PAW FriwaMini 6401410 User manual

PAW GmbH & Co. KG
Böcklerstr. 11, D-31789 Hameln, Germany
Phone: [phone], Fax: [phone]
E-mail: [email protected], Web: www.paw.eu
2017/07 99640141x-mub-en - V02 1
Installation and Operation Instructions
Domestic hot water module
FriwaMini - DN 15
FriwaMini with circulation - DN 15
FriwaMini
FriwaMini with circulation

1
General Information
2 99640141x-mub-en - V02 2017/07
Item no. 99640141x-mub-en - Version V02 - Issued 2017/07
Translation of the original instructions
We reserve the right to make technical changes without notice!
Printed in Germany – Copyright by PAW GmbH & Co. KG
PAW GmbH & Co. KG
Böcklerstraße 11
D-31789 Hameln, Germany

1
General Information
2017/07 99640141x-mub-en - V02 3
CONTENTS
1
General Information.........................................................................................................4
1.1 Scope of these instructions ..........................................................................................4
1.2 About this product ........................................................................................................5
1.3 Designated use ............................................................................................................5
2
Safety instructions ...........................................................................................................6
3
Product description..........................................................................................................7
4
Dimensioning and planning..............................................................................................8
4.1 Dimensioning of the tank..............................................................................................9
5
Circulation mode ...........................................................................................................10
6
Assembly and installation [specialist]..............................................................................11
7
Commissioning [specialist].............................................................................................14
7.1 Filling the primary circuit............................................................................................. 15
7.2 Commissioning of the controller ................................................................................. 16
7.3 Maximum withdrawal flow rate ...................................................................................18
7.4 Adjustment of the temperature ................................................................................... 20
8
Maintenance [specialist].................................................................................................21
9
Spare parts [specialist] ..................................................................................................22
9.1 Spare parts controller and insulation.............................................................................. 22
9.2 Spare parts primary circuit..........................................................................................23
9.3 Spare parts secondary circuit ..................................................................................... 24
10
Technical data...............................................................................................................25
10.1 Dimensional drawing..................................................................................................26
10.2 Pressure drop characteristic curve .............................................................................26
11
Commissioning report....................................................................................................27

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General Information
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1
General Information
1.1
Scope of these instructions
These instructions describe the installation, commissioning, function and operation of the
FriwaMini domestic hot water module. 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.
Station
Item
number
Controller
FC4.13
Pump
prim./sec.
Heat
exchanger
FriwaMini
6401410
Prim: Grundfos
UPM3 15-75
FlowEstimation
50 plates
FriwaMini
with circulation
6401415
Prim: Grundfos
UPM3 15-75
FlowEstimation 50 plates
Sec: Grundfos
UPM3 15-70 CIL3
Carefully read these instructions before installation and commissioning.
Save these instructions in the vicinity of the installation for future reference.

1
General Information
2017/07 99640141x-mub-en - V02 5
1.2
About this product
The domestic hot water module is a premounted group of fittings checked for tightness 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 at the cold water inlet
•Temperature sensor in the heating circuit flow line
•Flow meter at the domestic hot water outlet
•Primary and circulation pump can be isolated
•Manual vent valve for venting the heat exchanger
and the pump
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 limit values 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.

2
Safety instructions
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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
NOTICE
Material damage due to mineral oils!
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 from mineral oils, such as
Unisilikon L250L and Syntheso Glep 1 of the Klüber company or a silicone spray.
NOTICE
Malfunction!
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.

3
Product description
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3
Product description
Primary circuit
Connections
1
Primary side/heating side:
Return to the buffer tank
2
Primary side/heating side:
Flow from the buffer tank
3
Secondary side/DHW side:
Hot water supply, circulation
4
Secondary side/DHW side:
Cold water supply
5
Secondary side/DHW side:
Hot water outlet
Equipment primary circuit
A
Heat exchanger
B
Temperature sensor Pt1000
C
Ball valve
D
Ball valve with check valve
E
Primary pump
F
Manual vent valve
Equipment secondary circuit
G
Piston valve with drain valve (cold water inlet)
H
Piston valve with drain valve (hot water outlet)
I
Analogue flow rate sensor, VFS 2-40 l/min
J
Temperature sensor Pt1000
K
Pressure relief valve 10 bars
Only for the protection of the station.
Does not replace the pressure relief valve
that has to be mounted on site!
L
Circulation pump
M
Piston valve with drain valve (circulation)
Secondary circuit
Example: FriwaMini with circulation

4
Dimensioning and planning
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4
Dimensioning and planning
The FriwaMini is a domestic hot water module operating on the principle of a flow-type water
heater.
The DHW module will only work flawlessly if the installation meets certain requirements.
Please take some time to plan the installation.
WARNING
Danger of scalding due to hot water!
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 domestic hot water
module and the buffer tank.
The domestic hot water module must not be connected to a distribution
manifold of a heating circuit.
Mounting example
FriwaMini circulation with optional return distribution (item no. 640425).
Safety group
according to
DIN 1988

