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1. M M 48 8 2 2 ede ERS BEER I Shen 48 8 2 3 Defa lt setlings xii issevi 49 8 2 4 Messages ns ib b EE dr b d a 50 9 ET Ts ee eek 53 9 1 Maintenance schedule rae es Ense bene 53 92 Checking switching points is ilsir ien e Ue DE RR RU ee eR RE cte e UM et 54 9 3 ALI a a Eee E EE E cduaas EA AOE AE 56 9 3 1 Cleaning thetanks iR at et A O i iy 56 9 3 2 Cleaning the dirt trap tee e e n IRR ce ent d eiae e RR 57 9 4 Maintenance certificate e READ ERUNT ERROR QUER RD TU ERU que 58 9 5 IriSDeCtlOTs e rete e REIR REESE ERU PER a a aa pa 59 9 5 1 Pressure bearing components x a e ORE i GNU TRECE DUE Rud 59 9 5 2 Inspection prior to commissioning sressensenseonsenssenssnnssunssnnsnnssnnsennsennsonnsnnssnnssnnsensennssnnsennsenssonssnnssnnssnnsnnssnnsennsennsen 59 9 5 3 Inspection intervals cnnnart Siaa 59 10 Disassembly i cete see Iren 60 H 11 OK A 61 11 1 Reflex Customer Service 61 11 2 Conformity Ecc E 62 11 3 Certificate No of the design type examination cesssescsseccssecsseecssccsseccssecssscesscecsseesssecsseccuseesssessscesusecsucesssessueecsseesueecsneceneeess 64 114 GUA ATC pe UU 64 11 5 GOS SAY P 64 4 English Reflexomat with Basic controller 13 05 2014 1 Notes on the operating manual This operating
2. Height including control unit on tank 18 English Reflexomat with Basic controller 13 05 2014 Installation Installation Danger Electric shock Serious injury or death due to electric shock Anysystem 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 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 Caution Risk of injury due to falls or bumps Bruising from falls or bumps at system components during installation Wear personal protective equipment helmet protective clothing gloves safety boots Warning large weight Thedevices are very heavy Thus there is a risk of physical damage and accidents
3. Fault memory ER 01 xx 05 Fault type Date Time Parameter memory L PO xx x bar Date Time Tank info 00800 Reflexomat V1 00 Reflexomat with Basic controller 13 05 2014 English 45 7 8 Starting Automatic mode Automatic operation can be set after initial commissioning Start the automatic mode at the operator panel of the controller The following prerequisites must be met for automatic operation The device is filled with compressed air and water All required parameters are defined in the controller Press Auto for automatic mode at the controller operator panel The Auto LED at the operator panel illuminates to visually signal automatic mode Notice Initial commissioning is completed and the device is in continuous operation 46 English Reflexomat with Basic controller 13 05 2014 8 Operation 8 1 Operating modes 8 1 1 Automatic mode After successful commissioning start the Automatic mode from the device The Automatic mode is suitable for continuous device operation and the controller monitors the following functions Maintain pressure Compensate expansion volume e Automatic make up To start automatic operation press Auto at the controller operator panel The CO compressor and the PV1 solenoid valve are regulated by the controller so that the pressure remains constant at
4. Po Pst Pp 0 2 bar Enter the calculated value in the start routine of the controller see chapter 7 4 Modifying the controller s start routine on page 39 Pst hst 10 hs 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 height 18 m run on temperature 70 C safety temperature 100 C Calculation example Po Pst Pp 0 2 bar Pst h 10 P4718 m 10 P4 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 Reflexomat with Basic controller 13 05 2014 English 37 73 Controller 7 3 1 Operator panel 9 8 765 1 Error LED 7 Back to the previous menu The LED illuminates red during a fault alarm 2 Display 8 Auto For continuous operation 3 Auto LED 9 Forward to the next menu The LED illuminates green during automatic operation TheLED flashes green during manual operation The LED is not illuminated when the system is stopped 4 Stop 10 Menu For commissioning and entry of new values in the Call up the Customer menu controller 5 OK 11 Quit e Confirm actions Acknowledge mes
5. Riskof burning from escaping medium Maintain sufficient distance from the escaping medium Wear suitable personal protective equipment safety gloves and goggles for example Danger Electric shock Serious injury or death due to electric shock Anysystem 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 Themaintenance intervals depend on the operating conditions and the degassing times The annual maintenance is displayed upon expiry of the set operating time Use Quit to acknowledge the Maintenance recommended message Reset the maintenance counter in the Customer menu D Notice Maintenance work must be carried out and confirmed by specialist personnel or the Reflex Customer Service see chapter 9 4 Maintenance certificate on page 58 9 1 Maintenance schedule The maintenance schedule is a summary of maintenance tasks to be carried out regularly Maintenance task Conditions Interval A Check WE Service e Clean Check for leaks CO compressor A E Annually Screw connections of the compressed air connections Check switching points CO compressor cut in pressure Ex A Insuffi
6. 2 We hereby confirm that the control cabinets meet the essential requirements of the Low voltage Directive 2006 95 EC 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 equipment Applied assessment of conformity procedure according to the Pressure Equipment Directive 97 23 EU of the European Parliament and the Council of 29 May 1997 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
7. 36 7 1 Checking the requirements for COMMISSIONING sscsesccseecsseecsseccsecesseccssecsuccsseccssecsuccssecsssecssecesscesusecssecsuseesseecusecsueeesseessseesees 36 7 2 Determining the Po minimum operating pressure for the controller seeeseenssenzznnnnzanzznnnzzanaznanzzznanzanaznanznnazannzanazzznna 37 7 3 Controller i sie f a ta ti 38 7 3 1 Operator panel ics a eee e Ire Me PRENDAS OEE SEEN DERE esie PROP REN ERE RR EUER 38 7 4 Modifying the controller s start routine seessssecsssscsseccssccsseecssecsssccsseccnscesuccsscccuscesssccssecsuscesscesssecsuceesseesusecsueceueesuseesseesueersseeste 39 75 Tank venting tertie eet teinte urere rette lente rt tv ee tee 41 7 6 Filling the tanks with water ara REPRE tat ENQUIRIES DR RR EROR 41 7 7 Parametrising the controller in the Customer MENU escsesssseecseccsescsscccssecsuecssecsssecsscccsscesssecsscesuseesscesusecsuecesseesuseesseeeneerseeeste 42 7 8 Starting Automatic mode eet RI EORR IRR EBENSO EIER RB DOR 46 Reflexomat with Basic controller 13 05 2014 English 3 8 Operation M 47 8 1 SERIEM IPES E iu 47 8 1 1 Automatic Mode eU 47 8 1 2 Manual m de e fuq 47 8 1 3 SCOP TMOG M 48 8 2 Controller M een 48 8 2 1 Customer MENU
8. Useonly lifting gear suitable for transport and installation 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 PPP P rit Reflexomat with Basic controller 13 05 2014 English 19 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 ofthe 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 pLl gt DN 15 Conditions for the device installation No access by unauthorised personnel Frost free well ventilated room Room temperature 0 C to 45 C Level stable flooring Ensuresufficient 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 dewatering 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 Electric connection 230 V 50 Hz 16 A with upstream E
9. Article No 8652205 8652305 8652505 8652605 8652705 Diameter D 1200 mm 1200 mm 1500 mm 1500 mm 1500 mm Height H 2025 mm 2480mm 2480mm 3065mm 3590 mm Height h 185 mm 185 mm 220mm 220 mm 220 mm Height h1 305 mm 305 mm 334mm 334mm 334mm Height Hg Weight 465 kg 565 kg 795 kg 1080 kg 1115 kg Connection DN65 DN65 DN65 DN65 DN65 Height including control unit on tank Reflexomat with Basic controller 13 05 2014 English 17 10 bar type 350 500 750 1000 1500 2000 3000 Primary tank Article No 8654000 8654100 8654200 8651005 8651205 8651305 8651505 Secondary tank Article No 8654300 8654400 8654500 8653005 8653205 8653305 8653505 Diameter D 750 mm 750 mm 750 mm 1000 mm 1200 mm 1200 mm 1500 mm Height H 1340 mm 1600mm 2185mm 2065mm 2055mm 2515mm 2520 mm Height h 190 mm 190 mm 180 mm 165 mm 165 mm 165 mm 195 mm Height h1 190 mm 190 mm 180 mm 285 mm 285 mm 285 mm 310mm Height Hg Weight 230 kg 275 kg 345 kg 580 kg 800 kg 960 kg 1425 kg Connection in inches R1 R1 R1 R1 R1 R1 DN65 10 bar type 4000 5000 Primary tank Article No 8651605 8651705 Secondary tank Article No 8653605 8653705 Diameter D 1500 mm 1500 mm Height H 3100mm 3630 mm Height h 195 mm 195 mm Height h1 310mm 310mm Height Hg Weight 1950 kg 2035 kg Connection in inches DN65 DN65
