reflex `variomat` Pressurization station with automatic water make

reflex ’variomat’
Pressurization station with
automatic water make-up and deaeration
The reflex ’variomat’
can do much more than just maintaining the pressure
The pump-controlled ’variomat’ opens
up a completely new dimension of
pressurization stations for heating
and cooling circuits.
reflex ’variomat’:
it keeps the system pressure within
very restricted liwiths
it deaerates the content water
it makes up water automatically
Thus, the reflex ’variomat’ is the best
solution for increasing air problems, in
particular within closed heating installations, which, according to a study of the
Technical University of Dresden, arise
in more than 50 % of the installations.
The reflex ’variomat’ ensures air-free
installations up to the top floor and into
the last corner. Expensive decentralized air separators as well as the timeconsuming deaeration are things of the
past. An additional advantage: A special data interface (’variomat 2’) allows
the integration into the modern facility
management.
2
The high efficiency of the ’variomat’
principle has been proven at the Technical University of Dresden and has been
tried and tested in numerous application
examples. The combination of pressurization, deaeration, and water make-up
complies with all requirements for air-free
systems and requires only little maintenance.
reflex ’variomat’:
extensive program, great variety
of applications
’variomat 1’ and ’2-1’ single pump
systems for systems of up to 4 MW
’variomat 2-2’ double pump systems
for systems of up to 8 MW
also suited for systems with a glycol
content of up to 50%
fully automatic operation with data
interface for interconnection
(’variomat 2’) with state-of-the-art
facility management systems
silent method of operation for use
in noise-sensitive areas
proven in centrally heated
appartments and industrial
buildings, in district heating systems
and in closed-loop cooling circuits
Internationality: the control system
offers as much as 8 languages for
you to select
patented over flow function
over flow less prone to dirt
leasy start-up without mechanical
settings
optional Master-Slave control
for model ’variomat 2’
OLD
NEW
without ’variomat’
with ’variomat’
reflex ’variomat’
The high effectiveness of the multi-functional unit
The unpressurized VG primary vessel of the ’variomat’, which is closed towards the atmosphere, is not
only used for the deaeration of the heating water,
but also for the discharge and partial deaeration of
the make-up water. Thus, a partial flow of the heating
water is, dependent on the time, led through the
Conventional installation:
Water supersaturated with gas
results in system breakdowns
VG primary vessel and automatically bled and/or
deaerated because the gas solubility at this point is
lower than in the system. Using different deaeration
programs, the start-up and operating conditions
of the process can be optimally adjusted to the individual requirements and are electronically monitored.
The ’variomat’ installation:
Water which is effectively gasfree, thus no more air problems
g
Convincing:
the reflex ’variomat’ advantages in
the example of a heating system
Content
luck ... g
luck ... gluck
- no time-consuming decentralized subsequent bleeding
- no gargling sounds
- full thermal output at any time
Overview
2
3
Program
4
5
Function details 6
7
Elimination of mechanical
air separators
’variomat’
*
Protection of pumps against
air and cavitation
no under pressure, no
pressure drops in MAG
Entire circuit water:
less erosion and wear,
less formation of mud,
improved circulation
gas-free
sampling
- ’variomat’ maintains the correct pressure and displays it
- ’variomat’ deaerates
- ’variomat’ makes up water
automatically
8
The control
9
Control units
10
and accessories
No formation of bubbles on
the hot boiler heating surfaces,
consequently better heat
transfer
gassy
sampling
Technical
specifications
* To comply with VDI 203 regarding the necessary water
hardness for heating systems, we recommend the
compact, economical softening fitting reflex ’fillsoft’.
”Three functions in one device and a satisfied building
owner for whom air problems are finally things of the
past – the ’variomat’ is simply great!”
