Installation Guide
DSA 1 MINI
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Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL
1.0 Table of contents ............................................................................................................................................................................................................................................................1
2.0 Safety note .........................................................................................................................................................................................................................................................................2
3.0 Storage and Handling ..............................................................................................................................................................................................................................................5
4.0 Disposal ........................................................................................................................................................................................................................................................................5
5.0 Diagrams ..........................................................................................................................................................................................................................................................................6
6.0 Mounting ...........................................................................................................................................................................................................................................................................7
7.0 Installation and Start-up ........................................................................................................................................................................................................................................8
7.1 Heat transfer medium treatment ...........................................................................................................................................................................................................8
8.0 Commissioning ............................................................................................................................................................................................................................................................. 9
9.0 Electrical installation ..............................................................................................................................................................................................................................................10
9.1 Electrical diagrams ........................................................................................................................................................................................................................................11
10.0 Maintenance ...............................................................................................................................................................................................................................................................19
11.0 Troubleshooting .......................................................................................................................................................................................................................................................20
12.0 EC - Declaration of conformity ....................................................................................................................................................................................................................... 23
Contents
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2.0 Safety note
This section provides you with an overview of all relevant
safety aspects for optimum protection for you and your
personnel and the safe and fault-free operation of the unit.
The individual sections also contain specific, symbol-
-identified safety notes for averting immediate dangers.
General
The unit is built in accordance with the sound engineering
practise and follow all relevant EU regulations applicable
at the time of its development and production. The unit
can, however, entail dangers if it is used by unskilled or not
properly trained personnel or is used improperly or not as
intended.
Every person assigned to work on or with the unit must
therefore have read and understood the operating
instructions before the work begins. The operator is
recommended to have all relevant personnel confirm the
understanding of the operating instructions in writing.
Changes of any kind and additions to or conversions on
the unit are strictly forbidden, and all warranty and product
responsibly will on longer by covered by Danfoss District
Energy.
Operator/owner’s responsibility
• Always keep operating instructions close to the unit and
accessible for the installation, operating, maintenance
and cleaning personnel at all times.
• Only operate the unit within the product specified
pressure and temperature limits.
• Always keep safety devices freely accessible and check
regularly.
The information on safety at work applies to the European
Union ordinances and is applicable at the time the unit is
produced. The operator is obliged to determine the compli-
ance of the safety at work rules and regulations and must
observe and updated if new regulations is adopted by the
EU during the entire time of the unit’s life time.
Outside the EU the applicable safety at work legislation
and regional provisions and regulations must be complied.
In addition to the safety at work, notes in these operating
instructions, and the generally applicable safety, accident-
prevention and environmental protection regulations must
be observed and complied with for the specific area of
application.
The operator and the authorised personnel are responsible
for the fault-free operation of the unit, and for the clear
definition of responsibilities with the unit’s installation,
operation, maintenance and cleaning. The information
provided in the operating instructions must be followed
in full and unrestricted!
The operator must also ensure that:
- All residual risk that arises as a result from the point of
installation must be determined and minimized.
Safety note
Please always agree conversion and extension work
with the manufacturer. All safety, warning and operating
notices on the unit must always be kept in an easy to
read condition. Damaged signs or stickers must be
renewed immediately. Given setting values or ranges
must be observed.
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Proper use
The unit’s functional and operational safety is only guaran-
teed when used properly in accordance with the informa-
tion in this instruction.
Proper use also includes correct compliance with installa-
tion, operating, maintenance and cleaning instructions.
Any other use of the unit is forbidden and applies
as improper!
Claims of any kind against the manufacturer and/or their
agents for damages caused by improper use of the unit
shall be excluded. The operator and/or owner alone are the
sole responsible party for all damages caused by
improper use.
Safety at work
Adhering to the notes on safety at work dangers to people
and/or the system must be prevented. Ignoring or non-
-compliance with these notes can cause dangers to people
and property from mechanical effects or the failure of the
system and the entire workplace. Non-compliance with
safety regulations will result in the loss of all rights no
claims to damages.
Personal protection equipment
The following must personal protection equipment must be
worn when working on or with the unit:
• Protective gloves for protecting the hands against
abrasion, grazes, or deeper injuries and against contact
with hot surfaces.
• Protective glasses for protecting the eyes against
ejecting parts and hot liquid splashes.
• Safety shoes for protecting against falling parts and
slipping on slippery surfaces.
Safety note
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Residual risks
The unit weighs app. 50-50kg.
Possible harm! Danger of crushing.
Heavy weights can cause crushing dangers when
transporting, including with lifting gear.
Possible harm! Danger of burns.
