Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
MaintenanceManual
FlexfillerDigitalPressurisationEquipment
FlexfillerModels(125D,225D,150D,250D,280D)
MidiModels(125D,225D,150D,250D)
MiniModels(130D,230D)
Contents
AboutthisManual
ConventionsusedinthisManual
Typography
WheretofindmoreInformation
EquipmentOverview
PrincipalofOperation
Installation
PipeConnections
TypicalInstallationDiagram
FlowRestrictors(Midi&Minimodelsonly)
FlexfillerClearanceandConnectionRequirements
MidiClearanceandConnectionRequirements
MiniClearanceandConnectionRequirements
ElectricalPowerSupply
FaultContacts
PowerFilter
Commissioning
PreCommissioningChecklist
ControllerOverview
ControllerProgramming
HydraulicCommissioning
CommissioningRecord
Operation
FaultCodes
ShutdownProcedure
StartUpProcedure
Troubleshooting
Maintenance
WiringDiagram
ServiceLog
Spares
ElectricalItems(AllModels)
FlexfillerModels(125D,225D,150D,250D,280DS)
MidiModels(125D,225D,150D,250D)
MiniModels(130D,230D)
3
3
3
3
4
4
5
5
5
6
7
8
9
10
11
12
13
13
14
15
19
24
25
25
26
26
27
30
32
33
35
35
36
37
38
AboutthisManual
ThisOperationandMaintenanceManualcontainsallthenecessaryinformationtoinstall,
commission,operateandmaintainFlexfillerpressurisationequipment.
Itisrecommendedtoreadallpartsofthismanualbeforeundertakinganyworkontheequipment.
ConventionsusedinthisManual
Thismanualmakesuseofsymbolstoidentifykeypiecesofinformation.Pleasetakenoteofthe
followingsymbolsandtheirmeaning:
DANGERImportantsafetyrelatedinformationintendedtopreventinjuryand/or
damagetotheequipment,systemorproperty.
CAUTIONImportantinformationintendedtopreventdamagetotheequipment,
systemorproperty.
IMPORTANTImportantinformationintendedtoensurethattheequipmentfunctions
correctly.
USEFULUsefulinformationwhichmaybehelpful,butisnotnecessarilyrequiredfor
theunittofunctioncorrectly.
Typography
Thismanualmakesuseofdifferenttypographytoidentifydifferenttypesofinformation.
Italics
(RoundBrackets)
[SquareBrackets]
<InequalitySymbols>
Keywordsandphrases
Usedtoidentifyabuttononthedigitalcontroller
Aparameteronthedigitalcontroller
Amessage/faultcodedisplayedonthedigitalcontroller
WheretofindmoreInformation
ForfurtherinformationpleasevisittheFlamcoLimitedWebsiteatthefollowingURL:
www.flamco.co.uk
Alternatively,pleasecontacttheFlamcoLimitedheadofficeusingthedetailsbelow:
Phone:
Fax:
Email:
01744744744
01744744700
info@flamco.co.uk
EquipmentOverview
Thefunctionofthispressurisationunitistoprovideameansofautomatedwatertopuptosealed
heatingandcoolingsystems.Theequipmentisdesignedtoprovideperiodicwatertopupto
compensateforminorlossesinsystempressure(e.g.slowleaks,airventing,etc.).
Thisequipmentisnotdesignedtocopewithsuddenlossesofsystempressure(e.g.
manualdraining)ormajorwaterlosses(e.g.largeleaks).Theequipmentisalsonot
intendedtobeusedforwaterboostingapplications.
PrincipalofOperation
Thefollowingschematicshowstheinternalarrangementofapressurisationunit:
Thepressurisationunitisfittedwithabreaktank(1)whichisfilledfromthemainswatersupply(2)
viaafloatoperatedvalve(3).Thebreaktankisfittedwithanoverflow(4)incasethebreaktank
overfills,andaweiroverflow(5)incasetheprimaryoverflowfails.
Thepressurisationunitisconnectedintotheheatingsystem(6)viaanisolationvalve(7).
Thepressuresensor(8)monitorsthesystempressure.
Ifthepressuresensordetectsadropinpressure,thepump(9a)willpumpwaterfromthebreaktank
intothesystem.Oncetherequiredpressurehasbeenreached,thepumpwillstop.
Ontwinpumpmodels,asecondpump(9b)isprovided.Thetwopumpswillruninaduty/standby
configuration(i.e.theactivepumpwillalternatewitheachpumpstart).
Thepump(s)arefittedwithnonreturnvalves(10a,10b)topreventbackflow.
Adrainvalve(11)isprovidedfordrainingdowntheunitandforcommissioningpurposes.
Installation
Thispressurisationunitisnotdesignedtobeinstalledinanoutdoorenvironment.The
unitmustbeinstalledinafrostfreeenvironment,awayfromprecipitationandwater
sprays/jets.Ifthereisariskofflooding,theunitmustbeinstalledonaraisedplinth.
Pleaserefertotheappropriatedatasheetforthemaximumworkingpressureand
temperatureofthepressurisationunit.Theconditionsatthepointofconnectionto
thesystemmustnotexceedthesevalues.
PipeConnections
Toavoiddamagingthefloatvalve,themainswatersupplypipemustbeflushedbefore
connectiontothepressurisationunit.
Allpipeconnectionsmustbemadewithappropriatejointingcompound/PTFEtape.
IfPTFEtapeisused,caremustbetakentoensurethatthetapedoesnotobstructthe
orificeofthefitting.
Nonreturnvalves,pressurereducingvalvesandRPZvalvesmustnotbeinstalled
betweenthepressurisationunitandtheheating/coolingsystem.Thesedeviceswill
preventthepressuresensorfromreadingthesystempressure.
Thepressurisationunitandexpansionvesselshouldbeconnectedtothesystematthe
samepoint,toprovideaneutralpressurereading.Thispointofconnectionshouldbe
inthesystemreturn,onthesuctionsideofthecirculationpump.
