Related Manuals for CALPAK MARK5
Summary of Contents for CALPAK MARK5
- Page 1 TECHNICAL DOCUMENTATION THERMOSIPHONIC SOLAR WATER HEATERS MARK5 & SOLAR THERMAL COLLECTORS M5...
-
Page 2: Table Of Contents
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. -
Page 3: I) Introduction
EN 60335-1 and EN 60335-2-21. THERMAL FLUID Calpak fluid is a propylene glycol-based thermal fluid, non-toxic to the skin. It must be used diluted in water to provide anti-freezing and anti-corrosive properties. The advisable percentage is 33% of water THERMOSIPHONIC SOLAR WATER HEATERS &... -
Page 4: Permissible Snow Load And Mean Wind Velocity
volume. In case of very low environmental temperatures, increase the volume percentage according to the following table: Temperature (ºC) Percentage in water solution PERMISSIBLE SNOW LOAD AND MEAN WIND VELOCITY The collectors are tested according to the standards EN 12975-2. Through these tests, it is admitted that they can resist without any failure to a mechanical load up to 3000 Pa. -
Page 5: Ii) Technical Characteristics
TECHNICAL CHARACTERISTICS Technical data M5 flat plate selective collectors Type M5-210 M5-260 M5-260H M5-300 M5-300H 2.09 m 2.60 m 2.60 m 3.00 m 3.00 m Gross area (m²) Absorber area 1.99 m 2.48 m 2.48 m 2.84 m 2.84 m (m²) Aperture area (m²) 1.96 m... - Page 6 Collector • Aluminum flat plate selective absorber • Laser welded on copper harp • Rock wool insulation • Aluminium profile frame • Low iron tempered glass Tank • Enameled tank according to DIN 4753/3 • Insulation with expanded polyurethane, 50mm thick •...
- Page 7 Μ5 Μ5 Μ5 Μ5 Μ5 Μ5 Μ5 Μ5 Μ5 Model 125/ 160/ 160/ 160/ 200/ 200/ 200/ 200/ 300/ 300/ 2.6Η 2.6H Length 1230 1230 1230 2111 1520 1520 2111 1520 1996 1996 (mm) Α Dimensions [45/30 Depth 1684/ 1684/ 1973/ 1324/ 1684/...
- Page 8 M5 300/ M5 300/ Μ5 200/ Μ5 300/ Model Length (mm) Α 2553 2553 2553 3093 1684/ 1684/19 1973/22 1867/ Dimensions [45/30 Depth (mm) Β 1978 2152 degree inclination] 1700/ 1700/13 1989/15 1904/14 Height (mm) Γ 1326 178.4 System weight empty (kg) System weight full (kg) 337.2 463.2...
-
Page 9: Iii) Positioning Of The System
III) 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... -
Page 10: Iv) Installation Of System On A Flat Roof [Single Collector Models]
INSTALLATION OF SYSTEM ON A FLAT ROOF [Single Collector Models] 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 11 Attention! In the event that it is not possible to fix the system on the roof, it is mandatory to use the plus model supports for the system to maintain its structural robustness. In that case, switch the steps of the model with the ones on page 24. STEP 2 Attach the two feet at the lower part of the collector.
- Page 12 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. 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.
- Page 13 Β STEP 6 Ensure that the distance B between the centers 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 14 STEP 8 Using the holes in the collector's 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's feet are secured onto the structural layer of the roof and not on the insulation.
- Page 15 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 16 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 & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 15...
- Page 17 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 & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 16...
- Page 18 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 19 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. Attention! After finishing with STEP 16 tighten the nuts carefully THERMOSIPHONIC SOLAR WATER HEATERS &...
-
Page 20: V) Installation Of The Double System
V) INSTALLATION OF THE DOUBLE SYSTEM THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 19... - Page 21 STEP 1 Determine the position of the system according to the guidelines in the manual and install the two pillars and the V strut system as shown above. Attention! The factory-provided anchoring fasteners are appropriate for the majority of flat roof floors consisting of structural concrete protected with a thin coat of sealer.
- Page 22 STEP 2 Set the height H of the rear middle foot so that the distance between the tank holes is the specified one. Ensure that the pillars are vertical and tighten all nuts and bolts. STEP 3 Join the two collectors as shown in the figure to form a solid assembly. THERMOSIPHONIC SOLAR WATER HEATERS &...
