Flamco Flexcon M-K Compressor - automat expansion vessel

Transcription

1 Flexcon M-K Compressor - automat expansion vessel M-K EPS GB Installation and operating instructions 1999, Flamco

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3 Flamco UK Limited P.O. Box 9, Washway Lane, St. Helens, Merseyside WA10 6FE United Kingdom Telephone: Fax: Installation and operating instructions Flexcon M-K compressor-automat expansion vessel Dear customer, With the purchase of a Flexcon M-K automat expansion vessel, you are now the owner of a high quality product from Flamco. The Flexcon M-K automat expansion vessel offers a combination of trusted technique, operational reliability and simplicity with placing and operation. This installation manual is intended for siting and placing, and for the commissioning. The manual also contains a description of the operation of the Flexcon M-K automat expansion vessel. GB When you read this manual, you will find instructions concerning the installation, regulation and operation of this Flexcon M-K automat expansion vessel. We are convinced that you will quickly become acquainted with the technique of this Flexcon M-K automat expansion vessel, and the Automat will provide long-term and satisfactory operation in your installation. Should you have any questions about the Flexcon M-K automat expansion vessel that are not answered in the manual, we will be very pleased to answer them. Contents Page 1. General 4 2. Function and operation 5 3. Different versions 6 4. Siting and placing 9 5. Easycontrol control automat Flexcon control automat Commissioning and operation Maintenance - periodic inspections 24 Appendices: I - IX 25 3

4 1. General The Flexcon M-K automat expansion vessel is a diaphragm pressure expansion vessel, that keeps the preset pressure constant independent of the vessel contents. The vessel has the task of absorbing the expansion volume that arises through heating in a closed heating installation; when the temperature falls, the expansion is returned to the installation. The pressure is kept constant with the aid of a solenoid valve, which is operated depending on the preset working pressure, and a compressor, which provides oil-free air. As a result, by approximately, the full contents of the vessel are available as expansion space. The vessel is equipped with an interchangeable diaphragm, made of high quality butyl rubber, which divides the vessel into two spaces (air and water). The water is located in the diaphragm and the air in the space between the diaphragm and the wall of the vessel. 1.1 Fields of application The Flexcon M-K Automat expansion vessel is for use in closed heating installations according to DIN 4751 part 2, with system temperatures to a maximum of 120 C and also in closed cooling and air conditioning installations. Maximum continuous temperature acting of the diaphragm according to DIN 4751 part 3: 70 C With a temperature > 70 C in the expansion pipe-work between the heating installation and the M-K Automat expansion vessel, an intermediate vessel is connected in front of the expansion vessel to cool the expansion water. Maximum system temperature of the heating installation: 120 C The Flexcon M-K Automat expansion vessels can be supplied from 400 to 3500 litres in 5 and 10 bar versions. Other working pressures can be supplied on request. 1.2 Specifications and regulations The expansion vessels are subjected in the factory to a separate testing of the technical Überwachungsverein according to paragraph 14 of the Boiler Regulation (DampfkV). The type indication or the TÜV stamp is given on the type plate. The test data is added to the delivery. This test data contains: - manufacturing certificate for the construction and water pressure testing - factory certificate - inspection drawing (copy). The certificates are kept in the cabinet of the control automat! 1.3 Characteristics - Complete programme of models and versions. - Wide field of application through flexible possibilities of use. - Simple and inexpensive system, as a result of the flexible system connection and delivery, which is suited for immediate use. - Small placement requirement - large expansion volume in a small space. - Exchangeable diaphragm made of high quality butyl rubber. - System pressure kept constant within close tolerances. - Oil-free compressor in low-noise version. - Freely programmable control with a microprocessor, whereby the actual values in use are shown on a display. - Connection to a personal computer or combination with a building control system are possible. - Connection present for a general fault indication. - Safe operation through many years of experience and high manufacturing quality. 4

