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Notes on the operating manual 

 

 

 

Fillcontrol Auto Compact — 20.10.2020 - Rev. D 

 

English  — 3 

 

 

1

 

Notes on the operating manual 

This operating manual is an important aid for ensuring the safe and reliable 
functioning of the device. 
Reflex Winkelmann GmbH accepts no liability for any damage resulting from 
failure to observe the information in this operating manual. In addition to the 
requirements set out in this operating manual, national statutory regulations 
and provisions in the country of installation must also be complied with 
(concerning accident prevention, environment protection, safe and professional 
work practices, etc.). 
This operating manual describes the device with basic equipment and interfaces 
for optional equipment with additional functions. 

 

 

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 product operator and must be stored near the 
product for access at any time. 

 

2

 

Liability and guarantee 

The device has been built according to the state of the art and recognised safety 
rules. Nevertheless, its use can pose a risk to life and limb of personnel or third 
persons as well as cause damage to the system or other property. 
It is not permitted to make any modifications at the device, such as to the 
hydraulic system or the circuitry. 
The manufacturer shall not be liable nor shall any warranty be honoured if the 
cause of any claim results from one or more of the following causes: 
• 

Improper use of the device. 

• 

Unprofessional commissioning, operation, service, maintenance, repair or 
installation of the device. 

• 

Failure to observe the safety information in this operating manual. 

• 

Operation of the device with defective or improperly installed 
safety/protective equipment. 

• 

Failure to perform maintenance and inspection work according to 
schedule. 

• 

Use of unapproved spare parts or accessories. 

 

Prerequisite for any warranty claims is the professional installation and 
commissioning of the device. 

 

 

Note! 
Arrange for Reflex Customer Service to carry out commissioning and 
annual maintenance, see chapter 12.1 "Reflex Customer Service" on 
page 15 . 

 

3

 

Safety 

3.1

 

Explanation of symbols 

3.1.1

 

Symbols and notes used 

The following symbols and signal words are used in this operating manual.  

 

 DANGER 

 

Danger of death and/or serious damage to health 
• 

The sign, in combination with the signal word 'Danger', indicates 
imminent danger; failure to observe the safety information will result 
in death or severe (irreversible) injuries. 

 

 WARNING 

 

Serious damage to health 
• 

The sign, in combination with the signal word 'Warning', indicates 
imminent danger; failure to observe the safety information can result 
in death or severe (irreversible) injuries. 

 

 CAUTION 

 

Damage to health 
• 

The sign, in combination with the signal word 'Caution', indicates 
danger; failure to observe the safety information can result in minor 
(reversible) injuries. 

 

ATTENTION 

 

Damage to property 
• 

The sign, in combination with the signal word 'Attention', indicates a 
situation where damage to the product itself or objects within its 
vicinity can occur. 

 

 

 

Note! 
This symbol, in combination with the signal word 'Note', indicates 
useful tips and recommendations for efficient handling of the product. 

 

3.2

 

Personnel requirements 

Assembly, commissioning and maintenance as well as connection of the 
electrical components may only be carried out by knowledgeable and 
appropriately qualified electricians. 
 

3.3

 

Personal protective equipment 

 

 

Use the prescribed personal protective equipment as required (e.g. ear 
protection, eye protection, safety shoes, helmet, protective clothing, protective 
gloves) when working on the system. 
Information on personal protective equipment requirements is set out in the 
relevant national regulations of the respective country of operation. 
 

3.4

 

Intended use 

The device is a pressurisation unit for heating and cooling water systems. It is 
intended to maintain the water pressure and to add water within a system 
circuit. Operation can only take place in system circuits with static pressurisation 
that are sealed against corrosion using 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 minimized 
during operation. 
 

3.5

 

Inadmissible operating conditions 

The device is not suitable for the following applications: 
• 

Mobile system operation. 

• 

Outdoor operation. 

• 

For use with mineral oils. 

• 

For use with flammable media. 

• 

For use with distilled water. 

 

 

Note! 
It is not permitted to make any modifications to the hydraulic system or 
the circuitry. 

 

3.6

 

Residual risks 

This device has been manufactured to the current state of the art. However, 
some residual risk cannot be excluded. 

 

 CAUTION 

 

Risk of burns on hot surfaces 
Hot surfaces in heating systems can cause burns to the skin. 
• 

Wear protective gloves. 

• 

Please place appropriate warning signs in the vicinity of the device. 

 

 CAUTION 

 

Risk of injury due to pressurised liquid 
If installation, removal or maintenance work is not carried out correctly, there 
is a risk of burns and other injuries at the connection points, if pressurised 
hot water or hot steam suddenly escapes. 
• 

Ensure proper installation, removal or maintenance work. 

• 

Ensure that the system is de-pressurised before performing installation, 
removal or maintenance work at the connection points. 

 

 

 

 WARNING 

 

Risk of injury due to heavy weight 
The devices are heavy. Consequently, there is a risk of physical injury and 
accidents. 
• 

Use suitable lifting equipment for transportation and installation. 

 

Summary of Contents for Fillcontrol Auto Compact

Page 1: ...Fillcontrol Auto Compact 20 10 2020 Rev D GB Operating manual Original operating manual ...

