Operation&

MaintenanceManual

FlexfillerDigitalPressurisationEquipment
FlexfillerModels(125D,225D,150D,250D,280D)
MidiModels(125D,225D,150D,250D)
MiniModels(130D,230D)

Contents
AboutthisManual

ConventionsusedinthisManual

Typography

WheretofindmoreInformation

EquipmentOverview

PrincipalofOperation

Installation

PipeConnections

TypicalInstallationDiagram

FlowRestrictors(Midi&Minimodelsonly)

FlexfillerClearanceandConnectionRequirements
MidiClearanceandConnectionRequirements

MiniClearanceandConnectionRequirements

ElectricalPowerSupply

FaultContacts

PowerFilter

Commissioning

PreCommissioningChecklist

ControllerOverview

ControllerProgramming

HydraulicCommissioning

CommissioningRecord

Operation

FaultCodes

ShutdownProcedure

StartUpProcedure

Troubleshooting

Maintenance

WiringDiagram

ServiceLog

Spares

ElectricalItems(AllModels)

FlexfillerModels(125D,225D,150D,250D,280DS)
MidiModels(125D,225D,150D,250D)

MiniModels(130D,230D)

3
3
3
3
4
4
5
5
5
6
7
8
9
10
11
12
13
13
14
15
19
24
25
25
26
26
27
30
32
33
35
35
36
37
38

AboutthisManual
ThisOperationandMaintenanceManualcontainsallthenecessaryinformationtoinstall,
commission,operateandmaintainFlexfillerpressurisationequipment.
Itisrecommendedtoreadallpartsofthismanualbeforeundertakinganyworkontheequipment.

ConventionsusedinthisManual
Thismanualmakesuseofsymbolstoidentifykeypiecesofinformation.Pleasetakenoteofthe
followingsymbolsandtheirmeaning:

DANGERImportantsafetyrelatedinformationintendedtopreventinjuryand/or
damagetotheequipment,systemorproperty.

CAUTIONImportantinformationintendedtopreventdamagetotheequipment,
systemorproperty.

IMPORTANTImportantinformationintendedtoensurethattheequipmentfunctions
correctly.

USEFULUsefulinformationwhichmaybehelpful,butisnotnecessarilyrequiredfor
theunittofunctioncorrectly.

Typography
Thismanualmakesuseofdifferenttypographytoidentifydifferenttypesofinformation.
Italics

(RoundBrackets)
[SquareBrackets]
<InequalitySymbols>

Keywordsandphrases
Usedtoidentifyabuttononthedigitalcontroller
Aparameteronthedigitalcontroller
Amessage/faultcodedisplayedonthedigitalcontroller

WheretofindmoreInformation
ForfurtherinformationpleasevisittheFlamcoLimitedWebsiteatthefollowingURL:
www.flamco.co.uk
Alternatively,pleasecontacttheFlamcoLimitedheadofficeusingthedetailsbelow:
Phone:
Fax:

Email:

01744744744
01744744700
info@flamco.co.uk

EquipmentOverview
Thefunctionofthispressurisationunitistoprovideameansofautomatedwatertopuptosealed
heatingandcoolingsystems.Theequipmentisdesignedtoprovideperiodicwatertopupto
compensateforminorlossesinsystempressure(e.g.slowleaks,airventing,etc.).
Thisequipmentisnotdesignedtocopewithsuddenlossesofsystempressure(e.g.
manualdraining)ormajorwaterlosses(e.g.largeleaks).Theequipmentisalsonot
intendedtobeusedforwaterboostingapplications.

PrincipalofOperation
Thefollowingschematicshowstheinternalarrangementofapressurisationunit:

Thepressurisationunitisfittedwithabreaktank(1)whichisfilledfromthemainswatersupply(2)
viaafloatoperatedvalve(3).Thebreaktankisfittedwithanoverflow(4)incasethebreaktank
overfills,andaweiroverflow(5)incasetheprimaryoverflowfails.
Thepressurisationunitisconnectedintotheheatingsystem(6)viaanisolationvalve(7).
Thepressuresensor(8)monitorsthesystempressure.
Ifthepressuresensordetectsadropinpressure,thepump(9a)willpumpwaterfromthebreaktank
intothesystem.Oncetherequiredpressurehasbeenreached,thepumpwillstop.
Ontwinpumpmodels,asecondpump(9b)isprovided.Thetwopumpswillruninaduty/standby
configuration(i.e.theactivepumpwillalternatewitheachpumpstart).
Thepump(s)arefittedwithnonreturnvalves(10a,10b)topreventbackflow.
Adrainvalve(11)isprovidedfordrainingdowntheunitandforcommissioningpurposes.

Installation
Thispressurisationunitisnotdesignedtobeinstalledinanoutdoorenvironment.The
unitmustbeinstalledinafrostfreeenvironment,awayfromprecipitationandwater
sprays/jets.Ifthereisariskofflooding,theunitmustbeinstalledonaraisedplinth.
Pleaserefertotheappropriatedatasheetforthemaximumworkingpressureand
temperatureofthepressurisationunit.Theconditionsatthepointofconnectionto
thesystemmustnotexceedthesevalues.

PipeConnections

Toavoiddamagingthefloatvalve,themainswatersupplypipemustbeflushedbefore
connectiontothepressurisationunit.

Allpipeconnectionsmustbemadewithappropriatejointingcompound/PTFEtape.
IfPTFEtapeisused,caremustbetakentoensurethatthetapedoesnotobstructthe
orificeofthefitting.
Nonreturnvalves,pressurereducingvalvesandRPZvalvesmustnotbeinstalled
betweenthepressurisationunitandtheheating/coolingsystem.Thesedeviceswill
preventthepressuresensorfromreadingthesystempressure.
Thepressurisationunitandexpansionvesselshouldbeconnectedtothesystematthe
samepoint,toprovideaneutralpressurereading.Thispointofconnectionshouldbe
inthesystemreturn,onthesuctionsideofthecirculationpump.