5 2. Function and operation Figure 1 shows the Flexcon M-K automat expansion vessel as it is supplied, as a complete unit. Figure Steel vessel. 2. Exchangeable diaphragm made of high quality butyl rubber according to DIN 4807 part Control automat. 4. Oil-free compressor. 5. Combined sensor for contents and pressure. 6. Solenoid valve. 7. Diaphragm fracture sensor (available on request). 8. Safety valve on the air side of the vessel. 9. Float vent (available on request). 10. Compressor pressure pipe. The essential constructional components are: - vessel (1) - diaphragm (2) - control automat (3) - compressor (4) Measurement cable. 12. System connection. 13. Flexible high pressure hose. 14. Condensation drain cock. 15. Hood. 16. Earthing strip. 17. Foot height adjustment. 18. Adjusting bolt/transport protection. 19. Inspection opening. 20. Air cushion. 21. Expansion water. The diaphragm (2), which is in the vessel (1), accepts the expansion volume and functions as a separation wall between air and water. The control automat (3) guarantees that the pressure that is required in the installation can be set and maintained. The signals that are necessary for this are sent to the automat by a combined sensor (5). When the pressure increases, the automat switches the solenoid valve (6) on and, when the pressure decreases, the automat switches the compressor on. The Flexcon M-K automat expansion vessel can be fitted with the following microprocessor controls: Easycontrol 2000 control automat The Easycontrol 2000 control automat is designed for a single installation (a Flexcon M-K automat expansion vessel, if necessary with auxiliary vessel). For User instructions, see pages 12 to 16. Flexcon control automat The Flexcon control automat is prepared for a single circuit and parallel/failure change-over operation. For User instructions, see pages 17 to 22. The compressor (4) provides the automat expansion vessel with air that is free of oil. The feed and return of the expansion volume to and from the diaphragm is done at the system connection (12) through a flexible high pressure hose (13). The safety valve (8) is set to the relevant maximum working pressure of the vessel and protects against unpermitted overpressure. The water that condenses from the air can be removed from the air space (17) through the condensation drain cock (14). 5

6 3. Different versions The different versions that are described in the following can be supplied for the varied requirements that the heating installations place on the expansion installations. 3.1 Flexcon M-K automat expansion vessel The Flexcon M-K automat expansion vessel is supplied ready-for-use as a standard version in the sizes 400 to 3500 litres (upright model). The construction of the Flexcon M-K automat expansion vessel is shown in figure Flexcon M-K automat expansion vessel with auxiliary vessel Figure air side connection (flexible) plug electrical connection (control automat - solenoid valve) stop cocks fill and drain fit on site fill and drain The Flexcon M-K automat expansion vessel must be connected on the air and water sides to the auxiliary vessel (both with equal vessel volumes!). Here, the Flexcon M-K automat expansion vessel supplies the auxiliary vessel with compressed air and takes over the control. There are complete hose connections available for the coupling between the air spaces. The installation can be delivered with both control automats (Flexcon control automat or Easycontrol 2000 control automat). 3.3 Parallel operation or failure change-over operation with two Flexcon M-K automat expansion vessels* Figure air side connection (flexible) plug electrical connection plug stop cocks fill and drain fit on site fill and drain * Only with Flexcon control automat (see page 17). 6

7 Parallel operation (Master/Slave operation) During the parallel operation of two automat expansion vessels, one of the controls takes over command (becomes Master). The secondary control (the Slave) is given the actual measurement values (pressure and level) by the Master and the switching commands for solenoid valve and compressor. A change-over of Master and Slave is done manually. Failure change-over operation During failure change-over operation of two automat expansion vessels, one control is passive each time. The passive control only carries out the switching commands for the solenoid valve. The change-over between "active" and "passive" is done automatically. If the motor protection switch is activated with an active control automat, this automat is switched to the passive mode. This also happens after the preset change-over time has expired. 3.4 Operation during failure change-over operation with two compressors on one control automat* Version 1 - Flexcon M-K automat expansion vessel, combined with two compressor units. Figure Flexcon M-K 400 and Flexcon M-K Flexcon M-K 800 to Flexcon M-K 3500 * Only with Flexcon control automat (see page 17). 7

8 Version 2 - Flexcon M-K automat expansion vessel with auxiliary vessel, combined with a compressor unit. Figure electrical connection (control automat - solenoid valve) electrical connection (control automat - second compressor) air side connection (flexible) stop cocks fill and drain fit on site fill and drain With the two different versions, only one of the two compressors works. In the case of fault (the motor protection switch is activated) or after the change-over time has expired, a change-over is made to the other compressor. 3.5 Failure change-over operation with three Flexcon M-K automat expansion vessels* Figure 6 electrical connection control automat solenoid valve air side connection (flexible) electrical connection control automat solenoid valve air side connection (flexible) 5572 electrical connection control automats 1 and 2 stop cocks electrical connection control automats 2 and 3 stop cocks fill and drain fill and drain fill and drain fit on site fit on site With "failure change-over operation with three Flexcon M-K automat expansion vessels", two controls work in parallel (see point 3.3), the third control has a spare function (stand-by) and only receives the switching commands for the solenoid valve. The compressor is not switched on. In the case of a fault, the defective Automat expansion vessel goes to the "spare" state and the two other automats take over in parallel operation. A change-over between Master, Slave and Stand-by also occurs after the change-over time. * Only with Flexcon control automat (see page 17). 8

