INNOVATIVE PRESSURE COMPETENCE Pressure holding & degassing equipment

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1 Technomat Duo Plus Pressure holding Degassing Topping up Excess drain off Temperature measurement Oxygen measurement Pressure holding & degassing equipment

2 Advantage! Certified quality ade in Germany 2

3 Technomat Barnova Technomat DUO PLUS the compact power station which shows what it can do. The fully automatic pump-controlled compact station Duo Plus is used in large supply systems such as in district heating systems, in industry and in power stations. All of the advantages of the NOVA and DUO NOVA series have been included and integrated here. The innovative design of the control unit means that both standard systems as well as special systems are made in the same way, giving them their unmistakable identity. The pressure holding unit s job is to hold the idle pressure for all operating states and at The Palm Worth paper factory as a reference every point in the system, via the evaporating pressure at the highest permissible temperature or via the required static pressure. As a compact module, in accordance with the applicable standards the control unit contains all of the control components and fittings which are needed to maintain the pressure: the pumps, overflow valves, control and safety modules. All of the components are mounted on a base plate fully wired up and ready to use, including all of the fittings and connectors. All of the pipework uses round St 35.8 tubing to TRD 102, and is welded to X-ray quality. 3

4 Standard version Technomat Duo Plus Types 4.1 /.1 / 8.1 / 4.2 /.2 / 8.2 / 10.2 Applications - Hot water heating and cooling systems with up to 50 % glycol - Temperature controller 105 C to DIN EN (previously DIN 4751) - The system return temperature 70 C - maximum operating pressure 1.0 bar - from approx. 12 W to approx. 35 W Construction Built and tested with mark to Pressure Equipment Directive 97/23/EC and EN or AD Electromagnetic compatibility corresponding to 2004/108/EC and the requirements of the low voltage guidelines 200/95/EC. Degassing Entgasungsanschluß connection from von Systemrücklauf the system return NV EL EL Abtropfleitung Drip line zum Gully to the drain P1 Lieferung Barnova Barnova delivery Connection Anschluß to zum the system Systemrücklauf return DUO PLUS 4 / / 8 / 10 Temperature Einstellwert controller Temperaturregler setting < 105 C < 105 C with integrated degassing function, system mit integrierter Entgasungsfunktion return temperature < 70 C Systemrücklauftemperatur < 70 C Diaphragm expansion tank A diaphragm expansion tank (Technoflex HT, HN) should be built in on the pressure side of the pressure holding station, to minimise the switching frequency of the pumps and overflow valves for low variations of pressure or temperature. 4

5 Technomat The control unit - Base plate Solid construction with metal profiles, a single plate and crane lifting eyes - Pressure holding pumps ulti-stage with a mandatory start up every 24 h, manual - off - automatic switch, switch-over on fault and time monitor - Check valves Installed on the pressure side of the pumps to prevent the water in the system from flowing backwards into the tank(s) - Cap ball valves Locked to prevent unintentional closure - Overflow valves echanical and/or electrical versions for the controlled release of expanding water from the system into the tanks - Dirt traps Installed before the overflow valves to ensure fault-free operation - Emergency adjustable valve Installed in series with the overflow valves, with a bypass line for emergency operation of the pressure holding station should the valve fail - Pressure sensor Controls pumps, overflow valves and the emergency adjustable valve depending upon the pressure - Safety temperature monitor (STW or STB) onitors the temperature of the water in the system - IN pressure switch Controls the emergency adjustable valve - Top up Is switched by the level sensor and, controlled by the quantity, compensates for water losses in the system - Excess drain off This is switched by the level sensor and prevents too much water from accumulating in the tank(s) - Drain On both the pressure and suction sides - Flange cap shut-off valve To shut off the pressure holding station on the pressure side - Switching cabinet With a Barnova PLC Advantage! For higher safety requirements, additional pressure and level sensors can be used with switch-over on fault as standard. 5

