Installation Guide DSA WALL
Contents
1. When ordering spare parts always specify e Substation type e Serial production number e Part number article number if available e Quantity e Name e Desired shipping method post freight sea air express e Shipping address If needed provide a sketch or photo with remarks Spare part orders without the above specifications may not be ful filled In the absence of a desired shipping method the shipping method will be at the discretion of the supplier In the annex you can find a list of the most important suppliers of purchased components where spare parts may be requested follow ing the expiry of the warranty In such a case provide the manufac turer with comprehensive information about the used parts so that a replacement can be offered Danfoss District Enero VI IQ J1 02 DEN SMT PL Installation Guide DSA WALL A actuator 11 20 24 26 28 assembly 2 8 14 15 17 authorized personnel 5 26 29 B balancing valve 26 C circuit 2 9 10 11 12 18 19 23 28 circulation 12 26 commissioning 2 8 15 19 20 component 15 24 27 connections 8 11 13 14 15 19 24 25 27 control valves 11 controller 11 19 20 26 27 28 D District Heating 5 11 15 18 19 20 25 26 28 domestic hot water 2 12 drain 4 6 8 11 12 18 23 drinking water 4 11 DSAWALL 1 2 9 11 12 15 E electrician 3 15 24 employees 19 EPP 22 expansion vessel 2 23 24 27 F fittings 8 12 25 22. Installation Guide DSA WALL Please always keep the instructions close to the device Please read the operating instructions carefully before starting any work Attention Before starting up the station please check it for proper function and free of defects Original instruction Danfoss District Energy 10 41 DEN SMT PL Installation Guide DSA WALL ___ 0 0 Table of contents 0O Tapco COUSIN cile 2 gE OM Coin 2 Mg ie das Lc 3 1 1 Information about Operating INStFUCTIONS ccessssessssssecsssscsssecssssssessssucsessssesssscsssscsssssssssssecsssucsessssucassucassucassssaesssscsssucasesssucassucaesscaseacaeeassncasessaneeses 3 IZ APPC BE CUMIN SS aa 3 I3 EXPINatioh0F3yMbblbin ana 3 ISCHIA 3 Lo OMY FA AE OSC oiran ana 4 IRPI 4 7 SUBSHION ASI rai 4 R Pool 4 Ivy mer nici 5 PAE E e an adi 5 2 2 Responsibility of substation operator ou sssesecsssssesssscsssscsecsssscsssscsssscsecscsessssucsssusscssscsssscsssscsecsssucsssssassussucsesscsessesessssecassucaesussucassucassucassasseeasseasenss 5 23 eee 5 24 Possible alc 5 065 CROCE EI 5 2 60 Persomal PIOFECLVEGGUIPNCIT ssaa 6 2 7 Risks associated with the SUDSHATON liane 6 2 5 PATINY SUS W a E E E E A E EE T eee 7 2a occ 7 2 10 Steps to follow in the event of danger or accidents ccessssesssecssscsssscsessssecsesscsessssscsssucsssscsessssucsssucsessssucsssucsesscsesasscassucasesssesussucaesucseencseesceeasenss 7 211 Residual haz
3. Fill the secondary installation to the required static pressure 7 3 Primary side commissioning All work on the primary side of the system must be carried out in coordination with the local district heating company by suitably qualified and trained personnel Fill the substation by slowly open ing the shut off valve on the primary supply Also slowly open the shut off valve on the primary return Manually adjust the electronic controller to the valve open position If the medium is water set the flow pressure differential regulator or pressure regulator if available to the maximum flow rate according to capacity or preset differential pressure Than set up the pressure regulator if there is one to the designated value Check all connec tions for leaks and tightness and retighten with the required torque if necessary Rinse the primary site with the district heating medium and reclose the shut off valves Clean the strainers and adjust the electronic controller in accordance with the designated values in the enclosed supplier instructions Danfoss District Enero VINQ J1 02 Donfs Following installation initial start up and the execution of test runs by the manufacturer or its authorised representative the substation is handed over to the operator Afterwards the substation is operated as intended in accordance with the instructions in the Operator s Manual Installation and commissioning of the substation can b
4. edges and corners on and inside the substation or necessary tools can cause personal injury Any substation removal work must there fore be carried out only by a specialist A WARNING Do not drink Water in the installation which has not been used for a long period of time may not meet the quality standard for drinking water in certain conditions Prevent such use and drain or dispose of water used to run the substation A WARNING Electrical and electronic components lubricants and other excipi ents must be handled by hazardous waste treatment plants and may only be disposed by approved specialist companies Danfoss District Enero Installation Guide DSA WALL 2 0 Safety This section gives an overview of all the important security aspects of optimal protection of personnel as well as of safe and trouble free operation of the substation In addition these chapters include specific safety symbols in order to avert immediate safety hazards 2 1 General information Substation is built at the time of its development and manufactur ing according to existing accepted engineering standards and is safe to operate The substation can be dangerous if used by improperly trained personnel or used improperly or by unauthorised persons Any person authorised to work on or with the substation must read and understand the operating instructions before starting work We recom mend advising the operator to obtain confirmatio
5. always close the shut off valve on the district heating connection S NOTE To drain only the substation and not the whole installation close the shut off valves on the substation If the drain pipe is not connected to the drain valve connect the ap propriate hose or piping in accordance with local legal regulations A WARNING Risk of injury or damage Never operate the drain valve when the outlet is directed towards you or electrical devices Always secure all equipment so that it is not flooded by accident Before any operation always ensure that the water has cooled sufficiently Open the drain valve and wait until the circuit concerned has emptied Immediately after draining close the valve WARNING Risk of injury Even after draining there may still be water inside the heat ex changer and piping DEN SMT PL VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL 7 0 Commissioning The following actions must always be carried out only after com missioning e Initial start up of the substation see commissioning protocol in the attached annex e Restarting after complex substation maintenance e Restarting after the implementation of a new device e Restart following a malfunction of the substation e Restarting after shutdown or longer downtime Installation and initial commissioning of the substation is carried out by approved employees of the manufacturer or authorised partner companies Typ
6. and secure against being switched ON again e Ensure that the entire energy supply is physically separate from the substation and that stored residual power is properly discharged e Remove supplies and materials as well as any remaining processing materials in an environmentally friendly manner 1 8 Disposal If no withdrawal or waste management agreement has been con cluded disassemble the dismantled components for recycling e Metal to scrap material e Plastics to plastics recycling To dispose other components sort by material properties e Remove any residual media and dispose of properly media with additives e g glycol must comply with relevant legislation Remove operating materials such as lubricants oils fats cleaning agents and inhibitors from the substation in an environmentally friendly manner In this case use a suitable approved container for lubricants Mark the container with information about the content and level and date clearly Secure final disposal of the materials so that improper use is excluded VI IQ J1 02 S NOTE Contents of this instruction texts drawings images or other illus trations are copyrighted and subject to other intellectual property rights Any improper reuse is forbidden ATTENTION Using the wrong or faulty spare parts can lead to damage malfunction or total failure of the substation A WARNING Risk of injury Stored residual power components with sharp edges
