Installation Manual - Plumb Center Online
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1. A9093B 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 environmentally friendly paper e do2. B C D E F G H l Step NINE flow connection 1 Assemble and connect end fittings Female connection B T connection G amp Temperature sensor pocket H Sensor must 2 Remove securing pin from female end of collector be fitted on flow side of 3 Place rubber seal C in female end of collector collector area blocking lower chamber See diagram This applies to DF only please discard seal for HP for step T 4 Secure in position by relocating securing pin Varisol Installation Manual Connection Information In any solar panel system the return refers to the intake in the collector where liquid is 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 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 an
3. Pressure guage r 9 22mm connections x 4 ER ai 10 Temperature guage oT oe ey 1 11 Air separator Hd 12 Insulated fascia PEO 13 Pressure relief discharge point 0 ND VI A WD 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 station 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 p amp LA 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 Varisol Installation Manual Safety Vessel Connections Pressure Relief Valve PRV Rated at 6 bar the PRV may discharge heat transfer fluid Tyfocor LS which must be channelled into a solar discharge vessel capable of withstanding high
4. Tyfocor LS Tyfocor LS 120 80 100 6 A 10 way 20 way 30 way 60 30 fr SI Es Poly 10 way Ri Poly 20 way 50 od Poly 30 way j 2 Y 60 S P E 40 7 5 VA Pd 40 30 a 20 0 50 100 150 200 250 300 350 400 450 500 0 5 10 15 20 25 Flow Rate Itr hr Flow Rate Tyfocor LS l min Varisol Installation Manual Warranty Statement Kingspan Renewables Ltd Warranty Statement for Solar Goods Subject to the following provisions Kingspan Renewables warrants 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 period of 5 years for VARISOL FLOW CONDUITS 8 COVERS MANIFOLDS and KITS from their date of manufacture RESTRICTED PRODUCTS are limited to a period of 12 months warranty The warranty is given by Kingspan Renewables subject to the following conditions A The 20 year warranty period on Vacuum Tubes is conditional on installation by a Kingspan Solar Approved Installer and subject to the collector s being properly maintained according to the manufacturer s recommendations See Thermomax Installation Manual for further details Otherwise a default 5 year warranty period on Vacuum Tubes applies B Kingspan Renewables 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 C Kingspan R
5. until e Beware of hot transfer fluid engagement arrows line up and pull one tube e Drain collector loop at drain valve Contain the from the rest of the assembly Ensure tube is heat transfer fluid for appropriate disposal supported only apply force onto the manifold e Disconnect pipes from the manifold to disengage e Repeat process until all tubes are removed Disposal Dispose of separate materials in accordance with local regulations Please see the following pages for details of materials used in the construction of Varisol collectors and guidance on disposal of antifreeze Kingspan SOLAR Recycling Information Varisol DF Item No Material 1 Aluminium 2 EPDM Rubber 3 Bronze 4 PA66 30 GF 5 PA66 Natural 6 Stainless Steel T7 Copper 8 Glass 9 Brass 10 PPS Varisol HP Item No Material 2 EPDM Rubber 4 PA66 30 GF 6 Stainless Steel 7 Copper 8 Glass 9 Brass 10 PPS Varisol Installation Manual Disposal of Solar Anti Freeze Solution The solution we supply with our solar systems is a thermal transfer fluid based on 1 2 propylene glycol and water 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
6. 22 153 153 figures marked as such are estimates based on other measurements DF Expansion Vessel Sizing HP Expansion Vessel Sizing Collector Static Expansion Cooling Collector Static Expansion Area ZE Vessel Size m m Ltr 1 5 18 S 1 5 12 2 5 18 5 2 5 12 3 5 25 8 3 5 12 4 5 25 8 4 5 12 5 5 35 12 5 5 12 6 5 35 12 6 5 18 7 5 35 12 TA 5 18 8 5 50 18 8 5 18 9 5 50 18 9 5 18 When selecting a vessel for intermediate sizes the vessel should be selected by rounding area up to nearest m2 All sizes above are calculated based on a 17ltr system volume as an example For larger volumes the expansion vessel size should be recalculated Cooling vessel sizes are dependant on pipe dimensions