Danfoss Air Heating Surfaces

Transcription

1 MAKING MODERN LIVING POSSIBLE Installation Guide

2 Danfoss A/S is not liable or bound by warranty if these instructions are not adhered to during installation or service. The English language is used for the original instructions. Other languages are a translation of the original instructions. (Directive 200/42/EC) 2012 Copyright Danfoss A/S

3 Table of Contents 1 Electrical Heating Surfaces Electrical pre-heating surfaces Electrical after heating surfaces Placing an electrical heating surface Connecting an electrical heating surface Overview - System with one heating surface Overview - System with two heating surfaces Troubleshooting Waterborne Heating Surfaces Waterborne after heating surfaces Placing a waterborne heating surface Connecting a waterborne heating surface Call for Heating Troubleshooting Geothermal Heating Surfaces Geothermal heating surfaces Dimensioning of ground collectors Laying ground collectors Filling with brine Placing a geothermal heating surface Connecting a geothermal heating surface Troubleshooting Technical Data Electrical heating surfaces Waterborne heating surfaces Geothermal heating surfaces Electrical Heating Surfaces 1.1 Electrical pre-heating surfaces An electrical pre-heating surface is used to keep the Air system temperature above the freezing point. Air systems without pre-heating will gradually reduce the air intake volume during long term operation at outside temperatures below -3 C in order to prevent freezing. In a standard house this is an excellent solution, but in airtight buildings (typical low-energy constructions), the imbalance can cause a non-desirable negative pressure inside the house. Installing a pre-heating surface is therefore recommended here. The electrical pre-heating surface is built into the duct system on the outdoor air side. A: Extract air. B: Supply air. C: Outdoor air. D: Exhaust air. A E: Sensor before heating surface. F: Sensor after heating surface. B G: Supply cable to heating surface H: Supply cable to automatic function. I: Communication cable HRV unit -> external controller. J: Post-heating (to be insulated with 50 mm glass/mineral wool). K: External controller (must not be insulated). Note! The electrical heating surface must be installed by a certified electrician. I H 230V, 50 Hz K G F E C 50 cm J 50 cm D Danfoss Heating Solutions VIFKB502 3

4 1.2 Electrical after heating surfaces An electrical after heating surface is used to slightly raise the supply air temperature to prevent discomfort in the room. The electrical after heating surface is built into the duct system on the supply side. A: Extract air. B: Supply air. C: Outdoor air. D: Exhaust air. E: Sensor before heating surface. F F: Sensor after heating surface. G: Supply cable to heating surface H: Supply cable to automatic function. H I: Communication cable HRV unit -> external controller. J: Post-heating (to be insulated with 50 mm glass/mineral wool). K: External controller (must not be insulated). Note! The electrical heating surface must be installed by a certified electrician. 50 cm J 50 cm 230V, 50 Hz G K E A B I C D 1.3 Placing an electrical heating surface The heating surface must be placed at a minimum distance of 2 x the diameter of the duct size to the nearest obstacle (pipe bends, external filters or unit). An arrow on the heating surface indicates the air flow direction. The heating surface must be placed at least 30 mm from any wooden building components. The connection box should face upwards or horizontally - never downwards. The heating surface must be insulated with non-flammable insulating material. The cover of the surface s external controller must NOT be insulated, but must remain visible so that the manual over-heating protection can be deactivated if this is triggered unexpectedly. The two factory mounted PT-1000 sensors must be placed in the duct system 50 cm in front of and 50 cm behind the surface. Each sensor is marked if it should be placed before or after surface. If the sensors face the wrong way, the required operations cannot be achieved. Drill Ø8 mm holes in the duct and install the supplied rubber grommets, then place the sensors into the duct. Fix the sensors to the pipe with duct tape and insulate together with the rest of the duct system and heating surface. Insulation Rubber sleeve PT-1000 sensor 45 mm min. 2 x A mm A mm min. 2 x A mm 1.4 Connecting an electrical heating surface The mains lead from the supplied external controller (marked supply voltage 230 V, 50 Hz ) is connected to the mains power, using a suitable junction box. We recommend that the heating surfaces be supplied from a separate group. The power cable from the external controller (marked to heating surface ) is connected to the electrical heating surface, cf. electrical diagram. The supply cable for the heating surface is fed through the pre-punched holes in the heating surface junction box. A cable gland must be used to provide strain relief. The communication cable is mounted between the external controller and the ventilation system s serial input (also see the following pages). 4 VIFKB502 Danfoss Heating Solutions

