Kingspan Thermomax HP Series User manual

Installation, Operation & Maintenance
Manual for Systems that Begin With HP
Domestic Hot Water
Kingspan Solar Inc. 7510 Montevideo Dr. Jessup, MD 20794
[phone]

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Solar System Installation Guide
Contents
Kingspan Solar System Overview.................................................................................................................................. 3
Important Pre-Installation Information....................................................................................................................... 3
Installation Guidance ................................................................................................................................................. 4
Product Dimensions ....................................................................................................................................................... 4
Component Overview .................................................................................................................................................... 5
System Operating Description .................................................................................................................................. 6
Component Description................................................................................................................................................. 7
Evacuated Tubes ......................................................................................................................................................... 7
Manifold....................................................................................................................................................................... 7
Flexible Piping and Fittings ....................................................................................................................................... 7
Pump Station............................................................................................................................................................... 7
Solar Tank.................................................................................................................................................................... 7
Tyfocor Glycol Solution.............................................................................................................................................. 7
Thermostatic 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 Roof Kit................................................................................................................................. 13
KSK0016 – Joint Plate Roof Kit ................................................................................................................................14
C0599 – Surface mount 35° to 55° (A-Frame) ........................................................................................................ 15
C0591 – Sloping Roof Kit 20o Elevated ...................................................................................................................16
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

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Solar System Installation Guide
Stainless Steel Flexible Piping ................................................................................................................................. 22
Copper Piping............................................................................................................................................................ 24
Insulation...................................................................................................................................................................24
Pipe Supports ............................................................................................................................................................24
Roof Penetrations ..................................................................................................................................................... 24
Solar Controller.............................................................................................................................................................24
Programming............................................................................................................................................................. 25
System Commissioning ................................................................................................................................................ 26
Expansion Tank Commissioning............................................................................................................................. 26
Filling the Solar Loop ...............................................................................................................................................26
Setting the 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 .................................................................................................................................................................... 29
Collector Loop........................................................................................................................................................... 29
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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Solar System Installation Guide
Kingspan Solar System Overview
Solar hot water systems should be designed and sized correctly before commencing the installation. Proper design will
insure that a system is correctly sized to provide many years of optimized performance, contributing a significant
percentage of the annual domestic hot water demand of a building. A supplementary heating system such as oil or gas
boiler, heat pump, electrical immersion heater or wood boiler is required for periods where the solar cannot make
enough heat to meet the demand.
This guide covers the installation of solar domestic hot water systems. For larger and more complex systems Kingspan
provides a system design service to its customers and technical design consultants. 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.
The solar energy system described by this manual, when properly installed and maintained, meets the minimum
standards established by the SRCC. This certification does not imply endorsement or warranty of this product by SRCC.
Important Pre-Installation Information
The installation shall conform to all federal, state and local regulations, codes, ordinances and standards governing solar
water heating system installations, and the contractor shall adhere to sound building safety and trade practices. Special
consideration must be given to building code requirements for the penetration of structural members and fire rated
assemblies. Any penetrations shall not allow vermin infiltration.
The installer should consult www.osha.gov 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 working on elevated surfaces, as per OSHA requirements. Fall
protection equipment must be used with the proper training.
The homeowner and installer must confirm the location of all roof mounted components in advance of the installation.
The solar panels must be located in a structurally sound area of the roof that will not be shaded for the majority of the
day during all times of the year. Adjacent buildings and trees should be checked for possible winter shading before
commencing the installation.
Before the installation the installer shall inspect the condition of the roof and notify the homeowner of any existing roof
damage or necessary repairs.
The system has several safety features that will not allow the system to go outside of the maximum design temperature
and pressure requirements. The controller will monitor the system and insure that the temperatures do not rise to
extremes. In addition, a pressure relief valve on the solar loop and a temperature and pressure relief valve are provided
on the tank. The expansion tank on the solar loop will maintain the correct pressure, regardless of temperature. Check
with local regulations to see if an expansion tank is required on the domestic water side of the system. Under no
circumstances during the installation should these mechanisms be deleted, or overridden, as this could cause a severe
safety concern.
Any components that could be exposed to public traffic and are above 140°F should be insulated. Any other area that
may get above 140°F within the system should be labeled as such.
Tube and manifold boxes should be transported horizontally.
Care should be taken when opening boxes to prevent scratches or sudden shocks to the glass.

