Are there PSU placements in the LPU

Thermodual FLS-Combi flow water heater


1 Installation, commissioning and operating instructions Thermodual FLS-Combi flow water heater Always keep the operating instructions close to hand on the device! Read the operating instructions before starting any work! Danger! Danger! Before putting the device into operation, check that it is in a fault-free condition and that it is working properly. Original operating instructions Danfoss VI.MG.J2.03 1

2 1.0 General Information on the operating manual Applicable documents Explanation of symbols Liability and warranty Copyright protection Spare parts Disassembly Disposal Safety General Responsibility of the operator Proper use Possible misuse Occupational safety Personal protective equipment Dangers that may arise from the device EMERGENCY STOP switch Operating personnel What to do in the event of danger and accidents Hazard analysis Technical data Technical and main system data CE nameplate Legend and designations Function Structure and installation Structure and installation / general information Transport, packaging and storage Transporting pallets by forklift truck Transport inspection Packaging storage Installation Preparation for installation Primary-side connection, heating medium (e.g. MG.J2.03

3 1. General 1.1 Information on the operating instructions These operating instructions describe the installation, operation and maintenance of the system. Compliance with all specified safety information and handling instructions is a prerequisite for safe work and proper use of the system. In addition, the local accident prevention regulations and general safety regulations applicable to the area in which the system is used must be observed. The operating instructions are part of the product and must be kept in the immediate vicinity of the system's operator station, accessible to the installation, operating, maintenance and cleaning staff at all times. The graphic illustrations in these instructions are not necessarily to scale to better illustrate the facts and may vary slightly from the actual design of the system. In addition to these operating instructions, the operating instructions for the installed components apply. The information contained therein, in particular the safety information, must be observed! 1.2 Other applicable documents Unless otherwise stated, the individual components of the system are purchased assemblies from other manufacturers. All components used on the system have been subjected to risk assessments by their manufacturers. The conformity of the constructions with the applicable European and national regulations has been declared by the manufacturers of the components. The manufacturer's declarations of conformity and the operating, maintenance and repair instructions for the individual system components are inseparable parts of the system documentation. The instructions contained in the manufacturer's documents on safety, set-up and installation, operation, maintenance, dismantling and disposal of the components must be followed without restriction by the operating personnel of the system. 1.3 Explanation of symbols Important safety and technical information in these operating instructions are identified by warning notices. It is essential to follow the instructions in order to avoid accidents, personal injury and damage to property. WARNING! This symbol indicates dangers that can lead to impairment of health, injuries, permanent physical damage or death. Strictly adhere to the instructions given on work safety and be particularly careful in these cases! WARNING! Electric current hazard! This symbol draws your attention to dangerous situations caused by electric current. Failure to observe the safety instructions can result in serious injury or death. The work to be carried out may only be carried out by a trained electrician. DANGER! This symbol indicates instructions which, if ignored, can result in damage, malfunctions and / or failure of the system. NOTE! This symbol highlights tips and information that must be observed for efficient and trouble-free operation of the system. VI.MG.J2.03 Danfoss

4 1.4 Liability and warranty All information and instructions in these operating instructions have been compiled taking into account the applicable regulations, the current state of engineering and our many years of knowledge and experience. The actual scope of delivery may deviate from the explanations and drawings described here in the case of special designs, the use of additional order options or due to the latest technical changes. If you have any questions, please contact the manufacturer. We reserve the right to make technical changes to the product in the context of improving the usage properties and further development. Components such as Tools that are subject to wear and / or normal wear and tear when using the device as intended, as well as auxiliary and consumable materials such as grease, oils or cleaning agents are not covered by the guarantee. In addition, the obligations agreed in the delivery contract, the general terms and conditions as well as the delivery conditions of the manufacturer and the legal regulations valid at the time of the conclusion of the contract apply. These operating instructions must be read carefully before starting any work on and with the device, especially before commissioning! The manufacturer assumes no liability for damage and malfunctions resulting from non-compliance with the operating instructions. 1.5 Copyright protection The operating instructions are to be treated confidentially. It is intended exclusively for those who work on and with the system. The handing over of the operating instructions to third parties without the written consent of the manufacturer is not permitted. If necessary, contact the manufacturer. Duplications of any kind, including extracts, as well as the use and / or communication of the content are not permitted without the manufacturer's written approval. Violations oblige you to pay damages. We reserve the right to make further claims. The content information, texts, drawings, images and other representations are protected by copyright and are subject to further industrial property rights. Any improper use is punishable by law. 1.6 Spare parts Use only original spare parts from the manufacturer. If unapproved spare parts are used, all warranty, service, damage compensation and liability claims against the manufacturer or his agents, dealers and representatives are forfeited. DANGER! Incorrect or faulty spare parts can lead to damage, malfunctions or total failure of the system. 1.7 Dismantling For scrapping or scrapping, clean the device and dismantle it in accordance with the applicable health and safety and environmental protection regulations. See also: -> Hygiene. Before starting dismantling: switch off the device and secure it against being switched on again. Physically disconnect the entire energy supply from the device, discharge stored residual energy in accordance with the regulations. Remove operating and auxiliary materials as well as remaining processing materials in an environmentally friendly manner. WARNING! Risk of injury! Stored residual energies, angular components, points and corners on and in the device or on the required tools can cause injuries. All work when dismantling the device may therefore only be carried out by qualified personnel. WARNING! No drinking water! Drinking water in parts of the system that are not used for a long period of time may no longer be of drinking water quality. Prevent such use and empty the system components and dispose of the water. 4 Danfoss VI.MG.J2.03

5 1.8 Disposal If no return or disposal agreement has been made, the dismantled components can be recycled after they have been properly dismantled: Scrap metallic material residues. Send plastic elements for plastic recycling. Dispose of remaining components sorted according to material properties. Dispose of residual media properly. When introducing additives (e.g. glycol, etc.), the applicable legal provisions must be observed. Remove operating materials such as fats, oils, preservatives and cleaning agents from the device according to type and in an environmentally friendly manner. Use suitable collecting and storage containers that are approved for the operating materials concerned. Clearly mark the container with information about its content, level and date and store it until it is finally disposed of in such a way that it cannot be misused. DANGER! Electronic scrap, electronic components, lubricants and other auxiliary materials are subject to hazardous waste treatment and may only be disposed of by approved specialist companies! VI.MG.J2.03 Danfoss

