MAKING MODERN LIVING POSSIBLE Danfoss Air Installation manual for duct systems DANFOSS HEATING SOLUTIONS
Index 1 Before you start........................................................................... 3 2 Legislation................................................................................ 3 3 Dimensioning............................................................................ 3 4 Positioning manifold...................................................................... 3 5 Mounting manifold....................................................................... 4 6 Mounting inspection hatch............................................................... 5 7 Positioning supply air box on the floor.................................................... 5 8 Mounting supply air box on the floor...................................................... 6 9 Before casting............................................................................ 8 10 Positioning of valves on wall and ceiling.................................................. 10 11 Mounting valves on wall and ceiling...................................................... 10 12 Mounting Flex pipes..................................................................... 11 13 Insulation................................................................................ 14 14 Sound-damping the system.............................................................. 14 15 Positioning roof terminals and wall grills.................................................. 14 2 VIFYA102
1 Before you start In the following pages we will take you through the steps needed to properly install the duct system and fittings. If you follow these instructions, you can rest assured that your house will have a well-functioning and energy-efficient ventilation system. The installation manual for Danfoss Air units can be found in separate material. Please check the packing list to ensure that the shipment is complete, and inspect to ensure that no parts or components have been damaged. 2 Legislation Please be aware that systems are covered by applicable Danish legislation, and reference is made to: Danish Standard DS 428: Code of practice for technical measures for fire protection in ventilation systems Danish Standard DS 447: Code of Practice for mechanical ventilation installations. 3 Dimensioning When dimensioning there are few, but very important guidelines that must be followed: 1) We recommend that the combined pressure loss for fresh air intake + supply does not exceed 100 Pa. Fresh air intake + = 100 Pa Supply air 2) We also recommend that the pressure loss for extract + outlet does not exceed 100 Pa. 3) Main rules when dimensioning: Flow per pipe 25 m 3 /h Max. pipe length 16 m 25-30 m 3 /h 13 m 4) There should be no more than a 10 m difference between the shortest and longest pipes connected to the same manifold. 5) Min. pipe length is 5 m. Pressure loss values for the individual components can be found in the product catalogue. + = 100 Pa Extract Outlet 4 Positioning manifold Position the manifold (if possible) in the immediate proximity of the Danfoss Air ventilation unit, or determine its position based on an accompanying assembly drawing (if available). An assembly drawing should be considered to be a guide only; if the manifold in the drawing is positioned unsuitably in relation to the construction or to other technical installations, move the manifold so that the installation is not unnecessarily hindered. The manifold can be mounted on walls or the ceiling, or cast in concrete slabs depending on what is most appropriate in relation to routing. Manifold placed in insulating material on the floor before casting. Manifold positioned beneath ceiling inside climate shield. VIFYA102 3
5 Mounting manifold A silencer must be placed between ventilation unit and manifold - for supply as well as for extract (only supply is illustrated). The silencer should have the same diameter as the connecting pipe on the ventilation unit, and have a length of 600 mm. Fasten the manifold using the two brackets mounted beneath the base. Turn the brackets and fasten them to the substrate. If it is not possible to use the mounting brackets, the manifold can be fastened with metal strapping. To prevent possible nuisance, place a soft material (e.g. 2-3 mm of floor underlay) between the metal strapping and manifold. Close all unused spigots on the manifold with a plastic plug, type DEC-77 (item no. 089F0615). 4 VIFYA102
6 Mounting inspection hatch When mounting the inspection hatch, cut a hole in the manifold where the inspection is to be performed: max. diameter 150 mm max 150 x 150 mm Place the inspection hatch, type DCH-150x150 (item no. 089F0643) over the hole and fasten with 4 self-tapping screws. 7 Positioning supply air box on the floor Supply air box and grill should ideally be positioned against the wall at the following locations: beneath a window beneath a radiator beside a fireplace/stove To the extent possible, avoid placing the grill in the following places: underneath furniture near places where people relax for longer periods of time If an assembly drawing is enclosed, use it for guidance in positioning the box and grill. Note! Installing floor air extract is highly discouraged. VIFYA102 5
8 Mounting supply air box on the floor Place the supply air box in insulation material so that the distance to the top edge of the finished floor can be adjusted with the telescopic collar (collar can be extended by 100 mm). 220-320 mm Fasten the box with the two brackets mounted beneath the base. Turn the brackets and fasten them to the substrate. Mount an o-ring in the second groove on the Flex pipe. Mount the Flex pipe on the box. 6 VIFYA102
When the pipe is in place, fasten it by folding at least two of the four cut-outs in with a screwdriver or the like. Close unused spigots on the box and manifold with a plastic plug, type DEC-77 (item no. 089F0615). VIFYA102 7
9 Before casting What follows is an example of how a floor box can be mounted. The drawing shows the structure of an example solution. Note! A majority of the following photos are staged. Concrete Insulation material (EPS) Sand Lead the Flex pipe from underneath the insulation material. The recommended distance between the stand and insulation layer is 300 mm. Place a piece of EPS over the pipe ends before casting. Fasten to ensure that the position is maintained during casting. In this example, two pieces of soft steel are used for the fastening. After casting, remove the fastened insulation material and mount the floor box. 8 VIFYA102
