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!

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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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1.0 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.

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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.

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!

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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

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.

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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

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.

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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 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.

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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)

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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

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Figure 2: DSE FLEX packaging

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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.

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In the secondary circuit circulation pump transfers heated water to
the heating surfaces of other installations (e.g. ventilation equip­ment, drinking water or heating installations, etc.). If a controller
with weather compensation is installed at the substation, it has the
following essential functions:

• Measures flow temperature on the secondary side and
outdoor temperature

• Changes the stroke of the control valve on the primary side so
that it conforms to the required secondary temperature

• Limits the return temperature on the primary side to a value
preset in the controller

• Switches the secondary side circulating pump(s) on and off as
necessary and ensures frost protection

If required, special functions are available according to needs and de­signs. Refer to the instruction manual of the controller manufacturer.
All systems are offered upon request and manufactured in keeping
with the customer’s special operating conditions.

Due to the many different product variations, the circuit diagram
may differ from that presented below.

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