TCT Solar PROGRESSIV TUBE Installation And Operation Manual Download

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TABLE OF CONTENTS

Introduction

II.

Utilization

III.

System Characteristics

IV.

Pre-Installation Check List

Installation Precautions

VI.

Collector Orientation

VII.

Collector Mounting Hardware Options

VIII.

Roof Mounts

Load Bearing and Bracing

Roof Piping and Penetrations

Roof Mount Penetrations

South/North Roof Mounts

East/West Roof Mounts

Tile Roof Installations
1. On Top of Tile
2. Flush To the Roof

IX.

Ground Mounts

System Plumbing

XI.

System Insulation

XII.

Freeze Prevention

XIII.

Two or More collector Systems

XIV.

Direct Systems

XV.

Start Up Procedures

XVI.

Drain Procedures

XVII.

Maintenance and Operation

APPENDIX

SRCC

Section

FSEC

Section

INSTALLATION

DETAILS

TYPICAL ROOF BRACING

YOUR

NOTES

Please read and understand Installation and Operations Manual and safety
messages before installing, operating or servicing this solar water heater. Failure
to follow instructions and safety messages could result in death or serious injury.

Summary of Contents for PROGRESSIV TUBE

Page 1: ...Water Heater INSTALLATION and INSTALLING CONTRACTOR A Factory Direct Distributor of Solar Thermal Products and Equipment 6935 15th St E Suite 120 Sarasota FL 34243 Phone 941 360 9276 941 359 3848 Fax...

Page 2: ...s 1 On Top of Tile 2 Flush To the Roof IX Ground Mounts X System Plumbing XI System Insulation XII Freeze Prevention XIII Two or More collector Systems XIV Direct Systems XV Start Up Procedures XVI Dr...

Page 3: ...ality construction of the solar collector will provide you with years of energy saving trouble free operation HOT OUT COLD IN COLD OUT INSULATED PIPE HOT OUT The solar energy systems described by this...

Page 4: ...to the conventional gas electric water heater or as a conventional water heater only with the PROGRESSIVTUBE collector by passed The SRCC certified OG 300 system is a three way system designed for us...

Page 5: ...to illustrate proper installation techniques To ensure trouble free operation all installation work should be performed by qualified licensed contractors and in accordance with all local codes III SY...

Page 6: ...t Cold Water In 11 inlet outlet 5B 10 SRCC OG 300 3 WAY SYSTEM 9 11 9 inlet outlet COLD HOT MIX 8 7 6 5B 5A 4 3 2A Hot Water Out Cold Water In Cold Water Inlet Hot Water Outlet 1 2B 10 2 WAY SYSTEM FO...

Page 7: ...uality that meets these warranty criteria If water is too acidic pitting corrosion can occur If the situation is prolonged the corrosion action can result in pin hole leaks in the tubes Pitting corros...

Page 8: ...een 10 00 a m and 3 00 p m The location should be as close as possible to the conventional water heater to minimize the piping run which should not exceed 75 feet For optimum performance in the northe...

Page 9: ...g A Fixed Mount For installation parallel to the roof PTMS PTMS Part List A Clamps Qty 4 B Mounting Brackets Qty 4 C 3 8 x 1 Hex Head Cap Screws Qty 4 D 3 8 X 2 HEX HEAD CAP SCREWS QTY 4 E 3 8 Lock Nu...

Page 10: ...ion with additional angle of the roof or ground mounting Include Standoff Rear Legs STS STS PART LIST G Rear Leg Sq Tube 1 ft 2 ft 3 ft or 4 ft sq tube NOTE STANDOFF REAR LEGS INCLUDE H 3 8 x 2 Hex He...

Page 11: ...N 2 Foot 4 7 8 85 PT 30 CN 1 Foot 35 5 16 17 PT 30 CN 2 Foot 29 1 8 38 PT 30 CN 3 Foot 12 5 8 70 PT 40 CN PT 50 CN 1 Foot 47 13 PT 40 CN PT 50 CN 2 Foot 43 5 16 28 PT 40 CN PT 50 CN 3 Foot 34 45 PT 40...

