Reflex Servitec Installation, Operating And Maintenance Instructions

Installation, operating and maintenance instructions Status 09/04

General Overview, type key 3 Operating panel 4 Safety instructions, regulations and standards 5 Installation Scope of delivery 6 Place of installation 6 Installation 6 Installation diagrams 7 – 8 Electrical connection 9 – 10 Initial start-up Prerequisite for start-up 10 Starting routine 11 – 12 Filling and bleeding the pump 12 Vacuum test 12 Hydraulic balancing 13 Automatic operation 13 Cleaning dirt traps 14 Operation Automatic mode 15 Manual mode 15 Stop mode 15 Customer menu 16 – 17 Service menu 17 Summer operation 18 Default settings 18 Interface RS-485 18 Messages 19 Maintenance Maintenance instrucitions 20 Disassembly 21 Periodic check-ups 21 Reflex service 21 General description Operation 22 – 23 Operating parameters 23 Dimensions, weights 23 Applications 23 Electrical details 23 Declaration of conformity 24 Installation, maintenance and commissioning certificate 25

(only with ’servitec magcontrol’) 3 Overflow valve with integrated dirt trap and pressure gauge 4 Make-up solenoid valve 5 Pressure reducing valve make-up line with integrated dirt trap and pressure gauge 6 Ball valve 7 Additional solenoid valve (only with version gl; not shown here) 8 Pressure reducing valve overflow line with integrated dirt trap and pressure gauge 9 Manifold 10 Pump 11 Drain plug 12 Bleed screw 13 Switching cabinet IP 54 14 Pressure connection with nozzle 15 Connection hose 16 Water deficiency switch 17 Suction connection 18 Dipstick tube-deaeration unit 19 Vacuum gauge 20 Vacuum spray-tube 21 Filling and draining ball valve A Water meter (or contact water meter) B Non-return flap C Drain funnel D Wall bracket E Shut-off servitec magcontrol / 60 / gl gl - version for water glycol mixtures up to 50% glycol component Pump size Type: magcontrol - with pressure expansion vessels level control - with pressure maintaining stations ’servitec’ control unit Type key reflex ‘fillset’ (optional) 18 19 14 15 20 13 16 17 21 12 11 10 9 8 7 6 5 4 3 2 1 R O P Overview C D B A E ’servitec’ spray-tube

throughout the rest of the installation, ope- rating and mainten- ance instructions  Message line Display of the active deaeration program and dis- play of messages Pressure display (only with ’servitec magcontrol’) Display of current system pressure, flashes upon pressure fault Manual mode (→ p. 14) Stop mode (→ p. 14) System shutdown Automatic mode (→ p. 14) Brings up the custo- mer menu (→ p. 15) Make-up solenoid valve (item 4) Overflow solenoid valve (item 7) (only with version gl) vacant Pump (item 10) vacant Dry operation protection LED lights when the water deficiency switch has switched (item 25) Error LED signals mes- sages and switching of the floating contact in the customer menu end parameter input, leave customer menu in auto, manual, stop modes acknowledge messages (e.g. „ER06“ make-up time exceeded) page through the starting routine, page through the customer menu, change parameters select parameters, confirm input menu auto stop hand quit ok error Operating panel Permanent degas.

The attached conformity certification certifies the compliance with the directive 97/23/EC for pressure devices and 89/336/EC on the electromagnetic compatibility. Installation, operation, pre-operation test, periodic inspections according to the governing local regulations. The installation and the operation to be performed to the state of the art by skilled installation technicians and specially trained personnel. An approved inspection body must be notified of necessary tests before operation (only for ’servitec’ special systems, PS x V > 50 bar x litre) and after major changes in the installation, as well as of periodic inspections. For recommended inspection intervals, see section “Periodic Inspection”. Only vacuum spray-tubes without visible external damage to the pressure body may be installed and operated. The operator is obliged to read thoroughly the installation, operating and instruction manual before installation/ initial start-up, to follow the instructions and to confirm the expert installation and start-up in the installation and start-up certificate (→ p. 25). This is a warranty requirement. We recommend having the initial start-up and annual maintenance performed by your Reflex Service (→ p. 21). Attention! ’servitec’ is for the stationary, not for the mobile operation. The set warranty periods are only applicable if a maximum of 16.000 deaeration intervals per year is observed (→ maintenance p. 20). Changes to the ’servitec’, for instance welding operations on the spray-tube or interventions into the wiring are not permissible. Adherence to the parameters Details concerning manufacturer, year of manufacture, serial number and the technical data are provided on the name plate. Suitable safety measures for temperature and pressure protection in the supply unit must be taken to ensure the specified permissible maximum and minimum operating parameters (pressure, temperature) are adhered to. Use only in systems with non-toxic waters. Thermal protection In water heating systems, a warning instruction must be provided by the operator near the vacuum spray-tube if persons are at risk from excessive surface temperatures or a suitable thermal insulation. Careful when working on a hot system. There is a scalding hazard from water issuing especially from the screw connections, the bleed screw for the pump and the dipstick tube-deaeration unit and injury hazard through high temperatures when touching especially the vacuum spray-tube. Electrical connection The electrical wiring and connection must be performed by a qualified electrician according to the applicable local EVU and VDE regulations. De-energise the system before working on electrical components. Failure to heed these instructions especially the safety instructions can result in the destruction of and defects of the ’servitec’, endanger persons and impair operation. Any claims for warranty and liability are excluded if these instructions are violated. 5 reflex ’servitec’ General General safety instructions

