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Installation Guide

DSA 2 MAXI Substation

1.0 Content
1.0 Content ....................................................................................................................................................................................................................................1
2.0 Safety notes ..............................................................................................................................................................................................................................2
3.0 System overview .....................................................................................................................................................................................................................2
3.1 General about district heating substations..............................................................................................................................................................2
3.2 DSA 2 MAXI Substation....................................................................................................................................................................................................2
3.3 DSA 2 MAXI - example circuit diagram.......................................................................................................................................................................3
3.4 Electrical circuit diagrams...............................................................................................................................................................................................4
4.0 Visible components in the substation ............................................................................................................................................................................8
5.0 Installation and start-up - Step by step ..........................................................................................................................................................................8
5.1 Removing the cover panels............................................................................................................................................................................................8
5.2 Protective cardboard cover............................................................................................................................................................................................9
5.3 Removing the substation from the pallet.................................................................................................................................................................9
5.4 Moving substation to the installation place............................................................................................................................................................9
5.5 Installation place............................................................................................................................................................................................................. 10
5.6 Height adjustment......................................................................................................................................................................................................... 11
5.7 Pipe connections............................................................................................................................................................................................................ 11
5.7.1 Connection directions...................................................................................................................................................................................... 11
5.7.2 Dimensions for the pipe connections.......................................................................................................................................................... 12
5.8 Electrification................................................................................................................................................................................................................... 13
5.9 Controller settings.......................................................................................................................................................................................................... 13
5.9.1 Controller display and symbols...................................................................................................................................................................... 14
5.9.2 Operating the controller................................................................................................................................................................................... 14
5.9.3 Setting the date and time................................................................................................................................................................................. 15
5.9.4 Setting the heat curve....................................................................................................................................................................................... 16
5.9.5 Setting up limitations for flow temperature.............................................................................................................................................. 17
5.9.6 Manual control..................................................................................................................................................................................................... 18
5.9.7 Commissioning with one circuit.................................................................................................................................................................... 19
5.9.8 Sensor displays..................................................................................................................................................................................................... 20
5.9.9 Alarm........................................................................................................................................................................................................................ 20
5.9.10 Changing the favourite display for the user............................................................................................................................................ 22
5.9.11 Setting the room temperature..................................................................................................................................................................... 22
5.9.12 Setting domestic hot water temperature................................................................................................................................................ 22
5.10 Basic parameters, factory settings........................................................................................................................................................................... 23
5.11 Start-up............................................................................................................................................................................................................................. 24
6.0 Trouble shooting . ................................................................................................................................................................................................................ 24
Declaration of conformity ........................................................................................................................................................................................................ 26

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2.0 Safety notes


Read the instructions carefully before installation and start-up of
the substation. Danfoss does not bear responsibility for whichever
damages of device, which have not been mounted or stored in
accordance with following instructions.
To avoid injury of persons and damages to the device, it is absolutely necessary to carefully read and observe these instructions.
Necessary assembly, start-up and maintenance work must be
performed only by qualified and authorized personnel.

Warning of hot surface


The substation has got hot surfaces which can cause skin burns.
Please be extremely cautious in close proximity of the substation.
Warning of high pressure and temperature
The maximum temperature and pressure always have to be
checked on the product data label attached to the product.
Be aware of the installations permissible system pressure and
temperature. The risk of persons getting injured and equipment
being damaged increases considerably if the recommended
permissible operating parameters are exceeded.
The substation installation is equipped with safety valves which
must always be mounted in accordance with local regulations.
Warning of transportation damage
Prior to installing substation, please make sure that the substation has not been damaged during transportation. Be extremely careful when lifting or moving big and heavy substation.

3.0 System overview


3.1 General about district heating substations
The heating system of the property is connected to the district
heating network with the substation. Hot district heating water in
the district heating network runs through the heat exchangers in
the substation. District heating water does not enter the internal
network, just heat is transferred through the heat exchanger. The
substation distributes heat into the heating and domestic hot
water circuits.

District heating
energy plant

Domestic hot water

All substation functions are controlled with an electronic controller. The outdoor temperature is measured and the controller
adjusts the flow temperature to keep the room and domestic
hot water temperatures in the desired level. With the controller
you can change the property related settings (e.g. heating curve,
temperature limits), check the temperatures, change the settings,
create schedules etc.
3.2 DSA 2 MAXI Substation
Up to a certain point DSA 2 MAXI substation is standardized.
The final selection of components and the dimensioning of the
heat exchangers is done based on the requirements given by the
customer. This Installation Guide includes general instructions.
The more detailed information of the order can be found in the
product related documentation.

