Installation Manual
Contents
1. Themomax Installation Manual Standing Seam Metal Roof Kit A 1 D This roof kit may be used to secure directly onto standing seam roof types A metal roof kit requires a joint plate kit KSK0016 comprising two vertical side rails and adjustable plate connections The roof type will determine the clamp required The following metal roof clamps are for use with the joint plate kit KSK0016 KSK0025 Bulb standing seam KSK0026 Double folded standing seam KSK0025 Bulb KSK0026 Double Folded Standing Seam Clamps Standing Seam Clamps M10 holes located 13mm 5 om ce from edges of part r mm 51 mm Pg Irom edga of pari ry 193 49 men F 1 F a a rhe z 26 rami Kingspan SOLAR 13 1 Locate and secure the standing seam clamps at 2 Attach the side rails to the joint plate the appropriate distances indicated and attach the as shown joint plate to the standing seam clamp as shown 3 Locate manifold on side rails 4 Secure all clamps Themomax Installation Manual Connection Information 1 In any solar panel system the return refers to the intake in the collector where liquid is 1 4 returning to be reheated The flow refers to the collector side where the liquid is flowing to the heat exchanger Note It is essential that the collector temperature sensor is located in the flow of the collector The following illustration shows th2. Fill the loop until the pressure gauge just exceeds the required pressure and stop the pump and immediately close the fill connection Check pipe joints on the solar loop for leaks and check that pressure is not lost over a 30 minute period 10 If all the plumbing is sound set the system pressure by opening the return connection until the required pressure is met 11 Return the temperature gauges to the original position 12 The fill centre may now be disconnected 13 Cap the fill and drain points with the brass covers provided The pipes from the flush and fill centre should be connected as shown in the diagram below FLUSH AND FILL CENTRE Kingspan SOLAR Setting the flow rate hy The pump may only be run when the system has been filled as dry operation will damage the pump The desired flow rate is 1 litre per minute per m 10 tubes 1m2 1 Set the pump to the first soeed and run it manually from the controller See following paragraph If the desired flow rate is exceeded set the flow meter to the desired rate by adjusting the isolating valve with a flat headed screwdriver see diagram with the pump running Otherwise repeat this step at the next pump speed and continue until the desired flow rate is achieved Stop the pump Operating the pump in Manual mode for SC range controllers In order to run the pump in Manual mode slide the operating switch on the left side of
3. Input connection for 1 4 sensors Kingspan SOLAR Connection of first output pump R1 R1 of the SC controllers comprises a semiconductor relay TRIAC also suitable for RPM control with a maximum switching current displayed on the unit type plate Both the SC100 P and the SC200 contain an electromechanical relay R2 Note that the SC300 contains two RPM relays R1 and R2 as well as an electromechanical relay R3 The SC200 and SC300 are therefore suitable for controlling two pumps i e for an east west panel array or a stagnation configuration requiring a second pump Caution Avoiding damage and malfunctions When connecting an external relay or contactor or when connecting a pump which has its own electronic RPM control the controller output s RPM control must be deactivated see Setting the RPM control parameters in the Controller Manual Connection of second output R2 if required R2 on the SC100 contains a switched output via an electromechanical relay with a maximum switching current displayed on the unit type plate Note the wire bridge D1 must be connected Themomax Installation Manual 22 Commissioning the System E Inserting the tubes The evacuated tubes should be inserted at a time when there is very low light such as late afternoon when the sun is low and not particularly strong Alternatively the tubes should be covered This is important as tube connections ca
4. whether caused by the negligence of Kingspan Renewables Ltd its employees agents or otherwise which arise out of or in connection with the supply of the Goods or their use or resale by the Buyer 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 Kingspan Renewables Ltd 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 obligations in relation to the Goods if the delay or failure was due to any cause beyond the Company s reasonable control Without limiting the foregoing due to causes beyond the Company s reasonable control 10 For comprehensive details regarding Warranties and Liability please refer to the CONDITIONS OF SALES section 7 Kingspan Kingspan Renewables Limited 180 Gilford Road Portadown Co Armagh Northern Ireland BT63 5LF Tel 44 0 28 3836 4500 Fax 44 0 28 3836 4501 E mail info kingspansolar com www kingspansolar com Due to our continuing policy of development and improvement we reserve the right to alter and amend the specification as shown in this literature This brochure is printed on Te Ki environmentally friendly paper
