Halton Rex Expander Product manual

Halton Rex Expander (RX ) - Installation,
commissioning, and maintenance guide
Enabling Wellbeing All rights reserved ©Halton

Contents
1 Introduction ........................................................................................................................................................... 4
1.1 Copyright and disclaimers ............................................................................................................................ 4
1.2 About this document ..................................................................................................................................... 4
1.3 Summary of changes ................................................................................................................................... 4
1.4 Safety notes ................................................................................................................................................. 5
1.5 Contact information ...................................................................................................................................... 5
2 Product description ............................................................................................................................................... 6
2.1 Overview ....................................................................................................................................................... 6
2.2 Operating principle ....................................................................................................................................... 6
2.3 Structure and materials ................................................................................................................................ 9
2.4 Dimensions and weight .............................................................................................................................. 11
3 Transport, storage and handling ......................................................................................................................... 12
3.1 Pre-packing and packing ............................................................................................................................ 12
3.2 Shipping and handling ................................................................................................................................ 12
3.2.1 Handling the product .......................................................................................................................... 12
3.3 Checking the received equipment .............................................................................................................. 12
3.4 Unpacking ................................................................................................................................................... 12
3.5 ifting the equipment .................................................................................................................................. 13
3.6 Storing the equipment ................................................................................................................................ 13
4 Installation ........................................................................................................................................................... 14
4.1 Before you start .......................................................................................................................................... 14
4.1.1 Safety during installation .................................................................................................................... 14
4.1.2 Installation process ............................................................................................................................ 14
4.1.3 Installation requirements .................................................................................................................... 15
4.1.4 Checks before installation .................................................................................................................. 16
4.2 Step by step instructions ............................................................................................................................ 16
4.2.1 Installing the unit ................................................................................................................................ 16
4.2.2 Connecting the unit to the ductwork ................................................................................................... 16
4.2.3 Connecting the water circuit connections .......................................................................................... 17
4.3 Checks after installation ............................................................................................................................. 18
5 Commissioning ................................................................................................................................................... 19
5.1 Before you start .......................................................................................................................................... 19
5.1.1 Safety during commissioning ............................................................................................................. 19
5.1.2 Commissioning process ..................................................................................................................... 19
5.1.3 Commissioning information ................................................................................................................ 19
5.2 Step by step instructions ............................................................................................................................ 21
5.2.1 Adjusting the position of the manual actuator of HAQ control ........................................................... 21
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6 Maintenance ....................................................................................................................................................... 22
6.1 Before you start .......................................................................................................................................... 22
6.1.1 Safety during maintenance ................................................................................................................ 22
6.1.2 Checks before maintenance .............................................................................................................. 22
6.1.3 Maintenance information .................................................................................................................... 22
6.2 Maintenance schedule ............................................................................................................................... 22
6.3 Step by step instructions ............................................................................................................................ 22
6.3.1 Cleaning the unit ................................................................................................................................ 22
6.3.2 Opening the front panel ..................................................................................................................... 23
6.3.3 Filling in the maintenance documents ................................................................................................ 23
6.4 Checks after maintenance .......................................................................................................................... 23
7 End of life ............................................................................................................................................................ 24
7.1 Removing the product from use ................................................................................................................. 24
7.2 Recycling and waste disposal .................................................................................................................... 24
8 Troubleshooting and repairs ............................................................................................................................... 26
8.1 Troubleshooting .......................................................................................................................................... 26
8.2 Fault reporting and reclamations ................................................................................................................ 26
8.3 Spare parts ................................................................................................................................................. 26
9 Technical reference data .................................................................................................................................... 27
9.1 Connections: Electric actuator of HAQ control ........................................................................................... 27
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1 Introduction
1.1 Copyright and disclaimers
The contents of this document are strictly confidential and for information purposes only. Disclosing the information
in this document without an appropriate contract or permission by Halton to any third party is prohibited. This
document remains the sole property of Halton and may not be duplicated, borrowed, copied, amended, modified,
reproduced, transmitted or distributed to any third party without the prior written consent of Halton. Any information
held in this document or associated materials may only be used for the purpose specified in this document.
Halton disclaims any and all liability related to this document. Halton gives no explicit or implied warranties in terms
of this document. Any permitted use of the information included herein is at your own risk. Halton may amend or
replace the information included in this document at its sole discretion without further notice and liability.
All intellectual property rights or applications thereof, including without limitation copyright, model rights, patents,
trade secrets, trade names, trademarks, know-how (whether registered or unregistered) attributable to this
document remain the sole and exclusive property of Halton. No rights or licenses are granted.
1.2 About this document
This document provides the instructions on how to install, commission, and maintain the product. This document is
intended for properly trained persons performing these tasks.
Note: Project-specific variations are possible.
