Installation, service and operating instruction Alfa Laval Mini City

Installation, service and operating instruction Alfa Laval Mini City
Heating & domestic hot water substation for apartments and single family houses
DOC-1381, 2018-02-01
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Alfa Laval Mini City
Installation, service and operating instruction
Contents
1
General information .............................................................................................................. 6
1.1
1.2
1.3
1.4
1.5
1.6
Comfort ......................................................................................................................................................6
Installation .................................................................................................................................................6
Long-term security .....................................................................................................................................6
CE-marking................................................................................................................................................6
Information about the document................................................................................................................6
General warnings ......................................................................................................................................7
2
Operating instructions.......................................................................................................... 8
2.1
2.2
General operation ......................................................................................................................................8
Safety equipment/inspection .....................................................................................................................8
3
Product overview .................................................................................................................. 9
3.1
3.2
3.3
3.4
3.5
Product overview Mini City F1 ...................................................................................................................9
Product overview Mini City F2 ................................................................................................................ 10
Product overview Mini City F3 ................................................................................................................ 11
Product overview Mini City F4 ................................................................................................................ 12
Symbols on the first fix-jig ...................................................................................................................... 13
4
Installation ........................................................................................................................... 14
4.1
4.2
4.3
4.4
4.5
4.6
4.6.1
4.7
4.7.1
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
Unpacking............................................................................................................................................... 14
Preparation ............................................................................................................................................. 14
Mounting the first fix-jig .......................................................................................................................... 14
Mounting the substation ......................................................................................................................... 14
Mounting the expansion vessel and the safety equipment .................................................................... 15
Filling up the system ............................................................................................................................... 15
Filling up the tap water circuit ............................................................................................................ 15
Filling up and bleeding the heating circuit .............................................................................................. 15
Connect to heating network .............................................................................................................. 15
Connecting the electrical equipment ...................................................................................................... 16
Mounting options .................................................................................................................................... 16
Commissioning advice Mini City............................................................................................................. 16
General ................................................................................................................................................... 17
Dismantlement........................................................................................................................................ 17
Installing the room thermostat Round .................................................................................................... 17
Installing the control panel CM737 ......................................................................................................... 18
Installing the outdoor temperature sensor .............................................................................................. 20
Starting up sequence with component check ......................................................................................... 20
5
CM737- settings to be done after start-up ......................................................................... 21
5.1
5.2
5.3
Configure the control panel after installation .......................................................................................... 21
Setting the day........................................................................................................................................ 21
Setting the time....................................................................................................................................... 21
6
Room thermostat Round .................................................................................................... 22
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
General ................................................................................................................................................... 22
Control modes ........................................................................................................................................ 23
Changing control mode, OTC heating curve and max supply temperature ........................................... 23
OTC control mode, default setting ......................................................................................................... 24
Viewing the room temperature ............................................................................................................... 24
Viewing the set room temperature ......................................................................................................... 24
Changing temperature setting ................................................................................................................ 24
Setback ................................................................................................................................................... 24
Summer heating ..................................................................................................................................... 24
Display symbols...................................................................................................................................... 25
Fault messages on the room thermostat ................................................................................................ 25
Fault codes on room thermostat Round ................................................................................................. 26
Factory settings, room thermostat .......................................................................................................... 26
7
Control panel with room thermostat CM737 ..................................................................... 27
7.1
7.2
General ................................................................................................................................................... 27
Choosing the operating mode ................................................................................................................ 28
3
Alfa Laval Mini City
Installation, service and operating instruction
7.3
7.4
7.5
7.6
7.7
7.7.1
7.7.2
7.7.3
7.7.4
7.7.5
Temperature Enquiry with the Info-button (7) ........................................................................................ 28
Holiday function ...................................................................................................................................... 29
OTC heating curve ................................................................................................................................. 29
Parallel adjustment of heating curve ...................................................................................................... 29
Operating mode Auto ............................................................................................................................. 30
The Built-in Heating Program ............................................................................................................ 30
Reviewing the Heating Program ....................................................................................................... 30
Temperature Override ....................................................................................................................... 30
Disabling/enabling time periods ........................................................................................................ 30
Modifying the heating program .......................................................................................................... 31
8
Activation of installer parameters CM737 ......................................................................... 32
8.1
8.2
8.3
8.4
8.5
8.6
Entering the installer set-up mode ......................................................................................................... 32
Category 1 parameters: Control panel settings ...................................................................................... 33
Category 2 parameters: ECO-functions ................................................................................................. 33
Category 3 parameters: Setting and displaying sensor values .............................................................. 34
Category 4 parameters: Heating actuator settings................................................................................. 34
Category 5: Fault History........................................................................................................................ 34
9
Troubleshooting the control panel CM737 ........................................................................ 35
9.1
Fault codes on the control panel CM737 ............................................................................................... 36
10
Pump settings and pump performance ............................................................................. 37
10.1
10.1.1
10.1.2
10.2
10.3
10.4
10.5
10.6
Performance view ................................................................................................................................... 37
Operation status ................................................................................................................................ 37
Alarm status ...................................................................................................................................... 37
Setting view ............................................................................................................................................ 38
Toggling the settings of UPM3 ............................................................................................................... 38
Key lock function .................................................................................................................................... 38
Pump curve proportional pressure mode 2, PP2 ................................................................................... 39
Fault finding pump .................................................................................................................................. 40
11
12
Electrical connections ........................................................................................................ 41
Schematic diagram, main components ............................................................................. 42
12.1
12.2
12.3
12.4
Mini City F1............................................................................................................................................. 42
Mini City F2............................................................................................................................................. 42
Mini City F3............................................................................................................................................. 43
Mini City F4............................................................................................................................................. 43
13
Service instructions............................................................................................................ 44
13.1
Tap water service instructions ................................................................................................................ 44
13.1.1
Tap water temperature too low ......................................................................................................... 44
13.1.2
Tap water temperature too high ........................................................................................................ 44
13.1.3
Hot water temperature unstable or too low ....................................................................................... 45
13.2
Heating system service instructions ....................................................................................................... 45
13.2.1
Heating system temperature too high or too low .............................................................................. 45
13.2.2
No heating ......................................................................................................................................... 46
13.2.3
Heating temperature unstable ........................................................................................................... 48
13.2.4
Disturbing noise from the circulation pump or in the radiator system ............................................... 48
13.2.5
Heating system often needs topping up ............................................................................................ 49
14
Service actions for the installer ......................................................................................... 50
14.1
14.2
14.3
Check the function of the valve for hot water ......................................................................................... 50
Check the function of the heating actuator and valve ............................................................................ 51
Check the volume take-up and pressure equalizing of the expansion vessel ....................................... 51
15
Maintenance and repairs .................................................................................................... 52
15.1
15.2
15.3
15.4
15.5
15.6
15.7
Cleaning the heating media filter ............................................................................................................ 52
Cleaning the heating circuit filter ............................................................................................................ 52
Change pump components or the complete pump ................................................................................ 53
Change the hot water actuator and heat exchanger .............................................................................. 54
Change the hot water valve.................................................................................................................... 54
Change the heating actuator .................................................................................................................. 55
Change the heating valve ....................................................................................................................... 55
4
Alfa Laval Mini City
Installation, service and operating instruction
15.8
15.9
15.10
15.11
15.12
Change the heating circuit supply temperature sensor .......................................................................... 56
Change the outdoor temperature sensor ............................................................................................... 56
Change the DHWC check valve ............................................................................................................. 57
Change the expansion vessel ................................................................................................................ 57
Change the differential pressure control valve ....................................................................................... 58
16
Operating data and performance ....................................................................................... 59
16.1
16.2
Technical Data........................................................................................................................................ 60
Measure sketch ...................................................................................................................................... 60
17
Options ................................................................................................................................ 61
17.1
17.2
17.2.1
17.2.2
17.3
17.3.1
17.4
First fix-jig ............................................................................................................................................... 61
Differential pressure control valve, DPC ................................................................................................ 62
Setting the DPC valve ....................................................................................................................... 62
Flow rate graph of the DPC ............................................................................................................... 62
Safety thermostat ................................................................................................................................... 63
Parameters and recommended settings for under floor heating ....................................................... 63
Service bypass ....................................................................................................................................... 64
5
Alfa Laval Mini City
Installation, service and operating instruction
1 General information
Alfa Laval Mini City is a complete, ready-to-install heating network substation for hot water and heating. It is
designed for buildings with a connection to a heating network.
Alfa Laval has years of experience in heating network technology and has developed Alfa Laval Mini City with
well-planned pipe work and with all components easily accessible for inspection and future servicing.
1.1
Comfort
Mini City has fully-automatic temperature control for heating and hot water.
The hot water is controlled and maintained at the desired temperature.
The heating circuit is controlled in relation to outdoor temperature and/or desired room temperature by means
of a controller and temperature sensor.
1.2
Installation
Read this manual before installing the substation.
Compact dimensions, light weight, well arranged plumbing make installation easy.
A pre-programmed control unit and a power cable already fitted with a plug allow immediate start-up.
Mini City is designed for hanging on wall and is mounted on an insulated frame and includes an insulated
cover. Better insulation means less energy usage and better energy efficiency.
1.3
Long-term security
The heat exchanger plates and all piping are manufactured in acid-resistant stainless steel. All components are
closely matched and carefully tested for function in accordance with Alfa Laval’s quality assurance system
ISO9001:2008.
For future servicing requirements, all components are accessible and individually replaceable.
1.4
CE-marking
Alfa Laval Mini City follows the rules and legislation specified in the Declaration of Conformity.
To maintain the validity of the CE marking, only identical replacement parts must be used.
1.5
Information about the document
All pictures in this document are general images.
Mini City is available in different models and levels of equipment.
6
Alfa Laval Mini City
Installation, service and operating instruction
1.6
General warnings
The installation work must be carried out by an authorized installation contractor. Before the
system is taken into operation, it must be pressure tested in accordance with relevant
regulations.
The temperature and the pressure of the primary heating water are very high. Only qualified
technicians can work with the substation. Incorrect operation may cause serious personal injury
and result in damage to the building.
If the hot water temperature is set too high, people may be scalded. If the hot water temperature
is set too low, unwanted bacteriological growth may occur in the hot water system. This can
result in serious personal injury.
Parts of the substation may get very hot and should not be touched.
When starting up the substation: To avoid the risk of scalding, make sure that no-one draws any
hot water until the hot water temperature has been adjusted.
Start heating circulation by first opening the valves in the heating media supply and then return
lines, to avoid pollutions in the system. Open the valves slowly to avoid pressure surges.
Then open heat return and then supply.
Before the substation is connected to the electrical supply, make sure that the heating system is
topped up with water. Starting up the system without water will damage the circulation pump.
