MAKE UP LINE Substations Make Up substations for secondary heating circuits with heat load up to 8000 KW, and the static height up to 60 mwc

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1 MAKE UP LINE Substations Make Up substations for secondary heating circuits with heat load up to 8000 KW, and the static height up to 60 mwc Compact substations for water expansion control in heating installations (secondary side), with atmospheric tank and automatic make / fill up functions Designed for floor mounting Description Function The Make Up system has the function to discharge the soft water into an atmospheric tank via pressure relief valve(s) if the heating circuit develops a pressure value over the maximum set value or has the function to fill up the heating installation circuit via make up pump(s) if the pressure decreases below the minimum set value. The volume of filling up water or the leakage water from heating circuit is automatically replaced in water tank via solenoid valve. Also, the system: - is able to protect the pump in case of water lack; - can assure a sequential start of pumps; - is able to stop functioning pumps in case of pipe breaking; - can make automate switching on the second pump in case of failure function of the first; - assures the permanent monitoring of the water level in the atmospheric tank (minimum, normal and maximum); - assures the filtering of water. Purpose This system is suitable for maintaining the pressure between an overpressure given by water dilatation and an underpressure limit given by loses of water from different reasons in secondary heating circuit. Installation The MAKE UP LINE is a range of systems mounted on the secondary side of district heating systems or thermal plants with a maximum temperature of 115 o C and PN 6 / PN 10 in the flow circuit. Construction The construction is compact, simple and easy to use. The pipes are corrosion protected through galvanic treatment both on the inside and on the outside. The components selection (size and type) is made using a calculation method developed by Schmidt-Bretten Technology, member of Danfoss Group. Specific advantages - protection of the heating circuit at overpressure - automatic control of pressure in heating circuit - monitoring and remote control - a unitary system, ready to be mounted in site, easy to install for a minimal location site - very good performances when coupling with Schmidt heating substations DH-SMT/PL VD.EH.D1.02 Danfoss 02/2009 1

2 MAKE-UP LINE Substations Ordering The Make Up substation is made up of the pump group (see Table 1) and of the Storage tank (see Table 2) that are ordered separately. Table 1 Pump group range and their ordering codes Type Code no 004F F F F F F F F F F F F4105 Table 2 Atmospheric storage tank range and their ordering codes Storage tank volume [liters] Code no 200 CTK CTK CTK CTK CTK CTK CTK CTK CTK CTK CTK CTK CTK0113 Technical parameters: WORKING MEDIUM (heating circuit) Maximum temperature T max = 115 o C Nominal pressure PN 6 / PN 10 MAKE UP SOURCE Maximum temperature T max = 80 o C Nominal pressure PN 6 / PN 10 Electrical supply 3~ 400 V / 50 Hz Table 3 Low power Make up substations characteristics Type Pressure relief controller - range bar bar 3 11 bar 3 11 bar Electrical power [kw] 2 x x x x 1.1 DN collectors DN 40 DN 40 DN 40 DN 40 Table 4 Medium power Make up substations characteristics Type Pressure relief controller - range bar bar 3 11 bar 3 11 bar Electrical power [kw] 2 x x x x 1.5 DN collectors DN 50 DN 50 DN 50 DN 50 Table 5 High power Make up substations characteristics Type Pressure relief controller - range bar bar bar 3 11 bar Electrical power [kw] 2 x x x x 1.85 DN collectors DN 65 DN 65 DN 65 DN 65 2 VD.EH.D1.02 Danfoss 02/2009 DH-SMT/PL

3 MAKE-UP LINE Substations Design: R1 (R2): heating installation connection ELP VTM EVM P M FA VA V1.2 CV1 V2.2 CV2 VD1 VD2 PA1 PA2 L WT V1.1 V2.1 R3: soft water connection Components: PA1 (PA2) VD1 (VD2) EVM P L ELP Make up pump one or two pieces Excess pressure valve (pressure relief controller) one or two pieces Solenoid valve Pressure sensor Level switches Electric and control panel V1 (V2) VA CV1 (CV2) FA M WT VTM Shut off valve pump circuit Shut off valve fill up circuit Check valve Strainer Manometer Atmospheric water tank Closed pressure vessel (against pressure shocks) Main functions: Specific restriction - Maintains heating system pressure in very strict limits; - Protects the heating circuit against overpressure; - Fills up and makes up the heating circuit; - Recovers the discharged soft water from the heating system; - Monitors the water leakage and, in case of pipe breaking, stops the pumps; - Monitors the water level in atmospheric tank (minimum, normal and maximum); - Fills up water tank; - Protects pump in case of water lack; - Communicates via standardized RS485 optional modules - The soft water available flow should be larger than the necessary make up flow for heating circuit. DH-SMT/PL VD.EH.D1.02 Danfoss 02/2009 3

