Danfoss Termix BL Operating instructions

Brand: Danfoss

Model: Termix BL

Type: Operating instructions

InstallationGuide

TermixBL

1.0TableofContents

1.0TableofContents.............................................1

........................................................................2

2.0Functionaldescription......................................3

3.0Safetynotes.....................................................4

3.1SafetyNotes–general............................................4

4.0Mounting........................................................5

4.1Mounting...........................................................5

4.2Electricalconnections.............................................7

5.0Design.............................................................8

5.1Design...............................................................8

5.2Schematicdiagram................................................9

5.3Design...............................................................10

5.4Schematicdiagram................................................11

6.0Controls..........................................................12

6.1DHWtemperaturecontrol........................................12

6.2Other.................................................................13

6.3Maintenance........................................................14

7.0Troubleshooting..............................................15

7.1Troubleshootingingeneral......................................15

7.2TroubleshootingDHW............................................15

7.3Disposal.............................................................16

8.0Declaration......................................................18

8.1Declarationofconformity........................................18

DanfossDistrictEnergy

VI.EH.D3.02/LUK41570

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InstallationGuideTermixBL

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VI.EH.D3.02/LUK41570

DanfossDistrictEnergy

InstallationGuideTermixBL

2.0Functionaldescription

Instantaneouswaterheaterwithheatexchangerand

automaticcontrols.Designedforwall-mounting.

Application

TheTermixBLisawaterheaterwithautomaticcontrolsprepared

forachargingsystem.TheTermixBLissuitableforlargeapartment

houses,sportsarenasandschools,wherelargeamountsofhot

waterareneeded.Thehotwatersystemsareavailablein7different

sizeswithanoutputfrom70-222kW.TheTermixBLunitissupplied

withPUinsulatedplateheatexchangers.

Domestichotwater(DHW)

TheTermixBLisavailableforchargingsystemswithlarge

momentarydemandsforhotwaterorininstallationswithrelatively

lowsupplycapacity.TheTermixBLchargingsystemisdelivered

withDanfossautomaticcontrolsforregulationofthecharging

temperatureandthetemperatureinthehotwaterbuffertank.The

controlvalvewithintegratedpressurecontrolhelpstoavoidcyclic

variationsofthedifferentialpressureinthedistrictheatingsupply.

Domestichotwatercirculation

TheTermixBLsubstationissuppliedwithconnectionsforDHW

circulationincludingcirculationpumpandanon-returnvalveas

astandard.

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InstallationGuideTermixBL

3.0Safetynotes

3.1SafetyNotes–general

Thefollowinginstructionsrefertothestandarddesignof

substation.Specialversionsofsubstationsareavailableon

request.

Thisoperatingmanualshouldbereadcarefullybeforeinstallation

andstart-upofthesubstation.Themanufactureracceptsno

liabilityfordamageorfaultsthatresultfromnon-compliancewith

theoperatingmanual.Pleasereadandfollowalltheinstructions

carefullytopreventaccidents,injuryanddamagetoproperty.

Assembly,start-upandmaintenanceworkmustbeperformedby

qualiedandauthorizedpersonnelonly.

Pleasecomplywiththeinstructionsissuedbythesystem

manufacturerorsystemoperator.

Corrosionprotection

Allpipesandcomponentsaremadeofstainlesssteelandbrass.

Themaximumchloridecompoundsoftheowmediumshouldnot

behigherthan150mg/l.

Theriskofequipmentcorrosionincreasesconsiderablyifthe

recommendedlevelofpermissiblechloridecompoundsis

exceeded.

Energysource

Thesubstationisdesignedfordistrictheatingastheprimary

sourceofenergy.However,alsootherenergysourcescanbeused

wheretheoperatingconditionsallowitandalwaysarecomparable

todistrictheating.

Application

Thesubstationisdesignedtobeconnectedtothehouse

installationinafrost-freeroom,wherethetemperaturedoesnot

exceed50°Candthehumiditydoesnotexceed60%.Donotcover

orwallupthesubstationorinanyotherwayblocktheentrance

tothestation.

