Sunbank SB-40G User manual

Installation Manual
SB-40G / TZ58/1800-15C
SB-80G / TZ58/1800-30C

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Sunbank Quick Start Guide
Important points before you begin:
1. The evacuated tubes must be installed last.
The tubes quickly generate heat and need water in the tank to act as a load for the heat generated.
Keep the tubes in the box and covered until final step of installation. Do not touch heat pipe without
protective gloves as they get very hot.
2. Make sure that the heat pipes are fully inserted into the tank (about 6 inches).
First insert the condenser bulb of the heat pipe into the manifold until you feel the condenser bulb hit
against the end. Once fully inserted slide tube up to meet tank. Full instructions can be found in
section 11.
3. Use proper freeze protection
For installations in freeze prone areas, proper freeze protection is required. Descriptions of freeze
protection can be found on our website: https://thesunbank.com/freeze-protection. If possible, design
your installation in such a way that neither brass nor copper is used in any unconditioned (not heated)
space.
According to the SRCC, the freeze tolerance for this system is 23° F or -5° C. Freeze tolerance limits
are based upon an assumed set of environmental conditions. Extended periods of cold weather,
including ambient air temperatures above the specified limit, might cause freezing in exposed parts of
the system. It is the owner’s responsibility to protect the system in accordance with the supplier’s
instructions if the air temperature is anticipated to approach the specified freeze tolerance limit.
4. Put pipe dope on female and male threading then wrap with Teflon tape.
The threads on the openings to the Sunbank are such that they require at least 4 wraps of high quality
Teflon tape. To prevent leaks you should put pipe dope on the female threads and on the male
threads, then wrap Teflon tape over the male threads. This is a plumber’s trick and the best way to
avoid leaks.
5. Make sure to insert the temperature sensor the full 6 inches into the thermowell.
This is only applicable to installations that are installing the optional controller and heating element.
When inserting the temperature sensor into the black plastic cord grip make sure it goes all the way
up (about 6 inches) into the tank. Otherwise you will get a bad reading which can cause your system
to overheat if using the optional controller and heating element.

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Sunbank Quick Start Guide
Table of Contents
1. Included Parts ……………………………………………………………………………………… 4
2. Not Included Parts ……………………………………………………………………………………… 5
3. Project Overview ……………………………………………………………………………………… 6
4. Plumbing Diagram ……………………………………………………………………………………… 7
5. Tank Diagram ……………………………………………………………………………………… 9
6. Bracket Diagram ……………………………………………………………………………………… 10
7. Reinforce Roof ……………………………………………………………………………………… 11
8. Roof Attachments ……………………………………………………………………………………… 12
9. Insulation ……………………………………………………………………………………… 12
10. Filling the Tank ……………………………………………………………………………………… 13
11. Tube Installation ……………………………………………………………………………………… 13
12. Temp Sensor/Aux Heater ……………………………………………………………………………………… 14
13. Project Completion ……………………………………………………………………………………… 14
14. Plumbing Labels ……………………………………………………………………………………… 15
15. Operation & Maintenance ……………………………………………………………………………………… 16
16. Warranty ……………………………………………………………………………………… 17
17. Specification Sheet ……………………………………………………………………………………… 18
Notice:
The solar energy system described by this manual, when properly installed and maintained, meets the
minimum standards established by the SRCC. This certification does not imply endorsement or
warranty of this product by SRCC.
All installations should comply with building, plumbing, mechanical and fire code adopted by the
authority having jurisdiction or, in the absence of such codes, with the International Building Code,
International Plumbing Code, International Mechanical Code, and International Fire Code.
Sunbank accepts no responsibility for the misuse or improper installation of this product. This manual
is illustrative not comprehensive. It does not cover personal safety when working on a roof, for
example, or go into depth regarding structural, plumbing, or electrical work. The installer should have
the proper training and knowledge in these areas. If you do not have the proper plumbing, roofing,
and electrical experience then you should not attempt to install the Sunbank.

