Kingspan thermomax hp400 User manual

THERMOMAX HP400 & DF400
INSTALLATION MANUAL
Solar Thermal Energy
T: [phone]
www.kingspanthermomax.com

Introduction
Using this guide 1
Standard Kit Components 2
Important Pre-Installation information 3
Roof Kits
Overview 4
Sloping Roof Kit 5
Bolt Down Roof Kit 7
Surface Mount Kit 35˚-55˚ 8
Sloping Roof Kit 20˚Elevation 9
Sloping Roof Kit Horizontal 10
Surface Mount Kit 90˚ Horizontal 11
Surface Mount Kit 0˚ and 90˚ Vertical 12
Standing Seam Metal Roof Kit 13
Connection Information
Connection Kit and other connections 15
Pump Station 17
Safety vessel connections 18
Interconnection Kit 19
Inserting the tubes 20
Wiring the solar control panel 21
Commissioning the system 23
Decommissioning the system 24
Construction materials 25
Servicing and maintenance 26
Maintenance schedule record 27
Technical Information
Guidance notes 28
Wind loading 29
Technical Specification 30
Warranty Statement 31
Contents

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 Thermomax product models,
namely DF400 & HP400.
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.
❱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 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.
❱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, 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
Thermomax Installation Manual
Standard Kit Components
Dual Stream Pump Station SC400 Controller Roof Kit
with Brackets
Flexi Connections
Cooling Vessel
(DF400 only)
Expansion Vessel
Solar Antifreeze Fluid
Connection Kit
Manifold & Tube Holders

03
Sizing of safety equipment
Pipe Sizing (minimum of 15mm diameter pipework must be used)
Cooling Vessel Sizing (only required with DF400 systems)
It is strongly recommended that a cooling vessel is used with the DF400 collector to
protect the expansion vessel from stagnation temperatures.
Important Pre-Installation Information
Collector
Area
(m2)
Flow Rate
Ltr/hr
DF400
(mbar)
HP400
(mbar)
Pipe Diameter
Copper
External (mm)
2 120 15 8.54 4.11
3 180 15 12.57 10.47
4 240 15 17.08 8.22
5 300 22 21.11 14.58
6 360 22 25.14 20.94
8 480 22 33.68 25.05
Model Collector Area System Volume Static Height Vessel Size
(m
2
) (Ltrs)
HP400 2 17 5 18
3 17 5 18
4 18 5 18
5 19 5 18
DF400 2 19 5 18
3 20 5 25
4 22 5 25
5 24 5 35
Expansion Vessel Sizing
Cooling Vessel Sizing
Model Collector Area System Volume Static Height Vessel Size Cooling Vessel
(m
2
) (Ltrs) Size
DF400 2 19 5 18 5
3 20 5 25 8
4 22 5 25 8
5 24 5 35 12

04
Thermomax Installation Manual
Standard Roof Fixings
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 slate, tile or masonry finishes.
Roof kits and their relevant manufacturer codes:
Horizontal Installations (DF400 only)
With any DF400 installation where the collector is installed horizontally on a wall
façade or roof surface; the airvent on the collector manifold must be the highest
point of the collector, otherwise air in the system will remain in the pipes within the
collector tubes and be difficult to flush out. Airlocks in the pipes will stop circulation
through the system.
When the collector is orientated correctly, i.e. with the manifold slightly higher than
the base of the collector, (see below) air will be forced back into the system. In this
instance the air separator will prevent air from circulating.
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.
The distance between the vertical rails on each fixing kit should be between 600mm-
1100mm on 20 tube systems and 800-1400mm on 30 tube systems. This is illustrated
on each roof kit diagram.
Note that the fixing clamps on the side rails are preset for ease of on-site installation.
Roof Kits
5
1
2
3
8
7
6
4
Flat horizontal orientation
(option 6 above)
Minimum 2˚ angle
Wall horizontal installation
(option 5 above)
Fixing
Option Code Description HP
Suitable
DF
Suitable
1 KSK0217 or
KSK0220
400 Sloping Roof Kit Vertical
400 Bolt Down Roof Kit
YY
2 KSK0218 400 Surface Fixing A-Frame Kit
(35° - 55°)
YY
3 KSK0222 400 Sloping Roof Kit 20° Elevation Y Y
4 KSK0225 400 Sloping Roof Kit Horizontal N Y
5
KSK0219 400 Ground, Façade Fixing Kit
(Vertical & Horizontal) NY6
7
8 KSK0223 400 Awning Roof Kit Y Y

