Danfoss VX Compact 28 - 40 Operating guide

OperatingGuide
TermixVXCompact28-40

1.0TableofContents

1.0TableofContents.............................................1
........................................................................2
2.0Functionaldescription......................................3
3.0Safetynotes.....................................................4
3.1SafetyNotes–general............................................4
4.0Mounting........................................................5
4.2Start-up..............................................................7
4.3Electricalconnections.............................................9
5.0Design.............................................................10
5.1Design...............................................................10
5.2Schematicdiagram................................................11
6.0Controls..........................................................12
6.1Heatingcircuit......................................................12
6.2Other.................................................................15
6.3Maintenance........................................................17
7.0Troubleshooting..............................................18
7.1Troubleshootingingeneral......................................18
7.2TroubleshootingHE...............................................19
7.3Disposal.............................................................21
8.0Declaration......................................................22
8.1Declarationofconformity........................................22
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2.0Functionaldescription

Districtheatingsubstationforindirectheating.
Application
TheTermixVXCompact28-40isacompletesolutionfor spaceheatingwithoptimalsafety,efficientenergytransfer, service-friendlyconstructionandacompactdesign.Thesubstation isapplicable,ifaheatexchangerisrequiredoronaconversionto districtheating,wheretheexistingequipmentisunsuitablefor directconnection.TheTermixVXCompact28-40substationis ideal,whereahighlevelofsecurityagainstburstpipesandwater damageintheheatingsystemisrequired.
Districtheating(DH)
Thedistrictheatingcircuitisprefabricatedwithaflowcontroller withintegratedcontrolvalve,thermometersandballvalves.
Heating(HE)
Theheatingcircuitconsistsofaplateheatexchanger,safetyvalve, manometer,thermometers,ballvalves,drainvalve,airvalveand circulationpump.Theheatingtemperaturecanbecontrolled thermostaticallyorbyanelectroniccontrollerwithanoutdoor temperaturesensor.Dependingontheapplication,differentheat exchangersdimensionedforcentralorfloorheatingcanbeused.
Domestichotwater(DHW)
TermixVXCompact28-40issuppliedwithconnectionpipesfor aDHWtankonthesupplyline.
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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.Heating(HE)supply
2.Heating(HE)return
3.Districtheating(DH)supply
4.Districtheating(DH)return
5.Tankflowline(TFL)
6.Tankreturnline(TRL)
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby qualifiedandauthorizedpersonnelonly.
Dimensions(mm):H999xW1285xD423
Weight(approx.):70kg
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.
Mountingframe.
Thightening
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,Indirectheating
Filling:
1:Firstfill
Whencarryingoutfirstfill,theheatexchangermustbeslowlyfilled withwateruntilitreachesworkingpressure.
2:Pressuregauge
TheHEpressuregaugeindicatesthepressureoftheHEsystem.This instructionmustbefollowedstrictly,toavoiddangeroussituations.
3:Supplyhose
AballvalvewithplugisinstalledintheHEreturnline.Tofillthe system,theballvalvemustfirstbeclosed,theplugremovedand asupplyhoseconnected.Onre-openingtheballvalve,system fillcancommence.
4:Pre-pressure
Whenfillingthesystemwithwater,thepressuregaugeshouldbe observedclosely.Theexpansionvesselissuppliedpre-pressurised to0.5bar.Thepre-pressurerequiredateachsubstationwill dependonsystemhead(thedistancebetweenthelowestand highestpointinthesystem),forexample:
5:Fillingstop
Fillingmuststopwhenthepressuregaugeshowsapressure approximately1-2barhigherthanthepre-pressuresetting.The ballvalveisthenclosed,thehoseremovedandtheplugputback in.
Re-tightenconnections
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen putintooperation,re-tightenALLconnections.
Pump
Thepumpmustbeswitchedoffduringsystemfill.
Height(m)Pressure(bar)
0–50,5
5–101,0
10–15
1,5
15–202,0
Start-up:
1:Pumpspeed
Setthepumptohighestspeedbeforestart-up.
2:Startpump
Startthepumpandheatthroughthesystem.
3:Openshut-offvalves
Theshut-offvalvesshouldthenbeopenedandtheunitobserved asitentersservice.Visualcheckingshouldconfirmtemperatures, pressures,acceptablethermalexpansionandabsenceofleakage. Iftheheatexchangeroperatesinaccordancewithdesign,itcanbe puttoregularuse.
4:Ventsystem
Switchoffthepumpandventtheinstallationaftertheradiators havebeenwarmedup.
5:Adjustpumpspeed
Setthepumptothelowestspeedconsistentwithcomfortand electricityconsumption. Normallythechange-overswitchissetinthemidposition(default). Howeverforsystemswithunderfloorheatingorsinglepipeloop systems,itmaybenecessarytoturnthechange-overswitch upwards. Higherpumpspeedsareonlyusediftheheatingrequirement increases.
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Underfloorheating:
Pumpstopfunction
Ifthesubstationisusedinconnectionwithunderfloorheating,the circulationpumpmustbeconnectedtothepumpstopfunctionin theunderfloorheatingcontroller.Thepumpmustbestoppedif allunderfloorheatingcircuitsareclosed.
Warranty
Ifthisisnotpossible,thenflowmustbecontinuedthroughthe 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.
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
A
Heatexchanger,HE
F
Electroniccontroller
4
Safetyvalve,HE
9
Strainer
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Circulatorpump
20
Filling/drainvalve
25
Pressuregaugewithballvalve
26
Pressuregauge,HE
27
Actuator,HE
30
Flowcontrollerwithintegratedcontrolvalve
48
Airvent,manual
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5.2Schematicdiagram

