TROX DID-E2 Active Chilled Beams Installation Guide

TROX DID-E2 Active Chilled Beams

Specifications :

• Product: Active chilled beams Type DID-E2
• Manufacturer: TROX GmbH
• Model: DID-E2
• Phone: +49 (0) 2845 202-0
• Email: trox-de@troxgroup.com
• Website: www.troxtechnik.com

Product Overview:
The Active chilled beams Type DID-E2 is designed for efficient air conditioning in various settings. It includes features such as primary air spigot, terminal box for electrical connection, pressure measurement point, water connections, equipment casing, hanging brackets, ventilation grilles, hot and cold water circuits, heat exchanger, and safety cables.

Installation Manual:
The installation manual provides detailed instructions for fitting and installation companies, in-house technicians, technical staff, instructed persons, and qualified electricians or air conditioning technicians. It outlines safety notes, symbols for potential hazards, and regulatory compliance for safe installation.

Product Usage Instructions

• General Information:
  The manual is essential for safe working practices. It must be read and understood before initiating any work. Local health and safety regulations apply, and compliance with safety instructions is crucial to prevent accidents or property damage.

• Safety Notes:
  The manual includes safety notes with signal words indicating the degree of hazard. It is important to follow all safety instructions meticulously to avoid accidents, injuries, or property damage. The manual should be retained with the system documentation and accessible at all times.

• Warranty Claims :
  Safety notes may be integrated into individual instructions to facilitate adherence. Signal words such as DANGER, WARNING, CAUTION, NOTICE, and ENVIRONMENT are used to highlight potential hazards and precautions.

FAQ :

• Q: What should I do if I encounter a hazardous situation while using the Active chilled beams Type DID-E2?
  A: In case of a hazardous situation, immediately refer to the safety notes in the manual and follow the prescribed precautions to ensure safety.

Active chilled beams
Type DID-E2

TROX GmbH

• Heinrich-Trox-Platz
  D- 47504 Neukirchen-Vluyn

• Phone: +49 (0) 2845 202-0

• Fax: +49 (0) 2845 202-265

• Email: trox-de@troxgroup.com

• Internet: http://www.trox-technik.com

Product overview

Fig. 1: Schematic illustration DID-E2-VC

1. Primary air spigot
2. Terminal box for electrical connection of volume flow controller (only with version VC)
3. Pressure measurement point (only with version VC)
4. Rating plate
5. Water connections, valve with actuator (optional)
6. Water connections, lockshield (optional)
7. Equipment casing
8. Hanging brackets (4 pieces)
9. Sliding spigot for supply air (optional)
10. Ventilation grille for supply air (optional)
11. Hot water circuit
12. Cold water circuit
13. Ventilation grille for secondary air (optional)
14. Safety cable for securing the ventilation grille
15. Installation subframe for ventilation grille for secondary air (optional)
16. Heat exchanger
17. Pipe connection for direct valve connection (optional)

General information

• General information
• About this manual
• This manual is intended for use by fitting and installation companies, in-house technicians, technical staff, instructed persons, and qualified electricians or air conditioning technicians.
• 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 the general safety regulations for the area of application of the ventilation unit also apply.
• This manual must be given to the system owner when handing over the system. The system owner must include the manual with the system documentation. The manual must be kept in a place that is accessible at all times.
• Illustrations in this manual are mainly for information and may differ from the actual design.
• Other applicable documentation
  • Project-specific documents (if any)

Explanation of symbols

• Safety notes

• Symbols are used in this manual to alert readers to areas of potential hazard. Signal words express the degree of the hazard.

• Comply with all safety instructions and proceed carefully to avoid accidents, injuries and damage to property.

• DANGER!

• Imminently hazardous situation which, if not avoided, will result in death or serious injury.

• WARNING!
  Potentially hazardous situation which, if not avoided, may result in death or serious injury.

• CAUTION!
  Potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• NOTICE!
  Potentially hazardous situation which, if not avoided, may result in property damage.

• ENVIRONMENT!Environmental pollution hazard.

• Tips and recommendations
  Useful tips and recommendations as well as information for efficient and fault-free operation.

Safety

• Safety notes as part of instructions
  Safety notes may refer to individual instructions. In this case, safety notes will be included in the instructions and hence facilitate following the instructions. The above listed signal words will be used.

