Danfoss Termix BL Operating guide

OperatingGuide

TermixBL

1.0TableofContents

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

........................................................................2

2.0Functionaldescription......................................3

3.0Safetynotes.....................................................4

3.1SafetyNotes–general............................................4

4.0Mounting........................................................5

4.1Mounting...........................................................5

4.2Electricalconnections.............................................7

5.0Design.............................................................8

5.1Design...............................................................8

5.2Schematicdiagram................................................9

5.3Design...............................................................10

5.4Schematicdiagram................................................11

6.0Controls..........................................................12

6.1DHWtemperaturecontrol........................................12

6.2Other.................................................................14

6.3Maintenance........................................................15

7.0Troubleshooting..............................................16

7.1Troubleshootingingeneral......................................16

7.2TroubleshootingDHW............................................17

7.3Disposal.............................................................18

8.0Declaration......................................................22

8.1Declarationofconformity........................................22

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2.0Functionaldescription

Instantaneouswaterheaterwithheatexchangerand
automaticcontrols.Designedforwall-mounting.

Application

TheTermixBLisawaterheaterwithautomaticcontrolsprepared
forachargingsystem.TheTermixBLissuitableforlargeapartment
houses,sportsarenasandschools,wherelargeamountsofhot
waterareneeded.Thehotwatersystemsareavailablein7different
sizeswithanoutputfrom70-222kW.TheTermixBLunitissupplied
withPUinsulatedplateheatexchangers.

Domestichotwater(DHW)

TheTermixBLisavailableforchargingsystemswithlarge
momentarydemandsforhotwaterorininstallationswithrelatively
lowsupplycapacity.TheT ermixBLchargingsystemisdelivered
withDanfossautomaticcontrolsforregulationofthecharging
temperatureandthetemperatureinthehotwaterbuffertank.The
controlvalvewithintegratedpressurecontrolhelpstoavoidcyclic
variationsofthedifferentialpressureinthedistrictheatingsupply.

Domestichotwatercirculation

TheT ermixBLsubstationissuppliedwithconnectionsforDHW
circulationincludingcirculationpumpandanon-returnvalveas
astandard.

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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
qualifiedandauthorizedpersonnelonly.
Pleasecomplywiththeinstructionsissuedbythesystem
manufacturerorsystemoperator.

Corrosionprotection

Allpipesandcomponentsaremadeofstainlesssteelandbrass.
Themaximumchloridecompoundsoftheflowmediumshouldnot
behigherthan150mg/l.
Theriskofequipmentcorrosionincreasesconsiderablyifthe
recommendedlevelofpermissiblechloridecompoundsis
exceeded.

Energysource

Thesubstationisdesignedfordistrictheatingastheprimary
sourceofenergy.However,alsootherenergysourcescanbeused
wheretheoperatingconditionsallowitandalwaysarecomparable
todistrictheating.

Application

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

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.

Pleaseobserveinstructionscarefully

Toavoidinjurytopersonsanddamagetothedevice,itisabsolutely
necessarytoreadandobservetheseinstructionscarefully.

Warningofhighpressureandtemperature

Beawareoftheinstallation’spermissiblesystempressureand
temperature.

Themaximumtemperatureoftheflowmediuminthesubstationis
120°C.

Themaximumoperatingpressureofthesubstationis16bar.

Theriskofpersonsbeinginjuredandequipmentdamagedincreases
considerablyiftherecommendedpermissibleoperatingparameters
areexceeded.

Thesubstationinstallationmustbeequippedwithsafetyvalves,
however,alwaysinaccordancewithlocalregulations.

Choiceofmaterial

Choiceofmaterialsalwaysincompliancewithlocallegislation.

Safetyvalve(s)

Werecommendmountingofsafetyvalve(s),however,alwaysin
compliancewithlocalregulations.

