Danfoss H28, H35, H42 Operating guide

Instructions

Kompakt H28/35/42

1.0 Table of contents

1.0	Table of contents......................................................................................................................................................................................................................			1
2.0	Safety notes................................................................................................................................................................................................................................			2
3.0	Storage and Handling.............................................................................................................................................................................................................			2
4.0	Disposal.......................................................................................................................................................................................................................................			2
5.0	Diagram - Example..................................................................................................................................................................................................................			3
	5.1	H 228 / H 235 / H 242 ECL 200/P30 (with connection pipes for DHW cylinder on supply line).........................................................		3
	5.2	H 328 / H335 / H342 ECL 300/C66 (with connection pipes for DHW cylinder on supply line)...........................................................		4
	5.3	H 242 ECL 200/P30 (with connection pipes for DHW cylinder on supply line - Customized solution with twin pump)........		5
6.0	Main components  ...............................................................................................................................................................................................................			6
	6.1	H 228 ECL 200/P30.........................................................................................................................................................................................................		6
		6.1.1 Measurements .....................................................................................................................................................................................................		6
		6.1.2 Connections..........................................................................................................................................................................................................		6
	6.2	H 328 ECL 300/C66........................................................................................................................................................................................................		7
		6.2.1 Measurements......................................................................................................................................................................................................		7
		6.2.2 Connections..........................................................................................................................................................................................................		7
	6.3	H 235/H 242 ECL 200/P30...........................................................................................................................................................................................		8
		6.3.1 Measurements......................................................................................................................................................................................................		8
		6.3.2 Connections..........................................................................................................................................................................................................		8
	6.4	H 335/H 342 ECL 300/C66...........................................................................................................................................................................................		9
		6.4.1 Measurements.....................................................................................................................................................................................................		9
		6.4.2 Connections.........................................................................................................................................................................................................		9
7.0	Mounting  .............................................................................................................................................................................................................................			10
	7.1	Protective cardboard and film wrapping...........................................................................................................................................................		10
	7.2	Moving substation to the installation place......................................................................................................................................................		10
	7.3	Removing the substation from the pallet..........................................................................................................................................................		10
	7.4	Lifting the substation................................................................................................................................................................................................		10
	7.5	Mounting.......................................................................................................................................................................................................................		11
	7.6	Variable connection possibilities...........................................................................................................................................................................		11
	7.7	Tightening of connections.......................................................................................................................................................................................		11
	7.8	Connection of expansion vessel............................................................................................................................................................................		11
	7.9	Heat meters, Fitting pieces......................................................................................................................................................................................		12
	7.10 Mounting of outdoor temperature sensor (S1)................................................................................................................................................			12
	7.11 Mounting of immersion sensor .............................................................................................................................................................................			13
8.0	Filling, Start-up.......................................................................................................................................................................................................................			13
9.0	Manometer and filling.........................................................................................................................................................................................................			14
10.0 Electrical connections..........................................................................................................................................................................................................				14
11.0 Description..............................................................................................................................................................................................................................				15
12.0 Heating circuit........................................................................................................................................................................................................................				15
	12.1 Temperature control...................................................................................................................................................................................................			15
	12.2 Heating circuit, temperature control ECL 200/P30........................................................................................................................................			16
	12.3 Heating circuit, temperature control H 328/35/42 ECL 300/C66...............................................................................................................			17
		12.3.1 Differential pressure controller .................................................................................................................................................................		17
13.0 Circulation pump  ..............................................................................................................................................................................................................				18
	13.1 Alternative Circulation pump Grundfos Magna 25-100................................................................................................................................			18
	13.2 Alternative Circulation pump Grundfos Magna-D 32-120F.........................................................................................................................			19
14.0 Domestic hot water  .........................................................................................................................................................................................................				20
	14.1 Domestic hot water temperature control .........................................................................................................................................................			20
	14.2 2-vay valve + actuator...............................................................................................................................................................................................			20
15.0 Maintenance...........................................................................................................................................................................................................................				21
16.0 Troubleshooting.....................................................................................................................................................................................................................				22
	16.1 Troubleshooting - Heating.......................................................................................................................................................................................			22
	16.2 Troubleshooting - Domestic hot water...............................................................................................................................................................			24
17.0 EC-Declaration of Conformity...........................................................................................................................................................................................				26
Danfoss District Energy			VI.GP.B1.02	DKDHR		1

Instructions	Kompakt H 28/35/42

2.0 Safety notes

Instructions

This operating manual should be read carefully before installation and start-up of the substation. 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.The risk of persons being injured and equipment damaged increases considerably if the recommended permissible operating parameters are exceeded.