6 2. Safety This section gives an overview of all important safety aspects for optimal protection of the personnel as well as for the safe and trouble-free operation of the device. In addition, the individual chapters contain specific safety instructions marked with symbols to prevent immediate danger. 2.1 General At the time of its development and manufacture, the device was built in accordance with the applicable, recognized rules of technology and is considered to be operationally safe. The device can, however, pose a risk if it is used by improperly trained personnel, improperly or not as intended. Every person assigned to work on or with the device must therefore have read and understood the operating instructions before starting work. The operator is advised to have the staff verifiably confirm their knowledge of the operating instructions. Changes of any kind as well as additions or modifications to the device are prohibited. All safety, warning and operating instructions on the device must always be kept in a legible condition. Damaged signs or stickers must be replaced immediately. The specified setting values ​​or ranges must be strictly adhered to. NOTE! You always coordinate modifications and expansion measures with the manufacturer. 2.2 Responsibility of the operator Always keep the operating instructions in the immediate vicinity of the device and always accessible to the installation, operating, maintenance and cleaning personnel. Only operate the device when it is in a technically perfect and operationally safe condition. Always keep safety devices easily accessible and check them regularly. The information on occupational safety relates to the regulations of the European Union valid at the time the device was manufactured. The operator is obliged to determine the compliance of the named work safety measures with the current status of the regulations and to observe new regulations during the entire period of use of the device. Outside the European Union, the work safety laws applicable at the place of use of the device as well as regional rules and regulations must be observed. In addition to the work safety instructions in these operating instructions, the general safety, accident prevention and environmental protection regulations for the area of ​​application of the device must be observed and complied with. The operator and the personnel authorized by him are responsible for the trouble-free operation of the device as well as for clear stipulations about the responsibilities for installation, operation, maintenance and cleaning of the device. The information in the operating instructions must be followed completely and without restriction! In addition, the operator must ensure that further hazards are determined in a risk assessment, which result from the special working conditions at the place of use of the device. all further work and safety instructions resulting from the risk assessment of the workplaces on the device are specified in operating instructions. It applies in the Federal Republic of Germany e.g. the Ordinance on Industrial Safety and Health (BetrSichV, BGBL I 2016). 2.3 Intended use The operational safety of the device is only guaranteed if it is used as intended in accordance with the information in the operating instructions. The system is used to provide heat energy from the supply network of an energy company or another heat generation system (e.g. boiler) by transferring the heat output to a customer's house system. Correct compliance with the assembly, operating, maintenance and cleaning instructions is also part of the intended use. Any additional and / or different use of the device is prohibited and is considered improper! Claims of any kind against the manufacturer and / or his authorized representatives due to damage resulting from improper use of the device are excluded. The operator and / or owner is solely liable for any damage caused by improper use. 6 Danfoss VI.MG.J2.03

7 2.4 Possible misuse The device is used within a system and may not have its own control or switch-off device. By installing suitable safety devices, the operator must ensure that the device can be shut down as soon as a dangerous situation or malfunction occurs. Any use of the system other than the intended use can lead to dangerous situations. Therefore: Only use drinking water heating systems as intended in accordance with the information in this document, in particular in compliance with the application limits specified in the technical data. Refrain from using the drinking water heating systems in any way beyond this or in any other way. Refrain from converting, upgrading or changing the construction or individual pieces of equipment with the aim of changing the area of ​​application or the usability of the drinking water heating systems. Note! z. B. Emergency stop button etc. WARNING! Danger from improper use! 2.5 Occupational safety By following the instructions on occupational safety, endangering people and / or the system can be prevented. Failure to observe these instructions can endanger people and objects through mechanical effects or the failure of the system and the entire workplace. Failure to observe the safety regulations will result in the loss of any claims for damages. 2.6 Personal protective equipment When working on and with the device, the following must always be worn: Protective work clothing is tight-fitting work clothing with low tear resistance, with tight sleeves and without protruding parts. It is mainly used to protect against being caught by moving machine parts. Do not wear rings, chains or other jewelry. Safety glasses to protect the eyes from flying parts and splashes of liquid. Protective gloves to protect hands from friction, abrasions, punctures or deeper injuries as well as from contact with hot surfaces. Safety shoes to protect against heavy falling parts and slipping on slippery surfaces. Safety helmet to protect against falling and flying parts and materials. VI.MG.J2.03 Danfoss

8 2.7 Dangers that may arise from the device The device has been subjected to a hazard analysis. The construction and design of the device based on this corresponds to the current state of the art. Nevertheless, residual risks remain! The device generates a strong jet of liquid when opening e.g. Drain or vent fittings. The device works e.g. with a maximum pressure of 10 bar on the drinking water side. All maximum operating parameters can be found on the nameplate. WARNING! Risk of injury! Risk of liquids splashing out under high pressure. Wear personal protective equipment for all work on the device! WARNING! Risk of injury! Sharp-edged housing parts and pointed corners can cause abrasions to the skin. Wear protective gloves when working on the device! The device works with electrical voltages up to 230 V and currents up to 16 A. WARNING! Electric current hazard! The electrical energies can cause extremely serious injuries. If the insulation or individual components are damaged, there is a danger to life. Before performing maintenance, cleaning or repair work, switch off the main switch and secure it against being switched on again. Disconnect the device from the power supply before doing any work on the electrical system. Do not remove any safety devices or disable them by making changes. WARNING! Risk of burns! Hot surfaces can cause severe burn injuries. Always wear protective gloves when working on the device! The device works with a maximum temperature according to the rating plate. Components in the device can contain automatic moving parts (motors, gears, etc.). The devices can be heavy. WARNING! Crushing hazard! During transport, even with hoists, crushing can occur due to heavy weights. The device can contain electrically moving components (motors, gears) which, if touched during operation, can also cause crushing. Always switch off the power supply and wear protective clothing when working on the device. 2.8 EMERGENCY STOP switch An EMERGENCY STOP switch is not integrated in the device. The operator must ensure that EMERGENCY STOP switches are installed in accordance with the applicable accident prevention regulations, if this is required by law. 8 Danfoss VI.MG.J2.03

