Danfoss VMTD-I Operating guide

OperatingGuide
TermixVMTD-Iwithcompleteinsulation

1.0TableofContents

1.0TableofContents.............................................1
........................................................................2
2.0VMTD-IinsuIHPTFunctionaldescription...........3
3.0Safetynotes.....................................................4
3.1SafetyNotes–general............................................4
4.0Mounting........................................................5
4.2Start-up..............................................................7
5.0Design.............................................................8
5.1Design...............................................................8
6.0Controls..........................................................10
6.1Heatingcircuit......................................................10
6.2DHWtemperaturecontrol........................................11
6.3Other.................................................................12
6.4Extras................................................................14
6.5Mountingplateforenergymeterdisplay.....................15
6.6Maintenance........................................................16
7.0Troubleshooting..............................................17
7.1Troubleshootingingeneral......................................17
7.2TroubleshootingDHW............................................18
7.3TroubleshootingHE...............................................19
7.4Disposal.............................................................21
8.0Declaration......................................................22
8.1Declarationofconformity........................................22
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2.0VMTD-IinsuIHPTFunctionaldescription

Districtheatingsubstationfordirectheatingand instantaneousdomestichotwaterwithflow-compensated temperaturecontroller .Designedforwall-mounting.
Application
TheTermixVMTD-Iisacompletesolutionwithbuilt-inwaterheater andadifferentialpressurecontrolledheatingsystem.Termix VMTD-Iisapplicableforsinglefamilyhousesandfordecentralized systems.
Districtheating(DH)
Thesubstationisprefabricatedwithadifferentialpressure controller,afittingpieceandsensorpocketsforinsertionofan energymeteraswellasstrainer.Thedisplayoftheenergymeteris tobemountedonabracketunderneaththesubstation.
Heating(HE)
Theheatingcircuitisdesignedfordirectgenerationofheat. Thedifferentialpressurecontrolsetstheoptimumoperation conditionsforradiatorthermostaticvalvesinordertoenable individualtemperaturecontrolineachroom.Inordertoenablea time-dependingtemperaturecontrolprogram,azonevalvewith actuatorisincluded,andaroomthermostatcanbeincludedas anoption.
Domestichotwater(DHW)
Thedomestichotwaterispreparedintheheatexchangerandthe temperatureisregulatedwithaflowcompensatedtemperature controllerwithintegrateddifferentialpressurecontroller.Theheat exchanger-whichisinsulated-coolstheDHwaterveryefficiently, therebycreatinganexcellentoperatingeconomy.TheIHPTvalve ensuresastablehotwatertemperaturebyvaryingloads,supply temperaturesandbyhighandvaryingdifferentialpressurewithout theneedforreadjustingthevalve.Thisprotectstheheatexchanger againstoverheatingandlimescaleformation.Furthermorethe IHPTvalvehasanintegratedidletemperaturecontroller,which keepsthehousesupplylinewarm.Thisshortensthewaiting periodsduringsummerwhentheheatingsystemisinreduced operation,whichisidealwherehighcomfortisrequested.AWRAS approvednon-returnvalveisfittedinthecoldwatersupply.
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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.
Themaximumoperatingpressureofthesubstationis10bar.PN16 versionsareavailableonenquiry.
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.Heating(HE)supply
4.Heating(HE)return
5.Domestichotwater(DHW)
6.Domesticcoldwater(DCW)
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby qualifiedandauthorizedpersonnelonly.
Connectionsizes:
DH+HE: DCW+DHW:
Dimensions(mm):
Withinsulation: H610xW540xD345
Weight(approx.):15kg
Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote themarkingsonthestation.
G¾”(int.thread) G¾”(int.thread)
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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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4.2Start-up

Start-up,Directheating
Theshut-offvalvesshouldbeopenedandtheunitobservedas itentersservice.Visualcheckingshouldconfirmtemperatures, pressures,acceptablethermalexpansionandabsenceofleakage. Iftheheatexchangeroperatesinaccordancewithdesign,itcanbe puttoregularuse.
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen putintooperation,re-tightenALLconnections.
Re-thightenconnections
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen putintooperation,re-tightenALLconnections.
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5.0Design

5.1Design

Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
B
Heatexchanger,DHW
N
Circulationconnection
9
Strainer
14
Sensorpocket,energymeter
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Differentialpressurecontroller
41
Fittingpiece,energymeter
63
Sieve
74
IHPTcontroller,DHW
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5.2Schematicdiagram

