FPTS 120L & 150L & 200L & 300L

THERMOSIPHON
SYSTEMS
INSTALLATION MANUAL

HARNESSING THE
SUN TO WORK FOR YOU
 ST 37-Sheet , AISI 316L stainless steel flexible heat exchanger
Capacity 120 ltr 150 ltr 200 ltr 300 ltr
Overlay Electro static painted steel
Insulation Polyurethane 50 mm, 42 density
Extra Heater – optional 2000 W. Heater
Net Weight 40 kg 45 kg. 65 kg. 82 kg.
Full Weight 160 kg. 195 kg. 240 kg. 332 kg.
Working Pressure 6 bar
Kingspan Solar FPW Kingspan Solar FPW
Kingspan Solar FPW 18 Kingspan Solar FPW 21
25 21 (2 pcs)
Dimensions 1927 x 927 x 90 mm 1988 x 1041 x 90 mm 1988 x 1218 x 90 mm 1988 x 1041 x 90 mm
Casing Material Electrostatic Painted Aluminium Case
Weight 34 kg 37,2 kg 44 kg 37,2 kg
Sealing Material EPDM & Silicone & Aluminium Frame
Gross Area 1.79 m2 2.07 m2 2.42 m2 2.07 m2
Aperture Area 1.62 m2 1.92 m2 2.24 m2 1.92 m2
Absorber Area 1.62 m2 1.90 m2 2.23 m2 1.90 m2
Absorber Material Alu-Selective Coated
Absorptance 95%
Emittance 3%
Welding Method Laser welding
Diameter of Absorber 8 mm 8 mm 8 mm 8 mm
Tube
Diameter of Header Tube 18 mm 18 mm 18 mm 18 mm

Number of Tubes 9 10 12 12
Glass Material Low Iron Tempered Glass
Transmittance of Glass 91%
Thickness of Glass 4 mm
Insulation Material High Density Rock wool
Density of wool 50 Kg/m3
1000 W/m2 and 30 0C 203 0C
Max. Operation Pressure 10 bar

Test Pressure 20 bar

Pressure Loss 1.6 bar
Back Sheet Embossed - finished Aluminium
Mounting Mode onto-roof, flat roof

2
PRODUCT RANGE

Kingspan Solar thermosiphon systems are available in the following models:

• FPTS 120, 150

• FPTS 200, 300

WARRANTY
Kingspan Solar guarantees the collectors integrated in the system for 10 years and guarantees the boilers for 6 years.
In this document the following symbols
will be found:

ATTENTION: for actions that demand

particular caution and preparation

FORBIDDEN: for actions that MUST NOT BE executed

GENERAL WARNINGS
If any fluid leaks from the tank
or the collector, shut off the main The solar system must be in
electrical supply and contact perfect condition when
immediately with your local dealer. received. If you notice a defect
contact with your local dealer
The solar system must be protected
against freezing by a thermal fluid, The solar system must be installed
that is suitable for solar thermal by a professional installer.
systems.

Verify the minimum outside temperature

that can occur in the installation
location and fill in the right quantity of
thermal fluid (for example -20 ºC
requires 40% propylene glycol to
water).

This document is part of the solar

system and must be kept in good
condition. In case it gets destroyed
or lost, contact your local dealer
to replace it.
FUNDAMENTAL RULES OF EMERGENCY
The thermal fluid used to fill the system
It is forbidden to install the solar must be correctly disposed. Fluid that is
system on the tile or flat roof without discharged from safety valves should
following the general labour rules. be collected in a container.

It is forbidden not to adjust the safety

valves and not check for their correct It is forbidden to intercept or tap the
function close circuit of the solar system

It is forbidden to make any change to

the solar system, to it’s components
or replace parts of the system
without the prior confirmation of
Kingspan Solar.

SYSTEMS DESCRIPTION
The thermosiphon system is a natural circulation system which produces hot water for domestic use. The system
contains all the necessary equipment to function. These are:

-The collector (s)

-The solar tank
-The support structure
-The assembly kit

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ASSEMBLY KIT COMPOSITION

QUANTITIES QUANTITIES
FOR FLAT ROOF FOR ONTO ROOF
DESCRIPTION PICTURE FPTS120L FPTS150L FPTS120L FPTS150L FPTS120L FPTS150L

