flamco Flamcomat User manual

TemplateA4_v20130506
ENG Flamco-Fill P
Installation and operating instructions
Supplementary document
Translation of the original operating instructions ––––––––––––––––––––––––––––––––––––– 3
DEU Flamco-Fill P
Montage-und Betriebsanleitung
Ergänzungsdokument
Orginalbetriebsanleitung –––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 8
NLD Flamco-Fill P
Installatie- en bedienings- instructies
Aanvullend document
Vertaling van de oorspronkelijke gebruiksaanwijzing–––––––––––––––––––––––––––––––––– 13
FRA Flamco-Fill P
Installation et mode d’emploi
Document supplémentaire
Traduction de la notice d’utilisation originale –––––––––––––––––––––––––––––––––––––––– 18
Flamcomat®, Flexcon®M-K
Flamco-Fill P
 www.amcogroup.com/manuals

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BE Flamco Belux
J. Van Elewijckstraat 59
B -1853 Grimbergen
[phone] info@amco.be
CH Flamco AG
Fännring 1
6403 Küssnacht
[phone] info@amco.ch
CZ Flamco CZ
Evropská423/178
160 00 Praha 6
[phone] info@amco.cz
DE Flamco GmbH
Steinbrink 3
42555 Velbert
[phone] info@amco.de
DK Flamco
Tonsbakken 16-18
DK-2740 Skovlunde
[phone] info@amco.dk
EE Flamco Baltic
Löötsa 4
114 15 Tallin
[phone] info@amco.ee
FI Flamco Finland
Ritakuja1
01740 Vantaa
[phone] info@amco.
FR Flamco s.a.r.l.
BP 77173
95056 CERGY-PONTOISE cedex
[phone] info@amco.fr
HU Flamco Kft.
H-2040 Budaörs, Gyár u. 2
H-2058 Budaörs, Pf. 73
[phone] info@amco.hu
NL Flamco B.V.
Postbus 502
3750 GM Bunschoten
[phone] support@amco.nl
PL Flamco Sp. z o. o.
ul. Akacjowa 4
62-002 Suchy Las
[phone] info@amco.pl
SE Flamco Sverige
Kungsgatan 14
541 31 Skövde
[phone] vvs@amco.se
UAE Flamco Middle East
P.O. Box 262636
Jebel Ali, Dubai
[phone] info@amco-gulf.com
UK Flamco Limited
Washway Lane- St Helens
Merseyside WA10 6PB
[phone] info@amco.co.uk
Contact

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ENG
English (ENG) Installation and Operating Instructions
Table of Contents
1. General safety instructions ............................................................................................................................................................................................................................................ 4
Appropriate use ........................................................................................................................................................................................................................................................................ 4
Warning symbols in this manual....................................................................................................................................................................................................................................... 4
Transportation, storage, unpacking................................................................................................................................................................................................................................ 4
Technical room.......................................................................................................................................................................................................................................................................... 5
External forces .......................................................................................................................................................................................................................................................................... 5
Inspection prior to commissioning, routine checks................................................................................................................................................................................................ 5
Electrical equipment inspections, routine inspection............................................................................................................................................................................................ 5
Maintenance and repairs...................................................................................................................................................................................................................................................... 5
Obvious misuse........................................................................................................................................................................................................................................................................ 6
Residual hazards...................................................................................................................................................................................................................................................................... 6
2. Product description ............................................................................................................................................................................................................................................................. 6
Mode of operation................................................................................................................................................................................................................................................................... 6
Marking......................................................................................................................................................................................................................................................................................... 8
Terminal diagram...................................................................................................................................................................................................................................................................... 9
Components, equipment ..................................................................................................................................................................................................................................................... 10
3. Installation ................................................................................................................................................................................................................................................................................. 11
 Installing,levelling,xing-Ensurestability!............................................................................................................................................................................................................... 11
Connecting the pipework..................................................................................................................................................................................................................................................... 11
Connecting the electrical supply...................................................................................................................................................................................................................................... 11
4. Starting up ................................................................................................................................................................................................................................................................................. 12
Commissioning ......................................................................................................................................................................................................................................................................... 12
 Conguration.............................................................................................................................................................................................................................................................................. 12
Recommissioning .................................................................................................................................................................................................................................................................... 12
5. Maintenance............................................................................................................................................................................................................................................................................. 12
Appendix 1. Technical data, general specications ................................................................................................................................................................................................... 13
Ambient conditions................................................................................................................................................................................................................................................................. 13
Minimum distances: clearance for service and repair........................................................................................................................................................................................... 13
Sample installation diagram............................................................................................................................................................................................................................................... 14
Appendix 2. Technical data and specications ............................................................................................................................................................................................................. 15
Pressure, temperature, volume, etc............................................................................................................................................................................................................................... 15
Weights and dimensions...................................................................................................................................................................................................................................................... 15
Appendix 3. Technical data and information for the electrical equipment................................................................................................................................................... 16
Declaration of incorporation............................................................................................................................................................................................................................................... 17

