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reflex ’variomat’Pressure-maintaining station
with automatic water make-up and deaeration
2
The reflex ’variomat’can do much more than just maintaining the pressure
The pump-controlled ’variomat’ opensup a completely new dimension of pres-sure-maintaining stations for heatingand cooling circuits.
Its three functions:it keeps the system pressure withinvery restricted limitsit deaerates the content waterit makes up water automatically
Thus, the reflex ’variomat’ is the bestsolution for increasing air problems, inparticular within closed heating installa-tions, which, according to a study of theTechnical University of Dresden, arisein more than 50 % of the installations.
The reflex ’variomat’ ensures air-free installations up to the top floor and intothe last corner. Expensive decentralized air separatorsas well as the time-consuming deaera-tion are things of the past.An additional advantage: A special datainterface allows the integration into themodern facility management.
The high efficiency of the ’variomat’principle has been proven at the Tech-nical University of Dresden and hasbeen tried and tested in numerous ap-plication examples. The combination ofpressure maintenance, deaeration, andwater make-up complies with all re-quirements for air-free systems and re-quires only little maintenance.
OLD
Shut-off on-site,recommended forsummer operation
’variomat’:extensive program, great varietyof applications
NEW
’variomat 1’ and ’2-1’ single pumpsystems for systems of up to 4 MW’variomat 2-2’ double pump systems for systems of up to 8 MWalso suited for systems with a glycolcontent of up to 50%fully automatic operation with data in-terface for interconnection with state-of-the-art facility managementsystemssilent method of operation for use innoise-sensitive areasproven in centrally heated apartments and industrial buildings,in district heating systems and inclosed-loop cooling circuitsInternationality: the control systemoffers as much as 8 languages foryou to select
The ’variomat’The high effectiveness of the multi-functional unit
The unpressurized VG primary vesselof the ’variomat’, which is closed to-wards the atmosphere, is not only usedfor the deaeration of the heating water,but also for the discharge and partialdeaeration of the make-up water. Thus,
a partial flow of the heating water is, dependent on the time, led through theVG primary vessel and automaticallybled and/or deaerated because the gassolubility at this point is lower than in thesystem. Using different deaeration pro-
grams, the start-up and operating condi-tions of the process can be optimallyadjusted to the individual requirementsand are electronically monitored.
“Three functions in one device and a satisfied buildingowner for whom air problems are finally things of thepast – the ’variomat’ is simply great!”
Conventional installation:Water supersaturated with gasresults in system breakdowns
Convincing: the ’variomat’-advantages in the exampleof a heating system
The ’variomat’ installation:Water which is effectively gas-free, thus no more air problems
Gassysampling
Gas-freesampling
’variomat’
3
– No time-consuming decentral-ized subsequent bleeding
– No gargling sounds– Full thermal output at any time
Elimination of mechanical air separators
Protection of pumps against airand cavitation
No formation of bubbles on thehot boiler heating surfaces, con-sequently better heat transfer
Entire circuit water:less erosion and wear, less formation of mud, improved circulation
– ’variomat’ maintains the cor-rect pressure and displays it
– ‘variomat’ deaerates– ‘variomat’ makes up water
automatically
4
reflex ’variomat’ – The programfor pressure maintenance, deaeration, and water make-up
reflex ’variomat 1’ up to 2 MW with 1 pump
Smooth pump startadditional TÜV-certifiedminimum pressure valveElectrical main switch
2 pumps with smooth start2 additional TÜV-certifiedminimum pressure valvesElectrical main switch load-dependent connection andmalfunction change-over
reflex ’variomat 2-1’ up to 4 MW with 1 pump
reflex ’variomat 2-2’ up to 8 MW with 2 pumps
VG primary vessel
Connection set
Control unit
VG primary vessel
Connection set
Control unit
VG primary vessel
Connection set
Control unit
BA
BA
BA BA
2 separateexpansion lines→ p. 18
230 V
Programmable floatinggroup faultsignal+ RS 485
P
from
the
syst
em
O W
Installationdetails→ p. 14
Watermake-upwater
230 V, fixed connection
Programmable floating group faultsignal+ RS 485
P
tow
ards
the
syst
em
from
the
syst
em
O W
Watermake-upwater
230 V, fixed connectionProgrammable floatinggroup faultsignal+ RS 485
P towards the system
O from the system
W
Water make-up water
reflex ’fillset’(optional)
reflex ‘fillset’(optional)
VF secondary vessel(optional)
reflex ’fillset’(optional)
VF secondary vessel(optional)
tow
ards
the
sys
tem
5
reflex ’variomat’
Maintain pressure, compensatethe expansion volumePump (A) and over-flow valve (B) are trig-gered in such a way that the pressureremains constant within the limits ± 0.2bar. The expansion water is fed (O) orcarried away (P) to/from the unpressuri-zed VG primary vessel using 2 separateexpansion lines.
