Fillcontrol, Fillset, Fillsoft

Water Make-Up Systems & Water Treatment

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Reflex has set itself the goal of supporting you with well thought-through solutions. Regardless of what you are planning 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!

We are only satisfied when you are.

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DiaphragmExpansionVessels

PressurizationSystems

Water Make-UpSystems &Water Treatment

Hot Water Storage Tanks & Heat Exchangers

Services

Deaeration Systems & SeparationTechnology

The Reflex

Product Range

33

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.

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 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.

Contents

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-upwater

Networked solutions for page 10 water make-up andwater treatment

Information, advice and page 12 design support

Technical data page 14

We are only satisfied when you are.

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Fillcontrol water make-up systems for heating and cooling water

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 act as pressure monitoring devices. With its Fillcontrol series, Refl ex is unveiling a wide range of solutions for the long-term and stable operation of the most varied types of systems.

In principle, every water make-up system consists of the make-up component and a system separator. System separation is required when making-up from potable water networks to prevent process water fl owing 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 make-up water network and the minimum operating pressure in the system.

Water make-up systems & water treatment

• Calculation of the fi lling pressure from the system's minimum operating pressure

• Leak detection over run time and cycles; reliable signaling of leaks and automatic interruption of make-up

• Monitoring of fi lling by means of a set fi lling time or fi lling pressure; fi lling stops when the set level is reached

• Faults signaled by display and fl oating 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 Refl ex pressurization stations

• Direct networking with all Refl ex pressurization stations and degassing systems thanks to the Control concept

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Refl ex 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 Refl ex Control concept. It combines all functions in a clear and intuitive user interface and can be easily networked with other sys-tems controlled by Refl ex Control, such as with Variomat and Refl exomat pressur ization stations or a Servitec degassing unit. Refl ex Control thus not only simplifi es automatic fi lling and make-up processes but also guarantees the perfectly controlled operation of the entire system.

The key-based Refl ex Control Basic with a 2-line LCD display and the following features is used with all Refl ex water make-up systems.

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Fillcontrol water make-up systems for heating and cooling water

Water make-up systems without pump

These systems are designed for the pressure-dependent addition of make-up water in systems with diaphragm expansion vessels. Water is added using the innate pressure in the fresh water system, which should be a minimum of 1.3 bar above the minimum operating pressure (p0) of the system for this purpose.

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 fresh water to flow into the system.

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 function-ality of the Reflex Control concept and the option to install a Reflex Fillset upstream for system separation.

System separator

Control valve Pressure sensor

Closed system

Reflex Control

Fresh waterp ≥ pO + 1.3 bar

pO

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 pressurization stations. The pressure generated by the pump permits make-up water to be added in systems with a minimum operating pressure (p0) of up to about 7 bar.

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 pressur-ization stations, the level falling below the filling level in the expansion vessel causes the control valve to open.

Pump-based Reflex water make-up systems

Fillcontrol Auto:The complete system with the full functionality of the Reflex Control concept as well as integral vessel 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.

Reflex Control

PumpPressure sensor

Fresh waterp ≥ 1 bar

System separation vessel

Closed system

Level sensor

pO

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Fillcontrol water make-up systems at a glance

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Water make-up systems & water treatment

With its Fillcontrol range, Refl ex enables controlled, automated water make-up with all common system confi gurations in heating, cooling and solar systems. For maximum design fl exibility 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 coeffi cient: 0.4 m³/hPerm. operating temperature: 70 °CPerm. excess operating pressure: 10 bar

Fillcontrol Plus

Adding make-up water can be this convenient in systems with diaphragm expan-sion vessels. The Fillcontrol Plus offers the full functionality of the Refl ex Control Basic, even for smaller systems. A Fillset can be installed upstream for system separation of potable water networks.

