Danfoss DSE FLEX Operating guide

Operating Guide

DSE FLEX

Please always keep the instructions close to the device!

Please read the operating instructions carefully
before starting any work.

Attention!
Before starting up the station, please check
it for proper function and free of defects!

© Danfoss |2018.02

Original instruction

VI.JV.J2.02 | 1

DSE FLEX

0.0 Table of contents

0.0 Table of contents ...........................................................................................................................................................................................................................2

1.0 General notes ..................................................................................................................................................................................................................................3

1.1 Information about Operating Instructions ......................................................................................................................................................................3

1.2 Applicable Documents ...........................................................................................................................................................................................................3

1.3 Explanation of symbols ..........................................................................................................................................................................................................3

1.4 Liability and Warranty ..............................................................................................................................................................................................................3

1.5 Copyright Protection ...............................................................................................................................................................................................................4

1.6 Spare parts ..................................................................................................................................................................................................................................4

1.7 Substation disassembly ..........................................................................................................................................................................................................4

1.8 Disposal .......................................................................................................................................................................................................................................4

2.0 Safety ...........................................................................................................................................................................................................................................5

2.1 General information ................................................................................................................................................................................................................5

2.2 Responsibility of substation 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 Risks associated with the substation ................................................................................................................................................................................6

2.8 Emergency stop switch .........................................................................................................................................................................................................7

2.9 Operators ....................................................................................................................................................................................................................................7

2.10 Steps to follow in the event of danger or accidents ...................................................................................................................................................7

2.11 Residual hazards / risk analysis ...........................................................................................................................................................................................8

3.0 Technical data .................................................................................................................................................................................................................................9

3.1 Technical information .............................................................................................................................................................................................................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 Hauling instruction .............................................................................................................................................................................................................16

6.3 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

2 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

1.0 General notes

1.1 Information about Operating Instructions

This manual describes the installation, operation and maintenance
of the substation. Compliance with all safety and operating instruc­tions is a prerequisite for the safe operation and proper use of the
substation. In addition, regulations applicable to the field of appli­cation of the substation, local accident prevention regulations and
general safety regulations must be followed. The operating manual
is part of the product and must be available at all times within the
immediate vicinity of the operating area of the substation for the
installation, operation, maintenance and cleaning responsible of
the substation.

1.2 Applicable Documents

Individual system components - unless otherwise indicated - are
components purchased from other manufacturers. All components
used in the substation have been subjected to their manufacturers’
risk assessments. Declarations of conformity with current European
and national legislation have been made by the manufacturers of
the components. Declarations of conformity, and operation, main­tenance and repair instructions for the individual components are
integral parts of the substation documentation.

1.3 Explanation of symbols

Important security and device-related information in these oper­ating instructions is marked by warning notices. The instructions
must be followed to prevent accidents, personal injury or property
damage.

The graphic illustrations in this manual are provided to better
represent the issues described, and are not necessarily to scale
and may differ slightly from the actual design of the substation.
In addition to these operating instructions, operating manuals
for all installed components on substation must be followed. The
information contained therein - particularly with regard to safety

- must be followed!

The instructions contained in the manufacturer’s documents for
security, set-up, installation, operation, maintenance, and disman­tling and disposal of the components must be followed strictly.

WARNING

This symbol indicates a danger that may result in damage to
health, injury, permanent physical injury or death. Please follow
the notes for working safely very carefully and take extreme care
in these situations!

WARNING

Electrical hazard! This symbol indicates danger from electricity.
Failure to follow safety procedures can result in severe injury or
death. This work may only be performed by a trained electrician.

1.4 Liability and Warranty

All information and instructions in this manual have been compiled
in accordance with applicable regulations and the current status of
engineering developments as well as our many years of knowledge
and experience. The actual scope of delivery may differ from the ex­planations and graphic representations of special versions described
here, as a result of additional accessories / order options or latest
technical changes. For questions, please contact Danfoss directly.
We reserve the right to make technical changes to the product in
the course of improvement of its functional properties and further
development. Items such as tools and equipment that may wear out
during use of the device, as well as auxiliary materials and supplies
such as oils, greases and detergents, are not covered by warranty.

ATTENTION

This symbol indicates a risk that may result in damage to, or
malfunction / failure of equipment if ignored.

