Pressurization systems

Heating , cooling & potable

Planning, calculating and equipment

in partnership with
 Contents
Calculation procedures 2

Pressurization systems
Heating and cooling circuits
Role of pressurization systems 3
Calculation parameters 3
Properties and auxiliary variables 4
Hydraulic integration 5
Special pressurization systems - overview 6
Reflex diaphragm expansion vessels 7
Heating systems 8-9
Solar energy systems 10 - 13
Cooling water systems 14 - 15
Reflex pressurization systems with external pressure generation 16 - 20
District heating systems, large-scale and special systems 21
Potable water systems
Hot water systems 22 - 23
Pressure booster systems 22 - 24

1
General information

Terms, code letters, symbols 25

 Calculation procedures

Calculation procedures

The aim of this guide is to provide you with the most important information Calculation forms
required to plan, calculate and equip Reflex pressurization
Calculation forms are provided for individual systems. Auxiliary variables
Overviews detail the most important auxiliary variables and properties for cal-
culation as well as relevant requirements for safety equipment.

Please contact us if you require any additional information.

Your specialist adviser will be happy to help.

Standards, The following standards and guidelines contain basic information on planning,
guidelines calculation, equipment and operation:

DIN EN 12828 Heating systems in buildings – Planning of hot

water heating systems
DIN 4747 T1 District heating systems, safety equipment
DIN 4753 T1 Water heaters and water heating systems
DIN EN 12976/77 Thermal solar systems
VDI 6002 (Draft) Solar heating for domestic water
VDI 2035 Part 1 Prevention of damage through scale formation in
domestic hot water and water heating installations
VDI 2035 Part 2 Prevention of damage through water-side
corrosion in water heating installations
EN 13831 Closed expansion vessels with built in diaphragm
for installation in water
4
DIN 4807 Expansion vessels
DIN 4807 T1 Terms...
DIN 4807 T2 Calculation in conjunction with DIN EN 12828
DIN 4807 T5 Expansion vessels for drinking water installations
DIN 1988 Technical rules for drinking water installations,
pressure increase and reduction
DIN EN 1717 Protection against pollution of potable water
DGRL Pressure Equipment Directive 97/23/EC
BetrSichV Ordinance on Industrial Safety and Health (as of
01/01/2003)
EnEV Energy Saving Ordinance

Planning The product-specific information required for calculations can be found in the
documentation relevant product documents and, of course, at ’www.altecnic.co.uk’.

Systems Not all systems are covered by the standards, nor is this possible. Based on
new findings, we therefore also provide you with information for the calculation
of special systems, such as solar energy systems, cooling water circuits, and
district heating systems.

With the automation of system operation becoming ever more important, pres-
sure monitoring and water make-up systems are thus also discussed, in addi-
tion to central deaeration and degassing systems.

Calculation program Computer-based calculations of pressurization systems and heat exchangers

can be performed via our Reflex calculation program, which is available for
use or download at www.reflex.de. Another option is to use our new ’reflex
pro app’!
Both tools represent a quick and simple means of finding your ideal solution.
 Pressurization systems
Heating and cooling circuits

Role of pressurization systems

Pressurization systems play a central role in heating and cooling circuits and perform three main tasks:
1. They keep the pressure within permissible limits at all points of the system, thus ensuring that the
authorized excess operating pressure is maintained while safeguarding a minimum pressure to prevent
vacuums, cavitation and evaporation.
2. They compensate for volume fluctuations of the heating or cooling water as a result of temperature
variations.
3. Provision for system-based water losses by means of a water seal.
Careful calculation, commissioning and maintenance are essential to the correct functioning of the overall system.

Calculation
parameters
tF tR

PAZ+ pSV
pst, H
Most common
pf configuration:
Circulating pump in
pfil, pi advance
p0 Expansion vessel in
return
PAZ =
suction pressure
maintenance
Definitions in accordance with DIN EN 12828 and following DIN 4807 T1/T2 based on the example 3
of a heating system with a diaphragm expansion vessel.

Pressures are given as overpressures and relate to the expansion vessel connection or the pressure
gauge on pressurization stations. The configuration corresponds to the diagram above.
pSV Safety valve actuation pressure The permissible excess operating
pressure must not be exceeded at
bar
0.2

PAZ+ = PLmax Pressure limiter any point within the system.

difference acc. to
Closing pressure

PLmax required in accor-

TRD 721 = ASV

dance with DIN EN 12828

if individual boiler output
> 300 kW

pf Final pressure Pressure in the system at

maximum temperature
Setpoint value range for
pressure maintenance=
normal pressure level

Ve Expansion volume

Normal pressure range

= Pressure maintenance
setpoint value between
pfil Filling pressure pi and pf
Pressure in the system at
filling temperature
pi Initial pressure Pressure in the system at
minimum temperature
Water seal VWS
VWS Water
0.3 bar

seal

to cover system-related
water losses
≥

p0 Minimum operating pressure Minimum pressure to avoid

= Input pressure for expansion vessel - Vacuum formation PLmin acc. to DIN EN 12828;
0.2 bar

PAZ = PLmin Minimum pressure limiter - Evaporation to ensure p0 in hot water

+ pe

- Cavitation systems, an automatic

pst Static pressure
≥

Pressure of liquid column based on water make-up system is

static height (H) recommended along with
an optional minimum
pressure limiter.
 Pressurization systems
Heating and cooling circuits

Properties and auxiliary variables

Properties of water and water mixtures

Pure water without antifreeze additive

t / °C 0 10 20 30 40 50 60 70 80 90 100 105 110 120 130 140 150 160

n/% 0 0.13 0.37 0.72 1.15 1.66 2.24 2.88 3.58 4.34 4.74 5.15 6.03 6.96 7.96 9.03 10.20
(+ 10°C of t)
pe / bar -0.99 -0.98 -0.96 -0.93 -0.88 -0.80 -0.69 -0.53 -0.30 0.01 0.21 0.43 0.98 1.70 2.61 3.76 5.18
∆n (tR) 0 0.64 1.34 2.10 2.50 2.91 3.79
ρ / kg/m³ 1000 1000 998 996 992 988 983 978 972 965 958 955 951 943 935 926 917 907

Water with antifreeze additive* 20% (vol.)

Lowest permissible system temperature -10°C
t / °C 0 10 20 30 40 50 60 70 80 90 100 105 110 120 130 140 150 160
n* / % 0.07 0.26 0.54 0.90 1.33 1.83 2.37 2.95 3.57 4.23 4.92 --- 5.64 6.40 7.19 8.02 8.89 9.79
(- 10°C of t)
pe* / bar -0.9 -0.8 -0.7 -0.6 -0.4 -0.1 --- 0.33 0.85 1.52 2.38 3.47 4.38
ρ / kg/m³ 1039 1037 1035 1031 1026 1022 1016 1010 1004 998 991 --- 985 978 970 963 955 947

Water with antifreeze additive* 34% (vol.)

Lowest permissible system temperature - 20°C
t / °C 0 10 20 30 40 50 60 70 80 90 100 105 110 120 130 140 150 160
n* / % 0.35 0.66 1.04 1.49 1.99 2.53 3.11 3.71 4.35 5.01 5.68 --- 6.39 7.11 7.85 8.62 9.41 10.2
(- 20 °C of t)
pe* / bar -0.9 -0.8 -0.7 -0.6 -0.4 -0.1 --- 0.23 0.70 1.33 2.13 3.15 4.41
ρ / kg/m³ 1066 1063 1059 1054 1049 1043 1037 1031 1025 1019 1012 --- 1005 999 992 985 978 970
n - Percentage expansion for water based on a minimum system temperature of +10°C (generally filling water)
4 n* - Percentage expansion for water with antifreeze additive* based on a minimum system temperature of -10°C or -20°C
∆v - Percentage expansion for water for calculation of temperature layer containers between 70°C and max. return temperature
pe - Evaporation pressure for water relative to atmosphere
pe* - Evaporation pressure for water with antifreeze additive
ρ - Density
* - Antifreeze Antifrogen N; when using other antifreeze additives, the relevant properties must be obtained from the manufacturer

Approximate calculation of water content Vs of heating systems

Vs = Qtot x vs + pipelines + other → for systems with natural circulation boilers
Vs = Qtot (vs - 1.4 l) + pipelines + other → for systems with heat exchangers
Vs = Qtot (vs - 2.0 l) + pipelines + other → for systems without heat exchangers
Installed heating output
Vs = + + = liters
Specific water content vs in liters/kW of heating systems (heat exchangers, distribution, heating surfaces)

Radiators Plates Convectors Ven- Floor heating

tF/tR
Cast iron Tube and steel tilation
°C
radiators radiators
60/40 27.4 36.2 14.6 9.1 9.0 Caution:
70/50 20.1 26.1 11.4 7.4 8.5 approximate values;
70/55 19.6 25.2 11.6 7.9 10.1 significant deviations
80/60 16.0 20.5 9.6 6.5 8.2 Vs = 20 l/kW possible in individual
90/70 13.5 17.0 8.5 6.0 8.0 nFH cases.
Vs** = 20 l/kW n
105/70 11.2 14.2 6.9 4.7 5.7
110/70 10.6 13.5 6.6 4.5 5.4
100/60 12.4 15.9 7.4 4.9 5.5
** If the floor heating is operated and protected as part of the overall system with lower flow
temperatures, vs** must be used to calculate the total water volume
nFH = percentage expansion based on the max. flow temperature of the floor heating

Approx. water content of heating pipes

DN 10 15 20 25 32 40 50 60 65 80 100 125 150 200 250 300
Liters/m 0.13 0.21 0.38 0.58 1.01 1.34 2.1 3.2 3.9 5.3 7.9 12.3 17.1 34.2 54.3 77.9
 Pressurization systems
Heating and cooling circuits

Hydraulic integration
The hydraulic integration of pressure maintenance in the overall
system greatly influences the pressure profile. This is made up
of the normal pressure level of the pressure maintenance and
the differential pressure generated when the circulating pump is
running. Three main types of pressure maintenance are distin-
guished, although additional variants exist in practice.