TypicalInstallationDiagram

FlowRestrictors(Mini&Midimodelsonly)
Pressurisationequipmentfittedwithaplastic,sideentrytorbeckvalvemustbefitted
withafilteranddependingonthemainswaterpressureaflowrestrictor.Failure
todothismayresultindamagetotheequipment.

Twodifferentflowrestrictorsaresuppliedwiththeequipment,bothofwhichincludeanintegral
filter.Theselectionoftheappropriateflowrestrictorisbasedonthemaximummainswater
pressureatthepointofinstallation.Pleaserefertothefollowingtableforselection.

MainsWaterPressure
14Bar
Above4Bar

Requirement
LowPressureRestrictor(coloured)
HighPressureRestrictor(white)FactoryFitted

Ifnorestrictorisrequired,thefiltermustberemovedfromoneoftherestrictorsandinstalledonits
own.Thefollowingdiagramshowshowtoremovethefilter:

Toinstalltheflowrestrictor/filter,holditbythetabandpushitintotheopeningofthefloatvalve
connection,asshowninthediagrambelow:

FlexfillerClearanceandConnectionRequirements

Connection

Size

Notes
Anisolationvalvemust
Mains
BSPM beinstalledonthemains
WaterFeed
waterfeedforservicing.
Guidanceondrainage
requirementsshouldbe
BreakTank
22mm
obtainedfromthelocal
Overflow
waterauthority.
Thepressurisationunit
andexpansionvessel
shouldbeconnectedto
thesystematthesame
point.

Thepointofconnection
System
BSPM shouldbeinthesystem
Connection /15mm return,onthesuction
sideofthecirculation
pump.

Nonreturnvalves,
pressurereducingvalves
andRPZvalvesmustnot
beused.

MidiClearanceandConnectionRequirements

Connection

Notes
Anisolationvalvemust
Mains
BSPM beinstalledonthemains
WaterFeed
waterfeedforservicing.
Guidanceondrainage
BreakTank
requirementsshouldbe
22mm
Overflow
obtainedfromthelocal
waterauthority.
Thepressurisationunit
andexpansionvessel
shouldbeconnectedto
thesystematthesame
point.

Thepointofconnection
System
BSPM shouldbeinthesystem
Connection /15mm return,onthesuction
sideofthecirculation
pump.

Nonreturnvalves,
pressurereducingvalves
andRPZvalvesmustnot
beused.

Size

MiniClearanceandConnectionRequirements

Connection

Notes
Anisolationvalvemust
Mains
BSPM beinstalledonthemains
WaterFeed
waterfeedforservicing.
Guidanceondrainage
requirementsshouldbe
BreakTank
22mm
obtainedfromthelocal
Overflow
waterauthority.
Thepressurisationunit
andexpansionvessel
shouldbeconnectedto
thesystematthesame
point.

Thepointofconnection
shouldbeinthesystem
System
BSPF
return,onthesuction
Connection
sideofthecirculation
pump.

Nonreturnvalves,
pressurereducingvalves
andRPZvalvesmustnot
beused.

Size

ElectricalPowerSupply
Thisequipmentmustbeelectricallyisolatedbeforeremovingthecovers.Cables
connectedtothevoltfreecontactsmaybesuppliedfromanothersourceandmay
remainliveaftertheunitisisolated.Thesemustbeisolatedelsewhere.

Allelectricalconnectionsmustbecarriedoutbyasuitablyqualifiedandcompetent
person.

Themainspowersupplytothepressurisationunitmustbeconnectedintothefusedterminalblock
asshownbelow:

Onsomelargermodels,thefusedterminalblockisreplacedbyafusedspur.Ifthisisthecase,the
powersupplymustbeconnectedintothefusedspur,asshownbelow:

Itisrecommendedtosupplypowertothepressurisationunitviaalockableisolator.
Thisshouldbeinstalledwithin2moftheequipment.

Thisequipmentcanbedamagedbythehighvoltagesproducedbyelectrical
installationtestingequipment.Whenperformingelectricalinstallationtests,the
equipmentmustbeisolatedfromthesupply.

10

FaultContacts
Thereare6voltfreefaultcontactswhichcanbeusedforconnectiontoaBMSsystem,orasaboiler
interlock.Theseareterminals112,locatedonthedigitalcontroller:

WiththeexceptionoftheCommonAlarm,itispossibletoconvertallotherfault
contactstonormallyclosed.Forfurtherinformationpleaserefertothecommissioning
sectionofthismanual.

11

PowerFilter
ThedigitalcontrollercanbeadverselyaffectedbyEMIandpowerspikes.Apower
filtermayberequiredifthesupplytotheequipmentisunstable(e.g.frequentpower
cuts),sharedbyequipmentwhichgenerateshighlevelsofEMI(e.g.inverters,IT
equipmentetc.)orisfittedwithabackupgenerator.
Ifrequired,apowerfiltercanbepurchasedseparatelyusingproductcodeFC100.
Thepowerfiltermustbeconnectedbetweenthetransformerandthedigitalcontroller,onthe
12VACline,asshowninthediagrambelow:

Becausethefilterisinstalledonthesecondarysideofthetransformer,thepolarityofthe
connectionsdoesnotmatter.
Forthefiltertofunctioncorrectly,thePELINEterminalmustbeconnectedtothe
chassiscommonearthpoint

12

Commissioning
ItishighlyrecommendedtohavethisequipmentcommissionedbyaFlamcoapproved
engineer.Anydamageorlossincurredthroughincorrectcommissioningbyan
unapprovedengineerwillnotbecoveredbythewarranty.

PreCommissioningChecklist
Thefollowingconditionsmustbemetbeforestartingthecommissioningprocess.
Failuretomeettheseconditionsmayresultininjuryordamagetotheequipment,
systemandproperty.

