Operating manual

and installation instructions

Variable air volume controller
Type TVR-Ex

TVR-Ex with electronic control

II 2G c II T5 / T6
II 2D c II T 80 C

TVR-Ex with pneumatic control

II 2G c IIB T5/T6
 Contents
1 General information______________________ 3
Other applicable documentation __________________3
Symbols used in this manual _____________________3
2 Safety and correct use ___________________ 4
General information regarding safety ______________4
Standards and guidelines _______________________4
Repair and replacement parts ____________________4
Environmental protection ________________________4
Correct use __________________________________4
Incorrect use _________________________________4
Residual risks ________________________________4
3 Product description ______________________ 5
Electronic control ____________________________5
System description ____________________________5
VAV controller ________________________________5
TCU II electronic controller ______________________5
Functional description __________________________6
Commissioning tool ____________________________6
Pneumatic control ____________________________7
System description ____________________________7
VAV controller ________________________________7
Functional description __________________________8
Flow rate control ______________________________8
Room pressure control _________________________8
4 Operation ______________________________ 9
General information __________________________9
Opening the VAV controller ______________________9
Closing the VAV controller _______________________9
Electronic control ___________________________10
Zero point correction __________________________ 10
TCU II electronic controller _____________________ 10
5 Technical data _________________________ 11
Product overview and dimensions ________________ 11
Electronic control ___________________________12
Pneumatic control ___________________________12
TROX GmbH
Heinrich-Trox-Platz
D-47504 Neukirchen-Vluyn
Phone +49(0)28452020
Fax +49(0)2845202265
E-mail trox@trox.de
www.troxtechnik.com
2 TVR-Ex Operating manual (8/2013)
6 Transport, storage, and packaging ________ 13
Delivery check _______________________________ 13
Transport on site _____________________________ 13
Storage ____________________________________ 13
Packaging __________________________________ 13
7 Installation ____________________________ 14
Safety______________________________________ 14
VAV controller _______________________________ 14
TCU II electronic controller _____________________ 15
8 Electrical connection ___________________ 16
Electronic control ___________________________16
Installation details ____________________________ 16
Notes on installation according to ATEX ___________ 16
General information ___________________________ 16
Connecting the actuator _______________________ 16
Connecting the differential pressure transducer _____ 16
Electrical connections _________________________ 17
9 Pneumatic connection __________________ 18
Pneumatic control ___________________________18
Installation details ____________________________ 18
Tubing _____________________________________ 18
10 Commissioning, operation _______________ 19
Testing before commissioning ___________________ 19
Operation ___________________________________ 19
Commissioning of electronic controllers ___________ 19
Commissioning of pneumatic controllers __________ 19
11 Maintenance ___________________________ 20
Inspection __________________________________20
Repair _____________________________________20
12 Troubleshooting ________________________ 21
13 Removal and disposal ___________________ 22
Removal ____________________________________22
Disposal ____________________________________22
14 ATEX type examination certificate_________ 23
A00000032577
Subject to change / All rights reserved TROX GmbH
 1 General information

This operating manual describes the variable air volume Symbols used in this manual
controller (VAV controller) Type TVR-Ex with the following
add-on modules:
Danger!
Electronic control Designates danger to life and limb due to electrical
Pneumatic control voltage.
To ensure complete functioning of the unit it is essential
to read this operating manual before starting any work, and
to comply with it. The manual must be given to the facilities Warning!
manager when handing over the system. The facilities Designates danger to life and limb.
manager must include the manual with the system
documentation.
The manufacturer does not accept any liability for any Important!
malfunction or damage resulting from non-compliance with Designates danger that can cause minor personal
these instructions or non-compliance with relevant statutory injury or damage to property.
regulations.
This operating manual is intended for specialist consultants,
developers, and operators of systems. This manual is also Note!
intended for people conducting the following work: Designates important notes or information.
Transport and storage
Installation
Electrical wiring
Pneumatic tubing
Commissioning
Operation
Maintenance and cleaning
Troubleshooting
Decommissioning, removal and disposal
Other applicable documentation
In addition to this operating manual, the following documents
apply:
Type examination certificate TV 05 7218 X
for VAV controller TVR-Ex with electronic or
pneumatic control
Instructions from the manufacturer of the electrical control
components
Differential pressure transducer ExCos-P500
Ex drive ExMax-5.10Y and YF
Terminal box ExBox-Y/S-SW
Auxiliary switch ExSwitch (optional)
Product information TCU II (PI/7.4/1/E/...)
Instructions from the manufacturer of the pneumatic
control components
Pneumatic controller RLP 100 F003
Pneumatic controller RLP 100 (F901/F915)
Pneumatic actuator AK31/41
Project-specific wiring documents