Deaeration
A partial flow of the heating water isrelieved in the VG primary vessel and,thus, degassed. You can select one of thefollowing deaeration modes:
Continuous deaeration: constant deaer-ation after the commissioning and afterrepairs in the supply system in order toquickly remove all the residual air fromthe systemFollow-up deaeration: is automaticallyenabled after the continuous deaerationand then runs after every pump cycleInterval deaeration: runs at a presenttime schedule
Water make-up
PIS
TIME
LIS
The unpressurized closed VG primary vesselhas two functions:1. Expansion water is reliably protected from
the admission of air in a bubble diaphragm.2. The purposeful expansion-relief of the net-
work content water separates and dichargesgasses.
The VG primary vessel capacity can be ex-panded by connecting multiple VF secondaryvessels in series.
The VG primary vessel warms up in heatingsystems. Therefore, the installation of a VWthermal insulation consisting of 50 mm FCKW-free soft foam with zipper and floor insulation isrecommended.
Control unit
VG primary vessel, VF secondary vessel
VW thermal insulation
Connectors are available for the quickconnection of the ’variomat’ to VG primaryvessels. These are equipped with a pro-tected shut-off for 1-pump systems. Withrespect to 2-pump systems, the protectedshut-off is located on the control unit.
The ’fillset’ with DVGW tested systemseparator, water meter, dirt pan, shut-off,and wall bracket is offered as an accesso-ry for the direct connection of the watermake-up device to a drinking water net-work. Can also be supplied with an option-al contact water meter.
Connection set
’fillset’
The volume of ejected free gasses aswell as water losses are automatically supplemented. The level measurementtakes place by evaluating the weight ofthe VG primary vessel. The water make-up, subject to the fill level in the VG pri-mary vessel, is monitored by a leakageamount monitor and is interrupted incase of malfunctions. The signals of acontact water meter can be evaluated(’fillset’ with contact water meter).
Example: ‘variomat’ single pump sys-tem in a heating system
Watermake-up
W O P
reflex ’fillset’(optional)
Control unit VG primary vesselwith VWthermal
insulation(optional)
VF secondary vessel(optional)Connection
set ‘MK 1’
O – Over-flow lineP – Pump lineW – Water make-up line
6
reflex ’variomat’Function details
Circ
uit
wat
erga
ssy
(ove
r-flo
w li
ne)
Wat
er m
ake-
up w
ater
gass
y(w
ater
mak
e-up
line
)
Circ
uit
wat
erga
s “f
ree”
(pum
p lin
es)
Water make-upwater
The expansion bendguarantees the pressurecompensation towardsthe atmosphere betweenthe vessel wall and thediaphragm.
The sounding pipedeaerationextracts the gasses fromthe tank and prevents are-aeration.
The diaphragmprotects the expansionwater from a direct airadmission.
The pressure expan-sion reliefat atmospheric pressureresults in the deaerationof the expansion water.
The pressure cell(level measurement)enables the determina-tion of the vessel filllevel.
Expansion linesDN → page 16
VG primary vessel
equipped with system separator andwater meter, it allows the direct con-nection of the water make-up deviceto the drinking water network
reflex ’fillset’ (optional)
The control unitguarantees maximum operating com-fort. All Reflex controls (’variomat’,’reflexomat’, ’gigamat’, ’servitec’)have been designed according to a uniform design guideline.
The hydraulic equipmentA tuned system with pressure-maintaining pump(s) and over-flowdevice(s) enables the hydraulicadjustment to differing installed systems and conditions.
The rotatable base plateenables the installation of the VG pri-mary vessel to the right, left or rearof the control unit for 1-pump sys-tems.
Control unit
The connection set con-nects the control unit withthe VG primary vessel.For 1-pump systems, theprotected shut-off is inte-grated in the connectionset. With respect to 2-pump systems, the pro-tected shut-off is locatedon the control unit.
Connection set
O PW
7
reflex ’variomat’
Pump line’variomat 1’with pumps starting normally’variomat 2’with pumps starting smoothly
Over-flow line O’variomat 1’fixed throttle for the hydraulic adjustment pump - over-flow-line
’variomat 2’TÜV-inspected over-flow valve for the hydraulic adjustment
Water make-up line WWhen the fill level in the VG primaryvessel is too low, the solenoid valveopens. For a connection to the drink-ing water network, ’fillset’ must beadded.
