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Duraflex EcoPress

Pressurisation Systems

Version 1.01
Duraflex EcoPress

Duraflex EcoPress
Pressurisation Systems - Pump Controlled

Pressure-maintaining station with automatic water


make-up and deaeration.
The pump-controlled EcoPress opens up a completely new dimension
of pressure-maintaining stations for heating and cooling circuits. Its five
functions are:
it keeps the system pressure within very restricted limits
it deaerates the content water
it makes up water automatically
maintaining system pressure within 50kPa
provides outputs to BMS systems

Thus, the Duraflex EcoPress is a solution to decrease air problems, especially


within closed heating installations, which, according to a study of the Technical
University of Dresden, arise in more than 50% of the installations.

The Duraflex EcoPress ensures air-free installations up to the top floor and
into the last corner.An additional advantage:A special data interface allows
the integration into the modern facility management.

The high efficiency of the EcoPress principle has been proven and tested in
numerous application examples.The combination of pressure maintenance,
deaeration, and water make-up complies with all requirements for air-free
systems and requires only little maintenance.

Automatic Heating reserves the right to change specifications without notice.


pg 2
Advantages

EcoPress / EcoPress Giga advantages against a Fillset with Pre charge Vessels
1. Pressure Control:
2. Degassing facility
3. Space Savings
4. Technology and Alarm Safety
5. Maintenance
6. Financial benefits

1. Pressure Control:
a. Keeps pressure +/- 0.2 bar limits
b. Spill valves, proportionally controlled motorised ball valves and not solenoids
c. Ball valves afford tighter volume/pressure control without clogging (as per solenoid valves)
d. No water hammer as sometimes happens with solenoids on other systems
e. No regular maintenance and checks as per pre charged vessels
f. Software with alarms protect the EcoPress/system via BMS
g. If unit is set up correctly then basically a fit and forget type installation.
h. High Integrity information output to your BMS so systeminformation may be mapped and safety parameters alarms to suit your requirements.

2. Degassing:
a. Integral atmospheric degassing facility (not available on fill, pre charge or other types)
b. If high temperature between 70deg C and 90 deg C use EcoVac Degassing
c. Degassing helps to improve hydraulic balancing and ensures circulating pumps run to curve.The risk of mechanical seal fail ure and damage to
windings on glandless pumps is significantly reduced due to good hydraulic properties.The flow characteristics of devices such as plate heat
exchangers, boilers etc will be found to be as published. All of these factors enable the specified system performance to be readily achieved
ensuring a timely handover to the final client.

3. Space Savings:
a. Acceptance Factor on these vessels 90%
b. One EcoPress vessel to 4 pre charge vessels (due to acceptance factors)
c. Cost savings on Vessel amount and also installation and materials (piping etc)

4. Technology and Alarm Safety:


a. Microprocessor technology includes power fail safe relay / soft starters / various alarms re high and low pressures and water reserve levels / error
messages. Manual checks of pumps, spill valves & fill solenoid/fillset P plus many other features. Real time log of alarm condi tions
b. All BMS outputs are volt free and most beneficial is an extension module which gives discrimination for HP/LP conditions etc.Analogue outputs
enable remote monitoring of system pressure and vessel volume.
c. Pumped system integrity monitored by multiple filling safety alarms monitoring water make up duration and repetitive filling.

5. Maintenance:
a. The operating system is easily understood and works with pre-programmed defaults operating around a single setting for the operator.
b. Minimal maintenance with yearly warning in display when service is scheduled.
c. All default parameters may be changed by a Automatic Heating Service Engineer to suit your system/BMS requirements.