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Sunbank Quick Start Guide
1. Included Parts
The basic Sunbank system includes:
1 –40 or 80 Gallon Tank
1 - Bracket (assembly required)
15 (40G) or 30 (80G) - Evacuated tube solar collectors (including aluminum fin,
stainless heat pipe, and cap assembly)
15 or 30 - Plastic tailstocks
15 or 30 - Dust rings
1 - Magnesium Anode
1 –½” Temperature and Pressure (T/P) Valve
1 –½” Hy-Vent Air Eliminator
1 –Auxiliary Electric Heater
Stand-alone accessories:
1 –Electronic temperature controller with sensor wire and thermowell
T/P Valve
Hy-Vent
Plastic Tailstock
Dust Rings (Black or White)
Controller
Thermowell

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Sunbank Quick Start Guide
2. Not Included Parts
The specific hardware necessary is installation and climate specific. This list is illustrative, not
comprehensive.
The Sunbank can be installed as a pre-heater with a bypass or as a standalone system. The
following parts list is for the basic pre-heater setup:
1 –roll of PEX or copper pipe (length and diameter dependent upon installation)
1 –roll of high quality Teflon plumbing tape
1 –bottle of thread sealant
1- 4.4 gallon potable water expansion tank
2 –¾” FNPT adapters to interface with tank inlet and outlet
2 –¾” FNPT caps (if not using side ports –most installations)
1 –½” brass plug (if not using thermowell)
2 –¾” MNPT drain valves
6 –T’s (diameter depends on PEX size chosen)
6 –Ball valves (see plumbing configuration diagram in Part 4 for explanation)
1 –Flashing to interface with the roof/building penetration point
1 –lead free mixing valve (also known as a tempering valve)
4 (40G) or 6 (80G) - roof attachments (type depends on roof surface –contact us for
suggestions)
Installation specific plumbing fittings to interface with existing plumbing
Pipe insulation and aluminum jacketing for outdoor pipe
Optional:
1 –3.25” x 10” x 6” register boot to interface with the tank
1 –freeze protection valve More info: https://thesunbank.com/freeze-protection/
Stand-alone system, you will need an additional:
1 –Roll of outdoor 12/2 wiring (for wiring auxiliary electric heater)

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Sunbank Quick Start Guide
3. Project Overview
1. Before starting an installation, it is necessary to know where you plan to mount the
Sunbank and where you plan to interface with the existing plumbing system. Once this is
clearly defined, you can purchase the necessary plumbing supplies.
2. If a permit is required in your jurisdiction contact us for more resources. We will provide
you with documents that you will need for a permit and can connect you with a structural
engineer, if necessary.
3. Assemble the Sunbank bracket and find the rafters/purlins over which you plan to mount
it. Lag flashed attachments to roof and mount bracket so that you can find the correct
roof/building penetration.
4. The next step is to run the plumbing to where you will interface with the existing
plumbing. Make the plumbing connections according to the Sunbank plumbing schematic.
5. Connect plumbing and fill with water (see instructions for how to fill properly in order to
take air out of system) and check for leaks. Do not seal up insulation until you have
checked for leaks.
6. Install tubes (kept in the box until now to prevent overheating). Tighten nuts to secure
tank bolts to the bracket.
7. Enjoy solar heated water.

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Sunbank Quick Start Guide
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4. Plumbing Diagram
We are including two plumbing diagrams and a photo of an installed plumbing configuration to help
explain how to plumb the Sunbank system. You can also look at our Youtube channel for more details.
The Sunbank can be installed as a stand-alone or a pre-heat system. The following diagrams/photo
show the pre-heat configuration. The stand-alone is the same but without the existing domestic water
heater and water heater bypass/shutoff valves.
Note: Drain the T/P valve to the gutter to avoid hot water on roof material

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Sunbank Quick Start Guide
5. Tank Diagram

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Sunbank Quick Start Guide
6. Bracket Diagrams
1) Flush mount for pitched roof (80G is twice as wide)
2) Flat roof and ground mount (80G is twice as wide)

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Sunbank Quick Start Guide
7. Reinforce Roof
Whether or not it is necessary to reinforce the roof depends on the existing roof structure. A structural
engineer is qualified to assess a roof and to prescribe reinforcement measures that must be performed
before installation. Send us an email for structural engineering referrals.
8. Roof Attachments
Roof attachments are specific to the type of roofing to which you are attaching the Sunbank and all
roof attachments should be approved by a structural engineer for the specific installation. For
mounting to most composition shingle roofs, we recommend a flashed L foot design like the Snap-N-
Rack Series 100 (pictured below) or a Quickmount QBase. Quickmount also makes attachments for
tile roofs and S-5! makes metal roof attachments.
Spec sheets, distributor information, and installation diagrams can be found on their websites:
www.snapnrack.com
www.quickmountpv.com
www.s-5.com
You can either attach the bracket directly to the roof attachments (first set of photos), or, it is often
advantageous to attach the roof attachments to solar rail (second set of photos) and then mount the
Sunbank bracket to the rail. This has the advantage of allowing the installer to put in more roof
attachment points, to spread out the weight between more rafters, and to have the final mounting
position be constrained by rafter position.