DEN-SMT/PL

District heating customer

Hot district heating water


Cool district heating water
Heating

Picture Energiateollisuus ry

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3.3 DSA 2 MAXI - example circuit diagram DSA 2 MAXI-I2B032-050-A150-MD-FI


- 2 circuits, circuit diagram example
After heating connection: domestic hot water and heating

25

TE2B

SUMMER
SHUT-OFF

TE2A

TV2

TV1

TE1A

25a

26

15 13
7
TE1B

27

46

64
TE2C

18
7

46

P2

27

27

29 7
27

P1

30

30
7 29

27

6
12 15

5
66

18

7
15 13

PE2

28
Temperatures and alarms on the controller display

8
11
65

16

Limit of the prefabricated substation


Options
1 Plate heat exchanger HE
2 Plate heat exchanger DHW
5 Strainer
6 Non-return valve
7 Ball valve
8 Circulation pump HE
11 Safety valve HE
12 Safety valve DHW
13 Thermometer
15 Manometer
16 Expansion vessel
18 Drain valve
25 Electronic Controller
25a Pump control bow
26 Outdoor temperature sensor
27 Temperature sensor
28 Pressure sensor
29 Actuator
30 Control valve
46 Balancing valve
64 Circulation pump DHW
65 Service valve
66 Filling valve

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3.4 Electrical circuit diagrams


DSA 2 MAXI with ECL controller

HE pump alarm

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3.4 Electrical circuit diagrams


DSA 2 MAXI with ECL controller

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DSA 2 MAXI Substation

3.4 Electrical circuit diagrams


DSA 2 MAXI without controller

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DSA 2 MAXI Substation

3.4 Electrical circuit diagrams


DSA 2 MAXI without controller

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4.0 Visible components in the substation


1. All substation functions are controlled and the operational
values are observed with the electronic controller.

2. Dial: navigation in the menus and changes in the operating


values by following the controller display.
3. Display: all settings, temperature information and mode are
found on the graphical display. Navigation in the menus and
changes in the settings are done following the display.

4. With the installation feet you can adjust the substation position directly and on the correct height. The adjustments can be
done up to 6 cm.
5. Connections to district heating, heating and domestic hot
water networks.
6. The cover panels protect the components in the substation and
add user safety. When installing or servicing the cover panels have
to be removed.

4
3

5.0 Installation and start-up - Step by step


5.1 Removing the cover panels
The cover panels have to be removed before moving
the substation to the installation place and installing it.
The panels are removed by lifting them up.
1. First remove the white panels from the front and back.
2. After that lift the grey panels.
The cover panels can be placed back on the substation when the
substation is installed and ready for use. The panels are placed
back in the opposite order when compared with taking them
away.

1
2

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5.2 Protective cardboard cover


Leave the cardboard cover on top of the substation during moving
and installation.

5.3 Removing the substation from the pallet


The substation is screwed on the pallet with the attaching feet.
Take off the screws pointed with arrows in the picture.

5.4 Moving substation to the installation place


DSA 2 MAXI substation can be moved to the installation place using several different ways, depending on the installation place and
how to get there.
Plan the most convenient route to the installation place. Be aware
not to break floor and wall surfaces, stairs, doorposts etc.
The substation includes delicate components.

Do not hurt yourself or damage the substation when lifting it!

1. Moving with a pallet truck.

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2. Lifting with a crane


It is possible to screw up lifting eyes in the top corners after removing detachable metal round pieces from the roof. This way substation can be lifted up by using straps.

5.5 Installation place


The installation place and the pipe connections for DSA 2 MAXI
substation can be planned in beforehand due to standardized
sizing.
The upwards oriented connections enable installation e.g. close to
the wall. Since the hot surfaces are hidden underneath the cover it
is possible to use the boiler room also for some other activities.

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5.6 Height adjustment


Adjust the substation straight horizontally and on the desired
height with the help of the installation feet. By turning the adjustment feet you can make up to 6 cm adjustments.

