Danfoss BTD MIX Operating guide

InstallationGuide

TermixBTDMIX

1.0TableofContents

1.0TableofContents.............................................1

2.0Functionaldescription......................................2

3.0Safetynotes.....................................................3

3.1SafetyNotes–general............................................3

4.0Mounting........................................................4

4.1Mounting...........................................................4

4.2Start-up..............................................................6

4.3Electricalconnections.............................................7

5.0Design.............................................................8

5.1Design...............................................................8

5.2Schematicdiagram................................................9

6.0Controls..........................................................10

6.1Heatingcircuit......................................................10

6.2DHWtemperaturecontrol........................................13

6.3Other.................................................................14

6.4Maintenance........................................................16

7.0Troubleshooting..............................................17

7.1Troubleshootingingeneral......................................17

7.2TroubleshootingDHW............................................17

7.3TroubleshootingHE...............................................18

7.4Disposal.............................................................19

8.0Declaration......................................................23

8.1Declarationofconformity........................................23

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InstallationGuideTermixBTDMIX

2.0Functionaldescription

Districtheatingsubstationfordirectheatingwithtankfor
domestichotwaterpreparationandwiththermostaticor
electroniccontrol.Designedforoor-mounting,alternatively
forwall-mounting.

Application

TheT ermixBTD-MIXsubstationisacompletesolutionforhotwater
andheatingsystemwithdifferentialpressurecontrolandmixing
loop.TheT ermixBTD-MIXisapplicableforsingle-familyhouses
orapartments.

Districtheating(DH)

Thesubstationisprefabricatedwithadifferentialpressure
controller,ttingpieceandsensorpocketsforinsertionofa
heatmeteraswellasstrainerandballvalves.Furthermorethe
substationisdeliveredwithamixingloopincludingpump,controls
andnon-returnvalve.

Heating(HE)

Theheatingcircuitisdesignedfordirectgenerationofheat.The
differentialpressurecontrolsetstheoptimaloperationconditions
forradiatorthermostaticvalvesinordertoenableindividual
temperaturecontrolineachroom.Themixingloopcreatesa
suitabletemperaturelevele.g.foroorheating.

Domestichotwater(DHW)

Thedomestichotwatercircuitconsistsofahotwatertankwithcoil
andself-actingthermostaticcontrolvalveorelectroniccontroller.
Thehotwatertankandcoilareenamelledandthetankcontains
amagnesiumanode.Thesubstationisdeliveredwithabuiltin
non-returnvalveandsafetyvalveaswellasanexpansionvessel
mountedinthecoldwatersupply.Furthermoreatemperature
andpressurereliefvalveaccordingtoBritishWRASstandards
iscomprised.Thewaterheaterissuppliedwithathermostatic
circulationvalve.

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InstallationGuideTermixBTDMIX

3.0Safetynotes

3.1SafetyNotes–general

Thefollowinginstructionsrefertothestandarddesignof
substation.Specialversionsofsubstationsareavailableon
request.

Thisoperatingmanualshouldbereadcarefullybeforeinstallation
andstart-upofthesubstation.Themanufactureracceptsno
liabilityfordamageorfaultsthatresultfromnon-compliancewith
theoperatingmanual.Pleasereadandfollowalltheinstructions
carefullytopreventaccidents,injuryanddamagetoproperty.
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
Pleasecomplywiththeinstructionsissuedbythesystem
manufacturerorsystemoperator.

Corrosionprotection

Allpipesandcomponentsaremadeofstainlesssteelandbrass.
Themaximumchloridecompoundsoftheowmediumshouldnot
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
qualiedandauthorizedpersonnelonly.

Pleaseobserveinstructionscarefully

Toavoidinjurytopersonsanddamagetothedevice,itisabsolutely
necessarytoreadandobservetheseinstructionscarefully.

Warningofhighpressureandtemperature

Beawareoftheinstallation’spermissiblesystempressureand
temperature.

Themaximumtemperatureoftheowmediuminthesubstationis
120°C.

Themaximumoperatingpressureofthesubstationis10bar.PN16
versionsareavailableonenquiry.

Theriskofpersonsbeinginjuredandequipmentdamagedincreases
considerablyiftherecommendedpermissibleoperatingparameters
areexceeded.

Thesubstationinstallationmustbeequippedwithsafetyvalves,
however,alwaysinaccordancewithlocalregulations.

Choiceofmaterial

Choiceofmaterialsalwaysincompliancewithlocallegislation.

Safetyvalve(s)

Werecommendmountingofsafetyvalve(s),however,alwaysin
compliancewithlocalregulations.

Connection

Thesubstationmustbeequippedwithfeaturesthatensurethat
thesubstationcanbeseparatedfromallenergysources(also
powersupply).

Emergency

Incaseofdangeroraccidents-re,leaksorotherdangerous
circumstances-interruptallenergysourcestothestationif
possible,andseekexperthelp.
Incaseofdiscolouredorbad-smellingdomestichotwater,closeall
shut-offvalvesonthesubstation,informtheoperatingpersonnel
andcallforexperthelpimmediately.

Storage

Anystorageofthesubstationwhichmaybenecessarypriorto
installationshouldbeinconditionswhicharedryandheated.

