UK Solar Manual Feb 13_LR

8/12/2019 UK Solar Manual Feb 13_LR

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COMPLETE COMMERCIAL

SOLAR THERMAL SOLUTIONS

TECHNICAL GUIDE


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COMPLETE SOLAR THERMAL SOLUTIONS

KINGSPAN SOLAR

INTRODUCTION 5

SOLAR RADIATION ACROSS THE UK & IRELAND 6

HOW IT WORKS: SOLAR THERMAL SYSTEM 7

BUSINESS CASE

WHY SOLAR THERMAL ENERGY? 8

IS MY BUILDING SUITABLE? 10

MARKET SECTOR APPLICATIONS 12

ENGINEERING, SERVICE & SUPPORT 14

COMMITTED TO GREEN BUILDINGS 16

CASE STUDIES 19

CONTENTS

PRODUCT RANGE 31

SOLAR THERMAL SYSTEMS PRODUCT OVERVIEW 32

KINGSPAN SOLAR HEAT PIPE COLLECTORS 34

KINGSPAN SOLAR DIRECT FLOW COLLECTOR 38

KINGSPAN SOLAR FRAMES 40

VARISOL, AWARD WINNING SOLAR COLLECTORS 42

FLAT PLATE SOLAR COLLECTORS 44

UNIQUE FEATURES OF KINGSPAN SOLAR TUBES 46

TUBE DESIGN 46 BENEFITS 47

EVACUATED TUBE COMPARISONS 50

FIN-IN-TUBE COPY / SINGLE-WALLED TUBE 50

SYDNEY TUBE / DOUBLE-WALLED TUBE 55

KINGSPAN PUMP STATIONS 56

SYSTEM TECHNICAL CONSIDERATIONS 59

SIZING GUIDELINES 60

COLLECTOR LAYOUT & ITS EFFECT ON THE SYSTEM 72

CONTROLS & MONITORING 79

SOLAR THERMAL SYSTEM CONTROLS,

COMPONENTS & MONITORING 80


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KINGSPAN SOLAR

PRODUCTRANGE

SYSTEM

TECHNICAL

CO

NSIDERATIONS

CONTROLS&

MONITORING

CERTIFICATI

ON

&

WARRANTYSTA

TEMENT

KINGSPAN

INTRODUCTION

CERTIFICATION & WARRANTY STATEMENT 87

HEAT PIPE COLLECTORS

HEAT PIPE COLLECTORS 88

DIRECT FLOW COLLECTORS 89

VARISOL HEAT PIPE COLLECTORS 90

VARISOL DIRECT FLOW COLLECTORS 92

HAIL IMPACT TEST CERTIFICATION 93

WARRANTY STATEMENT 95

KINGSPAN 97

INSULATED PANELS 98

BENCHMARK 99

INSULATION 100

INSULATED DOOR COMPONENTS 101

ACCESS FLOORS 101

This document is not for use as a design tool, it is for guidance only and designs should be reviewed by our technical team. All solar thermal systems should be fully designed by a competent engineer.Kingspan Group plc or any of its companies do not take responsibility for any systems designed using the following details. We recommend that you review your design with us.

All descriptions and specifications of products and procedures in this manual are current at the time of printing. However, Kingspan Environmental is continually involved in product testing andimprovement, and specifications and procedures are subject to change. We reserve the right to amend specifications and procedures without prior notice.

Regulations and Standards

The solar thermal system should be installed in compliance with current building regulations, all local standards and Health & Safety regulations. These regulations are statutory documents and takepriority over all recommendations within this document. For installation and operating procedures, please refer to the Installation and Operating manuals provided with the product.

For system design assistance, please contact our technical support team: +44 (0) 28 38364500.

PLEASE VISIT:

www.makethesunwork.com


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KINGSPAN SOLAR

KINGSPAN

14millionevacuated tubes

installed worldwide

40+countries in

which we operate

25+years knowledge and experience

to support your business

25offices across

Europe

Kingspan Environmental is part of Kingspan Group,

global leaders in sustainable building products for

energy and water efficiency. With manufacturing and

distribution operations worldwide, Kingspan is recognised

throughout the construction industry for innovation,

design, quality, technical expertise and service.

Kingspan Environmental offer an array of products

and services that provide renewable energy,

water management and environmental solutions.

Our Kingspan Solar thermal package solutions,

have been used on prestigious buildings across the

globe with great success.

Kingspan Solar offer complete solar thermal solutions

for commercial, industrial, institutional and residential

applications. Our evacuated tubes use the original and

best technology and have been successfully on the

market for over 25 years. We pride ourselves on not

only our world class product, but on the design,

engineering, and technical service we provide our

customers every time.


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KINGSPAN SOLAR

TOTALLY INTEGRATED

ENVIRONMENTAL SOLUTIONS

RENEWABLE ENERGY

Inspired thinking is at the heart of our renewableenergy offer. High performing wind turbines,

solar thermal tubes and panels, hot water

systems and heat pumps capture, store

and transform natural energy from the

sun and wind into reliable and highly

effective heating and cooling for

water and buildings.

ENVIRONMENTAL MANAGEMENT

Our high performance environmental

containers are at the forefront of plastics

technology while our award winning telemetry

solutions offer affordable level measurement

gauges and integrated energy management systems.

As well as remarkable products, we offer world class

consultancy and environmental services, whether its a

Kingspan system or not.

WATER MANAGEMENT

Our pioneering brands, Klargester for wastewater and

stormwater attenuation, and Kingspan Water for rainwater

harvesting, offer a portfolio of proven and ground breaking

water management technologies.

www.kingspanenv.com

www.kingspansolar.com

www.kingspanwind.com

KINGSPAN ENVIRONMENTAL HAS BEEN AT THE FOREFRONT OF INNOVATION FOR MORE THAN FIFTY YEARS.

Thought leaders in sustainability for the built environment, our gold standard products feature in the worlds most

sustainable buildings and are tried and tested in more than 60 countries. And because we manufacture and design our own

world-class components, delivery is quick and reliable.


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KINGSPAN SOLAR

BRISTOL LIDO OUTDOOR POOL, BRISTOL, UK


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KINGSPAN SOLAR

INTRODUCTION

SOLAR RADIATION ACROSS THE UK & IRELAND 6

HOW IT WORKS: SOLAR THERMAL SYSTEM 7

BUSINESS CASE

WHY SOLAR THERMAL ENERGY? 8

IS MY BUILDING SUITABLE? 10

MARKET SECTOR APPLICATIONS 12

ENGINEERING, SERVICE & SUPPORT 14

COMMITTED TO GREEN BUILDINGS 16

CASE STUDIES 19

INTRODUCTION


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KINGSPAN SOLAR

SOLAR RADIATION IS A GENERAL TERM FOR THE ELECTROMAGNETIC RADIATION EMITTED BY THE SUN.

It can be captured and converted into useful forms of energy, such as heat, using solar thermal collectors.

The technical feasibility and economical operation at a specific location depends on the available solar radiation.

The energy from the sun acting on the earths surface, over a 15 minute period, is more then the earths total energy

requirement for a year. The amount of yearly global radiation on a horizontal surface may reach over 2,200 kWh/m2 in

sunny regions. In Northern Europe, the maximum values are 1,100 kWh/m2 and are 943 kWh/m2 in London and 990 kWh/m2

in Rosslare, Ireland.The supply of solar radiation in UK

and Ireland differs by a factor of 10

between summer and winter, e.g.

Rosslare: 6.36 kWh/m2/day in June;

0.64 kWh/m2/day in December.

Global radiation comprises direct and

diffuse radiation. As sunlight passes

through the atmosphere, some of it is

absorbed, reflected and scattered by air

molecules, clouds and dust particles,

this is known as diffuse radiation.The portion of radiation that hits the

earths surface without any change in

direction is known as direct radiation.

In the UK and Ireland, diffused radiation

makes up between 40% (May) to 80%

(December) of the total solar energy

available in a year.

SOLAR RADIATION ACROSS

THE UK AND IRELAND


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PROCESS

All components work together to

heat water from sunlight:

Sunlight hits the solar

collector and heats thermal

transfer liquid passing

through it.

A pump circulates the heated

thermal transfer liquid from

the solar collector to the

water tank coil, where itsheat transfers to water

within the tank.

The pump returns the cooled

thermal transfer liquid to the

solar collector for reheating.

When needed, a back-up heat

source, such as a boiler,

on-demand water heater,

or electrical immersion

element, boosts the tank

water to the desired

temperature before it is

distributed to its end use.

The differential temperaturecontroller monitors and

regulates the circulation rate

of the thermal transfer liquid,

based on weather and hot

water demand.

The expansion tank regulates

system pressure as the

thermal transfer liquid

expands and contracts.

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KINGSPAN SOLAR

INTRODUCTION

Solar collectorthe efficiency and quality of

the collector determines the

performance of the whole

system.

