Flexcon M-P Pump automat 0664 Flex MP-eps GB Installation and operating instructions 1999, Flamco
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Installation and operating instructions Flexcon M-P pump automat Dear customer, GB With the purchase of the Flexcon M-P pump automat, you are now the owner of a high quality product from Flamco. The Flexcon M-P pump automat offers trusted technique, operational reliability and simplicity with installation and operation. This manual is intended for siting and placing, and for the commissioning. The manual also contains a description of the operation of the Flexcon M-P pump automat. We are convinced that you will quickly become acquainted with the technique of this Flexcon M-P pump automat. Should you have any questions about the Flexcon M-P pump automat 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 8 5.The Easycontrol automat 11 6.The Flexcon control automat 16 7.Commissioning and operation 22 8.Maintenance - periodic inspections 23 Appendices I - VI 24 3
1.General Flexcon M-P pump automats are used in closed heating installations, cooling and air conditioning installations with large water contents. The automats absorb the expansion volume that arises through heating in the installation. When the temperature falls, the required amount of water is again made available. Here, a servo-magnet valve is used to feed the expansion water into the diaphragm of the expansion vessel, and a pump is used to return the water to the installation. Flexcon M-P pump automats provide a considerably better solution than the pressure dictation systems that are known with installations for hot water production. The reason is that the expansion water is not connected to the atmosphere and, in this way, damage through corrosion is avoided. Thus, the Flexcon M-P pump automats ensure an accurate setting and maintenance of the pressure required in the installation. 1.1 Fields of application The Flexcon M-P pump automats can be used in closed heating installations, according to DIN 4751, Part 2, with water supply temperatures to a maximum of 120 C and also in closed cooling and air conditioning installations. The Flexcon M-P pump automats are designed for: Maximum allowed water supply temperature of the heating installation: 120 C Maximum continuous temperature loading of the diaphragms, according to DIN 4751, Part 3: 70 C Maximum allowed working pressure: 10 bar Special versions over 10 bar, on request. With a temperature > 70 C in the expansion pipe-work between the heating installation and the Flexcon M-P pump automat, a cooling vessel* is connected in front of the expansion vessel to cool the expansion water. The Flexcon M-P pump automats can be supplied in series with sizes of 200 to 5200 litres. * Flexcon V-B cooling vessels: volumes from 180 to 2000 litres maximum allowed working pressure: 5.0 to 10.0 bar 1.2 Specifications and regulations The diaphragm expansion vessels are pressure-less in the state for use. The vessels are designed for installations according to DIN 4751 part 2 after TRD 702. The test certificates (factory declaration) are included in the delivery and must be given to the locally responsible authorities for viewing. The installation and operating manual and the test certificates are kept in the cabinet of the automat! The test that must be carried out after the installation at the operational site must be organised by the exploitant. 1.3 Advantages of using the Flexcon M-P pump automat complete programme in size, design and pressure stages. broad applicability as a result of flexible possibilities of use. small placement surface - large expansion volume in a small space. use of low-noise pumps with high capacity to produce pressure, with automatic venting of the pump. storage of expansion water in pressure-less operating vessels with solid diaphragm made of high-quality butyl rubber. the pressure in the system is kept constant within tight limits, which means minimum pressure variations, independent of the state of the system. minimisation of pressure shocks and reduction of switching frequency of the pump and solenoid valve as a result of an integrated pressure control vessel. freely programmable control with a microprocessor, whereby the actual values in use and all operational states are shown on a display. connection to a personal computer or combination with a building control system possible. connection to a general fault indication present. safe operation through many years of experience and high manufacturing quality. 4
