Karl Phelan - Electrical Lighting Design & Solar Thermal Hot Water Installation

Karl Phelan B00036379
Karl Phelan
B00036379 BN039 BSc in sustainable and electrical control systems 2
John Kilcoyne Mini Project Year 2 Lighting Design / Solar Thermal May 3rd 2011 May 3rd 2011

Year 2 Mini Project Year 2 Semester 2
Submitted to Owen Flood John Kilcoyne Lecturer in Sustainable Electrical & Control Technology Blanchardstown Institute of Technology
May 3rd 2011
By Karl Phelan Student ITB
Acknowledgements
I would like to express my gratitude to a number of people who have gotten me this far in my studies and research. Firstly I would like to acknowledge the hard work and dedication of the lecturers in the Institute of Technology, Blanchardstown. They have shown great patience and have been very active in the development of this report. I would like to thank John Kilcoyne and Owen Flood especially for their help throughout this process. They have worked tirelessly throughout this semester to motivate and set me on the right track.
The help and support received from Thorlux Lighting in particular deserves acknowledgement. From my correspondence with their support staff to the layout of their online webpage, they have been nothing but obliging and helpful. I am indebted to several sustainable technologies companies who have supplied me with the information Ive needed to compile this report. I would like to thank Kingspan, Philips, Thorn, Thorlux, Alternative Energy Ireland to name but a few. In closing I would like to thank my colleagues in ITB for their help throughout this report.

Table of Contents
Title
Acknowledgements 1.0 Executive Summary 2.0 Introduction Section A 3.0 Electrical Lighting Design Installation 3.1 Lighting Design per Room 3.1.1 Main Show Room 3.1.2 Stores 3.1.2.1 Hallways 3.1.3 Loading Bay 3.1.4 Canteen 3.1.5 Works Managers Office 3.1.6 Toilets 3.1.7 Reception 3.1.8 Electrical Switch Room 3.1.9 Main Entrance Hall 3.1.9.1 Hallways 3.2 Lighting Design Components 3.2.1 Solow T5 (Smart) 3.2.2 Solow XL (Smart) 4 12 14 14 17 19 20 23 26 28 30 31 32 34 36 37 39
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3.2.3 Juno 3.2.4 XL-Five Prismatic 3.2.5 CL-Five 3.2.6 Base LED 3.2.7 Micro Bloc 3.2.8 Jupiter 3.2.9 Prismalux 3.2.10 Control and Switching Gear 3.2.10.1 Light Management System 3.2.10.2 Lux Level and PIR Sensors 3.2.10.3 Main Showroom/Stores Sensor Spec 3.2.10.4 Motionline 3.2.11 Wiring 3.3 Lighting Design Formulas and Factors 3.3.1 The Lumen Method 3.3.2 Utilisation Factor 3.3.3 Maintenance Factor 3.3.4 Room Index (K) 3.3.5 Space Height Ratio 3.3.6 Light Output Ratio 3.3.7 UF and MF Calculation 3.4 Technical Data and Calculations Per Room 5 41 42 43 44 45 46 47 48 48 51 53 54 55 56 57 58 58 58 59 59 60 61

3.4.1 Factors Affecting Luminaire Quantities 3.4.2 Lumen Output 3.4.3 Final Calculations Section B 4.0 4.1 Solar Technology System Components 4.1.1 Solar Collectors 4.1.2 Solar Cylinder 4.1.3 Pipe Work 4.1.4 Temperature Sensors 4.1.5 Differential Temperature Controller 4.1.6 Heat Transfer Fluid 4.1.7 Installation & Mounting of Solar System 4.1.8 Installation of Pipe Work 4.1.9 Flow Meter 4.1.10 Expansion Vessel 4.1.11 Pressure Gauge 4.1.12 Automatic Air Vent 4.1.13 Drain Valve 4.1.14 Pressure Relief Valve 4.1.15 Thermostatic Mixing Valve 4.1.16 Non Return Valve 6 70 72 73 75 78 79 80 81 82 83 84 85 86 87 88 88 89 90 62 65 68

4.1.17 Immersion Heater 5.0 Technical Calculations/System Components Sizing 5.0.1 Collector Area 5.0.2 Hot Water Demand 5.0.3 Sizing the Collector Array 5.0.4 System Flow Rate 5.0.5 Pipe Sizing 5.0.6 Pump Sizing 5.0.7 Expansion Vessel Sizing 6.0 7.0 8.0 9.0 Stagnation Prevention Working at Height Risk Assessment References Technical Drawings 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 Electrical Plan Wiring Plan Sensors Plan Building Plan Solar Plan Solar Cylinder Close Up View Side View Front View 7 91 92 93 95 97 98 99 100 102 103 106 110 112 113 114 115 116 117 118 119 120 121

10.0 Appendix A 122
10.1 Thorlux Solow T5 Smart 10.2 Thorlux Solow XL Smart 10.3 Thorlux Juno Exterior 10.4 XL-Five Prismatic 10.5 Thorlux CL-Five 10.6 Thorn Base LED 10.7 Thorlux Micro Bloc 10.8 Thorn Jupiter II 10.9 Thorlux Prismalux 10.10 Solow T5 Presence Detection 10.11 Thorlux Lighting Control Module 10.12 Thorlux LCM POD 10.13 Motionline 10.14 Lamp Data Sheets 10.15 Site Survey 10.16 Installation Checklist 10.17 Thermomax HP200 10.18 Thermomax HP200 Specifications 10.19 AEI Brochure 2009 10.20 Aeroline INOX Classic 10.21 8

