flamco Flexcon M-K Series Installation And Operating Instruction

Flexcon

®

M-K

ENG

Installation and operating instuction

DEU

Montage- und Bedienungsanleitung

NLD

Montage- en gebruikshandleiding

FRA

Installation et mode d’emploi

SPA

Instrucciones de instalación y funcionamiento

ITA

Istruzioni d’installazione e d’uso

DAN

Monterings- og driftsvejledning

SWE

Instruktioner för installation och drift

NOR

Installasjons- og bruksanvisning

FIN

Asennus-ja käyttöohjeet

POL

Instrukcja montażu i obsługi

HUN

Telepítési és üzemeltetési útmutató

CES

Návod k instalaci a obsluze

SLK

Návod na montáž a obsluhu

SLV

Priročnik za namestitev in uporabo

RUS

Инструкции по установке и эксплуатации

TUR

Kurulum ve İşletim Kılavuzu

Contact

Flamco B.V.

Amersfoortseweg 9
3751 LJ Bunschoten
Nederland

T [phone]
F [phone]
E [e-mail]

I www.flamco.nl

Flamco UK Ltd

Washway Lane
St Helens
Merseyside
WA10 6PB
United Kingdom

T [phone]
F [phone]
E [e-mail]

I www.flamco.co.uk

Flamco Middle East

PO Box 262636
Jebel Ali, Dubai
United Arab Emirates

T [phone]
F [phone]
E [e-mail]

I www.flamco-gulf.com

Flamco GmbH

Steinbrink 3
42555 Velbert
Deutschland

T [phone]
F [phone]
E [e-mail]
I www.flamco.de

Flamco AG

Fännring 1
6403 Küssnacht
Schweiz

T [phone]
F [phone]
E [e-mail]
I www.flamco.ch

Flamco Belux

J. Van Elewijckstraat 59
B - 1853 Grimbergen
BELGIE

T [phone]
F [phone]
E [e-mail]

I www.flamco.be

Flamco s.a.r.l.

ZI du Vert Galant
1 Rue de la Garenne
F-95310 Saint-Ouen-l’Aumône
FRANCE»

T [phone]
F [phone]
E [e-mail]

I www.flamco.fr

Flamco AG

Fännring 1
6403 Küssnacht
Suisse

T [phone]
F [phone]
E [e-mail]

I www.flamco.ch

Baxi Calefacción, S.L.U.

Salvador Espriu, 9-11
L’Hospitalet de Llobregat
08908 Barcelona,
España

T [phone]
F [phone]
E info@ baxicalefaccion.com

I www.baxicalefaccion.com

PROSYSTEM ITALIA Spa

Via Friuli Venezia Giulia 15
30030 Pianiga VE Italy

T [phone]
F [phone]
E [e-mail]

I www.flamco.it

Flamco Denmark

Tonsbakken 16-18
DK-2740 Skovlunde
Danmark

T [phone]
F [phone]
E [e-mail]

I www.flamco.dk

Flamco Sverige

Kungsgatan 14
541 31 Skövde
Sverige

T [phone]
F [phone]
E [e-mail]

I www.flamco.se

Wilo Norge AS

Stålfjæra 15
0975 OSLO
Norge

T [phone]
F [phone]
E [e-mail]

I www.flamco.no

LPO-Invest Oy

Engineering
Rikhard Nymanintie 16
00370 Helsinki
Suomi

P [phone]
F [phone]
S [e-mail]

I www.flamco.fi

Flamcon toimipiste

Technopolis-kiinteistö,
Teknobulevardi 3–5
01530 Vantaa
Suomi

P [phone]
F [phone]
S [e-mail]

I www.flamco.fi

Flamco Polska Sp. z o.o.

ul. Akacjowa 4
62-002 SUCHY LAS
Polska

T [phone]
F [phone]
E [e-mail]

I www.flamco.pl

Flamco Hungary Kft

2330 Dunaharaszti
Jedlik Ányos út. 25
Magyarország

A Pest megyei Bíróság mint Cégbíróság

T [phone]
F [phone]
E [e-mail]

I www.flamco.hu

Flamco CZ

Pod Parukářkou 14

130 00 Praha 3

Česká republika

T [phone]
F [phone]
E [e-mail]

I www.flamco.cz

CERTIMA s.r.o.

Pri Šajbách 46
831 06 Bratislava
Slovakia

T + 421 (0) 2 44/681601
F + 421 (0) 2 44/681603
E [e-mail]

I www.certima.sk

Duopol D.O.O.

Tržaška cesta 135

1000 Ljubljana
Slovenija

T [phone]
F [phone]
M [phone]
E [e-mail]

I www.duopol.si

ADL Company

21/2, Stromynka st.
Moscow, 107076
Russia

T [phone]
Ф [phone], 9338502
Эл.почта [e-mail]

Инт. www.adl.ru

Normtherm

Atatürk Cd. 68 /

10 34901 Gürpınar

ISTANBUL
TURKEY

T [phone]
F [phone]
E [e-mail]

I www.flamco.com.tr

5

Flexcon® M-K Installation and operating manual

Table of contents

1. Liability 6

2. Warranty 6

3. Copyright 6

4. General safety instructions 6

Warning symbols in this manual 6
Purpose and use of this manual 7
Qualifications required, assumptions 7
Competence development of personnel 7
Appropriate use 7
Receiving goods 8
Transportation, storage, unpacking 8
Operations room 8
Noise reduction 9

EMERGENCY-STOP / EMERGENCY-OFF

9

Personal protective equipment (PPE) 9
Exceeding permitted pressure / temperature levels 9
System water 9
Safeguards 9
External forces 10
Inspections prior to commissioning, routine checks 10
Inspections to ensure operation 10
Electrical equipment inspections, routine inspection 10
Maintenance and repair 10
Obvious misuse 11
Other hazards 11

5. Product description 11

Operating principle 11
Markings 12
Compressor unit ID no. 13
Control unit ID no. 13
Overview components 14

6. Installation 18

Set up 18
System connection 18
Gas compartment connection 20
Electrical installation 21

7. Commissioning 21

First-time commissioning 21
Commissioning, volume level and operating temperature 22
Control unit, commissioning 23
Overview menu options 23
Clarification of menu icons 24
Operating menu, options for configuration 25
Error messages 26
Restarting 29

8. Maintenance 29

Vessel draining / refilling. 30

9. Decommissioning, Dismantling 30
Appendix 1: Technical data, information 31

Ambient conditions 31
Minimum distances: clearance for service and repair. 31
Installation examples 32

Appendix 2: Technical data, information, hydraulic and pneumatic equipment 33

Operational values, volume and dimensions 33

Appendix 3: Technical data, information, electrical equipment 34

Compressor unit: nominal characteristics 34
Control unit, terminal plan standard 34

ENG

6

1. Liability

All data and information contained herein are correct at time of publication. This information is the result of our current findings
and experience to the best of our knowledge. We reserve the right to make technical changes subject to the future development
of the Flamco product referred to in this publication. Hence no rights may be derived from technical data, descriptions and illust­rations. Technical pictures, drawings and graphs do not necessarily correspond to the actual assemblies or parts as delivered.
Drawings and pictures are not to scale and contain symbols for simplification.

2. Warranty

Warranty specifications can be found in our General Terms and Conditions and do not form part of this manual.

3. Copyright

This manual must be used confidentially. It may be circulated among authorized personnel only. It must not be given to third
parties. All documentation is protected by copyright. Distribution or other forms of reproduction of documents, even extracts,
exploitation or notification of the contents hereof is not permitted, where not otherwise specified. Infringements are liable to
prosecution and payment of compensation. We reserve the right to exercise all intellectual property rights.

4. General safety instructions

Disregard or lack of attention to the information and measures in this manual may pose a hazard to people, animals, the environ­ment and tangible assets. Failure to observe the safety regulations and the neglect of other safety measures may lead to the
lapse of liability for damages in the event of damage or loss.

Definitions

• Operator: Natural person or legal entity, who owns the product and uses it or to whom use of the product is entrusted on the
basis of a contractual agreement.

• Principal: Legally and commercially liable client in the commission of building projects.

• Responsible person: The representative appointed to act by the main contractor or operator.

• Qualified person (QP): Any person whose professional training, experience and recent professional activity gives them the
requisite professional knowledge. This implies that such people have knowledge derived from relevant national and internal
safety regulations.

Warning symbols in this manual

Danger - electric current

Disregarding these warnings may:

• endanger health,

• cause death, fire or other damage,

• lead to the overloading of individual components and to damage,

• otherwise impair the unit’s function.

Caution - warning for mistakes and wrong basic assumptions

Consider the implications of errors and incorrect set-up conditions carefully!
Disregarding these warnings may lead to:

• serious personal injury,

• overloading of individual components and damage,

• impair the unit’s function.

!

7

Flexcon® M-K Installation and operating manual

Purpose and use of this manual

The following pages list the information, specifications, measures and technical data that allow the relevant personnel to use this
product safely and for the intended purpose. Responsible persons or those engaged by them carrying out the required services
must read this manual attentively and understand it. Such services include: storage, transportation, installation, electrical installa­tion, commissioning and re-starting, operation, maintenance, inspection, repair and dismantling.

Where the product is to be used in plants/facilities which do not comply with harmonized European regulations and relevant
technical rules and guidelines of professional associations for this field of application, the present document is purely for informa­tive and reference purposes. As this unit may be subject to unlimited inspection at all times, this manual must be kept in the
immediate vicinity of the installed unit, at least within the confines of the operations room.

