Installation Manual - Kingspan Environmental
Contents
1. Operating switch The following modes of COGS TOA Can be selected Manual for COMMS Oning and testing for function Automatic for automatic operation Off for switching off the outputs 4 Manual 4 Automatic 4 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 materials in accordance with local regulations Please see the following pages for details of materials used in the construction of Thermomax collectors and guidance on disposal of antifreeze 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 e2. 1 Attach brackets to roof at distance shown over 2 Assemble hinge brackets to roof brackets at distance shown over ri li Mae 3 Secure side rail to 4 Secure rear strut to 5 Adjust and secure lower bracket upper bracket side brace Ny aa S 4 G a Q 4 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 LJ Note Only the DF100 can be mounted in this horizontal position Drill required 1 Attach brackets to roof at distance shown 4 Secure locking pins to prevent slippage 2 Secure side rails to brackets 5 Locate manifold on side rails MW 3 Locate locking pin positions and drill holes 6 Locate support rails on side rails Themomax Installation Manual C0597 Surface Mount 90 Horizontal iy 1 O Note Only the DF100 can be mounted in this horizontal position f N 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 p Note Only the DF100 can be mounted in a horizontal or vertical position 1 1 1 Attach b
3. 22 Weight empty kg 25 54 8 81 4 25 Mounting Recommended Inclination Performance Data Efficiency eta O Based on Aperture 0 773 Based on Aperture Based on Aperture Based on Aperture 0 726 0 761 Based on Aperture 0 726 0 761 Based on Aperture 0 726 0 761 k1 W mek 1 45 1 55 1 36 1 55 1 36 1 55 1 36 k2 W mek2 0 0059 0 0058 0 0074 0 0058 0 0074 0 0058 0 0074 Solar Keymark Licence Nos 011 7SO60R HP200 011 7S125R HP250 011 7S904R Operating Data Flow Rate ltr h Rated 80 160 240 80 160 240 Minimum 60 120 180 60 120 180 Maximum 150 300 480 150 300 480 Maximum Operating Pressure 8 Bar 8 Bar 8 Bar 10 Bar 10 Bar 10 Bar Stagnation Temperature C 286 286 286 184 217 184 217 184 217 Heat Transfer Fluid Water Glycol Water Glycol Water Glycol Water Glycol Water Glycol Water Glycol Materials Absorber Coating Copper Selective Coating Copper Selective Coating Copper Selective Coating Copper Selective Coating Copper Selective Coating Copper Selective Coating Absorbance 95 95 95 95 95 95 Emissivity 5 5 5 5 5 5 5 Mounting Frame and Clips Stainless Steel Aluminium EPDM
4. D D D D D D D D D D D D D D D D 309 s s x x x x x x x x x x x s sz s S 3 gt B nm N N N N nm oa o o N D o oo N oO O N co N D oO a oo N _ 3 S z Q uu 1 s s y dn Buiddo1 p p u J p ji aq 1snuu s xoq p peys y AVTOS uedssuly yeyo BuIMO O u 1 9 duuooS pynous uo 5 dsul y Buluuuolid J e1sul u L k jqe L 9ueu zule WwW Kingspan SOLAR Technical Information 1 Wind Loading ot Stress and maximum load on the substance on flat roofs to DIN 1055 Prevention of Collector Slippage Weight Per Foot kg 20 Tube Collector Prevention of Collector Lifting Weight Per Foot kg 10 Tube Collector 30 Tube Collector 10 Tube Collector 20 Tube Collector 30 Tube Collector Height Above Grounaliin A B A B A B A B A B A B 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 Sh Stress and maximum load on the substance on flat roofs to DIN 1055 Prevention of Collector Slippage Weight Per Foot kg 20 Tube Collector Prevention of Collector Lifting Weight Per Foot kg 10 Tube Collector 30 Tube Collector 10 Tube Collector 20 Tube Collector 30 Tube Collector kerght Above 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 13
5. 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 Themomax Installation Manual Construction Materials J 24 m DF100 2 i Aluminium EPDM Brass Bronze Stainless Steel PA66 30 GF L Silicon ag fe S Vinyl 5 S EF Copper 11 5 z 0 Melamine T 1 Glass 5 Olo INIIAI AJ OO N HP200 Aluminium EPDM Brass Bronze Stainless Steel PA66 30 GF Silicon Vinyl Copper 0 Melamine 1 Glass O O N O OI I OO N Kingspan SOLAR Disposal of Solar Anti Freeze Solution 1 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 20 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 d
6. 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 2 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 connecting 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 d
7. 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 the connections to the manifold Return connection Manual airvent s caD E D CENE WS l r lt N a ar a k N Voge Manifold clip os a 2 Cs A F Ps z Ei s A F ES Female assembly Flow connection gt gt Male assembly fi iy a gt We Sensor pocket VQ 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 thr
8. separator 12 Insulated fascia 13 Pressure relief discharge point 1 2 3 4 5 6 7 8 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 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 5 Pressure Relief Valve PRV Rated at 6 bar the PRV may discharge heat transfer fluid Tyfocor LS which must be 1 T 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
