TCT Solar ProgressiceTube Installation And Operation Manual Download

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TCT S

OLAR

101 Copeland Street

Jacksonville, Florida 32204

www.tctsolar.com

[email protected]

ROGRESSIV

UBE

Passive Solar Water Heater

INSTALLATION

and

OPERATIONS MANUAL

Summary of Contents for ProgressiceTube

Page 1: ...TCT SOLAR 101 Copeland Street Jacksonville Florida 32204 www tctsolar com techsupport tctsolar com PROGRESSIVTUBE Passive Solar Water Heater INSTALLATION and OPERATIONS MANUAL...

Page 2: ...ons 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...

Page 3: ...quality construction of the solar collector will provide you with years of energy saving trouble free operation The solar energy systems described by this manual when properly installed and maintained...

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: ...ed 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...

Page 6: ...Out 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...

Page 7: ...quality 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 corr...

Page 8: ...tween 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 nort...

Page 9: ...ing 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...

Page 10: ...lation 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...

Page 11: ...T 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 45 CN PT 50 CN 1 Foot 47 13 PT 40 CN PT 45 CN PT 50 CN 2 Foot 43 5 16 28 PT 40 CN PT 45 CN PT 50 CN 3 Foot 34...

Page 12: ...and 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 c...

Page 13: ...e the pipe penetrations are downhill from the collector connections Water will not drain uphill C Roof Mount Penetrations Roof penetrations for mounting the collector can be any of the methods shown i...

Page 14: ...ation 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 fe...

Page 15: ...th the roof ridgeline The Fixed Mount system raises the collector approximately 2 5 inches above the roof to allow air to circulate under the collector and to prevent debris from accumulating along th...

Page 16: ...This installation is sometimes referred to as a sawtooth position For east or west facing roofs the piping connections should always face downwards see Drawing I When installed on a west roof the inle...

Page 17: ...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 to protect the underlying wat...

Page 18: ...izing 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 sho...

Page 19: ...e permanent 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...

Page 20: ...FOUNDATION FOR GROUND MOUNT INSTALLATION FRONT VIEW 50 TO 60 48 TO 50 FOR PT 40 CN PT 45 CN AND PT 50 CN 36 TO 37 FOR PT 30 CN 22 TO 23 FOR PT 20 CN STANDARD CONCRETE PIER SIDE VIEW THREADED J BOLT E...

Page 21: ...N STORAGE 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 S...

Page 22: ...use 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...

Page 23: ...ater 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...

Page 24: ...on 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 con...

Page 25: ...Do not solder near Freeze Valve Do not over tighten Use pipe dope or Teflon tape Do not insulate Freeze Valve From Collector C x F Flush Bushing 12 DO NOT INSULATE Or x F Adapter may be used instead o...

Page 26: ...35 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...

Page 27: ...ctors 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...

Page 28: ...efficiency 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 Fo...

Page 29: ...ITS ON SOUTH ROOFS THIS POSITION IS NOT ALLOWED THIS POSITION MUST BE WITHIN 15 OF ROOF CROWN THIS POSITION MUST BE OVER A LOAD BEARING WALL SUPPLY LINE RETURN LINE WEST FACING ROOF EAST FACING ROOF M...

Page 30: ...f 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 1600 F so the 20 copper stubs...

Page 31: ...lar 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 b...

Page 32: ...k the 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 si...

Page 33: ...aring 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...

Page 34: ...re 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: ...used 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 collect...

Page 36: ...lector Storage with Electric Water Heater PT 20 CN G ProgressivTube Integral Collector Storage with Gas Water Heater PT 30 CN G ProgressivTube Integral Collector Storage with Gas Water Heater PT 40 CN...

Page 37: ...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 Water Heater 8 Temper...

Page 38: ...e Integral Collector Storage with Tankless Water Heater PT 50 CN TL ProgressivTube Integral Collector Storage with Tankless Water Heater 12 Supply Shut Off Valve 13 3 way Ball Valve 14 2 way Ball Valv...

