Chromasun High?Temperature Thermal Collector System, Installation Manual

Page 1: ... 2011 Chromasun All Rights Reserved 1 1 1 1 Chromasun INSTALLATION MANUAL Chromasun High Temperature Thermal Collector System ...

Page 2: ...minimized NOTE IMPORTANT When in doubt please ask a Chromasun Representative For Technical Support please call 1 408 634 4104 Hazard Identification Warnings and cautions appear at appropriate sections throughout this literature Please read carefully WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazar...

Page 3: ...Mount Legs set of 2 per MCT Optional 9 2 3 2 Stand Clamps per MCT Optional 9 2 3 3 Header Pipes per MCT Optional 9 3 Measurements and Weights 11 4 Pre Installation Checklist 13 4 1 Inventory Check 13 4 2 Site Layout Checklist 13 5 Rigging Installation 14 5 1 Unpacking the MCT HT 14 5 1 1 Wood Pallet 14 5 1 2 Collapsing the Wood Pallet 17 5 2 Lifting and Mounting the MCT s 19 5 2 1 Parts List 20 5 ...

Page 4: ... SFC PCB with Expansion Board 31 7 1 2 Parts List 32 7 2 SFC Field Wiring Schematic 34 7 3 Power Data Ventilation PDV Interconnects 35 7 3 1 Parts List 35 7 4 Junction Boxes 38 7 5 SFC Expansion Board Signals 39 8 Desiccant Ventilation Hardware 40 ...

Page 5: ...order and bill of lading Visually inspect the exterior of the crate and the visible areas of the MCTs for signs of shipping damage If any damage is found the consignee should indicate such damage before signing the bill of lading and immediately file a claim with the carrier Unit Inspection If during unloading from the transport pallet job site inspection reveals damage to an MCT immediately file ...

Page 6: ...one at a time This is recommended to be done when the units are ready to be lifted onto the roof For a more detailed instruction how to do this please refer to the Unpacking the MCT HT section in the manual 1 3 Sling Kit Recommended Option Chromasun recommends the use of the optional Chromasun Sling Kit accessory The four legged bridled nylon strap kit is designed to be used with a crane to transp...

Page 7: ...ld Controller 1 1B 01 1B 02 1B 03 1B 04 1B 05 1B 06 1B 07 1B 10 1B 09 1B 08 JB1 1A 10 1A 09 1A 08 1A 07 1A 06 1A 05 1A 04 1A 01 1A 02 1A 03 1D 01 1D 02 1D 03 1D 04 1D 05 1D 06 1D 07 1D 10 1D 09 1D 08 JD1 JA1 1C 10 1C 09 1C 08 1C 07 1C 06 1C 05 1C 04 1C 01 1C 02 1C 03 JC1 Field Controller 2 2B 01 2B 02 2B 03 2B 04 2B 05 2B 06 2B 07 2B 10 2B 09 2B 08 JB2 2C 01 2C 02 2C 03 2C 04 2C 05 2C 06 2C 07 2C ...

Page 8: ...weight and has no external moving parts making it simple to mount and easy to maintain Using a 20X concentration Fresnel reflector optic the MCT generates temperatures up to 200 C 400 F and has a power output which peaks at 2 2kW depending on location weather and temperature The Chromasun MCT is perfect for process heat applications and ideal for integration with absorption refrigeration and heat ...

Page 9: ...Page 7 PVT MCT10A EN Receiver Pipe SS 304 A213 Tube Parallel Mirrors Figure 4 Schematic of sunlight being concentrated within an MCT Figure 3 Exploded view of an MCT HT ...

Page 10: ...irmware updating functionality The SFC takes instructions from the existing building system s either via analog signals dry contacts or over Ethernet using BacNET Modbus or LonWorks Consult the MCT Operation Manual for wiring and configuration details The SFC is connected to each string in the array by field installed conduit home runs that terminate in a Chromasun provided junction box From here ...

Page 11: ...onal Our Stand Clamps are used to secure the Mount Legs down to the Unistrut section The mounting portion of this manual was written for the use with our Stand Clamps If you choose to not use our Stand Clamps please consult an engineer for an alternative method These can be seen below in Figure 5 and Figure 6 2 3 3 Header Pipes per MCT Optional Our steel Header Pipes are the recommended product to...