TypicalInstallationDiagram
FlowRestrictors(Mini&Midimodelsonly)
Pressurisationequipmentfittedwithaplastic,sideentrytorbeckvalvemustbefitted
withafilteranddependingonthemainswaterpressureaflowrestrictor.Failure
todothismayresultindamagetotheequipment.
Twodifferentflowrestrictorsaresuppliedwiththeequipment,bothofwhichincludeanintegral
filter.Theselectionoftheappropriateflowrestrictorisbasedonthemaximummainswater
pressureatthepointofinstallation.Pleaserefertothefollowingtableforselection.
MainsWaterPressure
14Bar
Above4Bar
Requirement
LowPressureRestrictor(coloured)
HighPressureRestrictor(white)FactoryFitted
Ifnorestrictorisrequired,thefiltermustberemovedfromoneoftherestrictorsandinstalledonits
own.Thefollowingdiagramshowshowtoremovethefilter:
Toinstalltheflowrestrictor/filter,holditbythetabandpushitintotheopeningofthefloatvalve
connection,asshowninthediagrambelow:
FlexfillerClearanceandConnectionRequirements
Connection
Size
Notes
Anisolationvalvemust
Mains
BSPM beinstalledonthemains
WaterFeed
waterfeedforservicing.
Guidanceondrainage
requirementsshouldbe
BreakTank
22mm
obtainedfromthelocal
Overflow
waterauthority.
Thepressurisationunit
andexpansionvessel
shouldbeconnectedto
thesystematthesame
point.
Thepointofconnection
System
BSPM shouldbeinthesystem
Connection /15mm return,onthesuction
sideofthecirculation
pump.
Nonreturnvalves,
pressurereducingvalves
andRPZvalvesmustnot
beused.
MidiClearanceandConnectionRequirements
Connection
Notes
Anisolationvalvemust
Mains
BSPM beinstalledonthemains
WaterFeed
waterfeedforservicing.
Guidanceondrainage
BreakTank
requirementsshouldbe
22mm
Overflow
obtainedfromthelocal
waterauthority.
Thepressurisationunit
andexpansionvessel
shouldbeconnectedto
thesystematthesame
point.
Thepointofconnection
System
BSPM shouldbeinthesystem
Connection /15mm return,onthesuction
sideofthecirculation
pump.
Nonreturnvalves,
pressurereducingvalves
andRPZvalvesmustnot
beused.
Size
MiniClearanceandConnectionRequirements
Connection
Notes
Anisolationvalvemust
Mains
BSPM beinstalledonthemains
WaterFeed
waterfeedforservicing.
Guidanceondrainage
requirementsshouldbe
BreakTank
22mm
obtainedfromthelocal
Overflow
waterauthority.
Thepressurisationunit
andexpansionvessel
shouldbeconnectedto
thesystematthesame
point.
Thepointofconnection
shouldbeinthesystem
System
BSPF
return,onthesuction
Connection
sideofthecirculation
pump.
Nonreturnvalves,
pressurereducingvalves
andRPZvalvesmustnot
beused.
Size
ElectricalPowerSupply
Thisequipmentmustbeelectricallyisolatedbeforeremovingthecovers.Cables
connectedtothevoltfreecontactsmaybesuppliedfromanothersourceandmay
remainliveaftertheunitisisolated.Thesemustbeisolatedelsewhere.
Allelectricalconnectionsmustbecarriedoutbyasuitablyqualifiedandcompetent
person.
Themainspowersupplytothepressurisationunitmustbeconnectedintothefusedterminalblock
asshownbelow:
Onsomelargermodels,thefusedterminalblockisreplacedbyafusedspur.Ifthisisthecase,the
powersupplymustbeconnectedintothefusedspur,asshownbelow:
Itisrecommendedtosupplypowertothepressurisationunitviaalockableisolator.
Thisshouldbeinstalledwithin2moftheequipment.
Thisequipmentcanbedamagedbythehighvoltagesproducedbyelectrical
installationtestingequipment.Whenperformingelectricalinstallationtests,the
equipmentmustbeisolatedfromthesupply.
10
FaultContacts
Thereare6voltfreefaultcontactswhichcanbeusedforconnectiontoaBMSsystem,orasaboiler
interlock.Theseareterminals112,locatedonthedigitalcontroller:
WiththeexceptionoftheCommonAlarm,itispossibletoconvertallotherfault
contactstonormallyclosed.Forfurtherinformationpleaserefertothecommissioning
sectionofthismanual.
11
PowerFilter
ThedigitalcontrollercanbeadverselyaffectedbyEMIandpowerspikes.Apower
filtermayberequiredifthesupplytotheequipmentisunstable(e.g.frequentpower
cuts),sharedbyequipmentwhichgenerateshighlevelsofEMI(e.g.inverters,IT
equipmentetc.)orisfittedwithabackupgenerator.
Ifrequired,apowerfiltercanbepurchasedseparatelyusingproductcodeFC100.
Thepowerfiltermustbeconnectedbetweenthetransformerandthedigitalcontroller,onthe
12VACline,asshowninthediagrambelow:
Becausethefilterisinstalledonthesecondarysideofthetransformer,thepolarityofthe
connectionsdoesnotmatter.
Forthefiltertofunctioncorrectly,thePELINEterminalmustbeconnectedtothe
chassiscommonearthpoint
12
Commissioning
ItishighlyrecommendedtohavethisequipmentcommissionedbyaFlamcoapproved
engineer.Anydamageorlossincurredthroughincorrectcommissioningbyan
unapprovedengineerwillnotbecoveredbythewarranty.
PreCommissioningChecklist
Thefollowingconditionsmustbemetbeforestartingthecommissioningprocess.
Failuretomeettheseconditionsmayresultininjuryordamagetotheequipment,
systemandproperty.
Equipmentissitedinafrostfreearea,awayfromprecipitationandwatersprays/jets
Allnecessarypipe/electricalconnectionshavebeenmadetoasatisfactorystandard
Thetemperatureandpressureatthepointofconnectionarewithintheoperatinglimitsof
thepressurisationunit.