Pump station

Hot water storage tank

Back-up heat source

Hot water distribution

system

Solar controller

Expansion tank

A

A 1

2

3

1

2

3

4

4

B

B

G

G

F

F

E

E

D

D

C

C

HOW IT WORKS:

SOLAR THERMAL SYSTEM

FACTS

Solar thermal technology

transforms direct and diffuse

solar radiation into useful heat

using a solar collector, which

should face as closely as possible

to the south at an angle

perpendicular to the sun.


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KINGSPAN SOLAR

BUSINESS CASE:

WHY SOLAR THERMAL ENERGY?

THE SUN - AN UNLIMITED ENERGY RESOURCE

Every year the sun provides over 8000 times as much

energy as we consume worldwide. A well designed solar

thermal system can provide up to 70% of a buildings

annual needs.

This is why solar thermal systems are one of the most

cost-effective and environmentally-friendly renewable

energy solutions available reducing fuel bills and

greenhouse gas emissions.

Solar thermal energy enjoys many economic and

environmental advantages over other forms of energy

currently used, including:

Provides up to 96% solar energy

absorption with 5% emmissivity.

Generates heat energy even on

overcast and cloudy days.

High performance, tailored solutions

for hot water, central / space heatingand pool applications across a wide

range of building sectors.

Safe, reliable, durable and time-tested

with a design life of over 30 years.

Rapid installation and low

maintenance.

SUPERIOR SYSTEM PERFORMANCEREDUCE YOUR ENERGY BILLS

Cost effective: economical, mitigates

future energy shortages and price

increases.

Immediate and permanent savings.

Enjoy FREEhot water all year round.

MARKET-BASED INCENTIVES

Government incentives, for example

the Renewable Heat Incentive (RHI).

A solar hot water system can be cash

flow positive from day one.

A domestic solar hot water system

can last in excess of 25 years andpay for itself many times over.


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KINGSPAN SOLAR

INTRODUCTION

* Dependent on available incentives

ENVIRONMENTALLY FRIENDLY

Non-toxic systems.

Non-polluting:solar hot water

generation produces no greenhouse

gas emissions.

Non-consumptive:the suns radiation

is a limitless resource.Going green for commercial projects

has now become a PR advantage.

ACCESSIBILITY AND SECURITY

Security:the price of solar energy

does not fluctuate.

Instant distribution:there are no

expensive transportation costs for

solar energy because the sun shines

everywhere.

GROSS SYSTEM

COSTS

NATIONAL INCENTIVE SCHEMES

NATIONAL TAX CREDITS

NET SYSTEM

COSTS*


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KINGSPAN SOLAR

WHEN CONSIDERING A SOLAR THERMAL SYSTEM FOR YOUR BUILDING,

THERE ARE KEY FACTORS THAT NEED TO BE CONSIDERED.

As each project has individual requirements, Kingspan will develop a bespoke package, taking into account:

Location /

insolation level

KINGSPAN SOLAR TECHNICAL SERVICE

Orientation

Limiting

factors,

e.g. shading

Roof pitch /

slope Roof area

Hot water,

heating and/or

cooling demand

The checklist opposite provides an example ofa typical site assessment. To assist you further,Kingspan Solar offers a simple site assessmentform (right) that, once completed, allows ourtechnical team to size, design, and estimatesavings on your project.

BUSINESS CASE:IS MY BUILDING SUITABLE?


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KINGSPAN SOLAR

INTRODUCTION


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KINGSPAN SOLAR

INTRODUCTION

Commercial,industrial, and

agriculturalbusinesses using

a high volumeof hot water

HOME AND SMALL

BUSINESSES: Dish and laundry

washing.

Swimming pools.

Baths and showers.

Space and radiant

floor heating.

HEALTHCARE

APARTMENTS HOUSING

UTILITIESEDUCATION

HOTEL


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KINGSPAN SOLAR

ENGINEERING,

SERVICE & SUPPORT

FULL-SERVICE ENGINEERING

Each project is tailored to the exact specifications of the

individual brief and objectives. This means providing

world-class design consultancy, engineering expertise andcomprehensive advice from initial site visit and assessment

to detailed design drawings and concepts, delivery and

installation support.

We create a system tailored to the unique specifications of

your building and/or business, be it domestic, commercial or

industrial, in any country.

At Kingspan Solar, we offer our customers over 25 years of

solar thermal expertise and experience to supply technical

designs and cost effective solutions on all projects.

We can provide project specific Auto CAD schematics and

roof layouts along with individual reports produced for

each project.We offer a fast, project specific, tender bid and specification

service. We use T*Sol & Polysun, the world renowned solar

simulation software, for system sizing.

Call +44 (0) 28 38364500, to speak with one of our team,

or go online to submit an inquiry at www.kingspansolar.ie or

www.kingspansolar.co.uk, and well respond to your inquiry

with tailored solutions.

AT KINGSPAN SOLAR WE AIM NOT JUST TO MANUFACTURE AND SUPPLY HIGH QUALITY

SOLAR THERMAL SYSTEMS, BUT PROVIDE ENGINEERING, SUPPORT AND SERVICE THAT IS

SECOND TO NONE THROUGHOUT YOUR PROJECT OFFERING THE ULTIMATE, SINGLE-SOURCE

SOLAR SOLUTION.

Projectdesign concept

Kingspan Solar Service

Energy

assessmentand system

specification

Cost andpayback

proposal

Proposalreview and

approval

Installationtraining

Commissioningsupport

Example schematics

as supplied by the

Kingspan Solar

Design Team


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KINGSPAN SOLAR

INTRODUCTION

WARRANTY

The 20 year warranty on our evacuated tubes reinforces our

confidence in the quality and longevity of the product.

Please refer to our terms and conditions in the section

Specification and Warranty Statement, page 89.

CUSTOMER SERVICE

Our dedicated team provides focused customer service

including delivery scheduling and installer support, ensuring

a seamless, well co-ordinated customer experience.

To ensure high levels of satisfaction, we conduct customersurveys to gather important feedback that help us keep a

pulse on the marketplace.

SITE SERVICE SUPPORT

Our technical team provides off- and on-site installation

training and support in order to guide our installers to

deliver products that fulfill customers requirements and

expectations. Our team of fully qualified engineers provide

system checks and start-up support, ensuring installations

are fully operational and working from day of completion.

We offer a site inspection service throughout the installationprocess as well as advice on operation and maintenance.

GUINNESS BREWERY, DUBLIN, IRELAND


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KINGSPAN SOLAR

IN MARCH 2007, THE HEADS OF STATE AND

GOVERNMENT OF THE 27 EU COUNTRIES

ADOPTED A BINDING TARGET OF 20% FINAL

ENERGY CONSUMPTION FROM RENEWABLE

ENERGY BY 2020.

Attaining this goal requires that buildings be energy

efficient and include a means of producing energy fromrenewable resources.

THE ROUTE TO NET-ZERO ENERGY BUILDINGS

Kingspan solar thermal systems offer outstanding

performance and durability, providing a valuable contribution

to a buildings overall energy efficiency and carbon reduction

targets on the route to net-zero energy.

ENVELOPEFIRST

Highly insulated building

envelope.

ENERGY EFFICIENCYMEASURES (EEMS)

Building services and controls.

INSULATE & GENERATE

EnvelopeFirst + integrated

renewable technologies,

e.g., Kingspan Solar.

NET-ZERO ENERGYBUILDINGS

Optimised energy efficient

buildings that are energy

neutral over the course of

a year.

-CO2EEMs

Office

Healthcare

Education

Commercial& industrial

Retail

Leisure

Processing

Apartments

COMMITTED TO

GREEN BUILDINGS


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KINGSPAN SOLAR

INTRODUCTION

DESIGNING GREEN BUILDINGS

BREEAM

BREEAM sets the standard for best practice in sustainable

building design, construction and operation and assesses the

environmental performance of any type of building, new and

existing. BREEAM is used in a range of formats from country

specific schemes, adapted for local conditions, to

international schemes intended for the certification ofindividual projects anywhere in the world.

A number of Government departments or other public

bodies either require or encourage the use of BREEAM.

T*SOL

All systems should be

designed using computer

software to predict the

overall system performance.

The computer software used

by Kingspan, T*SOL, is third

party software that utilises

weather data from various

locations across the UK and

Ireland, collected every hour

for a typical year at that location.

The software also considers the load

patterns and tank sizes to accurately size these parts of a

system. Collector performance is predicted using data taken

from the Solar Keymark ratings that are used in Europe.

The overall report produces a good picture of how a system

is going to perform during a typical year. Below are typical

calculations output by T*SOL.

