Danfoss Termix HD MIX Compact 28 Operating instructions

Brand: Danfoss

Model: Termix HD MIX Compact 28

Type: Operating instructions

InstallationGuide

TermixHDMIXCompact28

1.0TableofContents

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

2.0Functionaldescription......................................2

3.0Safetynotes.....................................................3

3.1SafetyNotes–general............................................3

4.0Mounting........................................................4

4.1Mounting...........................................................4

4.2Start-up..............................................................6

4.3Electricalconnections.............................................7

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

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

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

6.0Controls..........................................................10

6.1Heatingcircuit......................................................10

6.2Other.................................................................12

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

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

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

7.2TroubleshootingHE...............................................15

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

8.0Declaration......................................................19

8.1Declarationofconformity........................................19

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InstallationGuideTermixHDMIXCompact28

2.0Functionaldescription

Districtheatingsubstationfordirectheatingwithmixingloop.

Application

TheTermixHDMIXCompact28isacompletesolutionfor

spaceheatingwithoptimalsafety,efcientenergytransfer,

service-friendlyconstructionandacompactdesign.

Districtheating(DH)

Thedistrictheatingcircuitisprefabricatedwithaowcontroller

withintegratedcontrolvalve,thermometersandballvalves.

Heating(HE)

Theheatingcircuitconsistsofthermometers,ballvalves,drain

valve,airvalveandcirculationpump.Theheatingtemperaturecan

becontrolledthermostaticallyorbyanelectroniccontrollerwith

anoutdoortemperaturesensor.

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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

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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InstallationGuideTermixHDMIXCompact28

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.Heating(HE)supply

4.Heating(HE)return

Connectionsizes:

DH+HE:

G1”(int.thread)

Dimensions(mm):

Withoutcover:

H970xW620xD420

Withcover:

H970xW640xD522

Weight(approx.):50kg

Authorizedpersonnelonly

Assembly,start-upandmaintenanceworkmustbeperformedby

qualiedandauthorizedpersonnelonly.

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

Ifastrainerissuppliedwiththestationitmustbettedaccording

toschematicdiagram.Pleasenotethatthestrainermaybe

suppliedloose.

Connections

Internalinstallationanddistrictheatingpipesconnectionsmustbe

madeusingthreaded,angedorweldedconnections.

Keyholeformounting.

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InstallationGuideTermixHDMIXCompact28

4.2Start-up

Start-up,Heatingwithmixingloop

Start-up:

1:Pumpspeed

Setthepumptohighestspeedbeforestart-up.

2:Startpump

Startthepumpandheatthroughthesystem.

3:Openshut-offvalves

Theshut-offvalvesshouldthenbeopenedandtheunitobserved

asitentersservice.Visualcheckingshouldconrmtemperatures,

pressures,acceptablethermalexpansionandabsenceofleakage.

Ifthesystemoperatesinaccordancewithdesign,itcanbeput

toregularuse.

4:Ventsystem

Switchoffthepumpandventtheinstallationaftertheradiators

havebeenwarmedup.

5:Adjustpumpspeed

Setthepumptothelowestspeedconsistentwithcomfortand

electricityconsumption.

Normallythechange-overswitchissetinthemidposition(default).

Howeverforsystemswithunderoorheatingorsinglepipeloop

systems,itmaybenecessarytoturnthechange-overswitch

upwards.

Higherpumpspeedsareonlyusediftheheatingrequirement

increases.

Re-thightenconnections

Afterwaterhasbeenaddedtothesystemandthesystemhasbeen

putintooperation,re-tightenALLconnections.

Pump

Thepumpmustbeswitchedoffduringsystemll.

Underoorheating:

Pumpstopfunction

Ifthesubstationisusedinconnectionwithunderoorheating,the

circulationpumpmustbeconnectedtothepumpstopfunctionin

theunderoorheatingcontroller.Thepumpmustbestoppedif

allunderoorheatingcircuitsareclosed.

Warranty

Ifthisisnotpossible,thenowmustbecontinuedthroughthe

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.

Disconnection

Thesubstationmustbeelectricallyconnectedsothatitcanbe

disconnectedforrepairs.

Outdoortemperaturesensor

Outdoorsensorsshouldbemountedsoastoavoidexposureto

directsunlight.Theyshouldnotbeplacedclosetodoors,windows

orventilationoutlets.

Theoutdoorsensormustbeconnectedtothestationonthe

terminalblockundertheelectroniccontrol.

Authorizedelectrician

Electricalconnectionsmustbemadebyanauthorizedelectricianonly.

Localstandards

Electricalconnectionsmustbemadeinaccordancewithcurrent

regulationsandlocalstandards.

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InstallationGuideTermixHDMIXCompact28

5.0Design

5.1Design

Yoursubstationmightlookdifferentthanthesubstationshown.