Theheating/coolingsystemisfittedwithasafetyvalveandexpansionvessel
Thefollowingconditionsmustbemetforthepressurisationunitandheating/cooling
systemtofunctioncorrectly.Iftheseconditionshavenotbeenmet,itisnotadvisable
toproceedwiththecommissioningprocess.
Thesystemconnectionhasbeenmadeintothesystemreturnheader/pumpsuction
Therearenononreturnvalves,pressurereducingvalvesorRPZvalvesinstalledbetweenthe
pressurisationunitandtheheating/coolingsystem
Theexpansionvesselisprechargedtothecorrectpressure(equaltofillpressure)
Itisadvisabletofilltheheating/coolingsystempriortocommissioning.Ifthisisnot
possible,thepressurisationunitcanbeusedtofillthesystemaftercommissioning.
Dependingonthesizeofthesystem,thismaytakeaconsiderableamountoftime.
Theheating/coolingsystemisfilledandpressurisedtotherequiredcoldfillpressure,with
thewateratambienttemperature(approximately).
13
ControllerOverview
Thefollowingimageshowsthefrontofthepressurisationunitdigitalcontroller.4buttonsare
providedforprogramming,andanLEDdisplaywhichshowsscrollingmessages.
Whenthecontrollerisfirstpoweredup,itwilldisplaythecontrollerversionnumber.
Thismanualrelatestocontrollerversion6.3.Ifthecontrollerisofadifferentversion,
theremaybedifferencesinthemenuitemsavailable.
OldControllerDesign
Onoldermodels,thedesignofthedigitalcontrollerisvisualydifferent.Theinternal
componentsareidenticalandthebuttonfunctionsremainthesame.
Theoldcontrollerdesignisshownbelow:
Wheninnormaloperation,thecontrollerwilldisplaythecurrentsystempressure.Ifafaultoccurs,
thecontrollerwilldisplayafaultcodeandproduceanaudiblealarm.
Innormaloperation,thefunctionsofthebuttonsareasfollows:
Button
SET
MUTE
+
14
Function
Press
MuteAudibleAlarm
Hold
ShowCurrentSystemPressure
ResetUnit
EnterProgrammingMenu
ControllerProgramming
Donotalteranysettingswithoutfirstunderstandingtheimplicationsofdoingso.
Incorrectsettingsmaycausedamagetotheequipment,systemorproperty.
Toentertheprogrammingmenu,holdthe(+)buttonuntilentercodeappearsonthescreen,
followedby0000withaflashingcursorafterthefirstdigit.
Togainaccesstotheprogrammingmenu,oneofthefollowingcodesmustbeentered:
CustomerCode
EngineerCode(V6.3)
EngineerCode(<V6.3)
Standardsetofoptions
Extendedsetofoptions
Extendedsetofoptions
2601
4706
0426
Toenterthecode,changethefirstdigitwiththe(+)and()buttons,thenpress(SET)tomoveonto
thenextdigit.Repeatforalldigits,thenoncethecorrectcodeisshownonthedisplay,press(SET)to
entertheprogrammingmenu.
Onceacorrectcodehasbeenentered,thefirstoption[COLDFILL]willappearonthescreen.
Onceinthemenu,thevalueofthecurrentmenuitemcanbechangedusingthe(+)and()buttons.
Oncethecurrentvaluehasbeenset,pressingthe(SET)buttonwillmoveontothenextoption.
Itisnotpossibletonavigatebackwardsthroughthemenu.Toreturntoaprevious
settinginthemenu,pressthe(SET)buttonrepeatedlytoscrollthroughtotheendof
themenu,andthenreentertheappropriatecode.
Ifthecontrollerloosespowerwhileintheprogrammingmenu,allchangesmadewill
beerased.Toconfirmallchanges,theendofthemenumustbereached,andthe
SAVING...messagemustbedisplayed.
15
Thetablebelowgivesdetailsofallmenuitems,intheorderthattheywillappear:
#
MenuItem
COLDFILL
HIGHSET
LOWSET
DIFFERENTIAL
FLOODLIMIT
PUMP1COUNT
PUMP1HOURS
Function
Therequiredfillpressure,i.e.pumpcutoutpressure.
Therecommendedsettingis0.3BARabovethestaticpressure
ofthesystem(0.1Barpermeterofstaticheight).
Forexample,a14mhighinstallationwillhaveastaticpressure
of1.4Bar,makingtherecommendedcoldfillpressure1.7Bar.
Itisnotpossibletoenteravaluehigherthanthecurrent[HIGH
SET]orlowerthanthecurrent[LOWSET]values.
Thehighpressurealarmsetting.
Ifthepressureinthesystemreachesthisvalue,the<HIGH
PRESSURE>alarmandcommonalarmwillbeactivated.
Therecommendedsettingis10%belowthesafetyvalverating.
Forexample,ifthesafetyvalveratingis3Bar,the
recommendedsettingis2.7Bar.
Itisnotpossibletoenteravaluelowerthanthecurrent[COLD
FILL]value.
Thelowpressurealarmsetting.
Ifthepressureinthesystemfallsbelowthisvalue,the<LOW
PRESSURE>alarmandcommonalarmwillbeactivated,andthe
pressurisationpumpswillnotrun.
Therecommendedsettingis0.5Barbelowthe[COLDFILL]
pressure.
Itisnotpossibletoenteravaluehigherthanthecurrent[COLD
FILL]value.
Thedifferentialbetweenthecutinandcutoutpressuresof
thepressurisationpumps.
Thecutinpressurewillbeequaltothe[COLDFILL]pressure,
minusthedifferentialpressure.
Forexample,ifthe[COLDFILL]pressureissetto1.5bar,and
thedifferentialsetto0.2Bar,thepumpcutinpressurewillbe
1.3Bar(1.50.2=1.3)
Themaximumcontinuousruntimeforeachofthe
pressurisationpumps.
