Danfoss Termix AT BTD User manual

Operatingguide
TermixATBTD
1.0TableofContents
1.0TableofContents.............................................1
2.0Functionaldescription......................................2
3.0Safetynotes.....................................................3
3.1SafetyNotes–general............................................3
4.0Mounting........................................................4
4.1Mounting...........................................................4
4.2Start-up..............................................................5
5.0MountinginstructionsTermixATBTDwall
cabinet............................................................6
5.1Mounting...........................................................6
6.0Design.............................................................8
6.1DesignTermixATBTD5pipes...................................8
6.2SchematicdiagramTermixATBTD5Pipes....................9
6.3DesignTermixATBTD4pipes...................................10
6.4SchematicdiagramTermixATBTD4Pipes....................11
7.0Controls..........................................................12
7.1DHWtemperaturecontrol........................................12
7.2Other.................................................................13
7.3Maintenance........................................................14
8.0Troubleshooting..............................................15
8.1Troubleshootingingeneral......................................15
8.2TroubleshootingDHW............................................15
8.3Disposal.............................................................16
9.0Declaration......................................................19
9.1Declarationofconformity........................................19
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT1

OperatingguideTermixATBTD
2.0Functionaldescription
Districtheatingsubstationwithtankfordomestichotwater
preparationandwiththermostaticcontrol.Designedfor
wall-mounting.
Application
TheTermixATBTDsubstationisacompletesolutionforhot
water.TheTermixATBTDisapplicableforsingle-familyhouses
orapartments.
Domestichotwater(DHW)
Thedomestichotwatercircuitconsistsofahotwatertankwithcoil
andself-actingthermostaticcontrolvalve.Thehotwatertankand
coilareenamelledandthetankcontainsamagnesiumanode.The
substationisdeliveredwithabuiltinsafetyvalve.
2DEN-GTVI.JV.Y3.02/LUK40692DanfossDistrictEnergy

OperatingguideTermixATBTD
3.0Safetynotes
3.1SafetyNotes–general
Thefollowinginstructionsrefertothestandarddesignof
substation.Specialversionsofsubstationsareavailableon
request.
Thisoperatingmanualshouldbereadcarefullybeforeinstallation
andstart-upofthesubstation.Themanufactureracceptsno
liabilityfordamageorfaultsthatresultfromnon-compliancewith
theoperatingmanual.Pleasereadandfollowalltheinstructions
carefullytopreventaccidents,injuryanddamagetoproperty.
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
Pleasecomplywiththeinstructionsissuedbythesystem
manufacturerorsystemoperator.
Corrosionprotection
Allpipesandcomponentsaremadeofstainlesssteelandbrass.
Themaximumchloridecompoundsoftheowmediumshouldnot
behigherthan150mg/l.
Theriskofequipmentcorrosionincreasesconsiderablyifthe
recommendedlevelofpermissiblechloridecompoundsis
exceeded.
Energysource
Thesubstationisdesignedfordistrictheatingastheprimary
sourceofenergy.However,alsootherenergysourcescanbeused
wheretheoperatingconditionsallowitandalwaysarecomparable
todistrictheating.
Application
Thesubstationisdesignedtobeconnectedtothehouse
installationinafrost-freeroom,wherethetemperaturedoesnot
exceed50°Candthehumiditydoesnotexceed60%.Donotcover
orwallupthesubstationorinanyotherwayblocktheentrance
tothestation.
Choiceofmaterial
Choiceofmaterialsalwaysincompliancewithlocallegislation.
Safetyvalve(s)
Werecommendmountingofsafetyvalve(s),however,alwaysin
compliancewithlocalregulations.
Connection
Thesubstationmustbeequippedwithfeaturesthatensurethat
thesubstationcanbeseparatedfromallenergysources(also
powersupply).
Emergency
Incaseofdangeroraccidents-re,leaksorotherdangerous
circumstances-interruptallenergysourcestothestationif
possible,andseekexperthelp.
Incaseofdiscolouredorbad-smellingdomestichotwater,closeall
shut-offvalvesonthesubstation,informtheoperatingpersonnel
andcallforexperthelpimmediately.
Storage
Anystorageofthesubstationwhichmaybenecessarypriorto
installationshouldbeinconditionswhicharedryandheated.
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
Pleaseobserveinstructionscarefully
Toavoidinjurytopersonsanddamagetothedevice,itisabsolutely
necessarytoreadandobservetheseinstructionscarefully.
Warningofhighpressureandtemperature
Beawareoftheinstallation’spermissiblesystempressureand
temperature.
Themaximumtemperatureoftheowmediuminthesubstationis
120°C.
Themaximumoperatingpressureofthesubstationis10bar.PN16
versionsareavailableonenquiry.
Theriskofpersonsbeinginjuredandequipmentdamagedincreases
considerablyiftherecommendedpermissibleoperatingparameters
areexceeded.
Thesubstationinstallationmustbeequippedwithsafetyvalves,
however,alwaysinaccordancewithlocalregulations.
Warningofhotsurface
Thesubstationhasgothotsurfaces,whichcancauseskinburns.
Pleasebeextremelycautiousincloseproximitytothesubstation.
Powerfailurecanresultinthemotorvalvesbeingstuckinopen
position.Thesurfacesofthesubstationcangethot,whichcancause
skinburns.Theballvalvesondistrictheatingsupplyandreturnshould
beclosed.
Warningoftransportdamage
Beforesubstationinstallation,pleasemakesurethatthesubstation
hasnotbeendamagedduringtransport.
IMPORTANT-Tighteningofconnections
Duetovibrationsduringtransportallangeconnections,screwjoints
andelectricalclampandscrewconnectionsmustbecheckedand
tightenedbeforewaterisaddedtothesystem.Afterwaterhasbeen
addedtothesystemandthesystemhasbeenputintooperation,
re-tightenALLconnections.
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT3