1.0 Executive Summary
The following report is on Lighting Design and Solar Design Technology. The report focuses on the components of Lighting and Solar Design and the calculations and formulas required to undertake such a project. The report was carried out between January 2011 and May 3rd 2011. The report was commissioned as part of the Mini Project Module, Semester 2, Year 2 in the Sustainable Electrical and Control Technology course in ITB (BN039). Guidelines for each part of the report were set out at the beginning which were to be followed. The report is based on the design of an Electrical Lighting Design and Solar Thermal Design at a car showroom in Swords, North County Dublin. The report consists of two sections. Section A deals with Lighting Design Technology. This section is broken down into several sub sections which deal with various aspects of Lighting Design. A brief introduction is given at the beginning outlining reasons for sustainable design and financial benefits. A breakdown is then given about each room. In these breakdowns the dimensions and factors affecting each room are stated and explained. In the next section the Luminaires used within this report are broken down and explained using data from the respective luminaires data sheet. Details of luminaires used, switching methods, and control methods are provided and a rationale is given for the use of each. The data sheets for all luminaires are given in the appendices.
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The last section in the lighting design report outlines the calculations used in each room with a detailed grid for ease of access. These have been calculated manually and verified with colleagues. Section B deals with the Solar Thermal Installation. Within this section outlines dictated that a solar thermal system was to be installed within the property in Swords, Co. Dublin. The parameters given were for a 300 litre solar cylinder to be installed for a max daily usage of 300 litres per day. This was a challenging aspect of the report but I enjoyed the research and learned some new things as I progressed as well as re-enforcing what I had already learned. As with the previous section, Section B is layed out in much the same way as the other. Part 1 deals with the need for sustainability and the benefits that can be provided by installing a solar thermal system in ones property. Following that each component is discussed and clearly explained with technical data from the specification sheet of each component. The Solar Thermal System used in this installation is the Thermomax HP200. I found this system to fit the needs of the customer best and was ideal for the task at hand. Once again all data sheets can be found in the appendix of this report in Section B. In the last section of the Solar Thermal report a chapter on Stagnation Prevention is provided. The dangers of stagnation and how to prevent such happening is discussed.
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Each section in this report is accompanied by several technical drawing which can also be found in the Appendices of this report. This report and its technical data conform to current industry guidelines and relevant standards.
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2.0 Introduction
The following report is on Lighting Design and Solar Design Technology. The report focuses on the components of Lighting and Solar Design and the calculations and formulas required to undertake such a project. The report was carried out between January 2011 and May 3rd 2011. The report was commissioned as part of the Mini Project Module, Semester 2, Year 2 in the Sustainable Electrical and Control Technology course in ITB (BN039). The objective of this report was to follow and adhere to the guidelines set out at the beginning whilst gaining a better understanding of the topics covered. The report is divided into several sections. Section A deals with Sustainable Lighting Design Technologies and the installation and selection of luminaires, control and switching technology and also the technical information and calculations used to back up the installation. Section B is concerned with the Solar Thermal Installation. The structure of this section is similar to that of section A. In part 1 of this section the components of a Solar Installation are discussed. Part 2 deals with the calculations used in this installation.
All sections come with technical data sheets and technical drawings which can be found in the rear of this report.
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3.0 Electrical Lighting Design Installation
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3.0
Lighting Design
Dennis Grange Motors is a business which deals in New and Second hand Cars sales and imports and servicing. The client understands that in this environmentally aware society customers acknowledge and are aware of green technologies and advances in technology. Dennis Grange Motors envisages that by having an environmentally carbon neutral premises that customers will look favourably on their business and will be prepared to deal with such a business over those who have not implemented measures to tackle their environmental impact. They believe that by introducing these measures that it will reflect on the brand of car they promote and stock. Apart from business motives, Dennis Grange Motors fully understands the impact that car emissions have on the environment and are fully dedicated to tackling these and have requested that their new premises be fully designed with sustainability in mind. The client has instructed us to design a sustainable lighting design system with energy saving measures for a reduced electrical and upkeep cost and to decrease to businesses carbon footprint. Apart from energy saving luminaries they have instructed us to install sustainable control and switching methods.
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3.1.0 3.1.1 Main Show room Lighting Design
The main room is the focal point of the property and will be the room that customers will be using the most. The client has instructed that the room will be used as the Main Showroom. As the clients business is mainly car sales and servicing, the main room must be large, open plan, and bright enough to emphasise the product (Car Brand etc). The main room, visible from the outside, has large front facing windows to allow natural light to enter the room during daylight hours. This will in turn reduce the need for lighting during these hours and in turn keep electrical costs to a minimum. The room itself is of a high bay design with an 8 metre ceiling. The room dimensions are 15.6x19.44 m2. The Working Plane is at approx 1 metre. The CIBSE guide recommends that this room be illuminated to a lux level of 500 Lux as show room sales and general car servicing takes place. This means colour judgement may be required on electrical cable etc. Good colour rendering is essential. The Utilisation Factor for this room is 0.6 as the luminaire is quite good but is at a height and there are a lot of windows. The Maintenance Factor in this room is 0.6 also as it is a relatively clean room but as mentioned before general car servicing takes place also.
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The luminaries selected for this room are the Thorlux Solow T5 Smart 4x54W by Thorlux. This was selected as it incorporates smart switching and lux level/occupancy sensors pre-fitted. They will be installed on metal trunking supported by roof beams. 24 luminaries will be sufficient to light this room. (Calculations in section 1.3.)
The version selected has a polycarbonate cover and smart switching pre installed.
Below is a sample of a similar set up.
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3.1.2 Stores
The stores room is the second largest room within the building. As the name suggests, this room will be used to keep files and car parts. A small part of the room will be partitioned to hold the Solar Thermal Hot Water Storage Cylinder which we will be introducing later in this report. This will not affect the lighting design installation. The stores room has a ceiling height of 4 meters. The room dimension is approximately 68.2m2. The Working Plane is at 1 metre. As there is little light in this room due to it having only one external wall a bright illuminance is required. The recommended lux level for this room is 150 Lux The Utilisation Factor in this room is 0.6 as the walls, ceilings, and floors are of a dark shade as the stores arent for customer use. The Maintenance Factor is 0.5 as old car parts and spares are kept here alongside the file stores. The luminaire selected for this room is the Thorlux SolowXL Smart (T5) 4x49W by Thorlux. This was selected for its smart switching and lux level sensors and also for its energy saving abilities and because its
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target illuminance is 150 lux at floor level which is what is needed. With these figures we have calculated that 4 luminaries are required to sufficiently illuminate this room.
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1.1.2.1 Hallways
There is a small hallway dividing the stores from the outside loading bay that allows access from the hallway into the showroom. As you will see in section 1.1.9 we will be using The Thorn Base LED luminaire to light up the hallway areas. This hallway is no different. The hallway is 10.36m2 with a ceiling height of 2.4m. The working plane is at ground level. The recommended Lux Level for a hallway is 100lx but as the hallways will be used by customer traffic we have set a Lux Level of 200lx. Lux Level: 200lx MF: 0.7 UF: 0.7 We have calculated that 7 luminaries are sufficient for this hallway.
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3.1.3 Loading Bay
The loading bay is to the front of the building to the right of the double doors of the main entrance. The loading bay is used to bring cars into the main showroom and service area. There is a large sliding factory shutter to allow entry and exit for large vehicles. The loading bay has no shelter and has no partition wall surrounding it. The plan of the building shows that the loading bay extends out to cover 40.34 m2 from the sliding shutter to the double doors of the main entrance. Working Plane is 1 metre. The recommended lux level, given by the CIBSE guide, for this area is 150 Lux. The Utilisation Factor for this area is assumed to be 0.6 as lighting will not be required during daylight hours (excluding Winter) and there are several street lamps surrounding the loading area. The Maintenance Factor is determined to be 0.5 as the loading bay is outdoors and is frequently used by motor vehicles and mechanics. The Luminaire selected for this area is the Juno Exterior Light 100W (LMP 9748) SON-T Plus by Thorlux. Lux level sensors will be installed in the Loading Bay. Two luminaries are required to illuminate this area.
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This luminaire was selected for its low light pollution and integral control gear. It is to be erected on a twin pole set-up in the middle of the loading bay. Below is an example of a similar set-up.
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3.1.4 Canteen
The canteen is a general staff area. Food is cooked, stored, and consumed here. The canteen contains a cooker, sink, microwave and fridge. Several tables and seats are also located in the canteen for staff leisure. The canteen is approx 13.71m2. The ceiling height is 2.4m tile. The Working Plane is at 0.75 metres. The CIBSE guide recommends a lux level of 300 lux for canteens and 500 lux for kitchens. Bearing that in mind a lux level of 400 Lux has been selected for this room. The Maintenance Factor for this room is 0.6 as it is kept relatively clean but food is also consumed in this location. The Utilisation Factor for this room is 0.7 as the interiors are painted a light shade of white with a plastic glazed chipboard countertop. The Luminaire selected for this room is the Thorlux XL-Five Prismatic Smart 4x14W (T5). 3 Luminaries will be sufficient for the canteen. As there is no external windows located in the canteen an occupancy sensor will be sufficient for control and switching. This luminaire was selected for its vibrant yet simplistic appearance and low power usage.
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3.1.5 Works Managers Office
The works managers office is the smallest room in the building. It is located through the main entrance doors to the second door on the right. The Manager of this Dennis Grange Motors branch will be located here. The room is 5.95m2 in size and contains one desk with a computer. The ceiling is 2.4m high tiled. The Working Plane is at 0.75 metres. There are two filing cabinets placed alongside the wall. The recommended Lux level for this room is 500 Lux as it is used as a general office. The Utilisation Factor in this room is 0.6. The room is decorated with dark colours with low reflectance and a carpeted surface. The Maintenance Factor is also assumed to be 0.6 as the room is carpeted and quite small. The Luminaire selected for this room is the Thorlux Surface Mounted CL-Five 2x14W (T5). A smart version of this luminaire was not used because the smallest lamp fitting available for that version would illuminate the room to an extraordinary level. An occupancy sensor will be sufficient as switching gear for this room. 4 Luminaries have been calculated to illuminate this room sufficiently.
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3.1.6 Toilets
The toilets are located at the south end of the property. There are two separate rooms for both male and female patrons of the building. In each toilet there are three cubicles two sinks and a large mirror. There is also a hand dryer and towel dispenser. The toilets are 10.2m2 each which brings the total combined area of both toilets to 20.4m2. For the purpose of lighting design we will take each room as a separate entity. The toilets both have a small lobby preceding them. A small Microdot fitting will be installed in each of these. Each toilet has a 2.4m high ceiling and a working plane of 0.75m The recommended Lux Level for toilets is 100 Lux. The Maintenance Factor in the toilets is 0.6. The toilets are regularly cleaned by a dedicated maintenance staff member. The Utilisation Factor of both rooms is 0.6. This is because the toilets are decorated with a green ceramic tile finish. The luminaries selected for the toilets are the Thorlux Micro Block 16W 2D fittings. Calculations state that 3 luminaries should be adequate to sufficiently illuminate each of the toilets, both male and female. Occupancy sensors will be installed in both male and female toilets.