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1. General safety instructions
The present document is a supplement to the installation and operating manual: Flamcomat, Doc.-
Nr.:00018/11-2010/eng.;FlexconM-K,MC00019/01-2011/engandmustonlybeusedwiththesebasicdocuments.Thegeneral
safety instructions contained therein apply in particular, as does the information on equipment, use and function.
FurtherproductinformationcanbeobtainedfromtherespectiveFlamcobranchofce(seepage2).
Forinstallationinstructionsandfurtherdocumentationinvariouslanguages,visitwww.amcogroup.com/manuals.
1.1 Appropriate use
Level-controlledtoppingupofsystemwater(heatcarrier)withfeedwaterinheatingandcoolingwatersystems.Thisservesto
compensateforoperationallossesinthesysteminordertokeeptheminimumsystempressureabovethellingleveltrackingvalue
in compressor-controlled or pump-controlled expansion automats.
Indoingso,theSPC(controlunitonthepressuremaintenanceunit)takesoversurveillanceofthelevel-controlledpressurisationunit
and, in line with demands, controls the pump integrated in the Flamco-Fill P.
The pressurisation unit's range of applications in terms of system pressure, or Flamco-Fill P system connection pressure, is between
1and9bar(PN10).Forheatingsystems,toppingupispermissibleasperDINEN12828,orinsystemswithmax.owtemperatures
upto105°C.Fordesignoutputsabove1MW,theowner/usermayneedtohandleadditionalsafety-relatedrequirements,where
appropriate,incooperationwithanotiedbody,inaccordancewithcurrentharmonisedEuropeanstandards.Systemwaterandlling
water are separated by a free outlet as per EN 1717 and DIN 1988.
1.2 Warning symbols in this manual
Warning of hazardous electrical voltage
Failuretoobservecancausefatalinjury,reorotherdamage,
or lead to overloading of individual components and to damage, or functional impairments.
Warning in case of errors and incorrect initial conditions.
Failure to observe can lead to serious personal injury, component overload and damage, or functional impairments.
1.3 Transportation, storage, unpacking
Theequipmentisdeliveredinpackingunitsincompliancewiththecontractualspecications,orrequirementsforspecictransport
methods and climate zones. They meet the requirements of the Flamco STAG GmbH packaging guidelines as a minimum.
Inaccordancewiththeseguidelines,thepressirisationunitaresuppliedpackedatonspecialpallets.Thesepalletsaresuitable
for horizontal transportation with suitable fork-lift trucks. The forks must be set to the widest possible outer dimensions in order
to prevent the load from tipping. The goods delivered must be moved at the lowest possible setting of the lifting equipment,
perpendicular to the forks. If the packages are suitable for lifting gear, they are marked at the appropriate lifting points.
Importantnote:Transportthepackedgoodstoapositionascloseaspossibletotheenvisagedset-uplocation;makesurethereisa
level, load-bearing surface on which the goods can be deposited.
Caution: After removing the unit from the pallet and packaging, take safety precautions to avoid impact, tipping and swinging. Use
an approach that prevents uncontrolled falling, sliding or tipping over. The goods may also be temporarily stored in their packaging.
Avoid stacking more than three packaging units. Use only permitted lifting gear and safe tools, and wear the required personal
protective equipment.

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ENG
1.4 Technical room
Denition:roomwhichmeetstheapplicableEuropeanorregionalregulations,Europeanandharmonisedstandardsandrelevant
technicalrulesandguidelinesoftheprofessionalassociationsforthiseldofapplication.Wheretheuseofllingequipmentis
concerned, these rooms generally have equipment for heat generation and distribution, water treatment and degassing, power supply
and distribution, and measurement, control and information technology.
Accessforunqualiedanduntrainedpersonsmustberestrictedorforbidden.
The set-up location of the pressurisation unit must guarantee that operations, servicing, testing, maintenance, assembly and
disassembly can occur permanently, without obstruction and safely. The surface forming the installation area for the equipment of
the pressurisation unit must ensure stability and support. Bear in mind that the maximum possible forces comprise the deadweight
includingthewaterll.Ifstabilitycannotbeguaranteed,thereisadangerthattheunitwilltipover,ormoveunderloadand,asa
consequence, cause malfunctions and injury to persons.
The ambient atmosphere must be free of electrically-conductive gases, high concentrations of dust and aggressive vapours. There is
the risk of explosion if any combustible gases are present.
Dependingontheprocess,thewatertemperaturecanriseto90°C;incaseofimproperoperation,itcanexceed90°C.Therefore
thereisadangerofinjurytopersonsthroughburnsand/orscalding.
Flooded equipment must not be operated. If electrical equipment short circuits, persons or other beings in the water will be
electrocuted. Furthermore, there is a danger of malfunction and partial or irreparable damage to individual components due to water
saturation and corrosion.
Electrical hazards:
The protection class of the electrically operated components prevents injury to persons through potentially fatal electrocution. The
protectionclassisatleastIP52(5:Protectedagainstaccesswithawire,dustprotected;2:Protectionagainstwater,diagonally
falling dripping water. The terminal box cover, the cover of the pump feed, the cable glands and the valve connector plugs must be
inspected for effectiveness of protection prior to commissioning.
Avoid welding work on additional equipment that is electrically connected to the control unit. Stray welding currents or an improper
earthconnectioncouldleadtothedangerofreandthedestructionofpartsoftheunit.
1.5 External forces
Preventanyadditionalloads(e.g.,theforcesofheatexpansion,owuctuationsordeadweightloads).Thesecanleadtocracksand
breaks in the water-bearing pipework, to a loss of stability, and also to failure – associated with serious personal injury and damage to
property.
1.6 Inspection prior to commissioning, routine checks
These checks guarantee operational safety and its continued presence in line with applicable European or regional regulations,
Europeanandharmonizedstandardsandpertinenttechnicalrulesandguidelinesoftheprofessionalassociationsforthiseldof
application.Therequiredinspectionsmustbearrangedbytheowneroroperator;aninspectionandmaintenancelogbookfor
scheduling and traceability of measures taken must be kept.
1.7 Electrical equipment inspections, routine inspection
Withoutprejudicetotheconsiderationsoftheinsurer/operator,itisrecommendedthattheelectricalequipmentrelatingtotheFlamco
pressurisationunitbedemonstrablyinspectedtogetherwiththeheating/coolingunitnotlessthanevery18months(seealsoDINEN
60204-12007).
1.8 Maintenance and repairs
Thellingequipmentmustbedisabledandpreventedfrombeingunintentionallyenableduntiltheinspectioniscompleted.Notethat
the safety circuits and data transmissions made while shutting down could trigger safety chains or generate incorrect data. Existing
instructions for the heating or cooling system as a whole must be observed. When shutting down hydraulic components, the related
partsmustbeswitchedoffusingthecapvalves/ballvalvesinstalledontheFlamco-FillPllingequipment.Thecomponentscanbe
drained and the pressure relieved via the pump's drain plug.
Caution:themaximumsystemwatertemperatureincomponentsthatconductindustrialwater(pumps,casings,hoses,pipelines,
peripheralequipment)canreach90°C;itcanexceedthisvalueincaseofimproperoperation.Thereisariskofburnsand/or
scalding.