Equipmentissitedinafrostfreearea,awayfromprecipitationandwatersprays/jets

Allnecessarypipe/electricalconnectionshavebeenmadetoasatisfactorystandard

Thetemperatureandpressureatthepointofconnectionarewithintheoperatinglimitsof
thepressurisationunit.
Theheating/coolingsystemisfittedwithasafetyvalveandexpansionvessel

Thefollowingconditionsmustbemetforthepressurisationunitandheating/cooling
systemtofunctioncorrectly.Iftheseconditionshavenotbeenmet,itisnotadvisable
toproceedwiththecommissioningprocess.

Thesystemconnectionhasbeenmadeintothesystemreturnheader/pumpsuction

Therearenononreturnvalves,pressurereducingvalvesorRPZvalvesinstalledbetweenthe
pressurisationunitandtheheating/coolingsystem
Theexpansionvesselisprechargedtothecorrectpressure(equaltofillpressure)

Itisadvisabletofilltheheating/coolingsystempriortocommissioning.Ifthisisnot
possible,thepressurisationunitcanbeusedtofillthesystemaftercommissioning.
Dependingonthesizeofthesystem,thismaytakeaconsiderableamountoftime.

Theheating/coolingsystemisfilledandpressurisedtotherequiredcoldfillpressure,with
thewateratambienttemperature(approximately).

13

ControllerOverview

Thefollowingimageshowsthefrontofthepressurisationunitdigitalcontroller.4buttonsare
providedforprogramming,andanLEDdisplaywhichshowsscrollingmessages.

Whenthecontrollerisfirstpoweredup,itwilldisplaythecontrollerversionnumber.
Thismanualrelatestocontrollerversion6.3.Ifthecontrollerisofadifferentversion,
theremaybedifferencesinthemenuitemsavailable.

OldControllerDesign
Onoldermodels,thedesignofthedigitalcontrollerisvisualydifferent.Theinternal
componentsareidenticalandthebuttonfunctionsremainthesame.
Theoldcontrollerdesignisshownbelow:

Wheninnormaloperation,thecontrollerwilldisplaythecurrentsystempressure.Ifafaultoccurs,
thecontrollerwilldisplayafaultcodeandproduceanaudiblealarm.
Innormaloperation,thefunctionsofthebuttonsareasfollows:
Button
SET
MUTE
+

14

Function
Press

MuteAudibleAlarm

Hold
ShowCurrentSystemPressure
ResetUnit
EnterProgrammingMenu

ControllerProgramming

Donotalteranysettingswithoutfirstunderstandingtheimplicationsofdoingso.
Incorrectsettingsmaycausedamagetotheequipment,systemorproperty.

Toentertheprogrammingmenu,holdthe(+)buttonuntilentercodeappearsonthescreen,
followedby0000withaflashingcursorafterthefirstdigit.
Togainaccesstotheprogrammingmenu,oneofthefollowingcodesmustbeentered:
CustomerCode
EngineerCode(V6.3)
EngineerCode(<V6.3)

Standardsetofoptions
Extendedsetofoptions
Extendedsetofoptions

2601
4706
0426

Toenterthecode,changethefirstdigitwiththe(+)and()buttons,thenpress(SET)tomoveonto
thenextdigit.Repeatforalldigits,thenoncethecorrectcodeisshownonthedisplay,press(SET)to
entertheprogrammingmenu.
Onceacorrectcodehasbeenentered,thefirstoption[COLDFILL]willappearonthescreen.
Onceinthemenu,thevalueofthecurrentmenuitemcanbechangedusingthe(+)and()buttons.
Oncethecurrentvaluehasbeenset,pressingthe(SET)buttonwillmoveontothenextoption.
Itisnotpossibletonavigatebackwardsthroughthemenu.Toreturntoaprevious
settinginthemenu,pressthe(SET)buttonrepeatedlytoscrollthroughtotheendof
themenu,andthenreentertheappropriatecode.
Ifthecontrollerloosespowerwhileintheprogrammingmenu,allchangesmadewill
beerased.Toconfirmallchanges,theendofthemenumustbereached,andthe
SAVING...messagemustbedisplayed.

15

Thetablebelowgivesdetailsofallmenuitems,intheorderthattheywillappear:
#

MenuItem

COLDFILL

HIGHSET

LOWSET

DIFFERENTIAL

FLOODLIMIT

PUMP1COUNT

PUMP1HOURS

Function
Therequiredfillpressure,i.e.pumpcutoutpressure.
Therecommendedsettingis0.3BARabovethestaticpressure
ofthesystem(0.1Barpermeterofstaticheight).
Forexample,a14mhighinstallationwillhaveastaticpressure
of1.4Bar,makingtherecommendedcoldfillpressure1.7Bar.
Itisnotpossibletoenteravaluehigherthanthecurrent[HIGH
SET]orlowerthanthecurrent[LOWSET]values.
Thehighpressurealarmsetting.
Ifthepressureinthesystemreachesthisvalue,the<HIGH
PRESSURE>alarmandcommonalarmwillbeactivated.
Therecommendedsettingis10%belowthesafetyvalverating.
Forexample,ifthesafetyvalveratingis3Bar,the
recommendedsettingis2.7Bar.
Itisnotpossibletoenteravaluelowerthanthecurrent[COLD
FILL]value.
Thelowpressurealarmsetting.
Ifthepressureinthesystemfallsbelowthisvalue,the<LOW
PRESSURE>alarmandcommonalarmwillbeactivated,andthe
pressurisationpumpswillnotrun.
Therecommendedsettingis0.5Barbelowthe[COLDFILL]
pressure.
Itisnotpossibletoenteravaluehigherthanthecurrent[COLD
FILL]value.
Thedifferentialbetweenthecutinandcutoutpressuresof
thepressurisationpumps.
Thecutinpressurewillbeequaltothe[COLDFILL]pressure,
minusthedifferentialpressure.
Forexample,ifthe[COLDFILL]pressureissetto1.5bar,and
thedifferentialsetto0.2Bar,thepumpcutinpressurewillbe
1.3Bar(1.50.2=1.3)
Themaximumcontinuousruntimeforeachofthe
pressurisationpumps.
Ifapumprunscontinuouslyforlongerthanthisperiod,the
pumpwillstopanda<FLOODLIMIT>alarmwillbeactivated.
Thisistopreventtheunitfrompumpinglargeamountsof
waterintheeventofalargeleak/burstpipe.
Forverylargesystems,thismayneedtobeincreased.
Thevaluecanbechangedinincrementsof10minutes,toa
maximumof990.
Thecumulativenumberofpumpstartsforpump1.
Thisisacumulativecounter,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Thecumulativeruntimeinhoursforpump1.
Thisisacumulativetimer,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.

