Suntrap Sol-250ME-32 Parts list manual

Copyright © 2012 Suntrap Pty Ltd All rights reserved ABN 87 117 052 85
Solar Hot Water
Installation Instructions
and Owners Manual
AS 2712 Lic 21687
SAI Global
WMKA Lic 21688
SAI Global
This Manual Covers 8 syste odels:
Electric Boost Models:
Sol-250ME-32: Sol-315ME-32: Sol-250ME-48: Sol-315ME-48
Solarius Range
( odelled to co ply with version 12 specifications of ORER require ents)
Gas Boost Models:
Sol-250NG26-32 / Sol-250LPG26-32: Sol-315NG26-32 / Sol-315LPG26-32:
Sol-250NG26-48 / Sol-250LPG26-48: Sol-315NG26-48 / Sol-315LPG26-48
October 2012 issue 5.5
Suntrap Pty Ltd
PO Box 31 4
Dural
NSW 2158
Tel: [phone]
Fax: [phone]
Plu bers/Installers – Please read this Manual
before atte pting the installation of the Suntrap
Solar Hot Water Syste
All Stainless
Steel Tank
with
10 year
Warranty
All Stainless
Steel Tank
with
10 year
Warranty
All Systems are available with either
Electric Boost or Gas Boost
Electric Boost Gas Boost

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Copyright © 2012 Suntrap Pty Ltd All rights reserved ABN 87 117 052 85
Contents
1 Suntrap Solar Hot Water systems – Small-scale Technology Certificates
2 About your Suntrap Solar Hot Water System
3 Suntrap Solar Hot Water Kit – Parts supplied
4 Schematic Diagram of the Suntrap Solar Hot Water System
5 Completed installation views of assembled parts
The Suntrap Solar Control Kit
7 Connections to the Suntrap Solar Collectors
8 Connections to the top of the Solar Hot Water Tank
9 Connections to the middle and bottom of the Solar Hot Water Tank
10 The completed Solar Hot Water Tank assembly
11 Check list immediately prior to commissioning System
12 Instructions for assembling and fitting the solar collectors
13 Completing the installation
14 Priming and filling the system
15 Specifications of the Suntrap Evacuated U Tube Solar Collector SLU-1500/1
1 Warranty and Refund Policy

2
Copyright © 2012 Suntrap Pty Ltd All rights reserved ABN 87 117 052 85
AS/NZS 4234:2007 Cli atic Zones
Used in determining the Small-scale Technology Certificates across Australia
1. Small-scale Technology Certificates
Calculated STCs for Suntrap Solarius Solar Hot water Products
The following table presents the calculated STCs and annual energy saving for the different
Suntrap Solarius solar configurations using SLU-1500/1 type evacuated tube collectors
Configuration
Annual Energy Saving (%) 10 Year S all-scale Technology
Certificate Allocation
Zone 1 Zone 2 Zone 3 Zone 4 Zone 1 Zone 2 Zone 3 Zone 4
Sol-250NG26-32 &
Sol-250LPG26-32
Sol-250NG26-48 &
Sol-250LPG26-48
Sol-315NG26-32 &
Sol-315LPG26-32
Sol-315NG26-48 &
Sol-315LPG26-48
Sol-250ME-32
Sol-315ME-32
Sol-250ME-48
Sol-315ME-48
88.4 92.4 72.8 59.3 30 32 29 26
89.8 93.5
89.7
79.8 69.6 42 44 42 37
26
70.4 57.5 38 33
38
41
22
41
30 30
32
38
26
28
68.0 22
39
70.9
74.0
43
60.4
45 43
26 28 26
33
39
80.2
56.9
80.4
56.7 26
88.3
80.1 85.8 68.1
89.2
85.0 71.1 58.1
94.5
91.4
85.4
84.1
93.0
S all-scale Technology Certificates (v.12)

