SOLAR Technical Manual Complete guide to Dimplex Solar Page 1 of 72 ST0133 – A 02/09
Technical manual SOLAR 1 Contents 1 CONTENTS 2 2 BEFORE YOU START 4 GENERAL 3 SOLAR THERMAL 3.1 INTRODUCTION 3.2 SOLAR RADIATION 3.1.1 Available solar radiation 3.1.2 Orientation 3.3 SOLAR THERMAL SYSTEM 3.3.1 Components of a solar thermal system 3.3.2 Function of a solar thermal system 4 DIMPLEX SOLAR PRODUCTS 4.1 DIMPLEX SOLAR COLLECTOR SOLC220 4.1.1 General description 4.1.2 Hydraulic collector connection 4.1.3 Roof fixing kits 4.1.4 Space requirement 4.1.4 Technical data 4.
Technical manual SOLAR 4.8 DIMPLEX SOLAR ACCESSORIES 4.8.1 General description 4.8.2 Corrugated flexible pipe SOLFH10/15 4.8.3 Feed through tiles SOLFTT and SOLFTM 5 SYSTEM SIZING 5.1 REQUIRED INFORMATION 5.2 SIZING GUIDE 6 PIPE WORK 6.1 TYPE OF PIPE WORK 6.2 PIPE WORK SIZING 6.3 PIPE WORK PRESSURE DROP 6.4 PIPE WORK LIQUID CONTENT 6.5 PIPE WORK FIXATION 6.6 PIPE WORK INSULATION 44 44 45 46 47 47 47 49 49 49 50 50 51 51 7 COMMISSIONING 52 8 OPERATION 53 8.1 CONTROL UNIT 8.
Technical manual SOLAR 2 Before you start General Thank you for your interest in Dimplex Solar products. We trust this manual will give you all the answers to the questions that you might have regarding the products. Although every care was taken to ensure the content of this manual is correct we do not accept any liability for claims resulting directly or indirectly from the application of the information contained in this manual. This manual is written specifically for the Dimples Solar product range.
Technical manual SOLAR in Figure 2, namely direct, reflected and diffuse radiation. The various types of radiation can occur in isolation but in most cases the radiation incident on a solar thermal collector is a combination thereof. <200 W/m² strong diffuse <600 W/m² diffuse <1000 W/m² direct <1200 W/m² direct + reflected Figure 2 – Forms of incident solar radiation The solar radiation available outside the earth’s atmosphere, the so called extraterrestrial radiation, has a density of 1367 W/m².
Technical manual SOLAR Figure 3 – UK and Ireland irradiation map (horizontal surface) 3.1.2 Orientation The solar irradiance shown in Figure 3 is an average value incident on the horizontal surface. As mentioned above, depending on the orientation and inclination of the solar collector the incident radiation onto the collector surface can vary although it might be in the same location. The terminology used to describe the exact location and orientation of a solar collector is described in Figure 4.
Technical manual SOLAR Zenith SUN La ti tud e Slope N W e ud git n Lo Azimuth S E Figure 4 – Terminology to describe location and orientation of solar thermal panel Figure 5 – Effect of orientation on incident radiation levels Page 7 of 72 ST0133 – A 02/09
Technical manual SOLAR Although the location of the solar thermal system can be described using the longitude and latitude of the installation, in practise the locality is being used to determine the location of the system. The effect of the orientation on the incident solar radiation levels can be seen from Figure 5. 3.3 Solar thermal system 3.3.
Technical manual SOLAR Each component in the solar thermal system fulfils a specific function which is described below: Solar thermal collector The solar thermal collector receives the solar radiation, converts it into thermal energy and passes it on to the heat transfer fluid. Heat transfer fluid The heat transfer fluid circulates through the solar collector, the pipe work and the heat exchanger. It transfers the energy gained by the collector into the storage device.
Technical manual SOLAR User The user varies from installation to installation but has a big influence on the operation of the solar thermal system. However, the system has all components to ensure the provision of the comfort levels that the user expects. 3.3.2 Function of a solar thermal system Bearing in mind the function of the individual components, the function of a solar thermal system is in principle very simple.