5 OBS: 120 Ohms modstand mellem klemme 2 & Gråt modbus stik, set fra tilslutningsside Klemme 1: Orange Klemme 2: Blå (+modstand) Klemme 3: Hvid/blå (+modstand) Klemme 4: Tom N L PE 24 2 Installation Guide 1. PT 1000 sensor, behind surface (control sensor). 2. PT 1000 sensor in front of the surface. 3. Communication cable between the HRV unit and mounting case (10 m, twisted pair, 2 pairs + display). 4. The power cable, 230 V, 50 Hz, should be connected to a separate 10 A group (3 m, 3G1.5). 5. Heating surface connection (3 m 3G1.5).. Over-heating thermostat with automatic re-closure (70 C). 7. The over-heating thermostat with manual closure (120 C). 8. Element. Note! The control box must not be insulated Solid state relæ PE N L Overview - System with one heating surface 1. Unit. 2. Heating surface controller. 3. CCM module. 4. Air Dial. 5. Serial cable, heating surface controller / unit.. Serial cable, CCM module / unit Mounting sequence - carried out on the serial socket in the unit 1. Twist together in pairs the serial cables with same colour. 2. Crimp-on ferrules are recommended. 3. Insert the cable pairs into the unit connector White / Orange 1 2. Orange 3. Black 4. White / Blue 5. Blue. Remove jumper between terminals 5 and 5. Insert the connector into the unit. Within four minutes the Air Dial will recognise the connected heating surface and automatically register it with the system New device found Danfoss Heating Solutions VIFKB502 5

6 1. Overview - System with two heating surfaces 1. Unit. 2. Heating surface 1 controller, without termination resistance. 3. Heating surface 2 controller, with termination resistance 4. CCM module. 5. Air Dial.. Serial cable, CCM module / unit. 7. Serial cable, controller 1 / unit. 8. Serial cable, controller 2 / controller Mounting sequence 1. Heating surface external controller 1 is mounted as shown in chapter 1.5. Remove the termination resistance T on heating surface Connect surface 1 to surface 2: 1. Orange / Orange 2. Blue / Blue 3. White-Blue / White-Blue 4. Empty White / Orange 1 2. Orange 3. Black 4. White / Blue 5. Blue. Remove jumper between terminals 5 and 4. Insert the connector into the unit. Within four minutes the Air Dial will recognise the connected heating surface and automatically register it with the system New device found VIFKB502 Danfoss Heating Solutions

7 1.7 Troubleshooting Error indication Reason Solution The surface does not automatically register, when connecting power to the control. The surface cuts out because of the over-heating protection. When a surface is connected, it can take up to four minutes before it is included in the network. A communication cable has not been connected correctly. The termination resistance is not correctly positioned for the last unit in the chain. Flow across the surface is too low. Duct sensors mounted incorrectly/ wrong way round. A component in the duct system is mounted too close to the heating surface (bend, filter, reduction, etc.). Wait four minutes and check the Air Dial, if any new units have been added to the system. Check if communication cables are mounted correctly and the colour codes between the individual cables are according to this guide. Make sure that a termination resistance is mounted only on the last unit in the system. Check for air passages in the system. This type of fault is often due to insulation material residue in the duct system. Once the fault has been found and corrected, the heating surface s over-heating protection is re-set manually. This is done using the red button on the top of the heating surface. Power to the actual ventilation system is then switched off briefly, after which operations can be re-started. Check the label on the temperature sensors; sensor labels show where the sensor should be placed in the system in relation to the heating surface. The component that is disrupting the airflow across the surface must be moved so that the heating surface is covered evenly. Fuses blown in main power supply The phase is overloaded. Supply the heating surface from a separate 10A fused group. Unpleasant draughts/smells Dust coating on the heating surface It can be expected, that an electrical heating surface will give off a slightly burnt smell when first used (or after a long period where it has not been in use). This is a short-term issue and will disappear in a short time. The smell is due to small particles of dust on the surface of the heating surface getting hot. The surface does not give off any heat The surface s over-heating protection has been triggered. The fuses in the surface s supply group have blown. Check for any foreign objects in the duct system. Once you have found and corrected the fault, the heating surface s over-heating protection must be re-set manually, which is done using the red button on the top of the heating surface. Power to the actual ventilation system will then be disconnected briefly, after which operation can be re-started. Change the fuses. 2 Waterborne Heating Surfaces 2.1 Waterborne after heating surfaces Waterborne after heating surfaces are installed in the supply air side of the duct system. They are used to raise the supply air temperature in order to prevent cold draughts, where air is taken in. The waterborne heating surface is connected to the building s central heating system with both supply and return. The heating surface has a built-in protection against frost burst. A: Extract air. B: Supply air. C: Outdoor air. D: Exhaust air. E: Sensor before heating surface. F: Sensor after heating surface. Note! Supply and return to the surface must be insulated. F + E A B C D Danfoss Heating Solutions VIFKB502 7

