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Reflex Variomat VS 1, Operating Manual, Page: 2 / 68

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Summary of Contents for Variomat VS 1

Page 1: ...Variomat 1 06 07 2016 Rev B GB Operating manual Original operating manual...

Page 2: ......

Page 3: ...ion 16 6 1 Installation conditions 17 6 1 1 Incoming inspection 17 6 2 Preparatory work 17 6 3 Execution 18 6 3 1 Positioning 18 6 3 2 Installation of add on components for the tanks 19 6 3 3 Tank ins...

Page 4: ...er 50 9 2 1 Service menu 50 9 2 2 Default settings 51 9 3 Messages 52 10 Maintenance 55 10 1 Maintenance schedule 56 10 2 Cleaning the dirt trap 57 10 3 Cleaning the tanks 58 10 4 Checking switching p...

Page 5: ...ling this equipment or performing any other work at the equipment is required to carefully read this manual prior to commencing work and to comply with its instructions The manual is to be provided to...

Page 6: ...ombination 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 com...

Page 7: ...nded 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...

Page 8: ...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 stea...

Page 9: ...into the expansion water The Variomat VS 1 provides the following safety features Optimisation of all pressure maintaining degassing and make up processes No direct intake of air thanks to a regulatio...

Page 10: ...e for continuous operation min max allowable temperature flow temperature TS Minimum maximum permissible temperature TS flow temperature Year built Year of manufacture min operating pressure set up on...

Page 11: ...act water meter DV Degassing valve WC Make up line VE Ventilation The device is a pressurisation station for heating and cooling water systems It is used for maintaining pressure making up and degassi...

Page 12: ...rovided by the MAG expansion tank Degassing Two EC expansion lines are required to degas the system water One line is intended for gas rich water from the system and the other one serves to return the...

Page 13: ...DV degassing valve Reducing sleeve Accessories with BOB pipe for TAZ temperature limiter Fillset for make up with water Fillset with integrated back flow preventer water meter dirt trap and locking m...

Page 14: ...ntrol units Permissible flow temperature Permissible operating temperature Permissible ambient temperature 120 C 70 C 0 C 45 C Type Power output kW Power supply V Hz A Degree of protection Number of R...

Page 15: ...nection inches Height H mm Height h mm 6 bar 200 634 37 G1 1060 146 6 bar 300 634 54 G1 1360 146 6 bar 400 740 65 G1 1345 133 6 bar 500 740 78 G1 1560 133 6 bar 600 740 94 G1 1810 133 6 bar 800 740 14...

Page 16: ...essurised 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...

Page 17: ...g Tighten the screws as necessary Preparing the device installation No access by unauthorised personnel Frost free well ventilated room Room temperature 0 C to 45 C 32 F to 113 F Level stable flooring...

Page 18: ...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 opt...

Page 19: ...mponents proceed as follows 1 Install the Reflex Exvoid 2 at the connection of the corresponding tank 2 Remove the protective cap from the degassing valve 3 Use the compression fitting to install the...

Page 20: ...tor and the pump are not interchanged Ensure correct connection of the pump to the primary tank Comply with the following notes regarding the installation of the primary tank and the secondary tanks A...

Page 21: ...up to 740 mm Connect the connection set 2 and 3 to the two free 1 inch barrel nipples at the tank flange Connect the connection set 4 of the secondary tank to the T joint at the outlet of the tank fl...

Page 22: ...ction of pipes or system equipment Ensure that pipes are connected from the device to the system without stresses being induced If necessary provide support structures for the pipes or equipment Conne...

Page 23: ...ke up line 5 Primary tank MAG Pressure expansion tank 6 Primary tank connection set If required install a diaphragm expansion tank MAG 35 litres Reflex N for example It reduces the switching frequency...

Page 24: ...r dimension Integrate with the V main flow volume of the system Viewed in the system flow direction the gas rich expansion line must be connected upstream of the expansion line transporting the degass...

