Water make-up systems &

water treatment technology

Fillcontrol, Fillset, Fillsoft

 We are only satisfied when
Reflex has set itself the goal of supporting you with well
thought-out solutions. Whatever job you need doing in
water supply engineering, why not put your trust in our
comprehensive range of products and accompanying tailored
services? We will ensure that your decision to opt for Reflex
is the right one in every respect – from advice and design to
installation and ongoing operation.

Reflex's mission is embodied in the company's slogan:

“Thinking solutions”. Reflex's strength is to think in terms of
solutions. Reflex develops ideas that help you to move forward
based on decades of experience, in-depth technical under-
standing and intimate knowledge of the industry!

2
you are.
Contents

We make sure that everything fits Fillcontrol water make-up page 4

systems for heating and
Heating, cooling and hot water supply systems – the demands cooling water
on supply equipment are varied and complex. Water plays a key
role in this. An adequate water level combined with good water
quality are crucial when it comes to the smooth and efficient
operation of your system. With its water make-up systems and Fillcontrol water make-up page 6
water treatment technology, Reflex is therefore creating the systems at a glance
basis on which heat transfer and storage, as well as the
interaction of all other system components, can operate.

Fillsoft water treatment page 8

technology for make-up water

Diaphragm Networked solutions for water page 10

Deaeration Expansion
Vessels
make-up and water treatment
Systems &
Separation
Technology
Information, advice and page 12
Pressurisation design support
The Systems
Water Make-Up Reflex
Systems & Product Range
Water Treatment
Technical data page 14

Hot Water
Storage Tanks &
Heat Exchangers
Services

Discover the extensive range of Reflex water make-up and water

treatment solutions in this brochure. From manually to automat-
ically controlled water make-up systems with water treatment,
including integration into pressure maintenance and degassing
control.

3
Water make-up systems & water treatment technology

Fillcontrol water make-up system

A lack of water in heating or cooling systems damages the operation of the pressure maintenance system used. As a result it
can lead to trapped air, massive circulation malfunctions, cavitation on the circulation pumps and, at worst, total failure of the
system. That is why water make-up systems are recommended in line with EN 12828, which simultaneously can act as pressure
monitoring devices. With its Fillcontrol series, Reflex is unveiling a wide range of solutions for the long-term and stable operation
of the different types of systems.

In principle, all sealed systems need a specific water make up device (manual or pump driven) according to the country of
installation. System backflow prevention is required when making-up from potable water networks to prevent process water
flowing back into the fresh water system. A differentiation is also made between systems with or without pumps, which are used
depending on the available pressure in the water make-up network and the minimum operating pressure in the system.

Reflex Control – the new control unit

The latest generation of Fillcontrol water make-up systems is
setting new benchmarks, both technically and visually. This is
primarily due to the newly developed Reflex Control concept.
It combines all functions in a clear and intuitive user interface
and can be easily networked with other systems controlled by
Reflex Control, such as with Variomat and Reflexomat pressuri-
sation stations or a Servitec degassing unit. Reflex Control thus
not only simplifies automatic filling and water make-up pro-
cesses but also guarantees the perfectly controlled operation of
the entire system.
The key-based Reflex Control Basic with a 2-line LCD display
and the following features is used with all Reflex water make-
up systems.
• Calculation of the filling pressure from the system's minimum
operating pressure
• Leak detection over run time and cycles; reliable signalling of
leaks and automatic interruption of water make-up
• Monitoring of filling by means of a set filling time or filling
pressure; filling stops when the set level is reached
• Faults signalled by display and volt free output
• Seamless integration and monitoring of Fillsoft softening
components: cartridge usage is reliably tracked and the need
for replacement displayed by an optional contact water meter
(standard interface) and integrated softening logic
• Pressure and level-dependent operation as standard:
­pressure-dependent operation via integral control and
­level-dependent operation by simple networking with
Reflex pressurisation stations
• Direct networking with all Reflex pressurisation stations and
degassing systems thanks to the Control concept

4
s for heating and cooling water
Water make-up systems without pump Water make-up systems with pump

These systems are suitable for the pressure-dependent make-
up in systems with diaphragm pressure expansion vessels.
Water is made-up using the pressure in the mains water
system, which should be a minimum of 1.3 bar above the
minimum operating pressure (p0) of the system.
Control valve Pressure sensor
Pump-based water make-up systems are ideal for the pres-
sure-dependent addition of make-up water with diaphragm
expansion vessels, as well as for the level-dependent addition
of make-up water with pressurisation stations. The pressure
generated by the pump permits make-up water to be added in
systems with a minimum operating pressure (p0) of up to about
7 bar.