5.7 Pipe connections


The substation is connected to the district heating network, heating, domestic hot water and circulation networks in the building
according to the connections and flow directions in the drawing.
The pipes equipped with the couplings are to be detached and
welded somewhere else but above the substation.

The connection to the district heating network can be done


only by a qualified installer accepted by the district heating
distributor.

The pipes must be mounted so that the strain caused by e.g. thermal expansion, does not harm the sustation. The pipes must be
equipped with brackets in order to prevent any torsional stress.
Prior to installation all pipes and connections have to be
cleaned and rinsed.
5.7.1 Connection directions

After cooling connection:

After cooling connection

After cooling connection

1. District heating supply


2. District heating return
3. Heating supply
4. Heating return
5. Cold water
6. Domestic hot water
7. Domestic hot water circulation

5. 6.

4.

7.

2.

1.

3.

Direct return connection

Direct connection:

Direct return connection

6.

4.

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2.

1.

5.

3.

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5.7.2 Dimensions for the pipe connections


The pipe connections are standardized and their places differ according to required capacity and the size of the substation.
In the after cooling connection both cold water and district heating return connection places are dependable on the size of the
required heat exchanger. The dimensions settle within the dimensions given in the dimensional pictures.
After cooling connection 1090 mm block
220-280

400

560 650-710

920

After cooling connection 1350 mm block


1090

100

100

460

460

370

220

300-420

250

Direct connection DN32


0
90
120

330

490

550

720 880-1000

1240 1350

470

Direct connection DN50


640

330

0 0
90
100

850 960 1090

490

640

860 950 1090

120

460

460

740

740
0 150

300

150

300

Direct connection DN65


0
90
100
120

240

470 560

730

890

1080 1190

1350

460

740

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5.8 Electrification
Since the internal electrical connections are factory made it is not
mandatory to use an electrician to connect the substation. The
contact plug is the main electrical switch in the substation.
The outdoor temperature sensor is to be installed on the north
side of the property at app. 3 m height where the outdoor temperature can be measured. There should be no ventilation window
at the close proximity to the measuring point. The other end of the
outdoor temperature sensor cable is to be connected into the control box. When connecting outdoor temperature sensor make
sure to remove the substation contact plug.
In case the length of the outdoor temperature sensor cable is not
long enough for your property, it is remmendable to change the
whole cable. This way extra joints are avoided. The minimum area
for the cable is 0.4 mm2 and the maximum length is 125 m. If you
choose to use the extra joint inspite of recommendation, protect
the jointing sleeve with the shrink cable.

20 m
20 m

Stick the contact plug into the wall socket fitted with a 10A/220V
fuse.
Wait for 10 s, turn the circulation pumps P1 (DHW) and P2 (HE) on
by pressing the operating switches.

Do not run the pumps without water.

5.9 Controller settings


Description
The ECL Comfort electronic weather compensated temperature
controllers are for use in district heating, central heating and cooling systems.
Energy savings are facilitated by weather compensation, adjustment of temperature according to schedule, optimization as well
as limitation of return temperature, flow and power. Functionalities
such as data logging and alarm functions are implemented in the
controller.
Property specific controller settings
There are some property related settings which are to be done
before starting up the substation. A complete controller instruction is included and the most important details are also enclosed
in this Installation Guide.

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5.9.1 Controller display and symbols


Symbol

Favourite display for the installer


Flow
temperature:
actual and
desired

Outdoor
temperature
Tempera- Room
tures
temperature

Return
temperature:
actual

DHW temperature

1= Heating circuit

State of
components
Primary return
temperature:
actual and
desired
Position
indicator for
navigation

Description

= DHW circuit
= Common controller

Menus with
values and
settings

System
pressure

Mode
= Manual mode
= Scheduled operation
= Comfort mode
= Saving mode
= Frost protection mode

Position indicator
Scheduled
operation
Comfort mode
Mode

Frost protection
mode
Manual mode

Display selection

Heating

Favourite display for the user


Circuits

1= Heating circuit

Date

= DHW circuit
= Common controller

Outdoor
temperature
Time
Schedule
Menus with values
and settings

Saving mode

Position indicator
for navigation
Desired room
temperature

Mode
= Scheduled operation
= Comfort mode
= Saving mode
= Frost protection mode
Display selection

DHW
Common
controller
Pump ON

Controlled components

Pumppu OFF
Actuator opens
Actuator closes

Alarm
Display selector

5.9.2 Operating the controller


The graphical monochrome display shows all temperature values, status information and is used for the setting of control parameters. Navigation, browsing and selecting is done by means
of the dial. You can navigate in the menus and change the values
by turning the dial left or right and pushing to confirm.
When a rectangle appears around the value or symbol, it is possible to do changes by turning the dial left or right.
You can always get back to your favourite display by going to the
top of the display and turning the dial so many times that Home
appears. If the dial has not been activated, the controller will after
20 min. revert to the favourite display.

