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
4 — English Fillcontrol Plus — 06.07.2016 - Rev. B
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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— English Fillcontrol Plus — 06.07.2016 - Rev. B
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
Fillcontrol Plus — 06.07.2016 - Rev. B English —
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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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— English Fillcontrol Plus — 06.07.2016 - Rev. B
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"