Installation Guide. DSA 2 MAXI Substation. 1.0 Content

Transcription

1 1.0 Content 1.0 Content Safety notes System overview General about district heating substations DSA 2 MAXI - example circuit diagram Electrical circuit diagrams Visible components in the substation Installation and start-up - Step by step Removing the cover panels Protective cardboard cover Removing the substation from the pallet Moving substation to the installation place Installation place Height adjustment Pipe connections Connection directions Dimensions for the pipe connections Electrification Controller settings Controller display and symbols Operating the controller Setting the date and time Setting the heat curve Setting up limitations for flow temperature Manual control Commissioning with one circuit Sensor displays Alarm Changing the favourite display for the user Setting the room temperature Setting domestic hot water temperature Basic parameters, factory settings Start-up Trouble shooting Declaration of conformity Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 1

2 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 absolutely 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 substation. 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 substation has not been damaged during transportation. Be extremely 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 controller. 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 Up to a certain point DSA 2 MAXI substation is standardized. The final selection of components and the dimensioning of the heat exchangers 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 Picture Energiateollisuus ry District heating customer Domestic hot water Heating 2 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

3 3.3 DSA 2 MAXI - example circuit diagram DSA 2 MAXI-I2B A150-MD-FI - 2 circuits, circuit diagram example After heating connection: domestic hot water and heating 25 25a TE1B TE1A TV1 TV2 SUMMER SHUT-OFF TE2A 26 TE2B P TE2C 1 P Temperatures and alarms on the controller display 28 PE 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 Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 3

4 3.4 Electrical circuit diagrams DSA 2 MAXI with ECL controller HE pump alarm 4 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

5 3.4 Electrical circuit diagrams DSA 2 MAXI with ECL controller Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 5

6 3.4 Electrical circuit diagrams DSA 2 MAXI without controller 6 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

7 3.4 Electrical circuit diagrams DSA 2 MAXI without controller Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 7

8 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 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 position directly and on the correct height. The adjustments can be done up to 6 cm 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 Installation and start-up - Step by step 5.1 Removing the cover panels The cover panels have to be removed before moving the substation 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 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

9 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 DSA 2 MAXI substation can be moved to the installation place using several 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. Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 9

10 2. Lifting with a crane It is possible to screw up lifting eyes in the top corners after removing detachable metal round pieces from the roof. This way substation can be lifted up by using straps. 5.5 Installation place The installation place and the pipe connections for DSA 2 MAXI 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. 10 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

11 5.6 Height adjustment Adjust the substation straight horizontally and on the desired height with the help of the installation feet. By turning the adjustment feet you can make up to 6 cm adjustments. 5.7 Pipe connections The substation is connected to the district heating network, heating, 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 connection to the district heating network can be done only by a qualified installer accepted by the district heating distributor. The pipes must be mounted so that the strain caused by e.g. thermal expansion, does not harm the sustation. The pipes must be equipped with brackets in order to prevent any torsional stress. Prior to installation all pipes and connections have to be cleaned and rinsed Connection directions After cooling connection: 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 Direct connection: Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 11

12 5.7.2 Dimensions for the pipe connections The pipe connections are standardized and their places differ according to required capacity and the size of the substation. In the after cooling connection both cold water and district heating return connection places are dependable on the size of the required heat exchanger. The dimensions settle within the dimensions given in the dimensional pictures. After cooling connection 1090 mm block After cooling connection 1350 mm block Direct connection DN32 Direct connection DN Direct connection DN DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

13 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 temperature 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 control 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. 20 m 20 m 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 cooling systems. Energy savings are facilitated by weather compensation, adjustment 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 instruction is included and the most important details are also enclosed in this Installation Guide. Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 13

14 5.9.1 Controller display and symbols Favourite display for the installer Flow temperature: actual and desired State of components Primary return temperature: actual and desired Position indicator for navigation Favourite display for the user Date Outdoor temperature Time Schedule Menus with values and settings Menus with values and settings Return temperature: actual System pressure Position indicator for navigation Desired room temperature 1 = Heating circuit = DHW circuit = Common controller Mode = Manual mode = Scheduled operation = Comfort mode = Saving mode = Frost protection mode Display selection 1 = Heating circuit = DHW circuit = Common controller Mode = Scheduled operation = Comfort mode = Saving mode = Frost protection mode Display selection Symbol Description Outdoor temperature Room temperature DHW temperature Position indicator Scheduled operation Mode Circuits Temperatures Controlled components Alarm Comfort mode Saving mode Frost protection mode Manual mode Heating Display selector DHW Common controller Pump ON Pumppu OFF Actuator opens Actuator closes Operating the controller The graphical monochrome display shows all temperature values, status information and is used for the setting of control parameters. 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 possible 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. 14 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