TVR-Ex Operating manual (8/2013) 3

 2 Safety and correct use
General information regarding safety
Only skilled qualified personnel are allowed to perform
the described work.
Only skilled qualified electricians are allowed to work on
the electrical system.
The installation location must be easily accessible and have
sufficient clearance for electrical connection and
maintenance.
It is essential to comply with the applicable regulations and
generally recognised engineering practices when working.
This applies in particular to the following German country
specific regulations or as appropriate in the country where
the installation is taking place:
ATEX Product Directive 94/9/EC =
Explosion Protection Ordinance (11th ProdSV)
Machinery Directive 2006/42/EC =
Machinery Ordinance (9th ProdSV)
Industrial Health and Safety Regulations (BetrSichV)
and the pertinent accident prevention regulations
Principles of prevention (BGV A1)
Electrical systems and operating equipment (BGV A3)
Standards and guidelines
The requirements in DIN VDE 0100 Part 610 apply to the
initial test in all cases.
Comply with the following rules when operating the system:
EN 50110-1 (VDE0105 Part 1)
EN 50110-2 (VDE0105 Part 2)
VDE 0105-100 (VDE0105 Part 100)
EN 60079-14 (VDE 0165 Part 1)
EN 13463-1 (with pneumatic control)
Industrial Health and Safety Regulations (BetrSichV)
The system must meet the applicable lightning protection
requirements.
Compliance with all additional relevant national and inter-
national standards and regulations for potentially explosive
atmospheres is required.
Repair and replacement parts
The TVR-Ex volume flow controller is a control unit specially
developed for potentially explosive atmospheres. To maintain
the protection function for explosive atmospheres, use only
genuine TROX replacement parts for repair.
The TVR-Ex volume flow controller must only be repaired by
the manufacturer or by skilled qualified personnel authorised
by the manufacturer.
Environmental protection
Dispose of packaging in an environmentally sound
manner.
Have used components or the used unit only disposed
of by an authorised company.
4 TVR-Ex Operating manual (8/2013)
Correct use
The TVR-Ex variable volume flow controller is designed
for volume flow control or room pressure control in room
air conditioning systems installed in potentially explosive
atmospheres.
It is suitable for controlling dust-free air, gases, mist and
vapours in accordance with the ATEX classification specified
on the unit.
The TVR-Ex volume flow controller may also be used in
explosive atmospheres caused by dust (only with electronic
control).
However, volume flow rate control of dust-laden media
is not permitted because dust contaminates the dierential
pressure transducer.
When the controller is used in potentially explosive areas
caused by dust, dust deposits of more than 5 mm on volume
flow controller casing must be avoided.
Incorrect use
The volume flow controller must not be used under the
following conditions:
In areas with potentially explosive atmospheres for which
the controller has not been approved
For volume flow rate control of dust-laden air
For volume flow rate control of aggressive media
Use in ventilation systems in which high levels
of dust and pollution, extreme humidity, or chemical
contamination may impair the function
Use outdoors without sufficient protection against the
effects of weather
In wet areas
Changes to the unit and the use of replacement parts that
have not been approved by TROX are not permitted.
Residual risks
TROX products are subject to strict quality controls during
manufacturing. In addition, function tests are performed
before shipment.
Damage can, however, occur during transport or installation
and impair the function of the unit.
In any case, the proper function must be checked by the
owner or operator of the plant during commissioning
and ensured through regular maintenance while the unit
is in use.
Under rare and unfavourable conditions and even when
the mentioned regulations are complied with, the function of
the controller might be impaired by electromagnetic fields.
This problem can usually be resolved by shielding or moving
the controller.
Foreseeable damage that might be caused by the failure
of control components should be anticipated and prevented.
 3 Product description
Electronic control

