due to
Electrical Trip
Voltage Problem Check phase voltage
and rectify
Insulation breakdowns Replace faulty component
Loose Terminals Tighten or replace as
necessary
Dirty contactor controls Clean and/or replace
Tripped Circuit Breaker Short circuit Trace and correct
Earth leakage or over
heating cables due to
high load
Meggar and replace as
necessary
Power fluctuations Contact electricity supplier
Lack Of Air Flow Blocked filters Clean or replace filters
Fans stopped Check electrical

Fresh Air Indoors
For more information
W: armcor.com.au
E: [e-mail]
P: [phone]
109–111 Northcorp Blvd
Broadmeadows Vic 3047