Acapella Installation Manual

Transcript

ACAPELLA joule acapella solar tubes installation manual ACAPELLA installation manual 1 2 Table of Contents: 04 05 06 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 Introduction Site survey Risk assessment Kit components Mounting Options Important Pre Installation Information Roof Mounting Options Collector Assembly Inserting Tubes Sloped Roof Bolt Mounting Kit Sloped Roof Tile Mounting Bracket Sloped Roof Slate Mounting Bracket Flat Roof Mounting Frame Collecting Flow and Return Pipework Stainless Steel Solar Pipe Pump Station Safety Vessel Connection Electrical Solar Controller Standard Solar System East/West Solar System Dual Store Solar System Commissioning Servicing and Maintenance ACAPELLA installation manual 3 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. Using 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 • Tube and manifold boxes should be transported horizontally. • Heavy goods should not be loaded on top of the kit boxes. • Care should be taken when opening boxes to prevent scratches or sudden shocks to the glass. • Do not use sharp objects to open the tube boxes. Installation Guidance • Unpack and install tubes only after the manifold and pipe work has been installed. • Do not leave the solar collector exposed to solar radiation when the solar loop and manifold have been drained. Collectors left exposed in a dry state must be covered to prevent possible long term damage. • Tubes must have a minimum elevation of 20˚ and a maximum of 70˚. • The pipework of the solar collector loop is to be earthed and the collector is to be lightening protected in accordance to local regulations. A solar panel installation must be performed in accordance with all Health & Safety legislation and local building/planning regulations for the relevant jurisdiction. Furthermore, the necessary electrical work required to install control equipment should be undertaken by a qualified electrical contractor. 4 Site Survey Degree of Over Shading Shading will reduce the overall performance of a solar system. During the planning stage of a solar system. Consid- eration should be given to the location of the collectors with the aim of minimising the effects of shading from high buildings, trees, etc. none / little / a lot Collector Fixing Surface 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) Orientation of Roof & Estimated Tilt Angle of Roof for Mounting Solar Collectors What is the Roof orientation (should be between East SE - West SW) Collector should be facing the equator Is an inclinded roof frame need to obtain required pitch? (yes/no) To calculate optimal angle of tilt multiple latitude x 0.7 for domestic hot water production Birr 37.16°, Cork 36.3°, Dublin 53.43° Estimating Hot Water Demand & Size of System Required No. of people using hot water in the house Any other exceptional water loads in the dwelling No. of People Solar Cylinder Size Size of Flat Panel System Size of Evacuated Tube 2 Panel System (4m2) 30 Tube System (2.83m2) 1-2 people 200 litres 3 Panel System (6m2) 40 Tube System (3.77m2) 3-5 people 300 litres Location of Solar Pump Station & Solar Controller Ensure the pump station is located in an area where it can be easily accessed for servicing & main- tenance (Confirm) Ensure that there is adequate space both left and right of pump station to allow easy access to remove pump in future. Ensure that the solar controller is located in an area that is easily accessible for the user (Confirm) Ensure that the controller is mounted at the ocrrct height for easy viewing. (Confirm) Existing Plumbing System What type of plumbing system is in the dwelling (vented or un-vented)? Is solid fuel incorporated into the plumbing system? Is there adequate access to route pipe work from solar collectors down to cylinder location? (yes/no) Is there space in the hot press to locate solar pump station? (yes/no) ACAPELLA installation manual 5 Risk Assesment Safe Roof Access To Work Is there adequate access to area of house to mount scaffolding or ladders? (yes/no) Is there steady and secure base on which to mount scaffolding or ladders? (yes/no) Are the scaffolding and or ladders fit for use intended? (yes/no) All installers trained in working at heights? (yes/no) Are all harness and other safety equipment working correctly? (yes/no) All work carried out should be in accordance with all relevant good pratices and or current building standards. All current regulations should be followed in relation to working at heights. Nothing stated in this guide takes pre- sedence over current standards. Condition