Apricus FPC-A User manual

ИНСТРУКЦИЯ
Apricus FPC-A26

Apricus FPC-A Flat Plate
Solar Thermal Collector
Installation and Operation Manual
International Edition
(Version 4 - Dec 2013)

Contents
................................................................................................1. Important Information!3
...........................................................................................................................................1.1. Scope of Manual!3
............................................................................................................................................1.2. Local Standards!3
.....................................................................................................................................1.3. Authorized Person(s)!3
...................................................................................................................1.4. Collector Dimensions & Weights!3
.........................................................................................2. Unpacking and Inspection!4
.............................................................................................................................................2.1. Component List!4
......................................................................................................................................................2.2. Inspection!4
............................................................................................................................................................2.3. Frame!4
............................................................................................................3. System Design!4
..............................................................................................................................................3.1. System Design!4
..................................................................................................................................................3.2. Avoid Shade!4
...........................................................................................................................................3.3. Installation Angle!4
.............................................................................................................................3.4. Collector Horizontal Slope!4
..........................................................................................................................3.5. Collector and Tank Location!5
.........................................................................................................................................3.6. Collector Direction!5
......................................................................................................................................3.7. Heat Transfer Fluids!5
...................................................................................................................................3.8. Correct System Sizing!6
.........................................................................................................................3.9. Stagnation and Overheating!6
............................................................................................3.10. Pressure and Temperature Control and Relief!6
.........................................................................................................................................3.11. Freeze protection!6
..............................................................................................................................................3.12. Wind Loading!7
..................................................................................................................................................3.13. Snow Load!7
...........................................................................................................................................3.14. Hail Resistance!7
......................................................................................................................................................3.15. Lightning!7
.....................................................................................................4. Collector Mounting!8
..............................................................................................................................................4.1. Frame Material!8
.............................................................................................................................................4.2. Roof Clearance!8
.........................................................................................................................................4.3. Galvanic Reaction!8
......................................................................................................................................4.4. Installation Planning!8
.............................................................................................................................4.5. Frame Assembly Process!8
.............................................................................................................................4.6. Roof Attachment Strength!8
.........................................................................................................................................4.7. Roof Penetrations!9
........................................................................................................................................4.8. Collector Mounting!9
...................................................................................................................4.9. Frame Components Diagrams!10
.......................................................................................................................4.10. Frame Component Details!12
.................................................................................................................................4.11. Angled Frame Guide!14
............................................................................................................................................4.12. Wall Mounting!15
.......................................................................................5. Piping & Collector Layout!16
....................................................................................................................................................5.1. Flow Rate!16
.....................................................................................................................................................5.1. Pipe Size!16
........................................................................................................................5.2. Single Collector Connection!16
...............................................................................................................5.3. Connection of Multiple Collectors!17
.............................................................................................................................................5.4. Pipe Insulation!17
.....................................................................................................................................................5.5. Air Purge!17
...........................................................................................................................................5.6. Pump Selection!18
..............................................................................................................5.7. Pressure Drop Graphs (FPC-A32)!18
.........................................................................................................6. System Control!19
.....................................................................................................................................................6.1. Controller!19
.........................................................................................................................6.2. Temperature Measurement!19
.............................................................................................................................6.3. Solar Controller Settings!19
..............................................................................................................7. Maintenance!19
......................................................................................................................................................7.1. Cleaning!20
......................................................................................................................................7.2. Other Components!20
.....................................................................................................................................................7.3. Insulation!20
.....................................................................................................................................7.4. Broken Glass Cover!20
..................................................................................................................................7.5. Draining the Collector!20
......................................................................................................................................7.6. Other Components!20
........................................................................................................8. Troubleshooting!21
..................................................................................................................9. Disclaimer!22
..........................................................................10. Manufacturer’s Limited Warranty!23
.......................................................................................11. Installation Record Form!24
Apricus FPC-A Flat Plate Solar Collector Installation and Operation Manual
Copyright © 2013 – Apricus Solar Co., Ltd A11.02.1.1-PB-V4 Page 2 of 24

