D6.3 - Guidelines for manufacturers
Contents
1. 3 It is recommended that the heat traps are pre installed to the tank D6 3 Guidelines for manufacturers and installers page 6 CombiSol WA 5 iNTeLeNEeET ENERGY Examples of editable detailed system layouts should be made available for the installer making it easy for him to provide to the user a detailed system layout of the specific system important for future maintenance Installation guidelines for installing the collector field in a way with good emptying behaviour over temperature protection shall be included in the installation manual The control of the different configurations and operating modes of the system should be explained in a clear and understandable way in the installation and user manuals Control settings should be specified A commissioning check list should be provided to the installer The manufacturer should agree with the installer that for all system installed the installer should send a copy of this check list to the manufacturer and a copy should remain at the user 1 2 4 Service and maintenance Recommended requirements for service and maintenance should be provided template for a service contract which the installer can offer the user should be provided Special reminder to keep the description of the actual system layout and control available for future maintenance should be included 1 3 Components 1 3 1 Collector The collector design should have good emptying behaviour Guidelines2. ccccccccccssseecsecccccssssseeeseecesessssueeeeeeccesssssseeeesecessssssuaeseeeesssssaaaeess 13 Figure 16 Temperature resistant collection tank made of metal left but not temperature resistant collection tank made of plastics right B cccccccsseeecccsesneeeecessaueeecesssaseeeeeeseaueeeeesssaasesssaseeeeessaaaeeesssaaaeeeesssaaeneeess 14 Figure 17 Good example of insulated pipe connections and combination of thermo siphon heat traps and insulation of pipes and all other cold bridges like air vent and thermometer Could however be better if already from the manufacturer these heat traps were integrated pre assembled in the store unit 3 15 Figure 18 Switch controlled circulation pump connected to switches in kitchen and bath room 3 15 D6 3 Guidelines for manufacturers and installers page 3 a oY ie SO INTELLIGENT ENERGY Introduction The guidelines given here are based on lessons learned in the CombiSol Project e Guidelines for best practise D2 1 e Guidelines for design and dimensioning 1 e Trend analysis for standardised systems Where is the market going 2 e 70 installed systems have been evaluated and analysed Where are the weak points where to take special care 3 e 40 solar combisystems were monitored and analyzed by energy balances on a monthly basis 4 The results from the systems evaluated and conclusions from the analysis done show that there are room for improvements bot
3. Expansion vessel is to be put on the cold side and connected in the top see figure or via heat trap Pressure setting and dimensioning should be done according to manufacturer s instructions for the specific type and size of installation ae right false Right and false way for connecting a expension vessel in a solar thermal system Figure 14 Connecting the expansion vessel 2 Check if stagnation cooler is necessary to be checked with manufacturer recommendations See tee mearra see io ane cee Aae em eE eee a Sisa i erTi LITA Sila a ee ee a i r j i i I 4 b ff Sis EErEE adien eanes rec ae mein Pe pi Eii f avert Prti gt 7 Figure 15 Stagnation cooler example 2 Safety line from safety valve shall be temeperature resistant and lead to temperature resistant container D6 3 Guidelines for manufacturers and installers page 13 C amas TF INTELLIGENT ENERGY CombiSol 12 S cuROPE Source AEE INTEC Austria OK Source ITW Germany NOT OK Figure 16 Temperature resistant collection tank made of metal left but not temperature resistant collection tank made of plastics right 3 2 3 6 Back up heater Before installing the solar system in connection with an existing back up boiler unit it is recommended to investigate possibilities relevance for exchanging this boiler unit at the same time If existing boiler unit is not exchanged
4. for connecting the collectors in series parallel depending on the number of collectors should be given order to keep a good emptying behaviour good flow distribution and low pressure loss for the whole collector field Figure 3 Collectors with good emptying behaviour 2 1 3 2 Storage Cold bridges to the tank should be avoided especially in the upper part always heated by the back up Pre installation of heat traps where possible is recommended Insulated caps for unused connection should be provided 1 3 3 Controller and sensors Simple controller and or controller leaving only few and logical choices to the installer should be used Location of sensor should be clearly described and suitable fixings fittings for the sensors should be used for good thermal contact and secure fixing D6 3 Guidelines for manufacturers and installers page Solr INTELLIGENT ENERGY CombiSo KA F i R ae s Source AEE INTEC Austria Figure 4 Temperature sensors fixed correctly 3 1 3 4 Solar loop Manufacturer should deliver and or give specifications for the piping including insulation pre insulated pipes are recommended Materials used shall fit the max temperatures and for the part placed outdoor fit the outdoor environment solar radiation rain birds insects Manufacturer should deliver and or give specifications for the pumps use of high efficiency pumps is recommended Figure 5 External pipe insulation g