System description
Variable air volume controllers (VAVs) of Type TVR-Ex
are designed to control airflows in potentially explosive
atmospheres.
The system consists of the VAV controller and the TCU II
electronic controller.
Protection is provided when only the VAV controller
is installed in the potentially explosive atmosphere.
The electronic controller must be installed outside of the
potentially explosive atmosphere.
VAV controller
The VAV controller is installed in the duct.
All attached control components are protected against
explosion.
The VAV controller includes:
Casing
Damper blade
Spigot connection
Lip seal
Cover
Arrow indicating the airflow direction
Equipotential bonding
Cable bushings
Terminal box
Dierential pressure transducer
Actuator
Auxiliary switch (optional)
Dierential pressure sensor

TCU II electronic controller

The TCU II electronic controller is not designed for use in
potentially explosive atmospheres. It must be installed out-
side the area with a potentially explosive atmosphere.
The electronic controller consists of the following parts:
Casing
PCB
Cover (not shown)
Note
For more information about the TCU II electronic controller,
see the TCU II product information (PI/7.4/1/E/...).

TVR-Ex Operating manual (8/2013) 5

 1 Product
3 1 PageHeaderToc
description
Electronic control

Functional description

TVR-Ex variable air volume controllers (VAVs) are used
for controlling airflows in potentially explosive atmospheres.
For this purpose, the airflow is measured using a dierential
pressure sensor which measures the pressure at several
points and calculates an average value. This sensor delivers
exact results for most ventilation applications with normal
upstream flow conditions.
The volume flow rate is controlled in a closed loop,
i.e. measurement comparison control.
A dierential pressure transducer converts the dierential
pressure into an electrical signal that is interpreted as an
actual value by the electronic controller. The setpoint value
comes from the fume cupboard control, supply or extract air
control or a DDC outstation.
The controller compares the actual value with the setpoint
value and alters the control signal of the damper actuator
if there is a dierence between the two values.
Wiring of the inputs follows the project control requirements.

Switch cabinet (supplied by the customer)

Supply voltage 230 VAC (supplied by the customer)
Supply voltage 24 VAC (supplied by the customer)
TCU II electronic controller
VAV controller
Differential pressure transducer
Actuator
Terminal box

Commissioning tool
For commissioning, the application specific parameters
have to be downloaded to the controller. Necessary hardware
and software is available from TROX; you may also request
commissioning support from our technical service.

Notebook
Connecting cable
Control panel connecting cable
Connection socket
TCU II electronic controller

6 TVR-Ex Operating manual (8/2013)

 2 Product
3 1 PageHeaderToc
description
Pneumatic control

System description
Variable air volume controllers (VAVs) of Type TVR-Ex
are designed for controlling airflows in potentially explosive
atmospheres.
The system consists of the VAV controller with 1 or 2
pneumatic controllers, depending on the application.
A pneumatic actuator acts on the damper blade depending
on the settings specified for the pneumatic controller.
VAV controller
The VAV controller is installed in the duct. All attached
control components are protected against explosion.
The VAV controller includes:

Casing
Damper blade
Spigot connection
Lip seal
Sticker showing the installation orientation
Cover
Arrow indicating the airflow direction
Equipotential bonding
Pneumatic connections
1 Operating pressure connection
6 Setpoint specification
+ Room pressure
Reference room pressure
Pneumatic controller RLP 100 F901/915 (optional)
Pneumatic controller RLP 100 F003
Pneumatic actuator
Dierential pressure sensor
Note
For more information about the RLP 100 pneumatic
controller, see the product information (E016MW2).

TVR-Ex Operating manual (8/2013) 7

 1 Product
3 1 PageHeaderToc
description
Pneumatic control

Functional description
Functional diagram
TVR-Ex variable air volume controllers (VAVs) are used for
controlling airflows in potentially explosive atmospheres.
For this purpose, the airflow is measured using a differential
pressure sensor which measures the pressure at several

points and calculates an average value. This sensor delivers
exact results for most ventilation applications with normal
upstream flow conditions.
The volume flow rate is controlled in a closed loop, i.e.
measurement comparison control.
A differential pressure transducer converts the differential
pressure into a pneumatic signal that is interpreted as an
actual value by the pneumatic controller.
The setpoint value comes from the fume cupboard control,
supply or extract air control or a DDC outstation (electro-
pneumatically converted). The controller can also use
a setpoint parameter.
The controller compares the actual value with the setpoint
value and alters the control signal of the damper actuator
if there is a difference between the two values.
The actual volume flow rate may be displayed by an indicator
unit with a low air throughput, or it may be used for controlling
the extract air by means of a cut-out relay (supplied by the
customer).
1 VAV controller
2 Damper blade
3 Differential pressure sensor
4 Pneumatic controller RLP100
5 Pneumatic actuator

