Reflex Servitec 30 Mobil User manual

Vacuum spray degassing
03.11.2014
Servitec 30 Mobil
GB Operating manual
Original operating manual

Contents
Vacuum spray degassing — 03.11.2014 English — 3
English
Vacuumspraydegassing
03.11.2014
Contents
1Notes on the operating manual ....................................................................................................................................................5
2Liability and guarantee ..................................................................................................................................................................5
3Safety ...............................................................................................................................................................................................6
3.1Explanation of symbols........................................................................................................................................................................ 6
3.1.1Symbols and notes used................................................................................................................................................... 6
3.1.2Safety symbols 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
4Description of the device ...............................................................................................................................................................9
4.1Description............................................................................................................................................................................................. 9
4.2Overview ..............................................................................................................................................................................................10
4.3Identification .......................................................................................................................................................................................11
4.4Function ...............................................................................................................................................................................................11
4.5Scope of delivery.................................................................................................................................................................................14
4.6Optional equipment and accessories ..............................................................................................................................................14
5Technical data ...............................................................................................................................................................................15
6Installation.....................................................................................................................................................................................17
6.1Installation conditions .......................................................................................................................................................................18
6.1.1Incoming inspection .......................................................................................................................................................18
6.2Preparatory work ................................................................................................................................................................................18
6.3Execution..............................................................................................................................................................................................19
6.3.1Hydraulic connection......................................................................................................................................................20
6.4Switching and make-up variants......................................................................................................................................................23
6.4.1Pressure-dependent "Magcontrol" make-up mode ..................................................................................................23
6.4.2Level dependent "Levelcontrol" make-up mode .......................................................................................................24
6.5Electrical connection ..........................................................................................................................................................................25
6.5.1Terminal diagram............................................................................................................................................................26
6.5.2RS-485 interface ..............................................................................................................................................................28
7Commissioning .............................................................................................................................................................................29
7.1Checking the requirements for commissioning.............................................................................................................................29
7.2Setting the minimum operating pressure for Magcontrol...........................................................................................................29
7.3Filling the device with water.............................................................................................................................................................30
7.4Controller .............................................................................................................................................................................................31
7.4.1Operator panel.................................................................................................................................................................31
7.4.2Modifying the controller's start routine.......................................................................................................................32
7.4.3Parametrising the controller..........................................................................................................................................33
7.5Starting Automatic mode..................................................................................................................................................................36
8Operation.......................................................................................................................................................................................37
8.1Operating modes ................................................................................................................................................................................37
8.1.1Automatic mode..............................................................................................................................................................37
8.1.2Manual mode...................................................................................................................................................................38
8.1.3Stop mode ........................................................................................................................................................................38
8.1.4Summer operation ..........................................................................................................................................................38
8.1.5Restarting .........................................................................................................................................................................39

Contents
4 — English Vacuum spray degassing — 03.11.2014
8.2Controller .............................................................................................................................................................................................39
8.2.1Customer menu...............................................................................................................................................................39
8.2.2Service menu....................................................................................................................................................................39
8.2.3Default settings ...............................................................................................................................................................40
8.2.4Messages ..........................................................................................................................................................................41
9Maintenance................................................................................................................................................................................. 44
9.1Maintenance schedule....................................................................................................................................................................... 45
9.2Cleaning ...............................................................................................................................................................................................45
9.2.1Cleaning the dirt trap...................................................................................................................................................... 45
9.3Maintenance certificate .....................................................................................................................................................................46
10Disassembly.................................................................................................................................................................................. 47
11Annex ............................................................................................................................................................................................ 49
11.1Reflex Customer Service ....................................................................................................................................................................49
11.2Conformity and standards.................................................................................................................................................................50
11.3Guarantee ............................................................................................................................................................................................50
11.4Glossary ................................................................................................................................................................................................50


Notes on the operating manual
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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 14 ..
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
device operator and must be stored near the device for access at any time.
2Liability and guarantee
The device has been designed using state-of-the-art technology and in accordance with generally recognised technical safety
regulations. 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.
Warranty and liability claims will not be accepted by the manufacturer if these can be traced back to one or more of the following causes:
• Improper use of the device.
• Improper start-up, operation, maintenance, servicing, 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 and accessories.
Prerequisite for warranty claims is the proper handling of the device.

