CTC Union Expansion EnergyFlex Manual

Providing sustainable energy solutions worldwide
162 505 78-1 2020-10-13
Important!
• Read carefully before use, keep for future reference.
• Translation of the original instructions.
Installation and Maintenance Manual
CTC Expansion EnergyFlex

162 505 78-1 2020-10-13
Installation and Maintenance Manual
CTC Expansion EnergyFlex

4CTC Expansion Energyflex
4.3.6 Pool ____________________________________ 23
4.3.7 Valve 2 tanks (Y30) ________________________ 23
4.3.8 Valve bedrock (Y31) _______________________ 23
4.4 Sensor installation ____________________________________________24
4.4.1 Sensor connection (extra low-voltage
protection) _______________________________ 25
4.4.2 Factory-fitted sensors _____________________ 26
4.4.3 Resistance level of the temperature sensors___ 27
4.5 Wiring diagram ________________________________________________ 28
4.6 Connection table for Expansion Card A3 ____________29
5. Detailed menu descriptions _______________________________ 30
5.1 Navigate on the touchscreen_____________________________30
5.2 Start menu ______________________________________________________30
Installer ___________________________________________________________________31
5.3 Define_____________________________________________________________31
5.3.1 Def. Diff thermostat function ________________ 31
5.3.2 Def. Pool ________________________________ 32
5.3.3 Def. Solar Panel __________________________ 32
5.3.4 Def. DHW/DHW circulation _________________ 32
5.4 Settings __________________________________________________________33
5.4.1 Settings Diff thermostat function_____________ 33
5.4.2 Settings Solar Panel _______________________ 33
5.4.3 Settings DHW circulation___________________ 37
5.4.4 Settings Pool_____________________________ 38
5.5 Operation data_________________________________________________39
5.5.1 Solar Panel ______________________________ 39
5.5.2 Operation data, Pool ______________________ 41
5.5.3 Operation data DHW circulation _____________ 41
5.6 Service____________________________________________________________42
5.6.1 Function test _____________________________ 42
5.7 Alarm texts and troubleshooting/
appropriate measures_______________________________________ 44
Innehållsförteckning
1. Technical data _______________________________________________________ 6
Delivery includes:________________________________________________________6
Accessories_______________________________________________________________6
2. EnergyFlex _____________________________________________________________ 7
2.1 System options__________________________________________________8
2.1.1 EnergyFlex schematic diagrams ______________ 9
2.1.2 EcoSol - Exemple CTCEcoHeat and
CTCEcoZenithi255 H/L ___________________ 10
3. System structure _________________________________________________ 11
3.1 Solar Panel______________________________________________________ 11
3.1.1 Solar system 1 ___________________________ 11
3.1.2 Solar system 2 ___________________________ 12
3.1.3 Solar system 2b with solar coil ______________ 13
3.1.4 Solar system 3 ___________________________ 14
3.1.5 System option: bedrock heating_____________ 15
3.2 Pool________________________________________________________________16
3.3 Diff thermostat function_____________________________________ 16
3.4 DHW circulation
(DHW circ)_______________________________________________________16
3.5 Parts list _________________________________________________________17
4. Installation____________________________________________________________ 18
4.1 Safety switch___________________________________________________19
4.2 Communication between extension card and
main product___________________________________________________19
4.3 High voltage ____________________________________________________19
4.3.1 Pump, solar panel (G30, PWM)
Wilo Stratos Para _________________________ 19
4.3.2 Circulation pump, solar collector (G30)
GrundfosUPM3Solar _____________________ 20
4.3.3 Pump bore hole charging (G31, on/off) _______ 22
4.3.4 Pump, intermediate heat exchanger solar
panels (G32) PWM ________________________ 22
4.3.5 Pump tank transfer (G46, on/off) ____________ 22
Enertech AB provides the information with reservation for any typing errors and subject to modification.
Information for the property owner to note
Complete the fields below. This information is useful if any servicing work is required
Product : Manufacturing number:
Installation company Tel. no.
Date Name
Electrical installation company Tel. no.
Date Name