of Roof  What are the centres of roof rafters where solar collector is to be mounted (eg 400mm)? (mm) What is the size of roof rafters (eg 6x2”, 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 by the number of roof fixing bolts or anchors used to hold the collector on the roof. This will give you the weight of the solar panels on each point of the roof. You must then carefully review the points where the collectors are connected to the roof to ensure that these exact points can take the anticipated load. Where there is signs of discolouration a closer examination will be requried. If black spots are found on the timber this indicates a leak which needs attention. If the timber appears brown and flaky then the timber may need to be replaced. If the situation is unclear a structural engineers report should be obtained prior to completing any further work. Effects of Snow Loads What is the estimated annual snow fall for this part of the country? The estimated snow load for all parts of ireland may be found from historical data located on Met Eireann’s website. www.met.ie What is the total extra weight to be assumed from a snow fall? Irish snow weighs approx 150kg per m3. To determine the extra weight the snow will add to the solar panels you may assume the following formula. (snow fall in meters x area of panel on the roof in m2 x 150kg/m3) When you find out the total extra weight of the snow add it to the total weight of the collector on the roof. 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. Effects of Wind Load The evacuated tube collector is exempt from consideration of wind loading for the same reason as the snow loading. When considering flat panels wind tests have been conducted that ensure that they and their fixing brackets can withstand all recorded wind forces in Ireland when mounted on a four storey house or less. 6 (mm) (kg) Pipework & Liquids Is anti freeze being used as the solar system fluid? (confirm) Ensure solder joints are not used throughout ther entire system (confirm) Ensure high temperature insulation is used throught all pipe work in solar system (confirm) Ensure white paste and hemp is used on all fitting connections throughout (confirm) Ensure you use Joule copper overflow and discharge vessel to recover fluid from safety valve (confirm) Water sample visually inspected and no signs of contamination visible (yes/no) Water Quality When installing the solar system it is important to check the quality of the existing incoming water to the hot water cylinder. If you are in doubt as to its purity a sample should be sent off to the department of health for testing. Fire Safety Ensure that there is no obvious risk to fire prevention by installing the solar system. (confirm) Ensure that all wires are not in direct connection with any un-insulated pipe work or plant that could cause a risk of burning (confirm) Legionella / Bacterial Growth Ensure that there is no dead legs in the existing plumbing system that could induce the growth of legionella. (confirm) Ensure that the stats controlling the boiler and the stat controlling the immersion are set to 60 °C or above. (confirm) Ensure that the client understands the risk of legionella and the standard procedures for reducing the risk of it forming. Also ensure that the client understands that you are their to install a solar thermal system and that you do not take any responsibility for auditing their hot water system for risk of legionnella forming. That you will endeavour to minimise the risk of it forming by the work that you carry out but any existing risk should be dealt with a certified professional. (confirm) ACAPELLA installation manual 7 Kit Components Standard Kit Components Solar Pump Solar Controller Solar Tubes & Profiles Solar Fluid Solar Expansion Vessel Mounting Options Bolt Mounting Option Tile Bracket Option Slate Bracket Option Aluminium Roof Flashing 4” Rubber Gasket Set Roof Flashing Options Lead Roof Flashing 8 Mounting Options Piping Options DN16 Duo Pipe DN20 Pipe Stainless Tails & Copper Installation Hose Mounting Set Over Voltage Lightning 3/4” Thermostatic Mixing Valve Cooling Vessel Discharge Vessel Optional Accessories ACAPELLA installation manual 9 Important Pre Installation Information Sizing of safety equipment Component sizes are relative to the volume of liquid in the system. Pipe sizing (minimum of 15 mm diameter pipework must be used) Collector Area (m2) Flow Rate ltr/hr Pipe Diameter Copper External (mm) Acapella 20 Tube (mbar) Acapella 30 Tube (mbar) Acapella 40 Tube (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 EXPANSION VESSSEL SIZING Model Collector Area (m2) System Volume (ltrs) Static Height Vessel Size Acapella 20 Tube 24 Acapella 30 Tube 24 Acapella 40 Tube 24 10 Roof Mounting options The Acapella product range is available with a choice of roof fixing options to suit many roof types, see diagram below for the most common fixings. The most common fixings are illustrated and explained in the following section and may be easily secured to slate, tile or masonry finishes. 