Rheem HBT200 User manual

This collector kit must be installed and serviced by a qualified person.
Please leave this guide with the householder.
Installation Instructions
Collector Kits
Collectors with Copper Waterways, Conetite Connections
for use in Direct Systems
using uncoated DR Brass Conetite fittings
HBT200, LCS, S
SOLAR COLLECTORS
WARNING: Plumber –Be Aware
Use copper pipe ONLY. Plastic pipe MUST NOT be used.
It is a requirement of a solar water heater installation that all
pipe work be in copper and not plastic, due to the effects of
high water temperatures.

2
WARNING: Plumber –Be Aware
The solar hot and solar cold pipes between the solar storage tank and
the solar collectors MUST BE of copper. All compression fittings must
use brass or copper olives.
The full length of the solar hot and solar cold pipes MUST BE insulated.
The insulation must:
be of a closed cell type or equivalent, suitable for a solar water
heating application and capable of withstanding temperatures of up to
150°C, which may be generated by the solar collectors under
stagnation conditions.
The specification of the chosen insulation material should be checked
with the insulation manufacturer prior to installation as different
materials may vary in temperature tolerance.
be at least 13 mm thick, however thicker insulation may be required to
comply with the requirements of AS/NZS 3500.4
be weatherproof and UV resistant if exposed
extend through any penetrations in the eaves, ceiling and roof
cover valves and fittings in the solar hot and solar cold pipe work
be fitted up to and cover the connections on both the solar storage
tank and the solar collectors.
Note: Failure to observe these requirements increases the risk of
freeze damage.
Uninsulated pipe work, including concealed in cavities and roof spaces or
where it may be in contact with a metal roof, may lead to freeze damage.
The system has NO WARRANTY for freeze damage if the solar hot and
solar cold pipes are not insulated in accordance with the installation
instructions.
The insulation is essential to assist in providing freeze protection, will
offer corrosion protection to a metal roof against water runoff over the
copper pipe, assist in avoiding accidental contact with the solar pipe work
as high temperature water can flow from the solar collectors to the solar
storage tank and also reduce pipe heat losses.
Plumber: It is important to refer to and read in full the complete
“Warning: Plumber – Be Aware” statement commencing on page 12.

3
CONTENTS
HOUSEHOLDER - This installation instruction booklet is
intended for the installer but you may find it of interest.
Components And Kit Contents ..................................................4
System Installation......................................................................6
Installation –Solar Storage Tank ...............................................8
Solar Collector Location .............................................................9
Roof Assembly Of Solar Collectors .........................................16
Connection Details ....................................................................22
Pipe Work Roughing In Dimensions........................................26
Installation –Solar Collectors ..................................................32
Warranty Note ............................................................................35
Notice to Victorian Customers from the
Victorian Plumbing Industry Commission.
This water heater must be installed by a licensed person
as required by the Victorian Building Act 1993.
Only a licensed person will give you a Compliance Certificate, showing that
the work complies with all the relevant Standards. Only a licensed person will
have insurance protecting their workmanship for 6 years. Make sure you use
a licensed person to install this water heater and ask for your Compliance
Certificate.

4
COMPONENTS AND KIT CONTENTS
SOLAR COLLECTOR KITS –CONETITE FITTINGS
For installation with a solar storage tank with a drain back heat exchanger.
Your solar water heater is designed for the solar collectors to be roof mounted
and the solar storage tank to be installed at ground or floor level. The collector
kits are suitable for:
Collector Kit –Conetite Fittings 1 Collector (uncoated brass conetites)
12104793 HBT200, LCS, S solar collectors
Collector Kit –Conetite Fittings 2 Collectors (uncoated brass conetites)
12104794 HBT200, LCS, S solar collectors
Collector Kit –Conetite Fittings Additional Collector
(uncoated brass conetites)
12104795 HBT200, LCS, S solar collectors
Note: One Additional Collector Kit is required for a third solar collector.
WARNINGS
Warning: Use uncoated DR Brass fittings only as part of an open circuit
system.
Warning: This parts kit shall not be used with J, KF, S200 or T200 steel
collectors. Use only with collectors which have copper waterways and conetite
style connections.