NOTE

This symbol highlights tips and information that must be followed
for the efficient and trouble-free operation of the substation.

In addition, the commitments agreed in the contract, such as the
general terms and conditions and the manufacturer’s terms of deliv
ery, and statutory regulations at the time the contract is concluded
shall apply.

NOTE

These operating instructions should be read carefully before starting
work on or with the substation, and in particular before commission­ing! The manufacturer will not accept claimsfor damage or faults
arising from non-compliance with these operating instructions.

-

VI.JV.J2.02

© Danfoss |2018.02 | 3

DSE FLEX

1.5 Copyright Protection

Operating instructions must be kept confidential. These are intend­ed exclusively for the persons employed on and with the substation.
Transfer of the operating instructions to third parties without writ­ten approval of the manufacturer is prohibited. If such approval is
required, please contact Danfoss directly.
This document and any others delivered with the substation are pro­tected by copyright. Copies (whether whole or in part) are allowed
only with the permission of the manufacturer. Violators will be liable
to prosecution. All other rights reserved.

1.6 Spare parts

Use only original spare parts from the manufacturer.
The use of non-approved spare parts will invalidate any guarantees,
or service, compensation and liability claims against the manufacturer
or its agents, distributors and representatives.

1.7 Substation disassembly

Clean and sort the substation parts and components in compliance
with applicable health and safety and environmental regulations.
Before starting disassembly:

• Switch the unit OFF and secure against being
switched ON again.

• Ensure that the entire energy supply is physically separate
from the substation and that stored residual power is properly
discharged.

• Remove supplies and materials as well as any remaining
processing materials in an environmentally friendly manner.

NOTE

Contents of this instruction – texts, drawings, images or other illus­trations are copyrighted and subject to other intellectual property
rights. Any improper reuse is forbidden.

ATTENTION

Using the wrong or faulty spare parts can lead to damage,
malfunction or total failure of the substation.

WARNING

Risk of injury! Stored residual power, components with sharp edges,
edges and corners on and inside the substation or necessary tools
can cause personal injury. Any substation removal work must there­fore be carried out only by a specialist.

1.8 Disposal

If no withdrawal or waste management agreement has been con­cluded, disassemble the dismantled components for recycling:

• Metal to scrap material

• Plastics to plastics recycling

• To dispose other components, sort by material properties

• Remove any residual media and dispose of properly media with
additives (e.g. glycol) must comply with relevant legislation

Remove operating materials such as lubricants, oils, fats, cleaning
agents and inhibitors from the substation in an environmentally
friendly manner . In this case, use a suitable, approved container for
lubricants. Mark the container with information about the content
and level, and date clearly. Secure final disposal of the materials so
that improper use is excluded.

WARNING

Do not drink!
Water in the installation which has not been used for a long period
of time may not meet the quality standard for drinking water in
certain conditions. Prevent such use and drain or dispose of water
used to run the substation.

WARNING

Electrical and electronic components, lubricants and other excipi­ents must be handled by hazardous waste treatment plants and
may only be disposed by approved specialist companies!

4 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

2.0 Safety

This section gives an overview of all the important security aspects
of optimal protection of personnel as well as of safe and trouble­free operation of the substation. In addition, these chapters include
specific safety symbols in order to avert immediate safety hazards.

2.1 General information

Substation is built at the time of its development and manufactur­ing according to existing, accepted engineering standards and is safe
to operate. The substation can be dangerous if used by improperly
trained personnel or used improperly or by unauthorised persons. Any
person authorised to work on or with the substation must read and
understand the operating instructions before starting work. We recom­mend advising the operator to obtain confirmation from staff proven
understanding of the instruction manual. Modifications of any kind
as well as additions or modifications to the substation are forbidden.
All substation security, warning and operating instructions must be
maintained in good legible condition. Damaged labels or stickers
must be replaced immediately. Specified values or ranges must be
strictly adhered to.

2.2 Responsibility of substation operator

NOTE

For modification and extension activities, always consult with 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

Operational safety is guaranteed only where the substation is used
properly and in accordance with the instructions / details in this
manual. A district heating substation is used to provide heat energy
from the district heating utility grid by transferring heat to customer
installation systems. Intended use also includes compliance with
instructions for installation, operation, maintenance and cleaning.

