Carefully read these instructions before installation and commissioning.
Save these instructions in the vicinity of the installation for future reference.
1 General Information
1.1 Scope of these instructions
These instructions describe the installation, commissioning, function and operation of the
domestic hot water module FriwaMega.
The chapters called [specialist] are intended for specialists only.
For other components of the system, such as tanks, controllers or pumps, please observe
the instructions of the corresponding manufacturer.
Optional:
Grundfos
Grundfos
UPM2 15-75 CIL2
2 x 60 plates
UPM XL 25-125
or
Grundfos
UPML 25-105 N
Grundfos
Grundfos
2 x 60 plates
UPM XL 25-125
Grundfos
UPML 25-105 N
Grundfos
2 x 60 plates
UPM XL 25-125
UPM2 15-75 CIL2
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1 General Information
1.2 About this product
The domestic hot water module is a premounted fitting group checked for leakage and used
to transfer the heat between the buffer tank and the domestic hot water circuit.
It contains a preset controller and important fittings for the operation of the system:
• Ball valves in the primary circuit
• Piston valves in the secondary circuit
• Pressure relief valve in the secondary circuit
• Premounted controller
• Temperature sensor on the cold water inlet
• Temperature sensors on the heating flow
• Temperature sensor on the domestic hot water outlet
• Flow meter on the domestic hot water outlet
• Fill and drain valve for draining the heat exchangers in the primary and secondary circuit
• Vent valve, primary and secondary, for venting the heat exchangers
1.3 Designated use
The domestic hot water module must only be mounted in heating installations between
the buffer tank and the domestic hot water circuit.
Due to its design, the station must be mounted and operated in a vertical position!
The technical data specified in these instructions must be observed.
Only use PAW accessories with the domestic hot water module.
Improper usage excludes any liability claims.
The wrapping materials are made of recyclable materials and can be disposed of
with recyclable materials.
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2 Safety instructions
WARNING
Danger of scalding due to hot water!
CAUTION
Risk of burns!
2 Safety instructions
The installation and commissioning as well as the connection of electrical components require
technical knowledge commensurate with a recognised vocational qualification as a fitter for
plumbing, heating and air conditioning technology, or a profession requiring a comparable level
of knowledge [specialist].
The following must be observed during installation and commissioning:
• relevant local and national regulations
• accident prevention regulations of the professional association
• instructions and safety instructions of this manual
Undesirable circulation of water in the primary circuit can cause the exit of water
of up to 90 °C at the withdrawal point.
External pumps must not be installed between the service water module
and the buffer tank.
The domestic hot water module must not be connected to a distribution
manifold.
The valves, fittings and the pump may heat up to more than 95 °C during
operation.
The insulating shell must remain closed during operation.
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2 Safety instructions
NOTICE
Material damage due to mineral oils!
NOTICE
Malfunction!
Mineral oil products cause lasting damage to seals made of EPDM, whereby the sealant
properties get lost. We do not assume liability nor provide warranty for damage to property
resulting from sealants damaged in this way.
It is imperative to avoid that EPDM gets in contact with substances containing
mineral oils.
Use a lubricant based on silicone or polyalkylene and free of mineral oils, such as
Unisilikon L250L and Syntheso Glep 1 of the Klüber company or a silicone spray.
The domestic hot water module must be integrated in the potential equalisation of the
electric installation. This can be guaranteed by establishing a potential equalisation
connection to the main potential connection according to regulations or by the connected
pipe system.
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3 Product description
Connections primary circuit
1
2
Equipment primary circuit
A
B
C
D
E
F
G
H
3 Product description
Flow from the buffer tank (warm)
Return to the buffer tank (cold)
Return ball valve
Check valve
Heat exchanger
Temperature sensor Pt1000
Drain valve
Primary pump
Check valve
Flow ball valve
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3 Product description
Connections secondary circuit
3
4
5
Equipment secondary circuit
a
b
c
Only for the protection of the station.
