Danfoss Termix One-B User manual

InstallationGuide
TermixOne-B
1.0TableofContents
1.0TableofContents.............................................1
2.0Functionaldescription......................................2
3.0Safetynotes.....................................................3
3.1SafetyNotes–general............................................3
4.0Mounting........................................................4
4.1Mounting...........................................................4
5.0Design.............................................................6
5.1Design...............................................................6
5.2Schematicdiagram................................................7
6.0Controls..........................................................9
6.1DHWtemperaturecontrol........................................9
6.2Maintenance........................................................10
7.0Troubleshooting..............................................11
7.1Troubleshootingingeneral......................................11
7.2TroubleshootingDHW............................................11
7.3Disposal.............................................................12
8.0Declaration......................................................15
8.1Declarationofconformity........................................15
DanfossHeatingVI.CW.J3.02/LUK38000DEN-GT1

InstallationGuideTermixOne-B
2.0Functionaldescription
Instantaneouswaterheaterwithheatexchangerand
thermostaticcontrol.Designedforwallmounting.
Application
TheTermixOneisaninstantaneouswaterheaterfeaturingsuperb
heatextractionandhighperformance.TheTermixOneissuitable
forats,single-familyhousesaswellasforsmallapartment
buildingswithupto10apartments.Thewaterheaterisavailablein
threesizes,eitherfor1apartment,for1‑4apartmentsorfor5up
to10apartments.TheTermixOneisapplicablefordecentralized
heatingsystems–aswellasfordistrictheatingnetworkswith
summeroperationatlowtemperaturesorchangesindifferential
pressure.TheTermixOneheatexchangercoolsoutthedistrict
heatingwaterveryefciently,therebycreatingaverygood
operationeconomy.
Domestichotwater(DHW)
Thedomestichotwaterispreparedintheheatexchangerand
thetemperatureisregulatedwithathermostaticcontrolvalve.
Thepatentedsensoracceleratoracceleratestheclosingofthe
DanfossAVTBvalveandprotectstheheatexchangeragainst
overheatingandlimescaleformation.Thesensoracceleratorand
AVTBvalvealsoworksasabypasskeepingthehousesupplyline
warm.Thisshortensthewaitingperiodsduringsummerwhenthe
heatingsystemisinreducedoperation.Thesensoraccelerator
helpstoensureastablehotwatertemperaturebyvaryingloads,
owtemperaturesanddifferentialpressurewithouttheneedfor
readjustingthevalve.Thereisnoadditionalpressurelossonthe
secondarysideoftheDHWheatexchangerwithathermostatic
control.Thereforethistypeofregulationcanbeusedbylow
pressureontheinthecoldwatermains.
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InstallationGuideTermixOne-B
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.
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InstallationGuideTermixOne-B
4.0Mounting
4.1Mounting
Installationmustbeincompliancewithlocalstandardsand
regulations.
Districtheating(DH)-Inthefollowingsections,DHreferstothe
heatsourcewhichsuppliesthesubstations.Avarietyofenergy
sources,suchasoil,gasorsolarpower,couldbeusedasthe
primarysupplytoDanfosssubstations.Forthesakeofsimplicity,
DHcanbetakentomeantheprimarysupply.
Connections:
1.Domesticcoldwater(DCW)
2.Domestichotwater(DHW)
3.Districtheating(DH)supply
4.Districtheating(DH)return
Connectionsizes:
DH:G¾”(int.thread)
DCW+DHW:G¾”(int.thread)
Dimensions(mm):
Type1+2withoutcover:
H428xW312xD155
Type1+2withcover:
H430xW315xD165
Type3withoutcover:
H468xW312xD155
Type3withcover:
H470xW315xD165
Weight(approx.):10–12kg
Authorizedpersonnelonly
Assembly,start-upandmaintenanceworkmustbeperformedby
qualiedandauthorizedpersonnelonly.
Thepipeplacementcandeviatefromtheshowndrawing.Pleasenote
themarkingsonthestation.
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InstallationGuideTermixOne-B
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.
Thightening
Duetovibrationduringtransport,allsubstationconnectionsmust
becheckedandtightenedbeforeinstallation.
Unusedconnections
Unusedconnectionsandshut-offvalvesmustbesealedwitha
plug.Shouldtheplugsrequireremoval,thismustonlybedoneby
anauthorizedservicetechnician.
Installation:
Strainer
Ifastrainerissuppliedwiththestationitmustbettedaccording
toschematicdiagram.Pleasenotethatthestrainermaybe
suppliedloose.
Connections
