oventrop ovsol, Installation Manual

Page 1: ...OVSOL Solar System Manual Solar hot water system installation guide for flat plate and evacuated tube systems...

Page 2: ...rack mounting kits 540 00 28 16 8 24 Piping the collector 33 Section Seven Flat Plate collector installation Flat Plate collector Dimensions and Technical Data 34 Flat Plate collector mounting system...

Page 3: ...5 16 SC 1 1 80 gallon OVSOL 5 16 SCE 1 1 80 gallon OVSOL 5 16 DC 1 1 80 gallon OVSOL 5 16 DCE 1 1 80 gallon OVSOL 5 24 SC 1 1 1 119 gallon OVSOL 5 24 SCE 1 1 1 119 gallon OVSOL 5 24 DC 1 1 1 119 gall...

Page 4: ...ng with the collector installation An effort has been made to conform procedures in this manual to the specifications of various governmental and agency solar programs Also many programs allow substit...

Page 5: ...d on a flat roof in an area that receives heavy snowfall the lower end of the units should be at least 18 above the roof level to minimize chances of snow build up on the bottom of the collectors Tran...

Page 6: ...tion angle Throughout the year the distance of the sun from the horizon will change from the longest on the first day of summer to the shortest on the first day of winter This translates to a 47 degre...

Page 7: ...plus or minus 5 from the recommended values listed above Another way to think of solar storage is as the fuel tank of the system It is used to store energy that can be used over the entire day In this...

Page 8: ...Flat plate collector 4 5 6 Using an external heat exchanger allows for either multiple or single tank configurations As long as the storage is sized correctly the tanks can be in any configuration Fo...

Page 9: ...X 15 246 Regusol X 25 318 7 Regusol X 15 462 Regusol EL130 189 Regusol X 25 287 8 Regusol X 25 528 Regusol X 15 216 Regusol X 25 328 9 Regusol X 15 243 10 Regusol X 25 270 11 Regusol X 25 297 12 Regu...

Page 10: ...sing a magnetic compass beware of standing near large metallic objects or power lines because they will affect the compass readings Shading Trees chimneys dormers other buildings new construction and...

Page 11: ...ystems the layout should integrate into the roofline For new construction integrating OVSOL collectors into the building s roof system should be addressed by the solar designer to the architect Sheddi...

Page 12: ...es Gross collector area OVSOL 5 8 22 28 sq ft OVSOL 5 16 44 67 sq ft Net absorber area OVSOL 5 8 19 37 sq ft OVSOL 5 16 38 75 sq ft Gross weight OVSOL 5 8 110 lbs OVSOL 5 16 220 lbs Inclination angle...

Page 13: ...t rail 85L x 1 5W x 1 0D inches Aluminum heatpipe manifold header 540 00 08 contains eight 8 tube connections Dimensions 76L x 6D inches 540 00 16 contains sixteen 16 tube connections Dimensions 38L x...

Page 14: ...f piping connection hardware not shown The bag contains 2 22 mm connection tee fittings 1 Manually operated air vent 1 Temperature sensor thermowell 2 22 mm to 3 4 inch adapter pipe 1 Tube of heatpipe...

Page 15: ...Dimensions 1 0H x 1 0D inches 44 Steel flat washer Dimensions 3 8 D nom inches 22 Split lock washer Dimensions 5 16 D nom inches 22 Hex nut Dimensions 5 16 D nom inches 540 00 28 8 and 540 00 28 16 a...

Page 16: ...0 08 and 540 00 16 Contents 1 22 mm straight compression coupling 1 Extruded aluminum manifold sleeve Dimensions 2W x 5 1 4D inches 1 Bottom support rail connection L bracket Dimensions 8L x 1 0W x 1...

Page 17: ...le for the center line of the roof rafter or truss Next pre drill two holes for each collector foot into the center line of the rafter using a drill bit smaller in diameter than the lag bolt supplied...

Page 18: ...posi tioned between the rafters to make sure the base plate has a structural member to screw into 2 Install the base plate with the square drive screws Mark the screw locations and apply polyurethane...