5. 137 137 JS 206 206 A Front feet B Back feet See page 7 for diagram Technical Specification Dimensions l 1996 x 1996 x 1996 x 2045 x 2045 x 2005 x 2005 x 2005 x enotno Matn REND In 709 x 1418 x 2127 x 1418 x 2127 x 709 x 1418x 2127 x 97 97 97 97 97 97 97 97 Weight kg 36 9 54 8 81 4 47 2 70 5 33 2 50 3 75 1 Volume 1 2 6 3 8 5 6 1 2 1 7 0 83 1 2 1 7 Max Field Size m4 10 12 15 16 18 8 10 12 Cu Pipe Diameter 2 3m2 15mm x 1 mm per panel area 4 9m2 22mm x 1 10 15m2 28mm x 1 2 16 20m2 35mm x 1 5 Max Operating Pressure bar 8 Min Slope 0 F Max Slope 7 90 70 Max Load kN m3 DIN 1055 5 2 5 Heat Transfer Medium Propylene Glycol suitable for evacuated tube collectors Pressure Drop Curves 40 35 HP 200 20 30 HP 200 30 HP200 10Way HP200 20Way e HP200 30Way Zz 7 7 HP 100 20 HP 100 30 Y a a Pressure Drop mbar Y S a 0 1 2 3 4 5 6 7 8 Flow Rate l min DF100 10Way i if DF100 20Way DF100 30Way 15 10 Flow Rate l min Pressure Drop mbar V l min Themomax Installation Manual Technical Specifications i DF100 HP100 150 HP200 250 1m 2m2 3m 2m2 3m2 1m 2m2 3m2 Number of Tubes 10 20 30 20 30 10 20 30 Dimensions Absorber Area m 1 002 2 004 3 020 2 006 3 009 1 007 2 01 3 021 Overall Di
6. Such as HT Armaflex from Armacell GmbH High temperature insulation is essential as regular pipe insulation will melt at temperatures experienced by solar pipes The wall thickness of the insulation should be equal to the diameter of the pipe The only pipes which should not be insulated are the pipes to the safety vessels as they should allow heat to dissipate when the system is experiencing excessive heat and pressure 15 Themomax Installation Manual 16 Pump Station The Kingspan Solar Thermomax product range offers both a single stream and a dual stream pump station Each pump station is available in two flow rates 2 12 litres and 8 28 litres The flow rate required on a system is typically 1 litre per minute per square metre installed Therefore a 2 12 litre pump station will be sufficient for systems up to 12m Key Drain connection Fill connection Flow meter Isolating valve Motorised pump 6 bar pressure relief valve Expansion vessel connection Pressure guage 9 22mm connections x 4 10 Temperature guage 11 Air separator 12 Insulated fascia 13 Pressure relief discharge point CONOoaABWNDN Connections of flow and return pipe work to the pump station are made with the straight compression fittings provided for direct copper connection C0784 Insulated Hose Stub Fitting When flexible stainless steel pipe is being used to connect to the pump statio
7. The solution also contains corrosion inhibitors and has been specifically designed for used in solar systems with elevated temperatures such as those experienced with Vacuum Tube Collectors Propylene Glycol is a widely used ingredient in pharmaceutical food cosmetic personal care flavours and animal feed applications Propylene glycol is not volatile but is miscible with water Propylene glycol is not harmful to aquatic organisms and is readily biodegradable however the disposal of the solution should be done in a responsible manner taking into consideration local Environmental and Health amp Safety legislation While the solution is not subject to registration as a hazardous material according to EEC directives the solution should be disposed of by special means There are a number of specialist companies that can deal with the disposal of propylene glycol A list of these companies is available upon request A copy of the EEC Safety Data sheet and Technical Information sheet is available upon request We recommend that you contact your local authority to check that they will accept the solution at special landfill collection points There are a number of specialist companies that can deal with the disposal of propylene glycol a list is available on request info kingspansolar com Themomax Installation Manual 20 Servicing and Maintenance g Users should regularly check the temperatures which the solar control panel is r
8. have been drained Collectors left exposed in a dry state must be covered to prevent possible long term damage e HP tubes must have a minimum elevation of 20 and a maximum of 70 e The dark blue side of the copper within the tube is the active surface e For DF100 system a heat dissipation loop heat dump is recommended please refer to pages 38 42 of the technical design guide e The pipework of the solar collector loop is to be earthed and the collector is to be lightening protected in accordance to local regulations For further technical support please contact the following numbers Ireland 1800 812 718 or UK 0845 812 0007 Health and Safety Precautions A solar panel installation must be performed in accordance with all Health amp Safety legislation and local building planning regulations for the relevant jurisdiction Furthermore the necessary electrical work required to install control equipment should be undertaken by a qualified electrical contractor Themomax Installation Manual Standard Kit Components yy Kingspan sovar 27 SE w Dual Stream Pump Station SC100 Controller Sloping Roof Kit with Brackets a ai e A Connection Kit Flexi Connections Expansion Vessel a Manifold amp Tube Holders Cooling Vessel DF100 only Tyfocor LS Additional Components 3 J Solar Roof Flashing Interconnection Kit 22mm Thermostatic Mixing Valve Note 28mm also available
