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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3.2 Symbols used in circuit diagrams
Pressure transmitter
4.0 Function and configuration
4.1 Function
The substation is an indirect compact substation, where heat transfer
from the district heating or cooling network to a secondary installation is realised via heat exchangers. This solution ensures hydraulic
system separation.
The basic idea of heat transfer in a compact substation is connecting the primary side of the piping to the district heating company’s
network, which supplies hot water within the appropriate parameters
(such as for pressure and temperature), and the secondary piping to
the customer’s installation on the other side. Network parameters
may vary depending on the season and may be higher during the
winter season and lower during the warmer months. Primary medium flow normally through shut-off valve and strainer In addition
for pressure and temperature measurements, usually pressure gauge
and thermometer are assembled, if it is needed according to the
specification of District Heating Utility on primary flow and/or return
pipe. Cooled heating water flows back through the primary return
pipline to the district heating network.
In a District Cooling system the chilled water is (lower temperature
for example 7 deg. C) is entering the heat exchanger through the
primary flow pipe and warmed water (for example 12 deg. C) it flows
back through the primary return pipe to the District Cooling network.
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In the secondary circuit circulation pump transfers heated water to
the heating surfaces of other installations (e.g. ventilation equipment, drinking water or heating installations, etc.). If a controller
with weather compensation is installed at the substation, it has the
following essential functions:
• Measures flow temperature on the secondary side and
outdoor temperature
• Changes the stroke of the control valve on the primary side so
that it conforms to the required secondary temperature
• Limits the return temperature on the primary side to a value
preset in the controller
• Switches the secondary side circulating pump(s) on and off as
necessary and ensures frost protection
If required, special functions are available according to needs and designs. Refer to the instruction manual of the controller manufacturer.
All systems are offered upon request and manufactured in keeping
with the customer’s special operating conditions.
Due to the many different product variations, the circuit diagram
may differ from that presented below.
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4.2 Danfoss Substation configuration possibilities
The substation can be used for various applications such as cooling / heating, domestic hot water and / or other water based heating system. Due to its flexibility, we have inserted in this document
only an example diagram, for the actual aplication please refer to
the manual. This is based on customer requests and the needed
application(s). The construction allows easy access to all components
for maintenance and servicing purposes. Heat transfer between the
district heating network and the building installation is achieved by
way of a heat exchanger, which ensures better heat transfer, higher
energy efficiency and reduced pressure loss.
Szafka sterownicza
Electrical box
TE
750
85
151 812 2670
E
E80S
PI PI
151A812
2B
753
95
151
812
PIPI
812
A
PI
QQ
812
151
15185 81
E
S
E
QQ
80
DHW
34
HE
34
In addition to the standard controller functions, the ECL310 offers
easy remote access via an internet page with data logging possibilities and energy optimization functions such as weather compensation and auto-tuning (adaptive settings for domestic hot water
parameters). Refer to the manual for the actual controller and apllication key.
By use of the Danfoss dimensioning program you can find out if the
application you need fits the Danfoss substation.
419
443151
171
813 150
395 182
171
151423153151 160 161
167181 812
812814
PI
PI PI
153
812 812 151
445
153
420
474 153470 419419419430 468 430
PI
419
423 419
PI
174
PI
PI
815 812
465395
411
PIPIPI
PI
PS
26 Control valve HE
34 Drain valve
35 Thermometer
70 Mud trap
75 Ball valve
80 Heat meter + sensors
81 DP controller + pressure point
84 Drain valve
85 Thermometer
95 Control valve DHW
150, 151 Ball valve
153 Strainer
160 Diaphragm
Figure 3: DSE FLEX configuration
75 819821
E
S
E
QQ
80
161 Water meter
164 Balancing valve
167 Pump
171 Drain valve
174 Thermometer
175 Temperature sensor
181 Temperature sensor
182 Thermometer
340, 341 Ball valve
343 Strainer
357 Pump
361 Drain valve
364 Thermometer
395 377
361
7542315375 160 161
365 Thermometer
376 Temperature sensor
377 Thermometer
395 Safety thermostat
398 Balancing valve
411 Ball valve
419 Pressure measurement
420 Safety valve
423 Check valve
430 Ball valve
443 Temperature sensor
445 Thermometer
465 Ball valve
820 340
357376 819
PI
PI PI
343
819 819 34175 8480
PI
377
468 Check valve
470 Pump
472 Balancing valve
474 Thermometer
488 Temperature sensor
750 Electronic controller
753 Outdoor sensor
811, 818 Pressure transmitter
812, 819 Manometer
813, 814 Safety valve
815, 822 Expansion valve
820, 821 Safety valve
822 819
PI
PS
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5.0 Transport, packaging and storage
Follow general safety rules during transport:
• Adapt transportation to local conditions
• Use only approved lifting gear and lifting equipment
with adequate load capacity
• Only attach the substation to suitable anchor points and
not to protruding machine parts or any component’s
eylet or hole.
