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Assembly instructions Evacuated- tube solar collector SUNPUR® OEM10/HP

Philippine GmbH & Co; Status:21/04/2011

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Table of contents

1. Introduction P. 3

Safety instructions

System tips P. 6

Planing sheme for maintenance P. 7

2. Roof installation

Roof mounting set, parts list P. 8

Connection set, parts list P. 9

Substructure for tiled and pantiled roofing P. 10

Installation on corrugated eternit or trapezoidal sheet roofs P. 12

Collector installation on sloped roofs P. 13

Flat roof elevated mounting P. 14

Prt list flat roof mounting set (for elevated mounting) P. 15

General information P. 15

3. Collector installation P. 16

Collector field connection P. 18

Vacuum tube replacement or rotation P. 18

4. Commissioning and filling P. 19

5. Technical data P. 20

Warranty conditions P. 20

Appendix � Technical modifications which serve to enhance the product or related accessories

are reserved. � The most current version of the installation instruction and additions as informations

of ststics can be downloaded at www.sunpur.de.

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1. Introduction These instructions give important details for installing the SUNPUR® OEM collectors and their installation and connection systems. The specialist company responsible for installation must also comply with applicable regulations while observing engineering standards. The dimensions contained in these instructions are only guideline indications taken from common practice. The specialist company is responsible for installed dimensions of the equipment. Philippine GmbH & Co. Technische Kunststoffe KG is not liable for the dimension details contained in the commercial range of equipment, as not all technical general conditions (snow load zones, building height, wind loads etc.) can be coordinated in the framework of a general product range. We would be happy to advise you in detailed project planning. The installing company has to ensure that the mechanical durability of the interface connections to the building shell is guaranteed, in particular, for its leak-tightness. Philippine GmbH & Co. Technische Kunststoffe KG components are designed according to anticipated loads and the current state of technology. Before starting installation please consider our guarantee terms on page 23. For twisting individual tubes please contact our customer service. Technical changes which improve product quality or ease of assembly do not constitute grounds for complaint.

Safety instructions

Terms and symbols used

"WARNING" This term and lettering will be used in conjunction with potentially hazardous situations, which could lead to severe bodily injury or death.

"CAUTION" This term and lettering will be used in conjunction with potentially hazardous situations, which could lead to slight bodily injury or to material damage.

This symbol will be used when the risk of injury or system damage is present if instructions are not complied with.

This symbol will be used when the risk of burning is present if hot surfaces or scalding liquids are contacted.

This symbol will be used when the risk of injury is present due to stumbling or falling.

This symbol will be used when the risk of injury is present due to falling objects.

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Product safety and hazards This product conforms with state-of-the-art technologies and applicable safety-related rules and regulations. Nonetheless, hazards associated with this product may exist.

For example, hazards can result from collector components becoming extremely hot during operation or due to solar radiation (risk of burning upon contact). Further hazards can result from glass breakage (lacerations), spurting hot fluids and steam emissions (scalding) or during roof work (crashing, falling).

The Vacuum tube collector OEM10/2HP must be installed, commissioned and operated only in a fault-free condition and in compliance with these instructions. It must be used exclusively for the intended purpose as described. Usage for purposes other than as described (improper utilisation) can be hazardous to persons and result in damage to the collector. Improper utilisation may be, for example, filling the collector with substances other than the authorized heat transfer agent or installing it on an insufficiently stable substrate.

Arbitrary conversions or modifications, except for those described in these instructions, are not authorised.

The Vacuum tube collector OEM10/2HP must be installed and operated in accordance with recognized engineering standards. Applicable national regulations for occupational safety and accident prevention must be observed and duly complied with. This applies in particular to roofing work. Lightening protection: As a rule, all electrical equipment in metal enclosures must be grounded. This applies to solar systems, as well. Pump units, pipelines, reservoirs and collectors must have potential equalization, meaning they must be connected to ground just as normal water pipes are. Grounding requires a very good conductive contact between the grounding point and the collector. Installation of grounding clamps can made on the collector frames. The supply- and return-sides of the solar circulation piping are to be connected to the building potential equalization in the shortest manner. Pertinent regulations such as those required by the VDE or country-specific regulations must be observed. Attention! Glass tubes are vacuum pressurised. Damage, external pressures, loading or torsion, localised stresses or violent forces will lead to an implosion. Injuries can result from flying bits of broken glass. Dismantling and disposal should be carried by specialist firms. All materials used can be recycled. Servicing of a solar system should be carried out by a licensed heating technician focusing primarily on the heat transfer fluid, while the collectors undergo a visual inspection. If damage or a loss of vacuum is detected, the tubes can be individually replaced on-site. The collector is self-cleaning due to a nano-coating on the vacuum tubes, yet, if heavy contamination is present, the collector can be cleaned with water. The use of industrial or abrasion-based cleaners is not permitted.

