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Danfoss Termix Compact 28 VVX-FI Operating instructions

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OperatingGuide
TermixCompact28VVX-FI
1.0TableofContents
1.0TableofContents.............................................1
........................................................................2
2.0Functionaldescription......................................3
3.0Safetynotes.....................................................4
3.1SafetyNotes–general............................................4
4.0Mounting........................................................5
4.1MountingtheCompactstation..................................5
4.2Start-up..............................................................14
4.3Electricalconnections.............................................15
5.0Design.............................................................16
5.1Design...............................................................16
5.2Schematicdiagram................................................17
6.0Controls..........................................................18
6.1Heatingcircuit......................................................18
6.2DHWtemperaturecontrol........................................21
6.3Other.................................................................22
6.4Maintenance........................................................24
7.0Troubleshooting..............................................25
7.1Troubleshootingingeneral......................................25
7.2TroubleshootingDHW............................................25
7.3TroubleshootingHE...............................................26
7.4Disposal.............................................................27
8.0Declaration......................................................31
8.1Declarationofconformity........................................31
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2.0Functionaldescription
Districtheatingsubstationforindirectheatingand
instantaneousdomestichotwater.
Spaceheatinganddomestichotwater(DHW)
TheTermixCompact28VVX-FIisacompleteunitforindirect
spaceheatinganddomestichotwaterfordistrictheatinginlarge
buildingssuchassportscentres,schools,blocksofatsetc.
Itcanbeusedforconnectiontoindirectdistrictheatinginplaces
wherethedistrictheatingplantrequiresahydraulicbreak.Itis
alsosuitableforconversiontodistrictheatingwhenthesecondary
heatingsystemisunsuitabletobeingconnectedtodirectdistrict
heatingorwhenaparticularlyeffectivesecurityagainstleakagein
theheatingsystemisrequired.
Efcientheatexchanger
Thesubstationisttedwithanefcientplateheatexchanger,
whichensuresthemostfavourableheatextractionandachieves
optimumcomfortandoperatingeconomy.
Electronicregulation
TheTermixCompact28VVX-FIisbuiltwithaplateheatexchanger
forinstantaneousdomestichotwaterproductionandheat
exchangerforspaceheating.Eachcircuitisalsosuppliedwithits
ownowcontroller.
Thisallowsthegreatestdegreeofindividualcontrol,thus
preventingoscillationatdifferentloads.Theelectroniccontrolleris
factorypre-set.Electricalcomponentsarepre-wired,andtheunitis
equippedwithaplugfor230Va.c.
Itisrecommendedthatbalancingvalvesareinstalledinthe
building’srisersintheheatsupplyandontheheatingsystem’s
returnlineimmediatelybeforetheunit.
Minimalheatloss
Completeinsulationoftheunitensuresminimalheatloss.
Easyinstallation
Theunitconsistsoftwomodules,oneforspaceheatingandone
fordomestichotwaterproduction,whichiseasilyassembled
intoonesinglemodule.Thismodulardesignmakesworkduring
installationsignicantlyeasier,astheweightissplitbetweentwo
modulesduringhandling.
Flexiblesolution
Pipeconnectioncanbemadefromeitherthetoporbottom,which
makesthissolutionhighlyexible.Atthesametime,bothspace
andtimearesavedwheninstalling.
Reliableandeasytoinstall
TermixCompact28VVX-FIisoperationallyreliable.Aquality
productmanufacturedinDenmarkwhichiseasytoinstalland
quicklycommissioned.
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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
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
Duetovibrationsduringtransportallangeconnections,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.Domestichotwater(DHW)
6.Domesticcoldwater(DCW)
7.Hotwatercirculation(HWC)
Connectionsizes:
DH+HE:
G1”(int.thread)
DCW+DHW:
G1”(int.thread)
HWC:
G¾”(int.thread)
Dimensions(mm):
Withinsulation:
H890xW1460xD400
Weight(approx.):95kg
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.
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Removethefront.
Removetheotherblocksandthewhitepolystyrene.
Attachthemountingrailtothewall.
Liftthestation’sheatingsection.
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Mountthestationasfartotheleftontherailaspossible.
Liftthestation’sinstantaneousdomestichotwaterpart.
Mounttheinstantaneousdomestichotwaterpartonthe
right-handsideofthettings.
Pushthetwopartstogether.Thetwomountingplatesmustclick
togetherintheoverlap.
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Attachthestationtothewallintheholesonthemountingplate.
Assemblethepowerconnectoronthehotwaterpartofthestation.
Forproperfunctionality,connectorsmustbepairedbycolour.
Installthesafetyvalve.
Installtheballvalves.
MountblockA(CifitistheMagnapump)ontheleft-handsideof
thepump.AttachblockEtoblockA/C,andattachittothepipe
abovethepumpbyclickingitinplace.
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MountblockB(DifitistheMagnapump)ontheright-handsideof
thepump.
MountblockF(GforVM2valve).Theblockishingedandcanbe
drawnaroundthevalve.AttachtheblocktoblockB/DandE.
MountblockL.Theblockishingedandcanbepulledaroundthe
UPM3pump.
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MountblockM.Theblockishingedandcanbedrawnaroundthe
valve.AttachtheblocktoblockL.
Mountthesmallfrontcover.
Mountthelargefrontcover.
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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
Ifastrainerissuppliedwiththestationitmustbettedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.
Connections
Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,angedorweldedconnections.
Keyholeformounting.
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4.1.2Pipeconnectionsup
Removethetopblock.
Removethepipeplugsatthetopofthestation.
RemoveU-clamps.
Removepipes.
Anglesandteesareturnedsothatpipescanbeinstalledfrom
above.
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Installthepipes.Districtheatingsupplypipestobeinterchanged.