2. Function and operation Functional diagram of a Flexcon M-P pump automat Figure 1 14 13 2 1 3 recommended on-site assembly from M-P 1000 l Steuerautomat 8 15 plug 19 20 17 18 4 5 7 16 11 6 12 9 10 20 6553 1 Steel vessel 2 Exchangeable diaphragm made from butyl rubber, according to DIN 4807, Part 3 3 Control automat 4 Heavy duty pump 5 Overflow valve 6 Pressure sensor 7 Contents sensor 8 Safety valve 9 Non-return valve 10 Dirt catcher 11 Pressure control vessel expansion pipe-work system connection 12 Ball valve 13 Floatvent 14 Aerator and de-aerator 15 Earth connection 16 Connecting pipe between diaphragm 17 Filling-drain cock 18 Pump vent (valve, floating vent) 19 Flexible hose connection 20 Safety valve - fit on site! Figure 1 shows the Flexcon M-P pump automat. In the standard version, the pump automat consists of the following two components: - Flexcon M-P diaphragm expansion vessel - Flexcon M-P automatic control of the pump The essential constructional parts of the two components are: - Flexcon M-P diaphragm expansion vessel vessel (1) diaphragm (2) - Flexcon M-P automatic pump control control automat (3) heavy duty pump (4) overflow valve (5) The diaphragm (2), which is in the expansion vessel (1), absorbs the expansion volume and functions as a separation wall between air and water. The control automat (3) guarantees that the system pressure which is set in the control is kept constant within tight limits. The signal that is necessary for this is sent to the automat by the pressure sensor (6). When the temperature rises, the pressure in the system increases. The overflow valve (5) opens and lets the expansion water flow into the Flexcon M-P diaphragm expansion vessel. When the temperature drops, the pressure in the system decreases. If the pressure falls below the set system pressure, the pump (4) switches on, and is switched off when the system pressure is reached. A check and a continuous indication of the filling level in the display (3) prevents the pump (4) from running dry or the vessel (1) from being filled to an unallowably high level. The Flexcon M-P pump automat can be fitted with the following microprocessor controls: Easycontrol automat The Easycontrol automat is designed for single installations (a Flexcon M-P expansion automat with coupling vessel). For operation, see pages 11 to 15. Flexcon control automat The Flexcon control automat is prepared for single installations, and for failure change-over operation by two pumps. For operation, see pages 16 to 21. 5
A solid diaphragm of butyl rubber divides the Flexcon M-P diaphragm expansion vessel into a water and gas space. The diaphragm prevents contact between the expansion water and atmospheric oxygen. Via a floating aerator and vent (13), air that is released from the heating water is optimally separated and prevents an enrichment of the heating water with air from the atmosphere. The safety valve (8) protects the pressure-less vessel (1) from unpermitted overpressure in the case of a failure. The supply and removal of expansion water to and from the diaphragm is done by the flexible high pressure hose (19) between the diaphragm expansion vessel and the automatic pump. The pressure control vessel (11) thus reduces the pressure shocks when the pump and the servo solenoid valve switch. 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 automats. If you wish to realise other versions, please contact your local Flamco representative. The design can be effectively realised with the help of the Flamco calculation diskette* for expansion vessels. * Available on request from the Sales Office of Flamco. 3.1 Flexcon M-P pump automat The standard version of the Flexcon M-P pump automat is supplied in two components: - Flexcon M-P diaphragm expansion vessel in the sizes 200 to 5000 litres (upright) with flexible high pressure hose - Flexcon M-P automatic control including a pump Figure 2 6554 Expansion pipe-work 3.2 Flexcon M-P pump automat with auxiliary vessel Figure 3 6555 Install on site Expansion pipe-work With a battery or series circuit of Flexcon M-P pump automats with an automatic pump (Flexcon M-P pump automat with auxiliary vessel), care must be taken that the expansion vessel is of the same size. The automats can be supplied with both control automats (Flexcon control automat or Easycontrol automat). 6
3.3 Parallel operation or failure change-over operation by two pumps* Figure 4 6556 Steuerautomat Plug Expansion pipe-work With the Flexcon M-P pump automat with one M-P control and two pumps, only one of the two pumps works during failure change-over operation. In the case of a fault (the motor protection switch becomes active), the system automatically switches over to the other pump. This is also done after expiry of the set change time, which serves to load the pumps evenly. * Only with Flexcon control automat - see page 16. 7
