Guide

Solar radiation and its solar collector use

In flat solar collectors possibility of conversion of solar radiation energy into usable heat is mainly dependent on total radiation which reaches the collector form all directions of semi sphere. Total radiation consists of direct radiation with the wavelength from the range of 0,3 ÷ 2,5 mm and long-wave scattered(diffusive) radiation which arose from refraction, reflection and partial absorbing of direct radiation in earth’s atmosphere. Total radiation in latitudes characteristic for Poland and optimal conditions(cloudless, clean sky in afternoon hours) is 850 ÷ 1100 kWh / m² in scale of year. By using APAREL solar collectors we can use over 70% of total radiation. In order to gather maximum energy, very meaningful is slope and directing the collector – described in further chapter of this catalogue.


Fig. Direct radiation and  scattered radiation at different day times

Direct radiation
Scattered radiation
A – Solar radiation
B –  Months


Fig. Balance of solar radiation power – optimal conditions


Structure of solar collector

APAREL is producing collectors in two versions: vertical and horizontal. Housing for such collectors is aluminum tank.




Over 10 years of experience in filed of producing flat collectors allowed APAREL to elaborate such collector structure that guarantees long durability and energetic efficiency. Currently there are produced two versions of collectors: vertical KSC-AE/200S-A and horizontal KCS-AE/200S-B. Main component of the collector is absorber which is made of copper elements both-side nickel-plated. Active side of collector is coated with galvanic, high selective layer of black chromium or sunselect. Such layers can guarantee high absorption of solar radiation and very small heat emission. Inside the collector there are coil pipes applied for receiving gained heat. Parallel to coil pipe there are small copper pipes through which flows heating fluid. The method of connecting plate with copper pipe inside absorbers guarantees them very good contact in the whole system, what results in collecting max. heat by heating fluid. The absorber is surrounded by housing in form of frame made from aluminum or in form of tank made from aluminum plate. Good collector’s insulation minimizes heat losses from collector to environment. Everything is covered with screen made of hardened glass which contains very small amount of iron, what decreases reflection losses.


 

1. Absorber
The Absorber Plate used in solar collector is made from 8 segments. Each segment consists of copper fin ultrasonically welded to copper riser, which provide excellent heat transfer to heating medium as well as high efficiency. The copper fins are both-side nickel-plated. Additionally active surface of absorber is coated either with black chrome or special selective cover based on BlueTec technology. All provide a superior surface, highly efficient in solar energy applications and excellent energy absorption.

2. Insulation
In order to limit heat losses, the solar collector has under absorber heat insulation made of 50 mm non-flammable mineral wool and additional heat insulation with thickness of 30 mm on the side of the absorber.

3. Tubing grid
The copper riser with diameter Ø8 mm.

4. Cumulative pipe
The cumulative pipe with diameter of Ø18 is made of copper. At the end of the pipe there is a connector.

5. Casing
The casing is made of aluminum sheet and aluminum sections in natural or brown colour.

6. Solar glass
The solar glass is made of special hail-resistance, prismatic, hardened solar glass with thickness of 4mm, low contents of oxides iron Fe2O3 and high transmittance of sun ray (91%).


Efficiency of solar collector

A basis for estimating collector’s heating properties is efficiency characteristics in relation to absorber’s surface according to the procedures described by norm ISO 9800-2 Efficiency of solar collector is defined as a ratio of heat energy gained by heating medium and irradiation of collector’s surface in a specified unit of time. Values which we use to estimate collector’s efficiency is an optical efficiency ηo, which is crucial in the situation when the difference between temperature in collector (TM) and ambient temperature (T0) is equal to zero. At higher collector’s temperatures (TM) caused by greater radiation heat losses become bigger making that for greater values of parameter (TM - T0 ) / I, the straight line, on the figure, below curves downwards. Efficiency of the collector is dependent on construction parameters (used materials, thermal insulation etc.) and exploitation conditions (efficiency of working sensor, irradiation, wind speed and direction.)