Input pressure maintenance (suction pressure maintenance)

The pressure maintenance is integrated before the circulat-
ing pump, i.e. on the suction side. This method is used almost Advantages:
exclusively since it is the easiest to manage. - Low normal pressure
level
pper - Operating pressure
psup pP ASV
> normal pressure,
Operating
thus no risk of vacu-
pSV pressure um formation
pper
Disadvantages:
- High operating pres-
pSV sure in the case of
ASV pf high circulating pump
Normal pressure setpoint value
pi pressure (large-scale
p i, p f p0, psup systems); pper must
be observed
Follow-up pressure maintenance The pressure maintenance is integrated after the cir-
culating pump, i.e. on the pressure side. When calculating the Advantages:
normal pressure, a system-specific differential pressure share - Low normal pressure
of the circulating pump (50 ... 100%) must be included. This level, provided the full
method is restricted to a limited number of applications solar pump pressure is not 5
energy systems. required
pSV, pper Disadvantages:
ASV
Normal pressure
pf - High normal pressure
pSV
pper
setpoint value pi level
p0 - Increased need to
pP observe the required
Operating
pressure supply pressure psup for
psup the circulating pump
p i, p f
according to manufac-
psup
turer specifications

Medium pressure maintenance The measuring point of the normal pressure level is
“moved” into the system by means of an analogy measure- Advantages:
ment section. The normal and operating pressure levels can - Optimized, variable
be perfectly coordinated in a variable manner (symmetrical, coordination of oper-
asymmetrical medium pressure maintenance). Due to the tech- ating and normal
nically demanding nature of this method, its use is restricted to pressure
systems with complicated pressure ratios, mainly in the field of Disadvantages:
district heating. - Highly demanding
pSV, pper
ASV with regard to system
pSV Operating technology
pressure
pper
ASV pf
Normal pressure
setpoint value
pi
p i, p f p0

psup
psup
pP

Reflex recommendation Use suction pressure maintenance! A different method

should only be used in justified exceptional cases.
Contact us for more information!
 Pressurization systems
Heating and cooling circuits

Special pressurization systems - overview

Reflex manufactures two different types of pressurization system:

Reflex diaphragm expansion vessels with gas cushions can function without auxiliary
energy and are thus also classed as static pressurization systems. The pressure is cre-
ated by a gas cushion in the vessel. To enable automatic operation, the system is ideally
combined with reflex ’magcontrol’ make-up stations as well as reflex ’servitec’ make-up
and degassing stations.

Reflex pressurization systems with external pressure generation require auxiliary

energy and are thus classed as dynamic pressurization systems. A differentiation is
made between pump- and compressor-controlled systems. While reflex ’variomat’ and
reflex ’gigamat’ control the system pressure directly on the water side using pumps and ’Degassing of heating
overflow valves, the pressure in reflex ’minimat’ and ’reflexomat’ systems is controlled on and cooling systems’
the air side by means of a compressor and solenoid valve. This brochure explains
when and why the use
of degassing systems
Both systems have their own advantages. Water-controlled systems, for example, are very is required, particularly
quiet and react very quickly to changes in pressure. Thanks to the unpressurized storage of in closed systems.
the expansion water, such systems can also be used as central deaeration and degassing
units (’variomat’). Compressor-controlled systems, such as ’reflexomat’, offer extremely
flexible operation within the tightest pressure limits, specifically within ± 0.1 bar (pump-
controlled approx. ± 0.2 bar) of the setpoint value.
A degassing function can also be implemented in this case in combination with reflex
’servitec’.

Our Reflex calculation program will help you identify the ideal solution.

6 Preferred applications are detailed in the following table. Based on experience, we

recommend that the pressure maintenance be automated – i.e. pressure monitoring
with timely water make-up – and that systems be automatically and centrally vented.
This eliminates the need for conventional air separators and laborious post-venting, while
ensuring safer operation and lower costs

Autom. Central
Standard pressure operation deaera-
maintenance Pressure with make- tion and Preferred output
Flow temp. up to 120°C maint. up degassing range

- Without additional equipment X --- ---

’reflex’ expan-
- With ’control’ make-up X X --- Up to 1,000 kW
sion vessel
- With ’servitec’ X X X

1 Single-pump system X X X 150 - 2,000 kW

’variomat’ 2-1 Single-pump system X X X 150 - 4,000 kW
2-2 Dual-pump system X X X 500 - 8,000 kW

- Without additional equipment X X X*

5,000 - 60,000 kW
- With ’servitec’ X X X
’gigamat’

- Special systems As required

- Without additional equipment X --- ---

’minimat’ - With ’control’ make-up X X --- 100 - 2,000 kW
- With ’servitec’ X X X

- Without additional equipment X --- ---

’reflexomat’ - With ’control’ make-up X X --- 150 - 24,000 kW
- With ’servitec’ X X X

* In the case of return temperatures < 70°C, re ex ’gigamat’ can also be used for degassing purposes without additional equipment
 Pressurization systems
Heating and cooling circuits

Reflex diaphragm expansion vessels

types: ’reflex N, F, S, G’
Nominal volume Vn The pressure in the expansion vessel is generated by a gas cushion. The
water level and pressure in the gas space are linked (p x V = constant).
Without degassing
Therefore, it is not possible to use the entire nominal volume for water
intake purposes. The nominal volume is greater than the water intake pf + 1
Vn = (Ve + VWS) pf - p0
Vn volume Ve + VWS by a factor of pf + 1 .
pf - p0
This is one reason why dynamic pressurization systems are preferable in
the case of larger systems and small pressure ratios (pf - p0). When using With reflex ’servitec’
reflex ’servitec’ degassing systems, the volume of the degassing pipe (5 pf + 1
liters) must be taken into account during sizing. Vn = (Ve + VWS + 5 l) pf - p0
Ve + VWS

Pressure monitoring The gas input pressure must be manually checked before commission-
Input pressure p0 ing and during annual maintenance work; it must be set to the minimum
Minimum operating operating pressure of the system and entered on the name plate. The
pressure planner must specify the gas input pressure in the design documenta-
tion. To avoid cavitation on the circulating pumps, we recommend that
the minimum operating pressure not be set to less than 1 bar, even in the
case of roof-mounted systems and heating systems in low-rise buildings. Input pressure maintenance
The expansion vessel is usually integrated on the suction side of the
p0 ≥ pst + pe + 0.2 bar
circulating pump (input pressure maintenance). In the case of pressure-
p0 ≥ 1 bar Reflex recommendation
side integration (follow-up pressure maintenance) the differential pres-
sure of the circulating pumps pP must be taken into account to avoid Follow-up pressure maintenance
vacuum formation at high points.
When calculating p0, we recommend the addition of 0.2 bar safety mar- p0 ≥ pst + pe + ∆pP
gin. This margin should only be dispensed with in the case of very small
7
pressure ratios.
Initial pressure pa This is one of the most important pressures! It limits the lower setpoint
Water make-up value range of the pressure maintenance and safeguards the water
seal VWS, that is the minimum water level in the expansion vessel.
Accurate checking and monitoring of the input pressure is only ensured
if the Reflex formula for the input pressure is followed. Our calculation Reflex formula for initial
program takes this into account. With these higher input pressures pressure
compared to traditional configurations (larger water seal), stable opera-
pi ≥ p0 + 0.3 bar
tion is assured. Known problems with expansion vessels caused by an
insufficient or even missing water seal are thus avoided. Particularly in
the case of small differences between the final pressure and input pres-
sure, the new calculation method can result in somewhat larger vessels.
However, in terms of enhanced operational safety, the difference is
insignificant.
reflex ’control’ make-up stations automatically monitor and secure the Reflex recommendation
initial or filling pressure. → reflex ’control’ make-up stations pf = pSV - ASV
Filling pressure pfil The filling pressure pfil is the pressure that must be applied, relative to pSV ≥ p0 + 1.5 bar
the temperature of the filling water, to fill a system such that the water for pSV ≤ 5 bar
seal VWS is maintained at the lowest system temperature. In the case of pSV ≥ p0 + 2.0 bar
heating systems, the filling pressure and initial pressure are generally for pSV > 5 bar
the same (lowest system temperature = filling temperature = 10°C). In
cooling circuits with temperatures below 10°C, for instance, the filling Closing pressure difference
pressure is higher than the initial pressure. acc. to TRD 721 ASV
SV-H 0.5 bar
Final pressure pf The final pressure restricts the upper setpoint value range of the pres- SV-D/G/H 0.1 pSV
sure maintenance. It must be set such that the pressure on the system 0.3 bar for
safety valve is lower by at least the closing pressure difference ASV in pSV < 3 bar
accordance with TRD 721. The closing pressure difference depends on
the type of the safety valve.
Degassing Targeted venting is very important, particularly in the case of closed
Deaeration systems; otherwise, accumulations of nitrogen in particular can lead to
troublesome malfunctions and customer dissatisfaction. reflex ’servitec’
degases and makes up water automatically.
 Pressurization systems
Heating and cooling circuits