notified immediately! The scope of delivery is described on the delivery note and the content indicated on the cardboard box. (→ p. 3) 1 Pallet with outer cardboard box with - ’servitec’ (pre-assembled) (content indicated on the outer - vacuum spray-tube (added in cardboard box) cardboard box) - dipstick tube-deaeration unit (added in cardboard box) with - foil pocket (attached to the ’servitec’) with - installation, operating and maintenance instructions - electric wiring diagram Possible accessories: 1 cardboard box - 'fillset' with water meter (added in cardboard box) 1 cardboard box - 'fillset' with contact water meter (added in cardboard box) Installation room requirements: − Frost-free well-ventilated room, room temperature > 0 to max. 45 °C − No unauthorized access − Level floor with adequate load capacity with drainage facility − Filling connection ND 15, according to DIN 1988 T 4 − Electrical connection to 230 V~, 50 Hz, 16 A with upstream fault current protection switch: triggering current 0.03 A − Remove ’servitec’ from the pallet and transport to the place of installation, ensuring that the ’servitec’ is carried by the frame. − When aligning the control unit ensure that the valves and feed facilities of the connection lines can be operated. − Install vacuum spray-tube (20) (nut M12). − Connect the union nut of the suction connection (17) with the pump (10) without any stress; insert the enclosed plastic washers if required. − Connect connection hose (15) to manifold (9). − Remove transport lock of the dipstick tube-deaeration unit (18) (see figure) and manually screw in dipstick tube-deaeration unit (18). − Retighten all screw connections. − When replenishing from the potable water system the 'fillset' (→ p. 3) or a system separator must be installed upstream. − If no ’fillset’ is intended for connection to the potable water system, a dirt trap (mesh size < 0.25 mm) must be installed upstream by the customer. − If automatic make-up is not connected, the connection (R) of the make-up line must be blanked off with a plug G 1/2". Scope of delivery Place of installation Installation

circuit water rich in gas low in gas 7 reflex ’servitec’ Installation − connect ’servitec’ with the system piping. The maximum permissible media temperature at the connection point is 70 °C (’servitec .../90 °C’ are applicable up to 90 °C), which is why it is installed in the system return in the case of heating systems. − connect in the immediate vicinity of the expansion line so that protection by way of the system safety valve is provided. Otherwise, additional protection will be required. − maintain a minimum distance between the connection points of 500 mm, − note flow direction, − rinse pipelines. Installation diagrams − Caution dirt! Connect connection lines from the top or as immersion pipe as shown. Never integrate edgeless from below (danger of contamination). − With ’servitec .../gl’ a dirt trap (mesh size 0.25 mm) must be provided in the overflow line O by the customer in order to protect the additional solenoid valve (7) from contamination. − ’servitec’ deaeration operation is ensured only if ’servitec’ is connected to a representative main flow of the system. The following minimum flow rates V must be maintained during operation. − Use the following pipe dimensions: R O P reflex ’fillset’ with potable water make-up reflex ’servitec’ Expansion vessel/ pressure maintenance Detail connection 20 25 20 V pSV Dewatering by customer max. 70 °C Detail connection R Make-up line O Overflow line P Pump line V servitec ... / 35 0.7 m³/h servitec ... / 60 1.1 m³/h ≥ 500 Main flow V circuit water rich in gas low in gas from above from below as immersion pipe or laterally welded edgeless from below not allowed DN 25 DN 20 DN 20

system side so that the temperature exposure remains ≤ 70 °C. When using softening systems, this should be installed between ’fillset’ and ’servitec’. If the shut-off at the connection point of ’servitec’ is closed when shutting down the circulating pumps, part flow deaeration remains operational. Notes to the installer: reflex ’servitec magcontrol’ in a multiple boiler system with hydraulic points and expansion vessel The combination ’servitec’ with com- pressor-controlled pressure-maintai- ning stations (e.g. ’reflexomat’) is especially recommended. The system, which was highly degassed by the ’servitec’, is softly cushioned by the ’reflexomat’. The water level in the expansion ves- sel is monitored by the control unit of the pressure maintaining station. The 230 V make-up signal LS of the pressure maintaining station triggers the make-up process with deaeration. Optimum deaeration operation is en- sured by connecting ’servitec’ in the main circuit water flow. On combining pump-controlled pre- ssure maintaining stations with ’ser- vitec’, we always recommend indivi- dual boiler protection with a diaphragm pressure expansion vessel (e.g. ’reflex’). Notes to the installer: reflex ’servitec levelcontrol’ and compressor pressure maintenance - an ideal combination reflex ’servitec’ deaeration stations solve „gas problems“ in three ways: no direct drawing in of air through controlled pressure maintenance no circulation problems through free bubbles in the circuit water reduction of corrosion risk through oxygen withdrawal from the filling and make-up water * Detail connection → p. 7 The circuits must be adjusted to suit local conditions. reflex ’fillset’ reflex ’servitec magcontrol’ Softening Potable water M M TIC TIC TIC TIC TIC M M Hydraulic points 20 20 25 ≥ 500* ≥ 500* reflex ’fillset’ reflex ’servitec levelcontrol’ ’reflexomat’ Potable water 20 20 25 230 V Signal Cable by customer Main volumetric flow Required flow pressure ≥ 1.3 bar Required flow pressure ≥ 1.3 bar LS Installation diagrams

(EVU) and VDE regulations. Pull the mains plug or de-energise the system before commencing work on electrical components. Comprehensive electrical connection diagrams are enclosed with these instructions and must be adhered to. The following information applies only to standard systems and is largely restricted to the connections required by customer. – loosen 4 cross-recess screws on the switching cabinet (13) – open lid – pass all cables to be connected through the PG screw connection. Attention! Use only PG screw connections suitable for the appropriate cable. – connect all cables (refer to the following and electrical wiring diagram). – for on-site protection, observe the connected loads on p. 23. Overview wiring diagram on the circuit board J2 terminals 7/8 (fourth from the left) occupied → Contact water meter can be evaluated Designation Terminal Signal Remarks Feed X0 / 1 L - wiring on the terminal block next to the fuses (230 V) X0 / 2 N - ’servitec’ is ready cabled with earthing plug X0 / 3 PE Feed X0 / 1 L1 (400 V) X0 / 2 L2 X0 / 3 L3 - feed on-site X0 / 4 N X0 / 5 PE Make-up (4) 4 Y1 (230 V) 5 N - is connected 6 PE Water deficiency 43 +24V DC - pass cable of the water deficiency switch (16) switch (16) 45 through the M16 screw connection for dry operation - pull plug from the circuit board and connect the protection the cable of the water deficiency switch on the outside in each case. Plug in the plug. The terminals 43 and 45 must be occupied. Polarity need not be observed. Dry operation pro- 13 - to be cabled by customer (optional) tection (floating) 14 Pump (230 V) 15 M1 'servitec 35 - 95' 16 N - is connected 17 PE Pump (400 V) - is connected, 'servitec 120' → electrical wiring diagram