Vessels and
accessories
11
Selection
12
Expansion
lines
12
Assembly
13
14
Installation
examples
15
16
17
Check list
18
Order info
19
Texts for
tenders
19
reflex ’variomat’
The program for pressurization, deaeration, and make-up
reflex ’variomat 1’
up to 2 MW with 1 pump
towards the system
from the system
2 separate
expansion lines
 p. 12
P
O
Installation
details
 p. 14
reflex ’fillset’
(optional)
Water
make-up
water
NS
B
A
230 V
Programmable floating
group fault signal
VG Basic vessel
Control unit
Connection set
smooth pump start
electrical main switch
4
from the system
up to 4 MW with 1 pump
towards the system
reflex ’variomat 2-1’
P
O
reflex ’fillset’
(optional)
Water
make-up
water
NS
B
A
230 V, fixed connection
programmable floating
group fault signal
+ RS 485 interface
VF Secondary
vessel
(optional)
VG Basic vessel
Control unit
Connection set
reflex ’variomat 2-2’
up to 8 MW with 2 pumps
2 pumps with smooth start
electrical main switch
load-dependent connection
and malfunction change-over
reflex ’fillset’
(optional)
Water makeup water
NS
P towards the system
O from the system
B
A
A
B
230 V, fixed connection
programmable floating
group fault signal
+ RS 485 interface
VF Secondary
vessel
(optional)
VG Basic vessel
Connection set
Control unit
Control unit
PIS
Pressurization, compensate
the expansion volume
Pump (A) and over-flow valve (B) are
triggered in such a way that the pressure
remains constant within the limits ± 0.2
bar. The expansion water is fed (O) or
carried away (P) to/from the unpressurized VG basic vessel using 2 separate
expansion lines.
Example: ’variomat’ single pump
system in a heating system
TIME Deaeration
A partial flow of the heating water is
relieved in the VG basic vessel and,
thus, degassed. You can select one of the
following deaeration modes:
Continuous deaeration: constant
deaeration after the commissioning and
after repairs in the supply system in
order to quickly remove all the residual
air from the system
Follow-up deaeration: is automatically
enabled after the continuous deaeration
and then runs after every pump cycle
Interval deaeration: runs at a according
to a pre-dertermined time schedule
LIS
reflex ’fillset’
(optional)
Water
make-up
O - Over-flow line
P - Pump line
NS - Water make-up line
NS
O
P
Control unit
VF Secondary
vessel
Connection
’SU R 1x1’
set
(optional) with flexible tube
connections
VG Basic vessel
(optional)
with
VW Thermal
insulation (optional)
5
Water make-up
The volume of ejected free gasses as
well as water losses are automatically
supplemented. The level measurement
takes place by evaluating the weight of
the VG basic vessel. The water make-up,
subject to the fill level in the VG basic
vessel, is monitored by a leakage amount
monitor and is interrupted in case of
malfunctions. The signals of a contact
water meter can be evaluated (’fillset’ with
contact water meter).
VG Basic vessel, VF Secondary vessel
Connection set
The unpressurized closed VG basic vessel
has two functions:
1. Expansion water is reliably protected
from the admission of air in a bubble
diaphragm.
2. The purposeful expansion-relief of the
network content water separates and
discharges gasses.
The VG basic vessel capacity can be
expanded by connecting multiple
VF secondary vessels in series.
Connectors are available for the quick
connection of the ’variomat’ to VG basic
vessels. These are equipped with a protected
shut-off for 1-pump systems. With
respect to 2-pump systems, the protected
shut-off is located on the control unit.
VW Thermal insulation
The VG basic vessel warms up in heating
systems. Therefore, the installation of a ’VW
Thermal insulation’ consisting of 50 mm CFC
free soft foam with zipper and floor insulation
is recommended.
reflex ’fillset’ (optional)
The ’fillset’ with DVGW tested system
separator, water meter, dirt pan, shut-off,
and wall bracket is offered as an accessory
for the direct connection of the water
make-up device to a drinking water network.
Can also be supplied with an optionalal
contact water meter.
reflex ’variomat’
Function details
VG Basic vessel
The expansion bend
guarantees the pressure
compensation towards
the atmosphere between
the vessel wall and the
diaphragm.
Expansion lines
DN  p. 12
equipped with system separator and
water meter, it allows the direct
connection of the water make-up device.
to the drinking water network.
P
The sounding pipe
deaeration extracts
the gasses from the
tank and prevents a reaeration.
gas-free
gassy
O
Circuit water
(Over-flow line)
Circuit water
(Pump line)
reflex ’fillset’ (optional)
NS
Water make-up water gassy
(Water make-up line)
Water make-up
water
The bladder
protects the expansion
water from a direct air
admission.
Control unit
The pressure expansion relief
at atmospheric pressure
results in the deaeration
of the expansion water.
The control
guarantees maximum operating
comfort. All Reflex controls
(’variomat’, ’reflexomat’, ’gigamat’, ’servitec’) have been designed according to a uniform
design guideline.
The pressure cell
(level measurement)
enables the determination of
the vessel fill level.
