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M-K Compressor Expansion AutomatInstallation and operating instructions

Dear Customer,

Thank you for purchasing the FLEXCON M-K Compressor Expansion Automat – a quality product from Flamco. This expansion automat from the proven M-K series offers you reliability, guaranteed operational readiness and ease of use.On the following pages we will present you with technical specifi cations, instructions and explanations that facilitate safe use in accordance with regulations. Persons responsible for transport, installation, commissioning, re-starting; operation, maintenance, checks and repairs must have read and understood these instructions.Please place these instructions in a place where they can be inspected at any time.We will be happy to answer any questions that are not covered by these instructions,

Contents

(Sections 1 – 7 belong together, not independent) Page

1. Exclusion of liability 2

2. Acceptance of goods 2 Inspection 2Type plate 2Transport 2Storage 3

3. Product description 3

Methodology 3Equipment 3Operating modes 5Accessories, additions 6

4. Safety instructions 7

Intended area of use 7Measures for hazard-free operation directions for safe use 8Avoiding excessive pressure 8Avoiding excessive temperature 8Residual hazards 8

5. Installation 9

Environmental conditions 9Base and setup 9System connection 9Gas compartment couplings 10Electrical installation 10

6. Start 10

Commissioning 10Programming 11Start and system temperature 11Re-start 12

7. Maintenance 12

8. Periodic testing, pressure equipment 12

Appendices

Appendix 1Technical data, specifi cations, hydraulic and pneumatic equipment

Dimensions, weights 13Minimum distances 14Example installations 15

Appendix 2Technical data, specifi cations, electrical equipment

Modules 19Flexcon control unit, M-K/S,

Operating mode menu. [Fault displays] 20Programming mode menu 21Service programming mode [Default settings] 22Standard terminal diagram 23Standard terminal diagram, accessories, additions 24Terminal diagram for special version [400/230V 3/PE ~50Hz] 25Terminal diagram for special version, accessories, additions [400/230V 3/PE ~50Hz] 26

SDS controller, M-K/U,Operating mode menu 27Programming mode menu. 28Service programming mode. [Default settings] 30Error list 30Standard terminal diagram. 31Standard terminal diagram, accessories, additions 32Terminal diagram for special version, accessories, additions [Valve pressure increase] 33Terminal diagram for special version [400/230V 3/PE ~50Hz] 34Terminal diagram for special version, accessories, additions [400/230V 3/PE ~50Hz] 35

35

Edition 0206© Flamco

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18502426 broch Flexcon M-K_UK.indd 118502426 broch Flexcon M-K_UK.indd 1 13-07-2006 08:55:2113-07-2006 08:55:21

www.flamco.nt-rt.ru

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1. Exclusion of liability

All the technical information, data and instructions contained in these operating instructions foroperations that can and are to be performed, are up to date at the time of editing.They contain our current knowledge and experience to the best of our understanding.We reserve the right to make technical modifi cations arising from the further development of theFlamco product presented in these operating instructions. For this reason, no claims may bederived from technical data, descriptions and illustrations.

Required operations within the scope of Flamco delivery must be performed by trainedand certifi ed specialists. This includes such persons having knowledge of applicable safetyconditions. Consequently, Flamco shall not be liable for any losses, subsequential losses,personal losses arising from the non-observance of safety conditions or as a consequence of thedisregard of standard precautionary measures when performing such services as transport,installation, commissioning, re-starting, operation, maintenance, testing and repair, even in theevent that these are not expressly described in these instructions.

Technical illustrations, drawings and graphs may not necessarily represent the actual module,individual components or spare parts supplied.Drawings are not to scale and contain symbols for the purpose of simplifi cation.

-Reference symbols used in the instructions.

Hazardous voltageIgnoring this can put your life in jeopardy, cause fi res or accidents destruction

For special considerationIgnoring this may result in reduced functioning ,overload or destruction

2. Acceptance of goods

Inspection

The items supplied (equipment, documentation) are listed in the shipping papers.The contents of the delivery must be immediately checked for completeness and transportationdamage upon arrival.Incorrect or missing items must be immediately identifi ed. Please note the contents (e.g., forhandling goods, notifi cations of defects...) of the general terms and conditions contained in theshipping papers.Compare the specifi cations on the type plate of the expansion vessel with the specifi cations ofyour order or the details of the relevant project.If this expansion vessel is used regardless of any differences which have been ascertained (notused in accordance with regulations), it will not be possible to exclude system faults or hazards topeople, animals or objects.

Type plate

- Gas pre-charge mark.The expansion vessel (basic and ancillary vessel) is under pressure on delivery, which, in standard situations, is an overpressure of 2.0 bar. This value may be smaller, depending on the order. The information is at eye-level on the operating side (user position).(Changes in ambient temperature can cause variations in the pre-charge.)

Transport

The basic and ancillary vessels of the unit are packed horizontally on disposable pallets and delivered fully assembled. Accessories or add-on equipment (e.g. Compressor Unit K04) can be packed separately or as a part of the automat unit packaging. The disposable pallets are suitable for horizontal transport using permitted forklift devices (e.g. forklift trucks, forklift stackers...). Always use the largest possible fork size for the pallet to prevent the load from tipping over.Position the object to be moved as low as possible, at right angles to the forks.

Hoist fi ttings on the vessel (welded lifting lugs) are to be used for lifting of the empty, uninstalled vessel that has been removed from its packaging.

Note: The transport guard (Pos. 46, page 4) provides necessary protection against collision duringthe setup of the expansion automat and must only be removed once this is complete!(Installation surface, setup, page 9)

Man

uf

acturer’s marking

Herstellerkennzeichen

Mar

que

distinctive du constructeur

0045

:::

HerstellungsjahrYear of manufactureAnnée de fabrication

:::

:::

:::

:::

:::

:

::

°C

Flamco STAG GmbH39307 Genthin GERMANY

Literlitre

Zulässige Betriebstemperatur min. / max.Permissible working temperature min. / max.

PrüfüberdruckTest overpressure

Zulässiger BetriebsüberdruckPermissible working overpressure

NenninhaltNominal volume

Serien-Nr.Serial-No.

TypType

bar

bar

litres

N° de série

Capacité nominale

Surpression d`essai

Surpression de service admissible

Température de service mini. / maxi. admissible

Type

Conformity mark

Manufacturer’s mark

Respective year of manufacture

Permitted operating temperature of the expansion vesselPermitted test overpressure of the expansion vessel

Permitted operating overpressure of the expansion vesselNominal capacity of the expansion vessel

Serial (production) number of the expansion vesselType rating of the expansion vessel

Manufacturer’s logo Manufacturer’s address


3


Transport (continued)

Once the automat has been removed from its packaging, it must be set up under safety measuresto avoid being damaged, tipped or shaken. Only use permitted load lifting devices.Depending on the transport method and the size of the expansion automat, various types of packaging may be used.Unless otherwise contractually agreed, the packaging meets the packaging guidelines of Flamco STAG GmbH.

Storage

Interim storage can also take place while packed. Conditions for this are: a closed, frost free room (dry..60...70 % relative humidity), free of vibrations, protected against heat and direct sunlight.Vessels or equipment parts that have been removed from the packaging must be placed in their fi nal position.The stability is to be ensured and the stacking of equipment should be avoided.

3. Product description

Methodology (Symbol)

Changes in the volume of the operating water )a* caused by temperature changes in closedheating or climate control systems generate different levels in the water compartment of theexpansion automat. The pressure in the gas compartment of the automat caused by this is ameasurable value that is continuously recorded by a pressure sensor and transmitted via a signalcable to a control unit.In the event of any difference, a comparison of these actual values with the programmablenominal values leads to the control of a compressor or pressure relief valve, which is linked withthe gas compartment by a common pressure control tube.In this way, the valve is opened as the level increases during system heating to relieve pressure(pressure reduction) and the compressor is switched on as the system cools and the level falls(pressure increase).A hystereses )b* may be set for controlling the valve or compressor, which ensures themaintenance of the set system pressure of a heating or climate control system with a modifi able,small tolerance.The levels recorded by a level sensor and assessed by the controller result, as in the case of thesystem pressure, to display values and once limit values have been reached, to control signalsthat enable an additional evaluation or the actuation of other units.

By choosing different nominal sizes of vessel, the option to connect several vessels, the selectionof different compressor capacities or operating modes and by changing the nominal values, theM-K compressor- expansion automats can be adjusted to the operating behaviour of a heating orclimate control system.

)a* Water types whose constituent materials do not pose any hazard to the operational readinessand do not damage or improperly infl uence (e.g. heating water) water-keeping parts of theAutomat (e.g. pressure-bearing components, diaphragm, vessel connection,...))b* Switch difference to the nominal value, only changes to the nominal value can be assessed.Small hystereses: the advantage is a small deviation from the nominal value, the disadvantageis a high switch frequency.Large hystereses: the advantage is a low switch frequency, the disadvantage is a large deviationfrom the nominal value.The programmable setting range on the M-K expansion automat, this switch difference,is 0.1 – 0.5 bar for as well the compressor (pressure increase), as for the pressure relief valve(pressure reduction). Standard models have a preset of 0.2 bar (total lag of 0.4 bar).

