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Instructions
DH compact substation
District heating compact substation
for indirect heating and domestic hot water systems
DH-SMT/FI
VI.KS.F1.02 © Danfoss 08/2006 1
Table of Contents
Table of Contents .......................................... 1
Safety notes ................................................... 1
Transportation .............................................. 2
Lifting and moving ....................................... 2
Storage ........................................................... 2
Mounting and settings ................................. 2
Pipe connections ...............................................3
Electrical connections ......................................3
Components ........................................................3
Filling, start-up ..............................................3
Maintenance .................................................. 4
Safety notes
Following instructions refer to the standard
design of the DH compact substation. Special
versions of substations are available on
request.
Danfoss does not bear responsibility for which-
ever damages of device, which have not been
mounted or stored in accordance with following
instructions. Therefore, please carefully read the
instructions before installation and start-up of the
substation.
To avoid injury of persons and damages to the
device, it is absolutely necessary to carefully read
and observe these instructions.
Necessary assembly, start-up and maintenance
work must be performed only by qualied and
authorized personnel.
Please comply with more accurate and detailed
instructions included in the technical documen-
tation delivered with the product or separately
by mail.
Those connections and shut-off valves, which
are ready for use, must be sealed with a plug.
The plugs can be removed only by qualied and
authorized personnel.
Warning of high pressure and temperature
The maximum temperature and pressure always
have to be checked on the product data label
attached to the product.
Be aware of the installation’s permissible system
pressure and temperature.
The risk of persons getting injured and equip-
ment being damaged increases considerably if the
recommended permissible operating parameters
are exceeded.
The substation installation is equipped with
safety valves which must always be mounted in
accordance with local regulations.
Warning of hot surface
The substation has got hot surfaces which can
cause skin burns. Please be extremely cautious in
close proximity of the substation.
Warning of transportation damage
Prior to installing substation, please make sure
that the substation has not been damaged during
transportation. Be extremely careful when lifting
or moving big and heavy substation.
DH compact substation for indirect heating and DHWInstructions
DH-SMT/FI
VI.KS.F1.02 © Danfoss 08/20062
Transportation
When receiving the substation please pay atten-
tion to following matters:
- there are no transportation damages,
- delivery is complete and in accordance with
the order
- sign the freight note and keep your copy of it.
In case of transportation damages, it is necessary
to ll the transportation damage form immedia-
tely. The form must be signed by the claimer and
the representative of the forwarding agent (e.g.
driver). Each forwarding agent driver has a form
for reporting transportation damages.
Lifting and moving
A wooden pallet is bound underneath the sub-
station in order to help moving and lifting the
substation. The substation should be moved
close to the installation place with the help of
the pallet truck.
Do not damage the substation when lifting it!
When lifting the substation, tie straps around the
wooden pallet placed underneath the substation.
The stress should not concentrate on the substa-
tion or its connections. The wooden pallet should
be used as a lifting and moving base as close to
the installation place as possible.
Storage
If the substation is stored prior to installation in a
warehouse or some other storage, make sure that
the place is dry and heated.
Mounting and settings
The substation must be installed and connected
by authorized service personnel only. Installation
must comply with the local standards and regu-
lations. Move the substation to the installation
place by following instructions given in section
“Lifting and moving”.
Leave adequate space around the substation for
mounting and maintenance purposes.
The DH compact substation is mounted directly
on the oor and it does not require clamping.*
In order to adjust the height and position of the
substation:
1) If adjusting feet are included, use them in order
to adjust the height. The substation should be
assembled straight horizontally. Pay attention
to adjusting all feet in correct way. Tighten the
tightening nuts in order to secure the stable
position.
2) If adjusting feet are not included, prepare a
levelled base in order to adjust height.
All connections must be checked and tightened
before the substation is installed. The connec-
tions may loosen during transportation.
Check that the product is according to designs
and specications included in the technical docu-
mentation.
All supporting structures assembled for the
period of transportation have to be removed
before the substation can be taken into use.
Prior to installation all pipes and connections
have to be cleaned and rinsed.
* does not apply to substations designed for wall-
mounting.
Adjusting feet are included in some substations.
Tightening nut
Instructions
DH-SMT/FI
VI.KS.F1.02 © Danfoss 08/2006 3
DH compact substation for indirect heating and DHW
Pipe connections
Make sure to connect pipes correctly according
to designs and specications included in techni-
cal documentation. Threaded, anged or welded
connections are used to connect the substation
into district heating network and internal net-
works.
Prior to start-up all pipes and connections have
to be checked.
The pipes must be mounted so that the strain
caused by e.g. thermal expansion, does not harm
the substation. The pipes must be equipped with
brackets in order to prevent any torsional stress.
Electrical connections
The electrical diagrams for electrication are
included in technical documentation. Internal
electrications are made in the factory.
The electric cables cannot be fastened with
the hot pipes. They need their own supporting
structures.
Components
Refer to technical documentation for detailed
instruction for all components (e.g. pumps, con-
trollers, heat exchangers).
Filling, start-up Before start-up pls check the following points:
Check points, before start-up
Pipes are connected according to the circuit diagram.
Drainage valves are closed.
Expansion vessel is connected with compact substation.
Threaded and anged connections are tightened.
Function of safety valves is checked.
Fill the substation with ow media and raise the
pressure slowly to working pressure.
When starting up the substation it should be air
vented. The shut o valve in the primary side on
the return side is opened and the shut o valve
on the supply side is closed. Air comes out by
opening the air vent valve.
After that the operation of the substation must
be observed. If the substation operates according
to designed parameters, it can be taken into
continuous use.
After start-up pls check the following points:
All Danfoss heat exchangers and substations have
been pressure tested according to PED 97/23/EC
(module H).
Make sure to give operating instructions to the
users of substation.
Check points, after start-up
Check temperatures.
Check pressures.
Thermal expansion.
Leakages.
Operation of pumps.
Flow directions.
DH compact substation for indirect heating and DHWInstructions
DH-SMT/FI
VI.KS.F1.02 © Danfoss 08/20064
Maintenance
It is necessary to check and maintain the sub-
station on regular basis in order to keep it in good
operating condition.
The frequency of maintenance and service
inspections should be done according to system
manufacturer’ recommendations and local legis-
lation.
General overview of the equipment should take
place at least twice a year (before and after the
heating season). More accurate service should
take place once a year by authorized personnel.
Service
Always use authorized service personnel when
the equipment needs service.
In guarantee matters please contact your local
Danfoss Sales Company.
At least following points should be observed before and after the heating season:
Check points, maintenance inspection
No leakages.
Supply and return temperatures and pressures should be according to designed values.
Extraordinary noises.
At least following points should be inspected once a year by authorized personnel:
Check points, service inspection
Clean the strainer if necessary.
Check supply and return temperatures.
Check the parameters of the controller.
Check pressure drops in the heat exchangers.
The cooling of district heating water should comply with the requirements given by the local
DH company.
Measure the pre-pressure in the expansion vessel.
Check that the operating point of the pump stays in allowed area of the pump curve.
The substation should always be lled with ow
media even if out of operation. During service
it can be temporarily drained but otherwise it
should stay lled at all times.
Oy Danfoss Ab
Danfoss LPM
Box 19
79101 LEPPÄVIRTA
Tel: +358 403 092 200
Fax: +358 403 092 281
www.danfoss.com · www.lpm.danfoss.
Danfoss LPM Sp. z o.o.
Tuchom 147
80-209 Chwaszczyno
Tel.: +48 58 512 91 00
Fax: +48 58 512 91 05
lpmpoland_sprzed[email protected]
www.danfoss.com • www.heating.danfoss.pl
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