Kelvinator KCT45036A User manual

Solar Hot Water Systems
Installation Manual

2 contents Kelvinator solar hot water systems
Congratulations and thank you for choosing our solar hot
water system. Before you install the hot water system, we
recommend that you read through the entire installation
manual, which provides instructions on the safe installation
of the hot water system.
To avoid the risks that are always present when you install
a hot water system, it is important that you read the safety
instructions carefully to ensure that the hot water system is
installed correctly and safely.
After unpacking the hot water system please check that it is
not damaged. If in doubt, do not install the hot water system
but contact your local Electrolux Customer Care Centre.
Meanings of symbols used in this manual are shown below:
warning
This symbol indicates information concerning your
personal safety
caution
This symbol indicates information on how to avoid
damaging the hot water system
environmental tips
This symbol indicates tips and information about
economical and ecological use of the hot water system
environmental tips
Information on disposal for users
• Most of the packing materials are recyclable.
Please dispose of those materials through your local
recycling depot or by placing them in appropriate
collection containers.
• If you wish to discard this hot water system or an old one
that has been replaced, please contact your local
authorities for the correct method of disposal.
warning
• Contact an authorised installer for installation of this
hot water system.
• Contact an authorised service technician for repair
or maintenance of this hot water system.
• If a power cord is to be replaced, replacement work
must be performed by authorised personnel only.
• Installation work must be performed in accordance
with the national standards by authorised personnel
only. Wrong connection can cause over heating or fire.
• This hot water system should be installed in accordance
with AS/NZS 3000 and your local electrical wiring rules.
Important safety instructions ........................................... 3
Specifications .................................................................... 4
General installation........................................................... 6
General installation of solar collectors ............................. 8
Components list ................................................................ 9
Roof installation – flat panel collectors........................... 10
Installation diagram –
electric boosted flat panel collectors ............................ 12
Installation diagram –
gas boosted flat panel collectors ................................... 13
Roof installation – evacuated tube collectors................. 14
Installation diagram –
electric boosted evacuated tube collectors .................. 17
Installation diagram –
gas boosted evacuated tube collectors ......................... 18
Installation – storage tank and solar controller.............. 19
Electrical installation....................................................... 23
Commissioning................................................................ 25
Troubleshooting .............................................................. 28
Notes............................................................................... 29
Warranty.......................................................................... 31
Conditions of use
This appliance is intended to be used in household and
similar applications such as:
• staff kitchen areas in shops, ofces and other working
environments.
• farm houses.
• by clients in hotels, motels and other residential type
environments.
• bed and breakfast type environments
Congratulations Contents

This Installation Manual has been prepared for qualied
installers of the hot water system. Please keep in a safe place for
future reference. Installation must be performed by a qualied
installer (for example, a licensed plumber or gas tter).
warning
For continued safety of this appliance it must be installed,
operated and maintained in accordance with the
manufacturers instructions.
For the installer
The installation must be done in accordance with the
information supplied in this Installation Manual.
For gas boosted installations, please refer to Warnings and
Cautions in the Gas Continuous Flow installation manual
supplied with the unit. All other relevant National, State or
Local regulations must also be conformed with and these
include (but are not limited to):
• Australian Standard AS3500.1 – Water Supply
• Australian Standard AS3500.4 – Hot Water Supply
• Australian Standard AS3000 – Electrical Installation
• Australian Gas Association Code AS5601 –
Gas Appliance Installation
• Local Water, Gas & Electrical Authority Regulations
Municipal Building Codes
Important safety instructions
Ensure the following safety instructions are read and
understood before commencing installation.
warning
If you do not follow these instructions exactly, a re or
explosion may result causing property damage, personal
injury or loss of life.
• This appliance is not intended for use by persons (including
children) with reduced physical, sensory or mental
capabilities or lack of experience and knowledge, unless
they have been given supervision or instruction concerning
use of the appliance by a person responsible for their safety.
• Children should be supervised to ensure that they do not
play with the appliance.
• If the solar hot water system is gas boosted and you smell
gas or smoke coming from the system:
– Do not try to light the hot water system.
– Do not touch any electrical switch
– Do not use any phone in your building
– Isolate the power at the main switchboard
– Check and isolate the main gas valve
– Immediately call your gas supplier from a neighbour's
phone. Follow the gas supplier's instructions
– If you cannot reach the gas supplier, call the
re department
• The piping system of the solar circuit is to be electrically
connected in the lower part of the building according to
local standards. The connection of the solar system to
an existing or to be created lightning protection system
or potential equalization may be implemented only by
authorised specialists.
• If the solar hot water system is gas boosted, ensure there
is proper ventilation to avoid oxygen deciency.
• Ensure that any water drained during installation does
not cause damage to the building or property.
• Be sure that the hot water system is well earthed in
order to avoid electric shock.
• The solar hot and solar cold pipes between the hot water
storage tank and solar collectors MUST BE copper
and fully insulated with closed cell polymer insulation
or similar (minimum thickness of 20mm). Thicker insulation
may be required to comply with the requirements of
AS/NZS 3500.4. Plastic pipe MUST NOT be used, as it
will not withstand the temperature and pressure of the
water generated by the solar collectors under stagnation
conditions. The solar collectors can generate extremely
high water temperatures of up to 272°C. Plastic pipe can
not withstand these temperatures. Failure of plastic pipes
can lead to the release of high temperature water
and cause severe water damage and flooding.
• The insulation must be weatherproof and UV resistant if
exposed to sunlight.
• All compression ttings must use brass or copper olives.
• The collectors must be lled with water before the
protective cover is removed to prevent damage to the
hot water system and harm to the installer.
• Ensure that the roof has the load bearing capacity
to withstand the weight of installation, including the
installers and the full collectors.
• Installation must be carried out in accordance with
local Occupational Health and Safety laws.
• Ensure that appropriate safety measures are taken to
prevent objects falling from the roof during installation.
• The standard roof mounting kit for the collectors supplied
with this unit is NOT suitable for cyclone prone areas.
If you are installing in a cyclone prone area, please
consult your local building authority for advice regarding
appropriate mounting requirements.
• The minimum inlet water pressure must be 150kPa.
• If the hot water system supply pressure exceeds 600kPa, a
pressure limiting valve must be tted to limit the pressure
to 600kPa. A cold water 700kPa pressure relief valve may
also need to be installed in the water inlet to the storage
tank according to local regulations.
• A 99°C/850kPa temperature and pressure relief valve
(supplied) must be installed near the top of the storage tank.
• Ensure that the discharge pipes of the pressure relief
valves are left open to the atmosphere at all times.
• The pressure-relief devices are to be operated regularly to
remove lime deposits and to verify that they are not blocked.
• If a supply cord is damaged, it must be replaced by the
manufacturer, its service agent or qualied persons in
order to avoid a hazard.
• The operation of the thermal cut-out on the hot water
storage tank indicates a possibly dangerous situation
(electric boosted installations only). Do not reset the
thermal cut-out until the hot water system has been
serviced by a qualied person.
• Solar hot water systems with at panel type collectors
are not designed to be installed in heavy frost or high
altitude areas 400m above sea level.
• This hot water system delivers water above 50°C
and a tempering valve must be installed to limit the
temperature of hot water to sanitary xtures primarily
used for the purpose of personal hygiene as per the
AS 3500 requirements.
• The temperature settings for the hot water system are
factory pre-set to ensure optimum energy efciency
whilst providing Legionella bacteria protection. The
temperature settings are therefore not adjustable by
the customer or installer.
Important Important safety instructions
Kelvinator solar hot water systems important safety instructions 3

