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.
DH -SMT/ PL
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 oC and PN 6 / PN 10 in the flow circuit.
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
1
Data sheet 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.
Pump group range and their ordering
Table 1
codes
Typ eCode no
Atmospheric storage tank range and their
Storage tank volume
Table 2
ordering codes
Code no
[liters]
EXP 203004F4094
EXP 204004F4095
EXP 205004F4096
EXP 206004F4097
EXP 403004F4098
EXP 404004F4099
EXP 4050 04F 4100
EXP 40600 4F4101
EXP 80200 4F 4102
EXP 80300 4F 4103
EXP 804004F4104
EXP 80500 4F 4105
200CT K0101
300CT K0102
400CTK0103
500CTK010 4
800CTK 0105
100 0C TK0106
120 0CT K0107
150 0CTK010 8
2000CTK0109
2500C T K0 110
3000C T K 0111
3500C T K 011 2
4000C T K 011 3
Technical parameters:
WORKING MEDIUM (heating circuit)
Maximum temperature T
Nominal pressure PN 6 / PN 10
= 115oC
max
MAKE UP SOURCE
Maximum temperature T
Nominal pressure PN 6 / PN 10
max
= 80oC
Electrical supply 3~ 400 V / 50 Hz
Table 3 Low power Make up substations characteristics
PA1 (PA2) Make up pump – one or two pieces
VD1 (VD2) Excess pressure valve
(pressure relief controller)
– one or two pieces
EVM Solenoid valve
P Pressure sensor
L Level switches
ELP Electric and control panel
R3: soft water
connection
V1 (V2) Shut off valve – pump circuit
VA Shut off valve – fill up circuit
CV1 (CV2) Check valve
FA Strainer
M Manometer
WT Atmospheric water tank
VTM 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.
Sizing Make Up substationThe 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
Figure 2
Fast selection of pump group by flow rate (for one pump) and static pressure
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
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 EXP 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
EXP 403 substation is suitable (code no is 004F4098).
From the heat load sizing diagram (Figure 1), for
EXP 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).