Weishaupt WHI freshaqua 22 #1 Service manual

Mounting and operating instructions
Fresh water station WHI freshaqua 22 83514302 ▪ 1/2017-08

EU conformity certification
Language 02
Product description Fresh water station
Type WHI freshaqua …
Manufacturer Max Weishaupt GmbH
Address Max-Weishaupt-Straße 14, DE-88475 Schwendi
The sole responsibility for issuing this conformity declaration lies with the manufacturer.
The content of the statement described above complies with the relevant harmonisation legislation of the European
Union:
EMC 2014/30/EU
LVD 2014/35/EU
Standard applied: EN 60335-1
Schwendi, 17/08/2016
Signed for and on behalf of:
MAX WEISHAUPT GMBH
ppa.
Dr. Schloen
Manager research and Development
ppa.
Denkinger
Manager Production and Quality Management

Installation and operating instructions
Fresh water station WHI freshaqua 22
83514302 ▪ 1/2017-08 ▪ Ext. PAW 3-32
1Information for the user ........................................................................................ 4
1.1User guidance ............................................................................................... 4
1.1.1Symbols ........................................................................................................ 4
1.1.2Target group ................................................................................................. 4
1.2Warranty and liability..................................................................................... 4
2Safety .................................................................................................................. 5
2.1Designated use ............................................................................................. 5
2.2Safety instructions ........................................................................................ 5
2.3Safety measures ........................................................................................... 6
2.4Electrical connection ..................................................................................... 6
2.5Structural modifications ................................................................................. 6
2.6Disposal ........................................................................................................ 6
3Product description .............................................................................................. 7
3.1Function ........................................................................................................ 8
3.2Serial number ............................................................................................... 8
3.3Technical Data Fresh Water Station ............................................................. 9
3.4Technical Data Pumps ................................................................................ 11
3.5PWM input signal (solar profile) .................................................................. 11
3.6Hydraulilc performance data ....................................................................... 12
4Dimensioning and Planning ............................................................................... 13
4.1Dimensioning the storage ........................................................................... 15
4.2Circulation mode ......................................................................................... 16
5Installation ......................................................................................................... 17
5.1Assembly .................................................................................................... 18
5.2Connection .................................................................................................. 19
5.3Controller connection .................................................................................. 19
6Operation ........................................................................................................... 20
7Commissioning .................................................................................................. 20
7.1Filling the primary circuit ............................................................................. 21
7.2Commissioning the controller ...................................................................... 22
7.3Maximum tapped flow rate .......................................................................... 23
7.4Setting the temperature .............................................................................. 25
8Maintenance ...................................................................................................... 26
9Spare parts ........................................................................................................ 27
9.1Spare parts list WHI freshaqua 22 #1 (40900015012) and
WHI freshaqua 22 #3 (40900019012) ......................................................... 27
9.2Spare parts list WHI freshaqua 22 #2 (40900015022) and
WHI freshaqua 22 #4 (40900019022) ......................................................... 29
10Commissioning log ............................................................................................ 31

Installation and operating instructions
Fresh water station WHI freshaqua 22
1 Information for the user
83514302 ▪ 1/2017-08 ▪ Ext. PAW 4-32
1Information for the user
These installation and operation instructions form part of the device and must be stored
at the place of use.
Carefully read these instructions before installation and commissioning.
1.1 User guidance
1.1.1 Symbols
DANGER
Immediate danger of high risk.
Non-observance will result in serious injuries or death.
WARNING
Danger of medium risk.
Non-observance may result in environmental damage,
serious injuries or death.
CAUTION
Danger of low risk.
Non-observance may result in property damage or slight
to moderate injuries.
NOTICE Important information.
1.1.2 Target group
This installation and operation manual is addressed to operators and qualified skilled
personnel. It must be observed by anyone working on the machine.
Work on the machine may only be performed by persons that have received the required
training or instruction.
Persons with restricted physical, sensory or mental abilities may work on the machine if
supervised or instructed by an authorised person.
Children may not play with the machine.
1.2 Warranty and liability
Warranty and liability claims for personal and material damage are void if they are due to
one or several of the following causes:
Use of the machine contrary to its designated use,
Non-observance of the installation and operation instructions,
Operation of the machine with non-operational safety or protective devices,
Continued use despite the presence of a defect,
Improper assembly, commissioning, operation and maintenance of the machine,
Unauthorised modification of the machine,
Installation of additional components that were not tested together with the machine,
Repairs carried out incorrectly,
Failure to use Weishaupt original parts
Defects in the supply lines,
Force majeure.