Heating systems
Calculation According to DIN 4807 T2 and DIN EN 12828

Configuration Usually in the form of suction pressure maintenance as per adjacent

diagram with circulating pump in advance and expansion vessel in return
– i.e. on the suction side of the circulating pump

Properties n, pe Generally properties for pure water without antifreeze additive → page 4

Expansion volume Ve Calculation of percentage expansion, usually between lowest temperature ’reflex’
’variomat’
Highest temperature tTR = filling temperature = 10°C and highest setpoint value adjustment of tem- ’gigamat’
perature regulator tTR ’reflexomat’

Minimum operating pres- Particularly in the case of low-rise buildings and roof-mounted systems,
sure p0 the low static pressure pst requires that the minimum supply pressure for
the circulating pump be verified on the basis of manufacturer specifica- Caution with roof-mount-
tions. Even with lower static heights, we therefore recommend that the ed systems and low-rise
minimum operating pressure p0 not be set to less than 1 bar. buildings
Reflex recommendation:
Filling pressure pfil Since a filling temperature of 10°C generally equates to the lowest system p0 ≥ 1 bar
Initial pressure pa temperature, the filling pressure and input pressure of an expansion ves-
sel are identical.
In the case of pressurization systems, it should be noted that filling and
make-up systems may have to operate at a level approaching the final
pressure. This only applies to ’reflexomat’.

Pressure maintenance In the form of static pressure maintenance with ’reflex N, F, S, G’ also in
combination with the make-up and degassing stations ’control’ and ’ser-
8 vitec’, or from approx. 150 kW as a ’variomat’ pressurization station for
pressure maintenance, degassing and water make-up, or in the form of a
compressor-controlled ’reflexomat’ pressurization station. → page 16

In systems with oxygen-rich water (e.g. floor heating with non-diffusion-

In the case of corrosion
resistant pipes), ’refix D’, ’refix DE’ or ’refix DE junior’ are used up to 70°C
risk, use ’refix’
(all water-carrying parts corrosion-resistant).

Degassing, deaeration, To ensure ongoing safe and automatic operation of the heating system,
water make-up the pressurization units should be equipped with make-up systems and
supplemented with ’servitec’ degassing systems. More information can be
found on page 28.

In-line vessels If a temperature of 70°C is permanently exceeded by the pressure main-

tenance, an in-line vessel must be installed to protect the diaphragms in
the expansion vessel.

Individual protection According to DIN EN 12828, all heat generators must be connected to
at least one expansion vessel. Only protected shut-offs are permitted. If
a heat generator is shut off hydraulically (e.g. in-line boiler circuits), the
connection with the expansion vessel must remain intact. Therefore, in the
case of multi-boiler systems, each boiler is usually secured with a separate
expansion vessel. This is only included in the calculation for the relevant
boiler water content.

Due to the excellent degassing performance

of ’variomat’, we recommend that the switch
frequency be minimized by also fitting a dia-
phragm expansion vessel (e.g. ’reflex N’) to
the heat generator in this case.
 Presurization systems
Heating and cooling circuits

’reflex N, F, G’ in heating systems

Configuration Input pressure maintenance, expansion vessel in return, circulating pump in

advance, observe information on page 9 for follow-up pressure maintenance.
Object:

Initial data
Heat generator 1 2 3 4
Heat output Qh = .......... kW .......... kW .......... kW .......... kW Qtot = .......... kW
Water content VW = .......... liters
System flow temperature tF = .......... °C
→ p. 4 Approximate water content
System return temperature tR = .......... °C Vs = .......... liters If R > 70°C,
vs = f (tF, tR, Q)
Water content known Vs = .......... liters ’V in-line vessel’
Highest setpoint value adjustment required
→ p. 4 Percentage expansion n
Temperature regulator tTR = .......... °C n = .......... %
(with antifreeze additive n*)
Antifreeze additive = .......... %
→ p. 4 Evaporation pressure pe at > 100°C
Safety temperature limiter tSTL = .......... °C pe = .......... bar
with antifreeze additive pe*)
Static pressure pst = .......... bar pst = .......... bar

Pressure calculation
1)
1)
Recommendation
Input pressure p0 = stat. pressure pst + evaporation pressure pe + (0.2 bar)
1) p0 = .......... bar Check rec. supply pres-
p0 = ....................... +.......................................+ (0.2 bar) = ............. bar
sure of circulation pump
Reflex recommendation p0 ≥ 1.0 bar
as per manufacturer
Safety valve actuation pSV → Reflex recommendation
specifications
pressure pSV ≥ input pressure p0 + 1.5 bar for pSV ≤ 5 bar
pSV = .......... bar Check compliance
pSV ≥ input pressure p0 + 2.0 bar for pSV > 5 bar
with perm. operat-
pSV ≥ ....................... +......................................................... = ............. bar 9
ing pressure
Final pressure pf ≤ safety valve pSV - closing pressure difference acc. to TRD 721
pf ≤ pSV - 0.5 bar for pSV ≤ 5 bar
pf = .......... bar
pf ≤ pSV - 0.1 x pSV for pSV > 5 bar
pf ≤ ................................ - ............................................... = ............. bar

Vessel
n
Expansion volume Ve = x Vs = ...................... x ............................. = .......... liters Ve = ......... liters
100
Water seal VWS = 0.005x Vs for Vn > 15 liters with VWS ≥ 3 liters
VWS ≥ 0.2 x Vn for Vn ≤ 15 liters VWS = ......... liters
VWS ≥ ..........x .... = ...................... x ............................. = .......... liters
Nominal volume
pf +1
Without ’servitec’ Vn = (Ve + VWS) x
pf - p0
With ’servitec’ Vn = (Ve + VWS + 5 liters) x pf +1 Vn = ......... liters
pf - p0
Vn ≥ ............................. x ............................................ = .......... liters
Selected Vn ’reflex’ = .......... liters
Initial pressure check
Without ’servitec’ pi = pf + 1 - 1 bar
Ve (pf + 1)(n + nR)
1+
Vn (p0 + 1) 2n
With ’servitec’ pi = pf + 1 - 1 bar
(Ve + 5 liters)(pf + 1) (n + nR) pi = .......... bar Filling pressure
1+
Vn (p0 + 1) 2n =
............................... Initial pressure
pi = - 1 bar = ............. bar
........................... at 10°C filling
1+
........................... temperature
Condition: pi ≥ p0 + 0.25...0.3 bar, otherwise calculation for greater nominal volume

Result summary
’reflex ...’ / ... bar ........... liters Input pressure p0 = ......... bar → check before commissioning
’refix ...’ / ... bar ........... liters Initial pressure pi = ......... bar → check make-up configuration
’refix’ only for oxygen-rich water Final pressure pf = ......... bar
(e.g. floor heating)
 Pressurization systems
Heating and cooling circuits

Solar heating plants (solar energy systems)

Calculation On the basis of VDI 6002 and DIN 4807 T2 Direct heating in a flat
collector or direct-flow
In the case of solar heating plants, the highest temperature cannot be tube collector
defined via the regulator on the heat generator, but instead is determined by
the stagnation temperature on the collector. This gives rise to two possible
calculation methods. SL

VC
RL

Indirect heating in a tube

collector according to the
heat pipe principle

RL
SL

VC
Heat pipe

Note manufacturer
specifications
for stagnation
Nominal volume Calculation without evaporation in the collector
temperatures!
10 The percentage expansion n* and evaporation pressure pe* are based on Nominal volume with-
the stagnation temperature. Since some collectors can reach temperatures out evaporation
of over 200°C, this calculation method cannot be applied here. In the case pf + 1
of indirectly heated tube collectors (heat pipe system), it is possible for sys- Vn = (Ve + VWS) pf - p0
tems to restrict the stagnation temperature. If a minimum operating pressure
of p0 ≤ 4 bar is sufficient to prevent evaporation, the calculation can usually
be performed without taking evaporation into account.

