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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