7. described in a standard operating procedure SOP Always follow local regulations as well as any existing ordinances on industrial safety and health e g in Germany BetrSichV BGBL 2002 3777 Any additional and or other use of the substation is forbidden and considered as improper use Any claims against the manufac turer and or its representative for any loss or damage as a result of improper use of the substation are excluded The operator and or owner shall be solely liable for any damage arising when the substation is used for any purpose other than Therefore e Use the district heating transfer station only for its intended purpose and in accordance with the information provided in this document particularly the limitations given in the technical data e Avoid any further or other use of the district heating transfer station e It is forbidden to change upgrade or modify the design or Failure to follow these instructions can result in mechanical or equipment failure that poses a danger to persons and goods and the entire workplace Failure to comply with safety regulations will invalidate any warranty DEN SMT PL Installation Guide DSA WALL 2 6 Personal protective equipment While working on and with the substation the following must be worn at all times Protective clothing is close fitting work clothing with low tensile strength and tight sleeves and without protruding parts Its main purpose is to gu
8. g Xp proportional band Incorrect controller setting s Tn integration time constant Read controller s user manual M run running time of the motorised control valve Secondary water tem perature oscillating or not constant Check and secure operating conditions Pressure Flow Differential pressure Control valve needs to be recalcu Contact our sales staff Primary control valve is too large i i lated replace if necessary responsible Turn off substation Check operating parameters Connection leakages flange and test for admissibility see fittings couplings label Check connections and tighten as necessary or replace seals Leakage of welds Turn off substation Contact customer service Leakage Leaks from fittings housing Tighten connection or replace c i ontact customer service Risk of scalding couplings component Leakage of gasket heat ex changers Pollution calcification Pressure hammers Fluctuating heating water supply Fluctuating primary differential pressure Fluctuating primary flow Tighten bolts Read heat exchanger Open and clean plates user s manual or contact Change seals if necessary customer service Leakage of brazed or welded heat exchangers Pollution calcification Pressure hammers Internal leakage of the heat Test heat exchanger and replace Contact customer service exchanger if necessary Incorrect adjustment and
9. must always be run in separate cable trays S NOTE Check the durability of wall material before installing A WARNING Risk of injury Improper installation and assembly can result in serious injury and or property damage Installation and assembly work may be performed only by qualified personnel in compliance with safety regulations Danfoss District Energ VI IQ J1 02 DEN SMT PL Installation Guide DSA WALL 6 2 Packing unpacking the substation The packaged product is supplied with a standard Euro pallet and is easy to transport by truck or forklift Remove the protective foil and unscrew the substation from the pallet Before moving the station identify the handling point The substation must not be transported with piping due to risk of damage DEN SMT PL VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL 6 3 Substation assembly Find and disassemble the support bracket atthe backofthe station Fix the support bracket to the wall with the attached screws Place the station on the support bracket and fix the main frame to the wall The substation must not be connected to the piping without screwing main frame to wall Danfoss District Enero VI IQ J1 02 DEN SMT PL Installation Guide DSA WALL 6 4 Draining station Locate the drain valves on the specific circuit which you would like to empty ATTENTION To drain the primary side
10. recommendations csssesesessssssesssscsescsssssscscseseesescseseseesesesescsesescassussesesesecsesesesesscsesesesscseseacaessssescacsessesesescsesseseaeseeseseaeaeseeseseaes 24 9 3 Heat exchanger maintenance cssssssscsssscsssssscessssscessecsssssscessesscassscsssesscassesseassecsssesscassecsenssecsssuesenseseseaseucsesucsenseuesesscuesesucscsecueaesucacsesscacseeusacsecassesscess 25 94 Maintenance VINA ALON rale 25 10 0 TOUD SOON sella 26 IO See ana 29 KW PPI cca 29 0 ileTrrrabn ea 30 DEN SMT PL VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL 1 0 General notes 1 1 Information about Operating Instructions This manual describes the installation operation and maintenance of the substation Compliance with all safety and operating instruc tions is a prerequisite for the safe operation and proper use of the substation In addition regulations applicable to the field of appli cation of the substation local accident prevention regulations and general safety regulations must be followed The operating manual is part of the product and must be available at all times within the immediate vicinity of the operating area of the substation for the installation operation maintenance and cleaning responsible of the substation 1 2 Applicable Documents Individual system components unless otherwise indicated are components purchased from other manufacturers All components used in the substation have be
11. sions and weight may vary depending on accessories selected Details of dimensions and weight are available before delivery to ensure trouble free transport and installation of the substation DEION DB ide di aldo MANUFACTURER BID MOSPRODUCTICH DATI ODE TIFE IPURPOGE OF UGE PED CATEGORY POWER SUPPLY VOLTAGE IPN CLASS DVM TEMPERATURE TS BMAX ALLOWED PRESSURE PS KCAPACITE TEMPERATURE PROGRAM HEAT EXCHANGER FLOW PACS SURE DROP eX af i ar BAR Li L mi ith kPa o ER a Sere SUBSTATION Danfoss Potand sp roo Tuchom ul hecna 46 Di Ma hvac 100007530 30431 CGS DAS WALL coca Pe Mr Cere Die WA ae et aan SUM OSE OM HEATING HW i 1 J i 3 Too 135 7a PASO Poe 2S i Sa 55 MBS L i I XBIFL 1 25 ETET FLYFF Em SECONDARY SECONDART anda D p 4 U fol Hoh Zina D j max 600 Figure 1 DSA WALL external dimensions Figure 2 DSA WALL packaging VI 10 J1 02 DEN SMT PL E Installation Guide DSA WALL 3 2 Symbols used in circuit diagrams Shut off valve Sensor in general direct immersion P Pump immersion Surface temperature M Balancing valve ni pee ET Control valve general sensor Strainers filters Safety thermostat Combi valve Xe DE XE sell pressure 3 way control valve Check val
12. 7 flat spanner 21 22 flow noise 28 H hazard 3 6 20 24 heat exchanger 2 9 11 12 22 24 25 26 27 heating supply 15 hot surfaces 6 installation 3 4 5 9 11 12 14 15 18 19 24 28 installer 24 Intended use 5 L loose components 15 DEN SMT PL M maintenance 2 3 5 6 7 11 12 19 24 25 Maintenance Plan 30 malfunction 3 4 19 29 O operator 2 5 7 19 P packing 16 personnel 5 7 8 14 15 19 20 24 26 29 primary connection 15 19 protective clothing 8 protective gloves 6 pump 11 12 20 24 26 28 R reconnection 6 24 29 risk 2 3 5 6 8 13 16 S safety rules 13 safety valve 12 23 24 27 scrap 4 secondary side 11 19 20 23 Seeger Circlip Ring Pliers 22 sensor 12 15 26 28 service 4 6 26 27 29 spare parts 4 29 strainer 2 11 12 15 19 21 24 28 substation 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 20 22 24 25 26 27 28 29 T technical requirements 12 thermometer 11 24 transport 6 9 13 14 16 troubleshooting 20 29 U unpacking 2 16 V voltage 9 19 20 26 W warranty 3 5 15 19 29 VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL Danfoss District Enero VI IQ J1 02 DEN SMT PL Installation Guide DSA WALL Danfoss Poland Sp z 0 0 Tuchom ul Teczowa 46 80 209 Chwaszczyno POLAND Tel 48 58 512 91 34 Fax 48 58 512 91 05 serwis danfoss pl www danfoss com Danfoss can accept no responsibil
13. Close the second shut off valves on the primary WARNING Electric shock hazard and secondary side Leaking water can subject the entire substation to dangerous volt A specialist company must be consulted for troubleshooting age Before starting any work switch the power OFF and ensure that it cannot be turned back on A WARNING Risk of burns In case of leakage on the primary side the medium may escape as steam at a temperature of more than 100 C Danger of burns 7 6 Commissioning after a failure or malfunctiong After a failure on the primary side always contact the local or district heating company Recommissioning is to be carried out by a special ist Company After a failure on the secondary side contact a specialist company Recommissioning is to be carried out by the specialist company 8 0 Operation The substation works in fully automatic mode During operation no personnel are required either in the area of the substation or within its immediate vicinity 8 1 Switching on To turn the substation on follow the requirements in the Commis sioning chapter 7 The substation can be turned on at the main switch of the electronic controller and will start to operate automatically 8 2 Switching off The substation can be turned off atthe main switch of the electronic controller and will stop automatically 8 3 Restarting after substation shutdown If the substation is to be turned off for a long per
