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Literature ref: 1C/02

Flexcon
standard expansion vessels
and sealed system equipment
for commercial heating and
air conditioning equipment

E
R

UKAS
D

GI E
STER QUALITY
MANAGEMENT

BS EN ISO 9001
Certificate No: FM 34109

Flamco UK Limited
Unit 4,
St. Michael’s Road,
Lea Green Industrial Estate,
St. Helens,
Merseyside WA9 4WZ.
Telephone: 01744 818100.
Fax: 01744 830400.
www.flamco.co.uk

1C
Flexcon standard expansion vessels

Introduction
Under the universally known and respected name of Flexcon, Flamco have the largest
range of kitemarked vessels and are the only commercial vessels issued with a
Certificate of Test by BSI.
Many years of research and development, coupled with well over twenty five years of
experience in the UK, have produced expansion vessels of the highest quality to give
a long and trouble free life. In addition to the standard range, vessels are available up
to 12,500 litre capacity.
To complement Flexcon expansion vessels, Flamco offer a full range of sealed system
accessories, Europe’s largest range of air separation and dirt removal equipment and
the most extensive and flexible range of packaged sealed system units - all from one
manufacturer.
Specifying and using Flexcon equipment ensures peace of mind knowing that you
comply with all regulations and have a direct link with the manufacturer.

Advantages Operation
l Flexibility of system design. Before filling the installation
Most design arrangements can be The diaphragm is pushed up against the
used unlike open systems which vessel wall by the factory pre-set initial
impose restrictions. gas charge. The gas charge supports the
pressure exerted by the static height of
l Architectural freedom. water above the vessel which is normally
No special tank room and no special 0.5, 1.0 or 1.5 bar.
load bearing structures associated
System Water from
with open systems.
connection heating system

l Cost saving. TEMP


FLEXCON

Installation time is reduced


considerably and equipment is less
expensive in most cases compared
with open systems. PRESSURE
FLEXCON

l Longer, more efficient system life.


Resulting from the virtual elimination On filling
of corrosion, and the unique rolling When the system is filled there will be a
action of the Flexcon diaphragm* . small amount of water in the Flexcon
vessel. Gas Flexible rubber
l Energy saving. charge diaphragm
Under normal operating conditions a
* The unique Flexcon design ensures that the
Flexcon sealed system does not use diaphragm is not stretched but will roll along
any energy. TEMP its sides, making it extremely durable to give a
FLEXCON
longer life.
l Elevated temperatures.
Elevated temperatures may be used
with Flexcon sealed systems. PRESSURE
FLEXCON

l No freezing.
Equipment is normally in a frost free At operating temperature
area. The total system water expansion is
l Localised boiling. taken up within the vessel. The pressure
has risen and the diaphragm is virtually
This is overcome by the system static with equal pressure on either side.
operating pressure.

l No pumping over.
This cannot happen with a Flexcon TEMP
sealed system. FLEXCON

l Maintenance free.
Flexcon equipment does not require
PRESSURE
any routine maintenance or on site FLEXCON

adjustment.
Flexcon standard expansion vessels

Specification Certification
Steel construction: To B.S. 4814:1990. Flexcon expansion vessels up to and
including 110 litre are kitemarked and
Sizes 2 - 80 litre: Deep drawn with separate clench joint as defined in approved by BSI. Expansion vessels up
B.S. 4814:1990. to and including 600 litre (except 300
litre) issued with a Certificate of Test by
BSI.
Sizes 110 - 1000 litre: All welded

Diaphragm: Flexible rubber with rolling action.

Maximum vessel 70OC. (Suitable for systems up to 90OC flow


temperature: temperature and may be used with an intermediate
vessel for higher system temperatures).

Maximum working pressure: See table below.

