Chromasun High?Temperature Thermal Collector System User manual

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©2011ChromasunAllRightsReserved
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1.1.1.1 
Chromasun
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INSTALLATIONMANUAL
ChromasunHigh‐TemperatureThermalCollectorSystem
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PVT‐MCT10A‐EN  Page|II
AbouttheManual
NOTE:IMPORTANT!Readthisentire
manualbeforebeginninginstallation,
wiring,orusageofthisproduct.

NOTE:Theinstallationofthis
equipmentmustcomplywithall
National,State,andLocalCodes.

NOTE:Bycarefullyreviewingthe
informationcontainedinthis
manual,andfollowingthe
instructionstheriskof:improper
operation,personalinjury,and/or
componentdamagewillbe
minimized.

NOTE:IMPORTANT!Whenindoubt
pleaseaskaChromasun
Representative!
ForTechnicalSupportpleasecall:
+14086344104
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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.
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CAUTION
Indicatesapotentiallyhazardoussituation
which,ifnotavoided,couldresultinaminor
ormoderateinjury.Itmayalsobeusedto
alertagainstunsafepractices.

CAUTION
Indicatesasituationthatcouldresultin,
equipmentorpropertydamage.

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TableofContents
1GeneralInformation................................................................................................................4
1.1BulkPackaging..............................................................................................................4
1.2DomesticShipment......................................................................................................4
1.3SlingKit(RecommendedOption).................................................................................4
2TheChromasunMCTSystem..................................................................................................5
2.1Background...................................................................................................................5
2.2KeyComponents...........................................................................................................6
2.2.1HighTemperatureMicro‐Concentrator(MCT‐HT)............................................6
2.2.2SolarFieldController(SFC)................................................................................8
2.2.3Power,Data,Ventilation(PDV)Interconnects..................................................9
2.3Optional/RecommendedComponents........................................................................9
2.3.1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
5.2.2ToolsList..........................................................................................................20
5.3MCTMountingProcedure..........................................................................................21
6MCTPlumbing.......................................................................................................................28
6.1PipingInter‐Connection..............................................................................................28
6.1.1PartsList..........................................................................................................28
6.1.2ToolsList..........................................................................................................28
6.2HeaderConnections...................................................................................................30
7SolarFieldController.............................................................................................................31

