OperatingGuide
TermixCompact28VX-FI/HWP/HWS
1.0TableofContents
1.0TableofContents.............................................1
2.0Functionaldescription......................................2
3.0Safetynotes.....................................................3
3.1SafetyNotes–general............................................3
4.0Mounting........................................................4
4.1MountingtheCompactstation..................................4
4.2Start-up..............................................................11
4.3Electricalconnections.............................................13
5.0Design.............................................................14
5.1Design...............................................................14
5.2Schematicdiagram................................................15
6.0Controls..........................................................18
6.1Heatingcircuit......................................................18
6.2Other.................................................................22
6.3Maintenance........................................................24
7.0Troubleshooting..............................................25
7.1Troubleshootingingeneral......................................25
7.2TroubleshootingHE...............................................26
7.3Disposal.............................................................28
8.0Declaration......................................................31
8.1Declarationofconformity........................................31
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2.0Functionaldescription
Districtheatingsubstationforindirectheating.
Spaceheating
TheTermixCompact28VX-FIisaheatexchangerunitforthe
productionofheatinginlargebuildingssuchassportscentres,
schools,blocksofflatsetc.Itcanbeusedforconnectiontoindirect
districtheatinginplaceswherethedistrictheatingplantrequiresa
hydraulicbreakontheplantside.Itisalsosuitableforconversion
todistrictheatingwhenthesecondaryheatingsystemissuitable
tobeingconnectedtodirectdistrictheatingorwhenaparticularly
effectivesecurityagainstleakageintheheatingsystemisrequired.
Itispossibletoconnectahot-watertank.
Efficientheatexchanger
Thesubstationisfittedwithanefficientplateheatexchanger,
whichensuresthemostfavourableheatextractionandachieves
optimumcomfortandoperatingeconomy.
Severalvariants
TermixCompact28VX-FIisbuiltwithaheatexchangerforspace
heating,flowcontroller,pump,electronicregulationoftheheating
circuitaswellasadirectoutletforahotwatertank.Theelectronic
controllerisfactorypre-set.Electricalcomponentsarepre-wired,
andtheunitisequippedwithaplugfor230Va.c.
Itisrecommendedthatdynamicbalancingvalvesareinstalledin
thebuilding’srisersintheheatsupplyandontheheatingsystem’s
returnlineimmediatelybeforetheunit.
TermixCompact28VX-FIisproducedinstandardconstructions:
•VXwithheatexchangerforindirectheating.
•VXwithheatexchangerforindirectheatingandintegrated
tankregulation.
Flexiblesolution
Pipeconnectioncanbemadefromeitherthetoporbottom,which
makesthissolutionhighlyflexible.Atthesametime,bothspace
andtimearesavedwheninstalling.
Minimalheatloss
Completeinsulationoftheunitensuresminimalheatloss.
Reliableandeasytoinstall
TermixCompact28VX-FIisoperationallyreliable.Aqualityproduct
manufacturedinDenmark,whichiseasytoinstallandquickly
commissioned.
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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
qualifiedandauthorizedpersonnelonly.
Pleasecomplywiththeinstructionsissuedbythesystem
manufacturerorsystemoperator.
Corrosionprotection
Allpipesandcomponentsaremadeofstainlesssteelandbrass.
Themaximumchloridecompoundsoftheflowmediumshouldnot
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-fire,leaksorotherdangerous
circumstances-interruptallenergysourcestothestationif
possible,andseekexperthelp.
Incaseofdiscolouredorbad-smellingdomestichotwater,closeall
shut-offvalvesonthesubstation,informtheoperatingpersonnel
andcallforexperthelpimmediately.
REACH
AllDanfossA/SproductsfulfilltherequirementsinREACH.
OneoftheobligationsinREACHistoinformcustomersabout
presenceofCandidatelistsubstancesifany,weherebyinform
youaboutonesubstanceonthecandidatelist:Theproduct
containsbrasspartswhichcontainslead(CASno:7439-92-1)ina
concentrationabove0.1%w/w.
Storage
Anystorageofthesubstationwhichmaybenecessarypriorto
installationshouldbeinconditionswhicharedryandheated.
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.