Flow rate control

Flow rate control
In accordance with the project-specific control task the
customer must provide a suitable pneumatic setpoint
adjuster. For variable volume flow rate control, this is a room
temperature controller, a setpoint value adjuster or a DDC TVR-Ex Room
outstation with electro-pneumatic converter. The output signal
of this transducer is used as a control variable by the RLP
100 pneumatic controller.
No setpoint adjuster is required for constant volume flow rate Setpoint
control. 1.3 bars adjuster, e.g.
room
Override controls can be implemented using pneumatic temperature
switches provided by the customer. controller
The volume flow rate actual value is available as a standard
linear, pneumatic signal. This signal can be used to control
a slave unit, for example in the extract air duct. A cut-out relay
is required for this application (to be provided by the
customer). Supply - extract tracking control is possible.
Room pressure control
Room pressure control
The best method for controlling near airtight rooms is to have
room pressure control in a cascade with volume flow control. TVR-Ex
The room pressure controller measures and controls the
differential pressure with regard to a reference room.
The volume flow rate setpoint value is influenced by the room Reference
p room
pressure controller.
The room pressure actual value and the volume flow rate 1.3 bars Room
actual value are available as standard linear pneumatic
signals.
Setpoint adjuster

8 TVR-Ex Operating manual (8/2013)

 2 Operation
4 1 PageHeaderToc
General information

Opening the VAV controller

Carry out the following steps to open the the VAV controller:
1. Unscrew and remove screws (4x) using a Phillips
screwdriver.
Important!
Be careful to not damage the protective conductor.
A protective conductor with self-locking cable lug
is fitted on the cover of the VAV controller.
Carefully open the cover of the VAV controller.
When pulling o the protective conductor, release
the fuse by pressing the latch mechanism.
2. Press both side parts of the cover slightly outwards
using a screwdriver.
3. Lift the cover by hand until the protective conductor can
be pulled o.
4. Loosen the protective conductor of the cover.
5. Remove the cover and put it down.
Closing the VAV controller
Carry out the following steps to close the the VAV controller:
1. Attach the protective conductor to the cover
(paying attention to the orientation of the cover).
2. Push the cover onto the VAV controller.
3. Screw in and tighten screws (4x) using a Phillips
screwdriver.

TVR-Ex Operating manual (8/2013) 9

 1 Operation
4 1 PageHeaderToc
Electronic control

Zero point correction

After installation and electrical wiring the zero point must
be corrected on the dierential pressure transducer because
the installation orientation has an influence on the measured
value. Also, it is necessary to correct it at the prescribed
maintenance intervals.

Note: Before correcting the zero point, connect the
dierential pressure transducer to the supply voltage for
about 15 minutes in order to achieve an even operating
temperature.

To correct the zero point, proceed as follows:

1 Pull the dierential pressure sensor tubes o the
dierential pressure transducer.
2 Use a tube of approx. 20 cm to connect the pressure
connections P+ and P- on the dierential pressure
transducer.
3 On the control panel of the dierential pressure
transducer, press the Enter key for more than 3 seconds
in order to change to parameter mode.
4 If a password has been allocated, enter the password and
confirm by pressing the Enter key.
5 Then use the arrow keys to call up the 0-point correction
menu item (menu item 18), and select it with the Enter
key.
6 Use the arrow keys to select Yes and start the correction
procedure with the Enter key.
7 After completing correction, call up the Save menu to
exit parameter mode.
To do this, select the Save data menu command and Dierential pressure transducer
confirm with the Enter key, after which the sensor is once Display
again in operating mode. Enter key
A flashing star on the display indicates signal acquisition Arrow keys
in operating mode.
8 Then push the dierential pressure sensor tubes back on.
Connection
Tube colour Dierential pressure transducer

Transparent Positive
Blue Negative

TCU II electronic controller

Opening the controller casing
Carry out the following steps to open the electronic controller:
1. Release the two crimp connections .
2. Pull the cover forwards and o.
Closing the controller casing
Carry out the following steps to close the electronic controller:
1. Put on the cover.
2. Tighten the crimp connections.

