COMPLETE COMMERCIAL SOLAR THERMAL SOLUTIONS TECHNICAL GUIDE
COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
CONTENTS
INTRODUCTION 5 PRODUCT RANGE 31
SOLAR RADIATION ACROSS THE UK & IRELAND 6 SOLAR THERMAL SYSTEMS PRODUCT OVERVIEW 32
HOW IT WORKS: SOLAR THERMAL SYSTEM 7 KINGSPAN SOLAR HEAT PIPE COLLECTORS 34
BUSINESS CASE KINGSPAN SOLAR DIRECT FLOW COLLECTOR 38
• WHY SOLAR THERMAL ENERGY? 8 KINGSPAN SOLAR FRAMES 40 • IS MY BUILDING SUITABLE? 10 VARISOL, AWARD WINNING SOLAR COLLECTORS 42 • MARKET SECTOR APPLICATIONS 12 FLAT PLATE SOLAR COLLECTORS 44 ENGINEERING, SERVICE & SUPPORT 14 UNIQUE FEATURES OF KINGSPAN SOLAR TUBES 46 COMMITTED TO GREEN BUILDINGS 16 • TUBE DESIGN 46 CASE STUDIES 19 • 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 CONTROLS & MONITORING 79
SIZING GUIDELINES 60 SOLAR THERMAL SYSTEM CONTROLS, COMPONENTS & MONITORING 80 COLLECTOR LAYOUT & ITS EFFECT ON THE SYSTEM 72 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR INTRODUCTION
CERTIFICATION & WARRANTY STATEMENT 87 KINGSPAN 97
HEAT PIPE COLLECTORS INSULATED PANELS 98
• HEAT PIPE COLLECTORS 88 BENCHMARK 99 • DIRECT FLOW COLLECTORS 89 INSULATION 100 • VARISOL HEAT PIPE COLLECTORS 90 PRODUCT RANGE • VARISOL DIRECT FLOW COLLECTORS 92 INSULATED DOOR COMPONENTS 101 • HAIL IMPACT TEST CERTIFICATION 93 ACCESS FLOORS 101 • WARRANTY STATEMENT 95 CONSIDERATIONS SYSTEM TECHNICAL CONTROLS & MONITORING
PLEASE VISIT:
www.makethesunwork.com CERTIFICATION & WARRANTY STATEMENT KINGSPAN
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 and improvement, 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 take priority 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. COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
KINGSPAN
Kingspan Environmental is part of Kingspan Group, global leaders in sustainable building products for energy and water efficiency. With manufacturing and 25+ 14million distribution operations worldwide, Kingspan is recognised years knowledge and experience evacuated tubes throughout the construction industry for innovation, to support your business installed worldwide design, quality, technical expertise and service.
Kingspan Environmental offer an array of products and services that provide renewable energy, + water management and environmental solutions. 25 40 offices across countries in Our Kingspan Solar thermal package solutions, Europe which we operate 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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TOTALLY INTEGRATED ENVIRONMENTAL SOLUTIONS
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 world’s 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.
RENEWABLE ENERGY Inspired thinking is at the heart of our renewable energy 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 WATER MANAGEMENT Our high performance environmental Our pioneering brands, Klargester for wastewater and containers are at the forefront of plastics stormwater attenuation, and Kingspan Water for rainwater technology while our award winning telemetry harvesting, offer a portfolio of proven and ground breaking solutions offer affordable level measurement water management technologies. gauges and integrated energy management systems. www.kingspanenv.com As well as remarkable products, we offer world class www.kingspansolar.com consultancy and environmental services, whether it’s a www.kingspanwind.com Kingspan system or not.
3 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
BRISTOL LIDO OUTDOOR POOL, BRISTOL, UK
4 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
INTRODUCTION 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
5 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SOLAR RADIATION ACROSS THE UK AND IRELAND
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 earth’s surface, over a 15 minute period, is more then the earth’s 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 earth’s 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.
6 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
HOW IT WORKS: SOLAR THERMAL SYSTEM
FACTS
Solar thermal technology transforms direct and diffuse A 1 solar radiation into useful heat using a solar collector, which
should face as closely as possible INTRODUCTION to the south at an angle perpendicular to the sun. E
PROCESS 2 D
All components work together to heat water from sunlight: 1 Sunlight hits the solar 4 C collector and heats thermal B transfer liquid passing through it. 2 A pump circulates the heated F thermal transfer liquid from G the solar collector to the 3 water tank coil, where its heat transfers to water within the tank. 3 The pump returns the cooled thermal transfer liquid to the Solar collector A solar collector for reheating. the efficiency and quality of the collector determines the 4 When needed, a back-up heat performance of the whole source, such as a boiler, system. on-demand water heater, or electrical immersion Pump station B element, boosts the tank C Hot water storage tank water to the desired D Back-up heat source temperature before it is distributed to its end use. E Hot water distribution system The differential temperature controller monitors and F Solar controller regulates the circulation rate G Expansion tank 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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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:
REDUCE YOUR ENERGY BILLS SUPERIOR SYSTEM PERFORMANCE MARKET-BASED INCENTIVES
Cost effective: economical, mitigates Provides up to 96% solar energy Government incentives, for example future energy shortages and price absorption with 5% emmissivity. the Renewable Heat Incentive (RHI). increases. Generates heat energy even on A solar hot water system can be cash Immediate and permanent savings. overcast and cloudy days. flow positive from day one. Enjoy FREE hot water all year round. High performance, tailored solutions A domestic solar hot water system for hot water, central / space heating can last in excess of 25 years and and pool applications across a wide pay for itself many times over. range of building sectors. Safe, reliable, durable and time-tested with a design life of over 30 years. Rapid installation and low maintenance.
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NATIONAL INCENTIVE SCHEMES INTRODUCTION NATIONAL TAX CREDITS
GROSS SYSTEM NET SYSTEM COSTS COSTS*
* Dependent on available incentives
ENVIRONMENTALLY FRIENDLY ACCESSIBILITY AND SECURITY
Non-toxic systems. Security: the price of solar energy Non-polluting: solar hot water does not fluctuate. generation produces no greenhouse Instant distribution: there are no gas emissions. expensive transportation costs for Non-consumptive: the suns radiation solar energy because the sun shines is a limitless resource. everywhere. Going ‘green’ for commercial projects has now become a PR advantage.
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BUSINESS CASE: IS MY BUILDING SUITABLE?
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:
Limiting Hot water, Location / Roof pitch / Orientation factors, Roof area heating and/or insolation level slope e.g. shading cooling demand
KINGSPAN SOLAR TECHNICAL SERVICE
The checklist opposite provides an example of a typical site assessment. To assist you further, Kingspan Solar offers a simple site assessment form (right) that, once completed, allows our technical team to size, design, and estimate savings on your project.
10 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR INTRODUCTION
11 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
BUSINESS CASE: MARKET SECTOR APPLICATIONS
Leisure – Hotels, camping Process and LEISURE grounds, health clubs, Manufacturing – Drying, spas, and water parks. industrial cooking, Medical Facilities – pasteurisation, and Hospitals, clinics and chemical manufacturing. retirement homes. Office. Education – Schools, Sports Facilities. colleges, universities, and Swimming Pools and campus accommodation. Water Parks. Residential – Apartment complexes.
SWIMMING POOLS AGRICULTURE
RETAIL OFFICE
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Commercial, industrial, and agricultural businesses using HEALTHCARE HOTEL a high volume of hot water INTRODUCTION
APARTMENTS HOUSING
EDUCATION UTILITIES
HOME AND SMALL BUSINESSES: Dish and laundry washing. Swimming pools. Baths and showers. Space and radiant floor heating.
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ENGINEERING, SERVICE & SUPPORT
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.
Energy Cost and Proposal Project assessment Installation Commissioning payback review and design concept and system training support proposal approval specification
Kingspan Solar Service
FULL-SERVICE ENGINEERING Each project is tailored to the exact specifications of the We can provide project specific Auto CAD schematics and individual brief and objectives. This means providing roof layouts along with individual reports produced for world-class design consultancy, engineering expertise and each project. comprehensive advice from initial site visit and assessment We offer a fast, project specific, tender bid and specification to detailed design drawings and concepts, delivery and service. We use T*Sol & Polysun, the world renowned solar installation support. simulation software, for system sizing. We create a system tailored to the unique specifications of Call +44 (0) 28 38364500, to speak with one of our team, your building and/or business, be it domestic, commercial or or go online to submit an inquiry at www.kingspansolar.ie or industrial, in any country. www.kingspansolar.co.uk, and we’ll respond to your inquiry At Kingspan Solar, we offer our customers over 25 years of with tailored solutions. solar thermal expertise and experience to supply technical designs and cost effective solutions on all projects.
Example schematics as supplied by the Kingspan Solar Design Team
14 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR INTRODUCTION
GUINNESS BREWERY, DUBLIN, IRELAND
CUSTOMER SERVICE WARRANTY Our dedicated team provides focused customer service The 20 year warranty on our evacuated tubes reinforces our including delivery scheduling and installer support, ensuring confidence in the quality and longevity of the product. a seamless, well co-ordinated customer experience. Please refer to our terms and conditions in the section “Specification and Warranty Statement”, page 89. To ensure high levels of satisfaction, we conduct customer surveys 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 installation process as well as advice on operation and maintenance.
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COMMITTED TO GREEN BUILDINGS
IN MARCH 2007, THE HEADS OF STATE AND THE ROUTE TO NET-ZERO ENERGY BUILDINGS GOVERNMENT OF THE 27 EU COUNTRIES Kingspan solar thermal systems offer outstanding performance and durability, providing a valuable contribution ADOPTED A BINDING TARGET OF 20% FINAL to a buildings overall energy efficiency and carbon reduction ENERGY CONSUMPTION FROM RENEWABLE targets on the route to ‘net-zero energy’. ENERGY BY 2020. Attaining this goal requires that buildings be energy efficient and include a means of producing energy from renewable resources.
Education
Apartments
Healthcare
Office
Commercial & industrial
Retail
Leisure
Processing
EEMs -CO2
ENVELOPEFIRST™ ENERGY EFFICIENCY INSULATE & GENERATE NET-ZERO ENERGY Highly insulated building MEASURES (EEMS) EnvelopeFirst™ + integrated BUILDINGS envelope. Building services and controls. renewable technologies, Optimised energy efficient e.g., Kingspan Solar. buildings that are energy neutral over the course of a year.
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DESIGNING GREEN BUILDINGS
BREEAM T*SOL BREEAM sets the standard for best practice in sustainable All systems should be building design, construction and operation and assesses the designed using computer environmental performance of any type of building, new and software to predict the INTRODUCTION existing. BREEAM is used in a range of formats from country overall system performance. specific schemes, adapted for local conditions, to The computer software used international schemes intended for the certification of by Kingspan, T*SOL, is third individual projects anywhere in the world. party software that utilises A number of Government departments or other public weather data from various bodies either require or encourage the use of BREEAM. locations across the UK and Ireland, collected every hour
SECTION WEIGHTING for a typical year at that location. The software also considers the load Category Part 1: Part 2: Building Part 3: Asset rating management rating Organisational rating patterns and tank sizes to accurately size these parts of a Energy 26.5% 31.5% 19.5% system. Collector performance is predicted using data taken from the Solar Keymark ratings that are used in Europe. Water 8.0% 5.5% 3.5% Materials and waste 13.5% 7.5% 16.0% The overall report produces a good picture of how a system Health and Wellbeing 17.0% 15.0% 15.0% is going to perform during a typical year. Below are typical Pollution 14.0% 13.0% 10.5% calculations output by T*SOL.