Installation and operating instructions
Fresh water station WHI freshaqua 22
2 Safety
83514302 ▪ 1/2017-08 ▪ Ext. PAW 5-32
2Safety
2.1 Designated use
The fresh water station must only be installed in heating systems between the buffer tank
and the domestic water circuit. Due to its construction, it must only be installed and
operated in a vertical position. The technical limit values specified in this instruction must
be considered.
Use only original accessories in connection with the fresh water station.
Using the station contrary to its designated use will invalidate all liability claims.
The wrapping materials are made of recyclable materials that can be recycled by
standard recycling operations.
2.2 Safety instructions
The following must be observed during installation and commissioning:
Relevant local and national regulations
Accident prevention regulations of the employers' liability insurance association
Instructions and safety instructions mentioned in these instructions
WARNING
Risk of scalding from hot water!
Due to the third party circulation, up to 90 °C hot water may run
out at the tapping point in the primary circuit.
No external pump may be installed between the fresh
water station and the buffer tank.
The fresh water station must not be connected to a
heating circuit distributor.
CAUTION
Risk of burns!
The valves and fittings and the pumps can become heated up to
more than 95 °C during operation.
The insulation must remain closed during operation.

Installation and operating instructions
Fresh water station WHI freshaqua 22
2 Safety
83514302 ▪ 1/2017-08 ▪ Ext. PAW 6-32
NOTICE Material damage due to mineral oils!
Mineral oil products cause permanent damage in the material,
resulting in its sealing characteristics getting lost.
We cannot be held liable for damage caused by seals damaged in
this way, and nor will we give warranty replacement for such
parts.
It is imperative to prevent the EPDM from making contact
with substances containing mineral oils.
Use a silicone- or polyalkylene-based lubricant free of
mineral oil such as Unisilikon L250L and Syntheso
Glep 1 from Klüber or a silicone spray.
NOTICE Malfunction!
The fresh water station must be integrated in the
potential equalisation of the electrical installation.
If this is not ensured by the connected pipework than
establish a correct potential equalisation connection to
the main potential connection.
2.3 Safety measures
Immediately eliminate safety-relevant defects and replace safety-relevant components
when they have reached the end of their service life due to their construction.
2.4 Electrical connection
When performing any work on live parts:
Observe the accident prevention regulations BGV A3 and local regulations,
Use tools according to EN 60900.
2.5 Structural modifications
Conversion measures are only allowed after prior approval in writing by the
Max Weishaupt GmbH.
Additional components may only be installed if they were tested together with the
machine.
Use only Weishaupt original parts.
2.6 Disposal
Dispose of the materials used properly and in an environmentally compatible manner.
In doing so, observe local regulations.

Installation and operating instructions
Fresh water station WHI freshaqua 22
3 Product description
83514302 ▪ 1/2017-08 ▪ Ext. PAW 7-32
3Product description
The fresh water station is a pre-assembled fitting group tested for leaks for transferring
heat between the buffer tank and the domestic water circuit.
It contains a preset controller as well as important fittings for operating the system:
Ball valves in the primary circuit
Piston valves in the secondary circuit
Safety valve in the secondary circuit
Pre-assembled controller
Temperature sensor on the cold water supply
Temperature sensor on the heating supply
Flow meter on the warm domestic water outlet
Lockable primary pump
Fill and drain valve for venting the heat exchanger and the pump
Connections
1 Secondary side: hot water outlet
2 Primary side: supply from buffer tank
3 Primary side: return to buffer tank
4 Secondary side: cold water inlet
Equipment
A Piston valve (warm water outlet)
B Fill and drain valve
C Safety valve, 10 bars
(Only for protection of the station. Does not replace the
safety valve that must be installed on-site.)
D Temperature sensor PT1000, rapid
E Primary pump
F Ball valve
G Ball valve with check valve
H Analogue flow rate temperature sensor VFS 2-40 l/min
J Heat exchanger
K Temperature sensor PT1000, rapid
L Piston valve (cold water inlet)