10 TVR-Ex Operating manual (8/2013)

 5 Technical data

Product overview and dimensions

Dimensions of the TVR-Ex

600 B3 300

536 C

H3
D

Keep clear to provide access to control components Dimensions [mm] Weight [kg]

NW D C B3 H3 Electrical Pneumatic1)
125 124 129 372 221 17.5 15.5
160 156 111 372 221 17.5 15.5
Dimensions of the TCU II electronic controller 200 199 182 463 311 19 17
250 249 157 463 311 19 17
315 314 289 627 461 23 21
400 399 246 627 461 23 21

84

TVR-Ex Operating manual (8/2013) 11

 5 Technical data
Electronic control Pneumatic control

Application range and ATEX identification Application range and ATEX identification
TVR-Ex with electronic control TVR-Ex with pneumatic control

10 C to 40 C at T6 0 C to 40 C at T6
Operating temperature/humidity 10 C to 50 C at T5 Operating temperature/humidity 0 C to 50 C at T5
Humidity acc. to EN60335-1 Humidity acc. to EN60335-1

External casing protection level IP42 External casing protection level IP42

ATEX directive 94/9/EC (ATEX) ATEX directive 94/9/EC (ATEX)

Tested by TV 05 7218 X Tested by TV 05 7218 X

Atmosphere: Gases II 2 G c II T5/T6 Atmosphere: Gases II 2 G c II B T5/T6
(gases, mists and vapours) Zones 1 and 2 (gases, mists and vapours) Zones 1 and 2

Atmosphere: Dusts II 2D c II T 80 C Atmosphere: Dusts not approved

Zones 21 and 22

Dierential pressure transducer Pneumatic volume flow controller

Supply voltage 24 VAC/DC +/-20% Pressure supply 1.3 bars 0.1

Nominal current 150 mA Actual value signal 0.2...1.0 bar

Power rating approx. 4 W Protection level IP30

Protection level IP66

IEC protection class I (earthed) Pneumatic actuator

Operating pressure range 0.3...0.9 bar
Actuator/spring return actuator Control pressure 0...1.2 bars

Supply voltage 24 230 VAC/DC 50/60Hz Protection level IP20

Power rating 120 VA max. Max. perm. pressure 1.5 bars

Protection level IP66

1
Required for achieving the actuator forces.

IEC protection class I (earthed)

The inrush current is 3 to 5 times higher than the nominal current, with a pulse
of a few milliseconds.
Power consumption incl. inrush current.

Auxiliary switch
Voltage 30 V 250 V

Inductive load AC cos = 0.6 5A 3A

Inductive load DC L/R = 3 s 5A 0.03 A

Protection level IP66

TCU II electronic controller

10C to 40C/0 to 98% RH
Operating temperature/humidity
non-condensing

Supply voltage 24 VAC 10% 50/60 Hz

Power rating 20 VA

Protection level IP20

Weight 1.7 kg

12 TVR-Ex Operating manual (8/2013)

 6 Transport, storage, and packaging

Important!
Danger of injury from edges and sheet metal
parts.
Always wear protective gloves when transporting
and installing the unit.

Important!
Be careful not to damage the VAV controller.
Handle the unit with care.
Do not lift the VAV controller by its control
components, the damper blade or differential
pressure sensor. Only lift the unit by lifting the
casing.
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.
A complete shipment includes:
TVR-Ex volume flow controller for electronic or pneumatic
control
TCU II electronic controller (only for version with
electronic control)
TVR-Ex operating manual
Transport on site
If possible, take the TVR-Ex volume flow controller in its
transport packaging up to the installation location.
Storage
If the device has to be stored temporarily:
Moisture and lack of ventilation can lead to oxidation, even
on galvanised components. Remove any plastic wrapping
in order to avoid oxidation.
Protect the device from dust and contamination.
Store the device in a dry place and away from direct
sunlight.
Do not store the device below -10C or above 60C.
Packaging
Properly dispose of packaging material.

TVR-Ex Operating manual (8/2013) 13

 7 Installation

Safety
Installation orientations of TVR-Ex with
Only skilled qualified personnel are allowed to perform pneumatic control
the described work on the volume flow controller.
Only skilled qualified electricians are allowed to work on the
electrical system.
The personnel must have been trained with regard to
the special conditions that apply to potentially explosive
atmospheres.