Roof installation safety instructions

CAUTION, RISK OF BURNING!

Collectors can become extremely hot when exposed to solar radiation. Risk of burning upon contact! After unpacking the collector, do not expose it to solar radiation for a lengthy period without protection. Carry out the roof installation only on a cloudy day or ensure the collector is adequately covered.

If possible, remove the collector from its packaging only after all mounting elements have already been installed on the roof. If multiple collectors are to be installed, remove only the respective collector being installed from its packaging before unpacking the next one.

A risk of falling exists anytime work is being performed on the roof, as well as when climbing up to, or down from the roof. Heed accident prevention regulations at all times and use appropriate fall protection devices.

WARNING, RISK OF FALLING!

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Unauthorised persons must not be allowed to climb up on the roof.

Please use work glove for the assambling to avouid injury.

WARNING, RISK OF INJURY!

When performing installation work on roofs, there is the danger of tools, installation material or the collector, itself, falling from the roof and causing injury to persons below. Prior to beginning installation work, cordon off the danger area on the ground and warn any persons present in the vicinity or in the building.

Ensure that children are kept clear of the area.

Who can install collectors? Installation planning, roof installation and commissioning of the Vacuum tube collector OEM10/2HP must be carried out only by those persons who, based on their professional qualifications, are familiar with the proper and safe execution of the installation process (specialized craftsman such as a roofer and/or a licensed heating technician).

Installation prerequisites

WARNING, RISK OF INJURY:

The collector must be mounted only on roofing, on which a stable and reliable attachment is warranted. If this is not warranted, there is a risk of damage to the collector or to the roof. In order to prevent injury to persons located on the ground below, it must be ensured that neither parts of the collector nor parts of the roofs are at risk breaking off and falling. Attachments must be able to withstand storm and snow loads.

Attention! Glass tubes are vacuum pressurised. Damage, external pressures, loading or torsion, localised stresses or violent forces will lead to an implosion. Injuries can result from flying bits of broken glass.

System tips / planning

Two persons are required for roof installations.

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The flow resistance in corrugated stainless steel piping is considerably higher than in copper piping. This must be considered when dimensioning the pump. Corrugated stainless steel pipes must never be laid horizontally, as otherwise air bubbles will form that cannot be removed from the system, even during the flushing process.

It must be ensured that the cross-section is not too small when bending soft twin CU piping. This will cause the flow resistance to increase considerably.

� The following points must be considered when planning the system:

• How much power will be consumed over what period of time?

• Is the demand continuous (weekends, holiday season)?

• How much power must be stored over what period of time in order to bridge those periods, in which energy take-off does not occur?

• Can an alternative energy usage, such as pool heating, solar cooling, heating networks, etc., be introduced?

• What is the current supply/return temperature of the heating system in use?

• Is floor heating/wall heating available?

• Combinations with domestic water heating?

• Arrangement of the collector field, installation variants?

• Line lengths, cross-sections and material composition � The max. operating temperature is 140 °C.

� The statics of every installation has to be prooved locally.

� Recommended diameter for the riser lines in a warm water-assisted system (3 collectors) = DN16 of corrugated stainless steel piping or 18 mm CU piping. Pumping recommendation 25/4 or 25/60

� Recommended diameter for the riser lines in a heating-assisted system (6 collectors) = DN20 of corrugated stainless steel piping or 22 mm CU piping. Pumping recommendation 25/60.

� Recommended diameter for the riser lines in a heating-assisted system (8 collectors) = DN20 of corrugated stainless steel piping or 22 mm CU piping. Pumping recommendation 25/80.

� 100 l buffer volume should be provided for each collector in a heating-assisted system. A risk of stagnation exists at lower buffer volumes.

� Volume flow rate: The volume flow rate is dependent on the temperature level the system is to be operated at. A volume flow rate of 0.5 to 1.0 l/m²*min. with relation to the aperture area is recommended.

� Flow speeds in the pipelines should not exceed 1 m/sec., as otherwise pressure losses will increase significantly. We recommend 0.3 to 0.5 m/sec.

� The specifications correspond to a total system pipe length of max. 2 x 20 m.

