oventrop OKF Series User manual

15
OKF-roof integration for slate and plain tile roofs,
basic set: item no. 136 12 93
OKF-roof integration for slate and plain tile roofs,
extension set: item no. 136 12 94
GB
Vertical installation
Valves, controls + systems
OK - lat-plate collector
Installation and operating instructions
Read installation and operating instructions carefully
before installing the collector.
The installation and operating instructions have to
remain with the user of the system.
Content:
Chapter Page
1. General information....................................................... 15
1.1. Information regarding operating instructions.................. 15
1.2 Symbol explanation......................................................... 15
1.3 Liability............................................................................. 15
1.4 Copyright ......................................................................... 15
2 Safety notes ................................................................... 16
2.1 Correct use/
Initial operation ................................................................ 16
2.2 Personnel......................................................................... 16
2.3 Specific risks ................................................................... 16
2.4 Other valid documents .................................................... 16
2.5 Important standards, rules, and EC directives
for the installation of solar collectors .............................. 16
3 Transport and handling ................................................. 16
3.1 Advice before installation . . . . . . . . . . . . . . . . . . . . . . . 17
4 Installation ...................................................................... 18
4.1 Basic set for vertical roof integration............................... 18
4.2 Extension set for vertical roof integration........................ 19
4.3 Installation field................................................................ 20
4.4 Collector installation........................................................ 22
5 Dimensions and technical data.................................... 27
5.1 Pressure loss chart OK .................................................. 28
5.2 Hydronic circuitry............................................................. 28
1 General information
1.1. Information regarding operating instructions
These installation instructions give important advice as to the han-
dling of the collectors. The observance of all mentioned safety
notes and instructions is paramount for safe working conditions.
These operating instructions are to be read carefully before working
at or with the collector and especially before initial operation!
The instructions should remain with the Regusol station or the
storage cylinder so that they are always at hand.
1.2 Symbol explanation
Safety guidelines are displayed by symbols. These guidelines are
to be observed to prevent accidents, damage to property and
malfunctions.
WARNING!
Signalizes that nonobservance of guidelines may result
in injuries.
Working with sharp-edged sheet metal pieces
Attention – Risk of open injuries.
ATTENTION!
Emphasises danger which may cause damage to the
appliance.
!
NOTE!
Emphasis s sugg stions and oth r us ful information
of op rating instructions.

1.3 Liability
The manufacturer does not accept liability for damages or mal-
functions caused by nonobservance of the operating instructions.
1.4 Copyright
The operating instructions are confidential. They are exclusively
for persons dealing with the collector. Transfer of the operating in-
structions to a third person without written approval of the manu-
facturer is inadmissible.