6
The hydraulic equipment
A tuned system with pressurization pump(s) and over-flow
device(s) enables the hydraulic
adjustment to differing installed
systems and conditions.
Connection set
The rotatable base plate
enables the installation of the
VG basic vessel to the right,
left or rear of the control unit for
1-pump systems.
The connection set
connects the control
unit with the VG basic
vessel. For 1-pump
systems, the protected
shut-off is integrated
in the connection set.
With respect to 2-pump
systems, the protected
shut-off is located on the
control unit.
The hydraulics in detail
P NS Ü
Pump line
’variomat 1’
with pumps starting normally
’variomat 2’
with pumps starting smoothly
Over-flow line O
’variomat’
with motor ball-valve
- Auto-function: patented
Water make-up line NS
When the fill level in the VG
basic vessel is too low, the
solenoid valve opens. For a
connection to the drinking water
network, ’fillset’ must be added.
Connection VG Basic vessel
using connection set
reflex ’variomat 1’ - hydraulic module
7
reflex ’variomat 2’ - hydraulic module
reflex ’variomat’
Technical specifications
Operation parameters
Electro-technical data
max.
perm.
max.
max. perm. Sound
level
operating
flow
operating ambient
press./bar temp./° C temp./° C temp./° C ca. dB
electr.
Power
kW
Pump
smooth
start
Degree
of protection
230 V
50 Hz,
Connection
three-pin plug,
5 m cable
reflex ’variomat’ 1-pump system
variomat 1
10
120*
> 0 - 70**
> 0 - 45
55
0.75
no
IP 54
120*
2-1/60
10
2-1/75
10
120*
2-1/95
10
120*
reflex ’variomat’ 2-pump system
2-2/35
10
120*
2-2/60
10
120*
10
120*
2-2/75
2-2/95
10
120*
> 0 - 70**
> 0 - 70**
> 0 - 70**
> 0 - 45
> 0 - 45
> 0 - 45
55
55
55
1,10
1,10
1,10
yes
yes
yes
IP 54
IP 54
IP 54
> 0 - 70**
> 0 - 70**
> 0 - 70**
> 0 - 70**
>
>
>
>
55
55
55
55
1,50
2,20
2,20
2,20
yes
yes
yes
yes
IP 54
IP 54
IP 54
IP 54
Pump Typee
No. of pumps
Technical design
0
0
0
0
-
45
45
45
45
*
according to the highest possible setting - temperature regulator 105 °C,
in accordance with DIN EN 12828
** 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
Inspection
Microprocessor control
Control
Pressurization pump(s)
8
Over-flow
motor ball-valve
1 Water make-up
solenoid valve
Toggel and malfunction
switching
Operating display
Clear text
LED (’variomat 2’)
Fault indication
Clear text
LED
Collective alarm
Water deficiency
Data output
Parameter setting
in customer menu
Queries in customer menu
Malfunction memory
Parameter memory
Amount of water
make-up water
Main switch,
fixed
connection to
terminal strip
load-dependent switching at shortfall of
pa and a switching off at pa + 0,2 bar
’variomat 2’ with soft start-up
continuous opening when exceeding
from pe and closing at pe - 0,2 bar;
automatic toggle switching and
malfunction changeover switching for
2-pump systems; opens in deaeration
modes continuous, interval or follow-up
water make-up when min. water level
of the VG vessel is not reached
of the pumps and solenoid valves for
2-pump systems
pressure in bar, water level in %,
function messages in the message line
hand-stop-auto, operating pump,
over-flow, water make-up
e. g. pressure min/max, water
deficiency, floating in the messag line
additional optical display for water
deficiency (’variomat 2’) and switching of
the floating contact
floating, programmable
floating (’variomat 2’)
RS-485 (’variomat 2’)
min. operating pressure p0 in bar,
deaeration mode, deaeration duration
period, date, time, 8 languages,
maintenance intervals
storage of the chronological order and
type of malfunction message
storage of the chronological order of
changes to the minimum operating
pressure
evaluation if using a ’fillset’ with
contact water meter possible
(’variomat 2’)
’variomat’ with CE symbol
VG and VF vessels built and inspected
as per EU pressure equipment directive 97/23/EU
Control options (’variomat 2’)
extension module isolating amplifier for
pressure and levels as well as 6 digital inputs
and 6 voltage-free outputs
communication module for offline operating
using a twin-core cable up to 1.000 m distance
bus module for the transfer of data between
the control interface (RS-485) and the central
process device
The control panel
(’variomat 2’)
Intervallentg.