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5.9.3 Setting the date and time


Set correct date and time in the controller.

Setting done
as with the
hours.

Getting out of the menu.

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Setting the
date same
way as time.

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5.9.4 Setting the heat curve


Due to different heat masses, heating system, insulation dimensions etc. it might be necessary to change the heat curve.

[oC]
150

2.2

2.6

3.0

3.5

4.0

140

Set the heat curve always according to HEVAC plans (functioning


temperature of the heating circuit). There you can find desired flow
temperatures for different outdoor temperatures.

130

1.8

120
110 1.4
100
90

1.0

80
70
60

0.6

50 0.4
40

0.3
0.2

30 0.1
20
10

Factory setting, the heat curve:

-40

-30

-20

-10

10

20

30

[oC]

Example heat curve for the floor-heating system:

Outdoor
Flow
Factory setting
Visible on the
is a typical heat temperature temperature display
C
C
curve for radiator
heating,
-30
75
(-30,75)
about 1.0
-15
60
(-15,60)
-5
50
(-5,50)
0
45
(0,45)
5
40
(5,40)
15
28
(15,28)

The heat curve


typically used
with floor-heating, about 0.4

Outdoor
temperature
C
-30
-15
-5
0
5
15

Flow
Visible on the
temperature display
C
45
(-30,45)
38
(-15,38)
34
(-5,34)
31
(0,31)
28
(5,28)
22
(5,22)

Changes in the heat curve


point by point.

Set the desired temperature.

Move to the following points.

Setting same
way as with the
previous point.

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Saving the new curve.

DSA 2 MAXI Substation


Getting out of the menu.

5.9.5 Setting up limitations for flow temperature


The flow temperature maximum limitation prevents too hot
water from going into the heating circuit, e.g. in the floor-heating
system.

Typical flow temperature


limitations in different heating
systems

When taking floor-heating system into use for the first time, the
max. limitation for flow temperature can be set e.g. at 27C. The
limitation temperature cuts off the heat curve when the temperature reaches the limit.
Later on after the concrete slab has dried the flow temperature
limitation can be raised to 45C which is typically used in the floorheating system.

Radiator heating
When taking floor-heating
system into use for the first time
(drying up concrete slab)
Floor-heating

Flow temperature
min C

max C

20

90

20

27

20

45

Typical max. limitation in the radiator heating circuit is 90C.

Setting the flow temperature


max. limitation.

Typical flow temperature max.


limitation: floor-heating 45C.

Setting the flow temperature


min. limitation.

Typical flow temperature max.


limitation: radiator heating 90C.

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The heat curve display by following the intructions in 5.9.4


Setting the heat curve.

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Typical flow temperature max.
limitation: When taking floorheating system into use for the
first time (drying up concrete
slab) 27C.

DSA 2 MAXI Substation


Example display of the heat
curve limiting temperature:
floor-heating heat curve, flow
temp. max limitation 27C.

Getting out of the menu.

The heat curve display by following the intructions in 5.9.4


Setting the heat curve.

Getting out of the menu.

Typical flow temperature min.


limitation is 20C.

5.9.6 Manual control


Manual control is typically used when installing or servicing. The
controlled components, valve, pump etc. can be controlled for
correct function.

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Do not leave the controller in Manual control mode after


finishing maintenance or service work. The normal mode is
Comfort mode
or when using schedules Scheduled
operation
.

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The valve is open.

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The valve is closed.

DSA 2 MAXI Substation


Getting away.

Changing back to Comfort mode.

5.9.7 Commissioning with one circuit


M1, P1

When commissioning the substation it might be necessary to


close a circuit, e.g. DHW circuit. The circuit in question can be
closed by forcing the control valve to close down.
The pump has to be stopped with an operating switch.

