technical data installation instructions operating and ......1.5 technical data - glk type figure...

Technical data Installation instructions

Operating and maintenance instructions

jumbosolar.de

GRAMMER Solar GmbHOskar-von-Miller-Str. 8

D-92224 AmbergTel.: +49/9621/30857-0

Fax: +49/9621/30857-10E-mail: [email protected]: www.grammer-solar.de

www.jumbosolar.de

Edition: January 2007

JUMBOSOLAR - GLK

TECHNICAL MANUAL

JUM

BO

SO

LAR

Technical manual 11/06

CONTENTS 1. JUMBOSOLAR – product description ................................................................................................... 1

1.1. Terminology, principle of functioning....................................................................................... 1

1.2. Scope of application ................................................................................................................... 2

1.3. Components – JUMBOSOLAR package ........................................................................................ 2

1.4. GRAMMER standard collector GLK - components .................................................................. 3

1.5. Technical data, collector sheet - GLK ....................................................................................... 4

1.6. Technical data - JUMBOSOLAR ..................................................................................................... 6

1.7. Collector arrangement ................................................................................................................ 6

2. Installation instructions

2.1. Mounting on inclined roofs ........................................................................................................ 7 2.1.1. Mounting on inclined roofs - scope of delivery ................................................................. 9 2.1.2. Short description – mounting on inclined roof (on roof) .................................................. 10 2.1.3. Roof lead-through........................................................................................................... 11 2.1.4. Roof hook systems......................................................................................................... 12 2.1.5. Mounting rails and attachment brackets......................................................................... 13 2.1.6. Serial connection and connection technology ................................................................ 13

2.2. Wall mounting ........................................................................................................................... 14 2.2.1. Wall installation package – scope of delivery ................................................................. 14 2.2.2. Short description – wall mounting................................................................................... 15

2.3. Mounting on flat roofs .............................................................................................................. 16 2.3.1. Mounting on flat roofs – scope of delivery ...................................................................... 16 2.3.2. Short description – mounting on flat roofs ...................................................................... 18 2.3.3. Roof surface ................................................................................................................... 18 2.3.4. Roof loading ................................................................................................................... 19 2.3.5. Interface end collector air ducting system ...................................................................... 19

3. Accessories ...................................................................................................................................... 20

3.1. Fan.............................................................................................................................................. 20

3.2. Differential temperature controller DeltaSol II ........................................................................ 20

3.3. Air ducting accessories............................................................................................................ 24

4. Fault correction – checking list....................................................................................................... 25

5. Safety information............................................................................................................................ 26

6. Maintenance information ................................................................................................................. 29

6.1. Collector cleaning ..................................................................................................................... 29

6.2. Duct system cleaning ............................................................................................................... 29

6.3. Air outlet grill and valve cleaning ............................................................................................ 29

6.4. Filter replacement ..................................................................................................................... 29

6.5. Checking the attachment of collectors and mounting frames .............................................. 30

7. Function diagram - JUMBOSOLAR ..................................................................................................... 31

MANUAL JUMBOSOLAR + GLK - 1 -

1 JUMBOSOLAR - PRODUCT DESCRIPTION

1.1 Terminology, principle of functioning

GRAMMER-JUMBOSOLAR ensures a healthy and productive indoor climate while at the same time saving on operating costs (also see: www.JUMBOSOLAR.de). As soon as the sun is shining, the JUMBOSOLAR collectors mounted on the roof or on the outside wall will deliver warmed fresh air, which is distributed through the building, draft-free, via a simple air distribution system 1.

• JUMBOSOLAR is a solar system delivered as a complete package: 20 m² solar air collectors from GRAMMER including mounting system.

• JUMBOSOLAR means a productive indoor climate: GRAMMER air collectors turn solar energy into warm fresh air. With the help of the accessories

included, it is distributed effectively through your building. In this way JUMBOSOLAR ensures a

pleasant, healthy and productive indoor climate.

• JUMBOSOLAR means climate protection: The heat produced with JUMBOSOLAR captured is entirely from environmentally-friendly solar energy

and will simultaneously reduce your primary energy consumption for both the ventilation and

heating of your buildings - a saving of up to 1400 litres of heating oil while at the same time

reducing climate-changing CO2 emissions by approximately 4 tonnes per year.

• JUMBOSOLAR means economy: The reduction in your operating costs by JUMBOSOLAR, the low investment costs, and the continually

changing energy costs and state grants for GRAMMER air collectors result in an economical solar

system. For example, the static break-even time for your entire JUMBOSOLAR package at the current

heating oil costs of 0.50 Euro/litre is usually below 10 years!

JUMBOSOLAR= 20m² GLK GRAMMER

solar-air-collectors

solar heated fresh airproduction halls, factories, warehouses, public buildings,

gymnasiums, sports halls, office buildings, restaurants, lounges, etc.

outer air

SolarAir

ventilatorcontroller

Figure: Function diagram - JUMBOSOLAR

1 Also see in this context the section "Functional diagrams"


1.2 Scope of application

• Production hall and workshop of any kind

• Sales rooms, storage rooms / storage hangars, office buildings

• Sports halls / indoor swimming pools

• Public buildings

• Restaurants / hotels

• Public venues and meeting rooms (e.g. cinema, casinos, smoking zones)

• Technical installations with requirements for warmed air (e.g. drying installations)

As a rule, JUMBOSOLAR can be used anywhere where ventilation and air conditioning systems are available or where there is a requirement for fresh air.

1.3 Components - JUMBOSOLAR package 2

• 20 m² solar air collectors type GLK, consisting of: - 1 piece filter collector GLK EF 3 - 6 pieces central collectors GLK M - 1 piece end collector GLK E

• Inclined roof mounting package, consisting of 10 pieces inclined roof mounting sets for GRAMMER solar air collectors GKK (standard)

• Roof lead-through DN 250, consisting of - Base plate made from lead sheet with collar and seal, - Tube lead-through – slide sleeve

• Tube fan including attachment flanges for the tube installation

• Solar controller, consisting of - Differential temperature controller DeltaSol II with rpm control - Collector temperature sensor PT 1000 - Room temperature sensor PT 1000

• Options: - Collector package for circulating air operation (for heating a circulating air system) - Mounting package for flat roof or the ground - Installation package for wall / facade

2 Parts lists: see "Mounting instructions"; for large installations: project-specific parts list 3 For the JumboSolar circulating air package: instead of GLK EF a second GLK E


1.4 GRAMMER standard collector GLK - components

The main component of the JUMBOSOLAR is the GRAMMER standard collector of the type GLK (GRAMMER Luft Kollektor – GRAMMER air collector). These air collectors, which have been tried-and-tested for nearly 30 years, are made from the following materials.

