ACAPELLA - jouleuk.co.uk · ACAPELLA installation manual 3 Table of Contents: 04 Introduction 05...

1ACAPELLA installation manual

ACAPELLAjoule acapella solar tubes installation manual


Table of Contents:

04 Introduction05 Site survey06 Risk assessment08 Kit components09 Mounting Options10 Important Pre Installation Information11 Roof Mounting Options12 Collector Assembly13 Inserting Tubes14 Sloped Roof Bolt Mounting Kit15 Sloped Roof Tile Mounting Bracket16 Sloped Roof Slate Mounting Bracket17 Flat Roof Mounting Frame18 Collecting Flow and Return Pipework19 Stainless Steel Solar Pipe20 Pump Station21 Safety Vessel Connection22 Electrical Solar Controller23 Standard Solar System24 East/West Solar System25 Dual Store Solar System26 Commissioning28 Servicing and Maintenance


4

Introduction

Solar hot water systems should be designed and sized correctly before commencing the installation. Proper design will ensure that a system is correctly sized to provide many years of optimised performance and most or all of the required hot water when the most solar radiation is available. However a supplementary heating system such as oil or gas boiler, heat pump or wood boiler is required for months which have less solar radiation. This guide will illustrate and explain how a system should be installed to conform to the Joule manufacturer guidelines for the Acapella product models. Us-ing this guide Stages of a solar installation are described in the following pages, with illustrations where necessary to explain how to install the relevant components, and contains general recommendations and important safety information.

Handling Guidance • Tubeandmanifoldboxesshouldbetransportedhorizontally.• Heavygoodsshouldnotbeloadedontopofthekitboxes.• Careshouldbetakenwhenopeningboxestopreventscratchesorsuddenshocks

to the glass.• Donotusesharpobjectstoopenthetubeboxes.

Installation Guidance• Unpackandinstalltubesonlyafterthemanifoldandpipeworkhasbeeninstalled.• Donotleavethesolarcollectorexposedtosolarradiationwhenthesolarloopand

manifoldhavebeendrained.Collectorsleftexposedinadrystatemustbecov-ered to prevent possible long term damage.

• Tubesmusthaveaminimumelevationof20˚andamaximumof70˚.• Thepipeworkofthesolarcollectorloopistobeearthedandthecollectoristobe

lightening protected in accordance to local regulations.

A solar panel installation must be performed in accordance with all Health & Safety legislationandlocalbuilding/planningregulationsfortherelevantjurisdiction.Further-more,thenecessaryelectricalworkrequiredtoinstallcontrolequipmentshouldbeundertakenbyaqualifiedelectricalcontractor.

4


DegreeofOverShadingShadingwillreducetheoverallperformanceofasolarsystem.Duringtheplanningstageofasolarsystem.Con-sid-erationshouldbegiventothelocationofthecollectorswiththeaimofminimisingtheeffectsofshadingfromhigh buildings, trees, etc.

none / little / a lot

CollectorFixingSurface

Is there enough room for the solar panels to sit on the required roof? (yes/no)

Is there enough between gulleys (top, bottom and both sides) to prevent leafs and debris from gathering around the panels?

(yes/no)

OrientationofRoof&EstimatedTiltAngleofRoofforMountingSolarCollectors

WhatistheRooforientation(shouldbebetweenEastSE-WestSW)

Collectorshouldbefacingtheequator

Is an inclinded roof frame need to obtain required pitch? (yes/no)

Tocalculateoptimalangleoftiltmultiplelatitudex0.7fordomestichotwaterproductionBirr37.16°,Cork36.3°,Dublin53.43°

EstimatingHotWaterDemand&SizeofSystemRequired

No. of people using hot water in the house

Any other exceptional water loads in the dwelling

No. of People SolarCylinderSize SizeofFlatPanelSystem SizeofEvacuatedTube

2PanelSystem(4m2) 30TubeSystem(2.83m2) 1-2people 200litres

3PanelSystem(6m2) 40TubeSystem(3.77m2) 3-5people 300litres

LocationofSolarPumpStation&SolarController

Ensurethepumpstationislocatedinanareawhereitcanbeeasilyaccessedforservicing&main-tenance (Confirm)

Ensurethatthereisadequatespacebothleftandrightofpumpstationtoalloweasyaccesstoremovepumpin future.