Equipment

The equipment components of the M-K expansion automat meet the safety requirements of therelevant EC directives and the specialist standards to be applied.Compliance is confi rmed by means of conformity declarations.The construction of the pressure vessels is designed in accordance with Directive 97/23/EC )c*and under consideration of the German AD Information Sheets )d*.Examination and cleaning openings for inspections are provided on the basis of practicalexperience (taking German standards into consideration).The conformity label CE0045 (on the type plate) identifi es the Notifying Body at which the conformity evaluation process according to Article 10 of this Directive has been tested and confi rmed.In line with the scope of use according to regulations, the corrosion allowance is 0 mm.This allowance may be higher , depending on the order.

)c* Directive of the European Parliament and Council for the harmonisation of legal provision ofmember states on pressure devices. Offi cial Journal of the European Communities L181.)d* Technical safety requirements for normal operation conditions, prepared by theassociations that cooperate in the Arbeitsgemeinschaft Druckbehälter (AD).Published by: Verband der technischen Überwachungs- Vereine e.V., 45038 Essen.

Pressure vessel

Diaphragm

(Gas pressure)Gas compartment

Symbol

Heating

Water compartment(Water pressure)

sensorPressure

or climate controlsystem

Compressor

Controller

M

sensor Level

Valve


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Confi guration (continued)

1 Type plate. 2 Steel expansion vessel,

exterior corrosion protection, untreated internally (inner coating ***). 3 Inspection opening. 4 Inspection opening DN 500,

M-K/S 6500 – 10000 litres. 5 Lifting lugs (for lifting). 6 Collision protection.

(gas compartment connections).7 Foot-height adjustment.8 Foot pressure plate, M-K/S 5000 – 10000 litres.9 Setting screw (transport guard,

level sensor, disassembly). 10 Manual breather valve. 11 Cap nut (collision protection of manual breathervalve ). 12 Floatvent **. 13 Quick-release coupling, coupling box. 14 Pressure hose, fl exible, coupling plug double-sided, length 3000 mm [**]. 15 Pressure hose, fl exible, expansion. 16 Pressure hose, fl exible, pressure sensor. 17 Pressure hose, fl exible, safety valve, M-K 400 – 3500 litres. 18 Pressure hose, fl exible, pressure increase 1; 2** )k*. 19 Pressure hose, fl exible, system connector, M-K/U, M-K/S 400 – 10000 litres. 20 System connector, M-K,

90° angle, 400 – 3500 litres. 21 System connector, M-K/U; M-K/S. 22 Connector module, expansion;

Safety valve, gas compartment; Expansion valve 1 (1.1; 1.2 ***) Relief valve 2; 2.1** )k*; Gas escape fuse 1; 2** )k*; Pressure connector, expansion: Pressure connector, pressure increase 1; 2** )k*.

23 Connector module, expansion***; Safety valve, gas compartment; Expansion valve 1; Pressure increase valve; Gas escape fuse;

35 Ball cock, condensate drain cock. 36 Flexcon control unit, M-K/S, page 19. 37 SDS controller, M-K/U, page 19. 38 SDS Directstart power part ***; 1 (2); page 19. 39 Electrical feed, compressor1; 2** )k*. 40 Electrical feed, SDS controller ***. 41 Signal wire, pressure sensor (<=30vDC; 42 Pressure sensor SELV). 43 Signal wire, level sensor (<=30VDC; 44 Level sensor SELV). 45 Diaphragm rupture sensor, feed ** (SELV). 46 Transport guard, level sensor. 47 Water compartment (expansion water). 48 Diaphragm (butyl). 49 Gas compartment.

)k* Second compressor unit

M-K/S:Basic vessel(Pos.36)M-K/U:Basic vessel(Pos.37)M-K:Ancillary vessel

SM:Single modePM:Parallel modeBM:Backup modeLM:Load dependant modeSELV:Safety extra-lowvoltage

PE- connector(protective earth)

Pressure connector, expansion: Pressure connector, pressure increase. 24 Safety valve, gas compartment. 25 Compressor unit K01 – K03, oil-free. 26 Second compressor unit

K01 – K03, oil-free; **. 27 Compressor unit K04, oil-free. 28 Second compressor K04, oil-free; **. 29 Compressor unit L6 – L14 (K420), 1 (2), oil-free; **. 30 Switch, TP- manual reset. 31 Intake opening, compressor. 32 Cool-air inlet, compressor. 33 Ball cock, vessel drainage ***. 34 Ball cock, system connector ***.

** Accessory, addition *** Special version

1

2

4

22

3

5

5

6

6

78

9

11

12 **

13

1324

Example illustrationsM-K/S 6500 LitreSM

M-K,partial view,from above.

Side viewfor below, right.

View from above.

15

15 16

16

18

19

35

36

41; 42

43; 44 (46)

41;42

25

32

39

3631

2

2

19

33 ***

34 ***21

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View from above.Partial view from rear.

12

3 5

5

5

6

6

9

2

13

13

13

13

13

1313

24

14 [**]15

19

15

16

16

17

21

8 18

720

22

25

26 **

25

30

37

31

32

35

35

31

37

39

43 43

41; 42

44 46

44 (46) 7

474849

2119

39

5 5

2417

32

M-K 600 Litre

Side viewM-K/U 600 LitreSM

M-K 600 LitreM-K/U 600 LitrePM / BM / LM

25

12 **

14 [**]

2

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FlamcoDirektstart 1SDS 400/230V 3/PE ~50/60Hz

12

3 1556

9

1011

12 **

1313

13

14

16

18

13

22

7

253231

31; 32

3637

38 ***

39

39

43

45 **

(2)

40 ***

44 (46)

11

14

6

15 16

103

5

29 ***

Example illustrationsM-K/U 600 Litre *** M-K/S 600 Litre M-K/S

M-K/U 600 LitrPartial view

M-K/U 600 Litre ***Partial view

221314

240 ***37

SM SM

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1

2

356

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1313

131313

13 13 13

1414 14

15

16

22 22 23 ***

13

29 ***27 27 28 **

31; 32

36

37

39

39 39

43

7

12 **

44 (46)

M-K/S 600 Litre M-K/U 600 Litre M-K/U 600 Litre ***SMPM / BM / LMSM

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Operating modes

The possible operating modes and their modifi cations depend on the supplied version of the M-K/S and M-K/U expansion automats. Fitting and programming are done in accordance with the order. (Installations of these systems with ancillary vessels [M-K] are preferably done at fi rst start A required accessory is the pressure hose connection**, per ancillary vessel; Example M-K/U – M-K, page 4.)

Single mode, M-K/S and M-K/U expansion automat.

The capacity of a single vessel and the power of a single compressor are available (K01…K04).(example SB, page 4) Parallel mode, M-K/S and M-K/U expansion automats.

The capacity of a single vessel and the power of two compressors are available (second compressor unit 2 K01…2 K04 **). The installation of required equipment for operation with a se-cond compressor unit is performed by manufacturer. Changing the mode of operation to backup mode (modifi cation to half of total compressor output) is possible by a trained, qualifi ed specialist. (Example PM)

Parallel mode of 2 expansion automats (Master- Slave mode), M-K/S.

The capacity of two automats (expansion vessels) and the power of two or four compressors are available (compressor unit K01…K04, per vessel or second compressor unit 2 K01…2 K04 **, per vessel). The installation of required equipment for operation with a second compressor unit takes place by manufacturer. The Master automat (primary) provides the current operating parameters and resulting switch commands to the Slave automat (subordinate). The defi nition of the Master/Slave or their modifi cation can be programmed by a trained, qualifi ed specialist. Necessary additions are the pressure hose connection** and a data cable (RS485) on site. (Example PM 2A)

Backup mode, M-K/S and M-K/U expansion automats.

The capacity of a single vessel and the power of a single compressor are available (second compressor unit 2 K01…2 K04 **). The installation of required equipment for backup operation takes place by manufacturer. A change from compressor 1 to compressor 2 takes place following activated motor protection, following an overload (operating power, operating temperature), or after the expiry of a programmable change time (to balance the operating times of each drive).Changing this mode of operation to parallel mode (change to the double compressor- capacity), is possible by a trained, qualifi ed specialist. (Example BM)

Backup mode of 2 M-K/S expansion automats.

The capacity of two automats (expansion vessels) and the power of a single compressor or two compressors are available (compressor unit K01…K04, per vessel or second compressor unit 2 K01…2 K04 **, per vessel). Installation for operation with a second compressor unit takes place by manufacturer. The controller on one automat is passive and receives the current operating parameters from the active controller and the resulting switch signals for the expansion valve 1 (1.1; 1.2 ***). The switch from passive to active takes place following activated motor protection resulting from an overload (operating power, operating temperature compressor 1, or 1 of 2, or both, at the active automats), after the expiry of a programmable change time, through the active controller, or when data (RS485) can no longer be received from the active controller. Necessary additions are the pressure hose connection** and and a data cable (RS485) on site. (Example BM 2A)

Load-dependent mode, M-K/U expansion automat.

