TROX EN-Ex CAV Terminal Unit Instruction Manual

TROX EN-Ex CAV Terminal Unit

Product Information

This product is the CAV terminal unit EN, manufactured by TROX GmbH. It is used for constant air volume control in supply and extract air ducts of ventilation and air conditioning systems. The terminal unit is equipped with a damper blade position display, allowing users to evaluate the throttle position of the damper blade. The unit also has an optional Vmin/Vmax actuator, which includes a potentiometer, a ‘Test’ push button, and an LED status display. The product is designed to be installed in various environments, but installation in humid rooms or rooms with dust-laden or aggressive air should be assessed individually.

Product Usage Instructions

1. Before starting any work, it is essential to read and fully understand the installation manual provided with the product.
2. Ensure compliance with safety notes and all instructions in the manual.
3. Follow local regulations for health and safety at work and general safety regulations.
4. In kitchen exhaust air systems, only use CAV terminal units if the extract air is cleaned effectively by highly efficient aerosol separators, following VDI2052 guidelines.
5. For a functional test of the actuator, press the ‘Test’ push button for more than 2 seconds. The actuator will run toward Vmin, then toward Vmax, and finally return to the starting position.
6. For transport and storage of the product, ensure proper handling and protection to prevent any damage.
7. If technical support is required, contact TROX Technical Support with the necessary information: product name, TROX order number, delivery date, and a brief description of the defect or issue.
8. During installation in humid rooms or rooms with dust-laden or aggressive air, assess the conditions individually to ensure proper functionality.
9. Qualified HVAC technicians should handle the installation, operation, and maintenance of the product. They should have sufficient professional or technical training, knowledge, and experience to carry out their duties safely and in compliance with relevant guidelines, safety regulations, and instructions.
10. Use safety shoes and follow appropriate safety measures when working with HVAC systems.

Product Overview

1. Damper blade

2. Bellows

3. Bellows inlet

4. Scales sticker

5. Display damper blade position Fig. 3

6. Hand wheel

7. Vmin-/Vmax actuator (optional)

8. Damper blade

9. Bellows

10. Bellows inlet

11. Scales sticker

12. Connection for equipotential bonding (latch) (2 × ground strap in supply package))

13. Display damper blade position Fig. 3

14. Hand wheel

Damper blade position display
The display is used to evaluate the throttle position of the damper blade, e.g. in order to optimise the control of the fan or the section regulation.
Attention: The display must not be adjusted.

1. Damper blade in maximum throttle position Reduce system pressure
2. Damper blade in open position – System pressure too low

Vmin/Vmax actuator (optional)

1. Vmax potentiometer
2. ‘Test’ push button
3. Vmin potentiometer
4. LED status display

LED status display:

• LED lit – Set position reached
• LED flashes once per second – Actuator moves
• LED flashes twice per second – Actuator blocks
• LED off – No power

Functional test actuator
Press the test push button (> 2 s)

• Actuator runs toward Vmin
• Actuator runs toward Vmax
• Actuator returns to starting position

Important notes

Information on the installation manual
This manual enables operating or service personnel to correctly install the product described below and to use it safely and efficiently.
It is essential that these individuals read and fully understand this manual before starting any work. The basic prerequisite for safe working is to comply with the safety notes and all instructions in this manual.
The local regulations for health and safety at work and general safety regulations also apply.

Correct use
CAV terminal units of type EN are used for constant air volume control in supply and extract air ducts of ventilation and air conditioning systems.
In kitchen exhaust air systems, CAV terminal units may only be used if it is ensured that the extract air is cleaned as well as possible by highly effective aerosol separators, observe VDI2052.
Installation in humid rooms and rooms with dust-laden or aggressive air has to be assessed individually.

TROX Technical Support
To ensure that your request is processed as quickly as possible, please keep the following information ready:

• Product name
• TROX order number
• Delivery date
• Brief description of defect or issue

Qualified staff

HVAC technician
HVAC technicians are individuals who have sufficient professional or technical training in the field they are working in to enable them to carry out their assigned duties at the level of responsibility allocated to them and in compliance with the relevant guidelines, safety regulations and instructions. HVAC technicians are individuals who have in-depth knowledge and skills related to HVAC systems; they are also responsible for the professional completion of the work under consideration.
HVAC technicians are individuals who have sufficient professional or technical training, knowledge and actual experience to enable them to work on HVAC systems, understand any potential hazards related to the work under consideration, and recognise and avoid any risks involved.