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7.1SFCHardware.............................................................................................................31
7.1.1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
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Page|3  PVT‐MCT10A‐EN
WhatisIncluded
NOTE:Readingthroughthismanualisa
necessity.TheChromasunmicro‐
concentrator(MCT)High‐Temperature
ThermalCollectorSystemrequiresattention
todetailforinstallation.
NOTE:Theinstallationofthisequipment
mustcomplywithallNational,State,and
LocalCodes.
CoreSystemComponents:
FullyAssembledMCTUnit(s)
SolarFieldController(s)(SFC’s)
Power,Data,Ventilation(PDV)
Interconnects(s)
JunctionBox(es)
Recommended(Optional):
SlingKit
oFourLeggedNylonBridle
MountingKit
oLegStands
oStandClamps
oAllrequiredFasteners
HeaderKit
oSteelHeaderPipes
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NOTE:Anymaterialsandworkrequiredto
preparetherooffortheMCTmustbe
providedforbytheinstallingcontractors.
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ShippingInspection
AssoonastheMCTarrivesatthejobsite:
Verifythatalloftheunitshavearrived
byinspectingtheshippinglabelsand
comparingthemtotheidentification
dataonthesales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aclaimwiththe
carrier.Donotinstallanydamagedparts
withoutappropriateChromasuncustomer
support’sapproval!
Visuallyinspecttheinternal
componentsforshippingdamagesand
formaterialshortagesassoonas
possible.Concealeddamagemustbe
reportedwithin15days
Ifconcealeddamageisdiscovered,stop
unpackingtheshipment.Ifpossible,
takephotosofthedamage.Theowner
mustprovidereasonableevidencethat
thedamagedidnotoccurafterdelivery
Notifythecarrierofdamage
immediately.Requestanimmediate
jointinspectionofthedamagewiththe
carrier.Donotattempttorepairany
partsuntilthedamageisinspectedby
thecarrierandyouhavereceived
instructionsfromChromasuncustomer
service.
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PVT‐MCT10A‐EN  Page|4
1GeneralInformation
1.1 BulkPackaging
LargeordersofMCTpanelsareshippedinbulkonreusablepallets.TheMCTsareintegralto
theshippingpalletandmustbedisassembledfromthepallettobeunloaded.Additionalparts
accompanytheMCTshippingpalletsinstandardcorrugatedpackaging.
1.2 DomesticShipment
UnitspurchasedwithinNorthAmericawillbeshippedviaaflatbedtruck.TheMCTunitsare
stackedinsetsoffive(5)inreusablewoodenpallets.TounloadtheMCT’sfromthepalletsthe
MCT’smustberemoved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transportMCTpanelsonto
theroofbylatchingontotheliftpointslocatedateachcorneroftheMCT.TheSlingKitportion
ofthisinstallationmanualwaswrittenforusewithourSlingKit.Ifyouchoosetonotuseour
SlingKitpleaseconsultanengineerforasafealternativeliftingmethodusingthedatafoundin
theweightandmeasurementsection.
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2TheChromasunMCTSystem
2.1 Background
TheChromasunHigh‐TemperatureThermalCollectorSystemconsistsoftwo(2)major
components:TheMCTHigh‐TemperatureCollector(MCT‐HT);andtheSolarFieldController.
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AnMCTinstallationwilltypicallyconsistofmanySFCunitsconnectedtooneormoreSolarField
Controllers.EachSFCcansupportupto40MCTs(4stringsof10unitseach).
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Thesetwocomponentscombinetoprovideanactivetrackingcollectorsystemthatisableto
provideconsistentthermalenergyupto200°C(400°F).
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Field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
10
2C
09
2C
08
JC2
2A
01
2A
02
2A
03
2A
04
2A
05
2A
06
2A
07
2A
10
2A
09
2A
08
JA2
ToBuildingHeating
Load
FromBuildingHeating
Load
TypicalMCTHigh‐TemperatureConcentratingSystemFieldLayout
Legend
1A
10
1A
10
JA1
MCT‐HT
StringJunctionBox
PDVHomerun
HHWSupply
HHWReturn
PDVConnection
Figure1:TypicalFieldlayoutoftheMCT‐HTSystem
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PVT‐MCT10A‐EN  Page|6
2.2 KeyComponents
2.2.1 HighTemperatureMicro‐Concentrator(MCT‐HT)
TheChromasunMicro‐ConcentratorMCT‐HTisanextgenerationhighperformancesolar
collector.Ithasbeendesignedpurposelyforrooftopintegration.TheMCTislowprofile,
lightweight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pumphardware.
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Figure2:ChromasunMCT‐HTpanelsatSCUBensonCenter
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ReceiverPipe
(SS304A213Tube)
ParallelMirrors
Figure4SchematicofsunlightbeingconcentratedwithinanMCT
Figure3ExplodedviewofanMCT‐HT

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PVT‐MCT10A‐EN  Page|8
2.2.2 SolarFieldController(SFC)
AChromasuninstallationwillfeatureoneormoreSolarFieldControllers,whichserveasthe
supervisorycontrollertotheindividualMCTunits.EachMCTSFCcanconnectuptofour(4)
stringsoften(10)MCTCollectors,foratotalof40MCTCollectorsperSFC.AdditionalMCTField
Controllerscanbeconnectedtoincreasethenumberofpanelscontrolledinthesystem.
TheSolarFieldControllersacttocontrolthefield,tellingtheMCTswhentoturnonandoffas
wellasprovidingdatalogging,alarm,andfirmware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,eachpanelisconnectedusing
Chromasun‐providedPDVinterconnects.Inthisway,theSFCsuppliespower,dataanddry
ventilationairtoeachMCTitcontrols.