Choiceofmaterial

Choiceofmaterialsalwaysincompliancewithlocallegislation.

Safetyvalve(s)

Werecommendmountingofsafetyvalve(s),however,alwaysin

compliancewithlocalregulations.

Connection

Thesubstationmustbeequippedwithfeaturesthatensurethat

thesubstationcanbeseparatedfromallenergysources(also

powersupply).

Emergency

Incaseofdangeroraccidents-re,leaksorotherdangerous

circumstances-interruptallenergysourcestothestationif

possible,andseekexperthelp.

Incaseofdiscolouredorbad-smellingdomestichotwater,closeall

shut-offvalvesonthesubstation,informtheoperatingpersonnel

andcallforexperthelpimmediately.

Storage

Anystorageofthesubstationwhichmaybenecessarypriorto

installationshouldbeinconditionswhicharedryandheated.

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby

qualiedandauthorizedpersonnelonly.

Pleaseobserveinstructionscarefully

Toavoidinjurytopersonsanddamagetothedevice,itisabsolutely

necessarytoreadandobservetheseinstructionscarefully.

Warningofhighpressureandtemperature

Beawareoftheinstallation’spermissiblesystempressureand

temperature.

Themaximumtemperatureoftheowmediuminthesubstationis

120°C.

Themaximumoperatingpressureofthesubstationis10bar.PN16

versionsareavailableonenquiry.

Theriskofpersonsbeinginjuredandequipmentdamagedincreases

considerablyiftherecommendedpermissibleoperatingparameters

areexceeded.

Thesubstationinstallationmustbeequippedwithsafetyvalves,

however,alwaysinaccordancewithlocalregulations.

Warningofhotsurface

Thesubstationhasgothotsurfaces,whichcancauseskinburns.

Pleasebeextremelycautiousincloseproximitytothesubstation.

Powerfailurecanresultinthemotorvalvesbeingstuckinopen

position.Thesurfacesofthesubstationcangethot,whichcancause

skinburns.Theballvalvesondistrictheatingsupplyandreturnshould

beclosed.

Warningoftransportdamage

Beforesubstationinstallation,pleasemakesurethatthesubstation

hasnotbeendamagedduringtransport.

IMPORTANT-Tighteningofconnections

Duetovibrationsduringtransportallangeconnections,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.Hotwatercirculation(HWC)

4.Domestichotwater(DHW)

5.Domesticcoldwater(DCW)

Connectionsizes:

DH+DCW+DHW:

G1”(int.thread)

HWC:

G¾”(int.thread)

Dimensions(mm):

Type2-5withoutcover:

H660xW510xD240

Type2-5withcover:

H800xW540xD360

Type6-8withoutcover:

H920xW720xD385

Type6-8withcover:

H920xW800xD450

Weight(approx.):20–40kg

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby

qualiedandauthorizedpersonnelonly.

Type2–5

Type6–8

Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote

themarkingsonthestation.

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InstallationGuideTermixBL

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.

Thightening

Duetovibrationduringtransport,allsubstationconnectionsmust

becheckedandtightenedbeforeinstallation.

Unusedconnections

Unusedconnectionsandshut-offvalvesmustbesealedwitha

plug.Shouldtheplugsrequireremoval,thismustonlybedoneby

anauthorizedservicetechnician.

Installation:

Strainer

Ifastrainerissuppliedwiththestationitmustbettedaccording

toschematicdiagram.Pleasenotethatthestrainermaybe

suppliedloose.

Connections

Internalinstallationanddistrictheatingpipesconnectionsmustbe

madeusingthreaded,angedorweldedconnections.

Keyholeformounting.

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InstallationGuideTermixBL

4.2Electricalconnections

Beforemakingelectricalconnections,pleasenotethe

following:

Safetynotes

Pleasereadtherelevantpartsofthesafetynotes.

230V

Thesubstationmustbeconnectedto230VACandearth.