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Sunbank Quick Start Guide
Bracket mounted directly to roof attachments:
Bracket mounted to rail which mount to roof attachments:
9. Insulation
All plumbing that is exposed to the elements should be adequately insulated and jacketed; how best
to do this will depend on the specifics of your installation and your climate. Below are examples of
insulation and jacketing systems. Aluminum jacketing for solar thermal projects can be found here:
http://www.buyinsulationproductstore.com. We have found that 6” aluminum flex duct and aluminum stack
vent are the products most commonly available at hardware stores and serve a similar function.

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Sunbank Quick Start Guide
A register boot will interface with the tank. You can use rivets or tek screws to connect the boot to the
tank and butyl tape to flash. Remember, don’t do this until you have filled the tank with water and
checked for leaks.
10. Setting the Tank
Before installing tubes, take the rubber thread covers and nuts off of the four bolts protruding from
the tank. Set the tank atop the saddle with the bolts resting in the saddle. Adjust the angle of the tank
so that the tubes follow a straight line from the tank to the plastic tailstocks. Place a tube on each side
of the tank to confirm the angle before tightening the nuts and filling the tank with water.
11. Filling the tank
Once the plumbing has been connected to the tank pressure test the system with air.
Make certain the drain valve is closed and open the T/P valve on the tank to allow air to escape. Open
the solar isolation valves to allow water to fill the Sunbank tank and immediately go to the roof to
close the T/P valve once water comes out and the tank is full. Close the solar bypass valve to force
cold water into the Sunbank. Check the tank and cold water lines for leaks and repair any found.
12. Tube Installation
The last step is to install the tubes. You can also find video instructions on our Youtube page.
1. Note tailstock comes apart. Unscrew the black plastic at the bottom of the bracket. Put the
dust ring around the top end of the evacuated tube
about 2 inches from the top. Use mild soap and
water to ease on the dust ring.
2. Put the bottom of the evacuated tube through the
end of the unscrewed plastic tailstock and pull the
heat pipe out of the tube about six inches.
3. Guide the condenser bulb of the heat pipe into the
tank socket until you hear it bottom out in the tank
(~4 inches). Rotate the tube if there is resistance.
4. Slide the tube so that it fits up against the tank.
Maintaining upward pressure on the tube, screw the
cap of the tailstock on to hold the tube in place. It
should screw easily—be sure that you have the
threading lined up. You can twist the tube to help
twist the tail stock. Do not overtighten.
5. Adjust the dust ring so that it fits snugly between the
tank and the tube.
6. Repeat.

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Sunbank Quick Start Guide
12. Temperature Sensor/Auxiliary Heater
While you are putting teflon tape on the temperature sensor thermowell you will notice that it extends
6 inches or so up into the tank. When you are installing the actual temperature sensor wire it is
important that it goes all the way to the end of this well. This ensures an accurate reading.
The temperature sensor wire is 150 feet long and it should be run in conduit protected from UV.
The controller comes with its own manual that will explain wiring, settings, and various functions.
13. Project Completion
Once the tubes are installed the system should be ready for use. Again, make sure that there are no
leaks at the fittings and that the insulation is sufficient and sealed appropriately.
The next time you should need to think about your Sunbank is to check and change the magnesium
anode. Like any water heater, this anode should be changed in order to keep the inner tank from
corroding. The frequency with which you should change this anode depends on the total dissolved
solids (TDS) of your local water supply. If you don’t have a good idea of your local TDS, Sunbank
recommends that you check the anode one year after installation and base future checks on the
amount of the existing magnesium anode that is left at this point.
Addendum:
Watts (Grundfos) Instant Hot Water Recirculation System
We recommend this system, now available on our website and elsewhere online, to prevent
overheating and freezing.
http://www.watts.com/InstantHotWater
This valve installs under the sink furthest from the Sunbank and uses the cold water line to circulate
hot water back to the Sunbank tank. The pump is controlled by the Sunbank controller and can be
programmed to turn on when the Sunbank is getting too hot. When the system comes on hot water is
circulated through the home’s plumbing lowering the temperature in the tank. Likewise, the controller
can be set on a timer during the winter to come on periodically throughout the night to prevent any of
the plumbing lines from freezing.
Stand-alone setup
If you are using the Sunbank as a stand-alone system, you will also be using the auxiliary electrical
heater and controller. The temperature sensor and heating element should be installed prior to filling
the tank with water and the wiring should be in conduit according to local building code.

