Danfoss EvoFlat 4.0 Installation guide [de]
Installation Guide
EvoFlat 4.0
Flat Stations for apartments, single- and multi-family houses
Complete heat-insulated flat stations for direct heating and instantaneous domestic hot water
EN
DE
FR
Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
EvoFlat 4.0 M EvoFlat 4.0 F EvoFlat 4.0 W
1. CONTENT
2. SAFETY NOTES ...............................................................................4
2.1 Safety Notes — general ......................................................................................4
3. MOUNTING ..................................................................................5
3.1 Mounting ....................................................................................................5
3.2 Start-up ......................................................................................................6
3.3 Electrical connections ........................................................................................6
4. MAIN COMPONENTS & DIMENSIONAL SKETCHES .............................................7
4.1 EvoFlat 4.0 M. Construction and Diagrams. ....................................................................7
4.2 EvoFlat 4.0 F. Construction and Diagrams. .....................................................................8
4.3 EvoFlat 4.0 W. Construction and Diagrams. ....................................................................9
EN
5. CONTROLS .................................................................................10
6. CIRCULATION ...............................................................................12
7. MAINTENANCE ..............................................................................13
8. TROUBLESHOOTING ........................................................................14
8.1 Troubleshooting in general ..................................................................................14
8.2 Troubleshooting: DHW ......................................................................................14
8.3 Troubleshooting HE .........................................................................................15
8.4 Disposal .....................................................................................................15
9. DECLARATION ..............................................................................16
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
2. SAFETY NOTES
2.1 Safety Notes — general
The following instructions refer to the standard design of flat stations.
It is not allowed to work with any kind of tool on the composite block — however only
when working HTC and circulation set — for mounting these.
This operating manual should be read carefully before installation and start-up of the
flat station. The manufacturer accepts no liability for damage or faults that result from
non-compliance with the operating manual. Please read and follow all the instructions
carefully to prevent accidents, injury and damage to property.
Assembly, start-up and maintenance work must be performed by qualified and au
thorized personnel only. Please comply with the instructions issued by the system
manufacturer or system operator.
Corrosion protection.
All pipes and components are made of stainless steel and brass.
The maximum chloride compounds of the flow medium should not be higher than
150 mg/l. The risk of equipment corrosion increases considerably if the recommended
level of permissible chloride compounds is exceeded.
Energy source.
The flat station is designed to be connected to decentralized heating installations with
various energy sources, such as district heating, central boiler (gas, oil, biomass, etc.),
solar, heat pump or a combination between them if the operating conditions allow it.
Application.
The flat station is designed to be connected to the house installation in a frost-free
room, where the temperature does not exceed 50 °C and the humidity does not exceed
80 %. Do not cover or wall up the flat station or in any other way block the entrance
to the station.
Choice of material.
Choice of materials always in compliance with local legislation.
Safety valve(s).
We recommend mounting of safety valve(s), however, always in compliance with local
regulations.
Noise level. ≤ 29,8 dB
Connection.
The flat station must be equipped with features that ensure that the flat station can be
separated from all energy sources (also power supply).
Emergency.
In case of danger or accidents — fire, leaks or other dangerous circumstances — interrupt
all energy sources to the station if possible, and seek expert help.
In case of discoloured or bad-smelling domestic hot water, close all shut-off valves on
the flat station, inform the operating personnel and call for expert help immediately.
Storage.
Any storage of the flat station which may be necessary prior to installation should be in
conditions which are dry and heated.
Reach.
All products of the EvoFlat series comply with the provisions of the REACH regulation.
We are therefore obliged to inform our customers about the presence of substances according to the SVHC candidate list, if they are present. We hereby inform you: This product
contains brass parts containing lead (CAS 7439-92-1) in a concentration above 1% (w/w).
Potential equalization / grounding.
Equipotential bonding is understood as all measures for eliminating electrical potential
differences (contact voltages), which can occur between eg two pipelines. Equipotential
bonding is an important measure for protection against electric shock. Equipotential
bonding reduces corrosion in the heat exchanger, instantaneous water heaters, district
heating stations and plumbing installations. Equipotential bonding should be in ac-
cordance with the provisions 60364-4-41: 2007 and IEC 60364-5-54: 2011.
Binding point is marked with a grounding symbol on the bottom right corner of the
mounting plate and there is a hole in the mounting plate and a label with grounding
symbol.
Disposal.
The station consists of materials that must not be disposed of with household waste.
Disconnect the entire energy supply and disassemble the product for disassembly and
dispose of it in accordance with local regulations.
