Cosmo CFWME User manual

INSTALLATION AND OPERATING MANUAL
COSMO FRESH WATER MODUL
CFWME/CFWMVEE

Content
1Scope of delivery................................................................................................. 3
1.1 Corresponding ball valve set CFWMEAS: ........................................................ 3
1.2 Delivery and transport....................................................................................... 4
2Standards and guidelines .................................................................................... 4
3Safety .................................................................................................................. 5
3.1 Safety instructions ............................................................................................ 5
4General information regarding the installation and operating manual ................. 6
4.1 Regulation......................................................................................................... 6
4.2 Settings............................................................................................................. 6
5Product description.............................................................................................. 7
5.1 Intended purpose.............................................................................................. 7
5.2 Applicable documents....................................................................................... 7
6Technical specifications....................................................................................... 8
6.1 General instructions.......................................................................................... 8
6.2 Dimensions / required space ............................................................................ 9
6.3 Pressure loss / pump characteristic curve ........................................................ 9
6.4 Corrosion protection ....................................................................................... 10
6.5 Calcification protection.................................................................................... 11
6.6 Pump information............................................................................................ 11
6.7 Gravity brake .................................................................................................. 11
7Assembly and installation .................................................................................. 12
7.1 Wall-mounted assembly ................................................................................. 12
7.2 Storage tank installation with accessories ...................................................... 12
7.3 Hydraulic connection with accessories ........................................................... 14
7.4 Electrical connection....................................................................................... 17
8Commissioning, functional test, Decommissioning............................................ 18
8.1 Start-up........................................................................................................... 18
8.2 Troubleshooting .............................................................................................. 19
8.3 Decommissioning ........................................................................................... 19
9Maintenance...................................................................................................... 20
9.1 Cleaning the heat exchanger.......................................................................... 20
10 Replacement parts / accessories ...................................................................... 21
11 COSMO hotline ................................................................................................. 21
12 EU Declaration of Conformity ............................................................................ 22
13 Warranty, availability guarantee, imprint............................................................ 23

3
1Scope of delivery
Item
Designation
1
Wilo PARA 15/7 iPWM2
2
Heating return with integrated Gravity brake
3
Plate heat exchanger, copper-soldered
Plate heat exchanger, solid stainless steel
4
CFWME control system
5
PT 1000 buffer supply
6
Base plate
7
Manual vent valve
8
Heat insulating shell
9
Huba- Sensore Typ 235 2-40 l/min
Mounting material set:
-Screws 8*70 DIN571
-Washer 8.4 DIN125
-Wall plug S10
KW
Cold water
WW
Hot water
The Replacement parts number can be found under 10 Replacement parts / accessories
1.1 Equipment ball valve set CFWMEAS:
Shut-off set for stand-alone station, consisting of 3 ball valves for storage tank flow and storage
tank return, as well as for the HW connection. The cold water connection must be equipped
with the required safety fittings in accordance with DIN 1988.

4
1.2 Delivery and transport
Check to make sure the product is complete and undamaged immediately after receipt. Any
damage or complaints must be reported immediately.
Observe the labels on the packaging without fail! The fresh water modul should only be
removed from its packaging at the place of installation.
2Standa rds and guidelines
Please observe the following standards, regulations and guidelines with regard to installation
and operation:
DIN EN 806 / DIN EN 1717 / DIN EN 806 / DIN 4708 / EN 12975
DVGW worksheet W 551 / worksheet W 553
EnEG (Energy Conservation Act)
EnEV (Energy Saving Ordinance)
Local regulations
DIN 18 380 (Heating systems and central water heating systems)
DIN 18 381 Gas, water and wastewater installation work
DIN 18 421 Thermal insulation work on thermotechnical systems
VDI 2035 (Prevention of damage in water heating installations)
DIN 4753 (Water heaters and water heating installations for drinking water
and service water)
VDE 0100 (Installation of electrical equipment)
VDE 0190 (Main equipotential bonding of electrical systems)
TrinkwV (Drinking Water Ordinance)
BGV (Accident prevention regulations of workers' compensation associations)

