2. Danfoss
  3. Termix Compact 28 VX-FI HWP

Danfoss Termix Compact 28 VX-FI HWP, Termix Compact 28 VX-FI HWS Operating instructions

  • Hello! I'm your chat assistant, and I've reviewed the Operating Guide for the Danfoss Termix Compact 28 VX-FI, HWP, and HWS district heating substations. This document provides detailed information on the functional description, safety notes, mounting, design, controls, troubleshooting, and disposal of these units. I'm ready to assist you with any questions you might have about these substations, including their installation, operation, and maintenance. Feel free to ask!
  • What is the maximum operating pressure of the substation?
    What is the maximum temperature of the flow medium in the substation?
    What should be done in case of discolored or bad-smelling domestic hot water?
    What materials are the pipes and components made of?
    What is the recommended storage condition for the substation prior to installation?
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:TermixCompact28VX-FI/HWP
DH+HE+TFL+TRL:G1”(int.thread)
Connectionsizes:TermixCompact28VX-HWS
DH+HE:G1”(int.thread)
TFL+TRL:G¾”(int.thread)
Dimensions(mm):
Withinsulation:H890xW905xD400
Weight(approx.):60kg
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualifiedandauthorizedpersonnelonly.
TermixCompact28VX-FI/HWP:
TermixCompact28VX-HWS:
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
10–151,5
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
AHeatexchanger,HE10Circulatorpump26Pressuregauge,HE
FElectroniccontroller14Sensorpocket,energymeter27AActuator,HE
4Safetyvalve,HE20Filling/drainvalve48Airvent,manual
9Strainer25Pressuregaugewithballvalve
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5.2Schematicdiagram
5.2.1SchematicdiagramTermixCompact28VX-FI
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
AHeatexchanger,HE14Sensorpocket,energymeter25Pressuregaugewithballvalve
FElectroniccontroller16Outdoorsensor26Pressuregauge
1Ballvalve18Thermometer27Actuator
4Safetyvalve19Surfacesensor30Flowcontrollerwithintegratedcontrolvalve
9Strainer20Filling/drainvalve48Airvent,manual
10Circulatorpump24Deliveredloosewithunit
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5.2.2SchematicdiagramTermixCompact28VX-FIHWP
DH
Supply
HE
Supply
DH
Return
HE
Return
DHW
HWC
DCW
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
5.2.3SchematicdiagramTermixCompact28VX-FIHWS
DH
Supply
HE
Supply
DH
Return
HE
Return
DHW
HWC
DCW
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
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Schematicdescription
AHeatexchanger,HE11Domestichotwaterpump25Pressuregaugewithballvalve
EHotwatertankwithcoil13Chargingpump26Pressuregauge
FElectroniccontroller14Sensorpocket,energymeter27Actuator
LBorderofdelivery16Outdoorsensor292-waymotorizedvalve
1Ballvalve18Thermometer30Flowcontrollerwithintegratedcontrolvalve
2Singlecheckvalve19Surfacesensor44Immersionsensor
4Safetyvalve20Filling/drainvalve48Airvent,manual
9Strainer24Deliveredloosewithunit69On/offvalve
10Circulatorpump
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.
6.1.3Electric2–waymotorizedvalve
Actuatorswithorwithoutsafetyfunctionareavailablefor3-point
controls.Spring-returnactuatorscanbeusedtoprovidesafety
shut-offintheeventofpowerfailure.
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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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