oventrop ovsol User manual

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

1
082809
table of contents
System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section One:
General Guidelines and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section Two:
Solar thermal system design guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section Three:
Collector Layout Orientation and Siting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Section Four:
Evacuated tube Collector Dimensions and Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evacuated tube collector shipping contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Evacuated tube collector mounting systems and shipping contents . . . . . . . .. . . . . . . . . . . 13
Section Five:
Flush Roof Mounting
Flush Mounting on Asphalt Shingles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Flush Mounting on Tile Roofs. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flush Mounting on Metal Seamed Roofs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Multiple Collector Arrays . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Piping the collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section Six:
Adjustable Angle Roof Mounting Assembly for 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 systems and shipping contents . . . . . . . . . . .. . . . . . . . . . . 35
Flat Plate collector tilt mounted nstallation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Flat Plate collector ush mounted installation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Flat Plate collector strut mounted installation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Section Eight:
System Piping
System Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Piping single tanks systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Piping two tanks systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Section Nine:
Component Installation
Tank dimensions and capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Regusol pumping station installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Controller Installation and Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Section Ten:
System Commissioning and Operation
Fill, Flush, and Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Commissioning / Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Section Eleven:
System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Section Twelve:
Oventrop Warranty . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2082809
system components
The OVSOL System for solar energy described in this manual, when properly installed
and maintained, meets the minimum standards established by the SRCC.
This certication does not imply endorsement or warranty of this product by the SRCC.
System Model
System Contents
OVF-32 OV 5-16 OV 5-8 Regusol
EL 130
Tank Capacity and Type
SIngle Coil Single Coil
Electric Dual Coil Dual Coil Electric
OVSOL 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 gallon -
OVSOL 5-24-DCE - 1 1 1 - - - 119 gallon
OVSOL FP-2-SC 2 - - 1 80 gallon - - -
OVSOL FP-2-SCE 2 - - 1 - 80 gallon - -
OVSOL FP-2-DC 2 - - 1 - - 80 gallon -
OVSOL FP-2-DCE 2 - - 1 - - - 80 gallon
OVSOL FP-3-SC 3 - - 1 119 gallon - - -
OVSOL FP-3-SCE 3 - - 1 - 119 gallon - -
OVSOL FP-3-DC 3 - - 1 - - 119 gallon -
OVSOL FP-3-DCE 3 - - 1 - - - 119 gallon
OVF-32 - Oventrop 4’ x 8’ at plate collector
OV 5-16 - Oventrop evacuated tube collector with 16 tubes
OV 5-8 - Oventrop evacuated tube collector with 8 tubes

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082809
OVSOL System
This manual provides installation instructions for OVSOL System for solar domestic hot water heating. The
OVSOL solar energy system described in this manual, when properly installed and maintained, meets the
minimum standards established by the SRCC.
This certication does not imply endorsement or warranty of this product by the SRCC.
Planning before the installation and use of the solar collector array should include:
l Solar hot water system design.
l Properly sized solar storage tank.
lProperly sized and insulated solar loop (plumbing circuit).
l An air bleed valve at the highest point in the collector circuit located for convenient access.
lRoof penetrations for piping to and from the collector.
lSystem components for closed loop solar systems—tank, heat exchanger, solar loop circulator,
pressure relief valve, solar controller, expansion tank, ll and drain valves, pressure and temperature
gauges.
lPropylene glycol (antifreeze) to provide protection from frost and high idle mode temperatures of
375 °F.
Requirements for each installation should be fully detailed by a system schematic and specications.
The assembly and installation instructions described in this manual have been carefully prepared. It is very
important to read these instructions thoroughly before proceeding with the collector installation. An effort has
been made to conform procedures in this manual to the specications of various governmental and agency solar
programs. Also, many programs allow substitution of manufacturers’ standards for program standards. If this
is the case, the enclosed manual can be used to comply with program standards. Cases where it is unclear
whether the enclosed manufacturers’ standards can be substituted for program standards should be brought to
the attention of the particular program administrator or to Oventrop Corporation for clarication.
Be certain to follow all applicable building and safety codes for installations of solar thermal collectors.
Compliance with local codes is essential. Local code requirements must be met for penetrating structural
members and re-rated assemblies. Collectors and piping must be installed in such a way that the performance
of any structural member or re-rated assembly is not reduced. Be especially aware of safety regulations when
working upon rooftops. It is the buyer’s responsibility to secure all permits and approvals before purchasing and
attempting the installation of this equipment.
Specications are subject to change without notice.
introduction
Installing Contractor
Company________________________________________
Installer’s name___________________________________
Address_________________________________________
City, State, Zip____________________________________
Phone Number____________________________________