The substation comes prepared with an electrical plug to be connected to the main supply. If
necessary, the plug-and-socket connection can be replaced with a permanent installation with an
all-pole isolate switch. This must be carried out by a qualified electrician.
7
Alfa Laval Mini City
Installation, service and operating instruction
2 Operating instructions
2.1
General operation
The temperature and pressure of the incoming heating network water are very high. The heat from the heating
network water is transferred to the heating and hot water systems of the building in the heat exchangers. The
heat is transferred through thin plates of acid-resistant stainless steel which keep the heating network water
separate from the systems in the building.
Mini City has automatic temperature control for hot water. This measures the temperature of the hot water in
the heat exchanger and automatically controls the primary flow.
The hot water temperature is controlled by a temperature control system which is set to about 50 ºC.
Setting the hot water temperature too low may result in unwanted bacteriological growth in the hot water
system.
The heating circuit is controlled in relation to outdoor temperature and/or desired room temperature by means
of a room thermostat or outdoor temperature sensor (option) or via a universal input.
When no heating flow is required, the heating circulation pump stops automatically, but is run occasionally to
prevent seizing up due to standing still for a long time.
After adjustment, the Mini City operates completely automatically. However, in areas with hard water it is
advisable to be attentive and to remedy any faults in good time. If the temperature of the hot water is too high;
the risk of lime deposits in the heat exchanger may increase.
The energy supplier registers the use of energy. Measurement is done by recording the flow of heating network
medium through the system, and by measuring the temperature difference between the medium’s supply and
return flow.
2.2
Safety equipment/inspection
•
Daily inspection to check for leaks from pipes or components.
•
Weekly inspection to make sure that the operation of the heating and hot water control systems is
stable and that the temperature does not fluctuate. Temperature variation causes unnecessary wear of
valves, thermostats and heat exchangers.
•
Every three months check the safety valves and the pressure in the heating system.
To check the operation of a safety valve, turn its wheel/knob until water escapes from the waste pipe of the
valve, then close the wheel/knob quickly. Occasionally a safety valve may open automatically to release excess
pressure. After a safety valve has been open it is important that it closes properly and does not drip.
8
Alfa Laval Mini City
Installation, service and operating instruction
3 Product overview
3.1
Product overview Mini City F1
3.
Heat exchanger for heating
4.
Control valve, heating circuit
5.
Actuator, heating circuit
6.
Temperature sensor connection, heating media
supply
7.
Filter for heating media
8.
Adapter for energy meter
14. Heating network media, supply
15. Heating network media, return
20. Heating circuit, return
21. Heating circuit, supply
22. Air vent valve
24. Connection box for electric power and sensors,
heating circuit
25. Room thermostat/control panel
(not shown in the picture)
26. Outdoor temperature sensor
(not shown in the picture)
27. Filter heating circuit
28. Pressure gauge for heating circuit
29. Filling valve
30. Safety valve for heating circuit
31. Expansion vessel heating circuit
32. Circulation pump, heating circuit
33. Supply temperature sensor, heating circuit
34. First fix jig including shut-off valves (option)
Picture 1
9
Alfa Laval Mini City
Installation, service and operating instruction
3.2
Product overview Mini City F2
1.
2.
Heat exchanger and temperature controller for hot
water
Control valve for hot water
3.
Heat exchanger for heating
4.
Control valve, heating circuit
5.
Actuator, heating circuit
6.
7.
Temperature sensor connection, heating media
supply
Filter for heating media
8.
Adapter for energy meter
9.
Check valve for cold water
10. Adapter for Cold water flow meter
11. Safety valve for domestic hot water
12. Adapter for Hot water flow meter
13. Safety temperature limiter hot water
14. Heating network media, supply
15. Heating network media, return
16. Cold water (cw)
17. Cold water outlet (cw)
18. Hot water (hw)
20. Heating circuit, return
21. Heating circuit, supply
22. Air vent valve
24. Connection box for electric power and sensors,
heating circuit
25. Room thermostat/control panel
(not shown in the picture)
26. Outdoor temperature sensor
(not shown in the picture)
27. Filter heating circuit
28. Pressure gauge for heating circuit
29. Filling valve
Picture 2
30. Safety valve for heating circuit
31. Expansion vessel heating circuit
32. Circulation pump, heating circuit
33. Supply temperature sensor, heating circuit
34. First fix jig including shut-off valves (option)
10
Alfa Laval Mini City
Installation, service and operating instruction
3.3
Product overview Mini City F3
1.
2.
Heat exchanger and temperature controller for hot
water
Control valve for hot water
3.
Heat exchanger for heating
4.
Control valve, heating circuit
5.
Actuator, heating circuit
6.
7.
Temperature sensor connection,
heating media supply
Filter for heating media
8.
Adapter for energy meter
9.
Check valve for cold water
10. Adapter for Cold water flow meter
11. Safety valve for domestic hot water
12. Adapter for Hot water flow meter
14. Heating network media, supply
15. Heating network media, return
16. Cold water (cw)
17. Cold water outlet (cw)
18. Hot water (hw)
20. Heating circuit, return
21. Heating circuit, supply
22. Air vent valve
24. Connection box for electric power and sensors,
heating circuit
25. Room thermostat/control panel
(not shown in the picture)
26. Outdoor temperature sensor
(not shown in the picture)
27. Filter heating circuit
28. Pressure gauge for heating circuit
29. Filling valve
30. Safety valve for heating circuit
Picture 3
31. Expansion vessel heating circuit
32. Circulation pump, heating circuit
33. Supply temperature sensor, heating circuit
34. First fix jig including shut-off valves (option)
11
Alfa Laval Mini City
Installation, service and operating instruction
3.4
Product overview Mini City F4
1.
2.
Heat exchanger and temperature controller for hot
water
Control valve for hot water
3.
Heat exchanger for heating
4.
Control valve, heating circuit
5.
Actuator, heating circuit
6.
7.
Temperature sensor connection,
heating media supply
Filter for heating media
8.
Adapter for energy meter
12. Adapter for Hot water flow meter
14. Heating network media, supply
15. Heating network media, return
16. Cold water (cw)
18. Hot water (hw)
20. Heating circuit, return
21. Heating circuit, supply
22. Air vent valve
24. Connection box for electric power and sensors,
heating circuit
25. Room thermostat/control panel
(not shown in the picture)
26. Outdoor temperature sensor
(not shown in the picture)
27. Filter heating circuit
28. Pressure gauge for heating circuit
29. Filling valve
30. Safety valve for heating circuit
31. Expansion vessel heating circuit *)
Picture 4
32. Circulation pump, heating circuit
33. Supply temperature sensor, heating circuit
34. First fix jig including shut-off valves (option)
*) included on model
12
Alfa Laval Mini City
Installation, service and operating instruction
3.5
Symbols on the first fix-jig
The first fix-jig has symbols that show which supply and return pipe that should connect to the different
connection points.
1
Heating circuit, return
2
Heating circuit, supply
3
Heating network media, supply
(primary inlet)
4
Heating network media, return
(primary return)
5
Hot water (hw)
Picture 5
6
Cold water outlet (cw)
7
Cold water (cw)
13
Alfa Laval Mini City
Installation, service and operating instruction
4 Installation
4.1
Unpacking
•
Remove the transport packaging and check that the product has not been damaged in transit and that
the consignment agrees with the specifications.
•
When lifting the unit take care not to apply stress to pipes and heat exchanger as this may weaken
them. Avoid lifting the unit by holding the heat exchanger.
Note: Risk of injury lifting heavy objects.
4.2
Preparation
•
Mini City must be placed on a wall, in upright position. Mount the unit and the first fix-jig using screws or
bolts suitable for the material of the wall and for the weight of the unit.
•
Choose a suitable installation area in accordance with official regulations.
The substation may generate sounds during operation caused by pumps, regulators systems, flows etc.
This should be taken in consideration during installation of the unit so that possible operational sounds
affect the surroundings as little as possible.
•
Alfa Laval recommends that the substation is mounted on well-insulated walls, such as outer walls or
on concrete walls.
•
Check the applicable regulations of the primary heating supplier. The available differential pressure
should be at least 50 kPa and at most 600 kPa.
•
Where the differential pressure is higher, a differential pressure controller should be added to the
installation.
4.3
Mounting the first fix-jig
•
Mount the first-fix-jig on the wall with two screws.
Make sure that there is enough space above for the substation and below for the expansion vessel.
Alfa Laval recommends having 900mm from floor to upper edge of the first fix-jig.
•
Close all valves.
•
Connect the pipe work to the first fix-jig connection points.
The temperature and the pressure of the primary heating water are very high.
Only qualified technicians can work with the substation. Incorrect operation may cause serious
personal injury and result in damage to the building.
•
4.4
The pipes should be pressure tested before installing the substation.
Mounting the substation
•
Before mounting the substation tighten the pipe connection Heating network media, supply and Heating
network media, return with 45Nm.
•
Remove the caps on the valves and lift the substation. Let the frame rest on the first fix-jig.
•
Mark the whole pattern and lift down the substation.
•
Fasten two screws to hang the substation on.
•
Place gaskets on the first fix-jig valves and lift the substation. Use hand power and fasten the nuts to
the valves on first fix jig.
•
Tighten with 45Nm.
•
Fasten the two screws that hold the substation.
•
Energy meters see 3 Product overview, must be installed at a prepared location, replacing a gauge
block, or following the instructions of the energy supplier.
•
If necessary the substation and first fix-jig can be assembled before mounting it on the wall.
14
Alfa Laval Mini City
Installation, service and operating instruction
4.5
Mounting the expansion vessel and the safety equipment
•
Mount the expansion vessel frame to the first fix-jig.
•
Mount the frame to the wall with four screws.
•
Mount the expansion vessel to the frame with the provided nut.
•
Connect the collection pipe assembly to the expansion vessel and tighten with 30Nm.
•
Take the short provided, hoses and connect it between the expansion vessel and the connection after
the pump.
•
Mount the provided draining pipe to the safety valve on the cold-water circuit.
•
Connect a hose or a pipe from the safety valves to the floor gully.
4.6
Filling up the system
•
Fill up the system with water by opening the valves on the first fix-jig.
The valves must be opened in the correct order to avoid pollutions in the system.
Open the valves slowly to avoid pressure surges.
4.6.1 Filling up the tap water circuit
•
Open the valves Cold water, Cold water outlet and Hot water.
•
Open all water taps in the building to get rid of trapped air. Let them be open until all air is gone.
4.7
Filling up and bleeding the heating circuit
•
Attach the provided long filing hose between the filling valves, to fill up the heating circuit.
•
Open the valves Heating circuit return and Heating circuit supply.
•
Open the filling valves.
•
Fill up the system until the manometer shows 1,6 Bar.
•
Close the filling valves.