With this option, it should be noted that an increased temperature load will
impact the antifreeze effect of the heat transfer medium in the long term.

Nominal volume Calculation with evaporation in the collector

For collectors with stagnation temperatures in excess of 200°C, evaporation Nominal volume with
in the collector cannot be excluded. In this case, the evaporation pressure evaporation
is only included in the calculation up to the desired evaporation point (110 - pf + 1
120°C). When calculating the nominal volume of the expansion vessel, the Vn = (Ve + VWS + VC) pf - p0
entire collector volume VC is included in addition to the expansion volume
Ve and the water seal VWS.

This is the preferred option, as the lower temperature has a lesser impact
on the heat transfer medium and the antifreeze effect is maintained for a
longer period.
 Pressurization systems
Heating and cooling circuits

Configuration Since the expansion vessel with safety valve in the return must be installed
such that it cannot be shut off from the collector, this inevitably leads to
follow-up pressure maintenance, i.e. integration of the expansion vessel on
the pressure side of the circulating pump.

Properties n*, pe* When determining the percentage expansion n* and the evaporation pres-
sure pe*, antifreeze additives of up to 40% must be taken into account in
accordance with manufacturer specifications.
’reflex S’
→ p. 4, properties for water mixtures with Antifrogen N

If calculating with evaporation, the evaporation pressure pe* is included up

to the boiling temperature 110°C or 120°C. The percentage expansion n* is With evaporation
then determined between the lowest ambient temperature (e.g. -20°C) and pe* = 0
the boiling temperature. n* = f (boiling temp.)

If calculating without evaporation, the evaporation pressure pe* and the Without evaporation
percentage expansion n* must be based on the stagnation temperature of pe* = f (stagnation temp.)
the collector. n* = f (stagnation temp.)

Input pressure p0 Depending on the calculation method employed, the minimum operat- Without evaporation
Minimum operating ing pressure (= input pressure) is adapted to the stagnation temperature p0 = pst + pe*(stagnation) + ∆pP
pressure in the collector (= without evaporation) or the boiling temperature (= with
evaporation). In both cases, the normal configuration of the circulating pump With evaporation 11
pressure ∆pP must be taken into account since the expansion vessel is p0 = pst + pe*(boiling) + ∆pP
integrated on the pressure side of the circulating pump (follow-up pressure
maintenance).
Enter set input pressure
on name plate
Filling pressure pfil As a rule, the filling temperature (10°C) is much higher than the lowest
Initial pressure pa system temperature, such that the filling pressure is greater than the initial
pressure.

Pressure maintenance Generally in the form of static pressure maintenance with ’reflex S’, also in
combination with ’magcontrol’ make-up stations.

In-line vessels If a stable return temperature ≤ 70°C cannot be guaranteed on the con-
sumer side, an in-line vessel must be fitted to the expansion vessel.
 Pressurization systems
Heating and cooling circuits

reflex ’S’ in solar energy systems with evaporation

Calculation method: The minimum operating pressure p0 is calculated such that no

evaporation occurs up to flow temperatures of 110°C or 120°C
– i.e. evaporation is permitted in the collector at stagnation
temperature.

Configuration Follow-up pressure maintenance, expansion vessel in return to collector.

Object:

Initial data
Number of collectors z .......... units
Collector surface area AC .......... m² ACtot = z x AC ACtot = .......... m² ACtot = ......... bar
Water content per collector VC ......... liters VCtot = z x AC VCtot = .......... liters VCtot = ......... liters
Highest flow temperature tF 110°C or 120°C Check compliance with
→ p. 4 Percentage expansion n* and n* = .......... % minimum supply pres-
Lowest ambient temperature ta - 20°C
evaporation pressure pe* pe* = .......... bar sure psup for circulating
Antifreeze additive .......... %
Static pressure pst .......... bar pst = .......... bar pumps acc. to manufac-
Difference at circulating turer specifications.
∆pP .......... bar psup = p0 - ∆�
pump ∆pP = .......... bar

Pressure calculation
Check compliance
Input pressure p0 = stat. pressure pst + pump pressure ∆pP + evaporation pressure pe* with perm. operat-
p0 = ........................... + .............................. + .................................... p0 = .......... bar ing pressure
= .......... bar
Safety valve actuation pSV → Reflex recommendation
pressure pSV ≥ input pressure p0 + 1.5 bar for pSV ≤ 5 bar
pSV = .......... bar
pSV ≥ input pressure p0 + 2.0 bar for pSV > 5 bar
pSV ≥ .................. + ............................................ = .......... bar
12 Final pressure pf ≤ safety valve pSV – Closing pressure difference acc. to TRD 721
pf ≤ pSV – 0.5 bar for pSV ≤ 5 bar
pf = .......... bar
pf ≤ pSV – 0.1 bar x pSV > 5 bar
pf ≤ .............................. – ................................. = .......... bar

Vessel
System volume Vs = collector vol. VCtot + pipelines + buffer tank + other
Vs = ......... liters
Vs = ............................ + .............. + ................ + ................
= .......... liters
Expansion n*
Ve = x Vs = ...................... + .................. = .......... liters Ve = ......... liters
volume 100
Water seal VWS = 0.005 x Vs for Vn > 15 liters with VWS ≥ 3 liters
VWS ≥ 0.2 x Vn for Vn ≤ 15 liters VWS = ......... liters
VWS ≥ .......... x .... = ........... x .................. = .......... liters
Nominal volume
pf +1
Vn = (Ve + VWS + VCtot ) x
pf - p0
Vn = ......... liters
Vn ≥ ............................. x ................................. = .......... liters
Selected Vn ’reflex S’ = .......... liters
Check of
initial pressure pi = pf + 1 – 1 bar
(Ve + VCtot)(pf + 1)
1+
Vn (p0 + 1)
............................... pi = .......... bar
pi = – 1 bar = .......... bar
..........................
1+
...........................
Condition: pi ≥ p0 + 0.25...0.3 bar, otherwise calculation for greater nominal volume
Percentage expansion Between lowest temperature (- 20°C) and filling temperature (usually 10°C)
n*F = .......... %
→ p. 6 n*F = .......... %
Filling pressure
p0 +1
pfil = Vn x – 1 bar
Vn - Vs x nF* - VWS pfil = .......... bar
pfil = ............................. x ..................... – 1 bar = .......... liters

Result summary
’reflex S’/10 bar ........... liters Input pressure p0 = ......... bar → check before commissioning
Initial pressure pi = ......... bar → check make-up configuration
Filling pressure pfil = ......... bar → refilling of system
Final pressure pf = ......... bar
 Pressurization systems
Heating and cooling circuits

reflex ’S’ in solar energy systems without evaporation

Calculation method: The minimum operating pressure p0 is set such that no

evaporation occurs in the collector – generally possible at
stagnation temperatures ≤ 150°C.
Configuration Follow-up pressure maintenance, expansion vessel in return to collector

Object:

Initial data
Number of collectors z .......... units
Collector surface area AC .......... m² ACtot = z x AC ACtot = .......... m² ACtot = ......... bar
Water content per collector VC ......... liters VCtot = z x AC VCtot = .......... liters VCtot = ......... liters
Highest advance temperature tF
→ p. 4 Percentage expansion n* and n* = .......... %
Lowest ambient temperature ta - 20°C
evaporation pressure pe* pe* = .......... bar
Antifreeze additive .......... %
Static pressure pst .......... bar pst = .......... bar Check compliance with min-
Difference at circulating imum supply pressure psup
∆pP .......... bar
pump ∆pP = .......... bar for circulating pumps acc. to
manufacturer specifications.
Pressure calculation psup = p0 - ∆pP

Input pressure p0 = stat. pressure pst + pump pressure ∆pP + evaporation pressure pe* Check compliance
p0 = ........................... + .............................. + .................................... p0 = .......... bar with perm. operat-
= .......... bar ing pressure
Safety valve actuation pSV → Reflex recommendation
pressure pSV ≥ input pressure p0 + 1.5 bar for pSV ≤ 5 bar
pSV = .......... bar
pSV ≥ input pressure p0 + 2.0 bar for pSV > 5 bar
pSV ≥ .................. + .................................................... = .......... bar
Final pressure pf ≤ safety valve pSV – Closing pressure difference acc. to TRD 721
pf ≤ pSV – 0.5 bar for pSV ≤ 5 bar 13
pf = .......... bar
pf ≤ pSV – 0.1 bar x pSV > 5 bar
pf ≤ .............................. – ................................. = .......... bar

