flamco Flexcon M-K Series User manual
1
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
Dear Customer,
Thank you for purchasing the FLEXCON M-K Compressor Expansion Automat – a quality product
from Flamco. This expansion automat from the proven M-K series offers you reliability, guaranteed
operational readiness and ease of use.
On the following pages we will present you with technical specifications, instructions and
explanations that facilitate safe use in accordance with regulations. Persons responsible for
transport, installation, commissioning, re-starting; operation, maintenance, checks and repairs
must have read and understood these instructions.
Please place these instructions in a place where they can be inspected at any time.
We will be happy to answer any questions that are not covered by these instructions,
Contents
(Sections 1 – 7 belong together, not independent) Page
1. Exclusion of liability 2
2. Acceptance of goods 2
Inspection 2
Type plate 2
Transport 2
Storage 3
3. Product description 3
Methodology 3
Equipment 3
Operating modes 5
Accessories, additions 6
4. Safety instructions 7
Intended area of use 7
Measures for hazard-free operation directions for safe use 8
Avoiding excessive pressure 8
Avoiding excessive temperature 8
Residual hazards 8
5. Installation 9
Environmental conditions 9
Base and setup 9
System connection 9
Gas compartment couplings 10
Electrical installation 10
6. Start 10
Commissioning 10
Programming 11
Start and system temperature 11
Re-start 12
7. Maintenance 12
8. Periodic testing, pressure equipment 12
Appendices
Appendix 1
Technical data, specifications, hydraulic and pneumatic equipment
Dimensions, weights 13
Minimum distances 14
Example installations 15
Appendix 2
Technical data, specifications, electrical equipment
Modules 19
Flexcon control unit, M-K/S,
Operating mode menu. [Fault displays] 20
Programming mode menu 21
Service programming mode [Default settings] 22
Standard terminal diagram 23
Standard terminal diagram, accessories, additions 24
Terminal diagram for special version [400/230V 3/PE ~50Hz] 25
Terminal diagram for special version, accessories, additions [400/230V 3/PE ~50Hz] 26
SDS controller, M-K/U,
Operating mode menu 27
Programming mode menu. 28
Service programming mode. [Default settings] 30
Error list 30
Standard terminal diagram. 31
Standard terminal diagram, accessories, additions 32
Terminal diagram for special version, accessories, additions [Valve pressure increase] 33
Terminal diagram for special version [400/230V 3/PE ~50Hz] 34
Terminal diagram for special version, accessories, additions [400/230V 3/PE ~50Hz] 35
35
Edition 0206©Flamco
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18502426 broch Flexcon M-K_UK.indd 118502426 broch Flexcon M-K_UK.indd 1 13-07-2006 08:55:2113-07-2006 08:55:21
www.flamco.nt-rt.ru
2
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
1. Exclusion of liability
All the technical information, data and instructions contained in these operating instructions for
operations that can and are to be performed, are up to date at the time of editing.
They contain our current knowledge and experience to the best of our understanding.
We reserve the right to make technical modifications arising from the further development of the
Flamco product presented in these operating instructions. For this reason, no claims may be
derived from technical data, descriptions and illustrations.
Required operations within the scope of Flamco delivery must be performed by trained
and certifi
ed specialists. This includes such persons having knowledge of applicable safety
conditions. Consequently, Flamco shall not be liable for any losses, subsequential losses,
personal 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.
Technical illustrations, drawings and graphs may not necessarily represent the actual module,
individual components or spare parts supplied.
Drawings are not to scale and contain symbols for the purpose of simplification.
-Reference symbols used in the instructions.
Hazardous voltage
Ignoring this can put your life in
jeopardy, cause fires or accidents
destruction
For special consideration
Ignoring this may result in
reduced functioning ,overload
or destruction
2. Acceptance of goods
Inspection
The items supplied (equipment, documentation) are listed in the shipping papers.
The contents of the delivery must be immediately checked for completeness and transportation
damage upon arrival.
Incorrect or missing items must be immediately identifi
ed. Please note the contents (e.g., for
handling goods, notifications of defects...) of the general terms and conditions contained in the
shipping papers.
Compare the specifications on the type plate of the expansion vessel with the specifi
cations of
your order or the details of the relevant project.
If this expansion vessel is used regardless of any differences which have been ascertained (not
used in accordance with regulations), it will not be possible to exclude system faults or hazards to
people, animals or objects.
Type plate
- Gas pre-charge mark.
The expansion vessel (basic and ancillary vessel) is under pressure on delivery, which, in
standard situations, is an overpressure of 2.0 bar. This value may be smaller, depending on the
order. The information is at eye-level on the operating side (user position).
(Changes in ambient temperature can cause variations in the pre-charge.)
Transport
The basic and ancillary vessels of the unit are packed horizontally on disposable pallets and
delivered fully assembled. Accessories or add-on equipment (e.g. Compressor Unit K04) can be
packed separately or as a part of the automat unit packaging. The disposable pallets are suitable
for horizontal transport using permitted forklift devices (e.g. forklift trucks, forklift stackers...).
Always use the largest possible fork size for the pallet to prevent the load from tipping over.
Position the object to be moved as low as possible, at right angles to the forks.
Hoist fittings on the vessel (welded lifting lugs) are to be used for lifting of the empty, uninstalled
vessel that has been removed from its packaging.
Note: The transport guard (Pos. 46, page 4) provides necessary protection against collision during
the setup of the expansion automat and must only be removed once this is complete!
(Installation surface, setup, page 9)
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0045
:
:
:
Herstellungsjahr
Year of manufacture
Année de fabrication
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
°C
Flamco STAG GmbH
39307 Genthin
GERMANY
Liter
litre
Zulässige Betriebstemperatur min. / max.
Permissible working temperature min. / max.
Prüfüberdruck
Test overpressure
Zulässiger Betriebsüberdruck
Permissible working overpressure
Nenninhalt
Nominal volume
Serien-Nr.
Serial-No.
Typ
Type
bar
bar
litres
N° de série
Capacité nominale
Surpression d`essai
Surpression de service admissible
Température de service mini. / maxi. admissible
Type
Conformity mark
Manufacturer’s mark
Respective year of manufacture
Permitted operating temperature of the expansion vessel
Permitted test overpressure of the expansion vessel
Permitted operating overpressure of the expansion vessel
Nominal capacity of the expansion vessel
Serial (production) number of the expansion vessel
Type rating of the expansion vessel
Manufacturer’s logo Manufacturer’s address
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3
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
Transport (continued)
Once the automat has been removed from its packaging, it must be set up under safety measures
to avoid being damaged, tipped or shaken. Only use permitted load lifting devices.
Depending on the transport method and the size of the expansion automat, various types of
packaging may be used.
Unless otherwise contractually agreed, the packaging meets the packaging guidelines of
Flamco STAG GmbH.
Storage
Interim storage can also take place while packed. Conditions for this are: a closed, frost free room
(dry..60...70 % relative humidity), free of vibrations, protected against heat and direct sunlight.
Vessels or equipment parts that have been removed from the packaging must be placed in their
final position.
The stability is to be ensured and the stacking of equipment should be avoided.
3. Product description
Methodology (Symbol)
Changes in the volume of the operating water )a* caused by temperature changes in closed
heating or climate control systems generate different levels in the water compartment of the
expansion automat. The pressure in the gas compartment of the automat caused by this is a
measurable value that is continuously recorded by a pressure sensor and transmitted via a signal
cable to a control unit.