9. 7 206 206 A Front feet B Back feet See page 7 for diagram Technical Specification Dimensions l 1996 x 1996 x 1996 x 2005 x 2005 x 2005 x Wee Meum Wein zs leite iu 709 x 1418 x 2127 x 709 x 1418 x 2127 x 97 97 97 97 97 97 Weight empty kg 36 9 54 8 81 4 33 2 50 3 75 1 Volume l 2 6 3 8 5 6 0 83 1 2 17 Max Field Size m7 10 12 15 8 10 12 Cu Pipe Diameter 2 3m2 15mm x 1 mm per panel area 4 9m2 22mm x 1 10 15m 2 28mm x 1 2 16 20m 2 35mm x 1 5 Max Operating Pressure bar 8 Min Slope 0 20 Max Slope 90 70 Max Load kN m2 DIN 1055 5 2 5 Heat Transfer Medium Pressure Drop Curves ap ESR Ah HP ey ub Propylene Glycol suitable for evacuated tube collectors Themomax Installation Manual Technical Specifications gt HP200 250 Number of Tubes Dimensions Absorber Area m3 1 002 2 004 3 020 1 007 2 01 3 021 Overall Dimensions mm 1996x709x97 1996x1418x97 1996x2127x97 2005x709x97 2005x1418x97 2005x2127x97 Width of Manifold mm 709 1418 2127 709 1418 2 Length tube and manifold mm 1996 1996 1996 2005 2005 2005 Depth mm 9 97 97 97 ey 97 Aperture Area m3 ROM 2 15 3 23 1 07 2 16 3 23 Fluid Volume ltr 1 8 3 6 5 6 0 6 Tal lat Inlet and Outlet Dimensions mm 22 22 22 22 22
10. 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 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 Q mm KSKOO69 ver 2 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 Ge environmentally friendly paper
11. Stainless Steel Aluminium EPDM Stainless Steel Aluminium EPDM Stainless Steel Aluminium EPDM Stainless Steel Aluminium EPDM Stainless Steel Aluminium EPDM Glass Low Iron Transm 0 92 Low Iron Transm 0 92 Low Iron Transm 0 92 Low Iron Transm 0 92 Low Iron Transm 0 92 Low Iron Transm 0 92 Vacuum 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 Quality Certification Solar Keymark Yes Yes Yes Yes Yes Yes Kingspan SOLAR Warranty Statement A Kingspan Renewables Ltd Warranty Statement for Solar Subject to the following provisions Kingspan Renewables warrants that the Goods will be free from 2 9 defects in material and workmanship for a period of 20 years in relation to VACUUM TUBES and a period of 5 years for 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 Thermomakx Installation Manual for further details Otherwise a default 5 year
12. d Installer Network and technical design consultants 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 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
13. d 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 notified 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
14. 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 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 agree
15. hes Roof kits and their relevant manufacturer codes Option Code Description Suitable for HP Suitable for DF 1 C0590 Sloping roof kit V Y or KSK0012 Bolt down roof kit Y Y 2 C0599 Flat roof A frame kit 85 55 Y yY 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 Horizontal Installations DF100 only With any DF100 installation where the collector is installed horizontally on a wall fagade 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 St SO el er T nM L r f Ef 1 _ gt ca a U c Minimum 2 angle J r Sannn r gt Metal Roof Fixings Kingspan also su
16. is 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 overleaf 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 level noted overleaf The service engineer should complete the table overleaf the shaded boxes should be completed if the system requires refilling ON uoud l UBIS WeU yud s ie1 p J u B5ug s qn uo 4131386 wnneq jo uonoadsu Buipe iu Hd Jana z JJnuv e721 MO 4 ulli Jaye Buas j ss n uoisuedxd aunsseid W JS S Gulli 10jeq Bues j ss an uoisuedxd uono dsul Jo eGq C e ig ig g ig gig gig ig g gig g Ig lg lg ig g ig ig Ig ig g S D D D D D D D
17. kit may be used to secure directly through tile or slate surfaces h Q go N aA gt SAN we AAS 4 N 2 k Aae eg gt h Pa SZ P SSD SD SY N SS SD she A KO 1 cD F r aS T 1 Locate the rafters beneath the roof material and 2 Insert the rawl plug provided if drill to a depth of 120mm with a 12mm drill bit necessary and fix the bolt with a spanner 3 Locate the nut above the rubber roof seal and tighten 4 Stabilise the flat fixing plate by tightening to ensure a good seal is made on the fixing surface the attached nuts above and below the plate 5 Attach the roof rails to the four fixing plates using the bolts provided 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 m2 an additional vertical support rail 07 C0596 may be obtained Please refer to the wind loading table page 27 J g Ma E es 1 Attach front and rear brackets to surface at distance shown 2 Secure side rail to front bracket 3 Secure side rail to rear bracket 4 Secure side bracing bracket to side rail J lt I lt Y Ey 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
18. nected 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 Model Max Number of collectors DF100 x 30 tubes 5 HP200 x 30 tubes 4 Insert 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 Kingspan SOLAR Inserting tubes 5 DF100 Tubes 1 Open manifold lid by removing front seal strip Place tube in tube clips on both support rails Slide tube into manifold connection while slightly 1 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
