FLEXCON EXPANSION VESSELS. Flamco FLEXCON Flexcon. Expansion vessels FLEXCON FLEXCON M. Flamco FLEXCON V-B.

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1 FLEXCON EXPANSION VESSELS Flamco 1 Flexcon Expansion vessels FLEXCON 2-80 FLEXCON FLEXCON M Flamco FLEXCON V edition / UK

2 Flamco Flexcon the first name in expansion vessels Flamco has over 50 years of knowledge and experience in the design and production of expansion vessels. Flexcon vessels, a name associated with the very highest levels of quality, are readably available throughout the UK distributor network. are available with a certificate of test by SI. meet all European guidelines and bear the CE mark. FLEXCON 2-4 Flexcon vessels are S 4814:1990 certified and a kitemarked range of expansion vessels up to 1000L. The two halves of the vessel are coated prior to assembly. Flexcon vessels are supplied in stackable cardboard packaging, each box containing clear mounting instructions. The diaphragm has exceedingly low permeability. Flamco employees will be happy to give you advice and support. They are just a telephone call away and can even come to you. A modern computerised production line with test and inspection points is your guarantee of consistent, high quality. 1.2

3 FLEXCON 8-12 FLEXCON FLEXCON FLEXCON FLEXCON M The Flexcon M range has a replaceable diaphragm. The Flexcon M range can be fitted with an automatic air removal valve. Flamco s standard programme covers a wide range of expansion vessels from 2 8,000 litres with a sizable choice of nitrogen pre-charge and maximum operating pressures. The Flexcon M range has a high efficiency up to 72.5%. The Flexcon M expansion vessel is fitted with a pressure gauge as standard. FLEXCON QUALITY IS OUR REPUTATION! A Flexcon M range offers a long life installation with a range of options to suit even the most unsual requirements. The Flexcon M range can be fitted with an adjustable system connection. 1.3

4 o o o o Flamco Flexcon a name you can rely on Flexcon diaphragm expansion vessels are made of top-quality steel and come with a high gloss epoxy coating. Together with the clench ring this design offers a high in quality and reliable product. FLEXCON For ease of assemble the water connection thread is not coated. All Flexcon vessels have a nitrogen pre-charge. The rolling action of the Flexcon diaphragm provides the vessel with a longer life. The unique clench ring design damages neither the diaphragm nor the two halves of the vessel. Used in up to 80 litres complies with S 4814:1990. The pre-charge valve on Flexcon 8-80 litres is recessed for protection C C C C bar bar bar bar When the system is cold, the nitrogen pre-charge prevents fluid entering the vessel. As the system is heated the expansion vessel begins to fill with system fluid. All of the systems expansion is accommodated. The Prescor valve will open should the system exceed it s maximum working pressure. 1.4

5 FLEXCON ADVANTAGES: Flexcon offer the largest range of kitemarked and SI certified expansion vessels. All confirm to pressure equipment directive PED 97/23/EC. Flexcon diaphragms are suitable for use with glycol up to 50% by volume. FLEXCON FLEXCON M All Flexcon M vessels above 1200 litres are serviceable. A Flexvent Super floatvent can be fitted to the top of the Flexcon M (optional). Flexcon M expansion vessels are fitted with an inspection port (above 1200 litres). Flexcon M expansion vessels are fitted with an adjustable foot (above 2800 litres). 1.5

6 Flamco Flexcon expansion vessels give you more The are suitable for use on heating and cooling installations. The large range of Flexcon models can provide the solution you need. Flexcon Top expansion vessels for use up to 6 bar. Flexcon Solar expansion vessels for use on Solar installations. Flexcon intermediate vessels to prevent the diaphragm being exposed to system high temperatures. FLEXCON TOP 8-25 Flexcon Top The Flexcon Top range (2-80 litres) have a maximum working pressure of 6 bar. Maximum working pressure of 2 80 litres: 6 bars. Maximum working pressure of 8-80 litres: Maximum working pressure of litres: 8 bars. 10 bars. Flexcon Solar A complete programme of Flexcon Solar expansion vessels from litres. Flamco products used in a solar-powered installation 1. Solar collector. 2. Heat exchanger. 3. Pump. 4. Flamco vent valve and Flamco air pot. 5. Thermometer in return circuit. 6. Thermometer in feed circuit. 7. Pressure gauge. 8. low-off cock. 9. Flamco safety valve. 10. Overflow vessel. 11. Flexcon Solar expansion vessel. 12. Flexcon intermediate vessel (if required). 13. Flamco connection set. 1.6

