5 1 Calpak Products Mark5 Manual

TECHNICAL DOCUMENTATION
THERMOSIPHONIC SOLAR WATER HEATERS MARK5

& SOLAR THERMAL COLLECTORS M5
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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.
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. INSTALLATION OF STAND ALONE COLLECTORS ON A FLAT ROOF PAGE 34
X. INSTALLATION OF COLLECTOR ARRAYS ON A FLAT ROOF PAGE 39
XI. INSTALLATION OF COLLECTOR ARRAYS UP TO 20m² PAGE 44
XII. INSTALLATION OF STAND ALONE COLLECTOR ON INCLINED ROOF PAGE 45
XIII. FUNCTION AND MAINTENANCE PAGE 50
THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

TECHNICAL DOCUMENTATION / PAGE 1
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 3000 Pa.

SYSTEM COMPONENTS
1. Collector
2. Tank
3. Support Base System
4. Thermal fluid (propylene glycol)
5. 1 pressure relief valve for the closed circuit
6. 1 safety non-return valve for the domestic cold water line
7. Insulated connecting pipes
8. Pipe fittings
SAFETY EQUIPMENT
Items 5 and 6 in the above list are provided for system safety.
Both valves conform to END 1489 standard.
When system is not used for a period exceeding 3 days, overheating of the system may cause very high
tapping temperatures. It is recommended to install an automatic thermostatic mixing valve or a T&P
valve.
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)

II) TECHNICAL CHARACTERISTICS
Technical data M5 flat plate selective collectors
Type M5-210 M5-260 M5-260H M5-300 M5-300H

Gross area (m²) 2.09 m2 2.59 m2 2.59 m2 2.99 m2 2.99 m2
Absorber area (m²) 1.99 m2 2.48 m2 2.48 m2 2.84 m2 2.84 m2
Aperture area (m²) 1.96 m2 2.44 m2 2.44 m2 2.83 m2 2.83 m2
W x L x H (mm) 1230*1697*85 1230*2107*85 2107*1230*85 1500*1997*85 1997*1500*85
Weight (kg) 34,5 47 47,5 48,5 51
Absorber capacity
1,5 1,8 2 2,2 2,4
(l)
Housing aluminum frame
Absorber Selective aluminum
Absorption 95 + 2
Emission (%) 4+2
Number of tubes 14 14 18 17 18
Absorber tube Dia. 8 mm
Glass 3.2 mm low iron mistlite tempered glass
Transmittance of
>0,90
glass (%)
Insulation 40 mm Rockwool, density 50kgr/m3
Stagnation temp at
1000 W/m² and 177,6 C
30C
Max.operating
10
pressure (bar)

C
A
B
Collector
 Aluminum flat plate selective absorber
 Ultrasonic welded on copper harp
 Rock wool insulation
 Aluminium profile frame
 Low iron tempered glass
Tank
 Enameled tank according to DIN 4753/3
 Insulation with expanded polyurethane, 50mm thick
 Magnesium anode cathodic protection according to DIN 4753/6
 Electrical resistance 3,5 KW
 Heat exchanger to connect to a boiler (model TRIEN)
Base
● Heavy duty bespoke anodized aluminium profiles
● Optimized construction
● CNC production for superior accuracy and quality
● Unified system for all systems for ease of installation
● Superior anchoring to roof
Safety Equipment
● Pressure relief valve for the closed circuit mounted on tank to END 1489
● Safety non return valve for the domestic cold water line to END 1489

Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 Μ4 M4 Μ4
Model 125/ 160/ 160/ 160/ 200/ 200/ 200/ 200/ 300/ 300/
2.1 2.1 2.6 2.6Η 2.1 2.6 2.6H 3.0 3.0 3H
Length
1385 1385 1385 2107 1710 1710 2107 1710 2310 2310
Dimensions (mm) Α
[45/30 Depth 1684/ 1684/ 1973/ 1324/ 1684/ 1973/ 1324/ 1867/ 1867/ 1515/1
degree (mm) Β 1892 1892 2247 1488 1892 2247 1488 2152 2152 722
inclination] Height 1700/ 1700/ 1989/ 1370/ 1700/ 1989/ 1370/ 1904/ 1904/ 1552/
(mm) Γ 1326 1326 1531 1093 1326 1531 1093 1476 1476 1228
System weight empty (kg) 88.3 102.5 115 115.5 120.5 133 133.5 134.5 167.2 169.7
System weight full (kg) 207.8 255 267.8 268.5 314 326.8 327.5 328.7 464.4 467.1
Optional electrical
3,5 3,5 3,5 3,5 3,5 3,5 3,5 3,5 3,5 3,5
resistance (kW)
Tank
118 151 151 151 192 192 192 192 295 295
volume (l)
Tank
weight
53.8 68 68 68 86 86 86 86 118.7 118.7
empty
Tank (kg)
Tank
weight 171.8 219 219 219 278 278 278 278 413.7 413.7
full (kg)
Length
1385 1385 1385 1385 1710 1710 1710 1710 2310 2310
(mm)
Diameter
500
(mm)
Dimensio
1230* 1230* 1230* 2107* 1230* 1230* 2107* 1500* 1500* 1997*
ns of
1697* 1697* 2107* 1230* 1697* 2107* 1230* 1997* 1997* 1500*
collector
85 85 85 85 85 85 85 85 85 85
(mm)
Number
of 1 1 1 1 1 1 1 1 1 1
collectors
Gross
area per
2.09 2.09 2.59 2.59 2.09 2.59 2.59 2.99 2.99 2.99
collector
(m²)
Weight
Collectors per
collector 34,5 34,5 47 47,5 34,5 47 47,5 48,5 48,5 51
empty
(kg)
Max.
Working 177,6 C
temp.
Thermal
liquid per
1,5 1,5 1,8 2,0 1,5 1,8 2,0 2,2 2,2 2,4
absorber
(l)
Max.
collector
circuit 2 MPa
working
pressure

Μ4 Μ4 M4 M4
Model 200/ 300/ 300/ 300/
4.2 4.2 5.2 6.0
Length
2553 2553
Dimensions (mm) Α
[45/30 Depth 1684/ 1684/ 1973/ 1867/
degree (mm) Β 1892 1892 2247 2152
inclination] Height 1700/ 1700/ 1989/ 1904/
(mm) Γ 1326 1326 1531 1476
System weight empty (kg) 155 187.7 212.7 215.7
System weight full (kg) 350 485.7 511.3 515.1
Optional electrical
3,5 3,5 3,5 3,5
resistance (kW)
Tank
volume 192 295 295 295
(l)
Tank
weight
86 118.7 118.7 118.7
Tank empty
(kg)
Tank
weight 278 413.7 413.7 413.7
full (kg)
Length
1710 2310 2310 2310
(mm)
Diameter
500
(mm)
Dimensio 1230* 1500*
1230* 1230*
ns of 2107* 1997*
1697* 1697*
collector 86 86
86 86
(mm)
Number
of
2 2 2 2
collector
s
Gross
area per
2.09 2.09 2.44 2.83
collector
(m²)
Weight
Collectors per
collector 34,5 34,5 47 48,5
empty
(kg)
Max.
working 177,6 C
temp.
Thermal
liquid per
1,5 1,5 1,8 2,2
absorber
(l)
Max.
collector
circuit 2 MPa
working
pressure

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do 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.

IV) INSTALLATION OF SYSTEM ON A FLAT ROOF [Single Collector Models]
SOUTH
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.
TABLE Α
TANK 125/160 L 200 L* 300 L
DISTANCE A [mm] 1192 1480 1944
*Mark 4 200/2.1 & Mark 4 200/2.6 systems: Distance A (mm) is 1192
ATTENTION: Failure to fix the pillars to the roof material will eventually result in support structure
failure under extreme loading conditions. The anchoring of the system to the flat roof floor should be
implemented with devices that are appropriate to the floor material.
In order to avoid humidity problems or water penetration (rain/snow) in the roof, the pipes which are
entering the roof must be very well sealed. Local building engineer should provide you with precise
guidelines depending on the kind of roof construction and/or local legislation. The same applies to the
system anchoring points, regardless of the devices used for the installation.

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.

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.

Β
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
*Mark 5 200/2.1 & Mark 5 200/2.6 systems: Distance B (mm) is 1090
STEP 7
Tighten the 4 collector securing bolts.