9 4. Siting and placing Important pleae note The Flexcon M-K unit must be free to move. - Place on a flat clean base. - Make sure the minimum headroom is available above the vessels. - Use adjustment feet to give vertical position. - Do not use rigid connections for any services. - The flexible hose provided must be used for connecting the Flexcon M-K unit to the system (auxiliary vessels may be connected with rigid pipework). - Push fit air hoses are provided where necessary. - For convenience locate the K-04 compressor within reach of the air hose supplied. - Lockshield valves must be used for system isolation - do no use ball valves. - Wiring to the make up unit and between Flexcon M-K controls and to the K-04 compressor when used is to be supplied by the contractor. Before commissioning remove the protection bar on the Flexcon M-K front foot load sensor (raise Flexcon M-K unit by the setscrew, remove retaining screw and bar, lower Flexcon M-K unit and loosen setscrew). The automat expansion vessels are supplied on a pallet. Appendix IX gives the dimensions and weights The Flexcon M-K automat expansion vessels must be sited in a closed space with a temperature range between 5 C and 40 C. Here, the floor must be sufficiently sturdy and flat. The automat expansion vessel and, if applicable, the auxiliary vessel must be sufficiently accessible for service. b a c The following table and sketch give the minimum distances. Vessel size a b c (l) (cm) (cm) (cm) > c Above the top inspection opening, there must be a free space of: - min mm for Flexcon M-K 0400 to 1600 litres - min mm for Flexcon M-K 2000 to 3500 litres. Note! To guarantee an accurate measurement of the contents, the following points must be followed: The Flexcon M-K automat expansion vessel must be vertical and free! 5573 * * measurement sensor with transport protection * measurement points (placing points) for the spirit level (length about 1m) The transport protection of the measurement sensor must be removed after placing, so that the combined sensor (contents and pressure) can stand free on a flat base. The foot height adjustment of the two other vessel feet make the required safe vertical position of the expansion vessel possible. The exact vertical placing must be done with a spirit level on the marked axes, according to the drawing. The high pressure hoses supplied with the delivery provides the required flexibility. The zero level setting of the vessel contents may only take place when the vessel is empty and placed vertically! Do not fill the compressor automat expansion vessel with water before commissioning and make sure that the valve with drain device is closed. 9

10 The Flexcon M-K automat expansion vessel is supplied ready-for-use as a unit. For this reason, the automat only requires the following connections: - system connection Vessel size Size of connection Flexcon M-K 400 to 800 G 1!/4 /DN 32 Flexcon M-K 1000 to 1600 G 1!/2 /DN 40 Flexcon M-K 2000 G 2 /DN 50 Flexcon M-K 2800 to 3500 G 2!/2 /DN 65 - electrical connection 230 V / 50 Hz / 10 A with M-K/E Easycontrol (OL 202 compressor) 230 V / 50 Hz / 10 A with M-K/S control unit (K-01 compressor) 400 V / 50 Hz / 10 A with M-K/S control unit (K-02, K-03 and K-04 compressor) Note! Compressors from K-04 are not mounted on the vessels and must be connected to both the electrical and air sides (see appendices II to VIII)! Compressors larger than K-04 are available on request and must be set up locally with the aid of separate consoles. With the system connection, attention must also be paid to the following: - It must be possible to close off the expansion vessels from the heating installation. These valves must be protected against unforeseen closure (for example, a valve with wire and lead seal). - There must be a drain device between the valve and the expansion vessel (flexible connection). - Ensure that no welding material can fall on or enter the automat expansion vessel - The working temperature at the system connection may not be higher than 70 C (generally, this means the connection in the return pipe-work of the boiler). With the electrical connection, attention must also be paid to the following: - The voltage and the frequency value must correspond with the DIN VDE recommendations (nominal voltage + 10 %, - 15 %, frequency Hz). - A CEE wall socket (according to IEC 309-2) in 230 V or 400 V must be used for the connection. - The earth connection (zero earth potential difference) must be made to an earthing strip through the central earthing bolt of the control automat (see figure 1, item number 16), according to DIN VDE 0100 part Flexcon M-K automat expansion vessel The standard version of the Flexcon M-K automat expansion vessel (see figure 1, point 3.1) is supplied ready for use, just as the Flexcon M-K automat expansion vessel with two compressor units (see figure 4, point 3.4). Recommendation for placing Heating installation without mixing valve with controlled boiler temperature (e.g. LPHW system) Figure system connection (boundary of Flamco installation) 3 plug Boiler. 2. Installation parts (heating circuit). 3. Flexcon M-K Automat expansion vessel. 4. Safety valve. 5. Valve (with wire and lead seal). 6. Drain valve. 7. Vent. 10