Standard Capacity Max g Gas charge (bar) System Dimensions Weight Order code
range (litres) working
Standard Other
connec in mm. (Kg) g
Quote gas
pressure -tion charge when
(bar) 0.5 1.0 1.5 BSP (M) Aø B ordering

Flexcon 2 6 l 3/4" 194 152 2.2 FCST 002


Flexcon 4 6 l 3/4" 194 257 3.1 FCST 004
l

Flexcon 8 6 3/4" 245 280 4.4 FCST 008
l l
B

Flexcon 12 6 3/4" 286 313 5.8 FCST 012


Flexcon 18 6 l l 3/4" 328 306 7.5 FCST 018
Flexcon 25 6 l l 3/4" 358 359 9.6 FCST 025

Flexcon 35 6 l l l 3/4" 396 416 11.8 FCST 035


l l l
B

Flexcon 50 6 3/4" 437 473 15.1 FCST 050


l l l
A
Flexcon 80 6 1" 519 540 22.1 FCST 080

Flexcon 110 6 l l l 1" 484 784 29.0 FCST 110


A
Flexcon 140 6 l l l 1" 484 950 32.5 FCST 140
Flexcon 200 6 l l l l 1" 484 1294 41.6 FCST 200
B Flexcon 300 6 l l l l 1" 600 1328 56.9 FCST 300
Flexcon 425 6 l l l l 1" 790 1178 76.4 FCST 425
Flexcon 600 6 l l l l 1" 790 1538 92.9 FCST 600
Flexcon 800 6 l l l l 1" 790 1888 181.8 FCST 800
Flexcon 1000 6 l l l l 1" 790 2268 211.0 FCST 1000

Optional
Range Flexcon 110 10 l l 1" 484 784 38.5 FCST 110
Flexcon 140 10 l l 1" 484 950 44.6 FCST 140
l l
A
Flexcon 200 10 1" 484 960 49.3 FCST 200
Flexcon 300 10 l l 1" 600 1330 73.7 FCST 300
Flexcon 425 10 l l 1" 790 1180 105.5 FCST 425
B
Flexcon 600 10 l l 1" 790 1540 132.0 FCST 600
Flexcon 800 10 l l 1" 790 1888 181.8 FCST 800
Flexcon 1000 10 l l 1" 790 2268 211.0 FCST 1000

g Gas charge must be stated on order. e.g. Flexcon 25/05 = 25 litre vessel with 0.5 bar gas charge.
g Gas charge determines the maximum working pressure.
g Other gas charges supplied to suit.
Flexcon standard expansion vessels - Sizing

Sizing table for heating and air conditioning systems


Calculations based on B.S. 7074:1990 Code of Practice. Please note that multiple vessels may be used.
Larger vessels and higher pressures are available from the Flexcon ‘M’, ‘M-P’ and ‘MK’ range.

(up to) above expansion vessel


(up to) above expansion vessel
Maximum working pressure

Maximum working pressure


Chilled water with anti-freeze

Chilled water with anti-freeze


Condenser water up to 45OC

Condenser water up to 45OC


System water content

System water content


System static height
System static height
at expansion vessel -

at expansion vessel -
safety valve setting

safety valve setting


Total boiler rating

Total boiler rating


Water Content

Water Content
expansion vessel
Flexcon standard

expansion vessel
Flexcon standard
Heating Air cond Heating Air cond
82OC/71OC -itioning 82OC/71OC -itioning
Bar Metres Litres Kw Litres Type Bar Metres Litres Kw Litres Type
3 5 32 3 98 2/05 4 10 2117 176 6499 140/1
64 5 197 4/05 3204 252 9284 200/1
128 11 393 8/05 4536 378 13926 300/1
192 16 590 12/05 6426 536 19729 425/1
288 24 885 18/05 9073 756 27853 600/1
400 33 1229 25/05
560 47 1720 35/05 15 1676 140 5145 140/1.5
800 67 2457 50/05 2394 200 7350 200/1.5
1281 107 3931 80/05 3591 299 11025 300/1.5
1761 147 5405 110/05 5088 424 15619 425/1.5
2241 187 6880 140/05 7183 599 22050 600/1.5
3201 267 9828 200/05 9576 798 29400 800/1.5
4802 400 14742 300/05
6803 567 20885 425/05 20 1235 103 3791 140/2
9604 800 29484 600/05 1764 147 5416 200/2
2646 221 8124 300/2
10 134 11 413 12/1 3749 312 11509 425/2
202 17 619 18/1 5292 441 16248 600/2
280 23 860 25/1 7056 588 21663 800/2
392 33 1204 35/1 8821 735 27079 1000/2
560 47 1720 50/1
896 75 2752 80/1 25 794 66 2437 140/2.5
1233 103 3784 110/1 1134 95 3482 200/2.5
1569 131 4816 140/1 1701 142 5222 300/2.5
2241 187 6880 200/1 2410 201 7398 425/2.5
3361 280 10319 300/1 3402 284 10445 600/2.5
4762 397 14619 425/1 4536 378 13926 800/2.5
6723 560 20639 600/1 5670 473 17408 1000/2.5
8964 747 27518 800/1
5 15 3013 251 9250 200/1.5
15 252 21 774 35/1.5 4520 377 13876 300/1.5
360 30 1106 50/1.5 6403 534 19657 425/1.5
576 48 1769 80/1.5 9039 753 27751 600/1.5
792 66 2432 110/1.5
1008 84 3096 140/1.5 20 2494 208 7656 200/2
1441 120 4423 200/1.5 3740 312 11483 300/2
2161 180 6634 300/1.5 5299 442 16268 425/2
3061 255 9398 425/1.5 7481 623 22967 600/2
4322 360 13268 600/1.5 9975 831 30622 800/2
5762 480 17690 800/1.5
7203 600 22113 1000/1.5 25 1974 165 6061 200/2.5
2961 247 9091 300/2.5
20 448 37 1376 140/2 4195 350 12879 425/2.5
640 53 1966 200/2 5922 494 18182 600/2.5
960 80 2948 300/2 7897 658 24242 800/2.5
1361 113 4177 425/2 9871 823 30303 1000/2.5
1921 160 5897 600/2
2561 213 7862 800/2 30 1455 121 4466 200/3
3201 267 9828 1000/2 2182 182 6699 300/3
3091 258 9490 425/3
4364 364 13397 600/3
5819 485 17863 800/3
7273 606 22329 1000/3
Flexcon standard expansion vessels - Sizing

