Danfoss DH Compact substation Operating instructions

Brand: Danfoss

Model: DH Compact substation

Type: Operating instructions

Danfoss District Energy VI.KS.F2.02 DENSMT/PL

2. Safety notes

1. Table of Contents

Instructions

DH Compact Substation

District heating compact substation

for indirect heating,

domestic hot water, venting

and cooling system

1. Content...............................................................................................................................................................................................................................................1

2. Safety notes......................................................................................................................................................................................................................................1

3. Transportation.................................................................................................................................................................................................................................2

4. Lifting and moving.........................................................................................................................................................................................................................2

5. Storage...............................................................................................................................................................................................................................................2

6. Mounting and setting...................................................................................................................................................................................................................2

6.1 Pipe connections.....................................................................................................................................................................................................................3

6.2 Electrical connections...........................................................................................................................................................................................................3

6.3 Components.............................................................................................................................................................................................................................3

7. Filling, start-up.................................................................................................................................................................................................................................3

8. Maintenance.....................................................................................................................................................................................................................................4

Following instructions refer to the standard design of the

DH compact substation. Special versions of substations are

available on request.

Danfoss does not bear responsibility for whichever damages of

device, which have not been mounted or stored in accordance

with following instructions. Therefore, please carefully read the

instructions before installation and start-up of the substation.

To avoid injury of persons and damages to the device, it is

absolutely necessary to carefully read and observe these

instructions.

Necessary assembly, start-up and maintenance work must be

performed only by qualiﬁed and authorized personnel.

Please comply with more accurate and detailed instructions

included in the technical documentation delivered with the

product or separately by mail.

Those connections and shut-oﬀ valves, which are ready for use,

must be sealed with a plug. The plugs can be removed only by

qualiﬁed and authorized personnel.

Warning of high pressure and temperature

The maximum temperature and pressure always have to be

checked on the product data label attached to the product.

Be aware of the installation’s permissible system pressure and

temperature. The risk of persons getting injured and equipment

being damaged increases considerably if the recommended

permissible operating parameters are exceeded.

The substation installation is equipped with safety valves which

must always be mounted in accordance with local regulations.

The safety valves mounted on the secondary circuits are

designed to take over the volume excess due to overheating of

water in heat exchanger.

The customer is responsible to protect the secondary circuits

against all volume variations done by other causes than that

mentioned above.

The safety valves will not be mounted ahead any other closing

valves. Any other valve will not be mounted on its discharging

pipe.

Instructions DH Compact Substation

DEN-SMT/PL VI.KS.F2.02 Danfoss District Energy

Warning of hot surface

The substation has got hot surfaces which can cause skin

burns. Please be extremely cautious in close proximity of the

substation.

Warning of transportation damage

Prior to installing substation, please make sure that the

substation has not been damaged during transportation.

Be extremely careful when lifting or moving big and heavy

substation.

3. Transportation

When receiving the substation please pay attention to following

matters:

- there are no transportation damages,

- delivery is complete and in accordance with the order

- sign the freight note and keep your copy of it.

In case of transportation damages, it is necessary to ﬁll the

transportation damage form immediately. The form must be

signed by the claimer and the representative of the forwarding

agent (e.g. driver). Each forwarding agent driver has a form for

reporting transportation damages.

The unit may be dismantled to make transport easier. In this case

the following measures must be carried out:

- protect the unit parts from damages (measurement instruments,

electronic devices, electrical cables, pumps, pipes etc). Dismantling

and reassembling of components must be done according to

component O&M instructions

- avoid the entrance of impurities on valves and pumps bodies ,

pipes etc.

4. Lifting and moving

A wooden pallet is bound underneath the substation in order to

help moving and lifting the substation. The substation should be

moved close to the installation place with the help of the pallet

truck – forklift, and only on special occasions with the crane.

Manipulation with crane will be done under the supplier supervise

and hanging will be done by bottom pedestal, only.

Attention:

The packages weight must not exceed the maximum load of pallet

truck – forklift.

Manipulation must be done only by qualiﬁed/authorised

personnel.

Because the units are not very well body-centred structures,

special anchoring measures will be taken during manipulations

and deliveries, in order to avoid damages and accidents.

Do not damage the substation when lifting it! When lifting

the substation, tie straps around the wooden pallet placed

underneath the substation. The stress should not concentrate on

the substation or its connections. The wooden pallet should be

used as a lifting and moving base as close to the installation place

as possible.

5. Storage

If the substation is stored prior to installation in a warehouse or

some other storage, make sure that the place is dry and heated.

6. Mounting and settings

In order to adjust the height and position of the substation:

1) If adjusting feet are included, use them in order to adjust

2) If adjusting feet are not included, prepare a levelled base

in order to adjust height.