Ensure the secure fit of the slings!
• Ropes and belts must be equipped with a safety hook. Do not
use damaged or frayed cables. Do not fasten ropes or straps
to sharp edges or corners and do not knot or twist. Always
consider the centre of gravity before handling
• Never lift, pan or lower loads over people
• Always transport the substation with the utmost care and caution
• During vessel transport especially bear in mind that: insulation
must not be damaged during transport or removed (especially
when transporting over longer distances)
• Ensure suitable means of transport so that no deformation
arises on connections or vessel
• Avoid direct contact with ferrous materials
or surface destruction of stainless steel vessels
5.1 Transport of pallets by forklift
WARNING! Danger to life!
When lifting, panning and lowering ,there is a risk of serious personal
injury and damage from falling parts. Never stand under suspended
loads!
Packages mounted on pallets can be transported by forklift under
the following conditions:
• The forklift must be designated according
to the weight of the handling units
• Operator must be authorised (licensed) to operate the forklift
Procedure:
1. Drive the forklift with the forks between
or under the tie bars of the pallet
2. Drive the forks far enough to protrude from
the opposite side of the pallet
3. Make sure that the centre of gravity
is between the forks and cannot tilt
4. Lift the package and start transport
Follow safety rules:
• Use only approved lifting gear and lifting equipment
with adequate load capacity
• Only attach the substation to suitable anchor points
and not to protruding machine parts or eyelet components.
Ensure the secure fit of the slings!
• Ropes and belts must be equipped with a safety hook. Do not
use damaged or frayed cables. Do not fasten ropes or straps
to sharp edges and corners and do not knot or twist. Always
consider the centre of gravity before handling
• Never lift, pan or lower loads over people
• Always transport the substation with the utmost care and
caution
WARNING! Danger to life!
When lifting, panning or lowering, there is a risk of serious personal
injury and damage from falling parts. Never stand under suspended
loads!
5.2 Transport inspection
Immediately after delivery check for completeness and any transportation damage. In case of externally visible transport damage, do
not accept delivery or accept only conditionally. Note the extent of
damage on the transport documents / bill of delivery. Initiate a complaint. Claim defects that are not visible immediately after detecting, as claims for damages can be made only within the applicable
complaint periods.
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5.3 Packaging
Substations are delivered with different types of packaging. Packaging materials are primarily of wood, cardboard and plastics (foil,
foams). Strapping is in addition. Packaging material may also include
materials added to packages for moisture or frost protection (e.g.
silica gel bags, antifreeze, etc.). If no agreement has been made regarding the return of packaging material, the packaging material
remains with the customer.
Our transport packaging can be returned to Danfoss, at the manufacturing site. Please refer to the label.
5.4 Storage
After packages have been unloaded they must be stored until assembly in accordance with the attached shipping marks. Machine parts
and accessories packaged in separate boxes must not be unpacked.
For storage, the following rules apply:
• Dry storage. Relative humidity: up to 60%
• Ensure that packages are not stored outdoors. In addition,
ensure that the storage room floor is dry during storage
• Keep out of direct sunlight. Optimal storage
temperature 15 to 25 C°
• Keep dust-free
• Avoid mechanical vibrations and damage
• For long-term storage of more than three months,
conservation activities should be taken In severe weather
conditions, conservation must be renewed as necessary
WARNING!
Unpaid delivered transport packaging will not be accepted
by Danfoss.
Packaging materials must be utilised in an environmentally friendly
way and in accordance with the relevant waste disposal regulations.
6.0 Installation
WARNING! Risk of injury!
Improper installation and assembly can result in serious injury
and / or property damage. Installation and assembly work may be
performed only by qualified personnel in compliance with safety
regulations.
District heating transfer stations are usually completely pre-piped and
wired installations on a painted steel frame. All parts and components
are mounted or fixed to the frame. External substation connections
are marked with easily understandable labels / stickers. Integrated
adjustable feet are used to compensate for uneven ground.