Technical manual SOLAR A more detailed description of the function of the individual components follows in Chapter 4, Dimplex solar products. 4 Dimplex solar products The following section details the product features and relevant technical data of the components of the Dimplex solar offering. Where applicable a general description of the component’s function is given. 4.1 Dimplex solar collector SOLC220 4.1.
Technical manual SOLAR η = η 0 − a1 ⋅ Where: (t − t )2 tm − ta − a2 ⋅ m a G G η η0 a1 a2 G tm ta [-] [-] [W/m²/K] [W/m²/K²] [W/m²] [°C] [°C] [1] thermal collector efficiency optical collector efficiency/zero loss coefficient linear heat loss coefficient squared heat loss coefficient global incident radiation collector middle temperature collector ambient temperature 9 7 6 5 1 8 2 3 4 Figure 9 – SOLC220 heat loss modes The collector heat loss front (7) and collector heat loss back (8) are depend
Technical manual SOLAR Figure 10 – Thermal efficiency curve Dimplex SOLC220 flat plate collector Figure 10 shows that the higher the temperature difference between the collector module and the ambient is, the lower is the efficiency of the product. Due to the required operating conditions of various applications (see Figure 1) the collector has to operate at varying efficiencies.
Technical manual SOLAR - collector design collector pressure drop flow rate required system output Figure 11 shows the Dimplex SOLC220 collector with the pipe work attached to the absorber plate indicated. A B C D Figure 11 – Absorber pipe work Dimplex SOLC220 collector From Figure 11 it can be seen that the collector has 4 connections which can be used to connect the flow and return pipes of the installation and to connect the collectors between each other.
Technical manual SOLAR The flow and return of the collector are connected using a 800mm long insulated corrugated stainless steel flexible hose (9.1). The interconnections consist of short flexible bellows (10.1). The remaining connections are to be blanked off using the blanking pieces (9.2). The connections components are depicted in Figure 12 using the same references as in the installation manuals.
Technical manual SOLAR An overall view of possible collector connections is given in Figure 14 detailing also the pressure drop at nominal low-flow and high-flow flow rates. No. of collectors Flow rate Pres.
Technical manual SOLAR Although only the vertical collector orientation is shown, the same principles can be applied to the horizontal collector installation. The same applies for the positioning of the flow and return, it can be changed from left to right hand side as long as the sensor (indicated by dot) is moved accordingly.
Technical manual SOLAR On roof kits The on roof kits come as basic and extension kit. The basic kit has to be ordered for each first collector of a collector field, the extension kit for each additional collector in the installation. Corrugated tile Plain tile Slate Sheet metal Figure 17 – On roof mounting options As detailed in Figure 16 the on roof kits suit various types of roof coverings.
Technical manual SOLAR Integrated roof kit without flashings fitted Integrated roof kit with flashings fitted Figure 18 – Dimplex SOLC220 integrated roof kit without and with flashing kit fitted Free standing kits The free standing kit is designed for the vertical installation of the solar collector on even ground with a slope of 45° to 60°. For lower sloping angles shorted support struts can be ordered, allowing the collector to slope between 30° and 40°.
Technical manual SOLAR Figure 19 – Free standing kit row distance calculation details In addition to the row distance the fixation of the free standing kit to the mounting surface has to be considered carefully. Due to the shape of the flat plate collector considerable wind forces can act on the free standing kit installation. Ideally the free standing kit is bolted to a fixed structure.
Technical manual SOLAR mtot = n spt ⋅ m spt − ncol ⋅ mcol Where: mtot nspt mspt ncol mcol [kg] [-] [kg] [-] [kg] [4] minimum mass required number of supports in installation mass for each support (see Figure 20) number of collectors in installation mass of collector (SOLC220 = 34.5 kg) Figure 20 – Free standing kit support weight calculation details In some cases it might be required to prepare the load baring structure in advance to accept the fittings of the Dimplex solar free standing kit.
Technical manual SOLAR 4.1.4 Space requirement Depending on the mounting method the foot print required by the solar collector installation varies. The dimension for the on roof and free standing mounting kits do not include the space required to fit the connection pipes as these vary depending on the pipe feed through chosen. The dimensions provided for the integrated roof kits include the pipe work as the pipe feed through is part of the integrated roof kit.