Authorized personnel only
Assembly, start-up and maintenance work must
be performed by qualified and authorized personnel only.
-
Please observe instructions carefully
To avoid injury to persons and damage to the
device, it is absolutely necessary to read and observe these instructions carefully.
Warning of high pressure and temperature
Be aware of the installation’s permissible system
pressure and temperature.
The maximum temperature of the flow medium
in the flat station is 95 °C.
The maximum operating pressure of the flat station is 10 bar.
The risk of persons being injured and equipment damaged increases considerably if the recommended permissible operating parameters
are exceeded.
The flat station installation must be equipped
with safety.
Warning of hot surface
The flat station has got hot surfaces, which can
cause skin burns.
Please be extremely cautious in close proximity to
the flat station.
Power failure can result in the motor valves being
stuck in open position. The surfaces of the flat station can get hot, which can cause skin burns. The
ball valves on district heating supply and return
should be closed.
Warning of transport damage
Before flat station installation, please make sure
that the flat station has not been damaged during transport.
IMPORTANT — Tightening of connections
Due to vibrations during transport all flange connections, screw joints and electrical clamp and
screw connections must be checked and tightened before water is added to the system. After
water has been added to the system and the system has been put into operation, re-tighten ALL
connections. Check that all hairpins in click connections are completely pushed in.
Please notice
Interventions and reworking of our components
lead to the loss of warranty.
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
3. MOUNTING
3.1 Mounting
Installation must be in compliance with local standards and regulations.
Heat Source (HS) — In the following sections, HS refers to the heat source which supplies the flat stations. A variety of energy sources, such as oil, gas or solar power, could
be used as the primary supply to Danfoss substations. For the sake of simplicity, HS
can be taken to mean the primary supply.
Mounting:
Adequate space
Please allow adequate space around the flat station for mounting and maintenance
purposes.
Orientation
The station must be mounted so that components, keyholes and labels are placed
correctly. If you wish to mount the station differently please contact your supplier.
Drillings
Where substations are to be wall-mounted, drillings are provided in the back mounting plate.
Labelling
Each connection on the substation is labelled.
Before installation:
Clean and rinse
Prior to installation, all substation pipes and connections should be cleaned and rinsed.
Thightening
Due to vibration during transport, all substation connections must be checked and
tightened before installation. Check that all hairpins in click connections are completely
pushed in.
Authorized personnel only
Assembly, start-up and maintenance work must
be performed by qualified and authorized personnel only.
EN
Keyhole for mounting.
Please notice
Use of packaging types other than that with which
the device is delivered will void the warranty.
Unused connections
Unused connections and shut-off valves must be sealed with a plug.
Should the plugs require removal, this must only be done by an authorized service
technician.
Installation:
Strainer
If a strainer is supplied with the station it must be fitted according to schematic diagram.
Please note that the strainer may be supplied loose.
Connections
Connection to the household installation and district heating pipes connections must
be made using threaded, flanged or welded connections.
The internal connections of the flat station are made by click-fit connections.
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
3.2 Start-up
Start-up, Direct heating
The shut-off valves should b e opened and the unit observed as it enters service. Visual
checking should confirm temperatures, pressures, acceptable thermal expansion and
absence of leakage.
If the heat exchanger operates in accordance with design, it can be put to regular use.
After water has been added to the system and the system has been put into operation,
re-tighten ALL connec tions. Check that all hairpins in click connections are completely
pushed in.
Start-up, Heating with mixing loop (on the EvoFlat 4.0 M version)
Start-up:
1: Pump speed
Set the pump to its highest speed of rotation before start-up. On radiator systems,
the selector switch is normally set in “Variable curve / Proportional curve” setting, in
“max. pos.”. For floor heating systems, the selector switch is normally set in “Constant
curve” setting, in “max. pos.”.
2: Start pump
Start the pump and heat through the system.
3: Open shut-off valves
The shut-off valves should then be opened and the unit observed as it enters service.
Visual checking should confirm temperatures, pressures, acceptable thermal expansion and absence of leakage.
If the system operates in accordance with design, it can be put to regular use, — always
taking into account the conditions in the building.
4: Vent system
Switch off the pump and vent the installation after the system has been warmed up.
Please note that some pump types feature a built-in venting function. For others the
installation can be vented by using a vent valve in the flat station or on the radiators,
or, if appropriate, the air valve at the highest point of the system — For additional
information, please refers to the enclosed pump and manual.
Re-thighten connections
After water has been added to the system and
the system has been put into operation, re-tighten ALL connections.