Secure durability of ground based on total weight of equipment
(including water content). Take care that each connection is stressfree after assembly; the substation cannot be used as a fixed point.
NOTE!
The use of pipe wrenches for nuts and bolts is not permitted. Only
use a suitable spanner!
If substation parts or components must be removed due to
limited space for transport (corridors, elevators, small doors etc.),
ensure that they are reassembled exactly as they were in the
original place.
NOTE!
The mechanical separation of substation components through
sawing, cutting, etc. of cabling and / or frame parts and piping is
not permitted.
Pipe connections and fitting connections can be prepared as:
• Welding ends
• Flanged connections acc. EN 1092
• Threaded connections acc. DIN 2999 (internal / external)
• Threaded connections acc. DIN 2993/ISO 228 (external)
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6.1 Installation preparation
Substation installation should be carried out on a clean, flat surface.
Stand-alone substations usually come with integrated adjustable
feet, which can compensate for uneven ground. If not pre-assembled,
these are supplied as loose components in an accessory pack and
can be screwed into the appropriate nuts in the bottom area of the
frame. Then adjust the station horizontally.
6.1.1 Primary connection
The primary connection must be made by qualified personnel in
consultation with local / district heating supply companies if the
installation is connected to such network. The primary supply and
return must be connected to the designated devices or the substation shut-off valves.
The commissioning of primary side connections to the district heating network is usually done by the relevant local / district heating
company.
• If substation is delivered (ordered) without a strainer on
primary inlet site, make sure it is separately mounted
before substation is connected to the network to protect all
components from potential damage. If this requirement is not
respected it may result in loss of warranty.
• After installation of substation to the network it is required to
splash pipes between main strainer and substation to remove
any potential particles.
ATTENTION
In case not delivered with the station, it is mandatory to secure the
station against the risk of going outside the specified maximum
allowed temperature and pressure according to statutory and
regulatory requirements with pressure and/or with temperature
safety devices.
6.1.2 Secondary connection
A specialised installation company connects the secondary installation to the substation’s designated shut-off valve.
After installation of substation to the network it is required to splash
pipes between main strainer and substation to remove any potential
particles.
6.1.3 Electrical connection
Only a qualified electrician approved by a responsible electric utilities
company may carry out the electrical installation of the substation
in compliance with all applicable rules and regulations. The substation is completely wired and tested at the factory by default for the
delivered components. If the station is ordered without controller or
other electrical components the wiring and test are not performed. If
an outdoor sensor for substation control is ordered, this is enclosed
in the loose component box and should be installed as far as this is
possible on the north side of the building.
The electrical diagrams for electrification are included in technical
documentation. Internal electrifications are made in the factory.
The electric cables cannot be fastened with the hot pipes. They need
their own supporting structures.
The device should be properly installed and grounded by a qualified
technician. The appliance should be serviced only by qualified service
personnel. Repair interventions by unauthorized persons may cause
death, injury or serious malfunction.
WARNING! Risk of injury!
Improper installation and assembly can result in serious injury
and / or property damage. Installation and assembly work may be
performed only by qualified personnel in compliance with safety
regulations.
Before connecting, check that the rated voltage are indicated on
the nameplate corresponds to the voltage of power available. You
should also check the rated power of the device and make sure that
the wires have a cross section corresponding to the power of connected device. You must tighten the clamping screws.
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6.2 Draining station
Locate the drain valves on the specific circuit which you would like
to empty.
ATTENTION!
To drain the primary side, always close the shut-off valve on the
district heating connection.
NOTE!
To drain only the substation and not the whole installation, close
the shut-off valves on the substation.
If the drain pipe is not connected to the drain valve, connect the appropriate hose or piping in accordance with local legal regulations.
WARNING! Risk of injury or damage!
Never operate the drain valve when the outlet is directed towards
you or electrical devices. Always secure all equipment so that it is
not flooded by accident. Before any operation always ensure that
the water has cooled sufficiently.
Open the drain valve and wait until the circuit concerned has emptied.
Immediately after draining, close the valve.
WARNING! Risk of injury!
Even after draining, there may still be water inside the heat exchanger and piping.
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7.0 Commissioning
Commissioning must always be carried out before the following actions:
• Initial start-up of the substation
• Restarting after complex substation maintenance
• Restarting after the implementation of a new device
• Restart following a malfunction of the substation
• Restarting after shutdown or longer downtime
Installation and initial commissioning of the substation is carried out
by approved employees of the manufacturer or authorised partner
companies. Typically the local utility company must be involved in
work relating to heating connections. Typically the district heating
utility must be involved in work relating to primary connections.