⚠WARNING
Indicates important information that must be followed to avoid potentially hazardous
situations that could result in death, serious injury, or substantial property damage.
1. Important Information
1.1. Scope of Manual
a) This manual pertains only to the installation and operation of the Apricus FPC-A range of flat plate collectors.
Details for the installation, operation and maintenance of the complete solar system components should be provided
separately by their respective manufacturers.
b) This manual is primarily a reference document for installation officers, as the solar collector is not permitted to be
installed by non-authorised persons.
1.2. Local Standards
Installation must be completed in accordance with all relevant local standards and regulations.
1.3. Authorized Person(s)
a) The term “authorised person(s)” used throughout this document refers to a suitably qualified professional, who
holds relevant industry licenses or certificates required for the work completed during the installation process.
b) Installation may only be completed by authorised persons.
c) Unless otherwise specified in section 3, no part of any Apricus FPC-A solar collectors may be inspected, repaired
or maintained by anybody other than an authorised person(s).
1.4. Collector Dimensions & Weights
Specification
Model: FPC-A26
Model: FPC-A32
Length
1981mm / 78”
2444mm / 96”
Width
1223mm / 48”
1223mm / 48”
Height
80mm / 3.15”
80mm / 3.15”
Peak Output*
1706 W / 5820 Btuh
2114 W / 7213 Btuh
Aperture Area
2.26m2/ 24.3ft2
2.8m2/ 30.14ft2
Gross Area
2.42m2/ 26ft2
2.99m2/ 32.2ft2
Gross Dry Weight
40kg / 88 lbs
46kg / 101.4 lbs
Fluid Capacity
1.55L / 52.4 floz
1.8L / 61 floz
Absorber Sheet
0.4mm Aluminium Tinox Energy
0.4mm Aluminium Tinox Energy
Insulation
Melamine Foam
Melamine Foam
Glass Cover
3.2mm Hardened Glass
3.2mm Hardened Glass
Seals
HTV Silicone Rubber HTV
HTV Silicone Rubber HTV
Back Sheet
0.8mm 5052-H16 Aluminium
0.8mm 5052-H16 Aluminium
Collector Body
6063 Black Anodized Aluminium
6063 Black Anodized Aluminium
* TUV test report; G=1000W/m2 / 317.1 Btu/ft2
Apricus FPC-A Flat Plate Solar Collector Installation and Operation Manual
Copyright © 2013 – Apricus Solar Co., Ltd A11.02.1.1-PB-V4 Page 3 of 24

2. Unpacking and Inspection
2.1. Component List
a) Review the components list included in the collector manifold packing box. If any components are missing, or
additional parts are required, contact the local supplier.
2.2. Inspection
a) Check the glass cover to ensure it is not broken and the corners of the panel for any sign of damage that may
have occurred during transport.
2.3. Frame
a) Unpack the frame components that are packed separately (not supplied with the collector). See section 4 for
frame diagrams.
b) Depending on the roof surface, rubber pads, roof attachment straps, round feet, roof rails or U feet may be used
to attach the standard frame to the roof. These components are supplied separately from the standard frame.
⚠WARNING
THE CORNERS OF THE ALUMINIUM CASING CAN BE SHARP, SO HANDLE
CAREFULLY AND WEAR PROTECTIVE GLOVES.
3. System Design
3.1. System Design
System design should be completed prior to commencing installation. Solar collectors need to be installed correctly
to ensure high efficiency, and most importantly, safe and reliable operation. Please seek professional advice for the
design and installation of seek solar heating system. Only authorised installers are permitted to install the solar
collector. Apricus does not provide warranty coverage and will not be held liable for any damage to person or
property that results from solar collectors that are installed by unauthorised persons.
3.2. Avoid Shade
a) Collectors should be located so that shading does not occur for at least the 3 hours either side of 12 noon local
time.
b) Partial shading due to small objects such antennas and small flues, is not of great concern.
3.3. Installation Angle
a) For optimal annual solar output, install the collector at an angle equal to the location’s latitude. An angle of +/- 10o
is acceptable, and will not greatly effect output.
b) If the system is likely to exceed demand in the summer, install the collector at an angle 15-20ogreater than the
latitude of the location which will help reduce summer output and maximise winter output.
E.g. Latitude of 30o, install at 45-50o.
c) The collector may be installed from 0o(flat) to 90o(vertical) angle.
d) The collector may be installed in a portrait or landscape orientation. See also section 3.4 about vent plugs.
3.4. Collector Horizontal Slope
a) If installing on an horizontal angle ensure the outlet it
at the highest point to allow air to purge.
b) If used in a drain-back system, the collector may be
sloped to achieved desired drainage of the heat
transfer fluid. A minimum slope of 1.4” per foot or 1.2o
is recommended. X✓
Apricus FPC-A Flat Plate Solar Collector Installation and Operation Manual
Copyright © 2013 – Apricus Solar Co., Ltd A11.02.1.1-PB-V4 Page 4 of 24