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3.1.7 Reception The Reception is located to the immediate left as you walk through the entrance doors. The entrance is 6.9m2 in size and has a working plane of 0.75m. The ceiling height is 2.4m. The recommended Lux Level for the reception area is 300 Lx. The Maintenance Factor for the reception area is 0.6. The reception is kept moderately clean as it is a focal point in the property. The Utilisation Factor is set at 0.6 also. This is because the room is painted with a glossy bright peach colour.
The luminaire selected for this room is the Thorn Jupiter II 1x28W (T16). The Reception will be fitted with a combined occupancy sensor and lux level sensor.
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3.1.8 Electrical Switch Room
The Electrical Switch Room is located in the main entrance hall. The Switch room is the centre for all electrical connections, safety devices, breakers etc. The control centre for the lighting system is also located in this room. The room is 3.6m2 with a ceiling height of 2.4m. The working plane in the switch room is between 1.0m and 1.2 m. The recommended Lux Level for the Electrical Switch Room is 150lx. The Maintenance Factor in the switch room is 0.7 as the room is kept relatively clean and free of obstacles for ease of access. The Utilisation Factor in the switch room is 0.6 because of its small size and the nature of the room. The luminaire selected for this room is the Thorlux Prismalux 26W TCT. The lamp was selected for its low power load and high colour rendering ability @3500K. This will benefit any technicians working in the switch room. No sensors will be installed in this set up.
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3.1.9 Main Entrance Hall
The Main Entrance Hall will be the first point of access for most customers and as such should be treated as a first impression. Dennis Grange Motors will be providing refreshments and meeting stations for its customers and employees for discussions in this area. For this reason the lighting level must be sufficient and visually pleasing to the customers. It must also allow them to read documents and view pictures with ease. The colour rendering of the lamp selected below is sufficient for these requirements. The room itself has an area of 13.51m2 and a ceiling height of 2.4m tiled. The working plane is about 0.75m also. According to the CIBSE guide the recommended Lux Level in this area is 200lx. The hall is kept clean because of its purpose and is maintained daily by dedicated support staff. For this reason the Maintenance Factor for the Hall is 0.7
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The Utilisation Factor for the Hall is also 0.7. The decor is a bright colour and there are two windows allowing light into the room. The selected luminaries for the Entrance Hall are the Thorn Base LED. The lamp selected for this fitting is the BaseLED 165 MRE 1X12W LED L927. It has a colour rendering of 3500K. Calculations have shown that 10 Luminaries are sufficient for the Entrance Hall.
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3.1.9.1 Hallways
The hallways adjoin the Main Entrance to the right of the switch room. They must be lit sufficiently for patrons and staff to navigate with ease. As the hallways are a continuation of the main entrance the parameters for lighting design will not be changing. The ceiling is 2.4m. There are 2 sections of the hallway to take into account. Section 1: This section is 5.5m2 in size and has a tiled ceiling. UF: 0.7 MF: 0.7 Recommended Lux Level: 200lx Section 2: This section is 3.75m2 in size and has a tiled ceiling. UF: 0.7 MF: 0.7 Recommended Lux Level: 200lx As the parameters are the same as the main entrance it is only logical to select the same luminaire and lamp fittings for this area also.
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In Section 1: We will be required to install 4 Thorn Base LED luminaries with the lamp selected for this fitting to be BaseLED 165 MRE 1X12W LED L927. In Section 2: As with Section 1 we will be using Thorn Base LEDs with the BaseLED 165 MRE 1X12W LED L927 lamp. For this section we will require 3 luminaries.
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3.2
Lighting Design Components
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3.2.1 Solow T5 Smart
The Solow T5 Smart was chose for this installation simply because it was head and shoulder above the rest during design selection. The high bay luminaire makes it perfect for the large showroom and was perfect for what the client was looking for. The unique design of this luminaire provides excellent illumination even up to 10 metres. With a mounting height of 8 metres in mind we quickly decided this was the best choice. The smart version of the Solow T5 encompasses its own smart pod. The smart pod is an intelligent programmable lighting controller. It provides maintained illuminance, daylight linking, PIR control, and infra-red remote control. The Solow range is a very efficient energy saver and is highly efficient. The range when coupled with the smart system can achieve an electrical load of 70% of a clients annual load. Thats a saving of 70%. In this installation the Solow T5 Smart luminaries will be surface mounted to the re-enforced trunking at 8 metres high. This will be sufficient to allow to occupancy and lux level sensors to operate with negligible hassle. The luminaries will be connected to one another using a Motionline twocore low voltage bus. This will allow each luminaire to respond simultaneously when movement is detected or lux level change is triggered. 39
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3.2.2 SolowXL Smart
The SolowXL Smart Luminaire was selected for this installation for a number of reasons. The SolowXL is a high performance luminaire with a high performance arc. The sheer minimal size and weight of this luminaire provides benefits straight away. It can provide either a broad or narrow light distribution with output ratios of up to 97%. There are numerous mounting options available with this luminaire for varying low or high bay applications. This SolowXL comes with an integrated micro pod sensor which will control the light level and detects occupancy(Lux Level and Occupancy level sensors). As mentioned for the Solow T5, the Solow range alone can achieve savings of up to 70% The luminaire can be mounted up to a height of 10m and has options for emergency and autotest features. This includes both suspension and surface mounting. There is an option for an uplighting attachment if required. As with the Solow T5 Smart this luminaire will be surface mounted to busbar trunking and connected using Motionline to improve efficiency.
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The client has specified that savings are a priority and with this luminaire the clients expectations can be achieved and surpassed. Observe the following case study.
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3.2.3 Thorlux Juno
The loading bay caused a challenge as it outdoors and is not sheltered. Due to the nature of the clients business it is essential that the loading bay be illuminated; not only for safety reasons but for illumination of the brand. In sales, the brand must always be seen, and Dennis Grange Motors is no different. The Thorlux Juno was selected for the Loading Bay because it fits suitably to what the client needs. It has: Zero Upward Pollution Corrosive Resistant Cover Flat Toughened Safety Glass Integrated Control Gear
Installation of the Juno Luminaire will be done using a twin pole mount. A 100W SON-T Plus (LMP9748 Thorlux Catalogue) lamp will be used in the installation. The luminaries will be installed at an 8 metre height.
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3.2.4 Thorlux XL-Five Prismatic
The XL-Five Prismatic was chosen for the canteen because its shallow 65mm body will fit perfectly into the tiled ceiling. The XL-Five Prismatic comes with a steel body finished white which will fit aesthetically with the decoration in the canteen. The smart version come with a side arm suspension kit and is fitted with 3500K lamps. It will fit a square tile perfectly with its 600x600mm size. A colour render of 3500K will promote a relaxed atmosphere to the staff. The lamp chosen to fit this luminaire is the 14W T5 lamp (Cat No. LMP 10139). The smart version comes equipped with an occupancy and lux level sensor as standard.
Installation Guide in appendices.
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3.2.5 Thorlux CL-Five
The Thorlux CL-Five luminaire was selected for the managers office. This was chosen for a number of reasons. Firstly the managers office is quite small. Heavy load bearing lamp/luminaire wouldnt fit with the criteria for energy savings. The luminaire has high frequency regulating control gear as standard. The Smart version was not selected as the lumen output of the smart version well exceeded what is required to sufficiently light up the managers office. The luminaire has a perforated body which creates soft modelling. This helps the luminaire to fit into the natural decor of the room without standing out. The luminaire is 600x250mm in size and can support up to 3 T5 lamps. The product selected for the office will be the 2x14W T5 LG7:2005 version.
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3.2.6 Thorn Base LED
The Thorn Base LED was selected for the Main Entrance Hallway and also used in the other two hallways. This downlighter was selected for its unprecedented LED lighting performance and excellent colour rendering. Colour rendering is essential for the client as his business is in sales. As mentioned before the product must always be seen to the best of ability. The Base LED has brilliant colour rendering (3500K) and its diffuser controls glare and according to the data sheet even light. The Base LED consumes an average of 12W. Energy usage can be cut by up to 75% compared to an 18W compact fluorescent and 50W halogen mains downligters. The diffuser gives a wide, soft beam with equally good vertical and horizontal illuminance. The Base LED luminaire is being used with a BaseLED 165 MRE 1X12W LED L927 lamp and will be recessed within the tiling. Several rooms within the property will be using this luminaire/lamp setup.
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3.2.7 Thorlux Micro Block
The Thorn MicroBlock was mainly chosen because of its suitability for use in toilet areas and damp areas. The luminaire is IP43 rated, is fire resistant and as mentioned can withstand damp and wet areas. This makes its suitable for use in the toilets. The lamp being used is the 16W 2D produced by GE. (LMP 7333) The luminaire is 217x217mm in size.
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3.2.8 Thorn Jupiter
The Thorn Jupiter II was selected to be installed in the Reception area for its low power consumption of 31W. The Jupiter II is IP20 rated, fire resistant and rated up to 850 Celsius. The Jupiter II provides a broad, extended, horizontal and vertical illuminance. Mounting options for this luminaire include surface mounting and suspended mounting. Keyhole slots are provided for fixings. The lamp selected for this luminaire is the 28W T16 manufactured by GE.
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3.2.9 Thorlux Prismalux
The luminaire (Thorlux Prismalux) selected is a heavy duty bulkhead fixture. It was selected for this installation to be placed in the Electrical Switch Room. It was selected because of its robust and strongly framed body. The Prismalux is IP65 rated and is flame and water resistant. The Prismalux is ideal for industrial areas, power stations, cable tunnels, and pump rooms because of its reinforced body. Several lamp variations can be installed within the luminaire giving the client and installer a varied choice. The range of lamps catered for include GLS, SON, MBF and TC-F. The lamp selected for this installation is the 26W TC-T 1800lm output with a high colour render of 3500K. (LMP 11555) The colour render provides technicians with a brightly lit working area for any maintenance carried out in the switch room.
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3.2.10 3.2.10.1 Control and Switching Gear Light Management System
The Thorlux Lighting Control Module and LCM Receiver have been selected to be installed for the client. The Thorlux LCM system allows the user to combine the LCM modules with other lighting components through a plug and socket wiring system. Up to 20 luminaries can be connected to each LCM System although the LCM-POD (shown below) can be common to several LCM systems. Up to 100 LCM systems can be connected together and can also be connected to a Building Management System. The system allows for a simplified or complex layout. The LCM system is also very flexible and will allow for future layout changes. The LCM system can significantly reduce labour costs as the luminaries are simply plugged together.
The LCM control the timed dimming and switching of connected luminaries by reacting to the signals sent to it by the peripheral components such as the PIR, Lux Level and Infra-Red sensors.
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The switching cycle is programmed for a 22 minute time delay while using PIR control. The lights will dim after 14 minutes if no movement is detected.
A Typical Set-up is shown on the next page. (Image courtesy of Thorlux lighting_control_module_and_receiver.pdf (appendices))
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3.2.10.2 Lux Level and PIR Sensors
Unless otherwise stated all rooms will be fitted with a PIR sensor. The product selected to be installed throughout the building is the Thorlux LCM-POD. Many of the Luminaries selected come pre-fitted with PIR and occupancy sensors. The LCM-POD will be installed alongside any luminaire which does not have this feature pre-fitted. The LCM POD comes equipped with an Intelligent PIR system, a Daylight Sensor and also an Infra-Red sensor. The PIR system has a detection range of 2 metres when mounted at a height of 2.7 metres. As the sensors will be mounted at 2.4m height this should be sufficient to pick up movement within any of the rooms, excluding the high bay main showroom and stores room. The sensor is very sensitive even to small movements such as hand movements. An intelligent microprocessor provides protection against false triggers and has an automatic sensitivity and time delay adjustment. The Daylight Sensor has a sensitive photocell that offers automatic light level control through maintained illuminance/daylight control. It can be set from between 20-2000 Lux and can be remotely set using the Daylight Sensor Transmitter. The Infra-Red Receiver provides the option to override the Daylight Sensor at any time. 53