OperatingguideTermixATBTD
4.0Mounting
4.1Mounting
Installationmustbeincompliancewithlocalstandardsand
regulations.
Districtheating(DH)-Inthefollowingsections,DHreferstothe
heatsourcewhichsuppliesthesubstations.Avarietyofenergy
sources,suchasoil,gasorsolarpower,couldbeusedasthe
primarysupplytoDanfosssubstations.Forthesakeofsimplicity,
DHcanbetakentomeantheprimarysupply.
Connectionsizes:
Allconnections:G¾”(int.thread)
Dimensions(mm):
Withcover:
100L:H1180xW540xD520
150L:H1510xW540xD520
Weight(approx.):85–100kg
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
TermixATBTD5pipes
Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.
TermixATBTD4pipes
Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.
4DEN-GTVI.JV.Y3.02/LUK40692DanfossDistrictEnergy

OperatingguideTermixATBTD
4.1.1Installation
Mounting:
Adequatespace
Pleaseallowadequatespacearoundthesubstationformounting
andmaintenancepurposes.
Orientation
Thestationmustbemountedsothatcomponents,keyholes
andlabelsareplacedcorrectly.Ifyouwishtomountthestation
differentlypleasecontactyoursupplier.
Drillings
Wheresubstationsaretobewall-mounted,drillingsareprovided
inthebackmountingplate.Floormountedunitshavesupport.
Labelling
Eachconnectiononthesubstationislabelled.
Beforeinstallation:
Cleanandrinse
Priortoinstallation,allsubstationpipesandconnectionsshouldbe
cleanedandrinsed.
Tightening
Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.
Unusedconnections
Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.
Installation:
Strainer
Ifastrainerissuppliedwiththestationitmustbettedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.
Connections
Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,angedorweldedconnections.
4.2Start-up
Start-up,Directheating
Theshut-offvalvesshouldbeopenedandtheunitobservedas
itentersservice.Visualcheckingshouldconrmtemperatures,
pressures,acceptablethermalexpansionandabsenceofleakage.
Iftheheatexchangeroperatesinaccordancewithdesign,itcanbe
puttoregularuse.
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.
Re-thightenconnections
Afterwaterhasbeenaddedtothesystemandthesystemhasbeen
putintooperation,re-tightenALLconnections.
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT5

OperatingguideTermixATBTD
5.0MountinginstructionsTermixATBTDwallcabinet
5.1Mounting
Wallbracket
MounttheWallbracketaccordingtotheDrawing.
UseAtocenterthetankonthebracket.
B-AllpipethreadsareISO½” .
Mountthecontainerunitinthewallbracket.
6DEN-GTVI.JV.Y3.02/LUK40692DanfossDistrictEnergy

