Reflex Fillcontrol Plus User manual

Fillcontrol Plus 06.07.2016 - Rev. B
GB
Operating manual
Original operating manual

Contents
Fillcontrol Plus — 06.07.2016 - Rev. B English —
3
English
FillcontrolPlus
06.07.2016-Rev. B
Contents
1Notes on the operating manual.....................................................................................................................................................5
2Liability and guarantee...................................................................................................................................................................5
3Safety................................................................................................................................................................................................6
3.1 Explanation of symbols........................................................................................................................................................................6
3.1.1 Symbols and notes used...................................................................................................................................................6
3.2 Personnel requirements ......................................................................................................................................................................7
3.3 Personal protective equipment..........................................................................................................................................................7
3.4 Intended use..........................................................................................................................................................................................7
3.5 Inadmissible operating conditions.....................................................................................................................................................7
3.6 Residual risks .........................................................................................................................................................................................8
4Description of the device................................................................................................................................................................9
4.1 Description.............................................................................................................................................................................................9
4.2 Overview ................................................................................................................................................................................................9
4.3 Identification .......................................................................................................................................................................................10
4.3.1 Nameplate ........................................................................................................................................................................10
4.3.2 Type code..........................................................................................................................................................................10
4.4 Function ...............................................................................................................................................................................................11
4.5 Scope of delivery.................................................................................................................................................................................12
4.6 Optional equipment and accessories ..............................................................................................................................................12
5Technical data ...............................................................................................................................................................................13
5.1 Electrical system..................................................................................................................................................................................13
5.2 Dimensions and connections............................................................................................................................................................13
5.3 Operation .............................................................................................................................................................................................13
6Installation.....................................................................................................................................................................................14
6.1 Installation conditions .......................................................................................................................................................................15
6.1.1 Incoming inspection .......................................................................................................................................................15
6.2Preparatory work ................................................................................................................................................................................15
6.3 Execution..............................................................................................................................................................................................16
6.3.1 Wall mounting .................................................................................................................................................................16
6.3.2 Hydraulic connection......................................................................................................................................................17
6.4 Switching and make-up variants......................................................................................................................................................18
6.5 Electrical connection ..........................................................................................................................................................................20
6.5.1 Terminal diagram ............................................................................................................................................................21
6.5.2 RS-485 interface...............................................................................................................................................................23
6.6 Installation and commissioning certificate.....................................................................................................................................23
7Commissioning..............................................................................................................................................................................24
7.1 Requirements for initial commissioning .........................................................................................................................................24
7.2 Determining the P0minimum operating pressure for the controller.........................................................................................24
7.3 Filling the device with water.............................................................................................................................................................25
7.4 Parametrising the controller in the Customer menu ....................................................................................................................25
7.5 Function test........................................................................................................................................................................................25
7.6 Use the device to fill the facility system with water ......................................................................................................................26
7.7 Starting Automatic mode..................................................................................................................................................................26
8Operation.......................................................................................................................................................................................27
8.1 Operating modes ................................................................................................................................................................................27
8.1.1 Automatic mode..............................................................................................................................................................27
8.1.2 Manual mode ...................................................................................................................................................................27

Contents
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8.1.3 Stop mode ........................................................................................................................................................................28
8.1.4 Summer operation..........................................................................................................................................................28
9Controller ...................................................................................................................................................................................... 29
9.1 Operator panel ....................................................................................................................................................................................29
9.2 Configuring settings in the controller .............................................................................................................................................30
9.2.1 Customer menu...............................................................................................................................................................34
9.2.2 Service menu....................................................................................................................................................................34
9.3 Messages..............................................................................................................................................................................................35
10 Maintenance................................................................................................................................................................................. 38
10.1 Maintenance schedule.......................................................................................................................................................................39
10.2 Exterior leak test .................................................................................................................................................................................39
10.3 Maintenance certificate.....................................................................................................................................................................40
11 Disassembly.................................................................................................................................................................................. 41
12 Annex ............................................................................................................................................................................................ 42
12.1 Reflex Customer Service ....................................................................................................................................................................42
12.2 Guarantee ............................................................................................................................................................................................42
12.3 Conformity and standards.................................................................................................................................................................42

