reflex ’variomat’

Pressure-maintaining station
with automatic water make-up and deaeration
 The reflex ’variomat’
can do much more than just maintaining the pressure
The pump-controlled ’variomat’ opens
up a completely new dimension of pres-
sure-maintaining stations for heating
and cooling circuits.

Its three functions:

it keeps the system pressure within
very restricted limits
it deaerates the content water
it makes up water automatically

Thus, the reflex ’variomat’ is the best

solution for increasing air problems, in
particular within closed heating installa-
tions, which, according to a study of the
Technical University of Dresden, arise
in more than 50 % of the installations.

The reflex ’variomat’ ensures air-free

installations up to the top floor and into
the last corner.
Expensive decentralized air separators
as well as the time-consuming deaera-
tion are things of the past.
An additional advantage: A special data
interface allows the integration into the
modern facility management.

The high efficiency of the ’variomat’

principle has been proven at the Tech-

2
nical University of Dresden and has OLD
been tried and tested in numerous ap-
plication examples. The combination of
pressure maintenance, deaeration, and
water make-up complies with all re-
quirements for air-free systems and re-
quires only little maintenance.

NEW

Shut-off on-site,
’variomat’: recommended for
summer operation
extensive program, great variety
of applications

’variomat 1’ and ’2-1’ single pump

systems for systems of up to 4 MW
’variomat 2-2’ double pump systems
for systems of up to 8 MW
also suited for systems with a glycol
content of up to 50%
fully automatic operation with data in-
terface for interconnection with
state-of-the-art facility management
systems
silent method of operation for use in
noise-sensitive areas
proven in centrally heated
apartments and industrial buildings,
in district heating systems and in
closed-loop cooling circuits
Internationality: the control system
offers as much as 8 languages for
you to select
 The ’variomat’
The high effectiveness of the multi-functional unit
The unpressurized VG primary vessel a partial flow of the heating water is, grams, the start-up and operating condi-
of the ’variomat’, which is closed to- dependent on the time, led through the tions of the process can be optimally
wards the atmosphere, is not only used VG primary vessel and automatically adjusted to the individual requirements
for the deaeration of the heating water, bled and/or deaerated because the gas and are electronically monitored.
but also for the discharge and partial solubility at this point is lower than in the
deaeration of the make-up water. Thus, system. Using different deaeration pro-

Conventional installation: The ’variomat’ installation:

Water supersaturated with gas Water which is effectively gas-
results in system breakdowns free, thus no more air problems

Convincing: the ’variomat’-

advantages in the example
of a heating system

– No time-consuming decentral-
ized subsequent bleeding
– No gargling sounds
– Full thermal output at any time

’variomat’
Elimination of mechanical
air separators

Protection of pumps against air

and cavitation

3
No formation of bubbles on the
hot boiler heating surfaces, con-
sequently better heat transfer

Entire circuit water:

less erosion and wear,
less formation of mud,
improved circulation
Gassy Gas-free
sampling sampling

– ’variomat’ maintains the cor-

rect pressure and displays it
– ‘variomat’ deaerates
– ‘variomat’ makes up water
automatically

“Three functions in one device and a satisfied building

owner for whom air problems are finally things of the
past – the ’variomat’ is simply great!”
 reflex ’variomat’ – The program
for pressure maintenance, deaeration, and water make-up

reflex ’variomat 1’ up to 2 MW with 1 pump

2 separate
expansion lines
→ p. 18

Installation
details

towards the system

→ p. 14

from the system

reflex ’fillset’
(optional)

Water
make-up
P O W water

A B

230 V

Programmable floating
group faultsignal
+ RS 485

VG primary vessel Control unit

Connection set

Smooth pump start

reflex ’variomat 2-1’ up to 4 MW with 1 pump additional TÜV-certified
minimum pressure valve
towards the system

Electrical main switch

from the system

reflex ‘fillset’
(optional)

4 Water
make-up
P O W water

A B

230 V, fixed connection

Programmable floating
group faultsignal
+ RS 485

VG primary vessel Control unit

VF secondary vessel Connection set

(optional)
reflex ’variomat 2-2’
2 pumps with smooth start
2 additional TÜV-certified
minimum pressure valves
up to 8 MW with 2 pumps Electrical main switch load-
reflex ’fillset’ dependent connection and
malfunction change-over
(optional)

Water make-
up water
W
P towards the system
O from the system

A B A B

230 V, fixed connection

Programmable floating
group faultsignal
+ RS 485

VG primary vessel Control unit

VF secondary vessel Connection set

(optional)
 reflex ’variomat’

Control unit

Maintain pressure, compensate

PIS the expansion volume
Pump (A) and over-flow valve (B) are trig-
gered in such a way that the pressure
remains constant within the limits ± 0.2
bar. The expansion water is fed (O) or
carried away (P) to/from the unpressuri-
zed VG primary vessel using 2 separate
expansion lines.