Page 19: ...roof rafter If necessary use perforated plates to extend the tile roof hooks from the roof rafters or lag bolt into spanners or blocks between the rafters to get the width needed between collector fe...

Page 20: ...erhang to the right and left for an 8 tube module For a 16 tube module you may allow up to four tubes to overhang to the left and right of the seams The overhangs are necessary for better weight distr...

Page 21: ...t into the collector frame with square nuts Bolt the bottom tube support with square nuts on the second hole from the bottom of the vertical collector frame tighten bolts to avoid the bottom support f...

Page 22: ...ltiple Collector Array Dimensions Adding Collectors Collector Extension Kit If there is more than one collector you may add a coupler between the manifold ends to connected them together Disassemble t...

Page 23: ...300F elastomeric foam insultube or comparable Install and attach the connection cuff Tighten the screw slot bolt and nut to clamp the connection cuff The bottom rails are connected with a bottom suppo...

Page 24: ...Insultube and weather proofing against UV degradation Use insulation with a wall thickness of at least 3 4 Install compression tees at supply and return on collector manifold Make sure the compression...

Page 25: ...egrees A Inches number of total slots B Inches 0 N A N A 75 10 11 4 74 15 17 8 72 20 23 10 70 25 30 14 68 30 35 16 65 35 41 19 62 40 46 22 58 45 51 24 53 50 56 27 48 55 60 28 43 60 63 31 40 65 67 32 4...

Page 26: ...ion for each upper mounting foot Blocks installed in the attic may have to be positioned between the rafters to make sure the base plate has a structural member to screw into 2 Install the base plate...

Page 27: ...e Assembly Instructions Adjustable rack collector mounting kit 540 00 28 16 and 540 00 28 8 For adjustable tilt mounting A 2 1 3 Steps 1 through 6 should be completed before beginning assembly on the...

Page 28: ...h 6 and seventh 7 holes from the center of the rail 3 1 5 Parts 5 16 x 2 0 inch bolts 5 16 inch nuts 3 8 inch washers 1 0 inch aluminum spacers hinge leaves A hinge leaves C assembled collector frame...

Page 29: ...een front and rear feet center to center where the hinge leaf barrels will be set for accurate tilt The width between the feet should be maximum 48 on center for 16 tube collector For the 8 tube colle...

Page 30: ...ength in step 7 Step 5 Attach hinge leaf B to the top end of the back support rail Step 6 Attach hinge leaf C to the bottom end of the back support rail Parts 5 16 x 1 0 inch bolts 5 16 inch nuts 3 8...

Page 31: ...nge leaf C from front collector rail with the holes in the walls of the front foot bracket and insert bolt Step 9 Align hinge leaf B from back support rail with hinge leaf A from front collector rail...

Page 32: ...uts 1 2 inch washers pieces from step 9 assembled collector frame Step 10a Using the 1 2 inch bolt sets attach the 50 32 for 8 tube collector back cross bracing piece horizontally to the collector Ste...

Page 33: ...fold while turning the tube gently back and forth Adjust vacuum tube Keep blue selective coating side facing upward The rubber gasket atop the vacuum tube must be set within manifold hole in header to...

Page 34: ...high temperature Insultube and weather proofing against UV degradation Use insulation with a wall thickness of at least 3 4 Install compression tees at supply and return on collector manifold Make su...

Page 35: ...odel Part Number 3 x 7 540 03 07 4 x 8 540 04 08 4 x 10 540 04 10 Gross Collector Area 21 5 sqft 32 7 sqft 40 7 sqft Frame Height 86 inches 98 inches 122 inches Frame Width 36 inches 48 inches 48 inch...

Page 36: ...s OVF 21 OVF 32 OVF 40 Contents 4 Flat Plate Quick Lock collector clamp 2 Flat Plate Quick Lock collector clamp With locking screw 4 Triangle base bracket foot 4 2 inch bolt washer nut set 2 4 inch bo...

