Technische Alternative FRISTAR Bedienungsanleitung
FRISTAR
Version 2.01 EN
Manual version 3
Fresh water station
Operating manual
en
Table of contents
Safety instructions....................................................................................................................3
Mode of operation....................................................................................................................4
Hydraulic circuit diagram......................................................................................................4
Components.............................................................................................................................5
Installation................................................................................................................................6
Preparation..........................................................................................................................6
Installation............................................................................................................................7
Commissioning ........................................................................................................................7
Dimensions..............................................................................................................................8
Connection of a circulation line ................................................................................................9
Interchanging connections.....................................................................................................10
Cascade switching.................................................................................................................11
Hydraulic circuit diagram of a cascade with four FRISTAR fresh water stations................11
Cascade switching control with UVR61-3R or UVR63.......................................................12
Control of cascade switching with UVR1611 .....................................................................13
Cascade switching with circulation line..................................................................................13
Hydraulics schematic diagram...........................................................................................13
Circulation pump (optional)....................................................................................................14
Electrical circuit diagram........................................................................................................14
Controller settings..................................................................................................................15
Technical data........................................................................................................................16
Pressure loss characteristic curve plate heat exchanger:..................................................17
Pressure loss characteristic pump.....................................................................................17
Plate heat exchanger corrosion resistance........................................................................18
3
Safety instructions
These instructions are intended exclusively for authorised profes-
sionals. To avoid accidents and damage due to incorrect operation,
carefully read through these operating instructions before you start
working with the freshwater station. If you carry out any alterations to
the construction of the freshwater station or the safety devices, you
may invalidate your right to make guarantee claims. Always observe
the local regulations.
Intended use
The freshwater station may only be installed in heating systems between the buffer tank and
the drinking water circuit. The technical limit values specified in this manual must be consid-
ered.
Incorrect use will result in the negation of any liability claims.
Electrical connection
Any electrical connections must be made by qualified electricians. Connection cables must
be routed in the recesses provided in the insulated base in such a way that direct contact
with the pump casing and the pipes is prevented.
Before switching on, check whether the supply voltage matches that stated on the power rat-
ing plates of the pump and the controller. All connections must correspond to the local regu-
lations.
Safety standards during installation, commissioning and maintenance
Installation, commissioning and maintenance may only be carried out by qualified persons
who are familiar with these operating instructions.
Before you start work on the system, ensure that the system is switched off and all compo-
nents are cooled down. When replacing the pump, turn the 4 ball valves into the closed posi-
tion.
In multi-occupancy dwellings, legionella protection must be observed in accordance with the
local regulations.
WARNING! Dependent on the pump and system operating conditions, the sur-
face temperatures can be very high. Direct contact with the pump or pipes can
result in burns!
Important note:
The secondary flow rate (cold / hot water)
must never be more than 40 l/min!
4
Mode of operation
Through use of the instantaneous heating concept, drinking water is heated both hygienically
and with low energy consumption in the FRISTAR freshwater station.
If water is drawn from the mains, the primary circuit pump transports tank water from a buffer
tank through the plate heat exchanger.
On the secondary side of the heat exchanger the drinking water flowing through is heated to
the temperature set in the controller. The cooled tank water is returned to bottom layer of the
buffer tank.
The speed control of the primary circuit pump takes place in the FRISTAR controller based
on the measurements of the volume flow sensor in the hot water pipe (temperature Tww and
volume flow Vww) and the temperature sensor in the primary flow TPri). The pump is con-
trolled using wave packet control. The optimum matching of the control behaviour to the
pump and the heat exchanger guarantees perfect constant maintenance of the outlet tem-
perature.
