CALPAK MARK4 Guide

TECHNICAL DOCUMENTATION
THERMOSIPHONIC SOLAR WATER HEATERS Mark4
Thank you for placing your trust in our products. Calpak solar systems have been designed and
manufactured according to the strictest quality standards so that they may offer many years of top of
the range performance. For any clarifications regarding our products or this manual you may contact
one of our dealers, visit our website www.calpak.gr or contact us directly.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 1
TABLE OF CONTENTS
I. INTRODUCTION PAGE 2
II. TECHNICAL CHARACTERISTICS PAGE 4
III. POSITIONING OF THE SYSTEM PAGE 7
IV. INSTALLATION OF SYSTEM ON A FLAT ROOF [All models except 300/4.2] PAGE 8
V. INSTALLATION OF SYSTEM ON A FLAT ROOF [300/4.2 model] PAGE 18
VI. INSTALLATION OF SYSTEM ON INCLINED ROOF [All systems] PAGE 21
VII. HYDRAULIC CONNECTION OF SYSTEM [All systems] PAGE 28
VIII. ELECTRICAL CONNECTIONS PAGE 33
IX. FUNCTION AND MAINTENANCE PAGE 34

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 2
I. INTRODUCTION
SAFETY MEASURES
 Always use certified installation tools and full protection devices.
 In case you need to work near electrical wires, turn the electricity off.
 Always wear protective goggles, protective boots, gloves and masks in compliance with the
respective safety regulations.
TRANSPORT & HANDLING
The tanks and the collectors come packed in expanded polystyrene frames and stretch films, where
they must remain during all transportation and storage. The collectors must be transported in vertical
position, in order to avoid any damage. During installation keep the collector covered until the closed
circuit is filled with thermal fluid.
LIGHTING PROTECTION
Connect the metal part of the collector with the lighting protection system, if available or otherwise
connect them to an earth rod. For further information consult a specialist.
Thermal effects due to lightning currents are considered negligible (Annex E, paragraph E 5.10
standard EN 12976-2).
The mechanical loads on the components of the solar system due to lightning charges are too low and
the effect on durability and stability is considered negligible (Annex E, paragraph E 5.11 standard EN
12976-2).
The solar thermal system can be connected to the existing lightning protection at the roof of a
building, in order to be protected against any form of damage due to lightning. Additionally, please
note that the solar system is a natural circulation system and its electrical resistance is fed from the
main building switchboard, provided that there is always possibility of connecting the electrical
resistance of the storage tank to the building’s central earth. The electrical resistance is tested
according to standards EN 60335-1 and EN 60335-2-21.
THERMAL FLUID
Nox fluid is a propylene glycol based thermal fluid, non toxic to the skin. It must be used diluted in
water in order to provide anti-freezing and anti-corrosive properties. The advisable percentage is 33%
of water volume. In case of very low environmental temperatures, increase the volume percentage
according to the following table:
Temperature (ºC) -10 -15 -20 -25 -30 -35
Percentage in water solution
(%) 23 31 37 43 48 53
PERMISSIBLE SNOW LOAD AND MEAN WIND VELOCITY
The collectors are tested according to the standards EN 12975-2. Through these tests, it is admitted
that they can resist without any failure to a mechanical load up to 2400 Pa.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 3
SYSTEM COMPONENTS
1. Collector
2. Tank
3. Support Base System
4. Nox fluid (propylene glycol)
5. 1 pressure relief valve for the closed circuit
6. 1 safety valve for the domestic cold water line
7. Insulated connecting pipes
8. Pipe fittings
SYSTEM IDENTIFICATION
The tank and the collector/s which form a solar system are appropriately marked with metalized item
plates. These plates include the technical characteristics of the system and the unit serial number
according to paragraph 4.7 of EN 12976-1 and are placed on each part of the system (tank and
collector/s)

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 4
II) TECHNICAL CHARACTERISTICS
Technical
data
M4 flat plate selective collectors
Type M4-200 M4-210 M4-260 M4-260H M4-300 M4-300H
Gross area
(m²) 2.04 m2 2.13 m2 2.64 m2 2.64 m2 3.00 m2 3.00 m2
Absorber
area (m²) 1.83 m2 1.92 m2 2.40 m2 2.40 m2 2.80 m2 2.80 m2
Aperture
area (m²) 1.87 m2 1.96 m2 2.44 m2 2.44 m2 2.83 m2 2.83 m2
W x L x H
(mm) 986*2071*86 1244*1711*86 1244*2121*86 2121*1244*86 1502*1996*86 1996*1502*86
Weight (kg) 34,5 36 48 49 50 51
Absorber
capacity (l) 1,6 1,6 1,8 2,2 2,1 2,4
Housing aluminum frame
Absorber Selective aluminum
Absorption 95 + 2
Emission (%) 4 + 2
Number of
tubes 9 11 11 18 14 18
Absorber
tube Dia. 8 mm
Glass 3.2 mm low iron mistlite tempered glass
Transmittance
of glass (%) >0,90
Insulation 40 mm Rockwool, density 50kgr/m
3
Stagnation
temp at 1000
W/m² and
30C
177,6 C
Max.operating
pressure (bar)
10