3.5. Collector and Tank Location
a) The collector should be positioned as close as possible to the storage tank to avoid long pipe runs.
b) The storage tank should be located as close as possible to the most frequent hot water draw off points in the
building.
3.6. Collector Direction
a) The collector should face the equator, which if in the northern hemisphere is due South, and southern hemisphere
is due North. A deviation of up to 15o from due North or South is acceptable, and will have minimal effect on heat
output. The collector will still work even facing East or West, but will loose most of the afternoon sun or morning sun
respectively. The diagram below shows a variety of suitable installation positions for good solar exposure.
3.7. Heat Transfer Fluids
a) In regions where freeze protection is not a concern, water is the most appropriate heat transfer fluid. Water must
be potable rated (suitable for drinking) if the system is direct flow.
b) In all cases the water or other type of heat transfer fluid must meet the following quality requirements:
Total dissolved solids < 600 p.p.m. Total hardness < 200 p.p.m.
Chloride < 250 p.p.m. Free Chlorine < 5 p.p.m
Magnesium < 10 p.p.m. Sodium < 150 p.p.m
Electrical conductivity < 850 µS/cm pH 6.5 - 8.5
c) When using a direct flow system is used in an area with hard water (high mineral content), scale may slowly form
in the solar collector loop, gradually reducing performance, increasing pressure drop, and ultimately rendering the
system inoperable (due to flow restriction). In such regions, a water treatment system should be installed, which
either removes the scale forming minerals, or prevents formation of a scale layer.
Another option is the flush the system with suitable scale removing solution. Any solution used must consider
potable water safety and be suitable for use with copper piping.
d) In regions where freeze protection is required, it is advisable to use a closed loop system with a non-toxic grade
polypropylene glycol based heat transfer fluid. This liquid should be used directly, or mixed with water as per the
manufactures instructions. Periodic inspection of the glycol should be completed (annually), and replaced if
necessary ensuring that the liquid mets the requirements outlined in (b) above, or the glycol manufacturer’s
guidelines for liquid quality and replacement time.
e) Check with local regulations regarding the use of heat transfer fluids as some regions require precautions such as
dual wall heat exchangers, back-flow preventers or specific solar system pressure operating levels in order to
prevent drinking water contamination.
Apricus FPC-A Flat Plate Solar Collector Installation and Operation Manual
Copyright © 2013 – Apricus Solar Co., Ltd A11.02.1.1-PB-V4 Page 5 of 24

