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acapella
ACAPELLA
joule acapella solar tubes installation manual
ACAPELLA
installation manual
1
2
Table of Contents:
04
05
06
08
09
10
11
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13
14
15
16
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19
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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
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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
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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
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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
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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
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Collector Assembly
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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
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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
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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.
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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
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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
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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
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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
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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.
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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