16

Default
Value

1.0Bar

2.7Bar

0.5Bar

0.2Bar

10MINS

MenuItem

PUMP2COUNT

PUMP2HOURS

10

ALARMCOUNT

11

POWER
INTERRUPTED

12

PULSE

13

EXCESSIVE
START

14

SERVICE

15

FILLSYSTEM

Function
Thecumulativenumberofpumpstartsforpump2.
Thisisacumulativecounter,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Thecumulativeruntimeinhoursforpump2.
Thisisacumulativetimer,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Thecumulativenumberofallalarmincidents.
Thisisacumulativecounter,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Thecumulativenumberofpowerinterruptions(i.e.controller
turnedoff/powercut).
Thisisacumulativecounter,thevalueofwhichcannotbe
modified.Ifusingtheengineerscode,thecountercanbereset
tozerobyholdingthe(MUTE)button.
Whenenabled,ifapumphasbeeninactivefor60days,itwill
startandrunfor2seconds.
Thisistopreventthepumpsfromseizing.
Whenenabled,iftherearemorethan3individualpumpruns
withinan8hourperiod,theunitwillregisteran<EXCESSIVE
DEMAND>alarm.
Enablingthisoptionmaycausefalsealarmsonsomesystems.
Whenenabled,aservicereminderwillbedisplayedafter12
monthsfromwhentheoptionwasenabled.
Toresettheservicereminder,setthevaluetoNOandexitthe
menu.Then,reenterthemenuandsetthevaluetoYESagain.
Whenenabled,the<LOWPRESSURE>and<FLOODLIMIT>
alarmswillbedisabled,andpump1willruncontinuouslyforup
to24hoursuntilthecoldfillpressurehasbeenreached.
Oncethecoldfillpressurehasbeenreached,thisoptionwill
automaticallybedeactivated,andthelowpressurealarmand
floodlimitwillbereactivated.
Thisfunctionisusedtofillasystemthatisemptyoratlow
pressure.
Caremustbetakenusingthisoptionasthefloodlimitalarmis
disabled,increasingtheriskofflooding.
ThisoptioncannotbeenabledonMinipressurisationunits.

Default
Value

NO

NO

NO

NO

Ifusingthecustomercode,themenuwillendatthispoint.Afterpressing(SET)once
more,thecontrollerwilldisplaySAVING...andreturntonormaloperatingmode.If
usingtheengineerscode,additionalmenuitemswillbedisplayed.
Thefollowingsettingsareallpreprogrammedinthefactoryandshouldnotneedto
bemodifiedonsite.Ifthesesettingsappeartohavebeenreset,themostlikelycause
isapowerspike.Ifthisproblempersists,apowerfiltermayberequired.

17

Thefollowingsettingsareforexperiencedengineersonly.Incorrectconfigurationof
thesesettingscancausetheequipmentnottofunctioncorrectly,andmaycause
damagetotheequipment,systemorproperty.

MenuItem

16 PUMPSNUMBER

17

PUMPTYPE

18

PUMPSENSE

19

SENSORTYPE

20

SPC
CONTROLLER

21

GLYCOLUNIT

22

IDNUMBER

23

RELAY
INVERSION

24

OVERRUN

25

PRESSURE
ALARMAUTO
RESET

26

CASCADE

27

BOOST

28

FLOMAT

18

Function
Thenumberofpumpsinstalledinthepressurisationunit.
Thiscanbesettoeither1or2.
Thetypeofpumpinstalledinthepressurisationunit.
Therearetwooptions,whichareasfollows:
0CentrifugalPump
1PistonPump(miniunitsonly)
Disablingthisoptionwillstopthecontrollerfrommonitoring
thepumpsandgenerating<PUMPFAIL>faults.
Itisnotrecommendedtodisablethisoption.Pleaseconsult
FlamcoTechnicalbeforedoingso.
Thetypeofpressuresensorinstalledintheunit.
Therearefouroptionswhichareasfollows:
005VOutput,010BarRange
116VOutput,010BarRange
216VOutput,016BarRange
3
EnablesthelinktotheFlamcoSPCcontroller.
Thisoptionshouldonlybeenabledonpressurisationunits
whicharelinkedtoanSPCcontroller,whicharefoundon
FlamcomatandMKautomatequipment.
Enablesthelowglycollevelswitch.
Thisoptionshouldonlybeenabledonglycolpressurisation
units.
Auserconfigurableidentificationnumber.
Thisoptiondoesnotserveanyfunctionalpurpose.
Whenenabled,allnormallyopenfaultcontacts(i.e.allexcept
thecommonalarm)areconvertedtonormallyclosed.
Allowsthepumptocontinuerunningforasetperiodoftime
aftertherequiredpressurehasbeenreached.
Thiswillpreventthepumpsfromhunting.
Thevaluecanbesetfrom010seconds.
Whenenabled,the<HIGHPRESSURE>and<LOWPRESSURE>
alarmswillbeclearedautomaticallyifandwhenthepressure
returnstonormal.
Ifdisabled,thealarmsmustbemanuallyreset.
Allowsthepumpstooperateinduty/assistmode.
Aftereitherpumpstarts,theotherpumpwillstartafteraset
periodoftime.
ThisoptioncanbesettoOFF,or530seconds.
Whenenabled,thecontrollerwillallowingthepumpstorun
evenifthesystempressureiszero.
Whenenabled,thehighwaterinputisusedtotriggeratop
upsolenoidvalveconnectedtothesensorhealthyvoltfree
contact.
Thisoptionshouldonlybeenabledonunitswhichutilizea
solenoidvalveasthemeansoftopup.

