Summary of Contents for Kingspan Thermomax HP Series
- 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...
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Page 2: Table Of Contents
Standing Seam Metal Roof Kit ..........................17 Manifold Connection Kit ............................18 Manifold Interconnection Kit ..........................19 Pump Station ................................20 Expansion Tank ................................. 20 Safety Vessel Connections (Pressure Relief Valve (PRV)) ..................21 Kingspan Tribune Hot Water Tank ........................21 System Plumbing ................................22... - Page 3 Collector (Beware of high temperatures) ....................... 29 Disposal ..................................30 Servicing and Maintenance ............................30 Maintenance Schedule ............................. 31 Labels ..................................... 32 Troubleshooting ................................33 Technical Information ..............................34 Thermomax HP Series Solar Collectors ........................34 Construction Materials HP200 ............................ 35 Warranty ..................................36...
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Page 4: Kingspan Solar System Overview
Consult with your distributor for more information on this service. This guide will illustrate and explain how a system should be installed to conform to the Kingspan Solar guidelines for the Thermomax product models. -
Page 5: Installation Guidance
process. If the collector is shaded excessively, then a different location should be selected to mount the collector. For further technical support please contact the following number: 410 799 6600 or contact your Kingspan Solar distributor. Product Dimensions 20 Tube Collector... -
Page 6: Component Overview
Solar System Installation Guide Component Overview The following is a list of components offered by Kingspan Solar for a standard solar thermal domestic hot water system. C0629 - Thermomax HP Evacuated Tubes KEK0014 - SC-200 Controller (10 per box) KEK0015 – SC-300 Controller KSK0027 - Manifold Connection Kit KSP0123 - Stainless Steel Piping &... -
Page 7: System Operating Description
Solar System Installation Guide Tribune Hot Water Tank KSP0142 – Thermostatic Mixing Valve KSP0045 – 60 Gallon, Single Coil KSP0046 – 80 Gallon, Single Coil KSP0058 – 119 Gallon, Single Coil KSP0047 – 60 Gallon, Dual Coil KSP0048 – 80 Gallon, Dual Coil KSP0059 –... -
Page 8: Component Description
The solar hot water tank is similar to most other hot water heaters, with the exception that it provides more insulation and is designed for the temperatures that solar can generate. The Kingspan Tribune tank is also made from duplex stainless steel to give the maximum life and corrosion resistance to the tank that is on the market today. -
Page 9: Backup System
Solar System Installation Guide Backup System There are two options offered to provide a back up for your hot water if the solar does not produce enough energy. On sunny days, the solar will provide the majority if not all the energy you require for hot water. A backup system is required for cloudy days, or in winter months when the number of daylight hours are less. - Page 10 Solar System Installation Guide Manifold Boiler Backup Manifold Connection Kit Temperature Sensor Stainless Steel Evacuated Line Set Tubes Controller Solar Storage Tank Dual Stream Pump Station Thermostatic Mixing Valve Temperature Sensor Ball Valve Expansion Tank...
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Page 11: Component Installation
Solar System Installation Guide Component Installation Roof Kits 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 shingle, slate, tile or masonry finishes. -
Page 12: Attaching To A Metal Roof
Note that the fixing clamps on the side rails are preset for ease of on-site installation. Attaching to a Metal Roof Kingspan also supplies roof fixing kits for metal and other commercial roofs. The two options available utilize clamps so the metal roof is not penetrated. -
Page 13: C0590 - Sloping Roof Kit
Solar System Installation Guide C0590 – Sloping Roof Kit This roof kit may be used on a tiled roof. 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 (C0594) may be obtained. -
Page 14: Ksk0012 - Bolt Down Roof Kit
Solar System Installation Guide KSK0012 – Bolt down Roof Kit This roof kit may 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. -
Page 15: Ksk0016 - Joint Plate Roof Kit
Solar System Installation Guide KSK0016 – Joint Plate Roof Kit This roof kit is the same as the bolt down roof kit but it is supplied without the 4 bolts. The joint plate allows the support rails to be secured to the roof using various types of roof mounting products, e.g. ProSolar Fast Jack™ uprights. Guidelines for installing the Fast Jack™... -
Page 16: C0599 - Surface Mount 35° To 55° (A-Frame)
Solar System Installation Guide C0599 – Surface mount 35° to 55° (A-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 2.5kN/m , an additional vertical support rail (C0596) may be obtained. -
Page 17: C0591 - Sloping Roof Kit 20O Elevated
Solar System Installation Guide C0591 – Sloping Roof Kit 20o Elevated This roof kit provides an additional elevation of 20 from the sloping roof kit (C0590). -
Page 18: Standing Seam Metal Roof Kit
Solar System Installation Guide Standing Seam Metal Roof Kit A metal roof kit requires a joint plate kit (KSK0016) comprising two vertical side rails and adjustable plate connections. The roof type will determine the clamp required. KSK0025 – Bulb Standing Seam Clamps KSK0026 –... -
Page 19: Manifold Connection Kit
Solar System Installation Guide Manifold Connection Kit The connection kit enables copper or stainless steel piping to be connected to the supply (cold side) and return (hot side) ends of the manifold (or to a bank of up to 4 manifolds). Either side of the manifold can be used as the supply or return, however it is very important that the temperature sensor well is on the return side! Having this position backwards will cause the system to not function properly! The brass tee pieces accept 3/4"”... -
Page 20: Manifold Interconnection Kit
Solar System Installation Guide Manifold Interconnection Kit When joining manifolds together in series, it is necessary to use the interconnection kit which will support and align multiple collectors. All manifolds comprise of a male and female connection, enabling manifolds to be connected directly to one another. -
Page 21: Pump Station
13. Pressure relief discharge point Connections of the supply and return pipe work to the pump station are 1” ISO / BSPP connections. Kingspan Stainless Steel piping connections connect directly on to the pump station. Copper sweat adapters are available from Kingspan if copper piping is used. -
Page 22: Safety Vessel Connections (Pressure Relief Valve (Prv))
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 the single coil configuration this can be connected to a boiler or solar circuit. Twin coil tanks the lower coil is connected to a solar circuit and the top coil to a boiler system for backup. -
Page 23: System Plumbing
Stainless Steel Flexible Piping Kingspan Solar flexible stainless steel tubing is used to connect the key components of a solar thermal system together – the collector, pump station and storage tank – in a secure and timely manner. The tubing allows for a quick and professional installation, significantly reducing labor time. - Page 24 Solar System Installation Guide...