DHW
DCW
DH
Supply
DH
Return
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
B
Heatexchanger,DHW
1
Ballvalve
9
Strainer
DHW:DomesticHotWater DCW: DHSupply:DistrictHeatingSupply DHReturn:DistrictHeatingReturn HESupply:HeatingSupply HEReturn:HeatingReturn
DomesticColdWater
14
Sensorpocket,heatmeter
31
Differentialpressurecontroller
39
Connectionclosed
41
Fittingpiece,energymeter
63
Sieve
74
IHPTcontroller
HE Supply
HE Return
5.2.1Technicalparameters
Technicalparameters
Nominalpressure:PN10(PN16versionsareavailableonenquiry) Max.DHsupplytemperature: Min.DCWstaticpressure: Brazingmaterial(HEX): Heatexchangerstestpressure:30bar Soundlevel:≤55dB
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120°C
1.0bar Copper
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6.0Controls

6.1Heatingcircuit

6.1.1Differentialpressurecontroller
Thedifferentialpressurecontrollersmoothsoutthefluctuationsin pressurearrivingfromthedistrictheatingnetwork.Theoperating pressureinthesubstationisthusheldsteady.
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6.2DHWtemperaturecontrol

DHWtemperaturecontrol
TherearevarioustypesofDHWtemperaturecontrolusedin Danfosssubstations. DHWtemperatureshouldbeadjustedto45-50°C,asthisprovides optimalutilisationofDHwater.AtDHWtemperaturesabove55°C, thepossibilityoflimescaledepositsincreasessignificantly.
6.2.1IHPT90controller(45–65°)
IHPTisaself-actingflow-compensatedtemperaturecontrollerwith integrateddifferentialpressurecontroller. TheIHPToperatesatitsbestatDHsupplytemperaturesofupto 100°C. Byturningthehandlefortemperaturesettingin(+)direction thesettingisincreased,byturningitin(-)directionthesettingis decreased.
Turns*
0
1
2
3
4
5
6
7
*Startposition:Handleturnedfullyin(+)direction. Thevaluesareintendedasaguide.
Scale
7
661
5
455
352
248
144
043
DHWT emperatureSetting[°C]
64
58
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6.3Other

6.3.1Safetyvalve
Thepurposeofthesafetyvalveistoprotectthesubstationfrom excessivepressure. Theblow-offpipefromthesafetyvalvemustnotbeclosed.The blow-offpipeoutletshouldbeplacedsothatitdischargesfreely anditispossibletoobserveanydrippingfromthesafetyvalve. Itisrecommendedtochecktheoperationofsafetyvalvesat intervalsof6months.Thisisdonebyturningthevalveheadin directionindicated.
6.3.2Strainer
Strainersshouldbecleanedregularlybyauthorizedpersonnel.The frequencyofcleaningwoulddependonoperatingconditionsand themanufacturer’sinstructions.
6.3.3GTUPressureEqualizer
TheGTUPressureEqualizerabsorbstheexpansiononthe secondarysideoftheTermixwaterheatersandcanbeusedasa substitutetothesafetyvalve. Furthermorethepressureequalizerabsorbsapossibleincreasein pressure,soadischargeoutletisomitted. TheGTUPressureEqualizermaynotbeappliedinsystemswithhot watercirculation.
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6.3.4Fittingpiece
Thesubstationisequippedwithafittingpieceforenergymeter.
Assemblyofenergymeters:
1:Closeballvalves
ClosetheballvalvesonDHSupplyandDHReturn,ifthereiswater onthesystem.
2:Loosennuts
Loosenthenutsonthefittingpiece.
3:Removefittingpiece
Removethefittingpieceandreplaceitwiththeenergymeter.Do notforgetthegaskets.
4:Tightenconnections
Aftermountingoftheenergymeterremembertocheckand tightenallthreadedconnections.
Sensorpocket,energymeter
Thesensorsoftheenergymeterismountedinthesensorpockets.
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6.4Extras

6.4.1Circulationpipe
Thecirculationpipesetismounteddirectlyonthecontroller. Thesetincludescirculationpipe,singlecheckvalveandfitting. Whenmountingthehotwatercirculationdirectlyonthecontroller thehotwatercirculationtemperaturewillbeequaltotheidle temperature.Theidletemperatureisafewdegreeslowerthanthe setdomestichotwatertemperature.
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6.5Mountingplateforenergymeterdisplay

Bracketforthedisplayoftheenergymeterdeliveredloosewith theDistrictHeatingsubstation.
Mountthewallclipforthedisplayontothebracket.
Fixthebracketontothepipeclipsusingapairofpliers.
Slidethedisplayoftheenergymeterontheclip.
ThedisplayisnowneatlypositionedbelowtheDistrictHeating substation.
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6.6Maintenance

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
Idletemperaturetoolow(forstations equippedwithIHPT).
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.
Setpointtoolow.Turnthermostatin(+)direction.
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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7.3TroubleshootingHE