11 4.2 Flexcon M-K automat expansion vessel in cascade With the cascade circuits described in this paragraph, the vessels must be connected together on the air side by means of the high pressure hoses supplied (standard version: 3 m long). The following electrical connections must be made on site: Flexcon control automat/solenoid valve Connecting cable: 2 x 0.75 screened. Flexcon control automat/control automat Connecting cable 3 x 0.5 screened. - Flexcon M-K compressor-automat with auxiliary vessel (see figure 2, point 3.2). - Parallel operation or failure change-over operation with two Flexcon M-K automat expansion vessels (see figure 3, point 3.3). - Flexcon M-K automat expansion vessel with auxiliary vessel, combined with a compressor unit (see figure 5, point 3.4). - Failure change-over operation with three Flexcon M-K automat expansion vessels (see figure 6, point 3.5). For the connection diagrams for the terminal blocks of the Flexcon control automats: - see appendices I to VIII. Caution: Auxiliary vessels, automat expansion vessels with parallel operation or failure change-over operation must be set at the same height. 11

12 5. Easycontrol control automat To commission the Flexcon M-K automat expansion vessel, knowledge is required of the operation of the control automat. The Easycontrol control automat guarantees the user a simple control and operation. The control automat contains modern components such as a microprocessor, numeric display with two figures and status LEDs for the following indications: - current operational parameters - possible operational faults - desired parameter changes Input data that is not permitted is not accepted. Figure Technical data Control - Power supply voltages : 230 V 1/N/PE - Special version : 230 V 3/-/PE - Own consumption : approximately 20 W - Loadability of the relay : 8 A, 230 V Combined sensor (for contents and pressure) - Power supply voltage : DC V - Type of protection : IP 65 Solenoid valve - Operating range : 0-10 bar 5.2 Setting and commissioning The control automat is supplied with the system pressure, working pressure and settings for the water make up (ON and OFF) that you have asked for. If you did not specify the values with the order, then the control automat is made ready for use with the standard values in the factory (see point 5.2.1). By switching the main switch "ON" and pressing the relevant pushbutton, the actual programmed values will appear on the display: LED Operational parameters Water level (%) or Working pressure (bar) 12

13 If you have specified the operational values with the order, then you only need to perform the zero level setting (IV-operational step) in the programming mode (see point 5.2.1) for: - Working pressure (bar) - Water make up "ON" (%) - Water make up "OFF" (%) If no operational parameters were set beforehand or the set values have to be changed, then the following operational steps must be carried out: Changing the operational parameters To change the operational parameters, the following operational steps are required: - Main switch : OFF - Control automat : OPEN - Sliding switch (colour red) on the inside of the door: OPERATE SWITCH - Control automat : CLOSE - Main switch : ON The programming mode LED lights! Figure 9 Easycontrol (open) Sliding switch (red) On Programming 5575 In the programming mode, the display shows: 00 Keep I. Operational step Working pressure (bar) or Water replenisher "ON" (%) or Water replenisher "OFF" (%) key pressed for 3 seconds. The appropriate LED will light. The display will show the factory setting or the latest setting entered. Values of the factory parameters (without previous programming) Working pressure Value Flexcon M-K - 5 bar 2.8 bar Flexcon M-K - 10 bar 5.5 bar Water replenisher "ON" 15 % Water replenisher "OFF" 25 % 13