SECTION WEIGHTING

Category Part 1: Part 2: Building Part 3:Asset rating management rating Organisational rating

Energy 26.5% 31.5% 19.5%

Water 8.0% 5.5% 3.5%

Materials and waste 13.5% 7.5% 16.0%

Health and Wellbeing 17.0% 15.0% 15.0%

Pollution 14.0% 13.0% 10.5%

Transport 11.5% 18.5%

Landuse and ecology 9.5% 12.5% 5.0%

Management 15.0% 12.0%

ASSESSMENT SCORE ASSESSMENT RATING STAR RATING

< 10 Unclassified

10 25 Acceptable *

25 40 Pass **

40 55 Good ***

55 70 Very Good ****

70 85 Excellent *****

> 85 Outstanding ******

SOLAR ENERGY CONSUMPTION AS A PERCENTAGE OF TOTAL CONSUMPTION

DAILY MAXIMUM COLLECTOR TEMPERATURE


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KINGSPAN SOLAR

OUR COMMITMENT TO SUSTAINABILITY

Kingspans primary contribution to meeting our global

environmental challenges is to design, develop and supply

new systems and solutions in a highly responsible and

efficient manner.

Kingspan has set ambitious targets for reducing the effects

of our operations and products on the environment. In fact,

we have embarked on our own Net Zero Initiative, which in

essence aims to have all facilities running on entirely

renewable power by 2020. We continue to further our

engineering research and development programs to

maximise the life cycle performance and end of life

procedures of every product we manufacture.

Through its employees, Kingspan instills an environmental

awareness and responsibility that is reflected in the concept,

design, development and production of all its products

and services.

Kingspan promotes the use of construction techniques thatrespect the environment in terms of manufacturing,

transportation, site installation, waste and end-of-life.

We believe these construction methods are better

Manufacturing

Packaging

Distribution

Usage

DisposalMaterials

Energy efficiency and environmental sustainabilityare at the forefront of our thinking.

Gene M. Murtagh, Chief Executive, Kingspan Group.

COMMITTED TO

GREEN BUILDINGS

integrated, more efficient, faster and safer. Kingspan always

selects materials and systems to minimise the overall

ecological impact of buildings.

VISION

To be a global leader in sustainable business and establish

a leading position in providing sustainable, renewable and

affordable best practice solutions for the construction sector.

SUSTAINABILITY POLICY

Striving for sustainability in all our business products and

operations is our corporate and personal responsibility.

Kingspan Solar aims to adopt and apply best practice

sustainability principles by ensuring environmental, social

and economic parameters are considered in an integrated

way in product and service delivery. To this end, KingspanSolar will:

Incorporate the ethos of sustainability into the vision and

values of the organisation.

Continually improve operational performance through the

setting of long-term objectives and targets related to

sustainability and review progress regularly.

Comply or exceed applicable legal and policy

requirements related to the environmental and social

aspects of the organisation.

Optimise energy and raw material usage and prevent or

minimise pollution and environmental damage.

Communicate and actively promote awareness and

acceptance of this policy to everyone working for, or on

behalf of, the organisation (including employees,

shareholders, suppliers / sub-contractors and customers).

Ensure employees are given adequate training in

sustainability issues and are fully involved in helping

deliver the Sustainability Vision & Policy.


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KINGSPAN SOLAR

INTRODUCTION

LOCATION Bristol, UK

APPLICATION Domestic hot water and pool heating

CLIENT Bristol Lido / Solarsense

PRODUCT 720 Kingspan Solar Heat Pipe tubes

SAVINGS Estimated associated fuel savings

of over 2201 per annum

Bristol Lido, the oldest lido in the country, has been

transformed into a model of energy efficiency following

a two-year restoration.

The complex, including a 24-metre open-air swimming pool,

now features 720 Kingspan Solar Heat Pipe evacuated

tubes which generate up to 70% of the lidos annual hot

water needs.

The owners of the 150 year old Grade II listed Lido, are great

believers in conservation and wanted to find a way to heat

the vast amount of water used at the lido without relying on

expensive, fossil fuel resources. They conducted a great deal

of research into sustainable energy options ahead of the

restoration and Kingspan Solars Heat Pipe collectors were

the obvious answer. They tick all the boxes and far surpass

the competition in terms of delivering premium performance

matched with financial benefits.

The Heat Pipe collector enable the cost-effective heating of

water, whilst helping reduce carbon emissions in the process.

SAVING UP TO 70%OF ANNUAL HOTWATER NEEDS

CASE

STUDIES

BRISTOL LIDO SPA & SWIMMING POOL

BRISTOL, UK


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PRODUCES 10,000 kWhPER YEAR SAVINGAROUND 1,500

LOCATION Pembrokeshire, Wales, UK

APPLICATION Domestic hot water

CLIENT Hywel James / Llani Solar Ltd

PRODUCT 180 Kingspan Solar Heat Pipe evacuated tubes

PRODUCTION 10,000 kWh per annum

SAVINGS 1,500

An organic dairy farm in Pembrokeshire, has found the

perfect sustainable solution to its hot water needs.

The 500 acre farm, which houses a large organic dairy herd,

has installed 180 Heat Pipe evacuated tubes to generate

enough hot water to meet its demanding cleaning

requirements.

These high performance solar thermal collectors not onlygenerate up to 70% of the farms annual hot water needs,

they also deliver a dramatic reduction in its energy costs and

carbon emissions.

Hywel James, who runs the farm in Pembrokeshires Teifi

Valley, needed to find a way to heat 500 litres of water to

90C on a daily basis in order to clean the plant and its

equipment. Llani Solar Ltd specified 18m2 of Kingspan Solar

Heat Pipe collectors, installed on a specially constructed

south-facing canopy to maximise heat gain from the sun

and also to provide shelter outside the milking parlour.

The system is already reporting significant savings for thefarm, producing around 10,000 kWh of heat per year with

annual savings of around 1,500.

CASE

STUDIES

DAIRY FARM

TEIFI VALLEY, WALES, UK


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KINGSPAN SOLAR

INTRODUCTION

LOCATION Headingley, Leeds, UK

APPLICATION Domestic hot water and space heating support

CLIENT University Partnerships Programme (UPP)



of circa 2000 per annum

In preparation for the new intake of freshers, Leeds

Metropolitan University has unveiled a brand new

development of high quality purpose-built student flats.

In keeping with its ethical and environmentally sustainable

ethos, the six new cluster blocks feature 72m2 of Kingspan

Solars Heat Pipe evacuated tubes.

These superior performance solar thermal collectors notonly generate up to 70% of each buildings annual hot water

requirements, but also provide central heating support,

resulting in a dramatic reduction to both carbon emissions

and energy costs.

Carnegie Village is a 26m development situated on

Headingley campus, a self-contained student community in

the heart of Leeds. The new flats have been fitted with 720

Heat Pipe evacuated tubes solar thermal collectors that heat

two 500 litre cylinders per block.

The large-scale solar installation, carried out by Kingspan

Solar Accredited Installers, sees Leeds Metropolitan

University leading the way in sustainable thinking.

SAVING UP TO 70%OF ANNUAL HOTWATER NEEDS

CASE

STUDIES

LEEDS METROPOLITAN UNIVERSITY

LEEDS, UK


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KINGSPAN SOLAR

SAVINGS OF UP TO70% OF HOT WATER

LOCATION Leicester, UK


CLIENT Leicester College


SAVINGS Up to 70% of hot water

Leicester College, which is one of the largest in the UK,

is one of the first in the country to adopt evacuated tube

collector technology to service its hot water needs as part

of its commitment to sustainability.

As part of a dramatic overhaul to upgrade its facilities for

students and in keeping with Building Regulations, the

college replaced its old gas boilers with 300 Kingspan Solar

evacuated tubes, which heat a 3,000 litre thermal store.

The Kingspan Solar Specification team has designed the

system to meet 70 percent of its hot water needs

all-year-round.

The performance of the Kingspan Solar tubes has

been nothing but impressive. We get solar heated

water in record time and there is minimum

maintenance required.

Robin Dalby, Maintenance & Development Co-ordinator, Leicester College.

CASE

STUDIES

LEICESTER COLLEGE

LEICESTER, UK


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KINGSPAN SOLAR

INTRODUCTION

LOCATION NPRO Building, St. James Hospital, Dublin


CLIENT Health Service Executive

INSTALLER Haughton & Young Mechanical Contractor

PRODUCT 48m2 Kingspan Solar Heat Pipe tubes

Kingspan solar thermal range has been used as part of

a 28m project to build a new three storey multi-discipline

facility. The new NPRO Building will provide treatment

areas, staff accommodation and training suites at

St. James Hospital in Dublin.

The Kingspan Solar Specification team provided the system,

which saw the installation of 48m2 Kingspan Solar

evacuated tubes to provide heating to 2 x 2000ltr calorifiers.

The system met the demands of the project to achieve

considerable reduction on fossil fuel reliance and

enhancement of green sustainability credentials.

The system has performed extremely well and we are

delighted with the results to date even considering the

relatively poor year we have had weather wise. Again this

relates back to what we were told initially that evacuated

tube performance will not be compromised too much in

cloudy weather due to their ability to perform well in

diffused sunlight.