•
Bleed the heating system via the air vent valve and at the heating systems draining places e.g. radiator
valves.
•
If the pressure is low after bleeding the system, open the filling valves and fill up to 1,6 Bar again.
•
The first time the heating system is filled up, this procedure might have to be repeated several times.
•
When the pressure is correct and the heating system is drained from air, remove the filling hose.
4.7.1 Connect to heating network
•
Open the valves Heating network media, supply and Heating network media, return.
Start with supply then return.
•
When all connections are done and the all circuits are pressurized, look for leaks.
•
If connections need retightening after the installation has been taken into service, the system must be
depressurised. If the system is not depressurised, gaskets will be damaged.
15
Alfa Laval Mini City
Installation, service and operating instruction
4.8
•
Connecting the electrical equipment
Remove the lid that covers the connection box and loosen the connection box from the insulation.
1
Universal input for connecting e.g.
outdoor temperature sensor, flow switch,
relay contact, strap
2
Room thermostat
3
Supply temperature sensor
4
Actuator, heating
5
Power cable adapter
Picture 6
•
Install the room thermostat; see 4.13 Installing the room thermostat Round or 4.14 Using the control
panel CM737 as a room thermostat.
•
Connect the non-polarity contact from the room thermostat to the connection box.
Carefully press the cable into the trail in the insulation.
•
Mount the outdoor temperature sensor on the north side of the building, 2 metres above the ground, or
higher.
See 4.15 Installing the outdoor temperature sensor.
•
Connect the non-polarity contact from the outdoor temperature sensor to the connection box.
Carefully press the cable into the trail in the insulation.
•
Connect the correct power cable to connection box and press the box and cable into the trail in the
insulation.
•
Place the lid over the connection box.
•
Put the electrical cable into a wall outlet.
See 4.16 Starting up sequence with component check.
•
Mount the two insulation covers. Start with the top that covers the substation. Always use the handles
on the side when handling the cover
4.9
Mounting options
•
If the substation is connected to a system sensitive to high temperature or to a low temperature
system, for example floor heating, a safety thermostat must be mounted and activated before starting
up. For more information 17.3 Safety thermostat.
4.10 Commissioning advice Mini City
•
Adjust the hot water temperature by having a hot water tap open at normal flow rate.
Measure the temperature at the draw-off point with a thermometer. It takes about 20 seconds to get a
stable tap water temperature. The temperature should be minimum 50°C.
Alfa Laval recommends that the primary inlet temperature is at least 10º higher than the tap water
temperature. NOTE: Make sure that no cold water is mixed with the hot water while making this
adjustment.
Seal the hot water actuator after setting.
•
Set the control mode on the control panel.
Control panel Round has been pre-set at the factory to use control mode; Outside Temperature
Control (OTC control). To change control mode see 6 Room thermostat Round.
Control panel CM737 see 5 CM737- settings to be done after start-up.
The control panel has been pre-set at the factory to use Outdoor compensation (parameter 14:rC
set to 1 ). To change see 5.1 Configure the control panel after installation.
16
Alfa Laval Mini City
Installation, service and operating instruction
4.11 General
The property owner must be instructed in the operation, setting and care of the unit.
It is particularly important to provide information about the safety systems and about hazards that may arise in
relation to the high pressure and temperature of the primary heating water.
4.12 Dismantlement
When the time comes for the substation to be dismantled and scrapped it must be disposed of in the correct
manner in accordance with local or national regulations.
4.13 Installing the room thermostat Round
1 Removing power supply
2 Placement
3 Removing the dial
4 Removing the thermostat
5a Mounting direct on the wall
5b Mounting in wall socket
6 Connecting the cable
7 Mounting the thermostat
8 Mounting the dial
Picture 7
17
Alfa Laval Mini City
Installation, service and operating instruction
4.14 Installing the control panel CM737
The control panel CM737 can be used as a room thermostat.
Before installation make sure that the electrical power supply is disconnected.
Install the room thermostat at an appropriate location that is representative to the indoor temperature.
Picture 8
•
A suitable installation is about 1.5 meters above floor and on an inner wall.
•
The room thermostat must not be combined with other thermostats in the same control zone.
Use a suitable 2-conductor cable between the connection box and the operator control panel. With a conductor
area of 0.6 mm2, the maximum cable length is 50 metres. Maximum 5Ω/conductor. Install the cable ends in the
terminal, marked A and B, located in the operator control panel. Connect the plug to the connection box again.
The unit can now be connected to the electrical power.
After starting up, choose configuration and operating mode, see 5.1 Configure the control panel after
installation.
18
Alfa Laval Mini City
Installation, service and operating instruction
Picture 9
19
Alfa Laval Mini City
Installation, service and operating instruction
4.15 Installing the outdoor temperature sensor
Connect the outdoor temperature sensor to the electric box.
2
With a conductor area of 0.6 mm the maximum cable length is 50 metres, maximum 5Ω/conductor.
If the outdoor temperature sensor is connected later, for example in a construction period, the room thermostat
must be restarted and configurated.
Control panel Round: See 6.3 Changing control mode, OTC heating curve and max supply temperature.
Control panel CM737: Set parameter 14 according to requested compensation; see 5.1 Configure the control
panel after installation.
4.16 Starting up sequence with component check
The substation must be filled with water before starting the room thermostat, if not the pump can
be damage.
•
Put the electrical cable from the control panel into a wall outlet. We recommend using an earth fault
breaker.
•
A check of the actuator and pump function starts.
Check that the heating actuator knob turns and the pump function according to the following schedule:
o
o
o
o
o
•
10s actuator closes – turns clockwise - if not already closed
10s actuator opens - turns counter clockwise
10s actuator closes – turns clockwise
10s pump runs
150s actuator closes.
The next five minutes, the pump starts running and control begins to regulate to 37°C.
Note: Under certain operating conditions, 37°C is not reached within 5 min. The Actuator knob should however
have moved counter clockwise.
When start-up sequence is completed the room thermostat returns to last set control mode.
Note: If there is no heat demand the pump stops after the start-up sequence.
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Alfa Laval Mini City
Installation, service and operating instruction
5 CM737- settings to be done after start-up
1. Press the MAN (8) button for a fixed set point (no reduction) of the room temperature.
2. Adjust the room temperature with the increase/decrease buttons on the right (6).
By outdoor compensation this change represents a standard parallel shift of the heat curve, recalculated for
room temperature. For more details see chapter 7.6 Parallel adjustment of heating curve.
5.1
Configure the control panel after installation
The room thermostat can be configured in three different ways. All installation parameters can be found in the
parameter list, see 8 Activation of installer parameters CM737.
The control panel is pre-set to Outdoor compensation.
5.2
•
Outdoor compensation OTC, require a connected outdoor temperature sensor,
see 4.15 Installing the outdoor temperature sensor.
Set parameter 14:rC to 1.
•
Room compensation RTC, require a mounted room thermostat,
see 4.14 Using the control panel CM737 as a room thermostat.
Set parameter 14:rC to 0.
•
Outdoor and room compensation OTC & RTC, require a connected outdoor temperature sensor and a
mounted room thermostat see 4.15 Installing the outdoor temperature sensor and 4.14 Using the
control panel CM737 as a room thermostat.
Set parameter 14:rC to 2.
Setting the day
1. Press the DAY button to begin setting the day, (1-7=mon-sun).
Each press will move the day indicator one step forward.
After 7 it will start over again at 1.
Press the green
button to confirm
5.3
Setting the time
1. Press either of the
or
buttons once to enter timer setting mode.
The LCD screen flashes the time digits. When the unit is powered for the
first time the display shows 12:00.
2. Use the
or
buttons to set the correct time then press the green
button to confirm.
Each press of the buttons will change the time by one minute and holding
them down will change the time slowly at first and get progressively
quicker.
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Alfa Laval Mini City
Installation, service and operating instruction
6 Room thermostat Round
6.1
General
The room thermostat Round controls the supply temperature to the heating system.
First time the room thermostat is started is use default control mode Outside Temperature Control (OTC
control).
The room thermostat is programmable and has five different control modes to select between.
Features
• Ergonomic user interface.
• A simple twist of the dial will adjust the temperature set point up or down.
Picture 10
1
LCD display
2
Dial
3
Right touch button
4
Left touch button
Display (1)
The LCD has backlight; the backlight enables to read the data on the LCD in the dusk and dark.
The backlight is switched off 10 seconds after last use.
In operating mode 1-3, the room temperature is displayed by default in the window. The thermostat measures
the room temperature continuously in the room where it hangs.
Dial (2)
Turn the dial one "click" to see the setting of room temperature, if using control mode 1-3.
Turn the dial to change settings. Turn clockwise to increase and counter clockwise to decrease a setting.
Right touch button (3)
Use together with the left touch button to enter setting menu.
Left touch button (4)
Use together with the right touch button to enter setting menu.
Press to change parameter values and settings in different menus, change control mode, set max supply
temperature, change heat curve slope.
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Alfa Laval Mini City
Installation, service and operating instruction
6.2
Control modes
The room thermostat has five different control modes to select between; the default mode is Outside
Temperature Control (OTC control).
1. Room temperature control RTC
Supply setpoint is calculated based on the room temperature setpoint and the actual room temperature.
2. OTC control
Require a connected outdoor temperature sensor.
Supply setpoint is purely based on the outside temperature.
3. OTC control with room temperature compensation (OTC+RTC)
Require a connected outdoor temperature sensor.
Supply setpoint is based on the outside and room temperature.
4. Constant supply temperature (with closed contact)
Select a fixed supply temperature setpoint. The heat is on when the contact (pos 1, Picture 11) is
closed.
NOTE: Does not work with an outdoor thermostat connected.
5. Constant supply temperature (with open contact)
Select a fixed supply temperature setpoint. The heat is on when the contact (pos 1, Picture 11) is
open.
NOTE: Does not work with an outdoor thermostat connected.
1
2
Universal input for connecting e.g.. outdoor
temperature sensor, flow switch, relay contact,
strap
Room thermostat
3
Supply temperature sensor
4
Actuator, heating
5
Power cable adapter
Picture 11
6.3
Changing control mode, OTC heating curve and max supply temperature
Three different settings can be done:
o Control mode (1-5)
o Heating curve (4-40)
o Max supply temperature (30°-80°C)
•
Turn the dial down to 10°C.
•
Enter the setting menu by pressing both right and left touch button for 10 seconds.
•
Use the dial to choose control mode, 1-5.
Confirm the choice within 10 secs by pressing the left touch button.
•
Choose the heating curve with the dial, 4-40.
Confirm the choice within 10 secs by pressing the left touch button.
•
Choose max supply temperature with the dial, 30°-80°C.
Confirm the choice within 10 secs by pressing the left touch button.
•
When all settings are done wait a few seconds and the room thermostat automatically leaves the
setting menu.