Connection

Thesubstationmustbeequippedwithfeaturesthatensurethat
thesubstationcanbeseparatedfromallenergysources(also
powersupply).

Emergency

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

REACH

AllDanfossA/SproductsfulfilltherequirementsinREACH.
OneoftheobligationsinREACHistoinformcustomersabout
presenceofCandidatelistsubstancesifany,weherebyinform
youaboutonesubstanceonthecandidatelist:Theproduct
containsbrasspartswhichcontainslead(CASno:7439-92-1)ina
concentrationabove0.1%w/w.

Storage

Anystorageofthesubstationwhichmaybenecessarypriorto
installationshouldbeinconditionswhicharedryandheated.

Warningofhotsurface

Thesubstationhasgothotsurfaces,whichcancauseskinburns.
Pleasebeextremelycautiousincloseproximitytothesubstation.

Powerfailurecanresultinthemotorvalvesbeingstuckinopen
position.Thesurfacesofthesubstationcangethot,whichcancause
skinburns.Theballvalvesondistrictheatingsupplyandreturnshould
beclosed.

Warningoftransportdamage

Beforesubstationinstallation,pleasemakesurethatthesubstation
hasnotbeendamagedduringtransport.

IMPORTANT-Tighteningofconnections

Duetovibrationsduringtransportallflangeconnections,screwjoints
andelectricalclampandscrewconnectionsmustbecheckedand
tightenedbeforewaterisaddedtothesystem.Afterwaterhasbeen
addedtothesystemandthesystemhasbeenputintooperation,
re-tightenALLconnections.

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4.0Mounting

4.1Mounting

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

Connections:

1.Districtheating(DH)supply

2.Districtheating(DH)return

3.Hotwatercirculation(HWC)

4.Domestichotwater(DHW)

5.Domesticcoldwater(DCW)

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.

Type2–5

Connectionsizes:

DH+DCW+DHW:
HWC:

Dimensions(mm):

Type2-5withoutcover:
H660xW510xD240
Type2-5withcover:
H800xW540xD360

Type6-8withoutcover:
H920xW720xD385
Type6-8withcover:
H920xW800xD450

Weight(approx.):20–40kg

G1”(int.thread)
G¾”(int.thread)

Type6–8

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.

Keyholeformounting.

Tightening

Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.

Unusedconnections

Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.

Installation:

Strainer

Ifastrainerissuppliedwiththestationitmustbefittedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.

Connections

Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,flangedorweldedconnections.

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4.2Electricalconnections

Beforemakingelectricalconnections,pleasenotethe
following:

Safetynotes

Pleasereadtherelevantpartsofthesafetynotes.

230V

Thesubstationmustbeconnectedto230VACandearth.

Potentialbonding

Potentialbondingshouldbecarriedoutaccording
to60364-4-41:2007andIEC60364-5-54:2011.
Bondingpointonthemountingplatebelowrightcornermarked
withearthsymbol.

Disconnection

Thesubstationmustbeelectricallyconnectedsothatitcanbe
disconnectedforrepairs.

Outdoortemperaturesensor

Outdoorsensorsshouldbemountedsoastoavoidexposureto
directsunlight.Theyshouldnotbeplacedclosetodoors,windows
orventilationoutlets.

Theoutdoorsensormustbeconnectedtothestationonthe
terminalblockundertheelectroniccontrol.

Authorizedelectrician

Electricalconnectionsmustbemadebyanauthorizedelectricianonly.

Localstandards

Electricalconnectionsmustbemadeinaccordancewithcurrent
regulationsandlocalstandards.

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5.0Design

5.1Design

Yoursubstationmightlookdifferentthanthesubstationshown.

