flamco Fill-PE Installation And Operating Instructions Manual

© Flamco
www.flamcogroup.com
TP.04/02/09.EN Edition 2009 / EXP
Flamco Fill-PE
Installation and operating instructions
2
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
Flamco b.v.
P.O. box 115
2800 AC Gouda - Nederland
+31 (0) 182 591800
support@flamco.nl
Contents Page
1 General 3
1.1 About this manual 3
1.2 Other supplied documentation 3
1.3 Use of Flamco products 3
1.4 Further help and information 3
2 Safety 3
2.1 Intended use 3
2.2 Important information 3
2.3 Signs in this manual 3
2.4 Specifications 3
2.5 Safety devices 3
2.5.1 Avoiding excessive pressure 3
2.5.2 Avoiding excessive temperature 3
2.6 Signs on the automat 4
3 Description 5
3.1 Component overview 5
3.2 Controller SCU 6
3.3 Working principle 6
4 Transport and storage 7
4.1 Transport 7
4.2 Storage 7
5 Installation 8
5.1 Prepare for installation 8
5.2 Ambient conditions 8
5.3 Mounting dimensions 8
5.4 Hydraulic installation 9
5.5 Electrical installation 9
5.5.1 Basic electrical connections 10
6 Startup controller 11
6.1 Controller menu structure 11
6.2 Menu symbols 11
6.3 Working principle controller 12
6.4 Controller inputs 13
7 Maintenance and troubleshooting 14
7.1 Before maintenance 14
7.2 After a power failure 14
7.3 Maintenance interval 14
7.4 Change the automat for water treatment 14
7.5 Error messages 15
8 Disposal 17
9 Technical specifications 18
3
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
1 General
1.1 About this manual
This manual includes technical specifications, instructions and explanations that helps to use this automat safely. Read and understand all the instructions before you transport, install, commission, restart, operate or maintain the automat.
1.2 Other supplied documentation
General information of additional components, such as the pump and the sensors, is included in this manual. If additional documentation is supplied, also follow the instructions in those.
1.3 Use of Flamco products
According to order or execution complementary documentations can be added. Follow the positions performed in the dispatch papers.
1.4 Further help and information
Contact your local supplier for additional services as:
Training• Maintenance agreements.• Service contracts.• Repairs and improvements.•
2 Safety
2.1 Intended use
The automat is suitable for closed heating and air conditioning systems:
in which losses of system water are to be refilled;• are to be filled for the first time.•
2.2 Important information
The automat has safety devices intended to prevent injury and damage. Use the automat in the following way:
Have the installation be carried out by qualified personnel.• Comply with local legislation and guidelines.• Do not make modifications to the automat without prior written permission of Flamco.• Make sure that all automat covers and doors are closed when operating the automat.• Do not touch live voltage. The sensor units and the capacity pressure sensors operate with extra low safety • voltage.
Flamco shall not be liable for any losses arising from the non-observance of safety conditions or as a consequence of the disregard of standard precautionary measures when performing such services as transport, installation, commissioning, re-starting, operation, maintenance, testing and repair, even in the event that these are not expressly described in these instructions.
2.3 Signs in this manual
Identifies a hazard that could lead to personal injury including death/damage to the automat, damage to other equipment and/or environmental pollution.
Identifies an electric hazard that could lead to personal injury including death/ damage to the automat, damage to other equipment and/or environmental pollution.
Earthing Important information.
2.4 Specifications
The construction of the automat is designed in accordance with the norms DIN EN 1717 and DIN 1988.
2.5 Safety devices
The automat does not contain any safety components that prevent that the operation pressure and the operation temperature range are exceeded or go below a limit. Install components for the limitation of pressure and temperature in the system.
2.5.1 Avoiding excessive pressure
Appropriate safety valves that prevent that the maximum operation pressure is exceeded:
Open not later than the maximum allowable working pressure is reached.• Can conduct the occurring volume flow (including the maximum possible refilling volume) up to the 1.1-fold • of the maximum operation pressure; Have a proven reliability or are certified.•
Do not narrow the inlet or outlet piping of the safety valve.
2.5.2 Avoiding excessive temperature
Appropriate safety components:
Guarantee that the operation temperature range is not exceeded at any point of the system;• Are approved and tested on operation safety.•
Activate the pressure and temperature safety devices and check them regular on proper working.
4
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
2.6 Signs on the automat
The signs on the automat are part of the safety provisions. Do not cover or remove the signs. Inspect regularly if the signs are present and legible. Replace or repair signs that are illegible or damaged.
