OperatingGuide
TermixBL-FI
1.0TableofContents
1.0TableofContents.............................................1
........................................................................2
2.0Functionaldescription......................................3
3.0Safetynotes.....................................................4
3.1SafetyNotes–general............................................4
4.0Mounting........................................................5
4.1MountingtheCompactstation..................................5
4.2Electricalconnections.............................................13
5.0Design.............................................................14
5.1Design...............................................................14
5.2Schematicdiagram................................................15
6.0Controls..........................................................16
6.1DHWtemperaturecontrol........................................16
6.2Other.................................................................18
6.3Maintenance........................................................19
7.0Troubleshooting..............................................20
7.1Troubleshootingingeneral......................................20
7.2TroubleshootingDHW............................................21
7.3Disposal.............................................................22
8.0Declaration......................................................23
8.1Declarationofconformity........................................23
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2.0Functionaldescription
Instantaneouswaterheaterwithheatexchangerand
automaticcontrols.Designedforwall-mounting.
Application
TheT ermixBL-FIsubstationisaninstantaneouswaterheater
featuringsuperbheatextractionandhighperformance.The
substationisdeliveredwithautomaticcontrolspreparedfora
chargingsystem.
TheT ermixBL-FIissuitableforlargeapartmenthouses,sports
arenasandschools,wherelargeamountsofhotwaterareneeded.
Domestichotwater(DHW)
Thesubstationisfittedwithanefficientplateheatexchanger,
whichensuresthemostfavourableheatextractionandachieves
optimumcomfortandoperatingeconomy.
TheTermixBL-FIchargingsystemisdeliveredwithDanfoss
automaticcontrolsforregulationofthechargingtemperatureand
thetemperatureinthehotwaterbuffertank.Thecontrolvalve
withintegratedpressurecontrolhelpstoavoidcyclicvariationsof
thedifferentialpressureinthedistrictheatingsupply.
Domestichotwatercirculation
TheTermixBL-FIsubstationissuppliedwithconnectionsforDHW
circulationincludingcirculationpumpandanonreturnvalveas
astandard.
Flexiblesolution
Pipeconnectioncanbemadefromeitherthetoporbottom,which
makesthissolutionhighlyflexible.Atthesametime,bothspace
andtimearesavedwheninstalling.
Minimalheatloss
Completeinsulationoftheunitensuresminimalheatloss.
Reliableandeasytoinstall
TermixBL-FIisoperationallyreliable.Aqualityproduct
manufacturedinDenmark,whichiseasytoinstallandquickly
commissioned.
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3.0Safetynotes
3.1SafetyNotes–general
Thefollowinginstructionsrefertothestandarddesignof
substation.Specialversionsofsubstationsareavailableon
request.
Thisoperatingmanualshouldbereadcarefullybeforeinstallation
andstart-upofthesubstation.Themanufactureracceptsno
liabilityfordamageorfaultsthatresultfromnon-compliancewith
theoperatingmanual.Pleasereadandfollowalltheinstructions
carefullytopreventaccidents,injuryanddamagetoproperty.
Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.
Pleasecomplywiththeinstructionsissuedbythesystem
manufacturerorsystemoperator.
Corrosionprotection
Allpipesandcomponentsaremadeofstainlesssteelandbrass.
Themaximumchloridecompoundsoftheflowmediumshouldnot
behigherthan150mg/l.
Theriskofequipmentcorrosionincreasesconsiderablyifthe
recommendedlevelofpermissiblechloridecompoundsis
exceeded.
Energysource
Thesubstationisdesignedfordistrictheatingastheprimary
sourceofenergy.However,alsootherenergysourcescanbeused
wheretheoperatingconditionsallowitandalwaysarecomparable
todistrictheating.
Application
Thesubstationisdesignedtobeconnectedtothehouse
installationinafrost-freeroom,wherethetemperaturedoesnot
exceed50°Candthehumiditydoesnotexceed60%.Donotcover
orwallupthesubstationorinanyotherwayblocktheentrance
tothestation.
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.
Pleaseobserveinstructionscarefully
Toavoidinjurytopersonsanddamagetothedevice,itisabsolutely
necessarytoreadandobservetheseinstructionscarefully.
Warningofhighpressureandtemperature
Beawareoftheinstallation’spermissiblesystempressureand
temperature.
Themaximumtemperatureoftheflowmediuminthesubstationis
110°C.
Themaximumoperatingpressureofthesubstationis16bar.