FitU-clamps.
Fitthepipeplugsatthebottomofthestation.
Fitthetopblock.
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4.2Start-up
Start-up,Indirectheating
Filling:
1:Firstll
Whencarryingoutrstll,theheatexchangermustbeslowlylled
withwateruntilitreachesworkingpressure.
2:Pressuregauge
TheHEpressuregaugeindicatesthepressureoftheHEsystem.This
instructionmustbefollowedstrictly,toavoiddangeroussituations.
3:Supplyhose
AballvalvewithplugisinstalledintheHEreturnline.Tollthe
system,theballvalvemustrstbeclosed,theplugremovedand
asupplyhoseconnected.Onre-openingtheballvalve,system
llcancommence.
4:Pre-pressure
Whenllingthesystemwithwater,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.Visualcheckingshouldconrmtemperatures,
pressures,acceptablethermalexpansionandabsenceofleakage.
Iftheheatexchangeroperatesinaccordancewithdesign,itcanbe
puttoregularuse.
4:Ventsystem
Switchoffthepumpandventtheinstallationaftertheradiators
havebeenwarmedup.
5:Adjustpumpspeed
Setthepumptothelowestspeedconsistentwithcomfortand
electricityconsumption.
Normallythechange-overswitchissetinthemidposition(default).
Howeverforsystemswithunderoorheatingorsinglepipeloop
systems,itmaybenecessarytoturnthechange-overswitch
upwards.
Higherpumpspeedsareonlyusediftheheatingrequirement
increases.
Re-tightenconnections
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.
Pump
Thepumpmustbeswitchedoffduringsystemll.
Height(m)Pressure(bar)
0–50,5
5–101,0
10–15
1,5
15–202,0
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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).
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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OperatingGuideTermixCompact28VVX-FI
5.0Design
5.1Design
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
A
Heatexchanger,HE
10
Circulatorpump
26
Pressuregauge,HE
B
Heatexchanger,DHW
11
Domestichotwaterpump
27AActuator,HE
F
Electroniccontroller
14
Sensorpocket,energymeter
27BActuator,DHW
4
Safetyvalve,HE
20
Filling/drainvalve
48
Airvent,manual
9
Strainer
25
Pressuregaugewithballvalve
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5.2Schematicdiagram
DH
Supply
HE
Supply
DH
Return
HE
Return
DHW
DCW
HWC
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
A
Heatexchanger,HE
10
Circulatorpump
24
Deliveredloosewithunit
B
Heatexchanger,DHW
11
Domestichotwaterpump
25
Pressuregaugewithballvalve
F
Electroniccontroller
14
Sensorpocket,energymeter
26
Pressuregauge
X
Plugconnections
16
Outdoorsensor
27
Actuator
1
Ballvalve
18
Thermometer
30
Flowcontrollerwithintegratedcontrolvalve
2
Singlecheckvalve
19
Surfacesensor
40
Immersionsensor
4
Safetyvalve
20
Filling/drainvalve
48
Airvent,manual
9
Strainer
DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn
HESupply:HeatingSupply
HEReturn:HeatingReturn
DHW:
Domestichotwater
HWC:
Hotwatercirculation
DCW:
Domesticcoldwater
5.2.1Technicalparameters
Nominalpressure:
PN16
Max.DHsupplytemperature:
110°C
Min.DCWstaticpressure:
0.5bar
Brazingmaterial(HEX):
Copper
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB
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OperatingGuideTermixCompact28VVX-FI
6.0Controls
6.1Heatingcircuit
6.1.1Differentialpressurecontroller
Thedifferentialpressurecontrollersmoothsouttheuctuationsin
pressurearrivingfromthedistrictheatingnetwork.Theoperating
pressureinthesubstationisthusheldsteady.
6.1.2HEtemperaturecontrol
TheHEowtemperatureintheheatingcircuitiscontrolledbythe
HEtemperaturecontroller.
6.1.3Flowcontrollerwithintegratedcontrolvalve
Thecontrollerisaself-actingowcontrollerwithintegratedcontrol
valve.Thecontrollercloseswhensetmax.owisexceededand
canbeusedincombinationwithDanfosselectricalactuatorswith
orwithoutsafetyfunction.Springreturnmotorcanbeusedas
safetyfunctionbypowerfailure.
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6.1.4Electric2–waymotorizedvalve
Actuatorswithorwithoutsafetyfunctionareavailablefor3-point
controls.Spring-returnactuatorscanbeusedtoprovidesafety
shut-offintheeventofpowerfailure.
6.1.5Electroniccontrol
Substationswithelectroniccontrolmustbesetinaccordancewith
manufacturer´sinstructions.
Wheretheroomtemperatureiscontrolledbyradiatorthermostats,
itisrecommendedthatthermostatsbesetforminimum
temperatureineachroom.
6.1.6Outsidetemperaturesensor
Outdoorsensorsshouldbemountedsoastoavoidexposureto
directsunlight.Theyshouldnotbeplacedclosetodoors,windows
orventilationoutlets.
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OperatingGuideTermixCompact28VVX-FI
6.1.7Circulatorpump
TheUPML,UPMXLcirculatorpumpsaredesignedforcirculating
liquidsinheatingsystemswithvariableows,internallycontrolled
withthreeproportionalpressurecurvesandthreeconstant
pressure/powercurvestobeselectedviauserinterface.
EuP2015Ready.
TheMAGNA3circulatorpumpsaredesignedforcirculatingliquids
inheatingsystemswithvariableowswhereyouwanttooptimise
thesettingofthepumpdutypoint,thusreducingenergycosts.
EuP2015Ready.
6.1.8GrundfosUPML/UPMXLinstructions
PP=Proportionalpressure(fastash)
CP=Constantpressure(slowash)
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