Flamco Flamcomat Manuale utente

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ENG Flamco-Fill P

Installation and operating instructions

Supplementary document

Translation of the original operating instructions ––––––––––––––––––––––––––––––––––––– 3

DEU Flamco-Fill P

Montage-und Betriebsanleitung

Ergänzungsdokument

Orginalbetriebsanleitung –––––––––––––––––––––––––––––––––––––––––––––––––––––––––– 8

NLD Flamco-Fill P

Installatie- en bedienings- instructies

Aanvullend document

Vertaling van de oorspronkelijke gebruiksaanwijzing–––––––––––––––––––––––––––––––––– 13

FRA Flamco-Fill P

Installation et mode d’emploi

Document supplémentaire

Traduction de la notice d’utilisation originale –––––––––––––––––––––––––––––––––––––––– 18

Flamcomat®, Flexcon®M-K

Flamco-Fill P

 www.amcogroup.com/manuals

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BE Flamco Belux

J. Van Elewijckstraat 59

B -1853 Grimbergen

+32 2 476 01 01 info@amco.be

CH Flamco AG

Fännring 1

6403 Küssnacht

+41 41 854 30 50 info@amco.ch

CZ Flamco CZ

Evropská423/178

160 00 Praha 6

+420 602 200 569 info@amco.cz

DE Flamco GmbH

Steinbrink 3

42555 Velbert

+49 2052 887 04 info@amco.de

DK Flamco

Tonsbakken 16-18

DK-2740 Skovlunde

+45 44 94 02 07 info@amco.dk

EE Flamco Baltic

Löötsa 4

114 15 Tallin

+372 56 88 38 38 info@amco.ee

FI Flamco Finland

Ritakuja1

01740 Vantaa

+358 10 320 99 90 info@amco.

FR Flamco s.a.r.l.

BP 77173

95056 CERGY-PONTOISE cedex

+33 1 34 21 91 91 info@amco.fr

HU Flamco Kft.

H-2040 Budaörs, Gyár u. 2

H-2058 Budaörs, Pf. 73

+36 23 88 09 81 info@amco.hu

NL Flamco B.V.

Postbus 502

3750 GM Bunschoten

+31 33 299 75 00 support@amco.nl

PL Flamco Sp. z o. o.

ul. Akacjowa 4

62-002 Suchy Las

+48 616 5659 55 info@amco.pl

SE Flamco Sverige

Kungsgatan 14

541 31 Skövde

+46 500 42 89 95 vvs@amco.se

UAE Flamco Middle East

P.O. Box 262636

Jebel Ali, Dubai

+971 4 881 95 40 info@amco-gulf.com

UK Flamco Limited

Washway Lane- St Helens

Merseyside WA10 6PB

+44 1744 74 47 44 info@amco.co.uk

Contact

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English (ENG) Installation and Operating Instructions

Table of Contents

1. General safety instructions ............................................................................................................................................................................................................................................ 4

Appropriate use ........................................................................................................................................................................................................................................................................ 4

Warning symbols in this manual....................................................................................................................................................................................................................................... 4

Transportation, storage, unpacking................................................................................................................................................................................................................................ 4

Technical room.......................................................................................................................................................................................................................................................................... 5

External forces .......................................................................................................................................................................................................................................................................... 5

Inspection prior to commissioning, routine checks................................................................................................................................................................................................ 5

Electrical equipment inspections, routine inspection............................................................................................................................................................................................ 5

Maintenance and repairs...................................................................................................................................................................................................................................................... 5

Obvious misuse........................................................................................................................................................................................................................................................................ 6

Residual hazards...................................................................................................................................................................................................................................................................... 6

2. Product description ............................................................................................................................................................................................................................................................. 6

Mode of operation................................................................................................................................................................................................................................................................... 6

Marking......................................................................................................................................................................................................................................................................................... 8

Terminal diagram...................................................................................................................................................................................................................................................................... 9

Components, equipment ..................................................................................................................................................................................................................................................... 10

3. Installation ................................................................................................................................................................................................................................................................................. 11

 Installing,levelling,xing-Ensurestability!............................................................................................................................................................................................................... 11

Connecting the pipework..................................................................................................................................................................................................................................................... 11

Connecting the electrical supply...................................................................................................................................................................................................................................... 11

4. Starting up ................................................................................................................................................................................................................................................................................. 12

Commissioning ......................................................................................................................................................................................................................................................................... 12

 Conguration.............................................................................................................................................................................................................................................................................. 12

Recommissioning .................................................................................................................................................................................................................................................................... 12