and can be calculated on a Case by case basis or selected using the table above as a guideline Cooling Vessel only required with DF systems It is strongly recommended that a cooling vessel is used with the DF collector to protect the expansion vessel from stagnation temperatures Varisol Installation Manual 04 Roof Kits Standard Roof Fixings The Varisol product range is available with a choice of roof fixing options to suit many roof types see diagram below for the most common fixings Roof fixings are available for slate tiled double lap plain clay metal seam and concrete For others please contact Kingspan The most common fixings are illustrated and explained in the following section and may be easily secured to slate tile o
7. antifreeze level 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 7 years Maintenance schedule A qualified person should service the system at the recommended intervals using the maintenance schedule 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 Please see page 21 for maintenance schedule form Pressure Drop mbar Kingspan SOLAR Technical Information Wind Loading E 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 We
8. 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 Servicing and Maintenance Users should regularly check the temperatures which the solar control panel is recording 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 likely that the fluid is degrading It is recommended that the
9. not be limited 3 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 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 specification shall be notified to Kingspan Renewables 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 Renewables the Buyer shall not be entitled to reject the Goods 5 Kingspan Renewables 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 Kingspan Renewables unless carried out strictly in accordance with a method previously agreed by Kingspan Renewables 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 specification is n
10. 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 The expansion vessel must be located below the level of the connection from the pump station The expansion vessel supplied includes an appropriate corrugated hose and threaded connection to join the vessel to the pump station Temperature Reducing Vessel TRV DF ONLY Also known as a cooling vessel or stratification vessel the TRV is highly recommended Due to high temperatures which can be experienced within the solar loop the TRV reduces the temperature of the heat transfer fluid before it enters the expansion vessel and extends the lifetime of 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 TRV DF ONLY 4 q p L r PRV discharge point Wall bracket supplied 7 Discharge container TRV kit cml Dual stream pump station Kingspan SOLAR Wiring the Solar Control Panel 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 conne
11. Renewables VARISOL Installation Manual Kingspan GM AR Varisol Installation Manual Contents Introduction 1 Using this guide 1 Kit components 2 Important pre installation information 3 Roof kits Overview 4 Roof Kit Sizing 5 Collector Assembly Sloping Roof assembly 6 Installing Tubes T Attaching the connection kit 9 Pump station 11 Safety vessel connections 12 Wiring the control panel 13 Commissioning the system 15 Decommissioning the system 16 Recycling Information 17 Servicing and maintenance 18 Technical Information Wind loading 19 Technical Specification 19 Pressure drop curves 19 Warranty Statement 20 Maintenance Schedule Form 21 Kingspan SOLAR Introduction Solar hot water systems should be designed and sized correctly before commencing the Y installation Proper design will ensure that a system is correctly sized to provide many years y of optimised performance and most or all of the required hot water when the most solar radiation is avallable 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 consultants Please visit www kingspansolar com to locate an Accredited Installer or distributor in your area This guide will illustrate and explain how a system should be installed