Reflex Control
System separator PIS Mains water
p ≥ 1 bar
pO

Fresh water
Closed system
p ≥ pO + 1.3 bar
Closed system PIS
Reflex Control pO
LS
System separation Pressure sensor
vessel Pump Level sensor

They are very simple to operate. When the pressure falls below
the filling pressure at the pressure sensor, the water make-up
control valve opens and allows mains water to flow into the
system.
When operated with a diaphragm expansion vessel, the water
make-up control valve opens when the pressure falls below the
filling pressure on the pressure sensor – in the same way as in
a system without pump. When operated with pressurisation
stations, the level falling below the filling level in the expansion
vessel causes the control valve to open.

Reflex water make-up systems without pump Pump-based Reflex water make-up systems

Fillcontrol: Fillcontrol Auto Compact.

Water make-up system with stand-alone system pressure sen- The complete system with the full functionality of the Reflex
sor, complete with system separation. Control concept as well as integral tank for system separation.

Fillcontrol Plus: Fillcontrol Auto is also available in a version suitable for use
The modular water make-up solution with the full functionality with anti-freeze, for instance to connect to a mixing tank for
of the Reflex Control concept and the option to install a Reflex adding make-up water to solar systems.
Fillset from the mains feed for system separation.

5
Water make-up systems & water treatment technology

Fillcontrol water make-up system

With its Fillcontrol range, Reflex enables controlled, automated water make-up with all common system configurations in heating,
cooling and solar systems. For maximum design flexibility as well as full functionality and perfect networking with the entire
­system, from pressurization stations to softening solutions.

Fillcontrol

The compact solution for small systems with diaphragm expansion vessels.
The DIN EN 1717-compliant system separator is already built in; the control works fully
autonomously via the integral system pressure sensor.

Flow coefficient: 0.4 m³/h

Max. operating temperature: 70 °C
Max. excess operating pressure: 10 bar
Minimum supply pressure: ≥ 1.3 bar

Fillcontrol Plus

Adding make-up water is a requirement in systems with diaphragm expansion

vessels. The Fillcontrol Plus offers the full functionality of the Reflex Control Basic,
even for smaller systems. It can be operated in a pressure- and level-dependent
manner. A Fillset can be installed from the mains compliance regulations for system
separation of potable water networks.

Flow coefficient: 1.4 m³/h

Max. operating temperature: 90°C
Max. excess operating pressure: 10 bar

Fillcontrol Auto Compact

The Fillcontrol Auto Compact combines maximum flexibility and the highest operating
convenience. It works with your installed pumps fully independently of the pressure
of the freshwater system. It can be operated pressure- and level-dependent with the
setting being made simply on the Control itself. With level-dependent operation, the
pressurisation station and water make-up unit is linked to each other by the control.
The Fillcontrol Auto can be connected directly to the potable water network thanks to
the integral system separation vessel.

Water make-up volume: 0.12 to 0.18 m³/h

Max. operating temperature: 30 °C
Max. excess operating pressure: 10 bar
Working range: Up to 8.5 bar

6
s at a glance
Solenoid valve with ball valve for Reflexomat

If a Reflexomat pressurization station is used, water can be made-up directly by

means of a solenoid valve with ball valve. It is actuated by the Reflexomat's Reflex
Control when the pressure falls below the set vessel volume (240 V output). A Fillset is
fitted in the mains supply for system separation when making-up from potable water
networks.

Flow coefficient: 1.4 m³/h

Max. operating temperature: 90°C
Max. excess operating pressure: 10 bar

Fillcontrol Auto – version suitable for use with anti-freeze

The Fillcontrol Auto is also available as a version suitable for use with media
containing anti-freeze for special applications. The range of functions is identical
to that of the Fillcontrol Auto, except that there is no system separation vessel, as
generally glycol mixture from an open tank on site are used, such as mixing tanks in
solar systems. It can be operated in a pressure- and level-dependent manner.

Water make-up volume: ≤ 4 m³/h

Max. operating temperature: 70 °C
Max. excess operating pressure: 8 bar
Working range: Up to 5.5 bar

Fillset water make-up fittings

Fillset water make-up fittings provide system separation in line with DIN EN 1717,
thereby permitting the permanent connection of heating or cooling water systems to
potable water systems. Fillset can be used immediately for manual water make-up or
can be installed upstream of automatic solutions, like the Fillcontrol Auto.

