flamco Pro PDm 1.0, Operation & Maintenance Manual

Page 1: ...change designs and technical specifications of our products Errors and omissions excepted Rev 1 0 Aug 18 Page 1 44 Flamco Pro Range Pressurisation Equipment Pro PU 131 231 161 261 181 281 Pro PUm 131 231 161 261 Pro PDm 1 0 1 5 2 0 2 5 Operation Maintenance Manual ...

Page 2: ...ion 9 Pipe Connections 9 Typical Installation Diagram 9 Flow Restrictors Pro PUm Pro PDm Only 10 Pro PU Clearance and Connection Requirements 11 Pro PUm Pro PDm Clearance and Connection Requirements 12 Electrical Power Supply 13 Micro Controller 14 Fault contacts 14 Commissioning 15 Pre Commissioning Checklist 15 Controller Overview 16 Controller Programming 17 Program Parameter List 18 Hydraulic ...

Page 3: ...ction 28 Interrogate Controller 28 Test Unit Operation 28 Check Float Valve Operation 29 Check Float Switch Operation 29 Check Break Tank Water Condition 29 Check Strainer Pro PU units only 29 Check Expansion Vessel Pre Charge 29 Wiring diagram 30 Spare Parts 31 Spare kit list Pro PU 32 Spare kit list Pro PUm 34 Spare kit list Pro PDm 35 Troubleshooting 36 Service Logs 39 Warranty Details 40 Condi...

Page 4: ... Model Serial No Purchase date Purchase From Note It is highly recommended to have this equipment commissioned by a Flamco trained 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 commissioning or service please contact us Telephone 44 0 1744 744 744 Email service flamco co uk Import...

Page 5: ...opup Sensor Max Pressure Bar Differential Bar Topup Sensor Min Voltage 2 for MAmp Flood Limit Minutes Topup Sensor Max Voltage 10 for MAmp Excessive Start Quantity 0 to disable Slave Unit SPC Y N Excessive Start Time Hours Additive Unit Y N Overrun Seconds Counters Logs Pressure Alarm Auto Reset Y N Pump 1 Count All VFC Failsafe Y N Pump 1 Hours Hours Tank Solenoid Y N Pump 2 Count Tank Solenoid O...

Page 6: ...verlapping settings will cause system instability and nuisance alarm conditions If in any doubt please seek advice from a Sealed System professional A typical venting allowance is 0 3 bar added to the static height to give the cold fill pressure The Differential setting represents the allowable pressure loss before the pump activates and restores the cold fill pressure The Differential setting mus...

Page 7: ... CAUTION 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 It...

Page 8: ...nt 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 a warning overflow 4 in case the break tank overfills and a weir overflow 5 as the primary backflow protection The pressurisation unit is connected into the heating system 6 via an isolation valve 7 The pressure s...

Page 9: ...urisation unit The conditions at the point of connection to the system must not exceed 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...

Page 10: ...uipment 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 restricto...

Page 11: ... M An isolation valve must be installed on the mains water feed for servicing Break Tank Overflow 22 mm 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 circ...

Page 12: ...P M An isolation valve must be installed on the mains water feed for servicing Break Tank Overflow 22 mm 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 cir...

Page 13: ...carried 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 ...

Page 14: ...contacts which can be used for connection to a BMS system located on terminals 1 12 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 The other volt free contacts can be connected to the BMS and when the alarm is triggered this is sho...

Page 15: ...ng 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 header pump ...

Page 16: ...ler is first powered up it will display the controller version number This manual relates to controller version 10 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 operati...

Page 17: ...igit 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 PR00 Language will appear select E and then press and hold SET to move to next menu Once in the menu the value of the current menu item can be changed using the and buttons Once the current value has been set pressing the SET bu...

Page 18: ...essure 0 3 venting allowance 1 Bar 6 High Pressure Warning High pressure alarm 0 1 Bar 2 6 Bar 7 High Pressure Alarm System safety valve 10 2 7 Bar 8 Flood Limit 10 minutes 9 Excessive Start Quantity 0 10 Excessive Start Time 8 hours 28 Fill system N 45 Service Reminder Y N N 48 ID Number MODBUS ID number 1 49 Review Logs N 50 Counter for P1 used for Topup 51 Hours Run for P1 Topup 52 Counter for ...

Page 19: ...set 0 4 below the safety valve on installation 2 6 Bar 7 High Pressure Alarm Set 0 3 below the safety valve on installation 2 7 Bar 8 Flood Limit 10 minutes 9 Excessive Start Quantity 0 10 Excessive Start Time 8 hours 11 Pump Number 1 STANDARD OPTION 12 Pump Type Pump Type C current monitored centrifugal pump C Pump Type P current monitored Piston pump Pump Type R Not Current Monitored larger pump...

Page 20: ...st option N 27 Cascade Delay start time for activating both pumps together note 0 means that the pumps will NOT run together but operates as duty standby auto change over 0 Seconds disabled 28 Fill system N 29 Extended Mode N 30 not used N 31 Degassing Required Y N N 45 Service Reminder Y N N 46 Pump1 Max Hours Run Alarm to change Pump 9000 Pump when set to 0 the alarm is disabled 47 Pump 2 Max Ho...

