Assembly instructions

Assembly instructions 

Evacuated- tube solar collector SUNPUR ® OEM10/2DF 

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

OEM10DF -1

Table of contents 

1. Introduction P. 3 

Safety instructions P. 3 

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. 9 

Installation on corrugated eternit or trapezoidal sheet roofs P. 11 

Collector installation on sloped roofs P. 12 

Flat roof elevated mounting P. 13 

Installation on flat roofs and facades P. 14 

General information P. 15 

3. Collector installation P. 16 

Collector field connection P. 17 

Vacuum tube replacement or rotation P. 18 

4. Commissioning and filling P. 19 

5. Technical data P. 20 

Appendix 

Warranty conditions P. 21 

� 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. 

OEM10DF -2

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. 

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. 

OEM10DF -3

Product safety and risks 

This product is built to state of the art in agreement with the approved technical safety regulations. Despite this, 

there are still risks using this product. 

There are risks, for example, through heating up of assembly parts of the solar collector during its operation. There 

are other risks through breaking of glass (injury of cuts), spurting hot fluid and flowing steam (burning) or through 

falling when working on the roof. 

The evacuated-tube solar collector OEM 10 must be put into operation and used only under flawless condition and 

consideration of this instruction manual. It may be used only for the described purpose. If used for another purpose 

as described (misused), there are risks for persons and the solar collector can be damaged. Misuse of this product 

can be, for example, filling the collector with another substance than the approved heat transfer medium or 

assembling on surfaces that are insufficient in stability. 

Arbitrary alterations and changes apart from those described in the instruction manual are not permissible. 

The evacuated-tube solar collector OEM 10 must be mounted and operated according to the approved technical 

regulations. The respective national safety laws for employment protection and prevention of accidents must be 

carefully regarded and kept. This is especially imperative for work on the roof. 

Lightning protection: All electrical equipment items with a metal housing shall be earthed. This is also true for solar 

systems. The pump set, pipes, reservoirs and collectors must be provided with a potential equalisation, viz. be 

connected to earth just like any standard water pipe. Earthing requires a strongly conductive contact between the 

earthing point and the collector. The earthing clips can be installed at the collector frame. The solar circuit pipeline 

system shall be connected to the building’s potential equalisation over short runs both, for the feed and the return 

lines. 

Caution! The glass tubes are of the vacuum type. Damage, external pressure, loading or twisting, application of 

concentrated loads or force impact may cause implosion. Flying glass fragments may cause injuries. Removal or 

disposal to be done by specialist companies only. All materials used are recyclable. 

Solar systems should be maintained or services by duly licensed heating contractors, and mainly includes the heat 

transfer medium; collectors are merely subjected to visual inspection. Collectors should be replaced if damaged or 

if there is loss of vacuum. Isolated tubes shall not be replaced on site. 

Owing to its nano coating on the vacuum tubes, the collector is self-cleaning. However, should there be major 

contamination; the collector may be cleaned with water. Do not use any industrial cleaners based on abrasive 

cleaners. 

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. 

WARNING, RISK OF FALLING! 

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. 

OEM10DF -4

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. 

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

Please use work glove for the assambling to avouid injury. 

Who can install collectors? 

Ensure that children are kept clear of the area. 

Installation planning, roof installation and commissioning of the Vacuum tube collector OEM 20/2DFI 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). 

Two persons are required for roof installations. 

Installation prerequisites 

WARNING, RISK OF INJURY: 

When collectors are installed roofing where a stable attachment is not completely warranted, there is 

the risk of it coming loose, for example during a storm or due to heavy snow loading, and being 

damaged, damaging the roof or falling from the roof and injuring someone below. The collector must 

be mounted only on roofing, on which a stable and reliable attachment is warranted. 

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. 

OEM10DF -5

System tips / planning 

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 

� Max. operating temerature is 140°C. 

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

� Recommended diameter of the risers for a warm water support plant (3 solar collector panels) = DN 

16. Pump recommendation 25/4 or 25/60 

� Recommended diameter of the risers for a heating support plant (6 solar collector panels) = DN20. 