14. LL into the most demanding technical requirements If you have any questions please contact our sales support pax i 191 192 PTO 163 164 Figure 4 DSA WALL heating configuration Ste 6 351 349 348 347 346 345 770 769 768 767 766 765 764 7635 762 Figure 5 DSA WALL Domestic Hot Water configuration DEN SMT PL VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL 5 0 Transport packaging and storage Follow general safety rules during transport e Adapt transportation to local conditions e Use only approved lifting gear and lifting equipment with adequate load capacity e Only attach the substation to suitable anchor points and not to protruding machine parts or eyelet components Ensure the secure fit of the slings e Ropes and belts must be equipped with a safety hook Do not use damaged or frayed cables Do not fasten ropes or straps to sharp edges or corners and do not knot or twist Always consider the centre of gravity before handling e Never lift pan or lower loads over people e Always transport the substation with the utmost care and caution e During vessel transport especially bear in mind that insulation must not be damaged during transport or removed especially when transporting over longer distances e Ensure suitable means of transport so that no deformation arises on connections or vessel e Avoid direct contact with ferrous materials or surface destruction of stainless s
15. Requirements for commissioning ssssssssessssessssscsssscsecsssscsssucsessssucsssucsssscsessesscassucassucsessssucsssucasssssssssasesssucaseseassscsucsesscsssscsscsssucsssucassucaeassucsesseaseneaseees 19 72 Secondary side ON ISSION MA aa 19 Z3 Pimay sidecomMIisSsSlONNG Jean 19 7 4 Requirements for COMMISSIONING siccesssscscessnsesesevaxadecassnstasaiecnssoectoncsseae eiesssoacahsdncasnsscuinecsnnsexteonstaaanisanl ca NEON ARAR OaS EAEE EARANN 20 1 5 mel 6 121 81 GONIT a 20 7 6 Commissioning after a failure or malfunctioning c ccsssessessssessssecsssscsssscsscssscsssucssssssecsssessssscssssssessssucsssusassucsucsssscsssncsessssessssucaesscsesssaeeaseeassncaseees 20 oO OPON Lilla 20 SA e aa SEE EE EE E A E E A E A VN A E A E E E E E eavoarneaaoos 20 ME E S La 20 8 3 Restarting after substation SHUTAOWN uu ccsessssesssssssesscsessssecsescsesscsssssscsssucssssssucsssucsssscsussssucsssscsssusssssesucsssscassucsucassucassucsssucaessssucaesscacasaueacsucassncaseess 20 04 Service Geane Side cca 21 8 5 Service disassembly and replacement heat exchanger ccssssssssssssssssessssssscsssessssssscssssscsssessssssscsesssecsssecsesesscsescscsesecseseesesesesscsescaesessesesecess 22 8 6 Service Check Safety valve and expansion vessel ccesssssssssessessssessssecssssssessssecsssscsessssssssscsssucssssssucsssucassscsessesscsesscassscassssucassucaesucsesassseseescaeeess 23 DONNE buccia 24 dl SVI ara 24 9 2 Maintenance plan
16. Risk of injury The most important actions for main components and assemblies are In principle work may be carried out only by qualified and specially summarised under section 9 2 Other instructions for components trained personnel Avoid loosen tight clothing no loose sleeves not specified in this installation manual can be found separately in rings etc Always wear the following personal protective equip the accessory box and must be observed ment in the vicinity of the substation Safety glasses to protect the eyes from flying parts and fluids Safety footwear for protection against heavy falling objects and slipping on slippery surfaces WARNING Electrical shock hazard Work on electrical equipment may only be carried out by a qualified electrician in accordance with the safety regulations Switch OFF the electrical supply before starting work and secure against reconnection 9 2 Maintenance Plan recommendations Interval Maintenance Comments Check all connections If necessary re tighten and or replace seals Check all parameters to nominal actual values or arene If excessive restore proper parameters admissibility Every 2 months Cleaning of strainers If necessary refer to point 8 4 In case of visible damage perform a functional test General visual inspection of all components and if necessary replace the component Perform a functional test of the safety valve OPEN pie 394 Valve tone NS PENGON CME Refer to po
17. ages have been unloaded they must be stored until assem bly in accordance with the attached shipping marks Machine parts and accessories packaged in separate boxes must not be unpacked For storage the following rules apply e Dry storage Relative humidity up to 60 e Ensure that packages are not stored outdoors In addition ensure that the storage room floor is dry during storage e Keep out of direct sunlight Optimal storage temperature 15 to 25 C e Keep dust free e Avoid mechanical vibrations and damage e For long term storage of more than three months conservation activities should be taken In severe weather conditions conservation must be renewed as necessary a 6 0 Installation If substation parts or components must be removed due to limited space for transport corridors elevators small doors etc ensure that they are reassembled exactly as they were in the original place A WARNING Risk of injury Improper installation and assembly can result in serious injury and or property damage Installation and assembly work may be performed only by qualified personnel in compliance with safety regulations S NOTE The mechanical separation of substation components through sawing cutting etc of cabling and or frame parts and piping is not permitted District heating transfer stations are usually completely pre piped and wired installations on a painted steel frame All parts and components are moun
18. ard against snagging on moving machine parts Do not wear rings chains or other jewelry Protective gloves to protect the hands from friction abrasion puncture or deeper injury as well as from contact with hot surfaces 2 7 Risks associated with the substation The substation has been subjected to a risk analysis based on the design and construction of the substation and in correspondence with the current state of technology Nevertheless risks remain The substation can generate a hot stream of fluid or steam when e g a drain or air vent is opened WARNING Risk of injury Risk from liquids splashing under high pressure Wear personal protective equipment for all operations carried out on the sub Station The substation operates with high electrical voltages of up to 400 V and currents of up to 25 A A WARNING Electrical shock hazard Electrical energy can cause serious injury Damaged insulation or components can lead to serious injury or death e Switch OFF the main switch and secure against reconnection before performing any maintenance cleaning or repair Turn off the power switch when performing any work with the electrical system e Do not remove any safety devices or put out of operation The substation is supported by pneumatic components WARNING Risk of injury Risk from liquids splashing under high pressure Wear personal protective equipment for all operations carried out on the sub statio
19. ards nisk analysis rea 8 OT Rea 9 eA a eE ia ATA OM a A E E E N E N sac N A A E O I E E 9 o Cella 9 3 1 2 Dimensions and packaging cir TRI 9 32 Symbols Used INCIFCUILORGRAMN Sana 10 AO Funcuon and CONI GUAI sic 11 AE FUNC UON A E E TE E E E E A A einen 11 4 2 DSA WALL configuration possibilities Primary side sessesssseesssseesssseessseessseeesseesosseeosseeossseesnseressseeosserosseeoosseessseeossserosseressseeosserosseeossserssssesssserossee 11 4 3 DSA WALL configuration possibilities Heating side eseesesseesssseesssseessseessseeesseesssserosseeossseeonssressseessserosseeossseessseeossserosssressseeosserossseossserssseesssseeossee 12 4 4 DSA WALL configuration possibilities Domestic Hot Water side e esssesssseessseesssseessssersnseessseressseeosseesssseossseeossseeosserenssressseeosseeossserssseesssseeossee 12 45 DSA WALL modularily cca 12 5 0 Transport packaging and storage nno 13 Sl TPIS OM palets DY PR na 13 SPA ESA E E E AT PEA A I E IEE A A IEA anni 13 a P O a A E E EE T TA A E AA E ETE A E E II 14 54 O e A EE E elia 14 COE lc 14 61 TASTANATION preparation naacal 15 ol PAM CONNECCION eieaa ea Ea E EAT Ea EEAO eet E ene reer errr eee 15 ARE 2110 S EASE EEE eames eee EA E A AN O E A E A E E A E NE E N 15 Co EECa CONNEC EON e a E E E E S 15 62 Packaging NPackKINO TME SOS CANON recent 16 6 53 E EE EEAS h E E A T E A E A AT A A A ONAA I A E A A E 17 04 DAGS 1 0 ana 18 FO C ON ON iii 19 7 1
