Kingspan Thermomax HP Series, Installation Manual

Page 1: ...Installation Operation Maintenance Manual for Systems that Begin With HP Domestic Hot Water Kingspan Solar Inc 7510 Montevideo Dr Jessup MD 20794 800 231 7788...

Page 2: ...mostatic Mixing Valve 7 Backup System 8 Typical Configuration for Domestic Hot Water 8 Component Installation 10 Roof Kits 10 Attaching to a Metal Roof 11 C0590 Sloping Roof Kit 12 KSK0012 Bolt down R...

Page 3: ...e Flow Rate 27 Operating the Pump in Manual Mode 27 Other Relays 28 Thermomax HP Installation 28 Inserting HP Tubes 28 System Check 29 Leaving System Unused 29 Decommissioning the System 29 Electrical...

Page 4: ...for the 2001 Code of Federal Regulations Chapter 29 Part 1926 Safety and Health Regulations for Construction prior to undertaking the installation The installer must have proper safety equipment when...

Page 5: ...l the solar system must comply with all local state and federal codes Any building materials adjacent to solar components should not be exposed to elevated temperatures When installed the collector an...

Page 6: ...vacuated Tubes 10 per box KEK0014 SC 200 Controller KEK0015 SC 300 Controller KSK0027 Manifold Connection Kit KSP0123 Stainless Steel Piping Connections CO0627 20 Tube Manifold Tube Holders CO0629 30...

Page 7: ...e solar collectors on the roof are exposed to sunlight and transform the sun s energy into hot water An antifreeze fluid Tyfocor is pushed through the collector by the pump station and comes out sever...

Page 8: ...to attach the piping to the various parts of the system Pump Station The pump station provides flow between the collector and tank in the system In addition to the pump it has several safety features...

Page 9: ...rovide energy The element is sized at 4 5kW sufficient for most domestic applications The second uses a second coil in the tank and connects to your existing boiler See diagrams on the following pages...

Page 10: ...Boiler Backup Manifold Dual Stream Pump Station Expansion Tank Solar Storage Tank Stainless Steel Line Set Evacuated Tubes Manifold Connection Kit Thermostatic Mixing Valve Ball Valve Temperature Sen...

Page 11: ...r masonry finishes The manifold and support rails are installed on the side rails of the roof kits All components and the collector must be accessible for maintenance in the system Under no circumstan...

Page 12: ...om a supply store and must be purchased by the contractor It is imperative that the roof penetrations be sealed properly so as not to damage the structure Guidance can be found from National Roofing C...

Page 13: ...g at excessive heights or very exposed areas when the force acting upon the solar panel is greater than 2 5kN m 2 an additional vertical support rail C0594 may be obtained On the sloping roof kit a di...

Page 14: ...be used to secure directly through shingle tile or slate surfaces The support rails are secured to the roof using 12 bolts The 4 threaded end of the bolt is secured to the roof rafters 1 Locate the r...

Page 15: ...rside of the roof 2 Locate rafter and using a 3 8 drill bit break through the composite shingle over the rafter in the center of the shingle Drill pilot hole using a 3 16 drill bit 3 Insert the 5 16 s...

Page 16: ...Frame This A frame roof kit may be used for flat roof applications 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...

Page 17: ...16 Solar System Installation Guide C0591 Sloping Roof Kit 20o Elevated This roof kit provides an additional elevation of 20 o from the sloping roof kit C0590...

Page 18: ...Standing Seam Clamps KSK0026 Double Folded Standing Seam Clamps This roof kit may be used to secure directly onto standing seam roof types 1 Locate the standing seams at the appropriate distances ind...

Page 19: ...ion properly The brass tee pieces accept 3 4 copper type M pipe in a compression fitting on the return and supply connections Type L will have to be sanded to fit The following illustration shows the...

Page 20: ...to four manifolds can be connected in this fashion 1 Insert screws into plate ensuring screws do not protrude to upper side 2 Slide plate approximately half way into channel at bottom of manifold tha...

Page 21: ...be isolated at the pump station Simply spin the black knobs behind the temperature gages 90 clockwise to isolate the solar loop Expansion Tank It is recommended that the expansion tank is located bel...

Page 22: ...lated with environmentally friendly foam for an R value of 15 Kingspan Tribune tanks can be supplied in a single or dual coil configuration This allows a variety of back up heat sources to be used In...

Page 23: ...fittings or adaptors The piping for the system is sized for up to 2 30 tube collectors with a maximum length of 50 feet of piping The Kingspan stainless steel tubing solution includes the following f...

Page 24: ...23 Solar System Installation Guide...

Page 25: ...teel piping the roof penetrations are a bit more difficult Refer to local codes for exact requirements for your area It is often desirable to use a section of PVC piping for the tubing to come through...

Page 26: ...tion on wiring please consult the SC200 U or SC300U controller installation manual Programming The SC 200 U SC 300 U controllers are pre programmed with the following parameters Maximum temperature st...

Page 27: ...o Schroeder valve adaptor is required The parts to construct this can be purchased at a hardware store Connect this adaptor to the fill port on the pump station and pressurize the system using an air...

Page 28: ...r would have a flow rate of 1 0 3 gpm 1 Adjust the pump speed with the switch on the pump until it slightly exceeds the desired flow rate or if it is within the range of desired flow rates leave it at...

Page 29: ...max evacuated tubes have a patented feature that limits the temperature to 275 F in the tubes This protects all components within the system from overheating during prolonged stagnation periods Insert...

Page 30: ...pressure within the system 7 Verify that all roof penetrations are waterproof and the collector is firmly mounted to the roof It is a good idea to arrange a visit about a week after the system has bee...

Page 31: ...will display the minimum and maximum collector temperatures since the control panel was last reset If the collector temperatures have been excessively high over 338 o F it is recommended that the glyc...

Page 32: ...ck that the system pressure is maintained at the level noted below The service technician should complete the following the shaded boxes should be completed if the system requires refilling Upon commi...

Page 33: ...ng Fluid may be discharged at high temperature and pressure Warning No other fluid shall be used that would change the original classification of this system Unauthorized alterations to this system co...

Page 34: ...aker for that circuit blown Make certain the breaker is on for that circuit Replace the fuse with the identical type called out in the controller manual Reset the breaker for that circuit Temperature...

Page 35: ...ber eta0 0 792 0 778 k1 1 25 W m K 0 91 W m K k2 0 0088 W m K 0 01 W m K Test Report Performance Test Report BLG 10906 BLG 11006 Quality Test Report Flow Rate Rated 0 71 gpm 1 06 gpm Minimum 0 53 gpm...

Page 36: ...35 Solar System Installation Guide Construction Materials HP200...

Page 37: ...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 Solar Inc...