Unauthorised initial start-up is not allowed.
In order to commission the station the following conditions must
be met:
• Station is reassembled on site (if is the case)
• Commissioning must be approved by the district heating
utilities
• All screws and fasteners must be tightened
• Substation piping must be connected properly. It is prohibited
in connection to Domestic hot water system to use black steal –
risk corrosion heat exchanger
• Expansion tank is connected to the substation
• All impurities and leftover installation materials must be
removed from the piping
• The station must be properly connected to electricity: the
supply voltage must be applied to the main switch or circuit
breaker according to the electrical diagram
• Other electrical / mechanical on site works are done according
to electrical diagram
• The primary connection must be applied to the primary shut-off
valves within the necessary parameters
• The secondary installation should be filled (including the
substation) and vented (venting the pumps is necessary)
• Pressurisation must be ready with the required static pressure
• Venting / Drain valves are closed
• Desired time programmes and additional data for controller setup must be available
• The substation may only be put into operation when an
authorised specialist from the district heating company or an
expert from an installation company or an authorised specialist
from the commercial office has approved the correct condition
of the whole system.
• Make sure that the system is filled with water
• Make sure that a correct setup of temperature is made for
Domestic hot water. To ensure maximum heat exchanger
performance and life time Danfoss recommends maximum 60
deg. C.
Before commissioning, check that all safety-related rules and
regula tions have been taken into account.
• Working parameters for the substation’s plate type must match
the operating parameters of the local / district heating company
and the heating system.
• Begin with secondary side
• Open (slowly) the isolating valves on secondary circuits
• Fill the secondary installation with water accord ing to the water
quality rules. To avoid substation damage, ensure that pressure
during filling does not exceed the maximum allowable working
pressure.
• Vent all the secondary installation (heating and DHW)
• Before first use, the secondary side must be rinsed sufficiently
by the installation company. Fill the secondary installation to
the required static pressure.
• Check all connections for leaks and tightness, and retighten
with the required torque if necessary.
• Vent the pumps
• Move to primary side. All work on the primary side of the system
must be carried out in coordination with the local / district
heating company by suitably qualified and trained personnel.
• If the medium is water, set the flow / differential pressure
controller or pressure controller (if available) to the maximum
flow rate ac cording to capacity or preset differential pressure.
Than set up the pressure controller, if there is one, to the
designated value.
• Fill the substation by slowly opening the shut-off valve on the
primary supply. Also slowly open the shut-off valve on the
primary return. Manually adjust the electronic controller to the
“valve open” position.
• Vent (if is possible) the primary circuit
• Check all connections for leaks and tightness, and retighten
with the required torque if necessary.
• Rinse the primary site with the district heating medium and
reclose the shut-off valves. Clean the strainers.
• Switch on the main switch of the control panel (check automatic
fuses in control panel and pumps switches)
• If available start each pump manually and check the direction
of rotation
• Adjust the electronic con troller in accordance with the
designated values in the enclosed supplier instructions.
• Check the actuators
• Switch all pumps in auto mode
• The electronic controller is preset in the factory in accordance
with the data available to us. After commissioning, the
controller auto matically performs a self-test, displays a default
system code and automatically goes into operating mode.
Now a precise setting must be made in accordance with the
controller manufacturer’s manual. The manual is attached to the
station.
• Danfoss recommends the activation of all the needed
optimization and protective functions like motor pr. (motor
protection)
• Refer to technical documentation for detailed instruction for all
components (e.g. pumps, controllers, actuators).
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7.4 Requirements after commissioning
The folowing points must be checked after comisioning:
• Check temperatures
• Check pressures
• Check flows
• Thermal expansion
• Leakages
• Operation of pumps
• Control valves / actuators operation
• Flow directions
• Operation of controllers
• Noises
7.5 Fault and Shutdown
The heating controller, control valve actuator and heating pump are
connected to electric power supply.
Therefore:
- Immediately turn off the main switch or unplug the power cable
- Close the second shut-off valves on the primary
and secondary side
- A specialist company must be consulted for troubleshooting
WARNING! Electric shock hazard!
Leaking water can subject the entire substation to dangerous voltage. Before starting any work, switch the power OFF and ensure
that it cannot be turned back on.
