InstallationGuide
TermixDistributionunit
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.............................................8
5.0Wiring.............................................................9
5.1Wiringdescription.................................................9
5.2Wiringdiagram.....................................................9
6.0Design.............................................................10
6.1Design...............................................................10
6.2Schematicdiagram................................................11
7.0Controls..........................................................12
7.1Maintenance........................................................12
8.0Troubleshooting..............................................13
8.1Troubleshootingingeneral......................................13
8.2TroubleshootingDHW............................................13
8.3Disposal.............................................................14
9.0Danfossinstallationsguide...............................15
9.1Danfossinstallationsguide......................................15
10.0Declaration......................................................19
10.1Declarationofconformity........................................19
DanfossDistrictEnergy
VI.GP .O2.02/LUK40900
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InstallationGuideTermixDistributionunit
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VI.GP .O2.02/LUK40900
DanfossDistrictEnergy
InstallationGuideTermixDistributionunit
2.0Functionaldescription
TermixDistributionunit
Manifoldsystemforoorheating
TheTermixdistributionunitcanbedirectlyconnectedtothe
TermixVMTD,VMTDmixer,VXandVVXunits.Theunitissupplied
withmeterttingpiecefordomesticwater,safetysetorCombiluk
asrequired.
TheTermixdistributionunitforconnectionofwaterandheating
pipesinconnectionwithhiddenpipeinstallationsallowsforalarge
numberofconnectionsforcoldwater,hotwater,radiatorsandoor
heatingwithindimensionsof530x565x380mm(hxwxd).The
compactsolutionensuresthateventhoughallconnectionsarein
usetheunitstilltsintoa60cmcupboard.TheTermixdistribution
unitcanbemountedwithaspearinthegroundintheearlystages
ofbuilding.Whenthebuildingisnishedandprotectedagainst
thefttheTermixdistrictheatingunitcanbemounted.
Thereliabilityisveryhigh.Thewirelesscontrolscomplywiththe
newestEUstandards(868MHz)forelectronicequipment.Atthis
frequencytheriskofsignaldisturbancesfromotherelectronic
householdappliancesisverylow.
ThecontrolsfortheTermixdistributionunitincludeaprogram
forexerciseofvalvesandpumpandapumpstoptoprotectthe
circulationpump.
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InstallationGuideTermixDistributionunit
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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DanfossDistrictEnergy
InstallationGuideTermixDistributionunit
4.0Mounting
4.1Mounting
Installationmustbeincompliancewithlocalstandardsand
regulations.
Districtheating(DH)-Inthefollowingsections,DHreferstothe
heatsourcewhichsuppliesthesubstations.Avarietyofenergy
sources,suchasoil,gasorsolarpower,couldbeusedasthe
primarysupplytoDanfosssubstations.Forthesakeofsimplicity,
DHcanbetakentomeantheprimarysupply.
Connections:
Floorheatingowline(FHFL)
Floorheatingreturnline(FHRL)
Connectionsizes:
FHFL+FHRL:
G¾”(int.thread)
Dimensions(mm):
H710xW505xD175
Weight(approx.):20kg
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
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InstallationGuideTermixDistributionunit
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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DanfossDistrictEnergy
InstallationGuideTermixDistributionunit
4.2Start-up
Start-up,Heatingwithmixingloop
Start-up:
1:Pumpspeed
Setthepumptohighestspeedbeforestart-up.
2:Startpump
Startthepumpandheatthroughthesystem.
3:Openshut-offvalves
Theshut-offvalvesshouldthenbeopenedandtheunitobserved
asitentersservice.Visualcheckingshouldconrmtemperatures,
pressures,acceptablethermalexpansionandabsenceofleakage.
Ifthesystemoperatesinaccordancewithdesign,itcanbeput
toregularuse.
4:Ventsystem
Switchoffthepumpandventtheinstallationaftertheradiators
havebeenwarmedup.