Ensurethatthesolarcontrollerislocatedinanareathatiseasilyaccessiblefortheuser (Confirm)

Ensurethatthecontrollerismountedattheocrrctheightforeasyviewing. (Confirm)

ExistingPlumbingSystem

What type of plumbing system is in the dwelling (vented or un-vented)?

Is solid fuel incorporated into the plumbing system?

Isthereadequateaccesstoroutepipeworkfromsolarcollectorsdowntocylinderlocation? (yes/no)

Is there space in the hot press to locate solar pump station? (yes/no)

Site Survey


6

SafeRoofAccessToWork

Isthereadequateaccesstoareaofhousetomountscaffoldingorladders? (yes/no)

Istheresteadyandsecurebaseonwhichtomountscaffoldingorladders? (yes/no)

Arethescaffoldingandorladdersfitforuseintended? (yes/no)

Allinstallerstrainedinworkingatheights? (yes/no)

Areallharnessandothersafetyequipmentworkingcorrectly? (yes/no)

Allworkcarriedoutshouldbeinaccordancewithallrelevantgoodpraticesandorcurrentbuildingstand-ards.Allcurrentregulationsshouldbefollowedinrelationtoworkingatheights.Nothingstatedinthisguidetakespre-sedenceovercurrentstandards.

ConditionofRoof

Whatarethecentresofroofrafterswheresolarcollectoristobemounted(eg400mm)? (mm)

Whatisthesizeofroofrafters(eg6x2”,7x2”,8x2”)? (inch)

Are roof rafters cross braced? (yes/no)

Is any of the timber showing discolouration (indicating rot)? (yes/no)

To determine the total load on the roof you must get the total weight of the collectors and divide this weight bythenumberofrooffixingboltsoranchorsusedtoholdthecollectorontheroof.Thiswillgiveyoutheweight of the solar panels on each point of the roof. You must then carefully review the points where the col-lectorsareconnectedtotherooftoensurethattheseexactpointscantaketheanticipatedload.

Wherethereissignsofdiscolourationacloserexaminationwillberequried.Ifblackspotsarefoundonthetimberthis indicatesaleakwhichneedsattention.Ifthetimberappearsbrownandflakythenthetimbermay need to be replaced. If the situation is unclear a structural engineers report should be obtained prior to completinganyfurtherwork.

EffectsofSnowLoads

What is the estimated annual snow fall for this part of the country? (mm)

TheestimatedsnowloadforallpartsofirelandmaybefoundfromhistoricaldatalocatedonMetEireann’swebsite. www.met.ie

What is the total extra weight to be assumed from a snow fall? (kg)

Irishsnowweighsapprox150kgperm3.Todeterminetheextraweightthesnowwilladdtothesolarpanelsyou may assume the following formula. (snow fall in meters x area of panel on the roof in m2x150kg/m3)

Whenyoufindoutthetotalextraweightofthesnowaddittothetotalweightofthecollectorontheroof.The using this new weight examine the roof structure to ensure its suitability. You do not need to consider the snow load when installing evacuated tubes.

EffectsofWindLoad

The evacuated tube collector is exempt from consideration of wind loading for the same reason as the snow loading.Whenconsideringflatpanelswindtestshavebeenconductedthatensurethattheyandtheirfixingbracketscanwithstandallrecorded wind forces in Ireland when mounted on a four storey house or less.

Risk Assesment

6


Pipework&Liquids

Isantifreezebeingusedasthesolarsystemfluid? (confirm)

Ensuresolderjointsarenotusedthroughouttherentiresystem (confirm)

Ensurehightemperatureinsulationisusedthroughtallpipeworkinsolarsystem (confirm)

Ensurewhitepasteandhempisusedonallfittingconnectionsthroughout (confirm)

EnsureyouuseJoulecopperoverflowanddischargevesseltorecoverfluidfromsafetyvalve (confirm)

Water Quality

Water sample visually inspected and no signs of contamination visible (yes/no)

Wheninstallingthesolarsystemitisimportanttocheckthequalityoftheexistingincomingwatertothehotwatercylinder.Ifyouareindoubtastoitspurityasampleshouldbesentofftothedepartmentofhealthfor testing.

