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TCT Solar PROGRESSIV TUBE Installation And Operation Manual

Passive solar water heater
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®
P
T
ROGRESSIV
UBE
Passive Solar Water Heater
INSTALLATION
and
OPERATIONS MANUAL
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.com

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Summary of Contents for TCT Solar PROGRESSIV TUBE

  • Page 1 ® ROGRESSIV Passive Solar Water Heater INSTALLATION OPERATIONS MANUAL 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.com...

  • 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 Load Bearing and Bracing Roof Piping and Penetrations Roof Mount Penetrations South/North Roof Mounts East/West Roof Mounts Tile Roof Installations On Top of Tile...
  • Page 3 FLOW PATTERN ® The P solar water heater works simply on sunlight and your local water ROGRESSIV 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.

  • Page 4: Introduction

    ® ROGRESSIV NSTALLATION MANUAL 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 system, but only the methods ROGRESSIV included in this manual are endorsed by the manufacturer.

  • Page 5: Utilization

    UTILIZATION ® Passive Solar Water Heaters are designed as self-contained units that act ROGRESSIV 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 as direct solar water heaters.

  • Page 6: Vacuum Breaker

    2–WAY SYSTEM FOR ELECTRIC WATER SRCC OG 300 3-WAY SYSTEM HEATER outlet outlet inlet inlet Cold Water Hot Water Cold Water Hot Water Cold Water Hot Water Inlet Outlet Cold Water Hot Water Inlet Outlet 2-WAY SYSTEM FOR TANKLESS WATER 2-WAY SYSTEM FOR GAS WATER HEATER HEATER outlet...

  • Page 7: Pre-Installation Check List

    PRE-INSTALLATION CHECK LIST Check local codes for plumbing and roof load requirements. Installations must meet all local code requirements for penetrating structural members and fire rated assemblies. Obtain all applicable permits. Inspect the roof. If it is in poor condition, advise the homeowner before the installation is begun.

  • Page 8: Collector Orientation

    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 while being filled.
  • 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” 2 ¼” H CREWS E) 3/8”...
  • 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 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”...
  • Page 11 Drawing C - Flush Mount MOUNT DIMENSIONS AND ANGLES Collector Standoff Dim “A” Angle 1 Foot ” 26º PT-20-CN 2 Foot ” 85º PT-20-CN 1 Foot ” 17º PT-30-CN 5/16 2 Foot ” 38º PT-30-CN 3 Foot ” 70º PT-30-CN 1 Foot 47 ¾”...

  • Page 12: Roof Mounts

    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. Preparation of the roof area and procedures for anchoring to the roof members must be done carefully to avoid causing leaks or weakening the roof.

  • Page 13: Roof Mount Penetrations

    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.
  • 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 access.

  • Page 15: South/North Roof Mounts

    TYPE 3 TYPE 4 3/8” THREADED ROD WITH NUTS AND WASHERS ROOFING MATERIAL RAFTER OR ¼” X 1” STEEL 3” PENETRATION MIN. MATCHING SLEEPER AIN RAFTER WHEN STRAP (MIN.) USING LAG BOLTS PITCHPAN OR OTHER WATERPROOFING METHODS NOT ILLUSTRATED DRAWING G A METHOD OF LOCATING MOUNTING POINTS 4.

  • Page 16: East/West Roof Mounts

    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.

  • Page 17: Tile Roof Installations

    DO NOT MOUNT THE UNIT VERTICALLY DRAWING I WEST SLOPE EAST SLOPE F. Tile Roof Installations ® collectors are easily installed on tile roofs or flush to the roof with the ROGRESSIV tile abutted to the collector. Installation Details Q and Z in the Appendix illustrates these two methods.

  • Page 18: Flush To The Roof

    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 spanner mount across the rafters.

  • Page 19: Ground Mounts

    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.
  • Page 20 DRAWING J RECOMMENDED FOUNDATION FOR GROUND MOUNT INSTALLATION FRONT VIEW STANDARD CONCRETE PIER 50” TO 60” SIDE VIEW THREADED J- BOLT 4" EMBEDDED IN PIER 12" 10" 48” TO 50” FOR PT-40-CN AND PT – 50-CN 36” TO 37” FOR PT-30-CN 22”...
  • Page 21 DRAWING K CONSULT SYSTEMS PLACE FREEZE PREVENTION VALVE AS DRAWINGS FOR CONTROL CLOSE TO HOUSE AS POSSIBLE VALVES CONFIGURATION FREEZE PREVENTION VALVE PRESSURE RELIEF STORAGE COPPER PIPE TANK VACUUM BREAKER OR BOILER DRAIN BOILER DRAIN MAKE SURE PIPES ARE BELOW FROST LINE IN COLD CLIMATES INSULATE PIPES WITH PROPER UNDERGROUND INSULATION CONSULT SYSTEMS...

  • Page 22: System Plumbing

    SYSTEM PLUMBING ® unit can be installed as a pre-heater system or as a direct solar system. ROGRESSIV 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 to slope ¼”...

