Danfoss FLS-50 Operating guide

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Installation, start-up and operating instructions

Domestic Water Heater FLS-50

Always keep the operating manual near the device.

Read the operating manual before commencing work.

Notice! Before starting the device, make sure that it is not damaged and that it is in perfect working order.

DKDHR

VI.GE.T1.02 © Danfoss 12/2010

Installation, start-up and operating instructions FLS-50

1 General ............................................................................................................................................... 4

1.1 Information about the operating manual ............................................................................................................4

1.2 Supporting documents ...............................................................................................................................................4

1.3 Explanations of the symbols .....................................................................................................................................4

1.4 Warranty and liability ...................................................................................................................................................5

1.5 Copyright ..........................................................................................................................................................................5

1.6 Spare parts .......................................................................................................................................................................6

1.7 Dismantling ......................................................................................................................................................................6

1.8 Disposal .............................................................................................................................................................................6

2 Safety.................................................................................................................................................. 7

2.1 General ..............................................................................................................................................................................7

2.2 Responsibility of the operator ..................................................................................................................................7

2.3 Intended use ...................................................................................................................................................................7

2.4 Possible misuse ..............................................................................................................................................................7

2.5 Occupational safety .....................................................................................................................................................8

2.6 Personal protective equipment ...............................................................................................................................8

2.7 Potential hazards involving the device .................................................................................................................8

2.8 Emergency stop switch ...............................................................................................................................................9

2.9 Operating personnel ....................................................................................................................................................9

2.10 What to do in case of danger or accidents.........................................................................................................9

2.11 Residual hazards/risk analysis .............................................................................................................................. 10

3 Technical data .................................................................................................................................. 11

3.1 Technical and main system data ............................................................................................................................11

3.1.1 Circuit diagram ......................................................................................................................................................11

3.1.2. Bill of materials .....................................................................................................................................................11

3.1.3 Type plate .............................................................................................................................................................. 12

3.1.4 Pressure loss curve ............................................................................................................................................ 12

3.1.5 Capacity examples ............................................................................................................................................. 12

3.1.6 FLS-50 + options ................................................................................................................................................. 12

3.1.7. Dimensions and photo of components ..................................................................................................... 13

4 Function ........................................................................................................................................... 14

4.1 Function / General ...................................................................................................................................................... 14

5 Setup ................................................................................................................................................ 15

5.1 Assembly and installation/general ...................................................................................................................... 15

5.1.1 Figure FLS-50 ........................................................................................................................................................ 15

6 Transport, packing and storage .................................................................................................... 16

6.1 Transport pallets with a fork lift truck .................................................................................................................16

6.2 Transport inspection ................................................................................................................................................. 17

6.3 Packaging ...................................................................................................................................................................... 17

6.4 Storage ........................................................................................................................................................................... 17

7 Installation ....................................................................................................................................... 18

7.1 Assembly preparations ................................................................................................................ 18

7.1.1 Electrical connection .......................................................................................................................................... 18

7.1.2 Assembly of FLS-50 ............................................................................................................................................ 21

7.1.2.1 Assembling the basic device ................................................................................................................... 22

7.1.2.2 Assembling Option 1 ................................................................................................................................. 23

7.1.2.3 Assembling Option 2 ................................................................................................................................. 23

7.1.2.4 Assembling Option 3 ................................................................................................................................. 25

7.1.2.5 Assembling Option 4 ................................................................................................................................. 26

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Installation, start-up and operating instructions FLS-50

8 Start-up ............................................................................................................................................ 27

8.1 Controller ....................................................................................................................................................................... 27

8.2 Fault and shutdown................................................................................................................................................... 28

8.3 Restarting after a fault .............................................................................................................................................. 28

9 Operation .........................................................................................................................................28

9.1 Switching the device on ........................................................................................................................................... 28

9.2 Switching the device o ..........................................................................................................................................28

10 Maintenance ..................................................................................................................................29

10.1 Safety information ...................................................................................................................................................29

10.2 Maintenance work ................................................................................................................................................... 30

10.3 Measures after maintenance work ....................................................................................................................30

11 Faults .............................................................................................................................................. 31

11.1 Functional faults ........................................................................................................................................................ 31

11.2 Safety information ................................................................................................................................................... 32

11.3 What to do in case of faults................................................................................................................................... 32

12 Spare parts ..................................................................................................................................... 32

11.3 What to do in case of faults................................................................................................................................... 32

13 Appendix I ...................................................................................................................................... 33

13.1 Exchanger calculations ........................................................................................................................................... 34

13.2 Pressure loss curve, Primary pump .................................................................................................................... 39

13.3 Temperature sensor ................................................................................................................................................40

13.4 Temperature/ow meter .......................................................................................................................................44

13.5 Pressure loss curve, Circulation pump ............................................................................................................. 45

14 Appendix II ..................................................................................................................................... 46

14.1 Declaration of Conformity .................................................................................................................................... 47

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VI.GE.T1.02 © Danfoss 12/2010

Installation, start-up and operating instructions FLS-50

1 General 1.1 Information about the operating manual

This operating manual describes installation, operation and maintenance of the system. Compliance with the safety and handling instructions is a requirement for working safely and using the system properly. Apart from this, the local accident prevention regulations and general safety regulations applicable where the system is used must also be observed. The operating manual is a part of the product and should be kept accessible near where the system is operated at all times for installation,

1.2 Supporting documents

If not stated otherwise, the individual system components are purchased modules from other manufacturers. All the components used in the system have been subject to risk assessments by their manufacturers. The component manufacturers have declared that the design of the components complies with applicable European and national regulations. The manufacturers' conformity declarations and the operating, maintenance and repair

1.3 Explanations of the symbols

Important safety and technical information in this operating manual is marked with warning signs. The information must be observed to prevent accidents, injury and damage to property.

operation, maintenance and cleaning personnel. The graphics in this manual, which are intended to provide a better description of the facts, are not necessarily to scale and may deviate slightly from the actual system design. Apart from this operating manual, the operating instructions for the installed components should also be observed. The information contained in these – especially in relation to safety – must be complied with.

instructions for the individual components are inseparable elements of the system documentation. All the instructions on safety, assembly and installation, operation, maintenance, dismantling and disposal of the components contained in the manufacturers' documentation must be followed by operating personnel.

