Pressurisation Systems

Reflexomat, Variomat
Reflex—
a powerful brand for decades
Reflex Winkelmann GmbH—part of the Building+ With its energy-efficient and sustainable products,
Industry division—is a leading provider of highquality the company is already doing its bit to help the
heating and hot water supply technology systems. environment, as evidenced by its commitment to
Under its Reflex brand, the company, which has its sustainability and the climate policy goals agreed by
headquarters in Ahlen in the German region of the German Federal Government. This support is
Westphalia, develops, produces and sells not only built on proven technologies and future-oriented
diaphragm expansion vessels, but also innovative innovations. What’s more, Reflex Winkelmann GmbH
components and holistic solutions for pressure works together with others as equals, always maintains
maintenance, water make-up, degassing and water its focus on the customer and offers additional
treatment, storage water tanks and plate heat services such as its own factory service centre fleet and
exchangers, as well as hydraulic manifold and tank a comprehensive range of training options.
components. Reflex ­Winkelmann ­GmbH has about
2,000 employees worldwide, giving it an international
presence in all major markets.

2
Contents

Reflex City p. 4

Dynamic pressure maintenance p. 6

Reflexomat
Key advantages p. 9
Design, function and application p. 10
Product range p. 13
Make-up options p. 17
Selection and calculation p. 18
Installation and commissioning p. 20

Variomat
Key advantages p. 24
Design, function and application p. 26
Product range p. 30
Selection and calculation p. 36
Installation and commissioning p. 40

Network solutions using Reflex Control

Key advantages p. 44
Reflex Control overview p. 45
Communication overviews p. 46
Network solutions using Reflex Control p. 48

Services p. 50

New configuration software

Reflex Solutions Pro

rsp.reflex.de/en
→ Read more on page 50

3
 Reflex City
Variomat

Reflexomat Silent Compact

Reflexomat

4
 Variomat Giga

Reliable pressure maintenance for any requirements We offer a broad portfolio of pressurisation stations to enable
Living, shopping, working, manufacturing: cities are synonymous automated and precise pressure maintenance in systems with the
with diversity. The requirements for supply technology are as broadest spectrum of different requirements: Office buildings from
individual as the buildings themselves. Whether it’s a 5 kW facility in 100 kW heating capacity or more to power plants up to 300 MW,
a detached home or a safety-related cooling system in a computer water as hot as 250 °C or cooling water with -10 °C, flat buildings
centre—Reflex offers products and solutions for systems of all 10 m tall to high-rises up to 200 m tall, as well as customised
sizes and complexities. As shown in our Reflex City concept. solutions for complex hydraulic systems.

5
Pressurisation stations

Dynamic pressure maintenance

Basic principles of pressure maintenance

Pressure maintenance systems play a key role in heating, cooling The pressure changes in a closed heating, cooling or solar system
and solar systems, as well as in pressure boosting systems. when temperature or physical factors cause volume changes in the
Essentially, they have to perform three important tasks: system water. The fluctuations in pressure must be controlled in
these systems. This is achieved by maintaining pressure consistency
1. To keep the pressure within permissible limits at all points of the with the use of expansion vessels that accommodate these changes
system. This means the permissible operating pressure must not in volume and keep the pressure within permissible limits. Depending
be exceeded, but also that a minimum pressure has to be on the relevant application, optimum pressure maintenance can be
ensured to prevent vacuums, cavitation and vapourisation. achieved with two different pressure maintenance systems:
2. To compensate volume fluctuations in the system water due to Z
Static pressure maintenance system:
temperature fluctuation.
Diaphragm expansion vessels
3. Balance out system-related water losses, e.g. by providing Z
Dynamic pressure maintenance system:
a water seal.
Pressurisation stations

Advantages of dynamic pressure maintenance

Pressure maintenance stations are the next generation improve- a control unit that can be used to change the volume in a
ment on conventional diaphragm expansion vessels with static connected vessel and ensures highly efficient performance.
pressure pads. The difference in principle lies in the addition of This approach produces three key advantages:

1. Automated and monitored operation

The control unit offers all the opportunities associated with automated and monitored operation,
which is the decisive reason for a pressurisation station even for smaller capacities starting from
around 300 kW.

2. Smaller vessel volume saves space

Virtually the entire capacity of the expansion vessel can be used to accommodate expansion water.
As a result, vessel volume can be reduced by up to approximately ⅓ compared to a diaphragm
expansion vessel.

3. Reliable pressure maintenance

The minimum operating pressure is programmed on the controller, which automatically monitors
the pressure settings. Any deviations are immediately remedied to ensure reliable facility operation.

6
 Pressure maintenance

Pressurisation stations made by Reflex

A distinction is made between two types of dynamic pressure
maintenance system:

Compressor-controlled pressure maintenance: Reflexomat Pump-controlled pressure maintenance: Variomat

Z
A compressor controls the pressure on the gas side of the vessel. Z
Pumps are used to control the pressure on the water side.
Z
If the set pressure is exceeded, the overflow valve opens and Z
If the set pressure is exceeded, the overflow valve opens and
releases air from the expansion vessel. releases water from the system into the expansion vessel. If the
With the pressure dropping, water flows out of the system into pressure falls below the programmed setting, the pump activates
the expansion vessel. If the pressure falls below the programmed and conveys water from the expansion vessel into the system.
setting, the compressor cuts in and feeds air to the gas side of Z
Degassing is included in the performance specification of the
the expansion vessel. As a result, water is forced into the system.
Variomat: A timer controls a partial flow from system to
Z
Reflexomat can be upgraded with additional make-up and pressureless expansion vessel, where it depressurises. In slight
degassing equipment. The option for intelligent make-up and overpressure, released gases escape through a special valve.
degassing inclusion is already integrated in the control unit of Z
Make-up is also part of the performance specification. If the
Reflex Control.
water falls below the lower level, the leakage and tube fracture
detection capability ensures automatic make-up.

Air compressor Solenoid discharge

valve opens

Expansion water Overflow

Expansion water
flows in opens
flows in

Pressure maintenance pump

7
Pressurisation stations

Dynamic pressurisation

Compressor-controlled Pump-controlled

Compact design Custom designed units Applications up to 8 MW Applications > 4 MW

Reflexomat Silent Compact Reflexomat Variomat Variomat Giga

1 compressor 1 compressor 2 compressors 1 pump 1 pump 2 pumps 2 pumps

Up to 500 litres Without softstart

RSC RS …/1 RS …/2 VS 1 VS 2-1 VS 2-2 GS + GH

Control Basic Control Basic Control Touch Control Basic Control Touch Control Touch Control Touch
Control Touch

8
 Reflexomat

Key advantages
Reflexomat
Precise and reliable pressure maintenance Easy installation and commissioning
Flexible pressure maintenance within the tightest
Z
Supplied pre-assembled and ready for operation
Z

limits ±0.1 bar

Easy to install and put into service
Z

Standard systems with one or two compressor units

Z

Low-maintenance operation
Z

High-quality butyl diaphragm protects expansion

Z

water from air ingress

Highly modern, user-friendly controller Comprehensive system extension
With expandable microprocessor controller, the
Z
Automatic controlled make-up can be added in
Z

control concept Reflex Control (controlled by the level sensor on the RG primary
vessel)
Master-Slave operation enables parallel operation
Z

of up to 10 pressurisation stations (from RS 90/1) Combination with Reflex Servitec vacuum spray tube
Z

degassing (controlled via Reflexomat)

Fully automatic operation with data interface (from
Z

RS 90/1) for incorporation into modern building

management systems

9
Pressurisation stations

Design, function and application

Reflexomat design
Reflexomat
RS control unit RG primary vessel

+ Accessories

Air safety valve

Transport aid
(from 1,000 l)

Vessel
Control unit Available in 6, 10 and 16 bar

Controller with highly modern functions and design,

guarantees optimum ease of operation. All Reflex
controllers (Variomat, Reflexomat, Servitec) have been Anti-corrosion coating on
designed to meet uniform design guidelines the inside

MBM II
bladder rupture detector

Bladder
High-quality material
reliably protects the
expansion water from
air ingress

Flexible connection
ensures optimal operating
of the level control

Pressure pick-up
(level sensor)
For determining the
Maximum reliability and quiet Robust mounting skid for filling level
compressor, equalises up compressor and control unit
to 12 MW

10
 Reflexomat

Reflexomat–functional principle for heating

Low temperature
1 Temperature increase
2
The Reflexomat is fed the If the system temperature—and
minimum amount of water at with it, the pressure—increases,
the lowest system temperature. the controller responds immedi-
ately by opening the solenoid
discharge valve. The expansion
water can then be taken up by
the vessel.

