Flamco Flexcon m-k/c User manual

Flexcon®M-K/C

Contents

1 General 4

1.1 About this manual 4

1.2 Other supplied documentation 4

1.3 Use of Flamco products 4

1.4 Further help and information 4

2 Safety 4

2.1 Intended use 4

2.2 Important information 4

2.3 Signs in this manual 4

2.4 Specications 4

2.5 Safety devices 4

2.5.1Avoiding excessive pressure 4

2.5.2Avoiding excessive temperature 5

2.6 Signs on the automat 5

3 Description 6

3.1 Overview Flexcon M-K/C Automat 6

3.2 Controller SDS 230 V 1~ 7

3.3 Working principle 7

4 Transport and storage 8

4.1 Transport 8

4.2 Storage 8

5 Installation 9

5.1 Prepare for installation 9

5.2 Ambient conditions 9

5.3 Place the automat 9

5.4 Hydraulic installation 10

5.5 Electrical installation 10

5.6 Basic electrical connections 230V 1~ 11

5.7 Electrical connections accessories 12

6.1 Controller menu structure 13

6.2 Menu symbols 13

6.3 Working principle controller 14

6.4 Controller inputs 15

7 Fill the automat 16

7.1 Fill procedure 16

7.2 Filling examples 17

8 Maintenance and troubleshooting 18

8.1 After a power failure 18

8.2 Maintenance interval 18

8.3 Error messages 19

9 Disposal 20

11 Example hydraulic and pneumatic equipment 22

ENG

1 General

1.1 About this manual

This manual includes technical specifications, instructions and explanations that helps to use this automat safely. Read

and understand all the instructions before you transport, install, commission, restart, operate or maintain the automat.

1.2 Other supplied documentation

General information of additional components, such as the compressor and the sensors, is included in this manual. If

additional documentation is supplied, also follow the instructions in those.

1.3 Use of Flamco products

According to order or execution complementary documentations can be added. Follow the positions performed in the

dispatch papers.

1.4 Further help and information

Contact your local supplier for additional services as:

• Training,

• Maintenance agreements,

• Service contracts,

• Tooling service,

• Repairs and improvements.

2 Safety

2.1 Intended use

The purpose of the automat is to maintain the operating pressure in a system for closed water heating and climate

control.

2.2 Important information

The automat has safety devices intended to prevent injury and damage. Use the automat in the following way:

• Have the installation be carried out by qualified personnel.

• Comply with local legislation and guidelines.

• Do not make modifications to the automat without prior written permission of Flamco.

• Make sure that all automat covers and doors are closed when operating the automat.

• Do not touch live voltage. The sensor units, diaphragm rupture, and the capacity pressure sensors operate with

extra low safety voltage.

Flamco shall not be liable for any losses arising from the non-observance of safety conditions or as a consequence

of the disregard of standard precautionary measures when performing such services as transport, installation,

commissioning, re-starting, operation, maintenance, testing and repair, even in the event that these are not expressly

described in these instructions.

2.3 Signs in this manual

Identifies a hazard that could lead to personal

injury including death/damage to the automat,

damage to other equipment and/or

environmental pollution.

Earthing

Identifies an electric hazard that could lead to

personal injury including death/damage to the

automat, damage to other equipment and/or

environmental pollution.

Important information.

2.4 Specications

The construction of the automat is designed in accordance with Pressure Equipment Directive 97/23/EC.

2.5 Safety devices

Make sure that the installations that operate the automat cannot exceed the permitted operating overpressure

and temperature. The gas compartment is equipped with a safety valve. This valve does not prevent the operating

overpressure to exceed in a heating system.

2.5.1 Avoiding excessive pressure

To limit the pressure in the system, use safety valves that:

• open not later then the maximum allowable working pressure is reached.

• are in position, within 1.1 times the maximum allowable working pressure, to vent the arising capacity flow of the

generator.

• have a proven reliability or are certified.

Do not narrow the inlet or outlet piping of the safety valve.

ENG

2.5.2 Avoiding excessive temperature

Make sure that the permitted continuous operating temperature of 70 °C at the automat is not exceeded. Systems

with return line temperatures higher than 90 °C must have a cooling device coupled between the system and the

automat connection.

