Trox WK-D-WF Installation guide

Brand: Trox

Model: WK-D-WF

Category: Bicycle accessories

Type: Installation guide

Product overview

Fig. 1: Chilled ceiling WK-D-WF, example

1 Specially formed blade

2 Pipe (serpentine)

3 Fixing bracket

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.

Safety

Correct use

Cooling panels are primarily used for the cooling of

internal spaces; they use water to dissipate thermal

loads.

They can, however, be combined with a ventilation

system and be used for heating.

Incorrect use

WARNING!

Danger of injury or risk of damage to property

due to incorrect use!

Incorrect use of the cooling panels can lead to

dangerous situations.

Do not use cooling panels:

– in areas with potentially explosive atmos-

pheres

– outdoors

– in humid rooms

– in rooms with aggressive or dust-laden air

– at temperatures below the dew point

Modifying the unit or using replacement parts that

have not been approved by TROX is not permitted.

Staff

Qualification

The work described in this manual has to be carried

out by individuals with the qualification, training,

knowledge and experience described below:

Drywall installer

Drywall installers build indoor and outdoor drywall

(also called plasterboard) constructions, e.g. light-

weight partition walls, that meet the requirements

for thermal insulation, noise insulation, fire protec-

tion and protection from radiation. They also fit clad-

ding to walls and ceilings, for example plasterboard,

metal panels or wood, and insert the necessary

insulation.

Installation manual GB/en

Chilled ceiling

WK-D-WF

TROX GmbH

Heinrich-Trox-Platz

47504 Neukirchen-Vluyn, Ger-

many

Germany

Phone: +49 (0) 2845 2020

+49 (0) 2845 202-265

E-mail: [email protected]

http://www.troxtechnik.com

Chilled ceiling WK-D-WF 1

Drywall installers have the technical training, knowl-

edge and actual experience to enable them to

understand any potential hazards related to the

work under consideration, and recognise and avoid

any risks involved.

HVAC technician

HVAC technicians are individuals who have suffi-

cient 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 allo-

cated 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 sys-

tems; they are also responsible for the professional

completion of the work under consideration.

HVAC technicians are individuals who have suffi-

cient 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 recog-

nise and avoid any risks involved.

Personal protective equipment

Personal protective equipment is equipment that

protects the user against health or safety risks at

work.

Personal protective equipment must be worn for

various types of work; the protective equipment

required is listed in this manual together with the

description of each type of work.

Description of personal protective equipment

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, abra-

sions, punctures, deep cuts, and direct contact with

hot surfaces.

Safety shoes

Safety shoes protect the feet against crushing,

falling parts, and from slipping on slippery ground.

Repair and replacement parts

Only qualified personnel must repair the products,

and they have to use genuine replacement parts.

Transport, storage and packaging

Delivery check

Check delivered items immediately after arrival for

transport damage and completeness. In case of any

damage or an incomplete shipment, contact the

shipping company and your supplier immediately.

Transport, storage and packaging

Chilled ceiling WK-D-WF2

Transport on site

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.

Do not place any components on their exposed

side, otherwise the exposed side may become

damaged.

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 40 °C.

Relative humidity: 95 % max., no condensation

Packaging

Properly dispose of packaging material.

Installation

General installation information

Personnel:

HVAC technician

Drywall installer

Protective equipment:

Protective gloves

Industrial safety helmet

Safety shoes

CAUTION!

Danger of injury from sharp edges, sharp cor-

ners 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.

Installation

Chilled ceiling WK-D-WF 3

Please note:

Installation and connections to be performed

by others; fixing, connection and sealing mate-

rial to be provided by others.

Cooling panels to be installed above an open

cell ceiling should have a free area that is as

large as possible so as not to reduce the

cooling capacity more than necessary.

Provide devices for shut-off and venting.

Fix the product only to load-bearing structural

elements.

Continuous ceilings have to be designed to

carry at least the combined load of the cooling

panels plus accessories and contained water.

Suspensions used for cooling panels (rafts)

have to be designed to carry at least the com-

bined load of the panels plus accessories and

contained water. Choose enough fixing points

to fit the overall dimensions and the total

weight.

The installed cooling panels must be easily

accessible for inspection and cleaning.

Use only certified fixing systems that are suit-

able for carrying the intended load.

Use preferably threaded rods or suitable rail

systems for suspension.

Use all the provided suspension points.