12. To make a 44 tube collector join a standard 20 way rail to a 24 way the 24 way being made by cutting a 30 way rail to 1708mm e In the case of a sloping roof mounted collector the available rafter spacing should be considered when sizing the collector to ensure that an appropriate side rail spacing can be achieved Varisol Installation Manual Collector Assembly Sloping Roof 06 Fixing the rails Step One 1 Refer to mounting kit sizing on page 5 for bracket seperation 2 Attach brackets C to roof using M8x50 coachscrews E 3 Secure side rails A to lower brackets using M10x65 bolt assy Step Two 1 From upper end of each side rail slide 2 M8x16 bolt into position 2 Secure side rails A to upper brackets C using M8x20 bolt assy Kingspan SOLAR Attaching Support Rails Step Three 1 Refer to mounting kit sizing on page 5 for support rail lengths 2 Slide 2 M8 bolts into lower face of each support rail B 3 Attach 90 bracket G in 4 places using M8 nuts amp washers at locations illustrated 4 Attach upper and lower support rail to 90 bracket as shown below 400 600mm 10 Ss 600 1000mm 20 SS dae 800 1400mm 30 Installing the first tube Step Four 1 Align first tube with end of support rail and push home by clicking into rail push on upper push point only 2 Align lower tube support clip into rail and push home by clicking into rail push on l
13. ation option 5 above ATA A TATA LATATA TA 7 Minimum 2 angle Kingspan SOLAR Roof Kit Sizing The modular design of the Varisol collector means that any number of tubes can be assembled to make up the required collector size Since the mounting kit cross rails are 05 only supplied in 10 20 and 30 tube sizes it is necessary to cut the rails to length if an intermediate sized collector is required The table below gives the required length of rail for each given size Burrs and sharp edges should be removed Collector Number of Kit Type Required Support Side Rail Area tubes Rail Length Separation m mm mm 1 2 142 3 214 4 10 Tube Rail 285 5 712mm 356 6 427 7 498 8 569 350 450 9 640 350 550 1 10 TO 500 600 1 1 11 Mes 500 600 12 12 854 500 600 es 13 926 500 700 1 4 14 997 500 700 1 5 19 20 Tube Rail 1068 600 800 1 6 16 1423mm 1139 600 900 et ae 1210 600 900 1 8 18 1281 600 1000 1 9 19 1892 600 1000 2 20 1423 600 1100 2 1 21 1494 700 1200 2 2 22 1565 700 1200 2 3 23 1637 700 1200 2 4 24 1708 700 1200 2 5 25 30 Tube Rail 1779 700 1200 2 6 26 2135mm 1850 800 1300 2 21 1921 800 1300 2 8 28 1992 800 1400 2 9 29 2063 800 1400 3 30 2135 800 1400 Examples e To make an 18 tube collector simply take a 20 way rail and cut to 1281mm e
14. cting power to the solar control panel IMPORTANT The solar control panel must have a permanent electrical 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 5mm 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 Varisol Installation Manual 14 Wiring the Solar Control Panel Terminal Clamps in the lower part of the controller terminal cover removed pi LL P L Power connection terminal block L 1x phase conductor mains i
15. d 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 such as HT Armaflex from Armacell GmbH High temperature insulation is essential as standard 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 System Pressure The recommended system pressure is 1 bar 0 1 bar 1m static height Kingspan SOLAR Pump Station The Kingspan Solar product range offers both a single stream and a dual stream pump station Each pump station is available in various sizes to suit the 7 7 required flow rate of the system The flow rate required on a system is typically 1 litre per minute per square metre installed for systems up to 12m Therefore a 2 12 litre minute pump station should 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
16. e 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 omm ON uoyd j UBIS aueu JUL s ie19p Jesuibuy segni uo 49196 unieq jo uooadsu Buipes Hd JSA9 9Z2391 1 UY 9121 MO Su 494e Bulas 9ssan UoIsuedx3 ainsseid W JS S Su esojeq Bunyes 9Sssan UoIsuedx3 uonoadsu jo a eq o o o o o o o o o o o o o o o o o o o o o o o F y 85 D D D D D D D D D D 3 0 3 N N N N N N an mn a a co N o a 5 wm N an a 5 e N O O 00 N o oO w N O B S Bullies s nb Wa sAs y Ji pajejduwoo aq pinoys sexoq papeus y Buimoj oj ay ajajduoo pjinoys Jesuibus sones sy Av 10S uedssuly WO 3INP9YIS SIUBUAJUILBIN
17. en if the glass temperature remains cool 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 Openthe 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 the flow meter to ensure all air and liquid passes through the fill centre to filter any air and contaminants 4 Runthe 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 Fill the loop until the pressure gauge just exceeds the required pressure stop the pump and immediately close the fill connection Check pipe joints on the solar lo
