Apricus AP series Installation & Operation Manual Download

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AP Solar Collector

Installation & Operation Manual

International Edition - V16 - May 2013

Delivering Sustainable Hot Water Solutions

Summary of Contents for AP series

Page 1: ...AP Solar Collector Installation Operation Manual International Edition V16 May 2013 Delivering Sustainable Hot Water Solutions ...

Page 2: ...or Mounting 9 4 1 Frame Material 9 4 2 Frame Track Leg Spacing 9 4 3 Frame Component Diagrams 9 4 3 Galvanic Reaction 15 4 4 Installation Planning 15 4 5 Frame Assembly Process 15 4 6 Manifold and Bottom Track Attachment 15 4 6 Angled Frame Kits 15 4 7 Roof Attachment Strength 16 4 8 Wall Mounting 16 5 Piping Connection 16 5 1 Collector Connection to Plumbing 16 5 2 Temperature Sensors 16 5 3 Pipe...

Page 3: ...80 2005mm 80 2005mm 80 Overall Height 136mm 5 35 manifold only 154mm 6 06 manifold standard frame 136mm 5 35 manifold only 154mm 6 06 manifold standard frame 136mm 5 35 manifold only 154mm 6 06 manifold standard frame 136mm 5 35 manifold only 154mm 6 06 manifold standard frame 136mm 5 35 manifold only 154mm 6 06 manifold standard frame Overall Width 2 796mm 31 3 1356mm 53 4 1496mm 58 8 1636mm 64 4...

Page 4: ...ould be handled with care when transporting to avoid breakage a If standing boxes on end adhere to the direction arrows b If lying boxes down ensure the surface is flat c Adhere to the markings on the number of boxes that may be stacked d Do not stack any heavy or sharp objects on top of the boxes e Always secure boxes in place to avoid bouncing or sliding around during transport 2 2 Component Lis...

Page 5: ...e collector should face the equator which if in the northern hemisphere is due South and southern hemisphere is due North b The collector will still work even facing at angles East or West of the equator direction but a reduction in output will result depending on location and system configuration The diagram to the right provides a rough guide 3 3 Installation Angle a For optimal annual solar out...

Page 6: ...sed every 3 collectors e As many as 10 x AP 30 solar collectors may be connected in series as long as flexible connectors are used and maximum flowrate limit is adhered to as outlined above g Apricus does not warrant the collector against damage resulting from poorly managed header expansion and contraction 3 9 Heat Transfer Fluids a In regions where freeze protection is not a concern water is the...

Page 7: ... as high temperature may damage the valve and scale formation can rapidly block the vent hole The pressure and temperature relief valve on the tank may open to release pressure or heat as required Under such conditions the collector manifold will normally reach a maximum temperature of approximately 160oC 320oF Any heat returning from the collector is generally not enough to cause a continued incr...

Page 8: ... speed corresponds to the mid range of Category 2 cyclones US Saffir Simpson Scale For higher wind speeds additional frame components lower installation angle and reinforcement of roof attachment may be required Collector mounting in high wind regions 208km h 130mph should be reviewed and where required approved in writing by a qualified engineer c Refer to section 4 for specific roof attachment d...

Page 9: ...me materials as follows Stainless Steel Suitable for most applications Anodised Aluminium Stronger and more corrosion resistant than stainless steel these frames are suitable for high wind regions or environments that stainless steel is susceptible to tea staining discolouration surface corrosion 4 2 Frame Track Leg Spacing Collector S W 10 tubes 490mm 796mm 18 tubes 1050mm 1356mm 20 tubes 1190mm ...

Page 10: ...f Rail FR AL RR attachment option Round Foot FR SS RF attachment option Rubber Pad FR SRPAD or FR TRPAD attachment option Horizontal Brace FR SS HB Roof Strap FR SS ST __ attachment option U Foot FR SS UF attachment option Round Foot FR SS RF attachment option Roof Rail FR AL RR attachment option Roof Track FR AL RT attachment option U Foot FR SS UF attachment option X Brace FR AL XB 30T Rear Leg ...

Page 11: ...ail FR AL RR attachment option U Foot FR SS UF attachment option X Brace FR AL XB 30T Rear Leg FR AL RL __ 30D or 45D AL Standard Frame 30 tube Bottom Track FR AL BT 30T Front Track FR AL FT Roof Rail FR AL RR attachment option U Foot FR SS UF attachment option Tube Clips FR SS TC AL BT Rubber Pad FR SRPAD or FR TRPAD attachment option Roof Strap FR SS ST __ attachment option ...

Page 12: ...ttachment Ideal for commercial projects where multiple collector are installed in series Name XL Roof Rail Connector Part FR SS XLRR CON Notes Connects XL Roof Rails end to end Comes with 4 x FR BOLT M8x20 SPW NL fasteners Use FR SS XLRRCON to connect rails end to end Name AL Rear Leg 30 or 45o Part FR AL RL XX XX 30D or 45D Notes Rear leg for aluminium angled frame kits supplied with attachment p...

Page 13: ... are used All fasteners shown are included Rails and tracks are not included a b c Name Round Foot Part FR SS RF M8x50 Notes Large surface area with two holes for roof attachment Requires matching spacing of roof attachment points Comes with M8x50 Bolt for attachment to frame Tracks or Rails Name Roof Strap Part FR SS RS XX XX 60 or 100 indicating the length in cm Notes Suitable for used on flush ...