DH
Supply
DH
Return
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
A
Heatexchanger,HE
E
Hotwatertankwithcoil
F
Electroniccontroller
L
Borderofdelivery
1
Ballvalve
2
Singlecheckvalve
4
Safetyvalve
9
Strainer
10
Circulatorpump
11
Domestichotwaterpump
16
Outdoorsensor
18
Thermometer
19
Surfacesensor
20
Filling/drainvalve
21
Tobeorderedseparately
22
Testconnection
23
Ballvalve
24
Deliveredloosewithunit
25
Pressuregaugewithballvalve
26
Pressuregauge
27
Actuator
29
2-waymotorizedvalve
30
Flowcontrollerwithintegratedcontrolvalve
31
Differentialpressurecontroller
44
Immersionsensor
48
Airvent,manual
HE Supply
HE Return
DHW
HWC
DCW
DCW: DHW:DomesticHotWater HWC: DHSupply:DistrictHeatingSupply DHReturn:DistrictHeatingReturn HESupply:HeatingSupply HEReturn:HeatingReturn
5.2.1Technicalparameters
Technicalparameters
Nominalpressure: Max.DHsupplytemperature: Min.DCWstaticpressure: Brazingmaterial(HEX): Heatexchangerstestpressure:30bar Soundlevel:≤55dB
DomesticColdWater
HotWaterCirculation
PN16 120°C
0.5bar Copper
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6.0Controls

6.1Heatingcircuit

6.1.1Flowcontrollerwithintegratedcontrolvalve
Thecontrollerisaself-actingflowcontrollerwithintegratedcontrol valve.Thecontrollercloseswhensetmax.flowisexceededand canbeusedincombinationwithDanfosselectricalactuatorswith orwithoutsafetyfunction.Springreturnmotorcanbeusedas safetyfunctionbypowerfailure.
6.1.2Electric2–waymotorizedvalve
Actuatorswithorwithoutsafetyfunctionareavailablefor3-point controls.Spring-returnactuatorscanbeusedtoprovidesafety shut-offintheeventofpowerfailure.
6.1.3Electroniccontrol
Substationswithelectroniccontrolmustbesetinaccordancewith manufacturer´sinstructions. Wheretheroomtemperatureiscontrolledbyradiatorthermostats, itisrecommendedthatthermostatsbesetforminimum temperatureineachroom.
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6.1.4Outdoortemperaturesensor(ESMT)
Outdoorsensorsshouldbemountedsoastoavoidexposureto directsunlight.Theyshouldnotbeplacedclosetodoors,windows orventilationoutlets.
6.1.5Circulatorpump
TheUPML,UPMXLcirculatorpumpsaredesignedforcirculating liquidsinheatingsystemswithvariableflows,internallycontrolled withthreeproportionalpressurecurvesandthreeconstant pressure/powercurvestobeselectedviauserinterface.
EuP2015Ready.
TheMAGNA3circulatorpumpsaredesignedforcirculatingliquids inheatingsystemswithvariableflowswhereyouwanttooptimise thesettingofthepumpdutypoint,thusreducingenergycosts.
EuP2015Ready.
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6.1.6GrundfosUPML/UPMXLinstructions
PP=Proportionalpressure(fastflash) CP=Constantpressure(slowflash)
6.1.7HEpressuregauge
TheHEpressuregaugeindicatesthepressureoftheHEsystem.
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6.2Other

6.2.1Safetyvalve
Thepurposeofthesafetyvalveistoprotectthesubstationfrom excessivepressure. Theblow-offpipefromthesafetyvalvemustnotbeclosed.The blow-offpipeoutletshouldbeplacedsothatitdischargesfreely anditispossibletoobserveanydrippingfromthesafetyvalve. Itisrecommendedtochecktheoperationofsafetyvalvesat intervalsof6months.Thisisdonebyturningthevalveheadin directionindicated.
6.2.2Strainer
Strainersshouldbecleanedregularlybyauthorizedpersonnel.The frequencyofcleaningwoulddependonoperatingconditionsand themanufacturer’sinstructions.
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6.2.3Fittingpiece
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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6.3Maintenance

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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7.2TroubleshootingHE

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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7.3Disposal

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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