9 2.9 Operating personnel The device may only be operated and maintained by authorized, trained and instructed personnel. These personnel must have received special training on the dangers that may arise. A trained person is someone who has been instructed about the tasks assigned to them and the possible dangers of improper behavior and, if necessary, trained and instructed about the necessary protective devices and protective measures. Qualified personnel are those who, based on their technical training, knowledge and experience, as well as knowledge of the relevant provisions, can assess the work assigned to them and recognize possible dangers. If the personnel do not have the necessary knowledge, they must be trained. The responsibilities for operation and maintenance must be clearly defined and adhered to so that there is no unclear distribution of responsibilities from the point of view of safety. The device may only be operated and maintained by people who can be expected to perform their work reliably. Any way of working that impairs the safety of people, the environment or the device is to be avoided. Persons under the influence of drugs, alcohol or medication that affect their ability to react are not allowed to work on or with the device. When selecting personnel, the youth labor protection regulations of the respective country and, if necessary, occupational-specific regulations based on them must be observed with regard to the minimum age. The operator has to ensure that no unauthorized persons work on or with the device. Unauthorized persons such as visitors etc. must not come into contact with the device. You must keep a reasonable safe distance. The operator is obliged to report any changes to the device that impair safety to the operator immediately. Behavior in the event of danger and accidents In the event of danger or accidents, the device must be switched off by pressing an EMERGENCY OFF switch immediately. This can also be done by opening a protective door or protective window equipped with safety switches, which triggers the EMERGENCY STOP function when opened. Safety devices with an EMERGENCY STOP function are only to be operated in appropriate emergency situations. Safety devices must not be used to switch off the device normally. Always be prepared for accidents or fire! Keep first aid equipment (first aid kit, eye wash bottle, etc.) and fire extinguishers within easy reach. The personnel must be familiar with the handling and location of safety, accident reporting, first aid and rescue equipment. This ensures defense against dangers and the best possible help in the event of accidents. VI.MG.J2.03 Danfoss

10 2.11 Residual hazards / hazard analysis Location of the hazard Type of hazard Protection objective Measure Shut-off valves and fittings in the station Piping and components in the station Entire station Entire station Entire station Crushing when operated by hand Burns when touched Electric shock Splashing of liquids and / or steam under high pressure Overheating of the station or .Transmission of the heat to the connected house system beyond the permissible temperature, manual operation of the shut-off valves and fittings must be possible without risk. Safe contact when the station is open Safe contact with the station. Thermal insulation of pipes and components Information signs at the station Warning notices in the operating instructions Fulfillment of contact protection Protection in accordance with DIN 4747 T1 (hot water) or DIN EN 12828, DIN 1988 Protection in accordance with DIN 4747 T1 (hot water) or DIN EN The residual risk can be reduced during operation limit to the following alphabetical value according to Suva risk assessment: B5 / C4 / D3 / E2. The residual risk potential arises from failure to observe the above operating instructions. The assemblies were manufactured according to the explicit specifications of the operator, who is responsible for compliance with the specified parameters, selection and qualification of the operating personnel. The system is equipped with the following warning sign, on which the most important residual dangers are again pointed out: This system is only permitted to be operated by trained specialist personnel after carefully studying the enclosed documentation. Before commissioning, the system must be filled and completely vented. Exceeding the permissible operating pressure or the maximum permissible operating temperature according to the nameplate as well as any use other than the intended use is not permitted. Risk of burns from touching or escaping hot media (water / steam). Avoid touching the modules or wear suitable protective clothing! Risk of crushing when operating the modules. Risk of electric shock: before working on the electrical system, it must be disconnected from the power supply. All flange connections, screw connections as well as electrical clamp and screw connections must be checked and tightened if necessary before filling or commissioning the system! Only switch on the pumps when they are filled (no dry run!). Install properly before commissioning (if not fully assembled at the factory): - Safety valve / drain and vapor lines in accordance with DIN 4751 or DIN dirt trap in the primary flow / secondary return - Equipotential bonding in accordance with VDE 0100 part 540 (earthing / protective conductor / equipotential bonding) 10 Danfoss VI. MG.J2.03

11 3.0 Technical data 3.1 Technical and main system data You will find the main system data on the nameplate and the documents contained in the attachments (title sheet, circuit diagram, data sheet) CE nameplate The nameplate is attached to the system. It contains the following information: Manufacturer device no. Year of manufacture Type Power Design parameters Max. Permissible operating temperature Nominal pressure class Manufacturer Serial number / Prod.MG.J2.03 Danfoss

12 4.0 Function Flow systems provide heated drinking water when required. The water flowing into the cold water connection (1) is heated to the setpoint via a flow water heater (HEL) and made available to the consumer at connection (2). The relevant temperatures are measured via the electronic control (ECD) and the setpoints are kept constant in all operating states. For this purpose, the speed of the heating pump (HPU) is influenced in such a way that the outlet temperature always corresponds to the specified setpoint. Short-term peaks in demand are registered on the flow sensor (F1) in order to be able to intervene quickly and to avoid large temperature fluctuations. The cooled circulation water from the pipe network at connection (3) is constantly reheated in the flow-through water heater (HEL), even when the tap is idle, and the quantity is influenced by the temperature control (sensor) via the regulated circulation pump (CPU) so that only the necessary Quantity flows in order to keep the setpoint constant in the network. The heat demand for the peaks in demand must be ensured through the heating water buffer in the storage tank or a sufficiently high connection value. NOTE! The system can only be operated with a regulated heating pump (HPU) if there is no differential pressure between connections (4) and (5). 12 Danfoss VI.MG.J2.03