Page 25: ...ressure exceeds 6 bar Note If you use make up water from the potable water system you may need the Reflex Fillset for the WC make up line see chapter 4 6 Optional equipment and accessories on page 13...

Page 26: ...mber at the vessel base of the primary tank Replace this transport securing device with the pressure load cell In the case of a tank volume of 1000 l 1000 mm or more use the supplied screws to attach...

Page 27: ...Heat generator WC Make up line 2 MAG pressure expansion tank PIS Pressure transducer 3 Primary tank WV Make up solenoid valve 4 Control unit EC Degassing line For gas rich water from the system For de...

Page 28: ...tank ST Dirt trap 4 User supplied make up unit EC Degassing line For gas rich water from the system For degassed water into the system 5 Control unit LIS Level sensor WC Make up line District heating...

Page 29: ...ptional equipment and accessories on page 13 LIS Level sensor Using a softening system for the water make up Always integrate the device in the V main volume flow to ensure degassing the system water...

Page 30: ...source and secure it against unintentional reactivation 2 Remove the cover DANGER Risk of serious injury or death due to electric shock Some parts of the device s circuit board may still carry 230 V...

Page 31: ...Insufficient water 2 N fuse for solenoid valves 10 Motor ball valve energy connection 3 Overflow valve not for motor ball valve 11 Pressure analogue input 4 Group message 12 External make up request 5...

Page 32: ...ctivation of the make up Dry running protection of the pump Factory prepared sensor plug must be inserted on site 20 Level signal 21 Level 18 V 22 PE shield Pressure analogue input Display at the cont...

Page 33: ...LIS level Operating modes of the PU pumps Operating states of the motorised ball valve solenoid valve Values of the FQIRA contact water meter All messages see chapter 9 3 Messages on page 52 All entr...

Page 34: ...as follows 1 Open the housing cover of the Control Basic controller 2 Use a screened cable to connect the RS 485 interface to the main circuit board Terminal 29 A Terminal 30 B Terminal 31 GND 3 Conne...

Page 35: ...in accordance to the instructions provided in the Operating Manual The settings in the controller match the local conditions Note When any factory set values of the device are changed you must enter...

Page 36: ...dary 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 f...

Page 37: ...ler s start routine on page 38 pst pD dp 0 2 bar final pressure maintenance Addition of 0 2 bar recommended no addition in extreme cases Calculation example for P0 minimum operating pressure Heating s...

Page 38: ...r panel has extinguished Device name Variomat Standard software with various languages Language Prior to commissioning read the entire operating manual and verify the proper assembly Read the operatin...

Page 39: ...ill not possible confirm with Yes The start routine is terminated Use the customer menu to repeat the null balancing see chapter 7 6 Parametrising the controller in the Customer menu on page 42 Contac...

Page 40: ...filled with water Connect the water hose to the external water supply and the FD feed and drain cock 1 at the primary tank Check whether the shut off valves between control unit and primary tank are o...

Page 41: ...ng medium Wear suitable personal protective equipment safety gloves and goggles Vent the PU pump as follows Remove the vent screw 2 from the pump 1 and vent the pump until bubble free water escapes Sc...

Page 42: ...flash This date is used for entries in the fault memory Date The controller checks whether the level sensor signal matches the value entered for the VG primary tank in the controller see chapter 7 3 M...

Page 43: ...conditions apply Significant gauge pressure 0 5 bar above atmospheric pressure at the high point Little difference between the maximum temperature at the high point and the degassing temperature Smal...

Page 44: ...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 Max make...

Page 45: ...ed if YES has been set in the With softening menu option Manufacturer specification for the replacement interval of the softening cartridges regardless of the calculated soft water capacity The system...

Page 46: ...000 Information about the software version Variomat mkh V1 00 7 7 Starting Automatic mode The Automatic mode can be started as soon as the system is filled with water and the gases contained have been...

Page 47: ...rmation Continuous degassing Select this programme after commissioning and repairs of the connected system The device will continuously degas for a set period of time Free and dissolved gases are quic...