Designdescription

Electroniccontroller

Sensorpocket,energymeter

2-waymotorizedvalve

Singlecheckvalve

Filling/drainvalve

Differentialpressurecontroller

Strainer

Pressuregaugewithballvalve

Fittingpiece,energymeter

Circulatorpump

Actuator,HE

Airvent,manual

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5.2Schematicdiagram

Supply

Return

Yoursubstationmightlookdifferentthantheschematicdiagramshown.

Schematicdescription

Electroniccontroller

Outdoorsensor

Actuator

Ballvalve

Thermometer

2-waymotorizedvalve

Singlecheckvalve

Surfacesensor

Differentialpressurecontroller

Strainer

Filling/drainvalve

Fittingpiece,energymeter

Circulationpump

Deliveredloosewithunit

Airvent,manual

Sensorpocket,energymeter

Pressuregaugewithballvalve

DHSupply:DistrictHeatingSupply

DHReturn:DistrictHeatingReturn

HESupply:HeatingSupply

HEReturn:HeatingReturn

5.2.1Technicalparameters

Technicalparameters

Nominalpressure:

PN16

Max.DHsupplytemperature:

120°C

Soundlevel:≤55dB

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InstallationGuideTermixHDMIXCompact28

6.0Controls

6.1Heatingcircuit

6.1.1Differentialpressurecontroller

Thedifferentialpressurecontrollersmoothsouttheuctuationsin

pressurearrivingfromthedistrictheatingnetwork.Theoperating

pressureinthesubstationisthusheldsteady.

6.1.2AVTBcontroller(30–100°)

Thetemperaturesettingisasfollows:

1=35°C

2=55°C

3=75°C

4=95°C

5=100°C

Thevaluesareintendedasaguide.

Thermostaticcontrol

ThetemperatureoftheHEowlineisadjustedasfollows:

Toincreasetemperature,turnthehandleonthethermostatic

controllertoselectahighernumber.

Todecreasetemperature,turnthehandleonthethermostatic

controllertoselectalowernumber.

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6.1.3Flowcontrollerwithintegratedcontrolvalve

Thecontrollerisaself-actingowcontrollerwithintegratedcontrol

valve.Thecontrollercloseswhensetmax.owisexceededand

canbeusedincombinationwithDanfosselectricalactuatorswith

orwithoutsafetyfunction.Springreturnmotorcanbeusedas

safetyfunctionbypowerfailure.

6.1.4Electric2–waymotorizedvalve

Actuatorswithorwithoutsafetyfunctionareavailablefor3-point

controls.Spring-returnactuatorscanbeusedtoprovidesafety

shut-offintheeventofpowerfailure.

6.1.5Electroniccontrol

Substationswithelectroniccontrolmustbesetinaccordancewith

manufacturer´sinstructions.

Wheretheroomtemperatureiscontrolledbyradiatorthermostats,

itisrecommendedthatthermostatsbesetforminimum

temperatureineachroom.

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InstallationGuideTermixHDMIXCompact28

6.1.6Outdoortemperaturesensor(ESMT)

Outdoorsensorsshouldbemountedsoastoavoidexposureto

directsunlight.Theyshouldnotbeplacedclosetodoors,windows

orventilationoutlets.

6.1.7Circulationpump

TheGrundfosMAGNArangeisdesignedforheating,district

heatinganddomestichotwatersupplyinbuildingsonanyscale.

TheMAGNAsarespeed-controlledpumpswithbuilt-inintelligence

thatletsthemanalyzecurrentconditionsandadjusttheir

performanceaccordingly.

EnergylabellingclassA

6.2Other

6.2.1Strainer

Strainersshouldbecleanedregularlybyauthorizedpersonnel.The

frequencyofcleaningwoulddependonoperatingconditionsand

themanufacturer’sinstructions.

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6.2.2Fittingpiece

Thesubstationisequippedwithattingpieceforenergymeter.

Assemblyofenergymeters:

1:Closeballvalves

ClosetheballvalvesonDHSupplyandDHReturn,ifthereiswater

onthesystem.

2:Loosennuts

Loosenthenutsonthettingpiece.

3:Removettingpiece

Removethettingpieceandreplaceitwiththeenergymeter.Do

notforgetthegaskets.

4:Tightenconnections

Aftermountingoftheenergymeterremembertocheckand

tightenallthreadedconnections.

Sensorpocket,energymeter

Thesensorsoftheenergymeterismountedinthesensorpockets.

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InstallationGuideTermixHDMIXCompact28

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.

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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

qualiedandauthorizedpersonnelonly.

7.2TroubleshootingHE

ProblemPossiblecauseSolution

Toolittleornoheat.StrainercloggedinDHorHEcircuit

(radiatorcircuit).

Cleangate/strainer(s).

ThelterintheenergymeteronDHcircuit

clogged.

Cleanthelter(afterconsultingtheDH

plantoperator).

