Coolpower Products EMMA User manual

1
INSTALLATION MANUAL
ELITE
THE ENERGY AND MICROGENERATOR MANAGER LITE
OCTOBER 2016

2
CONTENTS
CONTENTS ...........................................................................................................................................................2
TABLE OF FIGURES ............................................................................................................................................... 4
1. GETTING STARTED......................................................................................................................................... 5
2. SAFETY..........................................................................................................................................................5
3. COMPONENTS INCLUDED WITH EMMA..........................................................................................................6
4. COMPONENTS THE INSTALLER NEEDS TO SUPPLY...........................................................................................7
INSTALL OVERVIEW..............................................................................................................................................8
Description of basic operation................................................................................................................................... 8
5. ELITE INSTALLATION......................................................................................................................................9
ELITE WALL MOUNTING ...................................................................................................................................................... 9
Procedure................................................................................................................................................................... 9
CABLE ENTRIES .................................................................................................................................................................. 9
Procedure:.................................................................................................................................................................. 9
POWER SUPPLY TO THE ELITE ............................................................................................................................................... 9
Procedure................................................................................................................................................................... 9
POWER SUPPLY TO THE ELITE ............................................................................................................................................. 10
Procedure:................................................................................................................................................................10
FIT IMPORT EXPORT CT PROCEDURE ...................................................................................................................................10
Procedure:................................................................................................................................................................10
IMPORT EXPORT CT WIRING.............................................................................................................................................. 11
Procedure:................................................................................................................................................................11
FIT GENERATION CT.........................................................................................................................................................11
Procedure:................................................................................................................................................................11
GENERATION CT WIRING ..................................................................................................................................................11
Procedure................................................................................................................................................................. 11
CONNECT EARTH .............................................................................................................................................................12
Procedure................................................................................................................................................................. 12
ATTACH FACEPLATE TO BACKPLATE .....................................................................................................................................12
Procedure................................................................................................................................................................. 12
POWER THROTTLE INSTALLATION ...................................................................................................................... 13
POWER THROTTLE WALL MOUNTING ..................................................................................................................................13
Power Throttle Lid Screws........................................................................................................................................ 13
Power Throttle keyhole mounting slots ...................................................................................................................13
POWER THROTTLE MAINS WIRING ......................................................................................................................................14
POWER THROTTLE TEMP SENSOR WIRING.............................................................................................................................15
Extended Earth incoming lead with ring terminal termination to screw connection. .............................................15
Power Input from Mains ..........................................................................................................................................15
Power output to load...............................................................................................................................................15
TEMPERATURE SENSORS....................................................................................................................................................16

3
Bonding the sensors to the hot water cylinder ........................................................................................................ 16
Using two sensors ....................................................................................................................................................16
THERMOSTAT ..................................................................................................................................................................16
POWER ON SEQUENCE....................................................................................................................................... 17
POWER ON THORTTLE....................................................................................................................................................... 17
Procedure................................................................................................................................................................. 17
POWER UP ELITE..............................................................................................................................................................17
Procedure................................................................................................................................................................. 17
PAIRING PROCESS ............................................................................................................................................................18
Procedure................................................................................................................................................................. 18
SETTING TIME AND DATE ..................................................................................................................................................18
Procedure................................................................................................................................................................. 18
VERIFICATION OF OPERATION ............................................................................................................................................19
Procedure................................................................................................................................................................. 19
6. INSTALLATION CHECKLISTS.......................................................................................................................... 19
7. FAULT CONDITIOONS AND INDICATION. ...................................................................................................... 20
Standard start up LED sequence:.............................................................................................................................20
Wireless fault condition sequence (Only on Wireless units): ...................................................................................21
Over temperature fault condition sequence:...........................................................................................................21
Input power fault condition sequence: ....................................................................................................................21
Over current or over voltage fault: .......................................................................................................................... 21
8. SUPPLY, CERTIFICATION & GUARANTEE ....................................................................................................... 22
Certificate Of Conformity.........................................................................................................................................22
9. TECHNICAL SPECIFICATIONS, OPERATING PARAMETERS............................................................................... 23
10. CONTACT DETAILS.................................................................................................................................... 23