FireSafety

Ensurethatthereisnoobviousrisktofirepreventionbyinstallingthesolarsystem. (confirm)

Ensurethatallwiresarenotindirectconnectionwithanyun-insulatedpipeworkorplantthatcouldcauseariskofburning

(confirm)

Legionella / Bacterial Growth

Ensurethatthereisnodeadlegsintheexistingplumbingsystemthatcouldinducethegrowthoflegionella. (confirm)

Ensurethatthestatscontrollingtheboilerandthestatcontrollingtheimmersionaresetto60°Corabove. (confirm)

Ensurethattheclientunderstandstheriskoflegionellaandthestandardproceduresforreducingtheriskof it forming. Also ensure that the client understands that you are their to install a solar thermal system and

thatyoudonottakeanyresponsibilityforauditingtheirhotwatersystemforriskoflegionnellaforming.Thatyouwillendeavourtominimisetheriskofitformingbytheworkthatyoucarryoutbutanyexisting

riskshouldbedealtwithacertifiedprofessional.

(confirm)


8

Kit Components

Solar Pump SolarController SolarExpansionVessel

Standard Kit Components

Mounting Options

SolarTubes&Profiles

BoltMountingOption TileBracketOption SlateBracketOption

Roof Flashing Options

LeadRoofFlashing AluminiumRoofFlashing 4”RubberGasketSet

SolarFluid

8


Mounting Options

Piping Options

DN16DuoPipe DN20Pipe StainlessTails&Copper

Optional Accessories

InstallationHoseMountingSet OverVoltageLightning 3/4”ThermostaticMixingValve

CoolingVessel


DischargeVessel

10

Important Pre Installation Information

Sizing of safety equipmentComponentsizesarerelativetothevolumeofliquidinthesystem.

Pipe sizing(minimumof15mmdiameterpipeworkmustbeused)

CollectorArea (m2)

FlowRateltr/hr

PipeDiameterCopperExternal

(mm)

Acapella20Tube(mbar)



2 120 15 8.54 1.18 4.11

3 180 15 12.57 2.87 10.74

4 240 15 17.08 2.36 8.22

5 300 22 21.11 4.05 14.58

6 360 22 25.14 5.74 20.94

8 240 22 33.68 6.92 25.05

EXPANSIONVESSSELSIZING

Model CollectorArea(m2)

SystemVolume(ltrs)

Static Height VesselSize

Acapella20Tube 24

Acapella30Tube 24

Acapella40Tube 24

10


Roof Mounting options

TheAcapellaproduct range isavailablewithachoiceof rooffixingoptions tosuitmanyrooftypes,seediagrambelowforthemostcommonfixings.Themostcommonfixingsareillustratedandexplainedinthefollowingsectionandmaybeeasilysecuredtoslate,tileormasonryfinishes.

Metal Roof FixingsJoulealsosuppliesrooffixingkitsformetalandothercommercialroofs.Twooptionsavailable utilise appropriate clamps so the fabric of the metal roof is not penetrated - seepagexx.Notetheminimumandmaximumdistancesoneachfixingkit.

Option Code Describtion1a RF-PA-MT-BO-X Slopedroofboltkitoption

1b RF-PA-MT-SL-X Slopedroofslatemountingbracketoption

1c RF-PA-MT-TI-X Slopedrooftilemountingbracketoption

2 SOL-FRF-X-25 25Degincreaseroofinclinedbracket

3 SOL-FRF-X-45 45Degflatroofinclinedroofbracket

X=2,3,4,5,6


1a1b 1c

23

12

Collector Assembly


Inserting Tubes

Aftertheframehasbeencompletelyassembledandthesystemhasbeenfilledandcommissioned the evacuated tubes can be inserted into the manifold.

1. Holdingthetubeinonehanduseyourotherhandtoslidetheheatpipeoutoftheglasstubebyabout6”.

2. Byapplyingforcetothemetalheatpipeguidethebulbintothemanifoldinthenextavailablesocket.

3. To ensure the bulb has been inserted fully, twist the metal heat pipe to remove any friction.

4. Onceyouaresurethatthemetalheatpipeandbulbareinsertedcorrectlyslidethe glass tube up towards the manifold.

5. Toeasetheglasstubesealinginsidethemanifoldsocketrublubricantaroundtherimoftheglass.Waterwillsufficeiflubricantisnotavailable.