3 4
Full capacity Cool down
At maximum system temperature, If the system cools down, the
the Reflexomat stores all the system pressure drops and the
expansion water and reaches the Reflexomat feeds the expansion
maximum filling level in normal water back into the system with
operation. the aid of the compressor. The
maximum pressure fluctuation is
±0.1 bar.

5
Make-up
If the water content in the vessel
sinks below the defined target
value, the Reflexomat auto­
matically opens the make-up
valve (optional accessory) to
balance out the water loss on
the system side.

Videos showing how our products work can

be found at
www.reflex-winkelmann.com/int/
services-downloads/video-area

11
Pressurisation stations

Applications
Reflex pressurisation stations always consist of a controller, hydraulic system and one or
more vessels. A huge range of customised solutions can be developed with the broad
selection of matching components and the extremely precise control design.

Reflexomat Silent Compact (RSC)

Z
Control unit on the expansion vessel
Z
Maximum performance on minimum footprint
Z
200-500 litre expansion vessel
Z
Up to 2 MW system capacity

Reflexomat (RS …/1)

Z
One compressor
Z
Up to 12 MW
Z
With separate control unit
Z
200-5,000 litre expansion vessel
Z
Any number of RF secondary vessels can be installed

Reflexomat (RS …/2)

Z
Two compressors
Z
Up to 24 MW
Z
With separate control unit
Z
200-5,000 litre expansion vessel
Z
Additional compressors and any number of RF secondary
vessels can be installed

Do your requirements extend beyond our standard

products? Our Project Sales Team can customise a
solution to suit your individual requirements:
[email protected]

12
 Reflexomat

Reflexomat product range

Reflexomat Silent Compact
d

Z
Compressor-controlled pressurisation system in a compact design for

Technical
features
heating- and cooling-watersystems
Z
Approval according to Pressure Equipment Directive 2014/68/EU
Z
Diaphragm according to DIN EN 13831 norm
Z
Degree of protection IP 54
h
Z
Max. operating pressure 6 bar
Z
Power supply 230 V / 50 Hz
Z
Max. operating temperature 70 °C
Z
Permissible ambient temperature 0 – 45 °C

h2
Z
With Control Basic controller, group fault signal and RS-485 interface for
c
internal communication
Z
Automatic water make-up via Fillvalve possible
Reflexomat Silent Compact
Z
Max. permissible system temperature 120 °C

Type Art. No. Raccord Electric Ø Height Height Weight

c power d h h2
Grey [kW] [mm] [mm] [mm] [kg]
RSC 200 8800200 G 1" 0.75 634 1,238 132 52.00
6 bar RSC 300 8800300 G 1" 0.75 634 1,538 133 69.00
70 °C RSC 400 8800400 G 1" 0.75 740 1,522 120 80.00
RSC 500 8800500 G 1" 0.75 740 1,741 120 93.00

+   Reflexomat Silent Compact Accessories

Type Art. No. Weight
[kg]
Bracket
Bracket 90° 8894500 0.10
Commissioning
Commissioning Cat. 3 7945725 0.00
Commissioning add. Cat. 3 7945726 0.00
Cap valve
Cap valve SU R 1" x 1" 7613100 0.57
Solenoid valve
Solenoid valve Fillvalve 7858300 0.95

  See Reflex Product Guide for details of other accessories

13
Pressurisation stations

Reflexomat control units

D D
w w

Reflexomat Control Basic Reflexomat Control Touch

Z
Compressor-controlled pressurisation system for Z
Power supply 230 V / 400 V
Technical
features

heating- and cood water systems Z

Group fault signal and RS 485 interface for internal
Z
Supply temperature 120 °C communication
Z
Max. operating temperature 70 °C Z
Control Touch with graphical user interface, permanent
display of operating parameters, wide array of interfaces,
Z
Permissible ambient temperature 0 – 45 °C
e.g. for control station connection, remote monitoring
Z
Degree of protection IP 54 and system additions

Type Art. No. Electric Electric Height Width Depth Weight

connection power h w D
6 bar 10 bar [kW] [mm] [mm] [mm] [kg]
RS control unit with 1 compressor
Control Basic
RS 90/1 mounted* – 8880111 – 230 V/50 Hz 0.75 395 340 523 21.00
RS 90/1 besides* – 8880211 – 230 V/50 Hz 0.75 683 470 550 25.00
Control Touch
RS 90/1 T – 8880210 – 230 V/50 Hz 0.75 921 480 491 32.00
RS 150/1 T – 8880311 8881311 400 V/50 Hz 1.10 921 480 491 45.00
RS 300/1 T – 8880411 8881411 400 V/50 Hz 2.20 921 370 630 48.00
RS 400/1 T – 8880511 8881511 400 V/50 Hz 2.40 921 565 670 62.00
RS 580/1 T – 8880611 8881611 400 V/50 Hz 3.00 921 636 803 84.00
RS control unit with 2 compressors
Control Touch
RS 90/2 T – 8882100 – 230 V/50 Hz 1.50 921 498 550 45.00
RS 150/2 T – 8883100 8883150 400 V/50 Hz 2.20 921 580 510 60.00
RS 300/2 T – 8884100 8884150 400 V/50 Hz 4.40 921 1,000 752 86.00
RS 400/2 T – 8885100 8885150 400 V/50 Hz 4.80 921 1,230 792 118.00
RS 580/2 T – 8886100 8886150 400 V/50 Hz 6.00 921 1,301 874 196.10
RS control unit without compressor for compressed air supplied on-site 1
Control Basic
RS mounted* 8881100 – – 230 V/50 Hz – 415 395 520 15.00
RS besides* 8881105 – – 230 V/50 Hz – 690 395 345 15.00
Control Touch
RS external air T* 8881400 – – 230 V/50 Hz – 683 470 600 18.00
1 
Includes solenoid valve for the supply of user-provided *mounted = attached controller up to RG 600
14 compressed air (article no.: 7913000) besides = adjoining controller from RG 800
User-supplied compressed air, filtered and oil-free external air = site provided compressed air
max. 10 bar
 Reflexomat

Reflexomat vessels
d

h2
h2 c
c

RG 500 RG 1000
Technical
features

Z
Replaceable bladder according to DIN EN 13831 Z
Max. operating temperature 70 °C
Z
Approval according to Pressure Equipment Directive Z
Max. permissible system temperature 120 °C
2014/68/EU

Primary vessel Secondary vessel

Type Art. No. Height Type Art. No. Height Connection Ø Height Weight
h2 h2 c d h
[mm] [mm] [mm] [mm] [kg]
RG 200 8799100 155 RF 200 8789100 155 G 1" 634 989 37.00
RG 300 8799200 155 RF 300 8789200 155 G 1" 634 1,289 60.70
RG 400 8799300 177 RF 400 8789300 177 G 1" 740 1,277 69.40
RG 500 8799400 177 RF 500 8789400 177 G 1" 740 1,497 78.70
RG 600 8799500 177 RF 600 8789500 177 G 1" 740 1,807 90.10
6 bar RG 800 8799600 177 RF 800 8789600 177 G 1" 740 2,272 110.30
70 °C RG 1000 8650105 193 RF 1000 8652005 460 DN65/PN6 1,000 2,025 308.60
RG 1500 8650305 186 RF 1500 8652205 460 DN65/PN6 1,200 2,020 328.00
RG 2000 8650405 186 RF 2000 8652305 460 DN65/PN6 1,200 2,480 380.00
RG 3000 8650605 220 RF 3000 8652505 490 DN65/PN6 1,500 2,480 795.00
RG 4000 8650705 220 RF 4000 8652605 490 DN65/PN6 1,500 3,053 1,100.00
RG 5000 8650805 220 RF 5000 8652705 490 DN65/PN6 1,500 3,588 1,115.00
RG 350 8654000 196 RF 350 8654300 196 DN40/PN16 750 1,340 230.00
RG 500 8654100 196 RF 500 8654400 196 DN40/PN16 750 1,600 275.00
RG 750 8654200 182 RF 750 8654500 182 DN50/PN16 750 2,179 345.00
RG 1000 8651005 168 RF 1000 8653005 286 DN65/PN16 1,000 2,062 580.00
10 bar
RG 1500 8651205 166 RF 1500 8653205 305 DN65/PN16 1,200 2,054 546.00
70 °C
RG 2000 8651305 166 RF 2000 8653305 284 DN65/PN16 1,200 2,514 485.00
RG 3000 8651505 195 RF 3000 8653505 490 DN65/PN16 1,500 2,532 954.00
RG 4000 8651605 195 RF 4000 8653605 490 DN65/PN16 1,500 3,107 1,192.00
RG 5000 8651705 195 RF 5000 8653705 490 DN65/PN16 1,500 3,642 1,286.00

