PowerFlow ERS MINI Manual de usuario
Important Information for your PowerFlow:
ERS MINI
• Installation and User Manual
IMPORTANT SAFETY INFORMATION, PLEASE READ AND UNDERSTAND
THIS MANUAL BEFORE COMMENCING WORK
Thank you for choosing PowerFlow
PowerFlow’s Mission is to continually develop efficient energy storage technologies in order to increase the
availability of low carbon generated power. This will contribute to CO2 reduction and help to protect our
planet for future generations, something all of us at PowerFlow are very passionate about.
Over five decades of combined experience has been deeply integrated into your PowerFlow product. From
its class leading efficiency, to the highest of safety standards, every component has been carefully
considered to ensure long lasting reliable operation. All of our products are fully designed and 100%
manufactured in the UK at our factory in Herefordshire, helping to support Great British manufacturing.
By purchasing PowerFlow Products, you are supporting the development of this important technology so
future generations can benefit and prosper from cleaner, greener more sustainable energy.
Ian Murray: Managing Director
PowerFlow Energy Ltd
Register Your Product.
Don’t forget to register your product on the PowerFlow website. Should you have a problem
within the 2 year warranty period or beyond, this will help PowerFlow to service your enquiry.
Visit: www.powerflowenergy.com/warrantyregistration
Contact Us
If you have any questions about our products, our website is designed to provide support. Should you not
find what you are looking for, you can contact us using the details below.
website: www.powerflowenergy.com
PowerFlow Energy Ltd
9 Harrow Road
Plough Lane
Hereford
HR4 0EH
United Kingdom
Tel: 01452 421271
Email: info@powerflowenergy.co.uk
Manual Version V1.5
Table of Contents
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Page 1 Foreword
Page 2 Table of Contents
Page 3 1. Introductory Information
1.1 Validity
1.2 Additional Information
1.3 Country Regulatory Network Parameters
Page 4 2. Safety Information
2.1 Appropriate Usage
2.2 Safety Instructions
2.3 Safety Notices
Page 5 3. Product Description
Page 6 4. Unpacking
4.1 Scope of Delivery
Page 7 - 9 5. Mounting
5.1 Selecting a Suitable Mounting Location
5.2 Product Dimensions
5.3 Overview of Connection panel
5.4 Ventilation mounting clearances
5.5 mounting clearances , multiple devices
Page 10 6. System Design
6.1 AC circuit protection
Page 11 7. Connector Assemblies
7.1 Power Connections
7.2 Current Clamp Connections
Page 12 8. Wiring Diagram
Page 13-15 9. Display and Control Elements
9.1 Switching ON and OFF
9.2 LED Status Indicators
9.3 Using The Manual Boost
9.4 Operation During Energy Recovery
9.5 Operation During No Load
9.6 Over Temperature
Page 16—17 10. Commissioning
10.1 Energising for the first time
10.2 System testing
10.3 Adjusting the existing heating system
10.4 Troubleshooting
Page 18 11. Technical Specification
1.1 Validity
Read fully and understand this manual before commencing work
This manual is for electrically skilled persons. The tasks described in this manual may be performed by
electrically skilled persons only. It describes the installation, commissioning, maintenance and warranty
procedures for the following PowerFlow Energy Recovery Systems:
• PowerFlow E.R.S MINI (ERS-MINI)
1. Introductory Information
1.2 Additional Information
You can find additional information on the design of the complete Energy Recovery system at
www.powerflowenergy.com. For electrical design information such as MCB, RCD and cable sizing, please
reference BS7671.
1.3 Country Grid Parameters
Using E.R.S MINI Inside and Outside the UK
E.R.S MINI is designed to be connected to an AC supply network with a nominal supply of 230V / 50Hz.
ERS MINI is designed to work alongside a grid connected renewable generator such as a wind or solar
system. E.R.S MINI does not connect directly to the generation system and therefore will not effect its
operation or any tariff rate that may be associated with it. In addition, it does not effect any grid connection
standards associated with the generation equipment.