Fig.. Efficiency at solar radiation intensity  I = 800 W / m²

Coefficient
Value
η0 A[-] 0,8519
K1 [W/m²K] 5,7715
K2 [W/m²K] 0,0174

η0 – Optical efficiency
X – Heat losses coefficient


Installation elements and example solutions of solar systems

Constituent elements of solar installation

Solar collector
Basic component of solar installation is solar collector, most often installed on the roofs of the family houses and other buildings. Very often we can meet collectors installed on balustrades. It is most useful to install them near to places where we use water most often e.g. kitchen, bathroom etc. By doing this we minimize length of connecting pipes and decrease heat energy losses during the flow of heating fluid. Installation of collectors on the roofs is made by using special supporting constructions.

Solar accumulator
Sun energy is available only during the day, sometimes with random variation. In order to use it effectively in the heating system it must be
accumulated. For that purpose we use accumulative storage reservoirs with thermal insulation made of polyurethane filler or mineral wool (thickness 55÷75 mm). These storage reservoirs are equipped with cloak or tubular heat exchanger. Most popular are equipped with tubular exchangers i.e. coil pipes. We can distinguish storage reservoirs with one and two coil pipes:
– storage reservoir with one coil pipe is most often used in such systems where solar installation was added to traditional heating system, after the boiler-room was built
– storage reservoirs with two coil pipes is most optimal solution for accumulating energy which is acquired from solar installation. It is characterized by good lamination of water temperature and it can be supplied by more than one source of energy (e.g. solar collectors and any conventional source of energy). It has two builtin exchangers in form of coil pipes: bottom one to which we connect solar installation and upper one to which we connect conventional source of energy in the periods of weak insolation. There are also options with additional heating set in form of electric heater. In the case of applying such solution we can diminish our investment costs.

Steering
Solar heating installation can be steered by use of controllers working together with temperature sensors which put in motion a circulator pump. The main task for the controller is to switch on the pump in the situation when the difference of temperatures is sufficient for exchange of heat between working fluid in collector and heating fluid in the reservoir or exchanger. The controller secures also system against reaching maximum value of temperature in storage reservoir or collector.

Pump system
In order to move the medium in fluidic installations there are used electric pumps, same as used in installations of central heating. Efficiency range of medium and pressure drops is rather not so big that’s why there should not be any problem with matching the circulator pump.

External heat exchanger
In complex installations consisting of more than ten collectors there are used external heat exchangers. They replace internal coil pipes in
reservoirs. They can be divided into two basic groups: disc exchangers, tubular exchangers (type JAD). Both these groups found their application in solar technology.
– Disc exchangers are made of several or tens of discs, on their surfaces there is exchange of heat. The power of exchanger depends on the number and size of the disc. Exchanger discs are combined in such a way that there are two independent circulations: primary and secondary. Each circulation has two blowdown connections. Exchangers can be soldered or twisted. They found their application in solar systems with big power.
– Tubular exchangers type JAD in their construction they create splice of smooth and crimped pipes what makes a kind of coat for the exchanger. Heating fluid flows through coil pipe whereas the fluid which is being heated flows countercurrently inside the coat of the exchanger.

Safety system
Solar installations with intermediate collector circulation are equipped with fittings typical for central heating systems. Against too high pressure in the system we have cumulative tank and safety valve, whereas air-escape installed in the top parts of circulation allows for precise venting. Between the outlet from the collector and reservoir there is check valve installed, which prevents from possible reverse circulation of hot water during the night.

System installation
Components of solar installation are connected with each other by use of pipelines very often made of copper tubes which are thermally insulated. Application of copper tubes in water installations practically solves the problem of durability. Their connections are made by soldering with soft tin solder and for bigger diameters with hard silver solder. All the pipelines should be insulated with materials which posses good thermal conductivity 0,03 ÷ 0,04 W / mK and resistance to high temperature above 100 °C.