Skilled qualified electrician
Skilled qualified electricians are individuals who have sufficient professional or technical training, knowledge and actual experience to enable them to work on electrical systems, understand any potential hazards related to the work under consideration, and recognize and avoid any risks involved.

Personal protective equipment
Personal protective equipment must be worn for any work in order to reduce health or safety hazards to the minimum.
The appropriate protective equipment for a job must be worn for as long as the job takes.

Industrial safety helmet
Industrial safety helmets protect the head from falling objects, suspended loads, and the effects of striking the head against stationary objects.

Protective gloves
Protective gloves protect hands from friction, abrasions, punctures, deep cuts, and direct contact with hot surfaces.

Safety shoes
Safety shoes protect the feet against crushing, falling parts, and slipping on slippery ground.

Limitation of liability
The information in this manual has been compiled with reference to the applicable standards and guidelines, the state of the art, and our expertise and experience of many years.
The manufacturer does not accept any liability for damages resulting from:

• Non-compliance with this manual
• Incorrect use
• Operation or handling by untrained individuals
• Unauthorised modifications

The actual scope of delivery may differ from the information in this manual for special constructions, additional order options or as a result of recent technical changes.

Transport and storage

Delivery check
Upon delivery, carefully remove the packaging and check the unit for transport damage and completeness. In case of any damage or an incomplete shipment, contact the shipping company and your supplier immediately. Put the product back into its packaging after the delivery check to protect it from dust and contamination.

Fixing and installation material
Fixing and installation material is not part of the supply package (unless stated otherwise), but has to be provided by others; it has to be suitable for the installation situation.

Transport on site

CAUTION!
Danger of injury from sharp edges, sharp corners and thin sheet metal parts! Sharp edges, sharp corners and thin sheet metal parts may cause cuts or grazes.

• Be careful when carrying out any work.
• Wear protective gloves, safety shoes and a hard hat.

Please note:

• Be careful when unloading or moving the product, and pay attention to the symbols and information on the packaging.
• If possible, take the product in its transport packaging up to the installation location.
• Use only lifting and transport gear designed for the required load.
• Always secure the load against tipping and falling.
• Do not move bulky items just by yourself. Get help to prevent injuries and damage.
• Only lift or hold the control unit at the housing, not at the damper blade, at the flow rate adjustment or at the actuator.

Storage

Please note:

• Store the product only in its original packaging
• Protect the product from the effects of weather
• Protect the product from humidity, dust and contamination
• Storage temperature: -10 °C to 50 °C.
• Relative humidity: 95% max., no condensation

Packaging
Properly dispose of packaging material.

Technical data

12600 m³/h

Volume flow rate control range| Approx. 25 to 100% of the nominal volume flow rate
Scale accuracy| ± 4%
Minimum differential pres- sure| 50 Pa
Maximum differential pres- sure| 1000 Pa
Operating temperature| 10 – 50 °C

Technical data of actuators

DC, max. 0,5 mA

Ambient tempera- ture| 10-50 °C
Ambient humidity| 5-90% r.h.

Dimensions and weight

Product-specific data for EN

Product specific data EN-D

Installation

Installation orientation
Installation position of handwheel (actuator) on top not permitted.

Observe the airflow direction!

Upstream conditions
The volume flow rate accuracy of CAV terminal units applies to a straight upstream section of the duct. Bends, junctions or a narrowing or widening of the duct cause turbulence that may affect volume flow rate measurement. Depending on the respective installation situation, information on the straight duct section upstream of the control unit must be observed.
Duct connections, e.g. branches off the main duct, must comply with EN 1505.

Note: If there is a shut-off damper installed in the flow direction upstream of the EN terminal unit, ensure that the shut-off damper is installed so that its damper blade shaft is located opposite the damper blade shaft of the EN and rotated by 90°.

Inflow at the open duct end (extract air mode)

The inflow at the open end of a duct causes strong turbulence. The stated volume flow rate accuracy can only be achieved with a straight upstream length, at least 5B or 5H (use larger dimension).
Alternatively, an inflow aid must be installed at the open line end upstream of the control unit:

The stated volume flow rate accuracy is achieved when an inflow aid is connected directly to the control unit.

Attaching sealing tape
To achieve the tightness class of the ducting, sealing tapes have to be installed between the ducting and the terminal unit at both sides of the flange, e.g. self-adhesive sealing tape.
Ensure that the sealing tape (Fig. 11/1) is attached flush with the flange.