Vessel
System volume Vs = collector vol. VCtot + pipelines + buffer tank + other Vs = ......... liters
Vs = ............................ + ............. + .................. + ................
= .......... liters
n*
Expansion volume Ve = 100 x Vs = ...................... + .................. = .......... liters Ve = ......... liters
Water seal VWS = 0.005 x Vs for Vn > 15 liters with VWS ≥ 3 liters
VWS ≥ 0.2 x Vn for Vn ≤ 15 liters VWS = ......... liters
VWS ≥ .......... x .... = ........... x .................. = .......... liters
Nominal volume
pf +1
Vn = (Ve + VWS ) x
pf - p 0
Vn = ......... liters
Vn ≥ ............................. x ................................. = .......... liters
Selected Vn ’reflex S’ = .......... liters
Check of
pf + 1
initial pressure pi = – 1 bar
Ve (pf + 1)
1+
Vn (p0 + 1)
............................... pi = .......... bar
pi = – 1 bar = .......... bar
..........................
1+
...........................
Condition: pi ≥ p0 + 0.25...0.3 bar, otherwise calculation for greater nominal volume
Percentage expansion Between lowest temperature (- 20°C) and filling temperature (usually 10°C)
n*F = .......... %
→ p. 6 n*F = .......... %
Filling pressure
p0 +1
pfil = Vn x – 1 bar
Vn - Vs x nF* - VWS pfil = .......... bar
pfil = ............................. x ..................... – 1 bar = .......... liters

Result summary
’reflex S’/10 bar ........... liters Input pressure p0 = ......... bar → check before commissioning
Initial pressure pi = ......... bar → check make-up configuration
Filling pressure pfil = ......... bar → refilling of system
Final pressure pf = ......... bar
 Pressurization systems
Heating and cooling circuits

Cooling water systems

Calculation On the basis of DIN EN 12828 and DIN 4807 T2

Configuration In the form of input pressure maintenance as per adjacent diagram with
expansion vessel on the suction side of the circulating pump, or in the form
of follow-up pressure maintenance.
’reflex’
Properties n* When determining the percentage expansion n*, antifreeze additives appro-
priate for the lowest system temperature must be included in accordance
with manufacturer specifications.
For Antifrogen N → p. 5

Expansion volume Ve Calculation of the percentage expansion n* usually between the lowest
system temperature (e.g. winter downtime: -20°C) and the highest system
temperature (e.g. summer downtime +40°C).

Minimum operating Since no temperatures > 100°C are used, no special margins are required. Enter set input
pressure p0 pressure on name
plate

Filling pressure pfil Initial In many cases, the lowest system temperature is less than the filling tem-
pressure pi perature, meaning that the filling pressure is higher than the initial pressure.

14
Pressure maintenance Generally in the form of static pressure maintenance with ’reflex’, also in
combination with ’control’ and ’servitec’ make-up and degassing stations.

Degassing, deaeration, To ensure ongoing safe and automatic operation in cooling water systems,
water make-up the pressurization units should be equipped with make-up systems and
supplemented with ’servitec’ degassing systems. This is particularly impor-
tant with cooling water systems, since no thermal deaeration effects apply.

In-line vessels Although ’reflex’ diaphragms are suitable for temperatures down to -20°C
and vessels to -10°C, the possibility of the diaphragms freezing to the con-
tainer cannot be excluded. We therefore recommend the integration of a
’V in-line vessel’ in the return to the refrigerating machine at temperatures
≤ 0°C.

Individual protection As in the case of heating systems, we recommend the use of individual
protection for multiple refrigerating machines.
→ Heating systems, p. 8.
 Pressurization systems
Heating and cooling circuits

’reflex N, F, S, G’ in cooling water systems

Configuration Input pressure maintenance, expansion vessel on suction side, circulating

pump, observe information on page 7 for follow-up pressure maintenance.
Object:

Initial data
Return temperature to refrigerating machinetR = .......... °C
Advance temperature to refrigerating machinetF = .......... °C
Lowest system temperature tSmin = ......... liters (e.g. winter downtime)
Highest system temperature tSmax = ......... liters (e.g. summer downtime)
Antifreeze additive = .......... % If R > 70°C, ’V
Percentage expansion n* →. 4 n* = n* at highest temp. (tSmax or tR) - n* at lowest temp. (tSmin or tF) n* = in-line vessel’
n* = .......... % required
.................................... - ............................. = .......... °C
Percentage expansion between lowest temperature and filling temperature = .......... °C nF* = .......... %
Static pressure pst = .......... bar pst = .......... bar

Pressure calculation 1)
Recommendation
1)
Input pressure p0 = static pressure pst + (0.2 bar)
1) p0 = .......... bar Check rec. supply pressure
p0 = ............................. + (0.2 bar) = .......... bar
pSV → Reflex recommendation of circulation pump as per
Safety valve actuation pressure manufacturer specifications
pSV ≥ input pressure p0 + 1.5 bar for pSV ≤ 5 bar
pSV = .......... bar
pSV ≥ input pressure p0 + 2.0 bar for pSV ≤ 5 bar
Check compliance
pSV ≥ ............................. + ................................. = .......... bar
with perm. operat-
Final pressure pf ≤ safety valve pSV – Closing pressure difference acc. to TRD 721
ing pressure
pf ≤ pSV – 0.5 bar for pSV ≤ 5 bar
pf = .......... bar
pf ≤ pSV – 0.1 bar for pSV ≤ 5 bar
pf ≤ .............................. – ................................. = .......... bar

Vessel 15
System volume Vs Refrigerating machines: .............. liters
Cooling registers : ................... liters
Buffer tanks : ................... liters
Vs = ......... liters
Pipelines : ................... liters
Other : ................... liters
System volume Vs : ................... liters
n* = .................................. = ..........
Expansion volume Ve = x Vs Ve = ......... liters
100 liters
Water seal VWS = 0.005x Vs for Vn > 15 liters with VWS ≥ 3 liters
VWS ≥ 0.2 x Vn for Vn ≤ 15 liters VWS = ......... liters
VWS ≥ ......... x ................. = ................................. = .......... liters
Nominal volume
pf +1
Without ’servitec’ Vn = (Ve + VWS ) x
pf - p0
pf +1
With ’servitec’ Vn = (Ve + VWS + 5 liters ) x Vn = ......... liters
pf - p0
Vn ≥ ............................. x .................................. = .......... liters
Selected Vn ’reflex’ = .......... liters
Initial pressure check
Without ’servitec’ pi = pf + 1 – 1 bar
Ve (pf + 1)
1+
Vn (p0 + 1)
pi = pf + 1 – 1 bar
(Ve + 5 liters) (pf + 1) pi = .......... bar
1+
Vn (p0 + 1)
pi = ........................... – 1 bar = .......... bar
...........................
1 + ...........................

pi = p0 + 0.25...0.3 bar, otherwise calculation for greater nominal volume

Filling pressure
pfil = Vn x p0 +1 – 1 bar
Vn - Vs x nF* - VWS pfil = .......... bar
pfil = ............................. x ..................... – 1 bar = .......... liters

Result summary
’reflex’ ..... / ..... bar ........... liters Input pressure p0 = ......... bar → check before commissioning
Initial pressure pi = ......... bar → check make-up configuration
Filling pressure pfil = ......... bar → refilling of system
Final pressure pf = ......... bar
 Pressurization systems
Heating and cooling circuits

Reflex pressurization systems with external pres-

sure generation
Types: ’variomat’, ’gigamat’, ’minimat’, ’reflexomat’

Application In principle, the same applies as for the selection and calculation of Reflex
diaphragm expansion vessels.
→ Heating systems page 8
→ Solar energy systems page 10
→ Cooling water systems page 14

However, such systems generally cover higher output ranges. → page 6

Nominal The main feature of pressurization systems with external pressure genera-
Ve + VWS volume Vn tion is that the pressure is regulated by a control unit independently of the Vn = 1.1 (Ve + VWS)
water level in the expansion vessel. As a result, virtually the entire nominal
volume Vn can be used for water intake purposes (Ve + VWS). This represents
a significant advantage of this method over pressure maintenance with
expansion vessels.