9. materials in accordance with 3 Collector Beware of high temperatures e Remove rubber retainer to release manifold lid e Unclip tube e Remove the rubber support retainers from around glass tube e Remove tube manifold clip e Remove tubes from manifold e Remove lid and separate materials e Remove Manifold and support rails and separate materials e Remove roof kit and separate materials e Reinstate roof local regulations Please see the following pages for details of materials used in the construction of Thermomax collectors and guidance on disposal of antifreeze Themomax Installation Manual Construction Materials J 24 Aluminium EPDM Brass Bronze Stainless Steel PA66 30 GF Silicon ag F Vinyl Copper Melamine q Glass iri ent Pat 11 aril NIIA AJOIN ajo HP100 amp nE Aluminium EPDM Brass Bronze Stainless Steel PA66 30 GF Silicon Vinyl Copper Melamine Glass NIO AJOIN ao Kingspan SOLAR 20 Aluminium EPDM Brass Bronze Stainless Steel PA66 30 GF Silicon Vinyl Copper Melamine Glass 23 0O COIN D O R sP ajo Disposal of Solar Anti Freeze Solution Ly The solution we supply with our solar systems is a thermal transfer fluid based on 1 2 propylene glycol and water
10. 217 Heat Transfer Fluid Water Glycol Water Glycol Water Glycol Water Glycol Water Glycol Water Glycol Water Glycol Water Glycol Materials Absorber Copper Copper Copper Copper Copper Copper Copper Copper Coating Selective Coating Selective Coating Selective Coating Selective Coating Selective Coating Selective Coating Selective Coating Selective Coating Absorbance 95 95 95 95 95 o5 95 95 Emissivity 5 5 5 5 5 5 5 5 5 Mounting Frame and Clips Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium Aluminium EPDM EPDM EPDM EPDM EPDM EPDM EPDM EPDM Glass Low Iron Low Iron Low Iron Low Iron Low Iron Low Iron Low Iron Low Iron Transm 0 92 Transm 0 92 Transm 0 92 Transm 0 92 Transm 0 92 Transm 0 92 Transm 0 92 Transm 0 92 Vacuum lt 10 6mbar lt 10 6mbar lt 10 6mbar lt 10 6mbar lt 10 6mbar lt 10 6mbar lt 10 6mbar lt 10 6mbar Temperature Limitation 95 135 95 135 95 135 95 135 95 135 Quality Certification Yes Yes Yes Yes Yes Yes Yes Yes Solar Keymark Kingspan SOLAR Warranty Statement P Kingspan Renewables Ltd Warranty Statement for Solar 2 9 Subject to the following provisions Kingspan Renewables Ltd warrants that the Goods will be free from defects in material and workmanship for a period
11. Insulated Hose Mounting Set 22mm 3 Port Diverter Valve Note 15 amp 28mm also available Stubfitting Kingspan SOLAR Important Pre Installation Information 1 Sizing of safety equipment O 2 Component sizes are relative to the volume of liquid in the system Therefore it is important that the Thermomax Technical Design Guide is consulted for each system Pipe Sizing minimum of 15mm diameter pipework must be used Collector Pipe Diameter Area Flow Rate Copper m3 Ltr hr External mm 2 120 1 18 4 11 3 180 15 125 2 87 10 47 4 240 15 17 08 2 36 S22 5 300 22 21 11 4 05 14 58 6 360 22 25 14 5 74 20 94 8 240 22 33 68 6 92 20 05 Expansion Vessel Sizing HP100 2 Iy 5 18 3 ie 5 18 4 18 5 18 5 19 5 18 HP200 2 i 5 18 3 17 5 18 4 18 5 18 5 19 5 18 DF100 2 19 5 18 3 20 5 25 4 22 5 Zo 5 24 5 35 Cooling Vessel Sizing only required with DF100 systems It is strongly recommended that a cooling vessel is used with the DF100 collector to protect the expansion vessel from stagnation temperatures Cooling Vessel Sizing DF100 2 19 5 18 5 3 20 5 25 8 4 22 5 25 8 5 24 5 35 12 Themomax Installation Manual Roof Kits 5 Standard Roof Fixings 04 The Thermomax product range is available with a choice of roof fixing options to suit many roof types see diagram below for the most common fixings The most common fixings are illustrated and explained in the following section and may be ea
12. Renewables THERM 2MAX Installation Manual ON aS Kingspan COIL AR Themomax Installation Manual Contents Introduction 1 Using this guide 1 Kit components 2 Important pre installation information 3 Roof kits Overview 4 Sloping Roof Kit 5 Bolt down roof kit 6 Surface mount 35 55 T Sloping roof 20 elevated 8 Sloping roof kit horizontal 9 Surface mount 90 horizontal 10 Surface mount 0 and 90 vertical 11 Standing seam metal roof kits 12 Connection Information Connection kit and other connections 14 Pump station 16 Safety vessel connections 17 Interconnection kit 18 Inserting the tubes 19 Wiring the control panel 20 Comissioning the system 22 Decommissioning the system 23 Construction materials 24 Servicing and maintenance 26 Technical Information Wind loading 27 Technical Specification 28 Warranty Statement 29 Kingspan SOLAR Introduction y Solar hot water systems should be designed and sized correctly before commencing the installation 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 gas boiler heat pump or wood boiler is required for months which have less solar radiation For large systems Kingspan provide a system design service to its Accredited Installer Network and technical design consulta
