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Variomat with Touch controller

1. If required install a diaphragm expansion tank MAG gt 35 litres Reflex N for example It reduces the switching frequency and can be also used in the individual protection of the heat generators According to DIN EN 12828 the installation of valves between the device and the heat generator is required for heating systems Otherwise protected shut off devices must be installed gt Notice Due to the optimal degassing capacity of the device we recommend the installation of a diaphragm expansion tank MAG gt 35 litre Reflex N for example 24 English Variomat with Touch controller 25 06 2014 EC expansion lines Because of the degassing function you must install two EC expansion lines One line from the system for the gas rich water One line to the system for the degassed water The DN nominal connection diameter for the EC expansion lines must be designed for the Po minimum operating pressure DNe 32 DNe 40 DNe 50 Variomat 2 1 X Variomat 2 2 35 X Variomat 2 2 X Po lt 3 5 bar Variomat 2 2 X Po gt 3 5 bar Calculation Po see chapter 7 2 Determining the Po minimum operating pressure for the controller on page 38 The DN nominal connection diameter applies to an expansion line length of up to 10 metres Beyond this length select the next larger dimension Integrate with the V main flow volume of the system View
2. 4 Set the system specific values for the individual areas Settings gt Customer Use the Left and Right buttons to select the display 002 Time value Use the Up and Down buttons to change the display value Confirm your entries with OK Press i to display a help text for the selected area lt ZX Press X to cancel your input without saving the new settings The controller automatically opens again the list 29ba 0 3 9 4 2 Service menu This menu is protected with a password It can be accessed only by the Reflex Customer Service A partial summary of the settings stored in the Service menu is proved in the Chapter Default settings see chapter 9 4 3 Default settings on page 54 Variomat with Touch controller 25 06 2014 English 53 9 4 3 Default settings The device controller is shipped with the following default settings Use the Customer menu to adjust these values to local conditions In specific cases it is possible to further adjust the values in the Service menu Customer menu Parameter Setting Remarks Language EN Display language Minimum operating pressure Po 1 8 bar see chapter 7 2 Determining the Po minimum operating pressure for the controller on page 38 Next maintenance 12 months Time left to the next due maintenance Floating alarm contact All see chapter 9 5 Messages on page 59 Make up Make up
3. 19 Stop gt 4h Device isin Stop mode e If appropriate set to for more than 4 hours Automatic mode 20 Max Make up volume Set value exceeded e Reset the Make up quantity OK meter in the Customer menu 21 Maintenance Set value exceeded Carry out maintenance OK recommended 24 Softening Water capacity setting Replace softening cartridges OK value or Time interval for replacement exceeded 30 1 0 module fault 1 0 module defective Contact the Reflex Customer Connection between Service option card and controller faulty Option card defective 31 EEPROM defective EEPROM defective Contact the Reflex Customer OK Internal calculation Service error 32 Undervoltage Supply voltage Check power supply exceeded 33 Adjustment parameter EPROM parameter Contact the Reflex Customer faulty memory defective Service 34 Main board Connecting cable Contact the Reflex Customer communication faulty defective Service Main board defective 35 Digital input voltage Short circuit ofinput Check the wiring at the digital faulty voltage inputs water meter for example 36 Analogue input voltage Short circuit ofinput Check the wiring at the faulty voltage analogue inputs pressure level 37 Ball valve input voltage Short circuitofinput Check wiring of the ball valve missing voltage Notice Messages identified with OK must be confirmed with the OK button on the display The device
4. Confirm acknowledge input e For continuous operation Scroll in the menu 5 Up and Down scroll bar 12 Set up menu button Scroll in the menu For the setting of parameters e Fault memory e Parameter memory e Display settings e Primary tank information Software version information 6 Scroll back button 13 Info menu button Cancel Displays general information e Move backward up to the main menu 7 Display help texts button e Opens help texts Variomat with Touch controller 25 06 2014 English 45 9 2 Calibrating the touch screen You can calibrate the touch screen when touching the desired buttons does not work satisfactorily 1 2 3 Switch the device off at the main switch Touch and hold with your finger the touch field Switch on the main switch while touching the touch field When starting the program the controller automatically switches to the Update Diagnostics function Touch the Touch calibration button Touch the displayed crosses on the touch screen after each other Switch the device off and on again at the main switch The touch screen is fully calibrated R S I Update Diagnostics Update Application SD card slow Update Application SD card fast Touch calibration e Start application Diagnostics R S I 09 04 14 11 53 38 ha ee Please touch the red cross 46 English Variomat
5. esse III lernen 10 4 3 1 N nieplate 5u 42a nes nn nn 10 4 3 2 Iype code u res E A EONS 10 4 4 FUNCtiOn aenn A A een een 11 4 5 Scope of deliveryiz n naseneierisieesnEiR kn B onen eeeehiifiehhedsnbnheieen 13 4 6 Optional equipment and accessories sscsscssecssesssssccsscsssccssscssssscesscssscsscssscsssccsscsusssucessceuscsscssscesscessesuscsucesscessesscessceseeeasecesensees 13 5 Technicaldata nn nenne 14 6 Installation ee 17 6 1 Installation condition S sc sisssecccsscsvsscsevcatscsscetesciscsseccosso necquvsandertenbeccidsnsuccossvbausghu cendsanenbecotassuuconssvbaseghecsbasabenbessidsanvconscvaasssbecnsazabentveen 18 6 1 1 INCOMING inspections iE E RAR a 18 6 2 Preparatory work 6 3 EXECUTION i R O E E ER E EEE E EA EA E AE EEE E 6 3 1 P siti ning seccsssscvcccsscsvssceavcscacssescccssacsueconssetusssnucexasatensucctaceuconsebnuscnyevedsatesceasiasabeconscebnddcuuevedsatehcecciasaavecesevanscsigesteiitendcsons 19 6 3 2 Installation of add on components for the tanks ccssssssssecssessseessssessesssssessusssssessscsssscssnscssesseseessaecsseessucssssesssseeses 20 6 3 3 Tank installation cecccscccccsssssseccnsssusssctvccctsssuevcasssssnvccesssandcabecscdsavsovcocsbscesccescandatecodsabaekcecabvcnssesascandsatavecdsaventsscavobsscenvvandens 21 6 3 4 Hydraulic connection uun easnsesessnsenssenesstuessmnsseaetenneenntennerinesesnneenneseohtennesreneenersnaeseneenneseshtennesrheeehstenegerheeheeer 23 6 3 5 Fitting the
6. Start routine Step 7 5 121 Tank size l Weight 149kg Volume 8001 Diam 740 mm 800 29ba 0 48 English Variomat with Touch controller 25 06 2014 The controller checks whether the level measuring signal matches the dimensional data of the primary tank The primary tank must be fully emptied see see chapter 6 3 6 Fitting the level sensor on page 27 7 Press OK Null balancing is executed If null balancing is not successfully completed you cannot commission the device In this event please contact Customer Service see chapter 12 1 Reflex Customer Service on page 71 Notice After successful conclusion of the start routine you are in Stop mode Do not yet switch to Automatic mode Null balancing The tank must be completely emptied for null balancing Execute null balancing now 29bar 0 Variomat with Touch controller 25 06 2014 English 49 9 4 Configuring settings in the controller You can configure the controller settings regardless of the currently selected and active operating mode 9 4 1 Customer menu 9 4 1 1 Customer menu overview Use the Customer menu to correct or determine system specific values In the course of commissioning the factory settings must be adjusted for the system specific conditions Notice Operation description see chapter 9 1 Operator panel on page 45 A three digit PM code is a
7. 06 2014 English 57 9 4 5 Degassing programmes overview No degassing This programme is useful when degassing is either impermissible or inadvisable This is the case when the temperatures of the media to be degassed exceed the permissible Variomat temperature of 70 C or the Variomat is combined with a Servitec vacuum degassing system Continuous degassing This programme is recommended after commissioning and repairs of the connected system The device will continuously degas for a set period of time Air bubbles within the system are quickly removed Start setting Automatic start after execution of the start routine during commissioning Activated from the Customer menu e Degassing time Can be set in the Customer menu dependent on the actual system Standard 12 h followed by automatic switch to Interval degassing mode Interval degassing The interval degassing is stored for continuous operation as default setting in the Customer menu Degassing is continuous during an interval An idling time follows an interval You have the option to limit the interval degassing to a specified time window You can set the times only in the Service menu Start setting e Automatic activation upon expiry of continuous degassing Degassing interval Standard 90 s Idling time Standard 120 min Start End 8 00 18 00 hours Run on degassing This degassing programme is harmoniously linked to the way the p
8. 1 Factory provided 31 M2 Flat plug for supply pump 2 Factory provided 45 E2 E2 Insufficient water switch 51 GND 52 24 V supply 53 0 10V correcting PV 2 overflow valve motor ball valve only in VS 2 2 Factory provided variable 54 0 10 V feedback 55 GND 56 24 V supply 57 0 10 V correcting PV 1 overflow valve motor ball valve Factory provided variable 58 0 10 V feedback Variomat with Touch controller 25 06 2014 English 33 6 5 2 Terminal plan operating unit 8 7 Fil K 9 e Ts T A fofefe fotol fofofefe fofefofel sees 12345 6 7 8910 A 151617 2 6 1 RS 485 interfaces 6 Analogue outputs for Pressure and Level 2 1 0 interface 7 Battery compartment 3 1 0 interface reserve 8 Supply voltage bus modules 4 SD card 9 RS 485 connection 5 10 V supply 10 RS 485 connection Terminei Signal Function Wirin number g g 1 A 5 B RS 485 interface On site S1 networking 3 GND S1 4 A 5 B RS 485 interface On site S2 modules Expansion or communication module 6 GND 52 18 Y2PE shield 19 Pressure ror see iiia nalogue outputs Pressure and Leve i 20 CNDA Standard 4 20 mA Onesie 21 Level 22 GNDA 7 5V 8 RxD 1 0 interface Interface to the main circuit board Factory 9 TxD 10 GND 101 11 5V 12 RxD 1 0 interface I
9. 7 6 Parametrising the controller in the Customer menu Use the Customer menu to display or correct system specific values In the course of commissioning the factory settings must be adjusted for the system specific conditions 77 For adjusting the default settings see chapter 9 4 Configuring settings in the controller on page 50 For information about controller operation see chapter 9 1 Operator panel on page 45 Starting Automatic mode Automatic operation is executed as conclusion of the initial commissioning The following prerequisites must be met for automatic operation The device is filled with compressed air and water All required settings are defined in the controller Start the automatic mode at the operator panel of the controller 1 Press AUTO Variomat VS 2 1 The PU pump and the PV overflow valve are NW regulated so that the pressure remains constant at a regulation of 0 2 bar Faults are displayed and evaluated 2 8 bar se NSP K LIS X System Continuous A l Notice The commissioning process is now concluded Notice The ST dirt trap in the DC degassing line must be cleaned after the expiry of the continuous degassing time at the latest see chapter 10 2 1 Cleaning the dirt trap on page 64 Variomat with Touch controller 25 06 2014 English 41 8 Operation 8 1 Operating modes 8 1 1 Autom
