Related Manuals for Reflex Reflexomat Series
Summary of Contents for Reflex Reflexomat Series
- Page 1 06.07.2016 - Rev. B Reflexomat with Touch controller with one compressor: RS 150/1, RS 300/1, RS 400/1, RS 580/1 with two compressors: RS 90/2, RS 150/2, RS 300/2, RS 400/2, RS 580/2 Operating manual Original operating manual...
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Page 3: Table Of Contents
Contents English Reflexomat with Touch controller 06.07.2016 - Rev. B Contents Notes on the operating manual..............................5 Liability and guarantee................................... 5 Safety........................................ 6 Explanation of symbols ..................................6 3.1.1 Symbols and notes used ..............................6 Personnel requirements ..................................7 Personal protective equipment ................................7 Intended use ...................................... - Page 4 Inspection prior to commissioning ..........................60 10.5.3 Inspection intervals ................................. 60 Disassembly ....................................61 Annex ......................................62 12.1 Reflex Customer Service ..................................62 12.2 Conformity and standards ................................. 63 12.3 Certificate No. of the CE type test ..............................64 12.4 Guarantee ......................................
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Page 5: Notes On The Operating Manual
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.). -
Page 6: Safety
Safety Safety 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. -
Page 7: Personnel Requirements
Safety 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. 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. -
Page 8: Residual Risks
Safety 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. •... -
Page 9: Description Of The Device
Description of the device Description of the device Description Reflexomat with touch control and one compressor • One "RG" primary tank as expansion tank. • Control unit. – Touch control with one compressor as stand-alone console. Note! The connection of "RF" secondary tanks to the "RG" primary tank is optionally possible. Reflexomat with touch control and two compressors •... -
Page 10: Overview
Reflexomat with touch control and one compressor Main switch "SV" safety valve Control unit "RF" secondary tank (optional) • Compressor(s) "EC" expansion line • "Reflex Control Touch" controller "LIS" level sensor "RG" primary tank 10 — English Reflexomat with Touch controller — 06.07.2016 - Rev. B... - Page 11 Reflexomat with touch control and two compressors Main switch "SV" safety valve Control unit "RF" secondary tank (optional) • Compressor(s) "EC" expansion line • "Reflex Control Touch" controller "LIS" level sensor "RG" primary tank Reflexomat with Touch controller — 06.07.2016 - Rev. B English — 11...
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Page 12: Identification
Description of the device 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. -
Page 13: Function
Control unit The control unit comprises one or – optionally – two "CO" compressor(s) and the "Reflex Control Touch" controller. Via the primary tank, the pressure is measured with the “PIS" pressure sensor and the water level with the “LIS" pressure load cell and the values then displayed in the controller display. -
Page 14: Scope Of Delivery
Solenoid “Fillvalve” with ball valve and Reflex Fillset for make-up with drinking water. • Make-up with pump: – Reflex Fillcontrol Auto, with integrated pump and a system separation vessel or Auto Compact • For water make-up and degassing: • Reflex Servitec 30 (25) •... -
Page 15: Technical Data
Technical data Technical data Control unit Note! The following values apply for all control units: – Permissible flow temperature: 120 °C – Permissible operating temperature: 70 °C – Permissible ambient temperature: 0 °C – 45 °C Type Power Power supply Degree of Number of RS- Electrical voltage... -
Page 16: Tanks
Technical data Tanks Primary vessel Secondary tank Type Diameter Ø "D" Weight Connection Height "H" Height "h" Height "h1" (mm) (kg) (inches) (mm) (mm) (mm) 6 bar - 200 6 bar - 300 1270 6 bar - 400 1255 6 bar - 500 1475 6 bar - 600 1720... -
Page 17: Installation
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. Reflexomat with Touch controller — 06.07.2016 - Rev. B English — 17... -
Page 18: Installation Conditions
Installation 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: Upon receipt of the goods, check the shipment for • completeness and • possible transport damage. Document any damage. -
Page 19: Execution
Installation 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: •... -
Page 20: Tank Installation
Installation 6.3.2 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. •... -
Page 21: Connection To The Facility System
Installation 6.3.3 Connection to the facility system CAUTION Risk of injury due to falls or stumbling Bruising caused by falls or stumbling over cables or pipes during installation. • Wear personal protective equipment (helmet, protective clothing, gloves, safety boots). • Ensure proper installation of cables and pipes between the control unit and the tanks. - Page 22 Notice! For details regarding the switching of Reflexomats or in-line vessels and the dimensions of the expansion lines, please see the planning documents. More information is also provided in the Reflex Planning Guide. 22 — English Reflexomat with Touch controller — 06.07.2016 - Rev. B...