Pump recommendation 25/80. 

� Recommended diameter of the risers for a heating support plant (8 collectors) = DN20 made of 

stainless steel corrugated tube or 18 mm copper tube. Pump recommendation 25/80. 

� For a heating support plant, 130 litres of buffer volume should be provided for each collector. There 

will be a risk of stagnation if the buffer volume is less. 

� Volume flow rate: The volume flow rate will be a function of the temperature level that is to be 

operated within the system. A volume flow rate of 0.5 to 1.0 litre/m²*min. in relation to the aperture 

area is recommended. 

� The flow velocity in the tubes should not be any larger than 1 m/sec. to avoid excessive pressure 

loss. We recommend 0.3 to 0.5 m/sec. 

� These values relate to the overall pipe length of the system of max. 2 x 20 m. 

� These values are merely standard values and should be precisely determined for a specific 

application. 

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 not be laid horizontally, as otherwise air bubbles 

will form that cannot be removed from the system, even during the flushing process. 

� Do not install small radii in the pipes. Rather use bends of 2 x 45 degrees instead of merely one 

bend of 90 degrees. 

� The solar station to the collector system merely accepts high-temperature fittings or insulation. In 

the event of stagnation, the pipes may heat up to more than 130°C. 

OEM10DF -6

For soft twin copper tube, make sure the cross-section does not get too small from bending. 

This would bring about a strong increase in the flow resistance. 

� The collector sensor should be installed with thermal compound. 

� Several collector sensors should be provided for larger fields of collector panels so that the solar 

control system will promptly react to the field condition. 

� The solar control system for external collector sensors should have interval control so that the 

sensor will be able to determine the temperature actually prevailing within the field of collector 

panels. 

Setting: e. g. from 08:00 to 18:00 hours, the pump is to run approximately five seconds at intervals 

of five minutes each. 

If more than 3 OEM 10/x collectors are to be switched in series, particular attention 

should be paid to pump dimensioning. 

2 collectors in line 

2 x collectors 

1 x connecting -set 2 in serieal 

1 x roof assembling 2-fold 

(dependent on roof covering 

6 collectors 




(dependent on roof 

6 collectors 


1 x connecting -set 3+3 



Planing sheme for maintenance 

If a collector has to be changed,there is a space of 

min. 20 cm required. 

(picture showes flat roof mounting) 

3 collectors in line 





8 collectors 





40-50cm 

OEM10DF -7 

min. 

20cm

2. Roof installation 

� Tiled & pantiled roofing 

Interlocking roof tile 

Flat roof pantile 

� Corrugated eternit or trapezoidal sheet roofing 

(not within the scope of delivery ) 

� Sloped roofs 

Roof mounting set, standard 

Description 

� Flat roof elevated mounting 

Bill of materials, roof installation kit, 

OEM 10/x collector 

� Roof hooks 

� Stainless steel bolt with fan nut 

� Cross- profile 40 x 40 

� End Cap 

� Phil. stop angle for collector 

� Profile connector set 

4-fould 

1,62 m 

3- fold 

2,44 m 

2- fold 

3,24 

Pcs. Pcs. Pcs. 

Hook roof 6 6 4 

Beam section Solo 05 cut to a length of 1.22 m each 2 4 0 



Philippine collector hooks 16 12 8 

Plastic end caps for Solo 05 section 4 4 4 

Hexagon head bolt M10x 25 acc. to DIN 933 A2 8 8 6 

Hexagon flanged nut with stop teeth M10 acc. to DIN 6923 A4 24 20 14 

Half-countersunk bolt M10*30 toothed for collector hook 16 12 8 

Section connector for beam section 2 2 0 

Instructions for installation SUNPUR 1 1 1 

OEM10DF -8

Standard connecting set 

List of items for connecting set OEM 

solar collector panels 10/X 

Piched roof fastening – falsework 

For classical pitched roof fastening, two rows of roof hooks, resp., roof-fastening 

elements will be fixed on the roof’s supporting substructure per solar collector panel 

rows The cross beam profile is fixed on these elements. Two cross beams each 

carry a module row, which is aligned and fastened over 4 collector hooks each on the 

cross beam. The solar collector panels are installed perpendicularly 

Horizontal slanted roof 

mounting 

facde mounting 

Connection 

3+3 

Connection 

4 in a row 

Vertical slanted roof 

mounting 

Connection 

3 in a row 

Connection 

2 in a row 

Description Pcs. Pcs. Pcs. Pcs. 

