Danfoss District Heating Substations Operating guide
Operating Guide
District Heating Substations
suitable for indirect heating / cooling, dhw production
and other water based heating systems
Always keep the instruction manual readily
available near the device.
Read the instruction manual before installation!
In case of wrong installation
Danfoss could change warranty terms!
Caution!
Before putting the device into service,
check if it is undamaged and in perfect operating condition.
© Danfoss | 2020.02
Original operating instructions
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District Heating Substations
Table of contents
1.0 General information ..........................................................................................................................................................................................................................3
1.1 Information on installation and operating instruction manual ....................................................................................................................................3
1.2 Other applicable documents .................................................................................................................................................................................................... 3
1.3 Explanation of symbols ...............................................................................................................................................................................................................3
1.4 Liability and warranty ................................................................................................................................................................................................................... 3
1.5 Copyright ..........................................................................................................................................................................................................................................4
1.6 Spare parts ....................................................................................................................................................................................................................................... 4
1.7 Dismantling ......................................................................................................................................................................................................................................4
1.8 Disposal ............................................................................................................................................................................................................................................4
2.0 Safety ................................................................................................................................................................................................................................................5
2.1 General information .....................................................................................................................................................................................................................5
2.2 Responsibility of the operator ................................................................................................................................................................................................5
2.3 Intended use ...................................................................................................................................................................................................................................5
2.4 Possible misuse ..............................................................................................................................................................................................................................5
2.5 Safety work ......................................................................................................................................................................................................................................5
2.6 Personal protective equipment ...............................................................................................................................................................................................6
2.7 Possible hazards of the device .................................................................................................................................................................................................6
2.8 Emergency stop switch .............................................................................................................................................................................................................. 7
2.9 Operating personnel ...................................................................................................................................................................................................................7
2.10 Actions in the event of danger or accidents .......................................................................................................................................................................7
2.11 Residual hazards / hazard analysis ........................................................................................................................................................................................ 8
3.0 Technical data ......................................................................................................................................................................................................................................9
3.1 Technical and main system data ..............................................................................................................................................................................................9
3.1.1 CE label ...................................................................................................................................................................................................................................9
3.1.2 Dimensions and packaging ............................................................................................................................................................................................ 9
3.2 Symbols used in circuit diagrams ......................................................................................................................................................................................... 10
4.0 Function and configuration ......................................................................................................................................................................................................... 10
4.1 Function ......................................................................................................................................................................................................................................... 10
4.2 DSE FLEX configuration possibilities ................................................................................................................................................................................... 11
5.0 Transport, packaging and storage ............................................................................................................................................................................................. 12
5.1 Transport of pallets by forklift .............................................................................................................................................................................................. 12
5.2 Transport inspection ................................................................................................................................................................................................................. 12
5.3 Packaging ..................................................................................................................................................................................................................................... 13
5.4 Storage ......................................................................................................................................................................................................................................... 13
6.0 Installation .......................................................................................................................................................................................................................................... 13
6.1 Installation preparation ......................................................................................................................................................................................................... 14
6.1.1 Primary connection ........................................................................................................................................................................................................ 14
6.1.2 Secondary connection ................................................................................................................................................................................................... 14
6.1.3 Electrical connection ...................................................................................................................................................................................................... 14
6.2 Draining station ........................................................................................................................................................................................................................ 17
7.0 Commissioning ................................................................................................................................................................................................................................. 18
7.1 Requirements for commissioning ...................................................................................................................................................................................... 18
7.2 Secondary side commissioning .......................................................................................................................................................................................... 18
7.3 Primary-side commissioning ............................................................................................................................................................................................... 18
7.4 Requirements for commissioning ...................................................................................................................................................................................... 19
7.5 Fault and Shutdown ................................................................................................................................................................................................................ 19
7.6 Commissioning after a failure or malfunctioning ........................................................................................................................................................ 19
8.0 Operation .......................................................................................................................................................................................................................................... 19
8.1 Switching on .............................................................................................................................................................................................................................. 19
8.2 Switching off .............................................................................................................................................................................................................................. 19
8.3 Restarting after substation shutdown .............................................................................................................................................................................. 19
8.4 Service / clean - strainer .......................................................................................................................................................................................................... 20
8.5 Service / disassembly and replacement - heat exchanger ......................................................................................................................................... 21
8.6 Service / Check - Safety valve and expansion vessel .................................................................................................................................................... 21
9.0 Maintenance .................................................................................................................................................................................................................................... 22
9.1 Safety warning .......................................................................................................................................................................................................................... 22
9.2 Maintenance plan (recommendations) ............................................................................................................................................................................ 22
9.3 Heat exchanger maintenance ............................................................................................................................................................................................. 23
9.4 Maintenance validation ......................................................................................................................................................................................................... 23
10.0 Troubleshooting ..................................................................................................................................................................................................................... 24
10.1 Safety .......................................................................................................................................................................................................................................... 27
11.0 Spare parts ................................................................................................................................................................................................................................ 27
12.0 Index .................................................................................................................................................................................................................................. 28
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1.0 General information
1.1 Information on installation
and operating instruction manual
This Instruction Manual describes installation, operation and maintenance of the system. Compliance with all specified safety instructions and operating instructions is a prerequisite for safe system
operation and handling. In addition, the local accident prevention
regulations and specific / general safety regulations, applicable to
the area where system is installed must be observed. The operating
instructions are part of the product and must be kept accessible
for installation, operating, maintenance and cleaning personnel at
all times in the immediate vicinity of the system’s operating area.