Page 12: ...d mounting hardware have been wind load tested to 180 mph and hundreds of units have survived storms with winds in excess of 180 mph The structural integrity of a collector is most important when cons...

Page 13: ...he pipe penetrations are downhill from the collector connections Water will not drain uphill DRAWING D COPPER PIPE SHINGLE INSULATOR CAULKING SHEATHING COOLIE HAT ROOFING FELT C Roof Mount Penetration...

Page 14: ...on in tone associated with external hammer blows to locate the run of the truss Most roofs are either asphalt or fiberglass shingles They are stapled or nailed in an overlapping pattern over the felte...

Page 15: ...the edge of the collector should be in parallel with the roof ridgeline The Fixed Mount system raises the collector approximately 2 5 inches above the roof to allow air to circulate under the collecto...

Page 16: ...t use the Adjustable Tilt Mount system The mounts are anchored to parallel rafters and the collector is installed perpendicular to the roof plane facing south at an angle equal to local latitude This...

Page 17: ...a hammer and removed or for a cleaner and quicker installation sawed out Remove as few tiles as possible because the area must be totally sealed upon the completion of the mount bracket installation...

Page 18: ...ng the tile slide the back of it under the first tile above the J Bracket Be sure to apply generous amounts of caulking compound between the sized tile the roof and the J Bracket The sized tile should...

Page 19: ...ermanent foundation A concrete HVAC pad or four standard concrete piers embedded at least halfway in the ground are the recommended foundations see Drawing J Be sure to coat the threaded end of the bo...

Page 20: ...ED FOUNDATION FOR GROUND MOUNT INSTALLATION FRONT VIEW STANDARD CONCRETE PIER 50 TO 60 48 TO 50 FOR PT 40 CN AND PT 50 CN 36 TO 37 FOR PT 30 CN 22 TO 23 FOR PT 20 CN SIDE VIEW THREADED J BOLT EMBEDDED...

Page 21: ...TORAGE TANK VACUUM BREAKER OR BOILER DRAIN BOILER DRAIN MAKE SURE PIPES ARE BELOW FROST LINE IN COLD CLIMATES COPPER PIPE INSULATE PIPES WITH PROPER UNDERGROUND INSULATION PRESSURE RELIEF CONSULT SYST...

Page 22: ...bronze or brass valves rated at 400 psi W O G and 100 psi at 3000 F There must be a shut off valve on the cold water supply and boiler drains on the supply and return sides of the solar loop It is re...

Page 23: ...r Some local codes will allow both valves to share the same drain line some will not A check valve is used only if a freeze prevention valve is installed It should be installed in the return solar loo...

Page 24: ...valve such as the Eaton Dole FP 35 The valve should be installed according to the manufacturer s recommendations and Drawing L on the return solar loop piping between the collector and the roof consul...

Page 25: ...INSULATE C x F Flush Bushing Copper pipe INSULATE To Storage Tank Drain Port Or x F Adapter may be used instead of bushing Valve must be installed with drain port down Caution Do not solder near Freez...

Page 26: ...7 17 2 22 5 26 8 33 5 21 16 6 21 8 26 0 32 5 15 6 20 5 24 4 30 5 20 15 3 20 0 23 8 29 8 14 3 18 8 22 4 28 0 19 14 1 18 5 22 0 27 5 13 3 17 4 20 7 25 9 18 13 1 17 2 20 5 25 6 12 3 16 1 19 2 24 1 17 12...

Page 27: ...rs are tilted up the piping can run behind them making a much cleaner looking installation The Alternative Configuration has improved aesthetics by flipping the second collector around so the pipe nip...

Page 28: ...ficiency see Drawing P Supply and return lines for multiple collector systems should be 1 diameter for systems up to four collectors 1 5 diameter for six collectors 2 diameter for ten collectors For l...