20. e During mainte nance the functionality of hand wheels or levers should be tested in terms of ease of use by opening and closing This will protect the ball plates and valve seats against dirt and limescale deposits See the manufacturer s instructions for the most common components in Annex I Heat exchanger Heat exchangers are designed for long term use Due to relatively high temperatures in particular cases lime and other deposits may appear on the inner surface In case of reduced performance the heat exchanger should be cleaned For detailed information please refer to the heat exchanger instructions Water quality To ensure maximum heat exchanger performance and lifetime fol low the Danfoss Guideline to Water Quality for Copper Brazed Plate Heat Exchanger VJ KV D3 02 or a newer version 9 4 Maintenance validation Following maintenance work but before turning on the substation please note the following e Check the tightness of all previously loosened threaded connections e Verify that all previously removed components have been reinstalled correctly e Ensure that all tools materials and other equipment used during maintenance have been removed from the work area e Clean up the work area remove any spilled substances and remove any waste from material processing e Make sure that the system and all unit safety devices are working properly again Danfoss District Energ VI IQ J1 02 DEN SMT PL Installa
21. e performed by employees of the manufacturer installers authorised by it or by a specialised installation company In any case the exist ence of a fully completed commissioning protocol see annex is a prerequisite for maintaining a substation warranty e The secondary installation should be filled including the substation and vented venting pumps are necessary e Pressurisation must be ready with the required base pressure e Desired time programmes and additional data for controller set up must be available e The substation may only be put into operation when an authorised specialist from the district heating company or an expert from an installation company or an authorised specialist from the commercial office has approved the correct condition of the whole system DEN SMT PL_ I Installation Guide DSA WALL 7 4 Requirements for commissioning The electronic controller is preset in the factory in accordance with the data available to us After commissioning the controller auto matically performs a self test displays a default system code and automatically goes into operating mode Now a precise setting can be made in accordance with the controller manufacturer s manual can be made The manual is attached to the station 7 5 Fault and Shutdown The heating controller control valve actuator and heating pump are connected to mains voltage A Therefore Immediately turn off the main switch or unplug the power cable
22. ective actuator or thermostat RePlace defective actuator or thermostat Contact district heating utility Adjust flow limiter settings Balancing valve not set correctly Set designated flow Check dimensioning Extend enlarge substation Contact our sales staff Substation is sized incorrectly usually primary control valve is calculate dimensions for new responsible too big or too small control valve and replace old one Reduced flow through heat Read heat exchanger user s Clean replace heat exchanger exchanger manual Outdoor sensor is placed incor Read electronic controller user s Place outdoor sensor correctly rectly manual Take the system out of operation Missing voltage supply gt actua and close valve manually After tor is in open position providing power supply go back into standard mode Incorrect controller setting s Check and correct setting s Read controller s user manual Check values and if necessary Defective sensor Replace the sensor replace sensor Defective control valve Clean or replace valve Defective actuator or thermostat Replace actuator thermostat ecg Ju i Hermostat capillary defective Circulation pump is not running Increase or decrease pump speed Set designated flow at the intended speed replace pump DEN SMT PL VI IQ J1 02 Danfoss District Enero Secondary water tem perature is too high Donfs Installation Guide DSA WALL Correct settings e
23. egulations at the time the contract is concluded shall apply S NOTE These operating instructions should be read carefully before starting work on or with the substation and in particular before commission ing The manufacturer will not accept claimsfor damage or faults arising from non compliance with these operating instructions DEN SMT PL DEN SMT PL Installation Guide DSA WALL 1 5 Copyright Protection Operating instructions must be kept confidential These are intend ed exclusively for the persons employed on and with the substation Transfer of the operating instructions to third parties without writ ten approval of the manufacturer is prohibited If such approval is required please contact Danfoss directly This document and any others delivered with the substation are pro tected by copyright Copies whether whole or in part are allowed only with the permission of the manufacturer Violators will be liable to prosecution All other rights reserved 1 6 Spare parts Use only original spare parts from the manufacturer The use of non approved spare parts will invalidate any guarantees or service compensation and liability claims against the manufacturer or its agents distributors and representatives 1 7 Substation disassembly Clean and sort the substation parts and components in compliance with applicable health and safety and environmental regulations Before starting disassembly e Switch the unit OFF
24. embly has been manufactured according to the explicit specifications of the customer who is responsible for com pliance with the parameters specified and the selection of qualified operating personnel The substation is equipped with the following warning on which the key residual risks are point out again DEN SMT PL VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL 3 0 Technical data 3 1 Technical information Main substation information can be found on the CE label as well as in documents contained in the appendices circuit and electrical diagram data sheet 3 1 1 CE label The CE label is attached to the substation It contains the following information e Manufacturer e Serial no e Production date year calendar week e Substation code Type Name e Applications e Category according to PED directive e Power supply voltage e PN class e Minimum and maximum operating temperatures e Maximum allowed pressure by maximum operating temperature Capacity e Temperature programme e Heat exchanger type e Volumetric flow e Pressure drop inside heat exchanger 3 1 2 Dimensions and packaging The DSA WALL compact district heating substation is delivered by Euro pallet The maximum substation delivery dimensions are 1200 x 800 x 600 mm The range of standard product dimensions and weights can be found in the technical datasheet The DSA WALL is manufactured upon customer request its dimen
25. en subjected to their manufacturers risk assessments Declarations of conformity with current European and national legislation have been made by the manufacturers of the components Declarations of conformity and operation main tenance and repair instructions for the individual components are integral parts of the substation documentation 1 3 Explanation of symbols Important security and device related information in these oper ating instructions is marked by warning notices The instructions must be followed to prevent accidents personal injury or property damage WARNIN This symbol indicates a danger that may result in damage to health injury permanent physical injury or death Please follow the notes for working safely very carefully and take extreme care in these situations A WARNING Electrical hazard This symbol indicates danger from electricity Failure to follow safety procedures can result in severe injury or death This work may only be performed by a trained electrician 1 4 Liability and Warranty All information and instructions in this manual have been compiled in accordance with applicable regulations and the current status of engineering developments as well as our many years of knowledge and experience The actual scope of delivery may differ from the ex planations and graphic representations of special versions described here as a result of additional accessories order options or latest technical c
