Danfoss Termix HD MIX Compact 28 Installation Manual

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InstallationGuide

TermixHDMIXCompact28

1.0TableofContents

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

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

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

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

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

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

4.2Start-up..............................................................6

4.3Electricalconnections.............................................7

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

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

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

6.0Controls..........................................................10

6.1Heatingcircuit......................................................10

6.2Other.................................................................12

6.3Maintenance........................................................14

7.0Troubleshooting..............................................15

7.1Troubleshootingingeneral......................................15

7.2TroubleshootingHE...............................................15

7.3Disposal.............................................................16

8.0Declaration......................................................19

8.1Declarationofconformity........................................19

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2.0Functionaldescription

Districtheatingsubstationfordirectheatingwithmixingloop.

Application

TheTermixHDMIXCompact28isacompletesolutionfor spaceheatingwithoptimalsafety,efcientenergytransfer, service-friendlyconstructionandacompactdesign.

Districtheating(DH)

Thedistrictheatingcircuitisprefabricatedwithaowcontroller withintegratedcontrolvalve,thermometersandballvalves.

Heating(HE)

Theheatingcircuitconsistsofthermometers,ballvalves,drain valve,airvalveandcirculationpump.Theheatingtemperaturecan becontrolledthermostaticallyorbyanelectroniccontrollerwith anoutdoortemperaturesensor.

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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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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.Heating(HE)supply

4.Heating(HE)return

Connectionsizes:

DH+HE:

G1”(int.thread)

Dimensions(mm):

Withoutcover:

H970xW620xD420

Withcover:

H970xW640xD522

Weight(approx.):50kg

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby qualiedandauthorizedpersonnelonly.

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.

Thightening

Duetovibrationduringtransport,allsubstationconnectionsmust becheckedandtightenedbeforeinstallation.

Unusedconnections

Unusedconnectionsandshut-offvalvesmustbesealedwitha plug.Shouldtheplugsrequireremoval,thismustonlybedoneby anauthorizedservicetechnician.

Installation:

Strainer

Ifastrainerissuppliedwiththestationitmustbettedaccording toschematicdiagram.Pleasenotethatthestrainermaybe suppliedloose.

Connections

Internalinstallationanddistrictheatingpipesconnectionsmustbe madeusingthreaded,angedorweldedconnections.

Keyholeformounting.

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4.2Start-up

Start-up,Heatingwithmixingloop

Start-up:

1:Pumpspeed

Setthepumptohighestspeedbeforestart-up.

2:Startpump

Startthepumpandheatthroughthesystem.

3:Openshut-offvalves

Theshut-offvalvesshouldthenbeopenedandtheunitobserved asitentersservice.Visualcheckingshouldconrmtemperatures, pressures,acceptablethermalexpansionandabsenceofleakage. Ifthesystemoperatesinaccordancewithdesign,itcanbeput toregularuse.

4:Ventsystem

Switchoffthepumpandventtheinstallationaftertheradiators havebeenwarmedup.

5:Adjustpumpspeed

Setthepumptothelowestspeedconsistentwithcomfortand electricityconsumption. Normallythechange-overswitchissetinthemidposition(default). Howeverforsystemswithunderoorheatingorsinglepipeloop systems,itmaybenecessarytoturnthechange-overswitch upwards. Higherpumpspeedsareonlyusediftheheatingrequirement increases.

Re-thightenconnections

Afterwaterhasbeenaddedtothesystemandthesystemhasbeen putintooperation,re-tightenALLconnections.

Pump

Thepumpmustbeswitchedoffduringsystemll.

Underoorheating:

Pumpstopfunction

Ifthesubstationisusedinconnectionwithunderoorheating,the circulationpumpmustbeconnectedtothepumpstopfunctionin theunderoorheatingcontroller.Thepumpmustbestoppedif allunderoorheatingcircuitsareclosed.

Warranty

Ifthisisnotpossible,thenowmustbecontinuedthroughthe by-pass.Failingthis,thepumpwillbeatriskofseizureandany remainingwarrantywillbewithdrawn.

Summeroperation:

Switchoffpump

Insummerthecirculationpumpmustbeswitchedoffandthe shut-offvalvetoHEsupplyclosed.

Runningpumpbi-weekly

Itisrecommendedtostartupthecirculationpump(for2minutes) onceamonthduringsummer;theshut-offvalveoftheHEsupply mustbeshut.

Electroniccontroller

Mostelectroniccontrollerswillstartupthepumpautomatically (pleasenotemanufacturer´sinstructions).

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4.3Electricalconnections

Beforemakingelectricalconnections,pleasenotethe following:

Safetynotes

Pleasereadtherelevantpartsofthesafetynotes.

230V

Thesubstationmustbeconnectedto230VACandearth.