05
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
KSK0229 - 400 Single Rail Sloping Roof Kit (Extra Wind Loading) may be obtained. Please
refer to the wind loading table – page 29.
On the sloping roof kit, a distance of 1400mm (minimum) and 1700mm (maximum) should
be observed between the top of the lower brackets and the top of the upper brackets.
KSK0217 - 400 Sloping Roof Kit
1. Slide back tile and attach lower
brackets to roof rafter
5. Locate manifold on side rails and
secure with upper clamp bolts
2. Secure side rails to lower bracket with
the pre-drilled holes to the bottom
1400-1700mm
600-1100mm (20)
800-1400mm (30)
6. Locate horizontal support
rails on the side rails
3. Attach upper brackets to roof rafters 4. Secure side rails to upper
brackets with sliding bolt fixing
'(7$,/%

06
Thermomax Installation Manual
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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
MCS012 Compliant Roof Hook Kit
1. Slide back tile and attach lower
and upper brackets to roof rafter 2. Secure side rails to upper bracket using nut and bolt supplied
3. Secure side rails to lower brackets
with nut and bolt supplied
'(7$,/%
4. Locate manifold on side rails and
secure with upper clamp bolts
5. Locate horizontal support
rails on the side rails

07
1400-1700mm
600-1100mm (20)
800-1400mm (30)
5. Attach the roof rails to the four fixing
plates using the bolts provided
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
roof material and drill to a depth
of 120mm with a 12mm drill bit
3. Locate the nut above the rubber
roof seal and tighten to ensure a good
seal is made on the fixing surface
2. Insert the rawl plug provided if
necessary and fix the bolt with a spanner
4. Stabilise the flat fixing plate by tightening
the attached nuts above and below the plate
KSK0220 - 400 Bolt Down Roof Kit

08
Thermomax Installation Manual
KSK0218 - 400 Surface Fixing A-Frame Kit 35° to 55°
5. Adjust and secure
rear brace
3. Secure side rail
to rear bracket
7. Locate support
rails on side rails
2. Secure side rail
to front bracket
6. Locate manifold
on side rails
4. Secure side bracing
bracket to side rail
1400mm
600-1100mm (20)
800-1400mm (30)
1. Attach front and rear
brackets to surface
at distance shown
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 (KSK0230 - 400 Single Leg Flat Roof Kit (Extra Wind Loading) may be
obtained. Please refer to the wind loading table – page 29.
Example of KSK0218 Kit
with additional high wind
loading leg KSK0230
B
B
A
A

09
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
6. Attach and secure
rear brace
4. Secure rear strut
to upper bracket
8. Locate support
rails on side rails
3. Secure side rail
to lower bracket
7. Locate manifold
on side rails
5. Adjust and secure
side brace
1800mm
1550-2050mm
600-1100mm (20)
800-1400mm (30)

10
Thermomax Installation Manual
Note – Only the DF400 can be mounted in this horizontal position.
Drill required
KSK0225 - 400 Sloping Roof Kit Horizontal
4. Tighten support rail
clamps to prevent slippage. 5. Locate manifold on side rails 6. Locate support rails on side rails
1. Attach brackets to roof
at distance shown 2. Secure side rails to brackets at both ends 3. Locate locking pins on the manifold and drill holes.
900-1100mm (20)
1200-1400mm (30)
700-1400mm

11
KSK0219 - 400 Ground, Facade Fixing Kit (Horizontal Configuration)
1. Attach brackets to surface
at distance shown above
4. Locate support rails
on side rails and tighten
the support rail camps.
2. Attach side rails
to brackets using
bolts provided
5. Locate manifold
on side rails
3. Locate locking pin
position on manifold
and drill holes.
6. Secure all clamps
600-1100mm (20)
800-1400mm (30)
1850mm
tifld
Note – Only the DF400 can be mounted in this horizontal position.