Installing the CAV terminal unit Personnel:
HVAC technician

Protective equipment:

• Industrial safety helmet
• Protective gloves
• Safety shoes

Before you install the product, take suitable precautions to protect air distribution components from contamination during installation (VDI 6022). If this is not possible, at least cover the product or take other precautions to protect it from contamination. In this case you have to ensure that the product cannot be started. Ensure that all components are clean before you install them. If necessary, clean them thoroughly. If you have to interrupt the installation procedure, protect all openings from the ingress of dust or moisture.

For installation please note:

• Fix the product only to the load-bearing structural elements.

• Load suspension systems only with the weight of the product. Adjacent components and connecting ducts must be supported separately.

• Use only approved and adequately sized fixing material (fixing material is not included in thes upply package).

• For maintenance or adjustment work, the device must be accessible after installation.

• Important: If there is a risk that the terminal unit could be subject to mechanical impact during operation, protect it accordingly; protection has to be provided by others.
  Be careful to not damage the unit accidentally:

• Handle the unit with care.

• Lift the unit only by lifting the entire casing.

• Never lift the unit by the damper blade, rotary knob or actuator.

1. Install suspension rods and bars (Fig. 12/4) at the installation location, at a distance of approx. L+100 mm.

2. Assemble the ducts (Fig. 12/3) and lead them up to the installation location of the terminal unit.

3. Insert seals (Fig. 12/6) between the flanges ‘Attaching sealing tape’ on page 9 (onsite).
   Observe the air direction arrow (Fig. 12/2) during installation.

4. Screw the terminal unit (Fig. 12/1) together with screws, washers and nuts M10 (Fig. 12/5).
   For version with acoustic cladding (EN-D)

   • Screw connection (Fig. 12/5) with screws and washers M8;
   • Insulate ducts up to the acoustic cladding of the terminal unit (on-site).

Electrical wiring

DANGER!
Danger of electric shock! Do not touch any live components! Electrical equipment carries a dangerous electrical voltage.

• Only skilled qualified electricians are allowed to work on the electrical system.
• Switch off the power supply before working on any electrical equipment.

Installation instructions
For installation of electrical actuators, the supply voltage and, if necessary, signal lines, must be connected. The connection is made according to the information on the actuators or connection diagrams in these instructions. Any project-specific wiring diagrams must be observed. The voltage ranges and the terminal connections specified on the actuators must be observed!

Personnel:

• Skilled qualified electrician

Observe the following during installation:

• Legal and official regulations, in particular VDE guidelines.
• Observe the technical connection rules (TCR) of the local grid operator.
• Wiring work for supply voltage and signal lines on site.
• The rating and manufacturing of customer-side connections and wiring must be carried out in accordance with the recognised rules of electrical engineering.
• Observe wiring guidelines and project-specific circuit diagrams of the actuators.
• The electrical connection to the actuator may only be performed if the installation has been carried out correctly.
• The 24 V supply voltage must only be provided with a safety transformer.
• If several actuators are connected to a 24 V mains supply, make sure that a common zero or earthing line is defined and not interchanged.
• The actuator contains no parts that can be replaced or repaired by the user and may only be opened by the manufacturer.
• Lay power supply lines in such a way that mechanical or thermal damage is excluded.
• Terminals for cables 0,5 – 2,5 mm², rigid and flexible, AWG 22-10

Strain relief
Units that are permanently installed in buildings are stationary electrical equipment for which no strain relief on the connecting cables is required.

Electrical wiring

Connection diagram Vmin-/Vmax switching E01, E02 ****

1. 1-wire control
2. 3-point control

Colour coding of the connecting cables E01, E02

Connection diagram variable volume flow E03

1. Room temperature controller
2. Actual value output (value to be set)

Colour assignment of the connecting cables E03

Room temperature control Fig. 14
A suitable room temperature controller or a DDC outstation with 0-10 VDC output 2-wire (terminals 1 and 3) connected. With a common supply voltage of 24 V, note that terminal 1 is also ground for the
control signal. Override control: With 24 VDC at terminal 3, the volume flow rate set at the Vmax potentiometer is started.

