Water make-up systems & water treatment technology

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1 Water make-up systems & water treatment technology Fillcontrol, Fillset, Fillsoft

2 We are only satisfied when Reflex has set itself the goal of supporting you with well thought-out solutions. Whatever job you need doing in water supply engineering, why not put your trust in our comprehensive range of products and accompanying tailored services? We will ensure that your decision to opt for Reflex is the right one in every respect from advice and design to installation and ongoing operation. Reflex's mission is embodied in the company's slogan: Thinking solutions. Reflex's strength is to think in terms of solutions. Reflex develops ideas that help you to move forward based on decades of experience, in-depth technical understanding and intimate knowledge of the industry! 2

3 you are. Contents We make sure that everything fits Heating, cooling and hot water supply systems the demands on supply equipment are varied and complex. Water plays a key role in this. An adequate water level combined with good water quality are crucial when it comes to the smooth and efficient operation of your system. With its water make-up systems and water treatment technology, Reflex is therefore creating the basis on which heat transfer and storage, as well as the interaction of all other system components, can operate. Fillcontrol water make-up page 4 systems for heating and cooling water Fillcontrol water make-up page 6 systems at a glance Fillsoft water treatment page 8 technology for make-up water Deaeration Systems & Separation Technology Water Make-Up Systems & Water Treatment Diaphragm Expansion Vessels The Reflex Product Range Pressurisation Systems Networked solutions for water page 10 make-up and water treatment Information, advice and page 12 design support Technical data page 14 Services Hot Water Storage Tanks & Heat Exchangers Discover the extensive range of Reflex water make-up and water treatment solutions in this brochure. From manually to automatically controlled water make-up systems with water treatment, including integration into pressure maintenance and degassing control. 3

4 Water make-up systems & water treatment technology Fillcontrol water make-up system A lack of water in heating or cooling systems damages the operation of the pressure maintenance system used. As a result it can lead to trapped air, massive circulation malfunctions, cavitation on the circulation pumps and, at worst, total failure of the system. That is why water make-up systems are recommended in line with EN 12828, which simultaneously can act as pressure monitoring devices. With its Fillcontrol series, Reflex is unveiling a wide range of solutions for the long-term and stable operation of the different types of systems. In principle, all sealed systems need a specific water make up device (manual or pump driven) according to the country of installation. System backflow prevention is required when making-up from potable water networks to prevent process water flowing back into the fresh water system. A differentiation is also made between systems with or without pumps, which are used depending on the available pressure in the water make-up network and the minimum operating pressure in the system. Reflex Control the new control unit The latest generation of Fillcontrol water make-up systems is setting new benchmarks, both technically and visually. This is primarily due to the newly developed Reflex Control concept. It combines all functions in a clear and intuitive user interface and can be easily networked with other systems controlled by Reflex Control, such as with Variomat and Reflexomat pressurisation stations or a Servitec degassing unit. Reflex Control thus not only simplifies automatic filling and water make-up processes but also guarantees the perfectly controlled operation of the entire system. The key-based Reflex Control Basic with a 2-line LCD display and the following features is used with all Reflex water makeup systems. Calculation of the filling pressure from the system's minimum operating pressure Leak detection over run time and cycles; reliable signalling of leaks and automatic interruption of water make-up Monitoring of filling by means of a set filling time or filling pressure; filling stops when the set level is reached Faults signalled by display and volt free output Seamless integration and monitoring of Fillsoft softening components: cartridge usage is reliably tracked and the need for replacement displayed by an optional contact water meter (standard interface) and integrated softening logic Pressure and level-dependent operation as standard: pressure-dependent operation via integral control and level-dependent operation by simple networking with Reflex pressurisation stations Direct networking with all Reflex pressurisation stations and degassing systems thanks to the Control concept 4