THE SYSTEM PERFORMSEXTREMELY WELL AND WEARE DELIGHTED WITH THERESULTS

CASE

STUDIES

ST. JAMES HOSPITAL

DUBLIN, IRELAND


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KINGSPAN SOLAR

LOCATION Cavan, Ireland


CLIENT Breffni Park Stadium

PRODUCT 300 Kingspan Solar Direct Flow tubes

PAYBACK < 6 years

As part of a L300,000 renovation, Kingspan Breffni Park

Stadium became the exclusive home to the first-ever

Kingspan Solar fresh-water module system.

Reducing carbon emissions, hot-water costs and with

payback in less than four years, the GAA stadium has been

hailed as a shining example, for its effective use of

renewable technology.

We have already been able to turn off our boilers,

which were powered by gas, saving us over L4,000

a year. Plus we are also able to use the hot water

generated by the system to heat our radiators.

Again saving us money!

Kieran Callaghan, Chairman of Kingspan Breffni Park committee

As part of the renovation project, Kingspan Environmentals,

Rainwater Harvesting system was also installed. It is used to

recycle excess water from the roof and pitch. This water is

also used for all the toilets and watering the field when

needed.

SAVING US OVERk4,000 A YEAR

CASE

STUDIES

BREFFNI PARK STADIUM

IRELAND


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KINGSPAN SOLAR

INTRODUCTION

LOCATION Clifton Campus, Nottingham, UK


CLIENT University Partnerships Programme (UPP)

INSTALLER MG Renewables

PRODUCTION 33,000 litres of hot water per day



of over 1000 per annum

A multi-million pound new build development at Nottingham

Trent University is benefiting from a major installation of

3960 Kingspan Solar Heat Pipe evacuated tubes, in what is

one of the UKs largest ever solar thermal projects.

The new Clifton Campus student accommodation was built using

the University Partnerships Programmes (UPP) Eco Residence

Model for sustainable development to considerably cut CO2

emissions and meet strict government targets.

Solar specialists MG Renewables specified 132 Kingspan Solar

evacuated tube collectors, covering over 6,000ft2 of roof area

across 12 accommodation blocks to service the hot water needs

of 727 students. Heat Pipe collectors were specified for their

high performance and reliability and are now delivering 33,000

litres of hot water every day, lowering energy bills and providing

a 61 tonnes per year reduction in CO2emissions.

People think the weather in the UK and Ireland isnt

suitable for solar power to work well, but that is a myth.

Solar energy systems such as Kingspan Solars workeven on overcast days.

Gerry Kennedy, Director, MG Renewables, Nottingham.

DELIVERING 33,000 LITRESOF HOT WATER PER DAY

CASE

STUDIES

NOTTINGHAM TRENT UNIVERSITY

NOTTINGHAM, UK


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KINGSPAN SOLAR

A leading tourism attraction and independent charity, the

Scottish Seabird Centre offers visitors an interactive

experience with a Discovery Centre, gift shop and caf.

The 9m2 installation of Kingspan Solars Heat Pipe evacuated

tube collectors is helping to dramatically reduce energy

costs and CO2emissions as part of the Centres ongoing

environmental initiative, Plan Green Zero.

Heat Pipe collectors were specified and fitted by Kinross

renewables supplier and installer, Glendevon Energy to

pre-heat water for the gas boiler system, providing up to

70% of the annual hot water for the cafeteria and kitchen.

We opted for Kingspan Solar collectors because they

were able to complement the specific design elements

of the project perfectly, while still delivering the

highest quality performance to meet the Centres

hot water needs.

Jamie Adams, Director, Glendevon Energy.

The installation is expected to contribute 6MWh to the

Centres hot water system each year, helping to avoid more

than 1,600kg of CO2emissions in the process.

PRODUCING 6MWhPER YEAR

CASE

STUDIES

LOCATION North Berwick, East Lothian, Scotland, UK

APPLICATION Hot water for kitchen and cafeteria

CLIENT Scottish Seabird Centre

INSTALLER Glendevon Energy

PRODUCT 90 Kingspan Solar Heat Pipe Tubes

SAVINGS 6MWh and 1,600kg CO2per year

SCOTTISH SEABIRD CENTRE

SCOTLAND, UK


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KINGSPAN SOLAR

INTRODUCTION

LOCATION Huyton, Liverpool and Bullwell, Nottingham, UK

APPLICATION Hot water, including 82 en-suite bedrooms

CLIENT LNT Construction - Ideal Care Homes

INSTALLER Solar Save UK - Kingspan Solar Accredited Installer

PRODUCTION 16.71 MWh per annum across two sites


SAVINGS Average savings of over 1000 per annum

A major project to build 35 care homes over a two-year

period has kicked off with the installation of 300 Kingspan

solar thermal Heat Pipe tubes across two sites in Liverpool

and Nottingham.

LNT Construction specified Heat Pipe tubes to help provide

hot water for the homes, and comply with SBEM and Part L

Building Regulations. The 150-tube installation at each of the

first two sites feed into pre-heat systems to meet the homes

domestic hot water needs. Across the two sites, the expected

annual contribution to the care homes hot water is 16.71 MWh,

helping avoid a significant 3,242kg of CO2 emissions.

LNT Group Mechanical Engineer, Tom Nutt, said, When

looking to integrate solar thermal technology into the project,

we wanted to be able to provide readily available hot water for

residents all year round. After Kingspans design team

produced an in-depth T*SOL simulation, it was clear that Heat

Pipe collectors would be the far superior choice, particularly in

terms of performance. Whats more, the tubes were installed

by Solar Save UK, a Kingspan Solar Accredited Installer, which

means were able to benefit from a 20 year warranty as well

as top quality workmanship.

SAVING 3,242KGOF CO2EMISSIONS

CASE

STUDIES

HURST PARK COURT CARE HOME, LIVERPOOL, UK

& FAIRWAY VIEW CARE HOME, NOTTINGHAM, UK


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KINGSPAN SOLAR

Singapore Changi International Airport, a major aviation

hub in Southeast Asia has installed one of the largest solar

thermal systems in Southeast Asia. The installation uses

more than 10,000 Kingspan Solar evacuated tubes.

Commissioned in 1996, the system comprises 350 evacuated

tube solar thermal collectors to heat 66,000 litres of water

in buffer tank storages.

The heat generated by the systems is used for staff

showering facilities in the Singapore Airport Terminal

Services (SATS) and for food preparation, cooling and

washing at in-flight catering centre in Changi International

Airport Services (CIAS).

SAVING UP TOk50,000 PER YEAR ONELECTRICITY BILL.

CASE

STUDIES

LOCATION Singapore

APPLICATION Food preparation, cooking, washing and

staff showering

CLIENT Singapore Changi International Airport

INSTALLER Connections International Pte Ltd

PRODUCT 10,500 Kingspan Solar Heat Pipe Tubes

SAVINGS Up to h50,000 per year on electricity bill

CHANGI INTERNATIONAL AIRPORT

SINGAPORE


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KINGSPAN SOLAR

INTRODUCTION

LOCATION Ogunquit, Maine, USA

APPLICATION Domestic hot water and space heating

CLIENT Cliff House Resort & Spa

INSTALLER Nelson & Small Energy Conservation

Products, Inc.

PRODUCT 70 Heat Pipe collectors

PAYBACK < 6 years

Committed to sustainability and preserving the

environment, the 5 star Cliff House Resort & Spa has

installed one of Maines largest solar thermal systems.

The installation uses 2,100 tubes on 70 collectors.

This solar installation will save an estimated 50,000 litres of

propane annually and reduce greenhouse gas emissions by

more than 63.5 tonnes per year.

Solar energy will be used to provide heat and hot water for

the Resorts Spa building, which includes 32 guest rooms and

10 treatment rooms. The Resort estimates it will reduce

fossil fuel consumption in this building by 30%. A grant from

the U.S. Department of Agriculture, as well as federal tax

credits, helped offset project costs and reduce payback to

less than six years.

Kingspan Solar not only supplied the collectors, but

designed, specified and supplied all the components,

programmed the controls and commissioned the entire

system prior to handover, providing the ultimate solarthermal solution.

SYSTEM PAYBACKLESS THAN 6 YEARS.

CASE

STUDIES

CLIFF HOUSE RESORT & SPA

MAINE, USA


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KINGSPAN SOLAR

ROBY LODGE CARE HOME, LIVERPOOL, UK

LONGFIELD ACADEMY FOR ARTS & SCIENCES, KENT, UK


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KINGSPAN SOLAR

32

KINGSPAN SOLAR EVACUATED TUBE COLLECTOR

The Kingspan Solar collector is the most efficient, longest

lasting solar collector on the market today. Made in Europe

since 1982, our evacuated tubes have withstood the test

of time.

Each collector consists of a highly insulated manifold and a

series of evacuated tubes. The vacuum inside each tube

provides perfect insulation, protecting the system from

outside influences, such as cold and windy weather or high

humidity.

