oventrop OVSOL System 5 User manual

OVSOL 5 Evacuated Tube Collector
Solar Domestic Hot Water Heating System
Regusol 130 EL
Innovation + Quality
OVSOL System 5
Solar Hot Water System
oventrop

system components
The OVSOL System 5 solar energy system described in this manual, when properly
installed and maintained, meets the minimum standards established by SRCC.
This certification does not imply endorsement or warranty of this product by SRCC.
lOV-5 16 tube evacuated tube collector
l SC 80 gallon solar storage tank
l Regusol 130 EL pumping and control station
I

OVSOL System 5
This manual provides installation instructions for OVSOL-5 evacuated tube collectors and the OVSOL System 5
(model: OV-S5) solar domestic hot water heating system. The OVSOL System 5 solar energy system described
in this manual, when properly installed and maintained, meets the minimum standards established by SRCC.
The OVSOL System 5 includes the OV-5 16 tube evacuated tube collector, the SC 80 gallon solar storage tank,
and the Regusol 130 EL pumping and control station.
This certification does not imply endorsement or warranty of this product by 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, fill 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 specifications.
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 specifications of various governmental and agency
solar programs. Also, many programs allow substitution of manufacturer’s 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 manufacturer’s standards can be substituted for program standards should be brought to
the attention of the particular program administrator or to Oventrop Corporation for clarification.
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 fire-rating assemblies. Collectors and piping must be installed in such a way that the performance
of any structural member or fire 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.
Specifications are subject to change without notice.
introduction
1
Installing Contractor
Company________________________________________
Installers name___________________________________
Address_________________________________________
City, State, Zip____________________________________
Phone Number____________________________________

table of contents
System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section One:
General Guidelines and Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section Two:
Collector Layout Orientation and Siting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section Three:
Collector Dimensions and Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section Four:
Collector Assembly
Flush Roof Mounting
Measure the Installation Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flush Mounting on Asphalt Shingles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Flush Mounting on Tile Roofs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Flush Mounting on Metal Seamed Roofs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembling the Collector Frame. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adding Collectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connect Piping . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installing the Vacuum Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Section Five:
Collector Assembly
Rack Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rack Diagram at 40 degrees tilt . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rack Diagram at 50 degrees tilt . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Section Six:
System Assembly
Installing the OVSOL System 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Piping the Solar Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Piping the Solar Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Oventrop Indirect Solar Hot Water Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Regusol 130EL Transmission Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Regusol 130EL Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Section Seven:
System Operation and Maintenance
Regusol 130EL Operation and Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Collector Flush, Leak Check and Fill Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Comissioning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
System Checks, Trouble Shooting & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Projections for Lifecycle of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Oventrop Warranty . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2
Rev 0108

Guidelines and Precautions
Installing Collector Arrays
It is not recommended to install more than four 16-tube collectors in a series (64 tubes). Larger
installations will require parallel piping for balanced flow through each array. Balancing valves should be
installed on multiple arrays. One roof mounting kit is needed for a single collector module. Each additional
collector will require an expansion kit.
Closed Loop and Drainback
OVSOL 5 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 -40oF. 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, collector tilt angles above 50° will shed snow from collectors 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 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
evacuated tubes.
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
In order to assure heat pipe delivery, a minimum inclination angle of 25° must be ensured for OV SOL-5
collectors. 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
3

section two
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 is critical to performance. The OVSOL-5 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 field 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 office, or a recent
isogonic chart of the United States
published by the U.S. Coast and
Geodetic Survey. Adjust your magnetic
compass 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.
4

The following chart will help you determine the tilt angle of roof pitches. For space heating systems, always
have collectors sloped at optimal tilt for winter performance.
Install a collector rack whenever necessary.
Integrating with Building Architecture
Maintaining a pleasing appearance to the buildings 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 are greater variations to tilt and orientation without large annual
losses, and in some cases may justify flush-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 roofline. 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- 5 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 flat 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 evacuated tubes.
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°
5

section three
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 26 gal/h: .17ft/hd
Aluminum nitride absorber
Vacuum grade: 10 mbar
6

