Reflex Fillcontrol Auto User manual

Fillcontrol Auto
22.09.2020 - Rev. C
GB
Operating manual
Original operating manual

Contents
2 —English
Fillcontrol Auto —22.09.2020 - Rev. C
English
FillcontrolAu to
22.09.202 0 -Rev. C
Contents
1Notes on the operating manual .............................................. 3
2Liability and guarantee............................................................ 3
3Safety ........................................................................................ 3
3.1 Explanation of symbols................................................................................ 3
3.1.1 Symbols and notes used........................................................ 3
3.2 Personnel requirements .............................................................................. 3
3.3 Personal protective equipment .................................................................. 3
3.4 Intended use ................................................................................................. 3
3.5 Inadmissible operating conditions............................................................. 3
3.6 Residual risks................................................................................................. 3
4Description of the device ......................................................... 4
4.1 Description.................................................................................................... 4
4.2 Overview ....................................................................................................... 4
4.3 Identification................................................................................................. 4
4.3.1 Nameplate............................................................................... 4
4.3.2 Type code ................................................................................ 5
4.4 Function......................................................................................................... 5
4.5 Scope of delivery .......................................................................................... 5
4.6 Optional equipment and accessories......................................................... 5
5Technical data........................................................................... 5
6Installation................................................................................ 6
6.1 Installation conditions ................................................................................. 6
6.1.1 Incoming inspection .............................................................. 6
6.2 Preparatory work.......................................................................................... 6
6.3 Execution....................................................................................................... 6
6.3.1 Floor mounting....................................................................... 6
6.3.2 Hydraulic connection ............................................................. 7
6.4 Switching and make-up variants................................................................ 7
6.5 Electrical connection.................................................................................... 8
6.5.1 Terminal diagram................................................................... 8
6.5.2 RS-485 interface...................................................................... 9
6.6 Installation and commissioning certificate ............................................... 9
7Commissioning .........................................................................9
7.1 Requirements for initial commissioning.................................................... 9
7.2 Determining the P0minimum operating pressure for the controller..... 9
7.3 Filling the device with water....................................................................... 9
7.4 Modifying the controller's start routine................................................... 10
7.5 Parametrising the controller in the Customer menu.............................. 10
7.6 Function test............................................................................................... 10
7.7 Use the device to fill the facility system with water ............................... 11
7.8 Starting Automatic mode.......................................................................... 11
8Operation ................................................................................11
8.1 Operating modes........................................................................................ 11
8.1.1 Automatic mode................................................................... 11
8.1.2 Manual mode........................................................................ 11
8.1.3 Stop mode............................................................................. 11
8.1.4 Summer operation............................................................... 11
8.1.5 Restarting.............................................................................. 12
9Controller.................................................................................12
9.1 Operator panel............................................................................................ 12
9.2 Configuring settings in the controller...................................................... 12
9.2.1 Customer menu.................................................................... 13
9.2.2 Service menu ........................................................................ 14
9.3 Messages..................................................................................................... 14
10 Maintenance ...........................................................................15
10.1 Maintenance schedule............................................................................... 15
10.2 Exterior leak test......................................................................................... 15
10.3 Cleaning the dirt trap................................................................................. 16
11 Disassembly.............................................................................16
12 Annex.......................................................................................16
12.1 Reflex Customer Service............................................................................ 16
12.2 Conformity and standards......................................................................... 16
12.3 Guarantee ................................................................................................ 16

Notes on the operating manual
Fillcontrol Auto —22.09.2020 - Rev. C
English —3
1Notes 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.
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 16 .
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 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.
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
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.

Description of the device
4 —English
Fillcontrol Auto —22.09.2020 - Rev. C
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.
4Description of the device
4.1 Description
The device is a make-up unit that is intended to maintain the water pressure and
provide mains make-up water in a system circuit.
•The pump draws water from a mains water supply via a system separator
tank and pumps it into the system circuit.
•The controller regulates and monitors the make-up process.
The device is designed for these system circuits:
•Heating water systems
•Cooling water systems
•Solar circuits
The device is used in combination with a user-supplied open system separator
tank.

Note!
An application without system separator tank is possible.
–For customised design and adjustment, see chapter 12.1 "Reflex
Customer Service" on page 16 .

Note!
In a solar circuit, you must have installed a system separator tank to
ensure a water/glycol mixture for the circuit.

Note!
It is possible to use the device for the initial filling with mains water into
the system circuit.
4.2 Overview
1
Control Basic controller
WC
Connections for the mains
water make-up lines
•Intake line to pump
•Pressure line to the
system circuit
2
"PIS" pressure transducer
3
Shut-off valve to "BV" system
4
"AV" venting screw
5
Pump
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 the type plate
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

