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  4. PROGRESSIV TUBE
  5. Installation And Operations Msnual

TCT Solar PROGRESSIV TUBE Installation And Operations Msnual

Summary of PROGRESSIV TUBE

  • Page 1

    Operations manual p rogressiv t ube ® passive solar 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 tech@solardirect.Com www.Shop.Solardirect....

  • Page 2: Table of Contents

    Table of contents i. Introduction ii. Utilization iii. System characteristics iv. Pre-installation check list v. Installation precautions vi. Collector orientation vii. Collector mounting hardware options viii. Roof mounts a. Load bearing and bracing b. Roof piping and penetrations c. Roof mount pen...

  • Page 3: Flow Pattern

    Flow pattern the p rogressiv t ube ® solar water heater works simply on sunlight and your local water pressure. There is no electrical energy needed to make it function. Once the system has been filled, it will operate on main water pressure or flow rates that are normal to your household. The simpl...

  • Page 4: Rogressiv

    P rogressiv t ube ® i nstallation manual i. Introduction this installation manual is intended to provide the requirements, recommendations, and guidelines necessary to achieve simplified installation and years of trouble free system operation. There are many ways to plumb a p rogressiv t ube ® syste...

  • Page 5

    Ii. Utilization p rogressiv t ube ® passive solar water heaters are designed as self-contained units that act as a solar collector and storage tank integrated into one piece of equipment. In most cases, they are utilized as a pre-heater to a conventional water heater; however, they can be installed ...

  • Page 6

    2–way system for electric water heater cold hot mi x 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 2-way system for gas water heater 8 7 6 5b 5a 4 3 2 hot water out cold water in cold water inlet hot water outlet 1 9 co l d ho t mix 11 9 inl...

  • Page 7

    Iv. Pre-installation check list 1. Check local codes for plumbing and roof load requirements. Installations must meet all local code requirements for penetrating structural members and fire rated assemblies. 2. Obtain all applicable permits. 3. Inspect the roof. If it is in poor condition, advise th...

  • Page 8

    5. Use 95/5 or 60/40 lead free solder for the collector piping because of the high temperature stagnation of the unit. 6. Keep the collector covered during installation. Even early morning sun can quickly heat up the absorber. It is most important that the unit be vented to the atmosphere before and...

  • Page 9

    Collector mounting options drawing 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 ¼” h ex h ead c ap s crews : q ty 4 e) 3/8” lock nuts: qty 8 f) c ross c hannels : q ty 2 9.

  • Page 10

    Drawing b - adjustable tilt mount for installation with additional angle of the roof or ground mounting include standoff rear legs-sts sts p art l ist 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 ¼” hex head cap screws: qty 2 i) 3/8” lock nuts: qt...

  • Page 11

    Drawing c - flush mount mount dimensions and angles collector standoff dim “a” angle pt-20-cn 1 foot 29 1/8 ” 26º pt-20-cn 2 foot 4 7/8 ” 85º pt-30-cn 1 foot 35 5/16 ” 17º pt-30-cn 2 foot 29 1/8 ” 38º pt-30-cn 3 foot 12 5/8 ” 70º pt-40-cn / pt-50-cn 1 foot 47 ¾” 13º pt-40-cn / pt-50-cn 2 foot 43 5/1...

  • Page 12

    Viii. Roof mounts the structure of the roof should first be examined to determine the dimensions of its members. Check applicable codes as to loading requirements. The roof penetrations should be located over an attic or similar space that is not blocked by a chimney, beams, or other obstacles. Prep...

  • Page 13

    Provide a waterproof seal. Another method is to make a flat copper flashing with an oversize tube, which is penetrated by the copper water pipe. A coolie cap is made from a reducing coupling that fits the oversized copper tube and is large enough for the copper water pipe to just pass through. It is...

  • Page 14

    Roofing material. Weather proof with appropriate sealant. Consult the waterproofing and roof attachment drawings details q – z in the appendix for additional details. In retrofit situations, rafters or roof trusses may be located from inside the attic if the crawl space is large enough to permit acc...

