Manual TwinSolar / TopSolar- Brochure

TWINSOLAR - SLK TOPSOLAR TECHNICAL MANUAL Installation information Technical information Operating and maintenance instructions www.twinsolar.comN°0680401011-01-2010S O L A R TWINSOLAR MANUAL 2 S O L A R Contents TwinSolar - TopSolar 1. Grammer TwinSolar – TopSolar...........................................................................4 1.1. What is the performance of a Grammer TwinSolar and TopSolar panels .....4 1.2. Grammer TwinSolar – TopSolar ...................................................................6 1.3. Accessory kits ...............................................................................................8 1.3.1. Collector installation kits ........................................................................8 1.3.2. External accessories..............................................................................8 1.4. Planning information for TWINSOLAR..........................................................9 1.4.1. Collector arrangement ...........................................................................9 1.4.2. Recirculating air version.......................................................................10 1.4.3. Air distribution system – planning information......................................10 1.5. Installation and maintenance information...................................................12 1.5.1. Important information TWINSOLAR – TOPSOLAR ....................................12 Collector orientation ...........................................................................................13 1.5.2 Fan.......................................................................................................13 1.6. Control TWINSOLAR ..................................................................................14 1.6.1. Control TwinSolar 1.3, TwinSolar 2.0...................................................15 1.6.2. Control TWINSOLAR 4.0 to 12.5 .........................................................16 1.6.3. TWINSOLAR – Comfort changeover kit...............................................18 1.6.4. Temperature measurement – control set – room thermostat ...............18 1.6.5. Operation with summer ventilation kit / wall ventilation ........................19 1.7. CHECK LIST –ERROR CORRECTION .....................................................20 1.8. Collector installation ....................................................................................21 1.8.1. Installation on inclined roofs.................................................................21 1.8.2. Wall installation with Grammer installation brackets …………………..28 1.8.3. Installation on flat roofs .......................................................................29 1.9 General maintenance information....................................................................31 1.9.1. GRAMMER air collector ...........................................................................31 1.9.2. Checking the fixing of collectors and mounting frames ............................31 1.9.3. Cleaning ...................................................................................................31 1.9.4. Air filter .....................................................................................................31 1.9.5. Air as heat transfer medium .....................................................................32 1.10. Safety information.........................................................................................32 1.10.1. Weather..................................................................................................32 1.10.2. Ladders ..................................................................................................32 1.10.3. Protection from falling objects ................................................................32 1.10.4. Protection against falling ........................................................................32 1.10.5. Rules of technology................................................................................33 TWINSOLAR MANUAL 3 S O L A R 2. TopSolar.............................................................................................................34 2.1. Info / Technical data....................................................................................34 2.2. Hot water generation – SolarBox SLK.........................................................36 2.3. Control ........................................................................................................37 2.3.1. Operation DeltaSol BS Plus.................................................................37 2.3.2. Control TOPSOLAR – Solar air supply system....................................38 2.3.3. Control TOPSOLAR – Solar generation of water for domestic use......40 2.3.4. Control TOPSOLAR – Under floor system...........................................42 2.3.5. Temperature sensors – arrangement/installation.................................44 2.4. CHECK LIST – TopSolar error correction ...................................................44 3. CAD-drawings ....................................................................................................45 3.1. Collectors ....................................................................................................45 3.2. TWINSOLAR fans .......................................................................................54 Imprint This manual is, including all its parts, copyrighted. Any use beyond copyright requires the consent of the company Grammer Solar GmbH. In particular, this applies to reproductions, translations and storage in EDP systems. Editor: Grammer Solar GmbH, Oskar-von-Miller-Str. 8, 92224 Amberg Important remarks You should execute your projects on the basis of your own plannings and calculations. Please respect the standards as well as the DIN-regulations valid. The images and texts printed in this manual only serve as examples. We exclude any liability for the completeness of the printed images and texts. If the contents imparted in the catalogue are used, so at the risk of each user. A publisher’s liability for incomplete, incorrect or false information and all hereof resulting damages is generally excluded. The current version of the manual can also be downloaded from the login area on http://www.grammer-solar.de. Errors and technical modifications excepted. Example: SolarAir-System, Waterhouse South Africa – www.wasserhaus-suedafrika.de TWINSOLAR MANUAL 4 S O L A R 1. GRAMMER TWINSOLAR – TOPSOLAR Heating and ventilation by means of solar energy GRAMMER TWINSOLAR is a mains-independent air collector system for heating and ventilating by means of solar energy. Because air is the heat transfer medium, TWINSOLAR is safe in operation and almost maintenance-free. GRAMMER TOPSOLAR the mains-operated alternative – a collector system similar to TWINSOLAR but without a photo-voltaic module. The photo-voltaic panel integrated in the collector ensures mains-independent operation of the system. With TWINSOLAR you will receive tried-and-tested collector technology based on 30 years of experience in the production of air collectors. 1.1. What is the performance of a Grammer TwinSolar and TopSolar panels Even when the solar radiation is low – i.e. when the sky is cloudy – GRAMMER TWINSOLAR starts working and conveys fresh, warm air into the building. During maximum solar radiation the temperature increase can be up to 40 degrees with a power output of 700 W/m². The maximum radiation intensity from the sun is – regardless of the time of year – 1000 Watt per m² collector surface. This peak power is observed particularly during cold and clear winter days . 70 % of this received solar energy is transformed into thermal energy by TWINSOLAR and delivered to the building. The collector capacities and increase in temperature provided also apply to TOPSOLAR. . TWINSOLAR MANUAL 5 S O L A R Dimensioning – optimum collector size The required size of TWINSOLAR and TopSolar systems depends principally on the room area to be heated. For the dimensioning of the collector size, the diagram below provides reference values. Collector dimensioning – reference value for a building with medium insulation standard 10 – 20 m² living area <-> 1 m² air collector Notes: - In the case of buildings with a good insulation standard or for installations in southern Europe 1 m² of collector area can heat and ventilate a living area of up to 20 m². - The reference values refer to an average room height of 2.5 m. - For permanently used buildings (e.g. dwelling houses) the simulation program Luftikuss can carry out a dimensioning computation providing information about the achievable energy saving. A Luftikuss demo-version is available at www.grammer-solar.de in the Login-area. TWINSOLAR MANUAL 6 S O L A R 1.2. Grammer TwinSolar – TopSolar Information / technical data You will receive your Grammer TWINSOLAR system completely ready for use, and it is easily installed. The PV modules integrated at the air inlet of one of the solar air collectors provide the electricity for the fan, the absorbers provides comfortable heat and the air channels convey the warmed fresh air to where it is needed. An automatic control ensures that all components work harmoniously together even when you are away. Scope of delivery of the TWINSOLAR collector packages: - Grammer high performance air collectors type SLK - Collector-integrated solar module - Fan inclusive Powerunit (APW) - TWINSOLAR Control (room thermostat for TWIN 1.3 / 2.0) solar control Collector-integrated air filter with change frame TWINSOLAR – certified quality As part of the EU research project IEA- Task 19, the Grammer air collector was measured in 1998 together with 6 further air collectors. In this test the Grammer air collector gave the best results. Based on this, in collaboration with the Fraunhofer Institut für solare Energiesysteme - ISE (Fraunhofer Institute for solar energy systems), we have developed the solar air collector SLK for small installations. More than 30 years of experience in the production of air-base solar collectors Characteristics of TWINSOLAR SLK ? solid and durable aluminium frame housing (sea water resistant) ? 