Activate the pressure and temperature safety devices and check them regular on proper working.

2.6 Signs on the automat

The signs on the automat are part of the safety provisions. Do not cover or remove the signs. Inspect regularly if the

signs are present and legible. Replace or repair signs that are illegible or damaged.

Achtung,

Attention,

gefährliche Spannung! Nurvom Fachpersonal zu öffnen.

Vor dem Öffnendes Gerätes spannungsfrei schalten.

high voltage! Opening by qualifiedpersonnell only.

Disconnect the unitfrom the power supply before opening it.

Der Kompressormotor ist thermisch gesichert und starter

automatisch, nach dem Rücksetzen dieser Sicherung.

Thecompressor motor is thermally protected and

will automatically restart when protector resets.

Flamco Group

P.O. Box 502

3750 GM Bunschoten

the Netherlands

On the automat the following product information can be

found:

A Contact information

B Warning sticker

C Type plate

Flamco Group

P.O. Box 502

3750 GM Bunschoten

the Netherlands

On the type plate the following product information can

be found:

A Type of the product

B Product serial number

C Year of manufacture

D Precharge pressure

E Permissible working overpressure

F Maximum diaphargm temperature

G Permissible working temperature

H Nominal volume

Do not use the automat when the

specifications on the type plate differ from

the order.

Enlever

le dispositif protecteur

de la transportation!

Remove the

Transport Lock!

TRANSPORTSICHERUNG

entfernen!

Do not yet remove the transport lock. Refer to

section 5.3.

3 Description

3.1 Overview Flexcon M-K/C Automat

18 1719

No. Name

1 Main switch

2 Cover

3 Cover screw

4 Type plate

5 Steel expansion vessel

6 Cable duct

7 Tensioning belt

8 Foot height adjustment

9 Flexible connection hose

10 Compressor

11 Air filter compressor

12 Cover door

13 Controller unit, 230 V, 50 Hz

14 Pressure relief solenoid

15 Capacitor (PE)

16 Transport lock

17 Level sensor

18 Diaphragm rupture sensor

19 Pressure maintaining solenoid

20 Safety valve

21 Pressure sensor

22 Gas compartment connection

ENG

3.2 Controller SDS 230 V 1~

3.3 Working principle

• If the temperature in a closed heating system or in a

climate control system (K) changes, the volume of the

operating water changes.

• As a result the water level in the water compartment

• (A) of the automat (D) changes.

• This results in a pressure difference in the gas

compartment (C).

• The pressure sensor (G) records the pressure of the

gas in the gas compartment and transmits the actual

pressure value to the control unit (H).

• The control unit compares the measured value with the

programmed nominal value.

• If necessary the compressor (I) or pressure maintaining

solenoid (F) will be activated.

• The level sensor (E) is installed to monitor the amount of

operating water in the automat.

No. Name

1 Operating panel, graphic display, LED error

display, Selector switch (click and roll).

2 Main switch. ON, glows red.

3 Pico fuse F1, Motor 1, T16A 250 V.

4 Pico fuse F2, Valve 1.1 and 2, T16A 250 V.

5 Serial no. of controller (Menu E2a 1).

6 Terminal strip, feed, inputs and outputs.

7 Serial interface, RS485

4 Transport and storage

4.1 Transport

The shipping papers list all the items, such as equipment and documentation. Ensure that the delivery

is complete and not damaged. The automats are packed horizontally on disposable pallets and are fully

assembled. Accessories can be packed separately or as a part of the automat.

Identify the items that are missing or not correctly delivered. Read the general terms and conditions in the

shipping papers.

MAX

• Transport the pallets vetically.

• Lift the automat just slightly.

The centre of gravity of the automat is at the

top. Be carefull not to tip over the automat.

Make sure that the lifting device can support

the automat. For weight and dimensions,

refer to chapter 10: Technical specifications.

4.2 Storage

Make sure that the storage space meets the ambient

conditions. Refer to section 5.2.

• Take care for an even floor.

• Do not stack automats.

ENG

5 Installation

5.1 Prepare for installation

N N N

Inform the test or certification agencies before installing the

automat. Follow the rules of these agencies.