Check that all hairpins in click connections are
completely pushed in.
5: Adjust pump speed
Set the pump to the lowest possible position, depending on the heating requirement
for the building — tak ing into account aspec ts such as cooling and power consumption.
If the heating requirement increases the pump setting can be changed by means
of the selector switch. Please refer to the enclosed instruction manual for detailed
information about setting ranges.
In the summer, you can switch off the power to the pump at the mains if you want to
save electricit y by not heating your home. It should be ensured that no inappropriate
hydraulic situation will occur, when the power to your pump is turned off.
For start-up and venting — see above and the enclosed pump manual.
3.3 Electrical connections
Before making electrical connections, please note the following:
Safety notes
Please read the relevant parts of the safety notes.
Point with picture of how the earth connection is to be mounted (the rail).
230 V
The flat station must be connected to 230 V AC and earth. Only valid for the M version
or F version when using room thermostat and TWA (as an option).
Disconnection
The substation must be electrically connected so that it can be disconnected for repairs.
Grounding / potential compensation
The station should be connected to a grounding point.
Authorized electrician
Electrical connections must be made by an authorized electrician only.
Local standards
Electrical connections must be made in accordance with current regulations and local standards.
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
4. MAIN COMPONENTS & DIMENSIONAL SKETCHES
4.1 EvoFlat 4.0 M. Construction and Diagrams.
36 69
64
613
8
1 2 3 4 5 6 7
65 65 65 65 65 65 4496
530
Connections:
1. Domestic cold water (DCW) inlet
2. Domestic hot water (DHW)
3. Domestic cold water (DCW) outlet
4. District heating (DH) supply
5. District heating (DH) return
6. Heating (HE) supply
7. Heating (HE) return
Options:
• HTC (183H0501)
• PWH- Circulation set (183H0500)
• Actuator TWA-Q NO 230V (082F1601)
DHW
DCW
DCW
DHW-C
DH
Supply
59
12
97
17
52A
30
2
52
4
EN
4 38
33
5
40
12
59 24
10
54
44
2 Plate heat exchanger DHW
4 Differential pressure controller
5 Stainer
6 Check valve
7 Ball valve
9 DHW circulation set with safety valve
(Wilo yonos Para Z)
10 Heating pump mixing cirquit
12 Safety valve
2
17
33
38
33
4
33
5
17 Air vent
23 Sensor pocket
24 Fitting piece for energy meter 3/4” × 110 mm
29 Sensor
30 Valve HE
33 Plug for heating cirquit
38 Hot Water Controller
40 Summer by-pass
52 Zone valve
54 Safety thermostat with TWA
59 Fitting piece for water meter 3/4” × 110 mm
~ 230 V
HE
54
Supply
DH
Return
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24
6
23
4 52 33 30
29
10
HE
Return
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
4.2 EvoFlat 4.0 F. Construction and Diagrams.
36 69
64
52
613
1 2 3 4 5 6 7
8
65 65 65 65 65 65 4496
Connections:
1. Domestic cold water (DCW) inlet
2. Domestic hot water (DHW)
3. Domestic cold water (DCW) outlet
4. District heating (DH) supply
5. District heating (DH) return
6. Heating (HE) supply
7. Heating (HE) return
Options:
• PWH- Circulation set (183H0500)
• Actuator TWA-Q NO 230V (082F1601)
DHW
530
2
52A
4
4 38
5
40
59 24
2 Plate heat exchanger DHW
4 Differential pressure controller
5 Stainer
7 Ball valve
9 DHW circulation set with safety valve
12 Safety valve
17 Air vent
23 Sensor pocket
24 Fitting piece for energy meter 3/4” × 110 mm
2
17
38 Hot Water Controller
40 Summer By-pass
52 Zone valve
52A TWA Q-NO 230V for zone valve (optional)