4 mm hail-proof single pane safety glass ? durable aluminium ribbed absorber ? high quality mono-crystalline or poly-crystalline solar module ? integrated air filters prevent contamination of the collector ? nominal power approx. 700 Watt / m² - theoretical efficiency > 80% ? 10 year warranty for the collector housing – minimum service life 25 years ? GRAMMER air collectors are grant supported (application forms on the Internet) TWINSOLAR MANUAL 7 S O L A RTechnical data for TWINSOLAR SLK (Technical Data TOPSOLAR: See Chapter 2.1) TECHNICAL DATA TWINSOLAR 1.3 TWINSOLAR 2.0 TWINSOLAR 4.0 TWINSOLAR 6.0 TWINSOLAR 8.0 TWINSOLAR 10.0 TWINSOLAR 4.5 TWINSOLAR 8.5 TWINSOLAR 12.5 Gross collector area [m²] 1.3 2.0 4.0 6.0 8.0 10.0 4.55 8.55 12. 55 Collector field dimensions LxW [m] 1.45 x 0.9 2.0 x 1.0 4.0 x 1 6.0 x 1 8.0 x 1 10.0 x 1 2.25 x 2.1 4.25 x 2.1 6.25 x 2.1 Thermal power peak [W] 700 1.200 2.400 3.600 4.800 6.000 2.700 5.100 7.500 Suitable for heated dwelling house area [m²] 10 – 20 15-30 40-50 60-80 80-100 100-120 40-60 80-100 120-150 Electr. power PV module [W] 10 23 57 57 114 114 57 114 114 Nominal rating fan [W] 4 18 50 50 100 100 50 100 100 Collector housing aluminium aluminium aluminium aluminium aluminium aluminium aluminium aluminium aluminium Collector weight [kg] 29 45 90 135 180 225 110 200 290 Fan type - arrangement ebmpapst high performance fans 4312NN axial integrated in collector 6224N axial integrated in collectorG1G 120 radial external G1G 120 radial external G1G 140 radial external G1G 140 radial external G1G 120 radial external G1G 140 radial external G1G 140 radial external Maximum air volume delivered, free-blowing [m³/h] 80 120 200 200 350 350 200 350 350 Max. external pressure [Pa] 25 30 80 80 130 130 80 130 130 Diameter of air outlet [mm] 125 125 160 160 160 160 160 160 160 Differential temperature control Thermostat Thermostat ? ? ? ? ? ? ? Solar controller TWINSOLAR Control with room sensor (type Pt 1000) - ? ? ? ? ? ? ? A data sheet with precise information on the SLK collector as well as information on the testing Institute, see appendix. Collector pressure losses TWIN- and TOPSOLAR 01234567891011120 100 200 300 400Airflow [m³/h][Pa/m] Diagram 1: Pressure losses per collector series length dependent on volume flow. Diagram 2: pressure losses at the inlet and outlet of the collector connecting pipe. Example: TOPSOLAR 10 with air supply 2x DN 160 mm and amount of air 300 m3/h. Diagram 1) 300 m3h – 6.5 Pa/m 6.5*10m = 65 Pa Diagram 2) DN 160 mm: 300 m3h – 9 Pa 2*9 = 18 Pa total:83 Pa 0246810120 100 200 300 400 500volume flow [m³/h]pressure loss [Pa]d = 160 mmd = 200 mm Diagram 2: Pressure losses at the inlet and outlet of the collector pipe connection Example: TOPSOLAR 10 with air supply 2x DN 160 mm and amount of air 300 m³/h Diagram 1) 300m³/h -> 6,5 Pa/m 6,5 * 10m = 65 Pa Diagram 2) DN 160 mm: 300m³/h -> 9 Pa 2 * 9 = 18 Pa Total: 83 Pa TWINSOLAR MANUAL 8 S O L A R 1.3. Accessory kits 1.3.1. Collector installation kits Installation on inclined roofs + stainless steel roof hooks for tiled roofs + aluminium installation rails, attachment brackets and screws + roof lead-through made from lead sheet, sealing profile and tube connection piece Installation on flat roofs + 20°, 30°, 45° and 60° mounting frame made from aluminium angle sections Installation on walls + aluminium multi angle (drilled + attachment material) + insulated wall lead-through 1.3.2. External accessories Pipe sound absorber (SD) + High performance sound absorber to reduce fan noise – is integrated into the system immediately adjoining to the fan in the pipe system Recommended accessory from TWINSOLAR 4.0 /TOPSOLAR Telephony sound absorber (TSD) +to prevent sound transmission (telephony sound) between two rooms connected by the same ventilating system. + Flexible pipe structure enables installation even in a narrow space and with difficult pipe ducts. It is therefore also available as an alternative to pipe sound absorbers in difficult installation situations. Non-return valve (RSK /. DOSU) + prevents air circulation from the room via the tube system into the collector Recommended accessory Fresh air disc valve + designer air outlet made from galvanised steel plate, painted white Comfort changeover kit + external utilisation of the collector-integrated PV module (Twin 2.0 – 10.0) + scope of delivery: Changeover switch, 5 m cable UV-resistant 3x1.0 mm² Summer ventilation kit + summer use of the collector-integrated PV modules for air extraction + scope of delivery: Direct current fan (12 Volt, 5,6 Watt) with wall lead-through, muffler and fresh air grill TWINSOLAR MANUAL 9 S O L A R1.4 Planning information for TWINSOLAR 1.4.1 Collector arrangement Standard arrangement variants Alternative arrangement variants TWIN- TOPSOLAR 4.5TWIN- TOPSOLAR 8.5TWIN- TOPSOLAR 12.5Abmessung:2.21 x 2,25 x 135 mm (4.55 m²)Abmessung:2.21 x 4,25 x 135 mm (8.55 m²)Abmessung:2.21 x 6,25 x 135 mm (12.55 m²) Notes: - All collector systems can be installed in a mirror arrangement or turned. - Further alignment versions and collector combinations up to 18 m² can be provided on request. - Precise CAD collector diagrams may be found in chapter 3 in this handbook TWIN-TOPSOLAR 4.5 dimensions: 2.12 x 2.25 x 135 mm (4.55m²) TWIN-TOPSOLAR 8.5 dimensions: 2.12 x 4.25 x 135 mm (8.55m²) TWIN-TOPSOLAR 12.5 dimensions: 2.12 x 6.25 x 135 mm (12.55m²)Elbow collector: The alternative versions for alignment are implemented with an elbow collector (SLKUM) at the end of two parallel collector series. The elbow collector has a gross collector surface of 0,5 m² and is similar to a standard SLK collector - dimensions 2,12 x 0,25 m Modular Construction: Starting from TWIN- TOPSOLAR 4.0 the system packages are composed of individual SLK collectors. TWINSOLAR MANUAL 10 S O L A R 1.4.2 Reirculating air version As standard, TWINSOLAR and TOPSOLAR arrangements are provided for so-called "fresh-air operation". This means that fresh outside air is sucked in via an air filter integrated into the collector. Optional recirculating air operation As an alternative to the fresh-air operation, the collector can also be fed with room air from the building or with fresh air via an external filter box (always plan it). This can be sensible in the case of the following applications: 1) Pure heating operation, no ventilation necessary. Room air from the building is warmed in the collector can then returned to the room. 2) Comfortable filter replacement in the loft. Instead of the more difficult filter replacement on top of the roof, the filter maintenance of an external filter box could be carried out easily in the loft. 1.4.3 Air distribution system – planning information ? Use spiral tubes made from galvanised steel plate of dimensions 125 mm and 160 mm ? Plastic tubes should not be used (evaporation, odour problems) ? A non-return valve must always be installed in the tube between the collector and the room. ? With TWINSOLAR 1.3 and 2.0 the fan is integrated in the collector. An external radial fan from TWINSOLAR 4.0 is delivered with the collector package. ? In the fresh air tube sound absorbers are to be built-in downstream of the fan (from TWN 4.0). ? If two neighbouring rooms are connected by the ventilation system, telephony sound absorbers are to be installed between them. ? All tubes carrying warm air are to be insulated. ? Tubes carrying cold air through warm rooms are to be insulated – prevention of condensation ? Keep the tube connection short in order to limit pressure drops and heat loss ? Observe the permissible pressure losses (table chapter 1.2 "Technical data" and the following rules of thumb External filter box Room air or external air TWINSOLAR MANUAL 11 S O L A RRules of thumb for dimensioning the ventilation system: Components TWIN 2.0 TWIN 1.3 TWIN- TOP-SOLAR 4.0 TWIN- TOP-SOLAR 6.0 TWIN- TOP-SOLAR 8.0 TWIN- TOP-SOLAR 10.0Diameter air supply to the collector 125 