Important!
Danger of injury from edges and sheet metal
parts.
Always wear protective gloves when transporting
and installing the unit.
Important!
Be careful not to damage the VAV controller.
Handle the unit with care.
Do not lift the VAV controller by its control
components, the damper blade or differential
pressure sensor. Only lift the unit by lifting the
casing.
VAV controller
Installation location
Select the installation location for the VAV controller such
that the control components remain accessible and there
is enough clear space at the inspection accesses. To do
this, provide at least 300 mm clear space in the opening
direction of the cover.
Be sure to install the unit according to the airflow direction
indicated by the arrow on the unit.
When installing elbows, flaps or other disruptive bodies,
provide a straight duct section of 5D upstream.
Pipe bends can be connected directly if the curvature
radius is at least 1D.
The installation orientation of the VAV controller
Installation with electronic control can be selected as required.
Install the VAV controller proficiently with suspension
points and secure with locknuts. Only load the suspension
points with the unit's own weight. Adjacent components
and connecting ducts must be supported separately.
Check the controller for dirt; clean it if necessary.
Push ducts (DIN 1506 or EN 13180) onto the spigot
connections; spigot connections are equipped with lip
seals.
Secure VAV controllers with screw or rivet connection onto
both spigot connections to prevent rotation.
Connect the onward ducting to the VAV controller in an Suspension
electrically conductive connection by means of ground
straps on both ends in order to provide the necessary Pipe clamp with
equipotential bonding. Make the connection self-locking. acoustic insulation
Connect the duct to the building's equipotential bonding. insert

Note!
The VAV controller can also be directly connected
to the building's equipotential bonding. There is Duct
a cable lug connection in the controller casing for
this purpose.
TVR-Ex

Ground strap Screw or rivet connection

14 TVR-Ex Operating manual (8/2013)

 7 Installation

TCU II electronic controller

Installation location
The electronic controller TCU II must be installed outside the Fixing holes
potentially explosive atmosphere.
The electronic controller can be screwed directly onto the wall
or inside a switch cabinet for this purpose.

Warning!
Risk of explosion if the electronic controller is
operated in a potentially explosive atmosphere.
Installe the electronic controller outside the
potentially explosive atmosphere.

Fixing holes

TVR-Ex Operating manual (8/2013) 15

 1 Electrical
8 1 PageHeaderToc
connection
Electronic control

Danger! Notes on installation according to ATEX

Danger of electric shock! Do not touch any
live components! Electrical equipment carries
a dangerous electrical voltage.
Only skilled qualified electricians are allowed
to work on the electrical system.
Switch off the power supply before working on
any electrical equipment.
Installation details
Connect the controller according to the project-specific wiring
diagrams. In doing so, observe the following requirements
and regulations:
Guidelines of VDE (German association for electrical,
electronic and information technologies) or appropriate
national guidelines
Requirements of the local electricity utility
Wiring guidelines and project-specific circuit diagrams
The standards and guidelines listed in chapter 2
Wiring diagram
Use separate grounds for the supply and signal cables.
The cables to be used must comply with ATEX. The type
of protection for the unit must not be impaired by connecting
cables. Irrespective of the type of protection, all cables
to be used must have been tested and approved according to
EN 50014, Appendix B (VDE 0170/0171, Part 1).
Further requirements on electrical installations in potentially
explosive atmospheres can be found in EN 60079-14
(VDE 0165, Part 1). Section 9, for example, contains infor-
mation on the connection of portable operating equipment.
General information
All cables must be led through the cable bushings provided
on the VAV controller casing. The connections are made
in the terminal box or in the connection box of the dierential
pressure transducer, which have been approved for use in
potentially explosive atmospheres.
Use of loose terminals in the terminal box or the connection
box is not permitted. Once the cables have been connected,
the cable bushings must be tightened firmly in order to ensure
IP protection (IP 66).
Unused openings for cable bushings in areas with potentially
explosive atmospheres must be plugged with certified
dummy plugs.
Connecting the actuator
The connections for the supply voltage and signal lines
of the actuator are made in the terminal box. The terminal box
is inside the VAV controller casing.
Connecting the differential pressure transducer
The dierential pressure transducer is also installed in the
VAV controller casing and has its own 'explosion-proof'
connection box for the wiring according to the project specific
wiring documents.
Once the VAV controller has been installed and wired,
the zero point must be corrected on the dierential pressure
transducer (see chapter 4 Operation).
Note
It is recommended that you use shielded cables for the signal
lines of the dierential pressure transducer and actuator.