• Collector box, galvanised

• Flange frame for series connection of the modules, galvanised

• Heat insulation made from mineral wool

• Separation sheet (between heat insulation and air channel)

• Ribbed absorber made from aluminium

• Cover made from a single pane of safety glass

Single pane safety glass cover

Connection frame

Aluminium ribbed absorberSheet metal rear wall

Insulation

Single pane safety glass cover

Connection frame

Aluminium ribbed absorberSheet metal rear wall

Insulation

Figure: Standard collector GLK (GRAMMER-Luft-Kollektor = GRAMMER air-collector)


1.5 Technical data - GLK

Type Figure Short description

Length

Width Height Weight Thermal power peak

[mm] [mm] [mm] [kg] [Wpeak ]

GLK F

175

End collector with integrated filter(filter class: G4)

2500

1003

80

1675

GLK M

175

Central collector

2500

1003

80

1675

GLK E

175

End collector with air connection part

2500

1003

80

1675

Table: Diagrams and technical data of the three different GRAMMER standard collectors GLK (note: collector width and height both without flange frame; it will add 2 x 31 mm both to width and height).

End collectors (GLK E and GLK EF) sealed air-tight with an end cover on one of the flange frames (end of the collector row).

With the end collector with air connection part (GLK E), the collector box (back of the collector) has a gap through which the air connection tube with a diameter of DN 2504 protrudes.

The end collector of the type GLK EF is instead equipped with a connection tube with an air filter in the collector box (back).

4 for large GLK installations: The diameter can be freely selected, e.g. 315 mm or 355 mm

GLK F air inlet

collector - back side

filter

L

H W

safety glass- cover

GLK

air connection GLK E collector -

back side


Data sheet with manufacturer information on the collector (extract) Information about the type and the testing organisation

Collector type / designation GLK M: Grammer air-base collector – central collector

Construction type Air-base collector

Manufacturer GRAMMER Solar GmbH

Testing organisation ARSENAL RESEARCH Austria, Vienna

Test according to STANDARD There is currently no standard covering air-base collectors

Test report IEA-TASK 19 SOLAR AIR SYSTEMS

Performance characteristic values (all data related to aperture surface) Feature Symbol Unit Typical values / examples

(related to aperture surface) Conversion factor for temperature differential (tm - ta) = 0 η0 - 0.82

Linear efficiency factor of collector a1 W/(m² x K) 4.2

Quadratic efficiency factor of collector a2 W/(m² x K) 0.034

Correction factor for angle of incidence Kθ(50°) - 0.96

Recommended range for throughflow m³/(h x m²) 30 to 100

Enclosure Dimensions (L x W x H) all mm 2500 x 1003 x 175

Material Steel plate, galvanised

Total weight of collector (filled) kg 75

Absorber Absorber material, material thickness connecting technology to the tube bundle

Aluminium, t = 0.6 mm no tube register

Material used in channels for heat transfer fluid Aluminium (absorber = air duct)

Contents of heat transfer fluid VA l 228 l (air duct)

Transparent cover Material, thickness, possible coating Single pane safety glass, 4 mm,

-

Thermal insulation Type, material Insulation mats, mineral wool

Thermal conductivity λ W/(m x K) 0.040

Thickness 60 mm (on the back) and 20 mm (on the sides)

Reference surfaces Gross surface AG m² 2.51

Aperture surface Aa m² 2.30

Limiting data for operation Idle temperature °C 150°C

Max. allowable working pressure bar0 Operation at underpressure

Permitted heat transfer fluid Air

Installation modes Types examples: mounted on the roof,

integratetd in the roof, mounted on or integrated in façade,

outdoor installation


1.6 Technical data – JUMBOSOLAR 5 • Gross collector area: 20 m² (2.5 m² per GLK module)

• Thermal rating: 13.4 kWp

• Solar yield 6: ~ 525 kWh/a/m²

• Air volume flow (possible range): 660 to 2,300 m³/h

• Dimensions of collector field: L x W x H = 20 m x 1 m x 0.175 m

• Nominal diameter of air connection: DN 250

• Weight per area including mounting system: max. 38 kg/m² (max. 760 kg total weight)

1.7 Collector arrangement

For JUMBOSOLAR installations, the individual collector modules are connected into a row by connecting the narrow sides of the flange frames to each other. This results in a "strip" of 20 m length and a width of 1 m (also see "mounting on inclined roofs"):

longitudinal section

top view

2500

air filter (integrated in GLK F)

absorber

8 x 2500 mm ( = 20000 mm )

2500

8 x 2500 mm ( = 20000 mm )2500

2500

cross section

10651003

9560

237

175

JumboSolar

collector - temperature sensor

210

380

DN 250

Figures: Arrangement in a row of standard collectors for JUMBOSOLAR

5 Large installations : project-specific, technical data 6 Depending on the installation and the location


2. INSTALLATION INSTRUCTIONS Before mounting the air collectors, all interfaces in contact with the solar installation must be defined and built as explained in the system design: roof lead-through (water-tight) and connection with the air ducting (= interface with air outlet from the collector system), air inlet into the collector system (for circulating air version), attachment onto the roof etc. In particular, all preparations for safety during the installation work must be made (protection against falling, protection against falling objects, verification of the roof strength by customer, conformity with the rules of technology).

2.1 Mounting on inclined roofs

In the JUMBOSOLAR collector package, a mounting set for inclined roofs is included as standard. For installation onto inclined roofs, the air collectors are attached by means of angle sections, mounting rails and roof hooks. The roof structure experiences an additional load from the weight of the collectors: static weight per area of the JUMBOSOLAR collector package (including mounting system): max. 38 kg/m².