mm 160 mm 160 mm 160 mm 160 mm Pipe DN 160 mm [m] *) 10 10 10 10 max. pipe DN 125 mm [m] *) 4 8 8 10 10 max. number of pieces, elbows *) 2 8 8 8 8 max. number of pieces, T-pieces – branches of pipes 1 2 3 4 max. number of pieces air supply disk valves DN 125 **) 1 2 3 4 5 Air quantity at 150 Pa air pressure external [m³/h] 120 bei 30Pa 80 bei 20Pa 200 200 350 350 *) This number applies to the longest (most unfavourable) string of pipes **) 2 outlets DN 125 can be replaced by 1 outlet DN 160 **) 3 outlets DN125 can be replaced by 1 outlet DN200 Air ducts for TWINSOLAR 1.3 / 2.0 The fans are designed for short tube connections only. The tube length of vertical tubes (see diagram) is limited. With TWINSOLAR 1.3 and 2.0 the fan is integrated in the collector and insulated against noise transmission. Normally an additional muffler is not required. Collector details Fig. 1: Filter on the back of the collector. Pull out to the side from the collector side Fig. 2: Air outlet On the back of the collector For TWIN 1.3 / 2.0 DN 125 mm From TWIN 4.0 DN 160 mm Fig. 3: Photo-voltaic module The photo-voltaic module is located at the glazing level of the collector or in the area of the (cooler) air inlet of the collector Fig. 4: Glass cover The glass cover consists of hail-resistant single pane safety glass Overview of tubes and fittings: You will be able to obtain suitable ventilation accessories from our local partners. The partner list can be found on the Internet at www.grammer-solar.com HTwin 2.0: H max = 3m TWINSOLAR MANUAL 12 S O L A R1.5 Installation and maintenance information 1.5.1 Important information TWINSOLAR – TOPSOLAR ? PV modules of the TWINSOLAR collector must be installed at a location which is never shaded. Even minor shading of the solar modules will result in a massive loss in performance. ? The air filter must be replaced at least once or twice a year ? Air-intake: Do not install the filter collector or air-intake close to a chimney, an exhaust air duct or near other dangerous or toxic gases. ? Adequate space is to be provided to allow the air filter to be removed from the collector from the narrow side ? Install the fans (external starting with TWINSOLAR 4.0) with insulation against transmission of vibrations ? Provide a sound absorber downstream of the fan (see diagram below) ? All electrical installations are to be carried out by an electrician in accordance with the VDE guidelines. ? All the screw connections on the collector installation kits are to be checked annually for tightness and, if necessary, tightened up. ? Integration into the building envelope: The space between the collector and the building envelope is to back-ventilate, while the masonry is to protect against intruding moisture. Maintenance and repair or replacement of a defective collector pane are only possible if there is about 4 cm surrounding area at the sides of the collector to dismantle the glazing profiles. Fig. 1: TWINSOLAR system with external fan (from TWIN 4.0) and a simple solar ventilation system Further system variations: ? Solar air supply system with hot water generation/ SolarBox ? Solar domestic ventilation ? Solar under floor heating You will find more information in chapter 2. TWINSOLAR MANUAL 13 S O L A RCollector orientation For optimum performance in the northern hemisphere, the collector should always be directed to the south, in the southern hemisphere to the north. However, deviations from the optimal direction of up to 45° only result in a minor reduction in the energy gain. Because a warm air collector system is mainly used to provide energy during the winter, spring and autumn, and as during these seasons the solar angle is relatively low, the collector should ideally be installed onto frames at a 45° to 60° angle from the horizontal. In areas where high snowfalls are to be expected, wall-mounting is recommended 1.5.2 Fan ? Commissioning: Only when the air-duct system is connected ? Vibration insulation from the duct system: flexible connection tubes (contained in the scope of delivery) are to be mounted on the inlet side and the pressure side. See fig. 3 ? Vibration insulation from the building: Install a hard foam support between the fan support and the sub–structure as well as rubber washers on the screws ? Noise from the air flow: Always install a muffler downstream of the fans ? Fan installation: Always on the suction side ? Never insulate fans and protect against heat accumulation: Danger of overheating ? Fans are not weather-proof or water-proof ? With TWINSOLAR 1.3 and 2.0 the fan is integrated in the collector (ready for operation). Fig. 2: Direct current fan G1G (installed externally downstream of the collector) Standard fan from TWINSOLAR 4.0 Fig. 3: Ventilator installed din pipes. Standard ventilator for TOPSOLAR -units - Solar air supply system Fig.4: Radial ventilators. Radial ventilators with external motors and highly temperature resistant (hot water generation) 21st June 21st September 21st March 21st December 8:33 hours 6:20 hours 4:00 hours Fig. 1: Position of the sun subject to season Quelle: DGS -Leitfaden Thermie [N] [W] [S] [Southern hemisphere ] TWINSOLAR MANUAL 14 S O L A R1.6 Control TWINSOLAR For the maximum utilisation of solar energy, the operator should note the following: ? The solar control automatically controls the operation of the TWINSOLAR systems as a function of radiation or collector temperature and room temperature. ? The desired maximum room temperature is to be set 2 to 3 °C higher at the solar controller than that set for the conventional heating system. (Preferential setting for solar energy) Fig. 1: TWINSOLAR 1.3 / 2.0 room thermostat TEM 73 A For limiting the maximum temperature from TWINSOLAR 1.3 and 2.0 (included in the delivery) Fig. 2: TWINSOLAR 4.0 – 12.5 TWINSOLAR Control PV-operated differential temperature controller (included in the delivery) POWERUNIT- APW (matching transformer) The POWERUNIT-APW provides optimal usage of the photo-voltaic modules at different radiation conditions and guarantees maximum solar gain. From TWINSOLAR 4.0 onwards these electronic parts are integrated into the socket of the ventilator in standard form. Fig. 3: PV system with maximum power unit (APW) Warranty: Never attempt to interfere with the collector technology or electronics yourself, because otherwise the warranty will become void. Should the collector develop a fault during the warranty period, we will repair the collector or deliver a replacement. APWDC fan Photo-voltaicmoduleMaximum power unit(APW)PV-driven DC fan+-+-TWINSOLAR MANUAL 15 S O L A R1.6.2. Temperature Control TWINSOLAR 1.3 und TWINSOLAR 2.0 – integrated start up switch The temperature control of all TWINSOLAR Compact collectors consists of the components Start up switch and thermostat control. Start up switch (pre-essembled in the collector): The thermostat starts the ventilator running, when the collector has reached a temperature of ca. 22°C; if the temperatur is lower than 17°C, the ventilator turns off. Thermostat control (included in the delivery): When achiving the adjusted maximum room temperature, the ventilator turns off TWINSOLAR 2.0 (1.3 from 2011) Compact TWINSOLAR 4.0, 4.5, 6.0 Compact Start up switch is accessible by the air outlet Start up switch is accessible when the collector connection is open Important informations: • Since September 2010, our TWINSOLAR 2.0-collectors are equipped with an additional start up switch. • From midyear 2011, the start up switch will be standard also in the TWIN 1.3 series. • Optionally, the start up switch can be briged respectively deactivated. In this case, the ventilator runs only depending on the irradiation and also with a collector temperature lower than 22°C. This alternative operating can make sens, if the focus is on the ventilation. Collector with integrated: - ventilator - pv-module Solar heated air Incoming air Thermostat Start up switch Deactivate bridge of ambient thermostat Deactivate bridge of thermostat Start up Thermostat TWINSOLAR MANUAL 16 S O L A R 1.6.2. Control TWINSOLAR Modular 4.0 – 12.5 In opposition to the simplified control of TWINSOLAR Compact, the TWINSOLAR Control with integrated differential temperatur control is used. Function: TWINSOLAR Control controls and monitors the operation of TWINSOLAR systems. The controller is provided with current by the collector integrated PV-module and works only on sufficient solar radiation. With too weak radiation or at night there will be no signal. The simple control compares the room and collector temperatures and switches the fan on or off depending on the temperature (differential temperature control). Once the desired room temperature has been reached the system will switch off. Fig .1:Function diagram - TWINSOLAR 4.0 - 12.5 Fig. 2 TWINSOLAR Control Manual operation With the left-hand button the "manual operation" menu (hand symbol) can be activated or terminated. By means of the right-hand button the fan (only whenthe PV module supplies sufficient power) can be started up manually. After approx. 