10. diaphragms are pressurised to this level and the water side in the tanks is vented Close the discharge ports of all tanks after the compressor has automatically shut down gt Notice Inspect all compressed air connections between the control unit and the tanks for leaks Subsequently slowly open all cap valves at the tanks to create the water side connection to the facility system 7 6 Filling the tanks with water Prerequisite for fault free filling is a make up pressure at least 1 3 bar above the set minimum pressure Po Without automatic make up Use the discharge ports or the facility system to manually fill the individual tank to approximately 30 96 of the tank volume see chapter 6 4 Make up and degassing variants on page 28 With automatic make up Thetanks are automatically filled to approximately 12 96 of the tank volume see chapter 6 4 Make up and degassing variants on page 28 Reflexomat with Basic controller 13 05 2014 English 41 77 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 Noticel Operation description see chapter 7 3 1 Operator panel on page 38 All grey marked menu items must be reviewed during commissioning Press Manual to switch to manual operation Press Menu to display the first main menu
11. operating pressure Maximum pressure Po 3 bar Differential pressured added to the Po minimum operating pressure Filling levels Insufficient water ON 5 Insufficient water OFF 12 Solenoid valve in overflow line CLOSED 90 Reflexomat with Basic controller 13 05 2014 English 49 8 24 Messages The display provides alarms in plain text and the ER codes shown in the list Use the arrow buttons to scroll through multiple alarms displayed at the same time see chapter 7 3 1 Operator panel on page 38 The fault memory stores the last 20 alarms for review see chapter 7 7 Parametrising the controller in the Customer menu on page 42 Alarm causes can be eliminated by the operator or a specialist workshop If this is not possible contact the Reflex Customer Service Notice When the cause for the alarm is eliminated you must acknowledge the fault with Quit at the controller s operator panel All other alarms are automatically reset as soon as the cause has been eliminated Notice Floating contacts setting in the Customer menu see chapter 7 7 Parametrising the controller in the Customer menu on page 42 ER Code Alarm Floating Causes Remedy Alarm reset contact 01 Minimum pressure YES Set value not reached Check set value in the Quit Water loss in the Customer or Service menu system Check water level Compressor fault Check com
12. 10 Disassembly Danger Electric shock 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 A 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 AN Caution risk of burning Excessive surface temperatures in heating systems can cause skin to burn Waituntil surfaces have cooled down or wear protective gloves The operator is required to attach corresponding warning notes in the device vicinity X 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 Ensurethatthe 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 u
13. 2 i uS al EA e p casanuusnaunnaccosasouccsuuss E S A 12 4 4 iai EY 13 4 5 SCOpe OF CELIVERY cafes e H 14 4 6 Optional equipment and accessories sssssscssssssessecssscssssssesssccssccsscsscssscssecessssuccssccssceusssscssscesscessssucssscesscescesscssscesscesecsuceseeeseessees 14 5 Technical data i a ia a Beretta aas dicU A RS erp DR ub dba dis o Ua 15 6 Installation ses ee cet 6 1 Installation conditions 6 1 1 INCOMING INSPECHON 2 SAB se 20 6 2 Preparatorv work erde 20 6 3 S LENTO e RD 21 6 3 1 RSE le 1 ges i sasvsnccouteosscasssescoetesvsesdesbavend cooucens cesscnsservenuecdasvoncdostenusdaayescsdsesovesassbavend ccouseucstauonssevsrunssavebescey 22 6 3 2 Tank installation M 23 6 3 3 Connection to the facility SySteM seesssescssescssccseccsseccsecsseecsscccuscesscecssecsusecssecsusecsucecssccsucecsseceuseesusecnseesueecsseessseesees 24 6 3 4 Fitting the level sensor een 27 6 4 Make up and degassing U TET 28 6 5 Electrical connection 31 6 5 1 Terminalidi gr m u de 32 6 5 2 D EH camo 34 6 6 Installation and commissioning certificate unsnneenssessennssensssunssennseunssnnnssennsennssennsnunssennssunssnunssennsennssnnnssunnsennssennsnunseenn 35 7 COMMISSIONING e PC
14. Overflow valve not for motor ball valve 11 Pressure analogue input 4 Group message 12 External make up request 5 Optional for second pressure value 13 Make up valve 6 Motor ball valve control connection 14 CO compressor 7 RS 485 interface 15 Mains supply 8 Shielding 32 English Reflexomat with Basic controller 13 05 2014 ain Signal Function Wiring 1 PE 2 N 230 V power supply via mains cable and plug Factory 3 L 4 PE 5N N Compressor for maintaining the pressure Factory 6M1 M1 7 Y2 Overflow solenoid valve 8 N S A Factorv 9 PE e For controlling pressure maintenance in the overflow line 10 Y1 T N 230 V output for make up ser options e Tocontrol a Reflex Fillcontrol for example 12 PE 13 COM 14 NC Group message floating User optional 15 NO 16 Notassigned External make up request 17 Make up 230 V Not used with the Reflexomat da 18 Make up 230 V 19 PE shield A T R Level analogue input Pre wired sensor plug Display at the controller must be attached on 21 Level 18V e Activation of the make up site 22 PE shield Pressure analogue input 23 Pressure signal Display at the controller Factory 24 Pressure 18 V Control of pressure maintenance 25 0 10 V correcting variable 36 0 10V feedback Motor ball valve 37 GND Notused with the
15. Setthe controller to Automatic more than 4 hours mode 20 Max Make up volume Set value exceeded Reset the Make up quantity Quit meter in the Customer menu 21 Maintenance Set value exceeded Perform maintenance and reset Quit recommended the maintenance counter upon completion 24 Softening Set value for soft Replace the softening cartridges Quit water capacity exceeded Time interval for replacement of the softening cartridge exceeded 30 I O module fault UO module defective Contact the Reflex Customer Connection between Service option card and controller faulty e Option card defective 31 EEPROM defective YES EEPROM defective Contact the Reflex Customer Quit Internal calculation Service error 32 Undervoltage YES Supply voltage not Check power supply achieved 33 Adjustment parameter EPROM parameter memory Contact the Reflex Customer faulty defective Service 34 Main board Connecting cable Contact the Reflex Customer communication faulty defective Service Main board defective 35 Digital input voltage Short circuit of input Check the wiring at the digital faulty voltage inputs water meter for example 36 Analogue input voltage Short circuit of input Check the wiring at the analogue faulty voltage inputs pressure level 52 English Reflexomat with Basic controller 13 05 2014 Maintenance 9 Maintenance Caution risk of burning
16. a minimum filling level of 5 96 9 Switch to Stop mode 10 Switch off the main switch Cleaning the tanks If necessary remove condensate from the tanks see chapter 9 3 1 Cleaning the tanks on page 56 54 English Reflexomat with Basic controller 13 05 2014 Activating the device 11 Switch on the main switch 12 Switch to Automatic mode Depending on the filling level and pressure the CO compressor and the automatic make up will be switched on 13 Slowly open the cap valves upstream of the tanks and secure them against unintended closing Checking Insufficient water Off 14 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 8 96 Checking Make up Off 15 If necessary check the make up value displayed at the controller The automatic make up is deactivated at a level display of 12 96 Maintenance is completed Notice If automatic make up is not connected you must manually fill the tanks with water to the recorded filling level P Notice The setting values for pressure maintenance filling levels and make up are provided in the chapter Standard settings see chapter 8 2 3 Default settings on page 49 Reflexomat with Basic controller 13 05 2014 English 55 Maintenance 9 3 Cleaning 9 3 1 Cleaning the tanks Caution risk of injury Maintenance work