Flow coeffi cient: 1.4 m³/hPerm. operating temperature: 90 °CPerm. excess operating pressure: 10 bar

Fillcontrol Auto

The Fillcontrol Auto combines maximum fl exibility and the ultimate in operating convenience and works with its built-in pump completely independently of the pressure of the fresh water network. It can be operated pressure- and level-dependent with the setting being made simply through the Refl ex Control unit. With level-dependent operation, the pressurization station and water make-up unit are networked to each other by the control. The Fillcontrol Auto can be connected directly to the potable water network thanks to the integral system separation tank.

Make-up volume: 0.12 to 0.18 m³/hPerm. operating temperature: 30 °CPerm. excess operating pressure: 10 bar

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Detailed product information can be found from page 14 onwards.

Fillcontrol water make-up systems at a glance

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Solenoid valve with ball valve for Refl exomat

If a Refl exomat pressurization station is used, water can be made-up directly by means of a solenoid valve with ball valve. It is actuated by the Refl exomat's Refl ex Control when the pressure falls below the fi lling pressure in the expansion vessel. A Fillset is fi tted upstream for system separation when making-up from potable water networks.

Flow coeffi cient: 1.4 m³/hPerm. operating temperature: 90 °CPerm. 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 water make-up vessels on site are used, such as mixing tanks in solar systems.

Make-up volume: ≤ 4 m³/hPerm. operating temperature: 110 °CPerm. excess operating pressure: 10 bar

Fillset water make-up fi ttings

Fillset water make-up fi ttings provide system separation in line with DIN EN 1717, thereby permitting the permanent connection of heating or cooling water systems and 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.

Refl ex 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

Refl ex Control devices• Fillset Compact is a particularly space-saving, simple version without

water meter

Flow coeffi cient: 0.8 m³/hPerm. operating temperature: 60 °CPerm. excess operating pressure: 10 bar

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Ca++

Mg++

Na+ Na+ Na+ Na+

Na+

Na+

Na+

Na+

Ca++Mg++

Fillsoft water treatment for make-up water

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Water make-up systems & water treatment

Modern boilers are expected to withstand constantly growing stresses on their heating surfaces, increasing the risk of deposits, particularly of lime, which 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 re-placeable 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.

Hard fresh water Soft filling and make-up water

Mode of operation

The target hardness of the filing and make-up water is deter-mined 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.

The water is softened according to the principle of cation ex-change. The hard fresh water is passed through the exchange column. The magnesium and calcium ions that form the hard-ness 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.

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Detailed product information can be found from page 14 onwards.

Fillsoft water treatment for make-up water

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Fillcontrol softening technology at a glance

Fillsoft softening units are the right choice even for smaller systems: They are cheap, effective and also easy for lay users to operate. Unlike with full desalination, there is no danger to the system, even with improper operation, as the acid-base buffer system is retained.

The benefi ts 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, effi cient 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 or Fillsoft II with two resin cartridges.

Perm. excess operating pressure: 8 barPerm. operating temperature: 40 °CSoft water capacity of Fillsoft I | II: 6,000 | 12,000 °dHSoft water volume: ≤ 0.4 m³/hHeight: 600 mm

resin cartridges.

Fillmeter programmable contact 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.

Perm. excess operating pressure: 10 barPerm. operating temperature: 65 °C

Fillsoft replacement cartridge

Quick and simple to install, the Fillsoft replacement cartridge restores full capacity.

Soft water capacity: 6,000 °dH

Softmix blending device

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 hard-ness can be adjusted by the controlled addition of fresh water using the Softmix blending device, thereby optimizing consumption accordingly.

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.

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Water make-up systems & water treatment

Networked solutions for water t reatment and water make-up

Manual fi lling and water make-up

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 fi ll the system is suffi cient even with very hard water.

Automatic fi lling and water make-up in systems with diaphragm expansion vessels

Fillcontrol + Fillsoft I + Fillmeter + External pressure sensor

Alternatively: Fillset + Fillsoft II + blending device + Fillcontrol Plus For heating systems in commercial buildings with pressure maintenance by diaphragm expansion vessels. The fi lling and water make-up process is essentially automatic and signals to a control center are also possible. Only the cartridge in the Fillsoft softening unit needs to be replaced manually.

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 effi ciency in heating systems. The recommended combinations of units should be determined against the background of a specifi c 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 Refl ex design support.

