Escolar Documentos
Profissional Documentos
Cultura Documentos
Table of Contents
Table of Contents
Table of Contents...................................................................................................... 2
1. Introduction ............................................................................................................ 3
2. The Solar Air Heater .............................................................................................. 4
3. Basics & Technical Requirements ..................................................................... 9
4. Bibliography ......................................................................................................... 23
5. Sources ................................................................................................................. 24
6. Appendix .............................................................................................................. 26
Table of Contents
Abbreviations
g-value
k-value
heat loss
kWh
kilowatt hour
watt
square meter
year
ESG
m/s
speed in meters/second
mass
W/m
emission coefficient
efficiency
absorption coefficient
Contents
1. Introduction
In the summer of 2008 I published my first instructions about warm air panels.
Since the initial idea to heat buildings through air heated by solar radiation the
Trubadu collectors have been further developed and refined in detail.
This third construction manual for building a solar heating panel arose from the
many experiences I gathered from my operating various collect collector types.
Previous measurements have shown that the efficiency of solar panel systems
does not only depend on upon the global solar radiation, but rather even more upon
the conditions under which they operate. These aspects were considered in the
realization of the Slime Line panel types.
Stefan Brandt
Operation
For many decades now, buildings have been heated and supplied with warmed
fresh air using solar thermal systems. The technique as compared to a hot water
collector is safe against frost and leaks in the collector causing structural damage.
Air as a heat-carrying medium has many advantages: air does not drip, does not
freeze and is always available in sufficient quantity. Air can be "moved" quickly, it
picks up heat and flows freely. In buildings air needs to be exchanged continuously
anyway for breathing and to dissipate moisture. It is therefore reasonable to use
that air at the same time for heating rooms.
The main components of the air collector is the absorber plate on which the
collected light energy from the sun is converted into heat, the air duct under the
absorber and an electric fan. The fascination for the collector lies in the simplicity of
its construction, using air as carrier of heat, and how it functions autonomously.
The operation is based on the principle of a full radiator. A black body absorbs
incident light radiation almost completely. It does not let radiation pass through nor
does it reflect or scatter it back. This absorbed radiation is converted into heat and
emitted as long wave heat radiation to the surrounding air. Surrounded by a
thermally insulated housing and a transparent cover disk the collector can use the
greenhouse effect. The longwave infrared radiation emitted from the black surface
continuously heats up interior of the collector due to the greenhouse effect.
Temperatures well above 100 degrees Celsius can be achieved in this way. This
accumulation of heat is used with cool air being brought into the collector with fans.
The air heats up at the absorber plate and the collector cools down. The warm air is
then used directly to heat rooms by passing it through a pipe system in the rooms
to be heated.
Air collector systems for heating need only relatively low temperatures, because the
temperature inside the collector need only be just above the air temperature in the
room to for it be heated. Thus, the solar air heaters are already energy efficient and
very effective even with little sunlight. Any higher temperature in the solar collector,
5
no matter how small, is thus used for heating rooms. This is a tremendous
advantage over conventional hot water collector systems for assisting heating,
which mostly feed into the cycle of heating radiators or underfloor heating - here,
depending on the type of heat distribution system a temperature of at least 30-55
C is required. The fresh air heating with air collectors is therefore a particularly
effective variant of utilizing solar energy. If a photovoltaic module is installed to
operate the fan then the collector can operate entirely autonomously.
When the sun is shining it produces an average of about 800 W/m - max. 1000
W/m. In Germany, this happens for about an average of 1,400 hours per year.
This is roughly equivalent to 1,200 kWh / m per year - heat, which can be used
easily. Using current state of the art technology about 5%-20% of home heating
needs can supplied using solar with a collector area of 5.5 m and an annual
operation time of 700 hours.
Basic information on reproduction:
The manual describes exactly how to build the Trubadu Slim Line collector. Air
collector systems can be varied simply and combined with existing heating
systems. Depending on the purpose and type of building modifications are required
or necessary. In part 1 of the instructions I want to convey some background
information, so individual adaptations for the respective building systems can be
made successfully.
2.2
General
The goal in developing the Trubadu solar air heater was to allow a cost effective
and simple construction in do-it-yourself fashion. All components are readily
available and the production of the collector costs between 150 and 220 per
square meter of collector area. The intention was to avoid a long period for
amortization.
2.3
Tools Needed
The construction of the collector should not be a problem for technically skilled
persons. A well-equipped hobbyist workshop, however, is a prerequisite.