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The maximum pressure in system water conducting components may be equal to the maximum set pressure for the applicable safety
valve.(UnitwithpermissibleoperatingoverpressureofPN10.)Useofeye/faceprotectorsisrequirediftheeyesorfacecouldbe
injuredbyyingpartsorsprayinguids.
Tostopelectricalequipment(controlunit,pumps,valves,peripheralequipment),isolatethepowersupplytothecontrolunit.The
power supply must remain switched off for the duration of the work.
Unauthorisedmodicationsto,andtheuseofnon-approvedcomponentsorreplacementparts,isprohibited.Thiscanresultin
serious injury to persons and endanger operational safety. They will also render any claim for damages against product liability void.
The recommended approach is to call in Flamco service to perform these services.
1.9 Obvious misuse
Operation at incorrect voltage and frequency.
Feeding into drinking water systems
Operationwithhazardousmaterials(poisonous,ammable).
Mobile application.
1.10 Residual hazards
•Crushingngerswhenxingthesidepaneltothehousing.Wearprotectiveclothing.
•Whenassemblingthesystem,bodyposturecancausefatigue;ifnecessary,planforbreaksintheassemblingprocess.
•Incorrect routing can cause pressure hoses to burst. Avoid kinking the hoses.
•Fire:professionalreprotectionmustbeensuredonsite.
2. Product description
The contents of this manual include information on the supplied standard equipment.
Whereappropriate,thisincludesinformationonoptionsorothercongurations.
If optional extras are supplied, further documentation is provided in addition to this manual.
2.1 Mode of operation
TheFlamco-FillPactsasapressurisationunitwithapump(9)andabreaktank(3,4and6);itcanbemountedonawalloron
optionalfeet(12and13),actuatedusinganelectricalconnectiontotheSPConthepressuremaintenanceunitprovidedbythe
customer.
Initially,theoatvalve(3)llsthebreaktank(4)uptothelimitvalue.Duringthisprocess,theowpressuremustbeabove1bar.As
soonasenoughwaterhaslledupinthesystemseparationvessel,thepressureswitch(8)startstomonitortheminimumllinglevel
sothatthedryrunmonitoringsignalfortheSPCcanbetakenfromtheFlamco-FillPterminalbox(11).Theinstallationofapressure
reducerisrecommendedifhighowpressures(>5bar)exist.
OncethellinglevelintheFlexconM-Kcompressor/automaticpressuremaintenanceunitorFlamcomatdropsbelowtheswitching
pointfortheFlamco-FillP,thepump(9)startstodeliverllingmediumtothesystem/expansionline(fortheFlexconMK)ortothe
expansionvessel(fortheFlamcomat).
Oncethellinglevelswitch-offpointintheFlamcomatbasicvesselisreached,thepump(9)isswitchedoffagainviatheSPC.
FortheFlexconM-K,thesystempressureincreasesthroughllingthesystem.FlexconM-Kexternalpressuremaintenanceunit
correctsthepressurebyreleasingairfromthegasplenum.ThevesselllinglevelincreasesduringthisprocessuntiltheFlamco-Fill
Pllingswitch-offpointisreached.