Qualifications required, assumptions

All personnel must have relevant qualifications to carry out the required services, and be physically and psychologically capable.

The area of responsibility, competence and supervision of personnel is the duty of the Operator.

Required service Professional group Relevant qualifications

Storage, Transportation Logistics, transport, warehousing Transport and warehousing specialist
Installation, dismantling, repair, mainte-

nance

Re-commissioning after installation of
extra components or modification

Testing

Commissioning after configuration
(generic), re-commissioning after power
cut, (work on the terminal and SPC
control unit)

Installation and building services
(HVAC)

HVAC specialist.

Person trained with knowledge from the
present manual.

Electrical installation

First and routine inspection of electrical
equipment

Electrical engineering Specialist in electrical engineering/

installation

Qualified person (QP) with certification in
Electrical Engineering

Inspection prior to commissioning
and routine inspection of
pressure equipment

Installation and building services
from a professional technical inspection
authority.

Qualified person (QP)

Competence development of personnel

Operating instructions are issued by Flamco representatives or others assigned by them during delivery negotiations or on
demand. Training for the required services, installation, dismantling, commissioning, operation, inspection, maintenance and
repair are part of the training / further education for service engineers of the Flamco branch offices or named service contractors.
Such training covers information about on-site requirements rather than performance.

On-site services include transportation, the preparation of an operations room with the requisite foundation engineering to
accommodate the system, and the requisite hydraulic and electrical connections, the electrical installation for the power source of
the expansion automat and installation of the signal leads for the IT equipment.

Appropriate use

Sealed water-based heating and cooling systems in which temperature-induced changes in the volume of the system water (the
heat transfering agent) can be absorbed and the required operating pressure is governed by a separate expansion automat.

The water-based heating systems are submitted to EN 12828. For temperatures above 105 °C or system capacities over 1 MW
additional rules and regulations may apply. The contractor / operator will need to consult with a notified body on additional safety
measures. Use in similar systems (e.g. heat transfer systems for process industry or technologically conditioned heat) may require
special measures. The complementary documents must be studied.

ENG

8

Receiving goods

The items delivered must be compared against the items listed on the shipping note and inspected for conformity. Unpacking,
installation and commissioning may be started only once the product has been checked and seen to conform with the intended
use as stated in the order process and contract. In particular, exceeding the permissible operating or design parameters may lead
to malfunctioning, component damage and personal injury. If not in line with conformity or if the delivery is incorrect in another
way, the product must not be used.

Transportation, storage, unpacking

The equipment is delivered in packing units in conformity with contract specifications or specifications required for certain
transportation methods and climate zones. They meet the requirements of the Flamco STAG GmbH packaging guidelines as a
bare minimum. In conformity with these guidelines, vessels are shipped horizontally and compressor or pump units upright, each
packed on disposable pallets. Accessories or additional equipment can be supplied separately (e.g. compressor unit K-04) or
may be shipped together with the vessel. These pallets are suitable for horizontal transportation with suitable fork-lift trucks. The
forks must be set to the widest possible outer dimensions in order to prevent the load from tipping over. When moving the article
in question, the forks must be in the lowest possible position, with the article at right angles to the forks. If the packages are
suitable for lifting gear, they will be marked at the appropriate lifting points. Important note: Transport the packed goods as close
as possible to the envisaged set-up location and make sure there is a horizontal, solid surface on which the goods can stand.

Caution: Please take precautions to make sure the vessel, once it has been removed from the pallet and the packaging, does not
bottom out, tip over or rock. Suitable lifting lugs are provided for lifting and moving suspended empty vessels prior to installation.
Such devices (lifting lugs) must be used in tandem; avoid side-pulling.

Once they have been removed from the pallet and the packaging, separately shipped compressors (K04) must be transferred by
pulling them over suitable levelled surfaces. Use methods that prevent uncontrolled falling, sliding or tipping over.

The goods may also be warehoused in their packaging. Once it has been removed from its packaging, the equipment must be
put in position, observing standard safety procedures. Do not stack the equipment. Use only permitted lifting gear and safe tools,
and wear the required personal protective equipment.

Operations room

Defenition: room which meets the applicable European regulations, European and harmonized standards and relevant technical rules and
guidelines of the professional associations for this field of application. For the use of the expansion automat as prescribed in this manual these
rooms generally contain equipment for thermal generation and distribution, water heating/cooling and top-up, power source and distribution,
such as measuring, control engineering, control technology and IT.

Access for unqualified and untrained persons must be restricted or forbidden.

The set-up location of the expansion automat must ensure that the operation, service, maintenance, inspection, repair, installation
and dismantling can be carried out unhindered and without danger. The floor of the set-up location for the pressurization unit
equipment must be such that stability is guaranteed and maintained. Bear in mind that the maximum possible forces can be
exerted from the net mass including the water volume. If stability cannot be guaranteed, there is a danger that the vessel will tip
over or move and, as a consequence in addition to functional defects may lead to personal injury. The ambient atmosphere must
be free of conductive gases, high concentrations of dust and vapours. There is the risk of explosion if any combustible gases are
present.

When the safety valve is opening to prevent overpressure in the vessel and when bladder leakage leads to overflowing at the
atmospheric pressure equalization port, system water will be drained off. Depending on the process, the water temperature can
rise to 70 °C and, in the case of improper operation exceed 70 °C. This brings a danger of personal injury by burns and/or
scalding. Ensure that such water can be drained without danger and that there is a safe drainage option or water collector
available to prevent damage from water in the system (consider the impact additives may have on the groundwater!).

Flooded equipment must not be operated. If electrical equipment short circuits, persons or other beings in the water will be
electrocuted. Furthermore, there is a danger of malfunction and partial or irreparable damage to individual components due to
water saturation and corrosion.

!

9

Flexcon® M-K Installation and operating manual

Noise reduction

Installations should be constructed with noise-reduction measures in mind. Especially vibrations of the assembly (pipework) can
be dampened by using insulation between contact surfaces.

EMERGENCY-STOP / EMERGENCY-OFF

The EMERGENCY-STOP facility required in line with directive 2006/42/EC is made available by the main power switch on the
control unit. This switch separates the electrical conductors and neutral conductors. When additional security measures with
EMERGENCY-OFF facility are required according to the operation of the heat generator, these are to be installed on-site.

Personal protective equipment (PPE)

PPE must be used when carrying out potentially dangerous work and other activities (e.g. welding), in order to prevent or
minimize the risk of personal injury if other measures cannot be taken. These must comply with the requirements specified by the
main contractor or operator of the operations room or the site in question. If no requirements are specified, to operate the
automat no PPE is required. Minimum requirements are well-fitting clothing and sturdy, closed and skidproof footwear.

Other services require the protective clothing and equipment necessary for the activity in question (e.g. transport and assembly:
well-fitting work clothing, foot protectors [safety shoes with toe caps], head protection [safety helmet], hand protection [protective
gloves]; Maintenance, repair and overhaul: well-fitting work clothing, foot protectors, hand protectors, eye/face protector [safety
goggles].

Exceeding permitted pressure / temperature levels

Equipment used in combination with the expansion automat must guarantee that the permitted operating temperature and the
permitted medium temperature (heat transfer medium) cannot be exceeded. Excess pressure and temperature may lead to
component overload, irreparable damage to components, loss of function and, as a result, to severe personal injury and damage
to property. Regular checks/inspections of these safeguards must be carried out.

System water

Water which is non-flammable, does not contain solids or long-fibre components and does not present a danger to operations
due to its contents, and will not affect or damage the water bearing components (e.g.: pressurized components, the bladder,
vessel connection) of the expansion automat.

System water containing components are pipelines, hoses connected to the vessel and system connections including valves and
fittings, and their casings, sensors or the vessel itself including the vessel bladder. Operation with improper media can lead to
impaired function, damage to components and, as a consequence, to serious personal injury and damage.

Safeguards

The equipment supplied is equipped with the required safety devices. To test their effectiveness or restore the set-up conditions,
the equipment must first be taken out of service. Taking the system out of service implies that power should be cut and hydraulic
connections blocked, to prevent accidental or unintentional re-connection.

Mechanical hazards:

Compressor casings and fanwheel casings prevent severe personal damage by turning parts. Before commissioning, check these
are fit for purpose and fixed in place. The safety valve that is placed at the compressed air compartment of the vessel ensures
that the compressor‘s maximum volumetric compressed air-flow is discharged when the pressurizing equipment malfunctions. It
is not intended to protect against excessive pressure within the heating or cooling installation.

Electrical hazards:

The international protection rating (IP) of electrically-operated components prevents personal injury by electrocution, which can
be deadly. The protection rating when equipped with K04 compressors is usually IP54 (5: access with wire impossible, dust
protected, 4: protected against splashing water). The protection class for compressors K01- K03 is IP23 (2: protected against
touch by finger, foreign body protection from ø12.5; 3: protection against water dripping up to 60° from vertical).The control unit
cover, the cover of the compressor, the threaded cable glands and the valve connector plugs must be inspected for effectiveness
prior to commissioning. The installed pressure and volume sensors are operated with protective extra-low voltage.

Avoid welding work on additional equipment which is electrically connected to the compressor and control unit. Stray welding
current or an improper earth connection could lead to the danger of fire and damage to parts of the automat (e.g. the control unit).

ENG

10

External forces

Avoid any additional forces ( e.g.: forces caused by heat expansion, flow oscillations or dead weights on the system connection).
These can lead to damage / leakage in water-bearing pipework, loss of stability of the appliance and furthermore to failure
connected to substantial material and personal damage.