3.8. Correct System Sizing
The solar collector should normally be sized to provide 90-95% of hot water requirements during summer period.
Depending on the location and hot water usage patterns this may provide 40-80% annual contribution to domestic
hot water.
3.9. Stagnation and Overheating
a) Stagnation refers to the condition that occurs when the pump stops running, due to pump failure, power blackout,
or as a result of a high tank temperature protection feature built into the controller, which turns the solar circulation
pump off.
b) If the system is designed to allow wet stagnation as a means of preventing tank overheating, the collector and
plumbing in close proximity may reach temperatures of >170oC / 338oF; therefore components that may be exposed
to the high temperatures such as valves, plumbing or insulation, should be suitably temperature rated.
c) For direct flow systems, if the system is allowed to stagnate, steam may form in the collector (depending on the
system pressure). In such a system, a temperature relief valve or auto air vent should NOT be installed on the
collector outlet, as high temperature may damage the valve, and scale formation can rapidly block the vent hole. An
exception are air vents that are design to not release steam and that are specifically design for solar system use.
The pressure and temperature relief valve on the tank may open to release pressure or heat as required.
Any heat returning from the collector is generally not enough to cause a continued increase in tank temperatures
(i.e. heat input is less than tank heat losses). A crackling noise may be heard in the solar flow and return lines when
hot water is used, as the pressure in the system drops and steam forms, this is normal.
3.10. Pressure and Temperature Control and Relief
a) For open loop systems, the normal operating pressure should be <500kPa / 72.5psi via use of a pressure limiting
(pressure reduction) valve on the mains cold supply line.
b) For open loop systems, it is acceptable for the system design to allow the solar collector to stagnate to prevent
additional heating of the storage tank (i.e. pump stoppage once tank temperature reaches 80oC / 177oF). The
pressure relief valve and expansion tank (if installed) must be able to accept/release the pressure increase that
occurs when the manifold stagnates, and should be rated to meet the maximum possible heat output of the solar
collector(s). See section 3.10 regarding stagnation and overheating.
c) For closed loop systems, the solar loop must operate at <500kPa / 72.5psi, and have an expansion vessel
installed to control liquid expansion. The system design MUST NOT allow stagnation of the collector as a standard
form of controlling tank temperature, unless the heat transfer fluid is rated for long term exposure to temperatures of
up to 200oC.
d) Any system design must provide means for allowing pressure release at no more than 850kPa or 125psi, using a
pressure and or pressure and temperature relief valve (PTRV), in accordance with local regulations. THE RELIEF
VALVE OR DRAIN TUBE MUST NOT BE SEALED OR BLOCKED
e) If installed inside a building a safe-tray must be installed beneath the hot water tank to safely collect any water
expelled from the pressure and temperature relief valve.
3.11. Freeze protection
Freeze protection must be implemented in any regions that experience freezing conditions at any time throughout
the year.
a) For areas with temperature not falling below –5oC / 23oF, simple low temp controller based freeze protection may
be used. (i.e. Pump circulates if the manifold temperature approaches freezing). If possible, backup protection in the
form of uninterrupted power supply (UPS) or freeze drip valve (which opens to allow water to dribble out if power
supply is cut) should also be installed. It is also important that the tank is heated at least once daily (to the bottom)
to ensure there is heat to keep the solar loop from freezing.
b) For areas with temperatures below –5oC / 23oF, a closed loop filled with an anti-freeze mix can be used to provide
freeze protection. Please refer to glycol manufacturer’s specifications about the temperature ranges the liquid can
withstand. See also 1.4 regarding water quality requirements. Anti-freeze liquids are normally required to be
potable water grade; please check with local regulations. The other option for cold temperatures is a drain back
systems whereby the collector drains empty of water each time the pump stops circulating. The collector and all
piping must be suitably sloped (1/4” per foot = 1.2oangle) to ensure full drainage.
c) Apricus does not warrant the solar collector against freeze related damage.
Apricus FPC-A Flat Plate Solar Collector Installation and Operation Manual
Copyright © 2013 – Apricus Solar Co., Ltd A11.02.1.1-PB-V4 Page 6 of 24