OperatingguideTermixATBTD
Sideplates
Fastentherightandleftsideplatesbyplacingthekeyholesover
thescrewsonthesidesofthewallbracket.
1Bottompanel
Slidetheslotsinthebottompanelontothe2bushesintheside
plates,andfastenthepanelwiththe2screwsinthefront.
2Topplate
Mountthetopplate.
3Frontcover
Mountthefrontcoverbyloweringthekeyholesontothescrews
inthesideplates.
4Clockpanel
Mounttheclockpanelbyloweringthekeyholesontothescrews
inthesideplates.
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT7

OperatingguideTermixATBTD
6.0Design
6.1DesignTermixATBTD5pipes
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
EHotwatertankwithcoil4Safetyvalve
SSiphon20Filling/drainvalve
1ABallvalve,DVGW41AFittingpiece,coldwatermains
2Singlecheckvalve59Differentialpressure/temperatureregulatorwithowlimiting
8DEN-GTVI.JV.Y3.02/LUK40692DanfossDistrictEnergy

OperatingguideTermixATBTD
6.2SchematicdiagramTermixATBTD5Pipes
DHW
DCW
CWM
DH
Supply
DH
Return
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
EHotwatertankwithcoil4Safetyvalve
1Ballvalve20Filling/drainvalve
1ABallvalve,DVGW41AFittingpiece,coldwatermains
2Singlecheckvalve59Differentialpressure/temperatureregulatorwithowlimiting
DHW:DomesticHotWater
DCW:DomesticColdWater
CWM:Coldwatermains
DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT9

OperatingguideTermixATBTD
6.3DesignTermixATBTD4pipes
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
EHotwatertankwithcoil4Safetyvalve
SSiphon20Filling/drainvalve
1ABallvalve,DVGW59Differentialpressure/temperatureregulatorwithowlimiting
2Singlecheckvalve
10DEN-GTVI.JV.Y3.02/LUK40692DanfossDistrictEnergy

OperatingguideTermixATBTD
6.4SchematicdiagramTermixATBTD4Pipes
DHW
DCW
DH
Supply
DH
Return
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Schematicdescription
EHotwatertankwithcoil4Safetyvalve
1Ballvalve20Filling/drainvalve
1ABallvalve,DVGW59Differentialpressure/temperatureregulatorwithowlimiting
2Singlecheckvalve
DHW:DomesticHotWater
DCW:DomesticColdWater
DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn
6.4.1Technicalparameters
Technicalparameters
Nominalpressure:PN10
Max.DHsupplytemperature:T–max=95°C
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT11

OperatingguideTermixATBTD
7.0Controls
7.1DHWtemperaturecontrol
DHWtemperaturecontrol
TherearevarioustypesofDHWtemperaturecontrolusedin
Danfosssubstations.
DHWtemperatureshouldbeadjustedto45-50°C,asthisprovides
optimalutilisationofDHwater.AtDHWtemperaturesabove55°C,
thepossibilityoflimescaledepositsincreasessignicantly.
7.1.1AB-QMcontroller(45–60°)
QTisaself-actingthermostaticactuatordesignedtobeused
asreturntemperaturecontrolthermostatinone-pipeheating
systems.
QTisdedicatedtobeusedwithAB-QMautomaticbalancing&
controlvalve.
AB-QMDN10-20(45-60°C)
QTSensorsetting(turns)
Temperaturesetting0123456
20%48,050,553,055,558,060,563,0
30%47,049,552,054,557,059,562,0
40%46,048,551,053,556,058,561,0
50%45,047,550,052,555,057,560,0
60%44,046,549,051,554,056,559,0
70%43,045,548,050,553,055,558,0
80%42,044,547,049,552,054,557,0
90%41,043,546,048,551,053,556,0
AB-QM(ow
setting)
100%40,042,545,047,550,052,555,0
Thevaluesareintendedasaguide.
12DEN-GTVI.JV.Y3.02/LUK40692DanfossDistrictEnergy

OperatingguideTermixATBTD
7.2Other
7.2.1Coldwatermeterttingpiece
Thesubstationisequippedwithattingpieceforcoldwatermeter.
Assemblyofcoldwatermeter:
1:Closeballvalves
Closetheballvalvesoncoldwater,ifthereiswateronthesystem.
2:Loosennuts
Loosenthenutsonthettingpiece.
3:Removettingpiece
Removethettingpieceandreplaceitwiththecoldwatermeter.
Donotforgetthegaskets.
4:Tightenconnections
Aftermountingofthecoldwatermeterremembertocheckand
tightenallthreadedconnections.
7.2.2Siphon
PlacedtheSiphondirectlyundertheSafetyvalve.
Ensurethatthedrainpipehasaminimuminternaldiameterof
32mm.
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT13

