Armcor HTC500 User manual

Installation and
Operation Manual
HTC – Humidity Temperature Control Unit
HTC500 – HTC6000
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Contents
Equipment Application 3
Safety 4
Location of Equipment 5
Minimum Access Requirements for Maintenance
Noise Levels
Fresh Air Inlet and Exhaust Air Outlet
Drainage
Installation Instructions 6
Unpacking and Inspection
Unit Handling
Lifting with a Crane
Lifting with a Forklift
Equipment Connections 7
Ductwork
Filters
Electrical Requirements
Mains Power Supply and Fusing
Standard Equipment Layout 8
Features 9
General Maintenance 11
General
Monthly Maintenance Schedules
Guide to How Frequency According to Usage is
Established
Three Monthly Checks Maintenance Schedules
Annual Maintenance Schedules
Warranty 12
What The Warranty Policy Covers
What The Warranty Policy Does Not Cover
The Warranty Will Not Apply If;
How to Make a Warranty Claim
Pre-start Checklist 13
Commissioning Checklist 14
2 HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021

The HTC series are packaged Humidity and Temperature
Control units designed to provide a practical solution
for temperature and humidity control where there is
a signicant requirement for fresh air. The reduction
of moisture content is achieved through the careful
design of compressor capacity, coil capacity and air
ow to cater for the specic ambient conditions. Where
standard airconditioning systems cope well with
recirculated return air temperatures up to 24°C, the
HTC can be designed to cope with much higher ‘air on’
conditions.
Humidity control involves reducing the temperature
below dew point, which is usually too cold for supply
air temperatures. To offset this the HTC incorporates
a condenser reheat coil so that the outlet air can be
tempered after the humidity control process. Standard
equipment conguration includes EC plug fans, stainless
steel drain tray and associated controls.
Equipment Application
HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021 3

WARNING
Improper installation, service, maintenance, or
use can cause explosion, re, 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
electrically isolated to avoid the possibility of
shock, injury, or damage to the equipment. There
may be more than one power supply circuit to
the unit.
Installation by Authorised Personnel
• Only trained and qualied 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 all
statutory 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.
Safety
4 HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021

It is important that the selected location for the equipment is suitable and
can adequately accommodate the unit’s physical size, the unit weight and
has safe and suitable access for correct operation and future maintenance
requirements.
Location of Equipment
Minimum Access Requirements
for Maintenance
• The unit must be mounted so that suf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 lters via access doors as required.
• Unless otherwise specied 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 wafe pad to be
used under the base frame and exible couplings be
tted to the supply and return ducts to reduce any
vibration transfer.
Fresh Air Inlet
• The location of the fresh air inlets must adhere to the
Australian Standards AS 1668.2.
• The fresh air intake should be positioned clear of
any objects which could obstruct the airow and be
a minimum distance of 6 metres from any exhaust
discharge ducts from the unit or any other adjacent
equipment. Refer to Australian Standards AS 1668.2.
• The fresh air inlet should be tted with a cowl or
other suitable means of weatherproong.
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 tting to which the line is being connected. Each
drain should be separately trapped.
• All condensate drains must have a ‘P” Trap tted 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.
HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021 5

Installation Instructions
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 of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 of despatch.
• Check unit rating plate to ensure the correct unit
matches the job specications.
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.
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 nish on
the fan unit).
• Where units have to be craned into position,
installers must check that the 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 onto 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 off the ground level and checking
stability before lifting any further or before
transporting the unit.
6 HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021

Equipment Connections
Ductwork
• Air distribution ductwork must be designed to allow
for the specied air ow 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 affect the fan performance,
particularly where duct bends cause a non-uniform
ow and swirl at the inlet. To reduce losses due
to fan systems effect, 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 affect the fan
performance. Armcor recommends a minimum of
1000mm of straight duct directly after the fan outlet.
Filters
• 50mm panel lters are a minimum recommendation
for all equipment.
• Filters MUST be tted to the fresh air inlet. Where
there is no provision for lters within the unit, the
installing contractor is responsible to incorporate
lters in the ductwork system external to the unit.
• It is recommended that temporary disposable lters
are used during construction & commissioning.
• Where a Heat Exchanger is incorporated in the
equipment, warranty will be void if lters are not
tted.
IMPORTANT: NEVER OPERATE A UNIT WITHOUT FILTERS
FITTED TO THE FRESH AIR INTAKE.
Electrical Requirements
• The power requirement and voltage are detailed on
the equipment technical specications (available at
armcor.com.au) and are on the identication/serial
number plate attached to each unit.
• An electrical diagram is attached to the electrical box
on the unit.
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 unit requires a main circuit breaker 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.
HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021 7

Standard Equipment Layout
Supply Air Fresh Air
Condensor
Fan
Condensor Reheat
EC Plug Supply Fan
DX Coil Filters
8 HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021

Features
Oil Sight Glass
Oil should be visible during operation after the unit has
stabilised.
Compressor
Control Board
TX Valve
All TX valves have adjustment for super heat settings.
8-11K is acceptable for R407C and R4100 gases.
HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021 9

