Sunamp Thermino 20 User manual

Keep these instructions in a safe place for future reference.
Thermino®Heat Battery Installation and User
Manual (US/CA)

Safety Notice
Symbols and Notices Used and Their Meanings
Symbols
Warning
Electric Hazard
Notice
Cross-reference
Warning Notices
Consequences
Likelihood
Death/serious injury (irreversible)
Potential risk
Damage/minor injury (reversible)
Potential risk
DO NOT install outdoors. This product is for indoor use only.
Improper installation, adjustment, alteration, service, or maintenance can cause property
damage, injury and death.
ONLY competent persons who are suitably qualified to carry out plumbing and electrical work
may undertake installations, repairs or relocations. Product training on the full range of
Thermino Heat Batteries is available through Sunamp Ltd or authorised training partners and is
recommended.
Only use this product for the intended purpose described in this manual.
There are no user-serviceable, adjustable or settable parts in this product.

Document Purpose
To instruct competent persons on how to safely install Thermino®Heat Batteries for the US and
Canadian markets. Competent persons are those suitably qualified to carry out plumbing and
electrical work. Product training on the full range of Thermino®Heat Batteries by Sunamp
Projects Inc or an authorised training partner is available.
Contents
Safety Notice............................................................................................................2
Document Purpose ..................................................................................................3
1. Safety Instructions ...........................................................................................5
1.1 Intended Use...............................................................................................5
1.2 Pre-installation Safety Advice .....................................................................5
1.3 Mechanical & Hydronic Safety....................................................................5
1.4 Electrical Safety...........................................................................................6
1.5 Water Safety ...............................................................................................6
1.6 User Competence, Qualification, and Approval .........................................6
1.7 Compliance with Local Codes and Regulations...........................................7
1.8 Post-Installation Safety...............................................................................7
1.9 Repair and Relocation.................................................................................8
2. Heat Battery Overview.....................................................................................9
2.1 Introduction................................................................................................9
2.2 Product Overview & General Construction ..............................................10
2.3 Hydronic Circuits & Connections ..............................................................13
2.4 Pressure (Head) Loss Characteristics ........................................................14
2.5 Technical Specification, Dimensions & Weight.........................................15
2.5.1 Net and Gross Weights ....................................................................15
2.5.2 Nominal Product Dimensions...........................................................16
2.5.3 Detailed Specifications.....................................................................16
3. Temperature Sensors & Control ....................................................................18
3.1 Temperature Sensors................................................................................18
3.1.1 Heat Battery Sensor Specification....................................................18
3.2 Generic Control Logic................................................................................18
4. Installation .....................................................................................................20
4.1 Installation Process...................................................................................20
4.1.1 Preparation: .....................................................................................20
4.1.2 Hydronic Connection:.......................................................................20
4.1.3 Temperature Sensor Control Connections:......................................21
4.1.4 Final Fit After Commissioning: ......................................................... 21

4.2 Water Supply Requirements.....................................................................23
4.2.1 General.............................................................................................23
4.2.2 Hard Water and Limescale...............................................................25
4.3 Location and Space Requirements ...........................................................25
4.4 Hydronic Requirements ............................................................................26
4.5 Temperature and Insulation Requirements..............................................27
5. Commissioning...............................................................................................28
5.1 Process......................................................................................................28
6. Operation.......................................................................................................29
6.1 Troubleshooting........................................................................................29
6.1.1 During Installation............................................................................29
7. Maintenance..................................................................................................31
7.1 Removal of Lid ..........................................................................................31
7.2 Cleaning ....................................................................................................31
7.3 Warranty...................................................................................................31
8. Recycling and Disposal...................................................................................32

1. Safety Instructions
You MUST read the whole manual before installing the product. Sunamp Projects
Inc. is not responsible for the failure of components not specified in this manual
and/or supplied by other manufacturers.
1.1 Intended Use
The intended use of the Thermino®range of products is for the provision of hot water
for domestic purposes using external charging of the Heat Battery. They are equivalent
to a reverse indirect water heater/storage tank and can be classified as a Primary
Thermal Store.
It is not intended for use with other charging methods or in applications other than
the provision of domestic hot water.
1.2 Pre-installation Safety Advice
•Sunamp Ltd is not responsible for the selection, specification or effectiveness of
equipment unless stated in writing. The responsibility lies with customers and
any experts or consultants involved in the design and/or installation.
•Where applicable, this manual should be read in conjunction with manufacturer
documentation for any components specified in the installation requirements of
this manual.
•Where necessary, refer to the Sunamp website (www.sunamp.com) for contact
and support information.
1.3 Mechanical & Hydronic Safety
•DO NOT install outdoors. This product is only suitable for installations indoors in
a frost-free environment, to avoid weather damage.
•DO NOT tilt the product more than 45 degrees during the transportation or
installation process.
•Install the product on a hard, solid, level surface that supports its weight.
•DO NOT use detachable hose sets to connect the system to water mains.
•All soldering, welding or brazing must be performed on tubes detached from the
Heat Battery (minimum 1 meter / 3.3 feet away).