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14 5.0 Structure and installation 5.1 Structure and installation / general information Drinking water heating systems are usually supplied as completely piped and wired systems. System connections are specified in the data sheet and in this manual. Ensure the load-bearing capacity of the wall or floor according to the total weight of the system (including the water content!). Pay careful attention to the adjustment of the prepared connections so that they can be connected without tension. Only use compliant connecting parts when connecting to the house system. Pay particular attention to permitted materials in the drinking water area and comply with all legal requirements. Galvanized pipes and fittings should be avoided at all costs to prevent corrosion. Check the correspondence of the connection type, the pressure rating and the dimension. Use approved seals and sealing materials. We use the following types of seals: Heating side: KLINGER top-sil-ml1 Drinking water side: EPDM A-KT WARNING! Risk of injury! Improper installation and assembly can result in serious personal injury and / or property damage. Installation and assembly work may therefore only be carried out by trained specialists in compliance with the safety regulations. NOTE! Check all connections before filling the system and tighten them if necessary. After commissioning, repeat this action again in a warm state. NOTE! The use of pipe wrenches for screw connections is not permitted. Use only matching keys! If system parts or components have to be dismantled due to limited accessibility (shafts, lifts, small access openings, etc.), make sure to reinstall or connect them true to the original after installation. NOTE! The (forcible) separation of system parts (sawing, cutting, etc.) from e.g. System-leading lines and / or frame parts are not permitted. 14 Danfoss VI.MG.J2.03

15 The following torques must be used for the above-mentioned type of seal (KLINGER top-sil-ml1) on the heating side: Size / torque 20 Nm 30 Nm 40 Nm 50 Nm 60 Nm 70 Nm 80 Nm 90 Nm 100 Nm 110 Nm 120 Nm G 3/8 " NOK RISK OK OK OK OK RISK DAM DAM DAM DAM G 1/2 "NOK RISK OK OK OK OK RISK DAM DAM DAM DAM G 3/4" NOK NOK RISK OK OK OK RISK DAM DAM DAM DAM G 1 "NOK NOK RISK OK OK OK RISK DAM DAM DAM DAM G 1 1/4 "NOK NOK RISK OK OK OK RISK DAM DAM DAM DAM G 1 1/2" NOK NOK RISK OK OK OK OK RISK DAM DAM DAM G 1 3/4 "NOK NOK NOK RISK OK OK OK OK RISK RISK DAM G 2 "NOK NOK NOK RISK OK OK OK OK RISK RISK DAM For the above type of seal (EPDM A-KT 90-00) on the drinking water side, the following torques must be used: Size / torque 5 Nm 10 Nm 15 Nm 20 Nm 25 Nm 30 Nm 35 Nm 40 Nm 45 Nm 50 Nm 55 Nm G 1/2 "NOK OK OK RISK DAM DAM DAM DAM DAM DAM DAM G 3/4" NOK OK OK RISK DAM DAM DAM DAM DAM DAM DAM G 1 "NOK NOK NOK RISK OK OK OK RISK DAM DAM DAM G 1 1/4" NOK NOK NOK RISK OK OK OK RISK DAM DAM DAM G 1 1/2 "NOK NOK NOK RISK OK OK OK RISK DAM DAM DAM G 1 3/4 "NOK NOK NOK RISK OK OK OK RISK DAM DAM DAM G 2" NOK NOK NOK RISK OK OK OK RISK DAM DAM DAM G 2 3/8 "NOK NOK NOK NOK RISK OK OK OK RISK DAM DAM G 2 1/2 NOK NOK NOK NOK RISK OK OK OK RISK DAM DAM NOK RISK OK DAM Not tight Risk, leaking OK Deformation of the seal When replacing, you should use the above-mentioned types of seal. When using other types / materials, ask the manufacturer or supplier about the optimal tightening torques in order to guarantee both tightness and to avoid destruction of the seal. Pay particular attention to the suitability of the type of seal you have chosen on the drinking water side. This applies both with regard to the maximum possible temperature and the maximum pressure occurring as well as the suitability in the corresponding medium. On the drinking water side, seals should always have a corresponding approval (e.g. KTW or DVGW W270 test, elastomer guideline). VI.MG.J2.03 Danfoss

16 6.0 Transport, packaging and storage Always adhere to the following safety rules: Transport must be adapted to local conditions. Use only approved hoists and slings with sufficient load-bearing capacity. Only attach the device to suitable attachment points, do not attach it to protruding machine parts or to the eyes of built-on components. Ensure that the lifting accessories are securely in place! Ropes and belts must be equipped with safety hooks. Do not use torn ropes or ropes with chafe marks. Do not put ropes and belts on sharp edges and corners, do not knot or twist them. Note the center of gravity of the device when hitting Never lift, swivel or lower loads over people. Always move the device with the greatest care and caution. WARNING! Risk of death! When lifting, swiveling and lowering, there is a risk of serious personal injury and property damage from falling parts. Never step under suspended loads! In the case of containers, the following must be observed in particular: The thermal insulation must not be damaged during transport and must be dismantled, especially for longer transport routes. Use suitable means of transport to ensure that no deformations occur on the connections or on the container shell. Direct contact with ferritic materials or destruction of the surface must be avoided with stainless steel containers! 6.1 Transporting pallets with a forklift truck Packaged items that are attached to pallets can be transported with a forklift truck under the following conditions: The forklift truck must be designed for the weight of the transport units. The driver must be authorized to drive the forklift. Attaching: 1. Drive the forklift with the forks between or under the bars of the pallet. 2. Retract the forks so that they protrude on the opposite side. 3. Make sure that the pallet cannot tip over if the center of gravity is off-center. 4. Lift the package and start the transport. WARNING! Risk of death! When lifting, swiveling and lowering, there is a risk of serious personal injury and property damage from falling parts. Never step under suspended loads! Transport by forklift 16 Danfoss VI.MG.J2.03

