CTC Union EcoZenith C 530 User manual

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Installation- and maintenance instructions
CTC EcoZenith
C 530 / 510
161 505 77-1 2014-01-16

Installation- and maintenance instructions
CTC EcoZenith
C 530 / 510
161 505 77-1 2014-01-16

FOR YOUR OWN REFERENCE
Complete the boxes below. They can be handy if something should happen.
Faults and misprints are excepted. The right to construction modifications is reserved.
Unit Manufacturing number
Installation engineer Telephone number
Installation date
Innehållsförteckning
FOR THE PROPERTY OWNER
Welcome _______________________________________________________________________ 5
Important to remember! ______________________________________________ 6
Safety Instructions _______________________________________________________ 6
1. Hot water ______________________________________________________________ 7
2. CTC EcoZenith C 530 design _____________________________ 8
3. CTC EcoZenith 510 design _________________________________ 9
4. Operation and maintenance _____________________________ 10
4.1 Safety valve for the tank and radiator system ______10
4.2 Draining the tank______________________________________________10
4.3 Operation stop_________________________________________________ 10
4.4 Noise problems________________________________________________10
FOR THE INSTALLATION TECHNICIAN
5. Transportation, unpacking and installation_____ 11
6. Pipe installation__________________________________________________ 15
7. Technical data ____________________________________________________ 16
Measurements____________________________________________________________ 17
Declaration of conformity__________________________________________ 18

5
CTC EcoZenith C 530 l 510
For the property owner
For the property owner
Welcome
You are now the owner of a CTC EcoZenith C 530 or CTC EcoZenith 510.
CTC EcoZenith C 530 is a buffer tank with a volume of just over 500 litres
and has among other features inbuilt solar and hot water coils for use,
for example, as the first tank in a wood boiler system.
CTC EcoZenith 510 is a volume increasing buffer tank of just over 500 litres
primarily for wood burning and solar panel systems. The tanks are well
insulated with 90 mm of polyurethane foam.

6
CTC EcoZenith C 530 l 510
For the property owner
Important to remember!
Pay special attention to the following points on delivery and during
installation:
• Transport and store CTC EcoZenith C 530 and 510 upright. A unit can
be laid
on its back for a short time if necessary.
• Remove the packaging, and, before installation, check that the unit has
not been damaged during transportation. Notify the forwarding agent if
any such damage
has occurred.
• Install CTC EcoZenith C 530 or 510 on a solid foundation, preferably a
concrete base.
If it is to stand on a soft carpet, plates must be placed
under the feet.
• Remember to leave a service space of minimum 1 m in front of the
unit. Space is also required around it for fitting the insulation and plastic
top. See section Transport, unpacking and installation in the section for
the installation technician.
CTC EcoZenith C 530 and 510 should also not be placed below floor
level.
Safety Instructions
Comply with the following safety instructions when handling, installing and
using
CTC EcoZenith C 530 and 510:
• Do not rinse off CTC EcoZenith C 530 and 510 with water.
• When handling the unit with a lifting eye or similar, ensure that the lifting
equipment,
eye bolts and other parts are not damaged. Never stand
under a hoisted unit.
• Never jeopardize safety by removing, for example, bolted covers or
hoods.
• Never jeopardize safety by deactivating safety equipment.
• Work on the unit may only be carried out by authorised personnel.
• Safety valve check:
• Check the safety valves for the boiler/system and hot tap water
regularly.
See section Operation and maintenance.

7
CTC EcoZenith C 530 l 510
For the property owner
0
100
200
300
400
500
600
700
800
20 25 30 35 40 45 50 55 60
Varmvattenvolym 40°C [liter]
Nedre tanktemperatur [°C]
Varmvattenkapacitet
EcoAir 125 Flöde 22 l/min
EcoAir 110 Flöde 12 l/min
EcoAir 110 Flöde 22 l/min
1. Hot water
CTC EcoZenith C 530 contains a total of about 40 metres of finned,
copper coil for heating water. This pre-heats the water through the lower
tank and then passes through the upper tank for the final temperature
increase. There are two coils running side-by-side through the tanks, which
allows for high flow rate with low pressure drop and can provide a large
amount of hot water
and associated comfort.
Hot water capacity
EcoAir 125 Flow 22 l/min
EcoAir 110 Flow 12 l/min
EcoAir 110 Flow 22 l/min
Lower tank temperature [°C]
Hot water volume 40 °C [litre]

