flamco Flexfiller 125D, Operation & Maintenance Manual

Page 1: ...e right to change designs and technical specifications of our products Rev 8 1 Aug 15 Page 1 44 Flexfiller Digital Pressurisation Equipment Flexfiller Models 125D 225D 150D 250D 280D Midi Models 125D 225D 150D 250D Mini Models 130D 230D Operation Maintenance Manual Rev 8 3 ...

Page 2: ...mmended to have this equipment commissioned by a Flamco approved engineer Any damage or loss incurred through incorrect commissioning by an unapproved engineer will not be covered by the warranty If you wish for Flamco to arrange this please contact us See contact details Please see the warranty section for details Remember to fill in details for future use for re commission unit Remember When ins...

Page 3: ...opriate DIFFERENTIAL Bar PUMP SENSE YES NO Delete as appropriate FLOOD LIMIT Minutes SENSOR TYPE 0 1 2 Delete as appropriate PUMP 1 COUNT SPC CONTROLLER NO PUMP 1 HOURS GLYCOL UNIT NO PUMP 2 COUNT ID NUMBER PUMP 2 HOURS RELAY INVERSION YES NO Delete as appropriate ALARM COUNT OVERUN POWER INTERRUPTED PRESSURE ALARM AUTO RESET YES NO Delete as appropriate PULSE YES NO Delete as appropriate EXCESSIV...

Page 4: ...tion Requirements 9 Midi Clearance and Connection Requirements 10 Mini Clearance and Connection Requirements 11 Electrical Power Supply 12 Fault Contacts 13 Commissioning Pre Commissioning Checklist 14 Controller Overview 15 Controller Programming 16 Program List 17 19 Hydraulic Commissioning 20 24 Operation Fault Codes 25 Shutdown Procedure 26 Start Up Procedure 26 Maintenance Maintenance informa...

Page 5: ...UTION Important information intended to prevent damage to the equipment system or property IMPORTANT Important information intended to ensure that the equipment functions correctly USEFUL Useful information which may be helpful but is not necessarily required for the unit to function correctly Typography This manual makes use of different typography to identify different types of information Itali...

Page 6: ...rrangement of a pressurisation unit The pressurisation unit is fitted with a break tank 1 which is filled from the mains water supply 2 via a float operated valve 3 The break tank is fitted with an overflow 4 in case the break tank overfills and a weir overflow 5 in case the primary overflow fails The pressurisation unit is connected into the heating system 6 via an isolation valve 7 The pressure ...

Page 7: ...ed these values Pipe Connections To avoid damaging the float valve the mains water supply pipe must be flushed before connection to the pressurisation unit All pipe connections must be made with appropriate jointing compound PTFE tape If PTFE tape is used care must be taken to ensure that the tape does not obstruct the orifice of the fitting Non return valves pressure reducing valves and RPZ valve...

Page 8: ...t both of which include an integral filter The selection of the appropriate flow restrictor is based on the maximum mains water pressure at the point of installation Please refer to the following table for selection Mains Water Pressure Requirement Below 1 Bar No Restrictor Install Filter Only 1 4 Bar Low Pressure Restrictor coloured Above 4 Bar High Pressure Restrictor white If no restrictor is r...

Page 9: ...on valve must be installed on the mains water feed for servicing Break Tank Overflow 22mm Guidance on drainage requirements should be obtained from the local water authority System Connection BSP M 15mm The pressurisation unit and expansion vessel should be connected to the system at the same point The point of connection should be in the system return on the suction side of the circulation pump N...

Page 10: ...valve must be installed on the mains water feed for servicing Break Tank Overflow 22mm Guidance on drainage requirements should be obtained from the local water authority System Connection BSP M 15mm The pressurisation unit and expansion vessel should be connected to the system at the same point The point of connection should be in the system return on the suction side of the circulation pump Non ...

Page 11: ...on valve must be installed on the mains water feed for servicing Break Tank Overflow 22mm Guidance on drainage requirements should be obtained from the local water authority System Connection BSP F The pressurisation unit and expansion vessel should be connected to the system at the same point The point of connection should be in the system return on the suction side of the circulation pump Non re...

Page 12: ...ed out by a suitably qualified and competent person The mains power supply to the pressurisation unit must be connected into the fused terminal block as shown below On some larger models the fused terminal block is replaced by a fused spur If this is the case the power supply must be connected into the fused spur as shown below It is recommended to supply power to the pressurisation unit via a loc...

Page 13: ...oller Fault contacts There are 6 volt free fault contacts which can be used for connection to a BMS system or as a boiler interlock These are terminals 1 12 located on the digital controller With the exception of the Common Alarm it is possible to convert all other fault contacts to normally closed For further information please refer to the commissioning section of this manual ...

Page 14: ...n the operating limits of the pressurisation unit The heating cooling system is fitted with a safety valve and expansion vessel The following conditions must be met for the pressurisation unit and heating cooling system to function correctly If these conditions have not been met it is not advisable to proceed with the commissioning process The system connection has been made into the system return...

