Installation Guide
ACS Substation
1
Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
1.0 Content ...................................................................................................................................................................................................................................1
2.0 Safety notes .............................................................................................................................................................................................................................2
3.0 System overview ....................................................................................................................................................................................................................2
3.1 General about district heating substations .............................................................................................................................................................2
3.2 ACS Substation ...................................................................................................................................................................................................................2
3.3 ACS - example circuit diagram .....................................................................................................................................................................................3
3.4 Electrical circuit diagrams ..............................................................................................................................................................................................4
4.0 Visible components in the substation ............................................................................................................................................................................8
5.0 Installation and start-up - Step by step ..........................................................................................................................................................................8
5.1 Removing the cover panels ...........................................................................................................................................................................................8
5.2 Protective cardboard cover ...........................................................................................................................................................................................9
5.3 Removing the substation from the pallet ................................................................................................................................................................9
5.4 Moving substation to the installation place ...........................................................................................................................................................9
5.5 Installation place ............................................................................................................................................................................................................ 10
5.6 Height adjustment ........................................................................................................................................................................................................ 11
5.7 Pipe connections ........................................................................................................................................................................................................... 11
5.7.1 Connection directions ..................................................................................................................................................................................... 11
5.7.2 Dimensions for the pipe connections ......................................................................................................................................................... 12
5.8 Electrification .................................................................................................................................................................................................................. 13
5.9 Controller settings ......................................................................................................................................................................................................... 13
5.9.1 Controller display and symbols ..................................................................................................................................................................... 14
5.9.2 Operating the controller .................................................................................................................................................................................. 14
5.9.3 Setting the date and time ................................................................................................................................................................................ 15
5.9.4 Setting the heat curve ...................................................................................................................................................................................... 16
5.9.5 Setting up limitations for flow temperature ............................................................................................................................................. 17
5.9.6 Manual control .................................................................................................................................................................................................... 18
5.9.7 Commissioning with one circuit ................................................................................................................................................................... 19
5.9.8 Sensor displays .................................................................................................................................................................................................... 20
5.9.9 Alarm ....................................................................................................................................................................................................................... 20
5.9.10 Changing the favourite display for the user ........................................................................................................................................... 22
5.9.11 Setting the room temperature .................................................................................................................................................................... 22
5.9.12 Setting domestic hot water temperature ............................................................................................................................................... 22
5.10 Basic parameters, factory settings .......................................................................................................................................................................... 23
5.11 Start-up ............................................................................................................................................................................................................................ 24
6.0 Trouble shooting ................................................................................................................................................................................................................. 24
Declaration of conformity ....................................................................................................................................................................................................... 26
General warranty conditions .................................................................................................................................................................................................. 28
1.0 Content
Installation Guide ACS Substation
2
DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
2.0 Safety notes
Read the instructions carefully before installation and start-up of
the substation. Danfoss does not bear responsibility for whichever
damages of device, which have not been mounted or stored in
accordance with following instructions.
To avoid injury of persons and damages to the device, it is abso-
lutely necessary to carefully read and observe these instructions.
Necessary assembly, start-up and maintenance work must be
performed only by qualified and authorized personnel.
Warning of hot surface
The substation has got hot surfaces which can cause skin burns.
Please be extremely cautious in close proximity of the substa-
tion.
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 installation’s 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.
Warning of transportation damage
Prior to installing substation, please make sure that the substa-
tion has not been damaged during transportation. Be extreme-
ly careful when lifting or moving big and heavy substation.
3.0 System overview
3.1 General about district heating substations
The heating system of the property is connected to the district
heating network with the substation. Hot district heating water in
the district heating network runs through the heat exchangers in
the substation. District heating water does not enter the internal
network, just heat is transferred through the heat exchanger. The
substation distributes heat into the heating and domestic hot
water circuits.
All substation functions are controlled with an electronic con-
troller. The outdoor temperature is measured and the controller
adjusts the flow temperature to keep the room and domestic
hot water temperatures in the desired level. With the controller
you can change the property related settings (e.g. heating curve,
temperature limits), check the temperatures, change the settings,
create schedules etc.
3.2 ACS Substation
Up to a certain point ACS substation is standardized. The final se-
lection of components and the dimensioning of the heat exchang-
ers is done based on the requirements given by the customer. This
Installation Guide includes general instructions. The more detailed
information of the order can be found in the product related
documentation.
