Kingspan Varisol Bedienungsanleitung
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
•Tubeboxesshouldbetransportedhorizontally.
•Heavygoodsshouldnotbeloadedontopofthekitboxes.
•Careshould be taken when opening boxes to prevent scratches or sudden
shocks to the glass.
•Donotusesharpobjectstoopenthetubeboxes.
Installation Guidance
•Unpackandinstalltubesonlyaftertheroofkitandpipeworkhasbeeninstalled.
•WithHPtubesonly,tubesmayberotatedafterthesystemhasbeenlled,
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.
•HPtubesmusthaveaminimumelevationof20°andandmaximumof70°
•Thedarkbluesideofthecopperwithinthetubeistheactivesurface.
•FortheDFsystem,aheatdissipationloop(heatdump)isrecommended
•Thepipework 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
andlocalbuilding/planningregulationsfortherelevantjurisdiction.
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
(DFonly)
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(minimumof15mmdiameterpipeworkmustbeused)
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 (onlyrequiredwithDFsystems)
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
ofthecollector,(seebelow)airwillbeforcedbackintothesystem.Inthisinstancetheair
separator will prevent air from circulating.
Roof Kits
Varisol Installation Manual
04
Flat horizontal orientation
(option4above)
Wall horizontal installation
(option5above)
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:
•Tomakean18tubecollectorsimplytakea20-wayrailandcutto1281mm.
•Tomakea44tubecollectorjoinastandard20-wayrailtoa24-way,the24-waybeing
made by cutting a 30-way rail to 1708mm.
•Inthecaseofaslopingroofmountedcollector,theavailablerafterspacingshouldbe
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.Attachbrackets(C)toroofusingM8x50
coachscrews(E)
3.Securesiderails(A)tolowerbrackets
using M10x65 bolt assy
Step Two
1. From upper end of each side rail, slide 2 M8x16 bolt into position
2.Securesiderails(A)toupperbrackets(C)usingM8x20boltassy
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.Slide2M8boltsintolowerfaceofeachsupportrail(B)
3.Attach90°bracket(G)in4placesusingM8nuts&washersatlocationsillustrated
4.Attachupperandlowersupportrailto90°bracketasshownbelow
07
Installing the first tube
Step Four
1.Alignrsttubewithendofsupportrailandpushhomebyclickingintorail(pushon
upperpushpointonly)
2.Alignlowertubesupportclipintorailandpushhomebyclickingintorail(pushon
lowerpushpointonly)
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
approximately50°torst
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
tenthtubeneedboltedtotherail)
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
Andere Handbücher für Varisol
2
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