7.6 Commissioning after a failure or malfunctiong
After a failure on the primary side, always contact the local or district
heating company. Recommissioning is to be carried out by a special
ist company.
After a failure on the secondary side contact a specialist company.
Recommissioning is to be carried out by the specialist company.
8.0 Operation
The substation works in fully automatic mode. During operation, no
personnel are required either in the area of the substation or within
its immediate vicinity.
8.1 Switching on
To turn the substation on, follow the requirements in the “Commissioning” chapter 7. The substation can be turned on at the main switch
of the electronic controller and will start to operate automatically.
8.2 Switching off
WARNING! Risk of burns!
In case of leakage on the primary side, the medium may escape
as steam at a temperature of more than 100°C. Danger of burns.
-
The substation can be turned off at the main switch of the electronic
controller and will stop automatically.
8.3 Restarting after substation shutdown
If the substation is to be turned off for a long period of time (i.e.
without power) in order to save energy, then proceed with restart as
for the first commissioning. Flushing of the system is recommended.
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8.4 Service / clean – strainer
Before you begin cleaning, perform the actions described at point
2 (draining the system) and check that no components will collide
when removing the mesh.
Use a suitable flat spanner to unscrew (counterclockwise) the cap
from the strainer, remove the mesh and clean it. Before closing the
strainer check the seal (for tightness and integrity). If necessary, replace it. Do not let the water splash on electrical components.
WARNING! Risk of injury!
Even after draining, there may still be water inside the strainer.
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8.5 Service / disassembly and replacement – heat exchanger
only brazed type
Before you begin any activities with the heat exchanger perform the
actions described at point 2 (draining the system).
Use a suitable flat spanner to unscrew the piping from the heat exchanger and Seeger Pliers to remove the heat exchanger from the
support frame.
WARNING! Risk of injury!
Even after draining, there may still be water inside the heat exchanger and piping.
8.6 Service / Check – Safety valve and expansion vessel
Locate the safety valves on the secondary side (these are separate
on the heating and domestic hot water circuit). If the drain pipe is
not connected to the safety valve, connect the appropriate hose or
piping in accordance with local legal regulations.
WARNING! Risk of injury or damage!
Never operate a safety valve when the outlet is directed towards
you or towards electrical devices. Always secure all equipment so
that it will not be flooded by accident.
Turn the lifting handle in the direction of the arrow until you hear
a click. Then the valve must be closed tight.
NOTE!
If a valve drips constantly, it is very likely that impurities have built up
in the seat. To clean the valve seat and seal, unscrew the head part.
Locate the connection for the expansion vessel.
Follow the expansion vessel servicing procedure for the relevant
vessel type.
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9.0 Maintnance
9.1 Safety warning
In the appendix you will find a summary of the most important technical requirements. It is recommended to hire an authorised installer
for frequent maintenance.
It is necessary to check and maintain the substation on regular basis
in order to keep it in good operating condition. The frequency of
maintenance and service inspections should be done according to
system manufacturer’s recommendations and local legislation.
The most important actions for main components and assemblies are
summarised under section 9.2. Other instructions for components
not specified in this installation manual can be found separately in
the accessory box and must be observed.
WARNING! Risk of injury!
In principle work may be carried out only by qualified and specially
trained personnel. Avoid loosen tight clothing (no loose sleeves,
rings, etc.). Always wear the following personal protective equipment in the vicinity of the substation:
- Safety glasses to protect the eyes from flying parts and fluids
- Safety footwear for protection against heavy falling objects and
slipping on slippery surfaces
WARNING! Electrical shock hazard!
Work on electrical equipment may only be carried out by a qualified
electrician in accordance with the safety regulations.
Switch OFF the electrical supply before starting work and secure
against reconnection.
9.2 Maintenance Plan (recommendations for maximum
performance and life time)
Failure to follow a maintenance plan can result in mechanical or
equipment failure that poses a danger to persons and goods and
the entire workplace. Failure to document a maintenance plan will
invalidate any warranty.
Interval Maintenance Comments
Check all connections If necessary re-tighten and / or replace seals
Every 2 months
Every 6 months
Every 12 months
Check all parameters to nominal / actual values or
admissibility
General visual inspection of all components
Perform a functional test of the safety valve
Perform a functional test of the electrical and electronic components, switches and so on
Perform an electrical test of the safety devices Temperature monitor, sensors and / or limiters
Clean strainers If necessary, refer to point 8.4
Perform a functional and usability check of all
components
Perform a visual inspection of substation’s appearance
Control of the heat exchanger
Perform a visual inspection of the heat meter and
water meter
Perform a visual inspection of the measuring
devices
Perform a visual inspection of the expansion vessels
The correct function of the pressure relief valve
should be checked by qualified personnel at initial
operation and then once a year
If excessive, restore proper parameters
In case of visible damage, perform a functional test
and if necessary replace the component
Open the safety valve for a short period of time.