The capacity of a single vessel and the power of two compressors are available (second compressor unit 2 K01…2 K04 **). Installation of required equipment for operation with a second compressor unit takes place by manufacturer. The activation or shutdown of compressor 2 is controlled following a comparison of achieved or achievable nominal values with programmed presets (PI- regulator). A change in the compressor start-up sequence takes place after the expiry of a programmed change time (balancing of the operating hours of each drive). Changing the mode of operation to backup mode (change to half of total compressor power), is possible by a trained, qualifi ed specialist. (Example LM)

Manual mode, M-K/U expansion automat.

Operating mode for test or service activities, for optional switching on or off of drives (compressor, valve), by trained, qualifi ed personnel. The automat is not active for expansion. (Example process display, manual mode)

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electronic control unitelectronic control unitstandard pressure controlstandard pressure control

enterenterpresspress

Example PM

ExamplePM

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ExamplePM 2A

Datacable

(RS485)

Pressurehoseconnection **

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ExampleBM

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ExampleBM 2A

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ExampleLM


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Accessories, additions.

Type Application Brief description

Pressurisation Unit [PU] to top up lost quantities of water from the drinking water network, whose fl owing pressure is at least 1.2 bar higher than the nominal system pressure. Controlled depending on the vessel level [l] and the make-up time [t]; [PUlt]. (Example installation, page 17; terminal diagram, page 32; 35; product information service, addition to fi lling.)

Degassing and fi lling system [PUlt].Used in accordance with the operating instructions for this item. When combined with the expansion automat, an external fi lling requirement may be possible.(terminal diagram, page 24; 26; 33))* product information service, addition to fi lling.) Filling system [PU] to top up lost quantities of water from a pressurised water network, whose fl ow pressure differential to the nominal system pressure is less than 1.2 bar. Used in accordance with the operating instructions for this item. (Installation example, page 15; 17;terminal diagram, page 24; 26; 33))* product information service, addition to fi lling.) This fl oatvent enables automatic venting of the water compartment, negating the need for manual venting. Delivery for commissioning takes place in an accompanying pack, installation is to be carried out on site. The upgrade requires an unpressurised vessel on the water supply side, and the breather valve must be uninstalled (Pos.12; 11; 10, page 4). Module, with fi ll and drain valve 1⁄20, for Changing the standard vessel connectors from threaded to DIN- fl ange (DN32...65; PN16;Use of cap valves with fl ange connector) The fl exible system connector on the fl ange of the basic vessel (M-KS...U) must be kept upright. (Installation example, page 15) Coupling hose for connecting gas compart-ments, when using several vessels with a common expansion control. (Pos.14 [**], page 4;Installation example, page, 15; 16; 17) Execution for extension of operating modes. Only compressors of the same capacity can be combined. Ancillary models (K04; L6... K420 *** must be installed on site. (Pos.26; 27; 28; 29 ***, page 4; terminal diagram, page 23...26; 31; 32; 34; 35)

Used in the event of stricter safety requirements. The upgrade requires an unpressurised vessel.(Pos.45, page 4; installation example, page 15;16; terminal diagram, page 24; 26))* For installations with the M-K/U expansion automat, SDS- Module 34 is a prerequisite. Additional module, timer, operating hours counter. Used for requirements with error diagnostics with date, time and display of operating times per drive (Motor 1; 2; Valve 1; 2; 3). The upgrade may be performed by a qualifi ed and trained specialist.(Terminal diagram, page 32; 35) Additional module, signal output: level, pressure analogue Used in requirements for analogue, additional value outputs of the vessel level and actual system pressure (0...10V). The upgrade may be performed by a qualifi ed and trained specialist. Evaluation, visualisation is to be performed on site.(Terminal diagram, page 32; 35)

M-KU[PUlt]

M-K/S[PUl] M-K/U )*[PUlt]

M-K/SM-K/UM-K

M-K/SM-K/UM-K

M-K/SM-K/UM-K

M-K/SM-K/UM-K

M-K/SM-K/U

M-K/SM-K )*

M-K/U

M-K/U

*** Special version

0.133m

Flamco-Fill STU (SDS)

Valve 3

Flexvent super

quittierenStörung EIN/AUS

min.

30 90

60

1200

defektSicherung StörungLaufzeit Wasser-

mangel

Typ PA

Wasserverbrauch

Flamco-Fill

Flamco Fill PA

connection Pressure hose

Flange connector Adapter


7


Additional module, diaphragm rupture sensor. Used in the event of stricter safety requirements. The upgrade may be performed by a qualifi ed and trained specialist.(Pos.45, page 4; installation example, page 17; terminal diagram, page 32; 35)

Additional module as combination: Module 32; 33 or 32; 34. Combinationsor 33; 34 or 32; 33; 34. Use, function in accordance with with 32...34 description of individual modules. (Terminal diagram, page 32; 35)

Additional module, PA contact. Delivered for use with Flamco Fill PA fi ll system or the external fi lling requirement ENA 1...3 with the SDS controller. The upgrade may be performed by a qualifi ed and specialist. (Terminal diagram, page 33; product information service, addition to fi lling.)

Fitted for the remote signalling of errors: Min.-, max. water Easy- Contact M-K/U level; min.-, max. operating pressure, motor protection, diaphragm rupture 2.0; 3.0 and collective fault signalling. For each error message, a red LED and a relay with a potential-free opener/closer is active. The diaphragm rupture output is only possible where a sensor is installed. (Internal switch, position 2.0: M-K/S, 3.0: M-K/U.)Necessary additions on site are a data cable(RS485) and a 230V L N PE 50Hz voltage supply.)* For compressors with internal temperature protection, the activation of this fuse is not displayed. Installation may be performed by a qualifi ed, trained specialist.(Terminal diagram, page 24; 26; 32; 35)

Additional module, remote display device. Used for remote Televisorprocess monitoring. Displays an identical process view of the SDS controller (active, passive drives, nominal values of the fi lling quantity, system pressure, level) with plain language message in the event of system errors and its remote acknowledgement.A necessary add-on on site is a data cable (RS485).The installation may be performed by a qualifi ed and trained specialist. (Terminal diagram, page 32; 35)

Additional module, analogue modem connector. Used for SDS process management over the fi xed network. Administration of up to 5 independent number blocks with confi gurable call process in the event of an error. Direct dialup or recall for process presentation and parameter modifi cation or presentation.Additional status reports from 4 independent and freely defi nable inputs, digital. Required on-site additions are: ana-logue telephone line, plug signal wire, signal cable (RS485), modem, PC connection. Installation may be performed by a qualifi ed, trained specialist. (Terminal diagram, page 32; 35)

Additional module, standard LONWorks bus connector. Used in data transfer for visualisation in LON networks and LON building management systems. Necessary additions on site are a data cable (RS485), a 230V L N PE 50Hz voltage supply and data evaluation by a competent LON system integrator. Installation may be performed by a qualifi ed and trained specialist. (Terminal diagram, page 32; 35)

Additional module, Service Stick. Used for saving, copying and transporting parameter fi les, recording and for processing the fi les by USB on the PC, sending the fi les to the Service Centre and reading the fi les modifi ed by Support.(Terminal diagram, page 31...35; com1a; com1b)

M-K/U

M-K/U

M-K/U

M-K/S )*M-K/U

M-K/U

M-K/U

M-K/U

M-K/U

4. Safety instructions

Intended scope of use.

Closed water heating and climate control system, in which changes in the volume of the operatingwater caused by temperature fl uctuations are to be balanced out and the required operating pressure to be guaranteed by the separate installation of an external expansion vessel.

The equipment can be found at pages 4; 5, the installation example for heating systems is on pages 15...18.

The following notes and explanations refer to heating systems. For climate control systems (cooling), relevant use applies (note).

Accessories, additions. (continued)

Type Application Brief description

Note

System Initial status Nominal status

Heating Cold Hot Vessel with Vessel with water prefi ll. water prefi ll and expansion capacity.

Climate control Warm Cold Vessel with Vessel with water prefi ll and water prefi ll. expansion capacity.

PA-contact

Membranbruch

Störung

Motorschutz

Max. Betriebsdruck

Min. Betriebsdruck

Max. Wasserstand

Min. Wasserstand

Anlage Betriebsbereit

SDS kompatibel

V2/0 V3/0 switch

Modem couplerSDS Analog

Flamco

Flamco

Bus couplerSDS LONWorks Standard

Standard


8


4. Safety instructions (continued)

Measures for hazard-free operation.

Product information, instructions and communications from the manufacturer contain, in the latest applicable edition, details on measures for hazard-free operation within the scope of application described therein. Other use or use that is not in accordance with regulations, customer conversions to the item or modifi cations of a system without the permission of the manufactu-rer fall outside the warranty and cannot preclude disruptions to function or hazards to people, animals or objects.

It is assumed that installations for operating the M-K Compressor Expansion Automat ensure that any exceeding of the permitted operating overpressure and the permitted operating temperature are reliably and dependably excluded. Safety devices for dealing with low and excessive pressure on the water supply side for operating the heating system (e.g. minimum, maximum pressure limiters) do not form part of the equipment supplied.