15 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. Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 15

16 5.9.4 Setting the heat curve Due to different heat masses, heating system, insulation dimensions 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. [oc] [oc] 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) (-15,60) (-5,50) 0 45 (0,45) 5 40 (5,40) (15,28) The heat curve typically used with floor-heating, about 0.4 Outdoor temperature C Flow temperature C Visible on the display (-30,45) (-15,38) (-5,34) 0 31 (0,31) 5 28 (5,28) (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. 16 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

17 Saving the new curve. Getting out of the menu 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 temperature 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 floorheating system. Typical flow temperature limitations in different heating Flow temperature systems min C max C Radiator heating When taking floor-heating system into use for the first time (drying up concrete slab) Floor-heating Typical max. limitation in the radiator heating circuit is 90 C. 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 following the intructions in Setting the heat curve.. Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 17

18 Typical flow temperature max. limitation: When taking floorheating 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 following the intructions in Setting the heat curve. Getting out of the menu. Typical flow temperature min. limitation is 20 C 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. 18 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

19 The valve is closed. Getting away. Changing back to Comfort mode 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 M2, P2 A1 DHW circuit control valve and circulation pump Heating circuit control valve and circulation pump 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. Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 19

20 5.9.8 Sensor displays Temperature and pressure information can be read on the controller display. All values can be found by going down the list. Getting out of the menu Alarm Alarm functions in the controller: pressure alarm, pump alarm and maximum temperature alarm (temperature limiting thermostatic function). As a sign of an alarm symbol appears on the display. Alarm overview shows which alarm is in question. 20 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

21 Pressure alarm. Max and min limitations (Alarm high, Alarm low) have to adapted to the building. Low X and high X values have been set based on the pressure transmitter included. Do not change! Pump alarm. The alarm disappears from the display when the pump is working again. Alarm value: 1=open contact (eg. Wilo) 0= closing contact (e.g. Grundfos) Max temperature limitation (temperature limiting thermostatic function). Max temperature limitation can be used e.g. in floor-heating system as a temperature limiting thermostatic function. Getting out of the menu. In a floor-heating system the maximum temperature limitation can be set at 50 C. Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 21

22 Changing the favourite display for the user After having done the installation settings, it is recommendable to change the favourite display to fit the user s needs Setting the room temperature The setting of the desired room temperature is important even if the room temperature sensor is not connected. It has an effect on the temperature in your property Setting domestic hot water temperature Changing the circuit. 22 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

23 Changing the desired temperature. Getting out of the menu Basic parameters, factory settings Heating circuit Setting Factory setting Own setting Comment Room temperature and setback temp. 20 C/ 16 C Heat curve 1.0 Note! In a floor-heating system the typical setting is 0.4. Limit for heating cut-out 18 C Flow temperature min. 20 C Flow temperature max. 90 C Note! In a floor-heating system change the max. temp. to 45 C. Proportional band Xp 85 K Integration time constant Tn 25 s Running time of the motorized control 120 s valve Neutral zone Nz 2 K Pressure alarm limit max 2.3 Pressure alarm limit min 0.8 Pressure alarm timeout 30 s Pump alarm, alarm value 1 1= open contact (e.g. Wilo) 0= closing contact (e.g. Grundfos) Pump alarm, timeout 20 s Max flow temperature limitation 90 C Note! In a floor-heating system change to 50 C. alarm (temperature limiting thermostatic function) Max flow temperature limitation alarm, timeout ΔT ALARM 60 s DHW circuit Setting Factory setting DHW temperature and setback temp. 58 C/ 55 C Flow temperature min. 45 C Flow temperature max. 65 C Proportional band Xp 9 K Integration time constant Tn 13 s Running time of the motorized 15 s control valve Neutral zone Nz 3 K Own setting Comment Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 23