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2.2.3 Power,Data,Ventilation(PDV)Interconnects
OurPower,Data,andVentilationInterconnectsarerequiredtoprovide,power,data,and
ventilationfromoneMCTtothenext.ThesecanbeseenbelowinFigure5.
2.3 Optional/RecommendedComponents
2.3.1 MountLegs(setof2perMCT)(Optional)
OurMountLegsenableinstallationoftheMCTattherecommendedanglefromaflatbase.A
flatbasebuiltfromUnistrut(orsimilarstructure)isrequired.Themountingportionofthis
manualwaswrittenforusewithourMountLegs.IfyouchoosetonotuseourMountLegs
pleaseconsultanengineerforanalternativemethod.ThesecanbeseenbelowinFigure5and
Figure6.
2.3.2 StandClamps(perMCT)(Optional)
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usetoconnecttheplumbingbetween
MCT’s(CarbonandStainlessSteelavailable).TheHeaderPipeportionofthisinstallation
manualwaswrittenforusewithourHeaderPipes.IfyouchoosetonotuseourHeaderPipes
pleaseconsultanengineerforanalternativemethod.ThesecanbeseenbelowinFigure6.
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Figure5:ComponentsfromFrontView
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Figure6:ComponentsfromRearView

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3MeasurementsandWeights
Table1:PhysicalCharacteristics
DimensionsSeeDiagramsBelow
Weight100kg220lb
UnitArea4.23m
2
45sq.ft.
WeightperUnitArea24kg/m
2
4.9lb/sq.ft.
WeightperUnitUnistrut38kg/m28lb/ft
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Figure7:MCTCanopyFront,Rear,TopandSideViews
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Figure8:MCTSideView
NOTE:TheMCTangleandcorrespondingheightoftherearlegvarydependingonsitelocation.
Thedesigningengineershouldspecifythepanelangleandthedistancebetweenrows
toavoidshading.TheChromasunMCTDesignManualshouldbereferencedformore
detailedinformation.For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BDimensionBDimensionC  DimensionC
0  0  3087 122 0 0
5  5  3075 121 269  11
10  10  3040 120 536  21
15  15  2982 117 799  31
20  20  2901 114 1056  42
25  25  2798 110 1305  51
30  30  2674 105 1544  61
35  35  2529 100 1771  70
40  40  2365 93 1984  78
45  45  2183 86 2183  86

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4Pre‐InstallationChecklist
4.1 InventoryCheck
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Makesurethatalltheunitsarepresent
Checkthecontainerstomakesuretheywerenotmistreatedordamaged
InspecttheMCT’sforanydistortionssuchas:
oShatteredGlass
oCracks
oObviousBends
oCollapsed/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willbeabletomounttherequired
numberofpanels
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5Rigging&Installation
5.1 UnpackingtheMCT‐HT
5.1.1 WoodPallet
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Step1.
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Theshippingpallet.
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Step2.
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Removethetwotopcrossbarswhichareheld
downby4X2.5”#10woodscrews.(8total)
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Step3.
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Removethetwotrianglepiecesfromoneside
ofthecrateonlytomaintainstructuralstability.
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Eachsideisheldinplaceby13X2.5”#10wood
screws.(26total)
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Step4.
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Removethetworectangularendpieces.
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Eachendpieceisheldinplaceby2X2.5”#10
woodscrews.Aswellas2X2”3/8”hexcap
bolts.
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Step5.
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CranetheMCTunitawaybyconnectingtothe
4liftingholeslocatedateachcornerofthe
MCT.
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Repeatsteps3through5untilalltheMCT’sareremoved
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Page|17  PVT‐MCT10A‐EN
5.1.2 CollapsingtheWoodPallet
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Step1.
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Arrangethepiecesasshownbelow.
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Onerowofendpiecesfitnicelyintothe
groovesbetweenthehorizontalslatsinthe
pallet.
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Theremaining4endpiecesarearrangedontop
oftheendpiecesalreadyonthepallet,upside
downtointerlock.
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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.
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Step2.
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ThefinalizedCollapsedWoodPallet.
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Step3.
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TheWoodPalletscanbestackedontopofeach
otherwhenreadytobeshippedbackto
Chromasun.
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Step4.
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ThePalletsreadytobeshippedback.
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