Service Germany
+49 0 3933 821 177
+49 0 3933 821 161
Fax.:
Tel.:
Service Nederland
+31 0 182 591 800 +31 0 182 522 557
Tel.: Fax.:
( )
)(
))((
KW 01/2008
STAG GmbH
39307 Genthin
30°C (Zulauf)
10 bar
max. Betriebstemperatur: Permissible working temperature:
Permissible working overpressure:
zulässiger Betriebsdruck:
Manufacturer-No.:
Herstell-Nr.:
Nachspeiseautomat flamco FILL PE
Flamco
A
B
C
On the automat the following product information can be found: A Type plate B Warning sticker C Contact information
KW 01/2008
AB12345
STAG GmbH
39307 Genthin
30°C (Zulauf)
10 bar
max. Betriebstemperatur: Permissible working temperature:
Permissible working overpressure:
zulässiger Betriebsdruck:
Manufacturer-No.:
Herstell-Nr.:
Nachspeiseautomat flamco FILL PE
Flamco
A
B
C
D
On the type plate the following product information can be found: A Type of the automat B Automat serial number C Permissible working overpressure D Permissible working temperature
Do not use the automat when the specifications on the type plate differ from the order.
operating instructions
5
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
2
4
5
1
3
6
14
13
7
8
12
11
10
9
3 Description
3.1 Component overview
No. Description
1
Inspection opening breaktank
2
Joint for pipe HT DN40 at overflow
3
Impulse water counter
4
Feed joint R½"
5
System joint G½"
6
Controller SCU with control panel and
terminal box
7
Breaktank
8
Floatswitch
9
Pressure sensor
10
Run-dry sensor
11
Terminal box pump
12
Pump and motor
13
Pump
14
Non return valve
6
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
3.2 Controller SCU
1
2 3
4
5
6
7
3.3 Working principle
The automat is installed to the heating or air conditioning system as well as to a supply, e.g. drinking water net. The automat compensates losses of system water automatically by the refill process. The refill process can be:
pressure controled;• level controled.•
P
G
J I
E FDB CA
H
Types of control:
Pressure controled: The system pressure is monitored by the pressure sensor (B). When the pressure is below a certain value the controller (F) switches ON the pump (D). The pump wil refill the system with water that is stored in a breaktank. The controller will switch OFF the pump after an adjustable pressure difference is reached. The refill time and -amount is protected and can be adjusted as welI.
Level-controlled: The breaktank uses a float switch to maintain its capacity. The breaktank has a overflow protection (G) and a run-dry sensor (E) to maintain a safe water level of breaktank. The impuls water counter gives information about the amount of water that is refilled in total.
No. Description
1
Control panel for the controller, graphical display,
LED for error display, selector switch (click and
roll)
2
Power switch, ON: flashes red
3
Internal fuse F1: T 16 A 250 V
4
Internal fuse F2: T 3,5 A 250 V
5
Hardware release, service menu E2
6
Terminal bars for
Electric supply;• sensors;• Impulse water counter;• External activation for refilling process;• Collective malfunction message;• Pump;•
7
Interface RS485.
7
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
4. Transport and storage
4.1 Transport
The shipping papers list all the items, such as equipment and documentation. Ensure that the delivery is complete and not damaged. The automats are packed horizontally on disposable pallets and are fully assembled.
Identify the items that are missing or not correctly delivered. Read the general terms and conditions in the shipping papers.
Transport the pallets horizontally.• Lift the automat just slightly.•
Make sure that the lifting device can support the automat. For weight and dimensions, refer to chapter 10: Technical specifications.
4.2 Storage
Make sure that the storage space meets the ambient conditions. Refer to section 6.2.
Take care for an even floor.• The automats can be stacked up.•
Do not stack up more then 3 automats.
8
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
5. Installation
5.1 Prepare for installation
Make sure that the surface can support the maximum weight of the automat, including the water. Refer to chapter 10: Technical specifications.
The automat is intended for wall-fastening.• The automat may not be affected by external forces.• No dirt may get into the automat and its accessories.• The installation place must have a floor drain or there must be enough drain for the overflow of the automat.• Install shut-off devices to the system and to the drinking water net on-site.• Plan enough free space around the automat for maintenance work.• Note the effective regulations regarding the use and the installation location and, if necessary, inform the • responsible testing and certification bodies prior to the launch of the system.