2.4
Frame Construction
The basic structure of the Slim Line collector consists of a simple wooden structure
made of planed, straight planks of pine or spruce. The height of the wood is
selected so that the collector frame can be clad in galvanized steel sections from
the company Knauf. The back panel consists of a sandwich construction made of
0.4 mm aluminum plate and 40 mm of rockwool. The heat losses through the back
support plate with rockwool insulation and the surrounding wooden frame are thus
negligible.
2.5
The air duct under the absorber plate is expanded with a 0.08 mm aluminum foil
folded as a square wave to increase the surface for heat transfer. The absorber
plate is additionally attached to the Knauf u shaped sections that are screwed at a
distance of 20 mm on the carrier plate. The air is led through a perforated exhaust
pipe, with the hole size is such that a uniform air flow is achieved in the individual air
ducts. Thus heat transfer is achieved even with slowly flowing air (laminar flow),
which is the major contribution to increasing the efficiency.
2.6
The Absorber
S - Line Trubadu collector is basically suitable for the use of two types of absorbers.
With the use of a selectively coated absorber plate, the highest total efficiency of
about 75% is achieved. However it has the high price and is available worldwide.
Since the Trubadu collectors are now being replicated worldwide information is also
provided for making minor changes (see Section 2.7.1) for the use of a blackened
plate. Using solar-absorbing paint to darkness you can still acheive a good
efficiency (around 65% - 68%), which is just a few percentage points below that of
selectively coated plates.
In areas where solar-absorbing paint and aluminum sheet are poorly available, you
can use 0.5 mm steel sheet and water-based black paint instead. Here, however,
only around 50% efficiency can be achieved.
The transfer of heat from a heat source (absorber plate) to the surrounding cooling
medium - in this case air occurs by convection. The absorber acts as a heat sink
and is responsible for delivering the excess heat to the ambient air.
A selectively coated sheet e.g. Alanod solar type mirotherm as used in many hot
water collectors has a much better heat utilization here. Due to the coating the heat
radiates in one direction only. This reduces the heat loss through the cover plate
and consequently the overall efficiency of the air collector system is increased.
2.7
The S - Line collector is designed for two types of absorbers. When using the
painted sheet a double air duct is required, when using the selectively coated sheet
only a single-sided air flow is used.
2.8
Cover Plate
Example:
Total energy transmittance
of an insulating glass pane
Toughened security glass (ESG) consists of a single plate of specially heattreated glass. The glass is heated during manufacturing to more than 600C and
then cooled quickly with cold air. It cools the outer zone of the glass faster than the
inner core. The result is basically two different directions of tension.
In this way the glass has a greater impact and shock resistance. In addition, the
tempered glass is insensitive to large temperature differences of up to 200 degrees.
If it breaks down at high load, it breaks into tiny crumbs without sharp edges. This
reduces the risk of injury compared to normal window glass significantly.
source: Wikipedia
Basics
A variety of electromagnetic waves hit the surface of the Earth. These range from
high frequency to very short wavelengths. A very small range with a wavelength of
10
about 380-780 nm is our visible light. This wavelength range is used for many types
of solar energy: photovoltaics, solar water heating and solar air heating in our case.
The total radiation consists of direct and diffuse solar radiation. Above the
atmosphere, it is about 1367 W / m, while passing through Earth's atmosphere,
due to scattering and attenuation there is a reduction, so that on average on a
cloudless summer day in about 900 - 1,000 watts / m light energy arrive on the
earth's surface.
3.2
The intensity and brightness of sunlight is dependent on the time of day, season
and geographic location of the site. The fixed position of the sun at any given time is
represented by the azimuth and the elevation angle of the sun. The elevation here
represents the angle between the sun and earth surface level as perceived by a
viewer at any given time. The azimuth angle indicates the direction from which the
sun appears.
For the latitude 51 north latitude we get the sun heights depending on the
following seasons:
Summer Solstice 21st June - midday: 62.5 degrees
Equinox March & September 21 - midday: 39 degrees
Winter Solstice 21st December - midday: 15.5 degrees
To obtain the maximum energy output in the collector, the sun should come at a
right angle to the collector surface. Since the operation of the hot air collectors is
mainly in the period from September to April, this will result in the following setup
angle:
Equinox March & September 21 - midday: 90 - 39 degrees = 51 degrees
As it is desired with increasingly colder days to get the best energy input, the angle
from 70 degrees + / - 5 degrees should be used, but using a vertical mounting of
the panels on a building wall can be done also. This has the advantage that there
may be no overheating due to the high sun in summer.