Information on reliable operating overpressure and the permitted operating temperature can can be found on the rating plate on the M-K/S, M-K/U, M-K pressure devices (Type plate, page 2; Pos.1, page 4)

• Avoiding excessive pressure.

When using the M-K Compressor Expansion Automat in water heating systems, it is assumed that the installations of heat generators include equipment that reliably prevents the permitted operating overpressure from being exceeded.

Suitable devices for limiting the pressure of the expansion vessels are safety valves that open as soon as the permitted operating overpressure is reached and are in a position, within 1.1 times the permitted operating overpressure, to vent the arising capacity fl ow of the generator. Feed and exhaust pipes for safety valves must be designed without a shutoff and must not contain any parts that could lead to a narrowing of the fl ow cross-section. Reliability for use and their suitability must be proven or certifi ed.The manufacturer’s instructions on safety valves and national regulations must be observed. (Note)

The safety valve installed on the gas compartment of the expansion automat ensures that the maximum gas capacity fl ow that can be fed through the compressor (external pressure generator) is bled off in the event that the pressure control system fails. This valve is not intended to prevent the reliable operating overpressure in a heat generating system from being exceeded.

• Avoiding excessive temperature.

When using the M-K Compressor Expansion Automat in water heating systems, it is assumed that the installations of heat generators include equipment that reliably prevents the permitted fl ow temperature from being exceeded. These devices must be created and installed in such a way that in practical operation an operating temperature permitted for the equipment components is not exceeded at any point of the equipment or system. Permissibility for use and their suitable must be proven or certifi ed. National regulations must be observed.

The arrangement of M-K Compressor Expansion automats in the heating system must be done in such a way that the permitted continuous temperature of 70 °C is not exceeded or exceeded only for a short time. Consequently, installation should preferably take place in the return.Where heating systems exist with return temperatures above 70 °C, installations for cooling the expansion water are to be connected to the expansion vessel in series.(e.g. intermediate vessel, without insulation; Installation example, page 15).

Residual hazards

• Exceeding the permitted vessel specifi cations by not activating safety devices for limiting temperature and pressure. Carry out regular checks on the function of these limiting devices. Risk of component overload.

• Pressure and temperature loads. Carry out work on the vessel only when the gas and water compartment is depressurised. Note that contact surfaces and any water that may need to be drained can reach a temperature of up to 70 °C, and can even exceed this in the case of improper operation. Risk of scalding or serious burns.

• Release of pressurised air from vessels under pressure at gas compartment couplings.

• Effects of fi re. Ensure structural fi re protection.

• Electrical voltage. Ensure that work on electrical equipment is carried out only by authorised specialists. Serious risk of electric shock if any body parts come into contact with live voltage (e.g. 230V 50Hz). (Sensors units, diaphragm rupture, capacity, pressure sensors, are operated with safety extra-low voltage.)


9


5. Installation

Use and the installation location are subject to binding regulations and provisions. Particular reference is made to the obligation to inform test or certifi cation agencies prior to the installation and starting of systems. In this case, the person responsible is to initiate the procedure with these agencies. Documents, conditions and calculations arising from the tests carried out under the procedure or other guidelines are to be observed when installing the system.If acceptance procedures are required for the installed object, the system must only be startedonce it has been confi rmed that the requirements imposed on the system have been satisfi ed.

- Perform the start/commissioning protocol.

Environmental conditions

The M-K Compressor Expansion Automats are to be installed in such a way that operation, testing and maintenance can be constantly guaranteed. This automat must be installed in an enclosed, frost-free room taking into consideration minimum distances (page 14; 13). The safe operating temperature in the vicinity of the automat is 5...40 °C. Higher temperatures can lead to function disruptions and to the overload of the compressor or compressors (no expansion). The placing of the compressor intake and cool-air openings must ensure that surrounding parts cannot be sucked in, an unobstructed fl ow of air is possible, and that no shorted fl ow between cool-air inlet and outlet can occur.

Ensure that the expansion automat is operated in a surrounding atmosphere that is free of electrically conducting gases, high concentrations of dust and vapours. A risk of explosion is posed by combustible gases, gas mixtures.

Base and setup.

The installation surface must be prepared so as to ensure and maintain installation safety.When preparing this surface, take into consideration the maximum weight of the complete automat, including the weight of the water (page 13).The guidelines of the responsible project leader of the total system apply. The following, general rules must also be observed.

- Equipment to be installed must be completely removed from the packaging.

- If the expansion automat (basic vessel) has been set up at the appropriate location and no other changes to the location are required, the transport protection of the level sensor must be removed. Avoid dust from coming into contact with this sensor and ensure a mounting surface that does not obstruct the functioning of the sensor (platform). Avoid fi xing to the ground.

(Types of fi xing that impermissibly infl uence the automat, such as: pouring concrete or plaster around the vessel feet, welds to the vessel or vessel foot, clamps and tighteners to the basic body or suspending the automat are not allowed.)

- Install now those accessories that are required for the expansion function (modules to the gas and water compartments) which result in shutdown after start 56 (e.g. fl oatvent ** Flexvent Super, Pos.12, page 4).

- Vertically adjust the vessel or vessels using the adjustable feet. Use a magnetic spirit level, rotated by 90° for use in vertical positions.

- Ensure that no additional external loads impact on the system.- Install expansion vessels and ancillary vessels at the same height.- When welding, do not allow welding materials to touch or enter equipment parts of the

expansion automat.

System connection

The system connection is to be manufactured as a connection to the heating system. Example installations can be found on pages 15...18. Observe the following instructions before fi lling and starting the M-K Compressor Expansion Automat.

- The connection should preferably be made in the return to the heat generator.- Ensure that this connection has a direct connection to the heat generator. Ensure that the

system connection of basic vessels is made only via the fl exible pressure hose delivered with the system.

- Install a shutoff device in the immediate vicinity of the automat-system connection, which can be protected against unintentional closure and preferably comes with a fi ll and drain valve for the water compartment of the vessel. If this item is missing, it must be installed separately.

- If several expansion vessels are installed, an additional valve must be installed in the expansion pipe in front of the collector pipe, which must also be secured against unintentional closure.

- Note that a temperature at the system connection greater than 70 °C (...90 °C) exceeds the permitted diaphragm load and can result in the destruction of the diaphragm.

(Complete insulation of the expansion pipe can increase the load temperature.)

** Accessory, addition


10


System connection (continued)

- Choose sealants, gauges, feed pipes depending on the project (must at least correspond to the maximum possible pressure and temperature values for this expansion pipe).

- The nominal widths of the expansion pipe (system or collective connection of the vessel or ves-sels, up to the return connection) must be chosen depending on the equipment to be installed and the distance to the return connection.

Note the recommendations from practical experience: - Expansion automat, single setup. Length of expansion pipe, > 5 m : Second-higher nominal connection width of the vessel; > 15 m or > 8 m with 3 pipe bends: Third-higher nominal connection width of the vessel; For distances > 22 m or > 15 m with additional pipe bends, the required nominal widths must

be determined from practical actual values. Avoid lengths greater than ...30 m... and install expansion pipes at the shortest distance that benefi ts fl ow.

- Expansion automats, battery installation, basic vessel, ancillary vessel. Combinations must be installed with the shortest distances between the individual system

connections of the vessel (minimum distances). If you are installing a collective pipe, up to 3 vessels: Fourth-higher nominal connection width of the single vessel; from 4 to 6 vessels: Sixth-higher nominal connection width of the single vessel.

The arrangement of the vessels should preferably be symmetrical, or the nominal width of the collector must be increased (Example series: M-K > M-K/U < M-K; M-K > M-K/S – M-K/S < M-K. Ideal: arrangement in a polygon.) For the return connection, follow the instructions for the expansion pipe.

Gas compartment couplings

Installations of several vessels (basic vessel, ancillary vessel) with common expansion controller and ancillary compressors (second compressor unit K04 **; L6...K420 ***), on the pressure vessel, require coupling of the gas compartments on site. In addition, the coupling boxes to be installed on the equipment (Pos.13) must be fi tted with the pressure hose connection ** (Pos.14) (snap-in). The coupling of the coupling plug (pressure hose connection) with the coupling box (quick-release connector) opens the gas compartment, while disconnection automatically seals the gas compartment. (Coupling examples: page 4; 5, Equipment) Hoses are to be arranged such that cross-sectional narrowing is permanently avoided.

Warning: Risk of accident through release of pressurised air. Note that the single-sided decoupling or coupling of the pressure hose can result in air escaping (pressure loss). Here, the escaping fl ow pressure amounts to up to 2 bar in a delivered vessel, or in the event of subsequent additions, to the available system pressure.Do not direct escaping pressurised air at people! Free, releasing hose ends move suddenly and can cause injuries.