Example: ‘variomat’ single pump sys-

TIME Deaeration tem in a heating system
A partial flow of the heating water is
relieved in the VG primary vessel and,
thus, degassed. You can select one of the
following deaeration modes:
Continuous deaeration: constant deaer- reflex ’fillset’
(optional)
ation after the commissioning and after W O P
Water
repairs in the supply system in order to make-up
quickly remove all the residual air from
the system
Follow-up deaeration: is automatically
enabled after the continuous deaeration
and then runs after every pump cycle
Interval deaeration: runs at a present
time schedule

Control unit VG primary vessel VF secondary vessel

O – Over-flow line with VW (optional)
Connection ‘MK 1’
P – Pump line set thermal
insulation 5
LIS Water make-up W – Water make-up line (optional)

The volume of ejected free gasses as

well as water losses are automatically
supplemented. The level measurement
takes place by evaluating the weight of
the VG primary vessel. The water make-
up, subject to the fill level in the VG pri-
mary vessel, is monitored by a leakage
amount monitor and is interrupted in
case of malfunctions. The signals of a
contact water meter can be evaluated
(’fillset’ with contact water meter).

VG primary vessel, VF secondary vessel Connection set

The unpressurized closed VG primary vessel
has two functions:
1. Expansion water is reliably protected from
the admission of air in a bubble diaphragm.
2. The purposeful expansion-relief of the net-
work content water separates and dicharges
gasses.
The VG primary vessel capacity can be ex-
panded by connecting multiple VF secondary
vessels in series.
VW thermal insulation
The VG primary vessel warms up in heating
systems. Therefore, the installation of a VW
thermal insulation consisting of 50 mm FCKW-
free soft foam with zipper and floor insulation is
recommended.
Connectors are available for the quick
connection of the ’variomat’ to VG primary
vessels. These are equipped with a pro-
tected shut-off for 1-pump systems. With
respect to 2-pump systems, the protected
shut-off is located on the control unit.
’fillset’
The ’fillset’ with DVGW tested system
separator, water meter, dirt pan, shut-off,
and wall bracket is offered as an accesso-
ry for the direct connection of the water
make-up device to a drinking water net-
work. Can also be supplied with an option-
al contact water meter.
 reflex ’variomat’
Function details

VG primary vessel
The expansion bend
guarantees the pressure
compensation towards
the atmosphere between
Expansion lines
DN → page 16
the vessel wall and the
O P diaphragm.
W
Water make-up
water The sounding pipe
deaeration

gas “free”
extracts the gasses from
Water make-up water gassy

reflex ’fillset’ (optional) gassy

the tank and prevents a
re-aeration.
(water make-up line)

equipped with system separator and

water meter, it allows the direct con-
(over-flow line)

The diaphragm
Circuit water

Circuit water
(pump lines)

nection of the water make-up device

to the drinking water network protects the expansion
water from a direct air
admission.
Control unit
The pressure expan-
sion relief
The control unit at atmospheric pressure
guarantees maximum operating com- results in the deaeration
fort. All Reflex controls (’variomat’, of the expansion water.
’reflexomat’, ’gigamat’, ’servitec’)
have been designed according to The pressure cell
a uniform design guideline. (level measurement)
enables the determina-
The hydraulic equipment tion of the vessel fill
A tuned system with pressure- level.
6
maintaining pump(s) and over-flow
device(s) enables the hydraulic
adjustment to differing installed
systems and conditions.

The rotatable base plate

enables the installation of the VG pri-
mary vessel to the right, left or rear Connection set
of the control unit for 1-pump sys-
tems. The connection set con-
nects the control unit with
the VG primary vessel.
For 1-pump systems, the
protected shut-off is inte-
grated in the connection
set. With respect to 2-
pump systems, the pro-
tected shut-off is located
on the control unit.
 reflex ’variomat’

The hydraulics in detail

W O P
Pump line
’variomat 1’
with pumps starting normally
’variomat 2’
with pumps starting smoothly

Over-flow line O
’variomat 1’
fixed throttle for the hydraulic
adjustment pump - over-flow-line

’variomat 2’
TÜV-inspected over-flow valve
for the hydraulic adjustment

Water make-up line W

When the fill level in the VG primary
vessel is too low, the solenoid valve
opens. For a connection to the drink-
ing water network, ’fillset’ must be
added.