COMPONENTS AND KIT CONTENTS
5
Part No
Kit Components and Description
12104793
one
collector
12104794
two
collectors
12104795
collector
add on
347229
Installation instructions roof kit
1
1
1
347587
Warning Sheet –DR Brass conetite kits
1
1
1
331847
Collector rail (1020 mm long)
2
-
-
331846
Collector rail (1650 mm long)
-
2
-
331851
Collector rail extension (1070 mm long)
-
-
2
330847
Collector straps
4
4
2
331844
Drive cleat
-
-
2
331928
Collector clamps
4
8
4
330350
Hex screw set S/S 5/16” x 3/4”
4
8
4
330354
Washer S/S 5/16”
4
8
4
330806
Nut S/S 5/16”
4
8
4
341390
Collector connector (collector union)
assembly conetite brass
-
2
2
341391
Collector bung (end plug) assembly
conetite brass
- consisting of:
1 x 344236 collector bung uncoated
1 x 344259 gland nut uncoated
2
2
-
344269
Sensor connector fitting conetite brass –
15BSP temp assbly direct - consisting of:
1 x 344268 fitting conetite -15BSP temp
sensor
1 x 344259 gland nut uncoated
1 x 088062 sensor nipple solar loline
1 x 087026 O ring 5/16” ID x 1/16 BS011
silicone
1
1
-
344278
Connector fitting conetite brass –15BSP
assbly direct - consisting of:
1 x 344267 fitting conetite -15BSP
1 x 344259 gland nut uncoated
1
1
331656
Olive ½” brass
2
2
-
331655
Nut compression G½
2
2
-
346025
Hot sensor assembly immersion
including 2 x 087025 O-ring 5/32” ID x 1/16”
1
1
-
346026
Hot sensor adaptor
1
1
-
123204
Label hot pipe / cold pipe
1
1
-
348071
Cable ties 150 mm long
10
10
-

6
SYSTEM INSTALLATION
THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING.
The system is suitable for installation with HBT200, LCS or S solar collectors
as part of a direct open circuit system installation.
The system is not suitable for installation above 400 metres altitude.
IMPORTANT NOTES
Working on roofs is and should always be considered a hazardous activity,
particularly early in the morning, late in the evening, when the roof is wet
and during and after periods of rain.
All work must be carried out in accordance with Local, State and Federal
Occupational Safety, Health and Welfare Regulations. In particular, the
requirements for safety whilst manual lifting, working at heights and on
roofs.
Installers must be competently trained in:
Height Hazard Assessment
Working at Height Procedures
Assessment / Use / Wearing of correct height safety equipment
(harnesses etc.)
All other relevant safety factors specific to the installation and
maintenance work to be compliant with suitable Occupational, Health
and Safety Regulations / Codes.
All relevant permits shall be obtained from the regulatory authorities before
commencing work to install the solar hot water system.
All work carried out must be performed by appropriately qualified
tradespeople or be suitably supervised for trades assistant duties.
Every care must be taken to protect and warn occupants of the building and
the public from personal injury which may occur from falling tools, roof
materials, fittings or any other hazards of a general nature.
Advise the occupants of any inconvenience which may occur due to
disconnection of existing water and electrical supplies.
The connection, attachment, integration or general association of other
equipment or parts which either directly or indirectly affect the operation or
performance of this equipment could void the manufacturer‟s warranty.

INSTALLATION
7
INSTALLATION STANDARDS
The water heater must be installed:
by a qualified person, and
in accordance with the installation instructions, and
in compliance with Standards AS/NZS 3500.4, AS/NZS 3000 and all local
codes and regulatory authority requirements.
In New Zealand, the installation must also conform with Clause G12 of the New
Zealand Building Code.
WATER HEATER APPLICATION
This water heater is designed for use in a single family domestic dwelling for
the purpose of heating potable water. Its use in an application other than this
may shorten its life.
If this water heater is to be used where an uninterrupted hot water supply is
necessary for the application or business, then there should be redundancy
within the hot water system design. This should ensure the continuity of hot
water supply in the event that this water heater was to become inoperable for
any reason. We recommend you provide advice to the system owner about
their needs and building backup redundancy into the hot water supply system.
DIRECT OPEN CIRCUIT SYSTEM INSTALLATION
A direct open circuit system has a collector circuit which is directly connected to
the potable water in the solar storage tank. Potable water from the solar
storage tank circulates through and collects heat gained by the solar collectors
and then circulates back into the solar storage tank.
Warning: Use uncoated DR Brass fittings only as part of an open circuit
system.
Freeze Protection
The system has a level of freeze protection designed to guard the system
against damage from freeze conditions. The system must be installed with the
full length of the solar hot and solar cold pipes insulated to offer protection
against freeze damage (refer to “Warning: Plumber Be Aware” on page 12).
Freeze conditions occur below 6°C.
The system has NO WARRANTY for freeze damage when installed above
400 metres altitude or if the solar hot and solar cold pipes are not insulated in
accordance with the installation instructions (refer to “Warranty Note” on
page 35). Note: The manufacturer‟s warranty against freeze damage applies
only to systems installed in Australia.

