Danfoss Termix AT BTD Operating Manual

Operatingguide

TermixATBTD

1.0TableofContents

1.0TableofContents.............................................1

2.0Functionaldescription......................................2

3.0Safetynotes.....................................................3

3.1SafetyNotes–general............................................3

4.0Mounting........................................................4

4.1Mounting...........................................................4

4.2Start-up..............................................................5

5.0MountinginstructionsT ermixATBTDwall

cabinet............................................................6

5.1Mounting...........................................................6

6.0Design.............................................................8

6.1DesignTermixATBTD5pipes...................................8

6.2SchematicdiagramT ermixATBTD5Pipes....................9

6.3DesignTermixATBTD4pipes...................................10

6.4SchematicdiagramT ermixATBTD4Pipes....................11

7.0Controls..........................................................12

7.1DHWtemperaturecontrol........................................12

7.2Other.................................................................13

7.3Maintenance........................................................14

8.0Troubleshooting..............................................15

8.1Troubleshootingingeneral......................................15

8.2TroubleshootingDHW............................................15

8.3Disposal.............................................................16

9.0Declaration......................................................19

9.1Declarationofconformity........................................19

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OperatingguideTermixATBTD

2.0Functionaldescription

Districtheatingsubstationwithtankfordomestichotwater
preparationandwiththermostaticcontrol.Designedfor
wall-mounting.

Application

TheTermixA TBTDsubstationisacompletesolutionforhot
water.TheT ermixATBTDisapplicableforsingle-familyhouses
orapartments.

Domestichotwater(DHW)

Thedomestichotwatercircuitconsistsofahotwatertankwithcoil
andself-actingthermostaticcontrolvalve.Thehotwatertankand
coilareenamelledandthetankcontainsamagnesiumanode.The
substationisdeliveredwithabuiltinsafetyvalve.

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3.0Safetynotes

3.1SafetyNotes–general

Thefollowinginstructionsrefertothestandarddesignof
substation.Specialversionsofsubstationsareavailableon
request.

Thisoperatingmanualshouldbereadcarefullybeforeinstallation
andstart-upofthesubstation.Themanufactureracceptsno
liabilityfordamageorfaultsthatresultfromnon-compliancewith
theoperatingmanual.Pleasereadandfollowalltheinstructions
carefullytopreventaccidents,injuryanddamagetoproperty.
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
Pleasecomplywiththeinstructionsissuedbythesystem
manufacturerorsystemoperator.

Corrosionprotection

Allpipesandcomponentsaremadeofstainlesssteelandbrass.
Themaximumchloridecompoundsoftheowmediumshouldnot
behigherthan150mg/l.
Theriskofequipmentcorrosionincreasesconsiderablyifthe
recommendedlevelofpermissiblechloridecompoundsis
exceeded.

Energysource

Thesubstationisdesignedfordistrictheatingastheprimary
sourceofenergy.However,alsootherenergysourcescanbeused
wheretheoperatingconditionsallowitandalwaysarecomparable
todistrictheating.

Application

Thesubstationisdesignedtobeconnectedtothehouse
installationinafrost-freeroom,wherethetemperaturedoesnot
exceed50°Candthehumiditydoesnotexceed60%.Donotcover
orwallupthesubstationorinanyotherwayblocktheentrance
tothestation.

Choiceofmaterial

Choiceofmaterialsalwaysincompliancewithlocallegislation.

Safetyvalve(s)

Werecommendmountingofsafetyvalve(s),however,alwaysin
compliancewithlocalregulations.

Connection

Thesubstationmustbeequippedwithfeaturesthatensurethat
thesubstationcanbeseparatedfromallenergysources(also
powersupply).

Emergency

Incaseofdangeroraccidents-re,leaksorotherdangerous
circumstances-interruptallenergysourcestothestationif
possible,andseekexperthelp.
Incaseofdiscolouredorbad-smellingdomestichotwater,closeall
shut-offvalvesonthesubstation,informtheoperatingpersonnel
andcallforexperthelpimmediately.

Storage

Anystorageofthesubstationwhichmaybenecessarypriorto
installationshouldbeinconditionswhicharedryandheated.

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.