Pressure monitoring When calculating the minimum operating pressure, we recommend the Suction pressure maintenance
Minimum operating addition of a 0.2 bar safety margin to ensure sufficient pressure at high p0 ≥ pst + pe + 0.2 bar
pressure p0 points. This margin should only be dispensed with in exceptional cases,
since this will otherwise increase the risk of outgassing at high points. Final pressure maintenance
p0 ≥ pst + pe + ∆pP
Initial pressure pa This restricts the lower setpoint value range of the pressure maintenance. If
16 the pressure falls below the initial pressure, the pressure pump or compres-
sor is activated before being deactivated with a hysteresis of 0.2 ... 0.1 bar
The Reflex formula for the initial pressure guarantees the required minimum pi ≥ p0 + 0.3 bar
of 0.5 bar above saturation pressure at the high point of a system.

pf ≥ pi + Ap
Final pressure pf The final pressure restricts the upper setpoint value range Condition: pf ≤ pSV - ASV
of the pressure maintenance. It must be set such that the pressure
on the system safety valve is lower by at least the closing pres-
sure difference ASV, e.g. in accordance with TRD 721. The overflow Closing pressure difference
or discharge mechanism must open, at the very latest, when the final acc. to TRD 721 ASV
pressure is exceeded. SV-H 0.5 bar
SV-D/G/H 0.1 pSV
Working range Ap of This depends on the type of pressure maintenance and is limited by the ini- 0.3 bar for
pressure maintenance tial and final pressure. The adjacent values must be followed as a minimum. pSV < 3 bar

Degassing Targeted venting is very important, particularly in the case of closed sys- Ap = pf - pi
Deaeration tems; otherwise, accumulations of nitrogen in particular can lead to trouble- ’variomat’ ≥ 0.4 bar
some malfunctions and customer dissatisfaction. reflex ’variomat’ systems ’gigamat’ ≥ 0.4 bar
are pre-equipped with integrated make-up and degassing functions, while ’reflexomat’ ≥ 0.2 bar
reflex ’gigamat’ and reflex ’reflexomat’ pressurization systems are ideally
supplemented with reflex ’servitec’ make-up and degassing stations.

Partial flow degassing is only useful when integrated in the representative

main flow of the system.
 Pressurization systems
Heating and cooloing circuits

Compensating In the case of heating systems that are equipped with pressurization sys-
volume flow V̇ tems controlled by an external energy source, the required compensating
volume flow must be determined on the basis of the installed nominal heat
output of the heat generators.
For example, with a homogeneous boiler temperature of 140°C, the specific
volume flow required is 0.85 l/kW. Deviations from this value are possible
upon verification.
Cooling circuits are generally operated in a temperature range < 30°C. The
compensating volume flow is approximately half that of heating systems.
Therefore, when making selections using the heating system diagram, only
half of the nominal heat output Q̇ must be taken into account.

To facilitate your selection, we have prepared diagrams allowing you to

determine the achievable minimum operating pressure p0 directly on the
basis of the nominal heat output Q̇ .

Redundancy due to To improve partial load behavior for pump-controlled systems in particular,
partial load behavior we recommend that use of dual-pump systems, at least as of a heating
output of 2 MW. In areas with particularly high operational safety require- Reflex recommendation:
ments, the operator frequently demands system redundancy. In this context, Configuration
it is practical to halve the output of each pump unit. Full redundancy is not 50% + 50% = 100%
generally required when you consider that less than 10% of the pump and as of 2 MW dual-pump
overflow output is required during normal operation. systems
→ ’variomat 2-2’ 17
Not only are ’variomat 2-2’ and ’gigamat’ systems equipped with two pumps,
but they also feature two type-tested overflow valves. Switching is per-
formed on a load basis and in the case of malfunctions.

’variomat’ ≤ 8 MW ’gigamat’ ≤ 60 MW ’minimat’ ≤ 2 MW ’reflexomat’ ≤ 24 MW

pump-controlled pump-controlled compressor-controlled compressor-controlled
 Pressurization systems
Heating and cooling circuits

reflex ’variomat’ in heating and cooling systems

Configuration Input pressure maintenance, ’variomat’ in return, circulating pump in ad-

vance, observe information on page 7 for follow-up pressure maintenance
Object:

Initial data
Heat generator 1 2 3 4
Heat output Qh = .......... kW .......... kW .......... kW .......... kW Qtot = .......... kW
Water content VW = .......... liters
System flow temperature tF = .......... °C
→ p. 4 Approximate water content
System return temperature tR = .......... °C Vs = .......... liters If R > 70°C,
vs = f (tF, tR, Q̇ )
Water content known Vs = .......... liters ’V in-line vessel’
Highest setpoint value adjustment required
→ p. 4 Percentage expansion n
Temperature regulator tTR = .......... °C n = .......... % tTR max. 105°C
(with antifreeze additive n*)
Antifreeze additive = .......... %
→ p. 4 Evaporation pressure pe at > 100°C
Safety temperature limiter tSTL = .......... °C pe = .......... bar If 110 < STL ≤ 120°C,
(with antifreeze additive pe*)
contact our specialist
Static pressure pst = .......... bar pst = .......... bar department

Pressure calculation
1)
p0 = stat. pressure pst + evaporation pressure pe + (0.2 bar)
Minimum operating 1)
1) p0 = .......... bar The higher the value of
pressure
p0 = ....................... +.......................................+ (0.2 bar) = ............. bar
p0 over pst, the better
Condition
p0 ≥ 1.3 bar
the degassing function;
Final pressure
pf ≥ minimum operating pressure p0 + 0.3 bar + working range ’reflexomat’ Ap pf = .......... bar 0.2 bar is required as a
pf ≥ .... ........................................ + 0.3 bar + 0.4 bar = ............. bar minimum
Safety valve actuation pSV ≥ final pressure + closing pressure difference ASV
pressure pSV ≥ pf + 0.5 bar for pSV ≤ 5 bar
pSV = .......... bar
pSV ≥ pf + 0.1 x pSV for pSV > 5 bar Check compliance
18 p SV ≥ ........................... +........................................................ = ............. bar
with perm. operat-
ing pressure
Control unit selection
Diagram valid for heating systems
for cooling systems tmax ≤ 30°C, only 50% of Qtot is to be considered
p0 p0
bar bar ’variomat 2-2’ recom-
mended for:
variomat 2-1/95 variomat 2-2/95 Special requirements
up to 120°C up to 120°C
with regard to supply
reliability
variomat 2-1/75 variomat 2-2/75 Outputs ≥ 2 MW
up to 120°C up to 120°C
Automatic, load-
specific activation and
fault changeover of
variomat 2-1/60
up to 120°C
variomat 2-2/60
up to 120°C
pumps and overflow
units for ’variomat 2-2’

variomat 1 variomat 2-2/35

up to 100°C up to 120°C
p0 = 1.3 bar
min. setting value
for continuous
degassing
Qtot/MW
Total heat output of heat generation system

’variomat 1’ ’variomat 2-1’ ’variomat 2-2/35’ ’variomat 2-2/60-95’ Minimum volume flow V in
system circuit at integration
V 2 m³/h 4 m³/h 2 m³/h 4 m³/h
point of ’variomat’

Vessel

Nominal volume Vn taking water seal into account

n + 0.5 Vn = .......... liters The nominal volume
Vn = 1.1 x Vs = 1.1 x ..................... x ....................= ............. bar
100 can be distributed
across multiple vessels.
Result summary
’variomat’ .................. liters Minimum operating pressure p0 .................. bar
VG basic vessel .................. liters Note:Final Due to thepfexcellent degassing
pressure performance
.................. bar of ’variomat’,
we generally recommend individual protection of the
VF secondary vessel .................. liters Note: Due to the excellent degassing performance of ’variomat’,
heat generator using ’reflex’ diaphragm expansion vessels.
VW thermal insulation .................. liters we generally recommend individual protection of the heat
generator using ’re ex’ diaphragm expansion vessels.
(for heating systems only)
 Pressurization systems
Heating and cooling circuits

reflex ’gigamat’ in heating and cooling systems

Configuration Input pressure maintenance, ’gigamat’ in return, circulating pump in advance,

observe information on page 7 for follow-up pressure maintenance
Object:

Initial data
Heat generator 1 2 3 4
Heat output Qh = .......... kW .......... kW .......... kW .......... kW Qtot = .......... kW
Water content VW = .......... liters
System water content Vs = .......... °C → p. 4 Approximate water content If R > 70°C, ’V
Vs = .......... liters in-line vessel’
vs = f (tF, tR, Q)
Highest setpoint value adjustment required
→ p. 4 Percentage expansion n
Temperature regulator tTR = .......... °C n = .......... % tTR max. 105°C
(with antifreeze additive n*)
Antifreeze additive = .......... %
→ p. 4 Evaporation pressure pe at > 100°C If 110 < STL ≤ 120°C, con-
Safety temperature limiter tSTL = .......... °C pe = .......... bar
with antifreeze additive pe*) tact our specialist depart-
Static pressure pst = .......... bar pst = .......... bar ment

