Danfoss EXP 203, EXP 204, EXP 403, EXP 205, EXP 206 Data sheet

Data sheet

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

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.

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.

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

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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.

Table 1

Pump group range and their ordering codes

Type	Code no
EXP 203	004F4094
EXP 204	004F4095
EXP 205	004F4096
EXP 206	004F4097
EXP 403	004F4098
EXP 404	004F4099
EXP 405	004F4100
EXP 406	004F4101
EXP 802	004F4102
EXP 803	004F4103
EXP 804	004F4104
EXP 805	004F4105

Table 2

Atmospheric storage tank range and their ordering codes

Storage tank volume	Code no
[liters]
200	CTK0101
300	CTK0102
400	CTK0103
500	CTK0104
800	CTK0105
1000	CTK0106
1200	CTK0107
1500	CTK0108
2000	CTK0109
2500	CTK0110
3000	CTK0111
3500	CTK0112
4000	CTK0113

Technical parameters:	WORKING MEDIUM (heating circuit)
	Maximum temperature		T		= 115oC
	Nominal pressure		max
			PN 6 / PN 10
	MAKE UP SOURCE
	Maximum temperature		T		= 80oC
	Nominal pressure		max
			PN 6 / PN 10
	Electrical supply		3~ 400 V / 50 Hz
Table 3 Low power Make up substations characteristics
Type	EXP 203		EXP 204			EXP 205	EXP 206
Pressure relief controller - range	1 ÷ 4.5 bar		1 ÷ 4.5 bar			3 ÷ 11 bar	3 ÷ 11 bar
Electrical power [kW]	2 x 0.55		2 x 0.55			2 x 0.75	2 x 1.1
DN collectors	DN 40			DN 40		DN 40	DN 40
Table 4 Medium power Make up substations characteristics
Type	EXP 403		EXP 404			EXP 405	EXP 406
Pressure relief controller - range	1 ÷ 4.5 bar		1 ÷ 4.5 bar			3 ÷ 11 bar	3 ÷ 11 bar
Electrical power [kW]	2 x 0.55		2 x 0.75			2 x 1.1	2 x 1.5
DN collectors	DN 50		DN 50			DN 50	DN 50
Table 5 High power Make up substations characteristics
Type	EXP 802		EXP 803			EXP 804	EXP 805
Pressure relief controller - range	1 ÷ 4.5 bar		1 ÷ 4.5 bar			1 ÷ 4.5 bar	3 ÷ 11 bar
Electrical power [kW]	2 x 0.75			2 x 1.1		2 x 1.5	2 x 1.85
DN collectors	DN 65			DN 65		DN 65	DN 65

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VD.EH.D1.02 © Danfoss 02/2009

DH-SMT/PL

Data sheet	MAKE-UP LINE Substations

Design:	R1 (R2): heating
	installation connection
				ELP
		P	VTM			EVM
				M		FA	VA
			V1.2	V2.2
			CV1	CV2
	VD1	VD2	PA1	PA2	L	WT
			V1.1	V2.1
							R3: soft water
							connection
	Components:
	PA1 (PA2)	Make up pump – one or two pieces			V1 (V2)	Shut off valve – pump circuit
	VD1 (VD2)	Excess pressure valve			VA	Shut off valve – fill up circuit
		(pressure relief controller)			CV1 (CV2)	Check valve
		– one or two pieces			FA	Strainer
	EVM	Solenoid valve			M	Manometer
	P	Pressure sensor			WT	Atmospheric water tank
	L	Level switches			VTM	Closed pressure vessel
	ELP	Electric and control panel				(against pressure shocks)

Main functions:	- 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

Specific restriction

- 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

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