15
Pressurisation stations

+   Reflexomat Accessories
I/O module Busmodule
Z
Two additional analogue outputs for Z
For exchanging data between controller
pressure and level control and central building management
system
Z
Six freely programmable digital inlets
Z
Six freely programmable floating outputs

Commissioning Bladder rupture detector

Z
7945600: Reflex commissioning Cat. 1 Z
Indication of membrane rupture in
for Reflexomat, Variomat, Servitec with vessels
one compressor/one pump Z
Consisting of an electrode relay and an
Z
7945704: Reflex commissioning add. electrode (factory fitted)
Cat. 1 for each additional system at the Z
Power supply 230 V/50 Hz
same location – one compressor/pump
Z
Floating output (changeover contact)
Z
7945630: Reflex commissioning Cat. 2
for Reflexomat, Variomat, Servitec with Z
Delivery only in combination with a
two compressors/pumps vessel with MBM coupling
Z
7945721: Reflex commissioning add.
Cat. 2 for each additional system at the Solenoid valve
same location – two compressors/ Z
Solenoid and ball valve
pumps
Z
For automatic water make-up with
Reflexomat

More information about the Reflex Control concept Master-Slave

is available from page 44 Z
Software Tool
Z
For the operation of up to ten Reflexomat units in a hydraulic
network over a distance up to 1,000 m

Type Art. No. Weight Type Art. No. Weight

[kg] [kg]
AG connection set Commissioning
AG connection set 1" 9119204 0.85 Commissioning Cat. 1 7945600 0.00
Busmodule Commissioning Cat. 2 7945630 0.00
Busmodule BACnet MS/TP 8860600 0.40 Commissioning add. Cat. 1 7945704 0.00
Busmodule BACnet-IP Touch 8860500 0.40 Commissioning add. Cat. 2 7945721 0.00
Busmodule Ethernet 8860300 1.90 Mounting bracket
Busmodule Modbus RTU Touch 9125592 0.40 Mounting bracket 90° 7881900 4.50
Busmodule Profibus DP 8860200 1.90 Solenoid valve
Busmodule Profibus DP Touch 9118042 0.40 Solenoid valve Fillvalve 7858300 0.95
Bracket Master-Slave
Bracket 115° 8894510 0.10 Master-Slave 7859000 0.10
Bracket 90° 8894500 0.10 Bladder rupture detector
I/O module Bladder rupture detector MBM II 7857700 0.62
I/O module RS 8858405 1.00

16
 Reflexomat

Make-up options
To ensure lasting reliable and automatic operation of the system, have to be entirely eliminated. Automatic make-up is already
we advise fitting the pressurisation equipment with make-up incorporated into the Reflexomat controller and is automatically
systems or adding Servitec degassing systems. This is particularly activated if the primary vessel reaches make-up level.
important for cooling water systems as any thermal venting effects

Automatic make-up with Reflex Fillvalve

230 V
Make-up is controlled by the Reflex Fillvalve solenoid valve using
the inherent pressure of the make-up water. If making up from
Fillvalve Fillset
the drinking water system, the Reflex Fillset with integrated
DVGW-tested system separator must be installed upstream.
Make-up water
Requisite flow
pressure: min. 1.3 bar
higher than the G½" connection
final pressure of the
Reflexomat

Automatic make-up with Reflex Fillcontrol

Reflex Fillcontrol Auto is a make-up station with integrated 230 V Fillcontrol Auto
pump (system separator vessel to isolate the system from the
drinking water system as stipulated in DIN 1988).
max. 5.5 bar,
Reflex Fillcontrol Auto is generally used when the fresh water 4 m³/h
seal pressure is too low for direct make-up without pump
support or when an intermediate vessel is needed to separate
the system from the drinking water system.

Make-up water
max. 6 bar

Make-up and degassing with Reflex Servitec

The Servitec vacuum spray tube degassing function centrally Servitec
degasses the system water and—in Levelcontrol mode—
ensures automated controlled make-up when the make-up level 230 V Make-up water

is reached in the Reflexomat's expansion vessel. When making

up from the drinking water system, the Reflex Fillset must be
installed upstream.
Fillset

Ideal connection: Reflexomat and Servitec

 For further details, please consult our brochure Z
Vacuum spray tube degassing with automatic
“Make-up systems and water treatment technology”
make-up
Z
Ensures that the system and make-up water are
nearly free of gas
Z
Avoids air problems caused by free gas bubbles
at system high points, or in circulating pumps or
control valves

17
Pressurisation stations

Selection and calculation

for heating systems up to 120 °C

Selection of Reflexomat control unit

p0 [bar]

10.0 Z
In this respect, the
9.0 Reflexomat Silent Compact
8.0 (RSC) is equivalent to the
RS 90/1
7.0

6.0 Alternative calculation method

5.0
Control unit with
4.0 1 compressor
0.2 bar [ ≤100 °C ]**
3.0 * 0.5 bar [105 °C ]**
p0 ≥ H [m] +
2.0
10 0.7 bar [110 °C ]**
RS RS RS RS RS 1.2 bar [120 °C ]**
1.0 90/1 150/1 300/1 400/1 580/1
0.5
1 2 3 4 5 6 7 8 9 10 11 12 * H = static height
·
Total output of the heat generating system Q [MW] ** Safety temperature

Reflexomat with one compressor

p0 [bar]
10.0

9.0

8.0

7.0

6.0

5.0 Control unit with 2 compressors

4.0

3.0
RS RS RS RS RS
2.0 90/2 150/2 300/2 400/2 580/2 Z
When selecting the control
1.0 unit for cooling water
0.5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 systems to 30 °C, only 50 %
·
Total output of the heat generating system Q [MW]
of the rated heat output
may be included in the
Reflexomat with two compressors calculation.

Selection of the expansion lines

Expansion lines DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100
1" 1¼" 1½" 2"
.
Q /kW
2,100 3,600 4,800 7,500 14,000 19,000 29,000
Length ≤ 10 m
.
Q /kW
1,400 2,500 3,200 5,000 9,500 13,000 20,000
Length > 10 m ≤ 30 m

If the expansion line is longer than 10 m, we recommend choosing a size larger.