FPTS200L FPTS300L FPTS200L FPTS300L FPTS200L FPTS300L

0
35 0
0 120

Plug ¾’’, Male 2 2 2

Plug X ¾’’, Female 2 2 2

Cable Tie, 450 X 4,8mm 1 1 1

Safety valve ½”, 4bars 1 1 1

Reducing nipple , 1 1 1
¾” Male/ ½”Male

Nipple,¾" 3 3 3

Connection, T, ¾" 1 1 1
ASSEMBLY KIT COMPOSITION

QUANTITIES QUANTITIES
FOR FLAT ROOF FOR ONTO ROOF
DESCRIPTION PICTURE
FPTS200 FPTS200 FPTS200 FPTS200 FPTS300
FPTS300 FPTS200 FPTS300
45-500 35-400 15 0 12 0 12 0-15 0

Flexible connection, 2970mm - - - - - - - 1

Flexible connection, 2170mm - - - 1 - - - -

Flexible connection, 440mm 1 - - - 1 - - -

Flexible connection, 550mm - - 1 - - - 1 -

Flexible connection, 2010mm 1 - - - 1 - - -

Flexible connection, 370mm - 1 - - - 1 - -

Flexible connection, 2120mm - - 1 - - - 1 -
Flexible connection, 2030mm - 1 - - - 1 - -
Flexible connection, 610mm - - - 1 - - - -

Flexible connection, 2310mm - - - - - - - 1

OPTIONAL

Expansion Tank, 8 Lt 1 1 - 1 1 1 - -

Expansion Tank, 12 Lt
- - 1 - - - 1 1

Automatic Air Vent ½” 1 1 1 1 1 1 1 1

Thermostat 1 1 1 1 1 1 1 1

Heater 1 1 1 1 1 1 1 1

Pressure reducer valve 1 1 1 1 1 1 1 1

Ring 6 6 8 6 6 6 8 8
FPTS 120L, 150L, 200L

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NEW KIT DESIGN
ASSEMBLY KIT COMPOSITION

FPTS 120L, 150L, 200L

PART DESCRIPTION
1 Plug ¾’’, Male
2 Nipple,3/4"
3 Valve, Safety, 4 bar, 1/2 ", the MSV / E (0207540)
4 Reducing nipple , ¾” Male/ ½”Male
5 Connection, T, 3/4"
6 End Cap 3/4" Female
7 Flexible connection,
8 Flexible connection,

3
1
4

2 2

2
5
TANK

6 1

COLLECTOR

7
FPTS 300L

8
NEW KIT DESIGN
ASSEMBLY KIT COMPOSITION

FPTS 300L

PART DESCRIPTION
1 Plug ¾’’, Male
2 Nipple,3/4"
3 Valve, Safety, 4 bar, 1/2 ", the MSV / E (0207540)
4 Reducing nipple , ¾” Male/ ½”Male
5 Connection, T, 3/4"
6 End Cap 3/4" Female
7 Flexible connection,
8 Flexible connection,
9 Flexible connection,

3
1 4

2 2

2
5
TANK

6 7

COLLECTOR COLLECTOR

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 IDENTIFICATION

Kingspan Solar thermosiphon systems are identified by the stickers on the sides of the the collector. On these stickers all
the details of the system are written. The information provided on the stickers are important for the future
identification of the system.

Removing the stickers will make the future identification difficult and will cause problems for the
service and warrantee procedure.

MOVING THE PRODUCT

Kingspan Solar’s thermosiphon system is well packaged in a way that the components will be delivered in good condition.
The packaging of the components should be removed at the place which will be installed.
Before removing the packaging make a final inspection of the system and count the components that were delivered.
Make sure that they are according to the assembly kit composition table.

The installer should follow all the safety rules.

Do not stand on the packed components. There is a possibility to cause a serious damage.

ASSEMBLYING THE SYSTEM

General directions

Assembly directions Risk during filling in the thermal fluid

The assembly of the thermosiphon system The filling-in procedure must be done in
must be done by a specialized technician. All a time that the sun radiation is not very
the components of the solar system are strong.
included in the packaging, as described in a
previous table. The thermal fluid must be mixed with
Before the assembly of the thermosiphon water in a specific quantity.
system check:
a.The good condition of all the components.
b.The exact position of the system and the right In case of cleaning internally the system
orientation. with water, take care that no quantity of
water remains inside the collector. This
In windy or snowy places, extra care must be will freeze and cause permanent
taken for these conditions. For further advice, damage. The collector must be always
contact Kingspan Solar. filled in with anti freeze liquid.