8 2.2 Placing a waterborne heating surface The heating surface must be placed at a minimum distance of 500 mm from any component in the duct system (pipe bends, external filters or unit). The heating surface is placed on the supply air side, after the ventilation unit. An arrow on the heating surface indicates the air flow direction. The heating surface is insulated on delivery and does not require any further insulation. The heating surface is designed to be mounted horizontally, but can also be mounted vertically if the heating surface is adequately supported, and if the direction of air flow is upwards. The two factory mounted PT-1000 sensors must be placed in the duct system 50 cm in front of and 50 cm behind the surface. Each sensor is marked if it should be placed before or after surface. If the sensors face the wrong way, the required operations cannot be achieved. Drill Ø8 mm holes in the duct and install the supplied rubber grommets,, then place the sensors into the duct. Fix the sensors to the pipe with duct tape and insulate together with the rest of the duct system and heating surface. Insulation Rubber sleeve PT-1000 sensor 45 mm 2.3 Connecting a waterborne heating surface Connection to the central heating system The waterborne heating surface is connected as shown in the below connection diagram. On delivery, the water heating surface s control valve is fully open and therefore ready for filling, even when switched off. We recommend that you install a dirt trap in the system, and that the shut-off valves be mounted close to the surface to make any subsequent servicing requirements easier. An air-bleed screw must be mounted at the highest point in the system. Fill the system with water and bleed out the air; the surface is then ready for use. Supply and return to the surface should be insulated safely with regard to the frost bursting risk. A: Shut-off valves (recommended). B: PT 1000 sensors mounted in duct. C: Air-bleeding screw (recommended). E D: Circulation pump (central heating system). J A C E: Expansion tank (normally part of the central heating system). F: Any calls for heating are set up with a potential-free relay. D I A G: Heating surface. H: Control valve with motor actuator. F I: Dirt trap. J: Central heating system. Note! Max. flow temp. 85 C, min. differential pressure 0.2 bar, max. differential pressure 4.0 bar, max. pressure level PN 10. B M H G 230 V 50 Hz Electrical connection Once the water heating surface has been filled with water and bled of air, it must be connected electrically. This is done by connecting the supplied power plug to the heating surface and connecting the supplied communication cable between the water heating surface and the ventilation system. 1. Unit. 2. Waterborne heating surface. 3. CCM module. 4. Air Dial. 5. Serial cable, heating surface / unit.. Serial cable, CCM module / unit. 230 V 50 Hz VIFKB502 Danfoss Heating Solutions

