Kingspan Varisol DF, Installation Manual

Page 1: ...Installation Manual ...

Page 2: ...it 10 Varisol Façade Roof Kit 11 Varisol A Frame Roof Kit 12 MCS012 Compliant Roof Hook Kit Option 13 Varisol Joint Plate Roof Kit 14 Connection Information 15 Pump Station 16 Safety Vessel Connections 17 Wiring the Solar Control Panel 18 Commissioning the System 20 Setting the Flow Rate 21 Decommissioning the System 22 Recycling Information 23 Disposal of Solar Anti Freeze Solution 24 Additional ...

Page 3: ...ntally Heavy goods should not be loaded on top of the kit boxes Care should be taken when opening boxes to prevent scratches or sudden shocks to the glass Do not use sharp objects to open the tube boxes Installation Guidance Unpack and install tubes only after the roof kit and pipe work has been installed With HP tubes only tubes may be rotated after the system has been filled pressure tested and ...

Page 4: ...s Dual Stream Pump Station SC400 Controller Bolt Down Roof Kit with Brackets Flexi Connections Cooling Vessel DF only Expansion Vessel Tyfocor LS Connection Kit Tubes Solar Roof Flashing Installation tool 02 Standard Kit Components Insulation pieces ...

Page 5: ...5 2 5 18 5 3 5 25 8 4 5 25 8 5 5 35 12 6 5 35 12 7 5 35 12 8 5 50 18 9 5 50 18 Collector Area m2 HP Expansion Vessel Sizing Static Height m Expansion Vessel Size Ltr 1 5 12 2 5 12 3 5 12 4 5 12 5 5 12 6 5 18 7 5 18 8 5 18 9 5 18 03 When selecting a vessel for intermediate sizes the vessel should be selected by rounding area up to nearest m All sizes above are calculated based on a 17ltr system vol...

Page 6: ...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 Roof Kits 04 Flat horizontal orientation option 4 above Wall horizontal installation option 5 above Minimum 2 angle Minimum 2 angle 2 Min FIXING OPTION KIT CODE DESCRIPTION SUITABLE FOR HP DF 1 KSK0226 VARISOL 10 S...

Page 7: ...d collector the available rafter spacing should be considered when sizing the collector to ensure that an appropriate side rail spacing can be achieved Roof Kit Sizing 05 Collector Number of Kit Type Required Support Side Rail Area tubes Rail Length Separation m2 mm mm 0 1 1 71 0 2 2 142 0 3 3 214 0 4 4 10 Tube Rail 285 0 5 5 712mm 356 0 6 6 427 0 7 7 498 0 8 8 569 350 450 0 9 9 640 350 550 1 10 7...

Page 8: ...racket 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 M8x16 bolt assy 06 A x2 A D E C F x2 x2 x4 B x2 C x4 D x10 E x8 F x4 G x4 ...

Page 9: ...ch upper and lower support rail to 90 bracket as shown below 07 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 lower push point only 3 Attach tube to rail using M8x16 bolts as shown below 1400 1700mm 400 600mm 10 60...

Page 10: ...ion 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 Installing additional tubes PUSH PUSH Step Seven 1 Continue with remaining tubes 2 Use M8 bolt washers and nut to lock fin...

Page 11: ...m of enclosure 6 Complete and attach technical label I 7 Close lid and secure with screw E G A A B F I D DF ONLY F I A B C D E F G H I Step Nine flow connection 1 Assemble and connect end fittings Female connection B Tee connection G Temperature sensor pocket H 2 Remove securing pin from female end of collector 3 Place rubber seal C in female end of collector area blocking upper chamber This appli...

Page 12: ...of material and drill pilot hole of ø 8mm to a depth of approx 120 mm 3 Screw the bolt in the rafter using spanner if required locate the nut above the seal rubber and tighten to provide good seal with fixing surface When using mcs seal KSK0315 tightening is not required Attach the rails using M8 x 20 bolts provided 2 Drill a hole in the tile slate in recommended size Complete Roof IMPORTANT IT IS...

Page 13: ...the support profile using M8 X 16 bolts provided 2 Maintain the distance from the edge of the profile as shown Drill the holes and attach the rails to the surface using coach screws and plugs provided 3 Secure the support rails and use M8 X 16 bolt provided to secure the first tube in the way shown IMPORTANT IT IS REQUIRED THAT 1ST LAST AND AT LEAST EVERY TENTH TUBE IN THE SYSTEM IS SECURED TO THE...

Page 14: ...e shown 3 Secure side bracing to bracket on the side rail in the desired position 2 Secure side rails to front and rear brackets Typical distances and rear strut locations required for specific angles IMPORTANT IT IS REQUIRED THAT 1ST LAST AND AT LEAST EVERY TENTH TUBE IN THE SYSTEM IS SECURED TO THE RAIL WITH M8 X 16 BOLTS PROVIDED 4 Secure tube support profiles with M8x16 bolts provided and secu...