In the event of any difference, a comparison of these actual values with the programmable
nominal values leads to the control of a compressor or pressure relief valve, which is linked with
the gas compartment by a common pressure control tube.
In this way, the valve is opened as the level increases during system heating to relieve pressure
(pressure reduction) and the compressor is switched on as the system cools and the level falls
(pressure increase).
A hystereses )b* may be set for controlling the valve or compressor, which ensures the
maintenance of the set system pressure of a heating or climate control system with a modifi
able,
small tolerance.
The levels recorded by a level sensor and assessed by the controller result, as in the case of the
system pressure, to display values and once limit values have been reached, to control signals
that enable an additional evaluation or the actuation of other units.
By choosing different nominal sizes of vessel, the option to connect several vessels, the selection
of different compressor capacities or operating modes and by changing the nominal values, the
M-K compressor- expansion automats can be adjusted to the operating behaviour of a heating or
climate control system.
)a*
Water types whose constituent materials do not pose any hazard to the operational readiness
and do not damage or improperly influence (e.g. heating water) water-keeping parts of the
Automat (e.g. pressure-bearing components, diaphragm, vessel connection,...)
)b* Switch difference to the nominal value, only changes to the nominal value can be assessed.
Small hystereses: the advantage is a small deviation from the nominal value, the disadvantage
is a high switch frequency.
Large hystereses: the advantage is a low switch frequency, the disadvantage is a large deviation
from the nominal value.
The programmable setting range on the M-K expansion automat, this switch difference,
is 0.1 – 0.5 bar for as well the compressor (pressure increase), as for the pressure relief valve
(pressure reduction). Standard models have a preset of 0.2 bar (total lag of 0.4 bar).
Equipment
The equipment components of the M-K expansion automat meet the safety requirements of the
relevant EC directives and the specialist standards to be applied.
Compliance is confirmed by means of conformity declarations.
The construction of the pressure vessels is designed in accordance with Directive 97/23/EC )c*
and under consideration of the German AD Information Sheets )d*.
Examination and cleaning openings for inspections are provided on the basis of practical
experience (taking German standards into consideration).
The conformity label CE0045 (on the type plate) identifies the Notifying Body at which the conformity
evaluation process according to Article 10 of this Directive has been tested and confirmed.
In line with the scope of use according to regulations, the corrosion allowance is 0 mm.
This allowance may be higher , depending on the order.
)c* Directive of the European Parliament and Council for the harmonisation of legal provision of
member states on pressure devices. Official Journal of the European Communities L181.
)d* Technical safety requirements for normal operation conditions, prepared by the
associations that cooperate in the Arbeitsgemeinschaft Druckbehälter (AD).
Published by: Verband der technischen Überwachungs- Vereine e.V., 45038 Essen.
Pressure vessel
Diaphragm
(Gas pressure)
Gas compartment
Symbol
Heating
Water compartment
(Water pressure)
sensor
Pressure
or climate
control
system
Compressor
Controller
M
sensor
Level
Valve
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4
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
Configuration (continued)
1Type plate.
2Steel expansion vessel,
exterior corrosion protection,
untreated internally (inner coating ***).
3Inspection opening.
4Inspection opening DN 500,
M-K/S 6500 – 10000 litres.
5Lifting lugs (for lifting).
6Collision protection.
(gas compartment connections).
7Foot-height adjustment.
8Foot pressure plate, M-K/S 5000 – 10000 litres.
9Setting screw (transport guard,
level sensor, disassembly).
10 Manual breather valve.
11 Cap nut (collision protection of
manual breathervalve ).
12 Floatvent **.
13 Quick-release coupling, coupling box.
14 Pressure hose, flexible, coupling plug
double-sided, length 3000 mm [**].
15 Pressure hose, flexible, expansion.
16 Pressure hose, flexible, pressure sensor.
17 Pressure hose, flexible, safety valve,
M-K 400 – 3500 litres.
18 Pressure hose, flexible, pressure increase 1; 2** )k*.
19 Pressure hose, flexible, system connector,
M-K/U, M-K/S 400 – 10000 litres.
20 System connector, M-K,
90° angle, 400 – 3500 litres.
21 System connector, M-K/U; M-K/S.
22 Connector module, expansion;
Safety valve, gas compartment;
Expansion valve 1 (1.1; 1.2 ***)
Relief valve 2; 2.1** )k*;
Gas escape fuse 1; 2** )k*;
Pressure connector, expansion:
Pressure connector,
pressure increase 1; 2** )k*.
23 Connector module, expansion***;
Safety valve, gas compartment;
Expansion valve 1;
Pressure increase valve;
Gas escape fuse;
35 Ball cock, condensate drain cock.
36 Flexcon control unit, M-K/S, page 19.
37 SDS controller, M-K/U, page 19.
38 SDS Directstart power part ***;
1 (2); page 19.
39 Electrical feed, compressor1; 2** )k*.
40 Electrical feed, SDS controller ***.
41 Signal wire, pressure sensor (<=30vDC;
42 Pressure sensor SELV).
43 Signal wire, level sensor (<=30VDC;
44 Level sensor SELV).
45 Diaphragm rupture sensor, feed ** (SELV).
46 Transport guard, level sensor.
47 Water compartment (expansion water).
48 Diaphragm (butyl).
49 Gas compartment.
)k* Second compressor unit
M-K/S:Basic vessel
(Pos.36)
M-K/U:Basic vessel
(Pos.37)
M-K:Ancillary vessel
SM:Single mode
PM:Parallel mode
BM:Backup mode
LM:Load dependant mode
SELV:Safety extra-low
voltage
PE- connector
(protective earth)
Pressure connector, expansion:
Pressure connector, pressure increase.
24 Safety valve, gas compartment.
25 Compressor unit K01 – K03, oil-free.
26 Second compressor unit
K01 – K03, oil-free; **.
27 Compressor unit K04, oil-free.
28 Second compressor K04, oil-free; **.
29 Compressor unit L6 – L14
(K420), 1 (2), oil-free; **.
30 Switch, TP- manual reset.
31 Intake opening, compressor.
32 Cool-air inlet, compressor.
33 Ball cock, vessel drainage ***.
34 Ball cock, system connector ***.
** Accessory, addition *** Special version
1
2
4
22
3
5
5
6
6
7
8
9
11
12 **
13
13
24
Example illustrations
M-K/S 6500 Litre
SM
M-K,
partial view,
from above.
Side view
for below, right.
View from above.
15
15 16
16
18
19
35
36
41; 42
43; 44 (46)
41;
42
25
32
39
36
31
2
2
19
33 ***
34 ***
21
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View from above.
Partial view from rear.