5
3Safety
3.1 Safety instructions
In addition to country-specific guidelines and local directives, the following technical
regulations must also be taken into account:
Important - risk of burning!
As the system can reach temperatures > 60 °C, there is a risk of
scalding and burning through contact with the components.
Danger –Electric shock!
Risk of fatal electric shock as a result of incorrect electrical
connections.
Electrical connections must exclusively be created by electricians
approved by energy suppliers and as per the locally applicable
regulations.
Disconnect the supply voltage prior to conducting any work.
Attention: Observe the water quality!
Risk of calcification: For mass concentrations of calcium carbonate
of > 1.5 mmol/l, the primary temperature must be limited to < 65°C.
For mass concentrations of calcium carbonate of > 2.5 mmol/l, a
softening system must be installed.
Corrosion: If the limit values under point 6.4 are exceeded, a solid
stainless steel heat exchanger must be used.
Solid stainless steel heat exchangers are to be used for aggressive
drinking water qualities that exhibit an electrical conductivity of >
500 μS/cm; please observe the detailed limit value table
The respective personal protective equipment must be worn when conducting any work on
the system/device; this includes ear protection, eye protection, safety shoes, hard hat,
protective clothing and protective gloves. Information regarding the personal protective
equipment can be found in the national directives of the respective country of operation.

6
4General informat ion regarding
the installation a nd operating
manual
This manual describes the installation, operation and maintenance of the COSMO-CFWME /
CFWMVEE fresh water modul.
This manual is intended for trained specialists with an adequate level of expertise in handling
heating systems, water pipe installations and electrical installations.
The installation and commissioning procedures should only be conducted by qualified,
specialist personnel.
The fresh water modul must only be installed and operated in dry areas that are protected
from frost.
Read this manual carefully before starting any installation work.
Non-compliance will invalidate all claims under the guarantee and warranty.
Illustrations are symbolic and may differ from product to product.
Subject to technical changes and errors.
This installation and operating manual must not be reproduced or made available to third
parties without prior written consent (section 2 German Copyright Act, section 823 Civil Code).
This installation and operating manual is to be handed over to the system operator and kept in
close proximity to the device.
4.1 Regulation
Observe the installation and operating instructions for the control unit used.
4.2 Settings
Set the hot water temperature and the circulation programme if necessary.
Observe the installation and operating instructions for the control unit used.

7
5Product descript ion
5.1 Intended purpose
The COSMO CFWME / CFWMVEE fresh water module is an electronically controlled hydraulic
assembly for heating drinking water based on a flow principle.
The tapping flow rate is recorded via an electronic flow rate sensor that has a measuring range
of 2 –40 l/min. The required primary flow rate is determined from the temperature of the
storage tank, the flow rate and the nominal temperature of the hot water. In order to achieve a
constant hot water temperature, the speed of the primary pump is varied by means of a PWM
signal.
The COSMO CFWME / CFWMVEE fresh water module should only be used to heat drinking
water in accordance with the Drinking Water Ordinance. The primary circuit must be filled with
heating water according to VDI 2035.
The COSMO CFWME / CFWMVEE fresh water module features solid stainless steel heat
exchangers and is intended for aggressive drinking water supplies.
5.2 Applicable documents
Also observe the installation and operating instructions for the various components used, such
as the control unit.

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6Technical specificat ions
6.1 General instructions
Designation/type
COSMO CFWME / CFWMVEE
Nominal output at 10-45/65°C (CW-HW/HF)
70 kW
Tapping capacity at nominal output
28.7 l/min
NL number at nominal output
4.5
Tapping capacity at 10-45/75°C (CW-HW/HF)
36 l/min
Output at 10-60/75°C (CW-HW/HF)
75 / 143 / 214 / 285 kW
Tapping capacity at 10-60/75°C (incl. cascades)
21.5 / 39 / 58,5 / 78 l/min
NL number (incl. cascades)
4,5 / 17/ 34 / 54
Capacity at 10-60/75°C, mixed to 45°C HW
69 kW
Tapping capacity at 10-60/75°C, mixed to 45°C HW
(incl. cascades)
30 / 55/ 83 / 111 l/min
Max. operating pressure
Heating circuit
Drinking water
3 bar
10 bar
Max. operating
temperature
Heating circuit
Drinking water
95 °C
65 °C
Connections
Heating circuit
Drinking water
¾
¾
Pressure loss on the service water side at nominal
output
0.8 bar
Max. pressure loss for piping on the heating side
50 mbar
Circulation pump
Power input
Wilo Para 15/7 iPWM2
3-45 W
Flow rate sensor
Huba sensor Typ 235 2-40 l/min
Electrical connection (mains control unit)
230 V AC/ 50-60 Hz
Materials
Housing/connecting components
CW617N (2.0402)
Plate heat exchanger CFWMC
Stainless steel, Cu soldered
Plate heat exchanger CFWMVEE
Stainless stell, stainless stell
soldered
Seals
AFM
Insulation
EPP foam 0.038 W/mK
When using the CFWMEVMV flow mixing valve, the nominal output is reduced to V' = 24 l/min
at 65°C/10-45°C due to the higher pressure losses in the primary circuit.