NOTICE! This symbol indicates instructions which, if not followed, may result in damage, malfunctions and/or failure of the system.

WARNING! This symbol indicates hazards that could aect health or cause injuries, permanent bodily harm or death. Observe the instructions on occupational safety closely and be especially careful in such cases.

WARNING! Risk of injury from electrical current. This symbol draws your attention to dangerous situations involving electrical current. If the safety instructions are not complied with, there is a risk of serious injury or death. Work must be carried out only by a qualied electrician.

NOTE! This symbol highlights hints that should be observed to ensure ecient, problem-free operation of the system.

VI.GE.T1.02 © Danfoss 12/2010

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Installation, start-up and operating instructions FLS-50

1.4 Warranty and liability

All data and information in this operating manual were compiled with consideration of applicable regulations, the current technical/ engineering development status and our many years of knowledge and experience. The actual scope of delivery may dier from the explanations and drawings shown here in case of special designs, if additional options are ordered or due to recent technical modications. If you have any questions, please contact the manufacturer.

1.5 Copyright

The operating manual should be treated as condential. It is intended only for people involved with the system. The operating manual may not be handed over to a third person without the written consent of the manufacturer. If you have any questions, please contact the manufacturer.

This operating manual should be read



carefully before any work is done to and with the device, especially before it is used for the rst time. The manufacturer accepts no liability for damage or faults that result from non-compliance with the operating manual .

We may make technical modications within the scope of improving performance characteristics and in the course of further development. The warranty does not cover components, such as tools, that are subject to normal wear when the device is used as intended or consumables such as grease, oil or cleaning agents. In all other respects, the obligations agreed in the delivery contract shall apply in addition to the manufacturer's general terms and conditions of business and terms and conditions of delivery and the statutory regulations applicable at the time the contract was concluded.

The information, texts, drawings, pictures



and other presentations are protected by copyright and are subject to other industrial property rights. Misuse of the above is indictable.

The content, including excerpts, may not be copied in any way whatsoever, nor may it be utilised or disclosed without the written consent of the manufacturer. Compensation shall be due in case of infringements of the above. We reserve the right to assert further claims.

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VI.GE.T1.02 © Danfoss 12/2010

Installation, start-up and operating instructions FLS-50

1.6 Spare parts

Use only the manufacturer's original spare parts.

1.7 Dismantling

To dispose of the device separately, clean it and dismantle it with consideration of applicable occupational safety and environmental protection regulations. See also: Hygiene.

WARNING! Risk of injury. Stored residual energies, sharp-edged components, sharp points and edges on

and in the device or on the required tools may cause injury. Therefore, all work to dismantle the device must be carried out only by qualied personnel.

WARNING! Not drinking water! Domestic water in system parts that have not been used



for a long period may not have drinking water quality. Please prevent use, empty the system parts and dispose of the water .

Wrong or faulty spare parts may cause damage, malfunctions or complete failure of the system.

If unapproved spare parts are used, this voids all warranty, service, compensation and liability claims against the manufacturer, its agents, dealers and representatives.

Before starting to dismantle the device: – Switch the device o and make sure that it

cannot be switched on again.

– Physically isolate the complete power supply

from the device, discharge stored residual energy properly.

– Remove operating and auxiliary materials and

residual processing materials in an environmentally friendly manner.

1.8 Disposal

If no return or disposal agreement has been made, when components have been properly dismantled dispose of the materials as follows:

• Scrap residual metal materials.

• Have plastic elements recycled.

• Sort and dispose of the other components

according to their properties.

• Dispose of residual media properly. Observe the

statutory regulations when discharging additives (glycol, etc.).

NOTICE!

Electric scrap, electronic components, lubricants and other auxiliary materials



are subject to special waste treatment and may be disposed of only by authorised specialist companies.

Remove substances such as grease, oil, preservatives and cleaning agents from the device separately and in an environmentally compatible manner. Use approved containers to catch and keep the respective substances. Until nal disposal, store containers, clearly marked with information about the content, level and date, in such a way that they cannot be misused.

VI.GE.T1.02 © Danfoss 12/2010

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Installation, start-up and operating instructions FLS-50

2 Safety

This section gives an overview of all important safety aspects for optimum protection of personnel and for the safe and fault-free operation of the device. The individual chapters also contain specic safety information, marked with symbols, to prevent direct hazards.

2.1 General

When it was developed and produced, the device complied with all applicable, acknowledged rules of technology and is deemed to be safe to operate. However, the device may harbour risks if it was installed by unqualied personnel or is not used for its intended purpose. Therefore, every person who is to work on or with the device must have read and understood the operating manual before commencing work. The operator is advised to have personnel conrm that they acknowledge the operating manual. Changes of any type, additions or conversions to the device are not allowed.

2.2 Responsibility of the operator

• Always keep the operating manual near the

device and make sure that it is accessible at all times for installation, operating, maintenance and cleaning personnel.

• Operate the device only in a technically faultless

and safe condition.

• Keep safety features freely accessible at all

times and check them regularly. Statements regarding occupational safety refer to the regulations of the European Union applicable at the time the device was manufactured. The operator must ensure that the listed occupational safety measures comply with the current status of the regulations and observe new regulations throughout the entire service life of the device. Outside the European Union the applicable occupational safety laws and regional regulations and provisions must be complied with. Apart from the occupational safety information in this operating manual, the general safety, accident prevention and environmental protection regulations applicable to the use of

NOTE! Always coordinate any changes or

extensions with the manufacturer.

All safety, warning and operating instructions for the device must be kept in a legible condition. Damaged signs or stickers must be replaced without delay. Specied settings and adjustment ranges must be complied with.

the device must be observed and complied with. The operator and his authorised personnel are responsible for fault-free operation of the device and for clear denition of responsibilities regarding installation, operation, maintenance and cleaning of the device. The information in the operating manual must be followed completely and absolutely. The operator must also ensure that – in a risk assessment other risks arising due to

the particular working conditions at the place where the device is installed are identied.