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 5
Collector
 Aluminum multifin selective absorber
 Ultrasonic welded on copper harp
 Rock wool insulation
 Aluminum profile frame
 Low iron tempered glass
Tank
 Enameled tank according to DIN 4753/3
 Insulation with expanded polyurethane
 Magnesium anode cathodic protection according to DIN 4753/6
 Electrical resistance 3,5 KW
 Heat exchanger to connect to a boiler (model TRIEN)
A
B B
C

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 6
Model
Μ4
125/
2.1
Μ4
160/
2.1
Μ4
160/
2.6
Μ4
160/
2.6Η
Μ4
200/
2.1
Μ4
200/
2.6
Μ4
200/
2.6H
Μ4
200/
3
Μ4
200/
3H
Μ4
200/
4.2
Μ4
300/
3H
Μ4
300/
4.2
Dimensions
[45/30
degree
inclination]
Length
(mm) Α 1244 1244 1244 2121 1520 1520 2121 1520 1996 2553 1996 2553
Depth
(mm) Β
1684/
1892
1684/
1892
1973/
2247
1324/
1488
1654/
1892
1945/
2247
1324/
1488
1867/
2152
1515/
1722
1654/
1978
1515/
1722
1684/
1978
Height
(mm) Γ
1700/
1326
1700/
1326
1989/
1531
1370/
1093
1700/
1326
1989/
1531
1370/
1093
1904/
1476
1552/
1228
1700/
1326
1552/
1228
1700/
1326
System weight empty (kg) 87 94 106 107 109 121 122 123 124 145 147 168
System weight full (kg) 210,6 251,6 263,8 265,2 312,6 324,8 326,2 327,1 328,4 350,2 424,4 446,2
Optional electrical
resistance (kW) 3,5 3,5 3,5 3,5 3,5 3,5 3,5 3,5 3,5 3,5 3,5 3,5
Tank
Tank
volume
(l)
122 156 156 156 202 202 202 202 202 202 275 275
Tank
weight
empty
(kg)
51 58 58 58 73 73 73 73 73 73 96 96
Tank
weight
full (kg)
173 214 214 214 275 275 275 275 275 275 371 371
Length
(mm) 1230 1230 1230 1230 1520 1520 1520 1520 1520 1520 1980 1980
Diameter 500 mm
Collectors
Dimensio
ns of
collector
(mm)
1244*1
711*86
1244*1
711*86
1244*2
121*86
2121*1
244*86
1244*
1711*
86
1244*2
121*86
2121*
1244*
86
1502*
1996*
86
1996*1
502*86
1244*1
711*86
1996*1
502*86
1244*1
711*86
Number
of
collector
s
1 1 1 1 1 1 1 1 1 2 1 2
Gross
area per
collector
(m²)
2.13 2.13 2.64 2.64 2.13 2.64 2.64 3.00 3.00 2.13 3.00 2.13
Weight
per
collector
empty
(kg)
36 36 48 49 36 48 49 50 51 36 51 36
Max.
working
temp.
177 ºC
Thermal
liquid per
absorber
(l)
1,6 1,6 1,8 2,2 1,6 1,8 2,2 2,1 2,4 1,6 2,4 1,6
Max.
collector
circuit
working
pressure
1 MPa

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 7
IΙI) POSITIONING OF THE SYSTEM
The installation area of the solar water heater must fulfill the following requirements:
1.1 The solar water heater must face the SOUTH (or NORTH in case the installation takes place in the
South hemisphere), and it is strongly recommended to use a compass to ensure this. Deviations of up
to 10-15does not affect substantially the system’s efficiency, but larger deviations may seriously
affect the performance.
1.2 In countries situated in latitude of 40, the collectors must be installed at an angle of 45against
the horizontal level. The collectors must be generally placed at an angle of 5over the latitude of the
installation area. Any decrease in this angle entails considerable decrease of the solar heater’s annual
performance.
1.3 In no case are the solar heaters to be placed in the shade, especially during winter time, when the
sun is lower in the sky. The minimum distance between the solar heater and any obstacle that causes
shadow should be no less than twice the height of the obstacle.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 8
IV) INSTALLATION OF SYSTEM ON A FLAT ROOF [All models except 300/4.2]
STEP 1
Install the tank support pillars at a distance A according to Table A. To ease installation, drill the roof
floor at an angle of approximately 10-15 degrees. Follow the instructions for positioning the system in
Chapter III. Use fasteners of appropriate length and type to ensure that the pillars and all base
components are secured onto the structural layer of the roof and not on the insulation. Use an
appropriate sealing material to prevent moisture from penetrating the roof material.
TABLE Α
TANK 125/160 L 200 L 300 L
DISTANCE A [mm] 1192 1480 1944
SOUTH
A