5CTC Expansion Energyflex
CTC Expansion EnergyFlex
With CTC Expansion EnergyFlex, you can control your
solar collectors or heat your pool, for example, directly
from the menus of your CTC product, providing an
integrated control system.
Positioning
Place the control unit indoors on a wall next to the
product. The control unit must be positioned so that
normal service procedures can be carried out. There
should be at least 0.5 m of free space in front of the
unit. Ensure that the screws fixing the cover to the unit
are easily accessible.
Safety instructions
Installation must be carried out by a qualified electrician.
This device can be used by children from the age of
three years and above and by people with reduced
physical, sensory or mental ability or lack of experience
or knowledge if they have been taught, either with
supervision or with the instructions provided, how to
use the device safely and understand the risks involved.
Children should not play with the device. Cleaning and
maintenance should not be carried out by children
without supervision.
System requirements
Program version for the display card must be
2014-12-19 or later.
CTC Expansion EnergyFlex complements the following
products with several additional functions (refer to the
"System Design" chapter.
CTCEcoHeat400
CTCEcoZenithi250/i255
CTC GSi
CTC GS
CTCEcoZenith i350/i360
CTCEcoVent i350F/i360F
Congratulations on your new product

6CTC Expansion Energyflex
C
B
Providing sustainable energy solutions worldwide
162201 22 2014-04-28
Installations- och skötselanvisning
CTC Solstyrning/
Expansionskort
DE
A
230V 1N~.
10 A
10 A
4 A
230V 1N~.
0/66k, 10/41.8k, 15/33.5k, 20/27.1k, 25/22k,
30/18k, 35/14.8k, 40/12.2k, 50/8.4k, 60/6.0k,
70/4.3k, 80/3.1k, 90/2.3k, 100/1.7k
-10/960, 0/1000, 10/1039, 20/1077, 30/1116,
40/1155, 50/1194, 60/1232, 70/1271,
80/1309, 90/1347, 100/1385, 120/1461,
140/1535
379 x 279 x 131 mm
EnergyFlex kit 400
Pipe kit, pre-bent pipes, connections
and insulation for “solar output”.
CTC Flowbox Installation kit GSi EHS
Accessories
The most important accessories for
supplementing solar energy and EnergyFlex are
shown below.
Delivery includes:
A 1 x electrical connection box with extension card
B 2 x NTC 22k sensors
C 2 x RJ-45 communication cables
D 1 x Installation and Maintenance Manual
E 1 x flange grommet including cable penetrations
Supply
Max fuse size
Total max. load CTCExpansion EnergyFlex
Max load relay output
Electrical data 3-way valve
Sensor (extra-low voltage protection), NTC22k,
°C/ohm
Solar panel sensor*, type PT1000,
°C/ohm
Measurements (w x h x d)
1. Technical data

7
CTC Expansion EnergyFlex
1
!Connecting external systems can seriously affect the operation and performance
of the indoor module and can therefore produce undesirable effects if the system
is not installed correctly.
If you are unsure how to make the connection, contact CTC for suggestions on
how to install the system.
2. EnergyFlex
EnergyFlex is a collective term that describes CTC’s unique options for
maximum flexibility and simple interconnection between difference heat
sources. The most common combination is a heat pump and electric boiler.
The CTC EcoZenith i250/i255, CTC EcoZenith i350/i360 and EcoVent
i350F/360F indoor modules are equipped for connection with:
• CTC EcoPart Heat Pump (ground source heat pump)
• CTC EcoAir Heat Pump (air/water heat pump)
All EnergyFlex heat pumps/indoor modules have built-in functionality so you
can easily supplement with:
• Solar Energy
• Additional tanks
• Water-jacketed stove
• Wood, electric, pellet and gas boilers
• Pool
EnergyFlex works with heat pumps/indoor modules CTC EcoHeat 400,
CTC EcoZenith i250/i255, CTC GSi, CTC GS, CTC EcoZenith i350/i360
and CTC EcoVent i350F/i360F.
iEnergyFlex Heat Pumps
•CTCEcoHeat 400
•CTC GS
•CTC GSi
iEnergyFlex Indoor Modules
•CTCEcoZenith i250/i255
•CTCEcoZenith i350/i360
•CTCEcoVent i350F/i360F
(CTC EcoZenith i550/i555
comes with a factory-fitted
extension card)
The picture shows the possible connections. The installation engineer fits expansion tank, safety valves, bleeders, etc. and sizes the system.