Installation and operating instructions
Fresh water station WHI freshaqua 22
3 Product description
83514302 ▪ 1/2017-08 ▪ Ext. PAW 8-32
3.1 Function
The fresh water stations WHI freshaqua are used for the comfortable and hygienic
heating of domestic water according to the continuous flow heater principle. Other than
in conventional domestic water storage tanks, the foodstuff water is not used for energy
storage and stored as hot water for hours or days. It is only heated when required using
a high-performance plate heat exchanger. The energy for heating the domestic water
comes from a buffer tank that can be heated by different systems - by solar systems as
well as by solid fuel boilers, oil / gas boilers, heat pumps or other systems.
The WHI freshaqua modules are well suited for use in combination with a thermal solar
system. The very good cooling of the heating water in the highly effective plate heat
exchangers leads to an increased efficiency of the solar circuit as the average
temperature of the solar circuit can be reduced due to the cold return.
In the event of great tapping differences, the WHI freshaqua fresh water stations always
have to guarantee a constant outlet temperature at the hot water tap.
The speed of the highly efficient EC pumps of the latest generation is controlled by a
high-performance closed-loop control always allowing the heating flow rate to be optimal-
ly set to the current tap capacity.
The closed-loop control receives the necessary information for adjusting the system from
a flow rate sensor and extremely fast temperature sensors that detect the smallest
temperature deviations immediately.
The WHI freshaqua can also be equipped with a highly efficient EC circulation pump as
an option. The closed-loop control can operate the pump in different circulation modes;
always adapted to the current system and requirements of the customer.
During commissioning, the circulation return temperature can be set individually on the
circulation system so that the recordable and traceable DVGW (551) requirements for a
maximum cooling of the circulation by 5 K can be fulfilled.
Thus, the WHI freshaqua offer perfect comfort, optimum hygiene and a future-orientated
energy saving operation.
3.2 Serial number
The serial number on the type plate clearly identifies each product. The serial number is
necessary for the Weishaupt after-sales service. In case of a complaint, please send us
the serial number of the product concerned and the completed commissioning report
(see page 31). The serial number is placed in the upper right corner of the support sheet
of the station.
Serial number:

Installation and operating instructions
Fresh water station WHI freshaqua 22
3 Product description
83514302 ▪ 1/2017-08 ▪ Ext. PAW 9-32
3.3 Technical Data Fresh Water Station
Dimensions WHI freshaqua 22 #1 and #3 WHI freshaqua 22 #2 and #4
Total height 645 mm 1116 mm
Total width 355 mm 446 mm
Total depth 249 mm
Centre distance, top 86 mm
Centre distance, bottom 47 mm
Primary pipe connection
(storage tank circuit) G ¾" female thread
Secondary pipe connection
(WHI freshaqua) G ¾" male thread, flat sealing
Safety valve outlet G ¾" female thread
Operating data
Max. admissible pressure primary: 6 bars, secondary: 10 bars
Min. flow rate 2 l/min
Operating temperature 2 – 95°C
Max. power Qmax 80 kW at Flowprim. 75° / DHWsec. 60° / DCWsec.10°
Flow rate at Qmax primary: 1400 l/h, secondary: 22 l/min
Operating temperature sensors -25 °C to +120 °C
Equipment
Safety valve secondary: 10 bars, suitable for domestic water
Primary pump High-efficiency pump with PWM control, 3-70 W
Secondary pump — High-efficiency pump
with PWM control, 3-70 W
Heat exchanger 30 plates
Flow rate sensor secondary: 1 x VFS, Measuring range: 2-40 l/min
Temperature sensor primary / secondary: 1 x PT1000 each, rapid
Check valve (in the ball valve) primary: 1 x 200 mm wc, can be opened