Steuerautomat Flamco 4. Siting and placing The Flexcon M-P pump automat is supplied as standard version in two packages. Appendix VI gives the main dimensions and weights. 1. Diaphragm expansion vessel 2. Automatic pump control The Flexcon M-P pump automat must be placed in closed spaces with a temperature between 5 C and 40 C. Here, the floor must be sufficiently sturdy and flat. Caution: The expansion vessel and the control must be installed at the same height. If this is not structurally possible, the expansion vessels may be placed higher than the control. The control is not allowed to be higher than the expansion vessels! Flexcon M-P pump automats must be so placed that they can operate without problems and can be maintained at all times. The following sketch and table contain the minimum distances. 5709 ab c c Vessel size a b c (l) (cm) (cm) (cm) =1600 50 065 80 > 1600 50 100 80 Note: Depending on the structural situation, the automatic pump control can be placed next to the vessel as required, by turning the vessel connection. Above the top inspection opening, there must be a free space of: - min. 650 mm for vessel sizes Flexcon M-P 200-1600 l - min. 1000 mm for vessel sizes Flexcon M-P 1600-5000 l Caution: To be able to safeguard a contents measurement according to regulations, attention must be paid to the following points: The diaphragm expansion vessel must be upright and free! The transport protection of the measurement foot must be removed after placing, so that the contents sensor can stand freely on a flat base. Steps 1 and 2 of the removal of the transport protection! 1.) 2.) 6557 Support points of the spirit level Removed transport protection (bent steel plate with fixing bolt) The foot height adjustment of the two other vessel feet makes the required safe upright placing of the Flexcon M-P diaphragm expansion vessel possible. The vertical placing must be done according to the sketch with a spirit level on the indicated axes. The required flexible hydraulic connection between the diaphragm expansion reservoir and the automatic pump control is provided by a metal high pressure hose that belongs to the delivery. 8
The zero level setting of the vessel contents may only take place with an empty and exactly vertical vessel! Before the commissioning of the expansion automat (see also chapter 7), no water may be added and the vessel must be kept separated from the mains (safety valve closed). After the components of the Flexcon M-P pump automat are placed, the following connections can be made: a) Hydraulic connections The connection of the installation to the automatic pump control can be stiff or flexible, but must be fitted with a shut-off valve. The connections are dependent on the chosen expansion pump, as follows: Pump type System connection M-P/1.0 G 1!/4 /DN 32 M-P/2.0 G 2 /DN 50 M-P/3.0 G 2 /DN 60 The connection between the control and the expansion vessel must be flexible. Here, the following must be taken into account: - It must be possible to shut the pump automat off from the installation. This valve must be protected against unintended closing (for example, a valve with a seal). - Welding activities must be so carried out that no welding material can fall on or enter the pump automat. - The maximum working temperature at the system connection may not exceed 70 C (generally speaking, the system connection must be coupled into the return pipe-work of the boiler). b) Electrical connection The control must be connected to 400 V, 50 Hz, 16 A. Here, attention must be paid to the following: - The voltage and the frequency values must correspond with the DIN VDE recommendations. - The connection must be made with a 400 V CEE wall socket (according to IEC 309-2). - The earth connection (zero earth potential difference) must be made to an earth leakage connection (according to DIN VDE 0100, part 540) through the central earthing bolt of the control automat (see figure 1, item number 13). c) Connection of the contents sensor for the contents level measurement The electrical connection of the contents sensor to the measurement foot of the diaphragm expansion vessel must be made on site with the cable which is supplied with the delivery (this is connected to the control in the factory). Here, the 5-pole round plug must be connected to with the measurement probe. Both the Flexcon M-P expansion automat in the standard version (chapter 3.1 figure 2) and the Flexcon M-P expansion automat with M-P automatic pump control in the version with two pumps (point 3.3 figure 4) are delivered ready for use in two components. Assembly recommendation: Flexcon M-P expansion automat Directly heated installation (Connection through protected shut-off valve) Figure 5 5711 8 9 5 6 6 5 4 1 7 7 2 3 1 Flexcon M-P expansion automat 2 Valve (with wire and lead seal) 3 Filling-drain cock (included in delivery) 4 Flexcon diaphragm expansion vessel 5 Safety valve 6 Flamco low water level protection 7 Pressure meter 8 Flexvent floating vent 9 Air separator 9
Assembly recommendation for the Flamco-Fill STA or PA automatic water replenisher The hydraulic coupling of a automatic water replenisher must be made according to figure 6. Figure 6 6558 Replenisher connection Coupling Pump type Coupling* M-P/1.0 Double nipple 1!/4 + T-piece 1!/4 -!/2-1!/4 M-P/2.0 Double nipple 2 + M-P/3.0 T-piece 2 -!/2-2 * is not part of the delivery 10