Connecting pipe left/right 1 m insulated, 

including nozzle size 15 on either end 2 2 2 2 

Bracket, cutting ring, 15 mm 1 1 1 1 

Connecting pipe 1 m insulated, size 18 

nozzle on either end 1 0 0 0 

T-piece cutting ring 15-15-15 1 1 1 1 

Carrying bracket size 15 for copper tubing 12 8 6 4 

Double cutting ring bolted connection 15-15 4 3 2 1 

Sensor sleeve 6 mm for size 15 cutting ring 1 1 1 1 

T-piece cutting ring bolted connection 15- 

18-15 1 0 0 0 

Flat roof mounting 

without brackets 

OEM10DF -9

Crossmember profile connection 

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

crossmember profile, ensuring 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. 

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. 

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 drill bit 

1. Determining the position of the cross beam 

The cross beam should run inserted about 1/5 of the height of the module 

from upper and lower module edge. Pay attention to the position of the tile 

for ventilation! The position of the cross beam for overlapping module rows 

is to be aligned with the roof tile rows. 

min 0,5 m 

min 0,5 m 

2. Select roof hooks and place them 

The roof hooks are placed perpendicularly according to the desired position 

of the cross beam. For the horizontal position: Normally a roof hook is 

placed on every second rafter. A roof hook is recommended each for the first 

two rafters in order to compensate for the strain through wind turbulence. A 

maximum of 0.4m should be projecting left and right of the cross beam. 

Maximum roof hook space is 1.8m. Place a hook on every rafter for areas 

with increased snow or wind exposure, or enquire about the exact guideline 

1.60 - 1.80 m 

values from the manufacturer (Note: different sizes of roof hooks are 

available!). Stronger roof hooks are recommended for module heights above 

1.6m! Adjustable roof hooks help the adjustment of height for uneven roofs. 

For very broad roof tiles, “right” roof hooks can be used additionally to the 

“left” standard hooks for the installation. A further extreme balance in the horizontal position can follow 

through the combination. 

3. Fixing the roof hooks 

The roof tile is pushed up. The bar of the roof hook lies perpendicularly or in the flat level of the roofing tile. 

Between tile and bar there shall be at least 5 mm space, if necessary, it is on the base plate of the roof hook 

accordingly. A sheet metal pan suitable for the roof tile form is generally recommended under every roof hook 

for expected snow weight and especially for pan tiles! The roof hooks are fixed on the rafters with at least 2 

screws -8mm, ca. 2/3 of the whole screw length, pre-bored. Pay attention that at least 70mm of the screw is in 

the rafter – if necessary, use longer screws! Lubricating the screws with grease avoids shearing when 

screwing in. The bar of the roof hook can be secured, if desired, with a rubber ring against forcing up of water 

from strong wind. 

OEM10DF -10

4. Replace covering tile 

Depending on the form of the roof tile, sanding may be necessary (use angle grinder with diamond disc!) so that 

the tile can be closed together with the roof hooks. 

5. More under “collector installation” (point 3) 

Hints from professionals: The fastening screws on the raft are extremely important for the entire static. 

pax-screws are not to be recommended because of the weak cross section on the 

head! Make sure that there is sufficient screw length for the counter-battens! 

Hints from professionals: Caution is necessary when very flat roofs are to be fitted with roof hooks! The 

installer of the collector can be made liable for possible subsequent leakage. 