4
TABLE OF FIGURES
Figure 1 Elite 3kW Supplied Parts .....................................................................................................................................6
Figure 2. Elite 3kW Installation Overview......................................................................................................................... 8
Figure 3. Elite Wall Mounting. ..........................................................................................................................................9
Figure 4. Cable Entry. ........................................................................................................................................................ 9
Figure 5. Fitting Elite Power Supply Unit ..........................................................................................................................9
Figure 6 Elite Power Supply Wiring................................................................................................................................. 10
Figure 7. Import Export CT placement............................................................................................................................10
Figure 8. Import Export CT wiring. ..................................................................................................................................11
Figure 9. Generation CT Placement. ...............................................................................................................................11
Figure 10. Generation CT Wiring.....................................................................................................................................11
Figure 11. Connect Earth to Elite. ...................................................................................................................................12
Figure 12. Attach Faceplate. ...........................................................................................................................................12
Figure 13 Power Throttle Lid Assembly ..........................................................................................................................13
Figure 14 Power Throttle Mounting Slots....................................................................................................................... 13
Figure 15 Power Throttle Mains Wiring..........................................................................................................................14
Figure 16 Mains Wiring and Earthing..............................................................................................................................15
Figure 17 OPB Control input board located in Power Throttle.......................................................................................15
Figure 18. Power On Throttle..........................................................................................................................................17
Figure 19. Power on Elite PSU.........................................................................................................................................17
Figure 20. Elite and Power Throttle Pairing Interface.....................................................................................................18
Figure 22. Setting Time and Date....................................................................................................................................18
Figure 21. Zigbee MAC Address. .....................................................................................................................................18
Figure 23. Home Screen and Operations. .......................................................................................................................19

5
1. GETTING STARTED
Before you begin installing EMMA, you will need:
A. This Installation Manual
B. Example installation schematic(s).
In addition to Figure 2. Elite 3kW Installation Overview.(included in this document), a selection of further
schematics are available on our website, or our engineers will have provided you with one specific to your
project. Choose the one most appropriate to your project. You need this to show the correct positioning of
components, including the Henley block.
C. Operation Manual (for programming, set-up screens etc.).
Available on website.
D. EMMA unit, components and optional extras supplied
with EMMA (see list below).
For ongoing updates, amendments and further information visit
the FAQ at:
http://www.coolpowerproducts.com
2. SAFETY
All installation and maintenance work must be carried out by a
properly trained and qualified electrician.
It is vital to ensure that the installation complies with local wiring
regulations.
The mains power supply must be disconnected before the cover is
removed.
If this unit is used in a way that doesn’t comply with this manual its safety features may be impaired.
The EMMA Power Throttle must be earthed in accordance with Figure 16 Mains Wiring and Earthing.
We have approved suppliers and
installers of EMMA throughout
Ireland, the UK and Europe. Call us
or see our website for details.
The Operation Manual and additional
installation schematics are available on
the Cool Power Products website:
www.coolpowerproducts.com

6
3. COMPONENTS INCLUDED WITH EMMA
Your EMMA system is supplied with:
Elite Controller
EMMA 4G Power Throttle unit.
Two 100Amp Current Transformers (CT’s)
oGeneration CT 100 Amp (May be larger or smaller depending on site requirements)
oImport Export CT 100Amp (May be larger or smaller depending on site requirements)
NTC 10K Temperature Sensor
OPTIONAL EXTRAS:
We supply Current Transformers to match or exceed the max import capacity and max generation
Figure 1 Elite 3kW Supplied Parts
2 x 100Amp Current
Transformers
Temperature Sensor
EMMA 4G Power Throttle
Elite Controller
Elite Power Supply unit

7
4. COMPONENTS THE INSTALLER NEEDS TO SUPPLY
The installer will need to supply:
All cable, as per the specifications below.
Required immersions and/or other loads for the system, if not already in place.
Loctite 315 thermally conductive adhesive and activator (Loctite 7386) to bond the temperature sensor to
the tank if a probe pocket is not available and a temp sensor is provided. These are available in Loctite's 315
Output Kit.
PHYSICAL DIMENSIONS
The dimensions of the EMMA 4G Power Throttle are 219mm wide (246mm wide with Aerial attached and upright) x
336.8mm high x 86.9mm deep. Weight 4.6kg
The dimensions of the Elite are 147mm wide x 87mm high x 36mm deep. Weight 212g
The dimensions of the power supply match a standard DIN rail mountable doorbell transformer with basic
dimensions of 88mm high x 65mm deep x 36mm wide. The front face of the unit is 45mm high to fit in a standard
fuse board. Weight 346g
The CT’s differ in size according to their Current rating. The standard CT’s supplied with a 3kW system are 100Amp.
100Amp CT has an Aperture of 16mm. Weight 81g each.
Temp Sensor 500mm lead length. Weight 31g.