External make-up signal only for ’servitec levelcontrol’ Use in systems with pump or compressor-controlled pressure maintenance. Make-up of ’servitec levelcontrol’ is controlled by way of an external signal: – pass the control cable for make-up through the appropriate screw connection (M16 or M20). – connect cable. Once all connections have been established, close switching cabinet door, tighten the four screws of the switching cabinet door and establish the power supply. The system version will appear in the display. The ’servitec’ control is now ready for initial start-up. Designation Terminal Signal Remarks external make-up 22a only with ’servitec levelcontrol’ control 22b - floating input for external 230 V make-up signal - cable example: Aggregate mes- 23 NC sage (floating) 24 COM - to be wired by customer (optional) 25 NO Contact water 43 +24 V DC - to be cabled by customer, additionally connect the meter (optional) 44 E1 the pins 7/8 on the jumper block J2 (see above figure) Pressure 39 +18 V transducer (2) 41 AE - is connected 42 PE We recommend that you have the following operations and the induction of the operating personnel carried out by your Reflex service (→ p. 21, chargeable service according to the applicable gross price list). – The installation of the ’servitec’ including vacuum spray-tube has been completed. – The water connection to the system has been established. – System pressure maintenance is in operation. – The connection system is at least roughly bled. – The system has been connected to the electrical mains system according to the applicable VDE and local EVU regulations. Start-up requirements 'servitec' 230 V 22a 22b 'reflexomat' 4 (Y1) 5 (N)

control is switched on for the first time. ’servitec’ type, for instance ’ser- vitec magcontrol’ or ’servitec levelcontrol’ will then appear in the display. Now press ok to get to the language selection: Select the language by means of the country's symbols, e.g. GB for the english language and confirm with ok. The note to read these operating instructions will appear. Confirm with ok. This display appears only with ’servitec magcontrol’. Set the minimum operating pressure according to the static head of your system (refer also to the following diagram) and confirm with ok. Example: Heating system Advance temperature: 70 °C (Evaporation pressure pD = 0 bar) Static pressure pst:11 mWc (11 mWc ~ 1.1 bar) Setting values: p0: = 1.3 bar pSV: = 3.0 bar Resulting pressures for make-up: ON: = 1.4 bar OFF: = 1.6 bar This display appears only with 'servitec magcontrol'. Set the safety valve response pressure of the heat generator and confirm with ok. SERVITEC ..... Country: GB D GB F NL PL Read operating instructions! Min.oper.press. P0 = 1.5 bar Saf.valve press. PS= 3.0 bar  ok  ok pSV [bar] = Safety valve response pressure on the heat generator pmax [bar] pe [bar] = End pressure maintenance pa [bar] = Starting pressure maintenance or filling pressure pF with expansion vessel p0 [bar] = pstatic + pevaporation + 0.2 bar (recommended) pst [bar] = static pressure (=static height [m] / 10) 0.3 bar ≥ 0.5 bar ≥ 0.3 bar 0...0.2 bar The working pressure range of the 'servitec' must be within the working range pa … pe of the pressure maintenance. pa = Make-up if pressure falls below the limit * * * Error message if pressure exceeds upper or falls below lower limits The starting routine commences when the control is switched on for the first time. It serves for the setting of the parameters required for the operation of ’servitec’. Should you have entered an incorrect value you can restart the starting routine by pressing the „quit“ button. Note: The starting routine can be run through only once, once this has been done parameter modifications and cheques have to be performed in the customer menu (→ p. 16). Starting routine  ok  ok  ok reflex ’servitec’ Initial start-up 11

buttons and confirm with ok. Then continue with minute (in this case: 46) and seconds (in this case: 29). First, set the current day (in this case: 29) with the arrow buttons and confirm with ok. Proceed with month (in this case: 11) and year (in this case: 01). At the end of the starting routine the question will be asked whether the operator wishes to leave the starting routine. If „YES“ is chosen and confirmed with ok, the system will auto- matically move into stop mode. It should initially also be left in the stop mode in order to take additional start-up measures. If „NO“ is selected, the starting routine is repeated. You have completed the starting routine and are in Stop mode (in this case: ’servitec magcontrol’ with pressure display). You are now in stop mode. Attention! Do not yet change to automatic mode. The ’servitec’ is in stop mode. Careful with high temperatures! Observe general safety instructions (refer page 5)! – Connect filling hose to the filling and draining ball valve (21) of the vacuum spray-tube. – Fill vacuum spray-tube, air is expelled through the dipstick tube-deaeration unit (18), the potable water pressure can then be read off the vacuum gauge (19). – Bleed the pump (10) by way of the bleed screw (12), the pump must not be running. – Close bleed screw; close the filling and draining ball valve (21). Switch on pump. Note: Do not fully unscrew the bleed screw. Wait until bubble-free water runs out. Repeatbleeding as required. Careful with high temperatures! Observe general safety instructions (→p. 5)! Perform the vacuum test conscientiously to guarantee the operation of the ’servitec’! – Close ball valve (6), ball valve (1) of the pump line is open Jump to manual mode Start system deaeration (SE, flashes), pump (10) starts after 50 seconds Switch off pump, after approximately 10 seconds of pump operation – Observe vacuum gauge (19), the pressure may not change within a period of approximately 10 minutes. If the pressure has increased, please check the screw connections on the vacuum spray-tube, the bleed screw (12) and dipstick tube-deaeration unit (18) and repeat the process. – If the vacuum test was successful - reopen the ball valve (6) Time: 18:46:29 Date: 29.11.01 Exit routine YES 1.7 bar STOP Filling and bleeding the pump Vacuum test    hand  ok  ok  ok 12 reflex ’servitec’ Initial start-up