8
INSTALLATION –SOLAR STORAGE TANK
SOLAR WATER HEATER STORAGE TANK LOCATION
The solar storage tank should be installed close to the most frequently used
outlet and its position chosen with safety and service in mind.
Consideration must also be given to the position of the solar storage tank in
relation to the solar collectors. There are limitations on both the maximum
length of the solar hot and solar cold pipes and the maximum height between
the solar storage tank and the solar collectors. Refer to “Solar Collector
Location” on page 9 and to “Pipe Lengths” on page 11.
Refer to the installation instructions supplied with the solar storage tank for
installation details of the solar storage tank.
Warning: Certain types of plastic pipe, such as Poly-butylene pipe, are not
suitable to be used as a hot water pipe between:
this water heater and a temperature limiting device, and
this water heater and a hot water outlet if a temperature limiting device is
not installed.
This water heater can produce water at a temperature and pressure which can
exceed the performance limits of these types of pipe. This may result in pipe
failure leading to severe water damage to the property. If one of these types of
plastic pipe is used as a hot water pipe in the property, then a temperature
limiting device must be installed between the water heater and this pipe work.

9
SOLAR COLLECTOR LOCATION
Consideration must be given to the position of the solar collectors in relation to
the solar storage tank. There are limitations on both the maximum length of the
solar hot and solar cold pipes and the maximum height between the solar
storage tank and the solar collectors. Refer to “Solar Storage Tank Location” on
page 8 and to “Pipe Lengths” on page 11.
The solar collectors must be installed in a shade free position.
The surrounding vicinity should be
checked for higher buildings or trees
which may cause shade at other times
of the year and for small trees which
may grow and shade the solar
collectors in the future.
For optimum performance, solar
collectors should be installed facing
towards the equator (i.e. north facing in
the southern hemisphere and south
facing in the northern hemisphere).
ALWAYS CHECK ORIENTATION
WITH A COMPASS. Where this
orientation is not practical, solar
collectors facing up to 45° from the
equator will receive about 4% less total
solar radiation.
For optimum performance, inclination of the solar collectors should be
approximately equal to 90% of the local latitude angle. The latitude of some
Australian cities are listed on page 10. Solar collectors may be installed at
the roof angle for simplicity of installation and appearance, but must never
be flat for a direct open circuit system. If the roof angle varies by 15° from
the optimum angle, the solar collectors will receive about 10% less total
solar radiation.
The collector kit is suitable for installations with an inclination of up to 45°.
Where the solar collectors are installed at inclinations greater than 45°, a
With Pitch frame is necessary. Refer to your local Solar Distributor for
details.
For a solar collector installation on a roof with a pitch less than 10°, a
Variable Pitch frame is required. Refer to your local Solar Distributor for
details.

