Danfoss Termix VMTD-F-B Installation Manual

InstallationGuide

TermixVMTD-F-B

1.0TableofContents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

6.2DHWtemperaturecontrol........................................11

6.3Other.................................................................11

6.4Maintenance........................................................14

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

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

7.2TroubleshootingDHW............................................15

7.3TroubleshootingHE...............................................16

7.4Disposal.............................................................17

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

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

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2.0Functionaldescription

Districtheatingsubstationfordirectheatingand
instantaneousdomestichotwater.

Application

TheTermixVMTD-F-Bisacompletesolutionwithbuilt-inwater
heaterandadifferentialpressurecontrolledheatingsystem.Termix
VMTD-F-Bisapplicableforsingleandmulti-familyhousesandfor
decentralizedsystems.

Districtheating(DH)

Thesubstationisprefabricatedwithadifferentialpressure
controller,attingpieceandsensorpocketsforinsertionofaheat
meteraswellasstrainerandballvalves.

Heating(HE)

Theheatingcircuitisdesignedfordirectgenerationofheat.
Thedifferentialpressurecontrolsetstheoptimumoperation
conditionsforradiatorthermostaticvalvesinordertoenable
individualtemperaturecontrolineachroom.Inordertoenablea
time-dependingtemperaturecontrolprogram,azonevalvewith
actuatorandaroomthermostatcanbeincludedasanoption.

Domestichotwater(DHW)

Thedomestichotwaterispreparedintheheatexchangerandthe
temperatureisregulatedwithathermostaticcontrolvalve.The
patentedsensoracceleratoracceleratestheclosingoftheDanfoss
AVTBvalveandprotectstheheatexchangeragainstoverheating
andlimescaleformation.TheheatexchangercoolstheDHwater
veryefciently,therebycreatingaverygoodoperatingeconomy.
ThesensoracceleratorandAVTBvalvealsoworksasabypass
keepingthehousesupplylinewarm.Thisshortensthewaiting
periodsduringsummerwhentheheatingsystemisinreduced
operation.Thesensoracceleratorhelpstoensureastablehot
watertemperatureregardlessofvaryingloads,owtemperatures
anddifferentialpressurewithouttheneedforreadjustingthevalve.

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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.Hotwatercirculation(HWC)(Optional)

2.Districtheating(DH)supply

3.Districtheating(DH)return

4.Coldwatermains(CWM)

5.Domesticcoldwater(DCW)

6.Domestichotwater(DHW)

7.Heating(HE)supply

8.Heating(HE)return

Connectionsizes:

DH+HE:

G¾”(int.thread)

CWM+DCW+DHW:

G¾”(int.thread)

Dimensions(mm):

Withoutcover:
H710xW528xD150
Withcover(mountonwallvariant):
H800xW540xD190
Withcover(built-inwallvariant):
H915–980xW610xD150

Weight(approx.):20kg

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.

Tightening

Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.

Unusedconnections

Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.

Installation:

Strainer

Ifastrainerissuppliedwiththestationitmustbettedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.

Connections

Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,angedorweldedconnections.

Keyholeformounting.

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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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

B

Heatexchanger,DHW

14

Sensorpocket,energymeter

O

Termixsensoraccelerator

31

Differentialpressurecontroller

7

Thermostaticvalve,DHW

41A

Fittingpiece,coldwatermains

9

Strainer

41BFittingpiece,energymeter

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5.2Schematicdiagram

DHW

CWM

DCW

DH

Supply

HE
Supply

DH

Return

HE
Return

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

B

Heatexchanger,DHW

31

Differentialpressurecontroller

7

Thermostaticvalve,DHW

41A

Fittingpiece,coldwatermains

9

Strainer

41BFittingpiece,energymeter

14

Sensorpocket,energymeter

DHW:DomesticHotWater
CWM:

ColdWaterMains

DCW:

DomesticColdWater

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

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

6.1Heatingcircuit

6.1.1Differentialpressurecontroller

Thedifferentialpressurecontrollersmoothsouttheuctuationsin
pressurearrivingfromthedistrictheatingnetwork.Theoperating
pressureinthesubstationisthusheldsteady.

6.1.2TP7000

TP7000electronic7dayprogrammableroomthermostat.
Signalsfromtheroomthermostatcanbeusedtocontrolzone
valves.

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6.2DHWtemperaturecontrol

DHWtemperaturecontrol

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

6.2.1AVTBcontroller(20–60°)

Thetemperaturesettingisasfollows:
1=20°C
2=35°C
3=50°C
4=60°C
5=70°C

Thevaluesareintendedasaguide.

TheAVTBoperatesatitsbestatDHsupplytemperaturesofupto
90°C.

Thermostaticcontrol

DHWtemperatureisadjustedasfollows:
Toincreasetemperature,turnthehandleonthethermostatic
controllertoselectahighernumber.
Todecreasetemperature,turnthehandleonthethermostatic
controllertoselectalowernumber.

6.3Other

6.3.1Safetyvalve

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

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6.3.2Strainer

Strainersshouldbecleanedregularlybyauthorizedpersonnel.The
frequencyofcleaningwoulddependonoperatingconditionsand
themanufacturer’sinstructions.

6.3.3GTUPressureEqualizer

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

6.3.4ReturntemperaturelimiterFJVR(10-80°C)

ThereturnlimitertypeF JVRautomaticallycontrolsthereturn
temperaturefromradiators,convectorsandunderoorheating
pipes.

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6.3.5Fittingpiece

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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6.4Maintenance

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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7.3TroubleshootingHE

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.

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.

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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.

7.4Disposal

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–2014.01.31

PlaceanddateofissueClausGjøderumMortensen

Quality&EnvironmentManager

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