9
6.2 Dimensions / required space
Dimensions and minimum space
required for assembly and
maintenance work
Optional accessories (CFWMEAS):
Mount storage tank flow, storage
tank return and HW ball valves
with a flat seal
Execute the HW connection
according to DIN 1988.
6.3 Pressure loss / pump characteristic curve
Specified pressure loss valid for heating side (primary) and drinking water side (secondary).

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6.4 Corrosion protection
To prevent corrosion damage to plate heat exchangers, the following drinking water values
must be observed:
Copper-soldered
Solid stainless steel
Chloride1(CL-)
< 250 mg/l at 50°C
< 100 mg/l at 75°C
< 10 mg/l at 90°C
Sulphate1(SO4
2-)
< 100 mg/l
< 400 mg/l
Nitrate (NO3-)
< 100 mg/l
No requirement
pH value
7.5 - 9.0
6 –10
Electrical conductivity (at
20°C)
10 - 500 µS/cm
No requirement
Hydrogen carbonate
(HCO3
-)
70 - 300 mg/l
No requirement
Ratio HCO3
-/ SO4
2-
> 1
No requirement
Ammonia (NH4
+)
< 2 mg/l
No requirement
Free chlorine gas
< 0.5 mg/l
Sulphite
< 1 mg/l
< 7 mg/l
Ammonium
< 2 mg/l
Hydrogen sulphide (H2S)
< 0.05 mg/l
No requirement
Free (aggressive) carbon
dioxide (CO2)
< 5 mg/l
No requirement
Iron (Fe)
< 0.2 mg/l
No requirement
Saturation index SI
-0.2 < 0 < 0.2
No requirement
Manganese (Mn)
< 0.05 mg/l
No requirement
Degree of hardness
4 –14 [Ca2+; Mg2+]/ [HCO3
-] < 0.5
Total organic carbon
(TOC)
< 30mg/l
No requirement
1 If the limit values for copper-soldered plate heat exchangers are exceeded, a solid stainless
steel plate heat exchanger must be used.
To prevent pitting corrosion in the domestic installation, no new
galvanised iron material must be installed downstream in the hot
water pipe of the copper-soldered plate heat exchanger without
forming a protective layer.
Solid stainless steel plate heat exchangers must be used in mixed
installations with zinc-coated iron materials (available on request).

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6.5 Calcification protection
Limescale deposits from the water increase significantly at temperatures of >55°C. Set the
temperature as low as possible for this reason.
Observe hygiene regulations!
In order to ensure the longest possible service life of the plate heat exchanger, the
manufacturer recommends using water softeners if the water hardness level is > 8.5°dH.
Water treatment measures to prevent scale formation (water softening)
Fresh water modul
without premix valve
Fresh water modul
with premix valve
CFWMEVMV
Mass concentration of calcium carbonate [mmol/l]
Tapping temperature
approx. 50°C
Tapping temperature
approx. 50°C
< 1.5 (equivalent to < 150 [mg/l] and < 8.4°dH)
None
None
1.5 to 2.5
(equivalent to 150 [mg/l] to 250 [mg/l] and 8.4°dH
to 14°dH)
Recommended
None
> 2.5 (equivalent to > 250 [mg/l] and > 14°dH)
Required
Recommended
In the case of calcareous water, the primary flow temperature can be limited to 65°C by a
thermal control valve. The tendency towards calcification that is caused by very hot storage
tanks in solar thermal or biomass systems can be reduced as a result.
Refer to the Maintenance section for recommendations on cleaning.
6.6 Pump information
PWM-Logik (PWM2)
< 7% pump off
7-12% Min. output (operation)
12-15% min. output (start-up)
15-95% proportional output range
> 95% max. output
6.7 Gravity brake
A gravity brake is installed in the
heating return to prevent incorrect
circulation. (see fig.)
The heat exchanger is to be vented
during the commissioning process by
using the manual vent valve.