13. al roofs Two options available utilise appropriate clamps so the fabric of the metal roof is not penetrated see page 12 Note the minimum and maximum distances on each fixing kit The distance between the vertical rails on each fixing kit should be between 600mm 1100mm on 20 tube systems and 800 1400mm on 30 tube systems This is illustrated on each roof kit diagram Note that the fixing clamps on the side rails are preset for ease of on site installation Kingspan SOLAR C0590 Sloping Roof Kit d In high wind load areas e g at excessive heights or very exposed areas when the force acting upon the solar panel is greater than 2 5kN m an additional vertical support rail 05 C0594 may be obtained Please refer to the wind loading table page 27 On the sloping roof kit a distance of 1400mm minimum and 1700mm maximum should be observed between the top of the lower brackets and the top of the upper brackets 2 Secure side rails to lower bracket with the pre drilled holes to the bottom 6 2 1 Slide back tile and attach lower brackets to roof rafter a S P J aA l Ze CRE Sa S Ke CPE 4 Secure side rails to upper brackets with sliding bolt fixing 3 Attach upper brackets to roof rafters 5 Locate manifold on side rails and secure with upper clamp bolts 6 Locate horizontal support rails on the side rails Themomax Installation Manual KSK0012 Bolt down Roof Kit T
14. art thereof for testing No tests carried out by the Buyer will be recognised by Kingspan Renewables Ltd unless carried out strictly in accordance with a method previously agreed by Kingspan Renewables Ltd as being suitable for the purpose 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 specification is notified to Kingspan Renewables Ltd in accordance with these Conditions Kingspan Renewables Ltd 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 Kingspan Renewables Ltd shall have no further liability to the Buyer Kingspan Renewables Ltd shall not be liable to the Buyer by reason of any representation unless fraudulent or any implied warranty condition or other term or any duty at common law including but without limitation the negligence of Kingspan Renewables Ltd its employees agents or otherwise or under the express terms of the Contract for any loss of production loss of profits or anticipated profits loss of contracts operation time or anticipated savings loss of business 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 consequential loss or damage or claim
15. cure lower bracket upper bracket side brace SW 8 iC l o l 4 gt O 6 Attach and secure rear brace 7 Locate manifold on side rails 8 Locate support rails on side rails Kingspan SOLAR C0593 Sloping Roof Kit Horizontal by Note Only the DF100 can be mounted in this horizontal position Drill required 1 Attach brackets to roof at 2 Secure side rails to brackets 3 Locate locking pin distance shown positions and drill holes 4 Secure locking pins to 5 Locate manifold on side rails 6 Locate support rails on prevent slippage side rails Themomax Installation Manual C0597 Surface Mount 90 Horizontal P 1 O Note Only the DF100 can be mounted in this horizontal position hi m 1 Attach brackets to surface 2 Attach side rails to brackets 3 Locate locking pin at distance shown above using bolts provided position on manifold and support rails and drill holes 4 Locate support rails on side rails 5 Locate manifold on side rails 6 Secure clamps Kingspan SOLAR C0595 Surface Mount 0 amp 90 Vertical J Note Only the DF100 can be mounted in a horizontal or vertical position 1 1 gl 1 Attach brackets to surface at 2 Attach side rails to brackets using distance shown above bolts provided 3 Locate manifold on side rails 4 Secure all clamps
16. e any authority to commit Kingspan Renewables Ltd to provide any service in relation to the Goods 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 suffered by the Buyer as a result of any breach of the obligations implied by Section 12 of The Sale of Goods Act 1979 shall not be limited If Kingspan Renewables fails to deliver the Goods for any reason other than any cause beyond the Company s reasonable control or the Buyer s fault then Kingspan Renewables Ltd 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 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 specification shall be notified to Kingspan Renewable Ltd 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 failure If delivery is not refused and the Buyer does not notify Kingspan Renewable Ltd the Buyer shall not be entitled to reject the Goods Kingspan Renewables Ltd shall be entitled to examine any Goods which are the subject of any claim by the Buyer and to remove such Goods or any p