6 The diaphragm tank - T echnomat DB A free-standing, unpressurised version - Butyl diaphragm Replaceable, to DIN 4807 part 3, as the water in the system heats up and expands, this accommodates it and keeps it safely separated from the atmosphere - Vacuum breaker elbow Compensates for the pressure difference between the diaphragm and the inside wall of the tank (vacuum breaker) - Level sensor Controls the topping up and draining off of water in the system - Degassing This uses a separate solenoid valve which allows part of the system s main return flow to flow from above, directly into the diaphragm s water-free space. This deliberate degassing for a particular period or at regular intervals extracts gases from the water in the system. - Vent Releases the extracted gases out into the atmosphere - Safety valve This is used when the trigger pressure for the heater s safety valve exceeds.0 bar and is thus higher than the tank s maximum operating pressure - Flange cap shut-off valve This is used to isolate the tank for holding etc. It is locked to prevent it from being unintentionally closed - Drain This is used to empty the tank - Add-on tank The capacity of the basic tank can be extended at will NV EL Abtropfleitung Drip line zum Gully to the drain EL Tip: For return temperatures in the system > 70 C the Barnova TECHNOCAT degassing function will come into action. Connection Anschluß zum to the system Systemrücklauf return T T T STW Barnova Lieferung Barnova delivery P1 Temperature reduction tank DUO PLUS 44 / / / 8 / / 810 / 10 Temperature controller setting > 105 C Einstellwert Temperaturregler < 105 C without integrated degassing function ohne integrierter Entgasungsfunktion System return temperature > 70 C Systemrücklauftemperatur 70 C For return temperatures > 70 C a temperature reduction tank is used to cool the water in the system down to 70 C. A safety temperature monitor or limiter serves to provide additional protection and will switch the heater off for temperatures above 70 C.

7 Technomat 1) Pressure holding pumps 5 2) Overflow valves (mechanical/electrical) 2a) Dirt trap a 3) Top up connection 4) Cap ball valve with integrated check valve 5) Switching cabinet ) Cap ball valve 7) Connecting flange to the tank 8) Base plate 9) Emergency adjustable valve 10) in. pressure switch 11) Pressure sensor 12) Safety temperature limiter 13) Pressure gauge 14) Drain 15) Flange cap shut-off valve 1) Excess drain off connection ) Diaphragm expansion tank 1 2) Level sensor 3) Safety valve (if required) 4) Solenoid valve (degassing) 5) Degassing valve ) Control pipe for unattended operation 8 7) High water sensor 8) Water shortage sensor 9) Pipe to control emptying of the system ) Pipe to control the flange cap shut-off valve 11) Flange cap shut-off valve for the tank 12) Tank drain 7

8 Standard version Technomat Duo Plus Types 4.3 /.3 / 8.3 / 10.3 unattended operation for 72 h Applications - Hot water systems - Temperature controller > 105 C - System return temperature > 70 C according to TRD 04 sheet 2, DIN EN and for unattended operation over 72 h - ax. operating pressure 1.0 bar - From about 12 W to approx. 35 W Control unit A safety temperature limiter and a minimum pressure switch are used as additional safety equipment. A pipe to permit unattended operation, adjusted to the size of the tank contains the high water and water shortage probe. Construction Built and tested with mark to Pressure Equipment Directive 97/23/EC and EN or AD Electromagnetic compatibility corresponding to 2004/108/EC and the requirements of the low voltage guidelines 200/95/EC. EL NV EL EL HWS WS Abtropfleitung Drip line zum Gully to the drain Connection Anschluß zum to the system Systemrücklauf return T T STB T PIN Lieferung Barnova Barnova delivery P1 DUO PLUS 44 / / / / 8 8 / 10 / 10 / BOB72h / Temperature Einstellwert controller Temperaturregler setting > >105 C without ohne integrierter integrated degassing Entgasungsfunktion function System Systemrücklauftemperatur return temperature > 70 C > 70 C 8