Also:

• Do not attach the automat to the ground.

• Do not pour concrete or plaster over the automat feet.

Make sure that the surface can support the

maximum weight of the automat, including the

water. Refer to chapter 10.

5.2 Ambient conditions

> 0,5 m

> 1 m

< 80 %

+5 °C..+40 °C

Make sure

• that the automat is installed in a closed, dry and frostfree

room;

• to maintain the minimum distances as indicated;

• that the atmosphere does not contain electrically

conducting gases or high concentrations of dust and

vapors. Risk of explosion when there are combustible

gases;

• that the vicinity is clean and welllit.

- Relative humidity: not condensating.

- Free of vibrations.

- Free from heat- and solar radiaton.

• that the automat is free from additional loads.

5.3 Place the automat

5.4 Hydraulic installation

• Connect the flexible hose to the automat.

• For installation, only use the flexible hose that is

delivered.

• Connect the expansion line.

• For an installation example refer to chapter 11.

• Install a shutoff device (A) with drain facility (B).

5.5 Electrical installation

• Make sure the main power switch is OFF.

• Disconnect the power supply.

OFF

• The cover holds the terminal layout.

ENG

5.6 Basic electrical connections 230V 1~

230 V

50 Hz

SELV

RS485

SELV

E D

28 29 30 31 32 33 34 35 36

27 26 25 24 23 22 21 20 19 9 8 7 6 5 4 3 2 1

10 11 12 13 14 15 16 17 18

Pressure maintaining

solenoid

Pressure relief

solenoid

Diaphragm rupture

sensor

Compressor

Common

failure

Nominal power

[kW]

Nominal current [A] Fuse wiring

connector [A]*

Nominal voltage

230 V: +6%; -10%

50 Hz: +1%; -1%

Protection type

IP54 (level sensor IP65)

0.25 2.7 6

SELV: Safety Extra Low Voltage

* Recommended value; Line safety switch, characteristic C

5.7 Electrical connections accessories

A,B, C(A)

230 V

50 Hz

A0 0 0 0 0 0 0 0

(A) SELV

Pressurisation Unit type NFE 1...(3) - MVE 2 Feeds the machine with water.

Make sure the water pressure is 1.2 bar above the installation working

pressure. The level sensor and the make-up time control the unit.

Degassing / ENA 5/10 For pressure step de-aeration of the installation. Can be

combined with a pressurisation unit.

Flamco-Fill PE pressurisation unit Feeds the installation with water through an

atmospheric breaktank and a pump. The level sensor and the make-up time

control the unit.

Easy contact 3.0 Used for the remote signalling of errors: min/max water level,

min/max operating pressure, motor protection, diaphragm rupture. For each

error message, a red LED and a relay with a volt-free opener/closer is active.

ENG

6 Startup controller

6.1 Controller menu structure

SYSTEM CONFIGURATIONSYSTEM DATASYSTEM CLASSIFICATION

Process display

(Symbols) ASystem

Error

Manual mode Act. pressure

Start

Actualllingtime, Actual level

quantity (Symbols)*

Service Menu

1Project number

2Software version

3Start

4Maintenance

5Error list

6Value statistics

7Operating hours

8Rellstatistics

9Change entry code

10 Back

Equipment Menu

1ID-Number

2Language

3Adjust., content

4Operating mode

5Filling

6Sensor

7Motor protection

8P. min prot

9Relief valve

10 Common failure

11 Back

Data menu

1System press.

2Level

3Filling

4Filling control

5Time, date

6Other

7Back

Code menu

Ku1

000001

Error list, activ (Acknowledge)

Selection menu 1

1Mode

2Data

3Service

4Back

Selection menu

1View

2Enter

3Back

6.2 Menu symbols

ID No ID number available. Controller not

configured.

Denied, not installed.

Outside parameter limits.

Outside reliable parameter limits.

Code required.

No adjustment at factory performed.

Manual operating mode.

No intervention possible.

Operating mode, view only.

No adjustment during operation performed.

No measurement value, quieting.

Entry confirmed.

Programming mode, enter.

Test mode.

Warning.

Save error. Settings not saved.

Wait.

6.3 Working principle controller

A B C D

Start up

• Switch off an installed refill equipment.