Display with message lines
using clear text LCD,
multilingual
Function diagram using LED
The control panel
(’variomat 1’)
45 %
2.2bar
Intervallentg.
Display with message lines
using clear text LCD,
multilingual
reflex ’variomat’
The control
Parameter setting
The following parameters are set object-based in the customer menu either by the reflex service or by the
customer himself. Other settings are possible subject to password protection. Extensive instructions are
provided in the installation, operating and maintenance instructions.
Language:
country-dependent
Date / Time:
current time and date for malfunction memory and p0-memory as well
as timing window for the deaeration
Deaeration mode:
Continuous deaeration - generally done during installation or after repair
operations to the system,
Interval deaeration
- high deaeration power, setting on the control unit
for extreme network conditions,
Follow-up deaeration - automatic activation after the continuous
deaeration, this deaeration mode with its relatively
low deaeration power is generally sufficient for
most systems.
Continuous deaeration run-time:
in dependence on the network volume
Recommendation: 12 h for network contents  20 m³/h
24 h bei network contents > 20 m³/h
Min. operating pressure p0: Calculation according to the formula below. For the example p0 = 2,0 bar
Example:
Calculation and setting of the minimum operating pressure
18 bar = 1,8 bar),
10
Heating system, static height 18 m (pst =
Flow 70°C, (pVerdampfung = 0 bar)
9
p0 = 1,8 bar + 0 bar + 0,2 bar (recommendation)
p0 = 2,0 bar  on-site setting
psv [bar] = safety valve actuation pressure on the heat generator
pmax [bar]
≥ 0.5 bar
p0 = min. operating pressure
= input value on the control
operating panel
pe
[bar] = final pressure = over-flow OPEN
0.3 bar
pa
[bar] = starting pressure = pump ON
0.4 bar
p0
[bar] = pstatic + pevaporation + 0.2 bar (recommandation)
pst [bar] = static pressure (= static height [m] / 10)
*
0...0,2 bar
error message if pressure is
too high or too low
pSV
H, pst
p0
≥ 0.3 bar
*
*
reflex ’variomat’
Control units and accessories
’variomat 1’, ’variomat 2-1’
Type
variomat
variomat
variomat
variomat
1
2-1/60
2-1/75
2-1/95
Control unit with 1 pump
Article-No.
p0
H
B
T
6910100
6910200
6910500
6910600
bar
≤ 2,5
≤ 4,8
≤ 6,5
≤ 8,0
mm
680
680
770
770
mm
530
530
530
530
mm
580
670
630
540
Connection
p
Rp 1
Rp 1
Rp 1
Rp 1
O
Rp 1
Rp 1
Rp 1
Rp 1
Weight
NS
Rp ½
Rp ½
Rp ½
Rp ½
VG
2xG1
2xG1
2xG1
2xG1
kg
25
28
35
37
NS
Ü
H
B
B
variomat 1
B
variomat 2-1/60
T
’variomat 2-2’
Type
10
variomat
variomat
variomat
variomat
H
H
2-2/35
2-2/60
2-2/75
2-2/95
variomat 2-1/75
variomat 2-1/95
T
T
Control unit with 2 pumps
Article-No.
p0
H
B
T
6911100
6911200
6911500
6911600
bar
≤ 2,5
≤ 4,8
≤ 6,5
≤ 8,0
mm
680
680
760
760
mm
700
700
700
700
mm
780
780
730
730
Connection
p
G 1¼
G 1¼
G 1¼
G 1¼
O
G 1¼
G 1¼
G 1¼
G 1¼
Weight
NS
Rp ½
Rp ½
Rp ½
Rp ½
VG
2 x G 1¼
2 x G 1¼
2 x G 1¼
2 x G 1¼
kg
54
58
72
76
Ü
H
H
B
variomat 2-2/35
variomat 2-2/60
B
T
reflex ’VE Extension module’ for ’variomat 2’
with additional isolating amplifier 0-10 V in the
control unit for pressure and level as well as 6
digital inputs and 6 voltagefree outputs
variomat 2-2/75
variomat 2-2/95
T
Master-Slave control’ for variomat 2’
for the operation of up to 10 ’variomat’ in
an hydraulic network at a distance of
1.000 m and more
upon request
Article-No.: 7997705
reflex ’Bus module’ for ’variomat 2’
reflex ’VK Communication module’ for ’variomat 2’
for the external operation of the control
unit using a triple-core cable up to 1.000 m
Article-No.: 7997800
for the transfer of data between the control interface (RS-485) and the central process device
upon request
’Lonworks’ Digital
’Lonworks’
’Profibus-DP’
’Ethernet’
Article-No.