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Copyright © 2012 Suntrap Pty Ltd All rights reserved ABN 87 117 052 85
2. About your Suntrap Solarius Solar Hot Water Syste
Congratulations for choosing a Suntrap Solar Hot Water System. All the systems are designed to have the Solar Collectors
mounted on the roof, and the Solar tank installed at ground level. Two sizes of Everlast Stainless steel solar hot water tanks are
used and have either an electric or gas boost as supplementary heating sources. Tanks have capacities of 250 litres or 315
litres with either a 3. KW heater, or a Bosch 2 e gas heater.
The Solar Tanks are suitable for installations either inside or outdoors. Tanks installed inside need to sit in a ‘Safe Tray’. If the area
in which the system is to be installed is subject to freezing conditions, then the hot and cold solar copper pipes must be fully
insulated with closed cell polymer insulation to offer protection against freeze damage.
All electrically boosted Suntrap Solar Hot Water systems are certified to be connected to a dedicated continuous electrical supply.
Risk of scalding
Be aware that the solar hot water temperature can cause scalding. Check the temperature before use. A temperature limiting device
(Tempering Valve) is provided with all Suntrap Solar Hot Water kits and must be fitted to avoid very hot water from the hot taps
(bathrooms, showers etc.)
Te perature adjust ent
On electrically boosted systems, the solar tank thermostat maintains the tank temperature during boosting and may be adjusted by a
licensed tradesperson if required. The Solar hot water tank thermostat temperature has been factory set and should not require
adjustment. The Solar hot water tank is also supplied with a Pressure and Temperature Relief valve (PTR 850 Valve) which
must not be tampered with.
The Tempering Valve is required to prevent scalding as solar hot water can be much hotter than just electrically heated water.
The Solar Control Unit will switch the solar pump on to circulate the water when there is a water temperature difference of 8 degrees
centigrade or more between the tank water temperature and the solar collector outlet water temperature (on the roof) and will
switch the pump off when the water temperature difference is 5 degrees centigrade. In the event of cold weather, the pump will
also run to ensure that a minimum water temperature of 4 degrees centigrade is maintained within the solar collectors (to
prevent the water within the solar collectors from freezing).
Safety
The tank is supplied with a Pressure and Temperature Relief valve, a Pressure Limiting Valve, and a thermostat. These devices
must be kept in working order at all times. High temperatures can exist in the solar pipes and precautions must be taken to
avoid young children touching them.
If any power cords or plugs are damaged, then these must be replaced by a licensed electrician.
To turn off the hot water
The water heater boost should remain on unless you plan to be away from home for length of time.
If you need to switch the system off (system close down), switch off the electrical water heater isolating switch (electric element
boost heating), switch off the power to the Solar Control Unit (solar heating), Shut off the cold water-in to the DuoValve (point C)
and close the Shut-off ball valve (point D) on the Solar control kit.
To turn on the water heater
Open the DuoValve (point C),- this allows cold water to enter the solar tank, switch on the Solar Control Unit and open the Shut-
off ball valve (point D) on the Solar Control kit, If the solar collectors have been drained then follow the instructions in section 14
of this document (14. Priming and filling the system).
Heater Boost control
Under ideal conditions, your solar hot water will be kept up to temperature by the solar collectors. However on cloudy and
overcast days and during the winter months, the boost heating element inside the solar water tank (electric boost systems) may
be activated to maintain your water temperature. The heating element (immersion heater), must have its own dedicated electrical
supply and must remain connected to the electrical supply at all times.
Water pressure
The water pressure used with this Solar Hot Water system must be a minimum of 200kpa.
Tank Sizes
250 litre 1. 2m(h) x 20mm dia. 315 litre 1.98m(h) x 20mm dia.
Solar collector roof space required
2 collectors 2.4m(w) x 1.8m(h) 3 collectors 3. m(w) x 1.8m(h)
Installers:
All installations ust be carried out by licensed plu bers or other authorised persons in accordance with the National
Plu bing and Drainage Code AS3500, and in addition, with any specific require ents of local water authorities.
Please fa iliarise yourself with all the diagra s and pictures before starting to connect the syste together.
Installation instructions begin at section 10.
So e diagra s/pictures are representative only and so e pictures are shown before pipe insulation has been fitted for
clarity. To co ply with AS2712 certification, the plu bing between the solar hot water tank and the solar collectors
ust be installed using 12 internal pipe dia eter with insulation thickness of 19 on the inlet pipe and 12
internal pipe dia eter with insulation thickness of 19 on the outlet pipe, both pipes using insulation aterial to
ISOpipe insulation standards. For Gas Boosted syste s the pipe between the Solar preheat tank and Gas Booster
ust use Ar aflex 19 thickness insulation.