Ifapumprunscontinuouslyforlongerthanthisperiod,the
pumpwillstopanda<FLOODLIMIT>alarmwillbeactivated.
Thisistopreventtheunitfrompumpinglargeamountsof
waterintheeventofalargeleak/burstpipe.
Forverylargesystems,thismayneedtobeincreased.
Thevaluecanbechangedinincrementsof10minutes,toa
maximumof990.
Thecumulativenumberofpumpstartsforpump1.
Thisisacumulativecounter,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Thecumulativeruntimeinhoursforpump1.
Thisisacumulativetimer,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
16
Default
Value
1.0Bar
2.7Bar
0.5Bar
0.2Bar
10MINS
MenuItem
PUMP2COUNT
PUMP2HOURS
10
ALARMCOUNT
11
POWER
INTERRUPTED
12
PULSE
13
EXCESSIVE
START
14
SERVICE
15
FILLSYSTEM
Function
Thecumulativenumberofpumpstartsforpump2.
Thisisacumulativecounter,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Thecumulativeruntimeinhoursforpump2.
Thisisacumulativetimer,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Thecumulativenumberofallalarmincidents.
Thisisacumulativecounter,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Thecumulativenumberofpowerinterruptions(i.e.controller
turnedoff/powercut).
Thisisacumulativecounter,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Whenenabled,ifapumphasbeeninactivefor60days,itwill
startandrunfor2seconds.
Thisistopreventthepumpsfromseizing.
Whenenabled,iftherearemorethan3individualpumpruns
withinan8hourperiod,theunitwillregisteran<EXCESSIVE
DEMAND>alarm.
Enablingthisoptionmaycausefalsealarmsonsomesystems.
Whenenabled,aservicereminderwillbedisplayedafter12
monthsfromwhentheoptionwasenabled.
Toresettheservicereminder,setthevaluetoNOandexitthe
menu.Then,reenterthemenuandsetthevaluetoYESagain.
Whenenabled,the<LOWPRESSURE>and<FLOODLIMIT>
alarmswillbedisabled,andpump1willruncontinuouslyforup
to24hoursuntilthecoldfillpressurehasbeenreached.
Oncethecoldfillpressurehasbeenreached,thisoptionwill
automaticallybedeactivated,andthelowpressurealarmand
floodlimitwillbereactivated.
Thisfunctionisusedtofillasystemthatisemptyoratlow
pressure.
Caremustbetakenusingthisoptionasthefloodlimitalarmis
disabled,increasingtheriskofflooding.
ThisoptioncannotbeenabledonMinipressurisationunits.
Default
Value
NO
NO
NO
NO
Ifusingthecustomercode,themenuwillendatthispoint.Afterpressing(SET)once
more,thecontrollerwilldisplaySAVING...andreturntonormaloperatingmode.If
usingtheengineerscode,additionalmenuitemswillbedisplayed.
Thefollowingsettingsareallpreprogrammedinthefactoryandshouldnotneedto
bemodifiedonsite.Ifthesesettingsappeartohavebeenreset,themostlikelycause
isapowerspike.Ifthisproblempersists,apowerfiltermayberequired.
17
Thefollowingsettingsareforexperiencedengineersonly.Incorrectconfigurationof
thesesettingscancausetheequipmentnottofunctioncorrectly,andmaycause
damagetotheequipment,systemorproperty.
MenuItem
16 PUMPSNUMBER
17
PUMPTYPE
18
PUMPSENSE
19
SENSORTYPE
20
SPC
CONTROLLER
21
GLYCOLUNIT
22
IDNUMBER
23
RELAY
INVERSION
24
OVERRUN
25
PRESSURE
ALARMAUTO
RESET
26
CASCADE
27
BOOST
28
FLOMAT
18
Function
Thenumberofpumpsinstalledinthepressurisationunit.
Thiscanbesettoeither1or2.
Thetypeofpumpinstalledinthepressurisationunit.
Therearetwooptions,whichareasfollows:
0CentrifugalPump
1PistonPump(miniunitsonly)
Disablingthisoptionwillstopthecontrollerfrommonitoring
thepumpsandgenerating<PUMPFAIL>faults.
Itisnotrecommendedtodisablethisoption.Pleaseconsult
FlamcoTechnicalbeforedoingso.
Thetypeofpressuresensorinstalledintheunit.
Therearefouroptionswhichareasfollows:
005VOutput,010BarRange
116VOutput,010BarRange
216VOutput,016BarRange
3
EnablesthelinktotheFlamcoSPCcontroller.
Thisoptionshouldonlybeenabledonpressurisationunits
whicharelinkedtoanSPCcontroller,whicharefoundon
FlamcomatandMKautomatequipment.
Enablesthelowglycollevelswitch.
Thisoptionshouldonlybeenabledonglycolpressurisation
units.
Auserconfigurableidentificationnumber.
Thisoptiondoesnotserveanyfunctionalpurpose.
Whenenabled,allnormallyopenfaultcontacts(i.e.allexcept
thecommonalarm)areconvertedtonormallyclosed.
Allowsthepumptocontinuerunningforasetperiodoftime
aftertherequiredpressurehasbeenreached.
Thiswillpreventthepumpsfromhunting.
Thevaluecanbesetfrom010seconds.
Whenenabled,the<HIGHPRESSURE>and<LOWPRESSURE>
alarmswillbeclearedautomaticallyifandwhenthepressure
returnstonormal.
Ifdisabled,thealarmsmustbemanuallyreset.
Allowsthepumpstooperateinduty/assistmode.
Aftereitherpumpstarts,theotherpumpwillstartafteraset
periodoftime.
ThisoptioncanbesettoOFF,or530seconds.
Whenenabled,thecontrollerwillallowingthepumpstorun
evenifthesystempressureiszero.
Whenenabled,thehighwaterinputisusedtotriggeratop
upsolenoidvalveconnectedtothesensorhealthyvoltfree
contact.