17. e connections to the manifold Return connection Manual airvent YO WY Manifold clip AY SC Female assembly 1 7 Flow connection Z 1 Tighten compression fitting to connection fitting flow and return 2 Tighten compression fitting to pipe work flow and return 3 Attach assembled fittings to manifold 4 Push clip all the way down until connection is fully retained 5 Pull gently on assembly to ensure proper engagement and retention Kingspan SOLAR Types of Connections The only pipes which should be used with a solar installation are copper pipe continuous flexible stainless steel or mild steel When using copper pipe only compression or brazed joints can be used Solder and galvanised fittings will not withstand high temperature or expansion and are therefore not suitable for solar pipe work PEX PLASTIC PEX ALU PEX or GALVANISED TUBING OR FITTINGS SHOULD NOT BE USED UNDER ANY CIRCUMSTANCES Flexible Pipe Connections Flexible pipe connections are recommended to connect the manifold through the building fabric and allow flexibility in connecting to the internal pipe work Flexible stainless steel pipes are available in both a 15mm and 22mm diameter If connecting one diameter pipe to another a suitable reducer compression fitting is recommended to make the connection Insulation All pipe work on the solar loop should be insulated with high temperature insulation
18. ecording With the SC range of controllers simply pressing the SET button on the fascia once will display the upper and lower collector temperatures since the control panel was last reset If the collector temperatures have been excessively high i e over 170 C it is recommended that the antifreeze level be checked using a refractometer by a qualified engineer A sample of the Tyfocor LS antifreeze fluid can be extracted from the pump station at the pump itself The large centre of the pump hub can be opened with a large flathead screwdriver This should be opened slowly until a few drops of the antifreeze fluid are released A sample of the fluid placed on the glass of the refractometer will display the level of antifreeze in the system If the antifreeze has lost its antifreeze properties the system should be refilled with fresh Tyfocor LS It is recommended that the solar system is serviced annually by a qualified engineer and immediately if the system shows evidence of having lost pressure or has discharged liquid at the pressure relief valve The Tyfocor LS antifreeze fluid should always be replaced after years Maintenance schedule A qualified person should service the system at the recommended intervals using the maintenance schedule below In addition the user should check the system pressure at regular intervals A visual inspection of the pressure gauge is required to check that the system pressure is maintained at the l
19. evel noted below The service engineer should complete the following the shaded boxes should be completed if the system requires refilling Upon Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 commissioning Date of inspection Expansion vessel setting before filling System pressure Expansion vessel setting after filling Flow rate Antifreeze level pH reading Inspection of barium getter on tubes Engineer details Print name Sign Telephone No Kingspan SOLAR Technical Information D Wind Loading ot Stress and maximum load on the substance on flat roofs to DIN 1055 Prevention of Collector Slippage Prevention of Collector Lifting Weight Per Foot kg Weight Per Foot kg 10 Tube Collector 20 Tube Collector 30 Tube Collector 10 Tube Collector 20 Tube Collector 30 Tube Collector EEE ALOT A B A B A B A B A B A B Ground m 8 76 102 76 102 116 155 26 65 26 65 41 100 8 to 20 129 178 129 178 195 269 57 125 51 125 80 191 Stress and maximum load on the substance on flat roofs to DIN 1055 Prevention of Collector Slippage Prevention of Collector Lifting Weight Per Foot kg Weight Per Foot kg 10 Tube Collector 20 Tube Collector 30 Tube Collector 10 Tube Collector 20 Tube Collector 30 Tube Collector EGJE ALNO A B A B A B A B A B A B Ground m 8 102 WA 102 Wl 156 256 TE 73 TE 73 111 Wi 8 to 20 i 287 ia 287 266 430 167
20. his roof kit may be used to secure directly through tile or slate surfaces 1 Locate the rafters beneath the roof material and drill to a depth of 120mm with a 12mm drill bit 3 Locate the nut above the rubber roof seal and tighten to ensure a good seal is made on the fixing surface 5 Attach the roof rails to the four fixing plates using the bolts provided 2 Insert the rawl plug provided if necessary and fix the bolt with a spanner 4 Stabilise the flat fixing plate by tightening the attached nuts above and below the plate Kingspan SOLAR C0599 Surface mount 35 to 55 In high wind load areas e g at excessive heights or very exposed areas when the force acting upon the solar panel is greater than 2 5kN m an additional vertical support rail 07 C0596 may be obtained Please refer to the wind loading table page 27 1 Attach front and rear brackets to surface at distance shown 2 g gq 2 Secure side rail to front bracket 3 Secure side rail to rear bracket 4 Secure side bracing bracket to side rail 5 Adjust and secure rear brace 6 Locate manifold on side rails 7 Locate support rails on side rails Themomax Installation Manual C0591 Sloping Roof Kit 20 Elevated h 1 Attach brackets to roof at distance shown over 2 Assemble hinge brackets to roof brackets at distance shown over 3 Secure side rail to 4 Secure rear strut to 5 Adjust and se