M2, P2
A1

An example: DHW circuit control


valve close down.
The valve is forced to close down.

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DHW circuit control valve and


circulation pump
Heating circuit control valve and
circulation pump
Alarm relay

STOP leaves the valve in closed


position.

Getting out of the menu.

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5.9.8 Sensor displays


Temperature and pressure information can be read on the controller display.

All values can be found by going


down the list.

Getting out of the menu.

5.9.9 Alarm
Alarm functions in the controller: pressure alarm, pump alarm
and maximum temperature alarm (temperature limiting thermostatic function). As a sign of an alarm
symbol appears on the
display.

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Alarm overview shows which


alarm is in question.

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Pressure alarm.

Max and min limitations (Alarm


high, Alarm low) have to
adapted to the building.
Low X and high X values have
been set based on the pressure
transmitter included. Do not
change!

Pump alarm. The alarm disappears from the display when the
pump is working again.

Alarm value:
1=open contact (eg. Wilo)
0= closing contact (e.g. Grundfos)

Max temperature limitation


(temperature limiting thermostatic function).

Max temperature limitation can


be used e.g. in floor-heating
system as a temperature limiting
thermostatic function.

Getting out of the menu.

In a floor-heating system the


maximum temperature limitation can be set at 50C.

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5.9.10 Changing the favourite display for the user


After having done the installation settings, it is recommendable
to change the favourite display to fit the users needs.

5.9.11 Setting the room temperature

The setting of the desired room temperature is important even


if the room temperature sensor is not connected. It has an effect
on the temperature in your property.

5.9.12 Setting domestic hot water temperature

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Changing the circuit.

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Changing the desired temperature.

Getting out of the menu.

5.10 Basic parameters, factory settings


Heating circuit
Setting

Factory setting
Room temperature and setback temp. 20 C/ 16 C
Heat curve
1.0
Limit for heating cut-out
18 C
Flow temperature min.
20 C
Flow temperature max.
90 C
Proportional band Xp
85 K
Integration time constant Tn
25 s
Running time of the motorized con120 s
trol valve
Neutral zone Nz
2K
Pressure alarm limit max
2.3
Pressure alarm limit min
0.8
Pressure alarm timeout
30 s
Pump alarm, alarm value
1
Pump alarm, timeout
Max flow temperature limitation
alarm (temperature limiting
thermostatic function)
Max flow temperature limitation
alarm, timeout TALARM

DHW circuit
Setting
DHW temperature and setback temp.
Flow temperature min.
Flow temperature max.
Proportional band Xp
Integration time constant Tn
Running time of the motorized
control valve
Neutral zone Nz
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Own setting

Comment

Note! In a floor-heating system the typical setting is 0.4.

Note! In a floor-heating system change the max. temp. to 45 C.

1= open contact (e.g. Wilo)


0= closing contact (e.g. Grundfos)

20 s
90 C

Note! In a floor-heating system change to 50 C.

60 s

Factory setting
58 C/ 55 C
45 C
65 C

Own setting

Comment

9K
13 s
15 s
3K
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5.11 Start-up
Check following point before start-up:
Check points, before start-up

Pipes are connected according to the designs.


Drainage valves are closed.
The temperature for the domestic hot water is set to +58C.
The outdoor temperature sensor is installed and connected.
Controller settings.
Connections are tightened.
Function of the safety valves is checked.

All Danfoss heat exchangers and substations have been pressure tested according to PED 97/23/EC (module H).
Make sure to give operating instructions to the users of the
substation.

Fill the substation with flow media and raise the pressure slowly to
working pressure.
When starting up the substation it should be air vented. The shutoff valve in the primary side on the return side is opened and the
shut-off valve on the supply side is closed. Air comes out by opening the air vent valve.
After that the operation of the substation must be observed. If the
substation operates according to designed parameters, it can be
taken into continuous use.

Check points, after start-up

Check temperatures
Check pressures.
Thermal expansion.
Operation of the pumps.
Flow directions.
Operation of the controls.

6.0 Trouble shooting


Problems
Heating

Room temperature is too low


i.e. flow temperature is too low.

Room temperature is too high


i.e. flow temperature is too high.

Disruption in the district heating


distribution.

Get in contact with the district heating


distributor.

The filter is clogged.

Get in contact with the district heating


distributor or with local Danfoss Sales
Company.

