Reflex Fillcontrol Plus User manual

Fillcontrol Plus
19.10.2020 - Rev. C
GB
Operating manual
Original operating manual

Contents
2 —English
Fillcontrol Plus —19.10.2020 - Rev. C
English
FillcontrolPlus
19.10.2020- 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 ...................................................................................4
4.4 Function .......................................................................................................4
4.5 Scope of delivery.........................................................................................5
4.6 Optional equipment and accessories ...................................................... 5
5Technical data .............................................................................5
6Installation...................................................................................5
6.1 Installation conditions ...............................................................................5
6.1.1 Incoming inspection................................................................. 5
6.2 Preparatory work........................................................................................5
6.3 Execution...................................................................................................... 5
6.3.1 Wall mounting........................................................................... 6
6.3.2 Hydraulic connection................................................................6
6.4 Switching and make-up variants .............................................................6
6.5 Electrical connection..................................................................................7
6.5.1 Terminal diagram......................................................................7
6.5.2 RS-485 interface ........................................................................ 8
6.6 Installation and commissioning certificate ............................................8
7Commissioning ...........................................................................8
7.1 Requirements for initial commissioning.................................................8
7.2 Determining the P0minimum operating pressure for the controller 8
7.3 Filling the device with water.....................................................................8
7.4 Parametrising the controller in the Customer menu ............................8
7.5 Function test................................................................................................8
7.6 Use the device to fill the facility system with water..............................9
7.7 Starting Automatic mode..........................................................................9
8Operation.....................................................................................9
8.1 Operating modes ........................................................................................9
8.1.1 Automatic mode........................................................................9
8.1.2 Manual mode.............................................................................9
8.1.3 Stop mode ..................................................................................9
8.1.4 Summer operation ..................................................................10
9Controller...................................................................................10
9.1 Operator panel ..........................................................................................10
9.2 Configuring settings in the controller ...................................................10
9.2.1 Customer menu .......................................................................11
9.2.2 Service menu............................................................................11
9.3 Messages....................................................................................................11
10 Maintenance..............................................................................13
10.1 Maintenance schedule.............................................................................13
10.2 Exterior leak test .......................................................................................13
11 Disassembly...............................................................................14
12 Annex .........................................................................................14
12.1 Reflex Customer Service ..........................................................................14
12.2 Conformity and standards.......................................................................14
12.3 Guarantee...................................................................................................14

Notes on the operating manual
Fillcontrol Plus —19.10.2020 - 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 14 .
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.
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.
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.

Description of the device
4 —English
Fillcontrol Plus —19.10.2020 - Rev. C
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 makeup station without a pump for heating and cooling water
systems. The controller regulates the water makeup for the plant system.
The device is suitable for two makeup systems:
•Freshwater makeup to plant systems with a diaphragm expansion tank.
•Freshwater makeup to plant systems with a pressurisation station.
4.2 Overview
1
"BV" shut-off valve
5
Cover (hinged)
2
"PIS" pressure transducer
6
Control Basic controller
3
"WV" make-up valve
WC
Mains water inlet/outlet
4
Console for wall mounting
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
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
Flow characteristic
kvs (m³/h)
Fillcontrol Plus P
1,4
E
3
Stainless steel model
1
2
3
4.4 Function
1
Fillset Impuls
2
"Fillsoft" softening system
3
Fillcontrol Plus
LIS
Filling level monitoring for level-dependent make-up
•External signal line to the controller
PIS
Pressure transducer for pressure-dependent make-up
•Internal signal line from the pressure transducer to the controller
WC
Make-up line to the device
DC
Make-up line to the system circuit
Fillcontrol Plus controls the make-up with mains water for the system circuit.
The controller monitors the following functions:
•Make-up time.
•Make-up cycles.
•Make-up quantity, if an optional contact water meter is installed.
The controller will detect small leaks in the system. When a leak is detected, the
controller interrupts the make-up with as soon as the make-up time or the make-
up cycles are exceeded.
Fillcontrol Plus supports two make-up variants:
•Pressure-dependent make-up with water in a system circuit with a
diaphragm expansion vessel ("Magcontrol" mode).
–The pressure transducer sends a signal to the controller if the
pressure drops below the minimum working pressure of the system
circuit. The make-up is released. Mains water is added to the system
circuit. For calculating the filling pressure into the system circuit, see
chapter 7.2 "Determining the P0minimum operating pressure for the
controller" on page 8 .
•Level-dependent make-up with water in a system circuit with a
pressurisation unit ("Levelcontrol" mode).
–A pressurisation unit monitors the filling level in the expansion
vessel. If the level drops below minimum, the pressurisation unit
sends a signal to the controller. The make-up is released. Mains water
is added to the system circuit.
The mode is set in the Customer menu, see chapter 9.2.1 "Customer menu" on
page 11 .
The controller may monitor additional function, if you combine various
accessories.
The following components are available as optional accessories:
•"Reflex Fillsoft" softening system.
•"Reflex Fillset" with "FQI" water meter.
•"Reflex Fillset Imuls" with "FQIRA+" contact water meter.