10. 8601005 8601205 8601305 8601405 Secondary tank Article No 8610705 8610905 8611005 8611205 8611305 8611405 A be 7986800 7987000 7987100 7993200 7993300 7993400 Diameter D 1000 mm 1200 mm 1200 mm 1500 mm 1500 mm 1500 mm Height H 2130mm 2130mm 2590mm 2590mm 3160mm 3695 mm Height h 350 mm 350 mm 350 mm 380 mm 380 mm 380 mm Weight 320 kg 465 kg 565 kg 795 kg 1080 kg 1115 kg Connection in inches G1 G1 G1 G1 G1 G1 16 English Variomat with Touch controller 25 06 2014 Installation Installation Danger Electric shock A A aeaa A A e Serious injury or death due to electric shock Any system in which the device is to be installed must be de energised Ensure that the system is locked and cannot be switched on by other personnel Installation work for the electric connection of the device must be carried out by an authorised electrician in compliance with electrical engineering regulations Caution risk of injury Incorrect installation or service work may cause burns and other injuries at the connections when hot water or steam suddenly escape at pressure Ensure proper installation Ensure that the system is de pressurised before performing service work at the connections Caution risk of burning e Excessive surface temperatures in heating systems can cause skin to burn Wait until surfaces have cooled down or wear protective gloves The operator is requir
11. Degassing line Forgas rich water from the system e For degassed water into the system 5 Reflex Fillset see chapter 4 6 Optional equipment and LIS Level sensor accessories on page 13 ST Dirt trap Single tank system lt 350 kW water temperature lt 100 C Use the Reflex Fillset with integrated system separator when using drinking water for make up Ifyou don t use a Reflex Fillset you must use an ST dirt trap with a mesh size gt 0 25 mm for the make up Notice The quality of the make up water must comply with the applicable standards such as VDI 2035 Ifyou cannot meet this quality use the Reflex Fillsoft to soften the make up water from the potable water network see chapter 4 6 Optional equipment and accessories on page 13 28 English Variomat with Touch controller 25 06 2014 6 4 1 2 Using a district heating substation Y E E E E E E E E E E E E E Ia E E E E E E E i i E E E E E E E E E E E E E E E E E E E E E E E E Y 1 District heating substation PIS Pressure transducer 2 Primary tank WV Make up solenoid valve 3 MAG pressure expansion tank ST Dirt trap 4 User supplied make up unit EC Degassing line e For gas rich water from the system e For degassed water into the system 5 Control unit LIS Level sens
12. ON 20 Make up OFF 25 Maximum make up quantity 0 Litres Only when With water meter Yes has been selected in the Customer menu under Make up Maximum make up time 20 minutes Maximum make up cycles 3 cycles within 2 hours Degassing Degassing programme Continuous degassing Continuous degassing time 12 hours Default setting Softening Only if With softening Yes Lock make up No In the case of soft water residual capacity 0 Hardness reduction 8 dH Target Actual Maximum make up quantity 0 Litres Soft water capacity 0 Litres Cartridge replacement 18 months Replace cartridge 54 English Variomat with Touch controller 25 06 2014 Service menu Parameter Setting Remarks Maintain pressure Pump ON Po 0 3 bar Differential pressured added to the Po minimum operating pressure Pump OFF Po 0 5 bar Differential pressured added to the Po minimum operating pressure Forced pump start 24h If the pump is standing still for 24 hours it is forced to run for 3 seconds Pump run time exceeded message 30 minutes The message is displayed after the pump runs for 30 minutes Overflow line CLOSED Po 0 5 bar Differential pressured added to the Po minimum operating pressure Overflow line OPEN Po 0 7 bar Differential pressured added to the Po minimum operating pressure Maxim
13. close the insulation with the zip fastener gt Notice For heating systems insulate the primary tank and the EC expansion lines against heat loss The cover of the primary tank does not require insulation as there is space between the diaphragm and the tank wall The secondary tanks do not require insulation either gt Notice Condensate formation requires insulation by the user 26 English Variomat with Touch controller 25 06 2014 6 3 6 Fitting the level sensor Attention Equipment damage Incorrect installation may result in damages to the LIS level sensor malfunctioning and incorrect measurements from the pressure pick up Comply with the instructions regarding the installation of the pressure pick up The LIS level sensor uses a pressure pick up This pressure pick up is to be installed after the primary tank has been placed at its final position see chapter 6 3 3 Tank installation on page 21 Comply with the following instructions Remove the transport securing device squared timber at the vessel base of the primary tank Replace this transport securing device with the pressure pick up Inthe case of a tank volume of 1000 I 1000 mm or more use the supplied screws to attach the pressure pick up at the vessel base of the primary tank The vessel base must not be subject to stress after the pressure pick up has been installed Avoid shock stresses by a subseq
14. drain cock with flexible connection set Accessories Article 3 Para 1 4 Control unit with safety valve 72 English Variomat with Touch controller 25 06 2014 Fluid group 2 Conformity assessment to module B D Labelling according to Directive 97 23 EC CE 0045 Safety valve air side Category IV See operating manual item SV Labelled and certified by the safety valve manufacturer pursuant to the provisions of the Directive 97 23 EC Certificate number of the EC Type Examination For a vessel size of 200 to 1000 litres 04 202 1 932 01 00051 For a vessel size of 1000 to 5000 litres 04 202 1 450 02 00712 Certificate No QA system Module D 07 202 1403 Z 0250 12 D0045 Notified body for the assessment of the QA system TUV Nord Systems GmbH amp Co KG Gro e Bahnstra e 31 D 22525 Hamburg Register No of the notified body 0045 Manufacturer Reflex Winkelmann GmbH Gersteinstra e 19 D 59227 Ahlen Germany Telephone 49 0 2382 7069 0 Fax 49 0 2382 7069 588 E mail info reflex de The manufacturer declares that the pressure equipment the assembly complies with the requirements of Directive 97 23 EC Norbert H lsmann Volker Mauel Members of the Board of Directors Variomat with Touch controller 25 06 2014 English 73 12 3 Certificate No ofthe design type examination Ty
15. equipment the Council of 29 May 1997 Applied assessment of conformity procedure according to the Pressure Equipment Directive 97 23 EU of the European Parliament and Pressure expansion tanks and pressure maintaining systems Device for universal application in heating solar and cooling water systems Type according to vessel assembly nameplate Serial number according to vessel assembly nameplate Year of manufacturing according to vessel assembly nameplate Maximum allowable pressure according to vessel assembly nameplate Test pressure according to vessel nameplate Minimum maximum permissible temperature according to vessel assembly nameplate Maximum continuous operation temperature for full and semi diaphragm according to vessel assembly nameplate Charging material Water inert gas or air according to vessel nameplate Standards and set of rules Pressure Equipment Directive prEN 13831 2000 or European Standard 13831 2007 or AD 2000 according to vessel nameplate Pressure equipment Vessel Article 3 Para 1 1 a 2 Annex Il Diagram 2 with Accessories Article 3 Para 1 4 Full diaphragm vent pipe equalising elbow and drain cock with flexible connection set Assembly Article 3 Para 2 2 comprising Vessel Article 3 Para 1 1 a 2 Annex Il Diagram 2 with Accessories Article 3 Para 1 4 Full diaphragm vent pipe equalising elbow and
16. height 18 m run on temperature 70 C safety temperature 100 C Calculation example Po Pst po 0 2 bar Pst hg 10 Pst 18 m 10 Ps 1 8 bar Pp 0 0 bar at a safety temperature of 100 C Po 1 8 bar 0 bar 0 2 bar Po 2 0 bar Notice Avoid dropping below the Po minimum operating pressure Vacuum vaporisation and cavitation are thus excluded 38 English Variomat with Touch controller 25 06 2014 Commissioning 73 Modifying the controller s start routine During commissioning you must once execute the start routine For executing the start routine see chapter 9 3 Modifying the controller s start routine on page 47 For information about controller operation see chapter 9 1 Operator panel on page 45 74 Filling the tanks with water The following information applies to the devices Control unit and primary tank Control unit and primary tank and one secondary tank e Control unit and primary tank and more than one secondary tanks Facility system System temperature Filling level of primary tank Heating system 50 C Approx 30 Cooling system lt 50 C Approx 50 7 4 1 Filling with a hose Preferably use a water hose to fill the primary tank with water when the automatic make up device is not yet connected e Usea vented water hose filled with water Connect the water hose to the external water supply and the FD feed and drain cock 1 at t
17. in the chapter Standard settings see chapter 9 4 3 Default settings on page 54 Variomat with Touch controller 25 06 2014 English 67 10 4 Maintenance certificate All maintenance tasks have been completed according to the Reflex Installation Operating and Maintenance Manual Date Service organisation Signature Remarks 68 English Variomat with Touch controller 25 06 2014 10 5 Inspection 10 5 1 Pressure bearing components Comply with all applicable national regulations for the operation of pressure equipment De pressurise all pressurised components prior to inspection see disassembly information 10 5 2 Inspection prior to commissioning In Germany follow the Industrial Safety Regulation Betriebssicherheitsverordnung Section 14 and Section 14 3 No 6 in particular 10 5 3 Inspection intervals Recommended maximum inspection intervals for operation in Germany pursuant to Section 15 of the Industrial Safety Regulation Betriebssicherheitsverordnung and the vessel classification of the device in diagram 2 of the EU Directive 97 23 EC applicable in strict compliance with the Reflex Installation Operation and Maintenance Manual External inspection No requirement according to Section 15 6 Internal inspection Maximum interval according to Section 15 5 if necessary suitable replacement actions are
18. menu to shut down interval degassing to save energy After Summer select the Interval degassing degassing programme in the Customer menu or Continuous degassing if required For a detailed description of the selection of degassing programmes see chapter 9 4 4 Setting degassing programmes on page 56 gt Notice The pressure maintaining feature of the device must remain operative in Summer Restarting 8 2 N Caution Risk of injury due to pump start e Injuries to your hand and damage to property at the pump due to a pump start De energise the pump prior to turning the pump at the fan wheel with a screwdriver After an extended standstill time the device is de energised or in Stop mode the PU pump may jam For this reason use a screwdriver to rotate the pump at the fan wheel of the pump motor before restarting Notice A jamming of the PU pump is prevented during operation thanks to forced starting action after 24 hours 44 English Variomat with Touch controller 25 06 2014 9 Controller 9 1 Operator panel 8 7 6 J i og 02 10 M N 5 AUTO A 11 m lt 42 BB X OK el Lt 1 2 3 4 1 Message line 8 Display value 2 Up and Down buttons 9 Manual mode button Set digits e For function tests 3 Right and Left buttons 10 Stop mode button Select digits e For commissioning 4 OK button 11 Automatic mode button