Connection VG primary vessel

using connection set

reflex ’variomat 2’ reflex ’variomat 1’

O O

protected shut-offs

Dirt pan
TÜV-certified over-
flow valve Solenoid valves Throttle for the
W for pressure regulation W
hydraulic adjustment
1. for the hydraulic or water make-up
adjustment
2. closes when minimum
pressure not reached
= functionally diverse
safety to the solenoid
valve
3. improved regulating Safety valves
characteristics due to for the protection of the
P behavior unpressurized vessels
from an inadmissible
excess pressure during the
operation
 reflex ’variomat’
Technical specifications

Operation parameters Electro-technical data

Permitted Permitted Permitted Permitted Noise Electrical Pump Protec- 230 V

oper. pres- flow operating environm. level power soft tion 50 Hz,
sure / bar temp. / °C temp. / °C temp. / °C appr. dB kW start- type connection
reflex ’variomat’ 1-pump system
variomat 1 10 100 > 0 - 70* > 0 - 45 55 0.75 no IP 54 three-pin plug,
5 m cable
variomat 2-1/60 10 120 > 0 - 70* > 0 - 45 55 1.10 yes IP 54
2-1/75 10 120 > 0 - 70* > 0 - 45 55 1.10 yes IP 54
2-1/95 10 120 > 0 - 70* > 0 - 45 55 1.10 yes IP 54 Main switch,
reflex ’variomat’ 2-pump system fixed
connection
variomat 2-2/35 10 120 > 0 - 70* > 0 - 45 55 1.50 yes IP 54 to terminal
2-2/60 10 120 > 0 - 70* > 0 - 45 55 2.20 yes IP 54 strip
2-2/75 10 120 > 0 - 70* > 0 - 45 55 2.20 yes IP 54
2-2/95 10 120 > 0 - 70* > 0 - 45 55 2.20 yes IP 54
Pump type * Mounted in system return line, diaphragm load of the expansion vessel max. 70°C;
Pump amount please contact us if there is an expected continuous temperature ≤ 0°C
Technical design

Microprocessor control Inspection

Control ’variomat’ with CE symbol, built and inspected as

Pressure main- load-dependent switching at shortfall per DIN 4751 T 2 for hot water heating systems
taining pump(s) of pa and switching off at pa + 0,2 bar VG- and VF vessels built and inspected as per
variomat 2 with soft start-up EU pressure equipment directive 97/23/EU
Over-flow- load-dependent opening when pe is
magnet valve(s) exceeded and closing at pe - 0,2 bar;
automatic toggle switching and mal-
8
function changeover switching for 2-
pump systems; opens in deaeration
modes continuous, interval or follow-up Control options
variomat 2 with additional TÜV-certified
minimum pressure valve Expansion module isolating amplifier for
1 water make-up Automatic water make-up when pressure and levels as well as 6 digital inputs
solenoid valve solenoid valve minimum water level and 6 voltage-free outputs
of the VG vessel is not reached Communication module for offline operating
Toggle and malfunc- of the pumps and solenoid valves using a twin-core cable up to 1000 m distance
tion switching for pump systems
Operating display
Clear text Pressure in bar, water level in %,
function messages in the message lines
LED hand-stop-auto, operating pump,
over-flow, water make-up
Operating display
Clear text e.g. pressure min/max, lack of water
floating
LED additional optical display for lack of
water and switching of the floating
contact
Malfunction collec- The control panel
tion point floating, programmable
Lack of water floating
Data output RS 485 Interval degas.

Parameter setting minimum operating pressure p0 in bar

in customer menu deaeration mode, deaeration duration Display with message lines using
period, date, time, clear text LCD, multilingual

8 languages, maintenance intervals Function diagram using LED

Queries in customer menu
Malfunction memory Storage of the chronological order and
type of malfunction message
Parameter memory Storage of the chronological order of
changes to the minimum oper. pressure
Water make-up Evaluation if using a ’fillset’ with water
amount contact meter possible
 reflex ’variomat’

Parameter settings

The following parameters are set object-based in the customer menu either by the reflex service or by the
customer himself. Other settings are possible subject to password protection. Extensive instructions are
provided in the installation, operating and maintenance instructions.
Language: country-dependent
Date / Time: current time and date for malfunction memory and p0-memory as well
as timing window for the deaeration
Deaeration mode: Continuous - generally done during installation or after repair
deaeration operations to the system
Interval deaeration - high deaeration power, setting on the control unit for
extreme network conditions,
Follow-up - automatic activation after the continuous deaeration,
deaeration this deaeration mode with its relatively low deaeration
power is generally sufficient for most systems

Continuous deaeration run: in dependence on the network volume

recommendation: 12 h for network contents ≤ 20 m³/h
24 h for network contents > 20 m³/h
Minimum operating Calculation according to the formula below. In the example p0 = 2.0 bar
pressure p0: If the system is to be run for longer than 1 hour in continuous deaeration
mode, then a minimum operating pressure p0 ≥ 1.3 bar is required.