E.R.S MINI can be used outside of the UK provided it is connected to the above stated network supply
standard and complies with any other local electrical standards required for connection.
Please note that if E.R.S MINI is connected to a supply network which is outside of its scope of operation it
will cause irrefutable damage to the device and will not be covered by any factory warranty.
It is important to ensure that the supply voltage and frequency are suitable before connection.
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2. Safety Information
2.1 Appropriate Usage
PowerFlow E.R.S MINI is a grid connected energy flow controller diverter designed solely to be used to-
gether with any grid connected solar PV or wind generation system. It can be used in energy battery back
up or off grid systems provided the electricity network complies to the appropriate grid standard.
Do not use E.R.S MINI for any other purpose other than described in this manual. Alternative uses or
modifications to the product are expressly NOT permitted. Any other use will void any warranty claims and
operation permissions.
2.2 Safety Instructions
The following terms will be used throughout this manual. Please observe the safety instructions.
DANGER: Danger to life due to high voltages.
• All work detailed by this instruction MUST be carried out by an electrical professional.
• Children may not play with or have access to ERS
WARNING: Risk of injury, illness or damage to property.
• All work detailed by this instruction should be carefully considered.
• Children may not play with or have access to ERS
IMPORTANT: Recommendations or advice that if not followed correctly may cause installation or system
problems and may result in additional product support or damage.
2.3 IMPORTANT: Safety and Legionella Advice
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IMPORTANT SAFETY INFORMATION
WARNING: Please take note of the following:
1. Risk of burns due to hot enclosure.
During operation the ERS enclosure may become hot to touch. Always use caution when touching the enclosure after
long periods of operation.
2. DO NOT place objects over the enclosure.
PowerFlow ERS uses the metal enclosure to dissipate heat. Covering the enclosure may cause product failure.
Please ensure
adequate ventilation is provided.
For further information refer to the installation guide.
3. DO NOT disassemble the ERS unit at any time.
PowerFlow ERS contains live parts inside, never disassemble the system.
Important: Legionella Advice
Legionella is a bacteria that can grow in water below 60ºC. It is common practice for hot water and heating systems to
raise the water temperature on a weekly basis over 60ºC in order to kill any bacteria growth. Due to the very nature of
ERS it is possible during periods of low energy export to partially heat the water. In systems without a second heating
source such as a boiler to ‘top up’ the water temperature, it is possible that unused warm water could remain in a tem-
perature range where bacteria can grow. Because the particulars of each installation are different, PowerFlow Energy
cannot take responsibility for controlling the risk of legionella. It is the installers responsibility to
ensure that this risk is controlled. Adequate water exchange and/or additional heating must be supplied in order to raise
the water temperature above 60ºC on a minimum of a weekly basis. This can be achieved in all electric homes by using
the external timer function to override the ERS system once per week. Further advice on Legionella can be found at
www.hse.gov.uk/legionnaires
!
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3. Product Description
5
PowerFlow E.R.S MINI is a grid connected energy diversion system which converts surplus AC
electrical energy, or export, from any grid connected solar or wind generator into heat via a hot
water or space heating resistive load element. By performing this function, surplus energy
generation, which is unable to be used, can be stored and used at a later time when demand
for hot water or heating is required. This results in less energy consumption and in turn leads
to cost savings.
E.R.S MINI is completely independent from the solar or wind generator other than it uses a
current measurement device or CT to calculate in which direction energy is flowing and how
much energy is available for storage. E.R.S MINI performs energy capture purely based on this
measurement alone. This enables E.R.S MINI to work during any time of the day and, together
with the solar or wind generator, to ensure that maximum energy capture is possible.
During times when export occurs, the amount of energy available continually changes due to
changes in generation and changes in building demand. E.R.S MINI automatically adjusts it’s
output power level input every 200 milliseconds to match export levels ensuring that only
surplus energy is sent to the heating load.