2.4 Possible misuse

WARNING. Hazard from improper use!

Any use of the substation apart from its intended use may lead
to dangerous situations.

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 additional and / or other use of the substation is forbidden
and considered as improper use! Any claims against the manufac­turer and / or its representative for any loss or damage as a result
of improper use of the substation are excluded. The operator and
/ or owner shall be solely liable for any damage arising when the
substation is used for any purpose other than.

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.

2.5 Safety work

Hazards to persons and / or the system can be prevented by fol­lowing the safety at work instructions.

VI.JV.J2.02

Failure to follow these instructions can result in mechanical or
equipment failure that poses a danger to persons and goods and
the entire workplace. Failure to comply with safety regulations will
invalidate any warranty.

© Danfoss |2018.02 | 5

DSE FLEX

2.6 Personal protective equipment

While working on and with the substation the following must be
worn at all times:

Protective clothing

is close-fitting work clothing with low tensile strength and tight
sleeves and without protruding parts. Its main purpose is to guard
against snagging on moving machine parts. Do not wear rings,
chains or other jewelry.

Protective gloves

to protect the hands from friction, abrasion, puncture or deeper
injury as well as from contact with hot surfaces.

2.7 Risks associated with the substation

Protective goggles

to protect the eyes from flying parts and liquid splashes.

Safety shoes

to protect from heavy falling parts and losing traction on slippery
surfaces.

Helmet

to protect against falling or 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!

Risk from liquids splashing under high pressure. Wear personal
protective equipment for all operations carried out on the sub­station!

The substation operates with high electrical voltages of up to 400 V
and currents of up to 25 A.

WARNING! Electrical shock hazard!

Electrical energy can cause serious injury. Damaged insulation or
components can lead to serious injury or death.

• Switch OFF the main switch and secure against reconnection
before performing any maintenance, cleaning or repair.

• Turn off the power switch when performing any work with the
electrical system

• Do not remove any safety devices or put out of operation

The substation is supported by pneumatic components.

WARNING! Risk of injury!

Risk from liquids splashing under high pressure. Wear personal
protective equipment for all operations carried out on the sub­station!

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 parts and sharp edges may cause abrasion to the
skin. Wear protective gloves when working on the substation.

WARNING! Risk of burns!

Hot surfaces can cause serious burns. For all operations carried
out on the substation always wear protective gloves!

Components inside of the station can contain automatically moving
parts (pumps, actuators, etc.). The devices can be very heavy.

WARNING! Danger of crushing!

During transport or lifting of the substation, bruising can occur
due to heavy weight. The substation may include electrical com­ponents (engines, transmissions) which may also cause bruising
if contacted while in operation. For all operations carried out on
the substation, always switch the main supply OFF and wear pro­tective clothing.

6 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

2.8 Emergency stop switch

The operator shall ensure that the emergency stop switch is installed
in accordance with applicable accident prevention regulations. The
operator must inform operations staff about the location and opera­tion of the emergency stop switch.

2.9 Operators

The substation may be operated and maintained only by authorised,
trained and instructed personnel. These personnel must receive spe
cial training on potential risks. An “instructed person” is a person who
has been informed of the tasks assigned to him/her and the potential
hazards of improper usage and, if necessary, who has been trained
and instructed in protective equipment and actions.
A “professional” is a person who, because of his/her technical train­ing, knowledge, and experience, as well as his/her knowledge of the
relevant provisions, can evaluate the work transferred to him/her and
recognise possible dangers.
If the staff do not have the knowledge required, then they must be
trained. Responsibilities for operation and maintenance must be
clearly defined and respected so that there is no unclear division of
responsibilities in terms of safety.

2.10 Steps to follow in the event of danger or accidents

In the event of an emergency or accident, the substation must be
switched OFF by immediately pressing the emergency stop switch.
This can be done by opening the safety door or protective window
equipped with safety switches that trigger the emergency stop func­tion when opened.
Safety devices with an emergency stop function are only to be used
in appropriate situations.