19. nection Kit 22mm Thermostatic Mixing Valve 28mm also available aa Insulated Hose Mounting Set 22mm 3 Port Diverter Valve Stubfitting 15 amp 28mm also available Kingspan SOLAR Important Pre Installation Information Sizing of safety equipment 0 3 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 m2 Ltr hr External mm 3 180 15 12 57 10 47 4 240 1S 17 08 8 22 5 300 22 21 11 14 58 6 360 22 25 14 20 94 8 480 22 33 68 25 05 Expansion Vessel Sizing HP200 2 17 5 18 3 17 5 18 4 18 5 18 5 ag 5 18 DF100 2 19 5 18 3 20 5 25 4 22 5 25 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 5 3 20 5 25 8 4 5 5 5 Themomax Installation Manual Roof Kits i 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 easily secured to slate tile or masonry finis
20. 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 join 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 1 PRV discharge point 2 Wall bracket supplied 3 Discharge container 4 TRV kit DF100 only 5 Expansion vessel 6 Dual stream pump station _ 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 con
21. one 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 ty 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 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 Th
22. ough 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 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 gauge 9 22mm connections x 4 10 Temperature gauge 11 Air
23. pply roof fixing kits for metal and other commercial 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 r 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 Soe 1 Slide back tile and attach 2 Secure side rails to lower bracket lower brackets to roof rafter with the pre drilled holes to the bottom L we r L E 4 Secure side rails to upper brackets with sliding bolt fixing CE ws 5 Locate manifold on side rails and 6 Locate horizontal support rails on secure with upper clamp bolts the side rails Themomax Installation Manual KSK0012 Bolt down Roof Kit This roof
24. rackets to surface at 2 Attach side rails to brackets using distance shown above bolts provided Qy Si 3 Locate manifold on side rails 4 Secure all clamps Themomax Installation Manual Standing Seam Metal Roof Kit 1 O This roof kit may be used to secure directly onto standing seam roof types KSK0025 Bulb standing seam KSK0026 Double folded standing seam A metal roof kit requires a joint plate kit KSKO016 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 KSKO016 KSK0026 Double Folded Standing Seam Clamps M10 holas located 13mm 5 from edges of part r a a KSK0025 Bulb Standing Seam Clamps WTO Pola location 12 13 man Ikem echje nt pari ia i rumi teme sl i _ 189 mant Kingspan SOLAR Standing Seam Metal Roof Kit 1 Locate and secure the standing seam clamps at the appropriate distances indicated and attach the joint plate to the standing seam clamp as shown 3 Locate manifold on side rails 2 Attach the side rails to the joint plate as shown 4 Secure all clamps Themomax Installation Manual 14 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
25. radiation when the solar loop and manifold 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 buildino 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 T Kine pan joes m was SC100 Controller Dual Stream Pump Station Sloping Roof Kit with Brackets a heg Connection Kit Flexi Connections wau Expansion Vessel Manifold amp Tube Holders Cooling Vessel DF 100 only Tyfocor LS Additional Components 3 Solar Roof Flashing Intercon
26. sition 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 guU 7 N FILL Ba Hoo k YE FLUSH AND FILL CENTRE H o l a i e ome Kingspan SOLAR 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 1m2 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 3 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 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 OPEN CLOSED 1 JEA ISOLATING VALVE gt T f m il T ma af ae 1 Foe i I Left side view of controller
27. tromechanical 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 J 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 can 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 d
28. uring 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 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 2 1 and the SC200 contain an electromechanical relay R2 Note that the SC300 contains two RPM relays R1 and R2 as well as an elec
29. uring 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 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 po
30. 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 Renewables 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
31. x Renewables x THERMK MAX Installation Manual Kingspan COI AD Themomax Installation Manual Contents Introduction Using this guide Kit components Important pre installation information O N Roof kits Overview 4 Sloping Roof Kit 5 Bolt down roof kit 6 Surface mount 35 55 7 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 Commissioning the system 22 Decommissioning the system 23 Construction materials 24 Servicing and maintenance 25 Maintenance schedule 26 Technical Information Wind loading 27 Technical Specification 28 Warranty Statement 29 Kingspan soLAR Introduction 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 provides a system design service to its Accredite
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