6. Financial Benefits
a. Quicker handover of whole project to client due to optimised hydraulic performance.
b. Enhanced system control ensures an almost constant pressure regardless of
temperature. Reduced risk of leakage from joints etc on existing pipe systems.
c. Less space taken with fewer vessels as space in many instances is a premium
d. Minimal maintenance cost with only Health Check cleaning of dirt traps and buffer
vessel gas charge required.

pg 3
Duraflex EcoPress

Duraflex EcoPress
Pressure Maintaining Stations

Automatic Heating reserves the right to change specifications without notice.


pg 4
Performance Data


EcoPress Operating Operating Enviro. Noise Electrical Electrical Pump Number
Model Pressure Temp Temp Level Power Soft of
kPa C C dB kW V / Hz Start Pumps

DV1 250 >0-70* >0-45 55 0.75 230 / 50 No 1


DV2-1/60 480 >0-70* >0-45 55 1.10 230 / 50 Yes 1
DV2-1/75 650 >0-70* >0-45 55 1.10 230 / 50 Yes 1
DV2-1/95 800 >0-70* >0-45 55 1.10 230 / 50 Yes 1
DV2-1/140 1300 >0-70* >0-45 55 2.20 230 / 50 No 1

DV2-2/35 250 >0-70* >0-45 55 1.50 230 / 50 Yes 2


DV2-2/60 480 >0-70* >0-45 55 2.20 230 / 50 Yes 2
DV2-2/75 650 >0-70* >0-45 55 2.20 230 / 50 Yes 2
DV2-2/95 800 >0-70* >0-45 55 2.20 230 / 50 Yes 2
DV2-2/140 1300 >0-70* >0-45 55 2.20 230 / 50 Yes 2

* Mounted in system return line, diaphragm load of the expansion vessel max. 70C;
please contact us if there is an expected continuous temperature < 0C
Main switch, fixed connection to terminal strip.

Options
Fillset
Equipped with system separator and water meter, it allows the direct connection
of the water make-up device to the drinking water network

pg 5
Duraflex EcoPress

Duraflex EcoPress
Control Units and Accessories

Dimensional Data
EcoPress 1 and EcoPress 2-1 control unit with 1 pump

Model p0 H W D Connection Weight


bar mm mm mm P O W kg
DV1 2.5 680 530 550 Rp 1 Rp 1 Rp Fi 25
DV2-1/60 4.8 680 530 670 Rp 1 Rp 1 Rp Fi 28
DV2-1/75 6.5 770 530 630 Rp 1 Rp 1 Rp Fi 35
DV2-1/95 8.0 770 530 540 Rp 1 Rp 1 Rp Fi 37
DV1-1/140 13.0 770 530 540 Rp 1 Rp 1 Rp Fi 57

EcoPress 2-2 control unit with 2 pumps

Model p0 H W D Connection Weight


bar mm mm mm P O W kg
DV2-2/35 2.5 680 700 780 G 1-1/4 G 1-1/4 Rp Fi 54
DV2-2/60 4.8 680 700 780 G 1-1/4 G 1-1/4 Rp Fi 58
DV2-2/75 6.5 750 700 780 G 1-1/4 G 1-1/4 Rp Fi 72
DV2-2/95 8.0 800 700 780 G 1-1/4 G 1-1/4 Rp Fi 76
DV1-2/140 13.0 800 700 780 G 1-1/4 G 1-1/4 Rp Fi 76

D
W

Automatic Heating reserves the right to change specifications without notice.


pg 6
Dimensional Data

VG primary vessel VF secondary vessel

Vessel Size D H h A Weight Vessel Size D H h A Weight


litres mm mm mm kg litres mm mm mm kg
VG200 634 1060 146 G1 37 VF200 634 1060 130 G1 37
VG300 634 1360 146 G1 54 VF300 634 1360 130 G1 54
VG400 740 1350 133 G1 65 VF400 740 1345 115 G1 65
VG500 740 1570 133 G1 78 VF500 740 1560 115 G1 78
VG600 740 1790 133 G1 94 VF600 740 1810 115 G1 94
VG800 740 2240 133 G1 149 VF800 740 2275 115 G1 149
VG1000 740 2690 133 G1 156 VF1000 740 2685 115 G1 156
VG1000 1000 2060 289 G1 320 VF1000 1000 2130 350 G1 320
VG1500 1200 2150 368 G1 465 VF1500 1200 2130 350 G1 465
VG2000 1200 2610 368 G1 565 VF2000 1200 2590 350 G1 565
VG3000 1500 2610 393 G1 795 VF3000 1500 2590 380 G1 795
VG4000 1500 3180 393 G1 1080 VF4000 1500 3160 380 G1 1080
VG5000 1500 3720 393 individual 1115 VF5000 1500 3695 380 G1 1115