To fasten the floor box, use the two pre-mounted brackets. Before post-casting around the box, raise the telescoping collar to a level just above the finished floor height. Tape the passage between the telescoping collar and the box itself. Tape a piece of insulation material in the box s opening. Finally, fill the area around the box with insulation material, and cast in place. When the concrete is dry, the telescoping collar can be loosened with a light blow and then lowered all the way down into the finished floor. In some cases, it may be easier to fill all or part of the hole with light expanded clay aggregate mixed with concrete. This will help prevent the relatively small pieces of insulation material from floating on the concrete during casting. VIFYA102 9
When the finished floor has been laid, pull out the box s adjustable insert and click the grill in place by using the 4 leaf springs. Place the grill in the insert and press the grill in place evenly on both sides. If a damper is selected for the grill, mount it beneath the grill by using the pre-mounted clips. The finished result. For wall mounting use a DPGW box, which is smaller and therefore fits in most inner walls. All physical dimensions of the DPGW box are listed in the product catalogue. To fasten the grill and mount the damper, use exactly the same method as for floor mounting. 10 VIFYA102
10 Positioning of valves on wall and ceiling The box and valves should be positioned in accordance with the room s function and design. The supply valve should preferably be positioned: near a fireplace/stove (if present) near a window above a radiator To the extent possible, avoid placing supply valves directly over areas where people may be located for longer periods of time, i.e. above beds, sofas, dining tables, etc. The extract valve should be mounted in wet rooms, e.g. the kitchen, bathroom and utility room. If possible, the valve should be positioned where moisture develops, i.e. near showers, sinks, etc. If an assembly drawing is enclosed, it should be used as a guide for positioning the box and valve. Note! Please be aware that there is a difference between supply and extract valves. 11 Mounting valves on wall and ceiling Mount the box so that the spigots to the valve are even with the finished wall/ceiling. The valve can then be pushed in place in the box (a supply valve is shown here). Correct valve placement. VIFYA102 11
12 Mounting Flex pipe Floor mounting Cut/furrow a route for the pipes in the insulation material. The width of the route should be adjusted to ensure a secure installation of the pipe. If it is not possible to fit the pipes into furrows in the insulation material, they can be fastened to the Rionet. The maximum distance between the fastening points/strips is 50-70 cm. To attain the greatest possible seal in the system, mount an o-ring at each end of all pipes. Place the o-ring in the second groove from the end before mounting the pipe in the desired manifold, box or coupler. The pipes can then be mounted in the manifold. When the pipe is in place, fasten it by folding at least two of the four cut-outs in with a screwdriver or the like. 12 VIFYA102
To keep concrete, building dust or other material from soiling the pipes during mounting, close all unused spigots. If the system is not used immediately after installation, the pipes must be sealed to prevent the accumulation of moisture. The pipes can be sealed with a plastic plug, type DEC (089F0613), or by closing the valves/grills. To the extent possible, avoid making sharp bends on the pipe, as this will increase the system pressure loss. Note! When all pipes are mounted, thoroughly clean the manifold via the connecting pipe. Wall/ceiling mounting Wall mounting is recommended exclusively for internal partitions to prevent thermal bridges and penetrations of the climate shield. For ceiling mounting, we also recommend mounting the pipes inside a climate shield. If this is not possible, the climate shield/damp-proof membrane must be thoroughly sealed with weather-resistant tape or the specially developed membranes shown here. For systems with geothermal surfaces, the supply pipe must be insulated with at least 30 mm of insulation material due to the risk of external condensation on the pipes. If the enclosed mounting brackets cannot be used, metal strapping can be used to fasten the boxes. It is important that the pipes are fully extended before fitting to minimise pressure loss in the system. VIFYA102 13
Here we see six correctly laid pipes beneath the ceiling on the inside of the climate shield. When the ceiling is set up, the length of the screws must be adjusted so that they do not penetrate the pipes. Connecting pipes in the coupling If it is necessary to extend or simply connect two pipe ends, this can be done using a coupling, type DPC (089F0607). Connect an o-ring in the second groove to both pipes that are to be connected. Completed couplings. 14 VIFYA102
13 Insulation It is important that the entire system is thoroughly insulated to minimise heat loss and prevent condensation. We recommend insulating pipes with at least 100 mm of insulation against cold surfaces. 14 Sound-damping the system Sound-damping the system is important for general comfort and wellbeing. Between the unit and manifold, mount a silencer with a length of 600 mm to reduce any noise that might otherwise be capable of spreading through the rest of the system and throughout the home. In some cases, it might also be advisable to mount silencer at the outlet and air inlet ends. 15 Positioning roof terminals and wall grills Roof terminals/wall grills are the visible part of the ventilation system from the outside. To the extent possible, they should therefore always be adapted to the architectural style of the house. We recommend positioning the terminals at least 3 metres apart measured vertically or 1 metre apart measured horizontally, always with the outlet terminal at the top. We also recommend placing terminals and grills on a north-facing or east-facing surface for optimal comfort. Note! The outlet should be positioned: - above the house s top window - at least one metre from the closest window 3 m 3 m 1 m VIFYA102 15
For generations now, Danfoss has been delivering solutions used in all aspects of heating and cooling, such as valves, thermostats, pumps and highly advanced control systems. The Danfoss Group consists of a global network of sales companies, agents and distributors, and Danfoss products are sold, serviced and valued around the world. Danfoss products also play an important role when it comes to creating optimal indoor climate and comfort. This has always been our legacy, and the new Danfoss Air system is set to carry on this proud tradition. Danfoss A/S Ulvehavej 61 DK-7100 Vejle Denmark Tel. +45 88 85 00 Fax +45 74 88 86 03 air@danfoss.com www.danfoss.com www.air.danfoss.com VIFYA102 www.danfoss.com