Technical manual SOLAR Figure 24 – Space requirement Dimplex SOLC220 free standing installation Page 23 of 72 ST0133 – A 02/09
Technical manual SOLAR 4.1.4 Technical data Figure 25 summarises the key technical data of the Dimplex SOLC220 solar thermal collector. Figure 25 – Technical data Dimplex SOLC220 collector 4.2 Dimplex solar control unit SOLCU1/2/3 4.2.1 General description Dimplex solar offer a range of solar control units with differing input and output options and functionality. All control units operate on the basic principles described in chapter 3.3.2.
Technical manual SOLAR A detailed description of the individual operation and function of the control units can be found in the respective installation and operating instructions. 4.2.2 Temperature sensors All Dimplex solar control units come with three PT1000 temperature sensors which can be extended as required. The polarity of the sensor contacts is not important. The length of the sensors delivered with each control unit is: - collector sensor: 1.5m - cylinder sensors (x2): 3.
Technical manual SOLAR 4.2.3 Technical data The main features of the Dimplex solar control units SOLCU1/2/3 are summarised in Figure 28. Figure 28 – Technical data overall view Dimplex solar control units SOLCU1/2/3 4.3 Dimplex solar pump unit SOLPU1/2 4.3.1 General description The Dimplex solar pump units SOLPU1 and SOLPU2 comprise a number of features aiding in the installation, commissioning, operation and maintenance of the solar thermal installation.
Technical manual SOLAR 02 01 03 16 04 15 05 14 13 06 12 07 08 11 09 10 Figure 29 – Components of Dimplex solar pump unit SOLPU1 and SOLPU2 Pump unit connections (1, 2, 10 and 13) The SOLPU1 pump unit connections can be utilised in three different ways: - 3/4” flat seal at the end of corrugated stainless steel pipe - 3/4”F x 22mm straight connection - 15mm reducing set The 15mm reducing set is included in the delivery of the SOLPU1 pump unit, the ¾” flat seal is part of the delivery of the Dimpl
Technical manual SOLAR flexible hose SOLFH10/15 is DN16 and only provides ¾” connections. Should this product be applied to the SOLPU2 a 1” to ¾” reducer has to be provided with sufficient sealing surface for the flat seal to sit against. The 1”F x 22mm or 1”F x 28mm straight connection has to be provided by the installer. 6 bar pressure relief valve (3) The 6 bar pressure relief valve is part of the safety components in the solar circuit. Its correct application is therefore important.
Technical manual SOLAR The centre valve of the flush and fill point is being used to adjust the flow rate if required. Figure 30 - Pump characteristics and pump unit pressure drop SOLPU1 and SOLPU2 Expansion vessel fixing kit (8) The expansion vessel fixing kit is not part of the scope of delivery of the pump units but is part of the standard Dimplex solar kits and is suitable for expansion vessels of up to 24 litre contents.
Technical manual SOLAR Insulation cover (12) The insulation cover avoids unnecessary heat loss from the solar loop and gives the pump unit its aesthetically pleasing appearance. 4.3.
Technical manual SOLAR Should the above conditions not be given, the motorised two port valve has to be installed in series to the twin thermostat. 4.3.
Technical manual SOLAR 4.4 Dimplex solar expansion vessels SOLEV 4.4.1 General description Dimplex solar offer an extensive range of expansion vessels from 18 to 80 litres. All expansion vessels are particularly suited for the application in solar thermal systems with a high temperature resistant membrane which has also excellent diffusion barrier characteristics in conjunction with the heat transfer medium used in solar thermal systems.
Technical manual SOLAR The expansion volume of the system Vep can be calculated using Equation 7. Vep = Vsys ⋅ β Where: [7] Vep Vsys β [l] [l] [-] system expansion volume total system volume heat transfer medium expansion coefficient (0.00085) The pressure relief valve pressure prv can as first approximation be used as 6 bar. However, to allow for some tolerance it is recommended to calculate the pressure relief valve pressure prv in accordance with Equation 8. p rv = pop ⋅ (1 − 0.