mances of the pump and the nozzle. – For adjustment of the pressure reducing valves (5, 8) and the overflow valve (3), loosen the safety screws - Jump into manual mode Start system deaeration (deaerating the system water) (SE, flashes) and when pump (10) is running, – set overflow valve (3) to the set value on the hand wheel (red), read pressure off pressure gauge (the green display on the hand wheel is only an orientation aid). – Regulate pressure-reducing valve (8, blue) of the overflow line to the set value and sub- sequently observe a complete deaeration cycle (→ p. 20): The water deficiency LED should not light up and the gas must be expelled before the next interval com- mences with pump restart. Quit system deaeration – With make-up connected: Start make-up deaeration (NE, flashes) Regulate pressure-reducing valve (5, blue) of the make-up line to the set value and check the flow on the water meter of the make-up line. Quit make-up deaeration Note: To regulate the valves (3, 5, 8), read the flow pressures from the appropriate pressure gauges. The pressure-reducing valve (5) for instance can only be set correctly with the solenoid valve (4) open. After all set values have been adjusted, recheck on the respecti- ve pressure gauge! – Retighten the valve safety screws (3, 5, 8) You can now change to automatic mode. Note: For the automatic mode of the 'servitec' it must be ensured that pressure mainte- nance of the system is operational and hydraulically connected with the ’servitec’! The system must have been roughly bled beforehand. Hydraulic balancing must have been completed! Start automatic mode „Permanent deaeration“ will appear in the display The ’servitec’ is now in operation. Commissioning by the reflex service is complete at this point!  hand  auto Automatic mode Pressure reducing valve 1.7 bar Permanent degas. Display (→ p. 4) after initial start-up of a ’servitec magcontrol’ in automatic mode Typ 35 : 3.2 bar Typ 60, 60 gl : 5.2 bar Typ 75, 75 gl : 5.7 bar Typ 95, 95 gl : 7.9 bar Typ 120, 120 gl : 9.7 bar Typ 50/90 °C : 3.3 bar Typ 75/90 °C : 5.3 bar Typ 95/90 °C : 7.0 bar Typ 120/90 °C : 8.7 bar 0.8 bar 1.0 bar   + -  quit  quit reflex ’servitec’ Initial start-up 13

Caution! Observe general safety instructions (→ p. 5)! Note: After expiry of the set permanent deaeration period, clean the dirt traps of the pressure reducing valves (5, 8) of the make-up and overflow lines (not part of reflex commissio- ning!). Do not forget dirt traps (for instance ’fillset’ item F) installed by customer. If the dirt traps are very dirty, fine setting (hydraulic balancing → p. 13) is required once more. The dirt traps should also be checked after the filling process or after extended opera- tion. – close ball valve (6), ball valve (1) of the pump line is open. Jump to stop mode – loosen union nuts of the valves (5, 8) – pull out operating unit (black) – clean dirt trap – reinstall operating unit with dirt trap – tighten union nut – Open ball valve (6) – Bleed the pump (10) by way of the bleed screw (12), the pump must not be running – Close bleed screw (12) – Start automatic mode After the initial start-up, permanent deaeration is activated for 24 hours in a normal case, automatically followed by intermittent deaeration (→ p. 15). Following permanent deae- ration, clean the dirt traps of the pressure reducing valves (5, 8).  stop  auto Dirt trap Operating unit Union nut Initial start-up is completed at this point! 14 reflex ’servitec’ Initial start-up

automatic mode, you can select from three deaeration programs if required. System cont- rol is active with all three deaeration programs. Make-up takes place automatically. Select from the customer menu (→ p. 16) Permanent deaeration – Intensive deaeration after start-up and repairs The deaeration cycles for the set continuous deaeration time (24 hours basic setting) will be executed successively. The control will then proceed with intermittent degas- sing automatically. On start-up, at least half of the system volume in the case of water systems should flow at least once by way of the ’servitec’, in the case of water/glycol mixtures, 5 times the system volume. Interval deaeration – Economy mode in automatic mode After 8 cycles (standard), a break (standard 12 hours) is observed before the next 8 deaeration cycles are started. This program is started automatically after the expiry of continuous deaeration or can be selected manually with systems already degassed. Interval deaeration will start at 08h00 each day. Make-up deaeration – Only deaerating the make-up water The system water will not be degassed. This operating mode is practical in summer mode (→ p. 18) or if general deaeration of the system water is not required. Manual mode is required for hydraulic balancing of the pressure reducing valves (5, 8) and the overflow valve (3) and for filling systems. There are two types of operation in manual mode: NE (make-up deaeration) and SE (system deaeration). System deaeration SE – system water is degassed System deaeration is active while is flashing. Acknowledge system deaeration The deaeration cycles (→ above) are successively executed in this type of operation. The system deaeration is required for hydraulic balancing of the pressure reducing valve (8) and the overflow valve (3) (→ p. 12). The maximum running period is displayed at the bottom right. After expiry of this time, the ’servitec’ moves into error. An error message will be output if the operating pressure falls below the minimum. Make-up deaeration NE – make-up water is degassed Make-up deaeration in manual mode is active for as long as is flashing. Acknowledge make-up deaeration This type of operation primarily serves for hydraulic balancing of the pressure-reducing valve (5) (→ p. 12). However, with ’servitec magcontrol’ it is also possible to fill the sys- tem. The filling time (with contact water meter also the filling quantity) will be monito- red. Once the filling pressure (pF, → p. 10) or the filling time (10 h) has been reached, make-up deaeration is terminated and an error message output. Again press the button to get to stop mode. In stop mode 'servitec' is not operational except for the display. Operation monitoring does not take place. All pumps or solenoid valves are switched off. The adjacent display appears when the „stop“ button is pressed. If the stop mode has been activated for longer than 4 hours, a message will be initiated. 1.7 bar Permanent degas. Display (→ p. 4) automatic mode with permanent deaera- tion with ’servitec magcontrol’  auto  hand 1.7 bar Interval degas. Display (→ p. 4) automatic mode with interval deaeration with ’servitec magcontrol’ NSP Make-up degas. Display (→ p. 4) automatic mode with make-up deaeration with ’servitec magcontrol’ NE SE 10 h Display (→ p. 4) ’servitec level- control’ flashes with system deaeration NSP NE SE 010 h Display (→ p. 4) ’servitec level- control’ flashes with make- up deaeration. NSP appears with 230 V or floating make-up signal Manual mode quit  quit  quit   Stop mode  stop STOP > 4 h 19 STOP reflex ’servitec’ Operation