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

Electroniccontroller

Sensorpocket,energymeter

2-waymotorizedvalve

Singlecheckvalve

Filling/drainvalve

Differentialpressurecontroller

Strainer

Pressuregaugewithballvalve

Fittingpiece,energymeter

Circulatorpump

Actuator,HE

Airvent,manual

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5.2Schematicdiagram

Supply

HE Supply

Return

HE Return

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

Electroniccontroller

Outdoorsensor

Actuator

Ballvalve

Thermometer

2-waymotorizedvalve

Singlecheckvalve

Surfacesensor

Differentialpressurecontroller

Strainer

Filling/drainvalve

Fittingpiece,energymeter

Circulationpump

Deliveredloosewithunit

Airvent,manual

Sensorpocket,energymeter

Pressuregaugewithballvalve

DHSupply:DistrictHeatingSupply DHReturn:DistrictHeatingReturn HESupply:HeatingSupply HEReturn:HeatingReturn

5.2.1Technicalparameters

Technicalparameters

Nominalpressure:

PN16

Max.DHsupplytemperature:

120°C

Soundlevel:≤55dB

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6.0Controls

6.1Heatingcircuit

6.1.1Differentialpressurecontroller

Thedifferentialpressurecontrollersmoothsouttheuctuationsin pressurearrivingfromthedistrictheatingnetwork.Theoperating pressureinthesubstationisthusheldsteady.

6.1.2AVTBcontroller(30–100°)

Thetemperaturesettingisasfollows: 1=35°C 2=55°C 3=75°C 4=95°C 5=100°C

Thevaluesareintendedasaguide.

Thermostaticcontrol

ThetemperatureoftheHEowlineisadjustedasfollows: Toincreasetemperature,turnthehandleonthethermostatic controllertoselectahighernumber. Todecreasetemperature,turnthehandleonthethermostatic controllertoselectalowernumber.

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6.1.3Flowcontrollerwithintegratedcontrolvalve

Thecontrollerisaself-actingowcontrollerwithintegratedcontrol valve.Thecontrollercloseswhensetmax.owisexceededand canbeusedincombinationwithDanfosselectricalactuatorswith orwithoutsafetyfunction.Springreturnmotorcanbeusedas safetyfunctionbypowerfailure.

6.1.4Electric2–waymotorizedvalve

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

6.1.5Electroniccontrol

Substationswithelectroniccontrolmustbesetinaccordancewith manufacturer´sinstructions. Wheretheroomtemperatureiscontrolledbyradiatorthermostats, itisrecommendedthatthermostatsbesetforminimum temperatureineachroom.

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6.1.6Outdoortemperaturesensor(ESMT)

Outdoorsensorsshouldbemountedsoastoavoidexposureto directsunlight.Theyshouldnotbeplacedclosetodoors,windows orventilationoutlets.

6.1.7Circulationpump

TheGrundfosMAGNArangeisdesignedforheating,district heatinganddomestichotwatersupplyinbuildingsonanyscale. TheMAGNAsarespeed-controlledpumpswithbuilt-inintelligence thatletsthemanalyzecurrentconditionsandadjusttheir performanceaccordingly. EnergylabellingclassA

6.2Other

6.2.1Strainer

Strainersshouldbecleanedregularlybyauthorizedpersonnel.The frequencyofcleaningwoulddependonoperatingconditionsand themanufacturer’sinstructions.

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6.2.2Fittingpiece

Thesubstationisequippedwithattingpieceforenergymeter .

Assemblyofenergymeters:

1:Closeballvalves

ClosetheballvalvesonDHSupplyandDHReturn,ifthereiswater onthesystem.

2:Loosennuts

Loosenthenutsonthettingpiece.

3:Removettingpiece

Removethettingpieceandreplaceitwiththeenergymeter.Do notforgetthegaskets.

4:Tightenconnections

Aftermountingoftheenergymeterremembertocheckand tightenallthreadedconnections.

Sensorpocket,energymeter

Thesensorsoftheenergymeterismountedinthesensorpockets.

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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.

Inspectionsshouldbecarriedoutminimumeverytwoyears.

SparepartscanbeorderedfromDanfoss.Pleaseensurethatany enquiryincludesthesubstationserialnumber.

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby qualiedandauthorizedpersonnelonly.

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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 qualiedandauthorizedpersonnelonly.

7.2TroubleshootingHE

ProblemPossiblecauseSolution

Toolittleornoheat.StrainercloggedinDHorHEcircuit

(radiatorcircuit).

Cleangate/strainer(s).

ThelterintheenergymeteronDHcircuit clogged.

Cleanthelter(afterconsultingtheDH plantoperator).

Defectiveorwronglyadjusteddifferential pressurecontroller.

Checktheoperationofthedifferential pressurecontroller–cleanthevalveseatif required.

Sensordefective–orpossiblydirtinthe valvehousing.

Checktheoperationofthethermostat– cleanthevalveseatifrequired.

Automaticcontrols,ifany,wronglysetor defective-possiblypowerfailure.

Checkifthesettingofthecontroller iscorrect–seeseparateinstructions. Checkthepowersupply.Temporary settingofmotorto“manual”control–see instructionsonautomaticcontrols.