Refer to point 8.6
Manually switch the pump or open and close the
actuator
For example, open and close the shut-off valves
Colour (rust), insulation
In case of contamination, clean / descale (refer to
point 9.3) as needed
Check legalisation period
Manometer, thermometer
Shape of vessels, tamper head, tightness of the
membrane
Turn the lifting handle in the direction of the arrow
until you hear a click
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9.3 Heat exchanger maintenance
The following is a list of important activities that should be performed
during maintenance. Additional information is included in the attached manufacturer’s instructions.
This abstract only provides information about the required steps. It
is important in any case to comply with all relevant legal and technical regulations and requirements pertaining to local conditions
and regulations (e.g. the home owner, district heating utilities, etc.)
Fittings:
In general, the fittings used are maintenance free. During maintenance, the functionality of hand wheels or levers should be tested
in terms of ease of use by opening and closing. This will protect the
ball, plates and valve seats against dirt and limescale deposits. See
the manufacturer’s instructions for the most common components
in Annex I.
Heat exchanger:
Heat exchangers are designed for long-term use. Due to relatively
high temperatures, in particular cases lime and other deposits may
appear on the inner surface.
In case of reduced performance, the heat exchanger should be
cleaned. For detailed information, please refer to the heat exchanger
instructions.
Water quality:
To ensure maximum heat exchanger performance and lifetime, follow the Danfoss “Guideline to Water Quality for Copper Brazed Plate
Heat Exchanger” – VJ.KV.D3.02 or a newer version.
9.4 Maintenance validation
Following maintenance work but before turning on the substation,
please note the following:
• Check the tightness of all previously loosened
threaded connections
• Verify that all previously removed components
have been reinstalled correctly
• Ensure that all tools, materials and other equipment used
during maintenance have been removed from the work area
• Clean up the work area, remove any spilled substances
and remove any waste from material processing
• Make sure that the system and all unit safety devices
are working properly again
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10.0 Troubleshooting
Electrical equipment which has failed and mechanical, pneumatic and
hydraulic components must be serviced only by qualified personnel
with the relevant specialties.
Information about all failures which cannot be eliminated through the
following actions is to be forwarded to the substation manufacturer
or to service partners authorised by Danfoss.
Malfunction Possible Solution Comment
Secondary water temperature is too low
Secondary water temperature is too high
Check if main switch is turn on
Lack of supply voltage
Lack of heat supply
- No primary system pressure
- Primary differential pressure is
too low
- Heating water flow is too flow
Incorrect controller setting(s) Check and correct settings Read controller’s user’s manual
Defective controller Replace controller Contact customer service
Closed shut-off valve(s) Open shut-off valves
Defective sensor Replace the sensor
Circulation pump(s) defective or
not switched ON
Heating pump(s) defective or not
switched ON
Balancing valve not set correctly
Circulation pump is not running
at the intended speed
Defective control valve Clean or replace valve
Defective actuator or thermostat
Substation is sized incorrectly usually primary control valve is
too big or too small
Reduced flow through heat
exchanger
Outdoor sensor is placed incorrectly
Missing supply voltage -> actuator is in open position
Incorrect controller setting(s) Check and correct setting(s) Read controller’s user manual
Defective sensor Replace the sensor
Defective control valve Clean or replace valve
Defective actuator or thermostat Replace actuator / thermostat
Circulation pump is not running
at the intended speed
Check cabling
Check fuses
Check and secure operating
conditions:
- Pressure
- Flow
- Differential pressure
Switch ON / replace circulation
pump(s)
Switch ON / replace heating
pump(s)
Adjust balancing valve to correct
value
Increase or decrease pump speed
/ replace pump
Replace defective actuator or
thermostat
Check dimensioning
Extend / enlarge substation
(calculate dimensions for new
control valve and replace old one)
Clean / replace heat exchanger
Place outdoor sensor correctly
Take the system out of operation
and close valve manually. After
providing power supply, go back
into standard mode
Increase or decrease pump speed
/ replace pump
Contact authorised personnel
or electric energy supplier
Contact district heating utility
Adjust flow limiter settings
Check values and if necessary
replace sensor
Set designated flow
Set designated flow
Contact our sales staff
responsible
Read heat exchanger user’s
manual
Read electronic controller user’s
manual.