8
CTC EcoZenith C 530 l 510
For the property owner
2. CTC EcoZenith C 530 design
The illustration below shows the design of the unit.
Top connection
For connecting an expansion
vessel and/or safety valve.
Upper tank
In the upper part of the tank, the
warm water in the coil is heated
up to the desired temperature.
Upper tank connections
The upper part of the tank, top
section, can be heated by a heat
pump and be connected to heat
sources such as an electric, gas,
oil or pellets boiler. Heat from a
wood boiler is also fed to this part.
The connections are symmetrically
placed on both sides of the tank.
Heat distribution pipe
The heat distribution pipes ensure
that heat from the solar coil is fed
up to the upper part and that cool
water, after a discharge of hot water,
is fed down to the lower part of the
tank to be heated up again by, for
example, solar heat or a heat pump.
Insulated tank divider
There is an insulated dividing plate
between the upper and lower parts
of the tank. This retains the higher
temperature water in the upper part,
to provide good hot water capacity,
and the lower temperature water
in the lower part for the best heat
exchange of solar heat.
Lower tank connections
A heat pump and solar coil can be
connected to the lower part of the
tank. Water to be heated by a
wood boiler is drawn from here.
The connections are symmetrically
placed on both sides of the tank.
Fresh water connections
The building’s fresh water supply
is connected here. The cold water
is fed down to the lower
part of the coiling.
Bivalent mixing valve
connection
Connection for a bivalent mixing
valve. A bivalent mixing valve has
two ports, and its primary purpose
is to take in radiator water from
the lower part of the tank.
Finned coil for hot water
CTC EcoZenith C 530 is equipped
with a well dimensioned, nned,
copper coil; no water heater that
would be susceptible to corrosion
is included. The temperature can
be kept low without the risk of
legionnaires’ bacteria forming.
Immersion heaters
CTC EcoZenith C 530 has three
connections for immersion heaters
(Immersion heaters are accessories).
Lower tank
In the lower part of the tank,
warm water is pre-heated
in the nned coil.
Solar coil connections
The well-dimensioned, 10 m long,
nned coil can be connected
directly to the solar panels.
Insulation
The tank is insulated with 90 mm
thick, moulded polyurethane foam
to minimise heat loss.

9
CTC EcoZenith C 530 l 510
For the property owner
3. CTC EcoZenith 510 design
The illustration below shows the design of the unit.
Immersion heater
CTC EcoZenith 510 is prepared
with tting for immersion heater
(Immersion heaters are accessories)
Insulation
The tank is insulated with 90 mm
thick, moulded polyurethane foam
to minimise heat loss.
Top connection
For connecting an expansion
vessel and/or safety valve.
Connections
Connections are placed
symmetrically on both sides
of the tank.

10
CTC EcoZenith C 530 l 510
For the property owner
4. Operation and maintenance
When your new CTC EcoZenith C 530 or 510 has been installed, you should,
together with the installation technician, ensure that the installation is optimal.
Let the technician show you how it works and should be maintained. Purge
the radiators after about three day’s operation and add water as necessary.
4.1 Safety valve for the tank and
radiator system
Check regularly that the valve is working properly by manually turning the
valve knob. Check that water comes out of the overflow pipe. The overflow
pipe outlet must always be open. Hot water can drip from the safety valve.
4.2 Draining the tank
There must be no electrical supply to the tank during drainage. The drain
valve is packaged
separately and can be connected directly onto one of the
lower connections, if one is free, or to a low lying pipe. When draining the
whole system, fully open the mixing valve, i.e. turn it as far as possible anti-
clockwise. Air must be applied to a closed system.
4.3 Operation stop
If there is a risk of the water freezing when the system is not in use, all the
water must be
drained from the tank and radiator system. The hot water
coils, which contain about eleven litres, are emptied by feeding a hose all
the way down inside the coils into the cold water connections and then
siphoning out the water.
4.4 Noise problems
Sudden changes in pressure in the tap water system may cause noise. This
is due to pressure surges which occur when, for instance, an older type of
instant closing mixer is turned off
quickly. The fault is not in CTC EcoZenith
C 530, and the problem can be easily rectified
by replacing the mixer with
a soft-closing one. In the case of noise from hard closing dishwashers and
washing machines, this can be rectified with a pressure surge damper, which
is also a viable alternative to soft closing taps/mixers. Minimizing pressure
surge benefits the whole of the tap water system generally.
If pouring sounds come from the unit, check that it is well purged. Turn
the boiler safety
valve to evacuate any air in the system. If the problem is
repeated, have a specialist check the cause.

11
CTC EcoZenith C 530 l 510
For the installation technician
For the installation technician
5. Transportation, unpacking
and installation
!The unit must be
stored and trans-
ported in an upright
position.
This section is intended for the technician responsible for one or several
of the installations needed for CTC EcoZenith C 530 and 510 to function as
desired
by the property owner. Take some time to go through the functions
and settings
with the property owner and answer any questions. Both CTC
EcoZenith C 530/510
and you will benefit by the user having good knowledge
of how the application works and should be maintained.
Transportation
Transport the unit to the installation site before removing the packaging.
Handle CTC EcoZenith C 530 and 510 in one of the following ways:
• Forklift
• Lifting eye which is fitted in the socket in the middle of the top of the
tank.
• Lifting straps around the pallet. NOTE! Can only be used with the
packaging still
in place. Be aware when handling that the unit’s centre of gravity is
high up.