19. operating manual Danger to life and or severe damage to health The corresponding warning symbol in combination with the Danger signal term indicates an imminent threatening danger which will result in death or severe irreversible injuries Severe damage to health The corresponding warning symbol in combination with the Warning signal term indicates a threatening danger which may result in death or severe irreversible injuries Damage to health The corresponding warning symbol in combination with the Caution signal term indicates a danger which may result in minor reversible injuries Attention e Damage to property This symbol in combination with the Attention signal word indicates a situation that may cause damage to the product itself or objects in its vicinity p Notice This symbol in combination with the Notice signal word indicates useful tips and recommendations regarding the efficient use of the product 3 1 2 Safety symbols used The following safety symbols are used in this operating manual They are also attached to the equipment or in its vicinity This symbol warns of electric voltage f This symbol warns of a hot surface This symbol warns of overpressure in conduits and connections 6 English Variomat with Touch controller 25 06 2014 3 2 Personnel requirements Only specialist personnel or specifically trained personnel may install and operate the equip
20. operation is otherwise interrupted The readiness for operation is maintained for all other messages They are displayed Notice If necessary you can set the output of messages via a floating contact in the Customer menu Variomat with Touch controller 25 06 2014 English 61 Maintenance 10 Maintenance Caution risk of burning Risk of burning from escaping medium Maintain sufficient distance from the escaping medium Wear suitable personal protective equipment safety gloves and goggles for example A Danger Electric shock e Serious injury or death due to electric shock Any system in which the device is to be installed must be de energised Ensure that the system is locked and cannot be switched on by other personnel Installation work for the electric connection of the device must be carried out by an authorised electrician in compliance with electrical engineering regulations The device is to be maintained annually The maintenance intervals depend on the operating conditions and the degassing times The annual maintenance is displayed upon expiry of the set operating time Use OK to acknowledge the Maintenance recommended message Reset the maintenance counter in the Customer menu P Notice Maintenance work must be carried out and confirmed by specialist personnel or the Reflex Customer Service see chapter 10 4 Maintenance certificate on page 68 62 Engli
21. thermal insulation sessssscssescsescsseccsscecssccsucecssecsseccssecsssecssecsscesusccssecsusecssecsusecsssecsseceuscessessueeesneesnseesee 26 6 3 6 Fitting the level sensor acssssssccsssssecsovecrnccetnesenceansveconsecnessstsceucennesensganebcconbecnessetssendconnevenngonedccosssnaesctisesndestaevedusonetceeys 27 6 4 Switching and Make Up Variants seecseccssecsssccsscccssccsseecsseccuscessecsusccensecsscessscssusccssecsssccsscessscesusecssccsuseesscecuecsucersseesuecsuecsnseesee 28 6 4 1 Function kein ER IRR Schienen 28 6 5 Electrical CONNEC ON esisiini iiien n i E Eik E E E a E ANS 31 6 5 1 Terminal plan connection COMPONENK c ssssssscssssssssccsssssessscsssccssccsssssccssecssssssssscsssccssecussssccsscsusesscesscsseecssecesesscessess 32 6 5 2 Terminal plan operating unit ussesessessennssennseunssennseunssennssunnseunssnnnssennennnnsnnsennnssennseunssnnnssennsnnnnsonssnnnssnnnsnennee 34 6 5 3 RS 485 interface 22ER Raise 35 6 6 Installation and commissioning Certificate esssssesccsssccssecssssecessscccssseecsuecesssecesssecesssecesssecesssecssuscessuscsesueecesuceesseeccnsecesneeessee 36 7 COMMISSIONING sscniscnissussnccsussscvnsesssceessnscodscasessosnssouseeseoascoesstscouuceveoussusobastaseonsosastiscousdedenbedhsosdsensncasenasennesdddenedesconssuseasncabesassonessasn 7 1 Checking the requirements for commissioning 72 Determining the Po minimum operating pressure for the controller escs
22. to be taken such as wall thickness measurement and comparison with the design specification which may be requested from the manufacturer Tightness test Maximum interval according to Section 15 5 possibly in conjunction with Section 15 10 Furthermore compliance with Section 15 of the Industrial Safety Regulation and Section 15 1 in particular in conjunction with Section 14 3 No 6 and Section 15 6 must be ensured The actual intervals must be determined by the user on the basis of a safety technical assessment taking into account the real operational conditions the experience with the operation and the charging material and the national regulations for the operation of pressure equipment Variomat with Touch controller 25 06 2014 English 69 Disassembly 11 Disassembly A Danger Electric shock e Serious injury or death due to electric shock Any system in which the device is to be installed must be de energised Ensure that the system is locked and cannot be switched on by other personnel Installation work for the electric connection of the device must be carried out by an authorised electrician in compliance with electrical engineering regulations Danger Electric shock Serious injury or death due to electric shock Some parts of the main board may still carry 230V voltage even with the device physically isolated from the 230 V power supply Before you remove the covers complet
23. with Touch controller 25 06 2014 9 3 Modifying the controller s start routine The start routine is used to set the required parameters for the device commissioning It commences with the first activation of the controller and can be run only once Parameters can be changed or checked in the customer menu after the start routine has terminated see chapter 9 4 1 Customer menu on page 50 A three digit PM code is assigned to the setting options Step PM code Description 1 Start of the start routine 2 001 Select the language 3 Remember Prior to installation and commissioning read the operating manual 4 005 Set the Po minimum operating pressure see chapter 7 2 Determining the Po minimum operating pressure for the controller on page 38 5 002 Set the time 6 003 Set the date 7 121 Select the primary tank nominal volume 8 Null balancing The primary tank must be empty The system checks whether the signal from the level sensor matches the selected primary tank End of the start routine The stop mode is active The system automatically displays the first page of the start routine when you switch on the device for the first time 1 2 Press OK The start routine moves to the next page Start routine Step 1 Start routine for system commissioning System type Variomat VS 2 1 CF TOK 2 7 bar 25 Continuous Select the requ
24. 1 3 Stop Oe sccasvcsasssvevszsonscaxc stecvuceassavessedseuseenteescssseonsedscaeevensatvevsd ondcosdessodvuccassrucssadeesotesdensessdhinueductncsasiavcbedeesterssersveisesass 44 8 1 4 Summer operati n aiuieihehelaiisRlabisin lee ida ORE E 44 8 2 ASIENS EAEAP SE VIERIE EEE RE OSEE TSS A AEE AEE EIRE 44 9 Eontr lleri u nee 45 9 1 Operator paneles sosisini oiio sentian eaa as eanas asoa esiayongesesyoneconnnesogaassiagonanssscauatuonedisnnagasssines sageasvagsscnnescasinaabeadss 45 9 2 Calibrating the touch screen ns cacbacusatacadeencaccccoavsccactuvacacaeasesclcchcaveetuslavienssecsdcaeess 46 9 3 Modifying the controller s start routine escsssescsssssccsssecesseecessseccsuscccsuscessscccsnsceesuscessuccesssecesusccesucessuccesusceesuseeesuseeesecessueeessaseets 47 9 4 Configuring settings in the Controller ssessssssccssscsssecccssccccssccccssscesuscecssscccsusccesuscessuccessuecessscessusecesusceesucceesuceecssceesuseeeeneeeesneeees 50 9 4 1 CUSTOMEF MAN Eaa ar a a a aaa a ET a Eaa a A AT EEE TEESE AERES Ea 50 9 4 2 AALE EI EAA SE EAA AE EEE EEA AA 53 9 4 3 Default Settihgs senya aa ai ER EE E lates BILD 54 9 4 4 Setting degassing ProgramMmMes ss icccccc cssisscesssssisssescossosnscscsedeatasinacassietdescsbsvsnsestuedocaatsnavasasstdescebssdovsesaniocasianiasaate aecebe 56 9 4 5 Degassing programmes OVErVICW scssssccsssccssecstscsseecsssccsscessccesscesseesnsccssscessecsssecssccenseceseesssecssscessecesscesseeensees
25. 4 IP 54 Voltage 230V 230V 230V 230V Control unit height 920 mm 920 mm 920 mm 920 mm Control unit width 700 mm 700 mm 720mm 720mm Control unit depth 780 mm 780 mm 800 mm 800 mm Weight 54 kg 58 kg 72 kg 76 kg Primary tank connection 2xG1 2xG1 2xG1 2xG1 Permissible gauge working According to According to According to According to pressure nameplate nameplate nameplate nameplate Test pressure pr EN 13831 1 43 pmax 1 43 pmax 1 43 pmax 1 43 pmax Permissible flow temperature 120 C 120 C 120 C 120 C ere 70 C 70 C 70 C 70 C Permissible ambient temperature 0 C 45 C 0 C 45 C 0 C 45 C 0 C 45 C Variomat with Touch controller 25 06 2014 English 15 Tanks a Primary tank Secondary tank Type 200 300 400 500 600 800 1000 Primary tank Article No 8600011 8600111 8600211 8600311 8600411 8600511 8600611 Secondary tank Article No 8610000 8610100 8610200 8610300 8610400 8610500 8610600 hace cae 7985700 7986000 7995600 7983900 7995700 7993800 7993900 Diameter D 634 mm 634 mm 740 mm 740 mm 740 mm 740 mm 740 mm Height H 1060 mm 1360 mm 1345 mm 1560 mm 1810 mm 2275mm 2685mm Height h 146 mm 146 mm 133 mm 133 mm 133 mm 133 mm 133 mm Weight 37 kg 54kg 65 kg 78 kg 94 kg 149 kg 156 kg Connection in inches G1 G1 G1 G1 G1 G1 G1 Type 1000 1500 2000 3000 4000 5000 Primary tank Article No 8600705 8600905
26. GB Thinking solutions Variomat with Touch controller with one pump VS 2 1 60 75 95 with two pumps VS 2 2 35 60 75 95 Operating manual Original operating manual 1 Notes on the operating manual sssssssssesssseccssssssecsssccsssessssssesssesssssensscssecosscesssessssnsssnscsssecsssecssscesscesseassenseessessaessasecsseeesees 5 2 Liability and Quarantee e inne 5 3 SIR ie eeinierreeeeeeskereeie 6 3 1 Explanation fsymbolsa uu nsnsese een nn RE seinshsndglae 6 3 1 1 Symbols and notes used un0000neonsssonesenusennsssnnseenensonssenessenessnusennessonsennessnnseenensenessnnstnnessenssnnussnnssenessenessnnstenessenesen 6 3 1 2 Safety symbols Used iiien ae EEE EEEE EEE 6 3 2 Personnel FOquire rmi nts casssvecsasccscsvicsnessscavssseodsoussassasaten Asan vcbcsstacosxeasovedequsen sdestassevaticwedeateexsoasseeuckaaarcdsanstastoasansavedecsues N RN 7 3 3 Personal protective CQUIPMENL ccsssccsssssssssecssecsscssessscssscssscssssssccsssssscsscssscssscessccussssccuscesscsssssscsssccssesuscssccusccusesscssscsssceasccusenscensess 7 3 4 Intendedi se n n 2ne ka Rah rn cocsbscayech wenensatnsvodaauaohcccabscnuset aieseeduevodosauekcceabic 7 3 5 Inadmissible operating conditions 3 6 Residual risks een ie EEE bene eiserne cous A 4 Description of the device 4 1 Description Rena En Renee 4 2 OVE W nahen ehe II TEE atavwecnssouscavtebsucaveeheck 9 4 3 Identification
