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)

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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.

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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.

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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.

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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).