The Thermo Dynamics Solar Boiler system is a revolutionary concept in solar domestic water heating systems. It is a solar preheat system using the external Side-Arm heat exchange system pioneered by Thermo Dynamics and the Micro-Flo® collector system for unsurpassed heat exchange efficiency.

 

Thermo Dynamics Ltd. warranties the Micro-Flo® collectors and Solar Boiler heat exchange module for ten (10) years, all other components are warranted for one (1) year.

Micro-Flo® collectors are available in 1.2m x 2.4m, (4' x 8'). The Solar Boiler system can have either one or two Micro-Flo® collectors installed. Collector mounting hardware is available for either sloped or flat roof installations.

Year round domestic and small commercial hot water preheat systems. Ideal for remote locations where power electrical power consumption is limited or unavailable.

None. Double freeze protection, using antifreeze and draindown, protects the system in cold climates. In hot climates over temperature protection is provided by inhibited glycol coupled with draindown and thermostatic tank protection.

Thermo Dynamics Ltd. (TDL) is a Canadian company engaged in the research, development, production, distribution and installation of solar thermal equipment. The company has been involved in the solar thermal industry since 1981 and operates from its head office and factory in Dartmouth, Nova Scotia, Canada, the sister city of Halifax situated on the Atlantic coast. The company's specialization is the glazed liquid-flat-plate (LFP) collectors with metal absorbers. TDL is a fully integrated solar thermal company with the ability to convert raw aluminum and copper into a high technology solar water heating system.

The Solar Boiler is available in two formats: SB32-9PV SB64-9PV All systems come with a Solar Boiler module, S-Series collector(s), a tubing kit to connect the Solar Boiler module to the collector, and a flush mounting kit for the collector. Storage tanks are supplied by the customer. The storage tank must have 1 unused port at the top of the tank and one unused port at the bottom of the tank.

4.1 Shipping Information:

System: SB32-9PV

Ship Weight: 94 kg (220 lbs)

102" x 6" 53" Collector "B"

18" x 11" x 30" Solar Boiler module

18" x 11" x 30" Hardware

System: SB64-9PV

Ship Weight: 141 kg (360 lbs)

102" x 6" 53" Collector "B"

102" x 6" 53" Collector "B"

18" x 11" x 30" Solar Boiler module

18" x 11" x 30" Hardware

 

Thermo Dynamics S32 flat plate liquid collectors are single glazed with low-iron tempered glass. The absorber consists of a single serpentine aluminum fin with an integral copper tube , which is completely surrounded by the aluminum and metallurgically bonded together. The back and sides are insulated with a 25 mm (1") layer of compressed fiberglass. The collector frame is extruded aluminum with a baked-enamel finish, (dark brown). Collector mounting is by way of a sliding bolt-track. Flush and racked collector mounting formats are easily accommodated.

Factory installed temperature sensors; absorber coatings: semi-selective paint surface

S32: 1.20 m x 2.47 m x 0.086 m

(47-3/8 in x 97-3/8 in x 3-3/8 in)

 

Gross area: 2.96 m2 (31.9 ft2)

Aperture area: 2.78 m2 (30.0 ft2)

Absorber area: 2.87 m2 (30.9 ft2)

 

Liquid capacity: 0.389 L (0.086 IG)

Model: S32A-P or S32B-P

Net: 45 kg (99 lb)

Shipping: 55 kg (120 lb)

(includes wooden crate)

See the Thermo Dynamics publication "S Series Solar Collectors - Technical Specifications" for more complete specifications on the Micro-Flo® collectors.

The Solar Boiler module is a Shell and Coil all copper heat exchanger and glycol reservoir. The heat transfer fluid in the solar loop circulates from the reservoir to the solar collectors and back through the coils of the heat exchanger by a positive displacement pump. The solar loop is closed from the atmosphere. A 862 kPa (60 psi) pressure relief valve is installed for safety. Circulation on the shell or water side of the heat exchanger is generated by natural circulation.

Freeze protection is provided by a solution of 40% Propylene Glycol USP and 60% distilled water in the solar loop. Propylene glycol does not freeze at the nominal freezing point (Freezing point -19°C (-2.4°F). The water in the system starts to form ice crystals and pumping becomes difficult. The 40/60 aqueous solution of Propylene Glycol provides burst protection to -51°C (-60°F).

The Solar Boiler module operates at atmospheric pressure. The storage tank is at city water pressure and the water will flow into the Solar Boiler module if there is a leak in the heat exchanger, diluting and dispelling the small volume of heat transfer fluid from the system. Propylene glycol is nontoxic food grade approved heat transfer fluid requiring a single wall heat exchanger.

The glycol reservoir in the Solar Boiler module will overflow onto the floor. Propylene glycol is clear (older propylene glycol may be slightly green and/or brown). The fluid has an oily, slippery feeling when rubbed between your fingers.

A high temperature limit sensor installed on the storage tank prevents the storage tank from exceeding 82°C (180°F). An adjustable tempering valve can be installed on the hot water outlet if required by the local plumbing code.

The boiling point of 40/60% aqueous solution of Propylene glycol/distilled water is 105°C (221°F). The maximum recommended bulk temperature is 163°C (325°F) and the maximum recommended film temperature is 191°C (375°F). The Solar Boiler is equiped with a 858 kPa, (125 psi) pressure relief valve (PRV) on the solar loop. In the event of a pump failing to circulate the glycol on a hot sunny day, the glycol expands in the solar collector, increasing the pressure in the solar loop, and thereby increasing the boiling point of the glycol to prevent boiling.

