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!

Original instruction

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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

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1.0General notes

1.1Information 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.

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.

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.

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.

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.

In addition, the commitments agreed in the contract, such as the general terms and conditions and the manufacturer’s terms of delivery, 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.

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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.

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.

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.

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!

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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

•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

NOTE

For modification and extension activities, always consult with the substation manufacturer.

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).

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.

2.5 Safety work

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.

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

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.

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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

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!

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.

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.

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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 special 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

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.

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.

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.

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2.11 Residual hazards / risk analysis

	Risk place	Risk type	Protective aim	Measure
	Shut-off valves and fittings	Crushing during	Manual operation of the	Due to construction, provide
			shut-off valves and fittings	enough space for ergonomic
	in the station	manual operation
			must be safe	operation
				Thermal insulation of pipes
	Piping and components	Burning when touched	Safe contact at the station	and components, signs at the
	in the station			station, warnings in the
				operating instructions
	Entire station	Electric shock	Safe contact with the station	Fulfilment of contact protection
				Protection according to local
	Entire station	Splashing of liquids and/or	Controlled reduction of excess	standards or legal regulations
		steam at high pressure	pressure in case of fault	(e.g. DIN 4747 T1
				or DIN EN 12828)
		Overheating the station		Protection according to local
		or transmitting heat to
			Turning off the heat supply	standards or legal regulations
	Entire station	a connected system at
			in case of failure	(e.g. DIN 4747 T1
		a temperature above
				or DIN EN 12828)
		what is permissible

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:

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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3.0Technical data

3.1Technical 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

3.1.2 Dimensions and packaging

DSE FLEX

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.

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Figure 1: DSE FLEX external dimensions

Figure 2: DSE FLEX packaging

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3.2 Symbols used in circuit diagrams

Pressure transmitter

4.0Function and configuration

4.1Function

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.

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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