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2 Safety notes
At the time of its development, the flat-plate collector was de-
signed and manufactured according to the valid, approved
rules of technology and is of high functional reliability.
The application of the collector may, however, involve certain
dangers if it is not used properly or correctly.
2.1 Correct use / Initial operation
The safety in operation is only guaranteed if the collector is
used correctly.
Installation and initial operation may only be carried out by a
qualified tradesman. The approved rules of technology are
valid for practical use and suitable measures for the prevention
of accidents have to be taken during installation on the roof.
Any other use of the collector is prohibited and not compliant.
Claims against the manufacturer and/or his authorized repre-
sentatives regarding damages resulting from incorrect use of
the collector will not be accepted.
2.2 Personnel
Installation, maintenance and repair may only be carried out
by a qualified tradesman.
WARNING!
Risk of injury!
Improper use may lead to extensive injuries to persons and
damage to property.
or this reason:
– Any work may only be carried out by qualified persons.
Due to his professional training, knowledge and experience
as well as his knowledge of the relevant standards and regu-
lations, the qualified gas and water specialist is in a position
to carry out any work at heating installations (solar plants) and
to recognize possible dangers.
Due to his professional training, knowledge and experience
as well as his knowledge of the relevant standards and regu-
lations, the qualified electrician is in a position to carry out
any work at electrical installations and to recognize possible
dangers.
Due to his professional training, knowledge and experience
as well as his knowledge of the relevant standards and regu-
lations, the qualified roofer is in a position to carry out any
work at the roof construction/roofing and to recognize possible
dangers.
2.3 Specific risks
The safety notes shown here as well as the warning notes in
other chapters of the instructions are to be observed in order
to reduce health risks and avoid dangerous situations.
2.4 Other valid documents
Apart from the operating instructions for the collector, the
below mentioned operating instructions of the complete solar
plant should be observed. Notes including these instructions
– especially the safety notes – must be observed!
• BDH information sheet no. 17 “Thermal solar plants” parts
1, 2 and 3
• BDH information sheet no. 27 “Solar heating support“ parts
1 and 2
• Pump operating instructions
• Controller operating and installation instructions
• Controller general functional description
• Controller hydronic schemes
• Storage cylinder operating and installation instructions
• Diaphragm expansion tank operating and installation instruc-
tions
• Operating and installation instructions of other components
of the heating system
• Or country specific rules and regulations
• urther information on the internet:
- www.oventrop.de
- www.bdh-koeln.de
2.5 Important standards, rules and EC directives for the
installation of solar collectors
• DIN EN 12975-1 Thermal solar plants and their
components – Collectors – Part 1: General specification
• DIN EN 12976-1 Thermal solar plants and their
components – Preassembled plants – Part 1:
General specification
• DIN V ENV 12977-1 Thermal solar plants and their
components – Customized plants – Part 1:
General specification
• DIN 1055-4 Impacts on structural framework – Part 4:
Wind load stressing
• DIN 1055-5 Impacts on structural framework – Part 5:
Snow and ice load stressing
• DIN 18421 Insulation of technical plants
• DIN 18338 Roof tiling and roof insulation work
• DIN 18339 Plumbing
• DIN 18382 Electrical cabling in buildings
• DIN VDE 0185 Lightning protection plants
• DIN VDE 0100 Installation of power plants up to 1000V
Current standards and guidelines must be observed.
3 Transport and handling
• Information regarding storage of collectors in open air
Lay down collectors with the pane facing upwards. Do not
cover the collectors in open air! Condensation water (e.g.
under a foil) may cause glass corrosion. Avoid direct ground
contact (put timber beams underneath). Avoid scratches on
the panes by separating the collectors with spacers (e.g.
wood battens). When leaning the collectors against walls or
similar, please keep a minimum inclination angle of 15° and
use spacers. Do not use cardboard as intermediate layer. In
case of improper storage, humidity may penetrate through
the vent holes.
• Range and limits of application
The collector is designed for use in thermal solar installations
for hot water supply and support of the heating system. Wa-
ter (Attention: Risk of frost!) or a water and glycol mixture
are to be used as operating medium in a closed circuit. Op-
erational conditions leading to a long-term reduction of the
dew point in the collector are inadmissible. This can be the
case if collectors are directly integrated into the solar circuit
of a heat pump.
• Thermal protection
To avoid damage to the solar circuit, the technical information
“Thermal protection” must be observed for installations with
4 or more OK collectors with antireflective glass as well as
for central roof heating.
• Frost damage
Collectors cannot be drained off completely after having
pressurised and flushed the system. Do not leave pure water
in the collector where it will be exposed to frost!
• Mounted, empty collector
Completed mounted and unfilled collectors must only be
exposed to the sun for a few days to avoid damage to the
seals. Alternatively only install seals before filling.
• Diffusion of vapour for integrated roof installations
With roof integration, the area below the collector field must
be protected from rising humidity and airlocks (foil with
vapour diffusion barrier, sufficient aeration of the roof under-
neath the collectors).
• Disposal:
The collector contains harzardous waste. Dismounted collectors
can be returned to the manufacturer Oventrop. They will be dis-
posed of professionally.