Page 48: ...Press Quit for the last time and the system moves in Stop mode Auto button Return to Automatic mode 30 2 5 bar PU1 PV1 WV1 Units with are selected and active Notice Manual operation can not be perfor...

Page 49: ...de remains active 8 5 Restarting CAUTION Risk of injury due to pump start up Hand injuries may occur when the pump starts up if you turn the pump motor at the impeller using a screwdriver Switch the p...

Page 50: ...oller 10 Menu Call up the Customer menu 5 OK Confirm actions 11 Quit Acknowledge messages 6 Manual For tests and maintenance tasks Selecting and changing parameters 1 Use OK 5 to select the parameter...

Page 51: ...36 Next maintenance 12 months Time left to the next due maintenance Floating alarm contact All see chapter 9 3 Messages on page 52 Make up Maximum make up quantity 0 Litres Only if make up has been se...

Page 52: ...auses Remedy Alarm reset 01 Minimum pressure YES Set value not reached Water loss in the system Pump fault Controller in Manual mode Check set value in the Customer or Service menu Check water level C...

Page 53: ...e Quit 07 Make up cycles Set value exceeded Check set value in the Customer or Service menu Seal any leak in the system Quit 08 Pressure measurement YES Controller receives incorrect signal Connect th...

Page 54: ...place the softening cartridges Quit 30 I O module fault I O module defective Connection between option card and controller faulty Option card defective Inform Reflex Customer Service 31 EEPROM defecti...

Page 55: ...t 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 wo...

Page 56: ...tream of PU pump Annually Clean ST dirt trap see chapter 10 2 Cleaning the dirt trap on page 57 Depending on the operating conditions Clear sludge from the primary tank and the secondary tanks see cha...

Page 57: ...est An inspection is also required after longer lasting operation Switch to Stop mode Close the ball vales upstream of the ST dirt trap 1 and the primary tank Slowly unscrew the dirt trap insert 2 fro...

Page 58: ...tch to Stop mode 2 Empty the tanks Open the FD feed and drain cocks and empty the tanks completely from water 3 Remove the hose connection between the primary tank and the device and the secondary tan...

Page 59: ...g the cut in pressure 5 Check the cut in and cut out pressure of the PU pump The pump cuts in at P0 0 3 bar The pump cuts out at P0 0 5 bar Checking the Make up On 6 If necessary check the make up val...

Page 60: ...d value for the Insufficient water OFF filling level message Insufficient water Off is displayed at the controller at a minimum filling level of 7 Checking Make up Off 16 If necessary check the make u...

Page 61: ...at 1 06 07 2016 Rev B English 61 10 5 Maintenance certificate All maintenance tasks have been completed according to the Reflex Installation Operating and Maintenance Manual Date Service organisation...

Page 62: ...iance with the Reflex Installation Operation and Maintenance Manual External inspection No requirement according to Annex 2 Section 4 5 8 Internal inspection Maximum interval according to Annex 2 Sect...

Page 63: ...of burns and other injuries at the connection points if pressurised hot water or steam suddenly escapes Ensure proper disassembly Ensure that the system is de pressurised before performing the disasse...

Page 64: ...tral 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 Technical hotline For questions about...

Page 65: ...d by compliance with the following standards regulations Pressure Equipment Directive prEN 13831 2000 or EN 13831 2007 or AD 2000 according to name plate of vessel Pressure equipment Vessel article 4...

Page 66: ...bar 120 C 07 202 1 403 Z 0013 2 D0045 You will find an up to date list under www reflex de zertifikate Type Certificate number Variomat Giga 1000 10 000 litres 6 bar 120 C 07 202 1 403 Z 0008 2 D0045...

Page 67: ......

Page 68: ...SI1418enB 9125062 11 17 Reflex Winkelmann GmbH Gersteinstra e 19 59227 Ahlen Germany Telephone 49 0 2382 7069 0 Fax 49 0 2382 7069 588 www reflex de...

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