Default
Value
2

YES

NO

NO
12
NO

YES

OFF

YES

NO

HydraulicCommissioning

1FloatValveSetting
Ensurethatthebreaktankfloatvalveissettoitslowestposition:

FlexfillerUnits

Mini&MidiUnits

Ifadrainvalveisfittedtothebreaktank,ensurethatitisclosed.Then,turnonthemainswater
supplyandallowthebreaktanktofill.
Whenthefloatvalveoperatesforthefirsttime,itmaynotcloseimmediately,causing
thebreaktanktooverfill.Oncetheinternalsofthevalvehavebeenfullywettedthis
shouldnotoccuragain.

2BleedingPumps
ThisstepisonlynecessaryforFlexfillerandMidiunits.ForMiniunits,moveontothenextstep.
Makesurethattheinternalisolationvalvewithinthepressurisationunitisclosedby
followingthestepsbelow.Failuretodothismaycauseinjuryordamagetothe
equipment,systemorproperty.

19


Attachalengthofhosetothehosetailonthedrainvalveandputtheotherendtodrain.Then,using
thecapofftheisolationvalve,openthedrainvalve:

Locatethebleedscrewonthepump.Thefollowingdiagramsshowexamplesoftypicalbleedscrew
locationsformostpumps:

Donotuseexcessiveforcewhentighteningthebleedscrewasthismaydamagethe
pumpcasing.

20


Ifthepumphasaplasticbleedscrewliketheoneshownbelow,donotuseexcessive
forceorattempttouseanytoolstoturnitasthismaydamagethepumpcasing.

ForcingPumpstoRun
Turnonthepowersupplytothedigitalcontrollerandwaitforthesystempressureto
appearonthedisplay.Then,enterthecode2601andgotothefirstsettinginthe
menu,coldfill.Whileatthispointinthemenu,holdingdownthe(MUTE)buttonwill
forcepump1torun,andholdingdownthe(SET)buttonwillforcepump2torun.
IfthecontrollerisolderthanV6.1thenthereisnowaytoforcepump2torunviathe
controller.Toforcethesecondpumptorun,theunitmustbeisolatedandthelive
wiresinterminals13and14mustbeswappedover.Thesecondpumpthenbecomes
pump1andcanbeforcedtorunviathecontroller.

Tobleedthepumps,thepumpsmustbestarted.Thenwhilethepumpisrunning,the
bleedscrewmustbeopeneduntilalltheairhasbeenremovedandonlywaterisbeing
discharged.Thebleedscrewcanthenbeclosed.

Failuretobleedthepumpsmayresultindamagetotheequipment,systemand
property.

Afterbleedingthepumps,closethedrainvalveandremovethehosefromthehose
tail.

21

3InitialStartup
Opentheinternalisolationvalvewithinthepressurisationunitbyfollowingthestepsbelow:

Flexfiller&MidiUnits

MiniUnits
Oncetheisolationvalveisopen,thepressuresensorwillbeabletoreadthesystempressure.
Turnonthepowersupplytothepressurisationunit.Dependingonthecurrentsystempressure,the
unitwillrespondinoneofthefollowingways:
Ifthesystempressureisbelowthelowpressurealarmsetting,thecontrollerwill
displayaLOWPRESSUREfaultandthepumpswillnotrun.Toclearthisfault,either
increasethesystempressureusingafillingloop,orenablethesystemfilloptionon
thepressurisationunit.
Ifthesystempressureisabovethehighpressurealarmsetting,thecontrollerwill
displayaHIGHPRESSUREfault.Toclearthisfault,useasuitabledrainpointto
removewaterfromthesystemuntilthesystempressureequalsthecoldfillpressure.
Ifthesystempressureisabovethelowpressurealarmsetting,butbelowthecoldfill
setting(byanamountequaltothedifferentialsetting),thepumpswillstart.Oncethe
systempressurehasreachedthecoldfillpressure,thepumpwillstop.
Oncetherequiredsystempressurehasbeenreached,thecontrollerwilldisplaythecurrentsystem
pressure.Theunitisnowinnormaloperation.

22

4Testing
Totesttheoperationofthepressurisationunitwhileconnectedtothesystem,thesystempressure
mustbeloweredslowlytosimulateaminorleak.
Thiscanbeachievedbyusingadrainpointonthesystem,thedrainpointonthepressurisationunit,
orbymanuallyopeningthesafetyreliefvalve.
Caremustbetakennottoletthepressuredroptooquickly.Ifthesystempressure
fallsbelowthelowpressuresetpoint,alowpressurefaultwillbedisplayedandthe
pumpswillnotrun.Thepressurisationunitisnotdesignedtocopewithasuddenloss
ofsystempressure,whichwouldbesymptomaticofacatastrophicfailuresuchasa
burstpipe.
Oncethesystempressurehasfallenbelowthecoldfillsetting(byanamountequaltothe
differentialsetting),thepumpshouldstartrefillingthesystem.Thepumpwillcontinuetorununtil
thecoldfillpressurehasbeenreached.
Thistestdemonstratestheprimaryfunctionofthepressurisationunit.Thistestmayberepeatedat
anytimetoconfirmtheoperationofthepressurisationunit.