17. and emptying for primary tank and the optional secondary tanks If more than one tank is used a collective line to the system is installed Use points with temperatures between 0 C and 70 C to connect to the system This is the return of the generator in heating systems and the flow in refrigeration systems At temperatures below or above 0 C 70 C you must install in line vessels between the system and the Reflexomat Notice For details regarding the switching of Reflexomats or in line vessels and the dimensions of the expansion lines please see the planning documents More information is also provided in the Reflex Planning Guide Reflexomat with Basic controller 13 05 2014 English 25 nst allation 6 3 3 2 Control unit connection The following describes the exemplary installation of the control unit before the primary tank and the connection of two secondary tanks Proceed accordingly for other installation variants 2600 2150 2150 t 0 C 70 C e e N RF Secondary tank PIS Pressure sensor RG Primary tank AC Compressed air line SV Safety valve EC Expansion line PV Overflow solenoid valve The PV overflow solenoid valve the PIS pressure transducer and the corresponding cables are factory installed on the primary tank Run the cable through the assembly pipe on the rear of the primary tank to t
18. can cause injuries if the connections have been installed incorrectly because condensate under pressure can suddenly escape Ensure proper connections for the draining of condensate Wear suitable personal protective equipment safety gloves and safety goggles for example Regularly clean the tanks from condensate The cleaning intervals depend on the local operational conditions Reflexomat RC Tanks with permanently installed diaphragm 1 Record the level value displayed at the controller 2 Press Manual at the operator panel to switch the controller into Manual mode 3 Remove the silencer from the PV overflow solenoid valve 4 Install a suitable hose in the PV overflow solenoid valve to drain condensate 5 Slowly open the PV overflow solenoid valve Manually add water if the pressure in the system drops heavily see chapter 6 4 Make up and degassing variants on page 28 Ifthe PV overflow solenoid valve discharges more than 5 litres of water or condensate you must check the diaphragm for rupture The tank must be replaced if the diaphragm has ruptured Close the PV overflow solenoid valve when the display indicates a 100 level Start the CO compressor to build up pressure Ifyou had to add water during draining the condensate you must monitor the pressure build up At excessive pressure rise drain water from the system accordingly Switch the controller into Automatic mode when the recorded level is
19. displayed at the controller Remove the hose from the PV overflow solenoid valve and re install the silencer 10 Maintenance is completed Reflexomat RS Ranks with replaceable diaphragm 1 Close the cap valves upstream of the tanks 2 Record the level value at the controller display and drain the water from the tanks 3 Switch off the main switch and pull the mains plug 4 Openthe discharge ports at the tanks to drain the condensate If more than 5 litres of water or condensate are discharged you must check the tanks Check the diaphragms for rupture e Check the tank interior walls for corrosion damage Close the tanks discharge ports Insert the mains plug into the power supply and switch on the main switch Open the cap valves upstream of the tanks and secure them against unintended closing Fill water and compressed air into the tanks until the recorded level value is displayed Maintenance is completed Notice Check the installation location of the tanks for sufficient ventilation if the tank interior wall are damaged by corrosion see chapter 6 2 Preparatory work on page 20 56 English Reflexomat with Basic controller 13 05 2014 Maintenance 9 3 2 Cleaning the dirt trap Regularly clean the ST dirt trap The cleaning intervals depend on the local operational conditions Switch to Stop mode 1 Press Stop on the controller s operator panel e Close the ball valves upstream and
20. displayed if YES has been set in the With softening menu option e Manufacturer specification for the replacement interval of the softening cartridges regardless of the calculated soft water capacity The system displays the Softening message Recommended maintenance messages Off Without maintenance recommendation 001 060 Maintenance recommendation in months For the output of messages to the floating contact see chapter 4 6 Optional equipment and accessories on page 14 yes Output of all messages no Output of all messages identified with xxx 05 for example Switch to the Fault memory main menu e Press OK to open the menu Usethe V A buttons to open the sub menu The last 20 alarms are stored with fault type date time and fault code See the chapter Messages for more information about the ER messages Switch to the Parameter memory main menu e Press OK to open the menu Usethe V A buttons to open the sub menu The last 10 entries of the minimum working pressure are stored with date and time The system displays the values for the volume and the diameter of the RG primary tank e Ifyou identify differences to the information provided on the primary tank s nameplate please contact the Reflex Customer Service Information about the software version MM Replacement 18 months Next maintenance 012 months Floating fault contact YES
21. downstream of the ST 1 dirt trap Slowly unscrew the dirt trap insert 2 from the dirt trap in order for the residual pressure to escape from the pipeline segment Pulithemesh 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 Re open the ball valves upstream and downstream of the ST 1 dirt trap Switch to Automatic mode Press Auto on the controller s operator panel 1 ST dirt trap 2 Dirttrap insert Notice Clean all other installed dirt traps in the Reflex Fillset for example Reflexomat with Basic controller 13 05 2014 English 57 9 4 Maintenance certificate All maintenance tasks have been completed according to the Reflex Installation Operating and Maintenance Manual Date Service organisation Signature Remarks 58 English Reflexomat with Basic controller 13 05 2014 9 5 Inspection 9 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 9 5 2 Inspection prior to commissioning In Germany follow the In
22. manual is an important aid for the safe and reliable function of the device The operating manual is intended to Avert dangers to personnel Understand the device e Obtain optimal functioning Early identify and rectify problems Avoid faults caused by improper use Prevent repair costs and downtimes Increase reliability and service life 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 14 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 device 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 t
23. option Customer menu Switch to the next main menu option Customer menu Standard software with various languages Language Adjust the Hour Minute and Second display when each begins to flash Time This time is used for entries in the fault memory Adjust the Day Month and Year display when each begins to flash Date This date is used for entries in the fault memory The controller checks whether the level sensor signal matches the value entered for the 196 1 7 bar RG primary tank in the controller see chapter 7 4 Modifying the controller s start Null balancing routine on page 39 Notice The RG primary tank must be completely empty One of the following messages appears on the display 0 96 0 bar Null balancing concluded successfully Null balancing concluded Confirm with the V button successfully Empty the tank and repeat the process Confirm with OK This message appears when null balancing has failed Select Yes or No on the display 0 96 0 bar Yes The RG primary tank is empty and the device is installed as per the instructions If Cancel null balancing No null balancing is still not possible cancel with Yes Contact your Reflex Customer Service No Check the prerequisites for the commissioning see chapter 7 1 Checking the requirements for commissioning on page 36 The controller s start routine is restarted Confirm