Stand clear of suspended loads, unless prop-

erly secured.

Check secure fixing after installation.

Take heed of any notes regarding the cooling

panels.

The product is intended for use in internal spaces,

preferably with a clear height between 2.60 m and

4.00 m. We strongly recommend combining the

panels with a mechanical ventilation system. Do not

connect the cooling panels to the water system until

the ventilation and air conditioning system has been

installed, and the cleanliness of both the system

and the room has been examined and documented.

Only work in pairs; preferably use a lift.

Installation types

Fig. 2: Freely suspended cooling panel (raft)

1 Ceiling slab or suspended ceiling

2 Cooling panels (rafts)

Freely suspended installation is possible with

all ceiling systems. A continuous airflow also

on the upper surface must be ensured. With

open cell ceilings, the cooling panels have to

be installed above the grid. The free area

should be as large as possible.

Installation

Chilled ceiling WK-D-WF4

Fig. 3: Freely suspended cooling panel (raft) with

acoustic insulation

1 Ceiling slab or suspended ceiling

2 Acoustic pad (optional)

3 Threaded rods or other suitable and approved

fixing material

4 Cooling panels (rafts)

If freely suspended as a raft, cooling panels

can be fitted with some type of acoustic insula-

tion material (to be fitted to the upper side).

Acoustic pads have to be fitted above the fixing

brackets to ensure that as much cooling

capacity as possible is maintained. Note that

the capacity will be reduced to some extent.

Fig. 4: Cooling panel integrated into continuous ceil-

ings

1 Ceiling slab

2 Continuous plasterboard or metal ceilings

3 Threaded rods or other suitable and approved

fixing material

4 Cooling panels (rafts)

Flush ceiling installation in continuous ceilings

is possible with or without adjacent gaps. The

cooling capacity that can be achieved depends

on the structure of the ceiling. Installation with

gaps allows for higher effective cooling capaci-

ties.

NOTICE!

Do not fix any attachments, screws, nails or

other pointed items to the cooling panels.

Such items will damage the copper serpentine

and impair the cooling or heating capacity.

Consult with the manufacturer beforehand if you

intend to install cooling panel constructions not cov-

ered by this installation manual. In addition to the

installation manual there may be, for example, a

drawing that shows the fixing points.

WK-D-WF cooling panels, notes on installation

Connecting the water pipes

If the pipe tails of cooling panels are provided with

stoppers (only upon request for specific projects),

remove the stoppers before you connect the panels

to the pipe network.

Installation

Chilled ceiling WK-D-WF 5

Each cooling panel has two water connection

points, one for the flow and one for the return. Do

not change the position of the water connections.

NOTICE!

We recommend using flexible hoses to make the

water connections because they ensure that no

significant loads are imposed on the cooling

panels. Flexible hoses also simplify disassembly

and maintenance.

Water connections on the cooling panel: copper

pipe tails, 12 x 1 mm, with bush. Suitable types of

connection: We recommend flexible hoses (acces-

sory FS). If you use flexible hoses, you need to pro-

fessionally debur the pipe tails, otherwise the hoses

may become damaged.

Fig. 5: Deburring

Do not thermally treat any part of the cooling panels

except for the pipe tails.

As for flexible hoses, we recommend using 90°

hoses.

Fig. 6: WK-D-WF connection

Technical data

Description Value

Max. operating pressure,

water side

20 bar; 6 bar with flexible

hoses

Max. operating temperature,

water side

75°C; 50°C with flexible

hoses

Heating: recommended flow

temperature

≤ 35°C for comfort

DANGER!

Risk of scalding.

Working on the hot water system carries a risk of

scalding.

– Only specialist personnel should work on the

water-side connections.

– Before working on the water-side connec-

tions, shut down, depressurise, and, if pos-

sible, cool down the system.

Cooling/heating capacities depending on Δt When

heating, surface temperatures > 35 °C should be

avoided as otherwise comfort will suffer.

Make any connections to the cooling panels in such

a way that the panels are not affected by external

conditions, e.g. by thermal expansion, weight of the

pipes, vibration, or tension.

Installation with regard to energy efficiency

Hydraulic balancing is necessary to ensure

economic operation of the system. When you

design the control circuits and the interconnec-

tion of cooling panels, enable turbulent water

flow in each group of panels.

Insulate the water pipes to prevent energy

losses and the formation of condensate when

cooling.