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Networked solutions for water t reatment and water make-up

Automatic water make-up and softening in systems with Variomat pressurization stations or Servitec degassing stations

A water make-up unit is integrated into the Variomat and Servitec. The Refl ex 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 fi lling water and make-up water is included and networked to the control. A Fillsoft II with blending device regulates water softening.

Automatic water make-up and softening in systems with Refl exomat pressurization stations

Refl exomat pressurization stations have logic for softening and water make-up integrated into the Refl ex Control. A solenoid valve with ball valve fi tted upstream and integrated into the controller is adequate as a control valve for water make-up. A Fillset Contact with contact water meter for determining the volume of fi lling water and make-up water is also included and networked to the control. A Fillsoft II with blending device regulates water softening.

With Fillcontrol Auto, Refl ex 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 fi ttings for system

separation have to be avoided by the use of a separation vessel.• When water-anti-freeze mixtures are used in systems.

The Refl ex Control scheme enables the Fillcontrol Auto to be integrated perfectly into systems with Refl exomat or Variomat pressurization stations and Servitec degassing stations.

Non-standard solutions for water make-up:

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Count on us - from the initial idea to the solution.

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.

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 can also provide you with a CAD library of our entire product range for integration into your construction programs.

Visit www.reflex.de/pro for further information and the option of downloading free of charge.

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 productsMonday to Friday from 8:00 to 16:30 +49 2382 7069-9546

Reflex Customer Service and Spare Parts Service To commission repairs, maintenance and commissioning and to order spare partsMonday to Friday from 8:00 to 16:30 +49 2382 7069-9505

Central phone numberFor general inquiries, to order brochures, contact a business partner or responsible field sales engineer Monday to Friday from 8:00 to 16:30 +49 2382 7069-0

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Water make-up systems & water treatment

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Count on us - from the initial idea to the solution.

Our product literature - designed to be used

Make sure your decisions about all your future steps are based on solid foundations – with Refl ex product information. You will fi nd everything you need to know about products and systems in our brochures and at www.refl ex.de. Well arranged and clearly explained – from the wider context to technical details.

Request the latest Refl ex brochures directly from your Refl ex fi eld sales engineer, via our central phone number or – even simpler – online as PDFs at www.refl ex.de.

Our fi eld sales team - always on the road for you

Our Refl ex fi eld sales team is your fi rst 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 www.refl ex.de under Contact Us to fi nd the fi eld sales representative responsible for your region.

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Technical dataMake-up station without pump

Fillcontrol Plus water make-up station without pump

Fillcontrol Auto water make-up station with pump

• Floating output (changeover switch) for collective message, max. contact load 230 V, 4 A• 230 V input for evaluation of an external make-up signal• Input for contact water meter (→ Fillset)

• Compact automatic water make-up unit*, can be used for systems with diaphragm expansion vessels in line with DIN 1988 and DIN EN 1717

• With system separator type BA• Controlled water make-up• Input pressure max. 10 bar• Output pressure 0.5 - 5 bar• Water make-up volume approx. 0.5 m3/h at ∆p = 1.5 bar

• Floating output (changeover switch) for collective message, max. contact load 230 V, 4 A• 230 V input for evaluation of an external make-up signal• Electrical connection 230 V/50 Hz Schuko plug with 2 m cable

Article no. 8812100

Article no. for stainless steel vers. 8812200 Input pressure Max. 10 bar

Perm. excess operating pressure 10 bar Minimum fl ow pressure p p0 + 1.3 bar1)

Perm. operating temperature 90 °C Max. normal pressure p0 + 4 bar2)

Width x Height 340 x 233 mm Connection voltage 230 V/50 Hz

Weight 2.5 kg Flow coeffi cient 3) KVS 1.4 m3/h

Inlet/outlet connection G ¾/G ½ Flow coeffi cient 4) KVS 0.7 m3/h

Article no. 8688500 Potable water connection Reinforced hose G

Article no. for anti-freeze 8812300 Overfl ow connection DN 32

Perm. excess operating pressure 10 bar Pump pressure Max. 8.5 bar

Perm. operating temperature 30 °C Supply pressure max. 6 bar 2)