•
After changing the control mode, wait at least 30 seconds and then restart the room thermostat. This is
to ensure correct function.
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Alfa Laval Mini City
Installation, service and operating instruction
OTC control mode, default setting
The room thermostat controls the indoor
temperature as a function of the measured outside
air temperature.
The heat curve is the ratio between the measured
outside air temperature and the calculated supply
water temperature.
The ideal heating curve is dependent on the type of
installation (radiators, convectors, etc.), the thermal
properties and the location of the property.
A heating curve ratio of 1 to 40 can be set. The
figure shows several heating curve ratios for a room
temperature setting of the 20°C without room
temperature compensation.
6.5
Supply water temperature (°C)
6.4
Heat curve 10 has been set at the factory.
.
Outside Temperature (°C)
Heating curve ratio is at room temperature setting of 20°C
Picture 12.
Viewing the room temperature
Note: Only valid with control mode 1-3.
The room temperature is displayed by default. The thermostat measures the room temperature continuously in
the room where it hangs.
6.6
Viewing the set room temperature
Note: Only valid with control mode 1-3.
The set temperature is the desired temperature in the room where the thermostat is located.
Check the set temperature; by rotating the dial ring one way or tactile click clockwise.
The set temperature will flash.
After five secs, the display returns to show the room temperature.
Note: During commissioning, the standard set temperature is 17 °C.
After power failure, the last set temperature will always be active.
6.7
Changing temperature setting
Change the temperature setting by rotating the dial ring. With each click counter-clockwise decreases the set
temperature with half a degree. Each click clockwise increases the temperature by half a degree.
During setting the temperature is flashing. At the desired temperature, allows the ring loose.
After five seconds, the display will show the actual room temperature or the set supply temperature, depending
on set control mode.
If using control mode 1-3 the thermostat will adjust the room temperature as closely as possible to the newly
set temperature.
6.8
Setback
In the absence and at night the thermostat can manually be set at a lower temperature to save energy.
In general, it is recommended a reduction of up to 5 ° C. Under the influence of the warm-up capacity of the
plant and the degree of isolation of the property may be desired another temperature drop.
6.9
Summer heating
The pump should stop within 300 seconds if measured outdoor temperature is higher than the pre-set
temperature Outside Limit (20°C).
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Alfa Laval Mini City
Installation, service and operating instruction
6.10 Display symbols
Control
mode
1
RTC
Display will show
Shows the actual room temperature with one decimal and
in 0.5 steps when the room temperature is used.
Shows the room temperature setpoint with one decimal
and in 0.5 steps when temperature control mode is OTC.
2
OTC
Shows the actual room temperature with one decimal and
in 0.5 steps when the room temperature is used.
3
RTC+OTC
4
Constant supply
temperature
with closed
contact
5
Constant supply
temperature
with open
contact
Shows the requested supply temperature when the room
temperature is not used.
Shows the requested supply temperature when the room
temperature is not used.
Heating on
Means there is a requirement for some heating
SummerHeating is active
There is an ongoing alarm
6.11 Fault messages on the room thermostat
If a spanner
On the display
is visible on the display there is an ongoing alarm.
Cause
Fault code is shown on 7-segments
Internal fault (like sensor fault)
There is no (valid) outside temperature
Room thermostat not connected to a correct connection box
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Alfa Laval Mini City
Installation, service and operating instruction
6.12 Fault codes on room thermostat Round
Fault code 0
No fault, power up
Fault code 1
Supply sensor or cable
Cause
Measured supply water temperature is below 0°C or above 100°C.
Actions
The control panel turn the pump off, and enter off mode (frost protection).
Check the supply sensor and its cable.
Outside sensor out of operating range. This fault code can only occur after the
measured outside temperature has been in range: -40°C to 60°C.
Fault code 2
Cause
Measured outside temperature is below -40°C or above 60°C
Actions
Fault code 3
Enter room compensation until a valid temperature has been measured.
Check the outside sensor and its cable.
Connection box temperature out of operating range
Cause
Measured environment temperature is below -0°C or above 60°C.
Actions
Fault code 4
The control panel turn the pump off, and enter off mode (frost protection).
Make sure that the substation is mounted in a well vented room.
Cannot reach the set supply water temperature
Cause
Air in the pump, low temp/ not district heating supply.
Actions
Vent the pump, check the control valve and actuator.
No communication between control panel and connection box
Fault code 7
Cause
The connection box does not communicate with the control panel (by OT) for 60
seconds.
Actions
Fault code 8
Cause
Fault is only cleared after a power break and OT communication is working again.
Check the control panel cable.
Outside sensor detected and heat demand input configured.
Outside sensor detected and heat demand input configured
Actions
Heat demand input doesn’t work
6.13 Factory settings, room thermostat
Setting/function
Control mode
Room Temp Setpoint
Constant Supply Temp Setpoint
OTC Ratio
Setpoint lock
Default Value
Setting/function
Default Value
OTC
Min Room setpoint
10.0°C
17.0°C
Max Room setpoint
27.0°C
40°C
Min Supply setpoint
0°C
10
Max Supply setpoint
60°C
Outside Limit (summerheating)
20°C
unlocked
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Alfa Laval Mini City
Installation, service and operating instruction
7 Control panel with room thermostat CM737
7.1
General
The rom thermostat CM737 controls the supply temperature to the heating system. When connecting unit to the
power supply, the room thermostat verifies the connected sensors and then automatically chooses to control by
room or outdoor temperature sensor or both.
Features:
• Ergonomic user interface.
•
Large LCD (Liquid Crystal Display) Screen.
•
Four independent temperature levels per day, from 5°C to 35°C.
•
Built-in Memory holds the user program indefinitely.
•
Holiday button saves energy by letting you reduce the temperature for 1 to 99 days.
•
7- days heating program to match your lifestyle, and maximizing energy savings.
Picture 13
1
2
3
4
5
LCD display
Time display
Heating indicator
Day indicator
Temperature display
6
7
8
9
10
Temperature change buttons
Temperature enquiry button
Operating mode buttons
OK button, green
Holiday function button
11
12
13
14
Program buttons
Copy day button
Day select button
Time change buttons
OK-button (9)
When changing settings/values in room thermostat, the numbers in the display is flashing.
Confirm the new settings with the green OK-button (9) and the new setting will be confirmed.
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Alfa Laval Mini City
Installation, service and operating instruction
7.2
Choosing the operating mode
The room thermostat can operate in three different modes; Automatic, Manual or Off.
To set the operating mode press either of the AUTO, MAN or OFF buttons. The screen indicates which mode is
currently active.
NOTE: Alfa Laval recommends the mode MAN.
•
MAN (fixed) the room thermostat acts with a fixed set point throughout the day.
The set point can be adjusted from 5°C to 35°C by using the
or
buttons.
The thermostat will continue to maintain this temperature until another operating mode or temperature
is selected.
•
AUTO (automatic) the room thermostat follows the built-in temperature program, default or modified.
A manually adjustment of the temperature with arrow “up” or “down” is only valid until next programmed
temperature change.
NOTE: The built-in heating program has been designed to provide normal comfort requirements, but to
customise the settings please see 7.7 Operating mode Auto.
•
7.3
OFF the room thermostat controls to a minimum temperature. Default setting of 5°C acts as a frost
protection to your home.
Temperature Enquiry with the Info-button (7)
Each value will be displayed for 3 second before returning to show the initial screen.
NOTE! The initial screen shows different temperatures depending on if the outdoor temperature sensor is
connected and the setting of parameter 14:rC in the room thermostat.
•
Target room temperature - with outdoor compensation.
•
Current room temperature – with room compensation.
Press ones on the info-button , the display will show one of following three:
1. EXT above the clock and a temperature.
The outdoor temperature sensor is installed correct and the controls
the heating.
Displayed temperature is present outside temperature, according to
the sensor.
Press ones more on the Info-button, in 3 seconds, to show the
supply temperature. Check that the temperature is reasonable buy
carefully touching the supply pipe.
2. Flashing temperature and no EXT above the clock.
The temperature flashing is the set point according to room
compensation and the room thermostat controls the heating without
the outdoor temperature sensor.
Press ones more on the Info-button, within 3 seconds, to see the
value of the outdoor sensor.
3. EXT above the clock and ---- instead of the outdoor
temperature.
This means that the outdoor sensor or its cable is damaged or not
connected.
Press ones more on the Info-button, in 3 seconds, to show the
supply temperature. Check that the temperature is reasonable buy
carefully touching the supply pipe.
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Alfa Laval Mini City
Installation, service and operating instruction
7.4
Holiday function
The holiday function allows you to set a constant temperature (default = 10°C) for a specified number of days
(from 1 - 99 days). This saves energy and related costs when the house is empty, but resumes normal
operation on the day of return.
To set the Holiday function:
1. Ensure the room thermostat is running in AUTO or MAN operating modes.
2. Press the holiday
the holiday indicator
button to display the holiday day’s counter and temperature setting, along with
.
3. Press the
or
button to confirm.
time buttons to set the holiday time (1-99 days) and press the green
4. Press the
or
button to confirm.
buttons to set the holiday temperature (5°C - 35°C) and press the green
The room thermostat will now control to the new temperature for the set number of days that the home is
vacant. At midnight, the holiday counter will be reduced by one until the selected number of days have passed.
The room thermostat will then return to former operation as set by the MAN or AUTO mode.
To cancel the HOLIDAY function or to exit the function at any time: press the
OTC heating curve
The CM737 controls the indoor temperature as a
function of the measured outside air temperature.
The heating curve is the ratio between the measured
outside air temperature and the calculated supply
water temperature.
The ideal heating curve is dependent on the type of
installation (radiators, convectors, etc.), the thermal
properties and the location of the property. A heating
curve ratio of 1 to 40 can be set. The figure shows
several heating curve ratios for a room temperature
setting of the 20°C without room temperature
compensation.
7.6
Supply water temperature (°C)
7.5
button a second time.
Heat curve 10 (15:OC) has been set at the factory.
.
Outside Temperature (°C)
Heating curve ratio is at room temperature setting of 20°C
Picture 14.
Parallel adjustment of heating curve
o
This example shows parallels of curve 10 by 19 C
o
and 21 C.
Supply water temperature (°C)
o
If any other room temperature set point than 20 C
is used the selected curve will be parallel
compensated.
Every change of the room temperature set point
o
from 20 C will change the supply temperature with
o
approximately 3 C. If the room temperature set
o
o
point is increased from 20 C to 21 C the supply
o
temperature will increase with approximately 3 C.
Outside Temperature (°C)
Picture 15
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Alfa Laval Mini City
Installation, service and operating instruction
7.7
Operating mode Auto
7.7.1 The Built-in Heating Program
The built-in heating program has four temperature level changes per day that can be set between 3.00am and
2.50am the following day - allowing the evening temperature to maintain after midnight. Each temperature level
can be set between 5°C and 35°C, and adjusted in 0.5°C increments.
