Installation Guide DSA 1 MINI. Contents

Transcription

1 Installation Guide DSA 1 MINI Contents 1.0 Table of contents Safety note Storage and Handling Disposal Diagrams Mounting Installation and Start-up Heat transfer medium treatment Commissioning Electrical installation Electrical diagrams Maintenance Troubleshooting EC - Declaration of conformity...17 Danfoss District Energy VM.HE.B2.02 DEN-SMT/PL 1

2 Danfoss District Energy DSA 1 MINI - Safety note 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. 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. 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 compliance 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, accidentprevention 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. 2 DEN-SMT/PL VM.HE.B2.02 Danfoss District Energy

3 Danfoss District Energy DSA 1 MINI - Safety note Proper use The unit s functional and operational safety is only guaranteed when used properly in accordance with the information in this instruction. Proper use also includes correct compliance with installation, operating, maintenance and cleaning instructions. 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. Any other use of the unit is forbidden and applies as improper! 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. Danfoss District Energy VM.HE.B2.02 DEN-SMT/PL 3

4 Danfoss District Energy DSA 1 MINI - Residual risks 2.1 Residual risk The unit has undergone a risk analysis as required by the Machinery directive and is preformed according to En 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. 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. The unit weighs app kg. Possible harm! Danger of crushing. Heavy weights can cause crushing dangers when transporting, including with lifting gear. 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! Possible harm! Danger of burns. Hot surfaces can cause serious burn injuries. Wear protective gloves when working on the unit! 4 DEN-SMT/PL VM.HE.B2.02 Danfoss District Energy

5 Danfoss District Energy DSA 1 MINI - Storage and handling / disposal 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. HANDLING When working on the substation suitable safety shoes must be worn. 4.0 Disposal Disposal instruction: This product should be dismantled and its components sorted, if possible, in various groups before recycling or disposal. Always follow the local disposal regulations. Danfoss District Energy VM.HE.B2.02 DEN-SMT/PL 5

6 Danfoss District Energy DSA 1 MINI - Diagrams 5.0 Diagrams 10 1 TE Primary supply Primary return 3* 2 3* 5 5 * MI TI M MI * TI * MI TI MI TI Q * Secondary supply Secondary return 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 OPR Strainer 12.* Heatmeter (Danfoss Sonometer) 13. Ball valves 14. Safety valve 15. Heat exchanger Danfoss XB37M-1 10 to Combined differential pressure and flow controller Danfoss AVQM with electrical actuators Danfoss AMV 10 or * Combined differential pressure and flow controller Danfoss AVQM with electrical actuators Danfoss AMV 13 or 23 3* 3* 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). 6 DEN-SMT/PL VM.HE.B2.02 Danfoss District Energy

7 Danfoss District Energy DSA 1 MINI - Mounting 6.0 Mounting 50 cm (recommended) H B T Connection options Primary and secondary Connections for 16/30/42/60 kw Connections for 75 kw C D C D D C D C 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 A B C D B A C D Connections: Tolerances ± 2 mm 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. Power Weight Dimensions in mm Model Connection dimension prim./sec. in kw in kg H W D 16 DSA 1 mini G1 PN16 (25) / Rp 1 PN DSA 1 mini G1 PN16 (25) / Rp 1 PN DSA 1 mini G1 PN16 (25) / Rp 1 PN DSA 1 mini G1 PN16 (25) / Rp 11/2 PN DSA 1 mini G1 PN16 (25) / Rp 11/2 PN The stations have weld sleeves on the primary-side. Danfoss District Energy VM.HE.B2.02 DEN-SMT/PL 7

8 Danfoss District Energy DSA 1 MINI - 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 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. The controller is intended for use in high voltage systems (230/240 Vac; 50 hz). Safety regulations must be observed to ensure a safe installation, operation and maintenance. 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 reductions, 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! 8 DEN-SMT/PL VM.HE.B2.02 Danfoss District Energy

9 Danfoss District Energy DSA 1 MINI - 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 VM.HE.B2.02 DEN-SMT/PL 9

10 Danfoss District Energy DSA 1 MINI - 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 ( 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 0.5 mm² shielded) from the meter s bus connection to the Danfoss District Energy DSA 1 MINI) Lightning 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 installed, the customer must be informed about the increased risk of direct and indirect lightning. 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 10 DEN-SMT/PL VM.HE.B2.02 Danfoss District Energy

