Reflex Variomat VS 1 User manual

Variomat 1 06.07.2016 – Rev. B
GB
Operating manual
Original operating manual

Contents
Variomat 1 — 06.07.2016 – Rev. B English —
3
English
Variom at1
06.07.2016–Rev. B
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
3.2 Personnel requirements ......................................................................................................................................................................7
3.3Personal 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 ................................................................................................................................................................................................9
4.3 Identification .......................................................................................................................................................................................10
4.3.1 Nameplate........................................................................................................................................................................10
4.3.2 Type code..........................................................................................................................................................................10
4.4 Function ...............................................................................................................................................................................................11
4.5 Scope of delivery.................................................................................................................................................................................13
4.6 Optional equipment and accessories ..............................................................................................................................................13
5
Technical data ...............................................................................................................................................................................14
5.1 Control unit..........................................................................................................................................................................................14
5.2 Tanks.....................................................................................................................................................................................................15
6
Installation.....................................................................................................................................................................................16
6.1 Installation conditions .......................................................................................................................................................................17
6.1.1 Incoming inspection .......................................................................................................................................................17
6.2 Preparatory work ................................................................................................................................................................................17
6.3 Execution..............................................................................................................................................................................................18
6.3.1 Positioning........................................................................................................................................................................18
6.3.2 Installation of add-on components for the tanks.......................................................................................................19
6.3.3 Tank installation ..............................................................................................................................................................20
6.3.4 Hydraulic connection......................................................................................................................................................22
6.3.5 Fitting the thermal insulation........................................................................................................................................25
6.3.6 Fitting the level sensor ...................................................................................................................................................26
6.4 Switching and make-up variants......................................................................................................................................................27
6.4.1 Function............................................................................................................................................................................27
6.5 Electrical connection ..........................................................................................................................................................................30
6.5.1 Terminal diagram............................................................................................................................................................31
6.5.2 RS-485 interface...............................................................................................................................................................33
6.6 Installation and commissioning certificate.....................................................................................................................................35
7
Commissioning..............................................................................................................................................................................36
7.1 Checking the requirements for commissioning.............................................................................................................................36
7.2 Determining the P0minimum operating pressure for the controller.........................................................................................36
7.3 Modifying the controller's start routine ..........................................................................................................................................38
7.4 Filling the tanks with water...............................................................................................................................................................40
7.4.1 Filling with a hose ...........................................................................................................................................................40
7.4.2 Filling with the solenoid valve in the make-up...........................................................................................................40
7.5 Venting the pump...............................................................................................................................................................................41

Contents
4 — English Variomat 1 — 06.07.2016 – Rev. B
7.6 Parametrising the controller in the Customer menu ....................................................................................................................42
7.7 Starting Automatic mode..................................................................................................................................................................46
8
Operation...................................................................................................................................................................................... 47
8.1 Automatic mode.................................................................................................................................................................................47
8.2 Manual mode ......................................................................................................................................................................................48
8.3 Stop mode............................................................................................................................................................................................48
8.4 Summer operation..............................................................................................................................................................................49
8.5 Restarting.............................................................................................................................................................................................49
9
Controller...................................................................................................................................................................................... 50
9.1 Operator panel ....................................................................................................................................................................................50
9.2 Configuring settings in the controller .............................................................................................................................................50
9.2.1 Service menu....................................................................................................................................................................50
9.2.2 Default settings ...............................................................................................................................................................51
9.3 Messages..............................................................................................................................................................................................52
10
Maintenance................................................................................................................................................................................. 55
10.1 Maintenance schedule.......................................................................................................................................................................56
10.2 Cleaning the dirt trap.........................................................................................................................................................................57
10.3 Cleaning the tanks..............................................................................................................................................................................58
10.4 Checking switching points ................................................................................................................................................................59
10.5 Maintenance certificate.....................................................................................................................................................................61
10.6 Inspection ............................................................................................................................................................................................62
10.6.1 Pressure-bearing components......................................................................................................................................62
10.6.2 Inspection prior to commissioning...............................................................................................................................62
10.6.3 Inspection intervals.........................................................................................................................................................62
11
Disassembly.................................................................................................................................................................................. 63
12
Annex ............................................................................................................................................................................................ 64
12.1 Reflex Customer Service ....................................................................................................................................................................64
12.2 Conformity and standards.................................................................................................................................................................65
12.3 Certificate No. of the CE type test.....................................................................................................................................................66
12.4 Guarantee ............................................................................................................................................................................................66