meters. In part, these were already processed within the starting routine during initial start-up. Additional parameter changes are possible here. Press the „menu“ button to get to the cus- tomer menu. This is where you can change operating parameters or view current statuses. Press the „menu“ button to access the customer menu. Press to leave the customer menu. This information appears in the display once the menu button has been pressed. You are now in the customer menu. Select the language by means of the national symbol, e.g. GB for the english language and confirm with ok. First, set the current hour (in this case: 18) with the arrow keys and confirm with ok. Pro- ceed with minute (in this case: 46) and second (in this case: 29). First, set the current day (in this case: 29) with the arrow keys and confirm with ok. Proceed with month (in this case: 11) and year (in this case: 01). This display appears only with ’servitec magcontrol’. Set the minimum operating pressure according to the static head of your system (→ p. 11) and confirm with ok. This display appears only with ’servitec magcontrol’. Set the safety valve opening pressure (→ p. 11) and confirm with ok. Select the deaeration program (→ p. 20) and confirm with the ok button. Select the duration of permanent deaeration (→ p. 15). The standard setting of 24 h is suf- ficient for water systems up to approximately 20 m³ capacity. Confirm with ok. Press , to get to the language selection: Change menu point Select parameters Confirm parameters Leave menu Select or change parameters (flashing values or symbols) CUSTOMERMENU Country: GB D GB F NL PL Time: 18:46:29 Date: 29.11.01 Min.oper.press. P0 = 1.5 bar Saf. valve pre ss PS = 3.0 bar Deaeration prog. Permanent degas. Cont. degas time ED = 012.0 h ok  ok  ok  ok  ok  ok  ok         ok  ok quit  ok  ok  ok  ok  ok quit reverse forward Change menu option 16 reflex ’servitec’ Operation

ter meter (10 litres per contact) if applicable can be reset here (YES). Confirm with the ok button. In this menu option it is possible to set the total make-up volume from which an alarm message will be triggered if more than 5000 litres have been replenished. This is where you set when the message „re- commended maintenance“ will be triggered. The counter counts backwards, i.e. when dis- playing 10 months the next maintenance will be due in 10 months' time. The maintenance control can be switched off. Here you can select whether all active alarms ought to switch the floating contact (pfK). If „NO“ is selected here, only the messages identified as „alarms“ in the message list on page 18 will result in the pfK being switched. Error memory display. This is where the last 20 faults including error code (for instance ER01, → p. 18) are chronologically displayed with the time and the date. 01 is the most re- cent, 20 is the oldest error. The parameter memory saves the last 10 changes of the minimum operating pressure po specifying the time and the date of the change. 01 is the most recent, 10 is the oldest change. Change menu option * * Select parameters Confirm parameters Select or change parameters (flashing values or symbols) Make-up vol. Vnsp = 001460 l Max-make-up-vol. Vmax = 005000 l Next maintenance TY = 12 months All messages PFK YES Error memory Parameter memory ok  ok  ok  ok  ok  ok  Displays the ’servitec’ type and the software version (for instance V1.04). MC → ’servitec magcontrol’ LC → ’servitec levelcontrol’ * Only when a contact water meter is used (plugging jumper → p. 10) SERVITEC MC V ...  auto  hand  stop    ok   ok   ok   ok   ok   ok  You have run through the complete customer menu once. You can now change to the desired operating mode. CUSTOMERMENU Leave menu quit Reverse Forward Change menu option Only for information: Only for information: Service menu A password-protected service level is installed in ’servitec’ controls, in which additional data can be changed. This is only possible by the Reflex service, telephone +49 23 82 / 70 69-550. or or reflex ’servitec’ Operation

– Continuous information concerning pressure – Information on the pump operating status (only ’servitec magcontrol’) – Information of the operating status of the solenoid valve for make-up – Information on the added value of the contact water meter – Information on all messages – Information from the error memory Connection of the interface with the primary control centre or similar – The interface is arranged on the display board in the switching cabinet door in the lower left corner. A four-pin plug (plug-type LP terminal, grid 3.81 mm, 4-pin, type 8813B/04OB) is required for connecting the interface. The plug can be obtained from the Reflex service. – Connect the interface with a screened cable twisted or stranded together in pairs, e.g. LJYCY (TP), 4 x 2 x 0.8 (max. total bus length = 1000 m) – When using a control centre or similar not equipped with an interface RS-485 but with an interface RS-232, an appropriate interface converter is required. – When using the communication module (optional) the interface is occupied by connecting the communication module. The protocol of the interface RS-485 can be requested from reflex service if required. Interface RS-485 Summer operation If the circulating pumps of the system are taken out of service during summer, deaeration of the mains content water can only be safeguarded if the shut-off between overflow line and pump line of the ’servitec’ is closed. If this cannot be ensured, the deaeration program should be set to make-up deaeration by way of the customer menu (→ p. 16). If the ’servitec’ was operated in the operating type make-up deaeration during summer, it should be reset to intermittent deae- ration or, if desired, to continuous deaeration after the circulating pumps have been switched on again. Sticking of the pump (10) is avoided through the positive start (24 h). Sticking of the pump cannot be excluded after prolonged disuse (’servitec’ de-energised or in stop mode). For this reason the pump rotor should be turned with the screwdriver prior to restarting. Standard settings Parameters have been reset in the data memory of the ’servitec’ which are based on research and operating experience. The most important are described in the following table. Parameter Setting Remark ’servitec ’servitec magcontrol’ levelcontrol’ Pressure Make-up ON p0 + 0.1 bar p0 min. operating pressure (→ p. 10) X Make-up OFF p0 + 0.3 bar X Pressure below minimum level = p0 X Pressure above maximum level pSV – 0.2 bar pSV safety valve response press. (→ p. 10) X Max. make-up volume 0 Only activated if control is set to contact X water meter (→ p. 9) Make-up The alarm message is triggered when Max. make-up time 20 min the make-up time or number of X X Max. make-up cycles in 2 h 3 cycles has been exceeded X X Filling Filling is terminated after 10 hours or on Maximum filling time 10 h reaching the filling pressure (p0 + 0,3 bar) X Deaeration interval Standard / gl Draw vacuum 02 s / 20 s Pump running, no spraying X X Injection time 30 s / 00 s Pump running, spraying X X Pushing out time 50 s / 50 s Pump off, spraying X X Idle time 05 s / 05 s Pump off, no spraying X X Interval-permanent deaeration Intermission 12 h 8 deaeration cycles are run every X X Deaeration cycles 8 12 hours X X Starting time interval deaeration 08 h 00 Interval deaeration will start at 08h00 X X each day (synchronization) Permanent deaeration time 24 h adjust time to the consumer system X X 18 reflex ’servitec’ Operation

