Reflex Servitec Instructions de montage
reflex ’servitec’
Vacuum spray-tube deaerator
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
Table of contents
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
3
reflex ’servitec’
General
1 Ball valve
2 Pressure measuring transducer
(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
CD
B
AE
’servitec’ spray-tube
4
reflex ’servitec’
General
Function LED's
LC Display
Operating mode
buttons
Control buttons
Note:
means „press button“
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.
’servitec’ is a deaeration and make-up station mainly consisting of a control unit and a vacuum spray-tube.
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
6
reflex ’servitec’
Installation
Note:
Please check the delivery for completeness and damage immediately after goods receiving! Transport damage must be
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
≥ 500
Main flow V
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:
RO P
reflex ’fillset’
with potable water
make-up
reflex ’servitec’ Expansion vessel/
pressure maintenance
Detail
connection
20 2520
VpSV
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
8
reflex ’servitec’
Installation
Preferably install ’servitec’ on the
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
MM
TIC
TIC
TIC
TIC
TIC
M M
Hydraulic points
202025
≥ 500*
≥ 500*
reflex ’fillset’
reflex ’servitec levelcontrol’’reflexomat’
Potable
water
202025
230 V
Signal
Cable by
customer
Main volumetric flow
Required flow pressure ≥ 1.3 bar
Required flow pressure ≥ 1.3 bar
LS
Installation diagrams
9
reflex ’servitec’
Installation
Electrical connection
Electrical cabling and connection must be performed by a qualified electrician according to the applicable local
(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
10
reflex ’servitec’
Installation, initial start-up
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)
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2
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