18
 Reflexomat

Selection of Reflexomat vessels

Vn [litres]

200
400
600
800
1,000
1,200
1,500
6 l/
kW
con
2,000 vec
tor Alternative calculation method
s
8.5
2,500 l/k
W
pla
tes
3,000 /v 0.031 [70 °C ]*
en
13

tila Vn ≥ Va x 0.045 [90 °C ]*

.5

tio
l/

n
0.054 [100 °C ]*
kW
ra
20

0.063
dia

[110 °C ]*
l/k

to

4,000
rs
W

* Design flow temperature

Vn = Nominal volume
VA = System water capacity

5,000
1 2 3 4 5 6 7 8 9 10 11 12 13 14
·
Installed output of heating surfaces Q  [MW]

Z
The nominal volume can be split Permissible operating pressure:
between multiple vessels (RG primary Z
Up to 800 litres: 6 bar
and RF secondary vessels). Z
350, 500, 750 litres: 10 bar
Z
More than 1,000 litres: 6 and 10 bar

Basic technical data Calculation Result

Output
· p0 ≥ H [m] bar + 0.2 bar [100 °C] Reflexomat with RS 90/1 control unit
Heat generator Q = 500 kW 10 Reflex primary vessel, 200 litres, RG 200
Water capacity VA= 5,000 litres
p0 ≥ 30 bar + 0.2 bar = 3.2 bar Reflex R 1x1 cap valve
Design temperature = 70 °C
Selection
10
Safety temperature = 100 °C
Vn ≥ VA x 0.031
Static height = 30 m
Vn ≥ 5,000 x 0.031 = 155 litres
example 

19
Pressurisation stations

Installation and commissioning

Installation notes
Z
When installing the oil meter, make sure it is always clean Room temperature
(no paint or coating, etc.). 0 °C to 45 °C
≥ 500
Z
Primary vessel connections to dynamic pressure maintenance
stations must always be flexible to ensure proper functional
performance of the level sensor.
Z
The vessels must be placed on a firm and level base, make sure
they are positioned at right angles and free standing. The control ≥ 600 ≥ 150
unit must be positioned at the same level as the vessels.
Z
When using secondary vessels, always use the same models
and sizes.
Note Please refer to our detailed operating instructions during
installation and commissioning.

Installation clearances

2-compressor system

Connection tube for on-site

installation

Installation
example

on site

20
 Reflexomat

Hydraulic integration
The hydraulic integration of the pressure maintenance into the Intake pressure maintenance (suction pressure maintenance)
facility system has a fundamental influence on the operating The pressure maintenance function is tied in upstream of the
pressure distribution. The latter is composed of the pressure level circulating pump, i.e. on the suction side. This type is the most
when pressure maintenance is not in operation and the differential commonly used as it is the easiest to control.
pressure when the circulating pump is running. We recommend the
use of upstream pressure maintenance:

Z
Direct connection of Reflexomat to heat generator Z
If the bladder is at risk of permanent exposure to
stress > 70 °C, Reflex V auxiliary vessels must be
Z
Low temperature stress on the bladder
incorporated into the expansion line

Z
Use suction pressure maintenance!
Z
Only deviate in justified exceptions.
Z
Please don’t hesitate to get in touch with us!

Working pressure

+
+

+ Idle pressure
S
- Pump
-

Refelxomat

Pressure curve with upstream pressure maintenance (suction pressure maintenance)

21
Pressurisation stations

Installation examples
Solution No- 05 Reflexomat Silent Compact
When installing the oil
meter, make sure it is
mounted on a base and
always clean (no paint
or coating, etc.).

Exvoid T Storatherm Heat

Primary vessel Exvoid steel
connections to dynamic Exdirt steel
pressurisation stations
must always be flexible
to ensure proper
functional performance
of the level sensor.

Sinus Collecteur compact

Reflex

Fillvalve
Fillset Impuls

Reflexomat Silent Compact

Fillsoft I

Solution No- 07 Reflexomat with 1 compressor and auxiliary vessel

If the temperature of
the media is less than Exvoid T
0 °C or more than 70 °C
at the pressure Storatherm Heat
maintenance
integration point into
the system, an auxiliary
vessel must be installed Exdirt V
to protect the bladder in
the expansion vessel.

Incorporate an auxiliary
vessel if the return flow Sinus Compact Manifold Sinus Compact Hydraulic Separator
temperature is > 70 °C!

Reflexomat
Reflex

Fillset

Fillvalve

Fillsoft II
Reflex V

22
 Reflexomat

Reflexomat with 2 compressors and Servitec degassing Solution No- 08

Servitec and Reflexomat
Exvoid T must communicate with
Exvoid T
each other (both are
fitted with a pressure
sensor).

An electrical connection
Exdirt
M M
on site must be put in
place between the
appliances.
>500 mm
Longtherm

.
HydroFixx Servitec must be set to
Levelcontrol mode.

Fillset Impuls Fillsoft II

Reflexomat

Servitec

Reflexomat with secondary vessel in a cooling water system Solution No- 17

Secondary vessels must
be the same and size as
the primary vessel.

Cold buffer vessel

Kälte-Pufferspeicher
In cooling applications,
the pressure
maintenance must be
tied into the warmer
medium to avoid
condensate on the
expansion lines.
Dew point violation is
usually prevented by
the load case at higher
temperatures.
Sinus Compact Manifold

Reflexomat

Reflex

Fillvalve
Fillset Impuls

Fillsoft I

These diagrams are only meant to visualise the interconnections.

Installation must be adapted to local conditions accordingly and must be specified in more detail.
23
 Pressurisation stations

Variomat Key advantages

Pressure maintenance, degassing and make-up Highly modern, user-friendly controller
in a single system
Easy function and modern design ensure optimum-
Z

Z
Reliable pressure maintenance within very operating convenience
tight limits
With extendable microprocessor controller
Z

Z
Efficient, atmospheric degassing of the system water Reflex Control
for long-term operational safety
Master-Slave operation enables parallel operation of
Z

Z
Automatic make-up depending on the filling level up to 10 pressure maintenance stations
Easy installation and commissioning Fully automatic operation with data interface for
Z

incorporation into modern building management

Z
Supplied pre-assembled and ready for operation
Z
Easy to install; no need for mechanical adjustments
Z
Low-maintenance operation

24
 Variomat

Comparison using a heating system as an example

Conventional installation Variomat installation

Z
No need for decentralised
venting

Z
Reliable pressure maintenance
thanks to automated and
monitored operation
Z
No risk of underpressure
forming, unlike MAG

Z
Circuit water with low gas
content:
less corrosion, sludge
formation and malfunctions,
better circulation
Z
Elimination of the need for
mechanical air separators

25
Pressurisation stations

Design, function and application

Variomat design
Variomat
VS control unit Connection set VG primary vessel

+ +

+ Accessories

Exvoid T
Air vent with check valve

Expansion band
Pressure equalisation between vessel and atmosphere

Butyl bladder
Isolates the air from the
water and protects the
system water against air
ingress
Pressure maintenance Controller
pump(s)
MBM II bladder
rupture detector

Flexible connection set

For the expansion line;
crucial to ensure proper
operation of the level
sensor

Pressure cell
Pressure relief tube Make-up tube (level sensor)
With motorised ball valve The solenoid valve opens For measuring the filling
and patent-protected automatically when the level level
automatic function in the primary vessel falls
below the set filling level

26
 Variomat

Variomat Giga design

Variomat Giga
GS control unit GH hydraulic module GG primary vessel

+ +

+ Accessories

Flexible connection
For the expansion line;
crucial to ensure proper
performance of the level
sensor

Pressure cell
(level sensor)
For measuring the filling
level

Safety valve
Safeguard for the GG and
Pressure relief tube GF vessels

Min.-pressure limiter
Connection
GG primary vessel
Connection DN 80/PN 6
DN 80/PN 16 expansion line
Make-up solenoid valve

Shut-off
Safeguarded against accidental Pump
closure Pump
Throttle valve

27
Pressurisation stations

Variomat–function principle

1 2 3
Low temperature Temperature increase Full capacity
The Variomat is fed the If the system temperature–and At maximum system tempera-
minimum amount of water with it, the pressure–increases, the ture, the Variomat stores all the
at the lowest system controller responds immediately by expansion water and reaches the
temperature. opening the pressure relief tube. highest filling level in normal
Expansion water flows into the operation.
pressureless vessel and is degassed
by means of pressure relief.

4 5 6
Cool down Make-up Continuous/interval degassing
If the system cools down, the If the water content in the vessel Pump and overflow ball valve are
system pressure drops and the sinks below the defined target both in operation. System pressure
Variomat feeds the expansion value, the Variomat automatically remains stable within the target
water back into the system opens the make-up valve to value range. System water is
with the aid of the pump. The balance out the water loss on the specifically channelled through the
maximum pressure fluctuation system side. primary vessel and degassed by
is ±0.2 bar. means of pressure relief.

28
 Variomat

Do your requirements exceed our standard products?

Our Project Sales Team can customise a solution to
suit your individual requirements:
[email protected]

Applications
By combining the various control and hydraulic designs, and Variomat Giga can even satisfy the extreme requirements of
different vessels, Variomat systems can meet requirements in a industrial heal supply and district heating supply.
whole host of different areas.