Connection VG primary vesselusing connection set
The hydraulics in detail
W O P
O
W
O
TÜV-certified over-flow valve
1. for the hydraulicadjustment
2. closes when minimumpressure not reached = functionally diverse
safety to the solenoidvalve
3. improved regulatingcharacteristics due toP behavior
Throttle for thehydraulic adjustment
reflex ’variomat 2’ reflex ’variomat 1’
protected shut-offs
Dirt pan
Solenoid valves for pressure regulation
or water make-up
Safety valvesfor the protection of theunpressurized vesselsfrom an inadmissible
excess pressure during theoperation
W
Permitted Permitted Permitted Permitted Noise Electrical Pump Protec- 230 Voper. pres- flow operating environm. level power soft tion 50 Hz,sure / bar temp. / °C temp. / °C temp. / °C appr. dB kW start- type connection
reflex ’variomat’ 1-pump system
variomat 1 10 100 > 0 - 70* > 0 - 45 55 0.75 no IP 54 three-pin plug,5 m cable
variomat 2-1/60 10 120 > 0 - 70* > 0 - 45 55 1.10 yes IP 542-1/75 10 120 > 0 - 70* > 0 - 45 55 1.10 yes IP 542-1/95 10 120 > 0 - 70* > 0 - 45 55 1.10 yes IP 54
reflex ’variomat’ 2-pump system
variomat 2-2/35 10 120 > 0 - 70* > 0 - 45 55 1.50 yes IP 542-2/60 10 120 > 0 - 70* > 0 - 45 55 2.20 yes IP 542-2/75 10 120 > 0 - 70* > 0 - 45 55 2.20 yes IP 542-2/95 10 120 > 0 - 70* > 0 - 45 55 2.20 yes IP 54
8
reflex ’variomat’Technical specifications
Microprocessor control
Control options
Expansion module isolating amplifier for pressure and levels as well as 6 digital inputs and 6 voltage-free outputsCommunication module for offline operatingusing a twin-core cable up to 1000 m distance
Inspection
’variomat’ with CE symbol, built and inspected as per DIN 4751 T 2 for hot water heating systems
VG- and VF vessels built and inspected as perEU pressure equipment directive 97/23/EU
Operation parameters Electro-technical data
* Mounted in system return line, diaphragm load of the expansion vessel max. 70°C;please contact us if there is an expected continuous temperature ≤ 0°C
Display with message lines usingclear text LCD, multilingual
Function diagram using LED
The control panel
Main switch,fixedconnectionto terminalstrip
Pump typePump amountTechnical design
Interval degas.
ControlPressure main- load-dependent switching at shortfalltaining pump(s) of pa and switching off at pa + 0,2 bar
variomat 2 with soft start-upOver-flow- load-dependent opening when pe ismagnet valve(s) exceeded and closing at pe - 0,2 bar;
automatic toggle switching and mal-function changeover switching for 2-pump systems; opens in deaerationmodes continuous, interval or follow-upvariomat 2 with additional TÜV-certifiedminimum pressure valve
1 water make-up Automatic water make-up whensolenoid valve solenoid valve minimum water level
of the VG vessel is not reachedToggle and malfunc- of the pumps and solenoid valves tion switching for pump systems
Operating display Clear text Pressure in bar, water level in %,
function messages in the message linesLED hand-stop-auto, operating pump,
over-flow, water make-upOperating display
Clear text e.g. pressure min/max, lack of waterfloating
LED additional optical display for lack ofwater and switching of the floatingcontact
Malfunction collec-tion point floating, programmableLack of water floating
Data output RS 485Parameter setting minimum operating pressure p0 in barin customer menu deaeration mode, deaeration duration
period, date, time, 8 languages, maintenance intervals
Queries in customer menuMalfunction memory Storage of the chronological order and
type of malfunction messageParameter memory Storage of the chronological order of
changes to the minimum oper. pressureWater make-up Evaluation if using a ’fillset’ with water
amount contact meter possible
Parameter settings
The following parameters are set object-based in the customer menu either by the reflex service or by thecustomer himself. Other settings are possible subject to password protection. Extensive instructions areprovided in the installation, operating and maintenance instructions.