Figures: Examples of standard collectors installed on inclined roofs


550700

250

8 x

2 50

0 =

20 0

00

1 065

1 80

02

500

2 50

01

800

1 40

02

500

2 50

02

500

dist

ance

s =

func

tion

of th

e ro

of c

onst

ruct

ion

/ dis

tanc

es o

f the

rafte

rsco

llect

or te

mpe

ratu

re s

enso

r

1 40

055

0250

Figures: Arrangement in a row and locating of the mounting rails 7 with the JUMBOSOLAR mounting system for inclined roofs (in this case circulating air version)

7 Positioning of the mounting rails: depends on the roof structure (rafters, purlins)

1

2

34

5

6

rafter

washer Ø 10,5

spring washer M 10

hexagonal head nut, M10, A2

Grammer - installation rail

Grammer - roof hook

self-drilling screw 5.5 x 25 mm, A2

attachment angles

washer Ø 8.4

wood screw 8 x 120 m

hammer-head-srew M10 x 30, A2, 28/15


2.1.1 Mounting on inclined roofs – scope of delivery:

The JUMBOSOLAR mounting package for inclined roofs includes 10 pieces mounting sets for inclined roofs (2 pieces for the filter collector and the end collector, 1 piece for each central collector), with each mounting set comprising the following individual components:

• 2 pce GRAMMER roof hooks, V2A; standard = roof hook types for roof tiles optional: for "beavertail" flat roof tiles, bitumen corrugated roof plates, fibre-reinforced cement plates, standing seam roofs, trapeze sheet metal roofs; special types on request

• 4 pce M 8 x 120 wood screws, galvanised

• 4 pce washers for M 8 screws, galvanised, d = 8.4 mm

• 1 pce GRAMMER mounting rail, aluminium, L = 1.15 m

• 2 pce A2 hammerhead screws, M10 x 30, 28/15 (roof hook rail)

• 2 pce M10 spring washers , V2A (roof hook rail)

• 2 pce hexagonal nuts for M10, V2A (roof hook rail)

• 2 pce attachment bracket, galvanised 50 x 50 mm, t = 3 mm, L = 150 mm, with long and round holes, pre-drilled with two rows of round holes ∅ 7 mm and one of long holes 11 x 100 mm 8

• 2 pce A2 hammerhead screws, M10 x 30, 28/15 (attachment bracket for rail)

• 2 pce M10 spring washers, V2A (attachment bracket for rail)

• 2 pce M10 washers, form R, d1=3xd, V2A; DIN 9021 A2 10.5 (attachment bracket for rail)

• 2 pce M10 hexagonal nuts, V2A (attachment bracket for rail)

• 4 pce self-drilling screws 5.5 x 25 mm; key size: 8, stainless steel (attachment bracket for collector)

• Weight of mounting set: 4.0 kg

The mounting system also includes the components for connecting the collector moduls:

• 28 pce M10 x 25 hexagonal head screws , V2A (for each collector connection: 4 pieces)

• 28 pce M10 hexagonal nuts, V2A (for each collector connection: 4 pieces)

• 3 pce silicone cartridges, neutral cross-linking

Note: The collectors are shipped on special pallets (approx. 650 kg including pallet, unloading of pallet by means of suitable lifting equipment: fork-lift truck, crane), the mounting accessories are shipped dismantled for easier transportation.

8 For the GLK version made from aluminium: 50 x 50 x 5 mm aluminium angle section, pre-drilled


2.1.2 Short description - mounting on inclined roof (on roof)

All safety measures have to taken before the mounting is started! 9

For installation the solar plant, a mounting team comprising 2 to 3 people is recommended

Measuring the collector fields (as free of shadows as possible, as far as possible in southerly direction)

Measuring of the roof lead-through (must not interfere with the rafters, purlins or similar structures) and

measuring of the attachment points for the roof hooks 10

Cover the roof tiles close to the roof lead-through and the roof hooks

Make a hole for the roof lead-though

Decide on the positions for the roof hook and mark

Attach the roof hooks to the rafters or the roof boarding (by means of compensation board)

Match the roof tiles to the roof hooks (if necessary, remove drip lip) and replace roof tiles

Fit the mounting rails onto the roof hooks (observe the vertical or horizontal alignment)

Mount the attachment brackets onto the mounting rails (if necessary, attach the brackets to the collector

first)

Connect the end collector air-tight to the collar on the back, push through the roof lead-through and

insert the two roof mounting sets for inclined roofs.

Apply an unbroken bead of a neutral cross-linking silicone onto the sealing surfaces of the flange frame

Place the second collector (central collector) into the mounting set and push close to the already

mounted collector

Screw the collector together via the two flange frames by means of the hexagonal screws and nuts (the

silicone applied earlier will ensure a permanent air-tight connection)

Mount the remaining collector in the same way until the collector row is complete

Fix the collectors to the attachment brackets by means of facade screws.

9 Details: see section "Safety information" 10 Details: see sections "Roof lead-through" and "roof hooks"


2.1.3 Roof lead-through

The roof lead-through of JUMBOSOLAR comprises a flexible lead plate (can be moulded to different tile shapes), a collar (DN 280, integrated water-tight into the lead plate), a roof seal and a short tube (DN 250, length 400 mm). With this tube connection (slide joint), the air-base collector system (end collector GLK E) is connected to the air duct connection.

Figure: Interface collector system – air duct system

The connection between the end collector and air duct connection is to be protected against sliding off the collector connection (silicone, self-tapping screws or clip).

Figure on the left: Roof lead-through with slide joint; Figure on the right: After mounting on a slate roof


2.1.4 Roof hook systems

The roof hooks are connected by means of wood screws (8 x 100 mm) to the rafters. In order to balance height differences for various types of tiles, wooden compensation boards are used. With this system, the collectors can be fitted either horizontally or vertically onto the roof.

30

Ø12

11

1545

2220,5

230

80

5

6

138

Figure above: GRAMMER standard roof hook (for roof tiles) Figure on left: Mounted standard roof hook (in this case: horizontal rail and Halfen rail system) Figure on the right: Roof hooks after mounting and the roof tiles it is fixed to

Figures: Slate hooks and sheet metal slates (left); clamp for standing seam metal roofs (centre) and dowel screw system for trapeze sheet metal roofs (right).