operation protection is signalled directly by a separate LED (→ p. 4). If several messages are active simultaneously, these can be directly displayed with . Most of the messages automatically acknowledge themselves once the cause has been remedied. Errors such as „make-up time 06“ or „make-up cycle 07“ must be acknowledged manually. An error and parameter memory is available for subsequent analysis (→ p. 16). For remote transmission it is possible to use the floating changer for the aggregate message, the floating contact for the dry operation protection and the RS-485 inter- face (→ p. 17). In the customer menu (→ p. 16) it is possible to select whether only the messages characterised as alarms or all messages will pass through the floating output. Messages ER Code Type of error Cause of errors Troubleshooting remedy 01 Pressure below – Water loss in the system – Correct leak minimum pressure p0 – Pressure maintenance incorrectly set – Acknowledge error („quit“ button) (alarm) or defective 02.1 Dry operation protection – Water deficiency switch (16) not wired up – Wire up water deficiency switch Time exceeded – No water enters the vacuum spray-tube (alarm) - Ball valve on inlet side closed – Open ball valve - Dirt trap of the pressure reducing valves – Clean dirt trap (5,8) dirty 02.2 Dry operation protection – Not enough water flows into the vacuum Number exceeded spray-tube (alarm) - Dirt trap of the pressure reducing – Clean dirt trap valves (5,8) dirty - Pressure reducing valves (5,8) or – Correct pressure setting on the pres- overflow valve (3) incorrectly set sure reducing valves, perform hydraulic balancing – Dipstick tube-deaeration unit (18) defective – Replace dipstick tube-deaeration unit 04.1 Pump – Pump fuse defective – Check fuse, replace if required fault – Pump blocked – Free pump (alarm) – Short circuit – Establish cause and rectify 06 Make-up time – Major leaks in the system – Correct leaks, acknowledge error exceeded (standard 20 min) – Make-up time inadequate for – Reduce make-up hysteresis downstream pressure maintenance of the pressure maintenance 07 Make-up cycles – Minor leaks in the system – Correct leaks, acknowledge error exceeded (standard 3 in 2 h) message 08 Pressure measurement – Pressure measuring transducer not – Check wiring, replace if required fault (alarm) connected or defective 10 Max. pressure – Pressure losses between ’servitec’ – Incorporate pressure measuring trans- exceeded and system excessive ducer in the system or use greater no- minal widths for the piping to the system – Expansion vessel in the system with – Check expansion vessel pre-pressure incorrect pre-pressure – Solenoid valve (4) fails to close – Inspect solenoid valve for dirt, clean or replace if required – PS in customer menu set too low – Co-ordinate PS setting with safety valve activation pressure of the system 11 Make-up quantity – Major leaks in the system – Correct leaks, acknowledge error within a make-up cycle – Make-up quantity inadequate for – Reduce make-up hysteresis of exceeded downstream pressure maintenance the pressure maintenance or increase maximum make-up quantity 12 Filling time – Max. filling time exceeded – Check filling status of the system, exceeded (standard 10 h) acknowledge error and refill if required 13 Filling quantity – Max. filling quantity exceeded – Check the filling status of the system, exceeded acknowledge error and refill if required 15 Make-up solenoid valve – Make-up solenoid valve (4) leaking – Inspect solenoid valve for dirt, (control) (contact water meter is counting without clean or change if required make-up request) 16 Power failure – – Check power supply 19 Stop > 4 h – ’servitec’ has been in stop mode for – Activate auto mode as applicable more than 4 h 20 Max. make-up quantity – The maximum make-up quantity set in – Acknowledge message exceeded (added) the customer menu has been exceeded (→ p. 16) Mainten. Maintenance interval – Reminder of the minimum annual – Perform maintenance rec. expired maintenance – Acknowledge message 30 EEPROM defective – EEPROM has internal – Change CPU board (alarm) calculation errors * * * * * Only if contact water meter is connected and activated in the control (→ p. 10 and 15)

The ’servitec’ must be maintained annually, but at least after 16.000 deaeration cycles (this corresponds to a continuous dea- eration time of approximately 14 days or a continuous deaeration time of 7 days + 1 year intermittent deaeration with standard setting). Maintenance operations may only be performed by specialists. We always recommend that you commission your Reflex service. To remind of the maintenance to be performed at least annually, the display "maintenance recommended" appears after expiry of the set operating time, which can be acknowledged with the „quit“ button. When carrying out maintenance operations on the vacuum spray-tube proper, this should first be depressurised by way of the filling and drain cock (21). Leak test – check for external leaks, especially pump, screw connections and dipstick tube-deaeration unit – seal if required Operational vacuum test – Procedure → p. 11, paragraph vacuum test Cleaning filter elements of the pressure-reducing valve (5, 8) – Procedure → p. 13, paragraph clean dirt trap Adjust pressure-reducing valves (5, 8) and overflow valve (3) – Procedure → p. 12, hydraulic balancing Check set values of the control – Procedure → p. 15, customer menu Check deaeration interval System deaeration – Jump into manual mode – Start system deaeration (SE, flashes) – Following the expiry of the push-out time (50 s) the pump (10) starts; vacuum is drawn, can be read off the vacuum gauge (21) – Pump (10) switches off (after 30 seconds or 20 seconds with gl), water deficiency LED may not light up – Version gl solenoid valve (7) opens when the pump is switched off – Water is sprayed in by way of the pressure connection with nozzle (22), vacuum is broken, gas is expelled, gas must be expelled before the next cycle can commence Make-up deaeration – Start make-up deaeration (NE, flashes) – Solenoid valve (4) of the make-up opens, the pump starts after 50 seconds and draws vacuum – Pump switches off (30 seconds or 20 seconds) – Water continues to be sprayed in via nozzle (22), vacuum is broken, gas is expelled, gas must be expelled before the next cycle can commence. – Deactivate make-up deaeration (NE, no longer flashes) Note: Once the gas has been completely expelled through the dipstick tube-deaeration unit and the water deficiency LED (red) has not come on during the injection process, maintenance is complete. – Start automatic mode  hand    auto 1.7 bar NE SE 10 h Display (→ p. 4) ’servitec mag- control’ flashes with system deaeration 1.7 bar NE SE 10 h Display (→ p. 4) ’servitec mag- control’ flashes with make-up deaeration quit  20 reflex ’servitec’ Maintenance