Highly efficient super fast heat transfer

Ease of installation and maintenance

Available in Direct Flow (DF400) and Heat Pipe (HP400

and HP450) options

Plug and play design

SOLAR THERMAL SYSTEMS

PRODUCT OVERVIEW

WE OFFER A RANGE OF SOLAR THERMAL SOLUTIONS TO

SUIT EVERY APPLICATION.

KINGSPAN SOLAR'S UNIQUE VARISOL DESIGN

World leading evacuated tubes and a new click-fit design,

combine to make the worlds first modular solar thermal

collector.

Varisol technology provides

a modern and adaptable

alternative to traditional

rigid manifold systems.

Its precise sizing and

modular flexibility means it

can be sized to the exact

requirements of the end

user, so they only use and

pay for what is needed for

ultimate results.

It is completely expandable so customers can grow their

solar systems as their needs change.

INSTALLATION COULDNT BE EASIER

Insert Varisol tube...

click into position.

rotate down...


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KINGSPAN SOLAR

PRODUCTRANGE

FLAT PLATE COLLECTOR

Kingspan also offers a range of durable and very efficient

flat plate collectors to meet the needs of a wide range of

applications from small residential systems to large scale

commercial installations.

Robust, durable and high performance, our flat plate panels

deliver excellent levels of efficiency combined with flexibility

in installation.

SYSTEM COMPONENTS

Kingspan also supplies a range of

components in order to provide complete

solar thermal solutions, including:

Pump Stations

Pump Stations contain a circulating pump

that circulates the heat transfer fluid

through the solar loop (see page 56).

Cylinders

In a solar system, the tank is almost as

important to the collection of energy as

the collector.

Kingspan Tribune tanks are designed

specifically for solar systems to

maximize their output.

Expansion Tanks

In closed loop systems, an expansion

tank is required to compensate for fluidexpansion and contraction.

Different sizes available.

ASME and non-ASME rated

tanks available.

Solar Controllers

Differential Temperature Controllers

are required to activate circulating

pumps and motorized valves and

monitor system performance. They can

record data from all sensors in the solar

thermal system.

Kingspan offers a wide range of

controllers for different system types

and requirements.

Many different accessories available including

LAN module, data logger and BACnet module.

Propylene Glycol

Kingspan Solar recommends Tyfocor Propylene Glycol,

a high temperature glycol formulated specifically for

solar thermal systems.


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HOW IT WORKS

An absorber plate is located inside a glass tube where a

vacuum is pulled to keep the losses to the environment aslow as possible. 99.999999% of the air is removed from

inside the glass enclosure during the manufacture of the

tubes to mimimize heat loss. The heat pipe is the method of

heat transfer from inside the tube to the manifold, where a

water glycol mixture flows past the condenser heat at the

top of the heat pipe and pulls the energy away.

On the back of the copper absorber plate is welded a small

copper tube. This tube is sealed at the bottom and, before it

is sealed at the top, a small amount of fluid is added to the

tube and a vacuum pulled inside the tube. The vacuum

inside the heat pipe causes the water to boil at 29,4 Cinstead of its usual 100C. The absorber plate collects

energy from the sun and becomes hot, causing the water in

the heat pipe to boil. The steam naturally rises up to the top

of the heat pipe and into the condenser head which is

located inside the manifold. Glycol flowing past the

condenser head causes the water to condense, heating the

glycol and causing the water to run back down to the bottom

of the heat pipe allowing the process to continue when

significant light is available (Figure 1).

The heat pipe is a very efficient method of transferring

the energy from the tubes to the glycol in the manifold.Each tube plugs into a dry socket in the manifold where the

glycol runs past it. This allows for individual tubes to be

removed from the system without having to drain the glycol.

The system can also be commissioned, flushed and filled

prior to inserting the tubes into the collectors, an important

point for large systems that need to be commissioned

before a building is occupied. When the time comes, simply

insert the tubes into the system and it is ready to produce

hot water.

Manifiold (glycol)

Manifiold (glycol)

Dry socket

Figure 1:How a Heat Pipe works.

Condenser

Heat Pipe

Steam

KINGSPAN SOLAR



KINGSPAN SOLAR


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KINGSPAN SOLAR

PRODUCTRANGE

The manifold itself is formed from heavy duty aluminum

extrusions on the front and back. Inside is the condenser

manifold where the heat transfer occurs between the

condenser and the glycol flowing past. To install the tubes

simply open the manifold cover, line the tubes up with the

manifold, and press them into place. When finished, close the

manifold cover and this will retain the tubes in position.

The manifold is the only area of the system that becomeshot and is not protected by a vacuum, so it is protected with

high tech melamine foam insulation. This insulation has a

very low U-value and is stable at the high temperatures the

collector can achieve.

The image above shows the other key components of the

heat pipe tube. The getter is a layer of barium that is

deposited on the inside of the tube after the vacuum is

drawn. This protects the vacuum over time from any air

molecules that may make their way through the glass.

If the vacuum is lost in one of the tubes, the getter will turn

white to indicate this. The TiNOx coating used on the tubes

is designed to absorb 96% of the suns energy that strikes it

while emitting only 4% back to the environment. This is

currently the best available coating for solar collectors.

End

Connection

Condenser Socket

Retaining Strip

Cover

Melamine Foam Insulation

Condenser Manifiold

Rubber EndBumper

TiNOx Selective Coating Soda Lime Glass Flexible Neck

Vacuum Area CopperAbsorber Plate

Getter

CondenserHead

Heat Pipe


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KINGSPAN SOLAR

OUR HEAT PIPE HAS A FEATURE THAT MAKES IT UNIQUE WHEN COMPARED TO ANY

OTHER EVACUATED TUBE ON THE MARKET TODAY:

THERMOSTATIC CONTROL

When the hot water storage reaches its maximum temperature, the solar pump stops and

additional heat will not be removed from the collector. This will cause the tubes to become

very hot. To protect the glycol in the manifold, our heat pipe tubes have a patented

thermostatic control device. This activates automatically in the condenser head and prevents

the temperature in the manifold from becoming hot enough to damage the glycol.

We offer two options for the unique temperature limitation device. When the temperature

rises to 90C/135C, a stack of bimetallic disks flexes, closing a valve that will not allow

additional steam from the heat pipe to enter the condenser head.

When flow is restored to the collectors and the temperature falls below 90C/135C, the

disks snap back and the valve reopens restoring the system to normal operation.

The HP450 range is designed for industrial applications where high water temperatures

are required for the purpose of wash downs, process heat, etc. The HP400 range is

designed for applications that require a lower input water temperature such as washing

and showering needs.

Normaloperation

Limitingtemperature

KINGSPAN SOLAR



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KINGSPAN SOLAR

PRODUCTRANGE

CERTIFIED EFFICIENCIES

Keymark KeymarkAperture Absorber

0 0.750 0.794

a1 1.18 1.25

a2 0.010 0.010

HP400 / HP450 2m2 3m2

Number of tubes 20 30

Dimensions

Absorber Area (m2) 2.01 3.021

Overall Dimensions (mm) 1952 x 1418 x 93 1952 x 2127 x 93

Width of Manifold (mm) 1418 2127

Length (tube and manifold) (mm) 1952 1952

Depth (mm) 93 93

Aperture Area (m2) 2.16 3.23

Fluid Volume (ltr) 1.2 1.7

Inlet and Outlet Dimensions (mm) 22 22

Weight (empty) (kg) 48 71

Mounting

Recommended Inclination () 20-70 20-70

Performance Data

Efficiency Based on Aperture Based on Aperture

Eta 0 0.75 0.75

a1 (W/m2K) 1.18 1.18

a2 (W/m2K2) 0.0095 0.0095

Solar Keymark L icence Numbers HP400: 01 1-751793

Operating DataFlow Rate (ltr/h)

Rated 160 240

Minimum 120 180

Maximum 300 480

Maximum Operating Pressure 10 Bar 10 Bar

Stagnation Temperature (C) 166 166

Heat Transfer Fluid Water / Glycol Water / Glycol

Materials

Absorber Copper Copper

Coating Selective Coating Selective Coating

Absorbance (%) 95 95

Emissivity (5) 5 5Mounting Frame and Clips Stainless Steel, Stainless Steel,

Aluminium, EPDM Aluminium, EPDM

Glass Low Iron - Transm. 0.92 Low Iron - Transm. 0.92

Vacuum


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KINGSPAN SOLAR

HOW IT WORKS

Direct flow solar collectors consist of a row of solar tubes

and a highly insulated manifold. The heat medium to be

heated is passed down through the collector tube within

a coaxial heat exchanger. The vacuum inside each tube

provides perfect insulation and therefore protects the

system from outside influences such as cold and windy

weather or high humidity. This vacuum insulation alsoensures that the energy collected from the sun is very

efficiently and effectively transferred into usable heat.