Inspections prior to commissioning, routine checks

They guarantee operational safety and its observance in line with applicable European regulations, European and harmonized
standards and relevant technical rules and guidelines of the professional associations for this field of application. The required
inspections must be arranged by the owner or operator; an inspection and maintenance log book for scheduling and traceability
of measures taken must be kept.

Inspections to ensure operation

(under the German implementation of Council Directive 89/665/EEC).

Pressure device, Vessel

Category
[Appendix II
The Directive
2014/68/EC,
Diagram 2]

Vessel
Nominal
Volume (l.)

Inspection prior to
commissioning
[§14]
Inspector

Routine Inspection [§15 (5)]
Timeframe, maximum period [a] / inspector
External Internal*

Strength*

III

400 / 6 bar
5000-10000/
3 bar

Qualified Person
(QP)

Not applicable
[§15 (6)]

5 / QP

10 / QP

IV

600-3500/
6 and 10 bar

Qualified Person
(QP)

Not applicable
[§15 (6)]

5 / QP

10 / QP

* [§15 (10)] In the case of internal inspections the visual inspection may be replaced by similar procedures and in
the case of strength tests the static pressure test may be replaced by similar, non-destructive procedures if said
tests would not otherwise be possible due to system design or not significant due to the system mode of
operation.

Electrical equipment inspections, routine inspection

Regardless of the prescriptions of the property insurer / operator it is recommended to inspect demonstrably the electrical
equipment of the Flexcon M-K together with the heating or refrigerating installation at least every 18 months (see also DIN EN
60204-1 (2007)).

Maintenance and repair

These services may only be carried out when the system is shut down, or if the expansion automat is not required. The pressuri­zation equipment must be taken out of service and guarded against unintentional re-starting until the maintenance work is
finished. Note that the safety circuits and data transmissions made whilst shutting down could trigger the safety chain or lead to
false information. Existing instructions for the heating or cooling unit as a whole must be observed. To stop hydraulic
components, block the relevant sections and drain them using the safe system water drains through the available drain connec­tions, and relieve the pressure.

Caution: The maximum system water temperature in conducting components (vessel, casings, hoses, pipelines, peripheral
equipment) may reach 70°C and, in the case of improper operation, may exceed that. This presents a danger of burns and/or
scalding. Temperatures of compressed air containing parts, especially the pressurisation connecting assembly, the compressed
air hoses for pressurisation and the function related uncovered parts of the compressor are depending on the duty cycle of the
compressor and the working pressure and may exceed 40 °C.

The maximum pressure of system water in conducting components may equal the maximum set pressure for the system safety
valve (max. 3, 6 or 10 bar). Use of eye/face protectors is required if the eyes or face could be injured by flying parts or spraying
fluids.

To stop electrical equipment (control unit, compressors, valves, peripheral equipment), cut power to the control unit. The power
supply must remain off for the period of the work. It is forbidden to alter or use non-original components or replacement parts
without authorization. Such acts may result in serious personal injury and endanger operational safety. They will also render any
claim for damages against product liability void.

It is recommended to contact the Flamco Technical Sales and Service department to carry out these kind of services
([phone] or in the UK: [phone]).

!

11

Flexcon® M-K Installation and operating manual

Obvious misuse

• Operation at incorrect voltage and/or frequency.

• Use in inappropriate system designs.

• Use of unpermitted installation materials.

Other hazards

• Overload of construction parts by the the occurence of unexpected extreme values.

• Operational continuity at risk in the case of changed, non-permissible ambient conditions.

• Operational continuity at risk in the case of safety-control parts being taken out of service or malfunctioning.

• Compressed air jets with compressed air compartment couplings of the pressurized vessel

.

•

Fire hazard: ensure professional fire protection on-site.

5. Product description

The contents of this manual consist of the specifications for a standard execution. Where appropriate, this includes information
on options or other configurations.

If optional extras are supplied, further documentation will be supplied in addition to this manual.

Additional Documentation

SPC module, volume / pressure analogue Doc. no. MC00049/11-2010/eng
SPC module, SD-card Doc. no. MC00050/11-2010/eng
SPC module, RS485, Data protocol Doc. no. MC00051/11-2010/eng
Wiring diagram SPCx-lw Doc. no. MC00055/11-2010/eng
SPC module Bus- Koppler LONworks Doc. no. MC00057/11-2010/eng
Minimum pressure limiter Doc. no. MC00059/11-2010/eng
Easycontact Doc. no. MC00060/11-2010/eng

Operating principle

The varying pressure levels due to temperature changes in heating or cooling systems are continuously monitored by the pressure
sensor in the compressed air compartment of the vessel. Comparison of these actual pressure levels with a programmable
nominal value leads to the triggering of the valve (release of pressure by means of compressed air discharge) in the event of the
value being exceeded (temperature rise), and triggering of the compressor (increase of pressure by means of filling the
compressed air compartment with compressed air) in the event of the pressure dropping below the nominal level (temperature
drop). The volume of water drained or fed in is made available or taken up by the vessel. Continuous comparison of the program­mable nominal values with the varying volumes registered by the vessel volume sensor prevents under- or over-filling, whilst
allowing volume increase by triggering extermal top-up devices.

M

Valve

Volume
sensor

Control unit

Compressor

Pressure
sensor

Water-filled

compartment

(water pressure)

Heating- or

cooling system

Compressed air

compartment

(gas pressure)

Bladder

Pressure vessel

ENG

Zulässiger Betriebsüberdruck
Permissible working overpressure
Surpression de service admissible

Nennspannung
Nominal voltage
Tension nominale

Zulässige Umgebungstemperatur min. / max.
Permissible ambient temperature min. / max.
Température de ambiante mini. / maxi. admissible

Nominale spanning

Toelaatbare werkdruk

Toelaatbare omgevingstemperatuur min. / max.

:
:
:
:

:
:
:
:

:
:

:
:

Typ
Type
Type
Type

Serien-Nr.
Serial-No.
N° d

e Série

Volgnummer

:
:
:
:

:
:
:
:

Nennstrom
Nominal current
Courant nominal

Zulässige Medientemperatur min. / max.
Permissible media temperature min. / max.
Température de média mini. / maxi. admissible

Nennleistung
Nominal power
Puissance assignée

Nominale stroom

Toegestane temperatuur media

Nominaal vermogen

:

:
:
:

:
:

:
:

00,00 Herstellungsjahr

Year of manufacture
Année de fabrication
Jaar van vervaardiging

:
:
:
:

kW

A

°C

bar

:
:

°C

:
:

Serien-Nr.

N° de série
Serial -No.

:

:
:

Herstellungsjahr

Année de fabrication

:

:

:

Year of manufacture

Tension assignée d'emploi

Bemessungsbetriebsspannung

Rated operat ional voltage V

:

:

:

Phasenzahl

Nombre de phase
Number of phases

:

:

:

Frequenz

Fréquence
Frequency

:

:

:

Volllastst rom

Courant de coupure

:

:

:

Bemessungskur zschluss-St rom

Mesure de la courant de court-circuit

:

:

:

Dokument ationsnummer

Numeró de dessin

:

:

:

Schutzart

Prot ection
Degree of protec tion

:

:

:

Typ:

Type :

:

Flamco STAG GmbH; Berliner Chaussee 29; 39307 Ge nthin; Germany

Cut-of f current A

Rated short-circui t current

A

Drawing number

Type

high voltage! Opening by qualified personnel only.

gefährliche Spannung! Nur vom Fachpersonal zu öffnen.

Disconnect the unit from the power supply before opening it.

Vor dem Öffnen des Gerätes spannungsfrei schalten.

Attention,

Achtung,

+24V / signal +

signal

23 45

_

+24V / signal +

67

+24V / signal +

+24V / signal +

189

pwm

10 11

mpl

12 13 14 16 17 19 20 22 2315 18 21 25 26

NL

24

28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 45 46 48 4941 44 47 51 5250

L

27

tc gs drs ps

mains supply

230V 50/60Hz

fault

34

BA

+

24V

_

21212121

1212

12

refill / drain

M1 V4 K1/MS1 M2 V5 K2/M S2

V1 V1.1 V2/2.1

pressure

niveau

high voltage

M3/3.1 V3/3.1

signal

_

signal

_

12

2

Com

NO NC

GND

1

niveaupressure

0-10V

refill / drain

F1/2 MS1/2

0-10V

Com

Com

COM RS232

=

Read the manual !

Bedienanweisung lesen !

ACHTUNG:

Trotz Netztrennung kann,

an den Klem men: 12; 13;

14; 16; 17, eine Spannung

von 250VAC anliegen !

ATTENTION:

Despite disconnecting from

the main power line, you can

maintain power 250VAC

on terminals: 12; 13; 14; 16; 17 !

p

Flamco 09544 0810

GND

GND

GND

GND

GND

GND

GND

GND

accessory

option

extra-low voltage

sensors

extra-low voltage

5A5A30

250

VDC
VAC

ohmic load

5A5A30

250

VDC
VAC

ohmic load

option

data op tion

high voltage

NLNL

NLNLNL N

COM RS485

12

SPC

terminal

SPCx-l w

!

Nach Montage:

Transportsicherung

entfernen.

After mounting:

Remove the transport

safety.

Après I'installation:

Retirez la sécurité des

transports.

Na montage:

Verwijder de veiligheid

van het vervoer.