24. tank up to 600 litres and one compact control unit One primary tank from 800 litres and one stand alone control unit LIS pressure pick up for level sensing Optional basic equipment for Reflexomat RS 90 1 4 6 Secondary tanks with flexible connection sets for the connection to the primary tank Optional equipment and accessories For make up with water Make up without pump Solenoid valve with ball valve and Reflex Fillset for make up with potable water Make up with pump e Reflex Fillcontrol Auto with integrated pump and a system separation vessel For water make up and degassing Reflex Servitec 30 25 Reflex Servitec 35 95 Reflex Fillset for make up with water With integrated system separator water meter dirt trap and locking mechanisms for the WC make up line Reflex Fillset Impulse with FOIRA contact water meter for make up with water Reflex Fillsoft for softening the make up water from the public water network Reflex Fillsoft is installed between Reflex 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 Lonworks e Profibus DP Ethernet Optional diaphragm rupture indicator only for Reflexomat RS 90 1 Notice Separate opera
25. the selection of Yes or No with OK 42 English Reflexomat with Basic controller 13 05 2014 Enter the value for the minimum operating pressure gt Notice Calculation of minimum operating pressure see chapter 7 2 Determining the Po minimum operating pressure for the controller on page 37 Switch to the Make up main menu Press OK to open the menu Use the V A buttons to open the sub menu If the water content is below the specified tank size add water see chapter 7 4 Modifying the controller s start routine on page 39 e Ifan automatic make up device Fillcontrol for example is installed make up will be actuated automatically otherwise the make up must be manually activated Terminate the water make up when the specified tank size is exceeded If an automatic make up device is installed make up will be shut off automatically otherwise the make up must be manually deactivated Ifyou have selected No for automatic make up the system will not return any further queries about the make up Pre selected time for a make up cycle Upon expiry of this set time the system interrupts the make up and returns the Make up time fault message If the set number of make up cycles is exceeded within two hours the system interrupts the make up and returns the Make up cycles fault message yes FQIRA contact water meter is installed see chapter 9 3 2 Cleaning the dirt trap on page 57 This
26. 2007 or AD 2000 according to vessel nameplate Pressure equipment Assembly Article 3 Para 2 2 comprising Vessel Article 3 Para 1 1 a 2 dash Annex Il diagram 2 with Accessories Article 3 Para 1 4 Complete diaphragm system connection and safety valve air side and possibly Accessories Article 3 Para 1 4 Control unit 62 English Reflexomat with Basic controller 13 05 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 ofthe Directive 97 23 EC Certificate number of the EC Type Examination Reflexomat Compact RC Tank size 0200 0800 litres 04 202 1 450 04 01952 Reflexomat RS Tank size 0200 0800 litres 04 202 1 932 01 00077 Tank size 1000 5000 litres 04 202 1 450 02 00714 Tank size 0350 5000 litres 04 202 1 450 02 00039 Tank size 1000 5000 litres 04 202 1 450 02 00715 Certificate No QA system Module D 07 202 1403 Z 0250 12 D0045 Notified body for the assessment of the QA system T V 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 5
27. 88 E mail infoGreflex 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 Reflexomat with Basic controller 13 05 2014 English 63 11 3 Certificate No ofthe design type examination Type 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 114 Guarantee The respective statutory guarantee regulations apply 11 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 fil
28. Fillsoft LIS Level sensor 4 Reflex Fillset Impulse EC Expansion line The Reflex Servitec degassing and make up station degasses the water from the facility system and the make up water The automatic water make up for the facility system is controlled by the pressure maintenance system Reflex Fillsoft additionally softens the make up water Reflex Servitec degassing and make up station see chapter 4 6 Optional equipment and accessories on page 14 Reflex Fillsoft softening systems and Reflex Fillset Impulse see chapter 4 6 Optional equipment and accessories on page 14 S Notice When using Reflex Fillsoft softening systems always install the Reflex Fillset Impulse Thecontroller evaluates the make up quantities and signals a required replacement of the softening cartridges 30 English Reflexomat with Basic controller 13 05 2014 Installation 6 5 Electrical connection Danger Electric shock 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 eve
29. GB Thinking solutions Reflexomat with Basic controller Reflexomat RS 90 1 Reflexomat Compact RC Operating manual Original operating manual 1 Notes on the operating manuall c cssscsssccssscssecssscsssssssscssscsnscsssccssccssecsusscnsccssscenscsusscasecsnscsusccusccasccsuscensccusccssscssssessccsncesssesees 5 2 Liability E ETIAM ray 5 3 ETIN PNE I M 6 3 1 ISO EDITO EIU M 6 3 1 1 Symbols and rotes used eter teet itte nenne cebasutevevcaivenss cobvonssigoreebaosse 6 3 1 2 Safety symbols used s irte rte eode eee eoe ede caseo e oe ede pen 6 3 2 Personnel requirements eere ei near dp pas POUR aa 7 3 3 Personal protective CQUIPMEN c secssssssscssecssessscsscssscssscssessscsssscssesusssscssscssscsussssscssccuscsssssscssscesscssssssscasccusecscesscesscesscsusssscesscenessees 7 3 4 intended Use 3 33 7 3 5 Inadmissible operating conditions eese tenerent rennen AI nenen 7 3 6 Residual TiS 8 4 Description of the device 4 1 Meis 4 2 OVELVIEWE MH 0 10 4 2 1 Reflexomiat COMpact RC gesessen lernen 10 4 2 2 Reflexomat RS 90 A us cs ate e e NER RR BRENNEN ndn 11 4 3 Identification zu een rar see 12 4 3 1 Namieplate ES 12 4 3
30. LCB 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 20 English Reflexomat with Basic controller 13 05 2014 6 3 Execution Attention Damage caused by improper installation to the device Ensure a stress free installation of the pipe connections between the device and the overall system For installation proceed as follows Position the device Complete the primary tank and the optional secondary tanks Create the water side connections of the control unit to the system Create the interfaces according to the terminal plan Install the water connections between optional secondary tanks to each other and to the primary tank Notice For installation note the operability of the valves and the inlet options of the connecting lines Remember that the connection of pipelines or equipment originating with the system may cause additional stresses Reflexomat with Basic controller 13 05 2014 English 21 Installation 6 3 1 Positioning Determine the device position e Control unit Primary tank Optional secondary tank The control unit can be installed on either side or in front ofthe primary tank The distance of the control unit to the primary tank results from the connection set supplied l I i 1 Notice Connecting secondary tanks is not poss
31. 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 37 Next maintenance 12 months Time left to the next due maintenance Floating alarm contact YES see chapter 8 2 4 Messages on page 50 Make up Make up ON 8 96 Make up OFF 12 96 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 30 minutes Maximum make up cycles 6 cycles within 2 hours 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 Service menu Parameter Setting Remarks Maintain pressure Compressor ON Po 0 3 bar Differential pressured added to the Po minimum operating pressure Compressor OFF Po 0 4 bar Differential pressured added to the Po minimum operating pressure Compressor run time exceeded message 240 minutes The message is displayed after the compressor runs for 240 minutes Overflow line CLOSED Po 0 4 bar Differential pressured added to the Po minimum operating pressure Overflow line OPEN Po 0 5 bar Differential pressured added to the Po minimum