11 Danfoss District Energy DSA 1 MINI - Electrical diagrams 9.1 Electrical diagrams Danfoss ECL 310 Controller with application key A337, A347, A367, A377 Danfoss District Energy VM.HE.B2.02 DEN-SMT/PL 11

12 Danfoss District Energy DSA 1 MINI - Wiring diagram Danfoss Controller OPR 0020 Wiring diagram Connection for Communication LON, TCP/IP or GPRS Rel1 XL1 Pump 1 Heating circuit 1 or boiler 2 Motor 1 Mix Heating A = Off Z = On Pump 2 heating circuit 2 Motor 2 Mix Heating A = Off Z = On Pump 3 Heating circuit 3 Motor 3 Mix Heating A = Off Z = On Pump 4 heating circuit 4 or boilerpump boiler 1 Motor 3 Mix Heating ZU = ON; Domestic hot water pump Boiler 1 for chargingmodule AUF = Off, N L N Z A N L N L N Z A N L N Z A N Z A K4 K5 K6 K7 K8 K9 K10 Rel12 Rel11 Rel10 Rel9 Rel8 Rel7 Rel6 Rel5 Rel4 Rel3 Rel2 XL4 BAT1 Lon-service Lon-reset Controller reset XL19 BB AA OK4 O 12V AB LonBus IN AB LonBus OUT FB; Remote control - 2pole shielded (max. 4 pc) 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 BO2; Boiler sensor Boiler 2 bottom, or potintial free relay PE; Pe for cable shield Ok; OUT open collector output OK2 OK1 12V Ok; OUT open collector output XL2 XL3 Seriel connector Glass tube fuse 3.15A F4 Supply heat meter 230VAC (Is NOT powered via the glass fuse) N L K1 Mains 230VAC PE = Protecting earth N = Null L = phase N L K2 TR1 Nopro Cemote control Nopro expansion module 4-20mA 0-10V Reserve GND Jumper Adress 3 1 Controller B02 + Controller B mA 4 2 XL1 0-10V jumper 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 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 12 DEN-SMT/PL VM.HE.B2.02 Danfoss District Energy

13 Danfoss District Energy DSA 1 MINI - 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. 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 importance for the total heat economy. It is therefore very important to observe the supply and return temperatures. Normal temperature difference is C. Please note, that the lowest district heating return temperature 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. 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. Danfoss District Energy VM.HE.B2.02 DEN-SMT/PL 13

14 Danfoss District Energy DSA 1 MINI - Troubleshooting 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 Troubleshooting - Heating Problem Possible cause Solution No heat Strainer clogged on DH og HE side (radiator circuit). Filter in district heating meter clogged. Defective differential pressure controller. Defective sensor Defective actuator. Defective motor valve - or possibly dirt in the valve housing. Automatic controls wrongly set or defective - possibly power failure. Pump out of operation. The pump is set at too low speed of rotation. Air pockets in the system. Clean strainer. Clean the filter (after consulting the district heating plant). Check the functions of the differential pressure controller - clean valve seat if required. Replace sensor Check the functioning of the actuator. Check the functions of the motor valve - clean valve housing if required. 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. Check that the pump is receiving power and that it runs. Control that there is no air in the pump housing - see pump manual. Set the pump at higher speed of rotation - see instructions on heating circuit. 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. Defective sensor. Defective controller. The controller does not react as it is should in accordance with the instructions. Adjust automatic controls, see instructions for automatic controls. Replace sensor. Call in automatic controls manufacturer or replace controller. 14 DEN-SMT/PL VM.HE.B2.02 Danfoss District Energy