5. it should be assured that the control of the solar part of the system and the back up system works without conflicts Units including solar and back up systems are recommended 2 3 Hot water units Separate hot water heat exchangers should be part of close to the storage to avoid heat loss 2 3 8 System Manufacturer should aim at system integration and pre assembling This gives easier cheaper installation and less little risk of errors In general there should be focus on system heat losses including especially cold bridges Pre installation of heat traps where possible is recommended Insulated caps for fittings and unused connection should be provided D6 3 Guidelines for manufacturers and installers page 14 fC Arahit ae D INTELLIGENT ENERGY CombiSol LA 5 e 3 A ait G Source AEE INTEC Figure 17 Good example of insulated pipe connections and combination of thermo siphon heat traps and insulation of pipes and all other cold bridges like air vent and thermometer Could however be better if already from the manufacturer these heat traps were integrated pre assembled in the store unit 3 2 3 9 Installation The installer should check if the return temperature is higher than necessary and take measures to lower it guidelines from manufacturer should be followed On demand hot water circulation system should be recommended See ait Source AEE INTEC Figure 18 Switch controlled circulation pump c
6. lower it with examples On demand hot water circulation system should be recommended D6 3 Guidelines for manufacturers and installers page 10 INTELLIGENT ENERGY CombiSoli S EUROPE E 2 Guidelines for installers 2 1 General The main focus for product and system improvements should not be on increasing the solar gains but much more on reducing heat losses in solar combisystems Integrated standardised systems units with pre installed closely connected components and one common controller are recommended 2 2 Paper and procedures 2 2 1 Documents for the user Installer should provide for the user e System layout principle diagram installer should recommend the user to put it a visible place see e g figure below e Description of the control of the system including which settings can be adjusted by the user e Commissioning report including check list for insulation and heat traps e Service manual describing service intervals and service points the installers should offer the user a service contract e Service contract Figure 10 System layout good example 3 2 2 2 Service and maintenance Recommended requirements for service and maintenance should be provided to the user Special reminder to keep the description of the actual system layout and control available for future maintenance should be included Template for service contract should be provided for the installer D6 3 Guidelines fo
7. PlankEnergl CombiSol Z CombiSol project Solar Combisystems Promotion and Standardisation D6 3 Guidelines for manufacturers and installers Editor Jan Erik Nielsen PlanEnergi Contributions from Alexander Th r Johann Breidler Gabriele Kuhness AEE INTEC Thomas Letz Guillaume Pradier Xavier Cholin INES Education Philippe Papillon Mickael Albaric CEA Ines Chris Bales SERC Barbara Mette Jens Ullmann ITW 2010 19 1 2011 DRAFT INTELLIGENT ENERGY F EUROPE W The sole responsibility for the content of this publication lies with the authors It does not necessarily reflect the opinion of the European Union Neither the EACI nor the European Commission are responsible for any use that may be made of the information contained therein Com CONTENTS FIQU Sa ow sce es es oe es ene ote sees ees 3 MOGUC HON earn neem eee ene ene eee ee eee eee ee eee ee ee eee ee ee 4 1 Guidelines for manufacturers 11 csecccnecccnenscenscnensenanscnensenaensenansenansenanseoensesensssensess 5 Mek GODOT AN erica snte mcr NR 5 1 2 Papers ANG procedures visevcsecscceswcesseesteveetencsusewusnessaecccmescuedesccesceusentsnsesineadeneasvscsnnesuiees 5 1 2 1 System specific design guidelines for the installer ccccccccccsssseceeeeeeseeeeeeeeeeeeeseeaeeeeseeseaees 5 Be E E E U E E A A E A E E E ok osnauads 6 1 2 3 VS rete MPI Gl e E E A E E E E E E sacs eczesnee ce 6 1 2 4 Service and maintenance eee eeeeee