1.3 Summary of changes
Release Date Description
1.0 15-Sep-2021 First release
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1.4 Safety notes
All information in this section is important and relevant for your safety. Pay special attention to these icons and the
related safety texts when used later in context in this document.
Cautions
CAUTION
FA ING HAZARD
Pay special attention and use proper equipment when working at height.
CAUTION
PERSONA INJURY HAZARD
Do not lift objects over 20 kg (44 lbs) alone. Use a lift or seek assistance.
CAUTION
PERSONA INJURY HAZARD
Follow all local health and safety regulations and use proper personal protective
equipment.
Notices
NOTICE
NOTICE
All installation, commissioning, and maintenance work must only be carried out by
qualified personnel.
NOTICE
NOTICE
All electrical work must only be carried out by qualified personnel.
1.5 Contact information
For contact information, see www.halton.com.
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2 roduct description
2.1 Overview
Figure 1. Halton Rex Expander
Compact CAV/VAV chilled beam with 4-way air distribution for suspended ceilings. Ensures silent and pleasant
room conditions even with higher cooling capacities.
Application area
▪ Cooling and ventilation in offices, hospital rooms, schools, and public spaces.
▪ Can be used in Halton’s demand-based ventilation systems.
Key features
▪ Active chilled beam with 4-way air distribution.
▪ Adjustable airflow using manual CAV or motorised VAV, with the Halton Air Quality (HAQ) control.
▪ Throw pattern expanded to corners, which ensures pleasant room conditions even with high cooling
capacities.
2.2 Operating principle
The primary supply air enters the plenum of the Halton Rex Expander chilled beam, from which it is diffused into
the room through the nozzles and supply slots. The air jets from the nozzles induce ambient room air efficiently
through the heat exchanger, where the air is cooled by means of the cool water circulating in the heat exchanger.
The supply slots direct the air jets horizontally along the ceiling surface, which prevents the feeling of draught.
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Figure 2. Operating principle of the Halton Rex Expander chilled beam
In figure Operating principle of the Halton Rex Expander chilled beam, the blue arrows show the supply air coming
through the supply slots. The red arrows show the ambient room air going through the front panel and the heat
exchanger.
Halton Air Quality (HAQ) control
Halton Air Quality (HAQ) control is used for adjusting or controlling the rate of the additional supply airflow in a
room space. In normal conditions, fresh supply air is provided through the nozzles. Whenever additional air is
needed (boost/VAV function), the HAQ control opens and provides more air. VAV stands for Variable Air Volume.
The HAQ control can also be used as a Constant Air Volume (CAV) damper, that is, it can be used for adjusting the
k-factor to achieve the correct airflow with a certain pressure level. This removes the need for changing or plugging
the nozzles of the Halton Rex Expander chilled beam.
Figure 3. VAV function: Supply air from nozzles (normal mode)
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Figure 4. VAV function with HAQ control: Supply air from nozzles and HAQ control (boost mode)
Figure 5. Manual actuator of HAQ control
Figure 6. Electric actuator of HAQ control
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2.3 Structure and materials
Figure 7. Halton Rex Expander parts
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No. art Description
1 Front panel Pre-painted galvanised steel
Polyester-painted, white (RA 9003), with special colours available.
2 Nozzles Nozzle plate: galvanised steel
3 HAQ control
(optional)
Painted galvanised steel
4 Actuator of HAQ
control (optional)
Electric actuator (shown in the figure): connecting cable length 0.9 m
Manual actuator: galvanised steel
5 Plenum Pre-painted galvanised steel
Polyester-painted, white (RA 9003)
6 Brackets Galvanised steel
7 Spigot Galvanised steel
8 Frame Pre-painted galvanised steel
Polyester-painted, white (RA 9003), with special colours available.
9 Connection pipes Copper. ø 12 mm with a wall thickness of 0.9–1.0 mm, fulfilling the
requirements of European Standard EN 1057:1996.
10 Coil/Heat
exchanger
Pipes: copper
Fins: aluminium
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2.4 Dimensions and weight
The dimensions are given in millimetres (mm).
Figure 8. Halton Rex Expander dimensions (RXP-600)
Figure 9. Halton Rex Expander dimensions (RXP-1200)
Weight:
roduct AQ model Dry mass (excl. water) [kg] Water volume [l]
RXP-600 NA 10.5 0.5
MA 11.4
MO 11.6
RXP-1200 NA 20.9 1.2
MA 21.8
MO 22.1
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3 Transport, storage and handling
3.1 re-packing and packing
Prior to packing, Halton inspects all products fully for any damages or physical faults. Halton inspects all
nameplates and identification tags against the purchase order and the Halton order confirmation to eliminate the
possibility of any mistakes or issues. If necessary, corrections are made.
Once the pre-packing procedure is complete, each product is sorted and packed according to weight and size.