5. Maintenance............................................................................................................................................................................................................................................................................. 12

Appendix 1. Technical data, general specications ................................................................................................................................................................................................... 13

Ambient conditions................................................................................................................................................................................................................................................................. 13

Minimum distances: clearance for service and repair........................................................................................................................................................................................... 13

Sample installation diagram............................................................................................................................................................................................................................................... 14

Appendix 2. Technical data and specications ............................................................................................................................................................................................................. 15

Pressure, temperature, volume, etc............................................................................................................................................................................................................................... 15

Weights and dimensions...................................................................................................................................................................................................................................................... 15

Appendix 3. Technical data and information for the electrical equipment................................................................................................................................................... 16

Declaration of incorporation............................................................................................................................................................................................................................................... 17

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1. General safety instructions

The present document is a supplement to the installation and operating manual: Flamcomat, Doc.-

Nr.:00018/11-2010/eng.;FlexconM-K,MC00019/01-2011/engandmustonlybeusedwiththesebasicdocuments.Thegeneral

safety instructions contained therein apply in particular, as does the information on equipment, use and function.

FurtherproductinformationcanbeobtainedfromtherespectiveFlamcobranchofce(seepage2).

Forinstallationinstructionsandfurtherdocumentationinvariouslanguages,visitwww.amcogroup.com/manuals.

1.1 Appropriate use

Level-controlledtoppingupofsystemwater(heatcarrier)withfeedwaterinheatingandcoolingwatersystems.Thisservesto

compensateforoperationallossesinthesysteminordertokeeptheminimumsystempressureabovethellingleveltrackingvalue

in compressor-controlled or pump-controlled expansion automats.

Indoingso,theSPC(controlunitonthepressuremaintenanceunit)takesoversurveillanceofthelevel-controlledpressurisationunit

and, in line with demands, controls the pump integrated in the Flamco-Fill P.

The pressurisation unit's range of applications in terms of system pressure, or Flamco-Fill P system connection pressure, is between

1and9bar(PN10).Forheatingsystems,toppingupispermissibleasperDINEN12828,orinsystemswithmax.owtemperatures

upto105°C.Fordesignoutputsabove1MW,theowner/usermayneedtohandleadditionalsafety-relatedrequirements,where

appropriate,incooperationwithanotiedbody,inaccordancewithcurrentharmonisedEuropeanstandards.Systemwaterandlling

water are separated by a free outlet as per EN 1717 and DIN 1988.

1.2 Warning symbols in this manual

Warning of hazardous electrical voltage

Failuretoobservecancausefatalinjury,reorotherdamage,

or lead to overloading of individual components and to damage, or functional impairments.

Warning in case of errors and incorrect initial conditions.

Failure to observe can lead to serious personal injury, component overload and damage, or functional impairments.

1.3 Transportation, storage, unpacking

Theequipmentisdeliveredinpackingunitsincompliancewiththecontractualspecications,orrequirementsforspecictransport

methods and climate zones. They meet the requirements of the Flamco STAG GmbH packaging guidelines as a minimum.

Inaccordancewiththeseguidelines,thepressirisationunitaresuppliedpackedatonspecialpallets.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. The goods delivered must be moved at the lowest possible setting of the lifting equipment,

perpendicular to the forks. If the packages are suitable for lifting gear, they are marked at the appropriate lifting points.

Importantnote:Transportthepackedgoodstoapositionascloseaspossibletotheenvisagedset-uplocation;makesurethereisa

level, load-bearing surface on which the goods can be deposited.

Caution: After removing the unit from the pallet and packaging, take safety precautions to avoid impact, tipping and swinging. Use

an approach that prevents uncontrolled falling, sliding or tipping over. The goods may also be temporarily stored in their packaging.

Avoid stacking more than three packaging units. Use only permitted lifting gear and safe tools, and wear the required personal

protective equipment.

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1.4 Technical room

Denition:roomwhichmeetstheapplicableEuropeanorregionalregulations,Europeanandharmonisedstandardsandrelevant

technicalrulesandguidelinesoftheprofessionalassociationsforthiseldofapplication.Wheretheuseofllingequipmentis

concerned, these rooms generally have equipment for heat generation and distribution, water treatment and degassing, power supply

and distribution, and measurement, control and information technology.

Accessforunqualiedanduntrainedpersonsmustberestrictedorforbidden.