8 hours, the next day or on leaving the menu item “manual operation” the control changes again into the automatic modus. Line operation: If the ventilator pictogram moves, the system is in operation Disable the system: Set max. room temperature to 5°C. DISPLAY MEASURED VALUES–information menu In the information menu the following measured values can be displayed by means of the "up" and "down" buttons: • Current collector temperature • Min. and max collector temperature (current • value) • Storage temperature = room temperature • Min. and max room temperature (current value) SETTING – programming With the left-hand button the "programming" menu can be activated or terminated. With the "Up" and "Down" buttons the following values to be set can be retrieved : • max (max. room temperature) approx. 23°C • dT max. (switching on difference) 6 K • dT max. (switching on difference) 3 K The modified values are to be confirmed and saved by pressing the right-hand button. Switching off: set maximum value to the smallest value(5°C) *) Additional remark dT max.: The unit switches on if the collector temperature is 6°C (dTmax=6K) higher than room temperature and runs as long as it is still 3°C (dTmin=3K) higher resp. achieve the max. temperature. For long stretches of pipe (cooling off), the values must be set higher (e.g. 12 or 8K). Important information: The delivery contains a "Quick info" about the controller in 5 languages. This "Quick info" in the appropriate language should be inserted in the slot provided for this on the back of the controller. TWINSOLAR MANUAL 17 S O L A RConnection diagram TWINSOLAR CONTROL Important information: ? Connection of solar module – observe POLARITY See Fig 2 and 3 ? Fitting of collector sensor (Fig.1). The sensor (moisten slightly) must be pushed into the intended opening on the end collector until it impacts (approx. 20 cm) and the cable must be connected to the Powerunit (APW). ? Do not locate the TWINSOLAR Control close to heat sources or in direct sunlight ? If no data cable is connected or if the TWINSOLAR Control is disconnected the fan will run purely depending on the radiation received (without temperature control) ? Please also observe the following chapters in this handbook: Fan Chapter 1.5.3 Checking list – fault correction Chapter 1.7 Fig. 4: Fan kit in the TWINSOLAR collector package External room sensor: An external room sensor (Pt 1000) can be connected to the open clamping block T2 of the TWINSOLAR control regulator instead of the integrated sensor. The conversion takes place in the basic setting menu from 0=internal to 1=external. This conversion is only possible within the first minute after clamping on the regulator. The integrated sensor does not have to be disconnected. Fig.3: Module connection plan for units with 1 or 2 modules Fig.2: Module socket on the collector (here 2 Modules) Abb.1: Kollektorfühlermontage Fig.1: Collector sensor fitting TWINSOLAR MANUAL 18 S O L A R1.6.3 TWINSOLAR – Comfort changeover kit Optional accessory TWINSOLAR 1.3 – 12.0 FUNCTION: The comfort changeover kit can be used to switch between fan operation and external utilisation of the collector-integrated PV module (e.g. radio, lamps etc.) from the room. OPERATING INFORMATION: External: The current from the PV modules can be utilised externally Off: The PV modules are switched off completely – the installation does not operate at all On: The collector works in solar heating and ventilation function Switch diagram for TWINSOLAR 1.3 / 2.0 Fig. 1: Changeover kit with cable Fig. 2: Changeover switch Switch diagram for TWINSOLAR 4.0 -12.5 -Solar-Luft-KollektorTSolar air collector Photo-voltaic moduleComfort change-over setMaximum power unitExternal PV utilisation7 Thermostat6 Thermostat5 Coll.room therm4 Coll.ext +3 Coll. ext -2 External -1 External + KomfortumschaltsetEinAusExternTwinsolar-KollektorThermostatexterne Nutzung(Twin 1.3 und 2.5) TWINSOLAR MANUAL 19 S O L A R 1.6.4 Temperature measurement – room device – room thermostat From TWINSOLAR 4.0: A room sensor (type PT1000) is integrated in the TWINSOLAR Control (Fig. 1). Alternatively, an external room sensor can be connected to the room device. (see page 16) For TWINSOLAR 2.0 the room temperature is measured by a room thermostat. Fig. 1 TWINSOLAR Control When arranging the room operating device or room thermostat please observe: ? Avoid direct irradiation by the sun ? Avoid the influence of extraneous heat sources ? Do not locate close to the supply air elements The correct function of the temperature sensor can be checked by means of the temperature resistance table using a resistance meter: Temperature in °C Resistance in Ohm Temperature in °C Resistance in Ohm -30 882 60 1232 -20 921 70 1271 -10 960 80 1309 0 1000 90 1347 10 1039 100 1385 20 1077 120 1461 30 1116 40 1155 50 1194 1.6.5. Operation with summer ventilation kit / wall ventilation During the summer, the collector-integrated PV modules can be used in combination with a fan for the wall installation (summer ventilation kit) for the ventilation of individual rooms. Technical data for wall ventilation: Nominal voltage: 12 Volt (7 – 14.5 Volt), Power rating: 5,6 Watt Max air flow: approx. 80 m³/h Electrical connection - TWINSOLAR 1.3 / 2.0 – Please observe "External utilisation" connection in chapter 1.6.1 and 1.1.1. - TWINSOLAR 4.0 – 10.0 - Please observe "External utilisation" connection in chapter 1.6.3. In this case a comfort change-over kit is necessary for operation. For TWINSOLAR 8.0 – 12.5 (24 Volt PV voltage) an additional choke (included in the delivery scope) has to be installed. Fig. 2 Wall fan (summer ventilation kit ) TWINSOLAR MANUAL 20 S O L A R 1.7 CHECK LIST – ERROR CORRECTION with TWINSOLAR Fault Possible cause – fault correction Max. room temperature achieved Irradiation is too weak Photovoltaic module is shaded. Slight shading, large effect Electronic maximum power unit. Check contact at the connection terminals – if necessary, tighten Correct polarity at the solar module and fan Check the connection cable between the solar module and the powerunit at the fan Module connection box at the collector: Check the feeder clamps for contact Check the data cable between the fan and TWINSOLAR Control solar controller. Note: If the data cable or the solar controller is disconnected the fan will run depending on the received radiation (without temperature control) only Fan does not run TWINSOLAR 2.0 (until series 02-2007) For operation with the comfort change-over kit, the collector connection box must be set in external. Check the terminal allocation at the thermostat, observe bridges when operating without thermostat Check the connection with the sensor and whether it has been placed at a sensible location. See chapter 1.6.2 Check the setting of the differential temperature – might be too large Check the maximum temperature setting – if the value is set too low, no heating operation will be possible The installation does not run in automatic operation The system is set to EIN (ON) at manual operation – Set to automatic operation, see chapter 1.6.2 The system runs continuously and without control The data cable for the TWINSOLAR installations is not inserted or there is difficulty making contact Provide muffler Install the fan with vibration insulation The fan runs too noisily The supply air valves are throttled too much – whistling noises If long sensor cables are laid along power cables, interferences can occur. Correction: Choose screened cables or a different cable path Varying temperature display In the case of TWINSOLAR systems at a very low levels of received radiation, temperature variations at the TWINSOLAR Control are possible. Check filter for contamination. Replace the filter at least 1 or 2 times per year Non return-valve jams. Check if mounting screws hinder the valve functions. Check mounting direction and position of the non return-valve. Duct system is blocked. Check that the ventilation tubes have an adequate free cross-section Power too low Check the system for shading. Even minor shading of the photovoltaics will lead to strong losses in power. TWINSOLAR MANUAL 21 S O L A R1.8 Collector installation 1.8.1 Installation on inclined roofs For installation on an inclined roof, individual compact collectors (e.g. TWINSOLAR 2.0) or several SLK-collectors elements are connected by means of roof hooks or supports to the rafters or to the roof structure. The roof structure experiences an additional load from the weight of the collectors. Whether or not a static calculation is required must be decided case by case. The SLK-collectors have a static weight of approx. 22. kg/m². In snowy regions more mounting rails and roof hooks are to be scheduled than included in the standard package You will obtain information and prices on request. Installation steps – short overview 1. Measure/determine the collector field on the roof (for collector diagrams see appendix) 2. Measure the location of the roof lead-through (consider location of rafters) Install the roof lead-through – cut a hole in the roof boarding and fit the lead sheet so that it is rain-proof. Pipe connections at the air connection from the collector to save about sheet metal screws or blind rivets 3. Install the roof hooks. Screw the roof hooks to the rafters. If necessary match heights by the means of inserted wood boards. 