There are 3 preset options available which will set the light level to the following accordingly. 1. Minimum Light Level 2. 50% Light Level 3. Maximum Light Level Only one LCM-POD may be connected to each Lighting Control Module. If improved PIR coverage is required Thorlux can provide addition LCMSensors. The sensors are easy to install and are designed for semi-recessing. No mains supply is required as a low voltage connection will suffice through an RJ45 data lead. Each room with this system in place will have its own Daylight Sensor Transmitter and Infra-Red ECO remote transmitter for manual lighting control.
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3.2.10.3 Main Showroom and Stores Sensors Specification
The Main Showroom and the Stores Area both have a higher ceiling height than the rest of the building. Conventional LCM-POD sensors will not be able to work to their optimal potential as they have a restricted height limit of 2.7m The combat this, smart luminaries have been installed in each room. These luminaries have PIR sensors that will work up to a height of 10m. In the Main Showroom the Solow T5 (Smart) has been installed while in the Stores Area the SolowXL Smart has been installed. These smart luminaries are designed for height and the pre-fitted sensor can compensate for this. Please find below a detailed image of the workings of those sensors from the Thorlux Installation Guide.
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3.2.10.4 Motionline
In both the Main Showroom and the Stores Area Motionline Technology will be used. Motionline Technology links together individual smart luminaries into a grouped system. A two wire low voltage bus allows the luminaries to communicate as a group. This will allow all luminaries connected to this group to respond simultaneously to any detections made by the sensors such as a movement in the sensors vicinity. Because all smart luminaries have PIR sensors, this provides complete PIR coverage of the floor space in the room which the luminaries are to be installed.
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3.2.11 Wiring
All wiring within this installation was done with 1.5mm 3 core flex cable with a 10 amp rating unless otherwise stated. Cables from the Main Showroom have been grouped together as is shown on the technical drawing.
57
3.3.0 Lighting Design Formulas and Factors
58

