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31

Kingspan Environmental Warranty Statement for Solar Goods 

(in brief)

Subject to the following provisions, Kingspan Environmental warrants that the Goods will be free from defects in material 
and workmanship for a period of 5 or 20 years in relation to VACUUM TUBES and a period of 5 years for VARISOL 
FLOW CONDUITS & COVERS, MANIFOLDS and KITS from their date of manufacture.  The warranty is given by Kingspan 
Environmental subject to the following conditions:

A.    A 5 year warranty period on Vacuum Tubes when such tubes are installed by a Certified Solar Installer. If the Vacuum 

Tubes are installed by a Kingspan Environmental Accredited Installer and subject to the collector(s) being properly 
designed, installed and maintained according to the manufacturer’s recommendations, then such products will carry a 
20 year warranty period. All the systems must be designed in accordance with the Kingspan Design Guide, and installed 
and maintained in accordance with the Thermomax Installation Manual.

B.     Kingspan Environmental shall be under no liability in respect of any defect in the Goods arising from any information 

drawing design or specification supplied by the Buyer

C.    Kingspan Environmental shall be under no liability in respect of any defect arising from fair wear and tear, willful 

or accidental damage, negligence, abnormal working conditions, failure to follow the Kingspan Environmental' 
instructions, misuse or alteration or repair of the Goods without approval

D.    The above warranty does not extend to parts materials equipment not manufactured by Kingspan Environmental in 

respect of which the Buyer shall only be entitled to the benefit of any such warranty or guarantee as is given by the 
manufacturer to the Company.

E.   The defect has been reported by the Buyer to Kingspan Environmental within the warranty period.

F.   The installation of the Goods having been carried out by fully trained and competent person(s).

G.    The Goods having been subjected to neither “prolonged stagnation conditions” nor exhibiting signs of “extreme 

temperature exposure”

1.  

The Buyer shall not make any statement or representation or give any warranty to any third party in respect of any 
Goods other than in the terms made or given by Kingspan Environmental to the Buyer nor shall the Buyer have any 
authority to commit Kingspan Environmental to provide any service in relation to the Goods.

2.    The Company's liability to the Buyer for death or injury resulting from its own or that of its employees' agents' or 

subcontractors' negligence and damage suffered by the Buyer as a result of any breach of the obligations implied by 
Section 12 of The Sale of Goods Act 1979 shall not be limited.

3.    If Kingspan Environmental fails to deliver the Goods for any reason other than any cause beyond the Company's 

reasonable control or the Buyer's fault then Kingspan Environmental shall only be liable to the Buyer for and the 
Company's liability shall be limited to the excess (if any) of the cost to the Buyer (in the cheapest available market) of 
similar goods to replace those not delivered over the Price of the Goods.

4.    The Buyer shall examine all delivered Goods forthwith. Any claim based on any defect in the quality or condition of 

the Goods or their failure to correspond with specification shall be notified to Kingspan Environmental within 7 days 
from the delivery date or where the defect was not apparent on reasonable inspection within a reasonable time after 
discovery of the failure. If delivery is not refused and the Buyer does not notify Kingspan Environmental the Buyer shall 
not be entitled to reject the Goods.

5.    Kingspan Environmental shall be entitled to examine any Goods, which are the subject of any claim by the Buyer, and 

to remove such Goods or any part thereof for testing. No tests carried out by the Buyer will be recognised by Kingspan 
Environmental unless carried out strictly in accordance with a method previously agreed by Kingspan Environmental as 
being suitable for the purpose.

6.    Any valid claim in respect of the Goods which is based on any defect in the quality or condition of the Goods or 

their failure to meet specification is notified to Kingspan Environmental in accordance with these Conditions 
Kingspan Environmental shall be entitled to repair or replace the Goods (or the part in question) free of charge or 
at the Company's sole discretion refund to the Buyer the Price (or a proportionate part of the Price) but Kingspan 
Environmental shall have no further liability to the Buyer.

7.    Kingspan Environmental shall not be liable to the Buyer by reason of any representation (unless fraudulent) or any 

implied warranty condition or other term or any duty at common law (including but without limitation the negligence of 
Kingspan Environmental its employees agents or otherwise) or under the express terms of the Contract for any loss of 
production loss of profits or anticipated profits loss of contracts operation time or anticipated savings loss of business 
or of expected further business loss of or corruption to data damage to the Buyer’s reputation or goodwill damages 
costs or expenses payable by the Buyer to any third party or any other indirect special or consequential loss or damage 
or claim (whether caused by the negligence of Kingspan Environmental its employees agents or otherwise) which arise 
out of or in connection with the supply of the Goods or their use or resale by the Buyer.

8.    Without prejudice to the provisions of clauses 3, 4, 5, 6 and 7 the entire liability of the Buyer under or in connection with 

the Contract shall not exceed the Price of the Goods.

9.    Kingspan Environmental shall not be liable to the Buyer or be deemed to be in breach of the contract by reason of any 

delay in performing or any failure to perform any of the Company's obligations in relation to the Goods if the delay or 
failure was due to any cause beyond the Company's reasonable control. Without limiting the foregoing, due to causes 
beyond the Company's reasonable control.

10.   For comprehensive details regarding “Warranties and Liability” please refer to the “CONDITIONS OF SALES” section 7.

Warranty Statement

Summary of Contents for thermomax df400

Page 1: ...THERMOMAX HP400 DF400 INSTALLATION MANUAL SolarThermalEnergy T 44 0 28 3836 4520 www kingspanthermomax com ...

Page 2: ...it 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 In...