5 s for heating and cooling water Water make-up systems without pump These systems are suitable for the pressure-dependent makeup in systems with diaphragm pressure expansion vessels. Water is made-up using the pressure in the mains water system, which should be a minimum of 1.3 bar above the minimum operating pressure (p 0 ) of the system. Water make-up systems with pump Pump-based water make-up systems are ideal for the pressure-dependent addition of make-up water with diaphragm expansion vessels, as well as for the level-dependent addition of make-up water with pressurisation stations. The pressure generated by the pump permits make-up water to be added in systems with a minimum operating pressure (p 0 ) of up to about 7 bar. Control valve Pressure sensor System separator PIS Mains water p 1 bar Reflex Control p O Fresh water p p O bar Closed system Closed system PIS Reflex Control System separation vessel Pump Pressure sensor p O LS Level sensor They are very simple to operate. When the pressure falls below the filling pressure at the pressure sensor, the water make-up control valve opens and allows mains water to flow into the system. When operated with a diaphragm expansion vessel, the water make-up control valve opens when the pressure falls below the filling pressure on the pressure sensor in the same way as in a system without pump. When operated with pressurisation stations, the level falling below the filling level in the expansion vessel causes the control valve to open. Reflex water make-up systems without pump Fillcontrol: Water make-up system with stand-alone system pressure sensor, complete with system separation. Fillcontrol Plus: The modular water make-up solution with the full functionality of the Reflex Control concept and the option to install a Reflex Fillset from the mains feed for system separation. Pump-based Reflex water make-up systems Fillcontrol Auto Compact. The complete system with the full functionality of the Reflex Control concept as well as integral tank for system separation. Fillcontrol Auto is also available in a version suitable for use with anti-freeze, for instance to connect to a mixing tank for adding make-up water to solar systems. 5

6 Water make-up systems & water treatment technology Fillcontrol water make-up system With its Fillcontrol range, Reflex enables controlled, automated water make-up with all common system configurations in heating, cooling and solar systems. For maximum design flexibility as well as full functionality and perfect networking with the entire system, from pressurization stations to softening solutions. Fillcontrol The compact solution for small systems with diaphragm expansion vessels. The DIN EN 1717-compliant system separator is already built in; the control works fully autonomously via the integral system pressure sensor. Flow coefficient: 0.4 m³/h Max. operating temperature: 70 C Max. excess operating pressure: 10 bar Minimum supply pressure: 1.3 bar Fillcontrol Plus Adding make-up water is a requirement in systems with diaphragm expansion vessels. The Fillcontrol Plus offers the full functionality of the Reflex Control Basic, even for smaller systems. It can be operated in a pressure- and level-dependent manner. A Fillset can be installed from the mains compliance regulations for system separation of potable water networks. Flow coefficient: 1.4 m³/h Max. operating temperature: 90 C Max. excess operating pressure: 10 bar Fillcontrol Auto Compact The Fillcontrol Auto Compact combines maximum flexibility and the highest operating convenience. It works with your installed pumps fully independently of the pressure of the freshwater system. It can be operated pressure- and level-dependent with the setting being made simply on the Control itself. With level-dependent operation, the pressurisation station and water make-up unit is linked to each other by the control. The Fillcontrol Auto can be connected directly to the potable water network thanks to the integral system separation vessel. Water make-up volume: 0.12 to 0.18 m³/h Max. operating temperature: 30 C Max. excess operating pressure: 10 bar Working range: Up to 8.5 bar 6

7 s at a glance Solenoid valve with ball valve for Reflexomat If a Reflexomat pressurization station is used, water can be made-up directly by means of a solenoid valve with ball valve. It is actuated by the Reflexomat's Reflex Control when the pressure falls below the set vessel volume (240 V output). A Fillset is fitted in the mains supply for system separation when making-up from potable water networks. Flow coefficient: 1.4 m³/h Max. operating temperature: 90 C Max. excess operating pressure: 10 bar Fillcontrol Auto version suitable for use with anti-freeze The Fillcontrol Auto is also available as a version suitable for use with media containing anti-freeze for special applications. The range of functions is identical to that of the Fillcontrol Auto, except that there is no system separation vessel, as generally glycol mixture from an open tank on site are used, such as mixing tanks in solar systems. It can be operated in a pressure- and level-dependent manner. Water make-up volume: 4 m³/h Max. operating temperature: 70 C Max. excess operating pressure: 8 bar Working range: Up to 5.5 bar Fillset water make-up fittings Fillset water make-up fittings provide system separation in line with DIN EN 1717, thereby permitting the permanent connection of heating or cooling water systems to potable water systems. Fillset can be used immediately for manual water make-up or can be installed upstream of automatic solutions, like the Fillcontrol Auto. Reflex offers the following Fillset versions: Fillset with integrated water meter for monitoring the water make-up volume Fillset Contact with contact water meter that can be evaluated by all Reflex Control devices Fillset Compact is a basic space-saving device without water meter Flow coefficient: 0.8 m³/h Max. operating temperature: 60 C Max. excess operating pressure: 10 bar Detailed product information can be found from page 14 onwards. 7