Technical data
Fillcontrol Auto —22.09.2020 - Rev. C
English —5
Information on the type plate
Meaning
at site
Set minimum operating pressure
max. pressure saftey valve
factory - aline
Factory set actuating pressure of the
safety valve
at site
Set actuating pressure of the safety
valve
4.3.2 Type code
No.
Type code (example)
1
Device designation
2
Auto
Fillcontrol Auto
A
5,5
3
Maximum working pressure (in bar)
1
2
3
4.4 Function
1
Pump "PU"
2
"Fillsoft" softening system
3
"FQIRA+" contact water meter
4
"BT" system separator vessel
5
"ST" dirt trap
WC
Make-up lines
•From the system separator tank to the pump (intake line)
•From the pump to the system circuit (pressure line)
Levelcontrol
External signal line for the Levelcontrol make-up variant
Magcontrol
Internal signal line for the Magcontrol make-up variant
•From the "PIS" pressure transducer to the controller
The device controller uses the pump to regulate the make-up with mains water
for the system circuit.
The controller monitors the following parameters:
•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. An integrated insufficient water protection sensor
deactivates the pump to prevent it from running dry.
You can set two make-up variants in the device, "Magcontrol" or "Levelcontrol".
These variants depend on the system circuit.
•Adding water to system circuits with a diaphragm expansion vessel
(Magcontrol).
The pressure transducer sends a signal to the controller if the pressure
drops below the minimum working pressure of the system circuit. The
controller activates the pump. mains water is added to the system circuit
from the system separator vessel. For calculating the filling pressure into
the system circuit, see chapter 7.2 "Determining the P0minimum operating
pressure for the controller" on page 9 .
•Adding water to system circuits with a pressurisation unit (Levelcontrol).
A pressurisation unit monitors the filling level in the expansion vessel.
When the filling level falls below the minimum level, the pressurisation
unit sends a signal to the device controller. The controller activates the
pump. mains water is added to the system circuit from the system
separator vessel.
The make-up variant is set in the Customer menu, see chapter 9.2.1 "Customer
menu" on page 13 .
The controller may monitor additional function, if you combine various
accessories.
The following components are available as optional accessories:
•"Reflex Fillsoft" water softening system
•"FQIRA+" contact water meter

Note!
For optional accessories, see chapter 4.6 "Optional equipment and
accessories" on page 5 .
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 accessories are available for this device:
•"FQIRA+" contact water meter.
•Expansions for Reflex Basic controllers.
–Bus modules
•Profibus DP
•Ethernet

Note!
Separate operating instructions are supplied with accessories.
5Technical data
Permissible ambient temperature
0 –35 °C
Degree of protection
IP 54
Noise level
55 dB
Electric output
750 W
Power supply
230 V / 50 Hz
Fusing
4 A
Number of RS-485 interfaces
2
Weight
18.6 kg
Height
690 mm
Width
470 mm
Depth
440 mm
Inlet connection
G 1 ¼"
Outlet (return) connection
G 1"
Delivery rate
4.2 m³/h
Max. supply pressure
10 bar
Max. working pressure
5.5 bar
Permissible gauge operating pressure
10 bar
Permissible operating temperature
70 °C

Installation
6 —English
Fillcontrol Auto —22.09.2020 - Rev. C
Performance chart
Make-up capacity in m3/hour
Make-up pressure in bar
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 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.
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 35 °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.
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
them being stressed or strained.
•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 9 .
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 Floor mounting
The device is installed on the floor. Select the attachment means according to
the floor properties.
Comply with the following instructions:
•The device is installed sufficiently close to the diaphragm expansion vessel.
You ensure so that the "PIS" pressure sensor is able to measure the filling
pressure.
•That it is possible to open and close the valves.
•Ensure sufficient space for installing the connection lines.

Note!
The "hst" static height is required to determine the minimum operating
pressure of the system circuit.

Installation
Fillcontrol Auto —22.09.2020 - Rev. C
English —7
Installation with user-supplied system separator tank
1
Pump "PU"
3
"BT" system separator vessel
2
"PIS" pressure transducer
4
"ST" dirt trap
During installation, observe the following points:
•Ambient temperatures up to 35 °C
•Pipe length (see table)
•"WC" make-up connection at must be least 100 mm above the "PU" pump
intake connection.
•Minimum diameter of the intake line and the pressure line (see table).
•Adherence to EN 1717
•Recommended nominal volume of the system separator tank of ≤ 200 l
•Overflow with sufficient dimensions to match the maximum possible water
supply is installed.
•A shut-off valve is installed in the supply to the system separator tank.
Nominal diameters of the intake and pressure lines depending on the required
make-up pressure
Make-up pressure
> 3.7 bar
≤3.7 bar
Pressure line ≤10 m
DN 32
DN 40
Pressure line ≤2 m
DN 32
DN 40

Note!
For installation at the same level, open the Customer menu to set the
"P0" minimum operating pressure to the "p0" initial pressure of the
"MAG" diaphragm expansion vessel, otherwise, you must correct with
"hst", see chapter 7.2 "Determining the P0minimum operating pressure
for the controller" on page 9 .
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.
Connection to the system circuit with a system separator tank for the make-up
with mains water.
1
Pump "PU"
WC
Make-up lines for mains water
•Intake line to pump
•Pressure line to the
system circuit
2
"Fillsoft" softening system
3
Contact water meter
4
"BT" system separator vessel
5
"ST" dirt trap
Comply with the following requisites for the installation and connection of an
open system separator tank.
•Make-up temperatures up to 70° C
•Pipeline lengths, see chapter 6.3.1 "Floor mounting" on page 6 .
•Outlet from the system separator tank at least 100 mm above the intake
connection of the "PU" pump.
–"WC" intake line to "PU" pump with constant incline to the system
separator tank.