Transport 11.5% – 18.5% SOLAR ENERGY CONSUMPTION AS A PERCENTAGE OF TOTAL CONSUMPTION 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 ****** DAILY MAXIMUM COLLECTOR TEMPERATURE
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COMMITTED TO GREEN BUILDINGS
OUR COMMITMENT TO SUSTAINABILITY “Energy efficiency and environmental sustainability Kingspan’s primary contribution to meeting our global are at the forefront of our thinking.”
environmental challenges is to design, develop and supply Gene M. Murtagh, Chief Executive, Kingspan Group. new systems and solutions in a highly responsible and efficient manner. integrated, more efficient, faster and safer. Kingspan always Kingspan has set ambitious targets for reducing the effects selects materials and systems to minimise the overall of our operations and products on the environment. In fact, ecological impact of buildings. we have embarked on our own Net Zero Initiative, which in VISION essence aims to have all facilities running on entirely “To be a global leader in sustainable business and establish renewable power by 2020. We continue to further our a leading position in providing sustainable, renewable and engineering research and development programs to affordable best practice solutions for the construction sector.” maximise the life cycle performance and end of life procedures of every product we manufacture. SUSTAINABILITY POLICY Striving for sustainability in all our business products and Through its employees, Kingspan instills an environmental operations is our corporate and personal responsibility. awareness and responsibility that is reflected in the concept, Kingspan Solar aims to adopt and apply best practice design, development and production of all its products sustainability principles by ensuring environmental, social and services. and economic parameters are considered in an integrated Kingspan promotes the use of construction techniques that way in product and service delivery. To this end, Kingspan respect the environment in terms of manufacturing, Solar will: transportation, site installation, waste and end-of-life. Incorporate the ethos of sustainability into the vision and We believe these construction methods are better values of the organisation. Continually improve operational performance through the
Packaging setting of long-term objectives and targets related to sustainability and review progress regularly. Distribution Comply or exceed applicable legal and policy requirements related to the environmental and social aspects of the organisation. Manufacturing 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 Usage sustainability issues and are fully involved in helping deliver the Sustainability Vision & Policy.
Materials Disposal
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CASE STUDIES
BRISTOL LIDO SPA & SWIMMING POOL BRISTOL, UK INTRODUCTION
LOCATION Bristol, UK Bristol Lido, the oldest lido in the country, has been APPLICATION Domestic hot water and pool heating transformed into a model of energy efficiency following CLIENT Bristol Lido / Solarsense a two-year restoration. PRODUCT 720 Kingspan Solar Heat Pipe tubes The complex, including a 24-metre open-air swimming pool, SAVINGS Estimated associated fuel savings now features 720 Kingspan Solar Heat Pipe evacuated of over £2201 per annum tubes which generate up to 70% of the lido’s 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 “SAVING UP TO 70% of research into sustainable energy options ahead of the restoration and Kingspan Solar’s Heat Pipe collectors were OF ANNUAL HOT the obvious answer. They tick all the boxes and far surpass the competition in terms of delivering premium performance WATER NEEDS” matched with financial benefits.
The Heat Pipe collector enable the cost-effective heating of water, whilst helping reduce carbon emissions in the process.
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CASE STUDIES
DAIRY FARM TEIFI VALLEY, WALES, UK
LOCATION Pembrokeshire, Wales, UK An organic dairy farm in Pembrokeshire, has found the APPLICATION Domestic hot water perfect sustainable solution to its hot water needs.
CLIENT Hywel James / Llani Solar Ltd The 500 acre farm, which houses a large organic dairy herd, PRODUCT 180 Kingspan Solar Heat Pipe evacuated tubes has installed 180 Heat Pipe evacuated tubes to generate PRODUCTION 10,000 kWh per annum enough hot water to meet its demanding cleaning SAVINGS £1,500 requirements.
These high performance solar thermal collectors not only generate up to 70% of the farm’s annual hot water needs, they also deliver a dramatic reduction in its energy costs and carbon emissions. “PRODUCES 10,000 kWh Hywel James, who runs the farm in Pembrokeshire’s Teifi PER YEAR SAVING Valley, needed to find a way to heat 500 litres of water to 90°C on a daily basis in order to clean the plant and its AROUND £1,500” 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 the farm, producing around 10,000 kWh of heat per year with annual savings of around £1,500.
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CASE STUDIES
LEEDS METROPOLITAN UNIVERSITY LEEDS, UK INTRODUCTION
LOCATION Headingley, Leeds, UK In preparation for the new intake of freshers, Leeds APPLICATION Domestic hot water and space heating support Metropolitan University has unveiled a brand new CLIENT University Partnerships Programme (UPP) development of high quality purpose-built student flats. PRODUCT 720 Kingspan Solar Heat Pipe tubes In keeping with its ethical and environmentally sustainable SAVINGS Estimated associated fuel savings ethos, the six new cluster blocks feature 72m2 of Kingspan of circa £2000 per annum Solar’s Heat Pipe evacuated tubes.
These superior performance solar thermal collectors not only generate up to 70% of each building’s annual hot water requirements, but also provide central heating support, resulting in a dramatic reduction to both carbon emissions “SAVING UP TO 70% and energy costs. OF ANNUAL HOT Carnegie Village is a £26m development situated on Headingley campus, a self-contained student community in WATER NEEDS” 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.
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CASE STUDIES
LEICESTER COLLEGE LEICESTER, UK
LOCATION Leicester, UK Leicester College, which is one of the largest in the UK, APPLICATION Domestic hot water is one of the first in the country to adopt evacuated tube CLIENT Leicester College collector technology to service its hot water needs as part PRODUCT 300 Kingspan Solar Heat Pipe tubes of its commitment to sustainability. SAVINGS Up to 70% of hot water 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 “SAVINGS OF UP TO all-year-round. 70% OF HOT WATER” “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.
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CASE STUDIES
ST. JAMES’ HOSPITAL DUBLIN, IRELAND INTRODUCTION
LOCATION NPRO Building, St. James’ Hospital, Dublin Kingspan solar thermal range has been used as part of APPLICATION Domestic hot water a €28m project to build a new three storey multi-discipline CLIENT Health Service Executive facility. The new NPRO Building will provide treatment INSTALLER Haughton & Young Mechanical Contractor areas, staff accommodation and training suites at PRODUCT 48m2 Kingspan Solar Heat Pipe tubes 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 “THE SYSTEM PERFORMS enhancement of green sustainability credentials. EXTREMELY WELL AND WE “The system has performed extremely well and we are delighted with the results to date even considering the ARE DELIGHTED WITH THE relatively poor year we have had weather wise. Again this relates back to what we were told initially that evacuated RESULTS” tube performance will not be compromised too much in cloudy weather due to their ability to perform well in diffused sunlight.”
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CASE STUDIES
BREFFNI PARK STADIUM IRELAND
LOCATION Cavan, Ireland As part of a L300,000 renovation, Kingspan Breffni Park APPLICATION Domestic hot water Stadium became the exclusive home to the first-ever CLIENT Breffni Park Stadium Kingspan Solar fresh-water module system. PRODUCT 300 Kingspan Solar Direct Flow tubes Reducing carbon emissions, hot-water costs and with PAYBACK < 6 years 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 “SAVING US OVER generated by the system to heat our radiators. k4,000 A YEAR” Again saving us money!’’ Kieran Callaghan, Chairman of Kingspan Breffni Park committee
As part of the renovation project, Kingspan Environmental’s, 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.
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CASE STUDIES
NOTTINGHAM TRENT UNIVERSITY NOTTINGHAM, UK INTRODUCTION
LOCATION Clifton Campus, Nottingham, UK A multi-million pound new build development at Nottingham APPLICATION Domestic hot water Trent University is benefiting from a major installation of CLIENT University Partnerships Programme (UPP) 3960 Kingspan Solar Heat Pipe evacuated tubes, in what is INSTALLER MG Renewables one of the UK’s largest ever solar thermal projects. PRODUCTION 33,000 litres of hot water per day The new Clifton Campus student accommodation was built using PRODUCT 3960 Kingspan Solar Heat Pipe tubes the University Partnerships Programme’s (UPP) Eco Residence
SAVINGS Estimated associated fuel savings Model for sustainable development to considerably cut CO2 of over £1000 per annum emissions and meet strict government targets.
Solar specialists MG Renewables specified 132 Kingspan Solar evacuated tube collectors, covering over 6,000ft2 of roof area “DELIVERING 33,000 LITRES across 12 accommodation blocks to service the hot water needs OF HOT WATER PER DAY” 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 CO2 emissions.
“People think the weather in the UK and Ireland isn’t suitable for solar power to work well, but that is a myth. Solar energy systems such as Kingspan Solar’s work even on overcast days.’’
Gerry Kennedy, Director, MG Renewables, Nottingham.
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CASE STUDIES
SCOTTISH SEABIRD CENTRE SCOTLAND, UK
LOCATION North Berwick, East Lothian, Scotland, UK A leading tourism attraction and independent charity, the APPLICATION Hot water for kitchen and cafeteria Scottish Seabird Centre offers visitors an interactive CLIENT Scottish Seabird Centre experience with a Discovery Centre, gift shop and café. INSTALLER Glendevon Energy The 9m2 installation of Kingspan Solar’s Heat Pipe evacuated PRODUCT 90 Kingspan Solar Heat Pipe Tubes tube collectors is helping to dramatically reduce energy
SAVINGS 6MWh and 1,600kg CO2 per year costs and CO2 emissions as part of the Centre’s 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 “PRODUCING 6MWh 70% of the annual hot water for the cafeteria and kitchen. PER YEAR” “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 Centre’s hot water needs.’’
Jamie Adams, Director, Glendevon Energy.
The installation is expected to contribute 6MWh to the Centre’s hot water system each year, helping to avoid more
than 1,600kg of CO2 emissions in the process.
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CASE STUDIES
HURST PARK COURT CARE HOME, LIVERPOOL, UK & FAIRWAY VIEW CARE HOME, NOTTINGHAM, UK INTRODUCTION
LOCATION Huyton, Liverpool and Bullwell, Nottingham, UK A major project to build 35 care homes over a two-year APPLICATION Hot water, including 82 en-suite bedrooms period has kicked off with the installation of 300 Kingspan CLIENT LNT Construction - Ideal Care Homes solar thermal Heat Pipe tubes across two sites in Liverpool INSTALLER Solar Save UK - Kingspan Solar Accredited Installer and Nottingham. PRODUCTION 16.71 MWh per annum across two sites LNT Construction specified Heat Pipe tubes to help provide PRODUCT 300 Kingspan Solar Heat Pipe tubes hot water for the homes, and comply with SBEM and Part L SAVINGS Average savings of over £1000 per annum 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. “SAVING 3,242KG LNT Group Mechanical Engineer, Tom Nutt, said, “When looking to integrate solar thermal technology into the project, OF CO2 EMISSIONS” we wanted to be able to provide readily available hot water for residents all year round. After Kingspan’s 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. What’s more, the tubes were installed by Solar Save UK, a Kingspan Solar Accredited Installer, which means we’re able to benefit from a 20 year warranty as well as top quality workmanship.”
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CASE STUDIES
CHANGI INTERNATIONAL AIRPORT SINGAPORE
LOCATION Singapore Singapore Changi International Airport, a major aviation APPLICATION Food preparation, cooking, washing and hub in Southeast Asia has installed one of the largest solar staff showering thermal systems in Southeast Asia. The installation uses CLIENT Singapore Changi International Airport more than 10,000 Kingspan Solar evacuated tubes. INSTALLER Connections International Pte Ltd Commissioned in 1996, the system comprises 350 evacuated PRODUCT 10,500 Kingspan Solar Heat Pipe Tubes tube solar thermal collectors to heat 66,000 litres of water SAVINGS Up to h 50,000 per year on electricity bill 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 “SAVING UP TO washing at in-flight catering centre in Changi International k50,000 PER YEAR ON Airport Services (CIAS). ELECTRICITY BILL.”
28 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
CASE STUDIES
CLIFF HOUSE RESORT & SPA MAINE, USA INTRODUCTION
LOCATION Ogunquit, Maine, USA Committed to sustainability and preserving the APPLICATION Domestic hot water and space heating environment, the 5 star Cliff House Resort & Spa has CLIENT Cliff House Resort & Spa installed one of Maine’s largest solar thermal systems. INSTALLER Nelson & Small Energy Conservation The installation uses 2,100 tubes on 70 collectors. Products, Inc. This solar installation will save an estimated 50,000 litres of PRODUCT 70 Heat Pipe collectors propane annually and reduce greenhouse gas emissions by PAYBACK < 6 years more than 63.5 tonnes per year.