4
Dimensioning and planning
2017/07 99640141x-mub-en - V02 9
4.1
Dimensioning of the tank
The following table helps you to calculate the approximately required volume of the buffer tank.
Temperature in
the buffer tank
Domestic hot water
temperature set at the
controller
Required tank volume
per litre of hot water
50 °C 45 °C 1.6 litres
60 °C*
45 °C
0.9 litre
50 °C 1.2 litres
55 °C 1.7 litre
70 °C
50 °C 0.9 litre
55 °C 1.1 litre
60 °C 1.3 litre
80 °C
50 °C 0.7 litre
55 °C 0.9 litre
60 °C 1.0 litre
*Calculation example for the dimensioning of the buffer tank:
Temperature of the buffer tank: 60 °C
Maximum withdrawal quantity needed: 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 post-
heating?
20 l/min x 20 min = 400 l
400 l x 0.9 = 360 l
The heated part of the buffer tank must have a volume of 360 litres.

5
Circulation mode
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5
Circulation mode
The domestic hot water module is equipped with a circulation pump.
For the operation of the circulation pump, three possible operation modes are stored in the
controller (see controller instructions, page 21).
•
Pulse-controlled operation
(depending on the demand / requirements):
The short actuation of a hot water tap (tap pulse: ~2 sec.) starts the circulation pump.
The circulation pump will then run for several minutes (adjustable).
•
Time-dependent operation:
The operation of the circulation pump can be set on a week clock within freely
selectable periods of time. In this operation mode, the circulation is activated at the
beginning of the period of time chosen. The circulation will stop after the end of the
chosen period of time.
•
Temperature-dependent operation:
In this operation mode, the circulation is only activated if the adjustable minimum
temperature at 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 each other as wished, f. ex. the time- and the
temperature-dependent operating modes. The circulation is only activated if the temperature at
the circulation temperature sensor falls below the required value and if the time window is
active.
Outside the time slot, the circulation pump can be activated by a tap pulse if the pulse-controlled
operation mode is additionally activated.
NOTICE
Damage to property!
When the DHW module is delivered, the circulation is not activated (see controller instructions,
page 15). During commissioning the operation mode must be selected and pre-set under all
circumstances. The revolution speed of the circulation pump must be defined by the PWM
signal (factory setting: 100 %).

6
Assembly and installation [specialist]
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6
Assembly and installation [specialist]
The domestic hot water module must only be connected with the storage tank by separate
connections for the 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)!
NOTICE
Damage to property!
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.
NOTICE
Damage to property!
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.
For example the make Flexofit S of the Flamco GmbH company or the make WD of the
Reflex Winkelmann GmbH company.
DHW
module
Fittings
Drain valve
Pressure relief valve
Return valve (non-return valve)
Possibly pressure reducing valve
Test valve
Shut-off valve
Hot water
Cold water

6
Assembly and installation [specialist]
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WARNING
Risk to life and limb due to electric shock!
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. An unintentional start of the motors is thus
avoided.
NOTICE
Damage to property!
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. The pipes in the heating circuit must
not exceed a length of 4 m (for DN 20).
2. Copy the measures for the mounting holes
to the wall. You can find a corresponding
drilling template (see on the right) on the
paper board under the domestic hot water
module.
3. Drill the holes and insert adequate wall
plugs into the holes.
4. Turn the screws into the wall plugs in such
a way that about 40 mm of each screw still
stick out.
5. Remove the insulating front shell.
6. Hang the domestic hot water module onto
the screws. Tighten the screws, so that the
sides of the insulation are flush to the wall.

6
Assembly and installation [specialist]
2017/07 99640141x-mub-en - V02 13
7. Connect the domestic hot water module
with the installation by using the piping
according to the adjacent figure.
1
Primary side:
return to the buffer tank,
connection: ¾" internal thread,
pipes
at least DN 20: 22 x 1 mm,
recommended DN 25: 28 x 1.5 mm
2
Primary side:
flow from the buffer tank,
connection: ¾" internal thread,
pipes
at least DN 20: 22 x 1 mm,
recommended DN 25: 28 x 1.5 mm
3
Secondary side:
hot water supply, circulation,
connection: ¾" external thread,
flat sealing
4
Secondary side:
cold water inlet,
connection: ¾" external thread,
flat sealing
5
Secondary side:
hot water outlet,
connection: ¾" external thread,
flat sealing
Pipe distance to the wall
(secondary) = 72 mm
Pipe distance to the wall
(primary) = 112 mm

7
Commissioning [specialist]
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7
Commissioning [specialist]
Note!
Slowly
open the valves in the pipes and in the module, in order to prevent pressure surges.
Functioning check valve
The primary circuit is equipped with a check valve
in the ball valve (D), in order to avoid unwanted
gravity circulation.
For venting and flushing the installation, the check
valve must be open. For this purpose, turn the ball
valve into the position
45°
.
In this position, the check valve is not operating.
For the operation of the installation, all (ball) valves
must be
completely
open (position
0°
).
Position 0°
Position 45°
Position 90°
Check valve is operating,
flow only in flow direction.
Check valve is not operating,
flow in both directions.
Ball valve closed,
no flow.
14