17 6.2 Transport inspection Check the delivery immediately upon receipt for completeness and transport damage. In the event of externally visible transport damage, do not accept the delivery or only accept it with reservations. Note the extent of the damage on the transport documents / delivery note of the carrier. Initiate complaint. Complain about hidden defects as soon as they are discovered, as claims for damages can only be made within the applicable complaint deadlines. 6.3 Packaging The devices are delivered in different packaging. The main packaging materials are wood, cardboard and plastics (foils, foams), but also, among others. Strapping. The packaging material can also include materials that are added to the packages for moisture or frost protection (e.g. silica gel bags, antifreeze, etc.). If no corresponding agreement has been reached on the return of the packaging material, the packaging material remains with the customer. NOTE! The packaging regulations that came into force on on provide that transport packaging can be returned to the supplier. We will take back our transport packaging, provided that it is sent to your local Danfoss department free of charge for us. Transport packaging that is delivered freight collect will not be accepted by us. DANGER! Environmentally friendly disposal in accordance with the relevant disposal regulations must be guaranteed. For this purpose, DANFOSS has concluded a contract with Interseroh AG, at whose collection points the packaging can be handed over. 6.4 Storage After unloading, the packages must be stored in compliance with the shipping markings until assembly. Packaged system parts and accessories must not be unpacked. The following regulations apply to storage: Store in a dry place. Relative humidity: max. 60%. It must be ensured that the packages are not stored outdoors. In addition, it must be ensured that the floor of the storage room is dry during storage. Protect from direct sunlight. Storage temperature 15 to 25 C Store dust-free. Avoid mechanical shocks and damage. In the case of longer storage over approx. 3 months, the preservation measures must be checked. The preservation may have to be renewed in aggressive weather conditions. VI.MG.J2.03 Danfoss

18 7.0 Installation WARNING! Risk of injury! Improper installation and assembly can result in serious personal injury and / or property damage. Installation and assembly work may therefore only be carried out by trained specialists in compliance with the safety regulations. Only use compliant connecting parts when connecting to the house system. Check the correspondence of the connection type, the pressure rating and the dimension. Pipe connections are usually: - Heating connections as welding ends - Flange connections in accordance with DIN EN (pressure levels PN 6 40) - Thread connections in accordance with DIN 2999 as internal or external thread - Thread connections in accordance with DIN 2993 / ISO 228 as external thread 7.1 Installation preparation Before starting installation, ensure that all assemblies and individual parts are complete and check that it is in perfect condition. For installation of the system in the installation room, please refer to the installation instructions or quick guides provided. DANGER! Damaged components must not be installed! Install only completely intact parts! 7.2 Connection on the primary side, heating medium (e.g. district heating) The connection on the primary side is carried out by specialist staff in coordination with the local / district heating supply company, provided the system is connected to such a supply network. The primary flow and return must be connected to the designated connections or shut-off valves of the system. In the case of district heating connections, the commissioning of the primary side is usually carried out by the responsible local / district heating supply company. Since the system does not have a dirt trap on the primary side orIf the filter is delivered, make sure that it is installed in front of the system in order to protect the components of the system from the ingress of dirt. Failure to do so could void the warranty. Before commissioning, remove all particles within the pipelines (rinse) of the system and the dirt trap. 7.3 Secondary-side connection, drinking water The secondary side is connected to the designated shut-off valves of the system by the installing specialist company. An approved water filter in accordance with regulations must also be installed on the drinking water side in front of the system. Rinse the complete system before commissioning and remove all dirt particles beforehand, including cleaning the backwash filter. These measures are also essential to maintain the warranty. 7.4 Electrical connection Only a specialist electrical installer approved by the responsible electricity supply company may carry out the electrical installation of the station in compliance with all applicable rules and regulations. The system is fully wired and tested at the factory. Before you start with the electrical connection, please note the following: Read the relevant passages in the section on warnings. The station must be connected to a 230 V AC network. The grid connection must be carried out in accordance with official regulations. The system must be fully wired and connected to an external main switch so that it can be switched off during maintenance, cleaning or repair work. 18 Danfoss VI.MG.J2.03

19 7.4.1 Electrical connection of electronic controllers The connection of the field devices and sensors can be seen in the separate document Installation Guide, ECL Comfort 310, P318. The wiring diagram for the entire device can be found in the appendix and in the documents that are also attached. VI.MG.J2.03 Danfoss

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21 7.5 Installation of the system Installation and connection of the device may only be carried out by authorized and qualified personnel. All local standards and regulations must be observed during installation. When installing, make sure that the system remains freely accessible for assembly and maintenance work. Before installing the system, all pipes and connections must be cleared of contamination. All screw connections and connections must be retightened, as they could have come loose due to vibrations during transport. The safety valve blow-off line must be established in accordance with the applicable local regulations. For installation of the system in the installation room, please refer to the installation instructions or quick guides provided. 7.6 Installation of the shift control option and buffer storage tank loading This option will be available from September 2018 and can be selected if a heating water buffer storage tank is available, e.g. because the maximum power (the connected load) is not sufficiently high. The heating buffer storage tank (optional / accessory) stores the amount of heat required when tapping is required. The primary thing here is that the return from the system can also be fed back into the buffer tank, depending on the temperature, via a 2-point switch valve (optional / accessory). This means that colder water can be fed into the storage tank at the bottom and warmer water at the top. This achieves optimal stratification in the buffer storage tank. The heating water temperature in the buffer tank is registered by the sensors S6 / S8 (optional / accessory). The on-site installation of the sensors (S5, S6, S8) and the switchover valve (X3) is necessary and must be connected as an accessory (return flow stratification set) (hydraulic and electrical). Please note that the effective usable volume can be reduced when using the shift control; increase the buffer volume if necessary. For the electrical connection, please refer to the enclosed installation guide, ECL Comfort 310, P318. If the setpoint temperature (S8) in the heating buffer cylinder is not reached, the controller can also start the heating pump HPU1 / P2 (optional) for charging the buffer cylinder (application ex.a or c) or the valve P2 / M2 (optional) opens (Application ex. B or d). The speed of the pump is not regulated and may have to be set manually on the pump or the required amount of heating water has to be regulated in some other way. This loading and monitoring can also take place externally via another system or another controller. The required settings in the electronic controller can be found in the enclosed instructions for the application key P318 (Operating Instructions - ECL Comfort 310, application P318). Example shift control and storage tank loading with application P318.11, ex. a VI.MG.J2.03 Danfoss