Theriskofpersonsbeinginjuredandequipmentdamagedincreases
considerablyiftherecommendedpermissibleoperatingparameters
areexceeded.
Thesubstationinstallationmustbeequippedwithsafetyvalves,
however,alwaysinaccordancewithlocalregulations.
Choiceofmaterial
Choiceofmaterialsalwaysincompliancewithlocallegislation.
Safetyvalve(s)
Werecommendmountingofsafetyvalve(s),however,alwaysin
compliancewithlocalregulations.
Connection
Thesubstationmustbeequippedwithfeaturesthatensurethat
thesubstationcanbeseparatedfromallenergysources(also
powersupply).
Emergency
Incaseofdangeroraccidents-fire,leaksorotherdangerous
circumstances-interruptallenergysourcestothestationif
possible,andseekexperthelp.
Incaseofdiscolouredorbad-smellingdomestichotwater,closeall
shut-offvalvesonthesubstation,informtheoperatingpersonnel
andcallforexperthelpimmediately.
REACH
AllDanfossA/SproductsfulfilltherequirementsinREACH.
OneoftheobligationsinREACHistoinformcustomersabout
presenceofCandidatelistsubstancesifany,weherebyinform
youaboutonesubstanceonthecandidatelist:Theproduct
containsbrasspartswhichcontainslead(CASno:7439-92-1)ina
concentrationabove0.1%w/w.
Storage
Anystorageofthesubstationwhichmaybenecessarypriorto
installationshouldbeinconditionswhicharedryandheated.
Warningofhotsurface
Thesubstationhasgothotsurfaces,whichcancauseskinburns.
Pleasebeextremelycautiousincloseproximitytothesubstation.
Powerfailurecanresultinthemotorvalvesbeingstuckinopen
position.Thesurfacesofthesubstationcangethot,whichcancause
skinburns.Theballvalvesondistrictheatingsupplyandreturnshould
beclosed.
Warningoftransportdamage
Beforesubstationinstallation,pleasemakesurethatthesubstation
hasnotbeendamagedduringtransport.
IMPORTANT-Tighteningofconnections
Duetovibrationsduringtransportallflangeconnections,screwjoints
andelectricalclampandscrewconnectionsmustbecheckedand
tightenedbeforewaterisaddedtothesystem.Afterwaterhasbeen
addedtothesystemandthesystemhasbeenputintooperation,
re-tightenALLconnections.
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4.0Mounting
4.1MountingtheCompactstation
Installationmustbeincompliancewithlocalstandardsand
regulations.
Districtheating(DH)-Inthefollowingsections,DHreferstothe
heatsourcewhichsuppliesthesubstations.Avarietyofenergy
sources,suchasoil,gasorsolarpower,couldbeusedasthe
primarysupplytoDanfosssubstations.Forthesakeofsimplicity,
DHcanbetakentomeantheprimarysupply.
Connections:
1.Districtheating(DH)supply
2.Districtheating(DH)return
3.Domestichotwater(DHW)
4.Domesticcoldwater(DCW)
5.Hotwatercirculation(HWC)
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.
Connectionsizes:
DH+DHW+DCW:
HWC:
Dimensions(mm):
Withinsulation:
Weight(approx.):60kg
G1”(int.thread)
G¾”(int.thread)
Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.
H890xW905xD400
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Removethefront.
Removeotherblocks.
Attachthemountingrailtothewall.
Liftthestation.
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Mountthestationonthemountingrail.
Attachthestationtothewallintheholesonthemountingplate.
MountblockAontheleft-handsideofthepump.AttachblockE
toblockA,andattachittothepipeabovethepumpbyclicking
itinplace.
MountblockBontheright-handsideofthepump.
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MountblockF.Theblockishingedandcanbedrawnaroundthe
valve.AttachtheblocktoblockBandE.
Mountthefrontcover.
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4.1.1InstallingtheCompactstation
Mounting:
Adequatespace
Pleaseallowadequatespacearoundthesubstationformounting
andmaintenancepurposes.
Orientation
Thestationmustbemountedsothatcomponents,keyholes
andlabelsareplacedcorrectly.Ifyouwishtomountthestation
differentlypleasecontactyoursupplier.
Drillings
Wheresubstationsaretobewall-mounted,drillingsareprovided
inthebackmountingplate.Floormountedunitshavesupport.
Labelling
Eachconnectiononthesubstationislabelled.