1a 3 1b 1c 2 Option Code Describtion 1a RF-PA-MT-BO-X Sloped roof bolt kit option 1b RF-PA-MT-SL-X Sloped roof slate mounting bracket option 1c RF-PA-MT-TI-X Sloped roof tile mounting bracket option 2 SOL-FRF-X-25 25Deg increase roof inclined bracket 3 SOL-FRF-X-45 45Deg flat roof inclined roof bracket X= 2, 3, 4, 5, 6 Metal Roof Fixings Joule also supplies roof fixing kits for metal and other commercial roofs. Two options available utilise appropriate clamps so the fabric of the metal roof is not penetrated see page xx. Note the minimum and maximum distances on each fixing kit. ACAPELLA installation manual 11 Collector Assembly 12 Inserting Tubes After the frame has been completely assembled and the system has been filled and commissioned the evacuated tubes can be inserted into the manifold. 1. Holding the tube in one hand use your other hand to slide the heat pipe out of the glass tube by about 6”. 2. By applying force to the metal heat pipe guide the bulb into the manifold in the next available socket. 3. To ensure the bulb has been inserted fully, twist the metal heat pipe to remove any friction. 4. Once you are sure that the metal heat pipe and bulb are inserted correctly slide the glass tube up towards the manifold. 5. To ease the glass tube sealing inside the manifold socket rub lubricant around the rim of the glass. Water will suffice if lubricant is not available. 1 2 2 3 4 ACAPELLA installation manual 13 Sloped Roof Boltbench Mounting Kit Mounting parallel srew mountingsystem General Note: Points 9-12, 17 and 18 of these instructions only apply when mounting more than two collectors! 1) 1: A = 1540 mm ±10 mm Measure 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) 3: Drill rafters - Ø 8mm 4) 4: Fasten bench screw, minimum screw depth ≥ 100mm 2) Roof fixing bolts are drilled down through the slate or tile covering the roof. The rubber gasket on the bolt keeps the penetration point in the roof weather proofed. The bolt is connected to the profile by use of a stainless steel L plate and nuts, bolts and washers. The bolt head slides through the profile to the desired location and the L bracket to fixed using the nut and washer. 14 12 Sloped Roof Tile Mounting Bracket Adjustable tile roof mounting brackets are an ideal solution when fixing a solar collector to a thick roof tile. The top piece can adjust to increase or decrease the height of the collector above the roof tile. The bracket is connected to the profile using nuts, bolts and washers. The bolt head slides through the profile to the desired location and then the bracket is fixed using the nut and washer. ACAPELLA installation manual 15 Sloped Roof Slate Mounting Bracket Slate roof brackets are an ideal bracket for fixing the solar collectors to thin flat slates. The bracket is connected to the profile using nuts, bolts and washers. The bolt head slides through the profile to the desired location and then the bracket is fixed using the nut and washer. 16 Flat Roof Mounting Frame The flat roof frame creates a pitch of 35Deg from a horizontal base. The frame is manufactured from 30x30mm angle aluminium. The frame consists of triangle nunber A frame pieces with two back and sloped bars. Each A frame connects to the collector profiles using nuts, bolts and washers. The frame is fixed to surface by installer. Preferred method f fixing to flat surface is dependent on type of surface and available supports. ACAPELLA installation manual 17 Connecting Flow & Return Pipework Connecting Flow & Return Pipework Tails – 075m Stainless Steel Each tail has been manufactured with a swivel nut on each end. This swivel nut screws directly onto one side of the panel system where the ¾” flat faced male thread connection is. A ¾” x ¾” flat face nipple must be used between the swivel nut on the collector and the swivel nut on the tails. Stainless Steel Solar Pipe When using solar pipe as flow and return pipe work then it is advisable that 0.75m long tails are not used also as this increases the number of joints in the system. The solar pipe should be reated as normal and be prepared for connecting. (see solar pipe page for further details). The swivel nut fitting on the solar pipe will screw directly onto on side of the collector system where the ¾” flat faced male thread connection is. A ¾” x ¾” flat face nipple must be used between the swivel nut on the collector and the swivel nut on the solar pipe. Connecting Panels Together The Acapella collector has a ¾” flat face male thread on one side and a swivel nut ¾” female on the other side. This means that each panel connects directly to the panel beside it. A fibre washer must be inserted between the flat face of the male thread and the internal of the female swivel nut. Insulation. 