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 160/ 200/ 200/ 300/
125/2,1 160/2,1 160/2,6 200/2,1 200/2,6
2,6Η 2,6H 3 3Η
DISTANCE
C [mm] 1304 1304 1304 2181 1304 1304 2181 1574 2071

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.

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.

STEP 12
Connect the brace system with the pillars. Do not tighten the bolts, ensure however that they are not
very loose.

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.

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.

V) INSTALLATION OF SYSTEM ON A FLAT ROOF [Double Collector Models]
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

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.
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.
NOTES
1. The anchoring of the system to the flat roof floor should be implemented with devices that
are appropriate to the floor material.
2. In order to avoid humidity problems or water penetration (rain/snow) in the roof, the pipes
which are entering the roof must be very well sealed. Local building engineer should provide
you with precise guidelines depending on the kind of roof construction and/or local
legislation. The same applies to the system anchoring points, regardless of the devices used
for the installation.

Figure 4. Front view of installed 300/4.2 system.
Figure 5.Rear view of installed 300/4.2 system.

VI) INSTALLATION OF SYSTEM ON INCLINED ROOF [All systems]
CAUTION: Check the capacity of the roof structure to bear the solar heater load in operation with the
constructor of the building or contact the local authorities.
STEP 1
Uncover the roof tiles at the lowest and the highest part of the area where the thermosiphonic system
will be installed. Install the 4 AGG brackets (or the AT – triangular type or the AR – special screw, if
needed) on the vertical, load bearing beams with appropriate screws, as shown on the drawing above.
Make sure that the distances A and B between any of the top holes on each bracket are set according
to Table 1. You may take advantage of the fact that there are 3 holes on the top of each bracket to
accommodate for different tile sizes. In case the AGG brackets do not coincide with the roof beams,
use the additional 20 cm extension piece for AGG brackets [right drawing].
TABLE 1
SYSTEM 125/2.1 160/2.1 160/2,6 160/2,6H 200/2,1 200/2,6 200/2,6H 200/3 300/3H 300/4.2
DIMENSION A
(mm)
1082 1082 1082 1082 1370 1370 1370 1370 1834 1834
DIMENSION B
2120 2120 2475 1765 2120 2475 1765 2475 2120 2120
(mm)

SYSTEM 200/4,2 300/4.2 300/5,2 300/6,0
DIMENSION A 1834
(mm)
1370 1834 1834
DIMENSION B 2120
2120 2475 2475
(mm)
STEP 2
Replace the roof tiles and install the two longitudinal base sections onto the AGG brackets. Make use
of the telescopic feature of the sections to adjust them to the appropriate length.

STEP 3
Install the transverse beam joining the two longitudinal sections.
STEP 4
Install the two support struts joining the transverse beam with the two longitudinal sections.

C
STEP 5
Install the two L beams supporting the collector. The distance C between the vertical mounting faces
of two beams should be set according to Table 2 to fit the height of the collector. Secure only the
bottom beam and slide the top beam upwards to ease collector installation.
TABLE 2
SYSTEM 125/2.1 160/2.1 160/2,6 160/2,6H 200/2,1 200/2,6 200/2,6H 200/3 300/3H 300/4.2
DIMENSION
C (mm) 1711 1711 2025 1244 1711 2025 1244 2011 1514 1711
SYSTEM 200/4,2 300/4.2 300/5,2 300/6,0

DIMENSION
C (mm)
1711 1711 2025 2011

STEP 6
Place the collector(s) on the base assembly. Tighten the bottom securing bolts against the bottom
support beam.
STEP 7
Slide the top support beam against the collector and tighten the support bolts. Tighten the support
beam onto the longitudinal base sections.

STEP 8
Adjust the tank support to a horizontal position and install the tank.
Figure 1: Components of the inclined roof base system.