Thisoptionshouldonlybeenabledonunitswhichutilizea
solenoidvalveasthemeansoftopup.
Default
Value
2
YES
NO
NO
12
NO
YES
OFF
YES
NO
HydraulicCommissioning
1FloatValveSetting
Ensurethatthebreaktankfloatvalveissettoitslowestposition:
FlexfillerUnits
Mini&MidiUnits
Ifadrainvalveisfittedtothebreaktank,ensurethatitisclosed.Then,turnonthemainswater
supplyandallowthebreaktanktofill.
Whenthefloatvalveoperatesforthefirsttime,itmaynotcloseimmediately,causing
thebreaktanktooverfill.Oncetheinternalsofthevalvehavebeenfullywettedthis
shouldnotoccuragain.
2BleedingPumps
ThisstepisonlynecessaryforFlexfillerandMidiunits.ForMiniunits,moveontothenextstep.
Makesurethattheinternalisolationvalvewithinthepressurisationunitisclosedby
followingthestepsbelow.Failuretodothismaycauseinjuryordamagetothe
equipment,systemorproperty.
19
Attachalengthofhosetothehosetailonthedrainvalveandputtheotherendtodrain.Then,using
thecapofftheisolationvalve,openthedrainvalve:
Locatethebleedscrewonthepump.Thefollowingdiagramsshowexamplesoftypicalbleedscrew
locationsformostpumps:
Donotuseexcessiveforcewhentighteningthebleedscrewasthismaydamagethe
pumpcasing.
20
Ifthepumphasaplasticbleedscrewliketheoneshownbelow,donotuseexcessive
forceorattempttouseanytoolstoturnitasthismaydamagethepumpcasing.
ForcingPumpstoRun
Turnonthepowersupplytothedigitalcontrollerandwaitforthesystempressureto
appearonthedisplay.Then,enterthecode2601andgotothefirstsettinginthe
menu,coldfill.Whileatthispointinthemenu,holdingdownthe(MUTE)buttonwill
forcepump1torun,andholdingdownthe(SET)buttonwillforcepump2torun.
IfthecontrollerisolderthanV6.1thenthereisnowaytoforcepump2torunviathe
controller.Toforcethesecondpumptorun,theunitmustbeisolatedandthelive
wiresinterminals13and14mustbeswappedover.Thesecondpumpthenbecomes
pump1andcanbeforcedtorunviathecontroller.
Tobleedthepumps,thepumpsmustbestarted.Thenwhilethepumpisrunning,the
bleedscrewmustbeopeneduntilalltheairhasbeenremovedandonlywaterisbeing
discharged.Thebleedscrewcanthenbeclosed.
Failuretobleedthepumpsmayresultindamagetotheequipment,systemand
property.
Afterbleedingthepumps,closethedrainvalveandremovethehosefromthehose
tail.
21
3InitialStartup
Opentheinternalisolationvalvewithinthepressurisationunitbyfollowingthestepsbelow:
Flexfiller&MidiUnits
MiniUnits
Oncetheisolationvalveisopen,thepressuresensorwillbeabletoreadthesystempressure.
Turnonthepowersupplytothepressurisationunit.Dependingonthecurrentsystempressure,the
unitwillrespondinoneofthefollowingways:
Ifthesystempressureisbelowthelowpressurealarmsetting,thecontrollerwill
displayaLOWPRESSUREfaultandthepumpswillnotrun.Toclearthisfault,either
increasethesystempressureusingafillingloop,orenablethesystemfilloptionon
thepressurisationunit.
Ifthesystempressureisabovethehighpressurealarmsetting,thecontrollerwill
displayaHIGHPRESSUREfault.Toclearthisfault,useasuitabledrainpointto
removewaterfromthesystemuntilthesystempressureequalsthecoldfillpressure.
Ifthesystempressureisabovethelowpressurealarmsetting,butbelowthecoldfill
setting(byanamountequaltothedifferentialsetting),thepumpswillstart.Oncethe
systempressurehasreachedthecoldfillpressure,thepumpwillstop.
Oncetherequiredsystempressurehasbeenreached,thecontrollerwilldisplaythecurrentsystem
pressure.Theunitisnowinnormaloperation.
22
4Testing
Totesttheoperationofthepressurisationunitwhileconnectedtothesystem,thesystempressure
mustbeloweredslowlytosimulateaminorleak.
Thiscanbeachievedbyusingadrainpointonthesystem,thedrainpointonthepressurisationunit,
orbymanuallyopeningthesafetyreliefvalve.
Caremustbetakennottoletthepressuredroptooquickly.Ifthesystempressure
fallsbelowthelowpressuresetpoint,alowpressurefaultwillbedisplayedandthe
pumpswillnotrun.Thepressurisationunitisnotdesignedtocopewithasuddenloss
ofsystempressure,whichwouldbesymptomaticofacatastrophicfailuresuchasa
burstpipe.
Oncethesystempressurehasfallenbelowthecoldfillsetting(byanamountequaltothe
differentialsetting),thepumpshouldstartrefillingthesystem.Thepumpwillcontinuetorununtil
thecoldfillpressurehasbeenreached.
Thistestdemonstratestheprimaryfunctionofthepressurisationunit.Thistestmayberepeatedat
anytimetoconfirmtheoperationofthepressurisationunit.