18 Stainless Steel Solar Pipe Stainless Steel Pipe Specification Silicone Cable Specification Insulation Specification ACAPELLA installation manual 19 Pump Station The Joule product range offers both a single stream and a dual stream pump station. The flow rate required on a system is typically 1 litre per minute, per square metre installed. Therefore a 2-12 litre pump station will be sufficient for systems up to 12m². 1. Insulating box (back) in EPP 2. Safety unit consisting of: manometer 0/10 bar, solar safety valves calibrated to 6 bars, 3/4” connection for expansion vessel 3. Security clips 4. Shutoff valves with integrated thermometers and check-valves 5. Solar pump 6. Visual flow balancing valve with filling and drain group 7. Hose connection 8. Insulating EPP box (cover) Connections of flow and return pipe work to the pump station are made vis the ¾” flat face thread connection on all points apart from the connection directly underneath the pump. This connection is to be made with 22mm smooth tube. 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 possible away from the collectors to help reduce the amount of high temperature fluid that comes in contact with the pump station. If the distance between the collector and heat store is short (>5m) then running extra pipe work over and back inside the attic space to increase the linear distance between pump station and collectors is recommended. 20 Safety Vessel Connection Pressure Relief Valve (PRV) Rated at 6 bar, the PRV may discharge heat transfer fluid which 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. The PRV should not be channelled into a drain or any pipe work which will allow it to enter the normal water course. Fitting the expansion vessel: It is recommended that the expansion vessel is located below the level of the connection from the pump station to prolong its life. Temperature Reducing Vessel (TRV) Also known as a ‘cooling vessel’ or ‘stratification vessel’, the TRV is highly recommended where the distance between collectors and pump station is less than five meters. The TRV ensures that enough fluid is present between the collectors and expansion vessel to prevent damage to the expansion vessel membrane. 1 6 2 4 3 1 PRV discharge point 2 Wall bracket (supplied) 3 Discharge container 4 TRV kit 5 Expansion vessel 6 Dual stream pump station 2 5 ACAPELLA installation manual 21 Electrical Solar Controller All electrical aspects of the installation should be undertaken by a qualified electrician. 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 electrical supply to the building is to be switched off for any period of time, the solar collector(s) should either be covered, or the system drained. In order to protect the normal operation of the control panel, it should be located at least 100 mm from insulated pipes which may become hot during operation. Control panels use PT1000 sensors containing twin core copper cable with a 0.75mm cross section. The sensors supplied are 1.5 metres in length. Sensor cables can be extended with twin core copper cable of 0.75mm diameter up to 50 metres and 1.50mm diameter between 50-100m. Screened cable should be used on the sensor cables to prevent RFI from electrical cables. All connections to extend the cables should be housed in a junction box for protection. The following diagrams show the connection of the solar pump and other relays on the Joule range of controllers. This should be read in conjunction with the Installation and Operation Manual supplied with each Joule control panel. 