District heating
energy plant
Hot district heating water
Cool district heating water
District heating customer
Domestic hot water
Heating
Picture Energiateollisuus ry
Installation Guide ACS Substation
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Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
3.3 ACS - example circuit diagram
- 2 circuits, circuit diagram example
After heating connection: domestic hot water and heating
25
15
15
15
28
64
46
7
6
27
27
27
26
5
7
8
16
65
11
66
18
27
27
18
13
13
1
2
7
6
12
30
30
29
29
7
7
46
7
7
25a
TE1A
TV1
TV2
TE1B
LS1
LS2
TE2C
TE2B
TE2A
P2
P1
PS
PE2
7
SUMMER
SHUT-OFF
Temperatures and alarms on the controller display
Limit of the prefabricated substation
Options
1 Plate heat exchanger HE
2 Plate heat exchanger DHW
5 Strainer
6 Non-return valve
7 Ball valve
8 Circulation pump HE
11 Safety valve HE
12 Safety valve DHW
13 Thermometer
15 Manometer
16 Expansion vessel
18 Drain valve
25 Electronic Controller
25a Pump control bow
26 Outdoor temperature sensor
27 Temperature sensor
28 Pressure sensor
29 Actuator
30 Control valve
46 Balancing valve
64 Circulation pump DHW
65 Service valve
66 Filling valve
Installation Guide ACS Substation
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DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
3.4 Electrical circuit diagrams
ACS with ECL controller
DATE DESIGNER
PAGE
WORK NO
DRAWING NO
HE pump alarm
Installation Guide ACS Substation
55
Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
DATE DESIGNER
PAGE
WORK NO
DRAWING NO
3.4 Electrical circuit diagrams
ACS with ECL controller
Installation Guide ACS Substation
6
DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
DATE
DESIGNER
PAGE
WORK NO
DRAWING NO
3.4 Electrical circuit diagrams
ACS without controller
Installation Guide ACS Substation
77
Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
DATE DESIGNER
PAGE
WORK NO
DRAWING NO
AUTOMATION DIAGRAM
3.4 Electrical circuit diagrams
ACS without controller
Installation Guide ACS Substation
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DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
4.0 Visible components in the substation
1. All substation functions are controlled and the operational
values are observed with the electronic controller.
2. Dial: navigation in the menus and changes in the operating
values by following the controller display.
3. Display: all settings, temperature information and mode are
found on the graphical display. Navigation in the menus and
changes in the settings are done following the display.
4. With the installation feet you can adjust the substation posi-
tion directly and on the correct height. The adjustments can be
done up to 6 cm.
5. Connections to district heating, heating and domestic hot
water networks.
6. The cover panels protect the components in the substation and
add user safety. When installing or servicing the cover panels have
to be removed.
5.0 Installation and start-up - Step by step
5.1 Removing the cover panels
The cover panels have to be removed before moving the substa-
tion to the installation place and installing it.
The panels are removed by lifting them up.
1. First remove the white panels from the front and back.
2. After that lift the grey panels.
The cover panels can be placed back on the substation when the
substation is installed and ready for use. The panels are placed
back in the opposite order when compared with taking them
away.
1
4
5
6
2
3
1
1
2
2
Installation Guide ACS Substation
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Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
5.2 Protective cardboard cover
Leave the cardboard cover on top of the substation during moving
and installation.
5.3 Removing the substation from the pallet
The substation is screwed on the pallet with the attaching feet.
Take off the screws pointed with arrows in the picture.
5.4 Moving substation to the installation place
ACS substation can be moved to the installation place using sev-
eral different ways, depending on the installation place and how to
get there.
Plan the most convenient route to the installation place. Be aware
not to break floor and wall surfaces, stairs, doorposts etc.
The substation includes delicate components.
Do not hurt yourself or damage the substation when lifting it!
1. Moving with a pallet truck.
Installation Guide ACS Substation
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DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
2. Lifting with a crane
It is possible to screw up lifting eyes in the top corners after remov-
ing detachable metal round pieces from the roof. This way substa-
tion can be lifted up by using straps.
5.5 Installation place
The installation place and the pipe connections for ACS substation
can be planned in beforehand due to standardized sizing.
The upwards oriented connections enable installation e.g. close to
the wall. Since the hot surfaces are hidden underneath the cover it
is possible to use the boiler room also for some other activities.
Installation Guide ACS Substation
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Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
5.6 Height adjustment
Adjust the substation straight horizontally and on the desired
height with the help of the installation feet. By turning the adjust-
ment feet you can make up to 6 cm adjustments.
5.7 Pipe connections
The substation is connected to the district heating network, heat-
ing, domestic hot water and circulation networks in the building
according to the connections and flow directions in the drawing.
The pipes equipped with the couplings are to be detached and
welded somewhere else but above the substation.
The pipes must be mounted so that the strain caused by e.g. ther-
mal expansion, does not harm the sustation. The pipes must be
equipped with brackets in order to prevent any torsional stress.
The connection to the district heating network can be done
only by a qualified installer accepted by the district heating
distributor.