Example: Calculation and setting of the minimum operating pressure

Heating system, static height 18 m (pst = 18 bar = 1.8 bar),

10
Flow 70°C, (pvaporization = 0 bar)
9
p0 = 1.8 bar + 0 bar + 0.2 bar (recommendation)
p0 = 2.0 bar → setting on-site

pSV [bar] = Safety valve actuation pressure on the heat generator

pmax [bar]
≥ 0.5 bar
pe [bar] = final pressure = over-flow OPEN
0.3 bar *
0.4 bar
pa [bar] = admission pressure = pump ON
≥ 0.3 bar
p0 = Minimum operating pressure p0 [bar] = pstatic + pvaporization + 0.2 bar (recommendation)
= Input value on control operating
panel pst [bar] = static pressure (= static height [m] / 10)
0...0.2 bar *
* Error message if pressure is too high or too low;
‘variomat 2’ also closes the mechanical over-flow
valve if the pressure is below p0

pSV

H, pst

p0
 reflex ’variomat’
Control units and accessories

’variomat 1’, ’variomat 2-1’ Control unit with 1 pump

Type Article No. p0 H W D Connection Weight

bar mm mm mm P O W VG kg
variomat 1 6910100 ≤ 2.5 680 530 550 Rp 1 Rp 1 Rp ½ 2 xG 1 25
variomat 2-1/60 6910200 ≤ 4.8 680 530 630 Rp 1 Rp 1 Rp ½ 2 xG 1 28
variomat 2-1/75 * 6910300 ≤ 4.8 750 530 630 Rp 1 Rp 1 Rp ½ 2 xG 1 35
variomat 2-1/75 * 6910500 > 4.8-6.5 750 530 630 Rp 1 Rp 1 Rp ½ 2 xG 1 35
variomat 2-1/95 * 6910400 ≤ 4.8 800 530 630 Rp 1 Rp 1 Rp ½ 2 xG 1 37
variomat 2-1/95 * 6910600 > 4.8-8.0 800 530 630 Rp 1 Rp 1 Rp ½ 2 xG 1 37
* please note the different p0-values when
placing an order → page 9

O - over-flow line
P - pump line
W
W - water make-up line
W
P
O
P O

W W
variomat 1 variomat 2-1/75
variomat 2-1/60 y vessel variomat 2-1/95 VG primary
vessel
D VG primar D

’variomat 2-2’ Control unit with 2 pumps

10
Type Article No. p0 H W D Connection Weight
bar mm mm mm P O W VG kg
variomat 2-2/35 6911100 ≤ 2.5 680 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 54
variomat 2-2/60 6911200 ≤ 4.8 680 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 58
variomat 2-2/75 * 6911300 ≤ 4.8 750 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 72
variomat 2-2/75 * 6911500 > 4.8-6.5 750 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 72
variomat 2-2/95 * 6911400 ≤ 4.8 800 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 76
variomat 2-2/95 * 6911600 > 4.8-8.0 800 700 780 G 1¼ G 1¼ Rp ½ 2 x G 1¼ 76
* please note the different p0-values when
placing an order
P O
P
O O - over-flow line
P - pump line
W - water make-up line

O O

H H

W
W

W W
variomat 2-2/35 ssel variomat 2-2/75 y vessel
variomat 2-2/60 VG primary ve variomat 2-2/95 VG primar
D D

Expansion module (optional) Communication module (optional)

additional isolating amplifier in the for the external operation of the con-
control unit for pressure and level as trol unit using a twin-core cable up
well as 6 digital inputs and 6 voltage- to 1000 m
free outputs
Article No.: 7997700 Article No.: 7997800
 reflex ’variomat’
Vessels and accessories

VG primary vessel VF secondary VW thermal insulation

vessel for heating systems
(optional) (optional)
Type ∅D H h A Weight Article no. Article no. Article no.
mm mm mm kg
200 634 1060 146 G 1 37 6600000 6610000 7985700
300 634 1360 146 G 1 54 6600100 6610100 7986000
400 740 1350 133 G 1 65 6600200 6610200 7995600
500 740 1570 133 G 1 78 6600300 6610300 7983900
600 740 1790 133 G 1 94 6600400 6610400 7995700
800 740 2240 133 G 1 149 6600500 6610500 7993800
1000 740 2690 133 G 1 156 6600600 6610600 7993900