Notes on the operating manual
Variomat 1 — 06.07.2016 – Rev. B English —
5
1
Notes 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 13 .
Note!
Every person installing this equipment or performing any other work
at the equipment is required to carefully read this
manual prior to commencing work and to comply with its instructions. The manual is to be provided to the device operator
and must be stored near the device for access at any time.
2
Liability 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 64 .

Safety
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— English Variomat 1 — 06.07.2016 – Rev. B
3
Safety
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.

Safety
Variomat 1 — 06.07.2016 – Rev. B 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 a pressure maintaining station for heating and cooling water systems. It is intended to maintain the water pressure and to
add water within a system. The devices may be used only in systems that are sealed against corrosion and with the following water
types:
•Non-corrosive
•Chemically non-aggressive
•Non-toxic
The ingress of atmospheric oxygen by permeation into the entire heating and cooling water system, make-up water and similar must be
reliably minimised during operation.
3.5
Inadmissible operating conditions
The device is not suitable for the following applications:
•Mobile system operation.
•Outdoor operation.
•For use with mineral oils.
•For use with flammable media.
•For use with distilled water.
Note!
It is not permitted to make any modifications to the hydraulic system or the circuitry.

Safet
y
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— English Variomat 1 — 06.07.2016 – Rev. B
3.6
Residual risks
This device has been manufactured to the current state of the art. However, some residual risk cannot be excluded.
CAUTION
Risk of burns on hot surfaces
Hot surfaces in heating systems can cause burns to the skin.
•Wear protective gloves.
•Please place appropriate warning signs in the vicinity of the device.
CAUTION
Risk of injury due to pressurised liquid
If installation, removal or maintenance work is not carried out correctly, there is a risk of burns and other injuries at the connection
points, if pressurised hot water or hot steam suddenly escapes.
•Ensure proper installation, removal or maintenance work.
•Ensure that the system is de-pressurised before performing installation, removal or maintenance work at the connection points.
WARNING
Risk of injury due to heavy weight
The devices are heavy. Consequently, there is a risk of physical injury and accidents.
•Use suitable lifting equipment for transportation and installation.

Description of the device
Variomat 1 — 06.07.2016 – Rev. B English —
9
4
Description of the device
4.1
Description
The Variomat VS 1 is a pump-controlled pressure maintaining, make-up and degassing station for heating and cooling water systems.
The Variomat is essentially a controller with pumps and at least one expansion tank. The expansion tank is fitted with a diaphragm to
divide the tank into an air space and a water space. preventing the ingress of atmospheric oxygen into the expansion water.
The Variomat VS 1 provides the following safety features:
•Optimisation of all pressure maintaining, degassing and make-up processes.
– No direct intake of air thanks to a regulation of the pressure maintenance with automatic 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.
4.2
Overview
1 "VE" aeration and de-aeration 6 "PU" pump
2 "DV" degassing valve 7 "FD" feed and drain cock
3 "PIS" pressure transducer 8 "LIS" level sensor
4 "PV" overflow valve WC Make-up connection
5 "WV" make-up valve EC Degassing connection
•Gas-rich water inlet
•Degassed water outlet