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 9
STEP 2
Attach the two feet at the lower part of the collector. Consult the drawing above for their positioning
relative to the collector as it affects the accuracy of the installation.
IMPORTANT: DO NOT REMOVE COLLECTOR COVER SHEET BEFORE CONNECTING THE SYSTEM!
STEP 3
Place the collector on the roof floor in front of the pillars as shown above.To ease next step slide the
collector securing bolts so that they are approximately in line with the slots on the pillars.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 10
Upper right side of the collector Upper left side of the collector
STEP 4
Lift the collector from the side close to the pillars at an angle of approximately 45 degrees. Move the
collector towards the pillars. Insert the securing bolts into the vertical slots of the pillars.
Upper right side of the collector Upper left side of the collector
STEP 5
Slide the remaining two securing bolts into the horizontal slots of thepillars.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 11
STEP 6
Ensure that the distance B between the centres of the tank support holes is in accordance with Table
B. If there is deviation you may make small adjustments ensuring that both pillars are vertical and that
the collector is centered between them.
TABLE Β
TANK 125/160 L 200 L 300 L
DISTANCE Β [mm] 1090 1378 1842
STEP 7
Tighten the 4 collector securing bolts.
Β

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 12
STEP 8
Using the holes in the collector feet as a guide, drill the roof floor and install the appropriate fasteners
to secure them. Alternatively you can use the below table. Use fasteners of appropriate length and
type to ensure that the collector feet are secured onto the structural layer of the roof and not on the
insulation. Use an appropriate sealing material to prevent moisture from penetrating the roof
material.
TABLE C
SYSTEM 125/2,1 160/2,1 160/2,6 160/
2,6Η 200/2,1 200/2,6 200/ 2,6H
200/
3
300/
3Η 300/4,2
DISTANCE
C [mm] 1304 1304 1304 2181 1304 1304 2181 1574 2071 2617

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 13
STEP 9
Place the tank on the roof floor with a small rotation backwards. Ensure that the securing bolts of the
tank do not touch the floor. Lift the tank and place it on the circular seats on top of the pillars. Rotate
the tank so that the tank securing bolts are inserted into the pillar slots.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 14
STEP 10
For ease of installation you may attach the cold water supply tube.
STEP 11
Install washers and the nuts on the tank securing bolts.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 15
STEP 12
Connect the brace system with the pillars. Do not tighten the bolts, ensure however that they are not
very loose.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 16
STEP 13
Using the hole of the brace foot as a guide drill the roof floor and install the securing bolt of the brace
foot by tightening the bottom nut. Use fasteners of appropriate length and type to ensure that the
collector feet are secured onto the structural layer of the roof and not on the insulation. The fastener
must protrude 7 cm from the roof floor to allow for adjustments.
STEP 14
Install the top washer and nut of the brace foot. Tighten until it is not loose. The middle nut must be
in contact with the brace foot.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 17
STEP 15
Tighten the middle bolt against the brace foot.
STEP 16
Tighten the 4 brace strut bolts. Make sure that all bolts are tight and that bolts are not loose on the
base system.

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 18
V) INSTALLATION OF SYSTEM ON A FLAT ROOF [300/4.2 model]
The procedure for installing the 300/4.2 model with the dual collectors is identical to the procedure in
the previous chapter except for Step 2 which must be replaced with the following.
Figure 1: The two collectors ready for installation with top and bottom braces and collector feet
installed.
Figure 2: Top brace and hydraulic connection between the collectors

THERMOSIPHONIC SOLAR WATER HEATERS / TECHNICAL DOCUMENTATION / PAGE 19
Figure 3.Bottom Brace
Follow Step 1 of Chapter IV to install the tank support pillars to the correct orientation and distance
for the 300L tank.
Place the two collectors side by side on the roof floor.
IMPORTANT: DO NOT REMOVE COLLECTOR COVER SHEET BEFORE CONNECTING THE SYSTEM!
Install the top and bottom braces between the collectors. The bolts should be tight enough to prevent
excessive free play while allowing sliding of the collectors towards each other.
Connect the absorber tubes between the collectors by the appropriate fittings. Ensure that the
collectors are parallel and as close to each other as possible. Tighten the fittings.
IMPORTANT: DO NOT MOVE THE DUAL COLLECTOR ASSEMBLY BEFORE ALL SECURING BOLTS ARE
TIGHTENED. FAILURE TO DO SO MAY RESULT IN DAMAGE TO ABSORBERS!
Centre the top and bottom braces and tighten the 4 securing bolts.
Ensure that the dual collector assembly is one body.
Install the collector feet according to Step 2 in Chapter IV.
Follow Steps 3-16 of Chapter IV to complete the installation.