Solar energy will be used to provide heat and hot water for the Resort’s 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 “SYSTEM PAYBACK the U.S. Department of Agriculture, as well as federal tax credits, helped offset project costs and reduce payback to LESS THAN 6 YEARS.” 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 solar thermal solution.
29 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
ROBY LODGE CARE HOME, LIVERPOOL, UK
LONGFIELD ACADEMY FOR ARTS & SCIENCES, KENT, UK
30 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
PRODUCT RANGE
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 PRODUCT RANGE
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
31 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SOLAR THERMAL SYSTEMS PRODUCT OVERVIEW
WE OFFER A RANGE OF SOLAR THERMAL SOLUTIONS TO SUIT EVERY APPLICATION.
KINGSPAN SOLAR EVACUATED TUBE COLLECTOR KINGSPAN SOLAR'S UNIQUE VARISOL DESIGN The Kingspan Solar collector is the most efficient, longest World leading evacuated tubes and a new click-fit design, lasting solar collector on the market today. Made in Europe combine to make the world’s first modular solar thermal since 1982, our evacuated tubes have withstood the test collector. of time. Varisol technology provides Each collector consists of a highly insulated manifold and a a modern and adaptable series of evacuated tubes. The vacuum inside each tube alternative to traditional provides perfect insulation, protecting the system from rigid manifold systems. outside influences, such as cold and windy weather or high Its precise sizing and humidity. modular flexibility means it can be sized to the exact Highly efficient – super fast heat transfer requirements of the end Ease of installation and maintenance user, so they only use and Available in Direct Flow (DF400) and Heat Pipe (HP400 pay for what is needed for and HP450) options ultimate results. ‘Plug and play’ design It is completely expandable so customers can grow their solar systems as their needs change.
INSTALLATION COULDN’T BE EASIER
Insert Varisol tube... rotate down...
click into position.
32 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
FLAT PLATE COLLECTOR SYSTEM COMPONENTS Kingspan also offers a range of durable and very efficient Kingspan also supplies a range of flat plate collectors to meet the needs of a wide range of components in order to provide complete applications from small residential systems to large scale solar thermal solutions, including: commercial installations. Pump Stations Robust, durable and high performance, our flat plate panels Pump Stations contain a circulating pump deliver excellent levels of efficiency combined with flexibility that circulates the heat transfer fluid in installation. 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. PRODUCT RANGE
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 fluid expansion 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.
33 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
KINGSPAN SOLAR HEAT PIPE COLLECTORS
Manifiold (glycol)
Condenser
Steam
Heat Pipe
Figure 1: How a Heat Pipe works.
HOW IT WORKS An absorber plate is located inside a glass tube where a The heat pipe is a very efficient method of transferring vacuum is pulled to keep the losses to the environment as the energy from the tubes to the glycol in the manifold. low as possible. 99.999999% of the air is removed from Each tube plugs into a dry socket in the manifold where the inside the glass enclosure during the manufacture of the glycol runs past it. This allows for individual tubes to be tubes to mimimize heat loss. The heat pipe is the method of removed from the system without having to drain the glycol. heat transfer from inside the tube to the manifold, where a The system can also be commissioned, flushed and filled water glycol mixture flows past the condenser heat at the prior to inserting the tubes into the collectors, an important top of the heat pipe and pulls the energy away. point for large systems that need to be commissioned before a building is occupied. When the time comes, simply On the back of the copper absorber plate is welded a small insert the tubes into the system and it is ready to produce copper tube. This tube is sealed at the bottom and, before it hot water. 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 °C Dry socket instead of its usual 100°C. The absorber plate collects energy from the sun and becomes hot, causing the water in Manifiold (glycol) 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).
34 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
The manifold itself is formed from heavy duty aluminum Cover extrusions on the front and back. Inside is the condenser Melamine Foam Insulation manifold where the heat transfer occurs between the Condenser Manifiold condenser and the glycol flowing past. To install the tubes Condenser Socket 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 becomes hot 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. End
Connection PRODUCT RANGE
Retaining Strip
TiNOx Selective Coating Soda Lime Glass Flexible Neck Condenser Head
Rubber End Vacuum Area Copper Getter Heat Pipe Bumper Absorber Plate
The image above shows the other key components of the If the vacuum is lost in one of the tubes, the getter will turn heat pipe tube. The getter is a layer of barium that is white to indicate this. The TiNOx coating used on the tubes deposited on the inside of the tube after the vacuum is is designed to absorb 96% of the sun’s energy that strikes it drawn. This protects the vacuum over time from any air while emitting only 4% back to the environment. This is molecules that may make their way through the glass. currently the best available coating for solar collectors.
35 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
KINGSPAN SOLAR HEAT PIPE COLLECTORS
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. Normal operation We offer two options for the unique temperature limitation device. When the temperature rises to 90˚C/135˚C, 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 90˚C/135˚C, 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 Limiting are required for the purpose of wash downs, process heat, etc. The HP400 range is temperature designed for applications that require a lower input water temperature such as washing and showering needs.
36 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
CERTIFIED EFFICIENCIES HP400 / HP450 2m2 3m2 Keymark Keymark Number of tubes 20 30 Aperture Absorber Dimensions
2 η0 0.750 0.794 Absorber Area (m ) 2.01 3.021 Overall Dimensions (mm) 1952 x 1418 x 93 1952 x 2127 x 93 a1 1.18 1.25 Width of Manifold (mm) 1418 2127 a2 0.010 0.010 Length (tube and manifold) (mm) 1952 1952 Depth (mm) 93 93 Heat Pipe Collector Efficiency Aperture Area (m2) 2.16 3.23 Fluid Volume (ltr) 1.2 1.7 0.9 Inlet and Outlet Dimensions (mm) 22 22 0.8 Weight (empty) (kg) 48 71 0.7 Mounting 0.6 Recommended Inclination (˚) 20-70 20-70 PRODUCT RANGE 0.5 Performance Data 0.4 Efficiency (-) Efficiency Based on Aperture Based on Aperture 400 W/m2 0.3 600 W/m2 Eta 0 0.75 0.75 0.2 800 W/m2 a1 (W/m2K) 1.18 1.18 1000 W/m2 0.1 a2 (W/m2K2) 0.0095 0.0095 0 Solar Keymark Licence Numbers HP400: 011-751793 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Operating Data Collector Temperature (˚C) Flow 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 5 Mounting Frame and Clips Stainless Steel, Stainless Steel, Aluminium, EPDM Aluminium, EPDM Glass Low Iron - Transm. 0.92 Low Iron - Transm. 0.92 Vacuum <10-6 mbar <10-6 mbar Temperature Limitation (˚C) 90 / 135 90 / 135 Quality Certification / Solar Keymark Yes Yes
37 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
KINGSPAN SOLAR DIRECT FLOW COLLECTOR
HOW IT WORKS DIRECT FLOW COLLECTORS ARE AVAILABLE IN Direct flow solar collectors consist of a row of solar tubes 2 DIFFERENT SIZES and a highly insulated manifold. The heat medium to be DF400 heated is passed down through the collector tube within 2m2 3m2 a coaxial heat exchanger. The vacuum inside each tube Number of Tubes 20 30 provides perfect insulation and therefore protects the Dimensions system from outside influences such as cold and windy Absorber Area (m2) 2.010 3.021 weather or high humidity. This vacuum insulation also Overall Dimensions (mm) 1952 x 1418 x 93 1952 x 2127 x 93 ensures that the energy collected from the sun is very Width of Manifold (mm) 1418 2127 efficiently and effectively transferred into usable heat. Length (tube and manifold) (mm) 1996 1996 Depth (mm) 97 97 THE VERSATILE SOLUTION Aperture Area (m2) 2.15 3.23 The flexible installation options of direct flow collectors Fluid Volume (ltr) 3.6 5.6 provide the perfect solution when the ideal position on the Inlet and Outlet Dimensions (mm) 22 22 building is not available. Weight (empty) (kg) 51 78 Mounting Direct flow systems can be installed on a pitched or Recommended Inclination (˚) 0-90 0-90 horizontal surface, and the tube can be rotated 25˚ to Performance Data Based on Based on compensate for installations that deviate from south. Aperture Aperture As the collector is a fully pumped unit, there is no minimum Efficiency angle for the collector. Eta 0 0.773 0.779 a1 (W/m2K) 1.43 1.07 This makes it most suitable for installations where the a2 (W/m2K2) 0.0059 0.0135 product needs to be installed below 20˚ or above 70˚. Solar Keymark Licence 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 Selective Coating Coating Absorbance (%) 95 95 Emissivity (5) 5 5 Mounting Frame and Clips Stainless Steel, Stainless Steel, 1 Ideal slope 40˚ Aluminium, Aluminium, 2 Roof kit angled 40˚ EPDM EPDM 3 Elevated 20˚ Glass Low Iron - Low Iron - Transm. Transm. 4 Horizontal ideal slope 0.92 0.92 5 Horizontal façade Vacuum <10-6mbar <10-6mbar 6 Flat Quality Certification / Yes Yes 7 Vertical façade Solar Keymark
38 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
Direct Flow Collector Efficiency Rubber end bumper
0.9 TiNOx selective coating 0.8 Soda lime glass 0.7 Vacuum area 0.6 Copper absorber plate 0.5 Getter 0.4 Efficiency (-) Efficiency 400 W/m2 0.3 600 W/m2 0.2 800 W/m2 2 0.1 1000 W/m 0 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Collector Temperature (˚C) RANGE PRODUCT
THE ROYAL DANISH ACADEMY OF FINE ARTS SCHOOL OF ARCHITECTURE, COPENHAGEN, DENMARK
39 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
KINGSPAN SOLAR FRAMES
SYSTEM COMPONENTS
Manifold Tube Retainer
Evacuated Tubes
Frame
Connection Kit
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 connections at the end of the manifold use a redundant the proper angle. All Kingspan frames are made from double o-ring seal to allow for expansion and contraction, extruded aluminum supports and stainless steel hardware if multiple manifolds are connected in series. The connection for the ultimate durability. Frames are supplied partially kit provides the adaptors necessary to adapt this to 22mm assembled with all clips in the correct locations and legs copper pipe at the end of bolted together, facilitating fast and accurate installation. collector banks. Connecting multiple Mounting the frame to the roof is another area that requires collectors is easy with the particular attention. The mount will depend on the type of roof interconnection kit. One and exactly how the collectors are to be mounted. Kingspan end of the manifold simply Solar offers a wide variety of mounting hardware and provides slides into the other and the experience to select the correct system for the application. the interconnection kit From asphalt shingle, to tile, to EPDM, we can help you choose provides the hardware to the correct mounting hardware for the application. properly align these end fittings.
40 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR PRODUCT RANGE PRODUCT
APARTMENT BLOCKS, GERMANY
CLIFF HOUSE RESORT & SPA, MAINE , USA
41 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
VARISOL, AWARD WINNING SOLAR COLLECTORS
THE REVOLUTIONARY NEW DESIGN OF VARISOL OFFERS A MODERN AND FLEXIBLE ALTERNATIVE TO THE RIGID MANIFOLD SYSTEM.
ADDITIONAL BENEFITS Delivering all the benefits of Kingspan Solar’s 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.
A copper pocket is over-moulded into the TECHNICAL SPECIFICATION DF HP polymer header to house the condenser Dimensions (mm) 1950 x 70.9 x 70.9 1965 x 70.9 x 70.9 and ensure a dry connection of the tubes. 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)
“Quick and easy to install, Varisol allows individual tubes to be simply clicked together to create solar collectors of varying sizes.”
42 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR PRODUCT RANGE PRODUCT
RETIREMENT HOME, ITALIAN ALPS
“This versatile product provides the perfect solution when the ideal position on the building is not available.”