3.3.1 The Lumen Method
The Lumen Method is used to calculate the number of Luminaries required to provide a maintained illuminance throughout a room. The quantity of lumens reaching the working plane is the main factor to be considered when undertaking a lighting design project. This light is known as an illuminance which is measured in lux. The formula below is a form of the Lumen method.
Where, E= The Maintained Illuminance F= The initial Lumen Output N= Number of Luminaries n= Number of lamps in each luminaire UF= Utilisation Factor MF= Maintenance Factor
59

3.3.2 Utilisation Factor
The amount of lumens emitted from a lamp that reach and are utilised by the working plane is known as the Utilisation Factor. This value would depend on a certain number of factors including room reflectances, room dimensions, the light output ratio of the fitting and several others including: 3.3.3 Type of Luminaire Size and Number of Windows And also the mounting height of Luminaries. Maintenance Factor
The maintenance factor gives an estimate of how lighting conditions will deteriorate through use. It refers to the illuminance give out by a lamp under certain conditions. Such conditions include those as under a dirty environment or if a lamp is aged as opposed to a clean environment or a newly installed lamp. 3.3.4 Room Index(K)
The Room Index (K) is the ratio of a room plan area to half the wall area set between the working plane and the mounting height of the luminaire.
Where, L= Length of Room W= Width of Room Hm= Distance between the Mounting Height of Luminaire the Working Plane of the room.
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3.3.5 Space Height Ratio
The Space Height Ratio (SHR) refers to the even distribution of luminaries in a room. It is the ratio of the centre to centre distance between adjacent luminaires to their height above the working plane. It is basically used to determine if the spacing used is uniform. The formula used is
Where, A= Total Floor Area N= Number of Luminaires Hm= Mounting Height of Luminaires 3.3.6 Light Output Ratio
The LOR refers to the effectiveness of a luminaire in transmitting the light from the lamp into the environment.
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3.3.7 UF and MF Calculation
This find out the total number of lumens that reach the working plane we must first do several calculations. The Utilisation Factor must be worked out. This is done by first calculating the Room Index (K). The formula for K is shown on a previous page. Using the utilisation factor, maintenance factor, room dimensions, and finally the recommended lux level, we can then calculate how many lumens are required and in turn the amount of luminaires. Below is a worked example. Works Managers Office: Room Index: The Managers Office has reflectances of 7,5,2 Ceiling=7, Walls=5, Floors=2 From the Thorlux Utilisation Tables we can see this corresponds to a 0.6 utilisation factor. The Maintenance Factor is determined by how clean the room is. Tables (Appendices) show that the works managers office has a maintenance factor of 0.6. The recommended lux level in this room is 500lx. The Lumen Method can now be used.
62
3.4.0 Technical Data and Calculations Per Room
63

3.4.1 Factors Affecting Luminaire Quantities
The tables below represent the following The Area of All Rooms The Recommended Lux Level as per the CIBSE Guide The Maintenance Factor for each room The Utilisation Factor for each room
The tables have been created so we can easily present to the reader the step by step process to determine the quantity of luminaries to be installed in each room.
Area Location Showroom Area 1 19.44 15.6 303.264 Lenght Width (m2)
R. Lux Lvl 500 MF 0.6 UF 0.6
Area Location Stores Area 1 Area 2 Total 8.04 7.283 4.643 37.32972 4.34 31.60822 68.93794 Lenght Width (m2)
R. Lux Lvl 150 MF 0.5 UF 0.6
Area Location Loading Bay Area 1 7.203 5.6 40.3368 Lenght Width (m2)
R. Lux Lvl 150 MF 0.5 UF 0.6
Location
Lenght Width Area
R. Lux
MF
UF
64

(m2) Canteen Area 1 5.44 2.52 13.7088 Lvl 400 0.6 0.7
Area Location Works Office Area 1 2.52 2.36 5.9472 Lenght Width (m2)
R. Lux Lvl 500 MF 0.6 UF 0.6
Area Location Main Entrance Area 1 Area 2 Total 3.365 3.277 2.077 6.989105 1.915 6.275455 13.26456 Lenght Width (m2)
R. Lux Lvl MF UF
100
0.6
0.6
Area Location Toilets Men Women Total 4.75 4.75 2.14 2.14 10.165 10.165 20.33 Lenght Width (m2)
R. Lux Lvl 100 MF 0.6 UF 0.6
Area Location Reception Area 1 2.76 2.5 6.9 Lenght Width (m2)
R. Lux Lvl 300 MF 0.6 UF 0.6
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Area Location Switch Room Area 1 3.365 1.08 3.6342 Lenght Width (m2) R. Lux Lvl 150 MF 0.7 UF 0.6
Area Location Hallways Area 1 Area 2 Area 3 Total 5.52 2.45 7.403 1 1.52 5.52 3.724 Lenght Width (m2)
R. Lux Lvl 100 MF 0.6 UF 0.6
1.44 10.66032 19.90432
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3.4.2 Lumen Output
The tables below show a rough estimation of the lumen output required per room. Legend: E Lux Level A Area U Utilisation Factor M Maintenance Factor
Lux Level x E Showroom Area 1 500 303.264 0.6 0.6 151632 0.36 421200 A U M Area UF x MF Lumen Output
Location Stores Area 1 Area 2 Total 37.32972 31.60822 150 68.93794 0.6 0.5 10340.691 0.3 34468.97
Location Loading Bay Area 1 150 40.3368 0.6 0.5 6050.52 0.3 20168.4
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Location Canteen Area 1 400 13.7088 0.7 0.6 5483.52 0.42 13056
Location Works Office Area 1 500 5.9472 0.6 0.6 2973.6 0.36 8260
Location Main Entrance Area 1 Area 2 Total 6.989105 6.275455 200 13.26456 0.7 0.7 2652.912 0.49 5414.106122
Location Toilets Men Women Total 100 10.165 10.165 20.33 0.6 0.6 2033 0.36 5647.222222
Location Reception Area 1 300 6.9 0.6 0.6 2070 0.36 5750
Location Switch Room Area 1 150 3.6342 0.6 0.7 545.13 0.42 1297.928571
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Location Hallways Area 1 Area 2 Area 3 Total 5.52 3.724 10.66032 100 19.90432 0.6 0.6 1990.432 0.36 5528.977778
The final figure lumen output is what is required to illuminate each room to its required level. The following table outlines which luminaires and lamps were selected respective of each room
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3.4.3 Final Calculations
70
SECTION B
Solar Thermal Installation
71
4.0 Solar Technology
The world we live in is fast running out of what we call fossil fuels. We can no longer rely on these fuels to power our lives, homes, and businesses. The sun, our closest star has an infinite source of energy that is just waiting to be tapped.
It is a widely believed myth that Ireland is not an ideal place to harness the suns energy. This is, as i said before, a myth. Ireland itself harnesses roughly around 60% of the suns energy as any region on the equatorial belt does.
Although in saying that, we harness this energy mostly between the months of April September, with 70% of the energy received by Ireland being harness able at this time. In fact about 25% of this energy is received in the months of June and July.
As we use more and more of solar energy to replace more conventional fuels we are reducing carbon emissions and promoting green energy at the same time. This can lead to reduced electrical bills and also reduces each and every citizens carbon footprint.
There are several types of solar technology that can be harnessed for different applications. Photovoltaic Active Solar Passive Solar
72