Does not replace the pressure relief
valve that has to be mounted on site!
d
e
f + g
h
i
j
k
Cold water supply
Hot water outlet
Hot water circulation
Piston valve hot water circulation
Piston valve cold water inlet
Pressure relief valve 10 bars, suitable
for domestic hot water
Temperature sensor Pt1000
Heat exchanger
FlowSonic 1-130 l/min
Drain valve
Temperature sensor Pt1000
Circulation pump
Piston valve hot water outlet
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4 Dimensioning and planning
WARNING
Danger of scalding due to hot water!
4 Dimensioning and planning
The FriwaMega is a domestic hot water module operating on the principle of a flow-type
water heater.
The FriwaMega will only work flawlessly if the installation meets certain requirements.
Please take some time to plan the installation.
Undesirable circulation of water in the primary circuit can cause the exit of water
of up to 90 °C at the withdrawal point.
External pumps must not be installed between the service water module
and the buffer tank.
Mounting example
The domestic hot water module must not be connected to a distribution
manifold.
FriwaMega with optional circulation set (additionally required, item no. 6404134GH7
or 6404135GH10)
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4 Dimensioning and planning
Temperature in
the buffer tank
Domestic hot water temperature
set at the controller
Required tank volume
per litre of hot water
4.1 Dimensioning of the tank
The following table helps you to calculate the approximately required volume of the buffer tank.
50 °C 45 °C 1.3 litres
45 °C 0.8 litre
60 °C
50 °C 1.0 litre
55 °C 1.4 litres
45 °C 0.7 litre
70 °C
50 °C 0.8 litre
55 °C 0,9 litre
45 °C 0.5 litre
80 °C
50 °C 0.6 litre
55 °C 0.7 litre
Calculation example for the dimensioning of the buffer tank:
Temperature buffer tank: 60 °C
Required withdrawal flow rate at the tap: 20 l/min
Domestic hot water temperature set at the controller: 45 °C
How large must the tank be to allow for a continuous withdrawal during 20 minutes
without reheating?
20 l/min x 20 min = 400 l
400 l x 0.8 = 320 l
The heated part of the buffer tank must have a volume of 320 litres.
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5 Circulation mode
Pulse-controlled operation
Time-dependent operation:
Temperature-dependent operation:
NOTICE
Damage to property!
5 Circulation mode
The domestic hot water module is optionally equipped with a circulation pump.
The FriwaMega without circulation can be subsequently equipped with a circulation set
(item no. 6404134GH7 or 6404135GH10) for an internal retrofitting.
Three different operating modes of the circulation pump are set at the controller
(see controller instructions, menu "Func" / "F02"):
•
(depending on the demand / requirements):
The short opening of a hot water tap (tap pulse: ~2 sec.) starts the circulation pump.
The circulation pump will then run for several minutes (adjustable).
•
The operation of the circulation pump can be set on a week clock within a freely
selectable period of time. The circulation will start at the beginning of the period
of time chosen. The circulation will stop after the end of the chosen period of time.
•
In this operating mode, the circulation only starts if the adjustable minimum temperature
on the circulation temperature sensor is not reached during the chosen period of
operation. The circulation stops after the required temperature has been reached or
after the end of the chosen period of time.
The operating modes can be combined with one another as wished, f. ex. the time- and the
temperature-dependent operating modes. The circulation is only active if the temperature at the
circulation temperature sensor falls below the required value and if the time window is active.
Outside the time window, the circulation pump can be started by a tap pulse if the
pulse-controlled operation mode is additionally activated.
When the Friwa is delivered, the circulation is not activated (see controller instructions, menu:
"Func" / "F02" set to "OFF"). Once the circulation line mounted, it is mandatory to select and
preset the operating mode. The revolution speed of the circulation pump must be determined
by the PWM signal (factory setting: 40 %).
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6 Assembly and installation [specialist]
NOTICE
Damage to property!
NOTICE
Damage to property!