Therefore it is necessary to know that tile manufacturers can guarantee only 

restrictedly for leak tightness with flat roof sloping. 

Following citing from a renowned tile manufacturer should help to recognise problems. 

Interlocking tile 

� Is normally recommended up to a minimum of 30 degrees 

� Is only recommended in special cases (tight sarking membrane, if necessary pasted) up to 24 degrees 

Flat roof tiles MZ3 

� Is normally recommended up to a minimum of 22 degrees 

� Is only recommended in special cases (tight sarking membrane, if necessary pasted) up to 16 degrees 

OEM10DF -11

Installation of corrugated cement asbestos panels or trapezoidal 

sheet metal roofs hanger bolt (hanger bolt installation) 

Tool- hints: Combination wrench SW 18, bore machine, if necessary additional nuts M12 for countering. 

Hanger bolts with wrench size, also heavy-duty screwdriver with insert piece 9mm or 8mm 

(depending on the type) 

So-called corrugated fastening elements consisting of special hanger bolts and a mounting plate are 

used for corrugated cement asbestos panels or trapezoidal sheet metal roofs (see pictures). They are 

placed perpendicularly according to the desired position of the cross beam. For the horizontal 

position: A fastening set is placed at least on every second rafter of the subconstruction. A maximum 

of 0.4m should be projecting left and right of the cross beam. Maximum fastening space is 1.6m. In 

areas with increased snow and wind exposure or by weak rafters (as used on plate covered roofs), 

place a fastening element on every rafter or enquire about the exact guidelines from the 

manufacturer. Normally a fastening set with a hanger bolt M12x300 is recommended. For special 

fastening types with lesser cross-distance, a version M10x200 is available. 

Fastening assembly sets 

The roof skin is bored on the appropriate places (hole diameter 14mm with M12, 

13mm for M10 screws). The bores are not positioned in the water-bearing slots but 

in the elevations of the plate profile! The fastening bore is made in the rafter through 

the installation bore (8.5mm). The hanger bolt should be screwed into the rafter at 

least 80 to 100mm. The hanger bolt should be turned so that only the metric 

threading and if possible, a piece of the smooth shaft of the sealing seat is jutting out 

of the roof skin. Two nuts can be countered upon each other on the surface of the 

screw to turn in the screw (see picture). Lubricating the screw with grease makes it 

easier to turn in! 

Make the sealing and check it 

The gasket is pushed to the bottom for the sealing and lightly pressed with the flange 

nut onto the roof skin. Be careful when pressing on corrugated cement asbestos 

panels – danger of breaking! 

More under “collector installation” (point 3) 

OEM10DF -12

Solar panel assembly on pitched roofs 

Cross beam 

Collector installation systems contain only profiles with proven static characteristics! Please look up the 

permissible supporting spaces in the system static! 

Installation hints for roof installation set 

1. Screw and align cross beam on the fastening points 

Push screw (in the right M10x25) in the groove of the cross beam profile and place roughly in gaps. Insert the 

first cross beam (beginning with the first screw) in the fastening row (roof hook, corrugated roof fixtures, plate 

fold clamps). Secure the first screw with a nut on the roof’s fastening at best, lift the rails slightly bent and then 

insert the screws one after the other and secure with nuts (do not pull tight as yet!). Extend cross beam profile 

with connecting plate if necessary. Compensate uneven heights on the roof 

a) From tiled or pan tiled roofs: Use vertically adjustable hooks or longer M10-screws for fastening with 

underlay. 

b) Corrugated cement asbestos panels or trapezoidal sheet metal roofs: Fit mounting plates on the 

hanger bolt through adjusting the mounting nuts applicably. 

c) Use longer M10 screws with underlay for fastening if necessary. 

Tool- hints: Combination wrench SW 15 

2. Control and pull all screws of the subconstruction tight 

Finally, the lowest rail is aligned in a straight position. After fastening the lowest row of rails, mount the ther rails. 

Pay attention to the side for exact alignment with the roof covering. 

After aligning all the cross beam rails, pull all the connecting screws tight! Use only special nuts with locking profile! 