23
CommissioningRecord
SiteReference:
PUReference:
EngineerName:
SiteContactName:
Company:
/ /
DateCommissioned:
ContactNo.:
YES/NODeleteasappropriate
FlamcoAccredited:
ContactNo.:
COLDFILL:
HIGHSET:
LOWSET:
DIFFERENTIAL:
FLOODLIMIT:
Bar
Bar
Bar
Bar
Minutes
PUMP1COUNT:
YES/NO
Deleteasappropriate
YES/NO
Deleteasappropriate
YES/NO
Deleteasappropriate
1/2
Deleteasappropriate
IDNUMBER:
Deleteasappropriate
0/1/2
GLYCOLUNIT:
Deleteasappropriate
0/1
SPCCONTROLLER:
RELAYINVERSION:
YES/NO
Deleteasappropriate
OVERUN:
POWERINTERRUPTED:
SENSORTYPE:
ALARMCOUNT:
PUMPSENSE:
PUMP2HOURS:
PUMPTYPE:
PUMP2COUNT:
Deleteasappropriate
PUMPSNUMBER:
PUMP1HOURS:
YES/NO
FILLSYSTEM:
PRESSUREALARMAUTORESET:
PULSE:
YES/NODeleteasappropriate
EXCESSIVESTART:
YES/NODeleteasappropriate
YES/NO
Deleteasappropriate
CASCADE:
SERVICE:
YES/NODeleteasappropriate
BOOST:
FLOMAT:
YES/NO
Deleteasappropriate
YES/NO
Deleteasappropriate
COMMENTS:
EngineerSignature:
CustomerSignature:
24
Dated:
/ /
/ /
Dated:
Operation
Oncecommissioned,thepressurisationunitshouldoperatewithoutanyuserintervention.
Undernormaloperatingconditions,thedisplaywillshowthecurrentsystempressureinBar.
Whiletheunitisfilling,thedisplaywillshow<PUMP1RUN>or<PUMP2RUN>dependingonwhich
pumpiscurrentlyrunning.
Iftheunitidentifiesafault,thedisplaywillshowtherelevantfaultcode.
Ifthepressurisationunitisshowingafaultcodeonthedisplay,holdingdownthe[SET]
buttonwillcausethecurrentsystempressuretobetemporarilyshownonthedisplay.
FaultCodes
Thefollowingtablegivesthemeaningsofallfaultcodesusedonthedigitalcontroller:
FaultCode
LOWPRESSURE
HIGHPRESSURE
Description
Thesystempressureisbelowthe[LOWPRESSURE]set
point.
Thesystempressureisabovethe[HIGHPRESSURE]set
point.
Thebreaktanklowlevelfloatswitchhasbeenactivated
Thebreaktankhighlevelfloatswitchhasbeenactivated
Thecontrollerhasdetectedafault(incorrectcurrentdraw)
ontherespectivepump
Therespectivepumphasrunforlongerthanthe[FLOOD
LIMIT]period
Thesignalfromthepressuresensorisoutofrange
Thelowglycolswitchhasbeenactivated(glycolunitsonly)
Therehavebeen4pumpstartswithinan8hourperiod
Thepressurisationunitisdueanannualservice
Auto/Manual
Reset
UserDefined
UserDefined
LOWH20
AutoReset
HIGHH20
AutoReset
P1FAIL
ManualReset
P2FAIL
P1FLOODLIMIT
ManualReset
P2FLOODLIMIT
ERR.1
ManualReset
LOWGLYCOL
AutoReset
EXCESSIVEDEMAND
ManualReset
SERVICE
ManualReset
Forpracticalguidanceondiagnosingandrectifyingfaults,pleaserefertothe
Troubleshootingsectionofthismanual.
25
ShutdownProcedure
Thepressurisationunitmustbeshutdownduringanyofthefollowingscenarios:
Workisbeingcarriedoutonthesystem.
Workisbeingcarriedoutonthepressurisationunit
Theheating/coolingsystemisbeingflushed
Toshutdownthepressurisationunit,pleasefollowthestepsbelow:
1. Isolatetheelectricalpowersupplytothepressurisationunit
2. Isolatethemainswatersupplytothepressurisationunit
3. Isolatethepressurisationunitfromthesystemusingtheinternalisolationvalve
4. Ifitisanticipatedthattheunitwillbeoutofcommissionformorethan24hours,itis
advisabletodrainthewaterfromthebreaktank.
StartUpProcedure
AttentionThisprocedureisforrestartingtheunitafterbeingshutdown(asdescribed
above).Forinitialstartupandcommissioningprocedures,pleaserefertothe
Commissioningsectionofthismanual.
Torestartthepressurisationunit,pleasefollowthestepsbelow:
1. Performavisualinspectionoftheunitandinstallationtocheckforsignsofdamage
2. Checkthebreaktankfordebris/depositsandremoveifnecessary
3. Turnonthemainswatersupplytothepressurisationunitandallowthebreaktanktofill
4. Opentheinternalisolationvalve
5. Turnonthemainspowersupplyandwaitforthecontrollertostart
6. Dependingontheconditionsinthesystem,theunitmaydisplayoneormorefaultcodesat
thispoint.Ifthishappens,pleaserefertotheTroubleshootingsectionofthismanualfor
guidance.
26
Troubleshooting
Ifforanyreasonthepressurisationunitdoesnotseemtobefunctioningcorrectly,pleasereferto
thetablebelowforalistofsolutionstoknownproblems.
Ifthepressurisationunitisshowingafaultcodeonthedisplay,holdingdownthe[SET]
buttonwillcausethecurrentsystempressuretobetemporarilyshownonthedisplay.
Symptom
LOWPRESSUREfaultis
displayedandthepumpsdo
notrun
HIGHPRESSUREfaultis
displayed
Problem
Solution
Theinternalisolationvalve
withintheunitisclosed
Opentheinternalisolation
valve
Thesystempressurehasfallen
belowtheLOWPRESSUREset
point
Increasesystempressureusing
afillingloop,orenablethe
SYSTEMFILLoption
TheSPCCONTROLLERoptionis
enabled
DisabletheSPCCONTROLLER
option
TheLOWPRESSUREsetpointis
toohigh
Reviewthesystem
specifications
Theinternalisolationvalve
withintheunitisclosed
Opentheinternalisolation
valve
Thesystempressurehasrisen
abovetheHIGHPRESSUREset
point
Decreasesystempressureusing
asuitabledrainpoint
Theexpansionvesselhasfailed
orlostitsprecharge
Checktheexpansionvesselpre
chargeandrechargeif
necessary
Theexpansionvesselis
undersized
Reviewtheexpansionvessel
selection
TheHIGHPRESSUREsetpointis Reviewthesystem
toolow
specifications
Alargeamountofwaterhas
beenlostfromthesystem
P1and/orP2FLOODLIMITis
displayed
Investigatecause
Therelevantpumpisairlocked
Bleedthepump
andnotpumpingwater
Theunitisundersizedforthe
system
Reviewunitselection
TheFLOODLIMITtimeistoo
short.