THE VERSATILE SOLUTION

The flexible installation options of direct flow collectors

provide the perfect solution when the ideal position on the

building is not available.

Direct flow systems can be installed on a pitched or

horizontal surface, and the tube can be rotated 25 to

compensate for installations that deviate from south.

As the collector is a fully pumped unit, there is no minimum

angle for the collector.

This makes it most suitable for installations where the

product needs to be installed below 20 or above 70.

DIRECT FLOW COLLECTORS ARE AVAILABLE IN2 DIFFERENT SIZES

KINGSPAN SOLAR

DIRECT FLOW COLLECTOR

DF400

2m2 3m2

Number of Tubes 20 30

Dimensions

Absorber Area (m2) 2.010 3.021

Overall Dimensions (mm) 1952 x 1418 x 93 1952 x 2127 x 93

Width of Manifold (mm) 1418 2127

Length (tube and manifold) (mm) 1996 1996

Depth (mm) 97 97

Aperture Area (m2) 2.15 3.23

Fluid Volume (ltr) 3.6 5.6

Inlet and Outlet Dimensions (mm) 22 22

Weight (empty) (kg) 51 78

Mounting

Recommended Inclination () 0-90 0-90

Performance Data Based on Based onAperture Aperture

Efficiency

Eta 0 0.773 0.779

a1 (W/m2K) 1.43 1.07

a2 (W/m2K2) 0.0059 0.0135

Solar Keymark L icence Numbers 011 - 7S1946 R 011 - 7S1946 R

Operating Data

Flow Rate (ltr/h)

Rated 160 240

Minimum 120 180

Maximum 300 480

Maximum Operating Pressure 8 Bar 8 Bar

Stagnation Temperature (C) 286 286

Heat Transfer Fluid Water / Glycol Water / Glycol

Materials

Absorber Copper Copper

Coating Selective SelectiveCoating Coating

Absorbance (%) 95 95

Emissivity (5) 5 5

Mounting Frame and Cl ips Stain less Steel , Stainless Steel ,Aluminium, Aluminium,

EPDM EPDM

Glass Low Iron - Low Iron -Transm. Transm.

0.92 0.92

Vacuum


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Vacuum area

Copper absorber plate

Getter

Rubber end bumper

TiNOx selective coating

Soda lime glass

39


KINGSPAN SOLAR

PRODUCTRANGE

Direct Flow Collector Efficiency

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0

20 30 40 50 60 70 80 90 100 110 120 130 140 150

Collector Temperature (C)

Efficiency

(-)

400 W/m

2

600 W/m2

800 W/m2

1000 W/m2

THE ROYAL DANISH ACADEMY OF FINE ARTS SCHOOLOF ARCHITECTURE, COPENHAGEN, DENMARK


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KINGSPAN SOLAR

Evacuated Tubes

Manifold

Tube Retainer

Connection Kit

Frame

Tube Retainer

MOUNTING HARDWARE (FRAMES) FOR OUR EVACUATED

TUBES (REFERS TO HEAT PIPE AND DIRECT FLOW)

Kingspan offers a selection of frames to hold the collector at

the proper angle. All Kingspan frames are made from

extruded aluminum supports and stainless steel hardware

for the ultimate durability. Frames are supplied partially

assembled with all clips in the correct locations and legsbolted together, facilitating fast and accurate installation.

Mounting the frame to the roof is another area that requires

particular attention. The mount will depend on the type of roof

and exactly how the collectors are to be mounted. Kingspan

Solar offers a wide variety of mounting hardware and provides

the experience to select the correct system for the application.

From asphalt shingle, to tile, to EPDM, we can help you choose

the correct mounting hardware for the application.

The connections at the end of the manifold use a redundant

double o-ring seal to allow for expansion and contraction,

if multiple manifolds are connected in series. The connection

kit provides the adaptors necessary to adapt this to 22mm

copper pipe at the end ofcollector banks.

Connecting multiple

collectors is easy with the

interconnection kit. One

end of the manifold simply

slides into the other and

the interconnection kit

provides the hardware to

properly align these end

fittings.

SYSTEM COMPONENTS

KINGSPAN SOLAR

FRAMES


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KINGSPAN SOLAR

PRODUCTRANGE

APARTMENT BLOCKS, GERMANY

CLIFF HOUSE RESORT & SPA, MAINE , USA


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KINGSPAN SOLAR

VARISOL, AWARD WINNING

SOLAR COLLECTORS

ADDITIONAL BENEFITS

Delivering all the benefits of Kingspan Solars market-leading

evacuated tubes, Varisol offers the combination of total

flexibility, high quality and proven performance.

The evacuated tubes are pre-assembled with the Varisol

connector for ease of installation and collector sizes of up to

150 tubes. The technology is suitable for both domestic and

commercial applications and is completely expandable

enabling customers to grow their solar thermal systems as

their requirements change.

Precision sizing means customers only need to pay for

exactly what they need. For installers they are quick and

easy to install and distributors benefit from improved stock

control with no manifolds to stock or invest capital in. They

are also environmentally friendly, using 100% recyclable

polymer material.

Varisol has lowered its carbon footprint by eliminating the

need for brazing and welding as well as energy intensive

materials, such as copper and aluminium. The system is also

more lightweight and requires less packing and boxes,

therefore minimising the impact of transport.

THE REVOLUTIONARY NEW DESIGN OF VARISOL OFFERS A MODERN

AND FLEXIBLE ALTERNATIVE TO THE RIGID MANIFOLD SYSTEM.

A copper pocket is over-moulded into the

polymer header to house the condenserand ensure a dry connection of the tubes.

Quick and easy to install, Varisol allowsindividual tubes to be simply clicked together

to create solar collectors of varying sizes.

TECHNICAL SPECIFICATION DF HP

Dimensions (mm) 1950 x 70.9 x 70.9 1965 x 70.9 x 70.9

Weight (kg) 2.2 2.13

Volume (l) 0.19 0.05

Max. Operating pressure 6 6

Min. slope 0 20

Max. Slope 90 80

Max. Load 2.5 2.5

Heat transfer medium Propylene Glycol Propylene Glycol

Max. field size 150 tubes = 21m2 (gross) 150 tubes = 21m2 (gross)


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KINGSPAN SOLAR

PRODUCTRANGE

This versatile product provides theperfect solution when the ideal positionon the building is not available.

RETIREMENT HOME, ITALIAN ALPS


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KINGSPAN SOLAR

FLAT PLATE

SOLAR COLLECTORS

HOW IT WORKS

Flat plates are a very simple method for capturing the

energy form the sun and turning it into hot water. A copper

plate is coated with a special coating that absorbs as much

of the suns radiation as possible. On the back of this plate

are a series of tubes that are welded directly to the back of

the plate. Glycol flows from a manifold on one end of the

collector to another manifold at the other end. As it passesthrough the tubes on the back of the plate, it is heated by

the energy that the plate has absorbed from the sun.

To keep as much energy in as possible, the collector plate is

surrounded on five sides by insulation. This insulation prevents

the loss of energy from the hot plate to the surrounding

environment. On the front side of the panel is a plate of glass

that the sun shines through. The glass also provides insulation

for the collector plate from the cold environment outside.

A frame around the outside holds everything together and

keeps moisture out.

Both ends of the manifolds have union fittings that allow for

a connection kit to be attached, or another panel. For arrays

of multiple collectors, one collector simply screws into the

next and seals with a flat washer. A plug is screwed into one

end of each of the manifolds and the connection kit added to

connect up an array of collectors.

Kingspan offers three sizes of flat plate.

This allows for optimal placement of thepanels on the roof and significantflexibility in the output of the system.


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KINGSPAN SOLAR

PRODUCTRANGE

KEY FEATURES

There are many flat plate products on the market today,

differing significantly in terms of design, construction

quality, performance and size. Kingspan flat plate collectorsoffer high efficiency, combined with robust design and

construction, providing solar thermal systems that are

designed to last and perform for many years.

SPECIFICATION / TYPE FPW25 FPW21 FPW18

Dimensions (mm) 1988 x 1218 x 90 1988 x 1041 x 90 1927 x 927 x 90

Weight (kg) 44 37.2 34

Sealing Mater ial EPDM & Silicone & Aluminium FrameGross Area (m2) 2.42 2.07 1.79

Aperture Area (m2) 2.24 1.92 1.62

Absorber Material Almeco Tinox Highly Selective Aluminium

Thickness (mm) 0.3 0.3 0.3

Absorptance (%) 95 95 95

Emittance (%) 4 4 4

Glass Material Low Iron Tempered Glass

Insulation Material Rockwool

Efficiency

eta 0 (zero loss efficiency - n0a) 0.785

k1 (W/m2K) (1st heat losscoefficient - A1a)

3.722

k2 (W/m2K2) (2nd heatloss coefficient - A2a)

0.012

Stagnation Temperatureat 1000 W/m and 30C

203C

GUATEMALA


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KINGSPAN SOLAR

UNIQUE FEATURES OF

KINGSPAN SOLAR TUBES

TUBE DESIGN

FIN-IN-TUBE DESIGN

In a evacuated tube system, a copper absorber plate is

welded to a heat pipe tube and sealed inside a single wall

glass tube to collect the suns energy. Most other evacuated

tubes are a Sydney design in which two glass tubes are

formed into a vacuum flask with the selective coating

surface on the inner glass tube and the absorber plate andhydraulic fittings are housed inside the cavity of an open

ended flask.