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SYSTEM DIMENSIONS and WEIGHT

FLAT ROOF

BOILER COLLECTOR MOUNTING KIT

Empty Weight (kg)
Dimensions Dimensions Weight
Model Weight Model Unit
(mm) (mm) (kg)
(kg) HP35° LP35°

FPTS 120 Ø 540 x 951 40 FPW18 1927 X 927 X 90 1 34 39,5 40,4

FPTS 150 Ø 540 x 1066 45 FPW21 1988 X 1041 X 90 1 37,2 41,8 43,7
FPTS 200 Ø 540 x 1200 65 FPW25 1988 X 1218 X 90 1 44 44,7 45,5
FPTS 300 Ø 540 x 1725 82 FPW21 1988 X 1041 X 90 2 74,4 49 49,8

ONTO ROOF

BOILER COLLECTOR MOUNTING KIT

Empty Weight (kg)
Dimensions Dimensions Weight
Model Weight Model Unit
(mm) (mm) (kg)
(kg) 0° 12°

FPTS 120 Ø 540 x 951 40 FPW18 1927 X 927 X 90 1 34 22 31,4

FPTS 150 Ø 540 x 1066 45 FPW21 1988 X 1041 X 90 1 37,2 24 33,7

FPTS 200 Ø 540 x 1200 65 FPW25 1988 X 1218 X 90 1 44 27 36

FPTS 300 Ø 540 x 1725 82 FPW21 1988 X 1041 X 90 2 74,4 29 39,5

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 ASSEMBLING THE SUPPORT BASE FOR FLAT ROOF

Shadow line

MODEL
LENGTH
FPTS 200 & FPTS 300
B A x 1,85
C D x 1,50
35 1475 mm
40 1625 mm
D
45 1739mm
50 1878 mm
35 2200 mm
40 2130 mm
E
45 2055 mm
50 1975 mm

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 ASSEMBLING THE SUPPORT BASE FOR FLAT ROOF

1R 2R

1L 2L

Tank Holder Aluminum profile 3R

Nut Screw Mounting Shoe

13
 ASSEMBLING THE SUPPORT BASE FOR FLAT ROOF

14
 ASSEMBLING THE SUPPORT BASE FOR FLAT ROOF

2
1R

2R
3R

1 Screw
Part Name Quantity
29
3
2 Nut 29
3 Tank Holder 2
4 Aluminum Profile 30 x 30 2
5 Mounting Shoe 230 X 40 X 40 4

2 screwed pieces Quantity

3R 30 X 5 mm 1 1L
2060 X 40 X 40 mm 1
1R
460 X 40 X 40 mm 1
2060 X 40 X 40 mm 1
1L
460 X 40 X 40 mm 1
3 screwed pieces
2415 X 40 X 40 mm 1
2R 1080 X 40 X 40 mm 1
700 X 40 X 40 mm
2415 X 40 X 40 mm
1
1
2L
2L 1080 X 40 X 40 mm 1
700 X 40 X 40 mm 1

40°

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ASSEMBLING THE SUPPORT BASE FOR ONTO ROOF

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 ASSEMBLING THE SUPPORT BASE FOR ONTO ROOF

Part Name Quantity 5

Support (Stainless
1 2
Steel)
2 Support (Black Painted) 4
2 3 8 x 60 Wood Screw 18
4 1 Screw 6
5 Screw 4
6 Nut 10
7 Tank Holder 2
1L 2415 X 40 X 40 mm 1
3 1R 2415 X 40 X 40 mm 1
8 Aluminum Profile 2 1

4 8
1L

3
6 5

8 1R

17

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 ASSEMBLING THE SUPPORT BASE FOR ONTO ROOF
Part Name Quantity
1 Support (Stainless Steel) 2
7 2 Support (Black Painted) 4
Installation of collector 3 8 x 60 Wood Screw 18
4 1Screw 6
at 12° + roof angle 5 Screw 12
4 6 Nut 18
7 Tank Holder 2
2415 X 40 X 40 mm 1
1L 2060 X 40 X 40 mm 1
460 X 40 X 40 mm 1
2415 X 40 X 40 mm 1
1R 2060 X 40 X 40 mm 1
460 X 40 X 40 mm 1
8 Aluminum Profile 2
1

3
4
2 8

1L 1
5

6
2 1R

Profile dimensions listed on 1L and 1R will enable position of the

collector to add 12° on the roof angle.