23

CommissioningRecord
SiteReference:

PUReference:

EngineerName:

SiteContactName:

Company:

/ /

DateCommissioned:

ContactNo.:

YES/NODeleteasappropriate

FlamcoAccredited:

ContactNo.:

COLDFILL:

HIGHSET:

LOWSET:

DIFFERENTIAL:

FLOODLIMIT:

Bar

Bar

Bar

Bar

Minutes

PUMP1COUNT:

YES/NO

Deleteasappropriate

YES/NO

Deleteasappropriate

YES/NO

Deleteasappropriate

1/2

Deleteasappropriate

IDNUMBER:

Deleteasappropriate

0/1/2

GLYCOLUNIT:

Deleteasappropriate

0/1

SPCCONTROLLER:

RELAYINVERSION:

YES/NO

Deleteasappropriate

OVERUN:

POWERINTERRUPTED:

SENSORTYPE:

ALARMCOUNT:

PUMPSENSE:

PUMP2HOURS:

PUMPTYPE:

PUMP2COUNT:

Deleteasappropriate

PUMPSNUMBER:

PUMP1HOURS:

YES/NO

FILLSYSTEM:

PRESSUREALARMAUTORESET:

PULSE:

YES/NODeleteasappropriate

EXCESSIVESTART:

YES/NODeleteasappropriate

YES/NO

Deleteasappropriate

CASCADE:

SERVICE:

YES/NODeleteasappropriate

BOOST:

FLOMAT:

YES/NO

Deleteasappropriate

YES/NO

Deleteasappropriate

COMMENTS:

EngineerSignature:

CustomerSignature:

24

Dated:

/ /

/ /

Dated:

Operation
Oncecommissioned,thepressurisationunitshouldoperatewithoutanyuserintervention.
Undernormaloperatingconditions,thedisplaywillshowthecurrentsystempressureinBar.
Whiletheunitisfilling,thedisplaywillshow<PUMP1RUN>or<PUMP2RUN>dependingonwhich
pumpiscurrentlyrunning.
Iftheunitidentifiesafault,thedisplaywillshowtherelevantfaultcode.
Ifthepressurisationunitisshowingafaultcodeonthedisplay,holdingdownthe[SET]
buttonwillcausethecurrentsystempressuretobetemporarilyshownonthedisplay.

FaultCodes
Thefollowingtablegivesthemeaningsofallfaultcodesusedonthedigitalcontroller:
FaultCode
LOWPRESSURE
HIGHPRESSURE

Description
Thesystempressureisbelowthe[LOWPRESSURE]set
point.
Thesystempressureisabovethe[HIGHPRESSURE]set
point.
Thebreaktanklowlevelfloatswitchhasbeenactivated
Thebreaktankhighlevelfloatswitchhasbeenactivated
Thecontrollerhasdetectedafault(incorrectcurrentdraw)
ontherespectivepump
Therespectivepumphasrunforlongerthanthe[FLOOD
LIMIT]period
Thesignalfromthepressuresensorisoutofrange
Thelowglycolswitchhasbeenactivated(glycolunitsonly)
Therehavebeen4pumpstartswithinan8hourperiod
Thepressurisationunitisdueanannualservice

Auto/Manual
Reset
UserDefined
UserDefined

LOWH20
AutoReset
HIGHH20
AutoReset
P1FAIL
ManualReset
P2FAIL
P1FLOODLIMIT
ManualReset
P2FLOODLIMIT
ERR.1
ManualReset
LOWGLYCOL
AutoReset
EXCESSIVEDEMAND
ManualReset
SERVICE
ManualReset

Forpracticalguidanceondiagnosingandrectifyingfaults,pleaserefertothe
Troubleshootingsectionofthismanual.

25

ShutdownProcedure
Thepressurisationunitmustbeshutdownduringanyofthefollowingscenarios:

Workisbeingcarriedoutonthesystem.
Workisbeingcarriedoutonthepressurisationunit
Theheating/coolingsystemisbeingflushed

Toshutdownthepressurisationunit,pleasefollowthestepsbelow:
1. Isolatetheelectricalpowersupplytothepressurisationunit
2. Isolatethemainswatersupplytothepressurisationunit
3. Isolatethepressurisationunitfromthesystemusingtheinternalisolationvalve
4. Ifitisanticipatedthattheunitwillbeoutofcommissionformorethan24hours,itis
advisabletodrainthewaterfromthebreaktank.

StartUpProcedure
AttentionThisprocedureisforrestartingtheunitafterbeingshutdown(asdescribed
above).Forinitialstartupandcommissioningprocedures,pleaserefertothe
Commissioningsectionofthismanual.

Torestartthepressurisationunit,pleasefollowthestepsbelow:
1. Performavisualinspectionoftheunitandinstallationtocheckforsignsofdamage
2. Checkthebreaktankfordebris/depositsandremoveifnecessary
3. Turnonthemainswatersupplytothepressurisationunitandallowthebreaktanktofill
4. Opentheinternalisolationvalve
5. Turnonthemainspowersupplyandwaitforthecontrollertostart
6. Dependingontheconditionsinthesystem,theunitmaydisplayoneormorefaultcodesat
thispoint.Ifthishappens,pleaserefertotheTroubleshootingsectionofthismanualfor
guidance.

26

Troubleshooting

Ifforanyreasonthepressurisationunitdoesnotseemtobefunctioningcorrectly,pleasereferto
thetablebelowforalistofsolutionstoknownproblems.
Ifthepressurisationunitisshowingafaultcodeonthedisplay,holdingdownthe[SET]
buttonwillcausethecurrentsystempressuretobetemporarilyshownonthedisplay.

Symptom

LOWPRESSUREfaultis
displayedandthepumpsdo
notrun

HIGHPRESSUREfaultis
displayed

Problem

Solution

Theinternalisolationvalve
withintheunitisclosed

Opentheinternalisolation
valve

Thesystempressurehasfallen
belowtheLOWPRESSUREset
point

Increasesystempressureusing
afillingloop,orenablethe
SYSTEMFILLoption

TheSPCCONTROLLERoptionis
enabled

DisabletheSPCCONTROLLER
option

TheLOWPRESSUREsetpointis
toohigh

Reviewthesystem
specifications

Theinternalisolationvalve
withintheunitisclosed

Opentheinternalisolation
valve

Thesystempressurehasrisen
abovetheHIGHPRESSUREset
point

Decreasesystempressureusing
asuitabledrainpoint

Theexpansionvesselhasfailed
orlostitsprecharge

Checktheexpansionvesselpre
chargeandrechargeif
necessary

Theexpansionvesselis
undersized

Reviewtheexpansionvessel
selection

TheHIGHPRESSUREsetpointis Reviewthesystem
toolow
specifications
Alargeamountofwaterhas
beenlostfromthesystem

P1and/orP2FLOODLIMITis
displayed

Investigatecause

Therelevantpumpisairlocked
Bleedthepump
andnotpumpingwater
Theunitisundersizedforthe
system

Reviewunitselection

TheFLOODLIMITtimeistoo
short.