Page 21: ...fitted to the break tank ensure that it is closed Then turn on the mains 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 Pro PU PUm PDm units Make sure that ...

Page 22: ...cifications of our products Errors and omissions excepted Rev 1 0 Aug 18 Page 22 44 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 23: ... to Run Turn on the power supply to the digital controller and wait for the system pressure to appear on the display Then enter the code 2601 Language menu will appear as default E Press and hold MUTE for pump 1 to run and Press and hold MUTE for pump 2 to run Key MUTE Pump 1 Run MUTE Pump 2 Run To bleed the pumps the pumps must be started Then while the pump is running the bleed screw must be ope...

Page 24: ...ps 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 system pressure equals the cold fill pressur...

Page 25: ...ow 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 equipment suitability guide in relation to...

Page 26: ...nings 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 acti...

Page 27: ...will be 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 v...

Page 28: ... system 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 the...

Page 29: ... 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 Pro PU 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 Ve...

Page 30: ... 2018 Flamco group All rights reserved We reserve the right to change designs and technical specifications of our products Errors and omissions excepted Rev 1 0 Aug 18 Page 30 44 Wiring diagram ...

Page 31: ...n 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 Kit No Kit Description ID Part Description Qty STA12503 Controller Std Pressurisation Unit 1 CONTROLLER v10 0 1 STA12500 Power Supply and Switch 3 ON OFF S...

Page 32: ...5 mm Compression Coupling 8 Brass Tee Twin pump only 9 Break Tank 18L c w wier overflow 10 Braided Hose 11 Combined Isolation Drain Valve 12 Pressure Transducer 0 10 Bar 1 6V Pressure Transducer 0 16 Bar 1 6V 181 281 Spare kit list Pro PU Kit No Kit Description ID Part Description Qty STA12505 Pump Flamco PQAm60 1 PQA60 PUMP 1 RING CRIMP 1 0 75 mm CABLE BLACK 1 03 2 1 2 NON RETURN VALVE 1 7 15 mm ...

Page 33: ... BSPT M 61155K 1 STA12511 Pump Pedrollo PQ3000 1 PQ3000 PUMP 3 PHASE 1 RING CRIMP 1 0 75 mm CABLE BLACK 1 03 2 1 2 NON RETURN VALVE PN16 1 7 COUPLING 15mm x BSPT 61055K 2 ELBOW 15mm x BSPT M 61155K 1 STA12518 Pump Fitting Kit 1 2 bsp 0 10b 7 15 mm x BSP C X Mi Coupling 2 15 mm x BSP C X Mi Elbow 1 10 Flexible Hose 2 2 Non return valve 1 STA12515 Pressure Transducer 1 6v 0 10b 12 TRANSDUCER 10 bar ...

Page 34: ...solation Drain Valve 7 Overflow Connection 8 Brass Tee 9 Float Switch Spare kit list Pro PUm Kit No Kit Description ID Part Description Qty STA12505 Pump Flamco PQAm60 1 PQA60 PUMP 1 RING CRIMP 1 0 75 mm CABLE BLACK 1 03 2 1 2 NON RETURN VALVE PN16 1 15 mm x BSP C X Mi Coupling 2 15 mm x BSP C X Mi Elbow 1 STA12506 Pump Flamco PQm81 BS 1 PQ81B PUMP 1 RING CRIMP 1 0 75 mm CABLE BLACK 1 03 2 1 2 NON...

Page 35: ...dication only Part List ID Description 1 FLAMCO 003 PUMP 2 FLEXIBLE HOSE 3 4 MM ELBOW 4 4 MM NYLON TUBE 5 4 MM BULKHEAD 6 Float Switch 7 FLOAT VALVE 8 OVERFLOW CONNECTION 9 COMBINED ISOLATION AND DRAIN 10 15 MM COPPER TUBE 11 15 X 15 X 1 2 TEE 12 TRANSDUCER Spare kit list Pro PDm Kit No Kit Description ID Part Description Qty STA12508 Pump Flamco 003 1 FLAMCO 003 1 RING CRIMP 1 0 75 mm CABLE BLACK...

Page 36: ...sing a 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 pr...

Page 37: ...controller 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...

Page 38: ...gth of 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 ...

Page 39: ... We reserve the right to change designs and technical specifications of our products Errors and omissions excepted Rev 1 0 Aug 18 Page 39 44 Service Logs This service log should be completed by the service engineer after each annual service ...

Page 40: ...ct is identified 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 Co...

Page 41: ...he UK and comply with the essential requirements of the applicable directives including but not limited to Pressure Equipment Directive 2014 68 EU Sound Engineering Practice RoHS Compliance Additional Information All appropriate components bear the CE mark prior to assembly and are bound by their individual applicable directives including but not limited to Pressure Equipment Directive 2014 68 EU ...

Page 42: ... 2018 Flamco group All rights reserved We reserve the right to change designs and technical specifications of our products Errors and omissions excepted Rev 1 0 Aug 18 Page 42 44 Notes ...

Page 43: ... 2018 Flamco group All rights reserved We reserve the right to change designs and technical specifications of our products Errors and omissions excepted Rev 1 0 Aug 18 Page 43 44 Notes ...

Page 44: ... right to change designs and technical specifications of our products Errors and omissions excepted Rev 1 0 Aug 18 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 ...