4 specications Kelvinator solar hot water systems
Specifications
Collector Flat panel (KCPF20A)
Collector dimensions per panel (mm) length 2002 x width 1025 x depth 80
Gross surface area 2.05m2
Aperture surface 1.81m2
Net weight 34.5kg
Operating positive pressure. max. 1000kPa
Stagnation maximum temperature 199°C
Header pipe outer diameter 22mm
Collector frame material Aluminium
Absorber material 0.12mm copper n with TiNOx selective coating
Glazing 4mm low iron tempered patterned glass
Insulation material 40mm glass wool
Collector Evacuated tube (KCPE12A)
Number of evacuated tubes per collector panel 12
Collector dimensions (mm) length 1390 x width 1640 x depth 100
Gross surface area 2.28m2
Aperture surface 2.0m2
Collector capacity 1.6L
Net weight 37kg
Operating positive pressure. max. 1000kPa
Stagnation maximum temperature 272°C
Collector header pipe outer diameter 15.0mm
Collector piping connections 1/2"
Collector frame material Anodised aluminium
Material selective absorber layer Aluminium nitrite

Kelvinator solar hot water systems specications 5
Specifications
Solar controller (KKSSUA)
Dimensions (mm) length 365mm x width 205mm x depth 100mm
Protection rating IPX4
Net weight 2.3kg
Operating positive pressure. max. 850kPa
Maximum water temperature 95°C
Circulation pump type UP15 – 14B
Circulation pump power 25W
Rated voltage of circulation pump AC 220-240V
Frequency 50Hz
Model number KCT27000A
KCT27036A
KCT34000A
KCT34036A KCT45036A
Diameter (mm) 648 648 730
Height (mm) 1390 1690 1715
Tank capacity (L) 270 340 450
Net Weight (kg) 95 110 140
Tank wall thickness (mm) 2.5 3 3
Element rating (if installed) 3.6kW 3.6kW 3.6kW
PTR valve pressure limit (kPa) 850 850 850
PTR valve temperature limit (°C) 99 99 99
PTR max energy release rate (kW) 10 10 10