4. Install the installation rails to the roof hooks. 5. Lay the collector sensor cable / PV connection cable and prepare connection. 6. Glue the sealing profile to the collector connections 7. Mount the collectors. 8. Connect the collectors by means of the quick-action clamps. 9. Assemble collector sensor, affiliate PV-connecting cable and check all the screws for secure attachment. This has to be repeated annually. Tool list: Open- end wrench M 15, M 17, screwdriver set, measuring tape, marker, hammer, boring machine with screw-element (Torx T40 Bit), electrical handsaw, angle grinder with stone disc (for bricks). Installation steps – comprehensive description 1st step – measure the roof CAD collector diagrams see chapter 3. Do not arrange the air inlet near flues and vents and for filter collectors plan enough room for the change of the filter. 2nd step – roof lead-through and collector connection The roof lead-through for the collector installation consists of a lead sheet with a flange collar with sealing profile as well as a tube connection piece (125 or 160 mm). The lead sheet is flexible and can be moulded to a wide range of tile shapes. CollectorRoof tileSealingprofileFlexiblelead plateTube nipplewith lip seal TWINSOLAR MANUAL 22 S O L A RGrammer air collectors are equipped with a round tube connection on the back of the collector. The sliding joint (pipe socket) included with the roof lead-through is pushed over the connection tube. The sliding joint must be protected against sliding off of the collector connection. This can, for example, be done by means of tapping screws or rivets. In the case of insulated roofs, the tube must be glued to the roof insulation film. 3rd step – install roof hooks The roof hooks are to be attached close to rafters and screwed to it tightly. Roof hook for slate roof Attachment of a roof hook for slate roofs Roof hook for corrugated tiles incl. attachment screws Knock out or cut out a recess for roof hook from the tile TWINSOLAR MANUAL 23 S O L A R Installed roof hook with an adjustment wood put under for height compensation Stair bolt with adapter plates Aluminium installation railConvextileConcavetileHangerboltConcavetileRoof Installation to a standing seam metal roof Convex/concave tiling 4. step – fit the installation rails to the roof hooks. Aluminium mounting rails ? For each of the end collectors two installation rails are provided ? For each middle collector normally one mounting rails is adequate (except in regions with high snow fall) TWINSOLAR MANUAL 24 S O L A R Aluminium installation rails – screw attachment Important for secure attachment After inserting into the aluminium rail, the rectangular threaded plate must be turned by 90° until it locks in and then it must be tightened by means of the hexagonal screw. Please also observe the safety information in chapter 1.10 5th step - lay the collector sensor cable / PV connection cable and prepare connection Connection boxes ? To each end collector a sensor connection box is fitted. The sensor must be connected to the control via a 2-pole cable (min. 2 x 0.8 mm²). ? The PV connection box (only for TWINSOLAR collectors) is to be connected via a 2-pole cable (min 2x1.5 mm²) to the PV module on the fan ? Observe the location of the connection boxes (You will find the dimensions in the collector mounting diagrams) ? Cable lead-through close to the roof lead-through 6th step - fix the sealing profile to the collector connections Collector connection sealing surface ? For sealing the collector connection, before mounting the collector, a sealing strip is to be stuck on ? (Self-adhesive) rubber sealing strips are included in the scope of delivery ? Stick the sealing strips to only one of the two collectors to be connected TWINSOLAR MANUAL 25 S O L A R 7th step – collector installation Collector attachment I ? On the back of the collector the collectors are fixed by means of Z-mounting brackets ? The Z-mounting brackets must be aligned onto the pre-installed aluminium mounting rails before installing the collector and then attached with t-head screws M8x30. Collector attachment II ? The collectors are screwed on to the aluminium mounting rails on the top side using fastening clamps M8x30 and T-head screws. Vertical installation ? By means of the mounting clamps the collectors are screwed to the mounting rails ? Mounting aid to prevent sliding off TWINSOLAR MANUAL 26 S O L A R 8th step – collector connection by means of quick-action clamps Collector connection ? The collectors are to be connected to each other by means of adjustable clamp locks ? Rubber sealing strips on the sealing surfaces ? Pins in the collector connection assist in the collector alignment ? The clamp locks are to be adjusted in such a way that the collectors are firmly pressed together ? The clamp locks are to be secured by means of a spring lock Arrangement variants Standard arrangement variant for installation on inclined roofs Usually air collectors are arranged as a long line of collectors Sort of adjustment chap.:1.4.1 Alternative arrangement variant – parallel installation Sort of adjustment chap. 1.4.1 TWINSOLAR MANUAL 27 S O L A R Parallel installation ? Parallel collector lines are mounted at a distance of 110 mm Deflection collector ? The deflection collector is connected by means of clamp locks to the collectors ? A rubber sealing strip is also to be stuck onto the sealing surfaces (description see step 6) ? In snow-rich regions the deflection collector must be supported by an additional mounting rail Example TOPSOLAR12.5 horizontal assembly TWINSOLAR MANUAL 28 S O L A R1.8.2. Wall installation with Grammer installation brackets 1. Preparation: Measuring out the collector area and determining the wall opening 2. The Aluminium multi-use brackets (Fig.1) must be installed to the wall using suitable screws or pins if necessary. 3. Attach slot nuts M8 (4 pieces) to the collector (Fig.2). 4. Attach set screw M8 x 25 (Fig.3 and pull tight for vertical installation. The collector can be put into the pre-installed multi-use bracket this way. 5. In the case of filter collectors, please make sure that there is enough space for changing the filters. A distance of at least 2 cm must be maintained between the back of the collector and the wall. 6. The heat insulated wall guide included in the kit must be installed in the direction of the flow and shortened according to the wall thickness. 7. All screw and pin attachments must be carried out carefully and their strength must be tested at regular intervals. The pins included in the delivery must be tested for their suitability for the respective surface. VARIATION 1: VERTICAL INSTALLATION Fig. 4: TWINSOLAR 2.0 Vertical mounting Fig. 1 Alu-multielbow with fastener Fig. 2 Swivel in sliding block Fig. 3 Set screw TWINSOLAR MANUAL 29 S O L A R VARIATION 2 : Horizontal installation Bumps on the wall can be smoothed out using the flexible collector screw fittings. Contrary to vertical mounting, the shanks must be turned when they are mounted.(Fig. 5) Fig: 5 Alu-multi bracket - Pro end-collector are 4 assembly brackets to use - Pro middle- collector are 2 assembly brackets sufficient Tool list: Open-end wrench M 13, 4 mm, Allen key, screwdriver set, measuring tape, marker, hammer, drill with screw element (cross slot Bit), for masonry percussion drill+ 10mm auger, depending on the wall-structure suitable tools for wall breakthrough. Please consider the safety instructions in capture 1.10. 1.8.3. Installation on flat roofs The installation kit is suitable for: ? Frame installation on top of flat roofs ? Frame installation on the ground, e.g. in the garden ? Wall installation with flexible angle of inclination Important information: ? The collectors are to be placed on top of the support triangles and are to be screwed on with the attachment clamps ? In the case of installation on top of flat roofs the system may need to be protected against wind loads (screw tight, weigh down, clamp down). Under favourable conditions the weight of the installation will be adequate. For this a wind load calculation has to be carried out ? All screw or dowel connections are to be made carefully. Safety in the wind ? In the case of a sensible roof cladding (e. g. membrane roof), support feet with underlayed building-protection mats must be used. ? Please also observe the safety information in chapter 1.10 TWINSOLAR MANUAL 30 S O L A R Variable elevation on flat roof - Pro end collector two assembly brackets are to use - Pro middle collector usually an assembly bracket is enough. Exception: snowy regions Note: The variable elevation on flat roof can be combined with the aluminium multi-angle from the wall-mounting package. So elevated facade systems can be realised. Tool list: Open-end wrench M 15, M 17, screwdriver set, measuring tape, marker, hammer, boring machine with screw element (cross slot Bit). According to the substructure suitable tools for mounting. TWINSOLAR MANUAL 31 S O L A R1.9 General maintenance information 1.9.1. GRAMMER air collector The GRAMMER air-base collector does not include any mechanically moving parts and is therefore maintenance free and intrinsically safe. 1.9.2. Checking the fixing of collectors and mounting frames The collector system on the roof will be properly secured by the installation company. However, it is exposed to movements from wind and gales. A regular checking routine should ensure that all screw connections are tight, in particularly after heavy gales. 