22 8.0 Commissioning The following measures must always be carried out when: Initial commissioning of the device (see commissioning report) Recommissioning after complex maintenance work on the device Recommissioning after relocating the device Recommissioning after troubleshooting the device. Recommissioning after shutdown or longer periods of inactivity Checking the water quality The installation and initial commissioning of the device is carried out as agreed by the manufacturer's employees, partner companies authorized by him or the specialist company installing the device. Unauthorized initial commissioning is not permitted. Before commissioning, check whether all safety regulations and provisions have been observed. Fill the house system with drinking water. To avoid damage, make sure that the pressure during filling does not exceed the maximum permissible operating pressure. NOTE! Observe the measures required to maintain the quality of the drinking water! In any case, the fully completed commissioning protocol (see attached documents) is a prerequisite for maintaining the system's warranty. Before the first start-up, the secondary side must be flushed sufficiently by the installation company. Check all connections for leaks and tight fit. Fill the system to the required static height. 8.1 Prerequisites for commissioning For the commissioning of the drinking water system, the following conditions must be met: - commissioning may have to be approved by the district heating supply company - all screw connections and fastenings must be tightened - the system must be properly connected in terms of pipes - all contamination and assembly residues must be removed must be removed from the pipelines - the system must be properly connected electrically and in terms of control technology, supply voltage must be applied to the main switch or automatic circuit breaker - the heating medium must be applied to the primary shut-off valves with the required parameters - the house system, including the system, must be filled and vented (pumps absolutely vent!) 8.2 Secondary-side commissioning, drinking water network Before commissioning, check whether all safety regulations and provisions have been observed. The operating data on the system's nameplate must match the operating data of the local / district heating company or the heating-side supply system and the house system (drinking water side). Fill the drinking water network with drinking water. To avoid damage, make sure that the pressure during filling does not exceed the maximum permissible operating pressure. Vent the system completely at the highest points. Before the first start-up, the secondary side must be flushed sufficiently by the installation company. Check all connections for leaks and tight fit. 8.3 Commissioning on the primary side All work on the primary side of the system may only be carried out in coordination with the local / district heating supply company by suitably trained and instructed specialists. Fill the system slowly using the shut-off valve in the primary flow. To do this, slowly open the shut-off valve in the primary return. When operating with an electronic control, the control valve (if present) must be set to the open position via manual operation. Set the flow rate / differential pressure regulator or pressure regulator (if available) to the maximum flow rate or the specified differential pressure. Set the existing pressure regulator to the projected value. Check all connections for tight fit and tightness, tighten with the required torque if necessary. Flush the primary side sufficiently, close the shut-off valves. Clean the dirt trap and set the electronic heating controller, if available, to nominal operation in accordance with the manufacturer's operating instructions included. 22 Danfoss VI.MG.J2.03

23 8.4 Controller The Danfoss electronic controller is preset at the factory. Connect the controller to the power supply. Confirm the language selection, set the date and time and the controller is now ready for use. The preset parameters are changed according to the operating instructions of the controller manufacturer, which are enclosed with the station. 8.5 Faults and shutdown The heating pump and other components such as control valves, sensors or thermostats are connected to the mains voltage. Immediately switch off the main switch or pull out the power plug. Close shut-off valves. It is essential to consult a specialist company to rectify the fault. - Disconnect the mains voltage - Close the shut-off valves on the primary and secondary side - It is essential to consult a specialist company to rectify the fault. The system must be ventilated when it is drained. Underpressure can lead to the destruction of system components or the possibly existing storage tank. WARNING! Risk of burns! If there are leaks on the primary side, hot water or steam can escape. Risk of burns! WARNING! Electric current hazard! Leaking water can put the entire system under life-threatening voltage. Before starting work, de-energize the system and secure it against being switched on again! 8.6 Re-commissioning after a malfunction After a malfunction, re-commissioning takes place with the specialist company. 8.7 Danfoss controller default settings Basic settings Component Name Parameter Parameter number Setting range Basic / start setting Application basic setting (start)> Type P318. xxxx Hydraulic type / control type (does not have to be set) Factory setting: FLS-COMBI b Pump code numbers 004X Charging temperature S3 primary flow min *) C 10 C 70 C charging temperature S3 primary primary flow *) C 90 C 70 C charging temperature heating / Return limitation circulation temperature S3 hot water / outlet HEX *)> heating circuit 1 (left bar)> time program / day active> setpoint SC 60 C 60 C S5 return primary C 40 C 65 C S9 circulation *) (normal / comfort mode) C 55 C 55 C S9 circulation *) (disinfection mode) OFF / C OFF 65 C *) sensor must be connected **) Note: This setting is only effective with active thermal disinfection, irrelevant 70 C bold values ​​differ from the default setting or must be set become! VI.MG.J2.03 Danfoss

24 8.7.2 Pump settings Component heating pump [P1] Cylinder charging pump [P2] Circulation pump [P3] Output control system parameters Max./Min. Parameter Max./Min. Parameter Max./Min. [kw] Type Application Code [%] [%] [%] [%] [%] [%] X Pump control b 004X not relevant X C Values ​​shown in bold deviate from the default setting or must be set! 24 Danfoss VI.MG.J2.03

