air heater s-line construction manual reader

8/9/2019 Air Heater S-Line Construction Manual Reader

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Solar Air Heater

Type S - Line

l

reading test !


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C i M l P 1

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


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Table of Contents

Abbreviations

g-value total energy transmittancek-value heat loss

kWh kilowatt hour

W watt

m square meter

a year

ESG toughened security glass

m/s speed in meters/second

m mass

W/m power in watts per square meter

emission coefficient

efficiency absorption coefficient


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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 themany 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 therealization of the Slime Line panel types.

The result is a warm air system in a modular design, which is characterized by a

low profile and offers the possibity to use various absorber types. By optimizing the

i fl h i d i b l h b b l hi h i h


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2. The Solar Air Heater

2.1 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.


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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


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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 Air Duct Construction

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 adistance 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.


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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.

An optimal absorber should acheive the following points:

1. It must be made from thin material that conducts heat well aluminum or

copper (possibly steel).

2. It must have a dark (preferably black) and maximum surface area.

For the solar collector two absorber variante are possible:

1. a selectively coated 0.4 mm thick aluminun plate by Alanod (type:mirotherm)

2. a 0.4 mm thick aluminum plate painted with solar-absorbing paint

Difference between painted aluminu m sh eet / selectively coated sheet

Th h bl k d i h l b bi i h di d d


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2.7.1 Double Ventilation

Air flow 1/3 above the absorber (boundary layer) and 2/3 in the air ducts below the

absorber plate.

This air flow for painted collector type is imperative to increase the efficiency. Above

the absorber, the so-called boundary layer is used to further suck the air. This is a

1-3 mm layer of air above the heated plate (boundary layer).

Image of collector with solar-absorbing paint

Absorber: painted metal, cover plate: ESG

1 / 3 of the air duct above the collector, laminar flow, boundary layer

2 / 3 the air flow beneath the collector, turbulent flow


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2.8 Cover Plate

Tougened security glass with 4 mm thickness is used for as covering material,

which can to be obtained from any glass retailer. Glass has high light transmission,

which is at about 85% for a single-glazed plate. This ensures that a maximum

energy of the sun passes through the plate and is converted into heat by the

absorber.

Example:Total energy transmittance

of an insulating glass pane


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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 Alignment of the Collector

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 aviewer 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 thefollowing seasons:


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.


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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.


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more efficient than in parallel. In my view the connection in parallel has significant

advantages that outweigh the slight loss in efficiency:

Lower temperature at collector output, temperatures above 55 should not

be injected into rooms used for living

Depending on the heat requirements individual units can be switched off

Optically better integration into the faade

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.


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5. Sources


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About Us:Idea & Development: Stefan Brandt

Text & Photos: Stefan Brandt

Print & Layout: Stefan Brandt

www.trubadu.de www.trubadu.com

[email protected]

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.
http://www.trubadu.de/http://www.trubadu.de/http://www.trubadu.com/http://www.trubadu.com/http://www.trubadu.com/http://www.trubadu.com/http://www.trubadu.de/


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Construction ManualSolar Air HeaterType S-Line

Part 2Stefan Brandt (Dipl.-Ing.)

1. Edition September 2011


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Table of Contents

1.0 Introduction2.0 Overview of Materials3.0 Collector Frame4.0 Air Duct5.0 Frame Panels6.0 Ventilation Pipe & Heat Deflector7.0 Absorber Plate8.0 Assembly Collector Body9.0 Fan

10.0 Accessories11.0 Diagrams12.0 List of Materials


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1.0 Introduction

This second part of the construction manual describes in great detail the structure of the S-Line Trubaducollector. 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 thiscollector. With the exception of the circle and the peeling drill special tools are not necessary. A reliablefunctioning and reaching a collector output of about 1500 watts is only assured by using the constructionmaterials 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 storesand 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.


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The TrubaduS-Line Collector

1.1 Introduction


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Front Back

1.2 Introduction

1070 mm

2 0 6 0 m m


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2.0 Overview of Materials - Tools


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2.6 Materials Differential Temperature Regulator

The differential temperature regulator from TowiTek is available as an assembled module. Only thetwo temperature sensors need be extended with cables. For this, a soldering iron is required. Thecable 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


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2.10 Materials Miscellaneous I

Wall mount for collector

Moisture protection box for

differential controller

Filter G3 for air grid

Insulation back of collector


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2.12 Materials - Screws

20 metal screws4,5*20 mm

16 wood screwsfor var. assembly3*30mm

12 floorboard screws3,8*50 mm

30 sheet metals screws 4,8*13 mm

8 wood screwsfor outer frame

4*60 mm

18 sheet metal screws 4 *15mm

8 hex bolts forwall mount M8 * 60

wood screwsfor var. assembly3*20 mm


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The outer frame and support frame are bolted together form a fixed unit and serve as a structural elementof 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 thelong boards can be compensated, however, when screwing the outer frame.