1.2 Other applicable documents
Unless stated otherwise , the individual components of the system
are modules purchased from other manufacturers. All components
used in the system have been subjected to risk assessments by
their manufacturers. The conformity of the design with the applicable European and national regulations has been declared by the
manufacturers of the components. The manufacturers’ declarations
of conformity, as well as the operating, maintenance and repair
instructions for the individual system components, are inseparable
parts of the system documentation.
1.3 Explanation of symbols
Important safety and device-related instructions in this operating
manual are marked by warning symbols. The instructions must be
followed in order to avoid accidents, personal injury and material
damage.
For presentation purpose of the described situations, the illustrations in this manual are not necessarily to scale and may differ
slightly from the actual design of the system.
In addition to this operating instruction manual, the operating
instructions for the installed components apply. The information
contained therein – in particular safety instructions – must be observed at all times.
The instructions for safety, assembly and installation, operation,
maintenance, disassembly and disposal of the components contained in the manufacturer’s documents must be followed by the
system’s operating personnel unconditionally.
WARNING!
This symbol identifies hazards that may result in adverse health
effects, injuries, permanent bodily injury or death. Ensure compliance with the instruction manual on work safety and take extra
care in these cases.
WARNING!
Electrical hazard. This symbol is alert for safety hazards involving
electricity. Failure to observe the safety instructions may result in
serious injury or death. Work required on electrical parts of the
system can only be carried out by a qualified electrician.
1.4 Liability and warranty
All information and instructions in this operating manual have been
compiled taking into account the applicable regulations, accepted
standards of good engineering practice, and our many years of expertise and experience. In the case of special versions, use of additional
order options or due to the latest technical changes, the actual scope
of delivery may differ from the explanations and drawings in this document. If you have any questions, please contact the manufacturer.
We reserve the right to make technical changes to the product as part
of improving the performance characteristics and product development. Parts such as tools subject to wear in the use of the device
and/or normal wear and tear, as well as auxiliary supplies and consumables such as greases, oils or cleaning agents, are not covered
by the warranty.
CAUTION!
This symbol indicates instructions, the non-observance of which
may result in damage, malfunctions and/or system failure.
NOTE!
This symbol highlights tips and information that must be observed
for effective and trouble-free operation of the system.
Additionally, the obligations agreed in the deliver y contract, the general terms and conditions of business, and the delivery conditions of
the manufacturer and applicable statutory regulations at the time of
the conclusion of the contract apply.
NOTE
These installation and operating instruction manual must be read
carefully before starting work on and with the device, particularly
before commissioning. The manufacturer accepts no liability for
damage or malfunctions resulting from non-compliance with the
installation and operating instructions.
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1.5 Copyright
The installation and operating instruction manual are to be treated
as confidential. They are intended solely for persons working on
and with the system. Transfer of the operating instructions to third
parties without the written consent of the manufacturer is not permitted. If necessary, contact the manufacturer.
Reproduction in any form – even in extracts – as well as utilization
and/or communication of the content are not permitted without the
written approval of the manufacturer. Violations will incur damages.
The right to further claims remains reserved.
1.6 Spare parts
Only use original spare parts of the manufacturer.
If non-approved spare parts are used, all warranty, service, damage
and liability claims against the manufacturer or its agents, dealers
and representatives are forfeited.
1.7 Dismantling
For disposal or scrapping, clean and dismantle the device in accordance with applicable health and safety and environmental regulations.