Actuator
Dierential pressure transducer
Terminal box
Signal line
Supply voltage

16 TVR-Ex Operating manual (8/2013)

 8 Electrical connection
Electronic control

Electrical connections
Room controller (supply and extract air)

Switch cabinet

Ex-approved actuator Differential pressure

(terminal box) transducer

VAV controller

TRA-RS TCU II terminal connections

Pos. Terminal Input/output Description

AI3...AI7 Analog input Additional analog inputs for optional functions
AI2 Analog input Actual dierential pressure
AI1 Analog input Additional analog inputs for optional functions
DI2 Binary input Day/night operation, volt-free contact closed = night (switch provided by the customer)
AO4 Analog output Flow rate control signal
DI1 Binary input Complete shut-o, volt-free contact closed = complete shut-o (switch provided by the customer)
BMS Binary output Alarm relay (volume flow rate deviation)
AO2 Analog output Actual volume flow rate
AO3 Analog output Total volume flow rate

Important!
The wiring diagram shown is an example. The wiring
documents supplied for the specific project apply.

TVR-Ex Operating manual (8/2013) 17

 1 Pneumatic
9 1 PageHeaderToc
connection
Pneumatic control

Danger!
Operation is only permitted with instrument air
that is free from oil, water and dust. Do not use
combustible gases, oxygen or oxygen-enriched
gases.
Installation details
Connect the VAV controller according to the project-specific
tubing diagrams and in compliance with the following
instructions:
All tubes must enter the VAV controller casing through
the bushings provided for this purpose.
Only use pneumatic tubes that have an inside diameter
of 4 mm and outer diameter of 6 mm.

Important!
The tubing diagrams shown are examples. The tubing
documents supplied for the specific project apply.

Tubing

Constant volume flow rate control Room temperature control Room temperature and room pressure control
Operating Operating Room Operating Room
temperature pressure temperature
pressure pressure controller controller

TVR-Ex TVR-Ex TVR-Ex supply air

Room
Reference room

Room temperature control with

shut-off function

Operating Room TVR-Ex TVR-Ex extract air

temperature
pressure controller

Tube connections
S1
1 Input for the operating pressure
(1.3 bars, 0.1 bar)
6 Input for the nominal volume flow rate
TVR-Ex (0.2 to 1.0 bar)

Shut-off function for building section + Input for the room pressure actual value
S1 closed: Room temperature control mode - Input for the reference room pressure actual
S1 open: shut-off value

18 TVR-Ex Operating manual (8/2013)

 2 1
10 Commissioning,
PageHeaderTocoperation

Warning! Commissioning of electronic controllers

Only authorised specialists are allowed
to commission the volume flow controller. Check the correct installation
Check the equipotential bonding
Testing before commissioning Check the wiring
To comply with Industrial Health and Safety Regulations
(BetrSichV), a system requiring monitoring must be tested by
an approved monitoring body before it is taken into operation
for the first time and before it is taken into operation after
a significant modification.
The correct condition with regard to assembly, installation Switch on the voltage
Correct the zero point of the dierential pressure transducer 1
and the installation conditions, as well as safe function, must
Load the control parameters 2
be tested with regard to the intended mode of operation. Switch on air conditioning systems
Operation
After commissioning and the setting of parameters,
the controller will operate independently and require no
intervention on the part of the plant operator.
Override control min
The statutory inspection intervals must be complied with. Log the actual value signal pw
In case of a malfunction, take the VAV controller out Override control max
of operation and repair it before commissioning it again. Log the actual value signal pw

1
See chapter 4, Operation.
2
The hardware and the software necessary for this are available from
TROX; you may also request commissioning support from our technical
service.