Figure 2: Installation and base system dimensions.
INSTALLATION
DIMENSIONS /
SYSTEM A B C
125/2,1 1082 2120 1711
160/2,1 1082 2120 1711
160/2,6 1082 2475 2025
160/2,6H 1082 1765 1244
200/2,1 1370 2120 1711
200/2,6 1370 2475 2025
200/2,6H 1370 1765 1244
200/3 1370 2475 2011
300/3H 1834 2120 1514
200/4.2 1370 2120 1711
300/4,2 1834 2120 1711
300/5.2 1834 2475 2025
300/6.0 1834 2475 2475
BASE DIMENSIONS
SYSTEM L1 L2 L3 L4
125/2,1 1116 1600 866 1240
160/2,1 1116 1600 866 1240
160/2,6 1116 2000 866 1240
160/2,6H 1116 1200 866 1560
200/2,1 1404 2000 866 1240
200/2,6 1404 2000 866 1240
200/2,6H 1404 1720 866 1560
200/3 1404 2000 866 1560
300/3H 1868 1600 866 2000
200/4.2 1404 1600 866 1560
300/4,2 1868 1600 866 2000
300/5.2 1868 2000 866 2000
300/6.0 1868 2000 866 2000

VII) HYDRAULIC CONNECTION OF SYSTEM [All systems]
Figure 3: Schematic of complete system. [1] Domestic cold water supply according to DIN EN 806 or
to country-specific regulations. [2] Water filter. [3] Pressure reduction valve MAX 10 bar. [4] Cut off
valve. [5] Non return valve + 10 bar safety valve. [6] Cold/hot mixer for domestic hot water use, e.g.
shower.
Figure 4: Thermosiphonic system layout and connections. [1] Domestic cold water supply, 10bar
safety valve + non return valve. [2] Hot water outlet. [3] Closed circuit, hot inlet port. [4] Closed
circuit, cold outlet. [5] 2.5 bar safety valve.
Figure 5: Thermosiphonic connection sizes.
Figure 6: Thermosiphonic connection sizes. System shown is not MK5, however the connection are
identical.

STEP 1
Connect the cold water supply tube and the safety and non-return valve onto the tank. To save time
you may start filling the tank at this point. When water starts overflowing from the hot water open
circuit outlet close the water supply.
STEP 2
Connect the hot water closed circuit tube between the collector and the tank. Ensure that the tube
follows an upwards route towards the tank. When tightening the fittings on the collector exit make sure
you use 2 spanners, 1 for tightening and 1 against to avoid damaging the absorber.

STEP 3
Connect the cold water closed circuit tube between the collector and the tank. Ensure that the tube
follows an upwards route towards the tank. When tightening the fittings on the collector inlet make
sure you use 2 spanners, 1 for tightening and 1 against to avoid damaging the absorber. Make sure the
length and shape of the tube is appropriate. Do not tighten the tube on the tank side.
STEP 4
Mix water and NOX fluid in a bucket according to the table in Chapter 1.

STEP 5
Detach the cold water closed circuit tube from the tank. Pour the solution slowly into the tube in order
to fill the collector. Let the liquid overflow through the outlet of the tank until no air bubbles come out
and then attach and tighten the cold fluid union to the tank. You may need to attach an auxiliary tube
to the cold water closed circuit tube so as to pour the solution from a point higher than the closed
circuit hot water inlet of the tank.
STEP 6
Complete filling the closed circuit with the solution from the safety valve outlet at the top of the tank.

STEP 7
Assuming the tank is filled with water and the closed circuit is filled with solution you may remove the
cover sheet from the collector at this point. If it is a sunny day the solution will start overflowing from
the safety valve outlet at the top of the tank as it heats up. If there is no overflow check that:
1. The closed circuit is filled.

2. There is no air in the closed circuit.
3. There are no leaks in the closed circuit connections.
Take the appropriate action until there is overflow.
STEP 8
Connect the domestic hot water tube. Turn on the domestic cold water supply and check for leaks. The
domestic water pressure should cause the closed circuit solution to overflow from the safety valve
outlet at the top of the tank. If there is no overflow perform the diagnostic tests of Step 7.

STEP 9
After approximately 20 minutes you may install the closed circuit safety valve at the top of the tank.

CHECKLIST BEFORE START - UP
NUMBER ACTION YES NO

Is the thermosiphonic system facing South for the North hemisphere
1
and North for the South hemisphere?
Did you check that the thermosiphonic system is not located in the
2
shadow throughout the whole year?
Was the collector installed with an installation angle between 15º -
3
45º?
Is the thermosiphonic system installed at least 1m distance from the
4
walls or the end of the roof?
5 Did you use the provided manual during installation?
6 Is max operational pressure 10bar?