43 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
FLAT PLATE SOLAR COLLECTORS
HOW IT WORKS Flat plates are a very simple method for capturing the environment. On the front side of the panel is a plate of glass energy form the sun and turning it into hot water. A copper that the sun shines through. The glass also provides insulation plate is coated with a special coating that absorbs as much for the collector plate from the cold environment outside. of the sun’s radiation as possible. On the back of this plate A frame around the outside holds everything together and are a series of tubes that are welded directly to the back of keeps moisture out. the plate. Glycol flows from a manifold on one end of the collector to another manifold at the other end. As it passes Both ends of the manifolds have union fittings that allow for through the tubes on the back of the plate, it is heated by a connection kit to be attached, or another panel. For arrays the energy that the plate has absorbed from the sun. of multiple collectors, one collector simply screws into the next and seals with a flat washer. A plug is screwed into one To keep as much energy in as possible, the collector plate is end of each of the manifolds and the connection kit added to surrounded on five sides by insulation. This insulation prevents connect up an array of collectors. the loss of energy from the hot plate to the surrounding
“Kingspan offers three sizes of flat plate. This allows for optimal placement of the panels on the roof and significant flexibility in the output of the system.”
44 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR PRODUCT RANGE PRODUCT
GUATEMALA
KEY FEATURES SPECIFICATION / TYPE FPW25 FPW21 FPW18 There are many flat plate products on the market today, Dimensions (mm) 1988 x 1218 x 90 1988 x 1041 x 90 1927 x 927 x 90 differing significantly in terms of design, construction Weight (kg) 44 37.2 34 quality, performance and size. Kingspan flat plate collectors Sealing Material EPDM & Silicone & Aluminium Frame offer high efficiency, combined with robust design and Gross Area (m2)2.422.071.79 2 construction, providing solar thermal systems that are Aperture Area (m ) 2.24 1.92 1.62 Absorber Material Almeco Tinox Highly Selective Aluminium designed to last and perform for many years. 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
2 k1 (W/m K) (1st heat loss 3.722 coefficient - A1a)
2 2 k2 (W/m K ) (2nd heat 0.012 loss coefficient - A2a) Stagnation Temperature 203˚C at 1000 W/m and 30˚C
45 COMPLETE SOLAR THERMAL SOLUTIONS 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 sun’s 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 and hydraulic fittings are housed inside the cavity of an open ended flask.
Heat Pipe Tube Cross Section Sydney Tube Cross Section
Low-iron content Borosilicate glass soda lime glass
Selective coating Selective coating
Vacuum
Copper heat pipe Copper absorber fin
Copper heat pipe Borosilicate glass
Absorber plate Vacuum
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 tube’s components and they will not corrode.
46 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
CARPE, SOUTH AFRICA PRODUCT RANGE PRODUCT
BENEFITS
There are three core objectives - The Hail Impact Test Performance Kingspan Solar's evacuated tubes are one of the few tubes Longevity from the major solar thermal manufacturers to have passed Consistency this European trial that is covered under EN 12975-2 These main objectives are fulfilled through the following: specification.
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 Shot impact point 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.
47 COMPLETE SOLAR THERMAL SOLUTIONS 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.
48 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
UNIQUE GLASS TO METAL SEAL SUPERIOR VACUUM The seal between the glass and the heat pipe where the pipe The vacuum and its insulation properties are the most emerges from the neck of the tube is critical to maintaining important elements of an evacuated tube. The vacuum is the vacuum and its insulation properties. The tubes feature a drawn to 1x10-6 mbar, signifying that 99.9999999% of the air patented hermetic seal that fuses metal and glass together. is removed from the tube. It is extremely difficult to remove The two materials are bonded so the seal remains intact this much air from any space in a commercial production under all operating conditions. 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 RANGE PRODUCT 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 Unique glass to metal seal Kingspan Solar tubes contain one of the best vacuum levels on the market.
Inferior product mechanical seal
49 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
EVACUATED TUBE COMPARISONS
KINGSPAN SOLAR EVACUATED TUBES LAST LONGER AND PERFORM BETTER THAN ANY OTHER EVACUATED TUBE ON THE MARKET.
In the following section, competitor’s 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
HIGH QUALITY HEAT PIPE SEAL Kingspan Solar Tube Competitor tube ✗
Heat pipe sealed with spin closing and TIG weld. Double protection with 100% automated Heat pipe sealed with inspection. a plug.
50 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
FLEXIBLE NECK Kingspan Solar Heat Pipe Tube Competitor tube ✗
High quality flexible stainless steel neck (relieves stress on the glass to metal seal with high quality, UV stable EPDM rubber flange. Stiff neck technology stresses the glass / metal seal. PRODUCT RANGE PRODUCT
TEMPERATURE LIMITATION DEVICE Kingspan Solar Heat Pipe Tube Competitor tube ✗
Unique patented and ‘patent pending’ temperature limiting technology used Empty heads – no mechanical within the Kingspan Solar condensers. temperature limitation.
QUALITY GLASS WELDING & BLENDS Kingspan Solar Tube Competitor tube ✗
Highly visible glass blend lines 30 years glass blending experience with often with air bubbles in the glass solar tubes. Processes perfected and blends which can result in fully automated. fractures after installation.
51 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
EVACUATED TUBE COMPARISONS
SYSTEM COMPARISON: KINGSPAN SOLAR VS. FIN-IN-TUBE COPY
HIGH QUALITY PROTECTIVE END BUMPER Kingspan Solar Tube Competitor tube ✗
High quality EPDM rubber end Low cost option protector on the tube. – no end protection.
SINGLE PIPE Kingspan Solar Tube Competitor tube ✗
Heat pipe is a single hermetically sealed Mechanical / soldered copper pipe within the join within the vacuum vacuum space. space.
52 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
HIGH QUALITY RUBBER FLANGE Kingspan Solar Tube Competitor tube ✗ PRODUCT RANGE PRODUCT
High quality rigid EPDM rubber flange. Insulates Thin rubber end flange to and protects the glass to hide the mechanical glass metal seal. to metal seal.
LARGER GETTER AREA, MORE ROBUST VACUUM Kingspan Solar Tube Competitor tube ✗
Getter flash shows consistent and Getter flash has undefined defined length at top end of tube. length at centre of tube.
53 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
EVACUATED TUBE COMPARISONS
SYSTEM COMPARISON: KINGSPAN SOLAR VS. SINGLE WALL / FIN-IN-TUBE
KINGSPAN SOLAR TUBE
Tube Diameter 65mm
TiNOx Selective Coating Flexible Neck Condenser Head
Rubber End Vacuum Area Getter Heat Pipe Bumper
SINGLE-WALLED TUBE
Tube Diameter 102mm ✗
Metal End Bumper Al Nitrate Coating Heat Pipe Condenser Head
Getter Mechanical Glass to Metal Seal
54 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SYSTEM COMPARISON: KINGSPAN SOLAR VS. SYDNEY / DOUBLE-WALL TUBE
KINGSPAN SOLAR HEAT PIPE TUBE
TiNOx Selective Coating Flexible Neck Condenser Head PRODUCT RANGE PRODUCT
Rubber End Vacuum Area Getter Heat Pipe Bumper
SYDNEY TUBE ✗ Rubber End Al Nitrate Coating Heat Pipe Outer Vacuum Inner Bumper (on inner glass) Glass Area Glass
Getter Mechanical Glass Condenser to Metal Seal Head
55 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
KINGSPAN PUMP STATIONS
ALL SOLAR THERMAL APPLICATIONS P REQUIRE A PUMP SYSTEM TO MOVE FLUID T T THROUGH THE SOLAR LOOP. KINGSPAN SOLAR RECOMMENDS THE USE OF CLOSED LOOP GLYCOL SYSTEMS AND OFFERS A SERIES OF PUMP STATIONS SUITED 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 Solar’s offering includes a wide variety to handle from small systems with Figure 2: Typical pump station without heat exchanger. only a few collectors to very large systems that require a custom design.
In a closed loop system, there are a large number of P components required to satisfy the maintenance and safety T T 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 Ball valve based on if they include the heat exchanger or not. Pressure All heat exchangers in the pump stations are double walled relief with positive leak detection. Most codes will require these for Check valve solar systems to separate the water and glycol mixture, even though the glycol mixture is termed ‘non- toxic’. Pump The controls are another thing that are closely tied with the Balance pump stations. The controls are required to activate the valve pumps when there is energy to be harvested from the solar collectors. The various different pump stations will require the Flow meter solar controllers to be programmed differently depending on Heat how the system is hooked up, etc. Kingspan Solar offers the exchanger speciality controls that go with the pump stations and Air provides a program for the particular system selected. separator This ensures that the overall solar system will function as intended. Figure 3: Typical pump station with built-in heat exchanger.
56 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SOLAR PUMP STATIONS A Kingspan Solar Pump Station provides a circulator for the A range of solar pumping stations are available for both solar system. In addition, most features that are required on domestic and commercial applications. The selection of the hydronic systems are provided on the pumping station, pump station depends on the size of the collector array, the making the piping of the system much faster than if all the required flow rate and the overall pressure loss in the system. devices had to be plumbed by hand. The pump operation is Our Standard Flow 2-12 LPM pump station is shown below. controlled by the solar controller, which will activate the For other options, please contact us. pump when there is energy to be gained from the sun.
340 I H G J PRODUCT RANGE PRODUCT
K F
E L 430 D
C
B
280
A 150 M
A Flow meter H Supply temperature / check & ball valve
B Flush / fill ports I Collector connections - 22mm compression (KSP0025). C Balance valve 28mm ISO228 male (KSP0033).
D Circulator pump J Flow temperature / check & ball valve
E Expansion tank connection K Air trap bleed 450 F Pressure gauge L Air trap
G Pressure relief valve M Tank Connections - 22mm compression (KSP0025). 28mm ISO228 male (KSP0033).
Figure 4: Solar pump station.
57 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
KINGSPAN PUMP STATIONS
LARGER SYSTEMS SMALLER PUMP SKIDS Kingspan has a wide range of pump skids for larger projects The smaller pump skids utilize up to three pumps in parallel as well. The larger stations are built on skids with electrical to achieve the desired flow rates. These pump stations are enclosures and all of the necessary components in place. available either with or without a heat exchanger. All pumps These units range from semi custom, all the way to full used on these systems are variable speed to optimize the custom pump skids, depending on the job and number of electrical and thermal efficiency of the specific system. collectors. FULL CUSTOM PUMP SKIDS All of these skids include all instrumentation required to For larger systems, Kingspan offers a full custom pump skids monitor the performance of the system and verify that it is design service to fit your needs. These units can include working properly. The controller included with these systems simplex or duplex pumps, fixed or variable speed pumps in comes preprogrammed for the particular system and all any configuration to meet your needs. If your project documentation is included for the installation. requires a custom pump skid, please contact Kingspan for design and specification assistance.
58 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SYSTEM TECHNICAL CONSIDERATIONS
SIZING GUIDELINES 60
COLLECTOR LAYOUT & ITS EFFECT ON THE SYSTEM 72 CONSIDERATIONS SYSTEM TECHNICAL
59 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SIZING GUIDELINES
SOLAR THERMAL SYSTEMS CAN BE USED IN A VARIETY OF OF COMMERCIAL AND DOMESTIC APPLICATIONS.
When using solar thermal for a particular application, SOLAR PERFORMANCE there are many things to consider in designing the system. We are all used to fossil fuels providing energy in our lives. This section provides information on what is required for a They provide the same energy regardless of the conditions solar thermal system and how Kingspan sizes based on outside; a gallon of propane provides 26.96 kWh on a cloudy information about the building. This section is for guidance and sunny day. Fossil fuels represent concentrated energy only and designs should be reviewed by our technical team. that was provided by the sun millions of years ago. All solar thermal systems should be fully designed by a competent engineer. Kingspan Group plc or any of its “A Kingspan solar thermal system can companies do not take responsibility for any systems designed using the following information. be very effective in replacing fossil fuel usage for up to 30 years with very little USES FOR SOLAR THERMAL ENERGY maintenance or replacement parts There are many processes that require heat energy. necessary.” The most common usage of solar thermal collectors is to heat domestic hot water. This is a simple application that The sun produces an abundance of energy, but it is spread requires minimal disruption to the existing systems in the out and requires much more collection area to provide building and excellent payback in most applications. equivalent energy to fossil fuels. A 30 tube collector will The energy created from the solar collectors can also be provide about as much energy on its peak day as a gallon of used to heat buildings, pools or for AC reheat. propane. However, unlike a gallon of propane the collector Most commercial buildings will use water or glycol for will continue to provide energy as long as it is exposed to transport of energy throughout the building for the heating sunlight instead of ending up as carbon dioxide and water. system and this is another application that is good to tap Solar systems can be utilised to offset a large portion of the into with solar thermal collectors. fossil fuels that we currently use, but they require a different Pools require large amounts of heat energy in order to offset method of sizing than traditional fossil fuel systems. the losses from evaporation and solar collectors can provide If everything is designed and sized correctly, the solar a large portion of this energy that is required. system can be very effective in replacing fossil fuel usage for up to 30 years with very little maintenance or replacement AC reheat is used when the air is over cooled to remove the parts necessary. 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.