14 Example: Working pressure (bar) The display shows: the figure in front of the decimal point is flashing. II. Operational step: Changing the "flashing figures" by operating the - and + keys, respectively and confirming with the Working pressure key. 2.8 If the displayed value remains unchanged, confirming this by pressing the Working pressure key. - the figure after the decimal point is flashing. III. Operational step Repeat Operational step II! To display and possibly change the programmed values for: Water replenisher "ON" and Water replenisher "OFF" the operational steps are the same as for the Working pressure example. Note! You can only change the values within the limits set by the factory. If the programmed values remain within the limits, the relevant LED goes out after approximately five seconds. If the programmed values are outside the limits, you must repeat the procedure with acceptable values. If you do change a parameter, you can change the values within the ranges given below: Working pressure Flexcon M-K - 5 bar Flexcon M-K - 10 bar Water replenisher "ON" Water replenisher "OFF" - Range of values 0.5 bar to 4.3 bar 0.4 bar to 8.7 bar - Range of values 5 % to 49 % - Range of values replenishing 2 % to replenishing 20 % Example: Water replenisher "ON" : 06 % Water replenisher "OFF" : 12 % Note: The minimum and maximum water levels are fixed, programmed values. Minimum water level : 05 % Maximum water level : 94 % If these value are exceeded or become too low, a fault report will follow (see point 5.3, Fault reports). Vessel contents - zero level setting Caution! The zero level setting of the vessel contents may only take place with an empty vessel (see also point 4, siting and placing). 14

15 IV. Operational step Key 0-level setting keep pressed in for three seconds. The zero level setting is closed, when the relevant LED goes out after approximately five seconds. If the LED flashes eight times, you ll have to repeat this operatinal step. Caution! After changing the values, you must change over to the operating mode because otherwise the automat expansion vessel will not operate (LED - operating mode)! After the preset operational parameters are changed, you must change over to the operating mode, as follows: Operational steps: - Main switch : OFF - Control automat : OPEN - Sliding switch on the inside of the door (figure 9) : OPERATE SWITCH - Control automat : CLOSE - Main switch : ON Note: Because the vessel or the M-K automat expansion is "empty", the following LED lights: Min. water level/min. working pressure alarm You must now fill the vessel or the M-K automat expansion (see point 7, Commissioning - operation). 5.3 Fault reports The control automat is equipped with a detailed fault indication. When a fault occurs, it is reported by the lighting of the fault LED, in combination with the operational parameter LED. The fault report disappears after the faults are removed with the relevant key. Caution! With a motor protection fault report, the contact for too high current strength has been activated. This fault may only be removed by a suitably qualified person. If you cannot clear this or other faults, please contact our customer service. 5.4 Connection of a general fault indication (Fault) Faults in the heating installation or the control are reported by the potential-free change-over contact. The contacts are connected to terminals x 1-11, 12 and 13 of the control automat (see appendix I, terminal plan). Warning! Even with a switched off control, there can be voltage on the connections of the fault relay (external power supply). 5.5 Connection of an automatic water make up Special Flexfiller Unit A potential-free contact is available on terminals x 1-9, 10 to control the automatic water make up. The contact closes at the water make up command from the control (see appendix I, terminal plan). Warning! Even with a switched off control there can be voltage on the connections of the automatic water make up (external power supply). 15

16 Flamco 5.6 Automatic leakage detection The Flexcon M-K automat expansion vessel can be supplied with a "leakage probe" for the signalling of possible damage to the diaphragm. With damage to the diaphragm, whereby water can penetrate into the air space of the diaphragm expansion vessel and especially whereby air can enter the installation, there is an immediate alarm indication on the display of the Flexcon control automat. 5.7 Connection to a personal computer or in combination with a building control system The Easycontrol 2000 control automat is so prepared that an uninterrupted remote transfer of data that is relevant for the control is possible if the customer wishes. In this way, a remote visualisation through a personal computer or a combination with a building control system is possible. - Connection to a personal computer Figure 10 Easycontrol control automat RS 485 Max. 1.2 km PC Interface RS In combination with a building control system You will receive the data that is necessary for this when you place the appropriate order. 16