Defectiveorwronglyadjusteddifferential

pressurecontroller.

Checktheoperationofthedifferential

pressurecontroller–cleanthevalveseatif

required.

Sensordefective–orpossiblydirtinthe

valvehousing.

Checktheoperationofthethermostat–

cleanthevalveseatifrequired.

Automaticcontrols,ifany,wronglysetor

defective-possiblypowerfailure.

Checkifthesettingofthecontroller

iscorrect–seeseparateinstructions.

Checkthepowersupply.Temporary

settingofmotorto“manual”control–see

instructionsonautomaticcontrols.

Pumpoutofoperation.Checkifthepumpisreceivingpowerand

thatitturns.Checkifthereisairtrappedin

thepumphousing–seepumpmanual.

Thepumpissetattoolowspeedof

rotation.

Setthepumpathigherspeedofrotation.

Pressuredrop–thepressuredropon

theradiatorcircuitshowslowerthan

recommendedoperatingpressure.

Fillwateronthesystemandcheckthe

functioningofthepressureexpansion

vesselifrequired.

Airpocketsinthesystem.Venttheinstallationthoroughly.

Limitingofthereturntemperature

adjustedtoolow.

Adjustaccordingtoinstructions.

Defectiveradiatorvalves.

Check–replace.

Unevenheatdistributioninbuilding

becauseofincorrectlysetbalancingvalves,

orbecausetherearenobalancingvalves.

Adjust/installbalancingvalves.

Diameterofpipetosubstationtoosmallor

branchpipetoolong.

Checkpipedimensions.

Unevenheatdistribution.Airpocketsinthesystem.Venttheinstallationthoroughly.

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InstallationGuideTermixHDMIXCompact28

DHsupplytemperaturetoohigh.

Wrongsettingofthermostatorof

automaticcontrols,ifany.

Adjustautomaticcontrols,–see

instructionsforautomaticcontrols.

Defectivecontroller.Thecontrollerdoes

notreactasitshouldaccordingtothe

instructions.

Callautomaticcontrolsmanufactureror

replacetheregulator.

Defectivesensoronself-actingthermostat.

Replacethermostat–orsensoronly.

DHsupplytemperaturetoolow.

Wrongsettingofautomaticcontrols,ifany.

Adjustautomaticcontrols–seeinstructions

forautomaticcontrols.

Defectivecontroller.Thecontrollerdoes

notreactasitshouldaccordingtothe

instructions.

Callinautomaticcontrolsmanufactureror

replacecontroller.

Defectivesensoronself-actingthermostat.

Replacethermostat–orsensoronly.

Wrongplacement/ttingofoutdoor

temperaturesensor.

Adjustlocationofoutdoortemperature

sensor.

Strainerclogged.Cleangate/strainer.

ToohighDHreturntemperature.

Toosmallheatingsurface/toosmall

radiatorscomparedtothetotalheating

requirementofthebuilding.

Increasetotalheatingsurface.

Poorutilizationofexistingheatingsurface.

Defectivesensoronself-actingthermostat.

Makesuretheheatisdistributedevenly

acrossthefullheatingsurface–openall

radiatorsandkeeptheradiatorsinthe

systemfromheatingupatthebottom.It

isextremelyimportanttokeepthesupply

temperaturetotheradiatorsaslowas

possible,whilemaintainingareasonable

levelofcomfort.

Thesystemissinglepipeloop.

Thesystemshouldfeatureelectronic

controlsaswellasreturnsensors.

Pumppressuretoohigh.Adjustpumptoalowerlevel.

Airinsystem.

Ventthesystem.

Defectiveorincorrectlysetradiator

valve(s).Singlepipeloopsystemsrequire

specialone-piperadiatorvalves.

Check–set/replace.

Dirtinthemotorizedvalveorinthe

differentialpressurecontroller.

Check–cleanout.

Defectivemotorizedvalve,sensoror

automaticcontroller.

Check–replace.

Electroniccontrollernotadjustedcorrectly.Adjustaccordingtoinstructions.

Noiseinsystem.

Pumppressuretoohigh.Adjustpumptoalowerlevel.

Heatloadtoohigh.

Defectivemotorizedvalve,sensoror

electroniccontroller.

Check–replace.

7.3Disposal

Disposal

Thisproductshouldbedismantledanditscomponents

sorted,ifpossible,invariousgroupsbeforerecycling

ordisposal.

Alwaysfollowthelocaldisposalregulations.

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8.0Declaration

8.1Declarationofconformity

8.1.1Category0withelectricalequipment

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

DanfossDistrictEnergy

VI.GP .E1.02/LUK42860

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InstallationGuideTermixHDMIXCompact28

Danfoss Termix HD MIX Compact 28 Operating instructions

Danfoss Termix HD MIX Compact 28 Operating instructions

Danfoss Termix HD MIX Compact 28 Operating instructions

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