•This product is NOT suitable for gravity-fed hot water systems.
•DO NOT immerse this product in water or any other liquid.
•DO NOT use any sharp objects in proximity of the Vacuum Insulation located at
the side of the Heat Battery.
DO NOT stack the Heat Batteries directly on top of each other, if using multiple Heat
Batteries.
These batteries are not factory fitted with high temperature safety cut-off devices and
therefore, if a heat source can deliver hot water greater than 185oF (85oC), a suitable
energy cut-off device set at 185oF (85oC) maximum must be fitted in the charging
circuit to prevent charging above its maximum permitted temperature and damage to
the Heat Battery.
The Heat Battery circuits MUST NOT be connected to a direct refrigerant circuit.
1.4 Electrical Safety
The product must be grounded correctly in accordance with state and local
regulations.
1.5 Water Safety
Minimum working pressure of the Heat Battery is 22 PSI / 0.15 MPa / 1.5 Bar. The
maximum working pressure of the Heat Battery is 145 PSI / 1.0 MPa / 10 Bar. See
Section 4.2.1 for detailed specifications.
Water temperatures over 125°F / 50°C can cause severe burns instantly or death from
scalds. The outlet temperature must be set as per this manual.
1.6 User Competence, Qualification, and Approval
•ONLY competent persons who are suitably qualified to carry out plumbing and
electrical work may undertake installations, repairs or relocations. Product
training on the full range of Thermino Heat Batteries is available through Sunamp
Projects Inc. or authorised training partners and is recommended.
•DO NOT allow children or any other unqualified or unapproved persons to install,
repair, clean, relocate, interfere or tamper with the product.

•This product is not designed for use by children, or persons with reduced physical,
sensory or mental capabilities, and should not be used by such persons unless
they can do so safely. Where necessary, such persons (or anyone with a lack of
experience or knowledge) should first be given supervision or instruction
concerning the use of the product by a person responsible for their safety.
1.7 Compliance with Local Codes and Regulations
•Installations, repairs and relocations must comply with all relevant local codes
and regulations, particularly concerning electrics, water supplies, building
regulations and manual handling operations, as issued by the relevant bodies.
•Water distribution and central heating installations (‘systems’) must comply with
all obligations and local codes.
•Obligations from local codes always override manufacturer documentation
where there is a conflict.
1.8 Post-Installation Safety
•All goods are sold subject to Sunamp Projects Inc.’s Conditions of Sale, as listed
on the company website.
•As Sunamp continuously improves products, they may be modified without
notice. In such circumstances, this manual and other relevant documentation
should be disregarded. Updated documentation will be produced, supplied with
new product ranges and made available on request.
•Once installed:
•Perform a test run to ensure normal operation.
•Explain all safety precautions to the end user.
•Provide a copy of this manual to the end user.
•It is the responsibility of the end user to supply this manual to any other
subsequent users.

1.9 Repair and Relocation
•DO NOT attempt to carry out repairs or maintenance before the system
components –including the Thermino - have cooled down to ambient room
temperature. To speed up the process, isolate the external heat source and open
hot water taps in the dwelling to draw off hot water and cool the system down.
•DO NOT attempt to move an assembled system without using appropriate lifting
equipment.
•There are no user-serviceable, adjustable or settable parts in this product.
•No access to the Phase Change Material (PCM) container (Cell) is required in the
field under any circumstances. Breaching the PCM containment will void the
warranty of the product.
SAVE THESE INSTRUCTIONS AND
PROVIDE A COPY TO THE END USER.