25 9.0 Operation The system is operated in automatic mode. During operation, no personnel is required in the area of ​​the system or in its immediate vicinity. 9.1 Switching on To switch on, please observe the requirements under point 8 Commissioning. The system can be switched on at the main switch of the electronic control and then works automatically. In the case of controls without their own main switch, this must be installed on site. 9.2 Switching off The switching off takes place at the main switch of the electronic control. In the case of controls without their own main switch, this must be installed on site. 9.3 Recommissioning For recommissioning after longer periods of inactivity, e.g. in Germany the conditions according to DIN 1988 Part 8 and VDI Please note other, corresponding local or country-specific requirements. There is a risk of scalding, especially after thermal disinfection. WARNING! Risk of scalding! When handling hot water, observe the safety regulations applicable to the product. Take care when handling hot operating materials, risk of burns! 9.4 Hygiene and thermal disinfection Thermal disinfection may have to be carried out in accordance with local or country-specific regulations, laws or other specifications. The procedure mentioned below is therefore only a possible suggestion. If the system is to be operated temporarily in the thermal disinfection function, please note the following: 1. Make sure that no hot water is drawn from the draw-off points. Operating materials can reach high temperatures. 2. Open the shut-off devices on the heating water side. 3. Switch on all pumps. 4. Set the setpoint for the valves to 70 C (for disinfection). 5. Heat the storage volume on the drinking water side (if available) and the hot water network including circulation line to 70 C (duration approx. 2-3 hours). 6. Let 70 degree water flow through each tap for approx. 3 minutes. This disinfects the lines. 7. After disinfection, set the regular setpoints again (recommended 60 C, i.e. set to automatic mode) slight painful severe scalding temperature sensation 0, effects of drinking water temperatures on skin surfaces, source: Dr. J.P. Bull, Industrial Injuries and Burns Unit, Medical Research Council The following guideline values ​​for the hazard potential must be observed: - 38 C safe temperature for bathing C Pain sensation from 10 seconds or longer C Pain sensation 6-2 seconds C Warning of scalding C Risk of scalding, briefly from 60 C Danger of scalding, extreme danger immediately above 70 C Source: Dr. Gabriele Elsäßer, Brandenburg State Health Authority Dr. J.P. Bull, Birmingham Accident Hospital VI.MG.J2.03 Danfoss

26 10.0 Maintenance 10.1 Safety instructions The annex contains an overview of the most important technical regulations. For the maintenance of the system you will find information in particular in DIN 1988, EN806, VDI 2895 and VDI 6023. It is recommended that you hire a local installation company to carry out regular maintenance work. The most important measures for certain components and assemblies are summarized under point 10.2. In the appendix you will also find the corresponding maintenance and operating instructions for individual components that must be observed. WARNING! Work on the device may only be carried out by qualified and specially trained personnel. Always wear the following personal protective equipment in the vicinity of the device: Tight-fitting clothing (no wide sleeves, rings, etc.) Safety glasses to protect the eyes from flying parts and liquids Safety shoes to protect against heavy falling parts and slipping on slippery surfaces. WARNING! Electric current hazard! Work on electrical equipment may only be carried out by qualified electricians in compliance with the safety regulations. Before starting work, switch off the electrical supply and secure it against being switched on again. Maintenance plan (recommendations) Interval of maintenance work Remarks Check all connections, if necessary retighten and / or replace seals every 2 months, additionally every 6 months, additionally every 12 months, check all parameters for setpoints / actual values ​​or permissibility.If exceeded: restore parameters as intended.Cleaning of backwash filters see also DIN 1988 / EN 806 General visual inspection of all components for damage in the event of visual damage Function check and, if necessary, replacement Function check of the safety valve, see also DIN 1988 / EN 806 Function check of electrical and electronic components, switches, etc. Manual switching on / off or opening and closing of motor drives For cleaning filters and dirt traps, see also DIN 1988 / EN 806 Testing of electrical temperature monitors and / or limiters Safety devices Functional check of all components for function, e.g. Open and close shut-off valves and operability Check the external condition Coloring (rust), heat insulation Check the heat exchangers In the event of contamination, clean / decalcify if necessary (see section 10.2) Clean the containers / storage tank see section Check the counting devices, observe the calibration period, check the display devices, pressure gauges, thermometers Checking the expansion vessels pre-pressure, load pressure, tightness of the membrane 26 Danfoss VI.MG.J2.03

27 10.2 Maintenance work The following lists essential activities that should be carried out as part of maintenance. Additional information can be found in the manufacturer's instructions enclosed in the appendix. The compilation does not claim to be complete. In any case, it is important to observe the legal and relevant technical regulations as well as the requirements of the local conditions and regulations (e.g. TAB s, regulations of the EVU, etc.) Fittings: In general, the fittings used are maintenance-free. As part of maintenance work, the functionality with regard to the mobility of handwheels orLevers can be checked by opening and closing. This prevents dirt and limescale residue from settling on balls, plates and valve seats. In Appendix I you will find the manufacturer's instructions for the most common components. Heat exchangers: During prolonged operation, heat exchangers are particularly prone to calcification due to the relatively high temperatures on the plates or pipes. As part of the above Maintenance work, these devices should be cleaned when their performance deteriorates. Brazed plate heat exchangers can be flushed. For thicker deposits, weakly inhibited acid solutions (e.g. 5% formic, acetic or phosphoric acid) can be used. The drawings show this arrangement: Flushing / cleaning of soldered plate heat exchangers Vessel: You will find information on this in separate attached documents Pipes: The pipes used are made of high quality stainless steel. If they are dirty, they can be treated like containers. You will find information on this in the operating instructions for stainless steel tanks. Measures after maintenance work After maintenance work and before switching on the device, note the following: Check all previously loosened screw connections for tightness. Check whether all protective devices, covers and container lids that were removed have been properly reinstalled. Make sure that all tools, materials and other equipment used have been removed from the work area. Clean the work area and remove any leaked substances such as Remove liquids, processing material, etc. Make sure that all safety devices of the device and the system are working properly again. VI.MG.J2.03 Danfoss