– all other work and safety information identied

in the workplace risk assessment is dened in operating instructions.

– the German Ordinance on Industrial Safety and

Health (BetrSichV, Federal Law Gazette I 2002,

3777) applies.

DKDHR

2.3 Intended use

The operating safety of the device is guaranteed only if it is used as intended in accordance with the data in the operating manual. Intended use also includes correct adherence to the installation, operation, maintenance and cleaning instructions.

2.4 Possible misuse

The device is installed inside a system and has no separate control. With the installation the operator must ensure that suitable safety features are available so that the device can be shut down in case of danger or faults.

VI.GE.T1.02 © Danfoss 12/2010

Any additional and/or other use of the device is not allowed and shall be deemed to be an unintended use. Claims of any kind against the manufacturer and/or his agents due to damage caused by unintended use of the device shall be excluded. The operator and/or owner shall be solely liable for all damage resulting from unintended use .

NOTE!

e.g. Emergency stop button, etc.

Installation, start-up and operating instructions FLS-50

2.5 Occupational safety

If the instructions on occupational safety are followed, this can prevent risks for persons and/ or the system. Non-compliance with these instructions can result in risks for persons and objects due to

2.6 Personal protective equipment

When working on the device, the following must be worn:

Industrial protective clothing

is tightly tting work clothing with low tear resistance, close tting sleeves and

with no protruding parts. Its main purpose is to protect the wearer when he or she is reaching into moving parts. Do not wear rings, chains or other jewellery.

Protective gloves

to protect the hands against friction, abrasion, puncture wounds or more



serious injuries caused by hot surfaces.

2.7 Potential hazards involving the device

The device was subjected to a risk analysis. The design and construction of the device based on this analysis are state of the art. However, there are residual hazards. The device generates a strong spray of liquid when the drainage or ventilation ttings are opened. The device works with a pressure of 10 bar.

WARNING! Risk of injury.

Risk of liquid spraying out under high



pressure. Wear personal protective equipment when carrying out all work on the device .

The device works with electrical voltages up to 230 V and currents up to 16 A.

WARNING! Risk of injury from electrical

current.



Electrical energies can cause very serious injuries. There is a danger to life if the insulation or individual components are damaged.

– Before carrying out any maintenance, cleaning

or repair work, switch o the main switch and make sure that it cannot be switched on again.

– If work is being carried out on the electrical

system, isolate it from the power supply.

– Do not remove or disable any safety facilities

by altering them.

mechanical eects or failure of the system and the entire workplace. Non-compliance with the safety regulations voids all claims for compensation.

Safety glasses

to protect the eyes against ying parts and splashes of liquid.



Safety shoes

to protect the wearer against falling parts and slipping on slippery oors.



Hard hat

to protect the wearer against falling and ying parts and materials.



WARNING! Risk of injury. Sharp-edged parts of the housing and



sharp corners can cause skin abrasions.

Wear protective gloves when working on the device.

WARNING! Risk of burning. Hot surfaces can cause serious burns. Always



wear personal protective equipment when

carrying out all work on the device .

The device works at a maximum temperature of 95°C.

Components in the device may contain automatic moving parts (motors, gears, etc.). The devices can be very heavy.

WARNING! Crushing hazard. When the device is being



transported, also if lifting equipment is used, crushing can occur due to the weight. The

device may contain components that move with electricity (motors, gears) which could also cause crushing if they are touched during operation. Always isolate the device and wear protective clothing when working on the device.



VI.GE.T1.02 © Danfoss 12/2010

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Installation, start-up and operating instructions FLS-50

2.8 Emergency stop switch

The device is installed inside a system and has no separate control. The operator must ensure that emergency stop switches in compliance with applicable accident prevention regulations are

2.9 Operating personnel

The device may be operated and maintained only by authorised, trained and instructed personnel. These personnel must have been instructed especially about potential risks. An instructed person is deemed to be a person who has been instructed about the work he or she has been entrusted with and the potential risks associated with improper behaviour and, if necessary, who has been instructed about the necessary safety features and safety measures. Trained personnel are deemed to be persons who, due to their professional training, knowledge and experience and knowledge of the relevant regulations, are able to assess the work they have been entrusted with and recognise potential risks. If personnel do not have the required knowledge, they must be trained. The responsibilities for operation and maintenance must be clearly dened and adhered to so that there is no unclear distribution of competency under the aspect of safety.

installed. The operator must prove that he has informed operating personnel about the location and functions of the emergency stop switches.

The device may be operated and maintained only by persons who can be expected to carry out their work reliably. The mode of working must not have an adverse eect on the safety of persons, the environment or the device. Persons under the inuence of drugs, alcohol or medication that slows their reactions may not carry out any type of work on or with the device. The choice of personnel must take account of the national young persons employment laws and any underlying job-specic regulations. Operators must also ensure that no unauthorised persons work on or with the device. Unauthorised persons, such as visitors etc., may not come into contact with the device. They must remain at an appropriately safe distance from the device. Users must report changes on the device that have an adverse eect on safety to the operator immediately.

2.10 What to do in case of danger or accidents

In case of danger or an accident, switch the device o immediately with an emergency stop switch. Safety features with an emergency stop function should be activated only in emergency situations. Safety features may not be used to switch the device o under normal conditions.

Always be prepared for accidents or re. Have rst aid facilities (medical kit, eye rinse bottles, etc.) and re extinguishers nearby. Personnel must be condent in the use of and know the locations of safety, accident reporting, rst aid and rescue facilities. This ensures that risks are averted and that the best possible assistance is given in case of accidents.