Note!
At make-up temperatures > 70 °C and the use in system circuits
without system separator tanks, you must plan according to the local
conditions, see chapter 12.1 "Reflex Customer Service" on page 16 .
6.4 Switching and make-up variants
Example diagram for a pressure-dependent make-up with water in a solar
installation with diaphragm expansion vessel.
1
Pump "PU"
WC
Make-up lines
•Intake line to "PU"
pump
•Pressure line to the
system circuit
2
"BT" system separator vessel
3
"ST" dirt trap
DN
Nominal diameter of the
make-up lines
In system circuits with a diaphragm expansion vessel, the "PIS" pressure
transducer in the device monitors the make-up with mains 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 controller
activates the pump. Mains water from the system separator tank is added to the
system circuit.
Proceed as follows:
1. In the Customer menu, set the device to "Magcontrol", see chapter 9.2.1
"Customer menu" on page 13 .
2. Connect the pressure line near the connection to the diaphragm expansion
vessel.
–This ensures that the "PIS" pressure transducer detects the filling
pressure required for the make-up with mains water.
–For calculating the filling pressure, see chapter 7.2 "Determining the
P0minimum operating pressure for the controller" on page 9 .
3. Do not use nominal diameters below the specified diameters for the
"WC"make-up lines, see chapter 6.3.1 "Floor mounting" on page 6 .
–You will avoid an undesired cycling of the make-up.
4. In solar plants, use the "BT" system separator tank to prepare the
water/glycol mixture.
–Size the system separator tank with at least 1.5 times the system
volume.

Installation
8 —English
Fillcontrol Auto —22.09.2020 - Rev. C
Typical diagram for level-dependent make-up with water in a system circuit with
a pressurisation unit.
1
Controller unit with a compressor for maintaining the pressure
2
Expansion vessel for pressurisation
3
Pump "PU"
4
"Fillsoft" softening system, optional accessory
5
Contact water meter, optional accessory
6
"BT" system separator vessel
7
"ST" dirt trap
WC
Make-up pipe
•Intake line to "PU" pump
•Pressure line to the system circuit
LIS
Pressure pick-up for calculating the filling level in the expansion vessel
A pressurisation unit monitors the filling level in the expansion vessel. When the
filling level in the expansion vessel falls below the minimum level, the
pressurisation unit sends a signal to the device controller. The controller
activates the pump. Mains water from the system separator tank is added to the
system circuit.
Proceed as follows:
1. In the Customer menu, set the device to "Levelcontrol", see chapter 9.2.1
"Customer menu" on page 13 .
2. The filling pressure for make-up with mains 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 9 .

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 5 .
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 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 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.
–For installer supplied fusing, comply with the connected loads of the
device , see chapter 5 "Technical data" on page 5 .
6. Install the cover.
7. Connect the mains plug to the 230 V power supply.
8. Activate the system.
The electrical connection is completed.
6.5.1 Terminal diagram
1
"L" fuse for electronics and solenoid valves
2
"N" fuse for solenoid valves
3
Solenoid valve (not for motor ball valve)
4
Group message
5
Not used
6
Not used
7
RS-485 interface
8
Shielding
9
Digital inputs
•Water meter
•Insufficient water
10
Not used
11
Pressure analogue input
12
External make-up demand (only with "Levelcontrol")
13
Not used
14
Not used
15
Mains supply
Terminal
number
Signal
Function
Wiring
1
PE
230 V power supply via mains
cable and plug.
Factory
2
N
3
L
13
COM
Group message (floating).
User, optional
14
NC
15
NO
16
Not assigned
External make-up demand for
level-dependent make-up.
•From a pressurisation
controller, for example.
(Set the controller to
"Levelcontrol")
User, optional
17
Make-up (230 V)
18
Make-up (230 V)

Commissioning
Fillcontrol Auto —22.09.2020 - Rev. C
English —9
Terminal
number
Signal
Function
Wiring
22
PE (shield)
Pressure analogue input.
•Display at the controller.
•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 (in
"Fillset Impulse", for example)
•Evaluation of the make-up.
•Contact 32/33 closed =
meter pulse.
User, optional
6.5.2 RS-485 interface
The following options are available via the interface:
•Data polling by the controller.
–Pressure
–Pump operating states.
–Cumulated quantity of the "FQIRA+" contact water meter.
–All messages, see chapter 9.3 "Messages" on page 14 .
–All entries in the fault memory.
•Communication with control centres.
•Communication with other equipment.