1000 Ltr

1000 Ltr

1000 Ltr

Type

Tempér ature de service mini. / maxi . admissi ble

Surpression de service admissible

Surpression d`essai

Capacité nominale

N° de série

litres

bar

bar

Type
Typ

Serial-No.
Serien-Nr.

Nomi nal volume
Nenninhalt

Permissible working overpressure
Zulässiger Betriebsüberdruck

Test over pressure
Prüf überdruck

Permissible working temperatur e min. / max.
Zulässige Betriebstemperatur mi n. / max.

litre
Liter

0045

Flamco STAG GmbH
39307 Genthin
GERMANY

°C

:

:

:

:
:
:

:
:
:

:
:
:

:
:
:

:

:
:

Année de fabrication
Year of manufacture
Herstellungsjahr

:
:
:

M

a

n

u

f

a

c

t

u

r

e

r

´

s

m

a

r

k

i

n

g

H

e

r

s

t

e

l

l

e

r

k

e

n

n

z

e

i

c

h

e

n

M

a

r

q

u

e

d

i

s

t

i

n

c

t

i

v

e

d

u

c

o

n

s

t

r

u

c

t

e

u

r

12

Markings

Name plate - Vessel: Name plate - Pump module:

Transport seal
(volume sensor):

Name plate - Control unit:

Electrical warnings:

Service:Warning compressed air pressure:

Terminal plan SPCx-lw:

Flamco B.V. - Bunschoten

www.amcogroup.com

Flexcon MK/U A 1000

Capacity / Inhalt / Inhoud / Contenance

Gas charge / Vordruck / Voordruk / Pression initiale

Max. working pressure / Max. zul. Betriebsüberdruck / Max. werkdruk / Pression de service max.

Test pressure / Prüfdruck / Testdruk / Pression d’épreuve

Max. temp. diaphragm / Max. Betriebstemp. Membrane / Max. temp. membraan / Temp. membrane max.

Min. working temperature / Min. Betriebstemperatur / Min. werktemperatuur / Température de service min.

Article code / Artikelnummer / Artikelnummer / Code article

litres

bar

bar

bar

°C

°C

0038

Service Nederland

Tel.: [phone]
Fax.: [phone]

Service Germany

Tel.: [phone]

Service Nederland

Tel.: [phone]
Fax.: [phone]

Service Germany

Tel.: [phone]

13

Flexcon® M-K Installation and operating manual

Alphabetic glossary of abbreviations in terminal plan

Note: mentioned switch settings are in current-free, un-switched situation.
accessory (SPC Extension volume, pressure analog, optional)
COM COM- interface; serial port
Com The common port
data (Data protocol, optional)
drs (Membrane rupture sensor, optional)
extra low voltage Protective low voltage
fault Error message, common failure message. Displayed switch setting is error.
high voltage Voltage as per markings on the automat
mains supply Power feed
mpl (Minimum pressure limiter, optional)
M3/3.1 V3/3.1 Motor 3 (top-up, optional) / 3.1 (drainage, optional);

Valve 3 (top-up) / 3.1 (drainage, optional)
M1 V4 K1/MS1 Compressor 1; Valve 4 (pressurization);
M2 V5 K2/MS2 Compressor 2; Valve 5 (pressurization);
niveau Level, content
ohmic load Ohmic load, resistance
option (not applicable)
pressure Pressure
pwm (Impulse water meter, optional)
ps (Pressure switch; Level switch min. level, top-up pump, optional)
refill / drain Top-up / (drain , optional)
sensors Sensors
tc (Temperature switch, optional)
V1; 1.1 Valve 1; 1.1; parallel, Pressurizing valve (Pressure loss)
V2; 2.1 Valve 2; 2.1; Discharge valve (compressor)

Compressor unit ID no.

[1] / [2] - [3] - [4]

[1]

Version

[2]

Compressor class,

curve range:

[3]

Compressor

manufacturer

[4]
Nom. frequency of the
operating voltage [Hz}

MK: Monocompressor
MV: Monovalve
DK: Dupocompressor
DV: Duovalve

11 (K01; 02)
31 (K03)
40 (K04)

1
2

50

60

Control unit ID no.

[1] - [2]

[1]

Controller

[2]

Casing and

execution;

SPCx
[x: Hardware version]

SPCx
[x: Hardware version]

lw: low output
(Total <=2.2kW)

ENG

14

Overview components

1 Basic steel vessel with built-in, exchangeable butyl-rub-

ber bladder for absorption of the expansion water. Exteri­or corrosion protected, interior untreated (interior coa-

ted***)
2 Vessel name plate
2a Control unit name plate
2b Advice to remove transport seal
2c Pressurisation warning
3 Inspection opening
4 Inspection opening M-K/U 6500-10000
5 Lifting hook, load suspension for transport
6 Anti-collision protection (compressed air connections)
7 Foot-height adjuster
8 Foot pressure plate M-K/U 5000-10000
9 Adjusting screw (transport seal volume sensor, removal)
10 Bleed valve
11 Cover nut (anti-collision protection for bleed valve)
12 Float vent**
13 quick-release coupling, connector
14 Pressure hose, flexible, couplings both sides, length

3000 mm**
15 Pressure hose, flexible, to compressed air comparment

of vessel
16 Pressure hose, flexible, to pressure sensor
17 Pressure hose, flexible, to safety valve, M-K 400-3500
18 Pressure hose, flexible, to compressor 1;2** )k*
19 Pressure hose, flexible, to system connection, M-K/U

400-10000
20 System connection M-K, angle 90° 400-3500 l
21 System connection M-K/U
22 Connection assembly pressurisation,
safety valve compressed air compartment
compressed air compartment valve 1 (1.1***),
discharge valve 2; 2.1** )k*,
non-return valve 1; 2** )k*,
pressure connection to compressed air compartment,
pressure connection to compressor 1; 2 )k*

23 Connection assembly pressurisation***,
safety valve compressed air compartment
compressed air compartment valve 1,
pressurisation valve ,
non-return valve,
pressure connection to compressed air compartment,
pressure connection to compressor
24 Safety valve to compressed air compartment
25 Compressor unit K01 - K03, oil-free
26 Second compressor unit K01 - K03, oil-free
27 Compressor unit K04, oil-free
28 Second compressor unit K04, oil-free
29 Compressor thermal protection, manual reset
30 Intake opening compressor
31 Cooling air inlet compressor
32 Ball valve vessel drain
33 Ball valve system connection
34 Ball valve condensate drain
35 Control unit SPCx-lw
36 Power cable compressor 1, 2** )k*
37 Signal wire pressure sensor (SELV)
38 Pressure sensor
39 Signal wire volume sensor (SELV)
40 Volume sensor
41 Bladder rupture sensor**
42 Transport seal pressure sensor
43 Water compartment (expansion water)
44 Bladder
45 Compressed air compartment

( Detail Pos. 22 )

M-K/U / K03

EB

** accessory, optional extra
*** available as special model
)k* second compressor unit
SELV: Safety Extra-Low Voltage design
(Safety Extra-Low Voltage)

M-K/U: Main vessel
M-K: Auxilliary vessel

EB: single operation
WB: automatic changeover
BL: load dependant operation

M-K/U / K03

EB

M-K/U / K04 )k*

WB / BL

M-K/U / K04

EB

( Detail Pos. 22 ) ( Detail Pos. 22 )

M-K

15

Flexcon® M-K Installation and operating manual

See page 11 for names of positions.

ENG

M-K/U / K03 )k*

WB / BL

M-K 6500 l.

Partial view (top)

M-K/U 6500 l. / K03

EB

M-K/U ***

EB

( Detail Pos. 22 ) ( Detail Pos. 23 )

16

See page 11 for names of positions.

*** external compressed air connection

17

Flexcon® M-K Installation and operating manual

SPCx-lw

1 Control unit SPCx
2 Control unit SPCx-lw
4 Main power switch L, N; On: “Red light”
6 Control unit cover open, inside view
7 Terminal port diagram (see terminal plan)
8 Name plate control unit
9 Electrical warnings
10 Service connection information
11 Port slots, Slot 1 - 4 (SPC Extension, optional)
(Openings for extra modules can be recovered via

breaking point)
12 Screw terminals I/O ports (see SPCx-lw terminal plan)
14 RS485 serial port connector (data protocol, optional)
15 LED warning lights, back lit *
LED, yellow on: Automatic mode off; controller is in confi-

guration mode or comissioning menu not completed.

LED, green on: The terminal is on; the SPC is connected

to the SPC terminal
LED, red on: system error, identical to pos. 23
16 Microfuse F1; 16A T; equipment protection
17 Microfuse F2; 400 mA T; additional equipment

protection Valve 1; 1.1; 2; (output port no.: 42; 43 / 45;46

/ 48; 49)
18 SPC Terminal (display and operating panel)
19 Graphic display with back light

(dimmer in energy-saving mode)
20 Sensor button: “Back” or functions as shown in the dis-

play.
21 Sensor button, unlock key functions
at information in display

or service connection by display marking
22 Sensor button: “Confirmed...Enter”
23 Sensor button: “Error call”
24 Sensor slider, selector
25 Back light on when key function is ready
26 SPC terminal feed wire
27 RS232 port, SPC terminal
29 Cap plugs, threaded cable gland mounting holes
30 Threaded cable glands

* additional indicators (analysis).

1

Cable glands,
standard execution

Cable glands,
maximum execution

ENG

18

6. Installation

Set up

• Remove the transport seal by the capacity sensor once the basic vessel has been erected in the
proposed place and no further positional changes are necessary. Try not to strike this sensor and
make sure the sensor is on a surface which does not impair the function of the sensor pressure-pad.

