joule ACAPELLA User manual

Acapella Installation Guide 1
Acapella
Installation Manual
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ONLINE WITHIN 28 DAYS OF
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JL-ACA-INS-001-03-2017

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2
Warranty Card
Please register your product online
Homeowner
Name
Address
Contact Tel.
Contact Email
Installer
Name
Address
Contact Tel.
Contact Email
Product Product
Installed
Serial Number Installation
Date
Cylinder Located on
cylinder badge
Solar Thermal Take from
solar controller
Solar PV Ser. No. from
String / Micro Inverter
Air Source Heat Pump Located on external
heat pump badge
Integrated Heat Pump
and Cylinder
Located on
cylinder badge
Underoor Heating Project ref. on
supplied schematic
Intergas Gas Boiler Located on
cylinder badge
Was a Pre-Plumbed
cylinder installed too?
Joule Advance Installer
I accept the terms and conditions in the installation manual
MUST BE COMPLETED AND
THEN REGISTERED ONLINE
TO COMPLETE WARRANTY

Acapella Installation Guide 3
Joule Product Warranty Terms & Conditions
1. The Buyer shall not make any statement or
representation or give any warranty to any
third party in respect of any, Goods other
than in the terms made or given by Joule
to the Buyer nor shall the Buyer have any
authority to commit Joule to provide any
service in relation to the Goods.
2. The Company’s liability to the Buyer for
death or injury resulting from its own or that
of its employees’ agents’ or subcontractors’
negligence and damage suered by the
Buyer as a result of any breach of the obli-
gations implied by Section 12 of The Sale of
Goods Act 1979 shall not be limited.
3. If Joule fails to deliver the Goods for any
reason other than any cause beyond the
Company’s reasonable control or the Buy-
er’s fault then Joule shall only be liable to
the Buyer for and the Company’s liability
shall be limited to the excess (if any) of the
cost to the Buyer (in the cheapest available
market) of similar goods to replace those
not delivered over the Price of the Goods.
4. The Buyer shall examine all delivered Goods
forthwith. Any claim based on any defect in
the quality or condition of the Goods or their
failure to correspond with specication shall
be notied to Joule within 7 days from the
delivery date or where the defect was not
apparent on reasonable inspection within a
reasonable time after discovery of the fail-
ure. If delivery is not refused and the Buyer
does not notify Joule the Buyer shall not be
entitled to reject the Goods.
5. Joule shall be entitled to examine any
Goods, which are the subject of any claim
by the Buyer, and to remove such Goods or
any part thereof for testing. No tests carried
out by the Buyer will be recognised by Joule
unless carried out strictly in accordance with
a method previously agreed by Joule as being
suitable for the purpose.
6. Any valid claim in respect of the Goods
which is based on any defect in the quality
or condition of the Goods or their failure to
meet specication is notied to Joule in ac-
Subject to the following provisions, Joule war-
rants that the Goods will be free from defects
in material and workmanship for a period of 20
years in relation to VACUUM TUBES and a peri-
od of 5 years for MANIFOLDS and KITS from their
date of manufacture. “RESTRICTED PRODUCTS”
are limited to a period of 12 months warranty. The
warranty is given by Joule subject to the following
conditions:
A The 20 year warranty period on Vacuum
Tubes is conditional on installation by a
Joule Solar Approved Installer, and subject
to the collector(s) being properly maintained
according to the manufacturer’s recommen-
dations. (See Joule Installation Manual for
further details). Otherwise a default 5 year
warranty period on Vacuum Tubes applies.
B Joule shall be under no liability in respect
of any defect in the Goods arising from any
information drawing design or specication
supplied by the Buyer.
C Joule shall be under no liability in respect of
any defect arising from fair wear and tear,
wilful or accidental damage, negligence, ab-
normal working conditions, failure to follow
the Joule’ instructions, misuse or alteration
or repair of the Goods without approval.
D The above warranty does not extend to
parts materials equipment not manufac-
tured by Joule Renewables in respect of
which the Buyer shall only be entitled to the
benet of any such warranty or guarantee
as is given by the manufacturer to the Com-
pany.
E The defect has been reported by the Buyer
to Joule within the warranty period.
F The installation of the Goods having been
carried out by fully trained and competent
person(s).
G The Goods having been subjected to nei-
ther “prolonged stagnation conditions” nor
exhibiting signs of “extreme temperature
exposure”.