Note!
If required, please request the RS-485 interface protocol from the Reflex
Customer Service.
•Connection details.
•Accessory information and data.
6.5.2.1 Connecting the RS-485 interface
Connect the interface as follows:
1. For connecting the interface use only a cable with these properties:
–LJYCY (TP), 4 × 2 × 0.8, maximum overall bus length 1000 m.
2. Use a shielded cable to connect the interface to terminals 29, 30, 31 of the
main board in the control cabinet.
–For connecting the interface, see chapter 6.5 "Electrical connection"
on page 8 .
3. When using the device with a control centre not supporting an RS-485
interface (RS-232, for example), you must use a corresponding adapter.
6.6 Installation and commissioning certificate

Note!
The installation and commissioning certificate can be found at the end
of the operating manual.
7Commissioning

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 Requirements for initial commissioning
The device will be ready for initial commissioning when the tasks described in
the "Installation" chapter have been completed. Note the following information
on initial commissioning:
•The device is installed.
•The water connections to the system circuit are established.
•The device shut-off valves are closed.
–Shut-off valve from the "DC" make-up line to the system circuit.
–Shut-off valve of the "WC" make-up line to the fresh water main.
•"PIS" pressure monitoring is ready.
•The electrical connection has been created according to applicable
national and local regulations.
Establish a 230 V power supply by plugging the power plug into a corresponding
outlet. The controller is in Stop mode.
7.2 Determining the P0minimum operating pressure for the
controller
The "P0" minimum working pressure for the device is used in system circuits with
a diaphragm expansion vessel.
Calculate the "P0" minimum working pressure for the device:
•The device is installed at the same level as the diaphragm expansion
vessel:
–hst = 0, P0 = p0*
•The device is installed at a lower level than the diaphragm expansion
vessel:
–P0= p0 + hst/10*
•The device is installed at a higher level than the diaphragm expansion
vessel:
–P0= p0 - hst/10*
*p0 in bar, hst in metres

Note!
Calculate the filling pressure for system circuit make-up using fresh
water as follows:
Filling pressure ≥ P0+ 0.3 bar

Note!
When planning, note that the working range of the device must come
within the pressurisation working range, which extends from the initial
pressure "PA" to the final pressure "PE".
7.3 Filling the device with water
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 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.

Commissioning
10 —English
Fillcontrol Auto —22.09.2020 - Rev. C
Fill water into the device:
1
Pump "PU"
3
"BT" system separator vessel
2
"PIS" pressure transducer
4
"ST" dirt trap
1. Open the shut-off valve to the mains water supply.
–The "BT" system separator vessel is filled with water from the public
water system.
2. Check the proper closing of the float valve in the system separator vessel.
–Water must not flow from the device overflow.
3. Slowly open the "BV" shut-off valve in the intake line from the system
separator vessel to the pump.
–The intake line and the pump are filled with water from the system
separator vessel.
Vent the pump:
1
"AV" vent screw
4. Remove the vent screw from the pump and vent the pump until bubble-
free water escapes.
–If necessary, manually turn the pump using a screwdriver at the fan
wheel until bubble-free water escapes.
5. Tighten the vent screw and ensure that is does not leak.
The device is filled with water.
7.4 Modifying the controller's start routine

Note!
During commissioning, you must once execute the start routine.
•For information about controller operation, see chapter 9.1
"Operator panel" on page 12 .
The start routine is used to set the required parameters for the device
commissioning. It commences with the first 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 9.2.1 "Customer menu" on
page 13 .

Note!
Plug in the mains 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
Meaning
Fillcontrol A
Device name
Language
Standard software in various languages.
Read the
operating
instructions
Prior to commissioning, read all of the operating
instructions and verify the proper assembly.
Min. op. pressure
Specify the value for the minimum operating pressure
(only with "Magcontrol" make-up variant).
•Calculation of the minimum operating pressure, see
chapter 7.2 "Determining the P0minimum operating
pressure for the controller" on page 9 .
Safety valve
pressure
Enter the value for the release pressure of the safety valve.
•This value may be the same as the release pressure
of the system circuit safety valve.
Time
Change the flashing display items for "Hour", "Minute",
and "Seconds" to the current time.
•The time of an alarm will be stored in the fault
memory.
Date
Change the flashing display items for "Day", "Month", and
"Year" to the current date.
•The date of an alarm will be stored in the fault
memory.
Terminate
routine?
Yes
The system displays this message after a successfully
completed start routine.
Select "Yes" or "No" on the controller display and confirm
with "OK" on the controller operator panel.
•Yes: The start routine is terminated, the device
automatically switches to Stop mode.
•No: The start routine restarts.
2.0 bar
STOP
The pressure is displayed only in "Magcontrol" make-up
mode.

Note!
After successful conclusion of the start routine, you are in Stop mode. Do
not yet switch to Automatic mode.

Note!
Set the "Magcontrol" or "Levelcontrol" make-up variant in the Customer
menu, see chapter 9.2.1 "Customer menu" on page 13 .
7.5 Parametrising the controller in the Customer menu
Use the Customer menu to display or correct system-specific values. In the
course of commissioning, the factory settings must be adjusted for the system-
specific conditions.
–For adjusting the default settings, see chapter 9.2 "Configuring settings in
the controller" on page 12 .
–For information about controller operation, see chapter 9.1 "Operator
panel" on page 12 .
7.6 Function test
At the device, execute a function test for the "PU" pump. Set the device
controller to manual mode. In manual mode, you manually activate and
deactivate the pumps.
•Press "Manual" on the controller's operator panel.
–The "Manual" LED at the operator panel illuminates to visually
indicate that Manual mode is active.
Select the "PU" pump. Selecting the pump
depends on the set make-up variant,
"Levelcontrol" or "Magcontrol".
2.0 bar
PU!
Filling