When connecting the plant to the lightning protection of the building, pay attention to the hints in the last section! 

OEM10DF -13

Flat roof elevation 

On a flat roof elevation, a module row of vertically aligned modules is normally 

fastened on a pair of cross beams. The pair of cross beams is in turn mounted on a 

row of supports. Most of the supports are available in different angles of approach: 30 

degrees yield the optimal annual degree of coefficiency, 45 degrees can optimise the 

yield of the island of panels in the winter half year, 20 degrees can be used as 

additional positioning on slightly sloped flat roofs. The cross beam profile is fastened 

on the supporting elements. Two cross beam profiles each normally carry a module 

row, which is aligned and fastened over the end and middle clamps on the cross 

beam. Special arrangements of modules are equally possible. Different types of 

supports allow the adjustment suitable to the different condition. 

Terms of reference of flat roof brackets 

Screwed angle support 

Screwed angle supports are used when the plant can be screwed 

directly on the ground or on a cemented weight on the flat roof.The 

standard angle-connecting piece is especially suited for larger 

modules. It is available in longer measurements for special usage on 

request (e.g. also for two rows module installation).The Prof. angle 

connecting piece is intended for normal cases of use. 

1. Mount the support and place on the roof surface. The lateral distance of the 

connecting support is to be selected according to the boundary conditions (building 

height, snow load, wind exposure, module height). 1.6 up to 1.8m is normally used. 

The lateral projection of the profile should be max. 0.4 to 0.5m. 

2. Fixing the supports. 

Collector quantity 2 3 4 5 6 

Quantaty brackets/ AL gravel pit tray 2 2 3 - 4 (3+3) 

� For installation on concrete elements: Bolt the supports up on 

the elements one by one. 

� For installation on a gravel trough: Bolt the supports up 

on the gravel trough one by one. 

3. Arrange supports in a row 

4. Fasten cross beam on the supports loosely 

Push the screw in the groove of the cross beam profile and distribute in rough 

spaces according to the space of the supports. Then fasten the first cross beam 

piece (beginning with the first screw) in the first connecting piece loosely. Then 

gradually line up the supports one after the other. Connect cross beam with 

connecting plate on the lowest side; the connection can be done on the support on 

standard angle supports. After aligning all the cross beam rails on the supports, pull 

all the connecting screws tight! Use only special nuts with locking profile! 

5. Place the frame, if necessary, in the right position 

6. Alle Schrauben der Unterkonstruktion fest anziehen bzw. 

kontrollieren 

7. For installation on a gravel trough only: Load the trough with gravel. 

8. Proceed as described at “Installation of collectors“ (section 3). 

OEM10DF -14

List of items for flat roof and facades mounting set for 

SUNPUR OEM10DF 

Flat roof and facades mounting 

Mounting elements comprised of a hanger bolt and a mounting plate 

(see pictures) are used on flat roof or façade installations. They are 

distributed in two series (for several overlapping collector fields, two 

series per field) according to the desired crossmember positions. The 

crossmembers should be spaced at 1.60 meters. The mounting plate 

spacing should be a maximum of 1.40 metres. The crossmember 

should project out no more than 0.4 m at the ends. 

Mounting set attachment 

2-fach 

1,62 m 

1.6 m 

max. 1.4 m 

Either hanger bolts for direct mounting to the flat roof or a loading construction is used for 

attaching the crossmember profiles. The loading construction is secured with concrete 

blocks. Observe the allowable roof loading. 

For façade installations, the bolts are screwed directly into the façade. Drill 12 mm holes for 

hanger bolts and use 12 dowels. The hanger bolt should be screwed in at least 80 to 100 

mm. 

The crossmember profile is fixed to the mounting plate with bolts (generally M10x25). Push 

a bolt into the crossmember profile narrow square groove, insert into the first plate and 

secure with fan nuts (do not tighten). Push the remaining bolts into the profile and plug into 

the mounting plate. Secure bolts with nuts (do not tighten yet). Straighten the profile and fix 

with the fan nuts. 