Example :

1. Loosen the screw.

2. CAUTION!
   Danger of finger entrapment when closing the lid.
   Be careful when closing the lid.

3. Tighten the screw.

Additional markers
In order to highlight instructions, results, lists, references and other elements, the following markers are used in this manual:

TROX Technical Service
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 the fault
• Online www.troxtechnik.com
• Phone: +49 2845 202-400

Warranty claims
The general delivery terms apply to warranty claims. For purchase orders placed with TROX GmbH, see “Section VI, Warranty Claims”, of the Delivery and Payment Terms of TROX GmbH, www.trox.de/en/.

Copyright

• This document, including all illustrations, is pro-tected by copyright and pertains only to the corresponding product.
• Any use without our consent may be an infringe-ment of copyright, and the violator will be held liable for any damage.
• This applies in particular to:
  • Publishing content
  • Copying content
  • Translating content
  • Saving content to electronic systems and editing it

Safety

Correct use
Active chilled beams provide centrally conditioned primary air (outdoor air) to rooms. Heat exchangers are used for additional cooling and/or heating.
Incorrect use

WARNING!

• Danger due to incorrect use!

• Incorrect use of the unit can lead to dangerous situations.

• Never use the unit:

  • in areas with potentially explosive atmospheres (EX);
  • in humid rooms;
  • in rooms with aggressive or dust-laden air.

• Personnel
  Qualification
  The work described in this manual has to be carried out by individuals with the qualification, training, knowledge and experience described below:

• Trained personnel
  Trained personnel are individuals who have sufficient professional or technical training, knowledge and actual experience to enable them to carry out their assigned duties, understand any potential haz-ards related to the work under consideration, and recognise and avoid any risks involved.

Technical data

connection hoses)
Max. operating temperature| 75°C (55°C, when using flexible connecting hoses)
Minimum operating temperature| 6°C

NOTICE!

• Water damage to property caused by condensate!
• If the temperature falls below the dew point, condensate will cause water damage to the device or building.
• Adjust the chilled water flow temperature so that it cannot fall below the dew point.

Dimensions and weights

Fig. 2: Dimension drawing DID-E2 with supply air spigot (-Z) and without volume flow controller, DID-E2-4 shown

1. Ø12 mm pipe, plain tails
2. G½” external thread and flat seal
3. G½” union nut and flat seal

Weights (4L, 123, R+L) [kg]

Nominal length (LN)| 1000 x 320| 1000 x 512| 1125 x 320| 1125 x 512| 1250 x 320| 1250 x 512
---|---|---|---|---|---|---
DID-E2| 15.5| 20.5| 17.0| 23.0| 19.0| 25.0
Supply air spigot Z| 1.7| 1.7| 1.9| 1.9| 2.1| 2.1
Installation subframe ERS| 1.4| 1.5| 1.6| 1.7| 1.8| 1.9
Contained water heat exchanger| 1.5| 2.5| 1.8| 3.0| 2.1| 3.5

Dimensions [mm]

Dimensions [mm]

Dimensions [mm]

ØD

123
158

Transport and storage

Transport

• 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.

• NOTICE!
  Carry the unit in pairs in order to prevent any damage.

• Fig. 4: Carrying the unit in pairs

• Use only lifting and transport gear designed for the required load. Always secure the load against tipping and falling.

• Upon delivery, carefully remove the packaging and check the unit for transport damage and completeness.

Storage

• Store the unit only in its original packaging
• Protect the unit from the effects of weather
• Protect the unit from humidity, dust and contamination
• Storage temperature: –10 to 50°C
• Relative humidity: 95% max., non-condensing

Installation Operation

• Installation
  • Fixing the device
• Personnel:
• Trained personnel
• Protective equipment:
  • Industrial safety helmet
  • Safety shoes
  • Protective gloves
• Install the device before attaching the bulkhead!
• Only work in pairs; preferably use a lift

DANGER!

• Danger of death from the fall of a suspended unit!
• Only use fixing materials designed for the required load.
• Use all hanging brackets supplied.
• Stand clear of suspended loads, unless properly secured.
• Check secure fixing after installation.

• Install threaded rods
• Insert the device
• Fasten the device with threaded rods
• Fasten device with vernier

Connect the ductwork
Active chilled beams DID-E2 have an outdoor air or primary air spigot.

Fig. 6: DID-E2 air duct connection
The spigots are suitable for circular ducts according to EN 1506 or EN 13180.
Installing the plasterboard bulkhead
The DID-E2 active chilled beams must be clad with a plasterboard bulkhead provided by others after attachment to the ceiling. When doing so, the following points must be observed:

• The plasterboard bulkhead and material are provided by others.
• The plasterboard bulkhead must be self-supporting; the device must not bear any static loads of the plasterboard bulkhead.
• Install the plasterboard bulkhead so that the air distribution of the device is not affected.
• Remove sliding spigot for supply air (optional)

Hygiene VDI6022

• If there is a connection between the secondary air and the plasterboard bulkhead (e.g.
• Fig. 13), the VDI6022 must be observed, e.g. provide a cleaning option for the plasterboard bulkhead and for the heat exchanger of the ventilation device.
• We therefore recommend direct secondary air intake through the ventilation grille into the ventilation device Fig. 7.