Hydraulic circuit diagram
Temperature
Primary flow
Volume flow sensor
Hot water temperature Tww
Volume flow Vww
Pre-mixer
(recommended)
Safety valve max. 8 bar
Pump
5
Components
Flow
primary circuit
Return
primary circuit
Ball valve
Ball valve
with
gravity brake
Ball valve
Ball valve
Hot water
Secondary circuit
Cold water
Secondary circuit
Volume
flow sensor
Primary
sensor
Controller
Pump
Power cable
Plate heat
exchanger
Circulation
pipe connection
Ventilation
primary circuit
6
Installation
Preparation
A safety valve (max. 8 bar) must be installed in the cold water supply corresponding
to standards DIN 1988 und 4753, part 1 and TRD 721.
If the cold water pressure > 8 bar, fit a diaphragm pressure reducer max. 8 bar.
The installation of flushing equipment before and after the plate heat exchanger in
the primary and secondary circuits is recommended for descaling or cleaning as nec-
essary.
Special accessories: VMS pre-mixing set
If the tank is operated at a temperature higher than 70°C a pre-mixer that restricts the tem-
perature to less than 70°C must be used in the primary circuit.
The VMS pre-mixing set is suitable for both Fristar models (left pump, right pump).
Figure: Connection for Fristar with right pump
Technical data
Setting range:
45°C –65°C
Flow coefficient of mixing valve
4.5m³/h
Connections for Fristar
¾”
The thermal mixing valve is also available as an extra under the TMV designation.
Thread 3/4“
Thread 3/4“
Thread 3/4“
Thread 1“
7
Installation
Mounting position: Only vertical
Pull off the cowling in a forwards direction.
If necessary: Interchange the right/left connections (see chapter "Interchanging con-
nections").
Mark the fastening points, insert rawlplugs, fasten the station to the wall.
Fitting and connection of the pipe connections (3/4" outside thread connector). Plan for
as short as possible pipes in the primary circuit (tank -> freshwater station).
Electrical connection
The freshwater station is pre-wired ready for installation, connection to the electricity
mains takes place on site:
- using a plug in a wall socket or
- using a double pole isolator with a permanent connection.
Commissioning
Before filling the system, thoroughly flush both the primary and secondary side sys-
tems. To do this the locking bolt of the return valve with the gravity brake is placed in a
45° position so that it is non-operational.
Slowly fill the house system with drinking water via the secondary side ball valves.
Vent the house system at the draw-off valves.
Slowly fill the system with hot water via the ball valves in the primary flow.
Vent the primary circuit using the venting opening of the plate heat exchanger.
Set the pump to continuous operation and check pump running. Audible background
noise during operation of the circulating pump indicates air in the system. Warning!
Only start the pump when it is filled.
Check all connections, including in the freshwater station, for correct seating and leak-
tightness. If necessary, retighten to the necessary torque.
Activate the gravity brake at the primary system return valve (place locking bolt verti-
cally)
Place the cowling on the bottom part
Set the pump in automatic mode and select the setpoint temperature.
8
Dimensions
Housing dimensions:
W x H x D = 366 x 573 x 160 mm
38
38
160
470
562
562
228
¾“
¾“
¾“
¾“
9
Connection of a circulation line
The plate heat exchanger is provided with a connection for a circulation line. To lead the
circulation line through to the heat exchanger, the isolation cap must be cut out to suitable
dimensions.
Hydraulic circuit diagram with circulation line:
Connection
Circulation line
Heat
exchanger
Circulation
pump
Pump
10
Interchanging connections
For optimum matching of the pipelines to the freshwater station it is possible to interchange
the connections (right/left). Doing this does not change the circulation line heat exchanger
openings or the venting of the primary circuit.
Version Version
"Pump right" "Pump left"
Procedure:
1. Demounting of pipe elements 1 - 4 including pump from the heat exchanger
2. Removal of the pump and installation in the correct position.
3. Remount pump connection plug 5 on the other side.
4. Mounting of pipe elements 1 - 4 and the pump on the heat exchanger (see figures
above) on the other side, correct positional setup of the volume flow sensor
5. Commissioning according to the "Commissioning" chapter
Important: The primary and secondary connections must be exchanged together!
1
1
2
2
3
3
4
4
Pump
connection-plug
5
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