Note!
For optional accessories, see chapter 4.6 "Optional equipment and
accessories" on page 5 .

Technical data
Fillcontrol Plus —19.10.2020 - Rev. C
English —5
4.5 Scope of delivery
The scope of delivery is described in the shipping document and the content is
shown on the packaging.
Basic make-up equipment:
The pre-assembled device
Operating instructions.
4.6 Optional equipment and accessories
The following optional equipment and expansion functions are available for this
device:
•Fillset or Fillset Compact as add-on modules for drinking water systems.
•Softening with Reflex Fillsoft.
•Expansions for Reflex Basic controllers:
–I/O modules
–Bus modules:
•Profibus DP
•Ethernet

Note!
Separate operating instructions are supplied with accessories.
5Technical data
Permissible ambient temperature
> 0 –45 °C
Degree of protection
IP 54
Noise level
55 dB
Electric output
350 W
Power supply
230 V / 50 Hz
Fusing
4 A
Number of RS-485 interfaces
2
Weight (stainless steel)
1.7 kg (2.5 kg)
Height
340 mm
Width
320 mm
Depth
190 mm
Inlet connection
G ¾"
Outlet (return) connection
G ½"
Make-up output
≤ 1400 l/h
Max. supply pressure
10 bar
Max. delivery pressure
≤ 8.5 bar
Permissible gauge operating pressure
10 bar
Permissible operating temperature
60 °C
I/O module
optional
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 45 °C.
•Filling connection.
–If necessary, provide a DN 15 filling connection according to
DIN 1988 T 4.
•Electric connection: 230 V~, 50 Hz, 16 A with upstream ELCB: Tripping
current 0.03 A.
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 8 .
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.

Installation
6 —English
Fillcontrol Plus —19.10.2020 - Rev. C
6.3.1 Wall mounting
The device is installed at the wall. Bore holes for wall mounting are provided on
the rear of the console (1) housing.
Select the attachment means according to the wall properties and the weight (G)
of the device.
During installation, ensure that:
•The device is installed sufficiently close to the diaphragm expansion vessel.
•The fixtures can be operated.
•The feed connections of the pipes are not adversely affected.
6.3.2 Hydraulic connection
6.3.2.1 Connection to the facility system
1
Fillset Impuls
5
"BV" shut-off device
2
"Fillsoft" softening system
WC
Make-up line to the device
3
"WV" Make-up valve
DC
Make-up line to the system
circuit
4
Fillcontrol Plus
DN
Nominal diameter of the
make-up line
Prepare the connection as follows:
1. Select the "DN" nominal diameter for the make-up lines.
–At a length of up to 10 metres: DN 15.
–At a length of more than 10 metres: DN 20.
2. Connect the "DC" make-up line to the "BV"shut-off device.
3. Connect the "DC" make-up line to the system circuit.
4. Connect the "WC" make-up line to the "WV" make-up valve.
5. Connect the "WC" make-up line to the external mains water supply.
The make-up lines are connected.

Note!
Use a pressure reducer in the "WC" make-up line if the mains water
pressure exceeds 6 bar.

Note!
For selecting the make-up variants, see chapter 6.4 "Switching and
make-up variants" on page 6 .
6.4 Switching and make-up variants
Example of a pressure-dependent make-up with "Fillcontrol Plus".
1
Fillset
2
Fillcontrol Plus
3
Diaphragm expansion vessel MAG
PIS
Pressure sensor
WC
Make-up line to the device
DC
Nominal diameter of the make-up line
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 make-up is
released. Mains water is added to the system circuit.
Proceed as follows:
1. In the Customer menu, activate the "Magcontrol" mode, see chapter 9.2.1
"Customer menu" on page 11 .
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 8 .
3. Do not use nominal diameters below the specified diameters for the
"WC"make-up lines.
–You will avoid an undesired cycling of the make-up.
Example of a level-dependent make-up with "Fillcontrol Plus".
1
Fillset Impuls
2
"Fillsoft" softening system
3
Fillcontrol Plus
4
"Reflexomat" pressurisation unit
WC
Make-up line to the device
DN
Nominal diameter of the make-up line