5. The Easycontrol automat To commission and/or operate the Flexcon M-P pump automat, knowledge is required of the operation of the control automat. The user is guaranteed an easy check and operation as a result of the design of the Easycontrol automat with modern building elements, such as microprocessor, 2-digit display and Status LEDs for the display: - of the actual operational parameters - of the possible operational faults - of the desired parameter changes Input data that is not permitted is not accepted. Figure 7 5588 5.1 Technical data control - power supply voltage : 400 V 3/N/PE - own consumption : roughly 20 W - loadability of the relay : 8 A, 230 V contents sensor - power supply voltage : DC 11.5-30 V - type of protection : IP 65 pressure sensor - measurement range : 0-16 bar overflow valve (servo solenoid valve) - operating range (standard) : 0-10 bar 5.2 Setting and commissioning The control automat is supplied with the system or operating pressure that you have ordered, plus the settings for an automatic water replenisher (ON and OFF). If you did not indicate the system pressure with the order, then the control automat is ready for use with the standard values that are set in the factory (see point 5.2.1). By pressing the relevant key after the main switch is set to "ON", the following actual operational values appear on the display: LED operational parameters water level (%) or working pressure (bar) 11
If you did indicate the working parameters with your order, you only need to carry out the zero level setting (fourth operational step) in the programming mode (see chapter 5.2.1) for: - working pressure (bar) - automatic water replenisher "ON" (%) - automatic water replenisher "OFF" (%) If no working parameters were entered beforehand or if the set working parameters must be changed, you must carry out the relevant operational steps in the following section. 5.2.1 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 control panel : OPERATE SWITCH - control automat : CLOSE - main switch : ON The programming mode LED is lit! Figure 8 Easycontrol (open) Sliding switch (red) operate programming 6634 In the programming mode, the display shows the following: 00 First operational step Operate the. working pressure (bar) or automatic water replenisher "ON" (%) or automatic water replenisher (OFF) (%) key for three seconds. The relevant LED will light. The display will show the value that was entered in the factory or that was saved last! Values of parameters that the factory enters (without previous values!) working pressure values Flexcon M-P 10 bar 5.5 bar automatic water replenisher "ON" 15 % automatic water replenisher "OFF" 25 % 12
Example: Working pressure (bar) The following appears in the display: 2.8 - the figure after the decimal point "flashes" Second operational step: Correct the "flashing figure" by operating the keys - or + and confirm with the "Working pressure" key If the displayed value has to remain unchanged, you can confirm this by only operating the "working pressure" key. 2.8 - the figure in front of the decimal point "flashes" Third operational step: Repeat the second operational step! The operational steps are analogous to the "working pressure example" for the indication and if necessary the desired change of the entered values for: automatic water replenisher "ON" and automatic water replenisher "OFF" Note! The values can only be changed within the range limits that are previously set in the factory. If the set value is within the range limits, the relevant LED goes out after about five seconds. If the value is outside the range limits, the entry must be repeated with plausible values. If a change of the parameters is desired, the values can be changed within the following range limits: working pressure Flexcon M-P 10 bar automatic water replenisher "ON" automatic water replenisher "OFF" - range 0.5 to 8.7 bar - range 5 % to 49 % - range replenisher "On" + 2 % to replenisher "On" + 20 % Example - automatic water replenisher "ON" : 06 % - automatic water replenisher "OFF" : 12 % Note: The values for the minimum and maximum permitted water level are programmed as fixed values. min. water level : 05 % max. water level : 94 % If these values become too high or low during operation, this will cause a fault report (see also point 5.3 "Reporting - operational faults"). 13