Prior to installation all pipes and connections have to be
cleaned and rinsed.
5.7.1 Connection directions
1. District heating supply
2. District heating return
3. Heating supply
4. Heating return
5. Cold water
6. Domestic hot water
7. Domestic hot water circulation
After cooling connection:
After cooling connection
Direct return connection
5. 6. 7. 2. 1.
4. 3.
Direct connection:
After cooling connection
Direct return connection
5.
6.
7.
2.
1.
4.
3.
Installation Guide ACS Substation
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DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
5.7.2 Dimensions for the pipe connections
The pipe connections are standardized and their places differ ac-
cording to required capacity and the size of the substation.
In the after cooling connection both cold water and district heat-
ing return connection places are dependable on the size of the
required heat exchanger. The dimensions settle within the dimen-
sions given in the dimensional pictures.
0
300-420 550 720
880-1000 1240
1350
0
100
460
250
470
0
After cooling connection 1350 mm blockAfter cooling connection 1090 mm block
Direct connection DN32
90
100
120
460
740
0
240
470
560
730
890
1080
1190
1350
0
90
100
120
460
740
0
150
300
0
0
330
490
640
860
950
1090
Direct connection DN50
330
490
640
850
960
1090
0
90
120
460
740
0
150
0 300
Direct connection DN65
0
220-280
400 560
650-710
920
1090
100
460
220
370
Installation Guide ACS Substation
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Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
5.8 Electrification
Since the internal electrical connections are factory made it is not
mandatory to use an electrician to connect the substation. The
contact plug is the main electrical switch in the substation.
The outdoor temperature sensor is to be installed on the north
side of the property at app. 3 m height where the outdoor tem-
perature can be measured. There should be no ventilation window
at the close proximity to the measuring point. The other end of the
outdoor temperature sensor cable is to be connected into the con-
trol box. When connecting outdoor temperature sensor make
sure to remove the substation contact plug.
In case the length of the outdoor temperature sensor cable is not
long enough for your property, it is remmendable to change the
whole cable. This way extra joints are avoided. The minimum area
for the cable is 0.4 mm
2
and the maximum length is 125 m. If you
choose to use the extra joint inspite of recommendation, protect
the jointing sleeve with the shrink cable.
Stick the contact plug into the wall socket fitted with a 10A/220V
fuse.
Wait for 10 s, turn the circulation pumps P1 (DHW) and P2 (HE) on
by pressing the operating switches.
Do not run the pumps without water.
5.9 Controller settings
Description
The ECL Comfort electronic weather compensated temperature
controllers are for use in district heating, central heating and cool-
ing systems.
Energy savings are facilitated by weather compensation, adjust-
ment of temperature according to schedule, optimization as well
as limitation of return temperature, flow and power. Functionalities
such as data logging and alarm functions are implemented in the
controller.
Property specific controller settings
There are some property related settings which are to be done
before starting up the substation. A complete controller instruc-
tion is included and the most important details are also enclosed
in this Installation Guide.
20 m
20 m
Installation Guide ACS Substation
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DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
5.9.1 Controller display and symbols
5.9.2 Operating the controller
The graphical monochrome display shows all temperature val-
ues, status information and is used for the setting of control pa-
rameters. Navigation, browsing and selecting is done by means
of the dial. You can navigate in the menus and change the values
by turning the dial left or right and pushing to confirm.
When a rectangle appears around the value or symbol, it is pos-
sible to do changes by turning the dial left or right.
You can always get back to your favourite display by going to the
top of the display and turning the dial so many times that “Home”
appears. If the dial has not been activated, the controller will after
20 min. revert to the favourite display.
Favourite display for the user
Symbol Description
Tempera-
tures
Outdoor
temperature
Room
temperature
DHW temperature
Position indicator
Mode
Scheduled
operation
Comfort mode
Saving mode
Frost protection
mode
Manual mode
Circuits
Heating
DHW
Common
controller
Control-
led com-
ponents
Pump ON
Pumppu OFF
Actuator opens
Actuator closes
Alarm
Display selector
Favourite display for the installer
1
= Heating circuit
= DHW circuit
= Common controller
Mode
= Manual mode
= Scheduled operation
= Comfort mode
= Saving mode
= Frost protection mode
Menus with
values and
settings
Position
indicator for
navigation
Display selection
State of
components
System
pressure
Primary return
temperature:
actual and
desired
Flow
temperature:
actual and
desired
Return
temperature:
actual
1
= Heating circuit
= DHW circuit
= Common controller
Mode
= Scheduled operation
= Comfort mode
= Saving mode
= Frost protection mode
Desired room
temperature
Date
Outdoor
temperature
Time
Schedule
Menus with values
and settings
Position indicator
for navigation
Display selection
Installation Guide ACS Substation
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Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
5.9.3 Setting the date and time
Set correct date and time in the controller.