• Close the inflow valves.

• Switch on the controller (D).

A Display

B Error LED

C Navigation wheel

D ON/OFF switch controller

Use the navigation wheel (C) to navigate through the menus

an to confirm the input. The display (A) shows the menus. In

case of errors the error LED (B) is on.

2 sec...

•Hold down the navigation wheel for two seconds to go to

the process display, whatever the cursor position.

• In case of errors the process display switches from

[SYSTEM] to [ERROR] and the LED is on.

• The error messages, minimum water level, minimum

pressure alarm are consistent by the first start of

operation.

• It is possible to turn the wheel to switch between

[SYSTEM] and [ERROR].

• When [ERROR] is displayed press the wheel to go to the

error list. In case of more than one error, scroll trough the

errors. All errors are shown in accordance of appearance.

• When [SYSTEM] is displayed, press the wheel to go to

the option menu.

ENG

6.4 Controller inputs

Save

B 2

System

000000000001000001

Save BackSave BackSave Back

G3 2

D 1

Mode

Data

Service

Back

ID-number

Language

Adjust,content

Adjustment,valve

F1 24

Back

G 2

View

Enter

Back

Factory settings

Operational sett.

Back

G2a 1

Deutsch

Nederlands

English

Slovensky

F 1

System press.

Level

Filling control

Filling

G2 18

Norsk

Italiano

cesky

Back

G2 17

Svenska

Norsk

Italiano

cesky

F 5

Time, date

Other

Back

19.05.07

10:15:00

G 3 G3b 1

Start Back

124 kg

123

F1a 1

Nom. sys. press

G3b 2

BackStart

124

123 kg

G 11

P.min prot.

Relief valve

Common failure

Back

D 2

2,0 bar

Save Back

Nom.sys.press

Save Back

2,6 bar

X,x+Psteam+0,5bar

X,x bar

5,4

0,5

30.07.07

13:36:00

Save Back

30.07.07

13:36:00

Back Back

30.07.07

13:36:00

Save

(3 sec)

G3 3

Factory settings

Operational sett.

Back

Save Back

2,6 bar

5,4

0,5

F1 1

2,6 bar

ID-number

Language

Adjust,content

Adjustment,valve

Mode

Data

Service

Back

Nom.sys.press

Code

Language

Zero Setting Language

System pressure

Date/Time

Zero Setting

Date/Time

System pressure

• When entering program mode, the control for pressure maintenance is active.

• The code will be active 5 minutes after the latest input.

• Remove all unpermitted loads, supported objects or lateral loads from the basic automat.

• Perform a zero level adjustment. The zero adjustment procedure corrects deviations from test tolerances and sets

the level parameter to 0%.

• When you complete the programming procedure, the electrical parts of the compressor expansion automat are

ready for operation.

• By delivery the automat is pressurised. The normal pre-charge is an overpressure of 1.0 bar. The pre-charge can be

set lower, when the client orders so. The information about the pre-charge is displayed on the controller unit. If the

ambient temperature changes, variations in the pre-charge may occur.

• When ready, a value for level and pressure is shown in the display.

7 Fill the automat

7.1 Fill procedure

• Do not fill the automat before the necessary start measures are done.

• Turn off the main switch of any external filling device.

A B C D

Make sure all shutoff devices on the expansion feed

to the return connector (A) are closed.

A B C D

•Automatic filling equipment: Refill equipment type

FlamcoFill STA, PE, NFE-MVE2 starts on filling the vessel

on 12% after turning on the controller.

• Manual filling: Use the filling valve (A) to fill the automat.

• Fill the hydraulic compartment of the automat up to

12...20% (B).

• Close the filling valve (A) after the filling procedure, refer

to section 7.2.

• Make sure the pressure does not exceed the nominal

operating pressure.

Ensure that the pressure difference is at least

1.2 bar. A too high initial pressure disables the water

supply.

• Complete the procedure to start the heating or the cooling system.

• Fill the system completely.

• Vent the system completely.

• Make sure that the available electrical equipment is ready.

• Switch on the controllers, accessories and additions.

• Open the shutoff device on the expansion feed to the return connector slowly.

• Execute the start protocol. Refer to section 6.4.