2. Heat Battery Overview
2.1 Introduction
Thank you for choosing a Sunamp Thermino®Heat Battery, our innovative, super-
compact heat storage system based on Plentigrade® phase-change materials (PCM).
We are sure you will be delighted with the performance, compactness, ease of
installation and quality of our product.
Sunamp’s decade-long history of research and innovation in PCM technology has
made it the world-leading manufacturer in Heat Battery technology –developed,
designed and manufactured in the UK.
Sunamp has a wide portfolio of Heat Batteries for different applications. Please visit
our website (www.sunamp.com) or look at our catalogue for more information about
our portfolio for:
•Water heating
•Space-heating
•Combined space- and water-heating
•Cooling
The Sunamp Thermino®Heat Batteries are:
•Designed to produce domestic potable hot water service instantaneously
and on demand.
•Charged by an external heat source via a hydronic circuit only.
•Equivalent to a reverse indirect water heater/storage tank.
•Classified as a Primary Thermal store. By transferring heat from the PCM to
the mains water flowing through the heat exchanger, they produce hot
water instantaneously and on demand.
See the downloads section of our website (www.sunamp.com) for other useful
information on Sunamp products.

2.2 Product Overview & General Construction
The Thermino®range of thermal batteries is designed to be charged by an external
heat source only and are used for providing hot potable water instantaneously and on
demand.
The construction of the Heat Battery is shown in Figure. 1 & Figure 2. The thermal
Energy is stored by changing the state of Sunamp’s Plentigrade® Phase Change
Material (PCM) from solid to liquid via a flowing working fluid through the primary
circuit of the integrated heat exchanger. The thermal energy is then released by
changing the state of the PCM from liquid to solid and by transferring heat from the
PCM to the mains water flowing through the secondary circuit of the integrated heat
exchanger.
The PCM and the heat exchanger are housed in a sealed container/enclosure called
‘the Cell’. Although the Cell is sealed, the pressure inside the Cell is around the ambient
atmospheric pressure i.e. about 0.145 PSIG / 1.0 bar absolute (i.e. Approximately
atmospheric pressure) and is fitted with a one-way breather valve. The Cell is insulated
using highly efficient Vacuum Insulation Panels (VIP).
The heat batteries are fitted with temperature sensors for measuring the charge state
and can be used for controlling their operation via an external system and/or Heat
Battery controller. Do not remove or replace these sensors with other types unless
prior authorization by Sunamp has been received in writing.
The Plentigrade® P58 Phase-Change Material (PCM), has a phase transition
temperature (TPCM-PT) of 136.4°F (58°C).

Figure. 1: Heat Battery External
Item
Description
1
Heat Battery –Outer Case Main body
2
Heat Battery –Lid
3
Product Data badge / Serial number
4
Product Branding
5
Tube Entries via Rubber Grommets (3 sides)
6
Cable Entries / Blanks (3 sides)
Table 1: Reference Figure 1 Heat Battery External

Figure 2: Internal interfaces, lid removed (left), Top insulation removed (right)
Item
Description
1
3 layers of flexible Insulation, 2 layers to be fit around pipe exits.
2
Port identification labels –A B C D.
3
Cable Strain Relief–Interchangeable position with item 4
4
Blanking Bush –Interchangeable position with item 3
5
Temperature Sensor Location
6
PCM Cell One-way Breather Valve –Do not tamper or defeat!
7
4 X Port Connections - A B C D - 360 Degree ‘push fit’ elbows.
8
Ground connection point
9
The ‘Cell’ contains the PCM and Heat Exchanger.
10
Vacuum Insulation Panels (VIP)
Table 2: Reference Figure 2 Heat Battery internals

2.3 Hydronic Circuits & Connections
The Thermino range of batteries has two independent hydronic circuits:
1. The Primary Circuit for charging the Heat Battery via an external heat source.
Ports are labelled B and C.
2. The Secondary Circuit for discharging the Heat Battery for Potable Hot water
production. Ports are labelled A and D.
The heat is transferred between the PCM and the Primary and Secondary circuits using
an integrated heat exchanger inside the cell. The direction of flow through the ports is
key to the operation & control of the Heat Battery. See Figure 3 & Table 3 for details.
Figure 3: Heat Battery from Above showing the 3 possible tube exits.
Item
Description
A
Secondary Circuit –A –POTABLE HOT WATER
B
Primary Circuit –B –HEAT SOURCE FLOW
C
Primary Circuit –C –HEAT SOURCE RETURN
D
Secondary Circuit –D –POTABLE COLD WATER
Tube and cable entries are used depending on the installation location
Table 3: Reference Figure 3 Heat Battery entry/exits

