PRESSURE MANAGEMENTI N S P I R E D E F F I C I E N C Y

Renowned for developing innovative products, thecompany has built its success on quality, reliability andoutstanding customer service. The rapidly expandingrange of products include, gas �red condensing boilers,hot water generators and pressure managementequipment.

The patented Mikro�ll Electronic �lling device (EFD) is a clearmarket leader and is the most advanced �lling device availalbe,suitable for all applications large or small.

All Mikro�ll pressure management units are supplied as matchedunits together with a suitably sized expansion vessel. These factorytested packages usually require no site commissioning.

With over 60,000 already in use, Mikro�ll Pressure managementsystems are the products of choice throughout the commercialheating industry.

Mikro�ll Systems Ltd is a Midlands based British engineering company which specialises in the design and manufacture of high quality products for the commercial heating industry.

Now generally accepted within the building service industry, sealed or closed heating and chiller systems eliminate inherent problemsassociated with conventional open vented design.

Pumping over or drawing air through the vent pipe are eliminated, reduction of system corrosion and noise, greater �exibility in systemdesign, no water evaporation and increased pressures and temperatures are just some of the advantages associated with an unventedapplication.

The Mikro�ll range of pressurisation management equipment gives the designer and installer various levels of control with models creating up to �ve bar pressure.

INSPIRED | EFFICIENCY

This brochure has been designed toenable you to specify Mikro�ll with

con�dence. If you require any furtherinformation see Mikro�ll.com or

contact our technical department.

2 Pressure Management

MIKROFILL MIKROFILL EFD, MAXI AND EXPANSION

3 Pressure Management

INTRODUCTION TO SEALED SYSTEMS

In any heating or cooling system where water is the thermaltransfer �uid (Hydronic systems) there must be a method ofintroducing the initial charge of water, subsequent “topping up”as required and also a method of accommodating thevolumetric expansion of the water as temperatures within thesystem varies.

The traditional method was the use of a header tankpositioned at the highest point of the system. The �ll rate wascontrolled by gravity and an open vent into the header tankallowed for expansion, such an arrangement was described as, “ An open vented system”.

Although this system was simple and generally reliable itimposed many restrictions on system design and createdproblems with corrosion due to continual oxygenation of thesystem water, resulting in premature failure of components.

It is now accepted that it is best practise to seal the hydronicsystem, that is to say �ll the system with water, seal the systemand make allowances for expansion by one of the severalmeans available, the most popular being a suitably sized“expansion vessel”. The “topping up” of the system is managedby a pressurisation unit. Sealed systems o�er freedom ofdesign, drastically reduce corrosion within a system and allowlevels of control and protection not possible with “openvented systems”.

Mikro�ll manufacture a complete range of sealed systemequipment, including the Mikro�ll Electronic Filling Device, apatented unit that sets new standards forhydronic systems.

the control of

In any new sealed system where the boiler output is 70kw ormore it is a requirement that a pressure management systemmust be installed (BS6644).

PRESSURE MANAGEMENT PRODUCTS

Mikro�ll Electronic Filling Device The only WRAS approved product that can �ll any systemfrom empty and continuously manage the pressure in thatsystem. The Mikro�ll requires no pumps and utilises mainspressure to �ll. This patented principle is extremely reliableand consumes less electrical power than any otherpressurisation product.

The Pressure logic microprocessor o�ers many uniquefeatures and incorporates two levels of �ood protection, fullBMS and self diagnostics are standard features.

Mikro�ll MaxiSingle pump pressure manager is a conventionalpressurisation unit with a di�erence, in addition to the controlfeatures incorporated in the Pressure logic microprocessorthe Maxi range also incorporates low water level alarms,pump test buttons and are factory set as standard.

Mikro�ll Maxi Plus Twin pump pressure manager, as the Maxi speci�cation but with twin pumps, auto change over on pumps and pumpstatus indication.

High pressure versions are available for all Maxi models.