Page 12: ...PVT MCT10A EN Page 10 Figure 5 Components from Front View Figure 6 Components from Rear View ...

Page 13: ...ts Table 1 Physical Characteristics Dimensions See Diagrams Below Weight 100 kg 220 lb Unit Area 4 23 m2 45 sq ft Weight per Unit Area 24 kg m2 4 9 lb sq ft Weight per Unit Unistrut 38 kg m 28 lb ft Figure 7 MCT Canopy Front Rear Top and Side Views ...

Page 14: ... reference Table 2 shows Unistrut spacing based on collector slope Table 2 Appropriate MCT Angle and Length MCT Leg Stand Model Suggested Angle degrees Distance Between Unistruts mm Distance Between Unistruts in Rear Leg Length mm Rear Leg Length in Dimension A Dimension B Dimension B Dimension C Dimension C 0 0 3244 128 0 0 5 5 3232 127 283 11 10 10 3195 126 563 22 15 15 3133 123 840 33 20 20 304...

Page 15: ...acks o Obvious Bends o Collapsed Bent Terminals 4 2 Site Layout Checklist Make sure that there is Unistrut mounted on the roof Check to make sure the pitch between the Unistrut is correct Consult the Roof Design Layout provided by the supervising engineer and check to see that the spaces between banks side to side as well as front to back are correct Check to see that the length of strut provided ...

Page 16: ...VT MCT10A EN Page 14 5 Rigging Installation 5 1 Unpacking the MCT HT 5 1 1 Wood Pallet Step 1 The shipping pallet Step 2 Remove the two top cross bars which are held down by 4X 2 5 10 wood screws 8 total ...

Page 17: ...ral stability Each side is held in place by 13X 2 5 10 wood screws 26 total Step 4 Remove the two rectangular end pieces Each end piece is held in place by 2X 2 5 10 wood screws As well as 2X 2 3 8 hex cap bolts Step 5 Crane the MCT unit away by connecting to the 4 lifting holes located at each corner of the MCT ...

Page 18: ...PVT MCT10A EN Page 16 Repeat steps 3 through 5 until all the MCT s are removed ...

Page 19: ...into the grooves between the horizontal slats in the pallet The remaining 4 end pieces are arranged on top of the end pieces already on the pallet upside down to interlock The two triangle gussets are laid down on top of the end pieces and the top cross bars are laid down on top of that Step 2 The finalized Collapsed Wood Pallet ...

Page 20: ...PVT MCT10A EN Page 18 Step 3 The Wood Pallets can be stacked on top of each other when ready to be shipped back to Chromasun Step 4 The Pallets ready to be shipped back ...

Page 21: ...CT s This section of the MCT HT installation manual was written for the optional mounting kit which includes the MCT Stand Legs and the MCT Stand Clamps If these additional items were not purchased then please consult an engineer about alternate options ...

Page 22: ...arts List Part Part Name Quantity MCT w Mount Legs Refer to Order MCT Stand Clamp Refer to Order Unistrut Nut Refer to Order Unistrut Bolt Refer to Order 5 2 2 Tools List Part Part Name Impact Driver 6 Point Socket Driver Sling kit ...

Page 23: ... down parallel to each other Step 2 Loosen the short leg slightly so that it is able to swing down needs to be loosened on both sides Step 3 Lower the MCT panel onto the Unistrut so that the short leg is properly seated around the channel The long leg can remain folded in its resting position ...

Page 24: ...methods described for the first MCT Step 6 After lowering the next MCT place two spacer wedges between the MCT s taking caution to not place the blocks on the weld so that the blocks are seated flush Then push the next MCT up against the previous MCT Taking caution not to push too hard but just enough so that the MCT s are butted up against the spacer blocks ...

Page 25: ...Page 23 PVT MCT10A EN Step 7 Clamp down the front of the MCT s using a strut nut a stand clamp a washer and a bolt ...

Page 26: ...PVT MCT10A EN Page 24 Repeat Steps 5 through 7 until MCT row is complete ...

Page 27: ...9 Loosen the long leg so that it can swing down into position Then set the strut in the channel for the long leg like the short leg When the Legs are set tighten up both the front and the back legs Step 10 Clamp down the back of the MCT s using a strut nut a stand clamp a washer and a bolt ...