8CTC Expansion EnergyFlex
Example of wood-fired system with group of chargers. Energyflex can also be used to draw energy, e.g. to heat a
swimming pool.
2.1 System options
The flexibility in the heat pump/indoor module is optimised because the
products provide functionality for up to 5 basic systems:
• Solar system 1
Charging from solar panel only to H-tank (CTC EcoHeat 400/CTC
EcoZenith i255) or EHS-tank.
• Solar system 2
Charging from solar panel to buffer tank CTC EcoTank + CTC
EcoHeat400/CTC EcoZenith i255.
• Solar system 3
Charging from solar panel either to X-volume or to CTC EcoHeat 400/
CTC EcoZenith i255 or EHS-tank.
The solar energy systems also enable recharging of bedrock or collect
energy for an extra tank, with or without a solar coil.
• Diff thermostat function
The diff thermostat function is used to transfer heat from, for example,
a buffer tank or existing wood boiler to an H-tank or EHS-tank. The
diff thermostat function can be connected to an existing PCB in the
heat pump/indoor module, while "Solar systems 1, 2, 3" and the Pool
system require the product to be supplemented with the CTC Solar
Control/Extension Card accessory.
• Pool
The pool is connected to the heating circuit via a 3-way valve. A heat
exchanger should be fitted to separate the liquids.
Important for wood-fired heating
The integrated "Diff thermostat function" control initiates the charge from,
e.g., the existing wood-fired system or fireplace when the temperature is
higher than it is in the main tank.
Bear in mind that it can also be a good idea to install an automatic charger
that can protect the wood-fired system from condensation, etc.
If the wood-fired system needs more water than the 223 litres contained in
the main product (CTCEcoHeat 400 or CTCEcoZenith i255), the system
needs to be supplemented with an accumulator tank.

9
CTC Expansion EnergyFlex
M
HHX
EHS
EcoTank
H
EHS
M
HEHS
EHS
H
HB50
G50 G51
EHS
H
B46
G46
Y11
G99
G98
05
EHS
B47
2.1.1 EnergyFlex schematic diagrams
Solar system 2 Solar system 3Solar system 1
Solar: Heat bedrock option Solar: Alternative solar coil
(only "Solar system 2" with CTCEcoTank)
Diff thermostat system Pool system
The picture shows the possible connections. The installation engineer fits expansion tank, safety valves, bleeders, etc. and sizes the
system.

10 CTC Expansion EnergyFlex
H
2.1.2 EcoSol - Exemple CTCEcoHeat and CTCEcoZenithi255 H/L
CTC EcoHeat and CTC EcoZenith i255 H/L have a water volume of 223 litres with layered disc and solar output.
Solar output (3/4) is a part of EnergyFlex.
CTCEcoheat 400
(223 litres with layered disc and
solar output).
223 litres
223 litres
Solar output
(3/4)
223 litres
CTCEcoZenith i255 H/L
(223 litres with layered disc and solar
output).
Solar output (3/4)
H. Symbol for tank volume in CTC EcoHeat 400
and CTCEcoZenithi255.
The tank in the CTC EcoHeat 400 and CTC EcoZenith
i255 will be designated as H-tank (main tank).
Energy can be collected through the solar outputs (solar
panels, wood-fired boiler) or generated (swimming pool).
Available as accessories are pre-bent pipes with
couplings and insulation to facilitate installation.
The EnergyFlexkit400 pipe kit
accessory fitted to H-tank.