Basic calculation

System Water Content x Coefficient of Expansion


Vessel Size =
Expansion Vessel Efficiency

Expansion vessel efficiency (VE)


Coefficient of Expansion Max. Pressure - Min. Pressure
(water with no additives) VE =
Max. Pressure
Expansion coefficient

0.06
0.05
0.04 * Please note units must be in absolute
0.03 units (gauge pressure + 1 bar).
0.02 Maximum pressure = Maximum working
0.01 pressure at the expansion vessel.
0
0 10 20 30 40 50 60 70 80 90 100 110120
Minimum pressure = expansion vessel
O
Centigrade gas charge (normally dependent on the
system static height).

*Please note the expansion vessel efficiency must not exceed the maximum
stated by Flamco UK Ltd. Sizing charts have taken this into consideration.

Example (Basic Sizing)


Water content = 1000 litres. Static height = 10 metres.
s

System
Temperature = 82OC. Maximum working pressure = 3 bar.

Expansion vessel sizing (Gas charge 1 bar).


4-2
VE = = 0.5 Coefficient of expansion = 0.03
4
1000 x 0.03
Expansion vessel size = = 60 litres. (Use the nearest higher
0.5 size. e.g. Flexcon 80/1).

Heating and air conditioning systems -


Flexcon standard expansion vessels.
Sizing to B.S. 7074 (Heating and Air Conditioning Systems up to 5 bar).
Use the following criteria for calculations:
Water content = system water content + 10%.
Coefficient of expansion = use system highest temperature (not mean temp).
Maximum pressure = safety valve setting - 0.3 bar. (e.g. for 3 bar safety valve maximum pressure = 2.7 bar).
Minimum pressure = expansion vessel gas charge + 0.3 bar. (0.7 bar minimum).
(Note when sizing for chilled water systems use the ambient temperature as the maximum and double the expansion
coefficient if anti-freeze is used - it is assumed that a pressurisation unit is being used).
Systems above 5 bar. The maximum pressure = safety valve setting - 15%.
Systems operating at above 100OC. (Medium Temperature Systems).
The minimum pressure = static height + anti flash margin. (Static height is the vertical height above expansion vessel).
(Anti-flash margin of 11OC is recommended in the standard). A Flexcon intermediate vessel may be required. Contact
Flamco UK Ltd for details.
Flexcon standard expansion vessels

Accessories Flexcon pressure gauge.


