Kingspan Varisol User manual

Renewables
Installation Manual

Introduction 1
Using this guide 1
Kit components 2
Important pre-installation information 3
Roof kits
Overview 4
Roof Kit Sizing 5
Collector Assembly
Sloping Roof assembly 6
Installing Tubes 7
Attaching the connection kit 9
Pump station 11
Safety vessel connections 12
Wiring the control panel 13
Commissioning the system 15
Decommissioning the system 16
Recycling Information 17
Servicing and maintenance 18
Technical Information
Wind loading 19
Technical Specification 19
Pressure drop curves 19
Warranty Statement 20
Maintenance Schedule Form 21
Contents
Varisol Installation Manual

Solar hot water systems should be designed and sized correctly before commencing the
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 provide a system design service to its Accredited Installer
Network and technical design consultants. Please visit www.kingspansolar.com to locate an
Accredited Installer or distributor in your area.
This guide will illustrate and explain how a system should be installed to conform with the
Kingspan Renewables manufacturer guidelines for the Varisol Collector.
Using this guide
Stages of a solar installation are described in the following pages, with illustrations
where necessary to explain how to install the relevant components, and contains general
recommendations and important safety information.
Handling Guidance
•Tubeboxesshouldbetransportedhorizontally.
•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roofkitandpipeworkhasbeeninstalled.
•WithHPtubesonly,tubesmayberotatedafterthesystemhasbeenlled, 
pressure tested and is ready for operation.
•Do not leave the solar collector exposed to solar radiation when the solar loop and
collector 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andmaximumof70°
•Thedarkbluesideofthecopperwithinthetubeistheactivesurface.
•FortheDFsystem,aheatdissipationloop(heatdump)isrecommended
•Thepipework of the solar collector loop is to be earthed and the collector is to be lightning
protected in accordance to local regulations.
For further technical support please contact the following numbers,
Ireland - 1800 812 718 or UK – 0845 812 0007.
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
01

Standard Kit Components
Additional Components
Dual Stream Pump Station SC400 Controller Sloping Roof Kit
with Brackets
Flexi Connections
Cooling Vessel
(DFonly)
Expansion Vessel
Tyfocor® LS
Connection Kit
Tubes
Insulated Hose
Mounting Set
Solar Roof Flashing
22mm 3 Port Diverter Valve
Note - 15 & 28mm also available
22mm Thermostatic Mixing Valve
Note - 28mm also available
Stubfitting
Installation tool
Varisol Installation Manual
02

Sizing of safety equipment
Expansion vessel sizes are relative to the volume of liquid in the system. Therefore it is
important that the Thermomax ‘Technical Design Guide’ is consulted for each system.
Pipe Sizing(minimumof15mmdiameterpipeworkmustbeused)
Important Pre Installation Information
Collector
Area
m2
Pressure Drop - Tyfocor LS
Flow Rate
Ltr/hr
DF
Pressure
Drop mbar
HP
Pressure
Drop mbar
Pipe External
Diameter
mm
1 60 15 2
2 120 15 3.5
3 180 15 10
4 240 15 21
5 300 22 35*
6 360 22 53
7 420 22 80*
8 480 22 110*
9 540 22 153
2
3.5
10
21
35*
53
80*
110*
153
Collector
Area
m2
DF Expansion Vessel Sizing
Expansion
Vessel Size
Ltr
Cooling
Vessel Size
Ltr
Static
Height
m
1 5 18 5
2 5 18 5
3 5 25 8
4 5 25 8
5 5 35 12
6 5 35 12
7 5 35 12
8 5 50 18
9 5 50 18
Collector
Area
m2
HP Expansion Vessel Sizing
Static
Height
m
Expansion
Vessel Size
Ltr
1 5 12
2 5 12
3 5 12
4 5 12
5 5 12
6 5 18
7 5 18
8 5 18
9 5 18
03
When selecting a vessel for intermediate sizes, the vessel should be selected by rounding area up to nearest m².
All sizes above are calculated based on a 17ltr system volume as an example. For larger volumes the expansion
vessel size should be recalculated. Cooling vessel sizes are dependant on pipe dimensions and can be calculated
on a case by case basis or selected using the table above as a guideline.
* figures marked as such are estimates based on other measurements
Cooling Vessel (onlyrequiredwithDFsystems)
It is strongly recommended that a cooling vessel is used with the DF collector to protect
the expansion vessel from stagnation temperatures.