Language: country-dependent
Date / Time: current time and date for malfunction memory and p0-memory as wellas timing window for the deaeration
Deaeration mode: Continuous - generally done during installation or after repair deaeration operations to the systemInterval deaeration - high deaeration power, setting on the control unit for
extreme network conditions,Follow-up - automatic activation after the continuous deaeration,deaeration this deaeration mode with its relatively low deaeration
power is generally sufficient for most systems
Continuous deaeration run: in dependence on the network volumerecommendation: 12 h for network contents ≤ 20 m³/h
24 h for network contents > 20 m³/h
Minimum operating Calculation according to the formula below. In the example p0 = 2.0 barpressure p0: If the system is to be run for longer than 1 hour in continuous deaeration
mode, then a minimum operating pressure p0 ≥ 1.3 bar is required.
Example: Calculation and setting of the minimum operating pressure
pSV [bar] = Safety valve actuation pressure on the heat generator
pmax [bar]
pe [bar] = final pressure = over-flow OPEN
pa [bar] = admission pressure = pump ON
p0 [bar] = pstatic + pvaporization + 0.2 bar (recommendation)
pst [bar] = static pressure (= static height [m] / 10)
9
reflex ’variomat’
p0 = Minimum operating pressure= Input value on control operating
panel
≥ 0.3 bar
0...0.2 bar *
*
*Error message if pressure is too high or too low;‘variomat 2’ also closes the mechanical over-flowvalve if the pressure is below p0
≥ 0.5 bar0.3 bar
pSV
p0
H, pst
Heating system, static height 18 m (pst = bar = 1.8 bar),Flow 70°C, (pvaporization = 0 bar)
p0 = 1.8 bar + 0 bar + 0.2 bar (recommendation)
p0 = 2.0 bar→ setting on-site
0.4 bar
1810
10
reflex ’variomat’Control units and accessories
’variomat 1’, ’variomat 2-1’ Control unit with 1 pump
’variomat 2-2’ Control unit with 2 pumps
Expansion module (optional)
Type Article No. p0 H W D Connection Weightbar mm mm mm P O W VG kg
variomat 1 6910100 ≤≤ 2.5 680 530 550 Rp 1 Rp 1 Rp ½ 2 x G 1 25variomat 2-1/60 6910200 ≤≤ 4.8 680 530 630 Rp 1 Rp 1 Rp ½ 2 x G 1 28variomat 2-1/75 6910300 ≤≤ 4.8 750 530 630 Rp 1 Rp 1 Rp ½ 2 x G 1 35variomat 2-1/75 6910500 > 4.8-6.5 750 530 630 Rp 1 Rp 1 Rp ½ 2 x G 1 35variomat 2-1/95 6910400 ≤≤ 4.8 800 530 630 Rp 1 Rp 1 Rp ½ 2 x G 1 37variomat 2-1/95 6910600 > 4.8-8.0 800 530 630 Rp 1 Rp 1 Rp ½ 2 x G 1 37
additional isolating amplifier in thecontrol unit for pressure and level aswell as 6 digital inputs and 6 voltage-free outputsArticle No.: 7997700
Communication module (optional)
for the external operation of the con-trol unit using a twin-core cable upto 1000 m
Article No.: 7997800
O - over-flow lineP - pump lineW - water make-up line
Type Article No. p0 H W D Connection Weightbar mm mm mm P O W VG kg
variomat 2-2/35 6911100 ≤≤ 2.5 680 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 54variomat 2-2/60 6911200 ≤≤ 4.8 680 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 58variomat 2-2/75 6911300 ≤≤ 4.8 750 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 72variomat 2-2/75 6911500 > 4.8-6.5 750 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 72variomat 2-2/95 6911400 ≤≤ 4.8 800 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 76variomat 2-2/95 6911600 > 4.8-8.0 800 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 76
O - over-flow lineP - pump lineW - water make-up line
****
****
* please note the different p0-values whenplacing an order → page 9