• Using the foot-height adjuster, adjust the vessel until it is vertical. Use two vertical magnetic spirit
levels.

• Ensure that no external forces can be exerted on the basic vessel (e.g. tools laid on the vessel, things
leaning on the sides).

• Do not fix the basic vessel to the ground on which it is erected (do not use any sort of fastening which
can adversely affect the vessel, e.g. sinking the feet into concrete or lime, welding on the vessel or its
feet, clamps and ties on the body of the structure or appurtenances).

• Place the main vessel and the auxilliary vessel at the same height.

Advice:

• If the vessels are at different levels: the volume sensor reading will not be the actual volume in the
vessel. As a consequence, error messages, regardless of the actual (sufficient) water level in the
vessel, may impair the system’s ability to maintain pressure.

System connection

The system connection should be connected to the heating or cooling system.

Appendix 1 shows the installation diagram and example installation.

Please observe the following specifications before filling and commissioning the pressure-expansion
automat:

• The connection should preferably be made in the return flow of the heating or cooling system. Please
note that a temperature at the system connection > 70 °C would exceed the permissible bladder load
and possibly lead to damage to components. (Complete insulation of the expansion lines may
increase the temperature load on the bladder).

• Ensure that the connection from the main vessel to the system is made only by using the flexible
pressure hose that has been supplied with the vessel.

• Make sure that this connection is made solely with the heat/cool generator, and that there are no
external hydraulic pressure influences present at the point of entrainment (e.g. hydraulic balancers,
distributors).

• Use sealant and pipework relevant to the installation; however, please observe at least the maximum
permitted volumetric flow, pressure and temperature values for the expansion line in question.

• Fit isolating equipment in the immediate vicinity of the vesselconnection to the system that cannot be
closed unintentionally and preferably includes a fill and drain valve for the water compartments of the
vessel. If this equipment is missing, install this additionally.

• When several vessels are placed in a pressure maintenance system, an extra ball valve is required at
the expansion line before the connection to the main return line. It is recommended to seal this valve
to protect against unintentional closing.

• The nominal diameters of the expansion line (supply or return connection from one or more vessels to
the main return line) are to be chosen depending on the installed equipment and the distance to the
main return line.

Pay attention to these recommendations based on practical experience:

• Hint: install expansion lines as short as possible and as flow-efficient as possible.

Ball valve

19

Flexcon® M-K Installation and operating manual

Single vessel automat

Length of expansion line DN of the expansion line,

in relation to the vessel connection

> 5 m Two sizes bigger as vessel connection
> 15 m or > 8 m with 3 pipe bends Three sizes bigger as vessel connection
> 22 m or > 15m To be determined from actual values
> 30 m Avoid at all times!

Install combinations of multiple vessels with the shortes possible distance between each system connection of
the vessels (minimum required spaces for service and repair). Construct a collecting main as follows:

Multiple vessels automat

No. of main and auxilliary vessels DN of the expansion line,

in relation to the vessel connection

up to 3 Four sizes bigger as single vessel connection
4 to 6 Six sizes bigger as single vessel connection

Overview of pipe sizes

DN Ø mm Inch [PN 16] Vessel volume [Litres]

32 _42.4 1 ¼ _400 - _1000
40 _48.3 1 ½ 1200 - _1600

5000 - 10000
50 _60.3 2 _ 2000 _ _____
65 _76.1 2 ½ 2800 - _3500
80 _88.9 3 _

100 114.3 4 _
125 139.7
150 168.3
200 219.1
250 273.0

The vessels should preferably be positioned symmetrically or the nominal diameter of the connection lines
should be increased (Example order: M-K > M-K/U < M-K; M-K > M-K/U - M-K/U < M-K.
Ideal: positioning in polygon). For the return line the same guidelines apply as for expansion lines.

• Systems with flow temperatures > 100 °C may require a minimum pressure limiter.

Caution: close the ball valve at system flow.

Min. pressure

limiter

!

ENG

20

Gas compartment connection

Installations of one or more main vessels with one or more auxilliary vessels with combined pressure control and/or floor-standing
compressors** at the automat require a gas compartment connection to be constructed on-site. For this purpose plug the
pressure hose connection (lock in place)** into the connection-adapters mounted on the equipment. Plugging the connecting
plug (pressure hose connection) into the adapter (quick-release coupling) opens the gas compartment. Disconnecting automati­cally closes the gas compartment (connecting examples: see equipment). Arrange hoses in such a way, that constrictions are
avoided at all times.

Caution: compressed air jet. Note that if pressure hoses are connected or disconnected at one side this can lead to air being
discharged (pressure loss). At the same time the discharge pressure in standard supply situations is up to 2 bar or it corresponds
to the system pressure in the case of separately ordered optional extras. Do not point the compressed air jet at anybody! When
discharging compressed air, unrestrained hoses make uncontrolled whipping movements and can lead to injuries.

** optional accessory.

!

A

A

A

A

A A

A

21

Flexcon® M-K Installation and operating manual

Electrical installation

The provision of power supply, (protective) ground wire connection and line protection has to be made according to regulations of
the responsible power company and the applicable standards. Required data can be found on the name plate of the control unit,
the terminal plan (markings) and Appendix 3.

The connection to the power supply should be made through a CEE plug / socket combination with load switch. It should be a
snap-on type, to avoid unintended disconnections. This power connection should be marked accordingly, easy to handle and
placed appropriately in the vicinity of the automat.

Advice: install the potential equilization between earth connection and potential equalization conductor. The minimum diameter,
quality and type of the power cables should apply to the on-site applicable rules and regulations for this application. Electrical
power cable should be guides along cable gutters at all times.

The finished electronic installation allows the user to program the configuration

and system-dependent parameters into the control unit.

7. Commissioning

First-time commissioning

• Document the commissioning procedure (actions and settings).

• Check that all the installation and other actions prior to use have been carried out in full (e.g. power supply available and
connected, functioning or active fuses, seal tightness of the equipment, transport protection of the volume sensor removed).

Caution: Ensure that the basic vessel is not filled until all the commissioning measures have been completed.

• Fill and de-aerate the heating or cooling system (not the vessel!)

• Check the operational readiness of the top-up line.

• Open the valve at the top-up connection.

• Switch ON the control unit and run the start menu procedure see: Overview of menu entries, lines 9 .. 9-9).

• This startup procedure is followed by switching ON the top-up unit (optional, see installation example with FlamcoFill PE).

•

In other cases the main vessel or all vessels are to be filled with a minimum water supply. The amount of water to be filled should be around
20% of the vessel's volume based on practical experience. This value covers water losses and decreased filling levels caused by deaeration
during operation. (Note the pressure difference between the available compressed air pressure and the flow pressure of the filling equipment!
see also intructions for re-filling).

• Open the ball valve on the cold-leg entrainment (system connection).

• Seal the ball valve (open position).

• The completion of all the tasks to be carried out, the review of technical data, recommendations and explanations in this
manual lead to the pressure expansion automat being ready for operation.

!

ENG

22

Commissioning, volume level and operating temperature

Advice: If a different volume level is required than the self-established minimum level after start (operational ready and installed

top-up), the vessel should be filled according to the minimum required level needed for the actual system temperature, after
completing the commissioning procedure on the control unit. For better understanding study the diagram below and the
paragraph on maintenance, vessel draining and re-filling later in this document.

Actual temperature [°C]

Vessel target volume [%] (display control unit)

Actual temperature [°C]

Vessel target volume [%] (display control unit)

Example 1
Max. design temperature: 50 °C

Max. filling level: 92 %
Min. filling (top-up) level: 12 %
Min. filling temperature: 10 °C

Example 2

Max. design temperature: 80 °C

Max. filling level: 92 %
Min. filling (top-up) level: 12 %
Min. filling temperature: 10 °C

Example 3

Max. design temperature: 25 °C
Max. filling level: 92 %
Min. filling (top-up) level: 12 %
Min. filling temperature: 10 °C

Example 4
Max. design temperature: 40 °C

Max. filling level: 92 %
Min. filling (top-up) level: 12 %
Min. filling temperature: 10 °C

23

Flexcon® M-K Installation and operating manual

Control unit, commissioning

Overview menu options

Configuration menu

Date, time

Operating modeSTART

Pressure

settings

Operational

calibration

Turkish

German

4-20

4-1

(....)

(....)

9-9

9-8

9-7

9-1

2-2-1

2-2

10

Save configuration

to SD memory card

SD card

MAIN MENU

Menu

Data transfer

2

3 4 5 8 9

11

Pressure

8-1

Working pressure Top - up

Drain (....)

(....)