Warningofhotsurface

Thesubstationhasgothotsurfaces,whichcancauseskinburns.
Pleasebeextremelycautiousincloseproximitytothesubstation.

Powerfailurecanresultinthemotorvalvesbeingstuckinopen
position.Thesurfacesofthesubstationcangethot,whichcancause
skinburns.Theballvalvesondistrictheatingsupplyandreturnshould
beclosed.

Warningoftransportdamage

Beforesubstationinstallation,pleasemakesurethatthesubstation
hasnotbeendamagedduringtransport.

IMPORTANT-Tighteningofconnections

Duetovibrationsduringtransportallangeconnections,screwjoints
andelectricalclampandscrewconnectionsmustbecheckedand
tightenedbeforewaterisaddedtothesystem.Afterwaterhasbeen
addedtothesystemandthesystemhasbeenputintooperation,
re-tightenALLconnections.

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InstallationGuideTermixBTDMIX

4.0Mounting

4.1Mounting

Installationmustbeincompliancewithlocalstandardsand
regulations.
Districtheating(DH)-Inthefollowingsections,DHreferstothe
heatsourcewhichsuppliesthesubstations.Avarietyofenergy
sources,suchasoil,gasorsolarpower,couldbeusedasthe
primarysupplytoDanfosssubstations.Forthesakeofsimplicity,
DHcanbetakentomeantheprimarysupply.

Connectionsizes:

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.

Allconnections:

G¾”(int.thread)

Dimensions(mm):

Withcover:
H1720xW540xD640(typeBTD-MIX1)
H1870xW540xD640(typeBTD-MIX2)

Weight(approx.):90-130kg

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4.1.1Installation

Mounting:

Adequatespace

Pleaseallowadequatespacearoundthesubstationformounting
andmaintenancepurposes.

Orientation

Thestationmustbemountedsothatcomponents,keyholes
andlabelsareplacedcorrectly.Ifyouwishtomountthestation
differentlypleasecontactyoursupplier.

Drillings

Wheresubstationsaretobewall-mounted,drillingsareprovided
inthebackmountingplate.Floormountedunitshavesupport.

Labelling

Eachconnectiononthesubstationislabelled.

Beforeinstallation:

Cleanandrinse

Priortoinstallation,allsubstationpipesandconnectionsshouldbe
cleanedandrinsed.

Thightening

Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.

Unusedconnections

Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.

Installation:

Strainer

Ifastrainerissuppliedwiththestationitmustbettedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.

Connections

Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,angedorweldedconnections.

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4.2Start-up

Start-up,Heatingwithmixingloop

Start-up:

1:Pumpspeed

Setthepumptohighestspeedbeforestart-up.

2:Startpump

Startthepumpandheatthroughthesystem.

3:Openshut-offvalves

Theshut-offvalvesshouldthenbeopenedandtheunitobserved
asitentersservice.Visualcheckingshouldconrmtemperatures,
pressures,acceptablethermalexpansionandabsenceofleakage.
Ifthesystemoperatesinaccordancewithdesign,itcanbeput
toregularuse.

4:Ventsystem

Switchoffthepumpandventtheinstallationaftertheradiators
havebeenwarmedup.

5:Adjustpumpspeed

Setthepumptothelowestspeedconsistentwithcomfortand
electricityconsumption.
Normallythechange-overswitchissetinthemidposition(default).
Howeverforsystemswithunderoorheatingorsinglepipeloop
systems,itmaybenecessarytoturnthechange-overswitch
upwards.
Higherpumpspeedsareonlyusediftheheatingrequirement
increases.

Re-thightenconnections

Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.

Pump

Thepumpmustbeswitchedoffduringsystemll.

Underoorheating:

Pumpstopfunction

Ifthesubstationisusedinconnectionwithunderoorheating,the
circulationpumpmustbeconnectedtothepumpstopfunctionin
theunderoorheatingcontroller .Thepumpmustbestoppedif
allunderoorheatingcircuitsareclosed.

Warranty

Ifthisisnotpossible,thenowmustbecontinuedthroughthe
by-pass.Failingthis,thepumpwillbeatriskofseizureandany
remainingwarrantywillbewithdrawn.

Summeroperation:

Switchoffpump

Insummerthecirculationpumpmustbeswitchedoffandthe
shut-offvalvetoHEsupplyclosed.

Runningpumpbi-weekly

Itisrecommendedtostartupthecirculationpump(for2minutes)
onceamonthduringsummer;theshut-offvalveoftheHEsupply
mustbeshut.

Electroniccontroller

Mostelectroniccontrollerswillstartupthepumpautomatically
(pleasenotemanufacturer´sinstructions).

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4.3Electricalconnections

Beforemakingelectricalconnections,pleasenotethe
following:

Safetynotes

Pleasereadtherelevantpartsofthesafetynotes.

230V

Thesubstationmustbeconnectedto230VACandearth.

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

E

Hotwatertankwithcoil

F

Electroniccontroller

1A

Ballvalve,DVGW

7

Thermostaticvalve

9

Strainer

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Circulatorpump

14

Sensorpocket,energymeter

20

Filling/drainvalve

22

Testconnection

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Actuator,HE

41

Fittingpiece,energymeter

43

Ballvalveclosed

50

Diff.pressurecontrollerwithowlimiter

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