Danfoss BVX RO Operating guide

Operating Guide

Termix BVX RO

1.0	Table of Contents
1.0	Table of Contents .............................................	1	8.0	Declaration......................................................	27
	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2	8.1	Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	27
2.0	Functional description......................................	3
3.0	Safety notes.....................................................	4
3.1	Safety Notes – general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4
4.0	Mounting ........................................................	5
4.1	Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
4.2	Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
4.3	Electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
5.0	Design.............................................................	10
5.1	Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
5.2	Schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
6.0	Controls ..........................................................	12
6.1	Heating circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
6.2	DHW temperature control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	16
6.3	Other. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
6.4	Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	20
7.0	Troubleshooting ..............................................	21
7.1	Troubleshooting in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	21
7.2	Troubleshooting DHW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
7.3	Troubleshooting HE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
7.4	Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25

VI.HE.H3.02 / LUK40761 | 1

Operating Guide Termix BVX RO

2 | © Danfoss | 2019.04

VI.HE.H3.02 / LUK40761

Operating Guide Termix BVX RO

2.0 Functional description

District heating substation for indirect heating with tank for domestic hot water preparation and with thermostatic or electronic control. Connections at the top of the station.

Application

The Termix BVX RO substation is a complete solution for hot water and space heating with optimal safety, efficient energy transfer, servicefriendly construction and a compact design. The substation is used if a heat exchanger is required or on a conversion to district heating where the existing equipment is unsuitable for direct connection.

District heating (DH)

The substation is prefabricated with a differential pressure controller, fitting piece and sensor pockets for insertion of a heat meter as well as strainers and ball valves.

Heating (HE)

The heating circuit consists of a plate heat exchanger, safety valves, manometer, thermometers, ball valves, drain valve, air valves, expansion vessel and circulation pump. The temperature of the heating can be controlled thermostatically or by an electronic controller with an outdoor temperature sensor. Depending on the application, different heat exchangers dimensioned for central or floor heating will be used.

Domestic hot water (DHW)

The domestic hot water circuit consists of a hot water tank with coil and selfacting thermostatic control valve or electronic controller. The DHW tank and coil are enamelled and the tank contains a magnesium anode.

VI.HE.H3.02 / LUK40761

Operating Guide Termix BVX RO

3.0 Safety notes

3.1 Safety Notes – general

The following instructions refer to the standard design of substation. Special versions of substations are available on request.

This operating manual should be read carefully before installation and start-up of the substation. The manufacturer accepts no liability for damage or faults that result from non-compliance with the operating manual. Please read and follow all the instructions carefully to prevent accidents, injury and damage to property. Assembly, start-up and maintenance work must be performed by qualified and authorized personnel only.

Please comply with the instructions issued by the system manufacturer or system operator.

Corrosion protection

All pipes and components are made of stainless steel and brass. The maximum chloride compounds of the flow medium should not be higher than 150 mg/l.

The risk of equipment corrosion increases considerably if the recommended level of permissible chloride compounds is exceeded.

Energy source

The substation is designed for district heating as the primary source of energy. However, also other energy sources can be used where the operating conditions allow it and always are comparable to district heating.

Application

The substation is designed to be connected to the house installation in a frost-free room, where the temperature does not exceed 50 °C and the humidity does not exceed 60%. Do not cover or wall up the substation or in any other way block the entrance to the station.

Choice of material

Choice of materials always in compliance with local legislation.

Safety valve(s)

We recommend mounting of safety valve(s), however, always in compliance with local regulations.

Connection

The substation must be equipped with features that ensure that the substation can be separated from all energy sources (also power supply).

Emergency

In case of danger or accidents - fire, leaks or other dangerous circumstances - interrupt all energy sources to the station if possible, and seek expert help.

In case of discoloured or bad-smelling domestic hot water, close all shut-off valves on the substation, inform the operating personnel and call for expert help immediately.