- Page 23 Installation 6.3.3.2 Control unit connection The following describes the exemplary installation of the control unit before the primary tank and the connection of two secondary tanks. Proceed accordingly for other installation variants. Secondary tank PIS Pressure sensor Primary tank Compressed air line Safety valve Expansion line Solenoid valve...
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Page 24: Connection To An External Compressed Air Line
Safety valve Pressure gauge, site attachment Overflow solenoid valve Solenoid valve, supplied by Reflex Level sensor Instead of the compressor, a solenoid valve is actuated in the external compressed air line, which releases the compressed air for the vessel. The solenoid valve is activated by the controller. The electrical connection of the solenoid valve is made via the terminal for the compressor in the respective controller. -
Page 25: Fitting The Level Sensor
Installation 6.3.5 Fitting the level sensor ATTENTION Damage to the pressure load cell due to unprofessional installation Incorrect installation may result in damage to the "LIS" level sensor, malfunctioning and incorrect measurements from the pressure load cell. • Comply with the instructions regarding the installation of the pressure load cell. The "LIS"... -
Page 26: Make-Up And Degassing Variants
Preferably, you should use the Reflex Fillset with integrated system separator when using drinking water for make-up, see chapter 4.6 "Optional equipment and accessories" on page 14 . If you don't use a Reflex Fillset, you must use an "ST" dirt trap with a mesh size ≥... - Page 27 Installation 6.4.1.2 Make-up with pump Reflexomat RS with Reflex Fillcontrol Auto Reflexomat RS Dirt trap Fillcontrol Auto Expansion line Make-up line Level sensor Water make-up with Fillcontrol Auto is suitable for make-up at high system pressures of up to 8.5 bar, see chapter 4.6 "Optional equipment and accessories"...
- Page 28 Expansion line The Reflex Servitec degassing and make-up station degasses the water from the facility system and the make-up water. The automatic water make-up for the facility system is controlled by the pressure maintenance system. Reflex Fillsoft additionally softens the make-up water.
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Page 29: Electrical Connection
Installation 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. •... -
Page 30: Terminal Plan, Connection Component
Installation 6.5.1 Terminal plan, connection component Pressure Fuses Level Terminal Signal Function Wiring number Supply X0/1 230 V supply X0/2 User supplied Reflexomat RS 90 X0/3 X0/1 X0/2 400 V supply X0/3 User supplied Reflexomat RS 150 ... 580 X0/4 X0/5 Circuit board WV make-up valve... - Page 31 Installation Terminal Signal Function Wiring number Group message (floating) User, optional N.O. +18 V (blue) Analogue input, LIS level measuring User supplied at the primary tank AE (brown) PE (shield) +18 V (blue) PIS pressure sensor analogue input at the primary tank User, optional AE (brown) PE (shield)
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Page 32: Terminal Plan, Operating Unit
Installation 6.5.2 Terminal plan, operating unit RS-485 interfaces Analogue outputs for Pressure and Level I/O interface Battery compartment I/O interface (reserve) Supply voltage, bus modules SD card RS-485 connection 10 V supply RS-485 connection Terminal Signal Function Wiring number RS-485 interface User supplied S1 networking GND S1... -
Page 33: Rs-485 Interface
Installation 6.5.3 RS-485 interface Use theS1 and S2 RS-485 interfaces to retrieve all controller data and to enable the communication with control centres or other devices. • S1 interface – Using this interface, you can operate maximum 10 devices in a master/slave network. •... -
Page 34: Commissioning
This action is a prerequisite for the making of warranty claims. – Have the Reflex Customer Service carry out commissioning and the annual maintenance. Checking the requirements for commissioning The device is ready for commissioning when the tasks described in Chapter Installation have been concluded. Comply with the following instructions for commissioning: •... -
Page 35: Determining The P
Commissioning Determining the P minimum operating pressure for the controller The "P " minimum operating pressure is determined by the location of the pressure maintaining device. The controller calculates the switching points for the "PV" solenoid valve and the "CO" compressor from the "P "... -
Page 36: Modifying The Controller's Start Routine
Commissioning Modifying the controller's start routine Note! During commissioning, you must once execute the start routine. • For information about controller operation, see chapter 9.1 "Operator panel" on page 44 . The start routine is used to adjust the required parameters for the device commissioning. It commences with the first activation of the controller and can be run only once. - Page 37 Commissioning Start routine Step 2 2. Select the required language and conform your entry with "OK". (001) Language German English 2.7 bar 25 % Start routine Step 4 3. Select the calculated minimum operating pressure and conform your entry with "OK". (005) Min.