  • Page 15

    Type 3 type 4 3/8” threaded rod with nuts and washers d. South/north roof mounts most homes have a south facing roof. This roof area should be utilized for the collector location unless there are shade or aesthetic problems. Follow the guidelines in section vi collector orientation, while taking int...

  • Page 16

    The flush mount system, 2” x 6” pressure treated lumber blocks or exterior grade material are used to create the air space under the collector. See drawing c. To avoid potential roof damage from mildew and rotting it is not recommended for the collector to sit directly on the roof surface. Sometimes...

  • Page 17

    Do not mount the unit vertically east slope west slope drawing i f. Tile roof installations p rogressiv t ube ® collectors are easily installed on tile roofs or flush to the roof with the tile abutted to the collector. Installation details q and z in the appendix illustrates these two methods. For a...

  • Page 18

    C) clean off each location of all membrane grit, dirt, and tile debris. D) drill the four penetration holes into the roof. If using lag bolts, be sure the starter holes are in the center of the rafter. Because of the added difficulty of installing on tile roofs it is sometimes much easier to use a s...

  • Page 19

    F) remove the clear plastic protective lining on the jiffy seal. Lay the exposed side of the sealing compound on the membrane and press into the roof with palms of hands. G) after all four strips have been laid into place, use a rubber mallet and firmly hammer the entire strip down. H) remove the wh...

  • Page 20

    Drawing j recommended 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 in pier 4" 12" 10" 20

  • Page 21

    Drawing k place freeze prevention valve as close to house as possible consult systems drawings for control valves configuration boiler drain freeze prevention valve storage tank pressure relief copper pipe make sure pipes are below frost line in cold climates insulate pipes with proper underground i...

  • Page 22

    X. System plumbing a p rogressiv t ube ® unit can be installed as a pre-heater system or as a direct solar system. Consult the recommended system plumbing diagrams for the type of system to be installed. All piping must meet local code requirements for potable hot water service and must be installed...

  • Page 23

    Direct solar systems should not use plastic pipe to feed cold water to the tempering valve. The water from the collector can melt the pipe from the valve. High temperature cpv plastic pipe may be used down line of the tempering valve if a six foot copper stub is installed in the tempering valve befo...

  • Page 24

    Xii. Freeze prevention p rogressiv t ube ® collectors are virtually freeze proof throughout the sunbelt area of the country due to their thermal mass and heavy insulation. However, the pipes leading to and from the collector can freeze. Collector piping should be as short as possible and should pene...

  • Page 25: Model Fp-35

    Drawing l model fp-35 (valve opens at +/-38 ° f) from collector copper pipe insulate 12” do not insulate ¾” c x ½” f flush bushing copper pipe insulate to storage tank drain port or ¾” x ½” f adapter may be used instead of bushing valve must be installed with drain port down caution: • do not solder...

  • Page 26

    Pipe freeze times rubatex and armaflex k = 0.270 btu-in/hr-f-sq ft type m type l pipe id/od (in.) 0.811/0.875 0.785/0.875 insulation (r) 2.6 4.4 6.3 10.7 2.6 4.4 6.3 10.7 thickness (in.) 0.50 0.75 1.00 1.50 0.50 0.75 1.00 1.50 ambient (f) hours to freeze solid hours to freeze solid 30 89.0 116.7 139...

  • Page 27

    Xiii. Two or more collector systems households with more than six members or with a large hot water demand should consider having a two-unit system. Light commercial applications such as restaurants, car washes, housing with central hot water systems, bathhouses, and process hot water can be served ...

  • Page 28

    Multiple collector systems can be installed in series in non-freezing areas, but in order to drain the system each collector must have a boiler drain at the inlet connection and a boiler drain or vacuum breaker at the outlet connection. Never plumb more than two units in series. Plumbing three or mo...

  • Page 29

    Drawing n proper positioning of two units on south 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 facing roof east facing roof supply line return ...

  • Page 30

    Drawing p multi unit installation - parallel xiv. Direct systems direct solar systems are usually installed in low latitude areas of the world that have an abundance of sunlight. Since the solar collection day is longer and solar radiation is more intense, a p rogressiv t ube ® collector can easily ...