11CTC Expansion Energyflex
M
B6
B23 F2
F3
B30
B31
G30
G31
G32
01
04
H
Y11
Y11
Y11
Y31
B5
B47
EVK
The picture shows the possible connections. The installation engineer fits expansion tank, safety valves, bleeders, etc. and sizes the
system.
3. System structure
The various systems that can be connected to the product are shown here.
3.1 Solar Panel
The number of solar panels which can be connected depends on the volume of water in the product/tanks to which
the solar panels are to be connected. These diagrams are just basic outlines, so the exact placement may differ
in reality. The system should be supplemented with bleeders, expansion tanks and safety valves etc. in suitable
locations. A list of components is provided at the end of this chapter.
If the "Recharging of bedrock" function is selected, you can set the number of degrees by which the solar panel
should be warmer than the brine fluid in the bedrock for charging to start. If the panel is charging or can charge the
tank, tank charging is prioritised.
For menu settings. refer to the "Installer / Settings / Solar Panels" section.
3.1.1 Solar system 1
System design with solar heating only for H-tank (CTC EcoHeat 400/CTC EcoZenith i255)
or for EHS-tank (other EnergyFlex models).
Charging conditions (main conditions, factory settings)
Charging starts when the solar panel sensor (B31) is 7°C warmer than the H-tank sensor
(B6) or EHS-tank sensor (B47).
Charging stops when there is a difference of 3°C between the solar panel sensor and tank
sensor.
Set the temperature difference at which charging of the bedrock should start. The solar
panel must be this many degrees warmer than the brine in the borehole for charging to
start. If the panel is charging or can charge the tank, tank charging is prioritised.
Bedrock/ground source heating only

12 CTC Expansion Energyflex
M
B5
B6
B23 F2
B30
B31
G30
G31
G32
Y31
01 02
04
G46
B41
B42
F3
H
Y11
Y11
Y11
Y11
G99
G98
Bedrock/ground source heating only
3.1.2 Solar system 2
System design with H-tank (CTC EcoHeat 400/CTC EcoZenith i255)
and CTC EcoTank (buffer tank). It is not possible to connect an EHS-
tank to this system.
This system allows for a larger solar collector area since it carries a
greater volume of water and the energy can be stored in the bedrock.
Charging conditions (main conditions, factory settings)
Charging starts when the solar panel sensor (B31) is 7°C warmer than
the EcoTank sensor (B42).
Charging stops when there is a difference of 3°C between the solar
panel sensor and EcoTank sensor.
Charging from CTC EcoTank to H-tank compares the CTC EcoTank
sensor (B41) with the H-tank sensor (B6).
The picture shows the possible connections. The installation engineer fits expansion tank, safety valves, bleeders, etc. and sizes the
system.

13CTC Expansion Energyflex
M
B5
B6
B23
B31
G30
G31
01 02
04
G46
B42
F3
H
B41
Y11
Y11
Y11
G99
G98
Y31
B30
The picture shows the possible connections. The installation engineer fits expansion tank, safety valves, bleeders, etc. and sizes the
system.
3.1.3 Solar system 2b with solar coil
System design with H-tank (CTC EcoHeat 400/CTC EcoZenith i255)
and CTC EcoTank (buffer tank). It is not possible to connect an EHS-
tank to this system.
This system allows for a larger solar collector area since it carries a
greater volume of water and the energy can be stored in the bedrock.
Charging conditions (main conditions, factory settings)
Charging starts when the solar panel sensor (B31) is 7°C warmer than
the EcoTank sensor (B42).
Charging stops when there is a difference of 3°C between the solar
panel sensor and EcoTank sensor.
Charging from CTC EcoTank to H-tank compares the CTC EcoTank
sensor (B41) with the H-tank sensor (B6).
Bedrock/ground source heating only