Contents level - zero level setting Caution: The "operational zeroing", i.e. the zero level setting of the filling level may only take place with an empty vessel and with the transport protection removed (see also chapter 4 - Siting and placing). Fourth operational step Key zero level setting operate for three seconds. The zero level setting is finished when the appropriate LED goes out after about five seconds. If the LED flashes eight times, the operational step must be repeated. Caution! After finishing the value change, the equipment must be switched to the "operation" mode because the control cannot otherwise operate (operational mode LED)! The switch-over to the "operation" mode after the earlier set parameters are changed must be carried out as follows: Operational steps: - main switch : OFF - control automat : OPEN - sliding switch (colour red) on the control panel (fig. 9) : OPERATE SWITCH - control automat : CLOSE - main switch : ON Note! The following LED is lit because the vessel of the Flexcon M-P expansion automat is empty: Minimum water level/alarm for minimum working pressure The minimum water level fault serves as a protection against the pump running dry. The pump is blocked and switches off! The Flexcon M-P expansion automat of the expansion installation must be filled with water (see also chapter 7 "Commissioning - operation"). 5.3 Reporting - operational faults The control automat is equipped with a detailed fault indication. A possible fault report is given by the relevant "operational fault LED" lighting, in combination with the "operational parameter LED". To leave the fault reports after clearing the faults, operate the relevant key. Caution! With a motor protection fault, the contact for too high current has activated. This fault must be cleared by a qualified person! If you cannot clear the general or other faults, please contact our customer service department. 5.4 Connection of a general fault indication ("Fehler") Faults in the heating installation or the control are reported by the potential-free changeover contact. The contacts are connected to terminals x 1-11, 12 and 13 of the control automat (see "terminal plan" appendix I). 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 replenisher - Flamco-Fill Type STA or PA A potential-free contact is available on terminals x 1-9 and 10 to control the automatic water replenisher. The contact closes at the water replenish command from the control (see "terminal plan" appendix I). Warning! Even with a switched off control, there can be voltage on the connections of the fault relay (external power supply). 14
Flamco 5.6 Automatic leakage detection The Flexcon M-P pump automat can be supplied with a "leakage probe" to detect possible damage to the diaphragm. With damage to the diaphragm, whereby water penetrates the air space of the diaphragm expansion vessel and especially air enters the installation, there is an immediate alarm on the display of the Flexcon control automat. 5.7 Connection to a personal computer of a building control system The Easycontrol automat is so prepared that an uninterrupted remote transfer is possible of relevant control data, on request. 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 9 5576 Easycontrol control automat RS 485 Max. 1.2 km PC Interface RS 232 - Combination with a building control system You will receive the data that is necessary for this when you order this option. 15
6. The Flexcon control automat To commission or operate the Flexcon M-P pump automat, knowledge is required of the operation of the control automat. The design of the Flexcon control automat with modern components such as microprocessors and a digital display make it possible for the user to change the system settings and the user parameters in dialogue with the control. Input data that is not permitted is provided with commentary in the display, just as system faults. For the operation, a foil keyboard is fitted on the door of the control automat. Figure 10 Display Keyboard 5577 Flamco Control automat Main switch 6.1 Technical data General fault indication control - power supply voltage : 400 V 3/N/PE - own consumption : roughly 20 W - loadability of the relay : 2 A, 230 V pressure sensor - measurement range (standard) : 0-10 bar contents sensor - power supply voltage : DC 11.5-30 V - type of protection : IP 65 overflow valve (servo solenoid valve) - operating range (standard) : 0-10 bar 6.2 Setting and commissioning The control automat is supplied with the system pressure that you have ordered. 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. 16
Flamco After the main switch is set to "ON", the following appears on the display: Pressure Level 00.0 bar 000 % 01.7 Pump. 005 % 02.3 Vent. 095 % (Here, the system pressure was set to 2.0.) By pressing the <RET> key, you can call further menus: Operating hours Pump 1 000000 hours Pump 2 000000 hours Options Leakage probe : - (*) Parallel operation : - Failure change-over operation : - - = not present * = present Installation : M-P Working pressure : 10 bar Contents : XXXX L X = nominal vessel contents To change the operational parameters that are set in the factory, the control must be switched from the "BETRIEBS-Modus" (operational mode) to the "PROGRAMMIER- Modus" (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 11 Flexcon control automat (opened) On Programming 6559 Sliding switch (red) Caution! Automat operation is not possible in the programming mode. The programming mode is indicated by a flashing report "Fehler". 17