21. ical power supply which must not be interrupted either manually or with a time switch If the permanent electrical supply to the building is to be switched off for any period of time the solar collector s should either be covered or the system drained and the tubes removed In order to protect the normal operation of the control panel it should be located at least 100 mm from insulated pipes which may become hot during operation Control panels use PT1000 sensors containing twin core copper cable with a 0 75mm cross section The sensors supplied are 1 5 metres in length Sensor cables can be extended with twin core copper cable of 0 75mm diameter up to 50 metres and 1 50mm diameter between 50 100m Screened cable should be used on the sensor cables to prevent RFI from electrical cables All connections to extend the cables should be housed in a junction box for protection The following diagrams show the connection of the solar pump and other relays on the SC range of controllers This should be read in conjunction with the Installation and Operation Manual supplied with each SC control panel Power Supply Connection Sensor Connection The connection of PT1000 sensors is as shown below The polarity of the sensor cables is not relevant on each sensor The SC100 has four inputs as illustrated below However the SC200 and SC300 can receive five and six sensors respectively for larger system design and are connected in the same way
22. mensions mm 1996x709x97 1996x1418x97 1996x2127x97 2005x1418x97 2005x2127x97 2005x709x97 2005x1418x97 2005x2127x97 Width of Manifold mm 709 1418 2127 1418 2127 709 1418 2127 Length tube and manifold mm 1996 1996 1996 2005 2005 2005 2005 2005 Depth mm 97 om 97 Oy Oy om om 97 Aperture Area m3 1 07 Zl 3 23 Zale 3 24 1 07 2 16 3 23 Fluid Volume ltr ES 3 6 5 6 12 Wad 0 6 ami ea Inlet and Outlet Dimensions mm 22 22 22 22 22 22 22 22 Weight empty kg 25 54 8 81 4 47 2 70 5 25 50 3 75 1 Mounting Recommended Inclination 0 90 0 90 0 90 20 70 20 70 20 70 20 70 20 70 Performance Data Efficiency Based on Aperture Basedon Aperture Based on Aperture Based on Aperture Based on Aperture Based on Aperture Based on Aperture Based on Aperture eta O OLTE 0 773 0 773 0 739 0 739 0 726 0 761 0 726 0 761 0 726 0 761 k1 W m k 1 45 1 45 1 45 1 1 11 85 11 38 155 136 1 85 11 318 k2 W m k 0 0059 0 0059 0 0059 0 0074 0 0074 0 0058 0 0074 0 0058 0 0074 0 0058 0 0074 Solar Keymark Licence Nos 011 7S060R 011 7S314R HP200 011 7S125R HP250 011 7S904R Operating Data Flow Rate Itr h Rated 80 160 240 160 240 80 160 240 Minimum 60 120 180 120 180 60 120 180 Maximum 150 300 480 300 480 150 300 480 Maximum Operating Pressure 8 Bar 8 Bar 8 Bar 8 Bar 8 Bar 8 Bar 8 Bar 8 Bar Stagnation Temperature C 286 286 286 166 166 184 217 184 217 184
23. n the insulated hose stub fitting is required to make the connection The split ring within the fitting should be removed and placed over the second rib of the flexible pipe When the compression fitting is tightened the split ring will click twice as it positions itself and locks inside the fitting C0785 Insulated Hose Clamp Ring When the short flexible connection is being joined to stainless steel pipe work the insulated hose clamp ring is required to make the connection The split ring within the fitting should be removed and placed over the second rib of the flexible pipe When the compression fitting is tightened the split ring will click twice as it positions itself and locks inside the fitting Kingspan SOLAR Safety Vessel Connections Pressure Relief Valve PRV Rated at 6 bar the PRV may discharge heat transfer fluid Tyfocor LS which must be 1 channelled into a container capable of withstanding high temperature discharge and containing the total collector volume The container should be secured so it cannot be removed or spilled The PRV should not be channelled into a drain or any pipe work which will allow it to enter the normal water course Fitting the expansion vessel It is recommended that the expansion vessel is located below the level of the connection from the pump station to prolong its life The expansion vessel supplied includes an appropriate corrugated hose and threaded connection to joi