Reflex offers the following Fillset versions:

• Fillset with integrated water meter for monitoring the water make-up volume
• Fillset Contact with contact water meter that can be evaluated by all Reflex Control
devices
• Fillset Compact is a basic space-saving device without water meter

Flow coefficient: 0.8 m³/h

Max. operating temperature: 60 °C
Max. excess operating pressure: 10 bar

Detailed product information can be

found from page 14 onwards.

7
Water make-up systems & water treatment technology

Fillsoft water treatment technol

Modern boilers are expected to withstand constantly increasing heating surface loads, increasing the risk of deposits, particularly
of lime. This can reduce the boiler's performance and, at worst, lead to the failure of the boiler.
To avoid this, Reflex offers Fillsoft, a range of water treatment products with which filling water and make-up water can be sof-
tened in line with the standards. Reflex recommends that customers consider a Fillsoft softening solution for every water make-up
system, as they make a significant contribution to greater system safety with minimum outlay.

Construction Mode of operation

The core of the Fillsoft softening unit is a column with a re-
placeable cartridge in which the moving sodium ions are stored
in synthetic resin balls. This column has connections for fresh
water and filling or make-up water. A shut-off ball valve with a
test valve on the water make-up side completes the set-up.
The target hardness of the filling and make-up water is deter-
mined according to the boiler output and the capacity-specific
volume of the system (for instance in line with VDI 2035 T1).
The hardness of the fresh water is defined by the content of
magnesium and calcium ions.

Hard fresh water Soft filling and make-up water

Mg++ Ca++ Na+ Na+ Na+ Na+

Na+ Ca++

Na+

Na+

Na+ Mg++

The water is softened according to the principle of cation ex-

change. The hard fresh water is passed through the exchange
column. The magnesium and calcium ions that form the hard-
ness are exchanged by the sodium ions in the resin balls and
the water is softened. The cartridge needs to be replaced once
the capacity of the sodium ions has been exhausted.

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

Networked solutions for water m

The combination of Fillcontrol water make-up systems and Fillsoft softening technology is as obvious as it is sensible: in coor-
dinated solutions they make a decisive contribution to greater operational safety and efficiency in heating systems. The recom-
mended combinations of units should always be determined against the background of a specific system design. Below we would
like to outline a number of possible combinations to demonstrate the interplay and possible functions. Refer to pages 12/13 of
this brochure for more information on Reflex design support.

Manual filling and water make-up Automatic filling and water

make-up in systems with
­diaphragm expansion vessels

Fillset Compact + Fillsoft I + Fillmeter Fillcontrol + Fillsoft I + Fillmeter + Exter-

A solution for manual water make-up and
softening of heating water for detached
and semi-detached houses. The Fillset
Compact ensures the requisite system
separation required when making-up
from the potable water network; the fresh
water is automatically softened by the
Fillsoft I. One cartridge to fill the system
is sufficient even with very hard water.
nal pressure sensor
Alternatively: Fillset + Fillsoft II + Fillcon-
trol Plus
For heating systems in commercial
buildings with pressure maintenance by
diaphragm expansion vessels. The filling
and water make-up process is essentially
automatic and signals to a control centre
are also possible. Only the cartridge in
the Fillsoft softening unit needs to be re-
placed manually.

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ake-up and water treatment

Automatic water make-up and Automatic water make-up

softening in systems with and softening in systems with
­Variomat pressurisation stations ­Reflexomat pressurisation
or Servitec degassing stations ­stations

A water make-up unit is integrated into Reflexomat pressurisation stations have

the Variomat and Servitec. The Reflex
Control operates the control valve and
also takes over logic for softening and
water make-up. A Fillset Contact with
contact water meter for determining the
volume of filling water and make-up wa-
ter is included and networked to the con-
trol. A Fillsoft II regulates water softening.
logic for softening and water make-up
integrated into the Reflex Control.
A solenoid valve with ball valve fitted and
integrated into the controller is energised
for water make-up. A Fillset Contact with
contact water meter for determining the
volume of filling water and make-up
water is also included and networked to
the control. The water softening is
regulated by a Fillsoft II.

Non-standard solutions for water make-up:

With Fillcontrol Auto, Reflex is opening up new prospects where conventional

­systems could not be used due to the operating conditions.
• If water is to be made-up regardless of the fresh water pressure.
• When regular inspection obligations for separate fittings for system separation
have to be avoided by the use of a separation vessel.
• When water-anti-freeze mixtures are used in systems.

The Reflex Control scheme enables the Fillcontrol Auto to be integrated perfectly
into systems with Reflexomat.