7860000
7860100
7860200
7860300
reflex ’variomat’
Gefäße und Zubehör
200
300
400
500
600
800
1000
D
mm
634
634
740
740
740
740
740
H
mm
1060
1360
1345
1560
1810
2275
2685
h
mm
146
146
133
133
133
133
133
G
G
G
G
G
G
G
1
1
1
1
1
1
1
Weight
kg
37
54
65
78
94
149
156
1000
1500
2000
3000
4000
5000
1000
1200
1200
1500
1500
1500
2130
2130
2590
2590
3160
3695
350
350
350
380
380
380
G
G
G
G
G
G
1
1
1
1
1
1
320
465
565
795
1080
1115
Type
C
VG
Basic vessel
VF Secondary
vessel
(optional)
VW Thermal
insulation
for heating systems
(optional)
Article-No.
Article-No.
Article-No.
6600000
6600100
6600200
6600300
6600400
6600500
6600600
6610000
6610100
6610200
6610300
6610400
6610500
6610600
7985700
7986000
7995600
7983900
7995700
7993800
7993900
6600705
6600905
6601005
6601205
6601305
6601405
6610705
6610905
6611005
6611205
6611305
6611405
7986800
7987000
7987100
7993200
7993300
7993400
Vn Nominal volume [Litres]
D
Expansion lines
DN  p. 18
O P
NS
’fillset’
11
H
reflex ’fillset’ (optional)
connection group with DVGW-tested
system separator
Article-No.
Length Connection
mm
with standard water meter
6811105
293
R ½, R ½
with contact water meter
6811205
293
R ½, R ½
1.7
1.7
Connection set G 1
Article-No.
6940100
6940200
Weight
kg
2
3
Connection set G 1¼
Connection set
VG Basic vessel
with ’VW Thermal
insulation’ (optional)
VF Secondary vessel
with flexible tube
’SU R 1x1’ connections (optional)
(optional)
secured shut-off of secondary vessels,
PN 10 / 120 °C
Article-No.
SU R 1 x 1
7613100
Installation (optional)
for the connection of ’variomat’ double
pump systems to VG basic vessels
VG vessel
/ mm
480 - 740
1000 -1500
Control unit
reflex ’SU Lockshield valve’ (optional)
for the connection of ’variomat’ single ump
systems to VG primary vessels with secured
shut-offs and screw connections
VG Gefäß
/ mm
480 - 740
1000 -1500
h
Weight
kg
Article-No.
6940300
6940400
by our service department
Article-No.
Weight
kg
2
3
1-pump system
2-pump system
7945600
7945630
reflex ’variomat’
Selection Heating systems up to 120 °C
p0
bar
’variomat’ Control unit
for cooling water systems up to
30 °C only 50% of the nominal
heating power should be considered
when selecting the control unit
’variomat 1’, ’variomat 2-1’
*
EL DN 32
We recommend in the green
performance zone ≤ 500 kW
and Vn < 200 liters to
alternatively use
reflex ’servitec magcontrol’ + ’reflex’
 brochure reflex ’servitec’
Control unit with 1 pump
In performance ranges > 2 MW
we recommend using double
pump systems.
*
EL DN 32
variomat 2-1/60
EL DN 32
Min. operating pressure p0/bar
for the calculation → p. 9
H[m]
p0 ≥
+
10
0,2 bar [≤ 100 °C]
0,5 bar [ 105 °C]
0,7 bar [ 110 °C]
1,2 bar [ 120 °C]
Safety temperature
EL DN 25
variomat 1
Q / MW
p0
bar
H = static height
’variomat 2-2’
*
Control unit with 2 pumps
* please note the different p 0
per pump and
over-flow 50%
of the total power
values when placing an order
 p. 10
*
EL DN 40
12
EL
DN 50
Expansion lines (EL)
EL DN 40
EL
DN 50
 the entries in the accompanying
characteristic lines
variomat 2-2-35
Please observe,t he pressuredependent sizing of the 2-pump
systems.
EL DN 40
EL DN 50
EL DN 32
When the expansion lines are
> 10 m, we recommend increasing
the nominal width by one size.