5.2 Ambient conditions
> 1 m
> 0,5 m
1,3....1,7 m
< 80%
> 0 °C.....40 °C
KW 01/2008
STAG GmbH
39307 Genthin
30°C (Zulauf)
10 bar
max. Betriebstemperatur: Permissible working temperature:
Permissible working overpressure:
zulässiger Betriebsdruck:
Manufacturer-No.:
Herstell-Nr.:
Nachspeiseautomat flamco FILL PE
D
Flamco
Flamco
standard control unit
press enter
Make sure
that the automat is installed in a closed, dry and • frost-free room; to maintain the minimum distances as indicated;• that the atmosphere does not contain electrically • conducting gases or high concentrations of dust and vapors. Risk of explosion when there are combustible gases; that the vicinity is clean and well lit. •
- Relative humidity: not condensating.
- Free of vibrations.
- Free from heat- and solar radiation.
that the automat is free from additional loads.•
5.3 Mounting dimensions
A
D
E
B
C
Use the mounting set supplied with the automat. For wall mounting the following dimension apply: A. 286 mm B. 200 mm C. Ø15 mm D. 390 mm E. 495 mm
9
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
5.4 Hydraulic installation
Install the shut-off devices on-site in front of the tube joints.• Only work on non-pressurised and cooled-down pressure joints.• Use the installed pressure tubes.•
G ”
3
/8
G ”
Connect the supply line to the refilling supply.• If necessary, install a dirt trap at the drinking water • joint (0.2 mm). The minimum nominal diameter for the installation • line of the system and the supply line is DN 15.
Connect the installation line of the system.•
DN 40
Connect the drain/overflow.•
5.5 Electrical installation
Even if isolated from the mains, there can still be high voltage on the terminals of the controller SCU. This is the case, when external voltage is installed for an external refilling activation or the error inquiry. Do not touch any live joints or lines.
0FF
Switch off the power switch on the controller SCU.• Pull the power plug or switch off external • separators and secure these against a restart.
Unscrew the protective cover of the terminal box.• The descriptions of the terminal bars are on the • inside of the protective cover.
operating instructions
10
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
230V 50Hz
28 29 30 31 32 33 34 35 36
27 26 25 24
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18
RS485
RS485
20 1923 22 21
Common
failure
SELV
A
D
C B
press enter
standard pressure control
electronic control unit
SDS
D
Flamco
C
A
B
D
External
e.g.M-K/U
(Refill 230 V)
External
refill
(for potential free
contact)
INPUT INPUT
1
3
Nominal current [A] unit Fuse wiring connector [A]*
Nominal voltage Protection type
230 V: +6%; -10%
50 Hz - 60 Hz
IP54 (pressure sensor IP65)
3 10
SELV: Safety Extra Low Voltage * Recommended value; Line safety switch, characteristic C
Never connect terminal 11+12 and 21+22 at the same time. It will destruct the refill the SCU controller or the pressure holding control.
5.5.1 Basic electrical connections
operating instructions
11
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
6. Startup controller
6.1 Controller menu structure
6.2 Menu symbols
Ku2free FL1 FL2
Process display
A
A
Process display
System pressure
Control mode
Operating mode
total
Filling quantity
Error list, activ (Acknowledge)
(Symbols)
Error
10
Back
Back
Code menu
Selection menu
Selection menu 1
Service menu
Service menu
Project number
Software version
Start
Maintenance
Error list (Passive)
Value statistics
Operating hours
Refill statistics
System pressure
Special system press.
Liter / Puls
Water treatment
Filling quantity
Time, Date
Other
Other internal
ID-Number
Language
Litres counter
Water treatment
Control mode
Operating mode
Sensor
Motor protection
BackBack
Common failure
Change entry code
Back
Parameter menu
Parameter menu
Enter, with code
Hardwaremenu
Hardwaremenu
ID
No ID number available. Controller not configured. Pump
Denied, not installed. Outside parameter limits.
Impuls water counter.
P
Refill is pressure controled. Entry confirmed.
Code required. Programming mode, enter.
%
Refill is level controled. Test mode.
p
Pressure sensor. Warning.
No intervention possible. Save error. Settings not saved.
Operating mode, view only. Wait.
System separation box.
External refiil signal is connected (level controled operation only).
12
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
6.3 Working principle controller
A B C D
Start up
Switch off an installed refill equipment. Close the • inflow valves. Switch on the controller (D). •
A Display B Error LED C Navigation wheel D ON/OFF switch controller
Use the navigation wheel (C) to navigate through the menus an to confirm the input. The display (A) shows the menus. In case of errors the error LED (B) is on.
P
8,8 bar
Auto
Liter
%
100
2 sec...
Hold down the navigation wheel for two seconds • to go to the process display, whatever the cursor position.