Installation, assembly work, first start-up and maintenance work may be carried out only by qualified and authorized personnel in compliance with the safety regulations (both heating and electrical work).

Energy source

The substation is designed for district heating as the primary source of energy. However, also other energy sources can be used where the operating conditions allow it and always are comparable to district heating.

Application

The substation is designed only to operate with water or a water-glycol mixture (up to 40%), and other heating media may not be used. Connect the substation to the house installation in a frost-free room, where the temperature does not exceed 50 °C and the humidity does not exceed 60%. Do not cover or wall up the substation or in any other way block the entrance to the station.

Choice of material

Choice of materials always in compliance with local legislation.

Corrosion protection

The maximum chloride compounds of the flow medium should not be higher than 300 mg/l. The risk of equipment corrosion increases considerably if the recommended permissible chloride compounds are exceeded.

Safety valve(s)

We recommend mounting of safety valve(s), however, always in compliance with local regulations.

Sound level.

≤ 55 dB.

3.0Storage and Handling

Connection

The substation must be equipped with features that ensure that the substation can be separated from all energy sources (also power supply).

Warning of hot surfaces

Parts of the substation may become hot and hot surfaces can cause serious burns. Please be extremely cautious in close prox- imi-ty to the substation.

Warning of high pressure and high temperature

The stations work at a maximum supply temperature from the district heating network of 120°C and the stations work with a operating pressure of 16 bar, which may put the user at risk of burns from touching the surface or from the emissions of hot media (water/steam). The risk of persons being injured and equipment damaged increases considerably if the recommended permissible operating parameters are exceeded.

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 substation, inform the operating personnel and call for expert help immediately.

Warning of transport damage

Before substation installation, please make sure that the substation has not been damaged during transport. Always transport the substation with the utmost care and caution.

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.

(Do not overstrain! - See item 7.7)

If the substation is stored before installation, make sure that the place is dry and heated.

(Humidity max. 60% and storage temperature 5-70 °C).

Do not stack the unit higher than factory shipped. Units that are shipped in cardboard packaging are to be lifted by the carrying handles of the packaging. Transport / removals over great distances should be carried out on pallets.

During and after unpacking, the substation can be lifted by using straps, fitted around the pipes or it can be lifted by hand in the pipes Lifting in the pipes can cause leaks. ALWAYS re-tighten.

Handling

When working on the substation suitable safety shoes must be worn.

4.0Disposal

Dispose of packaging material in accordance with local regulations.

This product consists of materials, which must not be disposed of together with domestic waste. Switch off the complete power supply and dismantle the product and sort the components in various groups before disposal. Always observe the disposal rules of the local legislation.

2 DKDHR

VI.GP.B1.02

Danfoss District Energy

Instructions	Kompakt H 28/35/42

5.0Diagram - Example

5.1H 228 / H 235 / H 242 ECL 200/P30 (with connection pipes for DHW cylinder on supply line)

1	Plate heat exchanger, HE, with insulation

5Strainer

6Non-return valve

7Ball valve

8Circulation pump HE (P1)

11	Safety valve, HE 3,5 bar

13Thermometer

14Manometer

15Manometer

17	Air vent
19	Connection for expansion vessel

23Sensor pocket for heat meter ½“

24Fitting piece for heat meter, 3/4” x 110 mm

25Controller Danfoss ECL 200/P30

26Outdoor sensor Danfoss ESMT (S1)

27Sensor Danfoss ESM11 (S3 supply, S4 return)

29Danfoss actuator AVM 10 / 20 (M1)