Page 15: ...s first powered up it will display the controller version number This manual relates to controller version 8 0 If the controller is of a different version there may be differences in the menu items available When in normal operation the controller will display the current system pressure If a fault occurs the controller will display a fault code and produce an audible alarm In normal operation the...

Page 16: ...ode change the first digit with the and buttons then press SET to move onto the next digit Repeat for all digits then once the correct code is shown on the display press SET to enter the programming menu Once a correct code has been entered the first option COLD FILL will appear on the screen Once in the menu the value of the current menu item can be changed using the and buttons Once the current ...

Page 17: ...m will be activated and the pressurisation pumps will not run The recommended setting is 0 5 Bar below the COLD FILL pressure It is not possible to enter a value higher than the current COLD FILL value 0 5 Bar 4 DIFFERENTIAL The differential between the cut in and cut out pressures of the pressurisation pumps The cut in pressure will be equal to the COLD FILL pressure minus the differential pressu...

Page 18: ...n enabled if there are more than 3 individual pump runs within an 8 hour period the unit will register an EXCESSIVE DEMAND alarm Enabling this option may cause false alarms on some systems NO 14 SERVICE When enabled a service reminder will be displayed after 12 months from when the option was enabled To reset the service reminder set the value to NO and exit the menu Then re enter the menu and set...

Page 19: ... Pressurisation unit NO 21 ADDITIVE Not required on standard Pressurisation unit NO 22 ID NUMBER A user configurable identification number This option does not serve any functional purpose 01 23 RELAY INVERSION When enabled all normally open fault contacts i e all except the common alarm are converted to normally closed NO 24 OVERRUN Allows the pump to continue running for a set period of time aft...

Page 20: ...ins water supply and allow the break tank to fill When the float valve operates for the first time it may not close immediately causing the break tank to overfill Once the internals of the valve have been fully wetted this should not occur again 2 Bleeding Pumps This step is only necessary for Flexfiller and Midi units For Mini units move on to the next step Make sure that the internal isolation v...

Page 21: ... Attach a length of hose to the hose tail on the drain valve and put the other end to drain Then using the cap off the isolation valve open the drain valve Locate the bleed screw on the pump The following diagrams show examples of typical bleed screw locations for most pumps Do not use excessive force when tightening the bleed screw as this may damage the pump casing ...

Page 22: ... the MUTE button will force pump 1 to run and holding down the SET button will force pump 2 to run If the controller is older than V6 1 then there is no way to force pump 2 to run via the controller To force the second pump to run the unit must be isolated and the live wires in terminals 13 and 14 must be swapped over The second pump then becomes pump 1 and can be forced to run via the controller ...

Page 23: ...will display a LOW PRESSURE fault and the pumps will not run To clear this fault either increase the system pressure using a filling loop or enable the system fill option on the pressurisation unit If the system pressure is above the high pressure alarm setting the controller will display a HIGH PRESSURE fault To clear this fault use a suitable drain point to remove water from the system until the...

Page 24: ...pe Once the system pressure has fallen below the cold fill setting by an amount equal to the differential setting the pump should start refilling the system The pump will continue to run until the cold fill pressure has been reached This test demonstrates the primary function of the pressurisation unit This test may be repeated at any time to confirm the operation of the pressurisation unit Quick ...

Page 25: ... of all fault codes used on the digital controller Fault Code Description Auto Manual Reset LOW PRESSURE The system pressure is below the LOW PRESSURE set point User Defined HIGH PRESSURE The system pressure is above the HIGH PRESSURE set point User Defined LOW H20 The break tank low level float switch has been activated Auto Reset HIGH H20 The break tank high level float switch has been activated...

Page 26: ...e out of commission for more than 24 hours it is advisable to drain the water from the break tank Start up Procedure Attention This procedure is for restarting the unit after being shutdown as described above For initial start up and commissioning procedures please refer to the Commissioning section of this manual To restart the pressurisation unit please follow the steps below 1 Perform a visual ...

Page 27: ...m pressure read off another gauge Interrogate Controller The digital controller keeps a log of the number of pump starts and total hours run for each pump as well as the number of alarm activations and power interruptions It is advisable to take a note of these figures when servicing the unit as they may be helpful in diagnosing potential issues Fields are provided in the service log for these fig...

Page 28: ...If there is any dirt or debris in the water or deposits on the sides of the tank the tank should be drained down and cleaned Check Strainer Flexfiller units only Flexfiller pressurisation units are fitted with a mesh strainer in the connection at the bottom of the break tank This should be removed and inspected Depending on the condition this part may need to be cleaned or replaced Check Expansion...

Page 29: ...www flamcogroup com 2014 Flamco group All rights reserved We reserve the right to change designs and technical specifications of our products Rev 8 1 Aug 15 Page 29 44 Wiring diagram ...