Check values and if necessary
replace sensor
Actuator still open or thermostat
/ defective capillary
Set designated flow
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Malfunction Possible Solution Comment
Correct settings e.g.:
- Xp (proportional band)
Secondary water temperature oscillating or not
constant
Leakage*
Risk of scalding!
Unacceptable pressure
increase, constant blow
up of safety valve
Pressure surges,
water hammer
Incorrect controller setting(s)
Fluctuating heating water supply
- Fluctuating primary differential
pressure
- Fluctuating primary flow
Primary control valve is too large
Connection leakages ( flange /
fittings, couplings)
Leakage of welds Turn off substation Contact customer service
Leaks from fittings (housing /
couplings)
- Leakage of gasket heat exchangers
- Pollution / calcification
- Pressure hammers
- Leakage of brazed or welded
heat exchangers
- Pollution / calcification
- Pressure hammers
Internal leakage of the heat
exchanger
Incorrect adjustment and filling
pressure
Defective pressure equipment or
expansion vessel
Incorrect opening pressure / dimension or defective safety valve
Incorrect setting of pressure reducer / pressure relief controller
Secondary side - fluctuating supply temperatures
Secondary side - abruptly changing operating conditions:
- Disconnection of system parts
- Closing of valves
- Pumps switching OFF
Incorrect adjustment and filling
pressure
Defective pressure equipment or
expansion vessel
Incorrect opening pressure / dimension or defective safety valve
- Tn (integration time constant)
- M run (running time of the
motorised control valve)
Check and secure operating
conditions:
- Pressure
- Flow
- Differential pressure
Control valve needs to be recalculated, replace if necessary
Turn off substation:
- Check operating parameters
and test for admissibility ( see
label)
- Check connections and tighten
as necessary or replace seals
Tighten connection or replace
component
- Tighten bolts
- Open and clean plates
- Change seals if necessary
Replace heat exchanger Contact customer service
Test heat exchanger and replace
if necessary
Check vessel and pressurisation
(static pressure)
Replace component(s)
Replace safety valve
Check / correct device setting Read device user’s manual
Check control valve settings
(characteristics in particular)
Check control valve settings
(characteristics in particular)
Check system settings / interplay
of the entire system
Check vessel and pressurisation
(static pressure)
Replace component(s)
Replace safety valve
Read controller’s user manual
Contact our sales staff
responsible
Contact customer service
Read heat exchanger
user’s manual or contact
customer service
Contact customer service
Check and adjust parameters
Check and adjust parameters
*May not be applicable for some products or product variants.
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Malfunction Possible Solution Comment
Incorrect pump setting Check / correct setting Read pump manual
Check and correct settings of
balancing components
Check flow and hydraulic setup
Check if extraneous objects are
inside piping
Check functionality of non-return
valves (spring)
Check dimensioning
Extend / enlarge substation
(calculate dimensions for new
control valve and replace old one)
Clean the filter (after consulting
district heating plant)
Check functionality of differential
pressure controller
Replace defective actuator or
thermostat
Check the functions of the control valve - clean valve housing if
required
Check that the controller setting
is correct - see separate instructions. Check the power supply.
Temporary set the actuator to
“manual”
control - see the instructions for
heating circuit, manual control
Check that the pump is receiving
power and that it runs. Make sure
that there is no air in the pump
housing - see pump manual
Set the pump at a higher speed
of rotation - see instructions for
heating circuit
Read device user’s manual
Rinse the substation
Contact our sales staff
responsible
Clean valve seat if required
Check values and if necessary
replace sensor
Excessive noise
No heat
Missing hydraulic set-up
Flow noise (e.g. in pipes )
Loose parts inside components
System incorrectly dimensioned,
e.g. primary control valve is too
small
Defective control valve Clean valve
Defective pump impeller Replace pump
Strainer clogged on DH or HE side Clean strainer
Filter in district heating meter
clogged
Defective differential pressure
controller
Defective sensor Replace the sensor
Defective actuator or thermostat
Defective control valve or possibly dirt in the valve housing
Automatic controls incorrectly
set or defective - possible power
failure.