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 ASSEMBLING THE SUPPORT BASE FOR ONTO ROOF
Part Name Quantity
1 Support (Stainless Steel) 2
7 2 Support (Black Painted) 4
Installation of collector 3 8 x 60 Wood Screw 18
4 1Screw 6
at 15° + roof angle 5 Screw 12
4 6 Nut 18
7 Tank Holder 2
2415 X 40 X 40 mm 1
1 L 2060 X 40 X 40 mm 1
540 X 40 X 40 mm 1
2415 X 40 X 40 mm 1
1R 2060 X 40 X 40 mm 1
540X 40 X 40 mm 1
8 Aluminum Profile 2
1

3 4

2 8

1L 1
5

6
2 1R

Profile dimensions listed on 1L and 1R will enable position of the

collector to add 15° on the roof angle.

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 HYDRAULIC CONNECTIONS
Inside the support base’s carton box there
are all the necessary components to
connect the solar system.

A 6 bars safety valve should be connected before

the “COLD WATER”
inlet. This tube is indicated by a blue ring.

To connect the collector with the tank it

needs the two inox flexible tubes (photo 1).

The short tube is used to connect the up- Photo 2

Photo 1 right tube of the collector with the “SOLAR
FLOW” inlet, which is indicated by a red
plastic ring (Photo 2).

The second tube (long) is used to connect

the down-left tube of the collector with the
“SOLAR RETURN” which is indicated by a
blue plastic ring (Photo 3).

To the rest of the collector’s tubes adapt

the brass connectors with the plugs.

ATTENTION: For two collectors models,

the two collectors must be connected
together with the Ø22 X Ø22 unions.

The “HOT WATER” outlet is connected to Photo 3

the house consumption.
ELECTRICAL ELEMENT (optional)

In order to connect the electrical element :

-Unscrew and remove the external cover from the solar tank.
-In models that the electrical element is not standard, the tap
should be removed and adapt the electrical resistance.
-Set the thermostat at the desired temperature. Safety button
Thermostat

A certified electrician must do all electrical connections.

All the connections should be done according to the following
diagram.

ATTENTION: The connection must be done on the

thermostat - NOT directly on the resistance by bypassing
the thermostat. Ph N

The electrical resistance must be connected to the electrical

main, via a dual pole cut-off switch. The distance that
separates the connections must be AT LEAST 3mm wide.

FILL-IN THE SYSTEM

At the upper part of the tank, there are two openings. One of them is for filling-in the thermal
liquid and the other is the exit of the air during the fill-in procedure.

In one of them adapt the safety valve and to the other ,a plug.

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 THERMAL FLUID

Before using the system it is very important to do the

The system must be always full of thermal
following actions.
fluid. The percentage of it should be:
TEST AND FINAL CHECK PERCENTAGE TEMPERATURE C
Check all the pipes of the system for their right %
positioning and that everything seems correct. Check 5 -2
that the brass fittings and the connectors are tightened. 10 -4
15 -5
THERMAL FLUID
25 -10
The system should be filled with PROPYLENE GLYCOL
1,2 . This thermal fluid is used to protect the system 30 -14
against freezing. 35 -17
The thermal fluid must be mixed with water in a 40 -22
percentage that is necessary to protect the system. 50 -32
60 -49
80 -57
This thermal fluid is for solar applications. All of its
characteristics are indicated for this purpose.
The connection tubes must be well-
isolated.
The thermal fluid is non-toxic liquid.

The filling-in of the system must be

Do not use any automatic fill-in system. very slow in order to allow the air to
be removed from the closed loop.

The closed loop must not be under

pressure.

BEFORE USING THE SYSTEM

Before using the system make a final check.

Open all the valves and check for any kind of leakage. Repeat the inspection after 30 minutes.

If any leakage appears contact the installer immediately.

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MAINTENANCE

Once installed the solar water heater will function properly without
any further intervention required by the user.

When you do not use the solar water heater, during the
summer period, cover the collector (s) with a non-transparent
cover.
A normal solar water heater must be serviced every year (the
first service after 2 years). Attend to your local authorized
dealer.
Inspect the glasses of the heater, periodically. Clean them if
there is dust on them. This will keep the efficiency of the
system at high levels.

Any maintenance action executed by a non qualified person it

is prohibited.

CHECK

To complete the installation, please check the following

actions:

DESCRIPTION OK

Collector’s circuit

Verification of safety valves

Verification of connection tubes

Verification of any kind of leakage

Verification of the electrical connection

Verification of the stability of the support base

Verification that all the bolts and nuts are tightly screwed.

TROUBLESHOOTING

PROBLEM DESCRIPTION CAUSE ACTION

Low quantity of thermal fluid Fill-in thermal fluid

Low efficiency of the system
Leakage from the connection tubes Tight the connectors

Dirty glass covers Clean the glass covers

Leakage from the 6 bars safety High main pressure Install a pressure reducer
valve

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