4 Sizing Make Up substation The pump group is selected from low, medium or high range depending either on the heating power of the heating circuit deserved (Figure 1) or on the maximum thermal agent flow rate (Figure 2). A selection decision derives from the desired maximum pressure in the secondary heating circuit. Figure 1 Fast selection for pump group by heat load and static pressure p st [wmc] Q [kw] 4 VD.EH.D1.02 Danfoss 02/2009 DH-SMT/PL

5 Figure 2 Fast selection of pump group by flow rate (for one pump) and static pressure p st [wmc] q [cm/h] / one head pump The volume of expansion tank is calculated according to water volume from heating circuit and dilatation coefficient. For a fast selection of the expansion tank, can use the diagram - Figure 3. This diagram can be used either for standard application or for special applications (short networks with small diameter and with large water velocity in pipes). When the resulting volume from this diagram is larger than the selected standard storage tank volume, two or more tanks should be mounted in series. Figure 3 Fast selection for atmospheric expansion tank Expansion volume [liters] Q [kw] standard applications special application (for small networks) DH-SMT/PL VD.EH.D1.02 Danfoss 02/2009 5

6 Ordering examples: Mounting hydraulic recommended sketch: Example 1 A Make Up substation is selected to deserve a secondary heating circuit for a small network, with a maximum heat load of 2000 kw and a maximum 25 mwc static pressure. From the heat load sizing diagram (Figure 1), the 203 substation is suitable (code no is 004F4094). From the storage tank selection diagram (Figure 3), an atmospheric tank with 1000 liters capacity is recommended for a special application (code no CTK0106). Example 2 A Make Up substation is selected to deserve a secondary standard heating circuit with a maximum 10 m3/h flow rate and a maximum 20 mwc static pressure. From the flow rate sizing diagram (Figure 2), which is for one head pump, for 5.5 m3/h the 403 substation is suitable (code no is 004F4098). From the heat load sizing diagram (Figure 1), for 403 and static pressure of 20 mwc, we have 4500 kw. From the storage tank selection diagram (Figure 3), an atmospheric tank with 3500 liters capacity is recommended for a standard application (code no CTK0112). Dimensions: R3: soft water connection R3 ELP H h R1 VTM (R2): heating instalation connection WT additional WT VD1 PA1 This design has informative character 800 mm 800 mm Weight: Type Weight [kg] Type Weight [kg] Type Weight [kg] VD.EH.D1.02 Danfoss 02/2009 DH-SMT/PL

7 Storage tank: R3 De x s SIDE VIEW R5 R2 FRONT VIEW Code no Storage capacity [l] ΦD e s [mm] H [mm] h [mm] R1 R2 (R3) R4 R5 Weight empty [kg] CTK ¾ 1 1 ½ 48 CTK ¾ 1 1 ½ 66 CTK ¾ 1 1 ½ 73 CTK ¾ 1 1 ½ 88 CTK ¾ 1 1 ½ 133 CTK ½ 1 ¼ ½ 168 CTK ½ 1 ¼ ½ 181 CTK ½ 1 ¼ ½ 203 CTK ½ 1 ½ 1 ½ ½ 246 CTK ½ 1 ½ 1 ½ ½ 287 CTK ½ 2 1 ½ ½ 318 CTK ½ 2 1 ½ ½ 349 CTK ½ 2 2 ½ 529 R1 connection with soft water source R2(3) - connection with pump group R4 = overflow passage R5 = emptying connection DH-SMT/PL VD.EH.D1.02 Danfoss 02/2009 7

8 Danfoss Schmidt-Bretten Technology SRL 208 Oltenitei Drive Popesti-Leordeni Ilfov Romania Tel.: Fax: VD.EH.D1.02 Produced by Danfoss A/S 02/2009

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