1000 1000 2060 289 G1 320 6600700 6610700 7986800

1200 1000 2240 289 G1 330 6600800 6610800 7986900
1500 1200 2150 368 G1 465 6600900 6610900 7987000
2000 1200 2610 368 G1 565 6601000 6611000 7987100
2500 1200 3150 368 G1 680 6601100 6611100 7989900
3000 1500 2610 393 G1 795 6601200 6611200 7993200
4000 1500 3180 393 G1 1080 6601300 6611300 7993300
5000 1500 3720 393 individual 1115 6601400 6611400 7993400
10000 1500 6730 393 individual 1950 6601500 6611500 —
Vn Nominal volumes / liter ∅D
Expansion line
DN → page 18
O P
W

’fillset’
11

H
reflex ’fillset’ (optional)
Connection group with DVGW-tested sys-
tem separator
Article no. Length Connec- Weight
mm tion kg
with standard water meter h
6811100 405 G½, G¾ 2,8
with contact water meter Control unit Connection VG primary vessel ‘MK 1’ VF secondary vessel
set with flexible hose (no VW thermal insula-
6811200 405 G½, G¾ 2,8 connections tion required)
with VW thermal
insulation

Connection set G 1 reflex ’MK cap ball valve’ (optional)

for the connection of ’variomat’ single pump secured shut-off of secondary vessels
systems to VG primary vessels with secured
shut-offs and screw connections Article no.
MK 1 6830200
VG vessel Article no. Weight
∅ /mm kg
480- 740 6940100 2 Installation (optional)
1000-1500 6940200 3
by our service department
Article no.
Connection set G 1¼ Single pump system 7945600
Double pump system 7945630
for the connection of ’variomat’ double pump
systems to VG primary vessels
VG vessel Article no. Weight
∅ /mm kg
480- 740 6940300 2
1000-1500 6940400 3
 reflex ’variomat’
Selection Heating systems up to 120°C

p0
bar ’variomat 1’, ’variomat 2-1’
’variomat’ control units Control unit with 1 pump

*
In performance ranges > 2 MW
for cooling water systems up to we recommend using
30°C only 50% of the nominal hea- double pump systems.
ting power should be considered
when selecting the control unit *

We recommend in the green

performance zone ≤ 500 kW
and Vn < 200 liters to
alternatively use
’servitec magcontrol’ +
’reflex’.
→ Brochure ’servitec’
p0 = 1.3 bar
Minimum operating pressure p0/bar min. setting value in con-
For the calculation see also page 7 tinuous deaeration mode

0.2 bar [≤ 100°C]

H [m] 0.5 bar [ 105°C] Q / MW
p0 ≥ +
10 0.7 bar [ 110°C] p0
1.2 bar [ 120°C] bar ’variomat 2-2’
* Control unit with 2 pumps
Safeguarding temperature per pump and
H = static height over-flow valve 50%
of the total power
*
12
* please note the different p0-
values when placing an order
→ page 10

p0 = 1.3 bar
min setting value in con-
tinuous deaeration mode

’variomat’ VG, VF vessels

Total thermal output of the heat generation system Q / MW

Nominal volumes Vn VG, VF vessels

approximate value from the diagram
Standard values for 90/70°C
or heating systems
calculation according to Vn 6 l/kW
8.5 conv
the formula Liter l/kW ecto
rs
0.031 [ 70°C] flat
13 /ve
0.045 [ 90°C] ntil
Vn ≥ VA x .5 atio
0.054 [100°C] l/k n
W
0.063 [110°C] ra
dia
to
20

Setting- rs
l/k

temperature
W

Vn = Nominal volumes
VA = System water contents

The nominal volumes can be

distributed to several vessels
(VG primary vessel and VF Installed thermal output of the heating surfaces Q / MW
secondary vessel).
 reflex ’variomat’
Installation

reflex ’variomat 1’, ’variomat 2-1’ 1-pump system

Installation
details → page 14 max. 70°C
Set-up variation
Expansion lines
dimensioning
→ page 18

reflex ’fillset’
W O P
Water make-up

By turning the base plate it is

possible to mount the control
unit to the left, right or in front Control unit VG primary vessel VF secondary vessel **
of the VG primary vessel. Connection set G 1 reflex ’MK cap ball
valve line’
DN 25 on-site
530 500 *
900

reflex ’variomat 2-2’ 2-pump system

Set-up variation Installation

details
→ page 14 max. 70°C

Expansion lines
dimensioning
→ page 18
13
P O

reflex ’fillset’
W

Water make-up

By exchanging the end caps of the manifold

pipes it is possible to mount the control unit to
the left or right of the VG primary vessel
(Standard → left).

