Apricus Solar Water Heating System Installation and Operation ...

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8.2. Direct Flow Pump Station Technical DataApricus Solar Collector Installation & Operation Manual - USAPump StationDirect FlowOverall Depth8.375” / 213 mm (With Insulated Cover)Overall Height24.5” / 622 mmOverall Width17.5” / 444 mmWeight (Empty)24 lb. /10.9 kg.Solar Connection!” (7/8” OD copper) Quick Connect FittingTank Connection!” (7/8” OD copper) Quick Connect FittingPressure Relief Valve Connection!” FPTPressure Relief Valve Pressure75psi / 5.1barRecommended Max. Operating Pressure50psi / 3.5barMax. Operating Temperature 230°F / 110°CCirc. PumpGrundfos UPS 15-29 SFMax. Flow Rate20.5 gpmMax. Head9.7 ftFlow Meter Range0.5 – 4.0 gpmSystem Voltage120 VACAcceptable FluidsPotable grade water8.3. Unpackinga) Pull off front insulation casing - there are no screws or clips to undob) Check that the box contains ALL the materials listed below. Immediately report missing or damagedparts.QtyDirect Flow1 Direct Flow Pump Station with Controller and Insulated Cover1Pump Station Mounting Kit(1 x 1 3/8” Steel Sleeve)(2 x 3” Wall Screws)(2 x 1 1/2” Wall Screws)(1 x 1” Wall Screws)(4 x 1 1/2” Wall Anchors)(4 x Washers)1 Solar Controller Collector Temperature Sensor (RED)2 Solar Controller Tank Temperature Sensor (Gray)1Solar Controller Data Log Kit(1 x 1GB SD Card)(1 x SD Card / USB Adapter)8.4. 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 sureCopyright 2011 – Apricus Inc Doc: A7-05.4.1.4-PB-1.9 Page 72 of 126
Apricus Solar Collector Installation & Operation Manual - USAthat 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.8.5. 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 116 psi for at least 15 minutes or in linewith local 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 thatsmaller pipe 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.d) 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. If theincoming main’s pressure is higher than 50 psi a pressure reduction valve must be fitted.WARNINGIf incoming mainʼs pressure exceeds 50 psi a pressure reduction valve must be installed tolimit system pressure to no more than 50 psi.d) 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.e) Power Outage Drain Valve: This component is designed to allow slow flow through the collector in theevent of a power outage thus preventing freezing from occurring. It is therefore a backup to the normalcontroller based freeze protection function. The Power Outage Drain Valve should be connected to asuitable drain with the Onix pipe provided.Step 1. Slip the ring clamp onto the Onix tubing. Press the Onix tubing onto the barbed end of thedrain valve (a little water on the barbs will help). Place ring clamp over center of barbs and release.Copyright 2011 – Apricus Inc Doc: A7-05.4.1.4-PB-1.9 Page 73 of 126
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