Kingspan Solar's sealed glass tubes protect all components

inside a controlled environment where outside conditions

cannot affect heat production and heat transfer. Moisture will

not build up around the tubes components and they will not

corrode.

Heat Pipe Tube Cross Section Sydney Tube Cross Section

Low-iron contentsoda lime glass

Selective coating

Copper absorber fin

Copper heat pipe

Vacuum

Borosilicate glass

Borosilicate glass

Absorber plate

Selective coating

Copper heat pipe

Vacuum


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KINGSPAN SOLAR

PRODUCTRANGE

BENEFITS

There are three core objectives -

Performance

Longevity

Consistency

These main objectives are fulfilled through the following:

HIGH QUALITY GLASS

Outside air will seek to penetrate and compromise the

insulation properties of a vacuum quality glass can prevent

this from happening.

Our tubes are constructed of low-iron content soda lime

glass. We generally think of glass as being completely

transparent, but glass actually absorbs some of the light

passing through it, typically allowing only 94% of light to

assist the heating process. Low-iron content soda lime glass

has one of the highest transmission characteristics of any

high-strength glass on the market today.The test involves firing a one inch ice ball at 50 mph, five

times at the same point on the tube (image above). Kingspan

tested borosilicate glass to quantify the performance

difference as compared to soda lime glass.

Shot impact point

CARPE, SOUTH AFRICA

The Hail Impact Test

Kingspan Solar's evacuated tubes are one of the few tubes

from the major solar thermal manufacturers to have passed

this European trial that is covered under EN 12975-2

specification.


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KINGSPAN SOLAR

UNIQUE FEATURES OF

KINGSPAN SOLAR TUBES

STATE-OF-THE-ART MANUFACTURING

Kingspan Solar tubes are manufactured using European

sourced parts in a state-of-the-art facility in Northern

Ireland. The evacuated tube manufacturing process is fully

automated, removing the potential for human error and

providing consistently high levels of production quality.


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Inferior productmechanical seal

49


KINGSPAN SOLAR

PRODUCTRANGE

Unique glass to metal seal

UNIQUE GLASS TO METAL SEAL

The seal between the glass and the heat pipe where the pipe

emerges from the neck of the tube is critical to maintaining

the vacuum and its insulation properties. The tubes feature a

patented hermetic seal that fuses metal and glass together.

The two materials are bonded so the seal remains intact

under all operating conditions.

SUPERIOR VACUUM

The vacuum and its insulation properties are the most

important elements of an evacuated tube. The vacuum is

drawn to 1x10-6 mbar, signifying that 99.9999999% of the air

is removed from the tube. It is extremely difficult to remove

this much air from any space in a commercial production

environment without using state-of-the-art manufacturing

techniques.

Kingspan Solar tubes maintain their vacuum,continuing to perform for over 30 years.

All evacuated tubes use a barium getter to attract and

collect outgassed air or stray molecules that can infiltrate

the evacuated tube and degrade the vacuum. our tubes

provide the largest getter surface area in the industry,

maintaining their vacuum and continuing to perform for

over 30 years in many cases. It is not surprising that

Kingspan Solar tubes contain one of the best vacuum

levels on the market.


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KINGSPAN SOLAR

EVACUATED TUBE

COMPARISONS

In the following section, competitors tubes have been

photographed and compared to the Kingspan Solar tube to

demonstrate the key differences in quality and production.

The two types of evacuated tubes are:

Fin-in-tube or single wall tubes as discussed earlier, our

tube is a Fin-in-Tube type design which has the heat pipe

sealed inside a single wall glass tube; and

Sydney Tube or double wall tubes where two glass tubes

are formed into a vacuum.

This section aims to give an overview of the differences in

both types of tubes and outline of the main differences

between Kingspan Solar and other tubes on the market.

SYSTEM COMPARISON: KINGSPAN SOLAR VS. FIN-IN-TUBE COPY

KINGSPAN SOLAR EVACUATED TUBES LAST

LONGER AND PERFORM BETTER THAN ANY

OTHER EVACUATED TUBE ON THE MARKET.

Heat pipe sealed withspin closing and TIGweld. Double protectionwith 100% automatedinspection.

Heat pipe sealed witha plug.

HIGH QUALITY HEAT PIPE SEAL

Kingspan Solar Tube Competitor tube


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KINGSPAN SOLAR

PRODUCTRANGE

High quality flexible stainless steel neck (relieves stress on the glass tometal seal with high quality, UV stable EPDM rubber flange.

Unique patented and patent pendingtemperature limiting technology usedwithin the Kingspan Solar condensers.

Empty heads no mechanicaltemperature limitation.

TEMPERATURE LIMITATION DEVICE

Kingspan Solar Heat Pipe Tube

FLEXIBLE NECK

Kingspan Solar Heat Pipe Tube

30 years glass blending experience withsolar tubes. Processes perfected andfully automated.

Highly visible glass blend linesoften with air bubbles in the glassblends which can result infractures after installation.

QUALITY GLASS WELDING & BLENDS


Competitor tube

Stiff neck technology stresses the glass / metal seal.

Competitor tube


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KINGSPAN SOLAR

EVACUATED TUBE

COMPARISONS

SYSTEM COMPARISON: KINGSPAN SOLAR VS. FIN-IN-TUBE COPY

Heat pipe is a singlehermetically sealedcopper pipe within thevacuum space.

Mechanical / solderedjoin within the vacuumspace.

SINGLE PIPE


High quality EPDM rubber endprotector on the tube.

Low cost option no end protection.

HIGH QUALITY PROTECTIVE END BUMPER



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KINGSPAN SOLAR

PRODUCTRANGE

High quality rigid EPDMrubber flange. Insulatesand protects the glass tometal seal.

Thin rubber end flange tohide the mechanical glassto metal seal.

HIGH QUALITY RUBBER FLANGE


Getter flash shows consistent anddefined length at top end of tube.

Getter flash has undefinedlength at centre of tube.

LARGER GETTER AREA, MORE ROBUST VACUUM



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KINGSPAN SOLAR

EVACUATED TUBE

COMPARISONS

Metal End Bumper Al Nitrate Coating Heat Pipe

Getter Mechanical Glassto Metal Seal

CondenserHead

Tube Diameter 102mm

SYSTEM COMPARISON: KINGSPAN SOLAR VS. SINGLE WALL / FIN-IN-TUBE

Rubber EndBumper

TiNOx Selective Coating Flexible Neck

Vacuum Area Getter

CondenserHead

KINGSPAN SOLAR TUBE

SINGLE-WALLED TUBE

Tube Diameter 65mm

Heat Pipe


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KINGSPAN SOLAR

PRODUCTRANGE

SYSTEM COMPARISON: KINGSPAN SOLAR VS. SYDNEY / DOUBLE-WALL TUBE

Rubber EndBumper

Al Nitrate Coating(on inner glass)

Heat Pipe

Getter Mechanical Glassto Metal Seal

CondenserHead

OuterGlass

VacuumArea

InnerGlass

KINGSPAN SOLAR HEAT PIPE TUBE

SYDNEY TUBE

Rubber EndBumper

TiNOx Selective Coating Flexible Neck

Vacuum Area Getter

CondenserHead

Heat Pipe


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KINGSPAN SOLAR

KINGSPAN

PUMP STATIONS

ALL SOLAR THERMAL APPLICATIONS

REQUIRE A PUMP SYSTEM TO MOVE FLUID

THROUGH THE SOLAR LOOP.

KINGSPAN SOLAR RECOMMENDS THE USE

OF CLOSED LOOP GLYCOL SYSTEMS AND

OFFERS A SERIES OF PUMP STATIONSSUITED FOR USE IN THESE SYSTEMS.

Systems will differ in the number of collectors in them,

the length of piping and the type of heat exchanger used.

All of these parameters will affect the choice of the proper

pump station for the system. Kingspan Solars offering

includes a wide variety to handle from small systems with

only a few collectors to very large systems that require a

custom design.

In a closed loop system, there are a large number of

components required to satisfy the maintenance and safety

requirements of the system. The pump station is a collection

of these components in one small preassembled package.

One main difference between the various offerings is if a heat

exchanger is offered in the pump station. This will depend on

whether or not the heat exchanger is included within the tank.

The various Kingspan Solar offerings have been categorised

based on if they include the heat exchanger or not.