Disconnection

Thesubstationmustbeelectricallyconnectedsothatitcanbe

disconnectedforrepairs.

Outdoortemperaturesensor

Outdoorsensorsshouldbemountedsoastoavoidexposureto

directsunlight.Theyshouldnotbeplacedclosetodoors,windows

orventilationoutlets.

Theoutdoorsensormustbeconnectedtothestationonthe

terminalblockundertheelectroniccontrol.

Authorizedelectrician

Electricalconnectionsmustbemadebyanauthorizedelectricianonly.

Localstandards

Electricalconnectionsmustbemadeinaccordancewithcurrent

regulationsandlocalstandards.

DanfossDistrictEnergy

VI.EH.D3.02/LUK41570

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InstallationGuideTermixBL

5.0Design

5.1Design

Yoursubstationmightlookdifferentthanthesubstationshown.

Designdescription

Heatexchanger,DHW

Electroniccontroller,DHW

Singlecheckvalve

Domestichotwaterpump

Actuator

Flowcontrolwithcontrolvalve

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5.2Schematicdiagram

Schematicdiagramtype2-5(example)

DHW

Supply

Return

DCW

HWC

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

Heatexchanger,DHW

Safetyvalve

Actuator

Hotwatertank

Domestichotwaterpump

Flowcontrolwithcontrolvalve

Electroniccontroller,DHW

Chargingpump

Balancingvalve

Borderofdelivery

Thermometer

Immersionsensor

Ballvalve

Surfacesensor

Ballvalveclosed

Singlecheckvalve

Deliveredloosewithunit

Immersionsensor

5.2.1Technicalparameters

Technicalparameters

Nominalpressure:

PN16

Max.DHsupplytemperature:

120°C

Min.DCWstaticpressure:

0.5bar

Brazingmaterial(HEX):

Copper

Heatexchangerstestpressure:30bar

Soundlevel:≤55dB

DanfossDistrictEnergy

VI.EH.D3.02/LUK41570

DEN-GT

InstallationGuideTermixBL

5.3Design

Yoursubstationmightlookdifferentthanthesubstationshown.

Designdescription

Heatexchanger,DHW

Chargingpump

Electroniccontroller,DHW

Actuator

Singlecheckvalve

Flowcontrolwithcontrolvalve

Domestichotwaterpump

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VI.EH.D3.02/LUK41570

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5.4Schematicdiagram

Schematicdiagramtype6-8(example)

DHW

Supply

Return

DCW

HWC

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

Heatexchanger,DHW

Safetyvalve

Flowcontrolwithcontrolvalve

Hotwatertank

Domestichotwaterpump

Balancingvalve

Electroniccontroller,DHW

Chargingpump

Immersionsensor

Borderofdelivery

Thermometer

Ballvalveclosed

Ballvalve

Surfacesensor

Immersionsensor

Singlecheckvalve

Actuator

5.4.1Technicalparameters

Technicalparameters

Nominalpressure:

PN16

Max.DHsupplytemperature:

120°C

Min.DCWstaticpressure:

0.5bar

Brazingmaterial(HEX):

Copper

Heatexchangerstestpressure:30bar

Soundlevel:≤55dB

DanfossDistrictEnergy

VI.EH.D3.02/LUK41570

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InstallationGuideTermixBL

6.0Controls

6.1DHWtemperaturecontrol

DHWtemperaturecontrol

TherearevarioustypesofDHWtemperaturecontrolusedin

Danfosssubstations.

DHWtemperatureshouldbeadjustedto45-50°C,asthisprovides

optimalutilisationofDHwater.AtDHWtemperaturesabove55°C,

thepossibilityoflimescaledepositsincreasessignicantly.

Twovalvesincascade

Iftwothermostaticcontrolvalvesaremountedparallelincascade,

itisimportanttoadjustthevalvesaccordingtothefollowing:The

smallvalveisforcontrollingsmalltappingowsandthelargevalve

isforcontrollinglargetappingows.