Before starting the dismantling:
• Switch off the device and secure it against being
switched on again.
• Physically disconnect the all energy and/or power sources from
the device and discharge stored residual energy in accordance
with regulations.
• Remove operating and auxiliary materials and other processing
materials in an environmentally friendly manner.
NOTE!
The content, text, illustrations, images and other representations
are protected by copyright and are subject to additional industrial
property rights. Any improper use may be subject of legal action.
CAUTION!
Incorrect or faulty replacement parts can lead to damage,
malfunctions or total failure of the system.
WARNING!
Risk of injury! Stored residual energy, sharp edges, points and corners
on and in the device or on the required tools can cause injuries. All
work during dismantling of the device may therefore only be carried
out by qualified personnel.
1.8 Disposal
If no return or disposal agreement has been made, dispose of disassembled parts after proper dismantling as follows:
• Scrap metallic materials.
• Recycle plastic materials.
• Dispose of other components, sorted according
to the type of material.
• Dispose of residual media properly. When introducing additives
(e.g. glycol, etc.), the applicable regulations must be observed.
Remove used materials such as greases, oils, preservatives and cleaning agents from the device according to type and in an environmentally responsible manner. Use suitable collec tion and storage containers approved for the respective operating fluids. Label containers
with contents, fill level and date and store them protected against
misuse until final disposal.
WARNING!
Not drinking water!
Domestic water in parts of the system that are not used for a long
time may no longer be suitable for drinking. Prevent such use; drain
the system parts and dispose of the water.
WARNING!
Electronic waste, electronic components, lubricants and other auxiliary materials are subject to special waste treatment and may only
be disposed of by authorized specialist companies!
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2.0 Safety
This section provides an overview of all important safety aspects for
optimum protection of the personnel and for the safe and troublefree operation of the device. In addition, the individual subsections
contain specific safety instructions, marked with symbols, to avert
immediate dangers.
2.1 General information
The device is built in accordance with applicable and accepted rules
of good practice at the time of its development and production and
is considered safe to operate. However, the device may pose a hazard
if it is used by improperly trained personnel or is used improperly or
not as intended. Every person who is tasked with working on or with
the device must therefore have read and understood the operating
instructions before starting work. It is recommended that the operator
demonstrably confirms the personnel’s knowledge of the operating
instructions. Modifications of any kind, as well as attachments or conversions on the device, are prohibited. All safety, warning and operating instructions on the device must always be kept in a legible state.
Damaged signs or stickers must be replaced immediately. Specified
setting values or ranges must be strictly adhered to.
2.2 Responsibility of the operator
NOTE
For modification and extension activities, always consult
the substation manufacturer.
• Operating instructions must always be stored within the
immediate vicinity of the substation and must be accessible
at all times for installation, operation and maintenance and to
cleaning staff.
• Operate the substation only if it is in a proper
technical and safe operating condition.
• Check that safety devices are always kept freely
accessible test them regularly.
Information about industrial safety is based on the European Union
regulations valid at the time of manufacture of the substation. The
operator is obliged throughout the entire lifetime of the substation to conform to those safety actions designated in the current
rules and regulations and to comply with those in new regulations.
Outside of the European Union, the safety laws, local rules and
regulations applicable to the location where the substation operates must be followed.
2.3 Intended use
The operational safety of the device is only assured if it is used as
intended in accordance with the instructions in the operating manual.
The system serves to provide heat energy from the supply grid of
an energy company or other heat generation facility (e.g. boiler) by
transferring heat to a customer’s in-house system. Proper use also
includes correct compliance with the installation, operating, maintenance and cleaning instructions.
2.4 Possible misuse
WARNING. Hazard from improper use!
Any use of the substation apart from its intended use may lead
to dangerous situations.
2.5 Safety work
Hazards to persons and / or the system can be prevented by following the safety at work instructions.
In addition to the safety instructions in this manual, and for substation safety in general, accident prevention and environmental
protection regulations must be observed and followed. The operator and authorised personnel are responsible for the trouble-free
operation of the substation, as well as for the clear definition of responsibilities for installation, operation, maintenance and cleaning
of the substation. There must be no deviation from the information
in the operating instructions!
The operator shall also ensure that:
• Any further risks are identified in an assessment of risks arising
from the special working conditions at the operations site.
• That any additional work and safety instructions resulting from
the risk assessment of activities performed on the substation
are described in a standard operating procedure (SOP).
Always follow local regulations as well as any existing ordinances
on industrial safety and health (e.g. in Germany: BetrSichV, BGBL
I 2002, 3777).