Installation and operating instructions
Fresh water station WHI freshaqua 22
3 Product description
83514302 ▪ 1/2017-08 ▪ Ext. PAW 10-32
Material
Valves and fittings Brass
Seals: o-ring EPDM
Flat sealing AFM 34, free of asbestos
Check valve Hostaform
Pipes 1.4401 (AISI 316)
Insulation EPP,  = 0.041 W/(m K), fire class B2
Heat exchanger with copper soldering
(WHI freshaqua 22 #1 and #2)
Plates + connecting pieces: 1.4401 (AISI 316)
Solder: 99.99% pure copper
Heat exchanger with nickel soldering
(WHI freshaqua 22 #3 and #4)
Plates + connecting pieces: 1.4401 (AISI 316)
Solder: 99.99% nickel
Admissible medium
(WHI freshaqua 22 #1 and #2)
primary: heating water according to VDI 2035 / Ö-Norm H 5195-1
secondary: domestic water with a max. chloride content: ≤ 80 ppm
Admissible medium
(WHI freshaqua 22 #3 and #4)
primary: heating water according to VDI 2035 / Ö-Norm H 5195-1
secondary: domestic water with a max. chloride content: ≤ 300 ppm
Certification SVGW (1308-6180)
ACS (15 ACC NY 015)

Installation and operating instructions
Fresh water station WHI freshaqua 22
3 Product description
83514302 ▪ 1/2017-08 ▪ Ext. PAW 11-32
3.4 Technical Data Pumps
Grundfos UPM2 15-75 LowFlow Grundfos UPM2 15-75 CIL
Length 130 mm
Connections 1" male thread
Protection class IP 44
Max. pressure 1.0 MPa (= 10 bars)
Max. temperature 95 °C TF 95
I (1/1) 0.04-0.52 A
P1 3-70 W
Use in
WHI freshaqua 22 #1 and #3 Prim /
WHI freshaqua 22 #2 and #4 Prim Sec
Prim = Primary side (accumulator circuit) / Sec = Secondary side (circulation)
3.5 PWM input signal (solar profile)
PWM input
signal [%]
Pump status
< 6 Standby
6-8 Hysteresis
9-15 Min.
speed
16-90 Linear increase in
speed from rpm
min. to rpm max.
91-100 Max.
speed
Min.
Max.
Stop
PWM input signal [%]
Speed

Installation and operating instructions
Fresh water station WHI freshaqua 22
3 Product description
83514302 ▪ 1/2017-08 ▪ Ext. PAW 12-32
3.6 Hydraulilc performance data
WHI freshaqua 22
Flowrate[l/h]
Pressuredropdomesticwaterside
Residualdeliverypressureorpressuredrop[mbars]
CirculationUPM215‐75CIL
HeatingUPM215‐75LowFlow

Installation and operating instructions
Fresh water station WHI freshaqua 22
4 Dimensioning and Planning
83514302 ▪ 1/2017-08 ▪ Ext. PAW 13-32
4Dimensioning and Planning
The WHI freshaqua is a fresh water station that heats the domestic water according to
the continuous flow heater principle.
The system must fulfil certain requirements for the trouble-free function of the fresh water
station. Take a little time for the planning before assembly.
Due to their construction, the WHI freshaqua modules reduce the precipitation of scale in
the heat exchanger. For systems with a high total domestic water hardness and/or high
temperatures, a water treatment is recommended, in order to prevent scale formation.
WARNING
Risk of scalding from hot water!
Due to the third party circulation, up to 90 °C hot water may run
out at the tapping point in the primary circuit.
No external pump may be installed between the fresh
water station and the buffer tank.
The fresh water station must not be connected to a
heating circuit distributor.
The WHI freshaqua stations in the following table differ in the soldering material used for
the plate heat exchangers.
The choice of the heat exchanger depends on the requirements of the installation
location. Depending on the chemical composition of the water on the installation location,
an appropriate plate heat exchanger must be chosen.
Please observe the following table:
Heat exchanger
with copper soldering
Heat exchanger
with nickel soldering
Maximum chloride content
in the potable water ≤ 80 ppm ≤ 300 ppm
pH value 7.0 - 9.0 No limitation
Conductivity ≤ 500 μS/cm No limitation
Zinc-galvanised piping Unsuitable Suitable
Maximum pressure at 95 °C 17 bars 12 bars
Plate material 1.4401 (AISI 316)
Overview of the WHI freshaqua stations and the integrated heat exchangers:
Fresh water station -w- Part number Soldering material
of the heat exchanger
WHI freshaqua 22 #1 40900015012 Copper
WHI freshaqua 22 #2 40900015022 Copper
WHI freshaqua 22 #3 40900019012 Nickel
WHI freshaqua 22 #4 40900019022 Nickel