Pleaseobserveinstructionscarefully
Toavoidinjurytopersonsanddamagetothedevice,itisabsolutely
necessarytoreadandobservetheseinstructionscarefully.
Warningofhighpressureandtemperature
Beawareoftheinstallation’spermissiblesystempressureand
temperature.
Themaximumtemperatureoftheflowmediuminthesubstationis
110°C.
Themaximumoperatingpressureofthesubstationis16bar.
Theriskofpersonsbeinginjuredandequipmentdamagedincreases
considerablyiftherecommendedpermissibleoperatingparameters
areexceeded.
Thesubstationinstallationmustbeequippedwithsafetyvalves,
however,alwaysinaccordancewithlocalregulations.
Warningofhotsurface
Thesubstationhasgothotsurfaces,whichcancauseskinburns.
Pleasebeextremelycautiousincloseproximitytothesubstation.
Powerfailurecanresultinthemotorvalvesbeingstuckinopen
position.Thesurfacesofthesubstationcangethot,whichcancause
skinburns.Theballvalvesondistrictheatingsupplyandreturnshould
beclosed.
Warningoftransportdamage
Beforesubstationinstallation,pleasemakesurethatthesubstation
hasnotbeendamagedduringtransport.
IMPORTANT-Tighteningofconnections
Duetovibrationsduringtransportallflangeconnections,screwjoints
andelectricalclampandscrewconnectionsmustbecheckedand
tightenedbeforewaterisaddedtothesystem.Afterwaterhasbeen
addedtothesystemandthesystemhasbeenputintooperation,
re-tightenALLconnections.
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4.0Mounting
4.1MountingtheCompactstation
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
5.Tankflowline(TFL)
6.Tankreturnline(TRL)
Connectionsizes:
DH+HE:
G1”(int.thread)
TFL+TRL:
G¾”(int.thread)
Dimensions(mm):
Withinsulation:
H890xW905xD400
Weight(approx.):60kg
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.
Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.
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Removethefront.
Removeotherblocks.
Attachthemountingrailtothewall.
Liftthestation.
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Mountthestationonthemountingrail.
Attachthestationtothewallintheholesonthemountingplate.
Installthesafetyvalve.
Installballvalves.
MountblockA(CifitistheMagnapump)ontheleft-handsideof
thepump.AttachblockEtoblockA/C,andattachittothepipe
abovethepumpbyclickingitinplace.
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MountblockB(DifitistheMagnapump)ontheright-handsideof
thepump.
MountblockF(GforVM2valve).Theblockishingedandcanbe
drawnaroundthevalve.AttachtheblocktoblockB/DandE.
MountblockJandHaroundthevalveforthetankcontrol.
Mountthefrontcover.
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4.1.1InstallingtheCompactstation
Mounting:
Adequatespace
Pleaseallowadequatespacearoundthesubstationformounting
andmaintenancepurposes.
Orientation
Thestationmustbemountedsothatcomponents,keyholes
andlabelsareplacedcorrectly.Ifyouwishtomountthestation
differentlypleasecontactyoursupplier.
Drillings
Wheresubstationsaretobewall-mounted,drillingsareprovided
inthebackmountingplate.Floormountedunitshavesupport.
Labelling
Eachconnectiononthesubstationislabelled.
Beforeinstallation:
Cleanandrinse
Priortoinstallation,allsubstationpipesandconnectionsshouldbe
cleanedandrinsed.
Tightening
Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.
Unusedconnections
Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.
Installation:
Strainer
Ifastrainerissuppliedwiththestationitmustbefittedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.
Connections
Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,flangedorweldedconnections.
Keyholeformounting.
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4.1.2Pipeconnectionsup
Removethetopblock.
Removethepipeplugsatthetopofthestation.
RemoveU-clamps.
Removepipes.Anglesandteesareturnedsothatpipescanbe
installedfromabove.
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Installthepipes.Districtheatingsupplypipestobeinterchanged.
FitU-clamps.
Fitthepipeplugsatthebottomofthestation.
Fitthetopblock.
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4.2Start-up
Start-up,Indirectheating
Filling:
1:Firstfill
Whencarryingoutfirstfill,theheatexchangermustbeslowlyfilled
withwateruntilitreachesworkingpressure.