Total thermal output of the heat generation system Q / MW
’variomat’ VG, VF vessels
Nominal volume Vn
approximate value from the
diagram or calculation
acc. to formula
Vn  VA x
W
The nominal volumes can be
distributed to several vessels
(VG basic vessel and VF
secondary vessel).
Standard values for 90/70 °C
heating systems
6 l/k
Wc
onve
8.5
ctor
s
l/kW
flat
/ve
ntil
13
atio
.5
n
l/k
W
ra
dia
to
rs
l/k
Setting
flow temperature
Vn = Nominal volume
VA = System water contents
Vn
litres
20
0,031 [ 70 °C]
0,045 [ 90 °C]
0,054 [100° C]
0,063 [110 °C]
VG, VF vessels
Installed thermal output of the heating surface Q / MW
reflex ’variomat’
Installation
reflex ’variomat 1’, ’variomat 2-1’
1-pump system
Installation
detail
 p. 14
max. 70 °C
Set-up variation
Expansion lines
Dimensioning
 p. 12
reflex ’fillset’
NS Ü
Water make-up
By turning the base plate it is
possible to mount the control
unit to the left, right or in front
of the VG basic vessel.
P
Control unit
VG Basic vessel
Connection
set G 1
530
reflex ’variomat 2-2’
500 *
900
VF Secondary vessel **
reflex ’SU Lockshield
valve’ R 1x1
On-site line DN 25
2-pump system
Installation
detail
 p. 14
max. 70 °C
Set-up variation
Expansion lines
Dimensioning
 p. 12
13
P
Ü
Water make-up
reflex ’fillset’
NS
By exchanging the end caps of the manifold
pipes it is possible to mount the control unit to
the left or right of the VG basic vessel
(standard → left).
Control unit
VG Basic vessel
Connection set
G 1¼
Selection example
- Heat generator power
Q = 3000 kW
- Water content
VA = unknown
 approx. from the installed
heating power
Q = 3000 kW, Radiatoren, 90/70 °C,
no additional remote lines
- Set-up temperature
=
90 °C
- Safeguarding temperature
= 110 °C
- static height
=
25 m
 p0 
p0 
H [m]
10
25
10
700
 Vn from diagram
=
500 *
900
* 500 mm for vessels up to  740 mm
900 mm for vessels ab  1000 mm
** with flexible hose connection
reflex ’Communication module’
for remote control (optional  p. 10)
bar + 0,7 bar [110 °C]
bar + 0,7 bar
VF Secondary vessel **
reflex ’SU Lockshield
valve’ R 1x1
On-site line DN 25
3,2 bar
= 1800 litres
selected:
Control unit ’variomat 2-2/60’
+ VG Basic vessel (z. B.  1000) 1000 litres
+ VF Secondary vessel (z. B.  1000)
1000 litres
= 2000 litres
+ VW Thermal insulation
1000 litres
+ Connection set G 1¼,  1000
+ reflex ’SU Lockshield valve’ R 1x1
+ Expansion line
= DN 50
complete order information
 p. 19
-
we recommend 2-pump systems,
if 2 MW is exceeded
the VF Secondary vessel requires no
thermal insulation
reflex ’variomat’
Installation
Assembly, operating and maintenance instructions ...
and more on the internet, on CD and extra brochures
www.
.de
Extracts from the installation, operating, and maintenance instructions
Install the system vertically in a frost-free, ventilated room with
water drainage facilities.
Install the control unit and the vessels, preferably at the same level, the
control unit must in no case be mounted higher than the vessels! Install
the vessels vertically.
The pressure cell for the level measurement must be mounted on the
appropriate foot of the VG basic vessel. The VG basic vessel and the first
secondary vessel must always be flexibly connected with the supplied
connection set to ensure that the level measuring is not impaired.
No fixed fastening of the VG basic vessel to the floor.
The ’VW Thermal insulation’ for the VG basic vessel is recommended for
heating systems.
Rinse the connection lines prior to installation!
14
Detail:
Connection of ’variomat’
The function of the ’variomat’ deaeration is only ensured when the
connection of the ’variomat’ has been performed in a representative main
flow of the installed system. The following minimum volume flows V must
be maintained during the operation.
With an inclination of Dt = 20 K this reflects a minimum performance
setting of the accepting system of Q.