Page 28: ...e 26 Step 11 Place a spacer block and slide the 2nd MCT over to make sure that it is still seated tightly against the 1st MCT Step 12 Clamp down the back of the MCT s using a strut nut a stand clamp a washer and a bolt ...

Page 29: ...Page 27 PVT MCT10A EN Repeat Steps 8 through 12 until MCT row is complete ...

Page 30: ...with additional suggested connection methodologies Chromasun recommends use of the steel header pipes within the Piping Kit to interconnect MCT units together Given that these pipes define the pitch between MCT units it is critical that the panel to panel spacing is correct Failure to space correctly will result in the need to loosen the strut nuts and reposition the MCTs 6 1 1 Parts List Part Par...

Page 31: ...connections have the MCTs plumbed to a manifold not provided and then follow the piping outlined in the Basis of Design BOD document The included steel pipes are to be welded to the heating fluid pipes receivers on the MCT Figure 10 MCT Piping Interconnects 3 MCT s in Series ...

Page 32: ...nections Header Connections are beyond the scope of this manual Please consult an engineer for an approved solution A section is included in the Chromasun Design Manual with additional suggested connection methodologies Header Connection ...

Page 33: ...Page 31 PVT MCT10A EN 7 Solar Field Controller 7 1 SFC Hardware Figure 11 Open SFC 7 1 1 SFC PCB with Expansion Board Figure 12 SFC PCB w Expansion Board SFC Expansion Board SFC PCB Power Supplies ...

Page 34: ...PVT MCT10A EN Page 32 7 1 2 Parts List Part Part Name SFC_Enclosure SFC_Backplate SFC_PS_Backplate SFC_Power_Supply SFC_PCB SFC_PCB_Expansion SFC_Breaker_Switch ...

Page 35: ...Page 33 PVT MCT10A EN SFC_Power Supply_DC_Jumper SFC_Common_Wire_Jumper SFC_Live_Wire_Jumper ...

Page 36: ...ng water on the rooftop MCT HT units should always be able to vent the air inside otherwise there could be pressure build up or vacuum pressure inside the unit which could cause damage For the panel to panel connections PDV interconnects are used to supply ventilating air as well as power and data For each individual string a homerun from the SFC will provide the ventilation power and data 1 01 1 ...

Page 37: ...s List Part Part Name Quantity PDV Interconnects Refer to Order The power data and ventilation are all connected with the same type of liquid tight non metallic flex conduit Within the PDV interconnect shown in Figure 14 are data and power jumpers each with a connector on both ends for connecting to the MCT Figure 14 Power Data Desiccant Interconnect NOTICE Equipment Damage Do not unseal the PDV p...

Page 38: ...y to install The interior of the MCT is designed for indoor conditions By opening the Power Data port the interior of the MCT is exposed to the outdoor elements If any foreign objects i e moisture mold get inside they may heavily damage the MCT Also try to ensure that the installation of the Power Data and Desiccant interconnects are done during dry weather ...

Page 39: ...ve the Power Data Interconnect ready Figure 16 Cable and Port Step 5 Connect the Power and Data cables Figure 17 Aligned Power and Data Cables Step 6 Securely fasten the conduit into the conduit fitting Figure 18 Sealed Cable to Port ...

Page 40: ... Chromasun SFC This makes it so that bare wire can be used for the homeruns The wire is connected to the junction panel inside of the Chromasun SFC The bare wire is then run inside of an appropriate conduit specified in the design layout The bare wire terminates in the string end Chromasun Junction box Then the MCT HT panel connects to the Chromasun Junction Box with a PDV interconnect ...

Page 41: ...r SF Flow Switch Outputs Blue 1 Pump signal to BMS for solar pump 2 Desiccant System 3 Desiccant System 4 Desiccant System NOTE If your system does not have a component confirm with your Chromasun customized order If your Chromasun customized order confirms that you do not have that component use a wire to jumper their respective sensor inputs NOTE The connection for the inputs are made between th...

Page 42: ...the environment within the MCT HT units during this breathing Chromasun has engineered an active desiccant system The active desiccant system is included as part of the Solar Field Controller and operates automatically without need for configuration or maintenance Details on this system are not included in this manual Please contact Chromasun for further information ...