Internalinstallationanddistrictheatingpipesconnectionsmustbe
madeusingthreaded,angedorweldedconnections.
Keyholeformounting.
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InstallationGuideTermixOne-B
5.0Design
5.1Design
Yoursubstationmightlookdifferentthanthesubstationshown.
Designdescription
BHeatexchanger,DHW
OTermixsensoraccelerator
7Thermostaticcontroller,DHW
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InstallationGuideTermixOne-B
5.2Schematicdiagram
DH
SupplyDHW
DH
ReturnDCW
DH
SupplyDHW
HWC
DH
ReturnDCW
Yoursubstationmightlookdifferentthantheschematicdiagramshown.
Firstdiagram:TermixOne-Q-withGTU.
Seconddiagram:TermixOne-Q-withsafetyvalve.
Schematicdescription
BHeatexchanger,DHW7Thermostaticvalve
2Singlecheckvalve21Tobeorderedseparately
4Safetyvalve62GTUPressureequalizer
6Thermostatic/non-returnvalve
DHW:DomesticHotWater
DCW:DomesticColdWater
HWC:HotWaterCirculation
DHSupply:DistrictHeatingSupply
DHReturn:DistrictHeatingReturn
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InstallationGuideTermixOne-B
5.2.1Technicalparameters
Technicalparameters
Nominalpressure:PN16
Max.DHsupplytemperature:120°C
Min.DCWstaticpressure:0.5bar
Brazingmaterial(HEX):Copper
Heatexchangerstestpressure:30bar
Soundlevel:≤55dB
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InstallationGuideTermixOne-B
6.0Controls
6.1DHWtemperaturecontrol
DHWtemperaturecontrol
TherearevarioustypesofDHWtemperaturecontrolusedin
Danfosssubstations.
DHWtemperatureshouldbeadjustedto45-50°C,asthisprovides
optimalutilisationofDHwater.AtDHWtemperaturesabove55°C,
thepossibilityoflimescaledepositsincreasessignicantly.
6.1.1AVTBcontroller(20–60°)
Thetemperaturesettingisasfollows:
1=20°C
2=35°C
3=50°C
4=60°C
5=70°C
Thevaluesareintendedasaguide.
TheAVTBoperatesatitsbestatDHsupplytemperaturesofupto
90°C.
Thermostaticcontrol
DHWtemperatureisadjustedasfollows:
Toincreasetemperature,turnthehandleonthethermostatic
controllertoselectahighernumber.
Todecreasetemperature,turnthehandleonthethermostatic
controllertoselectalowernumber.
6.1.2Safetyvalve
Thepurposeofthesafetyvalveistoprotectthesubstationfrom
excessivepressure.
Theblow-offpipefromthesafetyvalvemustnotbeclosed.The
blow-offpipeoutletshouldbeplacedsothatitdischargesfreely
anditispossibletoobserveanydrippingfromthesafetyvalve.
Itisrecommendedtochecktheoperationofsafetyvalvesat
intervalsof6months.Thisisdonebyturningthevalveheadin
directionindicated.
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InstallationGuideTermixOne-B
6.1.3Strainer
Strainersshouldbecleanedregularlybyauthorizedpersonnel.The
frequencyofcleaningwoulddependonoperatingconditionsand
themanufacturer’sinstructions.
6.1.4GTUPressureEqualizer
TheGTUPressureEqualizerabsorbstheexpansiononthe
secondarysideoftheTermixwaterheatersandcanbeusedasa
substitutetothesafetyvalve.
Furthermorethepressureequalizerabsorbsapossibleincreasein
pressure,soadischargeoutletisomitted.
TheGTUPressureEqualizermaynotbeappliedinsystemswithhot
watercirculation.
6.2Maintenance
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.
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InstallationGuideTermixOne-B
7.0Troubleshooting
7.1Troubleshootingingeneral
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.
7.2TroubleshootingDHW
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.
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InstallationGuideTermixOne-B
7.3Disposal
Disposal
Thisproductshouldbedismantledanditscomponents
sorted,ifpossible,invariousgroupsbeforerecycling
ordisposal.
Alwaysfollowthelocaldisposalregulations.
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InstallationGuideTermixOne-B
DanfossHeatingVI.CW.J3.02/LUK38000DEN-GT13

InstallationGuideTermixOne-B
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InstallationGuideTermixOne-B
8.0Declaration
8.1Declarationofconformity
8.1.1Category0withoutelectricalequipment
EC–DeclarationofConformity
GeminaTermixA/S
MemberoftheDanfossGroup
Navervej15-17
DK-7451Sunds
Declaresonoursoleresponsibilitythatthebelowproducts:
Substations–Category0withoutelectricalequipment,
coveredbythisdeclarationareinconformitywiththefollowingdirectives,standardsandothernormative
documents,providedthattheyareusedaccordingtoourinstructions.
MachineryDirective2006/42/EC
DS/EN60204-1/A1:2009.Safetyofmachinery–
Part1–GeneralRequirements.
DS/EN12100:2011.Safetyofmachinery–Risk
assessment.
Sunds–2013.03.15
PlaceanddateofissueClausGjøderumMortensen
Quality&EnvironmentManager
DanfossHeatingVI.CW.J3.02/LUK38000DEN-GT15

InstallationGuideTermixOne-B
ProducedbyDanfossA/S©05/2013