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7Assembly and installation
7.1 Wall-mounted assembly
Mark and drill two 10mm holes as
per the adjacent illustration and
insert expansion anchors.
Locate the top screw and washer and
tighten until the screw head
protrudes approx. 1cm from the wall.
Suspend the station, align it
horizontally and secure it in place
using a second screw and washer.
Evenly tighten both screws.
7.2 Storage tank installation with accessories
7.2.1 Dimensions
To adapt to the size of the
buffer tan, the upper flow
pipe can be adapted to the
required length, and the
connection is made via a
compression fitting.
For larger distances, the
upper flow pipe Cu 22*1
must be extended

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7.2.2 Installation requirements
The COSMO CFWME / CFWMVEE can be attached directly to a buffer storage
tank (with simultaneous piping on the heating side) by means of a connection
set.
The storage tank must have a 1 ½" internal thread so that the station can be
connected.
The upper flow pipe can be shortened. The lower pipe has a constant length
The storage tank connections are arranged vertically one above the other.
The distances between the connections are within the illustrated range.
For further information, please refer to the separate instructions for the
connection set.

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7.3 Hydraulic connection with accessories
COSMO fresh water module CFWME
COSMO fresh water module CFWME
With circulation and return stratification
CFWMERES: Return stratification with 3-way switching valve and two PT1000 temperature
sensors (storage tank center & storage tank return)
Designation
Description
HW
Hot water
CW
Cold water
HF
Heating flow
HR
Heating return
CI
Circulation

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COSMO fresh water module CFWME
with pre-mixing function
COSMO fresh water module CFMWE
with pre-mixing function and return stratification
Flow mixing valve (CFWMEVMV): Flow mixing valve with thermal 3-way mixing valve, for pre-
mixing at frequent high temperatures of >70°C in the buffer storage tank. Example illustrations
with optional accessories.
Explanation:
Sensors
Designations
S1
Storage tank flow
S2
Storage tank return
S3
Circulation return
S4
Storage tank center for return stratification
This illustration does not claim to be exhaustive; it is not a replacement for specialist planning.

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Optional circulation set
Description:
The CFWMEZS circulation set with Wilo
Yonos Para Z 15/7.0 130 RKC and PT1000
temperature sensor is an
optional accessory for the CFWME
system. The set consists of the
circulation pump, 2 shut-off ball valves
with a backflow preventer and a
thermowell with PT1000 sensor. A
temperature sensor is always required
for all circulation methods.
Dimensions and minimum space
required for assembly and maintenance
work.
The temperature difference between the
circulation return and hot water is
adjusted via the red adjusting knob on
the pump
For further information, please refer to the separate instructions for the circulation set.

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7.4 Electrical connection
7.4.1 General instructions
Only authorised, specialist personnel are permitted to open electrical
housings and work on the electrical system after de-energising the
equipment. When establishing connections, make sure the terminal
assignments and polarity are correct. Protect the control unit and electrical
components against excess voltage.
The fresh water modul COSMO CFWME / CFWMVEE is pre-installed and wired ex works.
Connect the power cable to commission.
Please refer to the separate control unit instructions for more details.
7.4.2 Circulation pump
The pump is controlled exclusively via an external PWM signal. The green flashing LED display
indicates the standby mode. A green continuous light indicates the pump is operating at a
speed corresponding to the PWM signal. A red LED signals an error.
7.4.3 Regulation
Refer to the separate operating manual of the corresponding control unit for more detailed
information.
Electrical pump connection
L = brown
N = blue
PE = green/yellow
PWM connection
+ = brown
- = blue