1

2 2

3 4

14

Sloped Roof Bolt Mounting KitMounting parallel bench srew mountingsystem

12

1 )

2 )

3 )

4 )

General Note: Points 9-12, 17 and 18 of these instructions only apply when mounting more than two collectors!

1: A = 1540 mm ±10 mmMeasure the mounting points (for a suggestion see previous side)

2: Drill tiles - Ø 14mm (Note: On roofs with corrugated tiles do not drill boreholes in the tile trough!)

3: Drill rafters - Ø 8mm

4: Fasten bench screw, minimum screw depth ≥ 100mm

Rooffixingboltsaredrilleddownthroughthe slate or tile covering the roof. The rub-bergasketontheboltkeepsthepenetra-tion point in the roof weather proofed. The bolt is connected to the profile byuse of a stainless steel L plate and nuts, bolts and washers. The bolt head slides throughtheprofiletothedesiredlocationandtheLbracket tofixedusingthenutand washer.

14


Sloped Roof Tile Mounting Bracket

Adjustable tile roof mounting bracketsare an ideal solution when fixing a so-lar collector to a thick roof tile. The toppiececanadjusttoincreaseordecreasethe height of the collector above the roof tile.Thebracketisconnectedtothepro-file usingnuts,bolts andwashers. Theboltheadslidesthroughtheprofiletothedesired locationand then thebracket isfixedusingthenutandwasher.

15ACAPELLA installation manual 15ACAPELLA installation manual

16

Sloped Roof Slate Mounting Bracket

Slate roofbrackets are an ideal bracketfor fixing the solar collectors to thin flatslates. Thebracket isconnectedtotheprofileusingnuts,boltsandwashers.Theboltheadslidesthroughtheprofiletothedesired locationand then thebracket isfixedusingthenutandwasher.

16


Flat Roof Mounting Frame

Theflatroofframecreatesapitchof35Degfrom a horizontal base. The frame is manu-factured from30x30mmanglealuminium.The frame consists of triangle nunber A frame pieceswith two back and slopedbars.EachAframeconnectstothecollec-torprofilesusingnuts,boltsandwashers.The frame is fixed to surface by installer.Preferredmethodffixingtoflatsurfaceisdependent on type of surface and available supports.


18

Connecting Flow & Return Pipework

18

Connecting Flow & Return PipeworkTails – 075m Stainless SteelEachtailhasbeenmanufacturedwithaswivelnutoneachend.Thisswivelnutscrewsdirectlyontoonesideofthepanelsystemwherethe¾”flatfacedmalethreadcon-nectionis.A¾”x¾”flatfacenipplemustbeusedbetweentheswivelnutonthecol-lector and the swivel nut on the tails.

Stainless Steel Solar PipeWhenusingsolarpipeasflowandreturnpipeworkthenit isadvisablethat0.75mlongtailsarenotusedalsoasthisincreasesthenumberofjointsinthesystem.Thesolar pipe should be reated as normal and be prepared for connecting. (see solar pipe pageforfurtherdetails).Theswivelnutfittingonthesolarpipewillscrewdirectlyontoonsideofthecollectorsystemwherethe¾”flatfacedmalethreadconnectionis.A¾”x¾”flatfacenipplemustbeusedbetweentheswivelnutonthecollectorandtheswivel nut on the solar pipe.

Connecting Panels TogetherTheAcapellacollectorhasa¾”flatfacemalethreadononesideandaswivelnut¾”female on the other side. This means that each panel connects directly to the panel besideit.Afibrewashermustbeinsertedbetweentheflatfaceofthemalethreadandthe internal of the female swivel nut. Insulation.


Stainless Steel Pipe Specification

Silicone Cable Specification

Insulation Specification

Stainless Steel Solar Pipe

20

TheJouleproductrangeoffersbothasinglestreamandadualstreampumpstation.Theflowraterequiredonasystemistypically1 litreperminute,persquaremetreinstalled.Thereforea2-12litrepumpstationwillbesufficientforsystemsupto12m².

1. Insulatingbox(back)inEPP2. Safetyunitconsistingof:manometer0/10bar,solarsafetyvalvescali-

bratedto6bars,3/4”connectionforexpansionvessel3. Security clips4. Shutoffvalveswithintegratedthermometersandcheck-valves5. Solarpump6. Visualflowbalancingvalvewithfillinganddraingroup7. Hoseconnection8. InsulatingEPPbox(cover)

Connectionsofflowandreturnpipeworktothepumpstationaremadevisthe¾”flatface thread connection on all points apart from the connection directly underneath the pump.Thisconnectionistobemadewith22mmsmoothtube.