5:Adjustpumpspeed
Setthepumptothelowestspeedconsistentwithcomfortand
electricityconsumption.
Normallythechange-overswitchissetinthemidposition(default).
Howeverforsystemswithunderoorheatingorsinglepipeloop
systems,itmaybenecessarytoturnthechange-overswitch
upwards.
Higherpumpspeedsareonlyusediftheheatingrequirement
increases.
Re-thightenconnections
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.
Pump
Thepumpmustbeswitchedoffduringsystemll.
Underoorheating:
Pumpstopfunction
Ifthesubstationisusedinconnectionwithunderoorheating,the
circulationpumpmustbeconnectedtothepumpstopfunctionin
theunderoorheatingcontroller.Thepumpmustbestoppedif
allunderoorheatingcircuitsareclosed.
Warranty
Ifthisisnotpossible,thenowmustbecontinuedthroughthe
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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VI.GP .O2.02/LUK40900
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InstallationGuideTermixDistributionunit
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.
4.3.1Thermoactuators
Activatingthethermoactuators
Thethermoactuatorsaresuppliedwitha“rstopen”function,such
thattheyareslightlyopenforfrostprotectionuntiltheelectrical
controllerisinstalled.Duringcommissioning,the“rstopen”
functionisdisabledbyremovingtheredmountingsplitonthe
thermoactuator.
Pleasecheckthatthethermoactuatorscanfullyclosefollowing
disablementofthe“-rstopen”function.
Seetheinstallationguideincludedwiththethermoactuator.
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DanfossDistrictEnergy
InstallationGuideTermixDistributionunit
5.0Wiring
5.1Wiringdescription
Connectingthesystem’scirculationpump
Thesystem’scirculationpumpshouldbeconnectedtothe
contactrelayintheelectricaloorheatingcontroller,sothe
pumpcanautomaticallystartandstop,dependingonwhether
thethermoactuatorsareopenorclosed.Ifthepumppushes
againstclosedvalvesitcanoverheatandburnout.Theelectric
oorheatingcontrollerisnotapprovedtosupplypowertothe
circulationpump.
Thepumpmustthereforebesuppliedfromanexternalconnection
box,suchthatonlythe230Vphase(active)isfedthroughtherelay
contactontheelectricaloorheatingcontroller.
Theneutralandearthconnectionsmustnotentertheoorheating
controller.
5.2Wiringdiagram
Junctionbox
230VACconnector
plugwithEarth
DanfossCF-MC
MasterController
230VACpower
supply230Vplug
iscutoff!
Safetythermostat
PumpRelayin
DanfossCF-MC
MasterController
Circulatorpump
DanfossDistrictEnergy
VI.GP .O2.02/LUK40900
DEN-GT
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InstallationGuideTermixDistributionunit
6.0Design
6.1Design
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
J
Electroniccontrolleroorheating
35
Ballvalve/non-returnvalve
FHFL
Manifoldsystemforoorheatingowline
M
Electricalwiringbox
48
Airvent,manual
FHRL
Manifoldsystemforoorheatingreturnline
7
Thermostaticcontroller,HE
49
Safetythermostat
10
Circulationpump
55
Thermoactuator
20
Filling/drainvalve
10
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DanfossDistrictEnergy
InstallationGuideTermixDistributionunit
6.2Schematicdiagram
(A)
(M)
(B)
(C)
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
(A)
Termixunit
J
Electroniccontrolleroorheating
35
Ballvalve/non-returnvalve
(B)
Floorheatingowline
1
Ballvalve
39
Connectionclosed
(C)
Floorheatingreturnline
7
Thermostaticvalve
48
Airvent,manual
(M)
Electricalwiringbox
10
Circulationpump
49
Safetythermostat
20
Filling/drainvalve
55
Thermoactuator
6.2.1Technicalparameters
Technicalparameters
Nominalpressure:PN10(PN16versionsareavailableonenquiry)
Max.DHsupplytemperature:
120°C
Min.DCWstaticpressure:
0.5bar
Brazingmaterial(HEX):
Copper
Soundlevel:≤55dB
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VI.GP .O2.02/LUK40900
DEN-GT
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InstallationGuideTermixDistributionunit
7.0Controls
7.1Maintenance
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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VI.GP .O2.02/LUK40900
DanfossDistrictEnergy
InstallationGuideTermixDistributionunit
8.0Troubleshooting
8.1Troubleshootingingeneral
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.