ProblemPossiblecauseSolution
Toolittleornoheat.StrainercloggedinDHorHEcircuit
Unevenheatdistribution.Airpocketsinthesystem.Venttheinstallationthoroughly.
DHsupplytemperaturetoohigh.
DHsupplytemperaturetoolow.
(radiatorcircuit).
ThefilterintheenergymeteronDHcircuit clogged.
Defectiveorwronglyadjusteddifferential pressurecontroller.
Sensordefective–orpossiblydirtinthe valvehousing.
Automaticcontrols,ifany,wronglysetor defective-possiblypowerfailure.
Pumpoutofoperation.Checkifthepumpisreceivingpowerand
Thepumpissetattoolowspeedof rotation.
Pressuredrop–thepressuredropon theradiatorcircuitshowslowerthan recommendedoperatingpressure.
Airpocketsinthesystem.Venttheinstallationthoroughly.
Limitingofthereturntemperatureadjusted toolow.
Defectiveradiatorvalves.
Unevenheatdistributioninbuilding becauseofincorrectlysetbalancingvalves, orbecausetherearenobalancingvalves.
Diameterofpipetosubstationtoosmallor branchpipetoolong.
Wrongsettingofthermostatorof automaticcontrols,ifany.
Defectivecontroller.Thecontrollerdoes notreactasitshouldaccordingtothe instructions.
Defectivesensoronself-actingthermostat.
Wrongsettingofautomaticcontrols,ifany.
Defectivecontroller.Thecontrollerdoes notreactasitshouldaccordingtothe instructions.
Defectivesensoronself-actingthermostat.
Wrongplacement/fittingofoutdoor temperaturesensor.
Strainerclogged.Cleangate/strainer.
Cleangate/strainer(s).
Cleanthefilter(afterconsultingtheDH plantoperator).
Checktheoperationofthedifferential pressurecontroller–cleanthevalveseatif required.
Checktheoperationofthethermostat– cleanthevalveseatifrequired.
Checkifthesettingofthecontroller iscorrect–seeseparateinstructions. Checkthepowersupply.Temporary settingofmotorto“manual”control–see instructionsonautomaticcontrols.
thatitturns.Checkifthereisairtrappedin thepumphousing–seepumpmanual.
Setthepumpathigherspeedofrotation.
Fillwateronthesystemandcheckthe functioningofthepressureexpansion vesselifrequired.
Adjustaccordingtoinstructions.
Check–replace.
Adjust/installbalancingvalves.
Checkpipedimensions.
Adjustautomaticcontrols,–see instructionsforautomaticcontrols.
Callautomaticcontrolsmanufactureror replacetheregulator.
Replacethermostat–orsensoronly.
Adjustautomaticcontrols–seeinstructions forautomaticcontrols.
Callinautomaticcontrolsmanufactureror replacecontroller.
Replacethermostat–orsensoronly.
Adjustlocationofoutdoortemperature sensor.
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ToohighDHreturntemperature.
Noiseinsystem.
Heatloadtoohigh.
Toosmallheatingsurface/toosmall radiatorscomparedtothetotalheating requirementofthebuilding.
Poorutilizationofexistingheatingsurface. Defectivesensoronself-actingthermostat.
Thesystemissinglepipeloop.
Pumppressuretoohigh.Adjustpumptoalowerlevel.
Airinsystem.
Defectiveorincorrectlysetradiatorvalve(s). Singlepipeloopsystemsrequirespecial one-piperadiatorvalves.
Dirtinthemotorizedvalveorinthe differentialpressurecontroller.
Defectivemotorizedvalve,sensoror automaticcontroller.
Electroniccontrollernotadjustedcorrectly.Adjustaccordingtoinstructions.
Pumppressuretoohigh.Adjustpumptoalowerlevel.
Defectivemotorizedvalve,sensoror electroniccontroller.
Increasetotalheatingsurface.
Makesuretheheatisdistributedevenly acrossthefullheatingsurface–openall radiatorsandkeeptheradiatorsinthe systemfromheatingupatthebottom.It isextremelyimportanttokeepthesupply temperaturetotheradiatorsaslowas possible,whilemaintainingareasonable levelofcomfort.
Thesystemshouldfeatureelectronic controlsaswellasreturnsensors.
Ventthesystem.
Check–set/replace.
Check–cleanout.
Check–replace.
Check–replace.
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7.4Disposal

Disposal
Thisproductshouldbedismantledanditscomponents sorted,ifpossible,invariousgroupsbeforerecycling ordisposal.
Alwaysfollowthelocaldisposalregulations.
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8.0Declaration

8.1Declarationofconformity

Category0withoutelectricalequipment
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Category0withelectricalequipment
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