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Prisma 2.0 Technical Documentation Manual
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Prisma 2.0 Technical Documentation Manual

Thermosiphonic solar water heaters
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TECHNICAL DOCUMENTATION
THERMOSIPHONIC SOLAR
WATER HEATERS
Thank you for placing your trust in our products. Our 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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Summary of Contents for Prisma 2.0

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

  • 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 [Single collector systems] PAGE 8 V. INSTALLATION OF SYSTEM ON A FLAT ROOF [Twin collector systems] PAGE 16 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 Collector Tank Support Base System Thermal fluid (propylene glycol) 1 pressure relief valve for the closed circuit 1 safety valve for the domestic cold water line Insulated connecting pipes Pipe fittings SYSTEM IDENTIFICATION The tank and the collector/s which form a solar system are appropriately marked with metalized item plates.
  • Page 5 II) TECHNICAL CHARACTERISTICS Technical data PRISMA flat plate selective collectors Type Prisma 2.0 Prisma 2.5 Gross area (m²) 2.00 m 2.50 m Absorber area (m²) 1.90 m 2.37 m Aperture area (m²) 1.91 m 2.39 m W x L x H (mm)
  • Page 6 Collector Aluminum flat plate selective absorber   Ultrasonic welded on copper harp Rock wool insulation  Single piece pre-painted zinc coated alloy-steel (ArcelorMittal) casing  Colofast ® by BASF® reinforced collector body corners  Low iron tempered glass  Tank Enameled tank according to DIN 4753/3 ...
  • Page 7 Model 160/2 160/2.5 200/2.5 200/ 4 300/ 4 300/ 5 Width (mm) 1314 1314 1680 2594 2594 2594 Α Dimensions Length (mm) [45 degree 1624 1903 1903 1624 1624 1903 Β inclination] Height (mm) 1731 2010 2010 1731 1731 2010 System weight empty (kg) 87.15 93.4...

  • 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 IV) INSTALLATION OF SYSTEM ON A FLAT ROOF [All single collector models] The Prisma base system has been pre-assembled so as to maximise ease of use and safety. Check that the subassemblies are as shown in the figures below and make sure that you use the correct subassembly for each step.
  • Page 10 STEP 1 Identify the area where the system will be installed according to the guidelines in page 7. Identify South and install the two pillars as shown above. In the southern hemisphere point to the North. The distance between the two holes should be 1090 mm. Make sure that the two pillars are parallel and alighned.
  • Page 11 STEP 2 Carefully place the collector glass-down on a soft, flat surface such as packaging cardboard. Install the diagonals on the collector noting the orientation. Ensure that the rails are parallel and tighten the 4 collector bolts ensuring that you do not strip the threaded rivets from the collector shell.
  • Page 12 STEP 4 Lift the collector and drill holes on the roof surface. Install the appropriate anchors [not included, shown in gray]. Seal the floor so that moisture does not enter the roof material. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / JANUARY 2021 PAGE...
  • Page 13 STEP 4 Install the X-system at the back of the pillars in the following sequence: Remove bolt [1] and connect the lower end of the X brace beam as shown. Make sure of the orientation of the beam: the convex side should face the front of the system. Replace bolt [1] but do not fully tighten it.
  • Page 14 STEP 5 Remove tank securing bolts and washers and lower the tank in a controlled manner onto the pillars. Ensure that the coach bolts are properly seated into the slots. Install washers and tank securing nuts. Ensure that the pillars are vertical and that the tank is properly seated and tighten both tank securing nuts.
  • Page 15 TABLE 1 INSTALLATION DIMENSIONS DIMENSION 160/2 160/2.5 200/2.5 200/4 300/4 300/5 1090 1090 1090 1090 1090 1090 1135 1135 1135 1135 1135 1135 1296 1575 1575 1296 1296 1575 THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / JANUARY 2021 PAGE...
  • Page 16 V) INSTALLATION OF SYSTEM ON A FLAT ROOF [TWIN COLLECTOR MODELS] Follow step 1[p. 9] to install the two pillar assemblies. STEP 2 Assemble the diagonals on the pillars. Ensure diagonals are parallel and in line with the pillars. Ensure that the hole to hole distance is 1135 mm, install appropriate anchors and seal.
  • Page 17 Make sure that the coach bolts are properly seated, that the rails are perpendicular to the diagonals and that the base is aligned and tighten the nuts. STEP 4 Install the first collector on the rails. Use 4 collector spacers between the collector and the rail and install the hydraulic fittings. Center the fitting with respect to the rail and tighten the bolts taking care not to strip the thread.
  • Page 18 STEP 6 Slide the second collector towards the first so that the tubes are inserted into the connection fitting. [1] Tigthen the fitting. [2] Install and tightenthe second collector securing bolts. Assemble the X-system according to STEP 4 in page 12. Install the tank according to STEP 5 in page 13.

  • Page 19: 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 20 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 / JANUARY 2021 PAGE...
  • Page 21 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 / JANUARY 2021 PAGE...
  • Page 22 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 3 to fit the height of the collector. Secure only the bottom beam and slide the top beam upwards to ease collector installation. TABLE 3 DIMENSION 160/2...
  • Page 23 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 / JANUARY 2021 PAGE...
  • Page 24 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 / JANUARY 2021 PAGE...
  • Page 25 Figure 2: Installation and base system dimensions. See Table 4 for values. TABLE 4 DIMENSION 160/2 160/2.5 200/2.5 200/4 300/4 300/5 1090 1090 1090 1090 1090 1090 2000 2400 2400 2000 2000 2400 1600 1994 1994 1600 1600 1994 THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / JANUARY 2021 PAGE...

  • Page 26: Hydraulic Connection Of System [All Systems]

    VII) HYDRAULIC CONNECTION OF SYSTEM [All systems] Figure 3: Schematic of complete system. [1] Domestic cold water supply according to DIN EN 806 or to country-specific regulations. [2] Water filter. [3] Pressure reduction valve MAX 10 bar. [4] Cut off valve.
  • Page 27 Figure 5: Thermosiphonic connection sizes. Figure 6: Thermosiphonic connection sizes. System shown is not Prisma, however the connection are identical. THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / JANUARY 2021 PAGE...
  • Page 28 NOTE: System shown is not Prisma, however the procedure is identical. 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 29 STEP 3 Connect the cold closed circuit tube between the collector and the tank M-L. Ensure that the tube follows an upwards route towards the tank. ATTENTION: 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 30 STEP 5 Detach the cold 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.
  • Page 31 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 32 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 / JANUARY 2021 PAGE...
  • Page 33 TABLE 5 CHECKLIST BEFORE START - UP NUMBER ACTION YES NO Is the thermosiphonic system facing South for the North hemisphere and North for the South hemisphere? Did you check that the thermosiphonic system is not located in the shadow throughout the whole year? Was the collector installed with an installation angle between 15º...

  • 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 IX) INSTALLATION OF COLLECTOR ARRAYS UP TO 20m² DN 20 mm [3/4”] DN 25 mm [1”] THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / JANUARY 2021 PAGE...

  • Page 36: Function And Maintenance

    X) FUNCTION AND MAINTENANCE In order to protect the system from overheating, during high irradiation periods, it is highly recommended to install a T-P valve at the domestic hot water outlet, allowing the direct evacuation of the overheated sanitary water to the sewerage system. This T-P valve shall be set up to 60 °C. Otherwise cover the surface of the collector partially when there is low consumption or fully when there is no consumption at all (long period of absence).

This manual is also suitable for:

2.5160/2160/2.5200/2.5200/4300/4 ... Show all