18. enewables 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 instructions misuse or alteration or repair of the Goods without approval D The above warranty does not extend to parts materials equipment not manufactured by Kingspan Renewables 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 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 to the Buyer nor shall the Buyer have any authority to commit Kingspan Renewables 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 sub contractors 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
19. ight Per Foot kg 10 Tube Collector 20 Tube Collector 30 Tube Collector 10 Tube Collector 20 Tube Collector 30 Tube Collector PRI 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 plede li aeea A B A B A B A B A B A B Ground m 8 102 171 102 171 156 256 73 73 73 73 111 111 8 to 20 177 287 177 287 266 430 137 137 137 137 206 206 Dimensions per tube Length x Width x Height mm 1950 x 70 9 x 70 9 1955 x 70 9 x 70 9 Weight per tube kg 2 2 2 13 Volume per tube 0 19 0 05 Max Field Size m3 150 Tubes 21m Gross 15m Aperture 150 Tubes 21m Gross 15m Aperture Cu Pipe Diameter 1 3m2 15x1 15x1 comi 4 9m 22 x 1 22 x 1 10 15m2 28x1 2 28x1 2 16 20m2 35x1 5 35x1 5 Max Operating Pressure bar 6 6 Min Slope 0 20 Max Slope gt 90 80 Max Load kN m DIN 1055 5 2 5 2 5 Heat Transfer Medium Propylene Glycol suitable for evacuated tube collectors Pipe diameters calculated for 0 1l min tube and v_max 0 5m s Pressure Drop Curves DF Varisol Pressure Drop HP Varisol Pressure Drop
20. llowing 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 Varisol Installation Manual Standard Kit Components Sloping Roof Kit with Brackets SC400 Controller Dual Stream Pump Station a Flexi Connections Expansion Vessel Cooling Vessel DF only Tubes Tyfocor LS Additional Components 22mm Thermostatic Mixing Valve Installation tool Note 28mm also available 22mm 3 Port Diverter Valve Stubfitting Insulated Hose Note 15 amp 28mm also available Mounting Set Kingspan SOLAR Important Pre Installation Information Sizing of safety equipment 0 9 Expansion vessel 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 Pressure Drop Tyfocor LS y di Collector Pipe External Area Flow Rate Diameter m Ltr hr mm 1 60 lo 2 2 2 120 15 3 5 dd 3 180 15 10 10 4 240 15 21 21 9 300 22 35 35 6 360 22 53 53 Ti 420 22 80 80 8 480 22 uo 110 9 540
21. nput R1 R2 2x output TRIAC for pumps or valves X not used Lconst 2x phase conductor outputs permanent voltage N 4x neutral conductor common neutral conductors for mains power input and outputs Note Outputs R1 and R2 are protected by an electronic fuse 2 Protective conductor terminal block PE 4x protective earth common protective earth for power connection terminal block 3 Signals terminal block 1 4 4 x sensor input Pt1000 temperature sensor 5 1 x sensor input Pt1000 temperature sensor or pulse water meter input RS 1 x signal output potential free relay contact for safety extra low voltage PWM R1 2 x control output for PWM controlled high efficiency pumps PWM R2 7 x mass connection common mass for sensor inputs and control outputs 4 Pin strip for internal use only 5 Cableopeningsonthe rear side of the casing 6 Upper strain relief clamps 2 identical plastic links each with 2 strain relief clamps supplied in the scope of delivery 7 Lower strain relief clamps 8 Cable openings at the bottom of the casing Kingspan SOLAR Commissioning the System The evacuated tubes should be installed 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 can heat up considerably in a short space of time and have potential to cause injury ev
22. op 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 7 centre should be connected as O O shown in the diagram e q e a FILL i lt _ FLUSH AND FILL CENTRE 3 3 l Varisol Installation Manual Setting the flow rate 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 1m for systems up to 12m DO OPEN CLOSED 1 Set the pump to the first speed and run it manually from the controller see following paragraph 2 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 N 3 Stop the pump Operating the pump in Manual mode Functionality e Backlighting is red spanner symbol flashes for SC 400 500 controllers e The controller outputs pumps valves can be manually 1 Remove the front panel switched Possible