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4
cordance with these Conditions Joule shall
be entitled to repair or replace the Goods (or
the part in question) free of charge or at the
Company’s sole discretion refund to the Buyer
the Price (or a proportionate part of the Price)
but Joule shall have no further liability to the
Buyer.
7. Joule shall not be liable to the Buyer by
reason of any representation (unless fraudu-
lent) or any implied warranty condition or
other term or any duty at common law (in-
cluding but without limitation the negligence
of Joule its employees agents or otherwise)
or under the express terms of the Contract
for any loss of production loss of prots or
anticipated prots loss of contracts opera-
tion time or anticipated savings loss of busi-
ness or of expected further business loss of
or corruption to data damage to the Buyer’s
reputation or goodwill damages costs or
expenses payable by the Buyer to any third
party or any other indirect special or conse-
quential loss or damage or claim (whether
caused by the negligence of Joule its em-
ployees agents or otherwise) which arise
out of or in connection with the supply of the
Goods or their use or resale by the Buyer.
8. Without prejudice to the provisions of
clauses 3, 4, 5, 6 and 7 the entire liability of
the Buyer under or in connection with the
Contract shall not exceed the Price of the
Goods.
9. Joule shall not be liable to the Buyer or be
deemed to be in breach of the contract by
reason of any delay in performing or any
failure to perform any of the Company’s ob-
ligations in relation to the Goods if the delay
or failure was due to any cause beyond the
Company’s reasonable control. Without lim-
iting the foregoing, due to causes beyond
the Company’s reasonable control.
10. For comprehensive details regarding “War-
ranties and Liability” please refer to the
“CONDITIONS OF SALES” section 7.

Acapella Installation Guide 5
Table Of Contents
6 Pre-Installation Notes
7 First Fix Notes
10 Standard Kit Components
12 UK Pack Components
13 IE Pack Components
14 Solar Pipe Components
15 Setting Out The Roof
16 Roof Mounting Instructions
17 Inserting The Tubes
18 Sloped Roof - Bolt Mounting Kit
19 Sloped Roof - Tile Mounting Kit
20 Sloped Roof - Slate Mounting Kit
22 Flat Roof
23 Finishing Roof Work
• Inserting Temperature Probe Into The Panel
• Connecting Solar Pipe To The Panels
24 Single Orientation Single Cylinder
• Under Roof Remaining Work
• Wiring The System
• Commissioning The System
26 Dual Orientation Single Cylinder
• Under Roof Remaining Work
• Wiring The System
• Commissioning The System
28 Single Orientation Dual Cylinder
• Under Roof Remaining Work
• Wiring The System
• Commissioning The System
30 Service Record
Do not crosswire the power cable with the comms cable on the solar
pump. If you do this you will see a ashing green light on the pump. The
pump will not operate. The pump will be rendered obsolete and will need-
ed to be replaced with a new pump. This is not covered under a product
warranty.

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6
Pre-Installation Notes
Solar hot water systems should be designed and sized correctly before commencing the installa-
tion. 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 has boiler, heat pump or wood boiler is re-
quired for months which have less solar radiation. This guide will illustrate and explain how a system
should be installed to conrm to the Joule manufacturer guidelines for the Navitas 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 recom-
mendations 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 ojects 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. Collecters left exposed in a dry state must be covered to prevent possible
long term damage.
• Tubes must have a miniumum elevant of 20 degress and a maximum or 70 degrees. The pipe
work of the solar collecter loop is to be earthed and the collector is to be lightening protected in
accordance to local regulations.
• A solar panel installation must be perofrmed 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 undertak- en by a qualied elec-
trical contract.
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).
Flow Rate And Pressure Calculation
No. of
Tubes
Flow Rate
ltr/hr
Pipe Diameter
Copper External
(“BSP)
20 Tube
System
(mbar)
30 Tube
System
(mbar)
40 Tube
System
(mbar)
20 120 3/4”M 8.54 1.18 4.11
30 240 3/4”M 17.08 2.36 8.22
40 360 3/4”M 25.14 5.74 20.94

Acapella Installation Guide 7
First Fix Notes
Degree of Over Shading
None / Little / A lot
Shading will reduce the overall performance of a solar system. During the planning
stage of a solar system. Consideration should be given to the location of the collectors
with the aim of minimising the eects of shading from high buildings, trees, etc.
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 & Est. 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 domes-
tic hot water production
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
1-2 people 200 litres 2 Panel System (4m2) 30 Tube
3-5 people 300 litres 3 Panel System (6m2) 40 Tube
Location of Solar Pump Station & Solar Controller
Ensure the pump station is located in an area where it can be easily accessed for
servicing & maintenance
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 easily accessible area for the user
Ensure that the controller is mounted at the ocrrct height for easy viewing.