REACH

All Danfoss A/S products fulfill the requirements in REACH. One of the obligations in REACH is to inform customers about presence of Candidate list substances if any, we hereby inform you about one substance on the candidate list: The product

contains brass parts which contains lead (CAS no: 7439-92-1) in a concentration above 0.1% w/w.

Storage

Any storage of the substation which may be necessary prior to installation should be in conditions which are dry and heated.

Authorized personnel only

Assembly, start-up and maintenance work must be performed by qualified and authorized personnel only.

Please observe instructions carefully

To avoid injury to persons and damage to the device, it is absolutely necessary to read and observe these instructions carefully.

Warning of high pressure and temperature

Be aware of the installation’s permissible system pressure and temperature.

The maximum temperature of the flow medium in the substation is 120 °C.

The maximum operating pressure of the substation is 10 bar. PN 16 versions are available on enquiry.

The risk of persons being injured and equipment damaged increases considerably if the recommended permissible operating parameters are exceeded.

The substation installation must be equipped with safety valves, however, always in accordance with local regulations.

Warning of hot surface

The substation has got hot surfaces, which can cause skin burns. Please be extremely cautious in close proximity to the substation.

Power failure can result in the motor valves being stuck in open position. The surfaces of the substation can get hot, which can cause skin burns. The ball valves on district heating supply and return should be closed.

Warning of transport damage

Before substation installation, please make sure that the substation has not been damaged during transport.

IMPORTANT - Tightening of connections

Due to vibrations during transport all flange connections, screw joints and electrical clamp and screw connections must be checked and tightened before water is added to the system. After water has been added to the system and the system has been put into operation, re-tighten ALL connections.

4 | © Danfoss | 2019.04

VI.HE.H3.02 / LUK40761

Operating Guide Termix BVX RO

4.0Mounting

4.1Mounting

Installation must be in compliance with local standards and regulations.

District heating (DH) - In the following sections, DH refers to the heat source which supplies the substations. A variety of energy sources, such as oil, gas or solar power, could be used as the primary supply to Danfoss substations. For the sake of simplicity, DH can be taken to mean the primary supply.

Connections:

1.Hot water circulation (HWC)

2.Domestic hot water (DHW)

3.Domestic cold water (DCW)

4.Heating (HE) return

5.Heating (HE) supply

6.District heating (DH) return

7.District heating (DH) supply

Authorized personnel only

Assembly, start-up and maintenance work must be performed by qualified and authorized personnel only.

Connection sizes:

All connections: G ¾” (int. thread)

Dimensions (mm):

With cover:

H 1570 x W 540 x D 640 (type BVX 1–x) H 1870 x W 540 x D 640 (type BVX 2–x)

The connections are at the top of the station.

Weight (approx.): 120-150 kg

VI.HE.H3.02 / LUK40761

Operating Guide Termix BVX RO

4.1.1 Installation

Mounting:

Adequate space

Please allow adequate space around the substation for mounting and maintenance purposes.

Orientation

The station must be mounted so that components, keyholes and labels are placed correctly. If you wish to mount the station differently please contact your supplier.

Drillings

Where substations are to be wall-mounted, drillings are provided in the back mounting plate. Floor mounted units have support.

Labelling

Each connection on the substation is labelled.

Before installation:

Clean and rinse

Prior to installation, all substation pipes and connections should be cleaned and rinsed.

Tightening

Due to vibration during transport, all substation connections must be checked and tightened before installation.

Unused connections

Unused connections and shut-off valves must be sealed with a plug. Should the plugs require removal, this must only be done by an authorized service technician.

Installation:

Strainer

If a strainer is supplied with the station it must be fitted according to schematic diagram. Please note that the strainer may be supplied loose.

Connections

Internal installation and district heating pipes connections must be made using threaded, flanged or welded connections.

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VI.HE.H3.02 / LUK40761

Operating Guide Termix BVX RO

4.2 Start-up

Start-up, Indirect heating

Filling:

1: First fill

When carrying out first fill, the heat exchanger must be slowly filled with water until it reaches working pressure.