Commissioning of pneumatic controllers

Check the correct installation

Check the equipotential bonding
Check the tubing

Check and switch on the operating pressure

Switch on air conditioning systems

Override control min

Log the actual value signal pw
Override control max
Log the actual value signal pw

TVR-Ex Operating manual (8/2013) 19

 11 Maintenance

Warning! Check and possibly correct the sequence of control loops

Only authorised specialist personnel are allowed (room balance).
to perform the described maintenance measures. Clean the sensors, if contaminated.
Document maintenance work and measurement reports.
The VAV controller, the actuator and the electronic/ Repair
pneumatic controller are maintenance-free with regard to For safety reasons, any repair work affecting the protection
wear, but the VAV controller must be included in the regular function with regard to potentially explosive atmospheres
cleaning. must only be carried out by expert qualified personnel
Regular care and maintenance ensure operational or the manufacturer. Only genuine replacement parts must
readiness, functional reliability, and long service life of the be used. After a significant modification a renewed
VAV controller. commissioning test may be required.
The statutory regulations must be complied with during
maintenance. Maintenance service
The operator of the system is responsible for maintenance. Regular maintenance by TROX Service is recommended
The operator is responsible for creating a maintenance plan, in order to ensure operational readiness, functional reliability,
for defining the maintenance objectives, and for the and long service life of the unit.
functional reliability of the unit. TROX Service can establish the actual condition of the unit,
adapt or re-correct it if necessary and ensure that the unit
Units for installation in areas with potentially explosive is in proper condition after maintenance.
atmospheres must only be opened by the manufacturer.
However, the following components may be opened for Necessary adjustments and parameter setting can be
maintenance work: conducted as part of maintenance such that a high level of
safety is always maintained.
VAV controller casing
TCU II electronic controller casing
Actuator terminal box
Dierential pressure transducer connection box
Inspection
Inspection should be performed by a specialist in
accordance with statutory regulations and guidelines
(see chapter 2), however at least once a year.
The test of every single unit must be documented and
evaluated. If the requirements are not fully met, suitable
remedial action must be taken.
Inspection work
Danger!
Danger of electric shock! Do not touch any
live components! Electrical equipment carries
a dangerous electrical voltage.
Only skilled qualified electricians are allowed
to work on the electrical system.
Switch off the power supply before working on
any electrical equipment.

The following inspection work must be performed:

Remove contamination from the VAV controller that aects
its function. Remove significant dust deposits from the
controller casing.
Check all screws for firm seating and retighten if necessary.
Correct the zero point of the dierential pressure
transducer, see chapter 4 Operation (only with electronic
control).
Functional test of the control loops (including volume
flow rate) and, if necessary, correction of the set control
parameters.
Check that the measured values are plausible.
Check and possibly correct special functions (override
controls, alarm suppression on monitoring systems).
Check the optical and acoustic alarm emitters.

20 TVR-Ex Operating manual (8/2013)

 12 Troubleshooting

Most malfunctions can be rectified by the operator with

the help of the troubleshooting diagrams. If the malfunction
cannot be rectified, please contact TROX Service.

Electronic control - troubleshooting Pneumatic control - troubleshooting

Supply voltage correct? No Connect the supply Operating pressure No Connect pressure
voltage OK? supply

Yes Yes

Damper obstructed? Damper obstructed?

Does the actuator open No Eect of actuator Does the actuator open No Effect of actuator
and close? action correct? and close? action correct?
Controller faulty? Controller faulty?
Yes Yes

No No
Volume flow rate Vmin? Adequate pressure in Volume flow rate Vmin? Is the duct pressure
the duct? adequate?

Yes Measuring tubes to Are the measuring

Yes
the transducer OK? tubes to the transducer
OK?
No Volume flow rate Vmax? No
Volume flow rate Vmax?

Yes Yes

No Check control No Check control

Is the set flow rate signal Is the set volume flow rate
OK? signal OK?

Yes Yes

Is override control active? No Check window Is override control active? No Check window switch,
switch, etc. etc.

TVR-Ex Operating manual (8/2013) 21

 13 Removal and disposal

Removal
1. Switch o the ventilation system.
2. Switch o the power supply or operating pressure.

Danger!
Danger of electric shock! Do not touch any
live components! Electrical equipment carries
a dangerous electrical voltage.
Only skilled qualified electricians are allowed
to work on the electrical system.
Switch o the power supply before working
on any electrical equipment.

3. Disconnect the connecting cable or remove the tubing

4. Remove the unit.
Disposal
Once the volume flow controller has been taken out
of operation for good, have it disposed of properly by a
responsible organisation.

22 TVR-Ex Operating manual (8/2013)

 14 ATEX type examination certificate

TVR-Ex Operating manual (8/2013) 23

 14 ATEX type examination certificate

24 TVR-Ex Operating manual (8/2013)