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AllFlamco-FillPcongurationsaremadeviatheSPContheexternalpressuremaintenanceunit.
5 3
2 1
6
10
11
4
15
7
13
12
8
14
9
16
1. Non-return valve
2. Water meter with pulse output
3. Float valve
4. Break tank
5. Housing cover cap
6. Overow
7. Housing
8. Pressureswitch(dryrunprotection)
9. Pump
10. System connection
11.Connection/Terminalbox
12.Feet(Optionalextras)
13. Mounting bolts for optional feet
14. Housing side panel
15. Non-return valve
16.Externalprotectiveearth(PE)conductorconnection

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2.2 Marking
Unit name plate
Terminal box name plate (inside)
Unit type marking with notes about electrical safety on the terminal box
Terminal box service numbers

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ENG
2.3 Terminal diagram
98
98
3 43 3
3 43 3
1 91 8 2 0
1 8 1 9 2 0
P E
3
(gegn)
u1 w2
v1 u2
w1 v2
1
2
3
4
bl
bn
3
2
12
2
N L
G N DG N D
pw m ps re fill/ dra in
04.01.13
( 2 3 0 V 5 0 H Z )
8 9 3 3 3 4 1 8 1 9 2 0
P E
Watermeterwithpulser(IWZ) Dry-run protection Pump
(DS240)
Execution
As pressure switch
Conductor Color Code
bl Blue
bn Brown
ye/gn Yellow/Green
bl Black
wt White
gr Grey
External
pe
cable
connect to
housing
bn
bl Ye/gn
bn
wt
Explanation of the abbreviations used in the terminal diagram
Please note: The switch settings shown represent the current-free, non-switched state.
extra-low voltage Protective low voltage
high voltage Voltage as per markings
L Phase
N Neutral wire
PE Protectiveearth(PE)conductor
Pumpe/pump Pump motor
ps Pressure switch
pwm Pulse water meter

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2.4 Components, equipment
5 3
Feed
System
2 1
6
10
17
18
11
4
15
9
13
12
19
8
14
7
16
1. Non-return valve
2. Watermeterwithpulseoutput(IWZ/pwm)
3. Floatvalveforllingwithsystemseparation
4. Break tank
5. Cover for housing access to the break tank
6. Breaktankoverowconnection
7. Housing(onlyedgesportrayed;earthconnection
markedwithalabelonthefrontside)
8. Pressure switch for the pump's dry run protection
9. Pump
10. Pressure hose – connection to the system
11. Terminal box with connection contacts to the top hat rail
(andtransparentcover)
12. Feet as optional equipment
13. Threaded connections for Pos. 12
14. Removable housing side panel
(onlyedgesportrayed)
15.Non-returnvalve(preventsreverseowoutofthesystem
intothebreaktank).
16.Externalprotectiveearth(PE)conductorconnection
17. Terminal block for connecting the pressure switch
andfortheelectricalconnectiontotheSPC(tobeprovided
bythecustomer)
18. Terminal block for connecting the pulse water meter
andforelectricalconnectiontotheSPC(tobeprovidedby
thecustomer)
19. Terminal block for connecting the pump
andforelectricalconnectiontotheSPC(tobeprovidedby
thecustomer)

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3. Installation
3.1 Installing, levelling, xing - Ensure stability!
TheFlamco-FillPmustbeinstalled/assembledinawaythatpermanentlyensuresoperation,controlandmaintenance.Mountthe
unit on the wall in the vicinity of the pressure maintenance control unit and the hydraulic connection to the system in the technical
room.UseallfourØ10holesonthebackofthecasingtomountonsuitablebolts/hooks.SecuretheFlamco-FillPagainstaccidental
removal.
Alternatively,optionalfeet(inadditiontothesuppliesordered)canbeusedforinstallation.
Makesurethatthereisasufcientlylargeoordrainfortheunitinthetechnicalroomandthatoodingcanberuledout.
Duringtheinstallationprocess,donotallowwelddepositsordirttogetontoorintotheFlamco-FillPequipment!
3.2 Connecting the pipework
Please note:Onlyworkingtemperaturesofbetween3°Cand90°Catthepointofconnectionarepermissible.(Ifpossible,prevent
coldFlamco-FillPmediumcontactingthehotsurfacesoftheheater.Theaimshouldbeforamixturewithawarmermedium.)
Make sure that there is a direct connection to the heat source, and that no external hydraulic pressures are present at the ingress
point(e.g.,hydraulicbalancers,powerdistributions).
Connectacapvalve(tobeprovidedbythecustomer)behindtheFlamco-FillPunitsystemconnection(10).Followthesame
procedureontheinletsidebetweenthenon-returnvalve(1)andinlet.Ifcontaminationwithaparticlesizeofmorethan0.2mmis
expectedattheinlet,installacorrespondingdirttrap(tobeprovidedbythecustomer)intheinletpipeupstreamoftheunit.
If the pipework length is more than 10 metres from the feed-in point, the connection pipes must be at least 1".
Usesealantsandfeedlinesappropriatetotheinstallation;however,pleaseobserveatleastthemaximumpermittedvolumetricow,
pressure and temperature values for the pipework in question.
Finally,connecttheoverowpipeonthesystemseparationtank(DN40)tothedischargeonasuitableoverowfunnel(tobeprovided
bythecustomer).
Makesurethatallconnectionstotheunitarefreeofnozzleforceswithoutmechanicalbacklash!Avoidkinkingortwistingthe
connectinghoses!
3.3 Connecting the electrical supply
The customer must connect the power supply between the pressure maintenance unit SPC and the Flamco-Fill P terminal box.
Theconnectiontotheterminalbox,particularlytothe(protective)earthconductorsystem,andwire-to-wireshortcircuitprotector,
must be made in accordance with the regulations of the appropriate utility and with applicable standards. The type plate on the
terminalboxandtheterminaldiagram(marking)providetherequiredspecications.
Please note: Install equipotential bonding between the earth connection and equipotential bonding conductor. The minimum
diameter,qualityandtypeofthepowercablesmustreecttherulesandregulationsapplicableattheinstallationlocationforthis
application. Electrical power cables must be permanently routed in cable ducts.