Filter Dryer (Biow type)
Must be replaced if the system is opened.
Drip Tray Drains
All drains should be trapped externally to the unit.
Compressor Bracket
Do not remove compressor bracket, this bracket is for
transport and for the operation of the compressor.
Electrical Connection
Tighten all electrical connections before starting and
commissioning unit.
Phase Failure
Relay
Fan Control Card.
Adjust pots for speed
control of supply & exhaust fans
Pipe Clamps
Tighten all pipe clamps before starting. These clamps
may loosen in transport.
10 HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021

General Maintenance
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
lters and visual checks to monitor any operational
deciencies. The type of lter 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 conrm the frequency of cleaning
needed for the particular location. Regular change/
clean of lters 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 lters should last
approximately one month in normal commercial use,
or longer depending on usage.
• Cleanable Filters.
If lters are cleanable, they should be cleaned once a
month and the lter media should be replaced every
12 months.
Three Monthly Checks
Maintenance Schedules
• Repeat the monthly schedule.
• Check blower wheels for dirt build-up.
• Check all cabinet panels for correct tting, 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 main switch is turned off.
• 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).
HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021 11

The Armcor Air Solutions Warranty Policy should be read in conjunction
with the Terms and Conditions of Sale. These are available on our website
armcor.com.au
Warranty
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 rectied 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 caused by inadequate or interrupted
electricity supply.
• Damage caused by accident, misapplication, abuse,
alteration, tampering or servicing by anyone other
than an authorised 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 lter 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.
The Warranty Will Not Apply If;
• Any appliance plate is altered or removed.
• Armcor Air Solutions has not been notied within
48 hours of any fault occurring which may require
warranty work.
• Any unauthorized modication has been made to
the equipment or any part has been 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 (e.g.,
caravan, boat, crane).
How to Make a Warranty Claim
Complete a warranty form available on our website
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]
12 HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021

Pre-start Checklist
Unit Installation and Connections
Check that equipment is fully installed in accordance with the installation instructions
Visually check that air ows will not be obstructed
Electrical
Visually check all eld wiring
Tighten all electrical connections including all factory wiring connections
Ensure supply cable is the correct size
Check that required supply voltage is available on all phases
Check overload settings are correct (if applicable)
Filters
Check that the fresh air inlet has adequate lters before starting unit
Refrigeration
Ensure all access caps are tight
Check pipework is not rubbing against other pipes due to movement during transport
Leak test all caps and pressure connections after commissioning
Starting Unit
Check fans and Air Flow
Turn on all circuit breakers
Turn on control circuit and activate fans
Turn on supply fan, run and conduct an air balance (fans do not require phase rotation)
Check fan current draw for each fan individually
Check Compressor and Refrigeration System Operation
Crankcase heaters must be activated for 24 hours before operation (if tted)
WARNING - Check correct rotation for compressors
Turn on Compressor 1, run for 5 minutes
Turn on Compressor 2 (if applicable)
Record amp readings for each compressor
Superheat should be between 8-11°C on Cooling (R407C)
If superheat is high, add refrigerant slowly using liquid into the suction line.
Do not ood liquid into the suction line.
HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021 13

Commissioning Checklist
General
Air Filters: Overall Size and Number
Drain Pipe Traps and Vents tted to Indoor Unit as per Installation Instructions Y / N
Drain is Clearing Water Properly Y / N
Check Vibration of Outdoor Unit OK / EXCESSIVE
Check Vibration of Indoor Unit OK / EXCESSIVE
Belt Tensioning Adjusted Y / N
Paint Finish Checked and Repaired Y / N
Ducting
Total 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
Compressor Amps
Overload Settings
Compare with published Compressor Amps
Outdoor Fan Motor Amps
Indoor Fan Motor Amps
Boost Heater Element Amps
Total Unit Amps
Thermostat Settings (ºC)
Thermostat Operating Correctly Y / N
Contactors & Relays Operating Correctly Y / N
All Terminals Checked for Tightness and Label signed Y / N
Refrigeration
Pipe sizes: Suction / Liquid (mm) Suction: Liquid:
Line Lengths: Horizontal / Vertical / Total (m) H + V = Total
Oil Traps in riser if condenser is above evaporator Y / N
Evacuation done (minimum hold 500 microns for 15min) Y / N
Refrigerant Type
Amount of oil (ml) Added to System if Line Lengths over 30m (where units are
allowed beyond this length)
Superheat setting (ºC) (refer Installation Instructions)
Refrigerant Discharge Pressure on Cooling (kPa) Suction: Discharge:
Refrigerant Pressure on Heating (kPa) Suction: Discharge:
Refrigerant Leak Check Y / N
14 HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021

Commissioning Checklist
Performance
1 Fresh Air Temperature °C DB °C WB
2 Air off Heat Exchanger °C DB °C WB
3 Air off Cooling Coil °C DB °C WB
4 Air off Heat Exchanger (Supply Air) °C DB °C WB
Notes
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HTC – Humidity and Temperature Control Unit Installation and Operation Manual 2021 15

Fresh Air
Indoors
For more information
W: armcor.com.au
E: [e-mail]
P: [phone]
109–111 Northcorp Blvd
Broadmeadows Vic 3047
© 2021 Armcor Air Solutions reserves the right to
alter products and specications without notice
and does not accept responsibility for possible
errors and omissions in published documentation.
03/11/2021 | Version 1