Variomat (VS 1) Variomat (VS 2-1)

Z
One pump Z
Control Basic Z
One pump Z
Control Touch
Z
Up to 8 MW Z
200–500 litre Z
Up to 8 MW Z
200–5,000 litre
expansion vessel expansion vessel
Z
Without soft start Z
With soft start

Variomat (VS 2-2) Variomat Giga

Z
Two pumps Z
Control Touch Z
Two pumps Z
Additional pumps and
any number of VF
Z
Up to 8 MW Z
200–5,000 litre Z
> 4 MW
secondary vessels can
expansion vessel
Z
With soft start Z
Control Touch be installed
Z
1,000–5,000 litre
expansion vessel,
customised vessels
on request

29
Pressurisation stations

Variomat product range

Variomat control units

D D
w w

Variomat VS 1 Variomat VS 2-2 95

Z
Approval according to Pressure Equipment Directive Z
Permissible ambient temperature 0 – 45 °C
Technical
features

2014/68/EU Z
Sound pressure level ~ 55 dB (A)
Z
Variomat controller VS 1 with Control Basic control unit Z
Degree of protection IP 54
Z
From Variomat controller VS 2 with Control Touch Z
Connection water make-up Rp ½"
controller and softstart
Z
Group fault signal and RS 485 interface for internal
Z
Supply temperature 120 °C
communication
Z
Max. operating temperature 70 °C

Type Art. No. Max. Electric Connection Electric Height Width Depth Weight
p0 setting connection c power h w D
[bar] [kW] [mm] [mm] [mm] [kg]
Control unit VS with 1 pump
Control Basic control unit
6 bar
VS 1 8910100 2.5 230 V/50 Hz Rp 1" 0.70 681 470 570 25.00
70 °C
Control Touch control unit
VS 2-1/35 8910110 2.5 230 V/50 Hz Rp 1" 0.80 921 470 572 30.00
10 bar VS 2-1/60 8910200 4.8 230 V/50 Hz Rp 1" 1.10 921 470 572 36.90
70 °C VS 2-1/75 8910300 6.5 230 V/50 Hz Rp 1" 1.10 921 470 588 49.90
VS 2-1/95 8910400 8.0 230 V/50 Hz Rp 1" 1.10 921 470 588 51.40
16 bar
VS 1-1/140 8910500 13.0 400 V/50 Hz Rp 1" 2.20 964 470 557 47.00
70 °C
Control unit VS with 2 pumps
Control Touch control unit
VS 2-2/35 8911100 2.5 230 V/50 Hz G 1 ¼" 1.50 921 750 799 57.50
10 bar VS 2-2/60 8911200 4.8 230 V/50 Hz G 1 ¼" 2.20 921 750 799 61.10
70 °C VS 2-2/75 8911300 6.5 230 V/50 Hz G 1 ¼" 2.20 921 750 706 89.00
VS 2-2/95 8911400 8.0 230 V/50 Hz G 1 ¼" 2.20 921 750 706 92.00
16 bar
VS 1-2/140 8911500 13.0 400 V/50 Hz Rp 1 ¼" 2.20 964 750 698 85.00
70 °C

30
 Variomat

Variomat vessels & heat insulation

d d

c
h2
h2
c

Variomat VG 500 Variomat VG 1000 Variomat VW

Z
Replaceable bladder according to DIN EN 13831 Z
Max. operating temperature 70 °C
Technical
features

Z
Approval according to Pressure Equipment Directive Z
Max. permissible system temperature 120 °C
2014/68/EU Z
Optional heat insulation, 50 mm thick

Primary vessel Secondary vessel Heat insulation

Type Art. No. Height Type Art. No. Height Connec- Ø Height Weight Type Art. No. Weight
h2 h2 tion d h
c
[mm] [mm] [mm] [mm] [kg] [kg]
VG 200 8600011 146 VF 200 8610000 146 G 1" 634 1,057 33.70 VW 200 5990100 3.00
VG 300 8600111 146 VF 300 8610100 146 G 1" 634 1,357 55.20 VW 300 5990200 3.50
VG 400 8600211 133 VF 400 8610200 133 G 1" 740 1,344 72.20 VW 400 5991300 4.50
VG 500 8600311 133 VF 500 8610300 133 G 1" 740 1,564 81.10 VW 500 5990000 5.50
VG 600 8600411 133 VF 600 8610400 133 G 1" 740 1,807 96.80 VW 600 5990500 6.00
VG 800 8600511 133 VF 800 8610500 133 G 1" 740 2,272 109.90 VW 800 5990300 8.00
VG 1000/ VF 1000/ VW 1000/
6 bar 8600611 133 8610600 133 G 1" 740 2,737 156.00 5990400 8.00
740 740 740
70 °C
VG 1000/ VF 1000/ VW 1000/
8600705 348 8610705 348 G 1" 1,000 2,127 270.00 5991400 9.00
1000 1000 1000
VG 1500 8600905 346 VF 1500 8610905 346 G 1" 1,200 2,127 300.00 VW 1500 5991000 10.60
VG 2000 8601005 346 VF 2000 8611005 346 G 1" 1,200 2,587 400.00 VW 2000 5989700 13.00
VG 3000 8601205 375 VF 3000 8611205 375 G 1" 1,500 2,588 740.00 VW 3000 5108700 15.00
VG 4000 8601305 375 VF 4000 8611305 375 G 1" 1,500 3,160 820.00 VW 4000 5989800 17.00
VG 5000 8601405 375 VF 5000 8611405 375 G 1" 1,500 3,695 980.00 VW 5000 5991100 21.80

31
Pressurisation stations

Variomat connection set

2 connecting hoses
G 1" x G 1" with safe
shut-off

Variomat connections for systems with one pump

2 connecting hoses
G 1 ¼" x G 1"

Variomat connection set Variomat connections for systems with two pumps

Type Art. No. Weight

[kg]
Variomat connection set for systems with one pump
Connection set VS 1/VS 2-1 Ø 1,000–1,500 mm 6940200 1.90
Connection set VS 1/VS 2-1 Ø 480–740 mm 6940100 1.55
Variomat connection set for systems with two pumps
Connection set VS 2-2 Ø 1,000–1,500 mm 6940400 2.15
Connection set VS 2-2 Ø 480–740 mm 6940300 1.85

The secured shut-off for systems with 1 pump is

included in the connection set.
The secured shut-off for systems with 2 pumps is
included on the control unit.

32
 Variomat

More information about the Reflex Control concept

is available from page 44

+   Variomat Accessoires
I/O modules Busmodule
Z
Two additional analogue outputs for Z
For exchanging data between controller
pressure and level control and central building management
system
Z
Six free-programmable digital inputs
Z
Six free-programmable floating outputs

Master-Slave Valve
Z
Software Tool Z
Reliable make-up for special applications
Z
For the operation of up to ten Variomat/-Giga units Z
Part number available with pre-assembled
in a hydraulic network over a distance up to 1,000 m Safecontrol on request
Z
Rp ½"

Commissioning Bladder rupture detector MBM II

Z
7945600: Reflex commissioning Cat. 1 for Z
Indication of membrane rupture in
Reflexomat, Variomat, Servitec with one vessels
compressor/one pump Z
Consisting of an electrode relay and an
Z
7945704: Reflex commissioning add. Cat. 1 electrode (factory fitted)
for each additional system at the same Z
Power supply 230 V/50 Hz
location – one compressor/pump
Z
Floating output (changeover contact)
Z
7945630: Reflex commissioning Cat. 2 for
Reflexomat, Variomat, Servitec with two Z
Delivery only in combination with a
compressors/pumps vessel with MBM coupling
Z
7945721: Reflex commissioning add. Cat. 2
for each additional system at the same
location – two compressors/pumps