DKDHR

VI.GE.T1.02 © Danfoss 12/2010

Installation, start-up and operating instructions FLS-50

2.11 Residual hazards/risk analysis

Location of hazard Type of hazard Aim of protec tion Measure

Shut-o valves and ttings in the station

Piping and components in the station

Complete station Electric shock Safe contact with the station Protection against accidental

Complete station Splashing liquids and/or

Complete station Overheating of the station or

Crushing in case of manual operation

Can burn the skin if touched Safe contact with open

steam under high pressure

heat transfer to the connected house system in excess of the permitted temperature

Manual operation of the shut-o valves and ttings must be possible without danger.

station

Controlled reduction of excess pressure in the event of a fault

Stop heating in case of a fault Safety features acc. to DIN

The design leaves sucient space for ergonomic operation.

Thermal insulation of piping and components Warning signs at the station Warning information in the operating manual

contact

Safety features acc. to DIN 4747 T1 (hot water) and/or DIN EN 12828

4747 T1 (hot water) and/or DIN EN 12828

During operation, the residual hazard can be limited to the following alphabetical value according to Suva risk assessment: B5/C4/D3/E2. The residual hazard potential results from non-compliance with the above operating

instructions. The assemblies were produced according to the explicit specications of the operator, who is responsible for compliance with the specied parameters, selection and qualication of the operating personnel.

The system is equipped with the following warning sign, which points out the most important residual hazards:

The system must be operated only by trained , qualied personnel after they have studied the enclosed documentation in detail. Before the system is started for the rst time, it must be lled and completely deaerated. Exceeding the permitted operating pressure or the maximum permitted operating temperature according to the type plate or any other use apart from the intended use are not allowed.

Risk of burning from touching the surface or from the emissions of hot media (water/

steam). Avoid touching the assembly or wear suitable protective clothing.

Crushing hazard when operating the assemblies

Risk of electric shock before working on the electrical system, isolate it

All ange connections, screw joints and electrical clamp and screw connections must be checked and tightened if necessary before the system is lled and put into operation. Switch pumps on only when they are full (no dry running).

Before starting the system for the rst time, install it professionally (if not

completely assembled in the factory):

• Safety valve/drainage and steam piping according to DIN 4751 and/or DIN 1988

• Strainer in primary supply line/secondary return line

• Potential equalisation acc. to VDE 0100 Part 540 (earthing/earth wires/potential

equalisation)

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Installation, start-up and operating instructions FLS-50

3 Technical data

3.1 Technical and main system data

You will nd the main system data on the type

3.1.1 Circuit diagram

Installe d in top buer tank

Scope of del ivery

Buer tank Top

Buer tank

Return

Buer tank Middle

Buer tank B ottom

3.1.2. Bill of materials

1 Three-way mixer valve 2 Three-way valve On/O 3 Pump 4 Pump, circulation 5 Plate heat exchanger 6 Temperature/ow meter 7 Controller 8 Temperature sensor 9 Safety valve 10 Non-return valve 11 Shut-o valve 12 Temperature sensor 13 Temperature sensor 14 Temperature sensor

plate and in the documents in the appendixes (cover sheet, circuit diagram, data sheet).

CW ¾“

Circ. ¾“

HW ¾“

DKDHR

Optional accessories

Option 1: Temperature control, inlet Option 2: Circulation Option 3: Shut-o valves/ball valves Option 4: Stratication control

3.1.3 Type plate

The type plate is attached to the system. The type plate contains the following data: – Manufacturer – Device no. – Year of construction (year/calendar week) – Type – Power – Dimensioning parameters – Max. permissible operating temperature – Max. permissible operating pressure – Test pressure

VI.GE.T1.02 © Danfoss 12/2010

Example of type plate

Installation, start-up and operating instructions FLS-50

3.1.4 Pressure loss curve

3.1.5 Capacity examples

Capacity examples

Temperature

°C

10/45 20 50 60/20 18 10/45 14 34 50/27 21 10/45 25 60 75/16 15

10/55 18 55 75/20 15 10/55 12 36 60/30 18

* Max. chloride compounds 150 mg/l

Flow rate

l/min.

Power

Supply/Return

Primary

°C

Flow

Primary

l/min.

3.1.6 FLS-50 + Options

When possible options are used the pressure loss ratio changes as shown in the curve below. The TVM-H 25 mixing valve, among other elements, is recommended for primary-side installation with service water values with dH > 20. This means a recommended ow temperature of 65°C can be set.

FLS‐50+Optioner

60,00

55,00

50,00

45,00

40,00

35,00

30,00

dP[kPa]

25,00

20,00

15,00

10,00

5,00

0,00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Q[l/min]

H[m]

FLS‐50PRI

FLS‐50+Optioner

FLS‐50+AMZ113

FLS‐50+TVM‐H25

WiloRS15/6

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Installation, start-up and operating instructions FLS-50

3.1.7 Dimensions and photo of components

1 Three-way valve (option) 2 Three-way valve On/O (option)

3 Pump

4 Pump, circulation (option)

5 Plate heat exchanger 6 Temperature/ow meter 7 Controller 8 Temperature sensor

9 Safety valve (option)

10 Non-return valve

11 Shut-o valve (option)

Primary

Supply

Primary

Return

Primary Domestic

DHW DCW

hot water

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VI.GE.T1.02 © Danfoss 12/2010

130 mm

Installation, start-up and operating instructions FLS-50

4 Function

4.1 Function / General

The FLS-50 is a domestic hot water heater for a single household; the water is heated by an instantaneous water heater in combination with a buer tank. The hot water supply and hot water feed to the buer tank can generally be ensured with solar energy in combination with other energy sources, such as oil or gas boilers, district heating or heat pumps. The instantaneous ow process oers good protection against Legionella because the amount of warm water in the heat exchanger is kept to a minimum. The heat exchanger ensures an adequate supply of domestic hot water at supply temperatures from 50°C. The FLS-50 ensures a constant hot water temperature, even in case of peak ow and uctuation supply temperatures, so that the consuming devices are supplied with sucient hot water in all operating conditions.

Primary circulation system

The primary side consists of a pump, a nonreturn valve and a temperature sensor.

Secondary circulation system

The secondary side consists of a ow/ temperature sensor on the hot water side and a temperature sensor at the cold water inlet.

