CALPAK MARK4 Technical Documentation Manual
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CALPAK MARK4 Technical Documentation Manual

Thermosiphonic solar water heaters
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TECHNICAL DOCUMENTATION
THERMOSIPHONIC SOLAR WATER HEATERS Mark4
Thank you for placing your trust in our products. Calpak 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 our products or this manual you may contact
one of our dealers, visit our website www.calpak.gr or contact us directly.

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  • Page 1 TECHNICAL DOCUMENTATION THERMOSIPHONIC SOLAR WATER HEATERS Mark4 Thank you for placing your trust in our products. Calpak 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.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 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.

  • Page 3: Introduction

    INTRODUCTION SAFETY MEASURES Always use certified installation tools and full protection devices.  In case you need to work near electrical wires, turn the electricity off.  Always wear protective goggles, protective boots, gloves and masks in compliance with the ...
  • Page 4 SYSTEM COMPONENTS 1. Collector 2. Tank 3. Support Base System 4. Nox fluid (propylene glycol) 5. 1 pressure relief valve for the closed circuit 6. 1 safety 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 metalized item plates.

  • Page 5: Technical Characteristics

    II) TECHNICAL CHARACTERISTICS Technical M4 flat plate selective collectors data Type M4-200 M4-210 M4-260 M4-260H M4-300 M4-300H Gross area 2.04 m 2.13 m 2.64 m 2.64 m 3.00 m 3.00 m (m²) Absorber 1.83 m 1.92 m 2.40 m 2.40 m 2.80 m 2.80 m area (m²)
  • Page 6 Collector Aluminum multifin selective absorber  Ultrasonic 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 protection according to DIN 4753/6 ...
  • Page 7 Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 Model 125/ 160/ 160/ 160/ 200/ 200/ 200/ 200/ 200/ 200/ 300/ 300/ 2.6Η 2.6H Length 1244 1244 1244 2121 1520 1520 2121 1520 1996 2553 1996 2553 (mm) Α...

  • Page 8: Positioning Of The System

    IΙI) POSITIONING OF THE SYSTEM The installation area of the solar water heater must fulfill the following requirements: 1.1 The solar water heater must face the SOUTH (or NORTH in case the installation takes place in the South hemisphere), and it is strongly recommended to use a compass to ensure this. Deviations of up to 10-15does not affect substantially the system’s efficiency, but larger deviations may seriously affect the performance.

  • Page 9: Installation Of System On A Flat Roof [All Models Except 300/4.2]

    IV) INSTALLATION OF SYSTEM ON A FLAT ROOF [All models except 300/4.2] SOUTH STEP 1 Install the tank support pillars at a distance A according to Table A. To ease installation, drill the roof floor at an angle of approximately 10-15 degrees. Follow the instructions for positioning the system in Chapter III.
  • Page 10 STEP 2 Attach the two feet at the lower part of the collector. Consult the drawing above for their positioning 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 floor in front of the pillars as shown above.To ease next step slide the collector securing bolts so that they are approximately in line with the slots on the pillars.
  • Page 11 Upper right side of the collector Upper left side of the collector STEP 4 Lift 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 right side of the collector Upper left side of the collector STEP 5...
  • Page 12 Β STEP 6 Ensure that the distance B between the 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 them. TABLE Β...
  • Page 13 STEP 8 Using the holes in the collector feet as a guide, drill the roof floor and install the appropriate fasteners to secure them. Alternatively you can use 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.
  • Page 14 STEP 9 Place 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. Rotate the tank so that the tank securing bolts are inserted into the pillar slots.
  • Page 15 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 bolts. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 14...
  • Page 16 STEP 12 Connect the brace system with the pillars. Do not tighten the bolts, ensure however that they are not very loose. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 15...
  • Page 17 STEP 13 Using the hole of the brace foot as a guide drill the roof floor and install the securing bolt of the brace foot by tightening 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.
  • Page 18 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 loose on the base system. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 17...

  • Page 19: Installation Of System On A Flat Roof [300/4.2 Model]

    V) INSTALLATION OF SYSTEM ON A FLAT ROOF [300/4.2 model] The procedure for installing 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 for installation with top and bottom braces and collector feet installed.
  • Page 20 Figure 3.Bottom Brace Follow Step 1 of Chapter IV to install the tank support pillars to the correct orientation and distance for the 300L tank. Place the two collectors side by side on the roof floor. IMPORTANT: DO NOT REMOVE COLLECTOR COVER SHEET BEFORE CONNECTING THE SYSTEM! Install the top and bottom braces between the collectors.
  • Page 21 Figure 4. Front view of installed 300/4.2 system. Figure 5.Rear view of installed 300/4.2 system. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 20...

  • Page 22: Installation Of System On Inclined Roof [All Systems]

    VI) INSTALLATION OF SYSTEM ON INCLINED ROOF [All systems] CAUTION: Check the capacity of the roof structure to bear the solar heater load in operation with the constructor of the building or contact the local authorities. STEP 1 Uncover the roof tiles at the lowest and the highest part of the area where the thermosiphonic system will be installed.
  • Page 23 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 them to the appropriate length. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 22...
  • Page 24 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 longitudinal sections. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 23...
  • Page 25 STEP 5 Install the two L beams supporting the collector. The distance C between the vertical 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 SYSTEM 125/2.1...
  • Page 26 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 bolts. Tighten the support beam onto the longitudinal base sections. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 25...
  • Page 27 STEP 8 Adjust the tank support to a horizontal position and install the tank. Figure 1: Components of the inclined roof base system. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 26...
  • Page 28 Figure 2: Installation and base system dimensions. INSTALLATION DIMENSIONS / SYSTEM 125/2,1 1082 2120 1711 160/2,1 1082 2120 1711 160/2,6 1082 2475 2025 160/2,6H 1082 1765 1244 200/2,1 1370 2120 1711 200/2,6 1370 2475 2025 200/2,6H 1370 1765 1244 200/3 1370 2475 2011...

  • Page 29: Hydraulic Connection Of System [All Systems]

    VII) HYDRAULIC CONNECTION OF SYSTEM [All systems] STEP 1 Connect the cold water supply tube and the safety and non return valve onto the tank. To save time you may start filling the tank at this point. When water starts overflowing from the hot water open circuit outlet close the water supply.
  • Page 30 STEP 3 Connect the cold water closed circuit tube between the collector and the tank. Ensure that the 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 the length and shape of the tube is appropriate.
  • Page 31 STEP 5 Detach the cold water closed circuit tube from the tank. Pour the solution slowly into the tube in order to fill the collector. Let the liquid overflow 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 circuit tube so as to pour the solution from a point higher than the closed circuit hot water inlet of the tank.
  • Page 32 STEP 7 Assuming the tank is filled with water and the closed circuit is filled with solution you may remove the cover sheet from the collector at this point. If it is a sunny day the solution will start overflowing from the safety valve outlet at the top of the tank as it heats up.
  • Page 33 STEP 9 After approximately 20 minutes you may install the closed circuit safety valve at the top of the tank. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 32...

  • Page 34: Electrical Connections

    VIII) ELECTRICAL CONNECTIONS The electrical connections must be in compliance to the regulations applied in the country of installation and must always be realized by a certified electrician. Below is a diagram of how the power supply is connected to the heating element through the thermostat. ELECTRICAL CABLE HOLE...

  • Page 35: Function And Maintenance

    (long period of absence). For this purpose choose the specialized covers for Calpak M4 collectors. It is also possible to install an expansion vessel at the upper part of the tank, which will store the liquid of the closed circuit when expanding and prevent it from spreading in the atmosphere.

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