Apricus Solar Water Heating System Installation and Operation ...

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Apricus Solar Collector Installation & Operation Manual - USAEXT-30 Expansion Tank1(shipped in separate box)Expansion Tank Connection Kit(1 x Expansion Tank Mounting Bracket)1(1 x 1/2” FPT / 3/8” Barbed Onix)(1 x 1/2” MPT / 3/8” Barbed Onix )(2 x 3/8” Onix Ring Clamps)Expansion Tank Mounting Kit1(4 x 1 1/2” Wall Screws)(4 x 1 1/2” Wall Anchors)1 Expansion Tank Hose (black ONYX)7.4. Mountinga) Mounting Surface: The pump station can be mounted on most wall types using the provided screws. Ifbuilding structural members are not available a wooden board or the provided hollow wall anchors shouldbe used to provide secure attachment points.b) Pipe Layout: It is a good idea to layout all piping before securing the pump station in place, to make surethat everything fits properly and sensor cables can reach the tank, etc.c) To mount the pump station:Step 1. Mark and drill a pilot hole for center screw.Step 2. Mark and drill a pilot hole 6-1/4” left of center hole for controller bracket screw.Step 3. Insert steel sleeve in insulation around center hole.Step 4. Insert the plastic hollow wall anchors into the holes if building structural members are notavailable.Step 5. Using a Phillips head screwdriver and the appropriate screws and washers secure the pumpstation to the wall.7.5. Plumbing Connectiona) Leak Testing: Before commencing attachment of the pump station to the solar loop, the collector mustbe plumbed to the feed and return lines and an air pressure test to 116psi for at least 15min or in line withlocal codes and regulations. This is important because if there is a leak in the roof space it could causesignificant damage to the building. In addition, by doing the pressure test first, once the pump station isthen attached and fill and pressurization completed, piping on the roof and in the roof space can be ruledout if there is any pressure drop or leaks.b) Quick Connect: All pump stations provide 3/4” quick connect fittings both top and bottom. If you wish touse 1/2” or 3/4” flexible stainless steel piping for the solar loop, remove the quick connect fittings and useadditional fittings as required.c) Connection Process: Only standard hard drawn 3/4” copper pipe should be used for with quick connectfittings. If 1/2” or 3/8” copper is being used for the solar loop use standard adapters to reduce to that smallerpipe size.Step 1. Mark the copper pipe 1-3/8” from end of pipe.Step 2. De-burr the inside and outside of the pipe end to ease insertion and possible future removal.Step 3. Push the pipe into the push fitting until you can not see the mark.Step 4. Pull back on pipe to insure internal connection is secure.To remove pipe from push fitting, simultaneously push the plastic ring toward fitting while pulling pipe out offitting.Copyright 2011 – Apricus Inc Doc: A7-05.4.1.4-PB-1.9 Page 64 of 126
Apricus Solar Collector Installation & Operation Manual - USAd) Pressure Relief: The pressure relief valve is included as a safety device, designed to open at 75 psishould the system pressure rise to that level. This may occur if for example the expansion tank is not bigenough or some blockage occurs that prevent normal operation or extreme overheating occurs.e) Drain Pipe: The pressure relief valve drain pipe fitting is a 3/4” FPT connection. Install and tighten drainpipe fitting with two wrenches taking special care not to stress the pressure relief valve support pipe.WARNING- Pressure relief valve must NOT be blocked.- A drain pipe must be connected to the relief valve.- The drain pipe diameter must be no smaller than 3/4” and be able to withstandtemperature of up to 230° F (110°C).- Pressure relief piping must meet local codes7.6. Controller Connectionsa) The Apricus controller comes pre-installed on the left side of the pump station.b) Remove the controller cover by removing the screw with a small straight blade or star screwdriver. Pullthe cover straight off to expose the electrical (left) and sensor (right) terminal connections.c) Install system temperature sensors. (See section 6.4)Step 1. Insert collector sensor (RED high temp wire) into collector sensor well on the solar return sideof the collector. Route the wire along the return pipe to the pump station avoiding direct contact withthe pipe.NOTICEDo not install the sensor wires in direct contact with system pipes. Route sensor wires onthe outside of system pipe insulation whenever possible.Step 2. Insert storage tank sensor (GRAY wire) into storage tank sensor well. Route the wire along thereturn pipe to the pump station avoiding direct contact with the pipe.Step 3. Remove the wire strain relief bar on sensor terminal side of controller.Step 4. Connect the red collector sensor wire to T1 terminals (red and white wires).Connect grey storage tank sensor to T2 terminals (brown and white wires).Step 5. Replace wire strain relief bar.d) Sensors wires can be fed through the pump station and out the top to run along the collector return pipeor out the bottom along the tank return pipe (OUTSIDE THE INSULATION).e) Once all wires are connected to the controller the cover can be replaced.Copyright 2011 – Apricus Inc Doc: A7-05.4.1.4-PB-1.9 Page 65 of 126
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