Technical manual SOLAR p mp = p pc ⋅ Where: V EV − V pc [10] V EV pmp ppc VEV Vpc [bar] [bar] [l] [l] membrane pressure cold fill pressure expansion vessel volume pre-charge volume The expansion vessel membrane pressure pmp has to be adjusted before the system is being filled and pressurised. Once the theoretical expansion vessel volume has been calculated, the next larger available vessel is to be chosen. A sizing guide of the expansion vessel under the stated conditions is given in Figure 34.
Technical manual SOLAR 4.4.3 Technical data Figure 35 – Technical data Dimplex SOLEV expansion vessels 4.5 Dimplex expansion vessel fixing kit SOLVK1 4.5.1 General description The expansion vessel fixing kit SOLVK1 aids with the installation, maintenance and decommissioning of the solar thermal system.
Technical manual SOLAR It is not recommended to fit vessels larger than 24 litres using the expansion vessel fixing kit as faulty vessels gain considerably in weight and the wall bracket would not support the additional weight. The 500mm corrugated stainless steel hose allows the expansion vessel to be directly connected to the expansion vessel connection port of the Dimplex solar pump units SOLPU1 and SOLPU2. The quick fit connection is a combined retainer and vessel connection.
Technical manual SOLAR 4.6.2 Technical data Figure 38 – Technical data Dimplex solar heat transfer medium SOLHT20 4.7 Dimplex solar cylinders SCx 4.7.1 General description Dimplex offer a range of direct electric and indirect heated solar cylinders from 175 litre to 305 litre overall volume. An overall view of the products is given in Figure 39 and a summary of the key features is given in Figure 40.
Technical manual SOLAR SCx175/215/255/305sd 18 01 02 04 16 07 17 05 SCx175/215/255/305si 12 06 03 13 15 14 18 01 04 02 16 17 11 08 05 10 09 12 07 03 13 15 14 Figure 39 – Overall view Dimplex solar SCx unvented stainless steel cylinders Page 38 of 72 ST0133 – A 02/09
Technical manual SOLAR Figure 40 – Key features Dimplex solar cylinders SCx 4.7.2 Wiring integration Dimplex solar cylinders SCx There are several ways to integrate the Dimplex solar cylinders into an existing or a new central heating system. The principle plumbing and wiring schematics are shown for two systems in Figures 41 and 42. Please note that these illustrations do not show all the required components to ensure a safe and reliable operation of the systems.
Technical manual SOLAR Figure 41 – Auxiliary loop integration 2x motorised two port valve Page 40 of 72 ST0133 – A 02/09
Technical manual SOLAR Figure 42 - Auxiliary loop integration 1x motorised two port valve and mid-position valve Page 41 of 72 ST0133 – A 02/09
Technical manual SOLAR The integration of the solar thermal control and pump unit independent from manufacturer nomenclature is shown in Figure 43. Figure 43 – Solar loop integration 4.7.3 Hydraulic integration Dimplex solar cylinders SCx Should the cylinder range of 175 to 305 litres not be sufficient, any number of cylinders can be connected in parallel or in series to achieve higher storage volumes.
Technical manual SOLAR 4.7.
Technical manual SOLAR Figure 45 – Pressure drop Dimplex solar SCx cylinder coils 4.8 Dimplex solar accessories 4.8.1 General description To aid in the installation, commissioning, maintenance and the realisation of more complex systems Dimplex offer a range of accessories as summarised in Figure 46.
Technical manual SOLAR 4.8.2 Corrugated flexible pipe SOLFH10/15 The Dimplex solar flexible corrugated stainless steel pipe includes: - high temperature and weather resistant insulation - integrated 2 core sensor cable - wall fixings - connection fittings from the collector to the pump unit and from the pump unit to the cylinder - 10m or 15m length.
Technical manual SOLAR 4.8.3 Feed through tiles SOLFTT and SOLFTM The Dimplex solar feed through tiles are suitable for corrugated and plain tiles, slate roof coverings and sheet metal coverings depending on the type chosen: - SOLFTT: corrugated and plain tile, slate roof covering - SOLFTM: sheet metal roof covering, plain or corrugated For each pipe feed through one tile of the appropriate type is required. The product allows pipes and cables from 0 to 35mm to be fed securely into the roof.
