Danfoss DH Compact substation Operating instructions

Type
Operating instructions
1
Danfoss District Energy VI.KS.F3.02 DHSSRMT/PL
2. Safety notes
1. Table of Contents
Instructions
DH Compact Substation
District heating compact substation
for indirect heating,
domestic hot water, venting
and cooling system
1. Content...............................................................................................................................................................................................................................................1
2. Safety notes......................................................................................................................................................................................................................................1
3. Transportation.................................................................................................................................................................................................................................2
4. Lifting and moving.........................................................................................................................................................................................................................2
5. Storage...............................................................................................................................................................................................................................................2
6. Mounting and setting...................................................................................................................................................................................................................2
6.1 Pipe connections.....................................................................................................................................................................................................................3
6.2 Electrical connections...........................................................................................................................................................................................................3
6.3 Components.............................................................................................................................................................................................................................3
7. Filling, start-up.................................................................................................................................................................................................................................3
8. Maintenance.....................................................................................................................................................................................................................................4
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 whichever 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 qualied and authorized personnel.
Please comply with more accurate and detailed instructions
included in the technical documentation delivered with the
product or separately by mail.
Those connections and shut-o valves, which are ready for use,
must be sealed with a plug. The plugs can be removed only by
qualied 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 installations permissible system pressure and
temperature. The risk of persons getting injured and equipment
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.
The safety valves mounted on the secondary circuits are
designed to take over the volume excess due to overheating of
water in heat exchanger.
The customer is responsible to protect the secondary circuits
against all volume variations done by other causes than that
mentioned above.
The safety valves will not be mounted ahead any other closing
valves. Any other valve will not be mounted on its discharging
pipe.
Instructions DH Compact Substation
2
DHS-SRMT/PL VI.KS.F3.02 Danfoss District Energy
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.
3. Transportation
When receiving the substation please pay attention 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.
The unit may be dismantled to make transport easier. In this case
the following measures must be carried out:
- protect the unit parts from damages (measurement instruments,
electronic devices, electrical cables, pumps, pipes etc). Dismantling
and reassembling of components must be done according to
component O&M instructions
- avoid the entrance of impurities on valves and pumps bodies ,
pipes etc.
4. Lifting and moving
A wooden pallet is bound underneath the substation 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 – forklift, and only on special occasions with the crane.
Manipulation with crane will be done under the supplier supervise
and hanging will be done by bottom pedestal, only.
Attention:
The packages weight must not exceed the maximum load of pallet
truck – forklift.
Manipulation must be done only by qualied/authorised
personnel.
Because the units are not very well body-centred structures,
special anchoring measures will be taken during manipulations
and deliveries, in order to avoid damages and accidents.
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 substation or its connections. The wooden pallet should be
used as a lifting and moving base as close to the installation place
as possible.
5. 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.
6. Mounting and settings
In order to adjust the height and position of the substation:
1) If adjusting feet are included, use them in order to adjust
2) If adjusting feet are not included, prepare a levelled base
in order to adjust height.
* does not apply to substations designed for wall- mounting.
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.
The substation must be installed and connected by authorized
service personnel only. Installation must comply with the
local standards and regulations. 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.*
Instructions DH Compact Substation
7. Filling, start-up
6.1 Pipe connections
Make sure to connect pipes correctly according to designs and
specications included in technical documentation. Threaded,
anged or welded connections are used to connect the substation
into district heating network and internal networks.
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.
6.2 Electrical connections
The electrical diagrams for electrication are included in technical
documentation. Internal electrications are made in the factory.
The electric cables cannot be fastened with the hot pipes. They
need their own supporting structures.
The device should be properly installed and grounded by
aqualied technician. The appliance should be serviced only by
qualied service personnel. Repair interventions by unauthorized
persons may cause death, injury or serious malfunction.
electrical connection
Before connecting, check that the rated voltage are indicated on
the nameplate corresponds to the voltage of power available. You
should also check the rated power of the device and make sure
that the wires have a cross section corresponding to the power of
connected device. You must tighten the clamping screws.
6.3 Components
Refer to technical documentation for detailed instruction for all
components (e.g. pumps, controllers, heat exchangers).
All connections must be checked and tightened before the
substation is installed. The connections may loosen during
transportation.
Check that the product is according to designs and specications
included in the technical documentation.
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.
Check points, after start-up
Check temperatures.
Check pressures.
Thermal expansion.
Leakages.
Operation of pumps.
Flow directions.
Operations of controllers
Before start-up please 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 the
substation.
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 open-
ing 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.
Prior to installation all pipes and connections have to be cleaned
and rinsed.
All supporting structures assembled for the period of
transportation have to be removed before the substation can be
taken into use.
Warning!
The risk of personal injury from electrical shock.
• electrical connection terminals are energized equipment.
• Loose or improper connection sockets and plugs can cause
overheating of the terminals.
• Improper installation of terminal connections.
3
Danfoss District Energy VI.KS.F3.02 DHSSRMT/PL
Produced by Danfoss A/S © 08/2015
Instructions DH Compact Substation
8. Maintenance
VI.KS.F3.02
Danfoss District Heating SRL · 208 Oltenitei Drive · Popesti-Leordeni 077160 · Ilfov · ROMANIA
Tel.: +4031 222 20 10 · Fax: +4031 222 22 99 · oce.romania@danfoss.com
www.termocare.danfoss.com · www.danfoss.com
Danfoss Poland Sp. z o.o. · Tuchom, ul. czowa 46 · 80-209 Chwaszczyno · POLAND
Tel.: +48 58 512 91 34 · Fax: +48 58 512 91 05 · serwis@danfoss.pl · www.danfoss.com
It is necessary to check and maintain the substation 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’s recommendations and
local legislation.
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.
The O&M Instructions for main components must be observed.
Check points, maintenance inspection
No leakages.
Supply and return temperatures and pressures should be
according to designed values.
Extraordinary noises.
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.
At least following points should be observed before and after the
heating season:
At least following points should be inspected once a year by
authorized personnel:
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 the
substation.
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Danfoss DH Compact substation Operating instructions

Type
Operating instructions

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