Mikro�ll Expansion vessels Including compressor controlled units. All Mikro�ll Expansionvessels comply with the pressure vessel directive.

MIKROFILL ELECTRONIC FILLING DEVICE (EFD)

4 Pressure Management

MIKROFILL ELECTRONIC FILLING DEVICE (EFD)

The Mikro�ll EFD is a unique patented product that was invented and developed by Mikro�ll and is manufactured in our factoryin Worcestershire. The Mikro�ll has been continuously developed over the last 14 years and is now the undisputed marketleader in pressure management.

Unlike ”pump type”pressurisation systems the Mikro�ll utilises the power of mains water to �ll the system, whilst its patentedprevention feature ensures that the mains water is protected against harmful back�ow. The Mikro�ll is the mostand pressure management unit available.

complete �lling

Not only can it �ll any system from empty, it is also a WRAS approved �uid category 4 back�ow prevention device, so no“Filling loops” or RPZ valves are required. The Mikro�ll also o�ers the most precise pressure management, whilst consumingminimal electrical energy (less than 30 Watts operational, and 10 Watts at standby).

The units feature the Mikro�ll “Pressure logic” microprocessor which o�ers many bene�ts including two methods of �oodprotection, indication of water usage (in litres), hours run, and frequent use. The unit also includes BMS relays for high pressurealarm, low pressure alarm and a common fault alarm, as well as an inbuilt audible sounder.

The compact dimensions, ease of installation, and inherent reliability together with its other unique features combine to makethe Mikro�ll the pressure manager of choice amongst speci�ers and installers alike.

All the Mikro�ll pressure management units feature full self testing and diagnostics

5 Pressure Management

MIKROFILL MAXI AND MAXI PLUS

THE MIKROFILL MAXI AND MAXI PLUS RANGE OF PRESSURE MANAGEMENT UNITS

The Maxi range of units represent the best of conventional “pump type” pressure management units where every modelincorporates “Pressurelogic” microprocessor control including �ood protection, bronze pumps, water �lters, pump test buttons and self diagnostics. The Maxi Plus range of twin pump units also include auto changeover of duty pump.

The standard units are suitable for system cold �ll pressures of up to 2.9 bar, whilst the HP versions can �ll to 5 bar, and the UHP version can attain 7bar.

These sophisticated units have been continuously developed over the last 15 years, and have proven extremely reliable, the integral low water level sensor protects the pumps against damage due to running dry and the robust steel case is both functional and attractive. The microprocessor is door mounted to provide protection and enables easy access to pumps and �lters.

The Mikro�ll Maxi range shares much of its technology with the highly acclaimed Mikro�ll Electronic Filling Device, and as such o�ers the following bene�ts,

Two stage �ood protection, high pressure alarm, low pressure alarm and common alarm with volt free relays. Low water levelsand pump failure will activate the integral audible sounder are all standard features, whilst the LCD displays full statusinformation.

Water usage (in litres), frequency of use, hours run and full self diagnostic information is readily available. The units are supplied fully tested and matched to a suitably sized expansion vessel, ensuring that in most situations the units require no further site setting.

6 Pressure Management

MIKROFILL | EXPANSION VESSELS

The Mikro�ll N range of expansion vessels are intended foruse in sealed systems, heating or chilled water and have beendesigned to the highest speci�cation and meets or exceeds therequirements of 97/23/EC the CE norm for pressure vessels.The Butyl rubber diaphragm is suitable for workingtemperatures up to 120deg C, thereby eliminating the needfor a “gravity loop” and reducing installation time and cost.

The standard N range of Mikro�ll vessels extend to 1000 litresbut vessels up to 5000 litres are available to special order.

The Mikro�ll DE range of WRAS approved vessels arespeci�cally designed for use with potable water andincorporate a replaceable Butyl rubber diaphragm suitable for operating at 10 bar pressure and up to 90°c.

