DEVELOPMENT AND TEST OF AN INTELLIGENT WEB-BASED FUNCTIONALITY CHECK FOR SOLAR HEATING SYSTEMS

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1 DEVELOPMENT AND TEST OF AN INTELLIGENT WEB-BASED FUNCTIONALITY CHECK FOR SOLAR HEATING SYSTEMS SS Sandra Stettler 1 ; BS Bruno Schläpfer 2 ; RR Roger Ruch 3 ; AS André Salathé 3 ; PW Peter Wiesner 3 ; FK Franz Koch 3 ; WG Werner Gut 4 ; TS Thomas Schlegel 5 1: Egon AG, General Wille-Str. 59, CH-8706 Feldmeilen; energie@egonline.ch; 2: Ernst Schweizer AG, Metallbau, Geschäftsbereich Sonnenenergie, Bahnhofplatz 11, CH Hedingen, info@schweizer-metallbau.ch; 3: Industrielle Werke Basel, Margarethenstrasse 40, CH-4002 Basel, info@iwb.ch; 4: Steca Elektronik GmbH, Mammostrasse 1, D Memmingen, info@steca.com; 5: Meteotest, Fabrikstrasse 14, CH-3012 Bern, office@meteotest.ch; ABSTRACT Several field studies showed, that up to 1/3 rd of the solar thermal systems in Switzerland are substantially less effective than predicted or do not work at all. So far, no effective and wellpriced devices exist, which visualise and analyse the solar energy produced by solar thermal systems. In this project we develop a web-based functionality check using measurement data from the solar controller. With the aid of this functionality check, the efficiency of solar thermal systems shall be increased. The development process started in December 2012 and will be finished in autumn Until spring 2014, the functionality check will be tested in a field test with 10 solar thermal systems. The project team consists of 5 companies that are experienced as energy engineers, web-programmers, solar system owners, system providers, service staff and manufacturers of controllers and collectors. The goals of this team are: - assure an ideal system operation - support service and trouble-shooting of solar thermal systems - communicate and visualise the successful operation of the solar systems The function principle is quite simple: There exist solar controllers on the market that can measure and store all relevant system data e.g. in 1 minute intervals. These data sets are uploaded periodically to a web portal where the intelligent functionality check is hosted. This web portal offers individual functions for system owners, service staff and manufacturers. It visualises the energy production of the system as well as the other measurement data sets. It performs a detailed operating analysis of solar circuit, storages, stagnation, pumps, volume flow and power. The results of these analyses are available for the service staff and give them significant hints for optimising and trouble-shooting the solar systems. The web-based intelligent functionality check is tested during 12 months of field test with 10 solar thermal systems. Afterwards, the web-portal will also be made available for companies outside the project team.

2 Keywords: advanced control tool; solar heating systems; innovative solar controller; intelligent analysis algorithms; concurrent meteorological data; online information exchange INTRODUCTION Our Motivation: Increase the efficiency of solar thermal systems Solar thermal collectors can provide a substantial part of the heating energy of a building. But the owners of solar systems are mostly unaware of the amount of solar energy produced daily on their roof. So far, no effective and well-priced devices exist, which visualise and analyse the solar energy produced by solar thermal systems. Such a device is important for the owners, manufacturers and service-providers of solar thermal systems: - Several field studies showed, that up to 1/3 rd of the solar thermal systems in Switzerland are substantially less effective than predicted or do not work at all. With an intelligent functionality-check the operational reliability of solar systems would be enhanced. Amortisation time of the systems could be reduced thanks to higher productivity. - For photovoltaic systems it is a standard to visualize and control the solar electricity production with data loggers and web portals. This transparency makes photovoltaic systems more attractive to potential customers than solar thermal systems. - To place a solar thermal system into operation is a difficult task, especially if no information about the actual operating conditions exists. And trouble-shooting gets a time-consuming try and error work if no measurement data are available. Our Project Team: a strong consortium of engineers, solar system owners and the industry Thus, five companies have started a common project to develop and test an intelligent webbased functionality-check for solar thermal systems. These companies are: - Egon AG: An energy engineer office with experience in the development of webbased monitoring and control systems for energy consumption and production. - Ernst Schweizer AG, Metallbau: One of the main manufacturers of solar thermal collectors in Switzerland. Ernst Schweizer AG also sells complete solar thermal systems, puts them into operation and provides trouble-shooting. - Industrielle Werke Basel: The energy provider of the city of Basel offers a successful heating contracting. Industrielle Werke Basel owns and operates several hundreds of heating systems for their clients. A substantial part of them is equipped with a solar thermal system. - Steca Elektronik GmbH: Besides other electronic equipment, Steca Elektronik GmbH manufactures solar thermal controllers. Some of them can store measurement data of all important control points. These data are stored on a SD card or transferred via internet to a web server and thus made available for visualisation and analysis. - Meteotest: This meteorological office is specialized into web-based meteorological services. An important business segment are services for the solar energy sector. Besides these five companies, the project is also funded by the SFOE (Swiss Federal Office of Energy).

