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
Attaching the connection kit 10
Pump station 12
Safety vessel connections 13
Wiring the control panel 14
Commissioning the system 16
Decommissioning the system 17
Recycling Information 18
Servicing and maintenance 19
Technical Information
Wind loading 20
Technical Specification 20
Pressure drop curves 20
Warranty Statement 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.
•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.
•Thedarkbluesideofthecopperwithinthetubeistheactivesurface.
•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 SC100 Controller Sloping Roof Kit
with Brackets
Flexi Connections
Cooling Vessel
(DF100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
0302

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)
Cooling Vessel Sizing
It is strongly recommended that a cooling vessel is used with the collector to protect the
expansion vessel from stagnation temperatures.
Important Pre Installation Information
Collector
Area
m2
Varisol Pressure Drop - Tyfocor LS
Flow Rate
Ltr/hr
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
Collector
Area
m2
Varisol Collector Expansion Vessel Sizing
System Volume
Ltr
Expansion
Vessel Size
Ltr
Cooling
Vessel Size
Ltr
Static Height
m
1 18.9 5 18 5
2 20.8 5 18 5
3 22.7 5 25 8
4 24.6 5 25 8
5 26.5 5 35 12
6 28.4 5 35 12
7 30.3 5 35 12
8 32.2 5 50 18
9 34.1 5 50 18
Varisol Installation Manual
0302
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

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
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
3
1
2
5
4
Varisol Installation Manual
0504
Flat horizontal orientation
(option4above)
Wall horizontal installation
(option5above)
Minimum 2˚ angle
Minimum 2˚ angle
Option Code Description
1 KSK0039 Varisol 10 Sloping Roof Kit
KSK0040 Varisol 20 Sloping Roof Kit
KSK0041 Varisol 30 Sloping Roof Kit
KSK0062 Varisol 10 Bolt Down Roof Kit
KSK0063 Varisol 20 Bolt Down Roof Kit
KSK0064 Varisol 30 Bolt Down Roof Kit
2 KSK0042 Varisol 10 A Frame Kit
KSK0043 Varisol 20 A Frame Kit
KSK0044 Varisol 30 A Frame Kit
3, 4 and 5 KSK0065 Varisol 10 Façade Kit
KSK0066 Varisol 20 Façade Kit
KSK0067 Varisol 30 Façade Kit
2°
Min

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 should an
intermediate sized collector be 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
Varisol Installation Manual
0504
Collector Number of Required Cross Side Rail
Area tubes Rail Length Separation
m² mm mm
0.1 1 71
0.2 2 142
0.3 3 214
0.4 4 285
0.5 5 356
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 1068 600-800
1.6 16 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 1779 700-1200
2.6 26 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
0706
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 lengths
2.Slide2M8boltsintolowerfaceofeachsupportrail(B)
3.Attachsupportclamp(C)in4placesusingM8nuts&washersatlocationsillustrated
4.Lowersupportrailontosupportclamps(G)
5.SecuresupportrailtoclampusingM8nutsandwashers(D)
Varisol Installation Manual
0706
Inserting the first tube
Step Four
1. Slide 2 M8 nuts into front face of each support rail extrusion
2.Alignrsttubewithendofsupportrailandpushhomebyclickingintorail(pushon
upperpushpointonly)
3. Insert bolt and tighten nut
4.Alignlowertubesupportclipintorailandpushhomebyclickingintorail(pushon
lowerpushpointonly)
It should look like this:
1400 – 1700mm 400–600mm(10)
600–1000mm(20)
800–1400mm(30)
1500mm
100mm x4
B
G
D

Varisol Installation Manual
0908 Step Five
1. Rotate second tube approximately 50° to first tube, using arrow symbols on plastic
enclosure for guidance
2. Firmly insert male fitting of second tube to female connection of first tube
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 first and last tube corners
needtobesecuredintoboth)
Connecting additional tubes
50˚
2
1
PUSH
PUSH

Varisol Installation Manual
0908
Attaching the Connection Kit
Step Eight (returnconnection)
1.Placerubberseal(D)onmaleendofcollectorarea
(blockingupperchamber)
2.Open lid on left hand end tube fitting
3.Completeandattachtechnicallabel(I)
4.Assembleandconnectendttings(A,G,E)
5.Secureinpositionwithclip(F)
6.Ensureclip(F)legsprotrudeoutof
bottom of enclosure
7.Close lid and secure with screw
E
G
A
D
FI
Qty. Tubes
A B C
D E F
G H I
Step Seven
1. Continue with remaining tubes.
2. Use M8 bolt, washers and nut to lock final tube in place at Xand Y
Y
X

Varisol Installation Manual
1110
Connecting additional tubes
Step Nine (owconnection)
1.Placerubberseal(C)infemaleendof
collectorarea(blockinglowerchamber)
2.Remove securing pin from female
end of collector
3.Assembleandconnectendttings(B,G,H)
4.Secure in position by relocating securing pin
B
G
H
C
A B C D E F G H I

Varisol Installation Manual
1110
Connection Information
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 illustrations shows the connections to the manifold.
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.

Varisol Installation Manual
1312
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 Thermomax product range offers both a single stream and a
dual stream pump station. Each pump station is available in two flow rates,
2-12 litres/minute and 8-28 litres/minute.
The flow rate required on a system is typically 1 litre per minute, per square metre installed.
Therefore a 2-12 litre/minute pump station will 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
1312 Pressure Relief Valve (PRV)
Ratedat6bar,thePRVmaydischargeheattransferuid(Tyfocor®LS)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:
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)
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

Varisol Installation Manual
1514
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.
Power Supply Connection:
Sensor Connection
The connection of PT1000 sensors is as shown below.
The polarity of the sensor cables is not relevant on each
sensor. The SC100 has four inputs as illustrated below.
However the SC200 and SC300 can receive five and six
sensorsrespectively(forlargersystemdesign)andare
connected in the same way.
Input connection for 1-4 sensors:

Varisol Installation Manual
1514 R1oftheSCcontrollerscomprisesasemiconductorrelay(TRIAC),alsosuitableforRPM
control with a maximum switching current displayed on the unit type plate. Both the SC100
and the SC200 contain an electromechanical relay, R2.
Note that the SC300 contains two RPM relays, R1 and R2 as well as an electromechanical
relay, R3. The SC200 and SC300 are therefore suitable for controlling two pumps i.e. for an
east/west panel array or a stagnation configuration requiring a second pump.
Caution
Avoiding damage and malfunctions – When connecting an external relay or contactor, or
when connecting a pump which has its own electronic RPM control, the controller output’s
RPMcontrolmustbedeactivated(see“SettingtheRPMcontrolparameters”inthe
ControllerManual).
R2 on the SC100 contains a switched output via an electromechanical relay with a
maximumswitchingcurrentdisplayedontheunittypeplate.Notethewirebridge(D1)must
be connected.
Connection of first output/pump (R1)
Connection of second output (R2) if required

Varisol Installation Manual
1716 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and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
1716 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).
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.
Operating the pump in ‘Manual’ mode
(for SC range controllers)
In order to run the pump in ‘Manual’ mode, slide
the operating switch on the left side of the solar
control panel to the upper of the three positions.
On the screen, select the appropriate relay with
the up/down arrows and press the ‘Set’ button to
run the relay and to switch it off again.
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.
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 Thermomax 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
Left side view of controller
OPEN CLOSED

Recycling Information
Varisol Installation Manual
1918
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
1
16
8
4
3
2
5
2
6
6
2
9
9
2
4
2
10
7
2
6