Description of the device
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— English Variomat 1 — 06.07.2016 – Rev. B
4.3
Identification
4.3.1
Nameplate
The nameplate provides information about the manufacturer, the year of manufacture, the manufacturing number and the technical
data.
Information on nameplate
Meaning
Type Device name
Serial No. Serial number
min. / max. allowable pressure P Minimum/maximum
permissible pressure
max. continuous operating
temperature
Maximum temperature for
continuous operation
min. / max. allowable temperature
/ flow temperature TS
Minimum / maximum
permissible temperature /
TS flow temperature
Year built Year of manufacture
min. operating pressure set up on
shop floor
Factory-set minimum
operating pressure
at site Set minimum operating
pressure
max. pressure saftey valve factory -
aline
Factory-set opening
pressure of the safety
valve
at site Set opening pressure of
the safety valve
4.3.2
Type code
No.
Type code (example)
1 Control unit designation
2 Number of pumps Variomat VS 1, VG 500 l, VF 500 l
3 "VG" primary tank 1 2 3 4 5 6
4 Nominal volume
5 "VF" secondary tank
6 Nominal volume

Description of the device
Variomat 1 — 06.07.2016 – Rev. B English —
11
4.4
Function
1 Heating system WV Make-up valve
2 "MAG" pressure expansion tank PIS Pressure sensor
3 Reflex Fillset Impulse, see chapter 4.6 "Optional
equipment and accessories" on page 13 .
PV Overflow valve (motor ball valve)
4 Control unit PU Pump (pressure maintenance)
5 Hydraulic inlets
•For gas-rich water
•For degassed water
SV Safety valve
6 Primary tank air space EC Expansion line
•For gas-rich water
•For degassed water
7 Secondary tank air space FD Feed and drain cock
ST Dirt trap LIS Pressure load cell
FQIRA+ Contact water meter DV Degassing valve
WC Make-up line VE Ventilation
The device is a pressurisation station for heating and cooling water systems. It is used for maintaining pressure, making-up and
degassing the water in heating and cooling systems. It comprises a control unit consisting of a controller with hydraulics and at least
one expansion tank.
Expansion tank
One primary tank and multiple optional secondary tanks may be connected. A diaphragm separates the tanks into an air and a water
space, preventing the penetration of atmospheric oxygen into the expansion water. The "VE" line connects the air space with the
atmosphere. The primary tank is hydraulically flexibly connected to the control unit. The function of the "LIS" level measuring using a
pressure pick-up is thus ensured.

Description of the device
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— English Variomat 1 — 06.07.2016 – Rev. B
Control unit
The control unit contains the hydraulic system and the controller. The "PIS" pressure transducer records the pressure and the "LIS"
pressure pick-up registers the level; both values are displayed at the controller.
Maintaining pressure
The pressure in the system rises when the water is heated. When the pressure set at the controller is exceeded, the "PV" overflow valve
opens and drains water from the system into the primary tank, using the "EC" expansion line. The pressure within the system drops. The
pressure in the system drops when the water cools. When the pressure drops below the set value, the "PU" pump is activated and uses
the "EC" expansion line to transport water from the primary tank back into the system. The pressure in the system rises. The controller
ensures that the pressure is maintained, further supported by the stabilisation provided by the "MAG" expansion tank.
Degassing
Two "EC" expansion lines are required to degas the system water. One line is intended for gas-rich water from the system, and the other
one serves to return the degassed water to the system. During the degassing action, the "PU" pump and the "PV" overflow valve are in
operation. This transports a gas-rich partial flow of the system water V through the de-pressurised primary tank. Atmospheric pressure is
used to separate the free and dissolved gases and to discharge them through the "DV" degassing valve. The controller ensures the
hydraulic equalisation by regulating the stroke of the "PV" overflow valve (motor ball valve). There are three different modes for this
process: continuous, interval or run-on degassing.
Make-up
When the water level in the primary tank falls below the minimum, the "WV" make-up valve opens until the set level is again reached.
During the make-up process, the number of requests, the time and the make-up duration within a cycle are monitored. Using a FQIRA+
contact water meter, the system monitors each individual make-up volume and the overall make-up volume.