26. er draining there may still be water inside the heat ex changer and piping After releasing the heat exchanger push it back and down DEN SMT PL VI IQ J1 02 Danfoss District Energ Installation Guide DSA WALL 8 6 Service Check Safety valve and expansion vessel Locate the safety valves on the secondary side these are separate on the heating and domestic hot water circuit If the drain pipe is not connected to the safety valve connect the appropriate hose or piping in accordance with local legal regulations A WARNING Risk of injury or damage Never operate a safety valve when the outlet is directed towards you or towards electrical devices Always secure all equipment so that it will not be flooded by accident Turn the lifting handle in the direction of the arrow until you hear a click Then the valve must be closed tight S NOTE If a valve drips constantly it is very likely that impurities have built up in the seat To clean the valve seat and seal unscrew the head part Locate the connection for the expansion vessel Follow the expansion vessel servicing procedure for the relevant vessel type Danfoss District Enero VI IQ J1 02 DEN SMT PL Installation Guide DSA WALL __ 9 0 Maintnance 9 1 Safety warning In the appendix you will find a summary of the most important tech nical requirements It is recommended to hire an authorised installer A for frequent maintenance WARNING
27. filling Check vessel and pressurisation Check and adjust parameters pressure base pressure Unacceptable pressure i Defective pressure equipment or increase constant blow i Replace component s expansion vessel up of safety valve Incorrect opening pressure di Replace safety valve mension or defective safety valve ICONE ee Ting np gr Di Check correct device setting Read device user s manual ducer pressure relief controller Secondary side fluctuating sup Check control valve settings ply temperatures characteristics in particular Secondary side abruptly chang ing operating conditions Replace heat exchanger Contact customer service Check control valve settings characteristics in particular Check system settings interplay of the entire system Disconnection of system parts Closing of valves Pumps switching OFF WAlCHManiniGr Incorrect adjustment and filling Check vessel and pressurisation i Check and adjust parameters pressure base pressure Defective pressure equipment or Replace componenti s expansion vessel Incorrect opening pressure di Replace safety valve mension or defective safety valve May not be applicable for some products or product variants Pressure surges Danfoss District Energ VI IQ J1 02 DEN SMT PL Donfs Installation Guide DSA WALL Excessive noise No heat DEN SMT PL Incorrect pump setting Check correct setting Read pump manual Missing hydraulic set
28. hanges For questions please contact Danfoss directly We reserve the right to make technical changes to the product in the course of improvement of its functional properties and further development Items such as tools and equipment that may wear out during use of the device as well as auxiliary materials and supplies such as oils greases and detergents are not covered by warranty Danfoss District Enero VI IQ J1 02 Donfs The graphic illustrations in this manual are provided to better represent the issues described and are not necessarily to scale and may differ slightly from the actual design of the substation In addition to these operating instructions operating manuals for all installed components on substation must be followed The information contained therein particularly with regard to safety must be followed The instructions contained in the manufacturer s documents for security set up installation operation maintenance and disman tling and disposal of the components must be followed strictly ATTENTION This symbol indicates a risk that may result in damage to or malfunction failure of equipment if ignored S NOTE This symbol highlights tips and information that must be followed for the efficient and trouble free operation of the substation In addition the commitments agreed in the contract such as the general terms and conditions and the manufacturer s terms of deliv ery and statutory r
29. ically the local utility company is must be involved in work relating to heating connections Typically the district heating utility must be involved in work relating to primary connections Unauthorised initial start up is not allowed 7 1 Requirements for commissioning In order to commission the station the following conditions must be met e Commissioning must be approved by the district heating utilities All screws and fasteners must be tightened e Substation piping must be connected properly All impurities and leftover installation materials must be removed from the piping e The station must be properly connected to electricity the supply voltage must be applied to the main switch or circuit breaker e The primary connection must be applied to the primary shut off valves within the necessary parameters 7 2 Secondary side commissioning Before commissioning check that all safety related rules and regula tions have been taken into account Working parameters for the substation s plate type must match the operating parameters of the local district heating company and the heating system Fill the secondary installation with water accord ing to the water quality rules To avoid substation damage ensure that pressure during filling does not exceed the maximum allowable working pressure Before first use the secondary side must be rinsed sufficiently by the installation company Check all connections for leaks and tightness
30. int 8 6 Perform a functional test of the electrical and elec Manually switch the pump or open and close the Every 6 months tronic components switches and so on actuator Perform an electrical test of the safety devices Temperature monitor sensors and or limiters Perform a functional and usability check of all For example open and close the shut off valves components Perform a visual inspection of substation s appear Colour rust insulation ance In case of contamination clean descale refer to point 9 3 as needed Every 12 months l Perform a visual inspection of the heat meter and OER Check legalisation period water meter Perform a visual inspection of the measuring Manometer thermometer devices Perform a visual inspection of the expansion vessels aa rope Ea EEE Control of the heat exchanger DEN SMT PL VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL 9 3 Heat exchanger maintenance The following is a list of important activities that should be performed during maintenance Additional information is included in the at tached manufacturer s instructions This abstract only provides information about the required steps It is important in any case to comply with all relevant legal and tech nical regulations and requirements pertaining to local conditions and regulations e g the home owner district heating utilities etc Fittings In general the fittings used are maintenance fre
31. iod of time i e without power in order to save energy then proceed with restart as for the first commissioning Flushing of the system is recommended DEN SMT PL VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL 8 4 Service clean strainer Before you begin cleaning perform the actions described at point 2 draining the system and check that no components will collide when removing the mesh Secure the electrical components below strainer level with a metal sheet or foil Use a suitable flat spanner to unscrew counterclockwise the cap from the strainer remove the mesh and clean it Before closing the strainer check the seal for tightness and integrity If necessary re place it A WARNING Risk of injury Even after draining there may still be water inside the strainer Danfoss District Energ VI IQ J1 02 DEN SMT PL Installation Guide DSA WALL 8 5 Service disassembly and replacement heat exchanger Before you begin any activities with the heat exchanger perform the actions described at point 2 draining the system Gently remove the EPP cover by pulling it S NOTE Seeger Circlip Ring Pliers must be used to remove the heat exchang er This tool is not provided with the substation Use a suitable flat spanner to unscrew the piping from the heat ex changer and Seeger Pliers to remove the heat exchanger from the support frame A WARNING Risk of injury Even aft