60 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
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 Kingspan Solar has a simple site assessment form that, immersed in the tank, or an external plate type. When the once completed, allows our technical team to size, design, sun shines on the collectors, the solar pump activates and and estimate savings on each project. runs glycol through the collector manifolds. The solar collectors will raise the temperature of the glycol and this energy is system, but the software will provide a far more accurate transferred to the water in the tank via a heat exchanger. calculation of what is needed. Kingspan Solar will be happy The key information required for sizing these systems is how to run these solar reports for your project with a completed much water is used on a daily basis, when it is used and how site assessment form. much the solar collectors will produce. Determining the hot DETERMINING HOT WATER DEMAND water usage is the key factor in the design. The output of Solar hot water systems are sized very differently from the collectors is simulated in software using historical traditional water heaters. A traditional water heater will look
weather data from the location that the collectors are going CONSIDERATIONS at the maximum possible demand of the building and then SYSTEM TECHNICAL to be installed, along with calculations based on the usage size the tank and burner so that this demand can always be pattern of the building. These are critical factors in met. The only consideration for this is how many taps there determining the number of solar collectors and the size of are and how much they can flow. the tanks. Information in this section can be used to approximate the number of collectors and tank size in the 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.
Figure 5: HP collectors (standard using dual stream pump)
61 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SIZING GUIDELINES
A solar system is not designed to provide all of the hot water hot water, so one will have to be added. The simplest way to which is why a backup system is required. The backup measure hot water demand is using an ultrasonic flow meter. system should be sized normally because the minimum This meter simply attaches to the outside of the cold water contribution of a solar system is zero and the backup system pipe going into the water heater and will log how much must insure that all demand is met under all circumstances. water enters the water heater. The hot water delivery The backup system will not run as often as it would if the temperature and cold water temperature complete the data solar system were not there, but during some periods may needed to measure the hot water energy for the building. have to run at full capacity.
There are two ways to determine the demand from a “Kingspan will assist in the design, structure; measurement and estimation. Measuring is the sizing and specification of all best way to ensure that the solar system is sized properly. commercial solar thermal systems.” Most buildings will not have a measurement system for the
GWU, FOGGY BOTTOM CAMPUS, WASHINGTON DC
Typical T*SOL report
62 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
Ground water temperature: Important for sizing both the 90 12:00 solar collectors and the tanks. This will vary with season 80 Summer solstice with the highest temperature coming around August and 70 10:00 14:00 the lowest in February or March. 60 Equinox Shading: Also greatly affects the output of the collectors. 50 Any time the collectors are in a shadow, they will not 40 8:00 16:00 produce energy. This should be considered early on in the 30 project, as not all locations are a good fit for solar Winter 20 solstice systems. The sun’s path varies greatly depending on the Solar elevation (degrees) 6:00 18:00 10 time of year, so a device called a solar pathfinder should 0 be used to check if the shading is an issue and when it 30 80 130 180 230 280 330 occurs. Figure 6, right, shows the sun’s path at different East Solar azimuth (degrees) West
times during the year. Figure 6: Sun position chart illustrating how the sun moves across the Panel orientation: For optimal performance, the collectors sky throughout the year. should face due south. Slight deviations from south will not affect performance much; in fact they can be Consumption Type Hot water requirement per day and orientated within 45° of south and still have about the person at a temperature of 60°C (Ltr)
same performance. Average From - To Building recirculation loop: Most commercial hot water Retirement home 45 30 - 65 CONSIDERATIONS SYSTEM TECHNICAL systems will have a recirculation loop on them to provide Kitchen - breakfast 2 2 - 3 instant hot water at the taps throughout the building. Kitchen - noon / evening 5 4 - 8 This is a major source of energy loss from the hot water Swimming pool - public / private 40/20 – system. It is important to know the length, insulation and Sauna - public / private 70/35 – operating hours of the recirculation loop for aiding in sizing the system. The solar system has to be oversized Hospital 80 60 - 120 in order to help provide this energy. Sports facilities - total – 35 - 50 System operating temperature: Commercial systems Sports facilities - showers 25 20 - 30 generally operate at high temperatures to protect against Hotel (** - ***) 50 30 - 80 legionella bacteria growth in the tank. Some systems for Hotel (**** - *****) 80 80 - 150 laundry or dish service will operate at higher Guest house, inn 30 20 - 50 temperatures than this. The higher the temperature, Holiday house 40 30 - 50 the more solar collectors will be needed to provide the Camping site 20 15 - 35 energy for the system. Youth hostel, holiday hostel 20 15 - 30 Student hall of residence 25 15 - 60
Figure 7: Typical domestic hot water demand
63 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SIZING GUIDELINES
(A) CALCULATE THE HOT WATER HEAT REQUIREMENT The amount of energy to heat the daily hot water demand Again, continuing the example of the 4 person domestic (QHW) is calculated using the formula: household:
Q = Volume of Daily DHW x Cw x (ΔT) HW 2.40.4.(45-10) Vcyl = =224Ltr Volume of Daily Hot Water (l) (60 - 10) Cw = Specific heat capacity of water (1.16 Wh/kgK) The tank size is rounded up to the nearest available size, ΔT = Temperature difference between cold in this case = 250 Litres water temperature and desired water temperature (C) SIZING THE COLLECTOR AREA To size the required collector area the following formula Continuing example of 4 person domestic household: is used:
QHW = 160 x 1.16 Wh/kgK x (60-10) = 9280Wh = 9.28kWh ED AR = Therefore the heat requirement = 9.28 kWh/day SC
(B) CALCULATE THE STORAGE VOLUME Expanding this formula: For domestic solar systems typically the storage volume of the tank should be equal to 2 times the daily hot water No.ofDaysxQHW x Solar Fraction AR = demand. Yearly Solar Irradiation x Av. System Eff. To correctly size the storage volume the following formula should be used:
2.Vn.P. (Th - Tc) Vcyl = (Tdhw - Tc)
Vcyl = Minimum volume of tank (Ltr) Vn = DHW demand per person / day (Ltr) P = Number of people Th = Temperature of hot water at outlet (°C) Tc = Temperature of cold water Tdhw = Temperature of stored water
APARTMENT BUILDING, ARNSTADT, GERMANY
64 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SYSTEM EFFICIENCY The system efficiency is strongly dependent on the solar In undersized systems with small collector areas, the solar fraction of the system. When there is a high solar fraction fraction is low but the system efficiency is high. In oversized the system efficiency is lower. systems with large collector areas the solar fraction is high High solar fractions result in a higher return temperature to but the system efficiency is low. the solar collector, the effect of this is that less solar The counter effect of the 2 variables can be seen in irradiation can be absorbed by the collector, hence reducing Figure 8 below: the system efficiency.
Optimised for contribution and cost Maximum Maximum consumer collector yield coverage
SF CONSIDERATIONS SYSTEM TECHNICAL Solar Fraction SF System Efficiency SE
SE
Absorber Surface Area A
Figure 8: Relationship between solar fraction and system efficiency
65 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SIZING GUIDELINES
To simplify the selection of collector area, the following INSULATION graphs have been created to quickly determine the correct The insulation has to be UV stable where exposed to the collector size. sunlight and has to be resistant to high temperatures in If the same daily DHW demand was required using an excess of 170˚C. To prevent high heat losses through the evacuated tube collector, from Figure 9 below we would see pipework it is recommended to use insulation with a a collector area of 3m2 for a solar fraction of 60%. minimum thickness equal to half the pipe diameter and an U value in [W/(mK)] of U ≤ 0.035 [W/(mK)]. IMPORTANT It should be noted that REIA recommend an insulation For Kingspan Solar evacuated tube collectors we recommend thickness equal to 100% of the internal diameter. a minimum tank storage of 100 Ltrs per m2 of collector area, UNSUITABLE MATERIALS in this case: We do not recommend the use of the following material to 2 System sized as 3m of tube, therefore the tank volume be used in solar systems: should not be less than 3 x 100 Ltrs = 300 Ltrs. Plastic pipes (PEX) Multi-layer aluminium / plastic pipes (ALU-PEX) 10 Galvanised metal pipes 8 2 SUITABLE FITTINGS 6 60% Compression fittings 50% 4 Press fittings (with gasket rated for temperatures above 40% 150˚C) Absorber area in m 2 Brazed fi ttings 0 Fittings supplied with solar stainless steel tubing, i.e. 0 50 100 150 200 250 300 350 400 Waterway, Aeroline etc. DHW demand in Ltr/day, 45°C Note: The use of solder ring fi ttings on copper pipework is not recommended. Figure 9: Thermomax DF & HP evacuated tube collectors On long pipework, runs allowances should be made for expansion in the pipework, please see Figure 10 below. PIPEWORK AND PIPEWORK SIZING Suitable Materials Temperature Raise Steel Pipe Copper (°C) Expansion (mm/m) Expansion (mm/m) The following piping materials are suitable for use in a solar 50 0.48 0.66 system: 100 1.08 1.49 Black steel pipe (a.k.a. gun barrel) 120 1.32 1.83 Copper tubing Pipe expansion due to temperature Stainless steel tubing Figure 10:
66 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
PIPEWORK SIZING For domestic pipe sizing we recommend a minimum flow Figure 11 below shows recommended pipe sizing for typical rate of 60 Ltrs/hr/m2. For commercial systems lower domestic systems. minimum flow rates of 40 Ltrs/hr/m2 canbeused. Collector Flow Rate Pipe Diameter In order to minimise the pressure drop through the solar Area (m2) Ltr/hr Copper DF HP pipework, we recommend that the flow velocity through the External (mm) (mbar) (mbar) solar pipework should not exceed 1 m/s. 2 120 15 x 1 8.54 1.76
Ideally flow velocities between 0.4 and 1m/s should be used, 3 180 15 x 1 12.57 2.56 resulting in a pressure drop of between 1 and 2.5 mbar/m 4 240 15 x 1 17.08 3.52 pipe length. 5 300 22 x 1 21.11 4.32 The required internal diameter of the pipework can be sized 6 360 22 x 1 25.14 5.12 using the following equation: 8 240 22 x 1 33.68 7.04 Where: Vs i = Internal diameter (mm) Figure 11: Typical domestic pipe sizing i=4.6 v Vs = System flow rate (Ltr/min) = Velocity of fluid (m/s)
Pipework with an outside diameter of less than 15mm should never be used, in this example we would increase pipe size CONSIDERATIONS from 8mm to 13mm (= 15mm OD pipe with a 1mm wall SYSTEM TECHNICAL thickness).
ANCHOR TRUST CARE HOME, SURREY, UK
67 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SIZING GUIDELINES
Stagnation in a solar system can be caused by a number of STEAM REACH reasons such as: During stagnation the heat transfer fluid in the collectors Oversized systems may vaporise. The vapour will expand into the connecting pipe work. In large systems with direct flow collectors, the Undersized expansion vessel volume of heat transfer fluid in the collector will be large Poor set up of the system – it is essential that all solar and the vapour may travel a significant distance along the systems are installed and commissioned by fully trained connecting pipework. and technically competent installers who fully understand the requirements of a high performance solar thermal Where sensitive components such as pumps, valves and system expansion vessels may be affected by the high temperature vapour, a steam reach calculation should be performed to Air locks or leaks in the system assess the areas of the system that could be affected. Prolonged periods of low hot water demand. Using our range of control panels this can be overcome by using a heat dissipation function
THE ALPS, ITALY
68 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
There are several ways to combat overheating:
1. design the system and size it correctly, thus avoiding need for dissipation in many applications; 2. open a spill valve from at the top of the tank and allow hot water to spill out when the tank reaches its maximum temperature; 3. divert flow from the collectors through a wet or dry cooler to cool the flow from the collectors once the tank has reached temperature as per Figure 12; 4. utilise an existing facility to dump heat, such as an oversized cooling tower, a section of snow melt tubing in concrete, an AC reheat system or a pool.