8 Water make-up systems & water treatment technology Fillsoft water treatment technol Modern boilers are expected to withstand constantly increasing heating surface loads, increasing the risk of deposits, particularly of lime. This can reduce the boiler's performance and, at worst, lead to the failure of the boiler. To avoid this, Reflex offers Fillsoft, a range of water treatment products with which filling water and make-up water can be softened in line with the standards. Reflex recommends that customers consider a Fillsoft softening solution for every water make-up system, as they make a significant contribution to greater system safety with minimum outlay. Construction The core of the Fillsoft softening unit is a column with a replaceable cartridge in which the moving sodium ions are stored in synthetic resin balls. This column has connections for fresh water and filling or make-up water. A shut-off ball valve with a test valve on the water make-up side completes the set-up. Mode of operation The target hardness of the filling and make-up water is determined according to the boiler output and the capacity-specific volume of the system (for instance in line with VDI 2035 T1). The hardness of the fresh water is defined by the content of magnesium and calcium ions. Hard fresh water Soft filling and make-up water Mg ++ Ca ++ Na + Na + Na + Na + Na + Na + Ca ++ Na + Na + Mg ++ The water is softened according to the principle of cation exchange. The hard fresh water is passed through the exchange column. The magnesium and calcium ions that form the hardness are exchanged by the sodium ions in the resin balls and the water is softened. The cartridge needs to be replaced once the capacity of the sodium ions has been exhausted. 8

9 ogy for make-up water Fillcontrol softening technology at a glance Fillsoft softening units are the right choice even for smaller systems. They are inexpensive, effective and also user friendly in its operation. Unlike with full desalination, there is no danger to the system, even with improper operation, as the acid-base buffer system is retained. The benefits of Fillsoft in detail: Well thought-out complete program for water softening Simple installation, both as a stand-alone unit and also linked to a Fillcontrol water make-up solution Durable, efficient heat transfer, as limescale build-up on boiler surfaces is prevented Long-term protection of your system, as partial thermal and mechanical overloading by limescale build-up is avoided Maximum operational safety, as the system's ph remains stable even if incorrectly operated Ease of handling by simple cartridge replacement and disposal of used cartridges with household waste Fillsoft softening unit This softening unit is available in two basic versions, depending on the required capacity: Fillsoft I with one resin cartridge, or Fillsoft II with two resin cartridges. Fillmeter programmable digital water meter Fillmeter reliably displays when the resin cartridge has to be replaced. To do this, the Fillmeter calculates the achievable soft water volume based on the data entered and compares it with the actual measured value. Acoustic and visual signal and switching of a floating output (24 V) possible. Max. excess operating pressure: 10 bar Max. operating temperature: 65 C Fillsoft replacement cartridge Quick and simple to install, the Fillsoft replacement cartridge restores full capacity. Soft water capacity: Softmix blending device 6000 l The hardness of the soft water is reduced to values of below 0.11 dh following Fillsoft softening. This is often below the required target water hardness and also leads to increased consumption of Fillsoft cartridges. The target water hardness can be adjusted by the controlled addition of fresh water using the Softmix blending device, thereby optimising consumption accordingly. Max. excess operating pressure: 8 bar Max. operating temperature: 40 C Soft water capacity of Fillsoft I II: 6,000 12,000 dh Soft water volume: 0.4 m³/h Height: 600 mm Total hardness testing kit The total hardness testing kit includes everything you need to precisely determine your water hardness. Use this kit to precisely determine and monitor the hardness of fresh water and make-up water. Detailed product information can be found from page 14 onwards. 9

10 Water make-up systems & water treatment technology Networked solutions for water m The combination of Fillcontrol water make-up systems and Fillsoft softening technology is as obvious as it is sensible: in coordinated solutions they make a decisive contribution to greater operational safety and efficiency in heating systems. The recommended combinations of units should always be determined against the background of a specific system design. Below we would like to outline a number of possible combinations to demonstrate the interplay and possible functions. Refer to pages 12/13 of this brochure for more information on Reflex design support. Manual filling and water make-up Automatic filling and water make-up in systems with diaphragm expansion vessels Fillset Compact + Fillsoft I + Fillmeter A solution for manual water make-up and softening of heating water for detached and semi-detached houses. The Fillset Compact ensures the requisite system separation required when making-up from the potable water network; the fresh water is automatically softened by the Fillsoft I. One cartridge to fill the system is sufficient even with very hard water. Fillcontrol + Fillsoft I + Fillmeter + External pressure sensor Alternatively: Fillset + Fillsoft II + Fillcontrol Plus For heating systems in commercial buildings with pressure maintenance by diaphragm expansion vessels. The filling and water make-up process is essentially automatic and signals to a control centre are also possible. Only the cartridge in the Fillsoft softening unit needs to be replaced manually. 10