V
Q
variomat 1 variomat 2-1 variomat 2-2/35 variomat 2-2/60 - 95
2 m³/h
4 m³/h
2 m³/h
4 m³/h
47 kW
94 kW
47 kW
94 kW
 500
Main volume flow V
Pump line P
partial flow
from ’variomat’
gas-free
The longer
the distance
between the
connections,
the better.
Over-flow line O
partial flow
to ’variomat’
gassy
Caution dirt!

Integration of the pumps and over flow lines in the system in such a
way that no large particles of dirt can enter the system (→ detail).
Sizing of the expansion lines  p. 12

If the reflex 'fillset' is not installed, a dirt trap (mesh size 0.25 mm)
should be installed in the make-up line NS.
The connection lines
should be connected from
the top or, as shown, as
immersion lines in the
main line in order to avoid
direct ingress of coarse dirt
in the ’variomat’.
The dimension of the
expansion lines should be
selected according to the
details given on page 12.
reflex ’variomat’
Installation examples
General information
Individual protection: due to the high deaeration
performance of the ’variomat’, it is recommended to install a
diaphragm pressure expansion vessel (e.g. ’reflex N’) on
the heat generator also for single boiler systems in order to
minimize the number of cycles.
Connection line for water make-up: if the water makeup line is directly connected to the drinking water network,
then reflex ’fillset’ (shut-off, system separators, water
meter, dirt pans) must be added. If reflex ’fillset’ is not
installed a dirt pan with a minimum mesh width ≤ 0.25 mm
must be installed in order to at least protect the solenoid
valve of the water make-up device. The line between the
dirt pan and the solenoid valve must be kept as short as
possible and must be rinsed.
Integration into the system: the integration into the
system is to be performed as described on page 14 in
order to prevent the ingress of rough particles of dirt and
the overload of the ’variomat’ dirt pan. The piping for the
heating system and the drinking water make-up must be
rinsed prior to start-up.
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.
15
’reflex’
reflex ’fillset’ with integrated
system separator must be
added when connected to a
drinking water network.
Dirt-free
connection  p. 14
 500
tR  70 °C
1)
25 1)
15
Drinking water
P
O
NS
VG Basic
vessel
reflex ’fillset’
’variomat 1’
Boiler and system protection
Pressure maintenance, deaeration, and water make-up
Electrical connections must be in accordance with local
electricity company codes and regulations.
Direct connection of the water make-up
device to the drinking water network
Expansion lines with a length
of more than 10 m must be
installed in DN 32. → p. 12
reflex ’variomat’
Installation examples
reflex ’variomat 1’ in a district heating domestic station,
water make-up via district heating return
Notes to the installer
District heating water is generally best suited as water
make-up water. A water
treatment is not necessary.
Dirt-free
connection  p. 14
’reflex’
tR  70 °C, district heating return
 500
25 1)
P
VG Basic
vessel
Please coordinate with the
heating supplier! Pay attention to the terms of
connection!
tR  70 °C
O
15
1) Expansion
lines with a length
of more than 10 m must be
installed in DN 32  p. 12
NS
’variomat 2’:
For special requirements,
e.g. in the district heating,
there is an option card
available with 6 digital inputs
and 6 voltage-free output
contacts as well as pressure
and level outputs using an
isolating amplifier.
Please contact us.
Safety valve
on-site
’variomat 1’
Filtre Press. reducer
Connection of the water make-up device at the district
heating return, coordinate with heating supplier
Generator and system protection
Pressure maintenance, deaeration, and water make-up
16
reflex ’variomat 2-1’ in a system with central return
admixture, water make-up through softening device
Notes to the installer
reflex ’T blow tank’
’variomat’ must always be
connected within the main
volume flow in order to ensure that a representative
part of the flow can be degassed. In case of central
return admixture this is the
system side. Then the boiler
is equipped with an individual
protection.
Dirt-free
connection  p. 14
 500
’reflex’
tR  70 °C
25 1)
VG Basic
vessel
P
O
15
NS
Drinking
water
reflex ’fillset’
If the reflex ’fillset’ capacity
is exceeded (kVS = 1 m³/h),
then alternatively a suitable
connection group must be installed on-site in the water
make-up line. The mesh
width of the filter must not
exceed 0.25 mm.
1) Dimensioning
’variomat 2-1’
Boiler individual
protection
System protection
Pressure maintenance, deaeration, and water make-up
Electrical connections must be in accordance with local
electricity company codes and regulations.
