Danfoss VX Compact – Floor Station Operating guide

OperatingGuide

TermixVXCompact–FloorStation

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..............................................................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

TheT ermixVXCompact–FloorStationisacompletesolution
forspaceheatingwithoptimalsafety,efficientenergytransfer,
service-friendlyconstructionandacompactdesign.Thesubstation
isapplicable,ifaheatexchangerisrequiredoronaconversion
todistrictheating,wheretheexistingequipmentisunsuitable
fordirectconnection.TheTermixVXCompact–FloorStationis
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)

TermixVXCompact–FloorStationissuppliedwithconnection
pipesforaDHWtankonthesupplyline.

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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.

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

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

I

Connectionexpansiontank

4

Safetyvalve

9

Strainer

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Circulatorpump

20

Filling/drainvalve

25

Pressuregaugewithballvalve

26

Pressuregauge,HE

27

Actuator,HE

30

Flowcontrollerwithintegratedcontrolvalve

71

Airvent

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5.2Schematicdiagram

DH

Supply

DH

Return

TRL

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

A

Heatexchanger,HE

F

Electroniccontroller

I

Connectionexpansiontank

1

Ballvalve

4

Safetyvalve

9

Strainer

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

Tankflowline
Tankreturnline

10
16
18
19
20
24

TFL

Circulatorpump
Outdoorsensor
Thermometer
Surfacesensor
Filling/drainvalve
Deliveredloosewithunit

25

Pressuregaugewithballvalve

26

Pressuregauge

27

Actuator

30

Flowcontrollerwithintegratedcontrolvalve

39

Connectionclosed

40

Immersionsensor

HE
Supply

HE
Return

5.2.1Technicalparameters

Technicalparameters

Nominalpressure:
Max.DHsupplytemperature:
Min.DCWstaticpressure:
Brazingmaterial(HEX):
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB

PN16
120°C

0.5bar
Copper

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6.0Controls

6.1Heatingcircuit

6.1.1Differentialpressurecontroller

Thedifferentialpressurecontrollersmoothsoutthefluctuationsin
pressurearrivingfromthedistrictheatingnetwork.Theoperating
pressureinthesubstationisthusheldsteady.

6.1.2Flowcontrollerwithintegratedcontrolvalve

Thecontrollerisaself-actingflowcontrollerwithintegratedcontrol
valve.Thecontrollercloseswhensetmax.flowisexceededand
canbeusedincombinationwithDanfosselectricalactuatorswith
orwithoutsafetyfunction.Springreturnmotorcanbeusedas
safetyfunctionbypowerfailure.

6.1.3Electric2–waymotorizedvalve

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

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6.1.4Electroniccontrol

Substationswithelectroniccontrolmustbesetinaccordancewith
manufacturer´sinstructions.
Wheretheroomtemperatureiscontrolledbyradiatorthermostats,
itisrecommendedthatthermostatsbesetforminimum
temperatureineachroom.

6.1.5Outdoortemperaturesensor(ESMT)

Outdoorsensorsshouldbemountedsoastoavoidexposureto
directsunlight.Theyshouldnotbeplacedclosetodoors,windows
orventilationoutlets.

6.1.6Circulationpump

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

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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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Category1withelectricalequipment

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