Type Art. No. Weight Type Art. No. Weight

[kg] [kg]
Busmodule Commissioning
Busmodule BACnet MS/TP 8860600 0.40 Commissioning Cat. 1 7945600 0.00
Busmodule BACnet-IP Touch 8860500 0.40 Commissioning Cat. 2 7945630 0.00
Busmodule Ethernet 8860300 1.90 Commissioning add. Cat. 1 7945704 0.00
Busmodule Modbus RTU Touch 9125592 0.40 Commissioning add. Cat. 2 7945721 0.00
Busmodule Profibus DP 8860200 1.90 Master-Slave
Busmodule Profibus DP Touch 9118042 0.40 Master-Slave 7859100 0.10
I/O module Bladder rupture detector
I/O module VS 8997705 1.00 Bladder rupture detector MBM II 7857700 0.62
Valve
Valve Safecontrol 9119352 0.97

33
Pressurisation stations

Variomat Giga product range

Variomat Giga control & hydraulic module

Z
Pump-controlled pressurisation station with integrated water make-up

Technical
features
and degassing (Return ≤ 70 °C) for hot and cold water systems
Z
With two pumps and two overflow valves
Z
Max. operating pressure 16 bar
h Z
Supply temperature 120 °C
Z
Max. operating temperature 70 °C
Z
Sound pressure level ~ 55 dB (A)
Z
Connection Pump DN 80 / PN 16
D
w Z
Connection Primary vessel DN 80 / PN 6
Z
Connection water make-up Rp ½"
Variomat Giga Z
Control Touch control unit

Type Art. No. For hydraulic Max. p0 Electric Connection Electric Height Width
Depth Depth Weight
module setting connection c power h Pw[mm] D
[bar] [kW] [mm] [mm] [mm] [kg]
Control Units
GS 1.1 8912500 GH 50 /  GH 70 – 230 V/50 Hz – 2.20 921 380 477 8.00
GS 3 8912600 GH 90 /  GH 100 – 400 V/50 Hz – 6.00 921 380 477 8.00
Hydraulic modules
GH 50 8931000 – 4.0 230 V/50 Hz DN80/PN16 2.20 1,194 1,168 830 203.00
16 bar GH 70 8932000 – 6.0 230 V/50 Hz DN80/PN16 2.20 1,194 1,168 830 206.00
70 °C GH 90 8931400 – 8.0 400 V/50 Hz DN80/PN16 6.00 1,194 1,168 830 270.00
GH 100 8931200 – 9.5 400 V/50 Hz DN80/PN16 6.00 1,194 1,168 830 275.00

Two control units can also be connected in

parallel operation.
For example, two standard Variomat Gigas with
30 MW each can be combined to form a single
60 MW system.

34
 Variomat

Variomat Giga vessels

d d

h h

h2 h2

c c

Vase de base GG Vase complémentaire GF

Replaceable bladder to DIN EN 13831 Max. operating temperature 70 °C

Technical
features

Z Z

Z
Approval according to Pressure Equipment Directive Z
Max. permissible system temperature 120 °C
2014/68/EU

Primary vessel Secondary vessel

Type Art. No. Height Type Art. No. Height Connection Ø Height Weight
h2 h2 c d h
[mm] [mm] [mm] [mm] [kg]
GG 1000 8920105 285 GF 1000 8930105 285 DN65/PN6 1,000 2,127 270.00
GG 1500 8920305 285 GF 1500 8930305 285 DN65/PN6 1,200 2,127 340.00
6 bar GG 2000 8920405 285 GF 2000 8930405 285 DN65/PN6 1,200 2,587 430.00
70 °C GG 3000 8920605 314 GF 3000 8930605 314 DN65/PN6 1,500 2,588 651.00
GG 4000 8920705 314 GF 4000 8930705 314 DN65/PN6 1,500 3,163 890.00
GG 5000 8920805 314 GF 5000 8930805 314 DN65/PN6 1,500 3,698 980.00

+   Variomat Giga Accessories

SV1 safety valve Type Art. No. Weight
[kg]
Z
For additionally safeguarding GG and GF vessels at Commissioning
rated heat outputs > 10.5 MW Commissioning Variomat Giga 7945724 0.00
Miscellaneous accessories
SV1 safety valve 9119352 0.97

Further accessories can be found on page 33

35
Pressurisation stations

Selection and calculation

for heating systems up to 120 °C

Selection of Variomat control unit & Reflex control vessel

Selection of control units
Variomat with 1 pump Variomat with 2 pumps Selection of the expansion lines*

Selection of the control vessel(s)

p0 [bar] p0 [bar]
[total volume in litres]
14.0 14.0

13.0 13.0 140 l 200 l

140 l 300 l
12.0 12.0
VS
DN 32
11.0 1-1/140 11.0 VS
1-2/140 400 l
10.0 200 l 10.0

9.0 9.0 DN 40 DN 50

8.0 8.0
VS 80 l VS 140 l
7.0 2-1/95 7.0 2-2/95
DN 32
50 l 100 l 80 l
6.0 6.0 VS
VS 100 l
2-1/75 2-2/75
5.0 DN 32 5.0
50 l 80 l 80 l 140 l
4.0 VS 4.0
140 l VS
2-1/60 DN 32 100 l 200 l
3.0 3.0 2-2/60
80 l 100 l
DN 25 DN 32 50 l 200 l
2.0 2.0
VS 1 35 l 50 l 100 l VS 35 l 80 l 140 l
1.0 VS 2-1/35 1.0
2-2/35

0 1 2 3 4 0 1 2 3 4 5 6 7 8
·
Total output of the heat generating system Q [MW]

Selection of control units Selection of control vessels

Alternative calculation method Unlike pressure expansion vessels or compressor-controlled
pressure maintenance, gas cushions do not act as shock absorbers
0.2 bar [≤100 °C ]**
in pump-controlled pressure maintenance. A control vessel must
0.5 bar [105 °C ]** therefore be incorporated to absorb the shocks occurring when the
*
p0 ≥ H [m] + pump runs up and down.
10 0.7 bar [110 °C ]** * H = Static height
1.2 bar [120 °C ]** ** Safety temperature
If installed correctly, it does not share in the main task of maintain-
ing pressure. The dimensioning of a control vessel is dictated by the
characteristic values p0 and the expansion flow rate of the system,
rather than by the type of pressure maintenance station.
In the absence of individual protection and pump redundancy, we
recommend the rapid selection process described above when
dimensioning the control vessels.

* If the expansion line is longer than 10 m, we recommend choosing a size larger.

36
 Variomat

Selection of Variomat vessels

Vn [litres]

200
400
600
800
1,000 6 l/k
1,200 W co
nvect
ors
8.5
1,500 l/kW
plat
es/
ven
tilat
2,000 ion
13.
5l
/k
W
2,500 rad
iat Alternative calculation method
ors

3,000
20
l/ 0.031 [70 °C ]*
kW
Vn ≥ Va x 0.045 [90 °C ]*
0.054 [100 °C ]*
4,000

* Design flow temperature

Temps élémentaire pour Vn = Nominal volume
90/70 °C VA = System's water capacity
Systèmes de chauffage
5,000
1 2 3 4 5 6 7 8
·
Installed output of heating surfaces Q  [MW]

Z
Nominal volume Vn approximation from Z
The nominal volume can be split
sketch or calculated using a formula between multiple vessels (VG primary
and VF secondary vessels).

Customised solutions and higher outputs or

temperatures > 120 °C are available on request.

Basic technical data Calculation Result

Output p0 ≥ H [m] bar + 0.7 bar [110 °C] selected
· 10
Heat generator Q = 3,000 kW Variomat 2-2/60 control unit
Water capacity VA = non précisé + VG primary vessel (e.g. Ø 1,000) 1,000 litres
Selection
p0 ≥ 25 bar + 0.7 bar = 3.2 bar
(approximation from installed heat output 10 + VF secondary vessel (e.g. Ø 1,000) 1,000 litres
·
Q = 3,000 kW, radiators, 90/70 °C, no additional = 2,000 litres
district heating tubes) Nominal volume
from the sketch
VA = 1,800 litres
+ VW heat insulation 1,000 litres example 
Design temperature = 90 °C + G 1¼" connection set, Ø 1,000
Safety temperature = 110 °C + Reflex R 1x1 cap valve
Static height = 25 m + Expansion line = DN 50

37
 Pressurisation stations

Selection of Variomat Giga hydraulic module

p0 [bar]

Selection of the hydraulic module GH

10.0
Selection of the control vessel(s)
larger models on request [total volume in litres]
9.0 GH 100
600 l

8.0
300 l 400 l
GH 90
600 l
7.0

6.0
GH 70 200 l
5.0 Alternative calculation method
250 l
0.2 bar [≤100 °C ]**
4.0
140 l 0.5 bar [≤105 °C ]**
GH 50 300 l
* 0.7 bar [≤110 °C ]**
3.0 p0 ≥ H [m] +
250 l 10 1.2 bar [120 °C ]**
300 l 1.9 bar [130 °C ]**
2.0
2.8 bars [140 °C ]**

1.0 * H = Static height

** Safety temperature

1 2 3 4 5 10 15 20 21
·
Total output of the heat generating system Q [MW]

Z
When selecting the control unit for
cooling water systems to 30 °C, only
50 % of the rated heat output may be
included in the calculation.