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4. Starting up
4.1 Commissioning
Checkthattheinstallationandassemblyactionsarecomplete(e.g.,powersupplyavailable,functioningoractivatedfuses,
equipmentisfreefromleaks,stablesetupoftheunit).
Oncethecapvalve(tobeprovidedbythecustomer)ontheunithasbeenopenedandtheaccumulatorhasbeenlledwithfeed
medium, Flamco-Fill P is ready for operation.
4.2 Conguration
Initial conguration was completed at the factory (for original equipment), or – for retrotting – customer service congures
the Flamco-Fill P lling unit on the SPC!
WithintheSPCsubmenuitems[8-2]thecustomer/ownercanadjusttheswitchinglimitsforlling,asrequired.See:Basicinstallation
document and Flamcomat or Flexcon MK Installation and operating instructions.
Filling monitoring is automatically carried out by the SPC.
4.3 Recommissioning
Recommissioning(e.g.,afterextendedperiodsofinactivity/shutdownandmaintenance)assumesthatthesystemisfreefromleaks
and electrically correctly connected.
5. Maintenance
Any dirt traps which the customer may have installed must be cleaned at least every six months.
A leakage test and a function check of all components must be performed at least once a year.
Shouldavisualcheckofthesystemnecessitateother/furthermaintenance,thismayonlybeperformedbyqualiedpersonnel.

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Appendix 1. Technical data, general specications
1.1 Ambient conditions
Storage room
Room: Protected against: Ambient conditions:
Locked;
frost-free,
dry.
Directsunlight;
thermalradiation;
vibrations.
60-70%relativehumidity,non-condensing;
maximumtemperature50°C;
free of electrically conductive gases, combustible gas mixtures,
aggressive atmosphere.
Technical room:
Room: Protected against: Ambient conditions:
Locked;
frost-free,
dry.
Directsunlight;
thermalradiation;
vibrations.
60-70%relativehumidity,non-condensing;temperature3°Cto
40°C;freeofelectricallyconductivegases,combustiblegasmixtures,
aggressive atmosphere.
Caution: Higher temperatures may overload the drive system.
1.2 Minimum distances: clearance for service and repair.
mm
mm
mm

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1.3 Sample installation diagram
M -K
L
F la m c o-F I L L P
DN *
F la m c o-F I L L P
*
**
Supply temperature <105°C(STB<110°C)
Supply temperature <105°C(STB<110°C)
Example of level-
controlledllingwitha
Flamco-Fill P on a
Flexcon MK
Example of
level-controlled
llingwitha
Flamco-Fill P on a
Flexcon MK
Please note: If the
return line is routed horizontally, implement the
connectionfromabove(notfrombelow)toavoid
additional contamination
.
To be provided by the customer: System inlet,
system outlet,
llinginlet,componentcouplings.
Control unit
PLC
Terminal(8,9);33,34;18,19,20asperPLC
Filling water inlet
Coupling assembly *
Basic vessel*
System supply side
System supply side
Control module Flamcomat *
Cap valve**
Cap valve**
Scope of supply, standard.
Accessories
Compressor
pressure maintenance
unit with
PLC control
Heater
Heater
Terminal
box
Terminal
box
Filling water inlet
Terminal(8,9);33,34;18,19,20asperPLC
Hot leg
Hot leg
Cold leg
Cold leg

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Appendix 2. Technical data and specications
2.1 Pressure, temperature, volume, etc.
•Systempressure(downstreamoftheunit): 1to9bar(operatingpressurerange)
•Max.permissiblesystemoverpressure: 10bar(PN10)(onthesystemconnection)
•Flowrateofmedium:   uptomax.210litres/hat1bar;upto165litres/hourat9bar
•Operatingtemperature:   3tomax.90°C(attheFlamco-FillPconnectionpoint)
•Supplysidetemperatures:   >0to105°C
•Noiseinoperation:   ~55dB(A)
•Ambienttemperatureinoperation:  >0to40°C
• Inlet water temperature: 3 to 30 °C
•Fillingwaterminimumowpressure:  1bar
•Max.llingpressure:   10bar
2.2 Weights and dimensions
Weight:  Approx.24kg(empty).
System connection: G½" screw joint on reinforced hose.
Inlet connection: External thread Rp½".

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Appendix 3. Technical data and information for the electrical equipment
• Operating voltage: 230V 50 Hz 1 ph
• Rated power: 0.3 kW
• Nominal current: 2.5 A
• IP degree of protection: IP52