4082809
Guidelines and Precautions
Installing Collector Arrays
It is not recommended to install more than three 16-tube collectors in a series (64 tubes). Larger
installations will require parallel piping for balanced ow through each array. Balancing valves should
be installed on multiple arrays. One roof mounting kit is needed for each single collector module. Each
additional collector will require an expansion kit.
Closed Loop and Drainback
OVSOL collectors can be installed for both closed loop and drainback solar heating applications.
Freeze Tolerance Limits
Freeze tolerance limits are based upon the freeze and burst protection of the antifreeze used in the solar
closed loop, or the mixture of the glycol-to-water ratio. Oventrop NT-40 is a 40% glycol-to-water mix with
freeze protection to -6oF and burst protection to -60oF. Oventrop NT-50 is a 50% glycol-to-water mix with
freeze protection to -30oF and burst protection to -60oF. For additional protection, the Regusol 130 EL
control has an antifreeze function (“OCF”) that can be programmed to enable the circulator to protect the
antifreeze from freezing or thickening.
Shedding Snow
In regions of snow accumulation, evacuated tube collector tilt angles above 50° will shed snow from col-
lectors even after severe storms. Therefore, in heavy snow areas, it is critical that collectors be sloped to
at least a 50° tilt angle. If collectors are installed on a at 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.
Transport of Collector
The collector should be transported to the roof in parts and then assembled together on the rooftop.
Lightning Protection
In areas of high incidence of lightning, one lightning rod should be considered. If there is a ready-made
lightning protection device, please connect it with the collector.
Minimum Inclination Angle of Collector (for Evacuated tube collectors only)
In order to ensure heat pipe delivery, a minimum inclination angle of 25° is necessary for OV SOL-5 collec-
tors. If the tilt angle of the roof is not above 25°, please build necessary roof mounting racks.
Precautions
Temperatures in excess of 390 °F are possible in the condenser (top metal protruding bulb) when exposed
to bright sunlight or diffused insolation. DO NOT TOUCH the condenser. Store the tubes in a safe location,
away from the sun, during the installation of the roof mounting rack. Tubes are installed as the last step.
Oventrop Corporation will not be liable for burns or personal injury due to the touching of a hot condenser.
Handle the tubes with care to avoid accidental bending of the heat pipe at the condenser which may cause
damage to the heat pipe or the vacuum seal.
The maximum solar loop operating pressure is 87 psi. The pressure relief valve must be set to open below
87 psi. A 75 psi pressure relief valve is suggested. Normal operating pressures for a solar closed loop are
25 to 35 psi.
section one

