Danfoss TERMIX PM2+P Installation Manual

InstallationGuide

TermixWaterheater–PM2+P

1.0TableofContents

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

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

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

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

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

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

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

5.0Design.............................................................6

5.1Design...............................................................6

5.2Schematicdiagram................................................7

6.0Controls..........................................................9

6.1DHWtemperaturecontrol........................................9

6.2Maintenance........................................................10

7.0Troubleshooting..............................................11

7.1Troubleshootingingeneral......................................11

7.2TroubleshootingDHW............................................11

7.3Disposal.............................................................12

8.0Declaration......................................................15

8.1Declarationofconformity........................................15

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InstallationGuideTermixWaterheater–PM2+P

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2.0Functionaldescription

Instantaneouswaterheaterwithheatexchangerand
owcompensatedtemperaturecontroller.Designedfor
wall-mounting.

Application

TheT ermixWaterheaterisaninstantaneouswaterheaterfeaturing
superbheatextractionandhighperformance.TheTermixWater
heaterissuitableforats,single-familyhousesaswellasforsmall
apartmentbuildings.Thewaterheaterisavailableintwosizes,
eitherfor1apartment,orupto4apartments.TheTermixWater
heaterisapplicablefordecentralizedheatingsystems.Theheat
exchangerintheTermixWaterheatercoolsthedistrictheating
waterveryefciently,therebycreatingaverygoodoperation
economy.

Domestichotwater(DHW)

Thedomestichotwaterispreparedintheheatexchangerandthe
temperatureisregulatedbyaowcontrollerwithaintegrated
differentialpressurecontroller.

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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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InstallationGuideTermixWaterheater–PM2+P

4.0Mounting

4.1Mounting

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

Connections:

1.Domesticcoldwater(DCW)

2.Domestichotwater(DHW)

3.Districtheating(DH)supply

4.Districtheating(DH)return

Connectionsizes:

DH:

G¾”(ext.thread)

DCW+DHW:

G¾”(ext.thread)

Dimensions(mm):

Type1+2withinsulation:
H450xW300xD155
Type1+2withcover:
H470xW315xD155

Weightincl.cover:7–9kg(incl.packing)

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.

Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.

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5.0Design

5.1Design

Yoursubstationmightlookdifferentthanthesubstationshown.

Designdescription

B

Heatexchanger,DHW

9

Strainer

73

PM2+Pcontroller,DHW

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5.2Schematicdiagram

DHW

DCW

DH

Supply

DH

Return

GTU.
Maynotbeappliedtostationswithhotwater
circulation.

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

SchematicdescriptionwithPM2+P–withGTU

B

Heatexchanger,DHW

62

GTUPressureequalizer

63

Sieve

73

PM2+Pcontroller

DHW

DCW

DH

Supply

DH

Return

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

SchematicdescriptionwithPM2+P–withsafetyvalve

B

Heatexchanger,DHW

2

Singlecheckvalve

4

Safetyvalve

63

Sieve

73

PM2+Pcontroller

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DHW:DomesticHotWater
DCW:

DomesticColdWater

DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn

5.2.1Technicalparameters

Technicalparameters

Nominalpressure:PN10(PN16versionsareavailableonenquiry)
Max.DHsupplytemperature:

120°C

Min.DCWstaticpressure:

0.5bar

Brazingmaterial(HEX):

Copper
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB

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6.0Controls

6.1DHWtemperaturecontrol

DHWtemperaturecontrol

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

6.1.1PM2+Pcontroller

PM2+Pisaself-actingproportionalowcontrollerwithintegrated
differentialpressurecontroller.
ThePM2+PoperatesatitsbestatDHsupplytemperaturesofupto
100°C.
Byturningthehandlefortemperaturesetting,theindicatorof
temperaturesettingmovestowardsredorbluedot.Thismeans
thattemperaturesettingisincreasedordecreased.

6.1.2Safetyvalve

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

6.1.3Strainer

Strainersshouldbecleanedregularlybyauthorizedpersonnel.The
frequencyofcleaningwoulddependonoperatingconditionsand
themanufacturer’sinstructions.

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InstallationGuideTermixWaterheater–PM2+P

6.1.4GTUPressureEqualizer

TheGTUPressureEqualizerabsorbstheexpansiononthe
secondarysideoftheTermixWaterheatersandcanbeusedasa
substitutetothesafetyvalve.
Furthermorethepressureequalizerabsorbsapossibleincreasein
pressure,soadischargeoutletisomitted.
TheGTUPressureEqualizermaynotbeappliedinsystemswithhot
watercirculation.

6.1.5IdlecontrollerFJVR(10-80°C)

Theidlecontrollercankeeptheapplicationoronlythesupplyline
pre-heatedatnoload.

6.2Maintenance

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.

7.2TroubleshootingDHW

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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7.3Disposal

Disposal

Thisproductshouldbedismantledanditscomponents
sorted,ifpossible,invariousgroupsbeforerecycling
ordisposal.

Alwaysfollowthelocaldisposalregulations.

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8.0Declaration

8.1Declarationofconformity

Declarationofcompliance

We:

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

doherebyonourownresponsibilitydeclarethatthefollowingproducts:

TermixSubstations

coveredbythisdeclarationisinconformitywiththefollowingdirective(s),
standard(s)orothernormativedocument(s),
providedthattheproductsareusedinaccordancewithourinstructions.

EUDirectives:

MachineryDirective2006/42/EEC

ENISO14121-1Safetyofmachinery-Riskassessment
EN60204-1Safetyofmachinery-Electricalequipmentofmachines

EMCDirective2004/108/EEC

EN61000-6-22007Electromagneticcompatibility

-Genericstandard:Immunityindustry
EN61000-6-32007Electromagneticcompatibility

-Genericstandard:Emissionforresidential,commercialandlightindustry

PEDDirective97/23/EEC

AllsubstationsthatfallsunderArticle3.3andcategory1shallnotbeCE-marked
accordingtothisdirective,howeverallessentialsafetyrequirementsfromthe
PEDDirective97/23/EECarefollowedtoensurehydraulicsafety

Thisdeclarationisimmediatelyannulled,iftheproductisinterferedwithinanyway,
whichinterfereswiththeabovementioneddirectivesandstandards,
withoutthewrittenconsentfromGeminaT ermixA/S.

2010.01.05—Sunds

Timeandplace

LarsGinnerup

Responsibleforquality

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ProducedbyDanfossA/S©01/2012