The substation may only be operated and maintained by persons

-

who can be expected to reliably run their work. Any operation that
affects the safety of persons or the substation environment must be
avoided. Persons under the influence of drugs, alcohol or medication
that affects responsiveness must not perform any work with or on
the substation. When selecting personnel, the relevant country’s
youth employment protection regulations as well as any occupation­specific regulations that may exist must be followed with respect to
minimum age.
The operator must ensure that no unauthorised persons are work­ing on or with the substation. Unauthorised persons such as visi­tors, guest etc., must not come into contact with the substation.
You must maintain a reasonable safety distance. The user is obliged
to immediately report any issues which occur in the substation and
may affect the safety of the operator.

Safety equipment must not be used for normal shutdown of the
substation. Always be prepared for accidents or fire! Keep first-aid
equipment (first-aid kit, eye wash, etc.) and a fire extinguisher within
the substation area.
Personnel must be trained in the handling and location of safety
devices, accident procedures, first aid and rescue equipment. This
results in the prevention of dangerous situations and ensures the
best possible assistance in the event of an accident.

VI.JV.J2.02

© Danfoss |2018.02 | 7

DSE FLEX

2.11 Residual hazards / risk 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)

8 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

3.0 Technical data

3.1 Technical information

Main substation information can be found on the CE label as
well as in documents contained in the appendices (circuit and
electrical 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 FLEX

3.1.2 Dimensions and packaging

The reduced size of the base frame offers DSE FLEX the smallest foot
print in it’s product class. Most of the 2 circuit variants are not larger
then 1 Euro Pallet. The range of standard product dimensions and
weights can be found in the Data Sheet.

The DSE FLEX 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.

A2

Figure 1: DSE FLEX external dimensions

B

C

VI.JV.J2.02

Figure 2: DSE FLEX packaging

© Danfoss |2018.02 | 9

DSE FLEX

3.2 Symbols used in circuit diagrams

Pressure transmitter

4.0 Function and configuration

4.1 Function

The DSE FLEX is an indirect compact substation, where heat trans­fer from the district heating network to a secondary installation is
realised via plate 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.

10 | © Danfoss|2018.02

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.

VI.JV.J2.02

DSE FLEX

4.2 DSE FLEX configuration possibilities

The DSE FLEX platform can be used for various applications such
as heating, domestic hot water and / or other water based heating
system. Due to its flexibility, it is possible to deliver a 1-, 2- or 3-circuit
substation with possibility to make combinations between modules if
more circuits are required. 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 micro plate 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).

By use of the Danfoss dimensioning program you can find out if the
application you need fits DSE FLEX.

419

443151

171

813 150

395 182

171

151423153151 160 161

812814

PI

PI PI

812 812 151

445

153

420

474 153470 419419419430 468 430

167181 812

PI

153

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

VI.JV.J2.02

© Danfoss |2018.02 | 11

DSE FLEX

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

5.2 Transport inspection

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!

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.

12 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

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 us, free of delivery
charges, at:

WARNING!

Unpaid delivered transport packaging will not be accepted by us.

Danfoss Poland Sp. z o.o.
Tuchom, ul. Tęczowa 46
80-209 Chwaszczyno

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

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.

Packaging materials must be utilised in an environmentally friendly
way and in accordance with the relevant waste disposal regulations.

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)

NOTE!

The use of pipe wrenches for nuts and bolts is not permitted. Only
use a suitable spanner!

VI.JV.J2.02

© Danfoss |2018.02 | 13

DSE FLEX

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 (details in 6.3).

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.

6.1.2 Secondary connection

A specialised installation company connects the secondary installa­tion to the substation’s designated shut-off valve.

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. 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.

Electric and sensor cables must always be run in separate cable trays.

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.

14 | © Danfoss|2018.02

VI.JV.J2.02

Installation Guide DSE FLEX - Hauling instructions

DSE FLEX

6.2 Hauling Instructions

6.2.1
The packaged product is supplied with a standard Euro pallet and is
easy to transport by truck or forklift. Use the pallet for transportation
as long as possible.

6.2.2
Remove the protective foil and unscrew the substation from the
pallet (depending on the size and layout of the substation, place
and number of the fixings on the pallet may vary). Take care for the
environment.

6.2.3
Identify the lifting points and secure the hooks of the transportation
belt on the frame corner hole. Handling the substation in a different
way may lead to damages. Use standard equipment.

VI.JV.J2.02

© Danfoss |2018.02 | 15

Installation Guide DSE FLEX - Hauling instructions

DSE FLEX

6.2.4

Transport the substation by carrying it. During transport or lifting
of the substation, bruising can occur due to heavy weight. Respect
local weight / person regulation.