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082809
Solar thermal system design guidelines
Solar hot water systems are simple in principal but complicated in practice. This guide is designed to
describe and explain the process for designing a solar hot water system. There are many ways to
design a solar hot water system to achieve the same end result. The two system types that Oventrop
uses are external heat exchanger systems (i.e. the Regusol X) and Immersed coil heat exchangers (i.e.
internal coil tanks). All of Oventrop’s systems are based on one of these two variants.
Solar Design Basics
Incoming solar radiation at the earth’s surface on a perfectly clear day is approximately 300 BTU/H
per square foot. With that said, solar collector performance depends on several factors. These
factors include, but are not limited to: ambient temperature at the location of the solar collector,
required operating temperature of the working uid in the collector, incoming solar radiation
(energy), geographical location of the collector, shading of the collector, and inclination angle of the
collector.
The difference in temperature between the working uid and the ambient temperature drives the heat
loss of the solar collector. This temperature difference has the greatest inuence on the solar
collector’s thermal efciency. This efciency measures the solar collector’s ability to convert
incoming solar radiation to usable heat in the form of a hot working uid. This hot working uid can
be used for any application.
The availability of solar radiation (energy) is dependent on weather, time of year, site shading, and
collector inclination angle. Throughout the year, the distance of the sun from the horizon will
change from the longest on the rst day of summer to the shortest on the rst day of winter. This
translates to a 47-degree change in the sun’s angle with respect to the collector throughout the year.
The optimal inclination angle to minimize this change and maximize year-round performance is
equivalent to the latitude at which the collector is located. Shading at the collector site determines
the amount of available solar radiation to which the collector is exposed.
Understanding that all of the above factors affect the performance of the solar thermal collector,
one cannot make a location independent generalization of collector performance.
Design conditions are calculated as the maximum instantaneous solar radiation, in other words, the
most energy the system can handle at any given time. For design conditions we assume the collector
is at an operating efciency of 75%, on a clear day, facing south, with no shading. Due to this efciency the
maximum output of the solar collector at design is rated at 225 BTU/H per square foot. This value is in no
way a guarantee or estimate of any Oventrop collector’s performance. The table below shows the design
BTU/H
rating of each Oventrop solar collector.
Collector Type Design Conditions BTU/H rating
OV 5-16 Evacuated tube collector 6,277 BTU/H
OVF-21 Flat plate collector 4,230 BTU/H
OVF-32 Flat plate collector 6,615 BTU/H
OVF-40 Flat plate collector 8,280 BTU/H
Table 2, below, shows the design ow rates for each Oventrop collector type.
Collector Type Design Flow Rate per collector
OV 5-16 Evacuated tube collector 0.75 GPM
OVF-21 Flat plate collector 0.525 GPM
OVF-32 Flat plate collector 0.80 GPM
OVF-40 Flat plate collector 1.0 GPM
section two

6082809
These ow rates were chosen based on the collection area of each solar collector and the incoming solar
radiation at design conditions. The ow rates allow the collectors to achieve an 18 degree Fahrenheit temperature
rise across the solar loop.
‘The sun is the source, the system is the battery.’
Solar energy is only available for a limited time during each day. It is because of this that the energy must be
captured and stored for later use. The amount of energy stored is related to the system operating temperature
(i.e. radiant oor heat at 100F or fan coil units at 180F), the storage volume, and to the maximum temperature in
the storage vessel. Maximum energy storage [BTU’s] is calculated using equation 1, below.
Maximum Stored Energy = 8.33 x Storage volume [Gal] x (Max. tank temp. – System operating temp.)
Where, Storage volume is in gallons and all temperatures are in Fahrenheit. Optimization of this equation has
determined the design number of gallons per collector. The table below shows the number of gallons of storage
recommended per collector.
Collector Type Gallons of Storage per Collector
OV 5-16 Evacuated tube collector 66 Gallons
OVF-21 Flat plate collector 27 Gallons
OVF-32 Flat plate collector 41 Gallons
OVF-40 Flat plate collector 53 Gallons
These storage values are calculated for a national average. Since daily solar radiation varies signicantly from the
South to the North, these storage values are not required, only recommended. Less storage can be used in the
northern latitudes and more storage can be used in the southern latitudes. The storage values should only vary 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 way the daily load is matched to the daily collector output. Oventrop solar hot water
systems are designed to optimize the transfer of energy from the collectors to the solar storage vessel.
Small systems
Internal coil tanks are used for Oventrop smaller systems. This allows for the ease of installation for system
packages. Oventrop has pre-packaged solar domestic hot water systems for daily loads of 80 and 115 gallons.
Depending on location these packaged systems will provide between 30 and 70 percent of the annual domestic hot
water load.
Using a similar conguration as the pre-packaged systems, larger domestic hot water loads can be accommodated.
Variations of small systems are sized by tank size and can be arranged for up to 160 gallons and 230 gallons of daily
usage. These small systems are comfortably in the design range of the Regusol EL 130 solar pumping station. This
pumping station is designed for a maximum ow rate of four (4) gallons per minute. Because the Regusol EL 130 is
constructed in ¾”, the maximum ow rate is based on the maximum trouble free ow through ¾” pipe.
Medium systems
Medium systems are above the ow range established for the Regusol EL 130 and have increasingly larger storage
requirements. It is for these reasons that the Regusol-X pumping station with heat exchanger was developed.
External heat exchangers provide exibility of design and reduce cost when considering larger storage volume and
collector arrays. The Regusol-X is designed to be used with any storage vessel that is built for hot water storage; it
does not require internal heat exchangers.