59 Fitting piece for water meter 3/4” × 110 mm
DCW
59
DCW
12
DHW-C
DH
Supply
DH
Return
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7
9
24
33
38
33
4
23
5
40
23
52A
524
~ 230 V
HE
Supply
HE
Return
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
4.3 EvoFlat 4.0 W. Construction and Diagrams.
36 69
64
17
613
1 2 3 4 5
8
65 65 65 65 17496
530
Connections:
1. Domestic cold water (DCW) inlet
2. Domestic hot water (DHW)
3. Domestic cold water (DCW) outlet
4. Heating (HE) supply
5. Heating (HE) return
2
EN
4 38
33
5
40
59 24
2 Plate heat exchanger DHW
4 Differential pressure controller
5 Stainer
7 Ball valve
9 DHW circulation set with safety valve
12 Safety valve
17 Air vent
23 Sensor pocket
24 Fitting piece for energy meter 3/4” × 110 mm
2
38 Hot Water Controller
40 Summer By-pass
59 Fitting piece for water meter 3/4” × 110 mm
DHW
DCW
DCW
DHW-C
DH
Supply
DH
Return
© Danfoss | DCS-SGDPT | 2022.01
17
33
59
33
9127
23
40
24
38
4
33
5
23
33
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
5. CONTROLS
5.1 Zone valve
Heating block contains a zone valve. For F version without TWA. If a plastic cap is to
be fitted, the zone valve is closed.
5.2 Air vent
The station should be vented during start up.
5.3 Strainer
Strainers should be cleaned regularly by authorized personnel. The frequency of
cleaning would depend on operating conditions.
Note! Do not use tool to open the filter.
5.4 Summer bypass
The bypass thermostat is designed to keep the supply line warm.
Setting range: from 10 °C to 50 °C.
Scale setting (indicative).
Factory setting 3.
Scale setting
1 2 3 4
20 30 40 45
5.5
Mixing loop
The mixing loop creates a suitable temperature level e.g. for floor heating.
Setting range: Can be done by the FTC termostat.
FTC control
The FTC controls the mixing loop HE supply temperature.
Setting range from 15 °C to 50 °C.
The setting values may vary depending on the operating conditions.
It is important to set the supply temperature to the radiators as low possible.
NB! For houses that are heated exclusively with floor heating.
ALWAYS refer to the instructions from the floor supplier.
Factory setting: 50 °C.
Safety thermostat
The safety thermostat will shut the zone valve if the HE supply temperature is
above 55 °C.
If the temperature is lower, the safety thermostat will open the zone valve.
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
5.6 Mount EPP cover
To install heat and water meters, the insulation must be removed in the order 1, 2 and
3 and reassembled in the reverse order.
After both meters have been installed, the wiring of the heat meter to the calculator
must be laid (clamped) in the cable bar provided for this purpose. It is important to
ensure that no cables cross the insulating bars. Otherwise, there will be an uncontrolled
leakage of heat and the room may heat up unnecessarily.
EN
5.7 Fitting piece
The flatstation is equipped with a steel fit ting piece for energy meter and braz z fitting
piece for cold wather meter.
Mounting of energy meters:
1: Close ball valves
Close the ball valves on DH Supply and DH Return, if there is water on the system.
2: Loosen nuts (see pictures)
Loosen the nuts on the fitting piece.
3: Remove fitting piece
Remove the fitting piece and replace it with the energy meter. Do not forget the
gaskets.
4: Tighten connections
After mounting of the energy meter remember to check and tighten all threaded
connections.
5: Torques for connections at the Flatstation
Union nuts G 3/4” 45 Nm
Union nuts G 1” 45 Nm
Screw connections for fitting pieces 35 Nm
Piping of the heating circuit distributor 30 Nm
Note: When installing a heat and / or water meter, the respective manufacturer’s instructions must be observed.
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
6. CIRCULATION
6.1 Circulation
The pump must be mounted on the metal plate which must be mounted on the existing mounting rail.
Remove the plug on the side of the station (remove hair pin).
Mount the connection from the flex hose and secure it with the hair pin.
Electronic
For cutout for circulation, please
see instructional drawing.
Self acting
Note: A non-return valve must be fitted between the connection from the safety valve and
the ball valve.
6.2 HTC
Remove the plug on the side of the station (remove hair pin).
Mount the connection from the flex hose and secure it with the hair pin.
For cutout for HTC, please see
instructional drawing.
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HWR
HWS
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
7. MAINTENANCE
The flat station requires little monitoring, apart from routine checks. It is recommended to
read the energy meter at regular intervals, and to write down the meter readings.
Regular inspections of the flat station according to this Instruction are recommended, which
should include:
Strainers
Cleaning of strainers.
Meters
Checking of all operating parameters such as meter readings.
Temperatures
Checking of all temperatures, such as HS supply temperature and PWH temperature.
Connections
Checking all connections for leakages.
Safety valves (for the circulation)
The operation of the safety valves should be checked by turning the valve head in the
indicated direction.
Venting
Checking that the system is thoroughly vented.
Authorized personnel only
Assembly, start-up and maintenance work
must be performed by qualified and authorized
personnel only.
EN
Inspections should be carried out minimum every two years.