7 options Flexcon intermediate vessels In closed heating installations, the supply temperature can reach 160 C. The continuous temperature load on the diaphragm should not exceed 70 C. In order to restrict the temperature, it is necessary to include an intermediate vessel on the circuit. The Flexcon V- with max. working pressures of 6.0 and 10.0 bar and max. supply temperatures of 120 C and 160 C. The Flexcon VSV with max. working pressures of 6.0 and 10.0 bar and max. supply temperature of 140 C. FLEXCON V- Excessively-hot water flows from the system into the top of the intermediate vessel. The maximum feed temperature of the water is 160 C for Flexcon V-. The rate at which the expansion water cools depends on the capacity of the intermediate vessel. An intermediate vessel must not be insulated. The hot water mixes in the vessel with the cold water already present. Cooler water is fed into the expansion vessel. The temperature of the expansion water absorbed by the Flexcon expansion vessel remains under the maximum permissible temperature for the diaphragm. y using a Flexcon intermediate vessel, you can prevent damage to Typical Flexcon intermediate vessel connection diagram with Flexcon M vessel. the vessel from high temperatures. 1.7

8 Flamco A Flexcon Vesselpak is a complete system package A complete set of approved equipment that fits directly onto your system. This provides a compact and neat assembly of all necessary components for a sealed system. Max. working pressure 6.0 bar. Vesselpak A Vesselpak A includes: Flexcon expansion vessel, vessel manifold, Prescomano combined safety valve and pressure gauge, double check valve with test point, flexible braided hose with quick fit connections and 'O' ring seal, stop valve for connection to water mains, isolation valve, M 2 vessel mounting bracket with wall plugs and screws. VESSELPAK A Vesselpak Vesselpak is identical to type A except that a separate safety valve is supplied to allow for flexibility in mounting. Cubexpaks are available on request using a Cubex vessel with a working pressure of up to 3 bar. VESSELPAK The pre-charge of the Flexcon expansion vessel The pre-charge is the unladen pressure at ambient temperature on the nitrogen filler valve. The pressure must match the static height, rounded up to a factor of 0.5 bar. Precharge Pre-charge 0.5 bar Pre-charge 1 bar 1.8

9 Accessories for Flexcon expansion vessels Flamco provides accessories for: Attaching expansion vessels to the wall. Facilitating inspection of pre-charge in fitted expansion vessels. Replacing the expansion vessel without having to drain the installation. To be honest, I have no idea how many Flexcon vessels I ve installed in my time, but however many it is, it s a lot. There are a few things that are particularly important to me - quality and service on the part of the manufacturer and my customer s satisfaction. Flexcon vessels give me what I need, and you can t ask better than that. Flexconsole Plus This has the same specification as the conventional Flexconsole, but is also equipped with a Flexcon pressure gauge with valve cover, a Flexvent floatvent with valve cover, a Prescor safety valve set to 3.0 bars and a Flexfast isolating union. So that the wall mounting is always suitable and just right, the Flexconsoles are equipped with a wall plate with two slots. The red colour is the same as that of the Flexcon vessels. Installations with more than one boiler Per boiler: 1 Flexcon vessel (depending on the boiler capacity). 1 Prescor safety valve or Prescomano. 1 Flamco funnel. 1 Flexcon 1 /2 connector set. 1 Flexcon pressure gauge or pressure/thermometer combination. On the suction side of the pump(s): Flamco air separation equipment. On the return accumulator: 1 or more Flexcon M vessels. 1 Flexfiller pressurisation unit. Flexfast isolating union For Flexcon vessels from 2-25 litres. The Flexfast isolating union can be directly connected to the 3 /4 water connection of the Flexcon vessel. The other side of the Flexfast isolating union is connected to the installation with a 3 /4 male thread. You can now check the pre-charge of the Flexcon vessel quickly and easy or replace it without bleeding or draining the installation. Flamco makes it easy for you with practical accessories! 1.9