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Page 25: Copper Piping
Solar System Installation Guide Copper Piping Copper piping should be sweated with lead-free solder. For large installations, silver solder is required. Insulation All pipe work on the solar loop should be insulated with high temperature insulation. High temperature insulation is essential as regular pipe insulation will melt at temperatures experienced by solar pipes. -
Page 26: Programming
Solar System Installation Guide The solar circuit pump R1 is switched on as soon as the switch-on temperature difference between the collector array A1 (T1) and the storage tank B1 (T2) is reached. When the switch-off temperature difference between the collector array A1 (T1) and the storage tank B1 (T2) or a safety limit is reached, the solar circuit pump R1 is switched off again. -
Page 27: System Commissioning
Solar System Installation Guide System Commissioning Expansion Tank Commissioning The pressure in the expansion tank may need to be adjusted based on several system parameters. There is a Schroeder valve on the bottom of the expansion tank that is covered by a black piece of plastic. Remove this piece of plastic and using a tire pressure gage check the pressure in the expansion tank. -
Page 28: Setting The Flow Rate
Solar System Installation Guide 12) Return the temperature gauges to the original position. 13) The fill pump may now be disconnected. 14) Cap the fill and drain points with the brass covers provided. The flow and return pipes from the flush and fill center should be connected as shown in the diagram on the following page: Setting the Flow Rate The pump may only be run when the system has been filled as dry operation will damage the pump. -
Page 29: Other Relays
Solar System Installation Guide Other Relays 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. Thermomax HP Installation 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. -
Page 30: System Check
Solar System Installation Guide System Check If the sun is out, then it is possible to check the system function. If not, a time the following day should be scheduled to make sure the system is operating properly. Make sure to switch the controller to automatic mode (see page 28). This will activate the pump when the temperature conditions are met. -
Page 31: Disposal
Solar System Installation Guide Remove the rubber support retainers from around glass tube Remove tube manifold clip Remove tubes from manifold Remove lid and separate materials Remove Manifold and support rails and separate materials Remove roof kit and separate materials Reinstate roof Disposal All components are made from material that may be recycled. -
Page 32: Maintenance Schedule
Solar System Installation Guide Maintenance Schedule A qualified person should service the system at the recommended intervals, using the maintenance schedule below. 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 below. -
Page 33: Labels
Solar System Installation Guide Labels The following labels must be cut out, placed in the included plastic bags and be attached to the correct locations on the system Fill Drain Valve Solar Tank Isolation 50% Propylene Glycol / 50% Water – Normally Open Freeze Tolerance Limit –49°F Heat Exchanger Type SW AWWA Fluid Class II... -
Page 34: Troubleshooting
Solar System Installation Guide Troubleshooting PROBLEM CAUSE SOLUTION Check wiring at mains /pump • Mains/pump wiring is faulty Pump is not Drain and clean system thoroughly • Build up of limestone around heat operating exchanger Re-set breaker Breaker tripped • Return controller to automatic mode ‘AUTO’... -
Page 35: Technical Information
Solar System Installation Guide Technical Information Thermomax HP Series Solar Collectors Technical Specifications 20 Tube 30 Tube Dimensions Absorber Area 21.6 ft² 32.5 ft² Overall Dimensions 78 7/8” x 55 3/4” x 3 3/4” 78 7/8” x 83 3/4” x 3 3/4”... -
Page 36: Construction Materials Hp200
Solar System Installation Guide Construction Materials HP200... -
Page 37: Warranty
Price of the Goods. 8. Kingspan Solar Inc 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.