9 Technomat Custom version Technomat Duo Plus Types 4.3 /.3 / 8.3 / 10.3 unattended operation for 72 h Applications - Hot water systems - Temperature controller > 105 C - System return temperature > 70 C according to TRD 04 sheet 2, DIN EN and for unattended operation over 72 h - aximum operating pressure 40 bar and more - From 35 W Construction Built and tested with mark to Pressure Equipment Directive 97/23/EC and EN and AD 2000, each unit subject to German TÜV approval test. Electromagnetic compatibility corresponding to 2004/108/EC and meeting the requirements of the low voltage guidelines 200/95/ EC. Custom versions are individually planned, checked and built to customer specifications. Tip: Almost anything is possible, e.g. tanks up to 400 m 3, up to four pumps etc. Examples: If the volume of a tank is too large or if its operating temperature is too high, excluding the use of a diaphragm, once the level of water in the tank has reached its minimum, then the tank can be filled with nitrogen to a pressure of 0.2 bar, which must be ensured by an automatically switched pressure reduction station. The pressure will be maintained at a central value if you would like to limit the pressure rise in the system or set it differently. Using measuring cylinders on the pressure and suction sides of the circulating pumps, a central pressure is produced which is made up of the static pressure in the system together with the dynamic pressure from the circulating pumps. It is set via a throttle valves in the connecting lines to the measuring cylinders. ConnectionAnschluss Circulation pump, Umwälzpumpen suction Saugseite side Connection Anschluss Circulation Umwälzpumpen pump, Druckseite pressure side Pmax Pmin P1 P2 D D ittendruckflasche Central pressure cylinder NS HWS WS Drip line Abtropfleitung to the drain zum Gully STB O2 Barnova Lieferung delivery Barnova Connection Anschluss to zum the Systemrücklauf system return Drip Abtropfleitung line to zum the Gully drain DUO PLUS special Sonderausführung version 9

10 Technical data Electronic specifications and operating parameters System / / / / 10.3 kw A max. operating pressure (bar) max. holding pressure (bar) max. operating temperature ( C) max. ambient temperature ( C) Protection level IP 55 IP 55 IP 55 IP 55 IP 55 IP 55 IP 55 electrical connection 230 V / 50 Hz 230 V / 50 Hz 230 V / 50 Hz 400 V / 50 Hz 400 V / 50 Hz 400 V / 50 Hz 400 V / 50 Hz Equipment in the switching cabinet 1x busbar system 2x pump controllers 2x overflow valves 1x emergency adjustable valve 1x emergency off button 1x main switch 1x controller for max. pressure limit 1x controller for min. pressure limit, type varies with the type of equipment 1x controller for water shortage type varies with the type of equipment 1x controller for high water type varies with the type of equipment 1x safety temperature limiter type varies with the type of equipment 1x controller for top up 1x controller for excess drain off 1x level controller 1x evaluation unit for pressure signal 1x safety chain Reference object in Umea Floating signals on terminals: - Water shortage - in. pressure - General fault - Fault with the top up - Fault on pump 1 - Fault on pump 2 - Other signals are possible Selectable switching points - Pump 1 on / off - Pump 2 on / off - Overflow valve 1 open / closed - Overflow valve 2 open / closed - High water on / off - Water shortage on / off - Top up on / off - Excess drain off on / off - in. pressure on / off - ax. pressure on / off - Degassing on / off - Temperature measurement on / off - Oxygen measurement on / off Reference object in Fenne Indicator lights on the control panel - Controller on - Pump 1 on / off / fault - Pump 2 on / off / fault - Excess temperature in the expansion pipe - Water shortage - High water - in. pressure - Lamp test - Emergency adjustable valve Plain text messages in the control panel s display - Pump 1 on / off / automatic / manual mode / fault - Pump 2 on / off / automatic / manual mode / fault - Pump run time exceeded - Overflow valve 1 on / of - Overflow valve 2 on / of - Degassing on / off - Water shortage - High water - Pressure dropped below minimum level - aximum pressure exceeded - Top up time exceeded - Electrical power failure - Pressure sensor faulty - Temperature sensor faulty - Temperature limits exceeded - Oxygen sensor faulty - Oxygen limits exceeded - Diaphragm break report - Check dirt trap - aintenance interval - General fault - Electrical power failure - Level dropped below minimum 10