Phase­monitor

Min. pressure

limiter

Pressure

8-2 8-3 8-4

8-4-17

Menu

working pressure

Example:
P

SV

; Opening pressure safety valve 6 bar (System)

(From ordering specifications: <= Nominal pressure pump module)

P

E

; End pressure 5.4 bar
Safety valve, letter symbol DGH
P

SV

x 0.9 [PSV >= 3 bar]; PSV - 0.3 bar [PSV < 3 bar]
Safety valve, letter symbol H
P

SV

- 0.5 bar [PSV = 3 bar]

(From ordering specifications)

P

A

; Working pressure 2.5 bar (Adjustable range after module type)

P

A+

; Upper working pressure tolerance 0.2 bar (pre-set)

P

A-

; Lower working pressure tolerance 0.2 bar (pre-set)

(From ordering specifications)

P

+

; positive pressure 0.3 bar (pre-set, recommended)

P0; Indicated value, reference: P

A

- PA- - P+ = 2.5 - 0.2 - 0.3 = 2.0 bar

(e.g. : = P

static

+ P

vapour

+ P

dynamic

)

8-4-1

8-3-1 8-2-1 8-1-1

8-6

Level

Sensor

valves

Error message

Back to-

start menu

Order-

number

Equipment
information

Version

information

Maintenance

Error list

Operating hours

Top-up,

drain

11-1

11-4

11-5

11-6

11-7

11-8

Manufacturer,

supplier

(back tracing)

Module,

vessel,

Vessel calibration

(test)

Control unit,

software

hardware

(back tracing)

Date:

comissioning start,

vessel calibration

(statistics)

See: maintenance

History of occurred,

resolved errors,

error- nr., date, time

(analytics)

(statistics)

Quantities,

time

(statistics)

Repeat

Start menu (9)

Menu

Language

Menu

Date, time

Menu
Login

Configuration

menu

Start menu

Service menu

Read

manual

Operation menu

SPC - control unit

(Menu

working pressure

8-1-1)

Example:
Summer time - on

Date: 23.10.10

Time:
18 Hours
12 Minutes
57 Seconds

Row below:
Available options for
sensor buttons

Example:

Set pressure 2.0 bar.

Double compressor / compressor, valve: - off

Vessel volume 0%,

Error min. water level: - on (error no.: 19, 10)

Top-up valve 230V, self-protected, - on;

No impulse water meter, top-up volume < 10 l.

Temperature switch ON

(Hint: temperature system water > 70 °C)

Main switch ON;
SPC-Control unit with
Main menu ON;
Functionally active
cells and indicators
are back-lit.

- Menu 2: optional
module extension
required;

- Menu 3: date, time
check, change;

- Menu 4: language
check, change;

- Menu 5: N/A,
not required;

- Menu 8: Default
settings also change­ able after start or
as needed:

- Menu 8-1-1:
Use for
changing P

E

, PA ;

- Menu 8-2-2:
ON / OFF switch
for available
drainage;

- Menu 8-3-1:
Install according
to instruction,
then switch ON;

- Menu 8-4-1..17:
Layout of common
error message:
switch ON / OFF
as needed;

- Menu 9:

- Menu 9-1: view;

- Menü 9-7: execute;

- Menü 9-8: test,
change;

- Menu 9-9: operating
status determined,
execute.

ENG

24

Clarification of menu icons

Unlocking of key functions required
(auto-lock follows 10 minutes after last key stroke).
Unlock by holding the middle button until the energy
bar reaches the top.

Wait for evaluation to finish.

No input / output signal for volume sensor detected
(check volume sensor wiring connections).

Entry confirmed.

Entry cancelled, not applicable,
edit range exceeded.

Vessel volume calibration with value above upper
range limit (empty vessel, check for external forces
affecting the vessel, level the vessel,
repeat vessel level calibration).

Vessel volume calibration with value below lower
range limit ( check for external forces affecting the
vessel, level the vessel, repeat vessel level
calibration).

Error when saving, data loss (›› Service).

No value stabilization during vessel volume
calibration (check for external forces affecting the
vessel, repeat vessel level calibration).

Commissioning by Flamco

service engineer required.

Commisioning by Flamco

sales representative required

25

Flexcon® M-K Installation and operating manual

Operating menu, options for configuration

Operational display

SPC - control unit

(Over-) pressure,
read out at
pressure sensor
(example)

Vessel volume,
read out
(example)

Vessel­volume,
visual

Min. filling level ON
[Error- Nr.: 19; 10]

Max. filling level ON
[Error- Nr.: 11]

Top-up, self monitored

Valve,

230V 1~

Valve,
potential­free

Pumpe,

230V 1~

Valve,

230V 1~
ON

Valve,
potential-

free, ON

Pumpe,

230V 1~
ON

[Possible errors: error-no.: 14; 18; 22- 27]

Top-up, externally monitored

Signal,
230V 1~

Signal,

potential­free

Signal,
230V 1~
ON

Signal,

potential-

free, ON

[Possible consecutive errors:

error-no.: 19; 8; 10]

Indicated value of top-up in [hours] : [minutes] with impulse water meter in [litres].

Water treatment, remaining volume of conditioned water in litres,
(Top-up with pulse water meter required)
Value 0: conditioned water used up [possible error: error-no.: 55]

Drainage, self-monitored

Drainage, externally monitored

Valve,

230V 1~

Valve,
potential­free

Pumpe,

230V 1~

Valve,

230V 1~
ON

Valve,
potential-

free, ON

Pumpe,

230V 1~
ON

Signal,
230V 1~

Signal,

potential­free

Signal,
230V 1~
ON

Signal,

potential-

free, ON

[Possible errors: error-no.: 28; 29; 11]

[Possible consecutive error:

error-no.: 11]

Indicated value of drainage with impulse water meter in [litres].

Temperature limiter ON, (system water > 70 °C) [Possible error: No. 21]

(optional)

Maintenance mode ON
(Default: ON, when pumps have not been activated within a period of 14 days)

Compressor, discharge connection

opened, Pressure connection closed
(no non-return valve)

Compressor ON; discharge connection

closed, pressure connection opened
(pressure á)

Compressor

Compressor;
discharge valve opened

Pressurisation
valve

Pressurisation valve
(external compressed air
source)

Pressurisation valve

ON

Pressurisation

valve ON

(pressure â)

Compressor, ON

(pressure á)

Compressor, ON; discharge valve

closed

(pressure á)

ENG

26

Error messages

Procedures and values for error identification, evaluation and output have been tried in practice, prevent secondary failures and
invite user awareness. Please note that incorrect set-up conditions can lead to repeated errors and inhibit the intended use.
Examples of incorrect set-up conditions are: incorrect or no longer applicable design, outdated equipment, incorrect installation
and inadmissible operational parameters.

Common
failure
message
Menu line Nr.

Error, Name
[Cause; effect / measure]

Default

setting

Value Error

Code

- Voltage spike sensor (short circuit) ON 1

- Pressure sensor > 20mA ON 2

Signal out of sensor range or short circuit, no pressure read-out;
ball valve in cold-leg connection in incorrect position /
Check electrical installation, threaded round connector, sensor
range (4-20mA; 16bar), cold-leg connection, change sensor if
necessary » service;
Error off: self-resetting when error resolved.

- Pressure sensor < 4mA ON 3

Signal below sensor range or not connected,
no pressure read- out /
Check electrical installation, threaded round connector, sensor
range (4 -20 mA; 16 bar), change sensor if necessary » service;
Error off: self-resetting when error resolved.

- Volume sensor > 20mA ON 4

Signal out of sensor range or short circuit, no volume readout /
Check electronic installation, threaded round connection or
sensor range (FSI 1: 150-300; 2: 400-800; 3: 1000-2000; 4:
2500-5000; 5: 6500-10000), change sensor if necessary» service;
Error OFF: self-resetting when error resolved.

Volume sensor < 4mA ON 5

Signal out of sensor range or not connected, no volume read-out/
Check electrical installation, threaded round connector or sensor
range; change sensor if necessary» service;
Error OFF: self-resetting when error resolved.

8-4- 1 Pressure OFF
Minimum working pressure ON (actual pressure):

Default setting has been reached or not achieved;
Ball valve in vessel or cold-leg connection in incorrect position,
insufficient capacity of compressors, improper system layout, or
as consequence of error-no. : 10-16; 15-17; 19; 20; 22-27 /
Check system lay-out, electronic installation, compressors, valve
2; 2.1, leaks in the equipment and system and ball valve;
insufficient capacity diagnosed » service;
Error OFF: self-resetting when error resolved.

P

A

- PA- – 0,3 bar 8

Maximum working pressure ON (actual pressure):
Default setting has been reached or exceeded;
Ball valve in cold-leg connection in incorrect position, improper
system layout, or as consequence of error-no. : 11; 20 /
Check system lay-out, electronic installation, Valve 1; 1.1, valve
silencer, cold-leg connection, ball valve; if necessary » service;
Error OFF: self-resetting when error resolved.

P

A

- PA+ + 0,3 bar 9

8-4- 2 Vessel volume OFF
Minimum vessel volume ON:

Default setting has been reached or not achieved;
Compressor 1; 2 (valve 4,5) is turned OFF; with top-up feature
installed top-up is ON (rising level starting at 0%)/
See error-no.: 19;
Error OFF: self-resetting when error resolved.

5 % 10

Minimum vessel filling volume ON:
Default setting has been reached or not achieved;
Compressor 1; 2 (valve 4, 5) is turned OFF, no pressurisation;
May be followed by error-no.: 8; Execution without top-up feature,
insufficient initial filling or as consequence of error-no. : 22-27 /
Check top-up functioning, leaks in equipment, system lay-out; if
necessary re-fill manually, beware of error-no: 11 !
Error OFF: self-resetting when error resolved.

6 % 19

27

Flexcon® M-K Installation and operating manual

Common
failure
message
Menu line Nr.

Error, Name
[Cause; effect / measure]

Default
setting

Value Error

Code

Maximum vessel filling volume ON:
Default setting has been reached or exceeded;
Valves 1; 2 (3 is OFF) are switched OFF, Compressors 1; 2 (valve
4,5) are not switched ON; no pressure increase or decrease;
error-no.:(8) 9 can be consecutive error; improper system lay-out
of initial filling / Check functioning of valves 1; 2; 3; check valve,
re-calculate expansion volume, drain system water (beware of
error-no.: 19); Error OFF, when error is resolved and reset.