1.9.3. Cleaning According to our experience the cleaning effect of strong rainfall is adequate. In areas with strong environmental contamination or when large amounts of pollen have been released or dry periods last a long time, it may be useful to clean the glass surface with tap water and a sponge or car washing brush. 1.9.4. Air filter The collectors are protected by the intake air filter in the system of quality class EU 4 against internal contamination. The filters should be replaced after the period customarily used by the company or at the location as described in the general installation instructions, or every 6 months for collectors run on out-of-doors air or mixed air or, in the case of a pure circulating air system, every year before the beginning of the heating period (September) FILTER REPLACEMENT 1 to 2 x annually 1. Release the tension locks on the filter cover and take off the cover. 2. Pull out the filter cartridge and replace the filter mat with a new one. 3. Push the filter cartridge back into the collector. 4. Attach the cover using the tension locks. Hint: During intake of surrounding air the filter in the external filter box must be replaced. Glas-Abdeckung GlasscoverAttachmenthookTile roofRafter TWINSOLAR MANUAL 32 S O L A R1.9.5. Air as heat transfer medium Air does not experience phase changes (freezing or boiling) so all safety measures in this respect are not necessary. However, it cannot be excluded that after a longer period of standstill occasionally condensation will form on the inside of the cover, depending on the air humidity and low outside temperatures. After the system has been restarted this condensation will disappear by itself 1.10. Safety information 1.10.1. Weather Carry out the installation only when the weather is fair. Particularly for installations integrated into the roof, it should be observed that no precipitation is falling in order to prevent humidity from entering the building. If the wind freshens up, you should interrupt the installation in the interests of your own safety. Also remember that on very hot days with strong solar radiation, there is a risk of burns from hot metal parts. Under unfavourable conditions temperatures up to 150°C can occur (particularly at the absorber). 1.10.2. Ladders Ladders should be leaned at an angle of 65 – 75° to a secure support and they must reach at least 1 m above the highest point used to step off it. In addition, they should be secured against sliding, falling over, slipping off and sinking into the ground. Finally, ladders are only to be used to access points up to a height difference of 5 m. 1.10.3. Protection from falling objects Traffic areas and workplaces below have to be protected against objects dropping, falling, sliding or rolling off. The areas where people are endangered are to be marked and blocked off. 1.10.4. Protection against falling From a height of 3 m for work on an inclined roof of more than 20° to 60°, protection against falling is required (VBG, 37, § 8). TWINSOLAR MANUAL 33 S O L A ROne option is roof safety scaffolding. The vertical distance between workplace and safety installation may be no greater than 5 m. Alternatively, the top scaffolding support can also be designed as a safety platform. For roof steeper than 45° inclination special workplaces must be created (e.g. roofer chairs, roof ladders, wooden safety structures) A further option for fall protection for work on inclined roofs up to 60° are roof safety walls. They are also required from a fall height of 3 m and the vertical distance between workplace and safety installation may be no larger than 5 m. Safety walls must be at least 2 m higher than the workplaces to be protected by them. If roof safety scaffolding or roof safety walls are inappropriate, safety harnesses can also be used as fall protection. The safety roof hook should be preferably attached above the user to load bearing components. Do not use ladder hooks 1.10.5. Rules of technology The installations should correspond to the conditions on site, the local regulations and, not at least, to the rules of technology. In this context, the following are to be mentioned in particular: ? Installation on roofs DIN 18338 Roofing, DIN 18339 Plumbing DIN 18451 Scaffolding ? Connection of thermal solar installations DIN 4757 ? Electrical connection VDE 0100 Electrical equipment VDE 0185 Lighting protection systems VDE 0190 Main potential equalisation DIN 18382 Electrical cables in buildings The fan may only be started when the air duct system is connected. Under no circumstances, place hands into the moving fan. TWINSOLAR MANUAL 34 S O L A R2. TOPSOLAR The line operated alternative to TWINSOLAR TOPSOLAR comprises line operated air collector packages for heating and ventilation with solar energy including 230 volt ventilators and regulation. Collector systems similar to TWINSOLAR, but without a photo-voltaic module. Mounting packages and ventilation systems identical to TWINSOLAR. 2.1. Info / Technical data Scope of supply TOPSOLAR Collector packages: ? Grammer High performance air collectors Type SLK ? Ventilators installed in pipes - 230 Volt ? Solar control DeltaSol BS Plus – 230 Volt ? Collector integrated air filter with changeable frame TOPSOLAR 4.0 TOPSOLAR 6.0 TOPSOLAR 8.0 TOPSOLAR 10.0 TOPSOLAR 4.5 TOPSOLAR 8.5 TOPSOLAR 12.5 Gross- collector surface [m²] 4,0 6,0 8,0 10,0 4,55 8,55 12,55 Collector field dimensioning LxB [m] 4,0 x 1,006 6,0 x 1,006 8,0 x 1,006 10,0 x1,006 2,25 x 2,1 4,25 x 2,1 6,25 x 2,1 Thermic performance peak [W] 2.400 3.600 4.800 6.000 2.700 5.100 7.500 Suitable for surface to be heated 1) [m²] 40-50 60-80 80-100 100-120 40-60 80-100 120-150 Collector weight [kg] 90 135 180 225 110 200 290 Actual power output of the fan [W] 69 69 100 100 50 100 115 Fan type - alignment HE-160B Pipe installation HE-160B Pipe installation HE-160C Pipe installation HE-160C Pipe installation HE-160B Pipe installation HE-160C Pipe installation HE-200A Pipe installation Air supply at 150 Pa pressure [m³/h] 200 200 350 350 200 350 380 Diamter air outlet [mm] 160 160 160 160 160 160 160 Control of temperature difference DeltaSol BS Plus DeltaSol BS Plus DeltaSol BS Plus DeltaSol BS Plus DeltaSol BS Plus DeltaSol BS Plus DeltaSol BS Plus A data sheet with exact information on SLK collector as well as references to the testing institute can be found in the appendix. TWINSOLAR MANUAL 35 S O L A R Solar air supply system (Standard system) The solar air supply system is a simple and effective solution to heat and ventilate existing or new buildings with solar energy. Solar heated fresh or ambient air from the collector flows through a simple pipe system and air outlets into the rooms. In the case of dense building envelopes ventilation openings (e.g. ventilation in toilets, kitchen exhaust hood) are planned. Solar hot water generation through the solar box with integrated air and water heat exchanger is practical for additional use in summer. Further system variations: Domestic solar ventilation Solar air supply systems can be easily integrated into new or existing domestic ventilation systems. Solar heat flows into the rooms through the air distribution system of the ventilating units. If no solar heat is required for heating the rooms, the solar box produces hot water. Under floor solar heating Using the solar energy products offered, air is heated in a closed system through the collector and then led through walls. The heat energy is emitted to these structural parts in the process, stored in them and emitted to the rooms as a pleasant radiant warmth later on. Use of the hypocaust is possible without solar radiation using additional heating. If no solar heat is required for room heating, the solar box produces hot water. SOLITH wall storage heating Sand-lime brick under floor system For more information: see Solith brochure or on www.ks.fasenstein.de TWINSOLAR MANUAL 36 S O L A R2.2. Hot water generation – SolarBox SLK SolarBox SLK – Option Heating of drinking water ? All TWIN- and TOPSOLAR power systems from 8 m² collector surface onwards can be combined with hot water generation or with the solar box SLK. ? All necessary technical components are easily accessible in a compact form and thus also easy to install and maintain in a box for technical components. Detailed information: See installation instructions SolarBox (Download on www.grammer-solar.de) Storage package ? Solar pump group with safety fittings ? Expansion container 18 Litres ? 