2.1.5 Mounting rails and attachment brackets 11 The mounting rails are attached to the roof hooks by means of M10 x 20 hexagonal head screws, M10 spring washers and M10 threaded plates (made from V2A stainless steal).

On the mounting rails, the attachment brackets for the collectors are attached by means of M10 x 25 hexagonal head screws, M10 spring washers, M10 discs and M10 threaded plates. With the end collectors, ensure that the mounting rails are mounted at a sufficient distance from the connection tube or the filter. The collectors are then screwed to the attachment brackets by means of facade screws.

2 500

collector temperature sensor

1 400

1 06

5

250700

550 1 800

Figure on left: Arrangement of the mounting rails (approximate dimensions). Figure on right: GRAMMER mounting rail

2.1.6 Row connection and connection technology

Standard collectors are screwed to each other by means of the flange frames (rigid sheet metal section with holes at the corners) to form a row (M10 x 25 hexagonal head screws and M10 hexagonal nuts, made from V2A stainless steel).

collector 1

collector 2

collector connection frame

Figure – left: Connectors connected in a row of collectors by means of a flange frame Figure – right: For the air-tight connection of the collectors to each other, before screwing together, a silicone bead is applied to the narrow sides of the flange frames

Onto the sealing surfaces of the collector flanges, an unbroken silicone bead is applied before the collectors are joined together (note: use neutral cross-linking silicone). Note for special designs with deflections to the side: The collector connections on the side (side deflectors) are to be sealed on

their sealing surfaces to the rectangular duct using silicone.

11 For each filter collector (GLK EF) and each connecting collector (GLK E) provide two mounting rails, and for each of the central collectors (GLK M) provide one mounting rail. The positions of the mounting rails depend on the roof support structure; see also the drawing in the section "Mounting on slanted roofs"


2.2 Wall mounting

2.2.1 Wall mounting package – scope of delivery

The JUMBOSOLAR wall mounting package includes 8 wall mounting sets with each mounting set comprising the following individual components:

• 1 pce GRAMMER mounting rail, aluminium, L = 1.15 m

• 2 pce A2 hammerhead screws, M10 x 30, 28/15 (roof hook rail)

• 2 pce M10 spring washers , V2A (roof hook rail)

• 2 pce hexagonal nuts for M10, V2A (roof hook rail)

• 2 pce attachment bracket, galvanised 50 x 50 mm, t = 3 mm, L = 150 mm, with long and round holes,

pre-drilled with two rows of round holes ∅ 7 mm and one of long holes 11 x 100 mm 12

• 2 pce A2 hammerhead screws, M10 x 30, 28/15 (attachment bracket for rail)

• 2 pce M10 spring washers, V2A (attachment bracket for rail)

• 2 pce M10 washers, form R, d1=3xd, V2A; DIN 9021 A2 10.5 (attachment bracket for rail)

• 2 pce M10 hexagonal nuts, V2A (attachment bracket for rail)

• 4 pce self-drilling screws 5.5 x 25 mm; key size: 8, stainless steel (attachment bracket for collector)





• 3 pce silicone cartridges, neutral cross-linking

The wall lead-through comprises a double walled, heat insulated folded spiral seam tube (25 mm insulation) and a muffler.

12 For the GLK version made from aluminium: 50 x 50 x 5 mm aluminium angle section, pre-drilled


2.2.2 Short description – wall mounting

All safety measures must be taken before the mounting work is commenced!

(see also "Safety instructions")

For the installation of the solar plant, a mounting group is recommended consisting of 2 to 3 people

Measurements for determination of the location of the collector field (largely free of shadowing, directed

as closely as possible towards the southerly direction)

The protruding flanged frames of the collectors determine the spacing between the collector box – and

the wall or facade.

For filter collectors, please observe: At the narrow side sufficient space must be provided for the filter

replacement (minimum 600 mm free length in the direction of the solar installation)

Measuring for determination of the location of and construction (e.g. core hole drilling) of the wall lead-

throughs (must not interfere with installations in wall/facade, e.g. supports, pipes) and the collector field

(largely free of shadowing, directed as closely as possible in the southerly direction)

Attach heat insulated wall lead-through in the hole in the wall or facade and, if applicable, seal any

leaks between wall/facade and the wall lead-through.

Determine the locations of the mounting rails and mark them (horizontal alignment)

Attach mounting rails to the wall/face using an adequate mounting system (rawl plugs, weight per

collector module: 80 kg)

Mount the attachment brackets onto the mounting rails first

Mounting the collector: First of all place the end collector with the air connection tube between the

attachment brackets onto the mounting rails using 4 self-drilling screws (4 screws per attachment

bracket). Note: The attachment brackets are already equipped with holes for this purpose!

For sealing apply (neutral cross-linking) silicone to the flange frame

Insert the second between the attachment brackets onto the mounting rail and screw air-tight onto the

connecting collector via the flange frames (already with holes) by means of 4 pcs M10 x 25 hexagonal

screws and 4 pcs M10 hexagonal nuts, and then attach to the mounting rails using facade screws.

Then mount the remaining collector modules one after the other.


2.3 Mounting on flat roofs

The mounting package for flat roofs contains 10 triangular frames.

Each frame comprises a holding section, a front support section with collector attachment brackets and a rear support section. The angle sections are securely screwed through the prepared holes to form a triangle. It is recommended that all the triangular frames be mounted before starting to mount the collectors.