Fig. 7: DID-E2 installation example, without grille

1. Sliding spigot for supply air (optional)
2. Plasterboard bulkhead (provided by others)
3. Suspension (provided by others)
4. Installation subframe for secondary air grille (optional)

Mounting installation subframe for concealed screw fixing from supplied parts kit (optional)

• Folding of the provided brackets (5) along the perforation by 90°, so that narrow bends point outwards.
• Assemble the installation subframe using a plug-in connection so that insertion tabs hook in.
• Create an assembly opening in accordance with nominal size of the secondary air grille or pre-assembled installation subframe.
• The installation subframe should be assembled under the device (in the area of the heat exchanger) or at a distance from the device. The VDI 6022 must be observed here, e.g. provide cleaning option for plasterboard bulkhead.
• Fasten by clamping to the plasterboard bulkhead (clamping range 9-30 mm).
• Place one L-bracket (4) per long side above the ceiling in the opening.
• Push the installation subframe from below through the opening and place the bend underneath the ceiling, at the same time press the L bracket ((4) above) against the installation subframe (5) and fix it with screws (2). Assemble opposite L-bracket in the same way.
• Before installing the grille, install 2 diagonally offset safety cables (3) with securing sheets (1) on the installation subframe and grille.

1. Securing sheet
2. Screw
3. Safety cable
4. L-bracket
5. Installation subframe

Fig. 9: Installation subframe mounted

1. Securing sheet
2. Safety cable
3. Screw
4. L-bracket
5. Installation subframe

Fig. 10: Installation subframe clamping area

1. Securing sheet
2. Screw
3. Safety cable
4. L-bracket
5. Installation subframe
6. Bulkhead

CAUTION!

• Risk of injury from a falling secondary air grille
• If the secondary air grille is not secured, there is a risk of injury from the grille falling.
• Safety cables for securing the grille are provided on the optional installation subframe. When mounting the grille, attach the safety cables to the grille.
• If no installation subframe is being used, the grille must be secured on site against falling.
• Installation of sliding spigot for supply air (optional)
• Remove spigot from the device (keep screws)
• Create an assembly opening in accordance with the nominal size of the supply air grille / sliding spigot.
• Take into account the mounting range of the supply air sliding spigot. Range min. 38 mm / max. 78 mm from edge of the unit (supply air outlet of the unit) to room-side mounting opening.
• Push in the spigot from the outside through the plasterboard bulkhead into the device, and attach it on the inside to the device with screws (6 pieces).

Installation opening for ventilation grille and secondary air grille

• Installation opening with installation subframe
• L = Grille length to be ordered
• H = Grille height to be ordered

Installation opening without installation subframe

• L = Grille length to be ordered: L – 15 mm
• H = Grille height to be ordered: H – 15 mm

Fig. 13: DID-E2 bulkhead – air intake through open shadow gap

Minimum distance 50 mm, for distances between 50 and 150 mm, a reduction in performance of approx. 10% is expected, recommended distance ≥150 mm.

1. Plasterboard bulkhead (provided by others)
2. Sliding spigot for supply air
3. Ventilation grille for supply air (optional)
4. Suspension (provided by others)
5. Air intake through open shadow gaps
6. Connecting the water pipes

Personnel:

• Trained personnel
• Protective equipment:
• Industrial safety helmet
  1. Safety shoes
  2. Protective gloves
• Heat exchanger variants
  • 2-pipe system
  • 2 water connections for connection to the hot or cold water circuit
  • Operating mode: either cooling or heating
  • Switching between heating and cooling is possible in changeover mode with
• switching valve
• 4-pipe system
• 4 water connections for connection to the hot and cold water circuit
• 2 operating modes: cooling and heating Marking of the water connections
  • (blue) – Cold water circuit
  • (red) – Hot water circuit
• Water flow and return flow can be selected (in the respective circuit)
• Make sure that the water temperature does not fall below the dew point

Flexible hoses
External thread G 1/2″ (flat seal)| 22| Screw connection (rigid)
Flexible hoses
Union nut G 1/2″ (flat seal)| 24| Screw connection (rigid)
Flexible hoses
We recommend connecting with flexible hoses (accessories)

Screw connection (flexible hoses or screw connection)

• Screw connection
  • Ensure that the surfaces for seals are clean
  • Insert seal and tighten screw connection by hand.
• Risk of damage to the heat exchanger if not installed correctly!
• Always use a suitable tool to counter the tightening force in order to prevent any damage.
• Solder joint
  Clean the pipe ends and make a proficient solder joint.