Control unit VG primary vessel VF secondary vessel **

Connection set G 1¼ reflex ’MK 1 cap ball’
valve line DN 25 on-site
Selection example
700 500 *
- Heat generator power Q = 3000 kW 900
- water content VA = unknown
→ approximated from the installed
heating power * 500 mm for vessels up to ∅ 740 mm
Q = 3000 kW, radiators, 90/70°C, 900 mm for vessels up to ∅ 1000 mm
additional remote lines
- Set-up temperature = 90°C
- Safeguarding temperature = 110°C ** with flexible hose connections
- Static height = 25 m
H [m]
→ p0 ≥ bar + 0.7 bar [110°C]
10
p0 ≥ 25 bar + 0.7 bar = 3,2 bar
10
→ Vn from diagram = 1800 liters
selected:
Control unit ’variomat 2-2/60’
+ VG primary vessel (e. g. ∅ 1000) 1000 liters
+ VF secondary vessel (e.g. ∅ 1000) 1000 liters
= 2000 liters
+ VW thermal insulation 1000 liters
+ Connection set G 1¼, ∅ 1000 complete ordering information
+ ’MK 1 cap ball valve’ → page 19
- we recommend double pump systems if 2 MW is exceeded
- the VF secondary vessel requires no thermal insulation
 reflex ’variomat’
Installation

Extracts from the installation, operating, and maintenance instructions

Install the system vertically in a frost-free, ventilated room with

water drainage facilities.

Install the control unit and the vessels, preferably at the same
level, the control unit must in no case be mounted
higher than the vessels! Install the vessels vertically.

Connect the pumps and the over-flow lines in the system so no

coarse dirt can ingress (see detail). For the dimensioning of the
expansion lines see → page 18.

The pressure cell for the level measurement must be

mounted on the appropriate foot of the VG primary vessel. The
VG primary vessel and the first secondary vessel must always
be flexibly connected with the supplied connection set to
ensure that the level measuring is not impaired.

No fixed fastening of the VG primary vessel to the floor.

The VW thermal insulation for the VG primary vessel is

recommended for heating systems.

Rinse the connection lines prior to installation!

Detail:
Connecting of ’variomat’
14
The function of the ’variomat’ deaeration is only ensured when
the connection of the ’variomat’ has been performed in a repre-
sentative main flow of the installed system. The following mini-
mum volume flows V must be maintained during the operation.
With an inclination of ∆t = 20 K this reflects a minimum perfor-
mance setting of the accepting system of Q.

variomat 1 variomat 2-1 variomat 2-2/35 variomat 2-2/60 - 95

V 2 m³/h 4 m³/h 2 m³/h 4 m³/h
Q 47 kW 94 kW 47 kW 94 kW

≥ 500

The connection lines

Main volume flow V should be connected from
the top or, as shown, as
immersion lines in the
main line in order to avoid
Pump line P The longer the Over-flow line O
direct ingress of coarse dirt
partial flow from distance between partial flow to
’variomat’ the connections, ’variomat’ gas rich
in the ’variomat’
“gas-free” the better.

The dimension of the

expansion lines should be
selected according to the
details given on page 18.
 reflex ’variomat’
Installation examples

General information

Individual protection: due to the high deaeration perfor-
mance of the ’variomat’, it is recommended to install a di-
aphragm pressure expansion vessel (e.g. ’reflex N’) on the
heat generator also for single boiler systems in order to
minimize the number of cycles.
Integration into the system: the integration into the
system is to be performed as described on page 14 in or-
der to prevent the ingress of rough particles of dirt and the
overload of the ’variomat’ dirt pan. The piping for the heat-
ing system and the drinking water make-up must be rinsed
prior to the installation.
Connection line for water make-up: if the water make-
up line is directly connected to the drinking water network,
then reflex ’fillset’ (shut-off, system separators, water me-
ter, dirt pans) must be added. If reflex ’fillset’ is not in-
stalled a dirt pan with a minimum mesh width ≤ 0.25 mm
must be installed in order to at least protect the solenoid
valve of the water make-up device. The line between the
dirt pan and the solenoid valve must be kept as short as
possible and must be rinsed.

reflex ’variomat 1’ in a single boiler system

≤ 350 kW, < 100°C, water make-up with drinking water Notes to the installer

You do not need to install

any extra cap valves in the
expansion line.
’reflex’
15
reflex ’fillset’ with integrated
Dirt-free
connection → p. 14 system separator must be
≥ 500 added when connected to a
tR ≤ 70°C
drinking water network.