Page 29: ...ROOFS THIS POSITION MUST BE WITHIN 15 OF ROOF CROWN THIS POSITION MUST BE OVER A LOAD BEARING WALL THIS POSITION IS NOT ALLOWED DRAWING O MAXIMUM DISTANCE COLLECTOR MOUNT FROM ROOF CROWN 15 WEST FACIN...

Page 30: ...er lines a minimum 20 length of copper pipe must be plumbed to the collector s inlet and outlet connections CPVC can then be connected to the copper pipe CPVC cannot tolerate water temperatures above...

Page 31: ...loop piping Open the boiler drain on the return side 4 It is most important that the unit be vented to the atmosphere before and while being filled It is recommended that the collector be filled befo...

Page 32: ...he cold water supply A homeowner can tell if their system is working by turning on a hot water faucet in the house and allowing it to run for several minutes For Direct Systems this test is very simpl...

Page 33: ...ng the temperature difference between the supply and return piping Again these tests are best performed during the afternoon of a clear sunny day If the system is to be unused for a long period of tim...

Page 34: ...e freezing might occur must have a minimum of 1 5 of Rubatex or Armaflex pipe insulation or some other form of pipe insulation that has an R value of 10 7 or greater 6 There must be a cold water shut...

Page 35: ...ed in this system Warning Water could be discharged at high temperature and or pressure Open This Valve Before Filling Place a hose on or a bucket under this drain valve Open this valve The collector...

Page 36: ...r Out Cold Water In Cold Water Inlet Hot Water Outlet 1 2B 11 1 Supply Shut Off Valve 2 3 way Ball Valve 3 2 way Ball Valve 4 Tempering Valve 5 Boiler Drain 6 Pressure Relief Valve 7 Conventional Wate...

Page 37: ...r attempts as determined by the Manufacturer the Manufacturer will provide either a refund for the purchase price or a replacement Product at Manufacturer s option 4 FIVE YEAR LIMITED WARRANTY During...

Page 38: ...R HEATER ALSO ACTS AS BACKUP IF NEEDED GOOD FOR YEAR ROUND OPERATION 1 Supply Shut Off Valve 2 3 way Ball Valve 3 2 way Ball Valve 4 Tempering Valve 5 Boiler Drain 6 Pressure Relief Valve LEGEND A SOL...

Page 39: ...tie Label must read as follows SEE LABEL B 5 Give homeowner a copy of the Owner s Manual FSEC Certifications Warranty and local phone number of the installing contractor Go over all operations of the...

Page 40: ...some other means taken to vent the collector to the atmosphere could damage your system and void the warranty 2 Way System for Gas Water Heaters 2 Way System for Electric Water Heaters 8 7 6 5B 5A 4...

Page 41: ...ar Pre Heat Gas 2 Way System COLD HOT MIX 8 7 6 5B 5A 4 3 2 Hot Water Out Cold Water In Cold Water Inlet Hot Water Outlet 1 From Solar To Solar Closed Solar By Pass Instantaneous Gas 2 Way System 7 6...

Page 42: ...have at least one spacer block or rafter between bolts Roof Sealant Required between mounting block and shingles sheathing Boltholes shall be sealed to prevent moisture penetration Mounting Blocks Th...

Page 43: ...er Roof Sealant Required between mounting block to and shingles sheathing Bolt holes shall be sealed to prevent moisture penetration Fill bolthole with sealant prior to inserting bolt Mounting Blocks...

Page 44: ...will be required on the opposite side of the bolt away from the rafter 3 Two spacer blocks are required when the bolt is more than 2 from the rafter 4 When the mounting clips of adjacent collectors ar...

Page 45: ...IFY MAXIMUM DIMENSION NOTE 1 The bent portion of the J Bolt shall not be threaded 2 Roof Sealant is required between mounting block and shingles sheathing Boltholes shall be sealed to prevent moisture...