SOLAR COLLECTOR LOCATION
10
For an installation of collectors on a pitched roof in a cyclonic or high wind
area, a suitable With Pitch frame is required. Refer to your local Solar
Distributor for details.
The installation of these solar collectors on a suitable frame, subject to the
frame‟s design criteria not being exceeded:
is suitable for installation in geographic locations up to and within Wind
Region D (With Pitch frame) or up to and within Wind Region C (Variable
Pitch frame), as defined in the Building Code of Australia,
Australian / New Zealand Standard AS/NZS 1170.2:2002 and the
Australian Standard AS 4055-2006, and
provides an acceptable method of installation where it is necessary to
satisfy the requirements of the Building Code of Australia and
AS/NZS 3500.4 Clause 6.5.3.4 for high wind areas.
The installer must ensure the structural integrity of the building is not
compromised by the solar water heater installation and the roof structure is
suitable to carry the full weight of the solar collector(s). If in doubt the roof
structure should be suitably strengthened. Consult a structural engineer.
Each solar collector and its fittings weighs approximately 45 kg when full of
water.
Refer to the installation instructions supplied with the solar storage tank for
details on the installation of the solar storage tank.
Roof area required for solar collectors:
3 solar collectors –3.4 m wide x 2.0 m deep. Weight (full) 126 kg approx.
2 solar collectors –2.3 m wide x 2.0 m deep. Weight (full) 84 kg approx.
1 solar collector –1.2 m wide x 2.0 m deep. Weight (full) 42 kg approx.
LATITUDE OF SOME AUSTRALIAN CITIES
Adelaide
35°S
Cairns
17°S
Hobart
42°S
Port Hedland
20°S
Alice Springs
24°S
Canberra
35°S
Mildura
34°S
Rockhampton
24°S
Brisbane
27°S
Darwin
12°S
Melbourne
38°S
Sydney
34°S
Broken Hill
31°S
Geraldton
28°S
Perth
32°S
Townsville
19°S

SOLAR COLLECTOR LOCATION
11
PIPE LENGTHS
The solar hot and solar cold pipes between the solar storage tank and the solar
collectors shall:
be of bendable grade or hard drawn copper tube.
Annealed or soft copper shall not be used.
Direct Open Circuit System: have a continuous fall from the solar collectors
to the solar storage tank. Horizontal runs of pipe work are acceptable and
may be installed.
not exceed the maximum recommended combined lengths as specified in
the table.
Maximum recommended total combined pipe length (solar cold + solar hot)
and number of 90° bends
Pipe Size
1 or 2 Collectors
3 Collectors
Pipe Length
90° Bends
Pipe Length
90° Bends
DN15
40 metres
20
30 metres
20
DN20
NR
NR
40 metres
20
For each additional 90° bend, reduce the maximum total pipe length by 0.5 m.
For each additional metre of pipe length, reduce the number of 90° bends by two.
Note: One 90° elbow is equal to two 90° bends.
NR –not recommended, NA –not available
Notes:
It is important not to cross connect the solar cold and solar hot pipes to the
incorrect connections at the solar collectors and at the solar storage tank.
The solar cold pipe connects to the bottom of the solar collector and may
connect to either the left or right hand side. The solar hot pipe must connect
to the top of the solar collector diagonally opposite to the solar cold pipe
connection.
Direct Open Circuit System: The hot sensor connection is at the solar hot
outlet where the solar hot pipe connects to the solar collector.
Refer to “Warning: Plumber – Be Aware” on page 12.
It is essential for these requirements to be followed for the system to operate
correctly and efficiently. Solar pipe work which is oversized, or is too long, or
does not have a continuous fall can result in a reduction in performance or the
system not operating effectively.

SOLAR COLLECTOR LOCATION
12
WARNING: Plumber –Be Aware
The solar hot and solar cold pipes between the solar storage tank and
the solar collectors MUST BE of copper. All compression fittings must
use brass or copper olives.
The full length of the solar hot and solar cold pipes MUST BE insulated.
The insulation must:
be of a closed cell type or equivalent, suitable for a solar water
heating application and capable of withstanding temperatures of up to
150°C, which may be generated by the solar collectors under
stagnation conditions
The specification of the chosen insulation material should be checked
with the insulation manufacturer prior to installation as different
materials may vary in temperature tolerance.
be at least 13 mm thick, however thicker insulation may be required to
comply with the requirements of AS/NZS 3500.4
be weatherproof and UV resistant if exposed
extend through any penetrations in the eaves, ceiling and roof
cover valves and fittings in the solar hot and solar cold pipe work
be fitted up to and cover the connections on both the solar storage
tank and the solar collectors.
Note: Failure to observe these requirements increases the risk of
freeze damage.
Uninsulated pipe work, including concealed in cavities and roof spaces or
where it may be in contact with a metal roof, may lead to freeze damage.
The system has NO WARRANTY for freeze damage if the solar hot and
solar cold pipes are not insulated in accordance with the installation
instructions.
The insulation is essential to assist in providing freeze protection, will
offer corrosion protection to a metal roof against water runoff over the
copper pipe, assist in avoiding accidental contact with the solar pipe work
as high temperature water can flow from the solar collectors to the solar
storage tank and also reduce pipe heat losses.