Width x Height x Depth 387 x 610 x 280 mm Delivery rate 120 – 180 l/h

Width x Height x Depth (anti-freeze) 428 x 698 x 645 mm Req. inlet fl ow rate min. 360 l/h

Weight 17.5 kg 1)

Weight of anti-freeze 25 kg

Heating connection Reinforced hose G

Article no. 6811500 Input pressure Max. 10 bar

Perm. operating temperature 70 °C Minimum fl ow pressure 1) p0 + 1.3 bar

Width x Depth x Height 240 x 91 x 304 mmOutput pressure 0.5 - 5 bar(Factory system pressure 3 bar)

Empty weight 3 kg Connection voltage 230 V/50 Hz

Inlet/outlet connection R ½/R ½

Water make-up systems & water treatment

3) as a single assembly4) in conjunction with Fillset

1) without water volume2) if exceeded, fi t pressure reducing valve upstream

1) p0 = pst + 0.2 (recommendation)static pressure (= stat. height [m]/10)

* Use FE external pressure sensor with Fillsoft

1) p0 = Gas input pressure in expansion vessel= minimum operating pressure of the system

2) if exceeded, fi t pressure reducing valve upstream

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Fillset

Fillset Compact

Fillsoft I/II

• Connection group for water make-up systems in line with DIN 1988 and DIN 1717 for direct connection to potable water networks

• With DVGW-certifi ed system separator type BA• Input and output-side shut-offs• Including standard/contact water meter and wall bracket

• Connection group for water make-up systems in line with DIN 1988 and DIN 1717 for direct connection to potable water networks

• With DVGW-certifi ed system separator type BA• Input and output-side shut-offs

Article no. 1) 8811105 Inlet/outlet connection R ½/R ½

Article no. 2) 8811205 Input pressure Max. 10 bar

Perm. excess operating pressure 10 bar Minimum fl ow pressure 3) Max. 10 bar

Perm. operating temperature 60 °C Flow coeffi cient 4) kvs 0.8 m3/h

Width x Height 293 x 230 mm Flow coeffi cient 5) kvs 0.7 m3/h

Weight 1.7 kg

Article no. 8811305 Inlet/outlet connection R ½/R ½

Perm. excess operating pressure 10 bar Input pressure Max. 10 bar

Perm. operating temperature 60 °C Minimum fl ow pressure 1) p0 + 1.3 bar

Width x Height 175 x 214 mm Flow coeffi cient 2) kvs 0.8 m3/h

Weight 0.9 kg Flow coeffi cient 3) kvs 0.7 m3/h

Article no. for Fillsoft I 8811600 Weight of Fillsoft I 4.1 kg

Article no. for Fillsoft II 8811700 Weight of Fillsoft II 7.6 kg

Perm. excess operating pressure 8 bar Inlet/outlet connection Rp ½/Rp ½

Perm. operating temperature 40 °C Capacity of Fillsoft I 6,000 l x °dH

Height 600 mm Capacity of Fillsoft II 12,000 l x °dH

Max. continuous fl ow 0.4 m3/h

1) with standard water meter2) with contact water meter3) p0 = Gas input pressure in expansion vessel

= minimum operating pressure of the system

1) p0 = Gas input pressure in expansion vessel= minimum operating pressure of system

4) as a single assembly5) in conjunction with Fillcontrol Plus, Variomat, Refl exomat or Servitec

2) as a single assembly3) in conjunction with Fillcontrol Plus, Variomat, Refl exomat or Servitec

Accessories

Article no.

Fillmeter 9119193Softmix 9119219External pressure sensor 9112004Fillsoft cartridge 6811800Total hardness testing kit 6811900

FillmeterFillmeter

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Reflex Winkelmann GmbHGersteinstrasse 19

59227 Ahlen, Germany

Tel.: +49 2382 7069-0Fax: +49 2382 7069-588

www.reflex.de

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