Pleaseobserveinstructionscarefully

Toavoidinjurytopersonsanddamagetothedevice,itisabsolutely
necessarytoreadandobservetheseinstructionscarefully.

Warningofhighpressureandtemperature

Beawareoftheinstallation’ spermissiblesystempressureand
temperature.

Themaximumtemperatureoftheowmediuminthesubstationis
120°C.

Themaximumoperatingpressureofthesubstationis10bar .PN16
versionsareavailableonenquiry.

Theriskofpersonsbeinginjuredandequipmentdamagedincreases
considerablyiftherecommendedpermissibleoperatingparameters
areexceeded.

Thesubstationinstallationmustbeequippedwithsafetyvalves,
however,alwaysinaccordancewithlocalregulations.

Warningofhotsurface

Thesubstationhasgothotsurfaces,whichcancauseskinburns.
Pleasebeextremelycautiousincloseproximitytothesubstation.

Powerfailurecanresultinthemotorvalvesbeingstuckinopen
position.Thesurfacesofthesubstationcangethot,whichcancause
skinburns.Theballvalvesondistrictheatingsupplyandreturnshould
beclosed.

Warningoftransportdamage

Beforesubstationinstallation,pleasemakesurethatthesubstation
hasnotbeendamagedduringtransport.

IMPORTANT-Tighteningofconnections

Duetovibrationsduringtransportallangeconnections,screwjoints
andelectricalclampandscrewconnectionsmustbecheckedand
tightenedbeforewaterisaddedtothesystem.Afterwaterhasbeen
addedtothesystemandthesystemhasbeenputintooperation,
re-tightenALLconnections.

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OperatingguideTermixATBTD

4.0Mounting

4.1Mounting

Installationmustbeincompliancewithlocalstandardsand
regulations.
Districtheating(DH)-Inthefollowingsections,DHreferstothe
heatsourcewhichsuppliesthesubstations.Avarietyofenergy
sources,suchasoil,gasorsolarpower,couldbeusedasthe
primarysupplytoDanfosssubstations.Forthesakeofsimplicity,
DHcanbetakentomeantheprimarysupply.

Connectionsizes:

Allconnections:

G¾”(int.thread)

Dimensions(mm):

Withcover:
100L:H1180xW540xD520
150L:H1510xW540xD520

Weight(approx.):85–100kg

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.

TermixA TBTD5pipes

Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.

TermixA TBTD4pipes

Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.

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4.1.1Installation

Mounting:

Adequatespace

Pleaseallowadequatespacearoundthesubstationformounting
andmaintenancepurposes.

Orientation

Thestationmustbemountedsothatcomponents,keyholes
andlabelsareplacedcorrectly.Ifyouwishtomountthestation
differentlypleasecontactyoursupplier.

Drillings

Wheresubstationsaretobewall-mounted,drillingsareprovided
inthebackmountingplate.Floormountedunitshavesupport.

Labelling

Eachconnectiononthesubstationislabelled.

Beforeinstallation:

Cleanandrinse

Priortoinstallation,allsubstationpipesandconnectionsshouldbe
cleanedandrinsed.

Tightening

Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.

Unusedconnections

Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.

Installation:

Strainer

Ifastrainerissuppliedwiththestationitmustbettedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.

Connections

Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,angedorweldedconnections.

4.2Start-up

Start-up,Directheating

Theshut-offvalvesshouldbeopenedandtheunitobservedas
itentersservice.Visualcheckingshouldconrmtemperatures,
pressures,acceptablethermalexpansionandabsenceofleakage.
Iftheheatexchangeroperatesinaccordancewithdesign,itcanbe
puttoregularuse.

Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.

Re-thightenconnections

Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.

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OperatingguideTermixA TBTD

5.0MountinginstructionsT ermixATBTDwallcabinet

5.1Mounting

Wallbracket

MounttheWallbracketaccordingtotheDrawing.
UseAtocenterthetankonthebracket.
B-AllpipethreadsareISO½” .

Mountthecontainerunitinthewallbracket.

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Sideplates

Fastentherightandleftsideplatesbyplacingthekeyholesover
thescrewsonthesidesofthewallbracket.