Description of the device
Variomat 1 — 06.07.2016 – Rev. B English —
13
4.5
Scope of delivery
The scope of delivery is described in the shipping document 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 pressurisation equipment:
•The device on a pallet.
– Control unit and "VG" primary tank.
– Primary tank with accessories are packed on the tank base.
•"VE" aeration and de-aeration
•"DV" degassing valve
•Reducing sleeve
•"LIS" pressure pick-up
– Plastic sleeve with operating manual.
4.6
Optional equipment and accessories
The following optional equipment and accessories are available for this device:
•Thermal insulation for the primary tank.
•Secondary tanks
– Accessories are provided as a package at the tank base
•"VE" aeration and de-aeration
•"DV" degassing valve
•Reducing sleeve
•Accessories with BOB pipe for "TAZ+" temperature limiter
•Fillset for make-up with water.
– Fillset with integrated back flow 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.
•Servitec for make-up and degassing.
•Fillsoft for softening the make-up water from the public water network.
– The Fillsoft is installed between the Fillset and the device. The device controller evaluates the make-up quantities and signals
the required replacement of the softening cartridges.
•Enhancements for the device controller:
– I/O module for standard communication.
– Communication module for external operation of the controller
– Master-Slave-Connect for master controllers for maximum 10 devices.
– Combined switching to increase capacity and parallel switching of 2 hydraulically directly connected systems
– Bus modules:
•Lonworks Digital
•Lonworks
•Profibus DP
•Ethernet
•Diaphragm rupture monitor.
Note!
Separate operating instructions are supplied with accessories.

Technical data
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— English Variomat 1 — 06.07.2016 – Rev. B
5
Technical data
5.1
Control unit
Note!
The following values apply for all control units:
–
Permissible flow temperature:
–
Permissible operating temperature:
–
Permissible ambient temperature:
120 °C
70 °C
0 °C – 45 °C
Type
Power
output
(kW)
Power supply
(V / Hz , A)
Degree of
protection
Number of RS-
485 interfaces
I/O
module
Electrical voltage
control unit
(V, A)
Noise level
(dB)
Weight
(kg)
VS 1 0.75 230 / 50, 3 IP 54 1 No 230, 2 55 25

Technical data
Variomat 1 — 06.07.2016 – Rev. B English —
15
5.2
Tanks
Primary tank Secondary tank
Note!
Optional heat insulation is available for primary tanks, see chapter
4.6 "Optional equipment and accessories" on page 13 .
Type
Diameter Ø "D"
(mm)
Weight
(kg)
Connection
(inches)
Height "H"
(mm)
Height "h"
(mm)
6 bar - 200 634 37 G1 1060 146
6 bar - 300 634 54 G1 1360 146
6 bar - 400 740 65 G1 1345 133
6 bar - 500 740 78 G1 1560 133
6 bar - 600 740 94 G1 1810 133
6 bar - 800 740 149 G1 2275 133
6 bar - 1000/740 740 156 G1 2685 133
6 bar - 1000/1000 1000 320 G1 2130 350
6 bar - 1500 1200 465 G1 2130 350
6 bar - 2000 1200 565 G1 2590 350
6 bar - 3000 1500 795 G1 2590 380
6 bar - 4000 1500 1080 G1 3160 380
6 bar - 5000 1500 1115 G1 3695 380

Installation
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— English Variomat 1 — 06.07.2016 – Rev. B
6
Installation
DANGER
Risk of serious injury or death due to electric shock.
If live parts are touched, there is risk of life-threatening injuries.
•Ensure that the system is voltage-free before installing the device.
•Ensure that the system is secured and cannot be reactivated by other persons.
•Ensure that installation work for the electric connection of the device is carried out by an electrician, and in compliance with
electrical engineering regulations.
CAUTION
Risk of injury due to pressurised liquid
If installation, removal or maintenance work is not carried out correctly, there is a risk of burns and other injuries at the connection
points, if pressurised hot water or hot steam suddenly escapes.
•Ensure proper installation, removal or maintenance work.
•Ensure that the system is de-pressurised before performing installation, removal or maintenance work at the connection points.
CAUTION
Risk of burns on hot surfaces
Hot surfaces in heating systems can cause burns to the skin.
•Wear protective gloves.
•Please place appropriate warning signs in the vicinity of the device.
CAUTION
Risk of injury due to falls or bumps
Bruising from falls or bumps on system components during installation.
•Wear personal protective equipment (helmet, protective clothing, gloves, safety boots).
Note!
Confirm that installation and start
-up have been carried out correctly using the installation, start-up and maintenance
certificate. This action is a prerequisite for the making of warranty claims.
–
Have the Reflex Customer Service carry out commissioning and the annual maintenance.