Support frame Outer frame

3.0 Collector Frame


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The support frame is bolted from theinside with screws to the outer frame.The strips may have to be cut and fitted.Basically, make sure that the iner frame

and outer frame fit tightly along theentire length of the back.

3.2 Collector Frame

12 wooden screws3*30mm 12


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Width ofmineral woolinsulation

4 floorboard screws

3,8*50 mm

The cross support bars are nowfitted, the respective distancedepends on the width of the

insulation. With one screw eachsupport bar is bolted from theoutside. Basically make sure theinner frame and outer frame fittightly the entire length of theback.

Backside flush along theentire length

3.3 Collector Frame


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Before final assembly of the inner support platemark the drilling points for the air duct pieces.The air channel pieces can be cut to 1.84 cmlength and later be bolted directly to the cross

bars of the support frame.

Markings for drilling

flush

approx. 20 cm

4.1 Air Duct


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The pieces labeled in 4.2 are drilled with a 2.7 mm drill bit, so thatthe heads of the wooden screws do not slip through.

floorboard screws3.8*50 mm

4.2 Air Duct


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adhesive

After installing the insulation now thesecond aluminum plate is installed.The inner support plate serves toincrease the heat transfer surface andis glued for an air-tight and strongconnection with adhesive onto thesupport frame. If the sheet is too wideby a few millimeters, it can be cut withmetal shears.

4.3 Air Duct


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diameter 51 mm

35 mm

25 mm

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 outerframe on the left or right side.

Support frame


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4.5 Air Duct

51 mm opening for the ventilation pipe


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The paneling of the outer frame is made of rectangular galvanized panels for drywall building. Thesepanels 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 ofmetal screws. Make sure during installation of the panels that they overlap from top to bottom, sothat rain water cannot get in later.

5.0 Frame Panels


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Before the top frame cover panel is fitted, thetwo spacer bars are installed (same type as thesupport frame bars).

5.1 Frame Panels

Wooden screws3*30mm


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5.2 Frame Panels


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The thermal foil is used to increase theheat transfer surface. It is made of 0.05 mm

aluminum foil and loosely inserted into theduct. For folding use three spacer piecesthat have not been bolted to the supportplate yet. The folding is carried out asshown in the pictures. Small holes createdin the foil by folding the with the spacerpieces are not problematic and do notaffect the function of the collector.

6.6 Air Duct


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Now the installation of the sealing strip forthe cover plate follows. The PE tape is cut tothe appropriate length and halved in themiddle, so it has a width of about 2 cm. It isnow glued on the exterior galvanized metalpanels flush to the outer edge.

8.1 Assembly Collector Body


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8.2 Assembly Collector Body


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As already mentioned, the fan housing is made eitherof galvanized components as used for ventilation oralternatively PP pipe is used. In both variants, areduction piece of 110/50 mm PP pipe comes to use.These are available in the standard version but also inthe short version.

9.2 Fan


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Radial fans are characterized by a high

pressure buildup, which is necessary toovercome the air resistance in the collector.For optimum power delivery the fan needs acustom case in a spiral form like a snail shell.This is simulated by placing the fan on thewooden backing plate not in the center, butshifted to the side.

9.3 Fan


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You can see the approximate dimensions for the fanand reduction pipe on the two images. Importantly,note the gap between the fan and reduction pipe of 2-

3 mm. After final assembly the fan must must turneasily and not grind anywhere. Fan support plate andthe reduction pipe are pre-wrapped with a layer of PEfoam tape to ensure good positioning in the pipe ispossible.

9.5 Fan

2-3mmPE tape


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Fans and reduction pipe are each bolted to the casing with threesheet metal screws which are offset by 120 degrees. It is advisableto align fan and pipe reduction and then measure out and mark

the positions for the holes to be drilled.

9.6 Fan

screw positions

sheet metal screws 4 *15mm


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After that, the fully assembled controllersare placed in the fan housing. The cables

are routed through the cable guide andattached to the case with the two metalscrews on the mounting plate.