  • Page 23: System Insulation

    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 before the plastic pipe.

  • Page 24: Freeze Prevention

    XII. FREEZE PREVENTION ® collectors are virtually freeze proof throughout the Sunbelt area of the ROGRESSIV 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 penetrate the building as close to the conventional water heater as possible to minimize exposed runs of piping.
  • Page 25 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 Drain Port ¾” x ½” F Adapter may Storage be used Tank instead of bushing Valve must be installed with drain port down...
  • 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) 10.7 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 89.0 116.7...

  • Page 27: Two Or More Collector Systems

    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 with multiple collector systems.
  • 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 more units in series will greatly reduce the system’s efficiency (see Drawing P).
  • Page 29 DRAWING N THIS POSITION MUST BE PROPER POSITIONING WITHIN 15” OF ROOF CROWN. OF TWO UNITS ON SOUTH ROOFS. THIS POSITION MUST BE THIS POSITION IS NOT ALLOWED. OVER A LOAD BEARING WALL. DRAWING O MAXIMUM DISTANCE COLLECTOR MOUNT FROM ROOF CROWN 15” WEST FACING ROOF EAST FACING ROOF SUPPLY LINE...

  • Page 30: Direct Systems

    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 ®...

  • Page 31: Start Up Procedures

    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 water demand is made early the next morning before the sun has had enough time to recharge the unit.

  • Page 32: Drain Procedures

    Give Owner’s Manual and Warranty to homeowner and go over all operations of the system. For installation and operation of the instantaneous water heater, please follow the manufacturer operation manual. XVI. DRAIN PROCEDURES Position the flow control valve in the solar by-pass mode. Consult system valve position drawings.
  • 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 difference between the supply and return piping.

  • 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 following procedures are required for SRCC certified systems.
  • 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 the Owner’s Manual when air temperatures of 10°F or below are expected.
  • Page 36 SRCC CERTIFIED OG 300 THREE-WAY SYSTEM outlet 1. Supply Shut Off Valve inlet 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. Temperature/Pressure Relief Valve 9. Roof Flashing 10.
  • Page 37 LIMITED TEN-YEAR CONSUMER WARRANTY THERMAL CONVERSION TECHNOLOGY 101 C , FL 32204 OPELAND TREET ACKSONVILLE provide either a refund for the purchase price or a replacement Product at Manufacturer’s WHAT IS COVERED BY THIS WARRANTY ® The P Passive Solar Water Heater (Product) is warranted by Thermal option.
  • Page 38 ® SRCC OG 300 3-WAY SYSTEM ROGRESSIV LEGEND 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 A – SOLAR DIRECT USE ONLY DURING SPRING THROUGH FALL. FOR MAXIMUM SAVINGS, SHUT OFF BREAKER TO ELECTRIC WATER HEATER.

  • Page 39: Fsec Section

    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.
  • 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 early evening. Filling a hot, empty collector without this valve being opened or some other means taken to vent the collector to the atmosphere could damage your system and void the warranty.
  • Page 41 Electric 2-Way System Gas 2-Way System Instantaneous Gas 2-Way System From Solar To Solar To Solar From Solar To Solar From Solar Open Hot Water Cold Water Cold Water Open Cold Water Open Hot Water Cold Water Cold Water Hot Water Hot Water Cold Water Inlet...