For the highest possible yield we recommend horizontal installation with rotated tubes 

3-fach 

2,44 m 

4-fach 

3,24 m 

Description Pcs. Pcs. Pcs. 




Philippine collector hooks 8 12 16 

Plastic end caps for Solo 05 section 4 4 4 

Hexagon head bolt M10x 25 acc. to DIN 933 A2 6 8 8 

Hexagon flanged nut with stop teeth M10 acc. to DIN 6923 A4 14 20 26 

Half-countersunk bolt M10*30 toothed for collector hook 8 12 16 

Section connector for beam section 0 2 2 

max. 0.4 m 

OEM10DF -15

General instructions 

� All supports are statically calculated in relation to the boundary conditions (building height, snow load zones, 

module height, etc.). The permissible spaces for the supports are to be taken from the system static. 

� Make sure that the subconstruction can carry the additional roof load with regard to the snow. 

� Be aware that very large concentrated forces can turn up on the elevations on the fastening points with regard 

to the wind strain. For a combination of supports with fastening elements (e.g supports on hanger bolts, 

clamps, etc.) a proof of stability for the type of static must be done since these cases could not be listed in 

general system static. Likewise, a proof of static stability is to be carried out on the site. 

� The necessary loading for the force of gravity fastenings can be taken from the system static. It is important to 

note here that the roof-subconstruction must be able to carry the weight of the PV-plant additionally to the 

necessary load weights. 

� The static calculations of the supports are related to the vertical loads and not to the individual sides and tilting 

stability. It must be decided from case to case, whether the connecting supports can be made stable through 

additional diagonal bracings or similar. 

� Very often, only a force of gravity fastening without penetration of the roof skin is possible with dense roof skin. 

In these cases, special attention must be paid that building protection mats are used under the supports and 

that no stone from the gravel deposits or similar remains under the weights that can damage the roof skin. 

� Lightning protection: Fundamentally, all electrical equipment must be grounded with a metal housing. This is the 

same for the solar plant. Pump groups, pipelines, storage and collectors must have a potential equalisation, 

i.e. exactly as the normal water pipes which are connected to the earth. The grounding demands a very good 

conducting contact between the grounding point and the collector. The installation of the grounding clamps 

can be done on the collector frames. The solar circuit pipeline system is to be connected to the front as well as 

the back on short paths with the building’s potential equalisation. 

OEM10DF -16

3. Solar collector assembly 

Assemble the first collector 

On the floor 

1. Unpack the first collector. 

2. Subject the collector to visual inspection externally. 

The collector should be installed if intact and undamaged only. If it is 

damaged, report the damage to your retailer without undue delay. 

3. Insert the four collector hooks, two on the left and two on the right, 

into the longitudinal bars of the collector by means of the halfcountersunk 

bolts. The hooks should be installed so as to open downwards. To 

achieve this, insert the half-countersunk bolts into the hook and push into the 

longitudinal bar with the nut tightened by approximately two thirds (2/3). Use the 

angled “nose” as a calibration. Turn the half-countersunk bolt by one half turn 

(use a screwdriver) and use a box wrench to tighten the nut. Securely tighten the 

upper collector hooks at the same distance from the collecting case. The 

overhang is described in the chapter “Roof installation kit“ (item #2). 

Approximately one fifth (1/5) of the module height. Insert the bottom hooks slightly 

higher and merely tighten hand-tight such the collector can be mounted onto the 

two cross beams (step #5). 

On the roof 

4. Push one hexagon nut each with the nut tightened by approx. one half 

into the upper and the lower cross sections. Circumstances permitting, start 

installing the field of collector panels on the left hand side. The clearance to the 

outer cross beam edge should be approx. 1 cm. 

5. Mount the first collector onto the cross rail. 

6. Slightly undo the two bottom hooks and push downwards against the 

lower cross section, and securely tighten. 

7. Bolt the two outer collector hooks with the inserted hexagon bolt and the 

serrated nut to the cross section. Do this for the outer left collector hook only. 

