flamco Flexfiller 125D

Questions and Answers

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Beverly GreeneAug 20, 2025
What to do if LOW H20 fault is displayed on Flamco Portable Generator?
- J
  Jennifer OsborneAug 20, 2025
  If the LOW H20 fault is displayed on your Flamco Portable Generator, here are a few things you can check: * Make sure the mains water supply to the unit is turned on. * The fault will clear once the break tank has been re-filled if the mains pressure is poor. * Remove any non-standard electrical connections from terminals 19 & 20. * Consider replacing the low water float switch, or the digital controller if they have failed.
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John PorterAug 22, 2025
Why pressure reading does not match actual system pressure on Flamco Portable Generator?
- N
  Nicole VasquezAug 22, 2025
  If the pressure reading on your Flamco Portable Generator doesn't match the actual system pressure, there might be a few reasons: * Ensure the internal isolation valve within the unit is open. * Review the SENSOR TYPE setting. * Remove any non-return valve installed between the unit and the system. * The pressure sensor might have failed and needs replacement.
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Dr. Linda KentAug 25, 2025
What causes HIGH PRESSURE fault on flamco Flexfiller 125D?
- M
  mortizAug 25, 2025
  If your Flamco Portable Generator displays a HIGH PRESSURE fault, it could be due to a few reasons: * Check the expansion vessel pre-charge and re-charge if necessary. * Review the expansion vessel selection, as it might be undersized. * Review the system specifications, as the HIGH PRESSURE set point might be too low.
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Eric Hardy Jr.Aug 26, 2025
How to fix pump that runs but does not make up pressure in flamco Flexfiller 125D Portable Generator?
- B
  Beth CoffeyAug 26, 2025
  If your Flamco Portable Generator's pump runs but doesn't build up pressure, it might be air-locked. Try bleeding the pump to resolve this.
S
Samantha GonzalezAug 27, 2025
What to do if system pressure has risen above the HIGH PRESSURE set point in Flamco Portable Generator?
- M
  Maria StevensAug 28, 2025
  If the system pressure of your Flamco Portable Generator has risen above the HIGH PRESSURE set point, decrease the system pressure using a suitable drain point.
P
Paul LewisAug 29, 2025
What causes HIGH H20 fault on flamco Flexfiller 125D Portable Generator?
- E
  Eric WardAug 29, 2025
  If your Flamco Portable Generator displays a HIGH H20 fault, it could be due to: * A non-standard electrical connection into terminals 21 & 22. Remove any such connections. * A failure of the digital controller, which would require replacement.
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William StevensAug 31, 2025
What to do if ERROR 1 fault is displayed on Flamco Portable Generator?
- A
  austin76Aug 31, 2025
  If you see 'ERROR 1 fault' displayed on your Flamco Portable Generator, check the SENSOR TYPE option and review its setting. Also, the pressure sensor might have failed and require replacement.
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Melissa PattonSep 2, 2025
Why is the pump persistently becoming air-locked in flamco Flexfiller 125D?
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  jjenkinsSep 2, 2025
  If your Flamco Portable Generator's pump is persistently becoming air-locked, check the float valve flow restrictor selection, especially if you have mini and midi units.
A
Ashley BrownSep 4, 2025
Why is the break tank overfilling in flamco Flexfiller 125D Portable Generator?
- M
  Mike FergusonSep 4, 2025
  If the break tank in your Flamco Portable Generator is overfilling and discharging water, consider the following: * Check the float valve flow restrictor selection (mini and midi units only). * Set the float valve to its lowest possible position. * The float valve might have failed and needs replacement. * A pump non-return valve might have failed and needs replacement.
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jessicatuckerSep 6, 2025
Why is the pump repeatedly running in short bursts in flamco Flexfiller 125D?
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  Jason MunozSep 6, 2025
  If your Flamco Portable Generator's pump is repeatedly running in short bursts, it could be due to: * The internal isolation valve within the unit being partially closed. Fully open it. * Too much restriction in the connecting pipe work. Increase bore, reduce bends, or reduce length. * A pump non-return valve has failed, replace it. * The expansion vessel has failed or lost its pre-charge, check and re-charge if necessary. * The unit's connection point is too far from the expansion vessel. Move them closer.