Notes on the operating manual
Fillcontrol Plus — 06.07.2016 - Rev. B English —
5
1Notes on the operating manual
This operating manual is an important aid for ensuring the safe and reliable functioning of the device.
The operating manual will help you to:
• avoid any risks to personnel.
• become acquainted with the device.
• achieve optimal functioning.
• identify and rectify faults in good time.
• avoid any faults due to improper operation.
• cut down on repair costs and reduce the number of downtimes.
• improve the reliability and increase the service life of the device.
• avoid causing harm to the environment.
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. For
optional equipment and accessories, see chapter 4.6 "Optional equipment and accessories" on page 12 .
Note!
Every person installing 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 the device
operator
and must be stored near the device for access at any time.
2Liability 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 42 .

Safety
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— English Fillcontrol Plus — 06.07.2016 - Rev. B
3Safety
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 ti
ps and recommendations for efficient handling
of the product.

Safety
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3.2 Personnel requirements
Only specialist personnel or specifically trained personnel may install and operate the equipment.
The electric connections and the wiring of the device must be executed by a specialist in accordance with all applicable national and
local regulations.
3.3 Personal protective equipment
When working at the system, wear the stipulated personal equipment such as hearing and eye protection, safety boots, helmet,
protective clothing, protective gloves.
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 facility 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 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.

Safety
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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.

Descri
ption of the device
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4Description of the device
4.1 Description
The device is a makeup station without a pump for heating and cooling water systems. The controller regulates the water makeup for
the plant system.
The device is suitable for two makeup systems:
• Freshwater makeup to plant systems with a diaphragm expansion tank.
• Freshwater makeup to plant systems with a pressurisation station.
4.2 Overview
1 "BV" shut-off valve 5 Cover (hinged)
2 "PIS" pressure transducer 6 Control Basic controller
3
"WV" make-up valve
WC
Fresh water inlet/outlet
4 Console for wall mounting

Description of the device
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4.3 Identification
4.3.1 Nameplate
The nameplate provides information about the manufacturer, the year of manufacture, the manufacturing number and the 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 temperature
/ flow temperature TS
Minimum / maximum
permissible temperature /
TS flow temperature
Year built Year of manufacture
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
Type code
Fillcontrol Plus P 1,4 E
– : Standard
E : Stainless steel model
Volumetric flow rate "Kvs"

Description of the device
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4.4 Function
1 Fillset Impuls, see chapter 4.6 "Optional equipment and
accessories" on page 12 .
PIS Pressure transducer for pressure-dependent make-up
• Internal signal line from the pressure transducer to
the controller
2 "Fillsoft" softening system, see chapter 4.6 "Optional
equipment and accessories" on page 12 .
WC Make-up line to the device
3 Fillcontrol Plus DC Make-up line to the system
LIS Filling level monitoring for level-dependent make-up
• External signal line to the controller
Fillcontrol Plus controls the make-up with fresh water for the facility system.
The controller monitors the following functions:
• Make-up time.
• Make-up cycles.
• Make-up quantity, if an optional contact water meter is installed.
The controller will detect small leaks in the system. When a leak is detected, the controller interrupts the make-up with as soon as the
make-up time or the make-up cycles are exceeded.
Fillcontrol Plus supports two make-up variants:
• Pressure-dependent make-up with water in a facility system with a diaphragm expansion tank ("Magcontrol" mode).
– The pressure transducer sends a signal to the controller if the pressure drops below the minimum working pressure of the
facility system. The make-up is released. Fresh water is added to the facility system. For calculating the filling pressure into the
facility system, see chapter 7.2 "Determining the P0minimum operating pressure for the controller" on page 24 .
• Level-dependent make-up with water in a facility system with a pressure-maintaining station ("Levelcontrol" mode).
– A pressure-maintaining station monitors the filling level in the expansion tank. If the level drops below minimum, the pressure-
maintaining station sends a signal to the controller. The make-up is released. Fresh water is added to the facility system.
The mode is set in the Customer menu,see chapter 9.2.1 "Customer menu" on page 34 .
The controller may monitor additional function, if you combine various accessories.
The following components are available as optional accessories:
• "Reflex Fillsoft" softening system.
• "Reflex Fillset" with "FQI" water meter.
• "Reflex Fillset Imuls" with "FQIRA+" contact water meter.
Note!
For optional accessories, see chapter
4.6 "Optional equipment and accessories" on page 12 .