Electrical installation

The input terminals for the mains of the controllers Flexcon (S) control unit, SDS or of additions (e.g. Directstart power part ***) are to be connected at the place of installation via a CEE plug connector to the connection of the required operating voltage. The voltage distribution (e.g. safety power circuits), the cable protection and the goods, layout of the feeds must meet the regulations and provisions for this application at the place of installation. Ancillary compressors (e.g. K04; 2 K04 **) are supplied with an electrical feed that must be installed on site to the controller and to the drive of the compressor (compressors). When doing this, please observe the installation instruction on the terminal covers of the drive (drives). Install a grounding between the earthing boss and the grounding point (total equipment). The SDS Controller has protective insulation and for this reason does not require grounding between the controller and the grounding point.Avoid installations where cables may come into contact with water.Electrical feeds must be fi xed permanently using suitable cable guides.(Equipment, page 4; Modules, page 19; Terminal diagram, pages 23...26; 31...35)

6. Start

Commissioning

Before commissioning, the system and its technical safety equipment must be checked for compliance with the regulations that apply to the place of installation and to the scope of application.In Germany, this check is done by an authorised person (aP). In other countries, national regulati-ons must be observed.The manufacturer or operator of the system is responsible for proper testing and starting.

- Perform the start/commissioning protocol..- Test the system and performed installation actions for completeness (e.g. remove transport guard, install Flexvent Super **, gas compartment couplings). -Until the

necessary start measures have been completed, ensure that no fi lling takes place of the vessel or vessels (fi lling connections, shut-off devices, cap valves: ”CLOSED”). An installed fi lling device with a main switch must be ”Switched off”.


0,05

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Pos.14

Pos.13


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6. Start (continued)

Programming

The controller on the basic vessel is to be programmed depending on the confi guration and system.

- Flexcon Control Unit, M-K/S. The required procedure and possible setting changes can be found on page 21; 22;

menu programming mode.

Note: The active errors displayed after switching on the controller: min. water level; min. pressure alarm are logical. After switching to programming mode, the control for expansion (fi lling) is passive. Changed parameters become active when operating mode is reselected.

- Remove unpermitted loads (supported objects, lateral loads) from the basic vessel. - Perform the zero adjustment during operation. This prsocedure corrects deviations from test

tolerances when installing the basic vessel and sets the levelparameter to 0%. - Change the preset nominal system pressure (2 bar) to the permitted project value (note).

Note: Start and system temperature, page 12; §. 1. - Other parameters must be programmed depending on system requirements. - If 2 systems are operated in parallel, this setting must be performed after installation of the RS485 data cable. The controller programmed fi rst is the Master. Other measures, settings, changes are to be carried out identically, per controller. The service programming mode and the factory programmed presets can be found on

page 22, the operating displays on page 20, Operating mode menu.

- SDS controller, M-K/U. The required procedure and possible setting changes can be found on page 28; 29;

Menu programming mode.

Note: The active errors displayed after switching on the controller: min. level alarm limit, min. pressure alarm limit are logical. The controller is also active for expansion (fi lling) after the code has been entered (programming mode).Changed parameters become immediately active after being saved.

- Remove unpermitted loads (supported objects, lateral loads) from the basic vessel. - Perform the zero adjustment during operation. This procedure corrects deviations from test

tolerances when installing the basic vessel and sets the level parameter to 0%. - Change the preset nominal system pressure (2 bar) to the permitted project value (note).

Note: Start and system temperature, page 12; para. 1. - Other parameters must be programmed depending on system requirements. The identifi cation of start enables traceability, which also enables a time-dependent

diagnosis of the installed SDS- Module 32, timer, operating hours counter ** (errors, SDS- Module 43, analogue modem connection **). The service programming mode and the factory programmed presets can be found on

page 30, the operating displays on page 27, Operating mode menu. [ Specifi cation of menu lines (F5; F7a 1; 2; G7a 2; G8a 1) in the terminal diagrams, page 32; 33; 35, refers to the required change to presets during upgrades (**).]

The completed programming procedure (electrical installation) makes the compressor expansion automat electrically ready for operation.

Start and system temperature.

The installed, hydraulic compartment of the expansion automat is to be fi lled as far as the shutoff device on the expansion pipe, depending on the condition of the heating system.All present shutoff devices must now be opened.

- Installation of the water prefi ll for a non-operational, cold heating system. The basic vessel or all vessels with a common expansion controller (collective pipe), must be

fi lled with water before opening the shutoff device to the expansion pipe. From practical experience, the quantity of this water is ...20%... of the vessel capacity. This

value takes into consideration losses and a lower vessel level as a consequence of reduced gas quantities after a heated heat generating system.

(Filling example 1)- Set the nominal expansion capacity for operated, hot heating system. The basic vessel or all vessels with a common expansion controller (collective pipe), are to be

fi lled with the nominal expansion capacity from available system temperature including the water prefi ll, before opening the shutoff device to the expansion pipe.

To calculate this quantity, the design data for the nominal vessel size or the total of the nominal vessel sizes and the actual values of the heating system are required. Use the following example as the basis for your own calculation.

Vset = [( Dn’act × 80% ) / Dn’max ] + 10%* = 42.66% ~ 43% (Filling example 2) Dn’act = n’act –n’min = 1.0121 – 1.0003 = 0.0118 (50 °C; 10 °C) Dn’max = n’max - n’min = 1.0292 – 1.0003 = 0.0289 (80 °C; 10 °C) n’ [dm3/kg] Specifi c volume of the liquid water in saturated state.

* Accessory, addition

Note:

Nominal system pressure (working pressure PA)= Pressure from highest statistical heightof the heating system+Vapour pressure from the highest operatingtemperature of the heating system+Positive pressure at the highest pointof the heating system (0.3...0.5 bar)

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Start and system temperature. (continued)

If the fl ow pressure differential of the external supply when fi lling the automat for the fi rst time viaa fi ll and drain valve is insuffi cient, the preset system pressure (2 bar) must be set on the controller approx. 1.5...bar below the available fl ow pressure. During fi lling, observe the changing level value in the display (operation mode) of the controller, and interrupt the external supply when the nominal value is reached, correct a changed system pressure. Note that with several vessels (collective supply), a time-delayed level balance takes place. Installed fi lling devices ** fi ll from 0% of the value of the preset (pages 22; 30). Systems that include the capacity of the installed water quantity must be vented . A fallen level must be compensated to the nominal value by adding water.- Vent the diaphragm compartment (water compartment) at the manual vent of the vessel

(Pos.10; page 4). This measure is not necessary if a fl oatvent is installed **.- The procedure for starting the heat generator must be completed (settings to safety devices).

Fill the heating system completely and vent this system.- Check the available electrical equipment for common expansion control, for operational

readiness. Controllers, accessories, additions must be switched on.- Open the shutoff device on the expansion feed to the return connector (slowly).- Complete the start protocol.

Re-start

- Following a long downtime. Carry out maintenance. Drain the water compartments of the equipment and ensure that the

preconditions for installation (5.) are met and do the necessary actions for Starting (6.). Clean the equipment, remove slurry. Use the start protocol and in particular check system data which may require changing settings on the device.

- After a power failure. The parameters programmed at the controller remain unchanged, so that automatic operation

takes places automatically when power is restored. (Controller, accessories, additions switched on). The voltage for the SDS- Module 32, timer, operating hours counter ** is supported for several weeks. (Error no.: 28, page 30)

Note: Special operating conditions on this system (e.g. cooling below the set control value) can result in exceeding or not achieving permitted operating values of the vessels (Application safety, page 8; Electrical installation, page 10).

After a power failure, the condition of the expansion automat must be checked for integrity.

7. Maintenance

This action must be performed during system down time, otherwise ensure that no demands are placed on the expansion automat. The expansion equipment must be switched off and secured against being inadvertently started until maintenance is completed.Note the safety switches and remote data transfers which can lead to the activation of safety chains or error informationduring maintenance work. Existing instructions on the total project of the heating systemmust be considered. The measures allocated to the maintenance periods must also be carried out.- Use the maintenance protocol; draw up a maintenance plan.

8. Periodic testing, pressure equipment.

This must be performed under consideration of the requirements of the total system and must be certifi ed. It is to be carried out by the operator in accordance with prevailing rules and procedures of competition inspection at the site of installation. This test is done in Germany by an authorised person (aP). In other countries, the national regulations and conditions must be observed. For perform the test, the responsible person has these instructions, the conformity declaration and the acceptance drawing available. The minimum test periods and their contents, for application in Germany, are laid out below.

- Internal check: 5 years (test of pressure compartment: corrosion, deformations, damage.)- Pressure test : 10 years (water pressure test of the vessel pressure compartment with the

permitted test overpressure.)

* positions refer to page 4

Maintenance period Object Measure

Monthly, inMain load times;2 months, in Partial load times(summer operation).

Compressoroil-free (Pos.25; 26; 27; 28; 29)*

Clean fi lter unit, fi lter housing,intake opening. DryInstallation required!

Basic vessel Ancillary vessel(Pos.2)*

Drain condensate (Pos.35)*;Vent water compartment (Pos.10)*,Omit if airvent installed.

(summer operation).Before main load time.

Compressoroil-free(Pos.25; 26; 2728; 29)*

Function test (switch possible by changing nominal pressure,note working pressure differential!; Manual operation SDS controller.)

Note: Use spare parts approved by Flamco.

Maintenance period Object Measure

Annually, before the main load time.