32. Reflexomat 28 24 V supply 29 A 30 B RS 485 interface User optional 31 GND 32 24 V supply E1 Supply for E1 and E2 Factory E1 Contact water meter in Fillset for example see chapter 4 6 Optional equipment and accessories on page 14 39 i STORA the make up nm User optional If contact 32 33 is closed meter pulse E2 Insufficient water switch 34 Notused with the Reflexomat fcontact 32 34 is closed OK Reflexomat with Basic controller 13 05 2014 English 33 6 5 2 RS 485 interface Use this interface to retrieve all controller data and to enable the communication with control centres or other devices The following data can be requested Pressure and level Compressor operating states Operating states of the ball valve in the overflow line Operating states of make up via solenoid valve Cumulated quantity of the FQIRA contact water meter All messages see chapter 8 2 4 Messages on page 50 All entries in the fault memory gt Notice If required please contact the Reflex Customer Service for the protocol of the RS 485 interface details of the connections and information about the accessories offered 6 5 2 1 Connecting the RS 485 interface Use a shielded cable to connect the interface to terminals 29 30 31 of the main board in the control cabinet For connecting the interface see chapter 6 5 Electrical connection on page 31 When using th
33. a regulation range of 0 1 bar Faults are displayed and evaluated 8 1 2 Manual mode The manual mode is intended for test and service tasks Press Manual on the controller The Auto LED at the operator panel flashes to visually indicate that Manual mode is active Manual mode enables you to select the following functions and to perform a test run CO compressor PV1 overflow solenoid valve The solenoid valve of the WV1 make up You can switch several functions after each other and test them at the same time e Use the Switch up down keys to select the function 3096 2 5 bar COT Compressor co1 PVI WV1 PVT Solenoid valve in the overflow line Units with are selected and active WV1 Make up solenoid valve Press OK Confirm the selection or shut down of the individual functions Quit button Shut down of the individual functions in reverse order Press Quit for the last time and the system moves in Stop mode e Auto button Return to Automatic mode gt Notice Manual operation can not be performed if safety relevant parameters are exceeded Switching is blocked if safety relevant parameters are exceeded Reflexomat with Basic controller 13 05 2014 English 47 8 1 3 Stop mode The Stop mode is intended for the device commissioning Press Stop on the controller The Auto LED at the operator panel extinguishes Except for the displ
34. ables or pipes during installation Wear personal protective equipment helmet protective clothing gloves safety boots Ensure proper installation of cables and pipes between the control unit and the tanks 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 Ensurea stress free installation of the pipe connections between the device and the overall system Attention Equipment damage Damages to the cables and pipes between the tanks and the control unit Properly install the cables and pipes over the flooring 24 English Reflexomat with Basic controller 13 05 2014 Installation 6 3 3 1 Water side connection The following describes the exemplary installation of the control unit before the primary tank and the connection of two secondary tanks Proceed accordingly for other installation variants 2600 2150 2150 t 0 C 70 C e e N RF Secondary tank PIS Pressure sensor RG Primary tank AC Compressed air line SV Safety valve EC Expansion line PV Overflow solenoid valve To ensure the proper function of the LIS level sensor you must use the supplied hose to flexibly connect the primary tank to the system The EC expansion line provides secure locking
35. age 23 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 A Avoid shock stresses by a subsequent alignment of the vessel for example Useflexible hoses to connect the primary tank and if provided the first secondary tank Useonly the supplied connection sets Perform a null balancing of the filling level when the primary tank is aligned and fully emptied see chapter 7 7 Parametrising the controller in the Customer menu on page 42 Standard values for level measurements Primary tank Measuring range 2001 0 4 bar 300 5001 0 10 bar 600 10001 0 25 bar 1500 20001 0 60 bar 3000 50001 0 100 bar Reflexomat with Basic controller 13 05 2014 English 27 64 Make up and degassing variants The filling level is recorded in the RG 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 external make up is activated Make up without pump Reflexomat C
36. ake up water The Reflexomat is offered in two variants Reflexomat Compact RC One RG primary tank as expansion tank with up to 600 litres nominal volume Thecompact control unit is factory installed on the primary tank Allelectric and air connections between control unit and expansion tank are pre installed Reflexomat RS 90 1 One RG primary tank as expansion tank with up to 600 litres nominal volume TheRS90 1 compact control unit is factorv installed on the primary tank Allelectric and air connections between control unit and expansion tank are pre installed RG primary tank with a nominal volume from 800 litres The RS 90 1 control unit as stand alone console Theconnection of RF secondary tanks to the primary tank is optionally possible Notice It is not possible to connect secondary tanks to the Reflexomat Compact RC Reflexomat with Basic controller 13 05 2014 English 9 Description of the device 42 Overview 4 2 1 Reflexomat Compact RC 1 SV safety valve LIS level sensor 2 RC control unit Compressor e Reflex Control Basic controller EC expansion line 3 RG primary tank 10 English Reflexomat with Basic controller 13 05 2014 Description of the device 4 2 2 Reflexomat RS 90 1 6 5 Reflexomat RS 90 1 in compact design 4 5 6 Reflexomat RS 90 1 with stand alon
37. ay of information the device is non functional in Stop mode Function monitoring is stopped The following functions are deactivated The CO compressor shut off in Stop mode Thesolenoid valve in the PV overflow line closed in Stop mode Thesolenoid valve in the WV make up line closed in Stop mode 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 2 Controller 82 1 Customer menu Use the Customer menu to set the device controller during commissioning You can then correct or retrieve system specific values during operation see chapter 7 7 Parametrising the controller in the Customer menu on page 42 82 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 8 2 3 Default settings on page 49 48 English Reflexomat with Basic controller 13 05 2014 8 2 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
38. cient water e Make up with water Clean ST dirt trap A u Depending on the operating seechapter 9 3 2 Cleaning the dirt trap on page 57 conditions Annually Remove condensate from the primary tank and the secondary tanks if applicable A E e Annually seechapter 9 3 1 Cleaning the tanks on page 56 Reflexomat with Basic controller 13 05 2014 English 53 9 2 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 37 Level sensor at the primary tank Preparation 1 Switch to Automatic mode 2 Closethe cap valves upstream of the tanks 3 Record the displayed filling level value in 90 4 Drainthe water from the tanks Checking the cut in pressure 5 Checkthe cut in and cut out pressure of the CO compressor Thecompressor cuts in at Po 0 3 bar Thecompressor cuts out at Po 0 4 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 8 96 Checking Insufficient water On 7 Switch off the make up and continue to drain water from the tanks 8 Checkthe displayed value for the Insufficient water filling level message Insufficient water On is displayed at the controller at
39. dustrial Safety Regulation Betriebssicherheitsverordnung Section 14 and Section 14 3 No 6 in particular 9 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 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 Reflexomat with Basic controller 13 05 2014 English 59 Disassembly