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3.1 Declaration of incorporation
as per EC Machinery Directive 2006/42/EC Annex II B B for partly completed machinery
Declaration of incorporation
as per EC Machinery Directive 2006/42/EC Annex II B B for partly completed
machinery
_______________________________________________________________
Manufacturer person established in the Community
Flamco STAG GmbH is authorised to compile the relevant technical
Berliner Chaussee 29 technical documents
DE - 39307 Genthin Sabine Pietsch
Flamco STAG GmbH
Berliner Chaussee 29
29 DE - 39307 Genthin
Description and identication of the partly completed machine
Product/article Flamco-Fill P
Type Make up device
Serial number 17665
Project number PRJ-2012-11-28-0001 ‘
Trade name Flamco-Fill P)
I hereby declare that the following essential requirements of the Machinery Directive 2006/42/EC have been met
1.1.7, 1.1.8, 1.3., 1.3.7, 1.5.1, 1.5.2, 1.5.6, 1.5.13, 1.5.15, 1.5.16, 1.6.1, 2.2.1, 2.3, 3.2.1, 3.2.2, 3.3.4, 3.4, 3.4.3,
3.4.5, 3.5.1, 3.5.2, 3.6.1, 3.6.2, 4.1.2.1, 4.1.2.2, 4.1.2.3, 4.1.2.4, 4.1.2.5, 4.1.2.6, 4.1 .2.7. 4.1.2.8, 4.1.3, 4.2.2,
4.2.3, 4.3.1, 4.3.2, 4.3.3, 4.4.1, 4.4.2, 5.1, 5.2, 5.6, 6.1.1, 1.1.2, 6.3.1, 6.3.2, 6.3.3, 6.4.1, 6.4.3, 6.5
I further declare that the relevant technical documentation described in Annex VII, part B has been prepared;
I expressly declare that the partly completed machine fulls all the pertinent provisions of the following EC
directives
2006/42/EC Directive 2006/42/EC of the European Parliament and Council of 17 May 2006 on
machinery, and amending Directive 95/16/EC (new version) (1).
2006/95/EC Directive 2006/95/EC of the European Parliament and Council of 12 December 2006
on the harmonisation of the laws of Member States relating to electrical equipment
designed for use within certain voltage limits.
Reference to the harmonised standards applied in accordance with Article 7, Paragraph 2
EN 1717 Protection of Drinking Water
EN 60204-1:2006/A1:2009 Safety of Machinery - Electrical Equipment of Machines - Part 1: General
Requirements (IEС 60204-12005)
EN 14622 Devices to prevent pollution by backow of potable water - Air gap with circular
overow (restricted) - Family A, type F
The manufacturer or the authorised representative undertakes to transmit, in response to a reasoned request by the
national bodies, relevant information on the partly completed machinery. Said transmission shall be effected Paper.
Intellectual property rights remain unaffected by this!
Please note! The partly completed machine must not be put into service until the nal machinery into which it is
to be incorporated has been declared in conformity with the provisions of this Directive.
Genthin, 23/09/2014 ı
Place, date Signature
Roland Kiesswetter, Team Lead
R&D
Page 1/1

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Deutsch (DEU) Montage- und Bedienungsanleitung
Inhaltsverzeichnis
1. Allgemeine Sicherheitshinweise ................................................................................................................................................................................................................................. 19
Bestimmungsgemäßer Einsatzbereich.......................................................................................................................................................................................................................... 19
Warnzeichen in dieser Anleitung...................................................................................................................................................................................................................................... 19
Transport, Lagerung, Entpacken...................................................................................................................................................................................................................................... 19
Betriebsraum.............................................................................................................................................................................................................................................................................. 20
Äußere Kräfte............................................................................................................................................................................................................................................................................. 20
Prüfung vor Inbetriebnahme, wiederkehrende Prüfung........................................................................................................................................................................................ 20
Prüfungen elektrischer Ausrüstung, wiederkehrende Prüfung.......................................................................................................................................................................... 20
Wartung und Instandsetzung............................................................................................................................................................................................................................................. 20
Naheliegender Fehlgebrauch............................................................................................................................................................................................................................................. 21
Verbleibende Gefährdungen............................................................................................................................................................................................................................................... 21
2. Produktbeschreibung......................................................................................................................................................................................................................................................... 21
Arbeitsweise............................................................................................................................................................................................................................................................................... 21
Kennzeichnungen .................................................................................................................................................................................................................................................................... 23
Klemmenplan............................................................................................................................................................................................................................................................................. 24
Bauteile, Ausrüstung.............................................................................................................................................................................................................................................................. 25
3. Montage ...................................................................................................................................................................................................................................................................................... 26
 Aufstellen,Ausrichten,Verschrauben-Standsicherheitherstellen!............................................................................................................................................................... 26
Rohrleitungsanschlüsse herstellen ................................................................................................................................................................................................................................. 26
Elektroanschluss herstellen ................................................................................................................................................................................................................................................ 26
4. Inbetriebnahme....................................................................................................................................................................................................................................................................... 27
Erstinbetriebnahme................................................................................................................................................................................................................................................................. 27
 Parametrierung/Konguration.......................................................................................................................................................................................................................................... 27
Wiederinbetriebnahme.......................................................................................................................................................................................................................................................... 27
5. Wartung ....................................................................................................................................................................................................................................................................................... 27
Anlage 1. Technische Daten, Allgemeine Angaben..................................................................................................................................................................................................... 28
Umgebungsbedingungen .................................................................................................................................................................................................................................................... 28
 Mindestabstände,Wartungs-undMontageächen............................................................................................................................................................................................... 28
Installationsbeispiel................................................................................................................................................................................................................................................................. 29
Anlage2. Technische Daten und Angaben........................................................................................................................................................................................................................ 30
Druck, Temperatur, Lautstärke etc.................................................................................................................................................................................................................................. 30
Maße und Gewichte ............................................................................................................................................................................................................................................................... 30
Anlage 3. Technische Daten und Angaben der elektrischen Ausrüstung..................................................................................................................................................... 31
Einbauerklärung........................................................................................................................................................................................................................................................................ 31