Guidelines for designing and matching components
of solar installation

Angle of inclination of solar collectors
Very important role in proper utilization of solar energy radiation plays an angle of inclination of solar collector α in relation to horizontal plane. Angle of inclination depends on angle of incidence of solar rays because they should not be perpendicular to the surface of collector. Optimal angle of inclination should be 60° – in winter, 30° – in summer. In practice as it is 45° is recommended. 

Azimuth angle of solar collectors
Second parameter for setting properly the collector is azimuth, which should not be different than 0° (direction south). It is not always possible, that’s why aberration from southern direction to 45° is allowed (in the same time aberration towards western direction is less convenient).


Fig. Optimal angle of inclination in particular months
A – Collector's surface

Months I II III IV V VI VII VIII IX X XI XII
 Angle
α [º]
60 55 45 30 15 10 15 30 45 55 66 65


Installations for getting hot water
The simplest and in the same time the cheapest installation for heating water is gravitational installation (thermo siphon). In gravitational installations flow of medium is done automatically as a result of convection of warmer masses (with smaller density). Such circulation does not require circulator pump and automatic steering system, what makes possible to work in areas without power supply. More universal features have installations with forced circulation of the medium in the system: solar collectors – accumulative reservoir. Such installations can heat the water directly or indirectly. By applying direct circulation we restrain exploitation of installation only to warm period of the year (April-October), what is more we can cause faster fatigue wear of the absorber resulting from the contact of water with absorber. Such obstacles can be avoided in installations with forced indirect circulation. Circulation of heating medium is caused by single-phase circulation pump, which is controlled by controller of fluid temperature inside the collector and water in the reservoir. Very often we can meet version with common accumulative reservoir, where in the bottom part there is an exchanger of collector circulation and in the upper part an exchanger of boiler circulation or electric heater. There is also other version with separate accumulative reservoirs. Over 10 years experience of APAREL in production of solar collectors allowed for establishing appropriate instructions for designing and matching solar systems in such a way that we can satisfy all the requirements specified by the client. It is confirmed on the basis of instructions elaborated by well known and respected European producers. Before implementing solar system we should consider the following aspects:
– solar collectors can cover even 90% of the demand for energy needed to heat the water in summer period. In winter period their efficiency decreases because of worse radiation conditions, that’s why they can not be totally alternative source of energy. The system should be supported with additional conventional source of energy.
– Size of installation i.e. number of collectors and capacity of storage reservoir depends on the demand for hot water (number of people
living in the house, consumption rate)

Matching the capacity of storage reservoir for hot water and number of collectors
Table statement of advised amounts of hot water per one person:

Level of water
consumption
Amount of water
per on person
Vj [l]
Number of collectors
per on person
X [szt.]
low 40 ÷ 60 0,3 ÷ 0,5
medium 60 ÷ 80 0,5 ÷ 0,7
high 80 ÷ 100 0,7 ÷ 0,9


Vzas = Vj * n [l]

Vzas – capacity of storage reservoirs [l]
Vj – amount of water per one person [l / per.]
n – number of people


N = X * n
N – number of collectors needed for installation
X – number of collectors per one person
n – number of people

Remark!
In case of small installations (3 ÷ 8 persons) it is advised to choose systems for medium or high water consumption. In case of bigger systems (more than 8 persons) installation should be matched for low or medium water consumption.


Example choice of installation

Example 1
For 4 persons (medium level of water consumption was assumed). With consumption of hot water 70 l / person, total consumption is 280 l / day. We chose a bit bigger reservoir of 300 l capacity. Respectively number of collectors per one person is 0,6 coll. / person. For 4 members family we need 2,4 of collector. We assume 3 collectors of KSC-AE/200S type.

Example 2
For 20 persons (low level of water consumption was assumed) With consumption of hot water 50 l/person, total consumption is 1000 l/day. We chose a reservoir of 1000 l capacity. Respectively number of collectors per one person is 0,4 coll./person. For 20 persons 8 collectors.