3
1
2
5
4
Standard Roof Fixings
The Varisol product range is available with a choice of roof fixing options to suit many roof
types, see diagram below for the most common fixings. Roof fixings are available for slate,
tiled, double lap plain clay, metal seam and concrete. For others please contact Kingspan.
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 (DF only)
With any 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.
Roof Kits
Varisol Installation Manual
04
Flat horizontal orientation
(option4above)
Wall horizontal installation
(option5above)
Minimum 2˚ angle
Minimum 2˚ angle
2°
Min
2°
Min
Option Code Description Suitable Suitable
for HP for DF
1 KSK0039 Varisol 10 Sloping Roof Kit y y
KSK0040 Varisol 20 Sloping Roof Kit y y
KSK0041 Varisol 30 Sloping Roof Kit y y
KSK0062 Varisol 10 Bolt Down Roof Kit y y
KSK0063 Varisol 20 Bolt Down Roof Kit y y
KSK0064 Varisol 30 Bolt Down Roof Kit y y
2 KSK0042 Varisol 10 A Frame Kit y y
KSK0043 Varisol 20 A Frame Kit y y
KSK0044 Varisol 30 A Frame Kit y y
3, 4 and 5 KSK0065 Varisol 10 Façade Kit n y
KSK0066 Varisol 20 Façade Kit n y
KSK0067 Varisol 30 Façade Kit n y

The modular design of the Varisol collector means that any number of tubes can be
assembled to make up the required collector size. Since the mounting kit cross rails are
only supplied in 10, 20 and 30 tube sizes it is necessary to cut the rails to length if an
intermediate sized collector is required. The table below gives the required length of rail for
each given size. Burrs and sharp edges should be removed.
Examples:
•Tomakean18tubecollectorsimplytakea20-wayrailandcutto1281mm.
•Tomakea44tubecollectorjoinastandard20-wayrailtoa24-way,the24-waybeing
made by cutting a 30-way rail to 1708mm.
•Inthecaseofaslopingroofmountedcollector,theavailablerafterspacingshouldbe
considered when sizing the collector to ensure that an appropriate side rail spacing can
be achieved.
Roof Kit Sizing
05
Collector Number of Kit Type Required Support Side Rail
Area tubes Rail Length Separation
m² mm mm
0.1 1 71
0.2 2 142
0.3 3 214
0.4 4 10 Tube Rail 285
0.5 5 712mm 356
0.6 6 427
0.7 7 498
0.8 8 569 350-450
0.9 9 640 350-550
1 10 712 500-600
1.1 11 783 500-600
1.2 12 854 500-600
1.3 13 926 500-700
1.4 14 997 500-700
1.5 15 20 Tube Rail 1068 600-800
1.6 16 1423mm 1139 600-900
1.7 17 1210 600-900
1.8 18 1281 600-1000
1.9 19 1352 600-1000
2 20 1423 600-1100
2.1 21 1494 700-1200
2.2 22 1565 700-1200
2.3 23 1637 700-1200
2.4 24 1708 700-1200
2.5 25 30 Tube Rail 1779 700-1200
2.6 26 2135mm 1850 800-1300
2.7 27 1921 800-1300
2.8 28 1992 800-1400
2.9 29 2063 800-1400
3 30 2135 800-1400

Collector Assembly - Sloping Roof
Fixing the rails
Step One
1. Refer to mounting kit sizing on page 5 for
bracket seperation
2.Attachbrackets(C)toroofusingM8x50
coachscrews(E)
3.Securesiderails(A)tolowerbrackets
using M10x65 bolt assy
Step Two
1. From upper end of each side rail, slide 2 M8x16 bolt into position
2.Securesiderails(A)toupperbrackets(C)usingM8x20boltassy
Varisol Installation Manual
06
A x2
A
D
EC
F
x2
x2
x4
B x2
C x4
D x10
E x8
F x4
G x4

Attaching Support Rails
Step Three
1. Refer to mounting kit sizing on page 5 for support rail lengths
2.Slide2M8boltsintolowerfaceofeachsupportrail(B)
3.Attach90°bracket(G)in4placesusingM8nuts&washersatlocationsillustrated
4.Attachupperandlowersupportrailto90°bracketasshownbelow
07
Installing the first tube
Step Four
1.Alignrsttubewithendofsupportrailandpushhomebyclickingintorail(pushon
upperpushpointonly)
2.Alignlowertubesupportclipintorailandpushhomebyclickingintorail(pushon
lowerpushpointonly)
3. Attach tube to rail using MB x 20 bolts as shown below.
1400 – 1700mm 400–600mm(10)
600–1000mm(20)
800–1400mm(30)
x4
G
D
1500mm
100mm
B