12
CTC EcoZenith C 530 l 510
For the installation technician
Unpacking
When the CTC EcoZenith C 530 or 510 has been placed at the installation
site, the packaging can be removed. Make sure the unit has not been
damaged during transportation. Notify the forwarding agent of any
transportation damage. Also
check that the delivery is complete and in accordance with the list below.
Standard delivery - CTC EcoZenith C 530
• Tank - CTC EcoZenith C 530
• Additional package with:
• Installation and Maintenance Manual
• Safety valve 9 bar (tap water)
• Safety valve 2.5 bar (radiator system)
• Drain valve
• Adapter between the drain valve and the connection sleeve
• Cover plates for upper and lower tank connections, 8pcs
• Cover plates for solar connections, 2pcs
• Insulation for connection sleeves that are not used
• Screw 4.2 x 14 graphite grey, 25 off + 2 extra
• Screw 4.2 x 14 zinc grey, 4 off + 2 extra
• Additional package with rear insulation sections and top
Standard delivery - CTC EcoZenith 510
• Tank - CTC EcoZenith 510
• Additional package with:
• Installation and Maintenance Manual
• Sensor - upper and lower tank, 2 off
• Safety valve 2.5 bar (radiator system)
• Drain valve
• Adapter between the drain valve and the connection sleeve
• Cover plates for upper and lower tank connections, 4pcs
• Insulation for connection sleeves that are not used
• Screw 4.2 x 14 graphite grey, 21 off + 2 extra
• Screw 4.2 x 14 zinc grey, 4 off + 2 extra
• Additional package with rear insulation sections and top

13
CTC EcoZenith C 530 l 510
For the installation technician
Left rear insulation Pockets in the front insulation
Right rear insulation
The illustration shows
EcoZenith I550
Graphite-grey screw
(25 off)
Tension band
The illustration shows EcoZenith I550
Fitting rear insulation and top cover
The rear insulation sections and top cover should be fitted before the CTC
EcoZenith C 530 or 510 is placed against a wall or in a corner for pipe and
electrical connection. These parts are delivered separately and they are
easier to fit if there is space around the unit.
Begin with the left rear insulation. Turn out the insulation, locate it in the
pockets in the front insulation and then turn it in against the tank. Repeat
this procedure for the right rear insulation. Note that the right rear insulation
needs to be turned out quite a lot for it to locate easily in the pockets.
When the rear insulation is in place, tension bands can be used to hold it
firmly against the tank. Attach the insulation sections to each other using the
25 graphite-grey screws provided. The screw holes are factory prepared.
!The tension bands
can scratch the
surface of the insula-
tion. Use a piece of
cardboard or similar
to protect it.

14
CTC EcoZenith C 530 l 510
For the installation technician
Plastic top
The illustration shows EcoZenith I550
Zinc-grey screw (4 off)
Fit the plastic top at the front and tip it backwards to locate it under the
mixing valve actuator. Fit the 4 provided zinc-grey screws in the prepared
holes. Ensure that the top is correctly aligned with the front.

!The opening pressu-
re of the safety valve
must be determined
by the component
of the system that
can withstand the
lowest pressure.
15
CTC EcoZenith C 530 l 510
For the installation technician
6. Pipe installation
The installation shall be carried out in accordance with applicable heating
and hot water standard. The unit shall be connected to an expansion vessel
in an open or closed system. Remember to flush the radiator systems before
connecting.
Connections, position and dimensions
See Technical data.
Pipe installation of the product
If annealed piping is used, fit support sleeves
Mixing valve
Install a mixing valve for the hot tap water in order to avoid the risk of
scalding.
Safety valves
The CTC EcoZenith C 530 and 510 safety valves for the tap water circuit
and boiler are packaged separately. Drain pipes shall run to a draining gutter,
either directly, or,
if the distance is more than two metres, to a funnel. Water
can drip from the drain pipe.
The piping must have a slope to the draining
gutter, freezing risk must be avoided and it must be open/pressureless.
Radiator system filling valve
Fit the filling valve between the cold water connection and the radiator return
pipe, or between the cold water pipe and the expansion pipe.
Drain valve
Fit the drain valve (separate package) to one of the CTC EcoZenith C 530 /
510 lower connections. The adapter for this is provided in the package. The
drain valve can also be fitted into a low lying pipe.
Pressure gauge – system pressure
Fit a pressure gauge to the expansion pipe or radiator return pipe.
Expansion vessel connection
It is best to connect the CTC EcoZenith C 530 or 510 to a closed expansion
vessel. If an open system is used, the distance between the expansion
vessel and the highest radiator should exceed 2.5 metres, otherwise the
system will become oxygen saturated.
Insulation
For best efficiency, carefully insulate all parts of the piping, used connections
and unused plugged connections. Use supplied insulation parts and
complete with insulation of the type Armaflex with a thickness of at least
10-15mm or equivalent. Make sure that the insulation on the connections
reaches all the way up to EcoZeniths own insulation to avoid heat losses.