Beforeinstallation:
Cleanandrinse
Priortoinstallation,allsubstationpipesandconnectionsshouldbe
cleanedandrinsed.
Tightening
Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.
Unusedconnections
Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.
Installation:
Strainer
Ifastrainerissuppliedwiththestationitmustbefittedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.
Connections
Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,flangedorweldedconnections.
Keyholeformounting.
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4.1.2Pipeconnectionsup
Removethetopblock.
Removethepipeplugsatthetopofthestation.
RemoveU-clamps.
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Removepipes.Anglesandteesareturnedsothatpipescanbe
installedfromabove.
Installthepipes.Districtheatingsupplypipestobeinterchanged.
FitU-clamps.
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Fitthepipeplugsatthebottomofthestation.
Fitthetopblock.
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4.2Electricalconnections
Beforemakingelectricalconnections,pleasenotethe
following:
Safetynotes
Pleasereadtherelevantpartsofthesafetynotes.
230V
Thesubstationmustbeconnectedto230VACandearth.
Potentialbonding
Potentialbondingshouldbecarriedoutaccording
to60364-4-41:2007andIEC60364-5-54:2011.
Bondingpointonthemountingplatebelowrightcornermarked
withearthsymbol.
Disconnection
Thesubstationmustbeelectricallyconnectedsothatitcanbe
disconnectedforrepairs.
Outdoortemperaturesensor
Outdoorsensorsshouldbemountedsoastoavoidexposureto
directsunlight.Theyshouldnotbeplacedclosetodoors,windows
orventilationoutlets.
Theoutdoorsensormustbeconnectedtothestationonthe
terminalblockundertheelectroniccontrol.
Authorizedelectrician
Electricalconnectionsmustbemadebyanauthorizedelectricianonly.
Localstandards
Electricalconnectionsmustbemadeinaccordancewithcurrent
regulationsandlocalstandards.
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5.0Design
5.1Design
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
B
Heatexchanger,DHW
G
ElectroniccontrollerDHW
2
Singlecheckvalve
4
Safetyvalve
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Domestichotwaterpump
27
Actuator
30
Flowcontrolwithcontrolvalve
36
Balancingvalve
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5.2Schematicdiagram
DH
Supply
DH
Return
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
DHW
DCW
HWC
B
Heatexchanger,DHW
D
Hotwatertank
G
ElectroniccontrollerDHW
L
Borderofdelivery
1
Ballvalve
2
Singlecheckvalve
4
Safetyvalve
DHW:
DCW:
HWC:
DHSupply:
DHReturn:
5.2.1Technicalparameters
Technicalparameters
Nominalpressure:
Max.DHsupplytemperature:
Min.DCWstaticpressure:
Brazingmaterial(HEX):
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB
Domestichotwater
Domesticcoldwater
Hotwatercirculation
Districtheatingflow
Districtheatingreturn
PN16
110°C
0.5bar
Copper
11
Domestichotwaterpump
13
Chargingpump
18
Thermometer
19
Surfacesensor
21
Tobeorderedseparately
24
Deliveredloosewithunit
27
Actuator
30
Flowcontrolwithcontrolvalve
36
Balancingvalve
40
Immersionsensor
43
Ballvalveclosed
44
Immersionsensor
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6.0Controls
6.1DHWtemperaturecontrol
DHWtemperaturecontrol
TherearevarioustypesofDHWtemperaturecontrolusedin
Danfosssubstations.
DHWtemperatureshouldbeadjustedto45-50°C,asthisprovides
optimalutilisationofDHwater.AtDHWtemperaturesabove55°C,
thepossibilityoflimescaledepositsincreasessignificantly.
6.1.1Electroniccontrol
Substationswithelectroniccontrolmustbesetinaccordancewith
manufacturer´sinstructions.
Wheretheroomtemperatureiscontrolledbyradiatorthermostats,
itisrecommendedthatthermostatsbesetforminimum
temperatureineachroom.
6.1.2Flowcontrollerwithintegratedcontrolvalve
Thecontrollerisaself-actingflowcontrollerwithintegratedcontrol
valve.Thecontrollercloseswhensetmax.flowisexceededand
canbeusedincombinationwithDanfosselectricalactuatorswith
orwithoutsafetyfunction.Springreturnmotorcanbeusedas
safetyfunctionbypowerfailure.
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6.1.3Electric2–waymotorizedvalve
Actuatorswithorwithoutsafetyfunctionareavailablefor3-point
controls.Spring-returnactuatorscanbeusedtoprovidesafety
shut-offintheeventofpowerfailure.