Hot surfaces can cause serious burn injuries. Wear
protective gloves when working on the unit!
The unit can have sharp edges and corners.
Possible harm! Sharp-edged mounting plate and
brackets and pointed corners can cause cuts.
Wear protective gloves when working on the unit!
The unit weighs app. 50-50kg.
Possible harm! Danger of crushing.
Heavy weights can cause crushing dangers when
transporting, including with lifting gear.
The unit works with high voltages 230/240
Vac 50Hz and a maximum current on 6 A.
Possible Harm caused by electrical current!
The electrical forces can cause fatal injuries.
Damage on insulation or individual components
can endanger life.
– Switch main switch off (1F1) or disconnect supply,
before maintenance, cleaning or repair work and
secure or monitor against accidental or unintended
reengagement of the power supply.
– Do not remove any safety components or put
them out of service.
2.1 Residual risk
The unit has undergone a risk analysis as required by
the Machinery directive and is preformed according to
En14121. The unit design complies with the current state of
techno logy. Nonetheless there are residual risks! The unit
generates a strong liquid jet when opening the draining or
venting components, for example.
Possible harm caused by liquid squirting
under high pressure.
Wear personal protection equipment
with all work on the unit.
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3.0 Storage and handling
If the substation is stored before installation, make sure that
the place is dry and heated. (Humidity max. 60% and
storage temperature 5-70 °C).
Do not stack the unit higher than factory shipped.
Units that are shipped in cardboard packaging are to be
lifted by the carrying handles of the packaging.
Transport/removals over great distances should be carried
out on pallets.
During and after unpacking, the substation can be lifted
by using straps, fitted around the pipes or it can be lifted
by hand in the pipes Lifting in the pipes can cause leaks.
ALWAYS re-tighten.
4.0 Disposal
Storage and handling / disposal
HANDLING
When working on the substation suitable
safety shoes must be worn.
DH Standard 501L0278
Disposal instructions in DH-literature
1st issue, 2008-02
Page 1 of 1
Approved by Senior Vice President – Troels H. Petersen Language: en
1 Scope and field of application
This standard shall be observed when new technical literature or changes are designed
for DH products. The standard is valid throughout DH.
2 Purpose
The standard shall describe the rules for implementing disposal instructions in technical
DH literature (Data sheet, Instruction, etc.).
3 Disposal instructions for electronic products
In spite of, that none of the electronic and electro-mechanical DH-products are within
the scope of WEEE, it has been decided to put a relevant standard text and a bin-symbol
in the technical literature for these products (see clause 5).
The text and the bin-symbol do not relate to the WEEE, but emphasizes that Danfoss is
an environmental friendly company. Please notice that bin symbol with registration
number, below the bin, should not be used.
4 Disposal instructions for other products than electronic
There are no legal requirements to have disposal instructions included in technical DH
literature like data sheets or instructions for non electronic and non electro-mechanical
products. Nevertheless we foresee that there will be requirements in the future.
In order to prepare ourselves we therefore have decided to add a general disposal in-
struction also in this product group (see clause 5).
5 General disposal instruction
Following general text in connection with the waste bin shall be implemented in all
technical literature for DH products:
Disposal instruction:
This product should be dismantled and its components
sorted, if possible, in various groups before recycling or dis-
posal.
Always follow the local disposal regulations.
Abbreviations
DH: District Heating
Changes in relation to previous issue:
This standard is completely new.
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5.0 Diagrams
1. External sensor
2. Thermometer
3. Manometer
3.* Manometer (optional)
4. District heating Return temperature sensor
5. Air vent
6. Drainage
7. Connection for primary DHW preparation
8.* Safety thermostat
9. Connection to expansion vessel
10. Controller (Standard ECL310. Option ECL210
or OPR0020
11. Strainer
12. Heatmeter (Danfoss Sonometer)
13. Ball valves
14. Safety valve
15. Heat exchanger Danfoss XB37M-1 10 to 50
16. Combined differential pressure and flow controller
Danfoss AVQM with electrical actuators
Danfoss AMV 10 or 20
16.* Combined differential pressure and flow controller
Danfoss AVQM with electrical actuators
Danfoss AMV 13 or 23
DSA1 MINI – a substation for indirect connection to district
heating systems in micro- and macro- networks
Application
The DSA 1 MINI is designed for use in district heating
networks. DSA 1 MINI is perfect for use in both micro and
macro networks and also in Low temperature (LT) and High
temperature (HT) range. The DSA 1 MINI is furthermore
available both in a high pressure version (PN25) and low
pressure version (PN16).
