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