6 general installation Kelvinator solar hot water systems
General installation
The collector rails, unions, straps, clamps, bolts, nuts and
washers required for the installation are included in the
collector kit(s). Suitable screws will be required to x the
collectors to the roof.
The collectors and mounting kit are not designed to be
installed in cyclone prone areas. If installing in these areas or
other areas where a high level of windy and stormy conditions
exist, the collectors will need to be xed accordingly. Consult
the local authorities for advice regarding any additional
mounting instructions.
Use an appropriate amount of thread sealing tape or an
approved thread sealant in between all ttings.
Solar collector location
Consideration must be given to the position of the solar
collectors in relation to the hot water storage tank. The
maximum length of the solar hot and solar cold pipes must
be 10 metres one way (20 metres total) or less to full energy
efciency rating requirements.
• The solar collectors should be installed in a shade
free position.
• The solar collectors are to be installed facing toward
the equator (i.e. North). Where this orientation is not
practical, a system facing up to 45° from the equator will
have its efciency reduced by approximately 4%.
• Inclination of the solar collectors should be approximately
equal to 90% of the local latitude angle. Solar collectors
may be installed at the roof angle for simplicity of
installation and appearance, but must never be less than
10°. If the roof angle varies by 15° from the correct angle,
efciency will be reduced by 10%.
Latitudes of some Australian cities
Adelaide 35°S Port Hedland 20°S
Mildura 34°S Canberra 35°S
Brisbane 27°S Broken Hill 31°S
Darwin 12°S Geraldton 28°S
Rockhampton 24°S Cairns 17°S
Alice Springs 24°S Hobart 42°S
Melbourne 38°S Sydney 34°S
Townsville 19°S Perth 32°S
If the roof is flat or has a pitch less than or greater than the
recommended angle, a pitch stand may need to be installed
to allow the collectors to be mounted correctly. This stand
may need to be purchased from a local store or made
especially for the installation.
warning
PLUMBER BE AWARE!
• Water temperatures above 50°C can cause severe burns.
• All plumbing work must be carried out by a qualied
person and in accordance with the National Plumbing
Standard AS/NZS 3500.4 and local authority
requirements.
• Ensure the roof structure is suitable to carry the full
weight of the solar collectors. Each flat panel solar
collector and its ttings weigh approximately 45kg
when full of water. Each evacuated tube solar collector
and its ttings weigh approximately 47kg when full of
water. If in doubt the roof structure should be suitably
strengthened. Consult a structural engineer.
• Do not remove the solar collector packaging
completely, prior to the installation. Remove only
sufcient packaging material to enable the installation.
Upon completion of the installation it is necessary to
leave the solar collector packaging covering the glass
on the solar collector. The packaging should not be
removed until the solar hot water system has been
commissioned and is ready for use.
• Plastic pipe MUST NOT be used, as it will not withstand
the temperature and pressure of the water generated
by the solar collectors under stagnation conditions.
The solar collectors can generate extremely high
water temperatures up to 272°C. Plastic pipe cannot
withstand these temperatures and MUST NOT be used.
Failure of plastic pipe can lead to the release of high
temperature water and cause severe water damage
and flooding.
• There must be a continuous fall in the pipe work
between the solar collectors and the solar storage tank.
The highest point of the solar cold pipe and solar hot
pipe must be where they connect to the solar collectors,
to avoid the possibility of air locks occurring in the
system.
• Safety harnesses must be used when working at heights
and on the roof. If the roof is wet or dewy it will be very
slippery and installation work should not be carried out
until it has become dry.
The solar hot and solar cold pipes between the storage
tank and solar collectors MUST BE copper only and fully
insulated with closed cell polymer insulation or similar
(minimum thickness 20mm). Thicker insulation may be
required to comply with the requirements of AS/NZS 3500.4.
The insulation must be weatherproof and UV resistant. All
compression ttings must use brass or copper olives.
Note: Failure to observe this requirement may void the
warranty for freeze damage.
The insulation is essential to assist in providing freeze
protection. When installed on a metal roof, insulation will
ensure corrosion protection against water runoff over the
copper pipe, assist in avoiding accidental contact with the
pipe work and also reduce pipe heat loss.

Kelvinator solar hot water systems general installation 7
General installation
Pipe lengths
The solar hot and solar cold pipes between the hot water
storage tank and the solar collectors must:
• have a continuous fall from the solar collectors to the hot
water storage tank of 5 (1 in 10 grade).
• not exceed the maximum recommended length of 10
meters (20 meters total).
Notes:
• It is important not to cross connect the solar cold and
solar hot pipes to the incorrect connections.
• In the at panel solar hot water system, the solar cold
pipes connect to the bottom of the solar collectors
and the solar hot pipe connects to the top of the solar
collectors diagonally opposite to the solar cold pipe
connection.
• In the evacuated tube hot water system, both connections
are located at the top of the collector.
• The collector sensor must be located in the same end as
the collector array outlet connection on both flat panel
and evacuated tube collectors.
It is essential for these requirements to be followed for the
system to operate correctly and efciently. Solar pipe work that
is undersized, does not have the correct fall or is too long can
result in the solar hot water system not operating effectively.
Maximum height to collectors
The solar collectors must be the highest point of the system.
The maximum height of the solar installation, from the
base of the hot water storage tank to the top of the solar
collectors, is 9m. The pump supplied will not circulate closed
circuit uid through heights greater than 9m and solar gain
will not be achieved.
For heights greater than 9m, an auxiliary pump must be
installed above and within 1 m of the hot water storage tank.
Water quality
Water quality can vary in different locations and affect the
performance and safe operation of the hot water system.
If the water supply is not within the acceptable limits as
indicated below, the hot water system should not be
installed, and will not be covered by warranty from the
manufacturer. A suitable solution is to implement a water
pre-treatment process to bring the water quality to within
acceptable limits to support the installation.
The saturation index (SI) is a measure of the corrosive or
scaling properties of the water supply. Corrosive water (SI<-
1.0) can corrode copper components. In these conditions
warranty will not apply. Scaling water (SI>0.5) can cause
build up of CaCO3 (Calcium carbonate) which can impact
to the correct operation of moving parts within the system,
including the temperature and pressure relief valve. In these
conditions warranty will not apply.
Total Dissolved Solids (TDS) and water hardness can also
impact the life of the hot water system, and warranty does
not apply outside the following limits:
• TDS exceeding 600 p.p.m
• Electrical conductivity exceeding 850us/cm
• Total hardness exceeding 200 p.p.m
• Chloride exceeding 250 p.p.m
• Magnesium exceeding 10 p.p.m
• Sodium exceeding 150 p.p.m
• Acidity/Alkalinity must also be within the limits of
pH 6.5 - 8.5
Protecting the solar collectors
The solar collectors are designed to withstand impact and
be hail resistant, so it is not necessary to install any special
hail guards to protect these collectors. However, if it is
possible that the collectors could be damaged due to falling
branches, vandalism etc. it is recommended that guards are
made and installed to prevent damage to the collectors.
Note: The installation of protective guards will impact on the
performance of the collectors.
Frost protection and damage due to freezing
The solar hot water system has been approved to level 2 frost
protection and can therefore withstand frosty conditions.
However, it is not recommended to install at panel type
collectors in areas 400m above sea level. It is recommended
that evacuated tube type collectors are installed in high altitude
and frost prone areas. The warranty for frost damage will not
apply if the hot water system is damaged due to freezing when
using flat panel type collectors in high altitude areas. The
warranty for frost damage will also not apply to solar hot water
systems with either type of collectors installed if the pipe work
between the collectors and the hot water storage tank has
insufcient piping insulation.