2.3.1 Mounting package for flat roofs – scope of delivery

The JUMBOSOLAR mounting package for flat roofs includes 10 wall mounting sets, with each mounting set comprising the following individual components:

• 1 pce holding section: 60 x 60 x 6 mm aluminium angle section, L = 1057 mm, pre-drilled (see figure below, section no. 1)

• 1 pce front support section for an inclination angle of 45° (other angles are possible, section no. 2): aluminium angle section 50 x 50 mm, t = 5 mm, L = 1250 mm, pre-drilled

• 1 pce front support section for an inclination angle of 45° (other angles are possible, section no. 3): aluminium angle section 50 x 50 mm, t = 5 mm, L = 840 mm, pre-drilled

• 2 pce attachment brackets, galvanised, 50 x 50mm, t = 3mm, L = 150mm, 13 pre-drilled with two rows of round 7 mm holes and one of 11 x 100 mm long holes

• 2 pce M10 x 25, V2A hexagonal head screws (section no. 2 – attachment angles)

• 2 pce M10 washers, form R, d1=3xd, V2A; DIN 9021 A2 10.5 (section no. 2 - mounting rails)

• 2 pce M10 spring washers, V2A (section no. 2 – attachment brackets)

• 2 pce hexagonal nuts for M10, V2A (section no. 2 – attachment brackets)

• 4 pce self-drilling screw, 5.5 x 25 mm, key size 8, stainless steel (attachment bracket for collector)

• 3 pce hexagonal head screws M10 x 25, V2A (for screwing on the sections)

• 3 pce hexagonal nuts for M10, V2A (for screwing on the sections)

• 3 pce M10 spring washers, V2A (for screwing on the sections)





• 3 pce silicone cartridges, neutral cross-linking 13 For the GLK version made from aluminium: 50 x 50 x 5mm aluminium angle section, pre-drilled


55014001800250018001400

hexagonal head screw M 10 x 25 +hexagonal head nut M 10

2 x self-drilling screw 5.5 x 25 mm, A2

Al - angle section 50 x 50 x 5; L = 150mm; prepunchedoptional: vz.-sngle section 50 x 50 x 3mm, L = 150mm; prepunched

1

2

3

X5 x hexagonal head screw M 10 x 25 +hexagonal head nut M 10

45°

Figure – top: Arrangement of the collectors and mounting sets for flat roofs for JUMBOSOLAR Figure – centre: Mounting system for flat roofs for JUMBOSOLAR or GLK standard collectors Figure – below: Detail – attachment brackets


2.3.2 Short description – mounting on flat roofs

All safety measures must be taken before the mounting work is commenced! (also see "Safety instructions")

For the installation of the solar plant, a mounting group consisting of 2 to 3 people is recommended

Measurements for determination of the location of the collector field (largely free of shadowing, directed as closely as possible towards the southerly direction)

Screw mount the mounting frames and position them

Insert the end collector centrally onto the first mounting frame (secure against tipping over until the

connection to the second collector has been made)

Apply an unbroken bead of neutral cross-linking silicone onto the sealing surfaces of the flange frame

Insert the second collector (central collector) into the mounting set and shift it up to the already mounted

collector

Screw the collectors together at their flange frames (the silicone previously applied will result in a

permanent air-tight connection)

Continue in the same way with the remaining collectors until the collector row is complete

Arrange the frame mounting system squarely, at this stage it is still loose under the collectors

Attach the collectors to the attachment brackets by means of the facade screws

2.3.3 Roof surface

Depending on the roofing type, the following note should be observed:

Plastic sheeting roofs without chip covering: The frame mounting system has contact with the felt with the holding section (with the Asozell coating glued to the underside) without loading the film with sharp section edges. To allow water drainage when the base rails run across the drainage direction, the Asozell covering should be removed in places.

Plastic sheeting roofs with gravel covering: The frame support system has contact with the gravel layer. The load is evenly distributed via the gravel layer to the film below. This method has been tried and tested with a uniform gravel layer of >= 4 cm.

Standing seam roofs: The support sections are mounted depending on the orientation across or in parallel to the standing seams or they are clamped tight by means of screwed standing seam brackets or clamps. The attachment section should be selected to match the roof material (galvanised steel, aluminium, copper or stainless steel; e.g. KAL-ZIP, BEMO, RIB-ROOF).

Trapeze sheet metal roofs: When collectors are mounted on trapeze sheet metal roofs, the support frame system is screwed to the supporting roof structure below.

Eternit roofs: For Eternit roofs and roofs covered with bitumen corrugated plates, special roof hooks are available for mounting the collectors. Alternatively the support sections can also be directly screwed to the top of the corrugation of the roof structure. Screws and sealing washers form a water-tight seal in conjunction with the Asozell underlay beneath the support rails.


2.3.4 Roof loads – mounting on flat roofs 14 GRAMMER standard collectors of the type GLK have, including the mounting system for flat roofs, a maximum weight of 90.6 kg (1 pce GLK E of 80 kg plus 2 pce mounting sets of 5.3 kg each). This results in a maximum weight per area for installations on flat roofs of 44 kg/m².

For securing the solar installation against lifting, anchoring points in the roof construction are to be found which can e.g. be realised by lengthening the base rails until they reach a suitable point of the roof construction (observe loading capacity of the connection points).

If it is necessary to penetrate the roof seal, careful sealing of the anchoring points has to be provided observing the regulations for flat roof and DIN 18195 (Water-proofing of buildings).

It is also possible to utilise anchoring on heavy footings (for free-standing installations). For this the concrete element must be sufficiently heavy that the installation will still be held down securely at the maximum wind force to be expected. If concrete slabs are placed directly onto the roofing felt on the roof, a rubber underlay or something similar has to be provided beneath the slabs for the protection of the roof membrane.

2.3.5 Interface end collector air duct system

Figure: Construction of the collector connection for installation of GLK collectors onto a flat roof:

1: Inlet nozzle pre-mounted to the collector; 2: Collar for sealing the interface.

The GLK E end collectors have an air nozzle on the back which is designed as a pressed inlet nozzle DN 250 with a radius. The solar installation is connected to the main air duct via this nozzle and an insulated flexible tube or an insulated folded spiral seam tube. For protection against the ingress of rain water into the insulation, before mounting the flexible tube, or folded spiral seam tube the external tube has to be screwed to the collector box with a collar and has to be sealed.

14 Important note: The stability of the roof must be verified by the customer!


3 ACCESSORIES 3.1 Fan

For the transportation of the warmed fresh air, the JUMBOSOLAR complete package includes a centrifugal in-line fan of the RR 250 C type. It is integrated via the enclosed attachment sleeves into a tube system (DN 250).