* please note the different p0-values whenplacing an order
H
O
P O
VG primary vessel
W
D
H
W
O
VG primary vessel
W
D
H
variomat 2-2/75variomat 2-2/95
variomat 2-2/35variomat 2-2/60
variomat 2-1/75variomat 2-1/95
variomat 1variomat 2-1/60
W
W
W
OP
VG primary vessel
W
D
H
O
PO
VG primary vessel
W
D
P
11
reflex ’variomat’Vessels and accessories
VG primary vessel
Connection set G 1
for the connection of ’variomat’ single pumpsystems to VG primary vessels with securedshut-offs and screw connections
VF secondaryvessel
VW thermal insulation
reflex ’fillset’ (optional)
Connection group with DVGW-tested sys-tem separator
Connection set G 1¼
reflex ’MK cap ball valve’ (optional)
secured shut-off of secondary vessels
Installation (optional)
by our service department
Article no.Single pump system 7945600Double pump system 7945630
Article no.MK 1 6830200
Type ∅ D H h A Weight Article no. Article no. Article no.mm mm mm kg
200 634 1060 146 G 1 37 6600000 6610000 7985700300 634 1360 146 G 1 54 6600100 6610100 7986000400 740 1350 133 G 1 65 6600200 6610200 7995600500 740 1570 133 G 1 78 6600300 6610300 7983900600 740 1790 133 G 1 94 6600400 6610400 7995700800 740 2240 133 G 1 149 6600500 6610500 7993800
1000 740 2690 133 G 1 156 6600600 6610600 7993900
1000 1000 2060 289 G 1 320 6600700 6610700 79868001200 1000 2240 289 G 1 330 6600800 6610800 79869001500 1200 2150 368 G 1 465 6600900 6610900 79870002000 1200 2610 368 G 1 565 6601000 6611000 79871002500 1200 3150 368 G 1 680 6601100 6611100 79899003000 1500 2610 393 G 1 795 6601200 6611200 79932004000 1500 3180 393 G 1 1080 6601300 6611300 79933005000 1500 3720 393 individual 1115 6601400 6611400 7993400
10000 1500 6730 393 individual 1950 6601500 6611500 —
Article no. Length Connec- Weightmm tion kg
with standard water meter6811100 405 G½, G¾ 2,8
with contact water meter6811200 405 G½, G¾ 2,8
VG vessel Article no. Weight∅ /mm kg480- 740 6940100 2
1000-1500 6940200 3
for the connection of ’variomat’ double pumpsystems to VG primary vessels
VG vessel Article no. Weight∅ /mm kg480- 740 6940300 2
1000-1500 6940400 3
Control unit Connectionset
VG primary vesselwith flexible hose
connectionswith VW thermal
insulation
‘MK 1’ VF secondary vessel(no VW thermal insula-
tion required)
H
h
∅ D
’fillset’
Expansion lineDN → page 18
(optional)for heating systems
(optional)
WO P
Vn Nominal volumes / liter
Nominal volumes Vn
approximate value from the diagramorcalculation according tothe formula
0.031 [ 70°C]0.045 [ 90°C]0.054 [100°C]0.063 [110°C]
12
reflex ’variomat’Selection Heating systems up to 120°C
p0
bar
p0
bar
p0 = 1.3 barmin. setting value in con-tinuous deaeration mode
p0 = 1.3 barmin setting value in con-tinuous deaeration mode
In performance ranges > 2 MWwe recommend using
double pump systems.
per pump andover-flow valve 50%
of the total power
Standard values for 90/70°Cheating systems
Vn
Liter
*
*
*
*
’variomat 1’, ’variomat 2-1’Control unit with 1 pump
’variomat 2-2’Control unit with 2 pumps
VG, VF vessels
for cooling water systems up to30°C only 50% of the nominal hea-ting power should be consideredwhen selecting the control unit
’variomat’ control units
Minimum operating pressure p0/barFor the calculation see also page 7
0.2 bar [≤ 100°C]0.5 bar [ 105°C]0.7 bar [ 110°C]1.2 bar [ 120°C]
p0 ≥ +H [m]
10
Safeguarding temperatureH = static height
Setting-temperatureVn = Nominal volumesVA = System water contents
The nominal volumes can bedistributed to several vessels(VG primary vessel and VFsecondary vessel).