Varisol Installation Manual
08 Step Five
1. Rotate second tube
approximately50°torst
tube, using arrow symbols
on plastic enclosure for
guidance
2. Firmly insert male fitting
of second tube to female
connection of first tube,
ensuring o-ring protection
is removed first.
Step Six
1. Rotate second tube parallel
with first tube
2. Locate upper plastic enclosure
and lower tube support
clip in rail
3. Push home the upper and
lower fittings into the
support rail
(Note - only the first, last and every
tenthtubeneedboltedtotherail)
Installing additional tubes
PUSH
PUSH
Step Seven
1. Continue with remaining tubes.
2. Use M8 bolt, washers and nut to
lock final tube in place at Xand Y
50˚
2
1
Y
XFLOW
RETURN

09
Attaching the Connection Kit
Step Eight (returnconnection)
1.Assembleandconnectendttings(Male 
connection A, T connection G &
 AirbleedingvalveE)
2.Open lid on left hand end tube fitting
3.Placerubberseal(D)onmaleendofcollectorarea
(blockingupperchamber)ThisappliestoDFonly-pleasediscardsealforHP
4.Secureinpositionwithclip(F)
5.Ensureclip(F)legsprotrudeoutof
bottom of enclosure
6.Completeandattachtechnicallabel(I)
7.Close lid and secure with screw
E
G
A
D
FI
Qty. Tubes
A B C
D E F
G H I
Step Nine (owconnection)
1.Assembleandconnectendttings(Female
connection B, T connection G & Temperature
sensorpocketH)
2.Remove securing pin from female
end of collector
3.Placerubberseal(C)infemaleendof
collector area (blockinglowerchamber)
This applies to DF only - please discard seal for HP
4.Secure in position by relocating securing pin
B
G
H
C
A B C D E F G H I
Sensor must
be fitted on
flow side of
collector.
See diagram
for step 7
DF ONLY
DF ONLY

Varisol Installation Manual
10
Connection Information
System Pressure
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.
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/ArmaexfromArmacellGmbH).Hightemperatureinsulationisessentialasstandard
pipe insulation will melt at temperatures experienced by solar pipes.
The wall thickness of the insulation should be equal to the 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.
The recommended system pressure is 1 bar + 0.1 bar / 1m static height

11
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 guage
9 22mmconnections(x4)
10 Temperature guage
11 Air separator
12 Insulated fascia
13 Pressure relief discharge point
8
13
The Kingspan Solar product range offers both a single stream and a
dual stream pump station. Each pump station is available in various sizes to suit the
required flow rate of the system.
The flow rate required on a system is typically 1 litre per minute, per square metre installed
for systems up to 12m². Therefore a 2-12 litre/minute pump station should be sufficient 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.
C0784 – Insulated Hose Stub Fitting
When flexible stainless steel pipe is being used to connect to the pump station, the insulated
hose stub fitting is required to make the connection. The split ring within the fitting should be
removed and placed over the second rib of the flexible pipe. When the compression fitting is
tightened, the split ring will click twice as it positions itself and locks inside the fitting.
C0785 – Insulated Hose Clamp Ring
Whentheshortexibleconnectionisbeingjoinedtostainlesssteelpipework,theinsulated
hose clamp ring is required to make the connection. The split ring within the fitting should be
removed and placed over the second rib of the flexible pipe. When the compression fitting is
tightened, the split ring will click twice as it positions itself and locks inside the fitting.
Pump Station
6
9
9
8
7
5
4
3 3
2
1 1
2
4
5
7
9
9
6
11
12
13
10 10
12

Varisol Installation Manual
12 Pressure Relief Valve (PRV)
Ratedat6bar,thePRVmaydischargeheattransferuid(Tyfocor®LS)whichmust
be channelled into a solar discharge vessel, 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:
The expansion vessel must be located below the level of the connection from the
pump station.
The expansion vessel supplied includes an appropriate corrugated hose and threaded
connectiontojointhevesseltothepumpstation.
Temperature Reducing Vessel (TRV) (DF ONLY)
Also known as a ‘cooling vessel’ or ‘stratification vessel’, the TRV is highly recommended.
Due to high temperatures which can be experienced within the solar loop, the TRV reduces
the temperature of the heat transfer fluid before it enters the expansion vessel and extends
the lifetime of 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
1 PRV discharge point
2 Wall bracket (supplied)
3 Discharge container
4 TRV kit
5 Expansion vessel
6 Dual stream pump station
TRV
1
2
6
4
5
2
3
DF ONLY