Description of the device
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— English Fillcontrol Plus — 06.07.2016 - Rev. B
4.5 Scope of delivery
The scope of delivery is described in the shipping document and the content is shown on the packaging.
Proceed as follows:
1. Immediately after receipt of the goods, please check the shipment for completeness and damage.
2. Please notify us immediately of any transport damage.
Basic make-up equipment:
• The pre-wired device.
• Operating manual.
4.6 Optional equipment and accessories
The following optional equipment and expansion functions are available for this device:
• Fillset or Fillset Compact as add-on modules for drinking water systems.
• Softening with Reflex Fillsoft.
• Expansions for Reflex Basic controllers:
– I/O modules
– Bus modules:
• Lonworks Digital
• Lonworks
• Profibus DP
• Ethernet
Note!
Separate operating instructions are supplied with accessories.

Technical data
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5Technical data
Note!
The following values apply for all systems:
–
Permissible ambient temperature:
–
Degree of protection:
–
Noise level:
>0 °C – 45 °C
IP 54
55 dB
5.1 Electrical system
Type
Power output
(W)
Power supply
(V / Hz)
Fusing
(A)
Number of RS-485
interfaces
I/O module
Fillcontrol Plus 350 230 / 50 4 2 Optional
5.2 Dimensions and connections
Type
Weight
(kg)
Height
(mm)
Width
(mm)
Depth
(mm)
Device
connection
System
connection
Overflow
connection
Fillcontrol Plus 1.7 340 320 190 G ¾ G ½ –
Fillcontrol Plus stainless steel 2.5 340 320 190 G ¾ G ½ –
5.3 Operation
Type
Make-up capacity
(l/h)
Maximum feed
pressure
(bar)
Maximum delivery
pressure
(bar)
Permissible operating
gauge pressure
(bar)
Operating
temperature
(°C)
Fillcontrol Plus
≤
1400 10
≤
8.5 10 60

Installation
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— English Fillcontrol Plus — 06.07.2016 - Rev. B
6Installation
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 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.
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 falls or bumps
Bruising from falls or bumps on system 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, start-up and maintenance
certificate. This
action is a prerequisite for the making of warranty claims.
–
Have the Reflex Customer Service carry out commissioning and the annual maintenance.

Installa
tion
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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.
Proceed as follows:
1. Upon receipt of the goods, check the shipment for
• completeness and
• possible transport damage.
2. Document any damage.
3. Contact the forwarding agent to register your complaint.
6.2 Preparatory work
Preparing the device installation:
• Frost-free, well-ventilated room.
– Room temperature range: 0 °C to 45 °C.
• Filling connection.
– If necessary, provide a DN 15 filling connection according to DIN 1988 T 4.
• Electric connection: 230 V~, 50 Hz, 16 A with upstream ELCB: Tripping current 0.03 A.

Installation
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6.3 Execution
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 stresses being induced.
• If necessary, provide support structures for the pipes or equipment.
Note!
Starting up of the pump causes vibration in the device. This transfers loud noises into the system pipes.
–
Connect the pipes to the device using flexible connections.
In systems with a diaphragm expansion tank, the device must be installed in the vicinity of the tank. To ensure that the required filling
pressure for water make-up is recorded by the pressure transducer in the device. The filling pressure depends on the minimum operating
pressure of the facility system. For calculating the minimum operating pressure,see chapter 7.2 "Determining the P0minimum operating
pressure for the controller" on page 24 .
Proceed as follows for the installation:
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 Wall mounting
The device is installed at the wall. Bore holes for wall mounting
are
provided on the rear of the console (1) housing.
Select the attachment means according to the wall properties
and the weight (G) of the device.
During installation, ensure that:
•
The device is installed sufficiently close to the diaphragm
expansion tank. You ensure so that the "PIS" pressure
sensor is able to measure the filling pressure.
•
The fixtures can be operated.
•
The feed connections of the pipes are not adversely
affected.