� The specifications are reference values, which must be determined precisely for specific circumstances.

� Do not integrate small radii into the pipelines. It is better to use 2 x 45° elbows than one 90° elbow.

� Only high-temperature fittings and insulation are authorised for use from the solar station to the collector system. Pipelines can heat up to over 130°C due to stagnation.

� The collector sensor must be inserted with thermal compound.

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20 cm

20 cm

min. 20 cm

� Larger collector fields will require multiple collector sensors so that solar control will respond promptly to the state of the field.

� Max. 8 collectors may be connected in series. If you like to connect more than 8 HP collectors in line, you should make a dimensioning.

� Solar control for external collector sensors must be switched at intervals in order for the sensors to ascertain the current prevailing temperature in the collector field. Setting: e.g. from 8 AM to 6 PM; the pump should run for approx. 5 sec. every 5 min.

Connection: 4 Collectors in series 4 x Collectors 1 x Basic set (contains 2 clamps) 3 x Collector extensions (connectors) 1 x Roof installation set 4-fold (select according to roof covering) 8 Collectors with flexible extension 8 x Collectors 1 x Basic set (contains 2 clamps) 6 x Collector extensions (connectors) 1 x Collector extension, flexible (contains 2 clamps) 2 x Roof installation set 4-fold (select according to roof covering) 1 x Profile connector set because of the side-by-side roof mounting set arrangement 8 Collectors 2 x 4 in series 8 x Collectors 2 x Basic set (contains 2 clamps) 6 x Extensions 2 x Roof installation set 4-fold (select according to roof covering) (Pict. shows connection according to Tichelmann)

Planing sheme for maintenance

If a tube has to be changed, the header case cover from the manifold box must be opened. For the change is a space of min. 20 cm required.

On the foot side the foot cap has to be loosen. Therefore is a space of minimum 20 cm needed. The broken tube (200 cm) will be extractied above the food side. Lift up the tube over the next collector leg.

2. Roof installation

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1) Cross-profile 40 x 40

2) End cap

3) VA SK bolt M10 x 25 with fan nut

4) Roof hook (for pantile shown here; plain and slate tile also available)

5) Profile connector (from left to right)

When selecting mounting materials, consider the type of roof covering on which the collector is to be installed.

� Tiled & pantiled roofing

Interlocking roof tile

Flat roof pantile

� Corrugated eternit or trapezoidal sheet roofing

� Sloped roofs

� Flat roof elevated mounting

Roof mounting set, standard

Collector connection set Heat Pipe

Roof mounting set, parts list

2-fold 1,62 m

3-fold 2,44 m

4-fold 3,24 m

Nomenclature Quantaty Quantaty Quantaty Roof hooks (depending on set: slate, pan, plain) 4 6 6 Plastic end cap for support profile 4 4 4 Hexagon bolt M10x25 4 6 6 Flange nut w/ locking teeth M10 4 6 6 Installation Instructions, Heat-pipe collector 0 2 2 Installation Instructions, Roof mounting system 0 4 2 System statics, basic design 2 0 0 Support profile 1.22 m. 0 4 2 Support profile 1.62 m. 1 0 1 Support profile 2.02 m. 1 0 1 Profile connector 1 1 1

Assembly instruction SUNPUR 1 1 1

Connecting Basic

set 1000 mm

Connecting extension

set flexible Tee piece 22 mm

with immersion

Connecting

extension set

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Calculation: for the first collector for each additional collector 1 Basic connection set 1 Collector extension (rigid or flexible)

Select the roof mounting set according to the number of collectors and the roof covering. With side-by-side roof mounting sets, profile connector sets are required

Sloped roof installation – Support frame On the classic sloped roof installation, two rows of roof hooks or roof mounting elements are attached to the supporting roof substructure for each collector row. The crossmember profile will be attached to these elements. The heat-pipe collector works at angles ranging from 25° to 80°.

Crossmember profile connection

In order to connect the crossmember profiles, insert the bolt into the connector from above and slide it through the

Part list connecting set OEM 10/2HP

Part- number

2 in line

3 in line

4 in line

5 in line

6 in line

Phil nr. quantity quantity quantity quantity quantity

Connecting Basic set 1000 mm 1 follow up flexible hose isolated 1000 mm with 1“ AG flat sealing, 1 follow up flexible hose isolated 1000 mm with 1“ AG flat sealing with immersion sleeve , 2 clips

79584 1 1 1 1 1

Connecting extension set 1 insert self sealing, 1 tube agrafes

79585 1 2 3 3 4

Connecting extension set flexible 1 insert self sealing with flexcompensator , 2 clips

79586 0 0 0 1 1

Tee piece 1 tee piece with immersion sleeve, 1 clip 1 Tee piece with plug, 1 clip

79670 +

79671 1 1 1 1 1

min 0,5 m

min 0,5 m

1,60 – 1,80 m

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crossmember profile. It must be ensured that the hexagon bolt head does not wedge into the rectangular slot. Slide the connector up to halfway and bolt it in place. Repeat the step with the second crossmember. There must be no gap between the crossmember profiles.