’variomat’ VG, VF vessels
Vn ≥ VA x
We recommend in the greenperformance zone ≤ 500 kWand Vn < 200 liters to alternatively use’servitec magcontrol’ + ’reflex’.→ Brochure ’servitec’
please note the different p0-values when placing an order→ page 10
*
Total thermal output of the heat generation system Q / MW
Q / MW
Installed thermal output of the heating surfaces Q / MW
20 l/kW
13.5 l/kW radiators
8.5 l/kW flat/ventilation
6 l/kW convectors
complete ordering information→ page 19
Installationdetails
13
reflex ’variomat’Installation
reflex ’variomat 1’, ’variomat 2-1’ 1-pump system
reflex ’variomat 2-2’ 2-pump system
Water make-up
reflex ’fillset’
max. 70°C
Control unit VG primary vessel VF secondary vessel **
Connection set G 1
530 500 *900
reflex ’MK cap ballvalve line’
DN 25 on-site
Water make-up
reflex ’fillset’
Control unit VG primary vessel VF secondary vessel **
Connection set G 1¼ reflex ’MK 1 cap ball’valve line DN 25 on-site
* 500 mm for vessels up to ∅ 740 mm900 mm for vessels up to ∅ 1000 mm
** with flexible hose connections
Expansion linesdimensioning→ page 18
W O P
max. 70°C
Expansion linesdimensioning→ page 18
700 500 *900
Selection example
- Heat generator power Q = 3000 kW- water content VA= unknown
→ approximated from the installed heating powerQ = 3000 kW, radiators, 90/70°C, additional remote lines
- Set-up temperature = 90°C- Safeguarding temperature = 110°C- Static height = 25 m
→ p0 ≥ bar + 0.7 bar [110°C]
p0 ≥ bar + 0.7 bar = 3,2 bar
→ Vn from diagram = 1800 liters
selected:Control unit ’variomat 2-2/60’+ VG primary vessel (e. g. ∅ 1000) 1000 liters+ VF secondary vessel (e.g. ∅ 1000) 1000 liters
= 2000 liters+ VW thermal insulation 1000 liters+ Connection set G 1¼, ∅ 1000+ ’MK 1 cap ball valve’
- we recommend double pump systems if 2 MW is exceeded- the VF secondary vessel requires no thermal insulation
H [m]102510
Set-up variation
Set-up variation→ page 14
W
P O
→ page 14
By turning the base plate it ispossible to mount the controlunit to the left, right or in frontof the VG primary vessel.
By exchanging the end caps of the manifoldpipes it is possible to mount the control unit tothe left or right of the VG primary vessel(Standard → left).
Installationdetails
14
reflex ’variomat’Installation
Install the system vertically in a frost-free, ventilated room withwater drainage facilities.
Install the control unit and the vessels, preferably at the samelevel, the control unit must in no case be mounted higher than the vessels! Install the vessels vertically.
Connect the pumps and the over-flow lines in the system so nocoarse dirt can ingress (see detail). For the dimensioning of theexpansion lines see → page 18.
The pressure cell for the level measurement must be mounted on the appropriate foot of the VG primary vessel. TheVG primary vessel and the first secondary vessel must alwaysbe flexibly connected with the supplied connection set toensure that the level measuring is not impaired.
No fixed fastening of the VG primary vessel to the floor.
The VW thermal insulation for the VG primary vessel is recommended for heating systems.
Rinse the connection lines prior to installation!
Detail:Connecting of ’variomat’
The function of the ’variomat’ deaeration is only ensured whenthe connection of the ’variomat’ has been performed in a repre-sentative main flow of the installed system. The following mini-mum volume flows V must be maintained during the operation.With an inclination of ∆t = 20 K this reflects a minimum perfor-mance setting of the accepting system of Q.
The connection linesshould be connected fromthe top or, as shown, asimmersion lines in themain line in order to avoiddirect ingress of coarse dirtin the ’variomat’
The dimension of the expansion lines should beselected according to thedetails given on page 18.
Extracts from the installation, operating, and maintenance instructions
variomat 1 variomat 2-1 variomat 2-2/35 variomat 2-2/60 - 95V 2 m³/h 4 m³/h 2 m³/h 4 m³/hQ 47 kW 94 kW 47 kW 94 kW
Pump line P partial flow from
’variomat’“gas-free”
The longer thedistance betweenthe connections,the better.
Over-flow line Opartial flow to ’variomat’ gas rich
≥ 500
Main volume flow V
15
reflex ’variomat’Installation examples
General information
Individual protection: due to the high deaeration perfor-mance of the ’variomat’, it is recommended to install a di-aphragm pressure expansion vessel (e.g. ’reflex N’) on theheat generator also for single boiler systems in order tominimize the number of cycles.
Integration into the system: the integration into the system is to be performed as described on page 14 in or-der to prevent the ingress of rough particles of dirt and theoverload of the ’variomat’ dirt pan. The piping for the heat-ing system and the drinking water make-up must be rinsedprior to the installation.
Connection line for water make-up: if the water make-up line is directly connected to the drinking water network,then reflex ’fillset’ (shut-off, system separators, water me-ter, dirt pans) must be added. If reflex ’fillset’ is not in-stalled a dirt pan with a minimum mesh width ≤ 0.25 mmmust be installed in order to at least protect the solenoidvalve of the water make-up device. The line between thedirt pan and the solenoid valve must be kept as short aspossible and must be rinsed.
reflex ’variomat 1’ in a single boiler system ≤≤ 350 kW, < 100°C, water make-up with drinking water Notes to the installer
You do not need to install any extra cap valves in the expansion line.
reflex ’fillset’ with integratedsystem separator must beadded when connected to adrinking water network.