Make sure that the water temperature does not

fall below the dew point.

Provide devices for shut-off and venting.

Control valves, gate valves and safety valves

are required; if they are not part of the supply

package, they have to be provided by others.

Installation

Chilled ceiling WK-D-WF6

NOTICE!

Take suitable precautions to avoid contamination

of the cooling panels during installation, commis-

sioning and operation.

Filling the system

Fill the system and vent it. To fill the system, use

clean tap water (pH value 6.5 to 9) or a water glycol

mixture (max. 30% glycol). Vent the system com-

pletely as air will reduce its efficiency.

Checking the system for leaks

Check the system for leaks immediately after instal-

lation and then at regular intervals.

NOTICE!

Risk of damage to the copper serpentine due

to freezing water

If the chilled ceiling is not used after the system

has been filled, subzero temperatures may lead

to the water in the pipes freezing and hence to

damage to the chilled ceiling.

To prevent damage due to freezing water, com-

pletely drain the pipes.

NOTICE!

Temperatures below the dew point

Temperatures below the dew point should be

avoided as they lead to condensation which may

cause damage to the building structure.

Fixing types

Fig. 7: WK-D-WF fixing brackets – length < 2500 mm

Fixing types

Chilled ceiling WK-D-WF 7

Fig. 8: WK-D-WF fixing brackets – length ≥ 2500 mm

WK-D-WF suspension

Distribute the weight evenly.

Use preferably threaded rods M8 for suspension.

Use all fixing brackets.

Minimum distance from fixing bracket top edge to the ceiling slab: ≥ 80mm.

Installation

General information

Note:

Fix the product only to load-bearing structural

elements.

Load suspension systems only with the weight

of the product. Adjacent components and con-

necting ducts must be supported separately.

Use only approved and adequately sized fixing

material (fixing material is not included in the

supply package).

Dimensions and weights

Dimensions [mm]

Length 1000, 1500, 2000, 2500, 3000, 3500, 4000

Height 70

Width 400, 600, 800, 1000, 1200, 1400

Installation

Chilled ceiling WK-D-WF8

Fig. 9: WK-D-WF with Z-bracket in the middle (L >

2500 mm)

Fig. 10: WK-D-WF cross section

Weight [kg]

j234567

k400 600 800 1000 1200 1400

1000 7 10.5 14 17.5 21 24.5

1500 9.5 14 18.5 23 28 33

2000 11.5 17 23 28.5 34.5 40

2500 14.5 22 29 36.5 43.5 51

3000 17 25 33.5 42 50 58.5

3500 19 28.5 38 47.5 57 66.5

4000 21 32 42.5 53 63.5 74

j No. of blades

k L/BN [mm]

Weight: approx. 14 to 18 kg/m²

Combinations of cooling panel dimensions depend on the water-side pressure drop of the panels.

Installation

Chilled ceiling WK-D-WF 9

Initial commissioning, maintenance and

cleaning

Initial commissioning

Before you start commissioning:

Check that the cooling panels are correctly

seated.

Remove protective film, if any.

Check that the water connections have been

professionally made.

To ensure that the system is clean and free

from any contamination, flush it with plenty of

water again as part of commissioning. Monitor

the filling and draining procedures closely and

continuously.

Once all dirt particles have been removed, fill

the system with the operating fluid (water).

Take heed of the manufacturers' information

for all the installed components. Use only

water of the appropriate quality to fill the

system.

Ensure that all cooling panels are clean and

free from residues and foreign matter.

Ensure that the panels have been correctly

fixed and connected to air terminal devices, if

any.

Ensure that the water system has been filled

and vented.

Carry out a leakage test with air or water and

according to the applicable regulations.

Carry out hydraulic balancing of the control

zones.

For commissioning see also VDI 6022, part 1 – 'Hy-

giene requirements for ventilation and air-condi-

tioning systems and units'.

Maintenance and cleaning

Maintenance

Check the water quality regularly in order to prevent

corrosion.

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.

Do not use equipment for removing stubborn

contamination, e.g. scrubbing sponges or

scouring cream, as it may damage the sur-

faces.

Initial commissioning, maintenance and cleaning

Chilled ceiling WK-D-WF10

Trox WK-D-WF Installation guide

Brand: Trox

Model: WK-D-WF

Category: Bicycle accessories

Type: Installation guide

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Trox WK-D-WF Installation guide

Trox WK-D-WF Installation guide

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