8 general installation of solar collectors Kelvinator solar hot water systems
10 -15mm
from horizontal
inlet
20-30mm
from horizontal
30-45mm
from horizontal
horizontal
collector rail
outlet
Note: The solar collectors (both flat panel and evacuated
tube) must be installed at an angle from the horizontal.
This is to ensure that any air in the system will travel to
the air vent valve located on the outlet connection of the
collectors.
The distance between the end of the collector rail at the
outlet side of the solar collectors and the horizontal must be:
10 - 15 mm (for one solar collector)
20 - 30 mm (for two solar collectors)
30 - 45 mm (for three solar collectors)
If the roof material is uneven where the collectors are to be
installed, then it may be necessary to add an additional 10
mm to the above distances for each collector.
Space requirements
A
B
C
C
D
Space and load bearing requirements for evacuated
tube collectors
No. of
collectors
Dimension
A (mm)
Dimension
B (mm)
Weight when
full (approx.)
11400 1640 47kg
22800 1640 94kg
34200 1640 141kg
Dimensions C and D
• when determining the location for the collector ensure
that there is adequate space available for the water
connections and the xing of the mounting kit.
A
B
C
C
D
Space and load bearing requirements for flat
panel collectors
No. of
collectors
Dimension
A (mm)
Dimension
B (mm)
Weight when
full (approx.)
11025 2050 45kg
22050 2050 90kg
33075 2050 135kg
General installation of solar collectors

components list Kelvinator solar hot water systems 9
Components list
Supplied in kit: KKSSF2MA –
flat panel double roof mounting kit
Item No. Qty. Description
1 1 rail bottom for 2x flat panel collector
2 2 strap rail bottom
3 4 clamp flat panel collector
4 4 bolt, nut and washer assembly
52 strap top flat panel collector
62 self tapping screw
7 2 connector flat panel collector
Supplied in kit: KKSSF1MA –
flat panel single roof mounting kit
Item No. Qty. Description
8 1 rail bottom for 1x at panel collector
9 1 rail joiner
2 2 strap rail bottom
32 clamp flat panel collector
42 bolt, nut and washer assembly
5 1 strap top flat panel collector
6 1 self tapping screw
7 2 connector flat panel collector
Supplied in kit: KKSSE1MA –
evacuated tube single roof mounting kit
Item No. Qty. Description
10 1 rail bottom for 1x evacuated tube
collector
2 2 strap rail bottom
11 2clamp evacuated tube collector
42 bolt, nut and washer assembly
12 1strap top left evacuated tube collector
13 1strap top right evacuated tube collector
14 2 bracket top evacuated tube collector
62 self tapping screw
9 1 rail joiner
Supplied in kit: KCPF20A –
flat panel solar collector
Item No. Qty. Description
15 1flat panel collector
Supplied in kit: KCPE12A –
evacuated tube solar collector
Item No. Qty. Description
16 1evacuated tube collector
17 1connector evacuated tube collector
18 2connector sleeve support evacuated
tube collector
19 2connector to 1/2" male for evacuated
tube collector
Supplied in kit: KKSSURA –
roof fittings kit
Item No. Qty. Description
20 2connector to 1/2" male for at panel collector
21 2 stopper flat panel collector
22 2union 1/2" female to copper
23 2t-piece 1/2" female
24 2nipple 1/2" to 1/2" male
25 1 bush 1/2" male to 3/8" female
26 1 air vent valve 3/8" male
27 1 sensor pocket 1/2" male
28 1 sensor collector with wire 15m
Supplied in kit: KKSSUGA –
ground fittings kit
Item No. Qty. Description
29 1solar controller
30 4 screw xing solar controller
31 2bush 3/4" male to 1/2" female
24 5 nipple 1/2" to 1/2" male
23 1 t-piece 1/2" Female
27 1 sensor pocket 1/2" male
32 1 exible tube 1/2" female to 1/2" female
33 1 check valve 1/2" male to 1/2" female
22 2union 1/2" female to copper
34 1 tempering valve 50°C
Supplied with tank: KCT*****A –
tank and TP&R valve assembly
Item No. Qty. Description
35 1temperature and pressure relief valve
1/2" male
31 1 bush 3/4" male to 1/2" female
36 1 of
KCT27036A -
270L tank with 3.6kW element
KCT34036A -
340L tank with 3.6kW element
KCT45036A -
450L tank with 3.6kW element
KCT27000A -
270L tank without element
KCT34000A -
340L tank without element
Supplied with gas booster: KGC26S*A – gas booster
Item No. Qty. Description
37 4 screw gas booster xing
38 1 of
KGC26SNA -
26L/min solar gas booster - natural gas
KGC26SLA -
26L/min solar gas booster - LP gas