* does not apply to substations designed for wall- mounting.

the height. The substation should be assembled straight

horizontally. Pay attention to adjusting all feet in correct

way. Tighten the tightening nuts in order to secure the

stable position.

The substation must be installed and connected by authorized

service personnel only. Installation must comply with the

local standards and regulations. Move the substation to the

installation place by following instructions given in section

“Lifting and moving”.

Leave adequate space around the substation for mounting and

maintenance purposes.

The DH compact substation is mounted directly on the ﬂoor and

it does not require clamping.*

Instructions DH Compact Substation

7. Filling, start-up

6.1 Pipe connections

Make sure to connect pipes correctly according to designs and

speciﬁcations included in technical documentation. Threaded,

ﬂanged or welded connections are used to connect the substation

into district heating network and internal networks.

Prior to start-up all pipes and connections have to be checked.

The pipes must be mounted so that the strain caused by e.g.

thermal expansion, does not harm the substation. The pipes must

be equipped with brackets in order to prevent any torsional stress.

6.2 Electrical connections

The electrical diagrams for electriﬁcation are included in technical

documentation. Internal electriﬁcations are made in the factory.

The electric cables cannot be fastened with the hot pipes.

They need their own supporting structures.

6.3 Components

Refer to technical documentation for detailed instruction for all

components (e.g. pumps, controllers, heat exchangers).

All connections must be checked and tightened before the

substation is installed. The connections may loosen during

transportation.

Check that the product is according to designs and speciﬁcations

included in the technical documentation.

Check points, before start-up

Pipes are connected according to the circuit diagram.

Drainage valves are closed.

Expansion vessel is connected with compact substation.

Threaded and ﬂanged connections are tightened.

Function of safety valves is checked.

Check points, after start-up

Check temperatures.

Check pressures.

Thermal expansion.

Leakages.

Operation of pumps.

Flow directions.

Operations of controllers

Before start-up please check the following points:

All Danfoss heat exchangers and substations have been pressure

tested according to PED 97/23/EC (module H).

Make sure to give operating instructions to the users of the

substation.

Fill the substation with ﬂow media and raise the pressure slowly to

working pressure.

When starting up the substation it should be air vented. The shut

oﬀ valve in the primary side on the return side is opened and the

shut oﬀ valve on the supply side is closed. Air comes out by open-

ing the air vent valve.

After that the operation of the substation must be observed. If the

substation operates according to designed parameters, it can be

taken into continuous use.

Prior to installation all pipes and connections have to be cleaned

and rinsed.

All supporting structures assembled for the period of

transportation have to be removed before the substation can be

taken into use.

Danfoss District Energy VI.KS.F2.02 DENSMT/PL

Instructions DH Compact Substation

8. Maintenance

VI.KS.F2.02

Danfoss District Heating SRL · 208 Oltenitei Drive · Popesti-Leordeni 077160 · Ilfov · Romania

Tel.: +4031 222 20 10 · Fax: +4031 222 22 99 · oﬃce.romania@danfoss.com

www.termoﬁcare.danfoss.com · www.danfoss.com

Danfoss LPM Sp. z o.o. · Tuchom, ul. Tęczowa 46 · 80-209 Chwaszczyno

Tel.: +48 58 512 91 00 · Fax: +48 58 512 91 05 · lpmpoland@danfoss.com · www.danfoss.com

It is necessary to check and maintain the substation on regular

basis in order to keep it in good operating condition.

The frequency of maintenance and service inspections should be

done according to system manufacturer’s recommendations and

local legislation.

General overview of the equipment should take place at least

twice a year (before and after the heating season). More accurate

service should take place once a year by authorized personnel.

Service

Always use authorized service personnel when the equipment

needs service.

In guarantee matters please contact your local Danfoss Sales

Company.

The O&M Instructions for main components must be observed.

Check points, maintenance inspection

No leakages.

Supply and return temperatures and pressures should be

according to designed values.

Extraordinary noises.

Check points, service inspection

Clean the strainer if necessary.

Check supply and return temperatures.

Check the parameters of the controller.

Check pressure drops in the heat exchangers.

The cooling of district heating water should comply with the

requirements given by the local DH company.

Measure the pre-pressure in the expansion vessel.

Check that the operating point of the pump stays in allowed

area of the pump curve.

At least following points should be observed before and after the

heating season:

At least following points should be inspected once a year by

authorized personnel:

All Danfoss heat exchangers and substations have been pressure

tested according to PED 97/23/EC (module H).

Make sure to give operating instructions to the users of the

substation.

Danfoss DH Compact substation Operating instructions

Danfoss DH Compact substation Operating instructions

Danfoss DH Compact substation Operating instructions

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