The factory default program for heating is as:
Monday to Friday (Day 1 to 5)
Period
1
2
Time
6:30
8:00
Temperature
21 °C
18 °C
3
18:00
21 °C
4
22:30
16 °C
Saturday & Sunday (Day 6 & 7)
Period
1
2
Time
6:30
8:00
Temperature
21 °C
18 °C
3
18:00
21 °C
4
22:30
16 °C
7.7.2
Reviewing the Heating Program
To review or edit the heating program use the PROGRAM
or
buttons to navigate between the four
individual programming periods.
Use the DAY button to step through each day of the week, so the complete 7-day heating program can be
reviewed or edited.
7.7.3 Temperature Override
During AUTO mode, the programmed temperature can be adjusted manually. The ‘target’ temperature will be
displayed and flash for 5 seconds - during this time the
value.
or
or buttons can be used to modify the set
NOTE: This temperature override is cancelled at the next programmed temperature change.
7.7.4 Disabling/enabling time periods
Any of the heating period from 2 to 4 can be removed from (or returned to) the heating program profile.
To disable or enable time periods:
1. To disable unwanted periods, go to the desired period (2 to 4) using the PROGRAM
to navigate, ensure the correct period is highlighted with the flashing square symbol.
or
buttons
Press and hold the
button for at least 2 seconds and the display will indicate the period has been
removed from the program.
2. To enable periods again, follow the same procedure as above, navigating to the already disabled
period. To enable this period again, press and hold the
30
button for at least 2 seconds.
Alfa Laval Mini City
Installation, service and operating instruction
7.7.5 Modifying the heating program
To change the heating program:
a) Press either of the PROGRAM
or
programming mode.
buttons to enter the
The time /temperature settings for period
on Monday day 1 will
be flashing. The active period is highlighted by a flashing square
around the numbers at the bottom of the screen and the selected
day is shown with the day indicator.
b) To adjust the period, start time use the
or
buttons, the ‘OK?’ indicator will be displayed to
confirm the change. Holding the button down will change the time quickly.
Note: If you are pressing the
or
next period will be pushed forward.
buttons and the display flashes the next period, it means the
c) Once the required time is reached press the green
button to confirm.
Note: If the original time setting did not require adjustment press the green
step ‘d’.
d) The temperature setting for period
or
button to move to
on Monday (Day 1) will now be flashing. To adjust this, press the
buttons and confirm the setting again by pressing the green
button.
e) The next time and temperature period will now be active. Adjust this by repeating steps b - d above
until all four periods are set or press the AUTO button to run the program as set, at any time.
Chose how to set the program for the next day:
f) Press the COPY DAY button to copy Monday’s program into Tuesday. The display will go blank apart
from the ‘non-flashing’ day indicator, which indicates the day copied and the ‘flashing’ target day to
copy the program to. To accept this day, press the green
button. To select a different target day
press the DAY button until the ‘flashing’ day indicator is under the required day, and then accept it by
pressing the green
button.
Note: Once the target day is confirmed it becomes the day that is copied if the COPY DAY button is
pressed again.
Or
Press the DAY button to move the day indicator to Tuesday (Day 2). The program for that day can then
be adjusted by following steps b to e. Programs for the remaining days can be set in the same way,
using the DAY button to move to the next day.
To exit the programming mode, select the desired operating mode by pressing the AUTO, MAN or OFF
buttons.
Note: To run the adjusted program; select the AUTO mode.
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Alfa Laval Mini City
Installation, service and operating instruction
8 Activation of installer parameters CM737
Installer Mode is used to alter the system settings for specific applications, to use the special features of the
room thermostat in a different way or to alter the factory present parameters. Parameters are divided into
groups:
• Category 1 parameters: Control panel settings
8.1
•
Category 2 parameters: ECO-functions
•
Category 3 parameters: Setting and displaying sensor values
•
Category 4 parameters: Heating actuator settings
•
Category 5: Fault History
Entering the installer set-up mode
1. Press the OFF button.
2. Press and hold the
button and the two
PROGRAM
and
buttons together.
3. The unit will display the first parameter of
installer parameter group category 1.
4. Press the
or
button to change the
factory setting.
The display will flash indicating that a
change has been made.
5. Press the green
button to confirm the
change. The display will stop flashing.
6. Press the
parameter.
button to go to the next
7. Press the PROGRAM
button to go to
the next parameter category.
8. To exit installer mode, press the AUTO,
MAN or OFF button.
Picture 16
Picture 17
32
Alfa Laval Mini City
Installation, service and operating instruction
8.2
Category 1 parameters: Control panel settings
Parameter
AM-PM / 24hr Display
Parameter
N:o
1:CL
Factory
Default
Setting
24
Optional Setting
Display
24/12
Reset Time/ Temp
Program
(Only used in Auto mode)
2:rP
1
1/0
Upper room Temp Limit
Lower room Temp Limit
/freeze protection temp
Room Temperature
Offset
6:uL
7:LL
35
5
21 to 35
5 to 21
12:tO
0
-3 to +3
13:Pb
1.5
14:rC
1
1.5 to
3.0
0 or 2
15:OC
19:FS
10
1
1 to 40
0/1
Proportional Band Width
Control mode
1)
OTC heat curve
Reset Category 1 and 2
Parameters to Factory
Defaults
8.3
Description
24hr. or AM/PM clock display format
0: time or temp has been changed
1: Time / Temperature according to factory
setting
Set 1 To restore the factory setting
Upper room Temp Limit
Lower room Temp Limit /freeze protection
temp
adjustment room temp display
Room thermostat Proportional Band Width
0 – Room Temp control
1 – OTC control
2 – OTC control with room temperature
compensation
Set OTC heating curve
0: Settings in category 1, 2. 3 has been
changed
1: Restore category 1 and 2 (not 3) to
factory settings.
Category 2 parameters: ECO-functions
Parameter
Summer heating in OTC
mode
ECO function Summer
reduction in OTC mode
ECO function
Economy function
in OTC mode
Parameter
N:o
1:SH
Factory
Default
Setting
0
Optional Setting
Display
0 to 40
2:SL
20
10 to 30
3:Pd
10
0 to 20
Description
Minimum supply temp set point for heating.
0: function not active.
The outside temperature at which the
heating will switch off.
The economy function will be disabled if the
setting for summer heating is not 0
Difference between outside and calculated
heating supply temperature.
If the difference is less than 3:Pd value, the
heating will be switch off.
0: function not active.
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Alfa Laval Mini City
Installation, service and operating instruction
8.4
Category 3 parameters: Setting and displaying sensor values
Parameter
Maximum supply
2)
temperature set point
2)
DHW set point
Parameter
N:o
1:CH
Factory
Default
Setting
80
Optional Setting
Display
30 to 80
Description
Maximum supply temp set point for heating.
2:HS
80
-
Current Supply
temperature
3:St
Actual temp
0-100
Return temperature
4:rt
--
--
Not applicable
DHW temperature
5:Ht
--
--
Not applicable
6:Ot
Actual temp
-40°C to
60°C
Water pressure
DHW storage overnight
7:Pr
8:HO
-1
-0/1
Not applicable
Not applicable
DHW storage during
HOLIDAY
Low capacity control
9:HH
0
0/1
Not applicable
10:LD
1
0/1
Not applicable
Outside temperature
3)
3)
8.5
Not applicable
Display function
Display function
Category 4 parameters: Heating actuator settings
Changing category 4 must be carried out by an authorized service technician
Parameter
Proportional band
Integral time
Run time heating actuator
8.6
Parameter
N:o
P1
P2
P3
Factory
Default
Setting
0
1
15
Optional Setting
Display
0-255
0-255
1-60
Description
Proportional band for heating actuator, 1K.
Integral time for heating actuator, 0.1 /
minute.
Time needed to open or close valve
completely
Value x 10= time needed in seconds.
Category 5: Fault History
(use right arrow button under display to access)
Parameter
ParaFactory
meter
Default
N:o
Setting
Fault code log
FX
Fault code
Optional Setting
Display Description
Error code log has 10 posts. See.9.1 Fault
F1-F10
codes on the control panel CM737.
plus
fault
code
The alarm log contains the 10 latest errors, beginning with the most recent error.
01 is generated at each restart.
0, 1, 0, 1, 0, 1, 0, 1, 0, 1 – means that the system has been correct restarted five times.
1)
Only if the setting is allowed by the heating appliance. Standard settings and limits can be set by the heating appliance.
Only available if supported by the heating appliance.
3)
Only available if the outside temperature sensor is mounted.
2)
Notes: Always remember to press the green
Up Mode press the AUTO or MAN button.
button to confirm new Installer Set-Up setting. To exit the Installer Set-
34
Alfa Laval Mini City
Installation, service and operating instruction
9 Troubleshooting the control panel CM737
Symptom
A flashing
symbol
appears on the display within
one minute after the control
panel being powered on.
A
symbol appears
permanently (no flashing) on
the display.
Display is blank
Possible Cause
Remedy
The control panel receives
power supply from the
connection box, but no
information.
The control panel is not
connected to the correct
terminals of the connection box.
Communication error due to an
interrupt or short circuit in the
link between the connection box
and the control panel.
The control panel is not
connected to the correct
terminals of the connection box.
No power feed after the
installation of the control panel.
Check that the power supply
cable of the connection box is
connected.
Contact Alfa Laval.
The control panel is not
connected to the correct
terminals of the connection box
The power supply or the
communication link between the
control panel and the
connection box has been
interrupted for more than 8 hrs.
A flashing
symbol
appears on the display after the
control panel being operating
for a period
A flashing
symbol
appears on the display and the
room temperature is replaced
by “—“
The control box is showing an
error
Internal fault in the temperature
measuring circuit.
35
Check that the power supply
cable of the connection box is
connected.
After the power is restored the
time and day may need to be
adjusted – otherwise contact
your service technician.
Press the button, to see the
error code. See 9.1 Fault codes
on the control panel CM737
Contact your service technician.
Alfa Laval Mini City
Installation, service and operating instruction
9.1
Fault codes on the control panel CM737
If a spanner is visible on the display, there is an on ongoing alarm. Press the Info-button to view the fault code.
Error source
Error code
No fault (power-up)
0
Supply water temperature sensor or cable
1
Outside air temperature sensor out of range
2
Temperature in the connection box out of range
3
Cannot reach the set supply temperature
4
No communication between control panel and connection box
7
Fault code 0
This fault code can just be seen in the fault history, parameter settings category 5.
Not via the Info- button.
Fault code 1
Supply sensor or cable
Cause
Measured supply water temperature is below 0°C or above 100°C.