Diagrams
3*
3*
16
16
10
15
12
13
13 13
1311
11
Primary
supply
Secondary
supply
Primary
return
Secondary
return
3* 2
2
12 7
6 6
4
14 3 2
9
7
16
3* 5 5
15
10
1
*
*
4 8
*
MI TI M MI TI
MI TI
Q
MI
TE
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6.0 Mounting
Connection options
Primary and secondary
A minimum distance of 50 cm above the DSA 1 mini District Heat Transfer Station must be
observed to perform electrical work and further maintenance work.
Mounting
Power
in kW
Model Connection dimension prim./sec.
Weight
in kg
Dimensions in mm
H W D
16 DSA 1 mini DN 20 PN16 (25) /1"IG PN6 50 1000 700 420
30 DSA 1 mini DN 20 PN16 (25) /1"IG PN6 51 1000 700 420
42 DSA 1 mini DN 20 PN16 (25) /1"IG PN6 52 1000 700 420
60 DSA 1 mini DN 20 PN16 (25) /1 1/2"IG PN6 53 1000 700 420
75 DSA 1 mini DN 20 PN16 (25) /1 1/2"IG PN6 55 1000 700 420
The stations have weld sleeves on the primary-side.
C D C D
C
D
C
D
A B C D B A C D
312 125 312 125 70
68 100 127 125 88100 124 125
70
360 125
360 125
H
B
T
50 cm
Connections for 16/30/42/60 kW Connections for 75 kW
STANDARD PRODUCT
A Primary supply
B Primary return
C Secondary return
D Secondary supply
Option 1: BOTTOM AND TOP
C Secondary return
D Secondary supply
Option 2: RIGHT SIDE
C Secondary return
D Secondary supply
* Tolerances ± 2 mm
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Installation and commisioning
7.0 Installation and start-up
The unit may only be installed and commissioned by skilled
personnel that are experienced in installation, commission
and operating of the DSA product series. Proper transport
and professional storage must be ensured.
The controller is intended for use in high voltage systems
(230/240Vac; 50hz). Safety regulations must be observed to
ensure a safe installation, operation and maintenance.
The following must be observed before initial installation:
1. Flush out pipes (use side dummy plugs on primary line).
2. Fill the feed line first before slowly filling the return line.
7.1 Heat transfer medium treatment
Water in the heating system is primarily used as a heat
transfer medium and therefore plays a decisive role in
the safety and a fault-free system operation. The proper
preparation of the respective water is, however, often
simply forgotten. The Danfoss standard Guideline of Water
Quality for copper brazed Plate Heat Exchangers very
precisely regulates how, the heating medium is optimised
to ensure the product life time.
The consequential damage of not preparing or incorrect
preparation is often expensive for the system operator,
whereby the overall costs of a system interruption cannot
be estimated. Corrosion and general deposits/build-ups in
combination with oxygen cause red rust, which sticks to the
walls and in plastic pipes and causes cross section reduc-
tions, and in many cases flow constriction or interruption.
The consequences:
• Higher energy consumption
• Defective thermostat valves
• Defective control units
• Blocking pumps
• Damage on the heat exchanger
• Boiling noises
• Localised corrosion
• Defective heat meters
Proper water preparation provides extensive system safety
points, ranging from improved operation cost, prevention
of defect components, corrosion damage and reduced
maintenance costs.
Your installation engineer will be happy to advise you!
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Commissioning
8.0 Commissioning
Danfoss District Energy DSA 1 MINI
The Danfos District Energy DSA 1 MINI Station is the link
between the district heating supplier and the district heat
recipient. All system parts must be checked and harmonized
with one another to meet the district heating supplier and
the district heat recipient’s requirements.
It is important that the all relevant technical guidelines of
the local district heating supplier is applied and followed
to ensure correct installation of the primary-side in the
building supply section. The work must only be performed
by skilled personnel.
It must also be ensured that an easy accessible installation
point is selected for the district heating transfer station.
The relevant technological rules and regulations, in
particular the applicable standards, or where these are not
provided the applicable EN standards, must be complied
with.
Dear Commissioning Engineers!
This Danfoss District Energy DSA 1 MINI station is checked in
the factory for leaks before delivery. Leaks are however
possible due to the vibration caused by transport. Therefore
it is impotent to retightening before commissioning!
There are no warranties given for seals and wear and
tear parts.
Connections re-tightened
date:
installer:
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Electrical instructions
9.0 Electrical installation
When cabling and connecting the DSA 1 MINI the IEC
regulations and the regulations of local power supply
companies must be observed. This work must therefore
only be performed by skilled personnel.