Depending on the shipping requirements, the products are packed onto open pallets or pallets protected by
wooden covers. The products are secured to the pallets with plastic wrapping and straps.
3.2 Shipping and handling
Prior to loading the shipment, all packing and shipping documentation is checked.
One copy of the packing list is attached to each pallet, crate, or cardboard box in a waterproof plastic envelope.
Any additional copies of packing lists, customs invoices, shipping marks, and other documents are added
according to the client and shipping company requirements.
Use a forklift for loading or unloading the pallets.
Note: Some of the components can be delivered to the site in separate shipments.
3.2.1 Handling the product
To protect the product from damage or dirt, keep the product in its original box until it is needed for installation.
There is a product label in each box, which helps move the product in its correct location without the need for
unboxing.
When you take the product out of the box, do not lift the product by the pipes, as they damage easily, which leads
to leaking coils.
3.3 Checking the received equipment
1. Inspect the pallet or cardboard box and the products for any damage or missing parts. If you detect any
damage, or the shipment is incomplete, immediately file a claim with the shipping company.
2. Confirm that the products that you received are the ones that you ordered. If the products are not the ones
you ordered, see Fault reporting and reclamations for instructions.
3.4 Unpacking
Remove the straps and the plastic wrapping or other package covers from the pallets. Open the cardboard boxes.
Avoid damaging the products when you unpack them.
Note: The visible surface of the unit is protected with removable plastic coating. It protects the surface from dust,
dirt, and small scratches. It is recommended that you leave the plastic coating in place until the unit is taken into
use.
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3.5 Lifting the equipment
CAUTION
PERSONA INJURY HAZARD
Do not lift objects over 20 kg (44 lbs) alone. Use a lift or seek assistance.
Note: For information on the weight of the product, see Dimensions and weight.
When you take the product out of the box, do not lift the product by the pipes, as they damage easily, which leads
to leaking coils.
3.6 Storing the equipment
NOTICE
NOTICE
Do not expose the products to weather or store them outside.
NOTICE
NOTICE
Do no use any part of the products for climbing or support.
rotecting against moisture
The pallets onto which the products are stored enable air circulation inside the plastic wrappings. It is a strict
requirement that the products be stored in a dry indoor environment. Products must be protected against moisture
in any junction box or other closed enclosures. A dry indoor environment should not create moisture in junction
boxes, however, if necessary, additional moisture protection such as Silica Gel can be installed to the junction
boxes by the BUYER.
1. Store the products in a dry indoor area. Provide adequate mechanical protection at all times during storage
and during installation and construction activities.
2. Periodically check the products for any damage and repair or replace any component, wiring or piping that
shows signs of damage.
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4 Installation
4.1 Before you start
4.1.1 Safety during installation
CAUTION
FA ING HAZARD
Pay special attention and use proper equipment when working at height.
CAUTION
PERSONA INJURY HAZARD
Do not lift objects over 20 kg (44 lbs) alone. Use a lift or seek assistance.
Note: For information on the weight of the product, see Dimensions and weight.
CAUTION
PERSONA INJURY HAZARD
Follow all local health and safety regulations and use proper personal protective
equipment.
NOTICE
NOTICE
All installation, commissioning, and maintenance work must only be carried out by
qualified personnel.
NOTICE
NOTICE
All electrical work must only be carried out by qualified personnel.
4.1.2 Installation process
The main steps in the installation process are the following:
▪ Determining the installation place and orientation of the unit from the design drawings.
▪ Installing the unit.
▪ Connecting the unit to ductwork.
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▪ Connecting the water connections.
Note: When equipped with an electric actuator, the unit is part of a system. The needed wires are connected during
the installation phase of the system.
4.1.3 Installation requirements
When planning the orientation of the Halton Rex Expander chilled beam, the location of the supply air and water
circuit connections must be taken into account. The supply air spigot can be at either side of the unit or at the same
end with the water connections. The location can be easily changed on site, if needed.
The location of the actuator of the HAQ control (optional) must also be taken into account to ensure access to the
actuator. The actuator is located in the middle of the left side of the unit.
The Halton Rex Expander chilled beam can be attached directly to the ceiling surface (H = 220 mm) or suspended
using threaded drop rods (8 mm). The brackets for ceiling installation are located at the sides of the unit.
Figure 10. Installation points of the RXP-1200 (RXP-600) chilled beam
Because there are no moving parts in the Halton Rex Expander chilled beam, no anti-vibration protection is needed
when installing the unit or when connecting the unit to supply air or water circuit connections.
It is recommended that the main pipelines of the cooling and heating water circuits are installed above the level of
the heat exchanger to enable venting of the pipework.
The maximum operating pressure for chilled/hot water pipework is 1.0 MPa.
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4.1.4 Checks before installation
Make sure you have all the needed materials:
▪ The unit to be installed.
