Flamco FlexTherm Eco G1 Guide de l'utilisateur

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ENG Installation and operating instruction

FlexTherm Eco G1

Manual FlexTherm Eco G1

We reserve the right to change designs and technical specifications of our products.

ENG

Content

1. Introduction ................................................................................................................................. 4

1.1 General ..................................................................................................................................................................... 4

1.2 Symbols used ........................................................................................................................................................... 4

1.3 Abbreviations ........................................................................................................................................................... 4

1.4 Responsibillities ....................................................................................................................................................... 4

2. Safety........................................................................................................................................... 6

2.1 Advantages of FlexTherm Eco compact heat storage ................................................................................................. 7

3. Technical specifications ................................................................................................................. 8

3.1 Pressure Loss Characteristic..................................................................................................................................... 9

4. FlexTherm Eco Controller ..........................................................................................................10

4.1 Description ............................................................................................................................................................. 10

4.2 PCB identification ................................................................................................................................................... 10

4.3 Installer settings ..................................................................................................................................................... 11

5. Design of cold and hot water supplies .........................................................................................12

5.1 General requirements ............................................................................................................................................. 12

5.2 Water distribution network design.......................................................................................................................... 12

5.3 Hot water circuit including water safety device ....................................................................................................... 12

5.4 Hard water areas..................................................................................................................................................... 12

6. Installation Guidelines...............................................................................................................13

6.1 General wiring recommendations ........................................................................................................................... 13

6.2 FlexTherm Eco E storage ......................................................................................................................................... 13

6.2.1 Mains cold water and hot water supplies.............................................................................................................. 13

7. Electrical wiring........................................................................................................................14

8. Flextherm Eco + PV Power Diverter.................................................................................................15

8.1 FlexTherm Eco Controller Settings ......................................................................................................................... 15

8.2 Applicability ........................................................................................................................................................... 15

8.3 PV Diverter Configuration ....................................................................................................................................... 15

9. Commissioning .........................................................................................................................17

9.1 General ................................................................................................................................................................... 17

9.2 Pre-commissioning checklist .................................................................................................................................. 17

9.3 Commissioning process .......................................................................................................................................... 17

10. Maintenance.............................................................................................................................19

11. Troubleshooting .......................................................................................................................19

12. Decommissioning & disposal......................................................................................................20

12.1 Decomissinoning .................................................................................................................................................. 20

12.2 Disposal................................................................................................................................................................ 20

Manual FlexTherm Eco G1

We reserve the right to change designs and technical specifications of our products.

ENG

1. Introduction

1.1 General

The following instructions provide guidance for the installer and user of FlexTherm Eco G1.

The installation must be carried out by a competent installer in accordance with local codes and regulations for

plumbing, electrical installations and potable water supply.

CAUTION

Do not tilt the product more than 45 degrees during the transportation or installation process.

1.2 Symbols used

In these instructions the following symbols are being used to draw the user’s attention to information of

particular importance.

DANGER

lndicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

lndicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

1ndicates a hazardous situation that, if not avoided, could result in minor or moderate injury or material

damage.

Notice: Signals information that is considered important but not hazard related.

1.3 Abbreviations

The following abbreviations are used in the manual,

• BERV – Back-Expansion Relief Valve

• DSR – Demand Side Response

• PCBA – Printed Circuit Board Assembly

• PCM – Phase Change Material

• PRV – Pressure Reducing Valve

• VIP – Vacuum Insulation Panel

1.4 Responsibillities

Manufacturer’s Responsibilities

Our products are manufactured in compliance with the requirements of applicable EU & UK laws and regulations.

More information can be found in the Declaration of Conformity supplied with the Heat Battery.

As an innovative company committed to achieving net zero, Sunamp continuously improves its products, which

means that all specifications and other information stated in this manual are subject to change without prior

notice.

Manual FlexTherm Eco G1

We reserve the right to change designs and technical specifications of our products.

ENG

Our liability as the manufacturer may not be invoked in the following cases:

• Failure to abide by the instructions on using the Heat Battery.