11 ake-up and water treatment Automatic water make-up and softening in systems with Variomat pressurisation stations or Servitec degassing stations A water make-up unit is integrated into the Variomat and Servitec. The Reflex Control operates the control valve and also takes over logic for softening and water make-up. A Fillset Contact with contact water meter for determining the volume of filling water and make-up water is included and networked to the control. A Fillsoft II regulates water softening. Automatic water make-up and softening in systems with Reflexomat pressurisation stations Reflexomat pressurisation stations have logic for softening and water make-up integrated into the Reflex Control. A solenoid valve with ball valve fitted and integrated into the controller is energised for water make-up. A Fillset Contact with contact water meter for determining the volume of filling water and make-up water is also included and networked to the control. The water softening is regulated by a Fillsoft II. Non-standard solutions for water make-up: With Fillcontrol Auto, Reflex is opening up new prospects where conventional systems could not be used due to the operating conditions. If water is to be made-up regardless of the fresh water pressure. When regular inspection obligations for separate fittings for system separation have to be avoided by the use of a separation vessel. When water-anti-freeze mixtures are used in systems. The Reflex Control scheme enables the Fillcontrol Auto to be integrated perfectly into systems with Reflexomat. 11

12 Water make-up systems & water treatment technology Count on us from the initial id Reflex offers a range of services to assist you in finding the solution that best suits your needs. Take advantage of our combined expertise and experience and develop professional and expert solutions together with us, down to the very last detail. Our service numbers How can we help you? Please contact the relevant service number to ensure that you find the right person to deal with your inquiry as quickly as possible. Technical hot line For all questions about our products Monday to Friday from 8.00 a.m. to 4.30 p.m Reflex customer service To order repairs, maintenance and commissioning Monday to Friday from 8.00 a.m. to 4.30 p.m Central phone number For general inquiries, to order brochures, contact a business partner or responsible field sales engineer Monday to Friday from 8.00 a.m. to 4.30 p.m Made-to-measure design: With the Reflex Pro calculation program Take the easiest route to correct design and sizing: Reflex Pro is the proven, continuously developed software solution you can use to quickly and simply achieve precise results. The software is available in three versions and we also offer a CAD library of our products for integration into your construction programs. Visit for further information and the option of downloading free of charge. 12

13 ea to the solution. Our field sales team always on the road for you Our Reflex field sales team is your first point of contact when you need professional advice on site. From recommending relevant products to design and support in the preparation of a tender. You can rely on our experts! Call our central phone number or check out under Contact Us to find the field sales representative responsible for your region. Our product literature designed to be used Make sure your decisions about all your future steps are based on solid foundations with Reflex product information. You will find everything you need to know about products and systems in our brochures and at Well arranged and clearly explained from the wider context to technical details. Request the latest Reflex brochures directly from your Reflex field sales engineer, via our central phone number or even simpler online as PDFs at 13

14 Water make-up systems & water treatment technology Technical data Fillset Compact Connection group for water make-up systems in accordance with DIN 1988 and DIN 1717 for direct connection to potable water systems With DVGW-certified system separator type BA Input and output-side shut-offs Without water meter Article no Max. excess operating pressure 10 bar Max. operating temperature 60 C Width x Height 175 x 214 mm Weight 0.9 kg Inlet/outlet connection R ½/R ½ Minimum flow pressure 1) p bar Flow coefficient 2) k vs 0.8 m 3 /h Flow coefficient 3) k vs 0.7 m 3 /h 1) p0 = Gas input pressure in expansion vessel = minimum operating pressure of the system 2) As a single assembly 3) In conjunction with Fillcontrol Plus, Variomat, Reflexomat or Servitec Fillset Connection group for water make-up systems in line with DIN 1988 and DIN 1717 for direct connection to potable water networks With DVGW-certified system separator type BA Input and output-side shut-offs Including standard/contact water meter and wall bracket Fillset with standard water meter Fillset with contact water meter Article no Max. excess operating pressure 10 bar 10 bar Max. operating temperature 60 C 60 C Width x Height 293 x 230 mm 293 x 230 mm Weight 1.7 kg 1.7 kg Inlet/outlet connection R ½/R ½ R ½/R ½ Minimum flow pressure 1) p bar p bar Flow coefficient 2) k vs 0.8 m 3 /h 0.8 m 3 /h Flow coefficient 3) k vs 0.7 m 3 /h 0.7 m 3 /h 1) p0 = Gas input pressure in expansion vessel = minimum operating pressure of the system 2) As a single assembly 3) In conjunction with Fillsoft 14