The Danfoss District Energy DSA 1 MINI station is already
wired ready in the factory.
The electrical connection is performed in acc. with the
terminals plan of the installed controller.
Only use PT 1000 version sensors.
The Danfoss District Energy DSA 1 MINI mains connection
shall be performed via the earth leakage circuit breaker
installed in the connection box (1F1 6 A).
If a data transfer system (Danfoss Energy control system
DECS 2.0 or local Building management system) is installed
in the district heating network, a cable connection
(2 x 2 0.5 mm² shielded and twisted) must be used.
The heat meter connection includes the voltage supply
of 230 V and a data communication bus cable (2 x 0.5 mm²
shielded) from the meter’s bus connection to the Danfoss
District Energy DSA 1 MINI)
Lightening protection:
It is recommended that an transient protection module
with coarse and fine protection is installed, especially in
the supply cable for the DSA 1 MINIs.
If the transient protection module is not available or not in-
stalled, the customer must be informed about the increased
risk of direct and indirect lightening.
5 SAFETY RULES
1. Disconnect L1 and N before work!
2. Secure or monitor against reengagement power!
3. Check there is no voltage present!
4. Protect from adjacent voltage-carrying parts!
5. Follow the general electrical safety rules
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9.1 Electrical diagrams
9.1.1 Danfoss ECL 310 Controller with application key A337, A347, A367
Electrical diagrams
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Electrical diagrams
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Electrical diagrams
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9.1.2 Danfoss ECL 210 Controller with application key A237, A247
Wiring diagram
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Wiring diagram
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Wiring diagram
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Electrical diagrams
9.1.3 Danfoss Controller OPR 0020 Wiring diagram
OPR 0020 Factory-setting:
Circuit 1: Heating circuit, radiators or high temperatures (fans)
Circuit 2: Mixing circuit for radiators
Circuit 3: Mixing circuit for under floor heating
Circuit 4: Boiler
Pump 1 Heating
circuit 1 or boiler 2
N L
Motor 1 Mix Heating
A = Off
Z = On
Pump 2 heating
circuit 2
Pump 3 Heating
circuit 3
Pump 4 heating circuit 4
or boilerpump boiler 1
N LN Z AN LN LN L N Z AN Z AN Z A
Motor 2 Mix Heating
A = Off
Z = On
Motor 3 Mix Heating
A = Off
Z = On
Motor 3 Mix Heating
ZU = ON; Domestic hot water pump
Boiler 1 for chargingmodule
AUF = Off,
N LN L
Supply heat meter 230VAC
(Is NOT powered via the glass fuse)
Glass tube fuse 3.15A
Mains 230VAC
PE = Protecting earth
N = Null
L = phase
K3
K4
K5
K6
K7
K8
K9
K10
K3
Rel1Rel3Rel4Rel5Rel6Rel7Rel8Rel9Rel10Rel11Rel12 Rel2
F4
XL1
BAT1
Controller reset
Lon-reset
Lon-service
XL4
Connection for
Communication
LON, TCP/IP or GPRS
K3
K3
K3
K3
K3
K3
K3
K3
K3
K3
K3
K3
K3
AB LonBus IN
AB LonBus OUT
FB; Remote control - 2pole shielded
(max. 4 pc)
XL19
XL3
XL2
K1
K2
Seriel connector
BB AA
DISP; Display (max 2 pc/on FB)
MB; Mbus - Heat meter (2pole shielded)
AT; Outdoor temperature sensor
RL; Return temperature sensor
VL1; Secondary Supply temperature
sensor
VL2; Supply temperature sensor 2.
circuit
VL3; Supply temperature sensor 3.
circuit
BO1; Boiler sensor Boiler 1 top, or
supply temp. circuit 4
PE; Pe for cable shield
BO2; Boiler sensor Boiler 2 bottom,
or potintial free relay
Ok; OUT open collector output
Ok; OUT open collector output
OK4
OK3
12V
OK2
OK1
12V
TR1
1
2
Jumper
Reserve
3
4
Adress
Nopro Cemote control
4-20mA
0-10V jumper
4-20mA
0-10V
GND
Controller
B02 +
Controller
B02 -
Use Jumpers to address heating circuit
(Visible on circuit board)
Note:
Do not connect temperature sensors to other connectors than the intended.
Use only PT 1000 temperature sensors. Use only shielded wires for the communication
cabels. Ensure correct polarity + and - for the display and remote control.
Do not connect other secondary modules than Nopro modules
Nopro expansion
module
XL1
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Wiring diagram
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Maintenance plan
10.0 Maintenance
Maintenance work
Is only to be carried out by qualified and authorised
personnel.