Safety
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3Safety
3.1 Explanation of symbols
3.1.1 Symbols and notes used
The following symbols are used in this operating manual.
Danger
• Danger to life and/or severe damage to health
– The corresponding warning symbol in combination with the "Danger" signal term indicates an imminent
threatening danger which will result in death or severe (irreversible) injuries.
Warning
• Severe damage to health
– The corresponding warning symbol in combination with the "Warning" signal term indicates a threatening
danger which may result in death or severe (irreversible) injuries.
Caution
• Damage to health
– The corresponding warning symbol in combination with the "Caution" signal term indicates a danger which
may result in minor (reversible) injuries.
Attention!
• Damage to property
– This symbol in combination with the "Attention" signal word indicates a situation that may cause damage to
the product itself or objects in its vicinity.
Notice!
This symbol in combination with the "Notice" signal word indicates useful tips and recommendations regarding the
efficient use of the product.
3.1.2 Safety symbols used
The following safety symbols are used in this operating manual. They are also attached to the equipment or in its vicinity.
This symbol warns of electric.voltage.
This symbol warns of a hot surface.
This symbol warns of overpressure in conduits and connections.

Safety
Vacuum spray degassing — 03.11.2014 English — 7
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 used in facility systems for stationary heating and cooling circuits. 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
Minimise the entry of atmospheric oxygen due with permeation in the entire facility system and make-up with water.
Note!
Ensure the quality of the make-up water as specified by national regulations.
– For example, VDI 2035 or SIA 384-1.
3.5 Inadmissible operating conditions
The device is not suitable for the following applications:
• Outdoor operation.
• For the use with mineral oils.
• For the use with flammable media.
• For the 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 burning!
• Excessively hot surfaces in heating systems can cause burns on the skin.
– Wear protective gloves.
– Please place appropriate warning signs in the vicinity of the device.
Caution – risk of injury!
• 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 injury!
• The contact with glycol-containing water in facility systems for cooling circuits may cause skin and eye irritation.
– Wear personal protective equipment.
Caution – Weight!
• The device weight may cause physical damage or accidents.
– If necessary, have a second person help you with the assembly or disassembly.
Caution – Device damage during transport!
• Improper transporting procedures cause damage to the connections for degassing and make-up lines.
– Use suitable covers to protect the connections against damage.
– Transport the device only in vertical position.
Caution – Property damage during transport!
• Improper transporting procedures may cause damage to property.
– Fasten the device with suitable transport securing means such as straps.

Description of the device
Vacuum spray degassing — 03.11.2014 English — 9
4Description of the device
4.1 Description
The device is a mobile degassing and make-up station. The principal applications are heating and cooling circuits and new installations
of facility systems in which dissolved or free gases must be eliminated. The device uses a 3-ways motor ball valve for the hydraulic
control of the facility and make-up degassing and a vacuum for the degassing process itself.
The device provides the following safety features:
• No direct intake of air thanks to a regulation of the pressure maintenance with automatic water make-up.
• No circulation issues caused by free bubbles in the circuit water.
• Reduced corrosion damage due to oxygen removal from fill and make-up water.

Description of the device
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4.2 Overview
000206_001_R001
ErrorAuto
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WC DC
DC
8 7
1 2 3 4 5 6
1 Controller 6 "PIS" pressure transducer
2 Venting grille 7 "PU" vacuum degassing pump
3 "ST" dirt trap 8 Removable front shell
4 "DV" degassing valve WC Connection for the make-up with fresh water
5 "CD" 3-ways motor ball valve for the hydraulic regulation
of system and make-up degassing
DC Degassing connection
• Gas-rich water inlet.
• Degassed water outlet.

Description of the device
Vacuum spray degassing — 03.11.2014 English — 11
4.3 Identification
The nameplate provides information about the manufacturer, the year of manufacture, the manufacturing number and the technical
data.
Information on nameplate Meaning
000043_001_R001
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
4.4 Function
The device degasses the water from the facility system and the fresh water from the make-up line. It removes up to 90 percent of the
dissolved gases from the water. The degassing operation uses timer-controlled cycles.
A cycle comprises the following phases:
1. Vacuum is drawn
– The "PU“ pump draws a vacuum. The inlet to the "DC" pump remains closed.
2. Atomisation
– The inlet to the "PU" vacuum pump is opened. Depending on the actual demand, a partial flow of the gas-rich system water of
the facility system or the fresh make-up water are introduced through the "DC" or "WC" lines of the device. The water is then
finely atomised in the vacuum pump. The large surface of the atomised water and the large gas saturation headway to the
vacuum result in a degassing of the water. The degassed water is returned to the system via the vacuum pump.
3. Discharge
– The "PU" vacuum pump shuts off. The system continues to atomise and degas water. The water level in the vacuum pump rises.
The gases separated from the water are discharged into the ambient atmosphere via the "DV" degassing valve.
4. Idling time
– When the gas has been discharged, the device will remain in idle until the next cycle is started.

