Related Manuals for Kingspan thermomax hp400
Summary of Contents for Kingspan thermomax hp400
- Page 1 Solar Thermal Energy THERMOMAX HP400 & DF400 INSTALLATION MANUAL T: +44 (0) 28 3836 4520 www.kingspanthermomax.com...
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Page 2: Table Of Contents
Contents Introduction Using this guide Standard Kit Components Important Pre-Installation information Roof Kits Overview Sloping Roof Kit Bolt Down Roof Kit Surface Mount Kit 35˚-55˚ Sloping Roof Kit 20˚Elevation Sloping Roof Kit Horizontal Surface Mount Kit 90˚ Horizontal Surface Mount Kit 0˚ and 90˚ Vertical Standing Seam Metal Roof Kit Connection Information Connection Kit and other connections... -
Page 3: Using This Guide
For large systems, Kingspan provides a system design service to technical design consultants. This guide will illustrate and explain how a system should be installed to conform with the Kingspan Environmental manufacturer guidelines for the Thermomax product models, namely DF400 &... -
Page 4: Standard Kit Components
Thermomax Installation Manual Standard Kit Components Dual Stream Pump Station SC400 Controller Roof Kit with Brackets Connection Kit Flexi Connections Expansion Vessel Manifold & Tube Holders Cooling Vessel Solar Antifreeze Fluid (DF400 only) -
Page 5: Important Pre-Installation Information
Important Pre-Installation Information Sizing of safety equipment Pipe Sizing (minimum of 15mm diameter pipework must be used) Pipe Diameter Collector Flow Rate DF400 HP400 Copper Area Ltr/hr (mbar) (mbar) External (mm) 8.54 4.11 12.57 10.47 17.08 8.22 21.11 14.58 25.14 20.94 33.68 25.05... -
Page 6: Roof Kits
Minimum 2˚ angle Metal Roof Fixings Kingspan also supply 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. Note the minimum and maximum distances on each fixing kit. -
Page 7: Sloping Roof Kit
KSK0217 - 400 Sloping Roof Kit 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 KSK0229 - 400 Single Rail Sloping Roof Kit (Extra Wind Loading) may be obtained. Please refer to the wind loading table –... - Page 8 Thermomax Installation Manual MCS012 Compliant Roof Hook Kit For the installation to be installed to meet with MCS012 compliance, the following components must be combined to make a complete roof kit: KSK0221 – 400 joint plate roof kit KSK0317 – MCS012 tile roof hook kit 1.
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Page 9: Bolt Down Roof Kit
KSK0220 - 400 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 with MCS012 compliance, please use ‘bolt down seals’ (KSK0315) available separately. 1. Locate the rafters beneath the 2. - Page 10 Thermomax Installation Manual KSK0218 - 400 Surface Fixing A-Frame Kit 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/m , an additional vertical support rail (KSK0230 - 400 Single Leg Flat Roof Kit (Extra Wind Loading) may be obtained.
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Page 11: Sloping Roof Kit 20˚Elevation
KSK0222 - 400 Sloping Roof Kit 20° Elevation 1. Attach brackets to roof at distance shown over 2. Assemble hinge brackets to roof brackets at distance shown over 3. Secure side rail 4. Secure rear strut 5. Adjust and secure to lower bracket to upper bracket side brace... -
Page 12: Sloping Roof Kit Horizontal
Thermomax Installation Manual KSK0225 - 400 Sloping Roof Kit Horizontal Note – Only the DF400 can be mounted in this horizontal position. Drill required 1. Attach brackets to roof 2. Secure side rails to 3. Locate locking pins on the at distance shown brackets at both ends manifold and drill holes. -
Page 13: Surface Mount Kit 90˚ Horizontal
KSK0219 - 400 Ground, Facade Fixing Kit (Horizontal Configuration) Note – Only the DF400 can be mounted in this horizontal position. 1. Attach brackets to surface 2. Attach side rails 3. Locate locking pin at distance shown above to brackets using position on manifold bolts provided and drill holes. -
Page 14: Surface Mount Kit 0˚ And 90˚ Vertical
Thermomax Installation Manual KSK0219 - 400 Ground, Facade Fixing Kit (Vertical Configuration) Note – Only the DF400 can be mounted in a horizontal or vertical position. 1. Attach brackets to surface 2. Attach side rails to brackets at distance shown above using bolts provided 3. -
Page 15: Standing Seam Metal Roof Kit
KSK0221 - 400 Joint Plate Roof Kit (Standing Seam Metal Roof Kit Option) This roof kit may be used to secure directly onto standing seam roof types. A metal roof kit requires a joint plate kit (KSK0221) comprising two vertical side rails and adjustable plate connections. - Page 16 Thermomax Installation Manual Standing Seam Metal Roof Kit 1. Locate and secure the standing seam 2. Attach the side rails to the clamps at the appropriate distances joint plate as shown indicated and attach the joint plate to the standing seam clamp as shown 3.