Spare parts can be ordered from Danfoss.
Please ensure that any enquiry includes the flat station serial number.
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
8. TROUBLESHOOTING
8.1 Troubleshooting in general
In the event of operating disturbances, the following basic features
should be checked before carrying out actual troubleshooting:
• the flat station is connected to electricity,
• the strainer on the HS supply pipe is clean,
• the supply temperature of the HS is at the normal level,
• the differential pressure is equal to or higher than the normal (local) differential
pressure in the HS network – if in doubt, ask the HS plant supervisor.
8.2 Troubleshooting: DHW
Problem Possible cause Solution
Authorized personnel only
Assembly, start-up and maintenance work
must be performed by qualified and authorized
personnel only.
Too little or no domestic hot
water
DHW is available only at some
draw-off points.
DHW temperature too high DHW controller Adjust controller
Supply flow insufficient Collect data from the heat meter
Check the network pump — constant pressure
If necessary, close the bypass in the tap block on
the bathroom radiator
Check the function of the ball valves and open
if necessary
Vent the system throughly — see the instruction
Change the summer bypass setting if
necessary
Low temperature / variations in temperature at the
draw-off points
Strainer in the cold water supply line clogged. Clean strainer
Circulation pump out of operation , set at too low
speed of rotation (if DHW circulation is established)
Non-return valve defective or clogged
(if DHW circulation is established)
Defective DHW thermostat
Defective TPC-M controller Check the functions of the controller,
Calified heat exchanger Replace heat exchanger
Lack of cold water pressure Increase pressure
Defective thermostatic mixing valve Replace thermostatic mixing valve
Collect data from the heat meter
Change the positioning time of the mixer actuator
Change the heating curve if necessary
Position the switch-on sensor correctly on the
buffer line
Change cleaning periods for biomass boilers
Check the function of the circulation pump and
replace if required
Check the functioning of the non-return valve and
replace if required
Check the functioning of the DHW thermostat
and repace if necessary
and replace if required
DHW controller defective Check the functions of the controller,
Temperature drop during
tapping.
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Larger DHW flow than the flat station has been
designed for.
and replace if required
Reduce DHW flow
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Installation Guide EvoFlat 4.0 Flat Stations for apartments, single- and multi-family houses
8.3 Troubleshooting HE
Problem Possible cause Solution
Too little or no heat. Strainer in supply line clogged. Clean strainer(s)
The filter in the energy meter clogged. Clean the filter
Defective differential pressure controller. Replace main controller, TPC
Defective temperature sensors. Replace thermostat
Automatic controls, if any, wrongly set or defective
— possibly power failure.
Pump out of operation. Check if the pump is receiving power and that it
The pump is set at too low speed of rotation. Set the pump at higher speed of rotation.
Air pockets in the system. Vent the system throughly — see the instruction
Defective radiator valves. Check — replace
HS supply temperature
too high.
Noise in system. Pump pressure too high.
Too high HS return
temperature.
Defective TPC-M controller, alternatively differential
pressure controller. The controller does not reac t as
it should according to the instructions.
Noice from radiator valves.
Mass flow below the control range
Too small heating surface/too small radiators
compared to the total heating requirement of the
building.
Poor utilization of existing heating surface.
Defective sensor on self-acting thermostat.
The system is single pipe loop. The system should be equipped with electronic
Pump pressure too high. Set the pump at a lower speed of rotation.
Air in system. Vent the system throughly — see the instruction
Defective or incorrectly set radiator valve(s).
Single pipe loop systems require special one-pipe
radiator valves.
Dirt in the differential pressure controller. Check — clean out.
Defective motorized valve, sensor or automatic
controller.
Check if the setting of the controller is correct —
set coorectly or replace
turns. Check if there is air trapped in the pump
housing. See pump manual
See pump manual.
Replace TPC-M controller
Adjust pump to a lower level.
Check flow direction.
Reduce the spread and thereby increase the mass
flow
Increase total heating surface.
Make sure the heat is distributed evenly across
the full heating surface — open all radiators and
keep the radiators in the system from heating up
at the bottom. It is extremely important to keep
the supply temperature to the radiators as low
as possible, while maintaining a reasonable level
of comfort.
controls and return sensors.
See pump manual.
Check — set/replace.
Check — replace.
EN
8.4 Disposal
© Danfoss | DCS-SGDPT | 2022.01
Disposal
This product should be dismantled and its compo
nents sorted, if possible, in various groups before
recycling or disposal.
Always follow the local disposal regulations.
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