When locating the pump station consideration should be given to future access for maintenance. It is best practice to locate the pump as far downstream the system as possibleawayfromthecollectorstohelpreducetheamountofhightemperaturefluidthat comes in contact with the pump station. If the distance between the collector andheatstoreisshort(>5m)thenrunningextrapipeworkoverandbackinsidetheattic space to increase the linear distance between pump station and collectors is recommended.

Pump Station


PressureReliefValve(PRV)Ratedat6bar,thePRVmaydischargeheattransferfluidwhich must be channelled into a container capable of withstanding high temperature discharge and containing the total collector volume. The container should be secured so it cannot be removed or spilled.

ThePRVshouldnotbechannelledintoadrainoranypipeworkwhichwillallowittoenter the normal water course.

Fitting the expansion vessel: It is recommended that the expansion vessel is located below the level of the connec-tion from the pump station to prolong its life. TemperatureReducingVessel(TRV)Alsoknownasa‘coolingvessel’or‘stratificationvessel’,theTRVishighlyrecommendedwherethedistancebetweencollectorsandpumpstationislessthanfivemeters.TheTRVensuresthatenoughfluidispresentbetween the collectors and expansion vessel to prevent damage to the expansion vessel membrane.

Safety Vessel Connection

1 PRVdischargepoint

2 Wallbracket(supplied)

3 Dischargecontainer

4 TRVkit

5 Expansionvessel

6 Dualstreampumpstation

1

2

2

3

4

5

6

2222

Allelectricalaspectsoftheinstallationshouldbeundertakenbyaqualifiedelectrician.Note that for safety, the pump and sensor connections should always be wired prior to connecting power to the solar control panel.

IMPORTANT The solar control panel must have a permanent electrical power supply which must not be interrupted either manually or with a time switch. If the permanent electricalsupplytothebuildingistobeswitchedoffforanyperiodoftime,thesolarcollector(s) should either be covered, or the system drained. In order to protect the normaloperationofthecontrolpanel,itshouldbelocatedatleast100mmfromin-sulatedpipeswhichmaybecomehotduringoperation.ControlpanelsusePT1000sensorscontainingtwincorecoppercablewitha0.75mmcrosssection.Thesen-sorssuppliedare1.5metresinlength.Sensorcablescanbeextendedwithtwincorecoppercableof0.75mmdiameterupto50metresand1.50mmdiameterbetween50-100m.ScreenedcableshouldbeusedonthesensorcablestopreventRFIfromelectricalcables.Allconnectionstoextendthecablesshouldbehousedinajunctionbox for protection. The following diagrams show the connection of the solar pump andotherrelaysontheJoulerangeofcontrollers.ThisshouldbereadinconjunctionwiththeInstallationandOperationManualsuppliedwitheachJoulecontrolpanel.

Electrical Solar Controller

2626

Expansion VesselIMPORTANTPriortofillingthesystem,theexpansionvesselpressuremustbeset0.3Barbelowthesystempressure.Omittingtoperformthischeckwillresultinirregularpressurereadingsduringthecommissioningofthesystem.Thepressureischeckedat the base of the vessel and the bleed valve may be bled or topped up with a pump.

Filling the LoopItisimportantthatamotorisedflushandfillcentreisusedtofillandpressurisethesystemwithsolarfluidasfollows:

• Openthefillanddrainvalvestoallowtheliquidtocirculatearoundthesolarloop• Closetheisolatingvalveabovetotheflowmetertoensureallairandliquidpasses

throughthefillcentretofilteranyairandcontaminants.• Runthefillcentrepumptocirculatesolarfluidforapproximately60minutes.• Openandclosetheisolatingvalveintermittentlytocirculateairbubbleswhichmay

accumulate in the sight glass.• Returnisolatingvalvetoclosedposition.• Whenthesolarloophasbeenpurgedofair,closethedrainconnection–thefill

centre will begin to pressurise the solar loop.• Reopentheisolatingvalveabovetheflowmeterfully.• Filltheloopuntilthepressuregaugejustexceedstherequiredpressureandstop

thepumpandimmediatelyclosethefillconnection.Checkpipejointsonthesolarloopforleaksandcheckthatpressureisnotlostovera30minuteperiod.