Pumpoutofoperation.Checkifthepumpisreceivingpowerand

thatitturns.Checkifthereisairtrappedin thepumphousing–seepumpmanual.

Thepumpissetattoolowspeedof rotation.

Setthepumpathigherspeedofrotation.

Pressuredrop–thepressuredropon theradiatorcircuitshowslowerthan recommendedoperatingpressure.

Fillwateronthesystemandcheckthe functioningofthepressureexpansion vesselifrequired.

Airpocketsinthesystem.Venttheinstallationthoroughly.

Limitingofthereturntemperature adjustedtoolow.

Adjustaccordingtoinstructions.

Defectiveradiatorvalves.

Check–replace.

Unevenheatdistributioninbuilding becauseofincorrectlysetbalancingvalves, orbecausetherearenobalancingvalves.

Adjust/installbalancingvalves.

Diameterofpipetosubstationtoosmallor branchpipetoolong.

Checkpipedimensions.

Unevenheatdistribution.Airpocketsinthesystem.Venttheinstallationthoroughly.

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DHsupplytemperaturetoohigh.

Wrongsettingofthermostatorof automaticcontrols,ifany.

Adjustautomaticcontrols,–see instructionsforautomaticcontrols.

Defectivecontroller.Thecontrollerdoes notreactasitshouldaccordingtothe instructions.

Callautomaticcontrolsmanufactureror replacetheregulator.

Defectivesensoronself-actingthermostat.

Replacethermostat–orsensoronly.

DHsupplytemperaturetoolow.

Wrongsettingofautomaticcontrols,ifany.

Adjustautomaticcontrols–seeinstructions forautomaticcontrols.

Defectivecontroller.Thecontrollerdoes notreactasitshouldaccordingtothe instructions.

Callinautomaticcontrolsmanufactureror replacecontroller.

Defectivesensoronself-actingthermostat.

Replacethermostat–orsensoronly.

Wrongplacement/ttingofoutdoor temperaturesensor.

Adjustlocationofoutdoortemperature sensor.

Strainerclogged.Cleangate/strainer.

ToohighDHreturntemperature.

Toosmallheatingsurface/toosmall radiatorscomparedtothetotalheating requirementofthebuilding.

Increasetotalheatingsurface.

Poorutilizationofexistingheatingsurface. Defectivesensoronself-actingthermostat.

Makesuretheheatisdistributedevenly acrossthefullheatingsurface–openall radiatorsandkeeptheradiatorsinthe systemfromheatingupatthebottom.It isextremelyimportanttokeepthesupply temperaturetotheradiatorsaslowas possible,whilemaintainingareasonable levelofcomfort.

Thesystemissinglepipeloop.

Thesystemshouldfeatureelectronic controlsaswellasreturnsensors.

Pumppressuretoohigh.Adjustpumptoalowerlevel.

Airinsystem.

Ventthesystem.

Defectiveorincorrectlysetradiator valve(s).Singlepipeloopsystemsrequire specialone-piperadiatorvalves.

Check–set/replace.

Dirtinthemotorizedvalveorinthe differentialpressurecontroller.

Check–cleanout.

Defectivemotorizedvalve,sensoror automaticcontroller.

Check–replace.

Electroniccontrollernotadjustedcorrectly.Adjustaccordingtoinstructions.

Noiseinsystem.

Pumppressuretoohigh.Adjustpumptoalowerlevel.

Heatloadtoohigh.

Defectivemotorizedvalve,sensoror electroniccontroller.

Check–replace.

7.3Disposal

Disposal

Thisproductshouldbedismantledanditscomponents sorted,ifpossible,invariousgroupsbeforerecycling ordisposal.

Alwaysfollowthelocaldisposalregulations.

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8.0Declaration

8.1Declarationofconformity

8.1.1Category0withelectricalequipment

EC–DeclarationofConformity

GeminaT ermixA/S MemberoftheDanfossGroup Navervej15-17 DK-7451Sunds

Declaresonoursoleresponsibilitythatthebelowproducts:

Substations–Category0withelectricalequipment,

coveredbythisdeclarationareinconformitywiththefollowingdirectives,standardsandothernormative documents,providedthattheyareusedaccordingtoourinstructions.

MachineryDirective2006/42/EC

DS/EN60204-1/A1:2009.Safetyofmachinery– Part1–GeneralRequirements. DS/EN12100:2011.Safetyofmachinery–Risk assessment.

LVD–LowVoltageDirective–2006/95/EC

DS/EN60204-1/A1:2009.Safetyofmachinery– Part1–GeneralRequirements.

EMC–Directive–2004/108/EC

DS/EN61000-6-2/Corr.:2005.Electromagnetic compatibility–Genericstandard:Immunity industry. DS/EN61000-6-3:2007.Electromagnetic compatibility–Genericstandard:Emissionfor residential,commercial&lightindustry.

Sunds–2013.03.15

PlaceanddateofissueClausGjøderumMortensen

Quality&EnvironmentManager

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