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Water make-up systems & water treatment technology

Count on us – from the initial id

Reflex offers a range of services to assist you in finding the solution that best suits your needs. Take advantage of our combined
expertise and experience and develop professional and expert solutions together with us, down to the very last detail.

Our service numbers

How can we help you? Please contact the relevant service

number to ensure that you find the right person to deal with
your inquiry as quickly as possible.

Technical hot line

For all questions about our products
Monday to Friday from 8.00 a.m. to 4.30 p.m.
+49 2382 7069-9546
Reflex customer service
To order repairs, maintenance and commissioning
Monday to Friday from 8.00 a.m. to 4.30 p.m.
+49 2382 7069-9505
Central phone number
For general inquiries, to order brochures, contact a business
partner or responsible field sales engineer
Monday to Friday from 8.00 a.m. to 4.30 p.m.
+49 2382 7069-0
Made-to-measure design:
With the Reflex Pro calculation program
Take the easiest route to correct design and sizing: Reflex Pro is
the proven, continuously developed software solution you can
use to quickly and simply achieve precise results. The software
is available in three versions and we also offer a CAD library of
our products for integration into your construction programs.
Visit www.reflex.de/pro for further information and the option
of downloading free of charge.

12
ea to the solution.

Our field sales team – always on the road for you

Our Reflex field sales team is your first point of contact when
you need professional advice on site. From recommending
­relevant products to design and support in the preparation of
a tender. You can rely on our experts!

Call our central phone number or check out www.reflex.de un-

der Contact Us to find the field sales representative responsible
for your region.

Our product literature – designed to be used

Make sure your decisions about all your future steps are based
on solid foundations with Reflex product information. You will
find everything you need to know about products and systems
in our brochures and at www.reflex.de. Well arranged and clear-
ly explained – from the wider context to technical details.

Request the latest Reflex brochures directly from your Reflex

field sales engineer, via our central phone number or – even
simpler – online as PDFs at www.reflex.de.

13
Water make-up systems & water treatment technology

Technical data
Fillset Compact

• Connection group for water make-up systems in accordance with DIN 1988 and
DIN 1717 for direct connection to potable water systems
• With DVGW-certified system separator type BA
• Input and output-side shut-offs
• Without water meter

Article no. 6811305

Max. excess operating pressure 10 bar
Max. operating temperature 60 °C
Width x Height 175 x 214 mm
Weight 0.9 kg
Inlet/outlet connection R ½/R ½
Minimum flow pressure 1) p0 + 1.3 bar 1)
p0 = Gas input pressure in expansion vessel
Flow coefficient 2) kvs 0.8 m3/h = minimum operating pressure of the system
2)
As a single assembly
Flow coefficient 3) kvs 0.7 m3/h 3)
In conjunction with Fillcontrol Plus, Variomat, Reflexomat or Servitec

Fillset

• Connection group for water make-up systems in line with DIN 1988 and DIN 1717
for direct connection to potable water networks
• With DVGW-certified system separator type BA
• Input and output-side shut-offs
• Including standard/contact water meter and wall bracket

Fillset with standard water meter Fillset with contact water meter
Article no. 6811105 6811205
Max. excess operating pressure 10 bar 10 bar
Max. operating temperature 60 °C 60 °C
Width x Height 293 x 230 mm 293 x 230 mm
Weight 1.7 kg 1.7 kg
Inlet/outlet connection R ½/R ½ R ½/R ½
Minimum flow pressure 1) p0 + 1.3 bar p0 + 1.3 bar 1)
p0 = Gas input pressure in expansion vessel
Flow coefficient 2) kvs 0.8 m3/h 0.8 m3/h = minimum operating pressure of the system
2)
As a single assembly
Flow coefficient 3) kvs 0.7 m3/h 0.7 m3/h 3)
In conjunction with Fillsoft

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Fillsoft I/II

• Water softening device for initial filling and water make-up in heating systems
• Fillsoft I: Soft water capacity 6,000 l x °dH
• Fillsoft II: Soft water capacity 12,000 l x °dH
• Incl. shut-off with sample cock and segment connection*
• Fillset I incl. flow limiter

Fillsoft I
Fillsoft I Fillsoft II
Article no. 6811600 6811700
Max. excess operating pressure 8 bar 8 bar
Max. operating temperature 40 °C 40 °C
Height 600 mm 600 mm
Width 260 mm 380 mm
Max. continuous flow 0.4 m3/h 0.4 m3/h
Weight 4.1 kg 7.6 kg
Inlet/outlet connection Rp ½/Rp ½ Rp ½/Rp ½
Capacity 6,000 l x °dH 12,000 l x °dH Fillsoft II

The use of a water meter, e.g. Fillmeter, is required to monitor

the ­residual capacity.
* For the necessary system separation in accordance with DIN EN 1717 and DIN 1988, we
­recommend the Fillset Compact (→ p. 14)

Accessories

Fillmeter Article no. 9119193

Softmix Article no. 9119219
External pressure sensor Article no. 9112004
Fillsoft cartridge Article no. 6811800
Total hardness testing kit Article no. 6811900

External pressure sensor required for combination with Fillcontrol.