2.4 Pressure (Head) Loss Characteristics
The two hydronic circuits within the Thermino 20 heat exchanger are not split evenly,
and thus there are two respective curves for pressure loss for the primary and secondary
circuits.
The two hydronic circuits within the Thermino 40, 60 & 80 heat exchangers are split
evenly and thus both the Primary and Secondary circuit pressure loss (head) values can
be read in Figure 4 below respectively.
Figure 4: Pressure Loss Characteristics
0.0
2.5
5.0
7.5
10.0
12.5
15.0
17.5
20.0
22.5
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5
Pressure Loss (feet of head)
Flow Rate (Gal./min)
Thermino 20 - Secondary Circuit Thermino 20 - Primary Circuit
Thermino 40 Thermino 60
Thermino 80

2.5 Technical Specification, Dimensions & Weight
2.5.1 Net and Gross Weights
The Net and Gross Weights of all models are listed in the following Table 4. The Gross
Weight refers to the installed weight when the heat exchanger tubes in the Heat
Battery are filled with water. The Net Weight refers to an empty Heat Battery (i.e., no
water in the tubes).
Table 4: Model Weights
Thermino
Model
Gross Weight
Net Weight
(kg)
(lb.)
(kg)
(lb.)
Thermino 20
62
137
58
128
Thermino 40
116
256
109
240
Thermino 60
170
375
159
351
Thermino 80
212
467
199
439

2.5.2 Nominal Product Dimensions
The following Figure 5 and Table 5 show the product dimensions. The product
footprint and port positions are common across the range. The products only differ in
overall height.
Figure 5: Nominal Product Dimensions
Thermino Model
20
40
60
80
A
Length
mm
575
In.
22 5/8
B
Width
mm
365
In.
14 3/8
C
Height
mm
389
590
816
1001
In.
15 5/16
23 1/4
32 1/8
39 3/8
D
Outlet Position
mm
38
In.
1 1/2
E
Outlet Position
mm
78
In.
3 1/16
F
Outlet Position
mm
50
In.
2
Table 5: Reference Figure 5 –Nominal Product Dimensions.
2.5.3 Detailed Specifications
The table on the following page details the key technical performance data,
operating parameters & specifications for this product range.

Specification
Heat Battery Model (Thermino):
20 (70)
40 (150)
60 (210)
80 (300)
Water Content [Gal (L)]
Primary circuit Port B-C
0.29 (1.3)
0.81 (3.7)
1.17 (5.3)
1.41 (6.4)
Secondary circuit Port A-D
0.51 (2.3)
0.81 (3.7)
1.17 (5.3)
1.41 (6.4)
Total
0.80 (3.6))
1.62 (7.4)
2.34 (10.6)
2.82 (12.8)
Thermal Content at rated conditions [BTU (kWh)]
11940 (3.5)
23880 (7)
35820 (10.5)
47770 (14)
Equivalent Hot Water Cylinder Size [Gal (L)]
19 (71)
38 (142)
56 (212)
75 (284)
V40, Volume of Hot water available at 40°C [Gal (L)]
22 (85)
49 (185)
79 (300)
98 (370)
Standby heat loss rate (BTU/hr | (W))
65 (19)
92 (27)
106 (31)
116 (34)
Recommended maximum Hot Water flow rate [Gal/min (L/min)]
1.6 (6)
3.9 (15)
5.3 (20)
6.6 (25)
Minimum mains supply pressure at the inlet of Heat Battery [PSI (Bar)]
22 (1.5)
Maximum working pressure [PSI (Bar)]
145 (10)
Pressure loss characteristics
See Figure 4: Pressure Loss Characteristics
Recommended setting range for Hot Water TMV [°F (°C)]
113 - 131 (45 - 55)
Maximum Charging Flow temperature TCH-IN-MAX [°F (°C)]
176 (80)
Minimum Charging Flow temperature TCH-IN-MIN [°F (°C)]
149 (65)
Phase Change Material Transition Temperature TPCM-PT [°F (°C)]
136.4 (58)
Note the US gallon (US gal), defined as 3.785411784 L
Table 6: Thermino Data Table