Initial commissioning

WARNING!
Risk of explosion from the commissioning of damaged products
Commissioning damaged products in areas with potentially explosive atmospheres may lead to an explosion. This can cause serious or even fatal injuries as well as considerable damage to prop-erty.
Before you commission the terminal unit, check it for damage that could impair the movement of the damper blade; if the terminal unit has been damaged, replace it.

Before you start commissioning:

• Ensure that the device or unit has been correctly fixed and connected to the ducting.
• Ensure equipotential bonding of the device or unit.
• Ensure that the devices or units as well as the ventilation system are clean and that there are no residual matter and foreign objects.
• Important: If there is a risk that the terminal unit could be subject to mechanical impact during operation, protect it accordingly; protection has to be provided by others.
  For commissioning see also VDI 6022, part 1 –’Hygiene requirements for ventilation and air-conditioning systems and units’.

WARNING!
Risk of explosion!
Ignition sources, such as sparks, open flames or hot surfaces, can lead to explosions in an area with potentially explosive atmospheres.

• Get written permission before you start working in an area with potentially explosive atmospheres.
• Do not carry out any work in a potentially explosive atmosphere. To remove any potentially explosive atmosphere, purge the system with fresh air before you work on it.
• Use only tools that have been approved for use in areas with potentially explosive atmospheres.
  Failure to comply with these safety notes may lead to an explosion.

Volume flow rate setting ranges

Setting the volume flow rate

Sufficient duct pressure must be ensured for all operating conditions and for all control units. The measurement points for fan speed control must be selected accordingly.

1. Using the volume flow rate scale (Fig. 15/1), determine the setting value (1-10) for the desired volume flow rate (l/s, m³/h, or cfm).
2. Loosen the hexagon socket screw (M5x12/size 3) (Fig. 15/3).
3. Set the rotary knob to the determined value of the setting scale (Fig. 15/2) and fix it with the hexagon socket screw (Fig. 15/3).
   No further measurement or adjustment is necessary.

Setting Vmin/Vmax actuators

Factory setting:

• Vmin: 4
• Vmax: 8

1. Using the volume flow rate scale (Fig. 16/1), determine the setting value (1-10) for the desired volume flow rate (l/s, m³/h, or cfm).
2. Set the desired value at the Vmin potentiometer (Fig. 16/3).
3. Set the desired value at the Vmax potentiometer (Fig. 16/2).
4. Carry out a functional test using the test push button and check the scale position reached for the preset volume flow after the motorised adjustment process.

Example for actuator E01, E02:

• Given data:
  EN 300×200

  • Vmin 432 m³/h
  • Vmax 1854 m³/h

• Volume flow rate night-time operation 800 m³/h

• Volume flow rate day-time operation 1600 m³/h

• Settings according to scale Fig. 16:

  • Vmin potentiometer: 4.5
  • Vmax potentiometer: 9

Characteristics E03

1. Scale setting

2. Setpoint value w

   • Vmin: 0 V scale setting 4.5
   • Vmax: 10 V scale setting 9

3. Scale setting

4. Actual value U

   • Vmin: 4.5 V
   • Vmax: 9 V

Actual value signal
The actual value signal of actuator variant E03 corresponds to the current actuator position in the scale range and is not a measure of the actual volume flow rate, since the CAV terminal unit does not measure the volume flow rate but only controls it using the aerodynamic forces.

Maintenance and cleaning

Maintenance
It is the system owner’s duty to set up a maintenance schedule, taking the actual operating conditions (contamination, operating time etc.) of the ventilation system into consideration.

Important: Do not lubricate the bearings of the damper blade.
Maintenance jobs to be carried out regularly:

• Visually check the terminal unit for contamination, damage and corrosion. Remove contamination; if the terminal unit has been damaged, or if there is any corrosion, replace the terminal unit.
• Check the fixing of the terminal unit and of the connected ductwork.
• Check equipotential bonding.

Replacement parts and retrofitting

Incorrect replacement parts

WARNING!
Risk of injury from the use of incorrect replacement parts!
Incorrect or faulty replacement parts pose a risk to health and safety, and their use can cause malfunction, damage to property and total failure of equipment.

• Use only original replacement parts from TROX.

Retrofitting an electric actuator
The EN control unit can easily be retrofitted with an electric actuator.

Order code for retrofit kits:

Cleaning

Please note:

• The cleaning intervals given in the VDI 6022 standard apply.
• Clean surfaces with a damp cloth.
• Use only common household cleaners, do not use any aggressive cleaning agents.
• Do not use cleaning agents that contain chlorine.

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