10 Flamco Flexcon expansion vessels from 2-80 litres Flexcon diaphragm expansion vessels are made of top-quality steel and come with a high gloss epoxy coating. All Flexcon vessels are SI kitemarked to S 4814:1990. Max. working pressure 6.0 bar. Max. vessel temperature (diaphragm) 70 C. Max. supply temperature (boiler) 90 C. Max. working temperature (design) 120 C. Vesselpak includes a Flexcon expansion vessel, vessel manifold, Prescomano combined safety valve and pressure gauge, double check valve with test point, flexible braided hose with quick fit connections, stop valve, isolation valve, M 2 vessel mounting bracket. Vesselpak is identical to type A except that the safety valve is supplied separate to allow for remote installation. Versions and dimensions Flexcon 6 bar vessels Type Capacity Gas Dimensions in mm Connection Weight Code litres charge (male) in number bar ØA ØC D kg Flexcon /4 2.2 FCST 002 Flexcon /4 3.1 FCST 004 Flexcon /4 4.4 FCST 008 Flexcon /4 5.8 FCST 012 Flexcon /4 7.5 FCST 018 Flexcon /4 9.6 FCST 025 Flexcon / FCST 035 Flexcon / FCST 050 Flexcon FCST 080 FLEXCON FLEXCON D Versions and dimensions Vesselpak Type A 6 bar Type Capacity Gas Dimensions in mm Connection Weight Code litres charge mm in number bar ØA kg Vesselpak A FC VESSPAK 2 Vesselpak A FC VESSPAK 4 Vesselpak A FC VESSPAK 8 Vesselpak A FC VESSPAK 12 Vesselpak A FC VESSPAK 18 Vesselpak A FC VESSPAK 25 Versions and dimensions Vesselpak Type 6 bar Type Capacity Gas Dimensions in mm Connection Weight Code litres charge mm in number bar ØA kg Vesselpak FC VESS 2 Vesselpak FC VESS 4 Vesselpak FC VESS 8 Vesselpak FC VESS 12 Vesselpak FC VESS 18 Vesselpak FC VESS 25 Flexcon and Vesselpak: gas charge must be stated on order. Gas charge will determine the maximum working pressure. Other gas charges supplied to suit. VESSELPAK A VESSELPAK Ø C 1.10

11 Flamco Cubex expansion vessels from 8-80 litres Cubex diaphragm expansion vessels are made of top-quality steel and come with a high gloss epoxy coating. Max. working pressure 3.0 bar. Max. vessel temperature (diaphragm) 70 C. Max. supply temperature (boiler) 90 C. Max. working temperature (design) 120 C. Vesselpak includes a Cubex expansion vessel, vessel manifold, Prescomano combined safety valve and pressure gauge, double check valve with test point, flexible braided hose with quick fit connections, stop valve, isolation valve, M 2 vessel mounting bracket. Vesselpak is identical to type A except that the safety valve is supplied separate to allow for remote installation. Versions and dimensions Cubex 3 bar vessels Type Capacity Gas Dimensions in mm Connection Weight Code litres charge mm number bar ØA D kg Cubex /4 2.2 RV CUEX 08 Cubex /4 2.7 RV CUEX 12 Cubex /4 3.7 RV CUEX 18 Cubex /4 4.5 RV CUEX 25 Cubex /4 6.5 RV CUEX 35 Cubex / RV CUEX 50 Cubex RV CUEX 80 Versions and dimensions Cubexpak Type A 3 bar Type Capacity Gas Dimensions in mm Connection Weight Code litres charge mm number bar ØA D kg Cubexpak A RV CUPAK 08 Cubexpak A RV CUPAK 12 Cubexpak A RV CUPAK 18 Cubexpak A RV CUPAK 25 Cubexpak A RV CUPAK 35 CUEX CUEX CUEXPAK A D Versions and dimensions Cubexpak Type 3 bar Type Capacity Gas Dimensions in mm Connection Weight Code litres charge mm number bar ØA D kg Cubexpak RV CUPAK 08 Cubexpak RV CUPAK 12 Cubexpak RV CUPAK 18 Cubexpak RV CUPAK 25 Cubex and Vesselpak: gas charge must be stated on order. Gas charge will determine the maximum working pressure. Other gas charges supplied to suit. CUEXPAK 1.11