• Faulty or insuicient maintenance of system components protecting the Heat Battery.

• Failure to abide by the instructions on installing the Heat Battery.

Installer’s Responsibilities

The installer is responsible for the installation and the commissioning of the Heat Battery. The installer must:

• Ensure they are suitably qualified for the level of plumbing and electrical work required for the installation of

this Heat Battery.

• Read, understand and follow the instructions given in the manuals provided with the Heat Battery.

• Comply with the prevailing legislation and standards when carrying out the installation.

• Perform the initial start-up and carry out any checks necessary.

• Complete the commissioning procedure and checklist in this manual.

• Explain the installation to the user.

• If maintenance on system components is necessary, warn the user of the requirement to check the system

components to maintain the system in good working order.

• Give all the instruction manuals to the user.

User’s Responsibilities

To achieve optimum operation and longevity of the Heat Battery, the user must adhere to the following

instructions:

• Read and follow the instructions provided in the manuals provided with the Heat Battery.

• Call on qualified professionals to carry out installation, initial start-up and commissioning.

• Ask your installer to explain your installation to you.

• Ensure that system components are maintained as necessary.

• Keep the instruction manuals in good condition and close to the Heat Battery.

CAUTION

Children shall not play with the Heat Battery.

Cleaning and user maintenance shall not be made by children.

Children must be supervised to ensure they do not play with the Heat Battery.

Manual FlexTherm Eco G1

We reserve the right to change designs and technical specifications of our products.

ENG

2. Safety

The FlexTherm Eco range of advanced and compact heat storage uses Phase Change Materials (PCMs) to store heat

for producing hot water. Flamco heat storage can be classified as primary thermal because the hot water is heated

instantaneously on demand by transferring heat from the PCM to the mains water flowing through it.

The pipe connections and the construction of a FlexTherm Eco range of storage are shown in the figure above. The phase

change material (PCM) and the heat exchangers are housed in a sealed enclosure called ‘The Cell’. Although the Cell is

sealed, the pressure inside the Cell is around the ambient atmospheric pressure i.e. about 1.0 bar absolute. The Cell is

insulated using highly eicient vacuum insulation panels. The outer case and hydraulic and electrical connections are

designed so that multiple stores can be connected either in series or parallel.

The FlexTherm Eco range of heat stores have two independent hydraulic circuits for hot water preparation. The heat is

transferred between the PCM and the high power (HPC) and the low power (LPC) hydronic circuits by means of an integrated

heat exchanger inside the Cell.

The heat stores are fitted with temperature sensors for measuring the charge state and for controlling their operation when

connected to the controller. All standard models of the FlexTherm Eco range of heat stores are supplied with PCM58 which

has a phase transition temperature of 58 °C.

The heat stores models covered by this document are listed in table 1.1. This document does not cover sizing, selection,

configuration or design of the heating and hot water system in a building. It only covers installation and commissioning of

the selected compact heat storage for hot water preparation.

Generic range Description Models

FlexTherm Eco E These heat stores are heated by internal electric

heating elements only and therefore these heat

stores are equivalent to Direct vented or unvented

hot water cylinders

FlexTherm Eco 3E, FlexTherm Eco 6E,

FlexTherm Eco 9E

Table 2.1: FlexTherm Eco Range of heat storage

Manual FlexTherm Eco G1

We reserve the right to change designs and technical specifications of our products.

ENG

2.1 Advantages of FlexTherm Eco compact heat storage

The main benefits of the FlexTherm Eco compact heat storage compared with traditional hot water cylinders and hot water

only thermal stores are:

a. The heat is stored in the Phase Change Material and therefore the water content in the storage is less than 11 Litres and

the hot water is heated instantaneously on demand. Therefore:

• Easy installation because of low expansion volume.

• The risk of legionella build-up inside the store is eliminated, as there is no stagnation and the store is constantly

pasteurised.

b. Quicker and less costly installation.

c. Better insulation and no mandatory annual maintenance or inspections mean lower running costs than comparative

electric storage water heaters.

d. Operational needs: Smaller space, typically 2 – 3 times smaller than the equivalent hot water cylinders and clean

installation.