27. afety valve at site Set opening pressure ofthe safety valve 43 2 Type code No Type code 1 Control unit designation 2 Number of pumps Variomat VS 2 1 60 VG 500 I VF 5001 3 Pump type 123 4 5 6 4 Primary tank 5 Nominal volume 6 Secondary tank 10 English Variomat with Touch controller 25 06 2014 4 4 Function 7 6 5 1 Heating system WV Make up valve 2 MAG pressure expansion tank PIS Pressure sensor 3 Reflex Fillset Impulse see chapter 4 6 Optional PV Overflow valve motor ball valve equipment and accessories on page 13 Control unit PU Pump pressure maintenance 5 Hydraulic inlets SV Safety valve e For gas rich water e For degassed water 6 Primary tank air space EC Expansion line e For gas rich water e For degassed water 7 Secondary tank air space FD Feed and drain cock ST Dirt trap LIS Pressure pick up FQIRA Contact water meter DV Degassing valve WC Make up line VE Aeration and de aeration The device is a pressure maintaining station for heating and cooling water systems It is used for maintaining pressure making up and degassing the water in heating and cooling systems It comprises a control unit consisting of a controller with hydraulics
28. all the Fillset Impulse The device controller evaluates the make up quantities and signals a required replacement of the softening cartridges Notice The quality of the make up water must comply with the applicable standards such as VDI 2035 30 English Variomat with Touch controller 25 06 2014 Installation 6 5 Electrical connection Danger Electric shock e Serious injury or death due to electric shock Any system in which the device is to be installed must be de energised Ensure that the system is locked and cannot be switched on by other personnel Installation work for the electric connection of the device must be carried out by an authorised electrician in compliance with electrical engineering regulations Danger Electric shock Serious injury or death due to electric shock Some parts of the main board may still carry 230V voltage even with the device physically isolated from the 230 V power supply Before you remove the covers completely isolate the device controller from the power supply For the electrical connection you must differentiate between a connection component and an operating component 4 5 Example Control unit with one pump 1 Connection component cover hinged 4 Connection component rear 2 Operating component cover hinged 5 Cable bushings RS 485 interfaces Supply and fusing e Pressur
29. and at least one expansion tank Expansion tank One primary tank and multiple optional secondary tanks may be connected A diaphragm separates the tanks into an air and a water space preventing the penetration of atmospheric oxygen into the expansion water The VE line connects the air space with the atmosphere The primary tank is hydraulically flexibly connected to the control unit The function of the LIS level measuring using a pressure pick up is thus ensured Variomat with Touch controller 25 06 2014 English 11 Control unit The control unit contains the hydraulic system and the controller The PIS pressure transducer records the pressure and the LIS pressure pick up registers the level both values are displayed at the controller Maintaining pressure The pressure in the system rises when the water is heated When the pressure set at the controller is exceeded the PV overflow valve opens and drains water from the system into the primary tank using the EC expansion line The pressure within the system drops The pressure in the system drops when the water cools When the pressure drops below the set value the PU pump is activated and uses the EC expansion line to transport water from the primary tank back into the system The pressure in the system rises The controller ensures that the pressure is maintained further supported by the stabilisation provided by the MAG expansion tank Degassing Two EC ex
30. ater Remove the hose connection between the primary tank and the and the secondary tank if provided Remove the lower vessel covers from the tanks Remove any sludge from the covers and the spaces between the diaphragms and the tanks Reinstall the covers on the tanks Reinstall the hose connection between the primary tank and the and the secondary tank if provided Close the FD feed and drain cocks at the tanks Use the FD feed and drain cock to fill the primary tank with water see chapter 7 4 Filling the tanks with water on page 39 10 Switch to Automatic mode 2 8 NON pi e w Variomat with Touch controller 25 06 2014 English 65 10 3 Checking switching points Prerequisite for checking the switching points are the following correct settings Minimum operating pressure Po see chapter 7 2 Determining the Po minimum operating pressure for the controller on page 38 e Level sensor at the primary tank Preparation 1 Switch to Automatic mode 2 Close the cap valves upstream of the tanks 3 Record the displayed filling level value in 4 Drain the water from the tanks Checking the cut in pressure 5 Check the cut in and cut out pressure of the PU pump The pump cuts in at Po 0 3 bar The pump cuts out at Po 0 5 bar Checking the Make up On 6 If necessary check the make up value displayed at the controller The automatic make up is activated at a level display of 20 Check
31. atic mode After successful commissioning start the Automatic mode from the device The controller monitors the following functions e Maintain pressure Compensate expansion volume Degas e Automatic make up To start the Automatic mode proceed as follows 1 Press AUTO The PU pumps and the PV overflow valves are regulated so that the pressure remains constant at a regulation of 0 2 bar Faults are displayed and evaluated Automatic mode is activated Y U Variomat VS 2 1 2 8 bar System Continuous 42 English Variomat with Touch controller 25 06 2014 Operation 8 1 2 Manual mode The manual mode is intended for test and service tasks Manual mode enables you to select the following functions and to perform a test run PU pump PV1 overflow solenoid valve WV1 solenoid valve for the make up You have the option to simultaneously switch multiple functions and to test them in parallel Switch the function on and off by touching the corresponding button The button has a green background The function is switched off Press the desired button The button has a blue background The function is switched on 1 Press Manual mode Variomat VS 2 1 2 Select the desired function e PU1 Pump PV1 Overflow valve WV1 Make up solenoid valve The cont
32. d Air in the PU pump PV overflow valve does not close 06 Make up time Set value exceeded Severe water loss in the system Make up line connected Make up rate insufficient Make up hysteresis too high Change in Service menu if necessary OK 07 Make up cycles Set value exceeded Leakage in the system OK 08 Pressure measurement e Controller receives incorrect signal PIS pressure transducer defective Parted cable Plug inserted OK 09 Level sensor e Controller receives incorrect signal LIS oil pick up sensor defective Parted cable Plug inserted OK 10 Maximum pressure Set value exceeded PV overflow valve defective does not open ST dirt trap clogged OK 11 Make up quantity Only if With water meter is activated in the Customer menu Set value exceeded Check whether plausible for the monitoring time Leakage in the system Water quantity per contact incorrectly set in the Service menu OK ER Code Alarm Floating Causes contact Remedy Alarm reset 60 English Variomat with Touch controller 25 06 2014 15 Make up valve Contact water meter Check the WV make up OK measures without valve for leaks make up request 16 Power failure No power Check power supply
33. e and Level outputs e Floating contacts CO compressor connection 3 Touch control The following descriptions apply to standard systems and are limited to the necessary user provided connections 1 Shut down the system and secure it against unintentional reactivation 2 Remove the covers 3 Insert a suitable screwed cable gland for the cable bushing at the rear of the connection component M16 or M20 for example 4 Thread all cables to be connected through the cable glands 5 Connect all cables as shown in the terminal diagrams Connection component see chapter 6 5 1 Terminal plan connection component on page 32 Operating component see chapter 6 5 2 Terminal plan operating unit on page 34 Note that the fusing for the device connection is to be provided by the user see chapter 5 Technical data on page 14 Variomat with Touch controller 25 06 2014 English 31 6 5 1 Terminal plan connection component 4 2 45 44 43 42 39 lefet Telelel a 3 tofelofe 123 2 J2 16 cal 456 o g o z 3 o F2 F1 5 0 5AT 0 5AT AKA a SE 7 2a A aS a als e o AFFAIRE 82 I eo o g gi PE N L a Yi N PE Y2 N PE Y3 N PE Mi N PE M2 N PE FB1 FB2a FB2b 1 2 3456 789 101112 1314 27 15 16 17 31 18 19 20 21 22a 22b 1 Pressure 3 Fuses 2 Le
34. ed in system flow direction you must integrate the gas rich expansion line upstream of the expansion line transporting the degassed water Ensure that particulate dirt cannot enter and thus creating an overload of the ST dirt trap Connect the EC expansion lines according to the following installation variants P Notice The water temperature at the connection point of the EC expansion lines must be in the range of 0 C to 70 C The use of in line tanks does not increase the application range Because the thermal protection is not ensured due to the flow during the degassing phase Variomat with Touch controller 25 06 2014 English 25 6 3 4 2 Make up line WC make up line See Chapter Switching and make up variants for the various make up variants see chapter 6 4 Switching and make up variants on page 28 If you don t connect the automatic water make up you must close the connection of the WC make up line with a R 2 blind plug Prevent a potential device fault by ensuring manual water make up Install at least one ST dirt trap with a mesh size lt 0 25 mm close upstream to the make up solenoid valve Install a short line between the ST dirt trap and the solenoid valve gt Notice Use a pressure reducer in the WC make up line if the idle pressure exceeds 6 bar 6 3 5 Fitting the thermal insulation Install the thermal insulation 2 around the primary tank 1 and
35. ed to attach corresponding warning notes in the device vicinity Caution Risk of injury due to falls or bumps e Bruising from falls or bumps at system components during installation Wear personal protective equipment helmet protective clothing gloves safety boots Notice The proper installation and commissioning must be confirmed in the installation commissioning and maintenance certificate This certificate is prerequisite for any warranty claim Have the Reflex Customer Service carry out commissioning and the annual maintenance Variomat with Touch controller 25 06 2014 English 17 6 1 Installation conditions 6 1 1 Incoming inspection Prior to shipping this device was carefully inspected and packed Damages during transport cannot be excluded gt Notice After receipt of the goods please check the shipment for completeness and damage Document any transport damage Contact the shipper to register a claim for damage 6 2 Preparatory work max 45 C min O C pk gt DN 15 i Conditions for the device installation No access by unauthorised personnel Frost free well ventilated room Room temperature 0 C to 45 C e Level stable flooring Ensure sufficient bearing strength of the flooring before filling the tanks Ensure that the control unit and the tanks are installed on the same level Filling and dewateri