Actions
The control panel turn the pump off, and enter off mode (frost protection).
Check the supply sensor and its cable.
Fault code 2
Outside sensor out of operating range. This fault code can only occur after the
measured outside temperature has been in range: -40°C to 60°C.
Cause
Measured outside temperature is below -40°C or above 60°C
Actions
Enter room compensation until a valid temperature has been measured.
Check the outside sensor and its cable.
Fault code 3
Connection box temperature out of operating range
Cause
Measured environment temperature is below -0°C or above 60°C.
Actions
The control panel turn the pump off, and enter off mode (frost protection).
Make sure that the substation is mounted in a well vented room.
Fault code 4
Cannot reach the set supply water temperature
Cause
Air in the pump, low temp/ not district heating supply.
Actions
Vent the pump, check the control valve and actuator.
Fault code 7
No communication between control panel and connection box
Cause
The connection box does not communicate with the control panel (by OT) for 60 seconds.
Actions
Fault is only cleared after a power break and OT communication is working again.
Check the control panel cable.
36
Alfa Laval Mini City
Installation, service and operating instruction
10 Pump settings and pump performance
Mini City is equipped with the pump Grundfos UPM3 Auto L.
When the pump is switched on it runs with the factory pre-setting or the last setting.
The Mini City pump is pre-set to run with operation mode, proportional pressure mode 2, PP2.
Operation mode indicates with LEDs on the pump front.
1
2
Push button
LEDs
Picture 18
The user interface shows with LED:
• performance view (during operation)
– operation status
– alarm status
• settings view (after pressing the button).
10.1 Performance view
10.1.1 Operation status
Display
One green LED (flashing)
One green LED + one yellow LED
One green LED + two yellow LED
One green LED + three yellow
LED
One green LED + four yellow LED
10.1.2 Alarm status
Display
One red LED + LED 5
yellow
One red LED + LED 4
yellow
One red LED + LED 3
yellow
Indication
Standby
Low performance
Medium low performance
Medium high performance
Performance in % of P1 MAX
0
0-25
25-50
50-75
High performance
Indication
Rotor is blocked
Supply voltage too low.
Electrical error.
75-100
Pump operation
Trying to start again
every 1.33 seconds.
Only warning, pump runs.
Pump is stopped
because of low supply
voltage or serious failure.
37
Counter action
Wait or deblock the shaft.
Control the supply
voltage.
Control the supply
voltage / Exchange the
pump.
Alfa Laval Mini City
Installation, service and operating instruction
10.2 Setting view
To see used pump curve, press ones on the push button. After a few seconds, the pump return to show
performance view.
Settings
Pump curve
PP1
PP2
PP3
CP1
CP2
CP3
CC1
CC2
CC3
Function
Proportional-pressure curve
The head (pressure) is reduced at falling heat
demand and increased at rising heat demand.
The duty point of the pump will move up or down on
the selected proportional-pressure curve, depending
on the heating demand.
Constant-pressure curve
The head (pressure) is kept constant, irrespective of
the heating demand.
The duty point of the pump will move out or in on the
selected constant-pressure curve, depending on the
heating demand in the system.
Constant curve
The circulator runs on a constant curve, which
means that it runs at a constant speed or power.
The duty point of the circulator moves up or down on
the selected constant curve, depending on the heat
demand in the system.
CC4
10.3 Toggling the settings of UPM3
1. Press the button for more than 2 seconds and the circulator switches to "setting selection". The LEDs
flash and show the current setting mode.
Please note that if the key lock is enabled, the circulator will not switch to "setting selection". In this
case, unlock the key lock by pressing the button for more 10 seconds.
2. To select between the settings, instantly press the button until you find the setting you want.
If you pass a setting, you need to continue until the setting appears again as it is not possible to go
back in the settings menu.
3. Release the button for more than 10 seconds and the user interface switches back to the performance
view and the last setting is stored.
4. Press the button and the LEDs show the current setting for 2 seconds.
10.4 Key lock function
The purpose of the key lock function is to avoid accidental change of settings and misuse.
When the key lock function is enabled, all long key presses will be ignored.
If you press the key lock for more than 10 seconds, you can toggle between enabling/disabling the key lock
function.
38
Alfa Laval Mini City
Installation, service and operating instruction
10.5 Pump curve proportional pressure mode 2, PP2
Picture 19
Line type
Description
Constant Curve
Proportional Pressure
Constant Pressure
39
Alfa Laval Mini City
Installation, service and operating instruction
10.6 Fault finding pump
Before starting any work at the pump, switch off the power supply. Make sure that the power
supply cannot be switched on accidentally.
Be aware that capacitors will be live up to 30 seconds after the power supply has been switched
off.
Fault
Pump is not running.
No power supply
Cause
• System is switched off.
• A fuse in the installation is blown.
• The circuit breaker has tripped.
•
•
Power supply failure.
Controller is switched off.
•
Pump is blocked by impurities.
Noise in the system.
•
•
•
Pump is defective.
Air in the system.
Differential pressure is too high.
Noise in the pump.
•
Air in the pump.
•
Inlet pressure is too low.
Insufficient flow.
•
Pump performance is too low.
Pump LED5 is on.
Pump tries to restart every 1.5
sec.
Pump LED4 is on.
Pump LED3 is on.
Pump stops.
•
Rotor shaft is blocked
•
•
•
Pump is running.
Supply voltage is too low.
Serious failure.
Pump is not running.
Normal power supply.
40
Remedy
Check the system controller.
Replace the fuse.
Check the power connection and
switch on the circuit breaker.
Check the power supply.
Check the controller and its
settings.
Remove impurities. Deblock the
pump from the front of the control
box with a screwdriver
Replace the pump.
Vent the system.
Reduce the pump performance at
the pump.
Let the pump run. The pump
vents itself over time.
Increase the system pressure or
check the air volume in the
expansion tank.
Check the external controller and
the pump settings.
Deblock the rotor shaft by
pushing it with a screwdriver from
the front of the pump.
Check the supply voltage.
• Check the supply voltage.
• Exchange the pump.
Alfa Laval Mini City
Installation, service and operating instruction
11 Electrical connections
Picture 20
41
Alfa Laval Mini City
Installation, service and operating instruction
12 Schematic diagram, main components
12.1 Mini City F1
Picture 21
12.2 Mini City F2
Picture 22
42
Alfa Laval Mini City
Installation, service and operating instruction
12.3 Mini City F3
Picture 23
12.4 Mini City F4
Picture 24
43
Alfa Laval Mini City
Installation, service and operating instruction
13 Service instructions
To avoid the risk of scalding, make sure that no-one draws any water while servicing the
substation.
Grey marked service actions must be carried out by an authorized service technician.
NOTE! Make sure that the substation has been correctly installed.
13.1 Tap water service instructions
13.1.1 Tap water temperature too low
Reason
Action
Primary heating supply
too low
Check the primary inlet temperature
The temperature can be checked by means of the energy meter (min 65º C) or
contact the primary heating medium provider.
Adjust the handle on the control valve
Control the hot water temperature by turning the handle on the control valve, counter
clockwise for increased and clockwise to decrease tap water temperature.
Adjust the hot water temperature by having a hot water tap open at normal flow rate.
Measure the temperature at the draw-off point with a thermometer. It takes about 20
seconds to get a stable tap water temperature.
The temperature should be minimum 50°C.
Alfa Laval recommends that the primary inlet temperature is at least 10º higher than
the tap water temperature.
Handle on control valve
incorrectly positioned
NOTE: Make sure that no cold water is mixed with the hot water while making this
adjustment.
Filter for heating media
clogged
Hot water valve does
not work
Seal the hot water actuator after setting.
See 15.1 Cleaning the heating media filter.
See 14.1 Check the function of the valve for hot water.
13.1.2 Tap water temperature too high
Reason
Action
Handle on control valve
incorrectly positioned
Adjust the handle on the control valve
Control the hot water temperature by turning the handle on the control valve, counter
clockwise for increased and clockwise to decrease tap water temperature.
Adjust the hot water temperature by having a hot water tap open at normal flow rate.
Measure the temperature at the draw-off point with a thermometer. It takes about 20
seconds to get a stable tap water temperature.
The temperature should be minimum 50°C.
Alfa Laval recommends that the primary inlet temperature is at least 10º higher than
the tap water temperature.
Hot water valve and/or
actuator does not work
NOTE: Make sure that no cold water is mixed with the hot water while making this
adjustment.
Seal the hot water actuator after setting.
See 14.1 Check the function of the valve for hot water
If the water temperature is too high when the handle is in position 0, the actuator or
the exchanger is damaged and requires replacing.
44
Alfa Laval Mini City
Installation, service and operating instruction
13.1.3 Hot water temperature unstable or too low
Reason
Action
Alternating pressure on
primary side
Check available differential pressure and temperature at the primary heating
medium provider
Filter for heating media
clogged
See 15.1 Cleaning the heating media filter.
Check valve DHWC
defect
Check and change if necessary
See 15.10 Change the DHWC check valve.
13.2 Heating system service instructions
13.2.1 Heating system temperature too high or too low
Reason
Action
The heating control
equipment may need to
be adjusted
Check and adjust the heating curve
If needed the set heating curve can be fine-tuned. Increase/ decrease the room
temperature by parallel adjust the heating curve.
Control panel Round
See 6.3 Changing control mode, OTC heating curve and max supply temperature.
Control panel CM737
See 8.2 Category 1 parameters: Control panel settings and change the selected
heating curve with parameter 15 category 1.
Also see section 7.5 OTC heating curve and 7.6 Parallel adjustment of heating curve.
Heating supply
temperature sensor and
outdoor temperature
sensor does not work
The pressure in the
system is to low or there
is not enough water in
the heating system
Check that the heating supply temperature sensor and outdoor temperature
sensor are correctly sited and working.
Control panel Round:
Supply temperature can only be viewed in control mode 4 and 5.
Control panel CM737:
To confirm that sensors are connected and operating, press the info button on the
operator control panel, check that the specified temperatures are reasonable.
Check the pressure on the manometer and top up the system with water
The pressure should not be below 1.0 Bar in winter time or below 0.6 Bar in summer.
The circuit should only be topped up with fresh water when necessary. The water
used for topping up contains oxygen which can lead to corrosion in the system. The
circuit should therefore be topped up as seldom as possible. Fill up by opening the
top up valves until the pressure meter shows desired value, or up to maximum 2.0
Bar.
Then close the top up valve.
The safety valve opening pressure is 2.5 Bar.
45
Alfa Laval Mini City
Installation, service and operating instruction
Reason
Action
Air in the heating
system
Bleed the system
Disconnect the substation power supply cable.
Bleed the heating system via the air vent valve.
The pump is self-venting. Air in the pump may cause noise. This noise ceases after a
few minutes run time.