30Danfoss flow controller with integrated control valve AVQM

P, M and S refer to ECL Instruction manual

Danfoss District Energy

VI.GP.B1.02

DKDHR 3

Instructions	Kompakt H 28/35/42

5.2 H 328 / H335 / H342 ECL 300/C66 (with connection pipes for DHW cylinder on supply line)

1	Plate heat exchanger, HE, with insulation

4Differential pressure controller AVP-F

5Strainer

6Non-return valve

7Ball valve

8Circulation pump HE (P1)

9Cable for circulation pump (not part of dly) for DHW cylinder (P3)

11	Safety valve, HE 3,5 bar

13Thermometer

14Manometer with shut-off valve

15Manometer

17	Air valve
19	Connection for expansion vessel

23Sensor pocket for heat meter ½“

24Fitting piece for heat meter, 3/4” x 110 mm

25Controller Danfoss ECL 300/C66

26Outdoor sensor Danfoss ESMT (S1)

27Sensor Danfoss ESM11 (S3 supply, S4 return, S6 return DHW cylinder)

28Immersion sensor Danfoss ESMB (S5)

29Danfoss actuator (M1)

302-way valve VS2 / VM2

31Actuator Actuator AMV /10/150 (M2)

322-way valve VS2 / VM2

P, M and S refer to Danfoss ECL instructions

4 DKDHR

VI.GP.B1.02

Danfoss District Energy

Instructions	Kompakt H 28/35/42

5.3 H 242 ECL 200/P30 (with connection pipes for DHW cylinder on supply line - CUSTOMIZED SOLUTION WITH TWIN PUMP)

1	Plate heat exchanger, HE, with insulation

5Strainer

6Non-return valve

7Ball valve

8Twin pump for HE (P1)

11	Safety valve, HE 3,5 bar

13Thermometer

14Manometer with shut-off valve

15Manometer

17	Air valve
19	Connection for expansion vessel

23Sensor pocket for heat meter ½“

24Fitting piece for heat meter, 3/4” x 110 mm

25Controller Danfoss ECL 200/P30

26Outdoor sensor Danfoss ESMT (S1)

27Sensor Danfoss ESM11 (S3 supply, S4 return)

29Danfoss actuator (M1)

30Danfoss flow controller with integrated control valve AVQM

P, M and S refer to Danfoss ECL instructions

Danfoss District Energy

VI.GP.B1.02

DKDHR 5

Instructions	Kompakt H 28/35/42

6.0 Main components

6.1 H 228 ECL 200/P30

1 Plate heat exchanger

8 Circulation pump, HE (P1)

24Fitting piece for heat meter

25Electronic control

29Actuator AMV(10/20) (M1)

30Flow controller with integrated control valve AVQM

Please note:

Your substation may look different than the substation shown, as variants with other components may be supplied. The control function, however, is basically as stated in this instruction manual.

Instructions for the fitted components will be supplied together with the substation.

25

1

29

30

24

8

24

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	Primary					Secundary

6.1.1 Measurements

Dimensions without cover

H1350 x Wmax. 917 x D380 mm

6.1.2 Connections

Order:

1District heating (DH) supply

2District heating (DH) return

3Heating (HE) supply

4Heating (HE) return

5Cylinder supply

6Cylinder return

Connection sizes (example:

DH:	G1¼ (ET)
HE:	G1¼ (IT)
Cylinder:	G1” (ET)

Please note:

The connection sizes are adapted to the pipe dim. as follows: Pipe dim. 28 mm: 1¼ connection

Pipe dim. 35 mm: 1½” connection Pipe dim. 42 mm: 2” connection

6 DKDHR

VI.GP.B1.02

Danfoss District Energy

Instructions	Kompakt H 28/35/42

6.2 H 328 ECL 300/C66

1 Plate heat exchanger

4 Differential pressure controller AVP-F

8 Circulation pump, HE (P1)

24Fitting piece for heat meter

25Electronic controller

29Actuator AMV (10) (M1)

302-way valve VM2 /VS2

31Actuator AMV /10/150 (M2)

322-way valve VS2 / VM2

Please note:

Your substation may look different than the substation shown, as variants with other components may be supplied. The control function, however, is basically as stated in this instruction manual.

Instructions for the fitted components will be supplied together with the substation.