Control

The electronic controller in the FLS-50 ensures a constant hot water temperature. The controller receives signals from 3 sensors that measure the supply temperature in the primary side in the buer tank, the secondary ow rate, the cold water inlet and the hot water outlet. The electronic controller converts these signals for innitely variable speed control of the primary side pump that supplies the heat exchanger with energy from the buer tank as required.

Options

Options include a primary-side mixer valve, a primary-side switching valve and sensor, an installation kit for HW circulation, constant maintenance of the circulation temperature by power control of the pump and shut-o and non-return valves at the CW inlet.

Construction

All pipes are stainless steel with threaded connections. The entire mechanical construction is xed in a prefabricated EPP insulated cabinet by means of a click-in system and thus ensures stability and easy replacement of spare parts. The FLS-50 is to be installed vertically on the buer tank or on a wall next to the buer tank.

Installe d in top buer tank

Scope of del ivery

Buer tank Top

Buer tank

Return

1 Three-way valve 2 Three-way valve On/O 3 Pump 4 Pump, circulation 5 Plate heat exchanger 6 Temperature/ow meter 7 Controller 8 Temperature sensor 9 Safety valve 10 Non-return valve 11 Shut-o valve 12 Temperature sensor 13 Temperature sensor 14 Temperature sensor

Buer tank Middle

Buer tank B ottom

Optional accessories

Option 1: Temperature control, inlet Option 2: Circulation Option 3: Shut-o valves/ball valves Option 4: Stratication control

Circ. ¾“

DHW ¾“

DCW ¾“

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Installation, start-up and operating instructions FLS-50

5 Setup

5.1 Assembly and installation/general

Domestic water heater systems are usually delivered completely piped and wired in a foam insulated cabinet. All assemblies and components are xed in the insulated cabinet by means of a click-in system. System connections are specied in the data sheet and in these instructions. Make sure that the wall has the necessary load-bearing capacity for the system (including the weight of the water!). Examine the prepared connections carefully so that they can be joined without any tension.

5.1.1 Figure FLS-50

NOTE! Do not use a pipe wrench on screwed

joints. Use only a suitable spanner.

You will nd pictures of the device below.

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VI.GE.T1.02 © Danfoss 12/2010

Assembly holes

Installation, start-up and operating instructions FLS-50

6 Transport, packing and storage

WARNING! Danger to life When the system is being lifted, turned and lowered there is a risk of serious



personal injury and material damage from falling parts. Never stand beneath suspended loads.

Always observe the following safety rules: – Adapt transport to suit local conditions. – Use only approved lifting equipment and

lashing gear with adequate load-bearing capacity.

– Fix the device only on suitable lashing points,

not on protruding machine parts or on rings of built-on components. Make sure that the lashing sits securely.

6.1 Transport pallets with a fork lift truck

Packages that are xed on pallets may be transported by a fork lift truck under the following conditions:

• The fork lift truck must be designed to carry the

weight of the transport units.

• The driver must be authorised to drive the fork

lift truck.

Lifting:

1. Drive the fork lift truck with the forks

between or beneath the cross pieces of the pallet.

2. Drive the forks in so far that they protrude

from the other side of the pallet.

3. Make sure that the pallet cannot topple over if

the centre of gravity is not in the middle.

4. Lift the package and start transporting the

pallet.

WARNING! Danger to life

When the pallet is being lifted, turned

and lowered there is a risk of serious



personal injury and material damage from falling parts. Never stand beneath suspended loads.

– Ropes and straps must have safety hooks. Do

not use damaged ropes or straps with abraded areas. Do not place ropes or straps on sharp edges, do not knot or twist them. Pay attention to the centre of gravity of the device when

lashing. – Never lift, swivel or lower loads above people. – Always take great care and attention when

moving the device.

Transporting with a fork lift truck

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Installation, start-up and operating instructions FLS-50

6.2 Transport inspection

Check the delivery for completeness and transport damage immediately on receipt. In case of obvious transport damage, do not accept the delivery or accept it only with provisions. Record the extent of the damage on the transport documents/forwarder's delivery note.

6.3 Packaging

The devices are delivered in dierent forms of packaging. Packaging may include materials that are added to the packages as moisture or frost protection (e.g. silica gel bags, anti-freeze, etc.). If no other arrangement regarding returning the packaging material has been made, it remains with the customer.

NOTE!



The German Packaging Ordinance that came into eect on 1 December 1991 states that transport packaging may be returned to the

6.4 Storage

When the packages have been unloaded they must be stored until they are to be installed with consideration of the shipping marks. Packaged machine parts and accessories must not be unpacked. The following regulations apply to storage:

– Store in a dry place. Relative humidity:

max. 60 %.

– Make sure that the packages are not stored

outdoors. It must also be ensured that the oor of the storage room is dry while the parts are being stored.

Initiate a complaint. Complain about hidden defects as soon as they become obvious, as claims for compensation can be asserted only within the statutory period.

supplier. Our transport packaging may be returned to your local Danfoss department

as long as we do not incur

any costs. We will not accept transport packaging that is delivered and not prepaid.

NOTICE! Packaging must be disposed of in an environmentally compatible manner and

in agreement with the corresponding disposal regulations. For this purpose DANFOSS has signed an agreement with Interseroh AG and packaging may be deposited at the company's collection points.

– Protect the packages against direct sunlight.

Storage temperature 15 to 25 °C – store dust

free. – Avoid mechanical vibration and damage. – If parts are to be stored for a longer period,

longer than approx. 3 months, the conservation

measures should be checked. In case of

aggressive weather conditions, the

conservation may have to be renewed.

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Installation, start-up and operating instructions FLS-50

7 Installation

WARNING! Risk of injury. Improper installation and assembly can cause serious injury and/or material



damage. Therefore, installation and assembly work may be carried out only by qualied personnel in compliance with the safety regulations.

Pipe connections are generally:

- Heating connections as weld-on ends

- Flange connections acc. to DIN EN (pressure stages PN 6 … 40)

- Threaded connections acc. to DIN 2999 as female or male threads

- Threaded connections acc. to DIN 2993/ISO 228 as male threads

7.1 Assembly preparations

Before starting assembly, check that all assemblies and individual parts are complete and undamaged.