If the pressure of the cold water is more than 10bar, did you install a
7
pressure reducer?
8 Did you notice the statics?
Did you get required measures to prevent water penetration? Did
9
you seal accordingly?
Did you insulate all piping according to local weather conditions to
10
avoid freezing and UV damage?
11 Did you connect all the fittings?
12 Are all hydraulic connections free of heavy loads?
13 Did you check for leakages?
14 Did you use the original glycol for freezing protection?
15 Did you check that all valves are working properly?
16 Did you check the mounting system for visible damage?
17 Did an authorized electrician install the original electrical heater?
18 Did you install the system according to manual?
19 Are all connections done correctly (screws are tighten, etc.)
20 Is the tank fastening done correctly?
21 Did you do the starting up of the system according to manual?
22 Did you do a functional check 30 minutes after installation?

VIII) ELECTRICAL CONNECTIONS
The electrical connections must be in compliance to the regulations applied in the country of
installation and must always be realized by a certified electrician. Below is a diagram of how the power
supply is connected to the heating element through the thermostat.
ELECTRICAL
CABLE
HOLE
WATER OVERFLOW HOLE
IMPORTANT: The electrical connections plastic cover on the side of the water tank should be installed
as shown in the drawing above. The smaller hole is for the overflow of any water leaking into the
electrics cavity and should be placed at the lowest point of the cover. The electrical cable hole is larger
to accommodate for the diameter of the cable and protective sheath.
CAUTION: If you DO NOT connect the electrical resistance with the electrical panel of your house, you
need to earth the anode with the roof’s slab or with elsewhere made of concrete or wood and certainly
NOT with the electrical earthing in order to fulfill the warranty conditions of your solar water heater.

IX) INSTALLATION OF STAND ALONE COLLECTORS ON A FLAT ROOF
STEP 1
Place the collector on the roof floor and attach the collector feet on the collector as shown in the figure
above. Tighten the bolts so as to prevent any free play while still allowing rotation of the collector.
Attach the collector feet on the roof floor. Follow the instructions for positioning the system in Chapter
III. 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.

A
STEP 2
Use a small object to raise the top side of the collector from the floor just enough to be able to install
the support strut feet at a distance A [mounting hole to mounting hole] according to Table 1. For best
installation results the mating surfaces of the collector side and the support strut feet should be
tangential as shown in the figure above.
TABLE 1
COLLECTORS M5-210 M5-260 M5-260H M5-300 M5-300H
DISTANCE A [mm]
45 degrees installation 972 1240 697 1240 972
DISTANCE A [mm]
30 degrees installation 1390 1765 1007 1765 1390

STEP 3
Attach both support struts onto the support strut feet. Tighten the bolts until they are loose enough to
allow rotation.
STEP 4
Lift the collector from its top while raising one of the support struts.

STEP 5
Connect the top end of the support strut with the bolt on the collector side. Do not tighten the bolt
fully.
STEP 6
Connect the remaining support strut. Do not tighten the bolt fully.

STEP 7
Ensure that the collector is set up to the appropriate angle. The collector support feet can be used as
guides in setting the angle as they are cut at 45 degrees. The angle between the bolt, the bottom hole
and the horizontal is 30 degrees. When the correct angle is set tighten all 8 bolts [4 collector bolts and
4 bolts at the bottom part of the support struts].
X) INSTALLATION OF COLLECTOR ARRAYS ON A FLAT ROOF

STEP 1
Place the first collector on the roof floor and attach the collector foot on the collector on the end of the
array as shown in the figure above. Tighten the bolt so as to prevent any free play while still allowing
rotation of the collector. Attach the collector foot on the roof floor. Follow the instructions for
positioning the system in Chapter III. 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.
On the side where the next collector will be installed attach the bottom brace. Tighten the bolts
securing it on the collector but do not attach it on the floor.

STEP 2
Follow Steps 2-7 of Chapter VII to connect the support struts to the collector and set it at the
appropriate angle. Once the struts are secured secure the bottom brace to the floor.
STEP 3
Attach the top brace at the top of the collector.