ConsultFlamco
27
Symptom
P1and/orP2FAILisdisplayed
Problem
ThePUMPTYPEoptionisset
incorrectly.
ReviewPUMPTYPEsetting
Therelevantpumphasfailed
Replacepump
P2FAILisdisplayedbuttheunit ThePUMPSNUMBERoptionis
isasinglepumpmodel
incorrectlysetto2
LOWH20faultisdisplayed
HIGHH20faultisdisplayed
Solution
SetPUMPSNUMBERto1
Themainswatersupplytothe
unithasbeenisolated
Turnonthemainswatersupply
Themainspressureispoor
Thefaultwillclearoncethe
breaktankhasbeenrefilled
Anonstandardelectrical
Removeallnonstandard
connectionhasbeenmadeinto
electricalconnections
terminals19&20
Thelowwaterfloatswitchhas
failed
Replacelowwaterfloatswitch
Thedigitalcontrollerhasfailed
Replacedigitalcontroller
Anonstandardelectrical
Removeallnonstandard
connectionhasbeenmadeinto
electricalconnections
terminals21&22
Thedigitalcontrollerhasfailed
Replacedigitalcontroller
Theinternalisolationvalve
withintheunitisclosed
Opentheinternalisolation
valve
TheSENSORTYPEoptionisset
incorrectly
ReviewSENSORTYPEsetting
Anonreturnvalvehasbeen
installedbetweentheunitand
thesystem
Removenonreturnvalve
Thepressuresensorhasfailed
Replacepressuresensor
TheSENSORTYPEoptionisset
incorrectly
ReviewSENSORTYPEsetting
Thepressuresensorhasfailed
Replacepressuresensor
Pumprunsbutdoesnotmake
uppressure
Thepumpisairlockedandnot
pumpingwater
Bleedthepump
Thepumpispersistently
becomingairlocked
Thewrong/noflowrestrictoris
installedinthefloatvalve(mini
andmidiunitsonly)
Checkfloatvalveflowrestrictor
selection(miniandmidiunits
only)
Pressurereadingdoesnot
matchactualsystempressure.
ERROR1faultisdisplayed
28
Symptom
Problem
Solution
Thewrong/noflowrestrictoris
installedinthefloatvalve(mini
andmidiunitsonly)
Checkfloatvalveflowrestrictor
selection(miniandmidiunits
only)
Thebreaktankisoverfillingand Thefloatvalvepositionisset
dischargingwatertodrainor
incorrectly
overtheweir
Thefloatvalvehasfailed
Replacenonreturnvalve
Theinternalisolationvalve
withintheunitispartially
closed
Fullyopentheinternalisolation
valve
Therestrictioninthe
connectingpipeworkistoo
great
Increasebore/reducenumber
ofbends/reducelengthof
connectingpipework
Replacenonreturnvalve
Theexpansionvesselhasfailed
orlostitsprecharge
Checktheexpansionvesselpre
chargeandrechargeif
necessary
Thepointofconnectionofthe
unitistoofarawayfromthe
expansionvessel
Moveunit/expansionvessel
connectionpointscloser
together.
Theplastichousingofthe
digitalcontrollerhascome
apartandthePCBhasmoved
Reassemblethedigital
controllerhousingandensure
thatthePCBisproperlyseated
Thedigitalcontroller
Thecontrollerisbeingssubject
parametersarebeingcorrupted topowerspikes
Thefusehasblown
Fitasuitablepowerfilter
Replacethefuse
Themainspowersupplyisatan
Checkmainspowersupply
incorrectvoltageorfrequency
Thedigitalcontrollerdoesnot
powerupwhentheunitis
switchedon
SERVICEisdisplayedonthe
screen
Replacefloatvalve
Apumpnonreturnvalvehas
failed
Thepumpisrepeatedlyrunning Apumpnonreturnvalvehas
inshortbursts
failed
Thebuttonsonthedigital
controllerdonotrespond
Setthefloatvalvetoitslowest
possibleposition
The12Vtransformerhasfailed
ReplaceTransformer
Thedigitalcontrollerhasfailed
Replacedigitalcontroller
Theunitisdueanannual
service
Contactserviceengineer
29
Maintenance
Duetovariationsinoperatingconditions,andthevaryingloadsplacedonpressurisationunits,itis
notfeasibletoprovideaccuratepredictionsofcomponentlifespan.Themosteffectivemethodof
maintenanceistoinspectthepressurisationunitforearlysignsofcomponentfailureandtakeaction
accordingly.
Thefollowingmaintenanceproceduresshouldbeperformedatleastonceayear:
VisualInspection
Abasicvisualinspectionwillhighlightthemajorityofpotentialfaultsonapressurisationunit.Itis
recommendedtoperformavisualinspectionannually.However,duetothesimplicityofperforming
thesechecks,frequentinspectionsareencouraged.
Checkthedigitaldisplayforfaultcodes
Checkforsignsofleakage(e.g.water,mineraldeposits,corrodedcomponents/cabinet)
Checkthebreaktankoverflowforsignsofwaterdischarge
Checkflexiblehosesforsignsofdegradation(e.g.cracks)
Checkthatthepressurereadingonthedigitaldisplaycorrespondstotheactualsystem
pressure(readoffanothergauge)
InterrogateController
Thedigitalcontrollerkeepsalogofthenumberofpumpstartsandtotalhoursrunforeachpump,as
wellasthenumberofalarmactivationsandpowerinterruptions.Itisadvisabletotakeanoteof
thesefigureswhenservicingtheunit,astheymaybehelpfulindiagnosingpotentialissues.Fieldsare
providedintheservicelogforthesefigures.