  • Page 31

    In some areas, such as the caribbean, there is a brief period during the year in which rain and heavy cloud cover can reduce the thermal performance of the collector. This can be a problem if a large hot water demand is made on the collector in the late afternoon or evening and then another hot wate...

  • Page 32

    12. Give owner’s manual and warranty to homeowner and go over all operations of the system. 13. For installation and operation of the instantaneous water heater, please follow the manufacturer operation manual. Xvi. Drain procedures 1. Position the flow control valve in the solar by-pass mode. Consu...

  • Page 33

    Faucet in the household and allow the water to run. If it goes from cold to warm to hot, the system is working properly. This test is the same as for any conventional residential gas or electric water heater. For a more precise measurement follow the procedure above for comparing the temperature dif...

  • Page 34: Appendix

    Appendix srcc certified og 300 three-way system srcc section: the solar energy system described by this manual, when properly installed and maintained, meets the minimum standards established by the srcc. This certification does not imply endorsement or warranty of this product by srcc. The followin...

  • Page 35

    Freeze protection information the freeze protection method of this system is thermal mass and manual draining. In some areas an automatic freeze prevention valve may have been installed. This valve will open during freezing weather and allow a small flow of water. Drain the system as instructed in t...

  • Page 36

    Srcc certified og 300 three-way system 9 10 9 inlet outlet cold hot mi x 8 7 6 5b 5a 4 3 2a hot water 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. Convention...

  • Page 37: Limited

    37 limited ten-year consumer warranty thermal conversion technology 101 c opeland s treet , j acksonville , fl 32204 1. What is covered by this warranty the p rogressiv t ube ® passive solar water heater (product) is warranted by thermal conversion technology (the manufacturer), to be free of defect...

  • Page 38: Srcc Og 300 3-Way System

    38 p rogressiv t ube ® srcc og 300 3-way system col d hot mi x 6 5b 5a 4 3 2a 1 2b col d hot mi x 6 5b 5a 4 3 2a 1 2b col d hot mi x 6 5b 5a 4 3 2a 1 2b b – solar pre-heat for normal operation – conventional water heater also acts as backup if needed. Good for year round operation. 1. Supply shut of...

  • Page 39

    Fsec approved 2-way systems fsec section: the following procedures are required for fsec 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 sticker...

  • Page 40

    Open this valve before filling place a hose on or a bucket under this drain valve. Open this valve. The collector is now vented to the atmosphere. Fill the collector. Close this valve when water starts to flow out of it. It is strongly recommended that you refill your collector in the morning or ear...

  • Page 41

    Electric 2-way system co ld hot mi x 8 7 6 5b 5a 4 3 2 hot water out cold water in cold water inlet hot water outlet 1 open to solar from solar solar pre-heat electric 2-way system cold hot mi x 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 clo...

  • Page 42

    Installation details detail q spaced block with spanner mount pt base mount silcone sealant *spacer block(s) 1. Spacer blocks should be installed within 1 inch of the thru-bolt. 2. When bolt is within 2” of a rafter only one spacer block will be required on the opposite side of the bolt, away from t...

  • Page 43

    Installation details detail r lag bolt mounting pt base mount silicone sealant galvanized washer neoprene washer mounting block shingles **roof sealant * lead holes required – pre-drill lead holes for the shank at 100% of the shank diameter. Lead holes for the threads at 60-75% of the shank diameter...

  • Page 44

    Installation details detail s pitch pocket method pt base mount galvanized washer shingles silicone sealant neoprene washer **roofing cement mounting block pitch continer sheathing rafter 1-8d nail at each spacer spanner (2” x 4” min. For 16” span or 2” x 6” min. For 24” span). Washer jam nut nut *w...

  • Page 45

    Installation details detail t j-bolt mount pt base mount silcone sealant nut neoprene washer galvanized washer mounting block shingles sheathing roof sealant rafter 3/8” radius (max.) ½ “ (min.) 3/16” four j-bolts (min. Of 3/8”) specify maximum dimension note: 1. The bent portion of the j-bolt shall...