- Page 23 Attention! Do not remove collector covers. Attention! Use two opposing spanners to tighten the hydraulic fittings between the collectors to avoid damage to the absorbers. STEP 4 Place the collector assembly in front of the erect pillars. Rotate the assembly in a controlled manner and bring it in position.
- Page 24 Attention! : Observe the points raised in STEP 1 STEP 6 Install the middle strut between the rear middle foot and the top middle collector connector as shown in the figure. Ensure no free play is present and tighten the bolts. STEP 7 Install the bottom hydraulic fittings on the tank and remove the retaining nuts.
-
Page 25: V) Plus Models Installation
⚠ Caution! 3 people are required for this procedure. PLUS MODELS INSTALLATION In the event that it is considered impossible to fix the system on a roof, to maintain its robustness of the system, the corresponding Plus Model should be obtained. This compaction of the 5 points should be done on concrete blocks or iron beams. - Page 26 M30 – ALU 160-2.1 M45 – ALU 200-2.1 200-2.1 M30 – ALU 200-2.1 M45 – ALU 160-2.6 160-2.6 M30 – ALU 160-2.6 M45 – ALU 200-2.6 200-2.6 M30 – ALU 200-2.6 M45 – ALU 200-4.2 200-4.2 M30 – ALU 200-4.2 M45 –...
-
Page 27: Vi) Installation Of System On Inclined Roof [All Systems]
Follow the installation steps (STEP 2-STEP 11) as in the normal (non-plus) system on page 10. After finishing the steps, place the bottom beams of the PLUS model as in the picture below. Follow the same procedure for the double system. 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. - Page 28 STEP 1 Uncover the roof tiles at the lowest and the highest part of the area where the thermosiphon system will be installed. Install the 4 AGG brackets (or the AT – triangular type or the AR – special screw, if needed) on the vertical, load-bearing beams with appropriate screws, as shown on the drawing above.
- Page 29 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 & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 28...
- Page 30 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 & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 29...
- Page 31 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 32 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 &...
- Page 33 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 & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 32...
-
Page 34: Installation Dimensions
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 35: Vii) Hydraulic Connection Of System [All Systems]
VII) HYDRAULIC CONNECTION OF SYSTEM [All systems] Figure 3: Schematic of the complete system. [1] Domestic cold-water supply according to DIN EN 806 or country-specific regulations. [2] Water filter. [3] Pressure reduction valve MAX 10 bar. [4] Cut off valve. [5] Nonreturn valve + 10 bar safety valve. [6] Cold/hot mixer for domestic hot water use, e.g. shower. - Page 36 Figure 5: Thermosiphonic connection sizes. Figure 6: Thermosiphonic connection sizes. The system shown is not MK5, however, the connections are identical. THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 35...
- Page 37 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 the circuit outlet and close the water supply. STEP 2 Connect the hot water closed circuit tube between the collector and the tank.
- Page 38 Do not tighten the tube on the tank side. STEP 4 Mix water and Calpak fluid in a bucket according to the table in Chapter 1. THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS...
- Page 39 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 40 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 41 After approximately 20 minutes you may install the expansion vessel at the top of the tank. Screw the expansion vessel on top of the tank. STEP 10 Screw the release valve on top of the expansion vessel. THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 40...
-
Page 42: Checklist Before Start - Up
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 43: Viii) Electrical Connections
VIII) ELECTRICAL CONNECTIONS The electrical connections must comply with 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 44 STEP 1 Place the collector on the roof floor and attach the collector feet to the collector as shown in the figure above. Tighten the bolts to prevent any free play while still allowing rotation of the collector. Attach the collector feet on the roof floor. Follow the instructions for positioning the system in Chapter III.
- Page 45 STEP 2 Use a small object to raise the top side of the collector from the floor just enough to be able to install the support strut feet at a distance A [mounting hole to mounting hole] according to Table 1. For best installation results the mating surfaces of the collector side and the support strut feet should be tangential as shown in the figure above.
- Page 46 STEP 3 Attach both support struts onto the support strut feet. Tighten the bolts until they are loose enough to allow rotation. STEP 4 Lift the collector from its top while raising one of the support struts. STEP 5 Connect the top end of the support strut with the bolt on the collector side. Do not tighten the bolt fully.