15 Fillsoft I/II Water softening device for initial filling and water make-up in heating systems Fillsoft I: Soft water capacity 6,000 l x dh Fillsoft II: Soft water capacity 12,000 l x dh Incl. shut-off with sample cock and segment connection * Fillset I incl. flow limiter Fillsoft I Fillsoft II Article no Max. excess operating pressure 8 bar 8 bar Max. operating temperature 40 C 40 C Height 600 mm 600 mm Width 260 mm 380 mm Max. continuous flow 0.4 m 3 /h 0.4 m 3 /h Weight 4.1 kg 7.6 kg Inlet/outlet connection Rp ½/Rp ½ Rp ½/Rp ½ Capacity 6,000 l x dh 12,000 l x dh Fillsoft I Fillsoft II The use of a water meter, e.g. Fillmeter, is required to monitor the residual capacity. * For the necessary system separation in accordance with DIN EN 1717 and DIN 1988, we recommend the Fillset Compact ( p. 14) Accessories Fillmeter Article no Softmix Article no External pressure sensor Article no Fillsoft cartridge Article no Total hardness testing kit Article no External pressure sensor required for combination with Fillcontrol. Softmix Fillsoft cartridge Pressure sensor Fillmeter Measuring kit 15

16 Fillcontrol Plus Compact Compact automatic make-up station 1), can be used for systems with diaphragm expansion vessels in accordance with DIN 1988 and DIN EN 1717 With system separator type BA Controlled water make-up Water make-up volume approx. 0.5 m 3 /h at p = 1.5 bar Article no Net weight 3 kg Inlet/outlet connection R ½/R ½ Minimum flow pressure 2) p bar Output pressure 3) bar Input pressure Max. 10 bar Connection voltage 230 V/50 Hz 1) An external pressure sensor must be used in combination with Fillsoft 2) p0 = pst (recommendation) static pressure (= stat. height [m]/10) 3) System pressure, factory configuration 3 bar Fillcontrol Plus make-up station without pump To monitor system pressure on expansion vessels and for the automatic water make-up of the set initial pressure Incl. wall bracket With Control Basic control unit RS 485 interface, connection of bus/extension modules possible Capacity monitoring of a Fillsoft water treatment system possible Standard Stainless steel Article no Max. operating temperature 90 C 90 C Height x width x depth 320 x 340 x 190 mm 320 x 340 x 190 mm Weight 2.5 kg 2.5 kg Inlet/outlet connection G ¾/G ½ G ¾/G ½ Max. excess operating pressure 10 bar 10 bar Input pressure Max. 10 bar Max. 10 bar Minimum flow pressure p p bar 1) p bar 1) Max. normal pressure p bar 2) p bar 2) Connection voltage 230 V/50 Hz 230 V/50 Hz Flow coefficient 3) k vs 1.4 m 3 /h 1.4 m 3 /h Flow coefficient 4) k vs 0.7 m 3 /h 0.7 m 3 /h 1) p0 = Gas input pressure in expansion vessel = minimum operating pressure of the system 2) If exceeded, fit pressure reducing valve upstream 3) As a single assembly 4) In conjunction with Fillset 16

17 Fillcontrol Auto water make-up station with pump Fully automatic water make-up systems with integrated pump Fillcontrol Auto Compact with integrated water make-up tank as a means of system separation Fillcontrol Auto for water make-up on glycol mixtures, e.g. from an open tank glycol mixture Systems equipped with Control Basic for simple and clear operation RS 485 interface, connection of bus/extension modules possible Capacity monitoring of a Fillsoft water treatment system possible Including system separation in accordance with DIN 1988 and DIN EN 1717 with Fillcontrol Auto Compact Fillcontrol Auto Compact Fillcontrol Fillcontrol Auto Auto Compact Article no Max. excess operating pressure 10 bar 8 bar Max. operating temperature 30 C 30 C Height x width x depth 620 x 580 x 290 mm 690 x 470 x 440 mm Weight 17.5 kg 1) 25 kg 1) Pump pressure Max. 8.5 bar Max. 5.5 bar Heating connection G ½ G 1 Potable water connection G ½ Overflow connection DN 32 Supply pressure max. 5.5 bar 2) Delivery rate l/h 4 m 3 /h Req. feed capacity min. 360 l/h min. 360 l/h Suction connection at tank 1 ¼ Fillcontrol Auto 1) Without water volume 2) If exceeded, fit pressure reducing valve upstream 17

18 PI1308enA / / / Subject to technical modifications Reflex Winkelmann GmbH Gersteinstrasse Ahlen, Germany Tel.: Fax:

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