40. e air pressure set at the controller is exceeded the PV overflow solenoid valve opens and discharges air from the primary tank This allows water to flow into the primary tank and the water pressure within the system drops The water pressure in the system drops when the water cools When the air pressure drops below the set value the CO compressor cuts in and delivers air into the primary tank displacing the water in the primary tank The water pressure in the system rises Make up The addition of more water is controlled within the controller When the water level falls below the minimum in the primary tank the LIS pressure pick up sends a signal to the controller The controller actuates an external make up device Water is directly added into the system in a controlled manner by monitoring the make up time and the make up cycles Notice For optional equipment for water make up see chapter 4 6 Optional equipment and accessories on page 14 Reflexomat with Basic controller 13 05 2014 English 13 4 5 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 Reflexomat Compact RC One primary tank and one compact control unit Reflexomat RS 90 1 One primary
41. e console 1 SV safety valve RG primary tank 2 RS 90 1 control unit Compressor e Reflex Control Basic controller LIS level sensor 3 RF secondary tank optional EC expansion line Reflexomat with Basic controller 13 05 2014 English 11 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 A A min operating pressure set up on shop floor Factory set minimum operating pressure at site Set minimum operating pressure max pressure saftey valve factory aline Factory set opening pressure of the safety valve at site Set opening pressure of the safety valve 4 3 2 Type code No Reflexomat Compact RC type key RC control unit 2 Primary tank nominal volume Reflexomat RC 500 12 No Reflexomat RS 90 1 type key 1 Control unit designation 2 Number of co
42. e device with a control centre not supporting an RS 485 interface RS 232 for example you must use a corresponding adapter gt Noticel Eor connecting the interface use only a cable with these properties LJYCY TP 4 x 2 x 0 8 maximum overall bus length 1000 m 34 English Reflexomat with Basic controller 13 05 2014 6 6 Installation and commissioning 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 9 4 Maintenance certificate on page 58 For the installation Place date Company Signature For the commissioning Place date Company Signature Reflexomat with Basic controller 13 05 2014 English 35 7 Commissioning gt Notice The proper installation and commissioning must be confirmed in the installation commissioning and maintenance certificate This certificate is prerequisite for any warranty claim Havethe Reflex Customer Service carry out commissioning and the annual maintenance 7 1 Checking the requirements for commissioning The device is ready for commissioning when th
43. e protection safety boots helmet protective clothing protective gloves 000000 See the national regulation of your country for personal protective equipment required 3 4 Intended use The device is a pressure maintaining station for heating and cooling water systems It is intended to maintain the water pressure and to add water within a system The devices may be used only in systems that are sealed against corrosion and with the following water types Non corrosive Chemically non aggressive 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 ln mobile system operation Foroutdoors operation e Eor the use with mineral oils e Eor the use with flammable media e Eor the use with distilled water Notice Changes to the hydraulic system or interference with the interconnection are strictly prohibited Reflexomat with Basic controller 13 05 2014 English 7 Safety 3 6 Residual risks This device has been manufactured to the current state of the art However some residual risk cannot be excluded AN t Caution risk of burning Excessive surface temperatures in heating systems can cause skin to burn Wait until surfaces have cooled down or wear protective
44. e 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 facility system is filled with water and gas vented The electrical connection has been created according to applicable national and local regulations 36 English Reflexomat with Basic controller 13 05 2014 72 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 CO controller from the Po minimum operating pressure Actuating pressure for the Ps safety valve 20 5 bar Overflow valve OPEN final pressure Pe 1 berstr mventil AUF 0 1 bar berstr mventil ZU Kompressor AUS 0 1 bar Compressor ON initial pressure P 1 Kompressor EIN 0 3 bar Overflow valve CLOSED Compressor OFF Minimum operating pressure Po 0 0 2 bar Static pressure P og oaa aaa The Po minimum operating pressure is calculated as follows
45. er Service see chapter 8 2 1 Customer menu on page 48 no The start routine restarts Check the prerequisites for the commissioning see chapter 11 1 Reflex Customer Service on page 61 This message appears on the display only after null balancing has been successful Terminate routine Select Yes or No on the controller display and confirm with OK on the controller No operator panel yes The start routine is terminated the device automatically switches to Stop mode no The start routine restarts The level indication is at O 96 0 96 2 0 bar STOP Notice After successful conclusion of the start routine you are in Stop mode see chapter 7 1 Checking the requirements for commissioning on page 36 40 English Reflexomat with Basic controller 13 05 2014 Commissioning 7 5 Tank venting Caution risk of burning Excessive surface temperatures at the compressor can cause skin to burn Wear suitable personal protective equipment safety gloves for example Upon completion of the start routine you must vent the primary tank and the secondary tanks if applicable Open the tanks discharge ports to permit the air to escape Select Automatic mode on the controller s operator panel see chapter 8 1 1 Automatic mode on page 47 The CO compressor builds up the pressure required venting This pressure is 0 4 bar above the set minimum operating pressure The tanks
46. g display items for Day Month and Year to the current date The date of an alarm will be stored in the fault memory Select the size of the primary tank e Eor the primary tank data see the name plate or see chapter 5 Technical data on page 15 Reflexomat Language Read the operating manual Min op pressure Time Date 005001 740 mm GB 0093 kg Reflexomat with Basic controller 13 05 2014 English 39 Null balancing of the level sensor 196 1 7 bar Thecontroller checks whether the level measuring signal matches the dimensional Null balancing data of the primary tank The primary tank must be fully emptied see dg ref source inline Montage Niveaumessung dg ref source inline Upon successful conclusion of the null balancing confirm with OK on the controller 0 96 1 0 bar operator panel Null balancing concluded successfully Select Yes or No on the controller display and confirm with OK on the controller Cancel null balancing operator panel No yes The primary tank is fully emptied and the device is installed as per the instructions Ifnull balancing is still not possible confirm with Yes The start routine is terminated Use the customer menu to repeat the null balancing see chapter 6 3 4 Fitting the level sensor on page 27 Subsequently contact your Reflex Custom
47. gloves The operator is required to attach corresponding warning notes in the device vicinity AE 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 Thedevices are very heavy Thus there is a risk of physical damage and accidents Use only lifting gear suitable for transport and installation 8 English Reflexomat with Basic controller 13 05 2014 4 Description of the device 4 1 Description The Reflexomat is a compressor controlled pressure maintaining station for heating and cooling water systems The Reflexomat essentially comprises a controller and at least one expansion tank The additional connection of secondary tanks is optionally possible The expansion tank is fitted with a diaphragm to divide the tank into an air space and a water space preventing the ingress of atmospheric oxygen into the expansion tank The Reflexomat provides the following safety features e Optimisation of pressure maintenance and make up Nodirect intake of air thanks to a regulation of the pressure maintenance and optional automatic make up Nocirculation issues caused by free bubbles in the circuit water Reduced corrosion damage due to oxygen removal from m
