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Summary of Contents for Kingspan Varisol DF
- Page 1 Installation Manual...
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Page 2: Table Of Contents
Varisol Installation Manual Contents Introduction Using this guide Kit components Important pre-installation information Roof kits Overview Roof Kit Sizing Collector Assembly Sloping Roof assembly Attaching support rails Installing additional tubes Attaching the connection kit Bolt Down Roof Kit Varisol Façade Roof Kit Varisol A-Frame Roof Kit MCS012 Compliant Roof Hook Kit Option 13 Varisol Joint Plate Roof Kit... -
Page 3: Introduction
For large systems, Kingspan provide a system design service to its Accredited Installer Network and technical design consultants. Please visit www.kingspansolar. -
Page 4: Kit Components
Varisol Installation Manual Standard Kit Components Dual Stream Pump Station SC400 Controller Bolt Down Roof Kit with Brackets Flexi Connections Expansion Vessel Connection Kit Cooling Vessel Tyfocor® LS Tubes (DF only) Additional Components Solar Roof Flashing Installation tool Insulation pieces... -
Page 5: Important Pre-Installation Information
Important Pre Installation Information Sizing of safety equipment 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 Collector Pipe External... -
Page 6: Roof Kits
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 or masonry finishes. -
Page 7: Roof Kit Sizing
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 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. -
Page 8: Collector Assembly Sloping Roof Assembly
Varisol Installation Manual Collector Assembly - Sloping Roof 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. -
Page 9: Attaching Support Rails
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 & washers at locations illustrated 4. -
Page 10: Installing Additional Tubes
Varisol Installation Manual Installing additional tubes Step Five 1. Rotate second tube 50˚ 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. -
Page 11: Attaching The Connection Kit
Attaching the Connection Kit Step Eight (return connection) 1. Assemble and connect end fittings (Male connection A, Tee connection G & 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 lower chamber) This applies to DF only - please discard seal for HP 4. -
Page 12: Bolt Down Roof Kit
Varisol Installation Manual Bolt Down Roof Kit This roof kit may be used to secure directly through tile or slate surfaces. To convert this roof kit to meet mcs012 requirements please use bolt down seals (KSK0315) available separately. KSK0234 (10) Varisol Bolt Down Kit 1400–1700mm KSK0235 (20) Varisol Bolt Down Kit KSK0236 (30) Varisol Bolt Down Kit... -
Page 13: Varisol Façade Roof Kit
Varisol Façade Roof Kit This roof kit may be used to secure directly to flat roofs or facades in horizontal or vertical position (DFonly). KSK0237 (10) Varisol Façade Kit KSK0238 (20) Varisol Façade Kit 1400–1600mm KSK0239 (30) Varisol Façade Kit 70.9mm 1. -
Page 14: Varisol A-Frame Roof Kit
Varisol Installation Manual Varisol A-Frame Roof Kit This roof kit may be used to secure directly to flat roofs. KSK0240 (10) Varisol A-Frame Kit KSK0241 (20) Varisol A-Frame Kit KSK0242 (30) Varisol A-Frame Kit 1400–1700mm 400–600mm (10) 600–1000mm (20) 1000–1400mm (30) 1. -
Page 15: Mcs012 Compliant Roof Hook Kit Option
MCS012 Compliant Roof Hook Kit Option For the installation to meet MCS012 requirements the following components must be combined (depending on the number of tubes) to make the complete roof kit: KSK0319 (10) Varisol Joint Plate Kit KSK0320 (20) Varisol Joint Plate Kit KSK0321 (30) Varisol Joint Plate Kit + 2 x KSK0317 MCS012 Tile Roof Hooks Kit (2) 1400–1700mm 400–600mm (10) -
Page 16: Varisol Joint Plate Roof Kit
Varisol Installation Manual Varisol Joint Plate Roof Kit This roof kit may be used to secure system to the sloping roof in variety of combinations including options for standing seam and bulb seam metal roofs. KSK0319 (10) Varisol Joint Plate Kit KSK0320 (20) Varisol Joint Plate Kit KSK0321 (30) Varisol Joint Plate Kit 1400–1600mm... -
Page 17: Connection Information
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. -
Page 18: Pump Station
Varisol Installation Manual 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 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 . -
Page 19: Safety Vessel Connections
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 temperature discharge and containing the total collector volume. The container should be secured so it cannot be removed or spilled. -
Page 20: Wiring The Solar Control Panel
Varisol Installation Manual 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. - Page 21 Wiring the Solar Control Panel Terminal Clamps in the lower part of the controller (terminal cover removed) Power connection terminal block L: 1x phase conductor (mains input) 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.
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Page 22: Commissioning The System
Varisol Installation Manual Commissioning the System System Pressure The recommended system pressure is 1 bar + 0.1bar/ 1m static height. Expansion Vessel IMPORTANT: On systems up to 12m Collector area, 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. -
Page 23: Setting The Flow Rate
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 tubes=1m ) for systems up to 12m OPEN CLOSED 1. -
Page 24: Decommissioning The System
Varisol Installation Manual 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. -
Page 25: Recycling Information
Recycling Information Varisol DF Item No. Material Aluminium EPDM Rubber Bronze PA66 30%GF PA66 Natural Stainless Steel Copper Glass Brass Varisol HP Item No. Material EPDM Rubber PA66 30%GF Stainless Steel Copper Glass Brass... -
Page 26: Disposal Of Solar Anti-Freeze Solution
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. -
Page 27: Additional Notes
Additional notes for Australia and New Zealand The collector must be installed in accordance with the requirements of AS/NZS 3500.4 Plumbing and drainage - Heated water services or, in New Zealand by Building Code Clause NZBC G12. The installer should note that it is recommended to place a properly drained safe-tray under collectors, heaters or tanks where leakage would be likely to cause any damage. -
Page 28: Technical Specifications
Varisol Installation Manual Technical Specifications HP90 HP135 Max. Number of Tubes Dimensions/ tube Absorber Area (m 0.100 0.100 0.100 Width of Manifold (mm) 70.9 70.9 70.9 Length (tube and manifold) (mm) 1950 1955 1955 Depth (mm) 70.9 70.9 70.9 Aperture Area (m 0.105 0.106 0.106... -
Page 29: Technical Information
Technical Information Wind Loading Stress and maximum load on the substance on flat roofs to DIN 1055 Prevention of Collector Slippage Prevention of Collector Lifting 25° Weight Per Foot (kg) Weight Per Foot (kg) 10 Tube Collector 20 Tube Collector 30 Tube Collector 10 Tube Collector 20 Tube Collector... -
Page 30: Warranty Statement
Contract shall not exceed the Price of the Goods. 9. Kingspan Environmental 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. - Page 32 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 Due to our continuing policy of development and improvement we reserve the right to alter and amend the specification as shown in this literature.
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