1
2
35
5
5
6
6
9
2
13
13
13
13
13
13
13
24
14 [**]
15
19
15
16
16
17
21
818
720
2
2
25
26 **
25
30
37
31
32
35
35
31
37
3
9
43 43
41; 42
44 46
44 (46) 7
4
7
4
8
4
9
21
19
3
9
55
24
17
32
M-K 600 Litre
Side view
M-K/U 600 Litre
SM
M-K 600 LitreM-K/U 600 Litre
PM / BM / LM
25
12 **
14 [**]
2
0,025
0,025 0,025
Flamco
D
SDS
electroniccontrolunit
standardpressurecontrol
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Flamco
Direktstart1
SDS
400/230V3/PE~50/60Hz
1
2
315
56
9
10
11
12 **
13
13
13
14
16
18
13
22
7
25
32
31
31; 32
36
37
38 ***
39
39
43
45 **
(2)
40 ***
44 (46)
11
14
6
15 16
103
5
29 ***
Example illustrations
M-K/U 600 Litre *** M-K/S 600 Litre M-K/S
M-K/U 600 Lit
r
Partial view
M-K/U 600 Litre ***
Partial view
22
13
14 2
40 ***
37
SM SM
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Example illustrations
Flamco
D
SDS
electroniccontrolunit
standardpressurecontrol
enter
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Flamco
D
SDS
electroniccontrolunit
standardpressurecontrol
enter
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1
2
3
56
9
13
13
131313
13 13 13
14
14 14
15
16
22 22 23 ***
13
29 ***
27 27 28 **
31; 32
36
37
39
39 39
43
7
12 **
44 (46)
M-K/S 600 Litre M-K/U 600 Litre M-K/U 600 Litre ***
SMPM / BM / LMSM
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5
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
Operating modes
The possible operating modes and their modifications depend on the supplied version of the
M-K/S and M-K/U expansion automats. Fitting and programming are done in accordance with the
order. (Installations of these systems with ancillary vessels [M-K] are preferably done at first start
A required accessory is the pressure hose connection**, per ancillary vessel;
Example M-K/U – M-K, page 4.)
Single mode, M-K/S and M-K/U expansion automat.
The capacity of a single vessel and the power of a single compressor are available (K01…K04).
(example SB, page 4) Parallel mode, M-K/S and M-K/U expansion automats.
The capacity of a single vessel and the power of two compressors are available (second
compressor unit 2 K01…2 K04 **). The installation of required equipment for operation with a se-
cond compressor unit is performed by manufacturer. Changing the mode of operation to backup
mode (modification to half of total compressor output) is possible by a trained, qualified specialist.
(Example PM)
Parallel mode of 2 expansion automats (Master- Slave mode), M-K/S.
The capacity of two automats (expansion vessels) and the power of two or four compressors are
available (compressor unit K01…K04, per vessel or second compressor unit 2 K01…2 K04 **, per
vessel). The installation of required equipment for operation with a second compressor unit takes
place by manufacturer. The Master automat (primary) provides the current operating parameters
and resulting switch commands to the Slave automat (subordinate). The definition of the
Master/Slave or their modification can be programmed by a trained, qualified specialist.
Necessary additions are the pressure hose connection** and a data cable (RS485) on site.
(Example PM 2A)
Backup mode, M-K/S and M-K/U expansion automats.
The capacity of a single vessel and the power of a single compressor are available (second
compressor unit 2 K01…2 K04 **). The installation of required equipment for backup operation
takes place by manufacturer. A change from compressor 1 to compressor 2 takes place following
activated motor protection, following an overload (operating power, operating temperature), or
after the expiry of a programmable change time (to balance the operating times of each drive).
Changing this mode of operation to parallel mode (change to the double compressor- capacity),
is possible by a trained, qualified specialist. (Example BM)
Backup mode of 2 M-K/S expansion automats.
The capacity of two automats (expansion vessels) and the power of a single compressor or two
compressors are available (compressor unit K01…K04, per vessel or second compressor
unit 2 K01…2 K04 **, per vessel). Installation for operation with a second compressor unit takes
place by manufacturer. The controller on one automat is passive and receives the current
operating parameters from the active controller and the resulting switch signals for the
expansion valve 1 (1.1; 1.2 ***). The switch from passive to active takes place following
activated motor protection resulting from an overload (operating power, operating temperature
compressor 1, or 1 of 2, or both, at the active automats), after the expiry of a programmable
change time, through the active controller, or when data (RS485) can no longer be received from
the active controller. Necessary additions are the pressure hose connection** and and a data
cable (RS485) on site. (Example BM 2A)
Load-dependent mode, M-K/U expansion automat.
The capacity of a single vessel and the power of two compressors are available (second
compressor unit 2 K01…2 K04 **). Installation of required equipment for operation with a second
compressor unit takes place by manufacturer. The activation or shutdown of compressor 2 is
controlled following a comparison of achieved or achievable nominal values with programmed
presets (PI- regulator). A change in the compressor start-up sequence takes place after the expiry
of a programmed change time (balancing of the operating hours of each drive). Changing the
mode of operation to backup mode (change to half of total compressor power), is possible by a
trained, qualified specialist. (Example LM)
Manual mode, M-K/U expansion automat.
Operating mode for test or service activities, for optional switching on or off of drives
(compressor, valve), by trained, qualified personnel. The automat is not active for expansion.
(Example process display, manual mode)
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Example
PM 2A
Data
cable
(RS485)
Pressurehose
connection **
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BM
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Example
BM 2A
Data
cable
(RS485)
Pressurehose
connection **
0,025
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6
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
Accessories, additions.
Type Application Brief description
Pressurisation Unit [PU] to top up lost quantities
of water from the drinking water network,
whose flowing pressure is at least 1.2 bar higher
than the nominal system pressure.
Controlled depending on the vessel level [l] and
the make-up time [t]; [PUlt]. (Example installation,
page 17; terminal diagram, page 32; 35; product
information service, addition to filling.)
Degassing and filling system [PUlt].
Used in accordance with the operating
instructions for this item. When combined with
the expansion automat, an external filling
requirement may be possible.
(terminal diagram, page 24; 26; 33)
)* product information service, addition
to filling.)
Filling system [PU] to top up lost quantities of
water from a pressurised water network, whose
flow pressure differential to the nominal system
pressure is less than 1.2 bar. Used in
accordance with the operating instructions for
this item. (Installation example, page 15; 17;
terminal diagram, page 24; 26; 33)
)* product information service, addition
to filling.)
This floatvent enables automatic venting of the
water compartment, negating the need for
manual venting. Delivery for commissioning
takes place in an accompanying pack,
installation is to be carried out on site. The
upgrade requires an unpressurised vessel on
the water supply side, and the breather valve
must be uninstalled (Pos.12; 11; 10, page 4).
Module, with fill and drain valve 1⁄20, for
Changing the standard vessel connectors from
threaded to DIN- flange (DN32...65; PN16;
Use of cap valves with flange connector) The
flexible system connector on the flange of the
basic vessel (M-KS...U) must be kept upright.
(Installation example, page 15)
Coupling hose for connecting gas compart-
ments, when using several vessels with a
common expansion control. (Pos.14 [**], page 4;
Installation example, page, 15; 16; 17)
Execution for extension of operating modes.
Only compressors of the same capacity can be
combined. Ancillary models (K04; L6... K420 ***
must be installed on site. (Pos.26; 27; 28; 29 ***,
page 4; terminal diagram, page 23...26; 31; 32;
34; 35)
Used in the event of stricter safety requirements.
The upgrade requires an unpressurised vessel.
(Pos.45, page 4; installation example, page
15;16; terminal diagram, page 24; 26)
)* For installations with the M-K/U expansion
automat, SDS- Module 34 is a prerequisite.
Additional module, timer, operating hours
counter. Used for requirements with error
diagnostics with date, time and display of
operating times per drive (Motor 1; 2;
Valve 1; 2; 3). The upgrade may be performed
by a qualified and trained specialist.