Inspection
The operator or other authorised personnel is obliged to
perform inspections at regular intervals and if necessary
carry out maintenance work according to these and other
instructions. Within the scope of the above maintenance
work all strainers should be cleaned, all connections should
be tightened and the operation of the safety valves should be
checked by turning the valve head in the indicated direction.
Rinsing/cleaning of plate heat exchanger
Brazed heat exchangers can be rinsed. For optimum cleaning
the flow rate should be a min. of 1.5 times normal flow rate,
preferably in back-flush mode. This will remove any deposits
formed on the inside of the plate heat exchanger. In case of
more serious deposits, a cleaning liquid, approved by
Danfoss (f.ex. Kaloxi or Radiner FI) can be pumped through
the heat exchanger. Both are environmentally friendly
cleaning fluids and can be disposed of through the usual
domestic sewerage system. Afterwards rinse thoroughly
with large amounts of water.
Deacidification of plate heat exchanger
After long operation, because of the relatively high
temperatures in the plates or tubes, the heat exchangers are
expecially subject to calification. Any deacidification of the
plate heat exchanger is done as shown on the drawing to the
right. For brazed plate heat exchangers weak inhibited acid
solutions (e.g. 5% formic, acetic or phosphoric acid) may
be used.
Measures after maintenance work
After maintenance work and before switching the system
on again:
– Check that all screwed connections are tight.
– Check that all safety features, covers, that were removed,
have been replaced properly.
– Clean the working area and remove any spilled materials.
– Make sure that all tools, materials and other quipment that
were used, have been removed from the working area.
– Connect to energy supply and check for leaks.
– Vent the system.
– If necessary adjust the system again.
– Make sure that all safety features on the device and the
system work properly.
For the janitor or other supervisors
Meter reading
It is recommended to read the heat meter at regular
intervals, and to write down the meter readings.
Cooling / Return temperature reading
The cooling, i.e. the temperature difference between district
heating supply and district heating return is of great impor-
tance for the total heat economy. It is therefore very impor-
tant to observe the supply and return temperatures. Normal
temperature difference is 30-35 °C.
Please note, that the lowest district heating return tempera-
ture is directly dependent on the return temperature from
the heating circuit and the cylinder circuit. Therefore, please
observe these return temperatures.
Tightening of connections
When reading the heat meter, all fittings and connections
should be checked for leaks. If leaks are detected, contact
qualified and authori-zed personnel immediately.
Please note that the connections may be supplied with
EPDM rubber gaskets - in general connection sizes
from ¾” to and incl. 1½” for Kompakt H stations.
Therefore take care not to overstrain the union nuts,
as this may result in leaks. The manufacturer accepts no
liability for leaks that result from overstrain of union nuts.
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11.0 Troubleshooting
If operating disturbances occur, the following basic features
should be checked before carrying out actual troubleshooting:
- the substation is connected to electricity,
- the strainer on the district heating supply is clean,
- the district heating flow temperature is at normal level
(summer at least 60 °C, winter at least 70 °C),
- the differential pressure is higher than or equal to the normal
(local) differential pressure in the district heating network. -
If in doubt, ask the district heating plant,
- there is pressure on the system.
11.1 Troubleshooting - Heating
Troubleshooting
Problem Possible cause Solution
No heat
Strainer clogged on DH og HE side
(radiator circuit).
Clean strainer.
Filter in district heating meter clogged.
Clean the filter (after consulting the
district heating plant).
Defective differential pressure controller.
Check the functions of the differential
pressure controller - clean valve seat if
required.
Defective sensor Replace sensor
Defective actuator. Check the functioning of the actuator.
Defective motor valve - or possibly dirt
in the valve housing.
Check the functions of the motor valve -
clean valve housing if required.
Automatic controls wrongly set or
defective - possibly power failure.
Check if the setting of the controller is
correct - see separate instructions.
Check the power supply.
Temporary setting of actuator to “manual”
control - see instruction on heating
circuit, manual control.
Pump out of operation.
Check that the pump is receiving power
and that it runs. Control that there is
no air in the pump housing - see pump
manual.
The pump is set at too low speed of
rotation.
Set the pump at higher speed of rotation
- see instructions on heating circuit.
Air pockets in the system. Vent the installation thoroughly.
Uneven heat distribution Air pockets in the system. Vent the installation thoroughly.
Supply temperature too high
Wrong setting of automatic controls.
Adjust automatic controls, see instructions
for automatic controls.
Defective sensor. Replace sensor.
Defective controller. The controller does
not react as it is should in accordance
with the instructions.
Call in automatic controls manufacturer
or replace controller.
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