Selection of the expansion lines

Expansion lines DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100
1" 1¼" 1½" 2"
.
Q /kW
2,100 3,600 4,800 7,500 14,000 19,000 29,000
Length ≤ 10 m
.
Q /kW
1,400 2,500 3,200 5,000 9,500 13,000 20,000
Length > 10 m ≤ 30 m

If the expansion line is longer than 10 m, we recommend choosing a size

38
 Variomat

Selection of Variomat Giga vessels

Vn[litres]

35,000

30,000

25,000

 °C
110
20,000
 °C
100
Alternative calculation method
C
15,000 90 °
0.031 [70 °C ]*
Vn ≥ Va x 0.045 [90 °C ]*
Variant 1 70 °C
10,000 0.054 [100 °C ]*
Variant 2 0.063 [110 °C ]*

5,000 * Design flow temperature

Vn = Nominal volume
VA = System's water capacity

50 100 150 200 250 300 350 400 450 500

Va/m³

Z
Nominal volume Vn approximation from sketch or
calculated using a formula
Customised solutions and higher outputs or
Z
The nominal volume can be split between multiple temperatures > 120 °C are available on request.
vessels (GG primary and GF secondary vessels).

Basic technical data Calculation Result

·
Heat generator Q = 2x 6,500 kW p0 ≥ H [m] bar + 1.2 bar [120 °C] Variant 1 :
10 Vn for design flow temperature = 110 °C
= 13,000 kW
25 Vn = 0,063 x VA
Water capacity VA = 156 m³ p0 ≥ bar + 1.2 bar = 3.7 bar
10 = 0,063 x 156 m³ = 9.82 m³
Design flow
temperature = 110 °C

Design return
Variant 2 : Selection
Vn for average
temperature = 70 °C 110 + 70 °C

Safety temperature = 120 °C

system temperature
2
= 90 °C
example 
Static height = 25 m Vn = 0,045 x VA = 7.02 m³*

* The decision must be made after consultation with the

operator and—if the systems are subject to mandatory
testing—the Notified Body, as to whether the max.
flow temperature or e.g. the average system
temperature is to be used.

39
Pressurisation stations

Installation and commissioning

Installation notes
Z
Primary vessel connections must always be flexible to ensure
proper functional performance of the level sensor. Room
≥ 500 temperature
0 °C to 45 °C
Z
The connection set from the Reflex range of accessories must be
used to connect the vessels. The secondary vessel is connected
on site.
Z
Primary and secondary vessels must be installed on the same
≥ 600 ≥ 150
level (height) and close to each other.
Z
The control vessel is either tied into the expansion line or used
as individual protection for the generator. The upstream pressure
of control vessel p₀ must be set to the minimum operating
pressure p₀ of the pressure maintenance station. Differences in
static height must be taken into consideration.
Side and ceiling clearances to be observed during installation

≥ 500 mm*
VG primary VF secondary** max 70 °C
System with 1 pump | |
Room temperature
Integration detail
Fillset
0 °C to 45 °C p. 41

NS P Ü

Installation * 500 mm for vessels up to Ø 740 mm Control unit G 1" connection

** with flexible connection
examples
530 500*

System with 2 pumps ≥ 500 mm* VG primary VF secondary** max 70 °C

| |

Integration detail
Fillset p. 41

NS P Ü

* 900 mm for vessels more than Ø 1,000 mm Control unit G 1¼" connection
** with flexible connection 700 900*

40
 Variomat

Flow rates
The Variomat degassing function will only work reliably if the Variomat
Variomat is tied into a representative main flow of the facility
·
system. The following minimum flow rates V must be adhered to 1 2-1 2-2/35 2 -2/60-95
in operation. Given a spread of dT = 20 K, this corresponds to a ·
·  V 2 m³/h 4 m³/h 2 m³/h 4 m³/h
minimum design output of the customer's facility of Q. ·
Q 47 kW 94 kW 47 kW 94 kW

Hydraulic integration
To avoid any coarse dirt getting directly into the Variomat, the connection tubes must be
tied in from above, from the side, or from below as immersion tubes into the main line.
A minimum distance of 500 mm between the integration points must be observed.

≥ 500

≥ 500

≥ 500
from above from below from the side
immersion tube (optionally horizontal or vertical)

Caution: dirt!
Z
Tying the pump and pressure relief tubes into the system in Z
If the Fillset is not installed, at the very least a dirt trap (mesh-
such a way as to avoid the ingress of coarse dirt (see above). size < 0.25 mm) must be incorporated to protect the make-up
Dimensioning the expansion lines, see pages 36 and 38. solenoid valve.
Z
When connecting the make-up tube directly to a drinking Z
The tube between the dirt trap and the solenoid valve must
water system, a Reflex Fillset (shut-off, system separator, be kept as short as possible and must be flushed.
water meter, dirt trap) must be installed upstream.

Please refer to our detailed operating instructions

during installation and commissioning.

41
Pressurisation stations

Installation examples
Solution No- 09 Pressure maintenance and degassing by Variomat
Pump-controlled
pressure maintenance Exvoid T
with simultaneous
degassing in a Reflex
Variomat.

Reflex diaphragm M M

expansion vessel as
individual protection of Legionixx Reflex
the heat generator in
the return flow.
HydroFixx

Exdirt steel
Secondary vessel Primary vessel >500mm .

Storatherm Aqua
Fillset Impuls

Fillsoft I
Refix Variomat control unit

Solution No- 20 Variomat in cooling applications

Use of Servitec vacuum
Cold buffer vessel
Kälte-Pufferspeicher
spray tube degassing to
Exdirt steel
achieve maximum >500mm
degassing performance.
.

Reflex
Exvoid T
When combining
Servitec and Variomat,
>500mm
the degassing function .

on the Variomat must

be deactivated.

Automatic make-up of
pre-mixed heat transfer Kompaktverteiler

medium, vessel supplied Sinus Compact distributor

by installer.

When selecting the Variomat control unit

control unit for cooling
water systems to 30 °C,
only 50 % of the rated
heat output may be
included in the
calculation.

Servitec Primary vessel Secondary vessel

42
 Variomat

Variomat in Master-Slave operation Solution No- 14

Hydraulically connected
heating and cooling.
Exvoid T Exvoid T
A Master-Slave
con­figuration is only
>500 mm.
recommended if the
systems are
hydraulically connected
or the stations at
different levels;
examples include
Kompaktverteiler summer and winter
HydroFixx
HydroFixx

>500 mm
Sinus Compact distributor operation of cooling and
Cold buffer vessel
heating systems, or a

.
group of several heat
Primary vessel
generating systems.
Primary vessel Variomat control unit Variomat control unit

Fillset Impuls
Reflex

Fillsoft

Variomat Giga Solution No- 12

Pressure maintenance
in major facilities
Storatherm requiring large
Aqua Load Storatherm Heat quantities of heat and
hot water.
Exvoid steel

Connection of the
Refix vessels must be flexible.
M M Factory connections are
provided for this
Longtherm >500mm
.
purpose. The tube
connection between the
hydraulic units and the
Reflex
Sinus Compact distributor vessels must be
Primary vessel provided on site.
Exdirt steel

Variomat Giga controller

Fillset Impuls

Fillsoft II

These diagrams are only meant to visualise the interconnections.