SOLAR COLLECTOR LOCATION
13
WARNING: Plumber –Be Aware
The insulated copper pipe work:
should be fixed at suitable locations to prevent or reduce the
possibility of noise from water hammer and vibration from occurring
is not to be placed or installed in contact with plastic pipe work.
Likewise, plastic pipe work is not to be placed or installed in contact
with the insulated copper pipe work after the solar circuit is installed.
Direct Open Circuit System: 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. There MUST BE
a continuous fall in the pipe work between the solar collectors and solar
storage tank. Horizontal runs of pipe work are acceptable and may be
installed.
Plastic pipe MUST NOT be used, as it will not withstand the temperature
of the water generated by the solar collectors under stagnation
conditions. The solar collectors can generate extremely high water
temperatures of up to 150°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.
The pressure applied to the solar circuit and solar collectors during a
pressure test of a direct open circuit system MUST NOT exceed
1000 kPa, otherwise damage may result to the solar collectors.
Refer to “Pressure Testing” on page 15.
Upon completion of the installation of the solar collectors with conetite
fittings, the packaging material may be removed whether or not the solar
circuit is connected to the solar storage tank and / or the solar water
heater is commissioned, without damage to the solar collectors.

SOLAR COLLECTOR LOCATION
14
Maximum Height to Collectors –Direct Open Circuit
The maximum height of a solar installation, from the solar controller (circulator)
to the top of the solar collectors, is determined by the maximum recommended
total pipe length for the system and the water supply pressure.
The maximum recommended total pipe length of the solar circuit should not be
exceeded and a minimum water supply pressure of 200 kPa should be
available at the inlet to the system, otherwise the system performance may be
reduced or the solar circuit may not be purged of air during the commissioning
of the system.
Direct Open Circuit Solar
Pipe Work Installation Requirements

SOLAR COLLECTOR LOCATION
15
Pressure Testing
The solar water heater, including the collector circuit and solar collectors, is to
be isolated during the testing and commissioning of the heated water
reticulation system in a building, in accordance with Clause 11.1 and 11.3 (a) of
AS/NZS 3500.4.
It may be necessary to pressure test the collector circuit to comply with codes
and regulatory authority requirements or on other occasions where the solar
collectors and solar cold and solar hot pipe work are installed prior to the solar
storage tank, such as on a building site.
Direct Open Collector Circuit
Warning: The pressure applied to the solar circuit and solar collectors
during a pressure test of a direct open circuit system MUST NOT exceed
1000 kPa where HBT200, LCS or S collectors are installed, otherwise damage
may result to the solar collectors.
Direct Open System
If the solar collectors, solar pipe work and solar storage tank are installed and
commissioned together, then the flooding of the collector circuit with water
under mains pressure for a direct open circuit system and checking the pipe
work for leaks during the commissioning procedure can be substituted for the
pressure testing of the collector circuit.
Maximum Number of Collectors
The maximum recommended number of these selective surface collectors for
each tank size is:
Direct open circuit system
410, 415 litre tanks –3 x collectors
220, 260, 270, 325 litre tanks –2 x collectors
160, 165 litre tanks –1 x collector