Page 37: ...00 28 FPFM for all flat plate collectors OVF 21 OVF 32 OVF 40 Contents 2 Flat Plate Quick Lock collector clamp 2 Flat Plate Quick Lock collector clamp With locking screw 4 Triangle base bracket foot...

Page 38: ...F 32 OVF 40 Set of 4 clips These clips are used to attach and secure the flat plate collectors to strut mounting channel assemblies Required but not provided are strut channel strut locknuts bolts and...

Page 39: ...sitioned between the rafters to make sure the base plate has a structural member to screw into 2 Install the base plate with the square drive screws Mark the screw locations and apply polyurethane sea...

Page 40: ...nting figure 1 When mounting on a pitched roof figure 2 the table can be used by subtracting the roof pitch angle from the collector tilt angle to find the remaining angle for Table 1 With this method...

Page 41: ...ength from Table 1 Quick Lock collector clamp into front foot Attach two Quick Lock collector clamps with locking screws to bottom of the collector Keep the locking screws loose Secure the bottom Quic...

Page 42: ...ing conditions A manual air vent should be installed at the top of the collector on the outlet Soldered connections should be made with 95 5 solder The outlets of the collector are 1 copper pipe nippl...

Page 43: ...k the installation position for each lower mounting foot Blocks installed in the attic may have to be positioned between the rafters to make sure the base plate has a structural member to screw into 2...

Page 44: ...unting base plates Do not overtighten bolts Place the top of the collector down on the roof with the base plate positioned over a rafter Blocks installed in the attic may have to be positioned between...

Page 45: ...trut nuts or locknuts Required but not provided are strut channel strut locknuts bolts and washers Usually the Collectors are attached and secured to two horizontal load bearing strut channels placed...

Page 46: ...ion does not imply endorsement or warranty of this product by the SRCC System Model Piping Schematic page OVSOL 5 16 SC 46 OVSOL 5 16 SCE 47 OVSOL 5 16 DC 48 OVSOL 5 16 DCE 49 OVSOL 5 24 SC 50 OVSOL 5...

Page 47: ...V 5 evacuated tube collector and an 80 gallon glass lined tank with one internal coil An expansion tank is installed at the Regusol on the safety group Oventrop NT propelyne glycol antifreeze is fille...

Page 48: ...ne Glycol Antifreeze System Design Description The solar closed loop heating system consists of the Oventrop Regusol 130 EL pump and control station one OV 5 evacuated tube collector and an 80 gallon...

Page 49: ...he Oventrop Regusol 130 EL pump and control station one OV 5 evacuated tube collector and an 80 gallon glass lined tank with two internal coils An expansion tank is installed at the Regusol on the saf...

Page 50: ...130 EL pump and control station one OV 5 evacuated tube collector and an 80 gallon glass lined tank with two internal coils and an electric backup element An expansion tank is installed at the Regusol...

Page 51: ...one OV 5 evacuated tube collector and an 80 gallon glass lined tank with one internal coil An expansion tank is installed at the Regusol on the safety group Oventrop NT propelyne glycol antifreeze is...

Page 52: ...eating system consists of the Oventrop Regusol 130 EL pump and control station one OV 5 evacuated tube collector and an 80 gallon glass lined tank with one internal coil and an electric backup element...

Page 53: ...of the Oventrop Regusol 130 EL pump and control station one OV 5 evacuated tube collector and an 80 gallon glass lined tank with two internal coils An expansion tank is installed at the Regusol on the...

Page 54: ...usol 130 EL pump and control station one OV 5 evacuated tube collector and an 80 gallon glass lined tank with two internal coils and an electric backup element An expansion tank is installed at the Re...

Page 55: ...ne OV 5 evacuated tube collector and an 80 gallon glass lined tank with one internal coil An expansion tank is installed at the Regusol on the safety group Oventrop NT propelyne glycol antifreeze is f...

Page 56: ...ating system consists of the Oventrop Regusol 130 EL pump and control station one OV 5 evacuated tube collector and an 80 gallon glass lined tank with one internal coil and an electric backup element...