The heat curve is not correct.

Check the heat curve settings.

Failure in the heating circuit controls.

Get in contact with local Danfoss Sales


Company.

The circulation pump has stopped.

Turn the pump on, check e.g. heat relay.

Pressure in the heating circuit is too low.

Add water through the filling valve. Write


down the filling date.

Air in the heating circuit.

Remove air from the radiators, add water if


necessary.

Fouling in the heat exchanger.

Get in contact with local Danfoss Sales


Company.

The radiator thermostat is stuck or broken.

Get in contact with the installer.

The control valve is stuck.

Get in contact with local Danfoss Sales


Company.

The heat curve is not correct.

Check the heat curve settings.

The controller in the heating circuit is broken.


The control valve stays open/closed.

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Get in contact with local Danfoss Sales


Company.

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Installation Guide

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The controller is let in Manual control
mode.

Heating control does not work.

The controller, sensor or motorized control


valve is broken.
The control valve stays open/closed.

Set the controller to Comfort mode or


Scheduled operation mode.
Get in contact with local Danfoss Sales
Company.

The heat exchanger has an internal leakage.

Get in contact with the district heating


distributor and/or with local Danfoss Sales
Company.

The filling valve in the heating circuit leaks


into the heating circuit.

Get in contact with local Danfoss Sales


Company.

Pressure in the heating circuit is too low.

The heating circuit has too little water or the


ciruit has a leakage.

Add water into the circuit through the filling


valve. Write down the filling date. If this
happens often, get in contact with local
Danfoss Sales Company.

The return temperature in the heating circuit


is high.

The difference between district heating and


heating circuit return temperatures is big.

Get in contact with local Danfoss Sales


Company.

Water in the heating circuit increases and


excess water comes out through the safety
valve for the expansion vessel.

Problems
Domestic hot water (DHW)
DHW smells bad or is coloured.

DHW heat exchanger has an internal leakage.


DHW control does not work or the control
valve is broken.

Get in contact with local Danfoss Sales


Company.

DHW control valve is too big for the existing


conditions.
Temperature of DHW varies more than usual.

Inadequate DHW circulation.

Get in contact with the installer.

The filter is clogged.

Get in contact with the district heating


distributor.

The pressure difference is too big.


Trash in the control valve.

Get in contact with local Danfoss Sales


Company.

Other situations
Air lock in the pump.
The pump sounds strange.
The bearing in the pump is broken.
The control valve has a strong, whistling
sound.

The control valve is broken.

Stop the pump for a moment to remove the


air lock.
Get in contact with the district heating
distributor.

Pressure difference is too big in the district


heating network.

Get in contact with the district heating


distributor.

Water leaks on the floor in the boiler room or


the heat exchanger insulation is wet.

The heat exchanger has an external leakage.

Get in contact with the district heating


distributor and/or local Danfoss Sales
Company.

The pressure or the temperature of district


heating water differs significantly from the
normal.

Disruption in the district heating distribution

Get in contact with the district heating


distributor.

The outdoor temperature is not visible on


the display.

The outdoor temperature sensor has been


connected to the substation with the power
on.

Pull the substation contact plug out and


reconnect it.

Danfoss District Energy

VI.GE.K3.02

DEN-SMT/PL

25

Pressure equipment in accordance with the sound engineering practice


(Directive 97/23/EC, Article 3.3)

Pressure equipment in hazard category I


(Directive 97/23/EC, Article 9.)

Danfoss District Energy

VI.GE.K3.02

DEN-SMT/PL

26

DSA 2 MAXI Substation


Installation Guide

Declaration of conformity

Installation Guide

DSA 2 MAXI Substation

Declaration of conformity
Pressure equipment in hazard category II - III
(Directive 97/23/EC, Article 9.)
Disposal instruction:
This product should be dismantled and its components sorted, if possible, in various groups before recycling or disposal.
Always follow the local disposal regulations.
Danfoss District Energy

VI.GE.K3.02

DEN-SMT/PL

27

Installation Guide

DSA 2 MAXI Substation

Danfoss Poland Sp. z o.o. Tuchom, ul. Tczowa 46 80-209 Chwaszczyno


Tel.: +48 58 512 91 00 Fax: +48 58 512 91 05 info.den@danfoss.com www.danfoss.com

Produced by Danfoss A/S 05/2012

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