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Maintenance 

24 

  English  

Variomat Basic 

 22.07.2020 - Rev.

A

 

ER 

Code 

Alarm 

Floating 

contact 

Causes 

Remedy 

Alarm reset 

21

 

Maintenance 
recommended 

Set value exceeded. 

Perform maintenance and reset the 
maintenance counter upon completion. 

"Quit" 

24

 

Softening 

 

Set value for soft water capacity 
exceeded.

 

Time interval for replacement
of the softening cartridge 
exceeded.

Replace 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 defective 

YES 

 

EEPROM defective.

 

Internal calculation error.

Inform Reflex Customer Service. 

"Quit" 

32

 

Undervoltage 

YES 

Supply voltage not achieved. 

Check power supply. 

33

 

Adjustment parameter 
faulty 

YES 

EEPROM parameter memory 
defective.

Inform Reflex Customer Service. 

34

 

Communication 
Main board faulty 

 

Connecting cable defective.

 

Main board defective.

Inform Reflex Customer Service. 

35

 

Digital input voltage 
faulty 

Short-circuit of input voltage. 

Check the wiring at the digital inputs (water 
meter, for example). 

36

 

Analogue input voltage 
faulty 

Short-circuit of input voltage. 

Check the wiring at the analogue inputs 
(pressure/level). 

37

 

Input voltage 
Ball valve missing 

Short-circuit of input voltage. 

Check wiring of the ball valve. 

11

 

Maintenance 

 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 electrician, and in compliance with 
electrical engineering regulations.

 CAUTION 

Risk of burns 

Escaping hot medium can cause burns. 

 

Maintain a sufficient distance from the escaping medium.

 

Wear suitable personal protective equipment (safety gloves 
and goggles).

 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. 

The device is to be maintained annually.  

 

The maintenance intervals depend on the operating conditions 
and the degassing times.

The annual maintenance is displayed upon expiry of the set operating 
time. Use "Quit" to acknowledge the "Maintenance recommended" 
message. Reset the maintenance counter in the Customer menu. 



Note! 

Arrange for maintenance tasks must be carried out only by 
specialist personnel or Reflex Customer Service. 

11.1

 

Maintenance schedule 

The maintenance schedule is a summary of maintenance tasks to be 
carried out regularly. 

Activity 

Ch
ec

k

W

ai

Clea

n

Interval 

Check for leaks. 

 

"PU" pump.

 

Screw connections.

 

Check valve downstream of "PU" 
pump.

Annually 

Clean "ST" dirt trap. 

 

see chapter 11.1.1 "Cleaning the 
dirt trap" o
n page 25 .

Depending on the 
operating 
conditions 

Clear sludge from the primary tank 
and the secondary tanks. 

 

see chapter 11.1.2 "Cleaning the 
tanks" o
n page 25 .

Depending on the 
operating 
conditions 

Check the make-up switching points. 

 

see chapter 11.2 "Checking
switching points" o
n page 25 .

Annually 

Check the Automatic mode switching 
points. 

 

see chapter 11.2 "Checking
switching points" o
n page 25 .

Annually 

Summary of Contents for Variomat

Page 1: ...Variomat Basic 22 07 2020 Rev C EN Operating Manual Original operating manual ...

Page 2: ... 12 7 3 5 Fitting the thermal insulation 13 7 3 6 Fitting the level sensor 13 7 4 Switching and make up variants 14 7 4 1 Function 14 7 5 Electrical connection 15 7 5 1 Terminal diagram 15 7 5 2 RS 485 interface 16 7 6 Installation and commissioning certificate 16 8 Commissioning 16 8 1 Checking the requirements for commissioning 16 8 2 Variomat switching points 17 8 3 Modifying the controller s s...

Page 3: ...tion 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 combinati...

Page 4: ...gm to divide the tank into an air space and a water space preventing the ingress of atmospheric oxygen 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 regulation of the pressure maintenance with automatic make up No circulation issues caused by free bubbles...

Page 5: ...to the system During the degassing action the PU pump and the PV overflow valve are in operation This transports a gas rich partial flow of the system water V through the de pressurised primary vessel Atmospheric pressure is used to separate the free and dissolved gases and to discharge them through the DV degassing valve The controller ensures the hydraulic equalisation by regulating the stroke o...

Page 6: ...et freely as option Settings to be made by Reflex Customer Service see chapter 13 1 Reflex Customer Service on page 27 5 1 Technical data Housing Plastic housing Width W 340 mm Height H 233 6 mm Depth D 77 mm Weight 2 0 kg Permissible operating temperature 5 C 55 C Permissible storage temperature 40 C 70 C Degree of protection IP IP 64 Power supply 230 V AC 50 60 Hz IEC 38 Fuse primary 0 16 A time...

Page 7: ...r function Terminator settings Jumper Switch Settings I O module Control Basic Jumper J10 Activated X and J11 Deactivated DIP switch 1 Activated X and 2 Deactivated Jumper J3 1 and 2 as well as Activated X 3 and 4 Deactivated Slave function Terminator settings Jumper Switch Settings I O module I O module for expansion Control Basic Jumper J10 Activated X and J11 Deactivated X DIP switch 1 Activate...

Page 8: ...ital inputs and outputs can be set freely as option The setting is carried out by Reflex Customer Service see chapter 13 1 Reflex Customer Service on page 27 Location Signal evaluation Message text Fault memory entry Priority Signal on the input triggers the following action INPUTS 1 N C External temperature monitoring Yes Yes Solenoid valves are closed Solenoid valve 2 in overflow line 1 Solenoid...

Page 9: ... is voltage free Fusing is provided on the I O module s main circuit board 1 Microfuse F1 250 V 0 16 A slow Proceed as follows 1 Disconnect the I O module from the power supply Pull the power plug from the bus module 2 Open the terminal space cover 3 Remove the housing cover 4 Replace the defective fuse 5 Re attach the housing cover 6 Close the terminal space cover 7 Reconnect the power supply for...