STEP 4
Install the next bottom brace at a distance equal to the width of the collector (1300mm, from hole to
hole on the floor). Ensure that the two braces are in line.
STEP 5
Place the next collector on the braces. Install the bolts and tighten them enough to prevent free play
while allowing the collectors to slide towards each other. Tighten the hydraulic connections between
the two collectors and then the collector securing bolts.

STEP 6
Install the support strut. Before tightening the collector securing bolts ensure that the edge of the
collector is set at the appropriate angle.
STEP 7
Attach the top brace at the top of the collector.

STEP 8
Continue with the installation of the remaining required collectors following steps 4-7. The last collector
of the array should have a foot already attached before installation onto the braces. Tighten the
securing bolts on the braces first and then attach the collector foot to the floor.
STEP 9
Install the last support strut.

XI) INSTALLATION OF COLLECTOR ARRAYS UP TO 20m²
DN 32 mm [1 1/4”] HOT WATER OUTLET
DN 32 mm [1 1/4”]
DN 25 mm [1”]
INLET OF DN 25 mm [1”]
COLD WATER
DN 20 mm [3/4”]
DN 25 mm [1”]

XΙΙ) INSTALLATION OF STAND ALONE COLLECTOR ON INCLINED ROOF
CAUTION: Check the capacity of the roof structure to bear the solar heater load in
operation with the constructor of the building or contact the local authorities.
A PICTURE 1
PICTURE 2 PICTURE 3
STEP 1
Uncover the roof tiles at the lowest and the highest part of the area where the thermosiphonic system
will be installed. Install the 4 AGG brackets (or the AT – triangular type or the AR – special screw, if
needed) on the vertical, load bearing beams with appropriate screws, as shown on the drawing above
(pic.2). Make sure that the distances A and B (pic.1) between any of the top holes on each bracket are
set according to Table 1. You may take advantage of the fact that there are 3 holes on the top of each
bracket to accommodate for different tile sizes. In case the AGG brackets do not coincide with the roof
beams, use the additional 20 cm extension piece for AGG brackets (pic.3).

TABLE 1
2X 2X
M5-210 M5-260 M5-260H M5-300 M5-300H
COLLECTOR (S) M5-210 M5-260
DIMENSION A 1160 1160
940 940 940 940 940
[MM]
DIMENSION B 1930 2050
1930 2050 1700 2050 1770
[MM]
Note: The dimension B may be extended up to 700 mm so that the AGG enter the finishing tiles.
STEP 2
Replace the roof tiles and install the two longitudinal base sections onto the AGG brackets. Make use
of the telescopic feature of the sections to adjust them to the appropriate length.
STEP 3

Install the two L beams supporting the collector. The distance C between the vertical mounting faces
of two beams should be set according to Table 2 to fit the height of the collector. Secure only the
bottom beam and slide the top beam upwards to ease collector installation.
TABLE 2
2X 2X
M5-210 M5-260 M5-260H M5-300 M5-300H
DIMENSION C 1711 2121
1711 2121 1244 2011 1514
[MM]
STEP 4
Place the collector(s) on the base assembly. Tighten the bottom securing bolts against the bottom
support beam.

STEP 5
Slide the top support beam against the collector and tighten the support bolts. Tighten the support
beam onto the longitudinal base sections.
Figure 1: Components of the inclined roof base system.

Figure 2: Installation and base system dimensions.
2X 2X
M5-210 M5-260 M5-260H M5-300 M5-300H
DIMENSION A [MM] 940 940 940 940 940 1160 1160
DIMENSION B [MM] 1930 2050 1700 2050 1770 1930 2050
DIMENSION C [MM] 1711 2121 1244 2011 1514 1711 2121
COLLECTOR(S) L2 L3 L4
M5 210 2000 866 1240
M5 260 2000 866 1240
M5 260H 1720 866 1240
M5 300 2000 866 1240
M5 300H 2000 866 1240
2 x M5 210 2000 866 2000
2 x M5 260 2000 866 2000