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DEU
1. Allgemeine Sicherheitshinweise
DievorliegendeDokumentationistErgänzungzurMontage-undBetriebsanleitung:Flamcomat,Doc.-Nr.:MC00018/11-2010/ger;
FlexconM-K,Doc.-Nr.:MC00019/11-2010/gerundausschließlichmitdiesenBasisdokumentenanzuwenden!Inbesonderegeltendie
darin angegebenen allgemeinen Sicherheitshinweise sowie Mitteilungen zur Ausrüstung, Anwendung und Funktion.
WeitereProduktinformationensindüberdiezutreffendeFlamco-Niederlassungzuerhalten(sieheSeite2).
FürMontageanleitungenundErgänzungsdokumenteinverschiedenenSprachenschauenSieaufwww.amcogroup.com/manuals.
1.1 Bestimmungsgemäßer Einsatzbereich
NiveaugesteuerteNachspeisungvonZulaufwasserindasBetriebswasser(Wärmeträger)inHeizungs-undKühlwasseranlagen,dazu
dienend, betriebsbedingte Verluste in diesen Systemen auszugleichen, um den Mindestsystemdruck über die Nachführung des
Füllstandes in kompressorgesteuerten oder pumpengesteuerten Fremddruckhaltungen aufrecht zu erhalten.
DieSPC(SteuerunganderDruckhalteeinrichtung)übernimmtdabeidieÜberwachungderniveaugesteuertenNachspeiseeinrichtung
und steuert die integrierte Pumpe der Flamco-Fill P bedarfsgerecht an.
Der Einsatzbereich der Nachspeiseeinrichtung bzgl. des Systemdruckes bzw. des Druckes am Systemanschluss von
Flamco-FillPliegtbei1bis9bar(PN10).BeiHeizungswasseranlagendarfinSystemenachDINEN12828bzw.inSystememitmax.
Vorlauftemperaturenbis105°Cnachgespeistwerden.BeiAuslegungsleistungenüber1MWsinddurchdenBauherrn/Betreiber
gegebenenfalls mit einer benannten Stelle mögliche, zusätzliche sicherheitstechnische Anforderungen abzustimmen entsprechend
der geltenden europäischen Normung. Die Trennung von Betriebswasser und Nachspeisewasser wird über einen freien Auslauf
entsprechend DIN EN 1717 und DIN 1988 vorgenommen.
1.2 Warnzeichen in dieser Anleitung
Warnung vor gefährlicher elektrischer Spannung.
Missachtung kann Leben gefährden, Brände verursachen und Havarien auslösen,
zur Bauteilüberlastung und Zerstörung oder Funktionsbehinderung führen.
Warnung vor Fehlhandlungen und falschen Ausgangsbedingungen.
Missachtung kann zu schweren Personenschäden, Bauteilüberlastung und Zerstörung oder Funktionsbehinderung führen.
1.3 Transport, Lagerung, Entpacken
Die Lieferung der Ausrüstung erfolgt in Verpackungseinheiten, die der Ausführung gemäß Auftrag oder den Anforderungen aus dem
Transportweg und der Klimazone entsprechen. Sie erfüllen mindestens die Anforderungen der Verpackungsrichtlinien der Flamco
STAG GmbH.
Konform dieser Richtlinie werden die Flamco-Fill P statt Entgasungsanlagen liegend auf Sonderpaletten ausgeliefert. Diese Paletten
sind geeignet zum waagerechten Transport mit zulässigen Gabelhubgeräten. Richten Sie dazu das für die Palette größtmögliche
Gabelaußenmaß ein, um ein Kippen der aufgenommenen Last zu verhindern. Bewegen Sie den Liefergegenstand in der tiefsten,
möglichen Stellung, quer zu den Gabelpaaren. Sind Verpackungen zum Transport mit Anschlagmitteln geeignet, enthalten sie
Kennzeichnungen zu den erforderlichen Anschlagpunkten.
Wichtiger Hinweis: Transportieren Sie den verpackten Lieferumfang so nah wie möglich an den vorgesehenen Aufstellungsort und
nutzenSieeinewaagerechteAbstellächemittragfestemUntergrund.
Achtung: Das Aufrichten des von der Palette und der Umverpackung getrennten Aggregates, ist unter Sicherungsmaßnahmen
zur Vermeidung von Lastdurchschlagen, Lastkippen und Lastschaukeln auszuführen. Es sind Handlungen und Maßnahmen
erforderlich, die unkontrolliertes Lastfallen, Lastrutschen und Lastkippen verhindern. Ein Zwischenlagern kann auch im verpacktem
Zustand erfolgen. Ein Stapeln von mehr als drei Verpackungseinheiten ist zu verhindern. Verwenden Sie ausschließlich zugelassene
Lastaufnahmemittel, sicheres Werkzeug und tragen Sie die erforderliche Schutzausrüstung.