  • Page 46

    Installation details detail u cathedral ceiling pt base mount silicone sealant mounting block galvanized washer neoprene washer sheathing shingles jam nut nut washer roof sealant rafter four pre unit threaded thru-bolt 3/8” min. Cat, 2” x 4” min. If rafters are 2” x 4”, one 2” x 8” should be used be...

  • Page 47

    Installation details detail w extra tank insulation insulation shall not cover the pt valve or restrict its operation power line power line junction box the location of the tank manufacturer’s label should be identified on the exterior insulation by providing a cut-away access slot (leaving the cut-...

  • Page 48

    Installation details detail x flush pipe penetration grommet ¾” 90 “l” short radius solder 1-1/4” to 1-1/2” cap roof sealant flashing the following technique is used when it is desirable to have the inlet and outlet piping as close to the collector as possible. It is usually used when the collector ...

  • Page 49

    Installation details detail y solar direct with back-up solar pre-heat solar direct co l d ho t mix co l d ho t mix from solar to solar from solar to solar mixing valve mixing valve cold in cold in 3-way ball valve 3-way ball valve hot out hot out hot outlet cold inlet hot outlet cold inlet on/off s...

  • Page 50

    Carefully lift out the teflon frame and place in a secure location. Caution: even a slight breeze can turn the frame into a sail. 6. Remove the stainless steel rod that crosses over the top of the tank securing the two framewalls together. This rod is part of the unit’s high wind load reinforcement....

  • Page 51

    Typical roof bracing the following drawings are suggested techniques for roof structure bracing. These are not engineer certified drawings and all suggested bracing in these drawings are intended to be used with structurally sound roofs. Individual installations may require additional bracing. The c...

  • Page 52

    Side view – mount parallel to rafters 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” nominal stringer 3/8” x 3” lag bolt 52.

  • Page 53

    Suggested roof bracing for cathedral ceilings and 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” lag bolt 48” 2” x 4” x 6” treated wo...

  • Page 54: Your Notes

    Your notes 54.

  • Page 55: Progressivtube®

    The progressivtube passive solar water heater is a self-contained unit that acts as a solar collector and storage tank integrated into one piece of equipment. In most systems the unit is utilized as a pre-heater to a instantaneous or conventional water heater. It can also be used as a stand-alone h...

  • Page 56

    Reasons for installing the progressivtube® 1. Solar water heating reduces the monthly operating expense of the household. 2. Reduced operating expenses give homeowners more cash for discretionary purposes, savings, etc. 3. Solar water heaters are the only home appliance that saves money without redu...

  • Page 57

    What size do i need? First estimate your hot water demand in gallons per day; use the chart below for an average figure (note: add 15 gallons per additional person or 20 gallons per additional room). It varies widely with lifestyle (from 10 to 30 gallons or more per person) and with season (most peop...

  • Page 58

    Savings & return on investment an average family of four uses 70 gallons of hot water per day at a cost of $535 2 per year. The typical solar water heater will save 90% or more of the heating costs, or $482.00 per year. A typical heater of this size (pt-40cn) with installation averages $6650 minus a...

  • Page 59: Progressivtube®

    The progressivtube passive solar water heater is a self-contained unit that acts as a solar collector and storage tank integrated into one piece of equipment. In most systems the unit is utilized as a pre-heater to a instantaneous or conventional water heater. It can also be used as a stand-alone h...

  • Page 60

    Reasons for installing the progressivtube® 1. Solar water heating reduces the monthly operating expense of the household. 2. Reduced operating expenses give homeowners more cash for discretionary purposes, savings, etc. 3. Solar water heaters are the only home appliance that saves money without redu...

  • Page 61

    What size do i need? First estimate your hot water demand in gallons per day; use the chart below for an average figure (note: add 15 gallons per additional person or 20 gallons per additional room). It varies widely with lifestyle (from 10 to 30 gallons or more per person) and with season (most peo...

  • Page 62

    Savings & return on investment an average family of four uses 70 gallons of hot water per day at a cost of $535 2 per year. The typical solar water heater will save 90% or more of the heating costs, or $482.00 per year. A typical heater of this size (pt-40cn) with installation averages $6650 minus a...