Page 14: ...0o Angle Frame Kit APFR KIT SS __ 10D __T 10o Rear Leg FR SS RL 10D 2 2 2 3 3 SS 10o Angle Frame Kit APFR KIT SS __ 10D __T 10o X Brace FR SS XB 10D __T 1 1 1 1 1 SS 30o Angle Frame Kit APFR KIT SS __ 30D __T 30o Rear Leg FR SS RL 30D 2 2 2 3 3 SS 30o Angle Frame Kit APFR KIT SS __ 30D __T X Brace FR SS XB __T 1 1 1 1 1 SS 30 60o Adj Angle Frame Kit APFR KIT SS __ 30 60D __T 30 60o Rear Legs FR SS...

Page 15: ...use WD 40 or similar lubricant or anti gall powder grease c Do NOT over tighten stainless steel bolts Spring washers are provided on each bolt assembly to ensure they do not loosen over time 4 6 Manifold and Bottom Track Attachment a Both the manifold and frame bottom track are secured to the frame front tracks using special attachment plates These plates are already attached to the front tracks w...

Page 16: ... of to be installed below the collector to catch any such falling materials 5 Piping Connection 5 1 Collector Connection to Plumbing a Once the frame has been mounted and the manifold attached the manifold header may be connected to the system plumbing The plumbing connection must be completed before evacuated tubes are installed a Two header configuration are produced by Apricus but only one will...

Page 17: ...ine after the air vent with a ball valve allowing the mains pressure water to purge the collector of air Always remove or isolate the air vent after the air purge c Low Pressure Direct Flow Open Loop Run the pump at the highest speed settings forcing air out of the manifold and back into the tank If an auto air vent is installed on the outlet of the collector air will be automatically eliminated f...

Page 18: ...be cavitation air bubbles forming due to installation issues Pump may not have sufficient head pressure e Always use hot water rated pumps up to 110oC 232oF f Always install the pump on the flow line tank collector The pump should have an integrated non return valve or brass non return installed after the pump to prevent reverse flow of high temperature liquid which could damage the pump g Pressur...

Page 19: ...f the heat pipes where is needs to be all boxes of tubes or individual tubes need to be turned up side down and then returned to the upright orientation In addition before installing the tube and heat pipe they should be shaken up and down a couple of times heat pipe at top to ensure the powder has all returned to the bottom 6 2 Tube Heat Pipe Insertion a The heat pipe should still be pulled out o...

Page 20: ...tly in the bottom track g As each tube is inserted or alternatively once all tubes have been inserted secure the tubes to the bottom track using the stainless steel clips as follows STEP 1 Line up the clip with the hook on the bottom track and push down on one side until a click sound is heard STEP 2 While ensuring the clip is centered of the rubber cap push down the other side of the clip until i...

Page 21: ... are well insulated right to the manifold casing Y N 8 Sensor cable is not in contact with any metal objects is secured in place and protected from direct sunlight Y N 9 Insulation above roof level is protected against sunlight with aluminium foil wrap or equivalent Y N 10 Controller is configured correctly with freeze setting on if required Y N 11 System is fitted with pressure relief valve on th...

Page 22: ...components for more information The following maintenance may ONLY be completed by AUTHORISED PERSONS 8 3 Broken Tube Replacement a If a tube is broken it should be replaced as soon as possible to maintain maximum collector performance b The system will still operate normally and safely even with a tube broken c Any broken glass should be cleared away to prevent injury d To replace a tube follow t...

Page 23: ...tion valves in the off position while the collector is full of water and exposed to sunlight as the water will heat cause a pressure increase which may rupture fittings connections In good weather the water may be hot or have built up pressure so take care when opening the drain valve STEP 3 Allow the manifold to sit in a vented state for 5 10min to allow the manifold to boil dry may need longer i...

Page 24: ...mp running at night Bottom tank sensor not getting accurate reading Check operation of sensor Should be getting accurate reading of low tank temperature Ideal position of low tank sensor is ABOVE level of solar flow tank to solar port Fluid dumping from pressure relief valve on pump station Faulty pressure relief valve CL Replace pressure relief valve Fluid dumping from pressure relief valve on pu...

Page 25: ...RIC Electric not heating water Check operation and power supply to element May be on timer Check if element is on off peak power supply Any changes H Replace element if faulty Check controller boost settings if controller managed H Not enough hot water IF BOILER or GAS TANKLESS Booster not heating water Check gas fuel supply H Check operation of boiler heater Check controller boost settings H Chec...

Page 26: ...against Apricus until your claim has been submitted to Mediation for an informal dispute settlement and a decision has been reached LIMIT OF LIABILITY EXCEPT FOR THE EXPRESS LIMITED WARRANTY PROVIDED FOR HEREIN APRICUS HEREBY DISCLAIMS AND EXCLUDES ANY AND ALL OTHER WRITTEN OR ORAL EXPRESS WARRANTIES OR R E P R E S E N TAT I O N S A N Y I M P L I E D W A R R A N T Y O F MERCHANTABILITY OR IMPLIED ...

Page 27: ...aller s Name Installation Company Name Installation Company Ph Product Serial Number s Comments Signed by Installation Oﬃcer Signed by Customer IMPORTANT NOTES 1 Please only sign if you are happy with the service provided by the Installation Officer and the system is working properly 2 Keep this document as a record of the installation as it will be required in the case of any warranty claims Apri...

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