Fittings
Drain valve
Return valve (non-return valve)
Evtl. pressure reducing valve
Test valve
Shut-off valve
6 Assembly and installation [specialist]
The domestic hot water module FriwaMega must only be connected with the storage tank by
separate connections for flow and return. External pumps must not be installed between the
domestic hot water module and the buffer tank. The circulation of water causes considerable
temperature fluctuations.
The domestic hot water connection must be carried out in accordance with the relevant norms
(for example DIN 1988)!
Hot water
Pressure relief valve
DHW
module
Cold water
The pressure relief valve integrated in the station does not replace the safety groups of the
potable water connection as per DIN 1988. The pressure relief valve only protects the module
from overpressures in case of servicing.
If there are water supplies that may cause pressure surges (for example flush valves, washing
machines or dishwashers) connected to the same mains as the domestic hot water module,
we recommend the installation of water hammer arresters close to the place where these
pressure surges may be caused.
2014/11 99640766x-mub-en – V0313
6 Assembly and installation [specialist]
WARNING
Risk to life and limb due to electric shock!
NOTICE
Damage to property!
Top view
Prior to commencing electrical work on the controller, pull the mains plug!
Only after completing all installation work, plug the mains plug of the
controller into a socket. Thus, an unintentional start of the motors is
avoided.
The location of installation must be dry, load-carrying, frost-proof and protected against
ultraviolet radiation, in order to prevent material damage of the installation.
1. Determine the mounting location of the
domestic hot water module near the buffer
tank. In long pipes, the transmission
performance may be reduced due to higher
pressure losses.
2. Remove the station from the packaging.
3. Remove the station from the pallet and
position it at the location of installation.
4. Mount the enclosed stand feet in order to
compensate the unevenness of the floor.
5. The station can be mounted in a corner.
If you want to pull off the insulation shells,
you have to leave a space of about 20 cm
to the wall (see figure).
6. For the operation of the hydraulics and a
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subsequent servicing, you have to leave a
space of at least 60 cm to the front (controller)
and to one side (see figure).
6 Assembly and installation [specialist]
1
Primary side: flow from the buffer tank (hot)
2
Primary side: return to the buffer tank (cold)
3
Secondary side: cold water inlet
4
Secondary side: hot water outlet
5
Secondary side:
7. Connect the domestic hot water module with the installation by using the pipes as shown
in the figure below. When the station is delivered, the ball valves and piston valves are
closed, in order to protect the station against dirt. Before connecting the pipes, make
sure that the connections are free from dirt.
Connection: 1½" internal thread, flat sealing
Piping:
at least DN 40, 42 x 1,5 mm,
maximum length 4 m
Make sure to vent the Friwa at the highest point!
Connection: 1½" internal thread, flat sealing
Piping:
at least DN 40, 42 x 1,5 mm,
maximum length 4 m
Make sure to vent the Friwa at the highest point!
Connection: 1½" external thread, flat sealing
Connection: 1½" external thread, flat sealing
Hot water circulation, return
Connection: 1½" external thread, flat sealing
2014/11 99640766x-mub-en – V0315
7 Commissioning [specialist]
Note!
Slowly
Function check valve
180°
completely
0°
Check valve
Position 0°
flow only in direction of flow.
Position 180°
flow in both directions.
7 Commissioning [specialist]
open the valves in the pipes and in the module, in order to prevent pressure surges.
The ball valves (A) and (H) in the primary circuit are
equipped with check valves (B) and (G), in order to
avoid unwanted gravity circulation.
For venting and flushing the installation, the check
valves must be open. Turn the opening mechanism of
the check valves into the position
. The check
valve is not operating.
For the operation of the installation, all (ball) valves
must be
be closed again (position
open and the check valves must
).
(normal flow direction in the figure: downwards)
Check valve is operating,
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Check valve is not operating,
7 Commissioning [specialist]
WARNING
Danger of scalding due to hot water!