Page 30: ...www flamcogroup com 2014 Flamco group All rights reserved We reserve the right to change designs and technical specifications of our products Rev 8 1 Aug 15 Page 30 44 Wiring location list ...

Page 31: ...evelopment and minor design changes some components may be changed without notice Therefore the drawings may not accurately reflect the current production design If in any doubt about the compatibility of replacement parts please contact Flamco Image for indication only Description Part Code 1 Digital Controller MICRO CONTROL 2 Electrical Plate Fuse Block and 15V PSU SA 000 EP 001 SINGLE PUMP or 0...

Page 32: ...ation only Description Part Code 1 Pump Model 125D 225D Pedrollo PQA60 BSS PQA 60 Pump Model 150D 250D Pedrollo PQ81B BSS PQ81b Pump Model 280DS Pedrollo PQA90 FC039 2 Non Return Valve FC SC1 3 Braided Hose BSS FLEXHOSE 4 Pressure Transducer 0 10 Bar 1 6V 1 6V TRANSDUCER 5 Combined Isolation Drain Valve FCCG NO 6 Float Valve BSS P33 7 Overflow Connection BSS M021 8 Mesh Strainer N A 9 Float Switch...

Page 33: ...250D Image for indication only Description Part Code 1 Pump Model 125D 225D Pedrollo PQA60 BSS PQA 60 Pump Model 120D 250D Pedrollo PQ81B BSS PQ81b 2 Non Return Valve FC SC1 3 Braided Hose BSS FLEXHOSE 4 Pressure Transducer 0 10 Bar 1 6V 1 6V TRANSDUCER 5 Mini Float Valve BSS M003 6 Combined Isolation Drain Valve FCCG NO 7 Overflow Connection BSS M021 8 Mesh Strainer N A 9 Float Switch BSS R012 ...

Page 34: ...y Description Part Code 1 Pump All Models Model E EP77 BSS M024 2 Pressure Transducer 0 10 Bar 1 6V 1 6V TRANSDUCER 3 Ball Valve BSS M005 4 Overflow Connection BSS M021 5 Mini Float Valve BSS M003 6 Float Switch BSS R012 7 8mm Poly tube BSS M015 8 BSP M x 8mm Push Fit BSS M007 9 8mm Push Fit Tee BSS M008 10 8mm Hose Tail BSS M023 11 BSP F Tee BSS P62 12 Brass Locking Nut BSS M006 13 Flexible Pump ...

Page 35: ... filling loop or enable the SYSTEM FILL option The SPC CONTROLLER option is enabled Disable the SPC CONTROLLER option The LOW PRESSURE set point is too high Review the system specifications HIGH PRESSURE fault is displayed The internal isolation valve within the unit is closed Open the internal isolation valve The system pressure has risen above the HIGH PRESSURE set point Decrease system pressure...

Page 36: ...ller has failed Replace digital controller HIGH H20 fault is displayed A non standard electrical connection has been made into terminals 21 22 Remove all non standard electrical connections The digital controller has failed Replace digital controller Pressure reading does not match actual system pressure The internal isolation valve within the unit is closed Open the internal isolation valve The S...

Page 37: ... connecting pipe work A pump non return valve has failed Replace non return valve The expansion vessel has failed or lost its pre charge Check the expansion vessel pre charge and re charge if necessary The point of connection of the unit is too far away from the expansion vessel Move unit expansion vessel connection points closer together The buttons on the digital controller do not respond The pl...

Page 38: ...roup All rights reserved We reserve the right to change designs and technical specifications of our products Rev 8 1 Aug 15 Page 38 44 Service Logs This service log should be completed by the service engineer after each annual service ...

Page 39: ...www flamcogroup com 2014 Flamco group All rights reserved We reserve the right to change designs and technical specifications of our products Rev 8 1 Aug 15 Page 39 44 ...

Page 40: ...ed as a manufacturing defect it will be addressed as described above additional remedial works as a result of misuse incorrect handling incorrect installation or incorrect commissioning then the additional work is chargeable Installation costs and or consequential losses are not covered by this agreement Conditions of warranty DOS Date Of Supply DOC Date Of Commissioning Equipment Conditions Times...

Page 41: ...www flamcogroup com 2014 Flamco group All rights reserved We reserve the right to change designs and technical specifications of our products Rev 8 1 Aug 15 Page 41 44 Notes ...

Page 42: ...www flamcogroup com 2014 Flamco group All rights reserved We reserve the right to change designs and technical specifications of our products Rev 8 1 Aug 15 Page 42 44 Notes ...

Page 43: ...www flamcogroup com 2014 Flamco group All rights reserved We reserve the right to change designs and technical specifications of our products Rev 8 1 Aug 15 Page 43 44 Notes ...

Page 44: ...s reserved We reserve the right to change designs and technical specifications of our products Rev 8 1 Aug 15 Page 44 44 Flamco Limited Washway Lane St Helens Merseyside WA10 6PB United Kingdom T 44 1744 744 744 F 44 1744 744 700 E info flamco co uk ...