Collector Assembly
Flush Roof Mounting
Measure the Installation Area
Once the collector location is determined, lay out the 4 mounting feet of each collector within the
dimensions listed below:
OVSOL 5 8 tube collector: ‘A’ = 16 to 25 inches; ‘B’ = 63 to 80 inches
OVSOL 5 16 tube collector: ‘A’ = 48 to 66 inches; ‘B’ = 63 to 80 inches
Flush Mounting on Asphalt Shingles
Roof Mounting Kit ORMK-S
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 ‘A’ dimension falls on the 16-inch center. To locate the nearest rafters,
use a stud finder. 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 predrilled 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.
section four
A
8 tube: 16” - 25”
16 tube: 48” - 66”
center manifold on collector feet spacing
B
63” - 80”
7

If the collector feet are not in line with roof rafters, blocks may be nailed into the joint cavity and the feet
then lag-bolted to the block. Securing collector feet to the roof rafter may also be done by using a span-
ner, using nuts and an all-thread rod to bolt down the feet. An additional wood block between the trusses
must be placed beside the all thread rod to prevent bowing of the sheathing when tightening the nuts in
the all thread rod. Spanners may be required in areas prone to hurricane-force wind.
It is important that in any case the collector feet are bolted to the roof frame.
8

Flush Mounting on Tile Roofs
Roof Mounting Kit ORMEK-E
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 sheating has
been nailed into the roof rafters below. This is your
visual indicator for the rafters. Predrill small pilot holes to
find the center line of the rafters.
Install 4 collector feet by lag bolting feet into roof rafter.
If necessary, use the attached perforated plates to get
the width needed between collector feet.
Place the feet vertically so that the first 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.
9

Flush Mounting on Metal Seamed Roofs
Roof Mounting Kit ORMK-M
Mounting of Collector Feet
For seamed metal roofs.
Install the fixing components on the bite seam, tighten
the bolt and the back plates clamp on the bite seam.
No drilling is required.
Use spacer plate if necessary.
Place frame to the metal roof collector foot and then
fasten the bolts through the forth frame hole as the
drawing specifies. Tighten bolts to secure frame.
10

Assembling the Collector Frame
Place the vertical frame on the collector top and bottom
feet and install frame where it can be lined up with the
collector feet bolt holes. If possible, choose the fourth
hole from the top of the verticle frame to set the bolt into
the top collector foot.
Tighten bolts.
Attach the manifold support into the first and third holes
of the vertical collector frame. Bolt the manifold support
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 from
slipping. Line up the collector clips at the bottom tube
support rail to the manifold dry well fittings for the
evacuated tubes to line up square. There may need to
be a verticle adjustment, so don’t tighten the bolt
completely until a tube has been pre-fit.
Install one vacuum tube on either end, and check the
whole collector for square lines.
Install each vacuum tube from one end to the other.
11

Adding Collectors
Expansion Kit ORMEK-FR
If there is more than one collector connected together,
you may add a coupler between the manifold ends.
Disassemble the end cover with screwdriver.
Connect two header boxes with compression
couplings supplied- - keep distance of 2 - 1/8” between
the two header boxes.
Insert insulation in the collector cuff cavity. Install and
attach the connection cuff.
Tighten the screw to clamp the connection cuff.
2- 1/8”
12

Connect two bottom supports with the L-bracket and
tighten screws. Make sure that the bottom clips line up
with the manifold condenser holes above for square.
Connect Piping to the Manifold
With each roof mounting kit, there are adapters to pipe to
the manifold. Included are:
l Two compression tees to attach to the supply and
return terminations on each collector manifold or collector
array;
l Two copper pipe adapters that adapt from 22mm
copper pipe size (at compression tee) to 3/4” copper pipe.
Also included in some roof kits are two stainless steel
flexible hoses and additional compression couplings for
copper pipe adapters.
NOTE: Use 1/2” copper supply and return for collectors
with up to 24 tubes (one 8- and one 16-tube collector)
and 3/4” copper for collectors with a 4- to 16-tube
collector array. Preferably use Type L. Do not use PEX
plastic tubing. PEX tubing cannot withstand
temperatures above 200°F and will fail.
Always insulate outdoor tubing with 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 sure the compression ring is well onto
the copper pipe terminating the manifold so that the
compression ring will not slide off the pipe as the
compression nut is tightened.
Install the Thermowell, which is for the collector sensor,
on the return outlet tee. Solder the threaded thermowell
into the tee before installing the compression tee to the
header. Smear some heat transmission paste on the
sensor and insert the sensor into the Thermowell. Lock
sensor into place with set screw on the Thermowell.
Install the manual air vent on the manifold’s supply inlet
tee. If the piping rises above the collector on a closed
loop system, add an additional manual air vent at the
highest point of the loop.
13