12 Flamco Flexcon expansion vessels from litres Standard Flexcon vessels for heating and cooling installations. The Flexcon vessels shown below are suitable for a maximum operating pressure of up to 6 and 10 bar. Different pre-charge pressures are available on request. Versions and dimensions of Flexcon 6 bar vessels Type Capacity Gas Dimensions in mm Connection Weight Max. Code litres charge (male) in operating number bar pressure ØA ØC D kg in bars Flexcon FCST 110 Flexcon FCST 140 Flexcon FCST 200 Flexcon FCST 300 Flexcon FCST 425 Flexcon FCST 600 Flexcon FCST 800 Flexcon FCST 1000 * Gas charge must be stated on order. Gas charge will determine the maximum working pressure. Other gas charges supplied to suit. D FLEXCON Versions and dimensions of Flexcon 10 bar vessels Type Capacity Gas Dimensions in mm Connection Weight Max. Code litres charge (male) in operating number bar pressure ØA ØC D kg in bars Flexcon FCST Flexcon FCST Flexcon FCST Flexcon FCST Flexcon FCST Flexcon FCST Flexcon FCST Flexcon FCST * Gas charge must be stated on order. Gas charge will determine the maximum working pressure. Other gas charges supplied to suit. Ø C 1.12

13 Flamco Flexcon M expansion vessels from litres Flexcon M expansion vessels with exchangeable diaphragm for heating and cooling installations. Flexcon M vessels are suitable for a maximum operating pressure of 6 and 10 bars respectively. All Flexcon M vessels have a flange construction. The flange construction enables the butyl rubber diaphragm to be exchanged if necessary. Special versions of the Flexcon M expansion vessel, e.g. horizontal, are available on request. Versions of Flexcon M 6 and 10 bar vessels Type Capacity System Weight Code Weight Code litres connection 6 bar number 10 bar number vessel in kg 6 bar in kg 10 bar Flexcon M FC M FC M 080 I Flexcon M /4 115 FC M FC M 400 I Flexcon M /4 145 FC M FC M 600 I Flexcon M /4 180 FC M FC M 800 I Flexcon M /2 215 FC M FC M 1000 I Flexcon M /2 285 FC M FC M 1200 I Flexcon M /2 340 FC M FC M 1600 I Flexcon M FC M FC M 2000 I Flexcon M /2 510 FC M FC M 2800 I Flexcon M /2 620 FC M FC M 3500 I Flexcon M / FC M FC M 5200 I Flexcon M DN FC M FC M 6700 I Flexcon M DN FC M FC M 8000 I FLEXCON M Dimensions of Flexcon M 6 and 10 bar vessels Type Dimensions in mm ØD H C Ød Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M Flexcon M vessels with operating pressures of more than 10 bars can be delivered on request. Please state the desired gas charge when ordering. H Ø d Ø D C 1.13