Description of the device
12 — English Vacuum spray degassing — 03.11.2014
Degassing cycle sequence in the PU vacuum pump
Cooling water system ≤30 °C, System pressure 1.8 bar, "DC" system degassing in operation, "WC" make-up degassing closed.
000165_001_R001
M
1,8...1 bar
DV
M
WC DC
CD
M
-1 bar
DV
M
WC CD
M
-1...1,8 bar
DV
M
WC CD
M
1,8 bar
DV
M
WC DC
CD
1234
1 Vacuum is drawn 3 Discharge
2 Atomisation 4 Idling time
Degassing
The entire degassing process is hydraulically synchronised by the "CD" 3-ways motor ball valve and the device controller. The system
monitors the operating states and displays them at the controller. The controller provides 3 different degassing programmes and 2
different make-up variants for selection and setting.
Degassing programmes
Continuous degassing: For continued degassing over several hours or days in a sequence of degassing cycles without idling
periods. This programme is recommended after commissioning and repairs.
Interval degassing: Interval degassing comprises a limited number of degassing cycles. The system idles between the intervals.
This programme is recommended for continuous operation.
Make-up degassing: Make-up degassing automatically activated for every water make-up during continuous or interval
degassing. The process is the same as in continuous degassing. The degassing time is limited by the make-
up time.

Description of the device
Vacuum spray degassing — 03.11.2014 English — 13
Make-up variants
There are two make-up variants. Both are monitored via the make-up time and the make-up cycles.
000166_001_R001
230V
WC
M
DV
DC
MCD
DC
PIS
LIS
V
1 2 3 4 5 6 7 8
11 10 9
1 "WC" make-up line 7 "DC" degassing line (degassed water to the facility
system)
2 Optional add-on device (see Chapter Optional
equipment and accessories)
8 "DC" degassing line (gas-rich water from the facility
system)
3 Device 9 "CD" 3-ways motor ball valve
4 "DV" degassing valve 10 Device controller
5 "PU" vacuum pump 11 Signal line from the "LIS" level sensor of a pressure
maintaining station
6 "PIS" pressure transducer from the device
Magcontrol: For systems with diaphragm-type pressure expansion tank.
– Using the integrated "PIS" pressure sensor, the system registers and monitors the pressure in the
heating or cooling system. The make-up degassing process is activated as soon as the pressure drops
below the calculated filling pressure.
Levelcontrol: For systems with pressure maintaining stations.
– The pressure maintaining station uses the "LIS" pressure pick-up to determine the water level in the
expansion tank. The make-up function is triggered by a 230 V signal.
Note!
Ensure the correct connection of the device to the facility system.
– For the Levelcontrol make-up variant in particular, the signal line from the level sensor of the pressure maintaining
station must be connected to the device.

Description of the device
14 — English Vacuum spray degassing — 03.11.2014
4.5 Scope of delivery
The scope of delivery is described in the shipping document for the initial shipment and the content is shown on the packaging.
Immediately after receipt of the goods, please check the shipment for completeness and damage. Please notify us immediately of any
transport damage.
Basic degassing equipment:
• Device with transport unit
• 3 ball valves for degassing and make-up connections
• Operating manual
4.6 Optional equipment and accessories
The following optional equipment and accessories are available for this device:
• Fillset for make-up with water.
– Fillset with integrated backflow preventer, water meter, dirt trap, and locking mechanisms for the "WC" make-up line.
• Fillset Impulse with FQIRA+ contact water meter for make-up with water.
– If the Fillset Impulse with FQIRA+ contact water meter is installed in the make-up line, you can regulate the entire make-up
quantity and the soft water capacity of Fillsoft softening systems. The operational reliability of the device is assured and
prevents the automatic make-up during major water loss or small leaks.
• Fillsoft for softening the make-up water from the public water network.
– Fillsoft is installed between Fillset and the device. The device controller evaluates the make-up quantities and signals a
required replacement of the softening cartridges.
• Enhancements for the device controller.
• Use the RS-485 interface to retrieve various data from the controller and to communicate with control centres or other
devices.,see chapter 6.5.2.1 "Connecting the RS-485 interface" on page 28 . You need the following items for the
communication of the RS-485 interface with control centres or other devices:
– Bus modules for the communication with control centres
– Lonworks Digital
– Lonworks
– Profibus-DP
– Ethernet
– I/O module for standard communication
• Gas discharge measurement for an optimised degassing operation.
Note!
Separate operating instructions are supplied with accessories.