1.Thelargevalveisclosedcompletely(thehandleisturnedall

thewaytothetop).

2.Onetapisopened.

3.Thesmallvalveissetatthedesiredtemperature(50°C).Theset

pointismarkedandthevalveisclosedcompletely.

4.Severaltapsareopenedandthelargevalveisset3-5°Clower

thanthesmallvalve.

5.Thehandleofthesmallvalveisturnedbacktothemarked

point.

Pleasenote

Itisimportantthatthesmallvalveisset3-5°Chigherthanthe

largevalve;otherwiseitisnotpossibletocontrolthetemperature

ofsmalltappingowscorrectly.

6.1.1Electroniccontrol

Substationswithelectroniccontrolmustbesetinaccordancewith

manufacturer´sinstructions.

Wheretheroomtemperatureiscontrolledbyradiatorthermostats,

itisrecommendedthatthermostatsbesetforminimum

temperatureineachroom.

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VI.EH.D3.02/LUK41570

DanfossDistrictEnergy

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6.1.2Electric2–waymotorizedvalve

Actuatorswithorwithoutsafetyfunctionareavailablefor3-point

controls.Spring-returnactuatorscanbeusedtoprovidesafety

shut-offintheeventofpowerfailure.

6.2Other

6.2.1Safetyvalve

Thepurposeofthesafetyvalveistoprotectthesubstationfrom

excessivepressure.

Theblow-offpipefromthesafetyvalvemustnotbeclosed.The

blow-offpipeoutletshouldbeplacedsothatitdischargesfreely

anditispossibletoobserveanydrippingfromthesafetyvalve.

Itisrecommendedtochecktheoperationofsafetyvalvesat

intervalsof6months.Thisisdonebyturningthevalveheadin

directionindicated.

6.2.2Domestichotwaterpump

Important!

Itisnecessarytomountadomestichotwatercirculationpumpon

thewaterheatertoavoidregulationproblems.

Thecirculationpumpcannotbeswitchedoff,sincethiswillresult

inregulationproblems.(noowatthesensor).

DanfossDistrictEnergy

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InstallationGuideTermixBL

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.

Inspectionsshouldbecarriedoutminimumeverytwoyears.

SparepartscanbeorderedfromDanfoss.Pleaseensurethatany

enquiryincludesthesubstationserialnumber.

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby

qualiedandauthorizedpersonnelonly.

DEN-GT

VI.EH.D3.02/LUK41570

DanfossDistrictEnergy

InstallationGuideTermixBL

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

qualiedandauthorizedpersonnelonly.

7.2TroubleshootingDHW

ProblemPossiblecauseSolution

Strainerinsupplyorreturnlineclogged.Cleanstrainer(s).

DHWcirculationpumpoutoforderorwith

toolowsetting.

Checkcirculationpump.

Defectiveorcloggednon-returnvalve.

Replace–clean.

Noelectricity.Check.

Wrongsettingofautomaticcontrols,ifany.Toadjustanelectroniccontrollerfor

DHW,pls.noteenclosedinstructionsfor

electroniccontroller.

Scalingoftheplateheatexchanger.

Replace–rinseout.

Defectivemotorizedvalve.Check(usemanualfunction)–replace.

Defectivetemperaturesensors.

Check–replace.

ToolittleornoDHW.

Defectivecontroller.

Check–replace.

DCWisbeingmixedwiththeDHW,e.g.in

adefectivethermostaticmixingvalve.

Check–replace. Hotwaterinsometapsbutnotinall.

Defectiveorcloggednon-returnvalveon

circulationvalve.

Replace–clean.

Taptemperaturetoohigh;DHWtapload

toohigh.

Thermostaticvalveadjustedtoatoohigh

level.

Check–set.

Scalingoftheplateheatexchanger.

Replace–rinseout. Temperaturedropduringtapping.

LargerDHWowthanthesubstationhas

beendesignedfor.

ReduceDHWow.