When installing 2 roof mounting sets is series, one profile connector set must be ordered for each set.

Substructure for tiled and pantiled roofing

Standard roof hooks are used for interlocking roof tiles or pantiles, while special roof hooks are available for special tile forms.

1. Determine the position of the crossmember The crossmembers should run indented approx. 1/5 the module height from the upper and lower edges of the module. Consider the position of the ventilation tile! The position of crossmembers for module rows positioned above each other should be suitably adapted to the roof tile rows.

2. Select and distribute roof hooks The roof hooks should be distributed vertically according to the desired crossmember positions. The following applies in the horizontal: As a rule, one roof hook is affixed to every other rafter. In border areas, it is recommended that one roof hook be affixed to each of the first two rafters in order to compensate for increased loads due to wind gusts. The crossmember should project out no more than 0.4 m to the left and right. The maximum distance between roof hooks is 1.8 m.

In areas where a high level of snow or wind loading is expected, a roof hook should be affixed to each rafter or the manufacturer should be consulted for exact bench mark values (Note: various roof hook strengths are available!). Adjustable roof hooks compensate for height variations on uneven roofing. For very wide roof tiles, "right-hand" roof hooks can be used for mounting in addition to the standard "left-hand" roof hooks. The use of combinations can contribute to extremely wide horizontal compensation.

3. Roof hook attachment Slide the roof tile upwards. The roof hook fillet lies in the depression or in the flat plane of the roof pantile. An air gap of at least a 5 mm should remain between the tile and the fillet. If snow loads are expected, particularly with pantiles, it is generally recommended that a sheet metal seat be adapted to the roof tile form to fit underneath each roof hook! The roof hooks should be attached to the rafters with at least 2 bolts, 8 mm in diameter. Holes should be pre-drilled approx. 2/3 the total bolt length. Ensure that the bolt will grip at least 70 mm into the rafter or a longer bolt should be used accordingly! Lubricate the bolts with grease to prevent schearing when being tightened. If desired, the roof hook fillet can be outfitted with a rubber ring to protect against water buildup during strong winds.

4. Hanging the roof tiles Depending on the roof tile form, it may be necessary to grind it first (using an angle grinder with a small

Tool tip: Handy angle grinder with small diamond grinding wheel, socket wrench insert #13 with ratchet, drill with socket insert and torque limiter, brush with some grease for wood bolts, drill with 6 mm

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Professional tip: Rafter attachment bolts are extremely important for the overall statics. Spax screws are not recommended because of their weak cross-sections at the head! Sufficient bolt length must be ensured, especially for counter battens!

picture: Frankfurter pan

diamond grinding wheel) so that the tile with the roof hook will properly reseat.

5. Further information under "Collector installation" (Point 3)

The following example from a well-known roof tile manufacturer should help to detect any problems:

Interlocking roof tile

� As a rule, a minimum slope of 30 degrees is recommended � A minimum slope of 24 degrees may be recommended only in special cases (sealed or glued sarking

membrane)

Installation with corrugated eternit or trapezoidal sheet roof

Professional tip: Caution must be exercised if very flat roofs are to be outfitted roof hooks! The collector installer may be held liable for leakage that occurs at a later date. It should be known that tile manufacturers provide only a limited guarantee for leakage on flat-sloped roofs.

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Professional tip: The mounting plate should always be aligned upwards to ensure a favourable force distribution (as shown on the right).

Tool tip: Combination wrench SW 18, drill or additional nuts M12 for securing. For wrench size hanger bolts, a heavy-duty driver with 9 mm or 8 mm socket insert (depending on design).

Hanger bolts (Hanger bolt mounting) Please note that the accessories for the following installation are not within our scope of delivery. These must be procurred on-site.