(fixed bearing) All other collector hooks are merely hung into the beam section (movable bearing). 

8. Now, insert the carrying brackets in both collector terminals. 

Please insert flush left only. 

9. Now, slip the double crimp ring bolted connection from the 

connection kit onto the right copper tube. 

OEM10DF -17

Set the second collector 

1. 1-3 like the first collector 

2. Lay the second collector on the cross rails and hook it in. 

3. Insert both carrying brackets. Please insert flush left only. 

4. Push the collector against the first collector and make sure the double 

crimp ring bolted connection fits onto the copper tube of second collector 

without jamming. 

5. Slightly undo the two bottom hooks and push downwards against the 

bottom cross section, and securely tighten. 

To install three collectors in series, please repeat the procedure described at 

>Fixing the second collector

4. Setup and promptly filling 

Setup 

The collector can only be put into operation when it is free of air and must be deaerated again a few 

days after it has been in operation. An incomplete deaerated solar circuit can lead to grave disturbance 

in function! The collector may be operated only in a closed solar circuit. The collector may be filled and 

operated only with heat transfer mediums listed under "technical data". It should not be filled or 

operated with water. 

The compensation tank used must be set for 8 to 10 litres per module. For larger plants, a pre-tank may be 

necessary in front of the compensation tank. Please consult your systems partner on this. 

Up to 3 evacuated-tube collectors OEM 10 can be switched in a row as described. For the assembly of more than 3 

collectors in a field, they must be switched parallel with each other. 

For a parallel switching, more fields must provide for an equal distribution of flow in the single fields. The common 

switching for this, according to Tichlmann, is not normally sufficient for the smaller, single fields, since the pressure 

reduction is too less in the fields and the danger exists that a field cannot be properly flown through. We 

recommend therefore, a fixed or adjustable restrictor at the field output on the assembly. 

The path to the safety valve must always be opened. Only in this way, can arising impermissible high pressure be 

avoided. Make sure that the safety valve has an opening pressure of maximum 10 bars. 

Standard pumps are mostly equipped with safety valves up to 6 bar. 

The collector system is generally very hot in idle condition. temperature of over 100° C in the pipelines can occur in 

the basement. Please use appropriate solid temperature elements. 

OEM10DF -19

Filling 

The evacuated-tube collector OEM 10 DF may only be filled with undiluted heat transfer medium LS (made by 

Tyforcor) or Fernox Solar S1, promptly. 

Please consult the respective safety data sheets of the Tyforcor company. To fill and set up the 

plant, please pay attention to the instructions of your systems partner. 

If the empty collector gets very hot, it can be damaged. The solar circuit may therefore, not be filled if the collector is 

set out to direct rays from the sun or was shortly in the sun. Cover the collector at least an hour before if necessary, 

so that it can cool down. 

Before setting up the plant, a leakage test must be carried out and the collector (and solar circuit) must be 

completely deaerated. Manual filling pumps are not suitable, a jet pump (min. 800W. 40m conveying height) is 

necessary. The fill pressure should lie over 0.5 bar pressure in the compensation tank. 

The pump shall run at least 30 minutes before for pre-deaeration and be switched on and off several times. 

Thereby the heat transfer medium shall run into a container through a boiler, filling and emptying plug valve (KFEplug 

valve) built in the return line between heat exchanger and circulating pump and from there repressed with the 

jet pump back into the system. 

The plant is then deaerated if no air bubbles are visible in the heat 

transfer medium return flow. 

The following filling and flush fitting has proven to be good for the 

deaeration: 

The solar circuit can be filled after this. Follow all the steps of the 

manual of your systems- partner. 

