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Summary of Contents for Reflex Fillcontrol Plus
- Page 1 06.07.2016 - Rev. B Fillcontrol Plus Operating manual Original operating manual...
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Page 3: Table Of Contents
Use the device to fill the facility system with water ........................26 Starting Automatic mode .................................. 26 Operation ....................................... 27 Operating modes ....................................27 8.1.1 Automatic mode ................................27 8.1.2 Manual mode ................................... 27 Fillcontrol Plus — 06.07.2016 - Rev. B English — 3... - Page 4 Exterior leak test ....................................39 10.3 Maintenance certificate ..................................40 Disassembly ....................................41 Annex ......................................42 12.1 Reflex Customer Service ..................................42 12.2 Guarantee ......................................42 12.3 Conformity and standards ................................. 42 4 — English Fillcontrol Plus — 06.07.2016 - Rev. B...
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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
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. 6 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 7: Personnel Requirements
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. Fillcontrol Plus — 06.07.2016 - Rev. B English — 7... -
Page 8: Residual Risks
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. 8 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 9: Description Of The Device
Freshwater makeup to plant systems with a pressurisation station. Overview "BV" shut-off valve Cover (hinged) "PIS" pressure transducer Control Basic controller "WV" make-up valve Fresh water inlet/outlet Console for wall mounting Fillcontrol Plus — 06.07.2016 - Rev. B English — 9... -
Page 10: Identification
Set opening pressure of at site the safety valve 4.3.2 Type code Type code Fillcontrol Plus P – : Standard E : Stainless steel model Volumetric flow rate "K " 10 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 11: Function
Make-up line to the system Filling level monitoring for level-dependent make-up • External signal line to the controller Fillcontrol Plus controls the make-up with fresh water for the facility system. The controller monitors the following functions: • Make-up time. •... -
Page 12: Scope Of Delivery
• Expansions for Reflex Basic controllers: – I/O modules – Bus modules: • Lonworks Digital • Lonworks • Profibus DP • Ethernet Note! Separate operating instructions are supplied with accessories. 12 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 13: Technical Data
G ½ – Operation Type Make-up capacity Maximum feed Maximum delivery Permissible operating Operating (l/h) pressure pressure gauge pressure temperature (bar) (bar) (bar) (°C) ≤ 1400 ≤ 8.5 Fillcontrol Plus Fillcontrol Plus — 06.07.2016 - Rev. B English — 13... -
Page 14: 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. 14 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 15: Installation Conditions
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. Fillcontrol Plus — 06.07.2016 - Rev. B English — 15... -
Page 16: Execution
You ensure so that the "PIS" pressure sensor is able to measure the filling pressure. • The fixtures can be operated. • The feed connections of the pipes are not adversely affected. 16 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 17: Hydraulic Connection
Use a pressure reducer in the "WC" make-up line if the fresh water system pressure exceeds 6 bar. Note! For selecting the make-up variants, see chapter 6.4 "Switching and make-up variants" on page 18 . Fillcontrol Plus — 06.07.2016 - Rev. B English — 17... -
Page 18: Switching And Make-Up Variants
Installation Switching and make-up variants Example of a pressure-dependent make-up with "Fillcontrol Plus". Fillset Pressure transducer Fillcontrol Plus Make-up line to the device Diaphragm expansion tank MAG Nominal diameter of the make-up line In facility systems with a diaphragm expansion tank, the "PIS" pressure transducer in the device monitors the make-up with fresh water. - Page 19 Installation Example of a level-dependent make-up with "Fillcontrol Plus". Fillset Impuls "Reflexomat" pressure maintaining station "Fillsoft" softening system Make-up line to the device Fillcontrol Plus Nominal diameter of the make-up line The pressure maintaining station is fitted with a monitoring device for the filling level in the expansion tank. If the filling level drops below the minimum level in the expansion tank, the pressure maintaining station sends a signal to the device controller.
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Page 20: Electrical Connection
Note that the fusing for the device connection is to be provided by the user, see chapter 5 "Technical data" on page 13 . Install the cover. Connect the mains plug to the 230 V power supply. Activate the system. The electrical connection is completed. 20 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 21: Terminal Diagram
Solenoid valve (not for motor ball valve) Pressure analogue input Group message External makeup demand ("Levelcontrol" only) Not used Not used Not used Not used RS-485 interface Mains supply Shielding Fillcontrol Plus — 06.07.2016 - Rev. B English — 21... - Page 22 Contact water meter (in "Fillset Impuls", for example), see chapter 4.6 "Optional equipment and accessories" on page 12 . User, optional • Evaluation of the makeup. • Contact 32/33 closed = meter pulse. Not used. Pre-wired, bridged 22 — English Fillcontrol Plus — 06.07.2016 - Rev. B...