Corrugated eternit mounting elements comprised of a special hanger bolt and a mounting plate (see pictures) are used on corrugated eternit or trapezoidal sheet roofing. These are distributed vertically according to the desired crossmember positions. The following applies in the horizontal: An attachment set is affixed to at least every other rafter in the substructure. The crossmember should project out no more than 0.4 m to the left and right. The maximum distance between attachments is 1.6 m. In areas with a high level of snow or wind loading, or where weak rafters are present (such as often is the case with slab-covered roofs), an element should be affixed to each rafter. As a rule, an attachment set with an M12x300 hanger bolt is recommended. For sprecial mounting configurations with reduced cross-distances, an M10x200 version is also available.

Mounting set attachment Drill the roof covering at the appropriate locations (14 mm hole diameter with an M12 bolt, 13 mm hole diameter with an M10 bolt). Holes are not to be drilled in the water-bearing depressions of the panel profile but should be positioned in the elevated sections! The attachment hole (8.5 mm) is drilled through the mounting bracket hole into the rafter. The hanger bolt should be screwed into the rafter at least 80 to 100 mm. The hanger bolt should be screwed in so that only the metric thread and, if possible, a section of smooth shaft as a seat for sealing washer protrude from the roof covering. Two nuts countered together on the upper side of the bolt can be used for turning (see picture). Lubricate the bolts with grease for ease of turning! Establish and check leak-tightness.

Establish and check leak-tightness For sealing, a rubber washer is slid all the way down and lightly pressed into the roof covering with the flange nut. Extra caution should be taken when pressing the

washer onto corrugated eternit - risk of breakage!

Further information under "Collector installation" (Point 3)

Collector installation on sloped roofs

Crossmember profile

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Important: Lateral alignment must be at a precise 90 degree angle to the lower rail, as otherwise it will not be possible to align the absorbers flush throughout the overall field!

Collector mounting systems comprise only those profiles with verified static properties! Please refer to System statics for allowable support distances!

Installation information for roof mounting set

Tool tip: Combination wrench SW 15 1. Bolt and align the crossmember onto the attachment points

Slide the bolts (normally M10x25) along the crossmember profile slot, roughly estimating their separation. Then insert the first crossmember piece (beginning with the first bolt) into the attachment row (roof hook, corrugated roof brackets, sheet metal interlocking clamps). Ideally, fasten the first bolt onto the roof attachment with a nut, then lift the rail slightly and insert bolt for bolt, securing (but not yet tightening!) them with nuts. If necessary, extend the crossmember profile with crossmember connectors. Compensate for differing heights on uneven roofing. a) with tile or pantile roofs: Use height adjustable hooks or longer M10 underlaid bolts for attachment. b) with corrugated eternit or trapezoidal sheet roofs: Adequately fit the mounting plate onto the hanger

bolt by adjusting the attachment nut. c) with sheet metal interlocking roofs: use longer M10 underlaid bolts as necessary for attachment. The lower rail is subsequently adjusted until its line is flush. Following attachment of the lower railing row, further rails can be mounted. Ensure a precisely flush lateral alignment with the roof covering. The distance between the two rails equates to 3/5 the collector length.

After aligning the crossmember rails, all mounting bolts should be tightened! Use only special nuts with locking profile! Observe the instructions in the previous section when connecting the system to the building's lightening protection system!

2. Securely tighten or check all bolts on the substructure.

Tip: So-called "triples" can be used for establishing a right angle (e.g. 60 cm, 80 cm results in a diagonal of 100 cm).

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Flat roof elevated mounting

With flat roof elevated mounting, as a rule, a module row is mounted onto the crossmember-pair with modules vertically aligned. The crossmember-pair is mounted in turn on a row of stanchions. Most stanchions are available in various setting angles: 30 degrees results in the optimal annual degree of effectiveness, 45 degrees can optimize yields during winter months with isolated systems, while 20 degrees can be used, for example, to supplement positioning on slightly sloped flat roofing. The crossmember profiles are attached to the stanchion elements. As a rule, every two crossmember profiles support a module row, which is aligned and secured to the crossmembers by means of end- and middle-clamps. Special module configurations are also possible. Various types of stanchions make possible the adaptation to differing conditions.

Bolted angle stanchion

Bolted angle stanchions are used when the system can be either bolted directly to the ground or to concrete weights on the flat roof. The angle stanchion, Standard, is especially suited for larger modules. It is available for special applications, as well as for longer dimensions on request (e.g. also for double-row module installation). The angle stanchion, Profi, is designed for normal applications.

1. Assemble and distribute stanchions over the roof surface

Select the lateral distance between stanchions depending on the boundary conditions (building height, snow loads, wind loads, module height). Under normal conditions, 1.6 to 1.8 m is common. The lateral overhang of the crossmember should be no more than approx. 0.4 to 0.5 m.