The Mikromat range of vessels have been designed forspecial applications where space or very close operatingpressures are an issue. These compressor controlledexpansion vessels can accommodate almost three times thevolumetric expansion of a standard vessel thus drasticallyreducing the footprint of the vessel, alternatively they canvery accurately control the �nal working pressure on systemswhere pressure is an issue.

The Mikromat Expansion vessels are available in sizesup to 5000litres capacity

When supplied as part of any Mikro�ll pressure managementpackage the vessel will be set at the correct air charge and will include a service valve which enables the vessel to bedrained independently of the system if required.

MIKROFILL N RANGE EXPANSION VESSELS

WATER | A PRECIOUS RESOURCE

7 Pressure Management

WATER REGULATIONS

People used to think about water as an in�nite resource. They could use it, abuse it, pollute it and somehow it would clean itselfand always be in plentiful supply. The truth is our water supplies have to be carefully managed and protected to ensure we havesu�cient supply of clean, healthy, wholesome water.

The Water Fittings Regulations (or Byelaws 2000 in Scotland) are national requirements for the design, installation andmaintenance of plumbing systems, water �ttings and water-using appliances. Their purpose is to prevent misuse, waste, undueconsumption or erroneous measurement of water, and most importantly, to prevent contamination of drinking water. They replace the former Water Byelaws which each water supplier has administered for similar purposes for many years.

Where water or water-using equipment is used with �uids or materials which could contaminate the wholesome water supply,there must be adequate protection to stop back�ow of potentially contaminated water into other parts of the system, especiallydrinking water. The regulations de�ne Fluid Risk Categories by the type of contaminants which are present and specify theappropriate type of prevention device which must be �tted to guard against back�ow.

At Mikro�ll we are proud that the level of protection our equipment delivers has set new standards in back�ow prevention.Commercial Heating and Chilled water systems are de�ned as �uid risk category 4 and as such any device that is permanentlyconnected to the wholesome water supply and a heating or chilled water system must provide at a minimum that level of protection.

The Mikro�ll Electronic Filling Device (EFD) gives that level of protection, not only does the EFD �ll entire systems from empty andmanage a designed water pressure, it is the only device of its type to o�er �uid risk category 4 back�ow prevention built in.

Mikro�ll back�ow prevention, protecting what is our most precious resource.

ELECTRICAL CONNECTIONS

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EFD electrical data

• Supply: 230V 1ph 3 Amp• Full load current: 1 Amp• Start current: 1 Amp• Fuse rating: 3 Amp• BMS relays and boiler/chiller• Relays: volt free contacts

rated at 250VAC at 5 Amp • All relays are independantly

fused at 5 Amp

Maxi electrical data

• Supply: 230V 1ph 6 Amp• Full load current: 2.5 Amp• Start current: 4.5 Amp• Fuse rating: 6 Amp• BMS relays and boiler/chiller• Relays: volt free contacts rated

rated at 250VAC at 5 Amp • All relays are independantly

fused at 5 Amp

EXPANSION VESSEL SIZING

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The following factors a�ect the vessel selection and the appropriate values should be assigned:1. Total height of the system2. Flow/return temperature3. Pressure developed by circulating pump(s)4. Maximum allowable pressure in system as dictated by components in the system

(ie radiator, boilers, heater batteries)5. System water content

STEP ONECalculate the cold water �ll pressureThe cold �ll pressure must be in excess of the static head exerted by the height of the water in the system, above the pressurisation unitie. Height of system in meters + 3* = Cold �ll pressure (bar) *allow extra 3 meters to assist venting

10

NB. The cold �ll pressure is also the air/nitrogen charge pressure in the expansion vesselExample: Height of system = 12m then 12 + 3 = 1.5 bar cold �ll pressure and vessel charge pressure