24 5.11 Start-up Check following point before start-up: Check points, before start-up Pipes are connected according to the designs. Drainage valves are closed. The temperature for the domestic hot water is set to +58 C. The outdoor temperature sensor is installed and connected. Controller settings. Connections are tightened. Function of the safety valves is checked. All Danfoss heat exchangers and substations have been pressure tested according to PED 97/23/EC (module H). Make sure to give operating instructions to the users of the substation. Fill the substation with flow media and raise the pressure slowly to working pressure. When starting up the substation it should be air vented. The shutoff valve in the primary side on the return side is opened and the shut-off valve on the supply side is closed. Air comes out by opening the air vent valve. After that the operation of the substation must be observed. If the substation operates according to designed parameters, it can be taken into continuous use. Check points, after start-up Check temperatures Check pressures. Thermal expansion. Operation of the pumps. Flow directions. Operation of the controls. 6.0 Trouble shooting Problems Heating Room temperature is too low i.e. flow temperature is too low. Disruption in the district heating distribution. The filter is clogged. The heat curve is not correct. Failure in the heating circuit controls. The circulation pump has stopped. Pressure in the heating circuit is too low. Air in the heating circuit. Fouling in the heat exchanger. The radiator thermostat is stuck or broken. The control valve is stuck. Get in contact with the district heating distributor. Get in contact with the district heating distributor or with local Danfoss Sales Company. Check the heat curve settings. Get in contact with local Danfoss Sales Company. Turn the pump on, check e.g. heat relay. Add water through the filling valve. Write down the filling date. Remove air from the radiators, add water if necessary. Get in contact with local Danfoss Sales Company. Get in contact with the installer. Get in contact with local Danfoss Sales Company. Room temperature is too high i.e. flow temperature is too high. The heat curve is not correct. The controller in the heating circuit is broken. The control valve stays open/closed. Check the heat curve settings. Get in contact with local Danfoss Sales Company. 24 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

25 Heating control does not work. Water in the heating circuit increases and excess water comes out through the safety valve for the expansion vessel. Pressure in the heating circuit is too low. The return temperature in the heating circuit is high. The controller is let in Manual control mode. The controller, sensor or motorized control valve is broken. The control valve stays open/closed. The heat exchanger has an internal leakage. The filling valve in the heating circuit leaks into the heating circuit. The heating circuit has too little water or the ciruit has a leakage. The difference between district heating and heating circuit return temperatures is big. Set the controller to Comfort mode or Scheduled operation mode. Get in contact with local Danfoss Sales Company. Get in contact with the district heating distributor and/or with local Danfoss Sales Company. Get in contact with local Danfoss Sales Company. Add water into the circuit through the filling valve. Write down the filling date. If this happens often, get in contact with local Danfoss Sales Company. Get in contact with local Danfoss Sales Company. Problems Domestic hot water (DHW) DHW smells bad or is coloured. DHW heat exchanger has an internal leakage. Temperature of DHW varies more than usual. DHW control does not work or the control valve is broken. DHW control valve is too big for the existing conditions. Inadequate DHW circulation. The filter is clogged. The pressure difference is too big. Trash in the control valve. Get in contact with local Danfoss Sales Company. Get in contact with the installer. Get in contact with the district heating distributor. Get in contact with local Danfoss Sales Company. Other situations The pump sounds strange. The control valve has a strong, whistling sound. Water leaks on the floor in the boiler room or the heat exchanger insulation is wet. Air lock in the pump. The bearing in the pump is broken. The control valve is broken. Pressure difference is too big in the district heating network. The heat exchanger has an external leakage. Stop the pump for a moment to remove the air lock. Get in contact with the district heating distributor. Get in contact with the district heating distributor. Get in contact with the district heating distributor and/or local Danfoss Sales Company. The pressure or the temperature of district heating water differs significantly from the normal. Disruption in the district heating distribution Get in contact with the district heating distributor. The outdoor temperature is not visible on the display. The outdoor temperature sensor has been connected to the substation with the power on. Pull the substation contact plug out and reconnect it. Danfoss District Energy VI.GE.K3.02 DEN-SMT/PL 25

26 Declaration of conformity Pressure equipment in accordance with the sound engineering practice (Directive 97/23/EC, Article 3.3) Pressure equipment in hazard category I (Directive 97/23/EC, Article 9.) 26 DEN-SMT/PL VI.GE.K3.02 Danfoss District Energy

27 Declaration of conformity Pressure equipment in hazard category II - III (Directive 97/23/EC, Article 9.) 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 VI.GE.K3.02 DEN-SMT/PL 27

28 Danfoss Poland Sp. z o.o. Tuchom, ul. Tęczowa Chwaszczyno Tel.: Fax: info.den@danfoss.com Produced by Danfoss A/S 05/2012