Installation must be adapted to local conditions accordingly and must be specified in more detail.
43
 Pressurisation stations

Reflex Control Key advantages

Extremely modern, user-friendly control concept,
easy to operate and clearly structured
Z
Extendable microprocessor controller Z
Enables communication between Servitec facilities,
Reflex pressure maintenance stations, the Fillcontrol
Z
Reflex Control flexible control concept for fully
range, and a control centre
automatic operation with data interface for incorpo-
ration into modern building management

l Touch
Reflex Contro
Info » t
/ Hilfe Übersich
Informationen
Allgemeines
an
Anschlusspl
Diagnose
ng
Fehlerbehebu
16,6 bar 100%

44
 Reflex Control

Reflex Control overview

Controllers
Control Basic Control Touch Control Smart

Z
2-line LCD display Z
4.3" touch screen colour display Z
Access via Bluetooth interface
Z
8 operating keys Z
Graphical user interface Z
Parameterisation of the degas-
sing mode (continuous or
Z
2 status displays Z
Simply structured plain text
intermittent operation, number of
menus, incl. operating instructions
Z
Integrated control of system cycles) including days of the
and help documentation
pressure, degassing and water week and time
make-up Z
Integrated control of system Z
Fault message display
pressure, degassing and water
Z
Manual and automatic operation
make-up Z
System pressure checking
Z
Floating-contact external group Z
Manual and automatic operation Z
Software updates
fault signal
Z
Permanent display of key Z
currently available for Servitec
Z
Counting pulse inlet for contact
operating parameters on system Mini and Servitec S
water meter
diagram For further details, please
Z
RS-485 interface for BMS consult our brochure
Z
Intelligent plug-and-play function
connection via Busmodules “Vacuum spray-tube degassing”
management
Z
Key operating data can be
analysed and stored
Z
Wide array of interfaces:
→ 
1 × meter pulse inlet for
contact water meter
→ 
2 × floating outputs for fault
messages
→ 
2 × analogue parametrisable
outputs for pressure & level
→ 
2 × RS-485 interfaces for
connection to building
management system and
other networks
→ Slots for HMS Networks and
SD memory card

45
Pressurisation stations

Communication overview
Reflex Control Basic
GLT/BMS
Management level

External participants

Group fault signal

PLC

6 digital 1 digital
outputs output
(programmable)
Automation level

6 digital 2 analogue RS-485 Field buses

inputs outputs
(3x 24 V) (4–20 mA)
(3x 230 V)

I/O Module Bus-Module

6 digital Profibus DP
outputs
(programmable)
Ethernet
Modbus TCP
RS-485

485
Field level

RS-
485 RS-

485
Reflex Control Basic RS-
Master-Slave

Levelcontrol

Digital input

  RS-485 Interface   Analogue outputs   Digital inputs and outputs   Field bus

46
 Reflex Control

Reflex Control Touch

GLT / BMS
Management level

External participants

Dry-run protection
Group fault signal
PLC
Pressure
Level

6 digital 2 digital
outputs outputs
(programmable)
Automation level

6 digital 2 analogue 2 analogue RS-485 Field buses

inputs outputs outputs
(3x 24 V) (4–20 mA) (4–20 mA)
(3x 230 V)

I/O Module Bus-Module

6 digital Profibus DP Modbus RTU
outputs
(programmable)
Ethernet Profibus DP
Modbus TCP BACnet-IP
RS-485 BACnet-MS/TP

485
RS-
Field level

RS-
485

485
Reflex Control Touch RS-
Master-Slave
Interconnected configuration

Levelcontrol

Digital input

  RS-485 Interface   Analogue outputs   Digital inputs and outputs   Field bus

47
Pressurisation stations

Network solutions
using Reflex Control
The Reflex Control control concept ensures the flexible and easy Additional I/O and bus modules with the required interfaces are
networking of pressure maintenance, make-up and degassing. available for sophisticated requirements, e.g. complex hydraulic
Reflex Control Touch and Control Basic are standard equipped with systems with heating or cooling, or integrations to building
RS-485 data interface. management systems.

Type of bus module/Interface

Bus module Compact module

for Basic and Touch for Touch
Bus protocol
RS-485  –
Profibus DP  
Ethernet  –
Modbus TCP  –
Modbus RTU – 
BACnet-IP – 
BACnet-MS/TP – 

Master-Slave operation
Reflex Control really shows what it is capable of when connecting If the level of a Slave facility deviates by more than ±5% from the
multiple facility parts together. A Master/Slave configuration can Master, level equalisation is initiated. The hardware in the control-
switch up to ten pressure maintenance stations in hydraulically lers (Control Touch/ Basic) is ready for Master/Slave configuration.
coupled systems (e.g. combined heating/cooling network). In this In addition to the relevant wiring of the controllers, facility-specific
mode of operation, pressure maintenance is performed by one programming is required, which is performed by the Reflex
facility (Master), while the other facilities (Slaves) are only used for customer service team and which must be ordered as an option for
volume compensation. The relevant current level of the Master the relevant pressure maintenance station.
facility is transferred cyclically to the Slaves.

2
RL

2 Fillvalve
VL

Fillset

kW

Motorised

485
RS-
Reflexomat, Slave
1
VL
1
RL

kW
Reflexomat, Master

Two pressure maintenance stations as a Master/Slave configuration–using Reflexomats as an example

48
 Reflex Control

Your notes

49
Pressurisation stations

Reflex added value

Our digital services

Solutions Pro
The new generation Reflex configuration tool

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Complete product solutions quickly and easily system, just choose the application, then enter the relevant
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Reflex Training—expertise gives us the edge

into practice, refined and experienced straight away on Reflex
systems in a former manor house that has been refurbished to
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Realistic simulations and a comprehensive portfolio of systems help
to put the content learned to practical use, skilfully combining
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More information is available at www.reflex4experts.com/en

Close to our headquarters in Ahlen, professional craftsmen,
planners and operators gear up to meet the challenges posed by
heating and hot water supply in modern building technology. From
installation and planning to consulting and technical operation, the Reflex Training Center
Reflex Training Centre and its team aligns its programme to those
+49 2382 7069-9581
partners who want to learn more about technology, standards and
[email protected]
service from the horse’s mouth. Newly acquired expertise is put

50
 Services

Our performance promise—Reflex After-Sales & Service

Supply technology systems are becoming increasingly complex. Z
Compliance with statutory regulations and therefore
This is true for the technology as well for documentation and also with liability and warranty provisions
testing requirements. With Reflex After-Sales & Service, you remain Z
Systems optimally adapted for maximum efficiency
in good hands after your purchase. Our years of expertise special-
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ising in the Reflex product world ensure the full safety and
functionality of your system.
You can find more information
Z
Expertise and many years of experience with all Reflex products
about all our services at
Z
Qualified personnel with expertise in the latest products www.reflex-winkelmann.com/int/
and guidelines services-downloads/after-sales-service

Warranty extension to five years Registration is not only possible at the time of
From now on, you can register your system after it has been commissioning but is also valid for all systems
commissioned by us or by a service partner certified by us. If you with a manufacturing date of up to six months
enter into a maintenance contract at the same time, you are from the year of manufacture 2020.
entitled to a warranty extension to five years. Take advantage
of this opportunity easily at www.reflex-winkelmann.com/int/ With the new online service order, we are
services-downloads/after-sales-service/warranty on optimising the service for our customers even YEARS
our home page or simply use the sticker on your product to further. It takes just a few clicks to create GUARANTEE
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in our system. This makes our service even
faster and more customer friendly.

Factory service centre Technical hotline Commercial processing

+49 2382 7069-9505 +49 2382 7069-9546 +49 2382 7069-7505

[email protected] [email protected] [email protected]

51
Discover Reflex with augmented reality

Subject to technical modifications

RE1879enC / 9127864 / 02-2022
1 Scan QR-Code.
reflex.de/en/city 2 Download the
Reflex Smart City app 3 Scan the title of this ­brochure
and explore

Always up to date
Further product literature and materials can be
downloaded at or hard copies ordered from
www.reflex-winkelmann.com/int/services-downloads

Reflex Winkelmann GmbH

Gersteinstrasse 19
59227 Ahlen
Telephone: +49 (0) 238 270690
Technical Service: [email protected]