(Terminal diagram, page 32; 35)
Additional module, signal output: level, pressure
analogue Used in requirements for analogue,
additional value outputs of the vessel level and
actual system pressure (0...10V). The upgrade
may be performed by a qualified and trained
specialist. Evaluation, visualisation is to be
performed on site.
(Terminal diagram, page 32; 35)
M-KU
[PUlt]
M-K/S
[PUl]
M-K/U )*
[PUlt]
M-K/S
M-K/U
M-K
M-K/S
M-K/U
M-K
M-K/S
M-K/U
M-K
M-K/S
M-K/U
M-K
M-K/S
M-K/U
M-K/S
M-K )*
M-K/U
M-K/U
*** Special version
0.13
3
m
Flamco-Fill STU
(SDS)
Valve 3
0ERMISSIBLEWORKINGTEMPERATURE
0ERMISSIBLEWORKINGOVERPRESSURE
MAX"ETRIEBSTEMPERATUR
ZUL"ETRIEBSàBERDRUCK
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&LAMCO34!''MB(
'ENTHIN
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Flexvent super
quittieren
Störung EIN/AUS
min.
30 90
60
1200
defekt
Sicherung StörungLaufzeit Wasser-
mangel
Typ PA
Wasserverbrauch
Flamco-Fill
Flamco Fill PA
connection
Pressure hose
Flange connector
Adapter
3ECOND
#OMPRESSOR
UNIT+n+
>«À>}ÊÊ
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3$3-ODULE
3$3-ODULE
18502426 broch Flexcon M-K_UK.indd 618502426 broch Flexcon M-K_UK.indd 6 13-07-2006 08:55:3013-07-2006 08:55:30
7
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
Additional module, diaphragm rupture sensor. Used in the
event of stricter safety requirements. The upgrade may be
performed by a qualified and trained specialist.
(Pos.45, page 4; installation example, page 17; terminal
diagram, page 32; 35)
Additional module as combination: Module 32; 33 or 32; 34.
Combinationsor 33; 34 or 32; 33; 34. Use, function in
accordance with with 32...34 description of individual
modules. (Terminal diagram, page 32; 35)
Additional module, PA contact. Delivered for use with Flamco
Fill PA fill system or the external filling requirement ENA 1...3
with the SDS controller. The upgrade may be performed by a
qualified and specialist. (Terminal diagram, page 33; product
information service, addition to filling.)
Fitted for the remote signalling of errors: Min.-, max. water
Easy- Contact M-K/U level; min.-, max. operating pressure,
motor protection, diaphragm rupture 2.0; 3.0 and collective
fault signalling. For each error message, a red LED and
a relay with a potential-free opener/closer is active. The
diaphragm rupture output is only possible where a sensor is
installed. (Internal switch, position 2.0: M-K/S, 3.0: M-K/U.)
Necessary additions on site are a data cable
(RS485) and a 230V L N PE 50Hz voltage supply.
)* For compressors with internal temperature protection, the
activation of this fuse is not displayed. Installation may be
performed by a qualified, trained specialist.
(Terminal diagram, page 24; 26; 32; 35)
Additional module, remote display device. Used for remote
Televisorprocess monitoring. Displays an identical process
view of the SDS controller (active, passive drives, nominal
values of the filling quantity, system pressure, level) with plain
language message in the event of system errors and its
remote acknowledgement.
A necessary add-on on site is a data cable (RS485).
The installation may be performed by a qualified and trained
specialist. (Terminal diagram, page 32; 35)
Additional module, analogue modem connector. Used for
SDS process management over the fixed network.
Administration of up to 5 independent number blocks with
configurable call process in the event of an error. Direct
dialup or recall for process presentation and parameter
modification or presentation.
Additional status reports from 4 independent and freely
definable inputs, digital. Required on-site additions are: ana-
logue telephone line, plug signal wire, signal cable (RS485),
modem, PC connection. Installation may be performed by a
qualified, trained specialist. (Terminal diagram, page 32; 35)
Additional module, standard LONWorks bus connector. Used
in data transfer for visualisation in LON networks and LON
building management systems. Necessary additions on site
are a data cable (RS485), a 230V L N PE 50Hz voltage supply
and data evaluation by a competent LON system integrator.
Installation may be performed by a qualified and trained
specialist. (Terminal diagram, page 32; 35)
Additional module, Service Stick. Used for saving, copying
and transporting parameter files, recording and for
processing the files by USB on the PC, sending the files to
the Service Centre and reading the files modified by Support.
(Terminal diagram, page 31...35; com1a; com1b)
M-K/U
M-K/U
M-K/U
M-K/S )*
M-K/U
M-K/U
M-K/U
M-K/U
M-K/U
4. Safety instructions
Intended scope of use.
Closed water heating and climate control system, in which changes in the volume of the operating
water caused by temperature fluctuations are to be balanced out and the required operating
pressure to be guaranteed by the separate installation of an external expansion vessel.
The equipment can be found at pages 4; 5, the installation example for heating systems is on
pages 15...18.
The following notes and explanations refer to heating systems. For climate control systems
(cooling), relevant use applies (note).
Accessories, additions. (continued)
Type Application Brief description
Note
System Initial status Nominal status
Heating Cold Hot
Vessel with Vessel with
water prefill. water prefill and
expansion capacity.
Climate control Warm Cold
Vessel with Vessel with
water prefill and water prefill.
expansion capacity.
3$3-ODULE
3$3-ODULE
#OMBINATIONS
WITHx
PA-contact
3$3-ODULE
Membranbruch
Störung
Motorschutz
Max. Betriebsdruck
Min. Betriebsdruck
Max. Wasserstand
Min. Wasserstand
Anlage
Betriebsbereit
&LAMCO
SDSkompatibel
V2/0 V3/0 switch
2EMOTEDISPLAY
%ASY#ONTACT
TELEVISOR
3$3-ODULE
Modemcoupler
SDS
Analog
Flamco
Flamco
Buscoupler
SDS
3$3-ODULE
LONWorksStandard
,/.7ORKS
Standard
3$3-ODULE
18502426 broch Flexcon M-K_UK.indd 718502426 broch Flexcon M-K_UK.indd 7 13-07-2006 08:55:3213-07-2006 08:55:32
8
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
4. Safety instructions (continued)
Measures for hazard-free operation.
Product information, instructions and communications from the manufacturer contain, in the latest
applicable edition, details on measures for hazard-free operation within the scope of application
described therein. Other use or use that is not in accordance with regulations, customer
conversions to the item or modifications of a system without the permission of the manufactu-
rer fall outside the warranty and cannot preclude disruptions to function or hazards to people,
animals or objects.
It is assumed that installations for operating the M-K Compressor Expansion Automat ensure that
any exceeding of the permitted operating overpressure and the permitted operating temperature
are reliably and dependably excluded. Safety devices for dealing with low and excessive pressure
on the water supply side for operating the heating system (e.g. minimum, maximum pressure
limiters) do not form part of the equipment supplied.
Information on reliable operating overpressure and the permitted operating temperature can can
be found on the rating plate on the M-K/S, M-K/U, M-K pressure devices (Type plate, page 2;
Pos.1, page 4)
•Avoiding excessive pressure.
When using the M-K Compressor Expansion Automat in water heating systems, it is assumed
that the installations of heat generators include equipment that reliably prevents the permitted
operating overpressure from being exceeded.