11
The free program RET Screen can make a very good estimate of the solar
radiation at your location, which is on my web site for downloading.
The following table shows the average energy input on a horizontal and a 72
degree inclined surface for our site Liebenburg.
3.3
more efficient than in parallel. In my view the connection in parallel has significant
advantages that outweigh the slight loss in efficiency:
Is easier to construct
3.4
Idle Temperature
In summer, air collectors usually are not operated, they are idle. The result
achieved in this operating condition are temperatures that can reach 150 degrees.
The Trubadu air collector uses the self-cooling effect. Warm air rises and can freely
pass through the wide air intake to the outside, cooler ambient air passes through
the fan from below. Hereby with a wall mounting an idle temperature of only 90-95
degrees is reached.
3.5
Fire Protection
Even when idling temperatures of 150 degrees are reached with solar air collectors,
they are considered generally as uncritical under fire safety aspects. All materials
used in the interior of the collector are thermally stable up to at least 150 degrees.
3.6
Ventilation Pipe
For a good efficiency of the system there is a need to spread the cool outside air to
evenly through the collector. For collectors with a built-in fan, this is not feasible,
because the air flows more strongly in some areas of the collector than others. In
the S - Line collector, a specially made ventilation pipe is used. The different sizes
of suction holes ensure that the air flow is approximately the same in all the air
ducts. The choice of aluminmum as material for the tube is based on the fact that
high temperatures arise in an idle collector, which could possibly damage a plastic
pipe.
3.7
Small ventilators are typically referred to as a fan and belong to the air flow
machines. A fan consists of an impeller with blades, a drive motor and a housing for
14
5. Sources
25
26
About Us:
Idea & Development: Stefan Brandt
Text & Photos: Stefan Brandt
Print & Layout: Stefan Brandt
www.trubadu.de www.trubadu.com
S_Brandt@t-online.de
1. Edition 2011
nominal charge: 19,00 as ebook - 34,95 as DVD
An adaptation, alteration or manipulation of this copyrighted work in any way,
especially digitally, is not allowed.
The consent of the author is required for copying the material or its reproduction even partially - for third parties .
The construction of the solar air heaters is at your own risk - we do accept liability
for any damages of any kind (building / health) that occur during reproduction,
operation or assembly. The jurisdiction for any legal matters is Goslar.
Please note:
Research costs money!
I have had to invest several thousand Euros in materials, instrumentation and
software. I am pleased with the interest in my plans - but please refrain from
copying or modifying my PDF - files.
28
Construction Manual
Solar Air Heater
Type S-Line
Part 2
Stefan Brandt (Dipl.-Ing.)
1. Edition September 2011
Table of Contents
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
Introduction
Overview of Materials
Collector Frame
Air Duct
Frame Panels
Ventilation Pipe & Heat Deflector
Absorber Plate
Assembly Collector Body
Fan
Accessories
Diagrams
List of Materials
1.0
Introduction
This second part of the construction manual describes in great detail the structure of the S-Line Trubadu
collector. One should print out the instructions, as this helps for a better understanding during the assembly
steps. Sound craftsmanship skills and competent handling of tools are essential for the reconstruction of this
collector. With the exception of the circle and the peeling drill special tools are not necessary. A reliable
functioning and reaching a collector output of about 1500 watts is only assured by using the construction
materials given here. Different materials are possible but reduce the efficiency and thus performance.
A detailed parts list with prices is included in this manual. All components can be purchased in hardware stores
and specialist retailers. Individual components can also be bought at the Trubadu air heater shop
(www.trubadu.de/shop). The complete kit is also available there.
1.1
The Trubadu
S-Line Collector
Introduction
Front
Introduction
Back
2060 mm
1.2
1070 mm
2.0
2.6
The differential temperature regulator from TowiTek is available as an assembled module. Only the
two temperature sensors need be extended with cables. For this, a soldering iron is required. The
cable lengths should be adjusted to the conditions accordingly. One sensor is mounted inside the
collector, the other inside the room to be heated.
temperature sensor
2.10
Materials Miscellaneous I
Wall mount for collector
2.12
30 sheet metals screws 4,8*13 mm
Materials - Screws
18 sheet metal screws 4 *15mm
wood screws
for var. assembly
3*20 mm
12 floorboard screws
3,8*50 mm
20 metal screws
4,5*20 mm
8 wood screws
for outer frame
4*60 mm
16 wood screws
for var. assembly
3*30mm
3.0
Collector Frame
The outer frame and support frame are bolted together form a fixed unit and serve as a structural element
of the collector. Untreated wood should be used in each case, to prevent any vapors getting into the air.