24. n heat up considerably in a short space of time and have potential to cause injury while the glass temperature will remain low Please refer to page 17 for information on tube connection into the manifold Expansion Vessel IMPORTANT Prior to filling the system the expansion vessel pressure must be set 0 3 Bar below the system pressure Omitting to perform this check will result in irregular pressure readings during the commissioning of the system The pressure is checked at the base of the vessel and the bleed valve may be bled or topped up with a pump Filling the Loop It is important that a motorised flush and fill centre is used to fill and pressurise the system with Tyfocor LS as follows 1 Open the fill and drain valves to allow the liquid to circulate around the solar loop 2 Turn the hot and cold temperature gauges 45 clockwise 3 Close the isolating valve above to the flow meter to ensure all air and liquid passes through the fill centre to filter any air and contaminants 4 Run the fill centre pump to circulate the Tyfocor LS for approximately 20 minutes 5 Open and close the isolating valve intermittently to circulate air bubbles which may accumulate in the sight glass 6 Return isolating valve to closed position 7 When the solar loop has been purged of air close the bottom drain connection the fill centre will begin to pressurise the solar loop 8 Reopen the isolating valve above the flow meter fully 9
25. n the vessel to the pump station Temperature Reducing Vessel TRV Also known as a cooling vessel or stratification vessel the TRV is highly recommended with the Thermomax DF100 Due to high temperatures which can be experienced within the solar loop the TRV allows for additional expansion and reduces the temperature of the heat transfer fluid before it enters the expansion vessel Fitting the TRV With the direct flow vessel kit which includes the TRV a corrugated hose assembly is included to join the expansion vessel to the TRV from the pump station OMD lt p C 7 1 PRV discharge point 2 Wall bracket supplied 3 Discharge container 4 TRV kit DF100 only 5 Expansion vessel aac an 6 Dual stream pump station A N m Themomax Installation Manual Interconnection Kit Product Code C0674 When joining more than one manifold together it is necessary to use the interconnection kit 1 8 which will support and align multiple collectors All manifolds comprise a male and female connection enabling manifolds to be connected without the need for additional pipework The maximum number of manifolds which may be connected in series before connecting in parallel is shown in the table below G Model Max Number of collectors g DF100 x 30 tubes 5 HP100 x 30 tubes 6 9 HP200 x 30 tubes 4 I
26. n while slightly rotating tube until a clicking noise is heard Do not apply force If tube does not engage properly support the tube at the bellow section while pushing into the manifold connection until it clicks into position Gently pull on tube to ensure secure assembly Close tube retaining rubber on both support rails Repeat steps 2 to 5 for all tubes Close manifold lid ensuring proper engagement of front seal strip over whole length and on end caps Open manifold lid by removing front seal strip as shown on manifold end cap Place tube in tube clips on both support rails Slide tube into manifold connection while slightly rotating tube until TWO clicking noises are heard Do not apply force If tube does not engage properly support tube at bellow section while pushing into the manifold connection Gently pull on tube to ensure secure assembly Close tube retaining rubber on both support rails Repeat steps 2 to 5 for all tubes Close manifold lid ensuring proper engagement of front seal strip over whole length and on end caps Themomax Installation Manual 20 Wiring the Solar Control Panel E All electrical aspects of the installation should be undertaken by a qualified electrician Note that for safety the pump and sensor connections should always be wired prior to connecting power to the solar control panel IMPORTANT The solar control panel must have a permanent electr
27. nsert screws into plate ensuring screws do not protrude to upper side Slide plate approximately half way into channel at bottom of manifold that is fixed to side rails Tighten up screws to force plate against bottom of manifold do not overtighten Slide channel of next manifold on plate Push clip all the way down until connection is fully retained Assemble support rail connection plate to fixed support rails Assemble retaining plates and fittings po NO O1 BRB Kingspan SOLAR Inserting tubes 5 DF100 Tubes HP100 or HP150 Tubes HP200 or HP250 Tubes Slide tube into manifold connection while slightly 1 Open manifold lid by removing front seal strip 7 Q Place tube in tube clips on both support rails rotating tube until washer on bellow sits flush against manifold fitting Do not apply force if any problems are experienced check alignment of support rails to manifold Insert tube retaining clip to secure tube to manifold and rotate clip 360 to ensure a good connection Gently pull on tube to ensure secure assembly Close tube retaining rubber on both support rails Repeat steps 2 to 6 for all tubes Close manifold lid ensuring proper engagement of front seal strip over whole length and on end caps Open manifold lid by removing front seal strip as shown on manifold end cap Place tube in tube clips on both support rails Slide tube into manifold connectio