Installation
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6.3.2 Hydraulic connection
6.3.2.1 Connection to the facility system
Note!
Starting up of the pump causes vibration in the device. This transfers loud noises into the system
pipes.
–
Connect the pipes to the device using flexible connections.
1 Fillset Impuls 5 "BV" shut-off device
2 "Fillsoft" softening system WC Make-up line to the device
3 "WV" Make-up valve DC Make-up line to the system
4
Fillcontrol Plus
DN
Nominal diameter of the make-up line
Prepare the connection as follows:
1. Select the "DN" nominal diameter for the make-up lines.
– At a length of up to 10 metres: DN 15.
– At a length of more than 10 metres: DN 20.
2. Connect the "DC" make-up line to the "BV"shut-off device.
3. Connect the "DC" make-up line to the system.
4. Connect the "WC" make-up line to the "WV" make-up valve.
5. Connect the "WC" make-up line to the external fresh water system.
The make-up lines are connected.
Note!
Use a pressure reducer in the "WC
" make-up line if the fresh water system pressure exceeds 6 bar.
Note!
For selecting the make
-up variants, see chapter 6.4 "Switching and make-up variants" on page 18 .

Installation
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6.4 Switching and make-up variants
Example of a pressure-dependent make-up with "Fillcontrol Plus".
1 Fillset PIS Pressure transducer
2 Fillcontrol Plus WC Make-up line to the device
3 Diaphragm expansion tank MAG DC Nominal diameter of the make-up line
In facility systems with a diaphragm expansion tank, the "PIS" pressure transducer in the device monitors the make-up with fresh water.
When the required filling pressure for water make-up drops below the minimum value, the pressure transducer sends a signal to the
device controller. The make-up is released. Fresh water is added to the facility system.
Proceed as follows:
1. In the Customer menu, activate the "Magcontrol" mode, see chapter 9.2.1 "Customer menu" on page 34 .
2. Connect the pressure line near the connection to the diaphragm expansion tank.
– This ensures that the "PIS" pressure transducer detects the filling pressure required for the make-up with fresh water.
– For calculating the filling pressure,see chapter 7.2 "Determining the P0minimum operating pressure for the controller" on
page 24 .
3. Do not use nominal diameters below the specified diameters for the "WC"make-up lines.
– You will avoid an undesired cycling of the make-up.

Installation
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Example of a level-dependent make-up with "Fillcontrol Plus".
1 Fillset Impuls 4 "Reflexomat" pressure maintaining station
2 "Fillsoft" softening system WC Make-up line to the device
3 Fillcontrol Plus DN Nominal diameter of the make-up line
The pressure maintaining station is fitted with a monitoring device for the filling level in the expansion tank. If the filling level drops
below the minimum level in the expansion tank, the pressure maintaining station sends a signal to the device controller. The make-up is
released. Fresh water is added to the facility system.
Proceed as follows:
1. In the Customer menu, activate the "Levelcontrol" mode, see chapter 9.2.1 "Customer menu" on page 34 .
2. The filling pressure for make-up with fresh water must be at least 1.7 bar higher than the "P0" minimum working pressure, see
chapter 7.2 "Determining the P0minimum operating pressure for the controller" on page 24 .
Note!
You may combine the device with softening systems (Fillsoft, for example); available as optional accessories, see
chapter
4.6 "Optional equipment and accessories" on page 12 .

Installation
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— English Fillcontrol Plus — 06.07.2016 - Rev. B
6.5 Electrical connection
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.
DANGER
Risk of serious injury or death due to electric shock
Some parts of the device's circuit board may still carry 230 V voltage even with the device physically isolated from the power supply.
• Before you remove the covers, completely isolate the device controller from the power supply.
• Verify that the main circuit board is voltage-free.
The following descriptions apply to standard systems and are limited to the necessary user-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 carry 230 V
voltage even with the device physically isolated from the power supply. Before you remove the covers, completely isolate the device
controller from the power supply. Verify that the main circuit board is voltage-free.
3. Install a screwed cable gland suitable for the respective cable. M16 or M20, for example.
4. Thread all cables to be connected through the cable gland.
5. Connect all cables as shown in the terminal diagram.
– Note that the fusing for the device connection is to be provided by the user, see chapter 5 "Technical data" on page 13 .
6. Install the cover.
7. Connect the mains plug to the 230 V power supply.
8. Activate the system.
The electrical connection is completed.