When selecting the wooden exterior frame be careful to take undistorted material, small distortions of the
long boards can be compensated, however, when screwing the outer frame.
Support frame
Outer frame
3.2
Collector Frame
12 wooden screws
3*30mm 12
3.3
Collector Frame
4 floorboard screws
3,8*50 mm
Width of
mineral wool
insulation
4.1
Air Duct
approx. 20 cm
flush
4.2
Air Duct
The pieces labeled in 4.2 are drilled with a 2.7 mm drill bit, so that
the heads of the wooden screws do not slip through.
floorboard screws
3.8*50 mm
4.3
Air Duct
After installing the insulation now the
second aluminum plate is installed.
The inner support plate serves to
increase the heat transfer surface and
is glued for an air-tight and strong
connection with adhesive onto the
support frame. If the sheet is too wide
by a few millimeters, it can be cut with
metal shears.
adhesive
4.4
Air Duct
Now we drill the 51 mm hole into the outer frame. Here, the ventilation is inserted later.
Depending on whatever side the hole for the fan is later, the hole may be drilled into the outer
frame on the left or right side.
25 mm
35 mm
Support frame
diameter 51 mm
4.5
Air Duct
5.0
Frame Panels
The paneling of the outer frame is made of rectangular galvanized panels for drywall building. These
panels are made by the company Knauf for example. The sheet thickness is 0.4 mm, so can the panels
can be cut and bent easily. The holes in the panel are for attachment to the outer frame by means of
metal screws. Make sure during installation of the panels that they overlap from top to bottom, so
that rain water cannot get in later.
5.1
Frame Panels
Before the top frame cover panel is fitted, the
two spacer bars are installed (same type as the
support frame bars).
Wooden screws
3*30mm
5.2
Frame Panels
6.6
Air Duct
The thermal foil is used to increase the
heat transfer surface. It is made of 0.05 mm
aluminum foil and loosely inserted into the
duct. For folding use three spacer pieces
that have not been bolted to the support
plate yet. The folding is carried out as
shown in the pictures. Small holes created
in the foil by folding the with the spacer
pieces are not problematic and do not
affect the function of the collector.
8.1
8.2
9.2
Fan
As already mentioned, the fan housing is made either
of galvanized components as used for ventilation or
alternatively PP pipe is used. In both variants, a
reduction piece of 110/50 mm PP pipe comes to use.
These are available in the standard version but also in
the short version.
9.3
Fan
Radial fans are characterized by a high
pressure buildup, which is necessary to
overcome the air resistance in the collector.
For optimum power delivery the fan needs a
custom case in a spiral form like a snail shell.
This is simulated by placing the fan on the
wooden backing plate not in the center, but
shifted to the side.
9.5
Fan
You can see the approximate dimensions for the fan
and reduction pipe on the two images. Importantly,
note the gap between the fan and reduction pipe of 23 mm. After final assembly the fan must must turn
easily and not grind anywhere. Fan support plate and
the reduction pipe are pre-wrapped with a layer of PE
foam tape to ensure good positioning in the pipe is
possible.
2-3mm
PE tape
9.6
Fan
Fans and reduction pipe are each bolted to the casing with three
sheet metal screws which are offset by 120 degrees. It is advisable
to align fan and pipe reduction and then measure out and mark
the positions for the holes to be drilled.
screw positions
9.13
Fan
After that, the fully assembled controllers
are placed in the fan housing. The cables
are routed through the cable guide and
attached to the case with the two metal
screws on the mounting plate.