Suitable devices for limiting the pressure of the expansion vessels are safety valves that open as
soon as the permitted operating overpressure is reached and are in a position, within 1.1 times
the permitted operating overpressure, to vent the arising capacity flow of the generator. Feed
and exhaust pipes for safety valves must be designed without a shutoff and must not contain any
parts that could lead to a narrowing of the flow cross-section. Reliability for use and their
suitability must be proven or certified.
The manufacturer’s instructions on safety valves and national regulations must be observed.
(Note)
The safety valve installed on the gas compartment of the expansion automat ensures that the
maximum gas capacity flow that can be fed through the compressor (external pressure generator)
is bled off in the event that the pressure control system fails. This valve is not intended to prevent
the reliable operating overpressure in a heat generating system from being exceeded.
•Avoiding excessive temperature.
When using the M-K Compressor Expansion Automat in water heating systems, it is assumed
that the installations of heat generators include equipment that reliably prevents the permitted
flow temperature from being exceeded. These devices must be created and installed in such a
way that in practical operation an operating temperature permitted for the equipment components
is not exceeded at any point of the equipment or system. Permissibility for use and their suitable
must be proven or certified. National regulations must be observed.
The arrangement of M-K Compressor Expansion automats in the heating system must be done in
such a way that the permitted continuous temperature of 70 °C is not exceeded or exceeded only
for a short time. Consequently, installation should preferably take place in the return.
Where heating systems exist with return temperatures above 70 °C, installations for cooling the
expansion water are to be connected to the expansion vessel in series.
(e.g. intermediate vessel, without insulation; Installation example, page 15).
Residual hazards
•Exceeding the permitted vessel specifications by not activating safety devices for limiting
temperature and pressure. Carry out regular checks on the function of these limiting devices.
Risk of component overload.
•Pressure and temperature loads. Carry out work on the vessel only when the gas and water
compartment is depressurised. Note that contact surfaces and any water that may need to
be drained can reach a temperature of up to 70 °C, and can even exceed this in the case of
improper operation. Risk of scalding or serious burns.
•Release of pressurised air from vessels under pressure at gas compartment couplings.
•Effects of fire. Ensure structural fire protection.
•Electrical voltage. Ensure that work on electrical equipment is carried out only by authorised
specialists. Serious risk of electric shock if any body parts come into contact with live voltage
(e.g. 230V 50Hz). (Sensors units, diaphragm rupture, capacity, pressure sensors, are operated
with safety extra-low voltage.)
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18502426 broch Flexcon M-K_UK.indd 818502426 broch Flexcon M-K_UK.indd 8 13-07-2006 08:55:3413-07-2006 08:55:34
9
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
5. Installation
Use and the installation location are subject to binding regulations and provisions. Particular
reference is made to the obligation to inform test or certification agencies prior to the installation
and starting of systems. In this case, the person responsible is to initiate the procedure with these
agencies. Documents, conditions and calculations arising from the tests carried out under the
procedure or other guidelines are to be observed when installing the system.
If acceptance procedures are required for the installed object, the system must only be started
once it has been confirmed that the requirements imposed on the system have been satisfied.
- Perform the start/commissioning protocol.
Environmental conditions
The M-K Compressor Expansion Automats are to be installed in such a way that operation, testing
and maintenance can be constantly guaranteed. This automat must be installed in an enclosed,
frost-free room taking into consideration minimum distances (page 14; 13). The safe operating
temperature in the vicinity of the automat is 5...40 °C. Higher temperatures can lead to function
disruptions and to the overload of the compressor or compressors (no expansion). The placing
of the compressor intake and cool-air openings must ensure that surrounding parts cannot be
sucked in, an unobstructed flow of air is possible, and that no shorted flow between cool-air inlet
and outlet can occur.
Ensure that the expansion automat is operated in a surrounding atmosphere that is free of
electrically conducting gases, high concentrations of dust and vapours. A risk of explosion is
posed by combustible gases, gas mixtures.
Base and setup.
The installation surface must be prepared so as to ensure and maintain installation safety.
When preparing this surface, take into consideration the maximum weight of the complete
automat, including the weight of the water (page 13).
The guidelines of the responsible project leader of the total system apply. The following, general
rules must also be observed.
- Equipment to be installed must be completely removed from the packaging.
- If the expansion automat (basic vessel) has been set up at the appropriate location and no
other changes to the location are required, the transport protection of the level sensor must be
removed. Avoid dust from coming into contact with this sensor and ensure a mounting surface
that does not obstruct the functioning of the sensor (platform). Avoid fixing to the ground.
(Types of fixing that impermissibly influence the automat, such as: pouring concrete or plaster
around the vessel feet, welds to the vessel or vessel foot, clamps and tighteners to the basic
body or suspending the automat are not allowed.)
- Install now those accessories that are required for the expansion function (modules to the gas
and water compartments) which result in shutdown after start 56 (e.g. floatvent **
Flexvent Super, Pos.12, page 4).
- Vertically adjust the vessel or vessels using the adjustable feet. Use a magnetic spirit level,
rotated by 90° for use in vertical positions.
- Ensure that no additional external loads impact on the system.
- Install expansion vessels and ancillary vessels at the same height.
- When welding, do not allow welding materials to touch or enter equipment parts of the
expansion automat.
System connection
The system connection is to be manufactured as a connection to the heating system. Example
installations can be found on pages 15...18. Observe the following instructions before filling and
starting the M-K Compressor Expansion Automat.
- The connection should preferably be made in the return to the heat generator.
- Ensure that this connection has a direct connection to the heat generator. Ensure that the
system connection of basic vessels is made only via the flexible pressure hose delivered with
the system.
- Install a shutoff device in the immediate vicinity of the automat-system connection, which can
be protected against unintentional closure and preferably comes with a fill and drain valve for
the water compartment of the vessel. If this item is missing, it must be installed separately.
- If several expansion vessels are installed, an additional valve must be installed in the
expansion pipe in front of the collector pipe, which must also be secured against unintentional
closure.
- Note that a temperature at the system connection greater than 70 °C (...90 °C) exceeds the
permitted diaphragm load and can result in the destruction of the diaphragm.
(Complete insulation of the expansion pipe can increase the load temperature.)
** Accessory, addition
18502426 broch Flexcon M-K_UK.indd 918502426 broch Flexcon M-K_UK.indd 9 13-07-2006 08:55:3513-07-2006 08:55:35
10
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
System connection (continued)
- Choose sealants, gauges, feed pipes depending on the project (must at least correspond to the
maximum possible pressure and temperature values for this expansion pipe).
- The nominal widths of the expansion pipe (system or collective connection of the vessel or ves-
sels, up to the return connection) must be chosen depending on the equipment to be installed
and the distance to the return connection.
Note the recommendations from practical experience:
- Expansion automat, single setup. Length of expansion pipe,
> 5 m : Second-higher nominal connection width of the vessel;
> 15 m or > 8 m with 3 pipe bends: Third-higher nominal connection width of the vessel;
For distances > 22 m or > 15 m with additional pipe bends, the required nominal widths must
be determined from practical actual values. Avoid lengths greater than ...30 m... and install
expansion pipes at the shortest distance that benefits flow.
- Expansion automats, battery installation, basic vessel, ancillary vessel.
Combinations must be installed with the shortest distances between the individual system
connections of the vessel (minimum distances). If you are installing a collective pipe, up to
3 vessels: Fourth-higher nominal connection width of the single vessel; from 4 to 6 vessels:
Sixth-higher nominal connection width of the single vessel.