8. at exchangers depending on collector and storage size e Specification of size of expansion vessel and pressure setting depending on collector size and type piping and height difference between collectors and expansion vessel D6 3 Guidelines for manufacturers and installers page 5 i Ta NE a D INTELLIGENT ENERGY CombiSol i P EUROPE ay Double tank solution should normally be avoided as it typically increases the system losses more than the system gain As much system integration as possible is recommended e pre assembled components e integrated back up e one integrated controller for both solar and back up system 1 2 2 User manuals Manufacturer should provide a complete but simple and understandable user manual describing e the functioning of the system e user control possibilities with recommendations for settings e how the user detect if the system is not operating properly The user manual should also include e recommendation to make a service contract with installer e notice that the installer should fill out a commissioning check and supply the user and the manufacturer with copies 1 2 3 Installer manuals Besides the system specific design guidelines a detailed installation manual should be available Included here should be specifications how to avoid cold bridges and instructions on how to make the necessary heat traps Source Ines Education France Figure 2 Pipe connection with thermo siphon heat trap
9. ccccsseseccnauseecssuueeccsausuecsaueeeessueeeessauaeessaneeessaneesessaaas 8 Figure 5 External pipe insulation good quality of insulation and protection ccccccesseeeeeeeeneeeeeeeeeneeseeeseaneees 8 Figure 6 Connecting the expansion vessel 2 ccsssecccccccccccesseecececcsssssseeuseeceesessssseeeeeecesssssaaeneeeeeesssssaaaeeees 9 Figure 7 Stagnation Cooler example 2 ccccccccccsceecccsceseccnsuseccnsuueecnsaseccsacsesenscueeensasuessauaesesscuesensauesessages 9 Figure 8 Domestic hot water unit example placed directly to the unit 2 ccsccccssceesccetecetseceeteeeetaes 10 Figure 9 Okofen unit with all in one example placed directly to the unit 2 c cccccccesssseeeeeeeeeeeeeeseees 10 Figure 10 System layout good example B cccccssscceccccsseeeecceecseeeeccescauseeeesensueceeesssaeaeeeessaaaaeeeessaaaeseeessaas 11 Figure 11 Collectos with good emptying behaviour 2 scccccccsseccecceesneeeeceessueeeecesaseeseeesssaaseeessaaaeseeessaas 12 Figure 12 Temperature sensors fixed correctly B cccccseccccseeecccsneseccsauseeesaeeeessaneeesssaeeessaaeeesssaenesssaneneseas 12 Figure 13 External pipe insulation good quality of insulation and protection ccccsesececeeseeseeeseeneeeneeseens 13 Figure 14 Connecting the expansion vessel 2 ccccccccccccesseeeseccccessssseeeseeccessessseeseecessssssaeaeseeeeesessaaaeeess 13 Figure 15 Stagnation cooler example 2
10. eccccceeeeseeeeeeeeeeeeesseeeeeeceeeeesseeasseeeeeeeeesseeaseeeeeeeessuaeaeeeeeeeeeseaas 7 Med COMPONENTS cscecccccess cucsencseqeenccsseceasneusecenussuctasnseaeteccieweesectuasteocseucsuantucctwonseuecctatemcsnecteneseus 7 1 3 1 ONES TOM srectasauaiccireadenanatgncase E A E sue Gpectieayta ss uieadoreatusenaguieiaozones 7 ec SOE ee nn ee eee eee eee 7 139 Conrolerand SENSO S sssini AEEA eee A AEEA EREA EREE NAE R ANEKERE EREE 7 Toa OA DO esee E E ee ne ee 8 1 3 5 Expansion vessel and over temperature protection cccccccseeececseeeeeeeeeeeeecseeeeesaeeeeeeseneeeesaees 8 1 36 Back p IS ALON acancktnanawavian avicarehianedicnnshonicwhlsandivetenmcaumhiawpiccalishamensGadandigesinsansiinhdaxtiieuvanauseebatandlectssaenicaninesa 9 1 3 7 BU WN A LUTTE Soest entiation ie ase mado Saleem clits etre Gers gone AAEE mean Gee tev E E EAE nA 9 IES co E E A EE ee ee eee ee ee eee eee 10 1 3 9 PSST tM ic ore A E E E E E AE E E E E T N E E E EN 10 2 Guidelines for installers 1 1 1sccsesccensccenscnenecnennnnensnsenenscsansesansesansesensecnsenansensssenensenes 11 DN GEDA E A 11 22 Paperand OC IS scissa a 11 2 2 1 Documents for Me USET sa cecanstinn ces sahatueutnneiseuaslanticuysl cua dln sdeurenibensunsinatane sa STERA EAN s ETERRA ineei 11 222 OGVCE and Mantenan Creo sx eesesnndeecessyedscenendieaadlsvssnverediincwaddusidsicsntncedaadsmadeceasndieacddesescnnseiadendones 11 2 3 COMponentS sssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn
11. h at product and installation level so the guidelines here are indeed relevant The trend analysis shows that standardised integrated system units are now showing up in the market it is expected that this trend in general will lead to improved system performance D6 3 Guidelines for manufacturers and installers page 4 INTELLIGENT ENERGY CombiSol 3 fe f EUROPE gy 1 Guidelines for manufacturers 1 1 General The main focus for product and system improvements should not be on increasing the solar gains but much more on reducing heat losses in solar combisystems Integrated standardised systems units with pre installed closely connected components and one common controller are recommended 1 2 Papers and procedures 1 2 1 System specific design guidelines for the installer Manufacturer should provide detailed and understandable guidelines for and examples of system layout Drawings of example system layouts should be given for at least e installation in connection with fast reacting oil or gas back up e Installation in connection with slower reacting biomass back up Figure 1 System layout good example 3 Manufacturer should provide rules for sizing the system and its components depending on the space heating and hot water load estimated annual energy consumption of the house e Specification of collector and storage size depending on the energy consumption of the house e Specification of pump piping and he