ConsultFlamco

27

Symptom

P1and/orP2FAILisdisplayed

Problem
ThePUMPTYPEoptionisset
incorrectly.

ReviewPUMPTYPEsetting

Therelevantpumphasfailed

Replacepump

P2FAILisdisplayedbuttheunit ThePUMPSNUMBERoptionis
isasinglepumpmodel
incorrectlysetto2

LOWH20faultisdisplayed

HIGHH20faultisdisplayed

Solution

SetPUMPSNUMBERto1

Themainswatersupplytothe
unithasbeenisolated

Turnonthemainswatersupply

Themainspressureispoor

Thefaultwillclearoncethe
breaktankhasbeenrefilled

Anonstandardelectrical
Removeallnonstandard
connectionhasbeenmadeinto
electricalconnections
terminals19&20
Thelowwaterfloatswitchhas
failed

Replacelowwaterfloatswitch

Thedigitalcontrollerhasfailed

Replacedigitalcontroller

Anonstandardelectrical
Removeallnonstandard
connectionhasbeenmadeinto
electricalconnections
terminals21&22
Thedigitalcontrollerhasfailed

Replacedigitalcontroller

Theinternalisolationvalve
withintheunitisclosed

Opentheinternalisolation
valve

TheSENSORTYPEoptionisset
incorrectly

ReviewSENSORTYPEsetting

Anonreturnvalvehasbeen
installedbetweentheunitand
thesystem

Removenonreturnvalve

Thepressuresensorhasfailed

Replacepressuresensor

TheSENSORTYPEoptionisset
incorrectly

ReviewSENSORTYPEsetting

Thepressuresensorhasfailed

Replacepressuresensor

Pumprunsbutdoesnotmake
uppressure

Thepumpisairlockedandnot
pumpingwater

Bleedthepump

Thepumpispersistently
becomingairlocked

Thewrong/noflowrestrictoris
installedinthefloatvalve(mini
andmidiunitsonly)

Checkfloatvalveflowrestrictor
selection(miniandmidiunits
only)

Pressurereadingdoesnot
matchactualsystempressure.

ERROR1faultisdisplayed

28

Symptom

Problem

Solution

Thewrong/noflowrestrictoris
installedinthefloatvalve(mini
andmidiunitsonly)

Checkfloatvalveflowrestrictor
selection(miniandmidiunits
only)

Thebreaktankisoverfillingand Thefloatvalvepositionisset
dischargingwatertodrainor
incorrectly
overtheweir
Thefloatvalvehasfailed

Replacenonreturnvalve

Theinternalisolationvalve
withintheunitispartially
closed

Fullyopentheinternalisolation
valve

Therestrictioninthe
connectingpipeworkistoo
great

Increasebore/reducenumber
ofbends/reducelengthof
connectingpipework
Replacenonreturnvalve

Theexpansionvesselhasfailed
orlostitsprecharge

Checktheexpansionvesselpre
chargeandrechargeif
necessary

Thepointofconnectionofthe
unitistoofarawayfromthe
expansionvessel

Moveunit/expansionvessel
connectionpointscloser
together.

Theplastichousingofthe
digitalcontrollerhascome
apartandthePCBhasmoved

Reassemblethedigital
controllerhousingandensure
thatthePCBisproperlyseated

Thedigitalcontroller
Thecontrollerisbeingssubject
parametersarebeingcorrupted topowerspikes
Thefusehasblown

Fitasuitablepowerfilter
Replacethefuse

Themainspowersupplyisatan
Checkmainspowersupply
incorrectvoltageorfrequency

Thedigitalcontrollerdoesnot
powerupwhentheunitis
switchedon

SERVICEisdisplayedonthe
screen

Replacefloatvalve

Apumpnonreturnvalvehas
failed

Thepumpisrepeatedlyrunning Apumpnonreturnvalvehas
inshortbursts
failed

Thebuttonsonthedigital
controllerdonotrespond

Setthefloatvalvetoitslowest
possibleposition

The12Vtransformerhasfailed

ReplaceTransformer

Thedigitalcontrollerhasfailed

Replacedigitalcontroller

Theunitisdueanannual
service

Contactserviceengineer

29

Maintenance

Duetovariationsinoperatingconditions,andthevaryingloadsplacedonpressurisationunits,itis
notfeasibletoprovideaccuratepredictionsofcomponentlifespan.Themosteffectivemethodof
maintenanceistoinspectthepressurisationunitforearlysignsofcomponentfailureandtakeaction
accordingly.
Thefollowingmaintenanceproceduresshouldbeperformedatleastonceayear:
VisualInspection
Abasicvisualinspectionwillhighlightthemajorityofpotentialfaultsonapressurisationunit.Itis
recommendedtoperformavisualinspectionannually.However,duetothesimplicityofperforming
thesechecks,frequentinspectionsareencouraged.

Checkthedigitaldisplayforfaultcodes
Checkforsignsofleakage(e.g.water,mineraldeposits,corrodedcomponents/cabinet)
Checkthebreaktankoverflowforsignsofwaterdischarge
Checkflexiblehosesforsignsofdegradation(e.g.cracks)
Checkthatthepressurereadingonthedigitaldisplaycorrespondstotheactualsystem
pressure(readoffanothergauge)

InterrogateController
Thedigitalcontrollerkeepsalogofthenumberofpumpstartsandtotalhoursrunforeachpump,as
wellasthenumberofalarmactivationsandpowerinterruptions.Itisadvisabletotakeanoteof
thesefigureswhenservicingtheunit,astheymaybehelpfulindiagnosingpotentialissues.Fieldsare
providedintheservicelogforthesefigures.
Itisadvisabletoscrollthroughallthesettings(includingengineerssetting)andcheckthemagainst
thefiguresonthecommissioningreport.Ifthereareanydiscrepancies,checkfirstwithonsitestaff
toseeifthechangesaredeliberate.Ifnot,reconfigureappropriately.
Ifsettingsarepersistentlybecomingcorrupted,apowerfiltermayberequired.Please
refertotheInstallationsectionofthismanualformoreinformation.

