Operatingguide
TermixATBTD
1.0TableofContents
1.0TableofContents.............................................1
2.0Functionaldescription......................................2
3.0Safetynotes.....................................................3
3.1SafetyNotes–general............................................3
4.0Mounting........................................................4
4.1Mounting...........................................................4
4.2Start-up..............................................................5
5.0Design.............................................................6
5.1DesignTermixATBTD5pipes...................................6
5.2SchematicdiagramTermixATBTD5Pipes....................7
5.3DesignTermixATBTD4pipes...................................8
5.4SchematicdiagramTermixATBTD4Pipes....................9
6.0Controls..........................................................10
6.1DHWtemperaturecontrol........................................10
6.2Other.................................................................11
6.3Maintenance........................................................12
7.0Troubleshooting..............................................13
7.1Troubleshootingingeneral......................................13
7.2TroubleshootingDHW............................................13
7.3Disposal.............................................................14
8.0Declaration......................................................15
8.1Declarationofconformity........................................15
DanfossDistrictEnergy
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OperatingguideTermixATBTD
2.0Functionaldescription
Districtheatingsubstationwithtankfordomestichotwater
preparationandwiththermostaticcontrol.Designedfor
wall-mounting.
Application
TheTermixATBTDsubstationisacompletesolutionforhot
water.TheTermixATBTDisapplicableforsingle-familyhouses
orapartments.
Domestichotwater(DHW)
Thedomestichotwatercircuitconsistsofahotwatertankwithcoil
andself-actingthermostaticcontrolvalve.Thehotwatertankand
coilareenamelledandthetankcontainsamagnesiumanode.The
substationisdeliveredwithabuiltinsafetyvalve.
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OperatingguideTermixATBTD
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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OperatingguideTermixATBTD
4.0Mounting
4.1Mounting
Installationmustbeincompliancewithlocalstandardsand
regulations.
Districtheating(DH)-Inthefollowingsections,DHreferstothe
heatsourcewhichsuppliesthesubstations.Avarietyofenergy
sources,suchasoil,gasorsolarpower,couldbeusedasthe
primarysupplytoDanfosssubstations.Forthesakeofsimplicity,
DHcanbetakentomeantheprimarysupply.
Connectionsizes:
Allconnections:
G¾”(int.thread)
Dimensions(mm):
Withcover:
100L:H1180xW540xD520
150L:H1510xW540xD520
Weight(approx.):85–100kg
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
TermixATBTD5pipes
Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.
TermixATBTD4pipes
Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.
Preinstalled
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OperatingguideTermixATBTD
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.
Tightening
Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.
Unusedconnections
Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.
Installation:
Strainer
Ifastrainerissuppliedwiththestationitmustbettedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.
Connections
Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,angedorweldedconnections.
4.2Start-up
Start-up,Directheating
Theshut-offvalvesshouldbeopenedandtheunitobservedas
itentersservice.Visualcheckingshouldconrmtemperatures,
pressures,acceptablethermalexpansionandabsenceofleakage.
Iftheheatexchangeroperatesinaccordancewithdesign,itcanbe
puttoregularuse.
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.
Re-thightenconnections
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.
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OperatingguideTermixATBTD
5.0Design
5.1DesignTermixATBTD5pipes
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
E
Hotwatertankwithcoil
41A
Fittingpiece,coldwatermains
1A
Ballvalve,DVGW
59
Differentialpressure/temperatureregulatorwithowlimiting
4
Safetyvalve
6
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DanfossDistrictEnergy
OperatingguideTermixATBTD
5.2SchematicdiagramTermixATBTD5Pipes
DHW
DCW
CWM
DH
Supply
DH
Return
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
E
Hotwatertankwithcoil
41A
Fittingpiece,coldwatermains
1
Ballvalve
59
Differentialpressure/temperatureregulatorwithowlimiting
1A
Ballvalve,DVGW
4
Safetyvalve
DHW:DomesticHotWater
DCW:
DomesticColdWater
CWM:
Coldwatermains
DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn
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OperatingguideTermixATBTD
5.3DesignTermixATBTD4pipes
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
E
Hotwatertankwithcoil
4
Safetyvalve
59
Differentialpressure/temperatureregulatorwithowlimiting
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OperatingguideTermixATBTD
5.4SchematicdiagramTermixATBTD4Pipes
DHW
DCW
DH
Supply
DH
Return
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
E
Hotwatertankwithcoil
1
Ballvalve
4
Safetyvalve
59
Differentialpressure/temperatureregulatorwithowlimiting
DHW:DomesticHotWater
DCW:
DomesticColdWater
DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn
5.4.1Technicalparameters
Technicalparameters
Nominalpressure:
PN10
Max.DHsupplytemperature:
T–max=95°C
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OperatingguideTermixATBTD
6.0Controls
6.1DHWtemperaturecontrol
DHWtemperaturecontrol
TherearevarioustypesofDHWtemperaturecontrolusedin
Danfosssubstations.