- Page 38 Null balancing is executed. balancing. – If null balancing is not successfully completed, you cannot commission the device. In this event, please contact Customer Service, see chapter 12.1 "Reflex Customer Service" on page 62 . Execute null balancing now? 2.9 bar Note! After completing the start routine, you are in Stop mode.
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Page 39: Tank Venting
Commissioning Tank venting CAUTION Risk of burns on hot surfaces Excessive surface temperatures on the compressor can result in skin burns. • Wear suitable personal protective equipment (safety gloves, for example). Upon completion of the start routine, you must vent the primary tank and the secondary tanks, if applicable. •... -
Page 40: Starting Automatic Mode
Commissioning Starting Automatic mode Automatic operation is executed as conclusion of the initial commissioning. The following prerequisites must be met for automatic operation: • The device is filled with compressed air and water. • All required settings are defined in the controller. Start the automatic mode at the operator panel of the controller. -
Page 41: Operation
Operation Operation Operating modes 8.1.1 Automatic mode After successful commissioning, start the Automatic mode from the device. The Automatic mode is suitable for continuous device operation and the controller monitors the following functions: • Maintain pressure • Compensate expansion volume •... -
Page 42: Manual Mode
Operation 8.1.2 Manual mode The manual mode is intended for test and service tasks. Manual mode enables you to select the following functions and to perform a test run: • "CO1" compressor • Solenoid valve in "PV1" overflow line • Solenoid valve of the "WV1"... -
Page 43: Stop Mode
Operation 8.1.3 Stop mode The Stop mode is intended for the device commissioning. Except for the display of information, the device is non-functional in Stop mode. Function monitoring is stopped. The following functions are deactivated: • The "CO" compressor is switched off. •... -
Page 44: Controller
Controller Controller Operator panel Message line Display value "Manual mode" button "▼"/ "▲" buttons • For function tests. • Set digits. ""/"" buttons "Stop mode" button • Select digits. • For commissioning. "OK" button "Automatic mode" button • Confirm/acknowledge input. •... -
Page 45: Calibrating The Touch Screen
Controller Calibrating the touch screen You can calibrate the touch screen when touching the desired buttons does not work satisfactorily. 1. Switch the device off at the main switch. R-S-I Update/Diagnostics 2. Touch and hold with your finger the touch field. 3. -
Page 46: Configuring Settings In The Controller
Controller Configuring settings in the controller You can configure the controller settings regardless of the currently selected and active operating mode. 9.3.1.1 Customer menu – overview Use the Customer menu to correct or determine system-specific values. In the course of commissioning, the factory settings must be adjusted for the system-specific conditions. - Page 47 Controller 9.3.1.2 Setting the customer menu - "Time" example The setting of system-specific values is explained below using the setting of the time as example. To adjust the system-specific values, proceed as follows: 1. Press "Settings“. – The controller switches to the setting area. 800l 2.9 bar System...
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Page 48: Default Settings
Controller Settings > Customer Set the system-specific values for the individual areas. – Use the "Left" and "Right" buttons to select the display (002) Time value. – Use the "Up" and "Down" buttons to change the display 11:14 value. – Confirm your entries with "OK". - Page 49 Controller Service menu Parameter Setting Remarks Pressurisation Compressor "ON" + 0.3 bar Differential pressured added to the "P " minimum operating pressure. Compressor "OFF" + 0.4 bar Differential pressured added to the "P " minimum operating pressure. "Compressor run time exceeded" message 240 minutes The message is displayed after the compressor runs for 240 minutes.
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Page 50: Messages
The controller displays the messages with a help text. Message causes can be eliminated by the operator or a specialist workshop. If this is not possible, contact the Reflex Customer Service. Note! When the cause for the message is eliminated, you must acknowledge the fault with "OK" at the controller's operator panel. - Page 51 Controller ER Code Alarm Floating Causes Remedy Alarm reset contact Min. pressure – • Set value exceeded. • Check set value in the Customer "OK" or Service menu. • Water loss in the system. • Check water level. • Compressor fault. •...