This method of fast accurate power measurement, combined with fast reacting automated self
adjusting output power makes E.R.S MINI unique. By utilising these control techniques, the
maximum possible self consumption can be achieved through the system.
Only a single E.R.S MINI device can be used on a single phase. For three phase installation,
three devices can be used on each independent phase. E.R.S MINI has also be designed to be
used in conjunction with the PowerFlow Sundial battery storage system.
The diagram below illustrates a typical system layout.
4: Unpacking
Thank you for purchasing the PowerFlow Energy Recovery System, E.R.S MINI. Please read fully, and
take note of, the required installation conditions set out by this installation guide, before commencing
work. If you are unsure about installation, further design and installation advice can be found in the
full technical manual available for download at www.powerflowenergy.com. All electrical work
should be carried out by a competent, qualified person and all relevant building regulations should be
considered prior to installation.
ABCD
EFGH
Object Quantity Description
A1E.R.S MINI Device with integral mounting brackets
B1Current measurement clamp (CT)
C11 x 3 PIN IEC Male power OUT connector
D11 x 3 PIN IEC Female power IN connector
E11 x Current clamp connector & zip tie
F216A 4.0mm 2 pin push fit through connector with lever
G1M6 wall fixing set
H1Installation and User Manual.
4.1 Scope of Delivery
Please check the delivery for completeness and for any visible external damage. Contact your sup-
plier if anything is damaged or missing. Ensure that the Product Identification Documentation is
retained.
The following components should be included:
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5. Mounting
5.1 Selecting a Suitable Mounting Location
IMPORTANT: E.R.S MINI is rated to IP20. It is suitable for indoor installations only. It is also suitable for
damper environments such as un-heated garages or out buildings. Do not mount sundial in direct sunlight
due to heat absorption. The device will run hotter and become less efficient.
• The mounting method and location must be suitable for E.R.S MINI’s weight and dimensions. It has
been designed for wall mounting only in a near vertical orientation. Ensure suitable ventilation.
• The mounting location would normally be close to the main consumer distribution board.
• Only mount on a solid surface and take into account cable runs from the device.
• The mounting location must at all times be clear and safely accessible without the use of additional
equipment such as scaffolding or lifting platforms. Non-compliance with this recommendation may
restrict servicing.
Extended Mounting Criteria
• The connection panels must always face horizontally DO NOT MOUNT UPSIDE DOWN!
• Never mount with a sideways tilt
• If possible install E.R.S MINI at eye level due to the accessibility of the LED display. If future
service is required, this will also facilitate service work.
IMPORTANT
Temperature Considerations
Do not expose E.R.S MINI to direct sun light, as this can cause excessive internal heating
It is strongly recommended NOT to install E.R.S MINI into loft spaces due to increased heat during
Summer months. Installations in locations which can exceed 40˚C will reduce the ability to
operate efficiently and could reduce the life span of the device. Note: Any manufacturers warranty
will be void if devices are mounted in unsuitable locations.
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Vertical Mounting Titled backwards no
more than 15˚
Never mount
E.R.S MINI
with a forward tilt
Never mount
E.R.S MINI
Horizontally
IEC Power IN
connector Manual
Boost
Buon
Current
Clamp
165mm
108mm
20mm
75mm
40mm
40mm
50mm
Use 3 core
1.5mm² ex to
isolator, then
2.5mm to
consumer
board
IEC Power OUT
connector
20mm
Display
Power
Bar
5.2 Product Dimensions
5.3 Overview of Connection Panel
Object Description
AMain Power OUT connector
BMain Power IN connector
CCurrent Clamp connector
ABC
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CAUTION:
Observe the minimum clearance to walls and other devices.
This is to ensure that there is sufficient and suitable space for heat dissipation
5.4 Ventilation Mounting Clearances
100mm
100mm
150mm
50mm
5.5 Mounting Clearances for Multiple Devices
Horizontal Installation: 100mm minimum between devices
Vertical Installation: 150mm minimum between devices
100mm
100mm
150mm
250mm
100mm
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