If the storage tank is (partly) filled
Primary circuit
180°
0°
7.1 Filling the primary circuit
The system is under pressure. By opening the pressure relief valve, hot water
with a temperature of up to 90 °C may exit and cause personal injury.
Open the pressure relief valve slowly and with sufficient distance.
1. Slowly open the ball valves (A) and (H).
2. Open the check valves (B) and (G) at the
opening mechanism (
, see page 16).
3. Fill the storage tank using the already existing fill
valves until an operating pressure of about
1.5 bars* is reached.
Use appropriate water according to VDI 2035 /
ÖNorm H5195-1.
4. Vent the pipe system at the designated points
on site.
5. Check the operating pressure of the storage tank
after the venting and increase the pressure
if necessary.
6. Put the check valves (B) and (G) into operating
position (
, see page 16).
* 1.5 bars in the primary circuit = recommended minimum value
The pressure also depends on the individual system pressures and on the components of
the heating installation!
2014/11 99640766x-mub-en – V0317
7 Commissioning [specialist]
WARNING
Risk to life and limb due to electric shock!
7.2 Commissioning of the controller
Check if the sensors and the pumps are properly connected to the
controller and if the controller housing is closed.
Only under these circumstances, the mains plug of the controller can
1. Make sure that the integration of the
domestic hot water module in the potential
equalisation of the installation is correct.
2. Connect the domestic hot water module
to the mains (230 V, 50 Hz).
3. Remove the insulation and the front panel
of the controller (see controller manual,
page 5).
4. Select the manual operating mode ("H1")
in the selection menu of the controller.
Switch on the PWM signal of the pump
("100 %").
5. Let the pump run for several minutes to
deaerate the domestic hot water module.
be plugged into a socket.
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6. If the air noises have stopped, the pump
can be switched off. For this purpose,
select the manual operating mode ("H1")
in the selection menu of the controller.
7. Set the pump to automatic operation ("A").
7 Commissioning [specialist]
Secondary circuit
8. Slowly open the piston valves (b) and (k)
on the secondary side.
9. Open at least one withdrawal point for
domestic hot water (for example a tap) with
a flow rate of at least 10 l/min and let the
water run for about 2 minutes to deaerate
the secondary circuit. Close all withdrawal
points in the secondary circuit afterwards.
10. Manipulate the pressure relief valve (c)
to deaerate the heat exchanger.
11. Check the module for tightness and make
sure that the electronic components stay
dry.
12. Set the desired domestic hot water
temperature at the controller (see page 22).
The domestic hot water module is now ready
for operation.
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7 Commissioning [specialist]
Withdrawal flow rate [l/min]
Power [kW]
Boundary conditions:
Example 1
Temperature of the buffer tank
FriwaMega
Example 2
7.3 Maximum withdrawal flow rate
The following diagram illustrates the maximum withdrawal flow rate depending on the tank
temperature with a preset hot water temperature of 45 °C at the tap. The integrated control
prevents the temperature from falling, as long as the maximum flow rate is not exceeded
and as long as the water in the buffer tank maintains a sufficient temperature.
Domestic hot water temperature: 45 °C
The following examples illustrate the correlation between the domestic hot water temperature,
the withdrawal flow rate and the temperature of the buffer tank and show their impact on the
heat transfer capacity of the Friwa.
Example 1
Domestic hot water temperature at the withdrawal point: 45 °C
Temperature in the buffer tank: 60 °C
FriwaMega: maximum withdrawal flow rate: 123 l/min, transfer capacity: 300 kW
Example 2
Domestic hot water temperature at the withdrawal point: 45 °C
Maximum withdrawal flow rate: 120 l/min
FriwaMega: temperature in the buffer tank: ~70 °C, transfer capacity: 290 kW
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Cold water temperature: 10 °C
Maximum pressure loss on the domestic hot water side of the Friwa:
1000 mbars
7 Commissioning [specialist]
Withdrawal flow rate [l/min]
Power [kW]
Domestic hot water temperature: 45 °C, after heating to 60 °C and addition of cold water (10 °C)
Boundary conditions:
Temperature of the buffer tank
Example 2
Example 1
FriwaMega
The following diagram illustrates the maximum withdrawal flow rate at a domestic hot
water temperature of 45 °C at the tap, after the addition of cold water of 10 °C.