All heat exchangers in the pump stations are double walled

with positive leak detection. Most codes will require these for

solar systems to separate the water and glycol mixture, even

though the glycol mixture is termed non-toxic.

The controls are another thing that are closely tied with the

pump stations. The controls are required to activate the

pumps when there is energy to be harvested from the solar

collectors. The various different pump stations will require the

solar controllers to be programmed differently depending on

how the system is hooked up, etc. Kingspan Solar offers the

speciality controls that go with the pump stations and

provides a program for the particular system selected.

This ensures that the overall solar system will function as

intended.

Figure 2:Typical pump station without heat exchanger.

T TP

Figure 3:Typical pump station with built-in heat exchanger.

T T

P

Ball valve

Pressurerelief

Check valve

Pump

Balancevalve

Flow meter

Heatexchanger

Airseparator


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KINGSPAN SOLAR

PRODUCTRANGE

SOLAR PUMP STATIONS

A Kingspan Solar Pump Station provides a circulator for the

solar system. In addition, most features that are required on

hydronic systems are provided on the pumping station,

making the piping of the system much faster than if all the

devices had to be plumbed by hand. The pump operation is

controlled by the solar controller, which will activate the

pump when there is energy to be gained from the sun.

A range of solar pumping stations are available for both

domestic and commercial applications. The selection of the

pump station depends on the size of the collector array, the

required flow rate and the overall pressure loss in the system.

Our Standard Flow 2-12 LPM pump station is shown below.

For other options, please contact us.

Figure 4:Solar pump station.

A Flow meter

B Flush / fill ports

C Balance valve

D Circulator pump

E Expansion tank connection

F Pressure gauge

G Pressure relief valve

H Supply temperature / check & ball valve

I Collector connections - 22mmcompression (KSP0025).28mm ISO228 male (KSP0033).

J Flow temperature / check & ball valve

K Air trap bleed

L Air trap

M Tank Connections - 22mmcompression (KSP0025).28mm ISO228 male (KSP0033).

L

K

JI

M

B

C

D

E

F

A

H G

150

340

280

430

450


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KINGSPAN SOLAR

SYSTEM

TECHNICAL

CO

NSIDERATIONS

SIZING GUIDELINES 60

COLLECTOR LAYOUT & ITS EFFECT ON THE SYSTEM 72

SYSTEM TECHNICALCONSIDERATIONS


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KINGSPAN SOLAR

SOLAR THERMAL SYSTEMS CAN BE USED IN A VARIETY OF OF COMMERCIAL AND

DOMESTIC APPLICATIONS.

SIZING GUIDELINES

When using solar thermal for a particular application,

there are many things to consider in designing the system.

This section provides information on what is required for a

solar thermal system and how Kingspan sizes based on

information about the building. This section is for guidance

only and designs should be reviewed by our technical team.

All solar thermal systems should be fully designed by a

competent engineer. Kingspan Group plc or any of its

companies do not take responsibility for any systems

designed using the following information.

USES FOR SOLAR THERMAL ENERGY

There are many processes that require heat energy.

The most common usage of solar thermal collectors is to

heat domestic hot water. This is a simple application that

requires minimal disruption to the existing systems in thebuilding and excellent payback in most applications.

The energy created from the solar collectors can also be

used to heat buildings, pools or for AC reheat.

Most commercial buildings will use water or glycol for

transport of energy throughout the building for the heating

system and this is another application that is good to tap

into with solar thermal collectors.

Pools require large amounts of heat energy in order to offset

the losses from evaporation and solar collectors can provide

a large portion of this energy that is required.

AC reheat is used when the air is over cooled to remove the

humidity and then heated by a separate coil to bring the air

back up to the desired temperature. This is a great

application for solar because the demand is usually the

highest when the sun is out and shining.

In addition, many industrial processes use large amounts of

heat. The solar thermal system can provide a good portion

of the overall energy needs for these processes. Breweries

are a great example where a lot of energy is needed to heat

the beer to the desired temperature during the brewing

process.

SOLAR PERFORMANCE

We are all used to fossil fuels providing energy in our lives.

They provide the same energy regardless of the conditions

outside; a gallon of propane provides 26.96 kWh on a cloudy

and sunny day. Fossil fuels represent concentrated energy

that was provided by the sun millions of years ago.

The sun produces an abundance of energy, but it is spread

out and requires much more collection area to provide

equivalent energy to fossil fuels. A 30 tube collector will

provide about as much energy on its peak day as a gallon of

propane. However, unlike a gallon of propane the collector

will continue to provide energy as long as it is exposed to

sunlight instead of ending up as carbon dioxide and water.

Solar systems can be utilised to offset a large portion of the

fossil fuels that we currently use, but they require a different

method of sizing than traditional fossil fuel systems.

If everything is designed and sized correctly, the solar

system can be very effective in replacing fossil fuel usage for

up to 30 years with very little maintenance or replacement

parts necessary.

A Kingspan solar thermal system can

be very effective in replacing fossil fuel

usage for up to 30 years with very little

maintenance or replacement parts

necessary.


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KINGSPAN SOLAR

SYSTEM

TECHNICAL

CO

NSIDERATIONS

system, but the software will provide a far more accurate

calculation of what is needed. Kingspan Solar will be happy

to run these solar reports for your project with a completed

site assessment form.

DETERMINING HOT WATER DEMAND

Solar hot water systems are sized very differently from

traditional water heaters. A traditional water heater will lookat the maximum possible demand of the building and then

size the tank and burner so that this demand can always be

met. The only consideration for this is how many taps there

are and how much they can flow.

The solar system will be sized to meet a portion of the hot

water for the structure, but not all of the demand. Typically

this will be between 20% and 70% of the yearly demand for

the structure. There are several reasons for this:

1. There are more sun hours in the summer than in the

winter. Sizing a system to meet the winter demand will

mean that it is much too large in the summer.

2. The weather affects the output of the solar system.

Often, the storage will be large enough to allow solar

energy to be carried over from a sunny day to a cloudy

day, but several successive cloudy days will deplete the

solar storage and require a backup system.

3. Energy produced above what can be used in the building

must be dissipated. This prevents the overheating of

the system and will ensure a long life for all components.

Any energy that must be dissipated will not contribute to

the payback of the system.

DOMESTIC HOT WATER SYSTEMS

Domestic hot water systems are the most common use for

solar thermal energy (Figure 5). They are typically sized

to provide up to 70% of the overall hot water demand for

the structure and the balance is made up by a backup hot

water heater.

The solar collectors are typically mounted on the roof of the

building and plumbed to a heat exchanger that is either

immersed in the tank, or an external plate type. When the

sun shines on the collectors, the solar pump activates and

runs glycol through the collector manifolds. The solar collectors

will raise the temperature of the glycol and this energy is

transferred to the water in the tank via a heat exchanger.

The key information required for sizing these systems is how

much water is used on a daily basis, when it is used and how

much the solar collectors will produce. Determining the hot

water usage is the key factor in the design. The output of

the collectors is simulated in software using historical

weather data from the location that the collectors are going

to be installed, along with calculations based on the usage

pattern of the building. These are critical factors in

determining the number of solar collectors and the size of

the tanks. Information in this section can be used to

approximate the number of collectors and tank size in the

Kingspan Solar has a simple site assessment form that,

once completed, allows our technical team to size, design,

and estimate savings on each project.

Figure 5:HP collectors (standard using dual stream pump)


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KINGSPAN SOLAR

62

GWU, FOGGY BOTTOM CAMPUS, WASHINGTON DC

SIZING GUIDELINES

hot water, so one will have to be added. The simplest way to

measure hot water demand is using an ultrasonic flow meter.

This meter simply attaches to the outside of the cold water

pipe going into the water heater and will log how much

water enters the water heater. The hot water delivery

temperature and cold water temperature complete the data

needed to measure the hot water energy for the building.

A solar system is not designed to provide all of the hot water

which is why a backup system is required. The backup

system should be sized normally because the minimum

contribution of a solar system is zero and the backup system

must insure that all demand is met under all circumstances.

The backup system will not run as often as it would if the

solar system were not there, but during some periods may

have to run at full capacity.There are two ways to determine the demand from a

structure; measurement and estimation. Measuring is the

best way to ensure that the solar system is sized properly.

Most buildings will not have a measurement system for the

Kingspan will assist in the design,

sizing and specification of all

commercial solar thermal systems.

Typical T*SOL report


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KINGSPAN SOLAR

SYSTEM

TECHNICAL

CO

NSIDERATIONS

Ground water temperature:Important for sizing both the

solar collectors and the tanks. This will vary with season

with the highest temperature coming around August and

the lowest in February or March.

Shading:Also greatly affects the output of the collectors.

Any time the collectors are in a shadow, they will not

produce energy. This should be considered early on in the

project, as not all locations are a good fit for solarsystems. The suns path varies greatly depending on the

time of ye

UK Solar Manual Feb 13_LR

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