16
CTC EcoZenith C 530 l 510
For the installation technician
0
10
20
30
40
50
60
70
80
0 5 10 15 20 25 30 35 40 45
Tryckfall [kPa]
Flöde [l/min]
Tryckfallsdiagram varmvattenslingor
0
5
10
15
20
25
30
012345678910
Tryckfall [kPa]
Flöde [l/min]
Tryckfallsdiagram solslinga
7. Technical data
CTC EcoZenith C 530 CTC EcoZenith 510
Main dimensions on delivery mm 750 x 818 x 1700
Main dimensions when installed mm 886 x 935 x 1700
Weight kg 239 134
Insulation (Polyurethane, PUR) mm 90
Hot water capacity (40°C, 22 l/min)
>600
523
Tank temp 55°C, HP (EA125) permitted
Tank temp 65/55°C, electrical power 24 kW
permitted
litre
litre
Pressure drop at ow 40 litres/min bar 0,7
Volume - tank litre 540 555
Volume - hot water coil litre 11,4
Max operation pressure - tank bar 2,5
Max operation pressure - hot water coil bar 9
Hot water coil (nned) m 2 x 18,6
Hot water coil circulation (nned) m 0,6
Solar coil (nned) m 10
Pressure drop diagram – hot water coils
Flow [l/min]
Pressure drop [kPa]
Flow [l/min]
Pressure drop diagram – solar coil
Pressure drop [kPa]

17
CTC EcoZenith C 530 l 510
For the installation technician







11

8. Measurements
CTC EcoZenith C 530
1. Heat connection, G 1 1/4” int
2. Heat connection, G 1 1/4” int
3. Expansion vessel/Top con/Lifting socket, G 1 1/4” int
4. Solar coil, Ø18 mm
5. Cold water, Ø22 mm
6. Hot water, Ø22 mm
7. Hot water circulation, Ø22 mm
8. Connection for mixing valve prio 2, 28 mm
(Connections for prio 1 and return pipe
behind the front insulation, G 1” int)
9. Immersion heater connection, G 2” int
10. Immersion heater connection, G 2” int
11. Pocket for temperature sensor, Ø6.5 mm
CTC EcoZenith 510
1. Heat connection, G 1 1/4” int
3. Expansion vessel/Top con/Lifting socket, G 1 1/4” int
9. Immersion heater connection, G 2” int
11. Pocket for temperature sensor, Ø6.5 mm

Declaration of conformity
Försäkran om överensstämmelse
Déclaration de conformité
Declaration of conformity
Konformitätserklärung
Enertech AB
Box 313
S-341 26 LJUNGBY
försäkrar under eget ansvar att produkten
confirme sous sa responsabilité exclusive que le produit,
declare under our sole responsibility that the product,
erklären in alleiniger Verantwortung, dass das Produkt,
CTC EcoZenith
som omfattas av denna försäkran är i överensstämmelse med följande direktiv,
auquel cette déclaration se rapporte est en conformité avec les exigences des normes suivantes,
to which this declaration relates is in conformity with requirements of the following directiv,
auf das sich diese Erklärung bezieht, konform ist mit den Anforderungen der Richtlinie,
EC directive on:
Pressure Equipment Directive 97/23/EC, § 3.3
(AFS 1999:4, § 8)
Electromagnetic Compatibility (EMC) EN 2004/108/EC
Low Voltage Directive (LVD) EN 2006/95/EC
Överensstämmelsen är kontrollerad i enlighet med följande EN-standarder,
La conformité a été contrôlée conformément aux normes EN,
The conformity was checked in accordance with the following EN-standards,
Die Konformität wurde überprüft nach den EN-normen,
EN 14731:2006 EN 55014-1 /-2
EN 3834-2:2005 EN 61 000-3-2
EN 15614-1:2004 EN 60335-1, 2-21
EN 1418 EN 50366:2002, +A1
EN 287-1:2004
EN 10 204, 3.1B:2005
EN 10 025-1, -2, S 235 Jr-G2:2004
Ljungby 2009-11-20
Kent Karlsson
Technical Manager

Enertech AB. P.O Box 309 SE-341 26 Ljungby Sweden.
www.ctc.se, www.ctc-heating.com
161 421 50 10-01