11 Technomat Controller Normal display Temperature: C Oxygen: mg/l Pump 1: Pump 2: Rem. runtime: Water counter: h h m l Power On Display Pressure holding system barnova gmbh Version X.XX Normal mode displays the system pressure, the level in the tank as well as the states of the pump(s) (on / off, manual / 0 / automatic), of the top up / the drainage of excess water, the degassing and the two overflow valves System pressure: bar Level: % P1 P2 NS GAS BYP1 BYP2 The switch over for pump 1 is organised by button 1 for anual / 0 / Automatic. The same applies for pump 2 and button 2. In case of an error, the fault or warning will be shown in the lowest line. Continue with yes. In case of an error, it will be shown in plain text in lines 3 and 4 and can be acknowledged. Continue with yes. Shows the temperature and the oxygen level of the heating water, if there are any sensors Continue with yes. Shows the value of the two pressure sensors, if there are two sensors as well as the sensor which is currently active Press. sens. 1: bar Press. sens. 2: bar Active Switch over with 1 / 2 With button 1 switch over to sensor 1 as the active sensor, with button 2 switch over to sensor 2. Continue with yes. Shows the value of the two pressure sensors, if there are two sensors as well as the sensor which is currently active Lev. sens. 1: % Lev. sens. 2: % Active Switch over with 1 / 2 With button 1 switch over to sensor 1 as the active sensor, with button 2 switch over to sensor 2. Continue with yes. Shows the pump run times (for one or two pumps), the remaining time to run for the pumps as well as the water counter state (if set in the service menu) Continue with yes. Shows the number of the system and its production number Sys. no.:** ** Prod. no.:** ** Continue with yes. Shows the service phone numbers barnova gmbh # Service numbers# Tel1: Tel 2: Shows the current date and time Date Time Change with No Continue with yes, with no the current time can be entered. Start / stop the constant degassing. If the constant gas release is not yet running, then it can be started in the next step (the time set for the constant gas release): Start constant gas release? Time: YES h NO If the constant gas release is already running, then it can be stopped in the 11

12 next step. Apart from that the remaining time for the constant gas release will be shown: Constant gas release is running Remaining time: h YES=next NO=stop Yes or no will take you back to the starting menu. Changing the parameter menus The programming switches are in the electrical switching cabinet on the circuit board and, in their normal positions are LEFT UP and RIGHT DOWN. By switching to LEFT DOWN you will enter programming mode 1 = operator. The procedure for that and the options for settings and the display are as follows: Starting display Programming mode *1* 1: Operator 2: Service 3: Fault memory 4: Data logger 1. Parameters to be set by the operator (1) without password protection The menus shown depend upon the service settings. Setting the language Language: 0:German 1:English **_** setting the static height as well as the minimum and maximum pressures static height in. pressure: ax. pressure: maximum: m b b m The 4th line shows the limits for the parameter currently being entered (cursor flashes) The setting for the time delay for the error message about the pressure dropping below its minimum Delays in. pressure: Range: = no delay min The setting of the pressures to switch the base load pump on and off Switching points Base load pump Switch on bar Switch off bar If two pumps are used then the pressure settings for the peak load pump to switch on and off now follow Switching points Peak load pump Switch on bar Switch off bar The setting of the delay times for the base load pump Delay Base load pump Switch on sec Switch off sec Range: sec If two pumps are used then the delay times for the peak load pump now follow Delay Peak load pump Switch on sec Switch off sec Range: sec The setting of the pressure to trigger the degassing (this corresponds to the minimum pressure) Degassing: Trig. pressure: bar 00.0: without degassing The setting of the times for the gas release and the degassing Degassing: Gas release time: Degassing time m The degassing valve is active for the gas release period, during the degassing period it is inactive The times are shown alternately s 12