13
Wiring the Solar Control Panel
All electrical aspects of the installation should be undertaken by a qualified electrician.
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. If the
permanent electrical supply to the building is to be switched off for any period of
time, the solar collector(s) should either be covered, or the system drained and
the tubes removed.
In order to protect the normal operation of the control panel, it should be located at
least 100 mm from insulated pipes which may become hot during operation.
Control panels use PT1000 sensors containing twin core copper cable with a
0.75mm cross section. The sensors supplied are 1.5 metres in length.
Sensor cables can be extended with twin core copper cable of 0.75mm diameter up to
50 metres and 1.50mm diameter between 50-100m. Screened cable should be used
on the sensor cables to prevent RFI from electrical cables. All connections to extend
thecablesshouldbehousedinajunctionboxforprotection.
The following diagrams show the connection of the solar pump and other relays on the
SCrangeofcontrollers.ThisshouldbereadinconjunctionwiththeInstallationand
Operation Manual supplied with each SC control panel.

Varisol Installation Manual
14
Wiring the Solar Control Panel
1 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.
2 Protective conductor terminal block:
 PE4xprotectiveearth(commonprotectiveearthforpowerconnection)terminalblock
3 Signals terminal block:
 1–4:4xsensorinput(Pt1000temperaturesensor)
 5:1xsensorinput(Pt1000temperaturesensororpulsewatermeterinput)
 RS:1xsignaloutput(potential-freerelaycontactforsafetyextra-lowvoltage)
 PWMR1:2xcontroloutput(forPWM-controlledhigh-efciencypumps)
 PWMR2:7xmassconnection(commonmassforsensorinputsandcontroloutputs)
4 Pin strip, for internal use only
5 Cable openings on the rear side of the casing
6 Upperstrainreliefclamps(2identicalplasticlinks,eachwith2strainreliefclamps,suppliedinthescopeofdelivery)
7 Lower strain relief clamps
8 Cable openings at the bottom of the casing
Terminal Clamps in the lower part of
thecontroller(terminalcoverremoved)

15
The evacuated tubes should be installed at a time when there is very low light such as
late afternoon when the sun is low and not particularly strong. Alternatively the tubes
should be covered. This is important as tube connections can heat up considerably in
ashortspaceoftimeandhavepotentialtocauseinjuryeveniftheglasstemperature
remains cool.
Expansion Vessel
IMPORTANT: 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.
The pressure is checked at the base of the vessel and the bleed valve may be bled or
topped up with a pump.
Filling the Loop
It is important that a motorised flush and fill centre is used to fill and pressurise the
system with Tyfocor® LS as follows:
1. Open the fill and drain valves to allow the liquid to circulate around the solar loop
2. Turn the hot and cold temperature gauges 45˚clockwise.
3. Close the isolating valve above the flow meter to ensure all air and liquid passes
through the fill centre to filter any air and contaminants.
4. Run the fill centre pump to circulate the Tyfocor® LS for approximately 20 minutes.
5. Open and close the isolating valve intermittently to circulate air bubbles which may
accumulate in the sight glass.
6. Return isolating valve to closed position.
7. When the solar loop has been purged of air, close the bottom/drain connection – the
fill centre will begin to pressurise the solar loop.
8. Reopen the isolating valve above the flow meter fully.
9. Filltheloopuntilthepressuregaugejustexceedstherequiredpressure,stopthe
pumpandimmediatelyclosethellconnection.Checkpipejointsonthesolarloop
for leaks and check that pressure is not lost over a 30 minute period.
10. If all the plumbing is sound, set the system pressure by opening the return connection
until the required pressure is met.
11. Return the temperature gauges to the original position.
12. The fill centre may now be disconnected.
13. Cap the fill and drain points with the brass covers provided.
The pipes from the flush and fill
centre should be connected as
shown in the diagram:
Commissioning the System
FILL
DRAIN
FLUSH AND FILL CENTRE