3.12. Wind Loading
a) When installing the collector, wind loading must be considered.
b) The standard frame, and frames kits are all designed to withstand wind speeds of up to 208km/h / 130mph
without damage for installation angle of 45oand less. This wind speed corresponds to the mid range of Category 2
cyclones (US Saffir-Simpson Scale). For higher wind speeds additional frame components, lower installation angle
and reinforcement of roof attachment may be required. Collector mounting in high wind regions (>208km/h /
130mph) should be reviewed, and where required, approved in writing by a qualified engineer.
c) Refer to section 4 for specific roof attachment details for various frame options.
3.13. Snow Load
a) In areas prone to heavy snow falls the solar collectors should ideally be installed at an angle of 45oor greater to
help promote snow sliding off the panel.
b) The solar collectors are able to withstand a maximum snow loading of 300kg/m2 / 60lbs/ft2. Ensure that any
mounting brackets/stanchion or other framework is suitably rated for expected snow loading. Refer to local
regulations regarding snow loading guidelines.
3.14. Hail Resistance
a) The collector glass cover is able to withstand impact from large hail (>∅25mm /1”)
b) In areas prone to large hail (> ∅50mm / ∅3/4”) it is recommended to install at an angle of 45o or greater to provide
optimal protection.
c) If the glass is broken the collector will not operate properly and must be replaced.
3.15. Lightning
a) It is advisable to earth/ground the copper circulation loop of the collector to avoid lightning related damage, or
electrical safety issues.
Apricus FPC-A Flat Plate Solar Collector Installation and Operation Manual
Copyright © 2013 – Apricus Solar Co., Ltd A11.02.1.1-PB-V4 Page 7 of 24

4. Collector Mounting
Apricus offer mounting equipment to suit flush mounting on suitable pitched roof as well as installation where an angled
mount is required.
⚠WARNING
•All installations should only be completed on roofs that are in good condition and that can
structurally support the collector(s). The mounting points for the collector must always be
into structural members such as rafters, trusses or blocking.
•Ensure all roof attachment points are well sealed to avoid water leaks.
•Adhere to relevant local safety regulations when working on roofs.
4.1. Frame Material
a) Main frame components are made from anodised 6005-T5 aluminium which is strong, light-weight and corrosion
resistant.
b) Fasteners (bolts, nuts & washers) are made from 316 grade stainless steel.
4.2. Roof Clearance
a) Flush mounted collectors must have a minimum of 50mm / 2” clearance off the roof. This allows ventilation of the
roofing material and provides space for rain and leaves etc to pass under the collector.
4.3. Galvanic Reaction
a) Zinc galvanized components should NOT be installed in direct contact with stainless steel bolts or screws, as
galvanic reaction between the two metals can cause premature oxidation of the zinc coating and the steel
underneath.
b) Avoid using galvanized steel screws or bolts; instead use stainless steel components but ensure the hole in the
metal roof is large enough to prevent contact with the stainless steel screw/bolt. If galvanized components are used,
avoid direct contact between the two metals by using the rubber/plastic washers under the bolt head.
4.4. Installation Planning
a) Measure the roof and mounting frame to determine the location of the attachment points before completing any
roof word. Mark attachment points on the roof with chalk or marker to make the process easier.
4.5. Frame Assembly Process
a) Where possible, attach tracks to the collector at ground level, then carry to the roof.
b) Only gently tighten nuts until attachment to the roof is complete, then hand-tighten all bolts with hand spanner/
wrench or suitably sized socket. If using power socket drivers, set to low speed and adjust to suitable torque setting.
If nuts are not smooth when tightening use WD-40 or similar lubricant or anti-gall powder/grease.
c) Do NOT over-tighten stainless steel bolts. Spring washers are provided on each bolt assembly to ensure they do
not loosen over time.
4.6. Roof Attachment Strength
a) Frame attachment to the roof should be completed with suitable strength and quantity of stainless steel bolts/
screws.
b) Ensure the mounting surface or ballast is solid and able to withstand the forces that may be encountered during
high winds. Refer to local building codes for suitable requirements.
⚠WARNING
ALWAYS CONSULT BUILDING ENGINEER FOR APPROVAL OF INSTALLATIONS IN HIGH
WIND REGIONS.
Apricus FPC-A Flat Plate Solar Collector Installation and Operation Manual
Copyright © 2013 – Apricus Solar Co., Ltd A11.02.1.1-PB-V4 Page 8 of 24