Page 46: ...ADED THRU BOLT 3 8 MIN CAT 2 X 4 MIN IF RAFTERS ARE 2 X 4 ONE 2 X 8 SHOULD BE USED BETWEEN RAFTERS WITH 4 16D NAILS IN EACH END 2 16D NAILS AT END OF EACH CAT NOTE Cat s must fit tight between rafters...

Page 47: ...E TANK S ELECTRICAL JUNCTION BOX COVER INSULATION SHALL NOT COVER THE ACCESS AREAS TO THE THERMOSTATS ELEMENTS TANK S OUTER SHELL SUPER INSULATION OPTION If a junction box is installed on the outer sh...

Page 48: ...usually used when the collector is installed flush to a roof as in tile roof installations Sweat a copper 90 short radius L directly onto the inlet and outlet connections of the collector Protect the...

Page 49: ...aused by a defect in the unit 1 Repairs should be performed in the morning hours before the sun can heat the tank It is best to pick a morning when there is no wind to interfere with the removal of th...

Page 50: ...ver the leak area with a generous amount of solder 9 Replace the tank by pushing the inlet and outlet connections through the holes in the insulation and out the frame Allow the tank to drop into plac...

Page 51: ...should follow acceptable carpentry and construction techniques if additional measures are needed If the contractor has any questions or concerns then a structural engineer should be consulted SIDE VIE...

Page 52: ...ROOF 3 8 X 4 LAG BOLT 3 8 X 4 LAG BOLT ROOF BEAM 2 X 4 X 48 NOMINAL STRINGER 3 8 X 3 LAG BOLT 3 8 X 3 LAG BOLT FRONT VIEW 3 8 X 4 LAG BOLT 3 8 X 4 LAG BOLT ROOF ROOF BEAM 3 8 X 3 LAG BOLT 2 X 4 X 48 N...

Page 53: ...OTHER WIDE RAFTER SPANS 3 8 X 4 LAG BOLT ROOF 3 8 X 4 LAG BOLT 4 X 4 PURLIN ROOF BEAM SIMPSON U44 HANGER 48 SIMPSON U44 HANGER 3 8 X 12 LAG BOLT 3 8 X 5 LAG BOLT ROOF BEAM ROOF 4 X 4 PURLIN 3 8 X 12 L...

Page 54: ...YOUR NOTES 54...

Page 55: ...water consumption pattern daily weather conditions and variable amounts of available sunlight throughout the year The collector storage tank of the ProgressivTube absorbs solar radiation through its...

Page 56: ...homeowner is imme diately in a positive cash ow position because the utility savings are far greater than the mortgage SUPERIOR CONSTRUCTION GLAZING GASKETS A continuous gasket made of special long l...

Page 57: ...y PT 50CN 28 700 BTU Day Flow Pattern Series Test Pressure 300 PSI Design Pressure 150 PSI Maximum Design Temperature 350 F Normal Operating Temperature 40 200 F Wind Loading Testing to 180 MPH SPECIF...

Page 58: ..._______ ROI 1 Call for Your Cost on a Complete Do It Yourself Kit or Installation 2 Based on 72 F incoming water heated to 140 F in Florida with an electric rate of 0 10 per kilowatt plus standby heat...

Page 59: ...water consumption pattern daily weather conditions and variable amounts of available sunlight throughout the year The collector storage tank of the ProgressivTube absorbs solar radiation through its s...

Page 60: ...in a positive cash flow position because the utility savings are far greater than the mortgage payment increment for the solar water heater SUPERIOR CONSTRUCTION GLAZING GASKETS A continuous gasket m...

Page 61: ...400 BTU Day 8 33 kWh PT 50CN 28 700 BTU Day 8 42 kWh Flow Pattern Series Test Pressure 300 PSI Design Pressure 150 PSI Maximum Design Temperature 350 F Normal Operating Temperature 40 200 F Wind Loadi...

Page 62: ...OI 1 Call for Your Cost on a Complete Do It Yourself Kit or Installation 2 Based on 72 F incoming water heated to 140 F in Florida with an electric rate of 0 10 per kilowatt plus standby heat loss fro...

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