Technical data – centrifugal in-line fan:

- Connection – DN: 250 mm

- Volume capacity – free-blowing: 1,100 m³/h

- Electrical data: Voltage: 230 V, 50 Hz, current consumption: 0.81 A, power consumption: 185 W

- Weight: 5.0 kg

- Transport medium temperature: max. 55°C

- Noise pressure level within 1 m distance – emission from the housing: 55 dB(A)

Optionally, it is also possible to use a different fan. If this is done, it has to be observed that the air volume flow through the JUMBOSOLAR installation should be between 700 and 2,300 m³/h.

3.2 Differential temperature controller DeltaSol II

The purpose of the controller is to optimally match the components solar installation and ventilation system to each other, in order to gain maximum solar gains. The controller has therefore a decisive influence on the gain of a collector system.

Figure: Display/menu structure of DeltaSol II

Function: The controller compares the collector temperature TKL and the reference temperature TSP and controls the installation as a function of the set temperatures. Using an optional temperature sensor TH, however, an additional temperature value can be shown (e.g. the outside temperature). The controller also has an additional rpm control.


Operation of DoltaSol II: The RESOL DeltaSol® II controller is exclusively operated via the rotary pulse transmitter with integrated button. By turning the rotary pulse transmitter, the current control parameters are displayed one after the other. Once the parameter to be modified has been reached, the set value is activated by pressing the button [UC1]on the rotary pulse transmitter; the <SET> display will flash. Now the desired value can be set by pressing the knob. The setting is confirmed and completed by pressing the rotary pulse transmitter once again. Further operating information: see original operating instructions for the controller. On the front of the controller 3 LEDs are found with the following icons:

Relay control lamp Red: Relay 1 and 2 OFF (no solar operation) Green: Relay 1 and/or 2 ON (solar operation)

Fault control lamp Flashing yellow

Control lamp for manual operation Flashing yellow: Operating mode switch in position I or 0 (relay 1 on or off)

0 Relay switched off (switched off manually) Auto Automatic operation of the relay outputs (STANDARD SETTING) I Relay (R1 and R2) switched on (continuous operation or test operation)

Figure: Operating mode switch (on controller bottom) Measuring values and setting values:

Cha. Designation Measuring values or setting values (recommended) 15 KL Collector temperature * (measured value 2) SP Storage temperature (3) = room

temperature * (measured value 3)

TH Thermostat temperature 3rd temperature sensor

* (measured value 5)

DZ Current rotations per minute * DE Temperature differential for switching on 6 K DA Temperature differential for switching off 4 K SX Stored maximum temperature

As a rule 2 K above set value for the room thermostat,

depending on the ventilation system and the target temperature for the room

KG Collector limiting temperature (collector is switched off)

180°C N 16

KX Maximum collector temperature 160°C N KN Collector minimum temperature 0.0 N TE Switch-on temperature for thermostat Optional – this is a thermostat function TA Switch-off temperature for thermostat Optional - this is a thermostat function FN Functions 3 DM Minimum [UC2]rotations per minute 100% (minimum: 35%) PG

Programme number; *

15 All values marked with * are measured values 16 All value marked with ‚N’ are not relevant for the solar air technology


Electrical connection – observe the operating instructions enclosed with the controller!

Figure: Electrical connection of the DeltaSol Pro controller

If the collector temperature (2) exceeds the room temperature (storage temperature (3)) by the differential temperature set at the controller (1), the system will switch to EIN [UC3]and the fan (4) will transport warmed air to the connected rooms until the desired room temperature has been reached. An additional sensor can be connected in position (5) e.g. for measuring the outside temperature. This sensor will optionally also functions as a thermostat, which is completely independent of the solar function (for identical settings of TA and TE the thermostat function is deactivated).

Collector temperature

The temperature sensor for the collector temperature is already located in the end collector by the manufacturer. An installation, which does not introduce any heat bridges, and the selection of temperature-resistant materials (sensor tube and sensor cable are designed for temperatures above 130°C (silicone cables)) allow long-term trouble-free operation of the solar installation. The sensor also has, in addition to the starter function, an operating function for the collector installation.

Room temperature

For the positioning of the room sensor, the following criteria are to be observed:

• Do not locate close to the supply air elements Figure: Room temperature sensor • Avoid direct irradiation by the sun

• Do not locate within the range of other heat sources

• Observe the range of influence of doors and gates

• In dwellings locate e.g. in the living room

• In hangars locate, e.g. where people usually stay


Resistance sensor / PT 1000 sensor

As standard, temperature sensors of the FKP type are used (PT 1000 sensor, among other features, increases precision for use e.g. in conjunction with data loggers).

Checks: The resistance value at 20 °C must be approx. 1,078 Ω.

For the control technology, alternatively PTC resistance sensors of the FKY type can also be used.

Checks: The resistance value at 20 °C must be approx. 1,923 Ω.

Table: Resistance of the FKY (on the left) and the FKP temperature sensor

at a range of temperatures

Sensor cable

The sensor cables can be extended by means of a two-pole cable (2 x 0.8 mm² up to 50 m cable length; from 50 m cable length upwards: 2 x 1.5 mm²). For cable lengths above approx. 20 m, screened cables are to be used in order to prevent interference from the electric power network.


3.3 Air duct accessories

The air duct accessories for the distribution of the warm fresh air into the heated area always depends on the situation and the desires of the customer. Usually, the air duct accessories will be defined, delivered and installed by a specialist, local company.

Tube

Muffler

Bend Tube Tube

Flexibletube

Control valve

Tube

Nipple

Tube

Controlvalve

Crosspiece

Bend

Sleeve coupling

Sleevecoupling

Flexibletube

Supply air valve

Sleevecoupling

Sleevecoupling

Figure: air duct accessories – general overview.

Use folded spiral seam tubes made from galvanised steel plate or similar tubes with a nominal diameter of 250 mm. To prevent internal contamination to the GRAMMER air collectors, fresh-air installations are already fitted with an air filter of the quality class G4 in the filter collector GLK EF. For circulating air installations (without filter collector) a filter box is to be installed upstream of the collectors.