Operation
Fillcontrol Auto —22.09.2020 - Rev. C
English —11
Proceed as follows:
1. Press "Manual" on the controller's operator panel.
–"PU" flashes on the display to visually indicate that the pump has
been selected for the "Levelcontrol' make-up variant.
–Use the arrow keys at the operator panel to select "PU" on the
display. –"PU" flashes on the display to visually indicate that the
pump has been selected for the "Magcontrol' make-up variant.
2. Press "OK" on the controller's operator panel.
–The pump is switched on and the displays shows "PU!".
–The display must show values of ≥ 5 bar for the pressure for the
activated pump.
3. Press "OK" on the controller's operator panel.
–The pump is switched off and the displays shows "PU".
The function test for the pump is completed. Slowly open the "BV" shut-off valve
in the pressure line from the pump to the system circuit.

Note!
If the pressure does not rise when the pump is activated:
•Shut down the pump.
•Vent the pump, see chapter 7.3 "Filling the device with water" on
page 9 .

Note!
Execute a function test of the system separator tank according to the
user-supplied specifications.
7.7 Use the device to fill the facility system with water
You have the option to use the device to fill the system circuit with water. These
requirements must be met for the filling with water:
•The system circuit has not been previously filled with water.
•The system circuit has a maximum water volume up to 3,000 litres.
•It is a system circuit with a diaphragm expansion system.
Set the following operating modes at the controller:
•"Magcontrol" make-up, see chapter 9.2.1 "Customer menu" on page 13 .
•Manual operation, see chapter 8.1.2 "Manual mode" on page 11 .
Proceed as follows:
1. Press "Manual" on the controller's operator panel.
2. Use the arrow keys at the operator
panel to select "Fill" on the display.
10 h
2.0 bar
PU!
Filling
–"Fill" flashes on the display to visually indicate the selection.
3. Press "OK" on the controller's operator panel.
–The pump is switched on and the displays shows "Fill!".
–The controller calculates the required filling pressure. As soon as this
value has been attained, the controller automatically stops the filling
process.
The system circuit is filled with water.

Note!
Monitor the system for the entire automatic filling process.

Note!
If the maximum filling time (10 hours by default) is exceeded, the
system aborts the make-up process with an error message.
•After the cause has been found, acknowledge the error message
by pressing "Quit" at the controller's operating panel and
continue with the filling process, see chapter 9.3 "Messages" on
page 14 .
7.8 Starting Automatic mode
Automatic operation can be started after initial commissioning. The following
prerequisites must be met for automatic operation:
•"P0" minimum working pressure is entered in the controller.
•The device is filled with water.
•All required parameters are defined in the controller.
•The function test has been concluded.
Start the automatic mode at the operator panel of the controller:
•Press "Auto" for automatic operation.
•The "Auto" LED at the operator panel illuminates to visually signal
automatic operation.

Note!
The commissioning process is now concluded.
8Operation
8.1 Operating modes
8.1.1 Automatic mode
Use:
After initial commissioning has been successfully completed
Start:
Press "Auto" on the controller. The Auto LED lights up.
Functions:
Automatic operation is suitable for continuous operation of the device.
The controller monitors the make-up functions.
8.1.2 Manual mode
Use:
For testing and maintenance tasks.
Start:
Press "Manual" on the controller. The Auto LED at the operator panel flashes to
visually indicate that Manual mode is active.
Functions:
Selecting the functions depends on the set make-up variant, "Levelcontrol" or
"Magcontrol".
Manual mode allows you to select the following functions and to perform a test
run:
•Manual and deactivation of the "PU" pump with "Levelcontrol"
•Manual switching on and off of the "PU" pump or "Filling" in the
"Magcontrol" make-up variant.
1. At the controller's operator panel, use the arrow keys to select the "PU"
pump or "Fill" function.
2. Press "OK" at the controller's operator panel to switch on the "PU" pump or
"FIll" function. –"PU!" or "Fill!" is displayed to visually indicate that the
pump is being switched on.
3. Press "OK" at the controller's operator panel to switch off the "PU" pump or
"FIll" function. Displays "PU" or "Fill" to visually indicate that the pump is
being switched off.

Note!
The controller calculates the pressure required for filling. As soon as this
value has been attained, the controller automatically stops the filling
process.

Note!
Manual operations cannot be performed if safety-relevant parameters
would be exceeded. Switching is then disabled.
8.1.3 Stop mode
Use:
For device commissioning
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 in Stop mode.
Function monitoring is stopped.
•The "PU" pump is switched off.

Note!
The system returns an alarm if the Stop mode is activated for more than
4 hours.
If "Floating alarm contact?" in the Customer menu is set to "Yes", the
system outputs the alarm to the group alarm contact.
8.1.4 Summer operation
Use:
The make-up with mains water must be ensured even when the heating and
cooling systems are not operating. Do not shut down the device when the
pressurisation of the heating and cooling systems are in operation.

Controller
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Fillcontrol Auto —22.09.2020 - Rev. C
8.1.5 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 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.
After an extended standstill time (the device is de-energised or in Stop mode),
the "PU" pump may jam.
•Use a screwdriver to rotate the pump at the fan wheel of the pump motor
before restarting.