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1.4 Betriebsraum
Raum, der die Anforderungen aus den geltenden europäischen Verordnungen, europäischen- und harmonisierten Normen und
zutreffenden technischen Regeln und Richtlinien der Fachverbände für diesen Einsatzbereich erfüllt. Für die Anwendung der
Nachspeisung aus vorliegender Anleitung enthalten diese Räume im Regelfall Ausrüstungen zur Wärmeerzeugung und Verteilung, der
Wasseraufbereitung und Entgasung, der Elektroversorgung und Verteilung sowie der Mess-, Steuer-, Regel- und Informationstechnik.
EinZugangvonunqualiziertenundnichteingewiesenenPersonenistzubehindernoderauszuschließen.
Der Aufstellungsort der Nachspeiseeinrichtung muss sicherstellen, dass der Betrieb, die Bedienung, Wartung, Prüfung,
Instandsetzung,MontageundDemontagedauerhaftungehindertundgefahrlosmöglichist.DerBaugrund,dieAufstellächefürdie
Ausrüstung der Entgasungseinrichtung, muss sicherstellen, dass die Standsicherheit gewährleistet ist und aufrechterhalten wird. Es
sind die maximal möglichen Kräfte aus den Eigenmassen einschließlich der Wasserfüllung zu berücksichtigen. Bei unzureichender
Standsicherheit besteht die Gefahr von Lastkippen, Lastwandern und kann infolge dessen neben Funktionsstörungen zu schweren
Personenschäden führen.
Die Umgebungsatmosphäre muss frei von elektrisch leitenden Gasen, hohen Staubkonzentrationen und aggressiven Dämpfen sein.
Bei zündfähigen Gasen und Gasgemischen besteht Explosionsgefahr.
Verfahrensbedingt kann die Wassertemperatur bis 90 °C und bei unzulässigem Betrieb auch größer 90 °C betragen. Es besteht die
Gefahr von Personenschäden durch Verbrennung bzw. Verbrühung.
Der Betrieb unter Wasser stehender Ausrüstungen ist zuverlässig auszuschließen. Der Kurzschluss elektrischer Ausrüstungen
führt bei in diesem Wasser stehenden Personen und anderen Lebewesen zum Tod durch Stromschlag. Es besteht die Gefahr von
Funktionsbehinderungen und Bauteilschäden oder Zerstörung durch Wassersättigung und Korrosion.
Elektrische Gefährdungen:
Die Schutzart elektrisch betriebener Bauteile verhindert Personenschäden durch elektrischen Schlag, der zum Tode führen kann. Sie
beträgtmindestensIP52(5:GeschütztgegendenZugangmiteinemDraht,staubgeschützt;2:Wasserschutz;Schrägeinfallendes
Tropfwasser. Der Klemmkastendeckel, der Deckel der Einspeisung für die Pumpe, die Kabelverschraubungen und die Gerätestecker
der Ventile sind vor Inbetriebnahme auf ihre Schutzwirkung und den festen Sitz zu prüfen.
Verhindern Sie Schweißarbeiten an zu ergänzenden Ausrüstungsteilen, die leitend mit dem Steuermodul verbunden sind.
„Vagabundierende“ Schweißströme oder ein unzulässiger Masseanschluss führen zur Brandgefährdung und Zerstörung von Teilen
des Aggregates.
1.5 Äußere Kräfte
VermeidenSiejeglicheZusatzbelastungen(z.B.KräfteausWärmedehnung,StrömungsschwingungenoderEigenlasten).Diese
können zu Rissen und Brüchen in den wasserführenden Leitungen, zum Verlust der Standsicherheit und weiterhin zum Ausfall
verbunden mit schweren Sach- und Personenschäden führen.
1.6 Prüfung vor Inbetriebnahme, wiederkehrende Prüfung
Sie gewährleisten die Betriebssicherheit und deren Aufrechterhaltung nach den geltenden europäischen Verordnungen,
europäischen- und harmonisierten Normen und zutreffenden technischen Regeln und Richtlinien der Fachverbände für diesen
Einsatzbereich. Die erforderlichen Prüfungen sind durch den Eigentümer oder Betreiber zu veranlassen, ein Prüf- und Wartungsbuch
zur Planung und Rückverfolgung der Maßnahmen ist zu führen.
1.7 Prüfungen elektrischer Ausrüstung, wiederkehrende Prüfung
UnbeachtetderFestlegungendesSachversicherers/Betreiberswirdempfohlen,dieelektrischeAusrüstungder
Nachspeiseeinrichtung Flamco-Fill P zusammen mit der Heizungs- bzw. Kühlanlage vor Inbetriebnahme, mindestens jedoch alle 1,5
Jahrenachweislichzuprüfen.(sieheauchDINEN60204-1(2007)).
1.8 Wartung und Instandsetzung
Die Ausrüstung der Nachspeiseeinrichtung ist außer Betrieb zu setzen und bis zum Leistungsabschluss gegen unbeabsichtigte
Wiederinbetriebnahme zu sichern. Beachten Sie Sicherheitsschaltungen und Datenfernübertragungen, die während der Handlungen
zum Auslösen von Sicherheitsketten oder zu Fehlinformationen führen können. Bestehende Anweisungen zum Gesamtprojekt der
Heizungs- oder Kühlanlage sind zu beachten. Zum Stillsetzen hydraulischer Bauteile sind die betreffenden Abschnitte über die
bauseitiganderNachspeiseeinrichtungFlamco-FillPzuinstallierendenKappenventile/Kugelhähneabzusperren.Entleerungenund
eine Druckentlastung können über die Entleerungsschraube der Pumpe erfolgen.
Achtung:DiemaximaleTemperaturderBetriebswasserführendenBauteile(Armaturen,Schläuche,Rohrleitungen,
Ergänzungsausrüstungen)kannbis90°CundbeiunzulässigemBetriebaucheinenhöherenWerterreichen.EsbestehtdieGefahr
der Verbrennung bzw. Verbrühung.