Danfoss EvoFlat VX-F Stainless Steel Distribution Systems Installation Guide

Danfoss EvoFlat VX-F Stainless Steel Distribution Systems

Instructions

Please read these instructions carefully before installing and com-missioning this unit. The manufacturer accepts no liability for loss or damage resulting from failure to comply with these instructions for use. Read and follow these instructions carefully to prevent the risk of physical injury and/or damage to property. Exceeding the recommended operating parameters appreciably increases the risk of personal injury and/or damage to property.
Installation, commissioning and maintenance must be carried out by qualified and authorised personnel (both plumbing and electri-cal work).
Once the system has been installed and is operating, there is normally no need to alter the settings or other functions. The distribution sys-tem unit is very reliable and easy to operate.

Heat source
The distribution system is primarily designed for connection to dis-trict heating. Alternative energy sources can be used if the operating conditions are equivalent to district heating at all times.

Application
The Danfoss stainless steel distribution systems are prefabricated solu-tions for floor heating, which can be installed separately or be imple-mented with the Danfoss flat station range, in connection with a boiler or as an extension of an existing heating system.

Choise of materials
Only use materials that comply with local regulations.

Storage

Before installation, the unit(s) must be stored in a dry, heated (i.e. frostfree) room.
(Relative humidity max. 80 % and storage temp. 5 °C to 70 °C). The units must not be stacked higher than the limit at the factory. Units supplied in cardboard packaging must be lifted using the han-dles incorporated in the packaging. Units must be placed on pallets for transport/moving across large distances.
As far as possible, do not lift the unit by the pipes.
Retighten ALL pipe connections after transport/moving.

Disposal

Dispose of the packaging in accordance with the local regulations for disposal of used packaging materials. The unit is made of materials that cannot be disposed of together with household waste.
Close all energy sources and disconnect all connection pipes. Dis-connect and dismantle the product for disposal in accordance with the applicable local regulations for the disposal of the individual components.

Connection
It must be possible to cut off all energy sources to the system – includ-ing electrical connections – at all times.

Potential equalization/grounding
Potential equalization is an electrical equalizer connection to secure against user contact with dangerous voltage, which may occur for example between two piping systems. Potential equalization reduces corrosion in heat exchangers, water heaters, district heating units and plumbing installations. Equalization of potentials should be effected according to local regulations.

Warning! Hot surfaces
Parts of the unit may be very hot and can cause burn injuries.
Be very careful when you are in the immediate vicinity of the unit

Emergencies
In the event of fire, leaks or other hazards, immediately shut off all sources of energy to the unit, if possible, and call for appropriate assistance.
If the domestic hot water is discoloured or malodorous, shut off all ball valves on the unit notify all users and call for professional as-sistance without delay.

Warning about damage during transport

On reception of the unit, and before installing it, check for any evi-dence of damage during transport.
The unit must be handled and moved with the greatest care and attention.

NB! – Tightening of connections

Before filling the unit with water, ALL pipe connections MUST be retightened, as vibrations during transport may have caused leaks. Once the unit has been filled and the system is hot, ALL pipe connec-tions MUST be retightened once more. DO NOT OVERTIGHTEN THE PIPE CONNECTIONS.

General

The installation, connection and maintenance of the system must be performed by qualified and authorised personnel. Installation must always be performed in accordance with the applicable legislation and in compliance with these instructions.
The system must be installed so that it is freely accessible and can be maintained without unnecessary disruption. Lift the unit by its mounting plate/rear section (to maximum extent do not lift the unit by the pipes) and secure it to a solid wall or in the recess box using 4 expansion bolts or the like positioned in the two bore holes in the mounting plate. It is recommended that at least two people are involved in the installation.
Before commissioning, rinse all the pipes in the household piping system thoroughly to remove any impurities, and check and clean the dirt strainers in the unit.

Test and connections

Before filling the system with water, retighten all the pipe connections because vibrations and shocks during transport and handling may have caused leaks. Once the system has been filled with water, tighten all the pipe connections once more before performing pressure test for leaks. After heating of the system, check all the connections and retighten if necessary.
Please note that the connections may feature EPDM rubber gaskets! Therefore, it is important that you DO NOT OVERTIGHTEN the union nuts. Overtightening may result in leaks.
Leaks caused by overtightening or failure to retighten connections are not covered by the warranty.

• The Danfoss stainless steel distribution systems are prefabricated solu-tions for floor heating, which can be installed separately or be imple-mented with the Danfoss flat station range, in connection with a boiler or as an extension of an existing heating system.
• These solutions make it easier for the installer to order a ready-made plug & play construction for mounting of distribution pipes for the building section.
• The systems are available as standard solutions with 2 to 12 connec-tions and include manual air vent and drain valve.
• In addition the solutions include a flow meter to maintain the desig-nated flow rate.
• The solution SGC is fitted with an Icon™ master controller 230V and thermo-actuators TWA NC for control of the floor heating system.
• The distribution systems are used as built-in variants with a recess box, or as on the wall mounted variants.
• Recess boxes for built-in variants are available in five sizes H910/W610/D150 mm, H910/W690/D150 mm, H1350/W610/D150, H1350/W690/D150 and H1350/W850/D150 mm. Width 610 mm for distribution systems with up to 9 connections, width 690 mm for distribution sys-tems with up to 10 connections and width 850 mm for distribution systems with up to 12 connections.
• A mounting rail with ball valves for easy mounting in recess box or on the wall is available as an option.