17 6. The Flexcon control automat To commission or operate the Flexcon M-K automat expansion vessel, knowledge is required of the operation of the control automat. The design of the Flexcon control automat with modern components such as microprocessor and alphanumeric display makes it possible for the user to enter system settings and make changes to the operational parameters. Input data that is not permitted is not accepted and, just as faults in the system, is provided with read out in the display. For the operation, there is a tip keyboard fitted on the door of the control automat. Figure 11 Display Keyboard Flamco Control automat Main switch 6.1 Technical data Control - Power supply voltages : 230 V 1/N/PE 400 V 3/N/PE - Special version : 230 V 3/-/PE - Own consumption : roughly 20 W - Loadability of the relay : 2 A, 230 V Combined sensor (for contents and pressure) - Power supply voltage : DC V - Type of protection : IP 65 Solenoid valve - Operating range : 0-10 bar - Special version : 0-16 bar 6.2 Setting and commissioning General fault indication 5577 The control automat is supplied with the system pressure that you have asked for. If you did not indicate the system pressure with the order, then you can set it yourself. You can read the programmed values and their setting ranges on the display by scrolling through the menu points. 17

18 Flamco After the main switch is set to "ON", the following appears on the display: 5 bar version 10 bar version Pressure Level 02.0 bar 000 % 01.9 komp. 005 % 02.1 vent. 095 % Pressure Level 02.0 bar 000 % 01.8 komp. 005 % 02.2 vent. 095 % By pressing the <RET> key, you can call further menus: Operating hours Compressor 1 Compressor h h Betriebszeiten Kompressor 1 Kompressor h h Options Leakage probe : -(*) Parallel operation : -(*) Failure change-over operation : -(*/***) Optionen Lecksonde : -(*) Parallel-Betr. : -(*) Wechsel-Stör : -(*/***) - = not present * = present Installation Working pressure : M-K : 5 bar (10 bar) Anlage Betriebsdruck : M-K : 5 bar (10 bar) Contents : XXXX Inhalt : XXXX l X = nominal contents To change the operational parameters that are set in the factory, the control must be switched from the operating mode to the programming mode. Switching to the programming mode Operational steps: - Main switch : OFF - Control automat : OPEN - Sliding switch (colour red) on the inside of the door : OPERATE SWITCH - Control automat : CLOSE - Main switch : ON Figure 12 M-K control automat (opened) On Programming Sliding switch (red) 5578 Caution! Operation is not possible in the programming mode. The programming mode is indicated by a flashing report "fault"! 18

19 The display is as follows: Programming mode further with <RET> or switch on Programmier-Modus weiter mit <RET> oder: auf Betrieb schalten Operate <RET> key, the display now becomes: - Menu point 1 System pressure : 02.0 Allowed : XX.X - XX.X bar Confirmation : <RET> Systemdruck : 02.0 Zul. : XX.X - XX.X bar Bestätigung : <RET> The value can be changed within the indicated limits "XX.X to XX.X". Each time the <RET> key is operated, the next menu point appears. - Menu point 2 Min. water level : 05 % Allowed : 5 % to 50 % Confirmation : <RET> min. Wasserstand : 05 % Zul. : 5 % bis 50 % Bestätigung : <RET> (standard: 5 %) - Menu point 3 Max. water level : 95 % Allowed : 50 % to 95 % Confirmation : <RET> max. Wasserstand : 95 % Zul. : 50 % bis 95 % Bestätigung : <RET> (standard: 95 %) - Menu point 4 Min. pressure : 00.5 Allowed : X.X - XX.X bar Confirmation : <RET> Min.-Druck : 00.5 zul. : X.X - XX.X bar Bestätigung : <RET> The value can be changed within the indicated limits "X.X to XX.X". - Menu point 5 Max. pressure : 04.5 Allowed : XX.X - XX.X bar Confirmation : <RET> Max.-Druck : 04.5 zul. : XX.X - XX.X bar Bestätigung : <RET> The value can be changed within the indicated limits "XX.X to XX.X". - Menu point 6 Water make-up level switches on at : 04 % Allowed : 04 to 49 % Confirmation : <RET> Nachspeise-Niveau Einschalt : 04 % Zul. : 04 bis 49 % Bestätigung : <RET> - Menu point 7 Water make-up level switches off at : 10 % Allowed : XX to XX % Confirmation : <RET> Nachspeise-Niveau Ausschalt : 10 % Zul. : XX bis XX % Bestätigung : <RET> The value can be changed within the indicated limits "XX to XX". - Menu point 8 Parallel operation 1 : present 2 : not present Parallel-Betrieb 1 : vorhanden 2 : nicht vorhanden (see figure 3, point 3.3) 19