8
INSTALL OVERVIEW
Heat Store
Mains L1
Clamp-on thermostat or
temperature sensor.
Electric Immersion heaters
thermostat at 65⁰C.
Cylinder 1
Drawing No. EPRO 3kW with EC.
Date. 13 –06 –2015.
Scale. Not to Scale.
Service. EMMA Professional 3kW with Export Cut Off.
Client.
Project.
Address.
Engineer. Kieran Egan.
0 - 3kW Variable Supply
CYOZ 0.75mm 2 core cable
Mains cable
Legend
Electric Immersion heater
thermostat at 65⁰C.
Distribution Board
Correctly Sized
Fused Breaker Din Rail.
DC
AC
PV and/or Wind system
Inverter
Import/Export
Current
Transformers
Generation Current
Transformer
ELITE
Power
Supply
Mains Incoming
ELITE
CT1
ELITE
CT2
Fuse Spur
for
Immersion Elite
Power Throttle
Meter Box
Zigbee Wireless Comm’s
2 core sized to voltage and current capacity
CYOZ 0.75mm 2 core Screened Control cable
CYOZ 0.75mm 2 core Screened Control cable
Figure 2. Elite 3kW Installation Overview.
DESCRIPTION OF BASIC OPERATION
The Elite 3kW system has two separate components that are installed to make the system function.
The Elite is the control component which has 3 peripherals: a power supply and 2 current transformers used to
measure Voltage and Current 256 times per sine wave cycle. This power is registered on the Elites meter which is
also accessible from its touch screen showing cumulative Generation, Demand, Import and Export.
This allows the Elite to see real time power and power factor for the main incoming supply of import or export and
also for the generation for monitoring purposes.
Based on the import or export of power the Elite will communicate with the Power Throttle every 50 milliseconds
telling it to ramp up to use the exportable power or to ramp down to negate the imported power with its goal to
heat the hot water tank with as much renewable energy as possible.
The unit will stop heating the tank once the temperature sensor indicates the tank has reached its preset
temperature or if the stat cuts out in the immersion.
The unit can be used as a simple timer control for times of low renewable output to heat the tank as a standard
hotwater timer.
The Elite has the added benefit of a boost button to allow the user to quickly boost the tank temperature without
using the timer.

9
5. ELITE INSTALLATION
ELITE WALL MOUNTING
PROCEDURE
The Elite is normally installed in a convenient location under the Fuseboard.
1. Use a mini level to align the Elite backing box on the desired surface.
2. Holding the box in place mark the mounting surface through the 4
openings.
3. Drill the marked holes and install wall plugs.
4. Screw backing box in place.
Figure 3. Elite Wall Mounting.
CABLE ENTRIES
PROCEDURE:
1. The Elite backing box has 4 knockouts for wires to enter.
2. Select the most appropriate knockout based on which way the wires will
enter.
3. Using a slot screw driver punch through the weak plastic to make the hole.
4. Feed cables through as they are required.
5. Cable Entries are detailed in Figure 4. Cable Entry.
Figure 4. Cable Entry.
POWER SUPPLY TO THE ELITE
PROCEDURE
1. Snap Power Supply Unit (PSU) onto DIN rail in fuse board.
2. Use a 1 amp MCB to supply Live to the PSU.
3. Supply Neutral from the Neutral Bar.
4. The output from the PSU will be <12VAC and can be run in the
conduit to the elite circuit board.
Figure 5. Fitting Elite Power Supply Unit
4 x 30mm screw fixings
Conduit from
Fuseboard
Knockouts
Knockouts Knockouts
Knockouts
Knockouts
Live Neutral
Power Supply
Unit

10
POWER SUPPLY TO THE ELITE
PROCEDURE:
1. Using 0.75mm2 cable run a 3 core cable to the Elite Touch from the
Elite PSU
2. The output of the PSU is <12VAC and should be connected to
terminal J6 on the Elite Board as indicated in
3. Figure 6 Elite Power Supply Wiring.
4. When the cables are in place tighten the screws to clamp down for
termination at the PSU and at J6
5. See Figure 6 Elite Power Supply Wiring. for further details.
Figure 6 Elite Power Supply Wiring.
FIT IMPORT EXPORT CT PROCEDURE
PROCEDURE:
1. The Import Export CT should be fitted on the main incoming live
supply to the fuse board.
2. Make sure prior to clamping the CT closed that L is on the Fuseboard
side of the cable and K is on the utility meter side of the cable
3. Clamp the CT closed making sure not to pinch the cable on the
inside of the hinge.
4. See Figure 7. Import Export CT placement. for further details.
Figure 7. Import Export CT placement.
XBee
J
2
J
3
10
00
J
4J 5J 6
Earth
LKK
L
Fuse
board
Meter
LKMeter
Ensure the clip is
engage to keep the CT
closed
Import Export CT
Utility Meter
Utility Meter