Bleed the radiators.
Picture 25
Heating valve and/or
actuator does not work
See 14.2 Check the function of the heating actuator and valve.
Filter for heating media
clogged
See 15.2 Cleaning the heating circuit filter.
Differential pressure
control valve incorrectly
adjusted (option)
See 17.2 Differential pressure control valve, DPC.
13.2.2 No heating
Reason
Action
Closed radiator or floor
heating valves
Check that all radiator valves and floor heating valves are fully open
Circulation pump not
running
Check that the electrical power is on
Check the circulation pump
If the pump fails to start after stopping, try to start it at the highest setting.
See 10.6 Fault finding pump.
Check the heating parameters in room thermostat
If measured outdoor temperature is higher than target temperature, the pump should
not be operating.
Control panel CM737
Check the heating parameters in operator control panel
Summer reduction, parameter 2, category 2: If measured outdoor temperature is
higher than target temperature, the pump should not be operating.
Economy function, parameter 3, category 2:
If the calculated water supply temperature is not greater than the outside temperature
by this amount the heating will switch off.
If parameter 3 is 0, the pump operation will not be affected by this parameter.
46
Alfa Laval Mini City
Installation, service and operating instruction
Reason
Action
Heating supply
temperature sensor and
outdoor temperature
sensor does not work
Check that the heating supply temperature sensor and outdoor temperature
sensor are correctly sited and working.
The pressure in the
system is to low or there
is not enough water in
the heating system
Air in the heating
system
Control panel Round:
Supply temperature can only be viewed in control mode 4 and 5.
Control panel CM737:
To confirm that sensors are connected and operating, press the info button on the
operator control panel, check that the specified temperatures are reasonable.
Check the pressure on the manometer and top up the system with water
The pressure should not be below 1.0 Bar in winter time or below 0.6 Bar in summer.
The circuit should only be topped up with fresh water when necessary. The water
used for topping up contains oxygen which can lead to corrosion in the system. The
circuit should therefore be topped up as seldom as possible. Fill up by opening the
top up valves until the pressure meter shows desired value, or up to maximum 2.0
Bar.
Then close the top up valve.
The safety valve opening pressure is 2.5 Bar.
Bleed the system
Disconnect the substation power supply cable.
Bleed the heating system via the air vent valve.
The pump is self-venting. Air in the pump may cause noise. This noise ceases after a
few minutes run time.
Bleed the radiators.
Picture 26
Filter for heating media
clogged
See 15.2 Cleaning the heating circuit filter.
Differential pressure
control valve incorrectly
adjusted(option)
See 17.2 Differential pressure control valve, DPC.
47
Alfa Laval Mini City
Installation, service and operating instruction
13.2.3 Heating temperature unstable
Reason
Action
Alternating pressure on
primary side
Check available differential pressure and temperature at the primary heating
medium provider
Heating supply
temperature sensor and
outdoor temperature
sensor does not work
Check that the heating supply temperature sensor and outdoor temperature
sensor are correctly sited and working.
Control panel Round:
Supply temperature can only be viewed in control mode 4 and 5.
Control panel CM737:
To confirm that sensors are connected and operating, press the info button on the
operator control panel, check that the specified temperatures are reasonable.
Filter for heating media
clogged
See 15.1 Cleaning the heating media filter.
Differential pressure
control valve incorrectly
adjusted (option)
See 17.2 Differential pressure control valve, DPC
13.2.4 Disturbing noise from the circulation pump or in the radiator system
Reason
Action
Air in the system
Bleed the system
Disconnect the substation power supply cable.
Bleed the heating system via the air vent valve.
The pump is self-venting. Air in the pump may cause noise. This noise ceases after a
few minutes run time.
Bleed the radiators.
Picture 27
Air in the pump
Let the pump run
The pump vents itself over time.
Air in the pump may cause noise. This noise ceases after a few minutes run time.
Pump runs with
incorrect operating
mode
Check and change to recommended operating mode
See 10.3 Toggling the settings of UPM3.
Pump motor or pump
component damaged
See 15.3 Change pump components or the complete pump.
Differential pressure
control valve set too
high
See 17.2 Differential pressure control valve, DPC
48
Alfa Laval Mini City
Installation, service and operating instruction
13.2.5 Heating system often needs topping up
Reason
Action
Leaks in the substation
or in the system
Check the substation and the system for leaks
Leaks from the substation or the heating system cause pressure drop.
Contact your service technician if finding any leaks.
The expansion vessel
cannot handle the
changes in the system
See 14.3 Check the volume take-up and pressure equalizing of the expansion vessel
The heating system
safety valve is leaking
or does not work
Check the heating system safety valve
Check that the heating system safety valve is not leaking and that it works properly.
Check the safety valves’ function by turning the red wheel/knob until water runs out of
the valve’s waste pipe and then close the valve quickly.
49
Alfa Laval Mini City
Installation, service and operating instruction
14 Service actions for the installer
14.1 Check the function of the valve for hot water
Service actions must be carried out by an authorized service technician.
Close the shutoff valves for the Heating network supply and Heating network return together
with the cold and hot water.
After finishing repair; open the shutoff valves. Start with Heating network supply and then the
return line, to avoid pollutions in the system. Open the valves slowly to avoid pressure surges.
1. Disconnect the power feed to the substation.
2. Close the shut-off valves.
3. Unscrew the tap water actuator from the control valve.
If the valve is working it should be fully open when the actuator is
removed.
Check that hot water passes through the valve. Feel gently on a
pipe after the valve.
Picture 28
4. Carefully press the valve’s spindle with a tool and check the
valve’s travel and spring back.
NOTE: The valve may be very hot!
5. Turn the handle on the actuator; a small dip should move in and
out. If the dip does not move the actuator is damaged and
requires replacing.
6. Connect the power feed to the substation.
7. Open the shutoff valves.
Picture 29
50
Alfa Laval Mini City
Installation, service and operating instruction
14.2 Check the function of the heating actuator and valve
Service actions must be carried out by an authorized service technician.
The room thermostat must be without current when manoeuvring the actuator by hand.
Check the actuator by pulling out the electrical cable and refit it again; this
will start an automatic self-test off the actuator and pump.
See 4.16 Starting up sequence with component check.
Check the flow using the energy meter while test-running the valve.
If no energy meter is available, disconnect the heating actuator from the
valve. Close the actuator by turning the knob clockwise, this will make it
easier to reattach
If the valve is working it should be fully open when the actuator is
removed.
Carefully depress the valve’s spindle with a tool and check the valve’s
travel and spring back.
Note! The valve may be very hot
Picture 30
14.3 Check the volume take-up and pressure equalizing of the expansion vessel
Check the expansion vessel for possible leakage.
The cause may be that the expansion vessel cannot manage the volume changes on the heating side. The
expansion vessel may have to be replaced.
See 15.11 Change the expansion vessel.
Alternatively, the system´s total volume of water may be too high, i.e. the volume changes are too large for the
expansion vessel. If so, add extra expansion volume.
51
Alfa Laval Mini City
Installation, service and operating instruction
15 Maintenance and repairs
When carrying out repairs, please contact your local service partner.
Before starting out repairs always close the correct shutoff valves.
When dismounting a component there will be water coming out, hot and under pressure.
15.1 Cleaning the heating media filter
Service actions must be carried out by an authorized service technician.
The temperature and the pressure of the district heating water are very high. Only qualified
technicians can work with the district heating substation. Incorrect operation may cause serious
personal injury and result in damage to the building.
Before starting out repairs close the heating network supply and heating network return shutoff
valves.
After finishing repair; open the shutoff valves. Start with heating network supply and then the
return line, to avoid pollutions in the system. Open the valves slowly to avoid pressure surges.
1. Disconnect the power feed to the substation.
2. Close the shut-off valves.
3. Use a wrench and release the filter cover and remove the
cartridge.
4. Clean the filter with water and refit the cartridge. Screw the filter
cover with a momentum of 10-20 Nm.
5. Open the shutoff valves and connect the power feed to the
substation.
Picture 31
15.2 Cleaning the heating circuit filter
Service actions must be carried out by an authorized service technician.
Before starting out repairs, close the shutoff valves heating network supply, heating network
return, heating supply and heating return.
Release the pressure using the heating circuit safety valve.
After finishing repair, fill up the circuit and vent.
Open the shutoff valves, start with heating network supply and then the return line, to avoid
pollutions in the system. Then open heat return and then supply.
Open the valves slowly to avoid pressure surges.
52
Alfa Laval Mini City
Installation, service and operating instruction
1. Disconnect the power feed to the substation.
2. Close the shut-off valves.
3. Use a wrench and release the filter cover and remove the
cartridge.
4. Clean the filter with water and refit the cartridge. Screw the
filter cover with a momentum of 10-20 Nm.
5. Fill up the heating circuit using the toping up valve, vent the
heating circuit.
6. After final bleeding, the pressure should not be less than
1.0 bar in winter and not less than 0.6 bar in summer.
Picture 32
7. Open the shutoff valves and connect the power feed to the
substation.
15.3 Change pump components or the complete pump
Maintenance and repairs must be carried out by an authorized service technician.
Before starting out repairs, close the shutoff valves heating network supply, heating network
return, heating supply and heating return.
Release the pressure using the heating safety valve.
After finishing repair; fill up the heating circuit and vent.
Open the shutoff valves, start with heating return and then heating supply, then heating
network Supply and heating network return, to avoid pollutions in the system.
Open the valves slowly to avoid pressure surges.
Change the complete pump or just change the pump motor.
1. Disconnect the power feed to the substation, disconnect the power
cable to the pump.
2. Close the shut-off valves.
3. Choose alternative a or b.
a) When changing the complete pump, release the brass nuts with a
spanner and replace the pump.
Connect the pump cable.
b) Only changing the motor, release it by unscrewing four sockets
head cap screws and replace the motor.
Connect the pump cable.
4. Fill up the heating circuit using the top up valves. Vent the heating
circuit.
5. Open the shut-off valves and connect the power feed to the
substation.
6. After final bleeding, the pressure should not be less than 1.0 bar in
winter and not less than 0.6 bar in summer.
53
Picture 33
Alfa Laval Mini City
Installation, service and operating instruction
15.4 Change the hot water actuator and heat exchanger
The temperature and the pressure of the district heating water are very high. Only qualified
technicians can work with the district heating substation. Incorrect operation may cause serious
personal injury and result in damage to the building.
Before starting out repairs close the heating network supply and heating network return shutoff
valves.
After finishing repair; open the shutoff valves. Start with heating network supply and then the
return line, to avoid pollutions in the system. Open the valves slowly to avoid pressure surges.
1. Disconnect the power feed to the substation.
2. Close the shut-off valves.
3. Unscrew the actuator from the control valve.
4. Release the four nuts on the heat exchanger.
5. Refit a new heat exchanger and actuator.
Use new gaskets and tighten with 45Nm.