Setting done
as with the
hours.
Setting the
date same
way as time.
Getting out of the menu.
Installation Guide ACS Substation
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DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
5.9.4 Setting the heat curve
Due to different heat masses, heating system, insulation dimen-
sions etc. it might be necessary to change the heat curve.
Set the heat curve always according to HEVAC plans (functioning
temperature of the heating circuit). There you can find desired flow
temperatures for different outdoor temperatures.
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
-40 -30 -20 -10 0 10 20 30
[
o
C]
[
o
C]
1.0
1.4
0.6
0.2
1.8
2.2 3.0 3.52.6 4.0
0.1
0.3
0.4
Factory setting, the heat curve: Example heat curve for the floor-heating system:
Factory setting
is a typical heat
curve for radiator
heating,
about 1.0
Outdoor
temperature
°C
Flow
temperature
°C
Visible on the
display
-30 75 (-30,75)
-15 60 (-15,60)
-5 50 (-5,50)
0 45 (0,45)
5 40 (5,40)
15 28 (15,28)
The heat curve
typically used
with floor-heat-
ing, about 0.4
Outdoor
temperature
°C
Flow
temperature
°C
Visible on the
display
-30 45 (-30,45)
-15 38 (-15,38)
-5 34 (-5,34)
0 31 (0,31)
5 28 (5,28)
15 22 (5,22)
Changes in the heat curve
point by point.
Set the desired temperature.
Move to the following points.
Setting same
way as with the
previous point.
Installation Guide ACS Substation
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Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
Saving the new curve. Getting out of the menu.
5.9.5 Setting up limitations for flow temperature
The flow temperature maximum limitation prevents too hot
water from going into the heating circuit, e.g. in the floor-heating
system.
When taking floor-heating system into use for the first time, the
max. limitation for flow temperature can be set e.g. at 27°C. The
limitation temperature cuts off the heat curve when the tempera-
ture reaches the limit.
Later on after the concrete slab has dried the flow temperature
limitation can be raised to 45°C which is typically used in the floor-
heating system.
Typical max. limitation in the radiator heating circuit is 90°C.
Typical flow temperature
limitations in different heating
systems
Flow temperature
min °C max °C
Radiator heating 20 90
When taking floor-heating
system into use for the first time
(drying up concrete slab)
20 27
Floor-heating 20 45
Setting the flow temperature
max. limitation.
Typical flow temperature max.
limitation: floor-heating 45°C.
Setting the flow temperature
min. limitation.
Typical flow temperature max.
limitation: radiator heating 90°C.
The heat curve display by fol-
lowing the intructions in “5.9.4
Setting the heat curve”.
.
Installation Guide ACS Substation
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DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
Typical flow temperature max.
limitation: When taking floor-
heating system into use for the
first time (drying up concrete
slab) 27°C.
Example display of the heat
curve limiting temperature:
floor-heating heat curve, flow
temp. max limitation 27°C.
Getting out of the menu.
The heat curve display by fol-
lowing the intructions in “5.9.4
Setting the heat curve”.
Getting out of the menu.
Typical flow temperature min.
limitation is 20°C.
5.9.6 Manual control
Manual control is typically used when installing or servicing. The
controlled components, valve, pump etc. can be controlled for
correct function.
Do not leave the controller in “Manual control” mode after
finishing maintenance or service work. The normal mode is
“Comfort mode” or when using schedules “Scheduled
operation” .
The valve is open.
Installation Guide ACS Substation
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Danfoss District Energy VI.GE.K2.02 DEN-SMT/FI
The valve is closed.
Getting away.
Changing back to Comfort mode.
5.9.7 Commissioning with one circuit
When commissioning the substation it might be necessary to
close a circuit, e.g. DHW circuit. The circuit in question can be
closed by forcing the control valve to close down.
The pump has to be stopped with an operating switch.
M1, P1
DHW circuit control valve and
circulation pump
M2, P2
Heating circuit control valve and
circulation pump
A1 Alarm relay
An example: DHW circuit control
valve close down.
The valve is forced to close down.
STOP leaves the valve in closed
position.
Getting out of the menu.
Installation Guide ACS Substation
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DEN-SMT/FI VI.GE.K2.02 Danfoss District Energy
5.9.8 Sensor displays
Temperature and pressure information can be read on the con-
troller display.
All values can be found by going
down the list.
Getting out of the menu.
5.9.9 Alarm
Alarm functions in the controller: pressure alarm, pump alarm
and maximum temperature alarm (temperature limiting thermo-
static function). As a sign of an alarm symbol appears on the
display.
Alarm overview shows which
alarm is in question.
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