Flexible solutions
The Danfoss distribution systems are prepared for implementation with the Danfoss flat station EvoFlat VX-F.

Type SG:

Distribution system for floor heating without shunt, with flow meter. This variant is available with 2 to 12 connections.
Please note that the controller and actuators are pre-wired but deliv-ered in a separate box and mounted in the building site.

Type SGC:

Distribution system for floor heating without shunt, with flow meter and with Icon™ floor heating controller 230 V and thermoactuators TWA NC as standard. This variant is available with 2 to 12 connections.

Mounting rail set with ball valves available as a pre-assembled acces-sory set.

PRODUCT INTRODUCTION

Typ SGC fur VX-F, mit 2 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0982
Typ SGC fur VX-F, mit 3 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0983
Typ SGC fur VX-F, mit 4 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0984
Typ SGC fur VX-F, mit 5 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0985
Typ SGC fur VX-F, mit 6 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0986
Typ SGC fur VX-F, mit 7 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0987
Typ SGC fur VX-F, mit 8 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0988
Typ SGC fur VX-F, mit 9 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0989
Typ SGC fur VX-F, mit 10 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0990
Typ SGC fur VX-F, mit 11 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0991
Typ SGC fur VX-F, mit 12 Heizkreisen, Durchflussmesser, Icon™ 230 V, TWA-NC 230V| 145H0992
Unterputzkasten| Bestell-Nr.
---|---
Unterputzkasten H 910 × B 610 × T 150 mm, einschl. Montageshiene| 145H4900
Tür + Rahmen für Unterputzkasten 145H4900, H 910 × B 610 mm| 145H4901
Unterputzkasten H 910 × B 690 × T 150 mm, einschl. Montageshiene| 145H4902
Tür + Rahmen für Unterputzkasten 145H4902, H 910 × B 690 mm| 145H4903
Unterputzkasten H 1350 × B 610 × T 150 mm, einschl. Montageshiene| 145H4904
Tür + Rahmen für Unterputzkasten 145H4904, H 1350 × B 610 mm| 145H4905
Unterputzkasten H 1350 × B 690 × T 150 mm| 145H4906
Tür für Unterputzkasten 145H4906, H 1350 × B 690 mm| 145H4907
Unterputzkasten H 1350 × B 850 × T 150 mm| 145H4908
Tür für Unterputzkasten 145H4908, H 1350 × B 850 mm×| 145H4909
Basic type| Code No.
---|---
Distribution unit SG VX-F, 2 conn.| 145H0782
Distribution unit SG VX-F, 3 conn.| 145H0783
Distribution unit SG VX-F, 4 conn.| 145H0784
Distribution unit SG VX-F, 5 conn.| 145H0785
Distribution unit SG VX-F, 6 conn.| 145H0786
Distribution unit SG VX-F, 7 conn.| 145H0787
Distribution unit SG VX-F, 8 conn.| 145H0788
Distribution unit SG VX-F, 9 conn.| 145H0789
Distribution unit SG VX-F, 10 conn.| 145H0790
Distribution unit SG VX-F, 11 conn.| 145H0791
Distribution unit SG VX-F, 12 conn.| 145H0792
Distribution unit SGC VX-F, 2 conn. TWA| 145H0982
Distribution unit SGC VX-F, 3 conn. TWA| 145H0983
Distribution unit SGC VX-F, 4 conn. TWA| 145H0984
Distribution unit SGC VX-F, 5 conn. TWA| 145H0985
Distribution unit SGC VX-F, 6 conn. TWA| 145H0986
Distribution unit SGC VX-F, 7 conn. TWA| 145H0987
Distribution unit SGC VX-F, 8 conn. TWA| 145H0988
Distribution unit SGC VX-F, 9 conn. TWA| 145H0989
Distribution unit SGC VX-F, 10 conn. TWA| 145H0990
Distribution unit SGC VX-F, 11 conn. TWA| 145H0991
Distribution unit SGC VX-F, 12 conn. TWA| 145H0992
Recess boxes| Code No
---|---
Recess box H 910 × W 610 × D 150 mm, with mounting rail| 145H4900
Door for recess box 145H4900, H 910 × W 610 mm| 145H4901
Recess box H 910 × W 690 × D 150 mm, with mounting rail| 145H4902
Door for recess box 145H4902, H 910 × W 690 mm| 145H4903
Recess box H 1350 × W 610 × D 150 mm| 145H4904
Door for recess box 145H4904, H 1350 × W 610 mm| 145H4905
Recess box H 1350 × W 690 × D 150 mm| 145H4906
Door for recess box 145H4906, H 1350 × W 690 mm| 145H4907
Recess box H 1350 × W 850 × D 150 mm| 145H4908
Door for recess box 145H4908, H 1350 × W 850 mm| 145H4909

MAIN COMPONENTS & CONNECTION

• Air vent
• Drain valve
• Danfoss Icon™ controller
• Manifold w. 2-12 connecting pieces 90A. Thermo-actuator Danfoss TWA NC

Option:
Mounting rail set with 76 mm ball valves — Code No. 145H3938.