9 Mounting sequence - carried out on the serial socket in the unit 1. Twist together in pairs the serial cables with same colour. 2. Crimp-on ferrules are recommended. 3. Insert the cable pairs into the unit connector White / Orange 1 2. Orange 3. Black 4. White / Blue 5. Blue. Remove jumper between terminals 5 and 5. Insert the connector into the unit. Within four minutes the Air Dial will recognise the connected heating surface and automatically register it with the system.. Select which surface must be used, Comfort (constant intake temperature, usually recommended) or Total heating New device found Comfort 2.4 Call for Heating If the central heating system is fitted with weather compensation, it may be advisable to set up a potential-free call for heating. The call for heating is set up from the heating surface s control to the central heating system through a supplementary relay (the control s relay output is not potential-free, and must therefore be taken over an external relay). The heating surface control is located behind the steel plate on the front of the heating surface. A: Modbus. B: Call for heating clamp 27/ V, 4 A (not potential-free). C: Solid state relay. D: External supplementary relay, e.g. Hager 110 ES (not included in the Danfoss delivery). E: Clamps for external calls for heating in the central system. A B C + 2 Note! The electrical heating surface must be installed by a certified electrician. D NO E 230 V Danfoss Heating Solutions VIFKB502 9

10 2.5 Troubleshooting Error indication Reason Solution The surface does not automatically register, when connecting power to the control. The surface does not give off any heat. Air Dial issues a Frost Protection Alarm. When a surface is connected, it can take up to four minutes before it is included in the network. A communication cable has not been connected correctly. The termination resistance is not correctly positioned for the last unit in the chain. Air in the system. There is no hot water from the central heating system. The dirt trap is clogged. Actuator fault. The first time this is connected it could take up to 20 minutes before the valve and the actuator are ready for operation. The control is not calling for heat. Pump fault. Supply air coming out of the unit has a temperature beneath +5 C, before reaching the heating surface. Wait four minutes and check the Air Dial, if any new units have been added to the system. Check if communication cables are mounted correctly and the colour codes between the individual cables are according to this guide. Make sure that a termination resistance is mounted only on the last unit in the system. Bleed the system. Check the central heating system, and possibly set up a Call for Heating. Empty and clean the dirt trap; if necessary, flush the system. Disconnect the actuator and replace with a new (Danfoss AMV 130, no. 082H8037). Wait for minutes until both valve and actuator are ready for operation. The heating surface is not active, if the system is in Away Mode or if the Bypass is activated. Replace the circulation pump. Check that both valves are operational and that air is actually flowing over both circuits. Low temperatures are usually due to an unintentional blockage in the system s duct system. Does the building s central heating work? If the room temperature falls too low, there is no energy for the system to recover and this could also trigger a frost protection. Heat the system again, turn off the alarm on the remote control and switch off power to the ventilation system briefly; the system will then be ready for operation again. Supply air is not warm enough. Flow temperature is too low. Heatpump installations normally operate at low supply temperatures. You should always consider whether this is acceptable before trying to raise the supply temperature (as this often results in worse/more expensive operation of the central heating system). Flow is set too low on the ABQM valve. Flow is too low on the water side. The control is not calling for heat. The valve is supplied with a factory setting of 50% (max. flow = 75 l/h) If this is not enough, e.g. due to large volumes of air combined with a low supply temperature, the actuator can be removed (the union nut is ONLY ever tightened by hand). You now have free access to the control valve, which can be set to a higher value by pulling up the grey plastic collar and then turning it. The current value can be read from the red indicator line on the valve (100% = 150 l/h max. flow). Pressure loss to the surface is too great, or the circulation pump is running too low -> turn up the circulation pump and check that all possible shut-off valves or other throttle organs are fully open. The heating surface is not active if the system is in away mode, or if the bypass is activated. 10 VIFKB502 Danfoss Heating Solutions