  • Page 42: Installation Details

    INSTALLATION DETAILS DETAIL Q Spaced Block With Spanner Mount PT BASE MOUNT SILCONE SEALANT ROOF SEALANT** GALVANIZED WASHER *WOOD SPACED BLOCK(S) (SIZED TO NEOPRENE WASHER FIT SNUGLY BETWEEN SPANNER & ROOF MOUNTING BLOCK SHEATHING – 2 X 4 MIN.) SHINGLES SHEATHING 1-10D NAIL RAFTER...
  • Page 43 INSTALLATION DETAILS DETAIL R LAG BOLT MOUNTING PT BASE MOUNT SILICONE SEALANT GALVANIZED WASHER NEOPRENE WASHER MOUNTING BLOCK SHINGLES **ROOF SEALANT 2” MINIMUM SHEATHING * FOUR LAG BOLTS 3 X MINIMUM LENGTH RAFTER MIN.OF 1.5 TIMES SHANK DIAMETER OF BOLT Lead Holes Required –...
  • Page 44 INSTALLATION DETAILS DETAIL S PITCH POCKET METHOD PT BASE MOUNT NEOPRENE WASHER SILICONE SEALANT MOUNTING BLOCK GALVANIZED WASHER PITCH CONTINER SHINGLES **ROOFING CEMENT SHEATHING RAFTER 1-8D NAIL AT EACH SPANNER (2” X 4” MIN. FOR 16” SPACER SPAN OR 2” X 6” MIN. FOR 24” SPAN).
  • Page 45 INSTALLATION DETAILS DETAIL T J-BOLT MOUNT PT BASE MOUNT SILCONE SEALANT NEOPRENE WASHER GALVANIZED WASHER MOUNTING BLOCK SHINGLES SHEATHING RAFTER ROOF SEALANT 3/8” RADIUS (MAX.) FOUR J-BOLTS (MIN. OF 3/8”) 3/16” ½ “ (MIN.) SPECIFY MAXIMUM DIMENSION NOTE: The bent portion of the J-Bolt shall not be threaded. Roof Sealant is required between mounting block and shingles/sheathing.
  • Page 46 INSTALLATION DETAILS DETAIL U CATHEDRAL CEILING PT BASE MOUNT SILICONE SEALANT MOUNTING BLOCK GALVANIZED WASHER NEOPRENE WASHER SHEATHING SHINGLES WASHER ROOF SEALANT JAM NUT RAFTER FOUR PRE UNIT THREADED THRU-BOLT 3/8” MIN. CAT, 2” X 4” MIN. IF RAFTERS ARE 2” 2-16D NAILS AT END OF EACH CAT X 4”, ONE 2”...
  • Page 47 INSTALLATION DETAILS DETAIL W EXTRA TANK INSULATION POWER LINE INSULATION SHALL POWER LINE NOT COVER THE PT VALVE OR RESTRICT ITS OPERATION JUNCTION BOX SUPER INSULATION TANK’S OUTER SHELL INSULATION SHALL NOT COVER THE ACCESS AREAS TO THE THERMOSTATS / ELEMENTS INSULATION SHALL NOT COVER ENTRANCE LEAD WIRE OR THE TANK’S ELECTRICAL...
  • Page 48 INSTALLATION DETAILS DETAIL X FLUSH PIPE PENETRATION GROMMET ¾” 90 “L” SHORT RADIUS SOLDER 1-1/4” TO 1-1/2” 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 is installed flush to a roof, as in tile roof installations.
  • Page 49 INSTALLATION DETAILS DETAIL Y SOLAR DIRECT WITH BACK-UP SOLAR PRE-HEAT SOLAR DIRECT FROM SOLAR TO SOLAR FROM SOLAR TO SOLAR MIXING MIXING VALVE VALVE COLD IN COLD IN 3-WAY BALL 3-WAY BALL VALVE VALVE HOT OUT HOT OUT HOT OUTLET COLD INLET HOT OUTLET COLD INLET...
  • 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.

  • Page 51: Typical Roof Bracing

    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. contractor should follow acceptable carpentry and construction techniques if additional measures are needed.

  • Page 52: Front View

    SIDE VIEW – MOUNT PARALLEL TO RAFTERS ROOF 3/8” X 4” LAG 3/8” X 4” LAG BOLT 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”...
  • 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 48” SIMPSON U44 HANGER SIMPSON U44 HANGER 3/8” X 12” LAG BOLT 3/8”...

  • Page 54: Your Notes

    YOUR NOTES...
  • Page 55 ProgressivTube® ProgressivTube® SOLAR WATER HEATER SOLAR WATER HEATER 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.
  • Page 56 SUPERIOR CONSTRUCTION GLAZING: GLAZING GASKETS: Outer glazing is tempered low-iron solar A continuous gasket made of glass with 91% transmittance. Inner special long life EPDM synthetic glazing is Teflon film, known for its high FLUID CONNECTIONS: rubber is compressed by the glazing temperature tolerance (525°F) and its long caps to seal out the weather.
  • 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 people take longer and hotter showers in the winter).
  • Page 58 WHAT IS THE COST? Model Description List Price Your Cost PT-50 ProgressivTube 50 Gal Unit $6650.00 PT-40 ProgressivTube 40 Gal Unit $6450.00 PT-30 ProgressivTube 30 Gal Unit $5950.00 SAVINGS & RETURN ON INVESTMENT An average family of four uses 70 gallons of hot water per day at a cost of $535 per year.
  • Page 59 ProgressivTube® ProgressivTube® SOLAR WATER HEATER SOLAR WATER HEATER 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.
  • Page 60 SUPERIOR CONSTRUCTION GLAZING: GLAZING GASKETS: Outer glazing is tempered low-iron solar A continuous gasket made of glass with 91% transmittance. Inner special long life EPDM synthetic glazing is Teflon film, known for its high FLUID CONNECTIONS: rubber is compressed by the glazing temperature tolerance (525°F) and its long caps to seal out the weather.
  • 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 people take longer and hotter showers in the winter).
  • Page 62 WHAT IS THE COST? MSRP Installed Your Cost Model Description PT-50 ProgressivTube 50 Gal Unit $6650.00 $5500.00 PT-40 ProgressivTube 40 Gal Unit $6450.00 $5000.00 PT-30 ProgressivTube 30 Gal Unit $5950.00 $4500.00 SAVINGS & RETURN ON INVESTMENT An average family of four uses 70 gallons of hot water per day at a cost of $535 per year.

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