7
Commissioning [specialist]
2017/07 99640141x-mub-en - V02 15
7.1
Filling the primary circuit
WARNING
Danger of scalding due to hot water!
The system is under pressure. By opening the vent valve, hot water with a
temperature of up to 90 °C may exit and cause personal injury.
Open the vent valve slowly and with sufficient distance.
If the storage tank is (partly) filled
1. Slowly open the ball valve (C) by turning it into
position
0°
.
2. Fill the storage tank using the fill valves available
on site until an operating pressure of about
1.5 bars* is reached. Use heating water
compliant with the standards VDI 2035 /
ÖNorm H5195-1.
3. Manipulate the vent valve (F) cautiously to let the
air escape.
4. Close the vent valve (F).
5. Close the ball valve (C) by turning it into
position
90°
.
6. Slowly open the ball valve (D) by turning it into
position
45°
.
7. Manipulate the vent valve (F) cautiously to let the
air escape.
8. Close the vent valve (F).
9. Check the operating pressure of the storage tank
after the venting and increase the pressure if
necessary.
10. Open the ball valves (C) and (D) completely by
turning them into position
0°
.
Primary circuit
*1.5 bars in the primary circuit = recommended minimum value The pressure depends on the individual
system pressures and the components of the heating installation!

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Commissioning [specialist]
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7.2
Commissioning of the controller
WARNING
Risk to life and limb due to electric shock!
Check if the sensors and 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 be
plugged into a socket.
1. Connect the domestic hot water module to
the mains (230 V, 50 Hz) by using the
premounted connection cable.
2. Select "Manual mode" in the main menu of
the controller and set the pump to "HE1"
(PWM signal = 100 %), see controller
manual page 27.
3. Let the pump run for several minutes to vent
the domestic hot water module.
4. When the air noises do not stop, carefully
manipulate the vent valve (F) while the
pump is still running and let the air escape.
5. If the air noises have stopped, the pump can
be switched off.
6. To do so, select "Manual mode" in the main
menu of the controller and set the pump to
"AUTO".
7. Slowly open the piston valves on the
secondary side (G and H).
Primary circuit
Secondary circuit

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Commissioning [specialist]
2017/07 99640141x-mub-en - V02 17
8. Open a 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 vent the secondary
circuit. Close all withdrawal points of the
secondary circuit afterwards.
9. Make sure that the domestic hot water
module is correctly integrated into the
potential equalisation of the installation.
10. Set the desired domestic hot water
temperature at the controller (see page 20).
11. The domestic hot water module is now ready
for operation.
Secondary circuit

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Commissioning [specialist]
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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
avoids temperature drops as long as the maximum flow rate is not exceeded.
Withdrawal flow rate [l/min]
Power [kW]
Domestic hot water temperature: 45 °C
Boundary conditions:
Cold water temperature: 10 °C
Maximum pressure drop on the domestic hot water side of the DHW module: 1000 mbars
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 DHW module.
Example 1
Domestic hot water temperature at the withdrawal point: 45 °C
Temperature in the buffer tank: 50 °C
DHW module: max. withdrawal flow rate: 18 l/min, heat transfer capacity: 41 kW
Example 2
Domestic hot water temperature at the withdrawal point: 45 °C
Maximum withdrawal flow rate: 27 l/min
DHW module: temperature in the buffer tank: 60 °C, heat transfer capacity: 67 kW
FriwaMi
Temperature of the buffer tank
Example 2
Example 1

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Commissioning [specialist]
2017/07 99640141x-mub-en - V02 19
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
.
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:
Cold water temperature: 10 °C
Example 1
Domestic hot water temperature at the controller: 60 °C
Temperature in the buffer tank: 70 °C
DHW module: max. withdrawal flow rate: 31 l/min, heat transfer capacity: 77 kW
Example 2
Domestic hot water temperature at the controller: 60 °C
Maximum withdrawal flow rate: 21 l/min
DHW module: temperature in the buffer tank: ~65 °C, heat transfer capacity: 53 kW
FriwaMini
Temperature of the buffer tank
Example 1
Example 2

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Commissioning [specialist]
20 99640141x-mub-en - V02 2017/07
7.4
Adjustment of the temperature
Set the desired (maximum) domestic hot water temperature at the controller under
"Main menu / Hot water / T HW nom." (see controller instructions, page 19).
WARNING
Danger of scalding due to hot water!
In order to avoid scalding at the tap, the maximum domestic hot water
temperature set at the controller must not exceed
60 °C
.
Primary side
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 adjusted at the controller and on the temperature available in the buffer tank.
The recommended maximum domestic hot water flow rate through the domestic hot water
module is ~42 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 tap flow rate
consists of a mixture of hot and cold water.
The indicated heat transfer capacity is necessary to heat up the water quantity of the withdrawal
flow rate [l/min] from 10 °C to 45 °C.