1) Expansion lines with a length of

25 1) 15
more than 10 m must be in-
Drinking
stalled in DN 32. → page 18
P O W water
VG primary reflex ’fillset’
vessel 2) Throttle valve for the hydraulic
adjustment of the pump and
over-flow performance
2)

’variomat 1’

Boiler and system protection Direct connection of the water make-up

Pressure maintenance, deaeration, and water make-up device to the drinking water network

Electrical connections must be in accordance with local electricity company codes & regulations.
 reflex ’variomat’
Installation examples

reflex ’variomat 1’ in a district heating domestic station,

water make-up via district heating return Notes to the installer

District heating water is gen-

erally best suited as water
Dirt-free make-up water. A water
’reflex’
connection → p. 14 treatment is not necessary.
≥ 500
tR ≤ 70°C Please coordinate with the
heating supplier! Pay atten-
tR ≤ 70°C, district heating return

tion to the terms of connec-

tion!
25 1) 15
1) Expansion lines with a length
VG primary P O W of more than 10 m must be
vessel installed in DN 32.
→ page 18
2) 2) Throttle valve for the hydrau-
lic adjustment of the pump
and over-flow performance
For special requirements,
On-site
pressure
reducer
’variomat 1’ e.g. in the district heating,
there is an option card avail-
safety
filter
Filter Drumi valve
SV able with 6 digital inputs and
6 voltage-free output con-
Connection of the water make-up device at the dis- Generator and system protection tacts as well as pressure and
trict heating return, coordinate with heating supplier Pressure maintenance, deaeration, and water make-up level outputs using an isolat-
ing amplifier.
Please contact us.
16

reflex ’variomat 2-1’ in a system with central

return admixture, water make-up through softening device Notes to the installer
reflex ’ET
blowtank’ ’variomat’ must always be
connected within the main
volume flow in order to en-
sure that a representative
part of the flow can be de-
Dirt-free
gassed. In case of central re-
connection → p. 14 turn admixture this is the sys-
’reflex’ ≥ 500 tem side. Then the boiler is
tR ≤ 70°C
equipped with an individual
protection.
If the reflex ’fillset’ capacity is
25 1) 15
exceeded (kVS = 1 m³/h), then
P O W
Drinking
water
alternatively a suitable con-
VG primary reflex ’fillset’
vessel nection group must be in-
stalled on-site in the water
make-up line. The mesh
2)
width of the filter must not ex-
ceed 0.25 mm.
1) Dimensioning of the
’variomat 2-1’ expansion line
→ Reflex checklist for
Boiler indivi- System protection Connection of the water make-up pressure-maintaining
dual protection Pressure maintenance, deaeration, and water make-up through chemical water treatment
systems see page 18
2) Mechanical over-flow valve
for the limitation of the mini-
mum pressure and the hy-
draulic adjustment
Smooth pump start
addition, TÜV-certified
minimum pressure valve
Electrical connections must be in accordance with local electricity company codes & regulations. Electrical main switch
 reflex ‘variomat’

reflex ‘variomat 2-2’ in a multi-boiler system,

flow > 100°C, water make-up via softening equipment Notes to the installer

For water treatment sys-

reflex ’ET
blowtank’ tems, ’fillset’ with system
separator and water meter is
installed in front of the soft-
ening equipment.
Provide individual protection
Dirt-free with ’reflex’ for multi-boiler
connection → p. 14 systems.
’reflex’ ≥ 500
tR ≤ 70°C Multiple VF secondary ves-
P O sels can be connected.
1) 1) Dimensioning of the
expansion lines
W
Drinking
→ Reflex checklist for
VF primary VG secon-
water pressure-maintaining
reflex ’fillset’
vessel dary vessel systems see page 18
2) 2)
2) Mechanical over-flow valves
for the limitation of the mini-
mum pressure and the hy-
draulic adjustment
On-site
pipework ’variomat 2-2’
2 pumps with smooth start
2 additional, TÜV-certified
minimum pressure valves
Electrical main switch
load-dependent connection
17
System protection Connection of the water make-up device
Pressure maintenance, deaeration, and water make-up through chemical water treatment and malfunction change-
over

Electrical connections must be in accordance with local electricity company codes & regulations.
 Checklist for ’variomat’
expansion lines

reflex ’T
blow tank’
Selection according to DIN 4751 T2
→ Brochure Accessories

reflex ’EB
De-sludging tank’

particularly suited for older systems

→ Brochure Accessories

Q Expansion lines
kW

reflex ’variomat’ already contains cap ball valves. Therefore,

no other are required. The dimension of the expansion line
must be selected according to the following table.