Allowing the collectors to stagnate for an extended period of time will cause issues with the system in the long term. This is true of both flat plates and evacuated tube systems. Some systems, however require heat dissipation:
Figure 12: Heat dissipation Option A 1. systems with seasonal use, such as a resort that closes
down during the off season; and CONSIDERATIONS SYSTEM TECHNICAL 2. systems with changes in usage throughout the week, This is why it is crucial to design systems properly. Adding such as a school or office building, where they are not more collectors and increasing the solar fraction makes the used, or underutilized on weekends. system more susceptible to stagnation where there are long periods of sunlight. An error by which the system is Kingspan Solar offers a full line of components for heat oversized by 30%, may create serious stagnation issues. dissipation and will assist in selecting the correct Therefore it is always best to undersize systems and components for each individual project. underestimate the number of collectors.
69 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SIZING GUIDELINES
SWIMMING POOL, GAIARINE, ITALY
We can assist you with designing solar systems for the summer. Pool systems do not typically have any external following applications: storage, but rather use the water in the pool for energy Swimming Pools storage. This means that during the day the pool may rise in temperature several degrees above the set point and then Process Heat cool off at night. Heating System If the temperature cannot vary above a limit in a pool, then a SWIMMING POOLS system utilizing storage tanks can be used. At this point, the Swimming pools are a great use for solar thermal energy. system is designed much like a heating system with how the The collectors can be used to heat just the pool, or it can act storage interacts with the heating demand. as an additional energy sink for systems for hot water or A heat exchanger suitable for pools is required for all pool heating. Their low temperature provides for some of the systems. The chlorinated water cannot be run through the most efficient systems possible. solar system in any circumstance. For fresh water pools, a Pools use an incredible amount of energy, much more than stainless steel heat exchanger must be used and for salt most people would think. Indoor pools and outdoor pools are water pools, a titanium heat exchanger is required. very different in how the energy is lost and gained. Since the flow rate of the water from the pool through the existing boiler system is typically much higher than the solar SIZING POOL SYSTEMS flow rate, the heat exchanger will generally be a shell and Pool systems are sized at a maximum of 50% solar fraction. tube type rather than a plate type. A system sized at an annual solar fraction of 50% will produce 100% of the pool load on a sunny day in the
70 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
PROCESS HEAT Process heat refers to any application that requires heat in temperature and then heated by a separate system back up the form of hot water. Examples of this are in processing to the desired temperature. The overall energy provided in a milk, brewing beer, food products and other industrial system such as this is around 25% of the load. processes. These systems vary significantly, depending on For further information on solar thermal systems for heating application, demand, existing infrastructure, temperature of applications, please contact Kingspan Solar. the application, and when the energy is used. Kingspan Solar can assist with the design of these systems on a project CONCLUSIONS specific basis and advise what system specification is There are many applications where solar thermal systems required to achieve optimum operation. can be utilised to save money. Kingspan Solar can advise, design and size these systems specifically for a particular HEATING SYSTEMS application. The design of solar systems is different from Heating systems are another use for solar thermal energy. systems that use fossil fuels as energy and this must be Kingspan Solar evacuated tubes are an excellent fit for taken into account in the design. A well designed solar heating systems because of their high efficiency in cold system will provide years of performance and savings. conditions. Heating systems can refer to systems that are either used for traditional space heating or AC reheat, where “A well designed solar system will the air coming in to the building is cooled below the desired provide years of performance and savings.” CONSIDERATIONS SYSTEM TECHNICAL
NATIONAL TAIWAN UNIVERSITY, TAIWAN
71 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
COLLECTOR LAYOUT & ITS EFFECT ON THE SYSTEM
COMMERCIAL BUILDING APPLICATIONS, REQUIRING MANY ROOF-MOUNTED COLLECTORS, MUST BE CAREFULLY CONFIGURED SO ENERGY GENERATION IS MAXIMIZED AND THE SYSTEM FITS THE ROOF SPACE AVAILABLE.
Choosing how many collectors are in a bank will affect the choice for piping as well as the pump for the system. This section examines the choices that must be made when laying out collectors on the roof and how these choices impact the overall performance of the system.
GWU, FOGGY BOTTOM CAMPUS, WASHINGTON DC Inset: YARBOROUGH PAVILION, LINCOLN, UK
72 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
COLLECTOR ANGLE The majority of commercial applications will be installed on The solar fraction will also help determine the angle of the flat roofs, so the chosen collector frame will have to hold the collectors. As the solar fraction increases above 50%, the collectors at the correct angle for optimum energy collection panels should be tilted steeper to even out the summer and and production. The angle affects when the production will winter production. Typically, a solar fraction of 50% will be the highest. Sunlight shining straight on to the collector indicate that some days during the summer will produce will produce the highest output. more energy than the system can store, however this will vary some by location. The production cannot be exactly For northern regions, collectors that are orientated at 0.7 leveled by collector angle alone; even at 90° (horizontal) the times the latitude of the installation will produce the most production will be more in the summer than the winter due overall energy during the year; however the energy is to the length of the days. heavily biased to the summer time when the sun is the highest in the sky. Note: All collectors have restrictions on the angles at which To balance the production more evenly throughout the year, they can be installed. Please refer to individual data sheets the collectors should be set at the latitude of the installation. for further information. The time of year when the energy is most required should be examined. For example, if a school dormitory that is heavily occupied during the school year is to have a solar system added, then it should be tilted to the steepest angle possible to bias the production away from the summer months when CONSIDERATIONS it is not needed. SYSTEM TECHNICAL
ARNSTADT, SCHILLERSTRASSE, GERMANY
73 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
COLLECTOR LAYOUT & ITS EFFECT ON THE SYSTEM
SETTING FLOW RATES All solar thermal collectors can operate at a variety of flow The flow rate for the system should be selected carefully. rates, depending on the application. The flow rate will affect Flow rates that are too small will cause a large increase in the pressure drop of the collectors and also change the temperature across a bank of collectors, reducing efficiency temperature increase across the bank. Generally a low flow and potentially creating temperatures above where the rate is desired because it minimizes the pressure drop system is designed to operate. Flow rates that are too high through the system resulting in smaller pipes and less will cause the pump to shut on and off frequently causing energy to run the pump. The flow rate selected needs to take undue wear and tear on the pump. Ideally systems should the heat exchanger into account to ensure sufficient heat use a controller that measures the temperature increase and transfer from the solar system to the tank. adjusts the pump flow rate accordingly. Systems should be designed so that the temperature rating of the components The temperature increase across the collectors is driven by is not exceeded. the level of radiation, the angle of the sun and the outdoor temperature. Once the energy output of the collector is Generally systems with a lower solar fraction and larger known, the increase in temperature can be computed. storage will be able to utilise lower flow rates in the system. Systems that have high solar fractions, smaller storage, or those for heating, cooling, or high temperature industrial applications will need higher flow rates.
VIESTE HOTEL, ITALY
74 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
PRESSURE DROP Kingspan solar thermal collectors are designed to connect to With heat pipe collectors, the maximum number in series for each other to form banks with the use of an ‘interconnection most applications is five. Depending on other components in kit’. One end of the collector plugs directly into the other the system, this may be reduced to four. For flat plate end making a neat connection between the collectors. collectors, 8 vertical or 5 horizontal collectors may be connected in series. Flat plate collectors connect to one another in parallel, where as evacuated tube collectors connect in series. Calculating the pressure drop for the entire system is a more This changes the pressure drop in a bank of collectors difficult task. The piping, heat exchangers, valves, elbows and drastically (Figure 13). Evacuated tubes will increase in tees all make a difference in the pressure drop for the entire pressure drop as more are added where as flat plate system. This value is required for sizing the pump. Kingspan collectors will have similar drops in pressure as more Solar can assist in the correct sizing of the pump, as well as collectors are added to the bank. the piping in the system to make sure the pump is sized accurately. 14 BALANCING 12 The system flow will tend to go to the banks with the lowest 10 pressure drops in them, so a method of balancing the collectors is needed. There are two methods of doing this: 8
REVERSE RETURN (TICHELMANN) CONSIDERATIONS SYSTEM TECHNICAL 6 A reverse return or ‘Tichelmann’ system is a system where
4 the flow for any bank of collectors goes through the same Pressure Drop (foot of head) length of piping regardless of where it is located on the roof. 2 Figure 14 (overleaf) illustrates how this concept works. The first collector connected to the return will be the last 0 012345collector connected to the flow. Both flow and return pipe Flow Rate (GPM) work will run next to each other in the array to insure that
Figure 13: Pressure drop in heat pipe collector both lengths are equal. The pipe diameter must be the same length throughout the array so that the pressure drop is always the same for the supply pipe and return pipe. There are many factors to consider how many collectors can be connected in series before they have to be arranged in parrallel banks. For evacuated tubes this is manily dependant on the pressure drop for the overall system to size the pump, but there is a constraint that a single bank of collectors cannot exceed 4 GPM flow because of flow velocities in the copper manifold. Flat plates can have more connected together because they are connected in parallel rather in series, but consideration must be given to how evenly the flow will distribute through the collectors in parallel. As the banks get larger, the flow will become more uneven in the individual collectors within a bank.
75 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
COLLECTOR LAYOUT & ITS EFFECT ON THE SYSTEM
Figure 14: Reverse return system Figure 15: System with balancing valve
The advantage of this type of pipe system is that there is no 2. Where each of the collector banks are identical in need for extra components to balance the system; in theory construction a reverse-return (Tichelmann) pipe it is naturally balanced. The disadvantage is that the largest arrangement may be used. diameter of pipe must be used throughout the system, Using balance valves allows collectors to be in banks with increasing cost. The pipe run is generally longer as it must different numbers of collectors and the pipe diameter to be meander past all collectors, but often these systems need optimized for the flow rate going through it at any point in balancing valves because small differences in the system will the system. Balance valves do add an additional component not allow it to be perfectly balanced. Additionally, all collector to each collector bank, but allow for quick and easy banks must contain the same number of collectors, or the adjustability in the system. system will not be balanced. Reverse return works well for small systems where the collectors are tightly arranged on COLLECTOR SPACING the roof. For systems with multiple rows of collectors, the banks must be spaced sufficiently far apart so that they will not shade HYDRAULIC BALANCING each other. The general rule of thumb is that there should be On collector arrays with multiple banks of panels it is no shading from one bank to the next on the winter solstice important that the correct flow rate is achieved on each bank at noon. This will be the lowest that the sun will get in the of collectors. Incorrect flow rates, in particular low flow rates sky and will not prevent all shading between banks (the sun on individual banks can reduce the overall efficiency of the is at zero degrees when it sets all year), but will leave the system. In extreme cases the individual bank may stagnate collectors largely exposed during the critical times of day and this could result in damage to the collectors and other throughout the year. system components. MOUNTING The two methods to best achieve the correct hydraulic A wide variety of mounting kits is available to suit almost balance are high temperature balancing valves or a reverse- any installation. Where collectors are arranged in banks or return (Tichelmann) pipe arrangement: laid flat, sufficient space of approximately 500mm should be 1. Individual solar rated balancing valves (flowsetters) on left between each bank to allow for servicing. Due to the each bank are the preferred method of achieving the wind turbulence around the edges of the roof, we correct flow rates. Where the collector banks contain recommend that approximately 1 metre should be allowed varying numbers of panels or differently sized panels this between the collectors and the edge of the roof. is the only method of achieving the correct flow rates.