10 roof installation – at panel collectors Kelvinator solar hot water systems
Roof installation –
flat panel collectors
Fix the bottom straps using appropriate screws into the
roof struts or trusses making sure the bottom rail is inclining
towards the proposed outlet end of the collectors.
If installing on a tiled roof, place the tiles back into their
normal positions after xing the straps.
Preparing and xing the collectors
Unpack each collector and cut out the template on the back
of the cardboard packaging. Place the cut out template
on the front of each collector and x it with tape. This is
important as the collector connections will become very
hot once exposed to solar radiation and may cause a safety
hazard or prevent the installation of the pipe work to the
collectors. Carefully lift the collectors onto the roof and
place them in position, resting against the bottom rail of the
collector mounting kit already xed to the roof.
Before the collectors are xed to the roof and mounting kit, they
are to be connected together forming an array (two and three
collector installations only). Two compression union ttings are
used to join two collectors together (one for top and one for the
bottom) and are supplied in the mounting kit(s).
solar collectors
collector
manifold
pipes
compression
union
Slide the ttings onto one side of the collector manifold pipe
to be joined and then push both collectors together. The
collector manifold pipes should be inserted as far as possible
into both sides of the compression union tting.
Using two spanners, tighten each nut on the compression
union tting one side at a time, with one spanner used to
brace the tting in the middle. Tighten both sides of the
compression union tting until the copper olives are rmly
sealed against both collector manifold pipes.
This standard roof mounting kit is not suitable for cyclone
prone regions. Refer to the warning in the Important Safety
Instructions section.
Unpack the collector mounting kit(s) and check that all
components are included (see mounting kit contents table).
If you are installing three collectors, join the two bottom rails
together using the rail joiner.
Slide the bottom straps onto the bottom rail so that they are
evenly spaced and place the bottom rail assembly on the roof
in the installation location decided. If installing on an iron roof,
line up the bottom straps to the existing roong screws that
are xing the iron roong membrane to the struts.
If installing on a tiled roof lift up the tiles and line up the
bottom straps with the roof struts or trusses.

Kelvinator solar hot water systems roof installation – at panel collectors 11
Roof installation –
flat panel collectors
Collector pipe work connections
Open the ttings kit KKSSURA and check that all
components have been supplied (see components list).
Place two 1/2" male to collector compression union ttings
on the manifold pipes of the inlet and outlet of the collector
array (the inlet to the collector array will be at the bottom
and the outlet will be at the diagonally opposite corner at the
top). Tighten the nut using two spanners as before, sealing
the copper olive to the collector manifold pipes.
solar collector
1/2" male
to collector
compression union
collector
manifold
pipe
Place the stopper ttings from the kit onto the remaining
collector pipe work (also at diagonally opposite corners of
the collector array) and tighten as before with two spanners.
solar collector
stopper
collector
manifold
pipe
On the collector array outlet, install the two tee pieces, two
nipples, sensor pocket, 1/2" to 3/8" reducing bush, vent valve
and 1/2" female to copper union (see the diagram below).
Between the ttings use an appropriate thread sealant that
is capable of handling the high temperatures created by the
collectors. Ensure the vent valve is installed so that its vent is
pointing directly upwards, perpendicular to the ground (not
the roof).
vent valve
1/2" female to
copper union
sensor pocket
1/2" male to
collector union
1/2" to 3/8"
reducing bush
1/2"nipple
1/2"female T-piece
Once all the collectors are joined together (two or three
collector installations only), they should be correctly
positioned so that they are evenly distributed on the bottom
rail. Place the collector clamps on the bottom rail over the
top of the provided holes and insert the bolts through the
holes in the clamps and bottom rail. Place the washers
and nuts on the bottom of the bolts and tighten with two
spanners, rmly clamping the collectors to the bottom rail.
If installing on an iron roof, line up a top strap with a
horizontal roof strut (look for where the iron has been xed)
and the top side of the collector. Fix the top strap to the roof
strut by either using an existing roong screw or adding a
new one.
If installing on a tiled roof, lift a tile above the collector and
line up a top strap with a roof strut or truss and the top side
of the collector. Fix the strap to the roof strut or truss and
place the tile back to its normal position (same procedure as
xing the bottom strap).
Fix the top strap to the top side of the collector using a
supplied self tapping screw and repeat for each additional
collector (two or three collector installations only).