Page 57: ...f the Oventrop Regusol 130 EL pump and control station one OV 5 evacuated tube collector and an 80 gallon glass lined tank with two internal coils An expansion tank is installed at the Regusol on the...

Page 58: ...sol 130 EL pump and control station one OV 5 evacuated tube collector and an 80 gallon glass lined tank with two internal coils and an electric backup element An expansion tank is installed at the Reg...

Page 59: ...e OV 5 evacuated tube collector and an 119 gallon stainless steel tank with one internal coil An expansion tank is installed at the Regusol on the safety group Oventrop NT propelyne glycol antifreeze...

Page 60: ...heating system consists of the Oventrop Regusol 130 EL pump and control station one OV 5 evacuated tube collector and an 119 gallon stainless steel tank with one internal coil and an electric ele ment...

Page 61: ...of the Oventrop Regusol 130 EL pump and control station one OV 5 evacuated tube collector and an 119 gallon glass lined tank with two internal coils An expansion tank is installed at the Regusol on th...

Page 62: ...usol 130 EL pump and control station one OV 5 evacuated tube collector and an 119 gallon glass lined tank with two internal coils and an electric backup element An expansion tank is installed at the R...

Page 63: ...solar tank should include valves and piping for service A domestic hot water expansion tank can be installed on the cold water feed to the tanks The expansion tank should be installed downstream from...

Page 64: ...pipe for plumbing the tanks To prevent heat loss through the copper tubing insulate all tubing with at least 1 2 wall tube insulation This should include the cold water feed to the solar storage tank...

Page 65: ...ttom coil solar return from collector bottom coil solar supply to collector T P valve Locating the Water Heater The water heater should be located in an area where water leakage from the tank or conne...

Page 66: ...ure When such a location cannot be avoided a suitable drain pan must be installed under the water heater and the drain pan must be connected to a drain The water heater should be installed as close to...

Page 67: ...notes Remove transmission station from the packaging Pull the front insulation 1 from the control retainer 2 while pushing the control retainer against the back insulation 3 Now the control retainer c...

Page 68: ...Open vent with radiator vent key on deaerator to remove any air separated from solar transfer fluid Make sure thermometers are left in their vertical position as valve handles must be left open Check...

Page 69: ...ller should be sunlight resistant shielded copper wire with at least two conductors at 18 AWG 1 Unscrew the cross recessed screw of the cover and remove it from the housing 2 Wire the collector sensor...

Page 70: ...erature the collectors must be above the tank to begin solar circulation No change is necessary DT F differential turn off set point The second indicator will be DT F differential turn off set point D...

Page 71: ...ng 285o F OCX system cooling Factory setting OFF OCN Minimum collector limitation Factory setting OFF OCF antifreeze function Factory setting OFF The settings for the following displays are as follows...

Page 72: ...10 minutes to assure there is no solder flux or debris left within the collector loop piping This step may also be used to cool the collectors before filling the system with propylene glycol Fill Pro...

Page 73: ...l Regusol is wired and solar loop is air tested for leaks The collector loop can now be filled with the recommended anti freeze Once the solar loop is filled place Regusol thermometer handles in the...

Page 74: ...o remove air from antifreeze solution A Make sure check valves in Regusol are not stuck open B Replace controller C Check sensor circuits and wiring A Controller is not plugged in B Breaker tripped to...

Page 75: ...nstalled to protect not only the stainless steel solar storage tank and coils but also the existing hot water heater and its plumbing as well Trouble Shooting Trouble Probable Cause Remedy A Wait unti...

Page 76: ...lat plate collectors 15 20 years Dual or single coil indirect glass lined tanks good water quality 20 years Regusol 130 EL Oventrop PE Controller and sensors Wilo circulator 10 15 years All inquiries...

Page 77: ...r dismounting and consequential losses and damages Warranty claims must be received by Oventrop Corporation within the applicable warranty period and within thirty 30 days from when the cause for the...