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3.1 Advice before installation
– Risk of scalding at the collector connection as soon as the un-
covered collector is exposed to sunlight.
– Remove protection caps from the connections as soon as the
collector is exposed to sunlight. Risk of melting!
– Collectors must not be installed with the protective foil
Regulations for prevention of accidents during work on the roof
!
Collec or connec ions ge ho during sunshine
Do no expose he collec or wi h foil o rain
Do no moun collec or wi h foil on he roof

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4 Installation
4.1 Basic set for vertical roof integration
Basic set for roof integration, item no. 136 12 93 (collectors are not included)
Pos. Components: Basic set for roof integration Number per set
1Sheet metal cover, top (1 x left, 1 x right) 2
2Wooden support 2
3Collector connection hose + connection nipple G 1⁄2M x Ø 18 mm solder tailpipe 2
4Collector coupling hose 1
5Cellular rubber sealing tape 2
6oam rubber sealing tape (wedge-shaped) 2
7Collector bracket, top 4
8Metal side sheet 26
9Silicone T-profile 1
10 Gusset for roof covering, bottom (1 x left, 1 x right) 2
11 Metal sheet, bottom ( 1 x left, 1x right) 2
12 Collector bracket, bottom 4
13 Sheet metal strap, bottom 4
Seal 1⁄2" for connections 6
Clout nail 35
Dry wall screw 4 x 35 26
Dry wall screw 5 x 120 4
Plumber sealing screw 4.5 x 25 4

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4.2 Extension set for vertical roof integration
Extension set for roof integration, item no. 136 12 94 (collectors are not included)
Pos. Components: Extension set for roof integration Number per set
1Sheet metal cover, top 1
2Wooden support 1
3Collector coupling hose 1
4oam rubber sealing tape (wedge-shaped) 1
5Cellular rubber sealing tape 1
6Collector bracket, top 2
7Silicone T-profile 1
8Metal sheet, bottom 1
9Collector bracket, bottom 2
10 Sheet metal clamp, bottom 2
Seal 1/2” for connections 2
Clout nail 10
Dry wall screw 4 x 35 12
Dry wall screw 5 x 120 2
Plumber sealing screw 4.5 x 25 2

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4.3 Installation field
With plain tile roofs, keep existing roof battens as support and fix the additionally required battens according to the dimensional
specifications. Coverings without lathwork (roof slates etc.), fix collector brackets and all other components directly onto the base.
If possible, define installation field so that the distance between one side of the collectors and the lateral roof covering is approximately 35
mm. Cut tiles (roof slates) to size for the opposite side. With large roof coverings it is recommended to take the mean of the collector field.
Installation dimensions [mm]
Number of collectors Width of collector field Width of installation field A
1 collector 1,160 1,230
2 collectors 2,325 2,395
3 collectors 3,490 3,560
4 collectors 4,655 4,725
5 collectors 5,820 5,890
Dimensions for installation field and location of battens. Use battens of the same thickness as the existing ones.
Additionally required battens are marked grey (5 pieces); length of battens = A (width installation field)
Outer dimensions of collector (L x W) = 1,930 x 1,160.

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DE-XXX_EURO-C22-L22-Indach-Biber-Schiefer_MA-091012-1WA10019
Abb. 5 Indachmontage Längsschnitt
A
V
Longitudinal section roof integration
6
1
2
3
4
5
Roof integration - longitudinal section (upper drawing) and cross section (lower drawing)
1Roof batten, 2Counter lathing, 3oil, 4Rafters, 5Low diffusion foil, 6Ventilation space

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4.4 Collector installation
2
1
Installation tools: Tape measure, drill, crosshead bit PZ 2 and 3,
spanners sized 16, 19, 24 mm, hammer, cutter, silicone gun (if nec-
essary abrasive angle grinder with stone cutting disk).
Pipe conduit with foil: Cut foil in the shape of a trapeze, fold upper
part upwards and lower part downwards and fix onto the roof bat-
tens tightly. Humidity will escape sideways.
1. Align lower collector bracket with the roof batten and fix centrally
between two collectors and laterally at the edge of the collector
field.
2. Insert collectors (approx. distance between collectors 8 mm).
Insert silicone T-profile between collectors whilst pushing and pulling
to ease handling. Push collectors together flush with each other.
Screw upper collector bracket to the two collector edges with 2
dry wall screws 4 x 35 each.
Apply a thin layer of silicone between the edge of the T-profile and
the collector frame.

