Trox Technik WK-D-WF User manual

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: [phone]
[phone]
E-mail: [email protected]
http://www.troxtechnik.com
A00000087742, 03/2022, © 2021 TROX GmbH
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