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8Commissioning, functiona l test,
Decommissioning
Complete installation of all hydraulic and electrical components is a precondition for
commissioning.
8.1 Start-up
8.1.1 Leak testing and filling the system
Check all system components, including all pre-fabricated elements and stations, to ensure
they are leak-tight; seal any detected leaks accordingly. When doing so, adapt the test
pressure and test duration to match the respective piping system and the respective operating
pressure.
Fill the drinking water side with clean drinking water as per DIN 1988 only; bleed the air from
the system by gradually increasing the pressure.
Open the taps and slowly open the ball valve.
Only fill the heating system, including the primary side of the fresh water system, with filtered,
possibly treated water as per VDI 2035; bleed the system completely.
8.1.2 Initial commissioning process and functional test
Please observe the corresponding instructions for the control unit.
Task
Procedure
OK
Preparation and
inspection
Visual inspection of the installation.
Are all of the sensors installed and connected at the correct
locations?
Are all outputs connected?



Switch on the
control unit
Supply power to the control unit

Set up the control
unit
Please observe the instructions for the control unit.
Set the fresh water temperature (hot water temperature).
Adjust the circulation (optional).
Adjust the return stratification (optional)
Configure the cascades (optional)
___
_
___
__
Additional
settings
Adjust the pre-mix valve (optional)
___
__
Test the outputs
Activate all of the outputs individually in sequence and check to
make sure the pumps switch correctly.

Check function
Check the functionality of the hot water supply.
Check the functionality of the circulation (optional).
Check functionality of the return stratification (optional)
Check functionality of the cascades (optional)


Note:
Tapping flow rates of > 50 l/min are to be avoided, as these can also result
in permanent damage to the sensor.

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8.2 Troubleshooting
If an error message is output, it appears on the control unit display.
Please observe the corresponding instructions for the control unit.
Malfunction
Possible cause
Remedy
Pump noise
Air in the system
Bleed
Insufficient tapping quantity
Insufficient water pressure
Check pressure, increase if
necessary
Calcification in heat
exchanger
Decalcify/replace
Insufficient tapping
temperature
Incorrect adjustment on the
control unit
Check settings
Excessive pressure loss in the
piping on the heating side
Check the piping, change if
necessary
Drinking water does not heat
up
Control unit not in operation.
Check control unit
Air in the system.
Bleed
HW flow sensor not
connected correctly, or
defective.
Check, replace if applicable
Heating flow temperature
sensor not connected
correctly or faulty.
Check, replace if applicable
Pump faulty
Check, replace if applicable
Flow rate sensor defective
Check and replace if
applicable
8.3 Decommissioning
If the COSMO CFWME is decommissioned for a prolonged period, the power supply must be
disconnected.
For final decommissioning of the COSMO CFWME the power supply for all of the corresponding
system components must be disconnected; all of the relevant pipes and components must be
completely drained.
The decommissioning, dismantling and disposal processes should only be conducted by
qualified, specialist personnel. Components and materials must be disposed of in accordance
with the current applicable regulations.

20
9Ma intenance
The manufacturer recommends having the system serviced annually by authorised, specialist
personnel.
9.1 Cleaning the heat exchanger
Regularly clean the unit if deposit build-up can be expected due to unfavourable water quality
(e.g. extremely hard water or pronounced soiling). The cleaning process restores the original
condition of the heat exchanger.
There is the option of cleaning the unit by flushing it. To enable flushing and descaling, the heat
exchanger must be removed. The 3/4" connections of the PWT can be connected directly to
the flushing connections.
Flush the heat exchanger in the direction opposite to the normal flow direction using a suitable
cleaning solution.
Make sure any chemicals used for cleaning are suitable for stainless steel, copper or nickel.
Non-compliance may result in permanent damage to the heat exchanger! Use only chloride-
free water or water with a low chloride content and water hardness for cleaning solutions.
Choose the cleaning agent to match the type of contamination and resistance of the heat
exchanger plates. It is important to obtain confirmation from the cleaning agent manufacturer
that the cleaning agent will not cause corrosion of the heat exchanger plates to be cleaned.
Clean the heat exchanger as per the cleaning agent manufacturer's work instructions.
Neutralise any remaining acids in the system after cleaning; passivate all metal surfaces.
Passivation is mandatory to prevent any development of corrosion. Always rinse the clean
heat exchanger and system using a sufficient amount of fresh water. Always observe the
specifications provided by the cleaning agent manufacturer regarding use of the cleaning
agent.