16
ROOF ASSEMBLY OF SOLAR COLLECTORS
Notes:
Warning: This parts kit shall not be used with J, KF, S200 or T200 steel
collectors. Use only with collectors which have copper waterways and
conetite style connections.
These solar collectors have passed the AS/NZS 2712 requirements for
resistance to hailstone damage, so it is not normally necessary to fit a guard
to a collector. Stone Guards are available to provide a level of protection to
the collectors against vandalism or accidental damage. Refer to your local
Solar Distributor for details.
The manufacturer‟s warranty DOES NOT cover breakage of solar collector
glass. Check your insurance policy covers collector glass breakage.
Warning: No attempt should be made to remove or replace broken
collector glass.
The collector glass is not offered as a replacement part. Should the solar
collector require replacement, contact your local Solar Distributor for details.
Warning: Do not remove the solar collector packaging completely, prior
to the installation as the solar collector surface can become very hot.
Remove only sufficient packaging material to enable the installation of the
solar collectors.
Upon completion of the installation of the solar collectors with conetite
fittings, such as on a building site, the packaging material may be removed
whether or not the solar circuit is connected to the solar storage tank
and / or the solar water heater is commissioned, without damage to the
solar collectors.
The solar collector packaging must be removed completely prior to the
permanent operation of the water heater.
All connectors, unions, end plugs, brass fittings, collector straps and
collector rails required for the installation are included with the collector kit.
Suitable screws or anchors will be required to fix the collector straps to the
rafters for a pitched roof installation.
Clamps, screws, nuts and washers to secure the solar collector(s) to the
collector rails are included with the collector kit.
All olive compression fittings must use brass or copper olives. Use thread
sealing tape or an approved thread sealant on all fittings.

ROOF ASSEMBLY OF SOLAR COLLECTORS
17
Numbers in parentheses refer to items in the diagrams on page 32 (one solar
collector installation), page 33 (two solar collector installation) and page 34
(three solar collector installation).
DO NOT MODIFY THESE PARTS IN ANY WAY
1. Solar Collector Location: Select a suitable position for the solar
collectors. Refer to “Solar Collector Location” on page 9.
2. Collector Rail (bottom) –Pitched Roof Installation: Determine the
location of the bottom collector rail(s) (1). If more than two solar
collectors (17) are installed, locate the collector rail (1) from the Additional
Collector kit adjacent to the first collector rail (1) and join together using
the driver cleat (8) supplied in the Additional Collector kit.
Hook two collector straps (2) to each bottom collector rail (1).
Refer to Detail E on page 25.
Tile Roof: Remove the tiles on the next row above the position of the
collector rail (1) to expose the rafters. Ensure the collector rail (1) is
horizontal. Once in position, fix the collector straps (2) to the rafters, using
suitable screws or anchors. Replace the tiles.
Metal Roof: Ensure the collector rail (1) is horizontal. Once in position, fix
the collector straps (2) to the rafters, through the metal roofing material,
using suitable screws or anchors. Care should be taken not to mark
Colorbond or other metal roof sheet with a marking pen and to remove all
swarf from the metal roof as these can cause deterioration of the metal
roofing material.
Note: Fixings must penetrate only through the high point in the roof
material profile.
Note: A rise across the solar collectors from the solar cold connection side
up to the solar hot connection side is acceptable.
Solar Frame –Flat Roof Installation: Determine the location of the
Variable Pitch frame(s). Assemble and fix the frame(s) to the roof,
following the installation instructions provided with the frame(s).
3. Solar Collectors: Position the solar collectors (17) in the correct
configuration with the lower ends seated in the collector rail (1).
4. Collector Unions: For multiple solar collector installations, couple the
solar collectors (17) together using the collector unions (3) supplied in the
collector kit.
Refer to “Coupling Collector to Collector – Conetite Fittings”on page 22.

ROOF ASSEMBLY OF SOLAR COLLECTORS
18
5. Fixing Collector (Bottom): Ensure the solar collectors (17) are well
seated in the collector rail (1).
Pitched Roof Installation and Solar Frame –Flat Roof Installation: Clamp
the solar collectors (17) (two clamps per collector) to the collector rail (1),
using the clamps (13), hex screws, washers and nuts provided.
Refer to “Clamping Collector to Collector Rail” on page 23.
6. Collector Rail (top) –Pitched Roof Installation: Locate the second
collector rail (1) against the top end of the solar collectors. If more than two
solar collectors (17) are installed, locate the second collector rail (1) from
the Additional Collector kit adjacent to the first collector rail (1) and join
together using the driver cleat (8) supplied in the Additional Collector kit.
Hook two collector straps (2) to each top collector rail (1).
Refer to Detail F on page 25.
Tile Roof: Remove the tiles on the next row above the position of the top
collector rail (1) to expose the rafters. Once in position, fix the collector
straps (2) to the rafters, using suitable screws or anchors. Replace the
tiles.
Metal Roof: Once in position, fix the collector straps (2) to the rafters,
through the metal roofing material, using suitable screws or anchors. The
collector straps (2) may be cut to a length of approximately 100 mm to
retain the aesthetics of the installation.
Note: Fixings must penetrate only through the high point in the roof
material profile.
7. Fixing Collector (Top): Ensure the solar collectors (17) are well seated in
the collector rail (1).
Pitched Roof Installation and Solar Frame –Flat Roof Installation: Clamp
the solar collectors (17) (two clamps per collector) to the collector rail (1),
using the clamps (13), hex screws, washers and nuts provided.
Refer to “Clamping Collector to Collector Rail” on page 23.