9.13 Fan

sheet metal screws 4 *15mm

cable guide

11 0 Di


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Idle temperature collector S-Line (03.06.2011)

T-Max idle: 103

C

11.0 Diagrams


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List of Materials Trubadu S-Line Solar Air Heater

Info 1 Info 2 Measurements Info 3 Source Price Unit Total PriceFrame construction how builtframe wood frame construction untreated 92mm*24mm spruce/pine wood retailer 2,14 per meter 12,85 planed wood strips frame construction untreated 36mm*17mm spruce/pine wood retailer 0,99 10,00 support ar !lass/air !rid frame construction untreated 44mm*25mm spruce/pine wood retailer "nauf support piece #$ frame panelin! !al%ani&ed 100mm*40mm*2000mm "nauf plaster oard 'ardware store 2,25 per meter 14,63 Screws by List of Screws 'ardware store indi%idual 4,50

(luminum plate ac) co%erin! lan) 0 5mm*1000*2000mm metal retailer 35,00 piece 35,00 roc) wool insulation 40 mm t'ic) & + so%er / -oc)wool 'ardware store 6,00

Exhaust reduction piece 110/50 .( pipe 50 mm on 110 mm 'ardware store/ ru adu de 2,00 1 piece 2,00

unction 125 auf 125 spiral seam 125 mm/110 mm alternati%e . pipe 'ardware store/ ru adu de 7,00 1 piece 7,00 lid spiral seam spiral seam 125 mm/110 mm alternati%e . pipe 'ardware store/ ru adu de 1,99 1 piece 1,99 1 m spiral seam pipe spiral seam 100 mm alternati%e . pipe 'ardware store/ ru adu de 12,00 2 piece 12,00 radial fan apst e 'aust/suction 101 mm 12 /1 5 ( 150 m/' tru adu de 89,00 1 piece 89,00 fan casin! e 'aust/suction 20 mm t'ic) pl wood rest 'ardware store 1,00 1 piece 1,00

Covering securit !lass co%er plate 4 mm e act len!t' dimensions accordin! to collector !lass retailer 37,00 per m 74,00 sealin! perfile 1 ic'tun! en!t' dimensions accordin! to collector ru adu de 2,60 per lfmsealin! perfile 2 insulation en!t' dimensions accordin! to collector ru adu de 2,60 per lfm

insulation en!t' dimensions accordin! to collector 'ardware store 5,60 per roll 5,60 (luminum plate assem l of co%er plate side 25mm*40mm en!t' dimensions accordin! to collector metal retailer 2,50 per meter 10,00 (luminum plate assem l of co%er plate top 20mm*5mm en!t' dimensions accordin! to collector 'ardware store 3,90 per meter 3,90

Absorber assembly (luminum plate co%er plate on a or er support 0 5 mm 2000 mm * 1000 mm en!t' dimensions accordin! to collector metal retailer 35,00 per plate 35,00 selecti%el coated plate a sor er plate assem led 0 7 mm 2000 mm * 1000 mm en!t' dimensions accordin! to collector ru adu de 98,00 per piece 98,00

a sor er plate alternati%e 0 4 mm 2000 mm * 1000 mm en!t' dimensions accordin! to collector +lec''andel 35,00 per platesolar a sor in! plate a sor er plate/co%er plate 0 75 iters ru adu de 41,00 per 0 75 itersaluminum foil $ rmeleit lec' ca 4 m :auna au/ ru adu 2,20 per m 8,80 # panel a sor er support 28 mm*27mm*0 6mm "nauf plaster oard 'ardware store 3,50 per piece 21,00 aluminum pipe 50 mm diameter e 'aust undrilled 49 mm * 1090mm 1 mm t'ic) metal retailer 5,00 per piece 5,00

e 'aust finished drilling 50 mm * 1090mm 1 mm t'ic) ru adu de 26,00 per piece

Controller temperature differential controller control circuit oard ru adu de 26,00 per piece 26,00

control read to use module ;ull


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Miscellaneous:i)afle /!lues and seals insulation !eneral lac) 1 tu e campin! store/ ru adu de 7,50 per piece 7,50 wall mount wall assem l 40mm * 20mm 2 piece 'ardware store/ ru adu de 11,00 per piece 22,00 filter air filter


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Scre* list Measurements Amount

s'eet metal screws 4 8*13 a sor er plate 30

wood screws rofi -; 4 0*60 outer frame 8wood screws rofi -; 3*20 outer frame, !lass carrier top 4wood screws rofi -; 3*30 support frame, upper ars 18floor oard screws 3 8*50 22

self tappin! screws 4 5*25 outer panelin!, !lass carrier 28.e a!on wood screws 8*50 rac)et 8was'ers @8 rac)et 8s'eet metal screws 4*15 aluminun s'eet ac), fan 20metric screws @4*25 fan assem l 3was'ers @4 fan assem l 3

spacer pieces, carrier plate air duct,carrier pieces outside

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