After-sales service (Germany) Extension +49 23 82 / 70 69-... Fax E-Mail Management Paul Stahl Volker Lysk - 550 - 512 - 523 - 523 [email protected] [email protected] Disassembly Before periodic inspection or disassembly of the ’servitec’ system and or pressurized parts these have to be depressurized. 1. close ball valves (1), (6) of the control unit and (G) of the ’fillset’, 2. open ball valve (21) until spray-tube (20) is depressurized, 3. drain spray-tube through ball valve (21) completely, if necessary ventilation through screw-off of dipstick tube-deaeration unit (18). Periodic check-up Recommended max. inspection intervals for Germany according to § 15 (5) of the Plant Safety Ordinance and classification of the ’servitec’ spray-tube in table 2 of directive 97/23/EC: Valid with strict adherence to the ‚reflex‘ installation, operating and maintenance instructions: external inspection: no requirement internal inspection: maximum interval acc. to § 15 (5) strength test: maximum interval acc. to § 15 (5) The actual intervals must be laid down by the operator on the basis of a safety evaluation, ta- king due account of the actual operating conditions and the applicable national regulations.

range of system conditions. The main field of application are heating and cooling circuits and wherever air problems interfere with systems in form of dissolved or free gases. ’servitec’ vacuum spray-tube deaeration system removes up to 90% of the dissolved gases from the mains content water. The ’servitec ../gl’ was developed for glycol water mixtures up to 50% glycol component. With the type ../gl, high deaeration performances are also achieved with glycol water mixtures. Vacuum deaeration of a part flow of the circuit water takes place ac- cording to an optimised schedule with selected deaeration programs (→ p. 15). A part of the circuit water is atomised into the vacuum spray-tube (20) in which the vacuum is drawn through the pump (10). The large sur- face of the sprayed water and the intense vacuum result in the very high deaeration performance. The degassed water is returned to the system by the pump (10). There the water is again able to dissolve gasses. The gasses separated in the vacuum spray-tube are expelled through the dipstick tube-deaeration unit (18). This deaeration interval is repeated and both free as well as dissolved gases are removed from the circuit water. The deaeration interval The water from the make-up or discharge line is made available at the nozzle (14) at a constant pressure by way of the pressure reducing valves (5, 8) and the connecting hose (15). The deaeration cycle is a time-controlled process, which has been pre-programmed. Changing it in the service menu is only possible by the Reflex service. Injection time: The pump (10) starts. A vacuum (dependent on temperature) can be read off the vacuum gauge (19) after a short time. This is possible because the pump (10) draws more water from the vacuum spray-tube by way of the suction connection (17) than is able to flow in by way of the pressure connection with nozzle (14). For this reason the pump (10) is set to a constant working point by way of the overflow valve (3). Spraying through the nozzle commences as soon as the vacuum begins to be established or, with the version „gl“, with the opening of the solenoid valve (7) of the overflow line. The water level in the vacuum spray-tube (20) drops continuously while the pump (10) is running. The timing program and pressure setting have been selected so that the water deficiency switch (16) will not be activated. Pushing out time: The pump (10) switches off. The water continuous to be sprayed into the vacuum spray-tube by the system pressure (at least 1.3 bar). During the pushing out time (50 s) the water column in the vacuum spray-tube rises gradually. The vacuum is still maintained during this phase of the cycle. At the end of the pushing-out phase the rising water column compresses the removed gas within a few seconds, pushing it into the atmosphere by way of the dipstick tube-deaeration unit (18). Idle time: This is followed by the idle time during which re-deaeration takes place.

With the ’servitec magcontrol’, the pressure in the heating or cooling system is registered and monitored with the help of the pressure measuring transducer (2). If the filling pressure drops below pF = p0 + 0.1 bar, make-up deaeration is activated until pF = p0 + 0.3 bar has been reached. The time (20 minutes default setting), cycles (3 in 2 hours) and quantity control (optional - ’fillset’ with contact water meter) is active during this process. Make-up ’servitec levelcontrol’ With the ’servitec levelcontrol’, make-up takes place directly in the system dependent on the level in the vessel of the pressure maintaining station. The make-up function can be activated by way of a floating contact or an external 230 V~ signal. Time, cycle and optional quantity monitoring is activated. Operating parameters Permissible operating pressure ’servitec’ size 35, 50, 60 : 8 bar ’servitec’ size 75, 95, 120: 10 bar Permissible operating temperature : > 0 … 70 °C Perm. operating temp. ’servitec .../90°C’ : > 0 ... 90 °C Permissible advance temperature of the supply system : 120 °C Permissible ambient temperature : > 0 … 45 °C Part flow deaeration performance ’servitec ../35’ : < 0.35 m3/h ’servitec ../60’ : < 0.55 m3/h ’servitec ../60/gl*’ : < 0.55 m3/h Degree of separation for dissolved gases: < 90 % Minimum flow pressure for make-up : 1.3 bar Sound level : ca. 55 dB Nominal volume spray-tube ’servitec’ standard systems : 5 litre (without name plate on spray-tube) ’servitec’ special systems : acc. to name plate Dimensions and weights Dimensions Total height: 1180 mm Width: 610 mm Depth: 710 mm Recommended installation area Width: 1000 mm Depth: 1000 mm Weight: 33 - 45 kg Fields of application Heating and cooling water systems gl version for water mixtures up to 50% glycol component Deaeration of the mains content water with system volumes: ’servitec ../gl’, < 20 m3 ’servitec ../35’, < 60 m3 ’servitec ../60 - 120’ < 100 m3 Deaeration of make-up water, especially potable water up to 0.55 m3/h* * Larger stations on request Electrical details Output -’servitec 35’: 0.7 kW, protection 10 A, 230 V, 50 Hz - ’servitec 50, 60, 75, 95’: 1.1 kW, protection 10 A; 230 V; 50 Hz - ’servitec 120’: 1.5 kW, protection 10 A, 400 V, 50 Hz Degree of protection IP 54 Separate control protection through microfuse (500 mA) and the pump with a blow-out fuse (10 A) On-site connection - FI-protection switch 0.03 A - < 1.1 kW 230 V ’servitec’ ready to plug with 5 m connection cable for on-site outlet - from 1.5 kW 400 V on-site feeding on terminal strip