Installation
Fillcontrol Plus —19.10.2020 - Rev. C
English —7
The pressurisation unit is fitted with a monitoring device for the filling level in
the expansion vessel. If the filling level drops below the minimum level in the
expansion vessel, the pressurisation unit sends a signal to the device controller.
The make-up is released. Mains water is added to the system circuit.
Proceed as follows:
1. In the Customer menu, activate the "Levelcontrol" mode, see chapter 9.2.1
"Customer menu" on page 11 .
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 8 .

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.
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 ("Levelcontrol" only)
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.
Pre-wired
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)
22
PE (shield)
Pressure analogue input.
•Display at the controller.
•Activation of the make-
up.
–For the
"Magcontrol"
make-up variant
Pre-wired
23
- Pressure
(signal)
24
+ Pressure (+
18 V)
29
A
RS-485 interface.
User,
optional
30
B
31
GND
32
+ 24 V
(supply)
Supply for E1 and E2.
Pre-wired,
bridged
33
E1
Contact water meter (in "Fillset
Impuls", for example), see
chapter 4.6 "Optional
equipment and accessories" on
page 5 .
•Evaluation of the make-
up.
•Contact 32/33 closed =
meter pulse.
User,
optional

Commissioning
8 —English
Fillcontrol Plus —19.10.2020 - Rev. C
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 11 .
–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 7 .
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 (hst = 0) as the diaphragm
expansion vessel:
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
P0Minimum working pressure in bar
p0 Initial pressure, diaphragm expansion vessel, in bar
hst Static elevation in m

Note!
Calculate the filling pressure for the make-up with mains water into the
system circuit as follows:
Filling pressure ≥ P0+ 0.3 bar

Note!
During planning, take into account that the working range of the
device must be between the "PA" initial pressure and the "PE" final
pressure in the pressurisation working range.
7.3 Filling the device with water
Proceed as follows:
1. Connect the "BV" shut-off device (1) to the system circuit.
2. Carefully open the shut-off device in the "WC" mains water line.
7.4 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 10 .
–For information about controller operation, see chapter 9.1 "Operator
panel" on page 10 .
7.5 Function test
Perform a function test for the "WV" make-up valve.
•Set the device controller to manual mode, see chapter 8.1.2 "Manual
mode" on page 9 . In manual mode, you can manually open and close the
"WV" make-up valve.
Proceed as follows:
1. Press "Manual".
–"Levelcontrol" mode: "WV" flashes on the
display.
–"Magcontrol" mode: Use the arrow keys
to select "WV". "WV" flashes on the
display.
2.0 bar
WV!
Filling
2. Press "OK".
–The make-up valve opens. The displays shows "WV!".
–The water pressure displayed rises to the water pressure in the mains
water pipe.
–The make-up is completed when the display value no longer
increases. The make-up valve automatically closes after 10 s.
3. Press "OK".
–The make-up valve closes. The displays shows "WV".
The function test of the "WV" make-up valve is completed.

Operation
Fillcontrol Plus —19.10.2020 - Rev. C
English —9
7.6 Use the device to fill the facility system with water
In a pressure-dependent make-up, you have the option to use the device to fill
the system circuit with water. The following prerequisites must be met:
•The system circuit is not yet filled with water.
•The system circuit to be filled has a maximum water volume of 30000 litres.
•The shut-off valve to the system circuit is open.
–Carefully open the "BV" (1) shut-off valve.
Set the controller as follows:
•Select "Magcontrol" make-up, see chapter 9.2.1 "Customer menu" on
page 11 .
•Select Manual mode, see chapter 8.1.2 "Manual mode" on page 9 .
Proceed as follows:
1. Press "Manual".
2. Use the arrow keys to select "Filling".
–"Filling" flashes on the display.
2.0 bar
WV!
Filling
3. Press "OK".
–The system starts the filling process. The displays shows "Filling".
–The controller calculates the required filling pressure. As soon as the
filling pressure 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, see
chapter 9.3 "Messages" on page 11 .
•Press "Quit" at the operator panel to acknowledge the fault
message when the fault has been eliminated. The system
continues the filling process.
7.7 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.
In mode Levelcontrol:
•The Auto LED flashes.
•"WV" flashes on the display.
In mode Magcontrol:
•The Auto LED flashes.
Functions:
Selecting the functions depends on the set modes, "Levelcontrol" or
"Magcontrol".
Manual mode allows you to select the following functions and to perform a test
run:
•In mode "Levelcontrol":
Manual opening and closing of the "WV" make-up valve
•In mode "Magcontrol":
Manual opening and closing of the "WV" or "Filling" make-up valve.
In mode Levelcontrol:
1. Press "OK".
–The make-up valve opens. The displays shows "WV!".
2. Press "OK".
–The make-up valve closes. The displays shows "WV".
In mode Magcontrol:
1. Use the arrow keys to select "WV" or "Filling".
–"WV" or "Filling" flashes on the display.
2. Press "OK".
–The make-up valve opens or the filling process is started. The
displays shows "WV!" or "Filling".
3. Press "OK".
–The make-up valve closes or the filling process is stopped. The
displays shows "WV" or "Filling".