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Solar System Installation Guide
Do not use sharp objects to open the tube boxes.
Heavy goods should not be loaded on top of the kit boxes.
Installation Guidance
Unpack and install tubes only after the manifold and pipe work has been installed and the system has been
filled with glycol and purged.
Do not leave the solar collector exposed to solar radiation when the solar loop and manifold have been drained.
Collectors left exposed in a dry state must be covered to prevent possible long term damage.
HP tubes must have a minimum elevation of 20oand a maximum of 70o
All modifications to structural members to install 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 and mounting frame must be rigid enough to maintain the orientation of the
collector.
Shading of the collectors should be checked by using a solar pathfinder before beginning the installation
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 30 Tube Collector
Length
78 7/8”
78 7/8”
Width
55 ¾”
83 ¾”
Depth (without frame)
3 ¾”
3 ¾”
Weight (lbs.) 111 160
Fluid Volume (gal.)
0.32
0.45
Maximum Operating Pressure
116 psi

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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
(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 Tube Manifold & Tube Holders
C0560 - Tyfocor Propylene Glycol
KSP0015 - Dual Stream Pump Station KSP0008 – 5 gal. Expansion Tank with Bracket and Hose
KSP0009 – 7 gal. Expansion Tank with Bracket and Hose

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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 – 119 Gallon, Dual Coil
C0590 – Sloping Roof Kit
KSK0012 – Bolt Down Roof Kit
C0591 – 20° Elevation Kit C0599 – Flat Roof Fixing Kit (A-Frame)
System Operating Description
The solar system is designed to provide hot water for domestic use. The 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 several degrees warmer than when it entered the collector. The fluid then goes
through a heat exchanger coil in the hot water tank and heats the water in there for your use. A thermostatic mixing
valve provides water at the same temperature, even though the tank temperature may be much hotter than what would
be typically be used in the household. All this function is monitored by an electronic control that decides when enough
energy is present from the sun to turn the system on.

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Solar System Installation Guide
Component Description
Evacuated Tubes
This is the heart of the solar system. The evacuated tubes are what change the light energy from the sun and change it
into hot water. Inside the glass is a vacuum that prevents heat from being lost from the system. This prevents the loss
of most energy from the system meaning the maximum amount is available to heat water. The tubes may look delicate,
but they are actually quite strong. They are certified to withstand hail impacts of up to 1” in diameter (DIN EN12975-5)
and a snow load of over 3,000 lbs!
Please be careful when handling the tubes when it is sunny outside. The metal piece on the top (the condenser) can
become very hot and cause burns. Tube installation and removal should be conducted by a trained professional only.
Manifold
The manifold is what connects the tubes to the rest of the system. Inside the manifold is a tube where the glycol runs
past the condenser on the tubes and transfers the energy to the glycol mixture that runs through the solar loop. Each of
the tubes slides into a pocket in the manifold that the glycol solution flows around. This means there is no contact
between the glycol and the actual tubes themselves. Individual tubes can be replaced without having to drain the entire
system.
Flexible Piping and Fittings
Most systems will use flexible stainless steel piping for transporting the glycol mixture between the manifold and tank.
This piping and its insulation are designed for use in solar systems. Fittings are included 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 that are important to the overall operation of the solar system. Do not attempt, or remove any of the
connections to the pump station. Important information on the system is included on a label on the pump station.
Solar Tank
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. The tank has a
coil in the bottom that the Glycol mixture flows through and transfers the heat to the domestic hot water. There is no
mixing allowed between the fluids.
Tyfocor Glycol Solution
Your solar system comes with Tyfocor, a special antifreeze mixture for use in solar systems. Tyfocor is non toxic. It is
important that the fluid be maintained in line with the maintenance schedule provided in this document. See page 35
for more information.
Thermostatic Mixing Valve
The maximum temperature hot water should be delivered to your faucets is 120°F. Your solar system can store water at
temperatures up to 140°F and higher. In order to prevent scalding, a thermostatic mixing valve is connected the hot
water outlet from the tank, the hot water line to the house and the cold water supply. It mixes the hot water from the
tank and the cold water to make sure that the water that is delivered to your faucets is the same temperature regardless
of the tanks temperature.