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082809
The design limits for the Regusol-X are based on the pressure drop through the heat exchanger, the pump capacity,
and the maximum output of the heat exchanger. The table below lists the maximum number of collectors allowed to
be used with each Regusol-X.
For Single Speed Pumps
Collector Type
Maximum number
of collectors on one
Regusol EL130*
Maximum number
of collectors on one
Regusol-X 15**
Maximum number
of collectors on one
Regusol-X 25**
OV 5-16 Evacuated tube collector 3 6 8
OVF-21 Flat plate collector 7 9 12
OVF-32 Flat plate collector 56 8
OVF-40 Flat plate collector 45 6
Using an external heat exchanger allows for either multiple or single tank congurations. As long as the storage is
sized correctly the tanks can be in any conguration.
For Three Speed Pumps
Collector Type
Maximum number
of collectors on one
Regusol EL130*
Maximum number
of collectors on one
Regusol-X 15**
Maximum number
of collectors on one
Regusol-X 25**
OV 5-16 Evacuated tube collector 4 7 8
OVF-21 Flat plate collector 7 10 12
OVF-32 Flat plate collector 56 8
OVF-40 Flat plate collector 45 6
* No more than three (3) OV 5-16 tube collectors are to be piped in series through the Regusol EL130 without a
booster pump.
** No more than two (2) OV 5-16 tube collectors are to be piped in series through the Regusol X without a booster
pump.

8082809
Oventrop Solar Systems Sizing Chart
The following solar sizing charts shows various combinations of solar collector quantities to Regusol pumping stations an the
design solar storage volume.
Tank selections are up to the designer for Regusol X systems and larger.
Collector
Type
OV 5-16 Evacuated tube
collector
OVF-21 Flat plate collector OVF-32 Flat plate collector OVF-40 Flat plate collector
Number of
collectors
Pumping
Station
Storage in
Gallons
Pumping
Station
Storage in
Gallons
Pumping
Station
Storage in
Gallons
Pumping
Station
Storage in
Gallons
1 OVSOL 5-16 package N/A
1.5 OVSOL 5-24 package
2Regusol EL130 160 Regusol EL130 54 OVSOL FP-2 package Regusol EL130 106
3Regusol EL130 230 Regusol EL130 81 OVSOL FP-3 package Regusol EL130 159
4Regusol X-15 264 Regusol EL130 108 Regusol EL130 160 Regusol EL130 212
5Regusol X-15 330 Regusol EL130 135 Regusol EL130 205 Regusol X-15 265
6Regusol X-15 396 Regusol EL130 162 Regusol X-15 246 Regusol X-25 318
7Regusol X-15 462 Regusol EL130 189 Regusol X-25 287
8Regusol X-25 528 Regusol X-15 216 Regusol X-25 328
9Regusol X-15 243
10 Regusol X-25 270
11 Regusol X-25 297
12 Regusol X-25 324
For Single Speed Pumps
Collector
Type
OV 5-16 Evacuated tube
collector
OVF-21 Flat plate collector OVF-32 Flat plate collector OVF-40 Flat plate collector
Number of
collectors
Pumping
Station
Storage in
Gallons
Pumping
Station
Storage in
Gallons
Pumping
Station
Storage in
Gallons
Pumping
Station
Storage in
Gallons
1 OVSOL 5-16 package N/A
1.5 OVSOL 5-24 package
2Regusol EL130 160 Regusol EL130 54 OVSOL FP-2 package Regusol EL130 106
3Regusol EL130 230 Regusol EL130 81 OVSOL FP-3 package Regusol EL130 159
4Regusol EL130 264 Regusol EL130 108 Regusol EL130 160 Regusol EL130 212
5Regusol X-15 330 Regusol EL130 135 Regusol EL130 205 Regusol X-15 265
6Regusol X-15 396 Regusol EL130 162 Regusol X-15 246 Regusol X-25 318
7Regusol X-25 462 Regusol EL130 189 Regusol X-25 287
8Regusol X-25 528 Regusol X-15 216 Regusol X-25 328
9Regusol X-15 243
10 Regusol X-15 270
11 Regusol X-25 297
12 Regusol X-25 324
For Three Speed Pumps