Technical manual SOLAR 5 System sizing 5.1 Required information The sizing of solar thermal systems depends on a number of factors which require the use of solar simulation software to allow reliable solar fraction predictions. The information required to reliably specify a domestic solar thermal hot water system is shown in Figure 49.
Technical manual SOLAR Figure 50 – Dimplex solar initial sizing guide Page 48 of 72 ST0133 – A 02/09
Technical manual SOLAR For an initial assessment the following sizing guide (Figure 50) can be used to discuss the feasibility of solar. It is however recommended, following the completion of the sizing guide to complete the On Site Questionnaire as shown in Figure 49 and Appendix 11.1 to validate the initial sizing with a detailed solar fraction simulation.
Technical manual SOLAR Figure 51 – Suitable pipe diameters for various collector field sizes 6.3 Pipe work pressure drop To be able to determine the suitability of the circulation pump it is important to be able to calculate the pressure drop of the pipe work. Figure 52 summarises the approximate pressure drop Δp_pipe in 1m of pipe work at 0.5 and 0.7m/s assuming that the glycol pressure drop is 30% higher than that of water. Figure 52 – Pressure drop copper pipe per metre 6.
Technical manual SOLAR 6.
Technical manual SOLAR 7 Commissioning The commissioning of a Dimplex solar thermal system is a simple procedure as outlined in Figure 55.
Technical manual SOLAR Figure 55 – Dimplex commissioning procedure Part 2 8 Operation 8.1 Control unit In general the operation of the Dimplex solar thermal system is fully automatic and does not require any user intervention to ensure its efficient, safe and reliable operation. However, the solar control unit offers a number of useful information that might be of interest to the user.
Technical manual SOLAR - holiday and frost protection function - variable speed control of circulating pump Figure 56 – Display information and menu structure SOLCU1 Page 54 of 72 ST0133 – A 02/09
Technical manual SOLAR 8.2 Pump unit As for the whole system no manual intervention is required on the pump unit when the system is operating normally.
Technical manual SOLAR Check content discharge vessel Should any heat transfer medium be deposited in the discharge vessel which was not there from the beginning, the cause is to be established. Check roof feed-through for leaks The points at which the pipe work penetrates the primary and secondary protection layer are to be inspected if accessible. No leakage must be found at these points. Check condition of pipe insulation As detailed in Chapter 6.
Technical manual SOLAR Figure 58 – Overall view Dimplex solar maintenance procedure Page 57 of 72 ST0133 – A 02/09
Technical manual SOLAR 10 Product and kit listings The Dimplex solar product range is offered as kit or as individual components. The following listings detail all the kits and the individual components available. 10.1 Dimplex solar kits The Dimplex solar kits are packaged in such a way that all the required components are contained in the kit. Optional components are available but are not contained in the standard kits.
Technical manual SOLAR Figure 60 – Dimplex solar components overall view Page 59 of 72 ST0133 – A 02/09
Technical manual SOLAR 11 Dimplex literature structure Dimplex solar offers a range of literature to provide relevant information at all stages of the product life cycle from planning and design, installation and maintenance to operation and troubleshooting. Figure 61 summarises the available documents and their relevance at the various stages of the product’s application.
Technical manual SOLAR 12 Appendix 12.
Technical manual SOLAR 12.
Technical manual SOLAR Page 63 of 72 ST0133 – A 02/09
Technical manual SOLAR Page 64 of 72 ST0133 – A 02/09
Technical manual SOLAR 12.
Technical manual SOLAR 12.
Technical manual SOLAR 12.
Technical manual SOLAR Page 68 of 72 ST0133 – A 02/09
Technical manual SOLAR Page 69 of 72 ST0133 – A 02/09
Technical manual SOLAR Page 70 of 72 ST0133 – A 02/09
Technical manual SOLAR Page 71 of 72 ST0133 – A 02/09
Technical manual SOLAR 13 Notes and sketches Page 72 of 72 ST0133 – A 02/09