22 ACAPELLA installation manual 23 24 ACAPELLA installation manual 25 Commissioning Expansion Vessel IMPORTANT Prior to filling the system, the expansion vessel pressure must be set 0.3 Bar below the system pressure. Omitting to perform this check will result in irregular pressure readings during the commissioning of the system. The pressure is checked at the base of the vessel and the bleed valve may be bled or topped up with a pump. Filling the Loop It is important that a motorised flush and fill centre is used to fill and pressurise the system with solar fluid as follows: • Open the fill and drain valves to allow the liquid to circulate around the solar loop • Close the isolating valve above to the flow meter to ensure all air and liquid passes through the fill centre to filter any air and contaminants. • Run the fill centre pump to circulate solar fluid for approximately 60 minutes. • Open and close the isolating valve intermittently to circulate air bubbles which may accumulate in the sight glass. • Return isolating valve to closed position. • When the solar loop has been purged of air, close the drain connection – the fill centre will begin to pressurise the solar loop. • Reopen the isolating valve above the flow meter fully. • Fill the loop until the pressure gauge just exceeds the required pressure and stop the pump and immediately close the fill connection. Check pipe joints on the solar loop for leaks and check that pressure is not lost over a 30 minute period. • If all the plumbing is sound, set the system pressure by opening the return connection until the required pressure is met. • The fill centre may now be disconnected. • Cap the fill and drain points with the brass covers provided. 26 Setting The Flow Rate The pump may only be run when the system has been filled as dry operation will damage the pump. The desired flow rate is 1 litre per minute per m² (10 tubes=0.93m² / 1 panel =1.91m² ) Set the pump to the first speed and run it manually from the controller (see following paragraph). If the desired flow rate is exceeded, set the flow meter to the desired rate by adjusting the isolating valve with a flat headed screwdriver (see diagram) with the pump running. Otherwise repeat this step at the next pump speeds and continue until the desired flow rate is 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. Press down through all options until option HND1 is visible. • Press the centre button once • SET begins to flash • When SET is flashing use the UP & DOWN arrow buttons to change the setting from AUTO to ON • Press the centre button to confirm • Pump will start to run and warning lights will flash to alert you to the fact that the pump is running continuously. • When finished carry out the above steps and change ON back to AUTO ACAPELLA installation manual 27 Servicing and Maintenance Users should regularly check the temperatures which the solar control panel is recording. With the SC range of controllers, simply pressing the ‘SET’ button on the fascia 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, it is recommended that the antifreeze level be checked using a refractometer by a qualified engineer. A sample of the solar antifreeze fluid can be extracted from the 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 few drops of the antifreeze fluid are released. A sample of the fluid placed on the glass of the refractometer will display the level of antifreeze in the system. If the antifreeze has lost its antifreeze properties the system should be refilled with fresh solar fluid. It is recommended that the solar system is serviced annually by a qualified engineer and immediately if the system shows evidence of having lost pressure or has discharged liquid at the pressure relief valve. The solar antifreeze fluid should always be replaced after 7 years. Maintenance schedule A qualified person should service the system at the recommended intervals, using the maintenance schedule below. In addition the user should check the system pressure at regular intervals. A visual inspection of the pressure gauge is required to check that the system pressure is maintained at the level noted below. The service engineer should complete the following; the shaded boxes should be completed if the system requires refilling: 28 Upon comissioning Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Date of inspection Expansion vessel setting before filling System pressure Expansion vessel setting before filling Flow rate Antifreeze level pH reading Inspection of barium getter on tubes Engineer details Print name Sign Telephone No. ACAPELLA installation manual 29 30 ACAPELLA installation manual 31 JOULE IE A Kylemore Park West, Ballyfermot, Dublin 10 T +353 1 6237080 E [email protected] F +353 1 6269337 W www.joulesolutions.ie JOULE UK A Newport Business Park, Newbridge Road, Ellesmere Port, Cheshire, CH65 4LZ F +44 (0) 1513 568 336 E [email protected] W www.jouleuk.co.uk T t +44 (0) 1513 551 094 JOULE PL A 23-200 Kraśnik, ul. Towarowa 34. [email protected] 32 E W www.joule-pl.pl