• For adjustments during operations, refer to section 6.4.

ENG

7.2 Filling examples

Filling example I:

Maximum design temperature: 50 °C Maximum filling

level: 92% Water trap (minimum water supply), re-feed

level: 12% Minimum design temperature: 10 °C Actual

temperature: 44 °C Read out fill level = 74%

Filling example II:

Maximum design temperature: 80 °C Maximum filling

level: 92% Water trap (minimum water supply), re-feed

level: 12% Minimum design temperature: 10 °C Actual

temperature: 44 °C Read out fill level = 37%

10 20 30 40 50 60 8070

100

44 °C

~37 %

92 %

min. 10 °C

max. 80 °C

12 %

~74 %

92 %

min. 10 °C

44 °C

max. 50 °C

Filling example I Filling example II

V[%]

T [°C]

Vessel target volume

Actual temperature

Filling example III

Maximum design temperature: 25 °C

Maximum filling level: 92%

Water trap (minimum water supply), re-feed level: 12%

Minimum design temperature: 6 °C

Actual temperature: 22 °C

Read out fill level = 73%

Filling example II:

Filling example IV:

Maximum design temperature: 40 °C

Maximum filling level: 92%

Water trap (minimum water supply), re-feed level: 12%

Minimum design temperature: 6 °C

Actual temperature: 22 °C

Read out fill level = 35%

5 1 0 1 5 2 0 25 30 4035

100

22 °C

~35 %

92 %

min.6 °C

max. 40 °C

12 %

~73 %

92 %

min. 6 °C

22 °C

max. 25 °C

V[%]

T [°C]

Actual temperature

Vessel target volume

Filling example III Filling example IV

8 Maintenance and troubleshooting

• The water and the contact surfaces can • be 70 °C or more.•

• Wear the required protective clothing.•

• The floor can be wet or greasy. Wear protective shoes.

Release the pressure of the gas compartment and the water compartment before maintenance.

8.1 After a power failure

The programmed parameters of the controller do not change after a power failure.

• Check the condition of the expansion automat for integrity after a power failure.

8.2 Maintenance interval

Interval Component Activity

Annually Compressor oil-free Function test (switch possible by

changing nominal pressure, note

working pressure differential; manual

operation SCU controller).

Air duct module Function test (see compressor). Test

safety valve via lifting device.

Compressor oil-free Clean filter unit, filter housing, intake

opening.

Dry installation required!

Vessel(s) Drain condensate

Equipment

Automat connections

Shutoff devices

Seal test of all pressure

compartment connections on gas

and water compartment (visual

inspection). Checking of external

condition for damage, deformation,

corrosion.

5 years Internal check Check pressure compartment for

corrosion,

deformations and damage.

10 years Pressure test Test the automat for water

overpressure.

ENG

8.3 Error messages

Error

no.

Description Remark Reset Measure

1Min. pressure alarm

limit

The programmed value F1 6 is reached or

exceeded.

Test compressor (fuse). Interpretation,

check parameter choice.

2Max. pressure alarm

limit

The programmed value F1 7 is reached or

exceeded.

Check valve (fuse). Interpretation, check

parameter choice.

3Min. level alarm limit The programmed value F2 6 is reached or

exceeded. Equipment without fillcommand

or fillcommand with insufficient flow.

Adjust water, note error - No.5. Incorrect

interpretation or first filling. Check

expansion volume.

4Max. level alarm limit The programmed value F2 7 is reached or

exceeded (Pressure not maintained). A

Drain water, note error - No.5. Incorrect

interpretation or first filling. Check

expansion volume.

5Filling quantity The programmed quantity per day is

reached (value F2 5). Too high fill command B

Attention, leaking or failing installations

cause water damage and high costs.

Check equipment.

7Operating time

compressor

The programmed value F1 12 is reached or

exceeded. ATest compressor, air filter.

Flamco Service.

8Water supply The programmed value F4 6 is reached or

exceeded.

A,C

Diaphragm pressure to low, check water

supply.

9Valve 3 error Valve 3 of the refill equipment is not closed. Check valve 3. Clean or replace the

valve if neccessary.

10 Cycle time The programmed value F4 3 is reached

orexceeded.