1Bottompanel

Slidetheslotsinthebottompanelontothe2bushesintheside
plates,andfastenthepanelwiththe2screwsinthefront.

2Topplate

Mountthetopplate.

3Frontcover

Mountthefrontcoverbyloweringthekeyholesontothescrews
inthesideplates.

4Clockpanel

Mounttheclockpanelbyloweringthekeyholesontothescrews
inthesideplates.

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6.0Design

6.1DesignTermixA TBTD5pipes

Yoursubstationmightlookdifferentthanthesubstationshown.

Designdescription

E

Hotwatertankwithcoil

4

Safetyvalve

S

Siphon

20

Filling/drainvalve

1A

Ballvalve,DVGW

41A

Fittingpiece,coldwatermains

2

Singlecheckvalve

59

Differentialpressure/temperatureregulatorwithowlimiting

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6.2SchematicdiagramTermixA TBTD5Pipes

DHW

DCW

CWM

DH

Supply

DH

Return

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

E

Hotwatertankwithcoil

4

Safetyvalve

1

Ballvalve

20

Filling/drainvalve

1A

Ballvalve,DVGW

41A

Fittingpiece,coldwatermains

2

Singlecheckvalve

59

Differentialpressure/temperatureregulatorwithowlimiting

DHW:DomesticHotWater
DCW:

DomesticColdWater

CWM:

Coldwatermains

DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn

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OperatingguideTermixA TBTD

6.3DesignTermixA TBTD4pipes

Yoursubstationmightlookdifferentthanthesubstationshown.

Designdescription

E

Hotwatertankwithcoil

4

Safetyvalve

S

Siphon

20

Filling/drainvalve

1A

Ballvalve,DVGW

59

Differentialpressure/temperatureregulatorwithowlimiting

2

Singlecheckvalve

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6.4SchematicdiagramTermixA TBTD4Pipes

DHW

DCW

DH

Supply

DH

Return

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

E

Hotwatertankwithcoil

4

Safetyvalve

1

Ballvalve

20

Filling/drainvalve

1A

Ballvalve,DVGW

59

Differentialpressure/temperatureregulatorwithowlimiting

2

Singlecheckvalve

DHW:DomesticHotWater
DCW:

DomesticColdWater

DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn

6.4.1Technicalparameters

Technicalparameters

Nominalpressure:

PN10

Max.DHsupplytemperature:

T–max=95°C

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OperatingguideTermixA TBTD

7.0Controls

7.1DHWtemperaturecontrol

DHWtemperaturecontrol

TherearevarioustypesofDHWtemperaturecontrolusedin
Danfosssubstations.
DHWtemperatureshouldbeadjustedto45-50°C,asthisprovides
optimalutilisationofDHwater.AtDHWtemperaturesabove55°C,
thepossibilityoflimescaledepositsincreasessignicantly.

7.1.1AB-QMcontroller(45–60°)

QTisaself-actingthermostaticactuatordesignedtobeused
asreturntemperaturecontrolthermostatinone-pipeheating
systems.
QTisdedicatedtobeusedwithAB-QMautomaticbalancing&
controlvalve.

AB-QMDN10-20(45-60°C)

QTSensorsetting(turns)

Temperaturesetting

01

2

34

5

6

20%

48,050,553,0

55,5

58,060,563,0

30%

47,049,552,0

54,5

57,059,562,0

40%

46,048,551,053,556,058,561,0

50%

45,0

47,5

50,052,555,0

57,5

60,0

60%

44,046,549,0

51,5

54,056,559,0

70%

43,0

45,5

48,050,553,0

55,5

58,0

80%

42,0

44,5

47,049,552,0

54,5

57,0

90%

41,043,546,048,551,053,556,0

AB-QM(ow

setting)

100%

40,042,545,0

47,5

50,052,555,0

Thevaluesareintendedasaguide.

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7.2Other

7.2.1Coldwatermeterttingpiece

Thesubstationisequippedwithattingpieceforcoldwatermeter.

Assemblyofcoldwatermeter:

1:Closeballvalves

Closetheballvalvesoncoldwater,ifthereiswateronthesystem.

2:Loosennuts

Loosenthenutsonthettingpiece.