Page 39: ...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 40: ...Valve 4 Tempering Valve 5 Boiler Drain 6 Pressure Relief Valve LEGEND A SOLAR DIRECT USE ONLY DURING SPRING THROUGH FALL FOR MAXIMUM SAVINGS SHUT OFF BREAKER TO ELECTRIC WATER HEATER B SOLAR PRE HEAT...

Page 41: ...approved systems 1 The FSEC Approved Solar Energy System plumbing schematic must be followed when installing the system 2 All standards in the FSEC GP 7 80 must be met 3 Place the Freeze Protection s...

Page 42: ...r be vented to the atmosphere during refilling Refer to the Owner s Manual or the directions on the other side of this tag Only potable water is to be used in this system WARNING WATER COULD BE DISCHA...

Page 43: ...MIX 8 7 6 5B 5A 4 3 2 Hot Water Out Cold Water In Cold Water Inlet Hot Water Outlet 1 9 11 9 inlet outlet 10 7 6 5B 5A 4 3 2 Hot Water Out Cold Water In Cold Water Inlet 1 9 COLD HOT MIX 11 9 inlet ou...

Page 44: ...Solar 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...

Page 45: ...lock or rafter between bolts Roof Sealant Required between mounting block and shingles sheathing Boltholes shall be sealed to prevent moisture penetration Mounting Blocks This drawing shows the use of...

Page 46: ...eter 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 PT BASE MOUNT...

Page 47: ...container and shingles sheathing and between surfaces of mounting block and pitch container and mounting block and mounting angle Boltholes shall be sealed to prevent moisture penetration Mounting Bl...

Page 48: ...oisture penetration Mounting Blocks This drawing shows the use of a mounting block to provide the watertight seal between the mounting hardware and the roof Metal flashing sheets can be used instead o...

Page 49: ...ing hardware and the roof Metal flashing sheets can be used instead of the mounting block PT BASE MOUNT MOUNTING BLOCK SHEATHING SILICONE SEALANT GALVANIZED WASHER NEOPRENE WASHER RAFTER ROOF SEALANT...

Page 50: ...cable Assumes 4500 watt element s in electric water heater 4 Thermostat set point shall not exceed 120 F THE LOCATION OF THE TANK MANUFACTURER S LABEL SHOULD BE IDENTIFIED ON THE EXTERIOR INSULATION...

Page 51: ...roof installations Sweat a copper 90 short radius L directly onto the inlet and outlet connections of the collector Protect the collector s rubber pipe grommets from the soldering torch flame and hea...

Page 52: ...film 2 Drain the unit and disconnect the supply and return piping from the inlet and outlet connections 3 Remove the screws in the glass glazing cap strips on the top of the collector 4 Carefully lift...

Page 53: ...Cover 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 p...

Page 54: ...or 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...

Page 55: ...RS FRONT VIEW 3 8 X 4 LAG BOLT 2 X 4 X 48 NOMINAL STRINGER ROOF BEAM ROOF 3 8 X 4 LAG BOLT 3 8 X 3 LAG BOLT 3 8 X 3 LAG BOLT 3 8 X 4 LAG BOLT 2 X 4 X 48 NOMINAL STRINGER ROOF BEAM ROOF 3 8 X 4 LAG BOL...

Page 56: ...ND OTHER WIDE RAFTER SPANS 3 8 X 4 LAG BOLT 48 4 X 4 PURLIN ROOF 3 8 X 4 LAG BOLT ROOF BEAM SIMPSON U44 HANGER SIMPSON U44 HANGER 3 8 X 5 LAG BOLT 4 X 4 PURLIN ROOF 3 8 X 12 LAG BOLT ROOF BEAM 3 8 X 1...

Page 57: ...57 YOUR NOTES...

Page 58: ...58 101 Copeland Street Jacksonville Florida 32204 Tel 904 358 3720 Fax 904 358 3728 www tctsolar com techsupport tctsolar com Rev 6 2008...

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