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082809
section three
Collector Layout, Orientation, and Siting
Place the collector where it will receive the maximum amount of sunlight available in your location. OVSOL
collectors may be installed on a roof, against a south facing wall, or on the ground.
Orientation
Orientation and tilt are critical to performance. The OVSOL collectors should be oriented (faced) as close
to true south as practical, although they may be faced as much as 20° east or west of true south with less
than 5% loss in capacity. Because the earth’s magnetic eld is not aligned parallel to the earth’s north-
south axis, there are some parts of the United States where the needle of a magnetic compass can point as
much as 20° east or west of true north. There are several ways to determine true south in your area. You
can consult a local surveyor, a plot map in your
local tax ofce, or a recent isogonic chart of the
United States published by the U.S. Coast and
Geodetic Survey. Adjust your magnetic com-
pass reading according to the meridian nearest
to you. Do not use old charts, as there are
annual variations in the readings. When using
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 even fences may shade the collector array, especially in the winter when sun angles
are low and shadows are long. Be sure the collectors are placed where they will be not shaded by these
obstructions. As a rule, no more than 5% of the collector area should be shaded between the hours of 9:00
a.m. and 3:00 p.m. It is highly advised to make use of a solar site selector while determining suitability for a
collector site.
Angle of Inclination or Tilt Angle
For domestic water, use an optimum tilt of the site’s latitude plus 5°, although the slope may be 10° greater
or less with a capacity loss of under 5% for the system. For a solar space heating system, a steeper tilt
angle is important for optimal winter performance. The steeper tilt will favor winter system operations when
the sun is low in the sky. Therefore, for space heating systems chose a tilt of latitude plus 15°.
The variation of 10° either way will not seriously affect the total annual performance of the system, all other
things being equal.
The following chart will help you determine the tilt angle of roof pitches. For space heating systems, always

10 082809
have collectors sloped at optimal tilt for winter performance. Install a collector rack for tilt angle support
whenever necessary.
Integrating with Building Architecture
Maintaining a pleasing appearance to the
building’s architecture is important for adding solar collectors to a roof or on the ground. Most homes are
not oriented well for solar gain, so getting the collectors at just the right orientation and tilt may not integrate
well with the roof lines.
With domestic hot water systems, there may be greater variations to tilt and orientation without large annual
losses, and in some cases may justify  ush-mounting collectors. Space heating systems must have a
steep slope and be oriented within 30° of true south. For these larger space heating systems, the layout
should integrate into the roo ine. For new construction, integrating OVSOL collectors into the building’s
roof system should be addressed by the solar designer to the architect.
Shedding Snow
A tilt angle of 50° or more is necessary in regions of heavy snowfall and accumulation. Tilt angles of 50°
and above will shed snow from OVSOL evacuated tube collectors even after severe storms. It is critical in
heavy snow areas that the collectors be sloped to at least a 50° tilt angle. If collectors are installed on a  at
roof in an area which receives heavy snowfalls, 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 end of the collectors.
Shading
To avoid shading by collectors on each other, the front to front dimension must be 2.5 times the highest
point of the front collector.
Roof Pitch Tilt Angle
4/12 18°
6/12 26°
10/12 39°
Roof Pitch Tilt Angle
12/12 45°
14/12 49°
22/12 61°

11
082809
section four
Collector Dimensions and Technical Data
Dimensions of OVSOL 5 8 or 16 tube collectors
Technical Data:
OVSOL 5 - 8: 87.9L x 38.6W x 7.4D inches
OVSOL 5 -16: 87.9L x 76.4W x 7.4D inches
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: 25° to 90°
Typical operating temperature: 158 - 248 °F
Stagnation temperature: 375 °F
Pressure drop per module
at 1.0 gpm: 0.47 ft/hd
Aluminum nitride absorber
Vacuum grade: 10 mbar
Connection: Dn22 mm tting