3:Removettingpiece

Removethettingpieceandreplaceitwiththecoldwatermeter .
Donotforgetthegaskets.

4:Tightenconnections

Aftermountingofthecoldwatermeterremembertocheckand
tightenallthreadedconnections.

7.2.2Siphon

PlacedtheSiphondirectlyundertheSafetyvalve.
Ensurethatthedrainpipehasaminimuminternaldiameterof
32mm.

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OperatingguideTermixA TBTD

7.3Maintenance

Thesubstationrequireslittlemonitoring,apartfromroutine
checks.Itisrecommendedtoreadtheenergymeteratregular
intervals,andtowritedownthemeterreadings.

RegularinspectionsofthesubstationaccordingtothisInstruction
arerecommended,whichshouldinclude:

Strainers

Cleaningofstrainers.

Meters

Checkingofalloperatingparameterssuchasmeterreadings.

Temperatures

Checkingofalltemperatures,suchasDHsupplytemperatureand
DHWtemperature.

Connections

Checkingallconnectionsforleakages.

Safetyvalves

Theoperationofthesafetyvalvesshouldbecheckedbyturning
thevalveheadintheindicateddirection.

Venting

Checkingthatthesystemisthoroughlyvented.

Inspectionsshouldbecarriedoutminimumeverytwoyears.

SparepartscanbeorderedfromDanfoss.Pleaseensurethatany
enquiryincludesthesubstationserialnumber.

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.

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8.0Troubleshooting

8.1Troubleshootingingeneral

Intheeventofoperatingdisturbances,thefollowingbasicfeatures
shouldbecheckedbeforecarryingoutactualtroubleshooting:

•thesubstationisconnectedtoelectricity,

•thestrainerontheDHsupplypipeisclean,

•thesupplytemperatureoftheDHisatthenormallevel

(summer,atleast60°C-winter,atleast70°C),

•thedifferentialpressureisequaltoorhigherthanthenormal

(local)differentialpressureintheDHnetwork–ifindoubt,ask
theDHplantsupervisor,

•pressureonthesystem-checktheHEpressuregauge.

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.

8.2TroubleshootingDHW

ProblemPossiblecauseSolution

Strainerinsupplyorreturnlineclogged.Cleanstrainer(s).

DHWcirculationpumpoutoforderorwith
toolowsetting.

Checkcirculationpump.

Defectiveorcloggednon-returnvalve.

Replace–clean.

Noelectricity.Check.

Wrongsettingofautomaticcontrols,ifany.Toadjustanelectroniccontrollerfor

DHW,pls.noteenclosedinstructionsfor
electroniccontroller.

Scalingoftheplateheatexchanger.

Replace–rinseout.

Defectivemotorizedvalve.Check(usemanualfunction)–replace.

Defectivetemperaturesensors.

Check–replace.

ToolittleornoDHW.

Defectivecontroller.

Check–replace.

DCWisbeingmixedwiththeDHW,e.g.in
adefectivethermostaticmixingvalve.

Check–replace. Hotwaterinsometapsbutnotinall.

Defectiveorcloggednon-returnvalveon
circulationvalve.

Replace–clean.

Taptemperaturetoohigh;DHWtapload
toohigh.

Thermostaticvalveadjustedtoatoohigh
level.

Check–set.

Scalingoftheplateheatexchanger.

Replace–rinseout. Temperaturedropduringtapping.

LargerDHWowthanthesubstationhas
beendesignedfor.

ReduceDHWow.

Thermostaticcontrolvalvedoesnotclose

TemperaturedifferencebetweenDH
supplyandDHWsetpointtoolow.

Lowerthesetpointtemperatureor
increasetheDHsupplytemperature.

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OperatingguideTermixA TBTD

8.3Disposal

Disposal

Thisproductshouldbedismantledanditscomponents
sorted,ifpossible,invariousgroupsbeforerecycling
ordisposal.

Alwaysfollowthelocaldisposalregulations.

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OperatingguideTermixA TBTD

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9.0Declaration

9.1Declarationofconformity

Category0withoutelectricalequipment

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OperatingguideTermixA TBTD

ProducedbyDanfossA/S©10/2017