28. nts Please visit www kingspansolar com to locate an Accredited Installer or distributor in your area Details on how to size a solar system correctly can be found in our Technical Design Guide available for download from our website www kingspansolar com This guide will illustrate and explain how a system should be installed to conform with the Kingspan Renewables manufacturer guidelines for the Thermomax product models namely DF100 HP100 amp HP200 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 recommendations and important safety information Note Prior to installation the Technical Design Guide should be consulted to correctly specify the system components Handling Guidance e Tube and manifold boxes should be transported horizontally e Heavy goods should not be loaded on top of the kit boxes e Care should be taken when opening boxes to prevent scratches or sudden shocks to the glass e Do not use sharp objects to open the tube boxes Installation Guidance e Unpack and install tubes only after the manifold and pipe work has been installed e With the HP200 and HP250 only tubes may be installed after the system has been filled pressure tested and is ready for operation e Do not leave the solar collector exposed to solar radiation when the solar loop and manifold
29. of 5 years in relation to THERMOMAX SOLAR PRODUCTS The warranty is given by Kingspan Renewables Ltd subject to the following conditions A B mmo Kingspan Renewables Ltd shall be under no liability in respect of any defect in the Goods arising from any information drawing design or specification supplied by the Buyer Kingspan Renewables Ltd shall be under no liability in respect of any defect arising from fair wear and tear wilful or accidental damage negligence abnormal working conditions failure to follow the Kingspan Renewables Ltd design and installation instructions misuse or alteration or repair of the Goods without approval The above warranty does not extend to parts materials equipment not manufactured by Kingspan Renewables Ltd in respect of which the Buyer shall only be entitled to the benefit of any such warranty or guarantee as is given by the manufacturer to the Company The defect has been reported by the Buyer to Kingspan Renewables Ltd within the warranty period The installation of the Goods having been carried out by fully trained and competent person s The Goods having been subjected to neither prolonged stagnation conditions nor exhibiting signs of extreme temperature exposure 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 Kingspan Renewables Ltd to the Buyer nor shall the Buyer hav
30. sily secured to slate tile or masonry finishes Roof kits and their relevant manufacturer codes Option Code Description Suitable for HP Suitable for DF 1 C0590 Sloping roof kit V Y Y or KSK0012 Bolt down roof kit Y Y 2 C0599 Flat roof A frame kit 35 55 Y Y 3 C0591 Sloping roof 20 elevation V Y Y 4 C0593 Sloping roof kit H N Y 5 C0597 Fa ade kit H N Y 6 C0595 Fa ade kit V N Y 7 C0595 Fa ade kit V N Y 8 KSK0018 Awning roof kit Y Y Horizontal Installations DF100 only With any DF100 installation where the collector is installed horizontally on a wall fa ade or roof surface the airvent on the collector manifold must be the highest point of the collector otherwise air in the system will remain in the pipes within the collector tubes and be difficult to flush out Airlocks in the pipes will stop circulation through the system When the collector is orientated correctly i e with the manifold slightly higher than the base of the collector see below air will be forced back into the system In this instance the air separator will prevent air from circulating Flat horizontal orientation Wall horizontal installation option 6 above option 5 above ie Wen A il Minimum 2 angle TEREE il RE J 2 MINTT Metal Roof Fixings Kingspan also supply roof fixing kits for metal and other commerci
31. the solar control panel to the upper of the three positions On the screen select the appropriate relay with the up down arrows and press the Set button to run the relay and to switch it off again Other Relays ISOLATING VALVE gt TW W JN A x J Yn J Left side view of controller Operating switch The following modes of operation can be selected Manual for commissioning and testing for function Automatic for automatic operation Off for switching off the outputs a lt 4 Manual lt 4 Automatic lt off If any additional relays are set up on the system these should be tested in Manual mode as above to ensure the connections have been wired correctly Decommissioning the System Due to temperatures potentially exceeding 170 C and pressures greater than 6 bar a solar installation should only be decommissioned by a trained individual The system should be decommissioned in low light ideally in the morning when the solar loop should be coolest 1 Electrical e Isolate controller from mains e Remove cables to consumer units i e controller and pump e Remove sensors and associated cables e Remove earthing cables 2 Collector Loop e Beware of hot transfer fluid e Drain collector loop at drain valve Contain the heat transfer fluid for appropriate disposal e Disconnect pipes from the manifold Disposal Dispose of separate
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