3 Our Goals: assure the ideal system operation, support service and trouble-shooting, communicate and visualise the successful operation of solar systems Together we will develop and test an intelligent web-based functionality check for solar thermal systems. With this check, the following goals shall be reached: - Assure that the solar thermal systems work properly. Thanks to an ideal regulation of the solar system, the efficiency is enhanced and amortisation time is shortened. - Support service staff in case of trouble-shooting and putting systems into operation. Thanks to intelligent analyses, the check shall detect s and potential for optimisation. Early warnings in case of s prevent from severe long-term damages of the system parts. - The internet offers multifaceted possibilities to visualise the energy production and successful operation of the system to different user groups: to the service staff and the system owner, but in special formats also to the public, potential customers for solar thermal systems, authorities etc. METHOD A Comprehensive Function Principle: Data logging with the existing solar controller; visualisation and data analysis on a web portal with individual functions for system owners, service staff and manufacturers Main premise for visualisation and analysis of solar thermal systems is the collection of measurement data. This can be performed without any extra costs: Several controller manufacturers (e.g. Steca Elektronik GmbH), offer solar controllers that do not only control the solar thermal system but at the same time store all operating data on a SD card or transmit it via internet to a server of the manufacturer. Typical measurement data are 1-minute values of all relevant temperatures, pumps and switches, often also volume flow and energy production The measurement data are regularly uploaded to the web-server hosting the functionality check. Additionally, concurrent meteorological data (ambient temperature and solar irradiance) are fetched from weather satellites and nearby weather stations. After each import of measurement data, the measurement values are visualised on the web page and the functionality of the system is checked. The analysis results are made available for the service staff. The web portal also generates yearly PDF-reports for each system, which summarize its energy production and condition. The development of the web portal started in December 2012 and will be finished in autumn Months of Field Test with 10 Solar Thermal Systems The intelligent web-based functionality check is tested until spring 2014 with at least 10 typical solar thermal systems. They are chosen from Industrielle Werke Basel s population of solar thermal systems. All systems will be equipped with a solar controller that can store all operating data in 1-minute intervals. Additionally to the temperatures of the solar collector and the storages, also temperatures of the solar flow and return are measured. To allow for a calculation of the energy production, the volume flow is measured too. Figures 1 to 4 show pictures of some chosen solar systems.

4 Figure 1: Test system on a flat roof with 36 m 2 collector area. Source: Google Earth Figure 2: Test system on an inclined roof. Source: Lützelschwab GmbH Figure 3: Photo of the storage, pump and controllers of a test system. Source: Egon AG Figure 4: Example of a solar thermal controller. Source: Steca Elektronik GmbH RESULTS At the moment (April 2013), the web portal is still in the development phase. Figures 5 and 6 show a few PrintScreens of the actual status of the web portal. Detailed operating analysis of solar circuit, storages, stagnation, pumps, volume flow and power All measurement data are aggregated on a daily and monthly basis to provide significant system information for the service staff. Which analyses shall be performed was intensely discussed with service staff for solar thermal systems. Table 1 shows the analyses that are performed for the pump of a simple solar thermal system with just one collector field and one storage. Some of the analysis results have only informative character and are marked as info. Others detect system s and are marked as. The analysis methods will be tested and further developed during this project.

5 Figure 5: PrintScreen of overview page of the web portal. All solar thermal systems of the logged-in user are presented with photo, name, address and further important information. By clicking on a system, detailed information like measurement data and analysis results can be displayed. Figure 6: PrintScreen of the import page for a chosen solar system called Stiftung Solvita. At light grey days, no measurement data has been imported yet, at dark grey days measurement data has been imported successfully. At striped days the imported measurement data was not complete. If the imported measurement data would contain non plausible values, such days would be signed with a red cross.

6 Name Description Character Runtime 100% Runtime of the pump in hours. Sum of all minutes, info during which the pump was 100% (60 seconds) on. Total runtime Runtime of the pump in hours. Sum of all minutes, info during which the pump was on (1 to 60 seconds). Expected runtime Number of hours, when the irradiance as well as info collector and storage temperature indicate that the pump should be on. Pump off despite deltat Number of hours during which the pump was off, although storage and collector temperatures indicate that Pump on without deltat Pump on at stagnation Pump on when storage full the pump should be on. Number of hours during which the pump was on, although the temperature difference between collector and storage was too small to operate the solar system. Number of hours during which the pump was on, although the collector temperature exceeded its maximum operating temperature Number of hours during which the pump was on, although the storage temperature exceeded its maximum temperature. Table 1: List of the analyses performed for the solar pump of a solar thermal system A further focus of the tests is the calculation of a reference energy yield based on solar irradiance and ambient temperature with the following formula: Y = A R I η 0 IAM a 1 T F + T R a 2 2 T 2 F + T R (1) 2 where: Y = reference yield (Wh) A = total aperture area of the solar system (m 2 ) R = expected runtime (hours) I = irradiance on collector plane (W/m 2 ) η 0 = optical efficiency (-) IAM = incidence angle modifier (-) a 1 = 1 st order heat loss coefficient (W/m 2 /K) a 2 = 2 nd order heat loss coefficient (W/m 2 /K 2 ) T F = temperature of solar flow (K) T R = temperature of solar return (K) The comparison of this reference energy yield with the measured effective yield shall help to detect system s and to judge the effectiveness of the system. DISCUSSION & OUTLOOK The project partners Ernst Schweizer AG and Industrielle Werke Basel will use the intelligent web-based functionality check to improve the efficiency of their solar thermal systems, to simplify service and for trouble-shooting. Through these two companies, the web-based functionality check will also be provided directly to their installers and system owners. Egon AG will provide customized versions of the intelligent web-based functionality check also for other companies.

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