In the collector loop, the propylene glycol, when the pH is approximately 7, is non aggressive. All wetted parts are copper, stainless steel, carbon and brass.

The Solar Pump is a brass body, vane-type, positive displacement pump. The pump has special clearances and ethelyene-propylene seals for high temperature protection. It has a maximum output pressure of 500 kPa (73 psi). The nominal flow rate is 1.2 L/min. (0.32 USGPM). The pump has an integral built in strainer to remove any foreign particles from the solar loop. The pump is driven with an efficient DC motor. Nominal power consumption is 18 watts (1/40hp).

88°C (190°F)

500 kPa (73 psi)

The connection between the Solar Boiler module and the solar collectors is made with soft copper tubing

A copper tube kit is supplied for connecting the solar collectors to the Solar Boier module. The kit consists of two 9.53 mm (3/8") copper tubes, Armaflex foam insulation, and 16/2 communication wire. The insulation is put on the copper tubing on site by the installer.

LIFE-LINE®-C consists of two 9.53 mm (3/8") copper tubes. The tubing is insulated with non-hygroscopic glass fibre insulation and has a light gray PVC jacket. Two 14 gauge communication wires are included in the bundle. LIFE-LINE®-C is capable of withstanding working fluid temperature of 200°C (392°F) and pressure of 1.72 MPa (250 psi). The heat loss coefficient is 0.144 W/m-°C (0.083 Btu/hr ft-°F).

The Solar Boiler uses a proportional control strategy, achieved by the variable output of a 18W to 20W photovoltaic module. The variable collector flowrate and thermosyphonic flow between the Solar Boiler and the storage tank ensure that high quality water is supplied to the auxiliary heater throughout the year. The PV module drives the DC motor through a linear current booster to ensure good performance at low light levels.

1.1 Trade Names

Current at Peak Power 1.17 A

Voltage at Peak Power 17.1 DCV

Typical Peak Power 18.0 W

Short Circuit Current 1.19 A

Open Circuit Voltage 20.8 DCV

The Solar Boiler™ uses a Linear Current Booster to match the power delivery of the PV module to the DC motor under varying light condition. At peak irradiance the PV module runs the motor at rated speed, at lower light levels the LCB transforms the voltage into current to allow the motor to start. The motor runs at reduced speed at lower light levels providing a proportional control for the Solar Boiler™.

 

The controller also measures the collector temperature and the storage temperature to provide Dela T control.

Other features include high temperature storage shut off and high collector temperature shut off.

The Solar Boiler uses Thermo Dynamics high performance Shell-and-Coil heat exchanger mounted in the Side-Arm configuration. This system provides a highly stratified storage tank. The storage tank can be any commercially available tank with the correct connections.

The Shell-and-Coil heat exchanger is manufactured entirely from copper. The heat exchanger consists of several copper coils enclosed in a copper shell. All connections are brazed and are external to the shell.

The Solar Boiler utilises a high performance, Shell-and-Coil heat exchanger. Heat transfer area: 0.61 m2 (6.5 ft2). Overall heat transfer coefficient: 380 W/m2·K (67 Btu/h·ft2·°F).

Hot water in contact with copper tubing has shown a life expectancy in excess of 30 years. Corrosion inhibitors on the propylene glycol heat transfer fluid offer excellent protection in the collector loop.

The Shell-and-Coil heat exchanger is tested to 300 psi on the city water side and 120 psi on the collector side.

The Solar Boiler module is designed to work with many commercially available storage tanks. Minimum solar storage is 272 L (72 USG) of water. Tanks must be suitable for hot water service and have at least 2 ports (19 mm, 3/4") at the top of the tank and one bottom port. Most electric water heater tanks are suitable. Electric elements must not be activated.

The propylene glycol, used in the Solar Boiler, is a non toxic, food grade approved heat transfer fluid. It is commonly used in the food industry for high speed freezing of meats and poultry through direct immersion in the fluid, as well as an additive in many food items such as salad dressings, vanilla extract, etc.

Solution of Propylene Glycol, USP and distilled water.

No flash point and noncombustible

Maximum anticipated life span is 5 to 15 years.

The Solar Boiler system is shipped in three or four boxes depending on the collector configuration. One for the Solar Boiler module, one for the LIFELINE® tubing, and one or two for the solar collectors.

Two (2) men with a ladder and rope can easily mount collectors. The system may be installed with normal plumber's and carpenter's tools. Special tools are not required. The LIFELINE® flexible tubing, with the prepackaged components, reduces installation time 2 1/2 - 4 hours with an experienced crew.

The installation manual, with maintenance and troubleshooting procedures, is supplied with systems.

The system does not need to be shut down for vacation or winter periods. Initial system start-up should be carried out in early morning or late evening when the collectors are not under stagnation conditions.

Check for fluid loss in the collector loop every year. Check the pH of the collector loop fluid annually, and replace it if not between 6.0 and 7.0. Replace the collector fluid every five to fifteen years. The storage tank should be drained every year to prevent sedimentation. The backflushing procedure for the heat exchanger must be followed every year. The backflushing procedure is listed under the top of the Solar Boiler and in the installation manual.

National Solar Test Facility, Mississauga, Ontario. Date: February 25, 2009.

Model: SB64-9PV

System tested on indoor test bench using solar simulator.

Normal to incident radiation

Tank: 20°C (68°F)

Day: 3.3 m/s (10.8 ft/s)

300 L/Day @ 55°C.

 

(66 IG/DAY @ 131°F)

63.83 MJ (60.50 MBtu)

The system referred to in section 1.3 was simulated using WATSUN 12.1 and TMY weather data.

Halifax: 2,982 kWh, (10.2 MMBtu)