• Ifalltheplumbingissound,setthesystempressurebyopeningthereturnconnec-tion until the required pressure is met.

• Thefillcentremaynowbedisconnected.• Capthefillanddrainpointswiththebrasscoversprovided.

Commissioning


Setting The Flow RateThepumpmayonlyberunwhenthesystemhasbeenfilledasdryoperationwilldam-agethepump.Thedesiredflowrateis1litreperminuteperm²(10tubes=0.93m²/1panel=1.91m²)

Setthepumptothefirstspeedandrunitmanuallyfrom the controller (see following paragraph).Ifthedesiredflowrateisexceeded,settheflowme-tertothedesiredratebyadjustingtheisolatingvalvewithaflatheadedscrewdriver(seediagram)withthepumprunning.Otherwiserepeatthisstepatthenextpumpspeedsandcontinueuntilthedesiredflowrateis achieved. Stop the pump.

Turning The Solar Pump On Manually For Service:Press the left or down button the controller until the screen displays the time. Press and hold the down button for 3 seconds and the controller will enter the service menu.PressdownthroughalloptionsuntiloptionHND1isvisible.

• Pressthecentrebuttononce• SETbeginstoflash• WhenSETisflashingusetheUP & DOWN arrow buttons to change the setting

from AUTO to ON• Pressthecentrebuttontoconfirm• Pumpwillstarttorunandwarninglightswillflashtoalertyoutothefactthatthe

pump is running continuously.• WhenfinishedcarryouttheabovestepsandchangeONbacktoAUTO

2828

Usersshould regularlycheck the temperatureswhich thesolarcontrolpanel is re-cording.With theSCrangeofcontrollers,simplypressing the ‘SET’buttonon thefascia once will display the upper and lower collector temperatures since the control panel was last reset. If the collector temperatures have been excessively high i.e. over 170˚C,itisrecommendedthattheantifreezelevelbecheckedusingarefractometerbyaqualifiedengineer.Asampleofthesolarantifreezefluidcanbeextractedfromthe pump station at the pump itself. The large centre of the pump hub can be opened with a large flathead screwdriver. This should be opened slowly until a fewdropsoftheantifreezefluidarereleased.Asampleofthefluidplacedontheglassoftherefractometer will display the level of antifreeze in the system. If the antifreeze has lostitsantifreezepropertiesthesystemshouldberefilledwithfreshsolarfluid.Itisrecommendedthatthesolarsystemisservicedannuallybyaqualifiedengineerandimmediately if the system shows evidence of having lost pressure or has discharged liquidatthepressurereliefvalve.Thesolarantifreezefluidshouldalwaysbereplacedafter7years.

Maintenance scheduleAqualifiedpersonshouldservicethesystemattherecommendedintervals,us-ingthemaintenanceschedulebelow.Inadditiontheusershouldcheckthesystempressure at regular intervals. A visual inspection of the pressure gauge is required to checkthatthesystempressureismaintainedatthelevelnotedbelow.Theserviceengineer should complete the following; the shaded boxes should be completed if thesystemrequiresrefilling:

Servicing and Maintenance


Upon comissioning

Year1 Year2 Year 3 Year4 Year5 Year6 Year7

Dateofinspection

Expansionvesselsettingbeforefilling

System pressure

Expansionvesselsettingbeforefilling

Flowrate

Antifreeze level

pH reading

Inspection of barium get-ter on tubes

Engineerdetails

Print name

Sign

Telephone No.

32

JOULE IE

A KylemoreParkWest,Ballyfermot,Dublin10T +35316237080 F +35316269337E [email protected] W www.joulesolutions.ie

JOULE UKA NewportBusinessPark,NewbridgeRoad, EllesmerePort,Cheshire,CH654LZT t+44(0)1513551094 F +44(0)1513568336E [email protected] W www.jouleuk.co.uk

JOULE PL

A 23-200Kraśnik,ul.Towarowa34. E [email protected] W www.joule-pl.pl

ACAPELLA - jouleuk.co.uk · ACAPELLA installation manual 3 Table of Contents: 04 Introduction 05...

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