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8
First Fix Notes
Safe Roof Access To Work
Is there adequate access to area of house to mount scaolding or ladders? yes/no
Is there steady and secure base on which to mount scaolding or ladders? yes/no
Are the scaolding and or ladders t 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 cur-
rent 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 xing 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 aky 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.
Eects of Snow Loads
What is the estimated annual snow fall for this part of the country? mm
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? kg
Irish/UK 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 m2x 150kg/m3)
When you nd 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.

Acapella Installation Guide 9
Eects of Wind Load
The evacuated tube collector is exempt from consideration of wind loading for
the same reason as the snow loading.
When considering at panels wind tests have been conducted that ensure that
they and their xing brackets can withstand all recorded wind forces in Ireland
when mounted on a four storey house or less.
Pipework & Liquids
Is anti freeze being used as the solar system uid?
Ensure solder joints are not used throughout ther entire system
Ensure high temperature insulation is used throught all pipe work in solar system
Ensure white paste and hemp is used on all tting connections throughout
Ensure you use Joule copper overow & disch. vessel to recover uid from safety valve
Water Quality
Water sample visually inspected and no signs of contamination visible yes/no
Fire Safety
Ensure that there is no obvious risk to re prevention by installing the solar
system.
Ensure that all wires are not in direct connection with any un-insulated pipe
work or plant that could cause a risk of burning
Legionella / Bacterial Growth
Ensure that there is no dead legs in the existing plumbing system that could
induce the growth of legionella.
Ensure that the stats controlling the boiler and the stat controlling the immer-
sion are set to 60 °C or above.
Ensure that the client understands the risk of legionella and the standard proce-
dures 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 re-
sponsibility 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 certied professional.

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10
Standard Kit Components
UK Pack Comp. IE Pack Comp.
Code Description 20 30 40 20 30 40
Components for Solar Kits
SZ-I-000000020 20 Tube Manifold Tubes 1-21-2
SZ-I-000000030 30 Tube Manifold Tubes -1--1-
SKN-C-00000ERP Solar Controller Deltasol BS HE (ERP) 111111
SVE-0000000024 Solar Expansion Vessel 24Ltr 1 1 1 1 1 1
SVE-0000000035 Solar Expansion Vessel 35Ltr - - - - - -
SVE-0000000050 Solar Expansion Vessel 50Ltr - - - - - -
SVS-0000000000 Solar Expansion Vessel Connect 1 1 1 - - -
SZ-L-0D-0ERP-5 Solar Pump Station Dual ERP 5m 1 1 1 1 1 1
SKU-0000000020 20L Pre-Mixed Solar Fluid 1 1 1 1 1 2
SVB-000000000P Solar Discharge- Plastic 1 1 1 - - -
OZM-0000.75NRV Thermo Mixing Valve 3/4^ NRV 1 1 1 1 1 1
SZ-G-0G-000004 Solar Pipe Entry Gasket Set 4” - - - 1 1 1
SZ-G-0G-000000 Solar Pipe Entry Flashing 1 1 1 - - -
Roof Mounting Options Depending On Roof Type
SKRT-T-0000020 20 Tube Roof Mounting Kit - Tile 1 - - 1 - -
SKRT-T-0000030 30 Tube Roof Mounting Kit - Tile - 1 - - 1 -
SKRT-S-0000020 20 Tube Roof Mounting Kit - Slate 1 - - 1 - -
SKRT-S-0000030 30 Tube Roof Mounting Kit - Slate - 1 - - 1 -
SKRT-B-0000020 20 Tube Roof Mounting Kit - Bolt - - - 1 - 2
SKRT-B-0000030 30 Tube Roof Mounting Kit - Bolt - - - - 1 -