Connection of the water make-up
through chemical water treatment
of the
expansion lines
 Reflex checklist for
pressurization systems
on p. 12
smooth pump start
electrical main switch
reflex ’variomat’
reflex ’variomat 2-2’ in a multi-boiler system,
Flow > 100 °C, water make-up via softening equipment
Notes to the installer
For water treatment systems,
’fillset’ with system separator
and water meter is installed
in front of the softening
device.
reflex
’T Expansion
trap’
Provide individual protection
with ’reflex’ for multi-boiler
systems.
Dirt-free
connection  p. 14
 500
’reflex’
P
tR  70 °C
Multiple VF secondary
vessels can be connected.
Ü
1)
1)
NS
VF
Secondary
vessel
On-site
pipe work
Drinking
water
VG Basic
vessel
reflex ’fillset’
Dimensioning of the
expansion lines
 Reflex checklist for
pressurization systems
on p. 12
’variomat 2-2’
2 pump with smooth start
electrical main switch
load-dependent connection
and malfunction change-over
System protection
Pressure maintenance, deaeration, and water make-up
Electrical connections must be in accordance with local
electricity company codes and regulations.
Connection of the water make-up
through chemical water treatment
17
reflex ’variomat’
Check list
reflex
’T Expansion trap’
Selection
acc. to DIN EN 12828
 brochure Accessories
reflex
’EB Dirt collector’
particularly suited for older
systems
 brochure Accessories
Q
kW
Expansion
lines
 p. 12
18
reflex ’fillset’
’fillset’
TW
reflex ’variomat’
control unit
with VG Basic
vessel and
connection set
Connection group to drinking
water network with water
meter and system separator
VF Secondary vessel
Multiple VF secondary
vessels can be connected.
M
reflex ’SU
Lockshield valve’
’SU’ R 1x1
for VF Secondary vessels
 brochure Accessories
You will find these articles in this brochure.
You will find these articles in the specified brochures.
reflex ’variomat’
Order information
Order information
Article-No.
No.
Order information
’variomat’ Control unit
variomat 1
variomat 2-1/60
variomat 2-1/75
variomat 2-1/95
p0  2,5 bar
p0  4,8 bar
p0  6,5 bar
p0  8,0 bar
6910100
6910200
6910500
6910600
variomat 2-2/35
variomat 2-2/60
variomat 2-2/75
variomat 2-2/95
p0  2,5 bar
p0  4,8 bar
p0  6,5 bar
p0  8,0 bar
6911100
6911200
6911500
6911600
installierte
Nominal heating power
Heat generator-SV
Heat generator STB
static height
....... kW
....... bar
....... °C
’variomat’ Connection set
G 1  VG 480 - 740 mm
 VG 1000 - 1500 mm
6940100
6940200
for ’variomat’ 1-pump systems
G 1¼  VG 480 - 740 mm
 VG 1000 - 1500 mm
6940300
6940400
for ’variomat’ 2-pump systems
’variomat’ VG Basic vessel
....... litres
.....
’variomat’ Options
VW Thermal
....... litres
insulation
reflex ’fillset’
with standard water meter
with contact water meter
VF Second. vessel ....... litres
6811105
6811205
.....
reflex ’SU Lockshield valve’
7613100
reflex ’VE Extension module’
for ’variomat 2’
reflex ’VK Communication module’
for ’variomat 2’
reflex ’bus module’
for ’variomat 2’
Installation
1-pump systems
2-pump systems
for VG basic vessels 200 - 5000 litres
in heating systems
.....
19
7997705
7997800
for remote control operation
upon request
7945600
7945630
Texts for tenders,
from the cooperative research work with the
Technical University of Dresden...and more
www.
e. g. brochure
„Deaeration of heating and cooling systems“
from the cooperative research work with the
Technical University of Dresden
When and why is the use of deaeration systems
required also and especially in closed systems?
.de
Reflex –
Responsibility in the interests of the environment
New Reflex technologies are to provide
advantages not only to human beings,
but also to the environment. This is
the principle on which we base all our
development, planning, and manufacturing.
We comply with our responsibility as
manufacturer by the purposeful selection
of materials and production technologies - the environmental - impacts are
as low as possible.
PI0105enG / 9571046 / 05 - 11
Subject to technical modification
Reflex Winkelmann GmbH + Co. KG
Gersteinstrasse 19
59227 Ahlen
Germany
Phone +49 2382 70 69 - 0
Fax
+49 2382 70 69 - 558
www.reflex.de