48. he control unit Cables are factory installed in compact models Subsequently install the level sensor at the primary tank see chapter 6 3 4 Fitting the level sensor on page 27 Attach the cable to the LIS pressure pick up of the level sensor and run the cable to the control unit For compact models run the cable through the assembly pipe on the rear of the primary tank if it has not been factory installed The flexible compressed air hose is connected with the control unit Run the compressed air hose through the assembly pipe as well Ifyou install only the primary tank you must connect the compressed air hose directly to the AC compressed air connection ofthe primary tank Ifyou install secondary tanks you install first the supplied distributor at the compressed air connection of the primary tank Use the supplied connection sets to connect the secondary tanks 26 English Reflexomat with Basic controller 13 05 2014 6 3 4 Fitting the level sensor Attention Equipment damage e 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 2 Tank installation on p
49. ible with the Reflexomat Compact RC 22 English Reflexomat with Basic controller 13 05 2014 Installation 6 3 2 Tank installation 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 Comply with the following notes regarding the installation of the primary tank and the secondary tanks e Lo N All flange openings at the tanks are viewing and maintenance openings Install the primary tank and the 2600 2150 secondary tanks if provided with sufficient spaces at the sides and the top e Install the tanks on a level plane 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 nstall the control unit on the same level as the tanks i iJ E Reflexomat with Basic controller 13 05 2014 English 23 Installation 6 3 3 Connection to the facility system Caution Risk of injury due to falls or stumbling Bruises caused by falls or stumbling over c
50. is the prerequisite for the make up quantity monitoring and the operation of a softening system no A contact water meter is not installed standard model Only displayed if YES has been set in the With water meter menu option Use OK to delete the counter Press YES to reset the value displayed to 0 Press No to retain the displayed value Min op pressure 01 8 bar Make up ON at 08 96 Make up OFF at 12 90 Max make up time 010 min Max make up cycl 003 2h With water meter YES a dn an uda ua Make up quantity 0000201 Reflexomat with Basic controller 13 05 2014 English 43 This value is only displayed if YES has been set in the With water meter menu option When the set quantity is exceeded the system interrupts the make up process and returns the error message Max make up quantity exceeded This value is only displayed if YES has been set in the With water meter menu option yes The system offers more queries regarding the softening process no The system does not offer more queries regarding the softening process This value is only displayed if YES has been set in the With softening menu option yes The system stops the make up process when the set soft water capacity is exceeded no The system does not stop the make up process The system displays
51. led 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 64 English Reflexomat with Basic controller 13 05 2014 Thinking solutions Reflex Winkelmann GmbH Gersteinstra e 19 59227 Ahlen Germany Telephone 49 0 2382 7069 0 Fax 49 0 2382 7069 588 www reflex de 11421en 9125092 04 14
52. mpressors Reflexomat RS 90 1 RG 1000 I RF 1000 3 RG primary tank 1 23 4 5 6 4 Nominal volume 5 RF secondary tank 6 Nominal volume 12 English Reflexomat with Basic controller 13 05 2014 44 Function El ar 2 PS i SV SV PR 1 s d LIS Dad D lt A X lec ENSE CREME EE NU 2 3 4 1 Water make up with Fillcontroll Auto PIS Pressure sensor 2 RS 90 1 control unit SV Safety valve 3 Primary tank as expansion tank PV Overflow solenoid valve 4 Secondary tank as additional expansion tank LIS Pressure pick up WC Make up line EC Expansion line Expansion tanks One primary tank and multiple optional secondary tanks may be connected Diaphragms separate the tanks interiors in an air and a water space preventing the ingress of atmospheric oxygen into the expansion water The primary tank and the LIS level monitoring are connected to the control unit at the air side and to the facility system at the water side The pressure is protected at the air side by the SV safety valves of the tanks Control unit The control unit contains the CO compressor 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 If th
53. n 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 The following descriptions apply to standard systems and are limited to the necessary user provided connections 1 Shutdown the system and secure it against unintentional reactivation 2 Removethe cover 3 Install a screwed cable gland suitable for the respective cable M16 or M20 for example 4 Threadall cables to be connected through the cable gland 5 Connect all cables as shown in the terminal diagram see chapter 6 5 1 Terminal diagram on page 32 Note that the fusing for the device connection is to be provided by the user see chapter 5 Technical data on page 15 When all connections have been made according to the terminal diagram install the cover and connect the the mains cable with the 230 V power supply Reflexomat with Basic controller 13 05 2014 English 31 nstallation 6 5 1 Terminal diagram 1888 1 2 3 4 5 6 7 7 8 9 29 30 31 Y2 N PE Ao Be RS T0 315A T0 315A C C 10 11 12 16 17 18 Yi N PE 1 2 3 4 5 6 PE NUL PE M1 d 15 14 13 12 11 10 9 8 1 L fuse for electronics and solenoid valves 9 Digital inputs Water meter Insufficient water 2 N fuse for solenoid valves 10 Motor ball valve energy connection 3
54. nintended 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 discharge ports at the tanks until water and compressed air are completely removed Undo all hose and pipe connections to the tanks and the control unit of the device to the system and remove them completely If necessary remove the tanks and the control unit from the system area N cU PEE UPC UND n 60 English Reflexomat with Basic controller 13 05 2014 11 Annex 11 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 Reflexomat with Basic controller 13 05 2014 English 61 112 Conformity and standards Declaration of conformity for electrical installations in the pressure maintaining make up or degassing systems 1 We hereby confirm that the products meets the essential protection requirements as established in the Council Directive to approximate the laws of the Member States relating to electromagnetic compatibility 2004 108 EC The following Standards have been applied to assess the products Deutsches Institut f r Normung European Standard 61326 1 2006 10
55. o 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 Failureto perform maintenance and inspection work at due times 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 11 1 Reflex Customer Service on page 61 Reflexomat with Basic controller 13 05 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 operating manual Dangerto life and or severe damage to health Thecorresponding 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 Thec
56. ompact RC with solenoid valve and ball valve to i pade 2 zzj mi l HI u i LIS i Y l 2 1 Reflexomat Compact RC WC Make up line 2 Solenoid valve with ball valve LIS Level sensor 3 Reflex Fillset EC Expansion line ST Dirt trap Preferably you should use the Reflex Fillset with integrated system separator when using drinking water for make up see chapter 4 6 Optional equipment and accessories on page 14 If you 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 28 English Reflexomat with Basic controller 13 05 2014 Installation Make up with pump Reflexomat Compact RC with Reflex Fillcontrol Auto 1 Reflexomat Compact RC ST Dirt trap 2 Fillcontrol Auto EC Expansion line WC Make up line LIS Level sensor Water make up with Fillcontrol Auto is suitable for make up at high system pressures of up to 8 5 bar see chapter 4 6 Optional equipment and accessories on page 14 The ST dirt trap is part of the deliverables Reflexomat with Basic controller 13 05 2014 English 29 Make up with softening and degassing Reflexomat RS 90 1 and Reflex Servitec 1 Reflexomat RS 90 1 with stand alone console ST Dirt trap 2 Reflex Servitec WC Make up line 3 Reflex