TestUnitOperation
Thebestwaytotesttheoperationofthepressurisationunitistodrainwaterfromthesystem,
allowingthepressuretodropslowly.Oncethepressurefallsbelowthepumpcutinpressure([COLD
FILL][DIFFERENTIAL])thepumpshouldstart.Assoonasthepumpstarts,closethedrainpointand
allowthesystempressuretorise.Oncethe[COLDFILL]pressureisreached,thepumpshouldstop.
Iftheunitisatwinpumpmodel,thistestshouldberepeateduntilbothpumpshaverunand
successfullyrepressurisedthesystem.

30


CheckFloatValveOperation
Totesttheoperationofthebreaktankfloatvalve,firstensurethatthebreaktankoverflowhasa
suitablepathtodrain.
Gentlypushdownonthearmofthefloatvalveuntilitstartstodischargewater,thenreleasethe
floatvalvearm.Oncethearmhasbeenreleased,theflowofwatershouldstopwithinafewseconds.

CheckFloatSwitchOperation
Totesttheoperationofthebreaktanklowlevelfloatswitch,reachintothebreaktankandgently
pushthefloatswitchdownintothehorizontalposition.
Thedigitalcontrollershouldnowdisplaya<LOWH20>fault.
Releasethefloatswitchandobservethedisplay.Thefaultshouldclearafteradelayofafew
seconds.

CheckBreakTankWaterCondition
Performavisualcheckofthewaterinthebreaktank.Ifthereisanydirtordebrisinthewater,or
depositsonthesidesofthetank,thetankshouldbedraineddownandcleaned.

CheckStrainer(Flexfillerunitsonly)
Flexfillerpressurisationunitsarefittedwithameshstrainerintheconnectionatthebottomofthe
breaktank.Thisshouldberemovedandinspected.Dependingonthecondition,thispartmayneed
tobecleanedorreplaced.

CheckExpansionVesselPreCharge
Manyoftheproblemsexperiencedwithpressurisationequipmentcanbetracedbacktothe
expansionvessel.
Theexpansionvesselprechargepressuremustbecheckedafter2yearsandannuallythereafter.
Toperformthistest,theexpansionvesselmustfirstbedrainedofwater,thenagaugecanbe
connectedtotheSchradervalveonthevesseltomeasuretheprechargepressure.Theprecharge
shouldbeequaltothe[COLDFILL]pressuresetting.
Thepressurecanbeincreasedusingafootpump,aircompressororpressurisedair/nitrogen
cylinder.

Ifanyfaultsareidentifiedduringthesechecks,pleaserefertotheTroubleshooting
sectionofthismanual.Ifreplacementpartsarerequired,pleaserefertotheSpares

sectionforpartcodes.

31

WiringDiagram

32

ServiceLog
Thisservicelogshouldbecompletedbytheserviceengineeraftereachannualservice.

33

34

Spares
Thedrawingsonthefollowingpagesshowtheinternalcomponentsforarangeof
pressurisationequipment.Duetocontinuingdevelopmentandminordesignchanges,
somecomponentsmaybechangedwithoutnotice.Therefore,thedrawingsmaynot
accuratelyreflectthecurrentproductiondesign.Ifinanydoubtaboutthe
compatibilityofreplacementparts,pleasecontactFlamco.

ElectricalItems(AllModels)

*Imageforindicationonly
#
1
2
3
4
5

Description
DigitalController
12VMiniTransformer
1APowerFilter(optional)
PowerSwitch
FusedTerminalBlock

PartCode
MICROCONTROL
BSSMINITRANS
FC100
BSSF014
BSSR002

35

FlexfillerModels(125D,225D,150D,250D,280DS)

*Imageforindicationonly
#
1
2
3
4
5
6
7
8
9
10

36

Description
Pump
NonReturnValve
BraidedHose
PressureTransducer(010Bar,16V)
CombinedIsolation&DrainValve
FloatValve
OverflowConnection
MeshStrainer
FloatSwitch
BallValve

PartCode
SeeDatasheet
FCSC1
BSSFLEXHOSE
16VTRANSDUCER
FCCGNO
BSSP33
BSSM021
N/A
BSSRO12
BSSM005

MidiModels(125D,225D,150D,250D)

*Imageforindicationonly
#
1
2
3
4
5
6
7
8
9

Description
Pump
NonReturnValve
BraidedHose
PressureTransducer(010Bar,16V)
MiniFloatValve
CombinedIsolation&DrainValve
OverflowConnection
MeshStrainer
FloatSwitch

PartCode
SeeDatasheet
FCSC1
BSSFLEXHOSE
16VTRANSDUCER
BSSM003
FCCGNO
BSSM021
N/A
BSSR012

37

MiniModels(130D,230D)

*Imageforindicationonly
#
1
2
3
4
5
6
7
8
9
10
11
12
13

38

Description
Pump
PressureTransducer(010Bar,16V)
BallValve
OverflowConnection
MiniFloatValve
FloatSwitch
8mmPolytube
BSPMx8mmPushFit
8mmPushFitTee
8mmHoseTail
BSPFTee
BrassLockingNut
FlexiblePumpSupport

PartCode
SeeDatasheet
16VTRANSDUCER
BSSM005
BSSM021
BSSM003
BSSR012
BSSM015
BSSM007
BSSM008
BSSM023
BSSP62
BSSM006
BSSM022

Notes

39

Notes

FlamcoFlexfillerPressurisationManualV8.1

40