The most commonly used application of solar technology is active solar technology.
Active solar technology used solar collectors to trap the irradiance from the sun. This can then be used to heat fluid water heating systems and for spatial heating systems. The benefits of using solar thermal systems are limitless. If a system is correctly sized and efficiently installed; close to 60% of a residential or businesses heating requirements per annum can be obtained from using a solar thermal system. In fact during the summer months roughly 100% of the requirements can be met on a daily basis. Solar collectors are very efficient and can convert both direct and indirect (diffuse) sunlight into usable energy and heat. This is true even with overcast weather conditions. On a side note; as only 30% of Irelands solar irradiance is obtainable during the summer months it is advisable to have a backup system in place for such times.
The client Dennis Grange Motors understands the potential savings and to a more subtle extent the message that using such technology portrays about the brand of car it stocks to his customer base. The building the client occupies was built with a passive solar design and also with an active solar thermal system build in. It was designed to supply a maximum of 300 litres per day to the client and his customers. The system selected was an evacuated tube heat pipe collector arrangement with a dual coil cylinder. Further details, such as sizing, components and connectors will be discussed at a later time. 73
4.1 System Components
74

4.1.1 Solar Collectors
The solar collector array is the first point of contact and the main component of the Solar Thermal System.
The suns energy is collected here and is transferred in the form of heat through the transfer fluid and heat exchanger. This is transferred to the hot water cylinder.
There are two types of solar collector that can be used to harness the suns energy. They are: Flat Plate Solar Collector Evacuated Tube Solar Collector The type of collector used by the client is an evacuated tube solar collector. The reason that this type has been chose is the ease of installation over the heavier flat plate and the efficiency of using the tubes over the flat plate collectors.
The Thermomax Heat Pipe Collector HP200 System has been chosen as it is a well established system and is known to be an efficient and reliable system. It is designed for Northern European climates as it provides heat even in cold, windy and humid conditions.
The Thermomax HP200 System comes with a 5 75

year standard warranty, will supply 70% of the clients water needs and is 30% more efficient than a flat plate collector system.
The HP200 system has a unique feature in that it has a Temperature

HP200 Tube
Limitation Device. The Temp Limitation Device has a snap disk to limit temperature to 135 Degrees Celsius for commercial installations and 95 Degrees Celsius for domestic installations. The Temperature limitation device is fitted in the condenser bulb of the HP200 System.
The collector utilises a plug and play style design for an easy installation and for later additions.
The System itself will be placed on the south facade of the building facing south with an inclination of 37.4. An awning roof kit (Product Number KSK0018) will be used to anchor the system to the roof. This particular bracket was chosen because the building is located in a high wind load area and as the bracket will be placed at a height the extra protection is necessary.
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4.1.2 Solar Cylinder
The cylinder that will be used in this installation will be the AEI 300 litre stainless steel dual coil solar cylinder. This cylinder is ideal for the HP200 system being installed for Dennis Grange Motors as it has a capacity for
300 litres, as is required, it will fit an in-direct system, and it is designed for a solar thermal designed system. The AEI 300 Litre is ideal for this clients needs as it is tall and slim which will fit nicely into the desired location which is a partitioned room in the stores area. The cylinder itself is made from a high (duplex) grade stainless steel. This is better than the standard 316 grade and hugely superior than the 304 grade steel.
The cylinder also comes with a 25 year warranty, as standard, subject to it being reasonably maintained.
77

The cylinders are rated to 6 bar which is more than enough to cover mains pressure in any part of Ireland. For added peace of mind the AEI 300 Litre is tested to 9 bar before being delivered.
The AEI 300 Litre Stainless Steel model is fitted with the following:
Factor fitted temperature stats 2 port valves (Central Heating Control) Expansion Vessel A Pressure Reducing Set and Tun Dish
The AEI 300 litre Stainless Steel Cylinder will also come pre plumbed and pre insulated.
78
79

4.1.3 Pipe work
Pipes are used to provide a path to and from the collector to the cylinder. This is how the heat transfer fluid is circulated throughout the system. The fluid in the pipes can reach temperatures upwards of 170 Celsius (Max 135 with this HP200 System) so plastic pipes are not recommended.
Aeroline INOX Classic 22 is to be used in this installation. The INOX classic brand is a pre-insulated twin tube system. It will come pre insulated with 2x corrugated stainless steel tubes (Flow and Return). The pipe work is UV resistant and has a silicone temperature sensor line.
The Image above clearly shows the EPDM insulations enclosing the flow and return paths to the array. We can also see silicone temp sensor line.
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4.1.4 Temperature Sensors A temperature sensor will be installed at both the collector and at the storage cylinder. These will both be connected to the differential temperature controller located in the house. This will regulate the temperature according to the readings by controlling the circulating pump.
The picture on the left shows the temperature sensor line which will enable the temperature sensors (shown below) to determine the need for the circulating pump being activated or not.
81

4.1.5 Differential Temperature Controller As mentioned above, the Differential Temperature Controller has two sensors. One is located at the pre-heat cylinder and one located by the solar collector. The DTC will cause the pump to activate if the temperature on the collector sensor exceeds the cylinder sensor by a pre set level. The temperature differential is adjustable on the DTC controller and will usually have a differential of between 1-12celsius. Although, in saying that, a normal system will have a setting of between 4-8 Celsius.
The pump will switch off when the DTC reads that the temperature differential has fallen between the collector and the cylinder.
There are safety measure in place to ensure that the pump does not switch on and off repeatedly within short intervals (Hunting). It is usually set for a 2 minute delay and for this installation we will go by this recommended time span. For practicable purposes the client will be using the Thermomax SC100 DTC controller. The SC100 is equipped with a newly developed illuminated display with system monitoring.
82

4.1.6 Heat Transfer Fluid
The Heat Transfer Fluid transfers the heat from the solar thermal collectors to the water in the cylinder. The fluid is pumped around the system and will not come into contact with any water which is destined for human use or consumption. The pump will circulate the fluid around the system from the solar collectors down to the cylinder for heating of the water.
There are several solutions available to use in the solar thermal system. It has been decided that Tyfocor will be used in this system.
Tyfocor can be used at temperatures of up to 170 Celsius. The safety feature of the HP200 system means that this temperature will not be reached and it should not be a worry. 83