8.2TroubleshootingDHW
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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InstallationGuideTermixDistributionunit
8.3Disposal
Disposal
Thisproductshouldbedismantledanditscomponents
sorted,ifpossible,invariousgroupsbeforerecycling
ordisposal.
Alwaysfollowthelocaldisposalregulations.
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DanfossDistrictEnergy
InstallationGuideTermixDistributionunit
9.0Danfossinstallationsguide
9.1Danfossinstallationsguide
Installation-CF2
1. 2. 3.
7. 8.
x1
9.
x1 (= ch2)
x2 (= ch3)
x3 (= ch4)
ch1
ch2 ch4
ch3
10.
21.0
°c
ch4
4. 6.5.
x1
21.0
°c
11.
x
1
21.0
°c
x5
21.0
°c
A
B
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VI.GP .O2.02/LUK40900
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InstallationGuideTermixDistributionunit
Installation-CF2
12.B
x1
21.0
°c
13.B
15.B 16.B
14.B
12.A 13.A 14.A
x1
21.0
°c
x1
21.0
°c
x5
21.0
°c
A
B
R
R
Installation-CF2
1. 2. 3.
4.
ch4
5.
x5
x
1
21.0
°c
6.
x1 (= ch2)
x2 (= ch3)
x3 (= ch4)
ch1
ch2 ch4
ch3
R
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VI.GP .O2.02/LUK40900
DanfossDistrictEnergy
InstallationGuideTermixDistributionunit
DanfossDistrictEnergy
VI.GP .O2.02/LUK40900
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InstallationGuideTermixDistributionunit
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VI.GP .O2.02/LUK40900
DanfossDistrictEnergy
InstallationGuideTermixDistributionunit
10.0Declaration
10.1Declarationofconformity
Declarationofcompliance
We:
GeminaTermixA/S
MemberoftheDanfossGroup
Navervej15-17
DK-7451Sunds
doherebyonourownresponsibilitydeclarethatthefollowingproducts:
TermixSubstations
coveredbythisdeclarationisinconformitywiththefollowingdirective(s),
standard(s)orothernormativedocument(s),
providedthattheproductsareusedinaccordancewithourinstructions.
EUDirectives:
MachineryDirective2006/42/EEC
ENISO14121-1Safetyofmachinery-Riskassessment
EN60204-1Safetyofmachinery-Electricalequipmentofmachines
EMCDirective2004/108/EEC
EN61000-6-22007Electromagneticcompatibility
-Genericstandard:Immunityindustry
EN61000-6-32007Electromagneticcompatibility
-Genericstandard:Emissionforresidential,commercialandlightindustry
PEDDirective97/23/EEC
AllsubstationsthatfallsunderArticle3.3andcategory1shallnotbeCE-marked
accordingtothisdirective,howeverallessentialsafetyrequirementsfromthe
PEDDirective97/23/EECarefollowedtoensurehydraulicsafety
Thisdeclarationisimmediatelyannulled,iftheproductisinterferedwithinanyway,
whichinterfereswiththeabovementioneddirectivesandstandards,
withoutthewrittenconsentfromGeminaTermixA/S.
2010.01.05—Sunds
Timeandplace
LarsGinnerup
Responsibleforquality
DanfossDistrictEnergy
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InstallationGuideTermixDistributionunit
ProducedbyDanfossA/S©01/2012
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