6. Mount the actuator on the valve.
7. Open the shutoff valves and connect the power feed to the
substation.
Picture 34
15.5 Change the hot water valve
The temperature and the pressure of the district heating water are very high. Only qualified
technicians can work with the district heating substation. Incorrect operation may cause serious
personal injury and result in damage to the building.
Before starting out repairs close the heating network supply and heating network return shutoff
valves.
After finishing repair; open the shutoff valves. Start with heating network supply and then the
return line, to avoid pollutions in the system. Open the valves slowly to avoid pressure surges.
1. Disconnect the power feed to the substation.
2. Close the shut-off valves.
3. Unscrew the tap water actuator from the control valve.
4. Use a spanner to remove the control valve.
Note the arrow direction on the valve.
5. Mount a new valve; and take especially care to the arrow direction.
Use new gaskets and tighten with 45Nm.
6. Fasten the tap water actuator on the valve.
7. Open the shutoff valves and connect the power feed to the
substation.
54
Picture 35
Alfa Laval Mini City
Installation, service and operating instruction
15.6 Change the heating actuator
Maintenance and repairs must be carried out by an authorized service technician.
1. Disconnect the electrical power supply.
2. Disconnect the cable from heating actuator in the connection box.
3. Unscrew the heating actuator from the valve, the valve closes.
4. Cut off all straps that holds the actuator cable.
5. Make sure that new actuator is closed by turning the knob clockwise to
the closing position. Fasten the actuator, use only hand power.
6. Replace cable and straps.
7. Connect the power feed to the substation.
8. Check the function of the actuator during start up.
Picture 36
15.7 Change the heating valve
The temperature and the pressure of the district heating water are very high. Only qualified
technicians can work with the district heating substation. Incorrect operation may cause serious
personal injury and result in damage to the building.
Before starting out repairs close the heating network supply and heating network return
shutoff valves.
After finishing repair; open the shutoff valves. Start with heating network supply and then the
return line, to avoid pollutions in the system. Open the valves slowly to avoid pressure surges.
1. Disconnect the power feed to the substation.
2. Close the shut-off valves.
3. Unscrew the heating actuator from the control valve.
4. Use a wrench to remove the control valve.
Note the arrow direction on the valve.
5. Mount a new valve; and take especially care to the arrow
direction.
Use new gaskets and tighten with 45Nm.
6. Close the actuator by turning the knob clockwise to the
closing position. Fasten the actuator, use only hand power.
7. Open the shutoff valves and connect the power feed to the
substation.
55
Picture 37
Alfa Laval Mini City
Installation, service and operating instruction
15.8 Change the heating circuit supply temperature sensor
1. Disconnect the power feed to the substation.
2. Close the heating actuator by turning the knob clockwise to
its closing position.
3. Disconnect the quick-connect terminals and replace the
sensor with a new one.
4. Connect the power feed to the substation.
5. Check the sensors value on the control panel after 5 min.
Picture 38
15.9 Change the outdoor temperature sensor
1. Disconnect the power feed to the substation.
2. Close the heating actuator by turning the knob clockwise to its closing
position.
3. Unscrew the lid of the outdoor temperature sensor by turning it anticlockwise.
4. Unscrew the cables and loosen the cable fitting.
5. Install a new outdoor temperature sensor.
6. Connect the power feed to the substation.
7. Check the sensors value on the control panel after 5 min.
56
Picture 39
Alfa Laval Mini City
Installation, service and operating instruction
15.10 Change the DHWC check valve
Maintenance and repairs must be carried out by an authorized service technician.
Before starting out repairs, close the shutoff valves heating network supply, heating network
return, cold-water and hot water.
Release the pressure using the DHWC safety valve.
After finishing repair; fill up the hot water circuit and vent.
Open the shutoff valves, start with heating network Supply and then heating network return, to
avoid pollutions in the system. Open the valves slowly to avoid pressure surges.
1. Disconnect the power feed to the substation.
2. Close the shut-off valves.
3. Use a wrench and unscrew the pipe between the cold water
flow meter and safety valve hot water.
4. Remove the old check valve and mount a new.
NOTE! Make sure that the check valve is mounted in the
correct way.
Flow direction
Picture 41
Picture 40
5. Mount the pipe again.
6. Open the shutoff valves cold and hot water.
7. Vent the circuit by opening a hot water tap.
8. Connect the power feed to the substation. Open the shutoff valves heating network Supply and then
heating network return.
15.11 Change the expansion vessel
Maintenance and repairs must be carried out by an authorized service technician.
Before starting out repairs, close the shutoff valves heating network supply, heating network
return, heating supply and heating return.
Release the pressure using the heating circuit safety valve.
After finishing repair, fill up the circuit and vent.
Then open the shutoff valves, start with heating network supply and then the return line, to avoid
pollutions in the system.
Then open heat return and then supply. Open the valves slowly to avoid pressure surges.
1. Disconnect the power feed to the substation.
2. Close the shut-off valves.
3. Replace the expansion vessel.
4. Fill up the heating circuit using the toping up valve, vent the heating circuit.
5. Open the shutoff valves and connect the power feed to the substation.
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Alfa Laval Mini City
Installation, service and operating instruction
6. After final bleeding, the pressure should not be less than 1.0 bar in winter and not less than 0.6 bar in
summer.
15.12 Change the differential pressure control valve
Maintenance and repairs must be carried out by an authorized service technician.
The temperature and the pressure of the district heating water are very high. Only qualified
technicians can work with the district heating substation. Incorrect operation may cause serious
personal injury and result in damage to the building
Before starting out repairs close the heating network supply and heating network return shutoff
valves
After finishing repair; open the shutoff valves. Start with heating network supply and then the
return line, to avoid pollutions in the system. Open the valves slowly to avoid pressure surges.
1. Disconnect the power feed to the substation.
2. Close the shut-off valves.
3. Use a spanner to remove the differential pressure control valve.
Note the position of the P/T plugs on the valve.
4. Mount a new valve; and take especially care to the P/T plugs
position.
Use new gaskets and tighten with 45Nm.
5. Open the shutoff valves and connect the power feed to the
substation.
58
Picture 42
Alfa Laval Mini City
Installation, service and operating instruction
16 Operating data and performance
59
Alfa Laval Mini City
Installation, service and operating instruction
16.1 Technical Data
Main measures
• With cover
• Without cover
Weight
Electrical data
Transportation
Sound level
See Measure sketch
430x160x1480 (mm, WxDxH)
410x150x1440 (mm, WxDxH)
19kg, cover 2kg
230 V, 1-phase, 50 W
Total weight 29 kg, 0.2 m³
<55 dB (A) 1.6 m from floor, 1 m from unit
16.2 Measure sketch
Picture 43
60
Alfa Laval Mini City
Installation, service and operating instruction
17 Options
The mounting instructions are described for a new installation. If the kits are to be installed on an already
installed subsystem, release the water pressure and disconnect the electrical power supply before starting. The
options must be installed by an authorized installation contractor.
17.1 First fix-jig
The temperature and the pressure of the primary heating water are very high. Only qualified
technicians can work with the substation. Incorrect operation may cause serious personal injury
and result in damage to the building.
To save time and efficiency the installation, Alfa Laval offers a first-fix- jig including shut-off valves. The first fixjig is available in three different models, with four, six or seven shut-off valves.
Picture 45
Picture 44
Picture 46
1. Mount the first- fix-jig on the wall using two screws or bolts suitable for the material of the wall and for
the weight of the unit.
NOTE: Ensure that the substation will fit over the first fix-jig.
Alfa Laval recommends having 900mm from floor to upper edge of the first fix-jig.
2. Close all valves before connecting the incoming pipes; tighten with 45 Nm.
3. Remove the caps on the valves and flush all pipes by open and close the valves.
4. The incoming pipes can be pressure tested before the substation is mounted.
5. Remount the caps on the valves if the substation isn’t mounted directly.
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Alfa Laval Mini City
Installation, service and operating instruction
17.2 Differential pressure control valve, DPC
Note: Differential pressure control is not available on all models.
Adjusting the DPC must be carried out by an authorized service technician.
17.2.1 Setting the DPC valve
Set the valve to the differential pressure 60kPa.
Settings lower than 60kPa will affect the functionality.
Start with the valve at minimum position and then open with19
numbers of turns.
Use a 4mm hexagonal key.
NOTE: Always start from the minimum position of the valve, before
making new settings.
Picture 47
17.2.2 Flow rate graph of the DPC
Picture 48
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Alfa Laval Mini City
Installation, service and operating instruction
17.3 Safety thermostat
Heating system sensitive to high temperatures for example under floor heating must be equipped with a safety
thermostat. If the heating system is not equipped with the thermostat, the under-floor heating system and floors
in general might get damaged.
1. Disconnect the substation electrical power supply cable. Disconnect the
electrical plug on the circulation pump.
2. Connect the new power supply cable from the electrical box to the circulation
pump.
3. Reconnect the existing power supply cable to the connection on the electrical
box.
4. Install the thermostat.
5. Attach all electrical wires with the necessary number of straps. It is important
not to attach electrical wires on primary heating pipes and sharp edges.
Picture 49
6. Change parameters and recommended settings before starting up the system
with a safety thermostat.
17.3.1 Parameters and recommended settings for under floor heating
The following changes must be done before starting up Mini City with a safety thermostat.
1. Change the pump operating mode to constant pressure.
See 10.3 Toggling the settings of UPM3.
Control panel Round:
1. Change the supply temperature to maximum 45°C.
See 6.3 Changing control mode, OTC heating curve and max supply temperature.
2. Change room thermostat heat curve to 5.
See 6.3 Changing control mode, OTC heating curve and max supply temperature.
Control panel CM737:
Parameter
ParaSet to
meter
N.o
Category 1 parameters: Control panel settings
OTC heat curve
15:OC
5
Category 2 parameters: ECO-functions
ECO function
3:Pd
0
Economy function
in OTC mode
Optional Setting
Display
Description
1 to 40
Set OTC heating curve
0 to 20
Difference between outside and calculated
heating supply temperature.
If the difference is less than 3:Pd value, the
heating will be switch off.
0: function not active.
Category 3 parameters: Setting and displaying sensor values
Maximum supply
temperature set point
1:CH
45
30 to 80
63
Maximum supply temp set point for heating.
Alfa Laval Mini City
Installation, service and operating instruction
17.4 Service bypass
The Service bypass makes it possible to flush the pipes Heating Network media, supply and return, when the
substation is mounted.
1. Connect the service bypass between
connection Heating Network media, supply
and return.
Tighten with 45Nm.
Picture 50
2. Mount the expansion vessel on the right
side of the frame.
Picture 51
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