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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. The first uses an electrical
element in the tank to provide 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 for more
information.
The auxiliary heater is not connected to the solar system in any way and can provide hot water if the solar system
completely fails.
Typical Configuration for Domestic Hot Water
Electrical Immersion Backup
Dual Stream
Pump Station
Expansion
Tank
Solar Storage
Tank
Evacuated
Tubes
Thermostatic
Mixing Valve
Ball Valve
Temperature
Sensor
Temperature
Sensor
Manifold
Manifold
Connection Kit
Controller

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Solar System Installation Guide
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
Sensor
Temperature
Sensor
Controller

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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.
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 circumstance should
piping, or the collector frames be set up in such a way that they could cause ice dams.
Code
Description
C0627
20-Tube Manifold
C0628
30-Tube Manifold
Option Code Description
1
C0590
Sloping roof kit
1 KSK0012 Bolt Down roof kit
1
KSK0016
Joint Plate roof kit
2
C0599
Flat roof ‘A’ frame kit (35o – 55o)
3 C0591 Sloping roof 20
o
elevation

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Solar System Installation Guide
Note the minimum and maximum distances on each fixing kit.
The distance between the vertical rails on each fixing kit should be between 24” – 44” on 20 tube systems and 32” – 56”
on 30 tube systems. This is illustrated on each roof kit diagram.
The different widths will allow the installer the choice to either attach to the rafter, or miss them as the local code may
allow. Make certain the lag bolts included with the kit are long enough for the application. If it is desired to miss the
rafter, then a backer board, or a J bolt must be used. These are available separately from 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 Contractor’s Association. Some kits require roof flashing and a solar roof mounting kit, such as a
Fast Jack™. Others use a foot that is attached to the roof by lag bolts. For applications that use the foot, silicon sealant
must be used on the bottom of the foot, as well as around the lag bolts to seal.
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.
Please see page 17 for details.

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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/m2, an additional vertical support rail (C0594) may be obtained.
On the sloping roof kit, a distance of 55” (minimum) and 67” (maximum) should be observed between the top of the
lower brackets and the top of the upper brackets.

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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. Locate the rafters beneath the roof material and drill
to a depth of 4” with a 1/2” drill bit

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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™ uprights are listed below.
1. Use the dimensions in the above drawing to mark out (with chalk) the location of the mounting posts. The lag
bolt should be secured to the rafters or a backing board at the underside 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” stainless steel lag bolt and washer through the threaded base.
4. Cut through shingles for solar flashing plate to suit shape of the elevated section of the flashing. The lag bolt
should be located inside the cut-in area of the shingle. This ensures water will not flow under the flashing where
the lag bolt is located.
5. Slide flashing over the base and under the upper row of composition shingle.
6. Thread post through top or bottom of flashing into base.
7. Using a wrench, secure post into base
8. Seal flashing round post to waterproof with sealant

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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/m2, an additional vertical support rail
(C0596) may be obtained.

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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).

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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 – 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 indicated on the diagram
2. Situate the clamps in the four positions and secure using an appropriate tool
3. Position the flat fixing plate and secure with the bolt provided.
4. Attach the roof rails to the four fixing plates using the bolts provided

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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"” 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 connections to the manifold.
1. Tighten compression fitting to connection fitting
2. Tighten compression fitting to pipe work (If using the stainless steel kit, fittings are included)
3. Attach assembled fittings to manifold
4. Push clip all the way down until connection is fully retained
5. Pull gently on assembly to ensure proper engagement and retention
Supply Connection
Return Connection
Clip shown in unlocked position Clip shown in locked position

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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. Up 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 that is fixed to side rails
3. Tighten up screws to force plate against bottom of manifold (do not over tighten)
4. Slide channel of next manifold on plate
5. Push clip all the way down until connection is fully retained
6. Assemble support rail connection plate to fixed support rails
7. Assemble retaining plates and fittings