10

300.01

0.0120.0140.0150.0190.0230.03

0.045

350.0140.0160.0180.02

0.0250.030.040.06

400.0180.02

0.0230.0270.0320.04

0.0540.08

450.0230.0260.0290.0340.040.05

0.0690.1

500.0280.0310.0360.0410.05

0.0620.0820.125

550.0330.0370.0420.050.06

0.0740.100.15

600.0380.0420.05

0.0570.0680.0850.1150.175

650.0440.05

0.0570.0660.0790.10

0.1330.20

700.0520.0570.0660.0770.0920.1140.1550.23

750.0580.0640.0740.0850.1050.130.170.26

820.0670.0730.0830.100.120.150.200.30

850.0720.0820.0910.1080.130.160.22

0.325

900.080.09

0.1030.1170.1430.180.24

0.3675

Maximum System Temperature

87654321

Vess

el F

acto

r

Large Systems

Medium Systems

Small/chilled water systems

12ltrs/kW

10ltrs/kW

8ltrs/kW

STEP TWOEstablish the �nal working pressureThe �nal working pressure must always be below the safe working pressure of any components in the system, including the pressure relief valve.

STEP THREEESelecting the vessel factorUsing graph 1 strike a line through the required �nal working pressure to the right hand side of the graph, read o� the vessel factor at this intersection.

STEP FOURSelecting the system factorUsing the vessel factor obtained from graph 1 and the maximum system temperature, select a system factor from table 1Example: A vessel factor of 3 and a maximum temperature of 82˚c will give a system factor of 0.15.Please note: for chilled water systems we recommend using 30˚c as the maximum working temperature.

STEP FOURCalculating the expansion vessel sizeMultiplying the system water content by the system factor will result in the minimum expansion vessel size required.In most instances the actual water content of the system is impossible to ascertain and the following approximationbased on kilowatt rating of the system is acceptable.

DIMENSIONS

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EFD

MAXI & MAXI PLUS

APPLICATION

TECHNICAL | DATA

11 Pressure Management

RELAX, LET MIKROFILL HANDLE THE PRESSURE

At Mikro�ll we believe that the process of product selection be as straight forward as possible.

Pressurisation systems can be supplied as complete packages. The pressurisation unit, expansion vessel(s) and service valve* can be manufactured, tested and set to your speci�c system requirements, giving the peace of mind that factory matchedequipment only can.

*Mikro�ll service valves are the convenient answer to vessel associated maintenance tasks. The all in one service valve allowslockable vessel isolation, (inline with BS6644) drain point and a union connection for quick removal and reconnection.A suitable sized valve is included for each vessel at no additional cost with every packaged unit supplied.

N RANGE EXPANSION VESSELS

DE RANGE

N Range Technical Data

DE Range Technical Data

mm272272308308376mm441512512512634634634740740740740740

mm233315360480465mm495570680890785915

108510751295153019902430

mm

130mm175175175175225225225225225245245245

mm

320mm340370370370485485485570570570570570

3/4”3/4”3/4”3/4”3/4”

3/4”1”1”1”1”1”1”1”1”1”1”1”

kg1.92.63.54.65.4kg

12.517.020.528.636.745.052.065.079.085.0

103.0120.0

3 bar / 120˚cN 8/3

N 12/3N 18/3N 25/3N 35/3

6 bar / 120˚cN 50/6N 80/6

N 100/6N 140/6N 200/6N 250/6N 300/6N 400/6N 500/6N 600/6N 800/6

N 1000/6

Model ø D H h ø F A Weight

mm409480480634634740

mm740730840980

12801485

mm160152152144144133

1”1”1”

1 1/4”1 1/4”1 1/4”

kg25.027.032.050.055.085.0

10 bar / 95˚cDE 60DE 80

DE 100DE 200DE 300DE 500

Model ø D H h A Weight

MIKROFILL SYSTEMS LTDWEST COURTMERSE ROADNORTH MOONS MOATREDDITCH WORCESTERSHIRE B98 9HL

T: +44 (0)8452 60 60 20

F: +44 (0)8452 60 60 21

E: info@mikro�ll.com

W: www.mikro�ll.com MFS/PM10080087

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