DHWtemperatureshouldbeadjustedto45-50°C,asthisprovides
optimalutilisationofDHwater.AtDHWtemperaturesabove55°C,
thepossibilityoflimescaledepositsincreasessignicantly.
6.1.1AB-QMcontroller(45–60°)
QTisaself-actingthermostaticactuatordesignedtobeused
asreturntemperaturecontrolthermostatinone-pipeheating
systems.
QTisdedicatedtobeusedwithAB-QMautomaticbalancing&
controlvalve.
AB-QMDN10-20(45-60°C)
QTSensorsetting(turns)
Temperaturesetting
01
2
34
5
6
20%
48,050,553,0
55,5
58,060,563,0
30%
47,049,552,0
54,5
57,059,562,0
40%
46,048,551,053,556,058,561,0
50%
45,0
47,5
50,052,555,0
57,5
60,0
60%
44,046,549,0
51,5
54,056,559,0
70%
43,0
45,5
48,050,553,0
55,5
58,0
80%
42,0
44,5
47,049,552,0
54,5
57,0
90%
41,043,546,048,551,053,556,0
AB-QM(ow
setting)
100%
40,042,545,0
47,5
50,052,555,0
Thevaluesareintendedasaguide.
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OperatingguideTermixATBTD
6.2Other
6.2.1Coldwatermeterttingpiece
Thesubstationisequippedwithattingpieceforcoldwatermeter.
Assemblyofcoldwatermeter:
1:Closeballvalves
Closetheballvalvesoncoldwater,ifthereiswateronthesystem.
2:Loosennuts
Loosenthenutsonthettingpiece.
3:Removettingpiece
Removethettingpieceandreplaceitwiththecoldwatermeter.
Donotforgetthegaskets.
4:Tightenconnections
Aftermountingofthecoldwatermeterremembertocheckand
tightenallthreadedconnections.
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OperatingguideTermixATBTD
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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OperatingguideTermixATBTD
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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OperatingguideTermixATBTD
7.3Disposal
Disposal
Thisproductshouldbedismantledanditscomponents
sorted,ifpossible,invariousgroupsbeforerecycling
ordisposal.
Alwaysfollowthelocaldisposalregulations.
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OperatingguideTermixATBTD
8.0Declaration
8.1Declarationofconformity
8.1.1Category0withoutelectricalequipment
EU–DeclarationofConformity
GeminaTermixA/S
MemberoftheDanfossGroup
Navervej15-17
DK-7451Sunds
Declaresunderoursoleresponsibilitythattheproduct
Substation–Category0withoutelectricalequipment,
coveredbythisdeclaration,isinconformitywiththefollowingdirective(s),standard(s)orothernormative
document(s),providedtheproductisusedinaccordancewithourinstructions.
MachineryDirective2006/42/EC
DS/EN60204-1/A1:2009.Safetyofmachinery–
Part1–GeneralRequirements.
DS/EN12100:2011.Safetyofmachinery–Risk
assessment.
Sunds–2016.03.29
PlaceanddateofissueClausGjøderumMortensen
Quality&EnvironmentManager
DanfossDistrictEnergy
VI.JV.Y1.02/LUK40692
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OperatingguideTermixATBTD
ProducedbyDanfossA/S©04/2016
/