P
8,8 bar
Auto
Liter
%
100
P
8,8 bar
Auto
Liter
%
100
In case of errors the process display switches • from [SYSTEM] to [ERROR] and the LED is on. The error messages, minimum water level, • minimum pressure alarm are consistent by the first start of operation. It is possible to turn the wheel to switch between • [SYSTEM] and [ERROR]. When [ERROR] is displayed press the wheel to • go to the error list. In case of more than one error, scroll through the errors. All errors are shown in accordance of appearance. When [SYSTEM] is displayed, press the wheel to • go to the option menu.
operating instructions
13
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
6.4 Controller inputs
G5 3
D1
Hardware
Parameter Service Back
F1 6
Back
G2
ID number
Language
Litres counter Water treatment
Level controlled
Back
G2
1
Deutch Nederlands English Français
F4
System pressure
Special syst.press
Litre/pulse Water treatment
F6
Water treatment Filling quantity
Time, date
Other
G5
Language Liters counter Water treatment
Control mode
D2
Hardware
Parameter
Service Back
Save
19.05.07 10:15:28
Save Back
30.07.07
13:36:00
Save Back
30.07.07 13:36:00
Back
Back
30.07.07 13:36:00
Save
(3 sec)
Time and date
Language Zero Setting
Control mode
Language
Filling pressure
Start
Back
Press. controlled
Level controlled
G5 3
Water treatment
Litre/pulse
Special syst.press
F4
menu (only for the first time)
Maintenance
Software version
Projekt no.
E3
(3 sec)
G10
Sensor Motor prot. Common failure
Back
Press. controlled
Start
System
D3
Hardwaremenu Parametermenu
Back
Servicemenu
Back
Start
Date Time
Ku1
E3 2
E3 1
Ku1 Date Time
Back
Start
System
Start
System pressure
System
P
B2
View
Back
Enter, with code
Enter
G2 13
Portugues Pycck Norsk cesky
G2
14
Back
cesky
Norsk
Pycck
configuring F1-1 to F1-5
When entering the program mode, the control for pressure maintenance is active.• The code will be active 5 minutes after latest input.• Remove all unpermitted loads, supported objects or lateral loads from the basic automat.•
14
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
7 Maintenance and troubleshooting
The water and the contact surfaces can be 70 °C or more. • Wear the required protective clothing. • The floor can be wet or greasy. Wear protective shoes.•
7.1 Before maintenance
There can be life voltage on the terminal bars even when the main power supply is disconnected. Make sure all external power supplies (e.g. external refill equipment) are also disconnected from the automat.
A
Remove the side cover (A) to gain access to the internal parts. Both left and right covers can be removed.
Release the pressure of the water compartment before maintenance.
7.2 After a power failure
The programmed parameters of the controller do not change after a power failure. The SCU-unit (the clocktimer) has backup power for about one week.
Check the condition of the automat for integrity after a power failure.•
7.3 Maintenance interval
Confirm maintenance in the service menu.
Interval Component Activity
Annually Fill-PE Check leak tightness of joints, pumps and screw
connections.
If necessary, seal or tighten the screw connections.
Every year before the peak period On-site dirt trap in
the feed line
Clean the guards
7.4 Change the automat for water treatment
Switch off water treatment in the equipment menu and change the module.• Adjust the capacity in the parameter menu.• Switch on “water treatment” in the equimpent menu.•
15
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
7.5 Error messages
Nr. Message Description Reset Possible cause Troubleshooting
1
Minimum pressure
alarm
The system pressure reached the lo-
wer alarm limit. The lower alarm limit
is the adjusted value [pON] minus
[Min. alarm distance pON].
A
• Leakage.
• Inflow pressure too low.
• Pressure retaining adjusted wrongly.
• Solve leakage.
• Increase feed pressure.
• Check adjustments of pressure
retaining.
2
Maximum pressure
alarm
The system pressure reached the
upper alarm limit. The upper alarm li-
mit is the adjusted value [pSV] minus
[Max. alarm distance pSV].
A
• Pump does not switch off.
• The reaction pressure pSV of the
safety valve is adjusted too low.
• Check pump switch-off.
• Check the adjusted value for pSV.
• Check pre-pressure.
3
Protection against
dry running
Run-dry sensor delivers signal,
danger of running dry.
B
• System separation box empty.
• Inflow pressure too low.
• Dirt trap blocked.
• Sensor not electrically attached.
• Check supply.
• Increase feed pressure.
• Clean dirt trap.
• Open stop valve.
• Electrically attach the sensor.
5
Inflow amount too
low
Impulse water counter does not
provide water on refilling request.
A
Impulses of impulse water counter are
missing because:
• not electrically attached;
• Adjusted value for reaction time of the
impulse water counter is too low;
• Impulse water counter defective.