Declaration of conformity for ’servitec’ control units The manufacturer herewith confirms that the design, manufacture and testing of the ’servitec’ controls conforms with the requirements of the guideline of the council for the co-ordination of the legal requirements of the member states concer- ning electromagnetic compatibility and the low voltage guideline 89/336 EEC and 73/23 EEC. The following standards were used to evaluate the products with regard to electromagnetic compatibility and the low voltage guideline: EN 50081 part 1, in conjunction with EN 55022 and EN 60555 EN 50082 part 1, in conjunction with EN 55082 part 2 EN 60335 part 1 EN 60204 Hersteller: Manufacturer: Reflex Winkelmann GmbH + Co. KG Gersteinstraße 19, D-59227 Ahlen/Westf. Telefon: +49 23 82 / 70 69-0 Franz Tripp Telefax: +49 23 82 / 70 69-588 Geschäftsführer / Managing director Konformitätserklärung für die Baugruppe Vakuum-Sprührohr Declaration of conformity of an assembly Konstruktion, Fertigung, Prüfung von Druckgeräten Design – Manufacturing – Product Verification Angewandtes Konformitätsbewertungsverfahren nach Richtlinie für Druckgeräte 97/23/EG des Europäischen Parlaments und des Rates vom 29. Mai 1997 Operative Conformity Assessment according to Pressure Equipment Directive 97/23/EC of the European Parliament and the Council of 29 May 1997 ’servitec’ Vakuum-Sprührohr zur Entgasung von Heiz- und Kühlwassersystemen ’servitec’ vacuum spray-tube for deaeration of heating and cooling systems Beschickungsgut Wasser Operating medium Water Normen, Regelwerk Druckgeräterichtlinie, AD 2000 Standards Pressure Equipment Directive, AD 2000 Druckgerätegruppe Pressure Equipment Group Fluide Gruppe 2 Fluid group Kategorie (Behälter, Baugruppe, Sicherheitsventil) Modul Kennzeichnung gem. Druckgeräte- Category (vessel, assembly, safety valve) Module richtlinie Label acc. to Pressure Equipment Directive 97/23/EG I A CE Hersteller: Manufacturer Baugruppe: Artikel 3 Abs. 2.2 Behälter: Artikel 3 Abs. 1.1a) 2. Gedankenstr. (Anhang II Diagr. 2), Ventil (soweit vorhanden), Manometer (soweit vorhanden): Artikel 3 Abs. 3 assembly: article 3 paragraph 2.2 vessel: article 3 paragraph 1.1a) 2. bar (enclosure II Diagraph 2), valve (as available), manometer (as available): article 3 paragraph 3 Der Hersteller bescheinigt hiermit, daß Konstruktion, Herstellung und Prü- fung dieses Vakuum-Sprührohres den Anforderungen der Richtlinie 97/23/ EG / prEN 13831:2000 entsprechen. The manufacturer herewith certifies that construction, production and exami- mation of this vacuum spray-tube are in conformity with EU guideline 97/23/ EC / prEN 13831:2000 Franz Tripp Geschäftsführer / Managing director Reflex Winkelmann GmbH + Co. KG Gersteinstraße 19 59227 Ahlen/Westf. Germany Telefon: +49 23 82 / 70 69-0 Telefax: +49 23 82 / 70 69-588

Montage- und Inbetriebnahmebescheinigung Installation and commissioning certificate Die ’servitec’ wurde entsprechend der Reflex Montage-, Betriebs- und Wartungsanleitung montiert und in Betrieb genom- men. Die Einstellung der Steuerung entspricht den örtlichen Verhältnissen. Hinweis: Falls werksseitig eingestellte Werte verändert werden, so ist dies auf dem Typenschild (Mindestbetriebs- druck, SV-Ansprechdruck) bzw. in der Tabelle der Wartungsbescheinigung einzutragen. The ’servitec’ was installed and commissioned in accordance with the installation, operating and maintenance instructions. The control setting corresponds to the local conditions. Note: If values preset at the factory are changed, this must be entered in the rating plate (minimum operating pressure, safety valve activation pressure) and in the maintenance confirmation table. für die Montage / for the installation Ort, Datum / Place, date Firma / Company Unterschrift / Signature für die Inbetriebnahme / for commissioning Ort, Datum / Place, date Firma / Company Unterschrift / Signature Daten lt. Typenschild: Typ : servitec Herstell-Nr. : Wartungsbescheinigung Maintenance certificate Die Wartungsarbeiten wurden entsprechend der Reflex Montage-, Betriebs- und Wartungsanleitung durchgeführt. The maintenance operations were performed in accordance with the reflex installation, operating and maintenance instructions. Datum / Date Servicefirma / Service company Unterschrift / Signature Bemerkungen / Remarks Data as per rating plate: Type : servitec Manufacturing no.:

Reflex Winkelmann GmbH + Co. KG Gersteinstraße 19 59227 Ahlen Germany Telefon: +49 23 82 / 70 69-0 Telefax: +49 23 82 / 70 69-558 www.reflex.de