Manual FlexTherm Eco G1

We reserve the right to change designs and technical specifications of our products.

ENG

3. Technical specifications

Flamco compact heat stores are supplied with PCM58 and an integrated electrical heating element. The discharge

temperature from these standard compact heat storage models can be up to 75°C when fully charged and should therefore

be fitted with a thermostatic blending valve set to 55°C.

The overall dimensions and weights of the compact heat storage models in the FlexTherm Eco range are listed in table 2.1 and

their technical specification is listed in table 2.2. The pressure loss characteristics of the compact heat storage are tabulated in

tables 2.3a, 2.3b, 2.3c.

Table 3.1. Overall dimensions and weights of FlexTherm Eco compact heat storage range

Overall dimensions [mm] Net weight

Width Depth Height [kg]

FlexTherm Eco 3E 365 575 440 70

FlexTherm Eco 6E 365 575 640 125

FlexTherm Eco 9E 365 575 870 175

Table 3.2: Technical specification of FlexTherm Eco heat storage range

Size 3 Size 6 Size 9

Storage capacity –

Standard storage with

PCM58 [1]

[kWh] 3.5 7.0 10.5

Water content – Low

power circuit (LPC)

Water content – High

power circuit (HPC)

[L]

1.3

2.3

2.4

4.5

3.5

6.8

Equivalent hot water

cylinder size [2] [L] 71 142 212

V40, Volume of hot water

available at 40°C [3] [L] 85 185 300

• Heat loss rate

• ErP Rating class –

Hot water storage vessel

[kWh/24h]

[W]

[ - ]

0.48

20.0

0.67

28.1

0.77

32.1

Recommended

maximum HW flow rate [L/min] 6 15 20

Minimum cold water

supply pressure at inlet

to the heat storage

[bar]

[MPa]

1.50

0.15

1.50

0.15

1.50

0.15

Maximum working

pressure:

High power (HPC) and

Low power (LPC) circuits

[bar]

[MPa]

10.0

1.0

10.0

1.0

10.0

1.0

Hot water outlet

temperature at design

flow rate [4]

[°C] 55 55 55

Heat storage controller

• Electric heater supply

rating at 230V, AC, 50Hz

[5]

• Standby power

consumption – All

models

• Power rating of the

heater at 230V, AC, 50Hz

(‘e’ models only)

[A]

[W]

2,800

Manual FlexTherm Eco G1

We reserve the right to change designs and technical specifications of our products.

ENG

1) Storage operating as hot water heaters. Charged to 75 °C and then discharged using mains cold water at 10 °C until the hot water outlet temperature

dropped to 40 °C.

2) Calculated from the storage capacity of the heat storage and assuming that the hot water cylinder thermostat is set at 60 °C, mains cold water inlet

temperature is at 10 °C and the stored energy utilisation factor of cylinder is 0.85.

3) Calculated from the storage capacity of the heat storage.

4) Recommended setting for the hot water thermostatic blending valve.

5) Power supply for the standby electric heater vial local 2-pole isolator – Only for FlexTherm Eco E type of heat storage.

3.1 Pressure Loss Characteristic

Table 3.1a: Pressure loss characteristic of FlexTherm Eco 3E storage

Flow rate Low power circuit (LPC) High power circuit (HPC) HPC & LPC Circuits in parallel

[l/s] [m3/h] [bar] [kPa] [bar] [kPa] [bar] [kPa]

0.10 0.360 0.049 4.920 0.016 1.572 0.006 0.640

0.20 0.720 0.197 19.680 0.063 6.289 0.026 2.560

0.30 1.080 0.443 44.280 0.142 14.151 0.058 5.760

0.40 1.440 0.787 78.721 0.252 25.157 0.102 10.240

Table 3.1b: Pressure loss characteristic of FlexTherm Eco 6E storage

Flow rate Low power circuit (LPC) High power circuit (HPC) HPC & LPC Circuits in parallel