NOTICE! Damaged components must not be assembled. Install only fully intact parts.

7.1.1 Electrical connection

Only a qualied electrician may carry out the electrical installation of the station in compliance with all applicable rules and regulations. The FLS-50 is wired and tested in the factory.

Use only compliant connection parts to connect the system to the household system. Check compliance of the connection type, the pressure stage and the dimension.

Please ensure the following before you begin with the electrical connection:

• Read the relevant parts in the warning information section.

• The station should be connected to a 230 V AC power supply. The power connection must be carried out in accordance with ocial regulations.

• The system must be wired and connected to an external main switch so that it can be switched o for maintenance, cleaning or repair work.

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Installation, start-up and operating instructions FLS-50

Electrical connection Fresh water controller FWC3

Sensor side

max. 12V

Note

Extra low voltages max. 12VAC/DC

Connection in left terminal compartment

Terminal: Connection for: S1 PT1000 cold water (Optional, see below) S2 PT1000 circulation S3 PT1000 buer tank opt. S4 Supply primary opt. S5 VFS hot water (yellow wire) S6 VFS ow l/min (white wire) + VFS +5V DC (brown wire)

- Bridge sensor -

The PT1000 sensor can be poled any way.

Power supply side

230VAC

Danger

Power supplies 230VAC 50-60Hz

Connection in right terminal compartment

Terminal: Connection for: L Power supply outer cable L N Power supply neutral conductor N R1 Fresh water pump L N Fresh water pump N R2 Circulation pump L N Circulation pump N

The earth wire PE is connected to the PE metal terminal block

Relay R1: Only for controlling the speed of standard pumps, min.

Note

load 20VA

The sensor earth (S1-S4) and the VFS (green wire) are connected to the sensor terminal block - .

Sensor1/Cold water: If no sensor is connected, a temperature of 10°C is assumed for the cold water. See also 11.2 Sensor calibration on Page 22

Sensor mounting S3 contact sensor must be mounted on

the primary return before the switching valve.

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Installation, start-up and operating instructions FLS-50

Electrical connection Fresh water controller FWC4

Sensor side

max. 12V

Note

Extra low voltages max. 12VAC/DC

connection in left terminal compartment.

Terminal: Connection for: S1 PT1000 cold water (Optional, see below) S2 PT1000 circulation S3 Primary, return (opt.) S4 Primary, supply (opt.) S5 not occupied S6 0..10 V / PWM + not occupied

- Bridge sensor -

Power supply side

230VAC

Danger

Power supplies 230VAC 50-60Hz

Connection in right terminal compartment

Terminal: Connection for: L Power supply outer cable L N P o we r su pp ly n eu tra l conductor N R1 Fresh water pump L N Fresh water pump N R2 Circulation pump L N Circulation pump N R3 Valve, return L (opt.) N Valve, return N (opt.)

The PT1000 sensor can be poled any way

The earth wire PE is connected to the PE metal terminal block

Relay R1: Only for controlling the speed of standard pum ps, min.

Note

load 20VA

The sensor earth (S1-S4) is connected to the sensor terminal block - . The VFS sensor is inserted directly into the slot on the circuit board in the sensor terminal area

Sensor1/Cold water: If no sensor is connected, a temperature of 10°C is assumed for the cold water. See also 11.2 Sensor calibration.

Sensor mounting S3 contact sensor must be mounted on the primary return before the switching valve.

S4 tank sensor is provided and must be mounted at the top in the buer tank.

AMZ 113 switching valve is provided and must be mounted in the primary return and connected electrically to the Mate-n-lok.

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Installation, start-up and operating instructions FLS-50

7.1.2 Assembly of FLS-50

The device may be installed and connected only by authorised personnel. Installation must be in compliance with the local standards and regulations.

The FLS-50 must be equipped with features that ensure that the device can be separated from all energy sources.

When the device is being installed, attention must be paid that the domestic water heater remains accessible for assembly and maintenance work.

All pipes and connections must be cleaned and rinsed before installing the domestic water heater

IMPORTANT! Tighten all screws and connections since they may have become loose during transport.

The water heater is intended for wall installation. Fix the station to the wall with two bolts, screws, expansion plugs or similar.

With systems with a safety valve, a connection for drainage must be constructed in accordance with local regulations.

Assembly holes

All pipe connections have a thread ex factory

Earth:

H 375 x W 345 x D 250 mm

Connections:

1 Primary supply, 2 Primary return 3 DCW supply 4 DHW supply

Connection dimensions:

All connections: G¾ (IG)

Weight: Approx. 11 Kg

1 2 3 4

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Installation, start-up and operating instructions FLS-50

7.1.2.1 Assembling the basic device

The station is delivered in a foam insulated cabinet - as a click-in system. The station is installed in the bottom part of the insulated cabinet.

Please note: The buer tank temperature sensor is delivered separately and has to be installed on site and be connected to the controller. 3 m cable for the buer tank temperature sensor is preinstalled in the controller

1) Install the temperature sensor (delivered separately) at the top of the buer tank.

2) Install cable (preinstalled from controller) from the station to the temperature sensor.

3) Connect the temperature sensor to the cable.

4) Connect the power socket (Schuko) to 230 V AC.

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Installation, start-up and operating instructions FLS-50

7.1.2.2 Assembling Option 1

Primary mixer valve

7.1.2.3 Assembling Option 2

Circulation

The TVM-H is an automatic three-way mixer valve with inbuilt thermostat to maintain and ensure a constant temperature.

For further information, see the enclosed operating instructions TVM-H / TVM-W.

A complete circulation kit is available as an option for connecting a circulation system:

Gasket ¾" 24 x 17.5 x 3 mm (145.056) (1) Circulation kit, complete (oem. 134.102) (2) Gasket ¾" 24 x 17.5 x 3 mm (145.056) (1).

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Installing the circulation kit:

• Dismantle the double socket joint (in Point A).

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Installation, start-up and operating instructions FLS-50

• Install the gasket and circulation kit in Point A.

• Replace the double socket joint and the gasket (in Point B).