36. ely isolate the device controller from the power supply N Caution risk of burning Risk of burning from escaping medium Maintain sufficient distance from the escaping medium Wear suitable personal protective equipment safety gloves and goggles for example i Caution risk of burning Excessive surface temperatures in heating systems can cause skin to burn Wait until surfaces have cooled down or wear protective gloves The operator is required to attach corresponding warning notes in the device vicinity N Caution risk of injury Incorrect installation or service work may cause burns and other injuries at the connections when hot water or steam suddenly escape at pressure Ensure proper disassembly Ensure that the system is de pressurised before performing the disassembly e Prior to disassembly disconnect all water sided connections from the device Vent the device to de pressurise it Disconnect the system from the power supply and secure it against unintended reactivation Disconnect the power cable of the device from the power supply Disconnect and remove all cables from the terminals of the device controller Disconnect the secondary tank if provided on the water side from the system and the primary tank Open the FD feed and drain cocks at the tanks until they are completely empty and de pressurised Undo all hose and pipe connections to the tanks and the control unit of the device to
37. evice on a pallet Control unit and VG primary tank Connection kit in cardboard box and add on components in a plastic bag for the VG primary tank Plastic sleeve with operating manual Optional equipment and accessories Thermal insulation for the VG primary tank VF secondary tanks with add on components in a plastic bag and a set of flexible hoses 46 Optional equipment and accessories The following optional equipment and accessories are available for this device Fillset for make up with water Fillset with integrated back flow preventer water meter dirt trap and locking mechanisms for the WC make up line e Fillset Impulse with FQIRA contact water meter for make up with water Servitec for make up and degassing Fillsoft for softening the make up water from the public water network Fillsoft is installed between Fillset and the device The device controller evaluates the make up quantities and signals a required replacement of the softening cartridges Enhancements for the device controller 1 0 module for standard communication Master Slave Connect for master controllers for maximum 10 devices Bus modules Lonworks Digital e Lonworks Profibus DP e Ethernet Diaphragm rupture monitor Notice Separate operating instructions are supplied with accessories Variomat with Touch controller 25 06 2014 English 13 5 Technical data Control unit w
38. facility system is filled with water and gas vented The electrical connection has been created according to applicable national and local regulations Variomat with Touch controller 25 06 2014 English 37 7 2 Determining the Po minimum operating pressure for the controller The Po minimum operating pressure is determined by the location of the pressure maintaining device The controller calculates the switching points for the PV overflow valve and the PU pump from the Po minimum operating pressure Actuating pressure for the safety valve ps I 20 5 bar berstr mventil AUF Overflow valve CLOSED Pump OFF 4 0 2 bar Oberstromventil ZU Pumps AUS 0 2 bar Pump ON initial pressure pa _ Pumpe EIN 0 3 bar Overflow valve OPEN final pressure pe Minimum operating pressure Po 0 0 2 bar Static pressure ps omen ema mnea Se EDIE The Po minimum pressure is calculated as follows Po Pst Po 0 2 bar Enter the calculated value in the start routine of the controller see chapter 7 3 Modifying the controller s start routine on page 39 Pst hs 10 hst in metres Pp 0 0 bar for safety temperatures lt 100 C Pp 0 5 bar for safety temperatures 110 C Addition of 0 2 bar recommended no addition in extreme cases Calculation example for Po minimum operating pressure Heating system Static
39. he primary tank Check whether the shut off valves between control unit and primary tank are open supplied pre wired in open position e Fill the primary tank with water until the filling level has been reached 74 2 Filling with the solenoid valve in the make up 1 Use the Manual mode button to switch to Manual mode Variomat VS 2 1 2 Press the corresponding button for the WV make up valve until the specified filling level is reached Continuously monitor this process Ifa high water alarm is issued the WV make up valve will be automatically closed System 2 9 bar System Oe Continuous A 0 hl Variomat with Touch controller 25 06 2014 English 39 Commissioning 75 Venting the pump Caution risk of burning e Risk of burning from escaping medium Maintain sufficient distance from the escaping medium Wear suitable personal protective equipment safety gloves and goggles for example Vent the PU pump as follows Remove the vent screw 2 from the pump 1 and vent the pump until bubble free water escapes Screw the vent screw 2 back in and tighten Check the vent screw 2 for leaks 1 PU pump 2 AV vent screw 3 ST dirt trap Notice Repeat the venting process if the pump does not deliver 40 English Variomat with Touch controller 25 06 2014
40. ing Insufficient water On 7 Switch off the make up and continue to drain water from the tanks 8 Check the displayed value for the Insufficient water filling level message Insufficient water On is displayed at the controller at a minimum filling level of 5 9 Switch to Stop mode 10 Switch off the main switch Cleaning the tanks If necessary remove condensate from the tanks see chapter 10 2 2 Cleaning the tanks on page 65 66 English Variomat with Touch controller 25 06 2014 Activating the device 11 Switch on the main switch 12 Activate the make up 13 Switch to Automatic mode Depending on the filling level and pressure the PU pump and the automatic make up will be switched on 14 Slowly open the cap valves upstream of the tanks and secure them against unintended closing Checking Insufficient water Off 15 Check the displayed value for the Insufficient water OFF filling level message Insufficient water Off is displayed at the controller at a minimum filling level of 7 Checking Make up Off 16 If necessary check the make up value displayed at the controller The automatic make up is deactivated at a level display of 25 Maintenance is completed gt Notice If automatic make up is not connected you must manually fill the tanks with water to the recorded filling level gt Notice The setting values for pressure maintenance filling levels and make up are provided
41. ired language and conform your entry with Start routine Step 2 i OK 001 Language German u VLZ English ARN 27br 25 Variomat with Touch controller 25 06 2014 English 47 3 Select the calculated minimum operating pressure and conform your entry with OK e Calculating the minimum operating pressure see chapter 7 2 Determining the Po minimum operating pressure for the controller on page 38 4 Set the time Use the Left and Right buttons to select the display value Use the Up and Down buttons to change the display value Confirm your entries with OK The time of an alarm will be stored in the fault memory of the controller 5 Set the date Use the Left and Right buttons to select the display value Use the Up and Down buttons to change the display value Confirm your entries with OK e The date of an alarm will be stored in the fault memory of the controller 6 Select the size of the primary tank Use the Up and Down buttons to change the display value Confirm your entries with OK For the primary tank data see the name plate or see chapter 5 Technical data on page 14 Start routine Step 4 005 Min operating pressure p0 29br 0 Start routine Step 5 O 002 Time 09 30 29br 0 Start routine Step 6 5 003 Date l 03 04 14 CARR 29br 0
42. ith one pump Control unit VS 2 1 60 Control unit VS 2 1 75 Control unit VS 2 1 95 Type VS 2 1 60 VS 2 1 75 VS 2 1 95 Part No 8910200 8910300 8910400 Noise level 55 dB 55 dB 55 dB Electric output 1 1 kW 1 1 kW 1 1 kW Electric supply 230V 230V 230V Frequency 50 Hz 50 Hz 50 Hz Degree of protection IP 54 IP 54 IP 54 Voltage 230V 230V 230V Control unit height 920 mm 920 mm 920 mm Control unit width 470 mm 530mm 530mm Control unit depth 730mm 640 mm 640 mm Weight 33 kg 35 kg 37 kg Primary tank connection 2xG1 2xG1 2xG1 Sola gauge working According to nameplate According to nameplate According to nameplate Test pressure pr EN 13831 1 43 pmax 1 43 pmax 1 43 pmax Permissible flow temperature 120 C 120 C 120 C me m m 70 Permissible ambient temperature 0 C 45 C 0 C 45 C 0 C 45 C 14 English Variomat with Touch controller 25 06 2014 Control unit with two pumps Control unit VS 2 2 35 Control unit VS 2 2 60 Control unit VS 2 2 75 Control unit VS 2 2 95 Type VS 2 2 35 VS 2 2 60 VS 2 2 75 VS 2 2 95 Part No 8911100 8911200 8911300 8911400 Noise level 55 dB 55 dB 55 dB 55 dB Electric output 1 2 kW 2 2 kW 2 2 kW 2 2 kW Electric supply 230V 230V 230V 230V Frequency 50 Hz 50 Hz 50 Hz 50 Hz Degree of protection IP 54 IP 54 IP 5
43. mary tank The distance of the control unit to the primary tank results from the connection set supplied Variomat 2 2 The control unit can be installed on either side or in front of the primary tank The distance of the control unit to the primary tank results from the connection set supplied Variomat with Touch controller 25 06 2014 English 19 Installation 6 3 2 Installation of add on components for the tanks The add on components are packed in plastic bags and attached to the base of the devices e For tanks up to 740 mm DV degassing valve and reducing sleeve Rp 1 2 x Rp VE equalisation elbow For tanks from 1000 mm DV degassing valve and reducing sleeve Rp 1 x Rp VE equalisation elbow For add on components proceed as follows 1 Seal the DV degassing valve and the reducing sleeve and assemble 2 Install the assembly at the connection of the corresponding tank 3 Remove the protective cap from the DV degassing valve 4 Use the clamping ring screw connection to install the VE equalisation elbow for aeration and de aeration at the tanks 1000mm _ VE equalisation 2 DV degassing valve with reducing sleeve elbow 20 English Variomat with Touch controller 25 06 2014 6 3 3 Tank installation Attention Damage caused by improper installation Remember that the c
44. ment The electric connections and the wiring of the device must be executed by a specialist in accordance with all applicable national and local regulations 3 3 Personal protective equipment When working at the system wear the stipulated personal equipment such as hearing and eye protection safety boots helmet protective clothing protective gloves la O See the national regulation of your country for personal protective equipment required 3 4 Intended use e The devices are manufactured from steel with exterior coating the interior is uncoated The devices may be used only in systems that are sealed against corrosion and with the following water types Non corrosive Chemically non aggressive e Non toxic The ingress of atmospheric oxygen by permeation into the entire heating and cooling water system make up water and similar must be reliably minimised during operation 3 5 Inadmissible operating conditions The devices are not suited for the following conditions In mobile system operation For outdoors operation e For the use with mineral oils e For the use with flammable media e For the use with distilled water Notice Changes to the hydraulic system or interference with the interconnection are strictly prohibited Variomat with Touch controller 25 06 2014 English 7 Safety 3 6 Residual risks This device has been manufactured to the current state of the a