20 - Menu point 9 Zero level setting of the level probe further : <ESC> : <RET> Betriebs-Nullung des Kraftsensors durchführen: <ESC> weiter : <RET> <ESC> Zero level setting. Is the vessel empty? Yes : <RET> No : <ESC> <RET> (the vessel is empty) (the vessel is empty) Zero level setting. The vessel is not empty! Zero level setting is not possible! Press <RET> <RET> Zero level setting Weight Break Point OK : xxxx kg : <ESC> : <RET> <RET> RETURN TO THE MAIN MENU Caution! The zero level setting of the vessel contents may only take place with an empty vessel (see also point 4, siting and placing). The zero level setting may only be carried out if the electronics are at working temperature (roughly ten minutes after switching on). After the preset operational parameters are changed, the change-over to the operating mode must be carried out as follows: Operational steps: - Main switch : OFF - Control automat : OPEN - Sliding switch on the inside of the door (figure 12): ON - Control automat : CLOSE - Main switch : ON The Flexcon M-K automat expansion vessel is ready for use! Note: The general fault lamp is on because the vessel or the expansion installation is "empty" and for that reason the "minimum water level" fault is reported. You must now fill the M-K automat expansion vessel or the installation (see point 7: Commissioning - operation). 6.3 Fault reports The control automat is equipped with a general fault indication. The alarm relay energises when a fault occurs. The <Fault> lamp at the bottom of the display (figure 11) lights continuously. The faults are given separately in the display. With more than one fault at a time, the separate fault reports can be scrolled further with the <RET> key. After this, the following displays are possible: FAULT: min. water level clear fault! STÖRUNG: min. Wasserstand Störung beseitigen! This means that the entered minimum water level (point menu point 2) has not been reached. In this case, it is necessary to refill the installation by hand. 20

21 FAULT: max. water level clear fault! STÖRUNG: max. Wasserstand Störung beseitigen! Here, the preset maximum water level has apparently been exceeded. You can let water drain away with the aid of the drain devices that are fitted in the installation. FAULT: min. pressure alarm clear fault! FAULT: max. pressure alarm clear fault! STÖRUNG: min. Druck Alarm Störung beseitigen! STÖRUNG: max. Druck Alarm Störung beseitigen! Because the fault reports for the minimum pressure and maximum pressure alarms can have several causes, please contact our customer service. FAULT: motor protection clear fault! STÖRUNG: Motorschutz Störung beseitigen! With this fault, the contact for a too high current strength is activated. To clear this fault, the following steps must be carried out by a suitably trained operator: - Main switch : OFF - Control automat : OPEN - Operate the motor protection reset - Control automat : CLOSE - Main switch : ON To leave the fault reports after clearing the faults, operate the <ESC> key. If you cannot clear the displayed faults or other faults, please contact our customer service. 6.4 Connection of a general fault indication (Fault) Faults in the heating installation or the control are reported by the potential-free change-over contact. The contacts are connected to terminals 17, 18 and 19 of the Flexcon control automat. Terminal 17 is the common connection. The relay is used inversely. This means that the relay is energised when there are no faults (contact to terminal 19) and is de-energised when a fault occurs (contact to terminal 18). In this way, the reporting of a mains failure is also possible. The fault relay is also energised in the programming mode (see appendices IV - VIII, terminal plan). Warning! Even with a switched off control, there can be voltage on the connections of the fault relay (external power supply). 6.5 Connection of an automatic water make up Special Flexfiller Unit A potential-free contact is available on terminals 7 and 8 to control the automatic water make up. The contact closes at the water make up command from the control (see appendices IV - VIII, terminal plan). Warning! Even with a switched off control there can be voltage on the connections of the automatic water make up (external power supply). 6.6 Failure change-over operation The different versions that can be supplied for failure change-over operation are described under point 3 and point 4.2. The setting of the failure change-over operation in the Flexcon control automat requires special measures that can only be carried out by the manufacturer. 21

22 6.7 Automatic leakage detection The Flexcon M-K automat expansion vessel can be supplied with a "leakage probe" for the signalling of possible damage to the diaphragm. With damage to the diaphragm, whereby water can penetrate into the air space of the diaphragm expansion vessel and especially whereby air can enter the installation, there is an immediate alarm indication on the display of the Flexcon control automat. 6.8 Connection to a personal computer or in combination with a building control system The Flexcon control automat is so prepared that an uninterrupted remote transfer of data that is relevant for the control is possible if the customer wishes. In this way, a remote visualisation through a personal computer or a combination with a building control system is possible. - Connection to a personal computer Figure 13 Flexcon control automat Master Flexcon control automat Slave Flexcon control automat Slave RS 485 PC max. 1,2 km Interface RS In combination with a building control system You will receive the data that is necessary for this when you place the appropriate order. 22

