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
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InstallationGuideTermixBL
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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
qualiedandauthorizedpersonnelonly.
Pleasecomplywiththeinstructionsissuedbythesystem
manufacturerorsystemoperator.
Corrosionprotection
Allpipesandcomponentsaremadeofstainlesssteelandbrass.
Themaximumchloridecompoundsoftheowmediumshouldnot
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
qualiedandauthorizedpersonnelonly.
Pleaseobserveinstructionscarefully
Toavoidinjurytopersonsanddamagetothedevice,itisabsolutely
necessarytoreadandobservetheseinstructionscarefully.
Warningofhighpressureandtemperature
Beawareoftheinstallation’spermissiblesystempressureand
temperature.
Themaximumtemperatureoftheowmediuminthesubstationis
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
Duetovibrationsduringtransportallangeconnections,screwjoints
andelectricalclampandscrewconnectionsmustbecheckedand
tightenedbeforewaterisaddedtothesystem.Afterwaterhasbeen
addedtothesystemandthesystemhasbeenputintooperation,
re-tightenALLconnections.
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InstallationGuideTermixBL
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
qualiedandauthorizedpersonnelonly.
Type2–5
Type6–8
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.
Thightening
Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.
Unusedconnections
Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.
Installation:
Strainer
Ifastrainerissuppliedwiththestationitmustbettedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.
Connections
Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,angedorweldedconnections.
Keyholeformounting.
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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.
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InstallationGuideTermixBL
5.0Design
5.1Design
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
B
Heatexchanger,DHW
G
Electroniccontroller,DHW
2
Singlecheckvalve
11
Domestichotwaterpump
27
Actuator
30
Flowcontrolwithcontrolvalve
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5.2Schematicdiagram
Schematicdiagramtype2-5(example)
DHW
DH
Supply
DH
Return
DCW
HWC
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
B
Heatexchanger,DHW
4
Safetyvalve
27
Actuator
D
Hotwatertank
11
Domestichotwaterpump
30
Flowcontrolwithcontrolvalve
G
Electroniccontroller,DHW
13
Chargingpump
36
Balancingvalve
L
Borderofdelivery
18
Thermometer
40
Immersionsensor
1
Ballvalve
19
Surfacesensor
43
Ballvalveclosed
2
Singlecheckvalve
24
Deliveredloosewithunit
44
Immersionsensor
5.2.1Technicalparameters
Technicalparameters
Nominalpressure:
PN16
Max.DHsupplytemperature:
120°C
Min.DCWstaticpressure:
0.5bar
Brazingmaterial(HEX):
Copper
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB
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InstallationGuideTermixBL
5.3Design
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
B
Heatexchanger,DHW
13
Chargingpump
G
Electroniccontroller,DHW
27
Actuator
2
Singlecheckvalve
30
Flowcontrolwithcontrolvalve
11
Domestichotwaterpump
10
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5.4Schematicdiagram
Schematicdiagramtype6-8(example)
DHW
DH
Supply
DH
Return
DCW
HWC
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
B
Heatexchanger,DHW
4
Safetyvalve
30
Flowcontrolwithcontrolvalve
D
Hotwatertank
11
Domestichotwaterpump
36
Balancingvalve
G
Electroniccontroller,DHW
13
Chargingpump
40
Immersionsensor
L
Borderofdelivery
18
Thermometer
43
Ballvalveclosed
1
Ballvalve
19
Surfacesensor
44
Immersionsensor
2
Singlecheckvalve
27
Actuator
5.4.1Technicalparameters
Technicalparameters
Nominalpressure:
PN16
Max.DHsupplytemperature:
120°C
Min.DCWstaticpressure:
0.5bar
Brazingmaterial(HEX):
Copper
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB
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InstallationGuideTermixBL
6.0Controls
6.1DHWtemperaturecontrol
DHWtemperaturecontrol
TherearevarioustypesofDHWtemperaturecontrolusedin
Danfosssubstations.
DHWtemperatureshouldbeadjustedto45-50°C,asthisprovides
optimalutilisationofDHwater.AtDHWtemperaturesabove55°C,
thepossibilityoflimescaledepositsincreasessignicantly.
Twovalvesincascade
Iftwothermostaticcontrolvalvesaremountedparallelincascade,
itisimportanttoadjustthevalvesaccordingtothefollowing:The
smallvalveisforcontrollingsmalltappingowsandthelargevalve
isforcontrollinglargetappingows.
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
ofsmalltappingowscorrectly.
6.1.1Electroniccontrol
Substationswithelectroniccontrolmustbesetinaccordancewith
manufacturer´sinstructions.
Wheretheroomtemperatureiscontrolledbyradiatorthermostats,
itisrecommendedthatthermostatsbesetforminimum
temperatureineachroom.
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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.(noowatthesensor).
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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.
Inspectionsshouldbecarriedoutminimumeverytwoyears.
SparepartscanbeorderedfromDanfoss.Pleaseensurethatany
enquiryincludesthesubstationserialnumber.
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
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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
qualiedandauthorizedpersonnelonly.
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.
LargerDHWowthanthesubstationhas
beendesignedfor.
ReduceDHWow.
Thermostaticcontrolvalvedoesnotclose
TemperaturedifferencebetweenDH
supplyandDHWsetpointtoolow.
Lowerthesetpointtemperatureor
increasetheDHsupplytemperature.
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InstallationGuideTermixBL
7.3Disposal
Disposal
Thisproductshouldbedismantledanditscomponents
sorted,ifpossible,invariousgroupsbeforerecycling
ordisposal.
Alwaysfollowthelocaldisposalregulations.
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8.0Declaration
8.1Declarationofconformity
8.1.1Substationlabel
Normallythebelowmentioneddeclarationofconformityapplies:
"Substations-Category0withelectricalequipment".
Unlessttedwithayellowlabel(PEDKAT.1)onthesubstationlabel
thenthefollowingdeclarationofconformityapplies:"Substations-
Category1withelectricalequipment".
PED
KAT.
1
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
18
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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
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InstallationGuideTermixBL
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