Installing the vacuum tubes
Grease condenser with heat transmission paste.
Note: Use a glove or a cloth to apply the paste.
Do not touch a hot condenser which could be 390°F!
Keep tubes covered before installation. When tubes are
exposed to the sun, the temperature of the condenser
could be 390°F or higher.
Align the tube and slide the condenser gently into the
manifold while turning tube gently back and forth. Adjust
vacuum tube. Keep blue selective coating side facing
upward. Rubber gasket atop vacuum tube must be set
within manifold hole in header to securely seal heat pipe
in manifold.
Put the end cap of tube into the clip. If necessary, adjust
the location of the bottom support. The end of the tube
should rest on the rubber strip of the bottom support.
Close clip. Clip is sharp, use gloves to close clip.
14

section ve
15
Adjustable Roof Mounting Rack AT ANGLE
Assembling the collector frame
Choose the appropriate total mounting angle by adding the pitch of the roof to a tilt angle in Table 1. Cut the 2 longest
pieces of strut (galvanized steel) to the corresponding lengths (A) for the back legs.
Attach hinge leafs to the two back leg pieces (A) previously cut as shown in figures 1 and 2. On one end bolt the hinge leaf
A to holes 1 and 2.
On the other end of the back legs bolt the hinge leaf C in holes 1 and 2.
Set aside pieces.
Assemble Collector Rails
Attach hinge leafs to the collector rails (stainless steel) as shown in figures 2 and 3. Leaf B mounted on the upper part of the
collector rail is bolted through holes 9 and 10, with the barrel side pointed to the end. On that same end, using square nuts,
bolt the manifold supports to holes 1 and 3. At the other end of the collector rail, bolt the hinge leaf C to holes 1 and 2, with
the barrel out beyond the rail. Do not tighten the bolt in hole 2. The hinge leaf barrels on each rail must be 75 inches apart,
as shown in drawing.
Mount Collector
Attach collector feet to the mounting surface, parallel to each other, at the appropriate dimensions. Dimensions are avail-
able in Table 1.
Using the 5/16” bolts, connect the A and B leafs through the leaf barrels. Attach the collector rail hinge leaf C to the mount-
ed front foot for each rail (figure 3). Attach the back leg hinge leaf C to the mounted rear foot for each rail (figure 1).
On the back legs, using the 1/2” bolts, attach the 4’ 2” strut to the hole directly below hinge leaf B. The 4’ 2” strut is mounted
horizontally to tie the back two legs together.
Install the 4’ 10” piece as a cross brace with the 1/2” bolts as shown in drawing.
Center and bolt the bottom tube support in hole 2 of the collector rails. You must removed the loose bolt in order to do this.
Slide the header box into the mounting brackets on the top of the collector. Insert a tube at either end and check for parallel
lines.
Insert remaining tubes

16
A
16 tube: 47-1/4”
8 tube: 30 - 1/2”
A
16 tube: 47-1/4”
8 tube: 30 - 1/2”
C
16 tube
28-3/4”
A
Distance Between Rails
A
Distance Between Rails
C
Distance Between Collectors (Rails)
Rail Rail Rail Rail
ManifoldManifold
Leaf “C”
Figure 3
Figure 2
Leafs “A” and “B”
2 Inch 5/16” Bolts 1 Inch 5/16”
Bolts
1/2” Bolts
Back
Figure 1
1 Inch 5/16” Bolts
3 Inch 5/16” Bolts
48” for 16 tube collector
31” for 8 tube collector
B

17
Tilt Angle A Inches A Slots B Inches
0 N/A N/A 75”
10 13” 4 73.75”
15 19.5” 8 72.5”
20 25.5” 10 70.5”
25 31.75” 14 68”
30 37.5” 16 65”
35 43” 19 61.5”
40 48.25” 22 57.5”
45 53” 24 53”
50 57.5” 27 48.25”
55 61.5” 28 43”
60 65” 31 40”
65 68.5” 32 40”
70 72” 34 40”
The column (A Inches) measures the
dimension between hinge leaf barrels
on the back strut.
The column (B Inches) measures the
dimension between hinge leaf barrels
of the front and back feet.
The width between the feet should
be 48” on center fo 16 tube collec-
tor. For the 8 tube collector the width
between the feet should be 31” on
center.
Hinge Leaf “C”
Hinge Leaf “B”
Hinge Leaf “A”

18