57. orresponding warning symbol in combination with the Warning signal term indicates a threatening danger which may result in death or severe irreversible injuries A IET Damage to health Thecorresponding warning symbol in combination with the Caution signal term indicates a danger which may result in minor reversible injuries Attention 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 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 This symbol warns of a hot surface This symbol warns of overpressure in conduits and connections 6 English Reflexomat with Basic controller 13 05 2014 3 2 Personnel requirements Only specialist personnel or specifically trained personnel may install and operate the equipment The electric connections and the wiring ofthe 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 ey
58. pressor Controller in Manual Set the controller to mode Automatic mode 02 1 Insufficient water Set value not reached Check set value in the Make up disabled Customer or Service menu Air in the system Clean the dirt trap Dirt trap clogged Check functioning of the PV1 solenoid valve If necessary manually add water 03 High water YES Set value exceeded Check set value in the Make up disabled Customer or Service menu Water intake through Check functioning of the a leak in a thermal WV1 solenoid valve transfer medium of Drain water from the VG the user tank RG and RG tanks Check user s thermal transfer too small medium for leaks 04 1 Compressor YES Compressor disabled Check set values in the Quit Fuse defective Customer or Service menu Replace the fuse 50 English Reflexomat with Basic controller 13 05 2014 be activated in the Customer menu Set value exceeded Severe water loss in the system Customer or Service menu Check water loss in the system and repair if necessary ER Code Alarm Floating Causes Remedy Alarm reset contact 05 Compressor run time Set value exceeded Check set value in the Severe water loss in Customer or Service menu the system Check the water loss and Air lines leaking correct if necessary Solenoid valve in the Seal any leak in the air overflow line does not System close Check func
59. sages 6 Manual e Eor tests and maintenance tasks Selecting and changing parameters Use OK 5 to select the parameter Use the arrow buttons 7 or 9 to change the parameter value Use OK 5 to confirm the parameter Use the arrow buttons 7 or 9 to change the menu option Use Quit 11 to switch to different menu level 38 English Reflexomat with Basic controller 13 05 2014 74 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 8 2 1 Customer menu on page 48 Notice Plug in the contact plug to provide power 230 V to the controller You are now in Stop mode The Auto LED on the operator panel has extinguished Device name Standard software with various languages Prior to commissioning read the entire operating manual and verify the proper assembly Enter the value for the minimum operating pressure e Calculating the minimum operating pressure see chapter 7 2 Determining the Po minimum operating pressure for the controller on page 37 Change the flashing display items for Hour Minute and Seconds to the current time The time of an alarm will be stored in the fault memory Change the flashin
60. the Softening message This value is only displayed if YES has been set in the With softening menu option Hardness reduction is calculated from the difference of the overall water hardness of the raw water GHacuai and the target water hardness GHrarget Hardness reduction GHactual GHtarget 70H Enter the value in the controller Consult the manufacturer information for third party products This value is only displayed if YES has been set in the With softening menu option The attainable soft water capacity is calculated from the type of softening used and the specified hardness reduction Fillsoft I soft water capacity lt 6000 hardness red Fillsoft Il soft water capacity lt 12000 hardness red Enter the value in the controller Consult the manufacturer information for the values of third party products This value is only displayed if YES has been set in the With softening menu option It indicates the still remaining soft water capacity The soft ware capacity cannot be set and is calculated from the hardness reduction and the soft water capacity Max make up qty 0001001 With softening YES Lock make up YES NEN Hardness reduction 10 dH Eu Cap soft water 05000 Remaining cap soft w 000020 44 English Reflexomat with Basic controller 13 05 2014 This value is only
61. ting instructions are supplied with accessories 14 English Reflexomat with Basic controller 13 05 2014 Technical data 5 Technical data Reflexomat Compact RC Type RC 200 RC 300 RC 400 RC 500 Part No 8806405 8801705 8802805 8803705 Noise level 72 dB 72 dB 72 dB 72 dB Electric output 0 75 kW 0 75 kW 0 75 kW 0 75 kW Voltage 230V 230V 230V 230V Frequency 50 Hz 50 Hz 50 Hz 50 Hz Power Supply Plug Plug Plug Plug Degree of protection IP 54 IP 54 IP 54 IP 54 Diameter 634 mm 634 mm 740 mm 740 mm Height 1320 mm 1620 mm 1620 mm 1845 mm Weight 52 kg 69 kg 80 kg 93 kg Mechanical connection in inches R1 R1 R1 R1 Diaphragm to DIN 4807 T3 Fully installed Fully installed Fully installed Fully installed dl gauge womdng 6 bar 6 bar 6 bar 6 bar Permissible flow temperature 120 C 120 C 120 C 120 C ae 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 Reflexomat with Basic controller 13 05 2014 English 15 Technical data Reflexomat RS 90 1 Reflexomat RS 90 1 in compact design Reflexomat RS 90 1 with stand alone console Control unit Type RS 90 1 in compact design RS 90 1 with stand alone console RG primary tank volume Up to 600 litres From 800 litres Part No 8880111 8880211 Noise level 72dB 72dB Electric o
62. tioning of the PV1 solenoid valve 06 Make up time Set value exceeded Check set value in the Quit Water loss in the Customer or Service menu system Check water level e Make up line not Connect make up line connected e Make up rate insufficient e Make up hysteresis too low 07 Make up cycles Set value exceeded Check set value in the Quit Customer or Service menu Seal any leak in the system 08 Pressure measurement YES Controller receives Connect the plug Quit incorrect signal Check functioning of the pressure sensor Check the cable for damage Check the pressure transducer 09 Level sensor YES Controller receives Check functioning of the oil Quit incorrect signal pick up sensor Check the cable for damage Connect the plug 10 Maximum pressure Set value exceeded Check set value in the Quit Overflow line Customer or Service menu disabled Check functioning of the Dirttrap clogged overflow line Clean the dirt trap 11 Make up quantity With water meter must Check set value in the Quit Reflexomat with Basic controller 13 05 2014 English 51 ER Code Alarm Floating Causes Remedy Alarm reset contact 15 Make up valve Contact water meter Check the make up valve for leaks Quit measures without make up request 16 Power failure No power Connect to power 19 Stop gt 4 hours Device is in Stop modefor
63. utput 0 75 kW 0 75 kW Voltage 230V 230V Frequency 50Hz 50Hz Power Supply Plug with 5 metre cable Plug with 5 metre cable Degree of protection IP 54 IP 54 Width 395 mm 395 mm Depth 520mm 345 mm Height 415 mm 585 mm Weight 21 kg 25 kg Diaphragm to DIN 4807 T3 Exchangeable Exchangeable Permissible gauge working pressure 6 bar 10 bar 6 bar 10 bar Permissible flow temperature 120 C 120 C Permissible operating temperature 70 C 70 C Permissible ambient temperature 0 C 45 C 0 C 45 C 16 English Reflexomat with Basic controller 13 05 2014 Technical data Tanks Primary tank Secondary tank 6 bar type 200 300 400 500 600 800 1000 Primary tank Article No 8799100 8799200 8799300 8799400 8799500 8799600 8650105 Secondary tank Article No 8789100 8789200 8789300 8789400 87894500 87894600 8652005 Diameter D 634 mm 634 mm 740 mm 740 mm 740 mm 740 mm 1000 mm Height H 970 mm 1270 mm 1255 mm 1475 mm 1720mm 2185mm 2025 mm Height h 115 mm 115 mm 100 mm 100 mm 100 mm 100 mm 195 mm Height h1 155 mm 155 mm 140 mm 140 mm 140 mm 140 mm 305 mm Height Hg 1350 mm 1650 mm 1640 mm 1860mm 2110mm Weight 37 kg 54 kg 65 kg 78 kg 94 kg 149 kg 156 kg Connection R1 R1 R1 R1 R1 R1 DN65 6 bar type 1500 2000 3000 4000 5000 Primary tank Article No 8650305 8650405 8650605 8650705 8650805 Secondary tank

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