15 Danfoss District Energy DSA 1 MINI - Troubleshooting Problem Possible cause Solution Supply temperature too low Poor cooling Wrong setting of automatic controls. Defective controller. The controller does not react as it is should in accordance with the instructions. Outdoor sensor mounted or placed incorrectly. Strainer clogged. Too small heating surface / too small radiators compared to the total heating requirement of the building. Poor utilization of existing heating surface. The system is single - pipe. Adjust automatic controls, see instructions for automatic controls. Call in automatic controls manufacturer or replace controller. Mount/place outdoor sensor correctly. Clean strainer. Increase total heating surface. Make sure that the heat is distributed evenly across the full heating surface - open all radiators and keep the radiator in the system from heating up at the bottom. Higher temperature at the top and lower temperature at the bottom part of the radiators means that the system operation is correct. It is extremely important to keep the supply temperature to the radiators as low as ever possible, while maintaining a reasonable level of comfort Troubleshooting - Domestic hot water Problem Possible cause Solution No domestic hot water Defective or wrongly set differential pressure controller. Strainer on DH supply clogged. Defective actuator - or possibly dirt in the valve housing. Automatic controls wrongly set or defective - possibly power failure. Calified heating element. Inadequate cylinder capacity. Check the functions of the differential pressure controller - clean valve seat and capillary tubes if required - air and rinse capillary tubes. Clean strainer. Check the functions of the actuator - clean valve seat if required. Check if the setting of the controller is correct - see separate instructions. Check the power supply; Temporary setting of actuator to manual control - see instructions on heating circuit, manual control. Clean DHW cylinder with acid solution or replace heating element. Wait for heating / loading of the cylinder. You may check the specifications of the manufacturer conc. cylinder capacity. Danfoss District Energy VM.HE.B2.02 DEN-SMT/PL 15

16 Danfoss District Energy DSA 1 MINI - Troubleshooting Problem Possible cause Solution Not enough pressure on the hot water Long waiting time Temperature too low Temperature too high Variations in temperature Delcining temperature during tapping Poor cooling Strainer in cold water meter clogged. Circulation pump out of operation See No domestic hot water. Non - return valve on the circulation line defective (leads to mixing - and the circulation water pipes become cold during tapping). Defective actuator - possibly dirt in the valve housing. Automatic controls wrongly set or defective. Defective immersion sensor. Non - return valve on the circulation line defective (leads to mixing - and the circulation water pipes become cold during tapping). Defective or wrongly set differential pressure controller (set too low). Automatic controls wrongly set. Immersion sensor placed incorrectly. Calified heating element. Calified heating element. Clean strainer - possibly in consultation with the water supply company. Check whether the pump is running - whether the pump is receiving power. Control that there is no air in the pump housing - see pump manual. See No domestic hot water. Replace non - return valve. Check the functions of the actuator - clean valve seat if required. Check if the setting of the controller is correct, - see separate instructions. Replace immersion sensor. Replace non - return valve. Check the functions of the differential pressure controller - clean valve seat and capillary tubes if required, - air and rinse capillary tubes. Check that the controller has been correctly set - see separate instructions. Place immersion sensor correctly in accordance with the manufacturer instructions for the cylinder. You may contact Danfoss Redan A/S for further information. Clean DHW cylinder with acid solution or replace heating element. Clean DHW cylinder with acid solution or replace heating element. You may check the specifications of the manufacturer conc. cylinder capacity. 16 DEN-SMT/PL VM.HE.B2.02 Danfoss District Energy

17 Danfoss District Energy DSA 1 MINI - Declaration of conformity 12.0 EC - Declaration of conformity EC - Declaration of Conformity Danfoss District Heating SRL Danfoss District Energy Division 208 Oltenitei Street, Popesti-Leordeni, County Ilfov, ROMANIA Tel: ; Fax: Declares on our sole responsibility that the products mentioned below including all available power and control option: Small Substation Type Unistat 2013C, Unistat 1016A, DSA 1 Mini (Article 3 3 according to PED 97/23/EC) Main components on primary side: Heat exchangers, shut off valves, control valves and piping to which declaration relates, are in conformity with the following directives, standards and other normative documents, provided that they are used according to our instructions: Machinery Directive 2006/42/EC EN ISO : Safety of machinery - Risk assessment LVD Low Voltage directive /95/EC EN : Safety of machinery Part 1- General requirements EN :2010: Automatic electrical controls for household and similar use EMC directive 2004/108/EC EN :2007: Electromagnetic compatibility Generic standard: Immunity for residential, commercial and light industry EN :2007: Electromagnetic compatibility Generic standard: Emission for residential, commercial and light industry Year of affixed CE-mark: 2010 Bucharest 6 th of September, 2011 Place and date of issue Constantin Cucu, Quality Manager Danfoss District Energy VM.HE.B2.02 DEN-SMT/PL 17

18 Danfoss District Energy DSA 1 MINI The delivered station may vary from the pictures and diagrams in these instructions. Produced by Danfoss A/S 02/2012