Acapella Installation Guide 11
UK Pack Comp. IE Pack Comp.
Code Description 20 30 40 20 30 40
10m DN16 Solar Pipe Pack Standard System
SPD-16-10-0000 DN16 10m sol SS pipe duo ins 1 1 1 1 1 1
SZ-J-0000DN-16 solar tting joiner pack DN16 111111
15m DN16 Solar Pipe Pack Standard System
SPD-16-15-0000 DN16 15m sol SS pipe duo ins 1 1 1 1 1 1
SZ-J-0000DN-16 solar tting joiner pack DN16 111111
25m DN16 Solar Pipe Pack Standard System
SPD-16-25-0000 DN16 25m sol SS pipe duo ins 1 1 1 1 1 1
SZ-J-0000DN-16 solar tting joiner pack DN16 111111
* Pipe packs are not included in kit as standard. The requirement and length of these packs are
the responsibility of the contractor on site to order.
Flat Roof Frames - In Place Of Mounting Kits
SK-F-000-20-25 20 Tube Flat Roof Frame 25° - - - - - -
SK-F-000-30-25 30 Tube Flat Roof Frame 25° - - - - - -

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12
SZ-L-0D-0ERP-5 SKU-0000000020
SKN-C-00000ERP SVB-000000000P SVS-0000000000
OZM-0000.75NRV
UK Pack Components
SVE-0000000024
SVE-0000000036
SZ-G-0G-000000
Mounting Bracket Options
SKRT-B-0000020
SKRT-B-0000030
SKRP-T-00000001
SKRP-T-00000002
SKRP-S-00000001
SKRP-S-00000002

Acapella Installation Guide 13
OZM-0000.75HP
IE Pack Components
Excluding Flashing Kit
SZ-L-0D-0ERP-5 SKU-0000000020
SKN-C-00000ERP SVE-0000000024
SVE-0000000036
SZ-G-0G-000004
Mounting Bracket Options
SKRT-B-0000020
SKRT-B-0000030
SKRP-T-00000001
SKRP-T-00000002
SKRP-S-00000001
SKRP-S-00000002

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14
SZ-J-0000DN-16
Solar Pipe Components
Not Included In Standard Kit
SZF3/4-3/4-TEE SZF-22-3/4-TU0
Code Description
SPD-16-10-
0000
DN16 10m sol SS pipe duo ins
SPD-16-15-
0000
DN16 15m sol SS pipe duo ins
SPD-16-25-
0000
DN16 25m sol SS pipe duo ins
1 2 3 4
Cut pipe with splice
cutters
Insert single tting
and grab ring
Tighten to atten the
pipe end
Reassemble with
washer and tighten
again

Acapella Installation Guide 15
Setting Out The Roof
1 Panel Extension Flashing Kit
A
BC
D
E
F
Code Dimension
A 300mm
B 300mm
C 2,000mm
D (20 tube) 1,680mm
E (30 tube) 2,420mm
F (40 tube) 3,380mm
Mounting Orientations
Maimum 6 evacuated tube collectors vertically mounted
Tubes horizontally mounted
Tubes mounted above each other

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16
Roof Mounting Instrucions

Acapella Installation Guide 17
After the frame has been completely assembled and the system has been lled 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 suce if lubricant is not available.
1
Inserting Tubes
4
22
3

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18
Roof xing 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 prole by use of a stainless steel L plate and
nuts, bolts and washers. The bolt head slides
through the prole to the desired location and
the L bracket to xed using the nut and washer.
Sloped Roof - Bolt Mounting Kit

Acapella Installation Guide 19
Adjustable tile roof mounting brackets are an
ideal solution when xing a solar collector to a
thick roof tile. The top piece can adjust to in-
crease or decrease the height of the collector
above the roof tile. The bracket is connected to
the prole using nuts, bolts and washers. The
bolt head slides through the prole to the de-
sired location and then the bracket is xed using
the nut and washer.
Sloped Roof - Tile Mounting Kit

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20
Sloped Roof - Slate Mounting Bracket
30mm clearance
The elbow of the bracket must give at least 30mm clearance from the
rafter to bend down the roof i.e the elbow should be no less than 30mm
deep and then can be made to work with shims (packing). Brackets with
clearance of 40/45mm from the rafter probably won’t need shims.
Shims (packaging) are used to lift the roof anchor/bracket away from the
slate underneath the bracket.
Any contact between the ashing and the roof anchor/bracket could
cause a problem.