NOTICE!
Damage to the heat exchanger due to frost!
Only fill the heat exchanger if there is no danger of freezing.

Initial commissioning

• Before you start commissioning:

  • Check active chilled beams for correct position
  • Remove protective film, if any
  • Ensure that all active chilled beams are clean and free from residues and foreign matter

• NOTICE!
  Hygienic requirements for ventilation and air conditioning systems must be carried out in accordance with VDI 6022, Sheet 1.

• Check water connections for correct installation (connection hoses with oxygen diffusion barrier)

• NOTICE!
  The commissioning procedure is described in detail in BTGA rule 3.002

  •  Carry out leak and pressure tests
  • Flushing the system
  • Filling and venting the water-bearing system
  • Carry out hydraulic balancing of the control zones.
  •  Actual/target comparison of the water parameters of the filling water

• NOTICE!

• Parallel consideration of the requirements for preventing damage in water circuits in accordance with VDI/BTGA 6044 (cold water and cooling circuits) and VDI 2035 Sheet 1 (for hot water – heating systems) is the responsibility of the competent person. The water-bearing system must be assessed as a whole so that it complies with the applicable regulations in both cooling and heating mode. Filling and supplemental water must be filled into the system with the appropriate water quality in order to ensure the long-term operation of the system.

• Pressure testing
  A pressure test must be carried out pneumatically or hydraulically in closed water-based heating and cold or cooling water circuits in accordance with the general rules of technology or BTGA 3.002, and recorded. The hydraulic test should be carried out with the appropriate filling water quality. A pneumatic test is carried out with air or inert gas.

• Rinsing/Flushing
  Rinsing removes unwanted dirt particles from the water circuit. We recommend flushing with the appropriate filling water quality and taking a water sample at the end of the flushing process. Make sure that the system is completely emptied after the flushing process and then filled with suitable filling water.

• Filling the system
  After flushing, the system must be filled with suitable filling and supplemental water. Manufacturers’ information for all installed components must be observed. Particular attention must be paid to compliance with the quality of the filling and supplemental  water. During the water filling of the system, as well as during the necessary pressing or draining processes, it is recommended that these are permanently monitored.

• Venting
  Ensure complete venting to avoid problems in the system and to ensure full performance of the waterbearing systems. Since a continuously rising conduit to a venting point is usually impossible, thorough flushing is recommended until the system is air-free. Upstream installations must also be air-free so that no air is introduced into the ceiling system via supply lines

Electrical connection

• For ventilation devices with volume flow controller (VC), the electrical connection must be made once assembly is complete. Wiring is done in the terminal box Ä Fig. 1/2.
• 24 V supply voltage only via safety transformer.

Terminal connections

• Actual value signal
• MP bus connection

Maintenance and cleaning

• Maintenance
  • The water quality may change during operation.
  • The water quality must be monitored and documented at regular intervals to prevent corrosion.
• Cleaning
  Observe the following points when cleaning: Clean surfaces with a damp cloth. Use only common household cleaners, do not use any aggressive cleaning agents

Cleaning the heat exchanger

• Personnel :
  •  Trained personnel
• Protective equipment:
  • Industrial safety helmet
  • Safety shoes
  • Protective gloves
• CAUTION!
• Hot surface!
  • Danger of burn or scald injuries when working on the hot water system.
  • Before working on the unit, shut down the system, depressurise it and let it cool down.
• CAUTION! Danger of cutting your fingers on the fins of the heat exchanger
• The heat exchanger has thin fins, which are very sharp; when you touch them, there is a danger of your cutting your fingers.

To avoid injuries, proceed carefully and wear protective gloves when you work on the heat exchanger.

1. To clean the heat exchanger, depending on the installation situation, disassemble the secondary air grille or open the cleaning opening.
2. Carefully vacuum the heat exchanger with an industrial vacuum cleaner. Be careful to not damage any blades. We recommend using a soft brush attachment for cleaning.
3. After cleaning, screw-fix the grille and close the cleaning opening.

CAUTION!
Danger of head injuries from the fall of the induced air grille! Check that the induced air grille is securely fixed!

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