2. Stanchion attachment

� When mounting on concrete elements: Bolt down the individual stanchions onto the elements.

� When mounting on a gravel bed pan: Bolt down the individual stanchions onto the gravel bed pan.

3. Arrange the stanchions in a row 4. Loosely fasten the crossmembers to the stanchions

Slide the bolts along the crossmember profile slot, roughly estimating their separation according to the distance between stanchions. Then loosely fasten the first crossmember piece (beginning with the first bolt) onto the first stanchion. Then fasten all the stanchions together, one after the other. Connect the crossmember to the lower side of the connector plate; with the angle stanchion, Standard, the connection can be made to the stanchion. After aligning the crossmember rails on the stanchion, all mounting bolts should be tightened! Use only special nuts with locking profile!

5. Set the frame in the correct position, as necessary. 6. Securely tighten or check all bolts on the substructure. 7. Only when mounting on a gravel bed pan: Load the pan with gravel 8. Further information under "Collector installation" (Point 3)

Guidelines for using flat roof brackets

collector- quantaty 2 3 4 5 6 7 8 9 10

Quantaty beackets/ gravel bed pan 2 2 3 4 4 5 5 6 6

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General information � The statics for every stanchion have been calculated dependent on boundary conditions (building height, snow

load zones, module height, etc.). Allowable distances between stanchions can be found in the System statics.

� Regarding snow loads, it must be determined that the substructure can handle the additional roof loading.

� Regarding wind loading and especially with elevated mountings, it must be considered that the attachment points may be exposed to very large and concentrated forces. When combining stanchions with mounting elements (e.g. stancions on hanger bolts, clamps, etc.), strength verification must be carried out within the framework of the type statics, as these cases are not covered under the general System statics. Likewise, an on-site static verification of strength must be carried out.

� The required loading for gravity anchorageing can be found in the System statics. In this case, it must be ensured that the roof substructure can accept the extra weight of the solar heat system in addition to the required loading!

� The static calculations of the stanchions generally relate to the vertical loads and not to the very specific lateral

and tilt stabilities. It must be determined from case to case, whether the stanchion unions should be stabilised by means of diagonal or other bracing.

� With very thick roof coverings, gravity anchorageing without complete penetration of the roof covering is often

the only possibility. In these cases, it must be particularly ensured that building protection mats are used under the stanchions so that no gravel stones or other objects, which might damage the roof covering, will be trapped underneath the loading.

� Lightening protection: As a rule, all electrical equipment in metal enclosures must be grounded. � This applies to solar systems, as well. Pump units, pipelines, reservoirs and collectors must have potential

equalization, meaning they must be connected to ground just as normal water pipes are. Grounding requires a very good conductive contact between the grounding point and the collector. Installation of grounding clamps can made on the collector frames. The supply- and return-sides of the solar circulation piping are to be connected to the building potential equalization in the shortest manner. Please observe VDE guidelines.

Flat roof collector mounting set, parts list OEM 10/2HP

2-fach 1,62 m

3-fach 2,11 m

4-fach 3,24 m

Nomenclature Pcs. Pcs. Pcs. Plastic end cap for support profile 4 4 4 Hexagon bolt M10x25 4 6 6 Flange nut w/ locking teeth M10 4 6 6 Installation Instructions, Heat-pipe collector 1 1 1

Installation Instructions, Roof mounting system 1 1 1 System statics, basic design 1 1 1 Support profile 1.22 m. 0 3 2 Support profile 1.62 m. 2 0 0 Support profile 2.02 m. 0 0 2 Profile connector 0 2 2

Assambly instruction SUNPUR 1 1 1

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3. Collector installation On the ground

1. Unpack the first collector

2. Visually inspect the constituent external collector parts

The header and the pipes must be installed only in a fault-free condition. If damage is detected, please contact the respective distributor directly (each pipe must have a silvery gloss foot).

On the roof 3. Slide in and attach the headers

Securely tighten the first cylinder head bolt as a header case stop for the upper crossmember profile. The distance to the edge of the outer crossmember should be approx. 1 cm. Slide the headers into the crossmember profile from the other side, while turning in a "collector extension" (connector) with some lubricant between each header. The connectors serve as length compensators and connector components. Heed the correct positioning of the O-rings! Carefully slide together the headers from the other side so that the field is closed. Ensure correct seating of the connector sleeves! Securely tighten the second cylinder head bolt directly next to the last header and, in so doing, affix the field. For larger fields with 6 collectors, we recommend inserting a "Collector connector, flexible" with compensation element in the middle. Important: For affixing the headers, place one stop bolt each on the header in ront of and behind the "Collector connector, flexible".