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13. onnected to switches in kitchen and bath room 3 The installer should check if e g the storage is fully insulated from the manufacturer if not the installer should finish the insulation Especially insulation of the top part of the tank is VERY IMPORTANT D6 3 Guidelines for manufacturers and installers page 15 ig Aes Fe D INTELLIGENT ENERGY CombiSol 1 S EUROPE mm 3 Bibliography 1 Th r A etal 2010 D2 3 Guidelines for Design and Dimensioning 2 Th r A etal 2010 D2 4 Updated State of the Art Report Of Solar Combisystems Analysed within CombiSol 3 Th r A etal 2010 D5 4 Summary of the Qualitative Evaluation of Solar Combisystems 4 Letz T et al 2010 D4 4 Comparison of results of all monitored plants D6 3 Guidelines for manufacturers and installers page 16
14. ood quality of insulation and protection 1 3 5 Expansion vessel and over temperature protection Manufacturer should deliver and or give specifications for the expansion vessel Rules for pressure setting depending on collector size and type piping and height difference between collectors and expansion vessel should be clear to the installer Specification how to install expansion vessel to avoid unnecessary heat loss should be given D6 3 Guidelines for manufacturers and installers page 8 More oy INTELLIGENT ENERGY CombiSol i SJ EUROPE mm false Right and false way for connecting a expension vessel in a solar thermal system Figure 6 Connecting the expansion vessel 2 Cases where stagnation cooler is needed should be specified and manufacturer should deliver and or give specifications for such cooler y itt titans ait sine l ii SEERE EEEN pes i Ee ENRE Be B fel a ue bea pe rm SP Rec EREN BEE r s i a E ERR E lowe oA Figure 7 Stagnation cooler example 2 Specification for safety line from safety valve shall be given e Temperature resistant piping with right dimensions leading to temperature resistant container preferably showing indicating the fluid content 1 3 6 Back up heater Units including solar and back up systems are recommended and this is the trend seen lf manufacturer delivers only the solar part recommendations and examples
15. r manufacturers and installers page 11 TF INTELLIGENT ENERGY CombiSoliZ SJ EUROPE EE 2 3 Components 2 3 1 Collector The collector design should have good emptying behaviour Guidelines for connecting the collectors in series parallel depending on the number of collectors should be given order to keep a good emptying behaviour good flow distribution and low pressure loss for the whole collector field _ re ee q Figure 11 Collectos with good emptying behaviour 2 2 3 2 Storage Cold bridges should be avoided Pre installation of heat traps where possible is recommended Insulated caps for unused connection should be provided 2 3 3 Controller and sensors Sensor location is critical and immersion sleeves should fit the sensor diameter for good thermal contact Sensors should be secured fixed in the location Source AEE INTEC Austria Figure 12 Temperature sensors fixed correctly 3 2 3 4 Solar loop Manufacturer should deliver and or give specifications for the piping including insulation Materials used shall fit the max temperatures and for the part placed outdoor fit the outdoor environment solar radiation rain birds insects D6 3 Guidelines for manufacturers and installers page 12 pret CombiSol 77 D INTELLIGENT ENERGY Figure 13 External pipe insulation good quality of insulation and protection 2 3 5 Expansion vessel and over temperature protection
16. should be given how to connect to the different possible back up systems Interaction of solar and back up controllers should be described If certain back up system types are not feasible with the solar system this should be stated 1 3 7 Hot water units Separate hot water heat exchangers should be part of close to the storage to avoid heat loss page 9 D6 3 Guidelines for manufacturers and installers CamRit INTELLIGENT ENERGY CombiSol 1 SJ EUROPE E Domestic hot water unit Name PW M365 Figure 8 Domestic hot water unit example placed directly to the unit 2 1 3 8 System Manufacturer should aim at system integration and pre assembling This gives easier cheaper installation and less risk of errors iA kemm ee ee i Figure 9 Okofen unit with all in one example placed directly to the unit 2 In general there should be focus on system heat losses including especially cold bridges Pre installation of heat traps where possible is recommended Insulated caps for fittings and unused connection should be provided 1 3 9 Installation lt should be noted in the installer manual that it is very important that the solar system operates on as low temperatures as possible hence the return temperature from the heat distribution system should be as low as possible In the manual hints or references to hints should be given How to check if the return temperature is higher than necessary and how to
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