The distributors fits on the back plate of the recess boxes and also be mounted on the wall.

Recess boxes for built-in variants are available in three sizes:

• 2-9 circuits fits the:
  145H4900: Recess box H1350/W610/D150 mm

• 10 circuits fits the:
  145H4902: Recess box H1350/W690/D150 mm

• 11-12 circuits fits the:
  145H4908: Recess box H1350/W850/D150 mm

Mounting

Connect the distribution system to the household piping in accordance with the labelling on the unit and/or in accordance with the instructions in this manual.

Step 1
Recess box is built into the wall

Step 2
Installer connects the household pipes to mounting rail: DCW inlet, DHW, DCW outlet, DH supply, DH return (except floor heating) and insulates the pipes.
When installing, please ensure that there is enough space for pipe connection.

Step 3

• Mount distribution unit into position with 4 M8 nuts and connect floor heating of the distribution unit pipes to ball valves on mounting rail. Mount underfloor heating pipes to the manifolds.
• Pre-set each manifold loop based on the instructions on page 16 and then mount controller and actuators, which are delivered in a separate box. Mount underfloor heating pipes to the manifolds.
• Pre-set each manifold loop based on the instructions on page 16 and then mount controller and actuators, which are delivered in a separate box.

Step 4
Substation is placed in the recess box and connected to the 7 ball valves and fixed to the recess box with 2 M8 nuts and 2 washers M8x30 mm

Step 5
Mount the white frame after having painted the wall or mounted tiles, if necessary

Step 6
Mount door

Manifold with connecting pieces, with flow meter
Flow rate can be adjusted by turning the flowmeter. Please see enclosed pictures

CONTROL – FLOOR HEATING

• The distribution system SGC is provided with Icon™ controller 230 V as well as thermo-actuators TWA NC in accordance with the number of heating circuits.
• Please note that the controller and actuators are pre-wired but delivered in a separate box and mounted in the building site.
• Thereby connection to an electronic programmable room thermostat is enabled.
• Together with the room thermostat the TWA is used for ON / OF control of the system.
• Electrical wiring between thermo-actuator Danfoss TWA and controller is made on factory.
• Further wiring must be made on site.

Electrical connection

• The electrical connection of the substation must be performed by aqualified and authorised electrician in compliance with all applicable rules and regulations.
• The station should be connected to a 230 V AC power supply.
• The power supply / connection must be carried out in accordance with the applicable regulations and instructions

Wiring diagram

MAINTENANCE

Maintenance work
Is only to be carried out by qualified and authorised personnel.

Inspection

The water heater should be checked regularly by authorised personnel.
Any necessary maintenance must be performed in accordance with the instructions in this manual and other sets of instructions.
Measures after maintenance work

After maintenance work and before commissioning:

• Check that all screwed connections are tight.
• Check that all safety features, covers, that were removed, have been replaced properly.
• Clean the working area and remove any spilled materials.
• Clear all tools, materials and other equipment from the working area.
• Connect to energy supply and check for leaks.
• Vent the system.
• Carry out any necessary adjustment again.
• Make sure that all safety features on the device and the system work properly.

COMMISSIONING CERTIFICATE

• The unit is the direct link between the district heating supply network and the household piping system. All supply pipes and the pipes in the household piping system must be checked and rinsed before commissioning. Once the system has been filled with water, all pipe connections must be retightened before performing pressure test for leaks. The dirt strainers must be cleaned and the unit must be adjusted in accordance with the instructions in this manual.
• It is important to comply with all technical regulations and the applicable legislation in every respect.
• Installation and commissioning must only be performed by trained, authorised personnel.
• The unit is checked in the factory for leaks before delivery. Leaks are however possible due to vibrations caused by transport, hand-ling and heating of the system and therefore it is important to check all connections and to retighten if necessarys before commissioning.
• Please note that the connections may feature EPDM gaskets! Therefore it is important that you DO NOT OVER-TIGHTEN the connections.
• Over-tightening may result in leaks. Leaks caused by ove-rtightening or failure to retighten connections are not covered by the warranty
• This unit has been retightened, adjusted and commissioned

CONNECTIONS OVERVIEW

For distributions systems with more than 8 floor heating circuits

Danfoss A/S Climate Solutions
danfoss.com
+45 7488 2222
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