Itisadvisabletoscrollthroughallthesettings(includingengineerssetting)andcheckthemagainst
thefiguresonthecommissioningreport.Ifthereareanydiscrepancies,checkfirstwithonsitestaff
toseeifthechangesaredeliberate.Ifnot,reconfigureappropriately.
Ifsettingsarepersistentlybecomingcorrupted,apowerfiltermayberequired.Please
refertotheInstallationsectionofthismanualformoreinformation.
TestUnitOperation
Thebestwaytotesttheoperationofthepressurisationunitistodrainwaterfromthesystem,
allowingthepressuretodropslowly.Oncethepressurefallsbelowthepumpcutinpressure([COLD
FILL][DIFFERENTIAL])thepumpshouldstart.Assoonasthepumpstarts,closethedrainpointand
allowthesystempressuretorise.Oncethe[COLDFILL]pressureisreached,thepumpshouldstop.
Iftheunitisatwinpumpmodel,thistestshouldberepeateduntilbothpumpshaverunand
successfullyrepressurisedthesystem.
30
CheckFloatValveOperation
Totesttheoperationofthebreaktankfloatvalve,firstensurethatthebreaktankoverflowhasa
suitablepathtodrain.
Gentlypushdownonthearmofthefloatvalveuntilitstartstodischargewater,thenreleasethe
floatvalvearm.Oncethearmhasbeenreleased,theflowofwatershouldstopwithinafewseconds.
CheckFloatSwitchOperation
Totesttheoperationofthebreaktanklowlevelfloatswitch,reachintothebreaktankandgently
pushthefloatswitchdownintothehorizontalposition.
Thedigitalcontrollershouldnowdisplaya<LOWH20>fault.
Releasethefloatswitchandobservethedisplay.Thefaultshouldclearafteradelayofafew
seconds.
CheckBreakTankWaterCondition
Performavisualcheckofthewaterinthebreaktank.Ifthereisanydirtordebrisinthewater,or
depositsonthesidesofthetank,thetankshouldbedraineddownandcleaned.
CheckStrainer(Flexfillerunitsonly)
Flexfillerpressurisationunitsarefittedwithameshstrainerintheconnectionatthebottomofthe
breaktank.Thisshouldberemovedandinspected.Dependingonthecondition,thispartmayneed
tobecleanedorreplaced.
CheckExpansionVesselPreCharge
Manyoftheproblemsexperiencedwithpressurisationequipmentcanbetracedbacktothe
expansionvessel.
Theexpansionvesselprechargepressuremustbecheckedafter2yearsandannuallythereafter.
Toperformthistest,theexpansionvesselmustfirstbedrainedofwater,thenagaugecanbe
connectedtotheSchradervalveonthevesseltomeasuretheprechargepressure.Theprecharge
shouldbeequaltothe[COLDFILL]pressuresetting.
Thepressurecanbeincreasedusingafootpump,aircompressororpressurisedair/nitrogen
cylinder.
Ifanyfaultsareidentifiedduringthesechecks,pleaserefertotheTroubleshooting
sectionofthismanual.Ifreplacementpartsarerequired,pleaserefertotheSpares
sectionforpartcodes.
31
WiringDiagram
32
ServiceLog
Thisservicelogshouldbecompletedbytheserviceengineeraftereachannualservice.
33
34
Spares
Thedrawingsonthefollowingpagesshowtheinternalcomponentsforarangeof
pressurisationequipment.Duetocontinuingdevelopmentandminordesignchanges,
somecomponentsmaybechangedwithoutnotice.Therefore,thedrawingsmaynot
accuratelyreflectthecurrentproductiondesign.Ifinanydoubtaboutthe
compatibilityofreplacementparts,pleasecontactFlamco.
ElectricalItems(AllModels)
*Imageforindicationonly
#
1
2
3
4
5
Description
DigitalController
12VMiniTransformer
1APowerFilter(optional)
PowerSwitch
FusedTerminalBlock
PartCode
MICROCONTROL
BSSMINITRANS
FC100
BSSF014
BSSR002
35
FlexfillerModels(125D,225D,150D,250D,280DS)
*Imageforindicationonly
#
1
2
3
4
5
6
7
8
9
10
36
Description
Pump
NonReturnValve
BraidedHose
PressureTransducer(010Bar,16V)
CombinedIsolation&DrainValve
FloatValve
OverflowConnection
MeshStrainer
FloatSwitch
BallValve
PartCode
SeeDatasheet
FCSC1
BSSFLEXHOSE
16VTRANSDUCER
FCCGNO
BSSP33
BSSM021
N/A
BSSRO12
BSSM005
MidiModels(125D,225D,150D,250D)
*Imageforindicationonly
#
1
2
3
4
5
6
7
8
9
Description
Pump
NonReturnValve
BraidedHose
PressureTransducer(010Bar,16V)
MiniFloatValve
CombinedIsolation&DrainValve
OverflowConnection
MeshStrainer
FloatSwitch
PartCode
SeeDatasheet
FCSC1
BSSFLEXHOSE
16VTRANSDUCER
BSSM003
FCCGNO
BSSM021
N/A
BSSR012
37
MiniModels(130D,230D)
*Imageforindicationonly
#
1
2
3
4
5
6
7
8
9
10
11
12
13
38
Description
Pump
PressureTransducer(010Bar,16V)
BallValve
OverflowConnection
MiniFloatValve
FloatSwitch
8mmPolytube
BSPMx8mmPushFit
8mmPushFitTee
8mmHoseTail
BSPFTee
BrassLockingNut
FlexiblePumpSupport
PartCode
SeeDatasheet
16VTRANSDUCER
BSSM005
BSSM021
BSSM003
BSSR012
BSSM015
BSSM007
BSSM008
BSSM023
BSSP62
BSSM006
BSSM022
Notes
39
Notes
FlamcoFlexfillerPressurisationManualV8.1
40