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CALPAK MARK4, Technical Documentation Manual

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                     THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 1 

 

 

TABLE OF CONTENTS 

I.

 

INTRODUCTION   

 

 

 

 

 

 

PAGE 2 

II.

 

TECHNICAL CHARACTERISTICS 

 

 

 

 

 

PAGE 4 

III.

 

POSITIONING OF THE SYSTEM 

 

 

 

 

 

PAGE 7 

IV.

 

INSTALLATION OF SYSTEM ON A FLAT ROOF [All models except 300/4.2] 

PAGE 8 

V.

 

INSTALLATION OF SYSTEM ON A FLAT ROOF [300/4.2 model]  

 

PAGE 18 

VI.

 

INSTALLATION OF SYSTEM ON INCLINED ROOF [All systems]   

 

PAGE 21 

VII.

 

HYDRAULIC CONNECTION OF SYSTEM [All systems]   

                                PAGE 28 

VIII.

 

ELECTRICAL CONNECTIONS 

 

 

 

 

 

PAGE 33 

IX.

 

FUNCTION AND MAINTENANCE                                                               

 

PAGE 34 

 

 

 

 

 

 

 

 

 

Summary of Contents for MARK4

Page 1: ...lpak solar systems have been designed and manufactured according to the strictest quality standards so that they may offer many years of top of the range performance For any clarifications regarding o...

Page 2: ...ONING OF THE SYSTEM PAGE 7 IV INSTALLATION OF SYSTEM ON A FLAT ROOF All models except 300 4 2 PAGE 8 V INSTALLATION OF SYSTEM ON A FLAT ROOF 300 4 2 model PAGE 18 VI INSTALLATION OF SYSTEM ON INCLINED...

Page 3: ...oo low and the effect on durability and stability is considered negligible Annex E paragraph E 5 11 standard EN 12976 2 The solar thermal system can be connected to the existing lightning protection a...

Page 4: ...ty valve for the domestic cold water line 7 Insulated connecting pipes 8 Pipe fittings SYSTEM IDENTIFICATION The tank and the collector s which form a solar system are appropriately marked with metali...

Page 5: ...7 m2 1 96 m2 2 44 m2 2 44 m2 2 83 m2 2 83 m2 W x L x H mm 986 2071 86 1244 1711 86 1244 2121 86 2121 1244 86 1502 1996 86 1996 1502 86 Weight kg 34 5 36 48 49 50 51 Absorber capacity l 1 6 1 6 1 8 2 2...

Page 6: ...ic welded on copper harp Rock wool insulation Aluminum profile frame Low iron tempered glass Tank Enameled tank according to DIN 4753 3 Insulation with expanded polyurethane Magnesium anode cathodic p...

Page 7: ...6 2 Optional electrical resistance kW 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 Tank Tank volume l 122 156 156 156 202 202 202 202 202 202 275 275 Tank weight empty kg 51 58 58 58 73 73 73 73 73...

Page 8: ...but larger deviations may seriously affect the performance 1 2 In countries situated in latitude of 40 the collectors must be installed at an angle of 45 against the horizontal level The collectors mu...

Page 9: ...loor at an angle of approximately 10 15 degrees Follow the instructions for positioning the system in Chapter III Use fasteners of appropriate length and type to ensure that the pillars and all base c...

Page 10: ...ositioning relative to the collector as it affects the accuracy of the installation IMPORTANT DO NOT REMOVE COLLECTOR COVER SHEET BEFORE CONNECTING THE SYSTEM STEP 3 Place the collector on the roof fl...

Page 11: ...the collector from the side close to the pillars at an angle of approximately 45 degrees Move the collector towards the pillars Insert the securing bolts into the vertical slots of the pillars Upper r...

Page 12: ...centres of the tank support holes is in accordance with Table B If there is deviation you may make small adjustments ensuring that both pillars are vertical and that the collector is centered between...

Page 13: ...se the below table Use fasteners of appropriate length and type to ensure that the collector feet are secured onto the structural layer of the roof and not on the insulation Use an appropriate sealing...

Page 14: ...the tank on the roof floor with a small rotation backwards Ensure that the securing bolts of the tank do not touch the floor Lift the tank and place it on the circular seats on top of the pillars Rot...