11 3 Geothermal Heating Surfaces 3.1 Geothermal heating surfaces A: Extract air. B: Supply air. C: Exhaust air. D: Communication cable. E: Control. F: Power supply to the circulation pump. G: Outdoor air. H1: Sensor T1. H2: Sensor T2. I: Pre-filter (accessory, recommended). J: Condensate drain 3/8 RG A siphon must be mounted, e.g. Danfoss Air water trap (accessory). K: Shut-off valve, not supplied by Danfoss. L: Expansion tank, not supplied by Danfoss. M: Bleeding screw, not supplied by Danfoss. N: Safety valve bar, not supplied by Danfoss. O: Brine filling kit DN 20, contains 2 x shut-off valves, filling and return connectors and dirt trap. Delivered complete and ready insulated (accessory). P: Circulation pump l/h, not supplied by Danfoss. Q: Ground pipe m. A B D C L E H 2 +/- K N M Q H 1 J O P I F G 3.2 Dimensioning of ground collectors Use the table to dimension the necessary pipe length for the installation. You will need to know the air volume and the soil type. The sandier and drier the soil is, the less heat can be drawn from the ground, which is why more pipes need to be laid in this type of soil than in more normal (damper) soil. If you are in any doubt about the type of soil you have, you should allow for sandy soil as the extra cost of laying a couple of additional metres will not make any significant difference to the total installation costs. A: Dry sandy soil (15 W/m²) B: Normal soil (20-30 W/m²) Required pipe length [m] A B 0 [m³/h] Air volume Danfoss Heating Solutions VIFKB502 11

12 3.3 Laying ground collectors Before laying of ground heating pipes, make sure that all necessary permits are obtained from the local building authorities. Beware of other underground installations, such as water pipes, electric cables, gas pipes, sewage lines, etc. Ground collector pipes to be used are Ø40 mm PEL. The pipes are laid at a minimum depth of 1.5 m with a centre-to-centre distance of 1 m. The highest point of the ground collectors circuit must be next to the building so the system can be bled efficiently. Recommended brine: mixed with ethylene glycol or alternatively IPA (spirit) for frost protection to a minimum of -20 C. The illustration shows the laying of pipes in trenches: Centre-to-centre distance min mm Depth min mm The pipes can also be laid in individual tracks (not shown). When leading the ground collectors into the building it is important that the last 1.5 m of ground pipe up to the building is insulated with a porous insulation material (A). The installation must be pressure tested by an authorised installer before commissioning. Note! Supply and return to the surface must be insulated! mm A 1500 mm 3.4 Filling with brine The system should be rinsed and pressure tested with water, before it can be filled with brine. The system is then drained of water and the selected brine is poured in. We recommend that you assemble a filling kit for easy filling and possible draining of the system. Complete, pre-assembled kits can be ordered from Danfoss under part no 08U00 (DN 20). The pump should be set to a flow between l/h, depending on the length of pipe laid (the longer the pipe, the higher the flow). Note! The pump will be powered from the cable from the actual heating surface (pre-mounted). 12 VIFKB502 Danfoss Heating Solutions

13 3.5 Placing a geothermal heating surface The heating surface must be placed at a minimum distance of 500 mm from any component in the duct system (pipe bends, external filters or unit). The heating surface is placed on the outdoor air side, before the ventilation unit. The heating surface is insulated on delivery and does not require any further insulation. Install a Danfoss filter box type FBDU before the geothermal surface to protect it from dirt. An arrow on the heating surface indicates the air flow direction. The heating surface must be mounted horizontally in relation to the condensate drain - check with a spirit level (ill.). A siphon trap must be mounted to the condensate drain (ill.). The two factory mounted PT-1000 sensors must be placed in the duct system 50 cm in front of and 50 cm behind the surface. Each sensor is marked if it should be placed before or after surface. If the sensors face the wrong way, the required operations cannot be achieved (ill.). Drill Ø8 mm holes in the duct and install the supplied rubber grommets,, then place the sensors into the duct. Fix the sensors to the pipe with duct tape and insulate together with the rest of the duct system and heating surface. Rubber sleeve PT-1000 sensor Insulation 45 mm The geothermal heating surface must be mounted horizontally. Siphon trap on condensate drain. Mounting of the PT-1000 sensors. 3. Connecting a geothermal heating surface 1. Unit. 2. Geothermal heating surface. 3. CCM module. 4. Air Dial. 5. Serial cable, heating surface / unit.. Serial cable, CCM module / unit. 7. To circulation pump. 230 V 50 Hz Mounting sequence - carried out on the serial socket in the unit 1. Twist together in pairs the serial cables with same colour. 2. Crimp-on ferrules are recommended White / Orange 1 2. Orange 3. Black 4. White / Blue 5. Blue. Remove jumper between terminals 5 and 5. Insert the connector into the unit. Within four minutes the Air Dial will recognise the connected heating surface and automatically register it with the system New device found 3. Insert the cable pairs into the unit connector. Danfoss Heating Solutions VIFKB502 13