The set-up location of the pressurisation unit must guarantee that operations, servicing, testing, maintenance, assembly and

disassembly can occur permanently, without obstruction and safely. The surface forming the installation area for the equipment of

the pressurisation unit must ensure stability and support. Bear in mind that the maximum possible forces comprise the deadweight

includingthewaterll.Ifstabilitycannotbeguaranteed,thereisadangerthattheunitwilltipover,ormoveunderloadand,asa

consequence, cause malfunctions and injury to persons.

The ambient atmosphere must be free of electrically-conductive gases, high concentrations of dust and aggressive vapours. There is

the risk of explosion if any combustible gases are present.

Dependingontheprocess,thewatertemperaturecanriseto90°C;incaseofimproperoperation,itcanexceed90°C.Therefore

thereisadangerofinjurytopersonsthroughburnsand/orscalding.

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.

Electrical hazards:

The protection class of the electrically operated components prevents injury to persons through potentially fatal electrocution. The

protectionclassisatleastIP52(5:Protectedagainstaccesswithawire,dustprotected;2:Protectionagainstwater,diagonally

falling dripping water. The terminal box cover, the cover of the pump feed, the cable glands and the valve connector plugs must be

inspected for effectiveness of protection prior to commissioning.

Avoid welding work on additional equipment that is electrically connected to the control unit. Stray welding currents or an improper

earthconnectioncouldleadtothedangerofreandthedestructionofpartsoftheunit.

1.5 External forces

Preventanyadditionalloads(e.g.,theforcesofheatexpansion,owuctuationsordeadweightloads).Thesecanleadtocracksand

breaks in the water-bearing pipework, to a loss of stability, and also to failure – associated with serious personal injury and damage to

property.

1.6 Inspection prior to commissioning, routine checks

These checks guarantee operational safety and its continued presence in line with applicable European or regional regulations,

Europeanandharmonizedstandardsandpertinenttechnicalrulesandguidelinesoftheprofessionalassociationsforthiseld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.

1.7 Electrical equipment inspections, routine inspection

Withoutprejudicetotheconsiderationsoftheinsurer/operator,itisrecommendedthattheelectricalequipmentrelatingtotheFlamco

pressurisationunitbedemonstrablyinspectedtogetherwiththeheating/coolingunitnotlessthanevery18months(seealsoDINEN

60204-12007).

1.8 Maintenance and repairs

Thellingequipmentmustbedisabledandpreventedfrombeingunintentionallyenableduntiltheinspectioniscompleted.Notethat

the safety circuits and data transmissions made while shutting down could trigger safety chains or generate incorrect data. Existing

instructions for the heating or cooling system as a whole must be observed. When shutting down hydraulic components, the related

partsmustbeswitchedoffusingthecapvalves/ballvalvesinstalledontheFlamco-FillPllingequipment.Thecomponentscanbe

drained and the pressure relieved via the pump's drain plug.

Caution:themaximumsystemwatertemperatureincomponentsthatconductindustrialwater(pumps,casings,hoses,pipelines,

peripheralequipment)canreach90°C;itcanexceedthisvalueincaseofimproperoperation.Thereisariskofburnsand/or

scalding.

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The maximum pressure in system water conducting components may be equal to the maximum set pressure for the applicable safety

valve.(UnitwithpermissibleoperatingoverpressureofPN10.)Useofeye/faceprotectorsisrequirediftheeyesorfacecouldbe

injuredbyyingpartsorsprayinguids.

Tostopelectricalequipment(controlunit,pumps,valves,peripheralequipment),isolatethepowersupplytothecontrolunit.The

power supply must remain switched off for the duration of the work.

Unauthorisedmodicationsto,andtheuseofnon-approvedcomponentsorreplacementparts,isprohibited.Thiscanresultin

serious injury to persons and endanger operational safety. They will also render any claim for damages against product liability void.

The recommended approach is to call in Flamco service to perform these services.

1.9 Obvious misuse

Operation at incorrect voltage and frequency.

Feeding into drinking water systems

Operationwithhazardousmaterials(poisonous,ammable).

Mobile application.

1.10 Residual hazards

•Crushingngerswhenxingthesidepaneltothehousing.Wearprotectiveclothing.

•Whenassemblingthesystem,bodyposturecancausefatigue;ifnecessary,planforbreaksintheassemblingprocess.

•Incorrect routing can cause pressure hoses to burst. Avoid kinking the hoses.

•Fire:professionalreprotectionmustbeensuredonsite.

2. Product description

The contents of this manual include information on the supplied standard equipment.

Whereappropriate,thisincludesinformationonoptionsorothercongurations.

If optional extras are supplied, further documentation is provided in addition to this manual.

