Kingspan FPW18 User manual

Solar Thermal Energy
T: [phone]
www.kingspanthermomax.com
FPW FLAT PLATE
INSTALLATION MANUAL

Contents
Introduction
Using this guide 1
Technical Specifications 2
Construction of Collector 3
Mounting the Panel
A-Frame 4
On-roof Bracket Kit 5
On-roof Bolt Kit 6
In-roof cassette dimensions 7
In-roof cassette mounting 8
Connection Information
Connection guidance 29
Pipework 1st fix 30
Standard pipework connections 31
Dual Collector Installation 32
Pump Station 33
Safety Vessel Connections 34
Wiring the Solar Control Panel 35
Maintenance
Commissioning the System 37
Disposal of Solar Antifreeze Fluid 38
Servicing and Maintenance 39
Warranty Registration 39
Maintenance schedule record 40
Technical Information
Additional notes for other Regions 41
Decommissioning the System 42
Warranty Statement 43

01
Solar hot water systems should be designed and sized correctly before commencing
installation. Proper design will ensure that a system is correctly sized to provide many
years of optimised performance and most or all of the required hot water when the most
solar radiation is available. However a supplementary heating system such as oil or gas
boiler, heat pump or wood boiler is required for months which have less solar radiation.
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 Solar Thermal product models,
namely DF400, HP400, Varisol and FPW.
Using this guide
Stages of a solar installation are described in the following pages, with illustrations to
explain how to install the relevant components, and contains general recommendations
and important safety information.
Handling Guidance
❱Tube and manifold boxes should be transported horizontally to prevent damage.
❱Flat Plate Collectors should be stored vertically.
❱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 and flat plates only after the manifold and pipe work has been
installed.
❱With the HP400 and HP450 only, tubes may be installed after the system has been
filled, pressure tested and is ready for operation.
❱The solar thermal system should have permanent power supply with a fused spur. It
should never be turned off except during maintenance.
❱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 20˚ and a maximum of 70˚.
❱The dark blue side of the copper within the tube is the active surface.
❱For DF400 system and Varisol DF, a heat dissipation loop (heat dump) is strongly
recommended – please refer to the technical design guide. A heat dissipation loop is also
required for systems with a seasonal demand.
❱The pipework of the solar collector loop is to be earthed and the collector is to be
lightning protected in accordance to local regulations.
Health and Safety Precautions
A solar panel installation must be performed in accordance with all Health & Safety
legislation and local building/planning regulations for the relevant jurisdiction.
Furthermore, the necessary electrical work required to install control equipment should be
undertaken by a qualified electrical contractor.
Introduction

02
FPW Collector Installation Manual
Technical Specifications
Specification / Type FPW18 FPW21 FPW25
Dimensions (mm) 1929 x 933 x 91 1988 x 1041 x 90 1990 x 1222 x 91
Casing Material Electrostatically Painted (Black) Aluminium Case
Weight (kg) 34 37.2 44
Sealing Material EPDM & Silicone & Aluminium Frame
Gross Area (m²) 1.79 2.07 2.42
Aperture Area (m²)* 1.62 1.92 2.23
Absorber Area (m²) 1.59 1.89 2.23
Absorber Material Almeco Tinox Highly Selective Aluminium
Absorptance (%) 95 95 95
Emittance (%) 4 4 4
Welding Method Laser Welding
Heat Carrier Volume (ltr) 1 1.07 1.27
Number of Riser Tubes 9 10 12
Tube pitch (mm) 110 110 110
Glass Material Low Iron Tempered Glass
Transmittance of Glass 91% 91% 91%
Thickness of Glass (mm) 4 4 4
Insulation Material Rockwool
Thickness of wool (mm) 50 50 50
Base Sheeting Embossed Aluminium Sheet
Max. Operating Pressure 10 bar
Max. Collectors in Series 8
Efficiency
eta 0 (zero loss efficiency - n0a)* 0.785
a1(W/m²K) (1st heat loss coefficient)* 3.722
a2(W/m²K²) (2nd heat loss coefficient)* 0.012
Stagnation Temperature at 1000 W/m and 30˚C 203°C
IAM (50°)* 0.94
ηcal (40K, 1000W/ m2)* 0.617
* for energy labelling

03
Construction of Collector
The glass is sealed in the collector frame with EPDM and rubber. EPDM is used for sealing and it
is resistant to 150˚C and the aging effect of the sun. Silicone is applied between the EPDM and
glass. Regular rain cleans the glass. In locations with low rainfall, the glass must be cleaned. It
can be cleaned by ordinary cleaners and water. It should be noted that, the cleaner the glass, the
more efficient the collector.
Collector Cross Section

04
FPW Collector Installation Manual
Mounting the Panel: Flat Roof
A-Frame Kit
FPW18 SINGLE: KFP0024
FPW18 DOUBLE: KFP0025
FPW21 SINGLE: KFP0014
FPW21 DOUBLE: KFP0015
FPW25 SINGLE: KFP0049
FPW25 DOUBLE: KFP0050