- Page 47 STEP 6 Connect the remaining support strut. Do not tighten the bolt fully. STEP 7 Ensure that the collector is set up to the appropriate angle. The collector support feet can be used as guides in setting the angle as they are cut at 45 degrees. The angle between the bolt, the bottom hole, and the horizontal is 30 degrees.
-
Page 48: Ix) Installation Of Collector Arrays On A Flat Roof
INSTALLATION OF COLLECTOR ARRAYS ON A FLAT ROOF STEP 1 Place the first collector on the roof floor and attach the collector foot on the collector on the end of the array as shown in the figure above. Tighten the bolt so as to prevent any free play while still allowing rotation of the collector. - Page 49 STEP 2 Follow Steps 2-7 of Chapter VII to connect the support struts to the collector and set it at the appropriate angle. Once the struts are secured secure the bottom brace to the floor. STEP 3 Attach the top brace at the top of the collector. THERMOSIPHONIC SOLAR WATER HEATERS &...
- Page 50 STEP 4 Install the next bottom brace at a distance equal to the width of the collector (1300mm, from hole to hole on the floor). Ensure that the two braces are in line. STEP 5 Place the next collector on the braces. Install the bolts and tighten them enough to prevent free play while allowing the collectors to slide towards each other.
- Page 51 STEP 6 Install the support strut. Before tightening the collector securing bolts ensure that the edge of the collector is set at the appropriate angle. STEP 7 Attach the top brace at the top of the collector. THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 50...
- Page 52 STEP 8 Continue with the installation of the remaining required collectors following steps 4-7. The last collector of the array should have a foot already attached before installation onto the braces. Tighten the securing bolts on the braces first and then attach the collector foot to the floor. STEP 9 Install the last support strut.
-
Page 53: Installation Of Collector Arrays Up To 20M²
INSTALLATION OF COLLECTOR ARRAYS UP TO 20m² DN 32 mm [1 1/4”] HOT WATER OUTLET DN 32 mm [1 1/4”] DN 25 mm [1”] DN 25 mm [1”] INLET OF COLD WATER DN 20 mm [3/4”] DN 25 mm [1”] THERMOSIPHONIC SOLAR WATER HEATERS &... -
Page 54: Xi) Installation Of Stand Alone Collector On Inclined Roof
INSTALLATION OF STAND ALONE COLLECTOR ON INCLINED ROOF 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. PICTURE 1 PICTURE 2 PICTURE 3 STEP 1 Uncover the roof tiles at the lowest and the highest part of the area where the thermosiphonic system will be installed. - Page 55 TABLE 1 M5-210 M5-260 M5-260H M5-300 M5-300H COLLECTOR (S) M5-210 M5-260 DIMENSION A 1160 1160 [MM] DIMENSION B 1930 2050 1930 2050 1700 2050 1770 [MM] Note: The dimension B may be extended up to 700 mm so that the AGG enter the finishing tiles. STEP 2 Replace the roof tiles and install the two longitudinal base sections onto the AGG brackets.
- Page 56 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 M5-210 M5-260...
- Page 57 STEP 5 Slide the top support beam against the collector and tighten the support bolts. Tighten the support beam onto the longitudinal base sections. Figure 1: Components of the inclined roof base system. THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS TECHNICAL DOCUMENTATION / PAGE 56...
-
Page 58: Xii) Function And Maintenance
Figure 2: Installation and base system dimensions. M5-210 M5-260 M5-260H M5-300 M5-300H COLLECTOR (S) M5-210 M5-260 DIMENSION A [MM] 1160 1160 DIMENSION B [MM] 1930 2050 1700 2050 1770 1930 2050 DIMENSION C [MM] 1711 2121 1244 2011 1514 1711 2121 COLLECTOR(S) M5 210... -
Page 59: Xiii) Decomμissioning
50% of its initial state. Otherwise must be replaced. 2. If the closed circuit of the tank needs to be filled with Calpak Fluid (see page 1 for correct proportion) to ensure both the corrosion and antifreeze protection of the tank as well as the good performance of the heat exchanger.
Need help?
Do you have a question about the MARK5 and is the answer not in the manual?
Questions and answers