12 082809
Oventrop OV - 5 Evacuated Tube Solar Thermal Collector
(Eight tube model - 540 00 08, Sixteen tube model 540 00 16)
Contents:
OV - 5, evacuated tube with heatpipe
540 00 08 contains eight (8) tubes
540 00 16 contains sixteen (16) tubes
Dimensions: 79L x 4D inches
2 x Stainless steel collector support 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 5-1/4D inches
Bottom collector support rail
with steel spring clips
540 00 08 contains eight (8) tube
connections
Dimensions: 76L inches
540 00 16 contains sixteen (16) tube
connections
Dimensions: 38L inches
2 x Aluminum heatpipe
manifold header bracket
Evacuated tubes are shipped eight (8) to a box.

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082809
Flush Mounting Kit - Shingle Roof
540 00 28-FM
Contents:
4 - Metric thread hex head bolt
4 - Steel “shingle” roof hooks
Dimensions: 6L x 2W x 4-1/2H inches
Flush Mounting Kit - Tile Roof
540 00 28-TK
Contents:
4 - Metric thread hex head bolt
4 - Steel “tile” roof hooks
Dimensions: 6L x 2W x 4-1/2H inches
540 00 28-TK also contain one bag
of piping connection hardware (not
shown).
The bag contains:
2 - 22 mm connection tee ttings
1 - Manually operated air vent
1 - Temperature sensor thermowell
2 - 22 mm to 3/4 inch adapter pipe
1 - Tube of heatpipe condenser
thermal grease
540 00 28-FM also contain one bag
of piping connection hardware (not
shown).
The bag contains:
2 - 22 mm connection tee ttings
1 - Manually operated air vent
1 - Temperature sensor thermowell
2 - 22 mm to 3/4 inch adapter pipe
1 - Tube of heatpipe condenser
thermal grease
4 - Roof mounting ashing kits
Mounting hole

14 082809
6 - 5/16 x 2.5 inch hex head bolt
8 - 5/16 x 2 inch hex head bolt
8 - 5/16 x 1 inch hex head bolt
4 - 1/2 x 1.5 inch hex head bolt
2 - Back support rail (A) 66 inches
1 - Back cross brace 58 inches
(540 00 28-16 only)
1 - Back cross brace 50 inches
1 - Back cross brace 32 inches
(540 00 28-8 only)
2 - Hinge A
2 - Hinge B
4 - Hinge C
4 - Roof mounting bracket and  ashing kits
8 - Aluminum spacer bushing
Dimensions: 1.0H x 1.0D inches
44 - Steel  at 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 also
contain one bag of piping connection
hardware (not shown).
The bag contains:
2 - 22 mm connection tee  ttings
1 - Manually operated air vent
1 - Temperature sensor thermowell
2 - 22 mm to 3/4 inch adapter pipe
1 - Tube of heatpipe condenser thermal
grease
Adjustable Rack for evacuated tube collectors
- for eight (8) tube collector, 540 00 28-8
- for sixteen (16) tube collector, 540 00 28-16
Contents:

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082809
Flush mounting kit - Metal Seam Roof
540 00 28-MS
Contents:
4 - Metric thread hex head bolt
4 - Steel roof hooks
Dimensions: 6L x 2W x 4-1/2H inches
Metal seam clamp kit contains:
1 - Aluminum clamp block
1 - 3/8 x 3/4 inch hex head bolt
1 - Flat washer, 3/8 inch
4 - 3/8 x 3/4 inch set screw
4 - Metal seam clamp kit
Connection Kit for evacuated tube collectors
540 00 21, for 540 00 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 1.0H inches
2 - Metric thread hex head bolt
2 - Metric thread at washer
2 - Metric thread hex head nut
540 00 28-MS also contain one bag
of piping connection hardware (not
shown).
The bag contains:
2 - 22 mm connection tee ttings
1 - Manually operated air vent
1 - Temperature sensor thermowell
2 - 22 mm to 3/4 inch adapter pipe
1 - Tube of heatpipe condenser
thermal grease
Mounting hole