Page 15: ...RMOSIPHONIC SOLAR WATER HEATERS TECHNICAL DOCUMENTATION PAGE 14 STEP 10 For ease of installation you may attach the cold water supply tube STEP 11 Install washers and the nuts on the tank securing bol...

Page 16: ...THERMOSIPHONIC SOLAR WATER HEATERS TECHNICAL DOCUMENTATION PAGE 15 STEP 12 Connect the brace system with the pillars Do not tighten the bolts ensure however that they are not very loose...

Page 17: ...tening the bottom nut Use fasteners of appropriate length and type to ensure that the collector feet are secured onto the structural layer of the roof and not on the insulation The fastener must protr...

Page 18: ...ATER HEATERS TECHNICAL DOCUMENTATION PAGE 17 STEP 15 Tighten the middle bolt against the brace foot STEP 16 Tighten the 4 brace strut bolts Make sure that all bolts are tight and that bolts are not lo...

Page 19: ...nstalling the 300 4 2 model with the dual collectors is identical to the procedure in the previous chapter except for Step 2 which must be replaced with the following Figure 1 The two collectors ready...

Page 20: ...t excessive free play while allowing sliding of the collectors towards each other Connect the absorber tubes between the collectors by the appropriate fittings Ensure that the collectors are parallel...

Page 21: ...THERMOSIPHONIC SOLAR WATER HEATERS TECHNICAL DOCUMENTATION PAGE 20 Figure 4 Front view of installed 300 4 2 system Figure 5 Rear view of installed 300 4 2 system...

Page 22: ...eeded on the vertical load bearing beams with appropriate screws as shown on the drawing above Make sure that the distances A and B between any of the top holes on each bracket are set according to Ta...

Page 23: ...ATERS TECHNICAL DOCUMENTATION PAGE 22 STEP 2 Replace the roof tiles and install the two longitudinal base sections onto the AGG brackets Make use of the telescopic feature of the sections to adjust th...

Page 24: ...WATER HEATERS TECHNICAL DOCUMENTATION PAGE 23 STEP 3 Install the transverse beam joining the two longitudinal sections STEP 4 Install the two support struts joining the transverse beam with the two l...

Page 25: ...ical mounting faces of two beams should be set according to Table 2 to fit the height of the collector Secure only the bottom beam and slide the top beam upwards to ease collector installation TABLE 2...

Page 26: ...5 STEP 6 Place the collector s on the base assembly Tighten the bottom securing bolts against the bottom support beam STEP 7 Slide the top support beam against the collector and tighten the support bo...

Page 27: ...THERMOSIPHONIC SOLAR WATER HEATERS TECHNICAL DOCUMENTATION PAGE 26 STEP 8 Adjust the tank support to a horizontal position and install the tank Figure 1 Components of the inclined roof base system...

Page 28: ...44 200 2 1 1370 2120 1711 200 2 6 1370 2475 2025 200 2 6H 1370 1765 1244 200 3 1370 2475 2011 300 3H 1834 2120 1514 300 4 2 1834 2120 1711 SYSTEM BASE DIMENSIONS L1 L2 L3 L4 125 2 1 1116 1600 866 1240...

Page 29: ...may start filling the tank at this point When water starts overflowing from the hot water open circuit outlet close the water supply STEP 2 Connect the hot water closed circuit tube between the colle...

Page 30: ...tube follows an upwards route towards the tank When tightening the fittings on the collector inlet make sure you use 2 spanners 1 for tightening and 1 against to avoid damaging the absorber Make sure...

Page 31: ...rflow through the outlet of the tank until no air bubbles come out and then attach and tighten the cold fluid union to the tank You may need to attach an auxiliary tube to the cold water closed circui...

Page 32: ...ank as it heats up If there is no overflow check that 1 The closed circuit is filled 2 There is no air in the closed circuit 3 There are no leaks in the closed circuit connections Take the appropriate...

Page 33: ...THERMOSIPHONIC SOLAR WATER HEATERS TECHNICAL DOCUMENTATION PAGE 32 STEP 9 After approximately 20 minutes you may install the closed circuit safety valve at the top of the tank...

Page 34: ...should be installed as shown in the drawing above The smaller hole is for the overflow of any water leaking into the electrics cavity and should be placed at the lowest point of the cover The electri...

Page 35: ...ect or North for the South hemisphere 2 The collector is at the appropriate angle free of shadow and obstacles 3 All the connections are tight with no leaks 4 The tubes of the closed circuit have the...

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