32. ire ments standard shut off valves pos 345 762 placed on the cold water and circulation pipelines can be replaced with a multi valve which can include a combination of check valve strainer and safety valve The temperature sensor pos 377 connected to the control ler makes it possible to keep the temperature at a requested level Brass threaded strainers pos 347 764 protect dirt sensitive com ponents such as the pump pos 766 optional water meter pos 349 and heat exchanger from impurities Check valves pos 351 768 prevent components from being damaging by backflow and can prevent a non hygienic situation A pressure measurement can be made by separate manometers or a multipoint measurement In addition machine thermometers or thermomanometers pos 380 769 can be used to check the water temperature The domestic hot water piping is prepared from a combination of stainless steel components and brass fittings Due to the use of high performance plate in the heat exchanger and a pipe size of up to DN32 the DSA WALL is suitable for multifamily buildings 4 5 DSA WALL modularity Besides the two circuit station the DSA WALL product group also includes a one circuit station which is suitable for heating application Each substation is a separate module and can be easily connected to other modules Frame based primary modules are prepared for connection on the left or right This solution makes it possible to fit a DSA WA
33. ity for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved Produced by Danfoss A S 11 2014
34. mergency stop switch The operator shall ensure that the emergency stop switch is installed in accordance with applicable accident prevention regulations The operator must inform operations staff about the location and opera tion of the emergency stop switch 2 9 Operators The substation may be operated and maintained only by authorised trained and instructed personnel These personnel must receive spe cial training on potential risks An instructed person is a person who has been informed of the tasks assigned to him her and the potential hazards of improper usage and if necessary who has been trained and instructed in protective equipment and actions A professional is a person who because of his her technical train ing knowledge and experience as well as his her knowledge of the relevant provisions can evaluate the work transferred to him her and recognise possible dangers If the staff do not have the knowledge required then they must be trained Responsibilities for operation and maintenance must be clearly defined and respected so that there is no unclear division of responsibilities in terms of safety 2 10 Steps to follow in the event of danger or accidents In the event of an emergency or accident the substation must be switched OFF by immediately pressing the emergency stop switch This can be done by opening the safety door or protective window equipped with safety switches that trigger the emergency stop fu
35. n DEN SMT PL VI 1Q J1 02 Protective goggles to protect the eyes from flying parts and liquid splashes Safety shoes to protect from heavy falling parts and losing traction on slippery surfaces Helmet to protect against falling or flying parts and materials Therefore e Depressurise before starting any work on the substation Do not remove or alter any safety devices or put out of service e Do not change the default settings from the values or beyond the tolerance ranges specified in the operating manual The substation has sharp edges and corners A WARNING Risk of injury Sharp edged parts and sharp edges may cause abrasion to the skin Wear protective gloves when working on the substation A WARNING Risk of burns Hot surfaces can cause serious burns For all operations carried out on the substation always wear protective gloves Components inside of the station can contain automatically moving parts pumps actuators etc The devices can be very heavy WARNING Danger of crushing During transport or lifting of the substation bruising can occur due to heavy weight The substation may include electrical com ponents engines transmissions which may also cause bruising if contacted while in operation For all operations carried out on the substation always switch the main supply OFF and wear pro tective clothing Danfoss District Enero Installation Guide DSA WALL 2 8 E
36. n from staff proven understanding of the instruction manual Modifications of any kind as well as additions or modifications to the substation are forbidden All substation security warning and operating instructions must be maintained in good legible condition Damaged labels or stickers must be replaced immediately Specified values or ranges must be strictly adhered to 2 2 Responsibility of substation operator e Operating instructions must always be stored within the immediate vicinity of the substation and must be accessible at all times for installation operation and maintenance and to cleaning staff e Operate the substation only if it is in a proper technical and safe operating condition e Check that safety devices are always kept freely accessible test them regularly Information about industrial safety is based on the European Union regulations valid at the time of manufacture of the substation The operator is obliged throughout the entire lifetime of the substa tion to conform to those safety actions designated in the current rules and regulations and to comply with those in new regulations Outside of the European Union the safety laws local rules and regulations applicable to the location where the substation oper ates must be followed 2 3 Intended use Operational safety is guaranteed only where the substation is used properly and in accordance with the instructions details in this manual A district heating substatio
37. n is used to provide heat energy from the district heating utility grid by transferring heat to customer installation systems Intended use also includes compliance with instructions for installation operation maintenance and cleaning 2 4 Possible misuse A WARNING Hazard from improper use Any use of the substation apart from its intended use may lead to dangerous situations 2 5 Safety work Hazards to persons and or the system can be prevented by fol lowing the safety at work instructions Danfoss District Enero VI IQ J1 02 S NOTE For modification and extension activities always consult with the substation manufacturer In addition to the safety instructions in this manual and for sub station safety in general accident prevention and environmental protection regulations must be observed and followed The opera tor and authorised personnel are responsible for the trouble free operation of the substation as well as for the clear definition of re sponsibilities for installation operation maintenance and cleaning of the substation There must be no deviation from the information in the operating instructions The operator shall also ensure that e Any further risks are identified in an assessment of risks arising from the special working conditions at the operations site e That any additional work and safety instructions resulting from the risk assessment of activities performed on the substation are
38. nal heat exchangers it en sures better heat transfer and reduced pressure loss This results in a longer system life span and better reliability DEION DB ide di aldo VI IQ J1 02 Donfs In the secondary circuit circulating pump transfers heated water to the heating surfaces of other installations e g ventilation equip ment drinking water or heating installations etc Several heating circuit control valves are installed to allow adjustment of secondary temperatures on specific heating circuits If a controller with weather compensation is installed at the substation it has the following es sential functions e Measures flow temperature on the secondary side and outside temperature e Changes the stroke of the control valve on the primary side so that it conforms to the required secondary temperature e Limits the return temperature on the primary side to a value preset in the controller e Switches the secondary side circulating pump s on and off as necessary and ensures frost protection If required special functions are available according to needs and de signs Refer to the instruction manual of the controller manufacturer All systems are offered upon request and manufactured in keeping with the customer s special operating conditions Due to the many different product variations the circuit diagram may differ from that presented below Figure 3 DSA WALL Primary side configuration DEN SMT PL_ 9111 I