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.

Controller
10 —English
Fillcontrol Plus —19.10.2020 - Rev. C

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.
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 10 .
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 8
.
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.
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.

Controller
Fillcontrol Plus —19.10.2020 - Rev. C
English —11
Indication on the
display
Meaning
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 11 .
•YES: Output of all messages.
•NO: Output of all messages identified with "xxx"
("01", for example).
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 8
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
9.2.2 Service menu
This menu is protected with a password. It can be accessed only by the Reflex
Customer Service. A partial summary of the settings stored in the Service menu is
proved in the Chapter Default settings.
Service menu
Parameter
Setting
Remarks
Makeup
Pressure differential,
"NSP" makeup
0.2 bar
Only Magcontrol
Pressure differential,
filling pressure PF –P0
0.3 bar
Only Magcontrol
Water quantity for each
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
Messages with ER codes are displayed at the controller.
•Use the arrow keys at the controller operating panel to select the
messages.
•By selecting the "Fault memory" main menu in the Customer menu, you
display the last 20 alarms.
•Alarm causes can be eliminated by the operator or a specialist workshop.
•If required, please contact the Reflex Customer Service.

Controller
12 —English
Fillcontrol Plus —19.10.2020 - Rev. C

Note!
Confirm the elimination of the fault by pressing "Quit" at the controller
operator panel. All other alarms are automatically reset as soon as the
cause has been eliminated.

Note!
Group messages are issued via a floating contact which is set in the
Customer menu, see chapter 9.2 "Configuring settings in the controller"
on page 10 .
ER Code
Alarm
Group
message
Causes
Remedy
Alarm reset
01
Min. pressure
YES
The set value for the "P0" minimum
working pressure has been
exceeded.
•Water loss in the system.
•Expansion vessel defective.
•Check the system for leaks.
•Replace the expansion vessel.
•Check the function in manual
mode.
"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
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
Set value for the maximum pressure
has been exceeded.
•Safety valve defective.
•Insufficient dimensioning of
the pipeline to the system.
•Check the actuating pressure of the
safety valve.
•Replace the safety valve.
•Increase the diameter of the
pipeline to the system.
"Quit"
11
Make-up volume
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
Set value for the maximum filling
time has been exceeded.
•System volume too large
(≤ 3000Liter).
•Restart the filling process
"Quit"
13
Filling volume
•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"
15
Make-up valve
Make-up without demand
•"WV" make-up valve leaking
•Replace the "WV" make-up valve
16
Power failure
No power.
Check power supply.
–
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.

Maintenance
Fillcontrol Plus —19.10.2020 - Rev. C
English —13
ER Code
Alarm
Group
message
Causes
Remedy
Alarm reset
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 13 .
•Screw connections
x
x
Annually
Check the make-up function
•see chapter 7.5 "Function test" on
page 8 .
x
Annually
Check the system-specific set values in the
controller, see chapter 9.2.1 "Customer
menu" on page 11 .
•Minimum operating pressure "P0".
•Safety valve pressure "PSV".
x
Annually
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
14 —English
Fillcontrol Plus —19.10.2020 - Rev. C
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 Plus —19.10.2020 - Rev. C
English —15
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.
,
,

SI1417enC / 11-20
Reflex Winkelmann GmbH
Gersteinstraße 19
59227 Ahlen, Germany
[phone]
[phone]
www.reflex-winkelmann.com