Heating the water in swimming pools

Choice of number of solar collectors needed for heating the swimming pool More and more often solar collectors are used for heating the water in swimming pools. Keeping the optimal temperature 23 ÷ 24 °C in the swimming pool during the summer period requires installation of appropriate number of collectors. In the table below we present number of collectors for swimming pools with and without thermal shield (assumed average depth of the swimming pool is around 1,8 m):

Kind of swimming pool Number of collectors
N [coll. / m²]
Swimming pool without thermal shield 0,45 ÷ 0,55
Swimming pool with thermal shield
0,25 ÷ 0,35

Lk=N * Fb

Lk –  number of collectors
N – number of collectors per 1 m² of swimming pool surface [coll. / m²]
Fb – swimming pool surface [m²]


Choice of heat exchanger size

Most commonly used heat exchangers in case of swimming pools are exchangers type JAD. Size of exchanger (power) depends on the number of collectors matched for heating the water in swimming pool. Power of chosen exchanger must considerably exceed the power of installed collectors (8 times) in order to achieve appropriate efficiency of heat exchange:

Number of collectors

Exchanger size
[kW]
3 38
6 73
8 88
12 148
15 180
20 240



Supporting central heating system

Reheating of buildings by use of solar system is most efficient during spring and autumn seasons. Type of applied heating system plays here very important role. A condition for effective use of collectors is cooperation with low-temperature heating systems i.e. floor or wall one. Such installations can be made in two ways: without or with accumulative reservoir. Installations without accumulator can be applied only in case of small single-family houses. Then we decide on number of collectors accordingly to the size of reservoir, applying only small surplus for the need of central heating in number of 1 ÷ 2 collectors. Installations with additional buffering reservoir can be applied when the demand for heat needed for central heating system considerably exceeds the demand for hot water. On average we assume 1 m² of active collector’s surface for 10 m² of heated surface in well insulated buildings. In less insulated buildings this value should be doubled. Reservoir’s capacity is dependent on the number of applied collectors. On average we assume 40 ÷ 60 l of water in buffer for 1 m² of applied in the system collectors. As a heat exchanger most often plane exchanger is used. The size of the exchanger just like in case of swimming pools must be correspondingly bigger (in this case 4 times)

Number of collectors
Exchanger size
[kW]
10 60
15 90
20 120
25 150
30 180
35 210


Selection of pipes, circulator pump, safety valve and cumulative reservoir

We make the selection of circulation pump and diaphragm cumulative reservoir by following below instructions:
– Circulator pump should be able to work in constant mode in the following liquid temperature range of 20 °C ÷ 120 °C, temporarily pump can operate in the range of 20 °C ÷ 150 °C;
– Speed of flow of heating medium should be in the range of 0,3 ÷ 0,5 m/s, and the stream of flow in the range of 60 ÷ 120 dm³ / h (1 ÷ 2 dm³ / min / collector);
– Drop of pressure in the collector’s circuit should be 1,0 ÷ 2,5 mbar / mb of pipe.

After matching appropriate number of collectors next step is matching diameters of pipes. Most often copper pipes are used. In the table below we present chosen diameters of pipes in relation to the number of collectors applied. In case of larger systems (i.e. bigger number of collectors) the diameters of pipes should be matched individually. Solar circulation should be secured in such a way that heating fluid at maximum temperature of collector’s circulation could not be thrown out through the safety valve. It is achieved by proper choice of diaphragm cumulative reservoir. Capacity of reservoir should be more or less equal to capacity of primary circulation, i.e. sum of capacities of collectors, pipeline and heat exchanger(coil pipe, coat) in cumulative reservoir. What is more in case of solar systems, safety valve of 6 bar opening pressure should o be installed.