The expansion bend The sounding pipe deaeration


guarantees the pressure compensation towards extracts the gasses from the tank and
the atmosphere between the vessel wall and prevents a re-aeration.
the diaphragm.
The diaphragm
The control unit protects the expansion water from a
guarantees maximum operating comfort.All direct air admission.
controls have been designed according to a
The pressure expansion relief
uniform design guideline.
at atmospheric pressure results in the
The hydraulic equipment deaeration of the expansion water.
A tuned system with pressure-maintaining
The pressure cell (level measurement)
pump(s) and over-flow device(s) enables the
hydraulic adjustment to differing installed enables the determination of the vessel
systems and conditions. fill level.
The connection
set connects the control unit with the VG
primary vessel. For 1-pump systems,
the protected shut-off is integrated in
the connection set.With respect to
2-pump systems, the protected shut-off
is located on the control unit.

pg 7
Duraflex EcoPress

Duraflex EcoPress Giga


Pressurisation Systems - Pump Controlled

The EcoPress Giga Pressure-maintaining station is a real


power pack.
The Duraflex EcoPress Giga pressure-maintaining program is tailored to the
specific requirements of industrial and district heating.Within a capacity range
of up to approximately 20 MW, EcoPress Giga models with a modular design
are offered.The combination of various control and hydraulic systems allows
us to achieve a customer-friendly range of various models while maintaining a
high degree of standardization at the same time. In addition, the experts of our
development team plan and construct larger systems upon individual request.

EcoPress Giga is a premium quality system with a flexible, modular design


for heat generating systems up to and over 120C.
heating capacity up to 30 MW, up to 15 MW/120C, an automatic
selection by the customer is possible
two pressure-maintaining pumps
built-in controlled water make-up
fully automated operation for the integration into the modern facility
management with numerous options
possibility of triggering a EcoVac vacuum spray tube deaeration
depending upon the performance, 2 or 3 parallel connected overflow
valves with additional protection of the minimum operating pressure
internationality: you can select from 8 languages in the control unit,
any extension is possible

Innovative Technology and Reliability


The Duraflex EcoPress Giga offers by default an automatic, controlled water
makeup.The water make-up is controlled in dependence on the water level
in the GG primary vessel.An even more comfortable solution: Equip the
Duraflex EcoPress Giga with the Duraflex EcoPress EcoVac vacuum spray tube
deaeration. It does not only free the make-up water from dissolved gases,
but also ensures that the content water in the system is almost gas-free.Air
problems due to free gas bubbles at system high points, at circulating pumps
or control valves are a thing of the past!

Modular Design and Customisation


for heat generating systems up to and over 120C.
heating capacities up to 250 MW and more.
pressures also above 40 bar.
expansion volumes up to 160,000 liters.
medium pressure maintenance in case of complicated pressure conditions.
fully automated operation with individual operating program and SPS.
suitable for high temperature hot water plants.

Automatic Heating reserves the right to change specifications without notice.


pg 8
The expansion bend The dipstick deaeration
ensures the pressure compensation dissipates gases from the
towards the atmosphere between vessel and prevents
reservoir wall and diaphragm. a re-aeration.
Fillset (option)
Equipped with system separator and The butyl bubble
water meter, it allows the direct diaphragm
connection of the water make-up to protects the expansion
the drinking water network. water from direct air
GS control admission.