• Electrically attach the impulse water
counter.
• Extend adjusted value for reaction
time of the impulse water counter.
• If necessary, change impulse water
counter.
6
Pressure increase
amount
The pressure increase amount was
refilled. However, the system pressu-
re did not rise by at least 0.1 bar.
A
• Pump does not start.
• Water intake too low.
• Wrong adjusted value.
• Increase feed amount.
• Increase adjusted value.
7
Pressure increase
time
The system did not rise by at least
0.1 bar within the pressure increase
time.
A
• Pump does not start.
• Water intake too low.
• Wrong adjusted value.
• Increase feed amount.
• Increase adjusted value.
• Check, if magnet valve switches.
9
Pump feed error Refilling process without request.
A
• Pump does not switch off.
• Water counter impulses without pump
request.
• Check controller.
• Check electrical joints.
10
Interval of cycles Minimum interval between two refil-
ling cycles shortened. A
• Interval times of the system go below
limit.
• Leakage in the system.
• Check adjusted value.
• Solve leakage.
11
Number of cycles Maximum number of refilling cycles
within a time frame exceeded. A
• Too many refilling requests within the
time frame.
• Leakage in the system.
• Check adjusted value.
• Solve leakage.
12
Amount limit Maximum amount for a refilling cycle
exceeded. A
• Leakage in the system.
• Adjustment value for amount limitation
too low.
• Remove leakage.
• Check adjusted value.
13
Run-time limit Maximum time for a refilling cycle
exceeded. A
• Leakage in the system.
• Adjustment value for time limitation
too low.
• Solve leakage.
• Check adjusted value.
A: Necessary, reset possible within normal use (control restarts after resetting). B: No duty, automatic reset within normal use.
16
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
A: Necessary, reset possible within normal use (control restarts after resetting). B: No duty, automatic reset within normal use.
Nr. Message Description Reset Possible cause Troubleshooting
14
Filling amount
exceeded
Max. initial filling amount in filling
mode exceeded. A
• Leakage in the system.
• System not sufficiently filled, yet.
• Solve leakage.
• Check adjusted value.
• Re-activate filling mode.
15
Filling time excee-
ded
Max. initial filling time in filling mode
exceeded. A
• Leakage in the system.
• System not sufficiently filled, yet.
• Solve leakage.
• Check adjusted value.
• Re-activate filling mode.
16
Change module Amount of the water treatment
module exceeded.
A
Module capacity of the water treatment
exhausted.
Change module.
17
Voltage sensor Minimum sensor voltage below limit.
B
Blank defective. Change controller when repetitive.
18
Short circuit of
pressure sensor
Short circuit current loop pressure
sensor.
A
Short circuit. Check the electrical joints and cables.
19
Cable break of
pressure sensor
Interruption current loop pressure
sensor.
A
Cable break. Check the electrical joints and cables.
20
No date/time Real time clock has no valid time
information.
A
Time adjustment deleted after longer
dead-voltage condition.
Adjust time and date.
25
Maintenance date Maintenance date reached.
A
Maintenance required. Perform maintenance and confirm in
service menu.
17
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
8 Disposal
Comply with local legislations.
OFF
1
OFF
230 V
2
Make sure the system power switch • is OFF. Disconnect the power supply. •
Make sure the main power switch is OFF.• Drain the water.•
18
operating instructions
FLAMCO-FILL PE INSTALLATION AND OPERATING INSTRUCTIONS
TP.04/02/09.EN Edition 2009 / EXP
9 Technical specifications
H2
W2
W1
D2
D1
General
Type of protection
IP 54
Weight
ca. 25 kg
System installation
G ½”
Feed joint at the impulse water counter
R ½”
Pipe joint drain/overflow
DN40
Volume system separation box
12 litre
System data
Supply flow pressure
1 – 10 bar
System pressure
1 – 9 bar
Volume flow
max. 210 l/h
Temperature range supply
> 0 °C – 30 °C
Electrical data
Supply voltage
230 V, 50 Hz
Power input
0,3 kW
Mains fuse
230 V, 10 A (slow)
Load capacity collective malfunction message
230 VAC, 3 A
Influencing variables
Environmental temperature
> 0 °C – 40 °C during operation, -20 °C – 65 °C when transported and stored.
Relative humidity
< 80% during operation, when transported and stored -> non-condensing.
Main dimensions (nominal)
H2
495 mm
W1
380 mm
W2
320 mm
D1
320 mm
D2
215 mm
Nominal diameter Maximum line length system installation
DN15
10 m
DN20
20 m
DN25
30 m
Loading...