3. Temperature Sensors & Control
3.1 Temperature Sensors
The Thermino range of Heat Batteries is supplied with a factory-fitted sensor cable
comprising of three integrated temperature sensors, (S1, S2 & S3).
The sensors measure the internal temperature of the PCM in the centre of the Heat
Battery at three heights.
These can be used with a suitable external controller to manage the charging and
discharging of the battery. For wiring purposes, the sensor cable color coding is shown
in Fig. 6 and the specification of the sensors is given in the section below.
Figure 6: Temperature Sensor colour coding
3.1.1 Heat Battery Sensor Specification
•Sensor type: TDK NTC Thermistor, 10 kΩ, B57863S Series, 3988 K
•Further details are available via the NTC manufacturers’ website.
3.2 Generic Control Logic
The technical, performance and operating parameters are listed in Table 6. The
function and control strategy will depend upon the application and the external heat
source. However, a simple generic control logic based on the functional schematic
shown in Figure 7 is described below for guidance.
Note that the following guidance only applies if the Heat Battery ports have been
configured as detailed in this manual, Section 2.3:
•Charging Circuit (Primary): Top to Bottom - Port B to Port C
•Discharging Circuit (Secondary): Bottom to Top - Port D to Port A

Figure 7: Heat Battery Control logic and hydronic setup
•For efficient charging of the batteries, the charging circuit flow temperature,
TCH-IN must be:
o≥ TCH-IN-MIN
o≤TCH-IN-MAX
•To ensure that the battery is fully charged at the end of a charge cycle, the return
temperature, TCH-OUT, must be:
o≥ TPCM-PT + 9°F (or 5°C)
o≤ TCH-IN-MAX
•The Heat Battery charging can be activated when:
oTS2 < TPCM-PT
•The Heat Battery charging can be deactivated when:
oTS3 > TCH-IN-MIN
oTS2 > TCH-IN-MIN
oTS1 > TPCM-PT + 9°F (or 5°C)
•These batteries are not factory fitted with high temperature safety cut-off
devices and therefore if a heat source can deliver hot water greater than 185oF
(85oC), then, a suitable energy cut-off device set at 185oF (85oC) maximum must
be fitted in the charging circuit to prevent charging above its maximum permitted
temperature and damage to the Heat Battery.
T
CH
-
IN
T
CH
-
OUT
Charging
Circuit
T
DCH
-
OUT
T
DCH
-
IN
T
PCM
-
PT
T
CH
-
IN
-
MIN
T
CH
-
in
-
MAX
T
DCH
-
IN
-
MAX
T
DCH
-
IN
-
MIN
T
CH
-
IN
T
DCH
-
IN
T
DCH
-
OUT
Temperature
Discharging
Circuit

4. Installation
Always read the safety instructions in Section 1 of this manual before installing
the product.
4.1 Installation Process
4.1.1 Preparation:
•Assess the location of installation, considering spatial requirements, clearances,
cable and hydronic tube runs. See Figure 3 & Figure 10.
•Unpack and recycle packaging according to local disposal or recycling rules.
•Identify which side you wish to make a hydronic tube and cable entries (see
Figure 3 in Section 2.3).
•Prepare the system hydronics and electrics.
•Move the unit into position using appropriate lifting methods.
4.1.2 Hydronic Connection:
Note: The configuration of Heat Battery charging and discharging tube connections are
described in Figure 3.
•The potable cold water inlet connects to Port D;
•The potable hot water outlet connects to Port A;
•The heat source flow connects to Port B;
•The heat source return connects to Port C.
•Remove the lid. The lid is secured by 2 x M5 button head cap screws at the front
and two locating pins at the back (Figure 8):
•Remove 2 x M5 button head cap screws using a 3mm hex head and set
aside.
•Slide the lid forward, then lift the lid and set it aside.
•Remove the top two layers of insulation and set aside.
•Rotate the elbows to the side you wish to connect the hydronics (left, right or
back).
•Remove the respective rubber grommets in the outer housing and cut the centres
(with a cross) with a knife. Reinsert the cut grommets.
•Cut and prepare the necessary lengths of 3/4” ASTM B88 Type L - Blue copper
tube (OD 7/8” (22.2mm)) to suit the rest of the installation/system. Cross-
reference the fitting instructions of the push-fit elbows provided.
•Always cut the tube square, using a rotary tube cutter whenever possible. Ensure
the cutter wheel is appropriate for the copper tube.
•Deburr the tube end, both internally and externally and create a chamfer on the
outside of the tube.