The GS control in 6 basic models The pressure cell


ensures an excellent operating (level measurement)
comfort.All duraflex controls have allows to determine the
been designed according reservoir level.
to a uniform design guideline.
The flex connection
GH hydraulics
for the expansion line is
The 10 design models of the GH required for the proper
hydraulic system allows hydraulic function of the level
adjustment to suit all systems measurement.

pg 9
Duraflex EcoPress

Duraflex EcoPress Compact


Pressurisation Systems - Pump Controlled

The EcoPress Compact (compressor-controlled).


EcoPress pressurization stations regulate the pressure on the gas side of the
vessel by means of compressor:
When the set pressure is exceeded, the overflow valve opens and releases
air from the expansion vessel. Due to the drop in pressure on the air side,
water flows into the expansion vessel and pressure falls in the system.
If pressure falls below the set pressure, the compressor switches on and
pumps air into the air side of the expansion vessel, forcing water into the
system: the water level falls in the vessel and pressure rises in the system.

Additional units for water make-up and degassing can be added to the
EcoPress.The possibility of the intelligent integration of a water make-up
system is incorporated into the EcoPress Control.

EcoPress Compact
Compact compressor-controlled pressurization station for heating
and cooling water systems.
Perm. excess oprating presure 6 bar
Perm. flow temperature 120C
Perm. operating temperature 70C
Perm. ambient temperature 0-45C
Degree of protection IP 54

Tanks
Nominal volume 200-500 litres

Control Unit
Pressure maintenance with 1 or 2 compressors
Overflow valves

pg 10
Performance Data

EcoPress Operating Operating Enviro. Noise Electrical Electrical System


Model Pressure Temp. Temp. Level Power Connection
kPa C C dB kW V / Hz
RC 200 600 >0-70* >0-45 72 0.75 230 / 50 R1
RC 300 600 >0-70* >0-45 72 0.75 230 / 50 R1
RC 400 600 >0-70* >0-45 72 0.75 230 / 50 R1
RC 500 600 >0-70* >0-45 72 0.75 230 / 50 R1

* Mounted in system return line, diaphragm load of the expansion vessel max. 70C;
please contact us if there is an expected continuous temperature < 0C
Main switch, fixed connection to terminal strip.

Dimensional Data
Model D Hh Weight
mm mm mm kg
RC 200 634 1320 135 52
RC 300 634 1620 135 69
RC 400 740 1620 135 80
RC 500 740 1845 135 93

pg 11
More in the Duraflex range

Duraflex Calibre Duraflex Air and Dirt



Duraflex Calibre series: Separation
Expansion control of potable water
applications
Duraflex 'EcoVent'
Automatic air removal
Butyl diaphragm


Duraflex 'EcoTrap'
Duraflex Cobalt Dirt and Sludge Separation


Duraflex Cobalt series:
For potable water, water heating and
hydro-pneumatic well applications
Duraflex 'EcoTwin'
Replaceable diaphragm
Combined microbuble and
sludge separation


Duraflex OEM
Duraflex OEM series: Duraflex EcoPress
flat vessels for wall hung boiler Pump-controlled EcoPress opens a total
applications new dimension to pressure maintenance.

Duraflex EcoPress:
Pressure control within the narrowest limits

Duraflex refill unit Central deareation of system water content
Automatic water make-up
Automatic water make-up
Backflow prevention according to
AS3500 National Plumbing and
Drainage Code
Duraflex EcoPress
100 kPa 500 kPa
FLO
W
PR
EV
EN
TO
N
Gigamat
Including break tank, pump and B AC
K

pressure switch The duraflex gigamat pressure-maintaining


program is tailored to the specific requirements
of industrial and district heating.
Automatic Heating Pty Ltd ABN 90 446 545 923

DISTRIBUTED BY

Telephone 1800 337 959 Facsimile +61 3 9310 5655


Email sales@automaticheating.com.au
P.O. Box 35 Epping VIC 3076 Australia
www.automaticheating.com.au