Expansion lines with a length ofmore than 10 m must be in-stalled in DN 32. → page 18
Throttle valve for the hydraulicadjustment of the pump andover-flow performance
1)
2)
Electrical connections must be in accordance with local electricity company codes & regulations.
reflex ’fillset’
’reflex’
’variomat 1’
VG primaryvessel
1)25
2)
P O WDrinkingwater
tR ≤ 70°C
Dirt-freeconnection → p. 14
≥ 500
Boiler and system protectionPressure maintenance, deaeration, and water make-up
Direct connection of the water make-updevice to the drinking water network
15
16
reflex ’variomat’Installation examples
Notes to the installer
District heating water is gen-erally best suited as watermake-up water. A watertreatment is not necessary.
Please coordinate with theheating supplier! Pay atten-tion to the terms of connec-tion!
Expansion lines with a lengthof more than 10 m must beinstalled in DN 32.→ page 18
Throttle valve for the hydrau-lic adjustment of the pumpand over-flow performance
For special requirements, e.g. in the district heating,there is an option card avail-able with 6 digital inputs and6 voltage-free output con-tacts as well as pressure andlevel outputs using an isolat-ing amplifier.Please contact us.
Notes to the installer
’variomat’ must always beconnected within the mainvolume flow in order to en-sure that a representativepart of the flow can be de-gassed. In case of central re-turn admixture this is the sys-tem side. Then the boiler isequipped with an individualprotection.
If the reflex ’fillset’ capacity is exceeded (kVS = 1 m³/h), thenalternatively a suitable con-nection group must be in-stalled on-site in the watermake-up line. The meshwidth of the filter must not ex-ceed 0.25 mm.
Dimensioning of the expansion line→ Reflex checklist for
pressure-maintainingsystems see page 18
Mechanical over-flow valvefor the limitation of the mini-mum pressure and the hy-draulic adjustment
reflex ’variomat 1’ in a district heating domestic station,water make-up via district heating return
reflex ’variomat 2-1’ in a system with central return admixture, water make-up through softening device
Smooth pump startaddition, TÜV-certifiedminimum pressure valveElectrical main switchElectrical connections must be in accordance with local electricity company codes & regulations.
tR≤
70°C
, di
stric
t he
atin
g re
turn
tR ≤ 70°C
Dirt-freeconnection → p. 14
’variomat 1’
tR ≤ 70°C
Dirt-freeconnection → p. 14
’variomat 2-1’
reflex ’fillset’VG primaryvessel
VG primaryvessel
1)
2)
1)
2)
1)
2)
2)
P O W
P O WDrinkingwater
Connection of the water make-up device at the dis-trict heating return, coordinate with heating supplier
Generator and system protectionPressure maintenance, deaeration, and water make-up
Boiler indivi-dual protection
System protectionPressure maintenance, deaeration, and water make-up
Connection of the water make-upthrough chemical water treatment
On-site
Filter Drumi SV
≥ 500
≥ 500
25 15
1)25 15
’reflex’
’reflex’
reflex ’ET blowtank’
pressure reducer
filtersafety valve
17
reflex ‘variomat’
Notes to the installer
For water treatment sys-tems, ’fillset’ with systemseparator and water meter isinstalled in front of the soft-ening equipment.
Provide individual protectionwith ’reflex’ for multi-boilersystems.
Multiple VF secondary ves-sels can be connected.
Dimensioning of the expansion lines→ Reflex checklist for
pressure-maintainingsystems see page 18
Mechanical over-flow valvesfor the limitation of the mini-mum pressure and the hy-draulic adjustment
reflex ‘variomat 2-2’ in a multi-boiler system,flow > 100°C, water make-up via softening equipment
2 pumps with smooth start2 additional, TÜV-certifiedminimum pressure valvesElectrical main switchload-dependent connection and malfunction change-over
tR ≤ 70°C
Dirt-freeconnection → p. 14
’variomat 2-2’
reflex ’fillset’VG secon-dary vessel
VF primaryvessel
1)
2) 2)
1)
2)
P O
W
Electrical connections must be in accordance with local electricity company codes & regulations.
≥ 500
System protectionPressure maintenance, deaeration, and water make-up
Connection of the water make-up devicethrough chemical water treatment
Drinkingwater
’reflex’
reflex ’ET blowtank’
On-sitepipework
18
Checklist for ’variomat’expansion lines
reflex ’T blow tank’
Selection according to DIN 4751 T2→ Brochure Accessories
reflex ’EB De-sludging tank’
particularly suited for older systems→ Brochure Accessories
reflex ’fillset’
‘fillset’ Connection group to drinkingwater network with water meterand system separator
VF secondary vessel
Multiple VF secondary ves-sels can be connected.
reflex ’MKCap ball valves’
’MK 1’for VF secondary vessels
→ Brochure Accessories
Expansion lines
reflex ’variomat’ already contains cap ball valves. Therefore,no other are required. The dimension of the expansion linemust be selected according to the following table.