Connect the temperature sensor to the controller in terminal S2 and minus (÷).

Connect the pump to the controller in terminal R2, neutral and to the earth.

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Installation, start-up and operating instructions FLS-50

7.1.2.4 Assembling Option 3

Non-return valve and shut-o valve

The non-return valve and the ball valve can be installed directly on the station (see Photo 1) (please note: dismantle the double socket joint in Point A before installing the non-return valve and the ball valve), or on the circulation kit (see Photo 2).

Gasket ¾" 24 x 17 x 1 mm (171.040) (1) Non-return valve (135.120) (2) Gasket ¾" 24 x 17 x 1 mm (171.040) (1) Ball valve ¾" M/N (131.055) (3)

Photo 1

Photo 2

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Installation, start-up and operating instructions FLS-50

7.1.2.5 Assembling Option 4

In this version the station is built with the Sorel FWC 4 Controller. Cables for the switching valve and the sensors have to be wired on site.

The AMZ 113 is a three-way switching valve for optimum zone control.

For further information, see the enclosed operating instructions AMZ 113.

Connect the controller in terminal S3 and minus (÷).

Datablad ON/OFF Zoneventiler

Anvendelse

Anlægseksempler

2-vejs type AMZ 112

3-vejs type AMZ 113

2-vejs zoneventil AMZ 112 anvendes i centralvarme- og fjernvarmeanlæg til ON/ OFF regulering af enkelte eller flere varme/ køleflader.

Begge motorer kan styres af et SPST kontaktsæt med sluttefunktion eller en SPDT skiftekontakt. Motorerne er desuden forsynet med endestopkontakt til signal eller til start af pumpe, blæser eller kedel ved helt åben ventil. Der er mulighed for manuel betjening. Ventiler leveres med indvendigt gevind i str. DN 15, 20 og 25.

RA 2000 RA 2000

Zonestyring af radiatoranlæg

Styring af fastbrændsel i forbindelse med kedel Prioritetsstyring af varmtvandsbeholder

VD.HC.N1.01 © Danfoss 11/03 1

3-vejs zoneventil AMZ 113 er en skifteventil, der anvendes til fordeling af vandstrømme i f.eks kedelanlæg i forbindelse med fastbrændselskedel e ller til pri oritetsstyring.

TP7000 M/A

AMZ 112

Zonestyring af varmeblæsere

VVS-automatik 9.10.00

AMZ 112

RA 2000

Connect the three-way valve to the controller in terminal R3, neutral L and to the earth.

DKDHR

Installation, start-up and operating instructions FLS-50

8 Start-up The following measures must be carried out:

– The rst time the device is used (see appendix,

Start-up log)

– When the device is restarted after complex

maintenance work has been carried out

– When the device is restarted after having

been relocated

– When the device is restarted after a fault has

been rectied.

– When the device is restarted after it has not

been used for a long period

– Check the water quality. Max. 150 mg/l

Before start-up check that all safety regulations have been observed. Fill the household system with domestic water. To prevent damage, make sure that when the system is being lled the pressure does not exceed the permitted operating pressure.

8.1 Controller

The electronic controller is set in the factory.

Connect the controller to the power supply. Select the language, set the date and time and the controller is ready for operation.

NOTE!



Pay attention to the measures required to maintain domestic water quality. Important information can be found in the technical rules (see overview of regulations in the Appendix).

By agreement, the device is installed and started up for the rst time by the manufacturer's employees, authorised partner companies or the specialist installation company. Customers must not start the device for the rst time on their own.

In any case, the completed start-up log (see appendix) is a requirement for the device warranty.

Before the rst start-up, the installation company should rinse the secondary side adequately. Check that all connections are sealed and joined properly. Fill the system to the required static height.

SPECIAL WARNING!



If a circulation kit is connected, you must select menu item 5.4 "Circulation On" to switch on the circulation pump.

Changes to the settings can be made according to the controller manufacturer's instructions, which are enclosed with the station.

DKDHR

Installation, start-up and operating instructions FLS-50

9 Operation

The system is operated in automatic mode. During operation no personnel are needed near the system.

8.2 Fault and shutdown

WARNING! Risk of injury from electrical current. Leaking water can make the entire



system live, which can endanger life. Before starting work, isolate the system and make sure that it cannot be switched on again.

WARNING! Risk of burning.

In case of leaks on the primary side, water

at temperatures up to 95°C can escape.



Risk of burning.

8.3 Restarting after a fault

After a fault, the system is restarted by the specialist company.

9.1 Switching the device on

To switch the device on, pay attention to the requirements described in Section 8 " Start-up".

9.2 Switching the device o

The device is switched o at the main switch of the electronic controller.

The heating pump is connected to the power supply. Immediately switch o the main switch or remove the plug. Close the shut-o tting. It is important that you have a specialist company rectify the fault.

The system can be switched on at the main switch of the electronic controller and then it operates automatically.

DKDHR

Installation, start-up and operating instructions FLS-50

10 Maintenance

10.1 Safety information

The appendix contains an overview of the most

WARNING! Work on the device may be carried out only by qualied, specially trained

personnel. The following personal protection equipment must always be worn close to the device:

– Close tting clothing (no loose sleeves,

rings, etc.)

– Safety glasses to protect the eyes against

ying parts and liquids

– Safety shoes to protect the wearer against

falling parts and slipping on slippery oors.

WARNING! Risk of injury from electrical current. Only qualied electricians may work on



electrical systems observing the applicable safety regulations. Before starting work, switch of the power supply and make sure that it cannot be switched on again.

Maintenance schedule (recommendations)

Interval Maintenance work Comments

Check all connections tighten if necessary and/or replace gaskets

Check all parameters for set/target values and permissibility

General visual check of all components for damage

Check the functions of the safet y valve see also DIN 1988

Every 12 months

Check the functions of electric and elec tronic components, switches, etc.