2:Pressuregauge
TheHEpressuregaugeindicatesthepressureoftheHEsystem.This
instructionmustbefollowedstrictly,toavoiddangeroussituations.
3:Supplyhose
AballvalvewithplugisinstalledintheHEreturnline.Tofillthe
system,theballvalvemustfirstbeclosed,theplugremovedand
asupplyhoseconnected.Onre-openingtheballvalve,system
fillcancommence.
4:Pre-pressure
Whenfillingthesystemwithwater,thepressuregaugeshouldbe
observedclosely.Theexpansionvesselissuppliedpre-pressurised
to0.5bar.Thepre-pressurerequiredateachsubstationwill
dependonsystemhead(thedistancebetweenthelowestand
highestpointinthesystem),forexample:
5:Fillingstop
Fillingmuststopwhenthepressuregaugeshowsapressure
approximately1-2barhigherthanthepre-pressuresetting.The
ballvalveisthenclosed,thehoseremovedandtheplugputback
in.
Start-up:
1:Pumpspeed
Setthepumptohighestspeedbeforestart-up.
2:Startpump
Startthepumpandheatthroughthesystem.
3:Openshut-offvalves
Theshut-offvalvesshouldthenbeopenedandtheunitobserved
asitentersservice.Visualcheckingshouldconfirmtemperatures,
pressures,acceptablethermalexpansionandabsenceofleakage.
Iftheheatexchangeroperatesinaccordancewithdesign,itcanbe
puttoregularuse.
4:Ventsystem
Switchoffthepumpandventtheinstallationaftertheradiators
havebeenwarmedup.
5:Adjustpumpspeed
Setthepumptothelowestspeedconsistentwithcomfortand
electricityconsumption.
Normallythechange-overswitchissetinthemidposition(default).
Howeverforsystemswithunderfloorheatingorsinglepipeloop
systems,itmaybenecessarytoturnthechange-overswitch
upwards.
Higherpumpspeedsareonlyusediftheheatingrequirement
increases.
Re-tightenconnections
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.
Pump
Thepumpmustbeswitchedoffduringsystemfill.
Height(m)Pressure(bar)
0–50,5
5–101,0
10–15
1,5
15–202,0
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Underfloorheating:
Pumpstopfunction
Ifthesubstationisusedinconnectionwithunderfloorheating,the
circulationpumpmustbeconnectedtothepumpstopfunctionin
theunderfloorheatingcontroller.Thepumpmustbestoppedif
allunderfloorheatingcircuitsareclosed.
Warranty
Ifthisisnotpossible,thenflowmustbecontinuedthroughthe
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.
Potentialbonding
Potentialbondingshouldbecarriedoutaccording
to60364-4-41:2007andIEC60364-5-54:2011.
Bondingpointonthemountingplatebelowrightcornermarked
withearthsymbol.
Disconnection
Thesubstationmustbeelectricallyconnectedsothatitcanbe
disconnectedforrepairs.
Outdoortemperaturesensor
Outdoorsensorsshouldbemountedsoastoavoidexposureto
directsunlight.Theyshouldnotbeplacedclosetodoors,windows
orventilationoutlets.
Theoutdoorsensormustbeconnectedtothestationonthe
terminalblockundertheelectroniccontrol.
Authorizedelectrician
Electricalconnectionsmustbemadebyanauthorizedelectricianonly.
Localstandards
Electricalconnectionsmustbemadeinaccordancewithcurrent
regulationsandlocalstandards.