Summary

About this Manual

Conventions used in this Manual

Explains symbols and terminology used within the manual for clarity and safety.

Typography

Details the use of different text styles like italics and brackets to convey specific information types.

Where to find more Information

Provides contact details and website for additional product information and support.

Equipment Overview

Principal of Operation

Describes the fundamental working mechanism of the Flexfiller pressurisation unit and its components.

Installation

Pipe Connections

Details the requirements and considerations for making pipe connections to the pressurisation unit.

Typical Installation Diagram

Illustrates the recommended physical layout and connection points for installing the unit.

Flow Restrictors (Mini & Midi Models Only)

Guides on selecting and fitting the correct flow restrictor based on mains water pressure.

Flexfiller Clearance and Connection Requirements

Specifies minimum clearances and connection details for the Flexfiller model.

Midi Clearance and Connection Requirements

Specifies minimum clearances and connection details for the Midi model.

Mini Clearance and Connection Requirements

Specifies minimum clearances and connection details for the Mini model.

Electrical Power Supply

Outlines the correct and safe methods for connecting the unit to the electrical mains supply.

Fault Contacts

Details the available volt-free fault contacts for BMS integration or boiler interlock.

Commissioning

Pre-Commissioning Checklist

Lists essential checks to be completed before starting the commissioning process to ensure safety and functionality.

Controller Overview

Introduces the digital controller, its buttons, and the LED display functions.

Controller Programming

Explains how to access and navigate the controller's programming menu to adjust settings.

Program List

Provides a detailed breakdown of all programmable menu items, their functions, and default values.

Hydraulic Commissioning

Outlines the step-by-step procedure for the hydraulic setup and initial filling of the unit.

Operation

Fault Codes

Lists and explains all error codes displayed by the digital controller and their reset methods.

Shutdown procedure

Provides instructions on how to safely shut down the pressurisation unit for maintenance or other scenarios.

Start-up Procedure

Details the steps required to restart the unit after it has been shut down.

Maintenance

Visual Inspection

Describes essential visual checks to identify potential faults and ensure unit integrity.

Interrogate Controller

Explains how to access and interpret logged data from the digital controller for diagnostics.

Test Unit Operation

Details methods to test the unit's functionality by simulating pressure drops and pump activation.

Check Float Valve Operation

Guides on testing the break tank float valve's functionality and response to water level changes.

Check Float Switch Operation

Explains how to test the low-level float switch and its effect on the controller display.

Check Break Tank Water Condition

Advises on inspecting the break tank for cleanliness and the presence of debris.

Check Strainer (Flexfiller units only)

Outlines the procedure for inspecting and cleaning the mesh strainer specific to Flexfiller models.

Check Expansion Vessel Pre-Charge

Details the importance and method for checking the expansion vessel's pre-charge pressure.

Wiring Diagram

Provides a detailed electrical schematic showing the internal wiring connections of the pressurisation unit.

Wiring location list

Lists the colour coding and terminal connections for various components within the electrical box.

Spares

Flexfiller Models (125 D, 250 D, 150 D, 280 D)

Lists the part codes for components specific to Flexfiller models.

Midi Models (125 D, 250 D, 150 D, 250 D)

Lists the part codes for components specific to Midi models.

Mini Models (130 D, 230 D)

Lists the part codes for components specific to Mini models.

Troubleshooting

LOW PRESSURE fault is displayed and the pumps do not run

Addresses issues where the unit displays a low pressure fault and the pumps fail to activate.

P1 and;or P2 FAIL is displayed

Provides solutions for pump failure faults (P1 FAIL or P2 FAIL) indicated by the controller.

The break tank is overfilling and discharging water to drain or over the weir

Offers remedies for scenarios where the break tank is losing water through overflow.

Service Logs

Warranty Information

Warranty - What Is Covered?

Specifies the scope of the manufacturer's warranty for the equipment.

Warranty - What Is Not Covered?

Outlines conditions and scenarios that are excluded from the warranty coverage.

Conditions of warranty

Lists the prerequisites and requirements that must be met for the warranty to remain valid.

Contact Details

Provides Flamco's contact information for inquiries, support, and warranty claims.