45. missioning certificate Data shown on the nameplate Po Type Psy Serial number This device has been installed and commissioned in accordance to the instructions provided in the Operating Manual The settings in the controller match the local conditions Notice When any factory set values of the device are changed you must enter this information in the Maintenance certificate see chapter 10 4 Maintenance certificate on page 68 For the installation Place date Company Signature For the commissioning Place date Company Signature 36 English Variomat with Touch controller 25 06 2014 7 Commissioning P Notice The proper installation and commissioning must be confirmed in the installation commissioning and maintenance certificate This certificate is prerequisite for any warranty claim Have the Reflex Customer Service carry out commissioning and the annual maintenance 7 1 Checking the requirements for commissioning The device is ready for commissioning when the tasks described in Chapter Installation have been concluded Comply with the following instructions for commissioning The control unit is connected to the primary tank and the secondary tanks if provided The water connections of the tanks to the facility system are established The tanks are not filled with water The valves for emptying the tanks are open The
46. mme Continuous 011 Time continuous degassing 12 0h ix The controller opens the list of degassing programmes 29ba 0 56 English Variomat with Touch controller 25 06 2014 5 Toselect a menu item press the Up or Down scroll bar until this menu item is displayed Press the desired button No degassing is selected in this example Continuous degassing and interval degassing are deselected Confirm your selection with OK Degassing is deactivated 6 Press 011 Time continuous degassing 7 Set the time for continuous degassing Use the Left and Right buttons to select the display value Use the Up and Down buttons to change the display value Confirm your entries with OK Wea Press i to display a help text for the selected area Press X to cancel your input without saving the new settings The controller automatically opens again the list Settings gt Customer gt Degassing 010 Degassing programme No degassing Continuous degassing Interval degassing 2 9 bar 0 Settings gt Customer gt Degassing 010 Degassing programme Continuous 011 Time continuous degassing 12 0h 2 9 bar 0 Settings gt Customer gt Degassing 011 Time continuous degassing 2 9 bar 0 U Variomat with Touch controller 25
47. ne 49 0 2382 7069 0 Fax 49 0 2382 7069 588 www reflex de 11427en 9125160 06 14
48. ng option Provide a DN 15 filling connection according to DIN 1988 T 4 Provide an optional cold water inlet Prepare a drain for the drain water e Electric connection 230 V 50 Hz 16 A with upstream ELCB Tripping current 0 03 A Use only approved transport and lifting gear The load fastening points at the tanks must be used only as installation resources 18 English Variomat with Touch controller 25 06 2014 Installation 6 3 Execution Attention Damage caused by improper installation Remember that the connection of pipelines or equipment originating with the system may cause additional stresses to the device Ensure a stress free installation of the pipe connections between the device and the overall system For installation proceed as follows e Position the device Complete the primary tank and the optional secondary tanks e Create the water side connections of the control unit to the system e Create the interfaces according to the terminal plan Install the water connections between optional secondary tanks to each other and to the primary tank gt Noticel For installation note the operability of the valves and the inlet options of the connecting lines 6 3 1 Positioning Determine the positions for the control unit the primary tanks and the secondary tanks if used e Variomat 2 1 The control unit can be installed on either side or in front of the pri
49. nnection set 2 and 3 with the screw fittings and gaskets to the connections at the lower tank flange of the primary tank Ensure that you connect the connection set for the overflow collector to the connection 2 with the label 1 interchanging the connections may cause the pump to run dry For tanks up to 740 mm Connect the connection set 2 and 3 to the two free 1 inch barrel nipples at the tank flange Connect the connection set 4 of the secondary tank to the T joint at the outlet of the tank flange For tanks from 1000 mm Connect the connection set 2 to the 1 inch barrel nipple of the tank flange Connect the connection sets 3 and 4 to the T joint at the 1 inch barrel nipple of the tank flange gt Notice 1 2 3 2 1000mm w Adhesive label Pump connection set N Overflow collector connection 4 set Secondary tank connection set If necessary install the supplied connection set 4 at the secondary tank Connect the connection set 4 with a user supplied pipeline to the primary tank 22 English Variomat with Touch controller 25 06 2014 Installation a w gt Hydraulic connection 6 3 4 1 Connection to the facility system Caution risk of burning e Hot water vapour can cause burns to skin and eyes Install the blow off line from the control unit s safety valve so that a hazard
50. nsssensssnnnnsenn 74 12 4 EUR 6 DIR SEEE AAEE SEAE SEE ETES TA OIREET ESTEA OE E EE 74 12 5 GIOSSANY iina a i aE a EAE E AE Oa ES AE E DETE aE REA Ea E BSG 74 4 English Variomat with Touch controller 25 06 2014 1 Notes on the operating manual This operating manual is an important aid for the safe and reliable function of the device The operating manual is intended to Avert dangers to personnel e Understand the device e Obtain optimal functioning e Early identify and rectify problems e Avoid faults caused by improper use e Prevent repair costs and downtimes e Increase reliability and service life e Prevent damage to the environment Reflex Winkelmann GmbH cannot accept any liability for damage caused by ignoring this operating manual In addition to this operating manual you must comply with national legislation and regulations in the country of use accident prevention environment protection save and proper work etc This operating manual describes the device with basic equipment and interfaces for optional equipment with additional functions For optional equipment and accessories see chapter 4 6 Optional equipment and accessories on page 13 gt Notice Every person installing this equipment or performing any other work at the equipment is required to carefully read this operating manual prior to commencing work and to comply with its instructions The manual is to be provided to the de
51. nterface to the main circuit board 13 TxD reserve 14 GND 102 15 10 V 16 10 V supply Factory 17 FE 34 English Variomat with Touch controller 25 06 2014 6 5 3 RS 485 interface Use theS1 and 2 RS 485 interfaces to retrieve all controller data and to enable the communication with control centres or other devices S1 interface Using this interface you can operate maximum 10 devices in a master slave network 2 interface PIS pressure and LIS level Operating modes of the PU pumps Operating states of the PV solenoid valve in the overflow line Operating states of the WV solenoid valve in the overflow line Cumulated quantity of the FQIRA contact water meter All messages see chapter 9 5 Messages on page 59 All entries in the fault memory 6 5 3 1 Connecting the RS 485 interface e Usea shielded cable to connect the interface to terminals 1 6 of the main board in the control cabinet For connecting the interface see chapter 6 5 Electrical connection on page 31 When using the device with a control centre not supporting an RS 485 interface RS 232 for example you must use a corresponding adapter B gt Notice e For connecting the interface use only a cable with these properties LJYCY TP 4x 2 x 0 8 maximum overall bus length 1000 m Variomat with Touch controller 25 06 2014 English 35 6 6 Installation and com
52. onnection of pipelines or equipment originating with the system may cause additional stresses to the device Ensure a stress free installation of the pipe connections between the device and the overall system Attention Equipment damage The pump will be damaged if it is permitted to run dry Ensure that the connections for the overflow collector and the pump are not interchanged Ensure the correct connection of the pump to the primary tank Comply with the following notes regarding the installation of the primary tank and the secondary tanks All flange openings at the tanks are viewing and maintenance openings Install the primary tank and the secondary tanks if provided with sufficient spaces at the sides and the top e Install the tanks on a level plane e Ensure rectangular and free standing position of the tanks e Ifyou use secondary tanks in addition to the primary tank ensure that all tanks have the same type and dimensions Do not attach the tanks to the flooring to ensure the functioning of the LIS level sensor e Install the control unit on the same level as the tanks Variomat with Touch controller 25 06 2014 English 21 Align the primary tank The label 1 is located directly above the connection 2 for the overflow collector The distance of the primary tank to the control unit must match the length of the connection set Connect the co
53. operation Switch to Stop mode e Close the ball vales upstream of the ST dirt trap 1 and the primary tank Slowly unscrew the dirt trap insert 2 from the dirt trap in order for the residual pressure to escape from the pipeline segment e Pull the mesh from the dirt trap insert and rinse it with clear water Use a soft brush for cleaning Re insert the mesh into the dirt trap insert check the gasket for damage and screw the dirt trap insert back into the housing of the ST 1 dirt trap e Open the ball vales upstream of the ST dirt trap 1 and the primary tank Vent the PU pump see chapter 7 5 Venting the pump on page 40 Switch to Automatic mode 1 ST dirt trap 2 Dirt trap insert Notice Clean all other installed dirt traps in the Fillset for example 64 English Variomat with Touch controller 25 06 2014 Maintenance 10 2 2 Cleaning the tanks Caution risk of injury e Incorrect installation or service work may cause burns and other injuries at the connections when hot water or steam suddenly escape at pressure Ensure proper installation Ensure that the system is de pressurised before performing service work at the connections Clean the primary tank and the secondary tanks from sludge deposits 1 Switch to Stop mode 2 Empty the tanks Open the FD feed and drain cocks and empty the tanks completely from w
54. or WC Make up line District heating water is particularly suited as make up water Water treatment is not necessary Use an ST dirt trap with a mesh size gt 0 25 mm for the make up Notice You require approval by the supplier of the district heating water Variomat with Touch controller 25 06 2014 English 29 6 4 1 3 Use in a system with central return flow admixture IR H H H H i Fillsoft Fillset Impuls 1 a E FTA A D n 1 MAG pressure expansion tank WC Make up line 2 Heat generator PIS Pressure transducer 3 Primary tank WV Make up solenoid valve 4 Control unit ST Dirt trap 5 Reflex Fillsoft see chapter 4 6 Optional equipment and EC Degassing line accessories on page 13 For gas rich water from the system For degassed water into the system 6 Reflex Fillset Impulse see chapter 4 6 Optional LIS Level sensor equipment and accessories on page 13 Using a softening system for the water make up Always integrate the device in the V main volume flow to ensure degassing the system water It is the system side in systems with central return flow admixture or hydraulic switching points The tank of the heat generator must be fitted with an individual protective device When using Reflex Fillsoft softening systems always inst