Clean lters and strainers see also DIN 1988

Check the electric safety features Temperature monitor and/or limiter

Check all components for function and operability

Check outer condition Colouring (rust), thermal insulation

important technical regulations. For maintenance of the system you will nd information especially in DIN 1988, VDI 2895 and VDI 6023. We recommend that you arrange for a local installation company to service the system regularly. Section 10.2 contains the most important measures for specic components and assemblies. The appendix also contains the corresponding maintenance and operating instructions for individual components that should be observed.

In case any are exceeded: Restore the proper parameters

in case of obvious damage, check the functions and replace if necessary

Manual switching on and o and opening and closing of motor drive systems

e.g. open and close shut-o ttings

DKDHR

SPECIAL WARNING!



After maintenance work has been carried

out, all EPDM gaskets should be replaced.

Installation, start-up and operating instructions FLS-50

10.2 Maintenance work

The main jobs that should be carried out within the scope of maintenance are described below. Additional information can be found in the manufacturers' instructions in the appendix. This list is not complete. In any case, it is important that the statutory and other relevant technical regulations and requirements based on local conditions are observed (e.g. TABs, power company regulations, etc.)

Fittings: Generally, the ttings used are maintenance free. Within the scope of maintenance work the functions should be checked in terms of moveability of hand wheels and levers by opening and closing them.

This prevents dirt and calcium residues settling on balls, valve discs and valve seats. In Appendix I you will nd the manufacturers' instructions for the most common components.

Heat exchanger: After long operation, because of the relatively high temperatures the plates or tubes of heat exchangers are especially subject to calcication. Within the scope of the above maintenance work these should be cleaned if there is a reduction in power. Brazed plate heat exchangers can be rinsed. In case of more serious deposits, weak inhibited acid solutions (e.g. 5% formic, acetic or phosphoric acid) may be used. The drawing shows this arrangement:

Rinsing/cleaning brazed plate heat exchangers

Tank: Appendix 1 (No. 3) contains information about this.

10.3 Measures after maintenance work

After maintenance work and before switching the device on again, remember: – Check that all screwed connections are tight. – Check that all safety features, covers, tank lids

that were removed have been replaced properly.

– Make sure that all tools, materials and other

equipment that were used have been removed from the working area.

Tubes: The tubes used are made from high-quality stainless steel. If they are contaminated, they can be treated like the tank.

– Clean the working area and remove any

spilled materials, such as liquids, processing material.

– Make sure that all safety features on the

device and the system work properly.

DKDHR

Installation, start-up and operating instructions FLS-50

11 Faults

Faults in electrical systems or in mechanical or hydraulic components may be repaired only by specially trained and qualied personnel. In case of faults that cannot be rectied with the following measures, notify the manufacturer or an authorised service partner.

11.1 Functional faults

Fault Possible cause Rectifying the fault Comment

Domestic hot water temperature too low

Water hygien e at risk!

Domestic hot water temperature too high

Risk of sc alding.

Domestic hot water temperature uctuates or is not constant

Risk of sc alding.

Medium leaking

Risk of sc alding.

No power - Switch on the main switch - Check

No water supply

- no cold water pressure

Incorrec t controller setting(s) Correct settings Controller instructions

Closed shut-o tting(s) Open tting

Defective sensor Replace sensor

Supply pump defective or not switched on

Circulation pump defective or not switched on

Defective VFS valve Clean/ensure smooth operation or

System wrongly dimensioned - Check dimensioning

System unable to provide sucient water

Heat exchanger furred up Replace heat exchanger

Cavitation on the pump Increase primary system pressure Pump makes noises

- No power supply

- Electric drive open

Incorrec t controller setting(s) Correct settings Controller instructions

Defective sensor Replace sensor

Defective VFS valve Clean/replace valve

Incorrec t controller setting(s) Correct settings

Pump defec tive Replace pump

Leaking connections (ange/ screw joints)

Leaking ttings (housing/screw joints)

- Leaks from brazed heat exchangers

- Contamination/calcication Pressure surges

the inlet lines

- Check fuses/circuit breaker

Operating conditions - Pressure Volume

Switch on/replace

replace

- Extend/enlarge system

- Check dimensioning

- Extend/enlarge system

- Take system out of op eration

- Ensure power supply

- Manual emergency operation

- Controller gain

- Reset time

- Valve travel time

Switch system o

- Check operating parameters for permissibility (see type plate)

- Check connection, tighten if necessary, replace gaskets

- Check that t tings are installed correctly - Tighten stung (gasket) sleeves or replace component

Replace device See manufacturer's

Water supplier

Contact our exper t advisors

Controller instructions

See manufacturer's instructions or contact customer service

instructions or contact customer service

DKDHR

Installation, start-up and operating instructions FLS-50

11.2 Safety information

WARNING! If faults are not rectied properly, this can lead to serious injury and/or



material damage Therefore, faults may be rectied only by trained and authorised personnel.

12 Spare parts

11.3 What to do in case of faults

In all cases:

1. In case of faults that represent a direct danger

for people, property and/or operating safety, immediately stop the system with the emergency stop function.

2. In case of faults that do not cause such

dangers, switch the system o using the system controls, also interrupt the power supply to the system and make sure that it cannot be switched on again.

Use only the manufacturer's original spare parts.

NOTICE! Wrong or faulty spare parts and components from third-party



manufacturers can cause serious damage, incorrect functions or complete failure of the device.

If unapproved spare parts are used, this voids all warranty, service, compensation and liability claims against the manufacturer, its agents, dealers and representatives.

When ordering spare parts, you must provide: – Device type – Serial/Production No. – Part No. /Article Number (see bill of materials

circuit diagram)

3. Immediately notify the person responsible about the fault.

4. Have the type and scope of the fault identied by authorised, qualied personnel, determine the cause of the fault and have it rectied.

– Quantity – Name – Required form of delivery (post, freight, sea,

air, express)

– Shipping address – If necessary, a sketch or photo with comments Orders for spare parts without the above information cannot be handled. If no information about the type of shipping is provided, the parts will be delivered according to the supplier's preference. Appendix I also contains a list of the most important suppliers of bought-in components, where spare parts can also be requested after the end of the warranty period . In these cases, also notify the manufacturer about the installed parts in detail, so that equal replacements can be oered.

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