76 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
Collectors should NOT be left exposed for long periods commissioned, collector covers are available to prevent before commissioning. Long exposure to the sun when fluid exposure. It is also possible to rotate the tubes in Kingspan is not being circulated through the system will cause Solar panels (DF range only) to prevent the selective significant degradation of the fluid and possible damage to absorber coating (blue side) being exposed to the sun. solar collectors. Collectors should only be installed when the However, although this will minimise the solar irradiation required plant, tanks, pipework and controls etc have been falling on the absorbers, it is only recommended for short installed and tested. Where collectors need to be installed periods. for more than a few days before the system is
Reference Value Unit b2.00m h 1.20 m Beta 37.00 ˚
Gamma 13.12 ˚ b h Gamma at 21.12.12:00 -
β d1 Results α Reference Value Unit γ d6.75m CONSIDERATIONS d1 5.16 m SYSTEM TECHNICAL d
Figure 16: Diagram showing minimum spacing between collectors, data used = Dublin, collectors at 37˚
α = Roof pitch β = Collector inclination + roof pitch γ = Angle of sun above the horizon b = Height of solar collector: 1952mm Direct Flow collector = 1952mm Heat Pipe collector = 1952mm β α γ α d1 = b x sin( - ) / tan( - ) β α d=(bxcos( - )) + d1 h=√b2 –d2
CONCLUSIONS The arrangement of the collectors on a roof depends on Pressure drop through the system is important when sizing many factors. The arrangement must be determined in order pumps and piping. The system must be balanced to make to size other system components, such as pumps and heat sure the flow through each collector bank is equal exchangers. By varying the flow rate through the system, (depending on the number of collectors) and is at the value the temperature increase across the collectors can be which is designed. Also, if the banks are to have isolation controlled. Different systems will utilise different flow rates, valves, a pressure relief valve is required for safety. depending on the purpose and solar fraction of the system. These are all important considerations when designing a solar system.
77 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
TYRONE GAA, OMAGH, COUNTY TYRONE, NORTHERN IRELAND
78 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
CONTROLS & MONITORING
SOLAR THERMAL SYSTEM CONTROLS, COMPONENTS & MONITORING 80 CONTROLS & MONITORING
79 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SOLAR THERMAL SYSTEM CONTROLS, COMPONENTS & MONITORING
SOLAR THERMAL SYSTEM CONTROLS ARE AN INTEGRAL PART TO THE ENTIRE SYSTEM. THERE ARE SEVERAL DIFFERENT OPTIONS FOR SOLAR THERMAL CONTROLLERS THAT WILL PROVIDE THE NECESSARY FUNCTIONS FOR CONTROLLING MONITORING AND REPORTING.
CONTROLLING A SOLAR SYSTEM One option that is becoming more and more utilised is speed The basic algorithm for controlling a solar system is very control on the solar pump. This involves varying the speed of simple. A sensor is placed in the collector bank and another the pump depending on the rise in temperature that the in the bottom of the tank. When the difference in collectors are producing. The pump will run faster when the temperature between the sensors exceeds a set point, a sun is intense and slower when there is less sunlight. relay in the controller will close and activate the solar pump. This reduces the energy consumed by running the pump, The difference in temperature shows there is meaningful as well as short cycling of the pump whereby it turns on and energy to be collected. The pump will run until this off quickly because there isn’t much solar radiation. temperature difference falls below a threshold, meaning Some controllers offer variable speed (0 – 10V) outputs there is no longer energy to collect. instead of straight relays to connect to an inverter and vary the speed of the pump. Additionally, there are other points to monitor in the system. The controller examines the temperature in the tank and SOLAR CONTROLLERS ensures that the maximum temperature is never exceeded. Solar controllers are devices that are manufactured The temperature in the solar loop is also monitored and the specifically to control solar systems. The controllers will controller will shut down the solar pump if the temperature differ in the number and type of inputs, number and type of becomes so high that it may damage components in the outputs. solar loop. Solar controllers are a convenient and inexpensive way for More complicated systems can utilise additional functions in controlling commercial solar systems. the controller. A system that uses two tanks will utilise a They come preprogrammed with many of the common function in the controller that switches a valve between the systems already in them and are easy to connect to the tanks when a temperature set point is reached so that the overall system. The units provide excellent data logging solar energy is diverted to the correct tank. More than two capabilities and this data can be accessed over the Internet. tanks will simply utilise more inputs and outputs on the Where it is possible, Kingspan Solar includes a program on a controller. Systems with additional pumps can utilise memory card that is customized to your exact system to additional temperature sensors for activating the pumps. insure that all parameters are programmed properly in the Because the controller has a large number of inputs and controls. monitors the temperatures in key locations within the system, it is also often used for data recording. This usually means that the temperatures and flow rates measured by the controller are recorded on a memory card at regular time intervals. This data can then be recalled and processed to see how the solar system has been performing and provide an estimate of the system savings.
80 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
NORTH OF TURIN, ITALY
Solar Controller Summary SC300 SC400 SC500
System voltage 230 V (+_ 15 %), 50 Hz 115 ... 230 V~, 50/60 Hz 115 ... 230 V~, 50/60 Hz optional 115 V (+_ 15 %), 60 Hz
Own consumption_4W < _0.8W < _ < 0.8 W CONTROLS & MONITORING Inputs 6 5 5 T1 - T5: temperature recording (Pt1000) T1-T4: temperature recording (Pt1000) T1-T4: temperature recording (Pt1000)
T6: temperature recording T5: temperature recording T5: temperature recording (Pt1000) or pulse recording (Pt1000) or pulse (Pt1000) or pulse
Additional input 1 x direct sensor (flow rate / temperature) No additional inputs 1 x direct sensor (temperature / flow rate) 1 x direct sensor (temperature / pressure)
Outputs 3 2 2
R1 and R2: TRIAC output for RPM control R1 and R2: TRIAC output for RPM control R1 and R2: TRIAC output for RPM control R3: relay switched output
Additional output 1 x alarm output 1 x potential-free switching output for the safety 1 x potential-free switching output for the safety extra-lowvoltage extra-low voltage
Hydraulic schemes 40 11 11
Ambient temperature 0 °C ... +45 °C 0 ... +50 °C, 0 ... +50 °C
Data logging SD card No data logging SD card
Degree of protection IP 20 / DIN 40050 IP 22, DIN 40050 (without front panel: IP 20) IP22, DIN 40050 (without front panel: IP20)
Dimensions (XxYxZ) 170x170x46mm 110x160x51mm 110x160x51mm
Weight 450 g 350 g 370 g
81 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SOLAR THERMAL SYSTEM CONTROLS, COMPONENTS & MONITORING
PERFORMANCE MONITORING The Internet remote display allows permanent monitoring and Not only the momentary values for each solar energy system performance analysis of one or more solar energy systems. are visualised but also the changes in temperature over time The Kingspan Solar router allows visualisation of the using simple diagrams. If a heat meter is also used then, operation of solar thermal systems. in addition to momentary values, the system is capable of displaying energy balances and CO savings. By logging in Temperature and performance data are clearly displayed for 2 analysis in an Internet browser window. with a personal user name and password the operator can use the Internet to monitor the system from any location in the world. This allows simultaneous management and monitoring for correct operation of multiple systems. The raw data archived on the server can be downloaded for detailed analysis with the TS Analyzer 2 software. Historical information is permanently available for comparative monitoring of system functions. This allows malfunctions and the origins of faults to be quickly recognised, analysed and corrected, which greatly improves the operational reliability of the system.
OPERATION A Kingspan Solar controller cyclically sends measurements to the Inernet router. The device processes the data and forwards it to a central server via cable modem. The server archives this information and presents it visually in the Internet - as system images, graphics, tables, diagrams and even as a slide show. These visualisations can also be sent from the router to a smartphone or laptop via WLAN or via mediabox to a monitor or a projector. Figure 17: Internet router system
WABASCA WATER WORLD & FITNESS CENTER, WABASCA, CANADA
82 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
VARISOL INSTALLATION, IRELAND CONTROLS & MONITORING
APARTMENT BLOCKS, GERMANY
83 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SOLAR THERMAL SYSTEM CONTROLS, COMPONENTS & MONITORING
PUMPS FIXED SPEED CONTROL Pumps are a very important part of a solar system. The next thing that must be examined is the power rating on The sizing of pumps is covered in the components sizing the pump. The relays in all controllers have a maximum section, but here we look at the electrical side of the pumps. current that they may provide to the motor and operate at The motors on pumps are rated terms of the voltage, phase a particular voltage. The standard solar controllers, for and horsepower and it is very important to understand the instance, are able to handle motors that draw up to about meaning of these terms when choosing a pump for a 2 Amps at 115V. Most BMS systems will have 24VAC as an particular job. output and will require a magnetic starter, where as PLCs can be customized with several different voltage outputs, Most of the time the motor for a particular pump can be but their current output is quite small and will need to be specified with several different voltages and phases. A site run through a magnetic starter as well. visit to the building should examine the voltages that are available and ensure that there is enough extra power on a A magnetic starter is similar to a relay, but intended for circuit to handle an additional pump or pumps. The first higher currents and they have overload protection on them thing to examine is what voltages are available. On small to stop the motor if it exceeds its capacity. They are switched systems, 120V will typically be used because it is readily on via a small current that runs through a magnetic coil available and most small pumps are rated for this condition. and pulls an armature to another position to switch on a Larger systems will use either 240V or 480V because they much higher current through the contacts closed by the are more efficient at turning the pumps. armature. Figure 19 shows a cutaway of a relay exposing the components within. The spring switches the magnetic starter The voltage also helps determine the number of phases that off when the current is switched off to the coil. are available. 120V circuits in the North America are automatically single phase. 240V circuits can be either The magnetic starter can also operate at two different single phase (technically split phase), or three phase where voltages; the coil can be switched by 24VDC and the contacts as 480V systems are more than likely three phase. can connect 240VAC. The correct motor starters should be Determining the number of phases present is very important chosen based on the horsepower and voltage of the motor because it will dictate the motor that is chosen on the and the available switching voltage from the controller. pump and the design of the motor contactors used in the electrical system.
Contacts
Armature
Spring Coil
Yoke
Figure 18: Contactor Figure 19: Magnetic starter
84 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
The following table can be used to compute the current For larger systems, a Variable Frequency Drive (VFD) is rating of the motor. required. A VFD is a device that connects between the power supply and the pump and varies the frequency of Motor 115 V 230 V 230V 460V Horsepower Single Phase Split phase 3-phase 3-phase the current going to the pump motor to achieve different speeds. The speed of an AC motor is 1/6 4.4 2.2 – – dependent on frequency of the power being fed to it; 1 /4 5.8 2.9 – – in the UK and Ireland, this is always 50 Hz. The inverter 1/3 7.2 3.6 – – can change this frequency and thus the rotational
1/2 9.8 4.9 2.2 1.1 speed of the pump. A pump motor must be VFD duty rated in order to be used with a VFD. 3/4 13.8 6.9 3.2 1.6
1168.04.22.1The VFD needs an input from an outside control as to how fast it should spin the motor. This is usually a 1 1/2 20 10 6.0 3.0 0-10VDC, or 4-12mA signal. Some solar controllers can 2 24 12 6.8 3.4 supply this output (see Solar Controller Summary table 3 34 17 9.6 4.8 page 81). Most BMS will have the option for an analog 5562815.27.6output and PLCs can be configured for this if specified Note that these are peak currents and may vary by motor. Consult the literature provided by the pump in advance. There is a program in the inverter that will manufacturer to verify these values. translate the signal from the controller into the motor speed that will need to be programmed, along with the VARIABLE SPEED CONTROL motor parameters. It is desirable in solar systems to vary the motor speed depending on the amount of energy the solar system is Often times the VFD is skipped in solar systems collecting. This will help ensure the maximum output from because of its additional expense and the difficulty of CONTROLS & the system and reduce the energy used to run the pumps programming it. On large systems, the unit can pay for MONITORING within the system. A desired increase in temperature across itself within a few years with the electricity saved and the solar collector is set and the pump speed is varied to also provide an increase in the solar production. maintain this value. This is all handled in the controller. These systems generally last longer because the motor and pump aren’t being driven as hard as a fixed speed set up and they are also not being switched on and off as frequently.