6.2.1 Measurements

Dimensions without cover

H1350 x Wmax. 917 x D380 mm

6.2.2 Connections

Order:

1District heating (DH) supply

2District heating (DH) return

3Heating (HE) supply

4Heating (HE) return

5Cylinder supply

6Cylinder return

Connection sizes (example):

DH:	G1¼ (ET)
HE:	G1¼ (IT)
Cylinder:	G1” (ET)

Please note:

The connection sizes are adapted to the pipe dim. as follows: Pipe dim. 28 mm: 1¼ connection

Pipe dim. 35 mm: 1½” connection Pipe dim. 42 mm: 2” connection

25

1

29 31

30 32

24 8

4

24

	<![if ! IE]> <![endif]>DH return	<![if ! IE]> <![endif]>DH supply		<![if ! IE]> <![endif]>HE return		<![if ! IE]> <![endif]>HE supply		<![if ! IE]> <![endif]>Cylinder supply	<![if ! IE]> <![endif]>Cylinder return
		Primary						Secundary

Danfoss District Energy

VI.GP.B1.02

DKDHR 7

Instructions	Kompakt H 28/35/42

6.3 H 235/H 242 ECL 200/P30

1 Plate heat exchanger

8 Circulation pump, HE (P1)

24Fitting piece for heat meter

25Electronic controller

29Actuator AMV 20 (M1)

30Flow controller with integrated control valve AVQM

Please note:

Your substation may look different than the substation shown, as variants with other components may be supplied. The control function, however, is basically as stated in this instruction manual.

Instructions for the fitted components will be supplied together with the substation.

6.3.1 Measurements

Dimensions without cover

H1450 x Wmax. 1621 x D575 mm

6.3.2 Connections

Order:

1District heating (DH) supply

2District heating (DH) return

3Heating (HE) supply

4Heating (HE) return

5Cylinder supply

6Cylinder return

Connection sizes

DH:	G2” (IT)
HE:	G2” (IT))
Cylinder:	G1½” (IT)

Please note:

The connection sizes are adapted to the pipe dim. as follows: Pipe dim. 28 mm: 1¼ connection

Pipe dim. 35 mm: 1½” connection Pipe dim. 42 mm: 2” connection

1 30

29

24

8

25

24

<![if ! IE]> <![endif]>DH return	<![if ! IE]> <![endif]>DH supply		<![if ! IE]> <![endif]>HE return		<![if ! IE]> <![endif]>HE supply	<![if ! IE]> <![endif]>Cylinder supply	<![if ! IE]> <![endif]>Cylinder return
	Primary				Secundary

8 DKDHR

VI.GP.B1.02

Danfoss District Energy

Instructions	Kompakt H 28/35/42

6.4 H 335/H 342 ECL 300/C66

1 Plate heat exchanger

4 Differential pressure controller AVPF

8 Circulation pump, HE (P1)

24Fitting piece for heat meter

25Electronic controller

29Actuator AMV 20 (M1)

302-way valve VM2

31Actuator AMV 10 / 150 (M2)

322-way valve VS2 / VM2

Please note:

Your substation may look different than the substation shown, as variants with other components may be supplied. The control function, however, is basically as stated in this instruction manual.

Instructions for the fitted components will be supplied together with the substation.

6.4.1 Measurements

Dimensions without cover

H1450 x Wmax. 1485 x D575 mm

6.4.2 Connections

Order:

1District heating (DH) supply

2District heating (DH) return

3Heating (HE) supply

4Heating (HE) return

5Cylinder supply

6Cylinder return

Connection sizes (example):

DH:	G1½ (IT)
HE:	G1½ (IT))
Cylinder:	G1¼ (IT)

Please note:

The connection sizes are adapted to the pipe dim. as follows: Pipe dim. 28 mm: 1¼ connection

Pipe dim. 35 mm: 1½” connection Pipe dim. 42 mm: 2” connection

1
								29				31
				30									32
			24
								8									25
		24
											4

<![if ! IE]> <![endif]>DH return	<![if ! IE]> <![endif]>DH supply		<![if ! IE]> <![endif]>HE return		<![if ! IE]> <![endif]>HE supply	<![if ! IE]> <![endif]>Cylinder supply	<![if ! IE]> <![endif]>Cylinder return
	Primary				Secundary

Danfoss District Energy

VI.GP.B1.02

DKDHR 9