4.1.7 Installation and mounting of the solar system.
The Thermomax HP200 system can be installed in a variety of ways. These are shown below on the image.
The mounting option we have chosen to use is KSK0018 Awning Roof Kit. As we can see from the image above this is suitable for the Heat Pipe System we are installing. It will be placed on the south wall facing in a southerly direction with an angle of inclination at 37.4S. The recommended angle of inclination for the geographic location of Dublin is 37.4. This justifies the angle of inclination that we have chosen for this client. A technical drawing of this installation will be available in the appendices section of this report.
84

4.1.8 Installation of pipe work. The Solar Collector will be placed on an awning roof kit which will be placed on the south facade of the building. As it will be placed outdoors it will be necessary to penetrate the wall to fit the Aeroline pipe work. In order to cause minimum damage to the property of Dennis Grange Motors it will be necessary to use small bore holes that are sealed for protection of heat and from the elements. For this we will be using Link-Seal Modular Seal. The seal itself has a: Long life guarantee Protects against corrosion Temperature Resistant Can fit any size of pipe
85

4.1.9 Flow Meter
The flow meter is used to gauge and control the rate of flow for the heat transfer fluid. It is possible to control the flow of the fluid by using the valves on the flow meter. The flow meter is usually located within the pump station.
Sample Flow Meter
86

2.1.10 Expansion Vessel The expansion vessel is used to absorb the volume increase of the heat transfer fluid mix in the pressurised circuit as the temperature in the circuit increases. By using an expansion vessel in the system we can ensure that no damage will be done to the circuit or the solar thermal system as a whole as the increased volume can be contained in the vessel. The expansion vessel is basically a large tank that is fitted with an internal diaphragm. One side of the vessel is connected to the circuit itself which contains the water while the opposite side is basically full of air under pressure. There is a valve to allow the checking of pressure and to add more air if necessary. If the heating system is on the lower spectrum of use then the diaphragm will be pushed against the water inlet. As the pressure increases the diaphragm will move to increase the pressure on the air. Once compressed the air will cushion the pressure and relieve it, in essence, protecting the system. An 18 Litre Expansion Vessel comes as standard with the HP200 model.
Expansion tank included to the left.
87
4.1.11 Pressure Gauge As the name suggests the pressure gauge is fitted onto the system to monitor the pressure build-up within the circuit. It gives a graphical indication of the pressure within both the circuit and the cylinder. If the pressure was to get to much it could damage the system immensely and cause huge financial strain on the client. Normal working pressure would be 1 bar. A gauge measuring up to 4 bar should be sufficient.
88

4.1.12 Automatic Air Vent An automatic air vent is fitted at the highest point in the system. With out system as we are using 6m2 (Two 3m2 system) we would need to include two AAVs to ensure safety. An Automatic Air Vent purges air pockets from the system that may otherwise develop in liquid at high points within the circuit. The manufacturer recommends that with evacuated tube collectors the AAVs should be located on opposite ends of the collectors manifolds.
The fitting used for this installation will be a 22mm Spirax Sarco Solid Brass AAV.
89

4.1.13 Drain Valve A drain valve is used to drain unwanted liquid from the storage cylinder. Should a full drain of the system be needed this valve can be used to do this as it must be placed at the lowest point on the system. As with the other fittings a 22mm valve will be used in this system installation. 4.1.14 Pressure Relief Valve The pressure relief valve is an essential part of the safety components in the solar thermal system. Should the pressure in the system increase to an unmanageable level the pressure relief valve will open to relieve this. The PRV should have a minimum pressure relief of 3 bar. But for this installation we will be setting the pressure relieve to 6 bar. The valve must be positioned so that there is no restriction of flow between it and the
solar thermal collectors.
90

4.1.15 Thermostatic Mixing Valve The TMV is a valve which mixes hot water with cold water from the mains feed to ensure a safe output temperature for the clients use. As it is common practice to store hot water above 60 Celsius the need for the TMV is quite clear. For comfortable use of the hot water provided from the solar thermal system it is recommended to keep the water temperature below 50 Celsius (Max 48 Celsius) as temperatures above this can cause scalding. Installing a Thermostatic Mixing Valve can ensure that water is delivered at a comfortable temperature and it protects against legionnaires disease.
For this installation the ProMix 22-2 is to be used as it provides extreme stability of mixed water temperature even under varying conditions. It has a high flow design and can handle dynamic pressure.
91

4.1.16 Non Return Valve Non return valves are used to prevent backwards flow of water and the circulation of fluid when the pump is not active. For example, at night, when the storage cylinder is hotter than the collector the heat will try to flow in the direction of the solar collector. The non-return valve prevents this from happening.
92

4.1.17 Immersion Heater As mention before, all water should be heated to above 60 Celsius to prevent legionnaires disease. In order to ensure this an immersion heater can be used. This should be placed inside the storage cylinder as an back up to the solar thermal collectors.
93
5.0 Technical Calculations / System Components Sizing
94

5.0.1 Collector Area
The sizing of the collector area is one of the most important factors when designing a solar thermal system. The collector aperture area will determine how much energy we can extract from the sun. There are five factors when calculating the size of the collector array. 1. How many people require hot water (Usage) 2. Contribution of solar energy to the hot water load 3. Geographic Location 4. Orientation and Slope of the roof
5. Type of collector being used. Efficiency is also a factor when sizing the array. The collector area and the solar fraction (ratio of energy supplied by the sun as opposed to the required energy) also play a part.
95

The installer has to be careful when sizing the array as an oversized or even undersized array can damage the overall efficiency of the system. A high solar fraction will result in a higher temperature but a lower yield of solar irradiation. An oversized system will result in this higher solar fraction and hence lower yield An undersized system will result in low solar fraction and a higher yield A balance between these two is an ideal system.
The client is based in Ireland therefore a solar fraction of 55-60% is
normal. It has been assumed to be 60%
Above is a graphical representation of the previous summary.
96

5.0.2 Hot Water Demand
The amount of energy needed to heat the daily hot water demand is shown below.
QHW = Volume of Daily DHW x Cw x (T)
Summary:
QWH Daily Hot Water Demand DHW Domestic Hot Water Cw The Specific Heat Capacity of Water (This is 1.16 Wh/kgK or 4180 J kg-1 K-1) T The Temperature Difference between Incoming Cold and Required Hot Water
Calculation of the hot water demand is shown below.
DHW = 300 Litres Cw = 1.16Wh/kgK

97
Incoming Water Temp = 9.5 Celsius Required Water Temp = 60 Celsius Therefore: 300 x 1.16 x 50.5 = 17.574
98

5.0.3 Sizing of Collector Array
The formula for sizing the collector array is shown below:
This can be broken down to become the following:
No. of Days in Use 365 Hot Water Heat Req 17.574 Solar Fraction (Ireland) 60% ED = 384870.6
Yearly Irradiance (Dublin) 949 Av. System Eff. 73.0 (assumption) SD = 69277
So if
then
= 5.6m2
If a 5.6m2 size array is needed to heat 300 litres of water we will need a 6m2 system (2 x 3m2) Therefore a 60 tube system is to be installed for the client.
99