Thermostaticcontrolvalvedoesnotclose

TemperaturedifferencebetweenDH

supplyandDHWsetpointtoolow.

Lowerthesetpointtemperatureor

increasetheDHsupplytemperature.

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InstallationGuideTermixBL

7.3Disposal

Disposal

Thisproductshouldbedismantledanditscomponents

sorted,ifpossible,invariousgroupsbeforerecycling

ordisposal.

Alwaysfollowthelocaldisposalregulations.

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DanfossDistrictEnergy

InstallationGuideTermixBL

DanfossDistrictEnergy

VI.EH.D3.02/LUK41570

DEN-GT

InstallationGuideTermixBL

8.0Declaration

8.1Declarationofconformity

8.1.1Substationlabel

Normallythebelowmentioneddeclarationofconformityapplies:

"Substations-Category0withelectricalequipment".

Unlessttedwithayellowlabel(PEDKAT.1)onthesubstationlabel

thenthefollowingdeclarationofconformityapplies:"Substations-

Category1withelectricalequipment".

PED

KAT.

8.1.2Category0withelectricalequipment

EC–DeclarationofConformity

GeminaTermixA/S

MemberoftheDanfossGroup

Navervej15-17

DK-7451Sunds

Declaresonoursoleresponsibilitythatthebelowproducts:

Substations–Category0withelectricalequipment,

coveredbythisdeclarationareinconformitywiththefollowingdirectives,standardsandothernormative

documents,providedthattheyareusedaccordingtoourinstructions.

MachineryDirective2006/42/EC

DS/EN60204-1/A1:2009.Safetyofmachinery–

Part1–GeneralRequirements.

DS/EN12100:2011.Safetyofmachinery–Risk

assessment.

LVD–LowVoltageDirective–2006/95/EC

DS/EN60204-1/A1:2009.Safetyofmachinery–

Part1–GeneralRequirements.

EMC–Directive–2004/108/EC

DS/EN61000-6-2/Corr.:2005.Electromagnetic

compatibility–Genericstandard:Immunity

industry.

DS/EN61000-6-3:2007.Electromagnetic

compatibility–Genericstandard:Emissionfor

residential,commercial&lightindustry.

Sunds–2013.03.15

PlaceanddateofissueClausGjøderumMortensen

Quality&EnvironmentManager

DEN-GT

VI.EH.D3.02/LUK41570

DanfossDistrictEnergy

InstallationGuideTermixBL

8.1.3Category1withelectricalequipment

EC–DeclarationofConformity

GeminaTermixA/S

MemberoftheDanfossGroup

Navervej15-17

DK-7451Sunds

Declaresonoursoleresponsibilitythatthebelowproducts:

Substations–Category1withelectricalequipment,

coveredbythisdeclarationareinconformitywiththefollowingdirectives,standardsandothernormative

documents,providedthattheyareusedaccordingtoourinstructions.

MachineryDirective2006/42/EC

DS/EN60204-1/A1:2009.Safetyofmachinery–

Part1–GeneralRequirements.

DS/EN12100:2011.Safetyofmachinery–Risk

assessment.

LVD–LowVoltageDirective–2006/95/EC

DS/EN60204-1/A1:2009.Safetyofmachinery–

Part1–GeneralRequirements.

PressureEquipmentDirective97/23/EC

EMC–Directive–2004/108/EC

DS/EN61000-6-2/Corr.:2005.Electromagnetic

compatibility–Genericstandard:Immunity

industry.

DS/EN61000-6-3:2007.Electromagnetic

compatibility–Genericstandard:Emissionfor

residential,commercial&lightindustry.

Sunds–2013.03.15

PlaceanddateofissueClausGjøderumMortensen

Quality&EnvironmentManager

DanfossDistrictEnergy

VI.EH.D3.02/LUK41570

DEN-GT

InstallationGuideTermixBL

Danfoss Termix BL Operating instructions

Danfoss Termix BL Operating instructions

Danfoss Termix BL Operating instructions

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