Varisol Installation Manual
16 The pump may only be run when the system has
been filled as dry operation will damage the pump.
The desired flow rate is 1 litre per minute per m²
(10tubes=1m²)forsystemsupto12m²
1. Set the pump to the first speed and run it
manuallyfromthecontroller(seefollowing
paragraph).
2. If the desired flow rate is exceeded, set the
owmetertothedesiredratebyadjustingthe
isolating valve with a flat headed screwdriver
(seediagram)withthepumprunning.Otherwise
repeat this step at the next pump speed and
continue until the desired flow rate is achieved
3. Stop the pump.
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.
Operating the pump in ‘Manual’ mode
(for SC 400/500 controllers)
1. Remove the front panel.
2. Press the button for 2 seconds to
change the mode of operation.
3. Repeat step 2 if necessary.
4. Mount the front panel.
Functionality
•Backlightingisred,spannersymbolashes.
•Thecontrolleroutputs(pumps,valves)canbemanually
switched. Possible switching states
0: off
1: on
A: Automatic operation as per the settings in the
settings menu
•Current temperatures and operating hours can be displayed
(statusdisplay).
•When changing to manual mode all outputs are switched to A,
R1 is displayed.
Exception:Firstcommissioning(alloutputsat0).
•Typicalapplication:Functionaltest(maintenance),fault-nding.
Decommissioning the System
Due to temperatures potentially exceeding 170˚C and pressures greater than 6 bar, a solar
installation should only be decommissioned by a trained individual. The system should be
decommissioned in low light, ideally in the morning when the solar loop should be coolest.
Disposal
Dispose of separate materials in accordance with local regulations. Please see the following
pages for details of materials used in the construction of Varisol collectors and guidance on
disposal of antifreeze.
1. Electrical
•Isolatecontrollerfrommains
•Removecablestoconsumerunitsi.e.
controller and pump
•Removesensorsandassociatedcables
•Removeearthingcables
2. Collector Loop
•Bewareofhottransferuid
•Draincollectorloopatdrainvalve.Containthe
heat transfer fluid for appropriate disposal.
•Disconnectpipesfromthemanifold
3. Varisol Collector Disassembly
•RemoveM8boltfrommanifoldsupportrailon
the right hand end of the rail.
•Uncliprubberretaineronthetubesupport
•SlidetheVarisolremovalslidealongthe
manifold support rail strating at the right
hand end.
•Rotateeachtubeindividuallythrough50˚until
engagement arrows line up and pull one tube
from the rest of the assembly. Ensure tube is
supported; only apply force onto the manifold
to disengage.
•Repeatprocessuntilalltubesareremoved.
Setting the flow rate
ISOLATING VALVE
OPEN CLOSED

17
Recycling Information
Item No. Material
1 Aluminium
2 EPDM Rubber
3 Bronze
4 PA66 30%GF
5 PA66 Natural
6 Stainless Steel
7 Copper
8 Glass
9 Brass
10 PPS
Item No. Material
2 EPDM Rubber
4 PA66 30%GF
6 Stainless Steel
7 Copper
8 Glass
9 Brass
10 PPS
1
16
8
4
3
5
2
6
6
2
9
9
2
4
2
10
7
2
6
Varisol DF
Varisol HP

Varisol Installation Manual
18
Servicing and Maintenance
Users should regularly check the temperatures which the solar control panel is
recording. With the SC range of controllers, simply pressing the ‘SET’ button on the
fascia once will display the upper and lower collector temperatures since the control
panel was last reset. If the collector temperatures have been excessively high i.e. over
170˚C, it is likely that the fluid is degrading. It is recommended that the antifreeze level
checked using a refractometer by a qualified engineer.
A sample of the Tyfocor® LS antifreeze fluid can be extracted from the pump station at
the pump itself. The large centre of the pump hub can be opened with a large flathead
screwdriver. This should be opened slowly until a few drops of the antifreeze fluid are
released. A sample of the fluid placed on the glass of the refractometer will display the
level of antifreeze in the system. If the antifreeze has lost its antifreeze properties the
system should be refilled with fresh Tyfocor® LS.
It is recommended that the solar system is serviced annually by a qualified engineer and
immediately if the system shows evidence of having lost pressure or has discharged
liquid at the pressure relief valve. The Tyfocor® LS antifreeze fluid should always be
replaced after 7 years.
Maintenance schedule
A qualified person should service the system at the recommended intervals, using the
maintenance schedule. 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.
Please see page 21 for maintenance schedule form.
Disposal of Solar Anti-Freeze Solution
The solution 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.
Propylene Glycol is a widely used ingredient in pharmaceutical, food, cosmetic, personal
care, flavours and animal feed applications. Propylene glycol is not volatile, but is
miscible with water. Propylene glycol is not harmful to aquatic organisms and is readily
biodegradable; however the disposal of the solution should be done in a responsible
manner taking into consideration local Environmental and Health & Safety legislation.
WhilethesolutionisnotsubjecttoregistrationasahazardousmaterialaccordingtoEEC
directives the solution should be disposed of by special means. There are a number of
specialist companies that can deal with the disposal of propylene glycol. A list of these
companies is available upon request. A copy of the EEC Safety Data sheet and Technical
Information sheet is available upon request. We recommend that you contact your local
authority to check that they will accept the solution at special landfill collection points.
There are a number of specialist companies that can deal with the disposal of propylene
glycol, a list is available on request: [e-mail]