Page 15: ...012 Tile Roof Hooks Kit 2 1 Slide back tiles and attach lower and upper brackets to the rafter using supplied M8 X 50 coach screws Maintain the recomended spacing shown above 2 Discard supplied joint plate and retain M8 X 20 bolts washers and nuts 3 Using retained M8 x 20 bolts washers and nuts attach rails to the roof brackets IMPORTANT IT IS REQUIRED THAT 1ST LAST AND AT LEAST EVERY TENTH TUBE I...

Page 16: ... Set of 4 standing bulb seam bracket 1 X KSK0025 Set of 4 standing double folded seam bracket 1 X KSK0026 Set of 2 adjustable roof hooks MCS012 and DIBT Certified 2 X KSK0356 Available Standard Combinations Of Brackets Mounted directly to the support profile Set of 2 MCS012 approved roof hooks slate roofs 2 X KSK0316 Set of 2 MCS approved roof hooks roman and flat tile roofs 2 X KSK0317 IMPORTANT ...

Page 17: ...OULD 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...

Page 18: ...duct range offers both a single stream and a dual stream pump station Each pump station is available in various sizes to suit the 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 12m2 Therefore a 2 12 litre minute pump station should be sufficient for systems up to 12m2 Connections of flow and return pi...

Page 19: ...es 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 exte...

Page 20: ...rder 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 ...

Page 21: ...l 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 R2 2 x control output for PWM controlled high efficiency pumps 7 x mass connection common mass for sensor inputs and control outputs 4 Pin strip for internal use only 5 Cable openings on ...

Page 22: ...p to circulate the Solar Antifreeze Fluid for approximately 30 minutes For East West systems flush and fill each collector for approx 30 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...

Page 23: ... system these should be tested in Manual mode as above to ensure the connections have been wired correctly Operating the pump in Manual mode for SC 400 500 controllers 1 Remove the front panel 2 Press the button for 2 seconds to change the mode of operation 3 Repeat step 2 if necessary 4 Mount the front panel Functionality Backlighting is red spanner symbol flashes The controller outputs pumps val...

Page 24: ...eat transfer fluid for appropriate disposal Disconnect pipes from the manifold 3 Varisol Collector Disassembly Remove M8 bolt from manifold support rail on the right hand end of the rail Unclip rubber retainer on the tube support Slide the Varisol removal slide along the manifold support rail strating at the right hand end Rotate each tube individually through 50 until engagement arrows line up an...

Page 25: ... EPDM Rubber 3 Bronze 4 PA66 30 GF 5 PA66 Natural 6 Stainless Steel 7 Copper 8 Glass 9 Brass 10 PPS Item No Material 2 EPDM Rubber 4 PA66 30 GF 6 Stainless Steel 7 Copper 8 Glass 9 Brass 10 PPS 1 1 6 8 4 3 5 2 6 6 2 9 9 2 4 2 10 7 2 6 Varisol DF Varisol HP ...

Page 26: ...e 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 29 for maintenance schedule form Disposal of Solar Anti Freeze Solution The solution we supply with our solar systems is a thermal transfer fluid based ...

Page 27: ...epublic of Ireland Solar installations in the Republic of Ireland must be installed in accordance with the Irish Agrément Board certificate No 10 0345 which takes precedence over this installation document NSAI Agrément Irish Agrément Board is designated by Government to issue European Technical Approvals NSAI Agrément Certificates establish proof that the certified products are proper materials s...

Page 28: ... 50 0 96 0 96 0 96 ηcal 40k 1000W 0 704 0 682 0 686 Solar Keymark Licence Nos 011 751238F 011 751936R 011 751935R Operating Data Flow Rate L min Rated tube 0 1 0 1 0 1 Minimum tube 0 067 0 067 0 067 Maximum tube 0 25 0 25 0 25 Maximum Operating Pressure 6 Bar 6 Bar 6 Bar Stagnation Temperature C 240 100 192 Heat Transfer Fluid Water Glycol Water Glycol Water Glycol Max Load kN m2 DIN 1055 5 2 5 2 ...

Page 29: ...ector Slippage Prevention of Collector Lifting Weight Per Foot kg 10 Tube Collector A B A B A B A B A B A B 102 171 102 171 156 256 73 73 73 73 111 111 177 287 177 287 266 430 137 137 137 137 206 206 8 8 to 20 20 Tube Collector Height Above Ground m 30 Tube Collector 10 Tube Collector 20 Tube Collector 30 Tube Collector Weight Per Foot kg 45 Wind Loading Pressure Drop Curves Flow Rate ltr hr DF Va...

Page 30: ...s 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 Environmental within 7 days from the delivery date...

Page 31: ...re 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 Upon Commissioning Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10 Year 11 Year 12 Year 13 Year 14 Year 15 Year 16 Year 17 Year 18 Year 19 Year 20 Year 21 Year 22 Year 23 Year 24 Year 25 ...

Page 32: ...iterature This brochure is printed on environmentally friendly paper 1038_KSOL_Varisol Part Code B9093C 180 Gilford Road Portadown Co Armagh Northern Ireland BT63 5LF Tel 44 0 28 3836 4520 Fax 44 0 28 3836 4501 Technical Support Tel 0345 812 0007 E mail solar kingspan com www kingspansolar com For useful video demonstrations please scan ...