OperatingguideTermixATBTD
7.3Maintenance
Thesubstationrequireslittlemonitoring,apartfromroutine
checks.Itisrecommendedtoreadtheenergymeteratregular
intervals,andtowritedownthemeterreadings.
RegularinspectionsofthesubstationaccordingtothisInstruction
arerecommended,whichshouldinclude:
Strainers
Cleaningofstrainers.
Meters
Checkingofalloperatingparameterssuchasmeterreadings.
Temperatures
Checkingofalltemperatures,suchasDHsupplytemperatureand
DHWtemperature.
Connections
Checkingallconnectionsforleakages.
Safetyvalves
Theoperationofthesafetyvalvesshouldbecheckedbyturning
thevalveheadintheindicateddirection.
Venting
Checkingthatthesystemisthoroughlyvented.
Inspectionsshouldbecarriedoutminimumeverytwoyears.
SparepartscanbeorderedfromDanfoss.Pleaseensurethatany
enquiryincludesthesubstationserialnumber.
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
14DEN-GTVI.JV.Y3.02/LUK40692DanfossDistrictEnergy

OperatingguideTermixATBTD
8.0Troubleshooting
8.1Troubleshootingingeneral
Intheeventofoperatingdisturbances,thefollowingbasicfeatures
shouldbecheckedbeforecarryingoutactualtroubleshooting:
•thesubstationisconnectedtoelectricity,
•thestrainerontheDHsupplypipeisclean,
•thesupplytemperatureoftheDHisatthenormallevel
(summer,atleast60°C-winter,atleast70°C),
•thedifferentialpressureisequaltoorhigherthanthenormal
(local)differentialpressureintheDHnetwork–ifindoubt,ask
theDHplantsupervisor,
•pressureonthesystem-checktheHEpressuregauge.
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
8.2TroubleshootingDHW
ProblemPossiblecauseSolution
Strainerinsupplyorreturnlineclogged.Cleanstrainer(s).
DHWcirculationpumpoutoforderorwith
toolowsetting.
Checkcirculationpump.
Defectiveorcloggednon-returnvalve.Replace–clean.
Noelectricity.Check.
Wrongsettingofautomaticcontrols,ifany.Toadjustanelectroniccontrollerfor
DHW,pls.noteenclosedinstructionsfor
electroniccontroller.
Scalingoftheplateheatexchanger.Replace–rinseout.
Defectivemotorizedvalve.Check(usemanualfunction)–replace.
Defectivetemperaturesensors.Check–replace.
ToolittleornoDHW.
Defectivecontroller.Check–replace.
DCWisbeingmixedwiththeDHW,e.g.in
adefectivethermostaticmixingvalve.
Check–replace. Hotwaterinsometapsbutnotinall.
Defectiveorcloggednon-returnvalveon
circulationvalve.
Replace–clean.
Taptemperaturetoohigh;DHWtapload
toohigh.
Thermostaticvalveadjustedtoatoohigh
level.
Check–set.
Scalingoftheplateheatexchanger.Replace–rinseout. Temperaturedropduringtapping.
LargerDHWowthanthesubstationhas
beendesignedfor.
ReduceDHWow.
ThermostaticcontrolvalvedoesnotcloseTemperaturedifferencebetweenDH
supplyandDHWsetpointtoolow.
Lowerthesetpointtemperatureor
increasetheDHsupplytemperature.
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT15

OperatingguideTermixATBTD
8.3Disposal
Disposal
Thisproductshouldbedismantledanditscomponents
sorted,ifpossible,invariousgroupsbeforerecycling
ordisposal.
Alwaysfollowthelocaldisposalregulations.
16DEN-GTVI.JV.Y3.02/LUK40692DanfossDistrictEnergy

OperatingguideTermixATBTD
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT17

OperatingguideTermixATBTD
18DEN-GTVI.JV.Y3.02/LUK40692DanfossDistrictEnergy

OperatingguideTermixATBTD
9.0Declaration
9.1Declarationofconformity
Category0withoutelectricalequipment
DanfossDistrictEnergyVI.JV.Y3.02/LUK40692DEN-GT19

OperatingguideTermixATBTD
ProducedbyDanfossA/S©10/2017