Any other and/or different use of the device is prohibited and is
considered improper. Claims of any kind against the manufacturer
and/or its authorized representatives due to damage resulting from
improper use of the device are excluded. The operator and/or the
owner is solely liable for all damage resulting from improper use.
Therefore:
• Use the district heating transfer station only for its intended
purpose and in accordance with the information provided
in this document, particularly the limitations given in the
technical data.
• Avoid any further or other use of the district heating transfer
station.
• It is forbidden to change, upgrade or modify the design or
individual components for the purpose of changing the
station’s range of usability or application.
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2.6 Personal protective equipment
When working on and with the device personal protective equipment must be used in accordance to EU, national and local regulations , we strongly advice that you must always wear:
Protective clothing
Consisting of closely fitting workwear with low tear resistance,
with closely fitting sleeves and no protruding parts. It is mainly
used to protect against being caught by moving machine parts.
Do not wear rings, necklaces or other jewelry.
Protective gloves
To protect hands from friction, abrasions, punctures or deeper
injuries, as well as from contact with hot surfaces.
2.7 Possible hazards of the device
Safety goggles
To protect the eyes from flying objects and liquid splashes.
Safety footware
To protect against heavy falling parts and slipping on slippery
surfaces.
Protective helmet
For protection against falling objects and flying parts and materials.
The substation has been subjected to a risk analysis based on the
design and construction of the substation and in correspondence
with the current state of technology. Nevertheless, risks remain! The
substation can generate a hot stream of fluid or steam when e.g.
a drain or air vent is opened.
WARNING! Risk of injury!
Danger from spraying liquids under high pressure. Always wear
personal protective equipment when working on the device.
The substation operates with high electrical voltages of up to 400 V
and currents of up to 25 A.
WARNING! Electrical hazard!
The electrical energy can cause serious injuries. In the event of damage to the insulation or individual components, there is a danger
to life.
• Before carrying out any maintenance, cleaning or repair work,
switch off the main switch and secure it against being switched
on again.
• Disconnect the device from the power supply for all work on
the electrical system.
• Do not remove any safety devices or disable them by
modifications.
The substation is supported by pneumatic components.
Therefore:
• Depressurise before starting any work on the substation.
• Do not remove or alter any safety devices or put out of service.
• Do not change the default settings from the values or beyond
the tolerance ranges specified in the operating manual
The substation has sharp edges and corners.
WARNING! Risk of injury!
Sharp-edged housing parts and sharp corners can cause skin
abrasions. Wear protective gloves when working on the device.
WARNING! Risk of burning!
Hot surfaces can cause severe burn injuries. When working on
the device, always wear protective gloves. The device operates at
a maximum temperature as indicated on the label.
Components inside of the station can contain automatically moving
parts (pumps, actuators, etc.). The devices can be very heavy.
WARNING! Risk of crushing!
Heavy objects can cause crushing during transport, even with
lifting equipment. The device may contain electrically powered
moving components (motors, gearboxes) that can cause crushing
when touched during operation. When working on the device,
always switch off the power and wear protective clothing.
WARNING! Risk of injury!
Risk from liquids splashing under high pressure. Wear personal protective equipment for all operations carried out on the substation!
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2.8 Emergency stop switch
An emergency stop switch is not integrated in the device. The operator must ensure that emergency stop switches are installed in
accordance with the applicable accident prevention regulations, if
required by law.
2.9 Operating personnel
The device may only be operated and maintained by authorized,
trained and instructed personnel. This personnel must have received
specific instruction on the hazards that may occur.
An instructed person is someone who has been instructed and, if
necessary, trained on the tasks entrusted to them and the possible
hazards arising from improper conduct, and has been instructed on
the necessary protective devices and protective measures.
Qualified personnel are those who, on the basis of their professional
training, knowledge and experience, as well as knowledge of the
relevant provisions, are able to assess the work assigned to them
and recognize possible hazards.
If the personnel do not have the necessary knowledge, they must be
trained. The responsibilities for operation and maintenance must be
clearly defined and adhered to, so that there is no unclear allocation
of responsibilities with regard to safety.
2.10 Actions in the event of danger or accidents
In case of danger or accidents, the device should be switched off
immediately by activating an emergency stop switch. This can also
be done by opening a safety door or protective screen provided
with safety switches, which triggers the emergency stop function
when opened.
Safety devices with emergency stop function are only to be operated
in emergency situations.