2.1 Mode of operation

TheFlamco-FillPactsasapressurisationunitwithapump(9)andabreaktank(3,4and6);itcanbemountedonawalloron

optionalfeet(12and13),actuatedusinganelectricalconnectiontotheSPConthepressuremaintenanceunitprovidedbythe

customer.

Initially,theoatvalve(3)llsthebreaktank(4)uptothelimitvalue.Duringthisprocess,theowpressuremustbeabove1bar.As

soonasenoughwaterhaslledupinthesystemseparationvessel,thepressureswitch(8)startstomonitortheminimumllinglevel

sothatthedryrunmonitoringsignalfortheSPCcanbetakenfromtheFlamco-FillPterminalbox(11).Theinstallationofapressure

reducerisrecommendedifhighowpressures(>5bar)exist.

OncethellinglevelintheFlexconM-Kcompressor/automaticpressuremaintenanceunitorFlamcomatdropsbelowtheswitching

pointfortheFlamco-FillP,thepump(9)startstodeliverllingmediumtothesystem/expansionline(fortheFlexconMK)ortothe

expansionvessel(fortheFlamcomat).

Oncethellinglevelswitch-offpointintheFlamcomatbasicvesselisreached,thepump(9)isswitchedoffagainviatheSPC.

FortheFlexconM-K,thesystempressureincreasesthroughllingthesystem.FlexconM-Kexternalpressuremaintenanceunit

correctsthepressurebyreleasingairfromthegasplenum.ThevesselllinglevelincreasesduringthisprocessuntiltheFlamco-Fill

Pllingswitch-offpointisreached.

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AllFlamco-FillPcongurationsaremadeviatheSPContheexternalpressuremaintenanceunit.

5 3

2 1

1. Non-return valve

2. Water meter with pulse output

3. Float valve

4. Break tank

5. Housing cover cap

6. Overow

7. Housing

8. Pressureswitch(dryrunprotection)

9. Pump

10. System connection

11.Connection/Terminalbox

12.Feet(Optionalextras)

13. Mounting bolts for optional feet

14. Housing side panel

15. Non-return valve

16.Externalprotectiveearth(PE)conductorconnection

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2.2 Marking

Unit name plate

Terminal box name plate (inside)

Unit type marking with notes about electrical safety on the terminal box

Terminal box service numbers

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2.3 Terminal diagram

3 43 3

1 91 8 2 0

1 8 1 9 2 0

P E

(gegn)

u1 w2

v1 u2

w1 v2

N L

G N DG N D

pw m ps re ﬁll/ dra in

04.01.13

( 2 3 0 V 5 0 H Z )

8 9 3 3 3 4 1 8 1 9 2 0

P E

Watermeterwithpulser(IWZ) Dry-run protection Pump

(DS240)

Execution

As pressure switch

Conductor Color Code

bl Blue

bn Brown

ye/gn Yellow/Green

bl Black

wt White

gr Grey

External

cable

connect to

housing

Ye/gn

Explanation of the abbreviations used in the terminal diagram

Please note: The switch settings shown represent the current-free, non-switched state.

extra-low voltage Protective low voltage

high voltage Voltage as per markings

L Phase

N Neutral wire

PE Protectiveearth(PE)conductor

Pumpe/pump Pump motor

ps Pressure switch

pwm Pulse water meter

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2.4 Components, equipment

5 3

Feed

System

2 1

1. Non-return valve

2. Watermeterwithpulseoutput(IWZ/pwm)

3. Floatvalveforllingwithsystemseparation

4. Break tank

5. Cover for housing access to the break tank

6. Breaktankoverowconnection

7. Housing(onlyedgesportrayed;earthconnection

markedwithalabelonthefrontside)

8. Pressure switch for the pump's dry run protection

9. Pump

10. Pressure hose – connection to the system

11. Terminal box with connection contacts to the top hat rail

(andtransparentcover)

12. Feet as optional equipment

13. Threaded connections for Pos. 12

14. Removable housing side panel

(onlyedgesportrayed)

15.Non-returnvalve(preventsreverseowoutofthesystem

intothebreaktank).

16.Externalprotectiveearth(PE)conductorconnection

17. Terminal block for connecting the pressure switch

andfortheelectricalconnectiontotheSPC(tobeprovided

bythecustomer)

18. Terminal block for connecting the pulse water meter

andforelectricalconnectiontotheSPC(tobeprovidedby

thecustomer)

19. Terminal block for connecting the pump

andforelectricalconnectiontotheSPC(tobeprovidedby

thecustomer)

Questo manuale è adatto per i seguenti modelli

Indice

Lingue:

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