Connectormodule (Pos.22;23; 24)*

Function text (see Compressor);Test safety valve vialifting device.

EquipmentExpansionvessel;Connections;Shutoffdevices.

Seal test of all pressurecompartment connections on gas andwater compartment (visual check).Checking of externalcondition for damage,deformation, corrosion.

The operationally ready state must be recreated!

We recommend Flamco customer service for maintenance.


13


Appendix 1; Technical data, specifi cation, hydraulic and

pneumatic equipment.

Nominal values)4* System connect. M-K/U, M-K/S.

)1* Standard; )2* Flexvent Super; )3* Second compressor unit, K04.

Example illustrations

)6* ø750; )7* ø1000; )8* not 3 bar. )4* Compressor unit; )5* Second compressor unit **.

Weights

** Accessory, addition

Nominal operating values of pressure unit Main dimensions (Nominal)

Nominalcapacity

maximumpermittedoperatingpressure

maximumpermittedoperatingtemperature

maximumpermittedcont. temperatureat the diaphragm

Vesseldiameter

Opera-tingheight

Height Width Length min.

Length min.

SystemconnectionDin ISO 228-1

Tolerance: DIN28011; 28013; 28005-1.

D H1 H2 B L1 L2 S

[Litres] [bar] [ºC] [ºC] [mm] [mm] [mm] [mm] [mm] [mm] BSPShort code)1* )2* M-K/U M-K/S M-K )3* )4*

Total system mass. (Nominal weight, corrosion allowance: 0 mm, without water fi lling.)

Nominalcapacity

M-K/U M-K/S M-K

K01 - K03 )4* K04 )4* K01 - K03 )4* K04 ) 4*

Tabular value ++ 12 kg )5*

Tabular value+ 25 kg )5*

Tabular value + 12 kg )5* )8*

Tabular value + 25 kg )5*

6 bar 10 bar 6 bar 10 bar 3 bar 6 bar 10 bar 6 bar 10 bar 3 bar 6 bar 10 bar

[Litres] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg] [kg]

400 6 10 120 70 750 1065 1369 1454 975 995 820 400 225 G 1 1/4 DN32

600 6 10 120 70 750 1485 1789 1874 975 995 820 400 225 G 1 1/4 DN32

800 6 10 120 70 750 1585 2189 2274 975 995 820 400 225 G 1 1/4 DN32

1000 6 10 120 70 750 1585 2689 2774 975 995 820 400 225 G 1 1/2 DN40

1000 6 10 120 70 1000 1415 1775 1860 1225 1245 1070 400 100 G 1 1/2 DN40

1200 6 10 120 70 1000 1615 2025 2110 1225 1245 1070 400 100 G 1 1/2 DN40

1600 6 10 120 70 1000 1615 2525 2610 1225 1245 1070 400 100 G 1 1/2 DN40

2000 6 10 120 70 1200 1635 2277 2362 1425 1445 1270 400 0 G 2 DN50

2800 6 10 120 70 1200 1635 2877 2962 1425 1445 1270 400 0 G 2 1/2 DN65

3500 6 10 120 70 1200 1635 3677 3762 1425 1445 1270 400 0 G 2 1/2 DN65

5000 3 - 90 70 1500 1600 3550 3635 - 1785 1615 - 625 Rp 1 1/2 DN40

6500 3 - 90 70 1800 1600 3465 3550 - 2090 1920 - 475 Rp 1 1/2 DN40

8000 3 - 90 70 1900 1600 3565 3650 - 2190 2020 - 425 Rp 1 1/2 DN40

10000 3 - 90 70 2000 1600 3985 4070 - 2290 2120 - 375 Rp 1 1/2 DN40

400 153 188 166 201 - 157 192 170 205 - 130 165

600 183 228 196 241 - 187 232 200 245 - 160 205

800 218 258 231 271 - 222 262 235 275 - 195 235

1000 )6* 253 308 2666 321 - 257 312 270 325 - 230 285

1000 )7* 291 382 304 395 - 295 386 308 399 - 268 359

1200 313 418 326 431 - 317 422 330 435 - 290 395

1600 368 508 381 521 - 372 512 385 225 - 345 485

2000 453 618 466 631 - 457 622 470 635 - 430 595

2800 538 758 551 771 - 542 762 555 775 - 515 735

3500 648 938 661 951 - 652 942 665 955 - 625 915

5000 - - - - 980 - - - - 953 - -

6500 - - - - 1480 - - - - 1453 - -

8000 - - - - 1585 - - - - 1558 - -

10000 - - - - 1825 - - - - 1798 - -


14




Minimum distances

Nominal capacity Minimum size

A B C

[Liter] [mm] [mm] [mm]

400

650

800 500

600

800

1000

1000

1200

1600

2000

1000

2800

3500

5000

6500

8000

10000


15




Example installations of M-K/S, Flexcon control unit.


16




Example installations of M-K/S, Flexcon control unit.


17




Example installations of M-K/U, SDS control unit.


18


Appendix 1; Technical data, specifi cations, hydraulic and


Example installations of M-K/U, SDS control unit.


19


Appendix 2; Technical data, specifi cations, electrical equipment.

Modules

Flexcon Control Unit, MK-S 230V 50Hz (400V 50Hz) ***.



enterpress

M12 M16 M16 M16 M16 M20

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Flexcon control unit, M-K/S, operating mode menu.

Display 1Normal operating display in delivery condition of the controller. During standard initial programming the current actual values: pressure, level, the switch values compressor, valve and the limit value level are presented.

The “ESC” key leads to display 1 for any selected message.

Display, error no.: 5)*The programmed limit value is reached or exceeded.

(Display 14; page 21)

Display, error no.: 6)*The programmed limit value is reached or exceeded. (Diaphragm overload)(Display 15; page 21)

Display, error no.: 7)*The motor protection switch(es) are activated as a result of overfl ow or switched off manually (Pos. 1.6; 1.7; page 19).The activation of the ther-mal fuse (TP) in the drive of standard models (230V 50Hz) is not displayed! If this activates the fuse, a reset of compressors K01; K02; K03 must be performed manually (Pos. 30; page 4). The reset on a version with K04 takes place automatically (cooling).

Display, error no.: 8)*The signal requires the testing of the diaphragm for ruptures.(Only with installed diaphragm rupture sensor**) (Display 3)



(Display 17; page 21)

Display, error no.: 11)*In the version with a second unit (2 controllers**) the opera-ting modes are programmed differently. (Display 3)

Display 2Indication of the nominal switch times, total, for compressor drives 1 and 2.

Display 3Indication of the programmed additional functions **. (On: “ * “; Off: “ - “) See also page 5, Operating modes.

Display 4System classifi cation. Indicates: Type, nominal pressure, capacity of basic vessel (ancillary vessel**) and software version.

The “RET” button leads tothe displays 1- 4 and foravailable or not yetacknowledged errors(Fehler LED “On“) tothe displays 5- 11)*.

)*The lighting of the Fehler-LED signals a fault as a collective fault signal (one or more error).In the example, displays 5- 11 show the possible errors, whereby the actual sequence corresponds to the progress over time.Errors are to be acknowledged by pressing the “ESC” button.An error that can be acknowledged is signalled by the Fehler-LED “Off”,while this LED signal is retained for other non-acknowledgeable or not yet acknowledged errors. An error can be acknowledged when the error has been resolved or an operating condition is achieved within nominal values.

Controller operating panel


21




Display 13Indication nominal system pressure.(Psyst.nom. = Pstatic max. ++ Pvapour + Ppositive;Ppositive = 0.3...0.5bar)

Display 14Indication corresponds to limit value min., which generateserror no.: 5 when reaching display (Page 20)

Display 15Indication corresponds to limit value max., which generateserror no.: 6 when reaching display (Page 20)



Display 18Indication is value at startof the fi lling (note expansion capacityto be accepted).

Display 19Indication is value at endof the fi lling(note expansion capacityto be accepted).

Display 20Indication for versions with two units ** or two compressor units ** and factoryprogramming of the backupmode. The change timeenables operating times to be evened out.

Displays 13- 21In programming mode, the presets available in displays 13- 21 can or should be adjusted to the system requirements.

Correct the entries prior to start and use the rest phases of the heating system for latermodifi cation.

Modifi cations in displays13- 15 also change permissible values in dis-play 16- 19. Consequently these values must also be entered.

Touching a button allocated to a number changes the the value of the cursor position in the display.After the entry, the next cursor position is active for change.Please note the respec-tive indicated permissible ranges within which limits a correction is possible.If limits are exceeded, the cursor is in the ‘Home’ position (left) after touching “RET”.Subsequently, enter a value within the limits.

Cursor- interim settingscan be reset to the fi rst position by pressing “ESC”.

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Display 21Entry, indicate **1** for versionwith two units ** (Master-Slave) per unit. See also page 5, Operating modes.

Display 22Carry out at place of setupbefore fi rst start(cap valve system connectionand valve fi lling “OFF”).

Display 23Information on ensuring, that the basic vessel is aligned and free of additional loads or reliefs.

Display 24Entry of the actual-massavailable at the level sensorof the basic vessel.