▪ Instructions (this document, design drawings)
▪ The needed tools, for example:
▪ Board lifter
▪ adder
▪ Materials and tools needed for installing the unit to the ceiling.
▪ Materials and tools needed for connecting the air and water connections.
Note: The materials and tools needed for installing or connecting the unit are not included in the delivery.
4.2 Step by step instructions
4.2.1 Installing the unit
See also the following information:
▪Installation requirements
▪ifting the equipment
1. Make sure the unit is in good condition.
2. From the design drawings, determine the installation place.
3. From the design drawings, determine the orientation of the unit (the locations of the water circuit connections
and supply air spigot).
4. From the design drawings, determine the height of the unit according to the planned suspended ceiling. The
bottom surface of the unit should be on the same level as the bottom surface of the suspended ceiling.
5. Install the unit accordingly.
4.2.2 Connecting the unit to the ductwork
1. Remove any contamination from the ductwork.
2. Remove the plastic cover from the spigot of the unit.
3. Push the duct into the spigot of the unit. The spigot has a seal gasket.
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Figure 11. Connecting the duct
Figure 12. Securing the duct with blind rivets
4.2.3 Connecting the water circuit connections
If there are two connection pipes, the unit can be used for cooling or heating. If there are four connection pipes, the
outer pipes are used for cooling and the inner pipes for heating.
NOTICE
NOTICE
When tightening the fittings, be careful not to damage the pipes.
Connect the water circuit connections according to the design drawings. You can use, for example, push-fit fittings
or compression fittings. With compression fittings, to avoid damaging the pipes, use two wrenches to tighten the
fitting.
Note: It does not matter which way you connect the supply and return water connections. The flow direction in the
coil does not affect the performance of the unit.
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Figure 13. Connecting the pipes. Left: Push-fit fitting. Right: Compression fitting.
4.3 Checks after installation
Before commissioning can start, make sure the following has been taken care of:
▪ The unit is installed correctly.
▪ The unit is connected to the ductwork correctly.
▪ The water connections are connected correctly.
Note: The visible surface of the unit is protected with removable plastic coating. It protects the surface from dust,
dirt, and small scratches. It is recommended that you leave the plastic coating in place until the unit is taken into
use.
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5 Commissioning
5.1 Before you start
5.1.1 Safety during commissioning
NOTICE
NOTICE
All installation, commissioning, and maintenance work must only be carried out by
qualified personnel.
5.1.2 Commissioning process
Commissioning includes adjusting the settings and doing the required start-up tests. Commissioning is carried out
by Halton Field Service or an approved partner.
Note: When equipped with an electric actuator, the unit is part of a system. The needed settings are adjusted
during the commissioning phase of the system.
5.1.3 Commissioning information
Adjustment of the cooling capacity
The recommended cooling water mass flow rate is 0.02–0.10 kg/s, resulting in a temperature rise of 1–4°C in the
heat exchanger. To avoid condensation, the recommended minimum inlet water temperature of the heat exchanger
is 14–16°C.
Balancing and control of water flow rates
The water mass flow rates of the Halton Rex Expander chilled beam are balanced with adjustment valves installed
on the outlet side of the cooling water loops. The cooling capacity of the Halton Rex Expander chilled beam is
controlled by regulating the water mass flow rate.
Adjustment of the supply airflow rate
With a Halton Rex Expander chilled beam that does not have the Halton Air Quality (HAQ) control, the airflow
depends on the chamber pressure and the selected nozzle. With the HAQ control included, also the position of the
HAQ control must be taken into account.
The chamber pressure can be measured from a measurement tap under the front panel.
The total airflow rate is calculated using the formula below.
Total airflow rate
where
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qvAirflow rate [l/s] or [m³/h]
ΔpmMeasured static chamber pressure [Pa]
kDetermined according to the table below [l/s]. If calculating m³/h,
multiply by 3.6.
osition of
HAQ control RX /C-600 RX /D-600 RX /E-600 RX /C-1200 RX /D-1200 RX /E-1200
0 / no HAQ 1.1 1.6 2.5 2.1 2.9 4.7
11.7 2.1 3.1 2.6 3.5 5.3
22.2 2.7 3.6 3.1 4.0 5.8
32.7 3.2 4.1 3.7 4.5 6.3
43.2 3.7 4.6 4.1 5.0 6.8
53.7 4.1 5.1 4.6 5.5 7.3
64.1 4.6 5.5 5.0 5.9 7.7
74.5 5.0 5.9 5.5 6.3 8.1
84.9 5.4 6.3 5.9 6.7 8.5
95.3 5.7 6.7 6.2 7.1 8.9
Example:
The measured static chamber pressure is 70 Pa for RXP/E-600, and the position of the HAQ control is 3. The total
airflow rate is 4.1*√(70) ≈ 34.3 l/s.
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