The device should only be operated and maintained by persons who
can be expected to perform their work in correct and responsible
manner. Any operation which affects the safety of persons, the environment or the device is to be avoided. Persons who are under the
influence of drugs, alcohol or medication that affects their ability to
respond should not perform any work on or with the device.
When selecting personnel, minimum age requirements in the country’s youth employment legislation must be observed and, where relevant, applicable professional regulations. The operator must ensure
that no unauthorized persons work on or with the device. Unauthorized persons, such as visitors, etc., must not come into contact with
the device. They must maintain a reasonable safety distance.
The person using the device must immediately notify the operator
of any changes to the device that affect safety.
Safety devices must not be used for normal shutdown of the device.
Always be prepared for accidents or fires. Keep first aid equipment
(first aid kit, eyewash bottle, etc.) and fire extinguishers within easy
reach, EU and local regulations apply.
Personnel must be familiar with the handling and location of safety,
accident reporting means, first aid and rescue equipment. This ensures protection against hazards and the best possible assistance in
the event of accidents.
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2.11 Residual hazards / hazard analysis
Risk place Risk type Protective aim Measure
Shut-off valves and fittings
in the station
Piping and components
in the station
Entire station Electric shock Safe contact with the station Fulfilment of contact protection
Entire station
Entire station
During operation, residual risk can be limited to the following alphabetic values according to the Suva (Assessment and Reduction
of risks from machines) risk assessment: B5/C4/D3/E2. The residual
potential for danger arises from failure to comply with the above
instructions. The assembly has been manufactured according to the
explicit specifications of the customer, who is responsible for compliance with the parameters specified and the selection of qualified
operating personnel.
The substation is equipped with the following warning on which the
key residual risks are point out again:
Crushing during
manual operation
Burning when touched Safe contact at the station
Splashing of liquids and/or
steam at high pressure
Overheating the station
or transmitting heat to
a connected system at
a temperature above
what is permissible
Manual operation of the
shut-off valves and fittings
must be safe
Controlled reduction of excess
pressure in case of fault
Turning off the heat supply
in case of failure
Due to construction, provide
enough space for ergonomic
operation
Thermal insulation of pipes
and components, signs at the
station, warnings in the
operating instructions
Protection according to local
standards or legal regulations
(e.g. DIN 4747 T1
or DIN EN 12828)
Protection according to local
standards or legal regulations
(e.g. DIN 4747 T1
or DIN EN 12828)
Operation of this substation is permitted only by trained personnel after detailed study
of the enclosed documentation. The system must be filled and completely vented
before commissioning. Do not exceed the maximum allowable working pressure or
maximum allowable operating temperature specified on the label. Any use other than
the proper use is prohibited.
Risk of burns from touching or from the release of hot media (water/steam).
Avoid touching the substation or wear suitable protective clothing!
Risk of crushing during assembly and operation.
Risk of electric shock. Check that the substation is disconnected before
working with the electrical system.
All flange and threaded connections, fittings, electrical clamps and screw connections
must be checked and tightened as necessary before filling or commissioning.
Run pumps only when filled with water (no dry run!)
Before starting up the substation properly install the following (unless fully
assembled in factory):
- Safety valve, drain and air vent according to EN12828 or EN806, unless local
standards are available.
- Strainer in the primary flow and secondary return pipeline
- Equipotential bonding according to IEC60364-4-41:2005 (grounding / protective
conductor / potential equalisation), unless local standards are available
(e.g. DIN VDE 0100:540:2012-06)
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3.0 Technical data
3.1 Technical and main system data
The main system data can be found on the label as well as
the documents contained in the systems (title page, wiring
diagram, data sheet).
3.1.1 CE label
The CE label is attached to the substation.
It contains the following information:
• Manufacturer
• Serial no.
• Production date (year / calendar week)
• Substation code / Type (Name)
• Applications
• Category according to PED directive
• Power supply voltage
• PN class
• Minimum and maximum operating temperatures
• Maximum allowed pressure by maximum operating temperature
• Capacity
• Temperature programme
• Heat exchanger type
• Volumetric flow
• Pressure drop inside heat exchanger
DSE MAXI
3.1.2 Dimensions and packaging
The range of tailored product dimensions and weights can be found
in the manual.
The DSE is manufactured upon customer request; its dimensions
and weight may vary depending on accessories selected. Details
of dimensions and weight are available before delivery to ensure
trouble-free transport and installation of the substation.
B
A2
Figure 1: Danfoss Substations external dimensions
C
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