Display 25Set when limits are exceededas a result of unpermittedload or relief on the basic vessel.The required startingcondition is to be created andthe procedure repeated fromdisplay (13) 22.

Control.)* Service programming mode. )* removed

This programming enables the trained service engineers to modify furthercontrol parameters. Important presets, which are programmed at the factory,are shown below.

Option Leak probe **, standard : **2** not available (see display 3: “ – “).Option Leak probe **, as ordered : **1** available (see display 3: “ * “).

Option Backup (2 units **), standard : **2** not available (see display 3: “ – “).Option Backup, as ordered : **1** available (see display 3: “ * “). )*

Backup 2 on 1, as ordered:Second compressor unit **, parallel mode : **2** not available.Second compressor unit **, backup mode : **1** available.

Language, as ordered or : **1** (1: D; 2: GB; 3: F; 4: NL)

Factory zero setting of level sensor; vessel number : as ordered (PN3; 6; 10; vessel size)

Smoothing factor : **3**

Hysteresis, compressor 1 (2**), Valve 1, PN3 : *0.1* (Valve 1.1; 1.2 ***)Hysteresis, compressor 1 (2**), Valve 1, PN6; 10 : *0.2* (Valve 1.1; 1.2 ***)Turn-on delay compr. 1 (2 **), Valve 1 : *03sec* (Valve 1.1; 1.2 ***)Turn-off delay compr. 1 (2 **), Valve 1 : *01sec* (Valve 1.1; 1.2 ***)

Display 13; system pressure, as ordered or : *02.0* (default 2bar gas pre-pressure standard PN3; 6; 10)Display 14; min. water level : *05%*Display 15; max. water level : *95%*Display 16; min. pressure PN3 : System pressure minus 0.3 bar. Min. pressure PN6; 10 : System pressure minus 0.4 bar.Display 17; max. pressure PN3 : System pressure plus 0.3 bar. Max. pressure PN6; 10 : System pressure plus 0.4 bar.Display 18; Filling level On : *06%* (Falling level. On above 0%.)Display 19; Filling level Off : *08%* (Rising level.)Display 20; change time : *10 days*Display 21; Parallel mode (2 units **, Master- Slave), Standard : **2** not available (see display 3: “ – “). Parallel mode, as ordered : **1** available (see display 3: “ * “). )*

)* RS485 datacable required at site.



23



Flexcon control unit, M-K/S, standard terminal diagram.

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24



Flexcon control unit, M-K/S, standard terminal diagram.


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25



Flexcon control unit, M-K/S, terminal diagram for special version.

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26



Flexcon control unit, M-K/S, terminal diagram for special version.


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27



SDS controller, M-K/U, operating mode menu.

Operation menu.The fi rst display screen (start menu) contains the default factory settings of the controller. During standard initial programming, the process display (symbols) is shown with the currently avai-lable actual values for pressure, Level and fi lling time **.The cursor symbol (black line, inverted symbol colour) is the possible option line that enables a change or selection after touching/turning the selector switch. Holding down the selector switch (pressing until a change occurs), whatever the cursor position, goes to the process display (start menu). The lighting of the error LED and the cursor change from: [SYSTEM], to: [ERROR] inverse blinking, signals a fault as a collective fault signal (one or more faults. Following acknow-ledgement of the fi rst error, further fault displays can follow). In this situation, rotating the selector switch goes to the cursor: [SYSTEM] inverse blinking. Touching the selector switch in the case of [ERROR], goes to the active error list, in the event of[SYSTEM], to the option menu.... Option menu1.

Option menuThis menu enables the display (reading) or change (entry) of other menu contents. Entries are only possible after a code is entered, which is requested in the next menu after selecting: [Enter]. The example shown includes the: [VIEW]. An entered code is active for a further ..5.. min. after each signal that takes place within a period of ..5.. min. by turning or touching the selector switch.If this time is exceeded, the code must be re-entered. If no entries are performed for a period of ..10.. min., the menu will automatically close and the cursor returns to the process display (Start Menu).

Further sample displays, and graphs and symbols used are shown on the following pages.

Controller operating panel


enterpress

M12 M16 M16 M16 M16 M20

3/8

3/8

3/8

Project no.Project no.Software versionSoftware versionStartStartMaintenanceMaintenanceError listError list

Error listError listValue statisticsValue statisticsOperating hoursOperating hoursService-stickService-stickBackBack

System pressureSystem pressureLevelLevelDegassingDegassingFillingFillingTime, dateTime, date

FillingFillingTime, dateTime, dateWeek programWeek programOtherOtherBackBack

ID-numberID-numberLanguageLanguageContentsContentsAdjustmentAdjustmentOperationOperation

MotorprotectionMotorprotectionP.min protectionP.min protectionRelief valveRelief valveControl modeControl modeBackBack

ViewViewEnterEnterBackBack


ModeModeDataDataServiceServiceBackBack




Error listError list

BackBack

Error listError list

Int. TK Motor 1Int. TK Motor 1

AcknowledgeAcknowledge

Error listError list3

Level alarm Limit Level alarm Limit



Level alarm Limit Level alarm Limit



Int. TP Motor 1Int. TP Motor 1


ErrorError


28



SDS controller, M-K/U, programming mode menu.

The unit is active for pressure maintenance in the programming mode. Changed presets become immediately active when the [Save], [Start]cursor line is touch activated, a self-actuating change in the pre-menu, a change of the cursors to [Back], the symbol “ [✓] “ is removed or is activated with “[✓] “. Unreliable or impossible entries are identifi ed by relevant symbols and not saved. A change procedure can only be performed within identifi ed and permitted values. If parameters were changed and not saved or the [SAVE] or [START] button is marked as unreliable, then the [BACK] button goes to the previous menu without changing the preset (change not active).





ID-numberID-numberLanguageLanguageAdjustment, contentAdjustment, contentAdjustment, valveAdjustment, valveOperating modeOperating mode



LanguageLanguage

LanguageLanguage

LanguageLanguageDeutschDeutschNederlandsNederlandsEnglishEnglishFrançaisFrançais

BackBack


Adjustment at factoryAdjustment at factoryAdjustment during op.Adjustment during op.BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack



Motor protectionMotor protectionP.min protectionP.min protectionRelief valveRelief valveControl modeControl modeBackBack




Adjustment during op.Adjustment during op.

BackBack


BackBack


BackBack

00000 100000 1


enterpress

M12 M16 M16 M16 M16 M20

3/8

3/8

3/8


29




Changing system pressure, date / time, summer time, Identifi cation of commissioning.FillingFillingTime, dateTime, dateWeek programWeek programOtherOtherBackBack

FillingFillingTime, dateTime, dateWeek programWeek programOthersOthersBackBack

System pressureSystem pressureLevelLevelDegassingDegassingFillingFillingTime, dateTime, date

Error listError listValue statisticsValue statisticsOperating hoursOperating hoursService-stickService-stickBackBack



StartStartBackBack

StartStartBackBack

StartStartBackBack

StartStartBackBack

StartStartBackBack

FillingFillingTime, dateTime, dateWeek programWeek programOtherOtherBackBack

BackBack BackBack

Nominal systempress.Nominal systempress.






Summertime onSummertime on





Summertime offSummertime off





SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

SaveSave BackBack

K1K1

K1K1


30




Service programming mode.

This programming enables trained service engineers to modify further control parameters. Important pre-sets, which are programmed at the factory, are shown below.

** Accessory, add-on *** Special version

)1* As ordered **; )2* Export, without indication; )3* Compressor unit; )4* Second compressor unit **

Men F (Data)

Menu bar Enter

F1 System pressure

F1a 1 Nominal system pressure (gas pre-charge) 2.0 bar (area F1a 2...F1a 3)1*

F1a 2 Min. pressure (setting range, limit) PN6: 0.5 bar; PN10: 0.5 bar

F1a 3 Max. pressure (setting range, limit) PN6: 5.4 bar; PN10: 9.4 bar

F1a 4 Lower pressure deviation (hysteresis) - 0.2 bar

F1a 5 Upper pressure deviation (hysteresis) 0.2 bar

F1a 6 Lower alarm limit - 0.3 bar (F1a 1 + F1a 4 + F1a 6)

F1a 7 Upper alarm limit 0.3 bar (F1a1 + F1a 5 + F1a 7)

F1a 16 Change start sequence ** (Motors)4* 24 h

F1a 23 Motor run time 30 min.

F2 Level note Pressure increase (compressor) On above 8 % (F2a 5 + f2a 8);Pressure increase (compressor) Off with falling level from 6 % (F2a 5).

F2a 5 Dry run protection (diaphragm protection) 06 % (no pressure increase)

F2a 6 Lower alarm limit 05 %

F2a 7 Upper alarm limit 95 % (no pressure relief)

F2a 8 Alarm level hysteresis 02 %

F4 Filling ** Note: Filling On from 0 %, with fallinglevel from 9 %* (F2a 5 + F4a 1); Filling Off at 12 % (9 %* + F4a 2)

F4a 1 Filling On 03 % (falling level)

F4a 2 Filling quantity 03 % (rising level)

F5 Time, date **

Time menu CET = GMT + 1 hCEST = GMT + 2 h

F7 Other

F7a 1 Summer time On 03 (change on last Sunday in March [03] from 2 to 3 a.m.)