14 CTC Expansion EnergyFlex
M
M
HP
B5
B6
B23 F2
F3
B30
B31
G30
G31
G32
Y31
01
03
04
Y30
B41
B42
HX
Y11
Y11
Y11
G99
G98
B47
EVK
3.1.4 Solar system 3
H-tank (CTCEcoHeat400/CTCEcoZenithi255) or EHS-tank (for other
EnergyFlex models) with an extra volume tank (X volume, which may be an
accumulator tank/pool, etc.). This system allows for a very large solar collector
surface since it carries a greater volume of water.
Select this option if you want to prioritise the H-tank/EHS-tank or X-volume (03).
If X-volume is a connected pool, its chlorinated water should be separated
by means of a pool exchanger fitted between 3-way valve Y30 and the pool.
X-volume sensors (B41 and B42) must then be placed in the pool.
Charging conditions (main conditions, factory settings)
Charging starts when the solar panel sensor (B31) is 7°C warmer than the
EcoTank sensor (B42) or the H-tank sensor (B6) or EHS-tank sensor (B47).
Charging stops when there is a difference of 3°C between the solar panel
sensor and EcoTank sensor.
Exchange will take place when the prioritised tank reaches its charge
temperature.
Bedrock/ground source heating only
The picture shows the possible connections. The installation engineer fits expansion tank, safety valves, bleeders, etc. and sizes the
system.

15
CTC Expansion EnergyFlex
M
M
1
2
3
1
2
3
1
2
3
Y31 Y31
Y31
Y31
EHS
G31
1
2
3
The picture shows the possible connections. The installation engineer fits expansion tank, safety valves, bleeders, etc. and sizes the
system.
3.1.5 System option: bedrock heating
Bedrock charging can be activated in "Solar systems 1, 2 and 3".
See the figures below for pipe installation of 3-way valve Y31.
1. Flow from solar collector
2. Flow to tank
3. Flow to bore hole
3-way valve for bedrock heating must be installed with normal flow to the tank
(2). The valve is then without power (NC).
When relay receives power, the valve will switch flow to the bedrock (3) and also
start the brine pump (G31).
For "Recharging of bedrock" menu settings, refer to the "Installer / Settings /
Solar Panels / Recharging of bedrock" section.
Example of bedrock charging with "Solar system 1".
Bedrock charging can also be activated in "Solar systems 2 and 3".

16 CTC Expansion Energyflex
G40
M
M
B50
G51
Y50
M
B46 B47
Y11
G46
B7
3.2 Pool
A pool can be connected to the system using a 3-way
valve (Y50). A heat exchanger should be fitted to
separate the liquids.
When the pool is heated, the 3-way valve (Y50) changes
direction and the pool pump (G51) starts.
3.3 Diff thermostat function
The diff thermostat function is used to transfer heat
from, for example, a buffer tank or existing wood boiler
to an H-tank or EHS-tank.
The function compares the temperatures in the tanks.
When it is warmer in the buffer tank, charging is started
to the main tank/EHS-tank.
NB: For certain heat sources, such as solid fuel boilers,
automatic chargers are recommended for, among other
things, preventing condensation in the fire box.
The diff thermostat function cannot be used with "Solar
system2" (system with CTCEcoTank). This is because
the same circulation pump (G46) is used.
3.4 DHW circulation
(DHW circ)
The function allows DHW to circulate in the pipes
between the taps and the DHW tank, ensuring that the
DHW is hot when the taps are opened.
DHW circulation is connected as shown in the
schematic diagram.
Circulation pump (G40) is used to circulate the hot
water.
The picture shows the possible connections. The installation engineer fits expansion tank, safety valves, bleeders, etc. and sizes the
system.