6.1.4Domestichotwaterpump
Important!
Itisnecessarytomountadomestichotwatercirculationpumpon
thewaterheatertoavoidregulationproblems.
Thecirculationpumpcannotbeswitchedoff,sincethiswillresult
inregulationproblems.(noflowatthesensor).
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6.2Other
6.2.1Safetyvalve
Thepurposeofthesafetyvalveistoprotectthesubstationfrom
excessivepressure.
Theblow-offpipefromthesafetyvalvemustnotbeclosed.The
blow-offpipeoutletshouldbeplacedsothatitdischargesfreely
anditispossibletoobserveanydrippingfromthesafetyvalve.
Itisrecommendedtochecktheoperationofsafetyvalvesat
intervalsof6months.Thisisdonebyturningthevalveheadin
directionindicated.
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6.3Maintenance
Thesubstationrequireslittlemonitoring,apartfromroutine
checks.Itisrecommendedtoreadtheenergymeteratregular
intervals,andtowritedownthemeterreadings.
RegularinspectionsofthesubstationaccordingtothisInstruction
arerecommended,whichshouldinclude:
Strainers
Cleaningofstrainers.
Meters
Checkingofalloperatingparameterssuchasmeterreadings.
Temperatures
Checkingofalltemperatures,suchasDHsupplytemperatureand
DHWtemperature.
Connections
Checkingallconnectionsforleakages.
Safetyvalves
Theoperationofthesafetyvalvesshouldbecheckedbyturning
thevalveheadintheindicateddirection.
Venting
Checkingthatthesystemisthoroughlyvented.
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.
Inspectionsshouldbecarriedoutminimumeverytwoyears.
SparepartscanbeorderedfromDanfoss.Pleaseensurethatany
enquiryincludesthesubstationserialnumber.
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7.0Troubleshooting
7.1Troubleshootingingeneral
Intheeventofoperatingdisturbances,thefollowingbasicfeatures
shouldbecheckedbeforecarryingoutactualtroubleshooting:
•thesubstationisconnectedtoelectricity,
•thestrainerontheDHsupplypipeisclean,
•thesupplytemperatureoftheDHisatthenormallevel
(summer,atleast60°C-winter,atleast70°C),
•thedifferentialpressureisequaltoorhigherthanthenormal
(local)differentialpressureintheDHnetwork–ifindoubt,ask
theDHplantsupervisor,
•pressureonthesystem-checktheHEpressuregauge.
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.
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7.2TroubleshootingDHW
ProblemPossiblecauseSolution
ToolittleornoDHW.
Taptemperaturetoohigh;DHWtapload
toohigh.
Temperaturedropduringtapping.
Thermostaticcontrolvalvedoesnotclose
Strainerinsupplyorreturnlineclogged.Cleanstrainer(s).
DHWcirculationpumpoutoforderorwith
toolowsetting.
Defectiveorcloggednon-returnvalve.
Noelectricity.Check.
Wrongsettingofautomaticcontrols,ifany.Toadjustanelectroniccontrollerfor
Scalingoftheplateheatexchanger.
Defectivemotorizedvalve.Check(usemanualfunction)–replace.
Defectivetemperaturesensors.
Defectivecontroller.
DCWisbeingmixedwiththeDHW,e.g.ina
defectivethermostaticmixingvalve.
Defectiveorcloggednon-returnvalveon
circulationvalve.
Thermostaticvalveadjustedtoatoohigh
level.
Scalingoftheplateheatexchanger.
LargerDHWflowthanthesubstationhas
beendesignedfor.
TemperaturedifferencebetweenDH
supplyandDHWsetpointtoolow.
Checkcirculationpump.
Replace–clean.
DHW,pls.noteenclosedinstructionsfor
electroniccontroller.
Replace–rinseout.
Check–replace.
Check–replace.
Check–replace. Hotwaterinsometapsbutnotinall.
Replace–clean.
Check–set.
Replace–rinseout.
ReduceDHWflow.
Lowerthesetpointtemperatureorincrease
theDHsupplytemperature.
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7.3Disposal
Disposal
Thisproductshouldbedismantledanditscomponents
sorted,ifpossible,invariousgroupsbeforerecycling
ordisposal.
Alwaysfollowthelocaldisposalregulations.
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8.0Declaration
8.1Declarationofconformity
Category0withelectricalequipment
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