12 installation diagram – electric boosted at panel collectors Kelvinator solar hot water systems
Installation diagram - electric boosted flat panel collectors
Tiled roof – preferred method: Connect roof straps from bottom rail and top edge
of collectors to vertical roof beams. Secure with 2 screws at top of beams. Connect
roof straps from bottom rail and top of collectors to horizontal beams if vertical
beams are not accessible.
All numbered items are supplied with the hot water system. Please refer to the Components list for details. Items which are not numbered are not supplied and
need to be supplied by the installer in accordance with local plumbing requirements. Installation of this hot water system must be completed by an authorised and
licensed person in accordance with all local regulations, including AS3500 plumbing and drainage requirements and AS3000 electrical wiring standards.
Bottom rail connection viewed
from above
10 -15mm
from horizontal
bottom rail
assembly
1.5m
relief valve
uncontrolled
hot water outlet
(kitchen, laundry)
tempered (50°C)
hot water outlet
(bathrooms)
tempering
valve
20-30mm
from horizontal
30-45mm
from horizontal
Connecting strap viewed from
roof cavity
Components shown in grey are only used in 2 and 3 collector panel connections
Secure with 2 straps on top and
back edge of beam
Iron roof: Connect bottom rail
and top edge of collectors to
iron roof.
securing top centre
of panel
isolating
and non
return
valve
pressure limiting
valve (600kPa)
may be required
if pressure
exceeds 600kPa
pressure relief
valve (700kPa)
may be required
refer to local
plumbing
guidelines
drain
cold
inlet
flow
relief
valve
from
solar
return
horizontal
outlet
earth terminal neutral terminal
wiring terminal
block
element
thermostat
active terminal
conduit adaptor
goes in here and
locking ring holds it

Kelvinator solar hot water systems installation diagram - gas boosted at panel collectors 13
Installation diagram - electric boosted flat panel collectors
Tiled roof – preferred method: Connect roof straps from bottom rail and top edge
of collectors to vertical roof beams. Secure with 2 screws at top of beams. Connect
roof straps from bottom rail and top of collectors to horizontal beams if vertical
beams are not accessible.
All numbered items are supplied with the hot water system. Please refer to the Components list for details. Items which are not numbered are not supplied and need to be
supplied by the installer in accordance with local plumbing requirements. Installation of this hot water system must be completed by an authorised and licensed person in
accordance with all local regulations, including AS5601 gas installation requirements, AS3500 plumbing and drainage requirements and AS3000 electrical wiring standards.
Bottom rail connection viewed
from above
10 -15mm
from horizontal
bottom rail
assembly
relief valve
uncontrolled
hot water outlet
(kitchen, laundry)
tempered
(50°C)
hot water
outlet
(bathrooms)
tempering
valve
20-30mm
from horizontal
30-45mm
from horizontal
Connecting strap viewed from
roof cavity
Components shown in grey are only used in 2 and 3 collector panel connections
Secure with 2 straps on top and
back edge of beam
Iron roof: Connect bottom rail and
top edge of collectors to iron roof.
securing top centre
of panel
isolating
and non
return valve
pressure limiting
valve (600kPa) may be
required if pressure
exceeds 600kPa
pressure relief valve
(700kPa) may be
required refer to
local plumbing
guidelines
drain
return
flow
inlet
cold
inlet
flow
relief
valve
from
solar
return
horizontal
outlet
1.5m
inlet
inlet
outlet
outlet
gas
gas

14 roof installation – evacuated tube collectors Kelvinator solar hot water systems
Roof installation –
evacuated tube collectors
Fix the bottom straps into the roof struts or trusses using
appropriate screws, making sure the bottom rail is inclining
towards the proposed outlet end of the collectors.
If installing on a tiled roof, place the tiles back into their
normal positions after xing the straps.
Preparing and xing the collectors
Unpack each collector and check the contents against the
components list, being sure to leave the protective plastic
cover on each collector. This is important as the collector
connections will become very hot once exposed to solar
radiation and may cause a safety hazard or prevent the
installation of the pipe work to the collectors. Carefully lift
the collectors onto the roof and place them in position,
resting against the bottom rail of the collector mounting kit
already xed to the roof.
Before the collectors are xed to the roof and mounting kit,
they are to be connected together forming an array (two and
three collector installations only). The compression union
ttings supplied with the collectors are used to join the
collectors together.
Place the copper sleeve supports into the manifold pipes
of each collector. Slide the ttings onto one side of the
manifold pipe to be joined and then push both collectors
together. The collector manifold pipes shall be inserted as far
as possible into both sides of the compression union tting.
solar collectors
copper sleeve
support
collector
manifold
pipes
compression
union
Using two spanners, tighten each nut on the compression
union tting one side at a time, with one spanner used to
brace the tting in the middle. Tighten both sides of the
compression union tting until the copper olives are rmly
sealed against both collector manifold pipes.
This standard roof mounting kit is not suitable for cyclone
prone regions. Refer to the warning in the Important Safety
Instructions section.
Preparing the mounting kit
Unpack the collector mounting kit(s) and check that all
components are included.
Slide the bottom straps onto the bottom rail and join the
bottom rails together using the rail joiner(s) if you are
installing two or three collectors.
Adjust the straps on the bottom rail so that they are evenly
spaced and place the bottom rail assembly on the roof in the
installation location decided. If installing on an iron roof, line
up the bottom straps to the existing roong screws that are
xing the iron roong membrane to the struts.
If installing on a tiled roof lift up the tiles and line up the
bottom straps with the roof struts or trusses.