39. nc tion when opened Safety devices with an emergency stop function are only to be used in appropriate situations DEION DB ide di aldo VI IQ J1 02 The substation may only be operated and maintained by persons who can be expected to reliably run their work Any operation that affects the safety of persons or the substation environment must be avoided Persons under the influence of drugs alcohol or medication that affects responsiveness must not perform any work with or on the substation When selecting personnel the relevant country s youth employment protection regulations as well as any occupation specific regulations that may exist must be followed with respect to minimum age The operator must ensure that no unauthorised persons are work ing on or with the substation Unauthorised persons such as visi tors guest etc must not come into contact with the substation You must maintain a reasonable safety distance The user is obliged to immediately report any issues which occur in the substation and may affect the safety of the operator Safety equipment must not be used for normal shutdown of the substation Always be prepared for accidents or fire Keep first aid equipment first aid kit eye wash etc and a fire extinguisher within the substation area Personnel must be trained in the handling and location of safety devices accident procedures first aid and rescue equipment This results in the prevention of dangero
40. nstallation Guide DSA WALL 4 3 DSAWALL configuration possibilities Heating side The heating side of the DSA WALL offers piping of up to DN40 which allows the transfer of medium capacity on a wall mounted construc tion The base configuration includes e threaded shut off valves pos 164 192 e strainer pos 169 e pump pos 171 e pocket sensor pos 181 safety valve pos 183 A visual parameter such as temperature can be measured with a ther mometer or a thermomanometer pos 165 191 and pressure can be measured with a highaccuracy class manometer pos 168 187 Pressure measurements can also be made by way of a multipoint measurement using a soldered copper pipe The safety valve pos 183 can be located either on the supply 4 or the return 5 pipe in accordance with local legal regulations and the calculation method With an optional drain valve pos 175 it is possible to drain the sec ondary installation before performing maintenance or servicing For additional safety it is possible to order a built in safety thermostat pos 182 which ensures the highest level of security Depending on local legal regulations the DSA WALL offers a refilling line connection from the primary side or the hot water pipeline 4 4 DSAWALL configuration possibilities Domestic Hot Water side The basic domestic hot water configuration includes shut off valves pos 387 on the hot water pipe Depending on customer requ
41. ry Initiate a com plaint Claim defects that are not visible immediately after detect ing as claims for damages can be made only within the applicable complaint periods DEION DB ide di aldo VI IQ J1 02 WARNING Danger to life When lifting panning and lowering there is a risk of serious personal injury and damage from falling parts Never stand under suspended loads WARNING Danger to life When lifting panning or lowering there is a risk of serious personal injury and damage from falling parts Never stand under suspended loads DEN SMT PL Installation Guide DSA WALL 5 3 Packaging Substations are delivered with different types of packaging Pack aging materials are primarily of wood cardboard and plastics foil foams Strapping is in addition Packaging material may also include materials added to packages for moisture or frost protection e g silica gel bags antifreeze etc If no agreement has been made re garding the return of packaging material the packaging material remains with the customer A WARNING Unpaid delivered transport packaging will not be accepted by us Our transport packaging can be returned to us free of delivery charges at A Packaging materials must be utilised in an environmentally friendly way and in accordance with the relevant waste disposal regulations Danfoss Poland Sp z 0 0 Tuchom ul T czowa 46 80 209 Chwaszczyno 5 4 Storage After pack
42. tation see instructions for heating circuit Air in the system Vent the installation thoroughly The pump rotation speed is set too low VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL 10 1 Safety A WARNING Risk of injury Improper troubleshooting can lead to serious personal injury and or property damage Therefore troubleshooting of malfunctions may be performed only by trained and authorised personnel 10 2 Steps to take in the event of malfunction In summary e Immediately stop the substation using the emergency stop function when there are faults that can cause immediate danger to persons property and or operational security e Switch OFF the substation when there are faults that do not pose such dangers Additionally interrupt the power supply to the unit and secure against reconnection e Immediately inform superior about fault e Request authorised personnel to determine the nature and extent of the disorder and the cause of the malfunction and to repair the malfunction 11 0 Spare parts Use only original spare parts from the manufacturer WARNING Incorrect or faulty spare parts and or components from other manufacturers may cause serious damage to and or malfunction or failure of the substation Using non approved spare parts will invalidate all warranty service damage and or liability claims against the manufacturer or its agents distributors and representatives
43. tation with local district heating supply companies if the installation is connected to such network The primary supply and return must be connected to the designated devices or the substa tion shut off valves The commissioning of primary side connections to the district heat ing network is usually done by the relevant local district heating company e If substation is delivered ordered without a strainer on primary inlet site make sure it is separately mounted before substation is connected to the network to protect all components from potential damage If this requirement is not respected it may result in loss of warranty After installation of substation to the network it is required to splash pipes between main strainer and substation to remove any potential particles 6 1 2 Secondary connection A specialised installation company connects the secondary installa tion to the substation s designated shut off valve 6 1 3 Electrical connection Only a qualified electrician approved by a responsible electric utilities company may carry out the electrical installation of the substation in compliance with all applicable rules and regulations The substation is completely wired and tested at the factory by default If an outdoor sensor for substation control is ordered this is enclosed in the loose component box and should be installed as far as this is possible on the north side of the building Electric and sensor cables
44. ted or fixed to the frame External substation connections are marked with easily understandable labels stickers Integrated adjustable feet are used to compensate for uneven ground Pipe connections and fitting connections can be prepared as e Welding ends Secure durability of ground based on total weight of equipment including water content Take care that each connection is stress free after assembly the substation cannot be used as a fixed point S NOTE The use of pipe wrenches for nuts and bolts is not permitted Only use a suitable spanner DEN SMT PL VI IQ J1 02 e Flanged connections acc EN 1092 e Threaded connections acc DIN 2999 internal external e Threaded connections acc DIN 2993 ISO 228 external Danfoss District Enero Installation Guide DSA WALL 6 1 Installation preparation Substation installation should be carried out on a clean flat surface Stand alone substations usually come with integrated adjustable feet which can compensate for uneven ground If not pre assembled these are supplied as loose components in an accessory pack and can be screwed into the appropriate nuts in the bottom area of the frame Then adjust the station horizontally details in 6 3 The DSA WALL must be assembled and mounted onto the wall with the appropriate screws and dowels found in the loose components box 6 1 1 Primary connection The primary connection must be made by qualified personnel in consul