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5.0Design
5.1Design
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
A
Heatexchanger,HE
10
Circulatorpump
26
Pressuregauge,HE
F
Electroniccontroller
14
Sensorpocket,energymeter
27AActuator,HE
4
Safetyvalve,HE
20
Filling/drainvalve
48
Airvent,manual
9
Strainer
25
Pressuregaugewithballvalve
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5.2Schematicdiagram
5.2.1SchematicdiagramTermixCompact28VX-FI
DH
Supply
HE
Supply
DH
Return
HE
Return
TRL
TFL
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
A
Heatexchanger,HE
11
Domestichotwaterpump
25
Pressuregaugewithballvalve
E
Hotwatertankwithcoil
14
Sensorpocket,energymeter
26
Pressuregauge
F
Electroniccontroller
16
Outdoorsensor
27
Actuator
L
Borderofdelivery
18
Thermometer
29
2-waymotorizedvalve
1
Ballvalve
19
Surfacesensor
30
Flowcontrollerwithintegratedcontrolvalve
2
Singlecheckvalve
20
Filling/drainvalve
31
Differentialpressurecontroller
4
Safetyvalve
23
Ballvalve
44
Immersionsensor
9
Strainer
24
Deliveredloosewithunit
48
Airvent,manual
10
Circulatorpump
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5.2.2SchematicdiagramTermixCompact28VX-FIHWP
DH
Supply
HE
Supply
DH
Return
HE
Return
DHW
HWC
DCW
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
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5.2.3SchematicdiagramTermixCompact28VX-FIHWS
DH
Supply
HE
Supply
DH
Return
HE
Return
DHW
HWC
DCW
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
A
Heatexchanger,HE
11
Domestichotwaterpump
25
Pressuregaugewithballvalve
E
Hotwatertankwithcoil
13
Chargingpump
26
Pressuregauge
F
Electroniccontroller
14
Sensorpocket,energymeter
27
Actuator
L
Borderofdelivery
16
Outdoorsensor
29
2-waymotorizedvalve
1
Ballvalve
18
Thermometer
30
Flowcontrollerwithintegratedcontrolvalve
2
Singlecheckvalve
19
Surfacesensor
44
Immersionsensor
4
Safetyvalve
20
Filling/drainvalve
48
Airvent,manual
9
Strainer
24
Deliveredloosewithunit
69
On/offvalve
10
Circulatorpump
DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn
HESupply:HeatingSupply
HEReturn:HeatingReturn
TFL:
Tankflowline
TRL:
Tankreturnline
DHW:
Domestichotwater
HWC:
Hotwatercirculation
DCW:
Domesticcoldwater
5.2.4Technicalparameters
Nominalpressure:
PN16
Max.DHsupplytemperature:
110°C
Brazingmaterial(HEX):
Copper
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB
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6.0Controls
6.1Heatingcircuit
6.1.1Differentialpressurecontroller
Thedifferentialpressurecontrollersmoothsoutthefluctuationsin
pressurearrivingfromthedistrictheatingnetwork.Theoperating
pressureinthesubstationisthusheldsteady.
6.1.2Flowcontrollerwithintegratedcontrolvalve
Thecontrollerisaself-actingflowcontrollerwithintegratedcontrol
valve.Thecontrollercloseswhensetmax.flowisexceededand
canbeusedincombinationwithDanfosselectricalactuatorswith
orwithoutsafetyfunction.Springreturnmotorcanbeusedas
safetyfunctionbypowerfailure.
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6.1.3Electric2–waymotorizedvalve
Actuatorswithorwithoutsafetyfunctionareavailablefor3-point
controls.Spring-returnactuatorscanbeusedtoprovidesafety
shut-offintheeventofpowerfailure.
6.1.4Electroniccontrol
Substationswithelectroniccontrolmustbesetinaccordancewith
manufacturer´sinstructions.
Wheretheroomtemperatureiscontrolledbyradiatorthermostats,
itisrecommendedthatthermostatsbesetforminimum
temperatureineachroom.
6.1.5Outsidetemperaturesensor
Outdoorsensorsshouldbemountedsoastoavoidexposureto
directsunlight.Theyshouldnotbeplacedclosetodoors,windows
orventilationoutlets.
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6.1.6Circulatorpump
TheUPML,UPMXLcirculatorpumpsaredesignedforcirculating
liquidsinheatingsystemswithvariableflows,internallycontrolled
withthreeproportionalpressurecurvesandthreeconstant
pressure/powercurvestobeselectedviauserinterface.
EuP2015Ready.
TheMAGNA3circulatorpumpsaredesignedforcirculatingliquids
inheatingsystemswithvariableflowswhereyouwanttooptimise
thesettingofthepumpdutypoint,thusreducingenergycosts.
EuP2015Ready.
6.1.7GrundfosUPML/UPMXLinstructions
PP=Proportionalpressure(fastflash)
CP=Constantpressure(slowflash)
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