For the prevention of heat loss, the air duct systems are to be constructed with insulation when they are run outside buildings. For the same reason, a non-return valve is to be integrated into the fresh air duct system (prevention of warm air flowing out of the building). For minimising noise transmission, e.g. between two rooms, mufflers are to be integrated into the air duct system.


4. FAULT CORRECTION – CHECK LIST

Fault Possible cause – fault correction

Possibly the operating switch is set to AUS. Switch to EIN or AUTOMATIK.

Check contact at the connection terminals – if necessary, tighten up Fan does not run

Check that the ventilation tubes have an adequate free cross-section

Check the connection to the sensor and whether it has been placed at a sensible location

Check the setting of the differential temperature – might be too large The installation does not run in automatic operation

Check the maximum temperature setting – in case the value has been set too low so that no heating operation is possible

The system runs continuously and without control

Switch to EIN [UC4]in the operating menu - Set to AUTOMATIK [UC5]operation

Check if the fan installation has been made using vibration dampers

The supply air valves are throttled too much – whistling noises: Open valves appropriately

The fan runs too noisily

If necessary, re-fit muffler

1 wire control ! Observe the terminal allocations for N, L1 and L2 at the motor and the terminal allocation at the controller

For installations with motor valve: Motor valve does not work Check the adjustable stops on the motor

Temperature display fluctuating

If long sensor cables are laid along power cables, interference can occur Correction: Choose screened cables or a different cable path

Check filter for contamination. Replace the filter at least 1 or 2 times per year !!!

Power too low Duct system is blocked. Check that the air ducts are free across their cross-section


5 SAFETY INFORMATION

Weather

All mounting work (whether done by do-it-yourself or by a specialist company) should, if at all possible, only be carried out when the weather is relatively good.

Particularly for installations integrated into the roof, it should be observed that no precipitation is falling in order to prevent humidity from entering into the building. If the wind freshens up, you should interrupt the installation in the interest of your own safety.

Also observe that on very hot days, with strong radiation received from the sun, the risk of burns from possibly hot metal parts. Under unfavourable conditions, temperatures of up to 150 °C can occur (particularly at the absorber).

Ladders

Leaning ladders should be leaned at an angle of 65 – 75° to a secure support and they must reach at least 1 m above the highest used point.

In addition, they should be secured against sliding, falling over, slipping off and sinking into the ground. For climbing up, ladders may only be used for a height difference of up to 5 m. For larger heights, scaffolding has to be set up.

Figure: Information on how to use ladders

Protection from falling objects

While working on the roof, traffic areas and workplaces below have to be protected against objects dropping, falling or sliding or rolling off.

Any areas where people are endangered are to be marked and blocked off.

Figure: Information signs for work on roofs


Protection against falling, catch equipment

During work carried out on roofs above a height of 3 m and roof inclinations exceeding 20°, protection against falling is required (VBG, 37, § 8).

A further option of fall protection for work on inclined roofs up to 60° are roof safety walls. The vertical distance between the workplace and the safety installation may be no larger than 5 m. Safety walls must extend beyond the workplaces to be protected by at least 2 m (also observe the information provided by the employer's liability associations).

Figure: Diagram for the arrangement of scaffolding as fall protection with the dimensions to be observed

A further option for fall protection is roof safety scaffolding. For the installation of such scaffolding, it must be observed that the vertical distance between the workplace and the safety installation may be no larger than 5 m.

Figure: Diagram for the arrangement of a safety net Figure: Installed safety net and the dimensions to be observed

Safety nets should only be installed by specialists who are able to protect themselves effectively against falling during installation. During do-it-yourself installation, the mounting information of the manufacturer is to be closely observed.

In addition, it must be observed that for roof inclinations exceeding 45°, special workplaces have to be provided on the roof: such as roofer chairs, roof ladders, wooden safety structures.

Figure: Dimensions to be observed for the installation of safety nets


If roof safety scaffolding or a roof safety wall are inappropriate, safety harnesses can also be used as fall protection.

The safety roof hook should preferably be attached above the user to load bearing components. Do not use ladder hooks!

Figure: Safety harness

Rules of technology

The installations should correspond to the conditions on site, the local regulations and, not at least, to the rules of technology. Any required permissions are to be obtained.

In this context, these are to be mentioned in particular:

Mounting on roofs:

• DIN 1055-5 : Action on structures – Part 5 snow loads and ice loads

• DIN 18338 : Roof covering and roof sealing works[UC6]

• DIN 18339 Sheet metal works

• DIN 18451 Scaffolding works

Thermal solar installations:

• EN 12975, EN 12976, EN 12977 and DIN EN 12828

Air conditioning technology, air ducts:

• DIN 1946: Several standards on ventilation and air conditioning

• DIN EN 13779: Ventilation of non-resident buildings – General principles and requirements for the ventilation system and the air conditioning system

Electrical connection:

• VDE 0100 Erection of electrical equipment

• VDE 0185 Protection against lightning – General principles

• VDE 0190 Equipotential bonding of electrical equipment

• DIN 18382 Low voltage installations and medium voltage installations up to including 36 kV

• The fan may only be started up when the air duct system is connected. Under no circumstance place hands into the moving fan.


6 INSTALLATION INFORMATION

The GRAMMER air-base collector does not include any mechanically moving parts and is therefore maintenance-free. The moving parts in a solar air-base system are fans, stop valves and control valves. These moving parts must occasionally be checked for functioning.

In addition, the controller should be checked to ensure that the displayed values are plausible and that the control functions work properly. These system-specific components and settings will be checked during commissioning. The installation user will at the same time be introduced to their function and to the monitoring options available.

Air does not experience phase changes (freezing or boiling) so that no safety measures are required in this respect. However, after prolonged times of standstill and at low outside temperatures, occasional condensation on the inside of the glass cover cannot always be excluded. Shortly after starting up the installation it will disappear without further action.

6.1 Cleaning the collectors

According to our experience, the cleaning effect from strong rainfalls is adequate. In areas with strong environmental contamination, or where large amounts of pollen have been released or dry periods have lasted a long time, it may be useful to clean the glass surface with tap water and a sponge or car washing brush.

6.2 Cleaning the duct system

Adherence to the intervals required for the filter replacement will largely prevent any contamination of the duct system.