11.0 Diagrams
Idle temperature collector S-Line (03.06.2011)
T-Max idle: 103 C
Info 2
Measurements
Info 3
Source
Price
Unit
Frame construction
frame wood
planed wood strips
support bar glass/air grid
Knauf support piece UW
Screws by List of Screws
Aluminum plate
rock wool
frame construction
frame construction
frame construction
frame paneling
untreated
untreated
untreated
galvanized
92mm*24mm
36mm*17mm
44mm*25mm
100mm*40mm*2000mm
back covering
insulation
blank
0.5mm*1000*2000mm
40 mm thick
spruce/pine
spruce/pine
spruce/pine
Knauf plasterboard
2,14
0,99
per meter
12,85
10,00
2,25
35,00
per meter
individual
piece
14,63
4,50
35,00
6,00
plywood rest
hardware store/Trubadu.de
hardware store/Trubadu.de
hardware store/Trubadu.de
hardware store/Trubadu.de
trubadu.de
hardware store
2,00
7,00
1,99
12,00
89,00
1,00
1 piece
1 piece
1 piece
2 piece
1 piece
1 piece
2,00
7,00
1,99
12,00
89,00
1,00
glass retailer
Trubadu.de
Trubadu.de
hardware store
metal retailer
hardware store
37,00
2,60
2,60
5,60
2,50
3,90
per m
per lfm
per lfm
per roll
per meter
per meter
74,00
metal retailer
Trubadu.de
Blechhandel
Trubadu.de
Saunabau/Trubadu
hardware store
metal retailer
Trubadu.de
35,00
98,00
35,00
41,00
2,20
3,50
5,00
26,00
per plate
per piece
per plate
per 0.75 Liters
per m
per piece
per piece
per piece
35,00
98,00
Trubadu.de
Trubadu.de
hardware store
Conrad Elektronik
ebay oder Trubadu.de
hardware store
hardware store
Conrad Elektronik
26,00
98,00
1,99
15,00
120,00
0,70
2,95
0,70
per piece
per piece
per piece
per piece
per piece
per m
per PCK
per piece
26,00
wood retailer
wood retailer
wood retailer
hardware store
hardware store
metal retailer
hardware store
Total Price
how built
Exhaust
reduction piece 110/50
Junction 125 auf 125
lid spiral-seam
1 m spiral-seam pipe
radial fan by Papst
fan casing
HAT pipe
spiral-seam
spiral-seam
spiral-seam
exhaust/suction
exhaust/suction
101 mm
50 mm on 110 mm
125 mm/110 mm
125 mm/110 mm
100 mm
12 V/1.5 A - 150 m/h
20 mm thick
alternative HT pipe
alternative HT pipe
alternative HT pipe
Covering
security glass
sealing perfile 1
sealing perfile 2
alternative PE sealing tape
Aluminum plate
Aluminum plate
cover plate
Dichtung
insulation
insulation
assembly of cover plate
assembly of cover plate
4 mm
side
top
25mm*40mm
20mm*5mm
5,60
10,00
3,90
Absorber assembly
Aluminum plate
selectively coated plate
alternative aluminum plate
solar absorbing plate
aluminum foil
U-panel
aluminum pipe 50 mm diameter
alternative Alurohr 50 mm Durchmesser
Knauf plasterboard
8,80
21,00
5,00
Controller
temperature differential controller
control
alternative temperature differential controller control
moisture resistant case
control
plug power supply
power supply
alternative solar module
power supply
cable
assembly
shrink tubing
assembly
cable guide
fan
circuit board
ready to use module
alternative
assembled
12 Volt 18 Watts
40 - 50 Watts
0.7 1.5 mm
Full Gauge
AC adapter Item No.:
Extension for T-sensors
isolation sensors
for cable guide on fan casing
1,99
15,00
4,20
2,95
0,70
Miscellaneous
Sikaflex/glues and seals
wall mount
filter
velcro tape
air grid
insulation general
wall assembly
air filter
for air filter
exhaust opening
G3
black
40mm * 20mm
alternative of exhaust hoods
100 mm * 50 mm * 4mm
1 tube
2 piece
1 piece
15 cm
1 piece
camping store/Trubadu.de
hardware store/Trubadu.de
hardware store/Trubadu.de
textile retailer
hardware store
7,50
11,00
5,60
1,00
13,00
per piece
per piece
per piece
per piece
per piece
Total
7,50
22,00
5,60
1,00
13,00
557,21
Screw list
Measurements
4.8*13
4.0*60
3*20
3*30
3.8*50
self-tapping screws
Hexagon wood screws
washers
sheet metal screws
metric screws
washers
4.5*25
8*50
M8
4*15
M4*25
M4
Amount
absorber plate
outer frame
outer frame, glass carrier top
support frame, upper bars
spacer pieces, carrier plate air duct,
carrier pieces outside
outer paneling, glass carrier
bracket
bracket
aluminun sheet back, fan
fan assembly
fan assembly
30
8
4
18
22
28
8
8
20
3
3