2: Pressure gauge

The HE pressure gauge indicates the pressure of the HE system. This instruction must be followed strictly, to avoid dangerous situations.

3: Supply hose

A ball valve with plug is installed in the HE return line. To fill the system, the ball valve must first be closed, the plug removed and a supply hose connected. On re-opening the ball valve, system fill can commence.

Re-tighten connections

After water has been added to the system and the system has been put into operation, re-tighten ALL connections.

Pump

The pump must be switched off during system fill.

4: Pre-pressure
When filling the system with water, the pressure gauge should be
	Height (m)		Pressure (bar)
observed closely. The expansion vessel is supplied pre-pressurised
to 0.5 bar. The pre-pressure required at each substation will	0	– 5	0,5
depend on system head (the distance between the lowest and

	5 – 10		1,0
highest point in the system), for example:

5: Filling stop	10	– 15	1,5

Filling must stop when the pressure gauge shows a pressure	15	– 20	2,0

approximately 1-2 bar higher than the pre-pressure setting. The ball valve is then closed, the hose removed and the plug put back in.

Start-up:

1: Pump speed

Set the pump to highest speed before start-up.

2: Start pump

Start the pump and heat through the system.

3: Open shut-off valves

The shut-off valves should then be opened and the unit observed as it enters service. Visual checking should confirm temperatures, pressures, acceptable thermal expansion and absence of leakage.

If the heat exchanger operates in accordance with design, it can be put to regular use.

4: Vent system

Switch off the pump and vent the installation after the radiators have been warmed up.

5: Adjust pump speed

Set the pump to the lowest speed consistent with comfort and electricity consumption.

Normally the change-over switch is set in the mid position (default). However for systems with under floor heating or single pipe loop systems, it may be necessary to turn the change-over switch upwards.

Higher pump speeds are only used if the heating requirement increases.

VI.HE.H3.02 / LUK40761

Operating Guide Termix BVX RO

Under floor heating:

Pump stop function

If the substation is used in connection with under floor heating, the circulation pump must be connected to the pump stop function in the under floor heating controller. The pump must be stopped if all under floor heating circuits are closed.

Warranty

If this is not possible, then flow must be continued through the by-pass. Failing this, the pump will be at risk of seizure and any remaining warranty will be withdrawn.

Summer operation:

Switch off pump

In summer the circulation pump must be switched off and the shut-off valve to HE supply closed.

Running pump bi-weekly

It is recommended to start up the circulation pump (for 2 minutes) once a month during summer; the shut-off valve of the HE supply must be shut.

Electronic controller

Most electronic controllers will start up the pump automatically (please note manufacturer´s instructions).

VI.HE.H3.02 / LUK40761

Operating Guide Termix BVX RO

4.3 Electrical connections

Before making electrical connections, please note the following:

Safety notes

Please read the relevant parts of the safety notes.

230 V

The substation must be connected to 230 V AC and earth.

Potential bonding

Potential bonding should be carried out according to 60364-4-41:2007 and IEC 60364-5-54:2011.

Bonding point on the mounting plate below right corner marked with earth symbol.

Disconnection

The substation must be electrically connected so that it can be disconnected for repairs.

Outdoor temperature sensor

Outdoor sensors should be mounted so as to avoid exposure to direct sunlight. They should not be placed close to doors, windows or ventilation outlets.

The outdoor sensor must be connected to the station on the terminal block under the electronic control.

Authorized electrician

Electrical connections must be made by an authorized electrician only.

Local standards

Electrical connections must be made in accordance with current regulations and local standards.

VI.HE.H3.02 / LUK40761

+ 19 hidden pages

Danfoss BVX RO Operating guide

Table of Contents

2.0 Functional description

3.0 Safety notes

3.1 Safety Notes – general

4.0Mounting

4.1Mounting

4.2 Start-up

4.3 Electrical connections