14 Flamco Flexcon intermediate vessels Flexcon intermediate vessels for cooling of expansion water. CE-approved. Flexcon V- vessels from litres with a maximum working pressure of 6 or 10 bars respectively. At a feed temperature of C, the capacity of the Flexcon intermediate vessel must be 15% of the net expansion volume. At a feed temperature of C, this is 25% and at a feed temperature of C, this is 40%. Versions of Flexcon V- intermediate vessels Type Capacity Weight Weight Code number Code number 6 bar 10 bar 6 bar 10 bar version version 120 ºC 160 ºC litres in kg in kg version version Flexcon V FCV 180 FCV 180 I Flexcon V FCV 400 FCV 400 I Flexcon V FCV 600 FCV 600 I Flexcon V FCV 800 FCV 800 I ds FLEXCON V- Flexcon V FCV 1000 FCV 1000 I Flexcon V FCV 1200 FCV 1200 I Flexcon V FCV 1600 FCV 1600 I Flexcon V FCV 2000 FCV 2000 I H Dimensions of Flexcon V- intermediate vessels Type Dimensions in mm Connection ØD H c ds de Flexcon V /4 ext. 1 1 /4 int. Flexcon V /4 ext. 1 1 /4 int. Flexcon V /4 ext. 1 1 /4 int. Flexcon V /4 ext. 1 1 /4 int. C Ø D de Flexcon V /2 ext. 1 1 /2 int. Flexcon V /2 ext. 1 1 /2 int. Flexcon V /2 ext. 1 1 /2 int. Flexcon V ext. 2 int. ds FLEXCON VSV Versions of Flexcon VSV intermediate vessels Type Capacity Weight Weight Code number Code number 6 bar 10 bar 6 bar 10 bar version version 120 ºC 160 ºC litres in kg in kg version version Flexcon VSV FC VSV 200 FC VSV Flexcon VSV FC VSV 350 FC VSV Flexcon VSV FC VSV 500 FC VSV Flexcon VSV FC VSV 750 FC VSV Flexcon VSV FC VSV 1000 FC VSV H Dimensions of Flexcon VSV intermediate vessels Type Dimensions in mm Connection ØD H c ds de Flexcon VSV /2 ext. 1 1 /2 int. Flexcon VSV /2 ext. 1 1 /2 int. Flexcon VSV ext. 2 int. Flexcon VSV ext. 2 int. Flexcon VSV ext. 2 int. C de Ø D 1.14

15 Flamco Flexcon vessel calculation Vessel size = Expansion vessel efficiency (VE) VE = System water content x Coefficient of expansion Expansion vessel efficiency Max. pressure - Min. pressure Max. pressure *Please note pressure must be in absolute units (gauge pressure + 1 barg). Maximum pressure = Maximum working pressure at the expansion vessel. Minimum pressure = expansion vessel gas charge (normally dependent on the system static height) barg (0.7 barg minimum). *Please note the expansion vessel efficiency must not exceed the maximum stated by Flamco UK Ltd. Sizing charts have taken this into consideration. Maximum vessel efficiency Range Size Efficiency Flexcon 2-80 litres (62.5%) PW 8-80 litres 0.5 (50%) Challenger litres 0.5 (50%) Challenger litres 0.4 (40%) Example (basic sizing) System Water content = 1000 litres. Static height = 10 metres. Temperature = 82 o C. Maximum working pressure = 3 barg. Expansion vessel sizing (Gas charge 1 barg). 4-2 VE = = 0.5 (50%) Coefficient of expansion = Expansion vessel size = 1000 x = 64 litres. (Use the nearest higher size e.g. Flexcon 80/1). Coefficient of expansion (water with no additives) Heating systems - Flexcon standard expansion vessels. Sizing to.s (heating and systems up to 5 barg) Use the following criteria for calculations: Water content = system water content + 10%. Coefficient of expansion = use system highest temperature (not mean temp). Maximum pressure = safety valve setting - 10% (e.g. for 3 barg safety valve maximum pressure = 2.7 barg). Minimum pressure = expansion vessel gas charge barg. (0.7 barg minimum). 1.15

16 FLEXCON 2-80 FLEXCON EXPANSION VESSELS FLEXCON CONTENTS PAGE Choose quality - choose a Flexcon expansion vessel 1.2/1.3 Technical innovation in expansion vessels 1.4/1.5 give you more possibilities 1.6 Flexcon intermediate vessels 1.7 Flexcon vesselpaks 1.8 Flamco Flamco UK Limited Unit 4, St. Michael s Road Lea Green Industrial Estate St. Helens, Merseyside WA9 4WZ Tel.: +44 (0) Fax.: +44 (0) info@flamco.co.uk Accessories for Flexcon vessels 1.9 Tables and technical data 1.10/1.15 FLEXCON M The CD which accompanies this brochure contains much more information besides: fitting instructions, capacity tables, practical tips and safety, a calculation programme and information on Flexcon vessels in cooling and air-conditioning installations. Copyright Flamco UK Limited. No part of this publication may be reproduced or published in any way without explicit mention of the source. The data listed are solely applicable to Flamco products. Flamco UK Limited shall accept no liability whatsoever for incorrect use, application or interpretation of the technical information. Flamco UK Limited reserves the right to make technical alterations. Flamco UK Limited conditions of sale apply. FLEXCON V