1.2.
3. 4.
5. 6.
4 x

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1
2
Connect collectors whilst holding them firmly to avoid damage to
the collector connection. ATTENTION: Risk of scalding during sun-
shine!
Connect collectors to the solar circuit. Check all collector connec-
tions when carrying out leakage test.
Insert solar sensor into the sleeve. Close opening with the help of
the rubber plug which is slipped onto the cable. eed cable into
the roof.
Line up the wooden support against the collector and fix with the
help of dry wall screws 4 x 35 and 5 x 120.
Adjust tiles below the collectors and fix with dry wall screws. ix sheet metal clamps for lower sheet (1) and bend over onto tile
(2).
7. 8.
9. 10.
11. 12.

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Introduce both pieces of the gusset into the lower collector groove
(1 + 2) and push together (3).
Push down the upright metal side until flush with roofing.
ix individual metal side sheets onto the battens with clout nails. Insert metal sheets into the lower groove and align with the upper
edge of the upper batten. Starting from the bottom to the top,
mount metal sheets onto each neighbouring row of tiles with an
overlap.
Cover each metal sheet with a tile. it in lower metal sheets for roof covering.
13. 14.
15. 16.
17. 18.

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1
2
ix lower metal sheets for roof covering with sheet metal clamps. Bond cellular rubber sealing tape onto the upper collector edge.
Link upper metal connection sheets with each other by interlocking
them at the rebate points and fix with dorsal gusset plate.
Position upper metal closing sheet so as to fit groove into the col-
lector rebate.
Nail upper metal closing sheets onto the battens and align the up-
right metal side.
Bond black foam rubber sealing tape onto the upper metal cover
sheets along the groove.
19. 20.
21. 22.
23. 24

26
In areas prone to storm, secure metal cover sheets by fixing them
with 2 additional plumber sealing screws.
Completed OK integration - plain tiled roof
25.

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5 Dimensions and technical data
110
1032
1160
1930
Flat-plate collector Unit OKF- CK 22
Gross surface area m22.25
Outer dimensions (L x W x H) mm 1933 x 1163 x 110
Aperture surface area m22.02
Collector connection – G 1⁄2M
Weight kg 37
Absorption coefficient ␣95%
Emission coefficient ␧5%
Transmission τ96%
Collector tilt angle for roof integration Degree 27-85
Permissible pressure/suction load N/m22250
Stagnation temperature at 1000 W/m² and 30°C °C ca. 208
Max. permissible working pressure bar 10
Collector heat return kWh/m2> 525
Heat exchanger content l 1.3
Glass cover – 3.2 mm solar safety glass
with antireflective coating
Solar sensor (inner diameter) Ø 6 mm
Absorber –
Absorber made of aluminium heat
conducting steel sheet and copper
pipe, laser welded

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5.1 Pressure loss chart OKF
5.2 Hydronic circuity
NOTE!
With parallel connections, the different fields
must be hydraulically balanced. Use double regulating
and commissioning valves if required.

Vertical series connection (max. of 5 x OK -CK 22 in series)
DE-XXX_EURO-C22-L22-Indach-Biber-Schiefer_MA-091012-1WA10019
Solarfühler
A
V
DE-XXX_EURO-C22-L22-Indach-Biber-Schiefer_MA-091012-1WA10019
SolarfühlerS
V
Solar sensor Solar sensor Solar sensor
Solar sensor
or an overview of our global presence
visit www.oventrop.com.
Subject to technical modifications.
136129380 03/2012
Pressure loss [mbar]
low rate [l/min.]
5 OKF-CK 22 in series
4 OKF-CK 22 in series
3 OKF-CK 22 in series
2 OKF-CK 22 in series
1 OKF-CK 22 in series
Pressure loss for several collectors connected in series depending on the volume flow, heat transfer liquid: 40% glycol /
60% water at 40°C, pressure loss including collector coupling and connection hoses.