55. pansion lines are required to degas the system water One line is intended for gas rich water from the system and the other one serves to return the degassed water to the system During the degassing action the PU pump and the PV overflow valve are in operation This transports a gas rich partial flow of the system water V through the de pressurised primary tank Atmospheric pressure is used to separate the free and dissolved gases and to discharge them through the DV degassing valve The controller ensures the hydraulic equalisation by regulating the stroke of the PV overflow valve motor ball valve There are three different modes for this process continuous interval or run on degassing Make up When the water level in the primary tank falls below the minimum the WV make up valve opens until the set level is again reached During the make up process the number of requests the time and the make up duration within a cycle are monitored Using a FQIRA contact water meter the system monitors each individual make up volume and the overall make up volume 12 English Variomat with Touch controller 25 06 2014 45 Scope of delivery The scope of delivery is described in the shipping document and the content is shown on the packaging Immediately after receipt of the goods please check the shipment for completeness and damage Please notify us immediately of any transport damage Basic pressure maintaining equipment The d
56. pe Certificate number Reflexomat Compact RC 200 500 litres 6 bar 120 C 04 202 1 450 04 01952 Reflexomat RS 200 800 litres 6 bar 120 C 04 202 1 932 01 00077 1000 5000 litres 6 bar 120 C 04 202 1 450 02 00714 350 5000 litres 10 bar 120 C 04 202 1 450 02 00039 1000 5000 litres 10 bar 120 C 04 202 1 450 02 00715 Variomat 200 1000 litres 10 bar 120 C 04 202 1 932 01 00051 1000 5000 litres 10 bar 120 C 04 202 1 450 02 00712 Gigamat 1000 5000 litres 10 bar 120 C 04 202 1 450 02 00713 10000 Litres 10 bar 120 C 04 202 1 450 02 00062 Servitec DN 150 DN 250 10 bar 16 bar 120 C 04 202 1 450 03 00210 12 4 Guarantee The respective statutory guarantee regulations apply 12 5 Glossary System Heating climate control or other building services system to which the device is connected Hysteresis Delayed behaviour of an output variable relative to the input variable The input signal influences the output signal Cavitation Formation and dissolution of vapour filled cavities vapour bubbles in fluids Cumulated Cumulation of values Klixon Pressure safety cut out for the protection of the pump motor Permeation Process in which a substance permeate penetrates or migrates through a solid body 74 English Variomat with Touch controller 25 06 2014 Thinking solutions Reflex Winkelmann GmbH Gersteinstra e 19 59227 Ahlen Germany Telepho
57. r thanks to a regulation of the pressure maintenance with automatic make up No circulation issues caused by free bubbles in the circuit water Reduced corrosion damage due to oxygen removal from fill and make up water 4 2 Overview 1 4 Variomat with touch control and two pumps Variomat with touch control and one pump 1 Main switch 5 VF secondary tank 2 Control unit 6 VG primary tank Pump s Reflex Control Touch controller 3 VE equalisation elbow 7 FD feed and drain cock 4 DV degassing valve 8 LIS level sensor Variomat with Touch controller 25 06 2014 English 9 43 Identification 43 1 Nameplate The nameplate provides manufacturer information year of manufacture serial number and technical data Information on nameplate Meaning Type Device name Serial No Serial number min max allowable pressure P Minimum maximum permissible pressure max continuous operating temperature Maximum temperature for continuous operation min max allowable Minimum maximum temperature flow temperature permissible TS temperature TS flow temperature Year built Year of manufacture min operating pressure set up on shop floor Factory set minimum operating pressure atsite Set minimum operating pressure max pressure saftey valve factory aline Factory set opening pressure of the s
58. re 02 1 Insufficient water switch N7 2 Fault message Current messages 02 1 Insufficient water Possible causes Dry running protection during pump 1 operation Make up not excluded Dirt trap in make up line clogged Make up solenoid valve does not open Large gas quantities in the system Fault has been eliminated and can be acknowledged 0 4 bar 29 Variomat with Touch controller 25 06 2014 English 59 ER Code Alarm Floating Causes contact Remedy Alarm reset 01 Min pressure Set value exceeded Water loss in the system Fault at PU pump Check pump in manual mode OK 02 1 02 2 Insufficient water pump 1 Insufficient water pump 2 Only with Variomat 2 2 Set value exceeded Make up defective Dirt trap clogged solenoid valve does not open Air in the system If necessary manually add water 03 High water Set value exceeded Make up defective WV make up valve does not close Inflow from leak in the user s thermal transfer medium Tank too small Drain water from the tank 04 1 04 2 Pump 1 Pump 2 Only with Variomat 2 2 Pump does not start PU pump is stuck Motor defective 10 A fuse defective Contactor Klixon tripped OK 05 Pump run on time Set value exceeded Severe water loss in the system Cap valve at the intake side close
59. ressure maintenance feature works It has been designed for specific applications and Summer operation Please contact our Customer Service for more information Activation setting e Activated from the Customer menu e Degassing interval Start for each pump run for a degassing time that you can set in the Service menu Standard 4 s 58 English Variomat with Touch controller 25 06 2014 9 5 Messages The messages are impermissible deviations from the normal state They can be output either via the RS 485 interface or via two floating message contacts The controller displays the messages with a help text Message causes can be eliminated by the operator or a specialist workshop If this is not possible contact the Reflex Customer Service gt Notice When the cause for the message is eliminated you must acknowledge the fault with OK at the controller s operator panel gt Notice Floating contacts setting in the Customer menu see chapter 9 4 Configuring settings in the controller on page 50 To reset an error message proceed as follows 1 Touch the display The current fault messages are displayed 2 Touch a fault message The system displays the possible causes for the fault 3 When the fault is eliminated confirm the fault with OK Ole AUTO 2 8 bar Sy l NSP LIS aX System Continuous A Pee Current messages 01 Minimum pressu
60. roller displays the change of the filling level and the Gol pressure of the tank System 2 9 bar System Continuous berstr PV1 overflow valve motor ball valve Nachsp Solenoid valve of the WV1 make up Notice Manual operation can not be performed if safety relevant parameters are exceeded Switching is blocked if safety relevant parameters are exceeded Variomat with Touch controller 25 06 2014 English 43 Anayatinn Uperation 8 1 3 Stop mode The Stop mode is intended for the device commissioning Except for the display of information the device is non functional in Stop mode Function monitoring is stopped The following functions are deactivated The PU pump is switched off e The solenoid valve in the PV overflow line is closed The solenoid valve in the WV make up line is closed 1 Press STOP Variomat VS 2 1 U 2 8 bar System Continuous A gt Notice The system returns an alarm if the Stop mode is activated for more than 4 hours If Floating alarm contact in the Customer menu is set to Yes the system outputs the alarm to the group alarm contact 8 1 4 Summer operation The degassing of the network water is not necessary if the circulating pumps of the system are shut down during Summer because gas rich water cannot reach the device In this event use the Customer
61. rt However some residual risk cannot be excluded i Caution risk of burning Excessive surface temperatures in heating systems can cause skin to burn Wait until surfaces have cooled down or wear protective gloves The operator is required to attach corresponding warning notes in the device vicinity A Caution risk of injury Incorrect installation or service work may cause burns and other injuries at the connections when hot water or steam suddenly escape at pressure Ensure proper installation Ensure that the system is de pressurised before performing service work at the connections A Warning large weight e The devices are very heavy Thus there is a risk of physical damage and accidents Use only lifting gear suitable for transport and installation 8 English Variomat with Touch controller 25 06 2014 Description of the device 4 Description of the device 4 1 Description The Variomat is a pump controlled pressure maintaining make up and degassing station for heating and cooling water systems The Variomat is essentially a controller with pump and at least one expansion tank A diaphragm in the extension tank separates the same into an air and a water space preventing the penetration of atmospheric oxygen into the expansion water The Variomat provides the following safety features Optimisation of all pressure maintaining degassing and make up processes No direct intake of ai
62. seeste 58 9 5 IEA Le T EEDE EA ARASA SENEESE AOE EEAO AE AE TAI 59 10 vMalntenante una EERE A Ea 10 1 Maintenance schedule 10 2 Cleaning han aneneen essen nassen E E TAEA E AEE A E A 10 2 1 Cleamingithe dirt trapia aE E ievashasececeseccovayenscorusbssteabuaavsustaccvszyantesenssaieatapedvatnnaeconssottevese 64 10 2 2 Cleaning thetankS sasien a lee seele 65 10 3 Checking Switching Points sesssevsaecccccsencsesuoedeasssaaeconsvattesenascensetuvecesasnnasccnnvettecennsecaussaaceousaiadconnsettccansbcasuatccauspanseoruspedcecsagoayaraddeeiby 66 10 4 Maintenance certificate est dei en EAE EAE Ea 68 10 5 Inspedtion u 8 ETETETT EE EITTEA ETTA 69 10 5 1 Pressure bearing COMPONENS cssssccseecsssccsscecssesssscesecenssesnecessscenecessecsnscessscenssessssenseesnecsssesssseesnecessseesseersseenecsenesess 69 10 5 2 Inspection prior to COMMISSIONING seescesecseecsseecsseecsscecssecsseecssecsuscsssccsusecsseesssecsueccusccsssceusecsusecssecsusecssecsusecsseceneeese 69 10 5 3 Inspection intervals Assisiensis a arie NE e S iE a i ontani ai 69 11 Disassembly saiisesscesesssessestnccssscanaicosstacosenmneroedtentinnediaapanastacstiodandinclntardbadtadaadtivacteanieaneamnBineenteguanets 70 12 AE EA A RAA AAA A A Sl Bein 12 1 Reflex Customer Service ua ar RIES 12 2 Conformity and standards 12 3 Certificate No of the design type examination uessssenssssenssssennsssennsssennsssunnssennsssennsssennsssennsssunnsssunsssennsssennnssenesssen
63. sh Variomat with Touch controller 25 06 2014 10 1 Maintenance schedule The maintenance schedule is a summary of maintenance tasks to be carried out regularly Maintenance task Screw connections Check valve downstream of PU pump Conditions Interval A Check BF Service Clean Check for leaks Ee pump A Annually Clean ST dirt trap Depending on the operating see chapter 10 3 Checking switching points on page 66 A I see chapter 10 2 1 Cleaning the dirt trap on page 64 conditions Clear sludge from the primary tank and the secondary tanks A Depending on the operating see chapter 10 2 2 Cleaning the tanks on page 65 conditions Check the make up switching points A kania see chapter 10 3 Checking switching points on page 66 Check the Automatic mode switching points A Annai Variomat with Touch controller 25 06 2014 English 63 Maintenance 10 2 Cleaning 10 2 1 Cleaning the dirt trap Caution risk of injury e Incorrect installation or service work may cause burns and other injuries at the connections when hot water or steam suddenly escape at pressure Ensure proper installation Ensure that the system is de pressurised before performing service work at the connections The ST dirt trap must be cleaned after the expiry of the continuous degassing time at the latest An inspection is also required after longer lasting