17CTC Expansion Energyflex
Designation Designation Comment
01 H-tank Main tank (EcoHeat 400/EcoZenith i255).
02 EcoTank Buffer tank (CTC EcoTank or similar).
03 X-volume Extra volume tank (or pool)
04 Heat pump Cooling module in CTCEcoHeat, GS 600, GSi 600 or
CTCEcoPart.
05 Tank for differential thermostat
function
The water volume in the wood-burning system that energy is
taken from with the differential thermostat function.
B5 Upper sensor M-tank Measures the temperature in top section of EcoHeat/EcoZenith
(factory-fitted)
B6 Lower sensor M-tank Measures the temperature in bottom section of EcoHeat/
EcoZenith (factory-installed)
B23 Brine sensor Measures the brine temperature in the heat pump (factory-
installed)
B30 Sensor solar panel in Measures the return temperature to the solar panel, installed in
expansion card.
B31 Sensor solar panel out Measures the temperature from the solar panel, installed in
expansion card.
B41 Upper X-volume/EcoTank
sensor
Measures the temperature in the top section of the X-volume/
EcoTank, installed in expansion card.
B42 Lower X-volume/EcoTank
sensor
Measures the temperature in the bottom section of the
X-volume/EcoTank, installed in extension card.
B46 Sensor for differential
thermostat function Installed in the heat pump/indoor module.
B47 External heat source (EHS)
sensor Measures the temperature in the EHS-tank.
B50 Sensor pool Installed in expansion card.
F2 Solar/tank heat exchanger Heat exchanger for charging the tank.
F3 Solar/brine heat exchanger Heat exchanger for charging the brine.
G30 Circulation pump solar panel Pump from exchanger to solar panel, fitted in expansion card
G31 Circulation pump borehole
charging Pump from brine to exchanger, installed in expansion card.
G32 Circulation pump heat
exchanger Pumps from tank to exchanger, installed in expansion card.
G40 Circulation pump for DHW circ. Hot water circulation during the DHW circ. function.
G46 Pump tank transfer Pumps between H-tank/EHS-tank and EcoTank/Tank for diff
thermostat function.
G50/G51 Circulation pumps, pool
G98/G99 Expansion vessel
Y11 Non return valve
Y30 Valve 2 tanks Diverting valve, charging M-tank or X-volume, installed in
expansion card.
Y31 Brine 3-way valve Diverting valve, charging brine or tank, installed in expansion
card.
Y50 3-way valve, pool
3.5 Parts list

18 CTC Expansion EnergyFlex
Terminal block X1 with
automatic circuit breaker (F1)
Expansion card A3
Terminal blocks X6–X7. Terminal blocks X1–X4
4. Installation
Installation and connection must be undertaken by a qualified electrician. All
wiring must be installed according to applicable local regulations.
Open the control unit by undoing the four screws and pushing the plastic cover
to the side. Install the power supply, circulation pumps, valves and sensors.
Terminals for communication to
relay card (A2) and display(A1)
(RJ-45).
Power supply X1 Screws (x4) for
opening the unit.
Terminal block X5
!NB: Do not touch the PCB’s components. The
PCB can be damaged by static discharge.

19
CTC Expansion EnergyFlex
4.1 Safety switch
The installation should be preceded by an omnipolar safety switch according
to overvoltage category III, which ensures disconnection from all electric
power sources.
4.2 Communication between
extension card and main product
Use the RJ-45 cable provided as the communication cable. This must be
installed between the extension card/solar control and the relay and display
cards in the main product, from which control takes place. Remove the
existing RJ-45 cable between the relay and display cards and connect the
RJ-45 cable provided.
Connection: Relay card A2 -> Expansion card A3 -> Display card A1.
4.3 High voltage
Supply:
230 V 1N~.
Max. fuse size (group fuse) 10A.
Connected to terminal block marked L1, N, PE
4.3.1 Pump, solar panel (G30, PWM)
Wilo Stratos Para
230 V 1N~
Circulation pump G30 is powered separately (not from this unit).
The solar PWM pumps (G30 and G32) of model WILO Stratos PARA differ
from the other PWM pumps. If the PWM control signal is interrupted, the
solar pumps stop, whereas the other PWM pumps work at 100% power if
the signal is interrupted.
The PWM control signal is connected to the following terminal blocks:
Expansion cardX5:
Note the cable colours!
PWM+: white Terminal block X5: 1
GND: brown Terminal block X5: 2
Check the function by test running the pump in the "Installer/Service/
Function test/Solar" menu in the control system.

20 CTC Expansion EnergyFlex
Selected setting
2 s.
> 2 s. x
10 s.
1.
2.
Operation data Setting
4.3.2 Circulation pump, solar collector (G30)
GrundfosUPM3Solar
230 V 1N~
The circulation pump is connected to the following terminal blocks:
(G30) Circulation pump, expansion card X5:
Note the cable colours!
PWM+: brown X5 pole 1
GND: blue X5 pole 2
Check the function by test running the pump in the "Installer/Service/
Function test/Solar" menu in the control system.
The pump must be set to PWM C profile (default)