16 082809
A
8 tube: 16” - 25”
16 tube: 48” - 66”
center manifold on collector feet spacing
B
63” - 80”
Measure the Installation Area
Once the collector location is determined, lay out the four mounting feet of each collector within
the dimensions listed below:
Flush Mounting on Asphalt Shingles (for mounting with supplied ashing kit see next page)
Shingle Roof Kit (540 00 28-FM)
Mounting of Collector Feet
Collector feet may be lag bolted into the roof rafters. Since most roof trusses or rafters are built on 16-inch
centers, locate the comers so that the width dimension falls on the 16-inch center. To locate the nearest
rafters, use a stud nder. Once the rafter is located, drill a small diameter pilot hole to verify the rafter’s
center line. Be sure to lift the upper shingle and predrill into the underlying (covered) row to prevent water
leaks. Lift shingles carefully to avoid tearing. Always seal pilot holes not being used.
Mark the pilot hole 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. Apply a
generous amount of polyurethane sealant around and within the pre-drilled hole. Screw the collector feet in
place. Avoid over-tightening and stripping the lag bolts. You may apply a small amount of sealant to the lag
bolt heads to prevent water leakage. The important thing is to locate the collector feet atop roof joists so that
the weight of the collector is supported. Select rafters so that two tubes will overhang 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 rafters. The overhangs are necessary for better weight distribution.
Collector Assembly
Flush Roof Mounting
Collector foot measuring details for
Shingle Roof Kit (540 00 28-FM, Tile Roof Kit (540 00 28-TK), and
Metal Seam Roof Kit (540 00 28-MS)
8 tube collector: ‘A’ = 16 to 25 inches;
‘B’ = 63 to 80 inches
16 tube collector: ‘A’ = 48 to 66 inches; ‘B’ = 63 to 80
inches Roof Hooks
section ve

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082809
Installing the collector feet and ashing
No need to remove any shingles to install the ashing.
Base plate is rst screwed into a roof rafter or block and
ashing is slided under the roof shingle covering the
installed base plate.
Tools Required:
- Cordless drill with #2 square drive bits
- Tape measure, stud nder, chalk line
1. Locate the rafters and snap horizontal and vertical lines
to mark the installa-tion position for each upper mounting
foot. Blocks, installed in the attic, may have to be 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 sealant at
the penetrations. The baseplate must be securely at-
tached atop the roof and into the roofs structural member.
3. Install ashing by sliding it into place under then next
row of shingles. cover base plate with the ashing pocket .
4. Install the collector foot onto the ashing using
neoprene-bonded washer and stainless locking nut.
Flashing
Base Plate
Sealant must be applied to
any penetration of the roof
The bracket is to be fastened
to the base plate through the
hole closest to the vertical.

18 082809
Flush Mounting on Tile Roofs
Tile Roof Kit (540 00 28-TK)
Mounting of Collector Feet
On a tiled roof, it is generally easy to locate the rafters
by simply lifting out individual tiles at the desired foot
placement. You will see the where the sheeting has been
nailed into the roof rafters below. This is your visual
indicator for the rafters. Predrill small pilot holes to nd
the center line of the rafters.
Install four collector feet by lag bolting feet into 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 feet.
Place the feet vertically so that the rst angle on the roof
hook clears the top edge of the tile resting below.
Apply a generous amount of polyurethane sealant in
and around the lag bolt holes before tightening bolts
into place. Seal any other test holes made for pre-siting
rafters.
The collector feet must be aligned vertically and
horizontally.
Reinstall tiles around the collector feet.
See page 9 for ush mounting frame assembly
instructions.
Perforated plate

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082809
Flush Mounting to a Metal Seam Roof
Metal Seam Roof Kit (540 00 28-MS)
Mounting of Collector Feet
For each collector support rail, attach the rectangular
blocks in the hole fourth from the top and rst from the
bottom as shown by the image below.
On the top end in holes 1 and 3, using the square nuts,
attach the manifold bracket.
Secure the rails to the seams of the roof as seen in
the illustrations. Select seams so that two tubes will
overhang 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 distribution.
Once the rails are secured to the roof seams, the tube
support rail should be bolted into the second holes
from the bottom.
After installing the tube support rail, slide the manifold
through the manifold brackets at the top of the
collector.
Insert the two outer tubes and check for square lines.
Insert remaining tubes from one side to the other.
The bracket is to be fastened to
the metal seam clamp through
the hole closest to the vertical.