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Page 23: Rs-485 Interface
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. -
Page 24: Commissioning
This action is a prerequisite for the making of warranty claims. – Have the Reflex Customer Service carry out commissioning and the annual maintenance. Requirements for initial commissioning The device will be ready for commissioning when the tasks described in the "Installation" chapter have been completed. Comply with the information below on commissioning: •... -
Page 25: Filling The Device With Water
The make-up is completed when the value at the display no longer increases. The make-up valve automatically closes after 10 s. Press "OK". – The make-up valve closes. The displays shows "WV". The function test of the "WV" make-up valve is completed. Fillcontrol Plus — 06.07.2016 - Rev. B English — 25... -
Page 26: Use The Device To Fill The Facility System With Water
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. 26 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 27: Operation
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 operation can not be performed if safety-relevant parameters are exceeded. • The switch is blocked. Fillcontrol Plus — 06.07.2016 - Rev. B English — 27... -
Page 28: Stop Mode
The make-up with fresh water must be ensured even outside of the operation of the heating and cooling systems. Do not shut down the device when the pressure maintaining systems of the heating and cooling systems are in operation. 28 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 29: Controller
3. Use "OK" (5) to confirm the parameter. 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. Fillcontrol Plus — 06.07.2016 - Rev. B English — 29... -
Page 30: Configuring Settings In The Controller
The controller displays "Safety valve pressure“ if the "Magcontrol“ make-up variant is set. Safety valve pressure – Enter the activating pressure of the safety valve of the heat or cooling generator. 03.0 bar (006) 30 — English Fillcontrol Plus — 06.07.2016 - Rev. B... - Page 31 (031) YES: The system stops the make-up process when the set soft water capacity is exceeded. The system does not stop the make-up process. The system displays the "Softening" message. Fillcontrol Plus — 06.07.2016 - Rev. B English — 31...
- Page 32 Use the "▼▲" buttons to open the sub-menu. 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. ER 01…xx 32 — English Fillcontrol Plus — 06.07.2016 - Rev. B...
- Page 33 The last 10 entries of the minimum working pressure are stored with date and time. P0 = xx.x bar Date | Time Information about the software version Fillcontrol + V1.00 Fillcontrol Plus — 06.07.2016 - Rev. B English — 33...
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Page 34: Customer Menu
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, see chapter 9.2.2 "Service menu" on page 34 . -
Page 35: Messages
Alarm causes can be eliminated by the operator or a specialist workshop. • If required, please contact the Reflex Customer Service. 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. - Page 36 Inform Reflex Customer Service. • Connection between option card and controller faulty. • Option card defective. EEPROM defective • EEPROM defective. Inform Reflex Customer Service. "Quit" • Internal calculation error. 36 — English Fillcontrol Plus — 06.07.2016 - Rev. B...
- Page 37 Short-circuit of input Check the wiring at the digital faulty voltage. inputs (water meter, for example). Analogue input voltage Short-circuit of input Check the wiring at the analogue faulty voltage. inputs (pressure/level). Fillcontrol Plus — 06.07.2016 - Rev. B English — 37...
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Page 38: Maintenance
• Reset the maintenance counter in the Customer menu. Note! Maintenance tasks must be carried out only by specialist personnel or the Reflex Customer Service. • Confirm the maintenance tasks, see chapter 10.3 "Maintenance certificate " on page 40 . -
Page 39: Maintenance Schedule
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. Fillcontrol Plus — 06.07.2016 - Rev. B English — 39... -
Page 40: Maintenance Certificate
Maintenance 10.3 Maintenance certificate All maintenance tasks have been completed according to the Reflex Installation, Operating and Maintenance Manual. Date Service organisation Signature Remarks 40 — English Fillcontrol Plus — 06.07.2016 - Rev. B... -
Page 41: Disassembly
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. Fillcontrol Plus — 06.07.2016 - Rev. B English — 41... -
Page 42: Annex
Directive 2014/68/EU. Reflex Winkelmann GmbH Gersteinstraße 19 59227 Ahlen - Germany Telephone: +49 (0)2382 7069-0 Norbert Hülsmann Volker Mauel Fax: +49 (0)2382 7069-9588 Members of the Board of Directors E-mail: info@reflex.de 42 — English Fillcontrol Plus — 06.07.2016 - Rev. B... - Page 44 Reflex Winkelmann GmbH Gersteinstraße 19 59227 Ahlen, Germany Telephone: +49 (0)2382 7069-0 Fax: +49 (0)2382 7069-9588 www.reflex.de...
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