- Page 52 • Time interval for replacement of the softening cartridge exceeded. I/O module fault – • I/O module defective. Inform Reflex Customer Service. – • Connection between option card and controller faulty. • Option card defective. 52 — English Reflexomat with Touch controller — 06.07.2016 - Rev. B...
- Page 53 Controller ER Code Alarm Floating Causes Remedy Alarm reset contact EEPROM defective – • EEPROM defective Inform Reflex Customer Service. "OK" • Internal calculation error Undervoltage – Supply voltage too low. Check power supply. – Adjustment – EPROM parameter memory Inform Reflex Customer Service.
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Page 54: Maintenance
The maintenance intervals for the secondary tanks may be extended to 5 years if operation has been trouble-free. Note! Maintenance work must be carried out and confirmed by specialist personnel or the Reflex Customer Service, see chapter 10.4 "Maintenance certificate " on page 59 . -
Page 55: Checking Switching Points
Maintenance 10.2 Checking switching points Prerequisite for checking the switching points are the following correct settings: • Minimum operating pressure P , see chapter 7.2 "Determining the P minimum operating pressure for the controller" on page 35 . • Level sensor at the primary tank. Preparation 1. - Page 56 Maintenance Activating the device 11. Switch on the main switch. 12. Switch to Automatic mode. – Depending on the filling level and pressure, the "CO" compressor and the automatic make-up will be switched on. 13. Slowly open the cap valves upstream of the tanks and secure them against unintended closing. Checking Insufficient water "Off"...
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Page 57: Cleaning
Maintenance 10.3 Cleaning 10.3.1 Cleaning the tanks CAUTION Risk of injury due to pressurised liquid Injuries can occur during maintenance work if the connections have been installed incorrectly because condensate under pressure can suddenly escape. • Ensure proper connections for the draining of condensate. •... -
Page 58: Cleaning The Dirt Trap
– Press "Auto" on the controller's operator panel. "ST" dirt trap 2 Dirt trap insert Note! Clean all other installed dirt traps (in the Reflex Fillset, for example). 58 — English Reflexomat with Touch controller — 06.07.2016 - Rev. B... -
Page 59: Maintenance Certificate
Maintenance 10.4 Maintenance certificate All maintenance tasks have been completed according to the Reflex Installation, Operating and Maintenance Manual. Date Service organisation Signature Remarks Reflexomat with Touch controller — 06.07.2016 - Rev. B English — 59... -
Page 60: Inspection
Recommended maximum inspection intervals for operation in Germany pursuant to Section 16 of the Industrial Safety Regulation [Betriebssicherheitsverordnung] and the vessel classification of the device in diagram 2 of the Directive 2014/68/EC, applicable in strict compliance with the Reflex Installation, Operation and Maintenance Manual. External inspection: No requirement according to Annex 2, Section 4, 5.8. -
Page 61: Disassembly
Disassembly 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. •... -
Page 62: Annex
Annex Annex 12.1 Reflex Customer Service Central customer service Switchboard: Telephone number: +49 (0)2382 7069 - 0 Customer Service extension: +49 (0)2382 7069 - 9505 Fax: +49 (0)2382 7069 - 523 E-mail: service@reflex.de Technical hotline For questions about our products Telephone number: +49 (0)2382 7069-9546 Monday to Friday, 8:00 a.m. -
Page 63: Conformity And Standards
The object of the declaration described above is in conformity with the relevant Union harmonisation legislation - Pressure Equipment Directive Manufacturer 2014/68/EU of the European Parliament and of the Council of 15 May Reflex Winkelmann GmbH 2014. Gersteinstraße 19 59227 Ahlen - Germany Telefon: +49 (0)2382 7069 -0 Ahlen, 19.07.2016... -
Page 64: Certificate No. Of The Ce Type Test
10 bar – 120 °C 07 202 1403 Z 0413/2/D0045_Rev.1 350 – 5000 litres 10 bar – 120 °C 07 202 1403 Z 0411/2/D0045 You will find an up-to-date list under www.reflex.de/zertifikate. 12.4 Guarantee The respective statutory guarantee regulations apply. 64 — English... - Page 66 Reflex Winkelmann GmbH Gersteinstraße 19 59227 Ahlen, Germany Telephone: +49 (0)2382 7069-0 Fax: +49 (0)2382 7069-588 www.reflex.de...
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