Kelvinator solar hot water systems roof installation – evacuated tube collectors 15
Once all of the collectors are joined together (two or
three collector installations only), they should be correctly
positioned so that they are evenly distributed on the bottom
rail. Place the collector clamps on the bottom rail over the
top of the provided holes and insert the bolts through the
holes in the clamps and bottom rail. Place the washers
and nuts on the bottom of the bolts and tighten with two
spanners, rmly clamping the collectors to the bottom rail.
If installing on an iron roof, two top brackets supplied in the
mounting kit are to be used to x the collectors to the roof.
Line up the top brackets with a horizontal roof strut (look for
where the iron is xed) and the side of the collector array. Fix
the top brackets to the roof strut by either using an existing
roong screw or adding a new one.
Fix the top brackets to each side of the collector array with
the supplied self tapping screws.
If installing on a tiled roof, two twisted straps are to be xed
to the roof and each side of the collector array. The twisted
straps are to be xed so that the twisted ends are ush with
the sides of the collector array. It is important to determine
which strap is for the left hand side and which one is for the
right, before xing the strap to the roof. Lift the tiles above
each edge of the collector array and line up the appropriate
top twisted strap with a roof strut or truss and each side of
the collector array. Fix the flat end of the twisted strap to
the roof strut or truss and place the tile back to its normal
position. Fix the twisted end of the twisted strap to each side
of the collector array using the self tapping screws supplied
with the mounting kit.
Roof installation –
evacuated tube collectors

16 roof installation – evacuated tube collectors Kelvinator solar hot water systems
Roof installation –
evacuated tube collectors
On the collector array inlet install a 1/2” to copper union
onto the 1/2” male compression union tting making sure to
use a thread sealant.
1/2" female to
copper union 1/2" male to collector union copper support sleeve
Collector pipe work connections
Place the copper sleeve support into the inlet and outlet
manifold pipes of the collector array. Install a 1/2" male
compression union tting (supplied with the collectors) and
tighten the nut using two spanners as before, sealing the
copper olive to the collector manifold pipes.
collector
1/2" male
compression
union
Open the ttings kit KKSSURA and check that all
components have been supplied (see components list). Since
this kit is also used for flat panel type collectors there will be
some pieces which will not be used.
On the collector array outlet install a tee piece, 1/2" to 3/8"
reducing bush, vent valve, 1/2" nipple and 1/2" female to
copper union (see diagram below). Between the ttings
use a thread sealant that is capable of handling the high
temperatures created by the collectors. Ensure the vent
valve is installed so that its vent is pointing directly upwards,
perpendicular to the ground (not the roof).
vent valve
T-piece
1/2" female to
copper union
1/2" male to
collector union
1/2" to 3/8"
reducing bush
1/2"nipple

Kelvinator solar hot water systems installation diagram – electric boosted evacuated tube collectors 17
Installation diagram – electric boosted evacuated tube collectors
Tiled roof – preferred method: Connect roof straps from bottom rail and
top edge of collectors to vertical roof beams. Secure with 2 screws at top
of beams. Connect roof straps from bottom rail and top of collectors to
horizontal beams if vertical beams are not accessible.
All numbered items are supplied with the hot water system. Please refer to the Components list for details. Items which are not numbered are not supplied and
need to be supplied by the installer in accordance with local plumbing requirements. Installation of this hot water system must be completed by an authorised and
licensed person in accordance with all local regulations, including AS3500 plumbing and drainage requirements and AS3000 electrical wiring standards.
Bottom rail connection viewed
from above
10 -15mm
from horizontal
bottom rail
assembly
1.5m
relief valve
uncontrolled
hot water
outlet
(kitchen,
laundry)
tempered
(50°C) hot
water outlet
(bathrooms)
tempering
valve
20-30mm
from horizontal
30-45mm
from horizontal
Connecting strap viewed from
roof cavity
Components shown in grey are only used in 2 and 3 collector panel connections
Secure with screws on top
and back edge of beam
Iron roof: Connect bottom
rail and top edge of
collectors to iron roof.
Connecting top of
collectors to tiled
roof using twisted
metal straps.
isolating
and non
return
valve
pressure limiting
valve (600kPa)
may be required
if pressure
exceeds 600kPa
pressure relief
valve (700kPa)
may be required
refer to local
plumbing
guidelines
drain
cold
inlet
flow
Ø20mm
conduit
relief
valve
from
solar
return
horizontal
insert sensor here then
apply silicone to seal.
Cable tie the sensor
wire to outside of the
pipe insulation, ensuring
that the wire does not
touch the hot pipe.
outlet
earth terminal
earth
neutral terminal
wiring terminal
block
element
thermostat
active terminal
conduit adaptor
goes in here and
locking ring holds it
1/2"nipple

18 installation diagram – gas boosted evacuated tube collectors Kelvinator solar hot water systems
Installation diagram – gas boosted evacuated tube collectors
Tiled roof – preferred method: Connect roof straps from bottom rail and
top edge of collectors to vertical roof beams. Secure with 2 screws at top
of beams. Connect roof straps from bottom rail and top of collectors to
horizontal beams if vertical beams are not accessible.
All numbered items are supplied with the hot water system. Please refer to the Components list for details. Items which are not numbered are not supplied and need to be
supplied by the installer in accordance with local plumbing requirements. Installation of this hot water system must be completed by an authorised and licensed person in
accordance with all local regulations, including AS5601 gas installation requirements, AS3500 plumbing and drainage requirements and AS3000 electrical wiring standards.
Bottom rail connection viewed
from above
10 -15mm
from horizontal
bottom rail
assembly relief valve
uncontrolled
hot water outlet
(kitchen,
laundry)
tempered (50°C)
hot water outlet
(bathrooms) tempering
valve
20-30mm
from horizontal
30-45mm
from horizontal
Connecting strap viewed from
roof cavity
Components shown in grey are only used in 2 and 3 collector panel connections
Secure with screws on top
and back edge of beam
Iron roof: Connect bottom
rail and top edge of
collectors to iron roof.
Connect top of
collectors to tiled
roof using twisted
metal straps.
isolating
and non
return valve
pressure limiting
valve (600kPa) may be
required if pressure
exceeds 600kPa
pressure relief valve
(700kPa) may be
required refer to
local plumbing
guidelines drain
return
flow
inlet
cold
inlet
flow
relief
valve
from
solar
return
horizontal
outlet
1.5m
inlet
inlet
outlet
outlet
gas
gas
insert sensor here then
apply silicone to seal.
Cable tie the sensor
wire to outside of the
pipe insulation, ensuring
that the wire does not
touch the hot pipe.