However, should cleaning become necessary anyway, it can be done by means of suitable brushes and washing of the affected tube sections. Either monitoring holes are provided for this purpose or the affected tube sections have to be dismantled.

6.3 Cleaning the air outlet grilles and valves

If the air outlets have become contaminated they have to be cleaned. To do this, the affected parts have to be dismantled and washed with soapy water. In order to avoid damage to the surface, varnished grilled or plastic surfaces must be cleaned using gentle methods.


6.4 Filter replacement

GRAMMER air collectors are to be protected against internal contamination by installation of air filters of a minimum quality class of G 4 at the inlet.

An appropriate air filter is already integrated in the EF GLK filter collector. Otherwise a filter box can be mounted at the inlet.

The filter has to be replaced at least annually e.g. at the beginning of the heating period (in September). More frequent intervals may be required according to DIN specifications or depending on the degree of filter contamination.

Figure: GLK EF filter collector

IMPORTANT: Replace filter at least annually If the filter is not replaced frequently enough, contamination of the collector installation or a reduction in the collector performance will be the consequence !

Filter replacement in the collector:

In the case of collector-integrated fresh air filters (GLK EF), the end cover has to be removed for the filter replacement. This is done by loosening the screwed-on holder clamps. Then the filter cartridge is pulled out and the old filter mat is replaced by a new one. The loosely inserted support grille is to be cleaned and then to be reused. The inserting of the filter cartridge is made easier by placing a 950 mm sheet metal section against the absorber edges.

Filter replacement for an external filter box:

The filter replacement in the external filter box is done by opening the spring locks and replacing the filter medium.

6.5 Checking the attachment of collectors and mounting frames

The mounted solar installation is exposed to movement from wind and gales. Despite correct installation and securing of the solar installation, it must therefore be regularly inspected, in particular after strong gales, but at least every 2 years. During the inspection, it has to be checked that all screwed connections on the air collector system (collector connections, mounting frames) are tight.


deliv

ery

air

660

- 230

0 m

³/h

rang

e of

ap

plic

atio

n:ve

ntila

tion

and

hea

ting

with

sola

r air

colle

ctor

s - ty

pe

GRA

MM

ER G

LK

prop

oser

:

ass

et lo

catio

n:co

ntac

t per

son:

gros

s col

lect

or a

rea:

2

0 m

²

sola

r ai

r

exte

rnal

air

dat

e:

func

tion

dia

gram

:Ju

mbo

Sola

r, fre

sh a

ir op

era

tion,

sola

r fre

sh a

ir sy

stem

J

UM

BO

SO

LAR

GR

AM

ME

R- s

olar

air

col

lect

or G

LK g

ross

col

lect

or a

rea:

20

m²

7. FUNCTION DIAGRAM - JUMBOSOLAR

7.1 JUMBOSOLAR, fresh air operation, solar fresh air system


exte

rnal

air

deliv

ery

air

660

- 230

0 m

³/h

m³/h

m³/h

rang

e of

ap

plic

atio

n:ve

ntila

tion

and

hea

ting

with

sola

r air

colle

ctor

s - ty

pe G

RAM

MER

GLK

pro

pos

er:

ass

et lo

catio

n:co

nta

ct p

erso

n:

gros

s col

lect

or a

rea:

2

0 m

²

sola

r ai

r

exte

rnal

air

dat

e:

func

tion

diag

ram

:Ju

mbo

Sola

r, fre

sh a

ir /

mix

ed a

ir op

erat

ion,

sum

mer

ven

tilat

ion,

sola

r fre

sh a

ir sy

stem

J

UM

BO

SO

LAR

GR

AM

ME

R- s

olar

air

col

lect

or G

LK g

ross

col

lect

or a

rea:

20

m²

7.2 JUMBOSOLAR, fresh air operation and mixed air operation, summer ventilation, solar fresh air system


exte

rnal

air

deliv

ery

air

/ci

rcul

atin

g ai

r

660

- 230

0 m

³/h

m³/h

m³/h

rang

e of

app

licat

ion:

vent

ilatio

n a

nd h

eatin

gw

ith so

lar a

ir co

llect

ors -

type

GRA

MM

ER G

LK

pro

pos

er:

asse

t loc

atio

n:co

nta

ct p

erso

n:

gros

s col

lect

or a

rea:

2

0 m

²

sola

r ai

r

circ

ulat

ing

air

exte

rnal

air

dat

e:

func

tion

diag

ram

:Ju

mbo

Sola

r, fre

sh a

ir /

circ

ula

ting

air

/ m

ixed

air o

pera

tion,

su

mm

er v

entil

atio

n, so

lar d

eliv

ery

air s

yste

m

J

UM

BO

SO

LAR

GR

AM

ME

R- s

olar

air

col

lect

or G

LK g

ross

col

lect

or a

rea:

20

m²

7.3 JUMBOSOLAR, fresh air operation and circulating air operation, solar fresh air system


exte

rnal

air

deliv

ery

air

/ci

rcul

atin

g ai

r

660

- 230

0 m

³/h

m³/h

m³/h

rang

e of

app

licat

ion:

vent

ilatio

n a

nd h

eatin

gw

ith so

lar a

ir co

llect

ors -

type

GRA

MM

ER G

LK

prop

oser

:

asse

t loc

atio

n:co

nta

ct p

erso

n:

gros

s col

lect

or a

rea:

2

0 m

²

sola

r ai

r

circ

ulat

ing

air

exte

rnal

air

dat

e:

func

tion

diag

ram

:Ju

mbo

Sola

r, fre

sh a

ir /

circ

ulat

ing

air

/ m

ixed

air

oper

atio

n,

sum

mer

ven

tila

tion,

sola

r del

iver

y ai

r sys

tem

J

UM

BO

SO

LAR

GR

AM

ME

R- s

olar

air

col

lect

or G

LK g

ross

col

lect

or a

rea:

20

m²

7.4 JUMBOSOLAR, fresh air operation, circulating air and mixed air operation, summer ventilation, solar fresh air system

technical data installation instructions operating and ......1.5 technical data - glk type figure...

Documents