14 3.7 Troubleshooting Error indication Reason Solution The surface does not automatically register, when connecting power to the control. The surface does not give off any heat (winter operation) or does not cool (summer operation). Supply air is not cold enough (summer operations) ¹. When a surface is connected, it can take up to four minutes before it is included in the network. A communication cable has not been connected correctly. The termination resistance is not correctly positioned for the last unit in the chain. Air in the system. Not enough brine is flowing through the system. The control is not calling for heat/ cooling. Air in the system. The flow the pump is supplying is too low. Poor/missing insulation of brine pipes in the building and fresh-air intake for the unit. Wait four minutes and check the Air Dial, if any new units have been added to the system. Check if communication cables are mounted correctly and the colour codes between the individual cables are according to this guide. Make sure that a termination resistance is mounted only on the last unit in the system. Bleed the system. Examine and clean any dirt traps in the system. Check that the pump is running; if necessary turn up the pump. The geothermal surface is normally active at outside temperatures below freezing (pre-heating) and at high outside temperatures during the summer, when cooling is required. In the intervening periods the geothermal surface is often not needed so the pump will not be active at these times. Bleed the system. Check that any valves in the brine circuit are fully open, or turn up the pump. Insulate brine pipes and fresh-air intake to avoid losing cooling performance from the system. ¹ The expected intake air temperature on a summer s day is around C, depending on the length of piping and the soil conditions at the groundworks. 14 VIFKB502 Danfoss Heating Solutions

15 4 Technical Data 4.1 Electrical heating surfaces Type Ø 125 mm Ø 10 mm Ø 250 mm Connection, air Ø 125 mm Ø 10 mm Ø 250 mm Box Galvanised steel plate Galvanised steel plate Galvanised steel plate Max. output 900 W W W Installation Horizontal / upwards Horizontal / upwards Horizontal / upwards Safety thermostat Double, built-in, automatic re-closure at 70 C, manual re-closure at 120 C Double, built-in, automatic re-closure at 70 C, manual re-closure at 120 C Double, built-in, automatic re-closure at 70 C, manual re-closure at 120 C Weight 2.4 kg 3.2 kg 4. kg Length 375 mm 375 mm 375 mm Pressure loss curves for electrical heating surfaces (both pre-heating and after heating surfaces) [Pa] Ø125 Ø10 2 Ø [m3 /h] Danfoss Heating Solutions VIFKB502 15

16 4.2 Waterborne heating surfaces Connection, air Ø 250 mm Connection, water 3/8" RG, nipple Box Highly insulated, fire-resistant EPS shell (U-factor 0.8) Heating effect (winter) 820 W Installation Horizontal Max. water flow (W-AH 250) 150 l/h Weight. kg Dimensions (l x w x h) 00 x 250 x 335 mm Pressure loss curve for the air side [Pa] Pressure loss curve for the water side [KPa] [m 3/h] [l/h] Power output curve for the air side [W] /40/20 50/40/ [m 3 /h] 1 VIFKB502 Danfoss Heating Solutions

17 4.3 Geothermal heating surfaces Connection, air Ø 250 mm Connection, water 3/8" RG, nipple Box Highly insulated, fire-resistant EPS shell (U-factor 0.8) Max. heating surface (400 m³/h, temp. 70/40/20 ) W Heating effect (winter) 820 W Cooling effect (summer) 850 W (actual cooling to room) Installation Horizontal Max. brine flow l/h Weight. kg Dimensions (l x w x h) 00 x 250 x 335 mm Pressure loss curve for the air side [Pa] Pressure loss curve for the brine side [KPa] [m 3/h] [l/h] Danfoss Heating Solutions VIFKB502 17

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20 Danfoss A/S Heating Solutions Ulvehavevej Vejle Denmark Phone: Fax: heating.solutions@danfoss.com Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss Heating Solutions and the Danfoss Heating Solutions logotype are trademarks of Danfoss A/S. All rights reserved. VIFKB502 Produced by Danfoss Heating Solutions 05/2012