Installation
Variomat 1 — 06.07.2016 – Rev. B English —
17
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
Condition of the delivered device:
•Check all screw connections of the device for tight seating. Tighten the screws as necessary.
Preparing the device installation:
•No access by unauthorised personnel.
•Frost-free, well-ventilated room.
– Room temperature 0 °C to 45 °C (32 °F to 113 °F).
•Level, stable flooring.
– Ensure sufficient bearing strength of the flooring before filling the tanks.
– Ensure that the control unit and the tanks are installed on the same level.
•Filling and dewatering option.
– Provide a DN 15 filling connection according to DIN 1988 - 100 and En 1717.
– Provide an optional cold water inlet.
– Prepare a drain for the drain water.
•Electric connection, see chapter 5 "Technical data" on page 14 .
•Use only approved transport and lifting equipment.
– The load fastening points at the tanks must be used only as installation resources.

Installation
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— English Variomat 1 — 06.07.2016 – Rev. B
6.3
Execution
ATTENTION
Damage due to improper installation
Additional device stresses may arise due to the connection of pipes or system equipment.
•Ensure that pipes are connected from the device to the system without stresses being induced.
•If necessary, provide support structures for the pipes or equipment.
For installation, proceed as follows:
•Position the device.
•Complete the primary tank and the optional secondary tanks.
•Create the water-side connections of the control unit to the system.
•Create the interfaces according to the terminal plan.
•Install the water connections between optional secondary tanks to each other and to the primary tank.
Notice!
For installation, note the operability of the valves and the inlet options of the connecting l
ines.
6.3.1
Positioning
Determine the positions for the control unit and the "VG" and
"VF" tanks (if used).
–
The control unit can be installed on either side or in front of
the "VG" primary tank. The distance of the control unit to
the primary tank results from the connection set supplied.

Installation
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19
6.3.2
Installation of add-on components for the tanks
The add
-on components are packed in plastic bags and
attached to the base of the devices.
•
Pressure compensation elbow (1).
•
Reflex Exvoid with pre-fitted check valve (2)
•
"LIS" pressure pick-up
For add
-on components, proceed as follows:
1
. Install the Reflex Exvoid (2) at the connection of the
corresponding tank.
2
. Remove the protective cap from the degassing
valve.
3
. Use the compression fitting to install the pressure
compensation elbow (1) for aeration and
ventilation at the tanks.
Note!
Install the "LIS" pressure pick
-up only after finalising the installation of the primary tank, see chapter 6.3.6 "Fitting the
level s
ensor" on page 26 .
Note!
To ensure fault
-free operation, do not seal off the aeration and ventilation.

Installation
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— English Variomat 1 — 06.07.2016 – Rev. B
6.3.3
Tank installation
ATTENTION
Damage due to improper installation
Additional device stresses may arise due to the connection of pipes or system equipment.
•Ensure that pipes are connected from the device to the system without stresses being induced.
•If necessary, provide support structures for the pipes or equipment.
ATTENTION
Device damage resulting from dry running of the pump
If the pump is incorrectly connected, there is a risk of dry-running.
•Ensure that the connections for the overflow collector and the pump are not interchanged.
•Ensure correct connection of the pump to the primary tank.
Comply with the following notes regarding the
installation of
the primary tank and the secondary tanks:
•
All flange openings at the tanks are viewing and
maintenance openings. Install the primary tank and the
secondary tanks, if provided, with sufficient spaces at the
sides and the top.
•
Install the tanks on a level surface.
•
Ensure rectangular and free-standing position of the tanks.
•
If you use secondary tanks in addition to the primary tank,
ensure that all tanks are of the same type and dimensions.
•
Do not attach the tanks to the flooring to ensure the
functioning of the "LIS" level sensor.
•
Install the control unit on the same level as the tanks.
(All data in mm)