Designdescription

B

Heatexchanger,DHW

G

Electroniccontroller,DHW

2

Singlecheckvalve

11

Domestichotwaterpump

27

Actuator

30

Flowcontrolwithcontrolvalve

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5.2Schematicdiagram

Schematicdiagramtype2-5(example)

DH

Supply

DH

Return

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

B

Heatexchanger,DHW

D

Hotwatertank

G

Electroniccontroller,DHW

L

Borderofdelivery

1

Ballvalve

2

Singlecheckvalve

DHW:DomesticHotWater
DCW:
HWC:
DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn

DomesticColdWater
HotWaterCirculation

4

Safetyvalve

11

Domestichotwaterpump

13

Chargingpump

18

Thermometer

19

Surfacesensor

24

Deliveredloosewithunit

27

Actuator

30

Flowcontrolwithcontrolvalve

36

Balancingvalve

40

Immersionsensor

43

Ballvalveclosed

44

Immersionsensor

DHW

DCW

HWC

5.2.1Technicalparameters

Technicalparameters

Nominalpressure:
Max.DHsupplytemperature:
Min.DCWstaticpressure:
Brazingmaterial(HEX):
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB

PN16
120°C

0.5bar
Copper

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5.3Design

Yoursubstationmightlookdifferentthanthesubstationshown.

Designdescription

B

Heatexchanger,DHW

G

Electroniccontroller,DHW

2

Singlecheckvalve

11

Domestichotwaterpump

13

Chargingpump

27

Actuator

30

Flowcontrolwithcontrolvalve

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5.4Schematicdiagram

Schematicdiagramtype6-8(example)

DH

Supply

DH

Return

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

B

Heatexchanger,DHW

D

Hotwatertank

G

Electroniccontroller,DHW

L

Borderofdelivery

1

Ballvalve

2

Singlecheckvalve

DHW:DomesticHotWater
DCW:
HWC:
DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn

DomesticColdWater
HotWaterCirculation

4

Safetyvalve

11

Domestichotwaterpump

13

Chargingpump

18

Thermometer

19

Surfacesensor

27

Actuator

30

Flowcontrolwithcontrolvalve

36

Balancingvalve

40

Immersionsensor

43

Ballvalveclosed

44

Immersionsensor

DHW

DCW

HWC

5.4.1Technicalparameters

Technicalparameters

Nominalpressure:
Max.DHsupplytemperature:
Min.DCWstaticpressure:
Brazingmaterial(HEX):
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB

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PN16
120°C

0.5bar
Copper

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6.0Controls

6.1DHWtemperaturecontrol

DHWtemperaturecontrol

TherearevarioustypesofDHWtemperaturecontrolusedin
Danfosssubstations.
DHWtemperatureshouldbeadjustedto45-50°C,asthisprovides
optimalutilisationofDHwater.AtDHWtemperaturesabove55°C,
thepossibilityoflimescaledepositsincreasessignificantly.

6.1.1Electroniccontrol

Substationswithelectroniccontrolmustbesetinaccordancewith
manufacturer´sinstructions.
Wheretheroomtemperatureiscontrolledbyradiatorthermostats,
itisrecommendedthatthermostatsbesetforminimum
temperatureineachroom.

6.1.2Electric2–waymotorizedvalve

Actuatorswithorwithoutsafetyfunctionareavailablefor3-point
controls.Spring-returnactuatorscanbeusedtoprovidesafety
shut-offintheeventofpowerfailure.

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6.1.3Domestichotwaterpump

Important!

Itisnecessarytomountadomestichotwatercirculationpumpon
thewaterheatertoavoidregulationproblems.
Thecirculationpumpcannotbeswitchedoff,sincethiswillresult
inregulationproblems.(noflowatthesensor).

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6.2Other

6.2.1Safetyvalve

Thepurposeofthesafetyvalveistoprotectthesubstationfrom
excessivepressure.
Theblow-offpipefromthesafetyvalvemustnotbeclosed.The
blow-offpipeoutletshouldbeplacedsothatitdischargesfreely
anditispossibletoobserveanydrippingfromthesafetyvalve.
Itisrecommendedtochecktheoperationofsafetyvalvesat
intervalsof6months.Thisisdonebyturningthevalveheadin
directionindicated.