The display is as follows: Programming mode further with "RET" or switch on Operate <RET> key, the display now becomes: - Menu point 1 System pressure : 02.0 Allowed : 00.6-08.3 bar Confirmation : "RET" The value can be changed within the indicated range limits. 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" (standard: 5 %) - Menu point 3 Max. water level : 95 % Allowed : 50 % to 95 % Confirmation : "RET" (standard: 95 %) - Menu point 4 Min. pressure : 00.5 Allowed : X.X - XX.X bar Confirmation : "RET" Value can be changed within the indicated range limits "X.X to XX.X". - Menu point 5 Max. pressure : 04.5 Allowed : XX.X - XX.X bar Confirmation : "RET" 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" - Menu point 7 Water make-up level Switches off at : 10 % Allowed : XX to XX % Confirmation : "RET" Value can be changed within the indicated range limits "XX to XX". - Menu point 8 Maximum pump running time Allowed Confirmation : 10 min : 10 to 240 min : "RET" Value can be changed within the indicated range limits. 18
- Menu point 9 (Optional) Parallel operation 1: present 2: not present (for this, see point 3) - Menu point 10 Zero level setting of the contents sensor operate : "ESC" further : "RET" Caution! The zero level setting of the vessel contents may only take place with an empty vessel and removed transport protection! (See also chapter 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 operational mode must be carried out as follows: Operational steps: - main switch : OFF - control automat : OPEN - sliding switch on the inside of the door (figure 9) : ON - control automat : CLOSE - main switch : ON The Flexcon M-P pump automat 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 diaphragm expansion vessel of the Flexcon M-P pump automat (for this, see chapter 7: "Commissioning - operation". 6.3 Fault reports The control automat is equipped with a general fault indication. The alarm relay is deenergised when a fault occurs. The <Fehler> (Fault) lamp at the bottom of the display (figure 10) lights continuously. The faults are given separately in the display. With more than one fault at a time, the separate fault reports can be displayed by operating the <RET> key. After this, the following displays are possible: FAULT min. water level clear fault! This means that the entered minimum water level (point 6.2 - menu point 2) has not been reached. CAUTION: The min. water level fault serves as a protection against the pump running dry. The pump is blocked and switches off! In this case, it is necessary to refill the installation. FAULT max. water level clear fault! 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! 19
FAULT max. pressure alarm clear fault! FAULT running time of the pump clear fault! The fault reports for the minimum pressure and maximum pressure alarms, and also running time of the pump can have several causes. Therefore, please contact our Customer service department when one of these faults occurs. FAULT motor protection clear fault! With this fault, the relay for a too high current is activated. To clear this fault, the following steps must be carried out by a suitably qualified person: - 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 department. 6.4 Connection of a general fault indication ("Fehler") Faults in the heating installation or the control are reported by the potential-free changeover 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 "terminal plan" appendices III - V). 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 replenisher - Flamco-Fill Type STA or PA A potential-free contact is available on terminals 7 and 8 to control the automatic water replenisher. The contact closes at the water replenish command from the control (see "terminal plan" appendices III - V). Warning! Even with a switched off control, there can be voltage on the connections of the fault relay (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 3.3. The setting of the failure change-over operation in the Flexcon control automat requires special measures that can be obtained from the manufacturer. 6.7 Automatic leakage detection The Flexcon M-P pump automat can be supplied with a "leakage probe" to detect possible damage to the diaphragm. With damage to the diaphragm, whereby water penetrates the air space of the vessel and especially air enters the installation, there is an immediate alarm indication on the display of the Flexcon control automat. 20
6.8 Connection to a personal computer or a building control system The Flexcon control automat is so prepared that an uninterrupted remote transfer is possible of relevant control data, on request. In this way, a remote visualisation through a personal computer or a combination with a building control system is possible. Figure 12 5579 Flexcon control automat Master Flexcon control automat Slave Flexcon control automat Slave RS 485 PC max. 1,2 km Interface RS 232 - Combination with a building control system You will receive the data that is necessary for this when you order this option. 21