Note!
A jamming of the "PU" pump is prevented during automatic operation
thanks to forced starting action (after 24 hours).
9Controller
9.1 Operator panel
1
Error LED
•The Error LED illuminates in the event of a fault
2
Display
3
Auto LED
•The Auto LED illuminates green in Automatic mode
•The Auto LED flashes green in Manual mode
•The Auto LED is not illuminated when the system is stopped
4
OK
•Confirm actions
5
Stop
•For commissioning and entry of new values in the controller
6
"Back" to the previous menu
7
Manual
•For tests and maintenance tasks
8
Auto
•For continuous operation
9
"Forward" to the next menu
10
Menu
•Call up the Customer menu
11
Quit
•Acknowledge messages
Selecting and changing parameters
1. Use "OK" (5) to select the parameter.
2. Use the "▼" (7) or "▲" (9) arrow keys to change the parameter.
3. Use "OK" (5) to confirm the parameter.
4. Use the "▼" (7) or "▲" (9) arrow keys to switch to a different menu
option.
5. Use "Quit" (11) to switch to a different menu level.
9.2 Configuring settings in the controller
System-specific values can be corrected via the customer menu. In the course of
initial commissioning, the factory settings must first be adjusted for the system-
specific conditions.

Note!
For a description of the operation, see chapter 9.1 "Operator panel" on
page 12 .
All grey marked menu items must be reviewed during commissioning.
Press "Manual" to switch to manual operation.
Press "Menu" to display the first main menu option "Customer menu".
To navigate and set the values:
•Use the "▼▲" arrow keys to navigate and set the values in the selected
main menu.
•Press "OK" to open the next sub-menu.
•Press "OK" to confirm the changed setting in the sub-menu.
Indication on the
display
Meaning
Customer menu
Switch to the next main menu option.
Language
Standard software in various languages.
Time:
Adjust the "Hour", "Minute", and "Second" display when
each begins to flash.
This time is used for entries in the fault memory.
Date:
Adjust the "Day", "Month", and "Year" display when each
begins to flash.
This date is used for entries in the fault memory.
Fillcontrol /
Magcontrol
Select between the make-up variants "Levelcontrol" and
"Magcontrol".
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 pressure, see
chapter 7.2 "Determining the P0minimum
operating pressure for the controller" on page 9
.
Safety valve
pressure
The system displays the "Safety valve pressure" message
when you have set the "Magcontrol" make-up variant.
Specify the tripping pressure of the applicable safety
valve for the device protection. This is usually the safety
valve at the system heat generator.
Make-up
Switch to the "Make-up" sub-menu.
•Press "OK" to open the menu.
•Use the "▼▲" buttons to open the sub-menu.
Max. make-up time
010 min.
Pre-selected time for a make-up cycle. Upon expiry of
this set time, the system interrupts the make-up and
returns the "Make-up time" fault message.
Max. make-up
cycles
003 / 2 h
If the set number of make-up cycles is exceeded within
two hours, the system interrupts the make-up and
returns the "Make-up cycles" fault message.

Controller
Fillcontrol Auto —22.09.2020 - Rev. C
English —13
Indication on the
display
Meaning
With water meter.
YES
•YES: FQIRA+ contact water meter is installed, see
chapter 4.6 "Optional equipment and accessories"
on page 5 .
This is the prerequisite for the make-up volume
monitoring and the operation of a softening
system.
•NO: A contact water meter is not installed
(standard model).
Make-up volume
000020 l
Only displayed if "YES" has been set in the "With water
meter" menu option.
•Press "OK" to delete the counter.
•Press "YES" to reset the value displayed to "0".
•Press "NO" to retain the displayed value.
Max. make-up
volume
000100 l
This value is only displayed if "YES" has been set in the
"With water meter" menu option.
•When the set volume is exceeded, the system
interrupts the make-up process and returns the
error message "Max. make-up volume exceeded".
With softening
YES
This value is only displayed if "YES" has been set in the
"With water meter" menu option.
•YES: Further queries follow about softening.
•NO: The system does not offer more queries
regarding the softening process.
Disable make-up?
YES
This value is only displayed if "YES" has been set in the
"With softening" menu option.
•YES: The system stops the make-up process when
the set soft water capacity is exceeded.
•NO: The system does not stop the make-up
process. The system displays the "Softening"
message.
Hardness reduction
10 °dH
This value is only displayed if "YES" has been set in the
"With softening" menu option.
•Hardness reduction is calculated from the
difference of the overall water hardness GHactual
and the target water hardness GHtarget.
Hardness reduction = GHactual-GHtargetl °dH
Enter the value in the controller. Consult the
manufacturer information for third-party products.
Cap. soft water
05000 l
This value is only displayed if "YES" has been set in the
"With softening" menu option.
The attainable soft water capacity is calculated from the
type of softening used and the specified hardness
reduction.
•Fillsoft I, soft water capacity ≤ 6000/hardness red. l
•Fillsoft II, soft water capacity ≤ 12000/hardness
red. l
Enter the value in the controller. Consult the
manufacturer information for the values of third-party
products.
Remaining cap. soft
w.
000020 l
This value is only displayed if "YES" has been set in the
"With softening" menu option.
•Available soft water capacity.
Replacement
18 months
This value is only displayed 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
displays the "Softening" message.
Next maintenance
012 months
Recommended maintenance messages.
•Off: Without maintenance recommendation.
•001 –060: Maintenance recommendation in
months.
Floating fault
contact
YES
For the output of messages to the floating contact, see
chapter 9.3 "Messages" on page 14 .
•YES: Output of all messages.
•NO: Output of all messages identified with "xxx"
("01", for example).
Indication on the
display
Meaning
Fault memory˃
Switch to the "Fault memory" sub-menu.
•Press "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.
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 entries of the minimum working pressure are
stored with date and time.
V0.60
Information 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
EN
Display language
Fillcontrol XX
Magcontrol
For systems with diaphragm-type
expansion vessel
Minimum operating
pressure P0
1.5 bar
Only Magcontrol
see chapter 7.2 "Determining the P0
minimum operating pressure for
the controller" on page 9
Safety valve, pressure
3.0 bar
Tripping pressure for the safety
valve at the heat generator in the
system
Next maintenance
12 months
Time left to the next due
maintenance
Volt-free contact
NO
Only the messages marked in the
"Messages" list
Make-up
Maximum make-up volume
5000 litres
Only if controller with "With water
meter yes"
Maximum make-up time
20 minutes
Magcontrol
Maximum make-up cycles
3 cycles
within 2
hours
Magcontrol
Softening (Only if "With softening yes")
Shut off make-up
NO
In the event of soft water residual
capacity = 0
Hardness reduction
8°dH
= Setpoint –Actual
Maximum make-up volume
0 litres
Attainable make-up quantity
Soft water capacity
0 litres
Attainable water capacity
Cartridge replacement
18 months
Replace cartridge