Specific values 1)
Recommendation
1)
Minimum operating p0 = stat. pressure pst + evaporation pressure pe + (0.2 bar)
1) p0 = .......... bar
pressure p0 = ....................... +.......................................+ (0.2 bar) = ............. bar
Conditionp0 ≥ 1.3 bar
Final pressure pf ≥ minimum operating pressure p0 + 0.3 bar + working range ’reflexomat’ Ap pf = .......... bar
pf ≥ .... ................................. + 0.3 bar + 0.4 bar = ............. bar Check compliance
Safety valve actuation pSV ≥ final pressure + closing pressure difference ASV with perm. operat-
pressure pSV ≥ pf + 0.5 bar for pSV ≤ 5 bar ing pressure 19
pSV = .......... bar
pSV ≥ pf + 0.1 x pSV for pSV > 5 bar
pSV ≥ ....................... +........................................................ = ............. bar

Control unit selection

Diagram valid for heating systems STL ≤ 120°C
for cooling systems tmax ≤ 30°C, only 50% of Qtot is to be considered
p0
bar
GH 90

GH 70 For systems outside the

displayed output ranges,
please contact us

GH 50

Qtot/MW
Total heat output of heat generation system
The nominal volume
Vessel can be distributed
across multiple vessels.
Nominal volume Vn taking water seal into account
n + 0.5 Vn = .......... liters
Vn = 1.1 x Vs = 1.1 x ..................... x ....................= ............. bar
100

Result summary
GH hydraulic unit .................. Minimum operating pressure p0 .......... bar
GG basic vessel .................. liters Final pressure pf .................. bar
GF secondary vessel .................. liters
 Pressurization systems
Heating and cooling circuits

reflex ’minimat’ and ’reflexomat’ in heating and cooling systems

Configuration Input pressure maintenance, ’minimat’, ’reflexomat’ in return, circulating pump

in advance, observe information on page 7 for follow-up pressure maintenance
Object:

Initial data

Heat generator 1 2 3 4
Heat output Qh = .......... kW .......... kW .......... kW .......... kW Qtot = .......... kW
Water content VW = .......... liters
System flow temperature tF = .......... °C
→ p. 4 Approximate water content If R > 70°C, ’V
System return temperature tR = .......... °C Vs = .......... liters
vs = f (tF, tR, Q) in-line vessel’
Water content known Vs = .......... liters
Highest setpoint value adjustment required
→ p. 4 Percentage expansion n
Temperature regulator tTR = .......... °C n = .......... % tTR max. 105°C
(with antifreeze additive n*)
Antifreeze additive = .......... %
→ p. 4 Evaporation pressure pe at > 100°C
Safety temperature limiter tSTL = .......... °C pe = .......... bar
with antifreeze additive pe*) If 110 < STL ≤ 120°C,
contact our specialist
Static pressure pst = .......... bar pst = .......... bar
department

Pressure calculation
1)
Minimum operating p0 = stat. pressure pst + evaporation pressure pe + (0,2 bar)
1) p0 = .......... bar
pressure p0 = ........................... +.........................................+ (0.2 bar) = ........ bar 1)
Recommendation p0 ≥ 1.0 bar Recommendation
Final pressure pf ≥ minimum operating pressure p0 + 0.3 bar + working range ’reflexomat’ Ap
pf = .......... bar
pf ≥ .... ......................................... + 0.3 bar + 0.2 bar = ............. bar
Safety valve pSV ≥ final pressure + closing pressure difference ASV
actuation pressure pSV ≥ pf + 0.5 bar for pSV ≤ 5 bar
pSV = .......... bar
pSV ≥ pf + 0.1 x pSV for pSV > 5 bar
20
pSV ≥ ....................... +......................................................... = ............. bar Check compliance
with perm.
Control unit selection operating pressure

Diagram valid for heating systems

for cooling systems tmax ≤ 30°C, only 50 % of Qtot is to be considered
p0 p0
bar bar

VS 90/1 or ’minimat’ VS 90/2

VS 150/1 VS 150/2
VS 300/1 VS 300/2
VS 400/1 VS 400/2
VS 580/1 VS 580/2

Qtot/MW Automatic, load-specific activation

Total heat output of heat generation system and fault changeover of compres-
sors for VS .../2 control units

Vessel

Nominal volume Vn taking water seal into account The nominal volume
n + 0.5 Vn = .......... liters can be distributed
Vn = 1.1 x Vs = 1.1 x ..................... x ....................= ............. bar across multiple vessels.
100

Result summary
’reflexomat’ with Minimum operating pressure p0 .......... bar
Control unit VS ............/..... Final pressure pf .................. bar
RG basic vessel .................. liters
or
’minimat’ MG .................. liters
 Pressurization systems
Heating and cooling systems

District heating systems, large-scale and special

systems
Calculation The usual approach for heating systems, e.g. using DIN EN 12828, is often
not applicable to district heating systems. In this case, we recommend that
you coordinate with the network operator and the relevant authorities for
systems subject to inspection.

Contact us for more information!

Input pressure maintenance

Configuration In many cases, the configurations for district heating systems differ from
those used for heating installations. As a result, systems with follow-up and
medium pressure maintenance are used in addition to classic input pressure
maintenance. This has a direct impact on the calculation procedure.

Properties n, pe As a rule, properties for pure water without antifreeze additive are used.

Follow-up pressure maintenance

Expansion volume Ve Due to the frequently very large system volumes and minimal daily and
weekly temperature fluctuations, when compared to heating systems, the
calculations methods employed deviate from DIN EN 12828 and often
produce smaller expansion volumes. When determining the expansion coef-
ficient, for example, both the temperatures in the network advance and the
network return are taken into account. In extreme cases, calculations are
only based on the temperature fluctuations between the supply and return. Medium pressure maintenance

Minimum operating The minimum operating pressure must be adapted to the safety temperature 21
pressure p0 of the heat exchanger and determined such that the permitted normal and
operating pressures are maintained throughout the network and cavitation
on the pumps and control fittings is avoided. ’reflex’
’variomat’
’gigamat’
Initial pressure pa In the case of pressurization stations, the pressure pump is activated if the ’reflexomat’
special stations
pressure falls below the initial value. Particularly in the case of networks with
large circulating pumps, dynamic start-up and shutdown procedures must
be taken into account. The difference between pi and p0 (= PLmin) should then
be at least 0.5 ... 1 bar.

Pressure maintenance In the case of larger networks, almost exclusively in the form of pressure
maintenance with external pressure generation, e.g. ’variomat’, ’gigamat’,
’minimat’ or ’reflexomat’. With operating temperatures over 105°C or safety
temperatures STL > 110°C, the special requirements of DIN EN 12952, DIN
EN 12953 or TRD 604 BI 2 can be applied.

Degassing We recommend that heat generation systems that do not have a thermal
degassing system be equipped with a ’servitec’ vacuum spray-tube degas-
sing unit.
 Pressurization systems
Potable water systems

Potable water is essential to life! For this reason, the expansion ves-
sels in drinking water installations must meet the special requirements of
DIN 4807 T5. Only water-carrying vessels are permitted.

Hot water systems

Calculation According to DIN 4807 T5 → see form on p. 23 pi pSV V
V n Vt
Vp p0

Configuration As per adjacent diagram.

As a rule, the safety valve should be installed directly at the cold water inlet
of the water heater. In the case of ’refix DD’ and ’DT5’, the safety valve can
also be fitted directly before the flow fitting (in water flow direction), provided
that the following conditions are met:
’refix DD’ with T-piece:
Rp ¾ max. 200 l water heater
Rp 1 max. 1,000 l water heater
Rp 1¼ max. 5,000 l water heater
’refix DT5’ flow fitting Rp 1¼:
max. 5,000 l water heater

Properties n, pe Generally calculation between cold water temperature of 10°C and max. hot
water temperature of 60°C.
Enter set input pres-
Input pressure p0 The minimum operating pressure or input pressure p0 in the expansion ves- sure on name plate
Minimum operating sel must be at least 0.2 bar below the minimum flow pressure. Depending
pressure on the distance between the pressure reducing valve and the ’refix’ unit, the
input pressure must be adjusted to between 0.2 and 1.0 bar below the set
pressure of the pressure reducing valve.
22 Initial pressure pa The initial pressure is identical to the set pressure of the pressure reducing
valve. Pressure reducing valves are required in accordance with DIN 4807
T5 to ensure a stable initial pressure and thus achieve the full capacity of
the ’refix’ unit.

Expansion vessel In potable water systems according to DIN 1988, only water-carrying ’refix’
vessels meeting the specifications of DIN 4807 T5 must be used. In the
case of non-potable water systems, ’refix’ units with a single connection are
sufficient.
Pressure booster systems ’refix DT5’

Calculation According to DIN 1988 T5: Technical rules for drinking water installations,
pressure increase and reduction
Supply line

Configuration On the input pressure side of a PBS, ’refix’ expansion vessels relieve
the connection line and the supply network. The use of these units must be ’refix DT5’

agreed with the relevant water utility company.

Supply line

On the follow-up pressure side of a PBS, ’refix’ vessels are installed to

reduce the switch frequency, particularly in the case of cascade control
systems.
’refix DT5’ ’refix DT5’
Installation on both sides of the PBS may also be necessary.