300 Liters Solar storage device ? Solar control type DeltaSol BS Plus and sensor Pt1000 Hint: In areas with a risk of frost, mix glycol with the solar range of products. Basic sketch for hot water generation with solar air supply systems Solar air supply systems with integrated hot water generation are usually designed according to the following sketch. The components air/water heat exchanger and bypass valve are provided in a compact and easily accessible way in the SolarBox SLK. The SolarBox may only be employed with ventilators having a temperature resistance of at least 80 ° C. All TOPSOLAR Power packages contain temperature resistant ventilators. TWINSOLAR MANUAL 37 S O L A R 2.3. Control 2.3.1. Operation DeltaSol BS Plus The regulator is operated using the 3 push buttons belowr the display. Button 1 is used for scrolling down through the display menu or to increase set values. Button 2 is used correspondingly for the reverse function. For adjustment according to the last display channel keep button 1 pressed for approx. 3 seconds. If a set value is displayed appears. By pressing button 3 you can then change to input mode. ? Select the channel with buttons 1 and 2. ? Press button 3 quickly, blinks ( -Mode) ? Set the value with buttons 1 and 2. ? Quickly press button 3, the display appear again permanently and the set value has been saved. You can find further operating instructions in the original operating instructions for the regulator. Additional symbols in the display indicate the current system status: Symbol normal blinking Relay 1 active Relay 2 active Maximum storage limit active/ has exceeded maximum storage temperature Collector cooling function active/ re-cooling function active Option Frost protection active Minimum collector limit active/frost protection active Switching off the collector motor or emergency switching off of storage unit + Defective sensors + Manual operation active An adjustment channel has been changed to SET-Mode TWINSOLAR MANUAL 38 S O L A R 2.3.2. Control TOPSOLAR – Solar air supply system Function: The solar regulator DeltaSol BS Plus compares the collector temperature TKL to the reference temperature TSP and controls the set temperatures dependent on the temperatures set in the unit. Using an optional temperature probe TTH an additional temperature value can be shown (e.g. outside temperature). Displayed and set values Please note: Go to SPR and change language to “En” for English codes Channel Description Set values (recommended) COL Collector temperature * TST Storage temperature (room temperature) * n % Rotational speed in in % * h P Operating hours * (can be set back) Time Current Time * (can be adjusted to current time) Arr Unit type Factory setting(1) DT O Difference in temperature when switched on Factory setting (6 K) (for long stretches of pipe approx. 10K) DT F Difference in temperature when switched off Factory setting (4 K) (for long stretches of pipe approx. 8K) DT S Nominal difference in temperature Factory setting (10 K) RIS Increase Factory setting (2 K) S MX Maximum storage temperature (max. room temperature) ? 22 °C (ca. 2 °C above set value of room thermostat in conventional room heating. )EM Collector limit temperature 180 °C OCX Option collector cooling Factory setting (OFF) OCN Option collector minimum temperature Factory setting (OFF) OCF Option frost protection Factory setting (OFF) OREC Option re-cooling Factory setting (OFF) O TC Option tube collector Factory setting (OFF) OHQM Option calorimetry Factory setting (OFF) nMN Minimum rotational speed relay ld h hl R l i 1100 % HND1 Manual operation 1 Factory setting (Auto) HND2 Manual operation relay 2 Factory setting (Auto) LANG Language selection Choose “En” for English display codes * These values are only displayed values and cannot be re-adjusted. TWINSOLAR MANUAL 39 S O L A RElectrical connection Please observe the instructions for installing electrical parts enclosed with the regulator For installation of room sensor and collector sensor, see Chapter 2.3.5 If the collector temperature COL (S1) is higher than the temperature difference set on the regulator by room temperature TST (S2) the unit switches to EIN (ON) and the fan (R1) conveys heated air to the connected rooms till the desired room temperature is reached. An additional probe (e.g. for outside temperature) can be attached to position (S3). Switching between modes of selection You can switch between the following modes of selection with the setting channels HND1 and HND2: HND1=OFF: Relay 1 is switched off (manual switching off) HND1=Auto: Automatic operation for the relay outlets (STANDARD SETTING). HND1=On: Relay 1 is switched on (permanent or test operation). TWINSOLAR MANUAL 40 S O L A R2.3.3. Control TOPSOLAR – Solar generation of water for domestic use Function: With solar energy (TS1>TS2) the unit mainly heats up as long as the room has reached the desired room temperature (TS2). Secondly, the regulator checks whether energy is available for heating drinking water (T1>TS3). The unit then heats the storage device until the desired storage temperature has been reached (TS3) or the collector temperature is lower than the temperature in the storage unit. Displayed and set values Please note: Go to “SPR” and change language to “En” for English codes Channel Description Operation with solar box– set values ( d ( f hl )COL Collector temperature (TKL) * TST1 Storage temperature 1 ((((( (R )* TST2 Storage temperature 2 * n % Rotational speed of the fan in % * hP Operating hours * (can be set back) Time Current Time * (can be adjusted to current time) Arr Unit type 5 (important) DT1O Switching on temperature difference 1 Factory setting (6 K) DT1F Switching off temperature difference 1 Factory temperature (4 K) DT1S Nominal temperature difference 1 Factory setting (10 K) RIS1 Increase 1 Factory setting (2 K) S1MX Maximum storage temperature 1 (max room temperature) ? 23 °C (ca. 2 °C above set value of room thermostat in conventional room heating) DT2O Switching on temperature difference 2 9,5 K DT2F Switching off temperature difference 2 7 K DT2S Nominal temperature difference 2 Factory setting (10 K) RIS2 Increase 2 Factory setting (2 K) S2MX Maximum storage temperature 2 Factory setting (60 °C) EM Collector limit temperature ll k b h l )180 °C OCX Option collector cooling Factory setting (OFF) OCN Option collector minimum temperature Factory setting (OFF) TWINSOLAR MANUAL 41 S O L A ROCF Option frost protection Factory setting (OFF) PRIO Priority Factory setting (1) tST Delay time in positioning P d l iFactory setting (2) tUMW Delay time in loading Factory setting (15) OREC Option re-cooling Factory setting (OFF) O TC Option pipe collector Factory setting (OFF) OHQM Option calorimetry Factory setting(OFF) nMN Minimum rotational speed 50 % HND1 Manual operation relay 1 Factory setting (Auto) HND2 Manual operation relay 2 Factory setting (Auto) LANG Language choice Choose “En” for English display codes * These values are only displayed values and cannot be re-adjusted. Terminal connections SolarBox SLK Please also consider the short guide SolarBox (delivery SolarBox) TWINSOLAR MANUAL 42 S O L A R2.3.4. Control TOPSOLAR – Under floor system Function: The regulator DeltaSol BS Plus compares the collector temperature TKL with the reference temperature TSP in the hypocaust wall and controls the unit dependant on the set temperatures. When a maximum wall temperature has been reached (adjustable using the room thermostat) the unit switches off. An additional temperature value can be displayed using the temperature sensor TTH (e.g. outside temperature). Displayed and set values: Please note: Go to “SPR” and change language to “En” for English codes Channel Description Set values (recommended) COL Collector temperature (TKL) * TST Storage temperature ( i h (W d )* n % Rotational speed in % * h P Operating hours * (can be set back) Time Current time * (can be adjusted to correct time) Arr Unit type Factory setting (1) DT O Difference in temperature when switched on Factory setting (6 K) DT F Difference in temperature when switched off Factory setting (4 K) DT S Nominal temperature difference Factory setting (10 K) RIS Increase Factory setting (2 K) S MX Maximum storage temperature (max. wall temperature) ? 30 – 35 °C EM Collector limit temperature 180 °C OCX Option collector cooling Factory setting (OFF) OCN Option collector minimum temperature Factory setting (OFF) OCF Option frost protection Factory setting (OFF) OREC Option re-cooling Factory setting (OFF) O TC Option pipe collector Factory setting (OFF) OHQM Option calorimetry Factory setting (OFF) nMN Minimum rotational speed relay 100 % HND1 Manual operation relay 1 Factory setting (Auto) HND2 Manual operation relay 2 Factory setting (Auto) LANG Language choice Choose “En” for English display codes * These values are only displayed values and cannot be re-adjusted TWINSOLAR MANUAL 43 S O L A R Electrical connection: Please observe the instructions enclosed with the regulator for installation of electrical parts If the collector temperature (S1) is higher than the wall temperature(S2) by the difference in temperature set in the regulator, the unit switches to EIN (ON) and the fan conveys heated air to the connected hypocaust till the desired room temperature has been reached. An additional probe can be attached to position (S3) (e.g. for measuring outside temperature). The fan is operated through an external room thermostat. Once the desired room temperature has been reached, the fan switches off. Fig.1 Room thermostat Set room thermostat approx. 