Softmix Fillsoft cartridge Pressure Fillmeter Measuring

sensor kit

15
Fillcontrol Plus Compact

• Compact automatic make-up station1), can be used for systems with diaphragm
expansion vessels in accordance with DIN 1988 and DIN EN 1717
• With system separator type BA
• C ontrolled water make-up
• Water make-up volume approx. 0.5 m3/h at ∆p = 1.5 bar

Article no. 6811500

Net weight 3 kg
Inlet/outlet connection R ½/R ½
Minimum flow pressure 2) p0 + 1.3 bar
Output pressure 3) 0.5–5 bar 1)
 n external pressure sensor must be used in combination with Fillsoft
A
Input pressure Max. 10 bar 2)
p0 = pst + 0.2 (recommendation) static pressure (= stat. height [m]/10)
Connection voltage 230 V/50 Hz 3)
System pressure, factory configuration 3 bar

Fillcontrol Plus – make-up station without pump

• To monitor system pressure on expansion vessels and for the automatic water
make-up of the set initial pressure
• Incl. wall bracket
• With Control Basic control unit
• RS 485 interface, connection of bus/extension modules possible
• Capacity monitoring of a Fillsoft water treatment system possible

Standard Stainless steel

Article no. 8812100 8812200
Max. operating temperature 90°C 90°C
Height x width x depth 320 x 340 x 190 mm 320 x 340 x 190 mm
Weight 2.5 kg 2.5 kg
Inlet/outlet connection G ¾/G ½ G ¾/G ½
Max. excess operating pressure 10 bar 10 bar
Input pressure Max. 10 bar Max. 10 bar
Minimum flow pressure p p0 + 1.3 bar1) p0 + 1.3 bar1)
Max. normal pressure p0 + 4 bar2) p0 + 4 bar2) 1)
p0 = Gas input pressure in expansion vessel
Connection voltage 230 V/50 Hz 230 V/50 Hz = minimum operating pressure of the system
2)
If exceeded, fit pressure reducing valve upstream
Flow coefficient3) kvs 1.4 m3/h 1.4 m3/h 3)
As a single assembly
Flow coefficient4) kvs 0.7 m3/h 0.7 m3/h 4)
In conjunction with Fillset

16
Fillcontrol Auto – water make-up station with pump

• Fully automatic water make-up systems with integrated pump

• Fillcontrol Auto Compact with integrated water make-up tank
as a means of system separation
• Fillcontrol Auto for water make-up on glycol mixtures,
e.g. from an open tank glycol mixture
• Systems equipped with Control Basic for simple and clear operation
• RS 485 interface, connection of bus/extension modules possible
• Capacity monitoring of a Fillsoft water treatment system possible
• Including system separation in accordance with DIN 1988 and DIN EN 1717
with Fillcontrol Auto Compact
Fillcontrol Auto Compact

Fillcontrol Fillcontrol Auto

Auto Compact
Article no. 8688500 8812300
Max. excess operating pressure 10 bar 8 bar
Max. operating temperature 30 °C 30 °C
Height x width x depth 620 x 580 x 290 mm 690 x 470 x 440 mm
Weight 17.5 kg 1) 25 kg 1)
Pump pressure Max. 8.5 bar Max. 5.5 bar
Heating connection G½ G1
Potable water connection G½ –
Overflow connection DN 32 –
Supply pressure max. 5.5 bar 2) Fillcontrol Auto
Delivery rate 120–180 l/h 4 m /h
3

Req. feed capacity min. 360 l/h min. 360 l/h 1)

Without water volume
Suction connection at tank – 1¼ 2)
If exceeded, fit pressure reducing valve upstream

17
 PI1308enA / 9571351 / 12 - 13 / 5.000
Subject to technical modifications

Reflex Winkelmann GmbH

Gersteinstrasse 19
59227 Ahlen, Germany

Tel.: +49 2382 7069-0

Fax: +49 2382 7069-588
www.reflex.de