Installation – storage tank
and solar controller
Prepare the solar controller by installing a 1/2" nipple and
the flexible tube on the bottom connection of the solar
controller.
solar controller
connection
1/2" nipple
flexible tube
Place the solar controller in position above the “ow”
connection on the storage tank and line up the flexible
tube with the nipple on the “ow” connection. Fix the solar
controller to the storage tank using the screws provided. Do
not use any screws with a length longer than 13mm and if pre
drilling the holes is required, be very careful not to penetrate
too far into the storage tank. Use a spanner to connect the
exible tubing to the nipple of the “ow” connection of the
storage tank.
Install the check valve, nipple and 1/2” copper union to the
top of the solar controller with an appropriate thread sealant.
1/2" female to
copper union
1/2" nipple
check valve
solar controller
connection
Preparing the storage tank location
The storage tank shall be installed on a level surface,
preferably on a concrete platform so that it is elevated
slightly from the ground and has a uniform mounting surface
to spread its load. The storage tank shall be checked with a
spirit level to ensure it is level for a number of reasons:
• to ensure the correct positioning of the anode inside
the tank
• to ensure that any hot water is drawn from the very top
of the tank
• to assist air being dispelled during commissioning
Consideration should be given to any potential damage due
to water drainage or leakage. If leakage of water from the
hot water system has potential to cause property damage, a
properly drained safe tray is to be installed under the storage
tank. The relief valve drainage pipes will be required to be
plumbed to an outside drainage point.
Solar controller mounting and connections
Open the ttings kit KKSSUGA and check that all
components have been provided (refer to the components
list). It is recommended that the storage tank “ow”
connections be installed rst in order to determine the exact
location to mount the solar controller.
Install the tee piece, sensor pocket, 1/2" nipples and 3/4" to
1/2" reducing bush on the “ow” connection of the storage
tank using appropriate thread sealant (see diagram below).
FLOW
storage tank 'ow'
connection
sensor pocket
3/4" to 1/2"
reducing bush
T-piece
1/2" nipple
Kelvinator solar hot water systems installation – storage tank and solar controller 19

20 installation- storage tank and solar controller Kelvinator solar hot water systems
Installation – storage tank
and solar controller
20mm thermal
insulation around pipe
The storage tank “ow” connection is to be piped to the
inlet of the collector array. The outlet of the collector array is
to be piped to the “return” connection on the storage tank
and shall have continuous fall back to the storage tank. It
is recommended that the sensor cable be run at the same
time as the collector piping for convenience. Ensure that the
sensor cable is installed neatly, kept out of the way and is not
in contact with any potentially hot surfaces or copper piping.
If the tank is not to be installed until a later date, ensure that
the sensor plug is well protected and waterproofed (e.g. put in
plastic bag and cable tied in a safe location) until nal assembly.
Installation of storage tank inlet and outlet connections
Storage tank inlet connections
isolating
and non
return valve
pressure limiting
valve (600kPa)
may be required if
pressure exceeds
600kPa
pressure relief
valve (700kPa) may
be required refer
to local plumbing
guidelines
cold
inlet
to storage
tank inlet
An isolating and not return valve must be installed on the
inlet to the hot water system. If it is possible that the supply
pressure could exceed 600kPa, a pressure limiting valve shall
also be installed on the inlet piping. A pressure relief valve
may also need to be installed on the inlet to the hot water
system under local plumbing requirements.
If the hot water system is installed in a bad water quality
area where regular flushing is required due to sediment
build-up, a drain cock or valve is also to be installed on the
inlet piping.
On the storage tank return connection install a 1/2" copper
union, 1/2" nipple and 3/4" to 1/2" reducing bush with
appropriate thread sealant.
RETURN
storage tank return
connection
3/4" to 1/2"
reducing bush
1/2"
nipple
1/2"
nipple
Installation of pipe work between the collectors and
storage tank
The pipe work between the collectors and the hot water
storage tank is to be made of copper and be a minimum of
1/2" in diameter. It shall be covered with 20mm thick thermal
insulation to maintain the efciency of the system, prevent heat
loss and to allow the proper operation of the freeze protection.
Any piping insulation that will be exposed to sunlight must
also be UV resistant. The copper pipes shall be supported by
saddles and installed neatly with no sharp bends. The pipes
shall not exceed the recommended length of 10m (20m total)
and the height difference between the storage tank and the
collectors must not be greater than 9 meters. Penetrations
through the roong material must be neat, kept as small
as practical and made at the high point of the roof tile or
metal sheet. Exposed insulated pipe work between the solar
collectors and the penetration through the roong material
should be kept to a minimum to maintain the aesthetics of the
installation. The penetrations are to be waterproofed upon
installation of the pipe work and a boot shall be installed to
prevent any water from leaking into the premises.