13 Technomat The setting whether the degassing runs depending on the time (0 = constant, 1 = depends on time) Degassing time Enable 0 / 1 The setting for a top up in % of the level in the tank Top up On % Top up Off % minimum % maximum % The setting for the maximum top up time Top up On % Top up Off % Top up time min maximum 240 min Lock for the top up if the overflows are open Top up enabled for overflow ** ** 0 = no 1 = yes The settings for the top up for air conditioning mode in % of the tank level as well as the maximum top up time Air con. mode Top up On % Top up Off % Top up time min The setting for excess drain off in % of the tank fill level Excess drain off Switch on: % Switch off: % 0 = no excess drain off If the switch on level = 0 %, then no excess will be drained off The entry of the switch off level will then automatically be omitted Setting conditions: The switch on level must be higher than the level to turn the top up off The switch on level must be less than or equal to the high water level The switch off level must be lower than the switch on level The switch off level must be higher than the level to turn the top up off The setting for the switching pressures for the electrical overflows Switch on OF1 Switch off OF1 Switch on OF2 Switch off OF2 The switch on pressure must be between the max. pressure and the value for pump off. bar bar bar bar By switching the left switch up you will go to the normal display. The display will then look like this Please wait... BNHD V And you will be taken to the start menu. Service menu, password protected Contains all of the relevant data, which is factory-set and which is documented in the test and acceptance certificate. emory menu password protected All of the changes to the parameter menu are saved here as well as warning and alarm messages showing the date and time. The same applies for the data logger, which saves all of the operating states. Tip: See the installation and operating manuals for more info 13

14 Selecting Specifying your choice and order Your selection of the best Technomat pressure holding stations from the Duo Plus series should be made depending upon the minimum operating pressure p0 and on the system s nominal thermal capacity as well as the nominal volume Vn of the diaphragm expansion tank. The minimum operating pressure determines the required pump pressure and the thermal capacity of the corresponding amount of water to be pumped. Thermal power kw Temperature of the safety limiter C Supply temperature C Return temperature C Static height m Safety valve trigger pressure bar The nominal volume of the diaphragm expansion tank is determined by the amount of water in the system as well as by the corresponding operating temperatures. Calculation of the pump s capacity (volume flow rate Q) I I Heating systems: Power (kw) x 0.85 = hkw h I I Cooling systems: Power (kw) x 0.35 = hkw h Pump characteristic curves max. pump operating head (m) / / / Volume flow rate Q (m 3 /h) 14

15 Technomat Calculation of the required diaphragm expansion tank Calculation of the temperature reduction tank Ve = n V a 100 n Return temperature n 70 C V e = 0.5 x V a x 100 V a Vv = (V e + V v ) V n = 0.9 V a = the volume of water in the system V e = Expansion volume V v = precharged water V n = nominal volume Expansion coefficient Expansion factors n in % and the evaporation pressure pd in bar of excess pressure C n pd C n pd C n pd C n pd C n pd Example calculation kw = 21,000 Safety temperature limiter = 15 C Supply = 150 C Return = 105 C Static height =.5 bar Safety valve = 10.0 bar V a = 42 m 3 Tank 42,000 V e = 9.08 = litres ,000 V e = 0.5 = 210 litres 100 ( ) V n = = 4,470 litres 0.9 Selected: Technomat Duo Plus Temperature reduction tank V n = 0.5 x 42,000 x = litres 100 Selected: Technoflex TS 00 / 10.0 bar 15

16 Barnova GmbH Höhenweg Bad Laasphe, Germany Tel Fax info@barnova.de Branch office: Barnova GmbH Im Brühl Bad Laasphe-Feudingen, Germany