96 % 11

8-4- 3 Bladder rupture (optional) OFF

Bladder rupture sensor ON:
Water at electrodes of conductive sensors;
Compressors 1; 2 and valves 1; 2; 3 (4; 5) are switched OFF, no
pressure increase / decrease or top-up;
Error-no.: 8; 9 can be consecutive errors;
Suspected bladder rupture / open condensate drain valve. If the
opening results in water discharging continuously, the bladder
should be visually checked for ruptures and leaks (Advice: inspect
the vessel internally, which is part of the routine vessel inspection),
clean the inside of the vessel, if necessary » service;
Error OFF, when error is resolved and reset.

20

8-4- 4 Level top-up pump (optional) OFF

Minimum volume level top-up pump ON:
Break tank of top-up unit with insufficient volume level;
Top-up pump is turned off, no top-up function, feed pressure is
too low, feed-valve with insufficient flow rate, may be followed by
error-no.: 8; 10; 19 /
Check feed conditions;
Error OFF: self-resetting when error resolved.

18

8-4- 5

Minimum pressure limiter (optional)

OFF

Minimum pressure limiter ON:
The default setting at pressure limiter has been reached
(limiter has opened); compressors 1; 2 and valves 1; 1.1; 2; 2.1;3
(4; 5) are switched OFF (further pressure decrease will lead to
vapour buil-up in the installation) /
Check functioning of valves 1; 1.1 and check valve, check
equipment and installation for leaks (Error-no.: 8 is ON);
Error OFF, when error resolved (limiter reset) and reset.

17

8-4- 7 Motor runtime OFF

Motor runtime of Compressor 1 exceeded:
Default value has been reached or exceeded; suspected leakage
in equipment or sytem, insufficient pump capacity, ball valve in
vessel or cold-leg connection in incorrect position, improper
system lay-out; may be followed by error-no.: 8 /
Check system lay-out, electronic installation, compressors, leaks
in equipment and installation, ball valves; insufficient pump
capacity diagnosed, » Service;
Error OFF, when error is resolved and reset.

30 Minutes 15

Motor runtime of Compressor 2 exceeded: (see error-no.: 15) 30 Minutes 16

8-4- 8 Motor-circuit switch OFF

SPCx-lw: No current signal to motor ON

Motor 1

SPCx-lw: current-value is not reached, the temperature safety
switch of the motor has been triggered due to elevated working
temperatures, limiter has opened, (winding fault, power or
temperature overload, no motor ventilation, Exception: the power
supply installation of the motor is after signal „motor ON“ not
available or disconnected), may be followed by error-no. 8 /
Ensure that medium and ambient temperature (module) are within
admissible ranges, if necessary supply sufficient ventilation; Check
electronic installation, at recurring error » service;
K01...03 (11...31) Manual reset pos. 29 (Page 11);
Error OFF, when error is resolved and reset

…<0,0 A 12

Motor 2

(see error-no.: 12)

13

SPCx-lw: no current value after signal Motor ON … <0,0 A

ENG

28

Common
failure
message
Menu line Nr.

Error, Name
[Cause; effect / measure]

Default

setting

Value Error

Code

Motor 3; 3.1 (top-up, drainage, optional)

(see error-no.: 12)

14

8-4- 9 Top-up (optional) OFF

Top-up amount too low (pulse water meter, optional)
No pulse from pulse water meter after top-up request;
Valve 3, Motor 3 are switched OFF, feed pressure too low, valves
in incorrect position or not functioning properly, motor 3 with
insufficient pump capacity; Exception: signal leads not installed or
otherwise missing, water meter not functioning properly /
Check electronic installation, component functioning,
restore feed conditions;
Error OFF, when error is resolved and reset.

22

Uncalled-for top-up (pulse water meter, optional)

Pulse received from pulse water meter without request for top-up,
valve 3, motor 3 are switched OFF; Equipment in in flow direction
after the water meter or valve 3 is leaking or fails to close
(incorrect flow direction due to non-return valve blocking) /
Check functioning and leaks in the equipment;
Error OFF, when error is resolved and reset.

23

Minimum cycle distance exceeded 24
Maximum no. of cycles per timeframe exceeded. 25
Maximum top-up cycle amount exceeded (pulse water meter,

optional)

26

Maximum top-up cycle time exceeded 27

8-4- 10 Draining (optional) OFF

Draining amount too low (pulse water meter, optional). No pulse
from pulse water meter after draining request; valve 3.1, Motor

3.1 are switched OFF, feed pressure too low, valve in incorrect
position or not funcitoning properly, motor 3.1 with insufficient or
defective pump capacity; Exception: signal leads not installed or
otherwise missing, water meter not functioning properly /
Check electronic installation, component functioning, restore drain
conditions;
Error OFF, when error is resolved and reset.

28

Uncalled-for draining (pulse water meter, optional)
Pulse to pulse water meter without request for draining; valve 3.1,
motor 3.1 switched OFF; equipment may leak in flow direction
after the water meter or valve 3.1 fails to close (incorrect flow
direction due to non-return valve being blocked) /
Check component functioning, leaks in the equipment;
Error OFF, when error is resolved and reset.

29

8-4- 11 Conditioning (optional) OFF

Amount of additive in conditioning exceeded

55

8-4- 12 Service 1 OFF

Carry out service 1 (equipment service) 365d 56

8-4- 13 Service 2 OFF

Carry out service 2 (inspect vessel internally) 1825d 57

8-4- 14 Service 3 OFF

Carry out service 3 (strength test vessel) 3650d 58

8-4- 15 Service 4 OFF

Carry out service 4 (routine test electronic installation) 584d 59

8-4- 16 Date, time invalid

Backup power for date, time is too small, not available or
incorrect line entry of these data /
Redo or complete entry or when after complete entry error recurs
» service;
Error OFF: self-resetting when error resolved.

OFF 53

29

Flexcon® M-K Installation and operating manual

Restarting

After long periods of downtime:

• If this downtime was planned or scheduled, turn OFF the control unit and close off the ball valve to the system and the isolating
valve to the top-up line. After that decompress the vessel and then drain the water compartment. We recommend you carry out
maintenance before restarting.

• Use the commissioning records for restarting and check especially for system changes that lead to other operating conditions
of the expansion automat (e.g. working pressure).

If the power supply has failed:

• The target parameters and default settings for pressure, aeration and top-up will remain unchanged,
meaning automatic operation will resume automatically when power is restored (power on).
Extraordinary system operating conditions (e.g. cooling to below the default setting) may fall outside
the permitted settings of the expansion vessel.

Caution: please ensure that when the system cools down or warms up, the minimum or maximum
system pressure does not exceed or fall below the permitted operating pressure. Under- and
over-pressure safety for operation of heating or cooling systems are not within the standard scope
of supply with the Flexcon M-K.

Check the automat‘s operation once power supply has been restored and, if necessary, set the actual
date and time values (overview menu options).

8. Maintenance

The following additional or in the project pre-defined maintenance is to be carried out:

Service interval Component,

Standard scope of supply

Service activities, measures

Recommended:
Monthly during
peak sytem
demand; every
two months in
off-peak sytem
demand

Compressor, oil-free 25-28 )* Clean filter element, filter casing, air inlet;

Dry installation required! )a

Main vessel 1)*, Auxilliary vessel )* Drain condensate [34]*; )a

Deaerate water compartment [10]*; )b

)a: This procedure may be required due to special or temporary ambient conditions.
)b: To be conducted especially after initial fillings (not applicable when a float vent [12]* is installed).
When during repeated checks show that the above mentioned measures were not necessary, they are
to be conducted at least annually.

Annually Control unit 35)* Inspect and restore the required default

settings (overview menu options)

Compressor, oil-free 25-28)* Check function. To be carried out manually by

trained and certified personnel e.g. by
changing the working pressure, monitoring
operation during this pressure variation (See
overview menu options, 9-8).

Connection assembly 22-23)* Check function such as compressor, safety

valve through available air-intake equipment.

Equipment expansion automat,
connections, isolation valves

Check for leaks at all the connections to the
vessel at both compressed air- and water
compartments (visually). Check externally for
damage, deformation or corrosion and restore
operational readiness.

* Positions, page 11-13.

!

Message:

Message:

Message:

Message:

Carry out

equipment service!

Inspect vessel

internally!

Consider recurring

inspections, see general

safety instructions.

Carry out strength
inspection vessel!

Carry out recurring

inspection of electrical

equipment!

After completion of

service or planned

inspection the

applicable

service has to

be confirmed.!

Example:

Service 1 is due at:

20.12.2011; it results

in a message at this

day. After completion

of service, it should

be confirmed with the

[enter] key (entry
of date and time

in upper blank line).

ENG

30

Vessel draining / refilling.

If draining of expansion water in the main vessel or auxilliary vessels is necessary, please observe the following actions:

• Record the actual volume level (%) as shown on SPC control unit display.

• Reset to start menu (Overview menu options; menu-line 8-6).

• Switch the control unit OFF.

• Close the ball valve at the expansion line (System connection) and at the vessel connections.

• Carry out the required work on the vessel (drain, service, repair etc.).

• Switch the control unit ON and run start menu procedure (see overview menu options; menu-line 9...9-9).

• Fill the main vessel and (if applicable) the auxiliairy vessels. The self-adjusting volume level can be monitored in the display of
the control unit and the filling process should be interrupted on reaching the previously recorded target value.