Controller
14 —English
Fillcontrol Auto —22.09.2020 - Rev. C
9.2.2 Service menu
The Service menu is password-protected. Only Reflex service technicians are able
to access this menu, see chapter 12.1 "Reflex Customer Service" on page 16 .
Parameter
Setting
Comment
Make-up
Pressure differential, "NSP"
make-up
0.2 bar
Only Magcontrol
Pressure differential, filling
pressure PF –P0
0.3 bar
Only Magcontrol
Water volume per contact
10 l / K
Only if a water meter is installed.
Maximum filling contacts
OFF
Limits the filling volume.
Only if a water meter is installed.
9.3 Messages
The display provides alarms in plain text and the ER codes shown in the list. Use
the arrow buttons to scroll through multiple alarms displayed at the same time.
The fault memory stores the last 20 alarms for review, see chapter 7.5
"Parametrising the controller in the Customer menu" on page 10 .
Alarm causes can be eliminated by the operator or a specialist workshop. If this is
not possible, contact the Reflex Customer Service.

Note!
Clearing of the cause must be confirmed by pressing the “Ack” button on
the operator panel. All other alarms are automatically reset as soon as
the cause has been eliminated.

Note!
Floating contacts, setting in the Customer menu, see chapter 7.5
"Parametrising the controller in the Customer menu" on page 10 .
ER
Code
Alarm
Group alarm
Causes
Remedy
Alarm reset
01
Min. pressure
•Only with Magcontrol
YES
The set value for the "P0" minimum working
pressure has been exceeded.
•Water loss in the system.
•Expansion vessel defective.
•Fault at the "PU" pump.
•Check the system for leaks.
•Replace the expansion vessel.
•Check the function in manual mode.
–"PU" pump
"Quit"
02.1
Insufficient water
No water in the system separator vessel.
•Ball valve in make-up line closed.
•Dirt trap clogged.
•Float valve defective.
•Open the ball valve in the make-up
line.
•Clean the dirt trap.
•Replace the float valve.
04.1
Pump
YES
Pump does not start.
•"PU" pump is stuck.
•Pump motor defective.
•10 A fuse defective.
•Contractor (Klixon) tripped.
•Manually turn the pump to start.
•Replace the pump motor.
•Replace the fuse.
•Check the mechanical and electrical
functions of the pump motor.
"Quit"
06
Make-up time
Set time for the make-up time has been
exceeded.
•Severe water loss in the system.
•Make-up line not connected.
•Make-up rate insufficient.
•Make-up hysteresis too high.
•Check the system for leaks.
•Connect the make-up system.
•Check the make-up rate.
•Check the make-up hysteresis.
"Quit"
07
Make-up cycles
Set value for the make-up cycles has been
exceeded.
•Leakage in the system.
•Check the system for leaks.
"Quit"
08
Pressure measurement
•Only with Magcontrol
YES
Controller receives incorrect signal.
•Pressure transducer plug not plugged
in.
•Broken wire from "PIS" pressure
transducer.
•"PIS" pressure transducer defective.
•Plug in the plug.
•Replace the wire.
•Replace the "PIS" pressure
transducer.
"Quit"
10
Maximum pressure
•Only with 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 the system.
•Water volume per contact incorrectly
set in the Service menu.
•Check the system for leaks.
•Check the set value.
"Quit"
12
Filling time
•Only with Magcontrol
Set value for the maximum filling time has
been exceeded.
•System volume too large
(≤ 3000Liter).
•Restart the filling process
"Quit"
13
Filling volume
•Only with Magcontrol
and contact water meter
•System volume too large
(≤ 3000Liter).
•Water volume per contact incorrectly
set in the Service menu.
•If necessary, restart the filling process
•Set the water quantity per contact in
the Service menu.
"Quit"
16
Power failure
No power.
Check power supply.
–