Installation and operating instructions
Fresh water station WHI freshaqua 22
4 Dimensioning and Planning
83514302 ▪ 1/2017-08 ▪ Ext. PAW 14-32
Assembly example
Fresh water station WHI feshaqua 22 #2 with circulation kit and with optional
return distribution
In order to guarantee optimum closed-loop control, where possible no hydraulic pressure
drop should occur on the primary side (e.g., from the installation of a mud strainer, dirt
trap or mixing valve).

Installation and operating instructions
Fresh water station WHI freshaqua 22
4 Dimensioning and Planning
83514302 ▪ 1/2017-08 ▪ Ext. PAW 15-32
4.1 Dimensioning the storage
Using the following table, you can calculate the approximate required volume of the
buffer tank.
Temperature in the
buffer tank
Hot water temperature
set on the controller
Required storage volume
per litre of hot water
50 °C 45 °C 1.5 litres
45 °C 0.9 litres
60 °C 50 °C 1.2 litres
55 °C 1.6 litres
45 °C 0.7 litres
70 °C 50 °C 0.9 litres
55 °C 1.0 litres
45 °C 0.6 litres
80 °C 50 °C 0.7 litres
55 °C 0.8 litres
Calculation example for dimensioning the buffer tank:
Buffer tank temperature: 60 °C
Required tapped flow rate at the tap: 20 l/min
Domestic hot water temperature set on the controller: 45 °C
How large does the tank have to be if tapping is carried out for 20 minutes without
reheating?
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.

Installation and operating instructions
Fresh water station WHI freshaqua 22
4 Dimensioning and Planning
83514302 ▪ 1/2017-08 ▪ Ext. PAW 16-32
4.2 Circulation mode
The fresh water station WHI freshaqua 22 #2 and #4 is equipped with a circulation pump.
Three possible operating modes are stored in the controller for operating the circulation
pump (see also operating instructions of controller, menu "Func" / "F02"):
Pulse controlled operation (requirement dependent / demand):
The circulation pump is started by briefly opening a hot water tap point (tapping pulse:
~2 seconds). The circulation pump then only runs for a few minutes (can be set).
Time-dependent operation:
The operation of the circulation pump can be set on a week clock within a freely
definable time period. With this operating mode, the circulation is started at the beginning
of the set time period. The circulation is switched off after the set time period has
elapsed.
Temperature-dependent operation:
With this operating mode, the circulation is only started if the minimum temperature that
can be set on the circulation temperature sensor is not exceeded within the operating
period. The circulation is switched off after reaching the nominal temperature that can be
set or after the set time period has elapsed.
The operating modes can be combined as desired, e.g., time and temperature-
dependent operation. In doing so, the circulation is only active if the temperature on the
circulation temperature sensor has exceeded and the time window is active.
Outside the time window, the circulation pump can also be activated via a tapping mode
when the additional pulse controlled operation is activated.
NOTICE Damage to property!
In its delivery state, the circulation is not activated yet
(see operating instructions of the controller, menu "Func" / "F02"
to "OFF").
If the circulation line is installed, the operating mode must be
selected and pre-set under all circumstances. The revolution
speed of the circulation pump must be specified via the PWM
signal (factory setting: 40%).