Pump out of operation
The pump rotation speed is set
too low
Air in the system Vent the installation thoroughly
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10.1 Safety
WARNING! Risk of injury!
Improper troubleshooting can lead to serious personal injury and
/ or property damage. Therefore troubleshooting of malfunctions
may be performed only by trained and authorised personnel!
10.2 Steps to take in the event of malfunction
In summary:
• Immediately stop the substation using the emergency stop
function when there are faults that can cause immediate
danger to persons, property and / or operational security.
• Switch OFF the substation when there are faults that do not
pose such dangers. Additionally, interrupt the power supply to
the unit and secure against reconnection.
• Immediately inform superior about fault.
• Request authorised personnel to determine the nature and
extent of the disorder and the cause of the malfunction,
and to repair the malfunction.
11.0 Spare parts
Use only original spare parts from the manufacturer.
WARNING!
Incorrect or faulty spare parts and / or components from other
manufacturers may cause serious damage to and/or malfunction
or failure of the substation.
Using non-approved spare parts will invalidate all warranty, service,
damage and/or liability claims against the manufacturer or its agents,
distributors and representatives.
When ordering spare parts, always specify:
• Substation type
• Serial / production number
• Part number / article number (if available)
• Quantity
• Name
• Desired shipping method (post, freight, sea, air, express)
• Shipping address
• If needed, provide a sketch or photo with remarks
Spare part orders without the above specifications may not be fulfilled. In the absence of a desired shipping method, the shipping
method will be at the discretion of the supplier.
In the annex, you can find a list of the most important suppliers of
purchased components, where spare parts may be requested following the expiry of the warranty. In such a case, provide the manufacturer with comprehensive information about the used parts so that
a replacement can be offered.
AQ167786463757en-000402
© Danfoss | 2020.02 | 25
District Heating Substations
A
actuator 11, 20, 24, 26, 28
assembly 2, 8, 14, 15, 17
authorized personnel 5, 26, 29
B
balancing valve 26
C
circuit 2, 9, 10, 11, 12, 18, 19, 23, 28
circulation 12, 26
commissioning 2, 8, 15, 19, 20
component 15, 24, 27
connections 8, 11, 13, 14, 15, 19, 24, 25, 27
control valves 11
controller 11, 19, 20, 26, 27, 28
D
District Heating 5, 11, 15, 18, 19, 20, 25, 26, 28
domestic hot water 2, 12
drain 4, 6, 8, 11, 12, 18, 23
drinking water 4, 11
DSE FLEX 1, 2, 9, 11, 12, 15
E
electrician 3, 15, 24
employees 19
EPP 22
expansion vessel 2, 23, 24, 27
F
fittings 8, 12, 25, 27
flat spanner 21, 22
flow noise 28
H
hazard 3, 6, 20, 24
heat exchanger 2, 9, 11, 12, 22, 24, 25, 26, 27
heating supply 15
hot surfaces 6
I
installation 3, 4, 5, 9, 11, 12, 14, 15, 18, 19, 24, 28
installer 24
Intended use 5
L
loose components 15
M
maintenance 2, 3, 5, 6, 7, 11, 12, 19, 24, 25
Maintenance Plan 30
malfunction 3, 4, 19, 29
O
operator 2, 5, 7, 19
P
packing 16
personnel 5, 7, 8, 14, 15, 19, 20, 24, 26, 29
primary connection 15, 19
protective clothing 8
protective gloves 6
pump 11, 12, 20, 24, 26, 28
R
reconnection 6, 24, 29
risk 2, 3, 5, 6, 8, 13, 16
S
safety rules 13
safety valve 12, 23, 24, 27
scrap 4
secondary side 11, 19, 20, 23
Seeger Circlip Ring Pliers 22
sensor 12, 15, 26, 28
service 4, 6, 26, 27, 29
spare parts 4, 29
strainer 2, 11, 12, 15, 19, 21, 24, 28
substation 2, 3, 4, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,
22, 24, 25, 26, 27, 28, 29
T
technical requirements 12
thermometer 11, 24
transport 6, 9, 13, 14, 16
troubleshooting 20, 29
U
unpacking 2, 16
V
voltage 9, 19, 20, 26
26 | © Danfoss | 2020.02
W
warranty 3, 5, 15, 19, 29
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District Heating Substations
AQ167786463757en-000402
© Danfoss | 2020.02 | 27
District Heating Substations
28 | © Danfoss | DHS-SMDBT/PL | 2020.xx
AQ167786463757en-000402
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