63mm and 80mm gauge diameters. 0 to 4 bar
Prescor safety valves. range. In addition to the pressure indication, all
Specially designed for gauges have an adjustable red pointer with a
sealed systems with green segment to give correct working range.
non-stick seating. System connection
Pre-set, non-adjustable 63mm-1/4" BSP(M). 80mm-1/2" BSP(M).
with diaphragm seal
and quick release knob.
Maximum operating
Flexcon thermo/pressure gauge.
temperature 140OC.
80mm gauge diameter. 0 to 4 bar and 0OC to
Type Kw at Setting Inlet Outlet 120OC. Same features as the standard pressure
3 bar bar BSP(F) BSP(F) gauge plus the convenience of temperature
indication. Incorporates self sealing pocket to
1/2 125 3 1/2" 1/2" enable removal without draining down.
3/4 215 3 3/4" 3/4" System connection 1/2" BSP(M).

1 375 3 1" 1.1/4"


1.1/4 640 3 1.1/4" 1.1/2" Uni-Fil filling loops.
A complete set of fittings to meet Water Bye-Laws
Prescor 'S' safety for filling systems directly from the mains.
valves. Available for manual or automatic filling.
Designed for larger System connection 15mm/1/2" BSP.
installations with a
special seating to
ensure high discharge
capacity. Non-stick
seating, diaphragm Connecting groups.
seal and quick release A convenient drain cock and lockshield valve
lever. Maximum operat- connecting components to the system. Available
ing temperature 140OC. with or without pressure gauge.
System connection 1/2" BSP(M).
Type Kw at Setting Inlet Outlet
3 bar bar BSP(F) BSP(F)
1.1/4 700 3,4 or 5 1.1/4" 1.1/2"
1.1/2 920 3,4 or 5 1.1/2" 2"
System high and low pressure switches.
2 1350 3,4 or 5 2" 2.1/2"
Safety devices for wiring into the system controls.
Use one switch for each operation.
Safety valve funnel.
For fitting to the outlet
of the safety valves
to give a safe
atmospheric break
when piping away
the discharge.
The funnel swivels for Switchpak pressure switch assembly.
easy fitting. Larger A set of three components to provide a
sizes are available. convenient assembly for sealed system controls:
High pressure cut out switch, low pressure cut out
Type Inlet Outlet switch and switch assembly manifold.
BSP(M) BSP(F)
1/2 1/2" 1/2"
1/2 x 3/4 1/2" 3/4" Flamco venting and dirt removal equipment.
3/4 3/4" 1" Flexvent and Flexvent Super automatic air vents.
Flexair centrifugal action air separators.
Flamcovent micro-bubble air separators.
Flamcovent Clean air separators with dirt chamber.
Flexcon type A-S dirt interceptors.
Schematic commercial system details

LTHW sealed system Flexvent Super automatic air vent

High/low pressure
Prescor safety valves cut out switches
F = Funnel
LSV = Lockshield valve Pumps Flexvent Super automatic air vents
DC = Drain cock
(Connecting Group)

Flamcovent de-aerator

F F

DC

DC
Water supply

Boiler
Boiler
Uni-Fil
filling loop

LSV LSV
Flexfiller pressurisation unit

Flexcon expansion vessel (multiple vessels may be used)

MTHW sealed system Flexvent Super automatic air vent

High/low pressure
Prescor safety valves cut out switches
F = Funnel
Pumps Flexvent Super automatic air vents
LSV = Lockshield valve
DC = Drain cock
(Connecting Group)

Flamcovent de-aerator
Water
F F
DC

DC
supply
Boiler
Boiler

Uni-Fil
filling loop

LSV LSV LSV

Flexfiller pressurisation unit


Flexcon VSV intermediate vessel
Flexcon expansion vessel (multiple vessels may be used)

Chilled water sealed system Flexvent Super automatic air vent


Flexvent Super
automatic air vent High/low pressure
cut out switches
To system controls
F = Funnel
LSV = Lockshield valve
DC = Drain cock
(Connecting Group) Prescor safety valve
Flexcon expansion vessel (multiple vessels may be used)
Flamcovent de-aerator
Water supply
F DC Uni-Fil filling loop
Chiller
LSV Flexfiller pressurisation unit
Pump

Condenser water sealed system Flexvent Super


automatic air vent
To system controls

F = Funnel Prescor safety valve Cooling tower High/low pressure cut out switches
LSV = Lockshield valve
DC = Drain cock Flamcovent
Water supply
(Connecting Group) de-aerator
F DC Uni-Fil filling loop
Condenser
LSV Flexfiller pressurisation unit
Pump
Flexcon expansion vessel (multiple vessels may be used)

Flamco UK Limited reserve the right to alter specification and design without prior notice.

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