The domestic hot water temperature set at the controller is of 60 °C.
Cold water temperature: 10 °C
Example 1
Domestic hot water temperature at the controller: 60 °C
Temperature in the buffer tank: 70 °C
FriwaMega: maximum withdrawal flow rate: 133 l/min, transfer capacity: 324 kW
Example 2
Domestic hot water temperature at the controller: 60 °C
Maximum withdrawal flow rate: 150 l/min
FriwaMega: temperature in the buffer tank: ~75 °C, transfer capacity: ~365 kW
2014/11 99640766x-mub-en – V0321
7 Commissioning [specialist]
WARNING
Danger of scalding due to hot water!
7.4 Setting the temperature
Set the desired (maximum) domestic hot water temperature at the controller under "Para"
(see controller instructions, page 24).
The maximum domestic hot water temperature must not exceed 60 °C in order
to avoid scalding at the tap.
Primary circuit
The required temperature on the primary side in the buffer tank depends on the desired
domestic hot water temperature and on the required tap quantity. The temperature in the
buffer tank must be at least 5 K above the desired domestic hot water temperature.
Secondary side
The possible withdrawal flow rate [l/min] at the tap depends on the domestic hot water
temperature set at the controller and on the temperature available in the buffer tank.
The maximum domestic hot water flow rate through the module FriwaMega is of 130 l/min.
The following table illustrates the correlation between the storage tank temperature and the
maximum withdrawal flow rate at a water temperature of 45 °C at the tap (f. ex. single lever tap).
If the domestic hot water temperature set at the controller is above 45 °C, the withdrawal flow
rate consists of a mixture of hot and cold water.
The indicated heat transfer capacity is necessary to heat up the water to be withdrawn [l/min]
from 10 °C to 45 °C.
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8 Maintenance [specialist]
Temperature in
the buffer tank
Domestic hot water
temperature set
at the controller
Maximum flow rate
from the Friwa with
the set domestic hot
water temperature
Maximum withdrawal
flow rate at the tap for
a domestic hot water
temperature of 45 °C
Transfer capacity
of the Friwa
FriwaMega
FriwaMega
FriwaMega
50 °C
60 °C
70 °C
80 °C
45 °C 82 l/min - 199 kW
45 °C 123 l/min - 300 kW
50 °C 100 l/min 114 l/min 278 kW
55 °C 77 l/min 98 l/min 240 kW
45 °C 130 l/min* - 316 kW
50 °C 130 l/min* 148 l/min 361 kW
55 °C 112 l/min 143 l/min 358 kW
60 °C 94 l/min 133 l/min 324 kW
45 °C 130 l/min* - 316 kW
50 °C 130 l/min* 148 l/min 361 kW
55 °C 130 l/min* 166 l/min 406 kW
60 °C 121 l/min 172 l/min 419 kW
at a cold water temperature of 10 °C, reheating not considered
*maximum flow rate: 130 l/min, with a pressure drop of the FriwaMega of 1000 mbars
(for hydraulic reasons, higher values are only partly possible, measuring limit of the flow
rate sensor ~260 l/min)
8 Maintenance [specialist]
In order to guarantee an optimal control, no hydraulic pressure losses should occur on
the primary side (f. ex. due to the installation of a mud strainer, strainer or mixing valve).
2014/11 99640766x-mub-en – V0323
9 Spare parts [specialist]
NOTICE
9 Spare parts [specialist]
Complaints and requests/orders of spare parts will only be processed with information on
the serial number! The serial number is placed in the upper right corner of the support sheet
in the station.