Maintenance
Fillcontrol Auto —22.09.2020 - Rev. C
English —15
ER
Code
Alarm
Group alarm
Causes
Remedy
Alarm reset
19
Stop > 4 h
The device is in Stop mode for more than 4
hours.
Select Automatic mode.
–
20
Max. make-up volume
Set value for the make-up quantity has been
exceeded.
Reset the "Make-up volume" meter in the
Customer menu.
"Quit"
21
Maintenance recommended
Set value exceeded.
Carry out maintenance.
"Quit"
24
Softening
•Set value for the water capacity has
been reached.
•Time interval for replacement of the
softening cartridge has been reached.
Replace the softening cartridge.
"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
Under voltage
YES
Supply voltage too low.
Check power supply.
33
Adjustment parameter faulty
EEPROM parameter memory defective.
Inform Reflex Customer Service.
34
Main board communication
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).
10 Maintenance
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).
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.
The device is to be maintained annually.
•The maintenance intervals depend on the local operational conditions.
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.
10.1 Maintenance schedule
The maintenance schedule is a summary of maintenance tasks to be carried out
regularly.
Activity
Check
Wait
Clean
Interval
Check for leaks, see chapter 10.2 "Exterior
leak test" on page 15 .
•"PU" pump
•Screw connections
x
x
Annually
Cleaning the dirt trap
•see chapter 10.3 "Cleaning the dirt
trap" on page 16 .
x
Depending on the
operating
conditions
Check the make-up function
•see chapter 7.6 "Function test" on
page 10 .
x
Annually
Check the system-specific set values in the
controller, see chapter 9.2.1 "Customer
menu" on page 13 .
•Minimum operating pressure "P0".
•Safety valve pressure "PSV".
x
Annually

Note!
Compare the minimum working pressure with the initial pressure in the
diaphragm expansion vessel.
–If necessary, adjust the initial pressure in the diaphragm expansion
vessel.
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.

Disassembly
16 —English
Fillcontrol Auto —22.09.2020 - Rev. C
10.3 Cleaning the dirt trap
Clean the "ST" dirt trap according to the following intervals:
•Commissioning.
•Long lasting operation.
–Depending on the operating conditions.
•Long lasting standstill.
•At the latest, after one year in continuous operation.
1. Press "Stop" on the controller's operator panel.
–The device is non-functioning and the pumps are shut down.
2. Connect the ball valve upstream of the "ST" dirt trap in the make-up line to
the mains separator tank.
3. Slowly unscrew the dirt trap insert (2) from the dirt trap (1) in order for the
residual pressure to escape from the pipeline segment.
4. Pull the sieve from the dirt trap insert.
5. Rinse the sieve with clean water.
6. Use a soft brush to clean the sieve.
7. Reinsert the cleaned sieve into the dirt trap insert.
8. Check the seal of the dirt trap insert for damage.
9. Screw the dirt trap insert back into the housing of the "ST" dirt trap (1).
10. Open the ball valve upstream of the "ST" (1) dirt trap.
11. Switch to Automatic mode.
The dirt trap has been cleaned.

Note!
Clean all other installed dirt traps in the system circuit (in the Fillset, for
example).
•Repeat the steps described above to clean the dirt trap.
11 Disassembly
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.
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 burns on hot surfaces
Hot surfaces in heating systems can cause burns to the skin.
•Wait until hot surfaces have cooled down or wear protective safety
gloves.
•The operating authority is required to place appropriate warning signs
in the vicinity of the device.
CAUTION
Risk of injury due to pressurised liquid
If installation 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 steam suddenly escapes.
•Ensure proper disassembly.
•Ensure that the system is de-pressurised before performing the
disassembly.
Proceed as follows:
1. Prior to 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. Drain all water from the device.
7. If necessary, physically remove the device from the system.
The device is removed.
12 Annex
12.1 Reflex Customer Service
Central customer service
Central telephone number: [phone] - 0
Customer Service extension: [phone] - 9505
Fax: [phone] - 9523
E-mail: [email protected]
Technical Hotline
For questions about our products
Telephone number: [phone]
Monday to Friday 8:00 to 16:30
12.2 Conformity and standards
Device conformity declarations are available on the Reflex homepage.
www.reflex-winkelmann.com/konformitaetserklaerungen
Alternatively, scan the QR code:
12.3 Guarantee
The respective statutory guarantee regulations apply.

Annex
Fillcontrol Auto —22.09.2020 - Rev. C
English —17
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.
,
,

SI1415enC / 11-20
Reflex Winkelmann GmbH
Gersteinstraße 19
59227 Ahlen, Germany
[phone]
[phone]
www.reflex-winkelmann.com