4. Slide in and secure the foot adapter

Securely tighten the first cylinder head bolt in the lower crossmember as a foot adapter stop. The distance to the edge of the outer crossmember should be approx. 1 cm. Slide the foot adapter into the lower crossmember; 2 foot adapters are required er collector. Attention, the foot adapters are asymmetrical. The foot adapter overhang (approx. 2 cm) must always point outwards, as otherwise the pipes will have a skewed seating in the collector field. The foot adapters are subsequently bolted into the crossmembers with cylinder head bolts. A cylinder head bolt is required for fixing between every collector (2 foot adapters).

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5. Tube insertion

Remove the tubes from the cartons and check for loss of vacuum. If the foot is silvery, it is intact; if the foot is white, please contact your dealer immediately. Lubricate the header tube seals so the tubes can be turned in more easily. Brush the head of the heat-pipe-tube with thermal compound and carefully slide it into the header opening, turning it slightly at a flat angle. The tube can be turned in to approx. 1 cm against the stop.

Then pull down the tube approx. 1 cm into the retaining clamp on the back-side of the header until the tube anchors and can no longer loosen. Carefully pull back the tube until a slight resitance is encountered. Lean the tube on the foot retainer and press it into the retainer with a slight amount of

pressure. Align the tubes in a southerly direction so that the dark blue absorber is pointed directly at the midday sun (max. 30° from the roof surface level due to shadowing).

6. Clip header into the retaining clamp Slide up the header retaining clamp in such a manner that both slots on the two headers are seated inside the opening and the retaining clamp has enclosed the header.

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Collector field connection 1. Slide the insulated corrugated tube on the return (cold) side of the

collector field, enclosing both slots and securing with the clamps. Ensure correct seating! Guide the other end of the corrugated hose with 1" inner thread connector piece under the roof through the ventilation tile and connect it to the pump station riser-/downpipe.

2. Slide the insulated corrugated tube with the immersion sleeve on the

supply (hot) side of the collector field, enclosing both slots and securing with the clamps. Ensure correct seating! Guide the other end of the corrugated hose with 1" inner thread connector piece under the roof through the ventilation tile and connect it to the pump station riser-/downpipe.

3. The immersion sleeve located in the connector pipe serves as receptacle

for the collector sensor. Please insert this in the supply line with thermal compound in order to facilitate accurate temperature acquisition.

4. Visually inspect the entire system one more time. Further information under "Commissioning and filling"

More than 4 collectors in series If more than 4 collectors are to be connected in series, then flex-connectors are to be used instead of connector sleeves. These are secured on each side with a

clamp.

Vacuum tume replacement

See Collector installation from point 5

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Most safety valves in standard pump groups are rated at 6 bar.

4. Commissioning and peomptly filling

Commissionin

The collector should be put into service only when it is not exposed to direct solar radiation. A solar

circuit that has not been completely purged can cause severe operational malfunctions! The collector must be operated only in a closed solar circuit. The collector must be filled and operated using only a heat transfer agent as listed in the "Technical data" . Under no circumstances may it be filled or operated with water.

The equalising tank in use must be designed to handle up to 8 to 10 litres per deployed module. In larger systems, a buffer vessel installed upline from the equalising tank may be necessary. Please consult your system partner.

We recommend that a maximum of 8 vacuum tube collectors OEM10/2HP be connected in series, as described. If more than 8 collectors are to be installed in a field, these must be connected in parallel to each other.

The path to the safety valve must remain open at all times. Only then can the build-up of unacceptable high pressure in the system be prevented. It must be ensured that the safety valve opening pressure equates to maximum 6 bar.

In an idle state, collector systems are generally very hot. Pipeline temperatures of over 100°C can be expected all the way to the basement. Please use appropriate temperatur-resistant components.

Filling

The vacuum tube collector OEM10/2HP must be filled and operated only with undiluted LS heat transfer agent (from Tyfocor) or Fernox Solar S1, promptly

An empty collector can be damaged if it is extremely hot when being filled. For this reason, the solar circuit must not be filled when the collector is or has been recently exposed to direct solar radiation. Cover the collector for at least one hour prior to filling so it has time to cool down.