We recommend to select the nominal width in the next high-er dimension for expansion lines > 10 m.
variomat 1variomat 2-1/60variomat 2-1/75variomat 2-1/95variomat 2-2/35variomat 2-2/60
p0 > 3.5 barp0 ≤≤ 3.5 bar
variomat 2-2/75p0 > 4.5 barp0 ≤≤ 4.5 bar
variomat 2-2/95p0 > 6.0 barp0 ≤≤ 6.0 bar
DN 25X
DN 32
XXXX
DN 40
X
X
X
DN 50
X
X
X
reflex ’variomat’control unit with VG primary ves-sel and connec-tion set
QkW
Drinking water
You will find these articles in this brochure.You will find these articles in the specified brochures.
19
reflex ’variomat’Order information
’variomat’ control unitvariomat 1 p0 ≤≤ 2.5 barvariomat 2-1/60 p0 ≤≤ 4.8 barvariomat 2-1/75 p0 ≤≤ 4.8 barvariomat 2-1/75 p0 > 4.8-6.5 barvariomat 2-1/95 p0 ≤≤ 4.8 barvariomat 2-1/95 p0 > 4.8-8.0 bar
variomat 2-2/35 p0 ≤≤ 2.5 barvariomat 2-2/60 p0 ≤≤ 4.8 barvariomat 2-2/75 p0 ≤≤ 4.8 barvariomat 2-2/75 p0 > 4.8-6.5 barvariomat 2-2/95 p0 ≤≤ 4.8 barvariomat 2-2/95 p0 > 4.8-8.0 bar’variomat’ connection setG 1 ∅ VG 480 - 740 mm
∅ VG 1000 - 1500 mm
G 1¼ ∅ VG 480 - 740 mm∅ VG 1000 - 1500 mm
’variomat’ VG primary vessel
....... liters
’variomat’ options
VW thermal- ....... litersinsulation
reflex ‘fillset’with standard water meterwith contact water meter
VF secondary vessel ....... liters
reflex ‘MK1 cap ball valve’
Expansion module
Communication module
Installation 1 pump system2 pump system
Article no.
691010069102006910300691050069104006910600
691110069112006911300691150069114006911600
69401006940200
69403006940400
.....
.....
68111006811200
.....
6830200
7997700
7997800
79456007945630
Quantity Ordering information
installedNominal heating power ....... kWHeat generator SV ....... barHeat generator STB ....... °CStatic height ....... m
for ‘variomat’ single pump systems
for ‘variomat’ double pump systems
for VG primary vessel 200 - 5000liters heating systems
for connection to VG primary vessels
as shut-off for VF secondary vessels
for controls with isolating amplifierpressure + level
for remote control operation
Commissioning and maintenance are explained in the supplied installation, operating, and mainte-nance instructions. We recommend you to enlist the reflex service. Expansion vessels and pressure-maintaining stations must be maintained annually according to DIN 4807 T2.
“Deaeration of heatingand cooling systems”from the cooperativeresearch work with theTechnical University ofDresden
When and why is the useof deaeration systemsrequired also and especial-ly in closed systems?
“Pressure-maintenance,deaeration and watermake-up sys-tems – planning,
calculating,equipment”
“Pressure-maintainingsystems – collectedessays”
Here you find informa-tion on the equipmentof pressure-maintainingstations in heat generating systemsover 100°C.
For additional technical information and extensive tendering textsplease visit us on the Internet at www.reflex.de
e. g.
PI0
105A
eS
ubje
ct to
tech
nica
l mod
ifica
tions
- P
rinte
d in
Ger
man
y
Reflex Winkelmann GmbH + Co. KG
Gersteinstraße 19D - 59227 AhlenGermany
Phone: ++49 2382/70 69-0Fax: ++49 2382/70 69-558www.reflex.de
New Reflex technologies are to pro-vide advantages not only to human be-ings, but also to the environment. Thisis the principle on which we base allour development, planning, and manu-facturing. We comply with our respon-sibility as manufacturer by the pur-poseful selection of materials and pro-duction technologies - the environmen-tal - impacts are as low as possible.
Reflex – responsibility in the interests of the environment
