Chromasun High?Temperature Thermal Collector System User manual

©2011 Chromasun All Rights Reserved
1.1.1.1
Chromasun
INSTALLATION MANUAL
Chromasun High-Temperature Thermal Collector System

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:
[phone]
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 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.

Page | 1 PVT-MCT10A-EN
Table of Contents
1General Information................................................................................................................ 4
1.1 Bulk Packaging .............................................................................................................. 4
1.2 Domestic Shipment ...................................................................................................... 4
1.3 Sling Kit (Recommended Option) ................................................................................. 4
2The 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 .................................................. 8
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
3Measurements and Weights ................................................................................................. 11
4Pre-Installation Checklist....................................................................................................... 13
4.1 Inventory Check.......................................................................................................... 13
4.2 Site Layout Checklist................................................................................................... 13
5Rigging & 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
6MCT 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
7Solar 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
8Desiccant Ventilation Hardware............................................................................................ 40

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
NOTE: Any materials and work required to
prepare the roof for the MCT must be
provided for by the installing contractors.
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.

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.

Page | 5 PVT-MCT10A-EN
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.
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).
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).
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

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.
Figure 2: Chromasun MCT-HT panels at SCU Benson Center

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

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.
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.

Page | 9 PVT-MCT10A-EN
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.

PVT-MCT10A-EN Page | 10
Figure 5: Components from Front View
Figure 6: Components from Rear View

Page | 11 PVT-MCT10A-EN
3Measurements and Weights
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

PVT-MCT10A-EN Page | 12
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 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
3048
121
1110
44
25
25
2940
116
1371
54
30
30
2809
111
1622
64
35
35
2657
105
1861
73
40
40
2485
98
2085
82
45
45
2294
90
2294
90

Page | 13 PVT-MCT10A-EN
4Pre-Installation Checklist
4.1 Inventory Check
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
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 | 15 PVT-MCT10A-EN
Step 3.
Remove the two triangle pieces from one side
of the crate only to maintain structural 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.

PVT-MCT10A-EN Page | 16
Repeat steps 3 through 5 until all the MCT’s are removed

Page | 17 PVT-MCT10A-EN
5.1.2 Collapsing the Wood Pallet
Step 1.
Arrange the pieces as shown below.
One row of end pieces fit nicely 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.

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.