Prior to commissioning, a leak-tightness check must be made and the collector (and solar circuit) must be completely purged. Filling with a hand-pump is not suitable for this, so a jet-pump (min. 800 W, 40 m conveyance height) is required. Operating pressure should be 0.5 bar above the pressure in the equalising tank.

The filling pump should run for at least 30 minutes and be cycled on and off several times for purging. The system has been adequately purged when bubbles in the returning heat transfer agent are no longer visible over time. The fill and flush armature shown here has proven itself to be especially reliable for this purpose: With this device, the flow direction can be switched during the flushing process. This makes possible a more thorough purging of the pipelines.

Pict.: Fill and flush armature

Note the respective safety data sheet from Tyfocor. Comply with the pertinent instructions from your system partner when filling and operating the system.

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5. Technical data (OEM10/2HP collector) Dimensions in mm 2141 x 806 x 120 Specific heat capacity Ws/m2/K 24.029

Capacity η0 0.72 With relation to aperture area k1 0.67 k2 0.008 Collector yield KWh/m

2 a 610

i.a.w. ITW 5 m2

Aperture surface area (Ac) in m² 1.012 Total surface area in m² 1.726 Max. operating press. in bar 6 Max. stand-temperature in °C 160 Max. operating temperture in °C 140 Fluid volume in l 0.75 Weight in kg 25 Housing material Aluminium Frame AL-profile Optical loss Angle correction 97.0 Kb50°longi 0.88 Warranty 5 years

6. Warranty conditions for SUNPUR® tube collectors

� These Installation Instructions provide meaningful information for installing Philippine GmbH & Co. Technische Kunststoffe KG mounting systems.

� In addition to these Instructions, the specialist company responsible for installation must also comply with

applicable regulations while observing engineering standards.

� The information contained in the Installation Instructions regarding dimensioning and hydraulic connections has been gathered solely from practical experience. The planner is responsible for system design.

� The installing company is responsible for the mechanical durability of the interface connections to the building

shell and, in particular, for its leak-tightness. Philippine GmbH & Co. Technische Kunststoffe KG components are designed using state-of-the-art technologies for the loading expected.

� A guarantee cannot assumed for defects caused by third parties or, in particular, unprofessional installation

and/or commissioning, faulty or negligent handling, improper transport, excessive loading, unsuitable operating materials, defective construction work, unsuitable building ground or improper operation/utilisation.

� Philippine GmbH & Co. Technische Kunststoffe KG offers its warranty in accordance with legal provisions and

assumes liability for compensation of loss or damages only in cases of intent or gross negligence on its part.

� Product liability laws apply to cases involving personal injury or material damage resulting from product defect.

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The following warranty is offered over and above legally specified performance provisions:

� We offer a 5 year guarantee on the functionality of the collector module and the leak-tightness of the vacuum tubes.

� In addition, a 10 year product guarantee is offered on the service life and durability of the frame system

with proper handling and dimensioning according to static boundary conditions and under normal environmental and surrounding conditions.

� In the event of a warranty claim, the following prerequisites must be satisfied:

� Prerequisite for the guarantee is a professional construction and verification of annual servicing of the

complete system, including the heat transfer medium. � Ambient temperature exposure to the collector must not go below -40°C or exceed +85°C.

� Following removal of the protective packaging from the Philippine product (collectors, roof mounting set,

connection set), the presence of visible (obvious) defects must be excluded. � Claims must be reported without culpable delay to the respective contracting partner.

The warranty is no longer valid in the event of a culpable delay of the guarantee claim. � The warranty is no longer valid in cases of intentional or negligent installation of a faulty product.

Furthermore, only original Philippine installation and connection parts may be used.

� The warranty will also be deemed invalid if the customer allows changes and/or repairs to be made to a Philippine product by unauthorised persons without specific written endorsement.

� The minor discolouration of plastic parts over their service life does not impair product quality or performance

and will not be covered under warranty.

Processing the warranty claim � In the event of a warranty claim and following inspection, a replacement collector/ tube will be sent to the

customer free of shipping charges. The defective collector will be returned, cost-neutral for Philippine GmbH & Co. Technische Kunststoffe KG, or will be picked up subject to charge. Further consequential costs, in particular installation costs, will not be assumed to the extent that no legal claim for these exists. Please send bevor pictures and a short report of the damage bevor sending the goods to Philippine.

Recommendation

� The collector system should be insured under a building or a glass-breakage insurance policy. The installation must be reported to the insurance company. Many insurance companies also offer special solar system insurance packages. Ask your insurance consultant.

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