Page 3: ...ent 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 l...

Page 4: ...ation 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 ...

Page 5: ...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 m2 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 Sizin...

Page 6: ... 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 sh...

Page 7: ... 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 ...

Page 8: ... 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 ...

Page 9: ...se 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 ab...

Page 10: ... to side rail 1400m m 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 pa...

Page 11: ... 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 ...

Page 12: ...f 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 9 0 0 1 1 0 0 m m 2 0 1 2 0 0 1 4 0 0 m m 3 0 700 1400mm ...

Page 13: ...pport 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 t if ld Note Only the DF400 can be mounted in this horizontal position ...

Page 14: ...zontal 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 ...

Page 15: ... 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 ...

Page 16: ...e 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 ...

Page 17: ...ollector 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 con...

Page 18: ...ng 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 Gmb...

Page 19: ...p 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 poi...

Page 20: ...ansion 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 temp...

Page 21: ...ries before connecting in parallel is shown in the table below 1 Insert screws into plate ensuring screws do not protrude to upper side 2 Slide plate approximately half way into channel at bottom of manifold that is fixed to side rails 3 Tighten up screws to force plate against bottom of manifold do not overtighten 4 Slide channel of next manifold on plate 5 Push clip all the way down until connect...

Page 22: ...nsuring proper engagement of front seal strip over whole length and on end caps Inserting the tubes HP400 or HP450 Tubes 1 Open manifold lid by peeling back the front seal strip from the lid section only 2 Place tube in tube clips on both support rails and close retaining rubber 3 Slide the condenser of the tube through the front seal strip and into the pocket in the chamber of the manifold until ...

Page 23: ...he 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 ...

Page 24: ...ock 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 efficiency 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 t...

Page 25: ... the Solar Antifreeze Fluid for approximately 30 minutes For East West systems flush and fill each collector for approx 30 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 pr...

Page 26: ...or loop at drain valve Contain the heat transfer fluid for appropriate disposal Disconnect pipes from the manifold 3 Collector Beware of high temperatures Remove rubber retainer to release manifold lid Unclip tube Remove the rubber support retainers from around glass tube Remove tube manifold clip Remove tubes from manifold Remove lid and separate materials Remove Manifold and support rails and sep...

Page 27: ...5 2 5 2 2 1 Aluminium 2 EPDM 3 Brass 4 Bronze 5 Stainless Steel 6 PA66 30 GF 7 Melamine 8 Glass 9 Copper 1 Aluminium 2 EPDM 3 Brass 4 Bronze 5 Stainless Steel 6 PA66 30 GF 7 Melamine 8 Glass 9 Copper 3 5 9 7 1 6 5 2 3 5 2 5 5 6 1 7 1 1 2 5 3 2 6 5 2 5 4 5 9 2 6 9 7 9 9 8 5 9 ...

Page 28: ...ly 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 recommended that the antifreeze level be checked using a refractometer by a qualified engineer A sample of the Solar Antifreeze Fluid can be extracted from the pump station at the pu...

Page 29: ...g before filling System pressure Expansion vessel setting after filling Flow rate Antifreeze level pH reading Inspection of barium getter on tubes Engineer details Print name Sign Telephone No Upon Commissioning Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10 Year 11 Year 12 Year 13 Year 14 Year 15 Year 16 Year 17 Year 18 Year 19 Year 20 Year 21 Year 22 Year 23 Year 24 Year 25...

Page 30: ...Guidance for the Republic of Ireland Solar installations in the Republic of Ireland must be installed in accordance with the Irish Agrément Board certificate No 10 0345 which takes precedence over this installation document NSAI Agrément Irish Agrément Board is designated by Government to issue European Technical Approvals NSAI Agrément Certificates establish proof that the certified products are pro...

Page 31: ...DIN 1055 Prevention of Collector Slippage Prevention of Collector Lifting Weight Per Foot kg A 102 177 B 171 287 A 156 266 B 155 269 B 256 430 A 73 137 B 73 137 A 41 80 A 111 206 B 100 191 B 111 206 8 8 to 20 20 Tube Collector Height Above Ground m 30 Tube Collector 20 Tube Collector 30 Tube Collector Weight Per Foot kg 45 Wind Loading A Front feet B Back feet See page 8 for diagram 0 10 20 30 40 ...

Page 32: ...Nos 011 7S1946 R 011 751793R Operating Data Flow Rate ltr h Rated 160 240 160 240 Minimum 120 180 120 180 Maximum 300 480 300 480 Maximum Operating Pressure 8 Bar 8 Bar 10 Bar 10 Bar Stagnation Temperature C 313 313 167 167 Heat Transfer Fluid Water Glycol Water Glycol Water Glycol Water Glycol Max Field Size m2 12 15 15 15 Max Load kN m2 DIN 1055 5 2 5 2 5 Materials Absorber Copper Copper Copper ...

Page 33: ...he cost to the Buyer in the cheapest available market of similar goods to replace those not delivered over the Price of the Goods 4 The Buyer shall examine all delivered Goods forthwith Any claim based on any defect in the quality or condition of the Goods or their failure to correspond with specification shall be notified to Kingspan Environmental within 7 days from the delivery date or where the d...

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Page 36: ... the specification as shown in this literature REF KSK0069C Thermomax Manual ENG AUG 16 This brochure is printed on environmentally friendly paper Kingspan Environmental Ltd 180 Gilford Road Portadown Co Armagh BT63 5LF United Kingdom Tel 44 0 28 3836 4520 solar kingspan com www kingspanthermomax com ...

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