2°C h igher than thermosta t for convent iona l heat ing Room thermostate TWINSOLAR MANUAL 44 S O L A R2.3.5. Temperature sensors – arrangement/installation When placing the room temperature probe (Fig.1), the following criteria should be observed: ? Do not place in the vicinity of air supply elements ? Avoid direct radiation from the sun ? Avoid influence of heat from other sources Fitting the collector probe (Fig.2): The probe (moisten it slightly) must be pushed in at the intended opening at the end collector till it impacts (approx.20 cm). The cable should be attached to the solar regulator. Probe cable – extension with 2 x 0.75 mm² up to 50 m cable length, otherwise 1,5 mm² Functional control standard probe type Pt 1000: The resistance value at 20 °C is approx. 1077?. 2.4. CHECK LIST –TopSolar ERROR CORRECTION Problem Possible cause – solution Solar control is in manual operation set to AUS (OFF) – set to “automatic operation” , see 2.3.2. Check connecting clamps for contact – fix tightly if necessary Fan does not work Check ventilation pipes for free cross section Check probes for contact and appropriate placement Set temperature difference – could be too large Unit does not run automatically Check maximum temperature setting – it could be that the value set is too small so that no heating is possible . Unit runs continuously and in an unregulated manner Unit is set to ON in operating menu – set to automatic operation, see chapter 2.3.2 Install sound absorber Install fan with vibration dampening Fan is too loud Air supply valves could be to intensely throttled – whistling sounds 1 wire control Terminal connections N, L1 and L2 on the motor and the regulator should be observed. Motor valve is not functioning Check adjustable mechanical impact on the motor . Fluctuating temperature display If the probe lines are very long and have been laid next to lines leading to voltage, there can be disturbances. Suggestion: use insulated cables or other cable layouts. Check filters for dirt. Change filters at least once or twice a year. Return valve is stuck. Check whether screw fittings are hindering the valve function. Not performing well enough Pipe system is blocked . Check for free cross section Fig.1: sensor Fig.2 collector probe: TWINSOLAR MANUAL 45 S O L A R3. CAD-DRAWINGS 3.1. Collectors TWINSOLAR 1.3 – 2007 TWINSOLAR MANUAL 46 S O L A R10062000collector front~169cross-sectionAir outlet1401401 : 10air inletfan +filterØ125filter cartridge 290 x 250 mm exerpt collateral for replacementlocal section of fan136ESG safety glass~150connection boxPV - modulefan TWINSOLAR 2.0 TWINSOLAR MANUAL 47 S O L A R4000600longitudinal section M 1 : 20cross-section M 1 : 101006temperature sensor - connection box( 80x80x50 mm )380500single pane safety glass1200 mm example dimensions for rafters grate 600 mm at mounting on inclined roofsØ160140single pane safety glass2000end collectorbasic version with filterPV connection box (only for TWINSOLAR collectors) ( 94 x 65 x 57 )PV module for TWINSOLAR( 977 x 490 x 4 mm )260optional version with aircirculation socket1200work-rest blade for mounting oninclined roofs or in-roof 140filter collectorcollector connection with quick action clamps TOPSOLAR 4.0TWINSOLAR 4.0 ( with PV module )Heat insulationabsorber136TWINSOLAR 4.0 TWINSOLAR MANUAL 48 S O L A R6000longitudinal section M 1 : 251200 mm example dimensions for rafters grate 600 mmat mounting on inclined roofs140single pane safety glassØ160end collector1200temperature sensor connection box( 80x80x50 mm )20001006380600basic version with filter260PV connection box(only for TWINSOLAR collectors) ( 94 x 65 x 57 )optional version with air circulation socketwork-rest blade for mountingon inclined roofs or in-roof 12001200collector connectionwith quick action clamps middle collectorfilter collector140cross-section M 1 : 10single pane safety glassTOPSOLAR 6.0TWINSOLAR 6.0 ( with PV - module )heat insulationPV - Module for TWINSOLAR 6.0( 977 x 490 x 4 mm )136absorberTWINSOLAR 6.0 TWINSOLAR MANUAL 49 S O L A Rlongitudinal section M 1 : 308000cross-section M 1 : 101800work-rest blade for mountingon inclined roofs or in-roof single pane safety glass140Ø160temperature sensorconnection box( 80x80x50 mm ) end collector1200 mm example dimensions for rafters grate 600 mm at mounting on inclined roofs200010063807001200middle collectorsingle pane safety glassPV connection box (only for TWINSOLAR collectors) ( 94 x 65 x 57 )140basic version with filteroptional version with air circulation socket1200filter collectormiddle collector1200collector connection with quick action clamps 5122 x PV - module with TWINSOLAR ( each with 977 x 490 x 4 mm )8.0TOPSOLAR 8.0TWINSOLAR 8.0 ( with PV - module ) heat insulation136absorberTWINSOLAR 8.0 TWINSOLAR MANUAL 50 S O L A RTWINSOLAR 10.0 TWINSOLAR MANUAL 51 S O L A R1250225050010062122380temperature sensorconnection box( 80x80x50 mm )PV - module for TWINSOLAR 4.5( 977 x 243 mm )110260air deflection arealongitudinal section end collector M 1 : 20longitudinal section filter collector M 1 : 20optional version with air circulation socketPV - connection box (only for TWINSOLAR collectors) ( 94 x 65 x 57 )work-rest blade for mountingon inclined roofs or in-roof 140Ø160 basic versionwith filter 140collector connection with quick action clampsTOPSOLAR 4.5TWINSOLAR 4.5 ( with PV - module )250end collectorfilter collectordeflection collectorcross-section M 1 : 10single pane safety glassheat insulation136absorberTWINSOLAR 4.5 TWINSOLAR MANUAL 52 S O L A R1200optional version with air circulation socketwork-rest blade for mountingon inclined roofs or in-roof 4250PV - connection box (only for TWINSOLAR collectors) ( 94 x 65 x 57 )basic versionwith filtercollector connection with quick action clampsair deflection area250longitudinal section end collector M 1 : 30longitudinal section filter collector M 1 : 30middle collectorend collector1200TOPSOLAR 8.5TWINSOLAR 8.5 ( with PV - module )deflection collector600middle collectorfilter collectorheat insulation21221006cross-section M 1 : 10136Ø160temperature sensorconnection box( 80x80x50 mm )single pane safety glass140140380absorber2 x PV - module for TWINSOLAR 8.5( each with 977 x 490 x 4 mm )512600110TWINSOLAR 8.5 TWINSOLAR MANUAL 53 S O L A R TWINSOLAR 12.5 TWINSOLAR MANUAL 54 S O L A R 3.2. TWINSOLAR fans , , TWINSOLAR MANUAL 55 S O L A RData sheet with manufacturer information on the collector Information about the type and the testing organisation Collector type / designation SLK – Solar air-base collector Construction type Air-base collector Manufacturer GRAMMER Solar GmbH Testing organisation ARSENAL RESEARCH A-Wien, ISE D-Freiburg Test according to STANDARD There is currently no standard covering air-base collectors Test report SLK200305_01 (ISE), IEA-TASK 19 SOLAR AIR SYSTEMS Performance characteristic values (all values with respect to the aperture area) Feature Symbol Unit Typical values / examples (with respect to the aperture area) Conversion factor for temperature difference (tm – ta) = 0 ?0 - 0.834 Linear collector efficiency a1 W/(m² x K) 3.197 Squared collector efficiency a2 W/(m² x K) 0.034 Irradiation angle correction factor K?(50°) - 0.96 Pressure loss curve ?p = a1 x m + a2 x m² Recommended area for flow m³/(h x m²) 30 to 60 Specific (area) heat capacity (full) c J/(m² x K) Housing Dimensions (L x W x H) all mm 2000 x 1006 x 136 Material aluminium Total mass of the collector (full) kg 45 Absorber Absorber material, material thickness Connecting technology to the tube register aluminium, t = 0.6 mm no tube register Material of heat transfer medium ducts aluminium (absorber = air duct) Heat transfer medium contents VA l 55 l (air duct) Transparent covering Material, thickness, possible coating single pane safety glass, 4 mm, - Heat insulation Type, material insulation mats, mineral wool Heat conductivity ? W/(m x K) 0.040 Thickness 50 mm (on the back) or 20 mm (on the sides) Reference areas Gross area AG m² 2.01 Aperture area Aa m² 1.86 Effective absorber area AA m² 3.25 Limiting data for operation Temperature at standstill °C 150°C Permitted operating pressure bar operation at underpressure Permitted heat transfer medium air Installation modes Types on roof, in roof, separate installation, wall installation frame mounted or integrated TWINSOLAR MANUAL 56 S O L A R GRAMMER Solar GmbH Oskar-von-Miller-Str. 8 D-92224 Amberg Phone.: +49/9621/30857-0 Fax: +49/9621/30857-10 E-mail: info@grammer-solar.de Internet: www.grammer-solar.de www.twinsolar.de