Installation and operating instructions
Fresh water station WHI freshaqua 22
5 Installation
83514302 ▪ 1/2017-08 ▪ Ext. PAW 17-32
5Installation
The domestic water connection must be carried out according to the relevant standards
(e.g., DIN 1988)!
NOTICE Material damage!
The safety valve integrated into the station does not
replace the safety equipment of the domestic water
connection according to DIN 1988.
The safety valve merely protects the station from excess
pressures when maintenance is required.
Fresh
water
station
Service water fitting
Drain valve
Safety valve
Non-return valve
Pressure-reducing valve, if necessary
Test valve
Shut-off valve
Hot
water
Cold
water

Installation and operating instructions
Fresh water station WHI freshaqua 22
5 Installation
83514302 ▪ 1/2017-08 ▪ Ext. PAW 18-32
5.1 Assembly
WARNING
Risk to life and limb due to electric shock!
Prior to performing electrical work on the controller,
de-energise the system.
For more information, see enclosed installation and
operation instructions of the station controller.
Connect the fresh water station to the power supply
system (230 V, 50 Hz) only after completing all
installation tasks, filling and flushing. This avoids an
unintentional start of the motors.
NOTICE Material damage!
In order to avoid damaging the system, the installation
site must be dry, structurally safe and frost-free.
Furthermore, access to the closed-loop control and
safety equipment must be guaranteed at all times
during operation!
If tapping points are connected to the same network
as the fresh water station, in which pressure surges are
possible (e.g., flushing valves, washing machines or
dishwashers), we recommend the installation of water
hammer dampers near the device causing the
pressure surges.
1. Place the installation site of the fresh water station near the buffer
tank. With long connecting lines, the transfer capacity is reduced due
to higher pressure drops.
2. Transfer the dimensions for the drill holes onto the wall. A suitable
drilling pattern can be found on the carrying aid below the fresh water
station.
3. Drill the holes and insert the enclosed wall plugs. Make sure that the
ground has sufficient load-carrying capacity.
4. Screw the screw into the plug until it protrudes about 40 mm from the
wall.
5. Pull off the front shell.
6. Hang the fresh water station on the screws.
Tighten the screws so that the insulation on the sides rest against the
wall.

Installation and operating instructions
Fresh water station WHI freshaqua 22
5 Installation
83514302 ▪ 1/2017-08 ▪ Ext. PAW 19-32
5.2 Connection
Pipe the fresh water module with the system according to the diagram below.
Pipe gap from the wall
(secondary) = 107 mm
1 Secondary side:
hot water outlet
connection ¾" male thread, flat sealing
2 Primary side:
supply from buffer tank,
¾" female thread,
piping
minimum DN 20, 22 x 1 mm,
recommended DN 25, 28 x 1.5 mm
3 Primary side:
return to buffer tank,
¾" female thread,
piping
minimum DN 20, 22 x 1 mm,
recommended DN 25, 28 x 1.5 mm
4 Secondary side:
cold water inlet
connection ¾" male thread, flat sealing
Pipe gap from the wall
(primary) = 67 mm
5.3 Controller connection
WARNING
Risk to life and limb due to electric shock!
Prior to performing electrical work on the controller,
de-energise the system.
For more information, see enclosed installation and
operation instructions of the station controller.
Connect the fresh water station to the power supply
system (230 V, 50 Hz) only after completing all
installation work, filling and flushing.
This avoids an unintentional start of the motors.
The plug-in pump lines are permanently supplied with a
mains voltage of 230 V and cannot be switched off via
the controller.
The fresh water station is pre-wired in the factory. When using the circulation pump,
its connection can be obtained from the enclosed assembly instructions.

Installation and operating instructions
Fresh water station WHI freshaqua 22
7 Commissioning
83514302 ▪ 1/2017-08 ▪ Ext. PAW 20-32
6Operation
A detailed description of the operation of the controller can be found in the enclosed
controller manual.
7Commissioning
Observe the following safety instructions regarding the commissioning of the station:
NOTICE Note!
Open the valves in the lines and in the module slowly in order to
avoid pressure surges.
Check valve operation
The primary circuit is equipped with a gravity brake in ball valve (G) in order to prevent
undesired gravity circulation.
The gravity brake must be opened for venting and flushing the system.
For this purpose, turn the ball valve to position 45°. The gravity brake is not in operation.
All ball valves and valves must be opened completely for operating the system
(position 0°).
Ball valve with integrated check valve
(Normal direction of flow in the picture: downstream)
0° 45° 90°
Check valve in operation,
flow in flow direction only.
Check valve not in operation,
flow in both directions.
Ball valve closed,
no flow.
To actuate the ball valve, a handle is included in the delivery.