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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. The following illustration shows the connections to the manifold. - Page 18 Thermomax Installation Manual 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.
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Page 19: Pump Station
Pump Station The Kingspan Environmental Thermomax product range offers both a single stream and a dual stream pump station. The maximum flow rate required on a system is typically 1 litre per minute, per square metre installed for systems up to 12m... -
Page 20: Safety Vessel Connections
Thermomax Installation Manual Safety Vessel Connections Pressure Relief Valve (PRV) Rated at 6 bar, the PRV may discharge heat transfer fluid (Solar Antifreeze Fluid) which must be 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. -
Page 21: Interconnection Kit
Interconnection Kit When joining more than one manifold together, it is necessary to use the interconnection kit which will support and align multiple collectors. Failure to do this can result in leakage due to stress on hydraulic joints. All manifolds comprise a male and female connection, enabling manifolds to be connected without the need for additional pipework. -
Page 22: Inserting The Tubes
Thermomax Installation Manual Inserting the tubes DF400 Tubes 1. Open manifold lid by peeling back the front seal strip from the lid section only, 2. Place tube in tube clips on both support rails. 3. Slide tube into manifold connection while slightly rotating tube until washer on bellow sits flush against manifold fitting. -
Page 23: Wiring The Solar Control Panel
Wiring the Solar Control Panel All electrical aspects of the installation should be undertaken by a competent person. 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 24 Thermomax Installation Manual Wiring the Solar Control Panel Wiring layout for SC400 and SC500 only 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 25: Commissioning The System
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 26: Decommissioning The System
Thermomax 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 maximum flow rate for systems up to 120 solar tubes is 1 litre per minute per m (10 tubes=1m 1. -
Page 27: Construction Materials
Construction Materials DF400 Aluminium EPDM Brass Bronze Stainless Steel PA66 30%GF Melamine Glass Copper HP400 Aluminium EPDM Brass Bronze Stainless Steel PA66 30%GF Melamine Glass Copper... -
Page 28: Servicing And Maintenance
Thermomax Installation Manual Disposal of Solar Antifreeze Fluid The Solar Antifreeze Fluid 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 30 Thermomax Installation Manual 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.
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Page 31: 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) 20 Tube Collector 30 Tube Collector 20 Tube Collector 30 Tube Collector Height Above... -
Page 32: Technical Specification
Thermomax Installation Manual Technical Specifications DF400 HP400/450 Number of Tubes Dimensions Absorber Area (m 2.004 3.02 2.01 3.021 Overall Dimensions (mm) 1954x1416x93 1954x2125x93 1952x1418x93 1952x2127x93 Width of Manifold (mm) 1416 2125 1418 2127 Length (tube and manifold) (mm) 1954 1954 1952 1952 Depth (mm) -
Page 33: 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 36 Kingspan Environmental Ltd 180 Gilford Road Portadown | Co. Armagh BT63 5LF United Kingdom Tel.: +44 (0) 28 3836 4520 solar@kingspan.com www.kingspanthermomax.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.