23. otified to Kingspan Renewables in accordance with these Conditions Kingspan Renewables 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 shall have no further liability to the Buyer 7 Kingspan Renewables 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 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 whether caused by the negligence of Kingspan Renewables 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 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 Kingspan Renewables shall not b
24. ower push point only 3 Attach tube to rail using MB x 20 bolts as shown below Varisol Installation Manual Installing additional tubes Step Five 1 Rotate second tube approximately 50 to first tube using arrow symbols on plastic enclosure for guidance 2 Firmly insert male fitting of second tube to female connection of first tube ensuring o ring protection is removed first Step Six 1 Rotate second tube parallel with first tube 2 Locate upper plastic enclosure and lower tube support clip in rail 3 Push home the upper and lower fittings into the support rail Note only the first last and every tenth tube need bolted to the rail RETURN Step Seven 1 Continue with remaining tubes 2 Use M8 bolt washers and nut to lock final tube in place at X and Y Kingspan SOLAR Attaching the Connection Kit Step Eight return connection 1 Assemble and connect end fittings Male connection A T connection G amp Air bleeding valve E 2 Open lid on left hand end tube fitting 3 Place rubber seal D on male end of collector area blocking upper chamber This applies to DF only please discard seal for HP 4 Secure in position with clip F MI SAK LEO Se DO a Ne 3 2 N di AN Ensure clip F legs protrude out of bottom of enclosure 6 Complete and attach technical label I 7 Close lid and secure with screw
25. r masonry finishes Roof kits and their relevant manufacturer codes Option Code Description Suitable Suitable for HP for DF KSK0039 Varisol 10 Sloping Roof Kit KSK0040 Varisol 20 Sloping Roof Kit KSK0041 KSK0062 Varisol 30 Sloping Roof Kit Varisol 10 Bolt Down Roof Kit KSK0063 Varisol 20 Bolt Down Roof Kit KSK0064 Varisol 30 Bolt Down Roof Kit KSK0042 Varisol 10 A Frame Kit KSK0043 KSK0044 Varisol 20 A Frame Kit Varisol 30 A Frame Kit 3 4 and 5 KSK0065 Varisol 10 Fagade Kit KSK0066 Varisol 20 Fagade Kit Horizontal Installations DF only KSK0067 Varisol 30 Fagade Kit DIJI K ee X xX X IX x lt lt lt lt lt lt lt lt lt With any installation where the collector is installed horizontally on a wall facade 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 option 4 above Minimum 2 angle Wall horizontal install
26. switching states 0 off 2 Press the Jama button for 2 seconds to 1 on change the mode of operation A Automatic operation as per the settings in the settings menu 3 Repeat step 2 if necessary gt e Current temperatures and operating hours can be displayed 4 Mount the front panel status display e When changing to manual mode all outputs are switched to A R1 is displayed Exception First commissioning all outputs at 0 e Typical application Functional test maintenance fault finding Other Relays 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 3 Varisol Collector Disassembly e Isolate controller from mains e Remove M8 bolt from manifold support rail on e Remove cables to consumer units e the right hand end of the rail controller and pump e Unclip rubber retainer on the tube support e Remove sensors and associated cables e Slide the Varisol removal slide along the e Remove earthing cables manifold support rail strating at the right hand end 2 Collector Loop e Rotate each tube individually through 50
27. to conform with the Kingspan Renewables manufacturer guidelines for the Varisol Collector 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 Handling Guidance e Tube 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 roof kit and pipe work has been installed e With HP tubes only tubes may be rotated 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 collector 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 and maximum of 70 e The dark blue side of the copper within the tube is the active surface e For the DF system a heat dissipation loop heat dump is recommended e The pipework of the solar collector loop is to be earthed and the collector is to be lightning protected in accordance to local regulations For further technical support please contact the fo
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