oventrop OKF-CK 22 User manual

15
Valves, controls + systems
OK - lat-plate collector
Installation and operating instructions
OKF-roof integration for pan tiled roofs,
basic set: item no. 136 12 91
OKF-roof integration for pan tiled roofs,
extension set: item no. 136 12 92
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
GB
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.
Vertical installation

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2 Safety notes
At the time of its development, the flat-plate collector was designed
and manufactured according to the valid, approved rules of tech-
nology and is of high functional reliability.
The application of the collector may, however, involve certain dan-
gers 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 qual-
ified 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 represen-
tatives regarding damages resulting from incorrect use of the col-
lector 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 regulations,
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 regulations,
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 regulations,
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 instructions
• 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. Water
(Attention: Risk of frost!) or a water and glycol mixture are to be
used as operating medium in a closed circuit. Operational con-
ditions 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 pres-
surised 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 ex-
posed 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 dif-
fusion barrier, sufficient aeration of the roof underneath the col-
lectors).
• 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 91 (collectors are not included)
Pos. Components: Basic set for roof integration Number per set
1Metal cover sheet, 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
5oam rubber sealing tape (wedge-shaped) 7
6Cellular rubber sealing tape 2
7Bracket for roof integration, top 4
8Metal side sheet (1 x left, 1 x right) 4
9Silicone T-profile 1
10 Metal sheet fixing device 14
11 Gusset for roof covering, bottom (1 x left, 1 x right) 2
12 Support batten (2 x 1158 mm, 1 x 200 mm) 3
13 Sheet metal strap 6
Seal 1⁄2" for connections 6
Clout nail 12
Dry wall screw 4 x 35 12
Dry wall screw 4 x 70 10
Dry wall screw 5 x 120 4
Plumber sealing screw 4.5 x 25 4
Dry wall screw 4.2 x 13 4
6
4
9
13
10
11
12
1
2
3
7
5
8

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4.2 Extension set for vertical roof integration
Extension set for roof integration, item no. 136 12 92 (collectors are not included)
Pos. Components: Extension set for roof integration Number per set
1Metal cover sheet, top 1
2Wooden support 1
3Collector coupling hose 1
4oam rubber sealing tape (wedge-shaped) 2
5Cellular rubber sealing tape 1
6Bracket for roof integration, top 2
7Silicone T-profile 1
8Metal sheet fixing device 2
9Metal sheet, bottom 1
10 Support batten (1158 mm) 1
11 Sheet metal strap 3
Seal 1⁄2"for connections 2
Clout nail 10
Dry wall screw 4 x 35 8
Dry wall screw 4 x 70 5
Dry wall screw 5 x 120 2
Plumber sealing screw 4.5 x 25 2
Dry wall screw 4.2 x 13 2
10
9
8
11
4
1
2
3
6
7
5

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4.3 Installation field
Keep existing roof battens as support and fix the additionally required battens according to the dimensional specifications.
If possible, define installation field so that the distance between one side of the collectors and the lateral roof covering is approximately 15
mm. Cut tiles to size for the opposite side.
A
2231
2424
1890
100
60-130
15
Installation dimensions [mm]
Number of collectors Width of collector field Width of installation field A
1 collector 1,160 1,190
2 collectors 2,325 2,355
3 collectors 3,490 3,520
4 collectors 4,655 4,685
5 collectors 5,820 5,850
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)
Width installation field = n x collector width + n – 1 x 5 mm (collector distance) + 2 x 15 mm (distance to the edge).
Outer dimensions of collector (L x W) = 1,930 x 1,160.

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2380-2470
1930
1890
60-130
2231
2424
Longitudinal section of 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
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. ix support battens with a lateral projection of about 100 mm
using dry wall screws 4 x 70.
2. Insert collectors (approx. distance between collectors 5 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.

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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.
7. 8.
9. 10.
Insert lower metal integration sheet into the lower collector frame
groove (see enlarged view). The outer corners have to engage into
the outer frame groove.
ix lower metal sheets for roof covering at the marked position in
the collector frame with two drilling screws 4.2 x 13 (with washer).
11. 12.

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1
Insert the composite angled flashing sheets into the lower frame
groove in such a way that the upper notch (1) snaps into the collector
frame. The metal sheet must lie evenly on the battens.
Slide composite angled flashing sheet downwards until it snaps
into the latch of the lower corner.
Nail down the angled flashing sheets with four sheet metal fixing
devices.
Attach rubber sealing strip onto the upper collector edge.
Insert upper left flashing sheet into the left angled flashing sheet.
The upper locking rail of the metal cover sheet has to latch into the
upper collector frame groove (see enlarged view).
urther upper flashing sheets are connected by snapping them to-
gether.
13. 14.
15. 16.
17. 18.

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ix upper flashing sheet to the roof batten with two sheet metal
fixing devices.
Position the roofing tile supporting bar to allow the tile row to be
aligned with the tiles on the sides. Then fix to roof battens with
sheet metal strips.
Attach black foam rubber sealing strip onto the flushing sheets along
the groove.
ix each flushing sheet with two additional sheet metal fixings.
Attach foam rubber sealing strip onto the side flashing sheets
along the groove. Mount roofing tiles.
Roofing tiles above the collectors may have to be cut to size. Drill
holes into the pieces that have to be attached and screw onto bat-
tens.
19. 20.
21. 22.
23. 24.

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Completed OK integration - pan tiled roof
25. 26.
Along the side flashing sheets, the retaining edges of the roofing tiles
may have to be removed and the tiles trimmed to fit. ixing is carried
out via the tile fixing hole.
Pull off the adhesive strip protective foil of the lower aluminium skirt
and press to surface of roofing tiles.

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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.
136129180 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.