Page 10: ...stem components during installation Wear personal protective equipment helmet protective clothing gloves safety boots Note Confirm that installation and start up have been carried out correctly using the installation and commissioning certificate This action is a prerequisite for the making of warranty claims Have the Reflex Customer Service carry out commissioning and the annual maintenance 7 1 I...

Page 11: ...e Install the LIS pressure pick up only after finalising the installation of the primary vessel see chapter 7 3 3 Tank installation on page 11 Note To ensure fault free operation do not seal off the aeration and ventilation 7 3 3 Tank installation ATTENTION Damage due to improper installation Additional device stresses may arise due to the connection of pipes or system equipment Ensure that pipes ...

Page 12: ...skin and eyes Ensure that the blow off line of the safety valve is routed so that injuries are not possible ATTENTION Damage due to improper installation Additional device stresses may arise due to the connection of pipes or system equipment Ensure that pipes are connected from the device to the system without them being stressed or strained If necessary provide support structures for the pipes or...

Page 13: ...ne see chapter 4 6 Optional equipment and accessories on page 5 Reflex make up systems such as Reflex Fillset are designed for make up lines with a flow rate 1 m h 7 3 5 Fitting the thermal insulation Install the optional thermal insulation 2 around the primary tank 1 and close the insulation with the zip fastener Note For heating systems insulate the primary tank and the EC expansion lines agains...

Page 14: ...sed water into the system LIS Level sensor Single boiler system 350 kW water temperature 100 C Connect the Reflex Fillset with integrated system separator upstream when using mains water for make up If you don t connect a Reflex Fillset upstream use an ST dirt trap with a mesh size 0 25 mm for the make up Note The quality of the make up water must comply with the applicable standards such as VDI 2...

Page 15: ...ser provided connections 1 Disconnect the system from the power 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 be live with 230 V even after the device has been physically isolated from the power supply by pulling out of the mains plug Before you remove the co...

Page 16: ...s in the fault memory The following bus modules form part of the optional accessories available for interface communication Note 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 7 5 2 1 Connecting the RS 485 interface Circuit board of the Control Basic controller 1 DIP switch 1 2...

Page 17: ...st activation of the controller and can be run only once Parameter changes or checks are possible after the start routine in the customer menu is exited see chapter 10 2 Configuring settings in the controller on page 22 Note 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 Indication on the display Meanin...

Page 18: ...n the automatic make up device is not yet connected Use a vented water hose filled with water Connect the water hose to the external water supply and the FD feed and drain cock 1 at the primary vessel Check whether the shut off valves between control unit and primary vessel are open supplied pre wired in open position Fill the primary vessel with water until the filling level has been reached 8 4 ...

Page 19: ...ard values during commissioning can be between 12 and 100 hours The default setting is 12 hours Less times for continuous degassing are sufficient when the following 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 Small system volume with low initial ga...

Page 20: ...ss OK to open the menu Use the buttons to open the sub menu ER 01 xx 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 Indication on the display Meaning Parameter memory Switch to the Parameter memory sub menu Press OK to open the menu Use the buttons to open the sub menu P0 xx x bar Date Time The last 10 entr...

Page 21: ...he system moves in Stop mode Auto button Return to Automatic mode Note Manual operations cannot be performed if safety relevant parameters would be exceeded Switching is then disabled 9 3 Stop mode Use During maintenance work on the device Start Press Stop on the controller The Auto LED at the operator panel extinguishes Functions Except for the display of information the device is non functional ...

Page 22: ...e Service menu Customer menu Parameter Setting Comment Language DE Display language Minimum operating pressure P0 1 8 bar see chapter 8 2 Variomat switching points on page 17 Next maintenance 12 months Time left to the next due maintenance Volt free contact All Make up Maximum make up quantity 0 Litres Only if make up has been selected in the customer menu with With water meter Yes Maximum make up...

Page 23: ... necessary Open the cap valve Vent the pump Check functioning of the PV1 solenoid valve 06 Make up time Set value exceeded Water loss in the system Make up line not connected Make up rate insufficient Make up hysteresis too low Check set value in the Customer or Service menu Check water level Connect make up pipe Quit 07 Make up cycles Set value exceeded Check set value in the Customer or Service ...

Page 24: ... carried out by an electrician and in compliance with electrical engineering regulations CAUTION Risk of burns Escaping hot medium can cause burns Maintain a sufficient distance from the escaping medium Wear suitable personal protective equipment safety gloves and goggles CAUTION Risk of injury due to pressurised liquid If installation removal or maintenance work is not carried out correctly there...

Page 25: ...d 4 Remove the lower vessel covers from the tanks 5 Remove any sludge from the covers and the spaces between the diaphragms and the tanks Check the diaphragms for tearing Check the tank interior walls for corrosion 6 Reinstall the covers on the tanks 7 Reinstall the flange connection betweens the primary tank and the device and the secondary tank if provided 8 Close the FD feed and drain cocks at ...

Page 26: ...k 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 electrician and in compliance with electrical engineering regulations CAUTION Risk of burns...

Page 27: ...0 2382 7069 9523 E mail service reflex de Technical Hotline For questions about our products Telephone number 49 0 2382 7069 9546 Monday to Friday 8 00 to 16 30 13 2 Conformity and standards Device conformity declarations are available on the Reflex homepage www reflex winkelmann com konformitaetserklaerungen Alternatively scan the QR code 13 3 Guarantee The respective statutory guarantee regulati...

Page 28: ... 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 29: ...Annex Variomat Basic 22 07 2020 Rev A English 29 ...

Page 30: ...SI2033enA 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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