Input pressure p0 The minimum operating pressure or input pressure p0 in the ’refix’ vessel
Supply line

Initial pressure pa must be set approx. 0.5 ... 1 bar below the minimum supply pressure on the
suction side and 0.5 ... 1 bar below the switch-on pressure on the pressure
side of a PBS.

Since the initial pressure pi is at least 0.5 bar higher than the input pressure,
Enter set input pres-
a sufficient water seal is always ensured; this is an important prerequisite
sure on name plate
for low-wear operation.
In potable water systems according to DIN 1988, only water-carrying ’refix’
vessels meeting the specifications of DIN 4807 T5 must be used. In the
case of non-potable water systems, ’refix’ units with a single connection are
sufficient.
 Pressurization systems
Potable water systems

’refix’ in hot water systems

V pi pSV V n Vt
Vp p0
Object:

Initial data

Tank volume Vt = .......... liters

Heating output Q = .......... kW
Water temperature in tank tWW = .......... °C As per controller setting 50...60°C
→ p. 4 Percentage expansion n n = .......... %
Set pressure of pressure reducing valvepi = .......... bar
Safety valve setting pSV = .......... bar Reflex recommendation: pSV = 10 bar
Peak flow Vp = .......... m³/h

Selection according to nominal volume Vn

Input pressure p0 = set pressure of pressure reducing valve pi – (0.2...1.0 bar) p0 = .......... bar Set input pressure
p0 = .................................................. – .............. = ............. bar 0.2...1 bar below
pressure reducing
n x (pSV + 0.5)(p0 + 1.2)
Nominal volume Vn = Vt valve (depend-
100 x (p0 + 1)(pSV - p0 - 0.7)
ing on distance
Vn = .................................................. – .............. = ............. liters Vn = .......... liters between pressure
Selection according to brochure = ............. liters reducing valve and
’refix’)
Selection according to peak volume flow Vp

When the nominal volume of the ’refix’ unit. If this is the case, the 8-33 liter ves-
unit has been selected, it must be sel of the ’refix DD’ unit may have to be
checked for water-carrying vessels wheth- replaced with a a 60 liter ’refix DT5’ vessel
er the peak volume flow Vp resulting from to enable a higher flow rate. Alternatively, a 23
the piping calculation according to DIN ’refix DD’ unit with an appropriately dimen-
1988 can be implemented on the ’refix’ sioned T-piece may be used.

Recomm. max. Actual pressure loss

peak flow Vp* with volume flow V
’refix DD’ 8 - 33 Liter

’flowjet’
With or without ’flowjet’
T-piece duct Rp ¾ = standard ≤ 2.5 m³/h
∆p = 0.03 bar
(2.5 m³/h )
V [m³/h] 2
Vp
V T-piece Rp 1 (on-site) ≤ 4.2 m³/h negligible ∆p = .......... bar
T-piece
’refix DT5’ 60 - 500 liters
(7.2 m³/h )
V [m³/h] 2
With ’flowjet’ Rp 1¼ ≤ 7.2 m³/h ∆p = 0.04 bar

’refix DT5’ 80 - 3000 liters

Duo connection DN 50 ≤ 15 m³/h ∆p = 0.14 bar (15V m³/h )
[m³/h] 2

Vp
V Duo connection DN 65 ≤ 27 m³/h ∆p = 0.11 bar (27V m³/h )
[m³/h] 2
G = ..........
Duo connection Duo connection DN 80 ≤ 36 m³/h
negligible
Duo connection DN 100 ≤ 56 m³/h
’refix DE, DE junior’
Unlimited ∆p = 0
(non water-carrying)

* calculated for a speed of 2 m/s

Result summary
’refix DT5’ ........... liters Nominal volume Vn ............ liters
Input pressure p0 ............ bar
’refix DD’ ........... liters, G = .......... (standard Rp ¾ included)
’refix DT5’ ........... liters
 Pressurization systems
Potable water systems

’refix’ in Pressure Booster Systems (PBS)

Object:

Configuration ’refix’ on input pressure side of PBS

Installation: As agreed with the relevant

water utility company

Necessity: Applies if the following criteria are not met PBS

pin = switch-on pressure
- In the event of the failure of a PBS pump, the flow rate in pout = cut-out pressure
VmaxP = max. delivery
the PBS connection line must not change by more than rate of PBS

0.15 m/s
- If all pumps should fail, it must not change by more than
0.5 m/s
To con-
- During pump operation, the supply pressure must not V maxP
sumer
drop below 50% of the minimum value pminS and must be at
least 1 bar

Initial data: Max. delivery ’re x DT5’ with ’re x DT5’

Min. supply pressure pminS = .......... bar rate duo connection Vn = ..........liters
Max. delivery rate VmaxP = .......... m³/h VmaxP / m³/h Vn / liters Vn / liters
≤7 300 300
Selection acc. to
> 7 ≤ 15 500 600
DIN 1988 T5
> 15 --- 800

Input pressure p0 = min. supply pressure – 0.5 bar

p0 = .......... bar
p0 = ..................................... – 0.5 bar = ............ bar

Configuration ’refix’ on follow-up pressure side of PBS

24
- To restrict the switch frequency of pressure-controlled systems
Max. delivery head of PBS Hmax = .......... mWs
Max. supply pressure pmaxS = .......... bar
Switch-on pressure pin = .......... bar PBS
pin = switch-on pressure
Cut-out pressure pout = .......... bar pout = cut-out pressure
Max. delivery rate VmaxP = .......... m³/h VmaxP = max. delivery
rate of PBS
Switch frequency s = .......... 1/h
Number of pumps n = ..........
Electrical power of most Pel = .......... kW
powerful pump From
supply
To con-
sumer
connection

s - switch frequency 1/h 20 15 10

Pump output kW ≤ 4.0 ≤ 7.5 ≤ 7.5

pout + 1
Nominal volume Vn = 0.33 x VmaxP
(pout - pin) x s x n
Vn = ..........liters
Vn = 0.33 x ......................... x ............................= ............ liters

- To store the minimum supply volume Ve between activation and deactivation of the PBS
Switch-on pressure pin = .......... bar
Cut-out pressure pout = .......... bar
p0 = .......... bar
Input pressure ’refix’ p0 = .......... bar → Reflex recommendation: p0 = pin - 0.5 bar
Storage capacity Ve = .......... m³

Nominal volume Vn = Ve (pin + 1) (pout + 1)

(p0 + 1) (pout - pin)
Vn = ..........liters
Vn = ................................... x ............................= ............ liters
Selection according to brochure = ............ liters

Check of perm. excess operating pressure

pmax ≤ 1.1 pper Hmax [mWs]
10 pmax = .......... bar
pmax = pmaxS + bar = ............................= ............ bar

Result summary
’refix DT5’ ........... liters 10 bar Nominal volume Vn ............ liters
With duo connection DN 50 liters 10 bar Usable volume V0 ............ liters
’refix DT5’ ........... liters 16 bar Input pressure p0 ............ liters
 Terms, code letters, symbols

Terms
Formula letter Explanation See page (among others)
Ap Working range of pressure maintenance 16
ASV Closing pressure difference for safety valves 3, 7
n Expansion coefficient for water 4, 8, 24
n* Expansion coefficient for water mixtures 4, 11, 13
nR Expansion coefficient relative to return temperature 9
p0 Minimum operating pressure 3, 7, 16, 21, 22
pi Initial pressure 3, 7, 16, 21, 22
pe Evaporation pressure for water 4
pe* Evaporation pressure for water mixtures 4
pf Final pressure 3, 7, 16
pfil Filling pressure 3, 7
pst Static pressure 3, 7
pSV Safety valve actuation pressure 3, 7
psup Minimum supply pressure for pumps 5
pper Permissible excess operating pressure 5
V Compensating volume flow 17
Vs System volume 4
vA Specific water content 4
Ve Expansion volume 3, 7, 21
VC Collector content 10, 12
Vn Nominal volume 7, 16
VWS Water seal 3, 7
∆pP Pump differential pressure 5 27
ρ Density 4

Code letters Symbols

T – Temperature Shut-off valve
T Temperature test port
Fitting with protected shut-off and
TI Thermometer
draining
TIC Temperature regulator with display
TAZ + Temperature limiter, STL, STM Spring-loaded safety valve
P – Pressure
Check valve
P Pressure test port
PI Pressure gauge Solenoid valve
PC Pressure regulator
PS Pressure switch Motorized valve
PAZ - Pressure limiter - min, SPLmin
Overflow valve
PAZ + Pressure limited - max, SPLmax
L – Water level Dirt trap
LS Water level switch
LS + Water level switch- max Water meter
LS + Water level switch- min
System separator
LAZ - Water level limiter - min
Pump

Code letters accord- Heat consumer

ing to DIN 19227 T1,
“Graphical symbols and
code letters for process Heat Exchangers
technology”