12
Thermomax Installation Manual
Note – Only the DF400 can be mounted in a horizontal or vertical position.
KSK0219 - 400 Ground, Facade Fixing Kit (Vertical Configuration)
3. Locate manifold on side rails 4. Secure all clamps
600-1100mm (20)
800-1400mm (30)
1850mm
1. Attach brackets to surface
at distance shown above 2. Attach side rails to brackets using bolts provided

13
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. The roof type will determine the clamp required.
KSK0221 - 400 Joint Plate Roof Kit
(Standing Seam Metal Roof Kit Option)
KSK0025 – Bulb Standing
Seam Clamps
KSK0026 – Double Folded
Standing Seam Clamps
The following metal roof clamps are for use with the ‘joint plate kit’ KSK0221:
KSK0025 – Bulb standing seam
KSK0026 – Double folded standing seam
600-1100mm (20)
800-1400mm (30)
1400-1700mm

14
Thermomax Installation Manual
1. Locate and secure the standing seam
clamps at the appropriate distances
indicated and attach the joint plate to
the standing seam clamp as shown
2. Attach the side rails to the
joint plate as shown
Standing Seam Metal Roof Kit
3. Locate manifold on side rails 4. Secure all clamps

15
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.
1. Tighten compression fitting to connection fitting (flow and return)
2. Tighten compression fitting to pipe work (flow and return)
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
Connection Information
Return connection
Flow connection
Male assembly
Sensor pocket
Female assembly
Manifold clip
Manual airvent

16
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.
PEX / PLASTIC / PEX-ALU-PEX or GALVANISED TUBING OR FITTINGS SHOULD NOT BE
USED UNDER ANY CIRCUMSTANCES
Flexible Pipe Connections
Flexible pipe connections are recommended to connect the manifold through the building
fabric and allow flexibility in connecting to the internal pipe work.
Flexible stainless steel pipes are available in both a 15mm and 22mm diameter. If
connecting one diameter pipe to another, a suitable reducer compression fitting is
recommended to make the connection.
Insulation
All pipe work on the solar loop should be insulated with high temperature insulation (such
as HT/Armaflex from Armacell GmbH). High temperature insulation is essential as regular
pipe insulation will melt at temperatures experienced by solar pipes.
The wall thickness of the insulation should be equal to the internal diameter of the
pipe. The only pipes which should not be insulated are the pipes to the safety vessels as
they should allow heat to dissipate when the system is experiencing excessive heat and
pressure.

17
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 12m2.
Connections of flow and return pipe work to the pump station are made with the
straight compression fittings provided for direct copper connection.
Pump Station
Key
1 Drain connection
2 Fill connection
3 Flow meter
4 Isolating valve
5 Motorised pump
6 6 bar pressure relief valve
7 Expansion vessel connection
8 Pressure gauge
9 Pipe connections
10 Temperature gauge
11 Air separator (dual stream only)
12 Insulated fascia
13 Pressure relief discharge point
6
8
7
5
3
2
1
1
2
4
5
7
8
9
9
6
11
12
13 13
10
12
4
3
10
9
9
Dual Stream Single Stream

18
Thermomax Installation Manual
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.
The PRV should not be channelled into a drain or any pipe work which will allow it to
enter the normal water course.
Fitting the expansion vessel:
It is recommended that the expansion vessel is located below the level of the
connection from the pump station to prolong its life.
The expansion vessel supplied includes an appropriate corrugated hose and threaded
connection to join the vessel to the pump station.
Temperature Reducing Vessel (TRV)
Also known as a ‘cooling vessel’ or ‘stratification vessel’, the TRV is highly
recommended with the Thermomax DF400. Due to high temperatures which can be
experienced within the solar loop, the TRV allows for additional expansion and reduces
the temperature of the heat transfer fluid before it enters the expansion vessel.
Fitting the TRV:
With the direct flow vessel kit, which includes the TRV, a corrugated hose assembly is
included to join the expansion vessel to the TRV from the pump station.
Safety Vessel Connections
TRV
1
2
6
4
5
2
3
1PRV discharge point
2Wall bracket (supplied)
3Discharge container
4TRV kit DF100/400 only
5Expansion vessel
6Dual stream pump station