Number of collectors
[pcs.]
External diameter of the pipe
[mm]
1 ÷ 6 18
7 ÷ 9 22
10 ÷ 18 28
19 ÷ 25 35


Annual comparative, energetic balance for
solar installation with application of solar
collectors produced by "Aparel"

Number of collectors: 3 pieces
Collector type: APAREL KCS-AE/200S
Collector surface: 5,19 m2
Slope: 45º, geographical direction – south 0º
Installation type: 3 collectors + heated storage reservoir by electric heater 2 kW
Storage reservoir: 300 liters, temp., min 35 ºC / max 55 ºC
Energy needed to heat 300 l / day: 13,3 kWh
Month
Radiation
[kWh]
Energy yield from collectors
[kWh]
Total energy needed for heating water
[kWh]
Conventional energy
[kWh]
Demand satisfaction
[%]
Black chromium
Sunselect Black chromium
Sunselect
I 137,1
63,9 89,1 412,3 366,4 15,5 21,6
II 255,7 113,9 135,2 372,4 276,5 30,6 36,3
III 531,9 264,7 293,9 412,3 165,6 64,2 71,3
IV 729,3 337,9 353,1 399,0 79,1 84,7 88,5
V 853,7 399,1 400,3 412,3 31,2 96,8 97,1
VI 921,5 395,4 395,8 399,0 21,6 99,1 99,2
VII 859,5 409,8 410,2 412,3 20,5 99,4 99,5
VIII 794,1 397,0 397,5 412,3 33,3 96,3 96,4
IX 570,6 351,5 355,5 399,0 65,5 88,1 89,1
X 329,4 256,0 281,6 412,3 174,3 62,1 68,3
XI 151,8 77,0 100,1 399,0 340 19,1 25,1
XII 101,8 54,4 70,9 412,3 375,9 13,2 17,2
6236,4 3120,6 3283,2 4854,5 1949,9 64,1 67,5






Location, installation and ways of connecting collectors KSC-AE/200S

Location and installation
As it was presented before, active side of solar collectors should be exposed towards south direction with slope 30° - 60° depending on foreseen period of use, in case of whole year it would be around 45°. It is very important to choose proper place, not hidden by the trees and other buildings. Future user of solar collectors has practically 3 ways of their installation:
– on the roof of building,
– on the south wall of building or just next to it,
– on the ground
Each of this location variants has its advantages and disadvantages.  Most popular is to install collectors on roofs of buildings. Main advantage of such solution is that collectors mounted on the roof do not take any additional place and do not put a shade on the building. In most cases slope of the roof is suitable for direct installation of solar collectors without any additional supporting construction. On  flat roofs, collectors are installed on special supporting constructions
APAREL company offers its own original solutions for installation, taking into account most possible cases. Mounting elements were designed in such a way, that they can form any carrying construction. More detailed information concerning supporting constructions are available in separate catalogue devoted to installation and mountage.


Methods of joining solar collectors advised by "Aparel" company
Method and number of joined collectors KSCAE/ 200S is very meaningful in case of flow resistance. The biggest flow resistance we have in case of joint in series and the smallest in case of parallel joint. In the same time parallel joint has a certain disadvantage, it is hard to maintain equal flow intensity trough all the collectors. Solar collectors KSC-AE/200S is supposed to be placed in such a way that sensor’s plug of the first collector would be in the upper corner, what you can see at the figure below. During installation of collectors we should remove the plug from the first collector and put a head of temperature sensor into the hole deep inside the absorber’s pocket or screw in sensor’s selflocking plug with exit thread on 18 mm diameter pipe and place inside temperature sensor. Everything should be secured with silicon.

Joint in series
It is advised to join in series three vertical or six horizontal collectors. Input and output are connected by special screw with exit thread on 18 mm diameter pipe, whereas collectors are connected with each other by double-locking joints.

Parallel joint
It is advised to join parallel maximum six vertical or three horizontal collectors.

Parallel joint of solar collectors joined in series
During construction of large installations we can join parallel batteries earlier joined in series combined from max. 3 vertical or 6 horizontal collectors.

Parallel joint of parallel joined solar collectors
This solution similarly like in case of pervious one can be applied during construction of large installations, joining parallel batteries combined from max. 6 vertical or 3 horizontal collectors.


We offer professional help in range of:
– designing,
– advisory,
– installation service.

We invite to cooperation:
– fitters,
– designers,
– architects,
– everybody who is interested in unconventional sources of energy.