7. Commissioning and operation 7.1 Commissioning with a cold heating installation Valve closed, check the system pressure. Carry out a zero level setting of the operation while the vessel is empty. Check the pressure of the pressure control vessel and adjust if necessary and then open the shut-off valve. The setting of the pressure must be carried out as follows: In the state as supplied by the factory, the pressure control vessel has a pressure of 4 bar, the ball valve to the Flexcon M-P station (at the bottom of the vessel) is closed. The pressure of the pressure control vessel must locally be adjusted as follows: Pressure of control vessel* = system pressure - 0.6 bar Next, the ball valve must be opened. * If the pressure that is required for the operation in the pressure control vessel is above the pressure in the delivery state (4 bar), then this pressure must accordingly be raised for the commissioning with nitrogen! While the valve between the vessel and the installation is closed, fill the heating installation and vent Open vent shut-off of the floating vent ("red knob") on the vessel by turning it one full turn. Fill the Flexcon M-P pump automat (diaphragm expansion vessel) with the planned amount of water through the filling-drain cock in the expansion pipe-work. Vent expansion pipe-work Vent the automatic pump (see figure 8) commissioning system in operation Open valve to the installation : manually vent with the aid of valve or nipple : automatically vent Flexvent floating vent (during commissioning, open by turning the red knob one full turn!) 7.2 Commissioning with a heated installation With the valve between the vessel and the installation closed, check the set system pressure Carry out a zero level setting of the operation while the vessel is empty. Set pressure of the pressure control vessel DSB as follows: see point 7.1. Open vent shut-off of the floating vent ("red knob") on the vessel by turning it one full turn! Fill the vessel of the Flexcon M-P pump automat through the filling-drain cock. The filling level must correspond with the amount of water that is calculated for the actual expansion volume of the operational situation. Vent the automatic pump (see point 7.1). Open valve to the installation. Figure 13 Pump type: M-P/1.0 M-P/2.0 floating vent vent valve Pump type: M-P/3.0 floating vent with aerator valve vent nipple 6560 22
8. Maintenance - periodic inspections The DIN 4807/2 standard requires an annual maintenance and inspection for diaphragm expansion vessels. Besides the external condition of the vessel and the correct operation of the control, the pump and overflow valve must be checked for leakage and the dirt catcher must be checked and cleaned if required. Moreover, the connecting pipes must be checked for leakage. If the diaphragm expansion automat is a component of a boiler installation with boilers of group II with a water content of more than 2000 litres that must be inspected for the first time by an expert, then a supplementary annual external inspection by an expert must be prescribed, according to paragraph 16 of the Boiler Regulation (DampfV). In the other case, this check must be carried out by an expert. The intervals of the periodic inspections have been set as follows, independently of the Boiler Regulation, paragraph 16: - external check yearly - internal check every five years - water pressure check every ten years The checks must be carried out by an expert. We advise you to contract the customer service department of Flamco for the maintenance. (The test of the pressure of the pressure control vessel must take place at least once per year, in combination with cleaning the dirt catcher). This manual must be handed over to the owner and must be kept in the vicinity of the vessel. 23
Appendix I Easycontrol 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 II 5581 Control panel IEB-300-00003 connections Pump/compressor 24
Appendix III Flexcon control automat 5583 Motor protection 1 Motor protection 2 Protection 1 Protection 2 Power supply Compressor 1 Compressor 2 Terminal block Printed circuit board terminals I/O 25
Appendix IV 3-Phase one compressor 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 V 3-Phase two compressors 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 26
Appendix VI Main dimensions and weights for Flexcon M-P pump automats - Flexcon M-P diaphragm expansion vessel (lying on pallet) Type Dimensions mm Weight l x w x h kg M-P 0200 1350 x 0550 x 0650 0110 M-P 0400 1500 x 0750 x 0850 0125 M-P 0600 1900 x 0750 x 0850 0155 M-P 0800 2350 x 0750 x 0850 0190 M-P 1000 2900 x 0750 x 0850 0225 M-P 1200 2100 x 1000 x 1100 0285 M-P 1600 2600 x 1000 x 1100 0340 M-P 2000 2350 x 1200 x 1300 0425 M-P 2800 2950 x 1200 x 1300 0510 M-P 3500 3750 x 1200 x 1300 0620 M-P 5200 3650 x 1500 x 1600 1060 - Flexcon M-P pump automat Type Dimensions mm Weigth l x w x h kg M-P/1.0 590 x 500 x 1100 50 M-P/2.0 600 x 590 x 1100 60 M-P/3.0 600 x 590 x 1250 80 27