Page 2: ...on 6 6 4 Switching and make up variants 7 6 5 Electrical connection 7 6 5 1 Terminal diagram 8 6 5 2 RS 485 interface 8 6 6 Installation and commissioning certificate 8 7 Commissioning 8 7 1 Requirements for initial commissioning 9 7 2 Determining the P0 minimum operating pressure for the controller 9 7 3 Filling the device with water 9 7 4 Parametrising the controller in the Customer menu 9 7 5 F...

Page 3: ...safety information can result in death or severe irreversible injuries CAUTION Damage to health The sign in combination with the signal word Caution indicates danger failure to observe the safety information can result in minor reversible injuries ATTENTION Damage to property The sign in combination with the signal word Attention indicates a situation where damage to the product itself or objects ...

Page 4: ...3 Maximum working pressure in bar 1 2 3 4 4 Function 1 FQIRA contact water meter optional accessory 2 Fillsoft optional accessory 3 Fillcontrol Auto Compact PIS Pressure sensor WC Fresh water make up line to the device LS Signal line for insufficient water switch DC Make up line to the system circuit LIS External signal line from a pressurisation unit The device controller uses the pump to regulat...

Page 5: ...pressure in bar 6 Installation DANGER Risk of serious injury or death due to electric shock If live parts are touched there is risk of life threatening injuries Ensure that the system is voltage free before installing the device Ensure that the system is secured and cannot be reactivated by other persons Ensure that installation work for the electric connection of the device is carried out by an e...

Page 6: ...ation 1 Position the device 2 Create the water side connections of the device to the system Use connections with the same dimensions at the device for all lines 3 If required create the interfaces according to the terminal plan 6 3 1 Fitting the add on components WC Connection of the make up line to the mains separator tank OC Connection of the mains separator tank overflow DC Connection of the ma...

Page 7: ...into the system circuit LIS Level sensor To monitor the filling level in the pressurisation unit WC Make up line to the device ST Dirt trap at the shut off valve of the mains separator tank BT Mains separator tank PU Pump PIS Pressure sensor LS Insufficient water switch DN Nominal diameter of the make up line Water make up to system circuits with a pressurisation unit Pressurisation units are equi...

Page 8: ...ontroller for example Set the controller to Levelcontrol User optional 17 Make up 230 V 18 Make up 230 V 22 PE shield Pressure analogue input For output to the display For make up actuation For the Magcontrol make up variant Factory 23 Pressure signal 24 Pressure 18 V 29 A RS 485 interface User optional 30 B 31 GND 32 24 V supply E1 Supply for E1 and E2 Pre wired bridged 33 E1 Contact water meter ...

Page 9: ...or at the impeller using a screwdriver Switch the pump to a zero volts state before turning the pump at the fan wheel with a screwdriver ATTENTION Device damage due to pump start up Pump damage may occur when the pump starts up if you turn the pump motor at the impeller using a screwdriver Switch the pump to a zero volts state before turning the pump at the fan wheel with a screwdriver Fill water ...

Page 10: ...e up functions 8 1 2 Manual mode Use For testing and maintenance tasks Start Press Manual on the controller The auto LED on the controller operating panel and PU in the display flash as visual indicators of manual operation Functions After starting the manual mode you can manually activate and deactivate the pump Proceed as follows Press OK on the controller s operating panel to activate the pump ...

Page 11: ...en the make up variants Levelcontrol and Magcontrol Magcontrol In system circuits with a diaphragm expansion vessel Levelcontrol in system circuits with a pressurisation unit Min op pressure 01 8 bar The system displays the Minimum working pressure message when you have set the Magcontrol make up variant Enter the value for the minimum operating pressure Note Calculation of minimum operating press...

Page 12: ...ormation about the software version 9 2 1 Customer menu The device controller is shipped with the following default settings Use the Customer menu to adjust these values to local conditions In special cases it is possible to further adjust the values in the Service menu Parameter Setting Comment Language DE Display language Parameter Setting Comment Fillcontrol XX Magcontrol For systems with diaph...

Page 13: ...th Magcontrol Set value for the maximum pressure has been exceeded Safety valve defective Pipe to system has insufficient diameter Check the actuating pressure of the safety valve Replace the safety valve Install new pipe to the system with sufficient diameter Quit 11 Make up volume Only if With water meter is activated in the Customer menu Set value of the water meter has been exceeded Leakage in...

Page 14: ...2 1 Customer menu on page 12 Minimum operating pressure P0 Safety valve pressure PSV x Annually 10 2 Exterior leak test Check the following device components for leaks PU pumps and screw fittings Seal any leaks at the connections or replace the connections if required Seal leaking screw connections or replace if required 10 3 Cleaning the dirt trap Clean the ST dirt trap according to the following...

Page 15: ... dismantling block off all water side connections to the device 2 Disconnect the system from the power supply and secure it against unintended reactivation 3 Disconnect the power cable of the device from the power supply 4 Disconnect and remove all cables from the terminals of the device controller 5 Undo all hose and pipe connections between the device and the system and remove them completely 6 ...

Page 16: ... D EN Installation and commissioning certificate This device has been installed and commissioned in accordance with the instructions provided in the operating manual The settings in the controller match the local conditions Typ Type P0 PSV Fabr Nr Serial No ...

Page 17: ...SI1416enD 11 20 Reflex Winkelmann GmbH Gersteinstraße 19 59227 Ahlen Germany 49 0 2382 7069 0 49 0 2382 7069 9546 www reflex winkelmann com ...

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