The arrangement of the vessels should preferably be symmetrical, or the nominal width of the
collector must be increased (Example series: M-K > M-K/U < M-K; M-K > M-K/S – M-K/S
< M-K. Ideal: arrangement in a polygon.) For the return connection, follow the instructions for
the expansion pipe.
Gas compartment couplings
Installations of several vessels (basic vessel, ancillary vessel) with common expansion controller
and ancillary compressors (second compressor unit K04 **; L6...K420 ***), on the pressure vessel,
require coupling of the gas compartments on site. In addition, the coupling boxes to be installed
on the equipment (Pos.13) must be fitted with the pressure hose connection ** (Pos.14) (snap-in).
The coupling of the coupling plug (pressure hose connection) with the coupling box (quick-release
connector) opens the gas compartment, while disconnection automatically seals the gas
compartment. (Coupling examples: page 4; 5, Equipment)
Hoses are to be arranged such that cross-sectional narrowing is permanently avoided.
Warning: Risk of accident through release of pressurised air. Note that the single-sided decoupling
or coupling of the pressure hose can result in air escaping (pressure loss). Here, the escaping flow
pressure amounts to up to 2 bar in a delivered vessel, or in the event of subsequent additions, to
the available system pressure.
Do not direct escaping pressurised air at people! Free, releasing hose ends move suddenly and
can cause injuries.
Electrical installation
The input terminals for the mains of the controllers Flexcon (S) control unit, SDS or of additions
(e.g. Directstart power part ***) are to be connected at the place of installation via a CEE plug
connector to the connection of the required operating voltage. The voltage distribution (e.g. safety
power circuits), the cable protection and the goods, layout of the feeds must meet the regulations
and provisions for this application at the place of installation. Ancillary compressors (e.g. K04;
2 K04 **) are supplied with an electrical feed that must be installed on site to the controller and
to the drive of the compressor (compressors). When doing this, please observe the installation
instruction on the terminal covers of the drive (drives). Install a grounding between the earthing
boss and the grounding point (total equipment). The SDS Controller has protective insulation and
for this reason does not require grounding between the controller and the grounding point.
Avoid installations where cables may come into contact with water.
Electrical feeds must be fixed permanently using suitable cable guides.
(Equipment, page 4; Modules, page 19; Terminal diagram, pages 23...26; 31...35)
6. Start
Commissioning
Before commissioning, the system and its technical safety equipment must be checked for
compliance with the regulations that apply to the place of installation and to the scope of
application.
In Germany, this check is done by an authorised person (aP). In other countries, national regulati-
ons must be observed.
The manufacturer or operator of the system is responsible for proper testing and starting.
- Perform the start/commissioning protocol..
- Test the system and performed installation actions for completeness
(e.g. remove transport guard, install Flexvent Super **, gas compartment couplings). -Until the
necessary start measures have been completed, ensure that no filling takes place of the vessel
or vessels (filling connections, shut-off devices, cap valves: ”CLOSED”). An installed filling
device with a main switch must be ”Switched off”.
** Accessory, addition *** Special version
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18502426 broch Flexcon M-K_UK.indd 1018502426 broch Flexcon M-K_UK.indd 10 13-07-2006 08:55:3513-07-2006 08:55:35
11
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
6. Start (continued)
Programming
The controller on the basic vessel is to be programmed depending on the configuration and system.
- Flexcon Control Unit, M-K/S.
The required procedure and possible setting changes can be found on page 21; 22;
menu programming mode.
Note: The active errors displayed after switching on the controller: min. water level; min.
pressure alarm are logical. After switching to programming mode, the control
for expansion (filling) is passive. Changed parameters become active when operating
mode is reselected.
- Remove unpermitted loads (supported objects, lateral loads) from the basic vessel.
- Perform the zero adjustment during operation. This prsocedure corrects deviations from test
tolerances when installing the basic vessel and sets the levelparameter to 0%.
- Change the preset nominal system pressure (2 bar) to the permitted project value (note).
Note: Start and system temperature, page 12; §. 1.
- Other parameters must be programmed depending on system requirements.
- If 2 systems are operated in parallel, this setting must be performed after installation of the
RS485 data cable. The controller programmed first is the Master.
Other measures, settings, changes are to be carried out identically, per controller.
The service programming mode and the factory programmed presets can be found on
page 22, the operating displays on page 20, Operating mode menu.
- SDS controller, M-K/U.
The required procedure and possible setting changes can be found on page 28; 29;
Menu programming mode.
Note: The active errors displayed after switching on the controller: min. level alarm limit,
min. pressure alarm limit are logical. The controller is also active for expansion (filling)
after the code has been entered (programming mode).
Changed parameters become immediately active after being saved.
- Remove unpermitted loads (supported objects, lateral loads) from the basic vessel.
- Perform the zero adjustment during operation. This procedure corrects deviations from test
tolerances when installing the basic vessel and sets the level parameter to 0%.
- Change the preset nominal system pressure (2 bar) to the permitted project value (note).
Note: Start and system temperature, page 12; para. 1.
- Other parameters must be programmed depending on system requirements.
The identification of start enables traceability, which also enables a time-dependent
diagnosis of the installed SDS- Module 32, timer, operating hours counter **
(errors, SDS- Module 43, analogue modem connection **).
The service programming mode and the factory programmed presets can be found on
page 30, the operating displays on page 27, Operating mode menu. [ Specification of menu
lines (F5; F7a 1; 2; G7a 2; G8a 1) in the terminal diagrams, page 32; 33; 35, refers to the
required change to presets during upgrades (**).]
The completed programming procedure (electrical installation) makes the compressor expansion
automat electrically ready for operation.
Start and system temperature.
The installed, hydraulic compartment of the expansion automat is to be filled as far as the shutoff
device on the expansion pipe, depending on the condition of the heating system.
All present shutoff devices must now be opened.
- Installation of the water prefill for a non-operational, cold heating system.
The basic vessel or all vessels with a common expansion controller (collective pipe), must be
filled with water before opening the shutoff device to the expansion pipe.
From practical experience, the quantity of this water is ...20%... of the vessel capacity. This
value takes into consideration losses and a lower vessel level as a consequence of reduced gas
quantities after a heated heat generating system.
(Filling example 1)
- Set the nominal expansion capacity for operated, hot heating system.
The basic vessel or all vessels with a common expansion controller (collective pipe), are to be
filled with the nominal expansion capacity from available system temperature including the
water prefill, before opening the shutoff device to the expansion pipe.
To calculate this quantity, the design data for the nominal vessel size or the total of the
nominal vessel sizes and the actual values of the heating system are required. Use the following
example as the basis for your own calculation.
Vset = [( Dn’act × 80% ) / Dn’max ] + 10%* = 42.66% ~ 43% (Filling example 2)
Dn’act = n’act –n’min = 1.0121 – 1.0003 = 0.0118 (50 °C; 10 °C)
Dn’max = n’max - n’min = 1.0292 – 1.0003 = 0.0289 (80 °C; 10 °C)
n’ [dm3/kg] Specific volume of the liquid water in saturated state.