28 11.0 Malfunctions Malfunctions in electrical equipment as well as in mechanical, pneumatic and hydraulic components may only be remedied by specially trained specialists from these departments. In the event of malfunctions that cannot be remedied with the measures described below, inform the manufacturer or a service partner authorized by the manufacturer. Malfunctions Malfunction Possible cause Remedy Comment Drinking water temperature too low Drinking water hygiene at risk! Drinking water temperature too high Risk of scalding! Drinking water temperature fluctuates or is not constant Risk of scalding! Leakage of medium Risk of scalding! no power supply missing water supply - no cold water pressure - too low primary differential pressure - too little heating water quantity - switch on main switch - check supply line - check fuses / contactors operating conditions - pressure - quantity - create / secure differential pressure heating or media supplier incorrect controller setting (s) correct settings operating instructions controller closed Shut-off valve (s) defective sensor defective or not switched on charge pump (LPU) defective or not switched on heating (feed) pump (HPU) defective control valve defective drive or thermostat system incorrectly dimensioned system is being drawn over - no voltage supply - electric drive open open valves replace sensor switch on / replace switch on / replace clean / make normal, replace if necessary replace drive / thermostat - check dimensioning - expand / enlarge system - check dimensioning - expand system iterate / enlarge - shut down the system - establish power supply - if necessary, establish manual emergency operation contact our specialist adviser speak to our specialist adviser incorrect controller setting (s) correct settings operating instructions controller defective sensor defective control valve replace sensor clean valve / make normal or replace valve depends defective drive or thermostat Replace drive / thermostat drive open or thermostat / capillary defective Incorrect controller setting (s) Correct settings Operating instructions controller - control gain - reset time - valve running time / pump parameters fluctuating heating water supply - fluctuating primary differential pressure - fluctuating heating water volume Leakage in connections (flange / screw connections) Operating conditions - pressure - volume - create / secure differential pressure switch off system - check operating parameters for permissibility (see nameplate) - check connections, if necessary na Pull out or replace seals. Heat or media supplier. Leakage in welded seams. Switch off system. Contact customer service Check for correct fit and installation - retighten stuffing (sealing) bushings or change component - retighten bolts - open and clean - change seals Change device Operating instructions contact the manufacturer, if necessary contact customer service Operating instructions, contact customer service if necessary Operating instructions manufacturer, if necessary Contact customer service 28 Danfoss VI.MG.J2.03

29 11.2 Behavior in the event of malfunctions The following generally applies: 1. In the event of malfunctions that represent an immediate danger to people, property and / or operational safety, stop the system immediately using the EMERGENCY STOP function. 2. In the event of faults that do not cause such dangers, switch off the system via the system control, also interrupt the power supply to the device and secure it against being switched on again. 3. Immediately inform those responsible at the place of use about the fault. 4. Have authorized specialist personnel determine the type and scope of the malfunction, determine the cause and have the malfunction eliminated. WARNING! Improper troubleshooting can lead to serious personal injury and / or property damage. Faults may therefore only be carried out by trained and authorized specialists! 12.0 Spare parts Only use original spare parts from the manufacturer! If unapproved spare parts are used, all warranty, service, damage compensation and / or liability claims against the manufacturer or his agents, dealers and representatives are forfeited. When ordering spare parts, please state: Device type, serial / production no. Part no. / Article number (see parts list / circuit diagram) Quantity Description Desired shipping method (post, freight, sea, air, express) Shipping address, if necessary sketch or photo with comments ATTENTION! Wrong or faulty spare parts and components from third-party manufacturers can lead to serious damage, malfunctions or total failure of the device. Spare parts orders without the above information cannot be considered. If there is no information about the type of dispatch, dispatch will be made at the discretion of the supplier. Inform the manufacturer comprehensively about the parts used so that an equivalent replacement can be offered. VI.MG.J2.03 Danfoss

30 INDEX A General ... 3, 6, 14 Occupational safety ... 3, 6, 7 Structure ... 12, 14, 31 Switching off ... 4, 8, 23, 25, 26, 29 B Operating personnel ... 3, 9 Operation or operating instructions ... 3, 6, 9, 10, 21, 22, 23, 25, 26, 28 Intended use ... 6, 7 Operator ... 6, 7, 9, 10 Operating instructions. .. 3, 4, 6, 10 D Dismantling ... 3, 4, 5 Gasket, flow system, flow water heater E Switching on / on again ... 4, 8, 10, 23, 25, 26, 27, 28, 29 Electrical connection for disposal ... 3, 4, 5, 17 Spare parts ... 4, 29 F Qualified personnel ... 4, 9, 10, 14, 18, 22, 28, 29 Sensors ... 11, 12, 21, 28 Function. .. 3, 4, 9, 12, 26, 27, 28, 29 Malfunctions G Dangers ... 3, 6, 7, 8, 9, 10, 29 Warranty ... 4, 22, 29 H Liability ... 4 Hygiene I Commissioning / recommissioning ... 4, 10, 14, 18, 22, 23, 25 Installation / company ... 3, 6, 7, 14, 18, 22, 26 L Storage ... 16, 17 M Other applicable documents ... 3 Preparation for installation N EMERGENCY STOP (switch) ... 7, 8, 9, 29 P parameters ... 10, 11, 22, 26, 28 Pr mary side ... 18, 22, 23 Buffer storage tank loading R control, controller ... 11, 12, 19, 22, 23, 25 S circuit diagram ... 11, 29 Dirt trap shift control ... 10, 22, 26 Protective equipment ... 7, 8, 26 Safety glasses ... 7, 26 Protective gloves ... 7, 8 Safety helmet ... 7 Secondary side ... 18, 22 Safety (-...) ... 3, 6, 7, 8, 9 , 14, 16, 18, 22, 25, 26, 27, 29 Safety shoes ... 7, 26 Safety valve ... 10, 11, 21, 26 de-energized ... 8, 10, 14, 23 Storage ... 12 , 26 Faults ... 4, 28, 29 Faults and decommissioning T Technical data Thermal disinfection Transport (-) ... 8, 16, 17, 21 Transport inspection U Copyright protection ... 4 V Responsibility of the operator ... 6 Packaging. .. 16, 17 Presets ... 23, 24 W heat supply ... 18, 22 Maintenance ... 3, 6, 8, 18, 21, 22, 26, 27 Maintenance work ... 21, 22, 26, 27 Recommissioning ... 22, Danfoss VI.MG.J2.03

31 Appendix Structure / component positioning Hot drinking water Drinking water (cold) VI.MG.J2.03 Danfoss