6.2.5

Transport the substation by dragging it on the floor (the frame corner
presents no sharp edges).

6.2.6

In case of low clearances you can dismantle the highest subassembly
and you can dismantle the electrical box column in order to reach
the desired height (unscrew the locking bolts and lift the upper part
of the column).

16 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

6.3 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.

VI.JV.J2.02

© Danfoss |2018.02 | 17

DSE FLEX

7.0 Commissioning

The following actions must always be carried out only after com­missioning:

• Initial start-up of the substation (see commissioning
protocol in the attached annex)

• 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 is 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.

7.1 Requirements for commissioning

In order to commission the station the following conditions must
be met:

• Commissioning must be approved by the district heating utilities

• All screws and fasteners must be tightened

• Substation piping must be connected properly

• 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

• The primary connection must be applied to the primary
shut-off valves within the necessary parameters

Following installation, initial start-up and the execution of test runs
by the manufacturer or its authorised representative, the substation
is handed over to the operator. Afterwards, the substation is operated
as intended in accordance with the instructions in the Operator’s
Manual. Installation and commissioning of the substation can be
performed by employees of the manufacturer, installers authorised
by it or by a specialised installation company. In any case, the exist­ence of a fully completed commissioning protocol (see annex) is
a prerequisite for maintaining a substation warranty.

• 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

• Desired time programmes and additional data for controller
set-up 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.

7.2 Secondary side commissioning

Before commissioning, check that all safety-related rules and regula­tions 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. Fill the secondary installation with water accord­ing to the water quality rules. To avoid substation damage, ensure
that pressure during filling does not exceed the maximum allowable
working pressure. Before first use, the secondary side must be rinsed
sufficiently by the installation company. Check all connections for
leaks and tightness. Fill the secondary installation to the required
static pressure.

7.3 Primary-side commissioning

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. 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.

If the medium is water, set the flow / differential pressure controller
or pressure controller (if available) to the maximum flow rate ac­cording to capacity or preset differential pressure. Than set up the
pressure controller, if there is one, to the designated value. 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 and adjust the electronic
controller in accordance with the designated values in the enclosed
supplier instructions.

18 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

7.4 Requirements for commissioning

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 can
be made in accordance with the controller manufacturer’s manual
can be made. The manual is attached to the station.

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

The substation can be turned off at the main switch of the electronic
controller and will stop automatically.

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.

-

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.

8.4 Electrical panel

The Electrical panel is mounted always on the right side when facing
the substation. The bracket of the electrical panel is adjustable 90 deg
in rotation and in vertical direction up to 500 mm.

VI.JV.J2.02

© Danfoss |2018.02 | 19

DSE FLEX

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.

8.4.1 Service / access to parts

After the substation is connected to all the pipes (primary and sec­ondary) you can remove the diagonal support for better access to
serviceable parts (Eg. Actuator).

20 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

8.5 Service / disassembly and replacement – heat exchanger

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.

VI.JV.J2.02

© Danfoss |2018.02 | 21

DSE FLEX

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.

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)

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

Cleaning of strainers If necessary, refer to point 8.4

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

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

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

22 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

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

VI.JV.J2.02

© Danfoss |2018.02 | 23

DSE FLEX

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

24 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

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.

VI.JV.J2.02

© Danfoss |2018.02 | 25

DSE FLEX

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

26 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

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.

VI.JV.J2.02

© Danfoss |2018.02 | 27

DSE FLEX

A
actuator 11, 20, 24, 26, 28
assembly 2, 8, 14, 15, 17
authorized personnel 5, 26, 29

M
maintenance 2, 3, 5, 6, 7, 11, 12, 19, 24, 25
Maintenance Plan 30
malfunction 3, 4, 19, 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

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

W
warranty 3, 5, 15, 19, 29

28 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

VI.JV.J2.02

© Danfoss |2018.02 | 29

DSE FLEX

30 | © Danfoss|2018.02

VI.JV.J2.02

DSE FLEX

VI.JV.J2.02

© Danfoss |2018.02 | 31

DSE FLEX

32 | © Danfoss | DHS-SMT/PL | 2018.02

VI.JV.J2.02