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Copyright © 2012 Suntrap Pty Ltd All rights reserved ABN 87 117 052 85
Caring for your syste
At the top of the Solar hot water tank there is an 850kpa Pressure and Temperature Relief valve, and it is possible from time to time
that a small amount of water will escape from this valve when the water inside the tank expands during heating periods. This is quite
normal. Every months this valve should be manually operated to ensure that it is in working order. If at any time you believe that
your Suntrap Solar Hot Water system is not functioning correctly, then please give us a call.
Regular Care: Pressure and Temperature Relief (PTR) Valve: This valve is next to the top pipe of the solar tank at point J. The valve
should be checked at regular intervals and replaced every 5 years. To check that the valve is working properly, gently lift the lever
until water flows, then gently let the lever return to its original position. (See Loosing water from the Expansion Control Valve below)
Collector Glass: To assure that maximum efficiency is gained from the Hot water solar system, ensure that the solar collector glass
is kept free of dirt. Hose down the collectors with water and use a soft brush from time to time to keep clean.
Water not hot enough:
This may be caused by the following:
Insufficient sunlight – due to cloudy weather, or cool temperatures during winter – check that the booster heater is working in these
circumstances.
Booster heating not working – check that it is switched on at the electrical distribution panel.
Solar water not hot enough when con itions are goo – Check that the solar pump indicator is illuminated on the Solar Control Unit:
Check that the pump is plugged into the Solar Control Unit: Check that the Solar Control Unit is plugged into the electrical supply,
and switched on. Also check that the collectors have unrestricted access to the sun. 2 x solar collectors for a 315 litre tank, with a 3.
KW boost heater (or a gas booster) is an ideal combination and will provide the solar water temperatures required, under normal
working conditions, if the system is working correctly.
Air in system – Proper circulation of water is not being maintained – Ensure that the air vent is open (point K), then remove (purge)
any air from the system as described in sections 9 and 14. (9. Connections to the middle and bottom of the Solar Tank and (14.
Priming and filling the system)
Excessive use of water – The different Suntrap Solar Hot water System models are designed to cover the requirements of a small to
large number of users, each having their own demand on hot water. A greater demand will cause the water to cool, and longer use of
the booster will be required.
Loosing water from the Pressure an Temperature Relief Valve (Point J) – If thermostat in tank is set too high especially in Summer,
this can result in excessive use of electrical boost heating, leaving the solar heating little to do. This can lead to extremely high
temperatures and water expansion in the solar collectors and can result in excessive water exit from the PTR Valve. Secondary
electric boosting ensures that minimal water temperature is maintained and maximises the benefits and efficiency of solar heating
obtained from the sun. Suntrap systems are certified to use continuous electrical boosting.
Thermostat setting (Electric Boost) – A high tank temperature setting (active during boost times) should be avoided but may be
obtained by the adjustment of the tank thermostat (by a qualified electrician/tradesperson). Please also note that all hot water will
be tempered through the Tempering Valve to prevent scalding from the solar hot water.
Holi ays – When away for a period of time, close the system down. Switch off and unplug the solar controller and move the Shut
off ball-valve at point D to the off position, turn off the ‘mains water in’ at the DuoValve at point C, switch off the booster supply. If
freezing conditions are expected while away, leave the solar controller switched on and the Shut off ball-valve (point D) switched
on, so the Solar Hot water system will automatically defrost the Solar collectors as required, otherwise drain the solar collectors
and close the system down as above.
Installation Notes
In the Sydney area the ideal orientation and angle to mount the solar collectors for the winter sun (best for all round
performance) is for the solar collectors to face True North (approx 11 degrees West of Magnetic North) at an angle of 33
degrees. Suntrap U Tube collectors will also work horizontally at an efficiency of 84%, Standard roofs of 2 degrees will provide
an efficiency of approx 97%.
The system is designed to operate with the solar collectors installed on a roof at a height greater than the top of the solar hot
water tank, with the solar hot water tank installed at ground level. Insulated copper pipes to and from the solar collectors must be
direct, and each direction (flow and return) must always run in a continuous rise and fall situation.
The solar collector should be mounted so the Manifold is at the top (higher) level than the bottom of the solar collector.
The tank must be located onto a firm base and sufficient space must be provided around the solar hot water tank for servicing.
Tanks installed inside a property need to sit in suitably drained ‘Safe Tray’.
The Solar Hot Water system uses a different number of solar collectors depending on the system model being installed and the
maximum pipe lengths to and from the solar collectors should not exceed 40 meters. Keep the number of 90 degree bends in the
pipe work to the minimum. The system must be installed with all copper piping (with insulation thickness of 19mm all the way to
the solar collectors and back to the solar hot water tank, and for Gas Boosted systems use insulation thickness of 19mm on the
pipe between the Solar Preheat Tank and Gas Booster).
Warning - Roof assembly and installation of the solar collectors should be undertaken in cool conditions (early
morning) as the fittings can get too hot to handle and could cause injury if touched.
Warning – When purging the system using the purge valve at point G extreme caution must be taken as water expelled
at this point can be extremely hot. This is best carried out when the solar collectors are cool.
The installation must comply with the requirements of AS/NZS 3000 and AS/NZS 3500.4.
If the tank is to be installed inside a property, then it must be installed in a ‘safe tray’, so that in the event of a leak, the property
will not be damaged by water (AS/NZS 3500.4). Draining of the ‘safe tray’ must also comply with AS/NZS 3500.4.