* Accessory, addition
Note:
Nominal system pressure (working pressure PA)
= Pressure from highest statistical height
of the heating system
+Vapour pressure from the highest operating
temperature of the heating system
+Positive pressure at the highest point
of the heating system (0.3...0.5 bar)
0,05
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18502426 broch Flexcon M-K_UK.indd 1118502426 broch Flexcon M-K_UK.indd 11 13-07-2006 08:55:3613-07-2006 08:55:36
12
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
Start and system temperature. (continued)
If the flow pressure differential of the external supply when filling the automat for the first time via
a fill and drain valve is insufficient, the preset system pressure (2 bar) must be set on the controller
approx. 1.5...bar below the available flow pressure. During filling, observe the changing level value
in the display (operation mode) of the controller, and interrupt the external supply when the
nominal value is reached, correct a changed system pressure. Note that with several vessels
(collective supply), a time-delayed level balance takes place. Installed filling devices ** fill from 0%
of the value of the preset (pages 22; 30). Systems that include the capacity of the installed water
quantity must be vented . A fallen level must be compensated to the nominal value by adding water.
- Vent the diaphragm compartment (water compartment) at the manual vent of the vessel
(Pos.10; page 4). This measure is not necessary if a floatvent is installed **.
- The procedure for starting the heat generator must be completed (settings to safety devices).
Fill the heating system completely and vent this system.
- Check the available electrical equipment for common expansion control, for operational
readiness. Controllers, accessories, additions must be switched on.
- Open the shutoff device on the expansion feed to the return connector (slowly).
- Complete the start protocol.
Re-start
- Following a long downtime.
Carry out maintenance. Drain the water compartments of the equipment and ensure that the
preconditions for installation (5.) are met and do the necessary actions for Starting (6.). Clean
the equipment, remove slurry. Use the start protocol and in particular check system data which
may require changing settings on the device.
- After a power failure.
The parameters programmed at the controller remain unchanged, so that automatic operation
takes places automatically when power is restored. (Controller, accessories, additions switched
on). The voltage for the SDS- Module 32, timer, operating hours counter ** is supported for
several weeks. (Error no.: 28, page 30)
Note: Special operating conditions on this system (e.g. cooling below the set control value)
can result in exceeding or not achieving permitted operating values of the vessels (Application
safety, page 8; Electrical installation, page 10).
After a power failure, the condition of the expansion automat must be checked for integrity.
7. Maintenance
This action must be performed during system down time, otherwise ensure that no demands are placed on the expansion automat.
The expansion equipment must be switched off and secured against being inadvertently started until maintenance is completed.
Note the safety switches and remote data transfers which can lead to the activation of safety chains or error information
during maintenance work. Existing instructions on the total project of the heating system
must be considered. The measures allocated to the maintenance periods must also be carried out.
- Use the maintenance protocol; draw up a maintenance plan.
8. Periodic testing, pressure equipment.
This must be performed under consideration of the requirements of the total system and must be
certified. It is to be carried out by the operator in accordance with prevailing rules and procedures
of competition inspection at the site of installation. This test is done in Germany by an authorised
person (aP). In other countries, the national regulations and conditions must be observed. For
perform the test, the responsible person has these instructions, the conformity declaration and
the acceptance drawing available. The minimum test periods and their contents, for application in
Germany, are laid out below.
- Internal check: 5 years (test of pressure compartment: corrosion, deformations, damage.)
- Pressure test : 10 years (water pressure test of the vessel pressure compartment with the
permitted test overpressure.)
* positions refer to page 4
Maintenance period Object Measure
Monthly, in
Main load times;
2 months, in
Partial load times
(summer
operation).
Compressor
oil-free (Pos.25;
26; 27; 28; 29)*
Clean filter unit, filter housing,
intake opening. Dry
Installation required!
Basic vessel
Ancillary vessel
(Pos.2)*
Drain condensate (Pos.35)*;
Vent water compartment (Pos.10)*,
Omit if airvent installed.
(summer
operation).
Before main load
time.
Compressor
oil-free
(Pos.25; 26; 27
28; 29)*
Function test (switch possible by
changing nominal pressure,note
working pressure differential!;
Manual operation SDS controller.)
Note: Use spare parts approved by Flamco.
Maintenance period Object Measure
Annually,
before the main
load time.
Connector
module (Pos.22;
23; 24)*
Function text (see Compressor);
Test safety valve via
lifting device.
Equipment
Expansion
vessel;
Connections;
Shutoff
devices.
Seal test of all pressure
compartment connections on gas and
water compartment (visual check).
Checking of external
condition for damage,
deformation, corrosion.
The operationally ready state must be recreated!
We recommend Flamco customer service for maintenance.
18502426 broch Flexcon M-K_UK.indd 1218502426 broch Flexcon M-K_UK.indd 12 13-07-2006 08:55:3713-07-2006 08:55:37
13
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
Appendix 1; Technical data, specification, hydraulic and
pneumatic equipment.
Nominal values
)4* System connect. M-K/U, M-K/S.
)1* Standard; )2* Flexvent Super; )3* Second compressor unit, K04.
Example illustrations
)6* ø750; )7* ø1000; )8* not 3 bar.
)4* Compressor unit; )5* Second compressor unit **.
Weights
** Accessory, addition
4ASTE%3#DRCKEN
&EHLERABLESEN
MIT4ASTE2%4
(INWEISE
&EHLER
STEUERAUTOMAT
.ACH&EHLERBESEITIGUNG
2%4%3#
(
(
,ITRE-+3
&LAMCO
ELECTRONICCONTROLUNIT
STANDARDPRESSURECONTROL
ENTER
PRESS
$
3$3
(
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(
&LAMCO
ELECTRONICCONTROLUNIT
STANDARDPRESSURECONTROL
ENTER
PRESS
$
3$3
,
(
,
$
3
6IEW
FROMABOVE
490%
3%2)!,.
RPM RPM
LS
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LS
BAR PSI
CFM
HPK7HPK7
"
490%
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LS
BAR
LS
BAR PSI
CFM
HPK7HPK7
"
$,
3
6IEW
FROMABOVE
Nominal operating values of pressure unit
Main dimensions (Nominal)
Nominal
capacity
maximum
permitted
operating
pressure
maximum
permitted
operating
temperature
maximum
permitted
cont. temperature
at the diaphragm
Vessel
diameter
Opera-
ting
height
Height Width Length
min.
Length
min.
System
connection
Din ISO 228-1
Tolerance: DIN28011; 28013; 28005-1.
DH1H2 B L1L2S
[Litres] [bar] [ºC] [ºC] [mm] [mm] [mm] [mm] [mm] [mm] BSP
Short code
)1* )2* M-K/U M-K/S M-K )3* )4*
Total system mass. (Nominal weight, corrosion allowance: 0 mm, without water filling.)
