Danfoss DSA 1 MINI Operating instructions

Brand: Danfoss

Model: DSA 1 MINI

Type: Operating instructions

Installation Guide

DSA 1 MINI

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

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

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.

Danfoss District Energy DSA 1 MINI -

Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL

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

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

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.

Danfoss District Energy DSA 1 MINI -

Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL

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.

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

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

13 13

1311

Primary

supply

Secondary

supply

Primary

return

Secondary

return

3* 2

12 7

6 6

14 3 2

3* 5 5

4 8

MI TI M MI TI

MI TI

Danfoss District Energy DSA 1 MINI -

Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL

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

A B C D B A C D

312 125 312 125 70

68 100 127 125 88100 124 125

360 125

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

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

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!

Danfoss District Energy DSA 1 MINI -

Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL

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:

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

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

Danfoss District Energy DSA 1 MINI -

1111

Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL

9.1 Electrical diagrams

9.1.1 Danfoss ECL 310 Controller with application key A337, A347, A367

Electrical diagrams

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

Electrical diagrams

Danfoss District Energy DSA 1 MINI -

1313

Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL

Electrical diagrams

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

9.1.2 Danfoss ECL 210 Controller with application key A237, A247

Wiring diagram

Danfoss District Energy DSA 1 MINI -

1515

Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL

Wiring diagram

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

Wiring diagram

Danfoss District Energy DSA 1 MINI -

1717

Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL

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

K10

Rel1Rel3Rel4Rel5Rel6Rel7Rel8Rel9Rel10Rel11Rel12 Rel2

XL1

BAT1

Controller reset

Lon-reset

Lon-service

XL4

Connection for

Communication

LON, TCP/IP or GPRS

AB LonBus IN

AB LonBus OUT

FB; Remote control - 2pole shielded

(max. 4 pc)

XL19

XL3

XL2

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

OK4

OK3

12V

OK2

OK1

12V

TR1

Jumper

Reserve

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

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

Wiring diagram

Danfoss District Energy DSA 1 MINI -

1919

Danfoss District Energy VM.HE.B1.02 DEN-SMT/PL

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.

Danfoss District Energy DSA 1 MINI -

DEN-SMT/PL VM.HE.B1.02 Danfoss District Energy

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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Danfoss DSA 1 MINI Operating instructions

Danfoss DSA 1 MINI Operating instructions

Danfoss DSA 1 MINI Operating instructions

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