64. ssigned to the setting options PM code Description 001 Select the language 002 Setthe time 003 Setthe date Execute null balancing The primary tank must be empty The system checks whether the signal from the level sensor matches the selected primary tank 005 Set the Po minimum operating pressure see chapter 7 2 Determining the Po minimum operating pressure for the controller on page 38 Degassing gt 010 Degassing programme No degassing Continuous degassing Interval degassing Run on degassing 011 e Continuous degassing time Make up gt 021 e Make up ON at 022 e Make up OFF at 023 e Maximum make up time min 024 Maximum make up cycles 2 h 027 With contact water meter Yes No If Yes continue with 028 028 Reset make up quantity Yes No 029 e Maximum make up quantity 030 With softening Yes No If Yes continue with 031 031 e Block make up Yes No if water capacity is exhausted 033 e Hardness reduction dH GHactual GHtarget 032 Soft water capacity e Fillsoft I Soft water capacity 6000 hardness reduction Fillsoft Il Soft water capacity 12000 hardness reduction 50 English Variomat with Touch controller 25 06 2014 PM code Description 034 e replacement interval months for softening cartridges according to manufacturer 007 Main
65. sssecsssssccssesccssecccsseccesseccessccesssecesssccesssceesusecesnseessees 38 73 Modifying the controller s start routine essssssssccsssccsssecsessscccssecesssccssssecesuscessuscessuscecsuscessuscesssecesuscessusecesuseessuecesscessnssessuseesneses 39 7 4 Filling the tanks with water egienkespekeiiisenkieslssni session semeeeressingerne har 39 7 4 1 Filling with aih se 4 2 5 ern Es face cub easy ns casauade igenabhadscedudcdyantacsceceee uecnun oaseontuccovaataceets 39 74 2 Filling with the solenoid valve in the make up sssecssescseecsseecssescssccsseecssecsusecssecsusecssscuseesssecssecsuscesscesuceesueecsseeses 39 75 Ve tingthe OUI pevsccsssscssssss cccssteszccsasstasscocatencstnsscctaesgeegissauducstbtansdatansccdasy savages anasseaasanssaseusscaassuyacenvaeastetasauataseastcoassezeasepennaenanasauatie 40 7 6 Parametrising the controller in the Customer menu u nuneusssenssennssennssunnsennssennsnunseenssnnnnennnssunnsnunssonnseunssnnnsnunnsnnnssennssunssennseenn 41 Variomat with Touch controller 25 06 2014 English 3 77 St rting Automatic MOd ess ssccilsss ccccessicubonasanrcscanulecconscuckdaaicubesssesraccsseledtoeatachdevil tabs seuuseecenuegiesssnucevbisebcessuesesciacteginessoueceaenseeeey 41 8 Operation nenne AA E EAEN E aa N T AES 42 8 1 Operating MOA ESen rs R RE EA A EAE RaR EAR AAR 42 8 1 1 Automatic Modessa iii i 42 8 1 2 Manual mode ninni iiin E EAE R AE AERA AN RR ai 43 8
66. tenance interval months 008 Floating contact e Message selection gt Message selection only messages marked with V are output All messages All messages are output Fault memory gt History of all messages Parameter memory gt History of parameter input Display settings gt Brightness screen saver 009 Brightness 010 Screen saver brightness 011 Screen saver delay min Information gt Tank Tank information Software version Variomat with Touch controller 25 06 2014 English 51 9 4 1 2 Setting the customer menu Time example The setting of system specific values is explained below using the setting of the time as example To adjust the system specific values proceed as follows 1 Press Settings The controller switches to the setting area AUTO LOG Variomat VS 2 1 2 8 bar Sy System Continuous 2 Press Customer gt Settings The controller opens the Customer menu A a Service gt S 29bar 0 3 Press the required area Settings gt Customer The controller switches to the selected area Use the scroll bar to navigate through the list 001 Language m 002 Time N 11 21 003 Date 05 11 2013 Execute null balancing 29br 0 52 English Variomat with Touch controller 25 06 2014
67. the system and remove them completely If necessary remove the tanks and the control unit from the system area Re NaS 70 English Variomat with Touch controller 25 06 2014 12 Annex 12 1 Reflex Customer Service Central customer service Switchboard Telephone number 49 0 2382 7069 0 Customer Service extension 49 0 2382 7069 9505 Fax 49 0 2382 7069 523 E mail service reflex de Variomat with Touch controller 25 06 2014 English 71 12 2 Conformity and standards Declaration of conformity for electrical installations in the pressure maintaining make up or degassing systems as established in the Council Directive to compatibility 2004 108 EQ 1 We hereby confirm that the products meet the essential protection requirements approximate the laws of the Member States relating to electromagnetic The following Standards have been applied to assess the products Deutsches Institut f r Normung European Standard 61326 1 2006 10 the Low voltage Directive 2006 95 EC 2 We hereby confirm that the control cabinets meet the essential requirements of The following Standards have been applied to assess the products Deutsches Institut f r Normung European Standard 61010 1 2002 08 Occupational Health and Safety Regulations of the trade associations German BGV Para 2 Declaration of conformity for assemblies Design manufacture and testing of pressure
68. to persons in the vicinity is excluded gt Attention Damage caused by improper installation Remember that the connection of pipelines or equipment originating with the system may cause additional stresses to the device Ensure a stress free installation of the pipe connections between the device and the overall system Connection to the primary tank The control unit is positioned to the primary tank as determined by the selected installation variant and is connected to the tank using its connection set see chapter 6 3 3 Tank installation on page 21 The connections to the system are identified by adhesive labels on the control unit Pumpen Uberstr mung Nachspeisung Zur Anlage Zur Anlage Zum Behalter Pump to system connection Overflow valve to system Make up to system connection connection Variomat with Touch controller 25 06 2014 English 23 nstallation Connection to the system 1 2 t 0 C 70 C V ale 6 5 4 3 1 Heat generator 7 Control unit 2 For optional equipment and accessories see chapter 4 6 EC Degassing line Optional equipment and accessories on page 13 e Gas rich water from the system Degassed water to the system 3 Secondary tank LIS LIS level sensor 4 Reflex rapid action coupling R 1 x 1 WC Make up line 5 Primary tank MAG Pressure expansion tank 6 Primary tank connection set
69. uent alignment of the vessel for example Use flexible hoses to connect the primary tank and if provided the first secondary tank Use only the supplied connection sets Perform a null balancing of the filling level when the primary tank is aligned and fully emptied see chapter 9 4 Configuring settings in the controller on page 50 Standard values for level measurements Primary tank Measuring range 2001 0 4bar 300 500 I 0 10 bar 600 1000 0 25 bar 1500 2000 0 60 bar 3000 5000 0 100 bar Variomat with Touch controller 25 06 2014 English 27 6 4 Switching and make up variants 6 4 1 Function The filling level is recorded in the primary tank by the LIS level sensor and evaluated in the controller When the water level falls below the value specified in the controller s customer menu the WV make up valve opens gt gt Notice To complete the make up function from the drinking water system Reflex offers the Fillset with integrated system separator and Fillsoft softening equipment Fillsoft is installed between Fillset and the device see chapter 4 6 Optional equipment and accessories on page 13 6 4 1 1 Using a single tank system 5 1 Heat generator WC Make up line 2 MAG pressure expansion tank PIS Pressure transducer 3 Primary tank WV Make up solenoid valve 4 Control unit EC
70. um pressure Po 3 bar Differential pressured added to the Po minimum operating pressure Degassing Degassing time of interval degassing mode 90 seconds Idling time of interval degassing mode 120 minutes Interval degassing start 08 00 h Interval degassing end 18 00 h Filling levels Insufficient water ON 6 The PU pump is activated at a minimum filling level of 6 in the primary tank Insufficient water OFF 12 The PU pump is deactivated at a filling level of 12 in the primary tank Solenoid valve in overflow line CLOSED 90 Variomat with Touch controller 25 06 2014 English 55 9 4 4 Setting degassing programmes 1 Press Settings Variomat VS 2 1 The controller switches to the setting area 2 8 bar De S o NSP Lis aX System Continuous 2 Press Customer gt Settings The controller opens the Customer menu Service gt ix S 29bar 0 3 Press Degassing gt Settings gt Customer The controller switches to the selected area Use the scroll bar to navigate through the list 005 Min operating pressure p0 1 8 bar Degassing gt lt Make up gt 007 Maintenance interval 12 mont 29ba 0 4 Press 010 Degassing programme Settings gt Customer gt Degassing 010 Degassing progra
71. vel Merun Signal Function Wirin number g g Supply X0 1 L X0 2 N 230 V supply On site X0 3 PE X0 1 L1 X0 2 L2 X0 3 L3 400 V supply X0 4 N X0 5 PE Circuit board 4 y1 5 N WV make up solenoid valve User optional 6 PE 13 l 3 h TA Dry running protection message floating User optional 23 NC 24 COM Group message floating User optional 25 NO 35 18 V blue 36 GND LIS level sensing analogue input On site 37 AE brown at the primary tank 38 PE shield 32 English Variomat with Touch controller 25 06 2014 aera Signal Function Wiring Circuit board 39 18 V blue 40 GND PIS pressure sensor analogue input ser optional 41 AE brown at the primary tank i 42 PE shield 43 24 V Digital inputs User optional E1 Contact water meter 2 __16 r 44 E1 impet setivaklon BEER Factory provided 1 PE 2 N Voltage supply Factory provided 3 L 7 Y2 8 N PV 1 overflow valve motor ball valve 9 PE 10 Y3 11 N PV 2 overflow valve motor ball valve 12 PE 15 M1 16 N PU 1 pump Factory provided 17 PE 18 M2 19 N PU 2 pump only in VS 2 2 Factory provided 20 PE 21 FB1 Pump 1 voltage monitoring Factory provided 22a FB2a Pump 2 voltage monitoring Factory provided 22b FB2b External make up request together with 22a Factory provided 27 M1 Flat plug for supply pump
72. vice operator and must be stored near the device for access at any time 2 Liability and guarantee The product is manufactured to the latest engineering standards and acknowledged safety regulations Nevertheless risk of injury and death for the user and other parties and damage to the system and other property can arise from its use Modifications of the device such as changes of the hydraulic system or interference with the interconnection are strictly prohibited The liability and guarantee of the manufacturer are excluded when the malfunction can be traced back to one or more of the following causes Improper use of the device Improper commissioning operation maintenance servicing repair and installation of the device e Ignoring the safety notes in this operating manual Device operation with defective or improperly installed safety and or protective equipment e Failure to perform maintenance and inspection work at due times e Use of unauthorised replacement parts and accessories The precondition for any guarantee claims is the proper installation and commissioning of the device Notice Have the Reflex Customer Service carry out commissioning and the annual maintenance see chapter 12 1 Reflex Customer Service on page 71 Variomat with Touch controller 25 06 2014 English 5 Safety 3 Safety 3 1 Explanation of symbols 3 1 1 Symbols and notes used The following symbols are used in this

Variomat with Touch controller

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