F7a 2 Summer time Off 10 (change on last Sunday in October [10] from 3 to 2 a.m.)

Menu G (Modus)

Menu bar Enter

G2 Language

G2a 1 German

G2a 2G2a 3G2a 4G2a 5G2a 6G2a 7G2a 8G2a 9G2a 10G2a 11G2a 12G2a 13G2a 14G2a 15G2a 16

DutchEnglischFrenchPolishDanishFinnishHungarianSlovakianSpanishPortugueseRussianSwedishNorwegianItalianCzech

)1* )2* )1* )1* )1* )1* )1* )1* )1* )1* )1* )1* )1* )1* )1*

G5 Operating mode

G5a 2 Single mode )3*

G5a 3 Parallel mode ** )1* ; )4*

G5a 4 Backup mode ** )1* ; )4*

G5a 5 Load-dependent mode ** )4*

G7 Filling **

G7a 1 Off

G7a 2 Hours counter )1*

G8 Sensor **

G8a 1 Dia rupture sensor )1*

Error list Note: Error statistics, passive errors, Menu E5.

Display,Error no.Description.

Remark,Measure

1Pressure alarm limit

The programmed value F1a 6 is reachedor exceeded; Acknowledge. )*

2Pressure alarm limit

The programmed value F1a 7 is reachedor exceeded; Acknowledge. )*

3Level alarm limit

The limit value F2a 6 is reached orexceeded; Acknowledge. )*

4Level alarm limit

The limit value F2a 7 is reached orexceeded; Acknowledge.

5Filling quantity

The programmed quantity per day is reached(F4a 4); Acknowledge.

6Safety relay

Acknowledge(not acknowledgeable: SERVICE)

7Relay Motor 1


8Relay Motor 2


9Fuse Motor 1

The pico fuse, Pos.2.7; page 19, isdefective or missing; Acknowledge.

10Fuse Motor 2

The pico fuse, Pos.2.6; page 19, isdefective or missing; Acknowledge.

11Ext. TP Motor 1 ***

The motor protection relay, Pos.3.2; page 19,is Off or has actuated, 3~ ***; Acknowledge.

12Ext. TP Motor 2 ***

The motor protection relay, Pos.3.3; page 19,is Off or has actuated, 3~ ***; Acknowledge.

)* Self-acknowledging in normal mode.

Error list

Display,Error no.:Description.

Remark,Measure

13Int. TP Motor 1

The thermal overload protection in the drive is On;K01...K03: Manual reset (Pos.30; page 4);K04: Automatic reset (cooling);Acknowledge.14

Int. TP Motor 2

19Diaphragm rupture **

The diaphragm must be checked for ruptures;Only with installed diaphragm rupture sensor **;Acknowledge.

20Runtime Motor 1 The programmed value F1a 23 is reached;

Acknowledge.21Runtime Motor 2

27Voltage

The minimum circuit board voltage in the controller is not reached; Acknowledge.

28Voltage RTC **

The support voltage for the timer, operatinghours counter ** was too low, Acknowledge.

29Shorted, pressure

The input signal from the pressure sensor is >20mA; Acknowledge. )*

30Pressure, wire rupture

The input signal from the pressure sensor is <4mAor not available; Acknowledge. )*

31Shorted, level

The input signal from the Level sensor is >20mA;Acknowledge. )*

32Level, wire rupture

The input signal from the Level sensor is <4mAor not available; Acknowledge. )*

Examples of error messages can be found on page 27.


31



SDS controller, M-K/U, standard terminal diagram.

*) W

ork

ing

inve

rse

Contr

oller,

ele

ctr

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.)4

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te, r

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);P

ico

fus

e:T

16A

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V.

• Va

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1; 2

(F3)

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o f

use:

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0L 2

50V.

• E

lect

roni

cs;

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sors

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ly-

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no

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.

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0.55

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A (C

)

K03

1.1

kW7.

5 A

10 A

(C)

K04

1.1

kW7.

5 A

10 A

(C)


32



SDS controller, M-K/U, standard terminal diagram.

Accessories, additions.electronic control unitstandard pressure control

enterpress

Contr

oller,

ele

ctr

ical data

.)1

* S

ing

le m

od

e; )2

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acku

p m

od

e; )3

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aral

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od

e (L

oad

-dep

end

ent

mo

de)

; )4*

On

site

, rec

om

men

dat

ion

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min

alvo

ltag

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pe

Co

mp

ress

or

unit

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tor

1 )1

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2nd

co

mp

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unit

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tor

2 )2

*; )3

*

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min

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ow

er

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/ )3

*

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alcu

rren

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)1*;

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/ )3

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(CE

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K01 /

2 K

01

0.55

/

1.1

kW4.

0

/ 8.

0 A

6

/10

A (C

)•

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tor

2;

(F

1)

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rmal

ove

rlo

adp

rote

ctio

n(T

P in

tern

al);

Pic

o f

use:

T16

a 25

0V.

• M

oto

r 1;

(F

2)

The

rmal

ove

rlo

adp

rote

ctio

n(T

P in

tern

al);

Pic

o f

use:

T16

a 25

0V.

• Va

lve

1..3

; (F3)

Pic

o f

use:

T40

0L 2

50V.

• E

lekt

roni

cs;

Sen

sors

: Po

ly-

switc

hes,

non-

exch

ang

eab

le

K02 /

2 K

02

0.55

/

1.1

kW4.

0

/ 8.

0 A

6

/10

A (C

)

K03 /

2 K

03

1.1

/

2.2

kW

7.5

/

15.0

A10

/

20 A

(C)

K04 /

2 K

02

1.1

/

2.2

kW

7.5

/

15.0

A10

/

20 A

(C)


33



SDS controller, M-K/U, terminal diagram for special version.


0,025

Flamco


enterpress

Contr

oller,

ele

ctr

ical data

.)4

* O

n si

te, r

eco

mm

end

atio

n

No

min

alvo

ltag

eP

rote

ctio

nty

pe

No

min

al

po

wer

No

min

alcu

rren

tF

use

Wir

ing

)4*

Fus

eD

evic

e p

rote

ctio

n, in

tern

al.

230v

50H

zL;

N; P

E(C

EE

)

IP54

(Lev

else

nso

rIP

65)

16 W

120

mA

6 A

(C)

• Va

lve

1; (F3

)2.

2; (3

);P

ico

fus

e:T

400L

250

V.

• E

lect

roni

cs;

Sen

sors

: Po

ly-

switc

hes,

no

n-ex

chan

gea

ble

.


34




0,025

0,025

Flamco


enterpress


Contr

oller

ele

ctr

ical data

.)1

* S

ing

le m

od

e; )2

* B

acku

p m

od

e; )3

* P

aral

lel m

od

e (L

oad

-dep

end

ent

mo

de)

; )4*

At

cust

om

er, r

eco

mm

end

atio

n

No

min

alvo

ltag

eP

rote

ctio

nty

pe

Co

mp

ress

or

unit

Mo

tor

1 )1

* /

2nd

co

mp

ress

or

unit

Mo

tor

2 )2

*; )3

*

No

min

al

po

wer

)1*;

)2*

/ )3

*

No

mal

curr

ent

)1*;

)2*

/ )3

*

Fus

eW

irin

gp

rote

cto

r )4

*.)1

*; )2

* /

)3*

Fus

eD

evic

e p

rote

ctio

n, in

tern

al.

400V

50H

zL1

; L2;

L3

N; P

E(C

EE

).

IP54

(Lev

else

nso

rIP

65)

L6 /

2 L

60.

55 /

1.1

kW

2.0

/ 4.

0 A

3x4

/ 3

x6

A (C

)•

Pro

tect

ion

1;(F

1)

Pic

o f

use:

T16

A 2

50V.

• M

otor

1;

Mot

or p

rote

ctio

n re

lay

(Pos

. 3.2

; p

age

19).

• P

rote

ctio

n 2;

(F2

) P

ico

fus

e:T

16A

250

V.•

Mot

or 2

;M

otor

pro

tect

ion

rela

y (P

os. 3

.3;

pag

e 19

).

• Va

lve

1..3

; (F

3)

Pic

o f

use:

T40

0L 2

50V.

• E

lect

roni

cs;

Sen

sors

;P

olys

witc

hes,

non

-ex

chan

gea

ble

.

L8 /

2 L

80.

75 /

1.5

kW

2.5

/ 5.

0 A

3x6

/ 3

x6

A (C

)

L12 /

2 L

12

1.1

/ 2

.2 k

W3.

1 /

6.2

A3x

6 /

3x1

0 A

(C)

L14 /

2 L

14

1.5

/ 3

.0 k

W4.

2 /

8.4

A3x

6 /

3x1

6 A

(C)

K420 /

2 K

420

2.4

/ 4

.8 k

W4.

7 /

9.4

A3x

10 /

3x2

0 A

(C)


35





0,0250,025

0,025


enterpress

Direktstart 2400/230V 3/PE ~50/60Hz



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