Technical data
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5Technical data
000207_001_R001
ErrorAuto
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WC DC
DC
Type Servitec 30 Mobil
Part No. • 8828600 (model with "J" mains plug)
• 8828650 (model with earthed plug)
Width 600 mm
Height 1200 mm
Depth 500 mm
Weight 27 kg
Permissible gauge operating pressure 8 bar
Maximum inlet pressure for make-up 6 bar
Permissible operating temperature
• System degassing
• Make-up degassing
˃0 – 70 °C
˃0 – 30 °C
Permissible ambient temperature ˃0 – 45 °C
Degree of discharge
• Dissolved gases
• Free gases
≤90 %
100 %
Noise level 55 db
Degree of protection IP 54
Electrical power supply
• Output
• Fusing
• Voltage
• Frequency
470 W
10 A
230 V
50 Hz
Electrical power supply, controller
• Voltage
• Fusing
230 V
4 A
System volume *
• Va 100
• Va 50/50
12 m3
4 m3
Working pressure 0.5 – 3.0 bar
Make-up output 0.05 m3/ h
Connector for "DC" degassing line, internal thread (IG)
• To the device
• To the facility system
IG ½ "
IG ½ "
Connector for "WC" make-up line, internal thread (IG) IG ½ "
* Va 100 = 100 % water; Va 50/50 = water with anti-freeze portion to 50%

Technical data
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Approximate values for the maximal "Va" system volume to be degassed under extreme conditions during commissioning at a nitrogen
reduction from 18 mg/l to 10 mg/l.
000168_001_R001
1 Continuous degassing "t" [h] 2 System volume "Va" [m3]

Installation
Vacuum spray degassing — 03.11.2014 English — 17
6Installation
Danger – electric shock!
• Risk of serious injury or death due to electric shock.
– 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!
• 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 burning!
• Excessively hot surfaces in heating systems can cause burns on 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 at system components during installation.
– Wear personal protective equipment (helmet, protective clothing, gloves, safety boots).

Installation
18 — English Vacuum spray degassing — 03.11.2014
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 a complaint accordingly.
6.2 Preparatory work
000037_001_R001
max.45 °C
min.0 °C
≥ DN 15
Preparing the connection of the device to the facility system:
• Barrier-free access to the facility system.
• Level and solid placement surface for the device.
• Frost-free, well-ventilated room.
– Room temperature > 0 - 45 °C.
• Drain for drain water.
• Filling connection.
– DN 15 according to DIN 1988 T 4.
• Electric connection.
– 230 V~, 50 Hz, 16 A with upstream ELCB (tripping current: 0.03 A).

Installation
Vacuum spray degassing — 03.11.2014 English — 19
6.3 Execution
Caution – risk of injury!
• Bodily harm from a toppling device.
– Ensure sufficient stability of the device.
– Weigh down the bearing surface of the device's transport unit with suitable means.
Caution – damage from improper connection!
• Bear in mind that the device may be subject to additional stresses through the connection of piping or hose
connections to the facility system.
– Ensure that all connections to the facility system are free from stresses.
– If necessary, provide support structures for the pipes.
Caution – Property damage caused by leaks!
• Leaks in the connection lines to the device can cause damage to the facility system.
– Use only connection lines with appropriate resistance against the facility system temperature.
Note!
The screw connections at the device may loosen when the device is moved to another location.
– Prior to using the device check the screw connections for proper seating and sealing.
Note!
Avoid leaks at the connections.
– When connecting the device to the facility system, ensure that the connections for degassing and make-up are not
twisted.
Proceed as follows:
• Connect the device at the return flow side of the facility system.
– In this manner, you ensure that the device is operated within the permissible pressure and temperature ranges.
• In the case of a facility system with return flow admixture or a hydraulic switching point, connect the device upstream of the
switching point.
– In this manner, you ensure the water degassing in the "V" main volume flow at temperatures ≤70 °C.
The device is pre-wired and must be adapted for the local system conditions.
Proceed as follows:
1. Complete the water side connections from the device to the facility system.
2. Complete the electric connection as shown in the terminal plan, see chapter 6.5 "Electrical connection" on page 25 .
Note!
During connection, ensure the operability of the valves and the inlet options for the connecting lines.

Installation
20 — English Vacuum spray degassing — 03.11.2014
6.3.1 Hydraulic connection
6.3.1.1 Degassing line to the system
Installation detail of the "DC" degassing line
Install the "DC" degassing lines as shown below:
000171_001_R001
DCDC
≥ 500
DCDC
≥ 500
DC
DC
≥ 500
Proceed as follows:
• Prevent an overload of the "ST" dirt trap in the device caused by coarse dirt.
• Install the "DC" gas-rich degassing line upstream of the gas-poor degassing line when viewed in system flow direction.
• Preferably install at the return flow side of the facility system.
– The water temperature must be in the range of 0 °C to 70 °C to ensure sufficient degassing capacity.