DN 25 DN 32 DN 40 DN 50
variomat 1 X
variomat 2-1/60 X
variomat 2-1/75 X
variomat 2-1/95 X
variomat 2-2/35 X
variomat 2-2/60
p0 > 3.5 bar X
p0 ≤ 3.5 bar X
18 variomat 2-2/75
p0 > 4.5 bar X
p0 ≤ 4.5 bar X
variomat 2-2/95
p0 > 6.0 bar X
p0 ≤ 6.0 bar X

We recommend to select the nominal width in the next high-

er dimension for expansion lines > 10 m.

reflex ’fillset’
‘fillset’ Drinking Connection group to drinking
water
water network with water meter
and system separator

reflex ’variomat’
control unit with VF secondary vessel
VG primary ves-
sel and connec- Multiple VF secondary ves-
tion set sels can be connected.

reflex ’MK
Cap ball valves’
’MK 1’
for VF secondary vessels
→ Brochure Accessories

You will find these articles in this brochure.

You will find these articles in the specified brochures.
 reflex ’variomat’
Order information

Article no. Quantity Ordering information

’variomat’ control unit
variomat 1 p0 ≤ 2.5 bar 6910100
variomat 2-1/60 p0 ≤ 4.8 bar 6910200
variomat 2-1/75 p0 ≤ 4.8 bar 6910300
variomat 2-1/75 p0 > 4.8-6.5 bar 6910500 installed
variomat 2-1/95 p0 ≤ 4.8 bar 6910400 Nominal heating power ....... kW
variomat 2-1/95 p0 > 4.8-8.0 bar 6910600 Heat generator SV ....... bar
Heat generator STB ....... °C
variomat 2-2/35 p0 ≤ 2.5 bar 6911100
Static height ....... m
variomat 2-2/60 p0 ≤ 4.8 bar 6911200
variomat 2-2/75 p0 ≤ 4.8 bar 6911300
variomat 2-2/75 p0 > 4.8-6.5 bar 6911500
variomat 2-2/95 p0 ≤ 4.8 bar 6911400
variomat 2-2/95 p0 > 4.8-8.0 bar 6911600
’variomat’ connection set
G1 ∅ VG 480 - 740 mm 6940100 for ‘variomat’ single pump systems
∅ VG 1000 - 1500 mm 6940200
G 1¼ ∅ VG 480 - 740 mm 6940300 for ‘variomat’ double pump systems
∅ VG 1000 - 1500 mm 6940400
’variomat’ VG primary vessel
....... liters .....
’variomat’ options
VW thermal- ....... liters ..... for VG primary vessel 200 - 5000
insulation liters heating systems
reflex ‘fillset’
with standard water meter 6811100
with contact water meter 6811200 19

VF secondary vessel ....... liters ..... for connection to VG primary vessels

reflex ‘MK1 cap ball valve’ 6830200 as shut-off for VF secondary vessels
Expansion module 7997700 for controls with isolating amplifier
pressure + level
Communication module 7997800 for remote control operation
Installation
1 pump system 7945600
2 pump system 7945630

Commissioning and maintenance are explained in the supplied installation, operating, and mainte-
nance instructions. We recommend you to enlist the reflex service. Expansion vessels and pressure-
maintaining stations must be maintained annually according to DIN 4807 T2.

For additional technical information and extensive tendering texts

please visit us on the Internet at www.reflex.de

e. g. “Deaeration of heating “Pressure-maintaining “Pressure-

and cooling systems” systems – collected maintenance,
from the cooperative essays” deaeration
research work with the Here you find informa- and water
Technical University of tion on the equipment make-up sys-
Dresden of pressure-maintaining tems
When and why is the use stations in heat – planning,
of deaeration systems generating systems calculating,
required also and especial- over 100°C. equipment”
ly in closed systems?
 Reflex –
responsibility in the interests of the environment

New Reflex technologies are to pro-

vide advantages not only to human be-
ings, but also to the environment. This
is the principle on which we base all
our development, planning, and manu-
facturing. We comply with our respon-
sibility as manufacturer by the pur-
poseful selection of materials and pro-
duction technologies - the environmen-
tal - impacts are as low as possible.
Subject to technical modifications - Printed in Germany

Reflex Winkelmann GmbH + Co. KG

Gersteinstraße 19
D - 59227 Ahlen
Germany
Phone: ++49 2382/70 69-0
Fax: ++49 2382/70 69-558
PI0105Ae

www.reflex.de