XΙΙΙ) FUNCTION AND MAINTENANCE
In order to protect the system from overheating, during high irradiation periods, it is highly
recommended to install a T-P valve at the domestic hot water outlet, allowing the direct evacuation of
the overheated sanitary water to the sewerage system. This T-P valve shall be set up to 60 °C. Otherwise
cover the surface of the collector partially when there is low consumption or fully when there is no
consumption at all (long period of absence). For this purpose choose the specialized covers for Calpak
M4 collectors.
It is also possible to install an expansion vessel at the upper part of the tank, which will store the liquid
of the closed circuit when expanding and prevent it from spreading in the atmosphere. In this case the
safety valve is installed above the expansion vessel.
In case the solar heater’s performance drops, check that:
1. Orientation to the south is correct (or North for the South hemisphere)
2. The collector is at the appropriate angle, free of shadow and obstacles
3. All the connections are tight, with no leaks
4. The tubes of the closed circuit have the correct angle and do not generate siphoning
5. There are not any air bubbles in the closed circuit
6. The closed circuit is full of thermal fluid
7. There is no leakage or a mixing mistake in the domestic hot water supply.
For proper system maintenance a specialist should check every year (preferably September or
October):
1. The magnesium rod of the tank, which should be free from salt deposits and to a size larger
than 50% of its initial state. Otherwise must be replaced.
2. If the closed circuit of the tank needs to be filled with Nox Fluid (see page 1 for correct
proportion) to ensure both the corrosion and antifreeze protection of the tank as well as the
good performance of the heat exchanger.
3. The proper operation of the electrical resistance
4. If the safety valve at the cold water inlet is normally operating (if there are accumulated salts
and is not possible to be cleaned, it must be replaced).
5. If the collector’s glass is clean
6. Any other possible damage
XIV) DECOMΜISSIONING
Before decommissioning the system you must make sure local legislation is met. Contacting local
authorities is highly recommended.


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TECHNICAL DOCUMENTATION

THERMOSIPHONIC SOLAR WATER HEATERS MARK5

II. TECHNICAL CHARACTERISTICS PAGE 4

III. POSITIONING OF THE SYSTEM PAGE 7

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. INSTALLATION OF STAND ALONE COLLECTORS ON A FLAT ROOF PAGE 34

X. INSTALLATION OF COLLECTOR ARRAYS ON A FLAT ROOF PAGE 39

XI. INSTALLATION OF COLLECTOR ARRAYS UP TO 20m² PAGE 44

XII. INSTALLATION OF STAND ALONE COLLECTOR ON INCLINED ROOF PAGE 45

XIII. FUNCTION AND MAINTENANCE PAGE 50

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

TRANSPORT & HANDLING

Temperature (ºC) -10 -15 -20 -25 -30 -35

Percentage in water solution

PERMISSIBLE SNOW LOAD AND MEAN WIND VELOCITY

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

Both valves conform to END 1489 standard.

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

Type M5-210 M5-260 M5-260H M5-300 M5-300H

Absorber area (m²) 1.99 m2 2.48 m2 2.48 m2 2.84 m2 2.84 m2

Aperture area (m²) 1.96 m2 2.44 m2 2.44 m2 2.83 m2 2.83 m2

W x L x H (mm) 1230*1697*85 1230*2107*85 2107*1230*85 1500*1997*85 1997*1500*85

Weight (kg) 34,5 47 47,5 48,5 51

Housing aluminum frame

Absorber Selective aluminum

Emission (%) 4+2

Absorber tube Dia. 8 mm

Glass 3.2 mm low iron mistlite tempered glass

Insulation 40 mm Rockwool, density 50kgr/m3

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

*Mark 4 200/2.1 & Mark 4 200/2.6 systems: Distance A (mm) is 1192

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

*Mark 5 200/2.1 & Mark 5 200/2.6 systems: Distance B (mm) is 1090

Tighten the 4 collector securing bolts.

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

Install washers and the nuts on the tank securing bolts.

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

Tighten the middle bolt against the brace foot.

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

Figure 2: Top brace and hydraulic connection between the collectors

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

Place the two collectors side by side on the roof floor.

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.

THERMOSIPHONIC SOLAR WATER HEATERS & SOLAR THERMAL COLLECTORS

W x L x H (mm) 1230169785 1230210785 2107123085 1500199785 1997150085