45. teel vessels 5 1 Transport of pallets by forklift Packages mounted on pallets can be transported by forklift under the following conditions e The forklift must be designated according to the weight of the handling units e Operator must be authorised licensed to operate the forklift Procedure 1 Drive the forklift with the forks between or under the tie bars of the pallet 2 Drive the forks far enough to protrude from the opposite side of the pallet 3 Make sure that the centre of gravity is between the forks and cannot tilt 4 Lift the package and start transport Follow safety rules e Use only approved lifting gear and lifting equipment with adequate load capacity e Only attach the substation to suitable anchor points and not to protruding machine parts or eyelet components Ensure the secure fit of the slings e Ropes and belts must be equipped with a safety hook Do not use damaged or frayed cables Do not fasten ropes or straps to sharp edges and corners and do not knot or twist Always consider the centre of gravity before handling e Never lift pan or lower loads over people e Always transport the substation with the utmost care and caution 5 2 Transport inspection Immediately after delivery check for completeness and any trans portation damage In case of externally visible transport damage do not accept delivery or accept only conditionally Note the extent of damage on the transport documents bill of delive
46. temperature measurements usually pressure gauge and thermometer are assembled if it is needed according to the specification of District Heating Utility on primary flow and or return pipe The control valve with actuator is located on the primary return pipe Cooled heating water flows back through the primary return piping to the district heating network 4 2 DSA WALL configuration possibilities Primary Side Due to the different market requirements the basic configuration includes only control valves with actuators located on the primary return piping pos 42 84 In addition a substation may be ordered with a combination of shut off valves sensors and drain valve accord ing to specific customer request Threaded shut off valves pos 25 45 74 85 with composite gasket can withstand the most demanding district heating parameters The DSA WALL is prepared for two types of sensors pos 41 83 surface or immersion The optional drain valve pos 49 located on the return piping 2 allows water to be drained for maintenance or servicing purposes Due to its fixed dimensions and standardised connections it is easy to connect an additional primary module or prepare installations well before substation delivery The composite flat gasket allows for a durable and leakage free connection The primary side can be prepared up to DN32 The DSA WALL configuration is based on micro plate heat exchanger technology In comparison with traditio
47. tion Guide DSA WALL __10 0 Troubleshooting Electrical equipment which has failed and mechanical pneumatic and hydraulic components must be serviced only by qualified personnel with the relevant specialties Information about all failures which cannot be eliminated through the following actions is to be forwarded to the substation manufacturer or to service partners authorised by Danfoss Check if main switch is turn on Lack of voltage supply Check cabling Check fuses Contact authorised personnel or electric utility Lack of heat supply Check and secure operating No primary system pressure conditions Primary differential pressure is Pressure too low Flow Heating water flow is too flow Differential pressure Incorrect controller setting s Check and correct settings Read controller s user s manual Defective controller Replace controller Contact customer service Closed shut off valve s Open shut off valves a Cl Defective sensor Replace the sensor DAS sane ecee any replace sensor Circulation pump s defective or Switch ON replace circulation not switched ON pump s Secondary water tem Heating pump s defective or not Switch ON replace heating perature is too low switched ON pump s Adjust balancing valve to correct value Circulation pump is not running Increase or decrease pump speed Set designated flow at the intended speed replace pump Defective control valve Clean or replace valve Def
48. up ala siena a Read device user s manual Check flow and hydraulic setup Flow noise e g in pipes Check if extraneous objects are Rinse the substation inside piping ui Check functionality of non return Loose parts inside components valves spring Check dimensioning Extend enlarge substation Contact our sales staff calculate dimensions for new responsible control valve and replace old one System incorrectly dimensioned e g primary control valve is too small Defective pump impeller Replace pump 5 Filter in district heating meter Clean the filter after consulting clogged district heating plant Defective differential pressure Check functionality of differential Clean valve seat if required controller pressure controller replace sensor Defective actuator or thermostat a A SUSINO thermostat Check the functions of the con trol valve clean valve housing if required Check that the controller setting is correct see separate instruc Automatic controls incorrectly tions Check the power supply set or defective possible power Temporary set the actuator to failure manual control see the instructions for heating circuit manual control Defective control valve or pos sibly dirt in the valve housing Check that the pump is receiving power and that it runs Make sure that there is no air in the pump housing see pump manual Pump out of operation Set the pump at a higher speed of ro
49. us situations and ensures the best possible assistance in the event of an accident DEN SMT PL Installation Guide DSA WALL 2 11 Residual hazards risk analysis Manual operation of the Due to construction provide shut off valves and fittings enough space for ergonomic must be safe operation Shut off valves and fittings Crushing during in the station manual operation Thermal insulation of pipes and components signs at the station warnings in the operating instructions Entire station Electric shock Safe contact with the station Fulfilment of contact protection Piping and components Burning when touched Safe contact at the station in the station Protection according to local Splashing of liquids and or Controlled reduction of excess standards or legal regulations steam at high pressure pressure in case of fault e g DIN 4747 T1 or DIN EN 12828 Entire station Overheating the station or transmitting heat to Entire station a connected system at a temperature above what is permissible Protection according to local Turning off the heat supply standards or legal regulations in case of failure e g DIN 4747 T1 or DIN EN 12828 During operation residual risk can be limited to the following al phabetic values according to the Suva Assessment and Reduction of risks from machines risk assessment B5 C4 D3 E2 The residual potential for danger arises from failure to comply with the above instructions The ass
50. ve Expansion valve PE Pressure emitter ME Flow controller Differential pressure Heat meter gt controller Differential pressure Flow meter DX X Electromagnetic valve controller flow control Thermometer Differentia pressure controller flow limit Plate heat exchanger Domestic Cold Water Heating Supply District Heating Supply Manometer Safety valve Tube and shell heat exchanger eR Seana i lele DEN SMT PL VI IQ J1 02 Danfoss District Enero Installation Guide DSA WALL 4 0 Function and configuration 4 1 Function The DSA WALL is an indirect compact substation where heat trans fer from the district heating network to a secondary installation is realised via plate heat exchangers This solution ensures hydraulic system separation The basic idea of heat transfer in a compact substation is connect ing the primary side of the piping to the district heating company s network which supplies hot water within the appropriate parameters such as for pressure and temperature and the secondary piping to the customer s installation on the other side Network parameters may vary depending on the season and may be higher during the winter season and lower during the warmer months Primary me dium flow normally through shut off valve and strainer In addition for pressure and
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