[l/s] [m3/h] [bar] [kPa] [bar] [kPa] [bar] [kPa]

0.10 0.360 0.082 8.228 0.023 2.335 0.010 1.000

0.20 0.720 0.329 32.914 0.093 9.339 0.040 4.000

0.30 1.080 0.741 74.056 0.210 21.013 0.090 9.000

0.40 1.440 1.317 131.655 0.374 37.357 0.160 16.000

Table 3.1c: Pressure loss characteristic of FlexTherm Eco 9E storage

Flow rate Low power circuit (LPC) High power circuit (HPC) HPC & LPC Circuits in parallel

[l/s] [m3/h] [bar] [kPa] [bar] [kPa] [bar] [kPa]

0.10 0.360 0.114 11.405 0.034 3.405 0.014 1.424

0.20 0.720 0.456 45.620 0.136 13.619 0.057 5.695

0.30 1.080 1.026 102.644 0.306 30.643 0.128 12.814

0.40 1.440 1.825 182.478 0.545 54.477 0.228 22.781

Manual FlexTherm Eco G1

We reserve the right to change designs and technical specifications of our products.

ENG

4. FlexTherm Eco Controller

4.1 Description

The FlexTherm Eco controller is housed in the unit. The controller parameters can be changed on-site.

Power

>50%

>100%

Heating

Figure 4.1: Controller in FlexTherm Eco Units

4.2 PCB identification

Location of the switches and LEDs is shown in the figure below. Wiring connections for remote control input are shown,

using the 4-way plug in connector.

Standard Configuration

Flextherm Eco controller*

Note: This controller has been shipped with all Flamco Flextherm Eco products from serial # 5204 onwards. The following

advice relates to these products only. For products with a grey controller case please refer to the older version of this

manual.

S3 = Green

S1 = Blue

S2 = Red

Const Solar

N L E E L N

N Earth

PWM 0V T1 0V T2 0V +5V FV FT 0V

SW1

+5V

SDA

SCL

GND

PRG

D1 D3 D4

SW2

2.5mm² HT cables:

To heang element

via OHT

SW Version

Serial No.

Relay 1

Link 2

Link 1

Ingress to

Control box

Sensor

Cable 2.5mm2 Earth

to Outer Case

Neutral

Heater N

Heater L

Live

Coil N

Coil L

L1 L2 N1 N2 1234

S0 = Yellow

2.5mm²

Manual FlexTherm Eco G1

We reserve the right to change designs and technical specifications of our products.

ENG

Table 4.1: Controller connections

5V input/output 2 J1.6 (FV) Connect to GND for timed boost (user switch)

5V input/output 1 J1.7 (FT) Connect to GND to command element on (PV inverter)

GND J1.8 (0V) Ground for i/o signals

4.3 Installer settings

Options

Depending on the application, dierent options may be selected.

Holding switch SW1 down will show the current setting on the 4 LEDs. Holding this switch down for longer than 5 seconds

will cause the LEDs to cycle. Release switch SW1 when the wanted LED is illuminated, and this choice will be stored.

Please note: The setting for SW2 should always be in Mode 0, meaning that no LEDs are illuminated. This can be checked

by shortly holding SW2 to show the current mode or by holding SW2 for longer than 5 seconds to cycle through the modes

(release when no LEDs are illuminated).

Table 4.2: Controller options and explanation

LED # LED Colour/ Symbol Option Description Explanation

None

D4 D3 D2 D1

Power >50% >100% Heating

Normal mode This is the standard operational mode and is suitable for most

applications.

Power >50% >100% Heating

Deep discharge mode

In this mode the FlexTherm Eco E will call for heat once it has been

almost completely depleted. This mode can be used e.g. when

used as a pre-heat to a combi-boiler.

Note: Using this mode in and electric stand-alone installation can

lead to poor service.

D4 D3

Power >50% >100% Heating

Timer/Boost function mode

In this mode the Flextherm Eco E will only recharge if the circuit

on terminals 3/4 is closed (and remains closed while charging) or

if the boost button is engaged.

Power

>50%

>100%

Heating

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