5. Technical data (OEM10/2 Kollektor) 

Dimensions in mm 2120 x 775 x 110 

Performance η0 0,781 

k1 1,12 

k2 0,004 

Aperture surface (Ac) in m² 1,012 

gross surface in m² 1,628 

Max. operating time in bar 6 

Max. idle temp. in °C 296 

Max. operating temerature1 In °C 140 

Fluid vol. in l 1,49 

Weight in kg 26,8 

Spec. heat capacity Ws/m2/K 12.600 

Housing material PU-hard 

Frame AL-Profile 

Optical loss 

Conversion factors % 78,1 

Angle correction 97,0 

Kb50°longi 0.88 

Fig. 13: Fill and flush fitting 

OEM10DF -20

Terms of guarantee for SUNPUR ® tube collectors 

� These instructions for installation provide you with useful information regarding the assembly and installation 

of the fastening systems made by Philippine GmbH & Co. Technische Kunststoffe KG. 

� In addition to these instructions, the installation contractor shall observe and comply with any applicable codes 

or engineering standards. 

� The information contained in the instructions for installation in relation to dimensioning or hydraulic 

interconnection are merely practical pointers. The planning engineer shall accept responsibility for the 

configuration. 

� The installation contractor will be responsible for the mechanical stability and strength of the installed interface 

connections at the building envelope, and more specifically for their tightness. 

To achieve this, the components made by Philippine GmbH & Co. Technische Kunststoffe KG have been 

designed according to the expected loads and latest engineering standards. 

� No responsibility will be accepted for any defects caused by third parties, specifically through improper 

assembly, installation or commissioning, through faulty or negligent handling, through improper transportation, 

excessive use, improper equipment or resources, faulty construction work, inadequate ground or subsoil, or 

through improper operation or use. 

� Philippine GmbH & Co. Technische Kunststoffe KG will extend warranty pursuant to legal requirements and 

will accept liability for compensation for damages, however only in instances of intent or gross negligence. 

The German product liability law (ProdHaftG) shall apply in the event of injuries or damage to property arising 

from faulty product. 

The following guarantees will be extended beyond statutory warranty: 

� We warrant the good working order and operability of the collector modules as well as the tightness of the 

vacuum tubes for a period of five (5) years. 

� On top of that and subject to the proviso of proper handling and dimensioning under normal ambient and 

environmental conditions, we warrant a useful life and durability of the framework for a period of ten (10) 

years. 

Warranty will be extended subject to the following requirements: 

� Warranty will be extended subject to proper assembly and installation and evidence of the annual servicing of 

the whole system including the heat transfer fluid. 

� The ambient temperature of the collector should not be below –40 °C or above +85 °C respectively. 

� After removing the protective wrapping from the items made by Philippine (collectors, roof installation kit, 

connecting kit), inspect the items to detect or exclude visible flaws (apparent defects). 

Complaints should be reported without any undue delay to your dealer or direct to Philippine GmbH & Co. 

Technische Kunststoffe KG at the below number. 

Service hotline: +49 (0) 26 21 - 173 0 

E-mail: vksolar@philippine.de 

OEM10DF -21

If the complaint is reported with an undue delay claims under guarantee will lapse. 

Warranty claims will lapse where defective items are installed by intent or negligence. 

Moreover, only Philippine OEM installation or connection parts may be used. 

Warranty will also lapse where the customer performs interventions and/or has repairs on Philippine items 

performed by unauthorised persons without express written consent. 

Minor discolorations on plastic components during their service life will not affect or impair product quality or 

performance and will not be eligible for warranty claims. 

Warranty processing 

In the event of a warranty claim, and after inspection, a replacement collector will be sent to the customer freight 

paid. 

The defective collector will be returned cost-neutral for Philippine GmbH & Co. Technische Kunststoffe KG or 

picked up to a charge. 

No consequential costs, specifically costs of installation, will be accepted unless this should be provided for by law. 

Please send bevor pictures and a short report of the damage bevor sending the goods to Philippine. 

Recommendation 

A building insurance or glass breakage insurance should be taken out for the collector system. 

Installation should be reported to the insurers. Some insurers may offer a specific insurance for solar systems. 

Please ask your insurance adviser. 

OEM10DF -22

OEM10DF -23

OEM10DF -24

OEM10DF -25

Assembly instructions

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?