5.0.4 System Flow Rate
Kingspan recommend that a flow rate of no less than 60 Ltr/hour/m2 be used for pipe sizing in their Thermomax design guide.
This being said; the volumetric flow rate should be sized to ensure that it is large enough to cool the solar collector sufficiently. This will result in higher system efficiencies. The formula to determine flow rate is shown below:
m = Volumetric flow rate Q = Solar irradiance x collector efficiency W/m2 Cgw = Specific heat capacity of solar liquid. (Tyfocor LS = 0.98 Wh/kg K) = 10 K Solar Irradiance 949 Collector Efficiency 0.73 Specific heat capacity of solar liquid - 0.98 10 K Therefore M = 70.7 Ltrs/m2h Flow rate per tube =
= 1.18(m per min) x
60(tubes) = 7.08 ltrs/min

100

5.0.5 Pipe Sizing
The formula to determine the inside diameter of the pipe work is shown below:
i= 4.6
i Internal Diameter Vs System Flow Rate V Velocity of Fluid (m/s)

Therefore:
i= 4.6
= 20.4mm
The internal pipe size we have calculated is 20.4. The manufacturer recommends a 22mm pipe sizing for a 6m2 array so we will use this size.
101

5.0.6 Pump Sizing
When sizing a pump we need to take into account the flow rate and the head height of our array. We have calculated that the flow rate for our system is 7.08 ltrs/min. This will work out at 0.118ltrs/sec. From the chart below we can determine which pump setting should be used. It should be noted that a lot of installers set the pump setting to speed 3 as standard. This can be wasteful and unnecessary costly. Proper care and careful calculations should be used when determining the pump speed setting.
The above image is the speed setting graph for the KSP0020
102

As we can see that as we have a head height of 7 meters and a flow rate of .118ltrs/second we should have the pump on speed setting 2. The pump being used for this installation is the KSP0020.
103

5.0.7 Expansion Vessel Sizing
The expansion vessel can only be determined once we know the temperature rise expected; charge and blow off pressures and also the amount, or volume of heat transfer liquid that will be in the system. The expansion vessel is essential to the system as a whole. It protects against pressure rises and increased volumes. The following formula determines that sizing of an expansion vessel:
Vev Expansion Vessel Size Vv Safety Seal Vd Collector Volume Expansion Co-efficient of Heat Transfer Liquid Pe Safety Valve Rating -10% Po Minimum Working Pressure Vv 3 Litres (Recommended) Vd 3.4 0.085 (0.085 x 100/1 = 8.5%) Pe 5.4 + 1 = 6.4 Po 6.4 3.9 = 2.5 A 30L Expansion Vessel is required.
104
6.0 Stagnation Prevention
105

6.0 Stagnation Prevention
Although the HP 200 System has in place a Temperature Snap to prevent temperature rising above 135Celsius one should understand it is important to understand how to prevent stagnation. Stagnation is something that should be avoided at all costs. Temperatures in excess of 170 Celsius over a long period of time will cause stagnation of the heat transfer fluid within the system. The Tyfocor will degrade and its inhibitor properties also. This is evident by a brown colour appearing rather than the pink colour it should be. The solution should be tested each year and if necessary it should be replaced. It is possible to do this with a refractometer and some ph paper. Stagnation can occur for a number of reasons such as: Oversized Systems Undersized expansion vessels Air Locks within the System Poor Set Up of the System Prolonged Periods of Low Hot Water Demand
To prevent this, the manufacturer supplies a range of options. Heat can be dissipated through an emitter such as a radiator. Kingspan option A (Thermomax Design Guide) provides a system which monitors the system and will dissipate heat through a radiator that is connected on the solar side of the cylinder. The control panel has several options such as stagnation prevention and a thermostat that monitors temperature levels.
106

Should the temperature rise above a preset level (usually 80 Celsius) that heat will be diverted out through the radiator until the temperature is reduced to a set level (usually 60 Celsius).
107
7.0 Working at Height Risk Assessment
108

7.0 Working at Height and Risk Assessment
Working at height can always be a dangerous activity for any installer. While undertaking this installation we must be vigilant and respect the dangers associated with it. Regulations state that we must carry out a risk assessment on the site before starting work. Arrangements must be put in place for the following: Eliminating or minimising risks from working at height Safe systems for selecting suitable working equipment Avoid the risk if not working at height if possible. (This isnt possible in this installation) Safe systems of work for organising and performing work at height Safe systems for protecting people from the consequence of working at height The regulations and guidances outline practice for safe work at height. Falls should be prevented where at all possible. Especially when it is not practicable to avoid working at height. If this is the case you a required to take suitable and reasonable steps to ensure the safety or the installers while working at height. This is includes selecting the most suitable working equipment. This must be done in accordance with regulations. If steps cannot be put in place to prevent working at height an investigation into the consequences must be carried out. This includes taking measure to: Minimising the height (if possible) 109

Erecting guard rails on scaffolding Safety harnesses should also be considered
Priority should be given to safety rails over safety harnesses as prevention of a fall should be considered before protection during a fall. Within the regulations you are required to do the following: Follow the hierarchy of safe working at height regulations Assess the risk to help you decide how to work safely Make sure the installer working at height is responsible and competent Organise and plan work according to external risks such as weather, time of day and possible emergencies Manage risks from working on or around fragile surfaces Beware of falling objects Make use of appropriate work equipment Inspect the place of work and observe the working equipment regularly. These are the requirements of that must be observed when installing a Solar Thermal System.
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8.0 References
Material Type
PDF PDF PDF PDF PDF PDF PDF PDF Website Website Website PDF PDF PDF PDF PDF PDF PDF PDF PDF PDF PDF PDF PDF Website Website Website Website
Author
Kingspan Ltd. Kingspan Ltd. Kingspan Ltd. AEROLINE TUBE SYSTEMS BAUMANN GMBH Tyforop Chemie GMBH Kingspan Ltd. Alternative Energy Ireland Promix AEROLINE TUBE SYSTEMS BAUMANN GMBH Pipeline Seal & Insulator, Inc. Spirax Sarco Thorlux Lighting Ltd. Thorlux Lighting Ltd. Thorlux Lighting Ltd. Thorlux Lighting Ltd. Thorlux Lighting Ltd. Thorlux Lighting Ltd. Thorlux Lighting Ltd. Thorn Lighting Ltd. Thorn Lighting Ltd. Thorlux Lighting Ltd. Thorlux Lighting Ltd. CIBSE Francis Rhubinstein SEAI ESB Phillips Osram
Reference List
Thermomax Design Guide Thermomax HP200 Thermomax Leaflet Product Range Tyfo Data Thermomax Installation Guide Brochure 2009 Promix 22-2 http://www.tubesystems.com/ http://www.linkseal.com/ http://www.spiraxsarco.com/ie/ Solow T5 Smart Solow XL Smart Juno Exterior Light XL-Five Prismatic CL-Five Micro Bloc Prismalux Base LED Jupiter II Light Management System Light Management System - POD Lighting Guide Highbay lighting guide www.seai.ie www.ESB.ie http://www.lighting.philips.ie/ http://www.osram.com.sg/osram_sg/
Accessed
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Karl Phelan - Electrical Lighting Design &amp; Solar Thermal Hot Water Installation

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Karl Phelan B00036379

B00036379 BN039 BSc in sustainable and electrical control systems 2

Karl Phelan B00036379

May 3rd 2011

By Karl Phelan Student ITB

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

3.0 Electrical Lighting Design Installation

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Below is a sample of a similar set up.

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Lighting Design Components

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Installation Guide in appendices.

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan B00036379

Karl Phelan - Electrical Lighting Design & Solar Thermal Hot Water Installation

Karl Phelan - Electrical Lighting Design & Solar Thermal Hot Water Installation