05
On-roof Bracket Kit
Mounting the Panel: Flat Roof
FPW18 SINGLE: KFP0026
FPW18 DOUBLE: KFP0069
FPW21 SINGLE: KFP0016
FPW21 DOUBLE: KFP0068
FPW25 SINGLE: KFP0072
FPW25 DOUBLE: KFP0073

06
FPW Collector Installation Manual
Mounting the Panel: Flat Roof
On-roof Bolt Kit
FPW18 SINGLE: KFP0215
FPW18 DOUBLE: KFP0201
FPW21 SINGLE: KFP0202
FPW21 DOUBLE: KFP0203
FPW25 SINGLE: KFP0204
FPW25 DOUBLE: KFP0205

07
FPW Cassette Dimensions
220 mm
pan tiles 330 mm
260 mm
flat tiles
500 mm
100 mm220 mm
= collectors edge
Before mounting the cassettes, please check the dimensions above. Add the dimensions of the
cassettes to the collector dimensions using the table below.
Individual Collector Dimensions
Length (mm) Width (mm)
FPW18 1929 933
FPW21 1988 1041
FPW25 1990 1222

08
FPW Collector Installation Manual
4
5
1
2
3
6
7
8
8
9
9
10
11
12
13
13
14
15
16
1 = Left frontpart pan tiles
2 = centre frontpart pan tiles
3 = Right frontpart pan tiles
4 = Single fixation bracket
5 = Double fixation bracket
6 = left sidepart
7 = right sidepart
8 = connectionpart
9 = supporting plate
10 = left backpart
11 = centre backpart
12 = right backpart
13 = backpart connection
14 = Left frontpart flat tiles
15 = centre frontpart flat tiles
16 = right frontpart flat tiles
Usable from 21° roof pitch
>= 21°
Version2/10012013 Art-Nr. +30450
FPW In-roof Cassette Mounting Instructions

09
2
280-max 340 mm
1 2 3 14 15 16
80 mm
For the fixation of the
frontparts, place additional
roof battens as shown in
pict. no. 2.
Start the mounting with
the left frontpart. Just hook
it on the roof batten and fix
it with 4 sealing screws
(pict. 3 + 4)
3
1
Marking for
roof tiles
1 2 3 14 15 16
In-roof Mounting
+
If the tiles are higher than 40 mm,
cut them on the upper side as
shown in the picture.
> 40
mm
1
1

10
FPW Collector Installation Manual
In-roof Mounting
1
1
2
2
1
4
5
2
6Marking
1
2
Place the center frontpart
on the roof batten like
the left one and plug it
together with the left
frontpart until it fits to
the marked line on the left
frontpart (pict. 6). Then
fix it with 4 sealing screws
(pict. 7).
In the case of only 2
collectors please continue
with the right frontpart
(pict. 8).

11
In-roof Mounting
9
2
3
Marking
2
3
7
2
8
2
3
2
3
Place the right frontpart
on the roof batten like
the left and center one
and plug it together with
the center (left in the
case of only 2 collectors)
frontpart until it fits to
the marked line on the
center (left) frontpart
(pict. 9). Then fix it with 4
sealing screws.
1

12
FPW Collector Installation Manual
10
After the frontparts are
mounted, the next step is
to place the collectors
(pict. 10-12).
For details of the pipe
connections, see pages
30-32
12
11
1
1 2 3 14 15 16
In-roof Mounting

13
In-roof Mounting
13
1
4
4
Fix the left collector on the
outer side with a single
fixation bracket on EVERY
roofbatten!
14
5
Place a double fixation
bracket on EVERY roof
batten between the
collectors.
5
4
Place a single fixation
bracket on EVERY roof
batten on the outer side of
the last collector.
4
15

14
FPW Collector Installation Manual
In-roof Mounting
Place a 100 mm foam
gasket as shown in
pict. 18 and 19
6
17a
100 mm
16
6
1
17
6
1
1
6
18
6
1
Fit the left sidepart to
the collector as shown in
pict. 17 and 17a.

15
In-roof Mounting
19
1
6
20
6
1
6
1
6
1
6
1
21
Bend the flaps on the
left sidepart as shown
in pict. 20-21

16
FPW Collector Installation Manual
In-roof Mounting
6
1
22
24
6
1
Fix the left sidepart
with a fixation clip and
a nail on EVERY roof
batten.
6
1
6
1
23 Bend the flap on the
left frontpart over the
left sidepart.
Fix the bent flaps with
2 rivets.

17
In-roof Mounting
27
8
8
25
26
7
3
8
8
6
7
8
2
8
27a
Place the connection
parts as shown in pict.
26, 27 and 27a.
Mount the right
sidepart following
the same procedure
as for the left (pict.
16-24).

18
FPW Collector Installation Manual
In-roof Mounting
8 8
28
100 mm
29
8
8
30 Bend the flaps on
the lower side of the
connection part as
shown in pict. 30 and 31.
Place a 100 mm
foam gasket as
shown in pict. 28
and 29