ROOF ASSEMBLY OF SOLAR COLLECTORS
19
8. Connector: Fit a connector (10) to the inlet of the solar collector array.
Refer to “Coupling Cold and Hot Pipes to Collector – Conetite Fittings”on
page 22.
9. Sensor Connector: Fit a sensor connector (4) (with hot sensor port) to
the outlet of the solar collector array.
Refer to “Coupling Cold and Hot Pipes to Collector –Conetite Fittings” on
page 22.
10. End Plug (Collector Bung): Fit the end plugs (5) (collector bung)
assemblies to the two remaining solar collector connections.
Refer to “End Plug (Collector Bung) Assembly –Conetite Fittings”on
page 22.
11. Solar Cold and Solar Hot Pipes: Install the solar cold pipe from the solar
storage tank to the solar collectors (17) and the solar hot pipe from the
solar collectors (17) to the solar storage tank.
The solar hot and solar cold pipes should be a minimum DN15, but sized
to suit the installation for a direct open circuit system. Refer to “Pipe
Lengths” on page 11.
The solar hot and solar cold pipes must have a continuous fall from the
solar collectors to the solar storage tank. Horizontal runs of pipe work are
acceptable and may be installed for a direct open circuit system.
The full length of the solar hot and solar cold pipes must be insulated. The
insulation must be capable of withstanding the temperatures generated by
the solar collectors under stagnation conditions.
Warning: Plumber –Be Aware: It is important you refer to “Warning:
Plumber –Be Aware” on page 12 for further and important information
relating to the installation of the solar hot and solar cold pipes.
Refer also to installation diagrams on pages 32, 33 and 34 and to “Pipe
Work Roughing In Dimensions” on page 26.

ROOF ASSEMBLY OF SOLAR COLLECTORS
20
Notes:
Penetrations through the roofing material must be:
■at the high point of the roof tile or metal sheet
■made neatly and kept as small as practicable
■waterproofed upon installation of the solar hot and solar cold
pipes.
Exposed insulated pipe work between the solar collectors and the
penetration through the roofing material should be kept to a minimum
to maintain the aesthetics of the installation.
12. Connecting the Solar Cold and Solar Hot Pipes to Collectors: Connect
the solar cold pipe to the connector (10) at the inlet of the solar
collectors (17) and the solar hot pipe to the sensor connector (4) at the
outlet of the solar collectors (17) using the compression nuts (11) and
olives (12) provided.
Refer to “Coupling Cold and Hot Pipes to Collector –Conetite Fittings”on
page 22 and the installation diagrams on pages 33 and 34.
13. Hot Sensor Lead –Collector Connection: Insert the sensor probe of the
hot sensor lead assembly (9) into the sensor connector (4), ensuring the
„O‟ ring is in position on the probe. Lock it into position with the locking
washer and clip provided.
Hot Sensor Lead –Solar Storage Tank Connection: Run the hot sensor
lead down to the solar storage tank. An extension sensor lead is available
if the hot sensor lead is not long enough to reach the solar storage tank.
Refer to the Owner‟s Guide and Installation Instructions supplied with the
solar storage tank for the connection detail.
Tanks with top solar connections and integrated solar control unit: Connect
the hot sensor lead to the socket on the hot sensor lead protruding from
the top of the solar storage tank. The short sensor lead adaptor is not
required and can be discarded.
Tanks with side solar connections and separate solar control unit: Connect
the hot sensor lead to the hot sensor cable connecting socket located at
the underside of the solar control unit screwed to the side of the solar
storage tank. It may be necessary to use the short sensor lead adaptor to
enable the mating of the connections. If the short sensor lead adaptor is
not required it can be discarded.
14. Cable Ties: Secure the hot sensor lead at appropriate locations with the
cable ties (14) provided.