Advice: When filling the working pressure should be ca. 1.5 bar below the feed pressure of the feed line, or set as such (see
overview menu options, 9-8). Make sure that in the case of multiple vessels the volume levelling is delayed. Deaerate the water
compartment (Manual bleed valve, pos. 10, page 11; not applicable when automatic air vents are installed).

• Disconnect the filling equipment and check operational readiness.

• If needed reset the value for working pressure (see overview menu options, 9-8 or 8-1-1).

• Open all the previously closed valves (seal).

• Operational mode has been restored.

9. Decommissioning, Dismantling

At the end of the of the lifespan or at planned shut-down of the equipment please make sure that the equipment is turned off and
disconnected from the power supply. The hydraulic system connections and top-up connections (if available) should be closed
off.

Caution: water areas should first be made pressureless and empty when the destination or re-use of system water should be
designated in conformity with the applicable rules. This water may be treated, contain anti-freeze or other substances.

The designation of further processing of the construction parts should be carried out in agreement with the required waste
management service provider.

!

31

Flexcon® M-K Installation and operating manual

Appendix 1: Technical data, information

Ambient conditions

Storage

Room: Protected against: Ambient conditions:

closed;
frost free;
dry.

Sunlight;
Heat radiation;
Vibration.

60…70 % relative humidity, non-condensing;
Max. temperature 50 °C;

Operations room

Room: Protected against: Ambient conditions:

closed;
frost free;
dry.

Sunlight;
Heat radiation;
Vibration.

60…70 % relative humidity, non-condensing;
Temperatures 5 - 40 °C;
Free from conductive gases and combustible
gas mixtures.

Caution:

elevated temperatures may lead to

overload of the compressors.

Minimum distances: clearance for service and repair.

Minimum distances

Volume

[litres]A [mm}B [mm]C [mm]

400
600

800
1000
1200
1600

650

800 500

2000
2800
3500
5000
6500
8000

10000

1000

ENG

32

Installation examples

Flow < = 105 °C

Flow < = 105 °C

Flow < = 105 °C

Return
< = 70 °C

Return
< = 70 °C

Return
< = 70 °C

Heat generator

Heat generator

Heat generator

Standard scope of supply

Optional,
extension

Optional, retrofitting

Top-up feed
potable or
non-potable water

Top-up feed
potable water

Control equipment Flexcon M-K
Compressor unit *
Second compressor unit **
Compressor load balanced operation **
(Paralell operating compressor **)
(Automatic changeover compressor **)
Main vessel *
Bladder rupture sensor *
Flamco- Fill NFE 1.1-MVE2 **
Auxilliairy vessel **
Pressure hose connection **
Flamco- Fill PE **
Pressurisation valve ***

Auxilliairy vessel**

Pressure hose
connection **
(coupling gas
compartment)

Main vessel*

Main vessel*

Main vessel*

Bladder rupture

sensor **

Cap valve

System-

connection

System-

connection

System-

connection

Cap valve

Cap valve

Cap valve

Condensate drain* Condensate drain*

Condensate drain*

Compressed air connection

Condensate drain*

Cap valve

Control components M-K,
compressor unit *

Control components M-K,
compressor unit *; second compressor unit **

Control components M-K,
Pressurisation valve ***

Special order

33

Flexcon® M-K Installation and operating manual

Appendix 2: Technical data, information, hydraulic and pneumatic equipment

Operational values, volume and dimensions

Nominal

volume

Maximum

working

pressure

Maximum

working

tempera-

ture

Maximum

constant

tempera-

ture at

bladder

Vessel

diameter

Display

height

Height Width

B

(mm)

Length System

connec-

tion

[Litres] [bar] [°C] [°C] D

[mm]

H1

[mm]

H2*

[mm]

M-K/U M-K L2

[mm]S[Inches]

400 6 10 120 70 790 1065 1437 1015 860 225 G 1½
600 6 10 120 70 790 1485 1737 1015 860 225 G 1½

800 6 10 120 70 790 1585 2144 1015 860 225 G 1½
1000 6 10 120 70 790 1585 2493 1015 860 225 G 1½
1200 6 10 120 70 1000 1615 2025 1225 1070 100 G 1½
1600 6 10 120 70 1000 1615 2525 1225 1070 100 G 1½
2000 6 10 120 70 1200 1635 2277 1425 1270 0 G 2
2800 6 10 120 70 1200 1635 2877 1425 1270 0 G 2½
3500 6 10 120 70 1200 1635 3677 1425 1270 0 G 2½
5000 3 - 90 70 1500 1600 3550 1765 1615 625 Rp 1½
6500 3 - 90 70 1800 1600 3465 2070 1920 475 Rp 1½
8000 3 - 90 70 1900 1600 3565 2170 2020 425 Rp 1½

10000 3 - 90 70 2000 1600 3985 2270 2120 375 Rp 1½

* H2 with Flexvent Super = H2 + 85 mm

Dry weight of complete equipment [kg]

Nominal
volume

M-K/U M-K

K01 - K03 ** K04 **

Table value
+ 12 kg ***

Table value
+ 25 kg ***

[Litres] 3

bar6 bar

10

bar3 bar6 bar

10

bar3 bar6 bar

10

bar

400 - 90 117 - 166 201 - 77 104
600 - 105 140 - 196 241 - 92 127

800 - 120 165 - 231 271 - 107 152
1000 - 135 190 - 266 321 - 122 177
1200 - 313 418 - 326 431 - 290 395
1600 - 368 508 - 381 521 - 345 485
2000 - 453 618 - 466 631 - 430 595
2800 - 538 758 - 551 771 - 515 735
3500 - 648 938 - 661 951 - 625 915
5000 976 - - - - - 953 - ­6500 1476 - - - - - 1453 - ­8000 1581 - - - - - 1558 - -

10000 1821 - - - - - 1798 - -

** compressor unit

*** second compressor unit

400

Example: M-K/U

Example: MK/U

Top view (with K04)

ENG

34

Compressor unit: nominal characteristics

Type Nominal

voltage

(V)

Nominal

current

(A)

Nominal
capacity

(kW)

Fuse
line protection
(on-site, recommended)

K01

230 V ~1 N PE 50 Hz

4.0 0.55 6 A (C)

K02

230 V ~1 N PE 50 Hz

4.0 0.55 6 A (C)

K03

230 V ~1 N PE 50 Hz

7.5 1.1 10 A (C)

K04

230 V ~1 N PE 50 Hz

7.5 1.1 10 A (C)

Appendix 3: Technical data, information, electrical equipment

sensors

Pressure sensor Volume sensor

pressure

level

brown

blue

blue

Black

Signal -

Signal -

+ 24V / Signal +

+ 24V / Signal +

Plug

blue

blue

black

brown

Plug

Socket Socket

refill / drain

Valve 3**

Valve 1

Pressurisation Pressuris. Discharge. Discharge.

Valve 1.1

Valve 2 Valve 2.1**

Motor

Compressor 1

Feed-in

MAIN

Motor

Compressor 2

Yellow / Green

Blue

Brown

Yellow / Green

Blue

Brown

Yellow / Green

Blue

Brown

Yellow / Green

Blue

Brown

Yellow / Green

Blue

Brown

Yellow / Green

Blue

Brown

Yellow / Green

Blue

Brown

Control unit, terminal plan standard

EU Declaration of Conformity

EU Konformitätserklärung

Manufacturer Flamco BV
Hersteller Amersfoortseweg 9, 3750 GM Bunschoten, the Netherlands

Product description Compressor expansion automat

Produktbezeichnung Kompressor-Druckhalteautomat

Product type Flexcon M-K, M-K/U

Produkt Typ

This declaration of conformity is issued under the sole
responsibility of the manufacturer.

The object of the declaration described above is in conformity
with the relevant Union harmonisation legistation:

Die alleinige Verantwortung für die Ausstellung dieser
Konformitätserklärung trägt der Hersteller.

Der oben beschriebene Gegenstand der Erklärung erfüllt die
einschlägigen Harmonisierungsrechtsvorschriften der Union:

Machinery Directive / Maschinenrichtlinie

2006/42/EC

Pressure Equipment Directive / Druckgeräte-Richtlinie

2014/68/EU

Low Voltage Directive / Niederspannungsrichtlinie

2014/35/EU

EMC Directive / EMV-Richtlinie

2014/30/EU

The conformity of the product described above with the
provisions of the applied Directive(s) is demonstrated by
compliance with the following Standards / regulations:

Die Übereinstimmung des bezeichneten Produkts mit den
Vorschriften der angewandten Richtlinie(n) wird nachgewiesen
durch die Einhaltung folgender Normen / Vorschriften:

EN 61000-6-1 EN 61000-6-3 EN 13831 / AD 2000

Bunschoten, 07.10.2016

Signed for and on behalf of:

/ Unterzeichnet für und im Namen von:

FLAMCO BV B. Houtman

QSHE Manager

35

Flexcon® M-K Installation and operating manual

ENG

36

Flamco B.V.

Amersfoortseweg 9
3751 LJ Bunschoten
Nederland
T [phone]
F [phone]

E info@amco.nl

I www.amco.nl

Copyright Flamco B.V., Bunschoten, the Netherlands.
No part of this publication may be reproduced or published in
any way without explicit permission and mention of the source.
The data listed are solely applicable to Flamco products.
Flamco B.V. shall accept no liability whatsoever for incorrect
use, application or interpretation of the technical information.
Flamco B.V. reserves the right to make technical alterations.

MC00019/20161014