23 7. Commissioning - operation 7.1 Commissioning with a cold heating installation Valve (with drain device) closed, check the vessel pressure Carry out a "zero level setting of the vessel contents" while the vessel is empty. While the valve (with drain device) is closed, fill the heating installation and vent. Fill the Flexcon M-K automat expansion vessel with the necessary amount of water through the filling-drain cock in the expansion pipe-work. Open valve (with drain device) to the installation. Vent the Flexcon M-K automat expansion vessel through the vessel vent (if a Flexvent Super float vent is present, this is not required). 7.2 Commissioning with a heated installation Valve (with drain device) closed, check the vessel pressure. Carry out a "zero level setting of the vessel contents" while the vessel is empty. Fill the vessel with the amount of water that corresponds with the expansion volume and the heating state of the installation through the filling-drain cock. Open valve (with drain device) to the installation. Vent the Flexcon M-K automat expansion vessel through the vessel vent (if a Flexvent Super float vent is present, this is not required). 23

24 8. Maintenance - periodic inspections The DIN 4807 standard for diaphragm expansion vessels and automat expansion vessel specifies the requirement that maintenance and a check are carried out annually by an expert. Besides checking the exterior condition and operation of the components, especially the moment of commissioning and the connecting pipe-work must be checked for blockages. It is also necessary to tap off the condensation at regular intervals that has possibly collected in the vessel (see figure 1, point 14). The periods for the periodic inspections are laid down in the Drückbehälterverordnung (Pressure vessel regulation) or Dampfkesselverordnung (Boiler regulation) paragraph 16, as follows: - External check : annually - Internal check : 5 yearly - Water pressure check : 10 yearly All checks must be carried out by an expert. We recommend you to use the Flamco service for the maintenance. This manual must be handed over to the owner and must be kept in the vicinity of the Flexcon M-K automat expansion vessel. 24

25 Appendix I Easycontrol 2000 control automat Control panel Option Leakage probe Pressure Filling quantity Motor protection fault Fault Water make up Protection K 1 Solenoid valve Power supply 5580 Appendix III Control panel IEB connections 5581 Pump/compressor 25

26 Appendix III Control panel IEB connections 5582 Pump/compressor Appendix IV Flexcon control automat Motor protection 1 Motor protection 2 Protection 1 Protection 2 Power supply Compressor 1 Compressor Terminal block Printed circuit board terminals I/O 26

27 Appendix V 1-Phase one compressor Mains 1/N/PE 50 Hz 400 V/230 V Compressor 1 Valve 1 Valve 2 Valve 3 Water make up Fault Parallel operation Contents Pressure Leakage probe PE PE PE Terminal block Printed circuit board terminals I/O 5584 Appendix VI 1-Phase two compressors 5585 Mains 1/N/PE 50 Hz 400 V/230 V Compressor 1 Compressor 2 Valve 1 Valve 2 Valve 3 Water make up Fault Parallel operation Contents Pressure Leakage probe PE PE PE Terminal block Printed circuit board terminals I/O G = common O = normally open S = normally closed 27

28 Appendix VII 3-Phase one compressor 5586 Mains 3/N/PE 50 Hz 400 V/230 V Compressor 1 Valve 1 Valve 2 Valve 3 Water make up Fault Parallel operation Contents Pressure Leakage probe PE PE PE Terminal block Printed circuit board terminals I/O Appendix VIII 3-Phase two compressors 5587 Mains 3/N/PE 50 Hz 400 V/230 V Compressor 1 Compressor 2 Valve 1 Valve 2 Valve 3 Water make up Fault Parallel operation Contents Pressure Leakage probe PE PE PE Terminal block Printed circuit board terminals I/O G = common O = normally open S = normally closed 28

29 Appendix IX Dimensions and weights for Flexcon M-K automat expansion vessels (lying on pallets). Type Dimensions Weight (mm) (kg) L x W x H 5 bar 10 bar Flexcon M - K x 0900 x Flexcon M - K x 0900 x Flexcon M - K x 0900 x Flexcon M - K x 0900 x Flexcon M - K x 1100 x Flexcon M - K x 1100 x Flexcon M - K x 1250 x Flexcon M - K x 1250 x Flexcon M - K x 1250 x