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Sunbank Quick Start Guide
14. Plumbing Labels




COLD Line 
HOT from Sunbank 
If an issue arises, please call your
local installer:
____________________________
(phone #) ____________________

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Sunbank Quick Start Guide
15. Operation & Maintenance
Once the Sunbank is installed, the tank filled, and the valves turned according to the diagrams above,
your Sunbank is operational. Because your system is now pressurized via municipal or well water
pressure, the Sunbank delivers hot water by simply opening your hot water faucets.
Safety
Turn off power to water heater if it has been subjected to overheating, fire, flood, physical damage, etc.
Do not turn on heating element unless it is filled with water. Do not turn on heating element if cold
water supply shut-off valve is closed. If there is any difficulty in understanding or following these
instructions, it is recommended that a qualified person perform the work.
Draining the Tank
In order to drain the water heater, close V2 and V3. Attach a garden hose to the drain valve and direct the
hose to a drain. Open V4 and V5.
Vacation and Extended Shut Down
If you are going to be away from home for an extended period, two weeks or more - you may consider
deactivating the system so that it does not continue to heat the water tank while hot water is not being
used in the house.
If you choose not to perform the procedures listed below, call your installer to deactivate or reactivate
your system.
Deactivating the system is easy to complete in two steps.
1. Unplug the Sunbank controller.
2. Cover the collectors (or rotate them so that the opaque painted side is up, if you have painted them)
When you return, simply reverse the procedures to reactivate the system.
If the collectors are likely to be covered with snow for an extended time, or if the system will not be
used for one month or longer, the water heater and piping should be drained to prevent freezing or
stagnant water. Make certain the water heater is completely filled again before placing it in operation.
Maintenance
There is relatively little required maintenance for the Sunbank. Properly maintained, your solar water
heater system will provide years of dependable, trouble-free service.
Annually:

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Sunbank Quick Start Guide
1. Trim trees near collectors.
2. Lift and release the lever handle on the temperature and pressure relief valve to make certain the
valve operates freely.
At least every three to five years:
1. Check all valves and electrical equipment.
2. Change magnesium anode and flush tank
The evacuated tube collectors should last for 15 years without significant degradation.
The tank life depends on the local water quality, pressure, and how frequently the magnesium
anode is changed. Reducing the pressure fluctuations in the tank will increase its life. You can
reduce the pressure by:
a) installing a whole house pressure reducing valve if your incoming water pressure is above
60 PSI,
b) installing a T/P and pressure relief valve on the cold inlet to the Sunbank that releases
pressure at 58 PSI,
c) installing an appropriately sized expansion tank in the mechanical room on the cold side
Stainless steel tanks are the most durable and expensive tanks to produce, but if not properly
maintained in areas with hard water they can corrode which will shorten their working life.
Magnesium anode
Every Sunbank comes with a magnesium anode meant to protect the inner tank from corrosion. How
fast this sacrificial anode will corrode depends on your local water quality. We recommend that you
check the anode one year after installation and base future replacements on how much of the anode
remains. You can buy replacement anodes from Sunbank or your local hardware store.
16. Warranty
Sunbank offers a 10 Year Warranty for manufacturer’s defects on our evacuated tube collectors and a 1
year warranty on all other components of the system. This does not include damage that occurs during
or due to a faulty installation. Nor does it include damage from anything outside of Sunbank’s control,
such as an act of nature or Force Majeure. Sunbank will replace defective parts at no charge but will not
pay for or provide the labor to replace those parts.
In order to obtain warranty coverage, the customer should send a description of the problem with
photos to support the claim to [e-mail]. Proof of purchase, such as an invoice marked
‘PAID’ from Sunbank, is required as we do not warranty any products that were not sold by Sunbank.

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Sunbank Quick Start Guide