Nominal
capacity
M-K/U M-K/S M-K
K01 - K03 )4* K04 )4* K01 - K03 )4* K04 ) 4*
Tabular value +
+ 12 kg )5*
Tabular value
+ 25 kg )5*
Tabular value
+ 12 kg )5* )8*
Tabular value
+ 25 kg )5*
6 bar 10 bar 6 bar 10 bar 3 bar 6 bar 10 bar 6 bar 10 bar 3 bar 6 bar 10 bar
[Litres] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg]
400 6 10 120 70 750 1065 1369 1454 975 995 820 400 225 G 1 1/4 DN32
600 6 10 120 70 750 1485 1789 1874 975 995 820 400 225 G 1 1/4 DN32
800 6 10 120 70 750 1585 2189 2274 975 995 820 400 225 G 1 1/4 DN32
1000 6 10 120 70 750 1585 2689 2774 975 995 820 400 225 G 1 1/2 DN40
1000 6 10 120 70 1000 1415 1775 1860 1225 1245 1070 400 100 G 1 1/2 DN40
1200 6 10 120 70 1000 1615 2025 2110 1225 1245 1070 400 100 G 1 1/2 DN40
1600 6 10 120 70 1000 1615 2525 2610 1225 1245 1070 400 100 G 1 1/2 DN40
2000 6 10 120 70 1200 1635 2277 2362 1425 1445 1270 400 0 G 2 DN50
2800 6 10 120 70 1200 1635 2877 2962 1425 1445 1270 400 0 G 2 1/2 DN65
3500 6 10 120 70 1200 1635 3677 3762 1425 1445 1270 400 0 G 2 1/2 DN65
5000 3 - 90 70 1500 1600 3550 3635 - 1785 1615 - 625 Rp 1 1/2 DN40
6500 3 - 90 70 1800 1600 3465 3550 - 2090 1920 - 475 Rp 1 1/2 DN40
8000 3 - 90 70 1900 1600 3565 3650 - 2190 2020 - 425 Rp 1 1/2 DN40
10000 3 - 90 70 2000 1600 3985 4070 - 2290 2120 - 375 Rp 1 1/2 DN40
400 153 188 166 201 - 157 192 170 205 - 130 165
600 183 228 196 241 - 187 232 200 245 - 160 205
800 218 258 231 271 - 222 262 235 275 - 195 235
1000 )6* 253 308 2666 321 - 257 312 270 325 - 230 285
1000 )7* 291 382 304 395 - 295 386 308 399 - 268 359
1200 313 418 326 431 - 317 422 330 435 - 290 395
1600 368 508 381 521 - 372 512 385 225 - 345 485
2000 453 618 466 631 - 457 622 470 635 - 430 595
2800 538 758 551 771 - 542 762 555 775 - 515 735
3500 648 938 661 951 - 652 942 665 955 - 625 915
5000 - - - - 980 - - - - 953 - -
6500 - - - - 1480 - - - - 1453 - -
8000 - - - - 1585 - - - - 1558 - -
10000 - - - - 1825 - - - - 1798 - -
18502426 broch Flexcon M-K_UK.indd 1318502426 broch Flexcon M-K_UK.indd 13 13-07-2006 08:55:3713-07-2006 08:55:37
14
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
Appendix 1; Technical data, specification, hydraulic and
pneumatic equipment.
Minimum distances
Nominal capacity Minimum size
ABC
[Liter] [mm] [mm] [mm]
400
650
800 500
600
800
1000
1000
1200
1600
2000
1000
2800
3500
5000
6500
8000
10000
'MBNDP
ELECTRONICCONTROLUNIT
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ENTER
PRESS
%
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490%
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LS
BAR
LS
BAR PSI
CFM
HPK7HPK7
#
"
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"
%XAMPLEILLUSTRATION
,ITRE-+5-+
18502426 broch Flexcon M-K_UK.indd 1418502426 broch Flexcon M-K_UK.indd 14 13-07-2006 08:55:4013-07-2006 08:55:40
15
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
Appendix 1; Technical data, specification, hydraulic and
pneumatic equipment.
Example installations of M-K/S, Flexcon control unit.
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18502426 broch Flexcon M-K_UK.indd 1518502426 broch Flexcon M-K_UK.indd 15 13-07-2006 08:55:4213-07-2006 08:55:42
16
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
Appendix 1; Technical data, specification, hydraulic and
pneumatic equipment.
Example installations of M-K/S, Flexcon control unit.
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18502426 broch Flexcon M-K_UK.indd 1618502426 broch Flexcon M-K_UK.indd 16 13-07-2006 08:55:4313-07-2006 08:55:43
17
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
Appendix 1; Technical data, specification, hydraulic and
pneumatic equipment.
Example installations of M-K/U, SDS control unit.
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18502426 broch Flexcon M-K_UK.indd 1718502426 broch Flexcon M-K_UK.indd 17 13-07-2006 08:55:4413-07-2006 08:55:44
18
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
Appendix 1; Technical data, specifications, hydraulic and
pneumatic equipment.
Example installations of M-K/U, SDS control unit.
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18502426 broch Flexcon M-K_UK.indd 1818502426 broch Flexcon M-K_UK.indd 18 13-07-2006 08:55:4513-07-2006 08:55:45
19
&LAMCO M-K Compressor Expansion Automat
Installation and operating instructions
Appendix 2; Technical data, specifications, electrical equipment.
Modules
Flexcon Control Unit, MK-S 230V 50Hz (400V 50Hz) ***.
** Accessory, addition *** Special version
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18502426 broch Flexcon M-K_UK.indd 1918502426 broch Flexcon M-K_UK.indd 19 13-07-2006 08:55:4613-07-2006 08:55:46
20
&LAMCO
M-K Compressor Expansion Automat
Installation and operating instructions
Appendix 2; Technical data, specifications, electrical equipment.
Flexcon control unit, M-K/S, operating mode menu.
Display 1
Normal operating display
in delivery condition of the
controller. During standard
initial programming the current
actual values: pressure, level,
the switch values compressor,
valve and the limit value level
are presented.
The “ESC” key leads to
display 1 for any selected
message.
Display, error no.: 5)*
The programmed limit value is
reached or exceeded.
(Display 14; page 21)
Display, error no.: 6)*
The programmed limit value
is reached or exceeded.
(Diaphragm overload)
(Display 15; page 21)
Display, error no.: 7)*
The motor protection
switch(es) are activated as a
result of overflow or switched
off manually (Pos. 1.6; 1.7;
page 19).
The activation of the ther-
mal fuse (TP) in the drive
of standard models (230V
50Hz) is not displayed! If this
activates the fuse, a reset of
compressors K01; K02; K03
must be performed manually
(Pos. 30; page 4). The reset on
a version with K04 takes place
automatically (cooling).
Display, error no.: 8)*
The signal requires the testing
of the diaphragm for ruptures.
(Only with installed diaphragm
rupture sensor**) (Display 3)
Display, error no.: 9)*
The programmed limit value is
reached or exceeded.
Display, error no.: 10)*
The programmed limit value is
reached or exceeded.
(Display 17; page 21)
Display, error no.: 11)*
In the version with a second
unit (2 controllers**) the opera-
ting modes are programmed
differently. (Display 3)
Display 2
Indication of the nominal
switch times, total, for
compressor drives 1 and 2.
Display 3
Indication of the programmed
additional functions **.
(On: “ * “; Off: “ - “) See also
page 5, Operating modes.
Display 4
System classification.
Indicates: Type, nominal
pressure, capacity of basic
vessel (ancillary vessel**) and
software version.
The “RET” button leads to
the displays 1- 4 and for
available or not yet
acknowledged errors
(Fehler LED “On“) to
the displays 5- 11)*.
)*
The lighting of the Fehler-
LED signals a fault as
a collective fault signal
(one or more error).
In the example, displays
5- 11 show the possible
errors, whereby the
actual sequence
corresponds to the
progress over time.
Errors are to be
acknowledged by
pressing the “ESC”
button.
An error that can be
acknowledged is
signalled by the
Fehler-LED “Off”,
while this LED signal is
retained for other
non-acknowledgeable
or not yet acknowledged
errors.
An error can be
acknowledged when the
error has been resolved
or an operating condition
is achieved within
nominal values.
Controller operating panel
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