Figure 20: Variable Frequency Drive (VFD)
85 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
SOLAR THERMAL SYSTEM CONTROLS, COMPONENTS & MONITORING
VALVES Motorized valves are also common components on solar thermal systems. They are used to divert flow from one place to another and are actuated by the controls when a certain set of conditions is met. Valves will commonly be either two way or three way valves.
A two way valve is a simple switch; in one position it will allow flow through and in the other it blocks it. Two way valves are usually used in pairs where one valve will open and another close to divert flow from one portion of the system to another. This is used commonly when shifting flow between tanks.
Three way valves are another common type of valve in solar systems. They consist of an inlet and two outlets where the flow will be diverted to depending on the position of the valve. One outlet is considered the normally open position of the valve where flow will be diverted when no power is applied to the valve and the other is the normally closed position where Figure 21: Motorised 3 Port Valve flow will be diverted when the valve is activated. Valves can be power open, spring return (as described above) or power open / power close where energy is required to change the state of the valve in either direction.
Valves will have voltage and current ratings on them as well. For smaller valves, they will not draw much current and can be connected to the controller directly. Larger valves will require a relay to operate properly. To switch the valve form one position to another, a small motor and gears are used.
GALDERMA R&D SNC, SOPHIA ANTIPOLIS, BIOT, FRANCE
86 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
CERTIFICATION & WARRANTY STATEMENT
• 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 CERTIFICATION & WARRANTY STATEMENT
87 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
HEAT PIPE COLLECTORS
88 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
DIRECT FLOW COLLECTORS CERTIFICATION & WARRANTY STATEMENT
89 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
VARISOL HEAT PIPE COLLECTORS
90 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR CERTIFICATION & WARRANTY STATEMENT
91 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
VARISOL DIRECT FLOW COLLECTORS
92 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR CERTIFICATION & WARRANTY STATEMENT
TURIN, ITALY
93 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
HAIL IMPACT TEST CERTIFICATION
94 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
WARRANTY STATEMENT
KINGSPAN SOLAR WARRANTY STATEMENT FOR SOLAR Subject to the following provisions, Kingspan Solar warrants that the Goods will be free from defects in material and workmanship for a period of 20 years in relation to VACUUM TUBES and a period of 5 years for MANIFOLDS and KITS from their date of manufacture. “RESTRICTED PRODUCTS” are limited to a period of 12 months warranty. The warranty is given by Kingspan Solar subject to the following conditions:
A. The 20 year warranty period on Vacuum Tubes is conditional on 5. Kingspan Solar shall be entitled to examine any Goods, which are the installation by a Kingspan Solar Approved Installer, and subject to subject of any claim by the Buyer, and to remove such Goods or any the collector(s) being properly maintained according to the part thereof for testing. No tests carried out by the Buyer will be manufacturer’s recommendations. (See Installation Manual for recognized by Kingspan Solar unless carried out strictly in further details). Otherwise a default 5 year warranty period on accordance with a method previously agreed by Kingspan Solar as Vacuum Tubes applies. being suitable for the purpose. B. Kingspan Solar shall be under no liability in respect of any defect in 6. Any valid claim in respect of the Goods which is based on any defect the Goods arising from any information drawing design or in the quality or condition of the Goods or their failure to meet specification supplied by the Buyer. specification is notified to Kingspan Solar in accordance with these C. Kingspan Solar shall be under no liability in respect of any defect Conditions. Kingspan Solar shall be entitled to repair or replace the arising from fair wear and tear, wilful or accidental damage, Goods (or the part in question) free of charge or at the Company’s negligence, abnormal working conditions, failure to follow the sole discretion refund to the Buyer the Price (or a proportionate part Kingspan Solar’s instructions, misuse or alteration or repair of the of the Price) but Kingspan Solar shall have no further liability to the Goods without approval. Buyer. D. The above warranty does not extend to parts materials equipment 7. Kingspan Solar shall not be liable to the Buyer by reason of any not manufactured by Kingspan Renewables in respect of which the representation (unless fraudulent) or any implied warranty condition Buyer shall only be entitled to the benefit of any such warranty or or other term or any duty at common law (including but without guarantee as is given by the manufacturer to the Company. limitation the negligence of Kingspan Solar its employees agents or otherwise) or under the express terms of the Contract for any loss of E. The defect has been reported by the Buyer to Kingspan Solar within production loss of profits or anticipated profits loss of contracts the warranty period. operation time or anticipated savings loss of business or of expected F. The installation of the Goods having been carried out by fully trained further business loss of or corruption to data damage to the Buyer’s and competent person(s). reputation or goodwill damages costs or expenses payable by the G. The Goods having been subjected to neither “prolonged stagnation Buyer to any third party or any other indirect special or conditions” nor exhibiting signs of “extreme temperature exposure”. consequential loss or damage or claim (whether caused by the negligence of Kingspan Solar its employees agents or otherwise) 1. The Buyer shall not make any statement or representation or give which arise out of or in connection with the supply of the Goods or any warranty to any third party in respect of any Goods other than in their use or resale by the Buyer. the terms made or given by Kingspan Solar to the Buyer nor shall the Buyer have any authority to commit Kingspan Solar to provide 8. Without prejudice to the provisions of clauses 3, 4, 5, 6 and 7 the any service in relation to the Goods. entire liability of the Buyer under or in connection with the Contract shall not exceed the Price of 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’ 9. Kingspan Solar shall not be liable to the Buyer or be deemed to be in negligence and damage suffered by the Buyer as a result of any breach of the contract by reason of any delay in performing or any breach of the obligations implied by Section 12 of The Sale of Goods failure to perform any of the Company's obligations in relation to the
Act 1979 shall not be limited. Goods if the delay or failure was due to any cause beyond the CERTIFICATION &
Company's reasonable control. Without limiting the foregoing, due to WARRANTY STATEMENT 3. If Kingspan Solar fails to deliver the Goods for any reason other than causes beyond the Company’s reasonable control. any cause beyond the Company’s reasonable control or the Buyer's fault then Kingspan Solar shall only be liable to the Buyer for and 10. For comprehensive details regarding “Warranties and Liability” the Company’s liability shall be limited to the excess (if any) of the please refer to the “CONDITIONS OF SALES” section 7. 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 Solar 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 Solar the Buyer shall not be entitled to reject the Goods.
95 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
THE ROYAL DANISH ACADEMY OF FINE ARTS SCHOOL OF ARCHITECTURE, COPENHAGEN, DENMARK
96 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
KINGSPAN
INSULATED PANELS 98
BENCHMARK 99
INSULATION 100
INSULATED DOOR COMPONENTS 101
ACCESS FLOORS 101 KINGSPAN
97 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
KINGSPAN
INSULATED PANELS Kingspan Insulated Panels has established a leading global PowerPanel Integrated Solar PV Solutions position in design and manufacture of high quality, high PowerPanel is a fully integrated insulated panel and solar performance insulated panel systems for all sectors of the photovoltaic systems. The systems are suitable for new and construction industry. refurbishment applications and can be installed at the same time as the insulated roof panels. Insulated Panels’ websites contain downloads for construction details, model specifications and data sheets, CONTROLLED ENVIRONMENTS as well as product information, case studies, photo galleries Controlled Environment insulated panel systems are and much more. designed for use within temperature controlled and hygiene-safe environments. INSULATED ROOF & WALL SYSTEMS Kingspan’s range of insulated panels have been successfully FireSafe, hygienic and fibre-free, these insulated panel used worldwide on retail, distribution, commercial, industrial, systems are suitable for internal and external walls, roofs leisure, residential, healthcare and education projects. and ceilings with an internal ‘box within a box’ modular box The performance advantages of Kingspan Insulated Roof & system also available. Wall Systems are well recognised by property investors, www.kingspanpanels.com building owners, designers and contractors.
INTEGRATED SOLAR SOLUTIONS Renewable energy products complement roof and wall panels and can be easily integrated into any building project. Renewable energy can contribute significantly to the energy used within a building, thereby reducing bills and carbon footprint.
EnergiPanel Solar Air Heating System EnergiPanel™ is a new, innovative, insulated solar-air heating system designed for wall applications as a supplement to the main heating system.
98 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
BENCHMARK BENCHMARK is your reference point for the complete DESIGN WALL SYSTEMS insulated building envelope. Benchmark brings together all The Design Wall Series features a range of premium the elements to help create stunning architectural wall and insulated panels with distinctive profiles, textures and roof façades to fit your building designs and specifications. colours, laid vertically or horizontally, for complete design With a wide choice in colour and texture, from modern flexibility. metallic to warm wood finishes, BENCHMARK combines style ROOF SYSTEMS and performance, offering the complete façade solution A range of roof system featuring Envirodek insulated roof without compromise. deck designed for green roof systems, and Roofliner and Topspan insulated panels that are ideal for ENGINEERED FAÇADE SYSTEMS standing seam waterproofing systems BENCHMARK build options have been developed to and single-ply membranes. complement our range of metallic and non-metallic façades. Two systems, featuring insulated panel technology, create www.kingspanbenchmark.com high performance envelopes that are simple and fast to install, eliminating complexities in design when using one or a mixture of façades.
Konnect Wall System A revolutionary, factory pre-engineered multi-spanning module with excellent thermal, structural and fire performance providing the ideal platform for the BENCHMARK façade range.
Karrier Panel System an alternative building method to the Konnect Wall System, BENCHMARK Karrier Panel System is a unique insulated panel specifically KINGSPAN designed and tested to support the BENCHMARK range of façades. The system provides excellent weather resistance, thermal, acoustic, fire and Manufacturing structural performance. Sales
99 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
INSULATION Kingspan Insulation is a market leading manufacturer of ENGINEERED TIMBER SYSTEMS premium and high performance rigid insulation products and Kingspan Insulation offers a range of highly insulated and insulated systems for building fabric and building services airtight engineered timber building fabric systems for both applications. domestic and non-domestic buildings. The solutions include:
INSULATION FOR ROOFS, WALLS & FLOORS Kingspan TEK® Building System Kingspan Insulation has a vast product range including Kingspan TEK® Building System consists of structural premium performance rigid Kooltherm® insulation; high insulated panels (SIPs) connected with a unique jointing performance rigid Therma® insulation; and Unidek high system for walls and roofs, and intermediate floors using performance rigid extruded polystyrene insulation. I-beams or open web joists.
To complement the range Kingspan Insulation Factory Insulated Timber Frame Systems have developed Optim-R™, the next Kingspan insulated timber frame systems are widely used by generation insulation solution that developers, contractors and self-builders across the private is up to five times more energy and affordable housing market and are suitable for the efficient than other commonly construction of buildings up to six storeys high. available insulation materials. www.kingspaninsulation.com
100 COMPLETE SOLAR THERMAL SOLUTIONS KINGSPAN SOLAR
INSULATED DOOR COMPONENTS ACCESS FLOORS Kingspan manufactures a wide range of insulated door Kingspan Access Floors is the world’s leading raised access panels and hardware components that are used within floor and underfloor service distribution solution provider Industrial and Residential sectional overhead doors. with extensive knowledge and experience across a wide These components are incorporated into completed range of building types including office and data centre sectional door assemblies through approved partner applications. organisations who provide a complete supply, installation Floors voids are available with standard product from 20mm and aftercare service package. up to 2000mm, but a project specific design service is www.kingspandoor.com available for voids of any height.
Kingspan Access Floors manufactures wide range of products, including: steel encased chipboard core systems ready to accept loose lay carpet; lock down panels for added security; high quality laminated panels for data centres; panels laminated with wood stone or granite; systems offering enhanced acoustic properties; and even systems that provide an economical raised flooring platform.
www.kingspanaccessfloors.com KINGSPAN
101
180 Gilford Road, Portadown BT63 5LF
Tel: +44 (0) 28 38364500 Fax: + 44 (0) 28 38364501 www.kingspansolar.ie
Tadman Street, Wakefield, West Yorkshire WF1 5QU
Tel: +44 (0) 1924 376026 Fax: +44 (0) 1924 385015 www.kingspansolar.co.uk