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6.3Maintenance

Thesubstationrequireslittlemonitoring,apartfromroutine
checks.Itisrecommendedtoreadtheenergymeteratregular
intervals,andtowritedownthemeterreadings.

RegularinspectionsofthesubstationaccordingtothisInstruction
arerecommended,whichshouldinclude:

Strainers

Cleaningofstrainers.

Meters

Checkingofalloperatingparameterssuchasmeterreadings.

Temperatures

Checkingofalltemperatures,suchasDHsupplytemperatureand
DHWtemperature.

Connections

Checkingallconnectionsforleakages.

Safetyvalves

Theoperationofthesafetyvalvesshouldbecheckedbyturning
thevalveheadintheindicateddirection.

Venting

Checkingthatthesystemisthoroughlyvented.

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.

Inspectionsshouldbecarriedoutminimumeverytwoyears.

SparepartscanbeorderedfromDanfoss.Pleaseensurethatany
enquiryincludesthesubstationserialnumber.

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7.0Troubleshooting

7.1Troubleshootingingeneral

Intheeventofoperatingdisturbances,thefollowingbasicfeatures
shouldbecheckedbeforecarryingoutactualtroubleshooting:

•thesubstationisconnectedtoelectricity,

•thestrainerontheDHsupplypipeisclean,

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

•thedifferentialpressureisequaltoorhigherthanthenormal
(local)differentialpressureintheDHnetwork–ifindoubt,ask
theDHplantsupervisor,

•pressureonthesystem-checktheHEpressuregauge.

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.

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7.2TroubleshootingDHW

ProblemPossiblecauseSolution

ToolittleornoDHW.

Taptemperaturetoohigh;DHWtapload
toohigh.

Temperaturedropduringtapping.

Thermostaticcontrolvalvedoesnotclose

Strainerinsupplyorreturnlineclogged.Cleanstrainer(s).

DHWcirculationpumpoutoforderorwith
toolowsetting.

Defectiveorcloggednon-returnvalve.

Noelectricity.Check.

Wrongsettingofautomaticcontrols,ifany.Toadjustanelectroniccontrollerfor

Scalingoftheplateheatexchanger.

Defectivemotorizedvalve.Check(usemanualfunction)–replace.

Defectivetemperaturesensors.

Defectivecontroller.

DCWisbeingmixedwiththeDHW,e.g.ina
defectivethermostaticmixingvalve.

Defectiveorcloggednon-returnvalveon
circulationvalve.

Thermostaticvalveadjustedtoatoohigh
level.

Scalingoftheplateheatexchanger.

LargerDHWflowthanthesubstationhas
beendesignedfor.

TemperaturedifferencebetweenDH
supplyandDHWsetpointtoolow.

Checkcirculationpump.

Replace–clean.

DHW,pls.noteenclosedinstructionsfor
electroniccontroller.

Replace–rinseout.

Check–replace.

Check–replace.

Check–replace. Hotwaterinsometapsbutnotinall.

Replace–clean.

Check–set.

Replace–rinseout.

ReduceDHWflow.

Lowerthesetpointtemperatureorincrease
theDHsupplytemperature.

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7.3Disposal

Disposal

Thisproductshouldbedismantledanditscomponents
sorted,ifpossible,invariousgroupsbeforerecycling
ordisposal.

Alwaysfollowthelocaldisposalregulations.

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8.0Declaration

8.1Declarationofconformity

8.1.1Substationlabel

Normallythebelowmentioneddeclarationofconformityapplies:
"Substations-Category0withelectricalequipment".

Unlessfittedwithayellowlabel(PEDKAT.1)onthesubstationlabel
thenthefollowingdeclarationofconformityapplies:"Substations­Category1withelectricalequipment" .

Category0withelectricalequipment

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Category1withelectricalequipment

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